GTI-R Front bumper removal - without tears of sadness ...
First off - this page wouldn't exist without Chris Lloyd's offer to help me out.
Having the Workshop manual is one thing - getting this done easily and without loss of skin in the knuckle area, quickly ... that's something else. Thank you Chris.
After getting the bumper off for a repair to the grill I really didn't feel like jacking the car up one side then the other etc ...
So. I had a little think.
Here is my version of the bumper removal/refit "Chris style" as modified by meself!
First, have a good look at 2 things.
1) Check the way the bumper is fitted. I noticed a lot of tie wraps. Not good. Buy new fixings FIRST, otherwise it's a pointless exercise.
2) Your specialist tools ... this is "Bendy"
This nifty little tool will save you a LOT of time. It is a standard item made by Draper (pic has been reproduced here nearly actual size, when you click on it). You'll see that the important bits - the driver ends, the leverage and it only needs about 35mm clearance to either head. You'll only need the Phillips head.
The accepted way of getting at certain clips is to lift the car up on both front jack points in order to get clearance for a standard screwdriver. This tool avoids that problem - you CAN remove the front bumper without need of a jack. By turning the front wheels one way then the other whilst still on the ground this tool makes it possible to remove all the fixings necessary to get the bumper off without the need to jack up the car.
The rest of the explanation.
I've started these instructions with the bumper off ... huh?
Well, it's easier to visualise what the fixings are, where they are and how to remove them by seeing where they - err, fix.
Items marked above are referred to throughout the rest of this description ...
These clips attach the brake duct to the inner wing plastic moulding. Early types of clip need to be unscrewed with Bendy. Later types just need to be pushed in.
Each brake duct is fixed to the bumper at 3 points. New flat nuts and No 12 screws are best - I used 2 x no 12 and 1 x no 10 screw (with an undersize flat nut). Always add "repair" washers - they spread the load.
This screw holds the bumper firmly to the chassis. There is one on each wing.. That's it.
It's possible to remove/refit/adjust this screw without doing anything to the inner wing plastic guard. Honest - I did! It only needs a standard socket and extension bar. I used a standard 1/2" drive - no special tools.
Big "C" clips locate in the bumper reinforcement bar but that is about all they do. My car didn't have them. Instead a generous amount of Elephant poo (or equivalent) had been used. Same effect!
Each brake duct also attaches to the plastic inner wing with 3 nylon clips - hence the need for Bendy in the first place.
With "Bendy", some wheel turning and a bit of anger, the entire front bumper can be removed, re-fettled and replaced without the need to jack up the car.
Oh, and I re-welded the grill ... which was the entire reason for the exercise. Compare with the original flappy fitting. I might have gone overboard with the plastic weld....