Front Bumper, Assembly Overview

Front Bumper (From Model Year 2006) - Assembly Overview







1 - Screw
- 6 Nm

2 - Screw
- 23 Nm

3 - Bumper crossmember
- Bumper cover removed.
- To remove, remove bolts - 2 -.
- Disconnect harness connectors to signal horns and remove bumper crossmember from impact absorbers toward front.

4 - Pop rivet
5 - Signal horn
- To remove, drill off rivet heads.

6 - Support piece

NOTE: When turning adjustment screw, make sure mounting bracket raises.

- Before installing bumper cover, adjust support piece adjusting screw.
- Tighten adjustment screw to 2 Nm with a long Torx wrench - T30 - through holes in cover - arrows -.
- To disassemble, drill off pop rivet heads.

7 - Pop rivet
8 - Signal horn
9 - Brace for fender
10 - Guide piece
- Side piece of bumper cover must be clipped in between fender and guide piece.

11 - Screw
- 1 Nm

12 - Screw
- 1 Nm

13 - Bumper cover

NOTE: While installing, the following sequence described for assembling/bolting must be observed for correct assembly.

- Set cover onto vehicle and first clip the left and right side piece into guide parts - 10 -.
- Tighten nuts on fender connection.
- Tighten bolts - 12 - to wheelhousing liner.
- Loosely thread in bolts - 1 -.
- Close hood and check cover for projection and recess.
- If necessary, check position of cover and tighten bolts - 12 -.
- Tighten bolt on support piece to 2 Nm.
- Bumper cover, removing and installing.
- Crossmember, removing and installing.







Fender bolts

- Make sure when installing that the clips - 2 - are inserted onto threaded pins.
- Tighten nuts - 4 - after inserting bumper cover - 1 - in fender - 3 -.
- 4 - Nut (4 Nm)







Adjusting support piece

NOTE:
- When turning adjustment screw - 3 -, make sure mounting bracket - 4 - raises.
- If mounting bracket does not raise, place a small drop (very small) of locking compound D 000 600 A2 on the adjustment screw threads - 3 - and allow locking compound to dry.
- Turn adjustment screw up to dimension - a -.
- The mounting bracket raises when adjustment screw is turned due to the increased friction.

- Before installing bumper cover - 1 -, adjust adjusting screw - 3 - on support piece - 5 - to dimension - a - = 21 mm + 1 mm.
- Mounting bracket - 4 - must be screwed on completely (left-hand thread) for this.
- Adjustment screw - 3 - and mounting bracket - 4 - belong to delivery casing for support piece and are not replacement parts.
- When installing bolt - 3 -, mounting bracket - 4 - unscrews and holds the carrier piece - 2 - of bumper cover - 1 - in the designated position.
- The support piece - 5 - is secured to bumper cover - 6 - with pop rivets.







Clamping pins for noise insulation

- When removing bumper cover - 1 -, turn clamping pins - 2 - 180 � and remove from spring nut - 4 - on sound insulation - 3 -.







Removing guide piece

- Bumper cover removed.
- Unscrew bolts - 3 - and pull guide piece - 2 - downward out of fender - 1 -.
- When installing, bumper cover - 4 - must engage cleanly in guide piece.







Brace for wheelhousing liner

- For mounting front wheelhousing liner - 3 -.
- When installing brace - 1 -, tighten bolt - 2 -.
- 2 - Screw (10 Nm)