Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
S60 2008
S60 (-09) 2008

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
312694891.231269520, 31269518
Towbar, detachable




M8903845




 
Equipment
A0000162
A0000163
A0000161
A0000172
A0000165

IMG-213220

IMG-326933

IMG-213320


 
  

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!

Kit contents:

1. Crossmember

2. Screw M12 x 100 (x4)

4. Screw M12 x 50 (x2)

5. Washer (x4)

6. Washer, heat deflector plate

7. Screw (4.8 x 9.5 mm)

8. Protective cover

9. Seal (x4)

10. Strap

11. Protective bag

12. Decal

13. Detachable tow hitch

14. Blind rivet (x12)

15. Washer 24 x 13 x 7



Note!

We recommend that the work at steps 8, 11, 16 and 17 is carried out by two people.


 

Cargo compartment, preparations

1
A8800136
 

Cargo compartment, preparations

  • Turn the ignition key to position 0. Remove the ignition key from the ignition switch.


Note!

Wait at least five minutes before disassembling the connectors or removing other electrical equipment.


2
 

  • Install the cable harness connector for the tow hitch according to step 1 in the Installation Instructions for the appropriate cable harness.

3
M8902133
 

  • Fold up the floor hatch.

  • Press the clips in the centre until a "click" is heard. Pull out the clips.

  • Remove the plastic nut.

  • Repeat the operation on the right-hand side.

4
M8503264
 

  • Turn the handle (1) on the right and left-hand sides a quarter turn.

  • Fold the side panels inwards. Remove the panels.

  • Pull the tailgate sill trim panel (2) forwards on the right and left-hand sides until the two clips on each side release. Carefully pull the panel with some force as it is tightly secured.

  • Remove the wiring (3) for the cargo compartment lighting.

  • Pull the sill trim panel straight up until the four clips on the underside release. Remove the sill trim panel.

5
M8901860
 

    Remove:

  • the two nuts from the front edge of the battery holder and the screw from the rear edge

  • the battery holder

  • the cover

  • the battery negative lead

  • the battery, or move the battery to facilitate access.

6A
M8101297
6B
IMG-213364
 

Illustration A

    Remove:

  • the four perforated sections (1) of the insulation panel

  • the nuts (2) for the bumper

  • the antenna connector (3).

Illustration B

    Applies to cars with parking assistance

  • Detach the parking assistance module (PAM) from its location on the left-hand (model year 2005–) / right-hand (model year –2004) side of the cargo compartment.

  • Detach the smaller connector from the control module.

 

Preparations, rear suspension

7A
M8600564
7B
M8600581
 

Preparations, rear suspension

  • Raise the car.

  • Remove the rear wheels.

Illustration A only applies to cars with mudguards

  • Carefully drill out the rivets that hold the mudguard in place on both sides. Use a Ø6 mm (1/4") diameter drill bit.

  • Remove the mudflaps.

Illustration B applies to all cars

  • Unscrew the screw (1) almost all the way on the left and right-hand sides in the rear edge of the wheel arch.

  • Press the screw using a screwdriver until the loose end pieces on the inside of the bumper cover are pressed backwards.

  • Carefully drill out the rivets (2) underneath the bumper on both sides. Use a Ø6 mm (1/4") diameter drill bit. Do not damage any of the plastic components.


Note!

There may be another installation procedure with more blind rivets on older cars.


8A
M8600582
8B
IMG-213365
 

Illustration A

  • Pull the bumper backwards slightly. Bend out the sides (1) so that they detach from the mountings (2). Then pull the bumper backwards until it detaches completely.

  • Place the bumper on a clean underlying surface that will not damage the paint.

Illustration B

    Applies to cars with parking assistance

  • Detach the bumper in accordance with the above. Carefully pull the cable (3) out through the hole in the car.

  • Place the bumper on a clean underlying surface that will not damage the paint.

9
M2501103
 

    Remove:

  • the rivet (1) on the bracket (2) for the silencer. Use cutting nippers

  • the screws (3) on the bracket

  • the bracket by detaching the rubber mountings (4). The bracket will not be used again.

10
D8600247
 

  • Remove the screws (1) and the bracket (2) from the right side of the rear of the car. The bracket will not be used again.

 

Installing the detachable tow hitch (including the cable harness)

11A
M8903848
11B
M8903805
 

Installing the detachable tow hitch (including the cable harness)

Illustration A

  • Clean any underseal and dirt from the mating surfaces between the tow hitch crossmember (1) and the bodywork.

  • Install the screws (2, 4) from the underneath with the washers (5) between. Finger tighten. Install a washer plate (6) on the left-hand side on the front screw (4). This is to secure the rear mounting for the heat deflector plate using the screw (7), (see illustration B).

Illustration B

  • Install the heat deflector plate (1). Secure the heat deflector plate using the screw (7) for the washer plate (6).

  • Reinstall the rubber mounting (8) for the silencer.


    Hint

    Use soap to facilitate installation of the rubber mounting.


