Remove/install components for exhaust system - AR49.10-P-7100CW

WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.

ENGINES 156, 271, 272, 276 in MODEL 204

ENGINES 271, 272, 273, 276, 278 in MODEL 207

Exhaust system for engine 271

Fig 1: Identifying Exhaust System Components (Engine 271)

Courtesy of MERCEDES-BENZ USA

Exhaust system for engine 272

Fig 2: Identifying Exhaust System Components (Engine 272)

Courtesy of MERCEDES-BENZ USA

Shown: exhaust system for model 204.057 with code (920) Gasoline direct injection with stratified charge

Fig 3: Identifying Exhaust System Components (Model 204.057 With Code 920)

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of death caused by vehicle slipping or tilting off of the vehicle off the vehicle lift.	Align vehicle between vehicle lift columns 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 protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Risk of injury from cutting body parts or abrasion injury on sharp-edged vehicle components	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1.1i	Remove both lower engine compartment paneling	If necessary Model 204.9 Installation: Only install both lower engine compartment panelings after engine test run and leak test.	AR61.20-P-1105CY
1.2	Remove engine compartment paneling	If necessary Model 207, 204 except 204.9 Installation: Install lower engine compartment paneling only after engine test run and leak test.	AR61.20-P-1105EW
2	Disconnect electrical connector(s) for O2 sensor(s) and expose feed lines	If necessary: ↓ Remove/install heated O2 sensor: Model 204 with engine 156	AR07.52-P-5303CMG
		Model 204, 207 with engine 271	AR07.52-P-5303CW
		Model 204, 207 with engine 276	AR07.52-P-5303FH
		Model 204 with engine 272 without 4MATIC, model 207 with engine 272, 273	AR07.52-P-5303CV
		Model 204 with engine 272 with 4MATIC Model 207 with engine 278	AR07.52-P-5303CWX
3	Remove exhaust gas recirculation line	Vehicles with engine 272.982/984	AR14.20-P-1020-01CDE
			*BA27.40-P-1001-01E
		Model 204	*BA49.10-P-1031-01AC
		Model 204	*BA49.10-P-1032-01AC
		Model 207	*BA49.10-P-1040-01AE
		Model 207	*BA49.10-P-1041-01AE
4	Remove corresponding diagonal strut(s) at rear	Model 207.4, if necessary
			*BA61.10-P-1007-01H
			*BA61.10-P-1008-01H
			*BA61.10-P-1009-01H
5	Detach corresponding components of exhaust system at separating points and remove	Installation: Align components for exhaust system tension-free before tightening the bolted connections. Installation: Apply lubricating paste to exhaust rubber bearings (8). Lubricant paste	*BR00.45-Z-1002-06A
		Nut, exhaust manifold to cylinder head Engines 271, 272, 273, 276	*BA14.10-P-1001-01E
		Engine 156	*BA14.10-P-1001-01N
		Engine 278	*BA09.40-P-1001-01R
		Screw/bolt, CAT to exhaust manifold or exhaust manifold flange connection/front exhaust pipe: Engine 272, 273	*BA14.10-P-1002-01E
