Remove/install exhaust aftertreatment unit, replace if necessary

AR49.20-W-3000H

Remove/install exhaust aftertreatment unit, replace if necessary

06.08.2019

Engine

470.9, 471.9, 473.9 in model 963

with code M5Z (Engine version, Euro VI)

except code M5C (Engine version Euro VI, D)

except code M5L (Engine version Euro VI version 2)

except code M5M (Engine version Euro VI, with OBD-C)

except code M5R (Engine version, EEV)

except code M5Y (Engine version, Euro V)

except code U2G (Exhaust box)

Engine

470.9, 471.9, 473.9 in model 964

with code M5Z (Engine version, Euro VI)

except code M5C (Engine version Euro VI, D)

except code M5L (Engine version Euro VI version 2)

except code M5M (Engine version Euro VI, with OBD-C)

except code U2G (Exhaust box)

1

Exhaust aftertreatment unit

7

Electrical connector

12

Bolts

2

Electrical connector

8

Electrical connector

13

Exhaust tailpipe (fan-shaped)

3

AdBlue® return line

9

Electrical connector

14

Exhaust baffle plate

4

AdBlue® pressure line

10

Line package

A60

Exhaust aftertreatment (ACM) control unit

5

Exhaust flex pipe

11

Electrical connector

A67

AdBlue® metering device

6

Electrical connector

Shown: equipped and unequipped EATU

A

Unequipped EATU (delivery condition)

B

Equipped EATU

1

Exhaust aftertreatment unit

15

Heat shield

16

Heat shield

17

Carrier

18

Carrier

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

 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

 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 tilting the cab

AH60.80-N-0003-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

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

AH00.00-P-0015-01CW

Remove exhaust aftertreatment unit

1

Switch off ignition.

2

Tilt cab.

3

Remove electrical connector (11) from the exhaust gas aftertreatment control unit.

4

Remove rear fender section from the exhaust gas aftertreatment unit (1).

5

Unfasten line package (10).

6

Remove AdBlue® metering device and fasten to the frame.

 Do not disconnect electrical connector (2) and AdBlue® pressure and return line (4, 3).

7

Disconnect electrical connections (6, 7, 8, 9).

8

Remove exhaust flex pipe (5).

AR49.10-W-8000H

9

Remove mounting plates over the carriers (17, 18).

10

Remove exhaust gas aftertreatment unit (1) from the frame using a pallet forklift.


Use a suitable base such as a Euro pallet.
The exhaust tailpipe (13) or the EATU (1) can get damaged otherwise.

 Lift exhaust gas aftertreatment unit (1) approx. 5 cm and then pull outward.

Perform manual work for replacement – only then perform operation steps 11 to 16

11

Determine design level of the exhaust gas aftertreatment unit (1).

Topical note

Differentiating characteristics of exhaust aftertreatment unit

AH49.20-N-0001-04A

 The design of the exhaust gas aftertreatment units (1) was changed over time; as a result, different measures must be observed when replacing different generations of exhaust gas aftertreatment units (1).

12

Remove heat shields (15, 16).

13

Remove exhaust baffle plate (14) from the tailpipe (13) and from the exhaust gas aftertreatment unit (1).

Only for vehicles with exhaust baffle plate (14).

14

Detach/attach component parts of exhaust gas aftertreatment unit (1).

AR49.20-W-0001-01H



Exhaust aftertreatment unit, modified

BT49.20-W-0001-01A


The notes in the BT document must always be observed.
Consequential damage will occur otherwise due an improper repair.

 Some assembly parts are reused for replacing the EATU (1). This must be removed and attached together with the new parts to the new EATU (1).

 NOx sensor control unit bracket to exhaust aftertreatment unit

*BA49.10-N-1007-02A

 NOx sensor control unit to bracket

*BA49.10-N-1006-02A

 NOx sensor to exhaust aftertreatment unit

*BA49.10-N-1005-02A

 Exhaust temperature sensor to exhaust aftertreatment unit

*BA49.10-N-1004-02A

 Exhaust pressure sensor to sensor bushing

*BA49.10-N-1003-02A

 Carrier at exhaust aftertreatment unit

*BA49.10-N-1020-02A

15

Attach heat shields (15, 16).

