Removing and installing complete exhaust system

AR49.10-P-7000PI

Removing and installing complete exhaust system

11.3.10

 

Remove/Install

Danger!

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

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

AS00.00-Z-0010-01A

 Danger!

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

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

AS00.00-Z-0002-01A

 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 engine

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

AS00.00-Z-0005-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove bottom sections of sound-proofing capsule

AR94.30-P-5300P

2

Remove catalytic converter

AR49.10-P-5500PI



Notes on disposing of catalytic converters

OS49.10-P-1000-01A

3

Remove precatalytic converter

AR49.10-P-5510PI



Notes on disposing of catalytic converters

OS49.10-P-1000-01A

4.1

Unscrew temperature sensor and pressure lines at diesel particulate filter

Only with particulate filter code 474

AR14.40-P-1000PI

 Do not disconnect diesel particulate filter from the rear muffler (2).

 Union nut of pressure line to diesel particulate filter

*BA14.40-P-1002-01B

Bolt, clamp plate pressure lines

*BA14.40-P-1003-01B

Nut, diesel particulate filter to bracket

*BA14.40-P-1005-01B

5

Unscrew nuts (1) at exhaust system bracket

 Installation: Replace nuts (1).

 Nut of front exhaust system to bracket

*BA49.10-P-1001-01V

6

Unhinge exhaust system at exhaust rubber mounts (arrows)

 Have a second person assist you.

 Installation: Check exhaust rubber mounts (arrows) for wear and replace if necessary. Coat exhaust rubber mounts (arrows) with liquid lubricant.

Hook wrench

Lubricant

*BR00.45-Z-1002-06A

7.1

Remove rear muffler (2) with diesel particulate filter

Only with particulate filter code 474

 Have a second person assist you.



Notes on the disposal of diesel particulate filters

OS49.10-P-1000-02A

7.2

Remove rear muffler (2) with center exhaust pipe

Except Code 474 Particulate Filter

 Have a second person assist you.

8

Install in the reverse order



Check

9

Inspect installation position and clearance of exhaust system

 The exhaust system must be mounted free of tension, align exhaust system if necessary.

10

Start engine and inspect exhaust system for leaks.

Number

Designation

Engine
642
with code 474

BA14.40-P-1002-01B

Union nut of pressure line to
diesel particulate filter

Nm

20

BA14.40-P-1003-01B

Bolt, clamp plate pressure lines

Nm

5

BA14.40-P-1005-01B

Nut, diesel particulate filter to bracket

Nm

20

Number

Designation

Engine 642 in model 203, 209

BA49.10-P-1001-01V

Nut of front exhaust system to bracket

Nm

20

Number

Designation

Order number

BR00.45-Z-1002-06A

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

A 000 989 01 60