Remove/install mixing chamber

AR09.20-P-1320LFD

Remove/install mixing chamber

29.07.2016

Engine

642 in model 222

1

Screw/bolts

5

Vacuum hose

9

Screw/bolt

2

Electrical connection

6

Electrical connection

B5/1

Charge pressure sensor

3

Electrical connection

7

Screw/bolt

B17/8

Charge air temperature sensor

4

Electrical connection

8

Screw/bolt

 

Remove/install



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

1

Remove engine air intake duct downstream of air filter

AR09.10-P-8130OGE

2

Remove engine charge air duct

AR09.41-P-8622LFD

3

Remove fan unit

AR20.40-P-5050LF

4

Detach charge air cooler and place with attached coolant lines to one side

AR09.41-P-6819LFD

5

Remove the oil dipstick guide tube

AR18.40-P-3510LFD

6

Disconnect electrical connection (2) on throttle valve actuator

7

Disconnect electrical connection (3) from glow output stage

8

Disconnect electrical connection at charge air temperature sensor (B17/8)

9

Disconnect electrical connection on boost pressure sensor (B5/1)

10

Remove screw/bolts (1) on throttle valve actuator holder

 Bracket, throttle valve actuator to cylinder head

*BA09.41-P-1006-01J

11

Disconnect the electrical connection (6) and vacuum hose (5) on exhaust gas recirculation cooler bypass switchover valve

12

Remove CDI control unit from rubber mount and place to one side with attached lines

13

Remove screw/bolt (7) on glow output stage bracket

 M6

*BA00.10-P-1002-01A

14

Detach coolant line from glow output stage bracket

15

Unscrew screw/bolts (9)

 Installation: Replace seal.

 EGR line to charge air distributor

*BA14.20-P-1003-01G

16

Remove screw/bolts (8) for mixing chamber at the charge air manifold

 Screw/bolt, mixing chamber to charge air distributor

*BA09.20-P-1001-01Q

17

Push hose and tubing bracket on the mixing chamber flange upwards

18

Pull mixing chamber carefully to the front

19

Remove noise damper downstream of charge air cooler

AR09.40-P-6925LFD

20

Disconnect electrical connection (4) at glow output stage

Carry out operation steps 21 to 24 when replacing the mixing chamber

21

Detach glow output stage

AR15.20-P-4500LFD

22

Detach throttle valve actuator

AR07.51-P-1401LFD

23

Detach boost pressure sensor (B5/1)

AR09.41-P-2006OGE

24

Detach EGR bypass flap

AR14.20-P-7661LFD

25

Install in the reverse order

 Danger !

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

26

Carry out an engine test run

 Headless screws: bolts and nuts, coarse-pitch thread

Number

Designation

Model all

BA00.10-P-1002-01A

M6

8.8

Galvanized

Nm

9

Phosphated

Nm

9

10.9

Galvanized

Nm

13

Phosphated

Nm

12

12.9

Galvanized

Nm

16

Phosphated

Nm

14

 Intake manifold

Number

Designation

Engine 642

BA09.20-P-1001-01Q

Screw/bolt, mixing chamber to charge air distributor

M6

Nm

9

 Charge air pipe/charge air cooling

Number

Designation

Engine 642

BA09.41-P-1006-01J

Bracket, throttle valve actuator to cylinder head

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 642.82/83/85/86/87/886/887/9

BA14.20-P-1003-01G

EGR line to charge air distributor

Nm

13