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Remove/install mixing chamber - AR09.20-P-1320GZB

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ENGINES 642 in MODEL 164, 251 

Fig 1: Identifying Mixing Chamber Components (1 Of 2)
G06878064Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Mixing Chamber Components (2 Of 2)
G06878065Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Turbocharger without coolant cooling 

Fig 3: Identifying Turbocharger With Coolant Cooling
G06878066Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Turbocharger with coolant cooling 

Fig 4: Identifying Turbocharger Without Coolant Cooling
G06878067Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install     
DANGER Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, lift gates or sliding roof Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A
NOTES Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
1.1 Removes strut tower brace Model 164.8 only
IMPORTANT Remove strut tower brace from strut tower mounts.		 AR62.30-P-2500GY
1.2 Remove partition wall between wheel wells Model 251 only AR62.30-P-2400RT
2 Remove engine trim panel Model 164 AR01.10-P-2405GZB
Model 251 AR01.10-P-2405RTB
3 Remove right engine intake air duct upstream of left air filter    
4 Remove charge air hose downstream of the charge air cooler NOTESInstallation:  Check sealing ring and safety clamp for damage to avoid leakage. AR09.41-P-8625GZB 
5 Remove engine charge air duct on turbocharger (4)   AR09.41-P-8622GZB 
6 Remove bolts (6) on muffler (5) downstream of charge air cooler NOTESInstallation:  Check sealing ring for damage in order to avoid leakage on engine. AR09.40-P-6925GZB 
7 Remove oil dipstick guide tube   AR18.40-P-3510GZB
8 Unscrew bolts on bracket from throttle valve actuator (M16/6) TORQUE SPECIFICATION *BA09.41-P-1006-01J 
9 Disconnect electrical connector at the throttle valve actuator (M16/6)    
10 Disconnect electrical connectors from glow time output stage (N14/3)    
11 Unplug electrical plug connection on charge air temperature sensor (B17/8)    
12 Disconnect electrical connector on charge pressure sensor (B5/1)    
13 Disconnect electrical connector at EGR cooler bypass flap switchover valve (Y85) Vehicles as of model year 2009  
14 Unclip coolant line    
15 Detach vacuum hose on EGR cooler bypass flap switchover valve (Y85) Vehicles as of model year 2009  
16 Unscrew bolts on exhaust gas recirculation pipe from charge air distribution line IMPORTANTInstallation:  Install new gasket  
TORQUE SPECIFICATION *BA14.20-P-1003-01G 
17 Unscrew bolt for glow time output stage bracket (N14/3) on cylinder head TORQUE SPECIFICATION *BA00.10-P-1002-01A 
18 Unscrew bolts (1) from mixing chamber (3) on charge air manifold TORQUE SPECIFICATION *BA09.20-P-1001-01Q 
19 Unscrew bolts (2) from mixing chamber (3) on charge air manifold TORQUE SPECIFICATION *BA09.20-P-1001-01Q 
20 Push hose bracket and tubing bracket upwards on mixing chamber flange (3)    
21 Lift mixing chamber (3) up and out NOTESInstallation:  Replace sealing rings to avoid leaks and damage at the engine.  
22 Unscrew bolts on engine charge air duct downstream of charge air cooler On vehicles with coolant-cooled turbocharger (14b)  
TORQUE SPECIFICATION *BA09.41-P-1005-01J 
23 Pull engine charge air duct downstream of charge air cooler out of the mixing chamber On vehicles with coolant-cooled turbocharger (14b)
NOTESInstallation:  Replace sealing rings to avoid leaks and damage at the engine.		  
24 Install in the reverse order    
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
25 Carry out engine test run
HEADLESS SCREWS: SCREWS AND NUTS, COARSE-PITCH THREAD

Number Designation All models
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 Bolt, mixing chamber to charge air manifold M6 Nm 9
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation Engine 642
BA09.41-P-1005-01J Engine charge air duct downstream of charge air cooler to throttle valve actuator Nm 9
BA09.41-P-1006-01J Bracket, throttle valve actuator to cylinder head Nm 9
EXHAUST GAS RECIRCULATION

Number Designation Engines 642.82/83/85/86/87/9
BA14.20-P-1003-01G Exhaust gas recirculation pipe to charge air distribution line Nm 13
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