Body Components PDF

1998-2004 ACCESSORIES & BODY, CAB
Detachable Body Components - 170 Chassis

BASIC KNOWLEDGE
ELECTRICALLY ADJUSTABLE OUTSIDE REARVIEW MIRRORS, FUNCTION - GF88.79-P-
0005AA
MODEL 129, 140, 168, 170,
202 up to 31.5.97,
210 / (except 210.081 /281) up to 28.2.97
General
The outside rearview mirrors on both sides are electrically adjustable and equipped with defrosters.
Control of the adjustment motors in the outside rearview mirrors is accomplished according to the vehicle
model directly via
the outside rearview mirror adjustment switch, or with the
cockpit switch group
or with
the multi-function control module.
The mirror defroster and a thermostat are located on the rear of the mirror glass to which they are permanently
connected. The thermostat switches the heater on and off depending on the temperature.
On vehicles with code 275 a (memory package, driver's seat, steering column, rearview mirrors) the rearview
mirror adjustment can be stored for specific drivers.
With various vehicle equipment and national versions it is possible to fold the outside rearview mirrors down,
out and automatically dim the outside rearview mirror on the driver's side.
The outside rearview mirrors are concave for a wider field of view.

If the rearview mirror housing is unhooked with force, it must be hooked back in by pressing forcefully.
The familiar mechanism for folding to the front and rear with a certain resistance has been maintained.

2003 Mercedes-Benz SLK320
1998-2004 ACCESSORIES & BODY, CAB Detachable Body Components - 170 Chassis

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Friday, October 30, 2009 8:26:13 AM Page 1 2005 Mitchell Repair Information Company, LLC.
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Accident hazard!
Objects in rearview mirrors are closer than they appear.
MIRROR, STEERING COLUMN ADJUSTMENT, HEATED MIRRORS, LOCATION OF
COMPONENTS - GF88.79-P-0007-01A
Fig. 1: Locating Mirror, Steering Column, Heated Mirrors Components
DEFROSTER IN LEFT/RIGHT OUTSIDE REARVIEW MIRROR, FUNCTION - GF88.79-P-2000A
MODEL 168, 170, 202, 210
Function sequence
1. Function prerequisites
Key in ignition or glow/starter switch in position 2 (circuit 15).
2. Thermostat on rear of mirror glass measures temperature of mirror glass.

Electrically adjustable
outside rearview mirrors,
location of components
Model 168 GF88.79-P-0005-01GC

Defroster in left/right
outside rearview mirror,
function
Models 168, 170, 202,
210
GF88.79-P-2000A

Adjusting left/right
function
Models 170, 202, 210 GF88.79-P-2001A

Folding in/out left/right
function
Model 210 with code
500b
Model 168
Model 170
GF88.79-P-2002A

Automatic dimming
feature for outside
rearview mirror on
driver's side, function
Models 129, 140, 210
as of 1.6.96
Model 202 as of
1.8.96
GF88.79-P-2003A

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3. At a mirror glass temperature of <or =15 C the mirror defroster is switched on by the thermostat.
4. Upon reaching the temperature of >or =25 C on the mirror glass the mirror defroster is switched off by
the thermostat.
5. The mirror defroster continues to be switched on and off until the temperature on the mirror remains >or
=15 C.
FUNCTION, ADJUSTING LEFT/RIGHT OUTSIDE REARVIEW MIRROR - GF88.79-P-2001A
MODEL 202, 210
MODEL 170 except CODE (498) Japanese version
Fig. 2: Identifying Outside Rearview Mirror Vertical, Horizontal And Left/Right Adjustment
Function sequence
1. Function prerequisites
Key in ignition lock in position 2 (C. 15).
2. Switch (S21s8) turned to mirror to be adjusted (left or right). Outside rearview mirror vertical adjustment
(S21s6)
Outside rearview mirror horizontal adjustment (S21s7)
3. The position of the mirror glass is adjusted by the motor in the outside rearview mirror.

Mirror defroster,
location/purpose
Model 168 GF88.79-P-4103GC
Purpose and location of
components

Left/right outside rearview
mirror, purpose/location
GF88.79-P-3000A

Outside rearview mirror
adjustment switch,
purpose/location
GF88.79-P-3001A

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LEFT/RIGHT OUTSIDE REARVIEW MIRROR, LOCATION/PURPOSE - GF88.79-P-3000A
MODEL 129, 140, 170, 202 up to 31.5.97, 210 / (except 210.081 /281) up to 28.2.97
OUTSIDE REARVIEW MIRROR ADJUSTMENT SWITCH, LOCATION/PURPOSE - GF88.79-P-
3001A
MODEL 210 / (except 210.081 /281) up to 28.2.97
MODEL 170 except CODE (498) Japanese version
Fig. 3: Identifying Outside Rearview Mirror Vertical, Horizontal And Left/Right Adjustment
Outside rearview mirror adjustment switch, location - GF88.79-P-3001-01A
Model 210, model 170 except
Model 210
Purpose
Location on left and right sides of
vehicle

Purpose The outside rearview
mirror adjustment switch
serves for electrical
adjustment of both outside
rearview mirrors

Location Models 210, 170 except

GF88.79-P-3001-01A

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Fig. 4: Identifying Outside Rearview Mirror Vertical, Horizontal, Left/Right Adjustment And Mirror
Switch - Model 210
Model 170 except
Fig. 5: Identifying Outside Rearview Mirror Vertical, Horizontal And Left/Right Adjustment - Model
170 Except Japan
SELF-DIAGNOSTIC SYSTEM
MIRROR ADJUSTMENT, HEATED MIRRORS (MSC) DIAGNOSIS CONTENTS - AD88.79-P-
1001AZ
MODEL 170
A 12.5 [] 11 Mirror adjustment, heated
mirrors (MSC) diagnosis,
basic knowledge
D88.79-P-2001A
function check
AD88.79-P-3002A
troubleshooting
AD88.79-P-5001A
mirrors (MSC), testing
electrical system
AD88.79-P-6001A

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DIAGNOSIS TOOLS, MSC - AD88.79-P-2000-01GC
Fig. 6: Identifying Electrical Connection Set (201 589 00 99 00)
Fig. 7: Identifying Fuse Cable (124 589 37 63 00)
Commercially available tools
MIRROR ADJUSTMENT, HEATED MIRRORS (MSC) DIAGNOSIS PREVIOUS KNOWLEDGE -
AD88.79-P-2001A
MODEL 170
MIRROR ADJUSTMENT, HEATED MIRRORS (MSC) DIAGNOSIS OPERATIONAL CHECK -
AD88.79-P-3002A
Number Designation
WH58.30-Z-1001-09A Multimeter
Connection and use of test
equipment
AD00.00-P-1000AZ
Diagnostic tools, MSC AD88.79-P-2000-01GC
Survey of electric wiring
diagrams, detachable body
components, outside
rearview mirror
PE88.00-P-1100B
Mirror adjustment, heated
mirrors (MSC), location of
components
GF88.79-P-0007-01A

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MODEL 170
MIRROR ADJUSTMENT, HEATED MIRRORS (MSC) DIAGNOSIS TROUBLESHOOTING -
basic knowledge
AD88.79-P-2001A
Function check
Test step/Scope of test Operation/Requirement Specified value Possible cause/Remedy
1 Ignition: ON Mirror adjustment: AD88.79-P-6001-13A
Adjusting left outside
rearview mirror
Turn outside rearview
(S50) to left outside
rearview mirror position
and operate adjuster
up AD88.79-P-6001-13B
down AD88.79-P-6001-06A
to left
to right
AD88.79-P-6001-07A
2 Ignition: ON Mirror adjustment: AD88.79-P-6001-13A
Adjusting right outside
rearview mirror
Turn outside rearview
(S50) to right outside
rearview mirror position
and operate adjuster
up AD88.79-P-6001-13C
down AD88.79-P-6001-08A
to left
to right
AD88.79-P-6001-09A
3 Ignition: ON Both mirror glasses heat
up
AD88.79-P-6001-10A
Heated mirrors After approx. 1 minute feel
mirror glass with palm of
the hand
AD88.79-P-6001-11A

up to 12/96
With terminal 15 ON the
outside rearview mirrors
are heated continuously
as of 12/96
Cut-in and cut-out
temperatures with
terminal 15 ON
<15C: heated mirrors
ON
>25C: heated mirrors
OFF

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AD88.79-P-5001A
MODEL 170
MIRROR ADJUSTMENT, HEATED MIRRORS (MSC) TEST OF ELECTRICAL SYSTEM - AD88.79-
P-6001A
MODEL 170
basic knowledge
AD88.79-P-2001A
Troubleshooting
Complaint Possible cause Note Remedy
Complete mirror adjuster
inoperative
adjustment switch (S50),
voltage supply
AD88.79-P-6001-13A
Left outside rearview
mirror adjuster
inoperative
adjustment switch (S50)
AD88.79-P-6001-13A
Electrically adjustable left
outside mirror (M21/1)
AD88.79-P-6001-13B
AD88.79-P-6001-06A
AD88.79-P-6001-07A
Right outside rearview
mirror adjuster
inoperative
AD88.79-P-6001-13A
Electrically adjustable
right outside mirror
(M21/2)
AD88.79-P-6001-13C
AD88.79-P-6001-08A
AD88.79-P-6001-09A
Left heated mirror
inoperative
Left outside mirror,
voltage supply
AD88.79-P-6001-10A
Right heated mirror
inoperative
Right outside mirror,
voltage supply
AD88.79-P-6001-11A
illumination inoperative
Voltage supply,
illumination
AD88.79-P-6001-13D
basic knowledge
AD88.79-P-2001A
location of components
GF88.79-P-0007-01A
Survey of electric wiring PE88.00-P-1100B

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MSC test of electrical system left exterior mirror up/down adjustment motor - AD88.79-P-6001-06A
diagrams, detachable body
components, outside
mirror
Diagnostic tools, MSC AD88.79-P-2000-01GC

Check battery voltage Specified value: 11-14V

Fuses in order

Ignition key in position
"2" for voltage
measurements

Testing
1 Outside rearview mirror
adjustment switch, testing
electrical system, MSC
Voltage supply AD88.79-P-6001-13A
Actuation of electrically
adjustable left outside
mirror motors (M21/1)
AD88.79-P-6001-13B
Actuation of electrically
adjustable right outside
mirror motors (M21/2)
AD88.79-P-6001-13C
4 Left outside mirror
vertical adjustment motor,
testing electrical system,
MSC
AD88.79-P-6001-06A
5 Left outside mirror
horizontal adjustment
motor, testing electrical
system, MSC
AD88.79-P-6001-07A
6 Right outside mirror
vertical adjustment motor,
testing electrical system,
MSC
AD88.79-P-6001-08A
7 Right outside mirror
horizontal adjustment
motor, testing electrical
system, MSC
AD88.79-P-6001-09A
8 Left heated mirror, testing
AD88.79-P-6001-10A
Illumination AD88.79-P-6001-13D

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Fig. 8: MSC Test Of Electrical System Left Exterior Mirror Up/Down Adjustment Motor
MSC test of electrical system left exterior mirror in/out adjustment motor - AD88.79-P-6001-07A
Fig. 9: MSC Test Of Electrical System Left Exterior Mirror In/Out Adjustment Motor
MSC test of electrical system right exterior mirror up/down adjustment motor - AD88.79-P-6001-08A
Fig. 10: MSC Test Of Electrical System Right Exterior Mirror Up/Down Adjustment Motor
MSC test of electrical system right exterior mirror in/out adjustment motor - AD88.79-P-6001-09A

