Sport chassis kit, front and rear

Illustration A applies to the S60

• Remove the cargo compartment carpet at the rear edge. First turn the two handles (1) a quarter turn.
• Pull up the front of the cargo compartment carpet. Fold the front half back over the rear part of the carpet.
• Slide the entire carpet forward slightly. Twist slightly to remove the carpet through the tailgate opening. Remove the cargo compartment carpet.

Illustration B applies to the V70

Remove:

• the front floor hatch by lifting it slightly at the rear edge, and pull it from its mountings.
• the front insulation mat.

Applies to the S60

• Press the middle of the clips until a click is heard, and remove them. Also remove the plastic nut at the front edge of the panel.
• Repeat the operation on the right-hand side.

Applies to the S60

• Turn the handle (1) on the left and right-hand sides a quarter turn.
• Fold the side panels inwards. Lift the panels out.

Applies to the S60

• Remove the clips (1) from the left front side panel in the cargo compartment.
• Repeat the operation on the right-hand side.

Applies to the S60

• Fold both the rear backrests forward.

Applies to the S60

• Remove the clip (1) at the side of the left-hand side bolster.
• Pull out the left front side panel at the top edge, and remove the panel.
• Repeat the operation on the right-hand side.

Applies to both the S60 and V70

• Remove the foam rubber seal above the rear shock absorber mountings on the left and right-hand side.

Remove:

• the nut (1) to the shock absorber
• the screws (2) to the upper shock absorber bearing

• Raise the car.

Remove:

• the rear wheels
• the lower screw (1) to the shock absorber
• the shock absorber (2) and the upper bearing.

• Relieve the lower trailing arm (1). Use a workshop lift.
• Remove the screw (2) for the trailing arm.
• Carefully lower the mobile jack.
• Remove the spring (3) by pushing the trailing arm down.

Remove:

• the nut (1) for the anti-roll var. Use a Torx wrench as a counterhold to protect the rubber boot.
• the anti-roll bar's outer end (2) from the control arm's lower ball joint bolt (3).

Remove:

• the mountings (1) for the handbrake cables.
• the rear mountings (2) for the centre silencer.
• the screws (3) for the anti-roll bar mountings (4) from the base plate on the left and right-hand sides.
• the anti-roll bar (5). Pull the anti-roll bar out from the side while twisting it.

• Insert the new anti-roll bar from the side and over the exhaust pipe. Turn it at the same time to locate it in the correct position.
• Press the mountings (1) for the anti-roll bar up against the base plate mountings. Use the mobile jack.

Install:

• new screws (2) and nuts (2) and tighten to 80 Nm (60 ft.lbf.), see point en-GB0900c8af848d8299#KC01166106.
• the mountings for the handbrake cables (3) and tighten.
• the mountings (4) for the centre silencer.

Reinstall:

• the anti-roll bar's outer end to the control arm's lower ball joint bolt, see point en-GB0900c8af848d8299#KC01166105.
• the nut and tighten to 80 Nm (60 ft.lbf.). Use socket (part no. 9995500) and Torx wrench as a counterhold.

• Remove the rubber liner (1) for the spring turret. Position the liner on the new, or the old, spring. Adjust the rubber liner so that the groove (2) locates against the spring.

Подсказка: Lubricate the rubber liner using soap solution to facilitate installation.
- Install the spring in the turret with the rubber liner uppermost.
- Lift up the trailing arm slightly so that the spring is resting against the bottom of the trailing arm.

• Install the mobile jack under the trailing arm (1). Carefully press upwards. At the same time, adjust the position of the spring so that it aligns in the groove (2) on the bottom of the trailing arm.
• Press up and adjust the trailing arm into its mounting (3).
• Install the new screw (4) in the trailing arm as far in as possible.
• Position the mobile jack as indicated by the arrow (5). Align the screw (4) correctly. Tighten the screws loosely.

• Raise the new shock absorber (1) through the lower trailing arm and spring.
• Install the new bearing on the shock absorber through the spring so that the Volvo marking and the P/N are on the upper side. Align the three holes.
• Raise the shock absorber and the bearing up into the spring turret.
• Locate the shock absorber lower mounting (2) in the trailing arm.
• Install the new screw (3). Tighten to 80 Nm (60 ft lbf.)

Tensioner (P/N 999 5659) is used when working on the suspension. It is vital that the screwed joints to the rubber bushings are tightened in the normal position (in the same position as when the car is on the ground). The tensioners relieve the pressure on the components in the suspension when removing and installing. The tool is mounted on the rear axle using a mounting (P/N 999 5740). This means that it has no affect on the stability of the jack during work.

