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Adjust rear-end door - AR72.20-P-3510ES

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MODEL 212.2 

Fig 1: Adjusting Rear End Door (1 Of 2)
G09977424Courtesy of MERCEDES-BENZ USA
Fig 2: Adjusting Rear End Door (2 Of 2)
G09977425DANGERIMPORTANTIMPORTANTSPECIAL TOOLIMPORTANTIMPORTANTIMPORTANTIMPORTANTIMPORTANTSPECIAL TOOLIMPORTANTTORQUE SPECIFICATIONIMPORTANTIMPORTANTSPECIAL TOOLIMPORTANTTORQUE SPECIFICATIONIMPORTANTIMPORTANTCourtesy of MERCEDES-BENZ USA
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
IMPORTANT Notes on sensor system for trunk lid opening/closing   AH80.61-P-0001-01A
1 Check gap dimensions and transitions between tailgate (1) in relation to adjacent components Gap dimensions on hoods, doors and lids
IMPORTANT Dimensions "R1, S, U"
AR60.00-P-0700-01EW
Gap dimension *BE60.00-P-1005-01U 
SPECIAL TOOL Feeler gauge Figure
2 Loosen bolt (2) and completely push back stop lug (3) IMPORTANT At both sides of rear-end door (1).  
3 Remove rear center section paneling (5)    
4 Remove lock striker (4)    
  Adjusting in X-direction (X) and Y-direction (Y)     
5 Remove rear spoiler    
6 Remove covers above nuts (6)    
7 Loosen nuts (6) on left and right hinge (7), do not unscrew IMPORTANT If only one single hinge (7) is removed or installed, it is only necessary to adjust the rear-end door (1) at the corresponding hinge (7).  
8 Remove both gas-operated struts Remove/install gas-operated strut to rear-end door
IMPORTANT Do support rear-end door (1) with support. Helper required to hold rear-end door (1).
  AR72.20-P-3600CX 
9 Adjust rear-end door (1) in X-direction (X) and Y-direction (Y) IMPORTANT Helper required to hold rear-end door (1).
IMPORTANT If the adjustment range in the Y-direction (Y) is not sufficient, adjust rear-end (1) door by loosening bolts (8).
 
Gap dimension *BE60.00-P-1005-01U 
SPECIAL TOOL Feeler gauge Figure
10 Tighten nuts (6) on hinges (7) IMPORTANT Helper should hold rear-end door (1) until one nut (6) is screwed into each hinge (7).  
TORQUE SPECIFICATION Bolt/nut, rear-end door hinge to rear-end door *BA72.20-P-1001-02L 
11 Repair paint damage on nuts (6) with appropriate touch-up paint pen    
12 Remove covers above nuts (6)    
13 Install rear spoiler    
  Adjusting in Z-direction (Z)     
14 Remove headliner    
15 Remove drive unit from automatic rear-end door (1)    
16 Loosen bolts (8) on left or right hinge (7), do not remove IMPORTANT If only one single hinge (7) is removed or installed, it is only necessary to adjust the rear-end door (1) at the corresponding hinge (7).  
17 Adjust transition from rear-end door (1) to roof frame in Z-direction (Z) IMPORTANT Helper required to hold rear-end door (1). Top edge of rear-end door (1) should be flush with roof frame. Observe dimension "U".  
Gap dimension *BE60.00-P-1005-01U 
SPECIAL TOOL Feeler gauge Figure
18 Tighten bolts (8) on hinges (7) IMPORTANT Helper should hold rear-end door (1) until one bolt (8) is screwed into each hinge (7).  
TORQUE SPECIFICATION Screw/bolt, rear-end door hinge to body *BA72.20-P-1002-02L 
19 Install both gas-operated struts Remove/install gas-operated strut to rear-end door AR72.20-P-3600CX 
20 Repair paint damage on bolts (8) with appropriate touch-up paint pen    
21 Install lock striker (4) and screw in bolts to stop    
22 Adjust transition between rear-end door (1) and edges of rear fender and D-pillars by moving lock striker (4) in X-direction (X) IMPORTANT Rear-end door (1) must be flush with edges of rear fender and D-pillars.  
23 Tighten bolts on lock striker (4)    
24 Completely press in stop lugs (3) on both sides of vehicle    
25 Tighten screw (2) IMPORTANT At both sides of rear-end door (1).  
26 Install rear center section paneling (5)    
27 Install drive unit for automatic rear-end door (1)    
28 Install headliner    
CHECK VALUES FOR GAP DIMENSIONS

Number Designation MODEL 212.2
BE60.00-P-1005-01U Gap dimension Liftgate to roof Dimension "R" mm -
Liftgate to roof (spoiler removed) Dimension "R1" mm 9, 5 (±1, 5)
Spoiler to roof Dimension "R2" mm 5 (±1, 5)
Liftgate to rear fender Dimension "S" mm 4 (+1, 5/-1)
Liftgate to taillamp Dimension "T" mm -
Liftgate to bumper Dimension "U" mm 6 (±1, 5)
Liftgate to D-pillar Dimension "V" mm -
Rear window and D-pillar Dimension "X" mm -
Top sliding roof to roof Dimension "Y" mm 5 (±1, 5)
Rear window to liftgate, bottom Dimension "Z" mm 3 (±1, 5)
Picture -
REAR-END DOOR

Number Designation MODEL 212.2
BA72.20-P-1001-02L Bolt/nut, rear-end door hinge to rear-end door Nm 32
REAR-END DOOR

Number Designation MODEL 212.2
BA72.20-P-1002-02L Screw/bolt, rear-end door hinge to body Nm 40
Fig 3: Identifying Feeler Gauge (129 589 03 21 00)
G09977426Courtesy of MERCEDES-BENZ USA