Before fitting a replacement Diesel Particulate Filter, please ensure that the root cause of failure of the existing unit has been correctly diagnosed and rectified. Failure to correct any faults or defective components may result in damage to the replacement Diesel Particulate Filter and invalidate your warranty.
REMOVAL Disconnect the earth terminal from the vehicle battery. Lift the vehicle safely. Ensure the vehicle is secure before working underneath it. Identify any electrical connectors that link to any sensors on the Diesel Particulate Filter—disconnect the electrical connectors an ensure wires are completely free. Carefully remove any sensors and protect from damage until refitted. Loosen all retaining nuts and bolts that secure the Diesel Particulate Filter to the vehicle and other exhaust components. Any rusted or seized fittings may require application of penetrating oil or heat to ease removal. Ensure appropriate safety measures are undertaken when using naked flame heat sources. Remove all nuts and bolts and remove the Diesel Particulate Filter— assistance may be required if the unit is large and heavy.
RE-FITMENT Ensure all mating surfaces are clean and contaminant free. Always use a new fitting kit, ensure the nuts and bolts are used. DO NOT APPLY SEALANT OR EXHAUST PASTE! Doing so will damage your replacement Diesel Particulate Filter and invalidate your warranty. Refit the replacement Diesel Particulate Filter using a new fitting kit but do not fully tighten nuts and bolts. Re-install any sensors removed from the original unit—do not tighten fully. Inspect the areas around the replacement Diesel Particulate Filter and ensure there is no possibility of contact with the vehicle floor or other components. Fully tighten all nuts, bolts and sensors—take care not to over-tighten sensors. Ensure all sensor cables are secure and not in contact with the exhaust system. Lower the vehicle, start the engine and inspect the leakage. You may need to lift the vehicle for inspection access. Ensure any associated fault codes are cleared from the ECU. Perform a forced regeneration and update the ECU accordingly
1. The warranty terms for our Cooper DPF’s are 2 years or 40,000 kilometers. 2. DPF’s are only covered for structural failure. 3. A blocked DPF is not a warranty as the problem originates upstream of the DPF. 4. When the DPF light illuminates you must follow the instructions in the owners hand book, failure to comply could result in a blocked DPF. 5. Active DPF’s that use an additive to assist in regeneration must never be driven without this fluid, as this could result in a blocked DPF. 6. It is not advisable to run a DPF vehicle on Bio-Diesel. 7. When fitting a new active DPF the control unit must be readapted to the new DPF. 8. Regeneration will not take place when the fuel light is on, or with less than 20 litres of fuel in the tank. 9. Cooper DPF's will not be accepted for credit return if fitted to a vehicle, under any circumstances.