Denox 2.1

Table of contents
Applicability of instructions
System identification
Safety instructions
Test prerequisites
Test instructions
Cleaning instructions
System information
Fill substances and capacities
Maintenance work
System test - Overview
Hydraulic connection diagram
Installation positions and removal/
installation instructions – Overview
Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights
Applicability of instructions
These instructions describe the system:

Exhaust gas treatment
Denoxtronic 2.1 (DNOX 2.1)
These instructions apply to the following

manufacturers:
VOLVO
IVECO
CASE NEW HOLLAND
RENAULT TRUCKS (RVI)
SISU
NISSAN
DOOSAN
ISUZU
OTOSAN
WEICHAI
YUCHAI
Restriction:
* These instructions only apply to
vehicles with system <Exhaust gas treatment>
of type Denoxtronic 2.1 (DNOX 2.1).
If these instructions appear on selecting

a different vehicle, this means that
validity was extended to the vehicles
concerned at a later date.
Date of issue/update: 05.2013
Table of contents:
System identification
It must be ensured that the correct

vehicle has been selected and that the
system described in these instructions is
actually fitted.
The system (DNOX 2.1) can be identified as follows:

* If communication is possible and the
identification number read out has
already been registered, the system
can be identified with the aid of the
diagnostic tester.
* Component A61.3 (AdBlue delivery
module) fitted.
The installation position may vary
depending on the vehicle model.
The following version of the component <AdBlue delivery module> may be fitted:
* Version with component <Cooling circuit control valve>:

- Number of connections: 4.
- Vehicle-specific component <AdBlue metering module>
without fixed restrictor.
* Version with component <Cooling circuit adapter>:

with fixed restrictor.
1 = Cover for component <Exhaust gas treatment control unit>.

2 = Pressure equalization element.
4 = AdBlue inlet connection. <inlet>.
5 = Type designation.
6 = Drain plug (fitted as an option).
7 = Pressure connection for component <AdBlue metering module>.
8 = AdBlue return connection <BACKFLOW INLET>.
9 = AdBlue return connection <BACKFLOW OUTLET>.
10 = Filter housing.
J50.3 = AdBlue pre-filter.
X18 = Control unit plug connection.
* Version without component <Cooling circuit control valve> and without
component <Cooling circuit adapter>.
- Vehicle-specific component <AdBlue metering module> with fixed restrictor.

4 = AdBlue inlet connection <inlet>.
8 = Filter housing.
Further features of the system family DNOX 2.1:
* Self-diagnosis.
* AdBlue tank.
* AdBlue delivery module.
* AdBlue metering module.
* Spray attachment.
* AdBlue mixer.
* SCR catalytic converter.
* NOx sensor (fitted as an option).
Table of contents:
Safety instructions
When performing work on motor vehicles,

trailers and their components, attention
is always to be paid to comprehensive
safety instructions and damage warnings.
Safety instructions relate to possible
injury risks. Damage warnings indicate the
risk of possible material damage and
environmental hazards.
1. Safety instructions:
* General Safety instructions:
* Handling the substance <AdBlue >:
Further information:
* Structural safety regulations and general workshop safety are considered
to be self-evident and are thus not described in these instructions.
* It is assumed that the personnel working on the vehicle/system will be

appropriately qualified and carry out the work in the proper manner.
* In addition to the regulations listed here, attention is always to be paid
to the relevant local safety regulations.
* Country-specific safety regulations must always be heeded.
Test prerequisites
Heed safety instructions.
Attention:
If dosing takes place during testing, either the component <AdBlue metering module>
has to be removed or use has to be made of the component <Calibrating metering module>.
Never meter the substance <AdBlue> into the component <SCR catalytic converter>
or the system <Exhaust unit>.
Danger of destruction.
Wait at least 10 min after switching off the ignition before commencing all
electrical measurements (termination of run-on tests).
* Charging status of component <Battery 1> OK.
* Charging status of component <Battery 2> OK.
* Correct fill and quality of the substance AdBlue in line with the
pertinent standard and the specifications of the vehicle manufacturer.
* Make sure there are no traces of other

operating media left in the component <AdBlue tank>.
Heed further information in the Section <System test - Overview>.
* The operating medium <AdBlue> is not frozen.

Freezing point at approx. -11 °C.
* Engine in proper mechanical working order

E.g. with respect to:
- Cross-sectional constriction and
freedom from leaks of the system <Exhaust unit>.
- Freedom from leaks of the intake system.
- Crankshaft housing breather function.
- Valve timing and valve clearance.
- Cylinder compression/pressure loss.
* System <Exhaust gas treatment> OK.
- Cross-sectional constriction and freedom from leaks
of the system <AdBlue circuit>.
* Other systems influencing system <Exhaust gas treatment> OK.

