D49.10-1142-11
Shown on engine 642.993
1 Wiring harness
B85/2x1 Oxygen sensor connector
D49.10-1121-09
Shown on engine 642.992
with transmission 711.660
2 Bracket
3 Screw
4 Bolts
5 Screw
6 Shield
7 Turbocharger
14 Electrical connector
15 Wiring harness
16 Gasket
B19 Catalytic converter temperature sensor
B85/2 Oxygen sensor
8 Bolts
9 Catalytic converter
10 Screw
11 Screw
12 Hose clamp
13 Diesel particulate filter
| 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. | |
1 | Remove trim panel on right cylinder head cover | ||
2 | Disconnect connector on oxygen sensor (B85/2x1) and expose electrical wiring harness (1) | ||
3 | Remove temperature sensor upstream of catalytic converter | Engine 642.993 | |
4 | Remove bolts (3, 4, 5) and shield (6) | | |
| |||
5 | Unscrew bolts (8, 10) | Installation: Install new bolts (8). | |
| |||
6 | Remove bolt (11) | ||
7 | Remove exhaust gas recirculation pipe from exhaust collector pipe to exhaust gas recirculation bypass flap | Engine 642.993 | |
8 | Lift/jack up vehicle | ||
9 | Detach electrical connector (14) and expose electrical wiring harness (15) | Installation: Observe routing and attachment of electric wiring harness (15). | |
10 | Detach clamp (12) and disconnect catalytic converter (9) from diesel particulate filter (13) | | |
11 | Remove engine crossmember at rear | ||
12 | Remove bracket (2) from catalytic converter (9) and transmission and remove | Installation: Replace nuts on catalytic converter (9). | |
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| |||
13 | Lift out catalytic converter (9) downwards | Carefully pull catalytic converter (9) toward rear to prevent damaging detachable parts around. | |
Slightly push heat shield above catalytic converter (9) upward. Do not deform heat shield when pushing up | |||
Installation: Replace seal (16) and clip into exhaust gas turbocharger (7). Replace bolt (10) and screw in several turns. Hook in catalytic converter (9) with slit flange to bolt (10). | |||
On engine 642.993 install exhaust pipe of catalytic converter (9) in bracket of exhaust collector pipe to exhaust gas recirculation bypass flap and press in direction of exhaust gas turbocharger (7). | |||
14 | Remove catalytic converter temperature sensor (B19) | Only if catalytic converter (9) is replaced. | |
Installation: Check catalytic converter temperature sensor (B19) for damage; replace if necessary. Coat thread of catalytic converter temperature sensor (B19) with heat-resistant lubricant. | |||
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Paste | |||
15 | Remove oxygen sensor (B85/2) | Only if catalytic converter (9) is replaced. | |
Installation: Check oxygen sensor (B85/2) for damage, replace if necessary. Coat thread on oxygen sensor (B85/2) with heat-resistant lubricant. | |||
| |||
Paste | |||
| Clean | ||
16 | Clean sealing surface on exhaust system | ||
17 | Install in the reverse order | ||
| Checking | ||
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. | |
18 | Perform engine test run and inspect exhaust system in the area of catalytic convertor (9) for leaks |
Sensors
Number | Designation | Engine | Engine | ||
BA07.04-N-1001-01G | Temperature sensor to catalytic converter | Nm | 45 | 45 | |
BA07.04-N-1010-01G | Oxygen sensor on exhaust pipe | Nm | 45 | 45 | |
Turbocharger
Number | Designation | Engine | ||
BA09.40-N-1007-01Q | Bolt connecting catalytic converter to turbocharger | Nm | 20 | |
BA09.40-N-1010-01Q | Bolt, shield to holder | Nm | 8 | |
BA09.40-N-1011-01Q | Bolt, shield to exhaust collector pipe | Nm | 12 | |
Exhaust system
Number | Designation | Engine 642.992/993 | ||
BA49.10-N-1001-01M | Bolt, catalytic converter hose clamp to diesel particulate filter | Nm | 35 | |
BA49.10-N-1005-01M | Nut, front exhaust system to bottom bracket | Nm | 23 | |
BA49.10-N-1006-01M | Bolt connecting bracket of front exhaust system to transmission | Nm | 23 | |
Repair materials
Number | Designation | Order number |
BR00.45-Z-1005-06A | Paste, hot lubrication 1 kg, DB supply specification 6879.20 | A 000 989 76 51 |
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