Check values for gaps
Number | Designation | Model 221 | |||
BE60.00-P-1002-01R | Gap dimension | Front door to A-pillar | Dimension "D" | mm | 4.5 (0.5) |
Front door to fender | Dimension "E" | mm | 4 (0.5) | ||
Front door to rear door | Dimension "F" | mm | 4.5 (0.5) | ||
Trim strip at front door to roof frame | Dimension "G" | mm | 4.5 (0.5) | ||
Trim strip at rear door to roof frame | Dimension "H" | mm | 4.5 (0.5) | ||
Rear door to side section, bottom | Dimension "I" | mm | 4.5 (0.5) | ||
Front door cover to rear door cover | Dimension "S" | mm | 4.5 (0.5) | ||
See picture | |||||
BE60.00-P-1003-01R | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | 4 (0.5) |
Trunk lid to rear lamp unit | Dimension "K" | mm | 4 (0.5) | ||
Trunk lid to bumper | Dimension "L" | mm | 5.5 (1.5) | ||
Rear fender to rear lamp unit | Dimension "M" | mm | 2.5 (0.5) | ||
Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | 4 (0.5) | ||
See picture | |||||
Feeler gauge
129 589 03 21 00
Repair materials
Number | Designation | Order number |
BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
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 |
P63.10-3911-04
1 Install outer rear wheel well, rear fender (1), trunk lid, taillamps, rubber seal, rear locking eye and fit.
2 Check and adjust gaps:
rear door to bottom side section (I),
trunk lid to taillamp (K),
rear fender to taillamp (M),
trunk lid cover to taillamp (N).
Use feeler gauge.
3 Fasten outer rear wheel well and rear fender (1) with clamping pliers.
4 Remove trunk lid, taillamps, rubber seals and lock striker.
P63.10-3900-09
5 Drill dia. 6.5 mm rivet holes in outer rear wheel well (1) (area L).
6 Remove outer rear wheel well (1).
7 Deburr rivet holes on outer rear wheel well (1) on both sides.
8 Remove drill shavings using wet/dry vacuum cleaner
9 Coat insides of riveted joints with zinc dust paint.
P63.10-3902-09
10 Apply glue to mating surfaces in cross-hatched areas.
Observe pretreatment of bonding surfaces.
Refer to manufacturer specifications for adhesive curing and application times.
P63.10-3904-09
11 Install outer rear wheel well (1) and fasten with manual temporary fasteners.
12 Rivet outer rear wheel well (1) with Polygrip flat/round head rivet, dia. 6.414 (area L).
P63.10-3906-09
13 Weld in outer rear wheel well (1) with (areas N, O, P, Q and R).
P63.10-3910-09
14 Weld in outer rear wheel well (1) with (areas S, T, U, V, W and X).
15 Weld in outer rear wheel well (1) with (area Y).
16 Clean welds using round wire brush.
17 Remove grinding and drill shavings using wet/dry vacuum cleaner.
18 Coat weld and inner adjacent surfaces with zinc dust paint.