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Fig. 11: MSC Test Of Electrical System Right Exterior Mirror In/Out Adjustment Motor
MSC test of electrical system left mirror heater - AD88.79-P-6001-10A
Fig. 12: MSC Test Of Electrical System Left Mirror Heater
MSC test of electrical system right mirror heater - AD88.79-P-6001-11A
Fig. 13: MSC Test Of Electrical System Right Mirror Heater
MSC test of electrical system outside mirror adjustment switch - AD88.79-P-6001-13A
Voltage supply
Fig. 14: MSC Test Of Electrical System Outside Mirror Adjustment Switch - Voltage Supply
MSC test of electrical system outside mirror adjustment switch - AD88.79-P-6001-13B

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Actuation of electrically adjustable left outside mirror motors (M21/1)
Fig. 15: MSC Test Of Electrical System Outside Mirror Adjustment Switch - Actuation Of Electrically
Adjustable Left Outside Mirror Motors
MSC test of electrical system outside mirror adjustment switch - AD88.79-P-6001-13C
Actuation of electrically adjustable right outside mirror motors (M21/2)
Fig. 16: MSC Test Of Electrical System Outside Mirror Adjustment Switch - Actuation Of Electrically
Adjustable Right Outside Mirror Motors
MSC test of electrical system outside mirror adjustment switch - AD88.79-P-6001-13D
Illumination

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Fig. 17: MSC Test Of Electrical System Outside Mirror Adjustment Switch - Illumination
TESTING & REPAIR
REMOVE/INSTALL FRONT FENDERS - AR88.10-P-1000G
MODEL 170
Fig. 18: Identifying Front Fenders Remove/Install Components
Modification notes
30.4.98 Remove fender liner and
wheelhouse cover
eliminated
Previously step 3
30.4.98 Remove paneling from
outer A-pillar eliminated
Previously step 5

Remove/install

When replacing front
fender apply MB
permanent underbody

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protection, preserve with
cavity wax following
installation

Cavity wax
Use approved wax
preservatives, see ?

Wax preservative for
underbody
BB00.40-P-0385-01A
1 Open engine hood and
raise to vertical position
AR88.40-P-1000G
2 Remove bumper AR88.20-P-2000G
3 Press turn signal lamp (7)
toward rear and remove
Disconnect connector

4 Disconnect connectors
and remove turn signal
lamp (3)
Thereby press lock tab
for turn signal lamp to
side

5 Unscrew bolt (2) from
cutout for turn signal lamp
(3)

6 Loosen plastic screw (10)
until it no longer makes
contact with the front
fender (1)
Installation : When
tightening the plastic
screw, press front fender
in direction of turn signal
lamp.

7 Remove bolts (6)
Open front door to
stop , avoid damaging
paint.

8 Remove cover (9).
9 Remove bolts (8)
10 Unscrew bolt (4)
11 Unscrew bolts (5)
Installation : Ensure
that engine hood and front
door are correctly aligned
if necessary ?
align front fender.

Gap dimensions at hoods,
doors and covers
AR60.00-P-0700-01G
Gap dimension for engine
hood to fender
*BE60.00-P-1001-01A
Gap dimension for front
door to fender
*BE60.00-P-1002-01A

Fig. 19
12 Take off front fender (1)
13 Install in the reverse order

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Test and adjustment values, gap dimensions at hoods, doors and covers
Fig. 19: Identifying Feeler Gage (129 589 03 21 00)
REMOVING AND INSTALLING INNER FENDER IN FRONT FENDER - AR88.10-P-1300G
MODEL 170
Number Designation Model 170
BE60.00-P-
1001-01A
Gap dimension Engine hood to
fender
Dimension "A" mm4.0 (0.5)
Engine hood to
headlamp
Dimension "R" mm6.0 (+1/-0.5)
Engine hood to
radiator grille
Dimension "O" mm7.0 (+1/-0.5)
Radiator grill to
headlamp
Dimension "N" mm5.0 (+1/-0.5)
Fig., see AR60.00-P-
0700-01G
BE60.00-P-
1002-01A
Gap dimension Front door to A-
pillar
Dimension "B" mm-
Front door to
fender
Dimension "H" mm4.0 (0.5)
Front door to
rear door
Dimension "I" mm-
Front door to
roof
Dimension "C" mm-
Rear door to
upper side
section
Dimension "D" mm-
Rear door to
lower side
section
Dimension "J " mm-
Fender to A-
pillar
Dimension "Q" mm4.0 (1.6)
Front door to
rear fender
Dimension "P" mm4.0 (0.5)
0700-01G

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Fig. 20: Identifying Inner Fender In Front Fender Remove/Install Components
Revisions
REMOVING AND INSTALLING FRONT BUMPER - AR88.20-P-2000
Removing and installing front bumper - AR88.20-P-2000G
MODEL 170 up to 31.Jan.00
30.4.98 Removing wheelhouse
deleted
Previously step 1 AR88.10-P-1300G

Removal, installation
1 Remove wheel
2 Remove sound-proofing
capsule below engine

3 Remove inner fender (1)
Installation : Clip
inner fender (1) into cover
for wheelhouse inner
fender (2) (arrow)

4 Remove cover for
wheelhouse inner fender
(2)
On vehicles with
charge air cooler, press
charge air tube to side, if
necessary

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Fig. 21: Identifying Front Bumper Remove/Install Components - Model 170 Up To 31.Jan.00
Modification notes
30.4.98 Removal of road wheels
is no longer required
Previously step 2
30.4.98 Removal of wheel arch
panel is no longer
required
Previously step 5
30.4.98 Clip has been replaced by
screw (11) with collar nut
(12)
Step 6

Removing, installing
1 Open engine hood AR88.40-P-1000G
2 Separate the connectors
on the right and left turn
indicator lamps (7)

3 Remove the right and left
turn indicator lamps (7)
Disengage turn
indicator lock tabs by
pushing them to the side

4 Separate right and left fog
lamp connectors (9)
The connectors can be
reached through an
opening in the wheel arch
panel of the front fender.

5 Separate the connector
(10) for the outside
Cf. code (240a)
outside temperature

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BUMPER
Removing and installing front bumper - AR88.20-P-2000GA
MODEL 170 as of 1.2.00
temperature sensor indicator
6 Turn out the screws (11)
on both sides
Hold nut (12) steady.

7 Turn out the screws (2
and 5) on both sides and
take off the washers (3
and 6)

8 Screw off the nuts (4) on
both sides

*BA88.20-P-1001-01A
9 Remove bumper (1)
Pull the bumper down
slightly as you remove it
to avoid scratching the
surface

10 Modify the AMG-bumper
Cf. installation
instructions for
accessories:
?

Fit and install the new
AMG trim parts.
AZ88.00-P-0001I
BA88.20-P-1001-01A Nuts front bumper
attachment to
crossmember
Nm10

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Fig. 22: Identifying Front Bumper Remove/Install Components - Model 170 As Of 1.2.00

1 Remove left and right turn
signal lamps (7)
Press retaining lug on
turn signal lamps
downwards
AR82.10-P-4725C
2 Unscrew screws (2) on
both sides

3 Disconnect connectors (9)
for left and right fog
lamps
The connectors are
accessible through an
opening in the
wheelhouse cover in the
front fender.

4 Unscrew screws (see
arrows) on wheelhouse
cover

5 Remove engine
compartment paneling
AR61.20-P-1105A
6 Disconnect connector (10)
for outside temperature
sensor

N Unscrew left and right
nuts (4) on cross member

*BA88.20-P-1001-01A
8 Unscrew screw (5) with
washer (6) on both sides

9 Unscrew nuts (11) on

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BUMPER
REMOVE/INSTALL REAR BUMPER - AR88.20-P-2200G
MODEL 170
Fig. 23: Identifying Rear Bumper Remove/Install Components (1 Of 2)
both sides
10 Remove bumper (1)
To remove pull
bumper forward slightly
to avoid damaging paint.
Bumper is clipped in
area of radiator grille.

BA88.20-P-1001-01A Nuts for front bumper on
cross member
Nm10 2

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Fig. 24: Identifying Rear Bumper Remove/Install Components (2 Of 2)

Removal/installation
1 Remove paneling from rear
center section
AR68.30-P-4785G
2 Remove left and right side
paneling
AR68.30-P-4800G
3 Open trunk lid
Turn lid in normal
position

4 Fasten connector (10) for
trunk luggage cover
"closed limit switch
(S69/10) with tie strap
Do not damage
contact (10) of trunk
luggage cover "closed"
limit switch (S69/10) to
ensure proper function
Do not disconnect
connector.

5 Disconnect antenna lines
(9) from left rear bumper
antenna amplifier (A2/26)
and press grommet toward
outside
Do not damage
antenna lines (9) to
ensure for proper
function

Installation :
Grommet for antenna
lines (9) should be seated
securely in fender to
prevent water ingress

6 Unscrew nut (7) and
remove toothed lock
washer (8)

*BA88.20-P-1002-01A
7 Unscrew bolts (3) from
inner fender, remove
washers (4) and sealing
washers (5)
Installation : Check
sealing washers (5),
replace if necessary

8 Unscrew nut (2) from bolt
(1) on outer left and right

9 Remove bumper (6)
Remove bumper

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BUMPER
OPENING ENGINE HOOD, MOVING TO UPRIGHT POSITION, CLOSING - AR88.40-P-1000G
MODEL 170
Fig. 25: Identifying Engine Hood Opening/Closing Components
toward rear.
10.1 Modify the AMG-bumper
Installation : See
installation instructions
for accessories

Retrofitting AMG trims AZ88.00-P-0001I
BA88.20-P-1002-01A Nut for rear bumper on
rear center section
Nm10

Contact with components
under high voltage can
pose lethal hazard
Do not touch parts under
high voltage. People with
electronic implants (e.g.
heart pacemakers) should
not perform work on
ignition system.
AS15.10-Z-0001-01A
Opening
1 Pull lever on left below
instrument panel (1) to
Engine hood should
spring open, if necessary

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REMOVING AND INSTALLING ENGINE HOOD - AR88.40-P-3000G
MODEL 170
release engine hood (2) lift engine hood slightly
2 Press levers for safety
hooks (arrow) against stop
on engine hood (2) and
open engine hood until
the locking knob (4)
catches
Windshield wiper arm
must not be folded
forward
The locking knob
symbol "PRESS" should
be completely visible in
the opening in the gas
pressure strut cover tube

Moving to upright
position

3 Press locking knob
symbol "PRESS" in
opening in gas pressure
strut cover tube and move
engine hood (2) to upright
position until locking
knob (5) catches
The locking knob
symbol "PRESS" must be
completely visible in the
opening in the gas

Closing
4 Press locking knob
symbol "PRESS" in the
opening in the gas
and pull engine hood (2)
down against the pressure
of the gas pressure strut
(3)
The locking knob
symbol "PRESS" must be
completely visible in the
opening in the gas

5 Close engine hood (2)
Position hands on front
edge of engine hood only

6 Check locking function of
engine hood lock

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Fig. 26: Identifying Engine Hood Remove/Install Components


Sealing joints following
repairs
Includes sealing joints
on engine hood
AR97.10-P-4000G

Hollow cavity
preservation following
repair
Includes hollow cavity
preservation on engine
hood
AR97.20-P-1500G
1 Open engine hood (1) and
move to upright position
AR88.40-P-1000G
2 Unscrew bottom four
bolts (4) in engine hood
(1)

*BA88.40-P-1001-01A

The engine hood is
held in place by the safety
hooks on the engine hood
hinges (5)
Installation : Move
bolts to coincide with
pressure points in paint
Ensure that engine hood
fits correctly, if
necessary ?

