Preparations, Bumper Cover

APPLIES TO ALL MODELS

Fig 1: Identifying Bumper Cover Lower Edge Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the four screws securing the air baffle to the lower edge of the bumper cover.

Fig 2: Identifying Clips And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

Fig 3: Identifying Cover For Nozzles For Headlamp Washers

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the cover for the washer nozzle.
HINT: Carefully grip the cover. Pull the cover out until the catch becomes accessible from the underneath.

Press the catch up. Remove the cover. Do not damage the painted surfaces and washer nozzles.

Fig 4: Locate The Four Markings On The Inside Of The Bumper Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 5: View Of Drill Hole Markings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Locate the four markings on the inside of the bumper cover. Make a mark in the middle using a scriber.
Drill at the markings using a 3 mm (1/8") drill bit. Drill from the inside of the bumper cover.
Drill out the holes. Use a 8 mm (5/16") diameter drill bit.

Fig 6: Identifying Bumper Cover Hole Punching

Courtesy of VOLVO CARS OF NORTH AMERICA.

Make holes in the bumper cover using the hole punching tool P/N 9814069 . The hole punching tool sleeve and screw must be inside the cover.
Carefully deburr the inside as necessary.

Fig 7: View Of Cleaned Hole Surfaces

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 8: Applying Thin Layer Of Activator

Courtesy of VOLVO CARS OF NORTH AMERICA.

Apply a thin and even layer of activator to a surface around the holes that is slightly larger than a sensor holder. Allow to dry for at least 10 minutes.
Use: 8637076 - Activator.

Fig 9: Identifying Plastic Member Markings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Locate the two marks on the plastic member (the energy absorbent). Saw out following the two markings using a compass saw, only through the outer section.

NOTE:

On certain cars a foam member is available instead of the plastic member.

Remove the foam member from the collision member.
Make cut-outs for the inner sensors by sawing out according to the two markings through the entire thickness of the foam member.
Reinstall the foam member.

Fig 10: Identifying Cable Harness In Foam Member

Courtesy of VOLVO CARS OF NORTH AMERICA.

Cut out for the cable harness in the foam member by the two cut-outs. The cut-outs must be 25 mm (1") wide and 15 mm (9/16") deep.

Fig 11: View Of Tape Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.