* UNLESS ALL PRE-EXISTING VEHICLE FAULTS ARE IDENTIFIED AND RECTIFIED, REPEAT DAMAGE WILL OCCUR TO THE NEW DPF OR CAT.
* THE RESULTING DAMAGE IS NOT COVERED BY WARRANTY !
What Is A DPF ?
A Diesel Particulate Filter (DPF) is a device designed to reduce the emissions from diesel fuelled vehicles. The filter, traps particulate matter (soot) which it then when full, reduces to ash during regeneration. Regeneration is controlled by the correct driving cycle of the vehicle and its engine management system. Faults that occur with a vehicle can cause the DPF to become blocked or damaged and then regeneration is not possible.
What Are The Differences between DPFs manufactured out of Silicone Carbide (SiC) & Cordierite ?
(Ref.Info Only – needs to be rewritten)
The internal ceramic core of these devices can be manufactured in two types of materials, silicone carbide (SiC) or cordierite (C) material depending on the vehicles driving needs.
:: Almost all original equipment manufacturers (with few exceptions) use silicone carbide filters to buildtheir DPF.
:: It has a melting point around 2650°C.
:: Silicon carbide filters have also some weak points, due to its high coefficient of linear expansion (5.1mm/m-ºC (~25ºC through ±1000ºC) toward 1.7mm/m-ºC (~25ºC through ±1000ºC) of the cordierite), present packaging issues, to solve them small DPF SiC cores are made of single pieces, while larger DPF cores are made in segments, which are separated by aspecial cement so that heat expansion of the core will be absorbed by the cement, and not the package.
:: SiC cores are more expensive to produce than cordierite cores, however they are manufactures in similar sizes.
:: (2MgO-2Al2O3-5SiO2) that is also used at catalytic converter monoliths.
:: Diesel particulates filters look very similar to catalytic converter cores but with the unique difference that DPF cores have alternate channels plugged.
:: Cordierite filters provide excellent filtration efficiency due to its porosity.
:: Cordierite have also better thermal dilatation properties than the ones made or silicon carbide.This fact prevents thermal shock cracking from taking place when the DPF is used properly.
:: Cordierite filters are cheaper to produce than the ones made of silicone carbide.
DPF Troubleshooting & Replacement Solutions
The following diagnostic information may be helpful in if you are experiencing performance issues with your current DPF. Please use only as a guide as proper diagnosis and troubleshooting should only be carried out by a trained technician. There are numerous options available when seeking a DPF solution. Some are good – while others, well.. not so good. Listed below are the Pros & Cons of some of the solutions you’ll be confronted with when deciding upon a DPF replacement.
Cost: $20 – $300
:: Can work in less severe blockages.
:: Cannot truly “clean” – only assists in clearing soot & ash by burning
:: Not effective if the DPF is melted, damaged or severely blocked.
:: Only a temporary fix
– unless the correct DPF service procedures are also carried out.
:: Warranty on the product only.
Cost: approx $300 to $750
:: Not effective if the DPF is melted or damaged.
:: Can be lengthy process including shipping and turnaround.
:: Some operators do not properly dispose of the ash, which is carcinogenic
:: Reputable operators offer a warranty
Cost: approx $600
:: May not meet current Australian Emission Standards (equiv. Euro 4).
:: Long delivery time from UK or China, approx 8 weeks.
:: Lack of technical support.
:: What if it’s for the wrong model, chassis, engine or year?
:: Any warranty would be very difficult to claim
Cost: $399 -$900
:: Illegal for on road use. EPA fines in NSW
– up to $22,000 for an individual
– $44,000 for a corporation.
:: Replaces DPF with a straight pipe.
:: Needs an extra module to ‘trick’ the vehicle’s ECU
– falsifies DPF sensor readings.
:: Potential performance gain.
:: May void insurance cover due to vehicle not being ‘roadworthy’.
:: May not have any Warranty
Cost: $1000 – $1200
:: Quick & easy purchase within Australia.
:: The DPF is of unknown condition.
:: Impossible to reset the vehicles ECU properly.
– An ECU setting can only be reset to start from ‘0’ so as to suit a new DPF installation and cannot be set to suit a used, partially filled second hand DPF which will almost certainly cause ongoing error codes and issues.
:: Warranty may only last a week or seven days.
Cost: $800 to $1800
:: Sometimes may cost less than other options.
:: Quick & easy purchase within Australia.
:: Good to medium quality and fit depending on brand
:: ECU reset is designed for the installation of a new DPF.
:: Technical support.
:: 1 – 3 years warranty depending on brand.
Cost: $4500 – $10000
:: Quick & easy purchase within Australia
:: Good quality and fit
:: ECU reset is designed for the installation of a new DPF
:: Possible vehicle manufacturer technical support
DPF Diagnostic & Installation Guide
:: Continuous urban drive cycles.
:: Incorrect engine operating temperature – too cold.
:: Incorrect or contaminated lubricating oil – must be a “low solids” DPF oil.
:: Incorrect or contaminated fuel – Fuel additives, bio diesel.
:: Induction & intercooler system air leaks – check for split hoses and loose clamps
:: Blocked or split pressure sensor pipes and hoses
:: Faulty DPF temperature pressure sensors or pressure differential switch/sensors.
:: Internal DPF filter cracks
:: Faulty, damaged, poor quality or a poor quality hi-flow catalytic converter
:: EGR valve stuck or failed
:: Turbo failure, leaking turbo oil seals
:: Injectors leaking, stuck open or not calibrated
:: Where a “Wet Regeneration” system is fitted (Most French cars, some European Fords and Volvos) ensure the Eolys fuel additive tank is full. Dealers recommend a full fluid change when changing the DPF.
:: ECU must also be reset to zero according to the manufacturer’s specifications. (If the ECU is not reset correctly, the vehicle will continue to display the DPF Warning Light.
:: ECU Fault codes must be cleared using a suitable scanning tool.
:: Change the engine oil and reset the ECU oil change where applicable.
:: Do not use exhaust paste.
:: Fit DPF into all mounts and clamps and adjust for fit before tightening
:: Use only metal gaskets as composite will not last
:: Make sure that all joints are properly sealed.
:: Final step is change the engine oil a (because of fuel dilution during the regeneration process)