Remove/install mixing chamber

AR09.20-P-1320MCE

Remove/install mixing chamber

19.7.11



Remove

Danger!

Risk of death caused by vehicle slipping or toppling off the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

1

Raise vehicle with vehicle lift

2

Remove fender liner from left rear fender

AR88.10-P-1400MCC

3

Loosen nut (arrow A) at top on left boost pressure positioner (Y100)

4

Unscrew nut (1) from left boost pressure positioner (Y100)

5

Remove left boost pressure positioner (Y100) and lay down to side with lines connected

6

Remove bracket (6) on hose (7) from bracket (8)

7

Disconnect electrical connector of exhaust temperature sensor upstream of diesel particulate filter (DPF) (B19/9x1).

8

Disconnect electrical connector of exhaust temperature sensor upstream of exhaust gas turbocharger (B19/11x1)

9

Unclip connector (9) from bracket (8)

10

Unscrew bolts (5) on exhaust gas recirculation cooler (2) from mixing chamber bottom section (18)

11

Unscrew bolts (3) on exhaust gas recirculation pipe (4) from exhaust gas recirculation cooler (2)

12

Lower vehicle with vehicle lift

13

Remove throttle valve actuator

AR09.41-P-1321MCD

14

Loosen bolt clamps from charge air hose (13)

15

Unscrew bolts (16) and bolt (arrow B) and remove mixing chamber top section (12) with charge air hose (13)

 Remove seal between mixing chamber top section (12) and mixing chamber bottom section (18).

16

Remove exhaust gas recirculation switchover valve with bracket and lay down to side with electrical line and vacuum hoses connected.

AR14.20-P-7660MCD

17

Unscrew bolts (10) from air filter box (11) and lay air filter box (11) down to side

18

Disconnect electrical connector (15) from exhaust back pressure sensor (B60)

19

Detach vacuum line (14) from exhaust gas recirculation positioner

20

Remove cable tie (17) from transmission and mixing chamber bottom section (18) and lay wiring harnesses down to side

21

Unscrew bolts (19) and remove mixing chamber bottom section (18)

 Remove seal between mixing chamber bottom section (18) and remove exhaust gas recirculation cooler (2).

22

Remove exhaust back pressure sensor (B60)

When replacing mixing chamber bottom section (18).



Install

23

Install exhaust back pressure sensor (B60)

When replacing mixing chamber bottom section (18).



*BA07.04-P-1004-01J

24

Position bolts (5) on exhaust gas recirculation cooler (2) and fix in place with butyl cord

*BR00.45-Z-1085-01A

25

Position seal for exhaust gas recirculation cooler (2) on bolts (5)

 Use new gasket.

26

Position mixing chamber bottom section (18) on exhaust gas recirculation cooler (2)

 To facilitate positioning, counterhold exhaust gas recirculation cooler (2) with suitable screwdriver (20)

27

Screw in bolts (5) on exhaust gas recirculation cooler (2) to stop

 Ensure that seal between mixing chamber bottom section (18) and exhaust gas recirculation cooler (2) does not slip

28

Screw in bolts (19) on mixing chamber bottom section (18) to stop

29

Lift vehicle on lifting platform.

30

Tighten exhaust gas recirculation pipe (4) on exhaust gas recirculation cooler (2) with bolts (3)

 insert new seal between exhaust gas recirculation pipe (4) and exhaust gas recirculation cooler (2)



*BA14.20-P-1008-01E

31

Tighten bolts (5) for exhaust gas recirculation cooler (2) on mixing chamber bottom section (18)



*BA14.20-P-1003-01E

32

Lower vehicle with lifting platform

33

Tighten bolts (19) on mixing chamber bottom section (18)



*BA14.20-P-1005-01E

34

Position wiring harnesses and fix in place with cable tie (17) on transmission and mixing chamber bottom section (18)

35

Position air filter box (11) and tighten with bolts (10)

36

Position exhaust gas recirculation switchover valve with bracket on air filter box (11) and tighten bolts

AR14.20-P-7660MCD

37

Position mixing chamber top section (12) with seal and charge air hose (13) on charge air manifold and mixing chamber bottom section (18)

 Use new gasket.

38

Tighten bolts (16) and bolt (arrow B) on mixing chamber top section (12)

 Ensure that seal does not slip between mixing chamber top section (12) and mixing chamber bottom section (18).



*BA14.20-P-1004-01E

39

Tighten bolt clamps on charge air hose (13)

40

Install throttle flap positioner

AR09.41-P-1321MCD

41

Lift vehicle on lifting platform.

42

Push air intake hose onto air filter box (11)

43

Install fender line in left rear fender

AR88.10-P-1400MCC

44

Position left boost pressure positioner (Y100) and tighten nut (arrow A) and nut (1)

45

Clip connector (9) into bracket (8)

46

Connect electrical connector on exhaust temperature sensor upstream of diesel particulate filter (DPF) (B19/9x1)

47

Connect electrical connector on exhaust temperature sensor upstream of exhaust gas turbocharger (B19/11x1)

48

Fasten hose (7) with holder (6) to bracket (8)

49

Lower vehicle with lifting platform

 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 the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

50

Test run engine and check exhaust gas for leakage.

51

Read out fault memory, erase if necessary



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04MCC

52

Install interior flap above engine

AR88.40-P-1100-03MCC

Number

Designation

Engine
660.9

BA07.04-P-1004-01J

Exhaust back pressure sensor on mixing chamber

25

Number

Designation

Engine
660.950/
951

BA14.20-P-1003-01E

Bolt, exhaust gas recirculation positioner to mixed air housing bottom section

Nm

10

BA14.20-P-1004-01E

Bolt, mixed air housing top section to mixed air housing bottom section

Nm

10

BA14.20-P-1005-01E

Bolt, mixed air housing bottom section to transmission

Nm

20

BA14.20-P-1008-01E

Bolt connecting exhaust gas recirculation pipe to exhaust gas recirculation cooler

Nm

9

Number

Designation

Order number

BR00.45-Z-1085-01A

Butyl cord Terostat 81, 6 mm dia.

A 004 989 61 20