3.1 Aftertreatment Device

See Figure "Aftertreatment Device" for a picture of the Aftertreatment Device (ATD), that is composed of a Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF).
 1. Diesel Oxidation Catalyst
 6. DPF Outlet Pressure Sensor
 2. DOC Inlet Temperature Sensor
 7. Diesel Particulate Filter
 3. DOC Outlet Temperature Sensor
 8. DPF Inlet Pressure Sensor
 4. Sensor Junction Box
A= Engine Exhaust Inlet
 5. DPF Outlet Temperature Sensor
B= Exhaust Outlet
Figure , Aftertreatment Device
These components are listed in Table "ATD Component Descriptions" .
Component
Description
Diesel Oxidation Catalyst
A flow through device located at the ATD inlet that enhances the oxidation of hydrocarbons in order to reduce particulate emissions.
DOC Inlet Temperature Sensor
Measures exhaust gas temperatures entering the DOC.
DOC Outlet Temperature Sensor
Measures exhaust gas temperatures exiting the DOC.
Sensor Junction Box
Contains 2 pressure sensors & 2 temperature connectors.
DPF Outlet Temperature Sensor
Measures exhaust gas temperatures exiting the DPF.
DPF Outlet Pressure Sensor
Measures exhaust gas pressures exiting the DPF.
Diesel Particulate Filter
A device installed on a diesel engine system that captures and reduces particulate matter (PM) from the exhaust gas.
DPF Inlet Pressure Sensor
Measures exhaust gas pressures entering the DPF.
Table , ATD Component Descriptions

3.1.1 AFTERTREATMENT DEVICE REMOVAL

The ATD may be horizontally or vertically mounted depending on the vehicle chassis configuration. See Figure "Typical Mounting Views of an Aftertreatment Device" for a typical mounting view of the ATD. To remove the ATD, a suitable lifting or holding device is required. For example, to remove a horizontally mounted ATD from the underside of a vehicle chassis, use the Detroit Diesel approved DPF Lifting Device ( TLZ00785 ). See Figure "Diesel Particulate Filter Lifting Device (TLZ00785)" .
Figure , Typical Mounting Views of an Aftertreatment Device
Figure , Diesel Particulate Filter Lifting Device (TLZ00785)
Vertical mounts will require the use of a J-hook and an overhead lift. Additionally, depending on ground clearance, it may be necessary to jack up the vehicle. It may also be necessary to remove a body panel to gain access to the ATD location. Perform this procedure by the following steps:
WARNING
EYE INJURY
To avoid injury from flying parts when working with components under spring tension, wear adequate eye protection (face shield or safety goggles).
NOTICE
The DPF is fragile. Take special care when handling the DPF as it could be damaged or destroyed by dropping or sudden impact.
WARNING
PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component.
WARNING
PERSONAL INJURY
To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling.
Note : Cool down time after performing a parked regeneration is about 10 minutes of idling. The ATD will cool down faster with the truck idling then with the engine off.
1.
Park the vehicle on a level surface and chock the tires.
1.a
If necessary, remove body panel(s) or other obstruction and jack up vehicle.
2.
Center lifting device in position underneath ATD. See Figure "Lifting Device" .
Figure , Lifting Device
3.
Disconnect front temperature sensor connector from ATD chassis wiring harness.
4.
Disconnect junction box 10-pin connector. See Figure "Wiring Harness Components" .
 1. Front Temperature Sensor Connector
 2. 10-pin Connector
Figure , Wiring Harness Components
5.
Remove rear marmon clamp at connection between ATD outlet and exhaust pipe. See Figure "Marmon Clamps" .
6.
Remove front marmon clamp at connection between ATD inlet and turbocharger exhaust pipe.
 1. Front Marmon Clamp
 2. Rear Marmon Clamp
Figure , Marmon Clamps
WARNING
EYE INJURY
To avoid injury from flying parts when working with components under spring tension, wear adequate eye protection (face shield or safety goggles).
NOTICE
The DPF is fragile. Take special care when handling the DPF as it could be damaged or destroyed by dropping or sudden impact.
Note : Before removing support straps, ensure the lifting device is centered and supporting ATD as it contains fragile components that could be damaged.
7.
Carefully loosen lower fasteners securing both ATD support straps (they are under spring tension). Pull upper clip pin and remove clevis pin to release both support straps from chassis. See Figure "Clip Pin" .
 1. Clip Pin
Figure , Clip Pin
8.
Lower ATD from vehicle.

