Remove/install exhaust system complete - AR49.10-P-7000AC

ENGINE 113.988 in MODEL 203.076 /276

ENGINE 113.987 in MODEL 209.376 as of 24.4.04

ENGINE 156.982 in MODEL 209.377

Fig 1: Identifying Complete Exhaust System Remove/Install Components - Engine 113.988 In Model 203.076 /276

	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 at the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	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
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
1	Lift/jack up vehicle		AR00.60-P-1000P
2	Remove engine compartment paneling	Only remove rear engine compartment paneling	AR61.20-P-1105P
3	Disconnect left O2 sensor connector, upstream of TWC (G3/3x1) and right O2 sensor connector, upstream of TWC (G3/4x1).	Press connectors out of brackets. Loosen cable tie on left and remove cable from retaining clip.
4	Separate the left O2 sensor connector downstream of TWC (G3/5x1) O2 and the right sensor connector downstream of TWC (G3/6x1).	Press connectors out of brackets.
5	Detach the front exhaust system / catalytic converter at the exhaust manifold	Installation: Replace bolts, because the connection may loosen and the bolts may shear off if they are used again. Check rivet nuts in the exhaust manifold and replace them if required: ↓
		Replace rivet nuts in exhaust manifold.	AR49.10-P-5531-01DA
		Model 203.076/276, 209.376	*BA14.10-P-1002-01B
		Model 209.377	*BA14.10-P-1002-01N
		Caulking bolt	Figure
6	Support exhaust system
7	Unscrew bracket (3) for exhaust system on transmission by removing bolts (4)	Bring bracket together and fix in place using a cable tie (6).
			*BA49.10-P-1007-01A
8.1	Detach exhaust rubber mount (2) for exhaust system at left rear muffler (5a) and right rear muffler (5b)	Installation: Coat exhaust rubber mount (2) with liquid lubricant to ease installation. Model 203.076/276
		Lubricant	*BR00.45-Z-1002-06A
8.2	Detach exhaust rubber mount bracket for left rear muffler (5a) and right rear muffler (5b)	Installation: Coat the exhaust rubber mount (2) with liquid lubricant for the purpose of easier installation.
		Model 209.376/377
			*BA49.10-P-1019-01A
		Lubricant	*BR00.45-Z-1002-06A
9	Hook exhaust system on rear axle body bracket (7)	Installation: Check the exhaust rubber mount (2) and replace it if required.
10	Remove complete exhaust system
	Notes on disposing of catalytic converters		OS49.10-P-1000-01A
11	Install in the reverse order
12	Inspect installation position and clearance of exhaust system	The exhaust system must be installed free of stress, if necessary: ↓ Align exhaust system.
	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 running engine	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
13	Conduct engine test run and check exhaust system for leaks

EXHAUST MANIFOLD

Number	Designation		Engine 113.987/988/990/991
BA14.10-P-1002-01B	Flange connection, exhaust manifold and front exhaust pipes	Nm	20

EXHAUST MANIFOLD

Number	Designation		Engine 156
BA14.10-P-1002-01N	Flange connection for exhaust manifold/front exhaust pipe	Nm	20

EXHAUST SYSTEM

Number	Designation		Engines 112, 113 in model 203	Engine 112, 113 in model 209	Engine 156 in model 209
BA49.10-P-1007-01A	Bolt of exhaust bracket to transmission	Nm	20	20	20
BA49.10-P-1019-01A	Bolt, exhaust rubber mount bracket to frame	Nm	-	20	-

Fig 2: Identifying Cocking Bolt (103 589 01 39 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1002-06A	Lubricant	A 000 989 01 60