Remove/install primary catalytic converter (near-engine mounted)

AR49.10-P-5510PM

Remove/install primary catalytic converter (near-engine mounted)

13.11.06



Removing

Danger!

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

Align vehicle between columns of lifting platform and position 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 protective gloves, protective clothing and safety glasses.

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

3

Remove air filter housing

AR09.10-P-1150PM

4

Remove heat shield above turbocharger (110)

AR49.00-P-1000-01T

5

Dismount collar clamp (32) from turbocharger (110) to primary catalytic converter (120/1)

 Assembly device

*211589046300

6

Raise vehicle

AR00.60-P-1000P

7

Remove bottom section of soundproofing

AR94.30-P-5300P

8

Dismount collar clamp (22) from primary catalytic converter (120/1) to catalytic converter (111)

 Assembly device

*211589046300

9

Dismount primary catalytic converter (120/1) from bracket (7)

10

Take out primary catalytic converter (120/1) from above



Notes on disposing of catalytic converters

OS49.10-P-1000-01A



Install

11

Loosely mount primary catalytic converter (120/1) at bracket (7)

 Inspect exhaust rubber mount (7a) for wear, install new part if necessary.

12

Mount collar clamp (32) from turbocharger (110) to primary catalytic converter (120/1)

 Replace sealing cone (33).

 Assembly device

*211589046300

13

Mount collar clamp (22) from primary catalytic converter (120/1) to catalytic converter (111)

 Replace sealing cone (23).

 Assembly device

*211589046300

14

Fasten primary catalytic converter (120/1) at bracket (7)

 Self-locking nut, primary catalytic converter to bracket

*BA49.10-P-1007-01I

15

Check installation position and clearance of exhaust system

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

16

Install heat shield above turbocharger (110)

AR49.00-P-1000-01T

17

Install air filter housing

AR09.10-P-1150PM

 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

18

Check leaktightness of exhaust system when engine is running

19

Install trim panel of cylinder head cover

AR01.20-P-5014-02A

20

Install bottom section of soundproofing

AR94.30-P-5300P

21

Close engine hood

Model 203

AR88.40-P-1000P

Model 209

AR88.40-P-1000Q

Number

Designation

Engine
646.951/
961/962/
963/966 without code 474

BA49.10-P-1007-01I

Self-locking nut connecting primary catalytic converter to bracket

Nm

20