ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Bumpers

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REMOVAL & INSTALLATION



Pick-Up
FRONT

See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 1: Front bumper assembly -1981-85 Pick-up models



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Fig. Fig. 2: Example of signal light connector at back of bumper assembly



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Fig. Fig. 3: Loosening the bumper retainer bolts between the bumper and front wheel



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Fig. Fig. 4: Measurement of bumper gap between the top of the bumper and front fender



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Fig. Fig. 5: Front bumper assembly-Amigo and 1986-96 Pick-up models

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the parking light harnesses.
  4.  
  5. If equipped, disconnect the fog light harnesses.
  6.  
  7. Scribe alignment marks around the bumper brackets on the frame to ease installation and alignment.
  8.  
  9. Using a floor jack and piece of wood, or an assistant, support the bumper. Remove the bumper-to-frame retainer bolts, and pull the bumper away from the vehicle.
  10.  

To install:
  1. Position the bumper to the frame of the vehicle aligning the scribe marks and bumper bracket and frame holes. Secure the bumper in place with the retainer bolts. Tighten the bolts enough to secure the assembly in place.
  2.  
  3. Align the bumper until there is a gap of 0.63 in. (6mm) between the bumper and vehicle fender.
  4.  
  5. Tighten the bumper retainer bolts to 99-111 ft. lbs. (129-144 Nm).
  6.  
  7. Connect the parking light harnesses and fog lights, if equipped.
  8.  
  9. Connect the negative battery cable.
  10.  

REAR

See Figures 6, 7 and 8



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Fig. Fig. 6: Amigo and Pick-up rear standard bumper assembly



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Fig. Fig. 7: Amigo and Pick-up rear step bumper side assembly



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Fig. Fig. 8: Amigo and Pick-up rear step bumper center assembly

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the license plate harnesses.
  4.  
  5. Scribe alignment marks around the bumper brackets on the frame to ease installation and alignment.
  6.  
  7. Using a floor jack and piece of wood, or an assistant, support the bumper. Remove the bumper-to-frame retainer bolts, and pull the bumper away from the vehicle.
  8.  
  9. If replacing the metal portion of the bumper, remove the side bumper cap(s) retainer nut and bolts.
  10.  

To install:
  1. If removed, install the side bumper cap(s) using the retainer nut and bolt. Tighten the nut and bolt to 13-16 ft. lbs. (17-21 Nm).
  2.  
  3. Position the bumper to the frame of the vehicle aligning the scribe marks and bumper bracket and frame holes. Secure the bumper in place with the retainer bolts. Tighten the bolts enough to secure the assembly in place.
  4.  
  5. Inspect the bumper to make sure there is an even gap between the bumper and fenders.
  6.  
  7. Tighten the bumper retainer bolts to 69-83 ft. lbs. (90-108 Nm).
  8.  
  9. Connect the license plate harnesses.
  10.  
  11. Connect the negative battery cable.
  12.  

Amigo
FRONT

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the parking light harnesses.
  4.  
  5. If equipped, disconnect the fog light harnesses.
  6.  
  7. Scribe alignment marks around the bumper brackets on the frame to ease installation and alignment.
  8.  
  9. Using a floor jack and piece of wood, or an assistant, support the bumper. Remove the bumper-to-frame retainer bolts, and pull the bumper away from the vehicle.
  10.  

To install:
  1. Position the bumper to the frame of the vehicle aligning the scribe marks and bumper bracket and frame holes. Secure the bumper in place with the retainer bolts. Tighten the bolts enough to secure the assembly in place.
  2.  
  3. Align the bumper until there is a gap of 0.63 in. (6mm) between the bumper and vehicle fender.
  4.  
  5. Tighten the bumper retainer bolts to 99-111 ft. lbs. (129-144 Nm).
  6.  
  7. Connect the parking light harnesses and fog light, if equipped.
  8.  
  9. Connect the negative battery cable.
  10.  

REAR

See Figures 6, 7 and 8

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the license plate harnesses.
  4.  
  5. Scribe alignment marks around the bumper brackets on the frame to ease installation and alignment.
  6.  
  7. Using a floor jack and piece of wood, or an assistant, support the bumper. Remove the bumper-to-frame retainer bolts, and pull the bumper away from the vehicle.
  8.  
  9. If replacing the metal portion of the bumper, remove the side bumper cap(s) retainer nut and bolts.
  10.  

