Servicing air intake tract components (Mercedes-Benz M-Class W163)

Replacing the air cleaner filter element

1. Illustrative material on replacing the air cleaner filter element on models 163.113 (612 series engine) is presented in the illustration, to which all references in the text refer.

2. Remove the cylinder head cover trim panels.

3. Disconnect the wiring from the MAF sensor (B2/5).

4. Disconnect the air hose (4/2) from the air cleaner.

5. Remove the air intake (4/3).

6. Loosen the mounting bolts and remove the upper section of the air cleaner housing (4/1).

7. Remove the filter element (4/4).

8. If necessary, remove the lower section of the air cleaner housing (4/5) - pay attention to the pads underneath (from the engine side) washers.

9. Installation is carried out in the reverse order - do not forget to replace any damaged fastening clamps.

10. Finally, reset the filter element contamination level indicator (arrow).

Removal and installation the intake air temperature (IAT) sensor

1. IAT sensor installation details on 163.113 models (612 series engine) are shown in the illustration, to which all references found in the text refer.

2. Cut the tape bandage (1) securing the holder (3).

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

4. Press the fastening clips (arrows) together and release the sensor (B17) from the holder (3).

5. Remove the sealing ring (4), which must be replaced during assembly.

6. Installation is carried out in reverse order.

Attention! The sensor must be installed with the contact connector disconnected, otherwise there is a possibility of damaging the mounting brackets (arrows) as a result of overtightening them!

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

Removal and installation a turbocharger

1. Turbocharger installation details on models 163.113 (612 series engine) are shown in the illustration, to which all references found in the text refer.

2. Remove the lower section of sound insulation.

3. Remove the air cleaner (see above).

4. Remove the air hose (4/2).

5. Disconnect the air duct (110/6) from the turbocharger (110).

6. Disconnect the hose (4) from the vacuum block (110/10).

7. Unbolt the oil supply line (110/3) from the turbocharger and engine block - while loosening the union nut, hold the turbocharger from turning.

8. Remove the primary catalytic converter (120/1).

9. Unbolt the support bracket (3) from the engine crankcase.

10. Remove the turbocharger (110) complete with bracket (3) and oil drain line (110/4).

11. Disconnect the support bracket (3) and the oil drain line (110/4) from the turbocharger (110) - prepare to collect any spilled oil.

12. Installation is performed in the reverse order. Do not forget to replace all sealing elements. Tighten the union nuts of the oil lines only after installing the turbocharger.

13. Finally, check the engine oil level and make the appropriate adjustments if necessary (see Chapter Changing engine oil and oil filter).

Removal and installation the intercooler of the air supercharging tract

1. Installation details of the intercooler of the air-supply tract on models 163.113 (612 series engine) are shown in the illustration, to which all references found in the text refer.

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

3. Remove the headlights (1) with the covers (2).

4. Remove the front frame cross member (3).

5. Disconnect the electrical wiring connector (4) of the IAT sensor (B17).

6. Loosen the fastening clamps (5 and 6) and disconnect the air hoses (7 and 8) from the cooler heat exchanger (110/2).

7. Unscrew the mounting bolts (9) and remove the cooler (110/2).

8. Installation is carried out in reverse order.

Removal and installation the air distributor

1. Installation details of the air distributor of the air boost tract on models 163.113 (612 series engine) are shown in the illustration, to which all references found in the text refer.

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

3. Remove the powertrain trim panels (1 and 2).

4. Remove the lower section of sound insulation.

5. Disconnect the negative cable from the battery.

6. Drain the cooling system (see Chapter Checking the cooling system and frost resistance of the coolant, replacing the liquid).

7. Remove the fuel cooler (6).

8. Remove the fuel line (21) (see Section Removal and installation of fuel distribution line and injectors).

9. Remove the fuel line support brackets.

10. Unbolt the upper support bracket (8) of the air distributor (110/1).

11. Pump out the oil from the power steering reservoir and disconnect the hydraulic hose from the latter - immediately seal the open ends of the hose and fitting.

12. Disconnect the vacuum lines.

13. Remove the radiator overflow hose.

14. Remove the air duct (12) connected to the mixing chamber (5).

15. Remove the mixing chamber (5).

16. Remove the connecting pipe (13).

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

18. Remove the support bracket (10) securing the EGR system tube to the air distributor pipe.

19. Release the wiring harness running along the distribution pipe (110/1) from the clips - disconnect the contact connectors of the oil level sensor (B40), CKP (L5), boost pressure sensor (B28), intake port lock limit switch (S99) and starter motor (M1).



