I have a 1991 240 wagon. The P.O. Installed the incorrect bumpers and EA (Energy Absorbers - brackets that hold the bumpers to the car) There are 3 bolts each... I installed the proper rear units and bumper without any issues.

On the front of the car the PO did not secure the front EAs to the car with the large bolts. The small bolts (2 per EA) are fine. The problem is with the large bolts that go through the sills and EAs which are dropped in from the top.

The right (passenger)side bolt is too short to contact the weld nut. The longer right side bolt that was provided reaches the weld nut but is the wrong size (diameter / thread size)

The left (driver) side bolt is long enough, but the weld nut is missing. It also is too large (diameter) to fit through the hole where the weld nut should be.

What size (length and diameter) bolt should be there in each case? Fine or coarse thread? Would a nut-sert work on the driver's side. I suppose on the driver's side I could drill a large hole in the bottom of the sill to add a washer / nut set, but I'd rather not.

Any suggestions? Bolt size - process?

Thanks.

Pete

 

parts catalog only lists part numbers, not bolt sizes. qty 4 'flange screw' 946440 [part 11 below], and qty 2 'hexagon screw' 971003 [12], with washers 955899[13]. I'm betting this stuff should all be fairly hardened.

they don't show any nuts, the small 'flange screws' seem to go through 2 'guide washers' on each side, part 3534538 [9] and [10] (NLA)



from Volvo Front bumper, spoiler

 

Thanks for your quick reply. I found that the passenger side (that has the weld nut on the sill) was able to use a bolt from a donor car. The PO did a number of things that were irregular. The front bumpers were basically only held on by the 2 small bolts per side and not the large bolts. The bumpers might have fallen off or pulled off if attached to a rope.

Still a problem though...

The driver's side sill weld nut is missing, so I'm going to need to repair it. A nut-sert? I have a donor car bolt. Any suggestions on how to replace the missing weld nut on the sill?

Thanks!

 

Update... I drilled through the entire sill and got a longer bolt and secured the EA tube under the car. Not optimal, but better than nothing.

Car is pretty much done except for some little things that have been found after I got it running. It's not been run for 2 years.

Pete