Remove/install catalytic converter

AR49.20-P-0100MRT

Remove/install catalytic converter

23.10.2018

Engine

256.9 in model 222

1

Turbocharger

2

Catalytic converter

3

Heat shield

4

Electrical connectors

5

Bolts

6

Heat shield

7

Bolts

8

Heat shield

G3/1

Oxygen sensor downstream of catalytic converter

G3/2

Oxygen sensor upstream of catalytic converter

 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

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

 

Remove/install

1

Remove upper engine cover

AR01.10-P-2405MRT

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

2

Remove heat shield (3)

 Nut, heat shield to exhaust gas turbocharger

*BA09.40-P-1004-02MRT

3

Release and disconnect electrical connections (4)

4

Remove gasoline particulate filter

AR49.20-P-0016MRT

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

5

Remove screw/bolt/bolts (5)

 Screw/bolt/nut, catalytic converter to bracket

*BA49.10-P-1004-02MRT

6

Unclip electric line (arrow)

7

Remove heat shield (8)

 M61

*BA00.10-P-1002-04A

8

Remove heat shield (6)

 M61

*BA00.10-P-1002-04A

9

Remove bolts (7)

 Screw/bolt/nut, catalytic converter to bracket

*BA49.10-P-1004-02MRT

10

Remove clamp between exhaust gas turbocharger (1) and catalytic converter (2)

 Installation: Replace clamp if necessary.

 Profile clamp, exhaust system to exhaust gas turbocharger

*BA09.40-P-1001-02MRT

11

Lift catalytic converter (2) up and out

12

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

When installing new catalytic converter (2).

AR07.04-P-0086MRT

13

Remove oxygen sensor downstream of catalytic converter (G3/1)

When installing new catalytic converter (2).

AR07.04-P-0085MRT



Clean

14

Remove combustion and corrosion residue at connecting points

15

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

16

Perform an engine test run; check engine for functionality and exhaust system for leaktightness

17

Install center and lower engine compartment paneling

AR61.20-P-1105LF

18

Install upper engine cover

AR01.10-P-2405MRT

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Turbocharger

Number

Designation

Engine 256.9

BA09.40-P-1001-02MRT

Profile clamp, exhaust system to exhaust gas turbocharger

Nm

17

 Turbocharger

Number

Designation

Engine 256.9

BA09.40-P-1004-02MRT

Nut, heat shield to exhaust gas turbocharger

Nm

8

 Exhaust system

Number

Designation

Engine 256.9 in model 222

BA49.10-P-1004-02MRT

Screw/bolt/nut, catalytic converter to bracket

Nm

20