09109-40060 CAP, LEVER Denso Cross

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
DEF injector failures are occurring at early hours on I6 engine products leading to fault codes and inducements which causes customer downtime. Failed part returns indicate that a portion of the injectors is no fault found when tested at Caterpillar®. Caterpillar® is investigating the root cause of these injector replacements and to support the investigation is requesting that the following procedure is completed, documented, and sent to Caterpillar®.Solution
Complete the steps listed below and ensure that all DEF Quality, Injector Resistance and Dosing Accuracy Test are completed when requested by the associated troubleshooting guides. Once troubleshooting is completed, submit all information to the following email address: Blunier_Derek_W
Download Product Status Report including all ECMs and histograms.
Download Warranty Report from the engine ECM and aftertreatment ECM.
Illustration 1 g06067373
DEF Injector
Take a picture of the DEF injector part number and serial number as shown in Illustration 1.
Table 1
Media References
Engine Description Media Number
C9.3 Troubleshooting UENR0978
Testing and Adjusting UENR3402
Disassembly / Assembly UENR0130
C13 Troubleshooting UENR0955
Testing and Adjusting UENR4302
Disassembly / Assembly UENR0131
C15 / C18 Troubleshooting UENR0955
Testing and Adjusting UENR3351
Disassembly / Assembly UENR0132
Follow the correct troubleshooting procedure from Table 1 for each corresponding code. For troubleshooting C9.3 use , UENR0978 and for C13, C15, C18 engines use , UENR0955.
Table 2
DEF Quality Results
Step Instruction Completed
(Yes/No) Result
Comments Units
1 Follow the Testing and Adjusting procedure for "Diesel Exhaust Fluid Quality - Test"
2 DEF Contamination Test (include photo of test strip if possible) Pass/Fail
3 DEF Concentration Test % @ 20C
Table 3
Injector Resistance Measurement
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
2 Disconnect the DEF injector from the applicable harness.
3 Inspect the connector for damage or debris (if damaged take photo)
4 Measure the temperature of the injector (aluminum body) C
5 Connect two 398-4987 connectors to the DEF injector. The connectors must be used to prevent damage to the DEF injector connector.
6 Measure the resistance of the DEF injector. Ohms
Table 4
Dosing Accuracy Test
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Follow the Testing and Adjusting, Aftertreatment SCR System Dosing - Test.