Modification notes
Test and adjustment values for gap dimensions
Number | Designation | Model | |||
BE60.00-P-1003-01Q | Gap dimension | Rear door to side roof paneling | Dimension "L" | mm | 6.5 (-0.5/+1) |
Rear door to rear fender | Dimension "M" | mm | 4.0 (1) | ||
Rear door to rear side window | Dimension "N" | mm | 6.5 (1) | ||
Rear fender taillamp | Dimension "O" | mm | 2.5 (1) | ||
Rear fender to rear-end door | Dimension "P" | mm | 4.0 (1) | ||
See picture | |||||
BE60.00-P-1004-01Q | Gap dimension | Fuel filler flap | Dimension "Q" | mm | 4.0 (0.5) |
See picture | |||||
BE60.00-P-1005-01Q | Gap dimension | Bumper to taillamp | Dimension "R" | mm | 2.5 (1) |
Rear-end door to taillamp | Dimension "S" | mm | 3.5 (+1) | ||
Rear-end door to bumper | Dimension "T" | mm | 5.0 (2) | ||
Rear-end door to roof | Dimension "U" | mm | 4.5 (1) | ||
Taillamp in tailgate and taillamp | Dimension "V" | mm | 4.0(1.5) | ||
See picture | |||||
Feeler gauge
129 589 03 21 00
Repair materials
Number | Designation | Order number |
BR00.45-Z-1003-01A | Sealant, white, 310 ml, DB supply specification 6069.20 | A 001 989 63 20 |
BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
BR00.45-Z-1001-13A | Blind rivet 6.414 | A 003 990 35 97 |
BR00.45-Z-1002-13A | Polygrip countersunk head rivet, 6.414 | A 003 990 86 97 05 |
P63.50-3331-06
1 Install outer rear wheelhouse, rear fender (1), rear-end door, taillamps, rubber seal, striker and fit.
2 Check and adjust gaps:
Rear door to rear fender (1) (M)
Rear fender (1) to taillamp (O)
Rear fender (1) to rear-end door (P)
Fuel filler flap (Q)
Rear-end door to taillamp (S)
Rear-end door to roof (U)
Use feeler gauge.
3 Fasten outer rear wheelhouse with clamping pliers
4 Remove rear fender (1), taillamps, rubber seal, striker.
P63.10-3932-09
5 Drill dia. 6.5 mm rivet holes on rear outer wheelhouse (1) (areas H2, M, N, N1 and O).
6 Drill pilot holes on rear outer wheelhouse (1) (arrow).
7 Remove outer rear wheelhouse (1).
8 Deburr rivet holes on both sides.
P63.10-3936-09
9 Install outer rear wheelhouse (1), fit and secure with manual temporary fastener and clamping pliers.
10 Rivet outer rear wheelhouse (1) with Polygrip flat/round head rivet, dia. 6.414 (areas H2, M, N and O).
11 Rivet outer rear wheelhouse (1) with Polygrip countersunk head rivet, dia. 6.414 (area N1).
12 Weld in outer rear wheelhouse (1) with (areas F, G, H1, H3, J, K and L).
13 Weld in outer rear wheelhouse (1) with (areas D and E).
14 Grind MIG plug weld down flat (area D).
15 Position lug (arrow) on outer rear wheelhouse (1)
16 Clean spot welds on rear outer wheelhouse (1) with round wire brush (area F).
17 Coat outer rear wheelhouse (1) with zinc dust paint (areas E, F, N, N1 and O).
P63.10-3939-09
18 Apply body sealant to outer rear wheelhouse (1).
19 Install outer rear longitudinal member (2), fit and secure with manual temporary fastener and clamping pliers.
20 Drill dia. 6.5 mm rivet holes rear outer longitudinal member (2) (area P).
21 Rivet rear outer longitudinal member (2) with Polygrip flat/round head rivet, dia. 6.414 (areas A and P).
22 Rivet rear outer longitudinal member (2) with Polygrip countersunk head rivet, dia. 6.414 (area A1).
23 Drill pilot hole on rear outer longitudinal member (2) (area B1).
24 Weld in rear outer longitudinal member (2) with (areas B and B1).
25 Weld in outer rear wheelhouse (1) with (area C).
26 Clean welds using round wire brush.
27 Remove grinding and drill shavings using wet/dry vacuum cleaner.