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

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 Remove/Install Components

Courtesy of MERCEDES-BENZ USA

Exhaust system for engine 272 

Fig 2: Identifying Exhaust System Remove/Install Components

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 Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off of 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  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 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.	AS00.00-Z-0017-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1.1	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 required
			*BA61.10-P-1007-01H
			*BA61.10-P-1008-01H
			*BA61.10-P-1009-01H
5	Detach corresponding components of exhaust system at separation 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 Nut, exhaust manifold to cylinder head	*BR00.45-Z-1002-06A
		Engines 271, 272, 273, 276	*BA14.10-P-1001-01E
		Engine 156	*BA14.10-P-1001-01N
		Engine 278 Bolt, CAT to exhaust manifold or exhaust manifold flange connection /front exhaust pipe:	*BA09.40-P-1001-01R
		Engine 272, 273	*BA14.10-P-1002-01E
		Engine 156 Bolt, transmission to engine:	*BA14.10-P-1002-01N
		Transmission 716.6	*BA26.10-P-1001-01C
		Transmission 722.6	*BA27.40-P-1001-01B
		Transmission 722.9 Model 204:	*BA27.40-P-1001-01E
		Bolt, CAT holder to CAT except engine 276	*BA49.10-P-1001-01AC
		Bolt, CAT flange to center muffler except engine 276	*BA49.10-P-1005-01AC
		Bolt, exhaust line clamp at front right to front left except engine 276	*BA49.10-P-1007-01AC
		Bolt, exhaust pipe holder to transmission except engine 276	*BA49.10-P-1008-01AC
		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
		Bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	*BA49.10-P-1015-01AC
		Bolt, cross connection left rear to right rear	*BA49.10-P-1016-01AC
		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
		Bolt, EGR lines clamp to CAT except engine 276	*BA49.10-P-1032-01AC
		Bolt, bracket to transmission except engine 276	*BA49.10-P-1033-01AC
		Bolt, exhaust system holder to transmission for engine 276	*BA49.10-P-1035-01AC
		Bolt, exhaust system holder to exhaust flange for engine 276 Model 207:	*BA49.10-P-1036-01AC
		Bolt, catalytic converter to exhaust manifold	*BA49.10-P-1001-01AE
		Bolt, catalytic converter holder to catalytic converter	*BA49.10-P-1010-01AE
		Bolt, bracket to transmission	*BA49.10-P-1011-01AE
		Bolt, catalytic converter connecting pipe to catalytic converter	*BA49.10-P-1021-01AE
		Bolt, exhaust bracket to transmission	*BA49.10-P-1023-01AE
		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
		Bolt, cross connection left rear to right rear	*BA49.10-P-1035-01AE
		Bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	*BA49.10-P-1036-01AE
6	Remove 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 separation points
8	Check exhaust rubber mount (8) for damage and wear
9	Install in the reverse order
	Checking
10	Inspect 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 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
11	Test run engine and check exhaust system for leaks