Body kit Body kit Installation instructions, accessories

Transcription

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
Instruction No
30664733
Version
1.0
Part. No.
Body kit
© Volvo Car Corporation
Body kit- 30664733 - V1.0
Page 1 / 18
Equipment
A0000162
A0000163
A0000161
A0000214
A0000177
M0000232
M8401093
Body kit- 30664733 - V1.0
Page 2 / 18
R8401106
Body kit- 30664733 - V1.0
Page 3 / 18
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!
During installation the underlay must be kept at a temperature
of at least +15°C (60°F).
Note!
For cars with a tow hitch, sockets for the tow hitch (points
8-10) must be arranged before painting.
Note!
Spray paint according to the Service Manual “Touch up
spraying”, section 8 (80). Note that, before spraying, the
body kit must first be cleaned, sanded and then cleaned
again. See the instructions in the Service Manual.
Installing the front spoiler
1
Installing the front spoiler
Clean the lower section of the bumper cover. Wipe dry
Clean the joint between the upper and lower sections of the
bumper cover using isopropanol, P/N 1161721. Wipe dry
Body kit- 30664733 - V1.0
Page 4 / 18
Apply primer intended for tape for PP/EPDM components in the
joint between the upper and lower sections of the bumper cover.
Note!
Ensure no primer gets on painted surfaces.
M8401094
2
Detach the ends from the three protective tapes on the new
front spoiler. Fold up the ends so that they are accessible when
the spoiler has been suspended in place.
M8401080
3
Note!
It is necessary for two people to carry out the installation of the
new spoiler. It is important to lift the spoiler slightly from the
bumper cover when removing the protective tape, as there is
otherwise a risk of pulling off the protective tape.
Hook the spoiler onto the lower section of the bumper cover.
Ensure that all the tabs on the protective tape are folded up and
accessible
M8401097
Begin by pulling away the long piece of protective tape on the
front edge of the spoiler by lifting the spoiler slightly from the
bumper cover. Pull off the tape. Press the front edge of the
spoiler into place against the bumper cover as the protective
tape is pulled away
Repeat the above procedure for the ends of the spoiler
Press the spoiler into place all the way around where the tape is
located.
4
Ensure that the edge of the wheel arch on the new spoiler is
Body kit- 30664733 - V1.0
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edge to edge with the edge of the wheel arch on the lower
section of the bumper cover, on both sides
Take a 5 mm (3/16 ") diameter drill bit. Drill through the existing
hole in the spoiler and through the lower section of the bumper
cover on the right and left-hand sides.
M8401086
5
Install a blind rivet from the kit on either side in the drilled holes.
M8401087
6
Bend up the flexible mounting brackets on the left and right-hand
sides against the existing holes in the bumper cover
Install the blind rivets through the holes in the mounting brackets
and the bumper cover
Install a washer from the kit on top of the blind rivet. Tighten.
M8601140
Body kit- 30664733 - V1.0
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7
Bend up the flexible mounting brackets in the front edge / lower
edge of the spoiler against the bumper cover
Take a 5 mm (3/16 ") diameter drill bit. Drill through existing holes
in the mounting brackets and through the lower section of the
bumper cover
M8601154
Installing the rear spoiler
8
Installing the rear spoiler
Applies to cars with a tow hitch
Mark out the centre line for the spoiler by measuring from the
edge of the cut-out on the left-hand side where the panel will be
located to the corresponding edge on the right-hand side. Mark
the centre by drawing a line with a pen on a piece of tape.
M8601178
9
Cut out the template according to the marking that corresponds to
the existing tow hitch
Position the centre line of the template opposite the tape marking
on the spoiler. The lower edge of the template must be edge to
edge with the lower edge of the spoiler. Tape the template in
position.
Body kit- 30664733 - V1.0
Page 7 / 18
M8601179
10
Tape the lower edge of the template into place
Use a pen to mark along the template
Remove the template
Cut out the spoiler along the marked line
Smooth off the edges using a fine-toothed file.
M8601180
11
Remove the rear wheels
