Replace left firewall half - AR62.25-P-1110T

MODELS 211.0/2 

Fig 1: Identifying Left Firewall Half Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	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 undeburred vehicle parts.	AS00.00-Z-0017-01A
		Deburr replacement panels.
	Risk of death  cased by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist 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 high combustible materials. Risk of injury  caused by 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 hazard area. Use air extractor.	AS00.00-Z-0007-01A
	General information on body repair		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
1	Remove engine hood		AR88.40-P-3000T
2	Remove left front fender		AR88.10-P-1000T
3	Remove left front door		AR72.10-P-0500T
4	Remove left rear door		AR72.12-P-0600T
5	Remove left front seat		AR91.10-P-1000T
6	Remove foot mats
7	Cross member below instrument panel remove	Protect heater housing or AC housing against damage.
		Model 211.080/082/083/280/282/283/026/028/042/043/206/216/226/242/243/261/265/270
		Model 211.004/006/016/061/065/070/076/276	AR62.30-P-1250T
8	Remove pedal assembly for parking brake	Type 211.080/082/083/280/282/283	AR42.20-P-0510T
		Model 211.004/006/016/026/028/042/043/061/065/070/076/206/216/226/242/243/261/265/270/276
9	Remove or detach electric lines and vacuum lines in areas to be repaired
10	Remove front end with reinforcement		AR62.30-P-1570T
11	Remove exhaust system	Engine 646.951 in model 211.004
		Engine 646.961 211.006/206
		Engine 647.961 211.016/216
		Engine 271.943 211.043
		Engine 112.913 211.061/261	AR49.10-P-7000TB
		Engine 112.949 211.065/265
		Engine 113.967 211.070/270
		Engine 113.990 211.076/276
		Engine 112.917 211.080/280
		Engine 112.954 211.082/282
		Engine 113.969 211.083/283
		Engine 648.961 211.026/226	AR49.10-P-7000T
		Engine 628.961 211.028	AR49.10-P-7000TD
		Engine 271.941 211.042/242	AR49.10-P-7000TK
12	Remove engine	Engine 271.943 in model 211.043 with transmissions 716.628, 722.695
		Engine 113.967 in model 211.070 with transmission 722.901
		Engine 112.917 in model 211.080 with Transmission 722.667
		Engine 112.954 in model 211.082 with Transmission 722.668
		Engine 113.969 in model 211.083 with Transmission 722.672
		Engine 112.913 in model 211.261 with transmissions 716.623/634, 722.696
		Engine 112.949 in model 211.265 with transmission 722.618
		Engine 113.967 in model 211.270 with transmission 722.633/901
		Engine 113.990 in model 211.276 with transmission 722.643/901
		Engine 112.917 in model 211.280 with transmission 722.667
		Engine 112.954 in model 211.282 with transmission 722.668
		Engine 113.969 in model 211.283 with transmission 722.672
		Engine 648.961 in model 211.026/226 with transmission 722.626	AR01.10-P-2400TA
		Engine 271.941 in model 211.042/242 with transmissions 722.695, 716.628	AR01.10-P-2400TK
		Engine 646.951 in model 211.004 with transmission 716.604	AR01.10-P-2400T
		Engine 646.961 in model 211.006/206 with transmission 716.649
		Engine 647.961 in model 211.016/216 with transmission 716.649
		Engine 646.951 in model 211.004 with transmission 722.699	AR01.10-P-2400TB
		Engine 646.961 in model 211.006/206 with transmission 722.699
		Engine 647.961 in MODEL 211.016/216 with TRANSMISSION 722.640
		Engine 112.913 in model 211.061 with transmission 716.623/634, 722.696	AR01.10-P-2400TC
		Engine 112.949 in model 211.065 with transmission 722.618
		Engine 113.967 in model 211.070 with transmission 722.633
		Engine 628.961 211.028	AR01.10-P-2401TD
		Engine 113.990 in model 211.076	AR01.10-P-2400RVK
13	Remove front axle	Model 211.028/043/243/080/280/082/282/083/283
		Model 211.004/006/206/016/216/026/226/042/242/061/261/065/265/070/270/076/276	AR33.10-P-0100T
14	Remove detachable parts in area to be repaired
15	Cover all detachable body components remaining in vehicle (area to be repaired)	Tarpaulin (fireproof)
16	Equip straightening bench with modular members. cross members and straightening bracket set.	Observe enclosed set-up plans!
