Service Bulletin

Volvo Trucks North America

Greensboro, NC USA Trucks
Date Group No. Release Page

4.2010 258 84 1(18)

Aftertreatment Diesel Exhaust Fluid

(DEF) Tank,
Replacement
VN, VHD VERSION2

Aftertreatment Diesel Exhaust Fluid (DEF) Tank,

Replacement

W2056353

This information covers the service procedures for the replacement of the Aftertreatment
Diesel Exhaust Fluid (DEF) Tank on the VN, or VHD VERSION2 chassis.

Contents
• “Aftertreatment Diesel Exhaust Fluid (DEF) Tank, Replacement”, page 2

Note: Information is subject to change without notice. Illustrations are used for reference
only, and may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.

PV776-88960538 USA40510
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 2(18)

Service Procedures
2589-03-02-01
Aftertreatment Diesel Exhaust Fluid (DEF) Tank, Replacement

You must read and understand the precautions and

guidelines in Service Information, Group 20, "General
Safety Practices, Engine" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training before
you perform it.

Removal
DANGER
Coolant is toxic and can irritate the skin and poses a risk
of poisoning. Do not drink coolant. Use proper hand
protection when handling. Keep coolant out of reach of
children and animals. Failure to follow these precautions
can cause serious illness or death.

WARNING
You must use approved Aftertreatment DEF in the
Aftertreatment SCR system. Do not use DEF that is not
approved, because it could damage the aftertreatment
system permanently, decrease engine output and possibly
damage other engine components

CAUTION
Do not spill Aftertreatment DEF onto exposed connectors
when you disconnect hoses and components. If you spill
DEF on an unprotected connector, you must replace the
connector immediately. DEF is highly corrosive to metal,
particularly copper and aluminum. Do not try to clean DEF
off of the connectors with water or compressed air. They
are ineffective because DEF quickly oxidizes metal and
“creeps” into the wiring.

1
1
Apply the parking brake and place the shift lever in
neutral.
2
2
Unlatch and open the hood.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 3(18)

3
3
Remove all cables from the ground (negative) battery
terminals to prevent personal injury from electrical shock.

W2003815

4
4
Drain the engine coolant from the vehicle using the
coolant extractor DBT2V700.

W2004191

5
5
If equipped, remove the left side fairing (under the door).

W8055381

6
6
Clean the DEF tank and its mounting area.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 4(18)

7
7
Remove the plug and drain the DEF into an approved
container of appropriate size.

W2055831

1 DEF Tank Drain Plug

8
8
Disconnect the Aftertreatment Control Module (ACM)
wiring harness from the ACM.

Note: While performing the next 4 steps, place a suitable

container under the DEF tank to catch any DEF fluid.

W2054110

1 Aftertreatment Control Module (ACM)

2 ACM Wiring Harness Connector
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 5(18)

9
9
Cut the cable tie and disconnect the DEF pump wiring
harness connector.

Note: Cover the electrical connector with a plastic bag to

protect from possible damage from DEF fluid.

W2055460

1 Cable Tie
2 Wiring Harness
10
10
Mark to identify and remove the DEF inlet, backflow and
outlet lines from the pump.

W2055927

1 DEF Inlet Line

2 DEF Backflow Line
3 DEF Outlet Line
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 6(18)

11
11
Mark to identify and remove the coolant lines from the
pump.

W2055462

1, 2 — Coolant Lines
12
12
Position a floor jack under the DEF tank. Raise the jack
until it will support the weight of the tank.
13
13
With the help of an assistant, remove the fasteners from
the DEF Tank Bracket and remove the DEF tank.

W2055835

1 Fasteners
14
14
Remove the drain pan and dispose of the DEF properly.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 7(18)

15
15
With the DEF tank off the vehicle, remove the ACM from
the DEF tank.

W2054111

1 Fasteners
2 Aftertreatment Control Module
16
16
Remove the DEF lines from the sending unit and DEF
tank.

W2056354

1 DEF Inlet Line

2 DEF Backflow Line
3 DEF Outlet Line
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 8(18)

17
17
Mark to identify and remove all coolant lines from the
sending unit and DEF tank.

