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Home >> Ford Truck >> 2011 >> F 250 2WD Super Duty V8-6.7L DSL Turbo >> Repair and Diagnosis >> Powertrain Management >> Emission Control Systems >> Diesel Emissions Fluid (DEF) System >> Diesel Emissions Fluid Tank >> Service and Repair >> Removal and Replacement

Removal and Replacement




Reductant Tank

Removal

All vehicles

1. Drain the reductant tank. For additional information, refer to Reductant Tank Draining Procedures.

2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

3. NOTE: Inboard frame mounted reductant tank filler hose shown, outboard similar.

Detach the reductant tank filler hose cap retaining strap from the reductant tank filler hose.





4. NOTE: Inboard frame mounted reductant tank filler hose shown, outboard similar.

Remove the 3 reductant tank filler hose bolts.





Inboard Frame Mounted Reductant Tank

5. If equipped, remove the fuel tank shield. For additional information, refer to Fuel Tank and Filler Pipe - Exploded View in Fuel Tank and Lines - Gasoline and Diesel Fuel Tank and Filler Pipe - Exploded View.

6. Using a suitable lifting and lowering tool, support the reductant tank.

7. Remove the reductant tank bolt.





8. Remove the 3 reductant tank bolts.





9. NOTICE: Lower the reductant tank slowly. Not following this may damage reductant system components.

NOTE: While lowering the reductant tank, make sure the reductant tank filler hose is positioned loosely between the frame rail and the body panel.

Lower the reductant tank enough to access the reductant tank filler hose connections, electrical connector and reductant pressure line.

10. Disconnect the reductant tank electrical connector.
- Detach the connector pin-type retainer from the bracket.





11. Detach the reductant pressure line routing clip from the bracket.





12. Disconnect the 2 reductant tank filler hoses from the reductant tank.





Outboard Frame Mounted Reductant Tank

NOTE: On some chassis cab vehicles, the outboard frame mounted reductant tank can be mounted on the inboard side of the frame rail.

13. Disconnect the 2 reductant tank filler hoses from the reductant tank.





14. Disconnect the reductant tank electrical connector.
- Detach the connector pin-type retainer from the frame.





All Vehicles

15. NOTICE: Do not use any tools when disconnecting the reductant pressure line. The use of tools may cause a deformity in the clip components which may cause reductant leaks.

NOTE: Disconnect the reductant pressure line before disconnecting the reductant pressure line heater electrical connector.

NOTE: Inboard frame mounted reductant tank pressure line shown, outboard similar.

Disconnect the reductant pressure line from the reductant pump assembly.





16. NOTE: Make sure the reductant pressure line is disconnected from the reductant pump assembly before disconnecting the reductant pressure line heater electrical connector.

NOTE: Inboard frame mounted reductant tank pressure line shown, outboard similar.

Disconnect the reductant pressure line heater electrical connector.





Outboard Frame Mounted Reductant Tank

NOTE: On some chassis cab vehicles, the outboard frame mounted reductant tank can be mounted on the inboard side of the frame rail.

17. Remove the 2 reductant tank strap bolts and remove the straps.





All Vehicles

18. Remove the reductant tank.

Installation

All Vehicles

1. Position the reductant tank.

Outboard Frame Mounted Reductant Tank

NOTE: On some chassis cab vehicles, the outboard frame mounted reductant tank can be mounted on the inboard side of the frame rail.

2. Install the 2 reductant tank straps and 2 bolts.
- Tighten to 40 Nm (30 lb-ft).





All Vehicles

3. NOTE: Inboard frame mounted reductant tank pressure line shown, outboard similar.

Connect the reductant pressure line heater electrical connector.





4. NOTE: Inboard frame mounted reductant tank pressure line shown, outboard similar.

Connect the reductant pressure line to the reductant pump assembly.





Inboard Frame Mounted Reductant Tank

5. Connect the 2 reductant tank filler hoses to the reductant tank.





6. Attach the reductant pressure line routing clip to the bracket.





7. Connect the reductant tank electrical connector.
- Attach the connector pin-type retainer to the bracket.





8. Raise the reductant tank into the vehicle.

9. Loosely install the 3 reductant tank bolts.





10. Install the reductant tank bolt.
- Tighten to 20 Nm (177 lb-in).





11. Tighten the 3 reductant tank bolts.
- Tighten to 20 Nm (177 lb-in).





12. If equipped, install the fuel tank shield. For additional information, refer to Fuel Tank and Filler Pipe - Exploded View in Fuel Tank and Lines - Gasoline and Diesel Fuel Tank and Filler Pipe - Exploded View.

All Vehicles

13. NOTE: Inboard frame mounted reductant tank filler hose shown, outboard similar.

Install the 3 reductant tank filler hose bolts.





14. NOTE: Inboard frame mounted reductant tank filler hose shown, outboard similar.

Attach the reductant tank filler hose cap retaining strap to the reductant tank filler hose.





Outboard Frame Mounted Reductant Tank

15. Connect the reductant tank electrical connector.
- Attach the connector pin-type retainer to the frame.





16. Connect the 2 reductant tank filler hoses to the reductant tank.





All Vehicles

17. NOTICE: Always refill the reductant tank with new reductant to avoid reductant system contamination.

Fill the reductant tank.

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