ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Rear Bumper - 3-Door-4-Door-5-Door > < Rear Bumper Cover - 3-Door-5-Door

Focus 1999 (08.1998-12.2004)

Bumpers - Rear Bumper Cover—4-Door Focus 1999 (08/1998-12/2004)
Removal and Installation

General Equipment
Electric hand drill
Drill bit 5 mm
Hole cutter 29 mm
Hole cutter 35 mm
Hole cutter 70 mm

Removal

All vehicles
  1. Remove the upper pushpin retainers.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Detach the bumper cover from the fender splash shield on both sides.

  1. Detach the bumper cover from the fender on both sides.
    1. Remove the retaining nut.
    1. Remove the clip.

  1. Remove the lower pushpin retainers.
  1. Lower the vehicle.

  1. Remove the bumper cover side retaining nut on both sides.

  1. Remove the rear lamp cluster cover screws on both sides.

  1. Remove the bumper cover retaining nuts on both sides.

  1. CAUTION:
    CAUTION:The bumper cover ends must be pulled away from the fenders to prevent damage to the paintwork.
    NOTE:
    NOTE:With the aid of another technician, support the bumper cover.
    Detach the bumper cover from the fenders.
    1. Detach the clips.
    1. Disconnect the fog lamp and reversing lamp electrical connectors (if equipped).
Vehicles with parking aid
  1. NOTE:
    NOTE:With the aid of another technician, support the bumper cover.
    NOTE:
    NOTE:Bumper cover shown removed for clarity.
    Detach the parking aid sensor wiring harness from the bumper padding.
Vehicles with parking aid built up to 10/2001
  1. NOTE:
    NOTE:With the aid of another technician, support the bumper cover.
    Remove the parking aid sensors.
    1. Disconnect the electrical connector.
    1. Depress the tangs.
    1. Push the sensor through the bumper cover.
Vehicles with parking aid built 10/2001 onwards
  1. NOTE:
    NOTE:If not installing new sensor covers or sensor housings, remove them from the bumper cover.
    NOTE:
    NOTE:With the aid of another technician, support the bumper cover.
    Remove the parking aid sensors.
    1. Disconnect the electrical connector.
    1. Depress the tangs.
    1. Remove the sensor.
All vehicles
  1. Remove the bumper cover.
Vehicles with parking aid
  1. Remove the bumper padding.

Installation

Vehicles with parking aid
  1. NOTE:
    NOTE:Do not fully tighten the retaining nuts at this stage.
    Install the bumper padding.

  1. Install the bumper cover.
Vehicles with parking aid built up to 10/2001
  1. NOTE:
    NOTE:Use the templates supplied with the manufacturers instructions.
    NOTE:
    NOTE:Templates shown for reference.
    Cut out the parking aid sensor position templates.
    1. Left-hand side outer template.
    1. Left-hand side inner template.
    1. Right-hand side inner template.
    1. Right-hand side outer template.

  1. NOTE:
    NOTE:Bumper cover shown removed for clarity.
    NOTE:
    NOTE:Note the position of the upper and lower edges of the templates.
    NOTE:
    NOTE:Positional tolerance ± 5 mm.
    Using suitable tape, secure the parking aid sensor templates to the bumper cover as shown.
    1. Left-hand side outer template.
    1. Left-hand side inner template.
    1. Right-hand side inner template.
    1. Right-hand side outer template.

  1. Using a suitable center punch and hammer, mark the position of the parking aid sensor location holes.
  1. NOTE:
    NOTE:Bumper cover shown removed for clarity.
    Using a suitable electric hand drill and a 35 mm hole cutter, cut the bumper cover (+2 mm, - 0.0 mm).
    1. Left-hand side outer hole.
    1. Left-hand side inner hole.
    1. Right-hand side inner hole.
    1. Right-hand side outer hole.