- Engine management.
- Exhaust unit.
- CAN data bus.
* Level and quality of fuel, engine oil

and coolant OK and in line with
vehicle manufacturer's specifications.
* Exclusive use made of spare parts
approved for this vehicle/system
during previous repair or service work.
* All plug-in connections firmly
attached and not interchanged. This is
particularly important in the case of
crash vehicles, previous repairs and retrofitting work.
* Ground connection(s) of engine, body
and component <AdBlue delivery module> OK
System test - Overview:

Table of contents:
Test instructions
Vehicle-specific entries in the fault

memory of the component <Exhaust gas
treatment control unit> or the component
<Engine control unit> may be an indication
of faults at components which cannot be replaced on the vehicle.
AdBlue delivery module:

* In the event of fault entries indicating a defective component
<AdBlue delivery module>, the component <AdBlue delivery module>
must be checked and if necessary repaired or completely replaced.
* The following fault entries may be an indication of a fault in the component

<AdBlue delivery module>:
- AdBlue dosing quantity.
- Fault in power supply of component(s) <Sensors>.
- Internal leakage.
- External leakage.
* Fault entries relating to one of the components listed below may be an

indication of a defective component <AdBlue delivery module>:
- AdBlue delivery pump
- AdBlue pressure sensor
- AdBlue temperature sensor
- AdBlue filter
- AdBlue 4/2-way valve
- Cooling circuit control valve
- AdBlue heating control
- Pump/filter heating elements
AdBlue metering module:
* In the event of fault entries indicating a defective component
<AdBlue metering module>, the component <AdBlue metering module>
must be checked and if necessary repaired or completely replaced.
* The following fault entries may be an indication of a fault in the component

<AdBlue metering module>:
- AdBlue dosing quantity.
- NOx fault.
- Number of freeze cycles.
* Fault entries relating to one of the components listed below may be an

indication of a defective component <AdBlue metering module>:
- Metering module
- Metering valve
- Internal leakage.
- External leakage.
Incorrect fault entries may be an indication of an incorrect tank fill or

operation of the system with the admixture of diesel fuel:
* Inadequate AdBlue quality.
Table of contents:
* The components of the system <Exhaust
gas treatment> must be cleaned from
the outside before opening the system
or removing individual components.
Clean with water and a high-pressure cleaner if applicable.
* Use copious amounts of hot water to

completely remove any crystallized
AdBlue residue from components.
Dry all parts with compressed air.
Important information on cleanliness when

working on the <Exhaust gas treatment>
DNOX 2.1system and its components:
* To prevent the ingress of the substance AdBlue
into plug connections, always heed the sequence
when disconnecting and connecting wiring and hydraulic pipes.
Disassembly:
1. Unfasten the hydraulic pipe connection.
2. Disconnect the wiring.
Assembly:
1. Connect the wiring.
2. Fasten the hydraulic pipe connection.
* Use suitable covers to immediately

seal any open pipe connections on the
vehicle and only open again
immediately prior to installation of the component.
* The substance AdBlue has a very high
creep capacity and a very low viscosity.
Particular attention must be paid to
cleanliness so as to ensure proper
operation of the system following service work.
* Particles must not be allowed to ingress into the system.

Metal swarf and hard plastic particles are particularly hazardous.
Example(s):
- Large quantities of particles of a
size of < 0,05 mm will clog the filter.
- Particles of a size of 0,05...0,10 mm damage moving parts.
- Particles of a size of 0,1...0,4 mm cause leakage at O-rings.
- Particles of a size of > 0,4 mm damage the pump and the component <Metering valve>.
Table of contents:
System information
Exhaust gas treatment DNOX 2.1.

Version <DNOX 2.1> of the system <Exhaust
gas treatment> was developed for commercial vehicles fitted with a
component <SCR catalytic converter>.
The function of the system <DNOX 2.1> is
to reduce the nitrogen oxide content (NOx)
of the exhaust gas by metering the
operating medium <AdBlue> into the exhaust gas flow.
Handling the substance <AdBlue>: .
The system fitted in conjunction with the resultant

catalytic reaction produces the following changes
in the characteristic quantities listed below:
* Reduction in nitrogen oxide content.
* Reduction in particulate content.
* Reduction in fuel consumption by up to 5 %.
Infeed of the operating medium <AdBlue>

and control of the individual components
and functions are stored in a map.
Features of the system DNOX 2.1:

* Power supply: 24 V.
* The system is regulated by way of the component <Exhaust gas treatment control unit>.
* The substance used is AdBlue.
* The system has full diagnosis capability by way of the component
<Diagnosis socket (OBD)>.
* Compact design.
Attention:
The components of the system DNOX 2.1 are not to be dismantled.
Description of principle:
* After starting the engine, the control
unit evaluates the signals of the temperature sensors.
* The system DNOX 2.1 is activated if
comparison of the temperature sensors
is plausible and coincides with the
maps stored in the control unit.
* The component <AdBlue delivery pump>
draws the substance out of the
component <AdBlue tank> into the
component <AdBlue delivery module>.
* The component <AdBlue tank heating
valve> is actuated as required.
* The optimum substance temperature is -5...60 °C.
* The component <AdBlue delivery pump>
conveys the substance via the
component <AdBlue main filter> to the
component <AdBlue metering module>.
* The control unit detects the pressure
measured by the component <AdBlue pressure sensor>.
* The system pressure is regulated by
way of the component <AdBlue delivery pump>.
* Up to 2 sensors detect the current NOx
content in the exhaust system and
transmit this to the control unit via the system <CAN data bus>.
* The sensors are used for NOx
monitoring and not for control of the
system <Exhaust gas treatment>.
* On the basis of stored maps, the
control unit calculates the quantity
of the substance currently being
injected and actuates the component
<AdBlue delivery pump> and the
component <AdBlue dosing valve>.
Depending on the version, surplus
substance not dosed flows back via the
component <Cooling circuit control
valve>/via the component <Cooling
circuit adapter> or directly from the
component <AdBlue metering module>
into the component <AdBlue tank> to
cool the component <AdBlue metering module>.
Run-on function:
* After shutting off the engine, the
component <AdBlue 4/2-way valve> is
actuated to protect the system, with
the result that the component <AdBlue
delivery pump> conveys the substance
out of the pipes back into the component <AdBlue tank>.
On completion of drainage, the system is frost-proof.
If the system power supply to the

component <AdBlue delivery module> is
interrupted during the run-on test (e.g.
actuation of the emergency stop switch on
hazardous goods transporters), run-on is interrupted.
If the emergency stop switch is used
several times or always to stop the
engine, the component <AdBlue metering
module> may be damaged or destroyed.
Heating circuit description:

* The component <AdBlue tank> is heated by way of the engine coolant.
The component <AdBlue tank heating valve> is actuated as required.
* The component <AdBlue delivery module> is heated electrically.
* The following components may be heated either electrically or by means of coolant:
- AdBlue pipes.
The system functions correctly under the
following operating conditions:
* Ambient temperature -7...35 °C.
* Engine temperature > 70 °C.
* Altitude < 1600 m above sea level.
* The component <AdBlue tank> is not empty.
* Vehicle moving.
* Normal operating noise.
* Consumption of the operating medium
<AdBlue> corresponds to approx. 5...10 % of the fuel consumption.
* The component <Fault lamp> does not light.
* The component <Engine management fault lamp> does not light.
Note(s):
* The system <Exhaust gas treatment> is
governed by the sensor data of the
component <Engine control unit> and is
only active if the system <Engine
management> is functioning properly.
The following components are interlinked

by way of the system <CAN data bus>:
* Engine control unit.
* Exhaust gas treatment control unit.
* Other vehicle-specific systems.
System overview:
1 = AdBlue pipe.
A61.3 = AdBlue delivery module.
A61.4 = AdBlue metering module.
B13.7 = AdBlue tank level sensor.
B23.2 = AdBlue quality sensor.
B3.108 = AdBlue tank temperature sensor.
B3.109 = Exhaust temp. sensor downstr.
of SCR CAT.
B3.110 = Exhaust temp. sensor upstream
of SCR CAT.
B9.184 = NOx sensor.
E6.35 = Heating element return pipe.
E6.36 = Inlet pipe heating element.
E6.37 = Press. equalization pipe heating
element.
E6.38 = Met. module press. pipe heating
element.
E6.45 = Cooling circuit pipe heating
element.
E9.20 = AdBlue tank heating.
J22.25 = Oxidation catalytic converter.
J22.26 = SCR catalytic converter.
J22.33 = Blocking catalytic converter
(installed as option).
J50.1 = AdBlue tank.
J50.4 = AdBlue mixer.
Overview of component <AdBlue delivery module>:
Number of connections: 4.

Other components which are integrated but

not labelled/visible in the illustration:
- Exhaust gas treatment control unit.
- AdBlue delivery pump.
- AdBlue 4/2-way valve.
- AdBlue pressure sensor.
- AdBlue temperature sensor.
- Cooling circuit control valve (fitted as an option).
- Cooling circuit adapter (fitted as an option).
- AdBlue filter.
Overview of component <AdBlue delivery module>:
Number of connections: 2.
8 = Filter housing.
Other components which are integrated but

not labelled/visible in the illustration:
- Exhaust gas treatment control unit.
- AdBlue delivery pump.
- AdBlue 4/2-way valve.
- AdBlue pressure sensor.
- AdBlue temperature sensor.
- AdBlue filter.
Overview of component <AdBlue metering module>:
1 = Heat shield.
2 = AdBlue inlet connection.
3 = AdBlue return connection.
4 = Metering valve holder.
Y4.46 = Metering valve.
1 = Edge-type filter.
2 = Throttle valve.
A = Inlet connection direction of flow.
B = Return connection direction of flow.
Metering valve holder with edge-type

filter in supply and return connection and
with throttle valve.
This version is fitted with the system
<Exhaust gas treatment> type DNOX 2.1 in
conjunction with a component <AdBlue delivery module>
with no component <Cooling circuit control valve>.
Metering valve holder without edge-type

filter in supply and return connection and without throttle valve.
This version is fitted with the system
<Exhaust gas treatment> type DNOX 2.1 in
conjunction with a component <AdBlue delivery module>
with component <Cooling circuit control valve>.
Table of contents:
Fill substances and capacities
The system <Exhaust gas treatment> DNOX

