Body Frame - Removal, Replacement and Installation: Other Volvo S60 I

Rocker panel reinforcement, replacing

Pull out the damaged section.

Cut, grind or saw off the damaged sections.

Scheme 127

Align the new sill reinforcer.

Weld into place.

Scheme 128

Align the outer door sill.

Weld into place.

Scheme 129

Alternative cutting points.

Side member front, replacing

Special tools

9995797

9995798

9995799

Note. The illustrations in this service information are used for different model years and / or models. Some variation may occur. However, the essential information in the illustrations is always correct.

The extent of the deformation varies depending on the type of damage. Therefore different joining points have been tested. These joining points are shown below.

Note. It is extremely important that there is an offset of 70 mm at the point of the joint on the inner and outer section.

Removing the front side member, common information

Remove components. See FRONT SECTION, EXPOSING (-2003) or FRONT SECTION, EXPOSING (2004-).

Secure the car in an alignment bench.

Pull out the damaged section using puller tools 9995797 , 9995798

and 9995799 .

Check that the dimensions of the car are correct. See Front section, dimensions chart and Side members front, alignment chart .

Remove

1. the bumper rail
2. the light frame. See «Headlamp support frame, replacing»(ref-415523-S42430406482011081500000) .

Scheme 130

Cut the side member according to alternative (1) (see the illustration). Cut the side member 30 mm (M1) in front of the deformed kink.

Joining may be carried out as far as the deformation kink (3).

Drill or grind out the spot welds.

Pry off the component.

Grind the welding surfaces clean. Carry out the corresponding operation on the replacement part.

Note. Do not cut at the reinforcement (2)

Scheme 131

Scheme 132

Cut the replacement part.

Apply welding primer.

Align the replacement part. Use the measurement system on the alignment bench.

Secure and weld the replacement part into place.

Scheme 133

Start from the original joint (1). Position the new joint within the shaded area.

M1 = 150 mm

M2 = 350 mm

Carry out the corresponding join on the replacement part.

Drill or grind out the spot welds.

Pry off the component.

Grind the welding surfaces clean.

Note. It is extremely important to check that there is no deformation in the joining area.

Scheme 134

Apply welding primer.

Align the replacement part. Use the measurement system on the alignment bench.

Secure and weld the replacement part into place.

Scheme 135

Measure a suitable cutting point. Position the new joint behind the original joint (1).

Cut the section.

Carry out the corresponding join on the replacement part.

Drill or grind out the spot welds.

Pry off the component.

Grind the welding surfaces clean.

Scheme 136

Apply welding primer.

Align the replacement part. Use the measurement system on the alignment bench.

Secure and weld the replacement part into place.

Scheme 137

Position the joint through the hole (4).

Cut the section.

Drill or grind out the spot welds.

Pry off the component.

Grind the welding surfaces clean.

Scheme 138

Apply welding primer.

Align the replacement part. Use the measurement system on the alignment bench.

Secure and weld the replacement part into place.

Scheme 139

Measure a suitable cutting point.

Position the new joint (2) behind the original joint (1).

A = 50-230 mm

Carry out the corresponding join on the replacement part.

Drill or grind out the spot welds.

Pry off the component.

Grind the welding surfaces clean.

Scheme 140

Apply welding primer.

Align the replacement part. Use the measurement system on the alignment bench.

Secure and weld the replacement part into place.

Scheme 141

Measure out a 400 mm strip of tape.

Secure the tape to the side member. Begin at the hole for the brake line bracket.

Mark the joint using the template.

Cut the section.

Carry out the corresponding join on the replacement part.

Drill or grind out the spot welds.

Pry off the component.

Scheme 142

Scheme 143

Apply welding primer.

Align the replacement part. Use the measurement system on the alignment bench.

Secure and weld the replacement part into place.

Installing the front side member, common information

Install

1. the bumper rail
2. the light frame. See «Headlamp support frame, replacing»(ref-415532-S07405619862011120500000) .

Seal according to Body, sealant application chart .

Scheme 144

Dimension = 50 mm.

Weld the outer section of the light frame into place.

Scheme 145

The inner section of the light frame is secured by spot welding in the upper and lower side member.

Drill out the spot welds.

Install a new inner light frame.

Spot-weld to the upper and lower side member.

Note. The light frame must be positioned between the upper side member and the cover for the upper side member.

For dimensions (Scheme 146)and (Scheme 147).

Scheme 146

A7 = 927 mm

A8 = 839 mm

Scheme 147

A14 = 59 mm

A15 = 37 mm

A16 = 32 mm

Headlamp support frame, replacing

Dimension = 50 mm.

