1. Shut off engine and apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
2. Disconnect the batteries. Refer to OEM procedures.
3. Remove the four mounting bolts that secure the protective cover (1).
4. Remove the nuts and washers (1) holding the Diesel Exhaust Fluid (DEF) pump mounting bracket (4) to the
DEF tank bracket (2).
5. Remove the DEF pump (3) from the mounting studs.
6. Remove the two bolts (5) that fasten the DEF pump to the mounting plate. See graphic above.
7. Rotate the DEF pump upward to gain access to the Pressure Relief Valve.
8. The outer area of the DEF pump module must be free of dirt and any contaminants before removing the
valve.
9. Remove the plug screw (3) from the DEF pump module (1). See below graphic.
10. Use a ¼-in. fine thread bolt (UNF) (2) to remove the pressure relief valve (4), or the special tool supplied in
the DEF/Doser kit.
11. Thread the tool into the rear of the pressure relief valve and pull to remove.
Installation of the Diesel Exhaust Fluid Pump Pressure Relief
Valve
1. Press the new pressure relief valve (4) into the Diesel Exhaust Fluid (DEF) pump (1).
NOTICE
Using power tools on the DEF pump plug screw may cause stripping of the DEF pump
threads. Be sure to completely hand-tighten the plug screw (3) before torqueing.
2. Install the plug screw (3) and hand-tighten.
3. Torque the plug screw to 5 N·m (44 lb·in.).
4. Install the two bolts (5) that fasten the DEF pump (3) to the mounting bracket (4). Torque to 18 N·m (13
lb·ft). See below graphic.
5. Install the DEF pump and mounting bracket onto the mounting studs of the DEF tank bracket (2) and install
nuts and washers (1). Torque to 31 N·m (23 lb·ft).
6. Install the DEF pump protective cover (1). Install and torque bolts to 50 N·m (37 lb·ft)
7. Connect the batteries. Refer to OEM procedures.
8. Start the engine.
9. Using DiagnosticLink , perform an ADS Priming Function to prime the DEF system and check for leaks.
Removal of the Diesel Exhaust Fluid Pump Module Inlet Screen
1. Shut off engine and apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
2. Disconnect the batteries. Refer to OEM procedures.
3. Remove the Diesel Exhaust Fluid (DEF) pump cover.
4. Remove the DEF supply line from the DEF pump inlet fitting (1).
5. Remove the DEF inlet fitting from the DEF pump module.
6. Using a small pick, pull the filter screen (2) from the DEF pump module.
Installation of the Diesel Exhaust Fluid Pump Module Inlet
Screen
1. Install a new Diesel Exhaust Fluid (DEF) pump module filter screen (2) into the inlet port.
Note : Using power tools on the DEF pump inlet fitting may cause stripping of the DEF pump threads. Be sure to
completely hand-tighten the inlet fitting (1) before torquing.
2. Install the DEF line inlet fitting (1) in to the pump module and hand tighten the DEF line inlet fitting.
3. Torque the DEF line inlet fitting to 14 N·m (10 lb·ft).
4. Verify the DEF supply line and inlet fitting are free of dirt and DEF crystals and install DEF supply line.
5. Install the DEF pump protective cover. Install and torque bolts to 50 N·m (37 lb·ft).
6. Connect the batteries.
7. Start the engine.
8. Using DiagnosticLink , perform an ADS Priming Function to prime the DEF system and check for leaks.
Removal of the Diesel Exhaust Fluid Pump Module Coolant
Line Connector Fitting
1. Remove the screw (1) retaining the coolant connector fitting (2) to the Diesel Exhaust Fluid (DEF) pump
module (4).
2. Remove the coolant connector fittings from the DEF pump module