Remove/install components for exhaust system

AR49.10-P-7100EL

Remove/install components for exhaust system

08.01.2020

Engine

157, 276, 278 in model 212, 218

MODEL 212, 218 with CODE 920 (Gasoline direct injection with stratified charge), shown on MODEL 218.355

1

Connecting points for catalytic converter on NOx storage catalytic converters

11

Left rear muffler

G3/5

Left oxygen sensor downstream of catalytic converter

2

RH NOx storage catalytic converter

12

Right rear muffler

G3/6

Right oxygen sensor downstream of catalytic converter

3

LH NOx storage catalytic converter

14

Rear connecting strut

N37/5

Left NOx sensor control unit

4

Pipe clamps

B16

Temperature sensor upstream of NOx storage catalytic converter, right

N37/5b1

Left NOx sensor

5

Center muffler

B16/1

Temperature sensor upstream of NOx storage catalytic converter, left

N37/6

Right NOx sensor control unit

9

Left catalytic converter

G3/3

Left oxygen sensor upstream of catalytic converter

N37/6b1

Right NOx sensor

10

Right catalytic converter

G3/4

Right oxygen sensor upstream of catalytic converter

MODEL 212, 218 except CODE 920 (gasoline direct injection with stratified charge), shown on MODEL 218.373

4

Pipe clamps

5

Center muffler

9

Left catalytic converter

10

Right catalytic converter

11

Left rear muffler

12

Right rear muffler

G3/3

Left oxygen sensor upstream of catalytic converter

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

Shown on model 212 with engine 276.8

1

Separating clamp on ATL

7

Pipe clamp downstream of right CAT

14

Rear connecting strut

3r

Connecting pipe on the right

9

Left catalytic converter

G3/3

Left oxygen sensor upstream of catalytic converter

3l

Connecting pipe on the left

10

Right catalytic converter

G3/4

Right oxygen sensor upstream of catalytic converter

4

Pipe clamps

11

Left rear muffler

G3/5

Left oxygen sensor downstream of catalytic converter

5

Center muffler

12

Right rear muffler

G3/6

Right oxygen sensor downstream of catalytic converter

6

Connecting point upstream of CAT

 

Remove/install

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

Topical note

General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment

AH00.00-Z-0300-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove engine compartment paneling

If necessary.

AR61.20-P-1105EW

 Installation: Only install lower engine compartment paneling after the engine test run and leak test.

2

Disconnect electrical connection for the respective oxygen sensors (G3/3, G3/4, G3/5, G3/6) and expose feed lines

If necessary.

Engine 276.8 in model 212

AR07.52-P-5303ELS

Engine 276.9 in model 212, 218

AR07.52-P-5303EL

Engine 157, 278 in model 212, 218

AR07.52-P-5303ELB

3

Disconnect electrical connection for left NOx sensor (N37/5b1) or right NOx sensor (N37/6b1) and expose feed lines

ENGINE 276 in MODEL 212, 218 with CODE 920 (gasoline direct injection with stratified charge)
If necessary.

AR07.70-P-0001EL

4

Disconnect electrical connection for temperature sensor upstream of right NOx storage catalytic converter (B16) or temperature sensor upstream of left NOx storage catalytic converter (B16/1) of the respective NOx storage catalytic converter (2, 3) and expose feed lines

ENGINE 276 in MODEL 212, 218 with CODE 920 (gasoline direct injection with stratified charge)
If necessary.

AR07.70-P-0002EL

5.1

Remove exhaust manifold with left catalytic converter (9) or exhaust manifold with right catalytic converter (10)

Engine 276.9 in model 212, 218
with code 920 (Direct petrol injection with stratified charging)
If necessary.

AR14.10-P-4095EL

5.2

Remove ATL with exhaust manifold

If necessary.

Engine 276.8 in model 212, 218

AR09.40-P-6025ELS

Engine 157, 278 in model 212, 218

AR09.40-P-6025ELB

5.3

Remove exhaust manifold

Engine 276.9 in model 212, 218
except code 920 (Direct petrol injection with stratified charging)
If necessary.

AR14.10-P-3006EHV

6

Remove exhaust gas recirculation lines

ENGINE 276 in MODEL 212, 218 with CODE 920 (gasoline direct injection with stratified charge)
If necessary.

 Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner

*BA49.10-P-1040-01AE

 Bolt, clamp for exhaust gas recirculation line to catalytic converter

*BA49.10-P-1041-01AE

7

Remove front reinforcement brace from frame floor assembly

If necessary.

 Bolt, front reinforcement brace to frame floor assembly

*BA61.10-P-1002-01H

8

Loosen corresponding components of exhaust system at connecting points and remove

 Installation: Align components for the exhaust system before firmly tightening screw connections free of tension.

 Installation: Apply lubricating paste to exhaust rubber mounts.

 Bolt, catalytic converter to pipe

*BA49.10-P-1051-01AE

 Bolt, pipe clamp to exhaust gas turbocharger

*BA49.10-P-1050-01AE

 Bolt, catalytic converter to exhaust manifold

*BA49.10-P-1001-01AE

 Bolt, catalytic converter holder to catalytic converter

*BA49.10-P-1010-01AE

 Bolt, bracket to transmission

*BA49.10-P-1011-01AE

 Nut, catalytic converter holder to catalytic converter

*BA49.10-P-1012-01AE

 Bolt, catalytic converter pipe to catalytic converter

*BA49.10-P-1021-01AE

 Bolt, exhaust system bracket to transmission

*BA49.10-P-1023-01AE

 Bolt/nut, exhaust system bracket to exhaust system

*BA49.10-P-1024-01AE

 Bolt/nut, clamp for center muffler to pipe with catalytic converter

*BA49.10-P-1032-01AE

 Bolt/nut, center muffler clamp/SCR catalytic converter to rear muffler

*BA49.10-P-1033-01AE

 Bolt, vibration damper to center muffler

*BA49.10-P-1034-01AE

 Bolt, cross connection left rear to right rear

*BA49.10-P-1035-01AE

 Bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier

*BA49.10-P-1036-01AE

Antifriction paste, rubber parts 2.5 kg, DBL 6867.00

*BR00.45-Z-1002-06A



Clean

9

Remove combustion and corrosion residue at connecting points

10

Check exhaust rubber mount for damage and wear

11

Install in the reverse order



Check

12

Check installation position and unobstructed movement of all components of the exhaust system

 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

13

Perform an engine test run and check exhaust system for leaktightness

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1001-01AE

Bolt, catalytic converter to exhaust manifold

Nm

20

20

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1010-01AE

Bolt, catalytic converter holder to catalytic converter

Nm

35

35

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1011-01AE

Bolt, bracket to transmission

Nm

39

39

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1012-01AE

Nut, catalytic converter holder to catalytic converter

Nm

20

–

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1021-01AE

Bolt, catalytic converter pipe to catalytic converter

Nm

20

20

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1023-01AE

Bolt, exhaust system bracket to transmission

Nm

20

20

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1024-01AE

Bolt/nut, exhaust system bracket to exhaust system

Nm

20

20

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1032-01AE

Bolt/nut, clamp for center muffler to pipe with catalytic converter

Nm

35

35

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1033-01AE

Bolt/nut, center muffler clamp/SCR catalytic converter to rear muffler

Nm

35

35

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1034-01AE

Bolt, vibration damper to center muffler

Nm

20

20

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1035-01AE

Bolt, cross connection left rear to right rear

Nm

20

20

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1036-01AE

Bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier

Nm

20

20

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1040-01AE

Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner

Nm

9

9

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1041-01AE

Bolt, clamp for exhaust gas recirculation line to catalytic converter

Nm

9

9

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1050-01AE

Bolt, pipe clamp to exhaust gas turbocharger

Nm

15

15

 Exhaust system

Number

Designation

Engine 156, 157, 271, 272, 273, 276, 278 in model 212

Engine 157, 276, 278 in model 218

BA49.10-P-1051-01AE

Bolt, catalytic converter to pipe

Nm

20

–

 Frame floor assembly

Number

Designation

Model 212

Model 218

BA61.10-P-1002-01H

Bolt, front reinforcement brace to frame floor assembly

Nm

30

30

Repair materials

Number

Designation

Order number

BR00.45-Z-1002-06A

Antifriction paste, rubber parts 2.5 kg, DBL 6867.00

A 000 989 01 60