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

Suspension Front 19 illustrations ~832 words

Note. The following special tools are used for this installation: 999 5500, 999 5659, 999 5740 & 999 5740-1

Note. Carry out all the points in this instruction on the right and the left-hand sides, unless otherwise specified.

Scheme 132

Scheme 132: Preparations, Rear Suspension
Scheme 132: Preparations, Rear Suspension
  1. Fold both the rear backrests forward.

Scheme 133

Scheme 133
Scheme 133
  1. Remove the clip (1) at the left-hand side cushion
  2. Pull the top edge of the front cargo compartment panel out to access the upper lock for the side cushion.

Scheme 134

Scheme 134
Scheme 134
  1. Remove the cargo compartment carpet at the rear edge. Turn the two handles (1) a quarter turn.

Scheme 135

Scheme 135
Scheme 135
  1. Pull up the front of the cargo compartment carpet. Fold the front half back over the rear half of the cargo compartment carpet.

Scheme 136

Scheme 136
Scheme 136
  1. Slide the entire cargo compartment carpet forward slightly. Twist slightly to remove the cargo compartment carpet through the tailgate opening
  2. Remove the cargo compartment carpet.

Scheme 137

Scheme 137
Scheme 137
  1. Press the centers of the clips until a click is heard. Remove the clips
  2. Remove the plastic nut.

Scheme 138

Scheme 138
Scheme 138
  1. Turn the handle (1) a quarter of a turn
  2. Fold the side panels down. Lift the panels out.

Scheme 139

Scheme 139
Scheme 139
  1. Remove the clips (1) in the front side panel in the cargo compartment. Remove the panel.

Scheme 140

Scheme 140
Scheme 140
  1. Remove the foam rubber seal over the rear shock absorber mountings.

Scheme 141

Scheme 141: Installing the Shock Absorber
Scheme 141: Installing the Shock Absorber

Remove

  1. the nut (1) for the shock absorbers
  2. the screws (2) for the upper shock absorber bearings.

Scheme 142

Scheme 142
Scheme 142
  1. Raise the car.

Remove

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

Scheme 143

Scheme 143
Scheme 143
  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 144

Scheme 144
Scheme 144
  1. Remove the rubber liner (1) for the spring turret. Position the liner on the new spring. HINT: Lubricate the rubber lining using soap solution to facilitate installation. NOTE: Position the groove (2) in the rubber lining on the end of the spring.
  2. Insert the spring into the turret with the rubber liner first
  3. Lift up the trailing arm slightly so that the spring is resting against the bottom of the trailing arm.

Scheme 145

Scheme 145
Scheme 145
  1. Position 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 and adjust the trailing arm into the mounting (3)
  3. Install the new screw (4) in the trailing arm as far as possible
  4. Position the mobile jack according to the arrow (5). Adjust the screw (4) correctly in the trailing arm. Finger tighten the screw.

Scheme 146

Scheme 146
Scheme 146

Scheme 147

Scheme 147
Scheme 147
  1. Insert the shock absorber (1) through the lower trailing arm and the spring
  2. Install the new bearing and washer on the shock absorber through the spring so that the Volvo mark and part number are on the top. (Scheme 146)
  3. Insert the shock absorber, the bearing and the washer into the spring strut turret. Align the three holes with the spring strut turret
  4. Align the lower mounting (2) of the shock absorber in the trailing arm. (Scheme 147)
  5. Reinstall the screw (3). Tighten the screw. Tighten to 80 Nm (59 ft. lb.).

Scheme 148

Scheme 148
Scheme 148

Tensioner 9995659 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 attached to the rear axle using mounting 9995740 . This means that it has no effect on the stability of the hoist during work.

Install

  1. the threaded bar «9995659»(ref-403953-S17943043902011061000000) on the mounting «9995740»(ref-403953-S11754452602011061500000)
  2. mounting «9995740»(ref-403953-S11754452602011061500000) on the sub-frame
  3. the rails «9995740»(ref-403953-S11754452602011061500000) on the control arm
  4. the tensioner (1)
  5. Ensure that the rollers lie against the rails on both sides of the control arm.

Scheme 149

Scheme 149
Scheme 149
  1. Press the trailing arms up so that the distance between the points (1) and (2) is 397 mm 1 mm (15 5/8" 3/64")
  2. Tighten the screw in the inner mounting for the trailing arm. Tighten to 80 Nm (59 ft.lb)
  3. Remove the tensioner with the components included.

Scheme 150

Scheme 150
Scheme 150
  1. Lower the car slightly. Install both wheels. Tighten the wheels crosswise
  2. Install the new screws (1) in the upper shock absorber bearing. Tighten to 25 Nm (19 ft.lb.)
  3. Install the new nut (2) on the shock absorber. Tighten the nut. Tighten to 80 Nm (59 ft.lb) . Use the special tool «9995500»(ref-403953-S01856825912011061000000) and a Torx 40 3/8" square ratchet
  4. Lower the car completely. Tighten the wheels. Tighten to 110 Nm (83 ft.lb.) .

Reinstall

  1. the foam rubber seals over the rear shock absorber mountings
  2. the panels in the cargo compartment
  3. the cargo compartment carpet
  4. Fold the rear backrests into position.

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