2004 Volvo S60

pg. 129 Maintenance and service

Wiper blades

Replacing windshield wiper blades
1. Lift the wiper arm off the windshield and hold the blade at a 45° to the arm. Press the end of the plastic clip located on the arm.
2. Slide the wiper blade along the arm to release it from the hook. The entire hooked part of the wiper arm must pass through the opening in the wiper blade.
3. Pull the old blade free of the wiper arm. Install the new blade (installation is the reverse of removal) and make sure that it is properly attached to the wiper arm (clicks into place).

NOTE: For reasons of safety, you should change the windshield wiper blades as soon as they start to leave marks on the windshield or fail to wipe efficiently and cleanly.
To obtain maximum lifetime from a set of wiper blades, clean them with a stiff-bristle brush and warm, soapy water as part of a normal car wash.

Headlight wiper blades (certain models)
Pull the wiper blade in the direction indicated by the arrow in the illustration to remove it. Press the new wiper blade into place. The long section of the blade should point toward the grille. Check that the new blade is properly attached to the wiper arm.

pg. 130 Maintenance and service

Battery

Battery maintenance
The battery in your car is located under the floor of the trunk.

Driving habits and conditions, climate, the number of starts, etc. all affect the service life and function of the battery. In order for your battery to perform satisfactorily, keep the following in mind:

Check the fluid level in each cell in the battery every 24 months or every 15,000* miles (24,000 km), whichever is sooner. The fluid should be at the level shown in the illustration above (A)**.

Use a screw driver to open the caps and a flashlight to inspect the level.

If necessary, add distilled water. The level should never be above the indicator (A**).

The fluid level should be checked if the battery has been recharged.

After inspection, be sure the cap over each battery cell is securely in place.

Check that the battery cables are correctly connected and properly tightened. Route ventilation hose through opening in floor (see page 132)

Never disconnect the battery when the engine is running, for example when changing the battery.

The battery should be disconnected from the vehicle when a battery charger is used directly on the battery.

However, if the battery is being charged via the connecting points in the engine compartment (see page 98), the battery must be connected.

WARNING!

PROPOSITION 65 WARNING!
Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and reproductive harm. Wash hands after handling

* More frequently in warm climates.

** The level indicator inside the battery could be designed in various ways. See illustration.

pg. 131 Maintenance and service

Replacing the battery

Switch off the ignition.

Remove the retaining bracket and unscrew the cover over the battery. Wait at least 5 minutes after switching off the ignition before disconnecting the battery so that all information in the car's electrical system can be stored in the control modules.

Disconnect the negative (ground) cable first.

Disconnect the positive cable and pull the ventilation hose (see next page) from the battery.

Lift out the old battery and put a new battery into place.

Connect the positive cable first.

Connect the negative (ground) cable.

Be sure that the ventilation hose (see next page) is securely connected to the battery and that the other end of the hose is properly routed through the ventilation opening in the floor of the battery compartment.

Reinstall the cover and retaining bracket and screw it securely in place.

pg. 132 Maintenance and service

Battery (Contd)

Ventilation hose

WARNING!

- Never expose the battery to open flame or electric spark.
- Do not smoke near the battery.
- Battery fluid contains sulfuric acid. Do not allow battery fluid to contact eyes, skin, fabrics or painted surfaces. If contact occurs, flush the affected area immediately with water. Obtain medical help immediately if eyes are affected.

WARNING!

Ventilation hose: The battery generates hydrogen gas, which is flammable and explosive. The battery is fitted with a ventilation hose which vents hydrogen gas out of the battery compartment through a ventilation opening in the bottom of this compartment. If the battery must be replaced, it is essential that the ventilation hose is properly connected to the battery and that it is routed through the ventilation opening provided (see illustration).
Be sure the ventilation hose is free of debris. Only use replacement batteries equipped with a ventilation hose. Consult your Volvo retailer.

NOTE: After the battery has been disconnected or replaced, lock and unlock the car with the central locking system's remote control to reactivate such features as the power windows, sunroof, courtesy lighting, etc.

pg. 133 Maintenance and service

Bulbs

The following bulbs are used in the car:

1. Low beam 55W H7

2. Bi-Xenon headlights (option) 35W D2R

3. High beam 55W HB3

4. Brake light
    Fog light, rear P21W
P21W

5. Direction indicator, Parking light rear + front PY21W

6.Side marker light, rear
    Backup light P10W
21W BA 15s

7. Courtesy lighting 1.2 WSV7

8. Vanity mirror 5WSV8.5

9. License plate lighting
    Parking light in headlight W5W
W5W

10. Fog lights
    R-models 55W H1
55W H3

Never touch the glass of bulbs 1 or 2 with your fingers. Grease and oils from your fingers evaporate in the heat and will leave a deposit on the reflector, quickly damaging it.

