2005 Volvo S60 Service and Repair Manual

This factory service and repair manual for the 2005 Volvo S60 takes in the four-door sedan across 2.4, 2.5T, 2.5T AWD, R and T5 trims. Its engine list holds four DOHC gasoline inline-fives, pairing a naturally aspirated 2.4-liter with turbocharged 2.3-liter, 2.4-liter and 2.5-liter (154 cu in) versions. Procedures, specifications, torque values, wiring diagrams and diagnostics cover the engine, fuel and ignition systems, cooling, transaxle, drivetrain, brakes, suspension, steering and electrical system.

Engines covered

• 2.3L inline-five — DOHC, turbocharged, gasoline
• 2.4L inline-five — DOHC, naturally aspirated, gasoline
• 2.4L inline-five — DOHC, turbocharged, gasoline
• 2.5L inline-five (154 cu in) — DOHC, turbocharged, gasoline

Body styles covered

• 4-door sedan

Trims covered

• 2.4
• 2.5T
• 2.5T AWD
• R
• T5

Known issues on the 2005 S60. There are 3 recalls on the federal record for the 2005 S60. Certain 2005 S60 sedans carried a misprinted tire and loading label, which could lead owners to overload the car or set the wrong inflation pressure and risk a tire failure; correct labels went out by mail. The driver's airbag inflator on certain cars could burst during deployment after its propellant aged in heat and humidity, and a new driver airbag was fitted. Owners submitted 44 complaints: 7 on the engine and engine cooling, 6 on the electrical system, 6 on tires, 5 on the gasoline fuel system and 4 on structure. Tire and wheel specifications and electrical wiring diagrams relate to these systems.