Remove/install exhaust aftertreatment unit

AR49.20-D-1500TSF

Remove/install exhaust aftertreatment unit

28.08.2019

Engine

651 in model 910

Modification notes

28.08.2019

Work procedure revised

The whole document

1

Exhaust aftertreatment unit

3

Lines

8

Bolts

2

Electrical connector

5

Clip

10

Electrical wiring harness

 Danger

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

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

AS00.00-Z-0010-01A

 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

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 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

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

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S

Notes on repair work on suspension components

AH00.00-P-0100-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW



Remove

1

Fix steering wheel in center position.

AR46.20-D-0500-01TS

 Retainer device

*129589012100

 Tensioning nut

*906589002100

2

Remove NOx sensor with control unit upstream of SCR catalytic converter from exhaust gas aftertreatment unit (1).

AR49.20-D-2063TSF

3

Remove temperature sensor of diesel particulate filter from exhaust gas aftertreatment unit (1).

AR07.04-D-0005TSF

 Do not disconnect electrical connector.

4

Remove lambda sensor upstream of catalytic converter from exhaust gas aftertreatment unit (1).

AR07.04-D-0086TSF

5

Disconnect electrical connection (2).

6

Remove differential pressure sensor from bracket.

AR07.04-D-0025TSF

 Do not remove lines (3) from differential pressure sensor.

7

Remove electrical wiring harness (10) from bracket.

 Position electrical wiring harness (10) outside of working area.

8

Remove front wheel and tire assembly.

AR40.10-D-1100TS

9

Remove lower engine compartment paneling

Engine 651 in model 910
with code XM1 (Noise reduction)

AR61.20-D-1105TS

10.1

Remove rear muffler.

Engine 651 in model 910
except code K1D (WLTP exhaust generation)

AR49.10-D-4952TSF

10.2

Remove SCR catalytic converter downstream of exhaust gas aftertreatment unit (1).

Engine 651 in model 910
with code K1D (WLTP exhaust generation)

AR49.20-D-8121TSF

11

Secure vehicle on vehicle lift.

AR00.60-D-0100-01TS

 Commercially available devices/tools
Tensioning straps

12

Remove, support and lower front axle carrier.

AR33.10-D-0001-03TSF



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B


Lower front axle carrier by max. 20 cm.
Damage may occur otherwise.

 Commercially available devices/tools
Tensioning strap

13

Remove AdBlue® metering valve from exhaust gas aftertreatment unit (1).

AR49.20-D-2000TSF

 Do not disconnect electrical connector and lines.

14

Remove NOx sensor with control unit downstream of diesel particulate filter from exhaust gas aftertreatment unit (1).

AR49.20-D-2060TSF

15

Carefully push engine by hand forwards and support with major assembly mount.



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

16

Remove clamp (5).

 WIS Service Media
wsm://04_201900_81
Description of operation steps 16, 17

17

Remove exhaust gas aftertreatment unit(1).

 To do so, remove screws (8). Dispose of seal between exhaust gas turbocharger and exhaust gas aftertreatment unit (1).

 The exhaust gas aftertreatment unit (1) comprises the diesel particulate filter and SCR catalytic converter.

18

Disassemble exhaust gas aftertreatment unit (1).

If diesel particulate filter and/or SCR catalytic converter of exhaust gas aftertreatment unit (1) will be replaced.

AR49.20-D-0018-01TSF

 Assembly tool

*651589136300



Install

19

Assemble exhaust gas aftertreatment unit (1).

If diesel particulate filter and/or SCR catalytic converter of exhaust gas aftertreatment unit (1) will be replaced.

AR49.20-D-0018-01TSF

 Clamp, SCR catalytic converter to diesel particulate filter

*BA49.20-N-1003-01TSF

 Screw, diesel particulate filter holder to SCR catalytic converter holder

*BA49.20-N-1006-01TSF

 Assembly tool

*651589136300

20

Position exhaust gas aftertreatment unit (1) in installation position.

 Replace seal between exhaust gas turbocharger and exhaust gas aftertreatment unit (1).

 WIS Service Media
wsm://04_201900_82
Description of operation steps 20 to 26.

21

Install clamp (5).

 Do not yet tighten clamp (5).

22

Slightly screw in screws (8) by hand.

 Do not yet tighten screws (8).

23

Tighten clamp (5).

 Clamp, exhaust gas aftertreatment unit to exhaust gas turbocharger

*BA49.20-N-1002-01TSF

24

Tighten screws (8) at right bracket of diesel particulate filter of exhaust gas aftertreatment unit (1).

 Screw, exhaust gas aftertreatment unit to holder

*BA49.20-N-1005-01TSF

25

Tighten screws (8) at left bracket of SCR catalytic converter of exhaust gas aftertreatment unit (1).

 Screw, exhaust gas aftertreatment unit to holder

*BA49.20-N-1005-01TSF

26

Tighten screws (8) at center bracket of diesel particulate filter of exhaust gas aftertreatment unit (1).

 Screw, exhaust gas aftertreatment unit to holder

*BA49.20-N-1005-01TSF

27

Remove tools for engine support.



