Remove/install exhaust flex pipe

AR49.10-G-8000DD

Remove/install exhaust flex pipe

13.08.2019

Engine

900.9, 902.9, 924.9, 926.9 in model 000.001

Engine

925.9 in model 000.001

Shown with BlueTEC

1

Exhaust flex pipe

2

Injection nozzle

3

Flange

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

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

AS00.00-Z-0005-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

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

AS00.00-Z-0002-01A

Topical note

Assembly notes for flexible exhaust pipes

AH49.10-N-0302-01H

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H



Remove

1

Disconnect ground line on battery.

 See information from body manufacturer.

2

Remove injection nozzle (2) from the flexible exhaust pipe (1).

Only for BlueTEC.

AR49.20-G-2003DD

3

Remove flexible exhaust pipe (1).

4

Remove flange (3) from the old flexible exhaust pipe (1).



Install

5

Check new flexible exhaust pipe (1) for damage.

 Visual inspection.
In particular, check the lamellae of the new flexible exhaust pipe (1). Always install an undamaged flexible exhaust pipe (1).

If damage is present:



Replace flexible exhaust pipe (1).

6

Attach flange (3) to the new flexible exhaust pipe (1).

 It is necessary to install the flange (3) before installing the flexible exhaust pipe (1) so that it is fixed and flush.

 Bolt, clamp to exhaust pipe, muffler and exhaust flex pipe

*BA49.10-N-1001-01O

7

Install new flexible exhaust pipe (1).


Install flexible exhaust pipe (1) so that it is unstressed.
Otherwise, vibrations may cause cracks.

 Replace seals.

 Bolt, clamp to exhaust pipe, muffler and exhaust flex pipe

*BA49.10-N-1001-01O

 Bolt, clamp to exhaust pipe on valve fitting for engine brake/exhaust fitting

*BA49.10-N-1002-01O

8

Install injection nozzle (2) on the flexible exhaust pipe (1).

Only for BlueTEC.

AR49.20-G-2003DD

 Replace seal.

9

Connect ground line to battery.

 See information from body manufacturer.



Check

10

Start engine.

 See information from body manufacturer.

11

Check exhaust system for leak tightness while engine is running.

 Visual inspection.

12

Switch off engine.

 Exhaust system

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9

BA49.10-N-1001-01O

Bolt, clamp to exhaust pipe, muffler and exhaust flex pipe

Nm

50

 Exhaust system

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9

BA49.10-N-1002-01O

Bolt, clamp to exhaust pipe on valve fitting for engine brake/exhaust fitting

Nm

15