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Adjust front door - AR72.10-P-0550CW

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MODEL 166 except CODE (Z04) Light armoring except CODE (Z05) 

MODEL 204, 207, 212, 218 

Shown on model 204.002 

Fig 1: Adjusting Front Door - Shown On Model 204.002
G09977326Courtesy of MERCEDES-BENZ USA

Shown left side front door (1) on Model 204.0 

Fig 2: Adjusting Front Door - Shown On Left Side Front Door Model 204.0
G09977327Courtesy of MERCEDES-BENZ USA

Shown left side front door (1) on Model 204.0 

Fig 3: Adjusting Front Door - Shown On Left Side Front Door Model 204.0
G09977328Courtesy of MERCEDES-BENZ USA
INSPECT Checking     
DANGER Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A
    IMPORTANT On model 204, 207, 212 two different versions of upper hinges (13) can be installed. If an eccentric hinge leaf (11) is installed on the front door (1), the preliminary work required for reaching nuts (14) on the upper hinge (13) is eliminated.
The eccentric (20) is located on the top side (arrow) of the eccentric hinge leaf (11).		  
1 Check gap dimensions at front door (1) SPECIAL TOOL Feeler gauge
IMPORTANT Gaps on hoods, doors and covers:		 Fig 4
Model 166 AR60.00-P-0700-01GQ
Gap dimensions "E, F" *BE60.00-P-1001-01Z 
Model 204.0/2 AR60.00-P-0700-01CW
Gap dimensions "G, H, I, W" *BE60.00-P-1002-01U 
Model 204.3 AR60.00-P-0700-01CW
Gap dimensions "F, G" *BE60.00-P-1002-01W 
Model 204.9 AR60.00-P-0700-01WX
Gap dimensions "G, H, I, W" *BE60.00-P-1002-01U 
Model 207 AR60.00-P-0700-01EC
Gap dimensions "F, G" *BE60.00-P-1002-01W 
Model 212 AR60.00-P-0700-01EW
Gap dimensions "G, H, I, W" *BE60.00-P-1002-01U 
Model 218 AR60.00-P-0700-01EL
Gap dimensions "E, F" *BE60.00-P-1002-01O 
REMOVING Removing     
2 Remove left or right trim (3) IMPORTANT Completely depress parking brake pedal (7) toward front to remove paneling (3) on driver side.  
3 Expose nuts (5) IMPORTANT On model 204, 207 it is necessary to detach the insulation mat (4).
On model 166, 212, 218 it is necessary to remove the cap.		  
4 Remove dashboard cover (6). When adjusting driver side front door (1), if a standard hinge leaf (10) is installed.  
5 Remove parking brake cover (8) When adjusting driver side front door (1), if a standard hinge leaf (10) is installed.
Except model 166		  
6 Remove glove box When adjusting passenger side front door (1), if a standard hinge leaf (10) is installed.  
Model 166 AR68.10-P-1400GQ
Model 204.0/2/3 AR68.10-P-1200CW
Model 204.9 AR68.10-P-1200CY
Model 207 AR68.10-P-1400EC
Model 212 AR68.10-P-1200EW
Model 218 AR68.10-P-1400EL
7 Remove rear SAM control unit with bracket When adjusting passenger front door (1). Model 166 only AR54.21-P-1254GQ
8 Unscrew bolts (9) and remove fresh air/recirculated air flap actuator motor (M2/5) When adjusting passenger side front door (1), if a standard hinge leaf (10) is installed.
Except model 166
IMPORTANT Do not disconnect electrical connector (27).		  
9 Remove locking eye (2) IMPORTANT Mark installation position of lock striker (2) to facilitate installation.  
  Adjust     
10 Loosen bolts on lower hinge (12) on outside of A-pillar Model 204.3, 207  
11 Loosen bolts on upper hinge (13) on outside A-pillar Model 204.3, 207, if a standard hinge leaf (10) is installed.  
12 Loosen nuts (5) on bottom hinge (12) from A-pillar    
13.1 Loosen nuts (14) on top hinge (13) from A-pillar and adjust corresponding gap dimensions by moving front door (1). Then tighten nuts (14) If a standard hinge leaf (10) is installed.
IMPORTANT On model 204 a connection piece 3/8 to length of 77 mm and key width of 13 mm is required to tighten nuts (14). A corresponding extension (17) is required additionally at the driver side.
Connection piece 3/8 to 1/2 (15) and socket wrench (16)		  
SPECIAL TOOL Feeler gauge
IMPORTANT Gaps on hoods, doors and covers:		 Fig 4
Model 166 AR60.00-P-0700-01GQ
Gap dimensions "E, F" *BE60.00-P-1001-01Z 
Model 204.0/2 AR60.00-P-0700-01CW
Gap dimensions "G, H, I, W" *BE60.00-P-1002-01U 
Model 204.3 AR60.00-P-0700-01CW
Gap dimensions "F, G" *BE60.00-P-1002-01W 
Model 204.9 AR60.00-P-0700-01WX
Gap dimensions "G, H, I, W" *BE60.00-P-1002-01U 
Model 207 AR60.00-P-0700-01EC
Gap dimensions "F, G" *BE60.00-P-1002-01W 
Model 212 AR60.00-P-0700-01EW
Gap dimensions "G, H, I, W" *BE60.00-P-1002-01U 
Model 218 AR60.00-P-0700-01EL
