Installation instructions, accessories. Body kit

Size: px

Start display at page:

Download "Installation instructions, accessories. Body kit"

Bonnie Jacobs
6 years ago
Views:

1 Installation instructions, accessories Instruction No Version Part. No. Body kit IMG Volvo Car Corporation Body kit V1.1 Page 1 / 42

2 Equipment A A IMG IMG Page 2 / 42

3 IMG Page 3 / 42

4 INTRODUCTION Read through all of the instructions before starting installation. Notifications and warning texts are for your safety and to minimise the risk of something breaking during installation. Ensure that all tools stated in the instructions are available before starting installation. Certain steps in the instructions are only presented in the form of images. Explanatory text is also given for more complicated steps. In the event of any problems with the instructions or the accessory, contact your local Volvo dealer. Removal 1 Removal Rear bumper cover IMG Page 4 / 42

5 2 IMG IMG Page 5 / 42

4 IMG-240964 5A Illustration A Remove the bumper cover from the body by carefully prying off the ends using a weatherstrip tool.

6 4 IMG A Illustration A Remove the bumper cover from the body by carefully prying off the ends using a weatherstrip tool. Pull off the cover under the tail lamp and from the rear edge of the wing on each side. It is secured by four clips at the tail lamp and four in the rear edge of the rear wing. Pull the bumper cover straight back. Illustration B Unplug the connector for the licence plate lighting on the left side. If the car is equipped with reverse warning, then unplug the connector for this on the right side. 5B IMG IMG Page 6 / 42

6 Wheel housing edges Carefully bend loose the rear fender's panel starting at the trailing edge and then forward. Bend with the weatherstrip tool right at the side of the clips.

7 6 Wheel housing edges Carefully bend loose the rear fender's panel starting at the trailing edge and then forward. Bend with the weatherstrip tool right at the side of the clips. The panel is fastened with a catch at the trailing edge and five clips all the way around. The panel shall not be used again. Note! Do not damage the paint work. IMG Loosen the fender liner with the three clips from the panel's clips by first pressing it in until the three clips release, and then folding it down. Remove the three clips in the fender liner's upper edge and all clips in the fender edge. New clips are included in the kit. Clean the fender edge. IMG Page 7 / 42

8 8 IMG IMG Page 8 / 42

10 Carefully bend loose the front fender's panel starting at the leading edge and then backward. Bend with the weatherstrip tool right at the side of the clips.

IMG-256272 11 Loosen the fender liner with the three clips from the panel's clips by first pressing it in until the three clips release, and then folding it down.

9 10 Carefully bend loose the front fender's panel starting at the leading edge and then backward. Bend with the weatherstrip tool right at the side of the clips. The panel is fastened with a catch at the leading edge and seven clips all the way around. The panel shall not be used again. Note! Do not damage the paint work. IMG Loosen the fender liner with the three clips from the panel's clips by first pressing it in until the three clips release, and then folding it down. Remove the three clips in the fender liner's upper edge and all clips in the fender edge. New clips are included in the kit. Clean the fender edge. Repeat steps 6-11 for the other side. IMG Page 9 / 42

12 Front bumper cover Remove the panel to the left and right fog light by carefully pressing in the catches in the panel's upper edge with a weatherstrip tool and pull it loose.

10 12 Front bumper cover Remove the panel to the left and right fog light by carefully pressing in the catches in the panel's upper edge with a weatherstrip tool and pull it loose. The panel is fastened with six catches. IMG Steps apply to cars with 4-cylinder engine where electric engine heater is installed Remove the seven screws from the engine splash guard. J Page 10 / 42

11 14 Remove the left front wheel. Remove the five screws holding the bumper cover in the wing liner on the left and right-hand sides. J Remove the nut holding the left-hand wing liner to the front member. Bend the front edge of the left-hand wing liner up over the brake calliper. J Page 11 / 42

12 16 Remove the lock sleeve over the joint to the engine heater's cable on the left side by the stay on the sub-frame. Unplug the connectors. J Loosen the cable from the double clamp (1) at the brake pipe and from clamps along the side member's underside. J Page 12 / 42

