Remove/install lamp unit - AR82.10-P-4730CW

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MODEL 204.0/2/3

MODEL 212 up to model year 2014

Shown on MODEL 204.0 with CODE 600 (Headlamp cleaning system)

Fig 1: Lamp Unit Remove/Install Components - Shown On Model 204.0

Courtesy of MERCEDES-BENZ USA

	Risk of death due to high voltage in xenon headlamps. Risk of explosion /risk of fire caused by highly flammable materials in the vicinity of damaged xenon bulbs. Risk of injury caused by UV light, hot components at xenon headlamps and glass splinters produced by bursting xenon bulbs. Risk of poisoning caused by inhalation of mercury vapors and by toxic salts and mercury compounds being ingested or coming into contact with skin	Do not touch parts conducting high voltage. Persons with active electronic implants (e.g. cardiac pacemakers) must never work on xenon headlamps. Switch off the entire lighting system. Wear insulated safety shoes, safety glasses and protective gloves. Remove highly inflammable materials from the hazard area. Ensure sufficient ventilation in the working area.	AS82.10-Z-0001-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Remove/install
1	Carry out initial startup of left front lamp unit (E1) or right front lamp unit (E2)	MODEL 204.0/2 with CODE 614 (Bi-xenon headlamps for LHD vehicles) MODEL 204.0/2 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 204.0/2 with CODE 616 (Bi-xenon headlamps w. headlamp cornering fct.) MODEL 204.0/2 with CODE 618 (Bi-xenon headlamps f. left-side dr. traffic) MODEL 204.0/2 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 204.0/2 with CODE 622 (Intelligent Light System (right-hand traffic)) MODEL 204.3 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 204.3 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 204.3 with CODE 622 (Intelligent Light System (right-hand traffic)) MODEL 212 up to model year 2014 with CODE 614 (Bi-xenon headlamp unit) MODEL 212 up to model year 2014 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 212 up to model year 2014 with CODE 616 (Bi-xenon headlamps w. headlamp cornering fct.) MODEL 212 up to model year 2014 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 212 up to model year 2014 with CODE 622 (Intelligent Light System (right-hand traffic)) When replacing the left front lamp unit (E1) or the right front lamp unit (E2).
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		MODEL 204.0/2 as of model year 2012 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 204.0/2 as of model year 2012 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 204.0/2 as of model year 2012 with CODE 622 (Intelligent Light System (right-hand traffic)) MODEL 204.3 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 204.3 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 204.3 with CODE 622 (Intelligent Light System (right-hand traffic)) Installation: Note LAM number string on the left front lamp unit (E1) or right front lamp unit (E2).
2	Switch off ignition and remove transmitter key or KEYLESS-GO start/stop button from electronic ignition lock control unit
3	Remove left or right cover (1)	MODEL 204.0/2/3 When removing the left front lamp unit (E1) or the right front lamp unit (E2).
4.1	Detach front bumper	When removing left front lamp unit (E1) or right front lamp unit (E2).
		MODEL 212 up to model year 2014	AR88.20-P-2000EW
		MODEL 204.0/2/3 Mask off bumper using suitable adhesive tape in the area of the left front lamp unit (E1) or the right front lamp unit (E2). Otherwise the paint may be damaged.	AR88.20-P-2000CW
4.2	Remove front bumper	When removing left front lamp unit (E1) and right front lamp unit (E2).
		MODEL 204.0/2/3	AR88.20-P-2000CW
		MODEL 212 up to model year 2014	AR88.20-P-2000EW
5	Remove screw/bolt (7), release catch hook (8) and slide left or right telescopic nozzle (6) to the rear	MODEL 204.0/2/3 with CODE 600 (Headlamp cleaning system) MODEL 212 up to model year 2014 with CODE 600 (Headlamp cleaning system) Screw/bolt (7) remains in the left front lamp unit (E1) or right front lamp unit (E2). Ensure that journals (5, 9) are seated correctly in left front lamp unit (E1) or right front lamp unit (E2).
6	Press fender liner (3) to one side and remove screw/bolt (2) at rear at left front lamp unit (E1) or right front lamp unit (E2)
7	Remove screw/bolt (4) from rear at left front lamp unit (E1) or right front lamp unit (E2)
8	Push air duct segment next to left front lamp unit (E1) or right front lamp unit (E2) to one side, remove screw/bolt (10) and remove sleeve (11)	Sleeve (11) only present on model 204.0/2/3.
9	Remove left front lamp unit (E1) or right front lamp unit (E2) toward front until electrical connector can be disconnected
10	Disconnect electrical connector on rear of left front lamp unit (E1) or right front lamp unit (E2)
11	Remove left front lamp unit (E1) and right front lamp unit (E2)	Only screw in screws/bolts (2, 4, 10) until they make contact, as it may be necessary to check and adjust the gap dimensions after front bumper installation. Gap dimension between engine hood and headlamp, dimension "B".
		MODEL 204.0/2, 212	*BE60.00-P-1001-01U
		MODEL 204.3	*BE60.00-P-1001-01W
		Feeler gauge	Fig 2
12	Remove left xenon light control unit or right xenon light control unit	MODEL 204.0/2 as of model year 2012 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 204.0/2 as of model year 2012 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 204.0/2 as of model year 2012 with CODE 622 (Intelligent Light System (right-hand traffic)) MODEL 204.3 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 204.3 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 204.3 with CODE 622 (Intelligent Light System (right-hand traffic)) MODEL 212 up to model year 2014 with CODE 614 (Bi-xenon headlamp unit) MODEL 212 up to model year 2014 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 212 up to model year 2014 with CODE 616 (Bi-xenon headlamps w. headlamp cornering fct.) MODEL 212 up to model year 2014 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 212 up to model year 2014 with CODE 622 (Intelligent Light System (right-hand traffic)) When replacing left front lamp unit (E1) or right front lamp unit (E2).
		MODEL 204.0/2/3	AR82.10-P-4632CW
		MODEL 212	AR82.10-P-4632EW
13	Remove left front actuation module, LED exterior lighting or right front actuation module, LED exterior lighting	MODEL 204.0/2 as of model year 2012 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 204.0/2 as of model year 2012 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 204.0/2 as of model year 2012 with CODE 622 (Intelligent Light System (right-hand traffic)) MODEL 204.3 with CODE 615 (Bi-xenon headl. (LHD veh.) w. corn. function) MODEL 204.3 with CODE 621 (Intelligent Light System (left-hand traffic)) MODEL 204.3 with CODE 622 (Intelligent Light System (right-hand traffic)) When replacing left front lamp unit (E1) or right front lamp unit (E2).
			AR82.10-P-4655CW
14	Install in the reverse order
	Check
15	Check the adjustment of the left front lamp unit (E1), the right front lamp unit (E2) and the front fog lamps and correct, if necessary
	Check and correct the adjustment of the headlamps	MODEL 212 up to model year 2014	AP82.10-P-8260EW
	Check and correct the adjustment of the headlamps	MODEL 204.0/2/3	AP82.10-P-8260CW

