1999-2006 Volvo S80 Grille: Vertical Bar vs. Egg-Crate Facelift Guide
The most important difference in first-generation Volvo S80 grilles is the style change that occurred in 2004, and the two types are not interchangeable.
- The grille style changed in 2004. Pre-2004 models use a vertical bar grille, while 2004-2006 models use an 'egg-crate' mesh style. They are not interchangeable.
- When buying a used grille, the most critical inspection is for broken mounting tabs, as this will prevent a secure fit.
- Replacement is a simple DIY job that takes less than 15 minutes and only requires a screwdriver; the bumper does not need to be removed.
- A damaged grille is a cosmetic issue and does not prevent the car from being driven safely.
The 2004 Facelift: Two Grilles, One Generation
The single most important factor when replacing a 1999-2006 Volvo S80 grille is the mid-generation facelift that occurred for the 2004 model year. The grilles from the early and late periods have different shapes and mounting points and are not interchangeable without swapping the entire front bumper. Forum users have confirmed that attempting to fit a newer style grille into an older bumper does not work.
1999-2003: Pre-Facelift Vertical Bar Grille
Vehicles from 1999 to 2003 are equipped with a grille that features prominent vertical bars, often with a chrome surround. This style is sometimes referred to as the "waterfall" grille. OEM part numbers associated with this style include 9154736.
2004-2006: Post-Facelift 'Egg-Crate' Grille
Starting in 2004, the S80 received a facelift that included a new grille design. This later style features a square mesh pattern, often described as an 'egg-crate' or grid style. It gives the car a more modern appearance. OEM part numbers for this style include 8659947 and 30733001.
Warning: Before purchasing, you must confirm which style your vehicle has. A 2003 model will always have the vertical bar grille, and a 2004 model will always have the egg-crate grille. They cannot be swapped.
Symptoms of a Failing or Damaged Grille
Since the grille is a static, cosmetic part, 'failure' is almost always related to physical damage or cosmetic deterioration.
- Cracks and Breaks: The most common issue is physical damage from minor impacts, such as from parking blocks, road debris, or animals. This can lead to visible cracks or entire sections breaking off.
- Broken Mounting Tabs: The plastic tabs that hold the grille to the bumper are fragile. They can break during removal, installation, or from a minor impact, causing the grille to become loose or rattle.
- Peeling or Faded Finish: The chrome surround or painted finish can peel, bubble, or fade over time due to sun exposure and weather.
- Damaged or Missing Emblem: The Volvo emblem in the center can become delaminated, faded, or fall off entirely. There was a technical journal issued for later model Volvos regarding peeling emblems, suggesting it can be a common issue.
Buying a Used Grille: What to Check
A used OEM grille is often a better choice than a new aftermarket one due to superior fit and material quality. However, a thorough inspection is crucial.
- Confirm the Style: First and foremost, ensure you are buying the correct style for your year (pre- or post-2004).
- Inspect All Mounting Tabs: This is the most critical inspection point. Carefully check all the plastic tabs on the back of the grille. There are typically several clips on the top and bottom edges. If even one is broken, the grille may not sit flush or could rattle.
- Look for Hairline Cracks: Check the entire surface, especially around the mounting points and the emblem, for small cracks that could worsen over time.
- Examine the Finish: Hold the grille under a light and look for signs of peeling chrome, deep scratches, or heavy pitting from road debris. For black plastic versions, check for a chalky, faded appearance from sun damage.
- Check the Emblem: Is the emblem included? Is it in good condition? A new emblem can be surprisingly expensive, so getting a grille with a good one adds value.
Known Issues, TSBs, and Recalls
There are no specific recalls or Technical Service Bulletins (TSBs) for the grille itself on the 1999-2006 Volvo S80. Searches on the NHTSA database show recalls for this vehicle related to airbags, fuel system components, and ball joints, but none pertaining to the grille. The grille is a simple, non-electronic component with no associated safety defects that would warrant a recall.
Replacement Difficulty
- Difficulty: 1 out of 5
- Estimated Time: 0.25 hours
- DIY Feasible: Yes
Replacing the grille on a first-generation S80 is a very simple task that does not require removing the bumper. The grille is held in place by a series of integrated clips. The process involves using a long, flat-head screwdriver or a trim removal tool to carefully release the tabs on the bottom through the grille slats, and then reaching behind the top of the grille to release the upper tabs. Once the tabs are released, the grille pulls straight out. 🎬 Watch: Step-by-step Volvo P2 grille removal walkthrough Installation is a matter of aligning the new grille and pushing it firmly into place until all the clips engage.
Pro Tip: When releasing the plastic tabs, be gentle. They can become brittle with age. Pushing too hard can break the tab, making it difficult to secure the new grille. It's helpful to pull gently on the grille as you release each tab to keep it from re-engaging.
Cost Comparison
| Part Type | Estimated Cost |
|---|---|
| New OEM | $300 - $450 |
| New Aftermarket | $50 - $210 |
| Used OEM | $35 - $75 |
| Shop Labor | $0 (Typically a DIY job) |
Frequently Asked Questions
Can I install a 2004+ 'egg-crate' grille on my 2002 S80?
No, not without significant modification. The shape and mounting points of the post-facelift (2004-2006) grille are different and will not fit into the bumper of a pre-facelift (1999-2003) car. To perform this conversion, you would need to replace the entire front bumper assembly.
Does the grille have any electrical connectors?
No. The grille on the 1999-2006 Volvo S80 is a simple piece of plastic and/or chrome. It has no integrated sensors, cameras, or other electronic components that would require an electrical connection.
Is a cheap aftermarket grille a good option?
While new aftermarket grilles are inexpensive, they often have issues with fit and finish. The plastic may be more brittle, the chrome may peel sooner, and the mounting tabs may not align as perfectly as an OEM part. A good-condition used OEM grille is often a better value, providing factory-grade fit and durability for a similar price.
How do I remove the grille without breaking the clips?
The key is patience and using the right technique. Use a long, thin screwdriver to press down on the lower tabs while gently pulling the bottom of the grille outward. Once the bottom is free, you can reach your hand behind the top edge to feel for the upper tabs and release them. Avoid prying on the grille itself, as this can crack the frame.
Helpful Videos
Technical Specifications
OEM Part Numbers: 30733001 307330019 8659947 86599479 9154736 9176087 9178087 987429
Material: Plastic with optional chrome finish. Two distinct styles: Vertical Bar (1999-2003) and Egg-Crate (2004-2006).
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The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
- Volvo S80:
- 🎬 Helpful Videos
- 🛍️ Shop This Part
- The 2004 Facelift: Two Grilles, One Generation
- 1999-2003: Pre-Facelift Vertical Bar Grille
- 2004-2006: Post-Facelift 'Egg-Crate' Grille
- Symptoms of a Failing or Damaged Grille
- Buying a Used Grille: What to Check
- Known Issues, TSBs, and Recalls
- Replacement Difficulty
- Cost Comparison
- Frequently Asked Questions
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