Adjust rear-end door

AR72.20-S-1032S

Adjust rear-end door

27.06.2014

MODEL

639.6

with CODE W50 (2-wing rear-end door, 180 degrees)

without CODE D03 (Roof and rear-end doors, high version)

MODEL

639.6

with CODE W54 (2-wing rear-end door, 270 degrees)

without CODE D03 (Roof and rear-end doors, high version)

MODEL

639.6

with CODE W64 (2-wing rear-end door, 95 degrees)

without CODE D03 (Roof and rear-end doors, high version)

MODEL

639.7

with CODE W50 (2-wing rear-end door, 180 degrees)

MODEL

639.7

with CODE W54 (2-wing rear-end door, 270 degrees)

MODEL

639.7

with CODE W64 (2-wing rear-end door, 95 degrees)

Shown on model 639.7

1

Bolts, door hinge to body

2

Bolts, door hinge to rear-end door

3

Cover

4

Bolts for shackle on roof frame

5

Bolt for striker on lock cross member

6

Striker on roof frame

7

Striker on lock cross member

8

Door hinges

C1

Embossed edges

P

Hinged rear door to roof

Q

Hinged rear door to taillamp at top

R

Hinged rear door to taillamp at bottom

S

Hinged rear door to bumper at side

T

Hinged rear door to bumper at bottom

U

Hinged rear door to hinged rear door

 Danger !

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A



Check

1

Check gap dimensions P, Q, R, S, T, U

Gap dimensions on hoods, doors and lids

AR60.00-S-0700-01S

 The height of the embossed edges (C1) should be aligned with one another. Deviations in the height should not exceed max. 0.5 mm. The reference measurements apply only for repair work on bodies damaged in accidents.

Gap dimension

*BE60.00-N-1005-01B

 Feeler gauge

*129589032100

Set gap dimensions

2

Loosen bolts from door hinge on body (1) and bolts from door hinge on rear door (2)

3

Adjust gap dimensions P, Q, R, S, T, U

 The height of the embossed edges (C1) should be aligned with one another. Deviations in the height should not exceed max. 0.5 mm. The reference measurements apply only for repair work on bodies damaged in accidents.

 Feeler gauge

*129589032100

4

Tighten bolts on door hinge on body (1) and bolts on door hinge on rear door (2)

 Paint bolt heads.

 Bolt, door hinge to body

*BA72.20-N-1001-01B

 Bolt, door hinge to rear-end door

*BA72.20-N-1002-01B

5

Remove paneling (3)

Only if installed.

 Long wedge

*115589035900

6

Loosen bolts for striker on roof frame (4) and bolts for striker on lock cross member (5)

7

Position right and left rear door by horizontally adjusting striker on roof frame (6) and striker on lock cross member (7) flush

8

Tighten bolts for striker on roof frame (4) and bolts for striker on lock cross member (5)

 Bolt, striker to roof frame

*BA72.20-N-1013-01B

 Bolt, striker to end crossmember

*BA72.20-N-1012-01B

9

Install paneling (3)

Only if installed.



Check

10

Check rear-end doors for leakage

 Clamp piece of paper between rear-end doors and door frame seal at several points. It should be possible to pull the paper only with resistance. If required repeat adjustment.

11

Open and close both rear-end doors

 Check door hinges for easy motion and door locks for proper function.

12

Check gap dimensions P, Q, R, S, T, U

Gap dimensions on hoods, doors and lids

AR60.00-S-0700-01S

 The height of the embossed edges (C1) should be aligned with one another. Deviations in the height should not exceed max. 0.5 mm. The reference measurements apply only for repair work on bodies damaged in accidents.

Gap dimension

*BE60.00-N-1005-01B

 Feeler gauge

*129589032100

Test and adjustment values for gap dimensions

Number

Designation

MODEL 639.6 with CODE W50 except CODE D03 MODEL 639.6 with CODE W54 except CODE D03 MODEL 639.6 with CODE W64 except CODE D03

MODEL 639.7 with CODE W50 MODEL 639.7 with CODE W54 MODEL 639.7 with CODE W64

BE60.00-N-1005-01B

Gap dimension

Rear-end door to roof

Dimension "P"

mm

8,5 (1)

8,5 (1)

Rear-end door to taillamp, top

Dimension "Q"

mm

6 (2,5)

6 (2,5)

Rear-end door to taillamp, bottom

Dimension "R"

mm

6 (2,5)

6 (2,5)

Rear-end door to bumper, side

Dimension "S"

mm

7 (1)

7 (1)

Rear-end door to bumper, bottom

Dimension "T"

mm

7 (1)

7 (1)

Rear-end door to rear-end door

Dimension "U"

mm

6 (1)

6 (1)

For picture, see

AR60.00-S-0700-01S

AR60.00-S-0700-01S

Test and adjustment values for gap dimensions

Number

Designation

MODEL 636, 639.6/7/8 with CODE W65

BE60.00-N-1005-01B

Gap dimension

Rear-end door to roof

Dimension "P"

mm

–

Rear-end door to taillamp, top

Dimension "Q"

mm

–

Rear-end door to taillamp, bottom

Dimension "R"

mm

–

Rear-end door to bumper, side

Dimension "S"

mm

–

Rear-end door to bumper, bottom

Dimension "T"

mm

–

Rear-end door to rear-end door

Dimension "U"

mm

–

For picture, see

-

 Tailgate

Number

Designation

Model 639 with CODE W50/W64

Model 639 with code W54

BA72.20-N-1001-01B

Bolt, door hinge to body

Nm

23

23

 Tailgate

Number

Designation

Model 639 with CODE W50/W64

Model 639 with code W54

BA72.20-N-1002-01B

Bolt, door hinge to rear-end door

Nm

23

23

 Tailgate

Number

Designation

Model 639 with CODE W50/W64

Model 639 with code W54

BA72.20-N-1012-01B

Bolt, striker to end crossmember

Nm

20

20

 Tailgate

Number

Designation

Model 639 with CODE W50/W64

Model 639 with code W54

BA72.20-N-1013-01B

Bolt, striker to roof frame

Nm

20

20