W220 Exhaust System 20.

20. Exhaust System

20.1 Exhaust manifold
20.1.1 General description
Data and dimension The exhaust manifold is fitted between the cylinder head and the tur-
MultiductMaterial : nodular cast bochargers. The manifold consists of the multiducts and the exhaust
iron pipes with expansion bellows.
Weight: 8 kg The part called Multiduct, between the cylinder head and the exhaust
Test pressure: 10 bar
(water side)
pipes, acts as a bracket for the whole exhaust manifold, including the
Exhaust pipes insulation box.
Material : special, heat resistant The cooling water discharging from the cylinder head cools the Multi-
alloy nodular cast iron duct. The multiducts are vented through a venting pipe along the en-
Bellows : multiply design gine.
Material: heat resistant steel The cooling water flows through the Multiduct down to the HT-water
channel in the engine block.
The Multiduct also connects the air receiver in the engine block with
the inlet air channel in the cylinder head.
All the surfaces, engine block/Multiduct, cylinder head/ Multiduct and
exhaust pipes/Multiduct are sealed off.
The complete exhaust system is enclosed in an insulation box.

Caution ! The outside surfaces of the box get hot.

The exhaust gas temperature of each cylinder is checked by means of

sensors.

Note : For the exhaust pipes shemas, Cf. the chapters 200-205 of the
spare part catalogue.

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 20. Exhaust System W200

20.1.2 Expansion bellows - replacement

1 Remove the relevant panels of the insulation box.
2 Remove the screw fittings and remove the expansion bel-
lows.
3 Check that the exhaust pipe flanges are parallel and
coaxial to stop lateral forces from being applied on the bellows.
Use new screws with high-temperature grease and new V clamps
(Cf. Fig. 20-1 and spare part catalogue).

V clamp model
1 2

1. Exhaust pipe
2. Expansion bellow
3. V clamp

Fig. 20-1

If you have the other model with square flanges, change the seals (Cf.
Fig. 20-2.)

Caution ! The expansion bellows have a direction. The arrow on each ex-
pansion bellows must be in the direction of the exhaust air
flow.

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 W220 Exhaust System 20.

Square flange model

1 2 4 5
1. Exhaust pipe
2. Expansion bellow
3. Seal
4. Screw
5. Nut

3 3

Fig. 20-2

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 20. Exhaust System W220

20.1.3 Multiducts – replacement

Fig. 20-3

20.1.3.1 Multiduct removal (single multiduct) :

1 Drain the engine water circuit (under the cylinder head
level).
2 Remove the cylinder head (Cf. Chap 12.).
3 Remove the venting pipe and the exhaust gas temperature
sensor (Cf. Fig. 20-4).

1
1. Venting pipe
2. Exhaust gas temperature sensor

Fig. 20-4

4 Remove the screws of the exhaust pipes and of the isola-

tion box.
5 Remove the multiduct.

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 W220 Exhaust System 20.

20.1.3.2 Multiduct mounting (single multiduct)

1 Fit seal under the multiduct.
2 Align the multiduct with the other thanks to a metal ruler.
3 Tighten the multiduct to the block (Cf. Chap 07)
4 Screw the exhaust pipes and the isolation box (Cf. Chap
07).
5 Fit on place the cylinder head with the seal between the
cylinder head and the multiduct.
6 Coat the clamping screws between the cylinder head and
the multiduct with high temperature grease (Orapi paste).
7 Tighten the cylinder head (Cf. Chap )
8 Tighten the multiduct on the cylinder head (Cf. Chap 07).
The long spacers are near the cylinder head (Cf. Fig. 20-5).
9 Refit the venting pipe and the exhaust gas temperature
sensor (Cf. Fig. 20-4)

1. Short spacer
2. Long spacer
1

Fig. 20-5

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 20. Exhaust System W220

20.1.3.3 Multiduct removal (all multiducts) :

1 Remove the cylinder heads (Cf. Chap ).
2 Remove the venting pipes and the exhaust gas tempera-
ture sensors (Cf. Fig. 20-4).
3 Remove the exhaust pipes and the isolation box (Cf. Chap
20.1.2).
4 Remove the multiducts.
20.1.3.4 Multiduct mounting (all multiducts) :
a) For bank A :
1 Install cylinder heads A1 and A6 (or A9).
2 Tighten the cylinder head nuts by hand.
3 Fit seal under the multiducts A1 and A6 (or A9).
4 Tighten the multiducts to the block (Cf. Chap 07).
5 Remove the two cylinder heads
6 Using a metal ruler placed between multiducts A1 and A6
(or A9) align the other multiducts with their seal and tighten the
multiducts to the block (Cf. Chap 07)
7 Screw the exhaust pipes and the isolation box (Cf. Chap
07)
8 Fit on place the cylinder heads with the seal between the
cylinder head and the multiduct.
9 Coat the clamping screws between the cylinder heads and
the multiducts with high temperature grease (Orapi paste).
10 Tighten the cylinder heads (Cf. Chap ).
11 Tighten the multiducts on the cylinder heads (Cf. Chap
07). The long spacers are near the cylinder heads (Cf. Fig. 20-5).
12 Refit the venting pipes and the exhaust gas temperature
sensors (Cf. Fig. 20-4)
b) For bank B :
Same as bank A using cylinders heads and multiducts B1 and B6 (or
B9)

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 W220 Exhaust system 20

20.2 Waste gate

20.2.1 General description
The Waste Gate regulating valve is mounted as a by-pass between the
two turbo’s gas inlet and the turbo’s gas outlet bank A.
This valve regulates the gas/air ratio by controlling the air flow provi-
ded by the turbochargers.
This valve is electrically controlled by the “ WECS ” system.

12V220 waste gate location

Fig. 20-6

Nota : Don't forget to lubricate the waste gate system with Molycote
type grease ref M6E000071 (cf. Chap )

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 20 Exhaust system W220

18V220 waste gate location

Fig. 20-7

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