Remove/install catalytic converter

AR49.10-P-5500M

Remove/install catalytic converter

23.11.09

 

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 four support plates at the 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

 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



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

1

Open engine hood and move to vertical position

 After closing the engine hood check the locking function, for this step pull engine hood jerkily to the top.

AR88.40-P-1000M

2

Remove engine trim panel

Engine 275.950 in Model 215.376, 220.176.

AR01.10-P-2405LA

Engine 275.980 in Model 215.379, 220.179 with AMG vehicles, code 990.

AR01.10-P-2405IM

Right catalytic converter

3

Unplug connector of right O2 sensor upstream of CAT (G3/4x1)

 Unclip connector at charge air cooler (2), feed line of O2 sensor from retaining clamp.

4

Remove lower engine compartment paneling

Center and rear section.

AR61.20-P-1105M

5

Disconnect connector of right O2 sensor upstream of CAT (G3/6x1)

 Unclip connector at transmission oil pan (11), feed line of O2 sensor from retaining clamp.

6

Remove heat shield (13)

 Under right catalytic converter.

7

Remove from below bolts (3) of hose clamp (4) to turbocharger (6)

 Installation: Observe installation position of hose clamp (4). The hose clamp (4) is fixed through the cutout with the lug at the turbocharger (6).



*BA49.10-P-1002-01L

8

Detach bolt for catalytic converter bracket (10) at right transmission



*BA49.10-P-1008-01L

9

Separate flange connection (7)



*BA49.10-P-1002-01G

10

Unscrew nuts at catalytic converter bracket (12)

 Installation: Replace nuts (2 pieces).

11

Lift out catalytic converter (5)

 Removal: When unscrewing the catalytic converter, turn slightly to the engine side. At the same time ensure, that the O2 sensors are not damaged.

 Installation: Use emery cloth to remove combustion and corrosion residues at connection points.



Notes on disposing of catalytic converters

all

OS49.10-P-1000-01A

Left catalytic converter

12

Disconnect connector of left O2 sensor, upstream of CAT (G3/3x1)

 Unclip connector at charge air cooler (2), feed line of O2 sensor from retaining clamp.

13

Remove lower engine compartment paneling

 Center and rear section.

AR61.20-P-1105M

14

Disconnect connector of left O2 sensor, downstream of CAT (G3/5x1)

 Unclip connector at transmission oil pan (11), feed line of O2 sensor from retaining clamp.

15

Remove steering coupling

Model 215.376, 220.176 with engine 275.980

AR46.10-P-8000I

16

Remove from below bolts (3) of hose clamp (4) to turbocharger (6)

 Installation: Observe installation position of hose clamp (4). The hose clamp (4) is fixed through the cutout with the lug at the turbocharger (6).



*BA49.10-P-1002-01L

17

Detach bolt for catalytic converter bracket (10) at left transmission



*BA49.10-P-1008-01L

18

Separate flange connection (7) and flange connection (8)

 Installation: Check sealing ring (9a) and sealing ring (9b) for wear; replace if necessary.



*BA49.10-P-1002-01G

19

Detach exhaust rubbers at the rear axle

 Detach on exhaust side.

20

Feed through rear exhaust system to vehicle rear, until flange connection (7) and flange connection (8) is unobstructed

21

Unscrew nuts at catalytic converter bracket (12).

 Installation: Replace nuts (2 pieces).

22

Lift out catalytic converter (5)

 Removal: When unscrewing the catalytic converter, turn slightly to the engine side. At the same time ensure, that the O2 sensors are not damaged.

 Installation: Use emery cloth to remove combustion and corrosion residues at connection points.



Notes on disposing of catalytic converters

all

OS49.10-P-1000-01A

23

Install in the reverse order

24

Check installation position and clearance of exhaust system

 The exhaust system must be installed free of stress, if necessary:

Align exhaust system.

 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

25

Test run engine and check exhaust system for leaks

Number

Designation

Engine 275

BA49.10-P-1002-01G

Flange connection on exhaust pipes

Nm

20

Number

Designation

Engine 275.950

Engine 275.980

BA49.10-P-1002-01L

Bolt for catalytic converter pipe clamp at exhaust gas turbocharger

Nm

25

25

BA49.10-P-1008-01L

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

Nm

20

20