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 40 of 61
TB – 2859 Rev A
3) Pull the DEF head unit out until the bottom of the header is at the bottom of
the tank bore.
4) Angle the head unit and fold the filter element upwards. Continue to carefully
remove the header out of the tank bore until completely freed.
DO NOT pull directly out as this might damage the head unit and bore seal.
DEF Tank
Bore Seal
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 41 of 61
TB – 2859 Rev A
B)
MFHU Installation Instructions
5) Apply a thin layer of O-ring lubrication to the Bore seal O-ring.
6) Fold the filter element upward and position the bottom of the header inside the
tank bore at an angle. Work the header until the bottom of the header and filter
are inside the tank.
DO NOT push the MFHU directly into the tank as this could damage the 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 42 of 61
TB – 2859 Rev A
7) Position the DEF head unit in the desired orientation and press on the top of
the blue mounting base until it is completely seated in the tank bore.
DO NOT press directly on the fittings.
8) Replace the retaining ring on Head unit and install the retention screws using
the T25 Torx wrench. Recommended torque on screws is 20 - 30 in-lbs (2.26 –
3.38 N m).
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 43 of 61
TB – 2859 Rev A
3.5
DEF SUCTION FILTER
This section demonstrates the proper steps for removing and installing the DMC
series DEF Multifunction Head Unit DEF suction filter. As mentioned previously,
the DEF Suction Filter is located at the bottom of the Multifunction Head Unit
assembly thus requiring the head unit to be removed from the DEF reservoir. For
instructions on how to remove the MFHU, please refer to Section 3.4A.
DEF Suction
Tube
Filter Retention
Screw
DEF Suction
Filter
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 44 of 61
TB – 2859 Rev A
Filter Removal & Installation Procedure
NOTE: The following procedure begins after the MFHU has been removed from the
DEF reservoir. For instructions on removing the MFHU, please refer to Section 3.4A.
1) Locate the filter retention screw and remove using the T15 screw driver. Discard
the screw.
2) Pull the old filter off of the suction tube and discard.
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 45 of 61
TB – 2859 Rev A
3) Position the new filter’s suction tube housing onto the bottom of the suction tube
and press the filter flush against the bottom of the heater tube fin. Align the filter
so the filter retention screw can screw into the retention screw housing.
DEF Suction
Tube
DEF Suction
Tube Housing
Heater Tube Fin
Retention Screw
housing
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 46 of 61
TB – 2859 Rev A
4) Install the retention screw.
5) Once the retention screw is installed, the MFHU will be ready to be installed into
the tank. Refer to Section 3.4B for instructions.
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 47 of 61
TB – 2859 Rev A
3.6
LEVEL SENSOR
This section demonstrates the proper steps for removing and installing the Aircoupled Level sensor from the Multifunction Head Unit. The DEF level sensor is
a component of the Multifunction Head Unit Assembly thus requiring the head
unit to be removed from the DEF reservoir. For instructions on how to remove
the MFHU, please refer to Section 3.4A.
1) Once the head unit is removed from the tank assembly, ensure that the header
is an environment with minimal risk of contamination. Grip the Focus Tube and
hand loosen counter-clockwise until it becomes unattached from 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 48 of 61
TB – 2859 Rev A
2) Snip off the zip ties to remove the split wire loom from the wires connected to the
sensor. Remove and discard the zip tie.
3) Use groove lock pliers or a wrench to firmly grip the base of the sensor and turn
it counter clockwise to loosen it from 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 49 of 61
TB – 2859 Rev A
4) Lubricate the gasket of the new sensor with a thin layer of DEF compatible
petroleum jelly or oil, and then screw the new sensor into place until the bottom
lip of the sensor is touching the top of the head unit.
5) Use the groove lock pliers or wrench to tighten so that the wires are in the
original position (shown in second image below).
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 50 of 61
TB – 2859 Rev A
6) Locate where the focus tube will be positioned on the underside of the head unit.
Situate the focus tube so that the inner threaded side of the tube will be
tightened over top of the threaded projection from the sensor on the underside of
the head unit. Tighten focus by hand until snug.
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 51 of 61
TB – 2859 Rev A
7) Combine the wire looms and feed the new zip tie through the header base hook
and around the wire looms. Tighten only until the wire looms are secured. Clip off
the excess of the zip tie.
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 52 of 61
TB – 2859 Rev A
8) The head unit is ready to be reinstalled back into the tank. Refer to Section 3.4B.
4.0
TROUBLESHOOTING PROCEDURES
The following procedures are recommended for testing the components on the
Shaw DEF tank assembly in the field. If further assistance is required please
contact Shaw Development.
