Servicing air intake tract components (Mercedes-Benz G-Class W463)

Models 463.323 (M612)

Air purifier and air filter

1. Remove the cylinder head cover trim panels.

2. Disconnect the electrical wiring from the MAF hot-wire sensor (B2/5).

3. Remove the air intake (1).

4. Remove the air intake sleeve (2) of the boost tract - if necessary, prepare a replacement mounting clamp.

5. Unscrew the mounting bolts (4) and remove the upper section (cover) (3) of the air cleaner casing (11).

6. Remove the filter element (5).

7. Remove the rubber sealing rings (6) from the cylinder head cover - damaged rings must be replaced.

8. If necessary, unscrew the mounting bolts (8) with washers (9) and remove the lower section (7) of the air cleaner casing (11).



9. Installation is carried out in the reverse order - before installing the filter element (5), clean the dust removal valve (10), do not forget to reset the service indicator after replacing the element.

Assembling the air intake with the mass air flow (MAF) sensor

1. Remove the cylinder head cover trim panels.

2. Disconnect the MAF sensor wiring connector (1).

3. Disconnect the sleeve (2), unscrew the bolts (3) and remove the air cleaner cover (4).

4. Unscrew the bolts (5) and separate the air intake with the built-in MAF sensor (B2/6) from the cover (4) of the air cleaner - check the condition of the sealing ring, if necessary, prepare a replacement element.

5. Installation is carried out in reverse order.

6. Finally, clear the memory of the on-board diagnostic module (see Chapter Engine electrical systems).

Intake Air Temperature (IAT) Sensor

1. Remove the crankcase guard.

2. Disconnect the connector (1) of the IAT sensor wiring (B17).

3. Compress the retaining clips (arrows) and remove the IAT sensor (B17).

Attention! To avoid damaging the mounting brackets, do not remove or install the IAT sensor with the electrical wiring connected - if the brackets are damaged, the sensor must be replaced without fail!

4. Installation is carried out in reverse order.

5. Finally, clear the memory of the on-board diagnostic module (see Chapter Engine electrical systems).

Boost tract air duct

1. Drain the cooling system (see Chapter Routine care and maintenance).

2. Remove the suction sleeve (1).

3. Disconnect the air hose (2) from the turbocharger - do not forget to disconnect the electrical wiring (3) and the crankcase ventilation hose (4).

4. Remove the cooling system fan assembly (see Chapter Cooling, heating, ventilation and air conditioning systems), - do not forget to install the air conditioning system radiator/condenser protection screen (a metal or plastic plate measuring 400x680x1 mm equipped with a suitable support bracket).



5. Remove the cooling system hose (5).

6. Disconnect the cooling system hose (6) from the water pump.

7. Loosen the clamp (9) and remove the air hose (7) - the presence of a small amount of oil in the hose is acceptable and is explained by the normal functioning of the crankcase ventilation system.

8. Unscrew the bolts (10), loosen the bolt (11) and remove the air duct (12) of the boost tract.

9. Installation is carried out in the reverse order. Do not forget to check the condition of the sealing rings (8), replace them if necessary. Ensure that the mounting clamp (9) is seated correctly.

Mixing chamber

1. Remove the air distributor trim panel (1).

2. Disconnect the vacuum hose (2).

3. Release the spring retaining ring (6) and disconnect the air hose (3) from the mixing chamber (4) - prepare a replacement sealing ring (5).

4. Remove the mixing chamber (4) - do not forget to prepare a replacement sealing element (7).

5. Remove the pipe (8).

6. Carefully clean the seating surface of the mixing chamber.

7. Installation is carried out in the reverse order. Make sure that the spring retaining ring (6) is securely seated.

Air distributor

1. Open the hood and fix it in a vertical position.

2. Remove the cylinder head cover trim panels (1 and 2).

3. 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).



4. Disconnect the negative cable from the battery.

5. Remove the crankcase guard.

6. Drain the cooling system (see Chapter Routine care and maintenance).

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

8. Remove the fuel cooler (3).

9. Remove the fuel heating device (4).

10. Remove the fuel line (5) (see Section Removal and installation of fuel distribution line and injectors).

11. Remove the supporting mounting brackets (5) from the main line.

12. Remove the main fuel filter (6).

13. Unbolt the upper support (7) of the air distributor (8).

14. Using a hand pump, pump out the hydraulic fluid from the steering pump reservoir (11) (see Chapter Routine care and maintenance).

15. Disconnect the hydraulic hose (10) from the steering pump (11) - immediately seal the open ends of the hose and the union nut.

16. Remove the steering pump reservoir (9) (see Chapter Suspension and steering).

17. Disconnect the vacuum lines at the mixing chamber control unit.

18. Disconnect the air hose (12) from the mixing chamber (13) - if necessary, prepare replacement mounting clamps.

19. Remove the mixing chamber (13) (see above).

20. Remove the pipe (14) - prepare replacement sealing rings.

21. Remove the thermostat housing (see Chapter Cooling, heating, ventilation and air conditioning systems).

22. Remove the support bracket (15) securing the exhaust gas recirculation (EGR) system tract to the air distributor (8).



23. Disconnect the electrical wiring located behind the air distributor (8) (heater, CKP sensor and intake port shutoff actuator).

24. Unbolt the air distributor (8) from the lower support bracket (16).

25. Installation is carried out in the reverse order - make sure that all seating surfaces are cleaned most thoroughly, do not forget to replace any defective sealing elements.

26. Finally, check the relevant components of the engine cooling system for signs of developing leaks, deactivate the service mode of the TELE AID system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system) and clear the memory of the on-board diagnostic module (see Chapter Engine electrical systems).

Inlet Port Shut-Off Drive Electric Motor

1. 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).



2. Turn on the auxiliary battery and connect it to the standard battery, then disconnect the negative cable from the latter and insulate the pole terminal to avoid accidentally shorting it to the ground point W10.



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

4. Remove the crankcase guard.

5. Drain the cooling system (see Chapter Routine care and maintenance).

6. Remove the boost duct (see above).

7. Unscrew the bolt (1) and remove the rack (3) from the head of the spherical support (2), - try not to damage the rack.

8. Disconnect the electrical wiring connector (4) and remove the electric motor (M55) of the intake port shut-off drive.

9. Installation is carried out in the reverse order. Do not forget to deactivate the service mode of the TELE AID system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system) and clear the memory of the on-board diagnostic system module (see Chapter Engine electrical systems).

Turbocharger

1. Remove the cylinder head cover trim panels.

2. Remove the air cleaner (see above).

3. Remove the crankcase guard.

4. Disconnect the vacuum supply line (1) from the boost pressure control transducer (Y31/5).

5. Remove the boost duct (see above).

6. Remove the clamp (2) securing the turbocharger (3) to the primary catalytic converter (4), - prepare a replacement sealing cone (5).

7. Unbolt the oil supply line (6) from the engine crankcase and turbocharger (3) - prepare replacement sealing elements.

8. Unbolt the support bracket (7) from the bottom of the turbocharger (3).

9. Remove the clamp (8) securing the primary catalytic converter (4) to the exhaust pipe (10) - prepare a replacement sealing cone (5).

10. Separate the primary catalytic converter (4) from the engine crankcase.

11. Remove the turbocharger mounting bolts (3) to the exhaust manifold.

12. Lift the turbocharger (3) out of the engine compartment together with the oil drain line (11) - prepare a replacement sealing element.

13. Disconnect the drain line (10) from the turbocharger (3) - prepare to collect any spilled oil, and if necessary, prepare a replacement sealing element.

14. Installation is carried out in the reverse order. Make sure that the turbocharger is mounted on the bracket (7) without distortions and stress.

15. Finally, check the level of the relevant working fluids and clear the memory of the processor of the on-board self-diagnosis system (see Chapter Engine electrical systems).

Charge air cooler

1. Remove the crankcase guard.

2. Drain the cooling system (see Chapter Routine care and maintenance).

3. Remove the radiator (see Chapter Cooling, heating, ventilation and air conditioning systems).

4. Loosen the fastening clamps (3) and remove the left (2) and right (1) air intakes - replace the sealing ring if necessary.

Note: The presence of a small amount of oil in the sleeves is acceptable and is explained by the normal functioning of the crankcase ventilation system.

5. Disconnect the cooling system hoses (4 and 5).

6. After marking the connectors, disconnect the wiring from the coolant temperature sensors (6 and 7).

7. Disconnect the electrical wiring from the boost pressure sensor (8).

8. Loosen the nuts (10) and remove the support bracket (9).

9. Remove the mounting clamps (11) and remove the charge air cooler (12) - the cooler should first be separated from the bracket, then pulled up and out.

10. Installation is carried out in the reverse order - ensure that the mounting clamps (3) are seated correctly.

11. Finally, clear the memory of the on-board diagnostic system processor (see Chapter Engine electrical systems).

Resonator chamber with water collector

See Section Removal and installation air intake tract components.

Models 463.333 (M628)

Air purifier and air filter

1. Pull up and remove the power unit cover with built-in air cleaner (1).

2. Unscrew the fastening bolts (2), release the clamps (3) and remove the trim panels (4/1 and 4/2).

3. Remove the filter element (5) and install a replacement one in its place - make sure that the element is seated correctly.

4. Further installation is carried out in the reverse order of dismantling the components.

Air intake assemblies with mass air flow (MAF) sensors

1. Remove the air cleaner (see above).

2. Disconnect the connectors (3) of the electrical wiring of the left (B2/6) and right (B2/7) MAF sensors.

3. Loosen the mounting clamps (1 and 4) and remove the air intakes (2 and 5) with the MAF sensors built into them (B2/6 and B2/7 respectively).

4. Installation is carried out in reverse order.

Intake Air Temperature (IAT) Sensor

1. Remove the air cleaner (see above).

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

3. Remove the fastening bandage from the mounting brackets (3) - the bandage must be replaced without fail.

4. Disconnect the IAT sensor wiring connector (2) (B17).

5. Compress the retaining clips (arrows) and remove the IAT sensor (B17).

Attention! To avoid damaging the mounting brackets (3), do not remove or install the IAT sensor with the electrical wiring connected - if the brackets are damaged, the sensor must be replaced without fail!

6. Installation is carried out in the reverse order - do not forget to replace the sealing ring (4).

7. Finally, clear the memory of the on-board diagnostic module (see Chapter Engine electrical systems).

Boost tract air ducts

Left intake sleeve

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

2. Remove the air cleaner (see above).

3. Remove the left air intake assembly (2) complete with the MAF sensor (B2/6) (see above) and pull it out in the wheel arch.

4. Remove the cover (3) of the oil filter housing.

5. Remove the additional heater unit (A6) (see Chapter Cooling, heating, ventilation and air conditioning systems).

6. Unscrew the bolts (5), loosen one nut on the frame longitudinal beam, disconnect the support bracket (6) from the frame and remove the heat shield (4).

7. Unscrew the bolt (7) and remove the fan assembly casing (see Chapter Cooling, heating, ventilation and air conditioning systems).

8. Install the air conditioning radiator/condenser protection screen (a metal or plastic plate measuring 400x680x1 mm equipped with a suitable support bracket).

9. Remove the left lower air duct (see below).

10. Remove the bolts (8) from the connecting flange (9) of the cooling tract.

11. Loosen the clamp (10) and remove the left intake hose of the air boost tract (1).

12. Installation is carried out in reverse order.

Right intake manifold

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

2. Remove the air cleaner (see above).

3. Remove the left air intake assembly (2) complete with the MAF sensor (B2/6) (see above) and pull it out in the wheel arch.

4. Remove the oil filler neck trim panel (2).

5. Unscrew the bolts (3 and 4) and remove the cover (5) from the cylinder head.

6. Remove the fan assembly shroud (see Chapter Cooling, heating, ventilation and air conditioning systems) and install the air conditioning system radiator/condenser protection screen (a metal or plastic plate measuring 400x680x1 mm equipped with a suitable support bracket).

7. Remove the right lower air duct (see below).

8. Loosen the clamp (6) and remove the left intake hose of the air boost tract (7).

9. Installation is carried out in reverse order.

Left lower air duct

1. Jack up the car and place it on supports

2. Remove the air cleaner (see above).

3. Release the air intake (10) in the wheel arch.

4. Remove the fan assembly shroud (see Chapter Cooling, heating, ventilation and air conditioning systems) and install the air conditioning system radiator/condenser protection screen (a metal or plastic plate measuring 400x680x1 mm equipped with a suitable support bracket).

5. Remove the auxiliary heater unit (see Chapter Cooling, heating, ventilation and air conditioning systems).

6. Unscrew the bolts (14), loosen one nut on the frame longitudinal beam, disconnect the support bracket (13) from the frame and remove the heat shield (12).

7. Unscrew the bolts (3 and 5) and remove the connecting plates (4 and 6).

8. Clamp the low-pressure hose of the steering pump reservoir (16) and disconnect the high-pressure hose (15) from the latter - prepare to collect any spilled hydraulic fluid, immediately plug the open ends of the line and the connecting nipple.

9. Loosen the mounting bolts (9), then pull the air duct (1) together with the connecting pipe (2) away from the turbocharger (8) and the charge air cooler (7) and remove it by pushing it forward.

10. Installation is carried out in the reverse order - if necessary, replace the sealing rings (1a and 2a).

11. Finally, do not forget to remove air from the power steering system (see Chapter Suspension and steering).

Right lower air duct

1. Jack up the car and place it on supports

2. Remove the air cleaner (see above).

3. Remove the fan assembly shroud (see Chapter Cooling, heating, ventilation and air conditioning systems) and install the air conditioning system radiator/condenser protection screen (a metal or plastic plate measuring 400x680x1 mm equipped with a suitable support bracket).

4. Unscrew the bolts (3) and remove the connecting plate (4).

5. Remove the bolts (11 and 6).

6. Unscrew the bolts (7) and remove the connecting plate (8).

7. Pull the air duct (1) together with the connecting pipe (2) away from the turbocharger (9) and the charge air cooler (10) and remove it by pushing it backwards.

8. Installation is carried out in the reverse order - if necessary, replace the sealing rings (1a and 2a).

Intermediate air ducts

1. Remove the air cleaner (see above).

2. Remove the throttle actuator assembly with the upper air ducts (4) (see below).

3. Remove the fuel filter.

4. Unscrew the bolts (5) and remove the right intermediate air duct (1).

5. Disconnect the vacuum block (8) of the intake port shut-off drive from the rod (9), then unscrew the bolt (7) and move the block (8) to the side.

6. Unscrew the bolts (6) and remove the left intermediate air duct (2).

7. Installation is carried out in the reverse order - if necessary, replace the sealing rings (10 and 11).

Air distributor

1. Remove the air cleaner (see above).

2. Remove the air intake assemblies with MAF sensors (see above).

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

4. Remove the throttle actuator assembly with the upper air ducts.

5. Remove the intermediate air ducts (see above) - if necessary, prepare replacement sealing rings (3d and 4d).

6. Remove the brake booster vacuum line (1).

7. Remove the fuel injection line (see Section Removal and installation of fuel distribution line and injectors), - only on the left.

8. Remove the EGR actuators (Y27/9 and Y27/10)

9. Unscrew the bolts (2a) and remove the connecting pipe (2), - if necessary, prepare replacement sealing rings (2b).

10. Unscrew the bolts (4a and 4c) and remove the upper half of the left section of the air distributor (4), - prepare a replacement sealing gasket (4b).

11. Remove the vacuum block (21/7).

12. Unscrew the bolts (3a and 3c) and remove the upper half of the right section of the air distributor (3), - prepare a replacement sealing gasket (3b).

13. Disconnect the vacuum hoses from the vacuum control units (5c and 6c).

14. Remove the EGR cooler (7) (see Section Removal and installation the EGR cooler).

15. Unscrew the bolts (5a and 6a) and remove the air distribution lines (5 and 6) with the intake port shut-off drives.

16. Installation is carried out in reverse order.

Assembling the throttle actuator with upper air ducts

1. Remove the air cleaner (see above).

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

3. Disconnect the electrical wiring from the pressure sensor (B28).

4. Unscrew the bolts (4, 5) and move the cooling tract line (6) to the side.

5. Unscrew the bolts (7) and remove the connecting plate (8).

6. Remove the bolts (9 and 10) and move the cooling tract line (11) to the side.

7. Unscrew the bolts (12 and 13) and disconnect the EGR pipe (3), - prepare a replacement sealing ring.

8. Separate the air duct (2) from the intermediate sleeves (14 and 15), prepare replacement sealing rings.

9. Disconnect the electrical wiring from the throttle actuator (M16/5).

10. Remove the IAT sensor (see above).

11. Pull to separate the activator (M16/5) from the charge air cooler and remove it together with the air ducts (1 and 2) and the EGR pipe (3) - if necessary, prepare replacement sealing rings.

12. Installation is carried out in the reverse order - damaged sealing elements must be replaced.

Turbochargers

Right turbocharger

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

2. Remove the crankcase guard.

3. Disconnect the negative cable from the battery.

4. Remove the catalytic converter/front section of the exhaust system (see Section Removal and installation of the exhaust system).

5. Remove the air cleaner and air intake assembly with the MAF sensor (see above).

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

7. Remove the right lower air duct (9) and the boost system inlet hose (10) (see above).

8. Remove the starter (see Chapter Engine electrical systems).

9. Remove the heat shield in the right front wheel arch.

10. Remove the nut (1) on the exhaust manifold and the bolt (2) of the oil supply line (110/3) on the cylinder head, - prepare a replacement sealing ring.

Note: The self-locking nut (1) must be replaced; if necessary, also replace the bolt.

11. Unscrew the bolts (3) securing the oil return line (110/4) to the turbocharger (110) and pull the latter away from the engine - prepare to collect any spilled oil and select replacement sealing gaskets (from the turbocharger side) and seal (from the engine side).

12. Remove the bolt (4) on the support (5) of the turbocharger (110).

13. Unscrew the bolts (6), disconnect the connector (7) and release the wiring harness (8) from the clamps.

14. Pull back and remove the turbocharger (110), then unbolt the oil supply line (110/3) from it - prepare a replacement sealing gasket.

15. Installation is carried out in reverse order.

16. Finally, check the levels of the relevant working fluids and make adjustments if necessary.

Left turbocharger

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

2. Remove the crankcase guard.

3. Disconnect the negative cable from the battery.

4. Remove the catalytic converter/front section of the exhaust system (see Section Removal and installation of the exhaust system).

5. Remove the air cleaner and air intake assembly with the MAF sensor (see above).

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

7. Remove the auxiliary heater unit (see Chapter Cooling, heating, ventilation and air conditioning systems).

8. Remove the left lower air duct (8) and the boost system inlet hose (9) (see above).

9. Remove the heat shield in the left front wheel arch.

10. Remove the nut (1) on the exhaust manifold and the bolt (2) of the oil supply line (110/3) on the cylinder head, - prepare a replacement sealing ring.

Note: The self-locking nut (1) must be replaced; if necessary, also replace the bolt.

11. Unscrew the bolts (3) securing the oil return line (110/4) to the turbocharger (110) and pull the latter away from the engine - prepare to collect any spilled oil and select replacement sealing gaskets (from the turbocharger side) and seal (from the engine side).

12. Remove the bolt (4) on the support (5) of the turbocharger (110).

13. Unscrew the bolts (6), disconnect the connector (7) and release the wiring harness (8) from the clamps.

14. Pull back and remove the turbocharger (110), then unbolt the oil supply line (110/3) from it - prepare a replacement sealing gasket.

15. Installation is carried out in reverse order.

16. Finally, check the levels of the relevant working fluids and make adjustments if necessary.

Charge air cooler

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

2. Remove the air cleaner (see above).

3. Remove the crankcase guard.

4. Install the air conditioning radiator/condenser protection screen (a metal or plastic plate measuring 400x680x1 mm equipped with a suitable support bracket).

5. Remove the bolts (5).

6. Loosen the nut (4a), unscrew the bolt (4b) and remove the support bracket (4c).

7. Drain the cooling system (see Chapter Cooling, heating, ventilation and air conditioning systems).

8. Disconnect the cooling system lines (8, 9 and 10).

9. Unscrew the bolts (15 and 6) and remove the connecting plates (16 and 7).

10. Remove the bolts (11) and separate the air duct (1) complete with the intermediate sleeve (2) from the charge air cooler assembly (4).

11. Separate from the air duct (1) and remove the intermediate sleeve (2).

12. Separate the cooler (4) from the throttle actuator (M16/5) with the intermediate air duct (3) and remove it from the engine compartment.

13. Installation is carried out in the reverse order - do not forget to replace the defective sealing elements (2a and 3a).

14. Finally, fill the cooling system, correct the coolant level and check the system path for signs of developing leaks.

Resonator chamber with water collector

See Section Removal and installation air intake tract components.