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Adjust rear door - AR72.12-P-0650CW

MODEL 166 without CODE Z04 (Light armoring) without CODE Z05 (B5 armoring on special protection version) 

MODEL 204.0/2/9, 212.1/2, 218 

MODEL 212.0 without CODE Z04 (Light armoring) 

Shown on model 204.0 without code (299) PRE-SAFE 

Fig 1: Adjusting Rear Door - Shown On Model 204.0 Without Code 299
G09977374Courtesy of MERCEDES-BENZ USA

Shown on model 204.0 

Fig 2: Adjusting Rear Door - Shown On Model 204.0
G09977375Courtesy of MERCEDES-BENZ USA

Model 204.9 

Fig 3: Adjusting Rear Door - Shown On Model 204.9
G09977376Courtesy of MERCEDES-BENZ USA
INSPECT Check     
DANGER Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. No parts of the body or limbs should be within the operating area when the components are moving. AS00.00-Z-0011-01A
1 Check gap dimensions at rear door (1) MODEL 166 AR60.00-P-0700-01GQ
MODEL 204.0/2 AR60.00-P-0700-01CW
MODEL 204.9 AR60.00-P-0700-01WX
MODEL 212 AR60.00-P-0700-01EW
MODEL 218.3/9
IMPORTANT Gaps on hoods, doors and covers:		 AR60.00-P-0700-01EL
MODEL 166, gap dimensions "F, I" *BE60.00-P-1001-01Z 
MODEL 204, 212, gap dimensions "H, J, K, W" *BE60.00-P-1002-01U 
MODEL 218, gap dimensions "F, I" *BE60.00-P-1002-01O 
SPECIAL TOOL Feeler gauge Figure
2 Check upper gap lip (10) on side wall (11) MODEL 204.9
IMPORTANT The joint lip (10) must make contact with the top of the side wall (11) when the rear door (1) is closed		  
REMOVING Remove     
3 Switch off ignition and remove transmitter key or KEYLESS-GO stop/start button from the EZS control unit IMPORTANT KEYLESS-GO start/stop button only on vehicles with code (889) Keyless-Go.  
4 Remove locking eye (2) IMPORTANT Mark installation position of lock striker (2) to facilitate installation.  
5 Remove lower trim (3) on B-pillar    
6 Remove upper paneling from B-pillar and lay down to side MODEL 218
IMPORTANT Do not remove seat belt from upper B-pillar paneling.		  
7 Remove bolt (7) at automatic belt retractor (9) MODEL 166, 204.9, 212, 218 MODEL 204.0/2 with CODE 299 (PRE-SAFE)
IMPORTANT On model 204 with code (299) PRE-SAFE and on model 166, 212, 218 unscrew 2 bolts (7).		  
8 Route automatic belt retractor (9) upward out of retaining tab (arrow) on B-pillar MODEL 166, 204.9, 212, 218 MODEL 204.0/2 with CODE 299 (PRE-SAFE)
IMPORTANT Do not disconnect electrical connector (8), if necessary expose wiring harness.
Do not disconnect PRE-SAFE electrical connectors on vehicles with code (299) PRE-SAFE.
Ensure that seat belt does not roll up.		  
  Adjust     
9 Loosen B-pillar nuts (4) and adjust corresponding gap dimensions by moving rear door (1) On model 204.0/2 without code (299) PRE-SAFE, pull seat belt to side to loosen lower B-pillar nut (4).  
MODEL 166 AR60.00-P-0700-01GQ
MODEL 204.0/2 AR60.00-P-0700-01CW
MODEL 204.9 AR60.00-P-0700-01WX
MODEL 212 AR60.00-P-0700-01EW
MODEL 218.3/9
IMPORTANT Gaps on hoods, doors and covers:		 AR60.00-P-0700-01EL
MODEL 166, gap dimensions "F, I" *BE60.00-P-1001-01Z 
MODEL 204, 212, gap dimensions "H, J, K, W" *BE60.00-P-1002-01U 
MODEL 218, gap dimensions "F, I" *BE60.00-P-1002-01O 
SPECIAL TOOL Feeler gauge Figure
10 Tighten B-pillar nuts (4) TORQUE SPECIFICATION MODEL 166 *BA72.12-P-1003-01K 
TORQUE SPECIFICATION MODEL 204.0/2/9, 212 *BA72.12-P-1002-01O 
TORQUE SPECIFICATION
MODEL 218		 *BA72.12-P-1004-01J 
11 Loosen rear door bolts (5) on inner door panel and adjust transition from rear door to front door (1) by moving rear door (1) IMPORTANT The contour of the front door (1) must be flush with the contour of the rear door or project by a maximum of 1 mm.  
12 Move rear door (1) until joint lip (10) makes contact with side wall (11) at top in front area. MODEL 204.9  
