Home/Volvo/S60/Volvo S60 I (2000-2004)/Repair manual/Frames, Subframes & Crossmembers/Body Frame - Removal, Replacement and Installation: Overview
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Body Frame - Removal, Replacement and Installation: Overview Volvo S60 I

Frames, Subframes & Crossmembers 8 illustrations ~194 words

Scheme 86

Scheme 86: Replacing A-post and reinforcement

Cut off the damaged section.

Note. Do not cut the A-post lower than 100 mm from the roof edge. There is reinforcement below this.

Align the mating surfaces.

Align and secure the inner A-post.

Weld into place

Scheme 87

Scheme 87

Weld the bracket into place.

Measurements. See Body side, alignment chart .

Scheme 88

Scheme 88

Align and secure the cowl side reinforcement to the A-post reinforcement.

Tack weld.

Scheme 89

Scheme 89

Align and secure the outer cowl side to the outer A-post.

Weld into place.

Scheme 90

Scheme 90: B-post, replacing

Pull out the damaged section.

Cut, grind or saw off the damaged components.

The B-post cut is displaced as shown in the illustration.

Dimension C = 50 mm.

Scheme 91

Scheme 91

Secure the B-post inner door sill.

Weld into place.

Scheme 92

Scheme 92

Secure the B-post reinforcement.

Weld into place.

Scheme 93

Scheme 93

Align the outer B-post and outer door sill.

Saw and weld the sill and the door sill.

Spot-weld at the underside towards the rear of the sill.

Seam-weld the joint.