Install rear fender - AR63.50-P-1400-04P

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.004/006/ 007/008/016/ 018/020/035/ 040/042/043/ 045/046/052/ 056/061/064/ 065/081/084/ 087
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	-
		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-0700-01P
BE60.00-P-1003-01E	Gap dimension	Trunk lid to rear fender, top	Dimension "F"	mm	3.5 (± 1)
		Trunk lid to taillamp	Dimension "M"	mm	4 (± 1)
		Rear fender to taillamp	Dimension "U"	mm	-
		Rear fender to taillamp	See picture		AR60.00-P-0700-01P
BE60.00-P-1005-01E	Gap dimension	Fuel filler flap	Dimension "K"	mm	3.5 (± 0.5)
BE60.00-P-1005-01E	Gap dimension	Fuel filler flap	See picture		AR60.00-P-0700-01P

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

Fig 2: Identifying Bending Iron (129 589 00 27 00)

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 and fit rear fender.
Insert rear lamp, install rubber seal and locking eye.
Check and adjust gaps between rear fender/rear door and rear fender/trunk lid.
Use feeler gauge.

Fig 3: Adjusting Gaps Between Rear Fender/Rear Door And Rear Fender/Trunk Lid

Fig 4: Identifying Rear Fender Spot Welds Area (1 Of 2)
Rear fender .
In areas A .
A and B In area D .

Area .
Drill Ø 6 mm holes on outer longitudinal member (area C).
Rivet outer side wall and outer longitudinal member using steel/steel flat head rivets, Ø 6 x 14 mm (area C).
Take breaks while welding in area A to allow the metal to cool down for minimum heat distortion.

Fig 5: Identifying Rear Fender Spot Welds Area (2 Of 2)
Readjust spot weld flange on wheel well with crimping iron.
Spot weld flange on wheel arch panel .
Clean weld joints using wire brush.
Fill rear fender with body solder in crosshatched area and smooth.

Fig 6: Adjusting Spot Weld Flange On Wheel Well With Crimping Iron