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Install Firewall Half - Ar62.25-P-1110-05LW

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Model 205 

IMPORTANT The following operation steps are shown on the left side of the vehicle on model 205.0 and must be performed analogously on the right side in the event of damage.

  1. Install firewall (3), fit and fix in place.
  2. Drill rivet holes on firewall (3) with Ø 6.7 mm (area A).
    G13021778Courtesy of MERCEDES-BENZ USA
    G13021779Courtesy of MERCEDES-BENZ USA
  3. Drill rivet holes on firewall (3) with 0 6.7 mm (areas B, B2 and B3 ).

    IMPORTANT Drill rivet holes through present holes in body (areas B2 and B3 ).

  4. Remove firewall (3).
  5. Deburr rivet holes on firewall (3) and body on both sides.
  6. Remove drilling chips.
  7. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat bonding surfaces with zinc dust paint (areas B1 and B2 ).

    Otherwise adhesion problems may occur.

  8. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G12824035Courtesy of MERCEDES-BENZ USA
  9. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G12824036Courtesy of MERCEDES-BENZ USA
  10. Install firewall (3) and fix in place.
  11. Rivet firewall (3) with Ø 6.4x12 rivet (area A5 ).
  12. Rivet firewall (3) with 0 6.5x12.5 rivet (areas A6 ).
    G13021782Courtesy of MERCEDES-BENZ USA
    G13021783Courtesy of MERCEDES-BENZ USA
  13. Rivet firewall (3) with Ø 6.4x12 rivet (areas A3 ).
  14. Rivet firewall (3) with Ø 6.5x12.5 rivet (areas A4 ).
  15. Firewall (3) POLARAIZATION RESISTANCE SINGLE-ROW SPOT WELD (area C1).
  16. Drill present hole in body with Ø 7 mm bit (area C2 ).
  17. Firewall (3) SHIELDED GAS PLUG WELD (area C2 ).
  18. Model 205.0/2

    with code 494 (US version)

    Model 205.3/4

    Install reinforcement (7) and fix in place.

  19. Model 205.0/2

    with code 494 (US version)

    Model 205.3/4

    Reinforcement (7) SHIELDED GAS SEAM WELD (areas U).

    Shown on model 205.4 

    G13021784Courtesy of MERCEDES-BENZ USA
  20. Install firewall crossmember (5), fit and fix in place.
  21. Drill rivet holes on firewall crossmember (5) with 0 6.7 mm bit (areas E-i).
  22. Remove firewall crossmember (5).
  23. Deburr rivet holes on firewall crossmember (5) and deburr body on both sides.
  24. Remove drilling chips.
    G13021785Courtesy of MERCEDES-BENZ USA
  25. Apply sealant to foam part in firewall crossmember (5) in crosshatched areas.
    G13021786Courtesy of MERCEDES-BENZ USA
  26. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G13021787Courtesy of MERCEDES-BENZ USA
  27. Rivet firewall crossmember (5) with 0 6.4x12 rivet (areas E2 ).
  28. Rivet firewall crossmember (5) with 0 6.5x12.5 rivet (areas E3 ).
    G13021788Courtesy of MERCEDES-BENZ USA
    G13021789Courtesy of MERCEDES-BENZ USA
  29. Install wheel well (1) with straightening tool, fit and fix in place.
  30. Install crossmember (2), fit and fix in place.
  31. Drill rivet holes on wheel well (1) with 0 6.7 mm (areas A1 and A2 ).

    IMPORTANT Drill rivet holes through present holes in body (areas A2 ).

    G12823924Courtesy of MERCEDES-BENZ USA
  32. Drill rivet holes on crossmember (2) with 0 6.7 mm (areas B).
  33. Remove crossmember (2).
    G13021791Courtesy of MERCEDES-BENZ USA
  34. Drill rivet holes on wheel well (1) with 0 6.7 mm bit (area C).
  35. Remove wheel well (1) and straightening tool.
  36. Deburr rivet holes on wheel well (1), crossmember and body on both sides.
  37. Remove drilling chips.
  38. Coat insides of riveted joints in areas not bonded with zinc dust paint.

