Exhaust System - TDV6 3.0L Diesel (G2271030): Removal

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

WARNING: Use caution when you do work near a hot exhaust system. If this instruction is not followed, personal injury may occur.

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

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

Raise and support the vehicle on a suitable 2 post lift.
Refer to: LIFTING
Remove the engine undershield.
Refer to: ENGINE UNDERSHIELD
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- Remove the 3 fasteners.
- Remove the wheel arch air deflector.
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- Remove the 9 fasteners.
- Remove the 6 bolts.
- Remove the 3 nuts.
- Remove the right side undershield.
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- Remove the 4 bolts.
- Remove the cross member.
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- Disconnect the active exhaust actuator electrical connector.
- Release the wiring harness from the 2 clips.
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- Disconnect the 2 electrical connectors.
- Remove the 3 nuts.
- Release the post Selective Catalyst Reduction (SCR) NOx sensor module bracket.
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Release the wiring harness from the 3 clips.
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- Remove the 2 screws.
- Remove the cover.
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- Disconnect the electrical connector.
- Release the pre SCR NOx sensor module from the 4 clips.
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Release the wiring harness from the 2 clips.
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- Disconnect the post Diesel Particulate Filter (DPF) exhaust gas temperature sensor electrical connector.
- Release the wiring harness from the 3 clips.
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- Remove the 2 bolts.
- Release the hose clamp.
- Disconnect the DPF differential pressure sensor hose.
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- Release the hose clamp.
- Disconnect the DPF differential pressure sensor hose.
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- Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
- Release the wiring harness from the 3 clips.
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- Disconnect the pre DPF exhaust gas temperature sensor electrical connector.
- Release the wiring harness from the 3 clips.
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- Disconnect the DPF exhaust gas temperature sensor electrical connector.
- Release the wiring harness from the 5 clips.
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Reposition the electrical connector cover.
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Disconnect the Diesel Exhaust Fluid (DEF) injector electrical connector.
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- Release the DEF injector clamp.
- Reposition and secure the DEF injector to one side.
- Remove and discard the DEF injector clamp.
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 2 bolts.
- Release the clamp.
- Remove the exhaust cross-over pipe.
- Remove and discard the exhaust cross-over pipe gasket.
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Remove the nut.
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- Release the clamp.
- Release the Exhaust Gas Recirculation (EGR) valve inlet pipe.
- Remove and discard the EGR valve inlet pipe clamp.
- Remove and discard the EGR valve inlet pipe gasket.
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Release the DPF clamp.
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Remove the 2 bolts.
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- Release the DPF .
- Remove and discard the DPF clamp.
- Remove and discard the DPF gasket.
CAUTION: Make sure that the exhaust system is supported with suitable retaining straps.

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Remove the 5 mounting rubbers
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- Remove the 2 bolts.
- With assistance remove the exhaust system.
NOTE: Only do the following step(s), if a new component is to be installed.

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Remove the DPF exhaust gas temperature sensor.
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Use the special tool to remove the pre SCR NOx sensor.

Special Tool(s): JLR-303-1666
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Remove the differential pressure sensor pipe.
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Remove the post DPF exhaust gas temperature sensor.
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Remove the particulate matter sensor.

Special Tool(s): JLR-303-1646
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Use the special tool to remove the post SCR NOx sensor.

Special Tool(s): JLR-303-1666
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- Remove the bolt.
- Remove the front mass damper.
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- Remove the bolt.
- Remove the rear mass damper.
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- Remove the 2 mounting rubbers.
- Remove the 2 hanger brackets.