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Remove/install rear door hinge - AR72.12-P-2660CY

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MODEL 204.9 

MODEL 212.0 except CODE (Z04) Light armoring 

MODEL 212.1 

MODEL 212.2 

Shown on model 204.9 without code (299) PRE-SAFE 

Fig 1: Rear Door Hinge Remove/Install Components - Shown On Model 204.9 Without Code 299
G09977416Courtesy of MERCEDES-BENZ USA
REMOVING Removing     
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
1 Remove lower trim (7) on B-pillar    
2 Remove screw/bolt (3) from automatic belt retractor (2) When removing lower door hinge (1).
IMPORTANT On model 204 with code (299) PRE-SAFE and on model 212 unscrew two bolts (3).		  
3 Route automatic belt retractor (2) upward out of retaining tab (arrow) on B-pillar. When removing lower door hinge (1).
IMPORTANT Do not disconnect electrical connector (4). Do not disconnect electrical connectors PRE-SAFE on model 204 with code (299) PRE-SAFE and on model 212.
Ensure that seat belt does not roll up.		  
4 Remove bolt cap (9) on upper and lower door hinge (1) and unscrew bolt (9) NOTES Remove door hinges (1) only separately and when rear door (6) is closed. If it is necessary to remove both door hinges (1), install second door hinge (1) only after installing first door hinge (1), otherwise rear door (6) can be damaged and adjustment of rear door (6) can change.  
5 Unscrew bolts on rear door (8) on upper and lower door hinge (1).    
6 Remove B-pillar hinge leaf (1.1) from rear door hinge leaf (1.2)    
7 Unscrew nuts on B-pillar (5) on upper or lower door hinge (1).    
8 Remove B-pillar hinge leaf (1.1) on upper or lower door hinge (1)    
INSTALLING Install     
9 Insert B-pillar hinge leaf (1.1) into upper or lower door hinge (1) and tighten with new B-pillar nut (5) finger-tight. IMPORTANT It must still be possible to move the B-pillar hinge leaf (1.1).
The nuts on the B-pillar (5) are tightened later.
Replace damaged seal on B-pillar hinge leaf (1.1).		  
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
10 Install rear door hinge leaf (1.2) on B-pillar hinge leaf (1.1)    
11 Tighten bolt (9) on upper and lower door hinge (1) hand-tight IMPORTANT Use thread locking agent.  
Loctite 243 *BR00.45-Z-1066-01A 
12 Tighten bolts on rear door (8) on upper or lower door hinge (1) IMPORTANT Repair paint damage on bolt heads  
TORQUE SPECIFICATION *BA72.12-P-1001-01O 
13 Tighten bolt (9) on upper and lower door hinge (1) IMPORTANT Repair paint damage on bolt heads  
TORQUE SPECIFICATION *BA72.12-P-1003-01O 
14 Tighten nut on B-pillar (5) on upper and lower door hinge (1) TORQUE SPECIFICATION *BA72.12-P-1002-01O 
15 Check adjustment of rear door (6), adjust rear door (6) is necessary.   AR72.12-P-0650CW 
16 Insert automatic belt retractor (2) into retaining tab (arrow) on B-pillar When installing lower door hinge (1).  
17 Tighten bolt (3) on automatic belt retractor (2) When installing lower door hinge (1).
IMPORTANT On model 204 with code (299) PRE-SAFE and on model 212 tighten two bolts (3)		  
TORQUE SPECIFICATION Model 204 *BA91.40-P-1001-01P 
TORQUE SPECIFICATION Model 212 *BA91.40-P-1001-01Q 
18 Remove bottom section (7) from B-pillar.    
19 Repair paint damage on bolts head on rear door (8) on upper or lower door hinge (1)    
20 Install bolt cap (9) on upper or lower door hinge (1)    
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
21 Protect rear door (6) and B-pillar in area of upper door hinge (1) and lower door hinge (1) against corrosion; remove excessive wax. Wax preservative, aerosol *BR00.45-Z-1018-05A 
REAR DOOR

Number Designation Model 204 Model 212 without code Z04
BA72.12-P-1001-01O Bolt, door hinge to rear door Nm 34 34
BA72.12-P-1002-01O Nut, door hinge on B-pillar Nm 34 34
BA72.12-P-1003-01O Bolt at door hinge shaft Nm 34 34
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS

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

Number Designation Model 212.0 Model 212.1 Model 212.2
BA91.40-P-1001-01Q Screw at front automatic belt reel Nm 35 35 35
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1066-01A Loctite 243 A 613 989 09 71
BR00.45-Z-1018-05A Wax for the engine compartment (400 ml spray can) A 000 986 33 70 10
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