NHTSA ID Number: 10128903
Manufacturer Communication Number: SM1304
TSB/Document Date: 2018-02-21
Summary
Gen 4 Analog DEF Level Sensor Troubleshooting: Original Date of Issue: February 25, 2013 Revision: July 5, 2016 The Service Memorandum updates the model year range, engine models affected, and includes Tank Assembly information.
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 25 of 61
TB – 2859 Rev A
Lanyard Only Caps: To re-attach the lanyard, take the small opening of the
lanyard and slide it over the Lanyard Tab of the cap so that it fits into the groove.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 26 of 61
TB – 2859 Rev A
2.2
FILLING THE DEF TANK
When filling the DEF tank assembly, ensure the filling process or
procedure is in compliance with following cautionary notes provided below. If
further clarification for handling, storing, and transporting DEF is required, please
refer to ISO-22241. It is critical that vehicle operators safely and properly execute
refilling practice while adhering to these notes to avoid potential performance
related issues of the Shaw DEF system and SCR system.
Do not put DEF in the fuel tank, or any fluid other than DEF in the DEF reservoir.
This will cause engine damage and/or damage to the SCR unit.
Use only API (American Petroleum Institute) or DIN certified Diesel Exhaust Fluid
(per ISO-22241). Improper fluids or contaminated DEF may lead to high Nitrogen
Oxide emissions and damage the SCR system including the DEF assembly. If
the DEF tank is considered contaminated refer to Section 2.1.2. Contaminated
SCR systems should be serviced at an authorized dealer.
Do NOT use DEF beyond its expiration date or if it has been stored in conditions
over 86°F (30°C) for extended periods of time. This temperature exposure will
cause degradation to the DEF.
Do NOT attempt to top off the tank. Overfilling the tank can inhibit the tank’s
overall performance and potentially damage the assembly due to expansion of
the fluid.
Ensure the cap and adapter are clean prior to cap removal and filling; this helps
prevent tank contamination. Clean off any DEF that may have spilled onto the
tank to maintain cleanliness of the tank assembly.
2.2.1 STATION OR BULK FILLING VIA PUMP AND NOZZLE
Nozzle filling is the preferred method of refilling the DEF tank assembly.
All approved DEF fill stations should utilize magnetic actuating DEF nozzles
designed per ISO-22241. Shaw Development has designed the Shaw DEF
adapters in accordance with ISO-22241 to compliment the functionality of DEF
nozzles. Furthermore, Shaw DEF adapters are designed to prevent overfilling
when using the magnetic actuating DEF nozzle. The procedure below describes
how to fill the DEF tank with an ISO-22241 approved magnetic actuating DEF
nozzle.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 27 of 61
TB – 2859 Rev A
Nozzle filling the DEF tank Assembly
1) Prior to removing the DEF cap, inspect the outside surface of the cap and
surrounding areas for any signs of debris that may fall into the tank when the
cap is removed.
a. If debris has accumulated on the DEF tank assembly, clean it off before
removing the cap. Refer to section 2.1.1 for instructions on cleaning the
DEF tank assembly.
b. If no debris is found, continue to step 2.
2) Inspect the cleanliness of the underside of the DEF cap.
a. If the cap appears dirty, try to clean it off. Refer to Section 2.1.3 for
instruction on cleaning the DEF cap. Once cleaned, replace the cap firmly
on the DEF adapter.
b. If the cap does not appear dirty, refer to step 3
3) Set the cap aside unless the cap is attached to a lanyard. If the cap is not
attached to a lanyard, ensure that it is placed in a location where it is not
vulnerable to debris exposure.
4) Insert the nozzle securely into the inlet adapter.
5) Depress the nozzle handle, enabling DEF flow into the tank assembly.
6) Continue DEF flow until the nozzle automatically shuts off.
Do NOT repeatedly depress the nozzle handle after the nozzle’s initial automatic
shut-off as this might cause the DEF tank to overfill.
