1. Install a new gasket on the Diesel Oxidation Catalyst (DOC).
2. Slide the V-band clamp onto the Diesel Particulate Filter (DPF).
3. Assemble the DOC onto the DPF, verifying that the locating marks are aligned properly.
4. Position the V-band clamp and torque to 13 to 16 N·m (9 to 12 lb·ft).
Note : If the DOC is being replaced, Go to step 5. If not, Go to step 7.
5. Apply high temp anti-seize to the threads of the DOC inlet temperature sensor, but do not allow any to get
on the sensor probe.
Note : DO NOT use excessive amounts; anti-seize will squeeze out during installation. DO NOT over-tighten
sensors; damage to threads may occur.
6. Install the DOC inlet temperature sensor. Torque to 35 to 38 N·m (26 to 28 lb·ft).
7. Install DOC and DPF onto the stanchion.
8. Connect the batteries. Refer to OEM procedures.
9. Start the engine and check for leaks.
Removal of the 2-BOX (2V2) Diesel Particulate Filter
1. Shut off engine and apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
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 Aftertreatment System (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 and outlet V-band clamps.
7. Separate the DOC, DPF and DPF outlet assemblies from each other.
Note : If replacing the DPF, remove the DPF outlet temperature sensor and the Selective Catalytic Reduction
(SCR) Inlet NOx sensor.
8. Clean the DPF gasket surfaces.
Installation of the 2-BOX (2V2) Diesel Particulate Filter
1. Install new gaskets on the Diesel Particulate Filter (DPF).
2. Slide the V-band clamps onto the DPF.
3. Assemble the Diesel Oxidation Catalyst (DOC), DPF and DPF outlet housing, verifying that the locating
marks are aligned properly.
4. Position the V-band clamps and torque to 13 to 16 N·m (9 to 12 lb·ft).
5. Install DOC and DPF onto the stanchion.
6. Connect the batteries. Refer to OEM procedures.
7. Start the engine and check for leaks.
Selective Catalytic Reduction Catalyst Additional Removal
Information
The Selective Catalytic Reduction (SCR Catalyst) can be removed independently of the Diesel Oxidation Catalyst
(DOC) – Diesel Particulate Filter (DPF) section of the 2-BOX system.
Removal of the 2-BOX (2V2) Selective Catalytic Reduction
(SCR) Catalyst From the Stanchion
1. Shut off engine and apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
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 exhaust outlet stack (3) from the Selective Catalytic Reduction (SCR Catalyst).
6. Remove the SCR exhaust inlet clamp (1).
7. Remove the SCR outlet NOx sensor (5).
8. Remove the SCR outlet temperature sensor (6).
9. Disconnect the SCR inlet temperature sensor electrical connector (9) and remove from the mounting
bracket.
10. Remove the soot sensor (10).
11. Disconnect the Diesel Exhaust Fluid (DEF) Dosing Unit electrical connector (2).
12. Disconnect the DEF pressure and DEF return line from the DEF Dosing Unit.
Note : BODILY INJURY
13. Position the overhead lifting device over the SCR catalyst and connect the hooks at the lifting points (4).
Apply enough pressure to the lift points to prevent the unit from dropping when loosened.
14. Remove the upper (7) and lower (11) clamping strap nuts.
15. Lift the SCR catalyst away from the vehicle.
Installation of the 2-BOX (2V2) Selective Catalytic Reduction
(SCR) Catalyst Onto the Stanchion
1. Using the overhead lifting device, position the Selective Catalytic Reduction (SCR) catalyst on the vertical
stanchion, and secure it in position with the upper and lower mounting clamps. Do not tighten the straps at
this time.
2. Align the connection with the Aftertreatment Device (ATD), and using a new seal (3), install the SCR inlet
exhaust clamp (2). Tighten the clamp to 13 to 14 N·m (10 to 11 lb·ft.).
3. Check alignment, and tighten the clamping strap nuts incrementally, first to 20 N·m (15 lb·ft), then to 40
N·m (30 lb·ft). Install the jam nuts. Using a back-up wrench, tighten to 40 N·m (30 lb·ft).
NOTICE
When reusing a sensor, apply a small amount of anti-seize compound to the threads.
Excessive amounts of anti-seize will squeeze out when tightening, possibly contaminating
the sensor. New sensors already have a small amount of anti-seize compound on their
threads.
NOTICE
DO NOT over tighten sensors; damage to threads may occur.
4. Install the soot sensor (10). Use the soot sensor socket and torque the sensor to 50 N·m (37 lb·ft).
5. Connect the SCR inlet temperature sensor electrical connector (9) and install into the mounting bracket.
6. Install the SCR outlet NOx sensor (5). Use the slotted NOx sensor socket and torque the NOx sensor to 50
N·m (37 lb·ft).
7. Install the SCR outlet temperature sensor (6). Torque to 35 to 38 N·m (26 to 28 lb·ft).
8. Connect the DEF Dosing Unit electrical connector (2).
9. Connect the DEF pressure line and the DEF return line to the DEF dosing unit.
10. Install the exhaust outlet stack (3). Tighten the clamp from 37 to 50 N·m (27 to 37 lb·ft).
11. Install the heat shield. Tighten from 18 to 22 N·m (13 to 17 lb·ft)
12. Connect the batteries. Refer to OEM procedures.
13. Start the engine and check for leaks.