UREA TANK REMOVAL


  1. REMOVE FRONT BUMPER COVER

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  2. REMOVE UREA TANK PROTECTOR


    1. A003GG6

      Remove the 3 bolts and urea tank protector from the body.

  3. DISCONNECT WIRE HARNESS


    1. A003FWN

      Disconnect the connector from the urea tube with heater assembly.

    2. Pull the tabs of the connector as shown in the illustration and disconnect the connector from the urea pump

    3. A003G0N

      Disconnect the 2 connectors from the front side wiring sub-assembly.

    4. A003C00

      Detach the 2 clamps and disconnect the front side wiring sub-assembly from the urea tank sub-assembly.

  4. DISCONNECT UREA TANK FILLER PIPE ASSEMBLY


    1. Disconnect the urea tank breather tube of the urea tank filler pipe assembly from the urea tank sub-assembly.

      Note

      Check for dirt or mud on the urea tank sub-assembly and around the urea tank breather tube connector before disconnection. Clean if necessary.


      1. A003HK4E01
        Text in Illustration
        *a Retainer
        A003DCD Pull
        A003GWQ Pull Out

        Detach the claw of the retainer of the urea tank breather tube connector, pull up the retainer and disconnect the urea tank breather tube connector from the urea tank sub-assembly.

        Note


        • If there is any solidified urea solution (white solids) on the connection area, clean the solids off with a damp cloth, etc., before disconnecting the urea tank breather tube connector.

        • Be sure to disconnect the urea tank breather tube connector by hand.

        • Check for foreign matter in the urea tank sub-assembly and around the urea tank breather tube connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the urea tank sub-assembly and urea tank breather tube connector.

        • Put the urea tank sub-assembly and urea tank breather tube connector ends in plastic bags to prevent damage and foreign matter contamination.

    2. Disconnect the urea tank filler tube of the urea tank filler pipe assembly from the urea tank sub-assembly.

      Note

      Check for dirt or mud on the urea tank sub-assembly and around the urea tank filler tube connector before disconnection. Clean if necessary.


      1. A003CVHE01
        Text in Illustration
        *a Retainer
        A003DCD Pull
        A003GWQ Pull Out

        Detach the claw of the retainer of the urea tank filler tube connector, pull up the retainer and disconnect the urea tank filler tube connector from the urea tank sub-assembly.

        Note


        • If there is any solidified urea solution (white solids) on the connection area, clean the solids off with a damp cloth, etc., before disconnecting the urea tank filler tube connector.

        • Be sure to disconnect the urea tank filler tube connector by hand.

        • Check for foreign matter in the urea tank sub-assembly and around the urea tank filler tube connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the urea tank sub-assembly and urea tank filler tube connector.

        • Put the tank sub-assembly and urea tank filler tube connector ends in plastic bags to prevent damage and foreign matter contamination.

  5. DISCONNECT UREA TUBE WITH HEATER ASSEMBLY

    Note

    Check for dirt or mud on the urea pump and around the urea tube connector before disconnection. Clean if necessary.


    1. A003D0Q

      Detach the clamp and disconnect the urea tube with the heater assembly from the urea tank sub-assembly.

    2. Remove the urea tube with heater assembly from the urea pump.


      1. A003E6Y

        Detach the lock claw by lifting up the cover.

        Text in Illustration
        A003DCD Lift Up
      2. A003BE6

        Pinch the retainer of the urea tube connector, and then pull the urea tube connector off of the urea tube with heater assembly.

        Text in Illustration
        A003DCD Pinch
        A003GWQ Pull

        Note


        • If there is any solidified urea solution (white solids) on the connection area, clean the solids off with a damp cloth, etc., before disconnecting the urea tube connector.

        • Be sure to disconnect the urea tube connector by hand.

        • Check for foreign matter in the urea pump and around the urea tube connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the urea pump and urea tube connector.

        • Put the urea pump and urea tube connector ends in plastic bags to prevent damage and foreign matter contamination.

  6. REMOVE UREA TANK SUB-ASSEMBLY


    1. A003B68

      Loosen the clip and remove the 3 bolts and urea tank sub-assembly from the body.

