Table 45
Troubleshooting Test Steps
Values Results
9. Check for Suction Line Restrictions
A. Disconnect the suction line from DEF pump connection (3) and
DEF tank header connection (5).
B. Inspect the suction line for obstructions.
Possible obstructions are ice, DEF deposits, debris, or kinked lines.
Restrictions Result: An obstruction was found.
Repair: Flush the line with water or low-pressure air or re-
place the suction line.
Proceed to Test Step 12.
Result: An obstruction was not found.
Install the suction line.
Proceed to Test Step 10.
10. Check for a Leaking DEF Injector
A. Turn the keyswitch to the OFF position for 15 minutes.
Note: The keyswitch must be OFF until the “Wait to Disconnect”
lamp switches off to allow the DEF pump to purge, reset the code,
and reset the Diesel Exhaust Fluid Controller (DCU).
B. Remove the injector from the Clean Emissions Module (CEM).
Make sure the DEF, and electrical lines are still connected.
C. Insert the DEF injector into Tooling (A).
D. Turn the keyswitch to the ON position. Do not start the engine.
E. Connect to the electronic service tool.
F. Perform the “DEF Dosing System Verification Test” to pressurize
the system and inspect the injector for leakage.
Leakage Result: DEF is leaking from the DEF injector nozzle.
Repair: Replace the DEF injector. Proceed to Test Step
12.
Result: DEF is not leaking from the DEF injector nozzle.
Proceed to Test Step 11.
11. Flush DEF Tank and Replace the DEF Tank Header Filter
A. Carry out a diesel exhaust fluid tank flush. Refer to Operation
and Maintenance Manual, Diesel Exhaust Fluid Tank - Flush.
B. Replace the DEF tank header filters. Refer to Disassembly and
Assembly, Manifold (DEF Heater) - Remove and Install.
DEF tank
header
Result: The DEF tank has been flushed and the DEF tank
header filters have been replaced.
Proceed to Test Step 12.
12. Perform an Aftertreatment System Functional Test
A. Start the engine.
B. Connect to the electronic service tool.
C. Perform the “Aftertreatment System Functional Test” .
Test
successful
Result: The test is successful.
Return the unit to service.
Result: The test is not successful. There are more codes.
Repair: Troubleshoot the additional codes. Confirm that
the fault has been eliminated.
If the fault is still present, contact the Dealer Solutions Net-
work (DSN).
UENR4469-36 111
Symptom Troubleshooting
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