Automatic Level Control - Installation Instructions, Accessories: Other Volvo S60 I

Preparations, Cargo Compartment

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

1. Press the centers of the clips until a click is heard. Remove the clips. Also remove the plastic nut from the front edge of the panel.
2. Repeat the operation on the right-hand side.

Scheme 151

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

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

Scheme 152

1. Fold both the rear backrests forward.

1. Remove the clip (1) at the side of the left-hand side cushion
2. Pull out the top edge of the left front side panel. Remove the panel
3. Repeat the operation on the right-hand side.

Scheme 153

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

Scheme 154

Remove

1. the nut (1) for the shock absorber.

1. Raise the car.

Remove

1. the rear wheels
2. the lower screw (1) for the shock absorber
3. the shock absorber (2).

1. Relieve the load from the lower trailing arm (1). Use a mobile jack
2. Remove the screw (2) for the trailing arm
3. Carefully lower the mobile jack
4. Remove the spring (3) by pressing the trailing arm down.

Scheme 155

Remove

1. the nut (1) for the anti-roll bar. Use a Torx socket as a counterhold to protect the rubber boot
2. the outer end (2) of the anti-roll bar from the lower ball joint bolt (3) on the control arm.

Scheme 156

Remove

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

Scheme 157

1. Insert the new anti-roll bar from the side and over the exhaust pipe. At the same time, turn the anti-roll bar to get it into position
2. Press the mountings (1) for the anti-roll bar up against the base plate mountings. Use the mobile jack.

Install

1. new screws (2) and nuts (2). Tighten to 80 Nm (60 lbf.ft.) .
2. the mountings for the handbrake cables (3). Tighten the mountings
3. the mountings (4) for the center silencer.

Reinstall

1. the outer end of the anti-roll bar on the lower ball joint bolt for the control arm.
2. the nut. Tighten to 80 Nm (60 lbf. ft.) . Use socket (P/N 9995500) and a Torx socket as a counterhold.

Scheme 158

1. Remove the rubber liner (1) for the spring turret. Position the liner on the new spring. NOTE: The rubber liner should sit on the more compressed end of the spring and be partially protected by a plastic holder. Adjust the rubber liner so that the groove (2) aligns with the spring. HINT: Lubricate the rubber lining using soap solution to facilitate installation.
2. Insert the spring into the turret with the rubber liner first. At the same time pull down the trailing arm a little so that the spring can be located against the bottom of the trailing arm.

1. Position the mobile jack under the trailing arm (1)
2. Adjust the position of the spring so that it aligns in the groove (2) on the bottom of the trailing arm. At the same time carefully press up the trailing arm using the mobile jack
3. Press and adjust the trailing arm into the mounting (3)
4. Install the new screw (4). Insert the screw as far into the trailing arm and mounting as possible. Use a small jimmy bar to align the holes in the trailing arm and the mounting
5. Position the mobile jack under the rear mounting for the lateral link at the arrow (5). Adjust the trailing arm position so that the screw (4) can be threaded all the way into the trailing arm. Do not tighten the screw yet.

1. Insert the shock absorber (1) through the lower trailing arm and the spring
2. Insert the shock absorber up into the spring strut turret and the upper bearing
3. Align the lower mounting (2) of the shock absorber in the trailing arm
4. Install the new screw (3). Tighten to 80 Nm (60 lbf. ft.) .

Tensioner (P/N 999 5659) is used when working on the suspension. It is vital that the screwed joints for the rubber bushings are tightened in the normal position; in the same position as when the car is on the ground. The tensioner relieves the load on suspension components during removal and installation. The tool is secured to the rear axle using a mounting (P/N 999 5740B). This means that the stability of the lift is not affected during the work.

Install

1. the threaded rod (P/N 999 5659) on the mounting (P/N 999 5740B)
2. the mounting (P/N 999 5740B) on the sub-frame
3. the rails (P/N 999 5740B-1) on the control arm
4. the tensioner (1)
5. Ensure that the rollers are against the rails on both sides of the control arm.

1. Press the trailing arms up so that the distance between points (1) and (2) is 397 1 mm (15 5/8" 3/64").
2. Tighten the screw in the inner mounting for the trailing arm. Tighten to 80 Nm (60 lbf. ft.) .
3. Remove the tensioner and the associated components.

Scheme 159

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

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

1. Reinstall the panels in the cargo compartment
2. Reinstall the cargo compartment carpet
3. Fold the rear backrests into position.

Scheme 160

Remove

1. the front wheels
2. the link (1) for the anti-roll bar from the spring strut. Use a Torx socket as a counterhold. This is to protect the rubber boot.

Scheme 161

1. Measure the position of the stub axle and spring strut (A) as shown
2. Remove the ABS sensor cable (1) from the bracket on the spring strut.

Scheme 162

Remove

1. the bracket (1). The bracket will be used for the new shock absorber.
2. the screws (2) that hold the spring strut in the stub axle.

Scheme 163

Remove

1. the nuts and washers that secure the spring strut bearing to the car body
2. the spring strut from the stub axle. Pull the spring strut forward over the brake hose and down. NOTE: Do not damage the brake hose, ABS sensor cable or painted surfaces.

Scheme 164

1. Secure the spring strut in a vice, as shown.
2. Relieve the load on the spring using spring clamps (P/N 9995409). Position the spring clamps opposite each other and tighten alternately.

