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DesignDesignDesignDesign

Plastic, material informationPlastic, material informationPlastic, material informationPlastic, material information

S40 (04S40 (04S40 (04S40 (04----) and V50) and V50) and V50) and V50

IndeIndeIndeInde ComponentComponentComponentComponent MaterialMaterialMaterialMaterial

1 Bumper cover PP + EPDM

2 Grille in bumper cover PP + EPDM

3 Door sill PP + EPDM

T8

4 Lower door trim PP + EPDM

T8

5 Trim molding PP + EPDM

M26

6 Door mirror cover (painted) ABS

Door mirror foot (black) ASA

S40 (04S40 (04S40 (04S40 (04----))))

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IndeIndeIndeInde ComponentComponentComponentComponent MaterialMaterialMaterialMaterial

7 Outer door handle PA66 GF30

8 Spoiler (B5254T3) PUR

Spoiler (other engines) ABS

9 Bumper cover PP + EPDM

10 Handle, tailgate PC + ABS

V50V50V50V50

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Sheet metal, material informationSheet metal, material informationSheet metal, material informationSheet metal, material information

IndeIndeIndeInde ComponentComponentComponentComponent MaterialMaterialMaterialMaterial

7 Outer door handle PA66 GF30

8 End cover, trim rack / rail ASA + PC

9 Spoiler ABS

10 Bumper cover PP + EPDM

11 Tailgate handle PC + ABS

S40 (04S40 (04S40 (04S40 (04----))))

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V50V50V50V50

Galvanized componentsGalvanized componentsGalvanized componentsGalvanized components

In the above illustrations, those components

that are galvanized as replacement parts are

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indicated by a darker color (1).

Volvo uses a large number of body components

of single-, double-sided and extra-thickness

galvanized steel. This provides maximum anti-

corrosion protection. Take care not to damage

galvanized components when carrying out body

repairs, or when grinding or sanding.

On completing work, damaged galvanizing must

be replaced with single component filler primer.

S40 (04S40 (04S40 (04S40 (04----))))

V50V50V50V50

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HSS steelHSS steelHSS steelHSS steel

In the above illustrations, all components made

of HSS steel are indicated by a darker color (2).

The bodywork is made up of a number of

different steel materials. This is to optimize

collision safety, stiffness, fuel economy, etc.

The steel types described in this section areHSS steel (HSS = High Strength Steel). These

have a yield point of approximately 250 N/mm2.

The yield and breaking points are higher than

with normal steel plate.

The yield point increases when the material is

heat treated. HSS steel can therefore be more

difficult to align than ordinary steel plate.

When using an alignment bench, HSS

components can cause problems if the

counterhold is not correctly placed so that puller

has maximum effect. Note how the bodywork

reacts to tension and ensure that only the

deformed area moves.

Always follow the welding procedures shown in

VIDA.

Note!Note!Note!Note! HSS steel must not be heat aligned.HSS steel must not be heat aligned.HSS steel must not be heat aligned.HSS steel must not be heat aligned.

S40 (04S40 (04S40 (04S40 (04----) and V50) and V50) and V50) and V50

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Boron steelBoron steelBoron steelBoron steel

Boron steel comes under the HSS steel group.

The dark gray sections (3) in the illustration are

made of boron steel. Boron steel has a very

high yield and breaking point. The yield point is

approximately 1350 N/mm2 and particular

attention must therefore be paid to boron steel

during repair work.

When replacing boron steel components, it is

not possible to drill off spot welds. Grinding or

plasma cutting must be used instead.

Boron steel offers good welding capacity.

When producing boron steel, it is not possible

to galvanize the steel. These components must

therefore be rust-proofed particularly carefully.

Boron steel gets its strength through the

addition of the element boron. Boron steel also

contains a relatively large proportion of carbon.

The sheet profiles are formed between a press

and pad while the metal is red hot. The material

also cures here.

Note!Note!Note!Note! Boron steel must not be aligned or heated.Boron steel must not be aligned or heated.Boron steel must not be aligned or heated.Boron steel must not be aligned or heated.

Note!Note!Note!Note! Boron steel canBoron steel canBoron steel canBoron steel can only be joined whereonly be joined whereonly be joined whereonly be joined where

indicated. Mark carefully using a template. Use aindicated. Mark carefully using a template. Use aindicated. Mark carefully using a template. Use aindicated. Mark carefully using a template. Use a

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cutting disc or plasma torch.cutting disc or plasma torch.cutting disc or plasma torch.cutting disc or plasma torch.

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