Remove/install exhaust system

AR49.10-P-7142OLC

14.07.2020

Engine

654 in model 213, 238, 257

P49.10-3139-09

Shown on model 213 except code 971 (Exhaust system with DPF generation 1.5)

1	Bracket		3	Elastomer bearing		4	Rear muffler
2	Exhaust flap

P49.10-A104-79

Shown on model 213.011 with code 971 (Exhaust system with DPF generation 1.5)

1	Bracket	4	Rear muffler	B16/27	Temperature sensor downstream of SCR catalytic converter
2	Exhaust flap	5	Exhaust system	N37/8b1	NOx sensor downstream of SCR catalytic converter
3	Elastomer bearing	6	Reinforcement

P49.10-A109-79

Shown on model 257.319 with code 972 (Exhaust system with DPF generation 2.0)

1	Bracket	5	Exhaust system	N37/3	Underbody NOx sensor downstream of SCR catalytic converter
2	Exhaust flap	6	Reinforcement	N37/8b1	NOx sensor downstream of SCR catalytic converter
3	Elastomer bearing	B94/34	Underbody temperature sensor upstream of SCR catalytic converter	Y129/1	AdBlue® metering valve 2
4	Rear muffler

Shown on model 257

12	Bracket
13	Bracket

P49.10-3299-11

 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.Engine 654 in model 213.011/211	AS00.00-Z-0035-01A
 Warning	Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.	Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.	AS49.00-Z-0001-01A
 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
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
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	Engine 654 in model 213.011/211	AH00.00-Z-0300-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
 	Remove/install
1	Remove lower engine compartment paneling.	Engine 654 in model 257	AR61.20-P-1105FR
		Engine 654 in model 213, 238	AR61.20-P-1105LWE
		 Installation: Only install lower engine compartment paneling after leak test.
2.1	Release side underfloor panelings in area of reinforcement (6).	Engine 654 in model 213, 238
			AR61.30-P-1001LWE
2.2	Remove side underfloor paneling.	Engine 654 in model 257
			AR61.30-P-1001FR
3	Remove left rear diagonal strut.	Engine 654 in model 213.2, 238.4
			AR61.10-P-5142LWP
4	Remove NOx sensor downstream of SCR catalytic converter(N37/8b1).		AR49.20-P-2065OIH
5	Remove AdBlue® metering valve 2 (Y129/1) from exhaust system (5) and place to one side with connected lines.	Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0)
			AR49.20-P-0029OIH
6.1	Remove union nut and pull temperature sensor downstream of SCR catalytic converter (B16/27) out of exhaust system (5).	Engine 654 in model 213, 238, 257 with code 971 (Exhaust system with DPF, generation 1.5)
		 Installation: Coat thread of the union nut with hot lubrication paste.
		 Exhaust temperature sensor downstream of SCR catalytic converter	*BA07.04-P-1020-02A
		Paste, hot lubrication 1 kg, DBL 6879.20	*BR00.45-Z-1005-06A
		 Box wrench bit	*000589690300
6.2	Remove union nut and pull underbody temperature sensor upstream of SCR catalytic converter (B94/34) out of exhaust system (5).	Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0)
		 Installation: Coat thread of the union nut with hot lubrication paste.
		 Union nut, temperature sensor to catalytic converter	*BA07.04-P-1002-02A
		Paste, hot lubrication 1 kg, DBL 6879.20	*BR00.45-Z-1005-06A
		 Box wrench bit	*000589690300
7	Seal opening in exhaust system (5) with suitable stop plug.	 Record plug	*129589009100
8	Remove underbody NOx sensor downstream of SCR catalytic converter (N37/3).	Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0)
			AR49.20-P-2064OIH
9	Release and disconnect electrical connector from the exhaust gas flap (2).
10	Remove reinforcement (6).	 Bolt, rear reinforcement to frame floor assembly	*BA61.10-P-1004-01L
11	Support rear muffler (4).
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
	000 588 10 62 00 Support plate		WS26.00-P-3309B
12	Open clamp of exhaust system (5) at diesel particulate filter.	 Installation: Replace clamp and seal.
		 Engine 654 in model 257Clamp to diesel particulate filter and front exhaust system	*BA49.10-P-1001-02O
		 Model 238 with engine 654Clamp to diesel particulate filter and front exhaust system	*BA49.10-P-1003-02J
		 Model 213 with engine 654Clamp to diesel particulate filter and front exhaust system	*BA49.10-P-1003-02H
13	Remove bracket (12) from transmission.	 Engine 654 in model 238Bolt, holder for front exhaust system to transmission	*BA49.10-P-1018-02J
		 Engine 654 in model 213Bolt, holder for front exhaust system to transmission	*BA49.10-P-1018-02H
		 Engine 654 in model 257Bolt, holder for front exhaust system to transmission	*BA49.10-P-1016-02O
14	Remove screws of bracket (1).	 Engine 654 in model 257Bolt, decoupling element for exhaust system to exhaust system	*BA49.10-P-1007-02O
		 Model 238 with engine 654Bolt, bracket for decoupling element to body/exhaust system at front	*BA49.10-P-1011-02J
		 Model 213 with engine 654Bolt, bracket for decoupling element to body/exhaust system at front	*BA49.10-P-1011-02H
15	Remove exhaust system (5) from elastomer bearings (3).	 Installation: Wet elastomer bearings (3) with lubricant.
		Lubricant, rubber assembly 1 l	*BR00.45-Z-1010-06A
16	Remove the exhaust system (5).
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
	000 588 10 62 00 Support plate		WS26.00-P-3309B
		 Aid of helper required.
17	Remove exhaust gas flap (2) from exhaust system (5).	When replacing exhaust system (5).
		Engine 654 in model 257	AR14.20-P-1035OIB
		Engine 654 in model 213, 238	AR14.20-P-1035OLC
18	Remove bracket (13).	When replacing exhaust system (5).
		 Engine 654 in model 257Bolt/nut, holder to front exhaust system/transmission holder	*BA49.10-P-1015-02O
		 Engine 654 in model 238Bolt/nut, holder to front exhaust system/transmission holder	*BA49.10-P-1017-02J
		 Engine 654 in model 213Bolt/nut, holder to front exhaust system/transmission holder	*BA49.10-P-1017-02H
	Clean
19	Remove combustion and corrosion residues at separating point.
	Check
20	Check elastomer bearings (3) for damage and wear.	If damage is identified,
		
