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

Model 220.071 

1. 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.
2. Mark perpendicular center lines for the sensor mounting holes on the front side as per the diagram, starting from the center of the bumper.
   Fig 1: Positions For Making Holes In Bumper

   
3. 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.

4. 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: Identifying Bumper Hole Dimensions

   
5. Drill out bumper at 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.

6. Deburr the holes in the bumper.
   Fig 3: Identifying Proper And Improper Methods For Deburring Holes In Bumper

   
7. Make a recess for the anti-twist lock of the trim rings in the lower area of the mounting holes.
8. Insert trim ring (2) with installation housing (1) in the mounting holes of the bumper to test the fit.
   Fig 4: Identifying Trim Ring And Housing

   
9. Process the impact member of the bumper in the area of the sensor mounting holes as per the diagram.
   Fig 5: Identifying Sensor Mounting Holes Dimensions