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Front Bumper Wheel Liner Replacement on the Porsche 911 Carrera
 
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Pelican Technical Article:

Front Bumper Wheel Liner Replacement on the Porsche 911 Carrera

Time:

30 min

Tab:

$850

Talent:

**

Tools:

Flathead Screwdriver, Phillips Screwdriver, Torx set, Pliers or a Crowbar, Jack Stands, Floor Jack

Applicable Models:

 
Porsche 996 Carrera models (1999-05)
Porsche 996 Turbo, GT2, GT3 (2001-05)
Porsche 997 Carrera models (2005-08)
Porsche 997 Turbo, GT2, GT3 (2007-08)

Parts Required:

Front bumper cover

Hot Tip:

See if a good body shop can repair your front cover

Performance Gain:

Cleaner looking car

Complementary Modification:

Modify your 996 liners, install center radiator

Unless your Carrera was stored in a time capsule when it was purchased new, it's highly likely that you will have at least some type of cosmetic damage to your front bumper cover. The amount and depth of the damage is, of course, completely dependent upon the care of the driver. The Carrera that I picked up as the project car for this book was cheap, had been abused, and the front bumper cover wore all the scars of the car's previous life. That said, the inner wheel wells of the car were so damaged that while I was able to save and repair the front bumper cover, the wheel wells required a complete replacement. While both the 996 and 997 front bumpers are a single piece, the 997 bumpers have the turn signal indicators and headlight washer incorporated into the bumper. They are both similar to remove, but with a few exceptions that I will point out as we go.

The first step is to jack up the front of the car. Loosen the lug nuts on your wheels prior to jacking if you are planning on removing the wheelwell liners. The next step in removing the front bumper cover is to remove the screws that attach it to the top of the chassis. Remove the front trim panel by turning the plastic screws a half turn (996 only), the 997 trim is just secured with Velcro from below. The plastic trim panel can then be removed, exposing the screws securing the bumper.

Next, you need to pull out the side marker lamps from the corner; they pull straight out (996 only). After disconnecting the bulb from the unit, look in the area where the side markers where and you will see two small screws that needs to be removed. One facing outward, and one near the edge of the wheel well that screws upwards.

While you can pull the side markers straight out on the 997 there are two better and gentler ways. First, there is a small access hole in the fender lining behind the marker (see picture 8), inset a screwdriver in and gently push on the back of the clip securing the side marker. It will release and you can easily pull it out from the bumper. The other way is to just apply a little pressure to the marker, sliding it back and in towards the wheelwell. This will release the marker from its front mount. Once the marker is out disconnect it and set aside. There is a T30 screw behind the marker that can be accessed from the same hole that you used to remove the marker. Insert the screwdriver up through the hole and remove it.

On the 996, inside the wheel well of the driver and passenger side, locate and remove the main three fasteners that are used to attach the inner front wheel well liner to the front bumper (green arrow in Figure 5) which can be removed with either a crowbar or pliers (see inset picture of Figure 5).

On the 997 the front wheel liners are two pieces. You do not need to remove them to remove the bumper, but you do need to remove the two lower T30s that attach to the bottom of the bumper. I recommend removing the front liner as it is only held by four Torx screws and makes access to the headlight washer hose and turn signal wiring much easier.

Then, disconnect the temperature sensor that sits in a small hole near the front grille on the right side of the car (see inset picture of Figure 1) - the temperature sensor is a small device with a wire attached to it that looks a bit like a very short pencil. Finally, remove the screws that attach the bottom of the bumper cover to the car (Figure 3 and Figure 4).

On the 997 there are a few extra steps. There is a clip between the bumper and fender on each side that needs to be removed (see picture 6).

The clip is accessed from the front trunk. It is best to spray a little lubrication into the clip area first, especially if the clips have never been removed. Insert a hooked tool into the hole on the clip and pull straight out. I have removed several and some slide right out and others you have to pull so hard you think you are doing it wrong. There is nothing else holding the clips in, just take your time and watch that you don't damage your paint. With the clips removed and all of the hardware disconnected, you can pull the bumper cover straight forward a few inches.

On the 996s you can now just remove the bumper. On the 997s you will need to reach in and disconnect the wiring harness on the right side (see picture 7) and the hose connection for the headlight washer on the left (see picture 8). Now you can safely remove the bumper by continuing to pull it forward.

On the 996 removal of the wheel well liners is not quite as easy as pulling off the front bumper cover. First, remove the two road wheels. The wheel well liners are attached using plastic rivets which must be pried out and unscrewed one-by-one. Figure 7 shows the location of these seven rivets on the driver's side (passenger side is identical). If you're planning on replacing your shocks, then now would be a good time to do it.

Start in the front trunk by removing the black plastic cover piece near the front hood latch.
Figure 1

Start in the front trunk by removing the black plastic cover piece near the front hood latch. On the 996s four small fasteners hold this piece in place. Simply rotate them a half turn or so with a flathead screwdriver to loosen them up and remove. The 997 trim piece is held on by Velcro from bellow and can just be lifted and removed. Lift the trunk latch up to pull the plastic cover piece up and away from the front bumper. The inset photo also shows the temperature sensor that you need to remove from the grille clipped on the passenger side of the front bumper.

