Body Frame - General Information: Other Volvo V50 I рестайлинг

BODY SEAL, SEALING DIAGRAM

Note. As 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.

Scheme 56

Visible seal with high requirements for the finish.

The material must have been applied liberally but evenly. There must be no areas where excess sealant has gathered.

Use a rubber putty knife to smooth the surface.

See panel section A for the appearance of the bead.

Scheme 57

Visible seal with lower requirements for the finish.

The material should be liberally but evenly applied.

Lines and minor pitting is acceptable.

The sealant must not have been applied too thickly.

The dimension of the bead must be as in panel section B

B1 = min 0.5 mm; max 2.0 mm

B2 = min 4.0 mm; max 10.0 mm

B3 = min 2.0 mm

B4 = min 2.0 mm; max 4.0 mm

Scheme 58

Seal with no requirements for the finish.

The sealant must be liberally applied.

Minimum material thickness = 0.5 mm.

Lines, lumps and pools of up to 5 mm are acceptable.

The dimension of the bead must be as in panel section D

D1 = min 0.5 mm; max 5.0 mm

D2 = min 7.0 mm; max 50 mm

SPRAY SEALANT

P/N 116 1651 is a sprayable bodywork sealant that restores the vehicle to as-new condition after work on the body.

The sealant can be applied as a bead (class A and B) or sprayed on in a thin layer (class D) using a spray gun.

When applying as a bead, this type of sealant is very difficult to work on afterwards because of its runny consistency.

The sealant can be painted and hardens at a rate of approximately 3 mm every 24 hours.

WEATHERSTRIPS

Seal the joints between the panel sections when replacing panel sections such as the spare wheel well, tail panel etc. Class A and B (P/N 116 1377) sealing is suitable.

SEAL THAT CAN BE GROUND

For visible seals, such as the join between the cantrail and the roof panel on the S40 (04-), a sealing compound is required that

1. flows out without running
2. has the correct hardness
3. can be ground when hardened
4. has the correct flexibility.

The above criteria are satisfied by 3M 08115 , which has been tested and approved for sealing.

Note. 3M 08458 is not approved as a substitute for Volvo's bodywork adhesive.

Scheme 59

Install the soundproofing foam in the cavity to counter sound spreading through the body.

There are 2 types of soundproofing foam

Volvo soundproofing foam, P/N 681 7640

This comprises a wax-treated cylinder, 50x50 mm, P/N 681 7640. This can be compressed and inserted between the panel sections. More than one cylinder can be used if necessary.

3M 08463

This soundproofing foam is a 2 component product that starts to foam when the 2 components are mixed. This product is suitable for filling large cavities.

It is also suitable for inserting between the roof arch and the roof panel where foam is to be used. Follow the instructions from the supplier.

Scheme 60

RUSTPROOFING

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.

Scheme 61

Volvo product P/N 116 1682 is used for cavity protection.

Scheme 62

Scheme 63

Use a grease gun and a hose nozzle with a 360 degree spray range.

Insert the hose in the cavity. Spray while slowly removing the hose.

HINT: Measure the width X of the hole. Hold the nozzle X mm from a piece of cardboard to check that the spray is operating at the correct speed.

When carrying out repairs to the bodywork, the areas marked in gray in the illustrations must be rustproofed with a large amount of cavity protection (ML).

This applies for example to welded joins and areas that have been treated in some other way.

Scheme 64

Scheme 65

Volvo product P/N 116 1299 is used for stone-chip protection.

Apply stone-chip protection to those areas on the vehicle that are marked in gray in the illustration.

Use a body sprayer.

Scheme 66

Volvo product P/N 116 1299 is used for underbody protection.

Apply underbody protection to those areas on the vehicle that are marked in gray in the illustration.

Use a body sprayer.

WELDING, GENERAL (2005-10)

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.

Volvo bodies are manufactured to the highest quality. All bodywork repairs must therefore take place following the same principles. Use light tools. Take care of the surface coating, electro dip (ED) and phosphating.

Always use welding primer between welded panel flanges.

PRIOR TO WELDING

RESISTANCE SPOT WELDING

Resistance spot welding must primarily be used if the capacity of the welding equipment is matched to panel thickness. When carrying out resistance spot welding, grind down to bare metal.

Clean the surfaces with Scotch-Brite or similar to minimize zinc and phosphating damage. Apply welding primer between the panels.

Note. Always test weld in accordance with the method below. Always set the weld according to panel quality

PREPARATIONS

Punch replacement part for plug welding.

Select size of hole for plug welding according to the following panel thicknesses

8 mm for thicknesses less than 2.5 mm

10 mm or more for thicknesses above 2.5 mm.

Scheme 67

Test weld several test pieces. Break the panels apart and measure the size of the welding lens diameter (A), see illustration.

Scheme 68

Note. Use welding primer on all internal flanges.

Add filling primer if there is grinding damage.

Scheme 69

Grind down the plug weld.

WELDING, GENERAL (2011)

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.

Volvo bodies are manufactured to the highest quality. All bodywork repairs must therefore take place following the same principles. Use light tools. Take care of the surface coating, electro dip (ED) and phosphating.

Always use welding primer between welded panel flanges.

Resistance spot welding must primarily be used if the capacity of the welding equipment is matched to panel thickness. When carrying out resistance spot welding, grind down to bare metal.

Clean the surfaces with Scotch-Brite or similar to minimize zinc and phosphating damage. Apply welding primer between the panels.

Note. Always test weld in accordance with the method below. Always set the weld according to panel quality

Punch replacement part for plug welding.

Select size of hole for plug welding according to the following panel thicknesses

8 mm for thicknesses less than 2.5 mm

10 mm or more for thicknesses above 2.5 mm.

Test weld several test pieces. Break the panels apart and measure the size of the welding lens diameter (A), see illustration.

Note. Use welding primer on all internal flanges.

Add filling primer if there is grinding damage.

GRINDING DOWN PLUG WELD

Grind down the plug weld.