Bulletin No.: 10-06-04-013C
Date: Dec-2015

Subject:

Information on Diesel Exhaust Fluid (DEF) Filling Instructions, Frozen Tank Status and General
Information

Models:

2010 Chevrolet Express Vans
2011-2016 Chevrolet Express Vans, Silverado 2500-3500HD
2010 GMC Savana Vans
2011-2016 GMC Savana Vans, Sierra 2500-3500HD
Equipped with 6.6L Duramax™ Diesel Engine (RPOs LML, LGH)

Attention:

This Bulletin also applies to any of the above models that may be Export vehicles.

This Bulletin has been revised to add the 2016 Model Year and update information under DEF Filling Instructions. Please
discard Corporate Bulletin Number 10-06-04-013B.
This bulletin covers various topics related to the diesel exhaust fluid (DEF) system and is broken down by topic. Please provide a copy to customers as a
reference point. This bulletin does not address any specific service repairs, only general information regarding the intended operation of the DEF system.

DEF Filling Instructions
Customers or dealers may have comments on adding fluid to the DEF tank. The capacity of the tank is 20♦L (5.3♦gal) and the trucks are shipped with 7.5♦L
(2♦gal) from assembly.
DEF basically behaves like water and will freeze at -11°C (12°F) and will expand. This does not normally cause a problem if the DEF tank is not overfilled.
Adding more than the 20♦L (5.3♦gal) usable capacity may not allow for DEF expansion when frozen.
To prevent damage from freezing, during PDI do not add more than the 13♦L (3.5♦gal) allowed during PDI. This should be done just before delivery to the
customer.
Tip: To maximize driving range and to prevent over filling the tank, wait until the "Exhaust Fluid Range: 1000 miles (approximate) (1609km)" message appears
on the DIC. At this point, add up to 13 L (3.5 gal). Do not add more than 13 L (3.5 gal) of DEF. When using the CC&A DEF 3.78 L (1 Gal) 19286291 (88862660
(Canada) or 9.46 L (2.5 Gal) 19286292 (88863524 (Canada) fluid with the nozzle properly installed, when fluid reaches the top of the fill pipe, stop filling.
Instructions are provided on the bottle for proper nozzle installation. If another source of DEF is being used, when fluid initially reaches the top of the fill pipe,
stop filling and do not force additional fluid into the tank.

Frozen Tank Status

Condition
In operating temperatures of 15°F (−9°C) or less, customers may comment on an “Exhaust Fluid Range” message displaying on the DIC even though the DEF
fluid has been filled.

Cause
When the DEF is frozen, the level sensor cannot determine the fluid level in the tank. If this occurs the logic of the PCM will assume a default fluid level. The
logic will use the calculated range based on DEF dosing history and the assumed fluid level.
If there is a high learned dosing rate and the fluid has not thawed to where the pins of the level sensor can function, there is a possibility the “Exhaust Fluid
Range” message can set with the range from approximately 1609 km (1000 mi) to less than 482 km (300 mi), even though the tank is known to have fluid or be
full.

1

Correction
This is an operating characteristic of the system. However to increase or eliminate the range message, once the range drops below 482 km (300 mi), the DEF
tank should be refilled. This should allow refill detection to occur and turn off the range indicator. The operator must be sure not to overfill the DEF tank using
the instructions provided in this bulletin or in the owner’s manual.
When in frozen tank status, refill detections are not allowed until the warning strategy reaches the point at which the distance remaining is less than 482 km
(300 mi). The refill detection is dependent on the DEF thawing enough that the level sensor pins can be read. A fully frozen tank can take almost an hour to
detect a refill, after the vehicle is started.
This condition should not be confused with the situation described in PIP4864: “Low Or Speed Limited Diesel Exhaust Fluid Message (DEF) Will Not Reset”.
However it can be very difficult to differentiate the PIP4864 and the Frozen Tank Status. If there is any question about which condition has occurred, and there
is an updated calibration available through TIS, follow the instructions in PIP4864.

Tank Fill Level Status and DEF Range Remaining
The DEF system only provides range information from approximately 1609 km (1000 mi) and lower. If there is not any warning, the range is more than 1609 km
(1000 mi) at the current usage rate. The range can and will change based on the environmental conditions and vehicle use.
The scan tool does show information on tank capacity, however it only covers approximately 6.32 L (1.67 gal) of volume and is used to calculate the remaining
range starting with the 1609 km (1000 mi) remaining status using 3 pins to detect the level status.
Using the scan tool in the ECM, Data Display function, the following information is available:
Reductant Level

Pins Detecting
Fluid

Volume Detected

33%

1

1.25 L (0.33 gal)

66%

2

3.74 L (0.99 gal)

100%

3

6.32 L (1.67 gal)

Distance remaining calculation has 3 phases:

•

Phase 1 – Fixed consumption mode

•
•
•
•

Active only when vehicle is first flashed.
Distance remaining is calculated based on the volume estimated in the tank and a calibrated consumption rate.
The system transitions to Phase 2 after a calibrated distance and minimum dosed quantity of DEF.

