body components.pdf

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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 vehiclemodel 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 permanentlyconnected. 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 rearviewmirror 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





Accident hazard!

Objects in rearview mirrors are closer than they appear.

MIRROR, STEERING COLUMN ADJUSTMENT, HEATED MIRRORS, LOCATION OFCOMPONENTS - 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 adjustableoutside rearview mirrors,location of components

Model 168 GF88.79-P-0005-01GC

Defroster in left/rightoutside rearview mirror,

function

Models 168, 170, 202,210

GF88.79-P-2000A

Adjusting left/rightoutside rearview mirror,function

Models 170, 202, 210 GF88.79-P-2001A

Folding in/out left/rightoutside rearview mirror,function

Model 210 with code500b

Model 168

Model 170

GF88.79-P-2002A

Automatic dimmingfeature for outsiderearview mirror ondriver's side, function

Models 129, 140, 210

as of 1.6.96

Model 202 as of1.8.96

GF88.79-P-2003A





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 bythe 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 ofcomponents

Left/right outside rearviewmirror, purpose/location

GF88.79-P-3000A

Outside rearview mirroradjustment switch, purpose/location

GF88.79-P-3001A





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 ofvehicle

Purpose The outside rearviewmirror adjustment switchserves for electricaladjustment of both outsiderearview mirrors

Location Models 210, 170 except GF88.79-P-3001-01A





Fig. 4: Identifying Outside Rearview Mirror Vertical, Horizontal, Left/Right Adjustment And MirrorSwitch - Model 210

Model 170 except

Fig. 5: Identifying Outside Rearview Mirror Vertical, Horizontal And Left/Right Adjustment - Model170 Except Japan

SELF-DIAGNOSTIC SYSTEM

MIRROR ADJUSTMENT, HEATED MIRRORS (MSC) DIAGNOSIS CONTENTS - AD88.79-P-1001AZ

MODEL 170

A 12.5 [] 11 Mirror adjustment, heatedmirrors (MSC) diagnosis, basic knowledge

D88.79-P-2001A

A 12.5 [] 12 Mirror adjustment, heatedmirrors (MSC) diagnosis,function check

AD88.79-P-3002A

A 12.5 [] 13 Mirror adjustment, heatedmirrors (MSC) diagnosis,

troubleshooting

AD88.79-P-5001A

A 12.5 [] 21 Mirror adjustment, heatedmirrors (MSC), testingelectrical system

AD88.79-P-6001A





MODEL 170

MIRROR ADJUSTMENT, HEATED MIRRORS (MSC) DIAGNOSIS TROUBLESHOOTING -

Mirror adjustment, heatedmirrors (MSC) diagnosis, 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 outsiderearview mirror

Turn outside rearviewmirror adjustment switch(S50) to left outsiderearview mirror positionand operate adjuster

up AD88.79-P-6001-13B

down AD88.79-P-6001-06A

to leftto right

AD88.79-P-6001-07A

2 Ignition: ON Mirror adjustment: AD88.79-P-6001-13AAdjusting right outsiderearview mirror

Turn outside rearviewmirror adjustment switch(S50) to right outsiderearview mirror positionand 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 heatup

AD88.79-P-6001-10A

Heated mirrors After approx. 1 minute feelmirror glass with palm ofthe hand

AD88.79-P-6001-11A

up to 12/96

With terminal 15 ON theoutside rearview mirrorsare heated continuouslyas of 12/96 Cut-in and cut-outtemperatures withterminal 15 ON< 15°C: heated mirrors

ON > 25°C: heated mirrorsOFF





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





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





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 ElectricallyAdjustable Right Outside Mirror Motors

MSC test of electrical system outside mirror adjustment switch - AD88.79-P-6001-13D

Illumination





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 andwheelhouse covereliminated

Previously step 3

30.4.98 Remove paneling fromouter A-pillar eliminated

Previously step 5

Remove/install

When replacing frontfender apply MB permanent underbody





2003 Mercedes Benz SLK320



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 170BE60.00-P-1001-01A

Gap dimension Engine hood tofender

Dimension "A" mm 4.0 (± 0.5)