Adjust engine hood AR88.40-P-3020G
3 Unclip retainer (2) and
unhook gas pressure strut
(3) from engine hood (1)

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ENGINE HOOD
ADJUST ENGINE HOOD - AR88.40-P-3020G
MODEL 170
Fig. 27: Identifying Engine Hood Adjustment Components
at top
4 Unscrew the two top bolts
(4) in engine hood (1)

Have second person
secure engine hood
*BA88.40-P-1001-01A

Installation : Move
bolts to coincide with
impressions in paint

5 Remove engine hood (1)
with help of second
person and set down on
suitable surface
Avoid damaging
paintwork
Installation : Position
engine hood in safety
hooks on engine hood
hinges (5)

6 Reinstall in opposite
order

BA88.40-P-1001-01A Bolt on engine hood Nm10

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Adjustment in
longitudinal and vertical
directions

1 Open engine hood (1) AR88.40-P-1000G
2 Adjust bolts (4) on engine
hood hinge (5) and engine
hood (1)
For slight longitudinal
and height adjustment
For larger range of
adjustment, see step 4 - 10

3 Tighten bolts (4)

*BA88.40-P-1001-01A
4 Position engine hood
upright (1)
AR88.40-P-1000G
5 Remove gas-operated
strut (1) from top of
engine hood (2) and lay
down in engine
compartment

6 Close engine hood (1) AR88.40-P-1000G
7 Remove fender liner in
front fender
AR88.10-P-1300G
8 Loosen bolts (6) from
engine hood hinge (5) in
front fender

9 Adjust the engine hood
(1) so that the leading
edges of the front fenders
are flush with the engine
hood and the top edges
are in alignment
If a larger range of
adjustment is needed,
loosen engine hood catch
upper section, adjust and
tighten

*BA88.40-P-1004-01A
10 Tighten bolts (6) on
engine hood hinge (5)

*BA88.40-P-1005-01A
11 Adjust the height of the
stop buffer (4) so that the
top edges of the front
fenders and engine hood
(1) are flush
If required, shim
engine hood catch upper
section; if necessary ?
position radiator
crossmember (10)
higher/lower on strut (10)

12 Install gas-operated strut
Adjustment in
transverse direction

13 Loosen bolts (2) on
section (3)

14 Adjust left and right gaps

Fig. 19

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TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS
ENGINE HOOD
Gap dimensions at hoods,
doors and covers
AR60.00-P-0700-01G
15 Align engine hood catch
upper section (3) centrally
with lower section of
engine hood catch in
longitudinal and
transverse directions and
retighten

*BA88.40-P-1004-01A
16 Install fender liner in front
fender
AR88.10-P-1300G
17 Check safety hook for
proper function
For this purpose, close
engine hood, unlock and
check arrest on radiator
crossmember.

18 Close engine hood (1) AR88.40-P-1000G
19 Check engine hood catch
and safety hook for proper
function

BE60.00-P-
1001-01A
Gap dimension Engine hood to
fender
Dimension "A" mm4.0 (0.5)
Engine hood to
headlamp
Dimension "R" mm6.0 (+1/-0.5)
Engine hood to
radiator grille
Dimension "O" mm7.0 (+1/-0.5)
Radiator grill to
headlamp
Dimension "N" mm5.0 (+1/-0.5)
0700-01G
BA88.40-P-1001-01A Bolt on engine hood Nm10
BA88.40-P-1004-01A Bolt on engine hood catch
upper section
Nm8
BA88.40-P-1005-01A Bolt for hood hinge Nm10

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REMOVING AND INSTALLING ENGINE HOOD HINGE - AR88.40-P-3060G
MODEL 170
Fig. 29: Identifying Engine Hood Hinge Remove/Install Components

1 Remove engine hood AR88.40-P-3000G
2 Remove inner fender in
front fender
AR88.10-P-1300G
3 Mark installation position
of engine hood hinge (1)
This facilitates
installation

4 Unscrew bolts (2) and
remove engine hood
hinge (1)

Installation : Observe
marking on wheelhouse
panel
*BA88.40-P-1005-01A
Preserve engine hood
hinges with hollow cavity

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ENGINE HOOD
REMOVING AND INSTALLING PULL CABLE FOR ENGINE HOOD - AR88.40-P-3100G
MODEL 170
Fig. 30: Identifying Pull Cable For Engine Hood Remove/Install Components
wax.
Use approved wax
preservation agent, see
Service Microfiche,
Specifications for service
products, sheet no. 385
order

BA88.40-P-1005-01A Bolt on engine hood
hinge
Nm10

1 Open engine hood and
move to upright position
AR88.40-P-1000G
2 Unscrew screw (8) on
handle (7)

3 Pull handle (7) out of
arresting mechanism in
cover and unhook engine

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REMOVING AND INSTALLING ENGINE HOOD LOCK - AR88.40-P-3200G
MODEL 170
hood pull cable (5) from
handle (7)
4 Pull cable grommet (6)
out of firewall below fuse
box
that pull cable grommet is
properly seated in firewall

5 Fasten cord or wire to
pull nipple on engine
hood pull cable (5) on
inside
This facilitates
installation

6 Remove upper frame
cross member (10)

7 Unclip clip (4) on upper
frame cross member

8 Remove cover (3)
9 Remove bottom section
of engine hood lock (2)
AR88.40-P-3200G
10 Unhook engine hood pull
cable (5) from bottom
section of engine hood
lock (2) and unclip

11 Pull engine hood pull
cable (5) out between
headlamp and upper
frame cross member
Installation : Pay
particular attention to the
routing of the engine hood
pull cable

order

13 Check for proper function
14 Check locking function of
engine hood lock and
safety hook

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Fig. 31: Identifying Engine Hood Lock Remove/Install Components
MODIFICATION NOTES
30.6.98 Engine hood catch upper
section modified
Step 5.1 BT88.40-P-3200-01G

1 Open engine hood AR88.40-P-1000G
2 Remove bolts (3) and
remove engine hood
catch lower section (4)
from above

Installation : Grease
engine hood catch lower
section with MB sliding
paste
*BR00.45-Z-1004-06A
3 Detach engine hood pull
(5) from engine hood
catch lower section (4)
Slightly pull engine
hood pull

Installation : Note
correct routing of engine
hood pull cable

4 Remove engine hood
catch upper section (1)

Mark installation
position of engine hood
catch upper section on
engine hood
*BA88.40-P-1004-01A

Installation : Grease
*BR00.45-Z-1004-06A

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ENGINE HOOD
REPAIR MATERIALS
WORKSHOP EQUIPMENT
Matching cutout in hood inner panel - AR88.40-P-3200-01G
WORKSHOP EQUIPMENT
1. Carefully cover engine compartment, windshield and fenders.
section with MB sliding
paste
5.1 Align cutout in hood
inner panel
Only vehicles up to
chassis end number
005707 When replacing
section (1) if engine hood
is not replaced.
AR88.40-P-3200-01G
*WE58.40-Z-1004-03A

Engine hood catch upper
section modified
as of chassis end number
005708
BT88.40-P-3200-01G
6.1 Renew cavity
preservation in area of
section
Only vehicles up to
chassis end number
005707
AR97.20-P-1500G
8 Carry out function check
9 Check function of safety
hook
Do this by closing
engine hood, then release
and check catch on
radiator cross member

10 Check engine hood
alignment
if necessary ?
Adjust engine hood AR88.40-P-3020G
BA88.40-P-1004-01A Bolt, on engine hood
catch upper section
Nm8
Number Designation Order number
BR00.45-Z-1004-06A Lubricant A 001 989 46 51
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)

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Thoroughly remove chippings from cavities produced during repairs.
2. Mark cutout according to drawing.
Fig. 32: Identifying Hood Inner Panel Cutout Dimensions
3. Saw out cutout (arrow)
4. Deburr cut edges using a file
5. Carry out corrosion prevention measures
Fig. 33: Identifying Cutout Sawing Area
6. Mount engine hood catch upper section (1) in rearmost position
Actuating lever (2) must not touch front fold of engine hood. If necessary leave out rubber beading (3)
in this area.
7. Check function and adjustment

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Fig. 34: Identifying Engine Hood Catch Upper Section, Actuating Lever & Rubber Beading
REMOVING AND INSTALLING TRUNK LID - AR88.50-P-5000G
MODEL 170
Fig. 35: Identifying Trunk Lid Remove/Install Components


Sealing joints following
repair
Includes sealing joints
on trunk lid
AR97.10-P-4000G

Preserving hollow
cavities following repair
Includes preserving
hollow cavities in trunk
lid
AR97.20-P-1500G
1 Remove trunk lid and
striker eye
Do not separate striker
eye
AR88.50-P-5020G
2 Disconnect connectors (4)
3 Open or separate holder

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TRUNK LID
REMOVING, INSTALLING AND ADJUSTING TRUNK LID LOCK AND STRIKER EYE - AR88.50-
P-5020
Removing, installing and adjusting trunk lid lock and striker eye - AR88.50-P-5020G
MODEL 170 up to 31.1.00
(3) for electric wiring
harness and pull wiring
harness out of trunk lid
4 Mark position of hinge
lever on trunk lid (1),
loosen bolts (2) and
unscrew two bolts on
each side

*BA88.50-P-1009-01A
5 Unhook gas pressure strut
(5) from trunk lid with aid
of second mechanic,
unscrew bolts (2) and
remove trunk lid (1)

order
Check adjustment of
trunk lid, if necessary ?

Adjust trunk lid AR88.50-P-5200G
BA88.50-P-1009-01A Bolts for hinge lever on
trunk lid
Nm25

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Fig. 36: Identifying Trunk Lid Lock And Striker Eye Remove/Install Components - Model 170 Up To
31.1.00 (1 Of 2)
Fig. 37: Identifying Trunk Lid Lock And Striker Eye Remove/Install Components - Model 170 Up To
31.1.00 (2 Of 2)

1 Remove handle recess (3)
and cover (4)

2 Unscrew screws (5) and
remove latch section (2)
from trunk lid

*BA88.50-P-1006-01A
trunk lid lock (1) and
remove connecting rod
(9)

*BA88.50-P-1005-01A
4 Press off CL line (8) and
remove trunk lid lock (1)

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TRUNK LID
Removing, installing and adjusting trunk lid lock and striker eye - AR88.50-P-5020GA
and remove latch section
(2)

6 Mark position of striker
eye (11), unscrew screws
(10) and remove striker
eye (11)

*BA88.50-P-1007-01A
N Install in the reverse order
When installing trunk
lid lock (1) ensure that
seal is seated properly,
replace seal if damaged.
Check trunk lid fit, if
necessary: ?

BA88.50-P-1005-01A Screw for trunk lid lock
on trunk lid
Nm8
BA88.50-P-1006-01A Screw for latch section on
trunk lid
Nm8
BA88.50-P-1007-01A Screw for striker eye on
tubular frame
Nm10

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Fig. 38: Identifying Trunk Lid Lock And Striker Eye Remove/Install Components - Model 170 As Of
1.2.00
TRUNK LID

1 Remove cover (4)
2 Unclip connecting rod (9)
from handle (3) and
unhook latch section (2)

remove latch section (2)
from trunk lid

*BA88.50-P-1006-01A
and remove latch section
(2)

5 Mark position of striker
eye (11), unscrew screws
(10) and remove striker
eye (11)

*BA88.50-P-1007-01A
Check trunk lid fit, if
necessary: ?

BA88.50-P-1006-01A Screw for latch section on
trunk lid
Nm8

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REMOVING, INSTALLING TRUNK LID HANDLE WITH LOCK CYLINDER - AR88.50-P-5060G
Fig. 39: Identifying Trunk Lid Handle With Lock Cylinder Remove/Install Components - Model 170 As
Of 1.2.00 (1 Of 2)
Fig. 40: Identifying Trunk Lid Handle With Lock Cylinder Remove/Install Components - Model 170 As
Of 1.2.00 (2 Of 2)
BA88.50-P-1007-01A Screw for striker eye on
tubular frame
Nm10

1 Remove cover behind
trunk lid handle (1)

nut (22)
Nut (22) is located on
the rear of the left license

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REMOVE/INSTALL TUBULAR FRAME FOR TRUNK LID - AR88.50-P-5100G
MODEL 170
plate lamp (E19/1).
Installation : Replace
sealant on nut (22).
3 Remove cover (2) and
disconnect connection
leads for left and right
license plate lamps
(E19/1, E19/2)

4 Unclip connecting rod
(11)

5 Pry pneumatic line (31)
off with 7 mm open-end
wrench

6 Unscrew nut (12)
Installation : Replace
sealant on nut (12).

N Unscrew screws (13) with
plastic washers
Secure trunk lid handle
(1) from falling out with
one hand.

