Installation instructions, accessories. Body kit. Volvo Car Corporation Gothenburg, Sweden. Page 1 / 21 J

Transcription

1 Installation instructions, accessories Instruction No Version 1.4 Part. No Body kit J Volvo Car Corporation Body kit V1.4 Page 1 / 21

2 Equipment A A A A J Page 2 / 21

3 J Page 3 / 21

4 J Page 4 / 21

5 J Page 5 / 21

6 IMG Page 6 / 21

7 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. Note! On cars with towbar and/or with a T5 turbocharged engine, a cut-out must be made in the rear bumper cover's new spoiler (steps 17 A, B, C, D and 18). This should ideally be done before the new spoiler is painted. Note! Paint in accordance with the Service Manual "Touch up spraying", section 8 (80). Note that the body kit must be cleaned, ground and then cleaned again before painting in accordance with the instructions in the Service Manual. The structured door trim strips are treated in accordance with the instructions in step 1. Preparations, door trim strips Page 7 / 21

8 1A Preparations, door trim strips Dampen a Scotch-Brite grey 3M, P/N 07522, and wash/grind the plastic. Wipe dry. Place the parts in 60 C for one hour. Wash and wipe dry. Apply plastic primer and plastic filler in accordance with the paint supplier's instructions. Wipe and grind smooth. 1B A Paint in accordance with the paint supplier's instructions. A Installing the panels for the door sills Page 8 / 21

9 2 Installing the panels for the door sills Remove the three screws at the front edge of the rear wing liner. On some cars it may be necessary to remove the rear wheel first in order to remove the screws. J Position a shim between the front edge of the wing liner and the bodywork, so that the rear panel of the door sill is exposed. J Remove the three screws at the rear edge of the front wing liner. J Page 9 / 21

10 5 Secure the rear edge of the front wing liner. J Unscrew the centre screws on the seven clips on the underside of the panels for the door sills. Remove the screws. J Open the doors on one side Using a plastic weatherstrip tool, pry off the front and rear panels from the bodywork. Start at one end and continue along the entire panel until all the clips release. The front panel is secured with nine clips in the middle and a locating pin at the front edge. The rear panel is secured with a clip and a locating pin. The front panel sits in the rear panel and is secured to it by two mounting hooks. Do not damage the paintwork on the doors and door sills. J Page 10 / 21

11 8 Remove the rubber strip from the old panels. The rubber strip will be reused Place the panels to one side. The panels will not be used again Clean the surfaces where the new panels are to be installed Clean the rubber strip and install it on the new panel from the kit Install new clips and spring nuts (from the kit) on the new panels. Check on the old panels how the various clips and spring nuts are to be located. J Slide the rear panel section (from the kit) onto the long panel. J Page 11 / 21

12 10 Note! It is recommenced that two people press the panels into place. Press the new panels into place on the door sill using new clips from the kit. Ensure that all the clips have engaged Install the existing screws in the front/rear edge of the wheel arches, but do not tighten yet. The panels are tightened at the rear and front edges after adjusting the wing and door edge in step 12. Repeat all the above steps on the other side of the car. J Installing door trim strips 11 Installing door trim strips Open the rear door on one side Remove the two screws holding the door trim strip in place at the front and rear edges at the bottom of the door. J Page 12 / 21

13 12 Carefully pry off the door trim strip using a plastic weatherstrip tool. The door trim strip is secured with two clips (it is secured with four clips on the front door) Wipe clean the surfaces where the door trim strips were located Take the new door trim strip from the kit. Press new clips into place on the door trim strip. Press the door trim strip into place on the door Tighten the door trim strip to the bottom edge of the door. Use two new screws and washers from the kit Repeat steps 10 and 11 on all doors. J A Adjusting the rear wing. Illustration A Adjust the rear section of the door sill panel so that approximately the same horizontal play is obtained between the top edge of the door sill panel and the lower/front edge of the rear wing, as between the top edge of the door trim strip and door edge as in illustration A. At the same time, the top edge of the door sill panel must also be positioned correctly in relation to the lower edge/front edge of the rear wing, as in illustration B. Secure the door sill panel in the correct position and tighten the screws. Reinstall the rear wheel if this was removed. Tighten the wheel nuts. Tighten to 90 Nm (66 lbf. ft.). 13B J Repeat the above procedure for the front section and for the other side. Illustration B Adjusting the front wing. Illustration C Illustration D J Page 13 / 21

14 13C 13D J J Installing the spoiler on the rear bumper cover Page 14 / 21

15 14 Installing the spoiler on the rear bumper cover Remove the two screws (1) at the rear at the bottom of the bumper cover. J Remove the three screws (1) securing the bottom section of the rear bumper cover to the rear edge of the wheel arch, on the right and left-hand sides. J Remove the lower section of the bumper cover. Pry up the sixteen mounting hooks on the inside and remove the two clips in the ends. Pull off the lower section of the bumper cover. Place the lower section to one side. The lower section will not be used again. J Page 15 / 21

