Removal and installation the powertrain suspension supports (Mercedes-Benz G-Class W463)

Petrol models

Lateral supports

Support cushions

M112

1. Disconnect the ground wire from the battery (see Chapter Engine electrical systems).

2. Remove the air cleaner (1) (see Chapter Fuel and exhaust systems).

3. Remove the cooling fan assembly with viscous coupling (2) (see Chapter Cooling, heating, ventilation and air conditioning systems).

4. Disconnect the return hydraulic line (4) from the steering pump - immediately seal the open ends of the line and the nipple connector with pre-prepared plugs.



5. Unbolt the heat shields (4 and 5) from the frame, - release the left lambda probe wiring from the shield (5).

Note: Do not attempt to split the screen (5) into two halves.

6. Remove the bolts (8).

7. Unbolt the support brackets (6) of the ATF lines (7) from the upper and lower sections of the oil pan.

8. Suspend the power unit by both lugs, making sure that no components (in particular, screens (4 and 5)) or communication lines are pinched.

9. When dismantling the right support cushion, remove the heat shield (4) - if necessary, pull the power unit to the side.

10. Loosen the fastening nuts and remove the cushion assemblies (9) of the side supports of the power unit suspension.

Note: If the nuts are secured against turning, the pads may be turned out of the support brackets.

11. Installation is carried out in reverse order.

12. Finally, read the DTC codes and clear the on-board diagnostic system memory using the hand-held tester (HHT)/STAR DIAGNOSIS scanner (6511 1801 00) (See Chapter Engine electrical systems).

M113

1. Disconnect the ground wire from the battery (see Chapter Engine electrical systems).

2. Remove the air cleaner (1) (see Chapter Fuel and exhaust systems).

3. Remove the cooling fan assembly with viscous coupling (2) (see Chapter Cooling, heating, ventilation and air conditioning systems).

4. Disconnect the throttle actuator cable (3) from the throttle position sensor (TPS) (R25/2), then release the cable from the support bracket (4).

5. Release the Bowden cable (5) of the throttle cable from the bushing (6).

6. Remove the left ignition coils (7) (see Chapter Engine electrical systems).

7. Remove the mounting bracket (8).

8. Remove the upper section (9) of the left heat shield.

9. Unbolt the right heat shield (10) and the lower section (11) of the left shield from the frame - do not remove the shields from the frame.

10. Remove the MAF hot-wire sensor (B2/5) mounted in the air intake duct (see Chapter Fuel and exhaust systems).

11. Disconnect the vacuum line (13) from the brake booster servo assembly at the rear of the intake manifold.



12. Remove the screws (17).

13. Unbolt the ATF line (15) support bracket (14) from the lower and upper sections of the oil pan.

14. Disconnect the return hydraulic line (16) from the steering pump - immediately seal the open ends of the line and the nipple connector with pre-prepared plugs.

15. Suspend the power unit by both lugs, making sure that no components (in particular, screens (10 and 11)) and communication lines are pinched.

16. Unbolt and remove the heat shield (18), then, - if the right support cushion is being removed, - remove the right shield (10), - if necessary, pull the power unit to the side.

17. Remove the left intake section (19) of the exhaust system (see Chapter Fuel and exhaust systems).

Note: The fastening nuts must be replaced without fail.

18. Lower the unit, again making sure that no components are pinched.

19. Unbolt the connecting section (20) of the exhaust system.

20. Unbolt and remove the heat shield (21), - if necessary, pull the AT ventilation hose to the side.

21. Disconnect the lambda probe wiring connector (G3/3x1)

22. Remove the connecting section (20) of the exhaust system.

Note: The fastening nuts must be replaced without fail.

23. Suspend the power unit by the front eye, making sure that no components are pinched.

24. Unscrew the cushion (22) of the corresponding support from its bracket, - the fastening nuts must be fixed, - and remove it from the engine.

25. Installation is carried out in reverse order.

26. Finally, read the DTC codes and clear the on-board diagnostic system memory using the hand-held tester (HHT)/STAR DIAGNOSIS scanner (6511 1801 00) (See Chapter Engine electrical systems).

Support brackets

Left support

1. Remove the side support cushions (see above).

2. Remove the accessory drive belt (see Section Replacement of the auxiliary drive belt and elements of its tensioning mechanism).

3. Unbolt the compressor (1) K/V and, without disconnecting the refrigeration lines, move it to the side and secure it in the engine compartment.

4. Unbolt the bracket (2) of the left side support of the power unit suspension from the engine crankcase - the mounting bolts (3) must be replaced without fail.

5. Remove the bracket (2).

6. Installation is carried out in reverse order.

Right support

1. Remove the side support cushions (see above).

2. Remove the generator shield (1).

3. Unscrew the mounting bolts (3) and remove the bracket (2) of the right side support from the engine crankcase - the bolts (3) must be replaced without fail.

4. Installation is carried out in the reverse order - make sure that no communication lines are pinched between the bracket and the crankcase wall.

Rear support

1. Jack up the car and place it on supports.

2. Support the transmission (1) with a suitable jack.

3. Remove the bolts (2).

4. Loosen the self-locking nuts of the bolts (3) and remove the cross beam (4) - the nuts must be replaced without fail.

5. Unscrew the bolts (5) and remove the rear support assembly (6) of the powertrain suspension from the beam (6).

6. Installation is carried out in reverse order.

Diesel models

Lateral supports

Note: All self-locking fasteners must be replaced.

Left support

M612

1. Disconnect the ground wire from the battery (see Chapter Engine electrical systems).

2. On models with the corresponding configuration (code ET2), activate the service mode of the TELE AID emergency call system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).

3. Turn on the auxiliary battery and connect it to the standard battery, then disconnect the negative cable from the latter.



4. Jack up the car and place it on supports.

5. Remove the cylinder head cover trim panels (see illustration) Installation details of the trim panels of the cylinder head cover of the M612 engine).

6. Remove the air distributor (see Chapter Fuel and exhaust systems).

7. Remove the mounting bracket (1) of the air distributor/left side support bracket of the power unit suspension.

8. Remove the air cleaner (see Chapter Fuel and exhaust systems).

9. Remove the primary catalytic converter (see Chapter Fuel and exhaust systems).

10. Loosen the nut (2) securing the support cushion (3) to the bracket (4).



11. Connect the lifting rigging to both eyes of the power unit, making sure that no communication lines are pinched.

12. Unscrew the bolts (5 and 6) and separate the cushions (3) of both side supports from the frame.

13. Release the rear support cushion from its bracket (see below).

14. Suspend the power unit assembly on a winch, making sure that no components are pinched.

15. Unscrew the bolts (7a-d) securing the bracket (4) of the left side support.

16. Remove the cushion (3) and bracket (4).

17. Installation is carried out in reverse order.

Note: Tighten the bolts (7a-d) in alphabetical order: abcd).

18. On models with the corresponding configuration (code ET2), deactivate the service mode of the TELE AID system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).

19. Finally, read the DTC codes and clear the on-board diagnostic system memory using the STAR DIAGNOSIS scanner (6511 1801 00) (See Chapter Engine electrical systems).

M628

1. Follow the procedures in paragraphs 1, 4 and 8 (in the order listed) for M612.

2. Remove the MAF hot-wire sensor (B2/6) mounted in the left air intake manifold (see Chapter Fuel and exhaust systems).

3. Disconnect the air intake ducts on both fenders.

4. Remove the crankcase guard.

5. Remove the cooling fan shroud (see Chapter Cooling, heating, ventilation and air conditioning systems).

6. On models with the corresponding vehicle configuration (code H12), remove the additional heater (see Chapter Cooling, heating, ventilation and air conditioning systems).

7. Remove the left lower sleeve (1) of the air duct and the left air intake duct (2) (see Chapter Fuel and exhaust systems).

8. Loosen the nut (3) securing the cushion (5) of the left side support of the power unit suspension to its bracket (4).

9. Connect the lifting rigging to both eyes of the power unit, making sure that no communication lines are pinched.

10. Disconnect the exhaust system from the turbocharger (see Chapter Fuel and exhaust systems).

11. Unscrew the bolts (6 and 7) and separate the cushions (5) of the side supports of the power unit suspension from the frame.

12. Release the rear support cushion from its bracket (see below).

13. Suspend the power unit assembly on a winch, making sure that no components are pinched.

14. Unscrew the bolts (8a-d) securing the bracket (4) of the left side support.

Note: The head of the bolt (8a) is hexagonal, the other bolts (8b-d) are equipped with TORX type heads.

15. Remove the cushion (5) and bracket (4).

16. Installation is carried out in reverse order.

Note: Tighten the bolts (8a-d) in alphabetical order: abcd).

Right support

M612

1. Perform the procedures in paragraphs 1 through 6 for M612.

2. Remove the primary catalytic converter (see Chapter Fuel and exhaust systems).

3. Loosen the nut (2) securing the support cushion (3) to the bracket (4).

4. Connect the lifting rigging to both eyes of the power unit, making sure that no communication lines are pinched.

5. Remove the crankcase guard.

6. Connect the lifting rigging to both eyes of the power unit, making sure that no communication lines are pinched.

7. Unscrew the mounting bolts (3 and 4) and separate the cushions of both side supports from the frame.

8. Perform the procedures of paragraphs 13 and 14 for M612.

9. Unscrew the bolts (5a-d) securing the bracket (6) of the right side support.

10. Remove the cushion (2) and bracket (6).

11. Installation is carried out in reverse order.

Note: Tighten the bolts (5a-d) in alphabetical order: abcd).

12. On models with the corresponding configuration (code ET2), deactivate the service mode of the TELE AID system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).

13. Finally, read the DTC codes and clear the on-board diagnostic system memory using the STAR DIAGNOSIS scanner (6511 1801 00) (See Chapter Engine electrical systems).

M628

1. Follow the procedures in paragraphs 1, 4 and 6 (in the order listed) for M612.

2. Remove the MAF hot-wire sensor (B2/7) mounted in the right air intake manifold (see Chapter Fuel and exhaust systems).

3. Follow the procedures in paragraphs 4, 5 and 6 (in the order listed) for M628.

4. Remove the right lower sleeve (1) of the air duct and the right air intake duct (2) (see Chapter Fuel and exhaust systems).

5. Loosen the nut (3) securing the cushion (5) of the right side support of the power unit suspension to its bracket (4).

6. Then proceed according to the instructions given in paragraphs 9 through 16 for M628.

Rear support

1. The procedures for removing and installing the rear support of the powertrain suspension are completely analogous to those described above for gasoline models (see paragraphs 1 to 6 for petrol engines).