BODY SEAL
Note. As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the graphics is always correct.
Scheme 44
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 45
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 46
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
SEALING PRODUCTS
In order to meet Volvo's requirements, only approved sealing products may be used.
The products that have been tested for body sealing are listed below.
SPRAY SEALANT
P/N 116 1443 is a sprayable bodywork sealant that restores the car 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 (P/N 116 1444).
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 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.
HSS STEEL
The bodywork is made up of a number of different steels to provide optimal protection in the event of a collision, rigidity, fuel economy etc.
The types of steel in this section are High Strength Steel (HSS). This has a higher tensile strength and yield point than ordinary steel sheet.
The yield point increases when it is heat treated. HSS-steel can be more difficult to align than ordinary steel plate.
When using an alignment bench, HSS components can cause problems if the counterhold is not fully tightened. Note how the bodywork reacts to tension and ensure that only the deformed area moves.
Always follow the welding procedures shown in VIDA (Volvo scan tool).
Note. HSS-steel must not be heat aligned.
Scheme 47
BORON steel is in the same group as HSS steel.
The components marked in black are manufactured in Boron steel, The grey/dark grey sections in the graphics are High Strength Steel (HSS) with a yield point above 340 MPa and must therefore be treated with extra care during repair.
Boron steel is high tensile with a high breaking point.
When replacing Boron steel components, the welds cannot be drilled. Grind or plasma cut instead.
Boron steel has good tolerance for welding.
It is not possible to galvanise Boron steel during manufacture. These components must be rust-proofed extra thoroughly.
Note. Boron steel must not be bent or heated.
Note. Boron steel may only be joined where indicated in the method. Mark carefully using a template. Use a cutting disc or plasma cutter.
Scheme 48
Scheme 49
Scheme 50
EXTENDED INFORMATION
The steel can be divided into further subgroups based on the yield point, the force required to deform the steel. These groups are
HS (HIGH STRENGTH STEEL)
Steel with a yield point between 220-450 MPa (marked light grey in the graphic).
There are three main types of steel within this group
Phosphorous-alloy steel
This steel has a higher strength as a result of the use of phosphorous alloy.
HSLA steel (High Strength Low Alloy)
This is a low alloy steel, where alloys such as Vanadium, Niobium or Titanium are used to increase the yield strength.
DP steel (Dual Phase)
This steel is strengthened by heat treatment during manufacture. A two phase structure of iron and carbon is formed. DP steel will lose its strength if it is exposed to temperatures in excess of 300°C.
EHS (EXTRA HIGH STRENGTH STEEL)
Has a yield point between 450-800 MPa. EHS is light grey in the graphic.
Both HSLA and DP steel are within this group, although the strength has been further increased through the addition of greater alloy substances.
UHS (ULTRA HIGH STRENGTH STEEL)
Has a yield point between 800-1400 MPa. UHS is dark grey in the graphic.
There are two main types of steel within this group
DP steel
The strength is even higher due to an advanced manufacturing process and the greater quantities of alloys.
BORON steel
The additional of boron gives this steel greater strength. BORON steel also contains relatively high quantities of carbon. The profiles of the sheets are formed between a press and pad while the metal is red hot. The material also hardens here. These sections must not be straightened because of their extremely high strength.
WELDING, GENERAL
Note. The graphics in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the graphics 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
| CAUTION | Always remove the battery cables before welding in accordance with, see BATTERY, DISCONNECTING . |
| CAUTION | Locate the welding ground connection as close as possible to the welding point. |
| CAUTION | If the welding must be carried out in the immediate vicinity of an electronic unit then this must be removed. |
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 minimise 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
MAG WELDING
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 51
Test weld several test pieces. Break the panels apart and measure the size of the welding lens diameter (A), see illustration.
Scheme 52
Note. Use welding primer on all internal flanges.
Add filling primer if there is grinding damage.
| CAUTION | Make sure that the spot welds take properly on both panels. |
Scheme 53
Grind down the plug weld.
| CAUTION | Only grind welds, not the adjacent panel. |