2.1 is only to be filled with the
substance <AdBlue>.
Handling the substance <AdBlue>: .
Table of contents:
Maintenance work
The maintenance operations listed below

can be performed on the system <Exhaust
gas treatment> DNOX 2.1:
* Replace the component <AdBlue filter>
of the component <AdBlue delivery module>.
* Replace the component <AdBlue prefilter>
of the component <AdBlue delivery module>.
Attention:
Always perform the functional test <AdBlue
circuit system drainage> before detaching
the hoses or removing components.
Always heed the vehicle manufacturer's
instructions.
Removal and installation instructions:
Table of contents:
System test - Overview
The self-diagnosis of the system <DNOX 2.1>

covers both sporadic and static fault codes.
Self-diagnosis permits localization of a
fault within the system.
The control unit makes use of stored
substitute values to maintain engine
operation in spite of implausible sensor
values.
Function <Self-diagnosis> can be used to

implement the following in various systems:
* Identification
* Read error memory
* Erase error memory
* Actual values
* Actuators
* Adjustments / settings
* Special functions
Note(s):
* The scope of diagnosis depends on the
vehicle manufacturer and may differ.
The system can only be checked in full by

way of the diagnostic software functional tests.
Some functional tests may require the
simulation of certain actual values (e.g.
exhaust gas temperature).
In the diagnostic software the designation
for the individual functional tests may
differ from that used here.
Always adhere to the sequence indicated.
Attention:
If dosing takes place during testing,
either the component <AdBlue metering
module> has to be removed or use has to be
made of the component <Calibrating metering module>.
Never meter the substance <AdBlue> into
the component <SCR catalytic converter> or
the system <Exhaust unit>. Danger of destruction.
If the system test indicates a defective

component inside the component <AdBlue
delivery module> or the component <AdBlue
metering module>, the component <AdBlue
delivery module>/the component <AdBlue
metering module> must be completely
removed and repaired or replaced.
The opening and/or repairing of a
component on the vehicle is not permissible.
Checking and repair of system <DNOX 2.1>

components (e.g. component <AdBlue delivery module>,
component <AdBlue metering module>) are only to be performed
in appropriately equipped workshops.
Test procedure (keep to sequence):
Stage 1:
* Ensure compliance with all test prerequisites.
Test prerequisites:
Stage 2:
* Examine the system <Exhaust gas
treatment> for possibly incorrect filling.
Incorrect filling:
Stage 3:
* Operating medium circuit system bleeding:
Stage 4:
* Pressure build-up/pressure reduction test:
Stage 5:
* Pump delivery (max):
Stage 6:
* Metered quantity measurement:
Stage 7:
* System bleeding/operating medium circuit:
Stage 8:
* AdBlue heating control:
Table of contents:
System test
Incorrect filling
The tank is often incorrectly filled

on vehicles with a system <Exhaust gas
treatment> of type <DNOX 2.1>. In such
cases, the component <AdBlue tank> is
filled with diesel fuel or AdBlue with diesel fuel constituents.
Filling the tank incorrectly will lead

to damage or failure of the component
<AdBlue delivery module>.
If the system has been operated with
diesel fuel constituents in the AdBlue
circuit, there is a danger of
permanent damage to essential parts of
the component <AdBlue delivery module>.
Never flush or clean the system.

Flushing/cleaning cannot rectify
malfunctions. There is also a risk of
residual diesel fuel remaining in the
system and causing further damage.
Components already repaired may be
damaged again.
Oil test paper is used for the detection of diesel fuel.
* Tools required:
- Oil test paper (article no. 90760).
Supplier:
Machery - Nagel GmbH Co KG
www.mn-net.com
* Check the content of the component
<AdBlue tank>:
Place oil test paper in position.

To draw off fluid, use the dipstick of
the component <AdBlue tank> if
available.
If no dipstick is available, use can
be made of a suitable thin PVC hose.
Attention:
The items used must be absolutely
clean and free from oil and grease.
Insert the dipstick or hose in the

component <AdBlue tank> and pull it
out again.
Wipe the dipstick or hose over the oil test paper.
The test result is provided after a
short waiting time.
1 = No change in color of test strip,

no diesel fuel constituents present.
2 = Change in color of test strip,
diesel fuel constituents present.
Operation of the entire system must be

checked if testing of the system
<Exhaust gas treatment> reveals diesel
fuel constituents.
If necessary, the component <AdBlue

delivery module> and the component
<AdBlue metering module> must be
repaired or replaced.

