Remove/install catalytic converter - AR49.10-P-5500MNA

ENGINE 177 in MODEL 205

MODIFICATION NOTES

18.5.15	Align clamp between ATL and catalytic converter.	Operation step 10
26.5.15	Clamp, front exhaust system to turbocharger		BA49.10-P-1001-02E

Fig 1: Catalytic Converter Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Catalytic Converter Remove/Install Components (2 Of 2)

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 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
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Remove/install
1	Remove transmission		AR27.10-P-0505MNA
2	Disconnect electrical connection for left oxygen sensor (4) or right oxygen sensor (5) downstream of catalytic converter		AR07.04-P-0021MNA
3	Detach left and right CAT (14, 15) at center exhaust system		AR49.10-P-7283MNA
4	Remove left and right air filter housing		AR09.10-P-1150MNA
5	Remove cover (31)	Check for correct seating of the cover (31).
6	Remove screw/bolts (2) and remove heat shield (1) upwards	Bolt, top heat shield to side bracket/heat shield	*BA09.40-P-1006-01ZA
7	Unclip electrical lines (6, 7, 8, 9) from heat shield (10)
8	Remove screw/bolts (3) and remove heat shield (10) upwards	Bolt, rear heat shield to bracket	*BA09.40-P-1008-01ZA
		Bolt, top heat shield to side bracket/heat shield	*BA09.40-P-1006-01ZA
9	Remove left oxygen sensor (4) and right oxygen sensor (5)		AR07.04-P-0021MNA
10	Remove clamp (12) or clamp (13)	If one one-piece clamp (12) or clamp (13) it installed, this must be replaced. For a two-piece clamp (12) or clamp (13) replace the bolt and nuts.
		Clamp, front exhaust system to turbocharger For installation of the clamp (12) or clamp (13): ↓ Align clamp (12) or clamp (13) between the ATL and catalytic converter.	*BA49.10-P-1001-02E
			AR09.40-P-6018-01MNA
		Clamp, front exhaust system to turbocharger	*BA49.10-P-1001-02E
		Caulking bolt	Fig 3
11	Remove screw/bolts (17) from bracket (18)	Screw/bolt, butterfly bracket to catalytic converter	*BA49.10-P-1003-02E
12	Remove screw/bolts (16) from bracket (11)	Bolt, bracket for rear heat shield to crankcase	*BA09.40-P-1005-01ZA
13	Remove bracket (18) and bracket (11) upwards
14.1	Detach steering coupling from rack-and-pinion steering	For removal the left CAT (14)	AR46.10-P-8000LW
14.2	Detach heat shield over electrical lines (19)	For removal the right CAT (15)
15	Detach electrical lines (19) and place to one side	For removal the right CAT (15) Nut, positive line to busbar on firewall	*BA54.18-P-1001-02C
16	Remove left CAT (14) or right CAT (15) downwards
17	Remove left oxygen sensor (4) and right oxygen sensor (5)	When replacing the left or right CAT (14, 15)	AR07.04-P-0021MNA
	Clean
18	Remove combustion and corrosion residue at separating points
19	Install in the reverse order
	Check
20	Check installation position and unobstructed movement of all parts of the exhaust system
	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
21	Perform an engine test run and check exhaust system for leaktightness

TURBOCHARGER

Number	Designation		Engine 177.980
BA09.40-P-1005-01ZA	Bolt, bracket for rear heat shield to crankcase	Nm	9

TURBOCHARGER

Number	Designation		Engine 177.980
BA09.40-P-1006-01ZA	Bolt, top heat shield to side bracket/heat shield	Nm	9

TURBOCHARGER

Number	Designation		Engine 177.980
BA09.40-P-1008-01ZA	Bolt, rear heat shield to bracket	Nm	9

EXHAUST SYSTEM

Number	Designation		Engine 177.9 in model 205
BA49.10-P-1001-02E	Clamp, front exhaust system to turbocharger	Nm	20

EXHAUST SYSTEM

Number	Designation		Engine 177.9 in model 205
BA49.10-P-1003-02E	Screw/bolt, butterfly bracket to catalytic converter	Nm	20

WIRING HARNESS

Number	Designation			Model 205
BA54.18-P-1001-02C	Nut, positive line to busbar on firewall	M6	Nm	8
BA54.18-P-1001-02C	Nut, positive line to busbar on firewall	M8	Nm	16

Fig 3: Identifying Caulking Bolt (103 589 01 39 00)

Courtesy of MERCEDES-BENZ USA