DIESEL EXHAUST FLUID

Reference Book February 2010

DIESEL EXHAUST FLUID

The 3500 series Dodge chassis cab truck was introduced to dealerships in January 2007 as a blank canvas to attach up-fitter options such as flatbeds, towing accessories, and work site equipment packages. The emissions system for the 2007 truck was updated to the changing emissions standards to include emissions monitoring. With additional equipment such as a catalytic converter, diesel particulate filter, and an EGR valve and cooler, technicians were introduced to additional diagnostics and test procedures to keep the systems operating as efficiently as possible. The emissions standards are changing, and Dodge and Cummins are meeting the challenge head on with the introduction of the diesel exhaust fluid (DEF) system available on 3500, 4500, and 5500 series chassis cab trucks released in early 2010.

Figure 1: 2007 Cummins Cab Chassis Engine

February Contents
Why DEF? ............................................................................ 1 DEF Components .................................................................. 2 DEF Operation ...................................................................... 4 DEF Diagnosis ...................................................................... 5

Figure 2: 2007 Cummins Pick-up Truck Engine

February 2010 Master Tech Reference Book

WHY DEF?

In 2007, with the introduction of the diesel particulate filter, the regeneration process, and EGR system, the emissions standards went from 2.5 grams per brake horsepower of oxides of nitrogen (NOx) plus non-methane hydrocarbons (NMHC) to 1.2 grams. The emissions standards for 2010 state that all new diesel engines emit no more than 0.5 grams per brake horsepower of NOx plus NMHC.

Dodge dealers will carry the fluid, as will most truck stops and some other outlets. DEF is required to maintain proper operation of many diesel-powered vehicles, including heavy trucks, starting in 2010.

Figure 4: Diesel Exhaust Fluid

Figure 3: Diesel Emissions Ultra-low sulfur diesel fuel and the benefits of proper vehicle maintenance were also introduced to reduce emissions. To achieve the reduction from 1.2 grams per brake horsepower of NOx plus NMHC to 0.5 grams, additional components are needed to further treat the exhaust gases leaving the engine. To treat the exhaust gasses, a diesel exhaust fluid is injected into the exhaust system after the particulate filter. The diesel exhaust fluid causes a selective catalytic reduction (SCR) process to take place in the DEF system. Mopar diesel exhaust fluid is a 32.5% urea water solution that must meet ISO 22241 standards for diesel exhaust fluid. Non-Mopar diesel exhaust fluid must carry the American Petroleum Institute (API) certification for DEF. The fluid freezes at -11C (12F) and is very corrosive to metals and paints. DEF, which is a solution of water and urea, is then converted to ammonia by a chemical reaction in the exhaust system. The ammonia is then used in the catalyst to convert NOx to nitrogen gas and water vapor for release into the atmosphere.

DIESEL EXHAUST FLUID

DEF COMPONENTS

The DEF system consists of the following components: DEF tank DEF pump Engine coolant supply lines DEF injector assembly DEF dosing control unit SCR catalyst Upstream and downstream NOx sensor The DEF tank is mounted to the left side of the truck below the cab. The tank is an 8-gallon plastic unit that contains a removable module containing the level unit, heating lines, temperature sensor, and a fluid pickup and return. The filler neck is located just behind the cab on the left side of the vehicle. The tank contains a valve to ensure that fluid fill is shut off when the tank gets to a certain fill level. Use care if the tank is filled with a funnel, because it may be overfilled. Avoid overfilling the tank because the tank may rupture if the fluid freezes.

Figure 6: DEF Pump The DEF supply lines are high-pressure reinforced rubber lines with heater wires embedded in the jacket. The lines are similar to fuel lines with quick connectors. Coolant lines supply engine coolant for the heating pipes in the fluid tank. The lines also provide coolant to the DEF injector assembly, which is mounted on the exhaust pipe upstream of the SCR catalyst. The coolant ensures that the DEF injector does not overheat. The DEF injector is an electrically controlled unit that is similar to a gasoline injector but can handle the corrosive effects of DEF. The injector is serviced only as an assembly. Due to the tight tolerances on the injector assembly and also because the supplier performs testing on all failed components to understand the cause of the issue, do not remove the injector from the housing. When servicing the injector assembly, always replace the seal to prevent leaks in the system.

