Remove/Install Left Catalytic Converter - AR49.20-P-0101MNL

Engine 176 in model 217, 222 

MODIFICATION NOTES

23.05.2017

Clamp exhaust system front to exhaust turbocharger

BA49.10-P-1001-02N

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	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 o' the danger zone.	AS49.00-Z-0001-01A
	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
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove/install
1	Remove left-hand air filter housing	Only install top engine cover after the leak test.	AR09.10-P-1151MNL
2	Remove right air filter housing		AR09.10-P-1152MNL
3	Remove engine wiring harness (17) from elastomer bearings and place to one side	Wet elastomer bearings with lubricating paste. Antifriction paste, rubber parts 2.5 kg, DBL 6867.00	*BR00.45-Z-1002-06A
4	Check elastomer bearings of engine wiring harness (17) for damage	In case of a complaint ↓ Replace elastomer bearing.
5	Remove screws/bolts (15), and remove heat shield (16) upward	Bolt, upper heat shield to bracket/side heat shield	*BA09.40-P-1006-01ZA
6	Remove heat shield (14)
7	Remove bracket (5)	Bolt, rear heat shield bracket to crankcase	*BA09.40-P-1005-01ZA
8	Remove clamp (2) of left catalytic converter (1)	Pay attention to alignment of clamp (2). Leaks can occur otherwise. If a one-piece clamp (2) is installed, install two-piece clamp (2). For two-piece clamp (2), install new screws/bolts and nuts.	AR09.40-P-6018-01MNL
		Clamp, front exhaust system to turbocharger	*BA49.10-P-1001-02N
		Caulking bolt	Fig 1
9	Remove center and rear lower engine compartment paneling	Only install center and rear lower rear engine compartment paneling again after leak test.	AR61.20-P-1105LF
		Bolt, bracket for catalytic converter to catalytic converter/bracket	*BA49.10-P-1004-02N
10	Remove left catalytic converter (1) from bracket (7)	Bolt, butterfly holder to bracket/catalytic converter	*BA49.10-P-1002-02N
11	Remove bracket (10)	Bolt, bracket for catalytic converter to catalytic converter/bracket	*BA49.10-P-1004-02N
12	Remove clamp (11)	Exhaust system must be aligned so that it is free of tension before tightening bolted connections. Otherwise, leaks will occur in the exhaust system. Install new clamp (11). Clamp, front exhaust system to center exhaust system	*BA49.10-P-1008-02N
13	Secure left catalytic converter (1) against falling down
14	Remove transmission	Engine 176 in model 217, 222 with transmission 725.0 except code M005 (Vehicles with 4 MATIC/all-wheel drive)	AR27.10-P-0500MNL
		Engine 176 in model 217, 222 with transmission 725.0 with code M005 (Vehicles with 4 MATIC/all-wheel drive) Install front lower engine compartment lining only after leak test.	AR27.10-P-0500MNN
15	Remove left oxygen sensor upstream of catalytic converter		AR07.04-P-0081MNL
16	Remove left oxygen sensor downstream of catalytic converter		AR07.04-P-0082MNL
17	Remove bracket (13) and bracket (7)	Bolt, exhaust system bracket to front of crankcase	*BA49.10-P-1003-02N
18	Release left catalytic converter (1) and remove downward
19	Remove combustion and corrosion residues at flange connections
20	Remove vibration damper (12)	When replacing the left catalytic converter (1). Bolt, vibration damper to exhaust system	*BA49.10-P-1013-02N
21	Install in the reverse order
22	Check installation position and unobstructed movement left catalytic converter (1)	In case of a complaint ↓ Re-align left catalytic converter (1).
	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
23	Perform engine test run to test exhaust system function and check for leaks
24	Install front, center, and rear lower engine compartment lining		AR61.20-P-1105LF
25	Install upper engine cover

TURBOCHARGER

Number	Designation		Engine 176
BA09.40-P-1005-01ZA	Bolt, rear heat shield bracket to crankcase	Nm	9

TURBOCHARGER

Number	Designation		Engine 176
BA09.40-P-1006-01ZA	Bolt, upper heat shield to bracket/side heat shield	Nm	9

EXHAUST SYSTEM

Number	Designation		Model 217, 222 with engine 176
BA49.10-P-1001-02N	Clamp, front exhaust system to turbocharger	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 217, 222 with engine 176
BA49.10-P-1002-02N	Bolt, butterfly holder to bracket/catalytic converter	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 217, 222 with engine 176
BA49.10-P-1003-02N	Bolt, exhaust system bracket to front of crankcase	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 217, 222 with engine 176
BA49.10-P-1004-02N	Bolt, bracket for catalytic converter to catalytic converter/bracket	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 217, 222 with engine 176
BA49.10-P-1008-02N	Clamp, front exhaust system to center exhaust system	Nm	35

EXHAUST SYSTEM

Number	Designation		Model 217, 222 with engine 176
BA49.10-P-1013-02N	Bolt, vibration damper to exhaust system	Nm	20

Fig 1: Identifying Caulking Bolt (103 589 01 39 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1002-06A	Antifriction paste, rubber parts 2.5 kg, DBL 6867.00	A 000 989 01 60