Volvo 8670993 User manual

Instruction No Version Part. No.
8670993 1.0
Lowered sports chassis
Instruction No Version Part. No.
8670993 1.0
Lowered sports chassis
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 1 / 18

Equipment
A0000162 A0000161 A0000197 D0000219 M0000264 A0800088
A0800625 M0000265
M7600425
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 2 / 18

M7600426
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 3 / 18

M7600427
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 4 / 18

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.
Preparations, cargo compartment
1
M8502796
Preparations, cargo compartment
Remove:
the front floor hatch. First lift the rear edge up slightly. Pull the
floor hatch backwards out of the mountings
the front insulation panel.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 5 / 18

2
M8503575
Remove the foam rubber seal above the rear shock absorber
mountings on the left and right-hand sides.
Sports chassis kit, rear
Note!
Carry out points - on both sides.
Note!
If the anti-roll bar is to be replaced, carry out points - .
3
M7600370
Remove:
the nut (1) for the shock absorber
the screws (2) for the upper shock absorber bearing.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 6 / 18

4
D7600240
Raise the car.
Remove:
the rear wheels
the lower screw (1) for the shock absorber
the shock absorber (2) and the upper bearing.
5
D7600186
Relieve the load from the lower trailing arm (1). Use a mobile
jack
Remove the screw (2) for the trailing arm
Carefully lower the mobile jack
Remove the spring (3) by pressing the trailing arm down.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 7 / 18

6
D7600238
Remove:
the nut (1) for the anti-roll bar. Use a Torx socket as a
counterhold to protect the rubber boot
the outer end (2) of the anti-roll bar from the lower ball joint bolt
(3) on the control arm.
7
D7600187
Remove:
the mountings (1) for the handbrake cables
the rear mountings (2) for the centre silencer
the screws (3) for the anti-roll bar mountings (4) from the base
plate on the left and right-hand sides
the anti-roll bar (5) by pulling the anti roll bar out from the side
while twisting it.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 8 / 18

8
D7600188
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
Press the mountings (1) for the anti-roll bar up against the base
plate mountings. Use the mobile jack.
Install:
new screws (2) and nuts (2). Tighten to 80 Nm (60 lbf.ft.). See
point
the mountings for the handbrake cables (3). Tighten the
mountings
the mountings (4) for the centre silencer.
9
Reinstall:
the outer end of the anti-roll bar on the lower ball joint bolt for the
control arm. See point
the nut. Tighten to 80 Nm (60 lbf.ft.). Use socket (P/N 9995500)
and a Torx socket as a counterhold.
10
E6500370
Install the new upper shock absorber bearing in the spring turret.
Use the three screws from the kit and the two washers. Do not
tighten fully yet.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 9 / 18

11
D7600239
Remove the rubber liner (1) for the spring turret. Position the
liner on the new spring. Adjust the rubber liner so that the
groove (2) aligns with the spring.
Hint
Lubricate the rubber lining using soap solution to facilitate
installation.
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.
12
M7600346
Position the mobile jack under the trailing arm (1)
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
Press and adjust the trailing arm into the mounting (3)
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
Position the mobile jack under the rear mounting for the lateral
link at the arrow (5). Adjust the position of the trailing arm so that
the screw can be threaded all the way into the trailing arm. Do
not tighten the screw yet.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 10 / 18

13
D7600184
Insert the new shock absorber (1) from the kit through the lower
trailing arm and the spring
Raise the shock absorber and align it in the upper bearing in the
spring strut turret
Align the lower mounting (2) of the shock absorber in the trailing
arm
Install the new screw (3). Tighten to 80 Nm (60 ft.lb.).
14
A6500361
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:
the threaded rod (P/N 999 5659) on the mounting (P/N 999
5740B)
the mounting (P/N 999 5740B) on the sub-frame
the rails (P/N 999 5740B-1) on the control arm
the tensioner (1)
Ensure that the rollers are against the rails on both sides of the
control arm.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 11 / 18

