Remove/install exhaust system

AR49.10-P-7142OLI

Remove/install exhaust system

03.09.2019

Engine

654 in model 205, 253

Modification notes

03.09.2019

Document completely revised.

Shown on model 205.4

7

Cover

9

Underfloor paneling

11

Bottom engine compartment linings

8

Diagonal strut

10

Reinforcement

Shown on engine 654 without code M014 (uprated engine)

1

Exhaust system

4

Elastomer bearing

2

Clip

5

Decoupling element

3

Bolts

M16/57

Exhaust flap controller

Shown on model 253 with engine 654 without code M014 (uprated engine)

1

Exhaust system

4

Elastomer bearing

2

Clip

5

Decoupling element

3

Bolts

M16/57

Exhaust flap controller

Shown on engine 654 with code M014 (uprated engine)

12

Bracket

13

Bracket

 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

Remove bottom engine compartment linings (11).

AR61.20-P-1105LW

 Installation: Install bottom engine compartment linings (11) only after the leak test.

2

Remove underfloor panelings (9).

AR61.30-P-1001LW

3

Remove reinforcement (10).

 Bolt, rear reinforcement to frame floor assembly

*BA61.10-P-1004-01L

4

Remove cover (7).

Engine 654 in model 205.4, 253

5

Remove diagonal strut (8).

Engine 654 in model 205.4

 Bolt, rear diagonal strut to spare wheel well/body

*BA61.10-P-1008-01L

6

Remove bracket (12).

Engine 654 in model 205, 253
with code M014 (Engine uprated)

 M81

*BA00.10-P-1004-04A

7

Remove NOx sensor downstream of SCR catalytic converter (N37/8b1) from exhaust system (1).

AR49.20-P-2062OLI

8

Release and disconnect electrical connector of the exhaust gas flap controller (M16/57).

9

Support exhaust system (1).



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

10

Remove screws/bolts (3).

 Installation: Replace screws/bolts (3).

 Bolt, bracket for decoupling element to body/exhaust system at front

*BA49.10-P-1011-02H

11

Open clamp (2).

 Installation: Replace clamp (2) and seal.

 Clamp to diesel particulate filter and front exhaust system

*BA49.10-P-1003-02H

12

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

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

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

13

Remove exhaust system (1).



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.



Check

14

Check elastomer bearings (4) and decoupling element (5) for wear and damage.

If complaints are present,



replace elastomer bearings (4) and decoupling element (5).

 Nut, decoupling element for front exhaust system to bracket

*BA49.10-P-1012-02H

15

Modify bracket (13).

Engine 654 in model 205, 253
with code M014 (Engine uprated)
When replacing exhaust system (1).

 M81

*BA00.10-P-1004-04A

16

Change decoupling element (5).

When replacing exhaust system (1).

 Bolt, bracket for decoupling element to body/exhaust system at front

*BA49.10-P-1011-02H

17

Change the exhaust gas flap controller (M16/57).

When replacing exhaust system (1).

Engine 654 in model 205

AR14.20-P-1035OLI

Engine 654 in model 253

AR49.10-P-5507OLI



Clean

18

Remove combustion and corrosion residue at connecting points.

19

Install in the reverse order.

20

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

21

Perform engine test run and check leaktightness of exhaust system (1).

22

Install bottom engine compartment linings (11).

AR61.20-P-1105LW

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1004-04A

M81

Nm

23

33

 Exhaust system

Number

Designation

Model 205 with engine 654

Model 253 with engine 654

BA49.10-P-1003-02H

Clamp to diesel particulate filter and front exhaust system

Nm

14

14

 Exhaust system

Number

Designation

Model 205 with engine 654

Model 253 with engine 654

BA49.10-P-1011-02H

Bolt, bracket for decoupling element to body/exhaust system at front

M8

Nm

20

20

M10

Nm

50

-

 Exhaust system

Number

Designation

Model 205 with engine 654

Model 253 with engine 654

BA49.10-P-1012-02H

Nut, decoupling element for front exhaust system to bracket

Nm

20

20

 Frame floor assembly

Number

Designation

Model 205

Model 253

BA61.10-P-1004-01L

Bolt, rear reinforcement to frame floor assembly

Nm

23

24

 Frame floor assembly

Number

Designation

Model 205

BA61.10-P-1008-01L

Bolt, rear diagonal strut to spare wheel well/body

Nm

70

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67