Gap dimensions "E, F" *BE60.00-P-1002-01O 
TORQUE SPECIFICATION Model 204, 207, 212 *BA72.10-P-1002-01S 
TORQUE SPECIFICATION Model 218 *BA72.10-P-1004-01M 
13.2 Remove cap (18), loosen bolt (19) and adjust corresponding gap dimensions by turning eccentric (20). Then tighten bolt (19) If an eccentric hinge leaf (11) is installed.  
SPECIAL TOOL Feeler gauge
IMPORTANT Gaps on hoods, doors and covers:		 Fig 4
Model 166 AR60.00-P-0700-01GQ
Gap dimensions "E, F" *BE60.00-P-1001-01Z 
Model 204.0/2 AR60.00-P-0700-01CW
Gap dimensions "G, H, I, W" *BE60.00-P-1002-01U 
Model 204.3 AR60.00-P-0700-01CW
Gap dimensions "F, G" *BE60.00-P-1002-01W 
Model 204.9 AR60.00-P-0700-01WX
Gap dimensions "G, H, I, W" *BE60.00-P-1002-01U 
Model 207 AR60.00-P-0700-01EC
Gap dimensions "F, G" *BE60.00-P-1002-01W 
Model 212 AR60.00-P-0700-01EW
Gap dimensions "G, H, I, W" *BE60.00-P-1002-01U 
Model 218 AR60.00-P-0700-01EL
Gap dimensions "E, F" *BE60.00-P-1002-01O 
TORQUE SPECIFICATION Model 204, 207, 212 *BA72.10-P-1002-01S 
TORQUE SPECIFICATION Model 218 *BA72.10-P-1004-01M 
14 Tighten nuts (5) on bottom hinge (12) TORQUE SPECIFICATION Model 166 *BA72.10-P-1003-01O 
TORQUE SPECIFICATION Model 204, 207, 212 *BA72.10-P-1002-01S 
TORQUE SPECIFICATION Model 218 *BA72.10-P-1004-01M 
15 Tighten bolts on upper hinge (13) on outside of A-pillar Model 204.3, 207, if a standard hinge leaf (10) is installed.  
TORQUE SPECIFICATION *BA72.10-P-1002-01S 
16 Tighten bolts on lower hinge (12) on outside of A-pillar Model 204.3, 207  
TORQUE SPECIFICATION *BA72.10-P-1002-01S 
17 Loosen bolts (21) on inner door panel and adjust transition (A) to front fender (22) by moving front door (1) IMPORTANT The contour of the front fender (22) must be flush with the contour of the front door (1) or project by a maximum of 1 mm.  
18 Tighten bolts (21) TORQUE SPECIFICATION Model 166 *BA72.10-P-1002-01O 
    TORQUE SPECIFICATION Model 204, 207, 212 *BA72.10-P-1001-01S 
    TORQUE SPECIFICATION Model 218 *BA72.10-P-1003-01M 
IMPORTANT Notes on calculating tightening torque when using insertion tool with various effective lengths   AH00.00-P-0015-01CW
19 Insert lock striker (2) and screw in bolts (25) up to stop IMPORTANT It should still be possible to adjust the lock striker (2).  
20 Adjust transition (B) between front door (1) and rear door (26) by moving lock striker (2) IMPORTANT The contour of the front door (1) should be flush with the contour of the rear door (26) or the rear fender and should project by a maximum of 1 mm.  
21 Tighten bolts (25) TORQUE SPECIFICATION Model 166 *BA72.10-P-1004-01O 
TORQUE SPECIFICATION Model 204, 207, 212 *BA72.10-P-1004-01S 
TORQUE SPECIFICATION Model 218 *BA72.10-P-1009-01M 
INSTALLING Install     
22 Repair paint damage on screw heads (19, 21) IMPORTANT Repair screw heads (19) only if an eccentric hinge leaf (11) is installed.  
23 Install cap (18) If an eccentric hinge leaf (11) is installed.  
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 anticorrosion agents on flames or glowing hot 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
24 Protect front door (1) and A-pillar in area of upper door hinge (13) and lower door hinge (12) against corrosion; remove excessive wax Wax preservative, aerosol *BR00.45-Z-1018-05A 
25 Install fresh air/recirculated air flap actuator motor (M2/5) and tighten with bolts (9) If the front passenger door (1) is adjusted with a standard hinge leaf (10).
Except model 166		  
26 Install front SAM control unit with bracket IMPORTANT If passenger front door (1) has been adjusted.
Model 166 only		 AR54.21-P-1254GQ
27 Install glove box If the front passenger door (1) is adjusted with a standard hinge leaf (10).  
Model 166 AR68.10-P-1400GQ
Model 204.0/2/3 AR68.10-P-1200CW
Model 204.9 AR68.10-P-1200CY
Model 207 AR68.10-P-1400EC
Model 212 AR68.10-P-1200EW
Model 218 AR68.10-P-1400EL
28 Install parking brake cover (8) If the front driver door (1) is adjusted with a standard hinge leaf (10).
Except model 166		  
29 Install dashboard cover (6). If the front driver door (1) is adjusted with a standard hinge leaf (10).  
30 Glue on left or right damper mat (4) Model 204, 207  
31 Install cap at inside of lower A-pillar Model 166, 212, 218  
32 Install left or right paneling (3)    
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)
  See picture AR60.00-P-0700-01GQ
CHECK VALUES FOR GAPS

