IK0700097 - NEW Ultrasonic DEF Head Unit

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Title : NEW Ultrasonic DEF Head Unit
Applies To : All SCR Vehicles

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
06/26/2018 ­ Republished to address article feedback
05/21/2018 - Changed verbiage of DEF tank sending unit to DEF head unit
04/24/2018 ­ Part number change per feedback­ 4100837C1 to 4101226C1
04/03/2018 - Author updated for feedback purposes
02/09/2018 - Added part numbers and calibration IDs




DESCRIPTION
1. Overview
There is a NEW DEF head unit available. This document will guide the user through the differences between the two styles, when to replace a sensor, and
what tools/kits are available when diagnostics lead to replacing the DEF head unit.
The current style DEF head unit has a float to measure the level and an LED to measure the DEF quality, shown in Image 1 and 2 below. The NEW style
DEF head unit uses only ultrasonic waves to measure the level and DEF quality, shown in Image 3 below.

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IK0700097 - NEW Ultrasonic DEF Head Unit

Figure 1: Float ONLY DEF Head
Unit (FLS)

Figure 2: Float and Optical DEF Head Unit (QLS)

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Figure 3: Ultrasonic DEF Head Unit

2. Compatibility
The ultrasonic DEF head unit is compatible with all vehicles built between 2012 and present using SCR. Since the concentration sensor was not required
until federal emissions 2016, vehicles built prior to 2016 will use a sensor without concentration functionality. This ultrasonic sensor will look identical in
appearance to its counterpart with added concentration functionality.

NOTE: If an ultrasonic DEF head unit without concentration sensor functionality is installed on a vehicle
that requires the concentration sensor, fault codes will be present and the correct ultrasonic DEF head
unit must be installed.
The ultrasonic DEF head unit is only available for Cummins powered vehicles at this time. There are no calibration updates required to service the sensor.
Navistar powered vehicles will REQUIRE a calibration update to the ECM and ACM at the time the ultrasonic DEF head unit is installed for the first time.
1. Vehicles built from January 2016 to present with N9 or N10 engines will require an updated calibration. The last 4 digits of the calibration ID must be
NMR1, NMW1, or later.
2. Vehicles built before January 2016 with N9 or N10 engines will require an updated calibration.
3. Vehicles built from January 2016 to present with N13 engines will require an updated calibration. The last letter of the ACM calibration ID must be "C" or
later (eg. OYANDXC)
4. Vehicles built in 2015 with N13 engines will require an updated calibration. The last letter of the ACM calibration ID must be "C" or later (eg. OSANDXC)
5. Vehicles built before January 2015 with N13 engines will require an updated calibration. The calibration has not been released yet.
6. Vehicles built with A26 engines do NOT require an updated calibration. These engines were built with ultrasonic DEF head unit compatibility.

NOTE: Both Optical and Ultrasonic DEF head units will be available for service simultaneously. Ultrasonic
DEF head units will replace the float and optical DEF head units as inventory diminishes. Some tank sizes
will diminish inventory before others.

3. Ultrasonic DEF head Unit Boot Encapsulation Slow to Fill Alert
The new ultrasonic DEF head unit has a silicone boot encapsulation around the concentration sensor and the bottom of the level tube. The sensor is
suspectible to a delayed level reading due to the boot encapsulation which takes about five minutes to fill with DEF, but could take up to 15 minutes. Any time
a new ultrasonic DEF head unit is installed, it should be dunked in the DEF 2­3 times at a rapid pace to initialize some flow of DEF through the boot
encapsulation. If any low DEF level fault codes are active after installation such as 1761-17, 1761-18, or 1761-1, the boot encapsulation must be cleared of
any air. Refer to the Repair Steps section for instructions to service the DEF head unit. For new sensors experiencing interference issues, refer to item 4.
DEF Tank Cutting Tool.

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IK0700097 - NEW Ultrasonic DEF Head Unit

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If diesel fuel, oil, or coolant is ever found in the DEF tank, the sensor must be replaced.

4. Float and Optical DEF Head Unit Boot Kit
Some vehicles may experience aeration or other issues in which a float and optical sensor replacement is NOT required. For diagnostic procedures,
follow each associated FCAP. DEF head unit boot kit instructions and supplemental diagnosc steps for "bubble codes" are located in iKNow article
IK0700096.

