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Firewall Half Installation - Ar62.25-P-1110-05FR

Model 257, 290 

IMPORTANT The following operation steps are shown on the left side of the vehicle on model 257. In case of damage on the right side of the vehicle, these steps must be performed analogously.

Additional information can be found in the superordinate service document.

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

  1. Install firewall (3), fit and fix in place.
  2. Drill rivet holes with a diameter of 6.7 mm in firewall (3) (area A).
    G16555034Courtesy of MERCEDES-BENZ USA
    G16555035Courtesy of MERCEDES-BENZ USA
  3. Drill rivet holes with a diameter of 6.7 mm in firewall (3) (areas B1 , B2 , B3 ).

    IMPORTANT Drill rivet holes through existing holes in body (areas B2 , 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 in areas not bonded with zinc dust paint.

    NOTES Do not apply zinc dust paint to bonding surfaces.

    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.

    G16555036Courtesy 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.

    G16555037Courtesy of MERCEDES-BENZ USA
  10. Install firewall (3) and fix in place.
  11. Rivet firewall (3) with rivets with a diameter of 6.4x12 (areas A1 , A2 ).
  12. Rivet firewall (3) with rivets with a diameter of 6.5x12.5 (area A3 ).
    G16555038Courtesy of MERCEDES-BENZ USA
    G16555039Courtesy of MERCEDES-BENZ USA
  13. Rivet firewall (3) with rivets with a diameter of 6.4x12 (areas C1 , C3 ).
  14. Rivet firewall (3) with rivets with a diameter of 6.5x12.5 (areas C4 , C5 ).
  15. Firewall (3) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area C2 ).
  16. Firewall (3) SHIELDED GAS SEAM WELD (areas C6 , C7 ).

    IMPORTANT Perform inert gas welding at intervals and allow to cool down in between.

    This reduces heat distortion.

    G16555040Courtesy of MERCEDES-BENZ USA
  17. Install firewall crossmember (5), fit and fix in place.
  18. Drill rivet holes with a diameter of 6.7 mm in firewall crossmember (5) (areas D).
  19. Drill rivet holes with a diameter of 6.7 mm in firewall crossmember (5) (areas D1 ).
  20. Remove firewall crossmember (5).
  21. Deburr rivet holes on firewall crossmember (5) and deburr body on both sides.
  22. Remove drilling chips.
  23. 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.

    G16555041Courtesy of MERCEDES-BENZ USA
  24. 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.

  25. Apply sealant in area of foam part.
    G16555042Courtesy of MERCEDES-BENZ USA
  26. Install firewall crossmember (5) and fix in place.
  27. Rivet firewall crossmember (5) with rivets with a diameter of 6.5x12.5 (areas F1 , F2 ).
  28. Rivet firewall crossmember (5) with rivets with a diameter of 6.4x12. (areas F3 , F4 ).
  29. Rivet firewall crossmember (5) with a rivet with a diameter of 6.4 (area F5 ).
  30. Firewall crossmember (5) SHIELDED GAS SEAM WELD (area E).

    IMPORTANT Perform inert gas welding at intervals and allow to cool down in between.

    This reduces heat distortion.

    G16555043Courtesy of MERCEDES-BENZ USA
  31. Rivet firewall crossmember (5) with rivets with a diameter of 6.5x12.5 (areas G1 ).
  32. Rivet firewall crossmember (5) with rivets with a diameter of 6.4x12 (area G2 ).
  33. Rivet firewall crossmember (5) with rivets with a diameter of 6.5x14.5 (area G3 ).
  34. Firewall crossmember (5) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area H).
    G16555044Courtesy of MERCEDES-BENZ USA
    G16555045Courtesy of MERCEDES-BENZ USA
  35. Install wheel well (1), fit with straightening tools and fix in place.
  36. Install, fit and fix in place crossmember (2).
  37. Drill rivet holes with a diameter of 6.7 mm in wheel well (1) (areas I1 , I2 ).

    IMPORTANT Drill rivet holes through present holes in body (areas I2 ).

    G16555046Courtesy of MERCEDES-BENZ USA
  38. Drill rivet holes with a diameter of 6.7 mm in crossmember (2) (areas J).
  39. Remove crossmember (2).
    G16555047Courtesy of MERCEDES-BENZ USA
  40. Drill rivet holes with a diameter of 6.7 mm in firewall (3) (areas K, K1 ).

    IMPORTANT Drill rivet holes through existing rivet holes in body (areas K).

    G16555048Courtesy of MERCEDES-BENZ USA
  41. Drill rivet holes with a diameter of 6.7 mm in wheel well (1) (area L).
  42. Remove wheel well (1) and straightening tools.
  43. Deburr rivet holes on wheel well (1), crossmember and body on both sides.
  44. Remove drilling chips.
  45. 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.

    G16555049Courtesy of MERCEDES-BENZ USA
  46. 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.

    G16555050Courtesy of MERCEDES-BENZ USA
  47. Install wheel well (1) with straightening tools and fix in place.
  48. Rivet wheel well (1) with rivets with a diameter of 6.5x14.5 (areas M1 ).
  49. Rivet wheel well (1) with rivets with a diameter of 6.4x12 (areas M2 ).
  50. Rivet wheel well (1) with rivets with a diameter of 6.5x12.5 (areas M3 , M4 ).
  51. Rivet wheel well (1) with rivets with a diameter of 6.5x12.5 (area N1 ).
  52. Wheel well (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area N).
    G16555051Courtesy of MERCEDES-BENZ USA
  53. 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.

    G16555052Courtesy of MERCEDES-BENZ USA
    G16555053Courtesy of MERCEDES-BENZ USA
  54. Install crossmember (2) and fix in place.
  55. Rivet crossmember (2) with rivets with a diameter of 6.5x12.5 (areas P1 , P2 ).
  56. Rivet crossmember (2) with rivets with a diameter of 6.5x14.5 (areas P3 ).
  57. Crossmember (2) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area O).
    G16555054Courtesy of MERCEDES-BENZ USA
  58. Take over position for rivet hole (area Q2 ) at pedal pot (4) from old part and offset by dimension (q2).

    IMPORTANTDimensions: 

    q2 = 8 mm

  59. Install pedal assembly cup (4), fit and fix in place.
  60. Drill rivet holes with a diameter of 6.7 mm in pedal pot (4) (areas Q2 , Q3 ).
  61. Drill rivet hole with a diameter of 6.7 mm in pedal pot (area Q1 ).

    IMPORTANT The intermediate space is insufficient for riveting; for this reason, drill through firewall located behind this (area Q1 ).

  62. Remove pedal assembly cup (4).
  63. Drill hole with a diameter of 10 mm through firewall (3).
  64. Deburr rivet holes on pedal assembly cup (4) and body on both sides.
  65. Remove drilling chips.
  66. 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.

    G16555055Courtesy of MERCEDES-BENZ USA
  67. Install pedal assembly cup (4) and fix in place.
  68. Rivet pedal pot (4) with rivets with a diameter of 6.4x12 (areas R1 ).
  69. Rivet pedal pot (4) with rivets with a diameter of 6.5x12.5 (areas R2 , R4 ).
  70. Rivet pedal pot (4) with rivets with a diameter of 6.5x14.5 (area R3 ).
  71. Close hole in firewall with sealant.
    G16555056Courtesy of MERCEDES-BENZ USA
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