Volvo S60 - ANNEXE 931 User manual

S60
Section
Group
Weight(Kg/Pounds)
Year
Month
8
86
2004
04
Replaces issue: 2004 02
S60
Section
Group
Weight(Kg/Pounds)
Year
Month
8
86
2004
04
Replaces issue: 2004 02
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 1 of 14

Required tools
A0000162
A0000163
A0000161
A0000165
A0000214
A0000177
M0000232
M8401177
M8401178
A0000332
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 2 of 14

Any comments on this publication? Please contact your nearest dealer. Thank you!
Publication no: MA30664734, Issue: 2004 -04
Comments:..........................................................................................................
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From:...................................................................................................................
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Telephone no:................................................................................................... .
Telefax:...............................................................................................................
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 3 of 14

INTRODUCTION
●NOTE! Read through the entire text before carrying out
any work.
●The front page gives the date of this edition and the edition it
replaces
●The second page shows the tools needed for the installation and
the contents of the installation kit
●The illustrations display the procedure in order of operation. The
order of operation is repeated in the text section
●Cut out the text page in order to follow the illustrations and text at
the same time.
Body kit
Note!
During installation the underlay must be kept at a temperature of at least
+15 ° C (60 ° F). NOTE! For cars with a tow hitch, a cut-out for the tow
hitch (point 2) must be made before painting. NOTE! Spray paint
according to the Service Manual “Touch up spraying”, section 8 (80).
Note that, before spraying, the body kit must first be cleaned, then
sanded and then cleaned again. See the instructions in the Service
Manual.
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 4 of 14

1
M8401179
●Pry off the cover for the towing eyelet in the new spoiler. The cover will be
painted separately together with the spoiler.
2A
M8401180
2B
M8401181
2C
M8401182
On cars equipped with tow bars, cutting for the tow bar must be carried out in the new
lower section of the bumper cover. See illustrations A, B and C.
●Apply tape to the lower outside section of the bumper cover, opposite the
markings on the inside. This is to protect the paint from the saw when cutting the
cut-out for the tow hitch wiring connector. (Applies to cars with a painted lower
section)
● Cut the cut -out following the existing markings.
●Smooth off the sawn edges using a fine toothed file. Remove the tape.
Note!
Illustration A applies to cars with a fixed tow bar
Illustration B applies to cars with a detachable tow bar, EU
Illustration C applies to cars with a detachable tow bar, AUS
Illustration D applies to cars with a detachable tow bar, USA
Note!
Do not damage the lower painted surface section of the bumper cover. Cut so
that the raised edge on the inside remains. The raised edge marks the cut-out.
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 5 of 14

2D
M8401183
3
M8401184
●Remove the clip at the lower side of the face on the lower section of the front
bumper cover. Press in the centre pin and remove the clip. There is a new clip in
the kit
●Repeat the operation on the other side.
4
M8401185
●Remove the clips at the lower side of the face on the lower section of the front
bumper cover. Press in the centre pins and remove the clips. There are new
clips in the kit.
5
M8401186
●Turn the wheels to the right
●Insert a screwdriver in the space by the joint between the upper and lower
sections of the bumper cover. Press the hook holding the sections to each other.
At the same time pull out the side so that the hook releases. Force is required to
release the hook
●Repeat the operation on the other side.
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 6 of 14

6
M8401187
●Now pull off the entire lower section from the upper section. Place to one side. It
will not be reused.
7
M8401190
●Clean the joint where the new spoiler is to be positioned.
8
M8401192
●Take the new spoiler from the kit. Install the new spoiler in the same place where
the old lower section was positioned
●Check that it aligns in the grooves (1) correctly
●Press the spoiler into place properly. Ensure that all the hooks engage.
9
M8401191
●Bend the mounting bracket for the spoiler towards the mounting hole at the front
edge of the wheel arch
●Install a black clip with a long centre pin. Press into place
●Repeat the operation on the other side.
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 7 of 14

10
M8401195
●Bend the centre mounting brackets on the spoiler towards the corresponding
mountings on the bumper cover
●Install the grey clips with a short centre pin from the kit. Press into place.
11
M8401196
●Remove the screw in the lower edge of the side on the lower section of the rear
bumper cover
●Repeat the operation on the other side.
12
M8401197
●Pry off the panel for the cut-out for the towing eyelet. Cut off the strap. The
cover will not be reused.
13
M8401188
●Pull off the bumper cover ends from the car body on both sides.
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 8 of 14

14
M8401189
●Fold down the edge on the lower section of the bumper cover until the mounting
clips on one side can be accessed
●Remove the clips. Press in and remove the centre pins. New clips can be found
in the kit
●Repeat the operation on the other side.
15
M8401200
●Pull off the lower section of the bumper cover until the remaining hooks release
from the rear edge
●Place the lower section to one side. It will not be reused.
16
M8401207
●Disconnect the strap for the towing eyelet cover from the car body.
17
M8401201
●Clean the joint where the new spoiler is to be positioned.
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 9 of 14

18
M8401202
●Install the new spoiler where the old lower section was positioned
●Only press the spoiler into place in the hooks at the rear edge, not into the sides
yet.
19
M8401205
●Fold down the edge on the lower section of the bumper cover and the brackets
in the bodywork for installing the spoiler, so that the clips can be pressed into
place
●Take new clips from the kit. Press the spoiler mounting at the mounting brackets
in the car body into place
●Repeat the operation on the other side.
20
M8401206
●Press the spoiler ends on the right and left-hand sides into the corresponding
mountings in the car body
●Now check that all the hooks on the spoiler have engaged.
21
M8401204
●Fold the spoiler mounting bracket towards the spring clip. Tighten the spoiler
bracket to the mounting. Use a screw from the kit
●Repeat the operation on the other side.
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
Installation instructions, accessories - Body kit
Volvo Car Corporation G öteborg, Sweden
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
© VolvoCar Corporation, 2004 Printed in Sweden
30664734
Page 10 of 14