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FVC SP1127B Installation Manual

Sprinter van front bumper
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S PRI NTER VAN F R ONT B U MP ER
SP1127 B
INSTALLATION
GUIDE
F L AT L I N E VA N C O • S U P P O R T @ F L AT L I N EVA N C O . C O M • 8 8 8 - 6 6 7- 5 5 7 6
TOOLS REQUIRED
+
1/4" RATCHET
+
3/4" SOCKET
+
3/8" RATCHET
+
9/16" SOCKET AND WRENCH
+
T25 TORX
+
7/16" SOCKET AND WRENCH
+
T30 TORX
+
3/8" SOCKET AND WRENCH
+
7/32" ALLEN WRENCH
+
13MM SOCKET
+
5/32" ALLEN WRENCH
+
POWER DRILL
+
AUTO TRIM REMOVAL TOOL
+
BODY SAW
+
SNAP RING PLIERS
+
PAINTERS TAPE
+
SIDE CUTTERS
+
MARKER
+
12" EXTENSION
+
TAPE MEASURE
+
4" EXTENSION
INSTALL INFO
TIME TO INSTALL THIS PRODUCT: 5-6 HOURS
Additional help is suggested for a few of the install steps.
BEFORE YOU START
Please inspect the product and packaging upon
delivery to ensure there are no issues and that
all parts and hardware are accounted for.
Contact us ASAP if anything is missing at:
support@flatlinevanco.com
(NOT INCLUDED)
0 1

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Summary of Contents for FVC SP1127B

  • Page 1 INSTALLATION GUIDE S PRI NTER VAN F R ONT B U MP ER SP1127 B TOOLS REQUIRED (NOT INCLUDED) 1/4” RATCHET 3/4” SOCKET 3/8” RATCHET 9/16” SOCKET AND WRENCH T25 TORX 7/16” SOCKET AND WRENCH T30 TORX 3/8” SOCKET AND WRENCH 7/32”...

  • Page 2: Before You Start

    BEFORE YOU START All Flatline Van Co products must be properly assembled and secured before attaching to your vehicle. Improper attachment could result in an automobile accident, and could cause serious bodily injury or death to you or to others involved. You are responsible for assembling and securing Flatline Van Co products to your vehicle, checking the mounting points and attachments prior to use, and regularly inspecting the products for wear and or damage.
  • Page 3 BUMPER PACKAGE CONTENTS CENTER WELDMENT PASSENGER SIDE WING DRIVER SIDE WING WINCH CRADLE QTY: 1 QTY: 1 QTY: 1 QTY: 1 CUT TEMPLATE 1 FENDER LINER BRACKETS CENTER LIGHT BRACKETS CUT TEMPLATE 2 LICENSE PLATE BRACKET QTY: 1 QTY: 4 QTY: 1 QTY: 2 QTY: 1...
  • Page 4 SKID PLATE PACKAGE CONTENTS DRIVER KNUCKLE PASSENGER KNUCKLE BUMPER SKID PLATE ENGINE SKID PLATE QTY: 1 QTY: 1 QTY: 1 QTY: 1 SKID PLATE VENT SKID PLATE BRACKET 1 SKID PLATE BRACKET 2 QTY: 1 QTY: 1 QTY: 1 F L AT L I N E VA N C O • S U P P O R T @ F L AT L I N EVA N C O . C O M • 8 8 8 - 6 6 7- 5 5 7 6...
  • Page 5 BULL BAR PACKAGE CONTENTS BULL BAR QTY: 1 F L AT L I N E VA N C O • S U P P O R T @ F L AT L I N EVA N C O . C O M • 8 8 8 - 6 6 7- 5 5 7 6...
  • Page 6 WINCH FAIRLEAD CONTENTS WINCH FAIRLEAD FAIRLEAD HOOK FAIRLEAD HOOK PIN QTY: 1 QTY: 1 QTY: 1 F L AT L I N E VA N C O • S U P P O R T @ F L AT L I N EVA N C O . C O M • 8 8 8 - 6 6 7- 5 5 7 6...