Phase 2 – Dynamic consumption mode

•
•
•

Distance remaining based on volume of mass in tank and rolling average of urea consumption using 5 blocks of data.
At transition from Phase 1, the 5 blocks are populated with average consumption from Phase 1.
The moving average of consumption rate is then updated at calibrated intervals (currently 320 km (200 mi) for Silverado/Sierra models and 400 km
(250 mi) for Express/Savana vans.

•

Phase 3 – Level below 2nd pin

•
•
•
•

Dynamic consumption mode (same as Phase 2)
Separate mileage interval can be applied once in Phase 3.
Silverado/Sierra = 160 km (100 mi)
Express/Savana = 200 km (125 mi)

Refill Detection Chart
The following chart shows the parameters related to how the DEF system recognizes a fluid fill.
If the truck is parked on an incline, it is possible a stationary refill detection may require more than 3.7 L (1 gal) to be recognized. Driving refill detection should
still function properly.
If the tank is frozen, the detection process can be delayed.

2

Driving Refill Detection

Override Refill Detection

Fast Refill Detection

—

Stationary refill detection

Stationary refill detection

Vehicle speed must be greater than 9 km/h

—

Tank level is set to raw value from DLS
(0%, 33%, 66%, 100%)

Allowed in warning levels 5–8, “Exhaust fluid
low : Speed limited soon” thru “ Exhaust fluid

Allowed in warning levels 5–8, “Exhaust fluid
low : Speed limited soon” thru “ Exhaust fluid

empty refill now-4 mph max speed next fluid
fill” (Inducement without fuel refill detected)

empty refill now-4 mph max speed next fluid
fill” (Inducement)

Allowed in Warning Levels None (0) - 4, up
to but not including "Exhaust Fluid Low:
Speed Limited Soon"

Can require up to 20 seconds to complete

Must be on level ground to reduce error
(Tied to fuel refill detection)

—

May be followed by a driving refill detection

Allowed without fuel refill detection at highest
warning level “Exhaust fluid empty now —

(6 mph) to release filters
Engine on timer determines time allowed to
detect refill ( currently 240 seconds)

speed limited to 4 mph”
—

Once refill is detected, speed limitation is not

Once refill is detected, speed limitation is not

released until vehicle speed=0 mph which
means it must come to a complete stop

released until vehicle speed=0 mph which
means it must come to a complete stop

Warning Level Strategy
The following information describes the warning level strategy.
An adequate on-board supply of diesel exhaust fluid (DEF) is critical for the reduction of exhaust oxides of nitrogen (NOx) levels within the selective catalyst
reduction (SCR) stage. This vehicle provides the driver with an elaborate series of prompts and warnings that are initiated when the DEF level falls below a
calibrated value to insure the vehicle remains compliant to emissions regulations.
The engine control module (ECM) monitors the DEF level and consumption rate in order to calculate an estimated range in miles remaining until the DEF
reservoir is empty. DEF levels are detected by the position solid-state DEF level sensor. Typically, DEF warnings begin once the estimated mileage falls below
1,609 km (1,000 mi). Once initiated, DEF warnings grow increasingly more serious as the remaining mileage decreases without a DEF refill. The vehicle’s
current DEF warning level is displayed on the scan tool as Reductant Level Warning Indicator Command Level 1 through Level 9. If the vehicle is not in any
warning strategy, it will be displayed as “None.”

Warning Level 1
Warning Level 1 is triggered when the DEF level falls below the top-most position of the DEF Level Sensor and the estimated range remaining is greater than
1609 km (1000 mi). No prompts or warnings are presented to the driver.

Warning Level 2
Warning Level 2 is triggered when the estimated range remaining falls below 1,609 km (1,000 mi) based on current DEF consumption rates. The driver
information center (DIC) displays the message Exhaust Fluid Range X MI, where X is the estimated range remaining in miles. This message remains on the DIC
until acknowledged by the driver.

Warning Level 3
Warning Level 2 automatically advances to Warning Level 3 when the ECM detects an ignition ON to ignition OFF event. A level 3 warning remains active as
long as the estimated range remaining is greater than 644 km (400 mi) based on current DEF consumption rates. No prompts or warnings are presented to the
driver.

Warning Level 4
Warning Level 4 is triggered when the estimated range remaining falls below 644 km (400 mi) based on current DEF consumption rates. The message Exhaust
Fluid Range X MI, where X is the estimated range remaining in miles is displayed on the DIC. This message is also displayed at the beginning of each ignition
cycle. This message remains on the DIC until acknowledged by the driver.