Figure 5: DEF Tank The DEF pump assembly includes a pressure sensor, a two-way reversing valve, and an electric heater. The pump is mounted to the rear of the tank on the left frame rail and is serviced as an assembly. The pump also includes a serviceable filter. The two-way reversing valve on the pump is used to empty the DEF lines when the engine is shut off.

Figure 7: DEF Injector

February 2010 Master Tech Reference Book

The DEF dosing control unit communicates with the engine control module (ECM) to determine the amount of DEF to be injected. The module also controls the heater circuits, DEF injector, and DEF pump with an integrated reversing valve.

The SCR catalyst is a two-part design containing a low amount of precious metals, and lights off at 180C (356F). The first part forms nitrogen and H2O out of the ammonia from the DEF and NOx in the exhaust. The second part removes any residual ammonia smell by causing any residual ammonia to form nitrogen. NOx sensor modules are four-wire units that communicate with the ECM on the J1939 communication bus. Each sensor has a module that communicates with the ECM. The sensor and module are serviced together as an assembly. There is a downstream and upstream sensor and a module used to monitor the amount of NOx in the exhaust system. Note that the modules for the upstream and downstream NOx sensors contain different programming. The harness connectors are keyed differently to ensure that they are not swapped or that the wrong one is installed. The modules also have different part numbers to differentiate the locations. When replacing a NOx sensor, order the correct sensor for either the inlet or outlet location.

Figure 8: DEF Dosing Control Unit The module performs diagnostics on the inputs and outputs of the DEF system and reports the information to the ECM over a dedicated communication bus. The DEF system uses a dedicated communication bus that has the same properties as a CAN-C bus used for powertrain communication on gasoline vehicles. The dedicated communication bus (J1939) allows communication between the dosing control unit, NOx sensor modules, VG turbo actuator, and the ECM. The bus is not accessible with the scan tool, however, module information can be accessed by navigating to the ECM and viewing the Data tab. If the DEF level gets low or another malfunction is present, the module reports the condition to the ECM. The ECM illuminates the malfunction indicator lamp (MIL), displays warning messages to the driver through the electronic vehicle information center (EVIC), or both.

Figure 9: SCR Diffuser

DIESEL EXHAUST FLUID

DEF OPERATION

The DEF system has five modes of operation: Standby No Pressure Control Pressure Control Pressure Reduction Afterrun Standby Mode When the key is in the Run position with the engine off, the system enters Standby mode. There is no pressure in the system, and the system is waiting to start. No Pressure Control Mode In No Pressure Control mode, the engine is running, but there is no pressure in the system because the DEF may be too cold or frozen. The control module activates the heater circuits in the lines and pump, and opens the coolant control valve to allow engine coolant to flow through the heat exchanger in the DEF tank to warm the system. The valves in the pump are also actuated to ensure proper operation in cold weather. The time it takes to thaw the system depends on the temperature. For a system at -16C (4F), it could take 20 minutes to activate the system. Pressure Control Mode The Pressure Control mode is initialized when the DEF is above the freezing point of urea (-11C, 12F) and when the engine is running. There are three modes of pressure control that may not be seen on the scan tool: Refill Pressure Buildup Ventilation Since the system always enters the Pressure Control mode with empty lines, the pump activates to fill the lines with fluid. This is the Refill mode. The system enters another mode of Pressure Control called Pressure Buildup and Ventilation. The injector cycles to remove the air from the system. After the air is purged from the lines, the system enters Metering Control. In this mode, the DEF dosing control unit commands the DEF injector to inject fluid into the exhaust based on fuel usage rate and duty cycle. Typical usage for DEF is 1-2% of fuel usage, so the amount of DEF on a mileage basis will vary. Pressure Reduction Mode When the system detects a malfunction or the engine is shut down, the DCU enters a mode to reduce system pressure, called Pressure Reduction mode.

