Step-by-Step Guide to DPF Filter Removal & Refit

Introduction

A Diesel Particulate Filter (DPF) is designed to capture soot and harmful particulates from diesel exhaust gases. Over time, it becomes clogged and requires professional cleaning. To do this, garages must carefully remove and refit the DPF filter without causing damage.

Here’s a step-by-step guide for technicians and garages.

🔧 Tools & Equipment Needed

• Socket set & wrenches

• Screwdrivers

• Torque wrench

• Jack and jack stands (if underbody access is required)

• Safety gloves & goggles

• DPF cleaning machine (like UNIKO’s Fully Automatic DPF Cleaner)

• Replacement gaskets/clamps (if necessary)

🚗 Step 1: Safety First

• Park the vehicle on a flat surface.

• Let the exhaust system cool down completely.

• Disconnect the vehicle battery to prevent electrical faults.

🚗 Step 2: Locate the DPF

• The DPF is usually installed in the exhaust line, between the engine and the tailpipe.

• On most cars, it’s positioned close to the catalytic converter.

🚗 Step 3: Disconnect Sensors & Pipes

• Identify and carefully disconnect:

  • Temperature sensors

  • Pressure sensors

  • Any attached vacuum or electrical connections

• Label the connections if needed to avoid mistakes during refit.

🚗 Step 4: Loosen Clamps & Bolts

• Use the socket set/wrenches to loosen the bolts, clamps, and brackets holding the DPF in place.

• Some vehicles may require removal of protective covers or heat shields first.

🚗 Step 5: Remove the DPF Filter

• Gently slide the DPF out of its position.

• Be careful not to hit or drop it, as ceramic filters inside are fragile.

🚗 Step 6: Clean the DPF (Optional but Recommended)

• Use a DPF cleaning machine to flush out ash, soot, and oil residues.

• Ensure proper drying before reinstalling.

• Inspect for cracks or damage — if the filter is broken, replacement is necessary.

🚗 Step 7: Refit the DPF Filter

• Place the cleaned DPF back into its original position.

• Align it correctly with the exhaust system.

• Reattach clamps, bolts, and brackets securely (use a torque wrench where required).

🚗 Step 8: Reconnect Sensors & Pipes

• Reconnect all sensors and wiring to their correct positions.

• Double-check connections to avoid Check Engine Light (CEL) errors.

🚗 Step 9: Final Checks

• Reconnect the vehicle battery.

• Start the engine and check for exhaust leaks.

• Monitor dashboard warning lights.

• If needed, perform a forced regeneration or reset using a diagnostic scanner.

✅ Conclusion

Removing and refitting a DPF filter is a straightforward but delicate process. By following these steps, garages can ensure safe removal, proper cleaning, and correct reinstallation without damaging the filter.

Offering professional DPF cleaning services with machines like UNIKO India’s Automatic DPF Cleaning Machine not only restores performance but also helps vehicles pass PUC emission tests.

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