3.1.2 TEMPERATURE SENSOR REMOVAL

Perform the following steps to remove a typical temperature sensor:
1.
Remove top cover from the sensor junction box. See Figure "Temperature Sensor Removal" .
 1. DPF Inlet Pressure Sensor
 3. DPF Outlet Temperature Connection
 2. DOC Outlet Temperature Connection
 4. DPF Outlet Pressure Sensor
Figure , Temperature Sensor Removal
2.
Slide locking tab to the unlock position. Push on the release tab and pull electrical connection apart.
3.
Loosen temperature sensor nut using injector line socket ( J-46371 ). If needed, use a non-graphite lube. Pull sensor from aftertreament housing.

3.1.3 INSTALLATION OF TEMPERATURE SENSOR

Perform the following steps to install a typical temperature sensor:
1.
Apply a light coating of antiseizing compound to the threads of temperature sensor.
2.
Install the sensor into the aftertreatment housing and torque the nut to 35-39 N·m (26-29 lb·ft) using injector line socket ( J-46371 ).
3.
Push the electrical connection together and slide the locking tab into the lock position.
4.
Install the electrical connection into the junction box verifying that it is in the correct position.
5.
Install the top cover on to the junction box and install the bolt.

3.1.4 PRESSURE SENSOR REMOVAL

Perform the following steps to remove a typical pressure sensor:
1.
Remove the top cover from the sensor junction box. See Figure "Temperature Sensor Removal" .
2.
Slide locking tab to the unlock position. Push the release tab and remove the electrical connection from the sensor.
WARNING
EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
3.
Loosen both hose nuts, one from the sensor and the other from the aftertreatment port. Remove the hose and check for blockage. If blocked, soak the hose in the part cleaning tank and blow out with compressed air until clean and dry.
4.
Loosen the jam nut from the sensor and remove from junction box.

3.1.5 INSTALLATION OF PRESSURE SENSOR

Perform the following steps to install a typical pressure sensor:
1.
Install pressure sensor into the junction box. Torque jam nut to 20-25 N·m (15-18 lb·ft).
2.
Install electrical connection on to sensor. Slide locking tab into the lock position.
3.
Verify that the hose is clean and dry. Install hose assembly on sensor and aftertreatment port. Torque nuts to 15-17 N·m (11-13 lb·ft).
4.
Install cover back on sensor junction box and install the bolt.

3.1.6 PRELIMINARY INSPECTION

Perform the following steps to inspect a DPF core.
1.
Check all exhaust pipes, connections, gaskets, and V-bands for damage and signs of leakage. If damage or leakage is found, repair or replace as necessary. Refer to "3.1.6.1 Verify Repairs" .
2.
Check all electrical connections for corrosion, damage, and melted or spread pins. If damage is found, repair as necessary. Refer to "3.1.6.1 Verify Repairs" .
3.
Check all pressure hoses for damage, kinking, fraying, and plugging. If damage is found, repair as necessary. Refer to "3.1.6.1 Verify Repairs" .
4.
Check all pressure sensors for damage or plugging. If damage is found, replace sensor(s). Refer to "3.1.6.1 Verify Repairs" .
5.
If no damage, leakage, or plugging is found, disassemble the ATD and continue the inspection process. Refer to "3.1.7 DISASSEMBLY" .

3.1.6.1 Verify Repairs

Verify repairs as follows:
1.
Turn ignition OFF.
2.
Reconnect any electrical connections that were disconnected to perform the diagnosis.
3.
Clear all code(s) using DDDL 7.X.
4.
Start and bring the engine up to operating temperature (60°C [140°F]) or run engine for two minutes.
5.
Verify operation is satisfactory and no warning lamps illuminate. If warning lamps illuminate, troubleshoot the codes. If assistance is required, contact the Detroit Diesel Customer Support Center (800-445-1980).

3.1.7 DISASSEMBLY

Perform the following steps to disassemble the ATD:
1.
Identify the vertical weld mark using a paint marker. Place a demarcation on the inlet and outlet sections of the ATD for alignment purposes during reassembly. See Figure "Diesel Particulate Filter Weld Marks" .
Note : Even if the DPF section is being replaced, these markings will allow proper alignment of the new DPF section using the same weld mark.
Figure , Diesel Particulate Filter Weld Marks
2.
Place ATD on suitable work surface. See Figure "ATD on Work Bench" .
Figure , ATD on Work Bench
3.
Remove top cover from sensor box, disconnect both temperature sensors, refer to "3.1.2 TEMPERATURE SENSOR REMOVAL" . Disconnect pressure sensors, refer to "3.1.4 PRESSURE SENSOR REMOVAL" .
4.
Loosen both V-band clamps and position clamps out of the way.
5.
Carefully separate the three sections from each other. See Figure "Sections Separated" .
Figure , Sections Separated
6.
Remove graphite gaskets and discard. See Figure "Graphite Gaskets Removed" .
 1. Graphite Gaskets
Figure , Graphite Gaskets Removed
7.
If DPF is being replaced, remove sensor box.

