Remove/install components for exhaust system

AR49.10-P-7100CW

7.2.12

ENGINES 156, 271, 272, 276 in MODEL 204

ENGINES 271, 272, 273, 276, 278 in MODEL 207

Remove/install components for exhaust system

P49.10-2777-09

Exhaust system for engine 271

1 Catalytic converter with exhaust manifold

2 Connecting flange

3 Connecting pipe with catalytic converter

7 Rear muffler

8 Exhaust rubber mount

4 Pipe clamp

5 Center muffler

6 Vibration damper

P49.10-2782-09

Exhaust system for engine 272

4 Pipe clamp

5 Center muffler

8 Exhaust rubber mount

12 Right rear muffler

13 Front connecting strut

14 Rear connecting strut

9 Left catalytic converter

10 Right catalytic converter

11 Left rear muffler

P49.10-2958-09

Shown: exhaust system for model 204.057 with code (920) Gasoline direct injection with stratified charge

2 Connecting flange

4 Pipe clamp

5 Center muffler

8 Exhaust rubber mount

9 Left CAT (CAT with exhaust manifold)

10 Right CAT (CAT with exhaust manifold)

11 Left rear muffler

12 Right rear muffler

14 Rear connecting strut

G3/4 Right oxygen sensor upstream of catalytic converter

G3/5 Left oxygen sensor downstream of catalytic converter

G3/6 Right oxygen sensor downstream of catalytic converter

N37/5 Left NOx sensor control unit

N37/5b1 Left NOx sensor

N37/6 Right NOx sensor control unit

N37/6b1 Right NOx sensor

22 RH NOx storage catalytic converter

23 LH NOx storage catalytic converter

B16 Temperature sensor upstream of NOx storage catalytic converter, right

B16/1 Temperature sensor upstream of NOx storage catalytic converter, left

G3/3 Left oxygen sensor upstream of catalytic converter

 	Remove/install
Danger!	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
Danger!	Risk of injury to skin and eyes caused by handling hot or glowing objects.	Wear safety gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
Danger!	Risk of injury from grazing 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
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1.1	Remove both lower engine compartment paneling	If necessary
		Model 204.9	AR61.20-P-1105CY
		 Installation: Only install both lower engine compartment panelings after engine test run and leak test.
1.2	Remove engine compartment paneling	If necessary
		Model 207, 204 except 204.9	AR61.20-P-1105EW
		 Installation: Install lower engine compartment paneling only after engine test run and leak test.
2	Disconnect electrical connector(s) for O2 sensor(s) and expose feed lines	If necessary: 
		Remove/install heated O2 sensor:
		Model 204 with engine 156	AR07.52-P-5303CMG
		Model 204, 207 with engine 271	AR07.52-P-5303CW
		Model 204, 207 with engine 276	AR07.52-P-5303FH
		Model 204 with engine 272 without 4-MATIC, model 207 with engine 272, 273	AR07.52-P-5303CV
		Model 204 with engine 272 with 4MATIC	AR07.52-P-5303CWX
		Model 207 with engine 278
3	Remove exhaust gas recirculation line	Vehicles with engine 272.982/ 984	AR14.20-P-1020-01CDE
			*BA27.40-P-1008-01A
		Model 204	*BA49.10-P-1031-01AC
		Model 204	*BA49.10-P-1032-01AC
		Model 207	*BA49.10-P-1040-01AE
		Model 207	*BA49.10-P-1041-01AE
4	Remove corresponding diagonal strut(s) at rear	Model 207.4, if required
			*BA61.10-P-1007-01H
			*BA61.10-P-1008-01H
			*BA61.10-P-1009-01H
5	Detach corresponding components of exhaust system at separation points and remove	 Installation: Align components for exhaust system tension-free before tightening the bolted connections.
		 Installation: Apply lubricating paste to exhaust rubber bearings (8).
		Lubricant paste	*BR00.45-Z-1002-06A
		Nut, exhaust manifold to cylinder head
