
Volvo releases 6 position statments including scanning and diagnostics and EV battery handling
By onAnnouncements | Collision Repair | Repair Operations
Volvo recently uploaded six new position statements including an updated Scanning and Diagnostics Position.
Newly added position statements include Aluminum Inspection, EV Battery Handling, EV Welding, Glass Position, and Steering Column Inspections.
Each of the position statements warns that only genuine Volvo parts will help ensure safety, performance, and residual value.”
“Volvo’s latest technology incorporates numerous control modules, sensors, and camera systems that support various vehicle functions,” the Scanning and Diagnostics Position Statement says. “These components are an integral part of a vehicle’s operational systems. In a collision, these components could be damaged in ways that are not visually evident, so they must be inspected and evaluated, regardless of whether the vehicle displays a failure via the instrument cluster; this will help ensure that any possible lack of functionality will be discovered and resolved.”
Pre-repair scanning is a crucial step that is required prior to performing any and all work on the vehicle, the statement says. Post-repair scanning and diagnosis of the vehicle is required for any work that is done on the vehicle.
“This ensures the vehicle’s safety and autonomous systems are functioning correctly,” the statement says. “Any safety or autonomous systems activated during a collision may require further inspection, initialization, calibration, or replacement, demonstrating your diligence in the repair process.”
Examples of when pre- and post-scans should be performed include the removal and/or replacement of:
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- Windshields
- Bumpers, SRS sensors, PDC sensors, exterior mirrors, autonomous driver sensors, and cameras
- All lights including LED tail lights
- Computer-aided drivetrain
- Wiring harnesses
- Vehicle control units
- Seats
- Interior trim panels and components
- Disconnected/de-energized batteries
The position cautions that when a vehicle is connected to Volvo Information and Diagnostics for Aftersales (VIDA) for diagnostics or software download, a battery maintainer must be connected to ensure the 12V battery remains charged.
Volvo Aluminum Inspection Position
“At Volvo Cars, ensuring the safety and quality of our vehicles’ structural aluminum components extends to employing meticulous inspection methods, including detecting micro-cracks,” the position says. “Our dedication to safety and quality extends to employing precise inspection methods in the aluminum structures of our vehicles. These inspection methods are to be executed by specialized technicians proficient in interpreting inspection results and identifying even the minutest indications of micro-cracks within the aluminum structures of Volvo vehicles.”
Visual inspection is required for all vehicles that may have sustained structural damage, the statement says. Eddy Current Testing, Dye Penetrant Inspection, and Ultrasonic Testing are required if the visual inspection shows potential damage or micro-crack(s). If micro-cracking is detected, replacement of the component is required.
Inspections should include the following steps and methodologies:
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- “Visual Inspection: The initial step involves a meticulous visual inspection by trained professionals. This examination focuses on potential stress concentration or vulnerability areas to ascertain any visible signs of micro-cracks, including surface irregularities or anomalies. Trained professionals conduct a thorough visual inspection using magnification tools and lighting to scrutinize surfaces for irregularities, such as hairline cracks or fissures. Focus areas include weld joints, high-stress zones, and areas prone to fatigue, where micro-cracks might initiate and propagate.
- “Eddy Current Testing: Utilizing eddy current testing, a non-destructive method, to detect surface and near-surface flaws, including micro-cracks. This technique uses electromagnetic induction to identify changes in the material’s conductivity, alerting it to potential flaws without impacting the integrity of the aluminum. Eddy current testing utilizes a probe emitting electromagnetic fields that interact with the aluminum’s surface. Changes in the electromagnetic field due to surface irregularities, including micro-cracks, are detected and displayed for analysis by skilled technicians.
- “Dye Penetrant Inspection: This method involves applying a penetrant fluid to the aluminum surface, allowing it to seep into any surface openings, including micro-cracks. After a specified time, the excess penetrant is removed, and a developer is applied to draw out the penetrant from the cracks, making them visible for thorough examination. A penetrant fluid is applied to the aluminum surface, allowed to dwell, and thoroughly cleaned. A contrasting developer is applied, drawing out the penetrant from any surface cracks or discontinuities, making them visible under proper lighting conditions.
- “Ultrasonic Testing: Ultrasonic testing involves transmitting high-frequency sound waves into the aluminum structure. Any irregularities or discontinuities, such as micro-cracks, will reflect these waves differently, enabling their detection without damaging the structure. Ultrasonic waves are transmitted into the aluminum structure via a probe, and the reflected waves are analyzed for variations. Discontinuities, including micro-cracks, reflect waves differently, allowing their detection without causing harm to the aluminum structure.”
EV Battery & Vehicle Handling Post Collision Statement
“The car’s primary electrical system operates with 12V and powers the car’s primary electrical system, which includes most of the electrical equipment such as driver assistance and safety systems, navigation system, instruments and infotainment screen, onboard computers, and interior lighting,” the position says. “However, the high voltage battery is used when the car runs the electric motor. The battery is dimensioned to power the electrical system and functions specific to the car model. Under normal conditions, it is kept charged by the more prominent high-voltage battery. In addition to the primary electrical system, the car has a high-voltage system for electrical propulsion.”
Only authorized workshop personnel are allowed to handle high-voltage battery parts, the statement says. It also says replacing high-voltage batteries must only be performed by an authorized Volvo workshop.
It adds that the vehicle cannot be driven if the high-voltage battery is discharged. To charge the battery, the car’s smaller 12V battery needs to be sufficiently charged to have the capacity to power the car’s electrical system and start charging.
The high-voltage battery (complete) consists of:
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- A tray
- Multiple liquid-cooled cell modules
- Thermal insulation
- Electrical hardware
- A lid
Instructions for removal, replacement, and installation can be found in VIDA. It says and notes that when the high-voltage battery (complete) is mounted to the vehicle, it constitutes a large portion of the vehicle undercarriage.
The electrical hardware in the high-voltage battery (complete) includes but is not limited to:
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- The Battery Energy Control Module (BECM).
- The Cell Voltage- and Temperature units (CVTN).
- The Battery Disconnecting Unit (BDU) has contactors and fuses for high-voltage input and output.
- The Manual Service Disconnector (MSD) disconnects the high-voltage battery once the socket, Manual Service Disconnector (MSD), is removed.
- The high-voltage battery coolant temperature sensor, inlet, and the high-voltage battery coolant temperature sensor, outlet.
- The high-voltage battery (complete) does not have any diagnostics by itself, the position says. Diagnostics are handled by the BECM and internal control module. The BECM continuously monitors the battery, sets DTCs, and has readable parameters.
The mild hybrid 12V system uses the main battery to power components. The Central Electronic Module (CEM) regulates the battery charge, the statement says. It adds a belt that charges the battery, which creates power and sends it to the Integrated Starter Generator Module (ISGM). The ISGM transforms the power to the 48V DC for charging the 48V battery (MVBM) and sends power to the MId-Voltage Converter Module (MVCM) to convert to 12V for charging the main battery.
Volvo warns not to switch on the ignition post-collision until electrical systems are inspected for damage.
It also warns that if repair work cannot be started immediately, the vehicle should be positioned in a fire-protected area outdoors. A safety distance of 17 yards should be created between the vehicle and any combustible item. The vehicle should also be cordoned off 5 meters by 2.5 meters. A warning sign should be placed by the vehicle and the vehicle should be covered with a nonflammable weather-resistant cover to keep out moisture.
Repairers are also warned not to open the lid of the coolant tank and to not top up any fluids. Another warning says to not touch anything that is not clearly described in VIDA.
“Always assume the HV system and components are energized until their status can be verified by following the HV battery disconnecting and connecting procedure in VIDA,” the statement says.
Severe damage to the HV battery may result in a delayed release of toxic and/or flammable gasses or fire which could result in bodily injury or death, the statement says.
Any disconnection of the high-voltage battery must include the area being cordoned off with plastic links and posts for the entire repair.
The statement also says all persons working on electric vehicles should complete CPR training.
Prior to allowing the vehicle to enter the repair area, perform a visual inspection, the statement says. Repairers also should make sure there is adequate ventilation and that access to the vehicle is maintained for proper observation and access to emergency response, if needed.
Inspection of the battery enclosure includes looking for any external leaks, signs of moisture accumulation, corrosion, deformations, tears and cracks, signs of electrical arc, and damaged connectors. If found, contact your local Volvo Service Team, the statement says. If any electrical odors, fumes, smoke, sparks, flames, or bubbling/gurgling are observed during the inspection call emergency services.
Volvo gives multiple warnings at the top of its EV welding statement. First, only specially trained technicians may work with the high-voltage system, it says.
Many of the warnings echo the warnings in the EV vehicle and battery handling statement.
One warning says no open flames, burning materials, or sparks near the battery. Another says safety goggles are needed when working near the battery to protect against possible splashing of acid solution. Volvo also warns that if acid is swallowed, rinse the mouth with plenty of water and then drink plenty of water or milk. Do not induce vomiting and seek immediate medical attention.