    Illustration A

  • Tighten the screws (2). Tighten to 114 Nm (84 lbf.ft). Tighten the screws (4). Tighten to 81 Nm (60 lbf.ft), on both sides.

  • Underseal the car.

    Applies to Sweden only

  • Underseal only after the state roadworthiness inspection.

12A
M8601259
12B
M8601258
 

  • Install masking tape on the outside of the bumper to avoid damage from the base of the saw.

    Install masking tape opposite the cutting points and over the bumper cover.


Note!

Particular care must be taken when cutting out in the bumper on the R-line. The brackets for the air intake's mesh could be damaged.


  • Leave the masking tape in place throughout the installation procedure.

    Applies to cars with chassis number (CH 425000-) EU and Australia

  • Cut along the markings on the inside of the bumper to make the cut-out for the tow hitch. Cut out so that the marking lines remain in the bumper afterwards.

    Illustration B applies to the Australian tow hitch with chain mountings

  • Install masking tape opposite the smaller cutting lines.

  • Cut the material out inside the marking lines.

13A
M8601308
13B
M8601309
 

    Illustration A applies to cars with chassis number (CH –424999)

  • Centre the cutting template and position it against the edge, as illustrated.

  • Carefully mark out the cutting lines around the cutting template.

  • Cut along the markings on the inside of the bumper to make the cut-out for the tow hitch. Cut out so that the marking lines remain in the bumper afterwards.

    Illustration B applies to the Australian tow hitch with chain mountings

  • Install masking tape opposite the smaller cutting lines.

  • Cut the material out inside the marking lines.

14
M8903417
 

    Applies only to R-line

  • Apply masking tape on the outside of the exhaust pipe clip to avoid damage from the base of the saw. Leave the masking tape in place during installation.

  • Cut along the marked raised area and remove the cut-out area.

15
 

    Applies to all models

  • After cutting, smooth off the edges using a file.

16
M8601204
 

  • Install the cable harness for the tow hitch according to the Installation Instructions for the appropriate cable harness.

    When installing a 7–pin or 13–pin cable harness for the tow hitch, a cut-out (2) must be made in the lower edge of the bumper.

  • Loosely install the bumper. Make markings for the cut-out for the cable harness.

  • Cut out as illustrated so that there is room for the cable harness.

 

Finishing work and function test

17
M8601205
 

Finishing work and function test

  • If the mountings (1) have released from the rear edge of the wheel arch, reinstall the mountings. Press the mountings completely back into their grooves and screw in the screw several turns.

  • Applies to cars with parking assistance: Lift up the bumper in position. Pull the cable for the sensors through the hole for the bumper's guide, and pull the cable in from the inside.

  • Reinstall the bumper by pressing it forwards. Ensure that the four screws protruding from the bumper align with the holes in the car.

  • Before the bumper is completely installed, slide the top edge (2) into the grooves. Then slide the bumper fully in.

18
M8600586
 

  • Tighten the screw (1) on both sides.

  • Secure both sides of the bumper with blind rivets (2) from below.

  • Reinstall the nuts. Tighten the nuts to 18 Nm (14 lbf. ft.).

    Reinstall:

  • the antenna connector

  • the mudguards, if applicable

  • the rear wheels. Lower the car.

19
M8101296
 

Install new rubber tabs over the four installed screws as follows:

  • Align the rubber tabs (1, 4) edge to edge with the lining mat

  • Compress the rubber tab (2) slightly to align in the cut-out

  • Align the rubber tab (3) so that the lower edge is positioned edge to edge with the lining mat. Then cut off the section protruding from the lining mat. Do not remove too much.

  • If necessary, cut away the area around the screw heads, so that the screws are accessible.

20A
M8601207
20B
M8503942
 

  • Install the enclosed decal on the underside of the floor hatch as illustrated.

Illustration B applies to cars with integrated carrier bag holder in the cargo compartment floor

  • Install the enclosed decal under the elastic strap on the underside of the floor hatch, as illustrated.

  • In addition, use staples for the installation.

21
A8800137
 

  • Applies to cars with parking assistance: Connect the detached cable to the parking assistance module (PAM). Reinstall the control module.

  • Turn the ignition key to position II.

    Reinstall:

  • the battery, and connect the battery cables

  • the cover

  • the battery holder

  • the tailgate sill trim panel, and plug in the connectors for the cargo compartment lighting

  • the two side panels, incl. clips and plastic nuts

  • Fold the floor hatch back into place.

  • Remove the masking tape from the bumper.

22A
M8903715
22B
J8903481
 

Storing the towbar

Illustration A

  • Remove the tow hitch and place it in the protective bag.

  • Locate the protective bag beside the spare wheel and test location options.

  • Clean the surfaces to which the pieces of foam tape shall adhere.

Illustration B

  • Take the pieces of foam tape and apply them as illustrated.

23
J8903483
 

  • Place the tow hitch in the bag supplied and locate it on the previously adhered pieces of foam tape.

  • Thread the strap in one of the holes in the wheel and strap down the bag with the towbar onto the tyre.