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

MODEL 216, 221 

Shown on model 221 

Shown on model 221 

Shown on model 221 

Shown on model 221 

Shown on model 221 

Shown on model 221 

Shown on model 221 

Shown on model 221 

Shown on model 221 

Shown on model 221 

	Removing
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of explosion from pressurized spray cans	Protect cans from direct sunlight and temperatures above 50 °C	AS00.00-Z-0015-01A
	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-N-0001-01A
1	Remove lower engine compartment paneling	Vehicles without code (Z07) Top protection	AR61.20-P-1105SX
		Vehicles with code (Z07) Top protection	AR61.20-P-1105SXS
2	Remove front bumper		AR88.20-P-2000SX
3	Remove lamp unit		AR82.10-P-4730SX
4	Remove engine hood catch bottom section		AR88.40-P-3200SX
5	Remove apex seal (1)
6	Remove cover (2) on left and right
7	Remove engine cover (3)
8	Remove right air duct (4) and left air duct (5)
9	Remove bolts (19)
10	Remove stop buffer (21).
11	Open hood release cable coupling (6)
12	Separate hood release cable (7) from hood release cable coupling (6)
13	Pull out left and right radiator mounting clip (8)
14	Press left and right radiator mounting (9) together and pull out upward
15	Unclip threaded clip (10) from side radiator air guide (11) on left and right
16	Pull out lug (12) on side radiator air guide (11)
17	Unclip threaded clip (13) from top radiator air guide (14)
18	Unclip wiring harness with mounting clips (18)	With code 219 Distronic (DTR)
19	Disconnect electrical connector (17) on DTR radar sensor (A89b1) (16)	With code 219 Distronic (DTR)
20	Remove screws (15) on DTR radar sensor (A89b1) (16)	With code 219 Distronic (DTR)
21	Unclip hood release cable (7) from retaining clip (23)	Hood release cable (7) runs along the bottom of the middle front reinforcement (22).
22	Remove screws (32) from middle front reinforcement (22)
23	Remove center front reinforcement (22)
24	Remove top radiator air guide (14)
25	Remove fanfare horn (34)
26	Unscrew pressure line (24) to compressor unit from valve unit (25)
27	Unscrew pressure line (27) to central reservoir on valve unit (25)
28	Loosen nut (26) on valve unit (25)
29	Place valve unit (25) down to side
30	Unscrew nut (28)
31	Remove bolts (29)
32	Remove compressor (30) and place down to side
33	Disconnect cable strap (31) from compressor (30)
34	Remove frontal acceleration sensor (33)	Lay front acceleration sensor (33) down to side.
35	Unclip washer fluid hose (36) with mounting clip (37)	with code 600 Headlamp cleaning system
36	Clamp off washer fluid hose (36) with hose clamp (35)	with code 600 Headlamp cleaning system
37	Press retainer (39) into telescopic nozzle (38)	with code 600 Headlamp cleaning system
38	Remove telescopic nozzle (38)	with code 600 Headlamp cleaning system
39	Fasten washer fluid hose (36) and pressure line (24) with adhesive tape (48)	with code 600 Headlamp cleaning system
40	Pull washer fluid hose (36) and pressure line (24) out of crossmember	with code 600 Headlamp cleaning system
41	Unscrew nut (41)
42	Lay washer fluid reservoir (40) down to side
43	Remove bottom radiator air guide (43)
44	Unclip and remove side radiator air guide (44)
45	Fasten radiator with fastening belt (45)	Adapter for fastening belt	Fig 12
		Adapter for fastening belt	Fig 13
		Fastening belt	Fig 14
46	Remove screws (46) on left and right longitudinal members
47	Remove front module (47)
	Install
48	Install front module (47)
49	Screw front module (47) to left and right longitudinal members with screws (46)	Position bolts loosely.
50	Adjust front module (47)	Fit middle front reinforcement (22), lamp unit and front bumper for adjustment work.	AR62.30-P-1570-01SX
		Bolt, front end to longitudinal member	*BA62.30-P-1001-02F
		Screw for outer reinforcement to fender mount	*BA62.30-P-1002-02F
51	Adjust gap dimensions on hoods, doors and lids	Model 216 gap dimensions	AR60.00-P-0700-01SC
		Feeler gauge	Figure
		Engine hood to fender	*BE60.00-P-1001-01T
		Engine hood to headlamp	*BE60.00-P-1001-01T
		Engine hood to bumper	*BE60.00-P-1001-01T
		Model 221 gap dimensions	AR60.00-P-0700-01SX
		Feeler gauge	Figure
		Engine hood to fender	*BE60.00-P-1001-01R
		Engine hood to headlamp	*BE60.00-P-1001-01R
		Engine hood to bumper	*BE60.00-P-1001-01R
52	Apply wax preservation to connections on body	After adjustment work as well as removal and installation of front module parts.
		Preservation agent	*BR00.45-Z-1011-05A
		MB cavity wax preservation, 1 l	*BR00.45-Z-1015-05A
53	Remove center front reinforcement (22)
54	Loosen fastening belt (45) on radiator	Adapter for fastening belt	Fig 12
		Adapter for fastening belt	Fig 13
		Fastening belt	Fig 14
55	Remove fastening belt (45)
56	Install and clip in side radiator air guide (44)
57	Install bottom radiator air guide (43)
58	Install washer fluid reservoir (40)
59	Screw on washer fluid reservoir (40) with nut (41)
60	Thread washer fluid hose (36) and pressure line (24) through crossmember	with code 600 Headlamp cleaning system
61	Separate adhesive tape (48) from washer fluid hose (36) and pressure line (24)	with code 600 Headlamp cleaning system
62	Install telescopic nozzle (38)	with code 600 Headlamp cleaning system
63	Loosen hose clamp (35) from washer fluid hose (36)	with code 600 Headlamp cleaning system
64	Fasten washer fluid hose (36) with mounting clip (37)	with code 600 Headlamp cleaning system
65	Install frontal acceleration sensor (33)
66	Screw tight compressor (30) with bolts (29) and nut (28)
67	Fasten pressure line (24) with cable tie (31)
68	Screw tight valve unit (25) with nut (26)
69	Screw pressure line (27) to central reservoir on valve unit (25)
70	Screw pressure line (24) to compressor unit with valve unit (25)
71	Install fanfare horn (34)
72	Install top radiator air guide (14)
73	Install front center reinforcement (22)
74	Screw tight center front reinforcement (22) with screws (32)
75	Clip hood release cable (7) into retaining clips (23)
76	Install DTR radar sensor (A89b1) (16) and screw tight with screws (15)	With code 219 Distronic (DTR)
77	Connect electrical connector (17) to DTR radar sensor (A89b1) (16)	With code 219 Distronic (DTR)
78	Clip in wiring harness with mounting clips (18)	With code 219 Distronic (DTR)
79	Fasten top radiator air guide (14) with threaded clips (13)
80	Fasten lug (12) in side radiator air guide (11)
81	Fasten side radiator air guide (11) with threaded clip (10) on left and right
82	Press in radiator mount (9) on left and right
83	Press radiator mount clip (8) on left and right into radiator mount (9)
84	Connect hood release cable (7) to hood release cable coupling (6)
85	Connect hood release cable connector (6)
86	Screw in stop buffer (21)
87	Screw in screws (19)
88	Install right air duct (4) and left air duct (5)
89	Install engine cover (3)
90	Install cover (2) on left and right
91	Install apex seal (1).
92	Install detachable body components in area to be repaired
93	Install engine hood lock bottom section		AR88.40-P-3200SX
94	Install lamp unit		AR82.10-P-4730SX
95	Install front bumper		AR88.20-P-2000SX
96	Install lower engine compartment paneling	Vehicles without code (Z07) Top protection	AR61.20-P-1105SX
		Vehicles with code (Z07) Top protection	AR61.20-P-1105SXS

