Mercedes-Benz Cars 2000-05

Exhaust Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust pipe
     
    Manifold retaining bolts and manifold
     

  4.  

To install:

  1. Clean the gasket mating surfaces and install a new gasket.
  2.  
  3. Install or connect the following:

    Manifold and bolts. Torque bolts to 18 ft. lbs. (25 Nm), working from the middle outward.
     
    Exhaust pipe
     
    Negative battery cable
     

  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Plastic inner fender liners
     
    Exhaust manifold heat shields
     

  4.  


NOTE
If the bolts are difficult to remove or the threads show signs of damage, replace the rivet nuts in the manifold.



Exhaust system-to-manifold flanged connection mounting bolts
 
Front exhaust pipe at the transmission exhaust bracket
 
Exhaust manifold-to-cylinder head mounting bolts
 
Exhaust manifold
 

  1. Clean the gasket mating surfaces.
  2.  

To install:

  1. Install or connect the following:

    Exhaust manifold using new gaskets and nuts. tighten the nuts to 12 ft. lbs. (16 Nm).
     
    Front exhaust pipe to the transmission exhaust bracket
     
    Exhaust system to the manifolds and tighten the mounting bolts to 15 ft. lbs. (20 Nm)
     
    Exhaust manifold heat shields
     
    Plastic inner fender liners
     
    Front wheels and tighten the lug bolts to 110 ft. lbs. (150 Nm)
     
    Negative battery cable
     

  2.  
  3. Read fault memory, encode the radio and normalize the power windows.
  4.  
  5. Start the vehicle and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust pipe
     
    Manifold retaining bolts and manifold
     

  4.  

To install:

  1. Clean the gasket mating surfaces and install a new gasket.
  2.  
  3. Install or connect the following:

    Manifold and bolts. Torque bolts to 18 ft. lbs. (25 Nm), working from the middle outward
     
    Exhaust pipe
     
    Negative battery cable
     

  4.  

Diesel Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust pipe
     
    Manifold retaining bolts and manifold
     

  4.  

To install:

  1. Clean the gasket mating surfaces and install a new gasket.
  2.  
  3. Install or connect the following:

    Manifold and bolts. Torque bolts to 18 ft. lbs. (25 Nm), working from the middle outward
     
    Exhaust pipe
     
    Negative battery cable
     

  4.  

Inline 4- And 6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust pipe
     
    Transmission exhaust support, if equipped
     
    Air injection tube, if equipped
     
    Manifold retaining bolts and manifold
     

  4.  

To install:



Click image to see an enlarged view

Fig. Exploded view of the mounting-4-cylinder shown, inline 6-cylinder similar

  1. Install or connect the following:

    Manifold gasket and exhaust manifold. Torque the bolts in an even pattern.
     
    Air injection tube
     
    Transmission exhaust support
     
    Exhaust pipe with new self-locking nuts. Torque to 25 ft. lbs. (34 Nm).
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust pipe
     
    Transmission exhaust support if equipped
     
    Air injection tube if equipped
     
    Manifold retaining bolts and manifold
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the mounting-4-cylinder shown, inline 6-cylinder similar

  1. Install or connect the following:

    Manifold gasket and exhaust manifold. Torque the bolts in an even pattern
     
    Air injection tube
     
    Transmission exhaust support
     
    Exhaust pipe with new self-locking nuts. Torque to 25 ft. lbs. (34 Nm)
     
    Negative battery cable
     

  2.  

Inline 4- And 6-Cylinder Gasoline Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust pipe
     
    Transmission exhaust support if equipped
     
    Air injection tube if equipped
     
    Manifold retaining bolts and manifold
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the mounting-4-cylinder shown, inline 6-cylinder similar

  1. Install or connect the following:

    Manifold gasket and exhaust manifold. Torque the bolts in an even pattern
     
    Air injection tube
     
    Transmission exhaust support
     
    Exhaust pipe with new self-locking nuts. Torque to 25 ft. lbs. (34 Nm)
     
    Negative battery cable
     

  2.  

