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.

Fitting the fuel lines

Fig 1: Fuel Lines Secured To Mountings

Courtesy of VOLVO CARS OF NORTH AMERICA.

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

Fig 2: Removing Fuel Line From Fuel Pump

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

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

Fitting the fuel lines to the clips

Fig 3: Fuel Lines Secured To Mountings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fit the return line from the ejector pump (left-hand side).

Fitting the hand brake cable

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

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the rear suspension about 10 cm.

Remove the cable tie (A).

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

Raising the rear suspension with fuel tank

Fig 5: Lowering Rear Suspension And Fuel Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the rear suspension and fuel tank.

Make sure the fuel filler pipe does not foul the wing liner. Make sure the fuel line is clear of the body and that the fuel level sensor 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 lifting table. This prevents the rear suspension from tipping backward when lowered.

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

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

Fitting the retaining bolts for the rear axle member.

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

Courtesy of VOLVO CARS OF NORTH AMERICA.

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 16.5 mm holes (A) outside the rear retaining bolts, and the 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 .

Tightening the tank strap attachments

Fig 7: Identifying Tank Strap Bolt

Courtesy of VOLVO CARS OF NORTH AMERICA.

Tighten the tank strap attachments on both sides.

Remove the lifting table.

Fitting the fuel tank EVAP lines

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

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

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

Fitting the propeller shaft and driver

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

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fit the propeller shaft to the driver.

NOTE:

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

Check the contact surfaces of the viscous coupling and propeller shaft drivers 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.

Fitting the longitudinal stay mountings and jack attachments

Fig 10: Identifying Link Arms And Tensioner 999 5659

Courtesy of VOLVO CARS OF NORTH AMERICA.

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

Press up the link arms to their normal position.

See Use Of Tensioner 999 5659 .

Connect the left-hand three-way branching to the left-hand jack attachment.

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

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

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

Fitting the exhaust pipe

Fig 11: Identifying Rear Exhaust Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

rear exhaust pipe
silencers.

NOTE:

Check that there is clearance to the heat shields.

Fitting the filler pipe

Fig 12: Identifying Filler Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

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

Fitting the hatches and connections to the tank fitting

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

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

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.
connectors to the tank fitting, fuel pump and ABS system.

Positioning the luggage compartment floor mountings

Fig 14: Identifying Fasteners On Cargo Compartment Floor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Position:

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

Tighten the screws.

Fitting the rear wheels

Fig 15: Identifying Wheel Arch Liner And Mudflap

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

wheel arch liner and mudflap on rear edge on right-hand side.
rear wheels.

Refill the fuel tank.

Test drive and perform functional checks.