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:
03/29/2019 - Changed emission year from 2017 to 2016 to match EPA verbiage on tables 3,4, and 5
03/26/2019 - Update keywords for searchability. No content change.
01/10/2019 - Re-added/ Updated Table 3: 5 and 15 Gallon DEF Head Unit Kit Numbers Table
12/18/2018 - Updated 5 and 15 gal return hose table
09/05/2018 - Eliminated reference to retired iKNow aticle referencing field action repair between steps 4 and 5

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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 Figure 1 and 2 below. The NEW style DEF
head unit uses only ultrasonic waves to measure the level and DEF quality, shown in Figure 3 below.

Figure 1: Float ONLY DEF Head Unit
(FLS)

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

Figure 3: Ultrasonic DEF Head Unit

2. Compatibility

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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.

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.
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.
Cummins powered vehicles do not require a calibration change.
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 require an updated calibration.
6. Vehicles built with A26 engines do NOT require an updated calibration. These engines were built with ultrasonic DEF head unit compatibility.

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
susceptible 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 2-3 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.

If diesel fuel, oil, or coolant is ever found in the DEF tank, the sensor must be replaced.
4. 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.

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.
5. 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)

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Not Applicable

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.

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

18-637-01

4328516R1

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)

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

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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

KIT, 5 GAL DEF SENSOR (2013 EMISSIONS)
includes sensor, two DEF lines, and vent hose
KIT, 15 GAL DEF SENSOR (2013 EMISSIONS)
includes sensor, two DEF lines, and vent hose

No additional parts required

2016 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.

Reference table "2017 Emissions, 5 GAL Return Hose" to
determine the additional return hose that needs to be ordered

2016 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.

Reference table "2017 Emissions, 15GAL DEF Return Hose" to
determine additional return hose that needs to be ordered

2518077C92

2013-2015 Federal Emissions Year

2518080C92

2013-2015 Federal Emissions Year

2518078C92

2518081C92

No additional parts required

For 5 gallon DEF Tanks:
2016 EMISSIONS, 5GAL DEF RETURN HOSE (CHOOSE ONE BASED ON WHAT YOUR TRUCK WAS BUILT WITH)
DESCRIPTION

LENGTH
(mm)

LENGTH
(in)

"A" End Size
w/elect. Conn.

"A" End
Angle

"B" End "B" End
Size
Angle

REMOVE 4078908C1