Lexus ES Fine Mesh and Adaptive Cruise Control Fine Mesh Grilles Upper and Lower Replacements

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1 IMPORTANT: PLEASE KEEP THIS INSTRUCTION MANUAL FOR FUTURE REFERENCE! Lexus ES Fine Mesh and Adaptive Cruise Control Fine Mesh Grilles Upper and Lower Replacements Part # / Black Ice Part #1372-B Adaptive Cruise Control Part # AC / Black Ice Adaptive Cruise Control Part #1372-B012-13AC Stacked Part # / Stacked Adaptive Cruise Part # AC Upper Part # U-13 / Upper Black Ice Part #1372-B10U-13 Adaptive Cruise Upper Part # U-13AC / Black Ice Adaptive Cruise Upper Part #1372-B10U-13AC Stacked Upper Part # U-13 Stacked Adaptive Cruise Upper Part # U-13AC Lower Part # L-13 / Black Ice Lower Part #1372-B10L-13 / Stacked Lower Part # L-13 TOOLS REQUIRED Automotive grade masking tape, #2 phillips screwdriver, pliers, vibrating or jig saw, disc grinder, electric drill, 1/16 & 1/8 drill bits, razor blade or X-Acto knife, large and small flat blade screwdrivers, 9mm socket and ratchet, flat or semi-gloss black paint, solvent, glass cleaner and soft, clean cloths Open the hood and remove the factory push fasteners securing the radiator support panel cover and remove the cover. 2. Use a flat blade screwdriver to remove the factory push pin / rubber bumper securing the top of the factory bumper cover to the radiator support panel Remove the factory push pin from the outer edges of the factory grille. 4. Remove the factory push pin from the center of the factory grille.

2 Raise the vehicle to a comfortable working height on a lift or use a jack and jack stands. Do not rely on the jack alone to support the weight of the vehicle. If the jack fails, serious injury could occur! Apply masking tape to the factory grille and bumper cover as shown. 6. Use a flat blade screwdriver to rotate the inner wheel well mounting fasteners 90 degrees (1/4 turn) to unclip and remove them (one each side) Remove the plastic push pin securing the upper forward portion of the inner wheel well to the front fender. 8. Pull the inner wheel well out of the way and remove the 10mm phillips screws securing the corner of the bumper cover to the front fender (one each side) Remove the plastic insert from the bumper cover / fender attaching point. 10. Remove the 10mm phillips screws securing the sides of the lower aero pan to the bumper cover.

3 Remove the phillips screws securing the center of the lower aero pan to the bumper cover. 12. Apply masking tape to the fender and bumper cover where they meet Give several quick, firm tugs to unclip the bumper cover from the front fender mounting channel. 14. Pull straight out on the bumper cover to release it from the mounting channel under the headlights. With the help of an assistant, carefully lower the bumper cover to gain access to the driving light electrical connectors Disconnect the driver and passenger side driving lamp electrical connectors and the main harness connector on the passenger side. 16. With the help of an assistant, carefully place the bumper cover onto a flat, clean work area and unclip the lower bumper cover mounting tabs securing the edges of the factory grille.

4 Remove the lower factory grille (not reused). 18. Remove the plastic push pins (one each side) at the top outer corners of the factory grille Remove the factory philips screws from across the top edge of the upper grille insert. 20. Use a flat blade screwdriver to release the mounting tabs securing the factory upper grille to the bumper cover Remove the upper factory grille insert from the bumper cover. The upper mounting portion of the factory grille will be reused. Remove the two (2) phillips screws (one per side at the lower corners of the upper grille) that retain the factory chrome molding to the bumper cover (see arrow). 22. Remove the factory emblem from the grille by using a small, flat blade screwdriver to pry off the factory push retainers at the top of the emblem. Unclip the bottom of the emblem and remove it for installation on the mesh grille.

5 Use a vibrating or jig saw to carefully cut through the top webbing (where shown) connecting the factory upper mounting plate to the insert. 24. The trimmed upper portion of the factory upper grille insert should look like this once the cutting is finished. Smooth any rough edges with a small disc grinder. The top portion will be reused For Stacked grilles: Use a disc grinder to grind off the upper portion of the outer and center raised areas on the top of the factory upper grille mounting plate. 26. For Stacked grilles: Trim the raised portions of the plastic until they look similar to the above photo Cut out, overlap and tape together the templates found on the last page of this manual. Tape the upper template into place, making sure it aligns with the factory grille mounting tabs. Use an awl or similar pointed tool to mark each hole location, untape the template, flip it over and mark the holes on the opposite side. 28. Tape the lower template into place, making sure it aligns with the factory grille mounting tabs. Use an awl or similar pointed tool to mark each hole location, untape the template, flip it over and mark the holes on the opposite side.

