Remove/install exhaust aftertreatment unit, replace if necessary · ar4920w3000h · Mercedes-Benz WIS

AR49.20-W-3000H

Remove/install exhaust aftertreatment unit, replace if necessary

06.08.2019

Engine	470.9, 471.9, 473.9 in model 963
	with code M5Z (Engine version, Euro VI)
	except code M5C (Engine version Euro VI, D)
	except code M5L (Engine version Euro VI version 2)
	except code M5M (Engine version Euro VI, with OBD-C)
	except code M5R (Engine version, EEV)
	except code M5Y (Engine version, Euro V)
	except code U2G (Exhaust box)
Engine	470.9, 471.9, 473.9 in model 964
	with code M5Z (Engine version, Euro VI)
	except code M5C (Engine version Euro VI, D)
	except code M5L (Engine version Euro VI version 2)
	except code M5M (Engine version Euro VI, with OBD-C)
	except code U2G (Exhaust box)

Remove/install exhaust aftertreatment unit, replace if necessary

W49.20-1144-09

1	Exhaust aftertreatment unit	7	Electrical connector	12	Bolts
2	Electrical connector	8	Electrical connector	13	Exhaust tailpipe (fan-shaped)
3	AdBlue® return line	9	Electrical connector	14	Exhaust baffle plate
4	AdBlue® pressure line	10	Line package	A60	Exhaust aftertreatment (ACM) control unit
5	Exhaust flex pipe	11	Electrical connector	A67	AdBlue® metering device
6	Electrical connector

Shown: equipped and unequipped EATU

A	Unequipped EATU (delivery condition)
B	Equipped EATU
1	Exhaust aftertreatment unit
15	Heat shield
16	Heat shield
17	Carrier
18	Carrier