		Engine 156	*BA14.10-P-1002-01N
		Screw/bolt, transmission to engine: Transmission 716.6	*BA26.10-P-1001-01C
		Transmission 722.6	*BA27.40-P-1001-01B
		Transmission 722.9	*BA27.40-P-1001-01E
		Model 204: Screw/bolt, CAT holder to CAT except engine 276	*BA49.10-P-1001-01AC
		Screw/bolt, CAT flange to center muffler except engine 276	*BA49.10-P-1005-01AC
		Screw/bolt, exhaust line clamp at front right to front left except engine 276	*BA49.10-P-1007-01AC
		Screw/bolt, exhaust pipe holder to transmission except engine 276	*BA49.10-P-1008-01AC
		Screw/bolt, exhaust pipe holder to exhaust pipe except engine 276	*BA49.10-P-1009-01AC
		Nut, center muffler clamp to connecting pipe with catalytic converter	*BA49.10-P-1012-01AC
		Nut, exhaust rubber mount holder to rear axle	*BA49.10-P-1014-01AC
		Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	*BA49.10-P-1015-01AC
		Screw/bolt, cross connection left rear to right rear	*BA49.10-P-1016-01AC
		Screw/bolt, catalytic converter to exhaust manifold	*BA49.10-P-1024-01AC
		Nut, center muffler clamp to rear muffler except engine 276	*BA49.10-P-1025-01AC
		Screw/bolt, EGR lines clamp to CAT except engine 276	*BA49.10-P-1032-01AC
		Screw/bolt, bracket to transmission except engine 276	*BA49.10-P-1033-01AC
		Screw/bolt, exhaust system holder to transmission for engine 276	*BA49.10-P-1035-01AC
		Screw/bolt, exhaust system holder to exhaust flange for engine 276 Model 207:	*BA49.10-P-1036-01AC
		Screw/bolt, catalytic converter to exhaust manifold	*BA49.10-P-1001-01AE
		Screw/bolt, catalytic converter holder to catalytic converter	*BA49.10-P-1010-01AE
		Screw/bolt, bracket to transmission	*BA49.10-P-1011-01AE
		Screw/bolt, catalytic converter connecting pipe to catalytic converter	*BA49.10-P-1021-01AE
		Screw/bolt, exhaust bracket to transmission	*BA49.10-P-1023-01AE
		Screw/bolt, exhaust bracket to exhaust	*BA49.10-P-1024-01AE
		Nut, center muffler clamp to connecting pipe with catalytic converter	*BA49.10-P-1032-01AE
		Nut, center muffler clamp to rear muffler	*BA49.10-P-1033-01AE
		Screw/bolt, cross connection left rear to right rear	*BA49.10-P-1035-01AE
		Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	*BA49.10-P-1036-01AE
6	Detach vibration damper (6) on center muffler (5)	Engine 271, if necessary Model 204	*BA49.10-P-1018-01AC
		Model 207	*BA49.10-P-1034-01AE
	Clean
7	Remove combustion and corrosion residue at separating points
8	Check exhaust rubber mount (8) for damage and wear
9	Install in the reverse order
	Checking
10	Check installation position and unobstructed movement of all components of the exhaust system
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns from working near on the vehicle as it is being started or when the engine 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
11	Perform an engine test run and check exhaust system for leaktightness

