FRONT BUMPER DISASSEMBLY/ASSEMBLY [(E)]

id0910008004x2

Special Service Tool (SST)

49 JP05 2A0
 
HOLE CUTTER SET 26 (Part of 49 JP05 0A0)

Replacement part (4SD)

Rivet
 
Quantity: 4
 
Location of use: Air guide
Front side radar sensor bracket (with front side radar sensor)
 
Quantity: 2
 
Location of use: Front bumper face
Rivet (with front side radar sensor)
 
Quantity: 4
 
Location of use: Front side radar sensor bracket
Retainer bracket (with front ultrasonic sensor)
 
Quantity: 2
 
Location of use: Front bumper face
—
—

Replacement part (5HB)

Rivet
 
Quantity: 1
 
Location of use: Bracket
Front side radar sensor bracket (with front side radar sensor)
 
Quantity: 2
 
Location of use: Front bumper face
Rivet (with front side radar sensor)
 
Quantity: 2
 
Location of use: Front side radar sensor bracket
Rivet
 
Quantity: 2
 
Location of use: Bumper protector
Retainer bracket (with front ultrasonic sensor)
 
Quantity: 2
 
Location of use: Front bumper face
—

1.  Remove the following parts:

(1)  Headlight cleaner hose (with headlight cleaner system) (See HEADLIGHT CLEANER HOSE REMOVAL/INSTALLATION.)
(2)   Headlight cleaner nozzle (with headlight cleaner system) (See HEADLIGHT CLEANER NOZZLE REMOVAL/INSTALLATION.)
(3)  Headlight cleaner cover (with headlight cleaner system) (See HEADLIGHT CLEANER COVER REMOVAL/INSTALLATION.)
(4)  Front ultrasonic sensor short-cord (with front ultrasonic sensor or Mazda radar cruise control (MRCC) system) (See FRONT ULTRASONIC SENSOR SHORT-CORD REMOVAL/INSTALLATION.)
(5)  Front ultrasonic sensor (with front ultrasonic sensor) (See FRONT ULTRASONIC SENSOR REMOVAL/INSTALLATION.)
(6)  Retainer (with front ultrasonic sensor) (See FRONT ULTRASONIC SENSOR REMOVAL/INSTALLATION.)
(7)  Retainer bracket (with front ultrasonic sensor) (See FRONT ULTRASONIC SENSOR REMOVAL/INSTALLATION.)
(8)  Front radar sensor (with front radar sensor) (See FRONT RADAR SENSOR REMOVAL/INSTALLATION.)
(9)  Front side radar sensor (with front side radar sensor) (See FRONT SIDE RADAR SENSOR REMOVAL/INSTALLATION.)

2.  Disassemble in the order indicated in the table.

Warning
•  When removing the front side radar sensor bracket attached with double-sided adhesive tape, peel off the double-sided adhesive tape at the positions shown in the figure using a utility knife. Always wear gloves when using a utility knife. Using a utility knife with bare hands can cause injury.

Except Chinese specs.

am3zzw00024407

Chinese specs.

am3zzw00034921

4SD (except Chinese specs.)

am3zzw00035372

1
Lower grille molding
(See Clip Removal Note.)
2
Clip
3
Radiator grille
4
Air guide
(See Rivet Removal Note.)
5
Front side radar sensor bracket (with front side radar sensor)
(See Front Side Radar Sensor Bracket Installation Note.)
(See Rivet Removal Note.)
6
Hole cover
7
Seal plate
8
Center bumper garnish
9
Set plate
10
Bumper protector
11
Front bumper face

4SD (Chinese specs.)

am3zzw00034922

1
Lower grille molding
(See Clip Removal Note.)
2
Clip
3
Radiator grille
4
Air guide
(See Rivet Removal Note.)
5
Front side radar sensor bracket (with front side radar sensor)
(See Front Side Radar Sensor Bracket Installation Note.)
(See Rivet Removal Note.)
6
Hole cover
7
Seal plate
8
Bumper protector
9
Front bumper face

5HB

am3zzw00035373

1
Lower grille molding
(See Clip Removal Note.)
2
Clip
3
Radiator grille
4
Bracket
(See Rivet Removal Note.)
5
Cap
6
Front side radar sensor bracket (with front side radar sensor)
(See Front Side Radar Sensor Bracket Installation Note.)
(See Rivet Removal Note.)
7
Center bumper garnish
8
Bumper protector
(See Rivet Removal Note.)
9
Front bumper face

3.  When replacing the front bumper face with a new one, perform the following procedure (With front ultrasonic sensor):

(1)  Paint the front bumper.
(2)  Drill the holes in the position shown in the figure.
Drill hole diameter: 10 mm {0.39 in}
am3zzw00034923
Caution
•  If the SST is pulled out to the front side of the front bumper face, the painting could peel off. Pull out the SST to the backside of the front bumper face.
(3)  Set the SST to the positions shown in the figure.
am3zzw00033033
(4)  Tighten the bolt of the SST in the direction of the arrow shown in the figure and pass it through the front bumper face.
am3zzw00033034
(5)  Drill a hole at the remaining ultrasonic sensor installation position using the SST and the same method as Steps 3 and 4.
(6)  Remove burrs from the drilled holes.
(7)  Remove any grease or dirt from the retainer bracket installation surface of the front bumper face.
am3zzw00034418
(8)  Apply primer to the retainer bracket installation surface of the front bumper face.
(9)  Peel off the backing of the double-sided adhesive tape and install the retainer bracket.
am3zzw00034419
(10)  Press the retainer bracket to adhere the double-sided adhesive tape.

4.  Assemble in the reverse order of disassembly.


Clip Removal Note

1.  Detach the hooks using a tape-wrapped flathead screwdriver.

am3zzw00024410

2.  Remove the clip in the direction of the arrow shown in the figure.

am3zzw00024411


Rivet Removal Note

1.  When removing the rivet, perform the following procedure:

(1)  Secure the rivet pin from the front bumper face inside using needle-nose pliers.
am3zzw00018754
(2)  Use the following drill diameter.
Drill diameter:
4.1 mm {0.16 in}
Caution
•  If an inappropriate drill diameter is used, the front bumper face may be damaged.
(3)  Remove the rivet flange using a drill and remove the rivet.
am3zzw00018755
(4)  Remove any rivet shavings from the front bumper face.


Front Side Radar Sensor Bracket Installation Note

1.  If adhesive residue of the double-sided adhesive tape remains on the positions shown in the figure, remove any grease or dirt from the front bumper face.

Except Chinese specs.

am3zzw00024412

Chinese specs.

am3zzw00034924