5. DEF Tank Cutting Tool for Interference Issues During Installation
If a float and optical DEF head unit is replaced with an ultrasonic DEF head unit, some units may experience interference when installing the ultrasonic
DEF head unit in the tank. If any interference is witnessed, use the Ultrasonic Sensor Tank Cutting Tool. Refer to the Special Tools section to find the tool
part number and instructions.

NOTE: All 7 gallon sensors will likely experience interference when attempting to install
the ultrasonic sensor for the first time.

Do NOT remove the tie straps from the ultrasonic DEF head unit. If the tie straps are
compromised, the ultrasonic DEF head unit must be replaced.

6. 5 and 15 Gallon DEF Line Interference
If a float and optical DEF head unit is replaced with an ultrasonic DEF head unit on 5 and 15 gallon tanks, the DEF lines MUST be replaced. Without replacing
the DEF lines, the DEF head unit will not fit in its original location due to different DEF supply and return tube orientation. Refer to the Service Parts
Information section to find the 5 and 15 gallon ultrasonic head unit kits.

SYMPTOM(s)
N/A

SPECIAL TOOL(s) / SOFTWARE
DEF TANK CUTTING TOOL
If a float and optical DEF head unit is replaced with an ultrasonic DEF head unit, some units may experience interference when installing the ultrasonic
DEF head unit in the tank. Follow Step 1 below to determine if the DEF tank opening is large enough to support the ultrasonic DEF head unit.
Step 1. Measure the opening of the DEF tank. The opening should be at least 90 mm in diameter in any direction. If the DEF tank opening is not at least
90 mm, the Ultrasonic Sensor Cutting Tool should be used to cut the tank opening to a larger size. Refer to Table 1 below for DEF tank cutting tool part
number and instructions. The instructions are also included with the tool.

NOTE: All 7 gallon sensors will likely experience interference when attempting to install
the ultrasonic sensor for the first time.

Do NOT remove the tie straps from the ultrasonic DEF head unit. If the tie straps are
compromised, the ultrasonic DEF head unit must be replaced.

Table 1: DEF Tank Cutting Tool
Tool Description

Tool Number

Instructions

Ultrasonic Sensor Tank Cutting Tool

18­637­01

4328516R1

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IK0700097 - NEW Ultrasonic DEF Head Unit

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NOTE: Instructions are subject to revision, if printing discard after single use.

SERVICE PARTS INFORMATION
Ultrasonic DEF head unit will become available in PDCs as float and optical DEF head unit supply diminish. Therefore, some tank sizes will become
available before others. Refer to the overview in the Description section of this iKNow article to determine if this iKNow article applies.
DEF head unit must be ordered as critical unit down orders which requires a VIN to process the order. The part numbers for ultrasonic DEF head unit are
listed in Table 2 below.

Table 2: DEF Head Unit Part Numbers
Part Number

Emissions Year

Description

4097721C91

2016 to Present Federal Emissions Year

TANK, DEF, 5 GAL, HEAD UNIT, QLS

4097722C91

2016 to Present Federal Emissions Year

TANK, DEF, 7 GAL, HEAD UNIT, QLS

4097723C91

2016 to Present Federal Emissions Year

TANK, DEF, 9.5 GAL, HEAD UNIT, QLS

4097724C91

2016 to Present Federal Emissions Year

TANK, DEF, 12 GAL, HEAD UNIT, QLS

4097725C91

2016 to Present Federal Emissions Year

TANK, DEF, 15 GAL, HEAD UNIT, QLS

4097727C91

2016 to Present Federal Emissions Year

TANK, DEF, 16/23 GAL, HEAD UNIT, QLS

4097728C91

2017 to Present Federal Emission Year

TANK, DEF, 10.6/15.9/25.2 GAL TANK, HEAD UNIT, QLS

4099716C91

2013 to 2015 Federal Emissions Year

TANK, DEF, 9.5 GAL, HEAD UNIT, FLS

4099715C91

2013 to 2015 Federal Emissions Year

TANK, DEF, 7 GAL, HEAD UNIT, FLS

4099717C91

2013 to 2015 Federal Emissions Year

TANK, DEF, 16/23 GAL, HEAD UNIT, FLS

2518086C1

All ultrasonic DEF head unit

FILTER, SSI DEF SENSOR

2518087C1

All ultrasonic DEF head unit

KIT, DEF SENSOR SEAL (SSI)

NOTE: Federal emissions year is located in Service Portal > Components for the
associated VIN.