To install:
  1. If removed, install the side bumper cap(s) using the retainer nut and bolt. Tighten the nut and bolt to 13-16 ft. lbs. (17-21 Nm).
  2.  
  3. Position the bumper to the frame of the vehicle aligning the scribe marks and bumper bracket and frame holes. Secure the bumper in place with the retainer bolts. Tighten the bolts enough to secure the assembly in place.
  4.  
  5. Inspect the bumper to make sure there is an even gap between the bumper and fenders.
  6.  
  7. Tighten the bumper retainer bolts to 69-83 ft. lbs. (90-108 Nm).
  8.  
  9. Connect the license plate harnesses.
  10.  
  11. Connect the negative battery cable.
  12.  

Trooper
FRONT

See Figures 9 and 10



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Fig. Fig. 9: Trooper front bumper assembly-1984-94 models



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Fig. Fig. 10: Trooper front bumper assembly-1995-96 models

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the parking light and, if equipped fog light harnesses.
  4.  
  5. Scribe alignment marks around the bumper brackets on the frame to ease installation and alignment.
  6.  
  7. Using a floor jack and piece of wood, or an assistant, support the bumper. Remove the bumper-to-frame retainer bolts, and pull the bumper away from the vehicle.
  8.  
  9. On 1984-94 models, the rubber side caps are replaceable by removing the retainer nut and bolts, and lifting the cap off the center portion.
  10.  
  11. On 1995-96 models, the front fascia and bumper reinforcement are replaceable by removing the retainer bolts from the base of the fascia and back of the reinforcement.
  12.  

To install:
  1. Position the bumper to the frame of the vehicle aligning the scribe marks and bumper bracket and frame holes. Secure the bumper in place with the retainer bolts. Tighten the bolts enough to secure the assembly in place.
  2.  
  3. Align the bumper until there is an even gap between the bumper and vehicle fender.
  4.  
  5. Tighten the bumper retainer bolts to 36-43 ft. lbs. (47-56 Nm) for 1981-94 models or 37 ft. lbs. (50 Nm) on 1995-96 models.
  6.  
  7. Connect the parking light harnesses and fog lights, if equipped.
  8.  
  9. Connect the negative battery cable.
  10.  

REAR

See Figures 11 and 12



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Fig. Fig. 11: Trooper rear bumper assembly-1984-94 models



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Fig. Fig. 12: Trooper rear bumper assembly-1995-96 models

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the license plat harnesses, if equipped.
  4.  
  5. Scribe alignment marks around the bumper brackets on the frame to ease installation and alignment.
  6.  
  7. Using a floor jack and piece of wood, or an assistant, support the bumper. Remove the bumper-to-frame retainer bolts, and pull the bumper away from the vehicle.
  8.  
  9. On 1981-94 models, the rubber side caps are replaceable by removing the retainer nut and bolts, and lifting the cap off the center portion.
  10.  
  11. On 1995-96 models, the front fascia and bumper reinforcement are replaceable by removing the retainer bolts from the base of the fascia and back of the reinforcement.
  12.  

To install:
  1. Position the bumper to the frame of the vehicle aligning the scribe marks and bumper bracket and frame holes. Secure the bumper in place with the retainer bolts. Tighten the bolts enough to secure the assembly in place.
  2.  
  3. Align the bumper until there is an even gap between the bumper and vehicle fender.
  4.  
  5. Tighten the bumper retainer bolts to 36-43 ft. lbs. (47-56 Nm) for 1981-94 models or 37 ft. lbs. (50 Nm) on 1995-96 models.
  6.  
  7. Connect the license plate harness, if equipped.
  8.  
  9. Connect the negative battery cable.
  10.  

Rodeo
FRONT

See Figures 13, 14 and 15



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Fig. Fig. 13: Rodeo front bumper assembly-1991-94 models



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Fig. Fig. 14: Rodeo front bumper assembly-1995-96 models



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Fig. Fig. 15: Front bumper gap measurement-all models

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the parking light harnesses.
  4.  
  5. If equipped, disconnect the fog light harnesses.
  6.  
  7. Scribe alignment marks around the bumper brackets on the frame to ease installation and alignment.
  8.  
  9. Using a floor jack and piece of wood, or an assistant, support the bumper. Remove the bumper-to-frame retainer bolts, and pull the bumper away from the vehicle.
  10.  

To install:
  1. Position the bumper to the frame of the vehicle aligning the scribe marks and bumper bracket and frame holes. Secure the bumper in place with the retainer bolts. Tighten the bolts enough to secure the assembly in place.
  2.  
  3. Align the bumper until there is a gap of 0.63 in. (6mm) between the bumper and vehicle fender.
  4.  
  5. Tighten the bumper retainer bolts to 100 ft. lbs. (135 Nm).
  6.  
  7. Connect the parking light harnesses and fog lights, if equipped.
  8.  
  9. Connect the negative battery cable.
  10.  

