Install and weld in inner C-pillar side wall - AR63.10-P-0700-03PB

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.706/707/ 708/718/730/ 735/740/742/ 743/745/746/ 747/752/756/ 764
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	-
		Front door to roof	Dimension "C"	mm	-
		Rear door to C-pillar	Dimension "T"	mm	-
		Rear door to side piece, bottom	Dimension "J"	mm	-
		Front door to rear fender	Dimension "P"	mm	3.5 (+1.0/-0.5)
			See picture		AR60.00-P-0700-01PB
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	2.5 (± 0.5)
			See picture		AR60.00-P-0700-01PB
BE60.00-P-1004-01E	Gap dimension	Rear-end door to roof	Dimension "E"	mm	8.5 (+1)
		Rear-end door to rear fender	Dimension "M"	mm	3.5 (± 1)
		Rear-end door to taillamp	Dimension "L"	mm	4 (± 1)
		Rear-end door to bumper	Dimension "S"	mm	6.5 (-1.5)
		Rear-end door to D-pillar	Dimension "Q"	mm	-
			See picture		AR60.00-P-0700-01PB

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

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant	A 001 989 63 20
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
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

Fig 2: Installing Inner And Outer C-Pillar With Rear Fender

1. Fit and fix in place inner and outer C-pillar with rear fender.
2. Install rear lamp, rubber seal and locking eye.
3. Check gaps and adjust (arrows).

   Use feeler gauge!

4. Outer C-pillar (area M).
5. Outer C-pillar (areas N - Q).
6. Clean outer C-pillar in repair area, M and Q, using wire brush and coat with zinc dust paint.
   Fig 3: Identifying Outer C-Pillar Spot Welds Area

   
   Fig 4: Identifying Inner C-Pillar And Outer Reinforcement Spot Welds Area

   
7. Inner C-pillar and outer reinforcement (areas E, F, G, R and S).
8. Inner C-pillar and outer reinforcement (areas B and D).
9. Drill Ø 6 mm holes on outer C-pillar and rivet using steel/steel flat head rivets, Ø 6 x 14 mm (area T).
   Fig 5: Identifying Inner C-Pillar Spot Welds Area (1 Of 2)

   
10. Inner C-pillar (areas H and I).
    Fig 6: Identifying Inner C-Pillar Spot Welds Area (2 Of 2)

    
11. Inner C-pillar (areas U and Y).
12. Drill Ø 6.5 mm holes on inner C-pillar and rivet using Polygrip flat round head rivet, Ø 6.4 x 14 mm (areas V and W).
    Fig 7: Identifying Corrosion Protection Measures Area In C-Pillar Paneling

    
13. Remove grinding and drill shavings using wet/dry vacuum cleaner.
14. Perform corrosion protection measures in area of C-pillar paneling at outer rear wheel well (arrows).