GENERAL SERVICE BULLETIN6.7L/3.0L - Generation 2 Diesel Exhaust Fluid (DEF) System

18-7076

16 November

2018

Model:

Summary

DEF General Information and Service Tips - Gen 2

This GSB is intended to aid in diagnosis and determine if contamination is present.

Note: This information is not intended to replace or supersede any warranty, parts and service policy, Workshop Manual (WSM) procedures or technical training or wiring diagram information.

Reference the Owner's Manual, Powertrain Control/Emissions Diagnosis (PC/ED) Manual and WSM for complete information on the diesel exhaust fluid system description, operation, maintenance, diagnostics, component removal and installation, etc.

Service Instruction

General Information

• DEF is comprised of 67.5% highly purified and deionized water and 32.5% urea. The Workshop Manual and PC/ED reference DEF as reductant.

• It promotes the chemical reaction in the exhaust system that converts NOx into nitrogen (N2) and water (H20).

• Avoid any exposure to electrical components. DEF is highly corrosive and should be washed off with water immediately.

• It is normal for DEF to freeze at temperatures below 12°F (-11°C).

• Only API certified DEF should be used in Ford selective catalytic reduction (SCR) systems.

• Ford DEF bottles include a filler spout designed to fill Ford specific DEF tanks to the proper level.

Typical DEF usage

Figure 1

Ford2016-2018 F-650/750

2017-2018 F-Super Duty

2018 F-150

• This chart represents the average distance between DEF refills based on vehicle usage.

• Customer driving habits, ambient temperature, fuel quality and other factors that influence fuel economy will also impact DEF usage.

Reductant Tank Filling

DEF Tank Filling (Figure 2)

Figure 2

Item Description

1 Typical DEF Usage Chart

2 DEF Distance to Empty (Miles)

3 Primary Trailer Tow / Aggressive or City Drive Style

4 Steady Highway Driving

5 Pick-up w/ 3.31 axle

6 Pick-up w/ 3.55 axle

7 Pick-up w/ 3.73 axle

8 Pick-up w/ 4.30 axle

9 Chassis Cab - Non-PTO

10 Chassis Cab - PTO

11 Continuous PTO usage

12 Minimal PTO usage

• When DEF is frozen The PCM uses a calculation to determine DEF level and consumption.

• The DEF tank is designed with an air space for ice expansion when the DEF freezes attemperatures below 12°F (-11°C).

• Overfilling can result in damage to the tank or internal components. Dealerships should NOT top off the DEF tank on the pre-delivery inspection (PDI).

• In freezing conditions, The DEF gauge may not recognize a refill event until the DEF in the tank has completely thawed.

• All vehicles equipped with a diesel engine are filled with DEF at the assembly plant.

• The DEF tank is designed with an automatic shutoff feature to ensure the tank is filled to the correct level when using Motorcraft DEF bottles or filling station nozzles.

• When filling the DEF tank using the Motorcraft DEF bottles, the fluid in the bottle will stop flowing once the DEF tank is full.

• When using the nozzle at the filling station, the nozzle handle will click to indicate the tank is full.

• For complete information, please reference the Owner’s Manual on DEF tank filling.

Reductant Pump Assembly

The reductant pump assembly includes the reductant pump, reductant pressure sensor, reductanttemperature sensor and reductant heater. (Figure 3)

Figure 3

Reductant Pump

• The reductant pump contains a rotary vane pump, pressure sensor, temperature sensor and internal heating element.

• The reductant pump is a sealed unit and is only serviced as an assembly.

• The PCM regulates system pressure by controlling pump speed using pulse width modulation (PWM) signals to the reductant pump control module.

Reductant Pressure Sensor

• Provides pump pressure input to the PCM to control pump speed.

Item Description

1 Motor

2 Pump

3 Filter

4 Heater

5 Flange

• Reductant temperature sensor

• A thermistor device that provides feedback to the PCM. The PCM controls the reductant heating element based off of input from the reductant temperature sensor.

Reductant Heater

• The reductant heater is designed to create enough liquid DEF to maintain system functionality in cold climates, it may not thaw all of the DEF in the tank.

• The reductant heater receives voltage from the glow plug control module (GPCM) when reductant temperature approaches 12°F (-11°C).

Reductant Tank Assembly

The reductant tank assembly includes the reductant tank, reductant quality module, reductant pressure line heater and the reductant injector. (Figures 4 - 5)

Figure 4

Item Description

1 Cap

2 Tank Vent Line

Figure 5

Reductant Tank Cap

• The tank vents through the cap. Installing the incorrect cap can cause the tank to enter into a vacuum and deform the tank.

Reductant Quality Module

• An ultrasonic transducer and sensor assembly are incorporated with the reductant quality module. The transducer and sensor are used to measure DEF level, temperature and urea concentration.

• The reductant quality module is located at the bottom of the reductant tank and CANNOT be serviced separately.

• It communicates the level and concentration data to the PCM via the CAN2 network.

Reductant Pump Control Module

• The reductant pump control module receives a PWM signal from the PCM to control reductant pump motor speed and maintain reductant line pressure.

