Front Bumper Reinforcement: Service and Repair

Front Bumper (76.22.08)

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 disconnect ground cable from battery terminal.
3. Remove radiator surround and grill.
4. Raise ramp to working height.
5. Using wheel-free lifts, remove front wheels.
6. Remove wheelarch liners for access.
7. Remove undertray.
8. At each side of vehicle:
- Disconnect fog lamp, direction indicator and sidemarker lamp (where fitted) harness multiplugs.
- If headlamp powerwash is fitted, remove and discard plastic clip from hose and disconnect hose at RH side of bumper.







9. Slacken and 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 number plate and plinth from bumper cover.
13. Slacken and remove three bolts securing each fog lamp to bumper cover and remove both lamps from cover.







14. Release sidemarker lamp/reflector clips and remove both lamps/reflectors from bumper cover.







15. Remove direction indicators from bumper assembly.
16. Remove powerwash jet assemblies and hoses from top of bumper assembly.
17. Remove bumper blades.
1. Slacken and remove three screws securing each blade to bumper cover.
2. Slide each blade forward to release two side tangs from cover and remove blade from bumper.







18. Rotate three splitter vane fasteners 1/4 turn counter-clockwise and remove splitter vane from air intake.







19. Release tangs securing brake cooling ducts to cover and remove ducts from bumper.







20. Remove and discard four scrivets securing upper section of air intake to beam.







21. Drill out rivets securing upper section of cover to bumper beam.







22. Withdraw bumper beam from cover.

Installation

1. Position beam in cover, ensuring that tangs locate correctly in beam slots.
2. Using new fir tree fasteners, scrivets and rivets, secure beam to bumper cover.
3. Install fog lights, direction indicators, and side marker lamps/reflectors in bumper cover.
4. Fit chrome blades to top of casing locating tangs in slots and fit and tighten securing screws.
5. Fit powerwash jet assemblies to bumper cover.
6. Fit bumper assembly to vehicle. Refer to operation.
7. Position splitter vane in air intake and secure by rotating fasteners 1/4 turn clockwise.
8. Fit number plate and plinth.
9. Connect ground cable to battery terminal and fit battery cover.