Remove/install exhaust system complete

AR49.10-P-7000TY

Remove/install exhaust system complete

17.10.11

 

Remove/install

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Danger!

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



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

Danger!

Risk of death caused by vehicle slipping or toppling off of the vehicle lift.

Align vehicle between vehicle lift columns and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

1

Raise vehicle

AR00.60-P-1000TX

2

Detach rear section of lower engine compartment paneling

 Installation: Install engine compartment paneling only after engine test run.

AR61.20-P-1105TX

3

Remove crossmember (1)



*BA62.30-P-1001-01C

4

Unclip connector for left O2 sensor, upstream CAT (G3/3x1), connector for right O2 sensor, upstream CAT (G3/4x1), connector for left O2 sensor, downstream CAT (G3/5x1) and connector for right O2 sensor, downstream CAT (G3/6x1) from retaining clamps

5

Disconnect electrical connectors for O2 sensors

6

Remove catalytic converter bracket (2) and catalytic converter bracket (3) from transmission



*BA49.10-P-1006-01R

7

Support exhaust system (4) with a transmission jack and a transmission platform

Transmission jack
gotis://H_00.10_01.0

Transmission platform for passenger cars and commercial vehicles

gotis://A_25/35/49_02.0

8

Remove left catalytic convertor (5) and right catalytic convertor (6) from exhaust manifolds by undoing bolts (7, 8)

 Installation: Clean combustion and corrosion residues from connecting points and replace bolts (7, 8).



*BA49.10-P-1001-01R

9

Unhook exhaust system (4) from exhaust rubber mounts (9)

 To simplify removal:

Apply liquid lubricant to retaining brackets (10) and on holes of exhaust rubber mounts (9).

 Installation: Use liquid lubricant.

Lubricant paste

*BR00.45-Z-1002-06A

10

Lower exhaust system (4) and remove it completely

 Installation: Check exhaust rubber mounts (9) for wear and damage; replace if required.

11

Install in the reverse order



Checking

12

Check installation position and unobstructed movement of exhaust system (4)

 The exhaust system (4) must be mounted free of tension; align exhaust system (4) if required.

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

13

Conduct engine test run and inspect exhaust system (4) for leaks

Number

Designation

Model
219

BA62.30-P-1001-01C

Screw/bolt, crossmember to body

Nm

25

Number

Designation

Engine
113
in model
219

Engine
156
in model
219

BA49.10-P-1001-01R

Screw/bolt, catalytic converter to exhaust manifold

Nm

20

20

BA49.10-P-1006-01R

Screw/bolt, catalytic converter bracket to transmission

Nm

20

20

Number

Designation

Order number

BR00.45-Z-1002-06A

Antifriction paste, rubber parts 2.5 kg, DB supply specification 6867.00

A 000 989 01 60