ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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501-20A Safety Belt System > < Front Bumper

Focus 1999 (08.1998-12.2004)

Bumpers - Rear Bumper—Wagon 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. Remove the loadspace side trim panel insert on both sides.
    1. Remove the retaining screws.
    1. Move the side trim panel insert downwards.

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

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

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

  1. NOTE:
    NOTE:Bumper shown removed for clarity.
    Remove the bumper padding.
All vehicles
  1. Remove the bumper.

Installation

Vehicles with parking aid
  1. Install the bumper padding.

  1. Install the bumper.
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 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 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 shown removed for clarity.
    Using a suitable electric hand drill and a 35 mm hole cutter, cut the the bumper (+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 as shown (+0.5 mm, -0.0 mm).

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

  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 parking aid sensor rings.

  1. Install the parking aid sensors.
    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 hole.
    1. Left-hand side inner hole.
    1. Right-hand side inner hole.
    1. Right-hand side outer hole.

  1. NOTE:
    NOTE:Bumper shown removed for clarity.
    NOTE:
    NOTE:Note the position of the lower edges of the templates.
    NOTE:
    NOTE:Positional tolerance ± 5 mm.
    Using suitable tape, secure the parking aid sensor templates to the bumper as shown.
    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. NOTE:
    NOTE:Bumper shown removed for clarity.
    Using a suitable electric hand drill and a 29 mm hole cutter, cut the bumper.
    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 as shown (+0.5 mm, -0.0 mm).

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

  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 parking aid sensor rings.
  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.
    Install the parking aid sensor covers.

  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. Install the bumper padding.

  1. NOTE:
    NOTE:With the aid of another technician, support the bumper.
    NOTE:
    NOTE:Bumper shown removed for clarity.
    Attach the parking aid sensor wiring harness to the bumper padding.

  1. NOTE:
    NOTE:With the aid of another technician, support the bumper.
    Connect the parking aid sensor electrical connectors.
All vehicles
  1. Install the bumper.
  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 to the fender on both sides.
    1. Install the clip.
    1. Install the retaining nut.

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

  1. Install the bumper side retaining nut on both sides.

  1. Install the loadspace side trim panel insert on both sides.
    1. Move the side trim panel insert upwards.
    1. Install the retaining screws.

  1. Install the upper pushpin retainers.

501-20A Safety Belt System > < Front Bumper