8 Unclip lock cylinder (3)
from trunk lid handle (1)
(see arrows)


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Fig. 41: Identifying Tubular Frame For Trunk Lid Remove/Install Components (1 Of 3)

Remove/Install
1 Remove side paneling in
trunk
AR68.30-P-4800G
2 Remove cover plate (2)
from rear center section

*BA77.33-P-1006-01A

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SOFT TOP - MECHANICAL SYSTEM
TRUNK LID
Adjust tubular frame - AR88.50-P-5100-01G
MODIFICATION NOTES
3 Remove console (3) on
left and right

*BA77.33-P-1005-01A
4 Remove bolt (4) from
hydraulic cylinder to
tubular frame (1).

5 Separate connector (7)
6 Open electric wiring
harness (8) on tubular
frame (1) or cut open

7 Close trunk lid and pivot
toward rear
In this position the
trunk lid can be removed
by a mechanic.

lever (5), unscrew bolts
from hinge lever (6) and
remove trunk lid

When removing press
trunk lid lock
*BA88.50-P-1010-01A
9 Unscrew bolts (9) from
tubular frame hinge (10)
and remove tubular frame
(1).

*BA88.50-P-1011-01A
When replacing ?

Adjust tubular frame
Check trunk lid
adjustment, if necessary ?
AR88.50-P-5100-01G
BA77.33-P-1005-01A Bolt, console of roof
stowage in trunk
NM8
BA77.33-P-1006-01A Bolts, closing plate to rear
center assembly
NM8
BA88.50-P-1010-01A Bolt, hinge lever to
tubular frame
NM25
BA88.50-P-1011-01A Bolt, hinge of tubular
frame to rear center
assembly
NM25

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TEST AND ADJUSTMENT VALUES FOR TRUNK LID
SOFT TOP - MECHANICAL SYSTEM
SOFT TOP - HYDRAULICS
TRUNK LID
1. Check adjustment of striker (8) in relation to catch socket (7), adjust if necessary
Striker (8) should run into the catch socket (7) in the lateral direction in the middle and in the
longitudinal direction at the front edge
23.6.98 Procedure for adjustment
work changed
Steps 1 - 13
BE88.50-P-
1001-01A
Dimension "A" Fender upper
edge to* tubular
frame
Hydraulic system
unpressurized
mm30
Hydraulic system
pressurized
mm<or =33
Fig.,, see AR88.50-P-
5100-01G
BA77.33-P-1003-01A Bolts, catch for tubular
frame in trunk
NM8
BA77.33-P-1004-01A Bolts, catch socket on
tubular frame catches in
trunk
NM8
BA77.37-P-1001-
01A
Emergency actuation
valve (N) on
hydraulic unit
NM3
Fig., see AR77.50-P-3100G
BA88.50-P-1008-01A Bolt, striker to tubular
frame
NM10

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Fig. 44: Identifying Striker & Catch Socket
2. If required, correct longitudinal adjustment on striker (8). Adjust lateral direction on console (1)
Remove side paneling in trunk to adjust console (1)
Fig. 45: Identifying Console & Catch Socket
3. Open emergency actuation valve (N) to relieve pressure from hydraulic system.
Fig. 46: Identifying Emergency Actuation Valve
4. Open trunk lid and lay square tube (2) on fender in area of locks
Square tube approx.. 1500 mm long

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Protect fender against damage with adhesive tape.
Fig. 47: Identifying Square Tube On Fender In Area Of Locks
5. Measure distance (A) between square tube (2) and tubular frame (1) in middle of surface on tubular frame
(1).
6. Loosen bolts (3) for striker (4) from tubular frame (1)
7. Adjust tubular frame (1) in direction of arrow, check distance (A) n and tighten bolts (3).
Fig. 48: Identifying Square Tube, Tubular Frame, Bolts, Striker & Distance Measurement
8. Close emergency actuation valve (N) and build up pressure in hydraulic system by actuating Vario
roof
9. Measure distance between square tube and tubular frame again.
If the distance measured is outside the permissible tolerance adjust hydraulic cylinder

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Fig. 49: Identifying Emergency Actuation Valve
Adjust hydraulic cylinder
10. Open retaining bracket (4) and pull out bolt
An O-ring is located at the outside between fork head and tubular frame
11. Open counternut on fork head of hydraulic cylinder and then unscrew fork head with two turns
Fig. 50: Opening Retaining Bracket
12. Refasten hydraulic cylinder to tubular frame and lock tubular frame hydraulically.
When doing this check whether tubular frame lock engages properly. If this is not the case, correct
adjustment of fork head in small increments (11/21 turn) until locking is ensured
13. Measure (A) distance between square tube (2) and tubular frame (1) again.

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Fig. 51: Measuring Distance Between Square Tube And Tubular Frame
REMOVING AND INSTALLING HINGE LEVER FOR TRUNK LID - AR88.50-P-5120G
MODEL 170
Fig. 52: Identifying Hinge Lever For Trunk Lid Remove/Install Components

1 Open trunk lid
lever (1) on trunk lid

3 Unscrew screws (2)

*BA88.50-P-1009-01A
4 Close trunk lid, pivot to
rear with roof switch and
open trunk lid again

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TRUNK LID
ADJUST TRUNK LID - AR88.50-P-5200G
MODEL 170
5 Open or separate holders
(3) for wiring harness

strut (5) for wiring
harness

*BA88.50-P-1012-01A
7 Unhook gas pressure strut
(6) from hinge lever (1)

8 Close trunk lid
Do not damage seal
with locking yoke on
trunk lid. Leave trunk lid
pivoted to rear

9 Unscrew screws (7) in
tubular frame (8)

*BA88.50-P-1010-01A
remove hinge lever (1)

*BA88.50-P-1012-01A
order
Check adjustment of
trunk lid, if necessary ?

BA88.50-P-1009-01A Screw for hinge lever on
trunk lid
Nm25
BA88.50-P-1010-01A Screw for hinge lever on
tubular frame
Nm25
BA88.50-P-1012-01A Screw for wiring harness
strut on hinge lever
Nm8

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Fig. 53: Identifying Trunk Lid Adjustment Components (1 Of 2)
Fig. 54: Identifying Trunk Lid Adjustment Components (2 Of 2)
MODIFICATION NOTES
23.6.98 Scope of adjustment work
expanded
Step 1 - 12.1
Adjust
1 Open emergency
Open emergency

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actuation valve (N) on
hydraulic unit to stop with
6 mm Allen wrench
actuation valve only with
roof put down or closed
and ignition switched off
to avoid damaging the
seal on the emergency
actuation valve (N) which
would prevent pressure
from building up in the
system.
2 Loosen bolts (1) on hinge
lever (2)
Mark position of hinge
lever (2)

3 Loosen bolts (3) from
striker eye (4)

4 Align trunk lid in
longitudinal direction in
relation to taillamps and
tighten bolts (1) on hinge
lever (2)
*BE60.00-P-1003-01A

Bolt for hinge lever
on trunk lid
*BA88.50-P-1009-01A

Fig. 19
5 Adjust striker eye (4) on
tubular frame (5) in
relation to locking lug (6)
and retighten bolts (3).
The locking lug (6)
should hit in the center of
the striker eye (4) and the
trunk lid should close
easily.
Correct longitudinal
direction of striker eye (4)
with shims below striker
eye (4) if necessary.

Bolts for striker eye
on tubular frame
*BA88.50-P-1007-01A
6 Close trunk lid and check
height adjustment of trunk
lid in area of taillamps
Correct height
adjustment on striker eye
(4)

7 Adjust rubber buffer (7)
on hinge lever (2)
AR88.50-P-5200-01G
*BE60.00-P-1003-01A

Fig. 19
8 Adjust side stops (8) on
trunk lid

AR88.50-P-5200-02G
*BE60.00-P-1003-01A

Fig. 19
9 Close emergency
actuation valve (N) on
hydraulic unit with 6 mm
Allen wrench.
Emergency actuation
valve on hydraulic unit
*BA77.37-P-1001-01A

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TEST AND ADJUSTMENT VALUES FOR TRUNK LID
10 Open and close Vario roof
hydraulically

11 Check transitions from
trunk lid to fenders and
taillamps, correct if
necessary

12.1 Adjust tubular frame
Only if proper
adjustment is not possible
with the measures
performed previously
AR88.50-P-5100-01G
*BE88.50-P-1001-01A

Bolt of locks for
tubular frame in trunk
*BA77.33-P-1003-01A

Bolts for catch
socket on catch on tubular
frame in trunk
*BA77.33-P-1004-01A

Emergency actuation
valve on hydraulic unit
*BA77.37-P-1001-01A

Bolts for striker on
tubular frame
If required ?
*BA88.50-P-1008-01A
Remove side paneling in
trunk
AR68.30-P-4800G
BE60.00-P-
1003-01A
Gap dimension Trunk lid to top
of rear fender
Dimension "F" mm-
Trunk lid to
bottom of rear
fender
Dimension "M" mm-
Trunk lid to rear
fender
Dimension "F" mm5.0 (+1/-0)
Trunk lid to
taillamp
Dimension "M" mm5.0 (+1/-0)
Trunk lid to
bumper
Dimension "V" mm8.0 (0.5)
Rear fender to
taillamp
Dimension "U" mm3.0 (0.5)
0700-01G
BE88.50-P-
1001-01A
section to
Unpressurized
hydraulic system
mm30

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TRUNK LID
HYDRAULIC SOFT TOP
SOFT TOP - MECHANICS
Adjust rubber buffers on hinge lever - AR88.50-P-5200-01G
tubular frame Pressurized
hydraulic system
mm<or =33
5100-01G
BA88.50-P-1007-01A Bolt, striker eye to
tubular frame
Nm10
BA88.50-P-1008-01A Bolt, striker to tubular
frame
Nm10
BA88.50-P-1009-01A Bolt, hinge bracket to
trunk lid
Nm25
BA77.37-P-1001-
01A
Emergency actuation
valve (N) on
hydraulic unit
Nm3
Fig., see AR77.50-P-3100G
BA77.33-P-1003-01A Bolts, catch on tubular
frame in trunk
Nm8
BA77.33-P-1004-01A Bolts, catch socket on
catch, tubular frame in
trunk
Nm8
BE60.00-P-
1003-01A
of rear fender
Dimension "F" mm-

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Adjust rubber buffers only when Vario roof is open
1. Open locknut on rubber buffer (7)
2. Perform basic setting on rubber buffer Remove and turn in rubber buffers until dimension between
contact surface and hinge lever is approx. 26 mm (arrow).
Fig. 57: Identifying Locknut On Rubber Buffer
3. Coat contact surface of rubber buffer on hinge lever (arrow) with chalk
4. Close trunk lid
Trunk lid to
bottom of rear
fender
Dimension "M" mm-
Trunk lid to rear
fender
Trunk lid to
taillamp
Trunk lid to
bumper
Rear fender to
taillamp
0700-01G