Bi-Xenon headlight bulbs (option) contain trace amounts of mercury. These bulbs should always be disposed of by an authorized Volvo retailer.

WARNING!
Bi-Xenon headlights (option) - due to the high voltage used by these headlights, these bulbs should only be replaced by an authorized Volvo service technician.

Replacing high/low beam headlight bulbs
The headlight bulbs must be replaced from the engine compartment.

CAUTION:
Be sure to use bulbs of the correct type and voltage.

pg. 134 Maintenance and service

Bulbs (Contd)

Low beam bulb

To remove a defective bulb:

Switch off the ignition.

Open the hood.

Remove the plastic cover over the bulb (1) by turning it counterclockwise.

Remove the connector (2).

Loosen the retaining spring (3) by first moving it to the right and then moving it down, out of the way.

Pull out the defective bulb. Note the position of the guide lug on the base of the bulb (4).

To install a new bulb:

Insert the new bulb, without touching the glass, with the guide lug upward (1). The bulb will only seat properly in this position.

Move the retaining spring up and push it slightly to the left until it seats properly (2).

Press the connector into place on the bulb (3).

Reinstall the plastic cover and turn it clockwise until it is correctly in place (4). "TOP" must be upward.

NOTE: The vertical aim of the headlights should be adjusted by a Volvo retailer.

Side marker lights

Open the front door halfway.

From the inside of the fender, push the lamp housing out.

Turn the bulb holder 1/4 turn counterclockwise and pull it out from the lens.

Remove the defective bulb by pulling it straight out.

Insert a new bulb.

Reinsert the bulb holder in the lens and press the entire unit back into place on the fender.

pg. 135 Maintenance and service

To remove and install a high beam bulb (HB3):

Switch off all lights and turn the ignition switch to position 0.

Open the hood.

Remove the cover by twisting it counterclockwise.

Twist the bulb holder counterclockwise, pull it out and fit a new bulb. Note its position.

Refit the bulb holder. It can only be fitted in one way.

Screw the cover back on. The word TOP should be upwards

Changing the turn signal/parking light bulb at the left front corner

Switch off all lights and turn ignition key to position 0.

Pull out the bulb and its socket by twisting counterclockwise. Replace bulb.

Press the bulb and its socket back into place.

Check that the new bulb lights.

pg. 136 Maintenance and service

Bulbs (Contd)

Changing the turn signal/parking light bulb at the right front corner

Switch off all lights and turn ignition key to position 0.

Remove the radiator hose (1) from the radiator.

Remove the screw (2) to the filler pipe.

Pull the pipe (3) straight up.

Remove the ventilation hose (4) from the pipe.

Remove the bulb holder by turning clockwise.

Press the bulb inwards, turn it counterclockwise and remove it from the bulb holder.

Replace with a new bulb and reinsert the bulb holder in the lamp housing.

Check that the washer fluid reservoir gasket between the filler pipe and the holder is properly secured.

Put the filler pipe (3) back into place.

Reinstall the ventilation hose onto the filler pipe (4).

Tighten the screw (2) of the filler pipe.

Reinstall the radiator hose to the radiator (1).

Front fog lights (option)
Avoid touching the glass on the bulb with your fingers.

Switch off the ignition.

Turn the bulb holder slightly counterclockwise to release it.

Replace the bulb. The shape of the foot of the bulb corresponds to the shape of the bulb holder.

Reinstall the bulb holder by turning it slightly clockwise. "TOP" on the holder should be upward.

*H3 on R-models.

pg. 137 Maintenance and service

Replacing bulbs in the tail light cluster
All bulbs in the tail light cluster can be replaced from inside the trunk.

Switch off all lights and turn ignition key to position 0.

Unlock and fold down the side panel to access the bulbs.
The bulbs are located in two separate bulb holders, an upper and a lower. Each bulb holder has a locking pin.

Replace bulbs in the upper and lower bulb holders as follows:

To ease the work: disconnect the cable from the bulb holder.

Press the catches together and pull out the holder.

Replace the bulb.

Reconnect the cable.

Close and secure the side panel.

Location of bulbs

1. Brake light 21 W BA 15 s

2. Parking light (left side) 5 W BA 15 s

3. Fog light (one side) 21 W BA 5 s

4. Side marker lamp 10W

5. Turn signal PY 21 W

6. Back up light 21 W BA 15 s

High level brake light
These bulbs are of a special type. We recommend that you ask your Volvo retailer to replace this bulb.

pg. 138 Maintenance and service

Bulbs (Contd)

License plate lights

Switch off the ignition.

Loosen the screws with a torx screwdriver.

Carefully pull out the lamp housing.

Turn the bulb holder counterclockwise and pull it out.

Pull out the defective bulb and insert a new one.