    NOTES Do not apply zinc dust paint to bonding surfaces.

    Otherwise adhesion problems may occur.

    G12824048Courtesy of MERCEDES-BENZ USA
  39. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G12823927Courtesy of MERCEDES-BENZ USA
  40. Install wheel well (1) with straightening tool and fix in place.
  41. Rivet wheel well (1) with 0 6.5x12.5 rivets (areas F).
  42. Rivet wheel well (1) with 0 6.5x14.5 rivets (areas G).
  43. Rivet wheel well (1) with Ø 6.4x12 rivets (area J).
  44. Wheel well (1) POLARAIZATION RESISTANCE SINGLE-ROW SPOT WELD (area K).
    G13021794Courtesy of MERCEDES-BENZ USA
  45. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G12823930Courtesy of MERCEDES-BENZ USA
    G12823931Courtesy of MERCEDES-BENZ USA
  46. Install crossmember (2) and fix in place.
  47. Rivet crossmember (2) with Ø 6.4x12 rivets (areas M).
  48. Rivet crossmember (2) with Ø 6.5x12.5 rivets (areas N).
  49. Rivet crossmember (2) with Ø 6.5x14.5 rivets (areas O).
  50. Crossmember (2) POLARAIZATION RESISTANCE SINGLE-ROW SPOT WELD (area P).
    G13021797Courtesy of MERCEDES-BENZ USA
  51. Install connecting panel (6), fit and fix in place.
  52. Drill rivet holes on connecting panel (6) with Ø 6.7 mm bit (areas D1 and D2 ).
  53. Drill through holes in firewall with Ø 10 mm.

    IMPORTANT Since the intermediate space for riveting is not sufficient, drill through firewall behind in areas (D2 ).

  54. Drill rivet holes on connecting panel (6) with 0 6.7 mm (areas D3 and D4 ).

    IMPORTANT Drill rivet holes through present holes in body (areas D4 ).

  55. Remove connecting panel (6).
  56. Drill rivet holes on connecting panel (6) and body on both sides.
  57. Remove drilling chips.
  58. Coat insides of riveted joints in areas not bonded with zinc dust paint.

    NOTES Do not apply zinc dust paint to bonding surfaces.

    Otherwise adhesion problems may occur.

    G13021798Courtesy of MERCEDES-BENZ USA
  59. Apply 2-component adhesive to body in crosshatched areas.

    NOTES Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G13021799Courtesy of MERCEDES-BENZ USA
    G13021800Courtesy of MERCEDES-BENZ USA
  60. Install connecting panel (6) and fix in place.
  61. Rivet connecting panel (6) with 0 6.4x12 rivet (areas D5 ).
  62. Rivet connecting panel (6) with 0 6.5x12.5 rivet (areas D6 ).
  63. Close holes in firewall with sealant.
  64. Install pedal assembly cup (4), fit and fix in place.
  65. Drill rivet holes on pedal assembly cup (4) with 0 6.7 mm (areas S1 and S2 ).

    IMPORTANT The interspace for riveting is not sufficient, for this reason drill through firewall behind in area (S2 ).

  66. Remove pedal assembly cup (4).
  67. Drill through holes in firewall with Ø 10 mm.
  68. Deburr rivet holes on pedal assembly cup (4) and body on both sides.
  69. Remove drilling chips.
    G13021801Courtesy of MERCEDES-BENZ USA
  70. Apply 2-component adhesive to body in cross-hatched area.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G12824054Courtesy of MERCEDES-BENZ USA
  71. Install pedal assembly cup (4) and fix in place.
  72. Rivet pedal assembly cup (4) with Ø 6.4x12 rivet (areas T1 ).
  73. Rivet pedal assembly cup (4) with Ø 6.5x12.5 rivet (areas T2 ).
  74. Rivet pedal assembly cup (4) with 0 6.4x14.5 (area T3 ).
  75. Close holes in firewall with sealant.
    G13021803Courtesy of MERCEDES-BENZ USA
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