Exhaust System - TDV6 3.0L Diesel (G2020251): Installation

The following step(s) applies to: 

All vehicles

1. CAUTION: Make sure that new bolts are installed.
   NOTE: This step is only required if previously removed.

   Install the upper Noise Vibration and Harshness (NVH) damper.

   Renew Part: Mass damper bolt  Quantity: 1  .

   Torque  : 22 Nm 

2. CAUTION: Make sure that new bolts are installed.
   NOTE: This step is only required if previously removed.

   Install the lower NVH damper.

   Renew Part: Mass damper bolt  Quantity: 1  .

   Torque  : 22 Nm 

The following step(s) applies to: 

Vehicles with diesel particulate filter (DPF)

1. NOTE: This step is only required if previously removed.

   Install the Diesel Particulate Filter (DPF) pressure sensors.

   Torque  : 35 Nm 

The following step(s) applies to: 

All vehicles

1. CAUTION: This step must be carried out with the aid of another technician.

   With the aid of another technician install the exhaust and secure in position with the exhaust hanger bracket.

2. Make sure that the exhaust is fully supported with the aid of another technician install the 6 exhaust hanger brackets.
3. Correctly position the exhaust and secure in position with the exhaust to turbo clamp. Make sure a new gasket is installed.

   Renew Part: Exhaust pipe to turbocharger gasket  Quantity: 1  .

   Torque  : 10 Nm 

4. Install the 2 exhaust bracket bolts and 1 nut.

   Torque  : 25 Nm 

5. NOTE: This step is only required for left hand drive vehicles.
   • Connect the steering column lower shaft to the steering gear.
   • Make sure a new steering column lower shaft bolt is installed.

     Renew Part: Lower steering column to steering gear bolts  Quantity: 1  .

6. Install the exhaust cross over pipe and tighten the 2 bolts to the correct torque. Make sure a new gasket is installed.

   Renew Part: Crossover pipe gasket  Quantity: 1  .

   Torque  : 28 Nm 

7. Install the Exhaust Gas Recirculation (EGR) pipe and tighten the clamp to the correct torque. Make sure a new gasket is installed.

   Renew Part: Exhaust gas recirculation pipe gasket  Quantity: 1  .

   Torque  : 9 Nm 

The following step(s) applies to: 

Vehicles with diesel particulate filter (DPF)

1. Connect the lower Diesel Particulate Filter (DPF) pressure sensor hose.
2. Connect the upper DPF pressure sensor hose.
3. CAUTION: Take extra care not to damage the wiring harnesses.

   Connect the 2 electrical connectors for the DPF pressure sensors.

The following step(s) applies to: 

All vehicles

1. Install the cross member and tighten to the correct torque.

   Torque  : 55 Nm 

2. Install the engine undershield.

   Refer to: ENGINE UNDERSHIELD (G1898644)