Remove firewall half - AR62.25-P-1110-01CW

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: Locating Spot Welds & Separation Point On Crossmember Below Windshield

Courtesy of MERCEDES-BENZ USA

Dimension:

The following operation steps are shown on model 204.0.

Mark separation point on crossmember below windshield (1) (area A).
Cut crossmember below windshield (1) at separation point (area A).
Expose spot welds on crossmember below windshield (1) and firewall half (4) (areas B, C and D).
Mill off spot welds on crossmember below windshield (1) and firewall half (4) (areas B, C and D).

Fig 2: Identifying Spot Welds On Firewall Half (Areas E And F)
Courtesy of MERCEDES-BENZ USA
Expose spot welds on firewall half (4) (areas E and F).
Mill off spot welds on firewall half (4) (areas E and F).

Fig 3: Identifying Firewall Half & Crossmember Spot Welds & Bonded Areas
Courtesy of MERCEDES-BENZ USA
Expose spot welds on firewall half (4) and firewall crossmember (5) (areas G, H, I, J, K, L, M, N and O).
Mill off spot welds on firewall half (4) and firewall crossmember (5) (areas G, H, I, J, K, L, M, N and O).
Heat firewall half (4) and firewall crossmember (5) in crosshatched areas.
Cross-hatched areas are bonded.
Remove firewall half (4), firewall crossmember (5) and crossmember below windshield (1).
Grind mating surfaces on body down to bare metal in cross-hatched areas.
Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas P, Q, R and S).

Observe pretreatment of bonding surfaces (areas P, Q, R and S).
Remove shavings and drill chips.

Fig 4: Identifying Firewall Half And Firewall Crossmember Mating Surfaces
Courtesy of MERCEDES-BENZ USA