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Home >> Mercedes Benz >> 2013 >> GLK350 Base >> Repair and Diagnosis >> Engine Mechanical >> Exhaust >> Exhaust System - 204 Chassis >> Testing & Repair >> Remove/install components for exhaust system - AR49.10-P-7100CW

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 

Fig 1: Identifying Exhaust System Remove/Install Components - Engine 271
G10000256Courtesy of MERCEDES-BENZ USA

Exhaust system for engine 271 

Fig 2: Identifying Exhaust System Remove/Install Components - Engine 272
G10000257Courtesy of MERCEDES-BENZ USA

Exhaust system for engine 272 

Fig 3: Identifying Exhaust System Remove/Install Components - Shown On Model 204.057
G10000258Courtesy of MERCEDES-BENZ USA

Shown: exhaust system for model 204.057 with code (920) Gasoline direct injection with stratified charge 

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 self-locking nuts and bolts   AH00.00-N-0001-01A
1.1 Remove both lower engine compartment paneling If necessary  
Model 204.9
INSTALLATION IMPORTANT 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 IMPORTANT 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 4-MATIC, 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
TORQUE SPECIFICATION *BA27.40-P-1008-01A 
TORQUE SPECIFICATION Model 204 *BA49.10-P-1031-01AC 
TORQUE SPECIFICATION Model 204 *BA49.10-P-1032-01AC 
TORQUE SPECIFICATION Model 207 *BA49.10-P-1040-01AE 
TORQUE SPECIFICATION Model 207 *BA49.10-P-1041-01AE 
4 Remove corresponding diagonal strut(s) at rear Model 207.4, if required  
TORQUE SPECIFICATION *BA61.10-P-1007-01H 
TORQUE SPECIFICATION *BA61.10-P-1008-01H 
TORQUE SPECIFICATION *BA61.10-P-1009-01H 
5 Detach corresponding components of exhaust system at separation points and remove INSTALLATION IMPORTANT Align components for exhaust system tension-free before tightening the bolted connections.
INSTALLATION IMPORTANT Apply lubricating paste to exhaust rubber bearings (8).		  
Lubricant paste
Nut, exhaust manifold to cylinder head		 *BR00.45-Z-1002-06A 
TORQUE SPECIFICATION Engines 271, 272, 273, 276 *BA14.10-P-1001-01E 
TORQUE SPECIFICATION Engine 156 *BA14.10-P-1001-01N 
TORQUE SPECIFICATION Engine 278
Screw/bolt, CAT to exhaust manifold or exhaust manifold flange connection/front exhaust pipe:		 *BA09.40-P-1001-01R 
TORQUE SPECIFICATION Engine 272, 273 *BA14.10-P-1002-01E 
TORQUE SPECIFICATION Engine 156
Screw/bolt, transmission to engine:		 *BA14.10-P-1002-01N 
TORQUE SPECIFICATION Transmission 716.6 *BA26.10-P-1001-01C 
TORQUE SPECIFICATION Transmission 722.6, 722.9
Model 204:		 *BA27.40-P-1008-01A 
TORQUE SPECIFICATION Screw/bolt, CAT holder to CAT except engine 276 *BA49.10-P-1001-01AC 
TORQUE SPECIFICATION Screw/bolt, CAT flange to center muffler except engine 276 *BA49.10-P-1005-01AC 
TORQUE SPECIFICATION Screw/bolt, exhaust line clamp at front right to front left except engine 276 *BA49.10-P-1007-01AC 
TORQUE SPECIFICATION Screw/bolt, exhaust pipe holder to transmission except engine 276 *BA49.10-P-1008-01AC 
TORQUE SPECIFICATION Screw/bolt, exhaust pipe holder to exhaust pipe except engine 276 *BA49.10-P-1009-01AC 
TORQUE SPECIFICATION Nut, center muffler clamp to connecting pipe with catalytic converter *BA49.10-P-1012-01AC 
TORQUE SPECIFICATION Nut, exhaust rubber mount holder to rear axle *BA49.10-P-1014-01AC 
TORQUE SPECIFICATION Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier *BA49.10-P-1015-01AC 
TORQUE SPECIFICATION Screw/bolt, cross connection left rear to right rear *BA49.10-P-1016-01AC 
TORQUE SPECIFICATION Screw/bolt, catalytic converter to exhaust manifold *BA49.10-P-1024-01AC 
TORQUE SPECIFICATION Nut, center muffler clamp to rear muffler except engine 276 *BA49.10-P-1025-01AC 
TORQUE SPECIFICATION Screw/bolt, EGR lines clamp to CAT except engine 276 *BA49.10-P-1032-01AC 
TORQUE SPECIFICATION Screw/bolt, bracket to transmission except engine 276 *BA49.10-P-1033-01AC 
TORQUE SPECIFICATION Screw/bolt, exhaust system holder to transmission for engine 276 *BA49.10-P-1035-01AC 
TORQUE SPECIFICATION Screw/bolt, exhaust system holder to exhaust flange for engine 276
Model 207:		 *BA49.10-P-1036-01AC 
TORQUE SPECIFICATION Screw/bolt, catalytic converter to exhaust manifold *BA49.10-P-1001-01AE 
TORQUE SPECIFICATION Screw/bolt, catalytic converter holder to catalytic converter *BA49.10-P-1010-01AE 
TORQUE SPECIFICATION Screw/bolt, bracket to transmission *BA49.10-P-1011-01AE 
TORQUE SPECIFICATION Screw/bolt, catalytic converter connecting pipe to catalytic converter *BA49.10-P-1021-01AE 
TORQUE SPECIFICATION Screw/bolt, exhaust bracket to transmission *BA49.10-P-1023-01AE 
TORQUE SPECIFICATION Screw/bolt, exhaust bracket to exhaust *BA49.10-P-1024-01AE 
TORQUE SPECIFICATION Nut, center muffler clamp to connecting pipe with catalytic converter *BA49.10-P-1032-01AE 
TORQUE SPECIFICATION Nut, center muffler clamp to rear muffler *BA49.10-P-1033-01AE 
TORQUE SPECIFICATION Screw/bolt, cross connection left rear to right rear *BA49.10-P-1035-01AE 
TORQUE SPECIFICATION Screw/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  
TORQUE SPECIFICATION Model 204 *BA49.10-P-1018-01AC 
TORQUE SPECIFICATION Model 207 *BA49.10-P-1034-01AE 
CLEAN 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    
INSPECT Checking     
10 Inspect installation position and unobstructed movement of all components of the 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
11 Perform an engine test run and check exhaust system for leaks    
EXHAUST MANIFOLD