  • Page 7 BUMPER HARDWARE 3/8-16 X 1 FLANGED HEX 3/8-16 X 1 BUTTON HEAD 3/8-16 X 1.25 HEX BOLT CUT TEMPLATE 2 3/8 OVERSIZED FLAT WASHER HEAD SCREW HEX DRIVE SCREW QTY: 8 QTY: 1 QTY: 22 QTY: 2 QTY: 8 1/4-20 X 0.75 BUTTON 1/4 SCREW FLAT WASHER 3/8 FLAT WASHER 3/8-16 NYLON LOCKNUT...
  • Page 8 SKID PLATE HARDWARE M8-1.25 X 40 FLANGED 3/8-16 OVERSIZED FLAT 3/8-16 X 1 BUTTON HEAD 3/8-16 X 1 FLANGED HEX 3/8-16 FLAT WASHER HEX HEAD SCREW WASHER HEX HEAD SCREW HEAD SCREW QTY: 2 QTY: 6 QTY: 2 QTY: 6 QTY: 2 1/4-20 X 0.75 BUTTON 1/4-20 NYLON LOCKNUT...
  • Page 9 WINCH FAIRLEAD HARDWARE 1/2-13 X 1.25 FLANGED HEX 1/2-13 NYLON LOCKNUT 1/2” FLAT WASHER 0.625 RETAINING RING HEAD SCREW QTY: 2 QTY: 2 QTY: 2 QTY: 1 F L AT L I N E VA N C O • S U P P O R T @ F L AT L I N EVA N C O . C O M • 8 8 8 - 6 6 7- 5 5 7 6...
  • Page 10 INSTALL TOOLS REQUIRED FOR THIS STEP: STEP | 01 LAYOUT & INSTALL PREP 1.1 Safety Check: Disconnect battery (both if applicable) prior to performing any electrical work and ensure you are working on a flat surface (FIG 1). 1.2 Review Install Outllne: Thoroughly read all instructions and warnings before beginning installation.
  • Page 11 MASKING TAPE TOOLS REQUIRED FOR THIS STEP: STEP | 02 BUMPER COVER CUT LINES 2.1 Cut Line 1: Align Cut Line Template 1 to body lines (FIG 3) and lay flat against the surface (FIG 4). Use Masking Tape to hold in place.
  • Page 12 TOOLS REQUIRED FOR THIS STEP: PENCIL STEP | 02 BUMPER COVER CUT LINES 2.3 Tracing Cut Lines: Ensure Cut Line Template 2 edge aligns with cut outline in Cut Template 1 (FIG 7) and proceed to trace Cut Lines (FIG 8-10). F I G 7 F I G 8 F I G 9...
  • Page 13 MEASURING TAPE TOOLS REQUIRED FOR THIS STEP: MASKING TAPE PENCIL MARKER STEP | 02 BUMPER COVER CUT LINES 2.4 Cut Line 3: Measure and mark 12.5” down from the top of the Plastic Bumper Skin (FIG 11). Tape from mark to Cut Line 3 Notch (FIG 12+13).
  • Page 14 TOOLS REQUIRED FOR THIS STEP: T25 TORX T30 TORX PRY TOOL STEP | 03 BUMPER COVER REMOVAL 3.1 Remove Grill: Remove 3 screws on top of the grill with a T25 Torx. Retain these screws for future steps. 3.2 Bumper Cover Removal (Side): Remove fender well plastic rivets with a pry tool.
  • Page 15 TOOLS REQUIRED FOR THIS STEP: STEP | 03 BUMPER COVER REMOVAL 3.5 Release Bumper Cover (Sides): Pull outwards at the top corner of the fender well to release clips on both sides (FIG 19). 3.6 Release Bumper Cover (Front): Pull upwards around the center step area to help release the bumper (FIG 20).
  • Page 16 FLATHEAD SCREWDRIVER TOOLS REQUIRED FOR THIS STEP: STEP | 03 BUMPER COVER REMOVAL 3.7 Release Ambient Air Sensor: Remove Ambient Air Sensor from grill (FIG 23). 3.8 Release Fog Light Harnesses: Disconnect fog light harnesses before fully removing the Factory Bumper Skin. Squeeze tabs on both sides and pull downwards to release (FIG 24).
  • Page 17 TOOLS REQUIRED FOR THIS STEP: FLATHEAD SCREWDRIVER STEP | 03 BUMPER COVER REMOVAL 3.10 Release Camera Bezel (if applicable): If you aren’t able to disconnect the Camera from the Camera Bezel, use a small screwdriver to gently pry on the tabs of both sides of the Camera Bezel until it releases (FIG 27+28).
