0332209 JOHNSON END CAP

References
Reference: Disassembly and AssemblyReference: Operation and Maintenance Manual , Coolant - DrainRequired Tools
Table 1
Required Tools
Tool Qty Part Number Part Description
T1 2 385-1861 Plugs
T2 1 N/A Container for collection and disposal of the water used to flush the system
T3 Minimum 2 gal N/A Distilled water Flushing Procedure
Note: Refer to Disassembly and Assembly for the correct procedure if the instructions are not covered in this procedure.
Turn the key switch to the OFF position for 2 minutes. The key switch must be OFF for 2 minutes to allow the Diesel Exhaust Fluid (DEF) pump to purge, ensuring the system is free of pressurized DEF.Note: Allow the full 2 minutes after turning the key switch to the OFF position before turning the battery disconnect switch to the OFF position.
Drain the existing DEF from the DEF tank.Note: All DEF drained or flushed during this procedure must be disposed of as per local regulations and mandates.
Drain the engine coolant to an appropriate level that will allow the coolant lines to be removed from the tank header. Refer to Operation and Maintenance Manual for more information.
Illustration 1 g03406433
Typical example
(1) DEF suction line
(2) Manifold (DEF heater)
(3) Harness assembly
(4) Coolant supply to manifold (DEF heater)
(5) DEF backflow line
(6) Coolant supply to DEF pump
Remove the manifold (DEF heater) from the DEF tank. Plug the lines using plugs (T1).
Illustration 2 g06132482
(2) Manifold (DEF heater)
(7) DEF filter
(8) DEF filter
Remove filter (7) from manifold (DEF heater) (2), discard the filter.
Remove filter (8) from manifold (DEF heater) (2), discard the filter.
Illustration 3 g06130964
Typical example
Inspect the optical sensors (9) (if equipped) for visible debris. If visible debris is present, clean the optical sensors by wiping the sensors gently with a clean, soft cloth. If no visible debris is present on the optical sensors and a 3516-2 or 3100-2 Aftertreatment #1 DEF Concentration: Erratic, Intermittent, or Incorrectcode is active, then manifold (DEF heater) (2) assembly must be replaced.Note: The new manifold (DEF heater) with optical quality sensor is equipped on later engines.
Flush the DEF suction and backflow connections on the manifold (DEF heater) using distilled or deionized water. Install new filter (8) onto the manifold (DEF heater).
Install new filter (7) onto the manifold (DEF heater).
Do not dry inside the DEF tank with any type of cloth or paper towel. Fibers left in the tank will obstruct the DEF filters.
Position the suitable container under the DEF tank drain and flush the DEF tank thoroughly.
Reinstall the manifold (DEF heater) into the DEF tank using a new manifold (DEF header) gasket. Tighten the header bolts to 5 1 N m (44 9 lb in).
Illustration 4 g06130968
Typical example
(10) Connector for DEF suction line containing in-line filter
(11) DEF pump
(12) DEF filter cap
Replace the connector at the DEF pump inlet port. The connector contains an in-line filter which can only be replaced by replacing the connector assembly. Tighten the connector to 4.5 0.5 N m (40 4 lb in).
Replace the Diesel Exhaust Fluid (DEF) filter. Tighten the cap to 20 5 N m (15 4 lb ft).
Flush the DEF suction and backflow lines into a suitable container (T2) using distilled or deionized water (T3). The minimum quantity of distilled or deionized water that is required is 7.57 L (2 US gal).
Reconnect all lines to the DEF pump and to the manifold (DEF heater).Note: Use de-ionized water, distilled water, or Diesel Exhaust Fluid (DEF) to lubricate the O-ring seals of the connections of the diesel exhaust fluid lines before installation of the diesel exhaust fluid lines. If DEF has been used to lubricate the O-ring seals of the connections of the diesel exhaust fluid lines. The excess DEF must be cleaned from the connections of the diesel exhaust fluid lines.
Fill the DEF tank completely with new DEF. The new DEF must meet ISO 22241 standards.
Start the engine.
Connect to the electronic service tool.
Perform the "Aftertreatment System Functional Test" in the electronic service tool. This test will verify that the DEF system is working correctly following the flush and filter replacement.