4328540

Instruction Sheet
Urea Quality Sensor Boot Installation
4328540R1
Application
Various
Figure 1. Urea Quality Sensor Boot Installation Kit
Kit Contents
Urea Quality Sensor Boot Installation Kit
Description Quantity
Cover, Q DEF Sensor 1
Strap, Cable Lock 1
Heat Shrink Tube 1
Instruction Sheet 1
1
Read all safety instructions in the "Safety Information" section of the appropriate Engine Service or Diagnostic Manual.
Follow all warnings, cautions, and notes.
© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Kit Contents (cont.)
GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.
WARNING: To prevent personal injury and / or death, read all safety instructions in the “Safety
Information” section of the Engine Service Manual or Engine Diagnostic Manual.
WARNING: To prevent property damage, personal injury, and / or death, park vehicle on a hard, flat
surface, turn engine off, set parking brake, and install wheel chocks to prevent vehicle from moving in
either direction.
WARNING: To prevent personal injury and / or death, make sure the engine has cooled before
removing components.
WARNING: To prevent property damage, personal injury, and /or death, remove ground cable from
negative terminal of main battery before disconnecting or connecting electrical components. Always
connect ground cable last.
WARNING: To prevent personal injury and / or death, always wear safe eye protection when
performing vehicle maintenance.
WARNING: To prevent property damage, personal injury, and / or death, if the vehicle must be
raised, do not work under the vehicle supported only by jacks. Jacks can slip or fall over.
WARNING: To prevent property damage, personal injury, and / or death, allow heated materials to
cool prior to handling.
WARNING: To prevent personal injury or death, avoid contact with Diesel Exhaust Fluid (DEF) /
urea. Do not get DEF in eyes. In case of eye contact, immediately flush eyes with large amounts of
water for a minimum of 15 minutes. DEF contains urea. Do not swallow. If DEF is ingested, contact a
physician immediately. Reference the Safety Data Sheet (SDS) for additional information.
WARNING: To prevent property damage, personal injury, and / or death, seek service immediately
if Diesel Exhaust Fluid (DEF) contamination or Selective Catalyst Reduction (SCR) system fault is
detected. Failure to resolve the problems may result in a loss of engine power and vehicle speed, and
may cause an accident.
4328540R1 2
Kit Contents (cont.)
CAUTION: To prevent property / component damage, do not use open flames to apply heat to shrink
wrap.
CAUTION: To prevent property / component damage, do not allow shrink wrap debris to fall inside
the wrapped sensor.
CAUTION: To prevent property damage, proper care should be taken when handling, dispensing,
or transporting Diesel Exhaust Fluid (DEF), as it is corrosive to some metals and materials.
CAUTION: To prevent property damage, ensure coolant does not contaminate DEF tank.
CAUTION: To prevent property / component damage, do not cut secondary hole above the Urea
Quality Sensor (UQS). Hole must be offset to prevent damage to UQS.
Procedure
UQS Removal
1. Park vehicle on flat surface.
2. Shift transmission to Park or Neutral and set parking brake.
3. Install wheel chocks.
3 4328540R1
UQS Removal (cont.)
NOTE: Some vehicles do not require the DEF tank to be removed prior to removing the DEF head unit.
Certain DEF tanks can be loosened and repositioned to allow the DEF head unit to be removed.
4. Remove / reposition DEF tank from vehicle. Refer to SRT elemental steps.
5. Wipe residual coolant from DEF tank.
6. Remove / reposition DEF head unit from DEF tank. Refer to SRT elemental steps.
Figure 2. UQS and Bracket

1. UQS upper bracket
2. UQS bracket screw
WARNING: To prevent personal injury or death, avoid contact with Diesel Exhaust Fluid (DEF) /
urea. Do not get DEF in eyes. In case of eye contact, immediately flush eyes with large amounts of
water for a minimum of 15 minutes. DEF contains urea. Do not swallow. If DEF is ingested, contact a
physician immediately. Reference the Safety Data Sheet (SDS) for additional information.
7. Wipe residual DEF fluid from DEF head unit.
NOTE: 5-gallon DEF head units have two screws in the upper bracket.
8. Remove screw (Figure 2, Item 2) from upper bracket (Figure 2, Item 1).
4328540R1 4
UQS Removal (cont.)
Figure 3. DEF Head Unit Bracket Locking Tabs

