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Adjust front door - AR72.10-P-0550P

MODEL 203, 209 

Shown on model 203.0 

Fig 1: Identifying Front Door Adjustment Components
G04737788

Shown on model 203.0 

Fig 2: Identifying Locking Eye And Bolts
G04737789

Shown on model 203.0 

Fig 3: Identifying Inner Door Panel Bolts And A-Piller Screws
G04737790
INSPECT Check, adjust     
1 Remove locking eye (1) SPECIAL TOOL Torx bit set Figure
2.1 Check door gaps all the way around Model 203  
    SPECIAL TOOL Feeler gauge Figure
    Gap dimensions on hoods, doors and lids *BE60.00-P-1002-01E 
2.2 Check door gaps all the way around Model 209  
    SPECIAL TOOL Feeler gauge Figure
    Gap dimensions on hoods, doors and lids *BE60.00-P-1002-01G 
    Gap dimensions on hoods, doors and lids *BE60.00-P-1007-01G 
3 Loosen screws (3) and adjust gap by moving front door TORQUE SPECIFICATION Bolt on door hinge *BA72.10-P-1001-01A 
4 Loosen screws (4) and adjust driver door contour on hinge side by moving front door IMPORTANT Door paneling (H) should be flush with the front fender contour or should located max. 1 mm deeper.  
    IMPORTANT Bolt on door hinge *BA72.10-P-1001-01A 
    SPECIAL TOOL Torx bit set Figure
5 Install locking eye (1) SPECIAL TOOL Torx bit set Figure
6 Completely close front door and adjust contour by moving locking eye (1).    
7 Tighten bolts (2) TORQUE SPECIFICATION Screw on locking eye *BA72.10-P-1004-01A 
8.1 Inspect contour and fit at window surround (B) to roof paneling and front wall pillar, align if necessary Model 203  
8.2 Check contour and fit on window in relation to roof paneling and front wall pillar, adjust if necessary. Model 209  
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-1002-01E Gap dimension Front door to A-pillar Dimension "B" mm 6.5 (+1) 6.5 (+1)
Front door to fender Dimension "H" mm 3.5 (-0.5/+1) 3.5 (-0.5/+1)
Front door to rear door Dimension "I" mm 4 (-0.5/+1) 4 (-0.5/+1)
Front door to roof Dimension "C" mm 6.5 (+1) 6.5 (+1)
Rear door to C-pillar Dimension "T" mm - 6 (+1)
Rear door to side section, bottom Dimension "J" mm 3.5 (+1) 3.5 (+1)
Front door to rear fender Dimension "P" 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-1002-01E Gap dimension Front door to A-pillar Dimension "B" mm 6.5 (+1)
Front door to fender Dimension "H" mm 3.5 (-0.5/+1)
Front door to rear door Dimension "I" mm -
Front door to roof Dimension "C" mm -
Rear door to C-pillar Dimension "T" mm -
Rear door to side section, bottom Dimension "J" mm -
Front door to rear fender Dimension "P" mm 3.5 (+1.0/-0.5)
See figure in   AR60.00-P-0700-01PB
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number Designation Model 209.3 Model 209.4
BE60.00-P-1002-01G Gap dimension Front door to A-pillar Dimension "D" mm - 1
Front door to fender Dimension "E" mm 3.5 (-0.5/+1) 3.5 (-0.5/+1)
Front door to rear fender Dimension "F" mm 3.5 (-0.5/+1) 3.5 (-0.5/+1)
See figure in AR60.00-P-0700-01Q AR60.00-P-0700-01QA
BE60.00-P-1007-01G Gap dimension Soft top compartment cover/rear fender Dimension "O" mm - 3 (± 0 .5)
Soft top compartment cover/trunk lid Dimension "P" mm - 4.5 (± 1)
See figure in - AR60.00-P-0700-01QA
TORQUE SPECIFICATION FRONT DOOR

Number Designation Model 203 Model 209
BA72.10-P-1001-01A Screw on door hinge Nm 32 32
BA72.10-P-1004-01A Bolt to locking eye Nm 28 28
Fig 4: Identifying Feeler Gauge (129 589 03 21 00)
G04737791
Fig 5: Identifying Torx Bit Set (000 589 01 10 00)
G04737792