Regen issues international

Everyone has regen issues. You should not see smoke coming out. DPF lights will come on as indictors to the status of your system. Instructions on what to do are on the back of the sun visor and more detail should be in your owners manual. What kind of smoke are you seeing, what colour is it? Are you seeing it when driving at highway speeds, or during a parked regen? Some white-ish smoke may only be steam/condensation and therefore, normal.

 

It sounds like your DPF may need service. If you had two coolers done, I bet your engine was using coolant, and therefore burning it. The DPF can only take so much of that contamination before it starts to plug up and possibly crack. How many miles are on the truck? You may be due for a DOC and DPF cleaning. You shouldn't have to do two parked regens in a single day. The DPF is plugging up faster because the soot trapped in it isn't being properly burnt into ash. There are several causes of this from faulting sensor, partially plugged components and even corrupted ECM calibrations. Not all dealers have good techs that know how to properly dig into these problems. Some trucks end up over fueling due to plugged up boost sensors or mass air flow sensor improperly reading. These are all things that the dealer must look at unfortunately. I know it is frustrating as these problems tend to come and go. Hopefully someone can look at it again for you.

 

Diesel Oxidation Catalyst. This what makes the exhaust temps high enough to burn the collected soot into ash. The DOC is a separate section bolted together with the DPF. The exhaust flows through the DOC first. If the DOC is partially plugged or damaged you will have improper regens as the temps and exhaust flow through it will be below desired. They should be taking them out and getting a look at them to see if there is anything wrong.

 

The white smoke is hydrocarbon slip. The fuel being injected into the aft. system is not being oxidized effectively to regenerate effectively. The doser needs to be pulled and checked. If it hasnt been done the new gasket for it needs to be installed. The pre doc needs to be inspected and make sure its not face plugged or has a hole melted in it. Same goes for the DOC and dpf. Check for boost leaks and the 02 sensor and ebp and dpf tubes should be cleaned and the 02 sensor should be calibrated. I've done this to 3 units so far in the last week for regen complaints on these engines.