NHTSA ID Number: 10236685
Manufacturer Communication Number: TSB 23-2161
TSB/Document Date: 2023-05-31
Summary
Some 2018-2021 F-150 vehicles equipped with a 3.0L diesel engine, 2016-2022 F-650/F-750 vehicles equipped with a 6.7L engine, and 2017-2022 F-Super Duty vehicles equipped with a 6.7L engine and built on or before 08-Mar-2022 may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P21DD, P20BA. P20B9, P204C, P208A, P208B, P208C, P203B, P205B, P21CD and/or U02A2 in the powertrain control module (PCM). This may be due to water intrusion within connectors C3613 and/or C4851/C3610 on the reductant harness going to the reductant pump/heater assembly and the reductant level sensor/quality module. This may also be due to movement of the wiring harness causing terminal fretting. To correct the condition, follow the Service Procedure to replace the reductant tank harness, the reductant pump/heater assembly and/or the reductant tank, as well as securing the wiring harness using a cable zip tie fastener.
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TECHNICAL SERVICE BULLETIN
3.0L/6.7L - Illuminated MIL With Various Reductant System Related DTCs
23-2161
22 May 2023
This bulletin supersedes 22-2191. Reason for update: Revised Part List
Model:
Ford
2018-2021 F-150
Engine: 3.0L
2017-2022 F-Super Duty
Engine: 6.7L
Built on or before 08-Mar-2022
2016-2022 F-650/F-750
Engine: 6.7L
Summary
This article supersedes TSB 22-2191 to update the Part List.
Issue: Some 2018-2021 F-150 vehicles equipped with a 3.0L diesel engine, 2016-2022 F-650/F-750 vehicles
equipped with a 6.7L engine, and 2017-2022 F-Super Duty vehicles equipped with a 6.7L engine and built on or
before 08-Mar-2022 may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs)
P21DD, P20BA. P20B9, P204C, P208A, P208B, P208C, P203B, P205B, P21CD and/or U02A2 in the powertrain
control module (PCM). This may be due to water intrusion within connectors C3613 and/or C4851/C3610 on the
reductant harness going to the reductant pump/heater assembly and the reductant level sensor/quality module. This
may also be due to movement of the wiring harness causing terminal fretting. To correct the condition, follow the
Service Procedure to replace the reductant tank harness, the reductant pump/heater assembly and/or the reductant
tank, as well as securing the wiring harness using a cable zip tie fastener.
Action: Follow the Service Procedure to correct the condition on vehicles that meet all of the following criteria:
• One of the following vehicles:
- 2018-2021 F-150
- 2017-2022 F-Super Duty built on or before 08-Mar-2022
- 2016-2022 F-650/F-750
• 3.0L diesel or 6.7L diesel engine
• DTCs P21DD, P20BA. P20B9, P204C, P208A, P208B, P208C, P203B, P205B, P21CD and/or U02A2
stored in the PCM
Parts
Service Part
Number
Quantity Description
Unit of
Issue
Piece
Quantity
4L3Z-9276-AA
1
Sealing Pump To Tank Gasket
1
1
KC3Z-5J250A
1
Inboard Frame Mounted Reductant
Tank (F-Super Duty Pickup)
1
1
HC3Z-14407A
1
Inboard Frame Mounted Reductant
Tank Harness (F-Super Duty Pickup)
1
1
KC3Z-5J250B
1
Outboard Frame Mounted Reductant
Tank (F-Super Duty Chassis Cab)
1
1
HC3Z-14407B
1
Outboard Frame Mounted Reductant
Tank Harness (F-Super Duty Chassis
Cab)
1
1
JL3Z-5J250-A
1
Reductant Tank (F-150)
1
1
JL3Z-14407AA
1
1
1
Reductant Tank Harness (F-150)
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FC4Z-5J250H
1
1
1
FC4Z-14407C
1
Reductant Tank Harness (F-650/F750)
1
1
HC3Z-5J229B
1
Reductant Tank Pump/Heater
Assembly (All Vehicles)
1
1
W520804S439
1
4
1
F-Super Duty requires 2
different J-nut part
numbers
W719567S439
1
4
2
F-Super Duty requires 2
different J-nut part
numbers
W503300S450
1
Reductant Tank Retaining Strap Bolts
(F-650/F-750)
4
4
W520803S439
1
Reductant Tank Retaining Strap Jnuts (F-650/F-750)
4
4
TMRCL6
1
Natural Cable Tie, 6 In. 40 Lb - Or
Equivalent No Thicker Than 1.2 mm
(0.047 in.)
100
1
Reductant Tank (F-650/F-750)
Reductant Tank Retaining J-nut (FSuper Duty)
Reductant Tank Retaining J-nut (FSuper Duty)
Rotunda Technician Tools
Program part number
Parts
Parts To Inspect And Replace Only If Necessary
Service Part
Number
Unit of
Issue
Quantity Description
W716694-S300
If
Needed
Lower Reductant Tank Cover Access Door Retainer (F-Super Duty,
F-150)
PM-27-GAL
If
Needed
Diesel Exhaust Fluid (Only If The Reductant Tank Is Replaced)
PM-27-JUG
If
Needed
Diesel Exhaust Fluid (Only If The Reductant Tank Is Replaced)
4
1 Gallon
2.5 Gallons
Quantity refers to the amount of the service part number required to repair the vehicle.
Unit of Issue refers to the number of individual pieces included in a service part number package.
Piece Quantity refers to the total number of individual pieces required to repair the vehicle.
As Needed indicates the amount of the part may vary and/or is not a whole number. Parts can be billed out as nonwhole numbers, including less than 1.
If Needed indicates the part is not mandatory.
Labor Times
Description
Operation
No.
Time
2017-2022 F-250 - F-550 6.7L DIT Pick Up: Retrieve DTCs, Inspect Connectors And Replace
Harness Includes Time To Install Cable Tie (Do Not Use With Any Other Labor Operations)
232161A
0.6
Hrs.
2017-2022 F-250 - F-550 6.7L DIT Pick Up: Retrieve DTCs, Inspect Connectors And Replace
Harness And The Reductant Pump /Heater Assembly Includes Time To Install Cable Tie (Do
Not Use With Any Other Labor Operations)
232161B
1.5
Hrs.
2017-2022 F-250 - F-550 6.7L DIT Pick Up: Retrieve DTCs, Inspect Connectors And Replace
Harness And The Reductant Tank Assembly Includes Time To Install Cable Tie (Do Not Use
With Any Other Labor Operations)
232161C
1.3
Hrs.
2017-2022 F-350 - F-550 Chassis Cab 6.7L DIT: Retrieve DTCs, Inspect Connectors And
Replace Harness Includes Time To Install Cable Tie (Do Not Use With Any Other Labor
Operations)
232161D
0.6
Hrs.
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2017-2022 F-350 - F-550 Chassis Cab 6.7L DIT: Retrieve DTCs, Inspect Connectors And
Replace Harness And The Reductant Pump /Heater Assembly Includes Time To Install Cable
Tie (Do Not Use With Any Other Labor Operations)
232161E
1.6
Hrs.
2017-2022 F-350-F-550 Chassis Cab 6.7L DIT: Retrieve DTCs, Inspect Connectors And
Replace Harness And The Reductant Tank Assembly Includes Time To Install Cable Tie (Do
Not Use With Any Other Labor Operations)
232161F
1.4
Hrs.
2016-2022 F-650/F-750 6.7L DIT: Retrieve DTCs, Inspect Connectors And Replace Harness
Includes Time To Install Cable Tie (Do Not Use With Any Other Labor Operations)
232161G
0.5
Hrs.
2016-2022 F-650/F-750 6.7L DIT: Retrieve DTCs, Inspect Connectors And Replace Harness
And The Reductant Pump /Heater Assembly Includes Time To Install Cable Tie (Do Not Use
With Any Other Labor Operations)
232161H
1.6
Hrs.
2016-2022 F-650/F-750 6.7L DIT: Retrieve DTCs, Inspect Connectors And Replace Harness
And The Reductant Tank Assembly Includes Time To Install Cable Tie (Do Not Use With Any
Other Labor Operations)
232161J
1.4
Hrs.
2018-2021 F-150 3.0L Diesel: Retrieve DTCs, Inspect Connectors And Replace Harness
Includes Time To Install Cable Tie (Do Not Use With Any Other Labor Operations)
232161K
0.6
Hrs.
2018-2021 F-150 3.0L Diesel: Retrieve DTCs, Inspect Connectors And Replace Harness And
The Reductant Pump /Heater Assembly Includes Time To Install Cable Tie (Do Not Use With
Any Other Labor Operations)
232161L
1.4
Hrs.
2018-2021 F-150 3.0L Diesel: Retrieve DTCs, Inspect Connectors And Replace Harness And
The Reductant Tank Assembly Includes Time To Install Cable Tie (Do Not Use With Any Other
Labor Operations)
232161M
1.4
Hrs.
Repair/Claim Coding
Causal Part:
14407
Condition Code: 49
Service Procedure
NOTE: For DTCs P21DD, P20BA, P20B9, P204C, P208A, P208B, P208C this can indicate a concern with
connector C3613. For DTCs P21CD, P203B, P205B and/or U02A2 this can indicate a concern with connector
C4851 (F-Super Duty) or connector C3610 (F-150, F-650/F-750).
1. Disconnect and inspect C3613 (16 pin connector) at the reductant pump/heater assembly and C4851/C3610 (4
pin connector) at the reductant level sensor/quality module for signs of corrosion. Refer to the Workshop Manual
(WSM), Section 303-08 and the Wiring Diagram.
(1). Inspect both the harness side and component side of both connectors for signs of water intrusion. Focus on
all pins at connector C3613 and pins 1 and 4 at connector C4851/C3610. Inspect for signs of:
• Visible green corrosion on multiple terminals on the harness side of connector C3613. (Figure 1)
Figure 1
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• Corroded pins on the reductant pump/heater assembly at connector C3613. (Figure 2)
Figure 2
• Visible green corrosion on the reductant level sensor/quality module side of connector C4851/C3610. (Figure 3)
Figure 3
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• Visible green corrosion on the harness side of connector C4851/C3610. (Figure 4)
Figure 4
2. Follow the appropriate procedure:
(1). If no signs of corrosion or water intrusion are present on either connector or component, replace the reductant
tank harness only.
(2). If signs of corrosion or discoloration are present on the reductant tank harness connector C3613 or reductant
pump/heater assembly perform the following:
• If there is corrosion or discoloration on the reductant tank harness connector only and not on the reductant pump/heater
assembly, only replace the reductant tank harness.
• If there are signs of corrosion or discoloration on the reductant pump/heater assembly, replace both the reductant tank
harness and the reductant pump/heater assembly. Refer to WSM, Section 303-08.
(3). If signs of corrosion or discoloration are present on the reductant tank harness connector C4851/C3610 or the
reductant level sensor/quality module perform the following:
• If there is corrosion or discoloration on the reductant tank harness connector only and not the reductant level sensor/quality
module, only replace the reductant tank harness.
• If there are signs of corrosion or discoloration on the reductant level sensor/quality module, replace both the reductant tank
harness and the reductant tank (reductant level sensor/quality module built in).
NOTE: Do not add any dielectric grease to the electrical connectors.
3. Prior to installing the reductant tank, using a 40lb tensile strength cable zip tie fastener, secure the harness to the
reductant pump metal lock ring. (Figures 5-7)
Figure 5
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Figure 6
Figure 7
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© 2023 Ford Motor Company
All rights reserved.
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and
equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information
that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition
described affects your car or truck. Contact a Ford or Lincoln dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy
and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.
The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supersede
this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.
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TSB/Document ID: TSB 23-2161
Replacement Service Bulletin Number:
MFR Communication Date: 2023-05-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
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