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Autopapyrus · Toyota Prius (XW30, 3rd generation)
https://autopapyrus.com/guides/toyota/prius/front-bumper-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Toyota Prius (XW30, 3rd generation): Front Bumper Replacement

The front bumper on the Prius XW30 is held by hidden clips, screws in the fender liners, and several bolts along the top and sides. The job is doable in a home garage, but the body has many fragile plastic clips. You need a helper so you don't damage the paint or the connectors. The bumper may have fog lights, headlight washers and parking sensors installed in or on it, and their connectors must be disconnected.

Difficulty: Medium Time: 1.5-3 hours (without painting) Steps: 14

Parts

6
№PartGenuine part no.
01 Front bumper cover assemblywith or without openings for fog lights and headlight washers 52119-47933
52119-47968
52119-47932
02 Lower bumper grilleif needed 53102-47020
03 Bumper moldings and coversif needed
04 Plastic bumper clips and push pins
05 Bumper reinforcementif deformed 52021-47023
06 Bumper bracketsif deformed 52114-47140

Part numbers are from the manufacturer's original catalogue. Check them against your VIN before ordering.

Tools

6
  • Socket set and ratchet (mostly 10 mm)
  • Phillips screwdriver
  • flat-blade screwdriver or plastic clip remover
  • plastic panel pry tools
  • jack and jack stands
  • container for washer fluid (if equipped with headlight washers)
There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes and 5 more. See manuals →

Step by step

14 steps
  1. Open the hood and park the car on a level surface with the parking brake set. Cut the power: switch the Prius to OFF mode and wait a few minutes. For safety, disconnect the negative terminal of the 12 V battery, which is located in the cargo area. You don't need to touch the high-voltage system for a bumper replacement. Do not disassemble any orange cables or connectors.
  2. If needed, raise the front of the car on jack stands to make it easier to reach the bottom of the bumper. Or work with the wheels on the ground, turning the steering wheel to either side to access the fender liners.
  3. Remove the upper plastic cover above the radiator (the cover on the top of the radiator support). It is held by plastic clips. Pry the clips up one at a time; do not pull on the whole cover at once.
  4. Remove the splash shield (lower undertray) under the bumper. It is secured with screws and clips. Keep the fasteners together and remember where each one goes.
  5. Remove the screws and clips along the lower edge of the bumper, where it meets the lower shield.
  6. On both sides, fold back the front parts of the fender liners or remove them. Remove the screws and clips that connect the side edges of the bumper to the fender liners, as well as the fasteners between the bumper and the fender.
  7. Remove the bolts or screws along the top edge of the bumper, where the top of the bumper attaches to the radiator support. They are located under the cover you removed.
  8. If equipped with headlight washers, disconnect the hoses from the nozzles. Place a container underneath, as leftover fluid may leak out of the system. If equipped with fog lights, parking sensors or other sensors, disconnect their connectors. Press the locking tab on the connector and pull gently. Do not yank the wiring.
  9. Have your helper support the bumper on one side. Pull the bumper forward, starting at the edges near the wheel arches. The bumper sits on guides and retaining clips: release them one at a time, and do not pull with a sudden jerk.
  10. Place the removed bumper on a soft blanket. Transfer these parts from it to the new bumper: fog lights, grilles, mesh inserts, moldings, sensors, headlight washers, covers and brackets. Check the condition of the reinforcement and brackets: replace them if there are cracks or deformation.
  11. Install the new bumper. Connect the connectors and hoses (if there were any), then slide the bumper onto the guides and retaining clips on the sides and snap it into place. Align the gaps with the hood, headlights and fenders.
  12. Install all screws and bolts: first the upper and side ones, then the lower ones. Torque values for these small fasteners are low, so tighten them without overtightening. As a guideline for M6 screws and bolts into plastic parts: about 5-8 N·m (44-71 lb-in). Exact values for your model are not confirmed in publicly available sources, so keep the force moderate. Replace any broken clips with new ones.
  13. Reinstall the lower splash shield, the fender liners and the upper cover. Reconnect the battery terminal. Turn the ignition on and check that the fog lights, headlight washers and parking sensors work.
  14. Check the gaps around the perimeter, that there is no misalignment, and that the bumper does not wobble. If necessary, adjust the position before final tightening.

Common mistakes and warnings

  • Plastic clips break very easily in the cold, so work in a warm space and keep spare clips on hand
  • If your Prius has an adaptive cruise control radar, cameras or parking sensors, check that they work after replacing the bumper
  • Calibrating the radar may require special equipment at a repair shop
  • If the reinforcement, brackets or radiator support were damaged in a collision, have them inspected and repaired by a body shop
  • Work carefully when doing body work on a hybrid, especially near the high-voltage cables and the inverter: do not touch the orange cables