Install outer sidewall - AR63.10-P-0805-03TA

TEST VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 211.2
BE60.00-P-1002-01F	Gap dimension	Front door to A-pillar	Dimension "D"	mm	4.5 (-0.5/+1)
		Front door to fender	Dimension "E"	mm	4 (-0.5/+1)
		Front door to rear door	Dimension "F"	mm	4 (-0.5/+1)
		Front door to roof	Dimension "G"	mm	4.5 (-0.5/+1)
		Rear door to top of side section	Dimension "H"	mm	-
		Rear door to side section, bottom	Dimension "I"	mm	3.5 (-0.5/+1)
			See picture		AR60.00-P-0700-01T A
BE60.00-P-1003-01F	Gap dimension	Trunk lid to rear fender, top	Dimension "J"	mm	-
		Trunk lid to rear lamp unit	Dimension "K"	mm	-
		Trunk lid to bumper	Dimension "L"	mm	-
		Rear fender to rear lamp unit	Dimension "M"	mm	2.5 (1)
		Trunk lid license plate panel to rear lamp unit	Dimension "N"	mm	-
			See picture		AR60.00-P-0700-01T A
BE60.00-P-1004-01F	Gap dimension	Fuel filler flap	Dimension "O"	mm	3.5 (±0.5)
BE60.00-P-1004-01F	Gap dimension	Fuel filler flap	See picture		AR60.00-P-0700-01T A
BE60.00-P-1005-01F	Gap dimension	Liftgate spoiler/roof	Dimension "P"	mm	7 (-0.5/+1)
		Rear-end door to rear fender	Dimension "Q"	mm	4.5 (±1)
		Taillamp in rear-end door to taillamp	Dimension "R"	mm	5 (±1)
		Rear-end door to bumper	Dimension "S"	mm	6 (±1.5)
		Rear window and D-pillar	Dimension "T"	mm	4.5 (±1)
		Front door to roof	Dimension "U"	mm	4.5 (-0.5/+1)
		Front door to roof	See picture		AR60.00-P-0700-01T A

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

G07271094

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Spacer (000 589 87 63 00)

G07271095

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Bending Iron (129 589 00 27 00)

G07271096

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Set Of Covers (211 589 00 91 00)

G07271097

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Cover Panel (211 589 02 91 00)

G07271098

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Side Portal Frame (210 589 17 23 00)

G07271099

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Inspection And Welding Device (211 589 00 23 00)

G07271100

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Set Of Spacer Blocks (211 589 12 23 00)

G07271101

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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, white, 310 ml, DB supply specification 6069.20	A 001 989 63 20
BR00.45-Z-1003-05A	Cavity preservation, solvent-free (1 l container)	A 000 986 72 70 05
BR00.45-Z-1001-13A	Blind rivet 6.4 14	A 003 990 35 97

Fig 9: Identifying Gaps Between Rear Fender And Taillamp With Rear Window And D-Pillar

G07271102

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install side wall with portal frame and welding device, adapt and fix with clamping pliers.
Install and adapt roof paneling.
Use spacers.
Insert taillamp, install rubber seal and striker eye.
Use washers for adjusting the gaps and transitions.
Check and adjust gaps between:
Rear fender and taillamp

Rear window and D-pillar

Rear door and bottom side section

Liftgate and rear fender

Taillamp in liftgate and taillamp.

Use feeler gage.
Drill dia. 6.5 mm rivet holes (area P).
Remove rear fender and side wall.
Deburr rivet holes on both sides

Fig 10: Identifying MB Body Sealant Applying Areas On Foam Parts On Wheel Well And C-Pillar
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Apply MB body sealant on foam parts in cross-hatched areas on wheel well and C-pillar.
Damaged foam parts must be removed and replaced.

Fig 11: Identifying Side Wall Spot Welding Areas (Q, D, H, K, L, F And E)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
side wall (areas Q, D, H, K, L, F and E).
side wall (areas I, J and M).
rear fender (area A).
Make weld seam in intervals, let cool down, reduces heat distortion.
River rear fender and outer longitudinal member with Polygrip Ø 6.4x14 mm flat head rivets (area P).
side wall (area R).

Fig 12: Identifying Side Wall Spot Welding Areas (A, P And R)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
side wall (area B).
Make weld seam in intervals, let cool down, reduces heat distortion.
side wall (area C).

Fig 13: Identifying Side Wall Spot Welding Areas (B And C)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
side wall (area N).
Readjust spot welding flange on wheel well with crimping iron.
Spot weld flange position analog to undamaged vehicle side.

Fig 14: Identifying Side Wall Spot Welding Areas (N)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind down weld joints and clean with wire brush
Solder and smooth side wall in cross-hatched areas.

Fig 15: Identifying Side Wall Cross-Hatched Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.