Remove/install catalytic converter

AR49.10-P-5500VB

Remove/install catalytic converter

11.3.10

22.11.04

The electrical line for the O2 sensor upstream of CAT must no longer be clipped into the retaining clamp on the transmission during installation

Step 5.1

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 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.

AS00.00-Z-0002-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Lift/jack up vehicle

AR00.60-P-1000V

2

Detach lower engine compartment paneling

 Installation: Install engine compartment paneling only after engine test run.

AR61.20-P-1105V

3

Disconnect connector for left O2 sensor upstream of CAT (G3/3x1) and connector for left O2 sensor downstream of CAT (G3/5x1) and loosen cable tie

 Installation: Install new cable ties.

4

Unclip electrical line for left O2 sensor downstream of CAT (G3/5) from retaining clamp

5

Unclip electrical line for left O2 sensor upstream of CAT (G3/3) from retaining clamp on transmission

On vehicles with retaining clamp (up to vehicle ID number 042765)

 Installation: The electrical line for left O2 sensor upstream of CAT must not be clipped into the retaining clamp again otherwise the electrical line can be damaged.

6

Disconnect connector for left O2 sensor upstream of CAT (G3/3x1) and connector for left O2 sensor downstream of CAT (G3/5x1)

7

Unscrew nuts (1) and remove catalytic converter brace (2) from left catalytic converter (3) and right catalytic converter (4)

 Engine 272

*BA49.10-P-1004-01N

 Engine 113

*BA49.10-P-1015-01A

8.1

Support left catalytic converter (3) and right catalytic converter (4) with transmission jack and transmission platform

Engine 272

8.2

Support left catalytic converter (3) with transmission jack and transmission platform

Engine 113

9

Detach the left catalytic converter (3) from exhaust system (5) by removing bolts (6)

 Installation: Install new bolts.

 Engine 272

*BA49.10-P-1002-01N

 Engine 113

*BA49.10-P-1002-01A

10

Detach the right catalytic converter (4) from exhaust system (5) by removing bolts (8)

Engine 272

 Installation: Clean connecting points free of combustion and corrosion residues. Install new gasket (9) and bolts.



*BA49.10-P-1002-01N

 Danger!

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

11

Detach the left catalytic converter (3) from the exhaust manifold by unscrewing bolts (10)

 Installation: Clean connecting points free of combustion and corrosion residues. Replace bolts.

 Engine 272

*BA49.10-P-1001-01N

 Engine 113

*BA49.10-P-1009-01A

12

Press the exhaust system (5) to the back, pull out the left catalytic converter (3) from the exhaust system (5) and remove it

 Installation: Clean connecting points free of combustion and corrosion residues. Replace gasket (7).

13.1

Detach left O2 sensor upstream of CAT (G3/3) and left O2 sensor downstream of CAT (G3/5) from left catalytic converter (3)

 If replacing the LH catalytic converter.

 Installation: Coat the thread of O2 sensors with heat-resistant lubricant.



*BA14.00-P-1002-01A

Paste

*BR00.45-Z-1005-06A

13.2

Detach vibration damper from LH catalytic converter (3)

 Engine 272, if present



*BA49.10-P-1007-01N



Notes on disposing of catalytic converters

OS49.10-P-1000-01A

14

Install in the reverse order

15

Check installation position and unobstructed movement of exhaust system (5)

 The exhaust system must be mounted free of tension, align exhaust system 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.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

16

Conduct engine test run and inspect exhaust system (5) for leaks

Number

Designation

Engine
272
in model
171

BA49.10-P-1001-01N

Bolt, catalytic converter to exhaust manifold

Nm

20

BA49.10-P-1002-01N

Bolt, catalytic converter to central exhaust system

Nm

20

BA49.10-P-1004-01N

Nut of catalytic converter brace

Nm

20

BA49.10-P-1007-01N

Bolt, vibration damper to catalytic converter

Nm

22

Number

Designation

Engine
113
in model
171

BA49.10-P-1002-01A

Bolt of flange connection to exhaust pipe

Nm

20

BA49.10-P-1009-01A

Bolt, flange connection to exhaust pipe/exhaust manifold

Nm

20

BA49.10-P-1015-01A

Self-locking nut, rear muffler brace to rear muffler

Nm

20

Number

Designation

Engine
272

Engine 113.989

BA14.00-P-1002-01A

O2 sensor on catalytic converter

Nm

50

50

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51