I was very gentle and applied minimal pressure and I was ready to give up and heard a definite "click". I removed the whole bumper cover up to the middle section and reclipped it in place, exercing some pressure at an angle to make it properly click in place under the headlight. I noticed as you said that a few clips under the passenger side headlight were not 100% clicked in place it appeared that they were off my a hair. I worked on the passenger side only since the driver side was perfect. The plastic was warm and flexible after an hour of sitting there with heaters at the max. I worked in the garage and let everything get nice and warm. It was abnormally hot today for the season here and I gave it another go since this crooked look drove me nuts when I looked at the car. I'll give it another go next spring when the sun is shining and the plastic less brittle. I decided to stop the project for now because of the cramped space in my garage, the sub-zero freezing temperatures here and the risk of making matters worse for a mere 1/32" of difference. The gap near the wheel well on the passenger side is definitely smaller I can barely fit a fingernail in the gap and almost like pics I took when the car was new. I managed to nudge it back in place but not 100% as the driver side. I tried to make it look a bit better but only partially the bumper is almost rubbing on the headlight in the center corner because it looks it is not all the way in. The bracket support around the headlight slightly gives in when I push and it makes thing quite complicated to hook up. I tried pushing the passenger side but it did not go fully back where it was originally. Looks like the whole bumper is a tiny bit misaligned to the passenger side of the car if you can understand. You were right, the culprit was the passenger side headlight some tabs did not go fully in place when they did it the first time. I decided to remove it myself this morning and reinstall it after watching a few tutorials. However, since all the clips are in place, nothing seems to be broken and all is fine, I wonder if I'm expecting too much? The tolerance is still very narrow, just not as narrow as it was brand new. I called my body shop and they said to bring it back tomorrow they will look after it and try to adjust it. I found a couple of clips on YouTube where guys remove and reinstall this in a few minutes and they still have the factory fit. Everything is clipped in place and looks snug but for some reason, it is not as tight as it was out of the factory. I put the car in my garage to heat it up a bit and check the installation. It is visible on both sides, maybe a bit more on the passenger side. About 3 hours later I used my car and noticed a gap about the thickness of a quarter where the bumper meets the fender. When I picked the car up, I inspected the job with the tech guy and was quite happy. It is about 25% the cost of a new bumper and that is nice. They did a great job and the repair is now invisible to the untrained eye and since it is so low and under the bumper, I'm okay with this since I get to keep my OEM part and factory paint. I decided to take it to a specialized shop in my area that deal with bumper repair using plastic welding. Some rash and scraping at the contact spot at the lowest point of impact but unfortunately it cracked there for about 3 inches. It made a huge noise in the car and I stopped at the next exit to check the damage. I had about 2 seconds to react before it hit me and I was able to almost dodge it and I ran over it under my driver side fog light. The ice chunk was the size of a bowling ball and bouncing 6-8' high on the highway. I was following a semi-truck and a large chunk of ice was ejected from under the truck at high speed in my direction. I had a minor incident last week on the highway.
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