Thursday, December 1, 2011
2004–2005 Subaru WRX STI RS Grille Install Instructions
Subaru WRX – Aluminum Upper and Black Powder Coated Lower Grilles. Note: Please read the instructions completely before beginning the installation of your grilles.
Upper Grille:
Step 1: Open the hood and remove the upper grille. This is done using the flat blade screwdriver to press on the gibs (latches) to release the grille from the vehicle. The screwdriver needs to be able to reach deep to release the gibs holding the bottom portion of the grille. Be careful not break any of these plastic fasteners, but if you do – I’m sure the Subaru parts department can supply you with replacements.
Step 2: Turn the grille over and lie it on something soft (not pine needles ?) like a terry cloth towel. You need to remove the metal clips and the factory grille mesh. You then need to remove the protruding plastic tabs to which the previous mesh was attached. This can be done with a hack saw blade (quite easy) or an alternate cutting tool. Be Careful not to be too hasty and remove pieces that should not be removed like fingers.
Step 3: Place the aluminum grille behind the plastic trim making sure the good side is facing out. You can tell the good side as it feels smoother around the holes (less noticeable on the black grilles). You will then need to drill the holes as shown to attach the grille to the plastic using the provided zip ties. These should not be visible after installation is complete. Using the Zip ties provided attach the grille to the OEM shell then insure it is square (holes are level) and tighten, but not too tight. If you are installing the lower grille delay putting the upper grille back in place as it provides access to the rear of the lower grille during installation.
Lower Grille
Step 1. Drill 2 holes on each side of the front bumper cover. These holes need to be close to the back lip at the top and at the bottom. The zip ties will be going through the hole and around the back edge. All of this is black so even with the grille removed these holes will not be noticeable unless inspected in close detail. You should now have a total of 4 holes (2 on each end like the picture).
Step 2: Drill 2 more holes in the vertical brace. The holes shown are vertical, but horizontal will work better so that the zip tie will run along side the trim. It makes it disappear into the trim.
Step 3: Start all of the zip ties in the grille as shown. You should have 1 in each corner and 1 in the center along the top. Note that the zip tie starts from the back and then loops thru the adjacent hole. The “head” of the zip tie is flush against the back of the grille. This method will allow you to cinch the zip tie from the front of the grille. NOTE: Choose 4a or 4b method!
Step 4a: Loop a zip tie through the holes you drilled in the bumper cover. The bumper cover hole would be where my finger is pointing. Then just get the zip tie started so that it won’t pull apart. You will then be able to loop the first set of zip ties (from step 3) through the set of looped zip ties and then thru the head and out thru the grille.
