Firewall Half Removal - Ar62.25-P-1110-01FR

Model 257, 290 

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.

Fig 1: Firewall Half Component Location (Model 257, 290)

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1. Expose spot welds on pedal bowl (4) and cut out (areas A).

   Common spot welds of the pedal pot (4), firewall and firewall crossmember must be cut through two panel thicknesses.

2. Heat pedal bowl (4) in crosshatched area.

   Cross-hatched area is bonded.

3. Remove pedal assembly cup (4).

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4. Mark separating point on firewall crossmember (5) (area B).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   a = approx. 20 mm

   b = approx. 65 mm

5. Expose spot welds on firewall crossmember (5) and cut out (areas C).

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6. Expose spot welds on firewall crossmember (5) and cut out (areas D).

   Common spot welds of firewall crossmember (5) and firewall must be cut through two panel thicknesses.

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7. Heat firewall crossmember (5) in crosshatched areas.

   Cross-hatched areas are bonded with adhesive.

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8. Heat firewall crossmember (5) in crosshatched areas.

   Heat crossmember firewall (5) from inside (area D₁ ).

   Cross-hatched areas are bonded with adhesive.

9. Remove firewall crossmember (5).

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10. Expose spot welds on firewall (3) and drill through with a drill bit with a diameter of 6.5 mm (area E).
11. Expose spot welds on firewall (3) and cut out (areas F).

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12. Expose spot welds on firewall (3) and drill through with a drill bit with a diameter of 6.5 mm (areas G).
13. Cut solder points on firewall (3) (areas H).
14. Expose and cut off spot welds at firewall (3) (areas I, J).

    Common spot welds of connecting carrier and firewall (3) must be cut through two panel thicknesses (areas I).

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15. Heat firewall (3) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

16. Heat firewall (3) in crosshatched area.

    Cross-hatched area is bonded.

17. Remove firewall (3).

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18. Sand down mating surfaces to bare metal in cross-hatched areas.

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19. Sand down mating surfaces to bare metal in cross-hatched areas.
20. Remove grinding dust and drill chips.

    Observe pretreatment of bonding surfaces.

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