(Remove/Install Exhaust Aftertreatment Unit - AR49.20-P-1500OLC)

Engine 654 in model 213.### 2#, 238.### 2#, 257.### 2#

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 ol the hazard area.	AS49.00-Z-0001-01A
	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
	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 avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	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/install
1	Drain off coolant.	Engine 654 in model 257.### 2#	AR20.00-P-1142OIB
1	Drain off coolant.	Engine 654 in model 213.### 2#, 238.### 2# : Only install lower engine compartment paneling after leak test.	AR20.00-P-1142OLC
2	Remove fan unit.	Engine 654 in model 257.### 2#	AR20.40-P-5050OIB
		Engine 654 in model 238.### 2#	AR20.40-P-5050OLA
		Engine 654 in model 213.### 2# I installation: Do not install upper engine cover until after the leak test.	AR20.40-P-5050OLC
3	Remove bleed line from cooler and seal		AR20.20-P-7441-01RQ
3	Remove bleed line from cooler and seal	Record plug	Fig 3
4	Remove coolant hoses from the cooler and from the low-temperature circuit cooler and seal openings with protective covers.		AR20.20-P-7441-01RQ
4		Set of protective covers	Fig 5
5	Remove refrigerant lines from condenser.	Engine 654 in model 213.### 2#, 238.### 2#	AR83.30-P-6540LWO
5	Remove refrigerant lines from condenser.	Engine 654 in model 257.### 2#	AR83.30-P-6540OIB
6	Release and disconnect electrical connector on refrigerant pressure sensor.	Engine 654 in model 213.### 2# except code 1U6 (R744 refrigerant) Engine 654 in model 238.### 2#, 257.### 2#
		Engine 654 in model 238.### 2#	AR83.30-P-5430LWO
		Engine 654 in model 257.### 2#	AR83.30-P-5430MSA
		Engine 654 in model 213.### 2# except code 1U6 (R744 refrigerant)	AR83.30-P-5430LW
7	Unclip air duct segment from radiator package.
8	Take radiator package off brackets and I remove downwards.	Aid of helper required.
9	Remove exhaust system (2) from exhaust gas aftertreatment unit (1).		AR49.10-P-7142OLC
10	Remove heat shield (3).		AR49.20-P-0007-01OLC
10	Remove heat shield (3).	Bolt, heat shield for diesel particulate filter to timing case/crankcase/bracket for exhaust gas turbocharger/engine support/bracket	*BA14.40-P-1002-01F
11	Remove air intake line upstream of exhaust gas turbocharger.		AR09.40-P-0500OLC
12	Unscrew union nut (10), remove pressure line and seal openings with suitable stop plugs.	Union nut, pressure line to diesel particulate filter	*BA14.40-P-1001-01F
		Box wrench bit	Fig 4
		Record plug	Fig 3
13	Open clamp (9).	: Replace clamp (9) and seal
		Bolt, clamp for low pressure EGR line to diesel particulate filter	*BA14.20-P-1002-01Q
14	Remove screws (11)	Engine 654 in model 257.### 2# Bolt, bracket to diesel particulate filter	*BA49.10-P-1010-02O
		Engine 654 in model 238.### 2# Bolt, bracket to diesel particulate filter	*BA49.10-P-1009-02J
		Engine 654 in model 213.### 2# Bolt, bracket to diesel particulate filter	*BA49.10-P-1009-02H
15.1	Remove DPF differential pressure sensor (B28/8) and place on exhaust gas aftertreatment unit (1) with pressure lines connected.	Engine 654.9 in model 213.### 2#, 238.### 2#, 257.### 2#
			AR07.04-P-0025OLC
15.2	Remove hoses for the diesel particulate filter differential pressure sensor (B28/8) on the pressure lines and place to one side.	Engine 654.8 in model 213.### 2#, 238.### 2#, 257.### 2#
			AR07.04-P-0025OLN
16	Open clamp (12)	: Replace clamp (12) and seal
		Engine 654 in model 238.### 2# Clamp/flange connection catalytic converter to exhaust gas turbocharger	*BA49.10-P-1001-02J
		Engine 654 in model 213.### 2# Clamp/flange connection catalytic converter to exhaust gas turbocharger	*BA49.10-P-1001-02H
		Engine 654 in model 257.### 2# Clamp to catalytic converter and exhaust gas turbocharger	*BA49.10-P-1017-02O
17	Remove coolant hose (7) from coolant line (8) and seal openings with suitable stop plugs.	Hose clamp pliers	Fig 2
17		Record plug	Fig 3
18	Remove soundproofing upstream of poly-V-belt.
19.1	Release, disconnect electrical connectors (6) and expose lines.	Engine 654.9 in model 213.### 2#, 238.### 2#, 257.### 2#
19.2	Remove sensor unit for temperature sensors (B175).	Engine 654.8 in model 213.### 2#, 238.### 2#, 257.### 2#
			AR49.20-P-0015OIH
20	Remove AdBlue® metering valve (Y129) from exhaust gas aftertreatment unit (1) and place to one side with connected lines.		AR14.40-P-2000OLC
21	Unlock and disconnect the electrical connector on the NOx sensor control unit upstream of diesel oxidation catalytic converter (N37/12).		AR14.40-P-2063OLC
22	Remove screws (4).	Engine 654 in model 257.### 2# Bolt, catalytic converter to bracket	*BA49.10-P-1009-02O
		Engine 654 in model 213.### 2# Bolt, catalytic converter to bracket	*BA49.10-P-1006-02H
		Engine 654 in model 238.### 2# Bolt, catalytic converter to bracket	*BA49.10-P-1006-02J
23	Remove bracket (5).	Engine 654 in model 257.### 2# Bolt, bracket for catalytic converter to crankcase	*BA49.10-P-1008-02O
		Engine 654 in model 213.### 2# Bolt, bracket for catalytic converter to crankcase	*BA49.10-P-1007-02H
		Engine 654 in model 238.### 2# Bolt, bracket for catalytic converter to crankcase	*BA49.10-P-1007-02J
24	Remove the front part of the exhaust gas line.		AR14.20-P-7684-02OLC
		Bolt, clamp for high pressure EGR line to exhaust manifold	*BA14.20-P-1001-01Q
		Bolt, high pressure EGR line to crankcase	*BA14.20-P-1005-01Q
		Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve	*BA14.20-P-1006-01Q
		Set of protective covers	Fig 5
		Set of protective caps	Fig 1
25	Remove exhaust gas aftertreatment unit (1).	Aid of helper required.
	Clean
26	Clean sealing surface on exhaust gas turbocharger.
27	Clean sealing surfaces on exhaust gas aftertreatment unit (1).	When reusing the exhaust gas aftertreatment unit (1).
28	Install in the reverse order.
29	Read out and delete fault memory.
		Engine 654 in model 257.### 2#	AD00.00-P-2000-06FR
		Engine 654 in model 238.### 2#	AD00.00-P-2000-06LWO
		Engine 654 in model 213.### 2#	AD00.00-P-2000-04B
	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
30	Carry out engine test run and check engine for proper operation and leak tightness.
31	Install lower engine compartment paneling.	Engine 654 in model 257.### 2#	AR61.20-P-1105FR
31	Install lower engine compartment paneling.	Engine 654 in model 213.### 2#, 238.### 2#	AR61.20-P-1105LWE
32	Install upper engine cover.		AR01.10-P-2405OLC

