Install and weld in inner C and D-pillar side wall - AR63.10-P-0800-03PA

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
BE60.00-P-1005-01E	Gap dimension	Fuel filler flap	Dimension "K"	mm	3.5 (-0.5/+0.5)
			See picture		AR60.00-P-0700-01PA

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

Fig 2: Identifying Side Portal Frame (210 589 17 23 00)

Fig 3: Identifying Inspection And Welding Device (203 589 00 23 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
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).

   Remove and replace damaged foam parts.

   Fig 4: Identifying MB Body Sealant Applying Area

   
2. Install C and D-pillar inner side wall, outer rear wheel well and fit with outer C-pillar with bolts (1) and fix in place.
   Fig 5: C And D-Pillar Inner Side Wall, Outer Rear Wheel Well With Outer C-Pillar Fit With Bolts

   
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.

   Use feeler gauge!

   Fig 6: Installing C And D-Pillar Side Wall With Rear Fender

   
   Fig 7: Identifying C And D-Pillar Side Wall Spot Welds Area (1 Of 2)

   
6. C and D-pillar side wall (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 Polygrip flat round head rivet, Ø 6 x 14 mm (areas Q and R).
   Fig 8: Identifying C And D-Pillar Side Wall Spot Welds Area (2 Of 2)

   
9. C and D-pillar side wall (areas C, E-I and J).
10. Outer rear wheel well (area D).
11. Outer rear wheel well (area B).
    Fig 9: Identifying Outer Rear Wheel Well Spot Welds Area