LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2004 >> G55 >> Repair and Diagnosis >> Body & Frame >> Windows >> Doors & Windows -- Testing & Repair -- G-Class (463) >> Testing & Repair >> Adjust rear-end door - AR72.20-P-1032A

Adjust rear-end door - AR72.20-P-1032A

MODEL 463.220/221/222/224/225/227/228/230/231/232/233/240/241/243/244/245/246/247/249/270/271/320/321/322/323/324/325/327/328/330/331/332/333/336/340/341 Station wagon 

MODEL 463.248 except CODE (979) Special protection version 

MODEL 463.237/346 up to model year 2013/model refinement package 2012 

MODEL 463.236 except CODE (979) Special protection version up to model year 2013/facelift 2012 

Fig 1: Identifying Ball Stud
G07891183Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Locking Wedge
G07891184Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Locking Lug
G07891185Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Edge Guard
G07891186Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Cover
G07891187Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Locking Wedge
G07891188Courtesy of MERCEDES-BENZ USA
REMOVING Removing     
1 Remove ball pivot (1) from rear door    
2 Remove striker (2) on rear door    
3 Remove locking lug (3) on body    
4 Remove left edge protection (4) from rear door pillar    
5 Remove left paneling (5) from rear door pillar Model 463.220/221/224/225/227/228/230/231/232/233/240/241/320/321/324/325/327/328/330/331
Model 463.222/237/243/244/245/246/247/249/270/271/322/323/332/333/336/340/341/346
Model 463.236/248
AR68.30-P-4505GK
6 Remove cover from left rear electrical compartment    
7 Remove cover in left rear wheel well IMPORTANT Only on model 463 up to 9.96  
8 Remove door hinge cap IMPORTANT Only on model 463 up to 9.96  
9 Remove rear-end door lining Single-wing rear-end door with window AR72.20-P-6615G 
10 Adjust rear-end door in relation to body and rear-end door gap Single-wing rear-end door with window AR72.20-P-1032-01A 
*BE72.20-P-1001-01A 
11 Adjust striker (6) for rear door lock on rear door pillar IMPORTANT The closed rear-end door should have the same protrusion in relation to the rear-end door pillar for the specified measuring ranges. *BE72.20-P-1001-01A 
INSTALLING Install     
12 Install striker (2) on rear door IMPORTANT Tighten bolts so that locking wedge (2) can still be moved with hammer.  
13 Install locking lug (3) on body IMPORTANT Tighten bolts so that locking wedge (2) can still be moved with hammer.  
14 Adjust striker (2) and latch section (3) of rear door   AR72.20-P-1032-02A 
*BE72.20-P-1001-01A 
15 Open and close rear door several times.    
16 Screw in ball pivots (1) with shims NOTES Coat thread with thread lock, otherwise ball stud (1) can loosen.
IMPORTANT Do not yet tighten ball studs (1). Adhesive
*BR00.45-Z-1040-02A 
17 Adjust ball stud (1) of rear-end door Single-wing rear-end door AR72.20-P-1032-03A 
    TORQUE SPECIFICATION *BA72.20-P-1001-01A 
18 Grease striker (2), latch section (3) and ball stud (1) Vaseline *BR00.45-Z-1015-06A 
19 Install rear-end door paneling Single-wing rear-end door with window AR72.20-P-6615G 
20 Install door hinge protective cap IMPORTANT Only on model 463 up to 9.96  
21 Install cover in left rear wheel well IMPORTANT Only on model 463 up to 9.96  
22 Install cover on left rear electrical compartment    
23 Install left paneling (5) on rear door pillar Model 463.220/221/224/225/227/228/230/231/232/233/240/241/320/321/324/325/327/328/330/331
Model 463.222/237/243/244/245/246/247/249/270/271/322/323/332/333/336/340/341/346
Model 463.236/248
AR68.30-P-4505GK
24 Install left edge protection (4) on rear door pillar    
TEST VALUES - REAR-END DOOR

Number Designation       Model 461, 463
BE72.20-P-1001-01A Protrusion in relation to rear-end door pillar Measuring range 30 mm below top edge of door mm 0 to 1.5
      30 mm below character line (door ridge) mm 0 to 1.5
      150 mm above door bottom edge mm 0 to 1.5
REAR-END DOOR

Number Designation   Model 461, 463
BA72.20-P-1001-01A Ball stud on rear-end door Nm 20
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1040-02A Adhesive fastening, Loctite 648 A 003 989 32 71
BR00.45-Z-1015-06A Vaseline Karl Kappler GmbH & Co. KG,
Liebknechtstr. 48, D-70565 Stuttgart
Tel. +49 711 7868-481
Fax +49 711 7868-489
www.karl-kaeppler.de