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Mack MP8 Diesel Engine: EXHAUST AFTERTREATMENT SYSTEM MAINTENANCE

This checklist is for the after treament maintenance of your vehicle. The diesel particulate filter should be removed from the system and replaced at the recommended service interval.

MaintainX

12/28/2022

Mack MP8 Diesel Engine: EXHAUST AFTERTREATMENT SYSTEM MAINTENANCE

This checklist is for the after treament maintenance of your vehicle. The diesel particulate filter should be removed from the system and replaced at the recommended service interval.

Special Tools

Diesel Particulate Filter

The diesel particulate filter should be removed from the system and replaced at the recommended service interval. If the filter is not replaced, it will become clogged and increase exhaust back pressure. As back pressure increases, engine power and economy decline as does the ability of the system to remove undesirable emissions.

Removal

When the fairing (if present), braces and steps have been removed to permit access, remove the lines and sensors connecting the inlet module to the other modules.

Disconnect wiring and sensor connectors from the DPF and outlet modules. Cut tie straps securing the lower portion of the DPF harness to the muffler body. Also, remove the pressure differential sensor tube that connects to the outlet module.

Using a marker, make alignment marks on each of the module sections, above and below each V-band clamp.

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

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

Remove the fasteners that secure the DPF lower supporting bracket to the chassis frame bracket. This releases the weight of the DPF onto the transmission jack.

Lower the DPF unit and roll the transmission jack from the right side of the chassis to remove the lower portion of the DPF.

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

Separate the DPF from the outlet module.

Remove and discard the gaskets.

Inspect and replace the V-band clamps showing galled threads, cracks or heat damage. Clean all exposed gasket surfaces.

Installation

Install a new gasket between the outlet and DPF modules.

Using alignment marks made at disassembly, position the DPF over the outlet module and connect using the V-band clamp tightened to specifications.

Place a new high-temperature gasket on top of the DPF module.

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

Align the outlet module flange to the exhaust pipe.
Align the locator tab at 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.

Install the V-band clamp that joins the DPF and catalyst modules. Tighten the band clamp fastener to specification.

Install and tighten the V-band clamp that joins the outlet module to the exhaust pipe.

Secure the DPF bracket to the chassis frame bracket and tighten all fasteners to specification.

Remove the transmission jack from under the assembly.

Install the pressure differential sensor tube that connects to the outlet module and tighten fitting to specification.

Install the lines and sensors connecting the various modules to each other. Refer to torque specifications for the V-band clamp screws, lines and sensors in the SPECIFICATIONS section of this manual.

Install the fairing (if equipped), braces and steps that were removed to permit access.

Using Premium Tech Tool (PTT), ensure all soot trigger levels are reset back to zero.

VERTICAL BACK-OF-CAB UNIT

Removal

Remove the heat shield, stack, harness clamps, tie straps and V-band clamp at the exhaust elbow.

Disconnect all harness connectors.

Using a suitable lifting device, support the assembly. Remove the band clamps and mounting bracket from the stanchion.

Remove the assembly from the chassis and place it in the VBOC DPF support stand, 85111327, or equivalent.

Using a marker, make alignment marks on each of the module sections, above and below each V-band clamp.

Remove the pressure differential tube from the catalytic filter module.

Remove the V-band clamp joining the outlet module to the filter module.

With an assistant and a suitable lifting device, remove the outlet module from the DPF filter module.

Remove the V-band clamp joining the DPF filter module to the catalytic filter module.

Separate the DPF filter module from the catalytic filter module and discard the gasket.

Inspect and replace the V-band clamps showing galled threads, cracks or heat damage. Clean the exposed gasket surfaces.

Installation

Install a new gasket between the catalytic filter module and the DPF filter module.

Align the locator tab located on the bottom of the DPF filter module with the slot located in the top of the catalytic filter module. Install the DPF filter module onto the catalytic filter module and secure the modules together using a V-band clamp tightened to specification.

