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

ENGINES 156, 157, 273, 275, 278 in MODEL 216 

ENGINES 156, 157, 272, 273, 275, 276, 278 in MODEL 221 

Fig 1: Identifying Exhaust System Remove/Install Components - Shown On Engine 273
G10110817Courtesy of MERCEDES-BENZ USA

Shown on engine 273 

REMOVINGINSTALLING Remove/install     
DANGER 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
DANGER 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
DANGER 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 Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
1 Disconnect electrical connector for corresponding O2 sensors and expose feed lines If necessary AR07.52-P-5303SX
2 Remove bottom engine compartment paneling If necessary:  
Vehicles without top protection AR61.20-P-1105SX
Vehicles with top protection, code Z07
INSTALLATION IMPORTANT Only install lower engine compartment paneling after engine test run and leak test.		 AR61.20-P-1105SXS
3 Remove rear skid plate Vehicles with top protection, code Z07, if necessary AR61.40-P-1010SXS
4 Remove crossmember (1) If necessary  
TORQUE SPECIFICATION *BA62.30-P-1001-01F 
5 Detach corresponding part of exhaust system at separation points and remove IMPORTANT Engine 272, 273: Cut off right rear muffler (6) when replacing at separation point (arrow) identified by center punch marks with chain pipe cutter at right angles.
IMPORTANT Model 221 with engine 278: detach vacuum line for exhaust flaps in rear muffler at vacuum unit.
IMPORTANT Apply liquid lubricant to exhaust rubber mounts (7).
INSTALLATION IMPORTANT Engine 272, 273: Secure right rear muffler (6) using hose clamp (6a).
INSTALLATION IMPORTANT Align parts of exhaust system tension-free before tightening bolted connections.		  
TORQUE SPECIFICATION *BA49.10-P-1001-01Z 
TORQUE SPECIFICATION *BA49.10-P-1002-01Z 
TORQUE SPECIFICATION *BA49.10-P-1003-01Z 
TORQUE SPECIFICATION Except engines 157, 276, 278, *BA49.10-P-1004-01Z 
TORQUE SPECIFICATION Except engine 276, 278 *BA49.10-P-1005-01Z 
TORQUE SPECIFICATION *BA49.10-P-1006-01Z 
TORQUE SPECIFICATION Except engine 276, 278 *BA49.10-P-1007-01Z 
TORQUE SPECIFICATION Except engine 276, 278 *BA49.10-P-1008-01Z 
TORQUE SPECIFICATION *BA49.10-P-1009-01Z 
TORQUE SPECIFICATION Except engines 156, 157, 276, 278 *BA49.10-P-1010-01Z 
TORQUE SPECIFICATION *BA49.10-P-1011-01Z 
TORQUE SPECIFICATION Except engines 156, 157, 276, 278 *BA49.10-P-1012-01Z 
TORQUE SPECIFICATION Except engines 156, 157, 276, 278 *BA49.10-P-1013-01Z 
TORQUE SPECIFICATION Except engines 156, 157, 276, 278 *BA49.10-P-1014-01Z 
Lubricant paste *BR00.45-Z-1002-06A 
CLEAN Clean     
6 Remove combustion and corrosion residue at separation points    
INSPECT Checking     
7 Check exhaust rubber mount (7) IMPORTANT Check for wear and damage, and replace if necessary.  
8 Install in the reverse order    
INSPECT Checking     
9 Inspect installation position and unobstructed movement of all parts of exhaust system    
DANGER 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
10 Test run engine and check exhaust system for leaks    
CROSSMEMBER AND FRONT REINFORCEMENT

Number Designation Model 216 Model 221
BA62.30-P-1001-01F Bolt, cross member to transmission tunnel Nm 25 25
EXHAUST SYSTEM

Number Designation Engine 272 in model 221 Engine 273 in model 221 Engine 275 in model 221
BA49.10-P-1001-01Z Bolt, catalytic converter to exhaust manifold Nm 25 25 -
BA49.10-P-1002-01Z Nut, Torca clamp for center muffler to catalytic converter Nm 55 55 -
BA49.10-P-1003-01Z Bolt, rear muffler hose clamp to catalytic converter Nm 35 35 -
BA49.10-P-1004-01Z Bolt, hose clamp of rear muffler to center muffler Nm 35 35 -
BA49.10-P-1005-01Z Nut, muffler brace to rear muffler Nm 25 25 25
BA49.10-P-1006-01Z Bolt, rubber mount bracket to frame floor Nm 20 20 20
BA49.10-P-1007-01Z Nut connecting catalytic converter bracket to catalytic converter Nm 11 11 11
BA49.10-P-1008-01Z Bolt, catalytic converter bracket to transmission Nm 20 20 20
BA49.10-P-1009-01Z Bolt, exhaust rubber mount to rear axle carrier Nm 20 20 20
BA49.10-P-1010-01Z Bolt connecting catalytic converter clamp to exhaust gas turbocharger Nm - - 25
BA49.10-P-1011-01Z Bolt, catalytic converter bracket to top bracket/transmission housing Nm - - 20
BA49.10-P-1012-01Z Nut connecting Torca clamp of right catalytic converter to left catalytic converter Nm - - 55
BA49.10-P-1013-01Z Bolt connecting center muffler hose clamp to catalytic converter Nm - - 35
BA49.10-P-1014-01Z Bolt, tail piece of exhaust pipe to rear muffler Nm - - 8
EXHAUST SYSTEM

