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

MODEL 117, 156, 176, 242, 246 

MODIFICATION NOTES

2.8.13

Bolt, absorber to longitudinal member

MODEL 176, 246

BA62.30-P-1004-02C

Fig 1: Front Reinforcement And Crossmember

Courtesy of MERCEDES-BENZ USA

Fig 2: Front End Assembly Support

Courtesy of MERCEDES-BENZ USA

Fig 3: Front End Assembly Screws And Bolts

Courtesy of MERCEDES-BENZ USA

Fig 4: Front End Assembly Screws

Courtesy of MERCEDES-BENZ USA

	Risk of injury  due to fan starting unexpectedly	Do not reach into the rotation or hazard area of the fan. Wear closed and close-fitting work clothes.	AS20.40-Z-0001-01A
	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-N-0001-01A
	Remove/install
1	Remove all detachable parts in repair area
2	Check support (3)	Insert support (3) at bottom into engine mount and fasten at top to engine hood lock bracket.
		Support	Fig 6
3	Remove screws/bolts (4)	Tighten bolts (4) after fitting work with specified torque.
		Bolt, front end assembly to upper longitudinal member	*BA62.30-P-1001-02C
4	Remove bolts (5)	After fitting work, always tighten center bolt (5) first with specified torque, then outer bolts.
		Bolt, absorber to longitudinal member	*BA62.30-P-1004-02C
5	Remove front reinforcement (1) together with front crossmember (2)
6	Unscrew bolts (6, 7, 8) and remove front reinforcement (1) from front crossmember (2)
7	Remove detaching parts from front reinforcement (1)
8	Install in the reverse order
9	Fit front end with front reinforcement (1)	Remove bumper after adjustment work. First tighten center bolt (5) with specified torque, then outer bolts.
		Bolt, front end assembly to upper longitudinal member	*BA62.30-P-1001-02C
		Bolt, absorber to longitudinal member	*BA62.30-P-1004-02C
10	Adjust gap dimensions on lamp units and bumper	MODEL 117.3	*BE60.00-P-1006-01ZA
		MODEL 117.3	*BE60.00-P-1005-01ZA
		MODEL 117.3	*BE60.00-P-1003-01ZA
		MODEL 117.3	*BE60.00-P-1002-01ZA
		MODEL 156, 176, 242, 246	*BE60.00-P-1001-01AA
		Feeler gauge	Fig 5
11	Apply wax preservation to connections on body	After adjustment operations as well as removal and installation of front end assembly parts with front reinforcement. (1).
		Cavity preservation, solvent-free (1 l container)	*BR00.45-Z-1003-05A

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 156	MODEL 176
BE60.00-P-1001-01AA	Gap dimension	Engine hood to fender	Dimension "A"	mm	3, 5 (±1)	4, 0 (+1/-1, 5)
		Engine hood to headlamp	Dimension "B"	mm	3 (+1, 5/-1)	4, 0 (±1)
		Engine hood to bumper	Dimension "C"	mm	3, 5 (±1)	4, 0 (±1)
		Fender to headlamp	Dimension "D"	mm	3 (±1, 5)	4, 0 (+1/-1, 5)
		Bumper to headlamp (circumferential)	Dimension "E"	mm	3 (+1, 5/-2)	4, 0 (+1/-1, 5)
		Reinforcement to engine hood (exterior)	Dimension "F"	mm	-	-
		Fender to A-pillar	Dimension "G"	mm	3 (±1)	3, 5 (±1)
			Picture		AR60.00-P-0700-01NKX	AR60.00-P-0700-01NKB

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 242, MODEL 246 up to model year 2015	MODEL 246 as of model year 2015
BE60.00-P-1001-01AA	Gap dimension	Engine hood to fender	Dimension "A"	mm	4, 0 (+1/-1, 5)	3, 5 (±1, 0)
		Engine hood to headlamp	Dimension "B"	mm	4, 0 (±1)	2, 9 (±1, 3)
		Engine hood to bumper	Dimension "C"	mm	4, 0 (±1)	3, 0 (±1, 0)
		Fender to headlamp	Dimension "D"	mm	4, 0 (+1/-1, 5)	2, 4 (±1, 3)
		Bumper to headlamp (circumferential)	Dimension "E"	mm	4, 0 (+1/-1, 5)	2, 0 (±1, 2)
		Reinforcement to engine hood (exterior)	Dimension "F"	mm	39, 5 (-1)	39, 5 (-1)
		Fender to A-pillar	Dimension "G"	mm	3, 0 (±1)	1, 8 (±1, 0)
			Picture		AR60.00-P-0700-01NKB	AR60.00-P-0700-01NKB

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 117.3
BE60.00-P-1002-01ZA	Gap dimension	Engine hood to headlamp	Dimension "B"	mm	4, 0 (±1, 0)
			For picture, see		AR60.00-P-0700-01NKC

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 117.3
BE60.00-P-1003-01ZA	Gap dimension	Engine hood to bumper	Dimension "C"	mm	4, 0 (±1)
			For picture, see		AR60.00-P-0700-01NKC

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 117.3
BE60.00-P-1005-01ZA	Gap dimension	Front fender to headlamp	Dimension "D"	mm	3, 0 (±1, 5)
			For picture, see		AR60.00-P-0700-01NKC

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 117.3
BE60.00-P-1006-01ZA	Gap dimension	Bumper to headlamp (circumferential)	Dimension "E"	mm	3, 5 (+1, 5/-2, 0)
			For picture, see		AR60.00-P-0700-01NKC

FRONT END WITH FRONT REINFORCEMENT

Number	Designation		MODEL 156	MODEL 117
BA62.30-P-1001-02C	Bolt, front end assembly to upper longitudinal member	Nm	20	20

FRONT END WITH FRONT REINFORCEMENT

Number	Designation		MODEL 242	MODEL 176, 246
BA62.30-P-1001-02C	Bolt, front end assembly to upper longitudinal member	Nm	20	20

FRONT END WITH FRONT REINFORCEMENT

Number	Designation			MODEL 156	MODEL 117
BA62.30-P-1004-02C	Bolt, absorber to longitudinal member	Stage 1	Nm	125	120
		Stage 2		Loosen	Loosen
		Stage 3	Nm	125	120

FRONT END WITH FRONT REINFORCEMENT

Number	Designation			MODEL 242	MODEL 176, 246
BA62.30-P-1004-02C	Bolt, absorber to longitudinal member	Stage 1	Nm	120	125
		Stage 2		Loosen	Loosen
		Stage 3	Nm	120	125

Fig 5: Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Support (170 589 04 63 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