Fitting the rear suspension assembly

WARNING: This page is about a different car, the 2002 Volvo C70, 2001 Volvo C70, 2000 Volvo C70, 1999 Volvo C70, and 1998 Volvo C70. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Position Of Fuel Lines On Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the fuel lines

Position and secure the fuel lines to their mountings in the same order as they were removed.

Fig 2: Removing/Installing Fuel Lines At Fuel Pump

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Install:

the fuel line attachments between the fuel pump and fuel filter
the fuel lines from the fuel pump and ejector pump.

Fig 3: Identifying Position Of Fuel Lines On Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the fuel lines into the clips

Fit the return line from the ejector pump (LH side).

Fig 4: Identifying Pop Rivet And Cable Tie At Jack Attachment/Longitudinal Stay Brackets

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Fitting the hand brake cable

Raise the rear suspension about 10 cm.

Remove the cable tie (A).

Fit the hand brake cable with clips; use a pop rivet (ø 4 mm) (B).

Fig 5: Raising/Lowering Rear Suspension And Fuel Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raising the rear suspension

Raise the rear suspension with fuel tank.

Make sure the filler pipe does not foul the wheel arch liner. Make sure the fuel line is clear of the body and that the fuel gauge line does not get caught in the fuel strap brackets.

Lift up the tank fitting lines and fuel pump lines through the body (hatch).

CAUTION:

Secure the front part of the differential to the lift table. This prevents the rear suspension from tipping backward when lifted.

NOTE:

Check also that the fuel line between the fuel level sensor and the ejector pump does not foul the body when the rear suspension is lifted.

Adjust and secure the filler pipe's crash guard bracket.

Fig 6: Identifying Rear Axle Member Guide Holes And Rear Retaining Bolts

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Fitting the retaining bolts for the rear axle member

Apply a couple of drops of threadlock, part number 1161351-0, to each bolt.

Fit all the retaining bolts for the rear axle member.

NOTE:

Before fitting the rear axle to the body, measure the distance between the rear axle member guide ø 16.5 mm holes (A) outside the rear retaining bolts, and the ø 16 mm holes furthest to the rear on the side members. The distance between the holes should be 595 mm +/- 2 mm.

Tighten the outer bolts to 80 Nm and the center bolts to 50 Nm .

Fig 7: Identifying Tank Strap Bolt

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Tightening the tank strap attachments

Tighten the tank strap attachments on both sides.

Remove the lift table.

Fig 8: Identifying Fuel Lines, Plastic Clip, And Protective Cover

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Fitting the fuel tank EVAP lines

Install:

the brake pipe in the 4 clips
the fuel and EVAP lines
the lines to the protective cover
the protective cover, use new nuts and washers
protective covers.

Fig 9: Identifying Propeller Shaft And Special Tool (Holder) 9995561

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Fitting the propeller shaft and driver

Fit the propeller shaft to the driver.

NOTE:

Fit the propeller shaft as marked earlier. Refit the bolts in their original positions.

Check that the contact surfaces of the viscous coupling and propeller shaft driver are clean.

Tighten opposite bolts to 8 Nm . Then tighten opposite bolts to 30 Nm . Use holder 9995561 . Start by tightening the same bolt both times.

Fig 10: Identifying Link Arms And Tensioner 999 5659

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Fitting the longitudinal stay mountings and jack attachments

Fit the front longitudinal stay mountings and the jack attachments to the body.

Press up the link arms to their normal position.

See XXX (tension yoke) and XXX (normal position).

Connect the LH three-way branching to the LH jack attachment.

Fit the longitudinal stay brackets and the jack attachments using new bolts.

Tighten the 3 bolts for the longitudinal stay bracket to 65 Nm + 60° .

Tighten the bolt through the jack attachment to 105 Nm + 90° .

Fig 11: Identifying Rear Exhaust Pipe

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Fitting the exhaust pipe

Install:

the rear exhaust pipe
the silencers.

NOTE:

Check that there is clearance to the heat shields.

Fig 12: Identifying Fuel Filler Pipe

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Fitting the filler pipe

Fit the fuel filler pipe to the body with the rubber bellows and lock ring.

Fig 13: Identifying Front Cover And Connectors For ABS Sensor And Fuel Level Sensor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the hatches and connections to the tank fitting

Install:

the front and rear hatch in the body and the connector holder. Make sure the rubber seal around the wiring is properly fitted when the rear hatch is fitted.
the connectors to the tank fitting, fuel pump and ABS system.

Fig 14: Identifying Fasteners On Cargo Compartment Floor

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Positioning the luggage compartment floor mountings

Position:

the mounting at front edge of the luggage compartment floor. Fit the screws along the rear edge.
the hatch with the rear floor hatch.

Tighten the bolts.

Fig 15: Identifying Wheel Arch Liner And Mudflap

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Fitting the rear wheels

Install:

the wheel arch liner and mud flap on rear edge on right-hand side.
the rear wheels.

Refill the fuel tank.

Test drive and perform functional checks.