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Home >> Mercedes Benz >> 2016 >> G63 AMG >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Air Intake, Turbocharging - 463 Chassis >> Testing & Repair >> Remove/install charge air manifold >> Remove/install charge air manifold - AR09.41-P-1310GW

Remove/install charge air manifold - AR09.41-P-1310GW

ENGINES 157 in MODEL 463 

Fig 1: Charge Air Manifold Remove/Install Components (1 Of 2)
G10780017Courtesy of MERCEDES-BENZ USA
Fig 2: Charge Air Manifold Remove/Install Components (2 Of 2)
G10780018Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
    IMPORTANT The ground line on the battery must always  be detached before beginning work on the fuel system otherwise pressure will be lost in the fuel system through opening a vehicle door.  
1 Open engine hood and raise to vertical position   AR88.40-P-1000GG
2 Remove ME-SFI [ME] control unit   AR07.08-P-7008GW
3 Remove both air filter housings   AR09.10-P-1150GW 
4 Remove insulation between air filter housings and cylinder head cover    
5 Remove air plenum chamber and water collector   AR83.10-P-9998GW
6 Remove crash plate on high-pressure pumps and remove insulation from high-pressure pumps   AR07.02-P-1020GW
7 Detach vacuum line (8) for brake booster on vacuum pump and charge air manifold (1)    
8 Detach vacuum line (7) for centrifuge on charge air manifold (1)   AR01.20-P-2100GW
9 Disconnect engine wiring harness on charge air manifold (1) and cylinder head covers and lay down to the rear   AR01.00-P-2410-02GW
10 Remove high-pressure lines (11) NOTES Do not bend or kink high-pressure lines (11). This avoids damage and leakages.
INSTALLATION IMPORTANT The sealing cone for the high- pressure lines (11) must  be checked before assembly. The work instructions absolutely must  be observed for assembly work. A leak test on the high-pressure fuel circuit must be carried out after assembly: ↓		  
Check sealing cone on high-pressure lines (11). AR07.03-P-1010-03MM
Mount high-pressure lines (11). AR07.03-P-1010-02MMB
Check fuel high pressure circuit. AR07.03-P-1010-04MM
TORQUE SPECIFICATION *BA07.03-P-1001-01E 
TORQUE SPECIFICATION *BA07.03-P-1002-01E 
TORQUE SPECIFICATION *BA07.03-P-1003-01E 
TORQUE SPECIFICATION *BA07.03-P-1004-01E 
TORQUE SPECIFICATION *BA07.03-P-1005-01E 
TORQUE SPECIFICATION *BA07.03-P-1006-01E 
Cleaner from package *BR00.45-Z-1028-04A 
11 Disconnect electrical line (4) at charge air manifold (1)    
12 Detach purge line (10) on charge air manifold (1)    
13 Detach vacuum line (6) for boost pressure control pressure transducer (Y77/1) on vacuum pump    
14 Remove boost pressure control pressure transducer (Y77/1)   AR07.17-P-7002GW
15 Remove charge air ducts   AR09.41-P-8620GW 
16 Drain coolant   AR20.00-P-1142GW
NOTES Notes on coolant   AH20.00-N-2080-01A
17 Disconnect bleed lines on low temperature line (20)    
18 Remove poly-V belt   AR13.20-P-0001GW
19 Remove screw/bolts (28) and detach hydraulic line (29) on power steering pump, oil filter housing and bracket on left cylinder head cover TORQUE SPECIFICATION *BA46.30-P-1019-01B 
TORQUE SPECIFICATION *BA46.30-P-1020-01B 
TORQUE SPECIFICATION *BA46.30-P-1021-01B 
20 Remove screw/bolt (5) for low temperature line (20) TORQUE SPECIFICATION *BA09.41-P-1004-01O 
21 Detach power steering pump from coolant pump and from bracket below on timing case cover IMPORTANT Place power steering pump to the side with lines connected and secure with a cable tie to prevent it falling down. AR46.30-P-0500GW
TORQUE SPECIFICATION *BA46.30-P-1018-01B 
TORQUE SPECIFICATION *BA46.30-P-1023-01B 
22 Remove coolant expansion reservoir for low- temperature circuit with bracket (3) TORQUE SPECIFICATION *BA09.41-P-1010-01O 
23 Detach coolant return line (21) on oil filter housing TORQUE SPECIFICATION *BA09.41-P-1006-01O 
24 Detach coolant return line (21) on coolant hose (22)    
25 Detach coolant return line (23) on timing case cover TORQUE SPECIFICATION *BA09.41-P-1006-01O 
26 Detach coolant feed line (24) on oil dipstick guide tube (25) TORQUE SPECIFICATION *BA09.40-P-1009-01R 
27 Detach coolant hose (27) to coolant feed line (24)    
28 Detach bracket (26) for coolant feed line (24) on timing case cover TORQUE SPECIFICATION *BA09.41-P-1005-01O 
29 Remove screw/bolts (30) for charge air manifold (1) on cylinder heads TORQUE SPECIFICATION *BA09.41-P-1011-01O 
30 Lift charge air manifold (1)    
31 Disconnect electrical line (9) for front knock sensors and unclip on charge air manifold (1)    
32 Remove charge air manifold (1) with charge air cooler (2) upwards    
33 Detach charge air cooler (2) from charge air manifold (1) When replacing the charge air manifold (1)
IMPORTANT To do this remove screw/bolts (31) for charge air cooler (2) on charge air manifold (1)		  
TORQUE SPECIFICATION *BA09.41-P-1001-01O 
34 Detach throttle valve actuator from charge air manifold (1) When replacing the charge air manifold (1) AR07.51-P-1401GW
35 Install in the reverse order    
36 Pour in coolant   AR20.00-P-1142GW
37 Inspect cooling system for leaks   AR20.00-P-1010GW
38 Read out fault memory with STAR DIAGNOSIS and erase if necessary   AD00.00-P-2000-04A
DANGER 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
39 Carry out engine test run, checking the engine for leaks and proper operation    
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation Engine 157
BA09.41-P-1001-01O Screw/bolt, charge air cooler to charge air distribution line Nm 9
BA09.41-P-1004-01O Screw/bolt, low temperature line clamp to bracket Nm 9
BA09.41-P-1005-01O Screw/bolt, feed line to timing case cover Nm 9
BA09.41-P-1006-01O Screw/bolt, coolant line to timing case cover/oil filter housing Nm 9
BA09.41-P-1010-01O Screw/bolt, pressure transducer holder to charge air distribution line Nm 5
BA09.41-P-1011-01O Screw/bolt, charge air distribution line to cylinder head Nm 9
INJECTORS, INJECTION VALVES, LINES

