Test values for gap dimensions on hoods, doors and lids
Number | Designation | Model 211.2 | |||
BE60.00-P-1002-01F | Gap dimension | Front door to A-pillar | Dimension "D" | mm | 4.5 (-0.5/+1) |
Front door to fender | Dimension "E" | mm | 4 (-0.5/+1) | ||
Front door to rear door | Dimension "F" | mm | 4 (-0.5/+1) | ||
Front door to roof | Dimension "G" | mm | 4.5 (-0.5/+1) | ||
Rear door to top of side section | Dimension "H" | mm | - | ||
Rear door to side section, bottom | Dimension "I" | mm | 3.5 (-0.5/+1) | ||
See picture | |||||
BE60.00-P-1003-01F | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | - |
Trunk lid to rear lamp unit | Dimension "K" | mm | - | ||
Trunk lid to bumper | Dimension "L" | mm | - | ||
Rear fender to rear lamp unit | Dimension "M" | mm | 2.5 (1) | ||
Trunk lid license plate panel to rear lamp unit | Dimension "N" | mm | - | ||
See picture | |||||
BE60.00-P-1004-01F | Gap dimension | Fuel filler flap | Dimension "O" | mm | 3.5 (0.5) |
See picture | |||||
BE60.00-P-1005-01F | Gap dimension | Liftgate spoiler/roof | Dimension "P" | mm | 7 (-0.5/+1) |
Rear-end door to rear fender | Dimension "Q" | mm | 4.5 (1) | ||
Taillamp in rear-end door to taillamp | Dimension "R" | mm | 5 (1) | ||
Rear-end door to bumper | Dimension "S" | mm | 6 (1.5) | ||
Rear window and D-pillar | Dimension "T" | mm | 4.5 (1) | ||
Front door to roof | Dimension "U" | mm | 4.5 (-0.5/+1) | ||
See picture | |||||
000 589 87 63 00
Cover panel
Spacer
Feeler gauge
Set of covers
129 589 03 21 00
211 589 02 91 00
211 589 00 91 00
Welding bead catcher
230 589 01 98 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-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
BR00.45-Z-1003-05A | Cavity preservation, solvent-free (1 l container) | A 000 986 72 70 05 |
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 |
1 Fit outer wheel well with rear fender and fix in place.
2 Insert taillamp, rubber seal, spacer and lock striker.
Use washers for adjusting the gaps and transitions.
3 Check and adjust gaps:
Rear fender to taillamp
Rear window to D-pillar
Rear door to bottom side section
Rear door to rear fender
Taillamp in rear door to taillamp.
Use feeler gage!
P64.20-3167-03
P63.10-3191-09
4 Drill dia. 6.5 mm rivet holes (area C).
5 Remove rear fender and outer wheel well and deburr rivet holes on both sides
6 Install outer wheel well with manual temporary fasteners and fix in place with clamping pliers.
7 Rivet outer wheel well with Polygrip flat head rivets, Ø 6.4 x 14 mm (area C).
8 Outer wheel well (areas E, F, G and H).
9 Outer wheel well (areas A, B and D).
10 Outer wheel well (area E1).
11 Clean weld with wire brush.
12 Remove grinding and drilling chips using wet/dry vacuum cleaner.
13 Coat weld and inner adjacent surfaces with zinc dust paint.