Remove/Install Mixing Chamber - AR09.20-P-1320OGR

Engine 642 in model 166, 292

Courtesy of MERCEDES-BENZ USA

	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Remove/install
1	Remove engine air intake duct downstream of air filter		AR09.10-P-8130OGR
2	Remove engine charge air duct on ATL		AR09.41-P-8622OGR
3	Remove noise damper downstream of charge air cooler		AR09.40-P-6925GZB
		Check sealing ring for damage and replace if necessary.
4	Detach charge air hose downstream of charge air cooler from engine charge air duct downstream of charge air cooler		AR09.41-P-8625OGR
		Check sealing ring for damage and replace if necessary.
5	Disconnect electrical connection (2) on throttle valve actuator
6	Disconnect electrical connections (3, 4) at glow output stage
7	Detach electrical connection on charge air temperature sensor (B17/8)
8	Disconnect electrical connection on boost pressure sensor (B5/1)
9	Remove screw/bolts (1) on throttle valve actuator holder	Loosen bracket for cylinder head if necessary.
		Bracket, throttle valve actuator to cylinder head	*BA09.41-P-1006-01J
10	Disconnect electrical connections (6) and vacuum hose (5) on EGR cooler bypass flap vacuum valve
11	Remove screw/bolt (7) on glow output stage bracket on cylinder head	M6	*BA00.10-P-1002-01A
12	Detach coolant line from glow output stage bracket
13	Remove screw/bolts (9)	Replace seal.
		EGR line to charge air distributor	*BA14.20-P-1003-01G
14	Remove screw/bolts (8) for mixing chamber at the charge air distributor	Screw/bolt, mixing chamber to charge air distributor	*BA09.20-P-1001-01Q
15	Push hose and tubing bracket on the mixing chamber flange upwards
16	Remove mixing chamber upwards	Install new sealing rings.
17	Detach glow output stage	Only if mixing chamber is replaced	AR15.20-P-4500OGR
18	Detach throttle valve actuator	Only if mixing chamber is replaced	AR07.51-P-1401OGR
19	Detach boost pressure sensor (B5/1)	Only if mixing chamber is replaced	AR09.41-P-2006OGR
20	Detach EGR bypass flap	Only if mixing chamber is replaced	AR14.20-P-7661CD
21	Install in the reverse order
	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
22	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
		8.8	Phosphated	Nm	9
		10.9	Galvanized	Nm	13
		10.9	Phosphated	Nm	12
		12.9	Galvanized	Nm	16
		12.9	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