REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volvo S40 / V40 (from 1996 to 2000, the year of issue)

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Volvo
	S40 / V40
		General Information
		Operation and maintenance of car
		Design and specifications Engine
		Engine repair
		Transmission
		Brakes
		Front suspension and steering
		Rear suspension
		Engine Management System Fenix 5.1
		Electric. Wiring and components
		Body
			Overview
			Control body dimensions
			Ways of detail when restoring performance Body
			Body repair
				Repair of the body side
				Repair front end
				Repairing the rear ("sedan")
			Removal and installation of elements of the car body
		Diagrams

printable version

Repair front end

Fig. 11.35. Details of the spar and the mudguard

In Fig. 11.35 presents the details of the spar and the mudguard, supplied spare parts.

When repairing the front end can be carried out the following work:

1) replacement of the front side member, for which:

- Open access to the internal and external surfaces of the side member;

Fig. 11.36. Site Preparation of the new spar and spar for installation

- Pre-cut spar as shown in Fig. 11.36;

- Adjust the mating surfaces;

- Secure the new spar (size A should be 100 mm);

- Joint should be located at the site of 250 mm (dimension B);

- Fit the spar and insert in its place, secure it with pliers or lockable tack welding;

- Check the dimensions of the unit control the spar (see. Resp. Section);

Fig. 11.37. A method of connection is established spar with a body

Fig. 11.38. How to install the entire spar

- When they coincide weld spar (Fig. 11.37, 11.38);

- Follow, wherever possible, the resistance spot welding;

- On the other sites follow with plug welds (MAG);

2) replacement of the spar (see. Fig. 11.37), as follows:

- Open access to the job site;

- Pre-cut the damaged section;

- Drill or moved using the welding point;

- Remove the spar;

- Adjust the mating surfaces and apply primer welding;

- Fix the spar in the mounts.

- An electrical weld spar outside follow, wherever possible, the resistance spot welding;

- An electrical weld the inside;

Fig. 11.39. Connection method replaced the front wheel arches with a body and spar

3) replacing the front wheel arch (Fig. 11.39), including reinforcing element arch, for which:

- Cut replaced element;

- Drill or moved using its connections with mating parts;

- Smooth out the surface of the mating parts;

- Apply a welding primer;

- Fit and secure the wheelhouse;

- Weld the wheelhouse;

4) the replacement engine mounts, for which:

- Drill and remove the replaceable motor support;

- Clean and otrihtuyte support the installation location;

- Apply a welding primer;

- Secure the support of the engine lock;

- Check the installation of the bracket;

Fig. 11.40. Methods of fixing engine support

- Weld engine support (Fig. 11.40);

5) Replacement of the lower beam of the radiator, radiator upper beam and end panels, as follows:

- Cut delete items, departing 10-15 mm from the connection to the mating parts;

- Drill and remove their residues;

- Moved using spot welds;

- Remove the remains removed parts;

- Grind down to the bare metal;

- Apply a welding primer.

- Fix installed parts;

- Check the correctness of their installation;

Fig. 11.41. Ways of installed components

- Weld (Fig. 11.41).

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Repair of the body side

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Repairing the rear ("sedan")