1. General information
2. Operation and maintenance of the car
3. Design and technical characteristics of engines
4. Repair of the engine
5. Transmission
6. Brake system
7. Forward suspension bracket and steering
8. Back suspension bracket
9. Control system of the Fenix 5.1 engine
10. Electric equipment. Conducting and components
11. Body
11.1. General information
11.2. Control sizes of a body
11.3. Ways of connection of details at restoration of operational qualities of a body
11.4. Repair of a body
11.5. Removal and installation of elements of a body of the car
12. Schemes of electric equipment



11.3. Ways of connection of details at restoration of operational qualities of a body

For one-piece connection of body details at repair of a body Volvo recommends the ways given in tab. 11.1. If on the scheme several ways of welding are designated, it is possible to use any of them. If only one way is specified, it is necessary to use only it. An exception are contact spot welding which can be replaced with welding by electrorivets.

At repair of bodies of the Volvo cars it is impossible to apply gas welding at all.
At connection of details any of the specified ways use the ventilating exhaust equipment.

Bodies of the Volvo S40/V40 cars are made, mainly, with application of contact spot welding and pasting.
When performing repair work, in connection with distinction of technology of assembly and technology of repair of a body, Volvo recommends in places where repetition of contact spot welding is complicated, to apply electrorivet welding by the MAG method (Metal Active Gas), i.e. electric welding with the melting electrode in the environment of active (carbonic) gas, widely used at service stations. The welding which is correctly executed by the MAG method meets the qualifying standards, as from the point of view of durability, and appearance.
Before works on welding:
— plan work;
— exempt space about a welding zone from details and knots which can be damaged or can prevent carrying out welding works;
— be convinced that in a welding zone, especially in the hidden cavities, there do not pass plaits of conducting or separate wires;
— surely disconnect a negative wire of the rechargeable battery;
— provided that welding will be carried out near electronic blocks, they need to be removed in order to avoid damage of the last;
— have a mass wire as it is possible closer to the place of welding as otherwise in various electronic blocks the wandering currents capable to put them out of action can be switched;
— cover the interfaced surfaces with welding primer or welding sealant in order to avoid bystry emergence of through corrosion.
For obtaining good result it is necessary to carry out measurements as the restored or replaced knots, so repaired part of a body in general. If there are no sizes of the necessary part, they can be taken from an opposite whole part of a body or from a similar body of the whole car. As often as possible do assembly fitting rooms, using screws self-tapping screws, the fixed pincers, a tack welding in places, available to the subsequent separation.

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11.2. Control sizes of a body
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11.4. Repair of a body