Remove/install catalytic converter

AR49.10-P-5500PS

Remove/install catalytic converter

11.3.10

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off the lifting platform.

Align vehicle between columns of lifting platform and position the four support plates at lifting platform 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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Open engine hood

Model 203

AR88.40-P-1000P

Model 209

AR88.40-P-1000Q

2

Remove cylinder head cover trim

AR01.20-P-5014-02A



*BA01.20-P-1002-01G



*BA01.20-P-1003-01G

3

Remove air filter housing

AR09.10-P-1150PM

4

Remove heat shield

AR49.00-P-1000-01T



*BA07.04-P-1004-01G



*BA49.10-P-1012-01I



*BA49.10-P-1013-01I

5

Unclip electrical connector for O2 sensor upstream of CAT (G3/2) from cable holders and disconnect

6

Unclip electrical connector for electrical connector upstream of CAT (B19/7) from cable holders and disconnect

7

Detach differential pressure sensor (DPF) (B28/8) from bracket

 Do not disconnect molded hoses for pressure differential sensor (DPF) (B28/8) from pressure lines (3).



*BA07.04-P-1004-01G

8

Remove bolt (1) connecting catalytic converter hose clamp (111) to turbocharger



*BA49.10-P-1015-01I

9

Remove rear bottom part of soundproofing

AR94.30-P-5300P

10

Loosen flanged connection (2)



*BA49.10-P-1014-01I

11

Unscrew nuts (2a) from exhaust system bracket



*BA49.10-P-1018-01I

12

Remove bolts (3a, 3b)



*BA14.40-P-1003-01A



*BA14.40-P-1004-01A

13

Unscrew union nuts for pressure lines (3)



*BA14.40-P-1002-01A

14

Remove pressure lines (3) with pressure differential sensor (DPF) (B28/8) and heat shield bracket from above

15

Unclip electrical connector (5) for temperature sensor downstream of CAT (B19/8) from cable holder (6) and disconnect

16

Unscrew nut (1a) at catalytic converter bracket

 Secure catalytic converter (111) and diesel particulate filter (114) to prevent falling down.



*BA49.10-P-1001-01I

17

Unscrew nuts (2b) from bracket on transmission



*BA49.10-P-1017-01I

18

Take out catalytic converter (111) and diesel particulate filter (114) as a unit

 Installation: Replace sealing cone between turbocharger and catalytic converter (111).

19

Disconnect bolted connections between catalytic converter (111) and diesel particulate filter (114)

 Installation: Replace bolts.



*BA14.40-P-1001-01A

20

Remove catalytic converter (111) from diesel particulate filter (114)

 Carefully remove catalytic converter (111).

 Installation: Install new seal (4).



Notes on disposing of catalytic converters

OS49.10-P-1000-01A

21

Remove O2 sensor upstream of CAT (G3/2)

Only when replacing catalytic convertor (111)

 Installation: Coat thread of O2 sensor upstream of CAT (G3/2) with paste.



*BA07.04-P-1003-01G

Paste

*BR00.45-Z-1005-06A

22

Install in the reverse order



Checking

23

Check installation position and clearance of exhaust system

 The exhaust system must be mounted free of tension, align exhaust system if required.

 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

24

Check leaktightness of exhaust system when engine is running

Number

Designation

Engine
646.962/963/966

BA01.20-P-1002-01G

Bolt, cylinder head cover trim to cylinder head

Nm

9

BA01.20-P-1003-01G

Bolt, cover to charge air manifold.

Nm

9

Number

Designation

Engine
646.951/
961/962/
963/966

BA07.04-P-1003-01G

O2 sensor on catalytic converter

Nm

50

BA07.04-P-1004-01G

Bolt connecting pressure differential sensor to heat shield bracket

Nm

9

Number

Designation

Engine
646.951/
961/962/
963/966 with
code 474

BA14.40-P-1001-01A

Nut, bolted connection for diesel particulate filter to catalytic converter

Stage 1

Nm

10

Stage 2

Nm

30

BA14.40-P-1002-01A

Union nut connecting pressure line to
diesel particulate filter

Nm

20

BA14.40-P-1003-01A

Bolt for pressure line clamping plate

Nm

3

BA14.40-P-1004-01A

Bracket, pressure line to catalytic converter

Nm

3

Number

Designation

Engine
646.951/
961/962/
963/966 will
Code 474

BA49.10-P-1001-01I

Self-locking nut, catalytic converter bracket to CAT

Nm

20

BA49.10-P-1012-01I

Bolt, heat shield to cylinder head

Nm

9

BA49.10-P-1013-01I

Bolt, heat shield bracket to cylinder head

Nm

9

BA49.10-P-1014-01I

Self-locking nut connecting diesel particulate filter flange connection to pipe line

Nm

20

BA49.10-P-1015-01I

Bolt connecting catalytic converter hose clamp to turbocharger

Nm

15

BA49.10-P-1017-01I

Self-locking nut connecting diesel particulate filter to bracket at transmission

Nm

20

BA49.10-P-1018-01I

Self-locking nut, connecting pipe line to bracket

Nm

20

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51