Replace complete front end assembly together with reinforcement - AR62.30-P-1570P

WARNING: This page is about a different car, the 2009 Mercedes-Benz CLK350 and 2008 Mercedes-Benz CLK350. However, it is still accessible from the selected car via links, so may be relevant.

MODEL 203.0/2

MODEL 203.7## #A up to 970021

MODEL 203.7## #E as of 028195 up to 035817

MODEL 209.3 except CODE (P98) Black Series

MODEL 209.4

Fig 1: Identifying Front End Assembly Components

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Front Center Reinforcement, Nuts & Bolts

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Bolts

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Front End Assembly Reinforcement Components

Courtesy of MERCEDES-BENZ USA

	Removing
1	Remove front bumper	Model 203.0/2 except 203.076/276, Model 203.7	AR88.20-P-2000P
1	Remove front bumper	Model 209, 203.076/276
2	Remove lamp units	Model 203	AR82.10-P-4730P
2	Remove lamp units	Model 209	AR82.10-P-4730Q
3	Remove detachable parts in area to be repaired
4	Unscrew bolts (A, K) and remove center front reinforcement (1)
5	Remove air ducting for radiator
6	Fasten radiator with fastening belt		Fig 6
6	Fasten radiator with fastening belt		Fig 7
7	Unscrew bolts (B) on left and right
8	Unscrew bolts (E) on left and right
9	Remove front end
	Install
10	Install right absorber (6) and left absorber (5) on longitudinal member and tighten with bolts (E)	Position bolts (E) lightly
11	Screw front crossmember (4) to right bottom bracket (8) and left bottom bracket (7) and towing device console (15) with bolts (G) and nuts (C)	Position bolts (G) slightly
12	Center right absorber (6) and left absorber (5) on longitudinal member and tighten bolts (E)
13	Screw right connecting carrier (12) and left connecting carrier (11) to front crossmember (4) with bolts (I)	Tighten bolts (I).
14	Screw right outer reinforcement (2) and left outer reinforcement (3) to upper longitudinal members and right connecting carrier (12) and left connecting carrier (11) with bolts (B, F)	Tighten bolts (B, F) lightly.
15	Screw right crashbox strut (10) and left crashbox strut (9) to right absorber (6) and left absorber (5) with bolts (H)	Tighten bolts (H).
16	Screw on right upper bracket (14) and left upper bracket (13) with bolts (J)	Tighten bolts (J).
17	Screw on center front reinforcement (1) with bolts (A, K)	Tighten bolts (A, K) slightly.
18	Adjust front module	Fit headlamp unit and bumper for adjustment work.	AR62.30-P-1570-01P
		Model 203 Gap dimension between engine hood and fender, engine hood and headlamp and Engine hood to bumper	*BE60.00-P-1001-01E
		Model 209 Gap dimension between engine hood and fender, engine hood and headlamp and Engine hood to bumper	*BE60.00-P-1001-01G
			*BA62.30-P-1001-02A
			*BA62.30-P-1004-02A
			*BA62.30-P-1005-02A
			*BA62.30-P-1011-02A
19	Install front bumper	Model 203.0/2 except 203.076/276, Model 203.7	AR88.20-P-2000P
19	Install front bumper	Model 209, 203.076/276
20	Install lamp units	Model 203	AR82.10-P-4730P
20	Install lamp units	Model 209	AR82.10-P-4730Q
21	Adjust gap dimensions on engine hood	Model 203.0 except 203.076	AR60.00-P-0700-01P
		Model 203.2 except 203.276	AR60.00-P-0700-01PA
		Model 203.7	AR60.00-P-0700-01PB
		Gap dimension between engine hood and fender, engine hood and headlamp and Engine hood to bumper	*BE60.00-P-1001-01E
			Fig 5
		Model 209.3	AR60.00-P-0700-01Q
		Model 209.4	AR60.00-P-0700-01QA
		Gap dimension between engine hood and fender, engine hood and headlamp and Engine hood to bumper	*BE60.00-P-1001-01G
			Fig 5
22	Install detachable body components in area to be repaired

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.004/006/007/008/016/018/020/035/040/042/043/045/046/052/054/056/061/064/065/081/084/087/092	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	Dim. "A"	mm	3.5 (±1)	3.5 (±1)
		Engine hood to headlamp	Dim. "R"	mm	4 (-0.5/+1.5)	4 (-0.5/+1.5)
		Engine hood to bumper	Dim. "D"	mm	-	-
		Engine hood to bumper	See picture		AR60.00-P-0700-01P	AR60.00-P-0700-01PA

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.706/707/708/718/730/735/740/741/742/743/745/746/747/752/756/764
BE60.00-P-1001-01E	Gap dimension	Engine hood to fender	Dim. "A"	mm	3.6 (±1)
		Engine hood to headlamp	Dim. "R"	mm	4 (±0.5)
		Engine hood to bumper	Dim. "D"	mm	5
		Engine hood to bumper	See picture		AR60.00-P-0700-01PB

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

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

FRONT END ASSEMBLY WITH FRONT REINFORCEMENT

Number	Designation		Model 203	Model 209
BA62.30-P-1001-02A	Bolt connecting 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 connecting 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)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA