Procedures
AZ88.00-P-0001-02PA Converting Front Bumper
- as of 1.6.06
Do not damage paint.
1. Clean bores for center air inlet grate mounting clips.
Remove paint residues present with dia.7.2 mm 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.
3. 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).
Vehicles with headlamp cleaning system, code 600
4.1. 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).
5. Insert front basic carrier (17) on left and right into front bumper paneling (1) and fasten with clips (18) (6 each).
Observe precise seat when inserting; do not damage retaining lugs.
Ensure that the front basic carrier (17) arrests properly in the front bumper paneling (1) (see arrow).
Press clips onto assembly lugs with suitable tool. When installing, counterhold front bumper paneling (1), component springs back.
6. Install left and right reinforcement (8) on front bumper paneling (1) and fasten with clips (12) (6 each).
Observe precise seat when inserting; do not damage retaining lugs.
Ensure that the front basic carrier (17) arrests properly in the front bumper paneling (1) (see arrow).
Press clips onto assembly lugs with suitable tool. When installing, counterhold front bumper paneling (1), component springs back.
7. Connect reinforcement (8) and front basic carrier (17) with two expansion rivets (9) each.
Component Identification:
Vehicles with Parktronic system (PTS) code 220
8.1. Insert PTS wiring harness (21) removed from standard bumper into inner section (17) and fasten to brackets present.
Vehicles with Parktronic system (PTS) code 220
9.1. Arrest front PTS separation point (X26/27) in bracket of basic carrier (17) (see arrow).
Vehicles with Parktronic system (PTS) code 220
10.1. 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.
11. Insert left and right impact absorber (29) removed from standard bumper into front bumper paneling (1).
On vehicles with Parktronic system (PTS), code 220, ensure that PTS wiring harness is routed correctly. The routing is defined in the impact absorbers. Do not kink or crush PTS wiring harness.
12. Insert basic carrier (31) into front bumper paneling (1) and fasten with two expansion rivets (9) on left and right.
Observe precise seat, do not damage retaining lugs. The center basic carrier (31) should arrest properly.
Ensure that center basic carrier (31) is seated correctly on the upper attachment points of the front bumper paneling (1) (see arrow).
13. Insert center impact absorber (30) removed from standard bumper into front bumper paneling (1) and arrest.
The center impact absorber (30) should arrest properly in the center basic carrier (31).
13. Install spring nuts (6) for mounting left and right air inlet grate (6 each).
14. Install spring nuts (13) for mounting left and right front fog lamps (6 each).
15. Insert left front fog lamp (E5/1) and right front fog lamp (E5/2) into front bumper paneling (1) and install with three 4.8 x 19 combination bolts (15) each.
On models 211.077/ 277 each of the front fog lamps is installed with 4 combination bolts.
16. Insert center bottom reinforcement (5) into front bumper paneling (1) and fasten with hot melt adhesive.
On models 211.077/ 277 the left and right reinforcements are also inserted into the front bumper paneling (1) and fastened with hot melt adhesive.
17. Install left and right clips (11) on front bumper paneling (1).
The clips (11) are different for the left and right side.
18. Insert paneling bushings (36) on left and right into front bumper paneling (1).
19. Insert towing eye cover (24), removed from standard bumper, into front bumper cover (1) and hook in retainer.
Perform following steps only after installing front bumper paneling (1).
20. 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).
21. 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.
Before installing the license plate frame (25) insert center air inlet grate.Ensure that the center air inlet grate arrests properly in the mounting clips.
22. Insert left and right air inlet grate and fasten with 3 sheet metal screws (St3.5x22) each.