!Guide! Front Crash Bar Replacement - MK7 2011

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-Ford Fiesta Zetec JA8  08-13

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-Remove the 4 plastic clips along the centre of the bumper at the very top
 

-Remove the 2 T30 screws from the each headlight unit and pull the top of each headlight out of position

-Unplug both headlight connectors & pull the headlights up and out from a central position to pop them out of their receivers
 

-Remove the 2 T20 torx screws from the front edge of each front wheel arch liner
-Turn the 1 plastic scrivet at the front of the wheel arch liner a quarter of a turn anticlockwise with a Phillips attachment and then pop it out
-Pull the front of the wheel arch liner back for access

-Remove the 3 10mm bolts from the top side of the wing/bumper mating surface
-Push down on the wing and carefully pull up on the bumper to unclip it

-Repeat this on the other side of the car

-Locate the 2 tabs under the bumper at the front, push them both in and then pull the bumper forwards and off
 

-Attach wire or rope to the bonnet latch mechanism and anchor it to the lift point near the coil pack on the engine and also on the cast lift point at the alternator (The radiator will be free floating without the front crash bar)

-Remove the 6 8mm bolts that secure the front arms of the crash bar to the radiator shroud
-Remove the 1 central 10mm bolt that secures the crash bar to the support bracket
-Remove the 2 10mm bolts from the top of the radiator shroud
 

-Unbolt the horn with a 10mm socket
-Unsecure the thermistor and any electrical harness anchor points on the crash bar

-Remove the 4 13mm bolts either side of the crash bar going to the chassis legs
 

-Life the crash bar forwards and up to remove it
 

-Fit the new crash bar into position on the radiator shroud
-Fasten the 1 central 10mm bolt that secures the crash bar to the support bracket @ 23Nm

-Loosely fasten the 4 13mm bolts in each chassis leg to give the crash bar hands free support
-Make sure that the crash bar is lined up evenly on all sides then torque the 8 13mm bolts @ 48Nm
 

-Fasten the 6 8mm bolts that secure the front arms of the crash bar to the radiator shroud @ 15Nm
-Fasten the 2 10mm bolts from the top of the radiator shroud @ 28Nm

-Fasten the horn with a 10mm socket
-Make sure that the airbox pipe is seated correctly at the top of the radiator
-Secure the thermistor and any electrical harness anchor points to the crash bar


-Remove the wire/rope from the anchor points
 

-Install the bumper by lining it up at the top
-Install the 2 middle plastic clips along the centre of the bumper at the very top
-Push the 2 tabs in under the bumper, at the front

-Clip each side of the bumper into the wing, starting at the top
 

-Reinstall the 3 10mm bolts from the top side of the wing/bumper mating surface & nip them up

-Reposition the wheel arch liner

-Push the plastic scrivet back in and turn it a quarter of a turn clockwise with a Phillips attachment

-Reinstall the 2 metal torx screws along the front edge of the wheel arch liner with a T20 attachment

-Repeat this on the other side of the car
 

-Plug the headlight connector in & push the headlight down at a central position to clip it back into its receiver

-Reinstall the far end plastic clip, along the centre of the bumper at the very top

-Reinstall the 2 T30 screws for the headlight
-Repeat this on the other side of the car

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Useful sources:

Fitting a new crash bar to the Fiesta ST & how to use 7 Zap

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