Body, sealant application chart
Surfaces
Scheme 94
1. There must not be any sealant on the surface.
2. Seal with class A finish.
See Class A .
3. Seal with class B finish.
See Class B .
4. Seal with class D finish.
See Class D .
Engine compartment and windshield wiper well
Scheme 95
1 = free of sealant 35 mm diameter.
Scheme 96
M1 = minimum 20 mm.
1. Free of sealant 45 mm diameter.
Scheme 97
Front wheel arch
Scheme 98
1. There must not be any sealant on the surface.
Underside of the central floor
Scheme 99
1. Free of sealant.
2. Holes sealed.
3. Free of sealant 35x45 mm.
Underside of the rear floor and rear wheel well
Scheme 100
1. Free of sealant.
Scheme 101
2. Only as protection against wear.
M5 = minimum 40 mm.
M6 = minimum 110 mm.
M7 = minimum 50 mm.
Scheme 102
1. Free of sealant.
2. Only as protection against wear.
M2 = minimum 21 mm.
Scheme 103
M8 = maximum 5 mm.
2. Only as protection against wear.
Scheme 104
1. Free of sealant 45 mm diameter.
M3 = minimum 40 mm.
M4 = maximum 25 mm.
Scheme 105
M10 = 100 mm.
M11 = 45 mm.
M12 = 75 mm.
M13 = minimum 5 mm.
M14 = maximum 15 mm.
M15 = maximum 10 mm.
Scheme 106
1. Free of sealant 45 mm diameter.
2. Only as protection against wear.
M16 = 130 mm.
Scheme 107
1. Free of sealant 45 mm diameter.
M3 = minimum 40 mm.
M4 = maximum 25 mm.
M11 = 45 mm.
M12 = 75 mm.
M13 = minimum 5 mm.
M14 = maximum 20 mm.
M15 = maximum 10 mm.
Passenger compartment, internal
Scheme 108
1 Free of sealant 30 mm diameter.
Scheme 109
1. Free of sealant.
M17 = minimum 11 mm.
M18 = minimum 10 mm.
Scheme 110
1. Free of sealant.
Scheme 111
1. Free of sealant 35 mm diameter.
M19 = maximum 10 mm.
M20 = maximum 15 mm.
Scheme 112
1. Free of sealant 35 mm diameter.
M21 = 15 mm +/- 10 mm.
Cargo compartment, internal
Scheme 113
1. Drainage plug free of sealant.
M22 = maximum 15 mm.
M23 = maximum 2.5 mm.
Scheme 114
1. Drainage plug free of sealant.
2. Free of sealant 35 mm diameter.
Cargo compartment opening and rear section
Scheme 115
1. There must not be any sealant in the seal hole (1).
The thickness of the seal must not exceed 2.0 mm. (The seal deviates from the factory seal along the D-post).
Scheme 116
Roof
Scheme 117
The class of finish deviates from the seal from the factory along the side of the roof.
(original seal).
Scheme 118
Hinges
Scheme 119
1. Applied up to the weld.
Front side door
Scheme 120
1. Thickness of the seal on the lower edge of the door = maximum 1 mm.
Rear side door
Scheme 121
1. Thickness of the seal on the lower edge of the door = maximum 1 mm.
Scheme 122
When replacing the side member, the alignment bench and its units of measurement must be used.
Use a puller tool. See Aligning the rear frame member .
Pull out the bodywork to the correct dimension.
Remove 50 mm more of the cover for the side member than the side member (Dimension A).
Scheme 123
Spot-weld the reinforcement to the replacement part.
Scheme 124
Secure the rear side member.
Use the measurement system on the alignment bench.
Weld into place.
Scheme 125
Spot-weld the cover for the rear side member.
Scheme 126
Grind the welds.
Cut off the damaged section.
Grind clean.
Apply welding primer.
Secure the upper side member.
Weld into place.