Number Designation Engine 156
BA14.10-P-1001-01N Nut, exhaust manifold to cylinder head Nm 22
BA14.10-P-1002-01N Flange connection for exhaust manifold/front exhaust pipe Nm 20
EXHAUST MANIFOLD

Number Designation Engine 271 Engine 272 Engine 273 Engine 276
BA14.10-P-1001-01E Nut, exhaust manifold to cylinder head Nm 21 16 16 16
BA14.10-P-1002-01E Screw/bolt, catalytic converter to exhaust manifold Nm - 20 20 -
TURBOCHARGER

Number Designation Engine 278
BA09.40-P-1001-01R Nut, turbocharger/exhaust manifold to cylinder head M7 Nm 15
M8 Nm 20
EXHAUST SYSTEM

Number Designation Engine 156, 271, 272 in model 204 Engine 276 in model 204
BA49.10-P-1001-01AC Screw/bolt, catalytic converter holder to catalytic converter Nm 35 -
BA49.10-P-1005-01AC Screw/bolt, catalytic converter flange to center muffler Nm 20 -
BA49.10-P-1007-01AC Screw/bolt, exhaust line clamp at the front right to front left Nm 35 -
BA49.10-P-1008-01AC Screw/bolt, exhaust pipe bracket to transmission Nm 20 -
BA49.10-P-1009-01AC Screw/bolt, exhaust pipe bracket to exhaust pipe Nm 20 -
BA49.10-P-1012-01AC Nut, center muffler clamp to connecting pipe with catalytic converter Nm 35 35
BA49.10-P-1014-01AC Nut, exhaust rubber mount holder to rear axle Nm 23 23
BA49.10-P-1015-01AC Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier Nm 20 20
BA49.10-P-1016-01AC Screw/bolt, cross connection left rear to right rear Nm 20 20
BA49.10-P-1018-01AC Screw/bolt, vibration damper to center muffler Nm 20 -
BA49.10-P-1024-01AC Screw/bolt, catalytic converter to exhaust manifold Nm 20 20
BA49.10-P-1025-01AC Nut, center muffler clamp to rear muffler Nm 35 35
BA49.10-P-1031-01AC Screw/bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner Nm 9 -
BA49.10-P-1032-01AC Screw/bolt, exhaust gas recirculation line clamp to catalytic converter Nm 9 -
BA49.10-P-1033-01AC Screw/bolt, bracket to transmission Nm 39 -
BA49.10-P-1035-01AC Screw/bolt, exhaust system bracket to transmission Nm - 25
BA49.10-P-1036-01AC Screw/bolt, exhaust system bracket to exhaust flange Nm - 35
EXHAUST SYSTEM

Number Designation Engine 271, 272, 273, 276, 278 in model 207
BA49.10-P-1001-01AE Screw/bolt, catalytic converter to exhaust manifold Nm 20
BA49.10-P-1010-01AE Screw/bolt, catalytic converter holder to catalytic converter Nm 35
BA49.10-P-1011-01AE Screw/bolt, bracket to transmission Nm 39
BA49.10-P-1021-01AE Screw/bolt, catalytic converter connecting pipe to catalytic converter Nm 20
BA49.10-P-1023-01AE Screw/bolt, exhaust bracket to transmission Nm 20
BA49.10-P-1024-01AE Bolt/nut, exhaust bracket to exhaust Nm 20
BA49.10-P-1032-01AE Screw/bolt/nut, center muffler clamp to connecting pipe with catalytic converter Nm 35
BA49.10-P-1033-01AE Nut, center muffler clamp to rear muffler Nm 35
BA49.10-P-1034-01AE Screw/bolt, vibration damper to center muffler Nm 20
BA49.10-P-1035-01AE Screw/bolt, cross connection left rear to right rear Nm 20
BA49.10-P-1036-01AE Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier Nm 20
BA49.10-P-1040-01AE Screw/bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner Nm 9
BA49.10-P-1041-01AE Screw/bolt, exhaust gas recirculation line clamp to catalytic converter Nm 9
HOUSING

Number Designation Transmission 722.6 except 722.660/661/662/663/666/673/674 Transmission 722.9
BA27.40-P-1008-01A Screw/bolt, automatic transmission to engine M10X40 Nm 39 38
M10X90 Nm 39 38
M12 Nm - -
COMPLETE MANUAL TRANSMISSION

Number Designation Transmission 716.6
BA26.10-P-1001-01C Screw/bolt, transmission to engine Nm 40
FRAME FLOOR ASSEMBLY

Number Designation Model 207.4
BA61.10-P-1007-01H Screw/bolt, rear diagonal strut on spare wheel well Nm 80
BA61.10-P-1008-01H Screw/bolt, rear diagonal strut on longitudinal member Nm 80
BA61.10-P-1009-01H Screw/bolt, rear diagonal strut to bracket Nm 17
REPAIR MATERIALS

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