3.1.8 INSPECTION

Perform the following steps to inspect the ATD in detail:
1.
Visually inspect the outlet flange of the DPF for soot and coloration.
1.a
If a large amount of soot is found ( see Figure "Sooty Outlet Flange" and Figure "Excessively Sooty Outlet Flange" ), the DPF is defective. Replace the DPF.
NOTICE
If DPF is replaced, the root cause of its failure must be repaired. Failure to fix the cause will result in a premature DPF failure.
Note : If the DPF is defective and requires replacement under warranty, then pre-authorization is needed from the Detroit Diesel Customer Support Center (800-445-1980).
Figure , Sooty Outlet Flange
Figure , Excessively Sooty Outlet Flange
1.b
If the DPF is operating properly, the outlet flange surface will be a slight rust color except near the edges and sensor bosses which get marginally hotter. See Figure "Outlet Flange of Properly Operating Filter" and Figure "Sensor Boss on a Properly Operating Filter" .
Figure , Outlet Flange of Properly Operating Filter
Figure , Sensor Boss on a Properly Operating Filter
Note : The stripes on the outlet face of the DPF are normal and caused by the manufacturing coating process. See Figure "Filter Outlet Face" .
Figure , Filter Outlet Face
2.
Inspect the DOC for edge chips. See Figure "Typical Diesel Oxidation Catalyst Edge Chip" .
Figure , Typical Diesel Oxidation Catalyst Edge Chip
2.a
If the length along the circumference of any edge chip exceeds 20.0 mm (0.78 in.) or the total of all chip lengths exceeds 5% of the circumference, replace the DOC.
Note : If the DOC is defective and requires replacement under warranty, then pre-authorization is needed from the Detroit Diesel Customer Support Center (800-445-1980).
2.b
If any edge chip extends from the edge towards the center more than 5.0 mm (0.19 in.), replace the DOC.
3.
Inspect the DOC for face gouges. See Figure "Typical Diesel Oxidation Catalyst Face Gouge" .
Figure , Typical Diesel Oxidation Catalyst Face Gouge
3.a
If any gouge exceeds 6.2 mm (0.25 in.) in any direction or depth, replace the DOC.
3.b
If any gouge is within 25.4 mm (1.00 in.) of the edge of the substrate or within 37.5 mm (1.48 in.) of another gouge, replace the DOC.
4.
Inspect the DOC for face cracking. If any crack spans more than 10 cells, replace the DOC. See Figure "A Crack in the Diesel Oxidation Catalyst" .
Figure , A Crack in the Diesel Oxidation Catalyst
5.
Inspect the DPF for edge chips. See Figure "Typical Diesel Particulate Filter Edge Chip" .
Figure , Typical Diesel Particulate Filter Edge Chip
5.a
If the length along the circumference of any edge chip exceeds 25.4 mm (1.00 in.) or cumulative total of all chip lengths exceeds 71.8 mm (2.83 in.) of the circumference, replace the DPF.
5.b
If any edge chip extends from the edge towards the center by more than two cells, replace the DPF.
6.
Inspect the DPF for face gouges.
Figure , Typical Diesel Particulate Filter Face Gouge
6.a
If any gouge exceeds 12.7 mm (0.50 in.) in length, 6.3 mm (0.25 in.) in width, or 3.1 mm (0.12 in.) in depth, replace the DPF.
6.b
If any gouge is within 25.4 mm (1.00 in.) of the edge of the substrate or within 49.7 mm (1.96 in.) of another gouge, replace the DPF.
6.c
If there are more than five gouges or the total area gouged exceeds 5% of the total face area, replace the DPF.
7.
Inspect the DPF for face cracking. If a face crack spans more than 10 cells, replace the DPF. See Figure "A Crack in the Diesel Particulate Filter" .
Figure , A Crack in the Diesel Particulate Filter
8.
Inspect the DPF for missing plugs. If the face has any missing plugs, replace the DPF.
Note : A DPF cannot be missing any plugs, but extra plugs on the DPF face are normal and allowed. See Figure "Extra Plugs on a Diesel Particulate Filter Face" .
Figure , Extra Plugs on a Diesel Particulate Filter Face
9.
Inspect DPF outlet face for evidence of soot residue. See Figure "Evidence of Soot — Diesel Particulate Filter Outlet Face" . If soot is found, replace the DPF. Replacement of the DPF, for warranty consideration, requires pre-authorization from the Detroit Diesel Customer Support Center (800-445-1980). Standard core return procedure requires that the defective DPF or DOC must be returned in the same container that their replacements were shipped in.
 1. Outlet Face
 2. Soot
Figure , Evidence of Soot — Diesel Particulate Filter Outlet Face
10.
If no soot is found in step 1 or step 9 , DPF is serviceable. Follow instructions for DPF cleaning, if needed.
11.
Inspect inlet face for plugging. If DPF is plugged, with heavy oil residue, wet soot, or indications of coolant contamination, replace the DPF. Replacement of the DPF, for warranty consideration, requires pre-authorization from the Detroit Diesel Customer Support Center (800-445-1980).
Note : The most important means to qualify a failed or damaged filter is by visual inspection of the substrate. Additional failure modes detectable by visual inspection are: burn-through, substrate fractures, cell fusion, and cell damage. Diesel particulate filters that exhibit these conditions are also considered unusable, uncleanable, and may fail to perform correctly in their application. See Figure "Burn-Through Condition" for burn-through failure. If these failure modes are detected during inspection of the DPF, replace it. Replacement of the DPF, for warranty consideration, requires pre-authorization from the Detroit Diesel Customer Support Center (800-445-1980).
The substrate shown here has experienced a burn-through. See Figure "Burn-Through Condition" . The face of the filter has been partially melted, and the cell structure has been converted to molten ceramic. Filters that have experienced a burn-through are non-serviceable. Replace the DPF. Replacement of the DPF, for warranty consideration, requires pre-authorization from the Detroit Diesel Customer Support Center (800-445-1980).
Figure , Burn-Through Condition