The reversing valve changes direction and allows the fluid pressure to be vented back to the tank. During Pressure Reduction the injector is closed. Afterrun When the key is turned to the OFF position, the system enters the Afterrun mode. This mode purges fluid from the lines to prevent damage to the pump and lines due to fluid freezing. During the Line Purge mode, the reversing valve changes direction of fluid flow, the pump is activated, and the injector is opened to the exhaust to allow air into the lines. Prior to emptying the system, the DCU surveys the exhaust system temperature.

Figure 10: SCR Temperature Sensor and NOx Sensor If the exhaust temperature is too high, the hot exhaust gasses could damage the DEF components, so the system enters the TempWait mode. The control module monitors the exhaust temperature and proceeds when the temperature reaches a predetermined degree. During TempWait, the pump and injector are off. When the temperature is low enough, the system enters the Emptying mode as described earlier. The reversing valve reverses fluid flow, the pump is energized, and the injector is opened. This operating mode pumps the DEF back into the DEF tank to prevent the system from rupturing due to extreme cold where the fluid freezes. The customer may hear the DEF pump run during this step, and should be informed that the humming sound is normal. After the lines are cleared, the pump is turned off, the injector is closed, and the system waits to start the cycle again.

February 2010 Master Tech Reference Book

DEF DIAGNOSIS

The new DEF system requires that the customer maintain proper fill of the tank. The 8-gallon tank should only be filled with Mopar DEF or DEF that has the API certification label on the container. The proper fluid causes NOx in the engine exhaust to be reduced and the reduction is detected by the NOx sensors. Substandard fluid or the wrong fluid causes a DTC and possible no-start condition. DEF is tested using a litmus test or a diesel refractometer. Proper DEF registers around 9 pH using litmus strips. A refractometer registers 32.5% during a test of the fluid. Litmus paper is chemically treated with different colored dyes to react with the pH of a liquid. When the treated area comes in contact with the liquid, the paper will change colors to reflect the acidity of the liquid. A scale is used to compare the color of the paper to the scale, indicating the reading. When using litmus paper to test DEF, be sure to use paper that is able to read a pH level in the low range. Litmus paper that can properly read the pH levels in DEF can be obtained through Mopar. The refractometer used for DEF is different than the tool used for coolant diagnosis. The DEF refractometer uses a different scale than the coolant tool. The DEF test tool follows the same operational procedure. 1. Use the eyedropper to obtain a sample of the DEF to be tested. 2. Place a drop of DEF on the window and lower the cover. 3. Hold the tool perpendicular to a light source and view the reading through the eyepiece.

Figure 12: DEF Module Tool 10189 DEF is extremely corrosive to metals and paints. Be sure to clean up any spills and clean up any tools used on lines or components. Because the system must not be operated without DEF fluid, the EVIC displays level messages to the driver. If the fluid level drops to only 2 gallons (7.6 liters) in the tank, the message Low DEF Refill Soon alerts the driver to fill the tank. The message illuminates for approximately 450 miles (724 kilometers). If the fluid level gets down to 1 gallon remaining, the message Refill DEF Engine Will Not Restart In 500 miles (804 kilometers) displays in the EVIC. The message displays for approximately 500 miles (804 kilometers) and counts down the miles until the next warning. If the system is still not refilled, the message Refill DEF Engine Will Not Start displays, and the engine will not restart after being shut down. At this point, DEF must be added to the tank. Refer to diagnostic trouble code P203F in section 28 of TechCONNECT for the procedure that includes the correct DEF quantity to correct the fault. The system also enables a chime and an instrument panel indicator lamp when the warnings are displayed.

Figure 11: DEF Refractometer There is a special tool used to remove the fluid level module from the DEF tank. Special tool 10189 is needed to remove the lock ring from the tank when servicing the module.

DIESEL EXHAUST FLUID

The DEF system is designed to detect tampering and incorrect fluid usage. If the system detects a fault that could be a result of system tampering or using the incorrect fluid, the EVIC displayes the message Service DEF System See Dealer for 250 miles (402 kilometers). If the fault is still present after 250 miles (402 kilometers), the message Service DEF System Engine Will Not Start In 500 Miles See Dealer displays and counts down the miles for 500 miles (804 kilometers). If the fault is not repaired after the 500 miles (804 kilometers) are passed, the message Service DEF System Engine Will Not Start See Dealer displays, and the engine will not restart after being shut down.