Number Designation Engine 157
BA07.03-P-1001-01E Union nut, fuel line to fuel distributor Nm 22
BA07.03-P-1002-01E Union nut, fuel line to high-pressure pump Nm 22
BA07.03-P-1003-01E Screw/bolt, fuel line service valve to cylinder head cover Nm 9
BA07.03-P-1004-01E Screw/bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head Nm 14
BA07.03-P-1005-01E Screw/bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase Nm 9
BA07.03-P-1006-01E Screw/bolt, fuel line clamp to charge air distribution line Nm 6
POWER STEERING PUMP

Number Designation Model 463.272/273
BA46.30-P-1018-01B Screw/bolt, power steering pump to coolant pump Nm 20
BA46.30-P-1019-01B Screw/bolt, hydraulic line to power steering pump Nm 9
BA46.30-P-1020-01B Screw/bolt, hydraulic line to oil filter housing Nm 9
BA46.30-P-1021-01B Screw/bolt, hydraulic line to bracket Nm 9
BA46.30-P-1023-01B Screw/bolt, bracket for power steering pump to lower bracket Nm 20
TURBOCHARGER

Number Designation Engine 157
BA09.40-P-1009-01R Screw/bolt, coolant line clamp to bracket Nm 9
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Cleaner from package Adolf Wurth GmbH & Co. KG
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