Diesel Oxidation Catalyst – Diesel Particulate Filter Additional
Removal Information
The Diesel Oxidation Catalyst (DOC) – Diesel Particulate Filter (DPF) assembly can be removed independently
from the Selective Catalytic Reduction (SCR Catalyst) section of the 2-BOX (2V2) system.
Removal of the 2-BOX (2V2) Diesel Oxidation Catalyst/Diesel
Particulate Filter From the Stanchion
1. Shut off engine and apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
2. Disconnect the batteries. Refer to Original Equipment Manufacturer (OEM) procedures.
3. Allow the Aftertreatment System (ATS) time to cool.
4. Remove the heat shield.
5. Remove the pressure sensor tube from the Diesel Oxidation Catalyst (DOC) inlet boss (1).
6. Remove the pressure sensor tube from the Diesel Particulate Filter (DPF) outlet boss (5).
7. Disconnect the DOC inlet (3) and DOC outlet (4) temperature sensor electrical connectors and remove from
the mounting brackets.
8. Remove the Selective Catalytic Reduction (SCR) Inlet NOx sensor (10).
9. Remove the DPF outlet temperature sensor (9).
10. Disconnect the 47 pin electrical connector (3) from the sensor box.
11. Disconnect the Diesel Exhaust Fluid (DEF) pressure line (5) and the DEF return line (4) from the DEF
Dosing Unit.
12. Loosen the lower fasteners (8) on the diagonal support brace.
13. Remove the upper fasteners (7) on the diagonal support brace. Disconnect the diagonal support brace from
the lifting bracket that attaches to the vertical stanchion and swing it out of the way. Secure it as needed.
14. Remove the DOC inlet (1) and SCR inlet (2) exhaust clamps from the Aftertreatment Device (ATD). Support
the turbo outlet pipe as needed so there is no stress on the bellows.
15. Position the overhead lifting device over the ATD and connect the hooks at the lifting points. Apply enough
pressure to the lift points to prevent the unit from dropping when loosened.
16. Remove the upper (2) and lower (1) mounting clamp straps.
17. Lift the ATS away from the vehicle.
Installation of the 2-BOX (2V2) Diesel Oxidation Catalyst/Diesel
Particulate Filter onto the Stanchion
1. Using the overhead lifting device, position the Aftertreatment Device (ATD) on the vertical stanchion, and
secure it in position with the mounting clamps. Do not tighten the straps at this time.
2. Align the connection (1) with the Diesel Oxidation Catalyst (DOC) inlet (4), and using a new seal (3), install
the clamp (2). Tighten the clamp 13 to 14 N·m (10 to 11 lb·ft).
3. Align the connection (1) with the Selective Catalytic Reduction (SCR) inlet (4), and using a new seal (3),
install the clamp (2). Tighten the clamp 13 to 14 N·m (10 to 11 lb·ft).
4. Check all alignment marks, and tighten the upper (2) and lower (1) mounting straps incrementally, first 15
N·m (11 lb·ft), then final torque for the Diesel Particulate Filter (DPF) upper mounting strap (2) to 40 N·m
(30 lb·ft) and 25 N·m (19 lb·ft) for the lower mounting strap (1).
5. Install the jam nuts. Using a back-up wrench, tighten 40 N·m (30 lb·ft).
6. Position the diagonal support brace and install the upper mounting fasteners (7). Torque the upper and
lower fasteners to 66 to 86 N·m (49 to 63 lb·ft).
7. Disconnect the overhead lifting device.
8. Connect the DEF pressure line (5) and the DEF return line (4) to the DEF Dosing Unit.
9. Connect the 47-pin electrical connector (3) at the sensor box.
10. Install the DOC inlet (1) and DPF outlet (5) pressure sensor tubes and torque to 17 to 19 N·m (13 to 14
lb·ft).
11. Connect the DOC inlet (3) and DOC outlet (4) temperature sensor electrical connectors and install in the
mounting brackets.
12. Install the DPF outlet temperature sensor (9) and torque to 35 to 38 N·m (26 to 28 lb·ft).
13. Install the SCR inlet NOx sensor (10). Use the slotted NOx sensor socket and torque the NOx sensor to 50
N·m (37 lb·ft).
14. Install the heat shield and torque to 18 to 22 N·m (13 to 16 lb·ft).
15. Connect the batteries. Refer to OEM procedures.
16. Start the engine and check for leaks.
Removal of the 2-BOX (2V2) Diesel Oxidation Catalyst
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
2. Disconnect the batteries. Refer to Original Equipment Manufacturer (OEM) procedures.
3. Allow the Aftertreatment System (ATS) time to cool.
4. Remove Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) from the stanchion. Refer to
section “Removal of the 2-BOX (2V2) Diesel Oxidation Catalyst/Diesel Particulate Filter From the Stanchion” .
Note : Alignment is essential. Mark the position on the DOC, DPF, and DPF outlet housing (1) relative to the DOC
inlet and DPF outlet pressure sensor bosses, prior to disassembling. Improper assembly may result in leaks or
damage to the ATS.
5. Mark components alignment position relative to the DOC inlet and DPF outlet pressure sensor bosses.
6. With the assembly lying on the floor, remove the DPF inlet V-band clamp.
7. Separate the DOC and the DPF assemblies from each other.
Note : If replacing the DOC, remove the DOC inlet temperature sensor.
8. Clean the gasket surface on the DPF.