Number Designation Engine 273 in model 216 Engine 275 in model 216
BA49.10-P-1001-01Z Bolt, catalytic converter to exhaust manifold Nm 25 -
BA49.10-P-1002-01Z Nut, Torca clamp for center muffler to catalytic converter Nm 55 -
BA49.10-P-1003-01Z Bolt, rear muffler hose clamp to catalytic converter Nm 35 -
BA49.10-P-1004-01Z Bolt, hose clamp of rear muffler to center muffler Nm 35 -
BA49.10-P-1005-01Z Nut, muffler brace to rear muffler Nm 25 25
BA49.10-P-1006-01Z Bolt, rubber mount bracket to frame floor Nm 20 20
BA49.10-P-1007-01Z Nut connecting catalytic converter bracket to catalytic converter Nm 11 11
BA49.10-P-1008-01Z Bolt, catalytic converter bracket to transmission Nm 20 20
BA49.10-P-1009-01Z Bolt, exhaust rubber mount to rear axle carrier Nm 20 20
BA49.10-P-1010-01Z Bolt connecting catalytic converter clamp to exhaust gas turbocharger Nm - 25
BA49.10-P-1011-01Z Bolt, catalytic converter bracket to top bracket/transmission housing Nm - 20
BA49.10-P-1012-01Z Nut connecting Torca clamp of right catalytic converter to left catalytic converter Nm - 55
BA49.10-P-1013-01Z Bolt connecting center muffler hose clamp to catalytic converter Nm - 35
BA49.10-P-1014-01Z Bolt, tail piece of exhaust pipe to rear muffler Nm 8 8
EXHAUST SYSTEM

Number Designation Engine 156 in model 216 Engine 156 in model 221
BA49.10-P-1001-01Z Bolt, catalytic converter to exhaust manifold Nm 25 25
BA49.10-P-1002-01Z Nut, Torca clamp for center muffler to catalytic converter Nm 55 55
BA49.10-P-1003-01Z Bolt, rear muffler hose clamp to catalytic converter Nm 35 35
BA49.10-P-1004-01Z Bolt, hose clamp of rear muffler to center muffler Nm 35 35
BA49.10-P-1005-01Z Nut, muffler brace to rear muffler Nm 25 25
BA49.10-P-1006-01Z Bolt, rubber mount bracket to frame floor Nm 20 20
BA49.10-P-1007-01Z Nut connecting catalytic converter bracket to catalytic converter Nm 11 11
BA49.10-P-1008-01Z Bolt, catalytic converter bracket to transmission Nm 20 20
BA49.10-P-1009-01Z Bolt, exhaust rubber mount to rear axle carrier Nm 20 20
BA49.10-P-1011-01Z Bolt, catalytic converter bracket to top bracket/transmission housing Nm 20 20
EXHAUST SYSTEM

Number Designation Engine 157 in model 216/221
BA49.10-P-1001-01Z Bolt, catalytic converter to exhaust manifold Nm 25
BA49.10-P-1002-01Z Nut, Torca clamp for center muffler to catalytic converter Nm 55
BA49.10-P-1003-01Z Bolt, rear muffler hose clamp to catalytic converter Nm 35
BA49.10-P-1005-01Z Nut, muffler brace to rear muffler Nm 25
BA49.10-P-1006-01Z Bolt, rubber mount bracket to frame floor Nm 20
BA49.10-P-1007-01Z Nut connecting catalytic converter bracket to catalytic converter Nm 11
BA49.10-P-1008-01Z Bolt, catalytic converter bracket to transmission Nm 27
BA49.10-P-1009-01Z Bolt, exhaust rubber mount to rear axle carrier Nm 20
BA49.10-P-1011-01Z Bolt, catalytic converter bracket to top bracket/transmission housing Nm 20
EXHAUST SYSTEM

Number Designation Engine 276 in model 221 Engine 278 in model 216 Engine 278 in model 221
BA49.10-P-1001-01Z Bolt, catalytic converter to exhaust manifold Nm 25 25 25
BA49.10-P-1002-01Z Nut, Torca clamp for center muffler to catalytic converter Nm - 55 55
BA49.10-P-1003-01Z Bolt, rear muffler hose clamp to catalytic converter Nm 35 35 35
BA49.10-P-1006-01Z Bolt, rubber mount bracket to frame floor Nm 22 22 22
BA49.10-P-1009-01Z Bolt, exhaust rubber mount to rear axle carrier Nm 22 22 22
BA49.10-P-1011-01Z Bolt, catalytic converter bracket to top bracket/transmission housing Nm 20 20 20
REPAIR MATERIALS

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