Collision Repair Training | Australia
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Collision Repair Training | Australia
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Current Events/News: Advantage Online: 2005 Archives
COLLISION REPAIRS ON THE VOLVO XC90
November 14, 2005 - Volvo's only sport utility vehicle (SUV) was introduced in 2003 (see Figure 1). The XC90 SUV is a unibody design, so it has a lower center of gravity compared to body-over-frame SUVs. The 2005.5 model offers an optional V8 engine, a first for Volvo. This article highlights the body design and other points of collision repair interest on the Volvo XC90. Alloyed with Boron The inner B-pillar reinforcements and center roof rail are made of ultra-high-strength steel (UHSS) alloyed with boron (see Figure 2). If there is a sunroof, there is no center roof rail. These are the only extra structural parts on this vehicle made of UHSS alloyed with boron, compared with other Volvo vehicles on the same platform, the S60, S60R, S80, V70, V70R, and XC70. All of these models, including the XC90, have lower inner and outer rear body panels and door intrusion beams made of this type of steel. There are sectioning procedures for the rear body panels and inner B-pillar reinforcements in the Volvo service information. UHSS alloyed with boron cannot be straightened, but can be cut, drilled, and welded if the right tools and procedures are used (see "Working with UHSS Alloyed with Boron–An Update" in the September 22, 2005 issue of the Advantage Online). Aluminum Bumper Reinforcement Volvo uses aluminum for the front bumper reinforcement, the only body application for aluminum on the vehicle. The reinforcement is attached to the front lower rail with bolts and squeeze-type resistance spot welds (STRSW). In order to avoid galvanic corrosion with the steel rail, the spot welds are made through steel inserts imbedded into each end of the reinforcement (see Figure 3). Antenna Module and Cover The radio antenna, instead of being imbedded in glass, is mounted under the roof. This is a huge antenna, spanning the width of the vehicle. It can be removed from inside the vehicle after removing part of the headliner (see Figure 4). The antenna module can also be a global positioning system receiver and traffic message channel receiver, depending on the vehicle options. The antenna module is not open to the sky on top, but covered with a thermoset epoxy cover. The antenna module cover is attached with stationary glass urethane. Front Lower Crossmember Since the bumper height on an XC90 is higher than an average sedan or station wagon, Volvo added a lower crossmember to the front that matches the bumper height of a sedan. This crossmember, called a "collision member" by Volvo, is designed to collapse and absorb some of the collision energy in a front collision. It is bolted to the frame making it easy to replace (see Figure 5). Three-Piece Floor Pan The floor pan is serviced in three parts: the floor pan under the seats, trunk floor, and a battery compartment in the rear. Replacement is along factory seams. There are no sectioning recommendations for the floor. Structural Sectioning Options There are several structural sectioning options identified in the Volvo service information for the XC90. There are three options on the front lower rails: in the front, middle, and rear. The middle and rear sectioning options avoid an inner reinforcement on the outer rail half (see Figure 6). Besides the full rail, a shorter service part includes the inner and outer front portion up to the middle sectioning option. There is a full uniside service part available. There are also separate service parts for the pillars, rocker panels, and quarter panels. The B-pillar is serviced in three parts: an outer, inner, and the UHSS inner reinforcement. All three parts can be sectioned between the rocker panel and below the roof rail. The outer pillar stands out from the inner reinforcement below the door hinges, and at the bottom, the outer B-pillar is flared out and not attached to the inner reinforcement (see Figure 7). This is designed for easier replacement of just the outer pillar, if the collision did not affect the inner reinforcement. Cuts can be made around the door hinges, which are welded to the inner reinforcement, and the outer removed without affecting the hinges or the inner reinforcement. The outer quarter panel can be sectioned halfway up the C- and D-pillars. There is a specific sectioning location below a hole on the striker plate to avoid having to replace a heat-activated foam dam. There is one sectioning procedure for the rear rails. Although the service parts include the entire rear rail with a small section of the trunk floor and wheelhouse, and a full rail cover plate, the sectioning procedure only involves less than a third of the length of the rail. The procedure involves using the replacement inner reinforcement as a sleeve into the existing rail, and closing the rail on top with the replacement cover plate. As mentioned above, the UHSS alloyed with boron lower rear body panels can be sectioned. In fact there are two options for the inner panel and three options for the outer panel, including the center (see Figures 8 and 9). There are seven sectioning options for the mild steel rear aperture called the upper rear body panel. Rollover Prevention Unique to the XC90, at least for Volvo, is roll stability control and a rollover protection system. Roll stability control uses a gyroscope, or tilt sensor, under the front passenger seat to determine if the vehicle is losing balance around curves or sharp turns. The system responds to this unstable condition by braking one or more wheels to lower the engine torque and stabilize the vehicle. The system only works when the key is in position II (RUN) and the vehicle is moving over 10 km/h. The rollover protection system is controlled by the restraint system control module located in the center console. The module contains a rollover sensor which helps determine if the side tilt is exceeding 50–55° and the rate of the tilt is rapid. This way, the protection won't activate while in a non-emergency situation such as when changing a tire. If a rollover is determined to be imminent, all seat belt pre-tensioners and all side curtains deploy. There can be up to seven pre-tensioners and four side curtains if the vehicle has an optional third row of seats. Conclusion The first, and so far only, SUV from Volvo is a unibody design to help keep the center of gravity low. The XC90 is higher than other Volvo cars, however, so rollover prevention and protection has been added. There are several sectioning procedures available in the Volvo service information, which include sectioning the ultra-high-strength steel alloyed with boron that is used for the rear body panels and inner B-pillar reinforcements. This vehicle is the subject of an I-CAR Live program "Collision Repair Overview for the Volvo XC90 (VLV05)." It is one of six programs I-CAR is developing in cooperation with Volvo. Watch for it by year's end.
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