Making holes in bumper - AZ54.65-P-0001-02B

Model 210.2

Determine the pre-stamped Y0-marking in the center of the bumper on the inside of the bumper and transfer to the front side of the bumper.
Mark perpendicular center lines for the sensor mounting holes on the front side as per the diagram, starting from the center of the bumper.
1. a = 635 mm
2. b = 250 mm
  
  Fig 1: Identifying Making Holes In Bumper
  Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Cut out drilling templates, align the templates to the perpendicular center lines on the bumper and fix with adhesive tape.
The templates must precisely abut the contact edge (AK) shown in the diagram.
Center punch the center point of the 35 mm dia. holes on the drilling template on the bumper and drill through the bumper to 5 mm dia.

Fig 2: Aligning Templates To Perpendicular Center Lines On Bumper
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Drill out the predrilled drilling points to 35 mm dia.
When drilling out pay attention to the correct position of the drill or milling cutter. Position drill as per the diagram.
Deburr the holes in the bumper.

Fig 3: Drilling Holes In Bumper
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Make a recess for the anti-twist lock of the trim rings in the lower area of the mounting holes.
Insert trim ring (1) with installation housing (2) in the mounting holes of the bumper to test the fit.
To check the outer mounting holes, use trim ring with part no. 0 263 009 044 and to check the inner mounting holes, use trim ring with part no. 0 263 009 067. The part no. is embossed on the trim rings.

c = 2 mm

Fig 4: Identifying Trim Ring And Housing
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.