16

Attach exhaust baffle plate (14) to the tailpipe (13) and attach exhaust gas aftertreatment unit (1).

Only for vehicles with exhaust baffle plate (14).

Install EATU

17

Attach exhaust gas aftertreatment unit (1) to the frame with the aid of a pallet forklift.


Use a suitable base such as a Euro pallet.
The exhaust tailpipe (13) or the EATU (1) can get damaged otherwise.

18

Install mounting plates over the carriers (17, 18).

 Bolt, mounting plate to exhaust aftertreatment unit carrier

*BA49.10-N-1002-02A

19

Install flexible exhaust pipe (5).

AR49.10-W-8000H

20

Attach AdBlue® metering device to the exhaust gas aftertreatment unit (1).


If an exhaust gas aftertreatment unit (1) is replaced and a generation I unit is replaced with a generation II unit in the course of this replacement, the following must be observed: The modified screws (12), which are 4 mm shorter, must always be used for mounting the AdBlue® metering device.
Damage will occur to the EATU (1) otherwise.

 Install new seal and screw/bolts.

 AdBlue® metering device to EATU

*BA14.40-N-1016-02I

21

Connect electrical connectors  (6, 7, 8, 9).

22

Fasten line package (10).

23

Attach rear fender section to the exhaust gas aftertreatment unit (1).

24

Connect electrical connector (11) to the exhaust gas aftertreatment control unit.

25

Tilt back cab.

Perform manual work for replacement – only then perform operation steps 26 to 29

26

Update VeDoc documentation.

AR49.20-W-0006A

 The VeDoc documentation must be updated before the following operation steps was updated.
For workshops without VeDoc change authorization a form should be attached in the respective work instructions for this purpose.

27

"Re-hook" control unit or link to the exhaust gas aftertreatment unit (1).

AR14.40-W-2062-01A



Notes on: Linking exhaust aftertreatment (ACM) control unit and exhaust aftertreatment unit, form

OF49.00-W-1000-03A


It is necessary to "re-hook" the exhaust gas aftertreatment control unit over the central VeDoc team or link it to the exhaust gas aftertreatment unit (1).
Otherwise, no future "x actions," such as software updates will be possible.

 To do this the filled out form must be scanned in and sent as an attached file together with an XSF ticket to the central VeDoc team.

28

Update software in the exhaust gas aftertreatment control unit.


If the exhaust gas aftertreatment unit (1) is replaced and a generation I unit is replaced with a generation II unit in the course of this replacement, the software release must be updated.
Further workshop visits will be cause otherwise.

 One must ensure that in VeDoc there is either:
Code U1R (control code, AGN Box Wave 2)
or
Code U2E (control code, AGN Box Wave 2.2)
was already stored.

29

Perform teach-in processes on the exhaust gas aftertreatment control unit.

AR14.40-W-3001H


After the EATU (1) was replaced, the respective teach-in process must be carried out.
Non-teaching in leads to a renewed workshop visit.

 Exhaust aftertreatment, BlueTec®

Number

Designation

Engine 470.9, 471.9, 473.9

BA14.40-N-1016-02I

AdBlue® metering device to EATU

Nm

10

 Exhaust system

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA49.10-N-1002-02A

Bolt, mounting plate to exhaust aftertreatment unit carrier

Nm

225

225

 Exhaust system

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA49.10-N-1003-02A

Exhaust pressure sensor to sensor bushing

Nm

25

25

 Exhaust system

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA49.10-N-1004-02A

Exhaust temperature sensor to exhaust aftertreatment unit

Nm

30

30

 Exhaust system

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA49.10-N-1005-02A

NOx sensor to exhaust aftertreatment unit

Nm

50

50

 Exhaust system

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA49.10-N-1006-02A

NOx sensor control unit to bracket

Nm

12

12

 Exhaust system

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA49.10-N-1007-02A

NOx sensor control unit bracket to exhaust aftertreatment unit

Nm

12

12

 Exhaust system

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA49.10-N-1020-02A

Carrier at exhaust aftertreatment unit

M14x1.5

Nm

150

150