I searched online for instructions how to remove the front bumper on my BMW 535i (e60). I was out of luck. I found few scattered post without pictures, one decent write up with pictures but it required 3.5 hours of labor and BMW instructions, which were not very helpful. So I decided to help you guys out. I used this post as a guide and took a bunch of pictures in order to make things more clear. I hope it will help, or at least you wont have to pay a body shop for something you can do yourself in an hour. Doing this way you won’t have to remove the headlights and won’t need another person to help
1. Tools required. It is surprisingly easy to do as it requires only: extension (I used 8″ or 9″), 8mm socket, torx and … thats it. Keep in mind that my car does not have PDC and did not have fog lights at the moment, so some additional steps will be needed (I will update later)
2. Removing top 5 torx bolts. First you will have to remove the rubber cover which hides 5 torx screws. In order to do so just pull it up – it should come out easily. Underneath the cover just unscrew 5 bolts. Nothing complicated.
4. The tricky part.
a) It is not complicated you just need to know the steps. First, if you are working on the passenger side of your car, turn the wheels all the way to the right. Lift the car on a jack and I recommend using the stands. This way you will have some room to work under your bumper. Next, remove four 8mm bolts holding the weather shield.
b) There is another screw (long one) right on the top edge of the bumper. After you done removing bolts pry the underliner and wedge it behind the wheel. This will give you the opening to work behind the bumper.
c) After you have the underliner pushed back, look under the the fender. On the very top where the fender meets the bumper you will see a row of screws. You will have to remove the white (metal color) ones and there are two of them – both are 8mm. There is a very limited space – I could not take very sharp picture. Due to space constrains you will need extension. You dont have to remove the other screws there – they simply do not hold the bumper.
d) After you are done with passenger side you will have to do the same step on the driver side. Next step will be to pry the bumper outwards off the fender. You will have to use moderate force to separate it because it is being hold by this smart BMW clip. Start from the edge and wiggle it outwards. Don’t worry, you won’t brake it. After you remove one side do the same on the other side.
5. Assembly. I did it alone so I do not think any help is necessary. What I did are the steps one through four. First put the bumper back in place. Put the top bolts back in, then follow with the ones under the licence plate. This will hold the bumper in place. Do not tighten them yet – you will need some flexibility to move the bumper under the headlight and put it back in its place on the side of the fender. The rest is easy – just follow the steps. Do not forget to put these metal pieces back because without them the screws holding the underliner will end up in your tire…