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Press trunk lid closed carefully, do not slam!
5. Check chalk imprint on rubber buffers.
6. Adjust rubber buffers in increments until chalk marks uniform on both sides.
Check body transitions and closing forces on trunk lid permanently
Fig. 58: Identifying Contact Surface Of Rubber Buffer On Hinge Lever
7. Close locknut on rubber buffer (7)
8. Check adjustment of trunk lid when Vario roof is closed
Fig. 59: Identifying Locknut On Rubber Buffer
Adjust side stops on trunk lid - AR88.50-P-5200-02G
Test and adjustment values, gap dimensions at hoods, doors and covers
BE60.00-P-
1003-01A
of rear fender
Dimension "F" mm-
Trunk lid to
bottom of rear
fender
Dimension "M" mm-
Trunk lid to rear
fender

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1. Loosen mounting bolts on stops (8) and move stops completely toward inside
2. Coat stops (9) in trunk lid opening with chalk
3. Close trunk lid
Press trunk lid carefully backwards, do not slam!
Fig. 61: Identifying Mounting Bolts On Stops
4. Check chalk imprint on stops (8)
5. Adjust stops in increments toward outside until chalk marks uniform on both sides.
Check body transitions, gaps and closing forces on trunk lid permanently.
Trunk lid to
taillamp
Trunk lid to
bumper
Rear fender to
taillamp
0700-01G

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Fig. 62: Identifying Stops In Trunk Lid Opening
REMOVE/INSTALL OUTSIDE MIRROR COMPLETE - AR88.70-P-9000G
MODEL 168, 170, 208
Shown on model 170
Fig. 63: Identifying Outside Mirror Remove/Install Components - Shown On Model 170
Shown on model 208.3

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Fig. 64: Identifying Outside Mirror Remove/Install Components - Shown On Model 208.3
Shown on model 168
Fig. 65: Identifying Outside Mirror Remove/Install Components - Shown On Model 168

Remove/Install
1 Press paneling (1) off with
long wedge

Fig. 66
2.1 Remove door lining from
front door
Only on model 208.3, if a
door liner is installed
without assembly cover
(2).
AR72.10-P-1000K
2.2 Press assembly cover (2)
off with plastic wedge
Only on model 208.3, if
door liner is installed
with assembly cover (2)
and on model 170.

3 Separate electrical
connection (3)

4 Unscrew bolts (4) and

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Fig. 66: Identifying Long Wedge (115 589 03 59 00)
REMOVING, INSTALLING OUTSIDE MIRROR GLASS - AR88.70-P-9020G
MODELS 168, 170, 208
Fig. 67: Identifying Outside Mirror Glass Remove/Install Components
remove outside mirror

1 Fold the outside mirror
forward

2 Tip the top edge of the
mirror glass to the outside

3 Using a screwdriver, push
the retaining spring (1)
upward and remove the
mirror glass from the

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REMOVING AND INSTALLING OUTSIDE REARVIEW MIRROR COVER - AR88.70-P-9040G
MODEL 168, 170, 208
Shown on model 170
Fig. 68: Identifying Outside Rearview Mirror Cover Remove/Install Components - Shown On Model 170
Shown on model 168
Fig. 69: Identifying Outside Rearview Mirror Cover Remove/Install Components - Shown On Model 168
drive
Start with the bottom
side of the mirror glass
and work your way
upward, paying attention
to the support spring (3)
and seat point (arrows)

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COMMERCIALLY AVAILABLE TOOLS
REMOVING, INSTALLING MIRROR GLASS ADJUSTER DRIVE - AR88.70-P-9060G
MODELS 168, 170, 208
Fig. 70: Identifying Mirror Glass Adjuster Drive Remove/Install Components

Remove/install
1 Remove mirror glass AR88.70-P-9020G
2 Unscrew bolts (3)

*WH58.30-Z-1040-06A
3.1 Remove mirror adjusting
motor (M21/1m1,
M21/1m2)
Model 168 only
4 Remove frame (1) and
paneling for mirror
housing (2)
Mirror housing (2)
paneling and frame (1)
are screwed together.

Pay attention to
mirror housing frame and
paneling (arrows).

Number Designation
WH58.30-Z-1040-06A Torx screwdriver twist T10

1 Remove mirror glass AR88.70-P-9020G

*WH58.30-Z-1040-06A
3 Disconnect plug
connector (3) and remove
drive (1)

Number Designation

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REMOVING AND INSTALLING COVER ON MIRROR TRIANGLE - AR88.70-P-9080G
MODEL 170, 208, 168
Model 170
Fig. 71: Identifying Cover On Mirror Triangle Remove/Install Components - Shown On Model 170
Model 208.3
Fig. 72: Identifying Cover On Mirror Triangle Remove/Install Components - Shown On Model 208.3
Model 168

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Fig. 73: Identifying Cover On Mirror Triangle Remove/Install Components - Shown On Model 168
REMOVING AND INSTALLING EXTERIOR REARVIEW MIRROR ADJUSTMENT SWITCH -
AR88.79-P-3470G
MODEL 170
Fig. 74: Identifying Exterior Rearview Mirror Adjustment Switch Remove/Install Components

1 Remove cover on outside
rearview mirror
AR88.70-P-9040G
2 Remove drive for gear
adjustment
AR88.70-P-9060G
3 Remove complete outside
rearview mirror
AR88.70-P-9000G
remove cover (1)

*WH58.30-Z-1040-06A
5 Reinstall in opposite order
Model 208.3
Observe catches (arrows)

Number Designation

1 Remove center console AR68.20-P-2010G

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Fig. 75: Identifying Long Wedge (115 589 03 59 00)
REMOVING AND INSTALLING ROCKER PANEL - AR88.80-P-6000G
MODEL 170
Fig. 76: Identifying Rocker Panel Remove/Install Components
(1)
2 Press catch (2) in
direction of arrow with
long wedge

Fig. 66
3 Press outside rearview
mirror switch (S50)
downward out of center
console (1)
Installation : Pay
attention to correct
installation direction

order

1 Release and remove
lifting platform mounting
plate

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REMOVING AND INSTALLING PANELING ON OUTSIDE OF A-PILLAR - AR88.80-P-8500G
MODEL 170
Fig. 77: Identifying Paneling On Outside Of A-Pillar Remove/Install Components (1 Of 2)
Fig. 78: Identifying Paneling On Outside Of A-Pillar Remove/Install Components (2 Of 2)
REVISIONS
3 Release clips and pull out
4 Remove rocker panel (1)
that seal is seated properly
at front and rear.

5.8.96 Removal and installation
of cable (7) added
Steps 3 and 5 added
Figure 2 added
AR88.80-P-8500G

Removal

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TEST & ADJUSTMENT VALUES
TRUNK LID - BE88.50-P-1000-01A
Model 170
TEST AND ADJUSTMENT VALUES OF TRUNK LID
MAINTENANCE
LUBRICATE LOCK AND HINGES OF HOOD, OIL SAFETY HOOK AND CHECK FOR EASE OF
OPERATION - AP88.40-P-8821BA
1 Open Vario-roof
2 Turn paneling (1) outward
in upper area (2 insert
clips and clips) and pull
upward off of rubber
insert profile (2) at fender

3 Unhook cable (7) on
paneling (1)

Installation
4 Check rubber strip (3),
insert clips (4) and clips (5
and 6)
When replacing the
rubber strip (3) coat
retaining profile with
rubber lubricant to
facilitate installation

5 Hook cable (7) into top
clip (4)
During a head-on
collision the cable (7)
prevents the paneling (1)
from falling off

6 Hook cable (7) into
paneling (1), slide on
rubber profile (2) and
press into clips (4) at top
and clip (6) on A-pillar

7 Close vario-roof
BE88.50-P-
1001-01A
edge to tubular
frame
Hydraulic
unpressurized
mm30
Hydraulic under
pressure
mm<or =33
5100-01G

Microsoft
MODEL 124, 129, 140, 170, 208, 210
Fig. 79: Identifying Hood Hinges, Lock And Oil Safety Hook
REPAIR MATERIALS
RETROFITTING & CONVERSION
RETROFIT AMG TRIM PANELS - AZ88.00-P-0001
Retrofit AMG trim panels - AZ88.00-P-0001I
MODEL 170 Applicable to 29.2.00
1 Oil safety hook (arrow)
Use engine oil

2 Check ease of operation
of safety hook

3 Grease hood lock
(arrows)
*BR00.45-Z-1001-06A
Number Designation Order number
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51

The trim parts supplied with
the accessories and spare
parts are primed and must be
painted in the same color as
the vehicle before being
installed.

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PARTS ORDERING NOTES

In the Federal Republic of
Germany after conversion
installation approval is
required from an officially
recognized expert or inspector
from a motor vehicle test
center or a test engineer from
an officially recognized
supervisory organization.

Body kit, certificate Model
170.435/444/445/447/449/465
* For Germany only
OF88.00-P-1000-01BA

Remove
1 Remove front bumper

AR88.20-P-2000G
2 Remove rear bumper

AR88.20-P-2200G

Installation
3 Converting front bumper AZ88.00-P-0001-02H
4 Converting side paneling AZ88.00-P-0001-04I
5 Converting rear bumper AZ88.00-P-0001-03H
Part no. Designation Quantity
B6 603 6010 Front bumper complete without
HCS (code 600) consisting of:
1
HWA170 885 01 25 Paneling 1
HWA170 885 01 53 Center grille 1
HWA170 885 02 53 Left grille 1
HWA170 885 03 53 Right grille 1
N914 127 003 203 Spoiler screw 7
HWA210 820 01 56 Left fog lamp ass'y 1
HWA210 820 02 56 Right fog lamp ass'y 1
HWA170 885 01 14 Mount for left fog lamp 1
HWA170 885 02 14 Mount for right fog lamp 1
HWA210 540 01 08 LU wiring harness 2
N304 017 006 000 Screw M6x16 8
N913 002 006 009 Nut M6 8
N000 125 006 421 Washer 6x15 16
A002 994 81 45 Sheet metal nut 6
A011 990 27 01 Combination screw 4.8x19 6
A000 990 34 92 Spreading anchor 8

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B6 603 6013 Front bumper complete with
1
N304 017 006 000 Screw M6x16 8
N913 002 006 009 Nut M6 8
N000 125 006 421 Washer 6x15 16
B6 603 6011 Rear bumper complete
consisting of:
1
A002 990 97 97 Pop rivet 8
B6 603 6036 Side paneling kit, complete
consisting of
1
HWA170 698 01 54 Left side paneling 1
HWA170 698 02 54 Right side paneling 1
HWA170 698 01 30 Left front cover 1
HWA170 698 02 30 Right front cover 1
HWA170 698 03 30 Left rear cover 1
HWA170 698 04 30 Right rear cover 1
A201 698 02 14 Retaining strap 4
A170 686 00 74 Left protective strip 1
A170 686 01 74 Right protective strip 1
HWA202 988 02 81 Horn push-button 14
HWA202 988 04 81 Expanding anchor 4
N914 138 004 202 Bolt 14
HWA170 690 03 39 Velcro mounting rail 2
HWA202 989 02 71 Glue (Gurit-Essex) 1
A000 990 46 92 Rivet 8

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Converting front bumper - AZ88.00-P-0001-02H
Preparation
1. Remove standard bumper.
2. Disassemble standard bumper
3. Unscrew headlamps from inner carrier.
4. Remove side sliding arrests by drilling out pop rivets (A).
5. Remove side support panels by removing spreading rivets.
Fig. 80: Identifying Pop Rivets
6. Remove inner carrier and impact damper Press retaining lugs (B) for exterior surface out of anchoring
with screwdriver.
Assembly
7. Install inner carrier and impact damper
8. Press retaining lugs (B) into anchoring at top and bottom
9. Anchor side support plates in exterior surface using spreading rivets.
HWA170 690 01 62 Left cover strip ass'y 1
HWA170 690 02 62 Right cover strip ass'y 1
A170 584 00 55 LU adhesive foil 1
A170 997 01 86 Vehicle jack mount plug 4

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Fig. 81: Identifying Retaining Lugs
10. Rivet inner side member included with parts kit to exterior surface with pop rivets (A).
11. Hook center grill in front apron and fasten with screws included (arrows).
12. Insert outer grills.
Fig. 83: Identifying Center Grill Screws
13. Install headlamp:
Fasten headlamp mount to original mounting points (C).
Fasten headlamp to mount (D) and to lug (E).
Insert adapter cable into headlamp.