M111 And M271
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    On M271 engines, the catalytic converter is integrated with the manifold.



    Negative battery cable
     
    Exhaust pipe
     
    Oxygen sensor connector
     
    Transmission exhaust support, if equipped
     
    Air injection tube, if equipped
     
    Manifold retaining bolts and manifold
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the inline engine exhaust manifold mounting

  1. Install or connect the following:

    Manifold gasket and exhaust manifold. Torque the bolts in an even pattern to 16 ft. lbs. (21 Nm).
     
    Air injection tube
     
    Transmission exhaust support
     
    Exhaust pipe with new self-locking nuts. Torque to 25 ft. lbs. (34 Nm) on M111, 15 ft. lbs. (20 Nm) on M271
     
    Negative battery cable
     

  2.  

M112 And M113
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Inspect the rivet nuts in the manifold and replace as needed.



    Negative battery cable
     
    Engine undercover
     
    Exhaust pipes
     
    Air filter assembly
     
    Ignition coils for additional clearance, if necessary
     
    Heat shields on 4MATIC models
     
    Auxiliary coolant pump for additional clearance, if necessary
     
    Exhaust manifold
     

  6.  
  7. Installation is the reverse of removal. Use new gaskets. Torque the manifold mounting bolts to 12 ft. lbs. (16 Nm) and the exhaust system to the manifolds to 15 ft. lbs. (20 Nm).

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold-M112 engine, M113 similar

  8.  

M272 Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Air filter housing assembly
     
    Upper exhaust manifold nuts
     
    Catalytic converter and exhaust pipe
     
    Lower exhaust manifold nuts and manifold
     

  6.  
  7. Installation is the reverse of removal. Use new gaskets. Torque the manifold mounting bolts to 12 ft. lbs. (16 Nm) and the exhaust system to the manifolds to 15 ft. lbs. (20 Nm).
  8.  

V6, V8 & 12-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Exhaust pipes
     
    Fan shroud
     
    Engine mount for the manifold being serviced
     
    Fuel supply and return pipes, if removing left manifold
     
    Self-locking bolts and exhaust manifold
     

  6.  

To install:

  1. Inspect the rivet nuts in the manifold and replace as needed.
  2.  
  3. Install or connect the following:

    Manifold gasket and exhaust manifold. Torque the mounting bolts to 23 ft. lbs. (30 Nm).
     
    Fuel lines, if removed
     
    Engine mounts
     
    Fan shroud
     
    Exhaust pipes
     
    Engine under cover
     

  4.  
  5. Connect the negative battery cable, start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Exhaust pipes
     
    Fan shroud.
     
    Engine mount for the manifold being serviced
     
    Fuel supply and return pipes if removing left manifold
     
    Self-locking bolts and exhaust manifold
     

  6.  

To install:

  1. Inspect the rivet nuts in the manifold and replace as needed.
  2.  
  3. Install or connect the following:

    Manifold gasket and exhaust manifold. Torque the mounting bolts to 23 ft. lbs. (30 Nm)
     
    Fuel lines if removed
     
    Engine mounts
     
    Fan shroud.
     
    Exhaust pipes
     
    Engine under cover
     

  4.  
  5. Connect the negative battery cable, start the engine and check for leaks.
  6.  

V6, V8, And 12-Cylinder Gasoline Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Exhaust pipes
     
    Fan shroud.
     
    Engine mount for the manifold being serviced
     
    Fuel supply and return pipes if removing left manifold
     
    Self-locking bolts and exhaust manifold
     

  6.  

To install:

  1. Inspect the rivet nuts in the manifold and replace as needed.
  2.  
  3. Install or connect the following:

    Manifold gasket and exhaust manifold. Torque the mounting bolts to 23 ft. lbs. (30 Nm)
     
    Fuel lines if removed
     
    Engine mounts
     
    Fan shroud.
     
    Exhaust pipes
     
    Engine under cover
     

  4.  
  5. Connect the negative battery cable, start the engine and check for leaks.
  6.  

 
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