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WK2 OFF-ROAD FRONT BUMPER

INSTALL INSTRUCTIONS

TABLE OF CONTENTS

REVISION B

29 AUGUST 2022

PAGE

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Summary of Contents for WK2

Page 1: ...WK2 OFF ROAD FRONT BUMPER INSTALL INSTRUCTIONS REVISION B 29 August 2022 ...

Page 2: ...27 WK2 Off Road Front Bumper Number Plate Mount KIT 27 WK2 Off Road Front Bumper Advanced Parking Sensor KIT 28 Mounting WK2 Off Road Front Bumper 32 WK2 Off Road Front Bumper Apex Grille 34 WK2 Off Road Front Bumper Nomad Grille 35 Bumper Completion 36 Appendix 37 Troubleshooting 39 Box 1 WK2 Chassis Mounts Front Box 2 WK2 Off Road Front Bumper ORFB Box 3 WK2 Winch Cradle 2011 2015 OR 2016 Box 4 ...

Page 3: ...olt Zinc M10 x 25 Hex Head 10 9 Bolt Zinc M10 Wedge Lock Extended Washer SS316 Black M10 CL10 Hex Flange Nut Zinc M6 Bolt Head Protector Slotted M6 Nutsert Thinsheet SS316 M6 Sheetmetal Nut M N O P Q R S T U V 6 4 8 16 4 4 4 12 2 6 2 1 M6 x 40 Hex Head 10 9 Bolt Zinc M6 x 20 Hex Head CL70 Bolt SS316 M6 x 20 Socket Button Head CL50 Bolt SS316 Black M6 Wedge Lock Extended Washer SS316 Black M6 Hex F...

Page 4: ... C D E F G H 1 1 2 2 2 6 6 2 2 WK2 Winch Cradle Winch Cradle 2011 2015 Winch Cradle 2016 Chassis Strengthening Plate Left Right Bonnet Support Strut Left Right Top Mounting Plate M12 x 35mm Hex Head 10 9 Bolt Zinc M10 x 40mm Hex Head 10 9 Bolt Zinc M8 x 25mm Hex Head 10 9 Bolt Zinc M6 x 25mm Hex Head 10 9 Bolt Zinc I J K L M N O 6 6 2 2 2 2 4 1 M12 Wedge Lock Extended Washer Zinc Flake M10 Wedge L...

Page 5: ...unt Grille Bar Inner Left Right Mount Grille Bar Outer Left Right D E F 2 20 18 Vent Bar Gunmetal Left Right M6 x 20mm Socket Button Head CL50 Bolt SS316 BLACK M6 Hex Flange Nylock CL70 Nut SS316 WK2 OFF ROAD FRONT BUMPER MACH II AERO BAR All Variants A B C D E F A B C WK2 OFF R0AD FRONT BUMPER FUSION FAIRLEAD All Variants B C D E REF QTY DESCRIPTION REF QTY DESCRIPTION A B C 1 2 2 WK2 Off Road Fr...

Page 6: ...4 1 4 4 2 2 4 Blanking Plug 20mm Dia Head Sensor Sticker Sheet M6 x 60mm Countersunk Socket SS316 M6 Hex Flange Nylock CL70 Nut SS316 M6 x 12mm Button Head Socket SS316 M6 Flat Washer SS316 3 5mm 6G x 13mm Screw Self Tapping Zinc REF QTY DESCRIPTION REF QTY DESCRIPTION A B C D E 1 2 1 2 4 WK2 Off Road Front Bumper ACC Kit ACC Guard Textured Black ACC Mount Brackets Non Winch Left Right ACC Mount B...