16 17A Applies to cars with towbar On cars with a towbar, a cut-out for this must be made in the new spoiler for the bumper cover. See illustrations A, B C and D. Illustration A applies to cars with a fixed towbar Apply tape to the outside of the spoiler, opposite the markings on the inside. This is done to protect the paint from the saw when cutting out the cut-out for the tow hitch wiring connector. (Applies to painted spoilers.) Cut out the cut-out following the existing markings. 17B J Note! Do not damage the painted surface of the spoiler. Cut so that the raised edge on the inside remains. The raised edge marks the cut-out. Smooth off the sawn edges using a fine toothed file. Remove the tape. Illustration B applies to cars with a detachable towbar, AUS, and EU older models Illustration C applies to cars with a detachable towbar, USA Illustration D applies to cars with a detachable towbar, EU, new model P/N and (See type plate on towbar) 17C J Note! This marking is not on older spoilers, so draw the marking as follows: Height 100 mm, start from the marking furthest to the left in the illustration (1). Width 250 mm, start from the marking at the top of the illustration (2). The radius of the two corners is 30 mm. J Page 16 / 21

17 17D IMG Applies to cars with a T5 turbocharged engine Apply tape on the outside of the spoiler, opposite the two markings on the right and left-hand sides of the spoiler. This is done to protect the paint from the saw when cutting out the cutout for the tail pipe. (Applies to painted spoilers.) Cut out the cut-out following the existing markings. Note! Do not damage the painted surface of the spoiler. Cut so that the raised edge on the inside remains. The raised edge marks the cut-out. J Smooth off the sawn edges with a fine toothed file. Remove the tape. Touch up the paint according to the Service Manual "Touch up spraying", section 8 (80). Take six new spring nuts from the kit. Install the spring nuts on the sides of the new spoiler. Page 17 / 21

18 19 Applies to all models Clean the surfaces of the rear bumper cover where the new spoiler is to be secured Press the spoiler into place on the bumper cover. Ensure that all the catches engage. Do not damage the paintwork Take two new clips from the kit. Press the clips into place in the bottom of the bumper cover Take two new spring nuts from the kit. Install the spring nuts in the brackets in the bodywork where the spoiler is to be secured (illustration 12) Using new screws and washers, tighten the spoiler to the wing liners and the brackets in the bodywork. J Installing the spoiler on the front bumper cover 20 Installing the spoiler on the front bumper cover Remove the five screws securing the bumper cover and air baffle at the front edge of the wheel arches, on the left and right-hand sides. J Page 18 / 21

19 21 Applies to cars with a T5 turbocharged engine and that have an extra spoiler Drill out the eleven blind rivets securing the small extra spoiler at the bottom of the front bumper cover. Use a Ø6.5 mm (1/4" ) diameter drill bit. Place the spoiler to one side. The spoiler will not be used again. Remove any rivet swarf from the air baffle. J Remove the three screws securing the air baffle to the lower section of the bumper cover Pull the lower section of the bumper cover and the air baffle forwards until the air baffle can be unhooked from its rear mounting in the bracket under the radiator. Then carefully pull the air baffle down and away from the lower section of the bumper cover. Remove the air baffle. Note! Do not damage the outer ends of the air baffle. These can easily break off. J Disconnect the nineteen mounting hooks and the two clips farthest out to the sides on the inside of the bumper cover. These hooks and clips secure the lower section. Pull the lower section away and place it to one side. The lower section will not be used again. J Page 19 / 21

20 24 Take two brackets from the kit. Rivet the brackets to the underneath in the existing holes, by the sides of the new spoiler, for securing in the air baffle. J Take new clips from the kit. Install the clips in the upper holes on the right and left-hand sides of the new spoiler. J Clean the surfaces of the bumper cover where the spoiler is to be secured Press the spoiler into place on the bumper cover. Ensure that all the mounting hooks have secured Take two new clips from the kit. Install the clips in the outer ends of the bumper cover for securing the spoiler. J Page 20 / 21

21 27 Replace all five spring nuts on the air baffle. Use new spring nuts from the kit Reinstall the air baffle in the bumper and the mounting in the bracket in the radiator. Ensure that the front edge of the air baffle is correctly positioned in the bumper cover and the spoiler Tighten the brackets for the spoiler to the air baffle. Use new screws and washers from the kit Tighten the bumper cover and spoiler to the front edge of the wheel arches on both sides. Use new screws and washers from the kit Tighten the remaining screws securing the bumper cover to the front edge of the wheel arches on both sides. J Page 21 / 21