(Remove/Install Exhaust System - AR49.10-P-7142OLC)

Engine 654 in model 213, 238, 257 

Shown on model 213 except code 971 (Exhaust system with DPF generation 1.5) 

Courtesy of MERCEDES-BENZ USA

Shown on model 213.011 with code 971 (Exhaust system with DPF generation 1.5) 

Courtesy of MERCEDES-BENZ USA

Shown on model 257.319 with code 972 (Exhaust system with DPF generation 2.0) 

Courtesy of MERCEDES-BENZ USA

Shown on model 257 with code M014 (Engine increased performance) except code M005 (Vehicles with 4MATIC/all-wheel drive) 

Courtesy of MERCEDES-BENZ USA

	Risk of death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. Engine 654 in model 213.011/211	AS00.00-Z-0035-01A
	Risk of burn injuries,  suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning  caused by skin contact with solid components of the exhaust.	Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.	AS49.00-Z-0001-01A
	Risk of injury  caused by scraping 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
	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment	Engine 654 in model 213.011/211	AH00.00-Z-0300-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Remove/install
1	Remove lower engine compartment paneling.	Engine 654 in model 257	AR61.20-P-1105FR
		Engine 654 in model 213, 238 : Only install lower engine compartment lining after leak test.	AR61.20-P-1105LWE
2.1	Release side underfloor panelings in area of reinforcement (6).	Engine 654 in model 213, 238
			AR61.30-P-1001LWE
2.2	Remove side underfloor paneling.	Engine 654 in model 257
			AR61.30-P-1001FR
3	Remove left rear diagonal strut.	Engine 654 in model 213.2, 238.4
			AR61.10-P-5142LWP
4	Remove NOx sensor downstream of SCR catalytic converter (N37/8b1).		AR49.20-P-2065OIH
5	Remove AdBlue® metering valve 2 (Y129/1) from exhaust system (5) and place to one side with connected lines.	Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0)
			AR49.20-P-0029OIH
6.1	Remove union nut and pull temperature sensor downstream of SCR catalytic converter (B16/27) out of exhaust system (5).	Engine 654 in model 213, 238, 257 with code 971 (Exhaust system with DPF, generation 1.5) : Coat thread of the union nut with hot lubrication paste.
		Exhaust temperature sensor downstream of SCR catalytic converter	*BA07.04-P-1020-02A
		Paste, hot lubrication 1 kg, DBL 6879.20	*BR00.45-Z-1005-06A
		Box wrench bit	Fig 2
6.2	Remove union nut and pull underbody temperature sensor upstream of SCR catalytic converter (B94/34) out of exhaust system (5).	Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0) : Coat thread of the union nut with hot lubrication paste.
		Union nut, temperature sensor to catalytic converter	*BA07.04-P-1002-02A
		Paste, hot lubrication 1 kg, DBL 6879.20	*BR00.45-Z-1005-06A
		Box wrench bit	Fig 2
7	Seal opening in exhaust system (5) with suitable stop plug.	Record plug	Fig 1
8	Remove underbody NOx sensor downstream of SCR catalytic converter (N37/3).	Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0)
			AR49.20-P-2064OIH
9	Release and disconnect electrical connector from the exhaust gas flap (2).
10	Remove reinforcement (6)	Bolt, rear reinforcement to frame floor assembly	*BA61.10-P-1004-01L
11	Support rear muffler (4).
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
	000 588 10 62 00 Support plate		WS26.00-P-3309B
12	Open clamp of exhaust system (5) at diesel particulate filter.	: Replace clamp and seal.
		Engine 654 in model 257Clamp to diesel particulate filter and front exhaust system	*BA49.10-P-1001-02O
		Model 238 with engine 654Clamp to diesel particulate filter and front exhaust system	*BA49.10-P-1003-02J
