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

AZ88.00-P-0001-02CWA Converting Front Bumper
Model 204.0/2 as of model year 2012,
model 204.3

Check components removed from standard bumper before assembly and replace if damaged.
Pay attention to paint damage.





1 Drill five holes for assembling license plate frame from inside on front bumper paneling (1) (see arrows).
The hole positions of the corresponding holes are marked on the inside of the front bumper paneling (1).
2 Arrest license plate frame (2) and fasten to front bumper paneling (1) with the four bolts (3).
Tighten bolts only with screwdriver.
Shown with license plate cover for ECE.





3 Insert center grate cover (4) from rear into front bumper paneling (1) and arrest.
The towing eye cover (4) should arrest correctly in the front bumper paneling (1).





4 Insert HCS cover (headlamp cleaning system) (6) on right and left into front bumper paneling (1) from front and install bearing guides on HCS cover (6) on outer journals (see arrows).
5 Install HCS springs (7) on inner journals on right and left.
Ensure that HCS cover (6) is seated correctly on front bumper paneling (1).





6 Insert upper basic carrier () into front bumper paneling (1) and upper basic carrier (8) on left and right and arrest starting at side.
The upper basic carrier (8) should arrest properly in the front bumper paneling (1).
7 Fasten upper basic carrier (8) to front bumper cover (1) with two expansion rivets (10) (see picture at bottom).
8 Install suitcase corners (9) on right and left on upper basic carrier (8) and fasten with one expansion rivet (10) each (see picture at top).





9 Guide sheet metal rails (11) on right and right onto lug on upper basic carrier (8) (see arrow) and fasten with one expansion rivet (10) each.





10 Arrest wheelhouse cover (12) on right and left into front bumper paneling (1) and fasten with one expansion rivet (10) each.
The wheel arch covers (12) should arrest properly in the front bumper paneling (1).





Vehicles with pedestrian protection sensor

11 Fasten upper basic carrier (8) on right and left to center grate cover (4) with one expansion rivet each.





Vehicles with Parktronic system (PTS) code 220

12 Clip outer left front parking distance sensor (B8/1), center left front distance sensor (B8/2), inner left front distance sensor (B8/3), inner right front distance sensor (B8/4), center right front distance sensor (B8/5) and outer right front distance sensor (B8/6) into brackets on front bumper paneling (1).
Previously check whether a decoupling ring (transparent silicon ring) is installed on the parking distance sensors.

Vehicles with close range radar (NBR)

13 Insert front radar sensors (13) on right and left into upper basic carrier (8) on right and left and secure with NBR bracket (14).
The NBR bracket (14) should arrest properly in the upper basic carrier (8).

Vehicles with pedestrian protection

14 Screw left front bumper pedestrian protection sensor (B151/1) and right front bumper pedestrian protection sensor (B151/3) to upper basic carrier (8) wit one sheet metal clip nut M5 (16) each and one M5x20 mm bolt (17).
Observe information on preventing damage to electronic components due to electrostatic discharge





15 Route wiring harness (18) in front bumper paneling (1) and connect to pedestrian protection, PTS and NBR sensors depending on the equipment. Arrest PARKTRONIC front bumper electrical connector (X26/27) to upper basic carrier (8) on right.





16 Insert four insert clip nuts (20) on right and left into front bumper paneling (1).
On vehicles with LED daytime driving lights, and additional cutout is required (see circle).
The area to be cut out is marked on the inside of the front bumper paneling (1).
Properly arrest PARKTRONIC front bumper electrical connector (X26/27) to upper basic carrier (8) on right.
17 Depending on the variant, install corresponding lamp unit in right and left outer grate covers.
18 Insert left and right outer grate covers into front bumper paneling and install with four bolts each.





19 Insert impact absorber (21) into front bumper paneling (1) and upper basic carrier (8).
Ensure that impact absorber (21) is seated correctly in front bumper paneling (1).
Shown on ECE impact absorber





20 Insert basic carrier reinforcement (22) into front bumper paneling (1) on right and left and upper basic carrier (8) and arrest.
First arrest basic carrier reinforcements (22) at top, then at bottom and at last at center. Always maintain sequence when arresting.
The basic carrier reinforcements (22) should arrest properly in the front bumper paneling (1) and upper basic carriers (8).





21 Insert center basic carrier (23) into front bumper paneling (1) and arrest starting in center.
The center basic carrier (23) should arrest properly in the front bumper paneling (1).





22 Hook check strap on towing eye cover (24) into front bumper paneling (1) (see arrow).
23 Insert towing eye cover (24) into front bumper paneling (1) and arrest.
The towing eye cover (24) should arrest correctly in the front bumper paneling (1).