DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)
2.6 Diesel Exhaust Fluid Dosing System
2.6.1 Description and Operation of the DEF Dosing System
The Diesel Exhaust Fluid (DEF) doser is mounted to the Aftertreatment Device (ATD). The primary function of the
dosing unit is to inject a direct, fine spray of DEF into the ATD via an electronically controlled valve. The doser is
controlled by the Aftertreatment Control Module (ACM), which controls the amount of DEF injected into the
exhaust catalyst. The DEF pump module maintains 10 bar (145 psi) of DEF pressure to the doser inlet fitting (1).
The constant supply of DEF is used to cool the dosing unit. The cooling operation is critical, and must never be
interrupted or stopped during engine operation. There is a final filter located inside the doser to remove any
remaining unfiltered debris. The DEF pressure is monitored by a pressure sensor located inside the doser
housing. The remaining DEF is returned to the supply tank through the doser outlet fitting (2).
1. Doser Inlet Fitting
2. Doser Outlet Fitting
Fig 0.1, Doser Inlet and Outlet Fittings
2.6.2 Removal of the DEF Dosing Unit
Remove as follows:
NOTICE
Wait at least five minutes after shutting down the engine to disconnect the battery ground
cable. Disconnecting the battery ground cable too soon could prevent post-run cooling of
the DEF dosing unit after the engine is shut down.
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DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)
1. Shut off engine and apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
2. Disconnect the batteries.
3. If necessary, remove the passenger side steps. Refer to OEM procedures.
4. Disconnect the DEF supply (2) and return (1) lines from the DEF dosing unit. See graphic below. Using a
cable tie, tie the DEF lines high enough to avoid DEF draining out of the DEF system.
5. Disconnect the DEF doser electrical connector (2). See graphic below.
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DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)
6. Remove the three bolts (1) securing the DEF dosing unit to the mounting plate and discard bolts. See
above graphic.
7. Remove the DEF dosing unit and discard doser gasket.
2.6.3 Inspection of the DEF Dosing Unit
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DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)
1. Inspect the DEF doser inlet (1) and outlet (2) fittings for blockages. Clear blockages if found.
2. Inspect the DEF electrical connector for damaged pins or a cracked sensor connector body. Replace as
needed.
2.6.4 Installation of the DEF Dosing Unit
Install as follows:
1. Install a new gasket onto the Diesel Exhaust Fluid (DEF) dosing unit with the gasket legs facing outward.
See graphic below.
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DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)
2. Install the DEF dosing unit to the mounting plate by installing the three new bolts (1). See graphic below.
The new mounting bolts may be shorter than the original bolts. Torque to 10 N·m (7 lb·ft). Do not over-
torque the DEF dosing unit bolts as this will crush the gasket, causing leaks.
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DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)
3. Connect the DEF doser electrical connector (2). See graphic above.
NOTICE
To connect a Diesel Exhaust Fluid (DEF) line, push the line coupling onto the DEF port
male connector, then pull back gently on the coupling to engage the holding clip in the
locked position.
4. Connect the DEF supply (2) and return (1) lines to the DEF dosing unit. See graphic below.
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
5. Connect the batteries.
6. Using DiagnosticLink , perform an ADS Priming Function to prime the DEF system and check for leaks.
7. If removed, install the passenger side steps. Refer to OEM procedures.