  1. Using a suitable round file, cut the parking aid sensor cover location grooves in the bumper cover as shown (+0.5 mm, -0.0 mm).

  1. CAUTION:
    CAUTION:The bumper cover ends must be pulled away from the fenders to prevent damage to the paintwork.
    Remove the bumper cover.
    • Detach the clips.

  1. Install the sensor rings.

  1. Install the parking aid sensors (left-hand side shown).
    1. Install the sensor.
    1. Depress the tangs.
    1. Install the clamp.
Vehicles with parking aid built 10/2001 onwards
  1. NOTE:
    NOTE:Use the templates supplied with the manufacturers instructions.
    NOTE:
    NOTE:Templates shown for reference.
    Cut out the parking aid sensor position templates.
    1. Left-hand side outer template.
    1. Left-hand side inner template.
    1. Right-hand side inner template.
    1. Right-hand side outer template.

  1. NOTE:
    NOTE:Bumper cover shown removed for clarity.
    NOTE:
    NOTE:Note the position of the upper edges of the templates.
    NOTE:
    NOTE:Positional tolerance ± 5 mm.
    Using suitable tape, secure the parking aid sensor templates to the bumper cover as shown.
    1. Left-hand side outer template.
    1. Left-hand side inner template.
    1. Right-hand side inner template.
    1. Right-hand side outer template.

  1. Using a suitable center punch and hammer, mark the position of the parking aid sensor location holes.
  1. NOTE:
    NOTE:Bumper cover shown removed for clarity.
    NOTE:
    NOTE:Holes drilled at 6 degrees downwards into the bumper cover.
    Using a suitable electric hand drill and a 29 mm hole cutter, cut the bumper cover (+2 mm, -0.0 mm).
    1. Left-hand side outer hole.
    1. Left-hand side inner hole.
    1. Right-hand side inner hole.
    1. Right-hand side outer hole.

  1. Using a suitable round file, cut the parking aid sensor cover location grooves in the bumper cover as shown (+0.5 mm, -0.0 mm).

  1. CAUTION:
    CAUTION:The bumper cover ends must be pulled away from the fenders to prevent damage to the paintwork.
    Remove the bumper cover.
    • Detach the clips.

  1. NOTE:
    NOTE:Note the difference between the inner and outer parking aid sensor covers.
    NOTE:
    NOTE:Make sure the parking aid sensor covers are installed flush with the bumper cover.
    Install the parking aid sensor covers.

  1. Install the parking aid sensor rings.

  1. Install the parking aid sensors.
    1. Install the housing.
    1. Depress the tangs.
    1. Install the clamp.
    1. Install the sensor.
Vehicles with parking aid
  1. Remove the bumper padding.

  1. NOTE:
    NOTE:With the aid of another technician, secure the bumper padding using suitable wooden blocks for support.
    NOTE:
    NOTE:Use the holes made when cutting the parking aid sensor location holes as a guide.
    Using a suitable electric hand drill and a 70 mm hole cutter, cut the bumper padding.

  1. Install the bumper padding.

  1. Attach the parking aid sensor wiring harness to the bumper padding.

  1. NOTE:
    NOTE:With the aid of another technician, support the bumper cover.
    Connect the parking aid sensor electrical connectors.
All vehicles
  1. Install the bumper cover.
    • Connect the fog lamp and reversing lamp electrical connectors (if equipped).

  1. Install the bumper cover retaining nuts on both sides.

  1. Install the rear lamp cluster cover screws on both sides.

  1. Install the bumper cover side retaining nut on both sides.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the lower pushpin retainers.

  1. Attach the bumper cover to the fender on both sides.
    1. Install the clip.
    1. Install the retaining nut.

  1. Attach the bumper cover to the fender splash shield on both sides.
  1. Lower the vehicle.

  1. Install the upper pushpin retainers.

Rear Bumper - 3-Door-4-Door-5-Door > < Rear Bumper Cover - 3-Door-5-Door