Remove/install catalytic converter

AR49.10-P-5500TS

Remove/install catalytic converter

11.3.10

 

Remove/install

 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

Remove air filter housing

Except engine 646.8

AR09.10-P-1150T

Engine 646.8

AR09.10-P-1150TXX

2

Dismount the electrical line of the O2 sensor upstream of TWC (G3/2)

Except engine 646.8

AR07.04-P-0080TD

Engine 646.8

AR07.04-P-0080TX

3

Disconnect electrical connector at pressure differential sensor (DPF) (B28/8)

4

Remove heat shield above turbocharger

AR49.00-P-1000-01T

5

Unscrew bolt (1) of catalytic converter flange connection (111) to turbocharger



*BA49.10-P-1015-01I

6

Remove rear bottom part of soundproofing

AR94.30-P-5300T

7

Dismount flange connection (2) of diesel particulate filter at pipe line



*BA49.10-P-1014-01I

8

Unscrew nuts (2a) from support at transmission



*BA49.10-P-1018-01I

9

Remove temperature sensor upstream TWC (B19/7)

Except engine 646.8

AR07.04-P-0070TA

10

Remove temperature sensor downstream TWC (B19/8)

AR07.04-P-0070TB

11

Unscrew catalytic converter nut (1a) at catalytic converter bracket



*BA49.10-P-1001-01I

12

Secure catalytic converter (111) and diesel particulate filter (114) against falling down

13

Unscrew nuts (2b) from bracket at transmission



*BA49.10-P-1017-01I

14

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

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

15

Loosen bolt (3a) on clamping plate



*BA14.40-P-1003-01A

16

Unscrew bolt (3b) for bracket



*BA14.40-P-1004-01A

17

Slacken union nuts of pressure lines (3)



*BA14.40-P-1002-01A

18

Take out pressure differential sensor (DPF) (B28/8) together with pressure lines (3)

19

Unscrew the O2 sensor upstream of TWC (G3/2)

When replacing the catalytic converter (111)

 Installation: Coat thread of O2 sensor upstream of TWC (G3/2) with heat-resistant lubricant.



*BA07.04-P-1003-01G

Polyamide

*BR00.45-Z-1005-06A

20

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

 Installation: Replace bolts.



*BA14.40-P-1001-01A

21

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

 Remove diesel particulate filter (114) carefully, to avoid damaging ceramic body of catalytic converter (111).

 Installation: Note installation position.

 Installation: Install new seal (4).



Notes on disposing of catalytic converters

OS49.10-P-1000-01A

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

Test run engine and check exhaust system for leaks

Number

Designation

Engine
646.8 with
code 474

Engine
646.951/
961/962/
963/966

BA07.04-P-1003-01G

O2 sensor to catalytic converter

Nm

50

50

Number

Designation

Engine
646.8
with
code 474

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

10

Stage 2

Nm

30

30

BA14.40-P-1002-01A

Union nut connecting pressure line to
diesel particulate filter

Nm

20

20

BA14.40-P-1003-01A

Bolt, pressure line clamping plate

Nm

3

3

BA14.40-P-1004-01A

Bracket, pressure line to catalytic converter

Nm

3

3

Number

Designation

Engine
646.8

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

BA49.10-P-1001-01I

Self-locking nut, catalytic converter bracket to three way catalytic converter

Nm

20

20

BA49.10-P-1014-01I

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

Nm

20

20

BA49.10-P-1015-01I

Bolt connecting catalytic converter hose clamp to turbocharger

Nm

15

15

BA49.10-P-1017-01I

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

Nm

20

20

BA49.10-P-1018-01I

Self-locking nut, connecting pipe line to bracket

Nm

20

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