EXHAUST MANIFOLD

Number	Designation		Engine 156
BA14.10-P-1001-01N	Nut, exhaust manifold to cylinder head	Nm	22
BA14.10-P-1002-01N	Flange connection for exhaust manifold/front exhaust pipe	Nm	20

EXHAUST MANIFOLD

Number	Designation		Engine 271	Engine 272	Engine 273	Engine 276
BA14.10-P-1001-01E	Nut, exhaust manifold to cylinder head	Nm	21	16	16	16
BA14.10-P-1002-01E	Screw/bolt, catalytic converter to exhaust manifold	Nm	-	20	20	-

TURBOCHARGER

Number	Designation			Engine 278
BA09.40-P-1001-01R	Nut, turbocharger/exhaust manifold to cylinder head	M7	Nm	15
		M8	Nm	20

EXHAUST SYSTEM

Number	Designation		Engine 156, 271, 272 in model 204	Engine 276 in model 204
BA49.10-P-1001-01AC	Screw/bolt, catalytic converter holder to catalytic converter	Nm	35	-
BA49.10-P-1005-01AC	Screw/bolt, catalytic converter flange to center muffler	Nm	20	-
BA49.10-P-1007-01AC	Screw/bolt, exhaust line clamp at the front right to front left	Nm	35	-
BA49.10-P-1008-01AC	Screw/bolt, exhaust pipe bracket to transmission	Nm	20	-
BA49.10-P-1009-01AC	Screw/bolt, exhaust pipe bracket to exhaust pipe	Nm	20	-
BA49.10-P-1012-01AC	Nut, center muffler clamp to connecting pipe with catalytic converter	Nm	35	35
BA49.10-P-1014-01AC	Nut, exhaust rubber mount holder to rear axle	Nm	23	23
BA49.10-P-1015-01AC	Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	Nm	20	20
BA49.10-P-1016-01AC	Screw/bolt, cross connection left rear to right rear	Nm	20	20
BA49.10-P-1018-01AC	Screw/bolt, vibration damper to center muffler	Nm	20	-
BA49.10-P-1024-01AC	Screw/bolt, catalytic converter to exhaust manifold	Nm	20	20
BA49.10-P-1025-01AC	Nut, center muffler clamp to rear muffler	Nm	35	35
BA49.10-P-1031-01AC	Screw/bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner	Nm	9	-
BA49.10-P-1032-01AC	Screw/bolt, exhaust gas recirculation line clamp to catalytic converter	Nm	9	-
BA49.10-P-1033-01AC	Screw/bolt, bracket to transmission	Nm	39	-
BA49.10-P-1035-01AC	Screw/bolt, exhaust system bracket to transmission	Nm	-	25
BA49.10-P-1036-01AC	Screw/bolt, exhaust system bracket to exhaust flange	Nm	-	35

EXHAUST SYSTEM

Number	Designation		Engine 271, 272, 273, 276, 278 in model 207
BA49.10-P-1001-01AE	Screw/bolt, catalytic converter to exhaust manifold	Nm	20
BA49.10-P-1010-01AE	Screw/bolt, catalytic converter holder to catalytic converter	Nm	35
BA49.10-P-1011-01AE	Screw/bolt, bracket to transmission	Nm	39
BA49.10-P-1021-01AE	Screw/bolt, catalytic converter connecting pipe to catalytic converter	Nm	20
BA49.10-P-1023-01AE	Screw/bolt, exhaust bracket to transmission	Nm	20
BA49.10-P-1024-01AE	Bolt/nut, exhaust bracket to exhaust	Nm	20
BA49.10-P-1032-01AE	Screw/bolt/nut, center muffler clamp to connecting pipe with catalytic converter	Nm	35
BA49.10-P-1033-01AE	Nut, center muffler clamp to rear muffler	Nm	35
BA49.10-P-1034-01AE	Screw/bolt, vibration damper to center muffler	Nm	20
BA49.10-P-1035-01AE	Screw/bolt, cross connection left rear to right rear	Nm	20
BA49.10-P-1036-01AE	Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	Nm	20
BA49.10-P-1040-01AE	Screw/bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner	Nm	9
BA49.10-P-1041-01AE	Screw/bolt, exhaust gas recirculation line clamp to catalytic converter	Nm	9

HOUSING

Number	Designation		Transmission 722.9 in model 204	Transmission 722.9 in model 207
BA27.40-P-1001-01E	Screw/bolt, automatic transmission to cylinder crankcase	Nm	39	39

HOUSING

Number	Designation		Transmission 722.6 in model 204	Transmission 722.6 in model 207
BA27.40-P-1001-01B	Screw/bolt, automatic transmission to cylinder crankcase	Nm	39	39

COMPLETE MANUAL TRANSMISSION

Number	Designation		Transmission 716.6
BA26.10-P-1001-01C	Screw/bolt, transmission to engine	Nm	40

FRAME FLOOR ASSEMBLY

Number	Designation		Model 207.4
BA61.10-P-1007-01H	Screw/bolt, rear diagonal strut on spare wheel well	Nm	80
BA61.10-P-1008-01H	Screw/bolt, rear diagonal strut on longitudinal member	Nm	80
BA61.10-P-1009-01H	Screw/bolt, rear diagonal strut to bracket	Nm	17

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1002-06A	Antifriction paste, rubber parts 2.5 kg, DB supply specification 6867.00	A 000 989 01 60