Engine hood toheadlamp

Dimension "R" mm6.0 (+1/-0.5)

Engine hood toradiator 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 tofender

Dimension "H" mm4.0 (± 0.5)

Front door to

rear door

Dimension "I" mm-

Front door toroof

Dimension "C" mm-

Rear door toupper sidesection

Dimension "D" mm-

Rear door tolower side

section

Dimension "J" mm-

Fender to A- pillar

Dimension "Q" mm4.0 (± 1.6)

Front door torear fender

Dimension "P" mm4.0 (± 0.5)

Fig., see AR60.00-P-0700-01G






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 wheelhousedeleted

Previously step 1 AR88.10-P-1300G

Removal, installation

1 Remove wheel

2 Remove sound-proofingcapsule below engine

3 Remove inner fender (1) Installation : Clipinner fender (1) into coverfor wheelhouse innerfender (2) (arrow)

4 Remove cover forwheelhouse inner fender(2)

On vehicles withcharge air cooler, presscharge air tube to side, ifnecessary






Fig. 21: Identifying Front Bumper Remove/Install Components - Model 170 Up To 31.Jan.00

Modification notes

30.4.98 Removal of road wheelsis no longer required

Previously step 2

30.4.98 Removal of wheel arch

panel is no longerrequired

Previously step 5

30.4.98 Clip has been replaced byscrew (11) with collar nut(12)

Step 6

Removing, installing

1 Open engine hood AR88.40-P-1000G2 Separate the connectors

on the right and left turnindicator lamps (7)

3 Remove the right and leftturn indicator lamps (7)

Disengage turnindicator lock tabs by pushing them to the side

4 Separate right and left foglamp connectors (9) The connectors can bereached through anopening in the wheel arch panel of the front fender.

5 Separate the connector(10) for the outside

Cf. code (240a)outside temperature





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


1 Remove left and right turnsignal lamps (7)

Press retaining lug onturn signal lampsdownwards

AR82.10-P-4725C

2 Unscrew screws (2) on both sides

3 Disconnect connectors (9)for left and right foglamps

The connectors areaccessible through anopening in thewheelhouse cover in thefront fender.

4 Unscrew screws (seearrows) on wheelhousecover

5 Remove enginecompartment paneling

AR61.20-P-1105A

6 Disconnect connector (10)for outside temperaturesensor

N Unscrew left and rightnuts (4) on cross member

*BA88.20-P-1001-01A

8 Unscrew screw (5) withwasher (6) on both sides

9 Unscrew nuts (11) on





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 slightlyto avoid damaging paint.

Bumper is clipped inarea of radiator grille.

11 Install in the reverse order

Number Designation Model 170

BA88.20-P-1001-01A Nuts for front bumper oncross member

Nm 10 ± 2





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

Removal/installation

1 Remove paneling from rearcenter 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) fortrunk luggage cover"closed limit switch(S69/10) with tie strap

Do not damagecontact (10) of trunkluggage cover "closed"limit switch (S69/10) toensure proper function

Do not disconnect

connector.

5 Disconnect antenna lines(9) from left rear bumperantenna amplifier (A2/26)and press grommet towardoutside

Do not damageantenna lines (9) toensure for properfunction

Installation :Grommet for antenna

lines (9) should be seatedsecurely in fender to prevent water ingress

6 Unscrew nut (7) andremove toothed lockwasher (8)

*BA88.20-P-1002-01A

7 Unscrew bolts (3) frominner fender, remove

washers (4) and sealingwashers (5)

Installation : Checksealing washers (5),

replace if necessary

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

9 Remove bumper (6) Remove bumper





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 : Seeinstallation instructionsfor accessories

Retrofitting AMG trims AZ88.00-P-0001I



BA88.20-P-1002-01A Nut for rear bumper onrear center section

Nm 10

Contact with componentsunder high voltage can pose lethal hazard

Do not touch parts underhigh voltage. People withelectronic implants (e.g.heart pacemakers) shouldnot perform work onignition system.

