5036104 JOHNSON SHIM (T:1.0)

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Capping Kit 1
B - De-ionized Water 1
Ensure that all adjustments and repairs that are carried out to the Diesel Exhaust 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 Exhaust Fluid (DEF) for the system is 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.
At temperatures lower than −15° C (5° F), care should be taken when removing the Diesel Exhaust Fluid (DEF) line connectors that are attached to the tank, pump, and injector. To limit possible damage to the DEF line connectors, carefully apply heat to the area of the DEF line connectors.
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..
Turn the battery disconnect switch to the OFF position.
Illustration 1 g06146969
Illustration 2 g06146998
Typical examples
Ensure that the area around Manifold (DEF Heater) (3), Diesel Exhaust Fluid (DEF) pump (9), DEF injector (8) and DEF line (1), and DEF line (2), and DEF line (6) are clean and free dirt and debris. If necessary, use Tooling (B) and a suitable tool to clean the area around the DEF components..
Refer to the Original Equipment Manufacture (OEM) for the correct location of the manifold DEF heater (3), DEF pump (9), and DEF injector (8). Refer to the OEM for the correct routing of the DEF lines.
Disconnect DEF line (1) and DEF line (2) from manifold DEF heater (3).
Use Tooling (A) to cap manifold DEF heater (3). Use Tooling (A) to plug DEF line (1) and DEF line (2).
Disconnect the other end of DEF line (1) and DEF line (2) from DEF pump (9).
Use Tooling (A) to cap DEF pump (9). Use Tooling (A) to plug DEF line (1) and DEF line (2).
Disconnect DEF line (6) from DEF injector (8) and DEF pump (9).
Use Tooling (A) to cap DEF injector (8). Use Tooling (A) to plug DEF line (6).
Make temporary marks on cable straps for installation purposes. Cut the cable straps. Ensure that all cable straps are removed.
Ensure that no Diesel Exhaust Fluid (DEF) enters the harness assemblies or the harness connections.
Disconnect the OEM harness assemblies from harness assembly (4), harness assembly (5), and harness assembly (7) for the DEF lines.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B - De-ionized Water 1
Ensure that all DEF components are free from wear or damage. Replace any DEF component that is worn or damaged.
Illustration 3 g06146969
Illustration 4 g06146998
Typical examples
Route all DEF lines into the correct position before installation of the DEF lines. Ensure that the DEF lines are correctly routed.
Ensure that no Diesel Exhaust Fluid (DEF) enters the harness assemblies or the harness connections.
Connect the OEM harness assemblies to harness assembly (4), harness assembly (5), and harness assembly (7) for the DEF lines.
Remove the caps from manifold DEF heater (3) and plug from DEF line (1) and DEF line (2).
Connect DEF line (1) and DEF line (2) to manifold DEF heater (3).
Remove the caps from DEF pump (9) and plugs from DEF line (1) and DEF line (2). Connect the DEF lines to the DEF pump. Ensure that the DEF lines are correctly orientated.
Remove cap from DEF line (6). Connect the DEF line to DEF pump (9).
Install new cable straps. Ensure that all cable straps are installed.Note: Ensure that the cable straps meet OEM specification.
Prior to the installation of DEF supply line (6) to DEF