Test and adjustment values for gap dimensions
Number | Designation | Model | |||
BE60.00-P-1001-01I | Gap dimension | Fender/headlamps | Dimension "A" | mm | 2 (0.5) |
Engine hood to headlamp | Dimension "B" | mm | 4 (0.5) | ||
Bumper to headlamp | Dimension "C" | mm | 2 (0.5) | ||
Fender to side headlamps | Dimension "D" | mm | 2 (0.5) | ||
Fender to engine hood | Dimension "E" | mm | 4 (0.5) | ||
See picture | |||||
BE60.00-P-1002-01I | Gap dimension | Front door to A-pillar | Dimension "F" | mm | 5 (1) |
Roof to side roof frame | |||||
for glass | Dimension "G" | mm | 6 (2) | ||
for sheet metal | Dimension "G" | mm | 6 (1.5) | ||
Doors to side roof frame | Dimension "I" | mm | 5 (1) | ||
Door shells to side roof frame | Dimension "I1" | mm | 25 (1) | ||
Front door to rear door | Dimension "N" | mm | 4 (+1) | ||
Front door to fender | Dimension "Q" | mm | 4 (+1) | ||
See picture | |||||
BE60.00-P-1003-01I | Gap dimension | Rear fender to C-pillar | Dimension "H" | mm | 4 (0.5) |
Rear fender to trunk lid | Dimension "J" | mm | 4 (0.5) | ||
Rear fender to rear door | Dimension "K" | mm | 4 (0.5) | ||
Rear fender to bumper | Dimension "L" | mm | 2.8 (0.5) | ||
Rear fender to taillamp | Dimension "M" | mm | 2 (0.5) | ||
Bumper to taillamp | Dimension "O" | mm | 2 (0.5) | ||
Trunk lid to taillamp down | Dimension "P" | mm | 5 (0.5) | ||
See picture | |||||
BE60.00-P-1004-01I | Gap dimension | Fuel filler flap | Dimension "R" | mm | 3.5 (1) |
See picture | |||||
240 589 03 23 00
Spacer
Set of feeler gages
Feeler gauge
Bending iron
129 589 03 21 00
000 589 87 63 00
129 589 00 27 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-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-1003-13A | Blind rivet | A 003 990 98 97 |
BR00.45-Z-1002-13A | Polygrip countersunk head rivet, 6.414 | A 003 990 86 97 05 |
P63.50-2691-09
1 Install and fit rear fender, taillamp, locking eye and trunk lid.
Check and adjust gaps:
rear fender to C-pillar
rear fender to trunk lid
rear fender to rear door
rear fender to taillamp
trunk lid to taillamp at bottom
Use feeler gauge , spacers and set of gap gauges .
P63.50-2780-09
2 Drill 6.5 mm dia. rivet holes (area D).
3 Drill dia. 3.0 mm rivet holes on inside of rear fender (area N).
Only holes pre-drilled in new section.
4 Remove rear fender.
5 Drill pre-drilled holes on vehicle and new part with dia. 4.0 dia. bit (area N).
6 Deburr rivet holes on both sides.
7 Countersink rivet holes (area D).
8 Prepare cementing surfaces (areas N and N1).
Observe pretreatment of bonding surfaces.
9 Apply MB body sealant to foam part at entrance and to wheelhouse.
Damaged foam parts must be removed and replaced.
10 Apply adhesive to new rear fender (area N).
Refer to the manufacturer's information for the curing and working times of the adhesive.
P63.50-2774-06
11 Weld in rear fender with (areas B and Q).
12 Weld in rear fender with (area R).
If MIG welder is available, MIG weld area R as well.
13 Weld in rear fender with (area S).
14 Grind weld and brazed seam down flat (area R).
P63.50-2775-09
15 Weld in rear fender (areas E, F, G and H).
16 Readjust spot welding flange on wheelhouse with crimping iron.
Spot weld flange position analog to undamaged vehicle side.
P63.50-2771-09
17 Weld in rear fender with (areas J, M and I).
18 Drill holes (areas K and L).
19 Rear fender (areas K and L).
20 Rear fender (areas A and L1).
If MIG welder is available, MIG weld area R as well.
21 Grind inert gas welds down flat (areas A and L1).
22 Grind inert gas welds down flat (areas K and L).
P63.50-2769-09
23 Rear fender (area C).
24 Rear fender (area O).
If MIG welder is available, MIG weld area O as well.
25 Grind spot welds down flat (area C).
26 Grind weld and brazed seam down flat (area O).
27 Rivet rear fender and outer longitudinal member with Polygrip countersunk head rivet, dia. 6.414 mm (area D).
28 Rivet rear fender and C-pillar with Polygrip flat head rivet
dia. 4.014 mm (area N).
Use hand riveter.
29 Clean weld joints with wire brush.
30 Clean rear fender in cross-hatched area with wire brush.
31 Fill rear fender with body solder in cross-hatched area and smooth.