Remove/install rear door - AR72.12-P-0600M

MODEL 220

Fig 1: Identifying Rear Door Remove/Install Components

MODIFICATION NOTES

8.5.06

Nut on door hinge

Model 220

	Remove/install
1	Press molding strip (1) out of door control unit cover (2) with assembly wedge		Figure
2	Remove door handle cover (3) from door handle
3	Unscrew door control unit cover (2) from door lining (4) and press out with mounting wedge		AR72.12-P-1010M
			Figure
4	Disconnect door control unit connectors and remove cover
5	Unclip protective hose (5) from B-pillar
6	Disconnect CL line and electrical connectors from rear door and route through cable duct (6)	Remove door liner (4) from inner door panel in area of cable and plug connections with mounting wedge	Figure
7	Unscrew screws for door retaining strap (7) from B-pillar		*BA72.12-P-1004-01D
8	Unscrew nuts (8) from door hinges	Remove door with aid of second person, avoid damaging paint	*BA72.12-P-1003-01D
9	Lift rear door and remove upward, simultaneously pull CL line out of rear door through cable duct (6) together with electrical lines
10	Set down rear door	Avoid damaging paint
		When replacing a door, carry out seam sealing and cavity preservation
11	Install in the reverse order	Following installation, check joint dimensions throughout	Figure
		Gaps on hoods, doors and lids	AR60.00-P-0700-01M *BE60.00-P-1002-01A
		If necessary, adjust rear door	AR72.12-P-0650M

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

Number	Designation				Model 220.0/1	Model 220.875/878
BE60.00-P-1002-01A	Gap dimension	Front door to A-pillar	Dimension "B"	mm	8,0 (±0,5)	6,5 (±0,5)
		Front door to fender	Dimension "H"	mm	5,0 (±0,5)	5,0 (±0,5)
		Front door to rear door	Dimension "I"	mm	5,0 (±0,5)	-
		Front door to roof	Dimension "C"	mm	8,0 (± 0,5)	6,5 (±0,5)
		Rear door to top of side section	Dimension "D"	mm	5,0 (±0,5)	5,0 (± 0,5)
		Rear door to side section, bottom	Dimension "J"	mm	5,0 (±0,5)	5,0 (±0,5)
		Fender to A-pillar	Dimension "Q"	mm	-	-
		Front door to rear fender	Dimension "P"	mm	-	-
			See picture		AR60.00-P-0700-01M	AR60.00-P-0700-01MP

REAR DOOR TIGHTENING TORQUE

Number	Designation		Model 220
BA72.12-P-1003-01D	Nut on door hinge	Nm	25
BA72.12-P-1004-01D	Screw for door holder on body	Nm	14

Fig 2: Identifying Wedge Tool (110 589 03 59 00)

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