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

MODEL 204 

MODIFICATION NOTES

20.2.13	BA62.30-P-1004-02G "Tightening torque" added.	Operation step 4 and 17
17.6.13	Tightening torque BA62.30-P-1004-02G removed.	Operation step 4

Shown on model 204.0 

Fig 1: Identifying Front End Assembly With Reinforcement - Shown On Model 204.0 (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Front End Assembly With Reinforcement - Shown On Model 204.0 (2 Of 2)

Courtesy of MERCEDES-BENZ USA

Shown on model 204.0 

Fig 3: Identifying Front End Assembly With Reinforcement - Shown On Model 204.0

Courtesy of MERCEDES-BENZ USA

Shown on model 204.0 

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
	General information on body repair		AH60.00-P-0001-01A
1	Remove all detachable parts in repair area
2	Unscrew bolts (4.1 and 4.2)	Tighten bolts (4.1 and 4.2) with specified torque after fitting work.
		Bolt for attaching striker	*BA62.30-P-1003-02G
3	Remove reinforcement strut to crossmember (4)
4	Unscrew bolts (1.1 and 1.2)
5	Remove center front reinforcement (1)
6	Unscrew bolts (8.1, 8.2, 9.1 and 9.2)
7	Remove right strut (8) and left strut (9)
8	Unscrew bolts (2.1, 2.2, 3.1 and 3.2)	Tighten bolts (2.1 and 3.1) with specified torque after fitting work.
		Bolt, outer reinforcement to fender bracket	*BA62.30-P-1004-02G
9	Remove right outer reinforcement (2) and left outer reinforcement (3)
10	Unscrew bolts (10.1, 11.1, 12.1 and 13.1)	If installed!
11	Remove right strut (12) and left strut (13)	If installed!
12	Unscrew bolts (6.1 and 7.1)	Tighten bolts (6.1 and 7.1) with specified torque after fitting work.
		Bolt, crossmember mount on absorber	*BA62.30-P-1002-02G
13	Remove front crossmember (5), right bracket (10) and left bracket (11)	Right bracket (10) and left bracket (11) are not installed in all vehicles!
14	Unscrew bolts (6.2 and 7.2)	Tighten bolts (6.2 and 7.2) with specified torque after fitting work.
		Bolt, absorber mount on longitudinal member	*BA62.30-P-1001-02G
15	Remove right absorber (6) and left absorber (7)
16	Install in the reverse order
17	Fit complete front end	Fit headlamp unit and bumper for adjustment work.
		Bolt, absorber mount on longitudinal member	*BA62.30-P-1001-02G
		Bolt, crossmember mount on absorber	*BA62.30-P-1002-02G
		Bolt for attaching striker	*BA62.30-P-1003-02G
		Bolt, outer reinforcement to fender bracket	*BA62.30-P-1004-02G
18	Adjust gap dimensions on hoods, doors and lids	MODEL 204.0/2/3	AR60.00-P-0700-01CW
		MODEL 204.9	AR60.00-P-0700-01WX
		MODEL 204.0/2/9	*BE60.00-P-1001-01U
		MODEL 204.3	*BE60.00-P-1001-01W
		Feeler gauge	Fig 4
	Risk of explosion and poisoning  caused by solvent vapors and gasses. Risk of injury  to skin and eyes when working with anticorrosion agents	Never spray corrosion protection on flames or hot objects and keep well away from all potential sources of ignition. Use only in well-ventilated areas; wear respiratory protection.	AS97.00-Z-0001-01A
19	Apply wax preservation to connections on body	After adjustment operations as well as removal and installation of front end assembly parts with reinforcement.
		Cavity preservation, solvent-free (1 l container) Combination spray gun (corrosion protection)	*BR00.45-Z-1003-05A

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 204.0	MODEL 204.2
BE60.00-P-1001-01U	Gap dimension	Engine hood to fender	Dimension "A"	mm	4 (±1)	4 (±1)
		Engine hood to headlamp	Dimension "B"	mm	4 (±1)	4 (±1)
		Engine hood to radiator grille	Dimension "C"	mm	6 (±1)	6 (±1)
		Engine hood to bumper	Dimension "D"	mm	4 (±1,)	4 (±1,)
		Engine hood to A-pillar	Dimension "E"	mm	4, (±1)	4, (±1)
		Bumper to headlamp	Dimension "F"	mm	3 (±1)	3 (±1)
			Picture		AR60.00-P-0700-01CW	AR60.00-P-0700-01CW

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 204.9
BE60.00-P-1001-01U	Gap dimension	Engine hood to fender	Dimension "A"	mm	4 (±1)
		Engine hood to headlamp	Dimension "B"	mm	4 (±1)
		Engine hood to radiator grille	Dimension "C"	mm	-
		Engine hood to bumper	Dimension "D"	mm	6 (+3/-1)
		Engine hood to A-pillar	Dimension "E"	mm	4 (+1, /-1)
		Bumper to headlamp	Dimension "F"	mm	3 (+2/-1)
			Picture		AR60.00-P-0700-01W

CHECK VALUES FOR GAPS

Number	Designation				MODEL 204.3
BE60.00-P-1001-01W	Gap dimension	Engine hood to fender	Dimension "A"	mm	4 (±1)
		Engine hood to headlamp	Dimension "B"	mm	4 (±1)
		Engine hood to bumper	Dimension "C"	mm	6 (+1/-2)
		Engine hood to A-pillar	Dimension "D"	mm	4, (+2/-1)
		Bumper to headlamp	Dimension "E"	mm	2, (±1,)
			Picture		AR60.00-P-0700-01CW

FRONT END WITH FRONT REINFORCEMENT

Number	Designation			MODEL 204
BA62.30-P-1001-02G	Bolt, absorber mount on longitudinal member	Stage 1	Nm	90
		Stage 2	∠°	90

FRONT END WITH FRONT REINFORCEMENT

Number	Designation			MODEL 204
BA62.30-P-1002-02G	Bolt, crossmember mount on absorber	Stage 1	Nm	28
		Stage 2	∠°	135

FRONT END WITH FRONT REINFORCEMENT

Number	Designation		MODEL 204
BA62.30-P-1003-02G	Bolt for attaching striker	Nm	10

FRONT END WITH FRONT REINFORCEMENT

Number	Designation		MODEL 204
BA62.30-P-1004-02G	Bolt, outer reinforcement to fender bracket	Nm	10

Fig 4: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-05A	Cavity preservation, solvent-free (1 l container)	A 000 986 72 70 05