Procedures

AZ88.00-P-0001-02GZA Converting Front Bumper
- as of model year 09

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

Pay attention to paint damage.







1. Insert center cover grill (2) and center cover grill cover (3) from front into front paneling (1).

The catch tabs on the center cover grill (2) and center cover grill cover (3) must arrest correctly in the front bumper paneling (1).

2. Insert underride guard (4) from front into front paneling (1).

The catch tabs on the underride guard (4) must arrest correctly in the front bumper paneling (1).







3. Insert impact absorber (5) and basic carrier (6) into front paneling (1).

The catch tabs on the basic carrier (6) must catch correctly in the front paneling (1).







4. Fasten basic carrier (6) on top left and right to front paneling (1) with three blind rivets (7) and two expansion rivets (8) each.







5. Fasten basic carrier (6) outside left and right to front paneling (1) with one expansion rivet (9) each.







6. Fasten underride guard (4) to front paneling (1) with eight sheet metal nuts (10) and eight 4.8x19 round Allen head bolts (11).







7. Fasten bottom right and left underride guard (4) in front paneling (1) with one expansion rivet each (12).







8. Fasten basic carrier (6) in front paneling (1) with four lock nuts (14).







9. Install HCS [SRA] cover (15) with left and right HCS [SRA] spring (16) in front paneling (1).

For this purpose, pull bearing bracket on HCS [SRA] cover (15) apart and insert into bearing bores. Then close HCS [SRA] cover (15) and insert HCS [SRA] spring (16).







10. Install sheet metal nuts (17) for fastening right and left front fog lamps (8 each).
11. Insert left front fog lamp (E5/1) and right front fog lamp (E5/2) from front into front paneling (1) and fasten with four 4.2x19 round Allen head bolts (18).

The front fog lamps are marked on the corresponding side. The adjustment screws (20) should point downward.

12. Insert front fog lamp cover (19) on right and left from front into front paneling (1) and arrest.

The catch tabs on the front fog lamps covers (19) must catch properly in the front paneling (1).







Vehicles with Parktronic system (PTS) code 220
13. Route PTS wiring harness (21) with connected PTS ultrasonic sensors into front paneling (1) as shown in figure and fix in place at specified attachment points (see circles).

Vehicles with Parktronic system (PTS) code 220
14. 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).

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

Vehicles with Parktronic system (PTS) code 220
15. Clip outside temperature indicator temperature sensor (B14) into center cover grill (2).
16. Fasten left front engine compartment/bumper connector (X26/32) and right front engine compartment/bumper connector (X26/36) to basic carrier (6) with one retaining clip each.
17. Connect left front fog lamp (E5/1) and right front fog lamp (E5/2).







18. Hook check strap (21) into towing eye cover (22).
19. Hook check strap (21) into front paneling (1).
20. Insert towing eye cover (22) into front paneling (1) and arrest.

The catch tabs on the towing eye cover (22) should arrest properly in the front paneling (1).







21. Insert radiator air ducting (23) from front into front paneling (1) and arrest.

The catch tabs on the radiator air ducting (23) must catch properly in the front paneling (1) and basic carrier (6).

22. Fasten radiator air ducting (23) on upper right and left to basic carrier (6) with one expansion rivet (24) each.







23. Position license plate frame (25) at outside on center cover grill cover (3) and prepare for assembly.

Use license plate frame (25) as template for marking holes. The distance (a) between the outer edge of the license plate frame (25) and the edge of the air inlet in the front paneling (1) should be equal. Center license plate frame (25) (see picture at top) and align along contour of center cover grill cover (3) (see picture at bottom).

24. Drill four holes for assembling license plate frame (25) and install license plate frame (25) on center cover grill cover (3) with four F5x18 bolts.

Tighten bolts only with screwdriver.