Remove/install firewall bottom section

AR62.25-P-5752FF

Remove/install firewall bottom section

19.03.2019

Model

454.0

1

Center firewall lower section



Remove

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

1

Remove detachable parts in the repair area

2

Cover all detachable parts remaining in vehicle (area to be repaired)


Use fire-resistant tarps
To prevent damage as a result of flying sparks.

3

Position body on the straightening bench, check, and straighten if necessary

AR60.10-P-0100FF

4

Partially remove bottom left and right firewall

AR62.25-P-1100FF

5

Remove cross member

AR62.30-P-1352FF

6

Remove center firewall lower section (1)

AR62.25-P-1100-01FG

7

Prepare center firewall lower section (1) for installation

AR62.25-P-1100-02FG

Notes on replacing body parts

AH60.00-P-0027-01FF

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

8

Prepare connecting points on the body for the installation of the center firewall lower section (1)

AR62.10-P-1000-03FF

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

9

Set up Car-O-Flex holding system for the installation of the center firewall lower section (1)

 Determine positioning of the Car-O-Flex holding system with the Car-O-Tronic measuring system.



Install

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

10

Install center firewall lower section (1)

AR62.25-P-1100-03FG

Topical note

Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-N-0005-01A

11

Clean weld joints and metal flanges with a wire brush and clean repair areas

12

Prime repair area using primer filler

13

Supply standard seam seals with body sealant

AR97.10-P-4000FF

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

14

Supplement standard underbody protection with permanent underfloor protection

Underfloor protection 800 ml

*BR00.45-Z-1001-05A

15

Paint repair area adjacent surfaces

16

Partially install bottom left and right firewall

AR62.25-P-1100FF

17

Install cross member

AR62.30-P-1352FF

18

Remove Car-O-Flex holding system

19

Take body off the straightening bench and remove straightening bench

AR60.10-P-0100FF

AR60.10-P-0100FG

AR60.10-P-0100FH

AR60.10-P-0100FJ

20

Reinstall all removed assembly parts

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-05A

Underfloor protection 800 ml

A 001 986 46 10

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

A 000 986 34 42

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20