There are also three tests that can be initiated with the wiTECH application: DEF doser pump override test - requires measuring the amount of DEF pumped through the system in a set amount of time DEF tank heater override test - allows a technician to activate the driver circuits one at a time to test the output voltage to the tank or line heater DEF line heater override test - allows a technician to activate the relays one at a time to test the output voltage to the tank or line heater

ATTENTION MASTER TECH PARTICIPANTS:

A score of 80% or higher on at least 10 of the 12 Master Tech quizzes is one of the Technician Training Certification requirements. Quizzes must be completed by the end of the 2010 calendar year.

Figure 13: EVIC Display Care should be exercised when storing DEF. The fluid has a shelf life that is dependent on temperature. Temperature (Constant) 0C 10C (50F) 20C (68F) 30C (86F) 35C (95F) 40C (104F) 50C (122F) 60C (140F) Figure 14: Shelf Life of DEF When it is time to refill the tank, use the stored DEF then top off the tank with new fluid. Do not store DEF inside the cab of a truck or in a toolbox due to the accelerated degradation of DEF at elevated temperatures. Estimated Percent Life oo 75 years 11 years 23 months 10 months 4 months 1 month 1 week

February 2010 Master Tech Reference Book

ADDITIONAL DEF TOOLS AVAILABLE FROM PENTASTAR SERVICE EQUIPMENT

Your Equipment Specialists

Diesel Emission Service Cart

Due to the corrosive nature of DEF (Diesel Exhaust Fluid) special pumps and dollies are required for dispensing from 55 gallon drums. Required DEF prepping and servicing will begin Fall of 2009 for the Sprinters and 2010 for Dodge Ram 3500, 4500 and 5500 Commercial Chassis Cabs.

Fuel-Chief

DEF Service Carts

The Fuel-Chief Diesel Emission Service Carts are one of the industry's first allinclusive systems for refilling a vehicle's onboard tank. Each cart comes complete and has the following pump features: Up to 6 g.p.m. Maximum head 12'/Pumping DEF = 5.7 p.s.i. 40" suction tube. 120 volts AC, 60 Hz, 2 full load amps.

320-DEF-1
Includes:
DEF Series submersible pump Deluxe turbine digital meter Manual delivery nozzle 8' flexible delivery hose 2" standard bung adaptor Deluxe service cart

320-DEF-1A
Includes:
Same as 320-DEF-1 except also a Deluxe Automatic Delivery Nozzle

Poly Rotary Pump For DEF Fluids 320-JDI-10037

320-DEF-1

This low-cost delivery system includes a 6 g.p.m. flow-rate hand pump and a down tube for simple delivery of Diesel Emission Fluid. This easy-to-install pump system removes easily for clean changes between drums. Promo #CY10-11

Visit PSEdealerequipment.com or call to place your order.

All sales F.O.B. shipping point.

to order call 1-800-223-5623

DIESEL EXHAUST FLUID

Your Equipment Specialists

Balcrank true blue Diesel Exhaust Fluid Dispense Systems

For over 100 years Balcrank has designed and manufactured quality Lubrication Equipment. The tradition continues with true blue DEF dispense systems and outfits. true blue DEF (Diesel Exhaust Fluid) outfits are designed to make DEF refills convenient for technicians.

Portable Electric Outfit for Drums 44-1210-006 Features:

Heavy-duty cart easily holds and rolls up to 55 gallon drum. 110 volts AC stainless steel centrifugal pump 8 g.p.m. flow rate. Large semi-pneumatic tires allows for easy maneuvering of cart. Large non-marking rear caster built-in break for safe and secure dispensing. Easy Change Drum Quik PRO coupler system facilitates rapid drum change out. Automatic shut-off nozzle, stainless steel. Battery powered electronic meter with display. 3 suction hose included. 12 dispense hose included.

