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2004 Volvo S60 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volvo REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Volvo S60 car and truck
repair procedures including Volvo engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Volvo S60 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2004 Volvo S60 AUTOMOBILES
Air Bag System Precautions -> Volvo -> Disarming
Vehicle: 2004 Volvo S60 R 2.5 L5 GAS
- Obtain radio anti-theft code, then record station presets.
- On models equipped with microprocessor radio, turn radio off.
- On all models, turn ignition Off.
- Before disconnect...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Volvo S60 AUTOMOBILES
Volvo -> Fuel Filter Scheduled Maintenance -> 2004 S60 & V70 w/2.4L (B5244S6) Engine -> Normal Service -> Severe Service
Vehicle: 2004 Volvo S60 2.4 L5 GAS
Normal Service
...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Volvo S60 AUTOMOBILES
CV AXLE SHAFT, Replace -> Left Side -> Right Side
Vehicle: 2004 Volvo S60 2.4 L5 GAS
Left Side
- Raise and support vehicle on lift.
- Remove front wheel lug nuts.
- Remove splash guard under engine.
- Remove bolt for wheel hub driveshaft.
- Counterhold ball joint using suitable tool so that ball joint boot does not rotate.
- Press down on control arm using suitable tool until it contacts subframe. Position tensioning straps as close to ball joints as possible.
- Unhook spring strut and ball joint from control arm.
- Pull out spring strut and remove driveshaft from hub.
- Hold spring strut to one side using a tensioning strap for more space when removing driveshaft. Later models hav...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Volvo S60 AUTOMOBILES
Starter, Replace
Vehicle: 2004 Volvo S60 2.5 L5 GAS
- Disconnect battery ground cable.
- Remove intake manifold between front cover plate and air cleaner housing.
- On models equipped with turbo, loosen hose clamps between charge air cooler and electronic throttle module, disconnect electrical connector and remove charge air cooler hose.
- On all model...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Volvo S60 AUTOMOBILES
Cabin Air Filter Service -> Volvo -> 1999-2006 S80, 2001-09 S60, 2001-07 V70, XC70 & 2003-09 XC90
Vehicle: 2004 Volvo S60 T5 2.3 L5 GAS
The cabin air filter should be replaced every 15,000 miles. The filter should be replaced more often if air flow is less than normal.
- Remove the sound proofing panel from under the passenger side of the instrument panel.
- Remove the cabin air filter cover retaining screws, then the cover, Fig. .
- Press down on the cabin air filte...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Volvo S60 AUTOMOBILES
Volvo -> Anti-Lock Brake System (ABS)/Dynamic Stability & Traction Control (DSTC)/Stability Traction Control (STC) Warning Lamp ->
Vehicle: 2004 Volvo S60 T5 2.3 L5 GAS
The warning lamp is used to warn of an system fault. The lamp input monitors the condition of the system. The lamp will be lit during engine start-up, but should go out when the self-diagnostic sy...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Volvo S60 AUTOMOBILES
Radiator, Replace
Vehicle: 2004 Volvo S60 2.5 L5 GAS
- Remove electric cooling fan.
- On turbocharged models, disconnect charge air pipe from charge air cooler (CAC) on lefthand side. If necessary, use a hot air gun to make removal easier
- On all models, remove screws for radiator unit on front cover plate.
- Remove two upper screws holding radiator unit together.
- Remove expansion tank cap.
- Block upper radiator hose with lock grip pliers.
- Raise and support vehicle.
- Remove air baffles.
- Remove lower oil cooler hose from radiator unit. Collect oil in a suitable container.
- Remove screw for mounting for cable duct for engine wiring at front edge of...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Volvo S60 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Volvo S60 2.4 L5 GAS
- Rotate or lift the belt tensioner arm, using a suitable tool to relieve tension from dr...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Volvo S60 AUTOMOBILES
Component location diagrams for most 2004 Volvo S60 cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Diagram for 2004 Volvo S60 2.5 L5 GASComponents on diagram: |
 Telephone Components Diagram for 2004 Volvo S60 T5 2.3 L5 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2004 Volvo S60 AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Volvo S60 cars and light trucks sold in the U.S.
 2004 Volvo S60 R 2.5 L5 GAS Wiring DiagramComponents on diagram: |
 2004 Volvo S60 2.4 L5 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Volvo S60 AUTOMOBILES
OEM TSB listings for most 2004 Volvo S60 cars and light trucks sold in the U.S. from 1985+.
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Document: TRANSMISSION CONTROL MODULE (TCM), SOFTWARE (SW) - REVISED Vehicle: 2004 Volvo S60 2.4 L5 GAS Auto Systems: |
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Document: DIFFERENTIAL ELECTRONIC MODULE (DEM), SOFTWARE (SW) - REVISED Vehicle: 2004 Volvo S60 2.4 L5 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Volvo S60 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Volvo S60 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Volvo S60 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Volvo S60 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Volvo S60 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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