Emission Reduction Fluid Tank Reservoir Replacement

Emission Reduction Fluid Tank Reservoir Replacement

Special Tools

CH-38879-B - Fuel Pump Module Wrench

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 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.

3. Place the DEF tank assembly in a suitable, clean work area.

4. Remove the DEF tank supply pump module. Refer to Emission Reduction Fluid Supply Pump Module Replacement Service and Repair.

Disassembly Procedure




1. Disconnect the DEF wiring jumper harness connectors from the control module assembly (1), and from the reservoir heater connector (2).




2. Release the jumper harness retaining clips from the supply module lock ring (2). Release the clip retaining tab (1) and slide the clip upward to remove.

3. Remove the jumper harness.




4. Release the reservoir heater connector (1) from the retainer on the DEF tank. Carefully depress the lock tab (2) of the tank retainer, while sliding the connector forward.




5. Release the control module assembly (1) from the retainer on the DEF tank. Carefully depress the lock tab (2) on the underside of the control module, while sliding the module sideways away from the supply pump.




6. Carefully remove & discard the supply pump to reservoir cover o-ring seals (1). The seals will typically remain in the reservoir cover, but may be on the underside of the supply pump.

7. Wipe away any dried DEF crystallization residue from the reservoir cover supply pump.




8. Rotate the reservoir vent (1) inward.




9. Position the CH-38879-B - Fuel Pump Module Wrench (3), DEF supply pump module wrench, onto the supply module lock ring (4). Ensure the posts of the tool are positioned to fit securely onto opposing ribs of the lock ring.

10. Plug the reservoir cover to supply pump ports (1,2) to protect from dirt & debris.

11. Using a breaker bar attached to CH-38879-B - Fuel Pump Module Wrench loosen the lock ring. Reposition CH-38879-B - Fuel Pump Module Wrench as necessary to prevent damage to the reservoir level sensor and heater wiring.

12. Carefully remove the lock ring over the reservoir wiring.





Note: IF a prying tool is needed, use a rag on the tool to prevent damage to the cover, seal, and tank.

13. Carefully lift the reservoir cover (1) up just enough to free it from the seal (2).




14. Carefully work the reservoir seal (1) up and out of the neck of the DEF tank.




15. Carefully remove the seal (1) from around the reservoir cover and the reservoir wiring.




16. Using finger pressure only to rotate the reservoir assembly, position fingers against the level sensor bulkhead (1) and the ledge opposite the bulkhead (2).




17. Rotate the reservoir assembly (1) counterclockwise to release the lock tabs (2) at the bottom of the DEF tank, then lift the reservoir (3) out of the tank.




18. If the reservoir assembly is to be reused, inspect the DEF filter (1) at the bottom of the reservoir for damage, and for dirt and debris, other than dried DEF crystallization residue.

19. To remove dried DEF crystallization residue, use only a Low pressure clean water hose to spray the applicable surfaces of the reservoir assembly. Dried DEF crystallization residue will flush away with clean water.

20. Replace the DEF filter as necessary.




21. Wipe away any dried DEF crystallization residue from the tank seal.

22. Inspect the lower portion of the tank seal for deformity; taking a deeper set shape to the reservoir step (1), rather than returning to a mild shape for the reservoir step (1). Replace the seal if it is deformed.




23. Inspect the bottom of the DEF tank (1) for the presence of dirt and debris, and dried DEF crystallization residue.

24. If dirt and debris - other than dried DEF crystallization - are present inside the DEF tank, and if the reservoir is to be reused, replace the DEF filter at the bottom of the reservoir.

25. If dirt, debris, and/or dried DEF crystallization residue are present inside the DEF tank; using only a Low pressure clean water hose, spray the applicable surfaces inside the DEF tank. Dried DEF crystallization residue will flush away with clean water.




26. Using a suitable Clean, blunt object, carefully depress and hold open, the flapper valve (1) at the back of the DEF tank fill port.

27. While keeping the fill port open, pour out the contents of the tank into a suitable container for disposal.

28. Repeat steps 25-27 until the inside of the DEF tank is free of dirt, debris, and/or dried DEF crystallization residue.

Assembly Procedure




1. Align the reservoir lock tabs (1) to the reservoir retainer at the bottom of the DEF tank, and carefully lower the reservoir (2) into position.




2. Using finger pressure only to rotate the reservoir assembly, position fingers against the level sensor bulkhead (1) and the ledge opposite the bulkhead (2).




3. Rotate the reservoir clockwise to secure the lock tabs (1) at the bottom of the DEF tank. An audible "click" noise will be heard when the lock position is reached.




4. Carefully slide the seal (1) over the reservoir wiring and around the reservoir cover.




5. Carefully work the reservoir seal (1) down into the neck of the DEF tank, while simultaneously working the seal lower lip around the outside of the reservoir.




6. Inspect to ensure the seal is fully seated and to ensure the lower lip of the seal (1) is positioned correctly around the outside of the reservoir (2).




7. Carefully position the reservoir cover (1) to the tank seal (2).




8. Position the reservoir cover so that the cover alignment mark arrow (1) will be centered between the 2 long alignment marks (2) on the top of the tank.




9. Carefully slide the lock ring over the reservoir wiring.

10. Remove the plugs from the supply ports (1,2).

11. Hand tighten the reservoir lock ring only until snug.

12. Position the CH-38879-B - Fuel Pump Module Wrench (3), DEF supply pump module wrench, onto the supply module lock ring (4). Ensure the posts of the tool are positioned to fit securely onto opposing ribs of the lock ring.

13. Using a torque wrench attached to CH-38879-B - Fuel Pump Module Wrench tighten the lock ring. Reposition CH-38879-B - Fuel Pump Module Wrench as necessary to prevent damage to the reservoir level sensor and heater wiring. Tighten the lock ring to 85 Nm (63 lb ft).




14. Rotate the reservoir vent (1) outward.




15. Carefully install the new supply pump to reservoir cover o-ring seals. Position the smaller o-ring seal (1) over the port on the underside of the supply pump, and position the larger o-ring seal (2) into the port on the reservoir cover.

16. Install the DEF tank supply pump module. Refer to Emission Reduction Fluid Supply Pump Module Replacement Service and Repair.




17. Align the control module assembly (1) retaining slots to the mating slots on the retainer. Slide the module sideways toward the pump to secure the lock tab (2) on the underside of the module.




18. Align the reservoir heater connector (1) retaining slots to the mating slots on the retainer. Slide the connector into place to secure the lock tab (2) of the tank retainer.




19. Install the DEF wiring jumper harness into position as noted prior to removal.

20. Secure the jumper harness retaining clips to the supply module lock ring in the locations noted prior to removal. Slide the clip (2) downward to secure the clip retaining tab (1).




21. Connect the DEF wiring jumper harness connectors to the pump (1), pressure sensor (2), reverting valve (3), control module assembly (4), and to the reservoir heater connector (5).

Installation Procedure




1. Install the DEF tank (1). Refer to Emission Reduction Fluid Tank Replacement Emission Reduction Fluid Tank Replacement.

2. Install the DEF line (2).

3. Fill the DEF tank with approved DEF fluid.

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