13 18 Loosen the ground cable from the leading edge of the side member's outside. J Cut off the cable tie (1) that holds the cable to the left radiator bracket. J Page 13 / 42

14 20 Steps apply to cars with 5-cylinder engine where electric engine heater is installed Remove the seven screws from the engine splash guard. J Remove the left and right-hand front wheels. Remove the five screws holding the bumper cover in the wing liner on the left and right-hand sides. J Page 14 / 42

15 22 Remove the nut holding the left-hand wing liner to the front member. Bend the front edge of the left-hand wing liner up over the brake calliper. J Remove the lock sleeve over the joint to the engine heater's cable on the right side by the stay on the sub-frame. Unplug the connectors. Applies to cars for USA For cars to the USA there is no splice (joint) on the cable. Then this is loosened instead by the engine heater. J Page 15 / 42

16 24 Loosen the cable from the double clamp on the brake pipe on the right side in the engine compartment. J Remove the cable tie that holds the cable to the cable harness at the top in the engine compartment. J Page 16 / 42

IMG-256275 27 Loosen the cable from the double clamp by the

17 26 Loosen the cable from the clips along the metal edge in the trailing edge of the engine compartment. IMG Loosen the cable from the double clamp by the brake pipe in the top edge of the bulkhead on the left side. J Page 17 / 42

18 28 Loosen the cable from the double clamp (1) at the brake pipe and from clamps along the side member's underside. J Does not apply to cars for USA. Loosen the ground cable from the leading edge of the side member's outside. J Page 18 / 42

19 30 Cut off the cable tie (1) that holds the cable to the left radiator bracket. J Applies to all models Push in the centre of the five clips (1). Remove the clips. Remove the two screws (2). J Page 19 / 42

32A Illustration A Remove the covers for the nozzles for the headlamp washers on the right and left-hand sides. Carefully grip the cover. Pull the cover out until the catch becomes accessible.

20 32A Illustration A Remove the covers for the nozzles for the headlamp washers on the right and left-hand sides. Carefully grip the cover. Pull the cover out until the catch becomes accessible. Illustration B Press the catch up and remove the cover. Do not damage the painted surfaces or the high-pressure washer nozzles. 32B J J Remove the four screws that hold the bumper's lower part in the baffle. Remove the spring nuts that hold the baffle in the bumper casing's lower part on both sides. IMG Page 20 / 42

21 34A Illustration A Carefully pry off the corner of the bumper cover using a weatherstrip tool until the three hooks on the inside release. Illustration B Remove the bumper cover with air baffle by grasping the ends and pulling forwards until the remaining hooks under the lamps release. Note! Get help from a colleague for this procedure. 34B IMG Disconnect the connectors for the fog lamps or parking assistance if applicable. IMG Page 21 / 42

22 35 Door sill panel IMG Drive out the centre pin in the clips on the underside of the bottom sill's panel. On the two front clips, the centre pins may have to be drilled out to be able to remove the clips. Turn loose the panel from the bottom sill's underside so that the clips come loose. IMG Page 22 / 42

37 Remove the bottom sill's panel by carefully bending it loose directly opposite the clips along its entire length. Note! Do not damage the paint work. Remove the rubber strip from the panel.

23 37 Remove the bottom sill's panel by carefully bending it loose directly opposite the clips along its entire length. Note! Do not damage the paint work. Remove the rubber strip from the panel. Lay away the panel but the rubber strip is to be used again. Repeat steps for the other side. IMG Installation 38 Installation Rear spoiler Applies to cars with reverse warning Loosen the clips for the cable harness for the reverse warning's sensors from the lower part's catches. IMG Page 23 / 42

The lower part shall not be used again. Note! Do not damage the painted surface on the upper part.

24 39 Get help from a colleague for this procedure. Place the bumper casing on a surface that will not damage the painted surface. Carefully bend and pull loose the bumper's lower part from the upper part. It is fastened with catches all the way around. The lower part shall not be used again. Note! Do not damage the painted surface on the upper part. IMG Get help from a colleague for this procedure. Take the rear spoiler from the kit and press the upper part into it. Make sure that all catches engage. Note! Do not damage the painted surface on the upper part. IMG Page 24 / 42

25 41 Applies to cars with reverse warning Press in the clips for the cable harness for the reverse warning in the spoiler's catches. IMG Press on the reflectors from the kit on the spoiler's ends. Applies to cars for USA market Paint the covers from the kit according to information in VIDA "Repair painting section 8 (80)". Press on the covers. IMG Page 25 / 42

26 43 Insert the plastic string for the towing eye's in the rectangular hole in the lower edge of the opening. Press in the panel in the opening. IMG Applies to cars where the end-pipe is not to be visible. Press on the cover for the exhaust pipe opening so that the catch at the top edge engages. Press in the two clips in the slots on the cover. IMG Page 26 / 42

27 45 IMG IMG Page 27 / 42

28 47 IMG IMG Page 28 / 42

Place the bumper casing on a surface that will not damage the painted surface.

29 49 Front spoiler Loosen the holder from the bumper casing's upper part on both sides. IMG Get help from a colleague for this procedure. Place the bumper casing on a surface that will not damage the painted surface. Carefully bend and pull loose the bumper's lower part from the upper part. It is fastened with catches all the way around. The lower part shall not be used again. Note! Do not damage the painted surface on the upper part. IMG Page 29 / 42

30 51 Take the front spoiler from the kit. Note! The unpainted spoiler must be painted first. Clean the marked areas underneath the spoiler where the antichafing protector is to be located. Use isopropanol. Wipe dry. IMG Remove the protective tape from the anti-chafing protector. IMG Page 30 / 42

31 53 Position and secure the anti-chafing protector along the edges of the spoiler at the rear edge. IMG Press the anti-chafing protector at the rear edge forwards. IMG Page 31 / 42

32 55 Remove the protective tape from the anti-chafing protector. IMG Press the anti-chafing protector into place. IMG Page 32 / 42

33 57 Remove the protective tape from the anti-chafing protector. IMG Press the anti-chafing protector into place. Repeat steps for the other side. IMG Page 33 / 42

34 59 Press the front spoiler into the upper section. Make sure that all catches engage. Note! Do not damage the painted surface on the upper part. IMG Reinstall the bumper cover. Make sure that the spoiler fits in the leading edge on the baffle. IMG Page 34 / 42

35 61 Secure the bumper casing with the clips (1) and screws (2). J Pull up the high-pressure nozzle from the bumper casing and install the covers on both sides. IMG Connect the cable for the engine heater, if applicable. Route and clamp it in the same way as it was installed before. Replace cut cable ties with new ones. Note! Do not clamp the cable directly to AC pipes, fuel lines, brake pipes or power steering hoses and pipes. Make sure the cable does not chafe against sharp edges or moving parts in the engine compartment. Remount the front wheel and tighten the wheel bolts to 90 Nm (66 lbf.ft.). Page 35 / 42

36 64 Tighten the spoiler's brackets to the baffle. Tighten the baffle's outer screw on both sides. IMG IMG Page 36 / 42

37 66 IMG Door sill panel Get a new bottom sill panel and new clips from the kit. Replace all clips. Install the rubber strip from the old panel on the new. IMG Page 37 / 42

IMG-256297 69 Get new clips from the kit and secure

38 68 Press in the new panel in the bottom sill. Make sure all catches engage. IMG Get new clips from the kit and secure the panel in the lower edge. Repeat steps for the other side. IMG Page 38 / 42

39 70 Wheel housing edges Get the new panel and new clips for the fender edge from the kit. Install new clips in the panel. IMG Get new clips from the kit and install these around the fender edge. IMG Page 39 / 42

40 72 Reinstall the fender liner. Get new clips from the kit and press in to the fender liner. Press in the fender liner with clips in the fender edge's clips. Make sure that the clips really snap into place. IMG Press in the new panel on the fender edge. Make sure all catches engage. IMG Page 40 / 42

41 74 IMG IMG Page 41 / 42

42 76 IMG Repeat steps for all wheel housing edges. IMG Page 42 / 42

Installation instructions, accessories. Electric engine block heater, connector outlet, 4-cyl

Installation instructions, accessories Instruction No 31359444 Version 1.2 5 Part. No. 31359438 Electric engine block heater, connector outlet, 4-cyl IMG-247665 Volvo Car Corporation Electric engine block