Remove/Install Intake Port Shutoff - AR09.20-P-1314OGR

Engine 642 in model 166, 292

Courtesy of MERCEDES-BENZ USA

Fig 1: Intake Port Shutoff Components Location - Engine 642 In Model 166

Courtesy of MERCEDES-BENZ USA

	Risk of explosion caused by fuel Igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure	Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized.	AS07.16-Z-0001-01A
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel.	No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Notes about Common-Rail components		AH07.16-P-0002-01TX
	Remove/install
1	Remove exhaust gas ATL	Remove/install turbocharger	AR09.40-P-6020OGR
2	Remove oil supply connection fittings for ATL		AR09.40-P-6023OGR
3	Remove soundproofing on both cylinder head covers
4	Remove fuel filter
		Engine 642 in model 166 Engine 642 in model 292	AP47.20-P-0780EWO
5	Unfasten rail on the right	Unfasten rail on the right until the fuel line (13) can be removed. Do not kink fuel line (13).	AR07.03-P-1010OGR
6	Disconnect Electrical connection (11) from intake port shutoff actuator motor (M55)
7	Remove screw/bolts (12) on both clamps of the fuel line (13)	Fuel line to cylinder head cover/lifting eye/charge air manifold	*BA07.16-P-1022-01C
8	Unscrew fuel line union nut (13) on left rail	Seal the connections using suitable stop plugs. Check fuel line sealing cone (13) for damage; replace fuel line (13) if necessary.
		Fuel line between left and right tail	*BA07.16-P-1024-01C
		Record plug	Fig 3
9	Remove cage (15) for the fuel filter on charge air distributor (14)	Bolt, fuel filter cage to charge air manifold	*BA47.20-P-1001-02D
10	Disconnect electrical connections at fuel injectors for right cylinder head
11	Disconnect electrical connection (8) on camshaft Hall sensor
12	Disconnect electrical connections at the glow plugs	Pliers	Fig 2
13	Disconnect electrical connection (7) on coolant temperature sensor
14	Expose engine wiring harness (16) and detach cable duct (9) on charge air distributor (14) and on left cylinder head cover	Place engine wiring harness (16) and cable duct (9) to one side.
15	Remove bracket (10)
16	Remove screw/bolts (17) for intake port shut of actuator motor (M55) from charge air distributor (14)
17	Turn intake port shutoff actuator motor (M55) and unclip retaining clip (18) on left intake port shutoff linkage (19)	Replace retaining clip (18).
18	Turn adjusting lever (22) on intake port shutoff actuator motor (M55) until the retaining clip (20) in the right intake port shutoff linkage (21) is accessible and unclip the retaining clip (20) on the right intake port shutoff linkage (21)	Replace the retaining clip (20).
19	Remove intake port shutoff actuator motor (M55)
20	Install in the reverse order