Remove, install exhaust system complete - AR49.10-P-7000TB

ENGINE 112.913 in MODEL 211.061 /261 

ENGINE 112.949 in MODEL 211.065 /265 

ENGINE 113.967 in MODEL 211.070 /270 

ENGINE 113.990 in MODEL 211.076 /276 

ENGINE 112.917 in MODEL 211.080 /280 

ENGINE 112.954 in MODEL 211.082 /282 

ENGINE 113.969 in MODEL 211.083 /283 

ENGINE 156.983 in MODEL 211.077 /277 

Fig 1: Identifying Exhaust System Complete Components (1 Of 2)

Symbolic representation 

Symbolic representation 

Fig 2: Identifying Exhaust System Complete Components (2 Of 2)

	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		AH00.00-N-0001-01A
1	Remove rear engine compartment paneling		AR61.20-P-1105T
2	Disconnect connector for left O2 sensor upstream of the catalytic converter (G3/3x1) and connector for right O2 sensor upstream of the catalytic converter (G3/4x1) and expose electrical lines
3	Disconnect connector for left O2 sensor downstream of the catalytic converter (G3/5x1) and connector for right O2 sensor downstream of the catalytic converter (G3/6x1) and expose electrical lines
4	Fix shim and rubber shim with tie strap (arrow)	Model 211.076/ 077/ 276/ 277.
5	Loosen bolts (1a)		*BA49.10-P-1011-01A
6	Remove catalytic convertor bracket (1) from firewall catalytic convertor, right (157/1) and firewall catalytic convertor, left (157/2)	Model 211.061 /065 /070 /080 /082 /083 /261 /265 /270 /280 /282 /283.
			*BA49.10-P-1012-01A
7	Support exhaust system with transmission jack and transmission platform	Passenger car transmission platform	*WE58.40-Z-1018-11A
		Transmission jack	*WE58.40-Z-1030-11A
8	Remove firewall catalytic convertor, right (157/1) and firewall catalytic convertor, left (157/2) from the exhaust manifolds	Installation:  Check rivet nuts in exhaust manifold, replace if required:↓
		Replace rivet nuts in exhaust manifold.	AR49.10-P-5531-01DA
		Engine 112, 113	*BA14.10-P-1002-01B
		Engine 156	*BA14.10-P-1002-01N
		Caulking bolt	Figure
9	Loosen nuts at exhaust cross strut	Model 211.076/ 077/ 276/ 277.
			*BA14.10-P-1002-01N
10	Disengage the rear muffler (9a) from the exhaust rubber mount (9/1, 9/2)	To simplify removal: Apply liquid lubricant to the retaining brackets and onto the holes for the exhaust rubber mounts. Installation:  Use liquid lubricant.
		Lubricant	*BR00.45-Z-1002-06A
11	Remove crossmember (35)		*BA62.30-P-1001-01A
12	Lift out exhaust system	Lower the transmission jack and tilt the exhaust system 45° around the longitudinal axis. On model 211.076 /077 /276 /277 remove at an angle from the rear. Installation:  Check exhaust rubber mounts (9/1, 9/2), replace if worn.
		Passenger car transmission platform	*WE58.40-Z-1018-11A
		Transmission jack	*WE58.40-Z-1030-11A
	Notes on disposing of catalytic converters		OS49.10-P-1000-01A
13	Install in the reverse order
	Check
14	Inspect installation position and clearance of exhaust system	The exhaust system must be installed free of stress. 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 engine	Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
15	Conduct engine test run and inspect exhaust system for leaks

CROSSMEMBER AND FRONT REINFORCEMENT

EXHAUST MANIFOLD

EXHAUST MANIFOLD

EXHAUST SYSTEM

Fig 3: Identifying Caulking Bolt (103 589 01 39 00)