44-1210-006

Electric Outfit for Drums and IBCs Features:

110 volts AC stainless steel centrifugal pump 10 g.p.m. flow rate. Mounting plate for IBC for side and top mounting of outfit*. Easy Change SS Drum Valve coupler facilitates rapid IBC change out. Battery powered electronic meter with display. Automatic shut-off nozzle, stainless steel. 3 suction hose included. 12 dispense hose included.

Models:

44-1210-003S Side Mount Configuration 44-1210-003D Top Mount Configuration

*Electric outfits for Drums and IBCs are sold in two configurations: top or side mount. For IBC side mount use suffix S when ordering. Electric outfits for Drums are sold only with a top mount configuration. For Drum mounted outfits use suffix D when ordering. 44-1210-003D

Order online at PSEdealerequipment.com.

All sales F.O.B. shipping point.
Promo #CY10-12

to order call 1-800-223-5623

February 2010 Master Tech Reference Book

Your Equipment Specialists

Just One Drop!

94-F-OOK-108-456

DEF/Urea Refractometer

Diesel Emissions Fluid (DEF), also called by a brand name AdBlue, or generically called Urea, is required for Diesel catalyst emissions reduction systems found on new cars and trucks. DEF has a limited storage life, is subject to contamination, and must meet a purity level to be effective at emissions treatment and prevent trouble codes from being set. The easiest test method is applying one sample drop of DEF from the vehicle or storage container on a refractometer and view the purity level. It is absolutely necessary the solution consists of exactly 32.5% high purity urea. With the ETAS Refractometer a quick and reliable test can be done. One drop of DEF sufficient for test. Percentage scale with excellent readability. Fast and reliable test method. Simple to use.

to order call 1-800-223-5623 Order online at PSEdealerequipment.com

All sales F .O.B. shipping point.
Promo #CY10-26

DIESEL EXHAUST FLUID

Your Equipment Specialists

DEF Dispensing Equipment

651-801300 Samson DEF Hand Pump Package
Rotary PVC hand pump. Adjustable bung bushing and 3 piece down tube (for 5, 16 and 55 gallon drums). Dispense Hose 12' x 3/4". DEF turbine meter. Manual dispense nozzle.

Includes:

651-5500357 Samson Portable Air-Operated 55 Gallon Drum DEF Dispensing Package

Heavy-duty three wheel cart. Air-operated diaphragm pump with poly and stainless steel wetted parts and chamber. DEF filter. DEF turbine meter. Air filter regulator combo 1/4". Mini air shut-off valve 1/4". 2" bung mount suction kit for drum. Automatic shut-off DEF nozzle. Dispense hose 12' x 3/4"

651-801300

Includes:

651-550004

651-5500357

651-5500367 Samson Air-Operated Package for IBC Tote with Dispense Hose
Air-operated diaphragm pump with poly and stainless steel wetted parts and chamber. DEF filter. DEF turbine meter. Air filter regulator combo 1/4". Mini air shut-off valve 1/4". 2" bung mount suction kit for drum. Automatic shut-off DEF nozzle. Tote mount bracket. Dispense hose 12' x 3/4".

Includes:

651-550004 Samson Air-Operated Package for IBC Tote with Hose Reel
Includes:
Air-operated diaphragm pump with poly and stainless steel wetted parts and chamber. DEF filter. DEF turbine meter. Air filter regulator combo 1/4". Mini air shut-off valve 1/4". 2" Bung Mount Suction Kit for drum. Automatic shut-off DEF nozzle. Wall mount bracket for pump and hose reel. Dispense hose reel 30' x 5/8".

To order call 1-800-223-5623 Order online at PSEdealerequipment.com

All sales F.O.B. shipping point.
Promo #CY10-37

February 2010 Master Tech Reference Book

1-800-801-5420 millerspecialtools.spx.com

1-800-223-5623 PSEdealerequipment.com

2010 Chrysler Group LLC. All rights reserved. No part of these materials may be reproduced in any form, by photocopy or by any other means, or incorporated into any other information or material without the prior written permission of the copyright owner.

DIESEL EXHAUST FLUID