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

WARNING: This page is about a different variant/trim than selected.

WARNING: Observe due care when working near a hot exhaust system.

NOTE:

This procedure contains some variation in the illustration depending on the vehicle specification, but essential information is always correct.
This procedure contains illustrations showing certain components removed to provide extra clarity.

The following step(s) applies to:

All vehicles

Raise and support the vehicle on a suitable 2 post lift.
Refer to: LIFTING
Remove the engine undershield.
Refer to: ENGINE UNDERSHIELD (G1898644)
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Remove the cross member.

The following step(s) applies to:

Vehicles with diesel particulate filter (DPF)

CAUTION: Take extra care not to damage the wiring harnesses.

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Disconnect the 2 electrical connectors for the Diesel Particulate Filter (DPF) pressure sensors.
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Disconnect the upper DPF pressure sensor hose.
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Disconnect the lower DPF pressure sensor hose.

The following step(s) applies to:

All vehicles

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- Release the clamp and reposition the Exhaust Gas Recirculation (EGR) pipe away from the exhaust assembly.
- Remove and discard the EGR pipe gasket.
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- Disconnect the exhaust cross over pipe and reposition away from the exhaust system.
- Remove and discard the cross over pipe gasket.
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Remove the 2 exhaust bracket bolts and 1 nut.
NOTE:
- This step is only required for left hand drive vehicles.
- Note the steering column lower shaft to steering gear alignment marks.
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- Remove and discard the steering column lower shaft bolt.
- Disconnect the steering column lower shaft from the steering gear.
- Reposition the steering column lower shaft away from the exhaust assembly.
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- Remove the exhaust to turbo clamp and reposition the exhaust from the turbo assembly.
- Remove and discard the exhaust pipe to turbo gasket.
CAUTION: This step must be carried out with the aid of another technician.

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Remove the 6 exhaust hanger brackets. With the aid of another technician make sure that the exhaust system remains supported.
CAUTION: This step must be carried out with the aid of another technician.

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Make sure that the exhaust is supported with the aid of another technician. Remove the exhaust hanger bracket and then remove the exhaust from the vehicle with the aid of another technician.

The following step(s) applies to:

Vehicles with diesel particulate filter (DPF)

NOTE: Do not disassemble further if the component is removed for access only.

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Remove the DPF pressure sensors.

The following step(s) applies to:

All vehicles

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Remove the upper Noise Vibration and Harshness (NVH) damper.
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Remove the lower NVH damper.