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

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ENGINES 642 in MODELS 207, 212, 218

Fig 1: Mixing Chamber Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
1	Remove fan unit	Model 207	AR20.40-P-5050CW
		Model 212, 218	AR20.40-P-5050EW
2	Remove engine air intake duct downstream of air filter		AR09.10-P-8130OGE
3	Remove engine charge air channel upstream of charge air cooler	Check sealing ring for damage and replace if necessary. Leaks can occur otherwise.	AR09.41-P-8623OGE
4	Remove engine charge air duct on turbocharger		AR09.41-P-8622SXI
5	Remove right engine intake air duct hose upstream of air filter
6	Remove noise damper downstream of charge air cooler	Check sealing ring for damage and replace if necessary. Leaks can occur otherwise.	AR09.40-P-6925SXI
7	Unplug charge air hose downstream of charge air cooler	Unplug the charge air hose at the engine intake air duct downstream of the charge air cooler. Check sealing ring for damage and replace if necessary. Leaks can occur otherwise.	AR09.41-P-8625SXI
8	Disconnect electrical connector (2) at throttle valve actuator
9	Unplug electrical connectors (3, 4) at glow output stage
10	Disconnect connector from charge air temperature sensor (B17/8)
11	Disconnect electrical connector on boost pressure sensor (B5/1)
12	Remove bolts (1) on throttle valve actuator holder		*BA09.41-P-1006-01J
13	Disconnect electrical connector (6) on vacuum valve	For vehicles with an EGR bypass flap
14	Unscrew bolt (7) from glow output stage bracket on cylinder head		*BA00.10-P-1002-01A
15	Detach vacuum hose (5) on vacuum valve	For vehicles with an EGR bypass flap
			*BA14.20-P-1003-01G
16	Remove bolts (9) on pipe for the exhaust gas recirculation cooler	For vehicles with an EGR bypass flap Install new gasket
			*BA14.20-P-1003-01G
17	Remove bolts (8) for mixing chamber on charge air manifold		*BA09.20-P-1001-01Q
18	Push hose and tubing bracket on the mixing chamber flange upwards
19	Remove mixing chamber upwards	Replace sealing rings. Leaks and damage can occur on the engine otherwise.
20	Remove bolts on engine charge air duct downstream of charge air cooler		*BA09.41-P-1005-01J
21	Pull engine charge air duct downstream of charge air cooler out of the mixing chamber	Replace sealing rings. Leaks and damage can occur on the engine otherwise.
22	Install in the reverse order

HEADLESS SCREWS: SCREWS AND NUTS, COARSE-PITCH THREAD

Number	Designation				All models
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	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		Engine 642.82/83/85/86/87/886/9
BA14.20-P-1003-01G	Exhaust gas recirculation pipe to charge air distribution line	Nm	13