Repair instructions
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          DA-RM-02A052-00-001 - Gap and flush - Check and adjust - Closures
        Bonnet Structure
        Bonnet Latch
        Door Structure
        Door Hinge
        Door Latch
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Instructions
Body Panels and Closures / Closures / Closures Service Procedures / DA-RM-02A052-00-001 - Gap and flush - Check and adjust - Closures
1.  
Bonnet:
Section number
Description
Gap (mm)
Flush (mm)
1
Bumper to bonnet
3.0 +/- 0.5
1.5 +/- 1.0
2
Bumper side to bonnet
3.0 +/- 0.5
1.5 +/- 0.5
3
Fender to bonnet
3.0 +/- 0.5
1.0 +/- 1.0
4
Fender to bonnet line out
N/A
2.0 +/- 1.5
5
Bonnet to vent
1.5 +/- 0.5
0.5 +/- 0.5
6
Fender to bonnet rear
4.0 +/- 1.0
1.0 +/- 1.0
 
1.  
Door side:
Section number
Description
Gap (mm)
Flush (mm)
1
Door to fender
5.0 +/- 0.5
-1.0 +/- 0.5
2
Door to C-pillar
4.0 +/- 1.0
1.0 +/- 1.0
3
Quarter glass to B-pillar finisher
3.7 +/- 1.0
0.0 +/- 1.0
4
Door to bodyside upper
4.0 +/- 1.0
1.0 +/- 0.75
5
Door to bodyside upper
4.0 +/- 0.5
0.5 +/- 0.5
6
Door blade to bodyside lower
4.0 +/- 0.5
0.5 +/- 0.5
7
Applique to door blade
0.5 +/- 0.5
N/A
8
Door to winglet
0.5 +/- 0.5
N/A
9
Waste finisher to door
0.5 +/- 0.5
N/A
10
Door cantrail to seal finisher
1.0 +/- 0.75
1.5 +/- 0.75
11
Door glass to B-pillar finisher
4.0 +/- 1.0
0.0 +/- 1.0
12
Applique to winglet
0.5 +/- 0.5
N/A
13
Applique to bodyside upper
N/A
0.0 +/- 0.5
14
Cantrail finisher to quarter glass finisher
5.5 +/- 1.0
0.0 +/- 0.5
15
Bodyside lower to duct
0.5 +/- 0.5
0.0 +/- 0.5
16
Door to front fender
N/A
0.0 +/- 0.75
17
Door A-pillar to windscreen
6.0 +/- 2.0
N/A
18
A-pillar to cheater panel
1.0 +/- 0.75
N/A
19
Door to applique upper
1.5 +/- 0.5
0.5 +/- 0.5
20
Bodyside upper to bodyside lower
0.5 +/- 0.5
0.75 +/- 0.75
21
Door blade to door blade
0.0 +/- 0.5
N/A
22
Door A-pillar to applique
2.5 +/- 1.0
N/A
23
Cheater panel to door glass
3.0 +/- 1.0
N/A
24
Door to mirror arm
1.0 +/- 0.5
N/A
25
Bodyside lower to bodyside upper
N/A
0.0 +/- 0.5
 
 
Care Point:
Roof glass needs to be 2mm higher than the tailgate glass (6), but 2mm lower than the roof panel (1). Repeat for both sides.
 
1.  
Door upper:
Section number
Description
Gap (mm)
Flush (mm)
1
Roof panel to door glass / panel
5.5 +/- 1.0
2.0 +/- 1.0
2
Roof panel to door glass / panel
8 +/- 1.0
2.0 +/- 1.0
3
Roof to windscreen
4.0 +/- 1.0
2.0 +/- 1.5
4
Door roof glass to hinge cover
4.0 +/- 1.5
-1.0 +/- 1.0
5
Roof to hinge cover
5.5 +/- 1.0
1.0 +/- 1.0
6
Door roof glass to rear tailgate glass
5.0 +/- 1.5
2.0 +/- 1.5
7
Door cantrail to door glass / panel
5.0 +/- 1.5
4.0 +/- 1.5
8
Roof to rear tailgate glass
4.0 +/- 1.0
4.0 +/- 1.5
9
Roof to door cantrail
6.0 +/- 1.5
-2.0 +/- 1.25
10
Door hinge to hinge cover front
5.0 +/- 0.5
-0.5 +/- 0.5
11
Door hinge to hinge cover rear
5.0 +/- 0.5
-0.5 +/- 0.5
12
Door hinge to door glass / panel
5.5 +/- 1.0
0.5 +/- 0.5
13
Door hinge to hinge cover rear
5.0 +/- 0.5
0.5 +/- 0.5
14
Door cantrail to bulkhead glass
N/A
0.0 +/- 1.0
15
Door cantrail to bulkhead glass
N/A
0.0 +/- 1.0
16
Cantrail finisher to quarter glass finisher line out
N/A
0.0 +/- 0.5
 
1.  
Airbrake:
Section number
Description
Gap (mm)
Flush (mm)
1
Rear deck to airbrake
10.0 +/- 2.0
N/A
2
Bodyside upper to airbrake
4.0 +/- 1.0
-2.0 +/- 1.0
3
Bodyside upper to airbrake
4.0 +/- 1.0
-2.0 +/- 1.0
4
Airbrake to CHMSL
1.0 +/- 0.5
1.0 +/- 1.0
5
Rear lamp to airbrake
5.0 +/- 3.0
N/A
6
Heatshield to airbrake
6.0 +/- 2.0
N/A
 
   
   
   Note