Remove/install catalytic converter

AR49.10-P-5500OLE

Remove/install catalytic converter

22.02.2017

Engine

651 in model 205, 253

Shown on model 205

1

Catalytic converter

7

Clamp

2

Differential pressure sensor (DPF)

8

Clamp

3

Temperature sensor

9

Screw/bolt

4

Oxygen sensor

10

Pressure lines

5

Bracket

11

Nut

6

Bracket

12

Nuts

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Remove center and rear section of lower engine compartment paneling

AR61.20-P-1105LW

2

Remove air filter housing

AR09.10-P-1150OLD

3

Remove boost pressure control flap aneroid capsule

AR09.40-P-1002-01CD

"Yellow" locking paint

*BR00.45-Z-1027-07A

 Nut, vacuum unit to turbocharger

*BA09.40-P-1012-01P

 Vacuum tester

*201589132100

 Hand vacuum pump

*001589732100

4

Disconnect electrical connection on DPF differential pressure sensor (2)

5

Disconnect electrical connection for temperature sensor (3)

 The temperature sensor electrical connection (3) is attached to the right rear engine suspension lug.

6

Disconnect electrical connection of oxygen sensor (4) at connecting point

7

Unfasten electrical line of temperature sensor (3) at rear bracket (5) for air filter housing

8

Unfasten electrical line of oxygen sensor (4) at rear bracket (5) for air filter housing

9

Detach rear bracket (5) for air filter housing from bracket (6) and place to one side

 M61

*BA00.10-P-1002-04A

10

Loosen clamps (7, 8)

 Installation: Align clamps (7, 8) unstressed.

 Clamp, front exhaust system to catalytic converter/diesel particulate filter

*BA49.10-P-1005-02A

 Clamp, exhaust line for catalytic converter to turbocharger

*BA49.10-P-1001-02A

11

Unscrew screw/bolt (9) and detach pressure lines (10) from the catalytic converter (1)

12

Unscrew nut (11)

 Nut/screw/bolt, bracket to catalytic converter

*BA49.10-P-1002-02A

13

Unscrew nuts (12) until the CAT (1) can be removed

 Nut, bracket for catalytic converter to crankcase bracket

*BA49.10-P-1003-02A

14

Lift catalytic converter (1) up and out

 When removing the CAT (1), do not damage hoses of the DPF differential pressure sensor (2).

 Installation: Install new sealing rings.

15

Remove oxygen sensor (4)

When replacing catalytic converter (1).

AR07.04-P-0080OLD

16

Unscrew union nut of the temperature sensor (3) and pull out temperature sensor (3)

When replacing catalytic converter (1).

AR07.04-P-0004OLD



Clean

17

Remove combustion and corrosion residue at separating points

18

Install in the reverse order



Check

19

Check installation position and unobstructed movement of exhaust system

 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 buttoned-up and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

20

Perform an engine test run and check exhaust system for leaktightness

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1012-01P

Nut, vacuum unit to turbocharger

M6

Nm

9

 Exhaust system

Number

Designation

Engine 651 in model 205

Engine 651 in model 253

BA49.10-P-1001-02A

Clamp, exhaust line for catalytic converter to turbocharger

Nm

17

17

 Exhaust system

Number

Designation

Engine 651 in model 205

Engine 651 in model 253

BA49.10-P-1002-02A

Nut/screw/bolt, bracket to catalytic converter

Nm

20

20

 Exhaust system

Number

Designation

Engine 651 in model 205

Engine 651 in model 253

BA49.10-P-1003-02A

Nut, bracket for catalytic converter to crankcase bracket

Nm

20

20

 Exhaust system

Number

Designation

Engine 651 in model 205

Engine 651 in model 253

BA49.10-P-1005-02A

Clamp, front exhaust system to catalytic converter/diesel particulate filter

Nm

14

14

Repair materials

Number

Designation

Order number

BR00.45-Z-1027-07A

"Yellow" locking paint

Lackfabrik Bäder GmbH & Co. KG
Dieselstrasse 34
73734 Esslingen
Germany
Tel.: +49 711 381607
Fax. +49 711 383092