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

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ENGINES 642, 651 in MODEL 212, 218 

Exhaust system for engine 642 

Fig 1: Exhaust System Remove/Install Components - Exhaust System For Engine 642
G09976855Courtesy of MERCEDES-BENZ USA

Shown on ENGINE 642 

Fig 2: Exhaust System Remove/Install Components - Shown On Engine 642 (1 Of 2)
G09976856Courtesy of MERCEDES-BENZ USA
Fig 3: Exhaust System Remove/Install Components - Shown On Engine 642 (2 Of 2)
G09976857Courtesy of MERCEDES-BENZ USA

Shown on ENGINE 651 

Fig 4: Exhaust System Remove/Install Components - Shown On Engine 651 (1 Of 2)
G09976858Courtesy of MERCEDES-BENZ USA
Fig 5: Exhaust System Remove/Install Components - Shown On Engine 651 (2 Of 2)
G09976859Courtesy of MERCEDES-BENZ USA
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 Remove bottom sections of soundproofing INSTALLATION IMPORTANT Only install soundproofing bottom section after an engine test run and leak test. AR94.30-P-5300EW
2 Mount assembly tool (01) on decoupling element (15) NOTES When working on exhaust system, the decoupling element (15) can get damaged through bending or twisting of the exhaust pipe. The exhaust system can begin to leak at the decoupling element (15) as a result.  
SPECIAL TOOL Assembly tool (engine 642) Fig 6
SPECIAL TOOL Assembly tool (engine 651) Fig 7
3 Remove three-way catalytic converter (6) Engine 642 AR49.10-P-5500OGE 
4.1 Remove diesel particulate filter (2) and pressure lines for pressure differential sensor Engine 642 AR14.40-P-1000OGE
4.2 Remove catalytic converter diesel particulate filter unit (8) Model 212 with engine 651 except 4MATIC
Model 218 with engine 651		 AR49.10-P-5501CD 
4.3 Remove three-way catalytic converter (6) Model 212 with 4MATIC AR49.10-P-5500OMD 
5 Remove corresponding diagonal strut(s) at rear Model 212.2, if required  
TORQUE SPECIFICATION *BA61.10-P-1006-01H 
6 Loosen corresponding components of exhaust system at connecting points and remove IMPORTANT Check exhaust rubber mounts (4, 5) for damage and wear
INSTALLATION IMPORTANT Align components for exhaust system tension-free before tightening the bolted connections.
INSTALLATION IMPORTANT Apply lubricating paste to exhaust rubber bearings (5).		  
Antifriction paste, rubber parts 2.5 kg, DB supply specification 6867.00 *BR00.45-Z-1002-06A 
TORQUE SPECIFICATION Bolt connecting catalytic converter to turbocharger *BA49.10-P-1002-01AE 
TORQUE SPECIFICATION Bolt, diesel particulate filter clamp to turbocharger *BA49.10-P-1003-01AE 
TORQUE SPECIFICATION Nut attaching diesel particulate filter above *BA49.10-P-1004-01AE 
TORQUE SPECIFICATION Nut, catalytic converter clamp to diesel particulate filter *BA49.10-P-1005-01AE 
TORQUE SPECIFICATION Bolt, upper diesel particulate filter bracket to diesel particulate filter/cylinder crankcase *BA49.10-P-1006-01AE 
TORQUE SPECIFICATION Screw/bolt, diesel particulate filter bracket to oil pan *BA49.10-P-1008-01AE 
TORQUE SPECIFICATION Bolt/nut, bracket of diesel particulate filter to lower diesel particulate filter *BA49.10-P-1009-01AE 
TORQUE SPECIFICATION Bolt, bracket to transmission *BA49.10-P-1011-01AE 
TORQUE SPECIFICATION Bolt, connecting pipe clamp to diesel particulate filter *BA49.10-P-1020-01AE 
TORQUE SPECIFICATION Bolt, exhaust bracket to transmission *BA49.10-P-1023-01AE 
TORQUE SPECIFICATION Bolt/nut, exhaust bracket to exhaust *BA49.10-P-1024-01AE 
TORQUE SPECIFICATION Bolt, exhaust system to main floor panel *BA49.10-P-1025-01AE 
TORQUE SPECIFICATION Nut, suspension ring to connecting pipe *BA49.10-P-1026-01AE 
TORQUE SPECIFICATION Nut, rear muffler clamp to connecting pipe *BA49.10-P-1031-01AE 
TORQUE SPECIFICATION Bolt, cross connection left rear to right rear *BA49.10-P-1035-01AE 
TORQUE SPECIFICATION Bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier *BA49.10-P-1036-01AE 
TORQUE SPECIFICATION Transmission 711.67 *BA26.10-P-1001-01F 
TORQUE SPECIFICATION Transmission 716.6 *BA26.10-P-1001-01C 
TORQUE SPECIFICATION Transmission 722.6, 722.9 *BA27.40-P-1008-01A 
7 Remove combustion/corrosion residues at connecting points    
8 Install in the reverse order    
INSPECT Checking     
9 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
10 Test run engine and check exhaust system for leaks    
COMPLETE MANUAL TRANSMISSION

Number Designation Transmission 716.6
BA26.10-P-1001-01C Bolt, transmission to engine Nm 40
COMPLETE MANUAL TRANSMISSION

Number Designation Transmission 711.67
BA26.10-P-1001-01F Bolt, transmission to engine Nm 39
HOUSING

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

Number Designation Engine 642, 651 in model 212 Engines 642, 651 in model 218
BA49.10-P-1002-01AE Bolt connecting catalytic converter to turbocharger Nm 20 20
BA49.10-P-1003-01AE Bolt, diesel particulate filter clamp to turbocharger Nm 18 18
BA49.10-P-1004-01AE Nut attaching diesel particulate filter above Nm 20 20
BA49.10-P-1005-01AE Nut, catalytic converter clamp to diesel particulate filter Nm 15 15
BA49.10-P-1006-01AE Bolt, upper diesel particulate filter bracket to diesel particulate filter/cylinder crankcase Nm 20 20
BA49.10-P-1008-01AE Bolt, diesel particulate filter bracket to oil pan Nm 20 20
BA49.10-P-1009-01AE Bolt/nut, bracket of diesel particulate filter to lower diesel particulate filter Nm 20 20
BA49.10-P-1011-01AE Bolt, bracket to transmission Nm 39 39
BA49.10-P-1020-01AE Bolt, connecting pipe clamp to diesel particulate filter Nm 35 35
BA49.10-P-1023-01AE Bolt of exhaust bracket to transmission Nm 20 20
BA49.10-P-1024-01AE Bolt/nut, exhaust bracket to exhaust Nm 20 20
BA49.10-P-1025-01AE Bolt, exhaust system to main floor panel M8 Nm 20 20
M10 Nm 50 50
BA49.10-P-1026-01AE Nut, suspension ring to connecting pipe Nm 20 20
BA49.10-P-1031-01AE Nut, rear muffler clamp to connecting pipe Nm 35 35
BA49.10-P-1035-01AE Bolt, cross connection left rear to right rear Nm 20 20
BA49.10-P-1036-01AE Bolt, exhaust rubber mount holder to frame floor assembly/rear axle carrier Nm 20 20
FRAME FLOOR ASSEMBLY

Number Designation Model 212
BA61.10-P-1006-01H Bolt, mount for rear diagonal strut bracket on body Nm 60
Fig 6: Identifying Assembly Tool (642 589 01 63 00)
G09976860Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Assembly Tool (651 589 06 63 00)
G09976861Courtesy of MERCEDES-BENZ USA
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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