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

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ENGINE 112 in MODEL 203

ENGINE 112 in MODEL 209

ENGINE 113.968 in MODEL 209.375 /475

ENGINE 113.987 in MODELS 209.376 up to 23.4.04, 209.476

ENGINE 156.982 in MODEL 209.477

Shown on model 203

Fig 1: Identifying Complete Exhaust System Remove/Install Components - Shown On Model 203 (1 Of 2)

Shown on model 203

Fig 2: Identifying Complete Exhaust System Remove/Install Components - Shown On Model 203 (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
1	Lift/jack up vehicle		AR00.60-P-1000P
2	Remove engine compartment paneling		AR61.20-P-1105P
3	Remove left rear diagonal strut	Model 209.4 only Installation: The diagonal struts must only be built-in, if the vehicle is standing with the wheels on the ground.
4	Disconnect left O2 sensor connector, upstream of TWC (G3/3x1) and right O2 sensor connector, upstream of TWC (G3/4x1).	Press connectors out of brackets.
5	Separate the left O2 sensor connector downstream of TWC (G3/5x1) O2 and the right sensor connector downstream of TWC (G3/6x1).	Press connectors out of brackets.
6	Detach the front exhaust system / catalytic converter at the exhaust manifold	Installation: Install new bolts (1). Inspect rivet nuts in exhaust manifold, install new nuts if necessary: ↓
		Replace rivet nuts in exhaust manifold.	AR49.10-P-5531-01DA
		All except model 209.377	*BA14.10-P-1002-01B
		Model 209.377	*BA14.10-P-1002-01N
		Caulking bolt	Figure
7	Support exhaust system
8	Unscrew bracket (2) for exhaust system on transmission by removing bolts (3)		*BA49.10-P-1007-01A
9	Detach bracket (2) at front exhaust system/right and left catalytic converter	Installation: Check the tapping plate (4) and replace it if required. Replace nuts (5).
			*BA49.10-P-1008-01A
10	Push together bracket (2)
11	Remove bracket (6) for exhaust system on the underbody		*BA49.10-P-1010-01A
12	Remove complete exhaust system	Installation: Check the rubber mount (7) and bracket (6), replace if required. Install exhaust system free of stress.
	Notes on disposing of catalytic converters		OS49.10-P-1000-01A
13	Install in the reverse order

EXHAUST MANIFOLD

Number	Designation		Engine 112 except 112.951/976	Engines 113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969/971/980/981/982/984/986/992/993/995	Engine 113.987/988/990/991
BA14.10-P-1002-01B	Flange connection, exhaust manifold and front exhaust pipes	Nm	20	20	20

EXHAUST MANIFOLD

Number	Designation		Engine 156
BA14.10-P-1002-01N	Flange connection for exhaust manifold/front exhaust pipe	Nm	20

EXHAUST SYSTEM

Number	Designation		Engines 112, 113 in model 203	Engine 112, 113 in model 209	Engine 156 in model 209
BA49.10-P-1007-01A	Bolt of exhaust bracket to transmission	Nm	20	20	20
BA49.10-P-1008-01A	Self-locking nut to front exhaust pipe	Nm	20	20	20
BA49.10-P-1010-01A	Bolt securing exhaust system to underfloor	Nm	20	20	-

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