Description
Factory Volvo S60 Workshop Manual PDF (2001–2009, First Gen P2)
The first-generation S60 (P2 chassis) was Volvo’s entry into the compact executive sedan class. This is the factory PDF workshop manual covering its entire 2001-2009 production run in a flat, printable, readable format — separate from our VIDA/VADIS dealer software listing for the same vehicle.
Who This Manual Is For
DIY S60 owners who prefer a PDF they can print and bookmark, independent mechanics who don’t need VIDA’s interactive diagnostics, and anyone wanting a quick-reference document for common procedures.
Powertrain Coverage
| Component | Variants Covered |
|---|---|
| Petrol 5-cyl | 2.0T, 2.3T, 2.4T, 2.5T (B5244, B5254 series) |
| S60 R | B5254T4 300 hp 5-cylinder turbo + Haldex AWD + Four-C suspension |
| Diesel | D5 2.4L 5-cyl (D5244T series) |
| Transmissions | 5MT, 6MT, 5-speed Geartronic automatic |
| Drive | FWD and Haldex AWD (S60 R and AWD variants) |
| Model Years | 2001–2009 |
Common S60 Repairs Covered
| System | Procedures |
|---|---|
| 5-cyl turbo | PCV system service (common), timing belt replacement, turbo diagnosis |
| Angle gear (AWD) | Angle gear bushing/collar replacement (common S60 R issue) |
| Geartronic 5AT | Aisin AW55-50SN fluid service, valve body diagnostics |
| Four-C suspension | Electronic damper diagnosis, control module (S60 R) |
| Electrical | CEM module, ABS/DSTC, SRS airbag, climate control |
What’s Inside the Manual
Complete Volvo factory chapter set: diagnosis and specifications, engine management (5-cyl turbo and D5 diesel), fuel and exhaust, emission control, lubrication and mechanical, manual and Geartronic automatic transmissions, brake system with ABS/DSTC, front and rear axles, Haldex AWD and angle gear, steering, climate control (ECC), scheduled maintenance, lighting and switches, clutch, propeller shaft and rear differential, cooling system, full electrical with wiring diagrams, suspension (inc. Four-C for S60 R), wheels and tyres, body and chassis, interior trim, and safety systems.
Format & Delivery
Professional PDF — searchable, printable. Compatible with every OS and device. Instant download; lifetime re-downloads.
Frequently Asked Questions
Does this cover the S60 R?
Yes. The S60 R with B5254T4 300 hp 5-cylinder turbo, Four-C adaptive suspension, and Haldex AWD is fully covered.
Is this the same as the VIDA software version?
No — this is a flat PDF manual. The VIDA/VADIS dealer software is a separate product (see our Volvo S60 VIDA listing) with interactive wiring, VIN filtering, and fault-code integration.
What’s the common S60 issue?
PCV system failure on the 5-cyl turbo engines. Complete diagnostic and replacement procedure included.
Does this cover the D5 diesel?
Yes. The 2.4L D5 diesel with common-rail injection is covered including swirl-flap and DPF (later models) diagnostics.
What format is the manual?
PDF, searchable, printable. Instant download.
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