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.

Fig 1: Identifying Headlamp Wiper Holes

Courtesy of VOLVO CARS OF NORTH AMERICA.

Aligning the primed bumper

The bumper must be aligned before painting.

NOTE: If the car is equipped with headlamp wipers:

Make holes for the headlamp wipers on the reverse of the bumper cover as shown.

NOTE: Cars with diesel engines: Cut off a small section of the bumper cover.

Aligning painted bumpers

NOTE: If the car is equipped with headlamp wipers:

Make holes for the headlamp wipers on the reverse of the bumper cover as shown.

NOTE: Cars with diesel engines: Cut off a small section of the bumper cover.

NOTE: Do not use a saw or heat tools to cut.

Use a touch-up pen after cutting.

Fig 2: Identifying Bumper Cover Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

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 (P) for the headlamp wipers if applicable
Position the molding (M). 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
Install the sidemarker lamps
Apply double-sided adhesive tape on the left and right side spoilers (O)
Remove any grease from the surfaces. Secure the side spoilers (O) on the bumper cover
Install the clips
Install the spoiler (N) and the clips
Install the covers (P) for the headlamp wipers if applicable.

Fig 3: Identifying Bumper Support Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the impact absorber (L) in the bumper reinforcement (K) and the stops for the headlamp wipers (if applicable)
Install the bumper reinforcement (K) in the bumper cover.
Start at the ends and work inwards to the center
Ensure that all lugs align correctly
Install the cover strip (J) on the top.

Fig 4: Identifying Bumper Reinforcement Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

If the car has air conditioning (A/C):

Install the 2 foam components (H) in the bracket
- Install the right and left supports (F) in the bracket (E)
- 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
- Install the side supports (D) on the left and right-hand sides.
Install the 4 foam components (G) in the bumper reinforcement
- Install the right and left supports (F) in the bracket (E)
- 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
- Install the side supports (D) on the left and right-hand sides.

Fig 5: Identifying Connectors, Screws and Clips

Courtesy of VOLVO CARS OF NORTH AMERICA.

If applicable: Install the wiper motors for the headlamps. Install the washer hoses and wiper arms
Install the clips and covers. Alternatively install the fog lamp, screws and clips (B) (if applicable)
Install the horn and, if applicable the outside temperature sensor
Connect the connectors (A) for the sidemarker lamps
Install the other components on the bumper cover.