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14. Install bumper.
Fig. 84: Identifying Headlamp Mounting Points, Mount And Lug
Converting rear bumper - AZ88.00-P-0001-03H
Preparation
2. Disassemble standard bumper
3. Remove side sliding arrests by drilling out pop rivets (A).
4. Remove side support plates by removing spreading rivets.
5. Remove inner carrier, impact damper and antennas: Press retaining lugs (B) for exterior surface out of
anchoring with a screwdriver, remove radio antenna.
6. Remove spacer strip (spare wheel recess)
Assembly
7. Install inner carrier, impact damper and antennas.

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10. Rivet side sliding arrests in exterior surface.
11. Press radio antenna into lugs intended for this purpose and fasten with glue.
12. Install spacer strip on stay intended for this purpose.
13. Install bumper.
Converting side paneling - AZ88.00-P-0001-04I
Preparation
1. Remove sealing strip from door bottom edge.
2. Loosen sealing strips (A) and (B) from mounting elements with assembly wedge.
3. Remove mounting grommets on front and rear fender.
Fig. 87: Identifying Sealing Strips On Mounting Elements
4. Loosen sealing strip (C) from mounting elements with assembly wedge and remove snaps from
longitudinal member.

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Fig. 88: Identifying Sealing Strips For Mounting Elements
5. Remove sealing plugs from bottom of vehicle and replace with clip H WA202 988 01 81 (ensure that all
claws spread Then remove mounting screws (D).
6. Remove covers for jack mount.
Fig. 89: Identifying Mounting Screws
Final assembly
7. Pull in catch strap for rocker panel cover.
8. Degrease fender in areas (A) and (B) and glue on tufted strips.
Fig. 90: Identifying Fender Areas
9. Press AMG snaps (E) in entrance area, reinforce first and last snap with grommet (F) in addition.

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Fig. 91: Identifying AMG Snaps & Grommet
10. Remove protective layer from hook strap in rocker panel and ensure, that all hooks are exposed.
11. Apply glue to front and rear side paneling in groove (below hook strap) intended for this purpose.
12. Hook side paneling in at front fender with mounting lug and firmly press hook strap into tufted strip
starting at front.
13. In the entrance area fasten side paneling with Philips screws and in the vehicle floor area (front) with
spreading rivets and screws.
14. Clean gluing surface in entrance area. Remove backing foil for self-adhesive cover foil and cover screws
with it.
15. Clip in AMG cover strips.
16. Clean bottom edge of door.
17. Carefully move sealing strips together with clips (A) into holes starting at hinge side, do not hammer or
hit.
18. When all clips (A) are caught carefully catch pins (B) into clips (A).
Fig. 92: Identifying Clips & Catch Pins
Retrofit AMG trim panels - AZ88.00-P-0001J

The trim parts supplied with
the accessories and spare
parts are primed and must be
painted in the same color as
the vehicle before being
installed.

Microsoft

In the Federal Republic of
Germany after conversion
installation approval is
required from an officially
recognized expert or inspector
from a motor vehicle test
center or a test engineer from
an officially recognized
supervisory organization.

Body kit, certificate Model
170.435/444/445/447/449/465
* For Germany only
OF88.00-P-1000-01BA

Remove

AR88.20-P-2000G

AR88.20-P-2200G

Installation
3 Converting front bumper AZ88.00-P-0001-02I
4 Converting side paneling AZ88.00-P-0001-04J
5 Converting rear bumper AZ88.00-P-0001-03I
B6 603 6029 Front bumper complete without
1
N304 017 006 000 Screw M6x16 8
N913 002 006 009 Nut M6 8
N000 125 006 421 Washer 6x15 16

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A170 885 00 85 Protective guard (radiator grill) 1
HWA170 885 01 01 LU inner carrier 1
A170 885 00 81 License plate cover 1
A202 990 01 21 Bolt 2
B6 603 6035 Front bumper complete with
1
N304 017 006 000 Screw M6x16 8
N913 002 006 009 Nut M6 8
N000 125 006 421 Washer 6x15 16
A170 885 00 85 Protective guard (radiator grille) 1
A170 885 00 81 License plate cover 1
A202 990 01 21 Bolt 2
A170 880 01 05 Left HCS cover plate 1
A170 880 02 05 Right HCS cover plate 1
B6 603 6037 Rear bumper complete
consisting of:
1
A002 990 97 97 Pop rivet 8
B6 603 6036 Side paneling kit, complete
consisting of
1
HWA170 698 01 54 Left side paneling 1
HWA170 698 02 54 Right side paneling 1
HWA170 698 01 30 Left front cover 1
HWA170 698 02 30 Right front cover 1
HWA170 698 03 30 Left rear cover 1
HWA170 698 04 30 Right rear cover 1

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Converting front bumper - AZ88.00-P-0001-02I
Preparation
1. Remove standard bumper, radiator grill.
Assembly
2. Install radiator grill
3. Install inner carrier and impact damper
4. Press retaining lugs (B) into anchoring at top and bottom.
6. Rivet inner side member included with parts kit to exterior surface with pop rivets (A).
A201 698 02 14 Retaining strap 4
A170 686 00 74 Left protective strip 1
A170 686 01 74 Right protective strip 1
HWA202 988 04 81 Expanding anchor 4
N914 138 004 202 Bolt 14
HWA202 989 02 71 Glue (Gurit-Essex) 1
A000 990 46 92 Rivet 8
HWA170 690 01 62 Left cover strip ass'y 1
HWA170 690 02 62 Right cover strip ass'y 1
A170 584 00 55 LU adhesive foil 1
A170 997 01 86 Vehicle jack mount plug 4

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7. Hook center grill in front apron and fasten with screws included (arrows).
8. Insert outer grills.
Fig. 95: Identifying Center Grill Screws
9. Install headlamp:
Fasten headlamp mount to original mounting points (C).
Fasten headlamp to mount (D) and to lug (E).
Insert adapter cable into headlamp.
10. Install bumper.
Fig. 96: Identifying Headlamp Mounting Points, Mount And Lug

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Converting rear bumper - AZ88.00-P-0001-03I
Preparation
Assembly
2. Install inner carrier, impact damper and antennas.
5. Rivet side sliding arrests in exterior surface.
6. Press radio antenna into lugs intended for this purpose and fasten with glue.
7. Install spacer strip on stay intended for this purpose.
8. Install bumper.
Converting side paneling - AZ88.00-P-0001-04J
Preparation
1. Remove vehicle jack plug (C).
2. Remove standard side paneling.
3. Remove sealing strip from door bottom edge.
4. Install clip H WA202 988 01 81 on bottom of vehicle (ensure that all claws spread).
5. Install vehicle jack plugs (C) included.

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Fig. 98: Identifying Vehicle Jack Plugs
Final assembly
6. Pull in catch strap for rocker panel cover.
7. Degrease fender in gluing areas (A) and (B) and glue on tufted strips
Fig. 99: Identifying Fender Gluing Areas
8. Press AMG snaps (E) in entrance area, reinforce first and last snaps with grommet (F) in addition.
Fig. 100: Identifying AMG Snaps & Grommet
9. Remove protective layer from hook strap in rocker panel and ensure, that all hooks are exposed.
10. Apply glue to front and rear side paneling in groove (below hook strap) intended for this purpose.
11. Hook side paneling in at front fender with mounting lug and firmly press hook strap into tufted strip
starting at front.
12. In the entrance area fasten side paneling with Philips screws and in vehicle floor area (front) with
spreading rivets and screws.

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13. Clean gluing surface in entrance area. Remove backing foil from self-adhesive cover foil and use to cover
screws.
14. Clip in AMG cover strips.
15. Clean bottom edge of door.
16. Carefully move sealing strips together with clips (A) into holes starting at hinge side, do not hammer or
hit.
17. When all clips (A) are caught carefully catch pins (B) into clips (A).
Fig. 101: Identifying Clips & Catch Pins
Retrofit AMG trim panels - AZ88.00-P-0001N
MODEL 170 up of 1.3.01

The trim parts supplied
with the accessories and
spare parts are primed and
must be painted in the
same color as the vehicle
before being installed.
Some of the primed styling
items from the Apart
number group must be
ordered with ES2, code
9999!

The front AMG license
plate molding is not
included in the scope of
delivery! It must be
ordered separately
according to national
version.

After conversion, have
proper installation
confirmed by authorized
workshop on form sheet

Microsoft
TOW EYE
"Excerpt from EU Type
Approval". The form sheet
is to be kept in the vehicle
and to be handed over, if
required, to the responsible
persons.

Body kit, certificate
Only for models
170.444 /449 /465.
* For Germany only
OF88.00-P-1000-01BB

Remove

AR88.20-P-2000GA

AR88.20-P-2200G

Installation
3 Retrofit adapter on tow
eye
AZ88.00-P-0001-05A

Bolt for adapter on
tow eye
*BA00.60-P-1001-01A
4 Convert front bumper AZ88.00-P-0001-02M
5 Converting side paneling AZ88.00-P-0001-04N
6 Convert rear bumper AZ88.00-P-0001-03M
7 Install front bumper

AR88.20-P-2000GA
8 Installing rear bumper

AR88.20-P-2200G
Number Designation Model 170 with code 77
BA00.60-P-1001-01A Bolt for adapter on tow
eye
NM67 (2)
B6 603 60 049 Front bumper, complete without
1
A203 885 11 25 Paneling 1
A170 885 13 25 ECE covering (must be ordered
separately)
1
A170 885 14 25 Switzerland covering (must be
ordered separately)
1
A170 885 15 25 Italy covering (must be ordered 1

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Converting front bumper - AZ88.00-P-0001-02M
Preparation
separately)
A170 885 16 25 J apan covering (must be ordered
separately)
1
A170 885 17 25 USA covering (must be ordered
separately)
1
B6 603 60 55 Front bumper complete with
SRA (code 600) consisting of:
1
A203 885 10 25 Paneling 1
A170 885 13 25 ECE covering (must be ordered
separately)
1
A170 885 14 25 Switzerland covering (must be
ordered separately)
1
A170 885 15 25 Italy covering (must be ordered
separately)
1
A170 885 16 25 J apan covering (must be ordered
separately)
1
A170 885 17 25 USA covering (must be ordered
separately)
1
B6 603 60 56 Side paneling kit, complete
consisting of
1
A170 698 03 54 Left paneling 1
A170 698 04 54 Right paneling 1
A170 698 23 30 Left front cover (ES2 code 9999) 1
A170 698 24 30 Right front cover (ES2 code 9999) 1
A170 698 25 30 Left rear cover (ES2 code 9999) 1
A170 698 26 30 Right rear cover (ES2 code 9999) 1
B6 603 60 57 Rear bumper, complete (in
combination with standard rear
muffler) consisting of:
1
A170 885 12 25 Upper section paneling 1
A170 885 15 25 Paneling bottom section (not
included in parts kit)
1
B6 603 62 41 Rear bumper, complete (in
combination with rear muffler
accessories) consisting of:
1
A170 885 12 25 Upper section paneling 1
A170 885 13 25 Bottom section paneling 1

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2. Remove headlight (1).
3. Remove impact damper (2), inner section (3), mounting rails (4).
4. Remove windshield washer system round cover plate (5).
5. Remove moldings (6), license plate cover (7) and grate (8).
Assembly
6. Clip temperature sensor (9) into grate.
7. Reassemble and reinstall bumper in opposite order.
Fig. 102: Identifying Front Bumper Components
Converting rear bumper - AZ88.00-P-0001-03M
Preparation
1. Remove bumper
2. Remove inner section (1).
3. Remove impact damper (2) and antenna (3).
4. Remove upper rails (4).
5. Remove molding strips (5).
Assembly
6. Reassemble and reinstall bumper in opposite order.

