Replace rear door - AR72.20-P-3505PB

MODEL 203.7

Fig 1: Identifying Rear Door Replacement Components (1 Of 2)

Fig 2: Identifying Rear Door Replacement Components (2 Of 2)

MODIFICATION NOTES

9.5.06

"Disconnect/connect ground line on battery" removed

	Disassemble rear door
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof.	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	Risk of explosion and caused by poisoning solvent vapors and gasses. Risk of injury to skin and eyes when handling anticorrosion agents.	Never spray anticorrosion agents on flames or lowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.	AS97.00-Z-0001-01A
1	Remove license plate.
2	Remove rear door window (1).		AR67.20-P-2000PB
3	Remove antenna blocking circuit (2) on both sides.		AR82.62-P-7200P
4	Disconnect electric wiring harness, expose and remove through cable retainer.
5	Remove handle (3).		AR72.20-P-3650PB
6	Remove door lock (4)		AR72.20-P-2550PB
7	Remove center high-mounted stop lamp (5).		AR82.10-P-5375PB
8	Remove bracket (6) on both sides.
9	Remove spacer (7).
10	Remove side paneling (8) on both sides.
11	Remove gas-operated struts (9) on both sides.		AR72.20-P-3600PA
		Support	Figure
	Remove rear-end door
12	Remove screws (10)
13	Remove rear door with aid of helper and place down in suitable subsurface.
	Prepare new part for installation.
14	Fit new part with aid of helper.
15	Perform seam sealing.		AR97.10-P-4000P
16	Paint new part.	See Paintwork Manual.
	Install rear door
17	Install rear door with aid of helper.
18	Screw in screws (10)
	Assemble rear door.
19	Glue reinforcement to inner rear door panel.
20	Shim rear door and close.	The rear door should be opened slightly for installing the covering (11) and bottom window (12).
21	Prepare covering (11) of rear door for installation.		AR72.20-P-3530-02PB
		Templates	Fig 5
		Repair kit	*BR00.45-Z-1049-02A
22	Prepare rear-door for gluing in covering (11).		AR72.20-P-3530-04PB
23	Install covering (11) for rear door		AR72.20-P-3530-03PB
		Betapower II (2-component electric cartridge gun)	*WH58.30-Z-1002-20A
24	Install bottom glass (12) for rear door		AR67.20-P-3600-02PB
		Feeler gauge	Figure
		Betapower II (2-component electric cartridge gun)	*WH58.30-Z-1002-20A
		Repair kit	*BR00.45-Z-1049-02A
25	Install gas-operated struts (9) on both sides.		AR72.20-P-3600PA
		Support	Figure
26	Adjust rear-end door	After installing rear door window (1) the rear door can only be adjusted when the headliner is detached at the rear.
		Gap dimensions on hoods, doors and lids	*BE60.00-P-1004-01E
		Feeler gauge	Figure
27	Install rear door (1).		AR67.20-P-2000PB
28	Install antenna blocking circuit (2) on both sides.		AR82.62-P-7200P
29	Install side paneling (8).
30	Install spacer (7).
31	Install bracket (6)
32	Remove center high-mounted stop lamp (5).		AR82.10-P-5375PB
33	Install door lock (3).		AR72.20-P-2550PB
34	Install handle (4).		AR72.20-P-3650PB
35	Move electric wiring harness into rear door, route and connect.
36	Install license plate.
37	Install model designation		AR88.50-P-5050A
		Templates	Fig 5
38	Install Mercedes star
	Notes on cavity preservation	Model 124, 126, 129, 140, 170, 201, 202, 203, 208, 210, 215, 220, 463, 671	AH97.20-P-0001-01B
39	Preserve rear door with cavity wax.	See Paintwork Manual.
40	Perform function check

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.706/707/708/718/735/740/742/743/745/746/747/756/764
BE60.00-P-1004-01E	Gap dimension	Rear-end door to roof	Dimension "E"	mm	8.5 (+1)
		Rear-end door to rear fender	Dimension "M"	mm	3.5 (± 1)
		Rear-end door to taillamp	Dimension "L"	mm	4 (± 1)
		Rear-end door to bumper	Dimension "S"	mm	6.5 (-1.5)
		Rear-end door to D-pillar	Dimension "Q"	mm	-
		Rear-end door to D-pillar	See picture		AR60.00-P-0700-01PB

Fig 3: Identifying Feeler Gauge (129 589 03 21 00)

Fig 4: Identifying Support (170 589 04 63 00)

Fig 5: Identifying Templates (203 589 02 23 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-20A	Electric cartridge gun

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1049-02A	Repair kit	A 168 670 00 93