Removing and installing complete exhaust system - AR49.10-P-7000IM

ENGINE 275.950 in MODELS 215.376, 220.176 

ENGINE 275.980 in MODEL 215.379, 220.179 

Fig 1: Identifying Exhaust System Complete Remove/Install Components - Engine 275 (1 Of 2)

Shown on model 220.176 

Fig 2: Identifying Exhaust System Complete Remove/Install Components - Engine 275 (2 Of 2)

Shown on model 220.176 

Illustrated on model 220.179 

Fig 3: Identifying Exhaust Rubber Mount And Bolts

	Remove/Install
	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 below the hoist support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
1	Remove engine trim panel	Model 215,376, 220.176	AR01.10-P-2405LA
		Model 215.379, 220.179	AR01.10-P-2405IM
2	Disconnect right O2 sensor connector, upstream of TWC (G3/4x1) and left O2 sensor connector, upstream of TWC (G3/3x1) at charge air cooler (2)
3	Remove left O2ensor connector, upstream of TWC (G3/3)	Installation: Coat the thread with heat-resistant lubricant.
			*BA14.00-P-1001-01C
		Ring wrench socket	Fig 4
		Paste	*BR00.45-Z-1005-06A
4.1	Remove right O2 sensor connector upstream TWC [KAT]	Model 220.179, 215.379 Installation:  Coat the thread with heat-resistant lubricant.
			*BA14.00-P-1001-01C
		Ring wrench socket	Fig 4
		Paste	*BR00.45-Z-1005-06A
5	Remove lower engine compartment paneling	Only rear part.	AR61.20-P-1105M
6	Remove steering coupling
		Model 215.376, 220.176	AR46.10-P-8000I
7	Remove heat shield (13) below right three way catalytic converter
8	Separate right O2 sensor connector, downstream TWC (G3/6x1) and left O2 sensor connector, downstream TWC (G3/5x1) at transmission oil pan (11)
9	Support exhaust system (5) with transmission jack and transmission platform in the area of the flange connection	Passenger car transmission platform	*WE58.40-Z-1018-11A
		Telescoping transmission lifter 0.5 -1.0t	*WE58.40-Z-1030-11A
10	Unscrew from below bolt (3) of hose clamp (4) at turbocharger (6)	Installation:  Loosely screw on from below hose clamp (4) at turbocharger (6). Afterwards check from above correct installation position of hose clamp (4). Recess clearance (arrow) must catch in the lug (arrow) at the turbocharger (6). Use emery cloth to remove combustion and corrosion residues at connection points.
			*BA49.10-P-1002-01L
11	Dismount catalytic converters from catalytic converter bracket (10, 12) at transmission		*BA49.10-P-1008-01L
12.1	Unhinge left and right rear muffler from exhaust rubber mounts (9/1, 9/2)	Model 220.176, 215.376
12.2	Unscrew bolts (15) on left and right at the bracket of the exhaust rubber mount (9/2)	Model 220.179, 215.379
13	Detach reinforcement brace (35)		*BA61.10-P-1002-01D
14	Lower transmission jack and take out exhaust system (5)	Do not squeeze line terminals of O2ensors. Damage to plastic parts can lead to failure of the O2ensors.
	Notes on disposing of the catalytic converters	all	OS49.10-P-1000-01A
	Check
15	Check exhaust rubber mounts (9/1, 9/2) and sealing surfaces	Check for wear, replace if required:
		Lubricant	*BR00.45-Z-1002-06A
16	Install in the reverse order
	Check
17	Check installation position and unobstructed movement of exhaust system (5)	The exhaust system (5) must be installed free of tension, if required:↓ Align exhaust system (5).
	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.
18	Conduct engine test run and inspect exhaust system (5) for leaks

O2 SENSOR

EXHAUST SYSTEM

FRAME FLOOR

Fig 4: Ring Wrench Socket (000 589 71 03 00)