Procedures
AZ88.00-P-0001-02EW Converting Front Bumper
Check components removed from standard bumper before assembly and replace if damaged.
Pay attention to paint damage.
The upper right basic carrier (2) and upper left basic carrier (3) are preinstalled in the front paneling (1).
1. Drill holes for assembling license plate frame from inside of front paneling (1) (drill dia.=3 mm pilot hole and then drill out to dia.=8.5 mm).
The hole positions of the individual national versions are marked on the inside of the front paneling (1). ECE and USA national versions, also drill hole in center. This hole serves for the locating lug on the rear of the license plate frame.
2. Insert insert nuts (4) into front paneling (1).
3. Fasten license plate frame (25) to front paneling (1) with two bolts (26).
4. Hook check strap on towing eye cover (8) into front paneling (1).
5. Insert towing eye cover (8) into front paneling (1) and arrest.
The towing eye cover (8) should arrest correctly in the front paneling (1).
Vehicles with headlamp cleaning system, code 600
6. Install cover (16) with HCS [SRA] spring (18) on right and left in front paneling.
For purpose pull bearing bracket on HCS [SRA] cover (16) apart and insert into bearing holes in HCS [SRA] frame (17). Then close HCS [SRA] cover (16) and insert HCS [SRA] spring (18).
Shown on front paneling on model 207.
7. Insert center air inlet grate (5) into front paneling (1) and arrest.
The center air inlet grate (5) should arrest properly in the front paneling (1).
8. Insert air ducting end stop covers (6) on right and left into front paneling (1) and arrest.
The air ducting end stop covers (6) should arrest properly in the front paneling (1) and center air inlet grate (5).
9. Insert right and left air inlet grate (20), right and left front paneling (1) and arrest.
Left and right air inlet grate (20) should arrest properly in the front paneling (1).
10. Install clip fasteners on right and left on right and left air inlet grate (20).
The number of the required clip fasteners (2 to 5 on each side) varies according to the equipment.
11. Insert additional headlamp (23) into left and right air inlet grate (20) and fasten with the 4.8x19 sheet metal screws.
The number of 4.8x19 sheet metal screws varies according to the equipment.
12. Insert center lower center basic carrier (10) into front paneling (1) and arrest.
The center lower basic carrier (10) should arrest properly in the front bumper paneling (1).
13. Inert wiring harness removed from standard bumper into front paneling (1) and fix in place in mounts present.
Vehicles with code (220) Parktronic System (PTS)
14. Insert outer left, inner left, inner right and outer right front bumper radar sensors (A86/1b4), removed from standard bumper, into mounts of front paneling (1).
Before inserting sensors, check decoupling rings, replace if damaged.
15. Arrest frame wiring harness electrical connector and front bumper electrical connector (X26/28 or X26/38) in right upper basic carrier (2).
The frame wiring harness and front bumper electrical connectors (X26/28 or X26/38 depending equipment) must arrest properly in the right upper basic carrier (2).
16. Insert reinforcements (22) on right and left into front paneling (1), arrest and fasten with one blind rivet (7) each to right and left upper basic carrier (3).
The reinforcements (22) must arrest properly in the front paneling (1).
Vehicles with code (230) Exclusive parking assist
17. Insert front short range radar sensor units (A86/1) on right and left into reinforcement mounts (22) and secure with two fastening brackets (9) each.
18. Connect front short range radar sensor units (A86/1) on right and left to wiring harness.
Vehicles with code (U60) Pedestrian protection
19. Install one insert clip fastener (11) on right and left on right and left upper basic carrier (2, 3).
20. Install left front bumper pedestrian protection sensor (B151/1) and right front bumper pedestrian protection sensor (B151/3) on right and left with one bolt M5x20 (12) each and connect to wiring harness.
Shown on front paneling on model 207.
21. Install reinforcements (31) on right and left on front paneling (1) and fasten with one blind rivet (7) each.
Arrest reinforcements (31) on front paneling (1) twice (see arrows).
22. Instal right and left impact absorbers (13) and center impact absorber (14) in front paneling (1).
Position left and right impact absorbers (13) below bracket on left and right upper basic carrier and then "screw into" front paneling (1). Ensure that all catch tabs arrest properly. Push in center impact absorber (14) and arrest on center air inlet grate with catch tabs.