Drill out the blind rivets underneath on the right and left-hand
sides of the rear wheel arches
Remove the remains of the rivets.
M8401082
12
Clean the lower section of the bumper cover. Wipe dry
Clean the joint between the upper and lower sections of the
bumper cover using isopropanol, P/N 1161721. Wipe dry
Apply primer intended for tape for PP/EPDM components in the
joint between the upper and lower sections of the bumper cover.
Note!
Ensure no primer gets on painted surfaces.
Body kit- 30664733 - V1.0
Page 8 / 18
M8401096
13
Take the new rear spoiler. Press the spoiler into place on the
rear bumper cover
Check that it is correctly positioned in the corners at the rear
edges of the wheel arches
Take two pieces of tape. Apply the tape to the upper section of
the bumper cover and the new rear spoiler
Using a pen, mark a vertical line over both pieces of tape to mark
the position of the rear spoiler in relation to the bumper cover
Remove the rear spoiler from the bumper cover.
M8401107
14
Remove the protective tape from the mounting tape on the new
rear spoiler from the kit.
M8401081
15
Note!
It is recommended that three people centre and press the new
rear spoiler into place.
Hook the spoiler onto the lower section of the bumper cover by
first centring it against the marking on the bumper cover. Press
the spoiler into place. Continue to press it into place out towards
the sides and then around the ends
Press the spoiler into place all the way around where the tape is
located.
Body kit- 30664733 - V1.0
Page 9 / 18
M8401095
16
Ensure that the edge of the wheel arch on the new spoiler is
edge to edge with the edge of the wheel arch on the lower
section of the bumper cover, on both sides
Take a 5 mm (3/16 ") diameter drill bit. Drill through the existing
hole in the spoiler and through the lower section of the bumper
cover on the right and left-hand sides.
M8401083
17
Install a blind rivet from the kit on either side in the drilled holes.
M8401084
18
Bend up the flexible mounting brackets on the left and right-hand
sides against the existing holes in the bumper cover
Body kit- 30664733 - V1.0
Page 10 / 18
M8601145
19
Take a 5 mm (3/16 ") diameter drill bit. Drill through existing holes
in the underside of the spoiler and through the lower section of
the bumper cover.
M8601155
20
Install two spring clips (1) from the kit at the drilled holes
Install two spacers (2) between the spoiler and the bumper
cover
Install two screws (3) through the spoiler, spacers, bumper
cover and spring clips. Tighten
Tighten the screws. Tighten to 10 Nm (7 lbf.ft).
M8601146
21A
Illustration A
Cut off the original cover for the towing eyelet. Place the cover
to one side.
Illustration B
Install the cover for the towing eyelet on the spoiler. Insert the
hooks into the top edge and press the cover against the spoiler
Take a 6.5 mm (1/4” ) diameter drill bit. Drill out the two holes in
Body kit- 30664733 - V1.0
Page 11 / 18
the bottom edge of the hole for the towing eyelet, through the
existing holes in the cover
Remove any swarf
M8601147
Install the cover using two pressure clips from the kit.
21B
M8601148
22
Install the cover for the tail pipe on the spoiler. Insert the hooks
into the top edge and press it down against the spoiler
Check that the distance A is the same on both sides when
securing the cover for drilling
Take a 5 mm (3/16”) diameter drill bit. Drill out the two holes (1) in
the lower edge of the hole for the tail pipe, through the existing
holes (1) in the cover
Remove any swarf
Take a blind rivet from the kit and rivet the cover into place in the
spoiler
R8401108
Check that the distance A is the same on both sides when
securing the cover for drilling the holes (2). Position the holes out
at the edges, approximately the same distance from the edges
as the diameter of the holes (1). Check on the inside to ensure
that the holes are not positioned outside the edges, or on a
stiffener in the spoiler. If this is the case, move the holes
Mark out the holes and secure the cover in the correct position.
Drill the holes through the cover and the spoiler. Use a 5 mm
(3/16) diameter drill bit
Remove any swarf
Take a blind rivet from the kit and rivet the cover into place in the
spoiler.
Body kit- 30664733 - V1.0
Page 12 / 18
Installing the panels for the door sills
23
Installing the panels for the door sills
Take a 6.5 mm (1/4 ") diameter drill bit. Drill out the two blind