Weld the outer section of the light frame into place.

The inner section of the light frame is secured by spot welding in the upper and lower side member.

Drill out the spot welds.

Install a new inner light frame.

Spot-weld to the upper and lower side member.

Note. The light frame must be positioned between the upper side member and the cover for the upper side member.

For dimensions see scheme 32, see scheme 33, and see scheme 34

A7 = 927 mm

A8 = 839 mm

A14 = 59 mm

A15 = 37 mm

A16 = 32 mm

A14 = 59 mm

A15 = 37 mm

A16 = 32 mm

Side member upper, joining

The side member need not be replaced whole but can be joined.

Scheme 148

Cut off the damaged section.

Cut so that the member is 100 mm shorter than the cover.

(Dimension A).

Grind clean.

Cut the replacement part (upper side member)

Apply welding primer.

Secure the replacement part.

Weld into place.

Grind the welds.

Scheme 149

Note. Before the cover is installed the light frame procedure must be carried out. See Headlamp support frame, replacing .

Cut the replacement part (cover).

Weld into place.

Scheme 150

Secure the rear, outer section of the floor.

Weld into place.

Scheme 151

Secure the end of spare wheel well against the side members.

Weld into place.

Scheme 152

Spot-weld the battery shelf.

Scheme 153

The battery shelf must be secured with 11 spot welds.

Scheme 154

Grind the welds.

Cut off the damaged section.

Grind clean.

Apply welding primer.

Align and secure the wheel arch.

Weld into place.

Scheme 155

Secure the outer section of the wheel arch.

Weld into place.

Scheme 156

Secure the inner rear section of the wheel arch.

Note. Test install the rear fender.

Weld into place.

See Side member front, replacing

Side member, upper, replacing

See Side member, upper, replacing

Spare wheel well, replacing

See Spare wheel well, replacing

Wheel housing, front, replacing

See Wheel housing, front, replacing

Wheel housing, rear, replacing

See Wheel housing, rear, replacing

See Side member front, replacing

See Side member, upper, replacing

See Spare wheel well, replacing

See Wheel housing, front, replacing

See Wheel housing, rear, replacing

See Side member front, replacing

See Side member, upper, replacing

See Spare wheel well, replacing

See Wheel housing, front, replacing

See Wheel housing, rear, replacing

See Side member front, replacing

See Side member, upper, replacing

See Spare wheel well, replacing

See Wheel housing, front, replacing

See Wheel housing, rear, replacing

See Side member front, replacing

See Side member, upper, replacing

See Spare wheel well, replacing

See Wheel housing, front, replacing

See Wheel housing, rear, replacing

See Side member front, replacing

See Side member, upper, replacing

See Spare wheel well, replacing

See Wheel housing, front, replacing

See Wheel housing, rear, replacing

See Side member front, replacing

See Side member, upper, replacing

See Spare wheel well, replacing

See Wheel housing, front, replacing

See Wheel housing, rear, replacing

Preparatory work

Remove

1. the panel in the luggage compartment acc. to: «Side panel, cargo compartment, replacing»(ref-415318-S21199295202011081500000) MY -2003 See «Bumper rear, replacing»(ref-415517-S39902089852011081500000) and: «Bracket for the rear bumper»(ref-415532-S15794171602011081500000) MY 2004 See «Bumper rear, replacing»(ref-415517-S17509618042011081500000) MY 2005 See «Bumper rear, replacing»(ref-415517-S27993418052011081500000) .
2. tail lights acc. to: «Tail lamp, replacing»(ref-415246-S40629646402011081500000) MY -2003 See «Bumper rear, replacing»(ref-415517-S39902089852011081500000) and «Bracket for the rear bumper»(ref-415532-S15794171602011081500000) MY 2004 See «Bumper rear, replacing»(ref-415517-S17509618042011081500000) MY 2005 See «Bumper rear, replacing»(ref-415517-S27993418052011081500000) .
3. the rear bumper acc. to: MY -2003 See «Bumper rear, replacing»(ref-415517-S39902089852011081500000) and: «Bracket for the rear bumper»(ref-415532-S15794171602011081500000) MY 2004 See «Bumper rear, replacing»(ref-415517-S17509618042011081500000) MY 2005 See «Bumper rear, replacing»(ref-415517-S27993418052011081500000) .

Note. The bumper rail is made of BORON steel, see: HSS/BORON Steel .

Scheme 157

Pull out the damaged section.

Use puller tools acc. to: Aligning the rear frame member .

Use a straightening bench and the straightening bench's measurement system.