Install a new gasket between the outlet module and the DPF filter module.

With assistance, use a suitable lifting device to install the outlet module onto the DPF filter module. Ensure that the differential pressure tube does not become damaged during outlet module installation.

Install the V-band clamp to secure the outlet module to the DPF filter module and tighten clamp fasteners to specification. All clamps should now be aligned and tightened.

Install the pressure differential tube to the port on the catalytic filter module and tighten the fitting securely.

Lift the DPF muffler using a suitable lifting device and with assistance, position the muffler next to the frame-mounted stanchion, at the back of the cab.

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

Perform the following steps to align the DPF muffler into final position on the muffler stanchion:

Align the muffler inlet with the exhaust elbow.
Align the muffler upper supporting bracket to the stanchion and install the bolts loose.
Loosely install the upper supporting band clamp with attached bracket and install bracket bolts into the stanchion.
Loosely install the lower supporting band clamp.

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

Install the heat shield onto the DPF muffler.

Secure all fasteners and clamps that connect the DPF muffler to the stanchion. Tighten all clamps and muffler fasteners according to specification.

Disconnect the lifting device and remove the lifting chain from the muffler.

Reconnect the harness connectors for all temperature and pressure differential sensors on the DPF muffler.

Locate torque specifications for the V-band clamp screws, lines and sensors in the SPECIFICATIONS section of this manual.

Using the Tech Tool, ensure all soot trigger levels are reset back to zero.

Aftertreatment Fuel Injector

REMOVAL

Apply the parking brake and place the shift lever in neutral.

Disconnect all cables from ground (negative) battery terminals to prevent personal injury from electrical shock.

Remove P-clamp screws securing the AFI harness and fuel supply line.

Connect coolant extraction tool DBT2V700 to the drain fitting at the bottom of the radiator. Drain the coolant.

Disconnect the aftertreatment fuel injector double check valve assembly (CVA). Collect any residual fuel that might be in the fuel line in a suitable container.

Disconnect both the inlet and outlet coolant lines from the aftertreatment fuel injector fittings.

Disconnect the aftertreatment fuel injector wiring harness connector. Remove all clips and tie straps to allow the harness to hang free.

Remove and discard the aftertreatment fuel injector mounting bolts and spacers, and then remove the injector from the diffuser pipe attached to the turbocharger outlet.

Remove and discard the high-temperature gasket and steel plate gasket from the bottom of the injector.

INSTALLATION

Install a new high-temperature gasket and steel plate gasket onto the bottom of the aftertreatment fuel injector.

Apply high-temperature nickel-graphite anti-seize compound to new injector mounting bolt threads and insert the bolts into the spacers. Position the injector onto the diffuser pipe (attached to the turbocharger outlet) and hand start the bolts with spacers.

Secure the injector mounting bolts. Tighten the bolts according to specification.

Reconnect the aftertreatment fuel injector wiring harness connector. Secure the injector wiring harness with clips and tie straps.

Reconnect the coolant lines to the aftertreatment injector fittings and tighten to specification.

Connect the aftertreatment fuel injector fuel check valve assembly (CVA) and tighten to specification.

Install the P-clamp and screws to secure the AFI harness and fuel supply line to the diffuser.

Fill the engine cooling system with the recommended coolant using the coolant extractor.

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

Perform Aftertreatment Injector Adaptive Factor Reset using VCADS/Tech Tool.

Start the engine, check for leaks and proper operation. After shutdown, replenish fluids as necessary.

CLEANING

Apply the parking brake and place the shift lever in neutral.

Disconnect all cables from ground (negative) battery terminals to prevent personal injury from electrical shock.

Remove P-clamp screws securing the AFI harness and fuel supply line.

Disconnect the aftertreatment fuel injector double check valve assembly (CVA). Collect any residual fuel that might be in the fuel line in a suitable container.

Remove and discard the aftertreatment fuel injector mounting bolts and spacers, and then remove the injector from the diffuser pipe attached to the turbocharger outlet.