Warning Level 5
Warning Level 5 is triggered when the estimated range remaining is less than approximately 121 km (75 mi) based on current DEF consumption rates. The
message Exhaust Fluid Low - Speed Limited Soon, is displayed on the DIC. This message is also displayed at the beginning of each ignition cycle. This
message remains on the DIC until acknowledged by the driver.
3

Warning Level 6
Warning Level 6 is triggered when the estimated range remaining is less than approximately 0 km (0 mi) based on current DEF consumption rates. The driver
will hear four chimes on entering Warning Level 6. The DIC displays the following messages:

•

Exhaust Fluid Empty Refill Now

•

89 km/h (55 mph) Max Speed upon Restart

The messages are also displayed at the beginning of each ignition cycle. The Exhaust Fluid Empty Refill Now message remains on the DIC until acknowledged
by the driver. The 89 km/h (55 mph) Max Speed Upon Restart message is not acknowledgeable.
At the next ignition ON event, the system will advance from Warning Level 6 to Warning Level 7. If fuel is added to the vehicle without an ignition cycle the
system will advance to Warning Level 8.
In the event of a refill, the scan tool may show that fluid has been added, but the vehicle may not release from the warning level unless it is driven for greater
than 10 km/h (6 mph) for approximately five minutes.
If the vehicle speed has been limited and DEF has been added, it may take up to 30 seconds after engine start with the vehicle stopped for the EXHAUST
FLUID EMPTY message to clear. If the vehicle is driven prior to the DIC message clearing, the vehicle speed will still be limited. If the DIC message clears while
driving, the vehicle must be completely stopped to remove the speed limitation.
If DEF is added under freezing conditions, additional time may be required to remove speed limitations.

Warning Level 7
Warning Level 7 is active at the next ignition ON event. The driver will hear four chimes on entering Warning Level 7. The four chimes are repeated three more
times during this ignition cycle. The DIC displays the following messages:

•

Exhaust Fluid Empty Refill Now

•

Speed Limited to 89 km/h (55 mph)

The messages are alternately displayed every five seconds on the DIC. Both messages remain on the DIC until acknowledged by the driver; however, the
Speed Limited to 89 km/h (55 mph), remains locked on the DIC.
The DEF Indicator in the instrument panel flashes continuously. Warning Level 7 remains active until a refueling event is detected.
Vehicle speed is now limited to 89 km/h (55 mph) maximum.
In the event of a refill, the scan tool may show that fluid has been added, but the vehicle may not release from the warning level unless it is driven for greater
than 10 km/h (6 mph) for approximately five minutes.
If the vehicle speed has been limited and DEF has been added, it may take up to 30 seconds after engine start with the vehicle stopped for the EXHAUST
FLUID EMPTY message to clear. If the vehicle is driven prior to the DIC message clearing, the vehicle speed will still be limited. If the DIC message clears while
driving, the vehicle must be completely stopped to remove the speed limitation.
If DEF is added under freezing conditions, additional time may be required to remove speed limitations.

Warning Level 8
Warning Level 8 is triggered when the ECM detects that additional fuel was added without a refill of the DEF reservoir. The driver will hear four chimes on
entering Warning Level 8. The four chimes will repeat three more times during this ignition cycle. The DIC displays the following messages:

•

Exhaust Fluid Empty Refill Now

•

Speed Limited to 89 km/h (55 mph)

•

6 km/h (4 mph) Max Speed at Next Fuel Fill

The messages are alternately displayed every five seconds on the DIC. The three messages remain on the DIC until acknowledged by the driver. Once
acknowledged, the Speed Limited to 89 km/h (55 mph), and 6 km/h (4 mph) Max Speed at Next Fuel Fill, remain locked on the DIC.
The DEF Indicator in the instrument panel flashes continuously. The vehicle remains in Warning Level 8 until the DEF reservoir is refilled or a second refueling
event is detected.
Vehicle speed is limited to 89 km/h (55 mph) maximum.
In the event of a refill, the scan tool may show that fluid has been added, but the vehicle may not release from the warning level unless it is driven for greater
than 10 km/h (6 mph) for approximately five minutes.
If the vehicle speed has been limited and DEF has been added, it may take up to 30 seconds after engine start with the vehicle stopped for the EXHAUST
FLUID EMPTY message to clear. If the vehicle is driven prior to the DIC message clearing, the vehicle speed will still be limited. If the DIC message clears while
driving, the vehicle must be completely stopped to remove the speed limitation.
If DEF is added under freezing conditions, additional time may be required to remove speed limitations.

Warning Level 9
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Warning Level 9 is triggered on the next ignition cycle following a second refueling event without a refill of the DEF reservoir. The driver will hear four chimes on
entering Warning Level 9. The four chimes will repeat every three minutes until the DEF reservoir is refilled. The DIC displays the following messages: