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Body Gap Dimensions

The following are dimensions for the body gaps that are measured when manufacturing the vehicle.

The dimensions are an average value of the measurements on the new vehicles.

Measuring is done on a painted body.

On unpainted body, the gap increases by approx. 0.2 mm.

The dimensions vary from vehicle to vehicle. Use the dimensions in this method as a basis. 

There are no max. or min. dimensions given as there must be harmony in the gaps on the visible surface.

Final checks/adjustments must be performed when the vehicle is painted in the correct color. 

If a black unpainted front fender is installed on a white vehicle, it is very difficult to, see the size of the gap between the fender and door.

Level adjustment (applies for adjusting of doors, fenders and covers) 

GLL103472Courtesy of VOLVO CARS CORPORATION

The front part must be positioned above the part behind it as shown above, partly to overlap in case of a collision, partly to reduce wind noise. M1 = 0.5 mm.

Fig 1: Door Panel Gap Specifications And Measurement Locations
GLL159019Courtesy of VOLVO CARS CORPORATION
Fig 2: Front Body Panel Gap Specifications And Measurement Locations
GLL159020Courtesy of VOLVO CARS CORPORATION
Fig 3: Tailgate And Rear Body Panel Gap Specifications And Measurement Locations
GLL159021Courtesy of VOLVO CARS CORPORATION