    2. Remove the clip from the urea tank sub-assembly.

  7. REMOVE UREA PUMP


    1. A003GPVE01
      Text in Illustration
      *a Co-rotation Prevention Check Mark

      Apply a co-rotation prevention check mark to the urea pump from the urea tank sub-assembly.

      Note


      • The urea tank sub-assembly cutout is attached to protrusion on the urea tube with heater assembly.

      • If the urea pump and urea tank sub-assembly are not firmly attached and the urea pump gauge retainer is rotated, the urea pump will co-rotate and result in urea pump being damaged.

      • Make sure to apply co-rotation prevention check mark to prevent the urea pump from co-rotating.

    2. A003HKDE01
      Text in Illustration
      *1 Urea Pump gauge Retainer
      *a SST (Claw Set)
      *b Rib
      *c Cutout
      *d SST (Claw Set) Incorrect Installation Point (Rotational Start Point Mark of Urea Pump Gauge Retainer)

      Set 4 SSTs (claw sets) to the urea pump gauge retainer and temporarily install.

      SST
      09808-14031   ( 09808-01080, 09808-01090, 09808-01100 )

      Note


      • Align the cutout of SST (claw set) to the rib of the urea pump gauge retainer.

      • Do not place SST on the rotational start paint mark of the urea pump gauge retainer, otherwise SST (claw set) cannot be set correctly.

    3. A003GYGE01
      Text in Illustration
      *1 Urea Pump Gauge Retainer
      *a SST (Claw Set)
      *b Press
      A003DCD Pinch
      A003GWQ SST (Bolt)

      While firmly pressing the claw of SST into rib of the urea pump gauge retainer, tighten the bolt.

    4. A003CN3E01
      Text in Illustration
      *a SST (Plate)
      *b SST (Claw Set)
      A003DCD SST (Bolt)

      Temporarily install SST (plate) to SST (claw set) with 4 SSTs (bolts).

    5. A003HMPE01
      Text in Illustration
      *a Center of Urea Pump Gauge Retainer
      *b SST (Plate)

      Adjust the position of SST (plate) so that the setting hole of SST (handle) aligns with the center of the urea pump gauge retainer.

    6. A003H5NE01
      Text in Illustration
      *1 Urea Pump Gauge Retainer
      *a SST (Plate)
      *b SST (Claw Set)
      *c SST (Bolt)
      *d Rib
      A003DCD Press

      While firmly pressing SST (claw set) into rib of the urea pump gauge retainer, tighten SST (bolt).

    7. A003D1QE01
      Text in Illustration
      *a SST (Plate)
      *b SST (Handle)
      *c SST (Claw Set)
      A003DCD Loosen

      Install SST (handle) to SST (plate).

      SST
      09808-14031   ( 09808-01010, 09808-01020 )

    8. Slowly loosen the urea pump gauge retainer by approximately 90°.

      Note


      • Do not use any tools other than SST, such as screwdriver, etc.

      • Do not excessive force when pressing down on SST, as urea tube with heater assembly will place excessive force on the urea pump gauge retainer and be difficult to remove, and parts may be damaged.

      • Do not use an impact wrench or turn SST handle with excessive force, as parts may be damaged.

    9. While on person slowly loosens the urea pump gauge retainer, have another person press down the rising urea pump, securely attach the protrusion of the urea pump to the groove of the urea tank sub-assembly, and then remove the urea pump gauge retainer while making sure that the urea pump is properly aligned.

      Note


      • If the urea pump gauge retainer is turned while the urea pump and urea tank sub-assembly are not correctly aligned, urea pump will move with the urea pump gauge retainer, and the urea pump and urea tank sub-assembly may both be damaged.

      • Do not rotate the urea pump gauge retainer when the co-rotation prevention check mark is out of place.

      A003EZTE01
      Text in Illustration
      *a SST (Plate) *b SST (Handle)
      *c Person in Charge of Loosening *d Person in Charge of Supporting
      *e Co-rotation Prevention Check Mark - -
    10. A003F8C

      Remove the urea pump from the urea tank sub-assembly.

    11. A003AGO

      Remove the gasket from the urea tank sub-assembly.