		Celette straightening bench M8S http://gotis.aftersales.mercedes-benz.com
		Celette straightening bench Sevenne http://gotis.aftersales.mercedes-benz.com
		Set of Celette modular members 955.940 http://gotis.aftersales.mercedes-benz.com
		Celette additional member 955.908 http://gotis.aftersales.mercedes-benz.com
		Car-Bench straightening bench BT 17 http://gotis.aftersales.mercedes-benz.com
		Car-Bench straightening bench BT 43/1 http://gotis.aftersales.mercedes-benz.com
		Car-Bench universal crossmember set
		A 296 http://gotis.aftersales.mercedes-benz.com
		Multi-Z straightening set system MZ 450.000 http://gotis.aftersales.mercedes-benz.com
		Celette straightening bench 7211.300 (for model 211) http://gotis.aftersales.mercedes-benz.com
		Car Bench straightening bracket set 82441 (for model 211) http://gotis.aftersales.mercedes-benz.com
		Celette 7211.309 supplementary straightening set for Celette straightening bracket set 7211.300 for model S 211 http://gotis.aftersales.mercedes-benz.com
		Car-Bench 82450 supplementary straightening set for Car-Bench straightening bracket set 82441 (for model S 211) http://gotis.aftersales.mercedes-benz.com
		Celette 7211.308 supplementary straightening set for Celette straightening bracket set 7211.300 (for model S 211 4MATIC) http://gotis.aftersales.mercedes-benz.com
		Car-Bench 82451 supplementary straightening set for Car-Bench straightening bracket set 82441 (for model 211 4MATIC) http://gotis.aftersales.mercedes-benz.com
17	Place vehicle on straightening bench using two-column lift	Two-column lift http://gotis.aftersales.mercedes-benz.com
18	Attach vehicle to straightening bench
19	Set up side portal frame with inspection and welding device	Observe set-up plans enclosed!
		Side portal frame	Figure
		Test and welding device	Figure
20	Check installation position of A and B-pillar, align
21	Remove firewall half (3)		AR62.25-P-1110-01T
		Cutting templates	Figure
		Spot weld milling cutter	Figure
		Spherical milling cutter, dia. 12 mm
		Round wire brush, braided, dia. 70 mm
		Vario Drill WS 91 spot-weld loosening tool
		Cutting disc, dia. 65 mm, 80 m/s (max. 23.500 RPM)
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Body saw (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Tarpaulin (fireproof) Two-column lift http://gotis.aftersales.mercedes-benz.com
		Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com
22	Prepare connection points on body		AR62.10-P-1000-03T
		Round wire brush, braided, dia. 70 mm
		Abrasive disc, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
23	Preparing wheelhouse (2) for installation		AR62.20-P-1200-19T
		Round wire brush, braided, dia. 70 mm
		Hole punching pliers, 7 mm dia.
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
24	Preparing partition wall (1) for installation		AR62.20-P-1200-20T
			Figure
		Spot weld milling cutter
		Vario Drill WS 91 spot-weld loosening tool
		Round wire brush, braided, dia. 70 mm
		Abrasive disc, dia. 115 mm, 80 m/s (max. 13,250 RPM)
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
25	Preparing firewall half (3) for installation		AR62.25-P-1110-02T
		Hole punching pliers, 7 mm dia.
		Round wire brush, braided, dia. 70 mm
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
26	Preparing crossmember on firewall (4) and reinforcement on crossmember (5) for installation		AR62.25-P-1110-03T
		Spot weld milling cutter	Figure
		Vario Drill WS 91 spot-weld loosening tool
		Round wire brush, braided, dia. 70 mm
		Abrasive disc, dia. 115 mm, 80 m/s (max. 13,250 RPM)
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
27	Prepare crossmember below windshield for installation		AR62.25-P-1110-04T
		Round wire brush, braided, dia. 70 mm
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
28	Prepare A-pillar with side longitudinal member for installation		AR63.20-P-1150-06T
		Spot weld milling cutter	Figure
		Hole punching pliers, 7 mm dia.
		Round wire brush, braided, dia. 70 mm
		Abrasive disc, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Body saw (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
	Install
29	Install firewall half		AR62.25-P-1110-05T
	General notes on riveting		AH60.00-P-0003-01N
		Side portal frame	Figure
		Test and welding device	Figure
		Round wire brush, braided, dia. 70 mm
		Electrode miller
		Clamping pliers
		PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com
		Hand riveter
		Abrasive disc, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
		Cutting disc, dia. 65 mm, 80 m/s (max. 23.500 RPM)
		Manual temporary fastener, dia.
