AZ88.00-P-0001-02QA Converting Front Bumper

AZ88.00-P-0001-02QA Converting Front Bumper
- as of 1.6.05

Modification Notes:

Do not damage paint.







1. Clean holes for center air inlet grate mounting clips.

Remove paint residues present with 7.2 mm dia. bit or awl

2. Insert mounting clips (2) for center air inlet grate into cleaned holes (6 each).

The openings of the mounting clips (2) should point in the direction of travel.

Component Identification:

3. Hook in retaining strap covers (3) for mounting screw covers.

Install components in correct positions. The end with the stay (see arrow) is intended for hooking in the mounting screw cover. Hook in and close mounting screw covers after installing the bumper.







4. Install left and right chrome trim strips (4) into front bumper paneling (1).

Check arrest of chrome trim strips (4) on inside; if necessary, press in again (see arrow).







5. Fasten air ducting (5) to front bumper paneling with 4 expansion rivets (see arrow).







6. Install spring nuts (6) for fastening air inlet grate on left and right (6 each).







7. Install cable holder (7) on right air passage as illustrated.







8. Install right inner reinforcement (8), right outer reinforcement (9), left inner reinforcement (10) and left outer reinforcement (11) on front bumper paneling (1) and fasten with clips (12) (8 each).







9. Install spring nuts (13) on left front fog lamp (E5/1) and right front fog lamp (E5/2) as illustrated.







10. Insert left front fog lamp (E5/1) and right front fog lamp (E5/2) into front bumper paneling and install with 4 sheet metal screws (15) each.
11. Connect wiring harness (16) to left front fog lamp (E5/1) and right front fog lamp (E5/2).







12. Insert left impact absorber (29), center impact absorber (30) and right impact absorber (31) removed from standard bumper into front bumper paneling.

On vehicles with Parktronic system (PTS), code 220, ensure that PTS wiring harness is routed correctly. The routing is defined in the impact absorbers.







13. Insert inner section (17) into front bumper paneling (1).

Observe precise seat, do not damage retaining lugs.







14. Fasten inner section (17) with clips (18) in front bumper paneling (1) (8 each).

Press clips onto assembly lugs with suitable tool. When installing, counterhold front bumper paneling (1), component springs back.







15. Fasten inner section (17) at left and right side to front bumper paneling (1) with 8 blind rivets (19).

Component Identification:

16. Fasten swip clips (20) on outer right and left of headlamp cutouts with one blind rivet each.







Vehicles with Parktronic system (PTS) Code 220

17.1. Insert PTS wiring harness (21) removed from standard bumper into inner section (17) and fasten to brackets present.

On models 209.377/477 the PTS, front bumper connector (X26/27) is fastened to the inner section (17) at the bottom right using a cable tie.







Vehicles with Parktronic system (PTS), code 220

18.1. Arrest PTS, front bumper connector (X26/27) in inner section bracket (17) (see arrow).

On models 209.377/477 the front bumper PTS connector (X26/27) is fastened to the inner section (17) at the bottom right using a cable tie.







Vehicles with Parktronic system (PTS), code 220

19.1. Connect front bumper PTS sensor unit (A42) and insert into brackets

Before inserting front bumper PTS sensor unit (A42) check decoupling rings; replace if damaged.







Vehicles with headlamp cleaning system, code 600

20.1. Install HCS cover (22), removed from standard bumper, with HCS spring (23) into front bumper cover (1).

For this purpose, press bearing bracket on HCS cover (22) together and position on bearing pins. Then close HCS cover (22) and insert HCS spring (23) (see bottom figure).







21. Insert tow eye cover (24) removed from standard bumper into front bumper paneling and hook in retainer.







22. Insert center air inlet grille (32) and clip in temperature sensor.

Always insert center air inlet grate (32) before installing license plate frame.

Precisely insert center air inlet grille (32) into mounting clips (2) to ensure proper arresting.







23. Install license plate frame (25) at outside of front bumper paneling (1) and prepare for assembly.

Use license plate frame (25) as template for marking holes. The distance (a) between the license plate frame (25) and the left and right bumper strips should be equal. Align license plate frame (25) along contour of front bumper paneling (1) (see arrows).

24. Drill four holes for assembling license plate frame (25) and install license plate frame (25) on front bumper paneling (1) with four bolts (PT5x16)

Tighten screws only with screwdriver.

Completion after installing bumper







25. Hook retaining strap cover (3) into mounting screw cover (26) and insert mounting screw cover (26) (right and left).

Ensure that mounting screw cover (26) arrests correctly.







26. Insert left air inlet grate (27) and right air inlet grate (28) and fasten with 3 sheet metal screws each (St3.3.5x22).