Remove/install components for exhaust system

AR49.10-P-7100MR

Remove/install components for exhaust system

19.03.2015

ENGINE

274 in MODEL 204

ENGINE

274 in MODEL 212, 218

Shown on model 204 (except 204.9)

1

Catalytic converter

4

Bracket

7

Bracket

2

Bracket

5

Clamp

8

Rear muffler

3

Clamp

6

Center muffler

9

Bracket

Illustrated on model 204.9

1

Catalytic converter

5

Clamp

9

Bracket

2

Bracket

6

Center muffler

10

Clamp

3

Clamp

7

Bracket

4

Bracket

8

Rear muffler

 Danger !

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 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

 

Remove/install

1

Remove engine compartment paneling

ENGINE 274 in MODEL 204.9

AR61.20-P-1105CY

ENGINE 274 in MODEL 204 (except 204.9), 212, 218

AR61.20-P-1105EW

2

Disconnect electrical connections on oxygen sensors and expose feed lines

If necessary



Remove heatable oxygen sensor.

ENGINE 274.9 in MODEL 212
with CODE 924 (Bivalent natural gas drive)

AR07.52-P-5303MRC

ENGINE 274 in MODEL 204

AR07.52-P-5303MR

ENGINE 274 in MODEL 212
without CODE 924 (Bivalent natural gas drive)
ENGINE 274 in MODEL 218

AR07.52-P-5303MRS

3

Loosen corresponding components of exhaust system at respective connecting points and remove

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

 Installation: Apply lubricating paste at the elastomer bearings of the exhaust system.

 Model 204, screw/bolt exhaust rubber mount holder to frame floor assembly/rear axle carrier

*BA49.10-P-1015-01AC

 Model 204, screw/bolt, CAT clamp to ATL

*BA49.10-P-1034-01AC

 Model 204, nut, CAT holder to CAT

*BA49.10-P-1037-01AC

 Model 204, screw/bolt, CAT holder to crankcase/oil pan

*BA49.10-P-1038-01AC

 Model 204, nut, CAT clamp to exhaust system at the front

*BA49.10-P-1039-01AC

 Model 204, screw/bolt, clamp for exhaust system at the front to exhaust system at the rear

*BA49.10-P-1040-01AC

 Model 204, nut to exhaust bracket suspension

*BA49.10-P-1041-01AC

 Model 212, 218, screw/bolt exhaust rubber mount holder to frame floor assembly/rear axle carrier

*BA49.10-P-1036-01AE

 Model 212, 218, screw/bolt, CAT clamp to ATL

*BA49.10-P-1042-01AE

 Model 212, 218, nut, CAT holder to CAT

*BA49.10-P-1043-01AE

 Model 212, 218, screw/bolt, CAT holder to crankcase/oil pan

*BA49.10-P-1044-01AE

 Model 212, 218, nut, CAT clamp to exhaust system at the front

*BA49.10-P-1045-01AE

 Model 212, 218, nut to suspension for front exhaust system

*BA49.10-P-1046-01AE

 Model 212, 218, screw/bolt, clamp for exhaust system at the front to exhaust system at the rear

*BA49.10-P-1048-01AE

Antifriction paste, rubber parts 2.5 kg, DBL 6867.00

*BR00.45-Z-1002-06A



Clean

4

Remove combustion and corrosion residue at separating points

5

Check elastomer bearing for exhaust system for damage, check wear and replace if necessary

6

Install in the reverse order



Check

7

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

 Danger !

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

8

Perform an engine test run and check exhaust system for leaktightness

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 204

BA49.10-P-1015-01AC

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

Nm

20

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 204

BA49.10-P-1034-01AC

Bolt connecting catalytic converter clamp to exhaust gas turbocharger

Nm

15

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 212, 218

BA49.10-P-1036-01AE

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

Nm

20

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 204

BA49.10-P-1037-01AC

Nut, catalytic converter holder to catalytic converter

Nm

20

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 204

BA49.10-P-1038-01AC

Bolt, bracket for CAT to crankcase/oil pan

Nm

25

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 204

BA49.10-P-1039-01AC

Nut, clamp for CAT to front exhaust system

Nm

22

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 204

BA49.10-P-1040-01AC

Bolt, clamp for front exhaust system to rear exhaust system

Nm

35

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 204

BA49.10-P-1041-01AC

Nut to exhaust bracket mounting bracket

Nm

23

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 212, 218

BA49.10-P-1042-01AE

Bolt, catalytic converter clamp to turbocharger

Nm

15

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 212, 218

BA49.10-P-1043-01AE

Nut, catalytic converter holder to catalytic converter

Nm

20

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 212, 218

BA49.10-P-1044-01AE

Bolt, bracket for CAT to crankcase/oil pan

Nm

25

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 212, 218

BA49.10-P-1045-01AE

Nut, clamp for CAT to front exhaust system

Nm

22

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 212, 218

BA49.10-P-1046-01AE

Nut to front exhaust system mounting bracket

Nm

23

 Exhaust system

Number

Designation

ENGINE 274 in MODEL 212, 218

BA49.10-P-1048-01AE

Bolt, clamp for front exhaust system to rear exhaust system

Nm

35

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