Emission Reduction Fluid Leak Test

Emission Reduction Fluid Leak Test

Special Tools

* EN-41413-300 - Cap And Plug Kit - EVAP

* EN-48974 - Supercharger Cooler Pressure Tester Adapter Set

* EN-46091-1 - Intercooler Tester

Cleaning 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 (1) and pump supply module, the injection hose, and the fill hose assembly, to remove all dirt and debris.

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. Using a clean white shop towel, carefully dry connections and joints by hand to ensure dryness and cleanliness.

Removal Procedure

1. Drain the emission reduction fluid tank. Refer to Fuel Tank Draining ProceduresFuel Tank Draining (Emission Reduction Fluid) Procedures.

2. Remove the DEF tank. Refer to Emission Reduction Fluid Tank Replacement Emission Reduction Fluid Tank Replacement.

Leak Test Procedure




1. Remove the vent covers (1) on the supply module and tank.




2. Cap off the fill port (1) with EN-41413-308 - Cap and secure with a hose clamp.

3. Cap off the fill vent port (2) with the medium sized cap from EN-48974-20 - Supercharger Cooler Pressure Tester Adapter , the supply module vent (3) with EN-41413-306 - Cap , and the pump port (4) with EN-41413-307 - Cap.

4. Attach the smaller diameter hose from EN-48974-20 - Supercharger Cooler Pressure Tester Adapter adapter set to the tank vent (5) with a hose clamp.

5. Make sure the EN-46091-1 - Intercooler Tester is in the off position and attach it to shop air.

6. Pressurize the EN-46091-1 - Intercooler Tester to 5 psi.

7. Switch off the EN-46091-1 - Intercooler Tester.

8. Attach the EN-46091-1 - Intercooler Tester to the EN-48974-20 - Supercharger Cooler Pressure Tester Adapter hose on the DEF tank.




9. Switch the EN-46091-1 - Intercooler Tester (1) on to pressurize the tank. Make sure it is reading 5 psi.

10. Let it set for 10 min.

11. Check to see if there has been any pressure drop.

12. If there is a pressure drop, check for leaks in the seals, supply pump module, and DEF tank.

13. Repair the leak using the appropriate service parts and procedures and re-test for leaks.

Installation Procedure

1. Remove the clamps, caps, hose, and pressure regulator assembly.




2. Re-install the vent covers (1).

3. Install the DEF tank. Refer to Emission Reduction Fluid Tank Replacement Emission Reduction Fluid Tank Replacement.

4. Fill the DEF tank with approved DEF fluid.

5. With system operational, inspect for DEF fluid leaks.