Install C-pillar - AR63.20-P-0500-03Q

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 209.3
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)
			See picture		AR60.00-P-0700-01Q
BE60.00-P-1003-01G	Gap dimension	Trunk lid to rear fender, top	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	-
			See picture		AR60.00-P-0700-01Q
BE60.00-P-1004-01G	Gap dimension	Fuel filler flap	Dimension "L"	mm	3, 5 (± 0, 5)
BE60.00-P-1004-01G	Gap dimension		See picture		AR60.00-P-0700-01Q

Fig 1: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1003-01A	Electrode miller
WH58.30-Z-1003-02A	Clamping pliers
WH58.30-Z-1038-02A	Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firma Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1003-29A	Hand riveter

WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A	Inert gas welder
WE58.40-Z-1002-02A	Spot welder
WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner
WE58.40-Z-1003-14A	Blind rivet tool

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant	A 001 989 63 20
BR00.45-Z-1003-05A	Preservation agent	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	Rivet	A 003 990 35 97

Install C-pillar with hinge, trunk lid and rear fender, fit and fasten.
Install taillamp, rubber seal and locking eye.
Check and adjust gaps:
- Rear fender to taillamp
- Trunk lid to upper rear fender
- Trunk lid license plate panel to taillamp
- Trunk lid to taillamp
- Front door to rear fender
Use feeler gage.

Fig 2: Identifying Adjust Gaps Fender To Taillamp
Courtesy of MERCEDES-BENZ USA
Remove trunk lid and rear fender
Drill dia. 6.5 mm rivet holes (area C1, F and I).
Remove inner C-pillar and deburr rivet holes on both sides.

Fig 3: Identifying Rivet Holes Area
Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Polygrip Flat Head Rivets Area
Courtesy of MERCEDES-BENZ USA
Install inner C-pillar, fasten with clamping pliers and manual temporary fasteners.
Inner C-pillar (areas J and L).
Inner C-pillar (areas K and M).
Inner C-pillar (area N).
Rivet inner C-pillar with Polygrip flat head rivets, dia. 6.4 x 14 mm (area I).

Fig 5: Identifying Polygrip Flat Head Rivets Area
Courtesy of MERCEDES-BENZ USA
Inner C-pillar (areas C, D and E).
Rivet inner C-pillar
Polygrip flat head rivets, dia. 6.4 x 14 mm (area C1).
Inner C-pillar (area F1).
Clean spot welds with wire brush (area C).
Remove grinding residues with wet/dry vacuum cleaner and coat with zinc dust paint (area C).

Fig 6: Identifying Flat Head Rivets Area
Courtesy of MERCEDES-BENZ USA
Rivet inner C-pillar with
Polygrip flat head rivets, dia. 6.4 x 14 mm (area F).
Inner C-pillar (areas G).
Apply glue seam on outer C-pillar (area H1).
Install outer C-pillar and fasten with clamping pliers.
Outer C-pillar (area H2).
Outer C-pillar (area B).
Clean spot welds with wire brush.

Before installing rear fender clean bare surfaces with wet/dry vacuum cleaner and coat with zinc dust paint.