Remove/install catalytic converter diesel particulate filter unit

AR49.10-P-5501TA

Remove/install catalytic converter diesel particulate filter unit

11.3.10

6.8.05

O2 sensor to catalytic converter

Engine 648.961 with Code 494

*BA07.04-P-1003-01G

 

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

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A

1

Open engine hood

AR88.40-P-1000T

2

Remove cylinder head cover trim

AR01.20-P-5014-02C

 Bolt, cylinder head cover trim to cylinder head

*BA01.20-P-1002-01G

 Bolt, cover to charge air manifold

*BA01.20-P-1003-01G

3

Remove air filter housing

AR09.10-P-1150T

4

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

5

Detach differential pressure sensor (catalytic converter) (B28/8) from bracket, to do this, unscrew the bolt (1a)



*BA07.04-P-1006-01G

6

Detach heat shield above turbocharger

AR49.00-P-1000-01T

7

Remove and disconnect connector of O2-sensor upstream of catalytic converter (G3/2x1) and electrical connector (1) of temperature sensor upstream of catalytic converter (B19/7) from bracket at exhaust gas recirculation cooler

8

Expose electrical line to O2 sensor upstream of catalytic converter (G3/2) and to temperature sensor upstream of catalytic converter (B19/7)

 Installation: Install new cable ties.

9

Remove bolt (2) of flange connection between catalytic converter diesel particulate filter unit (115) and turbocharger (110)



*BA49.10-P-1015-01I

10

Detach catalytic converter diesel particulate filter unit (115) from bracket at exhaust manifold, for this step unscrew nut (3)



*BA49.10-P-1011-01I

11

Raise vehicle with vehicle lift

12

Remove rear part of bottom part of soundproofing

AR94.30-P-5300T

13

Disconnect electrical connector of temperature sensor downstream of catalytic converter (B19/8) and expose electrical feed line

14

Detach flange connection (4)



*BA49.10-P-1014-01I

15

Unscrew nuts (4a) from carrier at transmission



*BA49.10-P-1008-01I

16

Secure catalytic converter diesel particulate filter unit (115) against falling down

17

Unscrew nut (4b) from bracket on transmission



*BA49.10-P-1017-01I

18

Take out catalytic converter diesel particulate filter unit (115)

 Installation: Replace sealing cone between turbocharger and catalytic converter diesel particulate filter unit.

19.1

Remove bolt (3a).

When replacing the catalytic converter diesel particulate filter unit

 Bracket of pressure line to catalytic converter

*BA14.40-P-1004-01A

20.1

Slacken union nuts of pressure lines (3) and remove pressure differential sensor (catalytic converter) (B28/8) together with pressure lines (3)

When replacing the catalytic converter diesel particulate filter unit



*BA14.40-P-1002-01A

21.1

Remove temperature sensor upstream of catalytic converter (B19/7)

When replacing the catalytic converter diesel particulate filter unit

 Installation: Coat thread of temperature sensor upstream of catalytic converter (B19/7) with heat-resistant lubricant.



*BA07.04-P-1001-01G

Paste

*BR00.45-Z-1005-06A

22.1

Remove temperature sensor downstream of catalytic converter (B19/8)

When replacing the catalytic converter diesel particulate filter unit

 Installation: Coat thread of temperature sensor downstream of catalytic converter (B19/8) with heat-resistant lubricant.



*BA07.04-P-1002-01G

Paste

*BR00.45-Z-1005-06A

23.1

Remove the O2 sensor upstream of catalytic converter (G3/2)

When replacing the catalytic converter diesel particulate filter unit

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



*BA07.04-P-1003-01G

Paste

*BR00.45-Z-1005-06A



Notes on disposing of catalytic converters

OS49.10-P-1000-01A



Notes on disposing of diesel particulate filter

OS49.10-P-1000-02A

24

Install in the reverse order

25.1

Connect STAR DIAGNOSIS

When replacing the catalytic converter diesel particulate filter unit



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

26.1

Adapt the CDI control unit

When replacing the catalytic converter diesel particulate filter unit

 After replacing the catalytic converter diesel particulate filter unit, an adaptation of the CDI control unit must take place using STAR DIAGNOSIS in the menu item "Control unit adaptation".



Checking

27

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.

28

Test run engine and check exhaust system for leaks

Number

Designation

Engine
648

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
648.961 without code 494

BA07.04-P-1001-01G

Temperature sensor on catalytic converter

Nm

45

BA07.04-P-1002-01G

Temperature sensor on diesel particulate filter

Nm

45

BA07.04-P-1003-01G

O2 sensor on catalytic converter

Nm

50

BA07.04-P-1006-01G

Bolt, pressure differential sensor to bracket

Nm

10

Number

Designation

Engine
648.961

BA14.40-P-1002-01A

Union nut connecting pressure line to
diesel particulate filter

Nm

20

BA14.40-P-1004-01A

Bracket, pressure line to catalytic converter

Nm

3

Number

Designation

Engine 648.961

BA49.10-P-1008-01I

Self-locking nut, bracket to front exhaust system

Nm

20

BA49.10-P-1011-01I

Self-locking nut, three way catalytic converter to bracket

Nm

20

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

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51