Reinsert the bulb holder into the housing and turn it clockwise.

Reinstall the housing and screw it in place.

Door step courtesy lights

The door step courtesy lights are located under the dash on the driver's and passenger's sides. To replace a bulb:

Carefully insert a screwdriver and pry out the lens.

Replace the defective bulb.

Reinstall the lens.

Trunk lights

Carefully insert a screwdriver and pry out the lens.

Pry out the bulb and replace it.

Press the lens back into place.

pg. 139 Maintenance and service

Bulbs (Contd)

Front courtesy lights
These bulbs may be difficult for you to replace yourself. We recommend that you let an authorized Volvo retailer replace these bulbs if necessary.

Rear reading lights
These bulbs may be difficult for you to replace yourself. We recommend that you let an authorized Volvo retailer replace these bulbs if necessary.

NOTE: Other bulbs may be difficult for you to replace yourself. Let an authorized Volvo retailer replace these bulbs if necessary.

Vanity mirror lights*

Carefully insert a screwdriver and pry out the lens.

Pry out the bulb and replace it.

Carefully press the lower edge of lens onto the four tabs and press the upper edge of the lens into place.

* Certain models have one bulb, located above the mirror. The procedure for changing the bulb is the same.

pg. 140 Maintenance and service

Fuses

Replacing fuses
If an electrical component fails to function, it is possible that a fuse has blown. The fuse boxes are located in three different places:

A - Relays/fuse box in the engine compartment
B - Fuse box in the passenger compartment
C - Relays/fuse box in the trunk

A label on the inside of each cover indicates the amperage and the electrical components that are connected to each fuse.

The easiest way to see if a fuse is blown is to remove it. Pull the fuse straight out. If a fuse is difficult to remove, you will find a special fuse removal tool in the passenger compartment fuse box. From the side, examine the curved metal wire (see next page) to see if it is broken. If so, put in a new fuse of the same color and amperage (written on the fuse). Spare fuses are stored in the fuse box in the passenger compartment. If fuses burn out repeatedly, have the electrical system inspected by an authorized Volvo retailer.

WARNING!
Never use fuses with higher amperage that those stated on the following pages. Doing so could overload the car's electrical system.

pg. 141 Maintenance and service

Relay/Fuse box in the engine compartment
When replacing fuses, be sure to replace a blown fuse with a new one of the same color and amperage (written on the fuse).

1 - To open, press the plastic catches on the rear side of the fuse box cover and lift

Fuses in the engine compartment

No. Amperage

1 Accessories 25

2 Auxiliary lights (option) 20

3 -

4 Oxygen sensor 20

5 Crankcase ventilation heater, solenoid valves 10

6 Mass air flow sensor, engine control module, injectors 15

7 Throttle module 10

8 A/C compressor, Accelerator pedal position sensor, E-box fan 10

9 Horn 15

10 -

11 A/C compressor, ignition coils 20

12 Brake light switch 5

13 Windshield wipers 25

14 ABS/STC/DSTC 30

15 -

16 Windshield washers, headlight wipers/washers (certain models) 15

17 Low beam, right 10

18 Low beam, left 10

19 ABS/STC/DSTC 30

20 High beam, left 15

21 High beam, right 15

22 Starter motor 25

23 Engine control module 5

24 -

pg. 142 Maintenance and service

Fuses (Contd)

Fuses in the passenger compartment
Fuses are located inside the access panel on the end face of the dashboard. There are also a number of spare fuses.

No. Amperage
1 Low beam headlights 15
2 High beam headlights 20
3 Power driver's seat 30
4 Power passenger's seat 30
5 Speed-dependent power steering, vacuum pump 15
6 -
7 Heated seat, front left (option) 15
8 Heated seat, front right (option) 15
9 ABS/STC/DSTC 5
10 Daytime running lights 10
11 Daytime running lights 10
12 Headlight wipers (certain models) 15
13 Electric socket 12V 15
14 Power passenger's seat 5
15 Audio system, VNS 5
16 Audio system 20
17 Audio amplifier 30
18 Front fog lights 15
19 VNS display 10
20 -
21 Automatic transmission, shiftlock, extended D2 feed 10
22 Direction indicators 20
23 Headlight switch module, climate control system,
onboard diagnostic connector, steering wheel lever modules 5
24 Relay extended D1 feed: climate control system, power driver's seat, driver's info 10
25 Ignition switch, relay starter motor, SRS, engine control module 10
26 Climate control system blower 30
27 Active chassis FOUR-C 15
28 Electronic module - courtesy lighting 10
29 -
30 Left front/rear parking lights 7.5
31 Right front/rear parking lights, license plate lights 7.5
32 Central electrical module, vanity mirror lighting,
glove compartment light, interior courtesy lighting 10
33 Fuel pump 15
34 Power moonroof 15
35 Central locking system, power windows, left door mirror 25
36 Central locking system, power windows, right door mirror 25
37 Rear power windows 30
38 Alarm siren* 5