Microsoft
Fig. 103: Identifying Rear Bumper Components
Converting side paneling - AZ88.00-P-0001-04N
Preparation
1. Remove side paneling.
Assembly
2. Reinstall AMG side paneling in opposite order.

Microsoft
Fig. 104: Identifying AMG Side Paneling Components
Retrofitting adapter on towing eye - AZ88.00-P-0001-05A
TOWING EYE
1. Install adapter (1) to towing eye.
2. Lay towing eye ring (3) into trunk with jack.
3. For towing see operating instructions.
Number Designation Model 170 with code
772
BA00.60-P-1001-01A Screw for adapter on
towing eye
NM67 (2)

Microsoft
Fig. 105: Identifying Adapter & Towing Eye Ring
RETROFIT AMG REAR SPOILER - AZ88.50-P-0001A
MODEL 170

The rear spoiler is painted
in the accessories and
replacement part delivery
scope and must be
ordered according to the
color of the vehicle.

After conversion, have
proper installation
confirmed by authorized
workshop on form sheet
"Excerpt from EU Type
Approval". The form
sheet is to be kept in the
vehicle and to be handed
over to the responsible
persons if required.

Rear spoiler certificate * for Germany only OF88.30-P-1001-01A

Installation
1 Retrofit AMG rear spoiler AZ88.50-P-0001-01A

Microsoft
Retrofit AMG rear spoiler - AZ88.50-P-0001-01A

Only install the AMG rear spoiler in a closed room with a minimum temperature of 20 Celsius.
Clean the gluing surfaces to remove all dust and grease before cementing!
Mark dimensions
1. Mark a distance of 736 mm from the extreme edge of the trunk lid to the front edge of the spoiler on both
sides of the vehicle (see arrow).
The dimensions must be exact!
Mark the measured points using adhesive tape (TESA crepe or similar).
Fig. 106: Measuring Distance From Extreme Edge Of Trunk Lid To Front Edge Of Spoiler
Mark dimensions
2. Mark a distance of 509 mm from the center of the trunk lid edge to the edge of the spoiler (see arrow).
The dimensions must be exact!
Mark the measured points using adhesive tape (TESA crepe or similar).
A170 790 0088 AMG rear spoiler (order with paint
code, see EPC BM 170.466)
1

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Fig. 107: Measuring Distance From Center Of Trunk Lid Edge To Edge Of Spoiler
Preparing rear spoiler for installation
3. Pull back protective foil (1) for a length of approx. 100 mm at both extreme ends, top and bottom.
4. Pull off protective foil (2) for a length of approx. 100 mm to both sides of the center.
5. Pull off protective foil (3) from the short length of adhesive tape entirely.
6. Apply glue to marked points (arrows between pieces of adhesive tape)
Fig. 108: Identifying Protective Foil
Fig. 109: Identifying Protective Foils
Attaching rear spoiler
7. Align the rear spoiler with respect to the brake lamp and position with the exposed foil on the 509 mm

Microsoft
marking.
Fig. 110: Aligning Rear Spoiler With Brake Lamp
Fig. 111: Identifying Rear Spoiler
8. Lift the rear spoiler slightly and pull out the protective foil on both sides, paying attention to the 736 mm
marking.
9. Then press the rear spoiler down firmly from the center to the outsides.
Fig. 112: Pulling Out Protective Foil

Microsoft
Fig. 113: Pressing Rear Spoiler From Center To Outsides
After positioning, the rear spoiler must be pressed down firmly along the entire adhesive surface!
Maximum bonding is achieved only after approx. 72 hours at 20 Celsius!
Do not use a car wash within the first 24 hours!
Fig. 114: Identifying Rear Spoiler View
RETROFITTING TRUNK LID EMERGENCY RELEASE - AZ88.50-P-0002G
MODEL 170 with CODE (491) U.S. version Mechanical emergency release

Microsoft
Fig. 115: Identifying Trunk Lid Emergency Release Retrofit Components

The parts for retrofitting
the trunk lid emergency
release are given in the
part documents (Group
KG 75 trunk lid).

Removing
1 Remove latch section (3)
The latch section (3) is
replaced. Do not remove
trunk lid lock (1.1) or
(1.2)!

Model 170 up to 31.1.00 AR88.50-P-5020G

Model 170 as of 1.2.00 AR88.50-P-5020GA
2.1 Remove connection
linkage (2.2)
Model 170 as of
1.2.00.
The connection linkage
(2.2) is replaced.

Installation
3 Retrofit control cable (4) AZ88.50-P-0002-04G
4 Position latch section (3)
at its installation position
on the trunk lid

5.1 First insert connection
shaft (2.1) into guide on
latch section (3) and then
Model 170 up to 31.1.00

Microsoft
Retrofitting control cable - AZ88.50-P-0002-04G
1. Hook nipple on control cable (1) into emergency release handle (2) and route through guide in handle
recess (3).
2. Insert control cable sheath into mount on handle recess (3).
into guide on trunk lid
lock (1.1)
5.2 Hook new connection
linkage (2.2) into latch
section (3)
Model 170 as of 1.2.00
6 Install latch section (3)
and adjust

Model 170 up to 31.1.00 AR88.50-P-5020G

Model 170 as of 1.2.00 AR88.50-P-5020GA
7 Carry out operational
check

8 Place insert sheet for
trunk lid emergency
release in Owner's
Manual
Order number see
parts ordering notes.

Group 75 Latch section 1
Group 75 Connection linkage 1
Group 75 Handle assembly 1
6515955913 Insert sheet, Owner's Manual,
mechanical kit (order from
Storopack print company hotline -
telephone number:+49-
7123/64242)

Microsoft
Fig. 116: Identifying Control Cable, Emergency Release Handle & Handle Recess
3. Route control cable (1) through hollow space in trunk lid to installation position for locking part.
4. Clip handle recess (3) into cutout on trunk lid.
Fig. 117: Identifying Control Cable & Handle Recess
5. Hook nipple (arrow) on control cable (1) into moving lever (8) on locking part (4).
6. Install hose mount (6) with control cable (7) on mount (5).
Push hose mount (6) with control cable (7) into groove on mount (5).
Fig. 118: Identifying Nipple On Control Cable, Moving Lever, Locking Part, Hose Mount & Mount
COMPONENT MODIFICATIONS
HOOK OF SECURITY MODIFIED, OF THE UPPER PART OF THE CLOSING OF THE BOSS -
BT88.40-P-3200-01G
From the num. final of.chassis 005707

Microsoft
MODEL 170.### ## as of 005708
The hook of security, arranged in the upper part of the closing of the boss has been modified.
The hook of security has now a form in OR, closed (previously, in L). With it, it enlarges the security against an
opening done not desired of the boss. During the trip, if the blockade freed itself.
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: DETACHABLE BODY COMPONENTS,
EXTERIOR FLAPS - BA88.00-Z-9999AZ
MODEL all
Fender MODEL 163 BA88.10-P-1000-01A
Fenders MODEL 171, 210, 211,
220, 230, 240
BA88.10-P-1000-01B
Fenders MODEL 169.0 /3, 245.2 BA88.10-P-1000-01C
Fenders MODEL 216, 219, 221 BA88.10-P-1000-01D
Fenders MODEL 164.1 /8 BA88.10-P-1000-01E
Fenders MODEL 251 BA88.10-P-1000-01F
Fenders MODEL 204 BA88.10-P-1000-01G
Bumper MODEL 168, 170, 202,
203, 208.3 /4, 209, 210,
215, 220
BA88.20-P-1000-01A
Bumper MODEL 163 BA88.20-P-1000-01B
Bumper MODEL 169, 245 BA88.20-P-1000-01C
Bumper MODEL 219, 221 BA88.20-P-1000-01D
Bumper MODEL 164.1 /8 BA88.20-P-1000-01E
Bumper MODEL 251 BA88.20-P-1000-01F
Detachable body
components, underride
guard
MODEL 163 BA88.30-P-1000-01A
Detachable body
components, underride
guard
MODEL 164.1 /8 BA88.30-P-1000-01D
Engine hood MODEL 170, 171, 202,
203, 208.3 /4, 209, 211,
210
BA88.40-P-1000-01A
Engine hood MODEL 168, 414.700 BA88.40-P-1000-01B
Engine hood MODEL 163 BA88.40-P-1000-01C
Engine hood MODEL 199, 215, 220,
230, 461, 463 ...
BA88.40-P-1000-01D
Engine hood MODEL 240.078 /079/178BA88.40-P-1000-01E

Microsoft
BUMPER - BA88.20-P-1000-01A
Model 168, 170, 202, 203, 208, 210, 215, 220
Modification notes
Bumper
Engine hood MODEL 169, 245 BA88.40-P-1000-01I
Engine hood MODEL 219 BA88.40-P-1000-01J
Engine hood MODEL 164.1 /8 BA88.40-P-1000-01K
Engine hood MODEL 251 BA88.40-P-1000-01L
Engine hood MODEL 216, 221 BA88.40-P-1000-01M
Engine hood MODEL 204 BA88.40-P-1000-01N
Trunk lid MODEL 170, 171,
199.376, 202, 203,
208.3 /4, 209, 210, 211,
215, 220, 230
BA88.50-P-1000-01A
Trunk lid MODEL 240 BA88.50-P-1000-01B
Trunk lid MODEL 216, 219, 221 BA88.50-P-1000-01D
Trunk lid MODEL 204 BA88.50-P-1000-01E
Outside flaps MODEL 208.4, 209.4 BA88.60-P-1000-01A
Outside flaps MODEL 169.0 /3, 245.2 BA88.60-P-1000-01B
Outside flaps MODEL 219.3 BA88.60-P-1000-01C
Outside mirrors MODEL 171, 211, 230 BA88.70-P-1000-01A
Outside mirrors MODEL 216, 219, 221 BA88.70-P-1000-01B
Exterior rearview mirrors MODEL 221 BA88.70-P-1000-01C
Cover strips MODEL 219 BA88.80-P-1000-01A
21.3.01 Figure modified from 45
Nm to 55 Nm
Figure in line 1010 for
model 203 modified

Number Designation Model 168 Model 170 Model 202 Model 203 Model
208.3/4
BA88.20-P-
1001-01A
Nut of front
bumper to
cross member
Nm- 10 20 20 20
BA88.20-P-
1002-01A
Nut for rear
bumper on
rear center
section
Nm- 10 20 6 8
BA88.20-P-
1003-01A
Bolt of front
bumper to
headlight
housing
Nm- - - - 2

Microsoft
Bumper
BA88.20-P-
1004-01A
Bolt of front
bumper to
side of fender
on inside
Nm- - - 4 3
BA88.20-P-
1005-01A
Screw with
seal for rear
bumper on
side of fender
Nm- - - 8 5
BA88.20-P-
1006-01A
Bolt of front
bumper to
cross member
Nm3 - - 4 -
BA88.20-P-
1007-01A
Bolt of rear
bumper to
rear center
section
Nm3 - - - -
BA88.20-P-
1008-01A
Bolt of fog
light to
bumper
Nm- - - 3 -
BA88.20-P-
1009-01A
Bolt of
bumper to
side wall in
area of rear
light
Nm- - - 6 -
BA88.20-P-
1010-01A
Nut/screw for
rear bumper
on
longitudinal
member
Nm- - - 55 -
Number Designation Model 209 Model 210 Model 215 Model 220
BA88.20-P-
1001-01A
Nut of front
bumper to
cross member
Nm- 20 - -
BA88.20-P-
1002-01A
Nut for rear
bumper on rear
center section
Nm6 20 50 50
BA88.20-P-
1003-01A
Bolt of front
bumper to
headlight
housing
Nm- - - -
BA88.20-P-
1004-01A
Bolt of front
bumper to side
of fender on
inside
Nm4 - - -