Remove

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

Scheme 165

Remove

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

Scheme 166

1. Compress the new spring to a height of approximately 260 mm (10 1/4"). Use the spring clamps (P/N 9995409).

Scheme 167

Install

1. the shock absorber in the vice
2. the rubber bump stop (1) including the boot
3. the new spring (2). Align the lower end of the spring in the slot (3) in the lower section of the shock absorber
4. the washer (4)
5. the spring seat (5)
6. the retaining nut (6).

Scheme 168

1. Tighten the retaining nut. Tighten to 70 Nm (52.5 lbf. ft) . Use socket (P/N 9995469) and a Torx socket as a counterhold.

Scheme 169

Install

1. the upper bearing (1)
2. the washer (2)
3. a new nut (3). Tighten the nut to 70 Nm (52.5 lbf. ft) . Use socket (P/N 9995467) and a Torx socket as a counterhold
4. the cover.

1. Remove the spring tools by slackening them off alternately.

1. Install the spring strut on the car body. Use the new nuts and washers from the kit.
2. Tighten the three nuts for the spring strut bearing. Tighten to 25 Nm (18.5 lbf. ft.) .
3. Install the spring strut on the stub axle. Use new screws (1) and nuts (1) from the kit
4. Adjust to the value measured previously at (A), to obtain the correct camber angle
5. Tighten to 105 Nm (78.5 lbf. ft.) Angle-tighten to 90°. Use the protractor (P/N 9512050)
6. Reinstall the bracket for the ABS sensor cable.
7. Reinstall the ABS sensor cable in its bracket.
8. Install the link (1) for the anti-roll bar on the spring strut. Use a new nut
9. Tighten the nut. Tighten to 50 Nm (38 lbf. ft.) . Use socket (P/N 9995498) and a Torx socket as a counterhold
10. Reinstall both the front wheels. Tighten the wheel nuts crosswise
11. Lower the car completely. Tighten the wheels nuts on all wheels to 140 Nm (104 lbf. ft.) .

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

Scheme 170

Remove

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

1. 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.
2. Repeat the operation on the right-hand side.

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

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

1. Fold both the rear backrests forward.

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

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

Scheme 171

Remove

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

1. Raise the car.

Remove

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

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

Remove

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

Remove

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

1. 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.
2. Press the mountings (1) for the anti-roll bar up against the base plate mountings. Use the mobile jack.

Install

1. new screws (2) and nuts (2) and tighten to 80 Nm (60 ft.lbf.) .
2. the mountings for the handbrake cables (3) and tighten.
3. the mountings (4) for the center silencer.

Reinstall

1. the anti-roll bar's outer end to the control arm's lower ball joint bolt.
2. the nut and tighten to 80 Nm (60 ft.lbf.) . Use socket (part no. 9995500) and Torx wrench as a counterhold.

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

1. 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.
2. Press up and adjust the trailing arm into its mounting (3).
3. Install the new screw (4) in the trailing arm as far in as possible.
4. Position the mobile jack as indicated by the arrow (5). Align the screw (4) correctly. Tighten the screws loosely.

1. Raise the new shock absorber (1) through the lower trailing arm and spring.
2. 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.
3. Raise the shock absorber and the bearing up into the spring turret.
4. Locate the shock absorber lower mounting (2) in the trailing arm.
5. 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

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

1. Press the trailing arms up so that the distance between points (1) and (2) is 397 1 mm (15 5/8" 3/64").
2. Tighten the screw in the inner mounting on the trailing arm. Tighten to 80 Nm (60 ft.lb.) .
3. Remove the tensioner together with the component parts.

1. Lower the car slightly. Install both the rear wheels. Tighten the wheel nuts crosswise.
2. Install the new screws (1) in the upper shock absorber bearing. Tighten to 25 Nm (18.5 ft. lbf.) .
3. 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.

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

Applies to S60

1. Reinstall the panels in the cargo compartment.
2. Reinstall the cargo compartment carpet
3. Fold back the rear backrests.

Applies to V70

1. Reinstall the front floor hatch and insulation mat.

Sport Chassis Kit, Front

Remove

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

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

Remove

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

Remove

1. the nuts and washers retaining the spring strut bearing in the bodywork.
2. the spring strut from the wheel spindle. Move the spring strut forward over the brake pipe and downwards. NOTE: Do not damage the brake hose, the ABS line or painted surfaces.

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

Remove

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

Remove

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

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

Install

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

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

Install

1. the upper bearing (1)
2. the washer (2)
3. 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.
4. the cover.

1. Remove the spring tools by slackening off crosswise.

1. Install the spring strut in the bodywork using the new nuts from the kit.
2. Tighten the three nuts to the spring strut bearing. Tighten to 25 Nm (18.5 ft. lb) .
3. Install the spring strut on the wheel spindle. Use new screws (1) and nuts (1) from the kit.
4. To obtain the correct camber angle adjust (A) to the previously measured value.
5. Tighten to 105 Nm (78.5 ft.lbf.) and angle tighten 90°. Use protractor (part no. 9512050).
6. Reinstall the bracket for the ABS sensor line.
7. Reinstall the ABS sensor line in the bracket.
8. Install the anti-roll link (1) on the spring strut using a new nut.
9. Torque tighten the nut to 50 Nm (38 ft.lbf.) . Use socket (part no. 9995498) and Torx wrench as a counterhold.
10. Install both the front wheels. Tighten the wheel nuts crosswise.
11. Lower the car completely. Tighten the wheel nuts on all wheels. Tighten to 140 Nm (104 ft.lbf.) .