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 door Dimension "H" mm 4 (+1/-0.5) 4 (+1/-0.5)
Front door to roof frame Dimension "I" mm 15 (+0.5/-1) 15 (+0.5/-1)
Rear door to roof frame Dimension "J" mm 15.5 (+1/-0.5) 15.5 (+1/-0.5)
Rear door to side piece, bottom Dimension "K" 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)
  See picture AR60.00-P-0700-01CW AR60.00-P-0700-01CW
CHECK VALUES FOR GAPS

Number Designation Model 204.3
BE60.00-P-1002-01W Gap dimension Front door to fender Dimension "F" mm 4 (+1.5/-0.5)
Front door to rear fender Dimension "G" mm 4 (+1/-0.5)
See picture AR60.00-P-0700-01CW
CHECK VALUES FOR GAPS

Number Designation Model 204.9
BE60.00-P-1002-01U Gap dimension Front door to fender Dimension "G" mm 4.5 (±1)
Front door to rear door Dimension "H" mm 4.5 (±1)
Front door to roof frame Dimension "I" mm 10 (+2/-1)
Rear door to roof frame Dimension "J" mm 9.5 (+2/-1)
Rear door to side piece, bottom Dimension "K" mm 4 (±1)
Driver door cover to rear door cover Dimension "W" mm 4 (+1.5/-0.5)
  See picture AR60.00-P-0700-01WX
CHECK VALUES FOR GAPS

Number Designation Model 207.3 Model 207.4
BE60.00-P-1002-01W Gap dimension Front door to fender Dimension "F" mm 4 (+1.5/-0.5) 4 (+1.5/-0.5)
Front door to rear fender Dimension "G" mm 4 (+1/-0.5) 4 (+1/-0.5)
See picture AR60.00-P-0700-01EC AR60.00-P-0700-01EC
CHECK VALUES FOR GAPS

Number Designation Model 212.0/1 Model 212.2
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 door Dimension "H" mm 4.5 (+1/-0.5) 4.5 (+1/-0.5)
Front door to roof frame Dimension "I" mm 14 (±1.5) 14 (±1.5)
Rear door to roof frame Dimension "J" mm 13 (±1.5) 13 (±1.5)
Rear door to side piece, bottom Dimension "K" mm 4 (+1/-0.5) 4 (+1/-0.5)
Driver door cover to rear door cover Dimension "W" mm 4 (±1) 4 (±1)
  See picture AR60.00-P-0700-01EW AR60.00-P-0700-01EW
TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number Designation Model 218.3
BE60.00-P-1002-01O Gap dimension Fender to A-pillar Dimension "D" mm 3.5 (±1)
Front door to fender Dimension "E" mm 4.0 (-0.5/+1)
Front door to rear door Dimension "F" mm 5.0 (-0.5/+1)
B-pillar cover to front window Dimension "G" mm 10 (±1)
B-pillar cover to rear window Dimension "H" mm 10 (±1)
Rear door to side piece, bottom Dimension "I" mm 4.5 (±1)
  See picture AR60.00-P-0700-01EL
FRONT DOOR

Number Designation Model 166
BA72.10-P-1002-01O Bolt, door hinge on front door Nm 32
BA72.10-P-1003-01O Nut/bolt, door hinge to A-pillar Nm 32
BA72.10-P-1004-01O Bolt, locking eye to B-pillar Nm 24
FRONT DOOR

Number Designation Model 204 Model 207 Model 212 without code Z04 Model 212 with code Z04
BA72.10-P-1001-01S Bolt, door hinge on front door Nm 34 37 34 34
BA72.10-P-1002-01S Nut/bolt for door hinge on A-pillar Nm 34 37 34 34
BA72.10-P-1004-01S Bolt, locking eye to B-pillar Nm 24 24 24 24
FRONT DOOR

Number Designation Model 218
BA72.10-P-1003-01M Bolt, door hinge on front door Nm 34
BA72.10-P-1004-01M Nut/bolt, door hinge to A-pillar Nm 34
BA72.10-P-1009-01M Bolt, locking eye to B-pillar Nm 24
Fig 4: Identifying Feeler Gauge (129 589 03 21 00)
G09977329Courtesy 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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