Remove/install catalytic converter

AR49.20-P-0100MRH

Remove/install catalytic converter

13.12.2018

Engine

264 in model 213, 238, 257

1

Catalytic converter

2

Clip

3

Clip

4

Bolts

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Caution

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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

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

Notes on safety-relevant components

AH00.00-Z-0019-01A

 

Remove/install

1

Remove upper engine cover.

AR01.10-P-2405MRH

 Installation: Only install upper engine cover after the leak test.

2

Release and disconnect lambda sensor electrical connector upstream of catalytic converter (G3/2) and unclip electric line.

AR07.04-P-0086MRH

3

Release and disconnect lambda sensor electrical connector downstream of the catalytic converter (G3/1) and unclip electric line.

AR07.04-P-0085MRH

4

Remove center and rear sections of lower engine compartment lining.

Engine 264 in model 213, 238

AR61.20-P-1105LWE

Engine 264 in model 257

AR61.20-P-1105FR

 Installation: Only install center and rear lower rear engine compartment paneling again after leak test.

5

Remove clamp (3).

 Installation: Replace clamp (3).

 Engine 264 in model 238Bolt, exhaust system clamp to catalytic converter

*BA49.10-P-1002-02M

 Engine 264 in model 213, 257Clamp at catalytic converter and front exhaust system

*BA49.10-P-1002-02P

6

Remove clamp (2).

 Installation: Replace clamp (2).

 Engine 264 in model 238Screw/bolt, catalytic converter clamp to exhaust gas turbocharger

*BA49.10-P-1001-02M

 Engine 264 in model 213, 257Clamp at turbocharger and catalytic converter/front exhaust line

*BA49.10-P-1001-02P

7

Remove screws/bolts (4).

 Engine 264 in model 238Screw/bolt/nut, catalytic converter to bracket

*BA49.10-P-1004-02M

 Engine 264 in model 213, 257Clamp between rear muffler

*BA49.10-P-1004-02P

8

Remove catalytic converter (1).

9

Remove oxygen sensor upstream of catalytic converter (G3/2).

When replacing catalytic converter (1).

AR07.04-P-0086MRH

10

Remove lambda sensor downstream of catalytic converter (G3/1).

When replacing catalytic converter (1).

AR07.04-P-0085MRH



Clean

11

Remove combustion and corrosion residue at connecting points.

12

Install in the reverse order.

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

AS00.00-Z-0005-01A

13

Perform an engine test run; check the engine for proper operation and the exhaust system for leaks.

14

Install center and rear lower engine compartment lining.

Engine 264 in model 213, 238

AR61.20-P-1105LWE

Engine 264 in model 257

AR61.20-P-1105FR

15

Install upper engine cover.

AR01.10-P-2405MRH

 Exhaust system

Number

Designation

Model 238 with engine 264

BA49.10-P-1001-02M

Screw/bolt, catalytic converter clamp to exhaust gas turbocharger

Nm

17

 Exhaust system

Number

Designation

Model 213 with engine 264

Model 257 with engine 264

BA49.10-P-1001-02P

Clamp at turbocharger and catalytic converter/front exhaust line

Nm

17

17

 Exhaust system

Number

Designation

Model 238 with engine 264

BA49.10-P-1002-02M

Bolt, exhaust system clamp to catalytic converter

Nm

22

 Exhaust system

Number

Designation

Model 213 with engine 264

Model 257 with engine 264

BA49.10-P-1002-02P

Clamp at catalytic converter and front exhaust system

Nm

25

25

 Exhaust system

Number

Designation

Model 238 with engine 264

BA49.10-P-1004-02M

Screw/bolt/nut, catalytic converter to bracket

Nm

25

 Exhaust system

Number

Designation

Model 213 with engine 264

Model 257 with engine 264

BA49.10-P-1004-02P

Clamp between rear muffler

Nm

20

20