3.1.9 ASSEMBLY

Perform the following steps to assemble the ATD:
1.
On a work surface, position the three sections of the ATD.
2.
Wipe down outlet section with suitable cleaning fluid.
3.
Install new graphite gaskets. See Figure "Graphite Gasket Installation" .
 1. Graphite Gasket
Figure , Graphite Gasket Installation
4.
Join the three sections and slide the V-band clamps in position.
5.
Tighten the V-band clamps; torque to 16-18 N·m (12-13 lb·ft).
6.
Install sensor box, temperature sensors ( refer to "3.1.3 INSTALLATION OF TEMPERATURE SENSOR" ), and pressure sensors ( refer to "3.1.5 INSTALLATION OF PRESSURE SENSOR" ), if removed.

3.1.10 INSTALLATION

Perform the following steps to install the ATD:
1.
If necessary, remove body panel(s) or other obstruction and jack up vehicle.
2.
Place ATD on lifting device.
3.
Raise ATD into position under vehicle and align between turbocharger exhaust and exhaust pipe assembly.
WARNING
EYE INJURY
To avoid injury from flying parts when working with components under spring tension, wear adequate eye protection (face shield or safety goggles).
4.
Position support straps (they are under spring tension) around ATD. Reinstall clevis pin and upper clip pin. Tighten support straps to snug fit.
NOTICE
Do not use impact wrench as they can over torque the strap and damage the ATD.
5.
Install front marmon clamp at connection between ATD inlet and turbocharger exhaust pipe. Tighten marmon clamp to snug fit.
6.
Install rear marmon clamp at connection between ATD outlet and exhaust pipe. Tighten marmon clamp to snug fit.
7.
Torque marmon clamps to 6.8 N·m (60 lb·in) and support straps to 41 N·m (30 lb·ft).
8.
Lower lifting device and remove from under vehicle.
9.
Reconnect junction box 10-pin connector.
10.
Reconnect front temperature sensor connector to ATD chassis wiring harness.
WARNING
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.
11.
Start engine and inspect for exhaust leaks. If leaks found, repair as necessary.
12.
If necessary, lower vehicle and replace body panel(s) or other removed component.
WARNING
HOT EXHAUST
During parked regeneration the exhaust gases will be extremely HOT and could cause a fire if directed at combustible materials. The vehicle must be parked outside.
13.
Perform a parked regeneration.