Remove/install diesel particulate filter

AR49.20-P-1200OLI

Remove/install diesel particulate filter

05.08.2020

Engine

654 in model 205.### 1# , 253.### 1#

Shown on engine 654 without code M014 (Engine uprated)

1

Diesel particulate filter

2

Clip

3

Union nut

4

Charge air pipe

9

Turbocharger

10

Electrical wiring harness

11

Bracket

12

Bolts

Shown on engine 654 without code M014 (Engine uprated)

1

Diesel particulate filter

13

Differential pressure sensor

14

Exhaust gas recirculation line

15

Bolts

17

Screw

 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 to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Caution

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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on coolant level

AH20.00-P-1142-01CW

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

AH00.00-P-0015-01CW

 

Remove/install

1

Remove the catalytic converter.

AR49.20-P-0100OLI

2

Remove DPF differential pressure sensor (B28/8) with bracket; release and disconnect electrical connector.

AR07.04-P-0025OLI

3

Remove air intake line upstream of exhaust gas turbocharger (9).

AR09.40-P-0500OLI

4

Remove union nut (3), remove pressure line, and seal openings with suitable stop plugs.

 Union nut, pressure line to diesel particulate filter

*BA14.40-P-1001-01F

 Record plug

*129589009100

 Box wrench bit

*000589700300

5.1

Remove charge air pipe (4).

Engine 654 in model 205.### 1# , 253.### 1#
except code M014 (Engine uprated)

AR09.41-P-1326-01OLC

 Bolt, bracket for charge air pipe to charge air pipe/exhaust gas turbocharger

*BA09.40-P-1014-02B

 Screw/bolt to connection for charge air line to charge air line

*BA09.41-P-1005-01Y

 Screw/bolt, charge air line to support

*BA09.41-P-1006-01Y

 Set of protective covers

*001589019100

5.2

Remove the air duct housing.

Engine 654 in model 205.### 1# , 253.### 1#
with code M014 (Engine uprated)

AR09.20-P-0080OLI

6

Remove right heat shield under diesel particulate filter (1).

AR49.20-P-0007-01OLC

 Bolt, heat shield for diesel particulate filter to timing case/crankcase/bracket for exhaust gas turbocharger/engine support/bracket

*BA14.40-P-1002-01F

7

Remove exhaust system from diesel particulate filter (1).

AR49.10-P-7142OLI

8

Unclip electrical wiring harness (10) from the bracket (11).

9

Remove screws (12).

 Bolt, bracket to diesel particulate filter

*BA49.10-P-1009-02H

10

Remove screw (17).

 Bolt, bracket to diesel particulate filter

*BA49.10-P-1009-02H

11

Remove screws (15) and remove exhaust gas recirculation line (14).

 Installation: Replace screw/bolts (15).
Replace seals.

 Bolt, connecting point for high pressure EGR line

*BA14.20-P-1016-01Q

 Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve

*BA14.20-P-1006-01Q

12

Seal openings using suitable protective covers.

 Set of protective covers

*001589019100

 Set of protective caps

*001589009100

13

Suction off coolant from coolant expansion reservoir.

If necessary.

 Hand pump

*210589007100

14

Remove bleed line at the coolant expansion reservoir, place it to one side, and seal openings using suitable stop plugs.

AR20.20-P-7441-01RQ

 Record plug

*129589009100

15

Open clamp(2).

 Installation: Replace seal.
Replace clamp (2).

 Bolt, clamp for low pressure EGR line to diesel particulate filter

*BA14.20-P-1002-01Q

16

Remove diesel particulate filter (1).

 Aid of helper required.

17

Modify pressure lines with DPF differential pressure sensor (B28/8).

When replacing the diesel particulate filter (1).

 Union nut, pressure line to diesel particulate filter

*BA14.40-P-1001-01F

 Box wrench bit

*000589700300

18

Remove combustion and corrosion residue at connecting points.

19

Install in the reverse order.



Check

20

Check engine cooling system for leak tightness.

AR20.00-P-1010LW

 Turbocharger

Number

Designation

Engine 654 in model all
except code M014 (Engine uprated)

BA09.40-P-1014-02B

Bolt, bracket for charge air pipe to charge air pipe/exhaust gas turbocharger

Nm

8

 Charge air pipe/charge air cooling

Number

Designation

Engine 654

BA09.41-P-1005-01Y

Screw/bolt to connection for charge air line to charge air line

Nm

8

 Charge air pipe/charge air cooling

Number

Designation

Engine 654

BA09.41-P-1006-01Y

Screw/bolt, charge air line to support

Nm

8

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1002-01Q

Bolt, clamp for low pressure EGR line to diesel particulate filter

Nm

8

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1006-01Q

Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1016-01Q

Bolt, connecting point for high pressure EGR line

Nm

12

 Diesel particulate filter

Number

Designation

Engine 654

BA14.40-P-1001-01F

Union nut, pressure line to diesel particulate filter

Nm

20

 Diesel particulate filter

Number

Designation

Engine 654

BA14.40-P-1002-01F

Bolt, heat shield for diesel particulate filter to timing case/crankcase/bracket for exhaust gas turbocharger/engine support/bracket

Nm

8

 Exhaust system

Number

Designation

Model 205 with engine 654

Model 253 with engine 654

BA49.10-P-1009-02H

Bolt, bracket to diesel particulate filter

Nm

20

20