Installation as follows:
NOTICE
If the Diesel Oxidation Catalyst (DOC) and/or the Diesel Particulate Filter (DPF) is replaced,
all applicable fault code diagnostics should be completed and the root cause of the failure
must be repaired. Refer to the DDC-SVC-MAN-0208 Heavy Duty Aftertreatment Failure
Guide. Failure to make the necessary repairs may result in a premature failure of the
replacement component. Standard core return procedure requires that the defective DPF
or DOC be returned in the container that the replacement was shipped in.
1. Is the 1-BOX™ being replaced with a new 1-BOX?
1.a Yes; Go to step 2.
1.b No; Go to step 4.
2. Transfer rear mounting bracket over to the new Aftertreatment Device (ATD) and hand tighten the bolts.
3. Transfer all parts over to new ATD.
• ATS Harness Bridge and Harness
• Front Sensor Bracket
• Temperature, Pressure, NOx and Soot Sensors
• Diesel Exhaust Fluid Dosing Unit
• Aftertreatment Control Module (ACM) and Cover
• Diesel Particulate Filters
• Pressure Sensor Tube
• 1-BOX heat shields
4. Clean the gasket surfaces and install new gaskets onto the 1-BOX™ exhaust inlet and outlet.
5. Using ATD lifting device W060589003100, carefully raise the 1-BOX to the vehicle frame and align the 1
BOX mounting brackets to the holes in the vehicle frame.
6. Install the four bolts and nuts (1) on the front mounting bracket, attaching the 1-BOX to the front mounting
bracket. Hand-tighten the bolts.
7. Install the three bolts (1) and nuts attaching the rear mounting bracket to the vehicle frame. Torque to 174
N·m (128 lb·ft).
8. Torque the front side mounting bracket bolts and nuts to 87 N·m (64 lb·ft).
9. Connect both 18-pin electrical connectors (1).
NOTICE
To connect a Diesel Exhaust Fluid (DEF) line, push the line coupling onto the DEF port
male connector, then pull back gently on the coupling to engage the holding clip in the
locked position.
10. Ensure that the DEF pressure and return lines are routed correctly under the frame rail of the vehicle.
11. Connect the DEF pressure (2) and return lines (1) to the DEF dosing unit.
12. Connect the DEF pressure (3) and return line (4) heater electrical connectors at the DEF dosing unit.
13. Attach the DEF line mounting strap and nut to the 1-BOX.
Note : The exhaust system outlet pipe clamps are directional; verify correct installation.
14. Connect the exhaust system outlet pipe by installing the clamp. Torque to 9-10 N·m (79-88 lb·in.).
15. Connect the exhaust system inlet pipe by installing the clamp. Torque to 9-10 N·m (79-88 lb·in.)
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
16. Connect the batteries. Refer to OEM procedures.
17. Check for any leaks.
18. If removed, install the passenger side fairing. Refer to OEM procedures.