  • Page 18 TOOLS REQUIRED FOR THIS STEP: MASKING TAPE STEP | 04 REMOVE INTERNALS 4.1 Identify Internals: See FIG 31 to identify components to be released in the following steps: Camera, Cruise Control Radar Sensor, Center Support, Factory Bumper and Splash Guard. 4.2 Disconnect Camera: Press tabs on Camera Bezel (FIG 32) CENTER SUPPORT to disconnect from the wiring harness (FIG 33).
  • Page 19 TOOLS REQUIRED FOR THIS STEP: FLATHEAD SCREWDRIVER T25 TORX STEP | 04 REMOVE INTERNALS 4.3 Adaptive Radar Sensor: Use a small Flathead Screwdriver to gently pry the Adaptive Radar Sensor tab upwards (FIG 35). Push the sensor out of the center support from the back (FIG 36) and disconnect from the harness by pressing in tabs and pulling apart (FIG 37).
  • Page 20 TOOLS REQUIRED FOR THIS STEP: PRY TOOL 13MM SOCKET FLATHEAD SCREWDRIVER STEP | 04 REMOVE INTERNALS 4.5 Removing Factory Bumper Wiring: Unclip wiring harnesses to free visible wires from the factory bumper (FIG 39). 4.6 Removing Factory Bumper: Use a 13mm Socket to remove the (8) M8 bolts securing the factory bumper in place (FIG 40).
  • Page 21 TOOLS REQUIRED FOR THIS STEP: FLATHEAD SCREWDRIVER STEP | 04 REMOVE INTERNALS 4.7 Remove Splash Guard: Use a small Flathead Screwdriver to gently pry the Splash Guard (FIG 43) out from the van using the two tabs on either side (FIG 44). You may discard this piece after removal (FIG 45).
  • Page 22 TOOLS REQUIRED FOR THIS STEP: STEP | 05 FVC BUMPER ASSEMBLY FRONT BUMPER BOX WINCH AND OFF-ROAD LIGHTS (OPTIONAL) 5.1 Locate Bumper Components: The Bumper Assembly can be different depending on the configuration you ordered. See BULL BAR (OPTIONAL) FIG 47 for how each component arrives shipped and FIG 48 for a diagram of how each of the pieces come together.
  • Page 23 TOOLS REQUIRED FOR THIS STEP: 9/16” WRENCH 9/16” SOCKET STEP | 05 FVC BUMPER ASSEMBLY 5.2 Driver Side Wing: Attach the Driver Side Wing to the Center Weldment using (7ea) 3/8-16 Flanged Hex Head Screws, Washers and Nylon Locknuts in the locations shown in FIG 49+50.
  • Page 24 TOOLS REQUIRED FOR THIS STEP: 7/32” ALLEN WRENCH 9/16” WRENCH OR SOCKET STEP | 05 FVC BUMPER ASSEMBLY 5.4 Install Bull Bar (Optional): If you ordered the Bumper with Bull Bar, you will attach it to the assembly at this time. Remove the plates covering the access points as shown in FIG 53+54 and install the Bull Bar using the same hardware.
  • Page 25 5/32” ALLEN WRENCH 7/16” WRENCH OR SOCKET 3/4” WRENCH OR SOCKET STEP | 05 FVC BUMPER ASSEMBLY 5.5 Install Winch Fairlead: Remove the 1/4-20 Hardware that hold the plate covering the Winch Fairlead Mounting Holes (FIG 55) and install Fairlead using (2) 1/2-13 x 1.25 Flanged...
  • Page 26 13MM WRENCH OR SOCKET TOOLS REQUIRED FOR THIS STEP: STEP | 06 WINCH CRADLE INSTALL 6.1 Install Winch Cradle: Attach the Winch Cradle to the van’s frame by using factory hardware with Loctite from the locations shown in FIG 57. Attach your Clip Nuts in the locations shown at this time.
  • Page 27 TOOLS REQUIRED FOR THIS STEP: STEP | 06 WINCH CRADLE INSTALL 6.2 Install Winch: If running a Winch, attach the Winch to the Winch Cradle using the hardware provided with the Winch into the locations shown in FIG 59+60. NOTE - The Winch Cradle fits winches up to 24.25” L x 7.15” D x 10.52”...