Make sure that other vehicle dimensions are correct.

Scheme 158

Drill loose the upper backpiece so that the upper row of spot welds can be accessed.

Scheme 159

Grind off the spot welds with a grinder.

Cut loose the bumper rail acc. to the red marking, see illustration.

Note. Cover windows and interior to protect against grinding sparks, etc.

Scheme 160

Alternative cutting points

If the damage is less serious on one side, the member can be spliced as shown in the illustration.

Scheme 161

Scheme 162

Cut the spare part, align and weld on.

Use welding primer P/N 116 1342 .

Weld the upper edge with 12 spot welds and the lower edge with 30 spot welds, 4.5 mm in diameter.

Scheme 163

Fit the outer upper backpiece.

Weld into place.

Put putty on backpiece acc. to: Body, sealant application chart .

Note. Apply rustproofing after paint.

Reinstall the removed components in reverse order.

Install

1. the rear bumper acc. to: MY -2003 See «Bumper rear, replacing»(ref-415517-S39902089852011081500000) and: «Bracket for the rear bumper»(ref-415532-S15794171602011081500000) MY 2004 See «Bumper rear, replacing»(ref-415517-S17509618042011081500000) MY 2005 See «Bumper rear, replacing»(ref-415517-S27993418052011081500000)
2. tail lights acc. to: «Tail lamp, replacing»(ref-415246-S40629646402011081500000)
3. the panel in the luggage compartment acc. to: «Side panel, cargo compartment, replacing»(ref-415318-S21199295202011081500000) .

Scheme 164

HSS material

HSS is a common term for steel within certain strength parameters (high strength steel).

HSS stands for H igh S trength S teel.

The vehicles are constructed from a number of different steels, partly to obtain an optimized body (collision safety, rigidity, fuel economy, etc.) and partly to make them as easy to repair as possible.

The steels are divided into four groups according to their tensile yield stress, that is to say the force that is necessary to bring about plastic deformation of the material

These groups are

MS - M ild S teel. Trade steel with a highest tensile yield limit of 220 Mpa.

HS - H igh strength S teel. Steel with a yield point of 220 - 450 MPa.

EHS - E xtra H igh strength S teel. Steel with a yield point of 450 - 800 MPa.

UHS - U ltra H igh strength S teel. Steel with a yield point of 800 - 1400 MPa.

Soft Steel

This material is sometimes called commercial steel. This group of steels accounts for the highest proportion (50-60%) of the materials from which the car is made and it is used where the need for a stronger steel cannot be justified.

High-strength Steel

This group consists of three main types of steel

1. Phosphorus-alloy steel which gets some of its increased strength from the alloying constituent phosphorus.
2. HSLA steel ( H igh S trength L ow A lloy). This is a low-alloy steel which obtains some of its increased strength from the alloying constituents Vanadium, Niobium or Titanium.
3. DP steel ( D ual P hase). This steel gets its increased strength from the heat treatment it is given during manufacture. This is where a dual phase structure of ferrite (iron) and martensite (carbon) is formed. This steel loses its strength if exposed to temperatures above 300°C.

Extra High-strength Steel

This group includes both HSLA and DP steel but their strength is further increased with larger proportions of alloying constituents.

Ultra High-strength Steel

This group consists of two main types of steel.

DP steel. Here the strength has been successfully increased through an advanced manufacturing process and a higher proportion of alloying constituents.

BORON steel/Material

The strength of this material is obtained through the addition of the element Boron and also its comparatively large carbon content. The sheet metal sections are formed in the incandescent phase between punch and die where hardening of the material also takes place.

HSS steel

HSS-steel (HSS = High Strength Steel) has a higher yield point and ultimate tensile strength than ordinary sheet steel.

The yield point of the material increases with heat treatment.

HSS steel may therefore be more difficult to straighten than ordinary sheet steel.

1. All welding work should be carried out in accordance with this manual.

Note. "Heat-straightening" of the sheet steel, such as in an alignment bench, must not be performed.

When an alignment bench is used, HSS components may prove troublesome if the counterstay is not correctly positioned so that the maximum power of the puller is used.

It is therefore necessary to pay attention to the way the body reacts to the puller and make sure that only the deformed area moves.

All body parts are made of HSS.

The grey areas in the pictures have HSS with a yield point above 340 N/mm2 and extra care must therefore be taken when repairs are carried out.

Scheme 165

Scheme 166

Scheme 167

The parts marked black are made of BORON steel. BORON steel has an extremely high yield point and ultimate tensile strength. When replacing BORON steel body parts the spot welds cannot be drilled out and grinding or plasma cutting is used instead. BORON steel exhibits good weldability.

