Emission Reduction Fluid Tank Replacement
Emission Reduction Fluid Tank Replacement
Removal Procedure
Caution: The diesel exhaust fluid (DEF) system is part of the emission system for this vehicle, and must be serviced while observing extreme care to prevent foreign contamination of any kind from entering this system. If extreme care is NOT taken to prevent contamination from dirt, debris, fluids other than DEF, etc., reduced performance and/or damage to the DEF system may result.
* Cleanliness of the diesel exhaust fluid (DEF) system is crucial to ensure proper operation. Before opening any part of the DEF system, ensure connections and joints are thoroughly clean and dry of any dirt, debris, or other contaminants. Use only low pressure water and low pressure air, as directed.
* Diesel exhaust fluid (DEF) will have a tendency over time to develop areas of dried crystallization residue. Crystallization residue is a normal process for this fluid. Dried DEF crystallization residue can be wiped away, or flushed away with clean water, depending on location of the crystallization.
1. Ensure the ignition is OFF.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
3. Using only a Low pressure clean water hose, spray the upper surfaces of the Diesel Exhaust Fluid (DEF) Tank and pump supply module, the injection hose, and the fill hose assembly, to remove all dirt and debris.
4. 4. Using only a Low pressure air wand or air gun, direct air along the same surfaces to both dry and remove any further contaminants.
5. 5. Using a clean white shop towel, carefully dry connections and joints by hand to ensure dryness and cleanliness.
6. Drain the emission reduction fluid tank.
7. Disconnect the filler pipe and vent pipe from the tank. Refer to Emission Reduction Fluid Tank Opening Filler Replacement Emission Reduction Fluid Tank Opening Filler Replacement.
8. Cap both the vent hose and filler hose. Also cap the filler ports to prevent possible contamination.
9. Support the tank with a suitable jack. Remove the fuel tank strap fasteners (1) and remove the tank straps.
Caution: The diesel exhaust fluid (DEF) injection port extends out from the supply pump module directly above a DEF tank strap. Use extreme care when lowering or raising the DEF tank assembly, or damage to the DEF injection port on the supply pump module may result. Also, while lowering the assembly care should be taken to prevent the pressure sensor connector from contacting the truck frame rail.
10. Lower the tank enough to access and disconnect the electrical connectors (1) and the injection hose port (2) by squeezing both sides.
11. Cap both the injection hose fitting and the port of the supply pump.
12. Lower the tank (1) with a suitable tank.
Installation Procedure
1. Install the tank (1) with a suitable tank.
Caution: The diesel exhaust fluid (DEF) injection port extends out from the supply pump module directly above a DEF tank strap. Use extreme care when lowering or raising the DEF tank assembly, or damage to the DEF injection port on the supply pump module may result. Also, while lowering the assembly care should be taken to prevent the pressure sensor connector from contacting the truck frame rail.
2. Raise the tank enough to access and connect the electrical connectors (1) and the injection hose port (2).
3. Remove the caps for the injection hose fitting and the port of the supply pump.
Caution: Refer to Fastener Caution Fastener Caution.
4. Install the fuel tank strap fasteners (1) and tighten to 22 Nm(16 lb ft).
5. In order to clear the DEF lamp, allow the engine to reach normal operating temperature. Drive the vehicle to 32-48 km/h (20-30 mph) until the DEF lamp turns OFF automatically.