Remove/install exhaust system

AR49.10-P-7142MRH

Remove/install exhaust system

12.12.2018

Engine

264 in model 213, 238, 257

Modification notes

16.11.2018

Method description for gasoline particulate filter revised.

Operation steps 5, 6, 9, 14 added.

23.11.2018

Repair materials added.

Operation steps 12, 15.

Shown on engine 264 in model 238 except code 598 (Gasoline particulate filter (GPF) with sensor system)

1

Clip

4

Elastomer bearing

2

Bracket

M16/53

Left exhaust flap actuator motor

3

Exhaust system

Shown on engine 264 in model 238 with code 598 (Gasoline particulate filter (GPF) with sensor system)

1

Clip

5

Union nuts

2

Bracket

6

Screw

3

Exhaust system

B163/4

Temperature sensor upstream of gasoline particulate filter

4

Elastomer bearing

M16/53

Left exhaust flap actuator motor

 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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Remove center and rear sections of lower engine compartment lining.

Engine 264 in model 213, 238

AR61.20-P-1105LWE

Engine 264 in model 257

AR61.20-P-1105FR

 Installation: Only install center and rear lower rear engine compartment paneling again after leak test.

2

Remove left and right underfloor paneling.

Engine 264 in model 213, 238

AR61.30-P-1001LWE

Engine 264 in model 257

AR61.30-P-1001FR

3

Remove rear diagonal struts.

Engine 264 in model 213.2, 238.4

AR61.10-P-5142LWP

4

Remove rear reinforcement.

 Bolt, rear reinforcement to frame floor assembly

*BA61.10-P-1004-01L

5

Remove temperature sensor upstream of gasoline particulate filter (B163/4) and place to one side.

Engine 264 in model 213, 238, 257
with code 598 (Gasoline particulate filter (OPF) with sensor system)

AR07.04-P-0070MRH

6

Unscrew union nuts (5) and place lines to one side.

Engine 264 in model 213, 238, 257
with code 598 (Gasoline particulate filter (OPF) with sensor system)

 Installation: Coat thread with heat-resistant lubricating paste.

Paste, hot lubrication 1 kg, DBL 6879.20

*BR00.45-Z-1005-06A

 Union nut, line, differential pressure sensor, gasoline particulate filter

*BA07.04-P-1003-02B

 Box wrench bit

*000589700300

7

Disconnect electrical connector at left exhaust gas flap actuator motor (M16/53).

8

Support exhaust system(3).



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

9

Unscrew screw/bolt (6).

Engine 264 in model 213, 238, 257
with code 598 (Gasoline particulate filter (OPF) with sensor system)

 Engine 264 in model 213, 257
with code 598 (Gasoline particulate filter (OPF) with sensor system)Screw, bracket of pressure line to gasoline particulate filter

*BA49.10-P-1017-02P

 Engine 264 in model 238
with code 598 (Gasoline particulate filter (OPF) with sensor system)Screw, bracket of pressure line to gasoline particulate filter

*BA49.10-P-1016-02M

10

Remove clamp(1).

 Installation: Replace clamp(1).

 Engine 264 in model 238Bolt, exhaust system clamp to catalytic converter

*BA49.10-P-1002-02M

 Engine 264 in model 213, 257Clamp at catalytic converter and front exhaust system

*BA49.10-P-1002-02P

11

Unscrew nut of decoupling element from bracket (2).

 Engine 264 in model 213, 257Nut, decoupling element for front exhaust system to bracket

*BA49.10-P-1010-02P

 Engine 264 in model 238Nut, decoupling element for front exhaust system to bracket

*BA49.10-P-1008-02M

12

Remove elastomer bearings(4) from exhaust system (3).

 Installation: Lightly wet elastomer bearings (4) with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

13

Remove exhaust system (3).



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Helper required.



Check

14

Check decoupling element for damage and wear.

If complaints are present,



Replace decoupling element.

 Engine 264 in model 213, 257Nut, decoupling element for front exhaust system to bracket

*BA49.10-P-1010-02P

 Engine 264 in model 238Nut, decoupling element for front exhaust system to bracket

*BA49.10-P-1008-02M

15

Check elastomer bearings (4) for damage and wear.

If complaints are present,



Replace elastomer bearing(4).

 Installation: Lightly wet elastomer bearings (4) with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A



Clean

16

Remove combustion and corrosion residues from separating points.

17

Install in the reverse order.

18

Check installation position and for unobstructed movement of exhaust system (3).

If complaints are present,



Correct installation position of exhaust system (3).

 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

19

Perform engine test run and check exhaust system(3) for leak tightness.

20

Install center and rear lower engine compartment lining.

Engine 264 in model 213, 238

AR61.20-P-1105LWE

Engine 264 in model 257

AR61.20-P-1105FR

 Sensors

Number

Designation

Engine 264

BA07.04-P-1003-02B

Union nut, line, differential pressure sensor, gasoline particulate filter

Nm

20

 Exhaust system

Number

Designation

Model 238 with engine 264

BA49.10-P-1002-02M

Bolt, exhaust system clamp to catalytic converter

Nm

22

 Exhaust system

Number

Designation

Model 213 with engine 264

Model 257 with engine 264

BA49.10-P-1002-02P

Clamp at catalytic converter and front exhaust system

Nm

25

25

 Exhaust system

Number

Designation

Model 238 with engine 264

BA49.10-P-1008-02M

Nut, decoupling element for front exhaust system to bracket

Nm

20

 Exhaust system

Number

Designation

Model 213 with engine 264

Model 257 with engine 264

BA49.10-P-1010-02P

Nut, decoupling element for front exhaust system to bracket

Nm

20

20

 Exhaust system

Number

Designation

Model 238 with engine 264

BA49.10-P-1016-02M

Screw, bracket of pressure line to gasoline particulate filter

Nm

5

 Exhaust system

Number

Designation

Model 213 with engine 264

Model 257 with engine 264

BA49.10-P-1017-02P

Screw, bracket of pressure line to gasoline particulate filter

Nm

5

5

 Frame floor assembly

Number

Designation

Model 213

Model 238

BA61.10-P-1004-01L

Bolt, rear reinforcement to frame floor assembly

Nm

24

24

 Frame floor assembly

Number

Designation

Model 257

BA61.10-P-1004-01L

Bolt, rear reinforcement to frame floor assembly

Nm

24

Repair materials

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DBL 6879.20

A 000 989 76 51

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67