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Front Bumper Cover Removal
 
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Pelican Technical Article:

Front Bumper Cover Removal

Steve Vernon

Time:

1 hour1 hr

Tab:

$825 to $1,000

Talent:

**

Tools:

8mm socket, T30, T25 Torx, trim removal tool

Applicable Models:

BMW E65 7-Series (2002-08)

Parts Required:

New bumper cover

Hot Tip:

Get a friend to help and have something soft to lay it on once it is removed

Performance Gain:

Access to the headlights

The front bumper cover on the E65 can be removed rather simply. If you are careful you can do it by yourself and not damage the paint. The cover is more cumbersome than heavy. If you are worried about damaging it get a friend to help and have something soft to lay it on once it is removed.

Our project car did have the PDC or Parking Distance Control feature but if your vehicle does not you can skip the step about disconnecting the electrical connection for the sensor.

All the procedures shown are the same for both sides of the bumper.

There are several areas of the front bumper cover that you will need to work on to remove it.
Figure 1

There are several areas of the front bumper cover that you will need to work on to remove it. The parts of the front cover include: the front plastic trim pieces (yellow arrow), the lower air grilles (red arrow), the area between the headlights and grille (purple arrow, with the hood up) and the wheel well (blue arrow). You do NOT need to jack up the vehicle, remove the wheels or even the wheel well liners to remove the bumper cover. The procedures are the same for both sides of the car.

Use a trim removal tool, and gently pry out the two trim pieces that hold the PDC sensors on the front of the cover (red arrow) starting at the front of the bumper.
Figure 2

Use a trim removal tool, and gently pry out the two trim pieces that hold the PDC sensors on the front of the cover (red arrow) starting at the front of the bumper.

Work your way around towards the fender until the trim piece is free of the bumper cover.
Figure 3

Work your way around towards the fender until the trim piece is free of the bumper cover.

Disconnect the PDC sensors by squeezing in on the tabs (red arrows) and pulling it off the sensor.
Figure 4

Disconnect the PDC sensors by squeezing in on the tabs (red arrows) and pulling it off the sensor. The sensors will stay in the trim piece.

The pop up headlight washer covers (red arrow) will stay on the cover, as they are not attached to anything else.
Figure 5

The pop up headlight washer covers (red arrow) will stay on the cover, as they are not attached to anything else.

Using your trim removal tool gently pry out the license frame trim piece on the bumper cover.
Figure 6

Using your trim removal tool gently pry out the license frame trim piece on the bumper cover.

Remove the lower grilles by prying them with the trim removal tool and pulling them out with your hands.
Figure 7

Remove the lower grilles by prying them with the trim removal tool and pulling them out with your hands.

Remove the two 8mm bolts from the fender area.
Figure 8

Remove the two 8mm bolts from the fender area. One connects the fender to the cover (red arrow). One connects the cover to the lower tray (yellow arrow).

Use your trim removal tool to remove the plastic push/pull pin connecting the wheel well liner to the cover (red arrow).
Figure 9

Use your trim removal tool to remove the plastic push/pull pin connecting the wheel well liner to the cover (red arrow).

Use a T25 Torx and remove the four lower screws (red arrows) and the two from behind the license trim piece (yellow arrows).
Figure 10

Use a T25 Torx and remove the four lower screws (red arrows) and the two from behind the license trim piece (yellow arrows).

Use a T30 Torx to remove the two Torx screws on each side between the lights and radiator (red arrows).
Figure 11

Use a T30 Torx to remove the two Torx screws on each side between the lights and radiator (red arrows).

There are metal inserts in the cover to protect it from the Torx screws.
Figure 12

There are metal inserts in the cover to protect it from the Torx screws. Make sure to remove these before removing the cover, as they tend to fall out and get lost.

Release the connection between the cover and fender using a trim removal tool.
Figure 13

Release the connection between the cover and fender using a trim removal tool.

You can now slide the cover back off the bumper (red arrows).
Figure 14

You can now slide the cover back off the bumper (red arrows). The fog lights are still attached so don't try and walk away yet.

Disconnect each fog light by squeezing in on the tab and pulling the electrical connection off (red arrow).
Figure 15

Disconnect each fog light by squeezing in on the tab and pulling the electrical connection off (red arrow).

You now have access to the bumper and all of the systems behind the cover.
Figure 16

You now have access to the bumper and all of the systems behind the cover. Installation is the reverse of removal.


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Page last updated: Fri 12/2/2016 03:00:50 AM