Remove/install catalytic converter

AR49.10-P-5500RB

Remove/install catalytic converter

11.3.10

23.1.06

Self-locking nut, pipe clamp of catalytic converter to center exhaust system

Engine 275.951/954

*BA49.10-P-1011-01L



Removing

 Danger!

Risk of injury from grazing 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

1

Unclip connector for respective O2 sensor (G3/3x1, G3/4x1) from rear retaining spring on charge air cooler (1) and disconnect

2

Remove rear section of lower engine compartment paneling

AR61.20-P-1105R

3

Unclip connector for respective O2 sensor (G3/5x1, G3/6x1) from rear retaining spring and disconnect

4

Unclip electrical feed lines for respective O2 sensor (G3/5x1, G3/6x1) from clamping brackets

5

Cut off catalytic converter (4) with chain pipe cutter at right angles at the separation point marked by center punch mark (arrow) 

Chain pipe cutter



Clean

6

Deburr separation points and clean using an emery cloth free of combustion and corrosion residues

7

Remove catalytic converter (4) from turbocharger by removing bolts (5) and hose clamp (6)

 Replace hose clamp (6) and bolts (5).

8

Remove bolt (8) and catalytic converter (4) from catalytic converter bracket (7)



Notes on disposing of catalytic converters

OS49.10-P-1000-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

9.1

Remove O2 sensors from catalytic converter (4)

When replacing the catalytic converter (4)



Install

10.1

Coat thread on O2 sensors with heat-resistant lubricant and screw O2 sensors into catalytic converter (4)

When replacing the catalytic converter (4)



*BA14.00-P-1001-01C

Paste

*BR00.45-Z-1005-06A

11

Push pipe clamp (9) onto middle exhaust system (10)

12

Bring catalytic converter (4) into installation position and attach loosely to turbocharger, middle exhaust system (10) and catalytic converter bracket (7)

13

Align the catalytic convertor (4) and only then tighten pipe clamp (9) and then hose clamp (6)

 Install catalytic converter (4) free of tension.



*BA49.10-P-1011-01L



*BA49.10-P-1002-01L

14

Tighten bolt (8)



*BA49.10-P-1008-01L

15

Plug connectors for respective O2 sensors (G3/5x1, G3/6x1) together and clip into retaining spring

16

Clip electrical feed lines for respective O2 sensors (G3/5x1, G3/6x1) into clamping bracket

17

Plug connectors for respective O2 sensors (G3/3x1, G3/4x1) together and clip into rear retaining spring on charge air cooler (1)



Checking

18

Inspect installation position and unobstructed movement of all parts of the exhaust system

 The exhaust system must be installed free of stress.

 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 running engine

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

19

Run engine as a check and inspect exhaust system for leaks

20

Install rear section of the lower engine compartment paneling

AR61.20-P-1105R

Number

Designation

Engines
275, 285

BA14.00-P-1001-01C

O2 sensor at exhaust pipe/ exhaust manifold

Nm

50

Number

Designation

Engines 275.951/
954

BA49.10-P-1002-01L

Bolt for pipe clamp three way catalytic converter at exhaust gas turbocharger

Nm

25

BA49.10-P-1008-01L

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

Nm

20

BA49.10-P-1011-01L

Self-locking nut, pipe clamp of catalytic converter to center exhaust system

Nm

55

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51