Number	Designation				Model 216 up to model year 2011	Model 216 as of model year 2011
BE60.00-P-1001-01T	Gap dimension	Engine hood to fender	Dimension "A"	mm	3.5 (± 0.5)	3.5 (± 0.5)
		Engine hood to headlamp	Dimension "B"	mm	3.5 (± 0.5)	3.5 (± 0.5)
		Engine hood to A-pillar	Dimension "D"	mm	4.0 (± 0.5)	4.0 (± 0.5)
		Radiator grille/bumper	Dimension "C"	mm	5.0 (± 1.0)	2.0 (± 1.0)
		Engine hood to bumper	Dimension "P"	mm	5.0 (± 1.0)	5.0 (± 1.0)
		Bumper to headlamp	Dimension "Q"	mm	3.5 (± 0.5)	3.5 (± 0.5)
			See picture		AR60.00-P-0700-01SC	AR60.00-P-0700-01SC

Number	Designation				Model 221
BE60.00-P-1001-01R	Gap dimension	Engine hood to fender	Dimension "A"	mm	3.5 (± 0.5)
		Engine hood to headlamp	Dimension "B"	mm	3.5 (± 0.5)
		Radiator grille/bumper	Dimension "C"	mm	5 (± 1)
		Engine hood to bumper	Dimension "P"	mm	5 (± 1.5)
		Bumper to headlamp	Dimension "Q"	mm	3.5 (± 0.5)
		Bumper to fender	Dimension "R"	mm	3.5 (± 0.5)
			See picture		AR60.00-P-0700-01SX

Number	Designation		Model 216	Model 221
BA62.30-P-1001-02F	Bolt connecting front end to longitudinal member	Nm	55	55
BA62.30-P-1002-02F	Bolt, outer reinforcement to fender bracket	Nm	10	10

Number	Designation	Order number
BR00.45-Z-1011-05A	Cavity preservation, solvent-free (1 l container)	A 000 986 72 70 10
BR00.45-Z-1015-05A	Preservation agent	A 000 989 72 70 10