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Home >> Mercedes Benz >> 2019 >> Sprinter 3500XD 2D Cab Chassis >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Front End & Fire Wall >> Testing & Repair >> Prepare Firewall Half For Installation - Ar62.25-D-1110-02TS

Prepare Firewall Half For Installation - Ar62.25-D-1110-02TS

Model 907.### 1# 

REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1056-07A 1K-zinc dust paint A 000 986 28 00

IMPORTANT Additional information can be found in the superordinate service document.

The safety information in the superordinate service document must be observed.

  1. Mark separating points on firewall (1) (areas A and B).

    IMPORTANT Take over dimensions for separating points from vehicle.

  2. Cut firewall (1) at separating points (areas A and B).

    IMPORTANTCommercially available devices/tools 

    Body power jigsaw

  3. Dispose of larger remaining section of firewall (1).
  4. Grind down mating surfaces to bare metal in cross-hatched areas.

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

    IMPORTANT Sand down spot weld flanges to bare metal on both sides.

    G13788131
  5. Remove shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

  6. Zinc dust paint to insides of spot weld flanges.
    G13788132
  7. Mark separating point on reinforcement (2) (area C).

    IMPORTANT Take over dimensions for separating point from vehicle.

  8. Cut reinforcement (2) at separating point (area C).

    IMPORTANTCommercially available devices/tools 

    Body power jigsaw

  9. Dispose of larger remaining section of reinforcement (2).
  10. Grind down mating surfaces to bare metal in cross-hatched areas.

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

    IMPORTANT Sand down spot weld flanges to bare metal on both sides.

  11. Remove shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

  12. Zinc dust paint to insides of spot weld flanges.
  13. Mark separating point on paneling under windshield (3) (area D).

    IMPORTANT Take over dimensions for separating point from vehicle.

  14. Cut paneling under windshield (2) at separating point (area D).

    IMPORTANTCommercially available devices/tools 

    Body power jigsaw

  15. Dispose of larger remaining section of paneling under windshield (2).
    G13788133
  16. Grind down mating surfaces to bare metal in cross-hatched areas.

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

    IMPORTANT Sand down spot weld flanges to bare metal on both sides.

  17. Remove shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

  18. Zinc dust paint to insides of spot weld flanges.
  19. Mark separating point on suspension strut support upper section (4) (area E).

    IMPORTANT Take over dimensions for separating point from vehicle.

  20. Cut paneling under suspension strut support upper section (4) at separating point (area E).

    IMPORTANTCommercially available devices/tools 

    Body power jigsaw

  21. Dispose of larger remaining section of paneling under suspension strut support (4).
    G13788134
  22. Drill holes in suspension strut support upper section (4) with Ø 7 mm (area F).

    IMPORTANTCommercially available devices/tools 

    Hand drill

    IMPORTANT Take over dimensions for holes from vehicle.

  23. Grind mating surfaces down to bare metal in cross-hatched areas and around holes (area F).

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

    IMPORTANT Sand down spot weld flanges to bare metal on both sides.

  24. Remove drilling chips/shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

  25. Zinc dust paint to insides of spot weld flanges.
    G13788135
  26. Drill holes in suspension strut support lower section (5) with Ø 7 mm (areas G and H).

    IMPORTANTCommercially available devices/tools 

    Hand drill

    IMPORTANT Take over dimensions for holes from vehicle.

  27. Grind mating surfaces in cross-hatched areas and around holes down to bare metal (areas G and H).

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

  28. Remove drilling chips/shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

  29. Zinc dust paint to insides of spot weld flanges.

    IMPORTANT Sand down spot weld flanges to bare metal on both sides.

  30. Grind mating surfaces in cross-hatched areas down to bare metal on wheel well (6), reinforcements (7, 9) wheel well front section (8).

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

    IMPORTANT Sand down spot weld flanges to bare metal on both sides.

  31. Remove shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

  32. Zinc dust paint to insides of spot weld flanges.
G13788136