4.1
TEMPERATURE SENSOR
The temperature sensor is a straight forward thermistor (resistor that
varies with temperature). To verify the functionality of the sensor, disconnect the
temperature sensor connector and place a simple ohm meter across the two
temperature sensor leads (white wires, they are not polarized). (Refer to images
below).
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 53 of 61
TB – 2859 Rev A
(OHM READING)
Disconnect temperature sensor from vehicle
Use an ohm meter to get a reading from the connector
leads and correlate the reading to a temperature
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 54 of 61
TB – 2859 Rev A
To verify the accuracy of the sensor, identify the temperature sensor part
on the vehicle in the chart below. Using the measured resistance acquired from
the previous step, compare the expected temperature to the actual temperature
of the DEF.
Temperature Sensor Resistance Chart
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 55 of 61
TB – 2859 Rev A
4.2
LEVEL SENSOR
The procedure below describes how to test the Level Sensor. The sensor must
be wired to the vehicle with the vehicle running, because the Dosing Unit
completes the output circuit of the Level Sensor. However, the vehicle must be
off (no power to the sensor) during volume change in the tank. Failure to do so
will result in inaccurate voltage readings. It is recommended to conduct this test
at different DEF levels to ensure the sensor is recalibrating appropriately. To test
the sensor a simple volt meter across the yellow and black leads will correlate to
the DEF’s level, while a volt meter across the red and black leads will correlate to
the voltage being supplied to the unit. Prior to testing, ensure the sensor is
receiving the correct voltage form the battery source. At this printing, there are 4
different level senders, each for a specific engine application.
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 56 of 61
TB – 2859 Rev A
Level sensor wire reference and nomenclature
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 57 of 61
TB – 2859 Rev A
METHOD 1 (RECOMMENDED)
Unhook the connector and attach a jumper between the tank and vehicle connector.
While the vehicle is running, attach Insulation Piercing Test Clips to the power (Red) and Return
(Black) to ensure appropriate voltage is provided to the sensor. Next, attach the Clips to the
Signal (Yellow) and Return (Black) wires of the jumper to measure the signal voltage being
provided to the engine computer.
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 58 of 61
TB – 2859 Rev A
Use a volt meter to get a voltage reading from the connector leads (black wire to black lead and yellow
wire to red lead) and correlate the reading to a fluid level.
METHOD 2
While the vehicle is running, attach Insulation Piercing Test Clips to the power (Red) and Return
(Black) to ensure appropriate voltage is provided to the sensor. Next, attach the Clips to the
Signal (Yellow) and Return (Black) wires of the jumper to measure the signal voltage being
provided to the engine computer.
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 59 of 61
TB – 2859 Rev A
Use a volt meter to get a voltage reading from the connector leads (black wire to black lead and yellow
wire to red lead) and correlate the reading to a fluid level. The small pin is designed to allow selfhealing of the insulation, though one can also apply a small amount of Liquid Electrical Tape to the wire
after removal of the test clips.
NOTE: Clips can also be used on the red and black wires to get a voltage reading from the
vehicle.
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 60 of 61
TB – 2859 Rev A
5.0
FREQUENTLY ASKED QUESTIONS (F.A.Q.s)
What information should be collected before calling Shaw for troubleshooting
related issues?
Providing the following information will help in expediting the
troubleshooting process and Warranty process. The Italicized items are
required in order to process a warranty claim.
NOTE: All warranty claims must be submitted to the immediate supplier of the tank.
1) OEM of vehicle
2) Part number of suspect Shaw component (Level sensor, Tank assembly,
Coolant control Valve, etc.). If unable to acquire the part number, please
contact supplier.
a. If the issue is related to the DEF tank assembly, provide the serial
number of the DEF tank assembly (refer to image below for
location of SN)
3) All Fault Codes related to the incident
4) Vehicle mileage / hours of operation
5) Location of failure (City, State, Territory)
6) Date of failure
7) Description of failure
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 61 of 61
TB – 2859 Rev A
What could cause my DEF level gauge to read intermittently?
Intermittent level readings could be caused by a variety of circumstances
ranging from bent pin connectors, kinked wires, inadequate power
provided to sensor, etc. It is for this reason that Shaw has developed the
level sensor troubleshooting procedure referenced in section 4.2.
Performing this procedure safely and efficiently determines if the sensor is
suspect and is a good starting point for troubleshooting the rest of the
circuit. If there are specific questions regarding the procedure or the level
sensor please contact your Shaw Development parts provider.
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.
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TSB/Document ID: SM1304
Replacement Service Bulletin Number:
MFR Communication Date: 2016-07-05
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Communication Type: Service Bulletin/Repair Instructions
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- 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.
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