Converting front bumper - AZ88.00-P-0001-02SCS

Model 216 as of model year 2011 

Check components removed from standard bumper before assembly and replace if damaged.

1. Inert center air inlet grille (2) into front paneling (1) and arrest.

   Pay attention to paint damage.

   The center air inlet grille (2) should arrest properly in the front paneling (1).

   Fig 1: Identifying Front Paneling And Center Air Inlet Grille

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2. Install check strap (3) on towing eye cover (4) into front paneling (1), insert towing eye cover (4) into front paneling (1) and arrest.

   The towing eye cover (4) should arrest correctly in the front paneling (1).

   Fig 2: Identifying Front Paneling, Towing Eye Cover And Check Strap

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3. Insert air inlet grille (5) on right and left into front paneling (1) and arrest.

   The right and left air inlet grille (5) should arrest properly in the front paneling (1).

   Fig 3: Identifying Front Paneling And Air Inlet Grille

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4. Insert right and left front reinforcements (6) into front paneling (1) and install with 2 clip-type fasteners (7) each.
   Fig 4: Identifying Front Reinforcements, Clip-Type Fasteners And Front Paneling

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5. Insert right and left front reinforcements (8) into front paneling (1) and arrest.

   The right and left front reinforcements (8) must arrest properly in the front paneling (1).

   Fig 5: Identifying Front Paneling And Front Reinforcements

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6. Install right and left front reinforcements (8) on front paneling (1) and right and left front reinforcements with 2 clip-type fasteners (7) each.
   Fig 6: Identifying Front Reinforcements And Clip-Type Fasteners

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7. Insert right and left mounting rails (9) into right and left front reinforcements (8) and install on right and left reinforcement (8) and front paneling (1) with two blind rivets (10) each.

   Insert blind rivets (10) from top into front paneling (1), right and left front reinforcements (8) and right and left mounting rails (9) (see arrows).

   Fig 7: Locating Blind Rivets

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8. Install center front impact absorber (26) from front on center front reinforcement (11).
9. Insert center front reinforcement (11) into front paneling (1) and arrest in front paneling (1) and right and left front reinforcements (8).

   The center front reinforcement (11) should arrest properly in front paneling (1) and right and left front reinforcements (8).

   Fig 8: Identifying Front Paneling And Center Front Reinforcement

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10. Insert front short range radar sensor unit (A86/1) on right and left into front paneling (1) and arrest.

    The front short range radar sensor unit (A86/1) should arrest properly in front paneling (1).

    Fig 9: Identifying Front Short Range Radar Sensor Unit And Front Paneling

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11. Clip outer left front PTS ultrasonic sensor (B8/1), center left front PTS ultrasonic sensor (B8/2), inner left front PTS ultrasonic sensor (B8/3), inner right front PTS ultrasonic sensor (B8/4), center right front PTS ultrasonic sensor (B8/5) and outer right front PTS ultrasonic sensor (B8/6) into brackets on front paneling (1).
    Fig 10: Identifying Outer Left Front Pts Ultrasonic Sensor, Center Left Front Pts Ultrasonic Sensor And Front Paneling

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    Previously check whether a decoupling ring (transparent silicon ring) is installed on all PTS ultrasonic sensors.

    Check whether PTS ultrasonic sensors are seated correctly in front paneling (1), rework is possible.

12. Install springs (12) on pins of HCS cover (13).

    The outer ends of the springs (12) should be seated on the stay of the HCS cover (13).

13. Insert HCS cover (13) on right and left front into front paneling (1) and install on journals of right and left front reinforcements (8)

    Check whether HCS covers (13) are seated correctly in front paneling (1), rework if possible.

    Fig 11: Locating Springs And HCS Cover

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    Fig 12: Identifying PTS Wiring Harness And Center Impact Absorber

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14. First connect PTS wiring harness (14) to PTS ultrasonic sensors and right front short range radar sensor units.
15. Guide PTS wiring harness (14) on right from front through center impact absorber (15) toward rear.
16. Guide PTS wiring harness (14) on left from front through center impact absorber (15) toward rear.
17. First connect PTS wiring harness (14) to PTS ultrasonic sensors and left front short range radar sensor units.
18. Insert center impact absorber (15) into right and left front reinforcements (8) and center front reinforcement (11) and arrest.

    The center impact absorber (15) should arrest properly in the right and left front reinforcements (8) and center front reinforcement (11).

    Carefully guide catch tabs on center impact absorber (15) to prevent breakage. Do not pinch or kink PTS wiring harness.

    Fig 13: Locating Center Impact Absorber

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    Fig 14: Locating Cable Tie

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19. Install front bumper PTS connector (X26/27) in right front reinforcement (8).
20. Fix PTS wiring harness (14) in place at specified retaining points in right and left front reinforcements (8) and center impact absorber (15).

    Fix PTS wiring harness (14) on right in place at right front reinforcement (8) with cable tie (see arrow).

21. Insert right and left impact absorber (17) into center impact absorber (15) and right and left front reinforcements (8) and arrest.

    The right and left impact absorber (17) should arrest properly in the center impact absorber (15) and right and left front reinforcements (8).

    Carefully guide in catch tabs on right and left impact absorber (17), otherwise they could break off (see arrows).

    Fig 15: Locating Impact Absorber Catch Tabs

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22. Insert lower reinforcements (18) into front paneling (1) and arrest.

    The lower reinforcement (18) should arrest correctly in the front paneling (1).

    Fig 16: Identifying Lower Reinforcements And Front Paneling

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23. Install daytime running lamp trim (19) on daytime running lamp (20) and arrest.

    Properly arrest daytime running lamp trim (19) on daytime running lamps (20). The daytime running lamp trims (19) are coded by shape and thereby fit only the corresponding daytime running lamp (20).

    Fig 17: Identifying Running Lamps And Running Lamp Trim

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24. Insert daytime running lamps (20) on left and right from rear into right and left air inlet grille (5) and install with three 5 X20 pan head screws each.

    Install lug on daytime running lamp (20) into front paneling (1) (see arrow).

    Fig 18: Locating Lug

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    Fig 19: Identifying Front Paneling And Right/Left Front Reinforcements

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25. Mark holes for expansion rivets in right and left front reinforcements (8) and front paneling (1) and drill (Ø 5 mm).

    b 9 mm

    c 8 mm

    d 6 mm

26. Install left and right front reinforcements (8) on front paneling (1) with 2 expansion rivets (23) each.
27. Position license plate frame (25) outside of front paneling (1) and prepare for assembly.

    Use license plate frame (25) as template for marking holes. For measurement use distance (a) as well as distance (b). Die distance (a and b) between the outer edge of the license plate frame (25) and the measuring points should be equal. The distance between the ultrasonic sensors (b) and the center edge of the front paneling (1) (upper picture) serve as measuring points for distance (a). Align license plate frame (25) along contour of front paneling (1) (lower picture).

28. Drill four holes for installation license plate frame (25) and fasten license plate frame (25) to front paneling (1) using four bolts.

    Tighten bolts only with screwdriver.

    Fig 20: Locating Front Paneling And License Plate Frame Bolts

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