20. Loosen the mounting bolts and remove the air distributor pipe (110/1) from the lower support bracket (7).

21. Installation is carried out in the reverse order - do not forget to replace the sealing elements and faulty components.

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

Removal and installation the electric motor of the actuator for shutting off the intake port

1. Installation details of the electric motor for the intake port shut-off drive on models 163.113 (612 series engine) are shown in the illustration, to which all references found in the text refer.

2. On models with AT, remove the air distributor (see above).

3. On models with manual transmission, remove the left front wheel and wheel arch protection liner.

4. Remove the bolts (1).

5. Release the lock and carefully remove the support (3) from the ball head (2).

6. On models with manual transmission, disconnect the electrical wiring connector (4) of the electric motor (M55).



7. Remove the electric motor (M55) from the air distributor assembly (5).

8. Installation is carried out in the reverse order. Ensure that all positioning flaps are seated correctly, check that they move smoothly. Do not forget to replace the sealing elements.

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

Models 163.128

Replacing the air cleaner filter element

1. Illustrative material for replacing the air cleaner filter element on 628 models (628 series engine) is presented in the illustration, to which all references in the text refer.

2. Remove the six clamps (arrows) securing the air cleaner cover (1).

3. Remove the cover (1) and take out the filter element to be replaced from the air cleaner housing.

4. Installation is carried out in the reverse order - make sure the cover is seated correctly.

Removal and installation the intake air temperature (IAT) sensor

1. IAT sensor installation details on 163.128 models (628 series engine) are shown in the illustration, to which all references found in the text refer.

2. Open the hood.

3. Remove the engine intake fan hose routed in front of the air cleaner.

4. Disconnect the electrical wiring connector (1) of the sensor (B17), while simultaneously securing the mounting brackets (arrows) of the latter.

Removal and installation of turbochargers

1. Details of installation of turbochargers on models 163.128 (628 series engine) are shown in the illustrations, to which all references found in the text refer.

2. Remove the front wheels and wheel arch protectors.

3. Remove the air inlet ducts of both (right/left) air boost tracts (see below).

4. Remove the lower air ducts of both (right and left) air boost tracts (see below).

5. Loosen the nut (1) on the oil supply line support bracket (110/3).

6. Remove the bolt (2) and disconnect the oil supply line (110/3) from the cylinder head.

7. Disconnect the oil supply line (110/3) from the left turbocharger (110).

8. Remove the bolts (3) and disconnect the oil return line (110/4) from the turbocharger and engine crankcase.

9. Loosen the clamp securing the primary catalytic converter to the right turbocharger (110).

10. Fully loosen and remove the left three-way catalytic converter (TWC).

11. Remove the bolt (4) on the support bracket (5).

12. Disconnect the boost pressure regulator wiring (7) from the turbocharger (110).

13. Unscrew the mounting bolts (6) and remove the turbocharger (110) from the engine exhaust manifold.

Attention! Boost pressure regulators (Y100 and Y100/1) can only be replaced in a set with the corresponding turbocharger!

14. Installation is carried out in the reverse order. Do not forget to replace all sealing elements. Tighten the union nuts of the oil lines only after installing the turbocharger.

15. Finally, check the engine oil level and make the appropriate adjustments if necessary (see Chapter Changing engine oil and oil filter).

Removal and installation the intercooler of the air supercharging tract

1. Installation details of the intercooler of the air-supply tract on models 163.128 (628 series engine) are shown in the illustration, to which all references found in the text refer.

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

3. Remove both headlights.

4. Remove the upper front frame cross member.

5. Disconnect the air hose (2) from the right side of the cooler (1).

6. Remove the screws securing the connecting plates (3) on the left side of the cooler heat exchanger (1).

7. Loosen the mounting screws (arrows) and remove the cooler (1).

8. Installation is carried out in the reverse order - do not forget to replace the sealing elements.

Removal and installation the air distributor

1. Installation details of the air distributor of the air boost tract on models 163.128 (628 series engine) are shown in the illustrations, to which all references found in the text refer.

2. Remove the fuel filter (1) complete with support bracket.

3. Remove the valve block (2).

4. Remove the cylinder head cover linings (3) and disconnect the oil drain pipes from the injectors.

5. Remove the fuel lines (4).

6. Remove the bypass air ducts (5), - only for the lower section (6), - the air ducts (5) are removed together with the upper sections of the air distributor (7).

