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Home >> Mercedes Benz >> 2012 >> Sprinter 2500, Van Crew Extended >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Air Intake, Turbo Charging -- Model 906 (Engine 642) >> Testing & Repair >> Remove/Install Engine Charge Air Duct Upstream Of Charge Air Cooler - Ar09.41-D-8623SG

Remove/Install Engine Charge Air Duct Upstream Of Charge Air Cooler - Ar09.41-D-8623SG

ENGINES 642.896 /898 in MODEL 906 

Fig 1: Engine Charge Air Duct Upstream Of Charge Air Cooler Remove/Install Component Locations - Engine 642 in Model 906
G08211435Courtesy of MERCEDES-BENZ USA

Shown on engine 642.896 

REMOVE/INSTALL ENGINE CHARGE AIR DUCT UPSTREAM OF CHARGE AIR COOLER - ENGINES 642.896 /898 IN MODEL 906

REMOVINGINSTALLING Remove/install     
1 Lift/jack up vehicle   AR00.60-D-1000H
2 Open Henn coupling and remove charge air hose (8) from engine charge air duct (3) IMPORTANT Plug connections with protective hoods.
IMPORTANTInstallation:  Replace sealing ring.
AR09.41-P-1311-01AL 
SPECIAL TOOL Figure
3 Lower vehicle    
4 Remove air filter housing   AR09.10-D-1150SF 
5 Remove windshield fluid reservoir windshield washer system (1) and hand up to side IMPORTANT Do not detach lines connected AR82.35-D-6000SD
6 Remove electrical line (6) from engine charge air duct (3)    
7 Unscrew bolt (4) and pull out bracket (5)    
8 Remove bolts (7) IMPORTANTInstallation:  Screw all bolts (7) finger-tight, then tighten.  
TORQUE SPECIFICATION  
TORQUE SPECIFICATION  
SPECIAL TOOL Figure
9 Detach engine charge air duct (3) from noise damper (2) downwards and take out IMPORTANTInstallation:  Replace sealing ring on noise damper (2). Install new cable tie for electrical line (6) before installing engine charge air duct (3).  
10 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
11 Carry out an engine test run and check the engine around the engine charge air duct (3) for leaktightness    
CHARGE AIR PIPE/CHARGE AIR COOLING TORQUE SPECIFICATIONS - ENGINE 642

Number Designation Engine 642
BA09.41-N-1005-01O Bolt from engine charge air duct upstream of charge air cooler to holder Nm 9
BA09.41-N-1006-01O Bolt from engine charge air duct upstream of charge air cooler to engine support Nm 9
Fig 2: Identifying Set Of Protective Covers (001 589 01 91 00)
G08211436Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Flexible Head Wrench Set (001 589 81 09 00)
G08211437Courtesy of MERCEDES-BENZ USA