  • Page 28 9/16” WRENCH OR SOCKET TOOLS REQUIRED FOR THIS STEP: STEP | 06 WINCH CRADLE INSTALL 6.3 Install Center Light Brackets: If running Off-Road Lights, attach the Center Light Brackets to the Winch Cradle using (8) 3/8-16 Flanged Hex Head Screws, Washers and Nylon Locknuts into the locations shown in FIG 61+62.
  • Page 29 TOOLS REQUIRED FOR THIS STEP: STEP | 06 WINCH CRADLE INSTALL 6.4 Install Center Lights: If running Off-Road Lights, attach the Center Lights to the Center Light Brackets using the hardware provided with the lights in the locations shown in FIG 63+64. F I G 6 3 F I G 6 4 F L AT L I N E VA N C O •...
  • Page 30 FLATHEAD SCREWDRIVER TOOLS REQUIRED FOR THIS STEP: STEP | 07 MIGRATING WIRING HARNESSES 7.1 Disconnect Park Sensor Harness: Gently pry open the Park Sensor Bezel (FIG 65) that houses the Park Sensor to remove it from the Factory Bumper Skin (FIG 66). See FIG 67 for locations.
  • Page 31 TOOLS REQUIRED FOR THIS STEP: STEP | 07 MIGRATING WIRING HARNESSES 7.2 Install New Park Sensor Bezels: See FIG 68 for new Park Sensor Bezel locations. Install by aligning the notches in the Park Sensor Bezel to the cutouts in the Bumper. NOTE - The orientation of the Bezel corresponds to the direction in which the Park Sensor will be installed.
  • Page 32 RUN WIRING FOR LIGHTS UP HERE (IF APPLICABLE) STEP | 07 MIGRATING WIRING HARNESSES 7.3 Relocate Park Senor Harness to FVC Bumper: Set the Park YOU MAY NEED TO LOOSEN THIS TO CLEAR HARNESS Sensor Harness alongside the assembled Front Bumper, and fish the harness through the Driver’s Side Access Hole shown...
  • Page 33 STEP | 07 MIGRATING WIRING HARNESSES RUN WIRING FOR LIGHTS UP HERE (IF APPLICABLE) 7.4 Relocate Park Senor Harness to FVC Bumper: Repeat the YOU MAY NEED TO LOOSEN THIS TO CLEAR HARNESS process from Step 7.3 for the Passenger Side and fish the harness through the access hole shown in FIG 75+76.
  • Page 34 7.5 Install Off-Road Lights (optional): If you have additional Off-Road Lights to install, do so at this time and consolidate your wiring before attaching the assembled FVC Bumper to your Van. See FIG 77 for the location of the Off-Road Light OFF-ROAD LIGHT BRACKET Bracket within the Wing of the Bumper Assembly.
  • Page 35 TOOLS REQUIRED FOR THIS STEP: BODY SAW OR CUTOFF WHEEL STEP | 08 CUTTING FACTORY BUMPER 8.1 Cutting Factory Bumper: Place your Factory Bumper Cover on the ground or set of saw horses (FIG 79) and begin to make your cuts along the marked cut lines using a body saw or cutoff wheel (FIG 80+81).
  • Page 36 TOOLS REQUIRED FOR THIS STEP: BODY SAW OR CUTOFF WHEEL STEP | 08 CUTTING FACTORY BUMPER 8.2 Cutting Factory Bumper: When you reach the middle section, use a marker to extend the cut line and maintain the arc as you reach the center (FIG 82). Proceed to make your cut along the edge through to the other side (FIG 83+84).
  • Page 37 TOOLS REQUIRED FOR THIS STEP: BODY SAW OR CUTOFF WHEEL STEP | 08 CUTTING FACTORY BUMPER 8.3 Cutting Front Fender Liners: Using a Body Saw, cut off the protruding edge of the front Fender Liners as shown in FIG 85- 87.
  • Page 38 9/16” WRENCH OR SOCKET STEP | 09 INSTALL FVC BUMPER 9.1 Install FVC Bumper: To attach the FVC Front Bumper Assembly to the Winch Cradle, remove the Access Covers (FIG 88) and insert (4) 3/8-16 x 1.25 Hex Head Bolts with Washers and Loctite through the Center Weldment and into the Clip Nuts on the Winch Cradle (FIG 89).