With the front black plastic cover piece removed, you can see the two screws that hold the front bumper cover on to the chassis of the 996 (lower image).
Figure 2

With the front black plastic cover piece removed, you can see the two screws that hold the front bumper cover on to the chassis of the 996 (lower image). On the 997 (upper image) there are three screws that hold the bumper on (two shown, green arrows). You can also see the Velcro that holds the trim piece (blue arrows).

Underneath the car, there are a few more Phillips-head (996) and Torx head T30 (997) screws that attach the bumper cover to the chassis.
Figure 3

Underneath the car, there are a few more Phillips-head (996) and Torx head T30 (997) screws that attach the bumper cover to the chassis. Remove these.

At the very corner of the bumper, remove the one Phillips-head screw that attaches the wheel fender lining to the each corner of the bumper.
Figure 4

At the very corner of the bumper, remove the one Phillips-head screw that attaches the wheel fender lining to the each corner of the bumper. The bottom right photo shows the two plastic rivets (996) and Torxs (997) that are used to attach the wheel well liner to the chassis that must be removed.

On the 996, from inside the wheelwell of the driver and passenger side, locate and remove the main three fasteners that are used to attach the inner front wheel well liner to the front bumper (green arrow) which can be removed with either a crowbar or pliers (inset photo).
Figure 5

On the 996, from inside the wheelwell of the driver and passenger side, locate and remove the main three fasteners that are used to attach the inner front wheel well liner to the front bumper (green arrow) which can be removed with either a crowbar or pliers (inset photo).

On the 997, the front fender lining is secured in place by four Torx screws (T25).
Figure 6

On the 997, the front fender lining is secured in place by four Torx screws (T25). Remove the two lower Torx screws (green arrows, not visible) and the two screws by the vent (blue arrows). It helps to loosen but not remove the two Torxs that cover the overlap of the liner (yellow arrows).

Remove the corner turn signals by pulling out on the corner of the unit.
Figure 7

Remove the corner turn signals by pulling out on the corner of the unit. After removing the lamp, remove the Phillips-head screw behind it (bottom right inset photo) and the receptacle for the Phillips-head screw that must be removed from inside the wheel well by peeling the liner back (yellow arrow).

While you can pull the side markers straight out on the 997 there are two better and gentler ways.
Figure 8

While you can pull the side markers straight out on the 997 there are two better and gentler ways. First, there is a small access hole in the fender lining behind the marker (yellow arrow), inset a screwdriver and gently push on the back of the clip securing the side marker (blue arrow). It will release and you can easily pull it out from the bumper. The other way is to just apply a little pressure to the marker, sliding it back and in towards the wheelwell. This will release the marker from its front mount. Once the marker is out disconnect it and set aside. There is a screw behind the marker that holds the bumper to the body of the car. It can be accessed from the same hole that you used to remove the marker. Insert the screwdriver up through the hole and remove the screw.

On the 997 there is a clip between the bumper and fender on each side that needs to be removed.
Figure 9

On the 997 there is a clip between the bumper and fender on each side that needs to be removed. The clip is accessed from the front trunk. It is best to spray a little lubrication into the clip area first, especially if the clips have never been removed. Insert a hooked tool into the hole on the clip and pull straight out.

Pull the bumper straight away from the body a few inches.
Figure 10

Pull the bumper straight away from the body a few inches. On the drivers side, disconnect the headlight washer hose.

Next remove the electrical connection located on the passenger side.
Figure 11

Next remove the electrical connection located on the passenger side.

Here is aPicture of the turn signal unit along with the headlight washer.
Figure 12

Here is aPicture of the turn signal unit along with the headlight washer. The wash hose connects on the left side of the bumper and feeds both side, where as the electrical connector supplies both units from the right side.

The wheel well liners on the 996s, are attached using plastic rivets, which must be pried out unscrewed one-by-one.
Figure 13

The wheel well liners on the 996s, are attached using plastic rivets, which must be pried out unscrewed one-by-one. This photo shows the location of these seven rivets (green arrows). While you have your liners off you may want to modify them to increase your brake cooling (see Project 102W)

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Comments and Suggestions:
mark Comments: Do the headlights need to come out to remove the bumper cover on a 2008 Carrera s ?
June 8, 2016
  Followup from the Pelican Staff: No. - Nick at Pelican Parts  
Luv2rev Comments: Is 04 C4S duct cooling more like 997. My 99650460401 duct got knocked off. To reattach it does the front part of liner 99650412400 also need to be replaced for the duct to have something to attach to? Parts desk not very helpful but since you've torn down...help?Can the duct update to 997p82 be applied to C4S
October 29, 2014
  Followup from the Pelican Staff: I believe it attaches to the wheel well liner. If the attachment points are broken, you will have to replace the liner as well. - Nick at Pelican Parts  

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