Page 7: ... CL70 Nut SS316 M6 Flat Washer SS316 B A H G F E D C I J K WK2 OFF ROAD FRONT BUMPER NUMBER PLATE MOUNT KIT AUS H G F E D C I J K A B REF QTY DESCRIPTION REF QTY DESCRIPTION A B C D E F 1 1 2 2 4 4 WK2 Off Road Front Bumper Number Plate Mount Kit AUS Centre Plate AUS Side Plate AUS M10 x 25mm Socket Button Head CL70 Bolt SS316 Black M10 CL10 Hex Flange Nut M6 x 20mm Socket Button Head CL50 Bolt SS...

Page 8: ...ype parts and be taken from multiple vehicles IMPORTANT PROPER INSTALLATION IS ESSENTIAL TO THE PERFORMANCE OF THIS PRODUCT ONLY INSTALL THIS PRODUCT ON A 2011 2021 JEEP GRAND CHEROKEE ONLY USE THE PROVIDED HARDWARE FOR INSTALLATION DO NOT MODIFY THE STRUCTURE OF THIS PRODUCT IN ANY WAY CHECK PRODUCT REGULARLY FOR DAMAGE REPLACE IMMEDIATELY AT FIRST SIGN OF DAMAGE CHECK FASTENER TIGHTNESS REGULARL...

Page 9: ...ers Manual for basic instructions NOTE This can be a tricky process If you need some help we ve provided a How To article on our website www chiefproducts com au blogs how to 11555201 wk2 lower front fascia removal installation 3 Disconnect Fender Flares 1 Pull the wheel well lining from under the fender towards the inside 2 Push the 3 plastic tab style clips from the inside to release the front o...

Page 10: ... liner from bumper connection 2 Remove lower white clip from retainer by depressing the tag NOTE Use of a flathead screwdriver can help release plastic white clip Fender Bumper Retainer 8 Unclip Upper Facia 1 Unclip upper facia from wheel wells on each side drivers passengers 2 Unclip upper facia from head lights in engine bay on each side drivers passengers 3 Set aside the upper facia in a safe p...

Page 11: ...isconnect Parking Sensor Harness 1 Disconnect parking sensor wiring loom located on the right hand side behind wheel liner 2 Unplug sensor by releasing Red Locking Tab Locked Unlocked 11 Remove Bumper Fascia 1 With all plugs unclipped pull the complete Bumper Fascia from the vehicle 12 Remove ACC Camera 1 Disconnect wiring loom from ACC camera 2 Remove 2 M5 bolts holding the ACC camera bracket to ...

Page 12: ...OEM Tow Hook Bracket can now be removed NOTE This step is only required for WK2s with OEM Tow Hooks This diagram is taken from Mopar s official installation instructions 15 OEM Tow Hooks Remove OEM Tow Hooks 1 Unbolt 2 M10 bolts E in side diagram holding front of Tow Hook to vehicle 2 Unbolt 30mm Nut on backside F in side diagram and slide Tow Hook forward out of bracket NOTE This step is only req...

Page 13: ... Remove OEM Steel Bumper and set aside 18 Remove OEM Wiring Loom Bar 1 Disconnect all clips from wiring loom bar 2 Remove 1 M6 Bolt from each side Blue Square 3 Remove 1 M8 Bolt from each side Red Circle 4 Remove OEM Wiring Loom bar IF YOU HAVE A WINCH with WK2 RECOVERY POINT HOOK Go To Step 19 No WK2 RECOVERY POINT HOOK Go to Step 20 IF NON WINCH Go to Step 36 19 WINCH WK2 RECOVERY POINT HOOK Ins...

Page 14: ...H WK2 AIR SUSPENSION KIT Install Air Suspension Bracket 1 Slip the Air Suspension Bracket over the two fixed Air Suspension Bolts Red Circles 2 The mounting tabs on the Air Suspension Bracket should line up with the holes in the chassis 3 Re using 2 M8 Flanged Nuts from Step 17 fasten the Air Suspension Bracket to the Air Compressor 4 If you have a WK2 Air Suspension KIT install the Chassis Mounti...

