Test and adjustment values for gap dimensions
Number | Designation | Model | Model | |||
BE60.00-P-1003-01N | Gap dimension | Rear door to side roof paneling | Dimension "L" | mm | 6.5 (1) | - |
Rear door to rear fender | Dimension "M" | mm | 4.0 (1) | - | ||
Rear door to rear side window | Dimension "N" | mm | 6.5 (-0.5/+1) | - | ||
Rear fender to taillamp | Dimension "O" | mm | 2.5 (0.5) | 2.5 (0.5) | ||
Rear fender to rear-end door | Dimension "P" | mm | 4.0 (1) | 4.0 (1) | ||
See picture | ||||||
BE60.00-P-1004-01N | Gap dimension | Front fuel filler flap | Dimension "Q" | mm | 4.5 (0.5) | 4.5 (0.5) |
Rear fuel filler flap | Dimension "R" | mm | 4.0 (0.5) | 4.0 (0.5) | ||
See picture | ||||||
BE60.00-P-1005-01N | Gap dimension | Bumper to taillamp | Dimension "S" | mm | 2.5 (1) | 2.5 (1) |
Rear-end door to taillamp | Dimension "T" | mm | 4.0(1.5) | 4.0(1.5) | ||
Rear-end door to bumper | Dimension "U" | mm | 5.0 (2) | 5.0 (2) | ||
Rear-end door to roof | Dimension "V" | mm | 4.5 (1) | 4.5 (1) | ||
See picture | ||||||
P63.50-2967-06
1 Install rear outer wheel well, rear fender, rear-end door, taillamps, rubber seal, rear striker and fit.
2 Check and adjust gaps:
Rear door to rear fender (M)
Rear fender to rear-end door (P)
Rear fender to taillamp (O)
Rear-end door to taillamp (T)
Rear-end door to roof (V)
Front fuel filler flap (Q)
Rear fuel filler flap (R)
Use feeler gauge.
3 Fix outer rear wheel well in place.
4 Remove rear fender, taillamps, rubber seal, shackle.
Shown on model 169.0
P63.10-3727-09
Shown on model 169.0
5 Drill rivet holes on outer rear wheel well (1) with dia. 6.5 mm bit (areas A and B).
6 Drill pilot holes on outer rear wheel well (1) (arrows).
7 Remove outer rear wheel well (1).
8 Deburr rivet holes on both sides
P63.10-3731-06
9 Install outer rear wheel well (1), fit and fix in place.
10 Rivet outer rear wheel well (1) with Polygrip flat/round head rivets, dia. 6.414 (areas A and B).
11 Weld in outer rear wheel well (1) with (areas C, D, E, F, G and J).
Weld twice as many resistance spot welds on rear wheel well (1) because these areas were glued previously (areas D and E).
Shown on model 169.0
12 Weld in outer rear wheel well (1) with (areas H, I and K).
13 Grind MIG plug weld down flat (area I).
14 Position lug (3) on outer rear wheel well (1).
15 Clean resistance spot welds on outer rear wheel well (1) (area F).
16 Coat outer rear wheel well (1) with zinc dust paint (areas B and F).
P63.10-3738-09
Shown on model 169.0
17 Apply body sealant to outer rear wheel well (1).
18 Install outer rear longitudinal member (2), fit and fix in place.
19 Rivet outer rear longitudinal member (2) with Polygrip flat/round head rivets, dia. 6.414 (area L).
Use rivet marked with arrow in area (L) as Polygrip countersunk head rivet, 6.414.
20 Drill pilot hole on outer rear longitudinal member (2) (arrow)
21 Weld in outer rear longitudinal member (2) with (area N).
22 Weld in outer rear longitudinal member (2) with (area M).