Prepare firewall half for installation - AR62.25-P-1110-02CW

The following operation steps are shown on component for model 204.0.

1. Mark separation point on crossmember below windshield (1) (area A).

   Transfer separation point from vehicle (area A).

2. Cut crossmember below windshield (1) at separation point (area A).
3. Remove remaining section from crossmember below windshield (1.1).
   Fig 1: Identifying Crossmember Below Windshield Separation Point & Mating Surfaces

   Courtesy of MERCEDES-BENZ USA
4. Grind mating surfaces on remaining section of crossmember below windshield (1.1) down to bare metal in crosshatched areas.

   Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas B and C).

   Grind spot weld flanges down to bare metal on both sides.

   Observe pretreatment of bonding surfaces (areas B and C).

5. Grind mating surfaces on mounting console (2) and steering column tube mounting console (3) down to bare metal in crosshatched areas.

   Grind spot weld flanges down to bare metal on both sides.

6. Coat insides of spot weld flanges with zinc dust paint.

   Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (area D).

   Observe pretreatment of bonding surfaces (area D).

   Fig 2: Identifying Mounting Console And Steering Column Tube Mounting Console Mating Surfaces

   Courtesy of MERCEDES-BENZ USA

   Perform following operation steps 7,  8 and  9 only on model 212 and 218.

7. Expose spot welds on firewall half (4) (area E₁ ).
8. Mill off spot welds on firewall half (4) (area E₁ ).
9. Remove firewall half (4) from new part.
   Fig 3: Identifying Spot Welds On Firewall Half (Area E1)

   Courtesy of MERCEDES-BENZ USA
   Fig 4: Identifying Bonding Surfaces (Areas E, F, G And H)

   Courtesy of MERCEDES-BENZ USA
10. Grind mating surfaces on firewall half (4) down to bare metal in the crosshatched areas.

    Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas E, F, G and H).

    Grind spot weld flanges down to bare metal on both sides.

    Observe pretreatment of bonding surfaces (areas E, F, G and H).

11. Drill spot welds on crossmember on firewall (5) to Ø 6.5 mm (areas I, J and K).
12. Remove crossmember section from firewall (5.1).
    Fig 5: Identifying Spot Welds On Crossmember On Firewall (Areas I, J And K)

    Courtesy of MERCEDES-BENZ USA
13. Grind mating surfaces on crossmember on firewall (5) down to bare metal in crosshatched areas.

    Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas L, M and N).

    Observe pretreatment of bonding surfaces (areas L, M and N).

    Fig 6: Identifying Firewall Bonding Surfaces (Areas L, M And N)

    Courtesy of MERCEDES-BENZ USA