Page 15: ...Bolt Washer Combo installed in the previous step 3 Install the Bolt Washer combo into the bottom nut on the Chassis Mounting Bracket A 4 Do this for both sides passenger driver NOTE The install process is the same for both versions of the winch cradle 26 WINCH Install Bonnet Struts 1 Position 1 Bonnet Support Strut C against Winch Cradle A with the flange facing outwards or rearwards depending on ...

Page 16: ...er driver 4 Prior to tightening any chassis mount bolts check that mounts AND winch cradle are centred by measuring diagonally from headlamp corner to Chassis Mount Cradle These 2 measurements should be equal to within 4mm optimally to prevent fitment issues 28 WINCH Tighten Winch Cradle Bolts 1 Pull the Winch Cradle A as far forward as possible 2 Tighten 3 M12 x 35mm Bolts E 3 Do this for both si...

Page 17: ...inch Cradle A 2 Install 2 M10 Bolts provided with your winch to the front 2 nuts on your winch 3 Run both wires underneath the right headlight and into the engine bay 4 Connect onto Winch Cradle A as per winch instructions 31 WINCH Reinstall Plastic Push Clips 1 With 1 Plastic Push Clip removed earlier Step 12 reinstall to Winch Cradle A 2 Do this for both sides passenger driver 32 WINCH Tighten B...

Page 18: ... 1 Install Fusion Fairlead so that fastening bosses locate to the ORFB Centre red circle 2 Fasten using 2 M8 x 16mm Bolt C with M8 x 28OD Heavy Duty Flat Washers E Torque to 20Nm INSTALLATION COMPLETE WK2 WINCH CRADLE WK2 CHASSIS MOUNTS Front IF YOU HAVE WINCH WK2 SUMP PROTECTION PLATE Go to Step 45 WINCH NO WK2 SUMP PROTECTION PLATE Go to Step 46 36 NON WINCH WK2 Recovery Point Hook Bolt WK2 Reco...

Page 19: ...m Step 17 fasten the Air Suspension Bracket to the Air Compressor 4 If you have a WK2 Air Suspension KIT install the Chassis Mounting Bracket A on top of the Air Suspension Bracket so the tabs of the Air Suspension Bracket are sandwiched between the frame and the Chassis Mounting Bracket A NOTE The 2 M8 x 100mm Bolts Blue Circles and Chassis Mounting Bracket visible in the photo will NOT be on the...

Page 20: ...are fasten the bonnet strut back onto beam into the the new OEM bolt hole location without tightening 40 NON WINCH Tighten Mount Bracket 1 Tighten 2 M8 x 40mm Bolts Red Circle 2 M8 x 100mm bolts Blue Circle and 1 M6 x 25mm bolt Blue Square 2 Do this for both sides passenger driver NOTE Perform location checks with Chassis Mount tightened 42 NON WINCH BONNET STRUT Mark out and Drill New Bolt Hole 1...

Page 21: ... vehicle horn obstructs the new position of the bonnet strut bend the horn bracket slightly 44 NON WINCH Install Fairlead Cover to ORFB 1 Align studs on Fairlead Cover B through slots on ORFB A then fasten 4 M6 Flange Nylock Nuts Q to 10Nm NOTE Ensure Fairlead Cover fits relatively even before tightening INSTALLATION COMPLETE WK2 CHASSIS MOUNTS Front NON WINCH IF YOU HAVE WK2 Sump Protection Plate...

Page 22: ... unbolt 4 M6 x 40mm bolts and 4 M6 Bolt Head Protectors leaving the 2 M8 x 50mm Bolts fastened in the rear mounting points 47 M6 Nutsert Upgrade 1 We recommend to perform a M6 Nutsert Upgrade K before installing the ORFB parts supplied See http www chiefproducts com au installation wk2 m6 nutserts pdf 46 Install Bumper Mounts 1 Install Bumper Mount C to Chassis Mounting Bracket A 2 Locate the Brac...

