Install and weld in rear end assembly - AR64.20-P-1020-03PA

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	-
		Front door to rear fender	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)
		Rear fender to taillamp	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	-
		Rear-end door to D-pillar	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)
BE60.00-P-1005-01E	Gap dimension	Fuel filler flap	See picture		AR60.00-P-0700-01PA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant	A 001 989 63 20
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

Fig 1: Identifying Rear End Assembly Welding Areas (1 Of 5)

Install rear end assembly and fix in place using straightening tool.
Rear end assembly (areas K and L).
Rear end assembly (areas A and D).

Fig 2: Identifying Rear End Assembly Welding Areas (2 Of 5)

Fig 3: Identifying Rear End Assembly Welding Areas (3 Of 5)
Rear end assembly (areas N and M).
Rear end assembly (area O).
Spot welds (N) are accessible through opening in rear end (arrows) from inside.
Remove straightening tools.
Rear end assembly (areas I and J).

Fig 4: Identifying Rear End Assembly Welding Areas (4 Of 5)

Fig 5: Identifying Rear End Assembly Welding Areas (5 Of 5)
Rear end assembly (areas A to H).