Installing, connecting sensors - AZ54.65-P-0001-03FA

Model 210.2 as of 1.7.99 model year 99 

The measuring points are embossed on the inside of the bumper. The negative dimensions identify the right-hand half of the bumper, the positive dimensions identify the left-hand half of the bumper and the center of the bumper is identified with (Y0).

1. Mask the outside of the bumper below the impact damper with adhesive tape.
2. Determine the position of the pre-embossed YO marking at the center of the bumper on the inside of the bumper and transfer this to the masked surface on the front side of the bumper.
3. Plot the distance dimension (a) and (b) from the center of the bumper along the bottom edge of the impact damper to the left and right respectively and mark on the masked surface.
   Fig 1: Identifying Distance Dimension (A) And (B)

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Cut out drilling templates. Align the templates with the perpendicular center lines on the bumper and fix in position with adhesive tape.

   The templates must contact the lower edge of the impact damper precisely (the contact edge AK).

5. Align the center axis of drilling templates 1 - 4 parallel with the center of the bumper (Y0) and fix in position.

   Locate drilling templates 1 -4 from left to right on the inside of the bumper corresponding to the positive or negative dimension.

6. Mark center point of the 35 mm dia. hole and drill to 5 mm dia.
   Fig 2: Aligning Templates With Perpendicular Center Lines On Bumper And Fix In Position With Adhesive Tape

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Drill out the bumper to 35 mm dia. at the pre-drilled drilling points.

   When drilling pay attention to the correct position of the drill or milling machine. Position drill as shown in the figure.

8. Deburr holes in the bumper.
   Fig 3: Drilling Holes In Bumper

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. Make a recess (c) in the lower area of the mounting holes for the anti-twist lock of the trim rings (8).
10. Insert trim ring (8) in the mounting holes of the bumper to check the fit.
    Fig 4: Identifying Trim Ring In Mounting Holes

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Rework inside of the bumper in the area of the trim ring (8) (arrows).
    Fig 5: Identifying Trim Ring

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
12. Clip trim ring (8) onto installation housing (7).
13. Push isolating ring (6) onto the sensor (5) and lock sensor (5) in position in the installation housing.

    Ensure that the electrical connection of the sensor (5) always points towards the center of the bumper.

    Fig 6: Identifying Isolating Ring, Sensor And Lock Sensor

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. Insert sensor (5) in the mounting hole in the bumper.
15. Mount retaining spring (4) on installation housing (7) and brace against the bumper via the detents in the installation housing (7) (arrow).

    The tips of the retaining spring (4) point towards the bumper.

    Fig 7: Identifying Sensor, Retaining Spring And Housing

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
16. Insert wiring harness of ultrasonic sensors (10) inside the bumper from the inside and connect to the coupling (11a) (identified with a "1").
    Fig 8: Wiring Harness Diagram

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
17. Insert damping elements (13) in the bumper. Insert wiring harness of ultrasonic sensors (10) in the cable ducts of the damping element (13). Fix cable harness in position in the damping element with adhesive felt.
    Fig 9: Identifying 6-Pin Coupling, 5-Pin Sensor Coupling, Outer Right And 5-Pin Sensor Coupling Inner Right

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.