Removing and installing complete exhaust system (engine 272) - AR49.10-P-7000VA

ENGINE 272.942 in MODEL 171.454 

ENGINE 272.963 in MODEL 171.456 

Fig 1: Identifying Complete Exhaust System Components

Courtesy of MERCEDES-BENZ USA

	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.	-
	Risk of injury  from grazing 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.	-
	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.	-
1	Raise vehicle.	Position arms of the lifting platform in such a way that the bolts (2) of the rear diagonal struts (1) are accessible.	AR00.60-P-1000V
2	Remove rear diagonal struts (1).	Installation:  The bolts (2, 3) of the rear diagonal struts must only be tightened once the vehicle is standing horizontally on its wheels.
			*BA61.10-P-1005-01A
3	Detach the rear section of the lower engine compartment paneling	Installation:  Install engine compartment paneling only after the engine test run.	AR61.20-P-1105V
4	Unclip electrical connectors (G3/3x1, G3/4x1, G3/5x1, G3/6x1) and the electrical lines of the O2 sensors from the retaining clamps
5	Disconnect the electrical connectors (G3/3x1, G3/4x1, G3/5x1, G3/6x1) of the O2 sensors
6	Support the exhaust system (4) with a transmission jack and a transmission platform	Transmission jack	*WE58.40-Z-1030-11A
		Transmission plate	*WE58.40-Z-1018-11A
7	Detach the catalytic converters (5, 6) from the exhaust manifolds by unscrewing the bolts (7)	Installation:  Clean combustion and corrosion residues from the connecting points and replace the bolts.
			*BA49.10-P-1001-01N
8	Unhinge exhaust system (4) from exhaust rubber mounts (8)	To simplify removal: Apply liquid lubricant to the retaining brackets (9) and on the holes of the exhaust rubber mounts.
		Check exhaust rubber mount for wear, replace if required.
		Lubricant	*BR00.45-Z-1002-06A
			*BA49.10-P-1006-01N
9	Lower the exhaust system (4) and remove it completely
10	Install in the reverse order
	Check
11	Inspect installation position and unobstructed movement of exhaust system (4)	The exhaust system must be mounted free of tension, if required 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 engine	Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	-
12	Conduct engine test run and inspect exhaust system (4) for leaks

FRAME FLOOR

Number	Designation		Model 171
BA61.10-P-1005-01A	Self-locking bolt, rear diagonal strut at frame floor	Nm	60

EXHAUST SYSTEM

Number	Designation		Engine 272.942 in model 171	Engine 272.963 171
BA49.10-P-1001-01N	Bolt of catalytic converter to exhaust manifold	Nm	20	20
BA49.10-P-1006-01N	Bolt for exhaust rubber bearing bracket	Nm	20	20

WORKSHOP EQUIPMENT

WE58.40-Z-1018-11A	Transmission platform
WE58.40-Z-1030-11A	Transmission jack

REPAIR MATERIALS

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