Body - Supplement to Service Manuals
Section8
Group
81
No.
0001
Year
98
Month
11
850/S70/V70/C70
1992-
81-0001; Supplement to bodywork methods; 98/11
Background:
This Service Bulletin describes how the Service Manuals should be updated with new information. Make the following modifications to the listed Service Manual.
Service Manual: Section: Instructions:
Section 8 (81, 84) H7 Write in: "For S70N70 see Service
Body and glass Bulletin 81-0001"
850 1992-
TP 31940/2
H9 Write in: "A new welding method ap-
plies for 8501570N70. See Service
Bulletin 81-0001"
I4 Write in: "There is a new method
when replacing the roof on 5 doors.
See Service Bulletin 81-0001"
Section 8 (81) AG D1 Cross out illustration A8100589 and
Body A8100590 and the text that goes with
C70 1998- them. Write in: "See Service Bulletin
TP 8109031 81-0001"
AG D2 Cross out illustration A81000591.
Write in: "See Service Bulletin 81-
0001"
AH A1 Change existing dimensions:
A1: Cross out 1352 mm and write in
1350 mm
A2: Cross out 954 mm and write in
951 mm
A3: Cross out 995 mm and write in
996 mm
SUPPLEMENT TO WELDING METHODS
Supplementing welding methods
1
Welding symbols
Permissible welding methods are shown by the following symbols.
It only one method is indicated only that method can be used. The exception is spot welding which in future may be replaced with plug welding.
1 Spot weld
2 Plug weld
3 Seam weld
4 Stitch weld
5 Tackweld
6 Adhesive
2
Cargo compartment floor S70/V70, welding methods
A new welding method applies to the cargo compartment floor and replaces earlier methods listed in Service Manual:
Section 8 (81, 84)
Body and glass
850 1992-
TP 31940/2
Section H9
3
Cargo compartment floor C70, welding methods
A new welding method applies to the cargo compartment floor and replaces earlier methods listed in Service Manual:
Section 8 (81)
Body
C70 1998-
TP 8109031
Section AG D2
4
Rear side member, welding methods
The illustration displays the welding method that applies when replacing the side member in the rear section.
The member is delivered with the cover mounted. The information in the Service Manual where it states that the cover is delivered separately is incorrect.
REPLACING THE ROOF, 5-DOORS
1
Removing the roof, 5-doors
Cut off the roof with a (power) chisel
Grind off the panel remains.
Grind off the spot welds on the front and rear edges.
Grind off the seam welds at the four roof corners.
Cut away the PVC adhesive between the root and roof arch.
Note!
Do not heat. There is a risk of toxic fumes.
Lift off the roof
2
Mark the mating surfaces
Position the new roof panel on the roof arches.
Mark the roof arch positions with a pencil.
Lift off the roof.
Grind those areas to receive adhesive.
3
Drill the holes for plug welding
Drill 4 holes on each side for plug welding. The diameter of the holes should be 8 mm (1/3').
A=300 mm (1 ft.)
B=600 mm (2 ft.)
C=200 mm (0.65 ft.)
4
Apply welding primer
Apply welding primer on the windshield and rear windshield member.
Apply bodywork adhesive to the roof edges. Apply generously so that adhesive is pressed out when the roof is installed.
Do not apply adhesive where there will be plug welds.
Dimension D=30 mm (1 2/5").
5
Method for applying PUR adhesive
The PUR adhesive should be applied in 100 mm (4") long beads with 100 mm (4") gaps between the beads. The height of the beads should be 15 mm (3/5"). The roof arches that should have PUR adhesive applied is shown in the next illustration.
Dimension A=100 mm (4")
Dimension B=100 mm (4")
Dimension C=15 mm (3/5")
6
Apply PUR adhesive and install the roof
The front roof arch must not have any PUR adhesive applied. The rear root arch should only have a PUR-bead at the front edge.
The other arches must have a PUR-bead at both the front and rear edges.
Install the roof.
Align the roof.
Secure.
7
Weld the roof
Spot weld the front and rear edges.
Plug-weld the pre-drilled holes along the sides of the roof.
8
Bead weld the corners
Seam weld at the rear corners.
Grind the welds and remove excess adhesive.