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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), floor jack, wheel chocks, jack stands, safety glasses

Applicable Models:

Mercedes-Benz E320 (2003-09)
Mercedes-Benz E500 (2003-06)
Mercedes-Benz E55 AMG (2003-06)

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

Mercedes-Benz W211 models use a plastic bumper cover over a rigid strut-supported steel bumper. This cover is painted to match your vehicle. It is frequently scratched and damaged. The bumper cover can be replaced quite easily 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 W211. 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, and headlight washers. The headlight washers may be the biggest concern behind the bumper as they frequently leak. Once the bumper is removed, see our tech article on headlight replacing for information on the headlight washers.

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're 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 and supporting your vehicle.

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

Mercedes-Benz W211 models use a plastic bumper cover (red arrows) over a rigid strut-supported steel bumper.
Figure 1

Mercedes-Benz W211 models use a plastic bumper cover (red arrows) over a rigid strut-supported steel bumper. This cover is painted to match your vehicle.

Working in the wheel well, remove the two 8mm fasteners (green arrows).
Figure 2

Working in the wheel well, remove the two 8mm fasteners (green arrows). The right side is shown. The left side is similar.

Working at the lower radiator splash shield, remove the two 8mm fasteners (green arrows).
Figure 3

Working at the lower radiator splash shield, remove the two 8mm fasteners (green arrows).

Pull the lower radiator splash shield down away from the bumper and remove it.
Figure 4

Pull the lower radiator splash shield down away from the bumper and remove it.

Start by removing the front sections of the wheel well liners.
Figure 5

Start by removing the front sections of the wheel well liners. See our tech article on wheel well liners removing. Working inside the fender, at the junction of the front fender and front bumper, remove the T25 Torx fastener (red arrow). Once the fastener is removed, open the bumper retainer (blue arrow).

To unclip the bumper retainer, pull the end away from the bumper (blue arrow).
Figure 6

To unclip the bumper retainer, pull the end away from the bumper (blue arrow). Then slide the rear section of the retainer toward the front of the vehicle to remove it. Note the slot in the bumper cover (blue arrow). This slot is there to allow the retainer to remain attached to the fender while the bumper cover is removed. I find it easier to remove the fastener. Then lever the retainer open. Then slide the rear pin (red arrow) out of the fender and cover. Then remove the retainer from the vehicle. The left side of the vehicle is shown. Repeat the same procedure for the right side.

Working inside the front bumper, remove the ambient air temperature sensor from the bumper cover by pulling it straight out (blue arrow, left side only).
Figure 7

Working inside the front bumper, remove the ambient air temperature sensor from the bumper cover by pulling it straight out (blue arrow, left side only). Then disconnect the fog light electrical connector by squeezing the release tabs and pulling the connector straight off (red arrows). The left side of the vehicle is shown. Repeat the same process for the right side.

Working next to the horn (red arrow) (left side of vehicle has horn, right does not, light located in same area), remove the marker light (blue arrow) from the bumper cover by rotating the socket 90° counterclockwise and pulling it straight out.
Figure 8

Working next to the horn (red arrow) (left side of vehicle has horn, right does not, light located in same area), remove the marker light (blue arrow) from the bumper cover by rotating the socket 90° counterclockwise and pulling it straight out. The left side of the vehicle is shown. Repeat this step for the right side.

Working at the lower corner of the front bumper, remove the plastic rivet.
Figure 9

Working at the lower corner of the front bumper, remove the plastic rivet. The red arrow points to a plastic rivet. Using a trim panel tool, lever out the center pin. Then remove the rivet. The right side of the vehicle is shown. Do the same step for the left side.

Working at the center of the bumper at the grille, pull the end of the grille out of the bumper detaching the clips (red arrows).
Figure 10

Working at the center of the bumper at the grille, pull the end of the grille out of the bumper detaching the clips (red arrows). Once free, detach the grille where it mounts to the column (blue arrows) on the bumper cover. Reach into the cover and spread the clip (green arrows) to detach it. Be careful when doing this, as the grille is plastic and can break. Once free, you can reach into the bumper cover and remove the lower bumper cover fastener, as noted in the following step. I like to detach the end just enough to pull it out for access. If you want, continue detaching the grille to remove it completely. To reiterate, the left side of the vehicle is shown. Repeat this step for the right side.

With the grille pulled away (red arrow), remove the 10mm bumper fastener (blue arrow).
Figure 11

With the grille pulled away (red arrow), remove the 10mm bumper fastener (blue arrow). The left side of the vehicle is shown. Repeat for the right side.

Move to the headlights.
Figure 12

Move to the headlights. Remove the two bumper cover fasteners (red arrows). The upper fastener is 8mm. The lower fastener is 10mm. When removing the lower fastener, be sure not to lose the shimming washer, if it is in place (blue arrow). Your vehicle may not have a shimming washer.

With all the fasteners removed from the front bumper, slide the bumper cover forward to remove it.
Figure 13

With all the fasteners removed from the front bumper, slide the bumper cover forward to remove it. Have a friend nearby so you don't drop the bumper cover. When removing, be careful not to scratch the bumper cover or snag any previously disconnected items. The red arrow points to the bumper mounts on the body. You are sliding the bumper forward off of these.

To install the front bumper, start by sliding the bumper onto the mounts and onto the vehicle.
Figure 14

To install the front bumper, start by sliding the bumper onto the mounts and onto the vehicle. Then press the corners near the headlights together until they snap.

Then install the bumper retainers.
Figure 15

Then install the bumper retainers. Slide the pin (blue arrow) into the groove (red arrow). Then lever the retainer closed, like a hinge. Once it snaps into place, install the fastener. Then install the remaining bumper fasteners. Connect the electrical connectors. Then check alignment of the bumper to the body.

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Comments and Suggestions:
Boee Comments: I want to put on a facelift bumper on a pre facelift carw211 e220 03 will i need a new hood as well?
May 1, 2017
  Followup from the Pelican Staff: I would assume headlights as well, whatever was changed with facelift.

I opened a post in our forums. A Pelican community member may be able to answer your question. - Nick at Pelican Parts
 
redvette33 Comments: Where can I find part number to lower bumper cover Fastener 10 millimeter Bolt with shimming washer?
January 11, 2017
  Followup from the Pelican Staff: Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
FatGuy Comments: Awesome instructions I had someone remove the cover for paint and now i know i am short on hardware. Thanks Craig
December 18, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 

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Page last updated: Wed 7/26/2017 02:52:08 AM