a

Emissions Campaign 2020040007

First

Complete required
information

Second

38

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Emissions Campaign 2020040007

Name file: IC SW
Second

First

Third
Fourth
Fifth
21

End the DAS session.

Second
First
Third

22

Switch off the ignition.

23

Disconnect the diagnostic system.

24

Disconnect battery charger.

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Emissions Campaign 2020040007

Replacement of AEM Parts
25

Spray penetrating oil
on the threads of the
NOx sensor upstream
of SCR catalytic
converter (3), clamp
(16), clamp (21),
thread of the exhaust
gas temperature
sensor (12) and
clamp (15), as shown.
p
Exhaust system
should be cold in
order to carry out
the next steps. This
avoids injuries.
i
Observe the wait
period and details
provided by the
manufacturer of the
penetrating oil!

Removal of SCR Catalytic Converter

26

The NOx sensor
harness downstream
of the SCR catalytic
converter (5) should
be cut for ease of
removal.
i
The NOx sensor
downstream of the
SCR catalytic
converter (5) is to
remain in the SCR
catalytic converter
and to be returned
together.

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Emissions Campaign 2020040007

27

Loosen the clamp (15) at
tailpipe (13) connection.

28

Lift: Remove tailpipe (13)
from decoupling element
(arrow). Remove tailpipe (13)
from vehicle.

Lift

Ramps: place a rag (arrow B)
between the tailpipe (13) and
the rear axle. Also Place a rag
(arrow A) between the tailpipe
(13) and the floor. Lay tailpipe
on the floor.

29

Remove and dispose the
clamp (15).
i
Observe state-specific
regulations for disposal.

Ramps

30

Remove exhaust gas temperature sensor (12) upstream of
the SCR catalytic converter.
i
This is done by unscrewing the union nut on the exhaust gas
temperature sensor (12) in a counter-clockwise direction.
Position the exhaust gas temperature sensor (12) outside the
working area.

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Emissions Campaign 2020040007

31

Remove the screw on the clamp (16 of
the AdBlue® injection nozzle (17).

32

Remove and dispose clamp (16) at
injection nozzle with a suitable tool and
position the AdBlue® injection nozzle (17)
outside the working area.
i
Observe state-specific regulations for
disposal.

33

Remove and dispose the profile seal (18)
on the AdBlue® injection nozzle (17).
i
Observe state-specific regulations for
disposal.

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Emissions Campaign 2020040007

Remove and dispose the spring washer (14)
on the holding bracket of the SCR catalytic
converter (4).

36

i
To do this, remove the SCR catalytic
converter (4) from the decoupling
elements (20).

i
This is done by bending up the individual
locking fins with a screwdriver.
i
Observe state-specific regulations for
disposal.
35

Loosen the clamp (21) between the flex pipe
and the SCR catalytic converter (4).

Removal of Upstream NOx Sensor

38

Disconnect the electrical plug connection
(24) NOx sensor control unit upstream of
the SCR catalytic converter (23).

Remove the SCR catalytic converter (4).

i
Return the SCR catalytic converter (4)
to the originating parts department.
37

Remove and dispose the clamp (21).
i
Observe state-specific regulations for
disposal.

i
To do this, unlock the gray retaining
tab (24.1) by moving towards the cable
harness.
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Emissions Campaign 2020040007

39

Remove the NOx sensor control unit upstream of the SCR
catalytic converter (23) from the frame.

i
To do this, remove and dispose nuts (23.1).

40

Remove and dispose the remaining cable ties and retaining
clips (arrows) from harness (22) of the NOx sensor control
unit upstream of the SCR catalytic converter (23).

i
Observe state-specific regulations for disposal.

41

Remove NOx sensor upstream of SCR catalytic converter (3).
i
The control unit for the NOx sensor and the NOx sensor
upstream of the SCR catalytic converter (3) are a single unit.
i
Return the NOx sensor upstream of SCR catalytic converter
(3) to the originating parts department.

42

Clean the threads and the contact surfaces on the exhaust
pipe.

Removal of Downstream NOx Sensor

43

Remove the heat shield (25).
i
This is done by bending up the individual
locking fins with a screwdriver and
unscrew the clamping nuts (26) in a
counter-clockwise direction with a
screwdriver.

