Bumpers - Front Bumper Cover
Removal and Installation
Removal
WARNING: ENSURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF AREA BEFORE OPERATING RAMP.
1. Position vehicle on 4-post ramp.
2. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
3. Remove radiator surround and grill. Refer to 76.55.15 and
76.55.03.
4. Raise ramp to working height.
5. Using wheel-free lifts, remove front wheels.
6. Remove wheelarch liners for access.
7. Remove undertray. Refer to 76.22.90.
8. At each side of vehicle:
Disconnect fog lamp, directio n indicator and sidemarker
lamp (where fitted) harness multiplugs.
If headlamp powerwash is fitted, remove and discard
plastic clip from hose and disconnect hose on RH side of
bumper.
9. Remove bolts securing bumper assembly to mounting struts.
10. Lower 4-post ramp.
11. Carefully withdraw bumper casing and beam assembly
forward to clear guide blocks and remove assembly from
vehicle.
12. Remove three bolts securing each fog lamp to bumper cover
and remove both lamps from cover.
13. Release sidemarker lamp/refle ctor clips and remove both
lamps/reflectors from bumper cover.
14. Remove direction indicators fr om bumper assembly. Refer to
Section 417.
15. Release tangs securing brake cooling ducts to bumper cover
and remove ducts.
16. Remove powerwash jet assemb lies and hoses from top of
bumper assembly. Refer to 84.20.08.
17. Remove bumper blades.
1. Remove three screws secu ring each blade to bumper
cover.
2. Slide each blade forward to release two side tangs from cover and remove blades from bumper.
18. Rotate three splitter vane fasteners 1/4 turn counter-
clockwise and remove splitter vane from air intake.
19. Remove number plate and plinth.
20. Remove and discard four scrive ts securing upper section of
Installation
air intake to beam.
21. Drill out rivets securing beam to upper section of bumper
cover.
22. Withdraw cover from beam.
1. Position cover over bumper beam and secure with new fir tree
fasteners, scrivets and rivets.
2. Install fog lights, direction indicators, and side marker
lamps/reflectors in bumper cover.
3. Position chrome blades on top of cover, locating tangs in slots
and install securing screws.
4. Install powerwash jet assemblies on bumper cover. Refer to
84.20.08.
5. Position splitter vane in air intake and secure by rotating
fasteners 1/4 turn clockwise.
6. WARNING: ENSURE THAT ALL PERSONNEL AND
EQUIPMENT ARE CLEAR OF AREA BEFORE OPERATING RAMP.
Carefully slide bumper assembly onto fender guide blocks.
7. Raise ramp to working height.
8. Install but do not fully tighten bo lts securing bumper to struts.
9. Check clearance between top of bumper and bottom of fender.
If necessary, remove bumper, adjust guide blocks to achieve
correct clearance and refit bumper.
10. Connect harness multiplugs to foglamps, direction indicators
and where fitted side marker lamps.
11. Install harnesses into retaining clips at each side of cover.
12. Install powerwash hoses to jet assemblies and secure with
new plastic clips. Refer to 84.20.08.
13. Install radiator grill and su rround. refer to 76.55.03 and
76.55.15.
14. Check and as necessary adjust bumper cover to fender,
headlamps and radiator grill surround clearances. Refer to
Description and Operation in this section.
15. Fully tighten bumper assembly to strut securing bolts.
