DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

1.2007 254 34 1(23)

Trucks

Diesel Particulate Filter SystemMaintenance

D16F

Diesel Particulate Filter System, Maintenance

W2005786

This information covers the maintenance of the Diesel Particulate Filter (DPF) on avehicle equipped with a Volvo D16F engine.

Contents• “Special Tools” page 2.

• “Particulate Filter, Clean” page 3.

Note: Information is subject to change without notice.Illustrations are used for reference only, and may differ slightly from the actualvehicle being serviced. However, key components addressed in this information arerepresented as accurately as possible.

PV776-20177385 USA23053.ihval

DVolvo Trucks North America Date Group No. Page

Service Bulletin 1.2007 254 34 2(23)

Special ToolsFor special tools ordering instructions, refer to ToolsInformation, group 08.

W0002405 W0002398

J48112Diesel Particulate Filter Cleaner

85111327DPF Support Stand

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Service Bulletin 1.2007 254 34 3(23)

2545-11-02-03Particulate Filter, Clean

You must read and understand the precautions andguidelines in Service Information, group 20, "GeneralSafety Practices, Engine" before performing thisprocedure. If you are not properly trained and certifiedin this procedure, ask your supervisor for trainingbefore you perform it.

Filter MaintenanceThe ceramic Diesel Particulate Filter (DPF) must beremoved from the muffler canister and cleaned to removethe accumulation of particulate matter (PM) which ismostly soot and ash deposits. Special equipment isrequired to properly clean all the particulate matter fromthe small surfaces of the ceramic DPF. If the filter is notclean, it will become clogged and increase exhaust backpressure. As back pressure increases, engine powerand economy decline as does the ability of the systemto remove undesirable emissions.

Volvo uses two different designs for the DPF systems.These include the following:

• Compact• Vertical Back of Cab

Compact DPFDPF Filter Removal1Apply the parking brake and place the shift leverin neutral.

2

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Remove all cables from ground (negative) batteryterminals to prevent personal injury from electrical shock.

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Service Bulletin 1.2007 254 34 4(23)

3

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Remove the right side chassis fairing, if equipped.

4

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Remove the bolts and nuts securing braces and/or stepslocated between the angle wing brackets and remove.

5

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Remove outlet and mid-temperature sensors andP-clamps used to secure temperature sensor harnesses.Also, remove both pressure differential sensor tubes.

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Service Bulletin 1.2007 254 34 5(23)

6

W2005818

Using a marker, make alignment marks on each of themodule sections, above and below each band clamp.

7

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Remove the lower exhaust V-band clamp that connectsthe DPF outlet module to the exhaust pipe. Also, removethe V-band clamp that connects the catalyst module tothe filter module.

8

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Position a flat surface jack with a very stable support(such as a transmission jack) under the base of the DPF.

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Service Bulletin 1.2007 254 34 6(23)

9

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Remove the fasteners which secure the DPF lowersupporting bracket to the chassis frame bracket. Thiswill release the weight of the DPF lower portion ontothe transmission jack.

Note: Removing the lower bracket will release the weight.Ensure the transmission jack is properly positionedand level.

10Lower and roll the transmission jack out from the rightside of the chassis to remove the lower portion of DPF.

11

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Loosen the nut securing the large V-band clamp betweenthe exhaust outlet module and the filter module.

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Service Bulletin 1.2007 254 34 7(23)

12

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Lift to remove the diesel particulate filter module fromthe outlet module. Remove and discard the hightemperature gasket.

CAUTION

The following precautions should be consideredbefore handling the Diesel Particulate Filter (DPF)muffler components:A. Wear suitable eye protection.B. Wear suitable overalls or apron and heavy-dutygloves to avoid skin contact.C. Wear suitable respirator to avoid inhalation.D. Ensure adequate ventilation.

13Prepare the DPF filter to be air pressure cleaned inspecial cleaning equipment such as J48112 (DieselParticulate Filter Cleaner) or equivalent. Follow thecleaning equipment manufacturer’s instructions on howto best clean the filter.

14Inspect the two band clamps for galled threads, cracksor heat-damaged areas. Replace any clamp found tocontain any irregularity.

DPF Filter Installation1

W2005800

Before installation, clean all gasket sealing surfaces ofthe filter, catalyst and outlet modules. Place a newhigh temperature gasket on the clean outlet modulesealing surface.