		Replace elastomer bearings (3).
		Lubricant, rubber assembly 1 l	*BR00.45-Z-1010-06A
21.1	Check front decoupling element for damage and wear.	Engine 654 in model 213, 238 Engine 654 in model 257 except code 972 (Exhaust system with DPF, generation 2.0)
		If damage is identified,
		
		Replace front decoupling element
		 Engine 654 in model 238Nut, decoupling element for front exhaust system to bracket	*BA49.10-P-1012-02J
		 Engine 654 in model 213Nut, decoupling element for front exhaust system to bracket	*BA49.10-P-1012-02H
		 Engine 654 in model 257Nut, decoupling element for front exhaust system to bracket	*BA49.10-P-1006-02O
21.2	Check decoupling element at rear for damage and wear.	Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0)
		If damage is identified,
		
		Replace front decoupling element
		 Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0)Bolt, decoupling element for exhaust system to exhaust system	*BA49.10-P-1007-02O
22	Install in the reverse order.
	Check
23	Check installation position and for unobstructed movement of exhaust system (5) and correct if necessary.
 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
24	Perform engine test run and check exhaust system (5) for leaks.
25	Install lower engine compartment lining.	Engine 654 in model 257	AR61.20-P-1105FR
		Engine 654 in model 213, 238	AR61.20-P-1105LWE

 Sensors

Number	Designation		Engine 654
BA07.04-P-1002-02A	Union nut, temperature sensor to catalytic converter	Nm	45

 Sensors

Number	Designation		Engine 654
BA07.04-P-1020-02A	Exhaust temperature sensor downstream of SCR catalytic converter	Nm	45

 Exhaust system

Number	Designation		Model 257 with engine 654
BA49.10-P-1001-02O	Clamp to diesel particulate filter and front exhaust system	Nm	14

 Exhaust system

Number	Designation		Model 213 with engine 654
BA49.10-P-1003-02H	Clamp to diesel particulate filter and front exhaust system	Nm	14

 Exhaust system

Number	Designation		Model 238 with engine 654
BA49.10-P-1003-02J	Clamp to diesel particulate filter and front exhaust system	Nm	14

 Exhaust system

Number	Designation		Model 257 with engine 654
BA49.10-P-1006-02O	Nut, decoupling element for front exhaust system to bracket	Nm	20

 Exhaust system

Number	Designation		Model 257 with engine 654
BA49.10-P-1007-02O	Bolt, decoupling element for exhaust system to exhaust system	Nm	20

 Exhaust system

Number	Designation			Model 213 with engine 654
BA49.10-P-1011-02H	Bolt, bracket for decoupling element to body/exhaust system at front	M8	Nm	20
		M10	Nm	50

 Exhaust system

Number	Designation			Model 238 with engine 654
BA49.10-P-1011-02J	Bolt, bracket for decoupling element to body/exhaust system at front	M8	Nm	20
		M10	Nm	50

 Exhaust system

Number	Designation		Model 213 with engine 654
BA49.10-P-1012-02H	Nut, decoupling element for front exhaust system to bracket	Nm	20

 Exhaust system

Number	Designation		Model 238 with engine 654
BA49.10-P-1012-02J	Nut, decoupling element for front exhaust system to bracket	Nm	20

 Exhaust system

Number	Designation		Model 257 with engine 654
BA49.10-P-1015-02O	Bolt/nut, holder to front exhaust system/transmission holder	Nm	20

 Exhaust system

Number	Designation		Model 257 with engine 654
BA49.10-P-1016-02O	Bolt, holder for front exhaust system to transmission	Nm	20

 Exhaust system

Number	Designation		Model 213 with engine 654
BA49.10-P-1017-02H	Bolt/nut, holder to front exhaust system/transmission holder	Nm	20

 Exhaust system

Number	Designation		Model 238 with engine 654
BA49.10-P-1017-02J	Bolt/nut, holder to front exhaust system/transmission holder	Nm	20

 Exhaust system

Number	Designation		Model 213 with engine 654
BA49.10-P-1018-02H	Bolt, holder for front exhaust system to transmission	Nm	20

 Exhaust system

Number	Designation		Model 238 with engine 654
BA49.10-P-1018-02J	Bolt, holder for front exhaust system to transmission	Nm	20

 Frame floor assembly

Number	Designation		Model 213	Model 238
BA61.10-P-1004-01L	Bolt, rear reinforcement to frame floor assembly	Nm	24	24

 Frame floor assembly

Number	Designation		Model 257
BA61.10-P-1004-01L	Bolt, rear reinforcement to frame floor assembly	Nm	24

129 589 00 91 00

Record plug

000 589 69 03 00

Box wrench bit

Repair materials

Number	Designation	Order number
BR00.45-Z-1005-06A	Paste, hot lubrication 1 kg, DBL 6879.20	A 000 989 76 51
BR00.45-Z-1010-06A	Lubricant, rubber assembly 1 l	A 000 989 03 67

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