15
A6500362
Press the trailing arms up so that the distance between points
(1) and (2) is 397 ± 1 mm (15 5/8” ± 3/64”). Use the tools in point
Tighten the screw in the inner mounting for the trailing arm.
Tighten to 80 Nm (60 lbf ft.). See point
Remove the tensioner and the associated components.
16
M7600428
Lower the car slightly. Install both rear wheels. Tighten the wheel
nuts crosswise
Torque tighten the three new screws (1) in the upper shock
absorber bearing. Tighten to 25 Nm (18.5 lbf ft.)
Install the new washer (2) and the nut (2) 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.
17
Reinstall the foam rubber seals over the rear shock absorber
mountings
Reinstall the front insulation panel and the floor hatch.
Sports chassis kit, front
Note!
Carry out points - on both sides.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 12 / 18

18
D7600299
Remove:
the front wheels
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.
19
D7600300
Measure the position of the stub axle and spring strut (A) as
illustrated
Remove the ABS sensor cable (1) from the bracket on the
spring strut.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 13 / 18

20
M7700315
Remove:
the bracket (1). The bracket will be used for the new shock
absorber
the screws (2) that hold the spring strut in the stub axle.
21
D7600301
Remove:
the nuts and washers that secure the spring strut bearing to the
car body
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.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 14 / 18

22
M7600371
Secure the spring strut in a vice, as illustrated
Relieve the load on the spring using spring clamps (P/N
9995409). Position the spring clamps opposite each other and
tighten alternately.
Remove:
the cover (1)
the nut (2) and washer (2) at the upper bearing (3). Use socket
(P/N 9995467) and a Torx socket as a counterhold
the upper bearing (3).
23
M7600372
Remove:
the retaining nut (1) on the shock absorber. Use socket (P/N
9995469) and a Torx socket as a counterhold
the spring seat (2)
the spring (3)
the rubber bump stop (4) including the boot.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 15 / 18

24
D7600303
Compress the new spring to a height of approximately 260 mm
(10 1/4”). Use the spring clamps (P/N 9995409).
25
D7600304
Install:
thenewshock absorber in the vice
the new rubber bump stop (1) including the boot
the spring (2). Align the lower end of the spring in the slot (3) in
the lower section of the shock absorber
the washer (4)
the spring seat (5)
the retaining nut (6).
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 16 / 18

26
D7600309
Tighten the retaining nut. Tighten to 70 Nm (52.5 lbf. ft). Use
socket (P/N 9995469) and a Torx socket as a counterhold.
27
M7600373
Install:
the upper bearing (1)
the washer (2)
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
the cover.
Remove the spring tools by slackening them off alternately.
28
Install the spring strut on the car body. Use the new nuts and
washers from the kit according to point
Tighten the three nuts for the spring strut bearing. Tighten to
25 Nm (18.5 lbf. ft.).
29
Install the spring strut on the stub axle. Use new screws and
nuts from the kit
Adjust to the value measured previously at (A) according to point
, to obtain the correct camber angle
Tighten to 105 Nm (78.5 lbf.ft.) Angle-tighten to 90°. Use the
protractor (P/N 9512050)
Reinstall the bracket for the ABS sensor cable. See point
Reinstall the ABS sensor cable in its bracket.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 17 / 18

30
Install the link (1) for the anti-roll bar (see illustration ) on the
spring strut. Use a new nut
Tighten the nut. Tighten to 50 Nm (38 lbf.ft). Use socket (P/N
9995498) and a Torx socket as a counterhold
Reinstall both the front wheels. Tighten the wheel nuts
crosswise
Lower the car completely. Tighten the wheels nuts on all wheels.
Tighten to 140 Nm (104 lbf.ft.)
Check the wheel alignment.
Installation instructions, accessories Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Lowered sports chassis- 8670993 - V1.0
Page 18 / 18