BUMPER BARS 1 D-1

SECTION 1D
BUMPER BARS
INDEX
Ref. Subject Page Ref. Subject Page
1. DESCRIPTION .................................................. 10-1 2.3 REAR BUMPER BAR ASSEMBLY •
2. SERVICE OPERATIONS ................................ 1D·2 SEDAN .............................................................. 10-5
2.1 PAINT SYSTEM................................................ 1D·2 · Remove.................................................... 10-5
Recommended Materials .................. .. 1D·2 Disassemble .......................................... 10-5
Colour Finishing of Replacement Reassemble ......:..................................... 10-5
Parts ........................................................ 1D-2 Reinstall .................................................. 10-5
Repairing Colour Coat ........................ 1D·3 2.4 REAR BUMPER BAR ASSEMBLY •
Warning - Use of Body STATION WAGON .......................................... 10-6
Colour Lacquer ...................................... 10-3 Remove.................................................... 10-6
2.2 FRONT BUMPER BAR ASSEMBLY ............ 10-3 Disassemble .......................................... 10-6
Remove.................................................... 1D·3 Reassemble ............................................ 10-6
Disassemble .......................................... 1D-4 Reinstall .................................................. 10-6
Reassemble ............................................ 1D·4
Reinstall .................................................. 1D-4

1. DESCRIPTION
Front and rear bumper bar assemblies fitted to VL models are of polycarbonate construction. The centre of the 3 piece
front bumper bar facia illustrated in Fig. 1 D-1 is attached to a steel bumper bar support which in turn is bolted onto inner
support brackets (refer Fig. 1 D-1, Section A-A) attached to longitudinal frame members.

( SECTION B-8

FACIA ASM. FRONT

BUMPER SIDE RS

FACIA ASM. FRONT

SECTION A-A

BRACKET ASM.
SUPPORT BEAM
SECTION C-C INNER RS
BRACKET ASM.
� 20.0- 27.0 Nm SUPPORT BEAM INNER LS

& 6.0-8.0 Nm

Lt 1.5 - 2.0 Nm

Figure 1D-1

The front bumper bar side facias are bolted onto the centre facia as illustrated in Fig. 1 D-1, Section 8-8.
1D-2 BUMPER BARS

Brackets attached to the rear bumper bar facias on sedans and station wagons are attached to the back and rear
quarter panels with bolts and screws.

2. SERVICE OPERATIONS
2.1 PAINT SYSTEM
The paint system for the VL bumper bar facias and side
mouldings is relatively straight forward as long as the
correct materials are used. If normal refinish lacquers and
solvents are applied, the polycarbonate will be damaged
by the solvent, therefore, a warning label will be attached
to the exterior surface of all unpainted spare parts
supplied to the field.
CAUTION:
Painting - Cleansing of this part for painting must be by
methylated spirits wipe only. Do not use lacquer thinners
or other cleaning thinners, as these may damage the
plastic. Top coat with GMH approved paint and thinners
as specified in this Section.
The following service recommendations are compiled to
guide Dealerships, on the correct materials and methods
to be employed when refinishing VL series bumper bars
and side mouldings, also, preparing new parts for service
installation.

RECOMMENDED MATERIALS
Front and rear bumper bars and side facias installed on
VL series are made from high impact strength pol­
ycarbonate plastic.
It is essential that only GMH approved materials, paints
and thinners be employed when paint repair operations
are performed and when preparing new parts for installa­
tion to the vehicle.
Use of the wrong materials will affect finished quality and
the polycarbonate material.
The GMH approved materials are:
Methylated Spirits - for cleansing before painting.
Paint - Berger Polycarbonate Lacquer in the following
colours:
Silver GMH 4J022 Berger HH9991
Warm Grey GMH 4H016 Berger HH9989
Cool Grey GMH 4H015 Berger HH9990

Thinner - Berger LT226.

The Berger lacquer is a special acrylic lacquer developed
for polycarbonate and requires NO primer. The pol­
ycarbonate parts are moulded in-colour for ease of top
coating. When ordering spare parts, quote the GMH
colour number and name, for example, Warm Grey (GMH
4H016).

