Section 509 (Front Bumper): Replacement

HINT:

• The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
• A bolt without a torque specification is shown in the standard bolt chart (see SUSPENSION CONTROL SYSTEM ).

1. REMOVE FRONT FENDER LINER LH 
   1. Remove the 2 screws and 2 clips.
   2. Partially remove the fender liner.

   HINT:

   It is not necessary to fully remove the fender liner completely. Partially remove it so that the bumper cover can be removed in step ( 5).

   Fig 1: Removing Screws And Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE FRONT FENDER LINER RH 

   HINT:

   Use the same procedure described for the LH side.

3. REMOVE RADIATOR SIDE DEFLECTOR LH 
   1. Remove the 3 clips and deflector.
4. REMOVE RADIATOR SIDE DEFLECTOR RH 
   1. Remove the 3 clips and deflector.
5. REMOVE FRONT BUMPER COVER 
   1. Remove the 4 nuts.
      Fig 2: Removing Nuts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the 3 clips and 7 screws.
   3. Using a screwdriver, disengage the 2 claws and remove the bumper cover.
   4. Disconnect the 2 fog lamp connectors.
   5. w/ Clearance sonar system:

      Disconnect the 6 sensor connectors.

      Fig 3: Removing Clips, Screws And Bumper Cover

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE HEADLAMP CLEANER (FROM MOTOR TO JOINT) HOSE (W/ HEADLAMP CLEANER) 
   1. Disconnect the cleaner hose joint from the actuator.

      HINT:

      Be careful when removing the cleaner hose from the actuator, because washer fluid will spill.

   2. Disconnect the cleaner hose from the bumper cover.
7. REMOVE FRONT BUMPER ENERGY ABSORBER 
8. REMOVE RADIATOR SUPPORT REINFORCEMENT LOWER 
   1. Remove the 2 bolts.
   2. Unlock the 2 claws and partially remove the reinforcement lower by angling it towards yourself.

   HINT:

   It is not necessary to fully remove the reinforcement lower completely. Partially remove it so that the bumper reinforcement can be removed in step (9).

   Fig 4: Removing Bolts And Reinforcement Lower

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSY 
   1. Remove the 6 bolts and reinforcement.
10. REMOVE LASER SENSOR (W/ RADAR CRUISE) 
11. REMOVE FOG LAMP ASSY LH 
    1. Using a screwdriver, disengage the 2 claws and remove the fog lamp.

    HINT:

    Tape the screwdriver tip before use.

    Fig 5: Removing Claws And Fog Lamp

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE FOG LAMP ASSY RH 

    HINT:

    Use the same procedures described for the LH side.

13. REMOVE HEADLAMP CLEANER WASHER NOZZLE (W/ HEADLAMP CLEANER) 
    1. Using a screwdriver, pull out the front washer nozzle.

    HINT:

    Tape the screwdriver tip before use.

    Fig 6: Pulling Out Front Washer Nozzle

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE HEADLAMP CLEANER WASHER NOZZLE (W/ HEADLAMP CLEANER) 

    HINT:

    Use the same procedures described for the LH side.

15. REMOVE HEADLAMP WASHER ACTUATOR SUB-ASSY LH (W/ HEADLAMP CLEANER) 
    1. Remove the screw and actuator.
16. REMOVE HEADLAMP WASHER ACTUATOR SUB-ASSY RH (W/ HEADLAMP CLEANER) 
    1. Remove the screw and actuator.
17. REMOVE ULTRASONIC SENSOR NO.1 (w CLEARANCE SONAR SYSTEM) 
    1. Using a screwdriver, remove the retainer and sensor.

    HINT:

    Tape the screwdriver tip before use.

18. REMOVE FRONT BUMPER EXTENSION MOUNTING BRACKET 
    1. Remove the 2 screws and mounting bracket.
19. REMOVE FRONT BUMPER SIDE RETAINER LH 
    1. Use a drill that has a tip of less than "OSLASH" 4 mm (0.16 in.).
    2. Tape the drill tip as shown in the illustration.

       Dimension: 5 mm (0.20 In.) 

       HINT:

       Taping the drill tip is done to prevent excessive drilling.

    3. Gently place the drill tip onto the rivet, cut the rivet flanges and then remove the rivet.
       NOTE:

       • Pressing the drill tip onto the rivet strongly will cause the rivet to turn with the drill and the rivet will not be cut.
       • Do not prize the rivet hole with the drill. Doing so may damage the rivet hole and/or the drill.
       • Be careful as the cut rivet will be very hot.
    4. Remove the retainer from the bumper cover.
       Fig 7: Removing Retainer From Bumper Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE FRONT BUMPER SIDE RETAINER RH 

    HINT:

    Use the same procedures described for the LH side.

21. REMOVE FRONT BUMPER MOULDING 

    HINT:

    Remove the double-sided tape completely from the bumper. Double-sided tape interferes with the installation of the moulding to the bumper.

22. REMOVE FRONT BUMPER SIDE SEAL LH 
    1. Using a screwdriver, disengage the 4 claws and remove the side seal.

    HINT:

    Tape the screwdriver tip before use.

23. REMOVE FRONT BUMPER SIDE SEAL RH (W/O RADAR CRUISE) 

    HINT:

    Use the same procedures described for the LH side.

24. REMOVE FRONT BUMPER HOLE COVER LH 
    1. Using a screwdriver, disengage the 2 claws and remove the hole cover.

    HINT:

    Tape the screwdriver tip before use.

25. REMOVE FRONT BUMPER HOLE COVER RH (W/ RADAR CRUISE) 
    1. Using a screwdriver, disengage the 4 claws and remove the hole cover.

    HINT:

    Tape the screwdriver tip before use.

26. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSY 
    1. Install the reinforcement with the 6 bolts.

       Torque: 12.5 N.m (130 kgf.cm, 9 ft.lbf) 

27. INSTALL FRONT BUMPER SIDE RETAINER LH 
    1. Using an air riveter or hand riveter with nose piece, strike waterproof rivets of "OSLASH" 4.9 mm (0.19 in.) into the side retainer to install the rivet to the bumper cover.
    NOTE: If the rivet is not positioned perpendicularly to the bumper, the mandrel will bend and become damaged.
    Fig 8: Taping Screwdriver Tip

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. INSTALL FRONT BUMPER SIDE RETAINER RH 

    HINT:

    Use the same procedures described for the LH side.