Page 23: ... M10 x 25mm D with M10 Locking Washer F and M10 Flange Nut H combo for the top and 2 M6 x 20mm Button Head Socket E with M6 Flange Nylon Nut G NOTE Leave fasteners loose at this step ACC Mount Brackets Non Winch Rear view of 50 NON WINCH ACC Installing ACC with no WK2 WINCH CRADLE 1 Install O E radar with ACC Radar Cover using 2 M6 x 20mm Button Head Socket E M6 Locking Washer G and M6 Flange Nut ...

Page 24: ...in red by unclipping the clips and removing the screws 3 Pop lower centre grille out of Bumper Fascia 2017 S Limited Summit Bumper shown 52 BUMPER Mount Bracket Cut out 1 For some vehicle models the only necessary cut may be for the Mount Bracket slots verify your case using the appendix Hand tighten the Mounting Brackets C into place so they re free of movement 2 Offer the Bumper Fascia into the ...

Page 25: ...ill a hole in both top centre cut corners 56 BUMPER Bumper Fascia Trimming Stage 1 1 Starting from the holes drilled in the previous step trim across the top line 2 Cut vertical widths next then finally the lower cuts 3 Dress all trimmed edges using a smooth file NOTE Recommend cut order for best support when cutting 2017 S Limited Summit Bumper shown 2017 S Limited Summit Bumper shown 57 BUMPER B...

Page 26: ...he Bumper Fascia to give clearance to the winch rope cutting equally about the centreline 2 Dress all trimmed edges using a smooth file NOTE Check the clearance from the Winch drum diameter More or less cutting may be required 2017 S Limited Summit Bumper shown BUMPER FASCIA TRIMMING COMPLETE 58 BUMPER Bumper Fascia Trimming Stage 3 1 Using the already trimmed Bumper Fascia as a guide mark the lin...

Page 27: ...TALLATION START ORFB preparation Prior to bolting the ORFB A onto your vehicle it is recommended to fit chosen accessories on to ORFB before installing it onto the vehicle S Limited Summit models require the Bumper Fascia to be installed prior to fitting the ORFB onto the vehicle Overland Limited and Trail Hawk style Bumper Fascia s can be installed after the ORFB has been mounted IF YOU HAVE CENT...

Page 28: ...shown in the bottom 2 images trimming isn t needed Go to Step 69 65 ADVANCED PARKING SENSOR KIT Outer Parking Sensor Housing Trimming 1 Trim the cut out on both Sensor Outer Housing D PART CP188000 0063 CP1880000 0064 Using a Utility Knife to remove the recessed panel as shown 63 ADVANCED PARKING SENSOR KIT Identify which Harness Extension to Use 1 Inspect vehicle Inner Sensor harness plug that co...

Page 29: ...ANCED PARKING SENSOR KIT Retainer Install 1 Install 2 Sensor Retainer Outer Large E highlighted in blue using L for CP188000 0063 housing and R for CP188000 0064 housing 2 Using supplied M3 5 6G x 13mm Screw Self Tapping O highlighted in red secure retainer into place G 68 ADVANCED PARKING SENSOR KIT Install Sensors to Outer Housing 1 Install 2 retainers that allow best fit using L for CP188000 00...

Page 30: ...ion on the Bumper Fascia circled in red 2 Black Sensor Stickers J have been provided to change the sensors face colour if required NOTE Plastic Nylon Plug I can be painted to match vehicle colour with suitable paint G 70 ADVANCED PARKING SENSOR KIT Parking Sensor KIT Fitment 1 Locate both Sensor Housing Inner LH RH B to the Top Bar A as shown 2 Route the Harness Extension lead out of the housing e...

Page 31: ...s Go to Step 76 NOTE If Bumper Fascia can be installed after ORFB A as described in the ORFB installation notes delay this step 75 SUMMIT S LIMITED Reinstall Bumper Fascia 1 Reattach the Bumper Fascia and wheel liner to the vehicle 2 Ensure the Bumper Fascia has sufficient clearance from the ORFB A before tightening the fasteners into place NOTE This step may not be relevant depending on bumper va...

