Remove/install catalytic converter

AR49.10-P-5500TZ

Remove/install catalytic converter

25.1.12

 

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

Danger!

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.

Deburr repair panels.

AS00.00-Z-0017-01A



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

Danger!

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

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

1

Raise vehicle

AR00.60-P-1000TX

2

Detach rear section of lower engine compartment paneling

 Installation: Install engine compartment paneling only after engine test run.

AR61.20-P-1105TX

3

Remove crossmember (1)



*BA62.30-P-1001-01C

4

Unclip electrical connectors and electrical lines of the O2 sensors for catalytic converter (2) to be removed from retaining clamps

5

Detach electrical connectors of the O2 sensors of catalytic converter (2) to be removed

6

Support center muffler (3) with a transmission jack and a transmission platform

 When removing both catalytic converters.

Transmission jack

gotis://H_00.10_01.0

Passenger car transmission platform

gotis://A_25/35/49_02.0

7

Detach catalytic converter (2) from the exhaust manifold by removing screw/bolts (4)

 Installation: Clean connecting points of combustion and corrosion residues, replace screw/bolts (4).



*BA49.10-P-1001-01R

8

Remove catalytic converter (2) from center muffler (3) by removing screw/bolts (5)

 Installation: Clean connecting points free of combustion and corrosion residues. Install new seals (6) and screw/bolts (5).



*BA49.10-P-1002-01R

9

Remove catalytic converter (2) from catalytic converter bracket (7) and take out



*BA49.10-P-1007-01R



Notes on disposing of catalytic converters

all

OS49.10-P-1000-01A

10

Remove O2 sensors from respective catalytic converter (2)

 When replacing catalytic converter.

 Installation: Apply heat-resistant lubricant to the thread of O2 sensors.

 Engine 113

*BA14.00-P-1001-01A

Engine 156

*BA14.00-P-1002-01A

Paste

*BR00.45-Z-1005-06A

11

Install in the reverse order



Checking

12

Check installation position and clearance of exhaust system

 The exhaust system must be mounted free of tension; align exhaust system if necessary.

 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

13

Test run engine and check exhaust system for leaks

Number

Designation

Model
219

BA62.30-P-1001-01C

Screw/bolt, crossmember to body

Nm

25

Number

Designation

Engine
113
in model
219

Engine
156
in model
219

BA49.10-P-1001-01R

Screw/bolt, catalytic converter to exhaust manifold

Nm

20

20

BA49.10-P-1002-01R

Screw/bolt, catalytic converter to center muffler

Nm

20

20

BA49.10-P-1007-01R

Nut connecting catalytic converter bracket to catalytic converter

Nm

20

20

Number

Designation

Engine 113.940/941/
942/943/944/
948/960/961/
962/963/964/
965/966/967/
968/980/981/
982/984/986/
992/993/995

Engine 113.987/988/
990/991

BA14.00-P-1001-01A

O2 sensor on exhaust pipe/ exhaust manifold

Nm

55

50

Number

Designation

Engine
156

BA14.00-P-1002-01A

O2 sensor on catalytic converter

Nm

50

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51