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DPF modification instruction

This instruction explains the modification procedure.
It is the modification from the previous type to the new type.
The previous type: DPF muffler one flange type
The new type: DPF muffler two flange type

Outline of modification procedure Reference Page

1. Replace DPF muffler (together with DPF heater) 2
2. Remove parts to be scrapped 4
(Change the installing position of radiator reserve tank) 6
3. Assemble pressure sensing pipe and hose 9
4. Replace DPF controller (ECU) 13

1. Replace DPF muffler (together with DPF heater)

Previous DPF muffler (One flange type)

1-1. Removal Procedure

1) Remove the radiator cover. 2) Remove the counter-weight.
3) Open the engine hood, and disconnect the heater and temperature sensor connector.
4) Cut the tie-wrap and pull the heater and temperature sensor harness out
toward the rear side of the vehicle.
5) Disconnect the exhaust pipe from the muffler. *
6) Remove the DPF muffler ASSY.

1-2. Installation Procedure

The installation procedure is the reverse of the removal procedure. **

Note:
* Replace the gasket between the muffler and exhaust pipe with a new one.
** When the muffler ASSY is replaced, clear the DPF filter memory. (When DPF controller is
replaced at the same time, clearing memory is not necessary.)
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1-3. DPF muffler assembling procedure 7FDF15-J35 series
7FDF15-J35
Nut (16pcs) Spring washer (16pcs) Bolt (16pcs)

Outlet cap Jacket Assy Heater Assy

(see parts # (see parts # (see parts #
table below) table below) table below)

Gasket

Match with

Bolt tightening order

Tightening torque; 12 to 15Nm

Muffler parts # list

Common between 1DZ and 2Z

７FDF15-18 7FDF20-25 7FDF30-J35

Heater Assy (Inlet) 17510-33251-71

Jacket Assy 17520-33240-71
Outlet STD 17508-33250-71
cap Upswept muffler 17509-23360-71 17509-33250-71 17509-33280-71

Match marks
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7FD35-A50 series
7FD35-A50
Nut (16pcs) Spring washer (16pcs) Bolt (16pcs)

Outlet cap Heater Assy

(see parts # Jacket Assy (see parts #
table below) (see parts # table
table below)
Gasket (2pcs)

Match with

Bolt tightening order

Tightening torque; 12 to 15Nm

Muffler parts # list

7FD35 ７FD40-A50
Heater Assy (Inlet) 15510-30561-71
Jacket Assy 17520-33240-71
Outlet STD 17508-30550-71
cap Upswept muffler 17509-30550-71 17509-30560-71
 4/13

2. Remove parts to be scrapped

2-1. DPF valve fitting

In case of the truck with the DPF valve fitting with pipe branch,
replace the fitting with no pipe branch.

DPF valve

Remove this fitting

Pipe branch on

Fitting (with no pipe branch)

To blower sensor 17573-23440-71

Note:
Put sealing agent or wind sealing
tape on the thread portion
Arrow Tightening torque: 49Nm
Note:
Arrow directs to Blower sensor
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2-2. Back pressure sensing pipe and hose
In case of the truck with the DPF valve bracket with stainless pipe,
remove the following parts (A) to (G) shown below, then scrap those.

(A) Back pressure sensor

(B) Stainless pipe

(C) Hose

(D) Hose

(E) Inline filter

(B) Stainless
(F) Hose pipe

7FDF15-J35

(F) Hose
7FD35-A50

Stainless pipe
(G)
(G)

Exhaust pipe
7FDF15-J35 7FD35-A50
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2-3. Radiator reserve tank

1) In case of the truck which has the reserve tank at RH pillar side,
remove and scrap the reserve tank and tank bracket

Reserve tank bracket

7FDF15-J35 7FD35-A50

Note: Clamp for hydraulic cooler hose is re-used on 7FD35-A50 series.

2) Change the installing position of the reserve tank

In case of the 7FDF15-J35 truck with one battery, install it to LH pillar side.

7FDF15-J35
To reserve Clamp
tank 90464-00308

To radiator Bolt
91611-40820

Locate hose not to

be interfered with

Reserve tank
Reserve tank bracket
16470-23470-71 16507-13311-71: 7FDF15-18
16507-23320-71: 7FDF20-J35

<Note>
When rubber hose is fixed by clamp,
do not choke hose by excessive tight clamping.
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In case of 7FD35-A50 and the truck with two batteries in 7FDF20-J35,
install it on the hydraulic oil tank.

