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Isuzu DPF MAINTENANCE

The following lists the maintenance items required to properly perform the DPF Maintenance for most Isuzu DPF/SCR Systems. Disregard the SCR/DEF items for all pre-2010 applications.

DPF


EXHAUST AFTERTREATMENT
      DPF & SCR MAINTENANCE

Service the following:

  • SOOT/ASH CLEAN THE DPF CORE. 

  • SOOT CLEAN THE DOC CORE.

  • DPF FLANGE MOUNTING BOLTS

    • Inspect and replace all damaged and corroded DPF Flange Bolts/Nuts (M10).

  • CORE RETENTION

    • ​Ensure no loss in "DPF CORE RETENTION" and "DOC CORE RETENTION". 

  • DPF DIFFERENTIAL PRESSURE SENSOR TUBING

    • Clear the DPF Differential Pressure Sensor TUBING of any soot blockage. 

  • DEF CRYSTALLIZATION 

    • ​Inspect the SCR Catalyst and Mixer, remove and clean as needed.

  • DEF NOZZLE CLEANING

    • Remove the DEF Nozzle, clean all DEF Crystallization using distilled water. If DEF Nozzle is suspected to be in poor condition run the DEF NOZZLE FLOW TEST via PTT, to confirm correct volume of DEF Fluid passing through DEF Nozzle.

  • EXHAUST LEAKS 

    • Inspect the entire Exhaust System, repair any exhaust leaks found.

  • EXHAUST VALVE

    • Inspect the Butterfly EXHAUST VALVE upstream of the DPF and ensure it is cycling correctly, via Isuzu IDSS2 Software or Scan Tool.

  • OIL ENTRY INTO ENGINE INTAKE & CAC - INSPECTION

    • ​Inspect the Engine Intake and CAC for Oil Entry, as the DPF/SCR Systems will run poorly. Generally an old Oil Saturated CCV Filter/Screen or clogged Engine Air Filter will cause Oil Entry. Can also be due to failed Turbocharger and other issues. Make repairs as needed. 

  • FAULTS (ENGINE & DPF) - INSPECTION

    • Inspect all Faults present, make repairs as needed to ensure no elevated levels of engine soot production.

  • CLEAR ALL FAULTS

    • Any Active Fault will stop all DPF/SCR Function.

  • ECU SOFTWARE UPDATES

    • ​Check for any ECU Software Updates, update as needed via ISUZU IDSS2 or Scan Tool.

  • DPF PARKED REGEN or SCR PERFORMANCE - TEST

    • Perform a DPF Parked REGEN and/or SCR Performance Test and ensure passes (if Exhaust Temps do not rise over ~500F inspect the Exhaust Valve and Intake Throttle Valve, if Exhaust Temps do not rise over ~1,000 possible damaged DOC Core, Exhaust Leak, or Engine Fueling Issue). When running SCR Performance Test, once the DEF Nozzle has been cycled on for several minutes, ensure that the Outlet NOx Sensor value is less than 10% of the Inlet NOx Sensor value.


 

Replace the following:

  • Dimpled Steel GASKETS

  • Dimpled Steel Inlet GASKET

  • FLANGE BOLTS & NUTS M10 x 1.25 (as needed)

  • RUBBER TUBING - Differential Pressure Sensor (as needed)

  • DEF FLUID FILTER

  • DEF Fluid Tank BREATHER (if needed)


 

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