Remove firewall half - AR62.25-P-1110-01CW

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

Fig 1: Firewall Half Crossmember Spot Weld Area

Courtesy of MERCEDES-BENZ USA

Dimension:

The following operation steps are shown on model 204.0.

Mark separation point on crossmember below windshield (1) (area A).
Cut crossmember below windshield (1) at separation point (area A).
Expose spot welds on crossmember below windshield (1) and firewall half (4) (areas B, C and D).
Mill off spot welds on crossmember below windshield (1) and firewall half (4) (areas B, C and D).

Fig 2: Firewall Half Spot Weld Areas
Courtesy of MERCEDES-BENZ USA
Expose spot welds on firewall half (4) (areas E and F).
Mill off spot welds on firewall half (4) (areas E and F).

Fig 3: Firewall Half And Crossmember Spot Weld Areas
Courtesy of MERCEDES-BENZ USA
Expose spot welds on firewall half (4) and firewall crossmember (5) (areas G, H, I, J, K, L, M, N and O).
Mill off spot welds on firewall half (4) and firewall crossmember (5) (areas G, H, I, J, K, L, M, N and O).
Heat firewall half (4) and firewall crossmember (5) in crosshatched areas.
Cross-hatched areas are bonded.
Remove firewall half (4), firewall crossmember (5) and crossmember below windshield (1).
Grind mating surfaces on body down to bare metal in cross-hatched areas.
Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas P, Q, R and S).

Observe pretreatment of bonding surfaces (areas P, Q, R and S).
Remove shavings and drill chips.

Fig 4: Firewall Half Cross-Hatched Areas (P, Q, R And S)
Courtesy of MERCEDES-BENZ USA