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Hardware Remove DPF Filter

This document provides a 9-step guide to removing a Caterpillar diesel particulate filter (DPF) from various truck engine models for off-road use only. The steps include: 1) removing the DPF cover to access the filter; 2) marking and removing the filter and disconnecting sensors; 3) disconnecting the DPF sensor to prevent emissions system errors; 4) removing the filter canister and either replacing it or drilling holes in the filter; 5) reinstalling the drilled filter; 6) welding a plate over the exhaust outlet; 7) inspecting the welded outlet; 8) reinstalling covers; and 9) getting the engine control module retuned. Photos accompany several steps to illustrate

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Maykel Cruz
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348 views

Hardware Remove DPF Filter

This document provides a 9-step guide to removing a Caterpillar diesel particulate filter (DPF) from various truck engine models for off-road use only. The steps include: 1) removing the DPF cover to access the filter; 2) marking and removing the filter and disconnecting sensors; 3) disconnecting the DPF sensor to prevent emissions system errors; 4) removing the filter canister and either replacing it or drilling holes in the filter; 5) reinstalling the drilled filter; 6) welding a plate over the exhaust outlet; 7) inspecting the welded outlet; 8) reinstalling covers; and 9) getting the engine control module retuned. Photos accompany several steps to illustrate

Uploaded by

Maykel Cruz
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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CATERPILLAR DPF REMOVAL

- hardware changes guide -

Applicable on all truck makes, and all CATERPILLAR DPF engines C7S/C9S/C13 LEE/ C15 SDP
* Use on off-road vehicles in competition only. Not intended for vehicles used on public roads and
highways.

1st Remove DPF cover, so You can access DPF filter. See photo No1

Photo No1

2nd Once the cover is removed mark Your outer DPF hats so everything lines up when done.
Remove your outlet hat first, then unplug main plug in frame rail above DPF. Take off / remove
DPF filter / can. See photo No2.

Photo No2
3rd Now You need to unplug the DPF sensor plug (see photo No3), which is located at sensor box.
This plug has to stay unplugged, so the ECM can't communicate with DPF sensor.
If You want it to look plugged in (so You get a stock look) You can cut the connector pins inside the
plug, so it doesn't have the contact once it is plugged back in (so the signal can't go through).
IT IS ESENTIAL THAT THERE IS NO CONTACT BETWEEN THE PLUGS (male and female).
If the contact exist, truck will not work well.

Photo No3

4th Photo No4 shows DPF can once it is removed. We have two ways of deletion
- placing a DPF replacement canister instead of DPF
- drilling DPF
If You place the DPF replacement canister instead of the filter, You just put it, plug everything tight,
and go to step 6.

Most of clients decide to drill the DPF filter. You need to drill 1(one) 5inch hole, or 5(five) 1inch
holes.

Picture No4
5th Photo No5 shows a drilled DPF with one 5inch hole (it is OK to have 5 1inch holes instead).
Restore DPF filter using your previous marks to make sure DPF is clocked correctly for bracket
purposes.

Photo No5

6th Once You reinstalled the DPF (or placed DPF replacement canister instead). You need to weld
the hole from photo No6 (CGI line). It has to be welded tight (with a piece of a steal plate, apx. 2.5"
in diameter). We do this because we do not want exhaust traveling back up to intake of turbo area.

Photo No6
7th After You did the welding, take a look at picture No7, that's how output hat should look like with
plate welded in.

Picture No7

8th Now we are done regarding the hardware side. Get everything back (covers...), and You are good
to go.

9th Make sure that You got the ECM tuned. You also have 2 other manuals to read, one tells You
what needs to be set in ET (applicable for all truck makes and all CAT engines), and other tells You
what needs to be set in ESA (appliable for Kenworth and Peterbuilt trucks only).

* Use on off-road vehicles in competition only. Not intended for vehicles used on public roads and
highways.

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