Table of contents:
Hydraulic connection diagram
a) Version with component <cooling circuit control valve>:

- Component <AdBlue delivery module> with component
<cooling circuit control valve>.
without fixed restrictor.
b) Version with component <Cooling circuit adapter>:

- Component <AdBlue delivery module> with component
<Cooling circuit adapter>.
A22.30 = Exhaust line.

c) Version without component <Cooling circuit control valve> and without
component <Cooling circuit adapter>.

Table of contents:
installation instructions - Overview
Notes
Vehicle overview
Diagnosis socket (OBD)
AdBlue tank
AdBlue filter
AdBlue delivery module
AdBlue metering module
AdBlue mixer
SCR catalytic converter
AdBlue pipes
Heating elements
Exhaust gas treatment control unit
Relays and fuses
Table of contents:
installation instructions
Notes:
* These instructions apply to various

commercial vehicle makes and models.
* The installation positions differ depending on the vehicle model.
* An exact description of the installation position of the
individual components is not possible.
* Some of the illustrations of installation positions contained in
these instructions are not based on any particular vehicle.

installation instructions - Overview:
Table of contents:
Vehicle overview
Installing component treatment>:

Block diagram.
1 = AdBlue pipe.
2 = Data line.
A1.1 = Engine control unit.
System overview:
1 = AdBlue pipe.
E6.x = Heating elements.
Overview of component <Exhaust
line>:

B3.109 = Exhaust temp. sensor
downstr. of SCR CAT.
B3.110 = Exhaust temp. Sensor
upstream of SCR CAT.
J22.25 = Oxidation catalytic
converter.

Table of contents:
Diagnosis socket (OBD)
The vehicle-specific installation position

of the component < Diagnosis socket (OBD)>
must be established by way of the
corresponding diagnostic tester menu item
or from the vehicle manufacturer's documentation.

Table of contents:
AdBlue tank
1 = AdBlue pipe.
2 = Data line.
A1.1 = Engine control unit.
The component is located at the front of

the vehicle on the frame, usually next to
the component <Fuel tank>.
It may however also be integrated into
the component <Fuel tank>.
The distinguishing feature is a blue cap.
The following components are located

at/in the component <Fuel tank>:
* B13.7 (AdBlue tank level sensor).
* B23.2 (AdBlue quality sensor).
* B3.108 (AdBlue tank temperature
sensor).
* E6.37 (Press. equalization pipe heating
element) (fitted as an option).
* E9.20 (AdBlue tank heating).
* J50.3 (AdBlue pre-filter).

Table of contents:
AdBlue filter
The component <AdBlue filter> is fitted in

the component <AdBlue delivery module>.
The component <AdBlue pre-filter> is

located in the connection piece of the
AdBlue inlet connection <inlet>.
Note(s):
* A component <AdBlue pre-filter> may
also be fitted in the component <AdBlue tank>.
Removal and installation instructions:

Table of contents:
AdBlue delivery module
The component <AdBlue delivery module> is located on the vehicle frame or on a

separate holder behind the cab at the vehicle end of the component <Exhaust unit>.
The following components are located in

the component <AdBlue delivery module>:
* Exhaust gas treatment control unit.
* AdBlue delivery pump.
* AdBlue 4/2-way valve.
* AdBlue pressure sensor.
* AdBlue temperature sensor.
* Cooling circuit control valve (fitted as an option).
* Cooling circuit adapter (fitted as an option).
* AdBlue filter.
Attention:
Opening or repair of the component <AdBlue delivery module>
on the vehicle is not permissible.
In the event of a fault, the component <AdBlue delivery module>
must be replaced or dismantled for repair.

Table of contents:
AdBlue metering module
1 = Heat shield.
2 = AdBlue inlet connection.
3 = AdBlue return connection.
Y4.46 = Metering valve.
The component <AdBlue metering module> is located in

the component <Exhaust line> upstream of the component
<SCR catalytic converter>.
The component <AdBlue metering module> is
cooled by way of the substance <AdBlue>.
Attention:
If dosing takes place during testing, either the component
<AdBlue metering module> has to be removed or use has
to be made of the component <Calibrating metering module>.
Never meter the substance <AdBlue> into the component
<SCR catalytic converter> or the system <Exhaust unit>.
Danger of destruction.
In the event of a fault, the component

<AdBlue metering module> must be replaced
or dismantled for repair.