7) Remove the nozzle and replace the cap onto the adapter.
2.2.2 BOTTLE FILLING
Bottle filling is the least preferred method for refilling the DEF tank. Bottle
filling is considered a high risk refilling method for a variety of reason. Some of
these reasons include:
Increased potential for overfilling the tank assembly.
Increased potential for physical contact with the fluid.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 28 of 61
TB – 2859 Rev A
Increased potential for spillage.
It is highly recommended to fill the DEF tank assembly using an authorized
ISO-22241 approved DEF nozzle. The following procedure will provide
instructions for bottle filling the DEF tank assembly.
NOTE: Bottle filling should only be conducted with DEF containers that have been
approved by and have been stored in accordance with ISO-22241-3.
Additionally, ensure the container(s) are not contaminated with insoluble
particles in the fluid (i.e. insects or dirt), or bottles that have been knowingly
stored continuously at temperatures greater than 86°F (30°C) for more than 18
months.
Bottle filling the DEF tank assembly requires the use of Personal Protective
Equipment to include but not limited to goggles and gloves.
Bottle Filling the DEF tank assembly
1) Take the cap off of the Diesel Exhaust Fluid bottle. Twist the spout onto the
opening until it becomes locked into place (if applicable).
2) Prior to removing the DEF cap, inspect the outside surface of the cap and
adapter for any signs of debris that may fall into the tank when the cap is
removed.
a. If debris has accumulated on the DEF tank assembly, clean it off before
removing the cap. Refer to section 2.1.1 for instructions on cleaning the
DEF tank assembly.
b. If no debris is found, continue to step 3.
3) Insert the outlet end of the spout into the inlet of the adapter until the end of
the spout is seated completely in the fill port.
4) If attempting to top off the tank, fill the tank slowly while frequently checking
for the DEF fluid line to rise to the bottom of the adapter inlet. When checking
the fluid line in the tank, bring the DEF bottle to level and lower the bottle to
where the remaining DEF in the spout returns to the container. Then remove
the spout from the adapter inlet by hand and look for the fluid line inside the
tank adapter inlet. If the fluid line is not at the desired level, replace the spout
and continue refilling.
NOTE: DEF will not completely fill the spout of the bottle while flowing; air will also be
trapped inside.
5) When the reservoir has been filled, place the DEF cap back onto the tank.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 29 of 61
TB – 2859 Rev A
6) Uninstall the spout from the container and place the cap back on the bottle.
7) If the container still has DEF inside, store it for later use, otherwise, dispose
of the container and nozzle in the correct manner.
8) Clean any spilled DEF immediately with fresh water to prevent corrosion to
the system or vehicle components.
2.3
DRAINING THE DEF TANK ASSEMBLY
The DEF tank assembly is capable of quick draining via the removal of the
DEF drain plug. The following procedure describes how to safely remove the
DEF drain plug from a filled DEF tank assembly.
Refer to vehicles service manual for safety regulations and recommendations
when servicing the vehicle.
Draining of the DEF tank needs to be conducted in a well-ventilated area, as the
ammonia vapors may cause irritation.
NOTE: It is highly recommended that the volume of DEF drained from the DEF
reservoir be properly discarded to avoid potential contamination of the DEF
tank assembly. If the DEF is expected to be reused or stored for later use, the
fluid should be contained and stored in compliance with ISO-22241. Failure to
comply may result in degradation of the DEF.
DEF drain procedure via removal of the DEF drain plug
1) Turn vehicle off.
2) Position an auxiliary reservoir directly beneath the drain plug outlet. Ensure
that the opening of the auxiliary reservoir is wide enough for the DEF to flow
into with spillage, and the reservoir is large enough to carry the volume of
DEF in the DEF reservoir without spillage.
3) Remove the DEF cap and set aside on a clean surface.
4) Using the ¼” Allen Wrench, unscrew the drain plug from the reservoir by
turning in the counterclockwise direction. Place drain plug in a location that is
free from debris.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 30 of 61
TB – 2859 Rev A
5) Allow tank to drain to desired level.
