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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 Mixing Chamber - Ar09.20-D-1320SG

Remove/Install Mixing Chamber - Ar09.20-D-1320SG

ENGINES 642.896 /898 in MODEL 906 

Fig 1: Mixing Chamber Remove/Install Component Location - Engine 642 In Model 906
G08211411Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL MIXING CHAMBER - ENGINES 642.896 /898 IN MODEL 906

REMOVINGINSTALLING Remove/install     
1 Disconnect battery ground line   AR54.10-D-0003SD
2 Lift/jack up vehicle   AR00.60-D-1000H
3 Open coupling and remove charge air hose from fitting IMPORTANT Plug connections with protective hoods.
IMPORTANTInstallation:  Replace seal ring and coat with anti-friction paste.		  
SPECIAL TOOL Figure
Lubricant paste  
4 Unscrew bolts (5) from bracket (4), unscrew fittings (2) and throttle valve actuator (M16/48) TORQUE SPECIFICATION  
TORQUE SPECIFICATION  
5 Remove electrical wiring harness (6) from bracket (4) and unclip throttle valve actuator (M16/48)    
6 Disconnect electrical connector (3) at charge air temperature sensor (B17/15)    
7 Lower vehicle    
8 Remove air filter housing   AR09.10-D-1150SF 
9 Remove exhaust gas recirculation pipe (10) from exhaust gas recirculation valve to mixing chamber (9)   AR14.20-D-1060SG
10 Remove viscous fan clutch   AR20.40-D-5660SF
11 Unscrew bolts (12) TORQUE SPECIFICATION  
12 Unscrew bolt (13) and remove mixing chamber (9) toward front IMPORTANTInstallation:  Replace sealing ring (14) on charge air manifold (15) and seal (11).
Install mixing chamber (9) free of tension.		  
TORQUE SPECIFICATION  
13 Lift out mixing chamber (9) and disconnect electrical connector (7) from throttle valve actuator (M16/48)    
14 Disconnect electrical connector (8) at boost pressure sensor (B5/8)    
15 Remove fittings (2) and throttle valve actuator (M16/48) from mixing chamber (9) IMPORTANT Only if installing new mixing chamber (9). AR09.41-D-1321SG 
16 Detach boost pressure sensor (B5/8) on mixing chamber (9) IMPORTANT Only if installing new mixing chamber (9).  
TORQUE SPECIFICATION  
CLEAN Clean     
17 Clean sealing surfaces on charge air manifold (15), charge air hose (1) and fittings (2)    
18 Clean sealing surfaces on mixing chamber (9) IMPORTANT Only if mixing chamber (9) is not replaced.  
19 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
20 Test run engine and check connections for leaks in the area of mixing chamber (9)    
CHARGE AIR PIPE/CHARGE AIR COOLING - TORQUE SPECIFICATIONS - ENGINE 642

Number Designation Engine 642
BA09.41-N-1007-01O Bolt, engine charge air duct downstream of charge air cooler to throttle valve actuator Nm 9
BA09.41-N-1008-01O Bolt, throttle valve actuator holder to cylinder head Nm 9
BA09.41-N-1011-01O Bolt, boost air pressure sensor to mixing chamber Nm 6
BA09.41-N-1012-01O Bolt of mixing chamber to charge air manifold M6 Nm 9
BA09.41-N-1013-01O Bolt, mixing chamber to support brace M8 Nm 20
Fig 2: Identifying Set Of Protective Covers (001 589 01 91 00)
G08211412Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS - LUBRICATING PASTE

Number Designation Order number
BR00.45-Z-1002-06A Lubricating paste, rubber parts 2.5 kg, DB supply specification 6867.00 A 000 989 01 60
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