5 AND 15 GALLON DEF LINE INTERFERENCE
If a float and optical DEF head unit is replaced with an ultrasonic DEF head unit on 5 and 15 gallon tanks, the DEF lines MUST be replaced. Without replacing
the DEF lines, the DEF head unit will not fit in its original location due to different DEF supply and return tube orientation. Refer to Images 4 and 5 below to
see the differences in DEF tube orientation.

Figure 4: DEF tube orientation of 5/15 gallon
float/optical sensor

Figure 5: DEF tube orientation of 5/15
gallon ultrasonic sensor

Table 3 below is the comprehensive list of kits that should be ordered for 5 and 15 gallon DEF tanks ONLY when converting from float and optical DEF head
unit to ultrasonic DEF head unit. Use the table appropriately to find the correct part number to order.

Table 3: 5 and 15 Gallon DEF Head Unit Kit Numbers
Kit Number

Emissions Year

Description

Additional Parts

2518077C92

2013-2016 Federal Emissions Year

KIT, 5 GAL DEF SENSOR (2013 EMISSIONS)
includes sensor, two DEF lines, and vent hose

No additional parts required

2518080C92

2013-2016 Federal Emissions Year

KIT, 15 GAL DEF SENSOR (2013 EMISSIONS)
includes sensor, two DEF lines, and vent hose

No additional parts required

2518078C92

2017 and beyond Federal Emissions Year

KIT, 5 GAL DEF SENSOR (2017 EMISSIONS)
includes sensor, one DEF line, and vent hose.
Additional DEF line is required to be ordered
separately.

•

For WorkStar vehicles, 4101226C1 must be ordered.

•

For DuraStar vehicles, 4079659C1 must be ordered.

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IK0700097 - NEW Ultrasonic DEF Head Unit

2518081C92

2017 and beyond Federal Emissions Year

KIT, 15 GAL DEF SENSOR (2017 EMISSIONS)
includes sensor, one DEF line, and vent hose.
Additional DEF line is required to be ordered
separately.

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•

For DuraStar vehicles with regular cab height,
4101350C1 must be ordered.

•

For DuraStar vehicles with low cab height, 4096172C1
must be ordered.

NOTE: Federal emissions year is located in Service Portal > Components for the
associated VIN.

Refer to Repair Steps section below for assembly instructions.

DIAGNOSTIC STEP(s)
When fault codes are present, refer to appropriate Fault Code Action Plan (FCAP) to locate proper repair guidlines.

REPAIR STEP(s)
When servicing the ultrasonic DEF head unit and DEF lines, refer to Exhaust Aftertreatment System with SCR EPA 10 Service Manual for proper repair
instructions. Use the proper torque sequence from Figure 6 and Table 4 below.

Figure 6: Ultrasonic DEF head unit torque sequence
Table 4: Sensor Bolt Torque Sequence
Position

Torque (Nm) Cycle
Torque (Nm) Cycle 2
1

1

1-2

4-9

2

1-2

4-9

3

1-2

4-9

4

1-2

4-9

5

1-2

4-9

6

1-2

4-9

NOTE: Instructions are subject to revision, if printing discard after single use.

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 18050 - SCR Aftertreatment

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IK0700097 - NEW Ultrasonic DEF Head Unit

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Noun: 124 ­ Sensor Assembly Def Tank

Standard Repair Time(s):
Refer to the SRT Manual for Repair Times

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Comments

Created
Date

You received the following feedback From: dyyccw3 - Chris Wielenga Email Address: [email protected] Job Classification: AD006, Warranty Manager Dealer: SUMMIT
6/29/2018
DYYCCW3 MOTORS LTD Feedback: We had an EPA2015 truck w/Cummins ISX w/16 GAL tank, in the shop. The Parts Catalogue "Remark" for p/n 2510966C3 stated that ultrasonic sensor
9:29:06 AM
4097727C91 was to be used. However, the p/n matrix in this document says we need to use 4099717C91.
DY00184

You received the following feedback From: dy00184 - Shane Hoye Email Address: [email protected] Job Classification: SE006, Service Foreman Dealer: HILL INTL
TRUCKS NA LLC Feedback: We currently ran into some issues with getting the correct sensor for a jh440179. We order for 2017 unit and needed 2013 units. Id like to see a little
more clarification on the parts for this article as to aid in ordering the right parts. 4 of us looked at it and was cofused by some of it.

6/29/2018
11:40:40 AM

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