13 Tighten bolts on rear door (5) TORQUE SPECIFICATION MODEL 166 *BA72.12-P-1002-01K 
TORQUE SPECIFICATION MODEL 204.0/2/9, 212 *BA72.12-P-1001-01O 
TORQUE SPECIFICATION
MODEL 218		 *BA72.12-P-1003-01J 
14 Insert lock striker (2) and screw in bolts (6) up to stop IMPORTANT It should still be possible to adjust the lock striker (2).  
15 Adjust transition between rear door (1), rear fender and roof paneling by moving lock striker (2) IMPORTANT The contour of the rear door (1) must be flush with the contours of the rear fender and roof paneling or project by a maximum of 1 mm.  
16 Move striker eye (2) until joint lip (10) makes contact with side wall (11) at top in rear area MODEL 204.9  
17 Tighten bolts (6) TORQUE SPECIFICATION MODEL 166 *BA72.12-P-1004-01K 
TORQUE SPECIFICATION MODEL 204.0/2/9, 212 *BA72.12-P-1004-01O 
TORQUE SPECIFICATION
MODEL 218		 *BA72.12-P-1010-01J 
INSTALLING Install     
18 Insert automatic belt retractor (9) into retaining tab (arrow) on B-pillar MODEL 166, 204.9, 212.1/2, 218 MODEL 204.0/2 with CODE 299 (PRE-SAFE)  
19 Tighten bolt (7) on automatic belt retractor (9) MODEL 166, MODEL 204.9, 212, 218 MODEL 204.0/2 with CODE 299 (PRE-SAFE)
On model 204 with code (299) PRE-SAFE and on model 166, 212, 218 tighten 2 bolts (7).
IMPORTANT If necessary, fasten wiring harness.		  
TORQUE SPECIFICATION MODEL 166 *BA91.40-P-1004-01R 
TORQUE SPECIFICATION
MODEL 204.0/2/9		 *BA91.40-P-1001-01P 
TORQUE SPECIFICATION MODEL 212, 218 *BA91.40-P-1001-01Q 
20 Install upper paneling on B-pillar MODEL 218
IMPORTANT Ensure that seat belt is routed correctly.		  
21 Remove bottom section (3) from B-pillar    
22 Repair paint damage on bolt heads on rear door (5)    
DANGER 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, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. AS97.00-Z-0001-01A
23 Protect rear door (1) and B-pillar in area of upper door hinge and lower door hinge against corrosion; remove excessive wax Wax for engine compartment (400 ml spray can) *BR00.45-Z-1018-05A 
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number Designation MODEL 166
BE60.00-P-1001-01Z Gap dimension Engine hood to fender Dimension "A" mm 3, 8 (±1)
Engine hood to headlamp Dimension "B" mm 3, 9 (±1)
Engine hood to bumper Dimension "C" mm 5, 4 (±1, 5)
Fender to A-pillar Dimension "D" mm 3, 5 (±1)
Front door to fender Dimension "E" mm 4, 3 (±0, 7)
Front door to rear door Dimension "F" mm 4, 8 (±0, 7)
Rear door to rear fender Dimension "I" mm 4, 3 (±0, 7)
For picture, see AR60.00-P-0700-01G
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number Designation MODEL 218.9 MODEL 218.3
BE60.00-P-1002-01O Gap dimension Fender to A-pillar Dimension "D" mm 3, 5 (±1) 3, 5 (±1)
Front door to fender Dimension "E" mm 4, 0 (-0, 5/+1) 4, 0 (-0, 5/+1)
Front door to rear Dimension "F" door mm 5, 0 (-0, 5/+1) 5, 0 (-0, 5/+1)
B-pillar cover to front Dimension "G" window mm 10 (±1) 10 (±1)
B-pillar cover to rear Dimension "H" window mm 10 (±1) 10 (±1)
Rear door to side Dimension "I" piece, bottom mm 4, 5 (±1) 4, 5 (±1)
Fixed window on rear door to fixed window on rear side window Dimension "O" mm 7, 5 (±1) -
Picture AR60.00-P-0700-01EL AR60.00-P-0700-01EL
CHECK VALUES FOR GAP DIMENSIONS

Number Designation MODEL 204.0 MODEL 204.2
BE60.00-P-1002-01U Gap dimension Front door to fender Dimension "G" mm 4 (+1/-0, 5) 4 (+1/-0, 5)
Front door to rear Dimension "H" door mm 4 (+1/-0, 5) 4 (+1/-0, 5)
Front door to roof Dimension "I" frame mm 15 (+0, 5/-1) 15 (+0, 5/-1)
Rear door to roof Dimension "J" frame mm 15, 5 (+1/-0, 5) 15, 5 (+1/-0, 5)
Rear door to side Dimension "K" piece, bottom mm 4 (+1/-0, 5) 4 (+1/-0, 5)
Driver door cover to rear door cover Dimension "W" mm 4 (+1, 5) 4 (+1, 5)
Picture AR60.00-P-0700-01CW AR60.00-P-0700-01CW
CHECK VALUES FOR GAP DIMENSIONS

