Documentation

Volvo S60: Intercooler Replacement

My intercooler got damaged by some road debris, though they apparently have a habit of blowing anyway due to the high boost pressure used (particularly on diesel models).

This documentation details the process of removing and replacing the intercooler. No part of it is particularly difficult, but it's an involved process and takes some time (especially the first time). As a guide, it took me just short of 4 hours to do (fag breaks included).

I performed this process without lifting the car, however at times it was a little tight, so if I even repeat the process I'll probably put the car on ramps or stands.

 

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Volvo S60: Lower Control arm and Balljoint Replacement

After nearly 240,000 miles the rubbers on my lower control arm (or wishbone) were perished, and the lower balljoint (LBJ) was starting to feel questionable too.

This procedure is to replace both on the left hand side (i.e. Gearbox end of the engine). The procedure for the right hand side (i.e. Cambelt end) is almost exactly the same, but with one (fairly large caveat) - to access the front-mount bolts on the right hand side, you will need to raise that end of the engine by about 25mm. You can get away without this if you're very lucky (or have extremely shallow sockets) but for that side of the car, plan as if you're going to have to raise the engine slightly so that your ratchet doesn't foul on the sump.

Also, if you're doing the right hand side (offside), be very careful of the driveshaft - it's incredibly easy to accidentally pull the shaft out of the inner CV joint - if you do this you'll need to replace the driveshaft. It's a common occurrence when changing the offside control arm on the S60 and V70 apparently

I was in a bit of a hurry doing this job, and unfortunately forgot to take pictures. The pictures below were all taken after the fact.

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Volvo S60: Service Interval Reset

This is one of those things where the procedure's easy, but I use it so infrequently that I always have to look it up.

When a service is due, the S60 will display the message "Time for Regular Service". This documentation details the procedure to reset it once you've done the service.

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Volvo S60: Alternator Replacement

A few days ago, I started bearing noise (like air being released) from the general area of the auxillary belt. As it's freezing outside, I booked it into the garage and hoped it could make it the few days until the garage could see it.

Inevitably, it didn't. After starting the battery warning light came on, and as the belt was still on I checked the battery voltage - 11v and dropping, goodbye alternator bearing...

This documentation details the steps necessary to swap out the alternator on a 2003 Volvo S60 with a Diesel engine. The steps differ slightly for later years (you need to remove the radiator cooling fan to make space to get the alternator out, but can simply move the P/S pump out of the way rather than disconnecting it), but should be applicable for vehicles <= 2003. From what I've seen, it should also apply to V70's of the same age.

Some of the images are a little blurry because the weather was getting ready to snow on me, so there was quite a bit of shivering involved.

The whole process shouldn't take you more than a couple of hours, unless you have to wait for replacement parts to arrive. 

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Volvo S60: Headlight Unit Replacement

My 2003 S60 had a chip in the headlight lens, which over time, expectedly, developed into a crack.

This documentation details how to replace a headlight unit on Volvo S60's up to 2003 (there are some slightly different mountings on models from 2004 onwards). The procedure is more or less the same for both sides

The entire process doesn't take long, at most it should take a couple of hours

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