Remove/install catalytic converter

AR49.10-P-5500CO

11.3.10

ENGINE 642 in MODEL 204 up to model year 2009

P49.10-2570-06

Shown on model 211 with engine 642

1 Electrical connector

2 Hose clamp

3 Hose clamp

4 Nut

5 Catalytic converter

G3/2 Oxygen sensor upstream of catalytic converter

G3/2x1 Electrical connector for oxygen sensor upstream of catalytic converter

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
 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	Remove bottom part of noise encapsulation
2	Disconnect electrical connector (1) on catalytic converter temperature sensor (B19)	 Remove electrical connector (1) of catalytic converter temperature sensor (B19) from bracket.
3	Disconnect electrical connector for oxygen sensor upstream of catalytic converter (G3/2x1)	 Remove electrical connector for oxygen sensor upstream of catalytic converter (G3/2x1) from bracket.
4	Expose electrical line for oxygen sensor upstream of catalytic converter (G3/2)	 Installation: Install new cable ties.
5	Remove hose clamp (2) between catalytic convertor (5) and catalytic convertor pipe	 Installation: Check hose clamp (2); replace if necessary.
6.1	Release hose clamp (3) between catalytic convertor (5) and exhaust pipe for the diesel particulate filter	On vehicles with code (474) Particulate filter
		 Installation: Check hose clamp (3); replace if necessary.
			*BA49.10-P-1022-01AC
6.2	Loosen hose clamp between catalytic convertor (5) and exhaust pipe	On vehicles without a particulate filter
		 Installation: Check hose clamp; replace if necessary.
			*BA49.10-P-1022-01AC
7	Unscrew nuts (4) on catalytic converter (5) bracket	 Installation: Replace nut (4).
			*BA49.10-P-1011-01AC
8	Remove three-way catalytic converter (5)
	Notes on disposing of catalytic converters		OS49.10-P-1000-01A
9	Remove catalytic converter temperature sensor (B19)	Only when replacing catalytic convertor (5)
		 Installation: Coat thread of catalytic converter temperature sensor (B19) with heat-resistant lubricant.
			*BA07.04-P-1001-01G
		Paste	*BR00.45-Z-1005-06A
10	Install in the reverse order
	Checking
11	Check installation position and clearance of exhaust system	 The exhaust system must be mounted free of tension; align the 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
12	Test run engine and check exhaust system for leaks

 Sensors

Number	Designation		Engine 642 without particle filter	Engine 642 with particle filter


BA07.04-P-1001-01G	Temperature sensor on catalytic converter	Nm	45	45

 Exhaust system

Number	Designation		Engine 642, 646, 651 in model 204


BA49.10-P-1011-01AC	Nut, suspension ring to connecting pipe	Nm	20
BA49.10-P-1022-01AC	Clamp nut/bolt between catalytic converter/connecting pipe/diesel particulate filter	Nm	35

Repair materials

Number	Designation	Order number
BR00.45-Z-1005-06A	Paste, hot lubrication 1 kg, DB supply specification 6879.20	A 000 989 76 51

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