EXHAUST GAS RECIRCULATION

Number	Designation		Engine 654
BA14.20-P-1001-01Q	Bolt, clamp for high pressure EGR line to exhaust manifold	Nm	12

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-1005-01Q	Bolt, high pressure EGR line to crankcase	Nm	10

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

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 213 with engine 654
BA49.10-P-1001-02H	Clamp/flange connection catalytic converter to exhaust gas turbocharger	Nm	17

EXHAUST SYSTEM

Number	Designation		Model 238 with engine 654
BA49.10-P-1001-02J	Clamp/flange connection catalytic converter to exhaust gas turbocharger	Nm	17

EXHAUST SYSTEM

Number	Designation		Model 213 with engine 654
BA49.10-P-1006-02H	Bolt, catalytic converter to bracket	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 238 with engine 654
BA49.10-P-1006-02J	Bolt, catalytic converter to bracket	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 213 with engine 654
BA49.10-P-1007-02H	Bolt, bracket for catalytic converter to crankcase	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 238 with engine 654
BA49.10-P-1007-02J	Bolt, bracket for catalytic converter to crankcase	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 257 with engine 654
BA49.10-P-1008-02O	Bolt, bracket for catalytic converter to crankcase	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 213 with engine 654
BA49.10-P-1009-02H	Bolt, bracket to diesel particulate filter	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 238 with engine 654
BA49.10-P-1009-02J	Bolt, bracket to diesel particulate filter	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 257 with engine 654
BA49.10-P-1009-02O	Bolt, catalytic converter to bracket	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 257 with engine 654
BA49.10-P-1010-02O	Bolt, bracket to diesel particulate filter	Nm	20

EXHAUST SYSTEM

Number	Designation		Model 257 with engine 654
BA49.10-P-1017-02O	Clamp to catalytic converter and exhaust gas turbocharger	Nm	17

Fig 1: Identifying Set Of Protective Caps (001 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Hose Clamp Pliers (454 589 00 37 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Box Wrench Bit (000 589 70 03 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ USA