Remove/install catalytic converter diesel particulate filter unit

AR49.10-P-5501OLF

Remove/install catalytic converter diesel particulate filter unit

17.10.2016

Engine

651 in model 222

Modification notes

14.10.2016

Bolt, bracket for oxicat/torsion bar to front axle carrier

Engine 651 in model 222

BA49.10-P-1014-01AN

1

Electrical connector

2

Electrical connector

3

Electrical line

4

Clamp

5

Bracket

6

Electrical line

7

Clamp

8

Electrical connectors

9

Decoupling element

10

Catalytic converter DPF unit

11

Clip

B28/8

Differential pressure sensor (DPF)

10

Catalytic converter DPF unit

12

Clip

13

Nut

14

Bracket

15

Screw

16

Bolts

 Danger !

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

 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



Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Remove air filter housing

AR09.10-P-1150OLF

2

Unhook and disconnect electrical connection (1) for oxygen sensor

3

Disconnect electrical connection (2) at differential pressure sensor (DPF) (B288)

4

Unhook clamp (4) and detach electrical line (3) at bracket (5)

 Pay attention to correct routing.

5

Unhook electrical line (6) from clamp (7)

 Pay attention to correct routing.

6

Detach DPF differential pressure sensor (B28/8) with attached hoses at bracket (5)

 Differential pressure sensor to bracket

*BA07.04-P-1004-01L

7

Disconnect electrical connections (8)

8

Detach clamp (11)

 Installation: Replace sealing ring between catalytic converter DPF unit (10) and turbocharger.
Check clamp (11) for damage.

 Installation: Align components of the exhaust system before tightening the clamp (11) free of tension.

 Bolt, clamp for oxicat

*BA49.10-P-1011-01AN

9

Remove center and rear section of lower engine compartment paneling

AR61.20-P-1105LF

10

Detach clamp (12)

 Installation: Replace sealing ring between catalytic converter diesel particulate filter unit (10) and SCR catalytic converter.

 Installation: Align components of the exhaust system before tightening the clamp (12) free of tension.

 Bolt, clamp for oxicat

*BA49.10-P-1011-01AN

11

Unscrew nut (13) for elastomer bearing at bracket (14)

 Nut, mounting bracket to bracket

*BA49.10-P-1013-01AN

12

Secure catalytic converter diesel particulate filter unit (10) against falling down

 Helper required.

13

Remove screw/bolts (15, 16) and remove bracket (14)

 Bolt, bracket for oxicat/torsion bar to front axle carrier

*BA49.10-P-1014-01AN

14

Take out catalytic converter diesel particulate filter unit (10) downwards


Do not bend or turn decoupling element (9).
This can lead to leakage on the decoupling element (9).

15

Detach oxygen sensor upstream of catalytic converter

When replacing the catalytic converter diesel particulate filter unit (10)

AR14.00-P-5303OLF

16

Detach temperature sensors at CAT-DPF-unit (10)

When replacing the catalytic converter diesel particulate filter unit (10)

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

Paste, hot lubrication 1 kg, DBL 6879.20

*BR00.45-Z-1005-06A

 Union nut, temperature sensor upstream of diesel particulate filter

*BA07.04-P-1006-01L

 Union nut, temperature sensor upstream of CAT

*BA07.04-P-1005-01L

17

Detach pressure lines

When replacing the catalytic converter diesel particulate filter unit (10)

 Union nut/retaining screw, pressure line to diesel particulate filter

*BA14.40-P-1001-01E

18

Check elastomer bearing at CAT-DPF-unit (10) for damage and cracks

If necessary:



Replace elastomer bearing.

 Nut, mounting bracket to oxicat

*BA49.10-P-1012-01AN



Clean

19

Remove combustion and corrosion residue at separating points

20

Install in the reverse order

21

Connect diagnostic system, read out fault memory and delete if necessary



AD00.00-P-2000-04B



Check

 Danger !

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

22

Carry out an engine test run and check exhaust system for leaktightness

 Sensors, transmitters

Number

Designation

Engine 651

BA07.04-P-1004-01L

Differential pressure sensor to bracket

Nm

9

 Sensors, transmitters

Number

Designation

Engine 651

BA07.04-P-1005-01L

Union nut, temperature sensor upstream of CAT

Nm

45

 Sensors, transmitters

Number

Designation

Engine 651

BA07.04-P-1006-01L

Union nut, temperature sensor upstream of diesel particulate filter

Nm

45

 Diesel particulate filter

Number

Designation

Model 117, 156, 172, 176, 204, 205, 207, 212, 218, 222, 246, 253 with engine 651

BA14.40-P-1001-01E

Union nut/retaining screw, pressure line to diesel particulate filter

Nm

20

 Exhaust system

Number

Designation

Engine 651 in model 222

BA49.10-P-1011-01AN

Bolt, clamp for oxicat

Nm

20

 Exhaust system

Number

Designation

Engine 651 in model 222

BA49.10-P-1012-01AN

Nut, mounting bracket to oxicat

Nm

20

 Exhaust system

Number

Designation

Engine 651 in model 222

BA49.10-P-1013-01AN

Nut, mounting bracket to bracket

Nm

20

 Exhaust system

Number

Designation

Engine 651 in model 222

BA49.10-P-1014-01AN

Bolt, bracket for oxicat/torsion bar to front axle carrier

M8

Nm

25

M10

Nm

70

Repair materials

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DBL 6879.20

A 000 989 76 51