Prepare firewall half for installation - AR62.25-P-1110-02CW

WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.

MODEL 204, 212, 207.3, 218

The following operation steps are shown on component for model 204.0.

Mark separation point on crossmember below windshield (1) (area A).
Transfer separation point from vehicle (area A).
Cut crossmember below windshield (1) at separation point (area A).
Remove remaining section from crossmember below windshield (1.1).

Fig 1: Windshield Crossmember Separation Point
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces on remaining section of crossmember below windshield (1.1) down to bare metal in crosshatched areas.
Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas B and C).

Grind spot weld flanges down to bare metal on both sides.

Observe pretreatment of bonding surfaces (areas B and C).
Grind mating surfaces on mounting console (2) and steering column tube mounting console (3) down to bare metal in crosshatched areas.
Grind spot weld flanges down to bare metal on both sides.
Coat insides of spot weld flanges with zinc dust paint.
Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (area D).

Observe pretreatment of bonding surfaces (area D).

Fig 2: Mounting Console And Steering Column Tube Mounting Console
Courtesy of MERCEDES-BENZ USA

Perform following operation steps 7, 8 and 9 only on model 212 and 218.
Expose spot welds on firewall half (4) (area E1).
Mill off spot welds on firewall half (4) (area E1).
Remove firewall half (4) from new part.

Fig 3: Firewall Half Spot Welds Area
Courtesy of MERCEDES-BENZ USA

Fig 4: Firewall Half Crosshatched Areas (E, F, G And H)
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces on firewall half (4) down to bare metal in the crosshatched areas.
Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas E, F, G and H).

Grind spot weld flanges down to bare metal on both sides.

Observe pretreatment of bonding surfaces (areas E, F, G and H).
Drill spot welds on crossmember on firewall (5) to Ø 6.5 mm (areas I, J and K).
Remove crossmember section from firewall (5.1).

Fig 5: Firewall Crossmember Spot Weld Areas (I, J And K)
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces on crossmember on firewall (5) down to bare metal in crosshatched areas.
Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas L, M and N).

Observe pretreatment of bonding surfaces (areas L, M and N).

Fig 6: Firewall Crossmember Crosshatched Areas (L, M And N)
Courtesy of MERCEDES-BENZ USA