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Install outer side wall - AR63.10-P-0805-03PA

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number Designation Model 203.204/206/ 207/208/216 /218/220/235/ 240/242/243/ 245/246/252/ 254/256/261/ 264/265/281/ 284/287/292
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 6 (+1)
Rear door to side piece, bottom Dimension "J" mm 3.5 (+1)
Front door to rear fender Dimension "P" mm -
  See picture   AR60.00-P-0700-01PA
BE60.00-P-1003-01E Gap dimension Trunk lid to rear fender, top Dimension "F" mm -
Trunk lid to taillamp Dimension "M" mm -
Rear fender to taillamp Dimension "U" mm 2 (0.5)
  See picture   AR60.00-P-0700-01PA
BE60.00-P-1004-01E Gap dimension Rear-end door to roof Dimension "E" mm 6.5 (± 1)
Rear-end door to rear fender Dimension "M" mm 3.5
Rear-end door to taillamp Dimension "L" mm 4
Rear-end door to bumper Dimension "S" mm 5.5
Rear-end door to D-pillar Dimension "Q" mm -
  See picture   AR60.00-P-0700-01PA
Fig 1: Identifying Feeler Gauge (129 589 03 21 00)
G04738738
Fig 2: Identifying Side Portal Frame (210 589 17 23 00)
G04738739
Fig 3: Identifying Inspection And Welding Device (203 589 00 23 00)
G04738740
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant A 001 989 63 20
BR00.45-Z-1001-13A Rivet A 003 990 35 97
  1. Apply MB body sealant on foam parts (arrow).

    IMPORTANT Remove and replace damaged foam parts.

    Fig 4: Identifying MB Body Sealant Applying Area
    G04738741
  2. Install C and D-pillar side wall, outer rear wheel well and fit with outer C-pillar with bolts (1) and fix in place.
    Fig 5: Identifying C And D-Pillar Side Wall, Outer Rear Wheel Well Installed
    G04738742
  3. Install C and D-pillar side wall with rear fender and fit using straightening tool and fix in place.
  4. Install rear lamp, rubber seal and locking eye.
  5. Check and adjust gaps.

    IMPORTANT Use feeler gauge!

    Fig 6: C And D-Pillar Side Wall Installed With Rear Fender And Fit Using Straightening Tool And Fix In Place
    G04738743
    Fig 7: Identifying C And D-Pillar Side Wall Spot Welds Area (1 Of 2)
    G04738744
  6. C and D-pillar side wall POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas N, O and P).
  7. Drill Ø 6 mm holes in C and D-pillar side wall (areas Q and R).
  8. Rivet C and D-pillar side wall and outer roof frame using steel/ steel flat head rivets, Ø 16 x 14 mm (areas Q and R).
    Fig 8: Identifying C And D-Pillar Side Wall Spot Welds Area (2 Of 2)
    G04738745
  9. C and D-pillar side wall POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas C, E to J).
  10. Outer rear wheel well POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area D).
  11. Outer rear wheel well SHIELDED GAS SEAM WELD INTERRUPTED (area B).
    Fig 9: Identifying Outer Rear Wheel Well Spot Welds Area
    G04738746
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