REMOVAL AND INSTALLATION <6B3, 4N1, 4D5>


<6B3>


Pre-removal Operation
  • Under Skid Plate and Engine Room Under Cover Front Removal.

 Post-installation Operation
  • Under Skid Plate and Engine Room Under Cover Front Installation.

<Except Euro2>

Removal steps


·
 Spare wheel and spare tyre


1.
 Main muffler


2.
 Gasket
<<A>>
3.
 Catalytic converter


4.
 Seal ring
<<B>>
5.
 Right bank oxygen sensor (Front)
<<C>>
6.
 Right bank oxygen sensor (Rear)


7.
 Front catalytic converter (RH)


8.
 Gasket
<<B>>
9.
 Left bank oxygen sensor (Rear)


·
 Front suspension crossmember


10.
 Front catalytic converter (LH)


11.
 Gasket


12.
 Catalytic converter bracket


13.
 Rear floor heat protector panel


14.
 Front floor heat protector panel


15.
 Dash heat protector panel

<Euro2>

Removal steps


·
 Spare wheel and spare tyre


1.
 Main muffler


2.
 Gasket
<<B>>
3.
 Oxygen sensor
<<A>>
4.
 Catalytic converter


5.
 Seal ring


6.
 Exhaust front pipe (RH)


7.
 Gasket


·
 Front suspension crossmember


8.
 Exhaust front pipe (LH)


9.
 Gasket


10.
 Catalytic converter bracket


11.
 Rear floor heat protector panel


12.
 Front floor heat protector panel


13.
 Dash heat protector panel

<4N1>


Pre-removal Operation
  • Under Skid Plate and Engine Room Under Cover Front Removal.

 Post-installation Operation
  • Under Skid Plate and Engine Room Under Cover Front Installation.

<Except Euro2>

Removal steps


·
 Spare wheel and spare tyre


1.
 Main muffler


2.
 Gasket
<<D>>
3.
 Exhaust centre pipe


4.
 Seal ring


·
 Catalytic converter


5.
 Front floor heat protector panel


6.
 Front dash heat protector panel <Some models>


7.
 Dash heat protector panel

<Euro2>

Removal steps


·
 Spare wheel and spare tyre


1.
 Main muffler


2.
 Gasket
<<D>>
3.
 Exhaust centre pipe


4.
 Seal ring


5.
 Catalytic converter bracket


6.
 Exhaust front pipe


7.
 Gasket


8.
 Front floor heat protector panel


9.
 Front dash heat protector panel <Some models>


10.
 Dash heat protector panel

<4D5>


Pre-removal Operation
  • Under Skid Plate and Engine Room Under Cover Front Removal.

 Post-installation Operation
  • Under Skid Plate and Engine Room Under Cover Front Installation.

<Except Euro2>

Removal steps


·
 Spare wheel and spare tyre


1.
 Main muffler


2.
 Gasket
<<D>>
3.
 Exhaust centre pipe


4.
 Seal ring


5.
 Exhaust front pipe


6.
 Gasket


·
 Catalytic converter (Refer to GROUP 17 - Emission Control, Catalytic Converter ).


7.
 Front floor heat protector panel <4WD>


8.
 Dash heat protector panel

<Euro2>

Removal steps


·
 Spare wheel and spare tyre


1.
 Main muffler


2.
 Gasket
<<D>>
3.
 Exhaust centre pipe


4.
 Seal ring


5.
 Exhaust front pipe


6.
 Gasket


7.
 Exhaust front pipe heat protector


8.
 Exhaust front pipe


9.
 Gasket


10.
 Front floor heat protector panel <4WD>


11.
 Dash heat protector panel

REMOVAL SERVICE POINTS

<<A>> CATALYTIC CONVERTER REMOVAL
1.Remove some rubber hangers of the main muffler (the rearmost ones should be in situ) to allow sufficient clearance to remove the catalytic converter.
2.Rotate the catalytic converter 180° and take out it, being careful not to hit the crossmember.

<<B>> OXYGEN SENSOR REMOVAL
1.Remove the oxygen sensor connector connection, connector bracket and harness bracket.

2.Use special tool oxygen sensor wrench (MB991953) to remove the oxygen sensor.

<<C>> OXYGEN SENSOR REMOVAL

1.<Vehicles without rear cooler>
(1) Remove the oxygen sensor connector connection, connector bracket and harness bracket.
(2) Use the special tool oxygen sensor wrench (MB991953) and extension (50 mm) to remove the oxygen sensor.
2.<Vehicles with rear cooler>
(1) Remove the front catalytic converter (RH) and then oxygen sensor.

<<D>> EXHAUST CENTRE PIPE REMOVAL
Remove some rubber hangers of the main muffler (the rearmost ones should be in situ) to allow sufficient clearance to remove the exhaust centre pipe.