Reductant Pressure Line Heater

3 Reductant Pump Control Module

4 Reductant Pressure Line Heater

5 Reductant Quality Module

6 Reductant Pump Assembly

Item Description

1 Reductant Quality Module

2 Reductant Pump Assembly

• The reductant pressure line heater is integral to the reductant pressure line and receivesvoltage from the GPCM.

• Damage to the reductant pressure line requires replacement.

Reductant Injector

• The reductant injector is PWM solenoid controlled directly by the PCM.

• The injector receives reductant from the reductant pressure line and sprays into the exhaustupstream of the SCR Catalyst.

Reductant Contamination

Reductant Contamination (Figure 6 - 10)

Figure 6

Figure 7

Item Description

1 Contaminated DEF

2 Clean DEF

Figure 8

Figure 9

Item Description

Reductant pump assembly with petroleum contamination

Item Description

Refractometer, used to check reductant concentration

Figure 10

Item Description

1 Petroleum contamination results in deformation

2 The heating element is beginning to protrude from the rubber insulator

• Reductant system contamination may be in the form of petroleum (diesel fuel, fuel additives, gasoline, kerosene, grease/lube). Testing for petroleum contamination can prevent repeat repairs. Other types of contamination can include water and methanol.

• The Rotunda hydrocarbon contamination test kit should be used to determine petroleumcontamination in the reductant.

• In addition to the on-board DEF quality sensor, DEF concentration should be verified by using a DEF refractometer.

• The reductant obtained for testing should come directly from the tank and not from the injector. Petroleum will float to the fluid surface and adhere to the tank walls.

• Test for reductant contamination with the tank removed from the vehicle. Remove the pump and allow the DEF in tank to settle. This will allow any petroleum to float to the fluid surface for the most accurate results.

• Reductant contaminated with petroleum may have a different odor and turn from clear to a milky/cloudy substance.

• The DEF test strips will absorb petroleum and change to a darker color when the petroleum is absorbed into the strip. Clean DEF will not be absorbed by the strip and will bead off.

• Internal seals and heating elements will swell when petroleum is introduced, preventing the

Item Description

Reductant pump assembly without petroleum contamination

system from operating properly. In cases of HEAVY contamination, the heating element will protrude from the rubber insulator.

• Smaller amounts of petroleum contamination may be harder to detect. Let the pump air dry to disperse the ammonia odor. Look and feel for an oil residue or a hydrocarbon smell.

• If petroleum contamination is found in the DEF, the entire system will need to be replaced. This includes the tank, pump, heated line, fill pipe, cap and injector. Petroleum contamination is NON-WARRANTABLE.

• Warrantable repairs are for defects only, repairs required due to the use of improper fluids are not covered by the New Vehicle Limited, Extended Service Plan (ESP), or Service Part Warranty (SPW). Refer to the Warranty and Policy Manual for details.

Reductant Tank Exterior Cleaning:

• The exterior of reductant tanks are typically dirty and should be cleaned prior to servicing the system. It is imperative that the outside of the tank be clean prior to pump removal or outside debris will be introduced into the tank.

• Use clean low pressure water to remove any foreign material from the exterior of the reductant tank assembly and the surrounding area before pump removal. Regulated low pressure compressed air should be used to remove the residual water from the surrounding area.

Reductant Pump Installation

Reductant Pump Installation (Figure 11)

Figure 11

The heating element was pinched between the pump and the tank preventing the pump from sealing causing a leak.

• Remove the tank from the vehicle prior to pump removal and installation. Removing or installing the pump with the tank in the vehicle may result in damage to the reductant heatingelement and/or leaks from the pump-to-tank mating surface.

• The reductant pump is sensitive to impact damage from mishandling. If the pump is dropped, DO NOT re-install into vehicle.

Reductant Pressure Line Removal

Reductant Pressure Line Removal (Figures 12 - 13)

Figure 12

Item Description

1 The heating element has been pinched between the pump and the tank resulting in a leak. The pump could not seal properly if the element is pinched.

Figure 13

Item Description

1 Push supply line connector towards supply port, which will compress the thermal foam ring.

Item Description

1 While holding the connector in the compressed position with one hand, use the opposing hand to depress both blue tabs on the connector. DO NOT USE pliers or similar tool to depress blue tabs as this may cause over-compression and connector damage and not allow proper release. With the blue tabs depressed, pull the connector away from the supply module to remove the line.

SCR Catalyst and Mixer

Figure 14

Figure 15

Item Description

1 Twist Mixer

2 Grate Diffuser

Item Description

1 Reductant Injector

2 Reductant (DEF) mixing with NOx emissions

3 The diffuser breaks up and vaporizes the reductant droplets. The heat from the exhaust gases splits urea into carbon dioxide (CO2) and ammonia (NH3). The twist mixer evenly distributes the reductant in the exhaust gases.

For complete information please reference the Powertrain Control/Emissions Diagnosis (PC/ED) Manual >Section 1 Description and Operation > Engine Control Components for complete information and the Workshop Manual (WSM), Section 303-08C > Description and Operation.

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All rights reserved.

NOTE: This information is not intended to replace or supersede any warranty, parts and service policy, workshop manual (WSM) procedures or technical training or wiring diagram information.

4 The SCR catalyst is wash coated with copper and iron on a zeolite substrate and converts the incoming CO2 and NH3 into nitrogen (N2) and water (H20).