Table of contents:
Installation positions and
removal/installation instructions
AdBlue mixer

converter.
The component <AdBlue mixer> is

located in the component
<Exhaust line> directly
upstream of the component

Table of contents:
Installation positions and
removal/installation instructions
SCR catalytic converter

converter.
The component <SCR catalytic

converter> is located in the
component <Exhaust line>
downstream of the component
<Oxidation catalytic converter>.
Note(s):
* A component <Blocking catalytic converter>
may optionally be fitted downstream of the component

Table of contents:
AdBlue pipes
Attention:
Always perform the functional test <AdBlue
circuit system drainage> before detaching
the hoses or removing components.
Always heed the vehicle manufacturer's instructions.

Table of contents:
Heating elements
The following components are heated

electrically:
The following components are heated by way

of the engine coolant:
* AdBlue tank.
The following components may be heated

either electrically or by means of coolant:
* AdBlue pipes.
The component <AdBlue metering module> is

cooled by way of the substance <AdBlue>.

Table of contents:
Exhaust gas treatment control unit
Component <Exhaust gas treatment control unit>

is located in component <AdBlue delivery module>.
Note(s):
* Component <Exhaust gas treatment control unit>
is an integral part of component <AdBlue delivery module>
and cannot be replaced separately.

Table of contents:
Relays and fuses
The installation positions differ depending on the vehicle model.
Note(s):
* The installation positions of further components and components
can be found in the vehicle manufacturer's documentation.

Table of contents:
Removal/installation instructions
AdBlue filter
The following steps are described:

1. Removal and installation of the component <Filter cartridge>.
2. Removal and installation of the component <AdBlue pre-filter>.
Attention:
Always perform the functional test <AdBlue circuit system drainage> first.
Disassembly is only permissible when depressurized.
1. Removal and installation of component <Filter cartridge>:
Note(s):
* The illustrations show the procedure with the component
<AdBlue delivery module> removed.
Tools required:
* 0 986 613 295 (Extractor)

4 = AdBlue inlet connection. <inlet>.
Note(s):
* Some versions of the component <AdBlue delivery module>
do not have a drain plug fitted.
Removal:
After draining the system, screw out the
drain plug (6) and allow the component
<AdBlue filter> to drain off (run empty).
Dispose of the residual fluid in the proper manner.
Use new O-ring.
Moisten the O-ring with glycerine.
Tighten the drain plug.
Tightening torque(s):
2,0…2,5 Nm
Use a suitable tool to release the cover (1)
of the component J1.43 (Filter cartridge) and unscrew.
Unscrew the component J1.43 (Filter cartridge) from the cover.
Attention:
Always heed the procedure described in the
following if part of the component J1.43 (Filter cartridge)
is left in the filter housing on disassembly.
Use suitable pliers to carefully release
the part (2) of the component J1.43 (Filter cartridge) left in
the cover (1) and unscrew.
Screw the tool 0 986 613 295 (Extractor)
(1) into the part of the component J1.43 (Filter cartridge)
left in the housing and carefully pull out again.
Attention:
Do not touch the diaphragm of the component <AdBlue pressure sensor>.
Always use the prescribed tool!
The use of a different, unsuitable tool would destroy the diaphragm of the
component <AdBlue pressure sensor>.
Installation:
Moisten a new O-ring (1) with glycerine
and insert.
Screw the new component J1.43 (Filter cartridge)
with new compensating elements to the cover (1)
and insert into the filter housing.
Screw on the cover (1).
Tightening torque(s):
20...25 Nm
2. Removal and installation of component
<AdBlue pre-filter>:
Note(s):
* Disassembly destroys the component <AdBlue pre-filter>.
Removal:
Carefully insert a suitable tool into the component
J50.3 (AdBlue pre-filter) and pull it out of the connection.
Attention:
Do not damage the connections.
Installation:
Insert a new component J50.3 (AdBlue prefilter)
in the connection and carefully press in by hand until flush.
Maintenance work
Table of contents:
Control unit functions
AdBlue circuit system bleeding
The function <AdBlue circuit

system bleeding>under Special functions is used to bleed the
system A61.1 (AdBlue circuit).
Note(s):
* The functional test can only be
implemented if it is contained in the
vehicle-specific diagnostic software.
Prerequisite(s) for starting:

* Component <AdBlue metering module> removed
Or:
Component <Calibrating metering module> connected.
* All hydraulic pipes correctly connected
and in proper working order.
Information on functional test:

* On completion of the functional test, there must no longer be any air
bubbles in the hose to the component <AdBlue metering module>.

