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

Do not damage paint. 

1. Clean bores for center air inlet grate mounting clips.

   Remove paint residues present with dia. 7.2 mm bit or awl

2. Insert mounting clips (2) for center air inlet grate into cleaned holes (6 each).

   The openings of the mounting clips (2) should point in the direction of travel.

   Fig 1: Identifying Center Air Inlet Grate And Mounting Clips

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Install left and right chrome trim strips (4) into front bumper paneling (1).

   Check arrest of chrome trim strips (4) on inside; if necessary, press in again (see arrow).

   Fig 2: Locating Left/Right Chrome Trim Strips

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Vehicles with headlamp cleaning system, code 600 

1. 4.1 Install HCS cover (22), removed from standard bumper, with HCS spring (23) into front bumper cover (1).

   For this purpose, press bearing bracket on HCS cover (22) together and position on bearing pins. Then close HCS cover (22) and insert HCS spring (23) (see bottom figure).

   Fig 3: Identifying HCS Cover, Spring And Front Bumper Cover

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. 5 Insert front basic carrier (17) on left and right into front bumper paneling (1) and fasten with clips (18) (6 each).

   Observe precise seat when inserting; do not damage retaining lugs.

   Ensure that the front basic carrier (17) arrests properly in the front bumper paneling (1) (see arrow).

   Press clips onto assembly lugs with suitable tool. When installing, counterhold front bumper paneling (1), component springs back.

   Fig 4: Locating Front Basic Carrier In Front Bumper Paneling

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. 6 Install left and right reinforcement (8) on front bumper paneling (1) and fasten with clips (12) (6 each).

   Observe precise seat when inserting; do not damage retaining lugs.

   Ensure that the front basic carrier (17) arrests properly in the front bumper paneling (1) (see arrow).

   Press clips onto assembly lugs with suitable tool. When installing, counterhold front bumper paneling (1), component springs back.

4. 7 Connect reinforcement (8) and front basic carrier (17) with two expansion rivets (9) each.
   Fig 5: Identifying Front Basic Carrier In Front Bumper Paneling

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

   Vehicles with Parktronic system (PTS) code 220 

5. 8.1 Insert PTS wiring harness (21) removed from standard bumper into inner section (17) and fasten to brackets present.
   Fig 6: Identifying PTS Wiring Harness

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

   Vehicles with Parktronic system (PTS) code 220 

6. 9.1 Arrest front PTS separation point (X26/27) in bracket of basic carrier (17) (see arrow).
   Fig 7: Identifying Arrest Front PTS Separation Point

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   Vehicles with Parktronic system (PTS) code 220 

7. 10.1 Connect front bumper PTS sensor unit (A42) and insert into brackets

   Before inserting front bumper PTS sensor unit (A42) check decoupling rings; replace if damaged.

   Fig 8: Identifying Front Bumper PTS Sensor Unit

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. 11 Insert left and right impact absorber (29) removed from standard bumper into front bumper paneling (1).

   On vehicles with Parktronic system (PTS), code 220, ensure that PTS wiring harness is routed correctly. The routing is defined in the impact absorbers. Do not kink or crush PTS wiring harness.

   Fig 9: Identifying Left/Right Impact Absorber And Front Bumper Paneling

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. 12 Insert basic carrier (31) into front bumper paneling (1) and fasten with two expansion rivets (9) on left and right.

   Observe precise seat, do not damage retaining lugs. The center basic carrier (31) should arrest properly.

   Ensure that center basic carrier (31) is seated correctly on the upper attachment points of the front bumper paneling (1) (see arrow).

   Fig 10: Identifying Center Basic Carrier And Front Bumper Paneling

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
10. 13 Insert center impact absorber (30) removed from standard bumper into front bumper paneling (1) and arrest.

    The center impact absorber (30) should arrest properly in the center basic carrier (31).

    Fig 11: Identifying Center Impact Absorber And Front Bumper Paneling

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. 13 Install spring nuts (6) for mounting left and right air inlet grate (6 each).
12. 14 Install spring nuts (13) for mounting left and right front fog lamps (6 each).
    Fig 12: Installing Left/Right Air Inlet Grate Spring Nuts

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
13. 15 Insert left front fog lamp (E5/1) and right front fog lamp (E5/2) into front bumper paneling (1) and install with three 4.8 x 19 combination bolts (15) each.

    On models 211.077/277 each of the front fog lamps is installed with 4 combination bolts.

    Fig 13: Identifying Left Front Fog Lamp And Front Bumper Paneling

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. 16 Insert center bottom reinforcement (5) into front bumper paneling (1) and fasten with hot melt adhesive.

    On models 211.077/277 the left and right reinforcements are also inserted into the front bumper paneling (1) and fastened with hot melt adhesive.

    Fig 14: Identifying Center Bottom Reinforcement And Front Bumper Paneling

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
15. 17 Install left and right clips (11) on front bumper paneling (1).

    The clips (11) are different for the left and right side.

    Fig 15: Identifying Left/Right Clips On Front Bumper Paneling

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
16. 18 Insert paneling bushings (36) on left and right into front bumper paneling (1).
    Fig 16: View Of Paneling Bushings On Left/Right Front Bumper Paneling

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
17. 19 Insert towing eye cover (24), removed from standard bumper, into front bumper cover (1) and hook in retainer.
    Fig 17: View Of Eye Cover And Front Bumper Cover

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Perform following steps only after installing front bumper paneling (1).

18. 20 Install license plate frame (25) at outside of front bumper paneling (1) and prepare for assembly.

    Use license plate frame (25) as template for marking holes. The distance (a) between the license plate frame (25) and the left and right bumper strips should be equal. Align license plate frame (25) along contour of front bumper paneling (1) (see arrows).

19. 21 Drill four holes for assembling license plate frame (25) and install license plate frame (25) on front bumper paneling (1) with four bolts (PT516)

    Tighten screws only with screwdriver.

    Before installing the license plate frame (25) insert center air inlet grate. Ensure that the center air inlet grate arrests properly in the mounting clips.

20. 22 Insert left and right air inlet grate and fasten with 3 sheet metal screws (St3.5 x 22) each.
    Fig 18: View Of License Plate Frame On Front Bumper Paneling

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.