Preparations, front

Preparations, front

Applies to cars with manual gearboxes:

• Turn the ignition key to position "0", and take the key from the ignition switch.

Applies to cars with automatic gearboxes:

• Turn the ignition key to position "I".

Applies to all cars:

• Disconnect the battery negative lead.

  
  

  Note! Wait at least five minutes before disconnecting the connectors or removing other electrical equipment.

  
  

Illustration A applies to the V70

Illustration B applies to the S60 and XC70

• Press in the centres of the six clips until a click is heard. Remove the clips.

• Pull the top edge of the front forward.

• Put your hand into the inside and press the four catches, which are evenly spaced along the top edge, either up (applies to the V70, illustration A) or down (applies to the S60 and XC70, illustration B). Use a weatherstrip tool if necessary.

• Pull the front grille at the top until the catches release.

Illustration A applies to the V70

• Detach the front grille at the bottom by inserting a small screwdriver between the openings and pressing the three catches down.

• Remove the front grille and place it to one side.

Illustration B applies to the S60 and XC70

• Take a plastic weatherstrip tool and insert it between the front grille and bumper cover, and carefully prize the front grille away along the whole of the bottom edge. It is secured with three catches.

• Remove the front grille and place it to one side.

• Remove the intake manifold (1).

• Lift up the air cleaner (ACL) module by detaching it from its three mountings: one at the rear, one in the front and one at the left-hand end face. Use a small socket with an extension to press the four catches together, and detach the air cleaner (ACL) module.

• Move the air cleaner (ACL) module aside and affix it using a cord for example, as illustrated.

• Move the rubber seal (1) aside, on the left-hand side behind the front grille. Take the cable harness (2) from the kit and position it in the engine compartment. Following which, route the cable harness to the left of the headlamp at the top and through the cut-out in the body at the rubber seal.

• Move the rubber seal back, and make sure that it seals firmly.

Illustration A applies to the V70

• Grip the front grille (1) and guide the cable harness (2) through the sixth hole (3), counting from the left-hand headlamp.

Illustration B applies to the S60 and XC70

• Grip the radiator grille (1) and guide the cable harness (2) through the second hole at the bottom, counting from the left-hand headlamp.

Applies to all models:

• Reinstall the front grille and the clips which hold the front at the top.

Remove:

• the number plate

• the screws (1) for the number plate, and detach it.

Installation, auxiliary lights

Installation, auxiliary lights

• Take the auxiliary lights bracket (1) from the kit and secure it in the holes (2) for the number plate holder.

  S60 and V70: Use the lower holes in the bracket.

  XC70: Use the upper holes in the bracket.

• Drill with a Ø7 mm (9/32") diameter drill bit right in the centre of the holes (3) through the bumper cover and the bumper rail (which is located at different depths, depending on model):

Applies to cars up to and including model year -2004

S60: approx. 37 mm (1.46") behind the cover

V70: approx. 52 mm (2.05") behind the cover

XC70: approx. 51 mm (2.01") behind the cover




Note! Hold the drill horizontally.




Applies to cars from model year 2005-

S60: approx. 58 mm (2.28") behind the cover

V70: approx. 61 mm (2.40") behind the cover

XC70: approx. 73 mm (2.87") behind the cover




Note! Hold the drill horizontally.




• Remove the screws and auxiliary lights bracket.

• Drill the holes (1) with a drill bit (P/N 8633152), through the plastic with the thicker section of the drill bit, and through the bumper rail (2) with the thinner section of the drill bit, which has the dimension Ø7.3 mm (19/64").

  
  

  Note! It is important that the tip of the drill bit meets the hole that was previously drilled into the bumper rail.

  
  

• The flat surface on the drill bit shall drill out all plastic up to the bumper rail.

  
  

  Note! Hold the drill horizontally. Use a torch to check that there is no plastic swarf in the holes.

  
  

Illustration A

Applies to cars up to and including model year -2004

• Check that the surface (1), which the socket shall support against, is free from plastic.

• Install the two spacer sleeves in the holes.

S60: Length approx. 40 mm (1.57")

V70: Length approx. 53.5 mm (2.11")

XC70: Length approx. 60 mm (2.36")

• 
  

  Note! The spacer sleeves must protrude from the bumper cover at different lengths, depending on car model: S60: approx. 3 mm (0.12") from the bumper cover V70: approx. 1 mm (0.04") from the bumper cover XC70: approx. 9 mm (0.35") from the bumper cover

  
  

Illustration B

Applies to cars from model year 2005-

• Check that the surface (1), which the socket shall support against, is free from plastic.

• Install the two spacer sleeves in the holes.