Pressure build-up/pressure reduction test:
Table of contents:
Pressure build-up/reduction test
The functional test <Pressure buildup/

pressure reduction test> under Special functions
is designed to build up the operating pressure in the system
and check the operating medium circuit for leaks.
Note(s):

* Component <AdBlue metering module> removed.
* System A61.1 (AdBlue circuit) bled.
Operating medium circuit system bleeding:

* Compare the actual values displayed in
the tester to the vehicle-specific set values.
Possible faults if no pressure build-up occurs:

* Pressure in compressed air system too low.
* Component <AdBlue pre-filter> contaminated.
* Component <AdBlue filter> contaminated.
* Component <AdBlue delivery module> defective.
Pressure drop test:
* If the pressure drops below the
specified value, the leak must be
localized and the fault rectified
before performing any further work.
Possible faults:
* External leakage.
* Internal component <AdBlue delivery module> leakage.
* Component <AdBlue metering module> leaking.
Fault rectification:
Keep to sequence.
1. Visual inspection(s):
Check the pipes, connections and components for leaks (escape of fluid).
Rectify the fault and repeat the functional test <Pressure buildup/pressure reduction test>.
2. To limit the leak, the functional test must be repeated without the component
<AdBlue metering module>.
- If the test is OK, the component <AdBlue metering module> is defective.
- If the test is not OK, there are no leaks in the component <AdBlue metering module>
and the leakage is located in the component <AdBlue delivery module>.

Table of contents:
Pump delivery test (max)
The functional test <Pump delivery (max)> under Special functions

is used to check the maximum delivery of the component <AdBlue delivery pump>.
Note(s):
* Operation of the component <AdBlue
pressure sensor> can be checked by
means of the functional test.
Attention:
Use must always be made of the component
<Calibrating metering module> for
assessing the maximum delivery rate.
the system <Exhaust unit>. Danger of destruction.
Only for component <AdBlue delivery module>

with component <Cooling circuit control valve>:
If the functional test is performed on a
component <AdBlue delivery module> with
component <Cooling circuit control valve>,
the component <Cooling circuit control
valve> must be bypassed with a suitable
adapter pipe or the pipe must be detached
from the connection <BACKFLOW INLET> and
the substance collected in an appropriate
vessel.
Note(s):
* In contrast to the vehicle-specific component
<Calibrating metering module>, a fixed restrictor
is fitted in the component <AdBlue metering module>.
As a result, the component <Cooling circuit control valve>
Must be bypassed.

* Component <Calibrating metering module> connected.

* On completion of the functional test,
weigh the graduated beaker with the
quantity delivered and subtract the
weight of the beaker previously determined.
* Compare the calculated value for the
metered quantity to the set value and evaluate.
Possible faults:
* Component <AdBlue pre-filter> contaminated.
* Component <AdBlue filter> contaminated.
* Component <AdBlue delivery module> defective.

Table of contents:
Metered quantity measurement
The functional test < Metered quantity measurement>

under Special functions is used to check the component
<AdBlue metering module>.
Note(s):
It is only appropriate to check the dosing quantity if the functional test

<Pressure build-up/pressure reduction test> and the
functional test <Pump delivery (max)> have
been successfully implemented and the set
value for the maximum delivery rate was attained.
Attention:
the system <Exhaust unit>. Danger of
destruction.

* On completion of the functional test,
weigh the graduated beaker with the
quantity delivered and subtract the
weight of the beaker previously determined.
* Compare the calculated value for the
metered quantity to the set value and evaluate.
If the set value is not attained:
* Perform the functional test <Metered quantity measurement> with the
component <Calibrating metering module>.
Possible faults:
* Component <AdBlue metering module> defective.
* Component <Exhaust gas treatment control unit> defective.

Table of contents:
System bleeding/AdBlue circuit
The function <System bleeding/AdBlue circuit> under Special functions

is used to drain the system A61.1 (AdBlue circuit).
Note(s):

* All hydraulic and pneumatic pipes
correctly connected and in proper working order.

Table of contents:
AdBlue heating control
The components <Heating elements> of the

system <Exhaust gas treatment> can only be
checked by actuating the corresponding
diagnostic software actuator tests.
During the actuator test, the current
input of the corresponding component
<Heater element> can be checked with a current probe.
The following components are heated electrically:

The following components are heated by way

of the engine coolant:
* AdBlue tank.
The following components may be heated

either electrically or by means of coolant:
* AdBlue pipes.

Table of contents:
General safety instructions
For safety reasons, motor vehicles, trailers and their components

are only to be repaired, serviced and maintained by specially qualified
and trained personnel in appropriately equipped and authorized workshops.
Attention is always to be paid to the applicable version of the industrial

safety and environmental protection regulations prescribed by law,
accident prevention regulations, technical stipulations, standards and
manufacturer's instructions when performing work.
Machinery, equipment and tools are only to be used for their intended purpose,
Paying attention to the technical documentation and operating instructions of the
manufacturer. Furthermore, all equipment must be in a reliable safe condition.
Any personal protective equipment required, such as safety goggles or

protective clothing, must meet with requirements, be suited to the application
and be worn in the stipulated manner.
Exclusive use must be made for repair, service and maintenance work
of the spare parts, replacement components, accessories, lubricants
and other substances approved by the manufacturer
for the vehicle or vehicle model concerned.
Old components removed and used lubricants are to be disposed of in line

with the applicable disposal and environmental protection regulations.
Attention is to be paid to the warnings and safety instructions additionally