6 Use a 1/8 (.125 ) drill bit to drill through the marks made in the previous step. Connect the holes with the drill bit, creating small mounting slots to allow for slight left to right grille adjustments. 30. Align the upper mesh retaining bracket across the bottom edge of the factory upper grille opening (as shown). Align the upper mesh grille bar mounting studs through the slots in the retaining bracket and hand tighten the supplied #8-32 ESNA half nuts at this time Close-up of the installed mesh retainer, upper mesh grille bar and #8-32 ESNA half nuts. 32. Turn the bumper cover face down, align the mesh between the retainer and the mesh bar and make sure the top edge fits below the factory mounting tabs on the bumper cover (mesh grille shown, adaptive cruise mesh grille similar) For Stacked grilles: Turn the bumper cover face down, align the black mesh first between the retainer and the mesh bar and make sure the top edge fits below the factory mounting tabs on the bumper cover (mesh grille shown, adaptive cruise mesh grille similar). 34. For Stacked grilles: Align the chrome mesh second between the retainer and the black mesh and make sure the top edge fits below the factory mounting tabs on the bumper cover (mesh grille shown, adaptive cruise mesh grille similar).

7 For Stacked grilles, overlap the mesh as best you can. There are going to be areas that will not be overlapped as well as others. 36. Use the supplied 7/8 O.D. x 1/4 I.D. black plastic washers to secure the lower outer corners of the mesh to the bumper cover using the factory screws removed in Step For Stacked grilles: Install the supplied #10 S.S. pan head screws and the 7/8 O.D. x 1/4 I.D. large black plastic washers to secure the bottom portion of the mesh. 38. Make sure the upper mesh grille bar is perfectly centered. Tighten the installed #8-32 ESNA nuts to secure the bottom portion of the mesh Align the top portion of the upper factory grille insert cut apart in Step 23. Reinstall the factory screws removed in Step 19. Reinstall the factory pins removed in Step 18 (not shown). Make sure the factory weatherstrip mounting pins do not interfere with reinstalling the top portion of the factory upper grille insert. 40. For Stacked grilles: Align the top portion of the upper factory grille insert cut apart in Step 23. Use and awl or similar pointed tool to align the mounting holes and the alignment pins, then use vise-grips to secure the top plate to the bumper cover. Reinstall the factory screws removed in Step 19, then remove the vise grips. Re install the factory pins removed in Step 18 (not shown). Make sure the factory weatherstrip mounting pins do not interfere with rein stalling the top portion of the factory upper grille insert.

8 Press the upper portion of the factory grille insert cut apart in Step 23 into the back of the bumper cover until it snaps into place. Install the supplied #8 x 3/8 black truss head screws as shown onto each tab to prevent the factory cut portion from unclipping. 42. For Stacked grilles: Install the supplied #8 x 3/8 black truss head screws as shown onto each tab to secure the factory cut portion of the factory grille to the bumper cover mounting tab. The extra layer of mesh will prevent tab from snapping into place Install the lower mesh grille using the same procedure as the upper grille outlined in the previous steps Align the mesh with the inside edges of the mounting tabs (as shown) and use a 1/16 drill bit to drill a pilot hole at a mesh intersection near the back of the mounting tab Install the supplied #8 x 3/8 black truss head screws to secure the upper edge of the lower mesh section to the bumper cover. Repeat this procedure at all mounting tab locations. 46. For Stacked grilles: Install the supplied #8 x 5/8 black truss head screws to secure the upper edge of the lower mesh sections to the bumper cover. The chrome plated mesh section should be protruding past the top edge of the bumper cover mounting tab. Repeat this procedure at all mounting tab locations.

9 Tighten the installed #8-32 ESNA nuts to secure the bottom portion of the mesh. 48. Use pliers to bend the mounting pins back to keep the bottom edges of the bumper cover tight against the mesh grille bars. 49. Grind the back of the factory grille emblem until all edges are flush. 50. Apply the supplied.045 x 1 double faced tape to the back of the factory emblem (mesh grille application shown). 51. For Adaptive Cruise grilles: Install the supplied.045 x.250 double faced tape to the front of the adaptive cruise emblem mounting plate as shown. 52. Peel the backing off the double faced tape, align the supplied emblem mounting plate (adaptive cruise mesh grille shown, mesh grille emblem plate is solid in the center) over the emblem and press it firmly into place to set the tape.

