Removal and installation of the exhaust system (Mercedes-Benz G-Class W463)

Note: Each section of the exhaust system can be removed individually if necessary.

Attention! All self-locking elements of threaded fasteners must be replaced without fail!

Petrol models

Models 463.249/250 standard equipment

Except for models 463.250 (code K89) and 463.246 (AMG)

1. Remove the right post-catalytic lambda probe (G3/4) from the front section of the exhaust system and disconnect the electrical wiring (G3/4x1) from it.

2. Unscrew the left pre-catalytic lambda probe (G3/3) from the cross section of the exhaust system (6) and disconnect the electrical wiring (G3/3x1) from it.

3. Loosen the bolt connections (2/3) and separate the flange of the left front section (9) of the exhaust system from the right exhaust manifold - if necessary, replace the nuts (3).

4. On 463.250 models, remove the lower exhaust system mounting brackets (11).

5. Loosen the bolt connections (2/3) and separate the flange of the cross section (6) of the exhaust system from the right front section (9), - if necessary, replace the nuts (3).

6. Proceeding in a similar manner, separate the cross section from the left exhaust manifold - if necessary, replace the nuts (3).

7. Remove the bolts (10) and separate the cross section (6) from the transmission housing.

8. Disconnect the flange connections of the catalytic converters (5) to the front sections (9) of the exhaust system and to the main muffler (7).

9. Remove the catalytic converter section (5) from the rubber mounts (1) - if the catalytic converters are to be removed, release both brackets.

10. Separate the main muffler (7) from the rear muffler (8).

11. Loosen the bracket and remove the rear muffler (8) from the rubber mounts (1).

12. Installation is carried out in the reverse order - damaged sealing rings and rubber hangers must be replaced without fail. The same applies to the nuts (3) of the flange connections. Make sure that the exhaust system sections are installed without stress.

Note: Damaged components of the exhaust system must be replaced.

Models 463.250 with code K89 (G320)

Caution: When disposing of three-way catalytic converters (TWC), it is essential to comply with federal environmental protection laws!

1. Loosen the mounting clamp (2) and separate the exhaust pipe (1) from the main muffler (12).

2. Unbolt the exhaust pipe (1) from the support bracket (3) and remove it from under the vehicle.

3. Loosen the flange connections (5 and 6) securing the left front muffler (4).

4. Remove the muffler (4) from the support bracket (7).

5. Disconnect the electrical wiring from the upper and lower lambda probes on the left catalytic converter (8).

6. Remove the upper section of the heat shield (9).

7. Loosen the flange connection (10) of the left front section of the exhaust system.

8. Separate the bracket (11) from the frame and the left catalytic converter (8).

9. Loosen the flange connection (13) securing the main muffler (12) to the right front muffler (14).

10. Remove the main muffler (12).

11. Loosen the flange connection (15) securing the right front muffler (14) to the catalytic converter (17).

12. Separate the bracket (16) from the frame and remove the right front muffler (14).

13. Disconnect the electrical wiring from the upper and lower lambda probes on the right catalytic converter (17).

14. Remove the upper section of the heat shield (18).

15. Loosen the flange connection (19) securing the right catalytic converter (17) to the right front section.

16. Disconnect the bracket (20) from the frame and remove the right catalytic converter assembly (17).

17. Installation is carried out in the reverse order - make sure that the exhaust system sections are installed without stress.

Note: Damaged components of the exhaust system must be replaced.

Models 463.246 (G55 AMG)

Caution: When disposing of three-way catalytic converters (TWC), it is essential to comply with federal environmental protection laws!

1. Loosen the flange connection (5) of the left lower section of the exhaust system.

2. Loosen the flange connection (1) on the rear muffler assembly (2).

3. Remove the bracket (7) from the frame and dismantle the TWC unit (4).

4. Remove the rear muffler (2) from the hangers (3) and remove it from under the vehicle.

5. Disconnect the electrical wiring from the lambda probes at the top and bottom of the catalytic converter assembly (4) - the mounting straps should be cut.

6. Remove the top section of the left heat shield.

7. Installation is carried out in the reverse order - do not forget to install new harnesses for fastening the lambda probe electrical wiring.

Note: Damaged components of the exhaust system must be replaced without fail.

Diesel models

Caution: When disposing of three-way catalytic converters (TWC), it is essential to comply with federal environmental protection laws!

Models 463.323 (M612)

Main components of the exhaust system

1. Loosen the bolts (1 and 3) securing the front (2) and rear (4) brackets.

2. Loosen the left (5) and right (7) flange connections on the rear muffler (6), which should be supported beforehand. Prepare a replacement sealing cone.

3. Unbolt the middle section of the exhaust system (8) from the front (2) and rear (4) brackets and remove it from under the car; it would be wise to enlist the help of an assistant.

4. Loosen the flange connection (5) of the rear muffler (6) of the exhaust pipe (9) - prepare a replacement sealing cone.

5. Remove the rear muffler (6) and exhaust pipe (9).

6. Installation is carried out in reverse order.

Note: Damaged components of the exhaust system must be replaced.

Replacing the primary catalytic converter

1. Remove the cylinder head cover trim panels.

2. Remove the air cleaner (see Section Servicing air intake tract components).

3. Remove the clamp (1) securing the turbocharger (2) to the primary catalytic converter (3) - prepare a replacement sealing cone.



4. Remove the clamp (4) securing the primary catalytic converter (3) to the exhaust pipe (5) - prepare a replacement sealing cone.

5. Loosen the nuts (7) and remove the bracket (6) securing the catalytic converter (3) to the engine crankcase.

6. Remove the catalytic converter (3).

7. Installation is carried out in reverse order.

Models 463.333 (M628)

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

2. Remove the wheel arch protection liners (see Chapter Body).

3. Unscrew the mounting bolts (3 and 4) and remove the covers (1 and 2).

4. Unscrew the bolts (7) and remove the left (5) and right (6) heat shields.

5. Loosen the mounting clamps (8) on the turbochargers.

6. Support the main muffler (12) and loosen the clamps (11).

7. Remove the main muffler (12).

8. Release the clamps (13).

9. Support the front muffler assembly and catalytic converter and remove the bolts (14) on the bracket (15).

10. Pull the front muffler (16) away from the right catalytic converter (17) and remove it from the vehicle.

11. Remove the bolt (18) on the bracket (19) and remove the right catalytic converter (17).

12. Remove the bolt (20) on the bracket (21) and remove the left front muffler (22) by pulling it away from the left catalytic converter (23).

13. Remove the bolt (24) on the bracket (25) and remove the left catalytic converter (23).

14. Remove the exhaust pipe (10).

15. Installation is carried out in reverse order.

Note: Damaged components of the exhaust system must be replaced.