2002 2.4 AUTOMATIC L.H.D

Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
V70 2002
V70 (00-08) 2002

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
94999481.0
Roof spoiler with brake lamp




M8400560




Equipment
A0000162
A0000163
A0000161
A0000180
A0000214
A0000177
M0000232

M8901662





 
  

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.

1
M8400552
 

    Applies to unpainted roof spoilers

  • Clean the mating surfaces for the spoiler against the tailgate. Use a mixture of 30% windscreen washer fluid and 70% water. Wipe dry

  • Position the tape on the mating surfaces. Press the tape into place. Leave the thick outer protective film in place.


    Note!

    The tape must cure for 24 hours at a minimum of 20º C (68º F) before painting.


2
 

    Applies to unpainted roof spoilers

  • Spray paint according to the Service Manual "Touch up spraying", section 8 (80). The underneath of the spoiler must not be sprayed

  • Mask the underneath of the spoiler. Use the groove as a guide

  • Carefully grind the dividing edge.

3
M8301671
 

  • Open the tailgate

  • Remove the four screws (1) from the lower section of the panel on the tailgate

  • Grasp the edges of the panel. Carefully pull off the panel. The panel is secured by eight clips.

4
M8301672
 

  • Pull down the sides of the panel around the tailgate window to release it from the two clips

  • Grasp the upper section of the panel. Carefully pull the upper section of the panel to release the clips

  • Place the panel to one side.

5
M3903031
 

  • Remove the connector (1) from the brake lamp

  • Press the centre of the clip (2) until a click is heard

  • Remove the clip

  • Slide the brake lamp to the left to release it from the guide holes.

6
M8400685
 

    Pre-drilling

  • Open the tailgate

  • Punch and drill the hole (1) according to the markings. Use a 3 mm (1/8”) diameter drill bit at right angles to the surface.


    Note!

    Only drill through the first plastic layer as illustrated. Use a drill stop. Repeat the operation on the other side of the tailgate.


  • Punch and drill the hole (2) on the left-hand side according to the markings. Use a 3 mm (1/8”) diameter drill bit at right angles to the surface. Drill through both the plastic layers as illustrated. The hole is for cable lead-in.

    Hole enlarging

  • Drill out the hole (1) using a 10 mm diameter (25/64”) drill bit on the left and right-hand sides.


    Note!

    Only drill through the first plastic layer as illustrated. Drill at right angles to the surface. Use a drill stop.


  • Drill out the hole (2) on the left hand side. Use a 5.5 mm (7/32”) diameter bit. Drill at right angles to the surface. Drill through both plastic layers.

7
M8400864
 

  • Cut out the left and right drill templates from the kit using scissors as illustrated.

8
M8400681
 

    Pre-drilling

  • Position the left template on the upper left corner of the tailgate. See the illustration

  • Mark both holes through the template and inside the tailgate using an awl

  • Drill the markings at right angles to the surface. Use a 3 mm (1/8”) diameter drill bit.


    Note!

    Only drill through the first plastic layer at the hole (1). Use a drill stop. Drill through both layers at the hole (3).


  • Repeat the operation on the other side of the tailgate.

    Hole enlarging

  • Drill the hole (1) at right angles to the surface. Use a 16 mm (5/8”) diameter hole saw. Only drill through the first plastic layer. Use a drill stop

  • Drill the hole (3). Use a 10 mm (25/64”) diameter hole saw at right angles to the surface. Drill through both plastic layers

  • Repeat the operation on the other side of the tailgate.

9
 

  • Check that the roof spoiler aligns in the drilled holes. Ensure that the screws (from the kit) align with the nuts for the roof spoiler

  • Adjust the holes, if necessary, using a round file.

10
M8400553
 

  • Route the cable (1) through the spoiler. Thread a piece of steel wire or a thin plastic rod into the hole for the cable lead-in starting at the brake lamp. Tape the terminal pins and cable to the steel wire. Pull out through the hole.


    Note!

    Do not damage the pins.


  • Remove the covers (2)

  • Install the brake lamp. Use the two screws (3). Tighten to a maximum of 2.5 Nm (2 lbf.ft.). A greater torque may damage the threaded joint

  • Reinstall the covers.

11
M8000271
 

  • Clean the surfaces where the roof spoiler is to be installed. Use a mixture of 30% windscreen washer fluid and 70% water

  • Wipe dry.

12A
M8400554
12B
M8400555
12C
M8301702
 


Note!

To ensure the best results, it is recommended that two people press the roof spoiler onto the tailgate.


Illustration A

  • Remove the protective film from the tape.

Illustration B

  • Insert and pull the brake lamp cable through the hole in the tailgate

  • Press the spoiler into place on the tailgate.

Illustration C

  • Install the four screws (from the kit). Tighten the spoiler. Use an M6x10 screw in hole (1). Use an M6x14 screw in hole (2)

  • Tighten the screws. Tighten to a maximum of 4 Nm (2.9 lbf.ft). A greater torque may damage the threaded joint.

13
M3903032
 

  • Cut the rubber nipple (1) off the rubber grommet for the brake lamp. Do not damage the existing cables

  • Thread the brake cable from the roof spoiler between the hinges and tailgate behind the existing cable. Thread the brake cable through the hole in the rubber grommet and out of the hole in the corner of the tailgate

  • Use soap to facilitate the lead-in.

14
M8301675
 

  • Clean the rear windscreen by the brake lamp socket

  • Wet the window. Soak the tape which will cover the socket. Use a mixture of 30% windscreen washer fluid and 70% water

  • Apply the tape over the socket. Press out the water and air bubbles. Use a plastic card or similar

  • Reinstall the brake lamp.

15
M8301674
 

  • Drill holes in the tailgate for the attachment of the connector

  • Drill out the holes. Use a 6.5 mm (17/64”) diameter drill bit

  • Press in the tie strap with the clip.

16
M3903033
 

  • Take the connector (2) from the kit. Open the catch

  • Connect the cable harness for the spoiler to the connector. Connect the red (R) cable to position 1. Connect the black (SB) cable to position 5

  • Press the catch together

  • Connect the existing brake lamp cable (1) to the new connector as illustrated.

17
M3903034
 

  • Secure the connectors using the tie strap

  • Clamp the cables to each other. Use two tie straps from the kit.

18
 

  • Check the function of the brake lamp

  • Reinstall the panels on the tailgate

  • Post-tighten the screws for the spoiler to the correct torque. See point 12.