		6.4 mm, clamping area 0 to 15 mm, identification color silver
		Inert gas welder http://gotis.aftersales.mercedes-benz.com
		Spot welder http://gotis.aftersales.mercedes-benz.com
		Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com
		Polygrip flat/round head rivet, 6.4x14	*BR00.45-Z-1001-13A
		Sealant	*BR00.45-Z-1003-01A
		Preservation agent	*BR00.45-Z-1003-05A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
30	Unfasten vehicle from straightening bench
31	Lift vehicle with two-column lift	Two-column lift http://gotis.aftersales.mercedes-benz.com
32	Remove straightening bench.
33	Clean area to be repaired
34	Prime area to be repaired with primer/filler
35	Carry out seam sealing after repairs	Supplement standard sealing with MB body sealant.	AR97.10-P-4000T
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
36	Paint area repaired and adjacent surfaces
37	Hollow cavity preservation following repair work		AR97.20-P-1500T
	Notes on hollow cavity preservation		AH97.20-P-0001-01B
		Hollow cavity preservation gun Sata HRS no. 11072
		http://gotis.aftersales.mercedes-benz.com
		Preservation agent	*BR00.45-Z-1003-05A
38	Remove tarpaulin from all covered parts remaining in vehicle	Tarpaulin (fireproof)
39	Install parking brake pedal assembly	Type 211.080/082/083/280/282/283
		Model 211.004/006/016/026/028/042/043/061/065/070/076/206/216/226/242/243/261/265/270/276	AR42.20-P-0510T
40	Install engine	Engine 271.943 in model 211.043 with transmissions 716.628, 722.695
		Engine 113.967 in model 211.070 with transmission 722.901
		Engine 112.917 in model 211.080 with transmission 722.667
		Engine 112.954 in model 211.082 with transmission 722.668
		Engine 113.969 in model 211.083 with transmission 722.672
		Engine 112.913 in model 211.261 with transmissions 716.623/634, 722.696
		Engine 112.949 in model 211.265 with transmission 722.618
		Engine 113.967 in model 211.270 with transmission 722.633/901
		Engine 113.990 in model 211.276 with transmission 722.643/901
		Engine 112.917 in model 211.280 with transmission 722.667
		Engine 112.954 in model 211.282 with transmission 722.668
		Engine 113.969 in model 211.283 with transmission 722.672
		Engine 648.961 in model 211.026/226 with transmission 722.626	AR01.10-P-2400TA
		Engine 271.941 in model 211.042/242 with transmissions 722.695, 716.628	AR01.10-P-2400TK
		Engine 646.951 in model 211.004 with transmission 716.604	AR01.10-P-2400T
		Engine 646.961 in model 211.006/206 with transmission 716.649
		Engine 647.961 in model 211.016/216 with transmission 716.649
		Engine 646.951 in model 211.004 with transmission 722.699
		Engine 646.961 in model 211.006/206 with transmission 722.699	AR01.10-P-2400TB
		Engine 647.961 in model 211.016/216 with transmission 722.640
		Engine 112.913 in model 211.061 with transmission 716.623/634, 722.696	AR01.10-P-2400TC
		Engine 112.949 in model 211.065 with transmission 722.618
		Engine 113.967 in model 211.070 with transmission 722.633
		Engine 628.961 211.028	AR01.10-P-2401TD
		Engine 113.990 in model 211.076	AR01.10-P-2400RVK
41	Install front axle	Model 211.028/043/243/080/280/082/282/083/283
		Model 211.004/006/206/016/216/026/226/042/242/061/261/065/265/070/270/076/276	AR33.10-P-0100T
42	Install exhaust system	Engine 646.951 in model 211.004
		Engine 646.961 211.006/206
		Engine 647.961 211.016/216
		Engine 271.943 211.043
		Engine 112.913 211.061/261	AR49.10-P-7000TB
		Engine 112.949 211.065/265
		Engine 113.967 211.070/270
		Engine 113.990 211.076/276
		Engine 112.917 211.080/280
		Engine 112.954 211.082/282
		Engine 113.969 211.083/283
		Engine 648.961 211.026/226	AR49.10-P-7000T
		Engine 628.961 211.028	AR49.10-P-7000TD
		Engine 271.941 211.042/242	AR49.10-P-7000TK
43	Cross member below instrument panel Install	Protect heater housing or AC housing against damage.
		Model 211.080/082/083/280/282/283/026/028/042/043/206/216/226/242/243/261/265/270
		Model 211.004/006/016/061/065/070/076/276	AR62.30-P-1250T
44	Install electric leads and vacuum lines in area to be repaired
45	Install left front seat		AR91.10-P-1000T
46	Install foot mats
47	Install engine hood		AR88.40-P-3000T
48	Install left front door		AR72.10-P-0500T
49	Install left rear door		AR72.12-P-0600T
50	Install front end with front reinforcement		AR62.30-P-1570T
51	Install left front fender		AR88.10-P-1000T
52	Install all removed detachable body components

Fig 2: Identifying Side Portal Frame (210 589 17 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Inspection And Welding Device (211 589 00 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Cutting Templates (211 589 05 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Spot Weld Milling Cutter (201 589 00 51 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