AS15.10-Z-0001-01A

Opening

1 Pull lever on left belowinstrument panel (1) to

Engine hood shouldspring open, if necessary





REMOVING AND INSTALLING ENGINE HOOD - AR88.40-P-3000G

MODEL 170

release engine hood (2) lift engine hood slightly

2 Press levers for safetyhooks (arrow) against stopon engine hood (2) andopen engine hood untilthe locking knob (4)catches

Windshield wiper armmust not be foldedforward

The locking knobsymbol "PRESS" should be completely visible inthe opening in the gas pressure strut cover tube

Moving to uprightposition

3 Press locking knobsymbol "PRESS" inopening in gas pressurestrut cover tube and moveengine hood (2) to upright position until locking

knob (5) catches

The locking knobsymbol "PRESS" must becompletely visible in theopening in the gas pressure strut cover tube

Closing

4 Press locking knobsymbol "PRESS" in theopening in the gas pressure strut cover tubeand pull engine hood (2)down against the pressure

of the gas pressure strut(3)

The locking knobsymbol "PRESS" must becompletely visible in theopening in the gas pressure strut cover tube

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

6 Check locking function ofengine hood lock





Fig. 26: Identifying Engine Hood Remove/Install Components


Sealing joints followingrepairs

Includes sealing jointson 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) andmove 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 safetyhooks on the engine hoodhinges (5)

Installation : Move bolts to coincide with pressure points in paintEnsure that engine hoodfits correctly, if

necessary ?

Adjust engine hood AR88.40-P-3020G

3 Unclip retainer (2) andunhook gas pressure strut(3) from engine hood (1)



1998 2004 ACCESSORIES & BODY CAB D t h bl B d C t 170 Ch i



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 withimpressions in paint

5 Remove engine hood (1)with help of second

person and set down onsuitable surface

Avoid damaging paintwork

Installation : Positionengine hood in safetyhooks on engine hoodhinges (5)

6 Reinstall in oppositeorder


BA88.40-P-1001-01A Bolt on engine hood Nm 10





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




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 infront fender

AR88.10-P-1300G

3 Mark installation positionof engine hood hinge (1)

This facilitatesinstallation

4 Unscrew bolts (2) and

remove engine hoodhinge (1)

Installation : Observemarking on wheelhouse panel

*BA88.40-P-1005-01A

Preserve engine hoodhinges with hollow cavity

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





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, seeService Microfiche,Specifications for service products, sheet no. 385



BA88.40-P-1005-01A Bolt on engine hoodhinge

Nm 10


1 Open engine hood andmove to upright position

AR88.40-P-1000G

2 Unscrew screw (8) onhandle (7)

3 Pull handle (7) out ofarresting mechanism incover and unhook engine

, y p



Fig. 31: Identifying Engine Hood Lock Remove/Install Components

MODIFICATION NOTES

30.6.98 Engine hood catch uppersection modified

Step 5.1 BT88.40-P-3200-01G


1 Open engine hood AR88.40-P-1000G

2 Remove bolts (3) andremove engine hoodcatch lower section (4)from above

Installation : Greaseengine hood catch lowersection with MB sliding

paste

*BR00.45-Z-1004-06A

3 Detach engine hood pull(5) from engine hoodcatch lower section (4)

Slightly pull enginehood pull

Installation : Notecorrect routing of enginehood pull cable

4 Remove engine hood

catch upper section (1)

Mark installation position of engine hoodcatch upper section onengine hood

*BA88.40-P-1004-01A

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



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





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 followingrepair

Includes sealing jointson trunk lid

AR97.10-P-4000G

Preserving hollowcavities following repair

Includes preservinghollow cavities in trunk

lid

AR97.20-P-1500G

1 Remove trunk lid andstriker eye

Do not separate strikereye

AR88.50-P-5020G

2 Disconnect connectors (4)

3 Open or separate holder





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 wiringharness and pull wiring

harness out of trunk lid 4 Mark position of hinge

lever on trunk lid (1),loosen bolts (2) andunscrew two bolts oneach side

*BA88.50-P-1009-01A

5 Unhook gas pressure strut(5) from trunk lid with aidof second mechanic,unscrew bolts (2) andremove trunk lid (1)


Check adjustment oftrunk lid, if necessary ?

