Partially remove/install bottom section of firewall - AR62.25-P-1100P

MODEL 203.0 /2 /7, 209.3 /4 

Shown on model 203.0 

Fig 1: Identifying Bottom Section Of Firewall

	Remove
	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of death  caused by high voltage used for arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Injury hazard  from welding spatter and UV-light while welding. Risk of poisoning  caused by inhaling welding vapors.	Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor.	AS00.00-Z-0007-01A
	General information on repairs to body		AH60.00-N-0001-01A
	Measures for preventing damage to vehicles or components when performing arc welding work		AH00.00-N-0005-01A
	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on MB materials		AH98.00-P-9409-03A
1	Remove complete wheelhouse		AR62.20-P-1200P
2	Remove detachable parts in area to be repaired
3	Cover all detachable body components remaining in vehicle (area to be repaired)	Tarpaulin (fire-resistant)	*WH58.30-Z-1001-40A
4	Set up straightening bench with modular or crossmembers and straightening bracket set	Observe setup plans enclosed!
		Celette straightening bench M8S	*WE58.40-Z-1001-01E
		Celette straightening bench Sevenne	*WE58.40-Z-1001-01E
		Set of Celette module members 955.940	*WE58.40-Z-1007-01E
		Celette additional member 955.908	*WE58.40-Z-1008-01E
		Celette straightening bracket set 7203.300 (for model 203)	*WE58.40-Z-1029-01A
		Car-Bench straightening bench BT 17	*WE58.40-Z-1003-01E
		Car-Bench straightening bench BT 43/1	*WE58.40-Z-1003-01E
		Celette straightening bracket set 7203.309 (for model 203), as supplement to 7203.300	*WE58.40-Z-1031-01A
		Celette straightening bracket set 7209.309 (for model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C 209)	*WE58.40-Z-1042-01A
		Celette straightening bracket set 7203.310 (for model 203), only for new orders, includes supplement 7203.309	*WE58.40-Z-1032-01A
		Celette 7203.308 supplementary straightening bracket set for Celette straightening bracket set 7203.310 (for model 203 4MATIC)	*WE58.40-Z-1047-01A
		Car-Bench universal crossmember set A296	*WE58.40-Z-1010-01E
		Car-bench straightening bracket set 82434 (for model 203)	*WE58.40-Z-1030-01A
		Car-Bench 82445 supplementary straightening set for Car-Bench straightening bracket set 82434 (for model 203 4MATIC)	*WE58.40-Z-1048-01A
		Multi-Z straightening set system MZ 450.000	*WE58.40-Z-1006-01E
5	Place vehicle on straightening bench using two-post lift	Two-post lift	*WE58.40-Z-1001-05A
6	Attach vehicle to straightening bench
7	Separate bottom firewall section		AR62.25-P-1100-01P
		Spot weld milling cutter	Figure
		Spherical milling cutter, dia. 12 mm	*WH58.30-Z-1002-01A
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)	*WH58.30-Z-1024-04A
		Tarpaulin (fire-resistant)	*WH58.30-Z-1001-40A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Straight grinder (electric/pneumatic)	*WE58.40-Z-1002-03A
		Angular grinder (electric/pneumatic)	*WE58.40-Z-1003-03A
		Body saw (electric/pneumatic)	*WE58.40-Z-1004-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
8	Prepare firewall bottom section for installation		AR62.25-P-1100-02P
		Round wire brush, braided, dia. 70 mm	*WH58.30-Z-1001-03A
		Hole punching pliers, dia. 7 mm	*WH58.30-Z-1002-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
	Install
9	Install and weld in firewall bottom section		AR62.25-P-1100-03P
	General information on riveting		AH60.00-P-0003-01N
		Clamping pliers	*WH58.30-Z-1003-02A
		Power Bird blind rivet tool	*WE58.40-Z-1003-14A
		Hand riveter	*WH58.30-Z-1003-29A
		Blind rivets with manual temporary fastener, dia. 6.4 mm, clamping range 0 to 15 mm, identification color silver	*WH58.30-Z-1038-02A
		Tarpaulin (fire-resistant)	*WH58.30-Z-1001-40A
		Inert gas welder	*WE58.40-Z-1001-02A
		Drill (electric/pneumatic)	*WE58.40-Z-1001-03A
		Wet/dry vacuum cleaner	*WE58.40-Z-1005-03A
		Cavity preservation gun Sata HRS no. 11072	*WE58.40-Z-1006-08A
		Polygrip flat/round head rivet, 6.4 x 14	*BR00.45-Z-1001-13A
		Preservation agent	*BR00.45-Z-1003-05A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
		Sealant	*BR00.45-Z-1003-01A
10	Weld in wheelhouse		AR62.20-P-1200P
11	Unfasten vehicle from straightening bench
12	Lift vehicle with two-post lift	Two-post lift	*WE58.40-Z-1001-05A
13	Remove straightening bench.
14	Clean repair areas
15	Prime area to be repaired with priming filler
16	Carry out seam sealing after repairs	Model 203	AR97.10-P-4000P
		Model 209 Supplement standard seals with MB preservative.	AR97.10-P-4000Q
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
17	Paint firewall bottom section, wheelhouse and adjacent surfaces
18	Perform cavity preservation after repair work	Model 203.0	AR97.20-P-1500P
		Model 203.2	AR97.20-P-1500PA
		Model 203.7	AR97.20-P-1500PB
		Model 209	AR97.20-P-1500Q
	Notes on cavity preservation		AH97.20-P-0001-01B
19	Install all removed detachable body components

Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
WH58.30-Z-1002-02A	Hole punching pliers, dia. 7 mm
WH58.30-Z-1003-02A	Clamping pliers
WH58.30-Z-1038-02A	Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Company Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1003-29A	Hand riveter
WH58.30-Z-1001-40A	Tarp (fire-resistant)

WORKSHOP EQUIPMENT

WE58.40-Z-1029-01A	Celette straightening bracket set 7203.300 (model 203)
WE58.40-Z-1030-01A	Car bench straightening bracket set 82434, (model 203)
WE58.40-Z-1031-01A	Celette straightening bracket set 7203.309 (model 203), as supplement to 7203.300
WE58.40-Z-1032-01A	Celette straightening bracket set 7203.310 (model 203), only with new ordering contains addition 7203.309
WE58.40-Z-1042-01A	Celette straightening bracket set 7209.309 (model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C209)
WE58.40-Z-1047-01A	Celette 7203.308 supplementary straightening set for Celette straightening bracket set 7203.310 (model 203 4MATIC)
WE58.40-Z-1048-01A	Car-Bench 82445 supplementary straightening set for Car Bench straightening bracket set 82434 (model 203 4MATIC)
WE58.40-Z-1001-01E	Celette straightening bench
WE58.40-Z-1003-01E	Car-Bench straightening bench
WE58.40-Z-1006-01E	Celette Multi-Z straightening set system
WE58.40-Z-1007-01E	Celette module crossmember set 955.940
WE58.40-Z-1008-01E	Celette additional member 955.908
WE58.40-Z-1010-01E	Car-Bench universal cross member set A 296
WE58.40-Z-1001-02A	Inert gas welder
WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1002-03A	Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A	Body saw (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner
WE58.40-Z-1001-05A	Two-post lifting platform
WE58.40-Z-1006-08A	Cavity preservation gun
WE58.40-Z-1003-14A	Blind rivet tool

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant	A 001 989 63 20
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
BR00.45-Z-1003-05A	Preservation agent	A 000 986 72 70 05
BR00.45-Z-1001-13A	Rivet	A 003 990 35 97