44

Dispose the clamping nuts (26).
i
Observe state-specific regulations for disposal.

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Emissions Campaign 2020040007

Disconnect the electrical plug connection
(30) at the downstream NOx sensor
control unit (27).
i
To do this unlock the gray retaining tab
(29) by moving in the direction of the
arrow.

46

Remove the downstream NOx sensor control
unit (27).
i
To do this, remove and dispose the nut
fasteners (28) and cable ties (31).
i
Return the downstream NOx sensor control
unit (27) to the originating parts department.

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Emissions Campaign 2020040007

Installation of Upstream NOx Sensor
i
Completely remove the adhesive labels that are on the
new exhaust system and its components and leave no
residue.

47

Install new NOx sensor upstream of SCR
catalytic converter (3).

49

i
Push the gray retaining tab (24.1) in
the direction of the arrow to lock.

i
A 000 905 85 11 80 (included in
package A 642 905 20 00 85)
NOx sensor upstream of SCR catalytic
converter. Torque to: 60 Nm / 44.3 ft·lb
48

Install the NOx sensor control unit
upstream of the SCR catalytic converter
(23) on the frame.

Connect the electrical plug connection
(24) and lock the retaining tab (24.1).

50

Secure the harness (22) with cable ties
(arrows), as shown.
i
A 000 995 90 06 (1x)
A 007 997 56 90 (2x)

i
Use new fasteners (23.1)
N 000000 003477
NOx sensor control unit. Torque to:
9 Nm / 6.6 ft·lb

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Emissions Campaign 2020040007

Installation of SCR Catalytic Converter
51

Install a new profile seal (18) on the
AdBlue® injection nozzle (17).
i
Clean the sealing surface of the
AdBlue® injection nozzle (17)
before installation. If excess
crystallization of AdBlue® is
present, use water and a nonabrasive cloth to clean the
AdBlue® injection nozzle (17).
i
A 207 492 00 00

52

Position the new clamp (21) on the
exhaust pipe.

54

i
Screw connection point needs to be
pointed downward.
Clamp diesel particle filter on SCR
catalytic converter. Torque to:
35 Nm / 25.8 ft·lb

i
A 000 490 13 41
53

Install new SCR catalytic converter (4).
i
Make sure that the SCR catalytic
converter is correctly seated in the
decoupling elements (20).
i
A 906 490 36 00 80

Tighten the new clamp (21).

55

Install new spring nut (14) on the
holding bracket of SCR catalytic
converter (4).
i
A 123 994 13 45
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Emissions Campaign 2020040007

Install the AdBlue® injection nozzle (17).
i
Position the new profile clamp (16) on the
SCR catalytic converter (4) first.
i
A 000 995 11 33
i
Ensure correct positioning of the Adblue®
injection valve (17). The catch (arrows) of
the Adblue® injection valve must sit in the
groove of the exhaust pipe (4).

57

Install the screw on the new profile clamp
(16) on the AdBlue® injection nozzle (17).
i
Screw: Torque to 5 Nm / 3.7 ft·lb

58

Install the exhaust gas temperature sensor
(12) upstream of the SCR catalytic
converter.
i
Apply nickel anti-seize paste to threads
only. Avoid contact to the sensor.
A 000 989 76 51 (bulk paste; can be
applied to multiple vans)
i
Temperature sensor: Torque to
45 Nm / 33.2 ft·lb

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Emissions Campaign 2020040007

Installation of Downstream NOx Sensor

59

Install new NOx sensor control unit
downstream of the SCR catalytic
converter (4).
i
A 000 905 85 11 80 (included in package
A 642 905 20 00 85)
Use new nut fasteners (28):
N 000000 003477
NOx sensor control unit. Torque to:
9 Nm / 6.6 ft·lb

60

Connect the electrical plug connection
(30) and lock the retaining tab (29).
i
Push the gray retaining tab (29) in the
direction of the arrow to lock.

61

Install the new NOx sensor downstream
of the SCR catalytic converter (5) on the
new SCR catalytic converter.
i
NOx sensor downstream of catalytic
converter. Torque to: 60 Nm / 44.3 ft·lb

62

Tie back excess length of the harness (32)
in a loop. Secure harness (32) with cable
tie (31).
i
A 007 997 56 90 (1x)
p
Do not route the harness (32) under