rivets in the front edge of the rear wheel arch
M8401090
24
Take a 6.5 mm (1/4 ") diameter drill bit. Drill out the two blind
rivets in the rear edge of the front wheel arch
M8401089
25
Knock out the centres of the seven clips securing the bottom
edge of the door sill panel. The eighth rear clip must be drilled
out. Use a 5 mm (3/16”) diameter drill bit. Drill out the centre pin.
Remove the clip
Remove the lower section of the panel together with the clips
from the bodywork.
Body kit- 30664733 - V1.0
Page 13 / 18
M8401098
26
Remove the top edge / rear edge of the panel using a plastic
weatherstrip tool. The panel is secured with a clip in the rear
wing
Continue forwards. Pry out the panel along the door sills. The
panel is secured with eight clips
Then disconnect the panel from the front wing. The panel is
secured with two clips
Place the panel to one side.
M8401045
27
Clean the tops of the door sills along the car. Wipe dry
Clean using isopropanol P/N 1161721. Wipe dry.
M8401099
28A
Illustration A
Take a new panel and rubber strips from the kit. Press two new
clips into place on the panel. The rubber strips for the panels are
unique for the left and right-hand sides, as well as for front and
rear. Check on the old panels where each rubber strip is to be
located
Press new rubber strips into place on the panel.
Illustration B
Body kit- 30664733 - V1.0
Page 14 / 18
Note!
M8401039
The rear clip on the new rear rubber strips must be heated
with a soldering iron and pressed into place.
28B
R8401109
29
Apply adhesive (P/N 1161767) at the start of the radius and
inwards, on all projections on the vehicle sill. The bead of
adhesive must be approximately 4 mm (5/32”) wide.
M8102019
30
Remove the backing tape from the mounting tape on the panel.
Body kit- 30664733 - V1.0
Page 15 / 18
M8401079
31
Note!
It is necessary for two people to carry out the installation of the
new panel. Ensure that the panel is lifted to a sufficient height
in relation to the sill so that the panel does not smear the bead
of adhesive.
The front and rear edges of the wing liners must cover the ends
of the side panel. Align the panel with the car. Position the
locating pin in the centre hole on the top of the sill
Press the front and rear clips for the panel into place in the holes
in the sills
M8401048
Press the panel firmly into place against the sills along the
surfaces where the tape is located
Secure the bottom edge of the panel against the bodywork using
eight new clips from the kit
Remove any adhesive residue that has been pressed out.
32
Drill through the existing holes in the rear edge of the front wheel
arch and through the front end of the panel. Use a 5 mm (3/16”)
diameter drill bit
Remove any swarf
Secure the panel using two blind rivets (from the kit) at the rear
edge of the front wheel arch.
M8401049
33
Drill through the existing holes in the front edge of the rear wheel
arch and through the rear end of the panel. Use a 5 mm (3/16”)
diameter drill bit
Remove any swarf
Secure the panel using two blind rivets (from the kit) at the front
Body kit- 30664733 - V1.0
Page 16 / 18
edge of the rear wheel arch
Repeat points 23-33 for the other side
Reinstall the rear wheels. Tighten the wheel studs. Tighten to
140 Nm (103 lbf. ft).
M8401050
Installing door trim strips
34
Installing door trim strips
Remove the three retaining screws holding the lower front door
trim strips.
M8401091
35
Remove the lower door trim strip. Carefully pry off the panel
using a plastic weatherstrip tool. The panel is secured with two
clips
Clean the lower edge of the door where the trim strip was
located.
M8401092
36
Take the new door trim strip. Install two new clips from the kit
Position three self-adhesive spacer washers (from the kit) on
Body kit- 30664733 - V1.0
Page 17 / 18
the projections between the new door trim strip and the door,
through which the screws are to be tightened
Press the new trim strip into place on the door. Secure the trim
strip using the three screws
Repeat points 34-36 for the other doors. The trim strips on the
rear doors are secured with two screws.
M8400738
37
Note!
Leave the car indoors for 2 hours after carrying out the work.
Do not wash the car for 48 hours.
Body kit- 30664733 - V1.0
Page 18 / 18

Body kit Body kit Installation instructions, accessories

Transcription

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