Adjust trunk lid AR88.50-P-5200G


BA88.50-P-1009-01A Bolts for hinge lever ontrunk lid

Nm 25





Fig. 36: Identifying Trunk Lid Lock And Striker Eye Remove/Install Components - Model 170 Up To31.1.00 (1 Of 2)

Fig. 37: Identifying Trunk Lid Lock And Striker Eye Remove/Install Components - Model 170 Up To31.1.00 (2 Of 2)


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

2 Unscrew screws (5) andremove latch section (2)from trunk lid

*BA88.50-P-1006-01A

3 Unscrew screws (6) on

trunk lid lock (1) andremove connecting rod(9)

*BA88.50-P-1005-01A

4 Press off CL line (8) andremove trunk lid lock (1)





TRUNK LID

Removing, installing and adjusting trunk lid lock and striker eye - AR88.50-P-5020GA

MODEL 170 as of 1.2.00

5 Disconnect connector (7)and remove latch section

(2)

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

*BA88.50-P-1007-01A

N Install in the reverse order When installing trunklid lock (1) ensure thatseal is seated properly,replace seal if damaged.

Check trunk lid fit, ifnecessary: ?



BA88.50-P-1005-01A Screw for trunk lid lockon trunk lid

Nm 8

BA88.50-P-1006-01A Screw for latch section ontrunk lid

Nm 8

BA88.50-P-1007-01A Screw for striker eye ontubular frame

Nm 10





Fig. 38: Identifying Trunk Lid Lock And Striker Eye Remove/Install Components - Model 170 As Of1.2.00

TRUNK LID


1 Remove cover (4)

2 Unclip connecting rod (9)

from handle (3) andunhook latch section (2)

3 Unscrew screws (5) andremove latch section (2)from trunk lid

*BA88.50-P-1006-01A

4 Disconnect connector (7)and remove latch section(2)

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

*BA88.50-P-1007-01A

6 Install in the reverse order Check trunk lid fit, ifnecessary: ?



BA88.50-P-1006-01A Screw for latch section ontrunk lid

Nm 8





REMOVING, INSTALLING TRUNK LID HANDLE WITH LOCK CYLINDER - AR88.50-P-5060G

MODEL 170 as of 1.2.00

Fig. 39: Identifying Trunk Lid Handle With Lock Cylinder Remove/Install Components - Model 170 AsOf 1.2.00 (1 Of 2)

Fig. 40: Identifying Trunk Lid Handle With Lock Cylinder Remove/Install Components - Model 170 AsOf 1.2.00 (2 Of 2)

BA88.50-P-1007-01A Screw for striker eye ontubular frame

Nm 10


1 Remove cover behindtrunk lid handle (1)

2 Unscrew screws (21) andnut (22)

Nut (22) is located onthe rear of the left license





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 connectionleads for left and rightlicense plate lamps(E19/1, E19/2)

4 Unclip connecting rod(11)

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

6 Unscrew nut (12) Installation : Replacesealant 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)






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



Remove/Install

1 Remove side paneling intrunk

AR68.30-P-4800G

2 Remove cover plate (2)from rear center section

*BA77.33-P-1006-01A



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





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

roof9. Measure distance between square tube and tubular frame again.

If the distance measured is outside the permissible tolerance adjust hydraulic cylinder





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, correctadjustment 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.





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

2 Mark position of hingelever (1) on trunk lid

3 Unscrew screws (2) *BA88.50-P-1009-01A

4 Close trunk lid, pivot torear with roof switch andopen trunk lid again



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





actuation valve (N) onhydraulic unit to stop with

6 mm Allen wrench

actuation valve only withroof put down or closed

and ignition switched offto avoid damaging theseal on the emergencyactuation valve (N) whichwould prevent pressurefrom building up in thesystem.

