Welcome to the comprehensive service and repair guide for the Volvo S60, specifically covering the 2004 model year. This vehicle, belonging to the P2 generation (chassis code 393), exemplifies Volvo's enduring commitment to safety, reliability, and sophisticated Scandinavian design. Known for its robust engineering and advanced safety features, including a 5-star NHTSA rating for front and side crash tests and advanced systems like WHIPS and SIPS airbags, the S60 offers a premium driving experience. It was available with various engine options, including 2.4L and 2.5L turbo variants, and offered both manual and automatic transmissions, making it a versatile choice for discerning drivers. This factory service manual provides an extensive collection of procedures and technical data essential for the maintenance, diagnosis, and repair of your 2004 Volvo S60. It covers all major vehicle systems in detail, including the engine, transmission, brakes, electrical system, suspension, steering, and HVAC. With step-by-step instructions, detailed illustrations, and critical notes, this manual empowers both do-it-yourself owners and professional mechanics to efficiently troubleshoot issues, perform routine maintenance, and undertake complex repairs, ensuring the longevity and optimal performance of the vehicle. 🏷️ Basic Information Identification Make: Volvo Model: S60 Year: 2004 Generation Generation Code: P2 Codes Chassis Code: 393 👋 Introduction Market Position Target Audience: Do-it-yourself owners and experienced mechanics seeking comprehensive repair information. Competitive Analysis Value Proposition: Inexpensive way to keep vehicle working properly, avoids costly dealership repairs. Key Features Feature Benefit: Step-by-step instructions with high-quality illustrations ensure accuracy and ease of use. Feature Benefit 2: No waiting for shipping or paying for physical delivery, instant access via download. 📋 Manual Details Coverage Areas Primary Coverage: Complete Workshop Service and Repair Page Count Estimated Pages: Hundreds (specific number not provided, but described as extensive) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service Repair: Comprehensive procedures for engine maintenance, diagnostics, and repair. Transmission Service Repair: Detailed instructions for both automatic and manual transmission service. Brake System: Covers all aspects of the braking system, including ABS and electronic brake-force distribution (EBD). Wiring Diagram: Detailed and specific wiring diagrams for electrical system troubleshooting. Electrical System: In-depth coverage of all electrical components, circuits, and diagnostics. Suspension: Front and rear suspension component inspection, repair, and alignment procedures. Steering: Power steering system, steering column, and wheel alignment procedures. Cooling System: Radiator, thermostat, water pump, and fan system service. Fuel Injection: Fuel injector diagnostics, cleaning, and replacement procedures. Fuel System: Fuel pump, fuel filter, and fuel tank service. Emission System: Catalytic converter, oxygen sensors, and emission control component service. Heater Air Conditional: HVAC system operation, diagnosis, and repair, including refrigerant handling. Engine Control System: ECM/PCM diagnostics, sensor inputs/outputs, and driveability troubleshooting. Chassis Body: Body panel repair, chassis components, and structural information. Restraint System: Airbag system diagnostics, service, and replacement procedures. Interior: Trim removal, interior component service, and dashboard diagnostics. Differential Drive: Front and rear differential service and maintenance. Axle: Axle shaft and CV joint service. General Maintenance: Routine service procedures, fluid checks, and filter replacements. Periodic Lubrication: Lubrication points and recommended lubricants for various components. Procedures Included Diagnostic Procedures: Troubleshooting guides and diagnostic steps for common and complex issues. Repair Procedures: Step-by-step instructions for component removal, repair, and installation. Maintenance Procedures: Scheduled maintenance tasks, fluid changes, and inspections. Assembly Disassembly: Complete disassembly and reassembly guidance for major vehicle systems. Technical Depth Depth Level: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Documentation Quality: Hundreds of photos and illustrations, detailed drawings, and bolded figure numbers for clarity. Information Enhancements: Notes, cautions, and warnings highlighting critical information within procedures. 📊 Manual Specifications File Format Format: PDF Compatibility: Compatible with all PC-based Windows operating systems and Mac. Print Quality Printability: Printable without restriction, allowing users to print entire manual or specific pages. Binding Type Binding Style: Digital Download (user printable) Paper Type Physical Medium: Digital PDF file (can be burned to CD-ROM by user) Requirements Software Required: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Options: Likely includes 2.4L (B5244S, B5244S4) and 2.5L Turbo (B5254T2 - T5) engines, with manual covering all applicable variations. Performance Horsepower Range: Approximately 168 hp for naturally aspirated and 257 hp for T5 models (specific to engine variant). Torque Range: Approximately 170 lb-ft for naturally aspirated and 295 lb-ft for T5 models (specific to engine variant). Fuel System Injection Type: Electronic Fuel Injection (EFI) with multi-point or direct injection depending on engine variant. 🔧 Transmission Standard Transmission Options: Likely includes a 5-speed manual transmission (M56H) and a 5-speed automatic transmission (AW55-50SN). Optional Optional Transmission: All available transmission options for the 2004 S60 are expected to be covered. Features Transmission Control: Information on electronic transmission control modules (TCM) and associated sensors. 📐 Dimensions Exterior Length: Approx. 180.0 inches (4572 mm) Width: Approx. 70.5 inches (1791 mm)...