1. Bracket locking tab
2. UQS lower bracket
9. Using a flat head screwdriver, release locking tab (Figure 3, Item 1) from lower bracket (Figure 3, Item 2)
and remove upper bracket.
5 4328540R1
UQS Removal (cont.)
Figure 4. UQS in Lower Bracket

1. UQS
NOTE: Do not remove UQS wiring harness from UQS.

10. Remove UQS (Figure 4, Item 1) from lower bracket (Figure 4, Item 2).
4328540R1 6
UQS Installation
Figure 5. UQS with Cover

1. UQS
2. UQS plastic cover
3. Bubble escape hole
NOTE: UQS plastic cover must have hole on the side of the sensor that faces up when inserted in the
DEF bracket.
1. Place UQS cover (Figure 5, Item 2) onto UQS (Figure 5, Item 1) with bubble escape hole (Figure 5, Item 3)
face up.
7 4328540R1
UQS Installation (cont.)
Figure 6. UQS, Frame and Upper Bracket

1. UQS upper bracket
2. UQS
NOTE: Slight force may be required when pressing the UQS into the lower bracket.
NOTE: The edge of the UQS plastic cover must be covered by the upper bracket when installed.
2. Insert and press UQS (Figure 6, Item 2) into lower bracket (Figure 6, Item 3) until seated fully.
3. Place upper bracket (Figure 6, Item 1) over sensor and press down until both upper bracket locking tabs
engage with lower bracket.
4328540R1 8
Figure 7. UQS, Frame and Bracket

1. UQS bracket screw
2. UQS bracket
NOTE: 5-gallon DEF head units have two screws in the upper bracket.
4. Install screw (Figure 7, Item 1) into bracket (Figure 7, Item 2), and tighten screw securely.
NOTE: DEF head unit configuration varies depending on DEF tank. Shrink wrap tubing must be
positioned against tank guide boot except on 12-gallon tank DEF head units. To complete UQS Boot
installation procedure for 12-gallon DEF tank, proceed to Step 15.
9 4328540R1
Figure 8. DEF Head Unit with Shrink Wrap Tubing

1. Shrink wrap tubing (3-inch diameter)
2. Tank guide boot
5. Place tubing (Figure 8, Item 1) over DEF head unit until it touches boot (Figure 8, Item 2).
4328540R1 10
Figure 9. DEF Head Unit with Shrink Wrap Tubing Compressed

1. DEF head unit
wrap.
6. Using heat gun, apply heat to tubing (Figure 9, Item 2) until material is evenly compressed around the DEF
head unit (Figure 9, Item 1).
11 4328540R1
Figure 10. DEF Head Unit with Excess Shrink Wrap Tubing
1. Shrink wrap tubing
7. Using knife, remove excess shrink wrap tubing (Figure 10, Item 1) from end of DEF head unit.
4328540R1 12
Figure 11. Compressed Shrink Wrap Tubing – Secondary Hole

1. Hole measuring 1/4 x 1/4 inch
CAUTION: To prevent property / component damage, do not cut secondary hole above UQS. Hole
must be offset to prevent damage to UQS.
8. Using permanent marker, draw square measuring 1/4 x 1/4 inch (Figure 11, Item 1). Draw square 1/2 inch
from end of UQS and aligned with UQS cover hole.
9. Using X-Acto knife with new blade, cut square hole (Figure 11, Item 1) in tubing measuring 1/4 x 1/4 inch.
Cut three sides of square and hold remaining shrink wrap flap with pliers while cutting with X-Acto knife.
10. Install / reposition DEF head unit on DEF tank. Refer to SRT elemental steps.
11. Install / reposition DEF tank on vehicle. Refer to SRT elemental steps.
13 4328540R1
Figure 12. DEF Tank with Completion Indicator