* Please be aware that if this fuse is not intact, or if it is removed, the alarm will sound.

pg. 143 Maintenance and service

Fuses in the cargo compartment

No. Amperage
1 Rear electrical module, trunk lighting 10
2 Rear fog light 10
3 Brake light 15
4 Backup lights 10
5 Rear window defroster, Relay 15I - accessories 5
6 Trunk release 10
7 Folding rear head restraints 10
8 Central locking rear doors, fuel filler door 15
9 Trailer hitch (30 feed) 15
10 CD changer, VNS 10
11 Accessory control module (AEM) 15
12 -
13 -
14 Brake lights 7.5
15 Trailer hitch (15I feed) 20
16 Electric socket in trunk - accessories 15
17 All Wheel Drive control module 7.5
18

pg. 144 This page intentionally left blank

Contents | Top of Page

1. Low beam	55W H7
2. Bi-Xenon headlights (option)	35W D2R
3. High beam	55W HB3
4. Brake light Fog light, rear	P21W P21W
5. Direction indicator, Parking light rear + front	PY21W
6.Side marker light, rear Backup light	P10W 21W BA 15s
7. Courtesy lighting	1.2 WSV7
8. Vanity mirror	5WSV8.5
9. License plate lighting Parking light in headlight	W5W W5W
10. Fog lights R-models	55W H1 55W H3

1. Brake light	21 W BA 15 s
2. Parking light (left side)	5 W BA 15 s
3. Fog light (one side)	21 W BA 5 s
4. Side marker lamp	10W
5. Turn signal	PY 21 W
6. Back up light	21 W BA 15 s

Fuses in the engine compartment
No.	Amperage
1 Accessories	25
2 Auxiliary lights (option)	20
3 -
4 Oxygen sensor	20
5 Crankcase ventilation heater, solenoid valves	10
6 Mass air flow sensor, engine control module, injectors	15
7 Throttle module	10
8 A/C compressor, Accelerator pedal position sensor, E-box fan	10
9 Horn	15
10 -
11 A/C compressor, ignition coils	20
12 Brake light switch	5
13 Windshield wipers	25
14 ABS/STC/DSTC	30
15 -
16 Windshield washers, headlight wipers/washers (certain models)	15
17 Low beam, right	10
18 Low beam, left	10
19 ABS/STC/DSTC	30
20 High beam, left	15
21 High beam, right	15
22 Starter motor	25
23 Engine control module	5
24 -

No.	Amperage
1 Low beam headlights	15
2 High beam headlights	20
3 Power driver's seat	30
4 Power passenger's seat	30
5 Speed-dependent power steering, vacuum pump	15
6 -
7 Heated seat, front left (option)	15
8 Heated seat, front right (option)	15
9 ABS/STC/DSTC	5
10 Daytime running lights	10
11 Daytime running lights	10
12 Headlight wipers (certain models)	15
13 Electric socket 12V	15
14 Power passenger's seat	5
15 Audio system, VNS	5
16 Audio system	20
17 Audio amplifier	30
18 Front fog lights	15
19 VNS display	10
20 -
21 Automatic transmission, shiftlock, extended D2 feed	10
22 Direction indicators	20
23 Headlight switch module, climate control system, onboard diagnostic connector, steering wheel lever modules	5
24 Relay extended D1 feed: climate control system, power driver's seat, driver's info	10
25 Ignition switch, relay starter motor, SRS, engine control module	10
26 Climate control system blower	30
27 Active chassis FOUR-C	15
28 Electronic module - courtesy lighting	10
29 -
30 Left front/rear parking lights	7.5
31 Right front/rear parking lights, license plate lights	7.5
32 Central electrical module, vanity mirror lighting, glove compartment light, interior courtesy lighting	10
33 Fuel pump	15
34 Power moonroof	15
35 Central locking system, power windows, left door mirror	25
36 Central locking system, power windows, right door mirror	25
37 Rear power windows	30
38 Alarm siren*	5

No.	Amperage
1 Rear electrical module, trunk lighting	10
2 Rear fog light	10
3 Brake light	15
4 Backup lights	10
5 Rear window defroster, Relay 15I - accessories	5
6 Trunk release	10
7 Folding rear head restraints	10
8 Central locking rear doors, fuel filler door	15
9 Trailer hitch (30 feed)	15
10 CD changer, VNS	10
11 Accessory control module (AEM)	15
12 -
13 -
14 Brake lights	7.5
15 Trailer hitch (15I feed)	20
16 Electric socket in trunk - accessories	15
17 All Wheel Drive control module	7.5
18