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The closest wiring diagram I could find is for a 2002 S60, but it should be OK....
Locate it here:
http://www.volvowiringdiagrams.com/?dir=volvo/S60%20Wiring%20Diagrams
Pg 8 of the diagram says that fuse number 7 powers the Fan Controller. Is the fuse good?
Pg 44 illustrates the Fan System wiring.
4/71 = fan controller
6/29 = fan motor
7/8 = AC pressure sensor
7/16 = coolant temp sensor
Either the AC pressure sensor OR the Coolant sensor (or both at the same time) can trigger the fan, via the violet wire running from the CEM to the Controller. However, the coolant sensor performs double duty as it is also the sensor for the temp gauge, so if the gauge is working properly then you can probably eliminate that sensor from being a suspect. The AC pressure switch "could" be a suspect and that can be tested by unplugging it and jumping the wires.
A very likely suspect though is the fan controller. I assume that when you tested the fan motor you applied power to the white wire BETWEEN the controller and the fan motor. So if you're getting constant power through the red Controller wire (which you should get even with the key off) and you get a trigger signal through the violet wire, yet the fan won't run, then the Controller really starts to look guilty.
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Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)
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