Cover the opening in the diffuser pipe to prevent dirt and cleaning fluid from entering the exhaust system.

Remove and discard the high-temperature gasket and steel plate gasket from the bottom of the injector.

Carefully turn the AFI body and spray the injector tip with carburetor cleaning solution. Brush the injector tip with a stiff bristled nylon toothbrush. Repeat two or three times.

Inspect the injector tip to make sure it is thoroughly clean and all soot has been removed. Use a mirror if a clear view of the tip is not possible.

Install a new high-temperature gasket and steel plate gasket onto the bottom of the aftertreatment fuel injector.

Apply high-temperature nickel-graphite anti-seize compound to the new injector mounting bolt threads and insert the bolts into the spacers. Position the injector onto the diffuser pipe (which attaches to the turbocharger outlet) and hand start the bolts with spacers.

Secure the injector mounting bolts. Tighten the bolts according to specification.

Connect the aftertreatment fuel injector fuel check valve assembly (CVA) and tighten to specification.

Install P-clamp bolts to secure the AFI harness and fuel line.

Connect all previously disconnected cables to the ground (negative) battery terminals.

Using VCADS/Tech Tool, reset the AFI adaptive factor, clear codes and test the system for proper operation.

Source: MaintainX (Community Member)

Please note that any procedure, checklist, or other document available in the MaintainX Global Procedure Library is provided for general education and information only and does not constitute legal, medical, or financial advice. MaintainX makes the materials available AS IS and AS PROVIDED, without warranties of any kind. By downloading or using any such materials, you assume the risk that they may not be appropriate for your specific situation and agree that you are solely responsible for any such use, including compliance with applicable law and with meeting any conditions of product warranties.

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Special Tools

Diesel Particulate Filter

Removal

When the fairing (if present), braces and steps have been removed to permit access, remove the lines and sensors connecting the inlet module to the other modules.

Disconnect wiring and sensor connectors from the DPF and outlet modules. Cut tie straps securing the lower portion of the DPF harness to the muffler body. Also, remove the pressure differential sensor tube that connects to the outlet module.

Using a marker, make alignment marks on each of the module sections, above and below each V-band clamp.

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

Remove the fasteners that secure the DPF lower supporting bracket to the chassis frame bracket. This releases the weight of the DPF onto the transmission jack.

Lower the DPF unit and roll the transmission jack from the right side of the chassis to remove the lower portion of the DPF.

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

Separate the DPF from the outlet module.

Remove and discard the gaskets.

Inspect and replace the V-band clamps showing galled threads, cracks or heat damage. Clean all exposed gasket surfaces.

Installation

Install a new gasket between the outlet and DPF modules.

Using alignment marks made at disassembly, position the DPF over the outlet module and connect using the V-band clamp tightened to specifications.

Place a new high-temperature gasket on top of the DPF module.

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

Align the outlet module flange to the exhaust pipe.

Align the locator tab at 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.

Install the V-band clamp that joins the DPF and catalyst modules. Tighten the band clamp fastener to specification.

Install and tighten the V-band clamp that joins the outlet module to the exhaust pipe.

Secure the DPF bracket to the chassis frame bracket and tighten all fasteners to specification.

Remove the transmission jack from under the assembly.

Install the pressure differential sensor tube that connects to the outlet module and tighten fitting to specification.

Install the lines and sensors connecting the various modules to each other. Refer to torque specifications for the V-band clamp screws, lines and sensors in the SPECIFICATIONS section of this manual.

Install the fairing (if equipped), braces and steps that were removed to permit access.

Using Premium Tech Tool (PTT), ensure all soot trigger levels are reset back to zero.

VERTICAL BACK-OF-CAB UNIT

Removal

Remove the heat shield, stack, harness clamps, tie straps and V-band clamp at the exhaust elbow.

Disconnect all harness connectors.

Using a suitable lifting device, support the assembly. Remove the band clamps and mounting bracket from the stanchion.

