Part 1
Towbar, detachable
INTRODUCTION
- Read through all of the instructions before starting installation.
- Notifications and warning texts are for your safety and to minimize 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.
Towbar, detachable
Note! Some steps in these installation instructions are presented with illustration only.
Applies to all models
Applies to cars with skid plate
- Drill out the four rivets on the lower edge of the skid plate. Drill carefully and avoid enlarging the holes in the skid plate and the bumper cover. Use a - 6 mm (15/64") drill.
- Remove any chips and rivet residue.
- Slide the skid plate upwards and unhook it from the holder's (1) five catches on the upper edge.
Note! Exercise care with the skid plate and the finished surfaces.
Applies to cars with R-design
- Remove the clips.
- Repeat the operation on the other side.
Applies to all models
Note! Two persons should perform the following work.
Illustration A
- Unhook the catches at end of the bumper on the front edge on both sides. Carefully pull away the ends of the bumper cover until the catches at the rear edge of the rear wing and under the taillights release.
- Pull the bumper cover backward to release it.
Illustration B
- Disconnect the connectors under the right-hand tail lamp. The catch is underneath.
Applies to older car models
- Remove the screws.
Applies to newer car models
- Remove the pop rivets.
Use: cutting pliers.
Applies to cars with a single end pipe
- Loosen the front rubber mounting from the chassis.
Applies to cars with double end pipes
- Loosen the front rubber mounting from the chassis.
- Loosen the middle rubber mounting from the chassis.
Applies to all models
- Remove the bolts from the exhaust system's rear rubber mountings and lower the silencer until it stops.
- Turn down the rear rubber mountings.
- Remove the clips that hold the heat shield to the body.
- Pull out the radiation shield.
- Remove the cover plates from the inside of the side members on both sides.
- Thoroughly clean away splashes of underseal, putty or dirt from the plate surfaces on the insides of the side members where the reinforcements are to be located.
- Check that the contact faces inside the side members are clean. If necessary, clean opposite where the towing member's side plates are to be fastened.
- Take the towing member from the kit and insert the two side plates in the holes at the rear edge of the side members.
- Remove the bolts and the reinforcement bars from the kit. Two persons should work together to hold and adjust the position of the towing member when the bolts are inserted in the towing member's weld nuts.
Note! Ensure the reinforcement bars are positioned correctly, as illustrated.
- Tighten the screws alternately on both sides.
Tightening the screw joint
Tighten the screws to 140 Nm (103 lbf.ft.) and angle tighten to 60°. When angle tightening joints in confined areas a protractor cannot be placed on the torque wrench. Use the head of the hexagon bolt instead to determine the tightening angle. Use workshop lift part.no. 9985972 and fixture part.no. 9995972 under the silencer to position it for better access.
- Mark the bolt head's flange (1).
- Make a second mark (2) in the side member or reinforcement bar.
- Now tighten the screw so that the screw head marking (1) lines up with the marking (2) on the side member/reinforcement bar.
- Repeat for all screws.
- Spray/brush a thick coat of rust inhibitor on the marked surface on the radiation shield to remove the metallic gleam in the centre of the bumper cover cut-out.
Applies to older car models
- Tighten the radiation shield.
Applies to newer models
- Rivet the radiation shield.
Applies to all models
- Refit the mountings for the silencers and torque tighten the screws to 50 Nm (37 lbf.ft.).
Applies to cars with double end pipes
Applies to cars with a single end pipe
Applies to all models
- Apply low viscosity rustproofing agent to the marked bare sheet surfaces on both sides of the collision member, the rear edge of the rear side members on the right and left hand sides.
Applies to cars with R-design
- Remove the skid plate from the bumper cover.
Applies to cars without skid plate or R-design
- Apply tape to the outside of the bumper cover, opposite the markings on the inside. Do this to protect the paint from the saw when cutting out the cut-out for the tow hitch.
- Cut along the applicable marking. The checkered area is to be discarded
Note! Do not damage the painted surface of the bumper cover. Cut so that the raised edge on the inside remains. The raised edge marks the cut-out.
- Remove the tape.
- File the sawn edges smooth with a fine toothed file.
- Install the tow hitch connector with cable harness according to the appropriate installation instructions.
Applies to cars with skid plate or R-design
- Saw out according to the markings in the lower section of the bumper cover. The shaded surface is to be removed.
Note! Do not damage the painted surfaces. Cut so that the raised edge on the inside remains. The raised edge marks the cut-out.
- Smooth off the sawn edges with a fine toothed file.
Applies to cars with skid plate
- Tape the skid plate on the outside opposite, where it is to be sawn, to avoid the saw damaging the paintwork.
- Cut along the applicable marking. The checkered area is to be discarded
Note! Do not damage the painted surface of the skid plate. Cut so that the raised edge on the inside remains. The raised edge marks the cut-out.
- Remove the tape.
- Smooth off the sawn edges with a fine toothed file.
- Install the tow hitch connector with cable harness according to the appropriate installation instructions.