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

Engine 177 in model 205

Courtesy of MERCEDES-BENZ USA

Fig 1: Catalytic Converter Component Location - Model 205 With Engine 177

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
Notice	Notes on self-locking nuts and bolts		AH00.00-P-0001-01KOA
	Remove/install
1	Remove transmission.	Engine 177 in model 205 with transmission 722.93	AR27.10-P-0505MNA
2	Disconnect electrical connector of left lambda sensor (4) and/or right lambda sensor (5) downstream of catalytic converter.		AR07.04-P-0021MNA
3	Remove left and right catalytic converter (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	Unscrew screws (2) and remove heat shield (1) upwards.	Bolt, upper heat shield to bracket/side heat shield	*BA09.40-P-1006-01ZA
7	Unclip electric lines (6, 7, 8, 9) at heat shield (10).
8	Unscrew screws (3) and remove heat shield (10) upwards.	Bolt, rear heat shield to bracket	*BA09.40-P-1008-01ZA
		Bolt, upper heat shield to bracket/side heat shield	*BA09.40-P-1006-01ZA
9	Remove left lambda sensor (4) and/or right lambda sensor (5).		AR07.04-P-0021MNA
10	Remove clamp (12) and/or clamp (13).	: If a one-piece clamp (12) and/or clamp (13) is installed, replace this. For a two-piece clamp (12) or clamp (13) replace the bolt and nuts. Clamp, front exhaust system to turbocharger If clamp (12) and/or clamp (13) will be installed: ↓ Align clamp (12) and/or clamp (13) between exhaust gas turbocharger 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 2
11	Remove screws (17) from bracket (18).	Bolt, butterfly bracket to catalytic converter	*BA49.10-P-1003-02E
12	Remove screws (16) from bracket (11).	Bolt, rear heat shield bracket to crankcase	*BA09.40-P-1005-01ZA
13	Remove brackets (11, 18) in upward direction.
14.1	Remove steering coupling at rack-and-pinion steering.	For removal the left CAT (14)	AR46.10-P-8000LW
14.2	Remove heat shield above electric lines (19).	When removing right catalytic converter (15).
15	Remove electric lines (19) and place to one side.	When removing right catalytic converter (15). Nut, positive line to busbar on firewall	*BA54.18-P-1001-02C
16	Remove left catalytic converter (14) and/or right catalytic converter (15) downwards.
17	Remove left lambda sensor (4) and/or right lambda sensor (5).	When replacing left and/or right catalytic converter (14, 15).	AR07.04-P-0021MNA
	Clean
18	Remove combustion and corrosion residues from separating points.
19	Install in the reverse order
	Check
20	Check installation position and for unobstructed movement of all parts of 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 engine test run and check leak tightness of the exhaust system.

TURBOCHARGER

Number	Designation		Engine 177
BA09.40-P-1005-01ZA	Bolt, rear heat shield bracket to crankcase	Nm	9

TURBOCHARGER

Number	Designation		Engine 177
BA09.40-P-1006-01ZA	Bolt, upper heat shield to bracket/side heat shield	Nm	9

TURBOCHARGER

Number	Designation		Engine 177
BA09.40-P-1008-01ZA	Bolt, rear heat shield to bracket	Nm	9

EXHAUST SYSTEM

Number	Designation			Engine 177 in model 205
BA49.10-P-1001-02E	Clamp, front exhaust system to turbocharger	M6	Nm	8
BA49.10-P-1001-02E	Clamp, front exhaust system to turbocharger	M8	Nm	20

EXHAUST SYSTEM

Number	Designation		Engine 177 in model 205
BA49.10-P-1003-02E	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 2: Identifying Caulking Bolt (103 589 01 39 00)

Courtesy of MERCEDES-BENZ USA