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 204.0	MODEL 204.2
BE60.00-P-1001-01U	Gap dimension	Engine hood to fender	Dimension "A"	mm	4 (±1)	4 (±1)
		Engine hood to headlamp	Dimension "B"	mm	4 (±1)	4 (±1)
		Engine hood to radiator grille	Dimension "C"	mm	6 (±1)	6 (±1)
		Engine hood to bumper	Dimension "D"	mm	4 (±1, 5)	4 (±1, 5)
		Engine hood to pillar A-	Dimension "E"	mm	4, 5 (±1)	4, 5 (±1)
		Bumper to headlamp	Dimension "F"	mm	3 (±1)	3 (±1)
		Bumper to headlamp	Picture		AR60.00-P-0700-01CW	AR60.00-P-0700-01CW

CHECK VALUES FOR GAP DIMENSIONS

Number	Designation				MODEL 212.0/1	MODEL 212.2
BE60.00-P-1001-01U	Gap dimension	Engine hood to fender	Dimension "A"	mm	4 (±1)	4 (±1)
		Engine hood to headlamp	Dimension "B"	mm	4 (±1)	4 (±1)
		Engine hood to radiator grille	Dimension "C"	mm	-	-
		Engine hood to bumper	Dimension "D"	mm	4, 5 (±1, 5)	4, 5 (±1, 5)
		Engine hood to pillar A-	Dimension "E"	mm	4, 5 (±1, 5)	4, 5 (±1, 5)
		Bumper to headlamp	Dimension "F"	mm	3, 5 (±1, 5)	3, 5 (±1, 5)
		Bumper to headlamp	Picture		AR60.00-P-0700-01EW	AR60.00-P-0700-01EW

CHECK VALUES FOR GAPS

Number	Designation				MODEL 204.3
BE60.00-P-1001-01W	Gap dimension	Engine hood to fender	Dimension "A"	mm	4 (±1)
		Engine hood to headlamp	Dimension "B"	mm	4 (±1)
		Engine hood to bumper	Dimension "C"	mm	6 (+1/-2)
		Engine hood to A-pillar	Dimension "D"	mm	4, 5 (+2/-1)
		Bumper to headlamp	Dimension "E"	mm	2, 5 (±1, 5)
		Bumper to headlamp	Picture		AR60.00-P-0700-01CW

Fig 2: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA