Install firewall half - AR62.25-P-1110-05CW

WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Firewall And Firewall Half 6.7 mm Diameter Rivet Holes (Areas A, B, C And D)

Courtesy of MERCEDES-BENZ USA

The following operation steps are shown on model 204.0.

Remove firewall half (4), crossmember on firewall (5), inner A-pillar (9), fit and fix in place.
On model 204 use side portal frame with welding device for holding A-pillar and instrument panel carrier to adjust position.

On model 207.3, 212, 218 use side portal frame with straightening tool for holding A-pillar and instrument panel carrier to adjust position.
Drill Ø 6.7 mm rivet holes on crossmember on firewall (5) and firewall half (4) (areas A, B, C and D).

Fig 2: Identifying 6.7 mm Diameter Rivet Holes On Crossmember On Firewall And Firewall Half (Areas E, F, G, H, I And J)
Courtesy of MERCEDES-BENZ USA
Drill Ø 6.7 mm rivet holes on crossmember on firewall (5) and firewall half (4) (areas E, F, G, H, I and J).
Remove firewall half (4), crossmember on firewall (5), inner A-pillar and welding device or straightening tool for A-pillar mount and instrument panel carrier mount.
Deburr rivet holes on firewall half (4) and crossmember on firewall (5) on both sides.
Coat insides of those riveted joints that will not also be bonded with zinc dust paint.

Fig 3: Locating Firewall Half Rivets & Adhesive Areas
Courtesy of MERCEDES-BENZ USA
Apply 2-component adhesive in cross-hatched areas.
Apply 2-component adhesive from the bottom (area A₁ ).

Refer to the manufacturer's information for the curing and working times of 2-component adhesive.
Install firewall half (4), fit and fix in place.
Rivet firewall half (4) with Ø 6.4 x14 rivets (areas K and L).
Rivet fire wall half (4) with Ø 6.4 x14 rivets (areas M and O).
Mounting console (6) can only be riveted with front wheel well (area N).

Fig 4: Locating Fire Wall Half 6.4 X14 Diameter Rivets (Areas M And O)
Courtesy of MERCEDES-BENZ USA

Fig 5: Locating Crossmember On Firewall 6.5 x12.5 Diameter Rivets & Adhesive Areas
Courtesy of MERCEDES-BENZ USA
Apply 2-component adhesive in cross-hatched areas.
Refer to the manufacturer's information for the curing and working times of 2-component adhesive.
Install crossmember on firewall (5), fit and fix in place.
Rivet crossmember on firewall (5) with Ø 6.5 x12.5 rivets (area P).
Rivet crossmember on firewall (5) with Ø 6.5 x12.5 rivets (areas Q, R and S).

Fig 6: Riveting Crossmember On Firewall (Areas Q, R And S)
Courtesy of MERCEDES-BENZ USA

Fig 7: Identifying Steering Column Tube Mounting Console, Screws And Instrument Panel Crossmember
Courtesy of MERCEDES-BENZ USA
Install and adjust inner A-pillar (9).
On model 204 use welding device for holding A-pillar to adjust position.

On model 207.3, 212, 218 use straightening tool for holding A-pillar to adjust position.
Fix inner A-pillar in place (9).
Remove welding device or straightening tool.
Install instrument panel crossmember (7), fit and fix in place.
Install steering column tube mounting console (3), fasten with screws (8) to instrument panel crossmember (7) and fix in place.
Remove instrument panel crossmember (7).
Steering column tube mounting console (3) (area T).

Fig 8: Identifying Crossmember Below Windshield Weld & Adhesive Areas
Courtesy of MERCEDES-BENZ USA
Remove inner A-pillar (9).
Apply 2-component adhesive in cross-hatched areas.
Refer to the manufacturer's information for the curing and working times of 2-component adhesive.
Install crossmember below windshield (1), fit and fix in place.
Crossmember below windshield (1) (areas U and V).
Crossmember below windshield (1) (area W).
Before installing mounting console (2), completely install wheel well (10).
Install mounting console (2) and fit.
Mount welding device for top longitudinal member plane; at the same time use device to fix the pedal pot mounting console in place.
Drill mounting console (2) to Ø 6.7 mm (area X).
Remove mounting console (2).
Deburr rivet holes on both sides

Fig 9: Identifying Mounting Console Rivets (Area Y)
Courtesy of MERCEDES-BENZ USA
Apply 2-component adhesive on mating surfaces between mounting console (2) and firewall half (4).
Observe pretreatment of bonding surfaces.

Refer to the manufacturer's information for the curing and working times of 2-component adhesive.
Install mounting console (2).
Rivet console (2) with Ø 6.5x12.5 rivets (area Y).
Remove shavings and drill chips.