LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2021 >> S63 AMG 2D Convertible >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Collision - Front End And Fire Wall (217 Chassis) >> Front End And Fire Wall Body Repair >> Install Firewall Half - Ar62.25-P-1110-05LF

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

Model 217 

Model 222 

except code Z07 (B7 armoring on special protection version) 

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

G15300138Courtesy of MERCEDES-BENZ USA

Shown on MODEL 222 

  1. Install firewall (1), fit and fix in place.
  2. Drill Ø 6.7 mm rivet holes in firewall (1) (areas A and B).

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

    G15300139Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 

  3. Bend back tunnel end plate (4) and fix in place.
  4. Drill Ø 6.7 mm rivet holes in firewall (1) and tunnel end plate (4) (areas C).
  5. Bend tunnel end plate (4) to side and remove firewall (1).
  6. Deburr rivet holes on firewall (1), tunnel end plate (4) and body on both sides.
  7. Remove drilling chips.
    G15300140Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 

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

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

    G15300141Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 

  9. Install firewall (1) and fix in place.
  10. Rivet firewall (1) with Ø 6.4x12 rivet (areas D1 ).
  11. Rivet firewall (1) with Ø 6.5x12.5 rivet (areas D2 ).
  12. Bend back sheet metal flange (arrow).
  13. Firewall (1) SHIELDED GAS PLUG WELD (area E).
    G15300142Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 

  14. Bend back tunnel end plate (4) and fix in place.
  15. Rivet tunnel end plate (4) and firewall (1) with Ø 6.4x12 rivet (areas F1 ).
  16. Rivet tunnel end plate (4) and firewall (1) with Ø 6.5x12.5 rivet (areas F2 ).
    G15300143Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 

  17. Firewall (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area G).
  18. Firewall (1) SHIELDED GAS SEAM WELD (areas H and I).

    IMPORTANT Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

  19. Grind inert gas welds down flat (areas H and I).

    IMPORTANT Grind down flat only at beaded areas and contact surfaces on firewall crossmember (3) and windshield crossmember (2).

  20. Clean welds no longer accessible after installing firewall crossmember (3) and windshield crossmember (2) and coat with zinc dust paint.
  21. Install firewall crossmember (3), fit and fix in place.
  22. Drill Ø 6.7 mm rivet holes in firewall crossmember (3) (areas J and K).

    IMPORTANT Drill rivet holes through present rivet holes in firewall crossmember (3) (area J).

  23. Remove firewall crossmember (3).
  24. Deburr rivet holes on firewall crossmember (3) and body on both sides.
  25. Remove drilling chips.

    Shown on MODEL 222 

    G15300144Courtesy of MERCEDES-BENZ USA
  26. Apply 2-component adhesive to body in crosshatched areas.

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

    Shown on MODEL 222 

    G15300145Courtesy of MERCEDES-BENZ USA
  27. Install firewall crossmember (3) and fix in place.
  28. Rivet firewall crossmember (3) with Ø 6.5x12.5 rivets (areas L).
  29. Firewall crossmember (3) SHIELDED GAS SEAM WELD (areas M and N).

    IMPORTANT Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

  30. Grind inert gas weld down flat (area M).

    Shown on MODEL 222 

    G15300146Courtesy of MERCEDES-BENZ USA
  31. Install firewall crossmember section (5), fit and fix in place.
  32. Drill Ø 6.7 mm rivet holes on firewall crossmember section (5) (areas O, P and Q).

    IMPORTANT Drill rivet holes through present rivet holes in firewall crossmember and firewall crossmember section (5) (areas O and P).

    IMPORTANT Drill rivet holes and countersink (area O).

  33. Remove firewall crossmember section (5).
  34. Deburr rivet holes on firewall crossmember section (5) and body on both sides.
  35. Remove drilling chips.
    G15300147Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 

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

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

    Shown on MODEL 222 

    G15300148Courtesy of MERCEDES-BENZ USA
  37. Install firewall crossmember section (5) and fix in place.
  38. Rivet firewall crossmember section (5) with Ø 6.4x12 rivets (area R).
  39. Rivet firewall crossmember section (5) with Ø 6.4x14 countersunk head rivets (area S).
  40. Firewall crossmember section (5) SHIELDED GAS SEAM WELD (areas T1 and T2 ).

    IMPORTANT Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

    G15300149Courtesy of MERCEDES-BENZ USA
  41. Grind inert gas welds down flat (areas T1 ).

    Shown on MODEL 222 

    G15300150Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 

  42. Install windshield crossmember (2), fit and fix in place.
  43. Drill Ø 6.7 mm rivet holes in windshield crossmember (2) (area U1 ).

    Only if a riveter for punching and flow form rivets is not used for installation.

    IMPORTANT Transfer position of present rivet holes in body to new part.

  44. Drill Ø 6.7 mm rivet holes in windshield crossmember (2) (area U2 ).

    IMPORTANT Transfer position of present rivet holes in body to new part.

  45. Drill Ø 6.7 mm rivet holes in windshield crossmember (2) (area U3 and U4 ).
  46. Remove windshield crossmember (2).
  47. Deburr rivet holes in windshield crossmember (2) and body on both sides.
  48. Remove drilling chips.
    G15300151Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 

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

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

    G15300152Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 

  50. Install windshield crossmember (2) and fix in place.
  51. Rivet windshield crossmember (2) with Ø 6.5x12.5 rivets (area V1 ).

    IMPORTANT Flow form rivets with a clamping range of 3.35 mm to 4.1 "S2" can be used, if a riveter for punching and flow form rivets is used for installation.

  52. Rivet windshield crossmember (2) with Ø 6.5x12.5 rivets (areas V2 and V3 ).
  53. Windshield crossmember (2) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas W).
  54. Windshield crossmember (2) SHIELDED GAS SEAM WELD (areas X and Y).

    IMPORTANT Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion.

  55. Grind inert gas welds down flat (areas X).
scientia non olet · About LEMON Manuals