P49.10-2499-09
1 Crossmember
2 Catalytic converter bracket
3 Catalytic converter bracket
4 Exhaust system
8 Screw/bolts
9 Exhaust rubber mount
10 Retaining clip
5 Right catalytic converter
6 Left catalytic converter
7 Bolts
P49.10-2503-11
G3/3x1 Connector for left O2 sensor upstream of catalytic converter
G3/4x1 Connector for right O2 sensor upstream of catalytic converter
G3/5x1 Connector for left O2 sensor downstream of catalytic converter
G3/6x1 Connector for right O2 sensor downstream of catalytic converter
| Remove/install | ||
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. | |
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. | |
| Notes on self-locking nuts and bolts | ||
1 | Raise vehicle with vehicle lift | ||
2 | Detach rear section of lower engine compartment paneling | Installation: Install engine compartment paneling only after engine test run. | |
3 | Remove crossmember (1) | | |
4 | Unclip electrical connectors (G3/3x1, G3/4x1, G3/5x1, G3/6x1) and electrical lines for O2 sensors from retaining clamps | ||
5 | Disconnect electrical connectors (G3/3x1, G3/4x1, G3/5x1, G3/6x1) for O2 sensors | ||
6 | Detach catalytic converter brackets (2, 3) from transmission | | |
7 | Support exhaust system (4) with a transmission jack and a transmission platform | Transmission jack | |
Transmission plate for passenger cars and commercial vehicles | |||
8 | Remove right catalytic convertor (5) and left catalytic converter (6) from the exhaust manifolds, to do this, remove bolts (7, 8) | Installation: Clean combustion and corrosion residues from connecting points and replace bolts (7, 8). Check rivet nuts in exhaust manifolds and if required: | |
Replace rivet nuts in exhaust manifold. | |||
| |||
9 | Unhook exhaust system (4) from exhaust rubber mounts (9) at right and left | To simplify removal: Apply liquid lubricant to retaining brackets (10) and on holes of exhaust rubber mounts (9). | |
Lubricant paste | |||
10 | Lower and remove exhaust system (4) | Installation: Check exhaust rubber mounts (9) for wear and damage; replace if required. | |
11 | Install in the reverse order | ||
| Checking | ||
12 | Check installation position and unobstructed movement of exhaust system (4) | The exhaust system (4) must be mounted free of tension; align exhaust system (4) 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. | |
13 | Conduct engine test run and inspect exhaust system (4) for leaks |
Crossmember and front reinforcement
Exhaust system
Number | Designation | Engine | ||
BA49.10-P-1001-01T | Bolt, catalytic converter to exhaust manifold | Nm | 20 | |
BA49.10-P-1006-01T | Bolt, catalytic converter bracket to transmission | Nm | 20 | |
Repair materials
Number | Designation | Order number |
BR00.45-Z-1002-06A | Antifriction paste, rubber parts 2.5 kg, DB supply specification 6867.00 | A 000 989 01 60 |
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