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Pelican Technical Article:

Front Bumper Replacement

Nick Czerula

Time:

2.5 hours

Tab:

$400

Talent:

*****

Tools:

T20, T25, 8mm, 10mm (sockets)

Applicable Models:

BMW 525i/xi Sedan (2004-07)
BMW 528i xDrive Sedan (2009-10)
BMW 528i/xi Sedan (2008-10)
BMW 530i/xi Sedan (2004-07)
BMW 530xi Wagon (2006-07)
BMW 535i xDrive Sedan/Wagon (2009-10)
BMW 535i/xi Sedan (2008-10)
BMW 535xi Wagon (2008)
BMW 545i Sedan (2004-05)
BMW 550i Sedan (2006-10)
BMW M5 Sedan (2006-10)

Parts Required:

Fog light, horn, headlight washer, bumper cover

Hot Tip:

Get help from a friend when lifting bumper off car

Performance Gain:

Allows access to components behind bumper cover

Complementary Modification:

Install aftermarket bumper cover

In order to make the E60 (sedan) and E61 (wagon) bodies significantly lighter than the previous 5 Series (E39) model, BMW designed a reduced weight aluminum front end dubbed GRAV. The front end and bumper consist almost entirely of aluminum with a transition to steel in the front bulkhead area. The sedan and wagon bodies are identical in structure and design from the front bumper to the B-pillar.

BMW E60 models use a plastic bumper cover over a rigid strut-supported aluminum bumper. This cover is painted to match your vehicle. It is frequently scratched and damaged. The bumper cover can be replaced quite easily by following along with this tech article. You can replace a bumper cover with a factory part, or an aftermarket one if you want to upgrade the look of your E60. Remember to plan to have it painted before you install it, so leave yourself extra time.

In this article, I'll go over the steps involved with removing the front bumper cover. Removing it is required to service the A/C condenser, headlight assembly, horns, and headlight washers. The headlight washers may be the biggest concern behind the bumper as they frequently leak.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you are working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Raise the front of the vehicle and support it safely using jack stands. See our tech article on jacking up your vehicle.

Remove the engine splash shields. See our tech article on splash shield reinforcement plate removing.

Start by removing the center plastic bumper grille (red arrow).
Figure 1

Start by removing the center plastic bumper grille (red arrow).

Unclip the retaining clips (red arrow) and pull the top of the grille out of the bumper, then angle it as you remove it and pull the bottom of the grille out.
Figure 2

Unclip the retaining clips (red arrow) and pull the top of the grille out of the bumper, then angle it as you remove it and pull the bottom of the grille out.

Working at the corner of the bumper, unclip the top (red arrows) of the fog light trim piece.
Figure 3

Working at the corner of the bumper, unclip the top (red arrows) of the fog light trim piece. Then pull it out. Remove the top first and then feed out the bottom. Repeat this step for the opposite side of the vehicle.

Working at the top of the radiator support, remove the ten T30 Torx fasteners (green arrows).
Figure 4

Working at the top of the radiator support, remove the ten T30 Torx fasteners (green arrows).

Lift the radiator support in the direction of the green arrow to remove it.
Figure 5

Lift the radiator support in the direction of the green arrow to remove it.

Then, flip the radiator support (green arrow) over and rest it on the top of the engine.
Figure 6

Then, flip the radiator support (green arrow) over and rest it on the top of the engine.

Working under the vehicle, remove the four T25 Torx fasteners (red arrows).
Figure 7

Working under the vehicle, remove the four T25 Torx fasteners (red arrows).

Working in the wheel well, remove the two 8mm fasteners (green arrows).
Figure 8

Working in the wheel well, remove the two 8mm fasteners (green arrows). Then remove the 10mm fastener (red arrow). Repeat this step for the opposite side of the vehicle. Then, in top of the wheel well, pull back the wheel well liner to expose two 10mm fasteners. Working inside the bumper from below, remove the two 10mm fasteners (yellow arrows).

With all fasteners removed from the front bumper, pull the front corners away (red arrow) from the headlights to detach it.
Figure 9

With all fasteners removed from the front bumper, pull the front corners away (red arrow) from the headlights to detach it. Then slide the bumper out enough to access the electrical connectors for the fog lights (green arrow). Next, with help from a friend, slide the bumper off the support and remove it. When removing, be careful not to scratch the bumper cover or snag any previously disconnected items. To install the front bumper, start by partially installing the bumper while leaving enough space to access the electrical connectors. Reconnect the disconnected items. Then slide on the bumper cover and align it. Install all removed fasteners and check the alignment of the bumper to the body.

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Comments and Suggestions:
Mandorake Comments: I bought a used 2010 550i, and it had been in a previous wreck. The front bumper sticks slightly out on one of the cornersvery small, perhaps 1/8th an inch, is it worth taking the bumper off to see if something is causing this or could it just be the bumper not lining up right from the wreck?
June 16, 2015
  Followup from the Pelican Staff: Could just be the bumper needs to be adjusted. Try loosening the fasteners for the cover and moving it into place. If it won;t go, may require more serious body work. - Nick at Pelican Parts  

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Page last updated: Wed 12/7/2016 02:48:37 AM