Adapting rear bumper to S40 model

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: Foam Underlay

Courtesy of VOLVO CARS OF NORTH AMERICA.

Position the templates on the bumper, LH upwards to the left and RH upwards to the right on the bumper.

Use the curve (1) as an outline.

Cut out the material under the template.

File and grind the edges so that they are even.

Carry this out on both sides.

Fig 2: Identifying Bumper Cover Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

CAUTION: Avoid damaging the bumper during assembly. Put the bumper skin on foam at least 3 cm thick to avoid damage to the paintwork during assembling.

Apply double-sided adhesive tape to the spoilers (H)
Degrease the surface and bond the spoilers (H) to the bumper skin
Install the clips
Position the molding (G) and press it firmly down into the bumper skin. (First start at the outer ends and work inwards)
Check if all lugs are correctly aligned
Install the side markers
Install the side support (F) left and right.

Fig 3: Identifying Bumper Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the absorber (E) in the reinforcement (D)
Install reinforcement (D) in the bumper skin. (Note the positioning lugs (J) 4x).
Start pressing at the outer ends working inwards
Install clips (C)
Install the coverstrip (B).

Fig 4: Identifying Bumper Bracket

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the bracket (A) in the bumper. Start pressing at the outer ends working inwards
Check if all lugs are correctly aligned
Install remaining parts in the bumper skin if necessary.

Fig 5: Identifying Clips

Courtesy of VOLVO CARS OF NORTH AMERICA.

Only V40:
Install plastic support right and left and install clips (8 clips).