Front bumper — removal, installation and repair (Peugeot 405)

Front and rear bumper assemblies

Removal

1. Working underneath the base of the bumper, unscrew the three lower bumper mounting screws.

2. Working on one side of the vehicle, remove the three screws securing the outer edge of the wheel arch liner, then slide the liner back away from the bumper.



3. Unscrew the two nuts securing the front part of the bumper.





4. Unscrew the bolt that secures the side of the bumper to the wing.

5. On the other side of the car, unscrew the two nuts securing the front part of the bumper and the bolt securing the side part of the bumper to the wing.

6. Pull the bumper forward (two people), disconnect the wires from the fog lights and the headlight washer hose, being careful not to scratch the varnished surface of the fenders.

7. Remove the bumper from the car.

Installation

1. Install the bumper in the appropriate place without securing it.

2. Before securing the entire assembly, adjust the bumper to the rest of the body elements.

3. When driving on a cobblestone road, check whether the bumper is vibrating excessively.

Bumper repair

The bumpers are made of polypropylene, so they can be repaired by melting the material using a hot air device.

1. To facilitate repairs and to avoid damage to other body elements, the bumper should be removed.

2. Clean the parts to be welded with a mild solvent.

3. Place the parts to be welded together and hold them in place using a vice and a fixed holder.

4. If the bumper is deformed, follow these steps.



5. Soften the bumper with hot air, without allowing the material to melt.

6. Apply the bumper to a special form to give it its original shape.

(Original publication on the website peugeotbook.ru)

7. Wait 10 minutes for the bumper to cool.

Welding

1. Place the small tip onto the hot air gun.

2. Point the gun at the areas to be welded.

3. Move the gun in a continuous motion to cause the material to melt.

Attention! For welding, use a thin rod made of the same material as the bumper (taken from an old bumper).

Attention! The rod should be applied at a right angle to the weld seam.

Attention! It is necessary to weld in front of and behind the damaged area.

Attention! Welding must be performed on the inside of the damage.

4. Remove surface irregularities that arise during the welding process.

5. Use 150 grit sandpaper to sand the surface to be repaired, then polish it with 600 grit sandpaper using water.