E60: Fitting M-Sport Front Bumper

1. Bumper Removal:

1.1 Remove the bolt holding either corner of the bumper, just inside the wheel-arch, using a 10mm wrench. The edges of the bumper inside the wing should be free to pull out of join.

1.2 Remove the screws holding the wheel-arch liner to the front bumper using an 8mm socket. *If you are replacing your arch-liners then remove them entirely.

1.3 Remove the two screws from the lower centre of the bumper, using a T25-Torx socket, located just under the lip below each corner of the licence-plate.

1.4 Remove the two screws from the lower centre of the bumper using a T25-Torx socket, located inside each spotlight-grille recess.

1.5 Remove the five screws holding the upper-centre of the bumper along the top edge of the grille/slam panel using a T30-Torx socket.

1.6 The bumper should be free to move, so wiggle it forward and gently rest the front-centre on the ground.

1.7 Unplug the wiring to the spotlights and four parking-sensors (PDC).

1.8 Unfasten the wiring from the hooks along the inside edge of the bumper.

2. Preparing M-Sport Bumper:

2.1 Swap over the spotlight bulb-holders. They are removed by rotating a quarter-turn anti-clockwise.

2.2 Swap over the four parking-sensors (PDC). Remove them by pulling them out from the back while gently pressing from the outer side. They should fit the lugs on all E60 bumpers, regardless of year.

2.3 Ensure the grilles, headlight-washer hinges and springs are fitted to the bumper as they cannot be fitted once it is on.

2.4 On the car, remove the wiring from the foam-polystyrene blocks and remove the blocks from the car.

2.5 Fit the 'M-Paket' foam-polystyrene blocks to the car and re-insert the wiring to them, or if you do not have compatible foam blocks and are leaving them off, find a suitable route for the wiring over the top of the grille / air-ducts.

2.6 If you do not have 'M-Paket' brake-air-ducts on your bumper, then swap the existing ones left to right and flip them upside down to clear the M-Sport grille-recesses. 

3. Fitting M-Sport Bumper:

3.1 Place the M-Sport bumper in front of the car and reinsert the PDC/spotlight wiring to the hooks along the inside edge of the bumper.

3.2 Reconnect the wiring-plugs to each parking-sensor (PDC) and spotlight.

3.3 Lift the bumper up to the car, so the front-undertray slides above the deeper M-Sport lip and put one screw loosely into the centre hole on the top of the grille.

3.4 Hook each corner of the bumper round into the slot in the wheel-arch and replace the 10mm screws, but not tighten fully.

3.5 Find a suitable placement for the bumper, where the shut lines at either side of the headlight are as equal as possible. Do this one side at a time and fully tighten the 10mm screws.

3.6 *If you have the adapter-brackets on your bumper then fasten these to the two centre screw-holes from step 1.3.

3.7 Loosely replace the remaining four screws along the top of the grille / slam-panel, find a suitable placement for the grille panel where it does not disturb the shut-lines at the headlight corners and fully tighten the top screws using a T30-Torx socket.

3.8 Fit the M-Paket wheel-arch liners and fasten them to the bumper using the 8mm screws, or if you are keeping the SE ones, measure where the outer edge of the liner fouls the M-Sport bumper and cut a sliver off. One of the 8mm screw holes should still line up and hold the cut liner in place.

3.9 Replace the weather-strip trim to the top grille-panel.

3.10 Check the headlight-washers are clearing their apertures and refit the cover-caps.