Install Outer Sidewall - AR63.10-P-0805-03GQC
MODEL 292
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 292 | |||
|---|---|---|---|---|---|
| BE60.00-P-1003-01Z | Gap dimension | Liftgate to bumper at bottom | Dimension "L" | mm | 5, 5 (± 1) |
| Liftgate to rear fender | Dimension "J" | mm | 4, 0 (± 1) | ||
| Liftgate to bumper at side | Dimension "K" | mm | 5, 0 (± 2) | ||
| Liftgate to roof | Dimension "W" | mm | 5, 0 (± 1) | ||
| Liftgate to rear window | Dimension "O" | mm | 3, 0 (± 1, 0) | ||
| Rear fender to backup lamp | Dimension "M" | mm | 1, 0 (+1-/0, 5) | ||
| D-pillar to rear window | Dimension "V" | mm | 4, 5 (± 1, 5) | ||
| For picture, see | AR60.00-P-0700-01GQ | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint | A 000 986 34 42 |
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1035-13A | Blind rivet 6.4 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | A 000 991 76 32 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 012 989 17 71 |
The following steps are shown on the left side of the vehicle and must be performed analogously on the right side in the event of damage.
- Install outer side wall (1) and fit.
- Remove rear bumper, trunk lid, taillamp, seal and lock striker and fit.
- Check gap dimensions and adjust.
- Fix outer side wall (1) in place.
- Drill Ø 6.5 mm rivet holes on outer side wall (1) (area G 1).
- Remove rear bumper, trunk lid, taillamp, door seal and lock striker.
- Remove outer sidewall (1).
- Deburr rivet holes on outer side wall (1) on both sides.
- Remove shavings using wet/dry vacuum cleaner.
- Coat insides of riveted joints with zinc dust paint suitable for spot welding.
Do not apply zinc dust paint to bonding surfaces.
Otherwise there may be adhesion problems.
Observe pretreatment of bonding surfaces.
- On body in crosshatched areas Apply sealing mass.
- On outer side wall (1) in area G1 Apply 2-component adhesive.
- Install outer side wall (1), fit and fix in place.
- Rivet outer side wall (1) with
rivet press tool and blind rivets (area G 2 ).
- Outer side wall (1) with
(areas C, D, E, F and H).
- Outer side wall (1) with
(area I).
- Outer side wall (1) with
(areas A and B).
This ensures minimum heat distortion.
- Grind inert gas welds down flat.
- Clean MIG solder connections.
- Remove shavings using wet/dry vacuum cleaner.
- Solder surfaces on outer side wall (1) and smooth (areas A and B).
- Remove solder residues.