Remove/install mixing chamber

AR09.20-S-1320PS

Remove/install mixing chamber

27.07.2018

Engine

642 in model 470, 471

Modification notes

10.07.2018

Work procedure changed.

Operation steps 1, 14, 15,

2

Electrical connector

3

Vacuum hose

4

Switchover valve bypass

5

Bolts

6

EGR bypass flap

7

Throttle valve actuator

1

Mixing chamber

7

Throttle valve actuator

9

Bolts

10

Screw

11

Boost pressure sensor

 Warning

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 hazard area.

AS49.00-Z-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Disconnect ground line from battery.

AR54.10-S-0003P

2

Remove fan unit.

AR20.40-S-5050PS

 Installation: Only install upper engine cover after the leak test.

3

Remove diesel injection system control unit.

AR07.08-S-7009PS

4

Remove noise damper in front of charge air cooler.

AR09.40-S-6930PS

5

Remove clean air line.

AR09.10-S-8140PS

6

Remove charge air pipe downstream of exhaust gas turbocharger.

AR09.41-S-1333PS

7

Remove noise damper downstream of charge air cooler.

AR09.40-S-6925PS

8

Remove connection fitting downstream of charge air cooler.

AR09.41-S-8630PS

9

Remove the glow output stage.

AR15.20-S-4500PS

10

Disconnect electrical connector at throttle valve actuator (7).

11

Disconnect electrical connector (2) from boost pressure sensor (11).

12

Disconnect electrical connector at switchover valve bypass (4).

13

Remove vacuum hose (3) from switchover valve bypass (4) and seal openings with suitable stop plugs.

 Record plug

*129589009100

14

Remove screws (5).

 Screw, exhaust gas recirculation line to heat exchanger

*BA14.20-N-1002-01PS

15

Remove screw (10).

16

Remove screws/bolts (9).

 Installation: Position screws (9, 10) first, then tighten them.

 Screw/bolt, mixing chamber to charge air distributor

*BA09.41-N-1012-01O

17

Carefully pull mixer housing (1) forwards and remove.

 WIS Service Media
wsm://04_ 201800_08

 Installation: Replace O-rings and seal.

 Assembly tool

*000589936300

18

Seal openings using suitable protective covers.

 Set of protective caps

*001589029100

19

Remove throttle valve actuator (7).

If mixer housing (1) is replaced.

AR09.41-S-1330PS

20

Remove boost pressure sensor.

If mixer housing (1) is replaced.

AR09.41-S-2006PS

21

Remove exhaust gas recirculation bypass flap (6) with exhaust gas recirculation line attached.

If mixer housing (1) is replaced.

AR14.20-S-7661PS

22

Install in the reverse order.

 Warning

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 engine test run and in this connection check the engine in the area of mixer housing (1) for leaks.

 Charge air pipe, charge air cooling, mixer housing

Number

Designation

Engine 642

BA09.41-N-1012-01O

Screw/bolt, mixing chamber to charge air distributor

M6

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 642 in model 470, 471

BA14.20-N-1002-01PS

Screw, exhaust gas recirculation line to heat exchanger

Nm

9