Assembling front bumper
WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
Do not damage the bumper during disassembly.
Painted bumper cover
If the car is equipped with headlamp wipers:
Make holes for the headlamp wipers on the reverse of the bumper cover as shown.
NOTE:
Do not use a saw or heat tools to cut.
Use a touch-up pen after cutting.
CAUTION:
Do not damage the bumper during assembly. To avoid damage to the paintwork on the bumper cover, a foam underlay at least 3 cm thick must be used during assembly.
Install:
- the covers (K) for the headlamp wipers if applicable
- the molding (J). Press the molding down into the bumper cover. Press hard. (Start at the ends and work inwards to the center)
- Ensure that all lugs align correctly
- the sidemarker lamps
- the clips
- the spoiler and clips.
Install:
- the impact absorber (I) in the bumper reinforcement (H) and the stops for the headlamp wipers (if applicable)
- the bumper reinforcement (H) in the bumper cover.
Start at the ends and work inwards to the center
- install the bracket (E) in the bumper reinforcement. Start at the ends and work inwards to the center.
NOTE:
Slide in the support (F) so that the upper section runs above the bumper cover.
Some force is required to install the bracket.
Ensure that all the lugs align correctly.
Install the side supports (D) on the left and right-hand sides.
If the car has air conditioning (A/C):
- Install the four foam components (F)
- Install the two foam components (G) for the bracket.
If applicable:
Install:
- the wiper motors, washer hoses and wiper arms for the headlamps
- the clips and covers. Alternatively install the fog lamp, screws and clips (if applicable)
- the outside temperature sensor.