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Design
Plastic, material information
S40 (04-
(04-) and V50

IndexComponent Material
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 (04-
(04-)

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IndexComponent Material
7 Outer door handle PA66 GF30
8 Spoiler (B5254T3) PUR
Spoiler (other engines) ABS
9 Bumper cover PP + EPDM
10 Handle, tailgate PC + ABS

V50

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IndexComponent Material
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

Sheet metal, material information

S40 (04-
(04-)

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V50

Galvanized 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 (04-
(04-)

V50

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

S40 (04-
(04-) and V50

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Boron 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/mm 2 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! Boron steel must not be aligned or heated.

Note! Boron steel can only be joined where

indicated. Mark carefully using a template. Use a

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cutting disc or plasma torch.

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