LEMON Manuals: Even more car manuals for everyone
Home >> Smart >> 2015 >> Fortwo Electric Drive, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 69 (Exhaust Manifold, Emission Control System - 212 Chassis - 1 Of 2) >> Testing & Repair >> Remove/install exhaust manifold >> Remove/install exhaust manifold - AR14.10-P-3915CD

Remove/install exhaust manifold - AR14.10-P-3915CD

WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.

ENGINE 651 in MODEL 166, 172, 204, 207, 212, 218, 221 

Fig 1: Exhaust Manifold Remove/Install Components (1 Of 3)
G09974976Courtesy of MERCEDES-BENZ USA
Fig 2: Exhaust Manifold Remove/Install Components (2 Of 3)
G09974977Courtesy of MERCEDES-BENZ USA
Fig 3: Exhaust Manifold Remove/Install Components (3 Of 3)
G09974978Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER Risk of death  when touching components on vehicles with high-voltage on-board electrical system Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not  carry out any work on high-voltage on-board electrical systems. AS54.00-Z-0001-01A
DANGER 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
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
1 Remove cylinder head cover trim    
2 Remove engine MODEL 212.098/298  
      AR01.10-P-2400EH
3.1 Unfasten catalytic converter diesel particulate filter unit on cylinder head Model 166, 172, 204 (except 204.9), 207, 212 (except 212.08/09/28/29), 218, 221  
    MODEL 166 AR49.10-P-5501GQ
    Model 172, 204 (except 204.9), 207, 212 (except 212.08/09/28/29), 218 AR49.10-P-5501CD
    MODEL 221 AR49.10-P-5501SXI
3.2 Remove catalytic converter Model 204.9, 212.08/09/28/29 (except 212.098/298)  
      AR49.10-P-5500OMD
4 Remove boost pressure control flap aneroid capsule with bracket (7)   AR09.40-P-1002-01CD
    IMPORTANT To do this detach vacuum hose (8), remove nut (9) and screw/bolts (10, 11).
INSTALLATION IMPORTANT If screw/bolts (10) are round Allen head bolts, these must be replaced by heat-resistant hexagon head bolts.
INSTALLATION IMPORTANT Adjust boost pressure control flap aneroid capsule.		  
    TORQUE SPECIFICATION Fastening nut on turbocharger vacuum unit *BA09.40-P-1012-01P 
    "Yellow" locking paint *BR00.45-Z-1027-07A 
    SPECIAL TOOL Vacuum tester Fig 4
    SPECIAL TOOL Hand vacuum pump Fig 5
5 Remove screw/bolts (18) and remove heat shield (19) on exhaust manifold (6) IMPORTANT If installed.  
    TORQUE SPECIFICATION Bolt, shield to exhaust manifold *BA14.10-P-1002-01P 
6 Unscrew nuts (14, 15) and remove bracket (13) MODEL 204, 207, 212, 218, 221  
7 Remove screw/bolts (16, arrows) and take of holder (12) MODEL 204, 207, 212, 218, 221  
    TORQUE SPECIFICATION MODEL 204 *BA49.10-P-1029-01AC 
    TORQUE SPECIFICATION MODEL 207, 212, 218 *BA49.10-P-1006-01AE 
    TORQUE SPECIFICATION MODEL 221 *BA49.10-P-1011-01AJ 
8 Remove temperature sensor upstream of ATL (B19/11)   AR07.04-P-0071CD
9 Unfasten oil dipstick guide tube on holder (20) MODEL 166, 172  
      AR01.45-P-9600CD
10 Remove screw/bolts (21), remove bracket (20) and place to one side MODEL 166, 172  
    TORQUE SPECIFICATION Screw/bolt, air filter bracket to cylinder head *BA09.10-P-1001-01K 
11 Remove screws/bolts (1) and remove heat shield (2) TORQUE SPECIFICATION Bolt, shield to exhaust manifold *BA14.10-P-1002-01P 
12 Remove screw/bolts (3) INSTALLATION IMPORTANT Replace screw/bolts (3) and seals.  
    TORQUE SPECIFICATION Bolt, exhaust gas recirculation pipe to exhaust manifold *BA14.20-P-1002-01K 
13 Remove screws/bolts (4) INSTALLATION IMPORTANT Replace screw/bolts (4) and seals.  
    TORQUE SPECIFICATION Flange connection, exhaust manifold to turbocharger *BA09.40-P-1001-01P 
14 Loosen front and rear bracket for the ATL Model 166, 172, 204, 207, 212 (except 212.098/298), 218, 221 for sequential turbocharging AR09.40-P-6020CDA
    Model 204, 212 (except 212.098/298) for single-speed charging AR09.40-P-6020CDB
    MODEL 212.098/298
IMPORTANT In order to create a sufficient gap for extending exhaust manifold, the ATL must be lowered somewhat and the seal removed.		 AR09.40-P-6020EH
15 Disconnect ground line at the on-board electrical system battery MODEL 166, 172  
IMPORTANT Notes on battery   AH54.10-P-0001-01A
    MODEL 166 AR54.10-P-0003GZ
    MODEL 172
NOTES Insulate ground line of battery.
Unwanted contact of the disconnected ground line with the ground point of the battery can occur otherwise.
IMPORTANT Do not connect no-load current retention unit.		 AR54.10-P-0003W
16 Remove screw/bolt (23) and press heat shield (22) slightly downwards INSTALLATION IMPORTANT Ensure that the mounting bracket for screw/bolt (23) is not pinched by the heat shield (22) under the exhaust manifold.  
17 Unscrew nuts (5) and remove exhaust manifold (6) INSTALLATION IMPORTANT For the casting version of the exhaust manifold (6) as of an engine number D6519XX 30 174293, for which the smaller guide bore is located at the underside of the third cylinder, an additional centering sleeve made out of plastic is used for installation of the exhaust manifold (6).
This is attached to the lower fastening bore of the first cylinder on the exhaust manifold (6). During commissioning of engine plastic sleeve melts and must be reinstalled for later reassembly of the exhaust manifold (6).
Replace nuts (5).
For sheet steel version of the exhaust manifold (6) there is no centering sleeve required.
Observe tightening pattern of exhaust manifold (6).
↓
Tightening pattern for exhaust manifold		  
      AR09.40-P-6020-11CD
    TORQUE SPECIFICATION Nut on exhaust manifold to cylinder head for steel exhaust manifold *BA14.10-P-1001-01P 
    TORQUE SPECIFICATION Nut on exhaust manifold to cylinder head for cast exhaust manifold *BA14.10-P-1003-01P 
18 Remove the bearing plates (24) MODEL 166, 172  
19 Remove exhaust manifold (6)    
20 Take off seals Installation: Replace seals.  
INSPECT Check     
21 Check studs for damage and loose seating IMPORTANT Install new stud bolts if damaged and tighten loose stud bolts.  
    TORQUE SPECIFICATION Stud bolts, exhaust manifold to cylinder head *BA01.30-P-1003-01V 
CLEAN Clean     
22 Clean sealing surfaces on the exhaust manifold (6) and cylinder head NOTES Do not use any sharp-edged or pointed objects for cleaning sealing surface at cylinder head.
The sealing surfaces can get damaged otherwise.		  
23 Install in the reverse order    
DANGER 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 Carry out an engine test run and check exhaust system for leaktightness    
TIGHTENING TORQUES, CYLINDER HEAD

