Test and adjustment values for gap dimensions
Number | Designation | Model | |||
BE60.00-P-1002-01G | Gap dimension | Front door to A-pillar | Dimension "D" | mm | - |
Front door to fender | Dimension "E" | mm | 3.5 (-0.5/+1) | ||
Front door to rear fender | Dimension "F" | mm | 3.5 (-0.5/+1) | ||
Fig., see | |||||
BE60.00-P-1003-01G | Gap dimension | Trunk lid to top of rear fender | Dimension "G" | mm | 3.5 (0.5) |
Trunk lid to taillamp | Dimension "H" | mm | 3.5 (0.5) | ||
Trunk lid to bumper | Dimension "I" | mm | 5 (-1) | ||
Rear fender to taillamp | Dimension "J" | mm | 2 (0.5) | ||
Trunk lid cover to taillamp | Dimension "K" | mm | - | ||
Fig., see | |||||
BE60.00-P-1004-01G | Gap dimension | Fuel filler flap | Dimension "L" | mm | 3.5 (0.5) |
Fig., see | |||||
129 589 00 27 00
Bending jig
Feeler gage
129 589 03 21 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 |
P63.50-2541-06
1 Install rear fender and fit.
2 Insert taillamp and trunk lid cover, install rubber seal and striker eye.
3 Check and adjust gaps:
Rear fender to taillamp
Trunk lid to top of rear fender
Trunk lid cover to taillamp
Trunk lid to taillamp
Front door to rear fender
Use feeler gauge!
4 Drill dia. 6.5 mm rivet holes (area C).
5 Remove rear fender and deburr rivet holes on both sides.
P63.50-2542-06
6 Apply MB body sealant to foam
parts on C-pillar.
Replace damaged foam parts
(group 68).
7 Apply MB body sealant to adhesive surfaces on B and C-pillars.
P63.50-2551-09
8 Install rear fender and fit.
9 Weld in rear fender with (areas B, C1, F, G and H).
10 Rivet rear fender and outer longitudinal member with Polygrip flat head rivets, dia. 6.4 x 14 mm (area C).
P63.50-2552-09
11 Weld in rear fender with (areas I, J, K, L and M).
12 Weld in rear fender with (area K1).
13 Weld in rear fender with (areas A).
Weld area A at intervals, allowing seam to cool each time, thus causing minimum heat distortion.
P63.50-2561-09
14 Weld in rear fender and C-pillar with (area O).
15 Weld in rear fender with (areas D and E).
16 Place bending jig around spot weld flange on wheel
arch panel.
Bend over spot welding flange analog to undamaged
side of vehicle.
P63.50-2562-11
17 Grind welds down flat and clean with wire brush.
18 Flush rear fender with flushing tin in checked
area and smoothen.