Remove/install exhaust system

AR49.10-P-7142MRT

Remove/install exhaust system

05.12.2018

Engine

256.9, 264 in model 222

Modification notes

23.11.2018

Operation step added.

Operation step 11.

Shown on engine 256.9

1

Exhaust system

5

Elastomer bearing

2

Clip

6

Elastomer bearing

3

Screw

M16/53

Left exhaust flap actuator motor

4

Elastomer bearing

M16/54

Right exhaust flap actuator motor

Shown on engine 264

1

Exhaust system

5

Elastomer bearing

2

Clip

6

Elastomer bearing

3

Screw

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

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

 

Remove/install

1

Remove center and lower rear engine compartment linings.

AR61.20-P-1105LF

 Installation: Do not install the center and lower rear engine compartment paneling until after a leaktightness test.

2

Release side underfloor panelings in area of diagonal struts at rear frame floor assembly.

AR61.30-P-1001LF

3

Remove rear diagonal strut.

Engine 256.9, 264 in model 222
with code 398 (Panoramic roof with MAGIC SKY CONTROL)
with code 413 (Automatic panoramic sliding sunroof)

 Screw/bolt, rear diagonal strut to body

*BA61.10-P-1008-01K

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

*BA61.10-P-1009-01K

 Nut, rear diagonal strut to stop plate

*BA61.10-P-1010-01K

4

Remove rear reinforcement.

 Screw/bolt, rear reinforcement to frame floor assembly

*BA61.10-P-1004-01K

5

Disconnect electrical connector of right exhaust gas flap actuator motor (M16/54) and unclip electric line.

Engine 256.9 in model 222

6

Disconnect electrical connector of left exhaust gas flap actuator motor (M16/53) and unclip electric line.

7

Support exhaust system(1).



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

8

Remove clamp (2).

 Installation: Replace clamp (2).

 Clamp, gasoline particulate filter/center exhaust system connecting point to catalytic converter

*BA49.10-P-1006-02MRT

9

Remove exhaust system (1) from elastomer bearings (5).

 Wet elastomer bearings (5) with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

10

Remove exhaust system (1) from elastomer bearings (4).

Engine 256.9 in model 222

 Wet elastomer bearing (4) with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

11

Remove bolt (3) .

 Holder, decoupling element/gasoline particulate filter/center exhaust system

*BA49.10-P-1007-02MRT

12

Remove exhaust system (1) from elastomer bearings (6) and remove.

 Helper required.

 Installation: Wet elastomer bearings(6) with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A



Check

13

Check decoupling element for damage and wear.

If complaints are present,



Replace decoupling element.

 Holder, decoupling element/gasoline particulate filter/center exhaust system

*BA49.10-P-1007-02MRT

14

Check elastomer bearings (5, 6) for wear and damage.

If complaints are present,



Install new elastomer bearings (5, 6).

 Installation: Wet elastomer bearings (5, 6) slightly with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

15

Check elastomer bearings (4) for wear and damage.

Engine 256.9 in model 222

If complaints are present,



Replace elastomer bearing (4).

 Installation: Wet elastomer bearings (4) slightly 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.



Check

18

Check installation position and clearance of the exhaust system (1).

If complaints are present,



Correct the installation position of exhaust system (1).

 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 (1) for leaks.

20

Install center and rear lower engine compartment lining.

AR61.20-P-1105LF

 Exhaust system

Number

Designation

Engine 256.9 in model 222

Engine 264 in model 222

BA49.10-P-1006-02MRT

Clamp, gasoline particulate filter/center exhaust system connecting point to catalytic converter

Nm

25

25

 Exhaust system

Number

Designation

Engine 256.9 in model 222

Engine 264 in model 222

BA49.10-P-1007-02MRT

Holder, decoupling element/gasoline particulate filter/center exhaust system

Screw

Nm

20

20

Nut

Nm

23

23

 Frame floor assembly

Number

Designation

Model 222.0/1/9

BA61.10-P-1004-01K

Screw/bolt, rear reinforcement to frame floor assembly

Nm

50

 Frame floor assembly

Number

Designation

Model 222.0/1/9

BA61.10-P-1008-01K

Screw/bolt, rear diagonal strut to body

Nm

50

 Frame floor assembly

Number

Designation

Model 222.0/1/9

BA61.10-P-1009-01K

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

Nm

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

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67