1. Completion indicator (zip-tie – blue)
2. DEF tank bracket
NOTE: On 5-gallon DEF tanks, attach the completion indicator to a sender hose.
12. Attach completion indicator (Figure 12, Item 1) on top of tank bracket (Figure 12, Item 2).
13. Close and latch hood.
14. Remove wheel chocks.
4328540R1 14
NOTE: Steps 15 - 28 applies to 12-gallon DEF tanks only.
Figure 13. DEF Head Unit – 12-Gallon Tank

1. Tank guide boot
15. Remove tank guide boot (Figure 13, Item 1) from DEF bracket.
15 4328540R1
Figure 14. DEF Head Unit with Shrink Wrap Tubing – 12-Gallon Tank
2. Tank guide boot hole
16. Place tubing (Figure 14, Item 1) over DEF head unit. Shrink wrap tubing should cover tank guide boot hole
(Figure 14, Item 2).
4328540R1 16
2. Tank guide boot hole
wrap.
17. Using heat gun, apply heat to tubing until material is evenly compressed around the DEF head unit.
18. Using X-Acto knife with new blade, cut hole in shrink wrap tubing around tank guide boot opening (Figure
15, Item 2).
17 4328540R1
Figure 16. DEF Head Unit with Tank Guide Boot Hole – 12-Gallon Tank
1. Tank guide boot hole - shrink wrap cut
2. Tank guide boot
19. Install guide boot (Figure 16, Item 2) into tank guide boot hole (Figure 16, Item 1).
4328540R1 18
Figure 17. Compressed Shrink Wrap Tubing – Secondary Hole

1. Hole measuring 1/4 x 1/4 inch
CAUTION: To prevent property / component damage, do not cut secondary hole above UQS. Hole
must be offset to prevent damage to UQS.
20. Using permanent marker, draw square measuring 1/4 x 1/4 inch (Figure 17, Item 1). Draw square 1/2 inch
from end of UQS and aligned with UQS holes previously cut.
21. Using X-Acto knife with new blade, cut square hole (Figure 17, Item 1) in tubing measuring 1/4 x 1/4 inch.
Cut three sides of square and hold remaining shrink wrap flap with pliers while cutting with X-Acto knife.
19 4328540R1
2. DEF float
22. Using X-Acto knife with new blade, remove excess shrink wrap (Figure 18, Item 1) from between UQS and
DEF float (Figure 18, Item 2). Ensure shrink wrap does not impede the DEF float movement.
4328540R1 20
Figure 19. DEF Head Unit with Excess Shrink Wrap Tubing
23. Using knife, remove excess shrink wrap tubing (Figure 19, Item 1) from end of DEF head unit.
24. Install / reposition DEF head unit on DEF tank. Refer to SRT elemental steps.
25. Install / reposition DEF tank on vehicle. Refer to SRT elemental steps.
21 4328540R1
Figure 20. DEF Tank with Completion Indicator

1. Completion indicator (zip-tie – blue)
2. DEF tank bracket
26. Attach completion indicator (Figure 20, Item 1) on top of tank bracket (Figure 20, Item 2).
27. Close and latch hood.
28. Remove wheel chocks.
4328540R1 22

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Instruction Sheet

Urea Quality Sensor Boot Installation

Figure 1. Urea Quality Sensor Boot Installation Kit

Figure 2. UQS and Bracket

Figure 3. DEF Head Unit Bracket Locking Tabs

Figure 4. UQS in Lower Bracket

NOTE: Do not remove UQS wiring harness from UQS.

Figure 5. UQS with Cover

Figure 6. UQS, Frame and Upper Bracket

Figure 7. UQS, Frame and Bracket

Figure 8. DEF Head Unit with Shrink Wrap Tubing

Figure 9. DEF Head Unit with Shrink Wrap Tubing Compressed

Figure 11. Compressed Shrink Wrap Tubing – Secondary Hole

Figure 12. DEF Tank with Completion Indicator

Figure 13. DEF Head Unit – 12-Gallon Tank

Figure 17. Compressed Shrink Wrap Tubing – Secondary Hole

Figure 20. DEF Tank with Completion Indicator

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