		Engines 271, 272, 273, 276	*BA14.10-P-1001-01E
		Engine 156	*BA14.10-P-1001-01N
		Engine 278	*BA09.40-P-1001-01R
		Screw/bolt, CAT to exhaust manifold or exhaust manifold flange connection /front exhaust pipe:
		 Engine 272, 273	*BA14.10-P-1002-01E
		Engine 156	*BA14.10-P-1002-01N
		Screw/bolt, transmission to engine:
		 Transmission 716.6	*BA26.10-P-1001-01C
		Transmission 722.6, 722.9	*BA27.40-P-1008-01A
		Model 204:
		 Screw/bolt, CAT holder to CAT except engine 276	*BA49.10-P-1001-01AC
		 Screw/bolt, CAT flange to center muffler except engine 276	*BA49.10-P-1005-01AC
		 Screw/bolt, exhaust line clamp at front right to front left except engine 276	*BA49.10-P-1007-01AC
		 Screw/bolt, exhaust pipe holder to transmission except engine 276	*BA49.10-P-1008-01AC
		 Screw/bolt, exhaust pipe holder to exhaust pipe except engine 276	*BA49.10-P-1009-01AC
		Nut, center muffler clamp to connecting pipe with catalytic converter	*BA49.10-P-1012-01AC
		Nut, exhaust rubber mount holder to rear axle	*BA49.10-P-1014-01AC
		Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	*BA49.10-P-1015-01AC
		Screw/bolt, cross connection left rear to right rear	*BA49.10-P-1016-01AC
		 Screw/bolt, catalytic converter to exhaust manifold	*BA49.10-P-1024-01AC
		 Nut, center muffler clamp to rear muffler except engine 276	*BA49.10-P-1025-01AC
		 Screw/bolt, EGR lines clamp to CAT except engine 276	*BA49.10-P-1032-01AC
		 Screw/bolt, bracket to transmission except engine 276	*BA49.10-P-1033-01AC
		 Screw/bolt, exhaust system holder to transmission for engine 276	*BA49.10-P-1035-01AC
		 Screw/bolt, exhaust system holder to exhaust flange for engine 276	*BA49.10-P-1036-01AC
		Model 207:
		 Screw/bolt, catalytic converter to exhaust manifold	*BA49.10-P-1001-01AE
		Screw/bolt, catalytic converter holder to catalytic converter	*BA49.10-P-1010-01AE
		Screw/bolt, bracket to transmission	*BA49.10-P-1011-01AE
		Screw/bolt, catalytic converter connecting pipe to catalytic converter	*BA49.10-P-1021-01AE
		 Screw/bolt, exhaust bracket to transmission	*BA49.10-P-1023-01AE
		Screw/bolt, exhaust bracket to exhaust	*BA49.10-P-1024-01AE
		Nut, center muffler clamp to connecting pipe with catalytic converter	*BA49.10-P-1032-01AE
		Nut, center muffler clamp to rear muffler	*BA49.10-P-1033-01AE
		Screw/bolt, cross connection left rear to right rear	*BA49.10-P-1035-01AE
		Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	*BA49.10-P-1036-01AE
6	Remove vibration damper (6) on center muffler (5)	Engine 271, if necessary
		Model 204	*BA49.10-P-1018-01AC
		Model 207	*BA49.10-P-1034-01AE
	Clean
7	Remove combustion and corrosion residue at separation points
8	Check exhaust rubber mount (8) for damage and wear
9	Install in the reverse order
	Checking
10	Inspect installation position and unobstructed movement of all components of the exhaust system
 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 the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
11	Perform an engine test run and check exhaust system for leaks

 Exhaust manifold

Number	Designation		Engine 156


BA14.10-P-1001-01N	Nut, exhaust manifold to cylinder head	Nm	22
BA14.10-P-1002-01N	Flange connection for exhaust manifold/front exhaust pipe	Nm	20

 Exhaust manifold

Number	Designation		Engine 271	Engine 272	Engine 273	Engine 276


BA14.10-P-1001-01E	Nut, exhaust manifold to cylinder head	Nm	21	16	16	16
BA14.10-P-1002-01E	Screw/bolt, catalytic converter to exhaust manifold	Nm	-	20	20	-

Turbocharger

Number	Designation			Engine 278


BA09.40-P-1001-01R	Nut, turbocharger/exhaust manifold to cylinder head	M7	Nm	15
		M8	Nm	20