2 Loosen bolts (1) on hinge

lever (2)

Mark position of hinge

lever (2)

3 Loosen bolts (3) fromstriker eye (4)

4 Align trunk lid inlongitudinal direction inrelation to taillamps andtighten bolts (1) on hingelever (2)

*BE60.00-P-1003-01A

Bolt for hinge leveron trunk lid

*BA88.50-P-1009-01A

Fig. 19

5 Adjust striker eye (4) ontubular frame (5) inrelation to locking lug (6)and retighten bolts (3).

The locking lug (6)should hit in the center ofthe striker eye (4) and thetrunk lid should close

easily.Correct longitudinal

direction of striker eye (4)with shims below strikereye (4) if necessary.

Bolts for striker eyeon tubular frame

*BA88.50-P-1007-01A

6 Close trunk lid and check

height adjustment of trunklid in area of taillamps

Correct heightadjustment 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) ontrunk lid

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

Fig. 199 Close emergency

actuation valve (N) onhydraulic unit with 6 mmAllen wrench.

Emergency actuationvalve on hydraulic unit

*BA77.37-P-1001-01A



tubular frame Pressurized mm< or = 33





TRUNK LID

HYDRAULIC SOFT TOP

SOFT TOP - MECHANICS


Adjust rubber buffers on hinge lever - AR88.50-P-5200-01G

TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS

tubular frame Pressurizedhydraulic system

mm< or = 33

Fig., see AR88.50-P-5100-01G


BA88.50-P-1007-01A Bolt, striker eye totubular frame

Nm 10

BA88.50-P-1008-01A Bolt, striker to tubularframe Nm 10

BA88.50-P-1009-01A Bolt, hinge bracket totrunk lid

Nm 25


BA77.37-P-1001-01A

Emergency actuationvalve (N) onhydraulic unit

Nm 3

Fig., see AR77.50-P-3100G


BA77.33-P-1003-01A Bolts, catch on tubularframe in trunk

Nm 8

BA77.33-P-1004-01A Bolts, catch socket oncatch, tubular frame intrunk

Nm 8


BE60.00-P-1003-01A

Gap dimension Trunk lid to topof rear fender

Dimension "F" mm -



Press trunk lid closed carefully, do not slam!





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

Gap dimension Trunk lid to topof rear fender

Dimension "F" mm -

Trunk lid to bottom of rearfender

Dimension "M" mm-

Trunk lid to rearfender

Dimension "F" mm 5.0 (+1/-0)

Trunk lid to Dimension "M" mm 5.0 (+1/-0)






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.

taillamp( )

Trunk lid to bumper

Dimension "V" mm 8.0 (± 0.5)

Rear fender totaillamp

Dimension "U" mm 3.0 (± 0.5)

Fig., see AR60.00-P-0700-01G





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





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 fromfront door

Only on model 208.3, if adoor liner is installedwithout assembly cover(2).

AR72.10-P-1000K

2.2 Press assembly cover (2)off with plastic wedge

Only on model 208.3, ifdoor liner is installedwith assembly cover (2)and on model 170.

3 Separate electricalconnection (3)

4 Unscrew bolts (4) and

remove outside mirror





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



1 Fold the outside mirrorforward

2 Tip the top edge of the

mirror glass to the outside

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

drive

4 Di (2)





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

4 Disconnect connector (2)

5 Install in the reverse order Start with the bottomside of the mirror glassand work your wayupward, paying attentionto the support spring (3)and seat point (arrows)



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





Fig. 73: Identifying Cover On Mirror Triangle Remove/Install Components - Shown On Model 168

COMMERCIALLY AVAILABLE TOOLS

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 outsiderearview mirror

AR88.70-P-9040G

2 Remove drive for gearadjustment

AR88.70-P-9060G

3 Remove complete outsiderearview mirror

AR88.70-P-9000G

4 Unscrew screws (2) andremove cover (1)

*WH58.30-Z-1040-06A

5 Reinstall in opposite order Model 208.3Observe catches (arrows)

Number Designation

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


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

(1)

2 Press catch (2) in Fig. 66





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

2 Press catch (2) in

direction of arrow withlong wedge

Fig. 66

3 Press outside rearviewmirror switch (S50)downward out of centerconsole (1)

Installation : Payattention to correctinstallation direction


Removal, installation 1 Release and remove

lifting platform mounting plate



HWA170 690 01 62 Left cover strip ass'y 1

HWA170 690 02 62 Right cover strip ass'y 1





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 anchoringwith screwdriver.