  • Page 39 TOOLS REQUIRED FOR THIS STEP: BODY SAW OR CUTOFF WHEEL STEP | 09 INSTALL FVC BUMPER 9.2 Trim Fender Liners: Trim the Fender Liners so that they are able to be tucked inside the flanged edge of the Bumper Wings (FIG 90+91).
  • Page 40 POWER DRILL 7/32” DRILL BIT STEP | 09 INSTALL FVC BUMPER 9.3 Install Fender Liner Bracket to FVC Bumper: Loosely install the Fender Liner Brackets to the Bumper in the locations shown in FIG 91 using 1/4-20 Clip Nuts and Screws.
  • Page 41 TOOLS REQUIRED FOR THIS STEP: 7/32” ALLEN WRENCH 5/32” ALLEN WRENCH 9/16” WRENCH OR SOCKET 7/16” WRENCH OR SOCKET STEP | 10 SKID PLATE ASSEMBLY SKID PLATE VENT 10.1 Skid Plate Assembly: Find the components shown in FIG 95 and lay them down on a flat, non-abrasive surface for assembly.
  • Page 42 7/32” ALLEN WRENCH TOOLS REQUIRED FOR THIS STEP: 9/16” WRENCH OR SOCKET STEP | 10 SKID PLATE ASSEMBLY 10.7 Skid Plate Bracket 1: Loosely attach Skid Plate Bracket 1 using (2ea) 3/8-16 x 1 Button Head Hex Drive Screws, 3/8” Flat Washers and Nylon Locknuts (FIG 98).
  • Page 43 11.2 Install Skid Plate to FVC Bumper: With the Skid Plate loosely secured to the Van Mounts, attach the front of the Skid Plate to the FVC Bumper by threading (4) 3/8-16 x 1 Hex Drive F I G 101 Screws into the locations shown in FIG 102.
  • Page 44 5/32” ALLEN WRENCH TOOLS REQUIRED FOR THIS STEP: STEP | 12 FINAL CHECKS AND TRIM 12.1 Remove Adaptive Radar Sensor Faceplate and Bracket: Remove the Adaptive Radar Sensor Faceplate and Wrap- KEEP THIS AWAY Around Bracket to access the Radar Sensor Cavity (FIG 105). FROM WINCH 12.2 Position Adaptive Radar Sensor Harness: Fish the Adaptive Radar Sensor Harness down and through the new...
  • Page 45 TOOLS REQUIRED FOR THIS STEP: STEP | 12 FINAL CHECKS AND TRIM 12.4 Attach Trim Gaskets: Attach Trim Gaskets to the location shown in FIG 106+108 . (Repeat for Driver’s Side) F I G 10 6 F I G 10 7 F I G 10 8 F L AT L I N E VA N C O •...
  • Page 46 TOOLS REQUIRED FOR THIS STEP: STEP | 12 FINAL CHECKS AND TRIM 12.5 Replace Upper Bumper Skin: Hold the Upper Bumper Skin (that houses the grille) back into place in order to reconnect wiring harnesses (FIG 109). FOG LIGHTS 12.6 Reconnect Fog Lights: Reconnect Fog Light Harness to Van Fog Lights (FIG 110).
  • Page 47 TOOLS REQUIRED FOR THIS STEP: T25 TORX STEP | 12 FINAL CHECKS AND TRIM 12.9 Reposition Park Sensors: Plug the Park Sensors back in to their original locations as shown in FIG 113+114 and reconnect the Park Sensor Harness to back to the van. 12.10 Secure Upper Bumper Skin: Secure the Upper Bumper Skin to the van by using a T25 Torx and the three factory screws retained from step 3.1.
  • Page 48 INSTALL TOOLS REQUIRED FOR THIS STEP: SNAP RING PLIERS STEP | 12 FINAL CHECKS AND TRIM 12.11 Install Winch Rope to Hook: If you installed a Winch Fairlead, install the Winch Fairlead Hook to the Winch Rope by installing the stainless steel Pin and Internal Retaining Ring. NOTE - Snap ring pliers are required for this step.
  • Page 49 FVC (and see) from you! Head to the products and following along and we will make it right. FVC is product page and click “Leave a company of van and outdoor with your adventures. Tag us Review.”...