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

ENGINE 272.920 in MODEL 203.052 /252 /752 

ENGINE 272.940 in MODEL 203.054 /254, 209.354 /454 

ENGINE 272.960 in MODEL 203.056 /256 /756, 209.356 /456 

ENGINE 272.970 in MODEL 203.087 /287 

ENGINE 272.941 in MODEL 203.092 /292 

ENGINE 273 in MODEL 209 

Fig 1: Identifying Complete Exhaust System Remove/Install Components - Engine 272.920 In Model 203.052 /252 /752, Engine 272.940 In Model 203.054 /254, 209.354 /454 & Engine 272.941 In Model 203.092 /292 (1 Of 2)

Fig 2: Identifying Complete Exhaust System Remove/Install Components - Engine 272.920 In Model 203.052 /252 /752, Engine 272.940 In Model 203.054 /254, 209.354 /454 & Engine 272.941 In Model 203.092 /292 (2 Of 2)

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by 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
	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
1	Raise vehicle with lifting platform		AR00.60-P-1000P
2	Remove bottom engine compartment paneling		AR61.20-P-1105P
3	Remove left rear diagonal strut	Model 209.4 Installation:  The diagonal struts must only be built-in, if the vehicle is standing with the wheels on the ground.
			*BA62.30-P-1004-01A
4	Remove steering heat shield below catalytic converter on the left	Model 203.087 /092 /287 /292
5	Unclip electrical connectors and electrical lines for O2 sensors from the retaining clamps
6	Disconnect electrical connectors for O2 sensors
7	Remove catalytic converters from exhaust manifolds by removing bolts (1)	Installation:  Clean connecting points of combustion and corrosion residues, replace bolts (1). Check rivet nuts in exhaust manifolds and if required: ↓
		Replace rivet nuts in exhaust manifold.	AR49.10-P-5531-01DA
			*BA49.10-P-1001-01Y
8	Support exhaust system with transmission jack and transmission platform
9	Loosen bracket (2) on transmission by releasing bolts (3)		*BA49.10-P-1005-01Y
10	Remove bracket (2) from catalytic converter	Installation:  Check threaded plate (4), replace if necessary. Replace nuts (5).
			*BA49.10-P-1006-01Y
11	Push together bracket (2)
12	Remove exhaust system bracket (6) from underbody		*BA49.10-P-1004-01Y
13	Remove complete exhaust system	Installation:  Check rubber mount (7) and bracket (6); replace if necessary.
	Notes on disposing of catalytic converters		OS49.10-P-1000-01A
14	Install in the reverse order
	Checking
15	Check installation position and clearance of exhaust system	The exhaust system must be mounted free of tension; align exhaust system if necessary.
	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 engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
16	Test run engine and check exhaust system for leaks

CROSSMEMBER AND FRONT REINFORCEMENT

EXHAUST SYSTEM