Hose
16581-23350-71
Bracket
16572-23350-71 for 7FDF20-J35
16572-30510-71 for 7FD35-A50
Reserve tank
16470-30510-71

Tank bracket
Clamp
16506-23351-71
47338-13500-71
for 7FDF20-J35
Bolt, dry lock
Knob
67419-23000-71
51875-12240-71
2pcs
Clamp
Washer, plate 16791-23320-71
Bolt, W/washer
94612-10800
91611-40814, 2 pcs

E ring
96160-00700
Bracket
16507-23350-71

The overflow hose passes Clamp

through, above radiator hose 47338-13500-71, 2pcs
and under the air cleaner
Radiator
hose.
It is fixed by tie-wrap with the
air cleaner hose.
Tie-wrap（Clamp）:
90464-00345

Air

Reserve tank

Clamp (for 7FD35-A50)

56319-73600-71
<Note>
When rubber hose is fixed by clamp,
do not choke hose by excessive tight clamping.
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2-4. Change the wiring installing way at RH pillar
This is only for the truck which the reserve tank position is changed in 7FDF15-J35.
In case of 7FD35-A50, it is not necessary.

7FDF15-J35 Connected to back buzzer

Harness passes above the air
hose to air cleaner

Clamp
56121-20051-71
In case of the truck with intake air muffler, fix the
Bolt clamp by bolt together with air muffler.
91611-40816
connecter to air cleaner
vacuum switch

Adjust the harness installation not to be

applied excessive tension to the connector
Harness routes between the pillar harness for air cleaner vacuum switch.
and the plate for pillar cover.

View from front View from top

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3. Assemble pressure sensing pipe and hose

7FDF15-18

Harness bracket Assembled

56207-13351-71

Sensing pipe
17408-13350-71

Bolt, 2pcs Back buzzer

91611-40816
Hose To DPF muffler
95411-

Harness bracket 7FDF20-J35

"This is re-used part"

Back buzzer

Sensing pipe
17408-23440-71

Hose
Bolt, 2pcs 95411-10024 for 7FDF20-25
91611-40816 95411-10030 for 7FDF30-
J35
To DPF muffler
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7FD35-A50

Sensing pipe is fixed

with exhaust pipe
This bolt is
re-used

Clamp bracket To DPF

67905-30520- muffler

Hose
Bolt
95411-10019 for 7FD35
91651-40816
The clamp for hydraulic 95411-10030 for 7FD40- A50
cooler hose is re-used
Sensing pipe
17408-30520-71
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7FDF15-J35 In case of 2Z;

Note; "DENSO" mark should
Clamp (put on harness to
face to back pressure sensor.
alternator)

Back pressure sensor (Use new

part)

Alternator
Air cleaner

Hose In case of 1DZ;

95411-10048 Clamp (put on Hose)
23635-12620-71

Inline filter (Use new part)

17610-23670-71

Clamp Hose
23635-12620-71 95411-10007

Hose for 2Z
17937-23440-71
Hose for 1DZ
17937-23360-71

Exhaust pipe
Clamp is re-used
Insert the pipe to the hose until Sensing pipe
the marking is covered half.
Point;
Install sensing hose without sag and
interference

No good

1DZ engine truck

"DENSO" mark

1DZ engine truck 2Z engine truck

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7FD35-A50

Back pressure sensor Hose routes under air cleaner

(Use new part)
17550-23440-71
Air cleaner 7FD35:
Clamp is put on
cooler hose No.1
Hose 7FD40-A50 :
95411-10048 Clamp is put on
cooler hose No.2
Inline filter (Use new part)
17610-23670-71
See Note below
Hose 95411-10007
Cooler Clamp bracket
hose 67905-30520-71
Clamp 2pcs
23635-12620-71

Cooler
Hose
hose Sensing
17937-30520-71
i
Exhaust
Clamp is re-used
Clamp is re-used
Insert the pipe to the hose until the
marking is covered half.

Point; Install sensing hose without sag and interference

(If required, cut the hose in length) To back
pressure
No good Inline filter sensor

Note; "DENSO" mark should face to

back pressure sensor.
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4. Replace DPF controller (ECU)

Note:
Since the two wires from the controller to the outlet are both black,
put tags showing the connecting positions.

4-1. Removal Procedure

1) Open the engine hood, and disconnect the battery negative terminal.
2) Remove the step.
3) Remove the bracket set bolts.
4) Disconnect the wiring from the controller to the outlet.
5) Disconnect the controller connector.
6) Remove the controller ASSY.

4-2. Installation Procedure

1) Install the controller ASSY
24620-23365-71
1DZ
(24620-23364-71)
24620-23445-71
2Z
(24620-23444-71)
24620-30524-71
13Z
(24620-30523-71)

2) The installation procedure is the reverse of the removal procedure.

3) Replace AC voltage sticker label on step cover.

(= caution plate 57822-23440-71)

Note:
When the controller is replaced, turn the ignition switch ON and check no error occurrence.