ONCE FITTED AND THE ENGINE STARTED, THE PART IS NO LONGER REFUNDABLE.
Note! Exhaust gases are dangerous. Good ventilation is essential if the engine is running in the garage, even if only for a short period of time.
ITEMS TO CHECK BEFORE ASSEMBLY (defects that led to damage of the replaced DPF)
| Test stage : | Checked on : | Replaced on : | Comments : |
|---|---|---|---|
| Differential pressure sensors | |||
| Temperature sensors | |||
| EGR valve | |||
| Injectors | |||
| Sparking plugs | |||
| Motor thermostat/EGR | |||
| Intake Valve Actuator | |||
| Intake pipe | |||
| Upstream catalyst (if available) | |||
| Engine oil | |||
| DPF additive system |
ASSEMBLY INSTRUCTIONS FOR THE DIESEL PARTICULATE FILTER / DPF (only for PROs)
Note! To avoid accidents, the safety measures and devices required at the installation site must be in accordance with the instructions and rules for safety at work.
| WITHDRAWAL OF THE OLD DPF : | ASSEMBLY OF THE NEW DPF : |
| 1 Disconnect the negative battery cable. | 1 Clean the pipes or connecting flanges to ensure maximum tightness of the exhaust after installing the new filter. It is recommended to replace all gaskets and sensors. |
| 2 Lift the vehicle and ensure that it is securely locked in position. | 2 Install the new diesel particulate filter in place of the old one. Make sure it does not touch the chassis or any part of the car. |
| 3 Disconnect all sensors from the used DPF. If there are any (pressure) pipes to be retained, these should be removed and thoroughly cleaned. This will prevent your vehicle from possibly misdiagnosing the new Diesel Particulate Filter. | 3 Install all sensors and pressure tubes. Make sure they are in their corresponding slots. |
| 4 Loosen the DPF fixing bolts. If they are stuck, spray the rust with oil and/or heat the bolts with a gas torch. If using a torch, ensure that it does not burn the underside of the car and that the relevant health and safety guidelines are followed. | 4 Lower the vehicle to the ground, connect the negative battery cable. |
| 5 Remove the fixing screws and the old, worn-out DPF. | 5 Connect the Car Diagnostic Kit to the car's OBD connector and start the DPF replacement procedure. Otherwise it will not work properly ! |
| 6 Start the car engine and check that there are no leaks in the system. |
One of the main problems with many types of emissions is that a new, good diesel particulate filter can and will mask the real problem.
Diagnose the cause of the problem that led to the change of the DPF and make the repairs before fitting the new one, otherwise it will not work properly. Possible causes are:
excess unburnt fuel and overheating in the DPF, misfiring, ignition system failure, towing, malfunctioning spark plugs or glow plug wire. Other causes may be oil or antifreeze entering the exhaust or sealing compounds that may have contaminated the DPF core, a pressure sensor fault or broken exhaust system hangers.
Choosing the wrong fuel can also destroy the DPF.