S60: Length approx. 60 mm (2.36")

V70: Length approx. 63.5 mm (2.5")

XC70: Length approx. 75 mm (2.36")

• 
  

  Note! The spacer sleeves must protrude approx. 2 mm (0.08") from the bumper cover on all car models.

  
  

Only applies to the S60 and V70

• Drill two new holes in the number plate holder, as illustrated.

• Affix tie straps (1) in the holes in the auxiliary lights bracket, but do not tighten.

• Install the auxiliary lights bracket on the bumper using the screws (2) from the kit. Tighten loosely. The screws create their own threads in the drilled holes, which means that they may screw in stiffly.

• Guide in the two cable ends (1) in the three tie straps (2). Route the cables as illustrated.

• Adapt the length of the cable to the lamps. Press back any excess length of the cable outside of the front grille in through the front grille.

• Tighten the tie straps.

  
  

  Note! Tighten the two screws for the auxiliary lights bracket.

  
  

• Install a spacer washer (3) between the auxiliary lights bracket (4) and the expander nut (5) on both sides.

• Install the number plate and tighten it with the two screws.

Use auxiliary lights which are recommended by Volvo dealers.

• Remove the screw (1) and the cover.

• Press lightly on the lens (2).

• Fit a screwdriver (3) between the insert and the lamp housing, and prize carefully.

• Install the lamp housing on the auxiliary lights mounting with screw and nut. Tighten manually.

• Route the cable harness (1) with rubber grommet (1) into the holes in the lamp housing.

• Press the rubber grommet into the hole.

• Connect the blue (BL) cable to the lamp's cable, with a connector socket housing in between.

• Connect the black (SB) cable to ground on the light insert.

• Assemble the auxiliary light, as illustrated.

• Take the previously routed cable harness (1) and route it as illustrated.

• Plug the connector (2) into the pre-routed connector.

• Press in the relay (3) at the edge of the plate.

• Detach the existing screw (4) in the air cleaner (ACL) module bracket and connect the ground cable. Pull any excess length of the cable through the front grille and clamp it with the existing cables behind the headlamp using tie straps from the kit.

• Reinstall the air cleaner (ACL) module and the intake manifold.

  
  

  Note! Ensure that the wiring does not rub against sharp edges. If the wiring is rubbing, re-secure the wiring.

  
  

Illustration A

Applies to cars up to model year -2005

• Remove the cover from the fuse box in the engine compartment. Install a 20A fuse in position 2 (1).

• Reinstall the cover.

Illustration B

Applies to cars from model year 2006-

Installing the switch, applies to cars up to and including model year -2004

Installing the switch, applies to cars up to and including model year -2004

• Remove the panel in front of the gear selector lever. Pry off the panel using a plastic weatherstrip tool.

• Apply the handbrake, and move the gear selector lever as far back as possible.

• Remove the two screws from the dashboard environment panel.

• Carefully angle the dashboard environment panel using a plastic weatherstrip tool, so that the short side of the dashboard environment panel can be gripped with a couple of fingers.

• Remove the dashboard environment panel by pulling it straight down while maintaining the angle. The panel is fitted securely, so some force is required to detach it.

• Disconnect the connectors on the reverse of the dashboard environment panel. Place the dashboard environment panel to one side.

  
  

  Note! If any of the outer hooks fail then this must be rectified. See the section on the dashboard in the Workshop Manual in VIDA.

  
  

• Remove the cigarette lighter.

• Fit the dashboard environment panel as illustrated.

• Detach the surround (1) by carefully pressing the three catches (2) down in the holes (3) with a small screwdriver while prizing out the surround with a thin plastic weatherstrip tool. Start at the 12V socket (4) and prize up one corner. The surround is secured firmly so take care of the components.

  
  

  Note! The surround with three button places must be replaced with a surround with seven button places if necessary. This can be purchased separately.

  
  

Installing the switch, applies to all cars from model year 2005-

Installing the switch, applies to all cars from model year 2005-

• Remove the cover plug to the 12V socket.

• Carefully remove the panel for the keypad using a scriber with angled tip. Pull out one corner of the panel using the scriber until the catches release. It is secured with three catches on each long side. Continue to pull along the panel until all catches have released.

• Remove the dummy button and install the new switch (1) in any available position.

• Reinstall the surround and the cover plug.

Finishing work, installing and adjusting

Finishing work, installing and adjusting

• Align the auxiliary lights - headlamps for optimum beam pattern.

• Tighten the two screws, see step 17.

• Install the protective caps on the screw heads.

• If the auxiliary lights vibrate and this is disruptive then a top strut can be installed. The strut must be secured in the horn's mounting point (1).

• Turn the ignition key to position "II".

• Reconnect the battery negative lead

• Reinstall the floor hatch in the cargo compartment.