COLOUR FINISHING OF REPLACEMENT PARTS

Spare parts are supplied unpainted and require coating
before installation to the vehicle.
Observe the following procedures:-
1 . Order part with the plastic self colour to match the
required top coat colour.
2. Inspect surface. If slight transit damage is present,
this can be rectified by dry sanding with P400 paper.
3. Cleaning. Wipe the surface at least twice, using a
clean cloth soaked in methylated spirits. Wipe dry
using a new clean cloth each time.
 BUMPER BARS 1 D-3

4. Paint. Mix the polycarbonate lacquer to spraying

viscosity with approved thinners (approximately 1:1
ratio) and apply one full wet coat. Allow about two
minute flash time and apply a second full coat. It is
important that only sufficient paint to achieve
coverage is applied. Too high a paint thickness may
reduce adhesion. (Correct film thickness is
30-35 microns).
5. Drying. Allow 1O minutes air flash, then use a heat
lamp or similar set up to warm the painted surface
for 30 minutes (part surface temperature should not
exceed 90 degrees celcius). Lamp baking will speed
removal of the special slow solvents in the lacquer
and harden the paint film.

REPAIRING COLOUR COAT

Superficial damage to the paint film and/ or plastic
surface may be rectified by sanding and repainting. Parts
having deep gouges, etc., in the plastic surface should be
replaced, as repair methods using filling materials and
thinning down of the plastic section may reduce overall
impact strength.
CAUTION: Under no circumstances should paint be
washed off bumper bar facias with lacquer thinners. The
paint repair area should be to 'the nearest convenient
breakline. Spot repairs are not recommended due to
possible colour match problems.
1. Sanding. Depending upon the degree of damage.
P320 (or coarser grit) wet or dry paper may be
required for initial sanding. Finish sand with P400 grit
paper to remove sanding marks and dry scuff all
over the whole of the area to be resprayed.
2. Cleaning. Wipe the area to be painted at least twice,
using a clean cloth soaked in methylated spirits.
Wipe dry with a new clean cloth each time.
3. Painting. Mix the polycarbonate lacquer with appro­
ved thinners (approximately 1 :1 ratio) and spray the
repaired area to build colour followed by one wet
coat all over to achieve colour uniformity.
4. Drying. Allow 1O minutes air flash, then use a heat
lamp or similar set up to warm the painted surface
for 30 minutes.
CAUTION: Surface temperature of the part should not
exceed 90 degrees celcius.
Lamp baking will speed removal of the special slow
solvents in the lacquer and harden the paint film.

WARNING - USE OF BODY COLOUR LACQUER

Normal lacquers used for refinish painting of sheet metal
are not suitable for repainting the VL polycarbonate
bumpers and side facias.

2.2 FRONT BUMPER BAR ASSEMBLY

REMOVE
1. Chock rear wheels, then raise and support front of
vehicle on jack stands.
2. From within front end section of front wheel
openings, remove screws securing sides of front
bumper bar assembly to front fender brace assembly
(refer Fig. 1 D-2, Section B-8).
3. Disconnect horn assembly.
("---___)
1D-4 BUMPER BARS

4. With front bumper bar assembly fully supported and

from under front of vehicle, remove screws securing
support beam inner bracket assemblies from side
frames (refer Fig. 1 D-2, Section A-A) removing front
bumper bar assembly.

DISASSEMBLE
1. Place the front bumper bar assembly face down on a
clean protected surface.
2. Remove horn assembly.
3. Remove the support beam inner brackets and
support assemblies illustrated in Fig. 1D-2, Section
A-A, from the centre bumper bar facia assembly.
4. Remove the screws and nuts securing the front
bumper bar facia centre and side assemblies
together, refer in Fig. 1 D-1, Section 8-8.

BUMPER SLIDER ASM.

FENDER BRACE ASM. �

ffiSCREW

SECTION 8-B
&scREW
2 PLACES /
R & L SIDE

WASHER
2 PLACES
R & L SIDE

SIDE FACIA
BRACKET
& 3.5-5.0 Nm
A-A
ffi 40-54Nm
SECTION

Figure 10-2

REASSEMBLE
Reverse disassemble operations.
NOTE: Elongated slots in the front bumper bar support
beam and inner support brackets provide horizontal
adjustment for the bumper bar assembly.

