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Remove/Install Exhaust System - AR49.10-P-7142MRI

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Engine 264 in model 205, 253 

MODIFICATION NOTES

17.12.2019 Document completely revised.    
G14470951Courtesy of MERCEDES-BENZ USA

Shown on model 205.0 with Engine 264 with code U21 (AMG performance exhaust system) 

Shown on model 253 with Engine 264 

G14470952Courtesy of MERCEDES-BENZ USA

Shown on model 205.176 with Engine 264 

G14470953Courtesy of MERCEDES-BENZ USA

Shown on model 205 

G14470954Courtesy of MERCEDES-BENZ USA
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
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
WARNING 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 danger zone. AS49.00-Z-0001-01A 
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
Notice  Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
Notice  Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
Notice  Notes on self-locking nuts and bolts   AH00.00-P-0001-01K0A
REMOVINGINSTALLING Remove/install     
1 Remove center and rear sections of lower Engine compartment lining. INSTALLATION IMPORTANT Only install center and rear lower rear Engine compartment paneling again after leak test. AR61.20-P-1105LW
2 Remove left and right underfloor paneling.   AR61.30-P-1001LW
3 Remove reinforcement (8). TORQUE SPECIFICATION Bolt, rear reinforcement to frame floor assembly *BA61.10-P-1004-01L 
4 Remove temperature sensor upstream of gasoline particulate filter (B163/4). Engine 264 in model 205, 253 with code 598 (Gasoline particulate filter (OPF) with sensor system) AR49.20-P-0200MRI 
5 Remove union nuts (2), seal exposed connections with suitable stop plugs and place lines to one side. Engine 264 in model 205, 253 with code 598 (Gasoline particulate filter (OPF) with sensor system)
INSTALLATION IMPORTANT Coat thread with heat-resistant lubricating paste. First slightly tighten union nuts (2) by hand and then fully tighten.		  
    Paste, hot lubrication 1 kg, DBL 6879.20 *BR00.45-Z-1005-06A 
    TORQUE SPECIFICATION Union nut, line, differential pressure sensor, gasoline particulate filter *BA07.04-P-1003-02B 
    SPECIAL TOOL Record plug Fig 2
    SPECIAL TOOL Box wrench bit Fig 1
6 Support exhaust system (1).    
REFER TO SPECIAL TOOLS 000 588 10 62 00 Support plate   WS26.00-P-3309B
REFER TO SPECIAL TOOLS 000 588 11 62 00 Major assembly mount   WS01.00-P-0092B
7 Release and disconnect electrical connector a left exhaust gas flap actuator motor (M16/53). Engine 264 in model 205 with code U21 (AMG Performance exhaust system)
Engine 264 in model 253 with code U16 (Exhaust system with acoustic flap)		  
8 Remove screw (3). Engine 264 in model 205, 253 with code 598 (Gasoline particulate filter (OPF) with sensor system)
TORQUE SPECIFICATION Screw, bracket of pressure line to gasoline particulate filter		 *BA49.10-P-1017-02P 
9 Remove Clamp (4). INSTALLATION IMPORTANT Replace clip (4).
TORQUE SPECIFICATION Clamp at catalytic converter and front exhaust system		 *BA49.10-P-1002-02P 
10 Remove exhaust system (1) from bracket (5). IMPORTANT Helper required.
TORQUE SPECIFICATION Screw, bracket for decoupling element to front exhaust system		 *BA49.10-P-1009-02P 
11 Remove elastomer bearings (6) from exhaust system (1). INSTALLATION IMPORTANT Lightly wet elastomer bearings (6) with lubricant.
Lubricant, rubber assembly 1 l		 *BR00.45-Z-1010-06A 
12 Remove elastomer bearings (7) from exhaust system (1) and remove exhaust system (1).    
REFER TO SPECIAL TOOLS 000 588 11 62 00 Major assembly mount   WS01.00-P-0092B
REFER TO SPECIAL TOOLS 000 588 10 62 00 Support plate INSTALLATION IMPORTANT Lightly wet elastomer bearings (7) with lubricant. WS26.00-P-3309B
    IMPORTANT Helper required.
Lubricant, rubber assembly 1 l		 *BR00.45-Z-1010-06A 
INSPECT Check     
13 Check decoupling element for damage and wear. If there are problems,
↓
Replace decoupling element.
TORQUE SPECIFICATION Nut, decoupling element for front exhaust system to bracket		 *BA49.10-P-1010-02P 
14 Check elastomer bearings (6, 7) for wear and damage. If there are problems,
↓
Replace elastomer bearings (6, 7).
INSTALLATION IMPORTANT Lightly wet elastomer bearings (6, 7) with lubricant. Lubricant, rubber assembly 1 l		 *BR00.45-Z-1010-06A 
CLEANING Clean     
15 Remove combustion and corrosion residues from separating points.    
16 Install in the reverse order.    
17 Check installation position and for unobstructed movement of exhaust system (1). If there are problems,
↓
Correct installation position of exhaust system (1).		  
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
18 Perform Engine test run, check Engine for proper operation and exhaust system (1) for leaks.    
19 Install center and rear lower Engine compartment lining.   AR61.20-P-1105LW
SENSORS

Number Designation Engine 264
BA07.04-P-1003-02B Union nut, line, differential pressure sensor, gasoline particulate filter Nm 20
EXHAUST SYSTEM

Number Designation Model 205 with Engine 264 Model 253 with Engine 264
BA49.10-P-1002-02P Clamp at catalytic converter and front exhaust system Nm 25 25
EXHAUST SYSTEM

Number Designation Model 205 with Engine 264 Model 253 with Engine 264
BA49.10-P-1009-02P Screw, bracket for decoupling element to front exhaust system Nm 20 20
EXHAUST SYSTEM

Number Designation Model 205 with Engine 264 Model 253 with Engine 264
BA49.10-P-1010-02P Nut, decoupling element for front exhaust system to bracket Nm 20 20
EXHAUST SYSTEM

Number Designation Model 205 with Engine 264 Model 253 with Engine 264
BA49.10-P-1017-02P Screw, bracket of pressure line to gasoline particulate filter Nm 5 5
FRAME FLOOR ASSEMBLY

Number Designation Model 205 Model 253
BA61.10-P-1004-01L Bolt, rear reinforcement to frame floor assembly Nm 23 24
Fig 1: Identifying Box Wrench Bit (000 589 70 03 00)
G13770756Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Record Plug (129 589 00 91 00)
G13668531Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1005-06A Paste, hot lubrication 1 kg, DBL 6879.20 A 000 989 76 51
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
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