Remove/install exhaust aftertreatment unit · ar4920d1500tsf · Mercedes-Benz WIS

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

Remove/install exhaust aftertreatment unit

D49.20-0033-09

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

651 589 13 63 00

Assembly tool

906 589 00 21 00

Tensioning nut

129 589 01 21 00

Retainer device

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