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

Fig 1: Identifying Side Portal Frame (210 589 17 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Inspection And Welding Device (211 589 00 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant, white, 310 ml, DB supply specification 6069.20	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	Cavity preservation, solvent-free (1 l container)	A 000 986 72 70 05
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1001-13A	Blind rivet 6.4x14	A 003 990 35 97

Install inner A-pillar with side portal frame, check and welding gage and clamping pliers, fit and fasten.
Use spacers.
Remove test and welding gage for instrument carrier mount.

Fig 3: Identifying Inner A-Pillar With Side Portal Frame
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Cross Members Below Windshield, Firewall Half, Wheelhouse And Reinforcement
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install, fit and fasten upper cross member below windshield, lower cross member below windshield, firewall half, cross member at firewall, wheelhouse and reinforcement at cross member with cross member below instrument panel, straightening tool and clamping pliers.

Fig 5: Locating Rivet Holes Drilling Areas (H, AE, AF, AH And AS)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Drill dia. 6.5 mm rivet holes (areas H, AE, AF, AH and AS).

Fig 6: Locating Rivet Holes Drilling Areas (E, F, G, J, AJ, AK, AL, AR And AT)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Drill dia. 6.5 mm rivet holes (areas E, F, G, J, AJ, AK, AL, AR and AT).
Remove cross member below instrument panel.
Drill dia. 6.5 mm rivet holes (area AQ).
Install test and welding gage for instrument carrier mount.

Fig 7: Locating Rivet Holes Drilling Areas (AU And AV)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove check and welding gage for A-pillar mount
Install center A-pillar and longitudinal member with check and welding gage for A-pillar mount, fit and fasten.
Drill dia. 6.5 mm rivet holes (areas AU and AV).

Fig 8: Identifying Rivet Hole Drilling Areas (R And AW)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 9: Identifying Fire Wall Riveting And Welding Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove check and welding gage for A-pillar mount
Install A-pillar paneling with check and welding gage for A-pillar mount, fit and fasten.
Drill dia. 6.5 mm rivet holes (areas R and AW).
Remove check and welding gages, side portal frames, A-pillar paneling, center A-pillar, longitudinal member, inner A-pillar, wheelhouse, reinforcement on cross member, cross member on firewall, bottom cross member below windshield and half of fire wall and deburr rivet holes on both sides.

Fig 10: View Of Cross Member At Firewall And Wheelhouse
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install firewall half and fasten with clamping pliers and screw-on clamping grippers.
Weld in firewall half and main floor with (area I).
Weld in firewall with (area A).
Grind MIG welds down flat at connection surfaces.
Clean inner welding areas with wire brush and coat with zinc dust paint (area A).
Rivet firewall and drive shaft tunnel with Polygrip 6.4 x 14 mm dia. flat head rivets (areas G and J).
Areas connected with cross member to firewall are not riveted.
Install cross member at firewall and wheelhouse and fasten with clamping pliers and screw-on clamping grippers.
Remove wheelhouse.

Fig 11: Identifying Cross Member On Firewall And Firewall Head Riveting Areas (H, AE, AF And AH)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 12: Identifying Welding And Riveting Areas Of Wheelhouse And Firewall (AT, AY, BA And BB)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rivet cross member on firewall and firewall with Polygrip 6.4 x 14 mm dia. flat head rivets (areas H, AE, AF and AH).
Weld in cross member on firewall and firewall half with (areas AG and AX).
Clean inner welding areas with wire brush and coat with zinc dust paint (area AG).
Install wheelhouse and fasten with straightening tool, clamping pliers and screw-on clamping grippers.
Rivet wheelhouse and firewall half Polygrip 6.4 x 14 mm dia. flat head rivets (areas E, F and AT).
Weld in wheelhouse and firewall half with (areas AY, BA and BB).
Weld in wheelhouse and cross member at firewall with (area AZ).
Clean inner welding areas with wire brush and coat with zinc dust paint (area AY).
Rivet wheelhouse and cross member on firewall with 6.4 x 14 mm dia. Polygrip flat head rivets (areas H and AS).
Weld in wheelhouse and firewall half with (area BC).

Fig 13: Identifying Wheelhouse Welding Areas (Area BC)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install upper cross member below windshield, bottom cross member below windshield and inner A-pillar with cross member below instrument panel, straightening tool, side portal frame, check and welding gages, screw-on clamping gripper and clamping pliers, fit and fasten.
Tack weld upper cross member below windshield (area AI).
Remove cross member below instrument panel, check and welding gages, inner A-pillar and bottom cross member below windshield.

Fig 14: Identifying Welding Area Of Upper Cross Member Below Windshield (Area AI)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Weld in upper cross member below windshield with (area AI).
Weld in upper cross member below windshield with (area AM).
Rivet upper cross member below windshield and inner A-pillar with 6.4 x 14 mm dia. Polygrip flat head rivets (area AJ).
Clean inner welding areas with wire brush and coat with zinc dust paint (area AI).

Fig 15: Identifying Upper Cross Member Welding Areas (Area AI And AM)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 16: Identifying Welding Areas Of Upper And lower Cross Members Below Windshield (Areas BH And BG)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install bottom cross member below windshield, inner A-pillar and reinforcement on cross member with cross member below instrument panel, check and welding gages, screw-on clamping gripper and clamping pliers, fit and fasten.
Upper cross member below windshield, lower cross member below windshield and firewall (areas BH and BG).

