Remove, install catalytic converter

AR49.10-P-5500PI

Remove, install catalytic converter

11.3.10

 

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 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 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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove engine trim panel

AR01.10-P-2405PI

2

Remove right air filter housing

AR09.10-P-1150PI

3

Remove hose clamp (2) between catalytic convertor (5) and primary catalytic convertor

 Installation: Check hose clamp (2), replace if necessary.

 Bolt, primary catalytic convertor hose clamp to catalytic convertor

*BA49.10-P-1006-01V

4

Remove bottom sections of soundproofing

AR94.30-P-5300P

5

Detach connector for O2 sensor upstream TWC (G3/2x1)

 Remove connector O2 of sensor upstream TWC (G3/2x1) from bracket.

6

Expose electrical line of O2 sensor upstream TWC (G3/2)

 Installation: Install new cable ties.

7

Disconnect electrical connector (1) at temperature sensor of catalytic convertor (5)

 Remove electrical connector (1) of temperature sensor of catalytic convertor (5) from bracket.

8.1

Release hose clamp (3) between catalytic convertor (5) and exhaust pipe

Except code 474 Particulate Filter

 Installation: Check hose clamp (3), replace if necessary.

 Bolt, catalytic convertor hose clamp to diesel particulate filter and pipe connection

*BA49.10-P-1007-01V

8.2

Release hose clamp (3) between catalytic convertor (5) and diesel particulate filter

Only with particulate filter code 474

 Installation: Check hose clamp (3), replace if necessary.

 Bolt, catalytic convertor hose clamp to diesel particulate filter and pipe connection

*BA49.10-P-1007-01V

9

Unscrew nut (4) at catalytic convertor bracket (5)

 Installation: Replace nut (4).

 Nut, front exhaust system to bracket

*BA49.10-P-1001-01V

10

Remove three-way catalytic converter (5)



Notes on disposing of catalytic converters

OS49.10-P-1000-01A

11.1

Remove O2 sensor upstream of TWC (G3/2)

Only when replacing catalytic convertor (5)

 Installation: Coat thread of O2 sensor upstream of TWC (G3/2) with heat-resistant lubricant.

 O2 sensor at catalytic converter

*BA07.04-P-1003-01G

Paste

*BR00.45-Z-1005-06A

12.1

Remove temperature sensor of catalytic convertor (5)

Only when replacing catalytic convertor (5)

 Installation: Coat the thread of the temperature sensor of the catalytic convertor (5) with heat-resistant lubricant.

 Temperature sensor to catalytic converter

*BA07.04-P-1001-01G

Paste

*BR00.45-Z-1005-06A

13

Install in the reverse order



Checking

14

Inspect installation position and clearance of exhaust system

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

15

Check leaktightness of exhaust system when engine is running

Number

Designation

Engine
642 without particle filter

Engine
642 with particle filter

BA07.04-P-1001-01G

Temperature sensor to catalytic converter

Nm

45

45

BA07.04-P-1003-01G

O2 sensor to catalytic converter

Nm

50

50

Number

Designation

Engine 642 in model 203, 209

BA49.10-P-1001-01V

Nut connecting front exhaust system to bracket

Nm

20

BA49.10-P-1006-01V

Bolt connecting primary catalytic converter hose clamp to catalytic converter

Nm

17

BA49.10-P-1007-01V

Bolt, catalytic converter hose clamp to diesel particulate filter or pipe connection

Nm

17

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51