2005 Volvo S60 Service and Repair Manual

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Factory-Grade Data

2005 Volvo S60 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • 2.5T AWD Sedan 4-Door
  • 2.4 Sedan 4-Door
  • 2.5T Sedan 4-Door
  • R Sedan 4-Door
  • T5 Sedan 4-Door

Engines covered

  • 2.5L 2521CC l5 GAS DOHC Turbocharged
  • 2.4L 2435CC l5 GAS DOHC Naturally Aspirated
  • 2.5L 2521CC 154Cu. In. l5 GAS DOHC Turbocharged
  • 2.4L 2435CC l5 GAS DOHC Turbocharged
  • 2.3L 2319CC l5 GAS DOHC Turbocharged

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2005 Volvo S60 Recalls & Complaints

NHTSA #21V76600030/09/2021Component: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

Volvo Car USA, LLC (Volvo Car) is recalling certain 2001-2006 S80 and 2001-2009 S60 vehicles. The driver's air bag inflator may explode during deployment, due to propellant degradation occurring afte

Consequence

An inflator explosion may result in sharp metal fragments striking the driver or other occupants, re

Remedy

Dealers will replace the driver's air bag, free of charge. Owner notification letters were mailed N

NHTSA #10V56600008/11/2010Component: EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence

AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

Remedy

VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE

TSB #11032678

This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure Description and Service sections updated to clarify that vehicle reports are not required.

TSB #11032671

This is a TJ text only - The purpose of this TJ is to be a master reference list to easily identify any components that are on prior approval. This TJ will be regularily updated as items are added or removed from prior approval. Curren

TSB #11027173

This is a Technical Journal. Vehicle type and platform identification.

TSB #11020437

This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. C

TSB #11016002

Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing i

TSB #11015994

Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing i

TSB #11014113

This is a Technical Journal: Vehicle/Connectivity report checklist. To provide timely and high-quality feedback to the appropriate department or factory

TSB #11014112

This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. C

Showing the 8 most recent of 174 technical service bulletins on file with NHTSA.

20211109Component: SEATS

While I was driving I felt very hot under my buttock than I heard it pop and burst, I pulled over to check, oh my got (OMG) thanks God I'm safe! There was a burn on my car seat!

20190817Component: ELECTRONIC STABILITY CONTROL (ESC)

ANGLE/COLLAR GEAR/SLEEVE, HALDEX AWD. HUNDREDS OF THOUSANDS OF AWD VOLVOS HAVE THIS ISSUE YET VOLVO HAS NEVER TAKEN ACTION OR RECALLED PART. THIS IS JUST ONE OF MANY ISSUES THOUSANDS OF VOLVO'S HAVE.

20190817Component: POWER TRAIN

ANGLE/COLLAR GEAR/SLEEVE, HALDEX AWD. HUNDREDS OF THOUSANDS OF AWD VOLVOS HAVE THIS ISSUE YET VOLVO HAS NEVER TAKEN ACTION OR RECALLED PART. THIS IS JUST ONE OF MANY ISSUES THOUSANDS OF VOLVO'S HAVE.

20170913Component: SEAT BELTS

MY SEAT BELT GOT STUCK IN THE FRONT PASSENGER SIDE . NOW I'M GETTING A SERVICE MESSAGE ABOUT THE SRS SERVICE URGENT I DON'T KNOW WHY IT GOT STUCK BUT IT DID I CAN'T GET IT OUT OF SEAT BELT CLIP .

20160723Component: UNKNOWN OR OTHER

APPLIED BRAKE, ENGINE CONTINUED TO ACCELERATE. I HAD TO PUMP THE BRAKE SEVERAL TIMES RAPIDLY BEFORE THE ENGINE DECELERATED. THIS HAS OCCURRED ON SEVERAL OCCASIONS.

Showing the 5 most serious of 57 complaints filed with NHTSA.

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