Fig 17: Locating Lower Cross Member, Firewall Half And Reinforcement Welding Areas (Areas BD And BE)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rivet upper cross member below windshield, bottom cross member below windshield and right inner A-pillar with 6.4 x 14 mm dia. Polygrip flat head rivets (areas AJ, AK and AL).
Rivet reinforcement on cross member and cross member on firewall with 6.4 x 14 mm dia. Polygrip flat head rivets (area AS).
Weld in lower cross member below windshield, firewall half and reinforcement at cross member partly with (areas BD and BE).
Remove cross member below instrument panel and finish welding (areas BD and BE).

Fig 18: Identifying Upper/Bottom Cross Member And Inner A-Pillar Welding Areas (BF, D & O) & Rivet Area (AQ)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Weld in upper cross member below windshield, bottom cross member below windshield and inner A-pillar with (area BF).
Weld in firewall half, main floor and inner A-pillar with (area O).
Weld in inner A-pillar with (area D).
Rivet firewall half and inner A-pillar with 6.4 x 14 mm dia. Polygrip flat head rivets (area AQ).

Fig 19: Identifying Inner A-Pillar Welding Areas (Areas BJ, BR, C, D, Q & S)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Weld in inner A-pillar with (areas C, D and Q).
Grind MIG welds down flat at connection surfaces (areas C and D).
Weld in inner A-pillar and wheelhouse with (areas BJ and BR).
Weld in inner A-pillar with (area S).
Clean inner welding areas with wire brush and coat with zinc dust paint (areas C, D, S, Q, BJ and BR).
Weld in inner A-pillar and wheelhouse with (areas AO and BS).
Rivet inner A-pillar and cross member on firewall with 6.4 x 14 mm dia. Polygrip flat head rivets (area AR).
Clean inner welding areas with wire brush and coat with zinc dust paint (areas AO and BS).
Remove check and welding gage for A-pillar mount

Fig 20: Identifying Inner A-Pillar And Wheelhouse Welding Areas (AO And BS) & Rivet Area (AR)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 21: Identifying Longitudinal Member And Inner A-Pillar Welding Areas (L, M, BK & BL)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install center A-pillar and longitudinal member with check and welding gage, clamping pliers and screw-on clamping gripper and fasten.
Use spacers.
Weld in longitudinal member and inner A-pillar with (area BL).
Weld in longitudinal member and inner A-pillar with (areas L and BK).
Weld in longitudinal member with (area M).
Grind MIG weld down flat at connection surfaces (area M).
Remove center A-pillar.
Clean inner welding area with wire brush and coat with zinc dust paint (area BL).

Fig 22: Identifying A-Pillar And Upper Cross Member Welding Areas (BI, BN And U) & Rivet Areas (AU & AV)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install center A-pillar with check and welding gage, clamping pliers and screw-on clamping gripper and fasten.
Use spacers.
Rivet center A-pillar and longitudinal member with 6.4 x 14 mm dia. Polygrip flat head rivets (area AU).
Rivet center A-pillar and wheelhouse with 6.4 x 14 mm dia. Polygrip flat head rivets (area AV).
Weld in center A-pillar and longitudinal member with (area BN).
Weld in center A-pillar with (area U).
Weld in inner A-pillar, center A-pillar and upper cross member below windshield with (area BI).
Grind MIG weld down flat at connection surfaces (area U).
Clean inner welding areas with wire brush and coat with zinc dust paint (area U).
Remove check and welding gage for A-pillar mount

Fig 23: Identifying A-Pillar Panelling Welding Areas (AB, AP, K And BR) & Rivet Area (R)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install A-pillar paneling with check and welding gage, clamping pliers and screw-on clamping gripper and fasten.
Weld in A-pillar paneling with (areas K and AB).
Weld in A-pillar paneling and center A-pillar with (areas AP and BR).
Weld in with and grind down flat (areas AP and BR).
Rivet A-pillar paneling and longitudinal member with 6.4 x 14 mm dia. Polygrip flat head rivets (area R).

Fig 24: Identifying A-Pillar Welding Areas (P And T) & Rivet Area (AW)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rivet A-pillar paneling with 6.4 x 14 mm dia. Polygrip flat head rivets (area AW).
Weld in A-pillar paneling with (areas P and T).
Grind MIG welds down flat and clean with wire brush (areas P and T).
Install partition wall, fit and fasten with clamping pliers.
Drill dia. 6.5 mm rivet holes (areas AC and BM).
Spot-drill hole (area BQ).
Remove partition wall and deburr rivet holes on both sides.

Fig 25: Locating Hole Drilling Areas Of Partition Wall (AC, BQ And BM)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 26: Identifying Partition Wall Welding Areas (BO, BP, BQ And AD) & Rivet Areas (AC, BM)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install partition wall, fasten with clamping pliers and screw-on clamping grippers.
Weld in partition wall with (area BQ).
Weld in partition wall with (area AD).
Weld in partition wall and wheelhouse with (areas BO and BP).
Rivet partition wall and cross member on firewall with Polygrip 6.4 x 14 mm dia. flat head rivets (area AC).
Polygrip Rivet partition wall and wheelhouse with 6.4 x 14 mm dia. flat head rivets (area BM).
Remove vehicle from straightening bench and lift up.
Spot-drill hole at main floor from below (area G1).
Weld in main floor and firewall half with (area G1).
Fill B-pillar and longitudinal member paneling with filling solder in shaded areas and smooth.

Fig 27: Identifying Main Floor Drill Area (G1) & B-Pillar And Longitudinal Member Filling Solder Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.