DIESEL PARTICULATE FILTER HANDLING. Manual - part 5

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

1-S9

(2) V2607-CR-E4

Connector of Exhaust Temperature Sensor
1. Disconnect the connectors of exhaust temperature sensor (9),

(10), (11) and differential pressure sensor (13) from wiring
harness.

2. Remove the connectors of exhaust temperature sensor (9),

(10), (11) from the bracket.

3. Remove the clamps (8).
4. Remove the differential pressure sensor bracket (12).

Separation of Muffler Full Assembly (DPF)
1. Unscrew the screw of muffler flange.
2. Unscrew the muffler full assembly (DPF) mounting screws (2).
3. Remove the muffler full assembly (DPF) (1).

NOTE

• When installing and removing the DPF muffler, make sure

that the temperature sensor, differential pressure sensor,
and differential pressure pipe do not make contact with
surrounding parts.

(1) Exhaust Temperature Sensor (T2)
(2) Differential Pressure Pipe
(3) Differential Pressure Pipe
(4) Exhaust Temperature Sensor (T1)
(5) Exhaust Temperature Sensor (T0)
(6) Screw of Muffler Flange
(7) Muffler Flange
(8) Clamp

(9) Connector of Exhaust Temperature 

Sensor (T2)

(10) Connector of Exhaust Temperature 

Sensor (T1)

(11) Connector of Exhaust Temperature 

Sensor (T0)

(12) Differential Pressure Sensor 

Bracket

(13) Differential Pressure Sensor

(1) Muffler Full Assembly (DPF)

(2) Muffler Full Assembly (DPF) 

Mounting Screw

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

1-S10

(3) V2607-CR-TE4, V3307-CR-TE4

Connector of Exhaust Temperature Sensor
1. Disconnect the connectors of exhaust temperature sensor (7),

(8), (9) and differential pressure sensor (11) from wiring
harness.

2. Remove the connectors of exhaust temperature sensor (7), (8),

(9) from the bracket.

3. Remove the clamps (6).
4. Remove the differential pressure sensor bracket (10).

Separation of Muffler Full Assembly (DPF)
1. Unscrew the nut of muffler flange.
2. Unscrew the muffler full assembly (DPF) mounting screws (2).
3. Remove the muffler full assembly (DPF) (1).

NOTE

• When installing and removing the DPF muffler, make sure

that the temperature sensor, differential pressure sensor,
and differential pressure pipe do not make contact with
surrounding parts.

(1) Exhaust Temperature Sensor (T2)
(2) Exhaust Temperature Sensor (T1)
(3) Exhaust Temperature Sensor (T0)
(4) Nut of Muffler Flange
(5) Muffler Flange
(6) Clamp
(7) Connector of Exhaust Temperature 

Sensor (T0)

(8) Connector of Exhaust Temperature 

Sensor (T1)

(9) Connector of Exhaust Temperature 

Sensor (T2)

(10) Differential Pressure Sensor 

Bracket

(11) Differential Pressure Sensor

(1) Muffler Full Assembly (DPF)

(2) Muffler Full Assembly (DPF) 

Mounting Screw

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

1-S11

(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C

Connector of Exhaust Temperature Sensor
1. Disconnect the connectors of exhaust temperature sensor (2),

(3), (4) and differential pressure sensor (1) from wiring harness.

2. Remove the connectors of exhaust temperature sensor (2), (3),

(4) from the bracket.

3. Remove the clamps (5).
4. Unscrew the stay mounting bolt (7), and remove the DPF stay 1

(6).

Separation of Muffler Full Assembly (DPF)
1. Set chain sling by using shackle at two places (a) and (b) as

shown in the photograph.

2. Unscrew the screws of muffler flange (1).
3. Unscrew the muffler full assembly (DPF) mounting screws (2).
4. Lift up the muffler full assembly (DPF) safely, and separate it

from the engine.
NOTE

• When lifting the muffler full assembly (DPF), use caution so

that the pressure pipe 1 (3) does not hit the EGR pipe (4).

(1) Differential Pressure Sensor
(2) Connector of Exhaust Temperature 

Sensor T2

(3) Connector of Exhaust Temperature 

Sensor T1

(4) Connector of Exhaust Temperature 

Sensor T0

(5) Clamp
(6) DPF Stay 1
(7) Stay Mounting Bolt

(1) Screw of Muffler Flange
(2) Muffler Full Assembly (DPF) 

Mounting Screw

(3) Pressure Pipe 1
(4) EGR Pipe

(a) Shackle Set Position
(b) Shackle Set Position

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

1-S12

[3]  DISASSEMBLY OF DPF MUFFLER FULL ASSEMBLY

IMPORTANT

• Since the DPF that was dropped or given a shock cannot be reused even if there is no damage outwardly,

replace it with a new one.

• Be sure to loosen the temperature sensor tightening nut or the differential pressure pipe tightening nut

with crowfoot wrench to prevent the damage of the sensor or pipe.
If it is still hard to loosen, apply the lubricant spray to threaded portion and soak it with lubricant.
NOTE

• Always work in the workshop equipped with a electric hoist (including mobile hoist).
• Put a product (engine) on a stable ground, and set the parking brake.
• As the DPF muffler full assembly is hot just after the engine shutdown, make sure to start operation after

it gets cool.

• Make sure not to let any foreign substances enter the opening section during the operation.
• Make sure not to damage the DPF muffler full assembly by falling or impact as it contains a ceramic filter.
• Before removing the DPF muffler full assembly from a product (engine), connect the diagnosis tool

(Diagmaster), check the failure history, and save the project.

• Before removing the DPF for cleaning, keep the records of the engine serial number, filter comp (DPF)

part number, filter comp (DPF) serial number, catalyst (DOC) part number, catalyst (DOC) serial number,
and engine operating time, which are required in preparing the DPF cleaning order from.
Since the engine operating time is recorded in the ECU, check the operating time by connecting the
service tool (Diagmaster).

• When installing and removing the muffler full assembly (DPF), make sure that the temperature sensor,

differential pressure sensor, and differential pressure pipe do not make contact with surrounding parts.

(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4

DPF Filter Complete
1. Remove the DPF mounting clamp band (2).
2. Separate the DOC catalyst complete (10), DPF filter complete

(9) and DPF outlet body (7).

(1) Exhaust Temperature Sensor (T2)
(2) DPF Mounting Clamp Band
(3) Exhaust Temperature Sensor (T1)
(4) Exhaust Temperature Sensor (T0)
(5) DPF Stay

(6) Differential Pressure Pipe
(7) DPF Outlet Body
(8) Gasket
(9) DPF Filter Complete
(10) DOC Catalyst Complete