Replace complete front end assembly together with reinforcement

AR62.30-P-1570EW

Replace complete front end assembly together with reinforcement

22.2.11

 

Remove/install

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

Danger!

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

1

Remove all detachable parts in repair area.

2

Unscrew bolts (4.1, 4.2) and remove striker (4)

3

Unscrew bolts (1.1, 1.2) and remove center front reinforcement (1)

4

Unscrew bolts (8.1, 8.2, 9.1, 9.2) and remove struts (8, 9)

 On model 207 bolts (8.1 and 9.1) are located at the front of the front crossmember (5)

5

Unscrew bolts (5.1, 5.2) and remove supports (10, 11)

6

Unscrew bolts (2.1, 2.2, 3.1, 3.2) and remove outer reinforcement (2, 3)

7

Unscrew bolts (6.1, 7.1) and remove front crossmember (5)

 Installation:

Tighten bolts (6.1, 7.1) with specified torque before installing headlamp.

 Bolt, crossmember mount to absorber

*BA62.30-P-1002-02G

8

Unscrew bolts (6.2, 7.2) and remove absorber (6, 7)

9

Install in the reverse order

10

Adjust gap dimensions on hoods, doors and lids

Model 212

AR60.00-P-0700-01EW

 Feeler gauge

*129589032100

*BE60.00-P-1001-01U

Model 207

AR60.00-P-0700-01EC

 Feeler gauge

*129589032100

*BE60.00-P-1001-01W

 Fit headlamp unit and bumper for adjustment work.

11

Fit front end assembly with reinforcement

 Remove bumper after adjustment work.

 Bolt, absorber mount on longitudinal member

*BA62.30-P-1001-02G

 Bolt, striker bracket

*BA62.30-P-1003-02G

12

Apply wax preservation to connections on body

 After adjustment operations as well as removal and installation of front end assembly parts with reinforcement.

Preservation agent

*BR00.45-Z-1003-05A

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 A-pillar

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)

See picture

AR60.00-P-0700-01EW

AR60.00-P-0700-01EW

Number

Designation

Model 207.3

Model 207.4

BE60.00-P-1001-01W

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 bumper

Dimension "C"

mm

6 (+1/-2)

6 (+1/-2)

Engine hood to A-pillar

Dimension "D"

mm

4.5 (+2/-1)

4.5 (+2/-1)

Bumper to headlamp

Dimension "E"

mm

2.5 (1.5)

2.5 (1.5)

See picture

AR60.00-P-0700-01EC

AR60.00-P-0700-01EC

Number

Designation

Model
207.3

Model
207.4

BA62.30-P-1001-02G

Bolt, absorber mount on longitudinal member

Stage 1

Nm

90

90

Stage 2

°

90

90

BA62.30-P-1002-02G

Bolt, crossmember mount on absorber

Stage 1

Nm

28

28

Stage 2

°

135

135

BA62.30-P-1003-02G

Bolt for attaching striker

Nm

10

10

Number

Designation

Model
212

BA62.30-P-1001-02G

Bolt, absorber mount on longitudinal member

Stage 1

Nm

90

Stage 2

°

90

BA62.30-P-1002-02G

Bolt, crossmember mount on absorber

Stage 1

Nm

28

Stage 2

°

135

BA62.30-P-1003-02G

Bolt for attaching striker

Nm

10

Number

Designation

Order number

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05