7. Disconnect the line (8) from the vacuum pump, remove and move aside the bracket (9).

8. Disconnect the vacuum line (10) of the inlet port shut-off valve.

9. Remove the tape bandage (11) securing the transport pipeline.

10. Remove the bolts (12).

11. Remove the bolts (13) securing the EGR cooler.

12. Disconnect the cooling system hoses (14) from line (15).

13. Remove and set aside the cooling tract line (15).

14. Remove the support brackets (16) of the left and right EGR positioners.

15. Unscrew the mounting bolts (17) and remove the upper sections of the air distributor (7) together with the bypass sleeves (5).

16. Installation is carried out in the reverse order - do not forget to replace the sealing elements and faulty components.

Removal and installation intake hoses of the air boost tract

Installation details of the intake hoses of the air boost tract on models 163.128 (628 series engine) are shown in the illustrations, to which all references found in the text refer.

Left sleeve

1. Remove the left front wheel and wheel arch protection liner.

2. Disconnect the intake hose from the air distributor.

3. Unscrew the bolts (2) of the flange (3).

4. Unscrew the bolt (5) on the cylinder head cover.

5. Loosen the clamp (4) and remove the inlet sleeve (1).

6. Installation is carried out in reverse order.

Right sleeve

1. Disconnect the intake hose from the air distributor.

2. Disconnect the wiring from the boost pressure sensor.

3. Remove the bolt (2) on the cylinder head cover.

4. Loosen the clamp (3) and remove the inlet sleeve (1).

5. Installation is carried out in reverse order.

Removal and installation the lower hoses of the air boost tract

Installation details of the lower hoses of the air boost tract on models 163.128 (628 series engine) are shown in the illustrations, to which all references found in the text refer.

Left sleeve

1. Remove the lower section of sound insulation.

2. Remove the air boost tract sleeve (3).

3. Remove the bolts (1).

4. Loosen the upper screw of the connecting plate (5) on the inlet flange (4) of the turbocharger (6).

5. Unscrew the lower screw of the plate (5) on the air sleeve (2).

6. Disconnect the sleeve (2) from the flange (4) of the turbocharger (6) and remove it from the engine by lowering it down.

7. Installation is carried out in the reverse order - do not forget to replace the sealing ring.

Right sleeve

1. Disconnect the negative cable from the battery.

2. Remove the lower section of sound insulation.

3. Remove the protective covers of the electrical lines (6 and 7) of the starter (M1), - terminals No.30 and 50.

4. Remove the bolts securing the starter to the transmission dome.

5. Loosen the upper screw of the connecting plate (5) on the turbocharger inlet flange (4).

6. Remove the lower screw of the plate (5) on the air sleeve (1).

7. Disconnect the sleeve (2) of the air duct (1).

8. Remove the support brackets (3) from the lower section of the oil pan and from the air duct (1).

9. Remove the upper bracket (arrow) of the air duct from the engine crankcase.

10. Move the starter and ATF lines aside and disconnect the air hose from the turbocharger intake flange.

11. Pass the sleeve forward and remove it from the engine compartment.

12. Installation is carried out in the reverse order - do not forget to replace the sealing ring.

Removal and installation of bypass air ducts

1. Installation details of bypass air ducts on models 163.128 (628 series engine) are shown in the illustrations, to which all references found in the text refer.

2. Remove the powertrain trim panels.

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

4. Release the cooling lines from the bracket (2).

5. Disconnect the air hose (4) from the bypass hose (1).

6. Separate the power steering line (6) from the air hose.

7. Separate the EGR pipe (8) from the cylinder head connecting flange (arrow).

8. Disconnect the bypass hoses from the connecting pipes (5 and 7) and remove them from the engine.

9. Installation is carried out in the reverse order - do not forget to replace the sealing elements.

Removal and installation of intermediate connecting pipes

1. Details of installation of intermediate air ducts on models 163.128 (628 series engine) are shown in the illustration, to which all references found in the text refer.

2. Lift the power unit cover.

3. Remove the bypass ducts (see above).

4. Remove the fuel filter (3).

5. Loosen the screws (5) and remove the right connecting pipe (1).

6. Disconnect the rod (9) of the vacuum block of the inlet port (8).

7. Remove the screw (7) and move the vacuum block (8) to the side.

8. Unscrew the screws (6) and remove the left connecting pipe (2).

9. Installation is carried out in the reverse order - do not forget to replace the sealing rings (10 and 11).