0209551 JOHNSON OWNER'S MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
B - De-ionized Water 1
Ensure that all adjustments and repairs that are carried out to the Diesel Emission Fluid (DEF) system are performed by authorized personnel that have the correct training.Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.
Care must be taken to ensure that Diesel Emission Fluid (DEF) for the system are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Ensure that the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information.
Illustration 1 g03799260
Ensure that the area around Diesel Emission Fluid (DEF) injector (7) is clean and free dirt and debris. If necessary, clean the area around the DEF injector. Clean the area around the DEF injector with Tooling (B) and a suitable tool.
Disconnect the harness assembly from connection (3) on DEF injector (7). Use Tooling (A) to cap the harness assembly and the DEF injector.
Remove the Diesel Emission Fluid (DEF) line from connection (1) on the DEF injector (7). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Use Tooling (A) to cap connection (1) on DEF injector (7) and the DEF line.
Remove the coolant line from connection (2) and coolant line from connection (6) on DEF injector (7).
Use Tooling (A) to caps connection (2) and connection (6) on DEF injector (7).
Sufficiently loosen the Torx head bolt for V-band clamp (4) and remove DEF injector (7) and the V-band clamp from DOC (5). Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B - De-ionized Water 1
Ensure that the DEF injector and the DOC are free from wear or damage. Replace any component that is worn or damaged.
Illustration 2 g03799267
Illustration 3 g03799260
Ensure that surfaces (8), DOC (5), and DEF injector (7) is clean and free from damage and wear.
Position V-band clamp (4) onto DEF injector (7). Ensure that the V-band clamp is correctly orientated.
Install DEF injector (7) and align with peg (9) with Slot (X) in DOC (5).
Tighten the Torx head bolt for V-band clamp (4) hand tight. Ensure that the DEF injector and the V-band clamp are correctly seated onto the DOC.
Illustration 4 g03799285
Tighten the Torx head bolt for V-band clamp (4) to a torque of 11.5 N m (102 lb in).
Remove the caps from the harness assembly and connection (3) on DEF injector (7). Connect harness assembly to the connection on the DEF injector.
Prior to the installation of the DEF supply line, follow Step 8.a through Step 8.h in order to flush the DEF supply line.
Turn the battery disconnect switch to the ON position.
Connect the electronic service tool. Refer to Troubleshooting, "Electronic Service Tools" for the correct procedure.
Remove cap from the DEF supply line. Place the open end of the DEF supply line in a suitable container, with a capacity greater than 2 L (0.44 Imp gal).
Select the DEF dosing system accuracy test. Refer to Troubleshooting, "DEF Dosing System Accuracy Test" for the correct procedure.
Hold the DEF supply line above the suitable container. Run the DEF dosing system accuracy test for maximum of 90 second. Ensure that the DEF supply line is not immersed in the DEF fluid in the suitable container.
Turn the battery disconnect switch to the OFF position.
Use Tooling (B) to clean any DEF fluid from the end of the DEF supply line.
Remove the cap from connection (1) on DEF injector (7). Connect DEF supply line to connection (1) on the DEF injector.
Remove the caps from connection (2) and connection (6) on DEF injector (7). Install the coolant lines to the connection on the DEF injector. Ensure that the coolant lines are correctly installed.
Lightly tap the full circumference of the V-band clamp with a soft faced hammer in order to correctly seat the V-band clamp. Repeat Step 6 until the Torx head bolt reaches the correct torque value.
Turn the battery disconnect switch to the ON position.
Use the electronic service tool to perform a pressure test on the DEF system and check for leaks. Refer to Troubleshooting, "DEF Dosing System Verification Test" for further information.
Turn the battery disconnect switch to the OFF position. Disconnect the electronic service tool.
Turn the battery disconnect switch to the ON position.