Remove/Install Catalytic Converter - AR49.10-P-5500GQC

Engine 276.8 in model 166, 251, 292 

Shown on model 166 with engine 276.8 

Fig 1: Left/Right Catalytic Converter Components Location - Engine 276.8 In Model 166

Courtesy of MERCEDES-BENZ USA

	Risk of injury.  Skin or eye injuries may result when handling hot or glowing objects	Wear protective gloves, protective clothing Warning and safety glasses, if necessary.	AS00.00-Z-0002-01A
	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
Notice	Notes on self-locking Nuts and bolts		AH00.00-P-0001-01KOA
	Remove/install
1	Remove partition wall between wheel wells	Engine 276.8 in model 251	AR62.30-P-2400RT
2	Remove windshield wiper system	Engine 276.8 in model 251	AR82.30-P-6400RT
3	Remove left-hand air filter housing	For removal of the left CAT (3).	AR09.10-P-1150GQC
4	Remove right air filter housing	For removal the right CAT (2).	AR09.10-P-1150GQC
5.1	Remove underfloor paneling	Engine 276.8 in model 166, 292	AR61.30-P-1001GQ
5.2	Remove engine compartment paneling	Engine 276.8 in model 251	AR61.20-P-1105RT
6	Remove rear left heat shield (8f)	For removal of the left CAT (3). Bolt, turbocharger shield bracket to cylinder head	*BA09.40-P-1012-01W
		Bolt/ Nut for shield attachment	*BA09.40-P-1011-01W
7	Disconnect electrical connection of left oxygen sensor upstream of catalytic converter (G3/3) and the left oxygen sensor downstream of catalytic converter (G3/5)	For removal of the left CAT (3).
8	Remove left diagonal strut and left cross strut	For removal of the left CAT (3). Engine 276.8 in model 166	AR22.10-P-1180GQ
Engine 276.8 in model 251			AR22.10-P-1180GZD
9	Detach left CAT (3) from transmission holder (9)	Engine 276.8 in model 166, 251 For removal of the left CAT (3). Engine 276.8 in model 166 Bolt, exhaust system bracket to exhaust system	*BA49.10-P-1019-01AK
		Engine 276.8 in model 251 Bolt, catalytic converter bracket to catalytic converter	*BA49.10-P-1001-01X
9.2	Remove lower bracket of left catalytic converter (3)	Engine 276.8 in model 292 For removal of the left CAT (3).
Bolt, exhaust system bracket to exhaust system			*BA49.10-P-1019-01AK
10	Detach clamps (4, 5)	Engine 276.8 in model 251 Bolt, rear muffler hose clamp to catalytic converter	*BA49.10-P-1018-01X
		Engine 276.8 in model 166, 292 Bolt, exhaust system clamp to catalytic converter	*BA49.10-P-1012-01AK
11	Remove rear engine support	Engine 276.8 in model 166	AR22.10-P-1180GQ
	Engine 276.8 in model 292		AR22.10-P-4360OGR
12	Detach clamp (1) for left CAT (3) and remove to the bottom rear	For removal of the left CAT (3). left CAT (3)
		Installation: The dowel pin on hot end, must be set in the notch on the ATL. After screwing down the clamp (1) using the prescribed torque there should be no gap anymore on the clamp lock.
		Engine 276.8 in model 166, 292 Nut/ Bolt, profile clamp for exhaust gas recirculation pipe/catalytic converter to exhaust system/ exhaust gas turbocharger	*BA49.10-P-1004-01AK
		Engine 276.8 in model 251 Bolt, clamp for exhaust gas turbocharger/exhaust pipe to primary catalytic converter/catalytic converter	*BA49.10-P-1014-01X
13	Detach left oxygen sensor upstream of CAT. (G3/3) and left oxygen sensor downstream of CAT (G3/5) from left CAT (3)	When replacing the left catalytic converter (3)
14	Remove rear right heat shield (8f)	For removal the right CAT (2).
		Bolt/ Nut for shield attachment	*BA09.40-P-1011-01W
15	Disconnect electrical connection of right oxygen sensor upstream of catalytic converter (G3/4) and the right oxygen sensor downstream of catalytic converter (G3/6)	For removal the right CAT (2).
16	Remove right cross strut	For removal the right CAT (2).
		Engine 276.8 in model 166	AR22.10-P-1180GQ
		Engine 276.8 in model 251	AR22.10-P-1180GZD
17.1	Detach right CAT (2) from transmission holder (9)	Engine 276.8 in model 166, 251 For removal the right CAT (2).
		Engine 276.8 in model 166 Bolt, exhaust system bracket to exhaust system	*BA49.10-P-1019-01AK
		Engine 276.8 in model 251 Bolt, catalytic converter bracket to catalytic converter	*BA49.10-P-1001-01X
17.2	Remove lower bracket of right catalytic converter (2)	Engine 276.8 in model 292 For removal the right CAT (2).
		Bolt, exhaust system bracket to exhaust system	*BA49.10-P-1019-01AK
18	Detach clamp (1) for right CAT (2) and remove right CAT (2) to the bottom rear	For removal the right CAT (2).
		Installation: The dowel pin on hot end, must be set in the notch on the ATL. After screwing down the clamp (1) using the prescribed torque there should be no gap anymore on the clamp lock.
		Engine 276.8 in model 166, 292 Nut/ Bolt, profile clamp for exhaust gas recirculation pipe/catalytic converter to exhaust system/ exhaust gas turbocharger	*BA49.10-P-1004-01AK
		Engine 276.8 in model 251 Bolt, clamp for exhaust gas turbocharger/exhaust pipe to primary catalytic converter/catalytic converter	*BA49.10-P-1014-01X
19	Detach right oxygen sensor upstream of CAT (G3/4) and right oxygen sensor downstream of. CAT (G3/6) from right CAT (2)	When replacing the right catalytic converter (2)
20	Install in the reverse order
21	Clear fault memory using the diagnostic system
			AD00.00-P-2000-04A
	Check
	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
22	Carry out an engine test run and check exhaust system for leaktightness