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Service Bulletin 1.2007 254 34 8(23)

2

W2005810

Align the marks made at disassembly and carefullylower the filter module (with new gasket) into the outletmodule opening.

Note: Make sure the high temperature gasket remains inplace and has not become dislodged.

3Install the large V-band clamp over the filter module andposition the clamp to allow the tightening nut to alignwith the exhaust outlet port. Allow the V-band clamp toremain loose at this time.

4

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Place a new high temperature gasket on top of thefilter module.

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Service Bulletin 1.2007 254 34 9(23)

5

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Using the transmission jack, lift the lower section of theDPF muffler into position next to the chassis framebracket.

6

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Perform the following steps to align and lift the filter andoutlet module assembly into position:

• Align the outlet module flange to the exhaust pipe.• Align the locator tab at the top of the filter module with

the slot located in the bottom of the catalyst module.• Start all fasteners that connect the lower supporting

bracket to the chassis frame bracket.

Note: Make sure the high temperature gasket remains inplace and has not become dislodged.

7

W2005797

Install the large V-band clamp onto the catalyst moduleand secure the catalyst module to the filter module.Position the clamp to allow the tightening nut to align withthe exhaust outlet port. Both clamps should now align.Torque-tighten the clamp fastener to 20 Nm (177 in-lb).

20 Nm(177 in-lb)

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Service Bulletin 1.2007 254 34 10(23)

8

W2005911

Install the lower exhaust V-band clamp that connects theoutlet module to the exhaust pipe. Torque-tighten theclamp fastener to 7 ± 2 Nm (62 ± 18 in-lb).

Note: Inspect clamps for galled threads or deformedclamping surfaces. Replace clamps as required.

7 ± 2 Nm(62 ± 18 in-lb)

9

W2005908

Secure the DPF bracket to the chassis frame bracket.Torque-tighten the fasteners to 48 ± 8 Nm (35 ± 6 ft-lb).Remove the transmission jack.

48 ± 8 Nm(35 ± 6 ft-lb)

10

W2006027

Install outlet and mid-temperature sensors and P-clampsused to secure temperature sensor harnesses.Also, install both pressure differential sensor tubes.Torque-tighten to specifications.

Note: A high temperature anti-seizing compound shouldalways be applied to the threads of sensors, plugs orfittings in the exhaust system to avoid component seizureor corrosion.

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Service Bulletin 1.2007 254 34 11(23)

11

W2005956

Position the connector braces and/or steps locatedbetween the angle wing brackets and secure using boltsand nuts. Torque-tighten to specification.

12

W2005915

Reinstall the right side chassis fairing, if equipped.

13

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Install all previously removed cables to the ground(negative) battery terminals.

14Start the engine, check for leaks and proper operation.Fault codes may need to be cleared at this time.

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Service Bulletin 1.2007 254 34 12(23)

Vertical Back of Cab

DPF Filter Removal

1Apply the parking brake and place the shift leverin neutral.

2

W2003815

Remove all cables from ground (negative) batteryterminals to prevent personal injury from electrical shock.

3

W2005986

Remove the heat shield from the Diesel ParticulateFilter (DPF) muffler.

4

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Loosen the clamps and remove the exhaust stack fromthe DPF muffler outlet.

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Service Bulletin 1.2007 254 34 13(23)

5

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Remove the lower exhaust V-band clamp at the exhaustelbow.

6

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Remove the P-clamp fasteners that secure the DPFmuffler harness to the muffler stanchion and release theharness from the stanchion.

7Cut all tie straps securing the DPF muffler harness.

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Service Bulletin 1.2007 254 34 14(23)

8

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Disconnect the harness connectors from the pressuredifferential and NOx sensors.

9Disconnect the harness connectors from all temperaturesensors on the DPF muffler.

10

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Support the weight of the DPF muffler using a mobilefloor crane such as OTC 16-1815 or equivalent cranecapable of safely lifting the muffler. Position the craneand attach a chain using bolts, nuts and washers to thelifting eyes of the muffler.

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Service Bulletin 1.2007 254 34 15(23)

11

W2005992

Remove the lower support band clamp from the DPFmuffler.

12

W2005993

Remove the upper band clamp mounting bolts andremove the mounting bracket from the stanchion.

Note: Removing the upper band clamp mounting bracketwill release the weight of the DPF. Ensure the floor craneand chain are properly positioned.