Number Designation ENGINE 651
BA01.30-P-1003-01V Stud bolts, exhaust manifold to cylinder head Nm 20
AIR FILTER

Number Designation ENGINE 651
BA09.10-P-1001-01K Screw/bolt, air filter bracket to cylinder head Nm 9
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1001-01P Flange connection, exhaust manifold to turbocharger Stage 1 Nm 20
Stage 2 ∠° 90
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1012-01P Fastening nut on turbocharger vacuum unit M6 Nm 9
EXHAUST MANIFOLD

Number Designation ENGINE 651
BA14.10-P-1001-01P Nut on exhaust manifold to cylinder head for steel exhaust manifold Nm 30
EXHAUST MANIFOLD

Number Designation ENGINE 651
BA14.10-P-1002-01P Bolt, shield to exhaust manifold Nm 8
EXHAUST MANIFOLD

Number Designation ENGINE 651
BA14.10-P-1003-01P Nut on exhaust manifold to cylinder head for cast exhaust manifold Stage 1 Nm 15
Stage 2 Nm 35
EXHAUST GAS RECIRCULATION

Number Designation ENGINE 651
BA14.20-P-1002-01K Bolt, exhaust gas recirculation pipe to exhaust manifold Stage 1 Nm 12
Stage 2 ∠° 90
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 207 ENGINE 642, 651 in MODEL 212
BA49.10-P-1006-01AE Bolt, upper diesel particulate filter bracket to diesel particulate filter/crankcase Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 218
BA49.10-P-1006-01AE Bolt, upper diesel particulate filter bracket to diesel particulate filter/crankcase Nm 20
EXHAUST SYSTEM

Number Designation ENGINE 651 in MODEL 221
BA49.10-P-1011-01AJ Bolt, upper diesel particulate filter bracket to diesel particulate filter/cylinder crankcase Nm 20
EXHAUST SYSTEM

Number Designation ENGINE 642, 646, 651 in MODEL 204
BA49.10-P-1029-01AC Catalytic converter/diesel particle unit nut bolt/nut on crankcase Nm 20
Fig 4: Identifying Vacuum Tester (201 589 13 21 00)
G09974979Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Hand Vacuum Pump (001 589 73 21 00)
G09974980Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1027-07A "Yellow" locking paint Lackfabrik Bader GmbH & Co. KG
scientia non olet · About LEMON Manuals