Remove radiator grille.

• For additional information, please refer to the official Workshop Manual. Radiator Grille (501-08)

Remove the front bumper.

• For additional information, please refer to the official Workshop Manual. Front Bumper (501-19)

Remove and retain x2 parking aid sensors (S1) from the front bumper.

1. Disconnect the parking aid sensor harness from the parking aid sensor.
2. Remove the parking aid sensor from the front bumper.

Remove the arrowed tape and the arrowed clip securing the camera harness to the front wiring harness.

Disconnect the camera harness from the camera.

Remove the license plate and the license plate fixings.

Remove the license plate plinth if installed. Discard the license plate plinth.

Remove the fog lamp finisher.

• Release x7 clips.
• Remove the fog lamp finisher from front bumper.

Remove x6 fixings.

Remove the front bumper protector.

• Remove x2 fixings.
• Release x20 clips.
• Remove the front bumper protector.

Remove the camera housing and the front proximity camera from the front bumper grille part.

• Remove x3 fixings.

Remove the front bumper lower corner covers from both sides of the front bumper.

1. Disconnect the parking aid sensors. The quantity of parking aid sensors will vary depending on the vehicle specification.
2. Remove parking aid sensors as required to allow removal of the front bumper lower corner covers.

Identify the cut guide lines on the front bumper lower corner covers.

Use suitable tooling to cut the illustrated sections from the front bumper lower corner covers. Discard the removed sections.

• Use the cut guide lines on the front bumper lower corner covers.

Drill 4 holes in the lower corner of the front bumper carrier as illustrated. Repeat step for the other side of the front bumper.

• Use the arrowed markings on the front bumper lower corner to make sure the holes are drilled at the correct locations.
• 10 mm drill bit

Identify the cut guide lines on the lower corners of the front bumper carrier.

Use suitable tooling to cut the illustrated part from the front bumper carrier. Repeat step for the other side of the front bumper carrier.

• Use the cut guide lines on the front bumper carrier.

For Defender-X vehicles only, do not complete steps 21 to 26. Continue from step 27.

• Install the front grille taken from the removed front bumper protector, and install it to the Defender-X front bumper protector (VPLEB0441).
• Discard the front bumper protector that was removed from the vehicle. The front bumper protector (VPLEB0441) will be installed instead.

Mark a point at the centre of the front bumper protector.

• Make sure the mark is centred between the 2 parking aid sensor holes.

Drill a hole at the marked position.

• 22 mm drill bit

Identify the correct cut guide lines on the front bumper protector.

Use suitable tooling to cut the illustrated sections from the front bumper protector. Discard the removed sections.

• Use the cut guide lines on the front bumper protector.

Identify the correct cut guide lines on the front bumper protector for the parking aid sensor holes.

Use suitable tooling to drill the illustrated parking aid sensor holes in the front bumper protector. Discard the removed sections.

• Use the cut guide lines on the front bumper protector.
• The holes can be drilled using a 32 mm to 40 mm circular saw.

Identify the correct cut guide lines on the radiator grille.

Use suitable tooling to cut the illustrated sections from the radiator grille. Discard the removed sections.

• Use the cut guide lines on the radiator grille.

Remove the front section of the front wheel arch liner on both sides of the vehicle. For additional information, please refer to the official Workshop Manual. Front Wheel Arch Liner (501-02 Front End Body Panels)

Identify the cut guide lines on the front wheel arch liner.

Use suitable tooling to cut the section of the front wheel arch liner on both sides of the vehicle as illustrated. Discard the removed sections.

• Use the cut guide lines on the wheel arch liner.

Remove the x2 brake ducts.

1. Remove x4 brake duct fixings (S3) and retain.
2. Remove the x2 brake ducts and retain.

Release and aside the cooling pipe from the cooling module protector as illustrated.

1. Release the cooling pipe from the x2 arrowed clips and aside the cooling pipe.
2. Remove x2 clips (S4) and retain.

Remove the cooling module protector as illustrated.

1. Remove and retain x2 cooling module protector M12 bolts (S5).
2. Remove and discard x2 cooling module protector bolts as illustrated. Move aside the air conditioning pipes to allow access.
3. Remove and discard the cooling module protector.

Loosen x8 armature bolts to assist the installation of the front undershield support bar (A1).

Align and install the front undershield support bar (A1).

1. Align the front undershield support bar with the vehicle.
2. Align the ends of the front undershield support bar with the brackets as illustrated.
3. Make sure the holes for the bolts (S5) align with the holes in the subframe. Adjust the armature position to achieve correct hole alignment.
4. Install, but do not fully tighten x2 fixings (S5) to secure the front undershield support bar to the vehicle.

Secure the ends of the front undershield support bar.

1. Check the alignment of the front undershield support bar with the bracket as illustrated.
2. Install, but do not fully tighten x2 fixings (C1) to secure the front undershield support bar to the bracket.
3. Make sure the air conditioning pipes on both sides of the front undershield support bar are installed in the correct location.

Install the clips (S4) and correctly position the cooling pipe.

1. Install x2 clips (S4) to the front undershield support bar.
2. Install the cooling pipe to the x2 arrowed clips and position the cooling pipe as required.

Tighten fixings (S5) and (C1).

• Torque: 60Nm

Tighten x8 armature bolts.

• Torque: 55Nm

Install the x2 brake ducts to the front undershield support bar using x4 fixings (S3).

Install x8 rivet nuts (U) to the lower corners of the front bumper carrier. Then follow the process below or use a rivet nut fastening tool.

1. Install fixing (V) to each of the rivet nuts (U).
2. Tighten each fixing (V) to collapse the rivet nut it is installed into.
3. Remove all fixings (V) and retain.

Install the x2 lower brackets (L) to the front bumper carrier using x4 fixings (D), x8 washers (S) and x4 nuts (T).

Position the A-frame carrier (A) onto the front bumper carrier and make sure the x2 brackets (L) are positioned correctly.

1. Make sure the 4 arrowed cutouts in the A-frame carrier (A) are positioned correctly over the brackets (L) on both sides of the front bumper carrier.
2. If required adjust the position of the brackets (L).

Remove the A-frame carrier (A) from the front bumper carrier.

Tighten x4 fixings (D) that secure the x2 lower brackets (L) to the front bumper carrier.

• Torque: 12Nm

Install the 2 modified front bumper lower corner covers to the corners of the front bumper carrier.

1. Install parking aid sensors that were previously removed.
2. Connect the parking aid sensors. The quantity of parking aid sensors will vary depending on the vehicle specification.

Feed the camera harness through the illustrated hole in the grille part of the front bumper carrier. This is the hole to the side of the hole previously used by the camera.

• The camera harness must be accessible from the front of the bumper carrier.

Install the front bumper carrier to the front of the vehicle.

• Install x8 front bumper clips on both sides.
• Install x6 lower clips to the front bumper.
• Install and tighten the upper x5 fixings to the front bumper. Torque: 3.2Nm

Install the front bumper finisher.

• Install x7 clips.

Install the x2 upper brackets (E) to the front of the vehicle using the x4 fixings (D), x8 washers (S) and x4 nuts (T).

Position the A-frame carrier (A) against the front bumper and make sure the 2 brackets (E) are positioned correctly.

1. Make sure the arrowed cutouts in the A-frame carrier (A) are positioned correctly over the brackets (E) on both sides of the vehicle.
2. If required adjust the position of the brackets (E).

Remove the A-frame carrier (A) from the front bumper.

Tighten x4 fixings (D) that secure the 2 upper brackets (E) to the front bumper.

• Torque: 12Nm

Install the radiator grille. Take care when installing the radiator grille over the 2 upper brackets (E).

• Install x14 clips.
• Install the radiator grille.
• Install x4 clips.

Install the front bumper protector to the front bumper.

1. Feed the 2 centre parking aid sensor harnesses through the illustrated holes in the front bumper protector.
2. Install x20 front bumper protector clips.
3. Install and tighten x8 fixings. Torque: 4Nm

Install the fog lamp finisher to the front bumper.

• Install x7 clips.

Install the A-frame carrier (A) using x8 fixings (D) and the washers (S) to check the alignment.

1. Make sure the A-frame carrier location pin is aligned with the hole in the centre of the front bumper protector.
2. Align the A-frame carrier to the x4 brackets (E) and (L).
3. Install but do not fully tighten x8 fixings (D).

Make sure the gap between the arrowed edges on the A-frame carrier (A) and the arrowed edges on the front bumper are equal on both sides of the vehicle.

Remove the A-frame carrier (A) from the vehicle.

Install the fixings (G) to the A-frame carrier (A).

Install x14 rib locks (K) to the A-frame carrier (A).

Install x6 clips (H) to the A-frame carrier (A).

Position the A-frame carrier (A) close to the front bumper so the location pin on the A-frame carrier is aligned with the hole drilled in the centre of the front bumper bracket.

• Feed the harness for the parking aid sensors through the arrowed holes in the A-frame carrier (A) on both sides of the vehicle.

Install the A-frame carrier (A) using x8 fixings (D) and the washers (S).

1. Make sure the A-frame carrier location pin is aligned with the hole in the centre of the front bumper bracket.
2. Align the A-frame carrier to the x4 brackets (E) and (L).
3. Install but do not fully tighten x8 fixings (D).

Make sure the gap between the arrowed edges on the A-frame carrier (A) and the arrowed edges on the front bumper are equal on both sides of the vehicle.

Tighten x8 fixings (D).

• Torque: 12Nm

Prepare the A-frame cover (B) so the correct license plate plinth can be installed if required.

• Mark the location where the 2 holes should be drilled.

Drill 2 holes into the A-frame cover (B) at the illustrated positions. Arrowed locations are for China market license plate plinth.

• 2 mm drill bit

Drill 2 holes into the A-frame cover (B) at the illustrated positions. Arrowed locations are for NAS or Japan market license plate plinth.