“Always disconnect the 12V battery prior to welding, refer to VIDA’s Battery Disconnection and Connection instructions,” the statement says. “Always de-energize the high-voltage battery before welding. De-energize must only be performed by a certified trained technician, refer to VIDA’s High Voltage Battery: Disconnecting and Connecting. Locate the ground connection as close as possible to the welding point.”
Volvo says that if the welding must be carried out in the immediate vicinity of an electronic unit/high-voltage battery then the unit and battery must be removed.
These areas include, but are not limited to, the inner and outer rocker panels and the passenger floor pan.
“Unless otherwise specified in methods, always strive to use spot welding for repairs,” the position says. “Refer to VIDA for all approved welding methods by model. Unless otherwise specified in the method, the distance between the welds must be the same as the original design. Use extraction equipment. Always follow VIDA procedures when completing a weld repair. Refer to Welding General in VIDA for further assembly guidelines.
“Volvo glass, an integral part of our vehicles, not only provides a clear view but also serves as a critical structural component,” the statement says. “This reassures you that your investment in a Volvo vehicle is backed by robust engineering and design. Volvo Car USA LLC requires all windshields and panoramic roof glass replacement on Volvo vehicles to be performed according to Volvo standards at an authorized Volvo facility, using only Volvo Genuine glass and adhesives.”
Volvo glass also requires proper calibrations as well as operations of the glass-dependent safety systems. Volvo-specific adhesives ensure proper bonding to the glass to the vehicle’s body, providing the same strength qualities as if assembled at the factor and providing a minimal safe drive-away time once installed.
“Volvo Genuine glass is crafted to the same exacting standards as the original glass installed during assembly,” the statement says. “This precision engineering ensures perfect fit, exact tolerances, and maximum safety, instilling confidence in the quality of your Volvo vehicle.”
Repairers are warned that polyurethane (PU) adhesive and PUR adhesive can cause asthma-like symptoms if inhaled. Isocyanate vapor from primer, PU adhesive, or non-cured primer can also cause allergies in the respiratory tract. Anyone with a respiratory allergy may have an allergic reaction. Risk remains until the material is fully cured.
Volvo warns that PU and fully cured PUR adhesives can degrade if subjected to high temperatures. Isocyanide compounds can be released when grinding or welding near cured PU adhesive. Repairers are warned to ensure good ventilation, use a fresh air mask or carbon filter mask and never to touch the adhesive surface with fingers, always wear gloves
“The windshield is part of the vehicle’s collision protection. Always use genuine PUR adhesive kits,” the statement says. These are selected and tested by VOLVO and are the only ones for which VOLVO Cars will take responsibility for the result.”
“The steering column is a key component of the vehicle’s crash energy management system and is designed to absorb energy during an impact,” the statement says. “Even in minor accidents not including air bag deployments, the steering column can be compromised, affecting the vehicle’s safety systems and driver control. Therefore, Volvo Cars requires a thorough inspection of the steering column assembly following any collision event, regardless of the severity.”
Volvo says that the steering column is designed to collapse or deform in specific ways during a collision to protect the driver.
“Even minor impacts can cause internal damage that may not be visible,” the position says. “Failure to inspect and, if necessary, repair or replace the steering column may result in diminished crashworthiness in future incidents.”
Airbag mechanisms and sensors are housed in the steering column, the position says. Damage could prevent proper airbag deployment, leading to an increased risk of injury in accidents. It could also impair the driver’s ability to control the vehicle, leading to an increased risk of an incident.
Symptoms such as stiffness, excessive play, or misalignment can indicate underlying damage that requires attention, according to the position.
Technicians must thoroughly inspect the steering column assembly following any collision, it says.
The inspection should include, but not be limited to:
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- Visual and tactile checks for deformation, cracks, or misalignment in the column and surrounding components.
- Functional tests to ensure proper movement, responsiveness, and alignment.
- Diagnostic checks of any safety-related sensors or components housed within the steering column.
“Any damage, no matter how minor, requires replacement of the steering column,” the position says. “The results of the steering column inspection must be documented, including the technician’s findings, and retained as part of the vehicle’s repair records. Any replacements made to the steering column should adhere strictly to Volvo Cars guidelines and use new OEM-approved parts.”
All of the position statements can be found at www.oem1stop.com. The site provides vehicle repair technicians with easy access to the up-to-date repair information made available by participating automakers.
Images
Featured image shows how to isolate an EV as it awaits repair work/VOLVO
Diagram shows EV battery inspection points/VOLVO