Microsoft
ENGINE HOOD - BA88.40-P-1000-01A
MODEL 170, 171, 202, 203, 208, 209, 210, 211
Modification notes
Engine hood
BA88.20-P-
1005-01A
Screw with seal
for rear bumper
on side of
fender
Nm8 - - -
BA88.20-P-
1006-01A
Bolt of front
bumper to
cross member
Nm4 - - -
BA88.20-P-
1007-01A
Bolt of rear
bumper to rear
center section
Nm- - - -
BA88.20-P-
1008-01A
Bolt of fog
light to bumper
Nm3 - - -
BA88.20-P-
1009-01A
Bolt of bumper
to side wall in
area of rear
light
Nm8 - - -
BA88.20-P-
1010-01A
Nut/screw for
rear bumper on
longitudinal
member
Nm45 - - -
15.2.00 Value modified from 12
Nm to 8 Nm
Value in row 1001
changed for model 203

Number Designation Model 170 Model 171 Model 202 Model 203 Models
208.3/4
BA88.40-P-
1001-01A
Screw on
engine hood
Nm10 - 12 8 10
BA88.40-P-
1002-01A
Screw on
engine hood
hinge
Nm- - 10 10 -
BA88.40-P-
1003-01A
Screw on
engine hood
catch
Nm- 8 10 10 8
BA88.40-P-
1004-01A
Bolt on upper
section of
engine hood
catch
Nm8 8 10 10 8
BA88.40-P- Bolt for hood Nm10 - - - 12

Microsoft
Engine hood
TRUNK LID - BA88.50-P-1000-01A
Model 170, 171, 199, 202, 203, 208, 210, 211, 215, 220, 230
1005-01A hinge
BA88.40-P-
1006-01A
Bolt, radiator
grill to
engine hood
Nm- - - 3.5 -
BA88.40-P-
1007-01A
Bolt, engine
hood to
engine hood
hinge
Nm- 10 - - -
BA88.40-P-
1008-01A
Screw for
engine hood
hinge on
wheelhouse
liner
Nm- 10 - - -
BA88.40-P-
1009-01A
Bolt, safety
hook to
engine hood
Nm- 8 - - -
Number Designation Model 209 Model 210 Model 211
BA88.40-P-
1001-01A
Screw on engine
hood
Nm8 10 -
BA88.40-P-
1002-01A
Nuts on hood
hinge
Nm12 10 -
BA88.40-P-
1003-01A
Screw on engine
hood catch
Nm8 10 8
BA88.40-P-
1004-01A
Bolt on upper
section of engine
hood catch
Nm8 10 8
BA88.40-P-
1005-01A
Bolt for hood
hinge
Nm- - -
BA88.40-P-
1006-01A
Bolt, radiator grill
to engine hood
Nm- - -
BA88.40-P-
1007-01A
Bolt, engine hood
to engine hood
hinge
Nm- - 8
BA88.40-P-
1008-01A
Screw for engine
hood hinge on
wheelhouse liner
Nm- - 12
BA88.40-P-
1009-01A
Bolt, safety hook
to engine hood
Nm- - 8

Microsoft
Trunk lid
Number Designation Model 170 Model 171 Model 199 Model 202 Model 203
BA88.50-P-
1001-01A
Bolt at trunk
lid hinge to
side wall
Nm- - 20 10 10
BA88.50-P-
1002-01A
Screw to
trunk lid lock
Nm- - - 10 10
BA88.50-P-
1003-01A
Nut to
eccentric bolt
Nm- - - 25 25
BA88.50-P-
1004-01A
Bolt to
locking eye
Nm- - - 10 10
BA88.50-P-
1005-01A
Bolt, trunk
lid lock to
trunk lid
Nm8 9 - - -
BA88.50-P-
1006-01A
Bolt, locking
lug to trunk
lid
Nm8 - - - -
BA88.50-P-
1007-01A
Bolt, locking
eye to
tubular frame
Nm10 9 - - -
BA88.50-P-
1008-01A
Bolt, striker
to tubular
frame
Nm10 - - - -
BA88.50-P-
1009-01A
Bolt, hinge
bracket to
trunk lid
Nm25 - 20 - 8
BA88.50-P-
1010-01A
Bolt, hinge
lever to
tubular frame
Nm25 9 - - -
BA88.50-P-
1011-01A
Bolt, tubular
frame hinge
to rear center
section
Nm25 20 - - -
BA88.50-P-
1012-01A
Bolt, strut of
wiring
harness to
hinge lever
Nm8 - - - -
BA88.50-P-
1013-01A
Bolt, trunk
lid auxiliary
lock to trunk
lid
Nm- - - - -
BA88.50-P-
1014-01A
Nut, hinge
lever to trunk
lid
Nm- 20 - - -
BA88.50-P- Bolt, locking Nm- - - - -

Microsoft
Trunk lid
1015-01A wedge to
trunk lid
BA88.50-P-
1016-01A
Bolt, handle
plate to trunk
lid
Nm- 9 - - -
BA88.50-P-
1017-01A
Nut on trunk
lid hinge to
rear shelf
Nm- - - - -
BA88.50-P-
1018-01A
Nut,
actuation
bracket of
remote trunk
closing to
hinge bracket
of trunk lid
Nm- - - - -
BA88.50-P-
1019-01A
Nut, remote
trunk closing
to C-pillar
bolt-on point
Nm- - - - -
BA88.50-P-
1020-01A
Nut, remote
trunk closing
to bolt-on
point of rear
shelf sheet
metal
Nm- - - - -
BA88.50-P-
1021-01A
Bolt, guide
bolt to side
wall
Nm- 10 - - -
BA88.50-P-
1022-01A
Bolt, height
limiter to
carrier plate
Nm- - - - -
BA88.50-P-
1023-01A
Ball head
bolt to trunk
lid
Nm- 20 - - -
BA88.50-P-
1024-01A
Bolt,
retaining
plate to
hydraulic
distributor
Nm- - - - -
Number Designation Model
208.3/4
Model 209 Model 210 Model 211 Model 215
BA88.50-P-
1001-01A
Bolt at trunk
lid hinge to
Nm10 - 10 - 9

Microsoft
side wall
BA88.50-P-
1002-01A
Bolt on trunk
lid lock
Nm10 9 10 - 9
BA88.50-P-
1003-01A
Nut to
eccentric bolt
Nm25 - 25 - -
BA88.50-P-
1004-01A
Bolt to
locking eye
Nm10 9 10 9 9
BA88.50-P-
1005-01A
Bolt, trunk
lid lock to
trunk lid
Nm10 - - 9 -
BA88.50-P-
1006-01A
Bolt, locking
lug to trunk
lid
Nm- - - - 9
BA88.50-P-
1007-01A
Bolt, locking
eye to
tubular frame
Nm- - - - -
BA88.50-P-
1008-01A
Bolt, striker
to tubular
frame
Nm- - - - -
BA88.50-P-
1009-01A
Bolt, hinge
lever to trunk
lid
Nm- 8 (2) - 8 9
BA88.50-P-
1010-01A
Bolt, hinge
lever to
tubular frame
Nm- - - - -
BA88.50-P-
1011-01A
Bolt, tubular
frame hinge
to rear center
section
Nm- - - - -
BA88.50-P-
1012-01A
Bolt, strut of
wiring
harness to
hinge lever
Nm- - - - -
BA88.50-P-
1013-01A
Bolt, trunk
lid auxiliary
lock to trunk
lid
Nm- - - 9 9
BA88.50-P-
1014-01A
Nut, hinge
lever to trunk
lid
Nm- - - - -
BA88.50-P-
1015-01A
Bolt, locking
wedge to
trunk lid
Nm- - - - -
BA88.50-P-
1016-01A
Bolt, handle
plate to trunk
Nm- - - 9 -

Microsoft
Trunk lid
lid
BA88.50-P-
1017-01A
Nut, trunk lid
hinge to rear
shelf
Nm- - - 19 -
BA88.50-P-
1018-01A
Nut,
actuation
bracket of
remote trunk
closing to
hinge bracket
of trunk lid
Nm- - - 9 -
BA88.50-P-
1019-01A
Nut, remote
trunk closing
to C-pillar
bolt-on point
Nm- - - 9 -
BA88.50-P-
1020-01A
Nut, remote
trunk closing
to bolt-on
point of rear
shelf sheet
metal
Nm- - - 9 -
BA88.50-P-
1021-01A
Bolt, guide
bolt to side
wall
Nm- - - - -
BA88.50-P-
1022-01A
Bolt, height
limiter on
carrier plate
Nm- - - - -
BA88.50-P-
1023-01A
Ball head
bolt to trunk
lid
Nm- - - - -
BA88.50-P-
1024-01A
Bolt,
retaining
plate to
hydraulic
distributor
Nm- - - - -
Number Designation Model 220 Model 230
BA88.50-P-1001-
01A
Bolt at trunk lid
hinge to side wall
Nm9 9
BA88.50-P-1002-
01A
Bolt on trunk lid
lock
Nm9 9
BA88.50-P-1003-
01A
Nut to eccentric bolt Nm- -
BA88.50-P-1004- Bolt to locking eye Nm9 9

Microsoft
01A
BA88.50-P-1005-
01A
Bolt, trunk lid lock
to trunk lid
Nm- -
BA88.50-P-1006-
01A
Bolt, locking lug to
trunk lid
Nm9 -
BA88.50-P-1007-
01A
Bolt, locking eye to
tubular frame
Nm- -
BA88.50-P-1008-
01A
Bolt, striker to
tubular frame
Nm- -
BA88.50-P-1009-
01A
Bolt, hinge lever to
trunk lid
Nm9 -
BA88.50-P-1010-
01A
Bolt, hinge lever to
tubular frame
Nm- 10
BA88.50-P-1011-
01A
Bolt, tubular frame
hinge to rear center
section
Nm- 23
BA88.50-P-1012-
01A
Bolt, strut of wiring
harness to hinge
lever
Nm- -
BA88.50-P-1013-
01A
Bolt, trunk lid
auxiliary lock to
trunk lid
Nm9 9
BA88.50-P-1014-
01A
Nut, hinge lever to
trunk lid
Nm- 23
BA88.50-P-1015-
01A
Bolt, locking wedge
to trunk lid
Nm- 8
BA88.50-P-1016-
01A
Bolt, handle plate to
trunk lid
Nm- 9
BA88.50-P-1017-
01A
Nut on trunk lid
hinge to rear shelf
Nm- -
BA88.50-P-1018-
01A
Nut, actuation
bracket of remote
trunk closing to
hinge bracket of
trunk lid
Nm- -
BA88.50-P-1019-
01A
Nut, remote trunk
closing to C-pillar
bolt-on point
Nm- -
BA88.50-P-1020-
01A
Nut, remote trunk
closing to bolt-on
point of rear shelf
sheet metal
Nm- -
BA88.50-P-1021-
01A
Bolt, guide bolt to
side wall
Nm- -

Microsoft
BA88.50-P-1022-
01A
Bolt, height limiter
on carrier plate
Nm- 4
BA88.50-P-1023-
01A
Ball head bolt to
trunk lid
Nm- -
BA88.50-P-1024-
01A
Bolt, retaining plate
to hydraulic
distributor
Nm- 2

Microsoft

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Body Components PDF

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1998-2004 ACCESSORIES & BODY, CAB

Detachable Body Components - 170 Chassis

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