Solution K52326370
Tuesday, February 6, 2018 8:41:04 PM CET

Solution
Title (customer effect)

Volvo Chassis - Diesel Exhaust Fluid ( DEF ) Contamination In Fuel System, Inspection
And Repair - US10 to US14 ( Non-Common Rail Fuel System )

Cause

In cases where multiple Injector electrical faults and/or open or short circuits have
occurred, a check for the DEF contamination will need to be performed.

Solution

Overview
DEF in the fuel system can cause a multitude of problems. DEF will also crystallize in fuel as
it warms, which can result in blockages in several different locations of the fuel system. DEF
is also corrosive and will cause damage to several different types of metal, including carbon
steel, brass, aluminum, copper magnesium nickel and zinc. This includes electrical
components that DEF comes into contact with. DEF passage through fuel injectors will cause
misfires and short or open circuits as the internal components corrode and become clogged
with crystallized DEF. If a chassis has electrical codes (voltage, open circuit, short circuit)
logged for multiple injectors, DEF contamination should be one of the possible causes
considered.

Repair
Check The Fuel Currently In The Tanks
Diesel fuel is less dense than DEF. When allowed to separate, diesel will float on top of DEF.
1. Using an appropriate clear container (a beaker is a good example), obtain a fuel sample
from the bottom of the fuel tank.
2. Let the fuel sample sit for 10-15 minutes.
3. Visually inspect the fuel sample to see if separation is observed as shown in the picture
below:
- Putting a light behind the sample container can help highlight a separation line in the
sample

4. Remove both the primary and secondary fuel filters. Allow them to dry for two hours.
5. Visually inspect the top of the filters at that time for white crystals.

Check The Fuel Injectors
1. Connect to the chassis with Premium Tech Tool ( PTT ) and confirm the codes.
2. Follow Guided Diagnostics through checking injector circuit resistances.
3. If resistances are found to be out of spec, the valve cover needs to be removed and
resistance rechecked at the injector connector.
4a. If the resistance is within specs when checked at the injector connectors, there is a poor
connection or short in the Engine Harness that should be addressed first. Function will need to
be rechecked after the harness is repaired or replaced.
4b. If the same readings are observed at the injector connectors, the harness is not likely a
problem and the injectors will need to be removed and physically inspected.
5. Once injectors are pulled, dry the lower portion of the injector that is in contact with fuel
using a heat gun.
6. Check for the presence of DEF crystal or residue on the injector using a blacklight. DEF
will fluoresce (glow) under blacklight as shown below.

Crystallization in Normal Light

Crystallization in UV Light (Blacklight)

If DEF Is Confirmed To Be Present In The Fuel
The following operations will need to be performed:

• The fuel tanks need to be completely drained and thoroughly flushed with water.
The presence of pitting on the inside of the tank may require tank replacement. The
tank will need to be inspected following cleaning.
• The complete fuel system will need to be thorougly flushed.
• The system should be dried as thoroughly as possible prior to reassembly.

The following parts will need to be replaced:

• Fuel Injectors and sleeves
• Fuel pump
• Aftertreatment Hydrocarbon Injector ( AHI ) Module
• AHI nozzle
• AHI fuel/air supply line (line between AHI module and nozzle)
• Overflow valve in the cylinder head
• Fuel Filter base

• Note that DEF in the fuel system is a non-warrantable failure.

Solution visibility

Dealer distribution

Function(s)/component(s) affected
Function affected

SNV , engine , fuel system , injectors , DEF Dosing , SCR , Diagnostic tool

Function Group
Function Group

237 injector and delivery pipe , 254 catalytic converter; exhaust emission control
equipment , 258 emissions after-treatment

Customer effect
Main customer effect

stumble , regeneration , diagnostics/methodology , efficiency/abnormal behavior

Fluid problem

crystallisation , contamination

Fluid implicated

AdBlue , fuel

Road behaviour

driveability

Fault code(s)
US10 Fault Codes

SPN 651 FMI 3 , SPN 651 FMI 5 , SPN 652 FMI 3 , SPN 652 FMI 5 , SPN 653 FMI 3
, SPN 653 FMI 5 , SPN 654 FMI 3 , SPN 654 FMI 5 , SPN 655 FMI 3 , SPN 655
FMI 5 , SPN 656 FMI 3 , SPN 656 FMI 5

OBD 2013 Diagnostic

P020113 , P020213 , P020313 , P020413 , P020513 , P020613 , P026200 , P026500

Trouble Codes

, P026800 , P027100 , P027400 , P027700

Conditions

Vehicle operating mode
Frequency of occurrence of
problem

when driving , when stationary
always

Administration
Author

ut01793

Last modified by

RU4469V

Creation date

28-09-2016 17:09

Date of last update

06-02-2018 17:02

Status

Published

NA_VOLVO_Vehicle_Range
NA_VOLVO_Vehicle_Ra
nge

Conventional , VNR , VT , VNX , VNL , VNM , VHD , VAH

Engine family
Engine family

Volvo

Emission Standard
Emission Standard

US16 , US15 , US10 , US13 OBD , US14 GHG