Diesel models
Models 463.323 (M612)
EGR cooler installation details on models 463.323 (1 of 2)
1, 2, 3 - Cooling tract hoses; 4 - Vacuum line; 5 - Lid; 6 - Fuel heating device; 7 - EGR cooler; 8, 10, 13, 15 - Bolts; 11 - Hollow bolt of the nipple connection; 12 - Fuel return line; 14 - Bracket
EGR cooler installation details on models 463.323 (2 of 2)
16 — Exhaust system
1. Drain the cooling system (see Chapter Routine care and maintenance).
2. Remove the cylinder head cover trim panels.
3. Disconnect the cooling system hoses (1, 2 and 3).
4. Disconnect the vacuum line (4), move it together with the mounting clamp to the side and remove the cover (5).
5. Loosen the bolt (8) on the bracket (9), unscrew the bolt (10) and disconnect the fuel heating device (6) from the cooler (7).
6. Unscrew the hollow bolt of the union nut (11) securing the fuel return line (12) to the fuel line.
7. Unscrew the bolts (13) securing the bracket (14) and cooler (7). Remove the bracket (14).
8. Unbolt from the cylinder head and exhaust system (16) and remove the cooler (7).
9. Installation is carried out in the reverse order - do not forget to replace the sealing elements.
[Original published on the website MERCEDESMAN]
10. Finally, check the engine fuel and cooling system components for signs of developing leaks.
Models 463.333 (M628)
EGR cooler installation details on models 463.333 (1 of 2)
1 - Fuel filter; 2 - Connecting pipe; 2a, 2c, 3a, 3c, 3d, 4a, 4c, 4d, 7 - Bolts; 2b, 3b, 4b - Sealing gaskets; 3 - Right upper section of the air distributor; 4 - Left upper section of the air distributor; 5 - Left intermediate air duct; 6 - Right intermediate air duct; 8 - EGR cooler; 9 - Vacuum blocks of the inlet port shut-off drive; 10 - Throttle actuator with upper air ducts; 13 - Right air intake duct; 14 - Oil filler neck trim panel
EGR cooler installation details on models 463.333 (2 of 2)
11, 12 — Connecting pipes
A - Direction of cooler removal
B — Direction of cooler removal
1. Remove the crankcase guard.
2. Drain the cooling system (see Chapter Routine care and maintenance).
3. Remove the air cleaner (see Section Servicing air intake tract components).
4. Remove the right air intake duct (13) (see Section Servicing air intake tract components).
5. Remove the oil filler neck trim panel (14).
6. Remove the fuel filter (1) - the filter must be replaced.
7. Remove the left and right air intake assemblies with MAF sensors (see Section Servicing air intake tract components).
8. Remove the throttle actuator assembly with the upper air ducts (10) (see Section Servicing air intake tract components).
9. Remove the valve assembly (see Section Removal and installation the valve assembly).
10. Remove the EGR positioner (see Section Removal and installation EGR positioners).
11. Unscrew the bolts (2a and 2c) and remove the right connecting pipe (2). Prepare replacement sealing gaskets (2b).
12. Remove the bolts (3a, 3c and 3d) and remove the upper half of the right air distributor section (3). Prepare replacement sealing gaskets (3b).
13. Remove the bolts (4a, 4c and 4d) and remove the upper half of the left section of the air distributor (4). Prepare replacement sealing gaskets (4b).
14. Disconnect the vacuum hoses from the vacuum blocks (9) shutting off the right and left inlet ports.
15. Unscrew the bolt (7) and unbolt the vacuum block assembly (9) with the device for shutting off the left inlet port from the air distributor.
16. First pull up the rear side (A) of the EGR cooler (8), then push back the front side (B) and remove the cooler (7) from the connecting pipes (11 and 12). If necessary, have replacement O-rings ready.
17. Installation is carried out in reverse order.