Remove/install front door - AR72.10-P-0500E

MODEL 202

Fig 1: Identifying Front Door Remove/Install Components - Model 202 (1 Of 2)

Fig 2: Identifying Front Door Remove/Install Components - Model 202 (2 Of 2)

	Remove
1	Open crank window	Open front door
2	Remove cover (1) and open connector lock (11) by turning toward inside.		Fig 5
3	Remove seal (2) and unscrew bolt (13)
4	Unscrew bolts (3) and slightly pull door away from A-pillar	Hold door with 2nd mechanic Avoid damaging paint.
5	Unclip protective tube (4) from A-pillar and pull out connector (11)		Fig 3
6	Remove front door and set down	Avoid damaging paint
	When replacing a door perform seam sealing, cavity preservation and align doors	When replacing a door ↓ Check rubber seal for corrosion and clean if necessary
		Treat door frame in area of contact surface of rubber seal with MB body sealant Cavity preservation after repairs	*BR00.45-Z-1003-05A
		Stretching of doors	AR72.10-P-0700E
	Install
7	Move front door installation position	Avoid damaging paint
8	Install connector (11) and close lock by turning toward outside
9	Clip in protective tube (4)
10	Position front door to centering screws (5) with hinges and screw on with bolts (3) and tighten.		*BA72.10-P-1001-01A
			*BA72.10-P-1002-01A
11	Install cover (1)
12	Screw door catch to A-pillar with bolt (13) and tighten		*BA72.10-P-1003-01A
13	Remove seal (2)
14	Check gap dimensions at door all the way around	Gaps dimensions at hoods, doors and covers ↓	Fig 4
		Model 202.01/02/033/12/13	AR60.00-P-0700-01E
		Model 202.07/08/093/18/19	AR60.00-P-0700-01EA
		If applicable, adjust front door	AR72.10-P-0550E

TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS

Number	Designation				Model 202.01/02/033/12/13	Model 202.07/08/093/18/19
BE60.00-P-1002-01A	Gap dimension	Front door to A-pillar	Dim. "B"	mm	6.0 (+1)	6.0 (+1)
		Front door to fender	Dim. "H"	mm	5.0 (+1)	5.0 (+1)
		Front door to rear door	Dim. "I"	mm	6.0 (+1)	6.0 (+1)
		Front door to roof	Dim. "C"	mm	6.0 (+1)	6.0 (+1)
		Rear door to upper side section	Dim. "D"	mm	6.0 (+1)	-
		Rear door to lower side section	Dim. "J"	mm	5.0 (± 0.5)	5.0 (± 0.5)
		Fender to A-pillar	Dim. "Q"	mm	-	-
		Front door to rear fender	Dim. "P"	mm	-	-
		Front door to rear fender	Fig., see		AR60.00-P-0700-01E	AR60.00-P-0700-01EA

FRONT DOOR

Number	Designation		Model 202
BA72.10-P-1001-01A	Bolt to door hinge	Nm	37
BA72.10-P-1002-01A	Centering screw to door hinge on A-pillar	Nm	25
BA72.10-P-1003-01A	Bolt to door catch on A-pillar	Nm	25

Fig 3: Identifying Mounting Wedge (110 589 03 59 00)

Fig 4: Identifying Feeler Gage (129 589 03 21 00)

Fig 5: Identifying Socket Wrench (140 589 00 09 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-05A	Preservation agent	A 000 986 72 70 05