		Model 213 with engine 654Clamp to diesel particulate filter and front exhaust system	*BA49.10-P-1003-02H
13	Remove bracket (12) from transmission.	Engine 654 in model 213, 238, 257 with code M014 (Engine uprated) except code M005 (Vehicles with 4MATIC/all-wheel drive)
		Engine 654 in model 238 with code M014 (Engine uprated) except code M005 (Vehicles with 4MATIC/all-wheel drive) Bolt, holder for front exhaust system to transmission	*BA49.10-P-1018-02J
		Engine 654 in model 213 with code M014 (Engine uprated) except code M005 (Vehicles with 4MATIC/all-wheel drive) Bolt, holder for front exhaust system to transmission	*BA49.10-P-1018-02H
		Engine 654 in model 257 with code M014 (Engine uprated) except code M005 (Vehicles with 4MATIC/all-wheel drive) Bolt, holder for front exhaust system to transmission	*BA49.10-P-1016-02O
14	Remove screws of bracket (1)	Engine 654 in model 257Bolt, decoupling element for exhaust system to exhaust system	*BA49.10-P-1007-02O
		Model 238 with engine 654Bolt, bracket for decoupling element to body/exhaust system at front	*BA49.10-P-1011-02J
		Model 213 with engine 654Bolt, bracket for decoupling element to body/exhaust system at front	*BA49.10-P-1011-02H
15	Remove exhaust system (5) from elastomer bearings (3)	: Wet elastomer bearings (3) with lubricant. Lubricant, rubber assembly 1 l	*BR00.45-Z-1010-06A
16	Remove the exhaust system (5).
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
	000 588 10 62 00 Support plate	Aid of helper required.	WS26.00-P-3309B
17	Remove exhaust gas flap (2) from exhaust system (5).	When replacing exhaust system (5).
		Engine 654 in model 213, 238	AR49.10-P-5507OLC
		Engine 654 in model 257	AR49.10-P-5507OIB
18	Remove bracket (13)	When replacing exhaust system (5).
		Engine 654 in model 257Bolt/nut, holder to front exhaust system/transmission holder	*BA49.10-P-1015-02O
		Engine 654 in model 238Bolt/nut, holder to front exhaust system/transmission holder	*BA49.10-P-1017-02J
		Engine 654 in model 213Bolt/nut, holder to front exhaust system/transmission holder	*BA49.10-P-1017-02H
	Clean
19	Remove combustion and corrosion residues a separating point.
	Check
20	Check elastomer bearings (3) for damage and wear.	If damage is identified, ↓ Replace elastomer bearings (3).
		Lubricant, rubber assembly 1 l	*BR00.45-Z-1010-06A
21.1	Check front decoupling element for damage and wear	Engine 654 in model 213, 238 Engine 654 in model 257 except code 972 (Exhaust system with DPF, generation 2.0) If damage is identified ↓ Replace front decoupling element
		Engine 654 in model 238Nut, decoupling element for front exhaust system to bracket	*BA49.10-P-1012-02J
		Engine 654 in model 213Nut, decoupling element for front exhaust system to bracket	*BA49.10-P-1012-02H
		Engine 654 in model 257Nut, decoupling element for front exhaust system to bracket	*BA49.10-P-1006-02O
21.2	Check decoupling element at rear for damage and wear.	Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0) If damage is identified, ↓ Replace front decoupling element
		Engine 654.8 in model 257 with code 972 (Exhaust system with DPF, generation 2.0) Bolt, decoupling element for exhaust system to exhaust system	*BA49.10-P-1007-02O
22	Install in the reverse order.
	Check
23	Check installation position and for unobstructed movement of exhaust system (5) and correct if necessary.
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
24	Perform engine test run and check exhaust system (5) for leaks.
25	Install lower engine compartment lining.	Engine 654 in model 257	AR61.20-P-1105FR
		Engine 654 in model 213, 238	AR61.20-P-1105LWE

Fig 1: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Box Wrench Bit (000 589 69 03 00)

Courtesy of MERCEDES-BENZ USA