Remove/install exhaust system

AR49.10-P-7142MNL

Remove/install exhaust system

13.03.2018

Engine

176 in model 217, 222

Shown on model 222 with engine 176

1

Exhaust system

13

Strut

2

Clip

14

Strut

3

Clip

17

Elastomer bearing

4

Elastomer bearing

M16/53

Left exhaust flap actuator motor

10

Reinforcement

M16/54

Right exhaust flap actuator motor

11

Elastomer bearing

Shown on model 217.483 with engine 176

1

Exhaust system

17

Elastomer bearing

2

Clip

20

Struts

3

Clip

21

Struts

4

Elastomer bearing

M16/53

Left exhaust flap actuator motor

10

Reinforcement

M16/54

Right exhaust flap actuator motor

11

Elastomer bearing

 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

 Caution

Risk of injury caused by scraping 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

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-P-5000-01A

 

Remove/install

1

Raise vehicle

AR00.60-P-1000LF

2

Remove cover under trunk recess

Model 217 with engine 176

3

Detach side underfloor panelings in area of respective struts (13, 14, 20, 21)

AR61.30-P-1001LF

4

Remove struts (20, 21)

Engine 176 in model 217.483

 Screw/bolt, rear diagonal strut to bracket (to stop plate)

*BA61.10-P-1016-01K

 Screw/bolt, center diagonal strut to center diagonal strut

*BA61.10-P-1015-01K

 Screw/bolt, center diagonal strut to body/reinforcement

*BA61.10-P-1014-01K

 Screw/bolt, rear diagonal strut to bracket/spare wheel well

*BA61.10-P-1009-01K

 Screw/bolt, rear diagonal strut to body

*BA61.10-P-1008-01K

5

Remove struts (13, 14)

Model 222 with engine 176

 Nut, rear diagonal strut to stop plate

*BA61.10-P-1010-01K

 Screw/bolt, rear diagonal strut to bracket/spare wheel well

*BA61.10-P-1009-01K

 Screw/bolt, rear diagonal strut to body

*BA61.10-P-1008-01K

6

Remove reinforcement (10)

 Screw/bolt, rear reinforcement to frame floor assembly

*BA61.10-P-1004-01K

7

Release and disconnect electrical connectors at right exhaust gas flap actuator motor   (M16/54) and left exhaust gas flap actuator motor (M16/53)

8

Open clamps (2, 3)

 Installation:
Exhaust system (1) must be aligned so that it is free of tension before tightening screw connections.
Leaks in exhaust system (1) can otherwise occur.

 Installation: Replace clamps (2, 3).

 Clamp, front exhaust system to center exhaust system

*BA49.10-P-1008-02N

9

Remove elastomer bearings (4, 11, 17) from exhaust system (1)

10

Remove exhaust system (1) in downward direction

 Aid of helper required.

11

Check elastomer bearings (11, 17) for wear and damage

In case of a complaint



Replace relevant elastomer bearings (11, 17).

 Installation: Wet elastomer bearings (11, 17) with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

12

Check elastomer bearing (4) for wear and damage

In case of a complaint



Replace elastomer bearing (4).

 Installation: Wet elastomer bearing (4) with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

 Bolt, cross connection to engine carrier

*BA49.10-P-1007-02N

 Nut, cross connection for exhaust system left to right

*BA49.10-P-1006-02N

13

Remove combustion and corrosion residue at separating points

14

Install in the reverse order



Check

15

Check installation position and clearance of exhaust system (1) and correct if necessary

 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

16

Perform engine test run; as part of this check exhaust system (1) for leaks

 Exhaust system

Number

Designation

Model 217, 222 with engine 176

BA49.10-P-1006-02N

Nut, cross connection for exhaust system left to right

Nm

20

 Exhaust system

Number

Designation

Model 217, 222 with engine 176

BA49.10-P-1007-02N

Bolt, cross connection to engine carrier

Nm

20

 Exhaust system

Number

Designation

Model 217, 222 with engine 176

BA49.10-P-1008-02N

Clamp, front exhaust system to center exhaust system

Nm

35

 Frame floor assembly

Number

Designation

Model 217

Model 222.0/1/9

BA61.10-P-1004-01K

Screw/bolt, rear reinforcement to frame floor assembly

Nm

50

50

 Frame floor assembly

Number

Designation

Model 217

Model 222.0/1/9

BA61.10-P-1008-01K

Screw/bolt, rear diagonal strut to body

Nm

50

50

 Frame floor assembly

Number

Designation

Model 217

Model 222.0/1/9

BA61.10-P-1009-01K

Screw/bolt, rear diagonal strut to bracket/spare wheel well

Nm

50

50

 Frame floor assembly

Number

Designation

Model 222.0/1/9

BA61.10-P-1010-01K

Nut, rear diagonal strut to stop plate

Nm

50

 Frame floor assembly

Number

Designation

Model 217

BA61.10-P-1014-01K

Screw/bolt, center diagonal strut to body/reinforcement

Nm

50

 Frame floor assembly

Number

Designation

Model 217

BA61.10-P-1015-01K

Screw/bolt, center diagonal strut to center diagonal strut

Nm

17

 Frame floor assembly

Number

Designation

Model 217

BA61.10-P-1016-01K

Screw/bolt, rear diagonal strut to bracket (to stop plate)

Nm

50

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67