Remove/install catalytic converter

AR49.10-P-5500OLC

Remove/install catalytic converter

29.10.2018

Engine

654 in model 213.### 1# , 238.### 1# , 257.### 1#

Shown on model 213 with engine 654 without code M014 (Engine uprated)

1

Catalytic converter

2

Heat shield

3

Electrical connector

4

Electrical connector

5

Electrical line

6

Impact plate

Shown on model 238 with engine 654 and code M014 (Engine uprated)

6

Impact plate

6.1

Noise insulation

13

Plug-in connector

Shown on model 213 with engine 654 without code M014 (Engine uprated)

1

Catalytic converter

7

Electrical connector

8

Temperature sensor for diesel particulate filter

9

Bolts

10

Bolts

11

Pipe clamp

12

Pipe clamp

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Caution

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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove fan unit.

Model 238 with engine 654

AR20.40-P-5050OLA

Model 213 with engine 654

AR20.40-P-5050OLC

Engine 654 in model 257

AR20.40-P-5050OIB

 Installation: Only install upper engine cover after the leak test.

2

Attach radiator guard plate.



WF58.50-P-0110-01A

3

Remove noise insulation (6.1).

Engine 654 in model 213, 238, 257
with code M014 (Engine uprated)

4

Release and disconnect connector coupling (13) of vacuum line.

Engine 654 in model 213, 238, 257
with code M014 (Engine uprated)

5

Remove impact plate (6).

6

Release and disconnect electrical connector (7).

7

Release and disconnect electrical connectors (3, 4) and unclip electric lines (5) on catalytic converter (1).

8

Remove differential pressure sensor from heat shield (2) and place to one side with lines connected.

AR07.04-P-0025OLC

9

Remove heat shield (2).

AR07.04-P-0025OLC

10

Remove exhaust aftertreatment system injection nozzle from catalytic converter (1) and place to one side with lines connected.

AR14.40-P-2000OLC

11

Release and disconnect electrical connector of diesel particulate filter temperature sensor (8) and unclip electric line on catalytic converter (1).

AR07.04-P-0005OLC

12

Open pipe clamp (11).

 Installation: Replace seal.
Replace pipe clamp (11).

 Engine 654 in model 238Clamp/flange connection catalytic converter to exhaust gas turbocharger

*BA49.10-P-1001-02J

 Engine 654 in model 213Clamp/flange connection catalytic converter to exhaust gas turbocharger

*BA49.10-P-1001-02H

 Engine 654 in model 257Clamp to catalytic converter and exhaust gas turbocharger

*BA49.10-P-1017-02O

13

Open pipe clamp (12).

 Installation: Replace seal.
Replace pipe clamp (12).

 Engine 654 in model 238Clamp to catalytic converter and diesel particulate filter

*BA49.10-P-1002-02J

 Engine 654 in model 213Clamp to catalytic converter and diesel particulate filter

*BA49.10-P-1002-02H

 Engine 654 in model 257Clamp to catalytic converter and diesel particulate filter

*BA49.10-P-1002-02O

14

Remove screws (10).

 Engine 654 in model 238Bolt, catalytic converter to bracket

*BA49.10-P-1006-02J

 Engine 654 in model 213Bolt, catalytic converter to bracket

*BA49.10-P-1006-02H

 Engine 654 in model 257Bolt, catalytic converter to bracket

*BA49.10-P-1009-02O

15

Remove screws (9).

 Engine 654 in model 238Bolt connecting diesel particulate filter to catalytic converter

*BA49.10-P-1008-02J

 Engine 654 in model 213Bolt connecting diesel particulate filter to catalytic converter

*BA49.10-P-1008-02H

 Engine 654 in model 257Bolt, catalytic converter to diesel particulate filter

*BA49.10-P-1014-02O

16

Remove catalytic converter (1) upwards.

17

Remove temperature sensor from catalytic converter (1).

When replacing catalytic converter (1).

AR07.04-P-0004OLC

18

Remove NOx sensor with controller unit.

When replacing catalytic converter (1).

AR14.40-P-2063OLC

19

Install in the reverse order.

20

Read out and delete fault memory.



Engine 654 in model 238

AD00.00-P-2000-06LWO



Engine 654 in model 213

AD00.00-P-2000-04B



Engine 654 in model 257

AD00.00-P-2000-06FR

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

21

Carry out engine test run and check engine for proper leaktightness and leaktightness.

22

Install upper engine cover.

AR01.10-P-2405OLC

 Exhaust system

Number

Designation

Model 213 with engine 654

BA49.10-P-1001-02H

Clamp/flange connection catalytic converter to exhaust gas turbocharger

Nm

17

 Exhaust system

Number

Designation

Model 238 with engine 654

BA49.10-P-1001-02J

Clamp/flange connection catalytic converter to exhaust gas turbocharger

Nm

17

 Exhaust system

Number

Designation

Model 213 with engine 654

BA49.10-P-1002-02H

Clamp to catalytic converter and diesel particulate filter

Nm

16

 Exhaust system

Number

Designation

Model 238 with engine 654

BA49.10-P-1002-02J

Clamp to catalytic converter and diesel particulate filter

Nm

16

 Exhaust system

Number

Designation

Model 257 with engine 654

BA49.10-P-1002-02O

Clamp to catalytic converter and diesel particulate filter

Nm

17

 Exhaust system

Number

Designation

Model 213 with engine 654

BA49.10-P-1006-02H

Bolt, catalytic converter to bracket

Nm

20

 Exhaust system

Number

Designation

Model 238 with engine 654

BA49.10-P-1006-02J

Bolt, catalytic converter to bracket

Nm

20

 Exhaust system

Number

Designation

Model 213 with engine 654

BA49.10-P-1008-02H

Bolt connecting diesel particulate filter to catalytic converter

Nm

20

 Exhaust system

Number

Designation

Model 238 with engine 654

BA49.10-P-1008-02J

Bolt connecting diesel particulate filter to catalytic converter

Nm

20

 Exhaust system

Number

Designation

Model 257 with engine 654

BA49.10-P-1009-02O

Bolt, catalytic converter to bracket

Nm

20

 Exhaust system

Number

Designation

Model 257 with engine 654

BA49.10-P-1014-02O

Bolt, catalytic converter to diesel particulate filter

Nm

20

 Exhaust system

Number

Designation

Model 257 with engine 654

BA49.10-P-1017-02O

Clamp to catalytic converter and exhaust gas turbocharger

Nm

17