Remove/install exhaust system complete - AR49.10-P-7000GZ (ML500)

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ENGINE 113.964 in MODEL 164.1

Fig 1: Identifying Exhaust System Remove/Install Components (1 Of 5)

G05258972

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Exhaust System Remove/Install Components (2 Of 5)

G05258973

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Exhaust System Remove/Install Components (3 Of 5)

G05258974

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Exhaust System Remove/Install Components (4 Of 5)

G05258975

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Exhaust System Remove/Install Components (5 Of 5)

G05258976

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	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 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 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
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
1	Remove air filter housing		AR09.10-P-1150GZ
2	Unclip connector for left O2 sensor, upstream of TWC (G3/3x1) and electrical lines for left O2 sensors out of retaining clamps
3	Remove bolt (2) for catalytic converter bracket on catalytic converter		*BA49.10-P-1001-01S
4	Remove bolts (4) and stiffening strut on the left (3)		*BA22.10-P-1006-03G
			*BA22.10-P-1008-03G
5	Exhaust system complete using transmission jack and transmission platform
6	Remove bolts (6) and left catalytic converter (5) from exhaust manifold	Installation: Clean connecting points free of combustion and corrosion residues.
			*BA49.10-P-1002-01S
7	Unclip connector for left O2 sensor downstream of catalytic converter (G3/5x1) and electrical line for left O2 sensor from retaining clamps
8	Unplug connector for right O2 sensor upstream of TWC (G3/4x1)
9	Unclip connector for right O2 sensor, downstream of TWC (G3/6x1) and electrical lines out of retaining clamps
10	Detach right catalytic converter (8) by unscrewing the bolt (11)		*BA49.10-P-1001-01S
11	Unscrew bolts (12) and detach right catalytic converter (8) from exhaust manifold	Installation: Clean connecting points free of combustion and corrosion residues.
			*BA49.10-P-1002-01S
12	Remove bolts from center muffler exhaust rubber mount (13)		*BA49.10-P-1008-01S
13	Remove bolts (15) from outer exhaust rubber bearing (16)		*BA49.10-P-1008-01S
14	Remove bolts on inner exhaust rubber bearing (14)		*BA49.10-P-1007-01S
15	Remove complete exhaust system	With the aid of a helper.
	Checking
16	Check exhaust rubber mount (13), the inner exhaust rubber mount (14) and the outer exhaust rubber mount (16)	Check for wear, replace if required. Installation: Coat exhaust rubber mount with lubricant paste for easier installation.
		Lubricating paste	*BR00.45-Z-1002-06A
17	Install in the reverse order
	Checking
18	Check installation position and clearance of exhaust system	The exhaust system must be mounted free of tension, align exhaust system if required.
	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
19	Test run engine and check exhaust system for leaks

ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Model 164
BA22.10-P-1006-03G	Bolt, cross strut to engine crossmember	Nm	45
BA22.10-P-1008-03G	Bolt, cross strut to body	Nm	45

EXHAUST SYSTEM

Number	Designation		Engine 113.964 in model 164.1
BA49.10-P-1001-01S	Bolt, catalytic converter bracket to catalytic convertor	Nm	20
BA49.10-P-1002-01S	Bolt, flange connection to exhaust pipe/exhaust manifold	Nm	20
BA49.10-P-1007-01S	Bolt connecting exhaust rubber mount bracket (inner) to body	Nm	20
BA49.10-P-1008-01S	Bolt connecting exhaust rubber mount bracket (outer) to bumper bracket	Nm	12

REPAIR MATERIALS

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