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Remove/Install Components For Exhaust System - AR49.10-P-7100GQB

Engine 642, 651 in model 166 

G14238138Courtesy of MERCEDES-BENZ USA
WARNING Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
CAUTION 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 avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
Notes on self-locking Nuts and Bolts   AH00.00-N-0001-01A
REMOVINGINSTALLING Remove/install     
1 Lift vehicle with lifting platform.   AR00.60-P-1000GZ
2 Remove corresponding underfloor panelings. If necessary.  
    INSTALLATION IMPORTANT Only install underfloor paneling after the engine test run and leak test. AR61.30-P-1001GQ
3 Remove diesel particulate filter. If necessary.  
    Engine 642 in model 166 AR49.10-P-5501OGR 
    Engine 651 in model 166 AR49.10-P-5501GQ
4 Remove temperature sensor upstream of SCR catalytic converter at SCR catalytic converter. If necessary.  
    Engine 642, 651 in model 166
with code U42 (BlueTEC diesel exhaust treatment (SCR))		 AR14.40-P-2011GZB
5 Release and disconnect electrical connector of NOx sensor downstream of SCR catalytic converter and expose feed line. If necessary.  
    Engine 642 in model 166 with code U42 (BlueTEC diesel exhaust treatment (SCR))
Engine 642 in model 166 with code U77 (Diesel Emission control BLUETEC (SCR))		 AR49.20-P-2062OGR 
    Engine 651 in model 166 with code U42 (BlueTEC diesel exhaust treatment (SCR)) AR14.40-P-2038GQ
6 Release corresponding components of exhaust system at separating points and remove. INSTALLATION IMPORTANT Align components for the exhaust system before firmly tightening screw connections free of tension.
INSTALLATION IMPORTANT Apply lubricating paste to the decoupling elements.		  
    TORQUE SPECIFICATION Engine 651 in model 166 Bolt, exhaust input module clamp to turbocharger *BA49.10-P-1003-01AK 
    TORQUE SPECIFICATION Engine 642 in model 166
Engine 651 in model 166 Nut, exhaust system to rear cross member		 *BA49.10-P-1014-01AK 
    TORQUE SPECIFICATION Engine 642 in model 166
Engine 651 in model 166 Bolt, center exhaust rubber mount bracket to body		 *BA49.10-P-1010-01AK 
    TORQUE SPECIFICATION Engine 642 in model 166 Engine 651 in model 166 Bolt, clamp between rear diesel particulate filter and SCR catalytic converter (thick clamp, hexagon) *BA49.10-P-1009-01AK 
    TORQUE SPECIFICATION Engine 642 in model 166 Engine 651 in model 166 Bolt, clamp between rear diesel particulate filter and SCR catalytic converter (thin clamp, Torx) *BA49.10-P-1008-01AK 
    TORQUE SPECIFICATION Engine 642 in model 166
Engine 651 in model 166 Bolt, clamp between exhaust input module and oxidation catalytic converter		 *BA49.10-P-1007-01AK 
    TORQUE SPECIFICATION Engine 642 in model 166
Engine 651 in model 166 Nut, exhaust rubber mount to exhaust system/centering plate/strut		 *BA49.10-P-1006-01AK 
    TORQUE SPECIFICATION Engine 642 in model 166 Bolt, exhaust input module flange to turbocharger *BA49.10-P-1002-01AK 
    TORQUE SPECIFICATION Bolt, exhaust input module clamp to turbocharger *BA49.10-P-1003-01AK 
    Antifriction paste, rubber parts 2.5 kg, DBL 6867.00 *BR00.45-Z-1002-06A 
CLEAN Clean     
7 Remove combustion and corrosion residue at connecting points.    
INSPECT Check     
8 Check decoupling elements. IMPORTANT Check for wear and damage, and replace if necessary.  
    TORQUE SPECIFICATION Engine 642 in model 166
Engine 651 in model 166 Nut, exhaust rubber mount to exhaust system/centering plate/strut		 *BA49.10-P-1006-01AK 
9 Install in the reverse order.    
INSPECT Check     
10 Check installation position and unobstructed movement of all components of the exhaust system.    
WARNING 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
11 Perform engine test run and check leak tightness of the exhaust system.    
EXHAUST SYSTEM

Number Designation Engine 642 in model 166
BA49.10-P-1002-01AK Bolt, exhaust input module flange to turbocharger Nm 20
EXHAUST SYSTEM

Number Designation Engine 642 in model 166 Engine 651 in model 166
BA49.10-P-1003-01AK Bolt, exhaust input module clamp to turbocharger Nm - 17
EXHAUST SYSTEM

Number Designation Engine 642 in model 166 Engine 651 in model 166
BA49.10-P-1006-01AK Nut, exhaust rubber mount to exhaust system/centering plate/strut Nm 20 20
EXHAUST SYSTEM

Number Designation Engine 642 in model 166 Engine 651 in model 166
BA49.10-P-1007-01AK Bolt, clamp between exhaust input module and oxidation catalytic converter Nm 17 17
EXHAUST SYSTEM

Number Designation Engine 642 in model 166 Engine 651 in model 166
BA49.10-P-1008-01AK Bolt, clamp between rear diesel particulate filter and SCR catalytic converter (thin clamp, Torx) Nm 17 17
EXHAUST SYSTEM

Number Designation Engine 642 in model 166 Engine 651 in model 166
BA49.10-P-1009-01AK Bolt, clamp between rear diesel particulate filter and SCR catalytic converter (thick clamp, hexagon) Nm 35 35
EXHAUST SYSTEM

Number Designation Engine 642 in model 166 Engine 651 in model 166
BA49.10-P-1010-01AK Bolt, center exhaust rubber mount bracket to body Nm 18 18
EXHAUST SYSTEM

Number Designation Engine 642 in model 166 Engine 651 in model 166
BA49.10-P-1014-01AK Nut, exhaust system to rear cross member Nm 22 22
REPAIR MATERIALS

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