Diesel Emissions Fluid Pump: Service and Repair

Emission Reduction Fluid Supply Pump Module Replacement

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 (Gasoline) ProceduresFuel Tank Draining (Emission Reduction Fluid) Procedures.

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

Disassembly Procedure




1. Remove the DEF supply pump module shield (1).




2. Remove the DEF supply pump module insulators (1).

3. Note the routing of the DEF wiring jumper harness.




4. Disconnect the DEF wiring jumper harness connectors from the pump (1), pressure sensor (2), and reverting valve (3).




5. Remove the 3 DEF supply pump module retaining bolts (1).

6. Carefully lift the DEF supply pump module (2) to remove from the reservoir cover.




7. 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.

8. Wipe away any dried DEF crystallization residue from the reservoir cover supply pump ports (2).

Installation Procedure




1. 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.





Caution: Refer to Fastener Caution Fastener Caution.

2. Position the supply pump module (2) onto the reservoir cover and carefully press down into place.

3. Install the 3 supply pump module retaining bolts (1), and tighten the bolts to 5 Nm (3.7 lb in).




4. Connect the DEF wiring jumper harness connectors to the pump (1), pressure sensor (2), and reverting valve (3).




5. Install the DEF supply pump module insulators (1).




6. Install the DEF supply pump module shield (1).

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

8. Fill the DEF tank with approved DEF fluid.

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