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

28

Install NOx sensor with control unit downstream of diesel particulate filter at exhaust gas aftertreatment unit (1).

AR49.20-D-2060TSF

29

Install AdBlue® metering valve at exhaust gas aftertreatment unit (1).

AR49.20-D-2000TSF

30

Install front axle carrier.

AR33.10-D-0001-03TSF



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Commercially available devices/tools
Tensioning strap

 Screw/bolt, engine stabilizer mount to front axle carrier

*BA22.10-N-1001-01TSF

 Nut, torsion bar linkage to stabilizer bar

*BA32.35-N-1002-02TS

 Front bolt, front axle carrier to body

*BA33.10-N-1001-01TS

 Rear bolt, front axle carrier to body

*BA33.10-N-1002-01TS

 Screw, lower steering shaft to steering gear

*BA46.10-N-1001-05TS

31

Remove retainer of vehicle at vehicle lift.

32.1

Install rear muffler.

Engine 651 in model 910
except code K1D (WLTP exhaust generation)

AR49.10-D-4952TSF

 Engine 651 in model 910
with code XM1 (Noise reduction)
except code K1D (WLTP exhaust generation)
Do not yet install underfloor paneling.

32.2

Install SCR catalytic converter downstream of exhaust gas aftertreatment unit (1).

Engine 651 in model 910
with code K1D (WLTP exhaust generation)

AR49.20-D-8121TSF

 Engine 651 in model 910
with code K1D (WLTP exhaust generation)
with code XM1 (Noise reduction)
Do not yet install underfloor paneling.

33

Install front wheel and tire assemblies.

AR40.10-D-1100TS

34

Install electrical wiring harness (10) at bracket.

35

Install differential pressure sensor at bracket.

AR07.04-D-0025TSF

36

Connect electrical connector (2).

37

Install lambda sensor upstream of catalytic converter at exhaust gas aftertreatment unit (1).

AR07.04-D-0086TSF

38

Install temperature sensor of diesel particulate filter at exhaust gas aftertreatment unit (1).

AR07.04-D-0005TSF

39

Install NOx sensor with control unit upstream of SCR catalytic converter at exhaust gas aftertreatment unit (1).

AR49.20-D-2063TSF

40

Remove securing of steering wheel.

AR46.20-D-0500-01TS

 Retainer device

*129589012100

 Tensioning nut

*906589002100

41

Perform initialization of exhaust gas aftertreatment unit (1) with vehicle diagnosis system.

If diesel particulate filter and/or SCR catalytic converter of exhaust gas aftertreatment unit (1) were replaced.



Connect/disconnect diagnostic unit

AD00.00-D-2000-06TS



Check

 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

42

Perform engine test run and check exhaust system in terms of leak tightness.

43

Install underbody paneling.

Engine 651 in model 910
with code XM1 (Noise reduction)

AR61.30-D-1001TS

44

Install lower engine compartment lining.

Engine 651 in model 910
with code XM1 (Noise reduction)

AR61.20-D-1105TS

 Engine mounts, engine supports

Number

Designation

Model 910 with engine 651 with transmission 700.75

Model 910 with engine 651 with transmission 700.76

BA22.10-N-1001-01TSF

Screw/bolt, engine stabilizer mount to front axle carrier

Stage 1

Nm

60

60

Stage 2

°

120

120

 Front axle stabilizer bar

Number

Designation

Model 910

BA32.35-N-1002-02TS

Nut, torsion bar linkage to stabilizer bar

Nm

109

 Front axle carrier

Number

Designation

Model 910

BA33.10-N-1001-01TS

Front bolt, front axle carrier to body

Nm

175

 Front axle carrier

Number

Designation

Model 910

BA33.10-N-1002-01TS

Rear bolt, front axle carrier to body

Stage 1

Nm

120

Stage 2

°

90

 Steering wheel, steering column tube, steering shaft

Number

Designation

Model 907, 910

BA46.10-N-1001-05TS

Screw, lower steering shaft to steering gear

Nm

28

 Exhaust gas aftertreatment unit, diesel particulate filter, SCR catalytic converter

Number

Designation

Engine 651 in model 910

BA49.20-N-1002-01TSF

Clamp, exhaust gas aftertreatment unit to exhaust gas turbocharger

Nm

15

 Exhaust gas aftertreatment unit, diesel particulate filter, SCR catalytic converter

Number

Designation

Engine 651 in model 910

BA49.20-N-1003-01TSF

Clamp, SCR catalytic converter to diesel particulate filter

Nm

15

 Exhaust gas aftertreatment unit, diesel particulate filter, SCR catalytic converter

Number

Designation

Engine 651 in model 910

BA49.20-N-1005-01TSF

Screw, exhaust gas aftertreatment unit to holder

Nm

23

 Exhaust gas aftertreatment unit, diesel particulate filter, SCR catalytic converter

Number

Designation

Engine 651 in model 910

BA49.20-N-1006-01TSF

Screw, diesel particulate filter holder to SCR catalytic converter holder

Nm

23