Emissions Control Module, Removing And Installing: Installing

• Place the Assembly Aid: T10511  on the engine.

• Make sure the retaining bracket from the Assembly Aid: T10511  is pivoted in the direction of the plenum chamber bulkhead.
• Replace the bolts that were tightened with an additional turn.
• Replace the seals, self -locking nuts, and clamps for the emissions control module.
• Install all cable ties and heat shield boots back in the same location when installing.

Operating conditions:

• There is a risk of stress fractures and engine damage due to the emissions control module being installed under stress.
• Before installing make sure that this lifter is not difficult to move or fixed.
• The lifter must be easy to turn on the threads.
• Lubricant must only be applied to the threads and the retaining tabs must be free of lubricant.
• The bolt retaining tabs must be bent together so far that the lifter is taken with when the bolt is turned.

-- Check the lifters -arrow- for ease of movement.

-- Remove the lifter completely clockwise (left threads).

-- Clean difficult to move threads and if necessary coat with rust remover.

-- Bring the retaining tabs as follows with the Calibration Tool : T10512/1-2  to the functional dimension.

-- Slide the lifter -1- onto the Calibration Tool : T10512/1  .

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-- Insert the lifter -1- into the Calibration Tool : T10512/2  .

-- Bend back the retaining tabs by lightly hitting -arrow- the ball head with the heel of the hand.

-- Install the lifters all the way by hand and loosen again by approximately 45°.

-- Replace the seal -1- and screw-type clamp -2-.

-- Install the seal -1- on the emissions control module.

-- Remove the bolt for the clamp -2- and lay the clamp completely on the emissions control module entrance funnel. Do not bend the screw-type clamp.

-- Guide the emissions control module from below in the installed position, push upward and engage the bracket in the emissions control module mounting strap.

• The emissions control module now hangs balanced in the approximate installation position.

Emissions control module tightening sequence. 

• Replace the emissions control module bolts.

Step	Bolt	Steps
1.	Screw-type clamp -1-	Position above the sealing flange and install the bolt.
2.	Bolt -2-	Install hand-tight and immediately loosen 90°
3.	Screw-type clamp -1-	Tighten to 8 Nm; pay attention to TIP
4.	Bolt -2-	Tighten to 20 Nm
5.	Bolt -3-	Install and pull to engage. Do not tighten or turn the bolt.
6.	Bolts -4-	Install and pull to engage. Tighten the bolts to 20 Nm.
7.	Bolt -3-	Tighten to 20 Nm

TIP:

For accessibility reasons, the Exhaust Gas Temperature Sensor 2 -G448- should be installed before tightening the screw-type clamp -1-. Refer to Exhaust Gas Temperature Sensor 2 -G448-, REMOVING AND INSTALLING .

-- Remove the lifter (left-hand thread) -1- on the cylinder head using the Hex Ball Socket: 3247  in the -direction of the arrow- until stop, then tighten an additional 90°.

Tightening sequence continuation

Step	Bolt	Steps
8.	Bolt -5-	Install and pull to engage.
9.	Bolt -5-	Tighten to 20 Nm
10.	Bolt -5-	additional 90° turn.
11.	Bolt -5-	An additional 45° turn

-- Remove the Assembly Aid: T10511  .

-- Install the Exhaust Gas Temperature Sensor 4 -G648-. Refer to Exhaust Gas Temperature Sensor 3 -G495- /Exhaust Gas Temperature Sensor 4 -G648-, REMOVING AND INSTALLING .

The rest of the assembly is performed in reverse order of removal, noting the following:

AWD Vehicles: 

-- Fasten the driveshaft on the bevel box. Refer to the appropriate Driveshaft article .

-- Install the right drive axle on the bevel box. Refer to OVERVIEW - DRIVE AXLE .

Vehicles with Parking Heater: 

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-- Install the coolant pipes.

Continuation for All Vehicles: 

-- Install the EGR cooler. Refer to EGR COOLER, REMOVING AND INSTALLING .

-- Install the NOx Sensor -G295-. Refer to NOx Sensor -G295-, REMOVING AND INSTALLING .

-- Install the Exhaust Gas Temperature Sensor 3 -G495-. Refer to Exhaust Gas Temperature Sensor 3 -G495- /Exhaust Gas Temperature Sensor 4 -G648-, REMOVING AND INSTALLING .

-- Install the Heated Oxygen Sensor -G39-. Refer to Heated Oxygen Sensor -G39-, REMOVING AND INSTALLING .

Vehicles with Coolant Pipe above Emissions Control Module 

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-- Connect the coolant hose and place the hose clamp -1-.

-- Install the bolts -2- and -3- and tighten to 10 Nm.

Vehicles with Two Differential Pressure Lines: 

-- Connect the hoses and place the hose clamps -1-.

-- Tighten the bolt -3-.

-- Attach the connectors -3, 4 and 5-.

-- Attach the differential pressure sensors to the cylinder head cover. Refer to OVERVIEW - HEATED OXYGEN SENSOR .

Vehicles with One Differential Pressure Line: 

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-- Tighten the bolt -arrow-.

-- Connect the hose and set the hose clamps -A-.

-- Attach the differential pressure sensor to the cylinder head cover. Refer to OVERVIEW - HEATED OXYGEN SENSOR .

Continuation for All Vehicles: 

-- If equipped, install the Oxygen Sensor After Catalytic Converter -G130-. Refer to Oxygen Sensor after Catalytic Converter -G130-, REMOVING AND INSTALLING .

-- Install the subframe. Refer to SUBFRAME WITH STEERING GEAR, REMOVING AND INSTALLING .

-- Install the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- Fill the coolant. Refer to COOLANT, DRAINING AND FILLING WITHOUT COOLING SYSTEM CHARGE KIT - ELECTRIC VACUUM PUMP : VAS 6096/2 .

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

After replacing components, perform the necessary adaptations using the Vehicle Diagnostic Tester. Refer to PERFORM ADAPTATIONS AFTER COMPONENT REPLACEMENT .