Test and adjustment values, gap dimensions at hoods, doors and covers
Number | Designation | Model 202.01/02/033/ | |||
BE60.00-P-1002-01A | Gap dimension | Front door to A-pillar | Dim. "B" | mm | 6.0 (+1) |
Front door to fender | Dim. "H" | mm | 5.0 (+1) | ||
Front door to rear door | Dim. "I" | mm | 6.0 (+1) | ||
Front door to roof | Dim. "C" | mm | 6.0 (+1) | ||
Rear door to upper side section | Dim. "D" | mm | 6.0 (+1) | ||
Rear door to lower side section | Dim. "J" | mm | 5.0 (0.5) | ||
Fender to A-pillar | Dim. "Q" | mm | - | ||
Front door to rear fender | Dim. "P" | mm | - | ||
Fig., see | |||||
BE60.00-P-1003-01A | Gap dimension | Trunk lid to top of rear fender | Dim. "F" | mm | 4.5 (0.5) |
Trunk lid to bottom of rear fender | Dim. "M" | mm | 5.0 (0.5) | ||
Trunk lid to rear fender | Dim. "F" | mm | - | ||
Trunk lid to taillamp | Dim. "M" | mm | - | ||
Trunk lid to bumper | Dim. "V" | mm | - | ||
Rear fender to taillamp | Dim. "U" | mm | - | ||
Fig., see | |||||
Special tools
202 589 11 23 00
129 589 00 27 00
129 589 03 21 00
202 589 10 23 00
Template for right taillamp cutout
Template for left taillamp cutout
Feeler gage
Bending jig
202 589 00 37 00
201 589 00 27 00
Crimping pliers
Cross-shaped straightener
Workshop equipment
WE58.40-Z-1001-02A | Inert gas welder |
WE58.40-Z-1002-02A | Spot welder |
WE58.40-Z-1003-03A | Angle grinder (electric/pneumatic) |
1 Install trunk lid.
2 Install rear fender and fit.
3 Fasten rear fender with clamping pliers and sheet metal screws.
4 Install cross spindle and fasten.
5 Install striker for left rear door.
6 Check gap between rear fender and trunk lid and between rear fender and rear door and adjust
7 Check taillamp cutout with gage .
8 Tack weld rear fender in connection area of rear pillar, side longitudinal member and taillamp cutout.
9 Weld in rear fender with .
P63.50-0029-09
P63.50-0035-09
P63.50-0040-09
P63.50-0046-01
P63.50-0045-01
10 MIG weld rear fender and braze.
Areas: A
B
C
D
P63.50-0048-01
P63.50-0047-01
P63.50-0050-01
P63.50-0049-01
P63.50-0052-01
P63.50-0051-01
11 Crimp spot welding flange on left wheelhouse with crimping iron .
12 Press spot welding flange together with rabbeting pliers.
Crimp spot welding flange in
2-3 operations.
13 Remove trunk lid.
14 Grind visible welds and brazed seams down flat.
P63.50-0054-01
P63.50-0053-01
15 Fill rear fender and adjacent surfaces with solder and smooth (shaded areas).
16 Clean all remaining welds with wire brush.
P63.50-0055-01
Referenced documents
- ar6000p070001e Gap dimensions at hoods, doors and covers