Remove/install exhaust system complete

AR49.10-P-7000TX

Remove/install exhaust system complete

21.10.11

21.10.08

Value changed: bolt, clamp for exhaust gas recirculation to catalytic converter

Engine 272 in model 219

*BA49.10-P-1008-01R

 

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 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

 Danger!

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

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

AS00.00-Z-0010-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

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 electrical connectors (G3/3x1, G3/4x1, G3/5x1, G3/6x1) and electrical lines for O2 sensors from retaining clamps

5

Disconnect the electrical connectors (G3/3x1, G3/4x1, G3/5x1, G3/6x1) of O2 sensors

6

Remove left and right NOX sensor (nitrogen oxides) (N37/5b1, N37/6b1) from exhaust pipes

Engine 272.985

AR07.70-P-0001TX

7

Remove left and right temperature sensor upstream of NOX storage catalytic converter (B16, B16/1) from exhaust pipes

Engine 272.985

AR07.70-P-0002TX

8

Remove left and right exhaust gas recirculation line (43, 43/1) from exhaust pipes

Engine 272.985



*BA49.10-P-1008-01R

9

Detach the catalytic converter brackets (2, 3) from transmission



*BA49.10-P-1006-01R

10

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

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

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

11

Detach catalytic converters (5, 6) from exhaust manifolds by unscrewing bolts (7, 8)

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



*BA49.10-P-1001-01R

12

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).

Lubricant paste

*BR00.45-Z-1002-06A

13

Lower exhaust system (4) and remove it completely

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

14

Install in the reverse order



Checking

15

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

16

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

Number

Designation

Model
219

BA62.30-P-1001-01C

Bolt, crossmember to body

Nm

25

Number

Designation

Engine
272
in model
219

Engine
273
in model
219

BA49.10-P-1001-01R

Bolt, catalytic converter to exhaust manifold

Nm

20

20

BA49.10-P-1006-01R

Bolt, catalytic converter bracket to transmission

Nm

20

20

BA49.10-P-1008-01R

Bolt, exhaust gas recirculation hose clamp to catalytic converter

Nm

9

-

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