13

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With assistance, lift and remove the DPF mufflerassembly from the truck

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Service Bulletin 1.2007 254 34 16(23)

14

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With assistance, place the muffler assembly in mufflersupport stand 85111327.

85111327

15

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Remove the pressure differential tube from the catalyst.

16

W2005996

Remove the V-band clamp securing the outlet module tothe filter module.

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Service Bulletin 1.2007 254 34 17(23)

17

W2006000

With assistance, use a mobile floor crane to remove theoutlet module from the DPF filter.

18

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Remove the V-band clamp securing the filter moduleto the catalyst module.

19Remove the DPF filter module from the catalyst module.

CAUTION

The following precautions should be consideredbefore handling the Diesel Particulate Filter (DPF)muffler components:A. Wear suitable eye protection.B. Wear suitable overalls or apron and heavy-dutygloves to avoid skin contact.C. Wear suitable respirator to avoid inhalation.D. Ensure adequate ventilation.

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Service Bulletin 1.2007 254 34 18(23)

20Prepare the DPF filter to be air pressure cleaned inspecial cleaning equipment such as J48112 (DieselParticulate Filter Cleaner) or equivalent. Follow thecleaning equipment manufacturer’s instructions on howto best clean the filter.

21Inspect the two band clamps for galled threads, cracksor heat-damaged areas. Replace any clamp found tocontain any irregularity.

DPF Filter Installation

1Before installation, clean all gasket surfaces of the filter,catalyst and outlet modules.

2

W2005800

Install a new gasket onto the top of the catalyst module.

3

W2005801

Align the locator tab located on the bottom of the filtermodule with the slot located in the top of the catalystmodule. Install the DPF filter onto the catalyst andsecure the two modules together using a V-band clamptightened securely.

Note: Make sure the high temperature gasket remains inplace and has not become dislodged.

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Service Bulletin 1.2007 254 34 19(23)

4

W2005800

Install a new gasket onto the top of the filter module.

5

W2006000

With assistance, use a mobile floor crane to installthe outlet module onto the DPF filter. Ensure that thedifferential pressure tube does not become damagedduring outlet module installation.

Note: Make sure the high temperature gasket remains inplace and has not become dislodged.

6

W2005997

Install the V-band clamp securing the outlet module to thefilter module and tighten clamp fasteners securely. Allclamps should now be aligned and tightened.

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Service Bulletin 1.2007 254 34 20(23)

7

W2005995

Install the pressure differential tube to the catalyst portand tighten the fitting securely.

Note: A high temperature anti-seizing compound shouldalways be applied to the threads of sensors, plugs orfittings in the exhaust system to avoid component seizureor corrosion.

8

W2006002

Lift the weight of the DPF muffler using a mobile floorcrane and with assistance, position the muffler next to theframe-mounted stanchion, at the back of the cab.

9

W2006003

Align the slot in the muffler bottom with the tab on thestanchion.

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Service Bulletin 1.2007 254 34 21(23)

10Perform the following steps to align the DPF muffler intofinal position on the muffler stanchion:

• Align the muffler inlet with the exhaust elbow.• Align the muffler upper supporting bracket to the

stanchion and install bolts loose.• Loosely install the upper supporting band clamp

with attached bracket and install bracket bolts intothe stanchion.

• Loosely install the lower supporting band clamp.

11

W2005988

With all components aligned, install and secure the lowerV-band clamp at the inlet side of the muffler.

12

W2005986

Install the muffler heat shield onto the DPF muffler.

13Secure all fasteners and clamps that connect the DPFmuffler to the stanchion. Torque-tighten all clamps andmuffler fasteners to specifications.

14Disconnect crane and remove lifting chain from muffler.

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Service Bulletin 1.2007 254 34 22(23)

15

W2005990

Reconnect the harness connectors for the pressuredifferential and NOx sensors.

16Reconnect the harness connectors for all temperaturesensors on the DPF muffler.

17

W2005989

Install the P-clamp fasteners that secure the DPF mufflerharness to the muffler stanchion.

18Secure the harness using tie straps.

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Service Bulletin 1.2007 254 34 23(23)

19

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Install the exhaust stack onto the DPF muffler and secureusing two clamps. Tighten-tighten clamps to specification.

20

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Install all previously removed cables to the ground(negative) battery terminals.

21Start the engine, check for exhaust leaks and properoperation.

22Clear fault codes if necessary.