REINSTALL
Reverse removal operations.
 BUMPER BARS 1D-5

2.3 REAR BUMPER BAR ASSEMBLV -

SEDAN

REMOVE
1. From under rear quarter panels, remove screws and
fasteners securing lower section of side facias to
rear quarter panels (refer Fig. 1D-3, Section C-C).
2. From within rear end section of rear wheel opening,
remove screws securing the leading flanges of the
rear bumper side facias to quarter outer panels
illustrated in Fig. 1D-3, Section E-E.
3. Remove screw securing licence plate socket to rear
bumper bar centre facia, illustrated in Fig. 1D-3, View
'8'.
4. With rear bumper bar assembly fully supported,
remove nuts and screws securing rear bumper bar
assembly to rear end of vehicle, illustrated in
Fig. 1D-3, Sections A-A and 8-8, removing rear
bumper bar assembly.

DISASSEMBLE
Remove screws and nuts securing centre and side rear
bumper facia assemblies together, then separate (refer
Fig. 1D-3, Section D-D).

REASSEMBLE
Reverse disassembly operations.

REINSTALL
Reverse removal operations.

(" )
 ....
PUSH CONNECTORS THRU HOLE IN REAR END SCREW&
NUT
�OUTER PANEL AND FIT GROMMET AS SHOWN - m
4PLACES R&L-- �4PLACES R&L
� IN SECTION F-F
C
�
.,,ms::
SECTION D-D :a
m
D l>
:a
tn

SECTION E-E

SECTION F-F
DISTANCE PIECE REAR
Bu-MPER BAR BRACKET
\

& SCREW AND e�

�I 12,6:::::;<� WASHER ASM.
2 PLACES R&L
FASTENER
1 PLACE R&L

SECTION C-C
1 PLACE R&L VIEW [Al R&L SIDE
� 6.-8 Nm
SECTION B-B SECTION A-A ALL SECTIONS SHOW
& 12 - 16 Nm 2 PLACES R&L ASSEMBLED CONDITION
2 PLACES
& 3.5-6.5 Nm

Figure 1D-3

,.,-··--� ."
".__./ "-----./
 BUMPER BARS 1D-7

2.4 REAR BUMPER BAR ASSEMBLV -

STATION WAGON

REMOVE
1. Disconnect battery ground cable, then carefully prise
licence plate lamp assemblies from top of centre
facia and disconnect electrical connectors.
2. From under rear quarter panels, remove screws
securing lower section of side facias to rear quarter
panel and the screws securing the leading flanges of
the bumper facias to the outer panels (refer Fig. 1 D-
4, Section C-C and View 'A', Section E-E).
3. With tail gate raised and rear quarter inner trim panel
covers removed, remove screws securing rear bum­
per bar assembly to rear quarter panel (refer
Fig. 1 D-4, Section A-A).
4. From within spare wheel compartment and with rear
bumper bar assembly fully supported, remove nuts
securing assembly to back panel lower (refer
Fig. 1 D-4, Section 8-8) and remove assembly.

DISASSEMBLE
Remove nuts and screws securing bumper bar assembly
mounting brackets to centre facia and centre facia to
side facia(s) (refer Fig. 1 D-4, Sections 8-8 and D-D) then
remove side facia(s).

REASSEMBLE
Reverse disassembly operations.

REINSTALL

(_ . j
Reverse removal operations.

l_)
 ......
SCREW &
4 PLACES R/L
FACIA ASM. REAR BUMPER
SIDE RS m
C:
3::
SECTION D-D .,,
rn
SCREW ::0
1 PLACE R/L
m
\� � . l>
XI
t -�, en
SECTION E-E

FACIA ASM. REAR

BUMPER SIDE LS
DISTANCE PIECE
REAR BUMPER BRACKET
2PLACES

NUT 8 it. SCREW AND

2PLACES WASHER ASM.
2PLACES R&L
FASTENER
1 PLACE R/L

WASHER BUMPER ASM.

2PLACES
VIEW � R/L SIDE
SECTION C-C

SECTION B-B SECTION A-A

& 6-8 Nm

& 12-16Nm

� 3.5 - 6.5 Nm SECTIONS SHOW BUMPER BAR

IN INSTALLED CONDITION

Figure 10-4

/ ·-·--,

\�,