W49.20-1145-06

 Warning	Risk of injury caused by body parts being pinched or crushed as cab is tilted	Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.	AS60.80-Z-0001-01A
 Warning	Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
 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 tilting the cab		AH60.80-N-0003-01A
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Remove exhaust aftertreatment unit
1	Switch off ignition.
2	Tilt cab.
3	Remove electrical connector (11) from the exhaust gas aftertreatment control unit.
4	Remove rear fender section from the exhaust gas aftertreatment unit (1).
5	Unfasten line package (10).
6	Remove AdBlue® metering device and fasten to the frame.	 Do not disconnect electrical connector (2) and AdBlue® pressure and return line (4, 3).
7	Disconnect electrical connections (6, 7, 8, 9).
8	Remove exhaust flex pipe (5).		AR49.10-W-8000H
9	Remove mounting plates over the carriers (17, 18).
10	Remove exhaust gas aftertreatment unit (1) from the frame using a pallet forklift.	 Use a suitable base such as a Euro pallet. The exhaust tailpipe (13) or the EATU (1) can get damaged otherwise.
		 Lift exhaust gas aftertreatment unit (1) approx. 5 cm and then pull outward.
	Perform manual work for replacement – only then perform operation steps 11 to 16
11	Determine design level of the exhaust gas aftertreatment unit (1).
Topical note	Differentiating characteristics of exhaust aftertreatment unit		AH49.20-N-0001-04A
		 The design of the exhaust gas aftertreatment units (1) was changed over time; as a result, different measures must be observed when replacing different generations of exhaust gas aftertreatment units (1).
12	Remove heat shields (15, 16).
13	Remove exhaust baffle plate (14) from the tailpipe (13) and from the exhaust gas aftertreatment unit (1).	Only for vehicles with exhaust baffle plate (14).
14	Detach/attach component parts of exhaust gas aftertreatment unit (1).		AR49.20-W-0001-01H
	Exhaust aftertreatment unit, modified		BT49.20-W-0001-01A
		 The notes in the BT document must always be observed. Consequential damage will occur otherwise due an improper repair.
		 Some assembly parts are reused for replacing the EATU (1). This must be removed and attached together with the new parts to the new EATU (1).
		 NOx sensor control unit bracket to exhaust aftertreatment unit	*BA49.10-N-1007-02A
		 NOx sensor control unit to bracket	*BA49.10-N-1006-02A
		 NOx sensor to exhaust aftertreatment unit	*BA49.10-N-1005-02A
		 Exhaust temperature sensor to exhaust aftertreatment unit	*BA49.10-N-1004-02A
		 Exhaust pressure sensor to sensor bushing	*BA49.10-N-1003-02A
		 Carrier at exhaust aftertreatment unit	*BA49.10-N-1020-02A
15	Attach heat shields (15, 16).
16	Attach exhaust baffle plate (14) to the tailpipe (13) and attach exhaust gas aftertreatment unit (1).	Only for vehicles with exhaust baffle plate (14).
	Install EATU
17	Attach exhaust gas aftertreatment unit (1) to the frame with the aid of a pallet forklift.	 Use a suitable base such as a Euro pallet. The exhaust tailpipe (13) or the EATU (1) can get damaged otherwise.
18	Install mounting plates over the carriers (17, 18).	 Bolt, mounting plate to exhaust aftertreatment unit carrier	*BA49.10-N-1002-02A
19	Install flexible exhaust pipe (5).		AR49.10-W-8000H
20	Attach AdBlue® metering device to the exhaust gas aftertreatment unit (1).	 If an exhaust gas aftertreatment unit (1) is replaced and a generation I unit is replaced with a generation II unit in the course of this replacement, the following must be observed: The modified screws (12), which are 4 mm shorter, must always be used for mounting the AdBlue® metering device. Damage will occur to the EATU (1) otherwise.
		 Install new seal and screw/bolts.
		 AdBlue® metering device to EATU	*BA14.40-N-1016-02I
21	Connect electrical connectors (6, 7, 8, 9).
22	Fasten line package (10).
23	Attach rear fender section to the exhaust gas aftertreatment unit (1).
24	Connect electrical connector (11) to the exhaust gas aftertreatment control unit.
25	Tilt back cab.
	Perform manual work for replacement – only then perform operation steps 26 to 29
26	Update VeDoc documentation.		AR49.20-W-0006A
		 The VeDoc documentation must be updated before the following operation steps was updated. For workshops without VeDoc change authorization a form should be attached in the respective work instructions for this purpose.
27	"Re-hook" control unit or link to the exhaust gas aftertreatment unit (1).		AR14.40-W-2062-01A
	Notes on: Linking exhaust aftertreatment (ACM) control unit and exhaust aftertreatment unit, form		OF49.00-W-1000-03A
		 It is necessary to "re-hook" the exhaust gas aftertreatment control unit over the central VeDoc team or link it to the exhaust gas aftertreatment unit (1). Otherwise, no future "x actions," such as software updates will be possible.
		 To do this the filled out form must be scanned in and sent as an attached file together with an XSF ticket to the central VeDoc team.
28	Update software in the exhaust gas aftertreatment control unit.	 If the exhaust gas aftertreatment unit (1) is replaced and a generation I unit is replaced with a generation II unit in the course of this replacement, the software release must be updated. Further workshop visits will be cause otherwise.
		 One must ensure that in VeDoc there is either: Code U1R (control code, AGN Box Wave 2) or Code U2E (control code, AGN Box Wave 2.2) was already stored.
29	Perform teach-in processes on the exhaust gas aftertreatment control unit.		AR14.40-W-3001H
		 After the EATU (1) was replaced, the respective teach-in process must be carried out. Non-teaching in leads to a renewed workshop visit.

 Exhaust aftertreatment, BlueTec®

Number	Designation		Engine 470.9, 471.9, 473.9
BA14.40-N-1016-02I	AdBlue® metering device to EATU	Nm	10

 Exhaust system

Number	Designation		Engine 470.9, 471.9	Engine 473.9
BA49.10-N-1002-02A	Bolt, mounting plate to exhaust aftertreatment unit carrier	Nm	225	225

 Exhaust system

Number	Designation		Engine 470.9, 471.9	Engine 473.9
BA49.10-N-1003-02A	Exhaust pressure sensor to sensor bushing	Nm	25	25

 Exhaust system

Number	Designation		Engine 470.9, 471.9	Engine 473.9
BA49.10-N-1004-02A	Exhaust temperature sensor to exhaust aftertreatment unit	Nm	30	30

 Exhaust system

Number	Designation		Engine 470.9, 471.9	Engine 473.9
BA49.10-N-1005-02A	NOx sensor to exhaust aftertreatment unit	Nm	50	50

 Exhaust system

Number	Designation		Engine 470.9, 471.9	Engine 473.9
BA49.10-N-1006-02A	NOx sensor control unit to bracket	Nm	12	12

 Exhaust system

Number	Designation		Engine 470.9, 471.9	Engine 473.9
BA49.10-N-1007-02A	NOx sensor control unit bracket to exhaust aftertreatment unit	Nm	12	12

 Exhaust system

Number	Designation			Engine 470.9, 471.9	Engine 473.9
BA49.10-N-1020-02A	Carrier at exhaust aftertreatment unit	M14x1.5	Nm	150	150

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