Bumper: Service and Repair

BUMPER REPAIR\RENEWAL

Bumper Description

Each bumper comprises a beam mounted to the body via two strut assemblies and a moulded polypropylene cover incorporating side armatures and chrome plated plastic upper trims. The front bumper cover which is moulded to form a lower air intake for the cooling pack, also incorporates twin fog lamps, brake cooling ducts and side marker lamps or reflectors (dependent upon market). A plastic undertray secured to the lower edge of the front bumper and the BIW improves airflow and minimises the ingress of road grime in that area. Standard bumpers have glass mat thermoplastic (GMT) beams mounted on GMT struts. For certain markets, aluminium bumper beams are installed on menasco energy absorbing struts.

Bumper Cover Repair

Prior to commencing any work, bumper damage should be assessed for repairability and categorized in accordance with the following guidelines. Bumper covers that are torn or holed are not repairable and must be discarded.

CAUTION: Cosmetic appearance must not jeopardise safety. No attempt must be made to repair bumper covers damaged beyond category three. Damage of this extent will compromise the protective performance of the cover and it must be renewed. The thermo-setting nature of the cover material, precludes the repair of splits by heat or welding techniques.







Repair Materials

Repair of accepted damage for categories 2 and 3 may be carried out using 3M '5900 FPRM' (Flexible part repair material) or Kent Industries 'Urepatch'. Repair product manufacturers' recommendations and procedures must always be strictly followed.

Bumper Cover Refinishing

The paint refinishing system must be approved by Jaguar Cars Ltd., and be appropriate for polyurethane substrate application. It is essential that the finishing clear lacquer includes a plasticising ingredient (mixed to the manufacturer's recommendation) that will achieve the 'semi-flex' condition of the factory finished item.

Bumper Cover Support

Exposure to heat decreases bumper cover rigidity. Covers removed for repair must therefore be supported to prevent distortion and sagging during the paint curing process. Where the original bumper cover has been repaired, the beam will provide sufficient support for the centre section. It is recommended that the side armatures are supported as they would be on the vehicle. If a new cover is required, the beam may be temporarily fitted to provide the necessary support during refinishing.

CAUTION: During heat cure, the effective panel temperature must not exceed 95 degrees C.

Simple Jig Construction for Bumper Cover Support







Replacement Bumper Covers

Replacement covers are supplied in a primed condition and must be finished to match the vehicle in accordance with the procedures.

New bumper covers and replacement fixings such as bumper beam adjusters and guide blocks must be fitted and adjusted as detailed in the Bumper Setting Dimensions drawings.

Front Bumper Setting Dimensions







Rear Bumper Setting Dimensions