Galvanizing is not possible in the manufacture of BORON steel. It is therefore extremely important to treat these parts with corrosion inhibitor.

Note. BORON steel does not lend itself well to straightening.

Note. Making joints in BORON steel is allowed where the method employed indicates this. Prepare accurate templates and use a cutting wheel or plasma cutting equipment.

Note. BORON steel must not be heated

Note. Protect interior equipment and glass when grinding or plasma cutting.

Scheme 168

Bracket for the rear bumper

Removing the bracket for the bumper

Scheme 169

Scheme 170

Remove

1. the rear bumper according to «Bumper rear, replacing»(ref-415517-S39902089852011081500000)
2. Five screws
3. Four blind rivets according to «Removing rivets»(ref-415532-S00877212842011120500000) .

Installing the bracket for the bumper

Install

In reverse order.

Removing rivets

Special tool T9814075 SPRAY GUN Tool number: T9814075 Tool description: SPRAY GUN Tool boards

Scheme 171

Note. If the pop rivet spins, drill at a 45° angle against the pop rivet.

Pay attention to heat generation when drilling in pop rivet mounted in plastic part.

Remove drill burrs and any remains of the rivet.

If possible, put tape on the back to catch pop rivet.

Scheme 172

To avoid rattling if it is not possible to remove remains of rivet.

9814075

Scheme 173

Cantrail

Cut off the damaged section. See Joint and cutting points .

Roughly cut replacement part.

Align the two components which make up the inner cantrails in the car. Use holes as a guide.

Cut. See Joint and cutting points .

Remove excess materials.

Weld into place.

Scheme 174

Align cantrail reinforcements.

Weld into place.

Scheme 175

Roof side

Roughly cut the replacement part.

Align on car.

Saw through the two panels.

Remove excess materials.

Align the replacement part.

Weld into place.

Note. Remember to weld the T-Studs. P/N 981690 .

Joint and cutting points

Principles of joining

Note. When welding in the vicinity of the roof: Cover the interior components that have not been removed. This is to protect against welding drops and spray.

Scheme 176

Cut the A-post.

Dimension C = 50 mm.

Scheme 177

Cut the B-post.

Dimension C = 50 mm.

Scheme 178

Cut the C-post.

Dimension C = 50 mm.

Replacing roof arch, front and rear windshield frame

Grind off the spot welds.

Remove the damaged components.

Scheme 179

Check the distance between the roof arches.

Dimension M1 = 1157 mm.

Dimension M2 = 1135 mm.

Dimension M3 = 1416 mm.

Scheme 180

Install a new front or rear windshield frame.

Install a new roof arch.

Weld into place

Note. Cars with sun roof have no roof arch.

Roof panel, replacing

Grind off the spot welds on the front and rear windshield.

Grind off the laser weld along the sides.

If the car has a sun roof

Grind the off bead welds (three on each side) which retain the sun roof frame in the inner cantrail.

Cars without sun roof

Remove the roof arch from the roof using a putty knife or piano wire.

Remove the roof panel.

Lever carefully so as not to damage the cantrail.

Clean the roof arch. Replace if necessary.

Grind all mating surfaces to bare metal.

Scheme 181

Align the new roof panel.

Check the distance between the cantrails. See Roof arch, replacing .

Without sun roof

Mark the roof arch using a pencil.

Lift off the roof panel.

Grind those areas to receive adhesive.

Scheme 182

Drill three 6 mm holes in the roof panel on each side.

Drill the first hole at the center of the B-posts.

Drill the second hole 150 mm in front of the B-post center (Dimension A).

Drill the third hole 150 mm behind the B-post center (Dimension A).

Apply welding primer to the windshield and rear windshield members.

Scheme 183

Apply adhesive to the roof edges.

Apply generously so that adhesive is pressed out when the roof is installed.

Note. Do not apply any adhesive within 30 mm of the hole that is to be plug welded.

(Dimension B = 30 mm.)

Scheme 184

No sunroof: Apply primer to the roof arch.

Apply PUR adhesive to the roof arch.

Dimension A = 100 mm.

Dimension B = 100 mm.

Dimension C = 15 mm.

Scheme 185

Align the roof.

Scheme 186

Spot weld the front and rear edges.

Plug-weld the three holes at the B-post.

Wipe off excess adhesive.

If necessary: Use welding grips on the roof edges.

Scheme 187

If the car has a sun roof

Weld the frame for the sun roof to the cantrail.

(3 seam welds on each side)