2002 Ford Focus ZX5 - Five-Alarm Chili

The front grille needed to be removed to access some of the front bumper cover fasteners.

The bumper cover is held in place with numerous plastic fasteners located at the top and sides of the cover.

Remember to disconnect the foglight harnesses and side marker lights.

Roush Performance Parts supplies additional hardware for installation of many items such as the new foglights.

The new lower lamps require new harness ends to get them to mate up with the factory wiring. Roush includes these with the kit, so you don't have to drag your car by its harness to the Ford dealership to get the correct terminals.

The turning marker lights must be transplanted to the new bumper cover.

Somewhere in transit from office to body shop, we managed to lose the supplied plastic grilles for the various openings in the Roush body kit. Motor City came to the rescue and installed a wire mesh.

We found that the new foglights were a bit deeper than the stock lights, and the passenger-side one came in contact with one of our intercooler charge pipes. We simply cut off 2 inches from each end, which moved the pipe toward the driver and out of the interference range.

Having an extra set of hands is extremely helpful when installing the bumper covers.

The side skirts are fastened using a combination of two-part epoxy and several sheetmetal screws. Using the epoxy will help reduce sagging over time, though we have never seen a Roush body part sag. It's OEM-quality stuff.

There are a couple of holes at each end of the side skirt to secure the skirt to the car.

The rear bumper cover is held on by plastic fasteners just like the front. If you break or lose some of them, they are usually available at the local Ford dealer.

If you use some common sense in removing the bumper covers and not damage them in the process, you can always eBay the stock parts to help offset the cost of the body kit.

Since the Roush bumper cover hangs lower, bracket spacers are included with the kit to make up for the difference.

The new rear cover was mocked up so we could determine where we needed to cut the wire mesh. If you're using the supplied Roush grilles (which we lost), then you can skip the trimming step.