Number Designation MODEL 204.9 MODEL 212.0/1
BE60.00-P-1002-01U Gap dimension Front door to fender Dimension "G" mm 4, 5 (±1) 4 (+1/-0, 5)
Front door to rear Dimension "H" door mm 4, 5 (±1) 4, 5 (+1/-0, 5)
Front door to roof Dimension "I" frame mm 10 (+2/-1) 14 (±1, 5)
Rear door to roof Dimension "J" frame mm 9, 5 (+2/-1) 13 (±1, 5)
Rear door to side Dimension "K" piece, bottom mm 4 (±1) 4 (+1/-0, 5)
Driver door cover to rear door cover Dimension "W" mm 4 (+1, 5/-0, 5) 4 (±1)
Picture AR60.00-P-0700-01WX AR60.00-P-0700-01EW
CHECK VALUES FOR GAP DIMENSIONS

Number Designation MODEL 212.2
BE60.00-P-1002-01U Gap dimension Front door to fender Dimension "G" mm 4 (+1/-0, 5)
Front door to rear Dimension "H" door mm 4, 5 (+1/-0, 5)
Front door to roof Dimension "I" frame mm 14 (±1, 5)
Rear door to roof Dimension "J" frame mm 13 (±1, 5)
Rear door to side Dimension "K" piece, bottom mm 4 (+1/-0, 5)
Driver door cover to rear door cover Dimension "W" mm 4 (±1)
Picture AR60.00-P-0700-01EW
REAR DOOR

Number Designation MODEL 204 MODEL 212 except CODE Z04
BA72.12-P-1001-01O Bolt, door hinge to rear door Nm 34 34
REAR DOOR

Number Designation MODEL 212 with Code Z04
BA72.12-P-1001-01O Bolt, door hinge to rear door Nm 34
REAR DOOR

Number Designation MODEL 166 except CODE Z04/Z05
BA72.12-P-1002-01K Bolt, hinge to rear door Nm 32
REAR DOOR

Number Designation MODEL 204 MODEL 212 except CODE Z04
BA72.12-P-1002-01O Nut, door hinge on B-pillar Nm 34 34
REAR DOOR

Number Designation MODEL 212 with Code Z04
BA72.12-P-1002-01O Nut, door hinge on B-pillar Nm 34
REAR DOOR

Number Designation MODEL 218
BA72.12-P-1003-01J Bolt, hinge to rear door Nm 34
REAR DOOR

Number Designation MODEL 166 except CODE Z04/Z05
BA72.12-P-1003-01K Bolt/nut, hinge to B-pillar Nm 32
REAR DOOR

Number Designation MODEL 218
BA72.12-P-1004-01J Bolt/nut, hinge to B-pillar Nm 34
REAR DOOR

Number Designation MODEL 166 except CODE Z04/Z05
BA72.12-P-1004-01K Bolt, lock striker to C-pillar Nm 24
REAR DOOR

Number Designation MODEL 204 MODEL 212 except CODE Z04
BA72.12-P-1004-01O Bolt, lock striker to C-pillar Nm 24 24
REAR DOOR

Number Designation MODEL 212 with Code Z04
BA72.12-P-1004-01O Bolt, lock striker to C-pillar Nm 24
REAR DOOR

Number Designation MODEL 218
BA72.12-P-1010-01J Bolt, lock striker to rear fender Nm 24
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS

Number Designation MODEL 204.0 MODEL 204.2
BA91.40-P-1001-01P Screw/bolt at front automatic belt retractor Nm 32 32
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS

Number Designation MODEL 204.9
BA91.40-P-1001-01P Screw/bolt at front automatic belt retractor Nm 32
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS

Number Designation MODEL 212.0 MODEL 212.1
BA91.40-P-1001-01Q Bolt, front automatic belt retractor Nm 35 35
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS

Number Designation MODEL 212.2 MODEL 218.3
BA91.40-P-1001-01Q Bolt, front automatic belt retractor Nm 35 35
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS

Number Designation MODEL 218.9
BA91.40-P-1001-01Q Bolt, front automatic belt retractor Nm 35
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS

Number Designation MODEL 166
BA91.40-P-1004-01R Screw, automatic belt retractor to B-pillar Nm 35
Fig 4: Identifying Feeler Gauge (129 589 03 21 00)
G09977377Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1018-05A Wax for engine compartment (400 ml spray can) A 000 986 33 70 10
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