Remove/install exhaust system complete

AR49.10-P-7000IM

Remove/install exhaust system complete

21.10.11

 

Remove/install

Danger!

Risk of death caused by vehicle slipping or tilting 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



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

1

Remove engine trim panel

Model 215.376, 220.176

AR01.10-P-2405LA

Model 215.379, 220.179

AR01.10-P-2405IM

2

Disconnect right O2 sensor connector, upstream of CAT (G3/4x1) and left O2 sensor connector, upstream of CAT (G3/3x1) at charge air cooler (2)

3

Remove left O2 sensor connector, upstream of CAT (G3/3)

 Installation: Coat thread with heat-resistant lubricant.



*BA14.00-P-1001-01C

 Box wrench bit

*000589710300

Paste

*BR00.45-Z-1005-06A

4.1

Remove right O2 sensor connector upstream CAT]

Model 220.179, 215.379

 Installation: Coat thread with heat-resistant lubricant.



*BA14.00-P-1001-01C

 Box wrench bit

*000589710300

Paste

*BR00.45-Z-1005-06A

5

Remove lower engine compartment paneling

 Only rear part.

AR61.20-P-1105M

6

Remove steering coupling

Model 215.376, 220.176

AR46.10-P-8000I

7

Remove heat shield (13) below right catalytic converter

8

Separate right O2 sensor connector, downstream CAT (G3/6x1) and left O2 sensor connector, downstream CAT (G3/5x1) at transmission oil pan (11)

9

Support exhaust system (5) with transmission jack and transmission platform in the area of the flange connection

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

10

Remove from below bolt (3) of hose clamp (4) at turbocharger (6)

 Installation: Loosely screw on from below hose clamp (4) at turbocharger (6). Afterwards check from above correct installation position of hose clamp (4).

Recess clearance (arrow) must catch in the lug (arrow) at the turbocharger (6).

 Use emery cloth to remove combustion and corrosion residues at connection points.



*BA49.10-P-1002-01L

11

Detach catalytic converters from catalytic converter bracket (10, 12) at transmission



*BA49.10-P-1008-01L

12.1

Unhinge left and right rear muffler from exhaust rubber mounts (9/1, 9/2)

Model 220.176, 215.376

12.2

Remove screw/bolts (15) on left and right at the bracket of the exhaust rubber mount (9/2)

Model 220.179, 215.379

13

Detach reinforcement bridge (35)



*BA61.10-P-1002-01D

14

Lower transmission jack and take out exhaust system (5)

 Do not squeeze line terminals of O2 sensors. Damage to plastic parts can lead to failure of the O2 sensors.



Notes on disposing of catalytic converters

all

OS49.10-P-1000-01A



Checking

15

Check exhaust rubber mounts (9/1, 9/2) and sealing surfaces

 Check for wear, replace if required.

Lubricant paste

*BR00.45-Z-1002-06A

16

Install in the reverse order



Checking

17

Check installation position and unobstructed movement of exhaust system (5)

 The exhaust system (5) must be installed free of tension, if required:

Align exhaust system (5).

 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.

18

Conduct engine test run and check exhaust system (5) for leaks

Number

Designation

Engine
275, 285

BA14.00-P-1001-01C

O2 sensor on exhaust pipe/ exhaust manifold

Nm

50

Number

Designation

Engine 275.950

Engine 275.980

BA49.10-P-1002-01L

Bolt for catalytic converter pipe clamp on exhaust gas turbocharger

Nm

25

25

BA49.10-P-1008-01L

Self-locking nut of catalytic converter bracket to three way catalytic converter

Nm

20

20

Number

Designation

Model 220

Model 215

BA61.10-P-1002-01D

Collar bolt, rear reinforcement bridge to frame floor

Nm

23

23

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51

BR00.45-Z-1002-06A

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

A 000 989 01 60