Front Bumper Cover / Fascia: Service and Repair

Front Bumper Cover (76.22.78)

Removal

1. Position vehicle on 4-post ramp.
2. Remove battery cover and disconnect ground cable from battery terminal.
3. Raise vehicle to working height.
4. Remove and discard fasteners from both wheelarch liners and remove liners for access.
5. Remove wheelarch spoilers.
6. Using a thin plastic lever, carefully release front number plate from plinth..
7. Slacken and remove screws securing number plate plinth to overriders.
8. Remove and discard the eight rivets securing undertray to the bumper cover.







9. Remove and discard three fasteners securing undertray to lower crossmember and remove undertray.







10. At each side of vehicle:
- Disconnect fog lamp harness multiplug and where fitted, disconnect sidemarker lamp.
- Slacken and remove three bolts securing bumper cover to the fender lower flange.







11. Lower 4-post ramp.
12. Remove bumper cover from vehicle.
- Remove and discard the three fir tree fasteners securing bumper cover to BIW front upper cross-member.
- Remove six bolts securing bumper cover to front upper cross-member and remove cover from vehicle.







13. Slacken and remove three bolts securing each fog lamp to bumper cover and remove both lamps from vehicle.







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







Installation

1. Position fog lamps in bumper cover and fit and tighten securing bolts.







2. Fit and fully seat sidemarker lamps/reflectors in bumper cover.







3. Position and secure bumper cover to front upper cross-member.
- Position bumper cover over bumper beam and locate on upper cross-member using three new fir tree fasteners.
- Fit and tighten six cover to upper cross-member securing bolts.







4. Raise vehicle to working height.
5. At each side of vehicle:
- Fit and tighten three bolts securing bumper cover to fender lower flange.
- Connect harness multiplugs to fog lamps and where fitted, side marker lamps.







6. Fit undertray.
- Position undertray on vehicle and secure to lower cross-member with three new fasteners
- Secure undertray to bumper cover using eight new rivets.







7. At each side of vehicle, reposition and secure wheelarch spoiler and wheelarch liner using new fasteners.
8. Lower 4-post ramp.
9. Position front number plate plinth on overriders, fit and tighten securing screws and fit number plate to plinth.
10. Connect ground cable to battery terminal and fit battery cover.