Remove/Install Exhaust Aftertreatment Unit - AR49.20-P-1500MSA
Engine 256.9 In Model 213, 238
as of model year 2020
MODIFICATION NOTES
| 18.01.2022 | New operation steps added. | Operation steps 17, 18, 19, 20. | |
| 15.09.2021 | Remove shield of gasoline particulate filter differential pressure sensor (B163/3), release and disconnect electrical connector. | Operation step 5. | |
| 15.09.2021 | Remove heat shield between coolant expansion reservoir and exhaust gas aftertreatment unit (1). | Operation step 6. |
Fig 1: Exhaust Aftertreatment Unit Components Location - Engine 256.9 In Model 238 As Of Model Year 2020
| 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 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 of 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 upper Engine cover. | AR01.10-P-2405MSA | |
| 2 | Remove heat shield (3). | *BA09.40-P-1004-02MRT | |
| 3 | Remove heat shield (2). | *BA09.40-P-1004-02MRT | |
| 4 | Remove pressure hoses (10) from exhaust gas aftertreatment unit (1) and seal openings with suitable stop plugs. | Fig 3 | |
| Fig 2 | |||
| 5 | Remove shield of gasoline particulate filter differential pressure sensor (B163/3), release and disconnect electrical connector. | ||
| 6 | Remove heat shield between coolant expansion reservoir and exhaust gas aftertreatment unit (1). | ||
| 7 | Release and disconnect the electrical connections (4). | ||
| 8 | Remove electric line of lambda sensor upstream of catalytic converter (G3/2) from Engine. | AR07.04-P-0086MSA | |
| 9 | Remove electric line of lambda sensor downstream of catalytic converter (G3/1) from Engine. | AR07.04-P-0085MSA | |
| 10 | Remove electric line of temperature sensor upstream of gasoline particulate filter (B163/4) from Engine. | AR49.20-P-0200MSA | |
| 11 | Remove exhaust system from exhaust gas aftertreatment unit (1). | AR49.10-P-7142MSA | |
| 12 | Remove screws_(7). | *BA49.10-P-1005-02P | |
| 13 | Remove screws (8). | *BA49.10-P-1005-02P | |
| 14 | Release upper screw of heat shield (5) and release heat shield (5) from clip at heat shield (6). | *BA00.10-P-1002-04A | |
| 15 | Remove clamp (9) between exhaust gas turbocharger and exhaust gas aftertreatment unit (1). | *BA09.40-P-1001-02MRT | |
| 16 | Remove exhaust gas aftertreatment unit(1). | ||
| 17 | Remove lambda sensor upstream of catalytic converter (G3/2). | When replacing the exhaust gas aftertreatment unit (1). | AR07.04-P-0086MSA |
| 18 | Remove lambda sensor downstream of catalytic converter (G3/1). | When replacing the exhaust gas aftertreatment unit (1). | AR07.04-P-0085MSA |
| 19 | Remove differential pressure sensor with molded hoses from exhaust gas aftertreatment unit (1). | When replacing the exhaust gas aftertreatment unit (1). |
Fig 3 |
| 20 | Remove temperature sensor of gasoline particulate filter. | When replacing the exhaust gas aftertreatment unit (1). | AR49.20-P-0200MSA |
| Clean | |||
| 21 | Remove combustion and corrosion residue at connecting points. | Assembly cleaner | *BR00.45-Z-1028-04A |
| 22 | Install in the reverse order. | ||
| 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 an Engine test run; check the Engine for proper operation and the exhaust system for leaks. | ||
| 24 | Install center and rear lower Engine compartment lining. | AR61.20-P-1105LWE | |
| 25 | Install upper Engine cover. | AR01.10-P-2405MSA |
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1002-04A | M6 x 1 | Nm | 9 | 13 |
TURBOCHARGER
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA09.40-P-1001-02MRT | Profile clamp, exhaust system to exhaust gas turbocharger | Nm | 17 |
TURBOCHARGER
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA09.40-P-1004-02MRT | Nut/screw, heat shield to exhaust gas turbocharger/heat shield | Nm | 8 |
EXHAUST SYSTEM
| Number | Designation | Model 213 with engine 256 | Model 238 with engine 256 | |
|---|---|---|---|---|
| BA49.10-P-1005-02P | Bolt, catalytic converter to bracket | Nm | 20 | 20 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |