Several months ago I had an unfortunate experience that damaged the near side of the front bumper - no, I'm not going to admit to how I did it, just accept it was my fault, no-one else was involved and the car remained driveable but cosmetically an eye sore. I purchased a used bumper from a reputable breaker and that has sat in my back garden ever since awaiting a suitable time to fit it to the car. That day happened to be Tuesday so I put the replacement bumper into the back of the car and headed off to my friendly, tame mechanic's garage so we could fit it. For various reasons we didn't get started until about 4:30pm but we did watch a how-to video on YouTube in the meantime so had an idea of what to do.
Removing the old bumper starts with removal of the two front wheel arch liners; then it's simply
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a matter of undoing bolts, nuts and torx screws and removing those annoying panel clips that expand when you press a hard centre into them (dunno what they're called). There are several bolts cunningly hidden behind bits of flexible rubber trim That just leaves the exterior air temperature sensor to extract from its little hidey hole on the near side and a multi-pin connector to unplug on the drivers side. So far so good and only 30 minutes gone
Comparing the back of the old bumper with the "new" one reveals that a lot of parts have to be transposed from one to the other. Hmmm, coffee time. Most of the parts are fitted to the bumper using a multitude of press-fit clips but there are several rivets and small torx screws thrown in for good measure. Figuring out the correct sequence for removing these parts takes a bit of thought and discussion but we finally hit on a plan that seems to work and eventually we have two bare bumper skins, a pile of assorted bits that need fitting and several clear plastic bags with the nuts, bolts and other sundry fixings to do the fixing. At this point we are about two hours into the job and thinking the worst is over. Coffee time again
As it says in all the best workshop manuals "reassembly is simply the reverse of disassembly" - yeah, right! I thought getting all the press fit clips undone was hard but getting it all back together was even harder. Aligning everything so we could be sure all the clips were in place was a challenge as the bumper skin is really very floppy and we're being ultra careful not to damage it. Starting in the centre and working our way out towards the sides we eventually get everything in place, new rivets inserted and screws done up and it's all looking good. Well, except for the near side collision pressure sensor which got damaged in the original impact but had gone unnoticed until then. A replacement which will get fitted as and when arrived earlier today. After about three and a half hours of fairly continual work in a very cold (despite there being four space heaters on the go) workshop we are ready to offer up the "new" bonnet to the front of the car. Time for coffee break number three before we do that
It's finally plain sailing but we are resisting the urge to rush and get the job finished as now is not the time to forget something or mess up. The new bonnet is on the car and bolted up in about twenty minutes, after which we spend another ten adjusting the fit between the bumper and the wings and bonnet. At the end of four hours we are finished and the car is back looking good
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All that's needed now is a wash and polish to see how close the paint on the new bumper matches the rest of the car. At first glance it is close enough but we are in a workshop with rather poor lighting so it needs to be checked out in daylight, which I did yesterday and, whilst it's not a perfect match, it's close enough for me
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If SWMBO decides I can't live with the slight mis-match then I know a man who is pretty good with a spray gun
Right now I'm just happy the job's done but a couple of things have been learned; firstly, I'm really glad I didn't try to do the job on my own; secondly, my mate is an absolute flippin' star and finally, the person/team that designed such a complex bumper assembly needs shooting - very slowly
Sorry for the long winded post
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