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Remove/install O2 sensor - AR07.04-P-0080TA

ENGINE 648.961 in MODEL 211.026 /226 with CODE (474) Particulate filter 

ENGINE 648.961 in MODEL 211.023 /223 

Fig 1: Identifying O2 Sensor Components
G04987424
MODIFICATION NOTES

6.8.05 O2 sensor to catalytic converter Engine 648.961 with code 494 *BA07.04-P-1003-01G 
REMOVINGINSTALLING Remove/install     
DANGER Risk of injury  to skin and eyes caused by handling hot or glowing objects. Wear safety gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
DANGER Risk of injury  caused by fingers being jammed or pinched  when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. When moving components, ensure that no body parts or limbs are within the operating range of moving parts. AS00.00-Z-0011-01A
1 Open engine hood   AR88.40-P-1000T
2 Remove trim panel of cylinder head cover   AR01.20-P-5014-02C
    TORQUE SPECIFICATION Bolt, cylinder head cover trim panel at cylinder head *BA01.20-P-1002-01G 
    TORQUE SPECIFICATION Bolt of trim panel to charge air distribution pipe *BA01.20-P-1003-01G 
3 Remove air filter housing   AR09.10-P-1150T
4 Remove and disconnect connector of O2 sensor upstream of catalytic converter (G3/2x1) from bracket at exhaust gas recirculation cooler    
5 Expose electrical line to O2 sensor upstream of catalytic converter (G3/2) IMPORTANTInstallation:  Install new tie straps.  
6 Detach heat shield above turbocharger   AR49.00-P-1000-01T
7 Unscrew the O2 sensor upstream of TWC [KAT] (G3/2) IMPORTANTInstallation:  Coat thread of O2 sensor upstream of TWC (G3/2) with heat-resistant lubricant.  
    TORQUE SPECIFICATION *BA07.04-P-1003-01G 
    SPECIAL TOOL Socket Fig 2
    Paste *BR00.45-Z-1005-06A 
8 Install in the reverse order    
9.1 Connect STAR DIAGNOSIS and delete fault memory. After replacing the O2 sensor upstream of catalytic converter (G3/2)  
REFER TO SELF-DIAGNOSTIC SYSTEMS Connect STAR DIAGNOSIS and read out fault memory   AD00.00-P-2000-04A
    STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A 
DANGER Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near engine Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.		 AS00.00-Z-0005-01A
10 Conduct engine test run and inspect exhaust system for leaks    
TORQUE SPECIFICATION CRANKCASE VENTILATION, CYLINDER HEAD COVER

Number Designation Engine 648
BA01.20-P-1002-01G Bolt connecting trim panel of cylinder head cover to cylinder head Nm 9
BA01.20-P-1003-01G Bolt connecting cover to charge air distribution pipe. Nm 9
TORQUE SPECIFICATION SENSORS

Number Designation Engine 648.961 without code 494
BA07.04-P-1003-01G O2 Sensor to catalytic converter Nm 60
Fig 2: Identifying Wrench Socket (111 589 03 09 00)
G04987425
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1005-06A Paste A 000 989 76 51
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