Page 32: ...uitable points on either the ORFB A or the Bumper Fascia NOTE It may be necessary to wait for the Bumper Fascia to be reinstalled before attaching harness addressed in a later step 78 ALL VEHICLES NON WINCH Installing ORFB to Vehicle 1 Fit 4 M6 x 40 Bolts M circled in blue With M6 Wedge Lock Washers P slotting the the Bolt Head Protectors J into the lower bash plate area NOTE Leave fasteners loose...

Page 33: ...on the ORFB reconnect the harness back onto the vehicle 80 ALL VEHICLES ORFB Fastener Tightening 1 The hardware tightening process is done progressively As opposed to fully tightening one bolt at a time work your way across the ORFB progressively increasing the tightness of the bolts to help with alignment 2 4 M6 x 40mm Bolts on Lower Bash Plate 13Nm Dry or 11Nm Anti Seize 3 2 M12 x 20mm Bolts fro...

Page 34: ... 92 85 Preparing ORFB for Grille 1 Clip 2 M6 Sheetmetal Nuts L supplied at the highlighted tabs on the ORFB align the holes NOTE Take care to not scratch through the powder coat 84 Vehicle Bumper to ORFB Clearance Adjustment 1 If the Bumper fascia is contacting or there is too much clearance with the ORFB Bumper Support Brackets E can be used to better locate the vehicle bumper positioning 2 Once ...

Page 35: ...le Fascia 88 NOMAD GRILLE Install Nomad Grille 1 Locate LH and RH Mount Grille Inner Brackets B and LH and RH Mount Grille Outer Brackets C 2 Fasten M6 x 20mm Socket Button Head Bolt E with M6 Flange Nuts F into the highlighted holes do NOT tighten the bolts allow movement NOTE If ACC Non Winch Mount and or Side Mount Number Plate is installed remove fastener and install both brackets together 89 ...

Page 36: ...uards C using 4 M6 Socket Button Head screws O with M6 Locking Washers P 2 Trim vehicle OEM Wheel Liner to meet and attach to Stone Guards NOTE Additional cut outs on the stone guards give areas to tether the wheel liner Attachment point for wheel liners 90 NOMAD GRILLE Install Nomad Grille 1 Locate outer Vent Bar D to ORFB A with the smaller face pointing upward reference the Front View for orien...

Page 37: ...T mark and measure accurately from the centreline Failure to do so will result in issues with the install Check your measurements before starting trim Start by trimming the most prominent parts of the bumper obstructing clearance outlined below then review how much additional material needs to be removed to prevent the Bumper Fascia contacting the ORFB Test fit bumper during trimming process to ch...

Page 38: ... 38 40 455mm 320mm 1070mm 320mm 455mm 1070mm 455mm 320mm 1070mm 455mm 320mm 1070mm NOTE Some SRT Models benefit from cutting outer Bumper panel above the ORFB top face 2015 Jeep Grand Cherokee Overland 2017 Jeep Grand Cherokee Overland 2017 Jeep Grand Cherokee S Limited 2017 Jeep Grand Cherokee SRT ...

Page 39: ...on of these instructions from our website We occasionally make updates www chiefproducts com au installation wk2 roof rack pdf If you need additional help send us an email support chiefproducts com au MAINTENANCE FASTENERS Check fastener tightness regularly and tighten if required We recommend checking fasteners after every large off road trip CORROSION PROTECTION After an off road trip rinse all ...

Page 40: ...E Looking to share epic photos of your WK2 Send us your photos Unboxing Fully Installed Painted In Mud or out Adventuring in some beautiful location If you share with us we ll share with our followers UPLOAD www chiefproducts com au share EMAIL connect chiefproducts com au HASHTAG ChiefProducts GrandAdventure ...

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