• 2 mm drill bit

Drill 2 holes into the A-frame cover (B) at the illustrated positions. Arrowed locations are for EU market license plate plinth (VPLEB0435).

• 2 mm drill bit

Install the parking aid sensors (S1) to the parking aid sensor brackets that are part of the A-frame cover (B).

Position the A-frame cover (B) close to the A-frame carrier (A).

Connect the parking aid sensor harnesses to the parking aid sensors in the A-frame cover (B).

1. Make sure the parking aid sensor harness is accessible through the A-frame carrier (A).
2. Connect the parking aid sensor harness to the parking aid sensor on the A-frame cover (B).

Make sure both of the parking aid sensors are installed correctly and the parking aid sensor harness is connected as illustrated.

Install the A-frame cover (B) to the A-frame carrier (A).

1. Apply force at all positions where clips are located.
2. Make sure all clips are fully engaged.
3. Check the alignment of the A-frame cover (B).

Install x10 fixings (F) to secure the A-frame cover (B) to the A-frame carrier (A). The bolts (F) will pass through the clips (G). Check the alignment.

• Torque: 8Nm

Install x7 remaining rib locks (K) to the A-frame centre trim (C).

Install the camera bracket (J) to the A-frame centre trim (C).

1. Align and locate the camera bracket (J) to the A-frame centre trim (C).
2. Make sure the camera bracket is correctly installed as illustrated.
3. Install x2 fixings (I).

Install the A-frame centre trim (C) to the A-frame cover (B).

1. Install the A-frame centre trim top clips first and then push in the bottom clips.

Connect the front proximity camera (S2) to the camera harness.

• The camera harness will already have been fed through the grille part of the front bumper.

Install the camera housing (T) to the A-frame centre trim (C).

1. Carefully install the camera (S2) into the camera housing (T).
2. Install the camera housing (T) to the camera bracket (J). Make sure the camera housing is correctly engaged into the bracket (J).
3. Secure the camera housing to the camera bracket using the screw (I).

Install the license plate plinth to the A-frame cover (B) using x2 fixings (N) and the 2 holes drilled in install steps 46 to 49.

1. China market (VPLEB0434).
2. NAS / Japan market (VPLEB0436).
3. EU market (VPLEB0435).

Install the remaining x6 fixings (N) to the license plate plinth.

1. China market.
2. NAS or Japan market.
3. EU market.

Install the license plate to the license plate plinth.

• Install the hood latch panel finisher.
• Install x6 clips.

Use the supplied cleaner (Y) to clean the illustrated area of the front bumper lower corner cover.

1. Install the expedition corner cover (X) for masking purposes only.
2. Apply suitable tape to create a mask along the edges of the expedition corner cover.
3. Remove the expedition corner cover (X).
4. Use the supplied cleaner (Y) to clean a 10 mm strip from the edge of the tape.

Apply the supplied promoter (Z) to the illustrated area of the front bumper lower corner cover.

• Apply the promoter to a strip about 10 mm wide as illustrated.

Install the expedition corner cover (X) to the left side of the vehicle.

1. Align the expedition corner cover to the lower corner cover.
2. Apply pressure to the expedition corner cover to secure the cover to the promoter.
3. Install the x2 arrowed clips, that are part of the expedition corner cover, over the front bumper carrier as illustrated.

Install the screw (W) to secure the expedition corner cover (X) to the front bumper carrier.

Install, but do not fully tighten x4 fixings (V). The bolts must engage into the rivet nuts (U) installed to the front bumper carrier.

• Make sure the ends of the 4 lengths of protective strip are visible.

Install the modified front section of the front wheel arch liner. At this stage only install the top x2 retained fixings (S6). For additional information, please refer to the official Workshop Manual. Front Wheel Arch Liner (501-02 Front End Body Panels)

Install, but do not fully tighten x3 fixings (W) and the retained fixing (S6) to secure the wheel arch liner to the expedition corner cover (X) and the front bumper carrier.

• Follow the illustrated screw install sequence.

Remove the x4 lengths of protective strip from the sections of adhesive tape.

• Remove the protective strip from the adhesive tape by pulling on the arrowed ends of the protective strip. Follow the illustrated removal sequence.

Tighten x4 fixings (V).

• Torque: 2Nm

Tighten x4 fixings (W) and the retained fixing (S6).

Repeat steps 54 to 63 to secure the expedition corner cover on the other side of the vehicle.

Make sure the expedition corner covers (X) are correctly installed to both sides of the vehicle.

Remove x4 fixings. Keep x2 and discard the other x2. All fixings are the same.

Install the front undershield (B1) to the front undershield support bar (A1).

1. Align the 2 front undershield hooks with the 2 holes in the front undershield support bar.
2. Install the 2 front undershield hooks to the 2 holes in the front undershield support bar.
3. Make sure the front undershield is located correctly.

Install, but do not fully tighten x2 fixings from step 66.

Install, but do not fully tighten x2 fixings (D1).

Install x2 fixings (E1).

• Torque: 60Nm

Tighten x4 fixings.

• Torque: 60Nm

Make sure the front undershield (B1) is correctly installed.