contained in these instructions.
Safety instructions:
Table of contents:
Safety instructions
Use of testers.
When using testers, it is essential to

heed the technical documentation of the
manufacturer and in particular the safety instructions.
General information:
* All testers used must be appropriate
to and approved for the intended application.
* The testers and the associated safety
devices must be in a reliable safe condition.
* The equipment must exhibit the
relevant safety and approval marks.
* Work with testers is only to be
performed by trained personnel.
* Take care when using insulation
testers, as hazardous voltages can
occur at the measurement outputs of
the tester, at the test specimen and
in the surrounding area.
Special safety measures must be taken
before starting work when using
insulation testers.
Table of contents:
Safety instructions
Handling the substance <AdBlue>.
The substance <AdBlue> is a standardized

solution with the following components:
* 32,5 % urea.
* 67,5 % distilled water.
The substance has the following properties:

* Liquid.
* Colorless.
* Freezing point at approx. -11 °C.
Attention:
Always wear safety goggles when working on
systems with the substance <AdBlue>.
The substance is not classed as being a

hazardous substance. The water hazard
class is 1. The substance is only to be
stored in original containers and vessels
intended for this purpose. Storage in
foodstuffs containers is not permissible.
Attention must always be paid to the
information on the hazardous nature, toxic
properties, handling and disposal of the
substance outlined in the safety data
sheets and product descriptions.
The safety data sheets can be obtained

from the manufacturer.
Further information:
* The substance causes contact corrosion on many surfaces (e.g. paintwork,
metal, some plastics) and may destroy the areas affected.
Immediately rinse the wettened area thoroughly with copious amounts of clean water.
* Heed manufacturer's instructions regarding maximum storage periods and storage conditions.
* Use is only to be made of the substance approved by the vehicle manufacturer.
* Always wash hands thoroughly after
working with the substance <AdBlue>.
Change any items of clothing which
have come into contact with the substance.
* The substance <AdBlue> may cause
irritation of the skin, eyes and respiratory organs.
Measure(s):
* In case of inhalation:
Keep calm and ensure that there is sufficient fresh air.
Consult a doctor if necessary.
* In case of skin contact:

Rinse thoroughly with plenty of hot water and soap.
* In case of contact with the eyes:

Thoroughly rinse eyes under running water for approx. 15 min.
* In case of swallowing:
Rinse out mouth and then drink plenty of water.
System information
Table of contents:

Denox 2.1

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Denox 2.1

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Table of contents

These instructions describe the system:

These instructions apply to the following

If these instructions appear on selecting

Date of issue/update: 05.2013

It must be ensured that the correct

The system (DNOX 2.1) can be identified as follows:

* Version with component <Cooling circuit control valve>:

* Version with component <Cooling circuit adapter>:

1 = Cover for component <Exhaust gas treatment control unit>.

1 = Cover for component <Exhaust gas treatment control unit>.

When performing work on motor vehicles,

* It is assumed that the personnel working on the vehicle/system will be

Heed safety instructions.

* Charging status of component <Battery 1> OK.

* Charging status of component <Battery 2> OK.

* Make sure there are no traces of other

* The operating medium <AdBlue> is not frozen.

* Engine in proper mechanical working order

* Other systems influencing system <Exhaust gas treatment> OK.

* Level and quality of fuel, engine oil

System test - Overview:

Vehicle-specific entries in the fault

AdBlue delivery module:

* The following fault entries may be an indication of a fault in the component

* Fault entries relating to one of the components listed below may be an

* The following fault entries may be an indication of a fault in the component

* Fault entries relating to one of the components listed below may be an

Incorrect fault entries may be an indication of an incorrect tank fill or

* Use copious amounts of hot water to

Important information on cleanliness when

* Use suitable covers to immediately

* Particles must not be allowed to ingress into the system.

Exhaust gas treatment DNOX 2.1.

Handling the substance <AdBlue>: .

The system fitted in conjunction with the resultant

Infeed of the operating medium <AdBlue>

Features of the system DNOX 2.1:

If the system power supply to the

Heating circuit description:

The following components are interlinked

1 = Cover for component <Exhaust gas treatment control unit>.

Other components which are integrated but

Other components which are integrated but

Metering valve holder with edge-type

Metering valve holder without edge-type

The system <Exhaust gas treatment> DNOX

Handling the substance <AdBlue>: .

The maintenance operations listed below

Removal and installation instructions:

The self-diagnosis of the system <DNOX 2.1>

Function <Self-diagnosis> can be used to

The system can only be checked in full by

If the system test indicates a defective

Checking and repair of system <DNOX 2.1>

The tank is often incorrectly filled

Filling the tank incorrectly will lead

Never flush or clean the system.

Oil test paper is used for the detection of diesel fuel.

Place oil test paper in position.

Insert the dipstick or hose in the

1 = No change in color of test strip,

Operation of the entire system must be

If necessary, the component <AdBlue