Remove/install exhaust aftertreatment unit, replace if necessary

AR49.20-W-3000HC

Remove/install exhaust aftertreatment unit, replace if necessary

17.01.2020

Engine

470.9, 471.9, 473.9 in model 963, 964

with code U2G (Exhaust box)

Shown: Model 963 with code K7D (Exhaust system, tailpipe to right and outwards)

1

Exhaust aftertreatment unit

7

Air cleaner housing

13

Heat shield (upper)

2

AdBlue® return line

8

Air intake pipe (depends on vehicle equipment)

14

Bracket

3

AdBlue® pressure line

9

Fender liner segment

15

Crossmember (depends on cab equipment)

4

Conductor rail

10

Fender section

16

Exhaust tailpipe

5

Line package

11

Heat shield (right)

A60a

Aftertreatment control module (ACM) 3.0

6

Electrical connector

12

Heat shield (rear)

A67

AdBlue® metering device

17

Screw

18

Fastening bracket

20

Carrier

A

Removal variant (carriers remain on exhaust gas aftertreatment unit)

18

Fastening bracket

19

Screw

20

Carrier

B

Removal variant (carriers remain on vehicle)

Shown: equipped and unequipped EATU

1

Exhaust aftertreatment unit

C

Unequipped EATU (delivery condition)

D

Equipped EATU

 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

 Warning

Risk of burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue

Pour AdBlue into suitable containers only. Wait until the pressure is released before starting any work on the exhaust aftertreatment system.

AS14.40-Z-0001-01A

 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

 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

Notes on use, material properties and handling of AdBlue®

AH14.40-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

Align vehicle so that as horizontal as possible.

 The straightening out facilitates the removal/installation of exhaust gas aftertreatment unit (1). This is, in particular, relevant for air-sprung vehicles.

2

Switch off ignition.

3

Tilt cab.

4

Remove right side trim.

Only on vehicles with code C8Z (Side trim, aerodynamic)

5

Remove air intake pipe (8) together with bracket (14).

 As-built configuration can vary depending on vehicle equipment.

6

Remove rear heat shield (12).

7

Remove upper heat shield (13).

8

Remove right heat shield (11).

Only for vehicles without code C8Z (Side trim, aerodynamic)

9

Remove exhaust flex pipe.

AR49.10-W-8000H

10

Remove AdBlue® return line (2) and AdBlue® pressure line (3) at AdBlue® metering device (A67).

 Catch escaping AdBlue® in a suitable container and dispose of it in an environmentally friendly member.

11

Open conductor rail (4) and release line package (5) in this area.

12

Disconnect electrical connector (6) at aftertreatment control module 3.0 (A60a).

13

Support exhaust gas aftertreatment unit (1) by means of a pallet forklift.


Use suitable base such as a EUR pallet and/or squared timbers.
Tailpipe (16) and/or exhaust gas aftertreatment unit (1) can otherwise be damaged.

 The removal/installation of exhaust gas aftertreatment unit (1) is facilitated if this is supported so that tilted slightly towards vehicle frame during lifting.

14.1

Unscrew screws (17) and remove mounting plates.

If removal variant (A) is used.

14.2

Remove screws (19).

If removal variant (B) is used.

15

Remove exhaust gas aftertreatment unit (1) outwards using pallet forklift.

Mechanical work in case of replacement – Operation step 16 is only to be performed in this case

16

Detach/attach component parts of exhaust gas aftertreatment unit (1).

AR49.20-W-0001-01HC

 New exhaust gas aftertreatment units (1) are delivered without detachable parts. These must accordingly be removed from the old EATU and installed on the new EATU.

 AdBlue® metering device to EATU

*BA14.40-N-1016-02I

 Exhaust temperature sensor to exhaust aftertreatment unit

*BA49.10-N-1004-02A

 NOx sensor to exhaust aftertreatment unit

*BA49.10-N-1005-02A

 NOx sensor control unit to bracket

*BA49.10-N-1006-02A

 NOx sensor control unit bracket to exhaust aftertreatment unit

*BA49.10-N-1007-02A

 Carrier at exhaust aftertreatment unit

*BA49.10-N-1020-02A

 Differential pressure sensor to bracket

*BA49.10-N-1031-02A

 Exhaust gas aftertreatment control unit to holder

*BA49.10-N-1032-02A

Install EATU

17

Position exhaust gas aftertreatment unit (1) at installation location using pallet forklift.


Use suitable base such as a EUR pallet and/or squared timbers.
Tailpipe (16) and/or exhaust gas aftertreatment unit (1) can otherwise be damaged.

18.1

Fit mounting plates and screw in screws (17).

If removal variant (A) was used.

18.2

Screw in screws (19).

If removal variant (B) was used.

19

Connect electrical connector (6) to aftertreatment control module 3.0 (A60a).

20

Attach AdBlue® return line (2) and AdBlue® pressure line (3) to AdBlue® metering device (A67).

21

Attach line package (5) and close conductor rail (4).

22

Install exhaust flex pipe.

AR49.10-W-8000H

23

Install air intake pipe (8) together with bracket (14).

 As-built configuration can vary depending on vehicle equipment.

24

Install right heat shield (11).

Only for vehicles without code C8Z (Side trim, aerodynamic)

25

Install upper heat shield (13).

26

Install rear heat shield (12).

27

Install right side trim.

Only on vehicles with code C8Z (Side trim, aerodynamic)

28

Tilt back cab.

Additional work in case of replacement – Only perform operation steps 29 to 31 in this case

29

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.

30

"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).
No future "x actions" such as software updates will otherwise 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.

31

Update software in aftertreatment control module and perform teach-in processes at aftertreatment control module.

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.

 First update software in aftertreatment control module and then perform teach-in processes.

 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-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

M16x1.5

Nm

225

225

 Exhaust system

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA49.10-N-1031-02A

Differential pressure sensor to bracket

Nm

8

8

 Exhaust system

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA49.10-N-1032-02A

Exhaust gas aftertreatment control unit to holder

Nm

12

12