0392284 JOHNSON INST. CABLE ASSY.

Illustration 1 g03713516
View of the DEF pump module
(1) DEF backflow line connector
(2) DEF pressure line connector
(3) DEF suction line connector
Illustration 2 g03713528
View of the DEF tank and DEF tank header unit
(4) DEF backflow line connector
(5) DEF suction line connectorComplete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Values Results
1. Check the DEF Gauge
A. Turn the keyswitch to the ON position.
B. Check the current position of the DEF gauge.
C. Clean dirt and debris from around the tank filler cap before removing the cap. Add DEF to the DEF tank.
D. Check for a change in the gauge position.
E. If the gauge is in the full position, drain DEF from the tank and look for a change in the gauge position.
Gauge position
Result: The gauge did not move by adding or removing fluid to the tank.
Repair: Remove the DEF tank header and check for a stuck float.
If the float was not stuck, replace the DEF tank header. Return the unit to service.
If the float was stuck, repair the stuck float using the DEF Manifold Sensor Kit. Refer to Disassembly and Assembly, Manifold (DEF Heater) Sensor - Disassemble (Temperature, Level, Quality DEF Manifold Sensor) and Manifold (DEF Heater) Sensor - Assemble (Temperature, Level, Quality DEF Manifold Sensor)
Result: The gauge moved by adding or removing fluid to the tank.
Proceed to Test Step 2.
2. Check the DEF Suction and Backflow Line Connections
A. Check that the DEF suction and backflow lines are connected to the correct connectors.
Refer to Illustration 1 and Illustration 2.
DEF line connections
Result: The DEF lines have been installed to the incorrect connectors.
Repair: Connect the DEF lines to the correct connectors.
Refer to Illustration 1 and Illustration 2.
Result: The DEF lines are installed correctly.
Proceed to Test Step 3.
3. Inspect the DEF Lines for Leaks
A. Turn the keyswitch to the ON position. Do not start the engine.
B. Connect to the electronic service tool.
C. Perform the "DEF Dosing System Verification Test" to pressurize the system. Refer to Troubleshooting, "Service Tool Features" for more information.
D. Inspect all of the DEF lines for disconnected lines or leaks.
Leaks
Result: A leaking or disconnected line was found.
Repair: Repair or replace the faulty DEF line.
Result: A leaking or disconnected line was not found.
Proceed to Test Step 4.
4. Inspect the DEF Tank Filler Cap
A. Clean dirt and debris from around the filler cap before removing the cap. Blockages can be caused by a build-up of dirt/debris around the filler cap.
B. Remove the cap.
C. Visually inspect the DEF tank filler cap for blockages.
Filler cap
Result: The cap has a blockage.
Repair: Replace the cap.
Result: A blockage was not found.
Proceed to Test Step 5.
5. Check for Suction Line Restrictions
A. Disconnect suction the line from DEF pump module (3) and DEF tank header (5). Refer to Illustration 1 and Illustration 2.
B. Inspect the suction line for obstructions.
Possible obstructions are ice, DEF deposits, or debris.
Restrictions
Result: An obstruction was found.
Repair: Flush the line with water or low-pressure air or replace the suction line.
Result: An obstruction was not found.
Install the suction line.
Proceed to Test Step 6.
6. Replace the Filters and Flush the DEF Tank
A. Turn the keyswitch to the OFF position for 2 minutes.
B. Flush the DEF tank. Refer to Systems Operation, Testing and Adjusting, "Diesel Exhaust Fluid Tank - Flush" for the correct procedure.
C. Replace the DEF tank header filter and DEF pump filter. Refer to Systems Operation, Testing and Adjusting, "Diesel Exhaust Fluid Tank - Flush" for the correct procedure.
DEF filter
Result: The DEF tank was flushed and the filters were replaced.
Proceed to Test Step 7.
7. Check for a Leaking DEF Injector
A. Perform the DEF dosing system accuracy test. Refer to Systems Operation, Testing and Adjusting, "Aftertreatment SCR System Dosing Test" for the correct procedure.
DEF Dosing
Result: The quantity of DEF collected is not within the acceptable range.
Repair: Replace the DEF injector. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install"
Result: The quantity of DEF collected is within the expected range.
Repair: Replace the DEF pump. Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Pump - Remove and Install".