Remove/install exhaust system complete

AR49.10-P-7000VT

Remove/install exhaust system complete

17.10.11

 

Remove/install

Danger!

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

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

AS00.00-Z-0010-01A

 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 from grazing 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

1

Lift/jack up vehicle

 Position arms of lift platform in such a way that bolt (3) of the rear diagonal strut (1) on the right and left is accessible.

AR00.60-P-1000V

2

Remove rear diagonal strut, (1) on the right and left

 Installation: Bolt (2) and bolt (3) of the diagonal struts may only be tightened when the vehicle is standing with its wheels on the ground.



*BA61.10-P-1005-01A

3

Remove engine compartment paneling

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

AR61.20-P-1105V

4

Unclip the connector of left O2 sensor, upstream catalytic converter (G3/3x1), connector of right O2 sensor, upstream catalytic converter (G3/4x1), connector of left O2 sensor, downstream catalytic converter (G3/5x1), connector of right O2 sensor, downstream catalytic converter (G3/6x1) and electrical lines of O2 sensors from retaining clamps, separate and loosen the cable tie

 Installation: Install new cable ties.

5

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

6

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

 Installation: Clean connecting points free of combustion and corrosion residues, replace bolts the connection may not be tight and the bolts may shear off if they are reused.

 Check rivet nuts in exhaust manifold, replace if damaged.

AR49.10-P-5531-01DA



*BA49.10-P-1009-01A

 Caulking bolt

*103589013900

7

Unhook exhaust system (4) from exhaust rubber mounts (8)

 For easier disassembly: spread lubricant on retaining bracket (9) and bores of exhaust rubber mounts.

 Check exhaust rubber mount; replace if damaged.

Lubricant paste

*BR00.45-Z-1002-06A

8

Lower exhaust system (4) and remove it completely

9

Install in the reverse order

10

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

 The exhaust system must be installed free of stress, if necessary:

Align exhaust system.

 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

11

Carry out engine test run

 Check exhaust system (4) for leaks.

Number

Designation

Model 171

BA61.10-P-1005-01A

Self-locking bolt, rear diagonal strut to frame floor

Nm

60

Number

Designation

Engine
113
in model
171

BA49.10-P-1009-01A

Bolt, flange connection to exhaust pipe/exhaust manifold

Nm

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