The timing belt is very tricky to replace and requires a special tool to align the pulleys. It sounds like you may be off a tooth or two on the pulleys which will affect the cam position.
SOURCE: Problem with 2002 Volvo S60 automatic Gearbox
Make sure that you have the transmission software updated. Volvo has had many upgrades on their transmission's control software to address these exact symptoms.
Bret
RepairPal.com
SOURCE: Replace timing belt on Volvo S60
There is no room for error...... Zero clearance. If off one tooth it can and will bend valves. if you are one that just feels the need to get alittle dirty or just can't pay for the service, then get out your Haynes out and turn to .....Tune up, and look at replacing timming belt. Get a cam gear tool that locks them into place so as that they will not move when u have them lined up. make sure they are lined up with marks as said in book. then make sure crank as well as all marks are lined up acordingly. make sure belt marks are lined up with everything. i would reccomend using a volvo belt though cause it will have all the marks on it.However other company's make good quality belts also at a fraction of the price. So it is really up to you.
Good thing when doing timming belt is to also change out your timming belt tensioner. YES do this it will save you a engine in the long run. it is a moving part that will go bad, it will freeze up and snap timming belt. rip out teeth in thebelt and bend valves. So as a gen rule...When you change timming belt, Change belt tensioner at same time since you cant just change tensioner without changing or getting timming belt off. Remember to use your HAYNES. It is your friend and will save you money in the long run. Good luck... Hope this helps you.
SOURCE: adjusting headlights volvo s60 2002
There is 2 white 6mm adjustmentbolts on the backside of the headlight
SOURCE: 2002 Volvo S60 with Engine fault codes
THE 445 IS THE EVAP PURGE VALVE IT MAY BE BAD BOTH 446 IS SAME VAVLE YOU NEED TO SEE IF THE HOSE ARE GOOD ON THIS VAVLE MAKE SHERE NO CRACKS IF NOT PULL HOSES AND SEE IF SOMTHING IN VAVLE ITS NEAR THE CANSTER AND THAT IS NEAR THE GAS TANK UNDER CAR PUT CHECK GAS CAP MAKE SHERE ITS TIGHT HOPE THIS HELPS
SOURCE: need Volvo 04 s60 timing belt diagram and install
My apologies for the delayed response. I am going back and answering questions that were never answered.
Click on the following Link. It has all the Diagrams for the Timing Belt you will need.
Before Clicking, let me know if this helped.
Again my sincerest apologies...
http://www.2carpros.com/car_repair_information/year/2004/make/volvo/model/s60/2004_volvo_s60_timing_belt_diagram_marks.htm
As far as the install info, due to the sheer volume and number of steps that would have to be included, you may want to purchase a Haynes Manual or Chilton Manual at an auto parts store for around $20 to $25. The above site also has On-Line Repair Manual you can purchase.
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