Remove/install exhaust system

AR49.10-P-7142MSA

Remove/install exhaust system

09.11.2018

Engine

256 in model 213, 238, 257, 290

1

Clip

4

Elastomer bearing

2

Nut

M16/53

Left exhaust flap actuator motor

3

Exhaust system

M16/54

Right exhaust flap actuator motor

 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

 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

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

Remove center and rear lower engine compartment lining.

Engine 256.9 in model 213, 238

AR61.20-P-1105LWE

Engine 256.9 in model 257

AR61.20-P-1105FR

Engine 256.9 in model 290

AR61.20-P-1105FRX

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

2

Remove left and right underfloor paneling.

Engine 256.9 in model 213, 238

AR61.30-P-1001LWE

Engine 256.9 in model 257, 290

AR61.30-P-1001FR

3

Remove center reinforcement.

 Bolt, center reinforcement to frame floor assembly

*BA61.10-P-1003-01L

4

Remove rear diagonal struts.

Engine 256 in model 213.2, 238.4, 290

Engine 256 in model 290

AR61.10-P-5142FRX

Engine 256 in model 238.4

AR61.10-P-5142LWP

5

Release and disconnect left exhaust gas flap actuator motor electrical connector (M16/53) and place electric line to one side.

Engine 256.9 in model 213, 238, 257, 290
with code U78 (AMG sports exhaust system)

6

Release and disconnect right exhaust gas flap actuator motor electrical connector (M16/54) and place electric line to one side.

Engine 256.9 in model 213, 238, 257, 290
with code U78 (AMG sports exhaust system)

7

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

8

Remove clamp(1).

 Installation: Replace clamp(1).

 Clamp at catalytic converter and front exhaust system

*BA49.10-P-1002-02P

9

Unbolt nut (2).

 Nut, decoupling element for front exhaust system to bracket

*BA49.10-P-1010-02P

10

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

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

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

11

Remove the 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

 Aid of helper required.

12

Remove front bracket of exhaust system(3).

When replacing the exhaust system(3).

 Screw, bracket for decoupling element to front exhaust system

*BA49.10-P-1009-02P



Check

13

Check elastomer bearings(4) and front decoupling element for damage and wear and replace if necessary.

 Nut, decoupling element for front exhaust system to bracket

*BA49.10-P-1010-02P



Clean

14

Remove combustion and corrosion residue at connecting points.

15

Install in the reverse order.

16

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

17

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

18

Install center and rear lower engine compartment lining.

Engine 256.9 in model 213, 238

AR61.20-P-1105LWE

Engine 256.9 in model 257

AR61.20-P-1105FR

Engine 256.9 in model 290

AR61.20-P-1105FRX

 Exhaust system

Number

Designation

Model 213 with engine 256

Model 238 with engine 256

BA49.10-P-1002-02P

Clamp at catalytic converter and front exhaust system

Nm

25

25

 Exhaust system

Number

Designation

Model 257 with engine 256

Model 290 with engine 256

BA49.10-P-1002-02P

Clamp at catalytic converter and front exhaust system

Nm

25

25

 Exhaust system

Number

Designation

Model 213 with engine 256

Model 238 with engine 256

BA49.10-P-1009-02P

Screw, bracket for decoupling element to front exhaust system

Nm

20

20

 Exhaust system

Number

Designation

Model 257 with engine 256

Model 290 with engine 256

BA49.10-P-1009-02P

Screw, bracket for decoupling element to front exhaust system

Nm

20

20

 Exhaust system

Number

Designation

Model 213 with engine 256

Model 238 with engine 256

BA49.10-P-1010-02P

Nut, decoupling element for front exhaust system to bracket

Nm

23

23

 Exhaust system

Number

Designation

Model 257 with engine 256

Model 290 with engine 256

BA49.10-P-1010-02P

Nut, decoupling element for front exhaust system to bracket

Nm

20

20

 Frame floor assembly

Number

Designation

Model 213

Model 238

BA61.10-P-1003-01L

Bolt, center reinforcement to frame floor assembly

M10

Nm

23

23

M6

Nm

8

8

 Frame floor assembly

Number

Designation

Model 257

Model 290

BA61.10-P-1003-01L

Bolt, center reinforcement to frame floor assembly

M10

Nm

23

23

M6

Nm

8

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67