Remove the assembly from the chassis and place it in the VBOC DPF support stand, 85111327, or equivalent.

Using a marker, make alignment marks on each of the module sections, above and below each V-band clamp.

Remove the pressure differential tube from the catalytic filter module.

Remove the V-band clamp joining the outlet module to the filter module.

With an assistant and a suitable lifting device, remove the outlet module from the DPF filter module.

Remove the V-band clamp joining the DPF filter module to the catalytic filter module.

Separate the DPF filter module from the catalytic filter module and discard the gasket.

Inspect and replace the V-band clamps showing galled threads, cracks or heat damage. Clean the exposed gasket surfaces.

Installation

Install a new gasket between the catalytic filter module and the DPF filter module.

Align the locator tab located on the bottom of the DPF filter module with the slot located in the top of the catalytic filter module. Install the DPF filter module onto the catalytic filter module and secure the modules together using a V-band clamp tightened to specification.

Install a new gasket between the outlet module and the DPF filter module.

With assistance, use a suitable lifting device to install the outlet module onto the DPF filter module. Ensure that the differential pressure tube does not become damaged during outlet module installation.

Install the V-band clamp to secure the outlet module to the DPF filter module and tighten clamp fasteners to specification. All clamps should now be aligned and tightened.

Install the pressure differential tube to the port on the catalytic filter module and tighten the fitting securely.

Lift the DPF muffler using a suitable lifting device and with assistance, position the muffler next to the frame-mounted stanchion, at the back of the cab.

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

Perform the following steps to align the DPF muffler into final position on the muffler stanchion:

Align the muffler inlet with the exhaust elbow.

Align the muffler upper supporting bracket to the stanchion and install the bolts loose.

Loosely install the upper supporting band clamp with attached bracket and install bracket bolts into the stanchion.

Loosely install the lower supporting band clamp.

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

Install the heat shield onto the DPF muffler.

Secure all fasteners and clamps that connect the DPF muffler to the stanchion. Tighten all clamps and muffler fasteners according to specification.

Disconnect the lifting device and remove the lifting chain from the muffler.

Reconnect the harness connectors for all temperature and pressure differential sensors on the DPF muffler.

Locate torque specifications for the V-band clamp screws, lines and sensors in the SPECIFICATIONS section of this manual.

Using the Tech Tool, ensure all soot trigger levels are reset back to zero.

Aftertreatment Fuel Injector

REMOVAL

Apply the parking brake and place the shift lever in neutral.

Disconnect all cables from ground (negative) battery terminals to prevent personal injury from electrical shock.

Remove P-clamp screws securing the AFI harness and fuel supply line.

Connect coolant extraction tool DBT2V700 to the drain fitting at the bottom of the radiator. Drain the coolant.

Disconnect the aftertreatment fuel injector double check valve assembly (CVA). Collect any residual fuel that might be in the fuel line in a suitable container.

Disconnect both the inlet and outlet coolant lines from the aftertreatment fuel injector fittings.

Disconnect the aftertreatment fuel injector wiring harness connector. Remove all clips and tie straps to allow the harness to hang free.

Remove and discard the aftertreatment fuel injector mounting bolts and spacers, and then remove the injector from the diffuser pipe attached to the turbocharger outlet.

Remove and discard the high-temperature gasket and steel plate gasket from the bottom of the injector.

INSTALLATION

Install a new high-temperature gasket and steel plate gasket onto the bottom of the aftertreatment fuel injector.

Apply high-temperature nickel-graphite anti-seize compound to new injector mounting bolt threads and insert the bolts into the spacers. Position the injector onto the diffuser pipe (attached to the turbocharger outlet) and hand start the bolts with spacers.

Secure the injector mounting bolts. Tighten the bolts according to specification.

Reconnect the aftertreatment fuel injector wiring harness connector. Secure the injector wiring harness with clips and tie straps.

Reconnect the coolant lines to the aftertreatment injector fittings and tighten to specification.