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

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ENGINES 156, 272, 273 in MODEL 212

Exhaust system for engine 272

Fig 1: Exhaust System Remove/Install Components - Exhaust System For Engine 272

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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
	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
	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 on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Remove engine compartment paneling	If necessary Only install engine compartment paneling after engine test run and leak test.	AR61.20-P-1105EW
2	Disconnect electrical connector(s) for O2 sensor(s) and expose feed lines
3	Remove exhaust gas recirculation lines	Engine 272.983	AR14.20-P-1020-01EWD
			*BA27.40-P-1008-01A
			*BA49.10-P-1040-01AE
			*BA49.10-P-1041-01AE
4	Remove corresponding diagonal strut(s) at rear	Model 212.2, if required
4	Remove corresponding diagonal strut(s) at rear		*BA61.10-P-1006-01H
5	Loosen corresponding components of exhaust system at connecting points and remove	Align components for exhaust system tension-free before tightening the bolted connections. Apply lubricating paste to exhaust rubber bearings (8).
		Lubricant paste	*BR00.45-Z-1002-06A
		Screw/bolt, catalytic converter to exhaust manifold	*BA49.10-P-1001-01AE
		Screw/bolt, catalytic converter holder to catalytic converter	*BA49.10-P-1010-01AE
		Screw/bolt, bracket to transmission	*BA49.10-P-1011-01AE
		Screw/bolt, catalytic converter connecting pipe to catalytic converter	*BA49.10-P-1021-01AE
		Screw/bolt, exhaust bracket to transmission	*BA49.10-P-1023-01AE
		Screw/bolt, exhaust bracket to exhaust	*BA49.10-P-1024-01AE
		Nut, center muffler clamp to connecting pipe with catalytic converter	*BA49.10-P-1032-01AE
		Nut, center muffler clamp to rear muffler	*BA49.10-P-1033-01AE
		Screw/bolt, vibration damper to center muffler	*BA49.10-P-1034-01AE
		Screw/bolt, cross connection left rear to right rear	*BA49.10-P-1035-01AE
		Screw/bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier	*BA49.10-P-1036-01AE
		Screw/bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner	*BA49.10-P-1040-01AE
		Screw/bolt, exhaust gas recirculation line clamp to catalytic converter	*BA49.10-P-1041-01AE
		Transmission 716.6	*BA26.10-P-1001-01C
		Transmission 722.6, 722.9	*BA27.40-P-1008-01A
	Clean
6	Remove combustion and corrosion residue at separation points
7	Check exhaust rubber mount (8) for damage and wear
8	Install in the reverse order
	Checking
9	Inspect installation position and unobstructed movement of all components of the exhaust system
	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	Perform an engine test run and check exhaust system for leaks

EXHAUST SYSTEM

Number	Designation		Engine 156, 157, 271, 272, 273, 276, 278 in model 212
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 212
BA61.10-P-1006-01H	Screw/bolt, mount for rear diagonal strut bracket on body	Nm	60

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