Remove/install catalytic converter

AR49.10-P-5500RTM

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 vehicle lift and position four support plates at vehicle lift 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 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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



When working on exhaust system, connecting points have to be cleaned from combustion and corrosion residues before the installation of parts.

1

Detach lower engine compartment paneling (2)

AR61.20-P-1105RT

2

Remove bolt (4) on catalytic converter bracket (5) to catalytic converter



*BA49.10-P-1001-01X

3

Expose and detach connector for right O2 sensor downstream of TWC (G3/6x1)

4

Expose and detach connector for right O2 sensor upstream of TWC (G3/4x1)

Only Motor 156

5

Unclip electrical line of right O2 sensor upstream of TWC (G3/4) and electrical line of right O2 sensor downstream of TWC (G3/6) from metal clips

Only engine 156

 Only unclip electrical line of right O2 sensor upstream of TWC (G3/4) and electrical line of right O2 sensor downstream of TWC (G3/6) from metal clips; do not detach metal clips from their brackets. The metal clips will be destroyed otherwise!

6

Remove nuts as well as bolts (6) from flange (10)

 Installation: Check correct seating of sealing ring (9) and flange (10).



*BA49.10-P-1003-01X

7

Release clamp (7)

 Slide released hose clamp (7) towards rear on center muffler. Replace defective or corroded hose clamp.



*BA49.10-P-1018-01X

8

Support right catalytic converter (1) with transmission jack and transmission platform

9

Unhook exhaust system at exhaust rubber mounts (8)

 Installation: Coat exhaust rubber mount (8) with lubricant paste for purpose of easier installation.

Lubricating paste

*BR00.45-Z-1002-06A

10

Detach right catalytic converter (1) from right exhaust manifold



*BA49.10-P-1002-01X

11

Detach and expose connector for right O2 sensor upstream of TWC (G3/4x1)

Only Motor 113

 On engine 113.971, the position of connector for right O2 sensor upstream of TWC (G3/4x1) is in the right front above the transmission.

12

Detach and remove right catalytic converter (1) from center muffler

 Do not damage surrounding components.

 Installation: Ensure that installation position of sealing ring (9) and flange (10) is correct. The chamfer of the sealing ring as well as shoulder on the flange are pointing in the direction of the center muffler. Slide both parts onto right catalytic converter before it is positioned on center muffler.



Notes on disposing of catalytic converters

OS49.10-P-1000-01A

13

Detach right O2 sensor upstream of TWC (G3/4) and right O2 sensor downstream of TWC (G3/6) from right catalytic converter (1)

 Only when replacing the right catalytic convertor.

 Installation: Apply heat-resistant lubricant to the thread of the right O2 sensor upstream of TWC (G3/4) and right O2 sensor downstream of TWC (G3/6).



*BA14.00-P-1002-01A

Paste

*BR00.45-Z-1005-06A

14

Install in the reverse order



Checking

15

Check installation position and for unobstructed movement of entire exhaust system

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

 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

16

Conduct an engine test run and inspect exhaust system for leaks

Number

Designation

Engine
113.971

Engine
156

BA14.00-P-1002-01A

O2 sensor to catalytic converter

Nm

50

50

Number

Designation

Engine 113 in model 251

Engine
156 in model 251

BA49.10-P-1001-01X

Bolt, catalytic converter bracket to catalytic convertor

Nm

20

20

BA49.10-P-1002-01X

Bolt, flange connection to exhaust pipe/exhaust manifold

Nm

20

20

BA49.10-P-1003-01X

Self-locking nut, rear muffler flange connection to three way catalytic converter

Nm

20

20

BA49.10-P-1018-01X

Bolt, rear muffler hose clamp to catalytic converter

Nm

35

35

Number

Designation

Order number

BR00.45-Z-1002-06A

Lubricating paste, rubber parts 2.5 kg, DB supply specification 6867.00

000 989 01 60

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51