6) Rethread the plug onto the drain plug port by screwing in the clockwise
direction. Tighten the plug 40 - 60 in. lbs. (4.5 – 6.7 N m) of torque.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 31 of 61
TB – 2859 Rev A
7) Refill the tank to verify no leakage occurs.
40-60 in lbs
3.0
REMOVAL AND INSTALLATION INSTRUCTIONS
The following sections provide instructions for removing and/or installing various
components of the DEF tank assembly.
3.1
DEF TANK MOUNTING BRACKET
Complete DEF Tank assembly w/ mounting brackets and tank hanger assembly
Positioning of DEF tank assembly on vehicle
When mounting the DEF tank assembly onto a vehicle the following
criteria should be verified to prevent potential damage or impaired functionality to
the DEF tank assembly.
Avoid mounting DEF reservoirs in areas that are debris prone or exposed to high
temperatures as this may damage the reservoir and/or contaminate the DEF.
The bracket material should be compatible with intermittent exposure to DEF
such as splash.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 32 of 61
TB – 2859 Rev A
Ensure the tank assembly is protected from projectile debris during vehicle
operation. The degree of protection will vary with vehicle applications.
Ensure any hoses being routed in close proximity to the mounting brackets are
protected against any sharp edges, movement, and friction against the brackets,
as this could cause a leak and/or damage to the SCR System.
Ensure the tank assembly is not a step point.
Ensure the nozzle clearance meets ISO-22241 allowing for easy access for
filling and avoid areas where the reservoir could be exposed to service fluids.
The DEF tank assembly should be mounted with easy access to the drain port
on the bottom corner of the tank in the instance the tank may need to be drained.
Additionally, the drain port should be away from critical components on the
vehicle.
The tank should never be mounted in such a way that the tank becomes
deformed (i.e. concave/convex sidings, indentation, etc.)
If the DEF Tank Assembly is
mounted against a wall or on
multiple sides, a minimum of 9
mm standoff should be available
between the reservoir’s strap
grooves with the mounting
bracket wall or sides, and strap
bolts with mounting bracket wall
and sides, to allow room for
expansion.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 33 of 61
TB – 2859 Rev A
3.2
COOLANT HOSES
The coolant fittings used for the coolant hose interface on the Multifunction Head
Unit are hose bead fittings. The hose bead design enables easy disassembly for
servicing. (Refer to images below for visual aid)
Top view of MFHU w/ Hose Beaded Coolant Fittings
Procedure for installing Coolant Hoses:
The following procedure provides instructions for properly installing the
coolant hoses onto the coolant fittings of the head unit. This procedure displays
the use of worm clamps; however other forms of fasteners can be used.
NOTE: During initial installation, avoid removal of the fitting caps until the coolant hoses
are ready for installation. This prevents debris from entering the coolant lines.
1) Slide the hose clamp over the hosing before installing on the head unit.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 34 of 61
TB – 2859 Rev A
2) Push the hosing onto its respective coolant fitting. Refer to the arrows on the
mounting base indicating the direction of the coolant flow. The hose should
be pushed up onto the stopping point of the fitting.
3) Slide the hose clamp over the hose covering the fitting up to approximately
2/3 the length of the fitting.
4) Tighten with a flathead screwdriver until the clamp feels snug.
Do not over tighten the hose clamp as this may cut through the hosing and may
cause a fluid leak.
Ensure the clamp is oriented in such a way that does not conflict with the
installation of the other coolant and DEF hoses and for ease of future servicing.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 35 of 61
TB – 2859 Rev A
After assembly, confirm the hoses themselves aren’t kinked in any location, are
free of debris, and aren’t close to any kind of heat source and sharp edges.
3.3
DEF HOSES
The purpose of this section is to demonstrate the proper procedure for removing
and installing the DEF hoses. The DEF Hoses vary in length and connector size
and are in accordance with SAE J2044 fittings. Additionally, some DEF hoses
are electrically heated to prevent icing inside the hoses in cold environments. It is
important to verify hose length, quick connector size, and wire connector are all
correct prior to installation.
