101608-1640 ZEXEL 9 400 615 810 BOSCH INJECTION-PUMP ASSEMBLY 9400615810 1016081640 me072803

Removal Procedure
Illustration 4 g06465824When Diesel Exhaust Fluid (DEF) lines from the DEF injectors are removed for service, there is a possibility of small DEF quantity to be spilled over the DEF injector body.DEF forms a white, crystalline residue when allowed to dry. This reside can prevent proper sealing of the fittings when the hose is reinstalled. Refer to Illustration 4.DEF Hose Removal Procedure
After the engine is shut off, ensure that the purge cycle is completed before performing the procedure.
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Push the hose fitting toward the tube to relieve the force on the hose fitting. Refer to Illustration 5.
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Press and hold down the retainer clip button and pull the hose fitting off tube. Refer to Illustration 6.
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If hose fitting fails to release, place a compressed air nozzle up against gaps "A" and "B" and blow out dirt and debris for a few seconds on each gap Refer to Illustration 7. Then repeat steps 2 and 3.DEF Hose Cleaning Procedure
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DEF and other debris will interfere with the fitting functionality and will prevent sealing of the connector interface. Refer to Illustration 8.
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Soak the hose end in distilled water for about a minute. Refer to Illustration 9.
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Gently shake the hose dry. Refer to Illustration 10.
Do not use wipes or cloth to wipe the connector. This could introduce fibers into the DEF system and cause DEF pump or DEF injector error codes.DEF Hose Inspection Procedure
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Push the end of the retainer clip (D1). Refer to Illustration 11.
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Release the force on the clip (D2) to ensure that the clip travels freely. Refer to Illustration 12.
If clip does not travel freely, repeat the DEF hose cleaning procedure.
If clip does not travel freely after two or more cleaning attempts, the clip is damaged and the hose has to be replaced.Installation Procedure of DEF Hose Assembly
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Rinse the DEF injector body with distilled water with the electrical connector connected to the injector. Refer to Illustration 13.
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Insert the hose into the injector fitting until the retainer clip snaps into place and the tube comes to a stop. Refer to Illustration 14.
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Hold the molded portion of the hose and pull away from the injector to ensure it is fully seated and locked in place. Refer to Illustration 15.
If hose does not lock in place and pulls out, the hose end connection or clip has been damaged. Replace the DEF line.