Remove/install rear muffler

AR49.10-P-4823MCD

Remove/install rear muffler

23.11.09

7.1.09

Work procedure revised and adapted to vehicles with diesel particulate filter

Steps 3 to 25



Removing

Danger!

Risk of death caused by vehicle slipping or toppling off 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

1

Raise vehicle with vehicle lift

2

Remove rear apron

AR88.30-P-0502MCC

3.1

Lower rear muffler (1)

On vehicles with code (474) Diesel particulate filter (closed)

AR49.10-P-4823-01MCD

 For vehicles with code (474) Diesel particulate filter (closed) the catalytic converter diesel particulate filter unit is integrated in the rear muffler (1).

Telescopic lifter
gotis://H_00.10_01.0

3.2

Secure rear muffler (1) using cable ties to the rear apron mounts (2)

On vehicles without code (474) Diesel particulate filter (closed)

4

Unscrew bolts (3) or nuts on turbocharger (4)

 On vehicles with code (474) Diesel particulate filter (closed) the rear muffler (1) is secured with nuts in place of bolts (3).

5.1

Unhook rear muffler (1) from the rubber retainers (5)

On vehicles without code (474) Diesel particulate filter (closed)

5.2

Remove cable tie at connector of O2 oxygen sensor upstream of catalytic converter (G3/2x1)

On vehicles with code (474) Diesel particulate filter (closed)

6

Expose electrical wiring harness (6) for O2 sensor upstream of catalytic converter (G3/2) and disconnect connector for O2 sensor upstream of catalytic converter (G3/2x1)

7.1

Cut through cable tie and remove rear muffler (1)

On vehicles without code (474) Diesel particulate filter (closed)

7.2

Lower telescopic lifter and remove rear muffler (1) with seal

On vehicles with code (474) Diesel particulate filter (closed)

8

Unscrew O2 sensor upstream of catalytic converter (G3/2) from rear muffler (1)

When replacing rear muffler (1).

 Use a suitable 22 mm socket wrench.

9

Check rubber retainers (5) for damage and replace if required.

10

Remove exhaust gas temperature sensor upstream of diesel particulate filter (DPF)

When replacing rear muffler (1). On vehicles with code (474) Diesel particulate filter (closed).

11

Remove bracket of long and short pressure lines

When replacing rear muffler (1). On vehicles with code (474) Diesel particulate filter (closed).



Install

12

Install bracket of long and short pressure lines

When replacing rear muffler (1). On vehicles with code (474) Diesel particulate filter (closed).

13

Install exhaust gas temperature sensor upstream of diesel particulate filter (DPF)

When replacing rear muffler (1). On vehicles with code (474) Diesel particulate filter (closed).



*BA07.04-P-1002-01J

14

Screw in O2 sensor upstream of catalytic converter (G3/2) in rear muffler (1)

When replacing rear muffler (1).

 Use a suitable 22 mm socket wrench.



*BA14.00-P-1002-01B

15.1

Insert rear muffler (1) in the right retaining rubber (5) and fix to the left mount (2) of the rear apron with cable tie

On vehicles without code (474) Diesel particulate filter (closed)

15.2

Position rear muffler (1) using telescopic lifter and fix in place with seal and nuts on turbocharger (4)

On vehicles with code (474) Diesel particulate filter (closed)

Telescopic lifter
gotis://H_00.10_01.0

16

Contact connector for O2 sensor upstream of catalytic converter (G3/2x1) and route electrical wiring harness (6) for O2 sensor upstream of catalytic converter (G3/2)

 Ensure correct routing of electrical wiring harness (6) for O2 sensor upstream of catalytic converter (G3/2).

17.1

Secure connector of O2 oxygen sensor upstream of catalytic converter (G3/2x1) with cable tie

On vehicles with code (474) Diesel particulate filter (closed)

17.2

Insert rear muffler (1) in the left retaining rubber (5)

On vehicles without code (474) Diesel particulate filter (closed)

18.1

Position rear muffler (1) on turbocharger (4) and screw in bolts (3)

On vehicles without code (474) Diesel particulate filter (closed)



*BA49.10-P-1010-01J

18.2

Screw rear muffler (1) onto turbocharger (4) with nuts

On vehicles with code (474) Diesel particulate filter (closed)



*BA49.10-P-1011-01J

19.1

Separate cable tie

On vehicles without code (474) Diesel particulate filter (closed)

19.2

Position rear muffler (1)

On vehicles with code (474) Diesel particulate filter (closed)

AR49.10-P-4823-01MCD



*BA49.10-P-1012-01J

Telescopic lifter
gotis://H_00.10_01.0

20

Install rear apron

AR88.30-P-0502MCC

21

Lower vehicle with vehicle lift

 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

22

Conduct engine test run and check exhaust system around the rear muffler (1) for leaks

23

Read out fault memory, erase if necessary

On vehicles with code (474) Diesel particulate filter (closed)



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04MCC

Number

Designation

Engine
660.9

BA07.04-P-1002-01J

Temperature sensor on diesel particulate filter

Nm

45

Number

Designation

Engine
660.950/951

BA14.00-P-1002-01B

O2 sensor upstream of catalytic converter on catalytic converter

Nm

50

Number

Designation

Engine 660.950 without code 474

Engine 660.950/
951 with code 474

BA49.10-P-1010-01J

Bolt, rear muffler to turbocharger

Nm

20

-

BA49.10-P-1011-01J

Nut, rear muffler to turbocharger

Nm

-

30

BA49.10-P-1012-01J

Union nut, regeneration line to rear muffler

Nm

-

20