Install:

• the threaded rod (P/N 999 5659) on the mounting (P/N 999 5740).
• the mounting (P/N 999 5740) on the sub-frame
• the rails (P/N 999 5740-1) on the control arm
• the tensioner (1).
• Ensure that the rollers lie against the rails on both sides of the control arm.

• Press the trailing arms up so that the distance between points (1) and (2) is 397 ± 1 mm (15 5/8" ± 3/64"). Use the tools in point en-GB0900c8af848d8299#KC01166112.
• Tighten the screw in the inner mounting on the trailing arm. Tighten to 80 Nm (60 ft.lb.), see point en-GB0900c8af848d8299#KC01166110.
• Remove the tensioner together with the component parts.

• Lower the car slightly. Install both the rear wheels. Tighten the wheel nuts crosswise.
• Install the new screws (1) in the upper shock absorber bearing. Tighten to 25 Nm (18.5 ft. lbf.).
• Install the new nut (2) on the upper shock absorber. Tighten to 80 Nm (60 ft.lbf.). Use the special tool P/N 999 5500 and Torx 40 3/8" square ratchet.

• Reinstall the foam rubber seals over the rear shock absorber mountings.

Applies to the S60

• Reinstall the panels in the cargo compartment.
• Reinstall the cargo compartment carpet
• Fold back the rear backrests.

Applies to the V70

• Reinstall the front floor hatch and insulation mat.

Remove:

• the front wheels.
• the anti-roll bar link (1) from the spring strut. Use a Torx wrench as a counterhold to protect the rubber boot.

• Measure the position of the wheel spindle/spring strut (A) as illustrated.
• Remove the ABS sensor cable (1) from the bracket on the spring strut.

Remove:

• the bracket (1). Use the bracket on the new shock absorber.
• the screws (2) holding the spring strut in the wheel spindle.

Remove:

• the nuts and washers retaining the spring strut bearing in the bodywork.
• the spring strut from the wheel spindle. Move the spring strut forward over the brake pipe and downwards.

Примечание: Do not damage the brake hose, the ABS line or painted surfaces.

• Secure the spring strut in a vise, as illustrated.
• Compress the spring using the spring clamps (P/N 9995407). Position the spring clamps opposite each other. Tighten the spring clamps alternately.

Remove:

• the cover (1).
• the nut (2) and washer (2) for the upper mounting (3). Use socket (P/N 9995467) and Torx socket as a counterhold.
• the upper bearing (3).

Remove:

• the mounting nut (1) on the shock absorber. Use socket P/N 9995469 and a Torx-wrench as a counterhold.
• the spring seat (2).
• the spring (3).
• the rubber bump stop (4) and boot.

• Compress the new spring to a length of approximately 260 mm. Use the spring clamps (P/N 9995407).

Install:

• the new shock absorber in the vise
• the new rubber bump stop (1) including boot
• the spring (2). Locate the lower end of the spring in the cut out (3) in the lower section of the shock absorber.
• the washer (4)
• the spring seat (5)
• the mounting nut (6).

• Tighten the mounting nut to 70 Nm (52.5 ft.lbf.). Use socket (part no. 9995469) and Torx wrench as a counterhold.

Install:

• the upper bearing (1)
• the washer (2)
• new nut (3), and tighten the nut to 70 Nm (52.5 ft.lbf.). Use socket (part no. 9995467,) and Torx wrench as a counterhold.

• the cover.

• Remove the spring tools by slackening off crosswise.

• Install the spring strut in the bodywork using the new nuts from the kit, according to point en-GB0900c8af848d8299#KC01166120.
• Tighten the three nuts to the spring strut bearing. Tighten to 25 Nm (18.5 ft. lb).

• Install the spring strut on the wheel spindle. Use new screws (1) and nuts (1) from the kit.
• To obtain the correct camber angle adjust (A) to the previously measured value according to point en-GB0900c8af848d8299#KC01166118.
• Tighten to 105 Nm (78.5 ft.lbf.) and angle tighten 90°. Use protractor (part no. 9512050).
• Reinstall the bracket for the ABS sensor line according to point en-GB0900c8af848d8299#KC01166119.
• Reinstall the ABS sensor line in the bracket.

• Install the anti-roll link (1) on the spring strut using a new nut as illustrated en-GB0900c8af848d8299#KC01166117.
• Torque tighten the nut to 50 Nm (38 ft.lbf.). Use socket (part no. 9995498) and Torx wrench as a counterhold.
• Install both the front wheels. Tighten the wheel nuts crosswise.
• Lower the car completely. Tighten the wheel nuts on all wheels. Tighten to 140 Nm (104 ft.lbf.).