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1/31/22, 2:43 PM
Article
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Volvo Chassis - Diesel Exhaust Fluid ( DEF )
Contamination In Fuel System, Inspection And
Repair - US10 to US14 ( Non-Common Rail Fuel
System )
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Internal Content
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
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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
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blacklight. DEF will fluoresce (glow) under blacklight as shown below.
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Crystallization in Normal Light
Article
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.
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