W2056355

1, 2, 3, 4 — DEF Coolant Lines

18
18
Mark to identify DEF tank wiring harness connectors. Cut
cable ties and remove the sending unit and DEF tank
wiring harness from the DEF tank.

W2056356

1, 2, 3, 4 — Wiring Harness Connectors

5 — Cable Ties
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 9(18)

19
19
Remove fasteners and the DEF pump from the DEF tank.

W2055463

1 Fasteners
2 Bracket
3 DEF Pump
20
20
Remove the fasteners and the front cover from the DEF
tank.

W2056357

1 DEF Tank Cover

2 Fasteners
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 10(18)

21
21
Remove the rear mounting bracket from the DEF tank.

W2056358

1 — Fasteners
3 — DEF Tank Mounting Bracket
22
22
Remove the fasteners and both side covers from the
DEF tank.

W2056360

1 — Fasteners
2 — Washers
3, 4 — DEF Tank Side Covers
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 11(18)

23
23
Remove the fluid level sending unit from the tank.

W2055830

24
24
Remove the filler cap and splash shield from the DEF
tank.

W2056361

1 DEF Tank Cap and Splash Shield

Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 12(18)

Installation
1
1
Position both side covers on the DEF tank and hand
tighten fasteners.

W2056360

1 — Fasteners
2 — Washers
3, 4 — DEF Tank Side Covers
2
2
Install the fluid level sending unit into the DEF tank.

W2055830
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 13(18)

3
3
Position the rear mounting bracket onto the DEF tank
and hand tighten fasteners.

W2056358

1 — Fasteners
3 — DEF Tank Mounting Bracket
4
4
Position the front cover onto the DEF tank and hand
tighten fasteners.

W2056357

1 DEF Tank Cover

2 Fasteners
5
5
Torque-tighten all front cover fasteners to specification.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 14(18)

6
6
Torque-tighten all side cover fasteners to specification.
7
7
Torque tighten rear bracket fasteners to specification.
8
8
Position the DEF pump and fasteners into the DEF tank
and torque-tighten fasteners to specification.

W2055463

1 Fasteners
2 Bracket
3 DEF Pump
9
9
Clean the DEF fluid fittings on the pump with appropriate
solvent.
10
10
If installed previously, remove plastic bags from wiring
harness connectors.
11
11
Install DEF tank wiring harness, DEF fluid lines and
coolant lines to the DEF tank.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 15(18)

12
12
Secure the DEF tank wiring harness with cable ties.

W2056356

1, 2, 3, 4 — Wiring Harness Connectors

5 — Cable Ties
13
13
Connect the DEF inlet, backflow, and outlet lines to the
DEF pump.

W2055927

1 DEF Inlet Line

2 DEF Backflow Line
3 DEF Outlet Line
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 16(18)

14
14
Connect the coolant lines to the DEF pump.

W2056355

1, 2, 3, 4 — Coolant Lines
15
15
Install the ACM onto the DEF tank and torque-tighten
fasteners to specification.

W2054111

1 Fasteners
2 Aftertreatment Control Module
16
16
With the help of an assistant, use a floor jack to position
the DEF tank against the frame rail.
17
17
Install mounting bracket fasteners to the bracket on the
frame rail and hand tighten.
18
18
With DEF tank bracket and fasteners in place, lower and
remove floor jack.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 17(18)

19
19
Torque-tighten tank bracket fasteners and DEF tank
mounting fasteners to specification.
20
20
Connect wiring harness to DEF pump and ACM and
secure with cable ties.
21
21
Fill the DEF tank with only approved DEF fluid.
22
22
Install the splash shield and filler cap onto the DEF tank.
23
23
Refill the engine coolant into the vehicle using the coolant
extractor/filler DBT2V700.
24
24
Install all previously removed cables to the ground
(negative) battery terminals.

W2003815

25
25
If equipped, install the left side fairing under the cab.

W8055381

26
26
Start the engine and check for leaks and proper operation.
27
27
Clear any diagnostic trouble codes that may have
occurred.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 258 84 18(18)

28
28
Close and latch the hood.