Remove/install left exhaust manifold

AR14.10-P-3930BD

Remove/install left exhaust manifold

15.2.12

 

Remove/install

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1.1

Disconnect ground line at battery

 Installation: Code radio, clock and adjust stationary heater timer if necessary.

All models except Code 979.

AR54.10-P-0003G

Model 463.241 with code 979

AR54.10-P-0003PV

Model 463.248 with code 979

AR54.10-P-0003PM



Notes on battery

All models.

AH54.10-P-0001-01A

2

Remove engine cover with integral air filter.

 Remove by pulling vertically up and off the cylinder head covers.

3

Remove ignition coils (7) on left side.

AR15.12-P-2003A

4.1

Remove left sensor (G3/3) with its connector (G3/3x1).

M112 only

Makes it easier to remove the flange connection from the transverse exhaust pipe and left manifold.

AR14.00-P-5303AG

5

Remove the heat shield upper section (5).

 The heat shield consists off two sections bolted together.

6

Detach throttle cable from position sensor.

 M113. only

7.1

Separate the flange connection from transverse exhaust pipe (8) and left exhaust manifold (1).

 Only model 463.206/ 209/ 232/ 233/ 240/ 241.

 Installation:
If bolts (3) are hard to move or thread is damaged: 

Replace rivet nuts in exhaust manifold.

AR49.10-P-5531-01DA



*BA49.10-P-1003-01A

7.2

Disconnect flange connection from down pipe (10) and left exhaust manifold (1) en

 Only models 463.243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254.

 Installation:
If bolts (3) are hard to move or thread is damaged: 

Replace rivet nuts in exhaust manifold.

AR49.10-P-5531-01DA



*BA49.10-P-1003-01A

8

Separate connecting flange from cross-pipe (8) and left-side exhaust system.

 Only model 463.206/ 209/ 232/ 233/ 240/ 241.

 Installation:
If bolts (3) are hard to move or thread is damaged: 

Replace rivet nuts in exhaust manifold.

AR49.10-P-5531-01DA



*BA49.10-P-1003-01A

9

Unscrew retaining bolts (9) of transverse exhaust pipe (8) from the transmission



*BA49.10-P-1004-01A

10

Remove the heat shield lower section (6).

11

Remove left exhaust manifold (1)

Unscrew nuts (2) and extract exhaust manifold by lifting it upward.

*BA14.10-P-1001-01B

 Installation: Replace nuts (2), gaskets (4), studs.

12

Install in the reverse order

13

Read out fault memory with Hand-Held Tester (HHT)

Read out fault memory and erase using STAR DIAGNOSIS

 STAR DIAGNOSIS
Stored faults which can result from lines being disconnected or from simulation during removal and installation or test work, have to be processed and erased in the fault memories after completing the work



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

*WH58.30-Z-1048-13A

Number

Designation

Engines
112, 113
in model
463

BA49.10-P-1003-01A

Bolt of flange connection to crosspipe / exhaust system

Nm

25

BA49.10-P-1004-01A

Bolt of exhaust cross pipe to transmission

Nm

38

Number

Designation

Engine
112 except 112.951/
976

Engine 113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/993/
995

BA14.10-P-1001-01B

Nut to exhaust manifold

Nm

16

16

Number

Designation

WH58.30-Z-1048-13A

STAR DIAGNOSIS diagnosis system, Compact Passenger Car

6511 1801 00