10 For non-adaptive cruise grilles: Perfectly center the factory emblem over the upper mesh section as shown. It may be necessary to clip a wire or two (especially on Stacked grilles) to perfectly center the emblem. 54. Install the supplied small back plastic washers, #10 S.S. lock washers and #8-32 S.S. hex nuts (adaptive cruise mesh shown, mesh grille emblem plate is solid in the center). Tighten until the emblem is secure Apply black paint to everything behind the upper and lower grille openings on the vehicle at this time. If you choose not to paint items black, you will be able to see them through the mesh grille. 56. Install the supplied black cable ties to secure the factory wire harness and keep it from hanging down behind the lower grille opening Close-up of he supplied black cable tie installation. 58. Align the bumper cover back onto the vehcile and reverse the removal procedure. Peel off the protective cover from the upper and lower grille bars and use a mild solvent and a soft, clean cloth to remove any glue residue. Use alcohol or glass cleaner and a soft clean cloth to remove any solvent residue.

11 Trim the lower mounting tabs from the back of the factory front license plate bracket (if equipped). Reinstall the bracket using the factory 10mm hex screws. Remove all protective masking tape. Close the hood and lower the vehicle to finish.

12 Fine Mesh Part # Upper Fine Mesh Section Lower Fine Mesh Section Hardware Kit Emblem Mounting Plate x 1 Double Faced Tape #8-32 ESNA Half Nuts #8 x 3/8 Truss Head Screws Adaptive Cruise Fine Mesh Part # AC 1 Adaptive Cruise Upper Fine Mesh Section AC 1 Lower Fine Mesh Section Hardware Kit AC 1 Adpative Cruise Emblem Mounting Plate AC x.250 Double Faced Tape #8-32 ESNA Half Nuts Fine Mesh Black Ice Part #1372-B Upper Black Ice Mesh Section BI 1 Lower Black Ice Mesh Section BI 1 Hardware Kit Emblem Mounting Plate x 1 Double Faced Tape #8-32 ESNA Half Nuts #8 x 3/8 Truss Head Screws Adaptive Cruise Black Ice Fine Mesh Part #1372-B102-13AC 1 Adaptive Cruise Black Ice Upper Fine Mesh Section ACBI 1 Black Ice Lower Fine Mesh Section BI 1 Hardware Kit AC 1 Adpative Cruise Emblem Mounting Plate AC x.250 Double Faced Tape #8-32 ESNA Half Nuts

13 Stacked Mesh Part # Upper Chrome Fine Mesh Section Upper Black Fine mesh Section BI 1 Lower Chrome Fine Mesh Section Lower Black Ice Fine Mesh Section BI 1 Hardware Kit Emblem Mounting Plate x 1 Double Faced Tape #8-32 ESNA Half Nuts Upper Fine Mesh Part # U-13 1 Upper Fine Mesh Section Hardware Kit Emblem Mounting Plate x 1 Double Faced Tape Stacked Adaptive Cruise Mesh Part # AC 1 Upper Black Ice Mesh Section ACBI 1 Upper Chrome Fine Mesh Section AC 1 Lower Chrome Fine Mesh Section Lower Black Ice Fine Mesh Section BI 1 Hardware Kit AC 1 Adaptive Cruise Emblem Mounting Plate AC x.250 Double Faced Tape #8-32 ESNA Half Nuts Upper Black Ice Fine Mesh Part #1372-B10U-13 1 Upper Black Ice Fine Mesh Section BI 1 Hardware Kit Emblem Mounting Plate x 1 Double Faced Tape

14 Adaptive Cruise Upper Fine Mesh Part # U-13AC 1 Adaptive Cruise Upper Fine Mesh Section AC 1 Hardware Kit AC 1 Emblem Mounting Plate AC x.250 Double Faced Tape Upper Stacked Mesh Part # U-13 1 Upper Black Ice Mesh Section BI 1 Upper Chrome Fine Mesh Section Hardware Kit Emblem Mounting Plate x.1 Double Faced Tape Lower Fine Mesh Part # L-13 1 Lower Fine Mesh Section Hardware Kit Adaptive Cruise Upper Black Ice Fine Mesh Part #1372-B10U-13AC 1 Adaptive Cruise Upper Black Ice Fine Mesh Section ACBI 1 Hardware Kit AC 1 Emblem Mounting Plate AC x.250 Double Faced Tape Upper Stacked Adaptive Cruise Mesh Part # U-13AC 1 Adaptive Cruise Upper Black Ice Mesh Section ACBI 1 Upper Chrome Fine Mesh Section AC 1 Hardware Kit AC 1 Adaptive Cruise Emblem Mounting Plate AC x.250 Double Faced Tape Lower Black Ice Fine Mesh Part #1372-B10L-13 1 Lower Black Ice Fine Mesh Section BI 1 Hardware Kit

15 Lower Stacked Mesh Part # L-13 1 Lower Chrome Fine Mesh Section Lower Black Ice Fine Mesh Section BI 1 Hardware Kit Cut out, align and tape templates together. Cut out, align and tape templates together.

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