 Exhaust system

Number	Designation		Engine 156, 271, 272 in model 204	Engine 276 in model 204


BA49.10-P-1001-01AC	Screw/bolt, catalytic converter holder to catalytic converter	Nm	35	-
BA49.10-P-1005-01AC	Screw/bolt, catalytic converter flange to center muffler	Nm	20	-
BA49.10-P-1007-01AC	Screw/bolt, exhaust line clamp at the front right to front left	Nm	35	-
BA49.10-P-1008-01AC	Screw/bolt, exhaust pipe bracket to transmission	Nm	20	-
BA49.10-P-1009-01AC	Screw/bolt, exhaust pipe bracket to exhaust pipe	Nm	20	-
BA49.10-P-1012-01AC	Nut, center muffler clamp to connecting pipe with catalytic converter	Nm	35	35
BA49.10-P-1014-01AC	Nut, exhaust rubber mount holder to rear axle	Nm	23	23
BA49.10-P-1015-01AC	Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	Nm	20	20
BA49.10-P-1016-01AC	Screw/bolt, cross connection left rear to right rear	Nm	20	20
BA49.10-P-1018-01AC	Screw/bolt, vibration damper to center muffler	Nm	20	-
BA49.10-P-1024-01AC	Screw/bolt, catalytic converter to exhaust manifold	Nm	20	20
BA49.10-P-1025-01AC	Nut, center muffler clamp to rear muffler	Nm	35	35
BA49.10-P-1031-01AC	Screw/bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner	Nm	9	-
BA49.10-P-1032-01AC	Screw/bolt, exhaust gas recirculation line clamp to catalytic converter	Nm	9	-
BA49.10-P-1033-01AC	Screw/bolt, bracket to transmission	Nm	39	-
BA49.10-P-1035-01AC	Screw/bolt, exhaust system bracket to transmission	Nm	-	25
BA49.10-P-1036-01AC	Screw/bolt, exhaust system bracket to exhaust flange	Nm	-	35

 Exhaust system

Number	Designation		Engine 271, 272, 273, 276, 278 in model 207


BA49.10-P-1001-01AE	Screw/bolt, catalytic converter to exhaust manifold	Nm	20
BA49.10-P-1010-01AE	Screw/bolt, catalytic converter holder to catalytic converter	Nm	35
BA49.10-P-1011-01AE	Screw/bolt, bracket to transmission	Nm	39
BA49.10-P-1021-01AE	Screw/bolt, catalytic converter connecting pipe to catalytic converter	Nm	20
BA49.10-P-1023-01AE	Screw/bolt, exhaust bracket to transmission	Nm	20
BA49.10-P-1024-01AE	Bolt/nut, exhaust bracket to exhaust	Nm	20
BA49.10-P-1032-01AE	Screw/bolt / nut, center muffler clamp to connecting pipe with catalytic converter	Nm	35
BA49.10-P-1033-01AE	Nut, center muffler clamp to rear muffler	Nm	35
BA49.10-P-1034-01AE	Screw/bolt, vibration damper to center muffler	Nm	20
BA49.10-P-1035-01AE	Screw/bolt, cross connection left rear to right rear	Nm	20
BA49.10-P-1036-01AE	Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	Nm	20
BA49.10-P-1040-01AE	Screw/bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner	Nm	9
BA49.10-P-1041-01AE	Screw/bolt, exhaust gas recirculation line clamp to catalytic converter	Nm	9

 Housing

Number	Designation			Transmission 722.6 except 722.660/661/662/663/666/673/674	Trans-mission 722.9


BA27.40-P-1008-01A	Screw/bolt, automatic transmission to engine	M1040	Nm	39	38
		M1090	Nm	39	38
		M12	Nm	-	-

 Complete manual transmission

Number	Designation		Trans-mission 716.6


BA26.10-P-1001-01C	Screw/bolt, transmission to engine	Nm	40

 Frame floor assembly

Number	Designation		Model 207.4


BA61.10-P-1007-01H	Screw/bolt, rear diagonal strut on spare wheel well	Nm	80
BA61.10-P-1008-01H	Screw/bolt, rear diagonal strut on longitudinal member	Nm	80
BA61.10-P-1009-01H	Screw/bolt, rear diagonal strut to bracket	Nm	17

Repair materials

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

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