REAR

See Figures 16, 17 and 18



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Fig. Fig. 16: Rodeo rear bumper assembly-all models



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Fig. Fig. 17: Rodeo bumper position



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Fig. Fig. 18: Rodeo bumper alignment measurements

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the license plate harnesses.
  4.  
  5. Scribe alignment marks around the bumper brackets on the frame to ease installation and alignment.
  6.  
  7. Using a floor jack and piece of wood, or an assistant, support the bumper. Remove the bumper-to-frame retainer bolts, and pull the bumper away from the vehicle.
  8.  
  9. If replacing the metal portion of the bumper, remove the side bumper cap(s) retainer nut and bolts.
  10.  

To install:
  1. If removed, install the side bumper cap(s) using the retainer nut and bolt. Tighten the nut and bolt to 13-16 ft. lbs. (17-21 Nm).
  2.  
  3. Position the bumper to the frame of the vehicle aligning the scribe marks and bumper bracket and frame holes. Secure the bumper in place with the retainer bolts. Tighten the bolts enough to secure the assembly in place.
  4.  
  5. Align the bumper until there is a gap of 0.67 in. (17mm) between the bumper and vehicle fender.
  6.  
  7. Tighten the bumper retainer bolts to 27 ft. lbs. (37 Nm).
  8.  
  9. Connect the license plate harnesses.
  10.  
  11. Connect the negative battery cable.
  12.  

Hombre
FRONT

See Figures 19, 20 and 21



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Fig. Fig. 19: Hombre front bumper assembly



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Fig. Fig. 20: Front bumper impact bar assembly



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Fig. Fig. 21: Front bumper brace

  1. Disconnect the negative battery cable.
  2.  
  3. If necessary for better access, raise and support the front of the vehicle safely on jackstands.
  4.  
  5. If equipped, disconnect the fog light harnesses.
  6.  
  7. If equipped, remove the front fascia from the vehicle. This is accomplished by squeezing the retainers from behind the bumper, and pulling the fascia forward.
  8.  
  9. Remove the radiator grille. refer to the procedure in this section.
  10.  
  11. Remove the brace to bumper nut(s) and bolt(s).
  12.  
  13. Support the bumper (an assistant is most convenient here), then remove the bumper-to-frame retainers.
  14.  
  15. Carefully lower the bumper from the vehicle.
  16.  

To install:
  1. Position the bumper to the frame and install the retainer bolts. With the bumper level, tighten the retaining bolts to 30 ft. lbs. (40 Nm).
  2.  
  3. Install the front fascia.
  4.  
  5. Install the radiator grille.
  6.  
  7. Attach the fog lights, if equipped.
  8.  
  9. Lower the vehicle, and connect the negative battery cable.
  10.  

REAR

See Figures 22, 23 and 24



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Fig. Fig. 22: Hombre rear bumper assembly



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Fig. Fig. 23: Some Hombre models are equipped with a filler panel instead of a true bumper assembly



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Fig. Fig. 24: Hombre rear bumper extension

  1. Disconnect the negative battery cable.
  2.  
  3. If necessary, disconnect the license plate lamp harness.
  4.  
  5. Remove the nuts and bolts retaining the rear bumper brackets to the frame rail. Be sure to support the bumper when loosening and removing the retainers as most bumpers are secured only by these bolts.
  6.  

It may be easier to remove the bracket-to-bumper nuts and bolts and lower the bumper from the vehicle with the brackets still installed on frame. Check under the bumper to see how it is mounted, then make the decision based on ease of service.

  1. On some models, one or more additional braces may also secure the rear bumper. If necessary, disconnect the brace from the vehicle or the bumper, as applicable.
  2.  
  3. Carefully lower the bumper from the rear of the vehicle. If necessary, the bumper brackets may be removed from bumper at this time.
  4.  

To install:
  1. If the bumper brackets have been removed, install to the bumper and tighten the bolts to 20 ft. lbs. (26 Nm).
  2.  
  3. Position to bumper assembly to the frame, and secure in place with the retainer nuts and bolts. With the bumper level, tighten the nuts and bolts to 66 ft. lbs. (86 Nm).
  4.  
  5. Attach the license plate harness.
  6.  
  7. Connect the negative battery cable.
  8.  

 
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