Assembly

7. Install inner carrier and impact damper8. Press retaining lugs (B) into anchoring at top and bottom

9. Anchor side support plates in exterior surface using spreading rivets.

A170 584 00 55 LU adhesive foil 1A170 997 01 86 Vehicle jack mount plug 4





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.

14. Install bumper.





Fig. 84: Identifying Headlamp Mounting Points, Mount And Lug

Converting rear bumper - AZ88.00-P-0001-03H

Preparation

1. Remove standard bumper.

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 ofanchoring with a screwdriver, remove radio antenna.

6. Remove spacer strip (spare wheel recess)

Assembly

7. Install inner carrier, impact damper and antennas.

8. Press retaining lugs (B) into anchoring at top and bottom

9. Anchor side support plates in exterior surface using spreading rivets.

10. Rivet side sliding arrests in exterior surface.

11. Press radio antenna into lugs intended for this purpose and fasten with glue.

12 I ll i i d d f hi





12. Install spacer strip on stay intended for this purpose.

13. Install bumper.

Fig. 86: Identifying Retaining Lugs

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 fromlongitudinal member.





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 allclaws 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.




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



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 stripstarting at front.

12. In the entrance area fasten side paneling with Philips screws and in vehicle floor area (front) withs readin rivets and screws.



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.





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 code772

BA00.60-P-1001-01A Screw for adapter ontowing eye

NM 67 (± 2)





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 andreplacement part deliveryscope and must beordered according to thecolor of the vehicle.

After conversion, have proper installationconfirmed by authorized

workshop on form sheet"Excerpt from EU TypeApproval". The formsheet is to be kept in thevehicle and to be handedover 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

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

Part no. Designation Quantity

A170 790 0088 AMG rear spoiler (order with paintcode, see EPC BM 170.466)

1





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 bothsides 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).





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. Ali n the rear s oiler with res ect to the brake lam and osition with the ex osed foil on the 509 mm

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



Fig. 115: Identifying Trunk Lid Emergency Release Retrofit Components

The parts for retrofittingthe trunk lid emergencyrelease are given in the part documents (GroupKG 75 trunk lid).

Removing 1 Remove latch section (3) The latch section (3) is

replaced. Do not removetrunk 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 connectionlinkage (2.2) Model 170 as of1.2.00.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 connectionshaft (2.1) into guide onlatch section (3) and then

Model 170 up to 31.1.00

into guide on trunk lidlock (1.1)

5.2 Hook new connection

linkage (2.2) into latchsection (3)

Model 170 as of 1.2.00

6 Install latch section (3)





PARTS ORDERING NOTES

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 handlerecess (3).

2. Insert control cable sheath into mount on handle recess (3).

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 fortrunk lid emergencyrelease in Owner'sManual

Order number see parts ordering notes.

Part no. Designation Quantity

Group 75 Latch section 1

Group 75 Connection linkage 1

Group 75 Handle assembly 1

6515955913 Insert sheet, Owner's Manual,mechanical kit (order fromStoropack print company hotline -

telephone number:+49-7123/64242)

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



BA88.50-P-1022-01A

Bolt, height limiteron carrier plate

Nm - 4

BA88.50-P-1023-

01A

Ball head bolt to

trunk lid

Nm - -

BA88.50-P-1024-01A

Bolt, retaining plateto hydraulicdistributor

Nm - 2

2003 Mercedes-Benz SLK3201998-2004 ACCESSORIES & BODY, CAB Detachable Body Components - 170 Chassis

body components.pdf

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