After assembly, confirm the hoses themselves aren’t kinked in any location, are
free of debris, and aren’t close to any kind of heat source and sharp edges.
Install of DEF Hoses (Outward facing release tab):
1) Turn the hose so that the DEF fitting release tab can be accessed
Hose
Release Tab
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 36 of 61
TB – 2859 Rev A
2) Place thumb over the tab and push inwards, while simultaneously applying a
pulling force on the hose connector. Completely remove the hose off the
fitting.
3) Replace with new hose and connector, pushing onto the fitting until an
audible click can be heard and the hose and connector are locked into place.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 37 of 61
TB – 2859 Rev A
3.4
MULTIFUNCTION HEAD UNIT ASSEMBLY
The purpose for this procedure is to demonstrate the proper steps for installing
the Multifunction Head Unit in a DEF tank. Failure to adhere to the following
procedure increases the risk of damaging the DEF reservoir assembly and/or
personnel. Below is a list of terms used to describe different components of the
MFHU.
DEF Multifunction Head Unit Components Terminology
Level Sensor
Temperature
Sensor
Bore Seal
O-ring
Mounting
Base
Level &
Temperature
Sensor
Connectors
Level Sensor
Focus Tube
Filter
Element
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 38 of 61
TB – 2859 Rev A
Retaining
Ring
Retention
screws
A)
MFHU Removal Instructions:
Removal and installation of the Multifunction Head unit requires the use of
Personal Protective Equipment including but not limited to goggles and gloves.
1) . Using a T25 Torx Driver, unscrew the retention screws that secure the
Retaining Ring to the reservoir. Remove the retaining Ring.
T25 Driver
Retention
Screws
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2014 Shaw Development, LLC. All rights reserved.
Page 39 of 61
TB – 2859 Rev A
2) Using a flathead screwdriver, gently pry around where the head unit is
connected to the reservoir while simultaneously pulling on the top of the unit.
Continue until DEF mounting base is free from reservoir.
DO NOT pull on the wires or fittings.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
- Advanced VCI Box, Industry-leading J2534 Pass-Thru...
- High-Speed OEM-Level Diagnostics & Programming: Unlock true...
- Coverage for 17 Car Brands & Ultra Reliability: Works...
- User-Friendly RLink Platform & Expert Support: TOPDON’s...
- 6.6 ft USB-C Cable & Portable Storage Case: The RLink J...
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: SM1304
Replacement Service Bulletin Number:
MFR Communication Date: 2016-07-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
- [Notice] When you receive a used device, it may be a customer return resold by Amazon without inspection. You can exchange it for a new one through Amazon. As this situation is unavoidable, we sincerely apologize. For any issues, contacting us via Amazon's "Messages" is the best way. THINKSCAN 689BT Bidirectional Scan Tool Can Be Used Immediately After It is Turned On, Without Complicated Registration Process, Which is More Convenient & Quick.
- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA
Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU c0ding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations - 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Pr0gramming): Allows for Ford, for Lincoln, and for Mazda ECU pr0gramming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- 39+ Services/Resets/Adaptations/Relearns/Calibrations: XTOOL D7S full system car scanner diagnostic tool tackles 99% of common car issues through its 36+ special functions, including Oil Reset, EPB, SAS, BMS, Throttle Reset, Injector C0ding, ABS Bleed, TPMS Reset, Power Balance, etc and also covers specific-vehicle functions like Crank Sensor Relearn, ABS Initialization, Cylinder Power Balance, Fuel Trim Reset, Idle Relearn etc. This car diagnostic scanner enhances efficiency, making repairs and maintenance hassle-free. Tip: DO NOT for All vehicles, please check compatibility first
- Cost-effective ECU C0ding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln
. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase - OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
This product presentation was made with AAWP plugin.