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Zetti DPF Tool & The DPF Regeneration Process

The Zetti diagnostic tool can perform static regenerations as well as diagnose DPF faults. This hand held DPF Tool simply plugs into the vehicles diagnostic connector and can be used to diagnose codes, carry out the all important forced regeneration and even zero the DPF after replacement.

Zetti DPF Tool

– Push button operation

– Regenerates Diesel Particulate Filters

– Resets ECU when fitting new DPF

– Covers most DPFs in the Zetti range

– DPF fault code identification

– Resets EOLYS additive lights

– Handheld

– Supports vehicles from 2000 on

– No need to send cars away to the dealer

– Updates available for all new Zetti DPFs

– Download the latest vehicle updates straight to the device*

Covering major manufacturers and more:

dpftool_manufacturer

Modern diesel vehicles are fitted with complex anti-pollution systems. These systems require servicing and resetting which can only be completed via diagnostics. The Zetti DPF tool allows you to carry out numerous functions on the Diesel Particulate Filter system without having to send the car to a main dealer. The tool will reset the DPF light after the filter has been replaced, reset the additive level after it has been topped up, and burn off collected particles when a maximum fill level is reached by performing a static regeneration. It is only necessary to replace the DPF when this process breaks down and the filter becomes irreversibly clogged. The Zetti DPF reset tool covers the majority of our range of Diesel Particulate Filters.

*It is only necessary to replace the DPF when the filter becomes irreversibly blocked.

The DPF Regeneration Process

Engine-Warning-Light

Dependent on the vehicle a DPF may either need to be regenerated by one of the following methods:
Passive Regeneration: 

The DPF is constantly cleaned through a catalyst process when the vehicle is driven at a certain speed or length of time.

Active Regeneration: 

When the DPF reaches a predetermined level (usually 45% capacity) the ECU will make small adjustments to the fuel injection timing system to increase exhaust temperature to initiate the regeneration process. In order to reach this temperature the vehicle must be driven for a certain time period at a minimum speed. If frequent stop start driving takes place the opportunity does not exist for the vehicle to regenerate the DPF. In this case a warning light will illuminate on the dash to advise the DPF is partially full. The vehicle will need to be taken for a long drive to regenerate the DPF. If the DPF becomes to full to perform a regeneration on its own the DPF will have to undergo a “static” regeneration with the use of specialized diagnostic equipment. When a DPF becomes 90% it is no longer able to be regenerated and will have to be replaced.

Active Regeneration with additives: 

As per Active Regeneration but with the aid of an additive (EOLYS™) which is injected into the exhaust to lower the temperature required to perform the regeneration. Most commonly found in Peugeot and Citroën vehicles.

Regeneration will not take place when:

– The fuel light is on, or there is less than 20 litres of fuel in the tank.

– The ‘check engine’ light is on.

– Your foot is resting on the clutch pedal.

– DPF failure can be due to:

– Poor engine maintenance

– Malfunctioning pressure sensor/pipes (condensation in the pipes)

– Faulty temperature sensors

– Incorrect oil temperature

– Faulty EGR valve

– Damaged exhaust system

– Corrosion/fractures

– Incorrect fuel

– Short runs (lack of temperature)

What is a DPF and What to check when replacing.

What is a Diesel Particulate Filter (DPF) ?

A Diesel Particulate Filter (DPF) is a device designed to remove diesel particulate matter or soot from the exhaust. Unlike a Catalytic Converter, a DPF is not a flow through device. Exhaust gases are cleaned by passing through the walls of the DPF leaving particulate matter to accumulate on the inlet face of the DPF. Once the DPF reaches a certain level it must be cleaned. Through filter “regeneration” these soot particles are burnt off at high temperatures.

DPF-internal-diagram

Advice for DPF care

– When the DPF warning light illuminates you must follow the instructions in the owners manual immediately. Failure to comply could lead to a blocked DPF.

– Active DPF’s that use an additive fluid to assist in the regeneration process must never be driven without this fluid, as this could lead to a blocked DPF.

– When fitting a new active DPF or topping up the additive, the control unit must be reset to New DPF / Refilled Additive. (See Zetti DPF Tool section)

biodiesel

– It is not advisable to run a DPF vehicle on biodiesel.

– Always check the engine oil for diesel contamination, which can occur during the regeneration process. If the oil is contaminated then the engine oil and filter must be replaced.

What to check when replacing the DPF

Follow these steps when replacing a DPF:
  1. Ensure the root cause of the problem is rectified before replacing a DPF
  2. Use new mounting brackets
  3. Line up the DPF perfectly to avoid vibrations or anomalies in exhaust pressure
  4. Don’t hit the DPF with hammers or other rigid tools to avoid the monolith from breaking
  5. Do not use exhaust paste on the DPF
  6. Replace the engine oil of the vehicle
  7. Update the engine management software to tell the vehicle it has a new DPF fitted. (See Zetti DPF Tool article)

What is a Catalytic Converter and What to know when replacing.

What is a Catalytic Converter & How does it work?

Introduced to Australian motor vehicles in 1986, Catalytic Converters were fitted to unleaded petrol vehicles to clean up the noxious exhaust gases produced during operation. The role of the Catalytic Converter is to control the harmful emissions from the combustion process by converting the Hydrocarbons (HC), Nitrogen Oxides (NOx) and Carbon Monoxide (CO) into Carbon Dioxide (CO2), Nitrogen (N2) and Water Vapour (H2O).

cat-diagram

The Catalytic Converter is designed to last the lifetime of the vehicle, but this is not always the case.** The premature failure of the Catalytic Converter could be attributed to poor tuning of the vehicles ignition, not servicing the vehicle at regular intervals, road impact damage, driving through deep water or using non-compatible fuels and additives. These conditions need to be avoided by the owner of the vehicle.

* Not all cats are designed with heat shields.
** Different materials used in the manufacturers construction process may attribute to shorter life span of the cat.

Replacing the Catalytic Converter… What you need to know.

1 – Ensure any engine or emission faults are rectified before replacing the catalytic converter. Failure to correct a pre-existing emissions problem could result in a damaged catalytic converter.

2 – It is recommended to replace the Oxygen Sensor when the Catalytic Converter is replaced. For correct operation of the engine and Catalytic Converter, the vehicle must be fitted with an Oxygen Sensor. When combustion gases are flowing through the exhaust, they are picked up by the Oxygen Sensor and a signal is sent back to the ECU. This signal then helps to control the air/fuel mixture entering the combustion chambers for a better ‘burn’.

gasket-stud-nut-oxysensor

3 – Always use new mountings, gaskets and bolts to avoid leakage or fitment issues. This will ensure the correct fitment first time around. Always recommend new studs, bolts and nuts when replacing any part of the exhaust system.

4 – When replacing a Catalytic Converter it is essential to examine the complete exhaust system from the manifold to the tail pipe for damage, corrosion or leaking/blowing. Repair or replace as required. A simple test is to have the vehicle running at idle whilst on the hoist. Use a shop rag to block the tailpipe (without burning your hand) and listen for any exhaust leaks in the system. Two people will be required for a closer inspection of any joins/pipes. The use of a vapour or smoke machine will accuarately locate any exhaust leaks.

5 – After replacing the cat converter be sure to run the vehicle at 2500rpm until the electric fans kick in. Then run the vehicle for a further 1 minute until the new catalytic converter temperature reaches 350˚C to ensure it is lighting off and functioning properly .

6 – Do not use exhaust sealant upstream of the Catalytic Converter. This can be a fatal move when working on the exhaust system. Sealants can contain ingredients that will harm the operation of the Catalytic Converter and also damage the Oxygen Sensor.