Removing and installing complete exhaust system

AR49.10-P-7000PI

11.3.10

ENGINE 642 in MODEL 203, 209

Removing and installing complete exhaust system

P49.10-2525-12

1 Nuts

2 Rear muffler

 	Remove/Install
Danger!	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
 Danger!	Risk of injury to skin and eyes from handling hot or glowing objects.	Wear safety gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
 Danger!	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near engine	Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Remove bottom sections of sound-proofing capsule		AR94.30-P-5300P
2	Remove catalytic converter		AR49.10-P-5500PI
	Notes on disposing of catalytic converters		OS49.10-P-1000-01A
3	Remove precatalytic converter		AR49.10-P-5510PI
	Notes on disposing of catalytic converters		OS49.10-P-1000-01A
4.1	Unscrew temperature sensor and pressure lines at diesel particulate filter	Only with particulate filter code 474	AR14.40-P-1000PI
		 Do not disconnect diesel particulate filter from the rear muffler (2).
		 Union nut of pressure line to diesel particulate filter	*BA14.40-P-1002-01B
		Bolt, clamp plate pressure lines	*BA14.40-P-1003-01B
		Nut, diesel particulate filter to bracket	*BA14.40-P-1005-01B
5	Unscrew nuts (1) at exhaust system bracket	 Installation: Replace nuts (1).
		 Nut of front exhaust system to bracket	*BA49.10-P-1001-01V
6	Unhinge exhaust system at exhaust rubber mounts (arrows)	 Have a second person assist you.
		 Installation: Check exhaust rubber mounts (arrows) for wear and replace if necessary. Coat exhaust rubber mounts (arrows) with liquid lubricant.
		Hook wrench
		Lubricant	*BR00.45-Z-1002-06A
7.1	Remove rear muffler (2) with diesel particulate filter	Only with particulate filter code 474
		 Have a second person assist you.
	Notes on the disposal of diesel particulate filters		OS49.10-P-1000-02A
7.2	Remove rear muffler (2) with center exhaust pipe	Except Code 474 Particulate Filter
		 Have a second person assist you.
8	Install in the reverse order
	Check
9	Inspect installation position and clearance of exhaust system	 The exhaust system must be mounted free of tension, align exhaust system if necessary.
10	Start engine and inspect exhaust system for leaks.

 Diesel particulate filter

Number	Designation		Engine 642 with code 474


BA14.40-P-1002-01B	Union nut of pressure line to diesel particulate filter	Nm	20
BA14.40-P-1003-01B	Bolt, clamp plate pressure lines	Nm	5
BA14.40-P-1005-01B	Nut, diesel particulate filter to bracket	Nm	20

 Exhaust system

Number	Designation		Engine 642 in model 203, 209


BA49.10-P-1001-01V	Nut of front exhaust system to bracket	Nm	20

Repair materials

Number	Designation	Order number
BR00.45-Z-1002-06A	Lubricating paste, rubber parts 2.5 kg, DB supply specification 6867.00	A 000 989 01 60

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