Collision repairs on the Volvo S40/V50

NOTE: This article first appeared in the I-CAR Advantage Online, which is published and distributed free of charge. I-CAR, the Inter-Industry Conference on Auto Collision Repair, is a not-for-profit international training organization that researches and develops quality technical education programs related to collision repair. To learn more about I-CAR, and to subscribe to the free publication, visit http://www.i-car.com.

The all-new Volvo S40 sedan and V50 wagon have the most advanced body design in the current Volvo range. The new sedan was introduced in mid-year 2004 and replaces the S40 that was last produced in model year 2004, thus the “all-new” S40. The S40 shares a new platform with the V50 wagon. The V50 is slightly longer than the S40 with the extra length behind the rear wheels.

This article highlights the body design and other points of collision repair interest on the Volvo S40/V50.

Protecting The Passenger Compartment

These models integrate different strengths of high-strength steels. A bumper reinforcement assembly with crush initiators in the lower rail extensions and tailor-welded blank construction serve as planned deformation stages in a frontal collision. These, and other body engineering features, are designed to protect the passenger compartment.

The first deformation stage is the front bumper rail assembly called a “crashbox.” The crashbox will absorb collision energy up to about 16 km/h (10 mph). The reinforcement outer panel is high-strength steel. The inner panel is ultra-high-strength steel alloyed with boron. There is a similarly designed crashbox on the rear. These crashboxes and the door guard beams are the only locations for ultra-high-strength steel alloyed with boron. There are no repairs allowed on either the crashboxes or the door guard beams. They are replaced as bolted-on assemblies. The crashboxes are bolted onto the rails.

Two high-strength steel crossmembers also play a part in diverting collision energy away from the passenger compartment. These include the lateral crossmember and a crossmember tube included as part of the instrument panel. These two crossmembers form a box-like structure in the front that reduces the chance of the rails from bending inward in a frontal collision. The collision energy is transferred across the vehicle, compressing the lateral crossmember and creating tension on the crossmember tube. The compression and tension on the crossmembers offset each other, keeping the structure from bending inward.

Considerations For Repair

Anyone who has tried to cut through ultra-high-strength steel alloyed with boron can appreciate the fact that there are no repair recommendations on the crashboxes or door guard beams. There are other indications that Volvo designers were listening to repair technicians in the field when planning the S40/V50 models.

Removal of the headlamps could not be easier. A single locking plate, pulled straight up by hand, releases the entire headlamp assembly. The connector is disconnected and the assembly can be removed. Releasing a headlamp from earlier model sedans is a multi-step process.

Removing the outer door handles, a common task during repairs, is also simple. A plastic plug on the door shell is pried off, revealing a screw). The screw is turned four-to-five times to release the lock cylinder and handle. Also on the door shell, the door glass regulator is contained in a cassette that is removed as one unit. There is no paper or plastic vapor barrier to remove to access the regulator. The glass is easily removed first by pulling out two rubber plugs in the cassette and loosening two bolts.

Any technician who has tried to remove an instrument panel alone will appreciate special bolts installed in place of the top bolts. They allow the instrument panel to be pulled directly back and rest on the bolts while the remaining bolts and connectors on the panel backside are removed.

Structural Repairs

The Volvo service information includes several recommendations for partial replacement of the structural parts. The inner front lower rail service part has two optional cut lines for sectioning. Both cut locations avoid the inner reinforcement and the laser weld. There are also sectioning recommendations for the A-pillars, rocker panels, rear rails, and trunk floor. Specifications are listed in the Volvo service information.

Advanced Restraint System

The latest in restraint system technology is featured on the S40/V50. The passenger seat features an occupant classification system, which determines whether or not to deploy the passenger airbag depending on how much weight is detected in the seat. The parts of this system, including the bladder, weight sensor, and pressure sensor, are all replaced as one kit that includes the passenger seat foam. The parts are not serviced separately.

There are seat position sensors at the bottom of both front seats, which also help determine the size of the occupant. The front seat belts are not only equipped with pre-tensioners, but also adaptive force limiters. These assemblies modify the seat belt force on the chest to one of three levels based on the seat position, how far the seat belt is unrolled, and the severity of the collision.

As in all late-model Volvo vehicles, the S40/V50 also feature side airbags in the front seats, full-length side-impact curtain airbags on both sides, and a whiplash protection system to reduce the severity of neck injuries in a rear-end collision.

Steering System

Two highlights of the steering system on the S40/V50 are the adaptive collapsible steering column and the power steering pump.

The S40/V50 steering column collapses at two U-joints, moving the steering wheel inward. There is also a pyrotechnic charge on the steering column that deploys a pin, allowing the steering wheel to move closer to the instrument panel. The pin deploys only if there is a driver airbag deployment and the driver seat belt is in use. If the steering column collapses or the pyrotechnic charge deploys, the complete column must be replaced.

The power steering pump is electro-hydraulic. The hydraulic pump is driven by its own electric motor instead of the engine. This makes the power steering function more independent, allowing consistent steering efforts regardless of engine load or even engine operation. The electro-hydraulic, power-assisted steering assembly, which includes a control module, motor, pump, and fluid reservoir, is located directly behind the front bumper rail on the right side. Tests have shown that the unit will likely not be damaged in a 16 km/h (10 mph) collision.

Conclusion

The S40/V50 is a new platform for Volvo. Repair technicians who have worked on Volvo vehicles will find some things familiar and some things new.

I-CAR is developing a series of training programs with Volvo Cars of North America on repairing Volvo vehicles. These programs will be available to any I-CAR student. One of these programs still under development focuses on the S40/V50. Pay attention to the I-CAR web site for a release date and to find the program in your area.