Test values for gap dimensions on hoods, doors and lids
Number | Designation | Model | |||
BE60.00-P-1002-01E | Gap dimension | Front door to A-pillar | Dimension "B" | mm | 6.5 (+1) |
Front door to fender | Dimension "H" | mm | 3.5 (–0.5/+1) | ||
Front door to rear door | Dimension "I" | mm | 4 (–0.5/+1) | ||
Front door to roof | Dimension "C" | mm | 6.5 (+1) | ||
Rear door to C-pillar | Dimension "T" | mm | - | ||
Rear door to side piece, bottom | Dimension "J" | mm | 3.5 (+1) | ||
Front door to rear fender | Dimension "P" | mm | - | ||
See picture | |||||
BE60.00-P-1003-01E | Gap dimension | Trunk lid to rear fender, top | Dimension "F" | mm | 3.5 (1) |
Trunk lid to taillamp | Dimension "M" | mm | 4 (1) | ||
Rear fender to taillamp | Dimension "U" | mm | - | ||
See picture | |||||
BE60.00-P-1005-01E | Gap dimension | Fuel filler flap | Dimension "K" | mm | 3.5 (0.5) |
See picture | |||||
129 589 03 21 00
129 589 00 27 00
Bending iron
Feeler gauge
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-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 |
P63.50-2195-12
1 Install and fit rear fender.
2 Insert rear lamp, install rubber seal and locking eye.
3 Check and adjust gaps between rear fender/rear door and rear fender/trunk lid.
Use feeler gauge.
P63.50-2200-09
4 Rear fender.
P63.50-2204-06
5 In areas A and B . In area D .
Area E .
6 Drill Ø 6 mm holes on outer longitudinal member
(area C).
7 Rivet outer side wall and outer longitudinal member using steel/steel flat head rivets, Ø 6 x 14 mm (area C).
Take breaks while welding in area A to allow the metal to cool down for minimum heat distortion.
P63.50-2208-06
8 Readjust spot weld flange on wheel well with crimping iron.
9 Spot weld flange on wheel arch panel .
10 Clean weld joints using wire brush.
11 Fill rear fender with body solder in cross-hatched area and smooth.