Completely replace front end with reinforcement - AR62.30-P-1570P

MODEL 203, 209.3/ 4

Fig 1: Exploded View Of Front End With Reinforcement Components

Fig 2: Identifying Front End With Reinforcement Remove/Install Components (1 Of 3)

Fig 3: Identifying Front End With Reinforcement Remove/Install Components (2 Of 3)

Fig 4: Identifying Front End With Reinforcement Remove/Install Components (3 Of 3)

	Remove
1	Remove front bumper	Model 203 except model 203.076/276	AR88.20-P-2000P
		Model 209, 203.076/276	AR88.20-P-2000Q
2	Remove lamp unit	Model 203	AR82.10-P-4730P
		Model 209	AR82.10-P-4730Q
3	Remove detachable parts in area to be repaired
4	Unscrew bolts (A and K) and remove reinforcement at front center (1)
5	Remove air ducting for radiator
6	Fasten radiator with fastening belt	Adapter for fastening belt	Fig 6
		Fastening belt	Fig 7
7	Unscrew nuts (C) on left
8	Unscrew bolts (B) on left and right
9	Unscrew bolts (E) on right
10	Partially remove front end
11	Unscrew absorber on left (5) and right (6) from bolts (E) and remove
	Install
12	Install absorber on right (6) and left (5) on longitudinal member and tighten with bolts (E)	Position bolts (E) lightly
13	Screw on front crossmember (4) to absorber on right (6) and left (5) with right bottom bracket (8) and left (7) and towing device console (15) with bolts (G).	Position bolts (G) slightly
14	Center absorber on right (6) and left (5) at longitudinal member and tighten bolts (E)
15	Screw right connection carrier (12) and left (11) to front crossmember (4) with bolts (I)	Tighten bolts (I).
16	Screw outer right reinforcement (2) and left (3) to upper longitudinal member and right connection carrier (12) and left (11) with bolts (B and F)	Position bolts (B and F) slightly
17	Screw right crash box strut (10) and left (9) to absorber on right (6) and left (5) with bolts (H)	Tighten bolts (H).
18	Screw on right upper bracket (14) and left (13) with bolts (J)	Tighten bolts (J).
19	Screw on front center reinforcement (1) with bolts (A and K)	Position bolts (A and K) slightly.
20	Adjust front module	Fit headlamp unit and bumper for adjustment work.	AR62.30-P-1570-01P
		Bolt, front end to longitudinal member	*BA62.30-P-1001-02A
		Bolt for crash box	*BA62.30-P-1004-02A
		Bolt, reinforcement to fender bracket	*BA62.30-P-1005-02A
		Bolt, crossmember to crash box	*BA62.30-P-1011-02A
21	Install front bumper	Model 203 except model 203.076/276	AR88.20-P-2000P
		Model 209, 203.076/276	AR88.20-P-2000Q
22	Install lamp unit	Model 203	AR82.10-P-4730P
		Model 209	AR82.10-P-4730Q
23	Adjust gap dimensions on hoods, doors and lids	Model 203.0	AR60.00-P-0700-01P
		Model 203.2	AR60.00-P-0700-01PA
		Model 203.7	AR60.00-P-0700-01PB
		Engine hood to fender	*BE60.00-P-1001-01E
		Engine hood to headlamp	*BE60.00-P-1001-01E
		Engine hood to bumper	*BE60.00-P-1001-01E
		Feeler gauge	Figure
		Model 209.3	AR60.00-P-0700-01Q
		Model 209.4	AR60.00-P-0700-01QA
		Engine hood to fender	*BE60.00-P-1001-01G
		Engine hood to headlamp	*BE60.00-P-1001-01G
		Engine hood to bumper	*BE60.00-P-1001-01G
		Feeler gauge	Figure
24	Install detachable body components in area to be repaired

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.004/006/007/008/016/018/020/035/040/042/043/045/046/052/056/061/064/065/081/084/087	Model 203.204/206/207/208/216/218/220/235/240/242/243/245/246/252/254/256/261/264/265/281/284/287/292
BE60.00-P-1001-01E	Gap dimension	Engine hood to fender	Dimension "A"	mm	3.5 (±1)	3.5 (± 1)
		Engine hood to headlamp	Dimension "R"	mm	4 (-0.5/+1.5)	4 (-0.5/+1.5)
		Engine hood to bumper	Dimension "D"	mm	-	-
			See figure in		AR60.00-P-0700-01P	AR60.00-P-0700-01PA

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.706/707/708/718/730/735/740/742/743/745/746/747/752/756/764
BE60.00-P-1001-01E	Gap dimension	Engine hood to fender	Dimension "A"	mm	3.6 (± 1)
		Engine hood to headlamp	Dimension "R"	mm	4 (±0 .5)
		Engine hood to bumper	Dimension "D"	mm	5
		Engine hood to bumper	See figure in		AR60.00-P-0700-01PB

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

Number	Designation				Model 209.3	Model 209.4
BE60.00-P-1001-01G	Gap dimension	Engine hood to fender	Dimension "A"	mm	3.5 (± 0.5)	3 (± 1)
		Engine hood to headlamp	Dimension "B"	mm	3.5 (± 0.5)	4 (± 0.5)
		Engine hood to bumper	Dimension "C"	mm	4 (± 0.5)	5 (± 0.5)
		Engine hood to bumper	See figure in		AR60.00-P-0700-01Q	AR60.00-P-0700-01QA

FRONT END WITH FRONT REINFORCEMENT

Number	Designation		Model 203	Model 209
BA62.30-P-1001-02A	Bolt, front end to longitudinal member	Nm	57	55
BA62.30-P-1004-02A	Bolt for crash box	Nm	57	55
BA62.30-P-1005-02A	Bolt, reinforcement to fender bracket	Nm	8	10
BA62.30-P-1011-02A	Bolt, crossmember to crash box	Nm	-	32

Fig 5: Identifying Feeler Gauge (129 589 03 21 00)

Fig 6: Identifying Adapter For Fastening Belt (209 589 00 63 00)

Fig 7: Identifying Fastening Belt (211 589 05 63 00)