What is Diesel Exhaust Fluid (DEF) Made Of? The Experts Guide

What is Diesel Exhaust Fluid (DEF) Made Of? The Experts Guide

Uncategorized | 06/23/2025
Written by Stacy Conner

Fleet managers, operators, and drivers: if you use diesel trucks or diesel-powered vehicles for your business, you’ll want to know about DEF — diesel exhaust fluid. This essential liquid additive ensures your diesel engine lasts long and drives strong.

But, you’ll need to understand how DEF is made to enhance the life of your fleet engines. So, what is DEF fluid made of anyway?

DEF fluid — also known as aqueous urea solution 32% (or AUS 32 for short) — is made of 32.5% urea and 67.5% de-ionized water. Knowing this alone will earn you high fives while at trivia night, but to help your diesel engine last for years to come, you’ll want to read on to learn more about DEF’s application for diesel engines.

Equipment Experts here. In this article, we’ll discuss:

Fast facts about diesel exhaust fluid (DEF) for fleets

1. 2.5 gallons of DEF can last you about 800 miles of travel.
2. You can purchase DEF fluid at select establishments like Walmart, Flying J Truck Stops, Love’s Travel Stops, and many auto parts stores.
3. The Environmental Protection Agency (EPA) says that truck makers must include a staged warning system or gauge to inform a driver about how close their diesel and DEF system is to empty.
4. DEF fluid helps with reducing harmful emissions, emissions like nitrogen oxide (NOx).
5. DEF fluid is a mixture of deionized water and urea. This synthetic fluid is regulated by the American Petroleum Institute.

Understanding DEF for diesel-powered equipment and processes

A picture of semi trucks lined up in a row

First off, DEF can be used for many different applications. Construction, agriculture, and maritime vessels often use DEF for their work.

Diesel exhaust fluid (DEF) consists of 32.5% synthetic urea and 67.5% de-ionized water. This fluid is blended at these proportions to help reduce harmful emissions from being released into the atmosphere from diesel engines.

For example, the urea component of DEF undergoes a chemical reaction when introduced into a truck’s exhaust system. As the urea moves through the exhaust stream, the urea breaks down nitrogen oxides (NOx) into harmless nitrogen and water vapor.

In other words, DEF fluid is key to reducing harmful vehicle emissions into the atmosphere.

Why the need for diesel exhaust fluid?

Two mechanics working on the inside of a semi-truck on DEF fluid

Diesel exhaust fluid helps decrease nitrogen oxides and air pollution. This helpful fluid ensures heavy machinery and trucks operate within federal emissions guidelines.

But let’s step back for a minute for a single-sentence history lesson.

In 2010, the EPA required diesel engines to decrease their production of (NOx), which was accomplished with none other than diesel exhaust fluid (DEF).

From 2010 onwards, diesel trucks were built with a diesel tank and an extra diesel exhaust fluid tank. The second DEF tank has since helped curb noxious emissions released from diesel trucks.

The role of selective catalytic reduction (SCR) with DEF

A man working in the guts of a vehicle

Another pivotal process for dissolving ditty gases, NOx, and other particles produced by diesel truck engines is selective catalytic reduction (SCR).

What’s more, SCR has existed for many years, but only in 2010 has federal regulations mandated that SCR technology be used in tandem and within new diesel models.

“So, what’s the connection between SCR and DEF?” You might wonder.

For SCR to work, a reductant liquid agent is needed. Cue diesel exhaust fluid.

The synthetic vehicle-grade urea and deionized water are injected into a truck and large equipment exhaust stream. From there, DEF breaks down harmful emissions into non-hazardous nitrogen and water, thereby decreasing diesel-related emissions.

The interaction between SCR and DEF (We know the acronyms can be a lot. We apologize.) helps mitigate the environmental impact of new and used diesel engine-powered trucks. So, while DEF isn’t a fuel like gasoline, it also doesn’t contribute to the combustion process like gasoline does.

But, DEF works with SCR systems to neutralize harmful emissions.

DEF helps diesel engines meet strict environmental standards, making DEF an essential resource for fleet managers and truck drivers.

How much DEF weighs

A picture of bubbly oil

Fleet managers and operators: knowing how much your diesel engine fluid weighs is crucial for maximizing fuel efficiency and staying within federal weight regulations at, for example, border crossings.

As such, a gallon of diesel engine fluid clocks in at about nine pounds. If you’re planning cross-country transport, keeping in mind these fuel considerations will ensure your vehicle is equipped with the right amount of DEF for border crossings in the long haul ahead.

Why diesel exhaust fluid (DEF) is helpful for diesel engines

Mechanic wearing clear plastic glasses and a yellow hardhat

Specifically for diesel-powered engines and vehicles, using DEF systems with the right mixture of urea and deionized water is key to meeting environmental standards and minimizing the environmental impact of diesel vehicles.

As such, you’ll want to use high-quality diesel exhaust fluid that’s stored in a cool, dry place with the temperature being anywhere from 12 to 86 degrees Fahrenheit. Ensuring the right mixture and proper storage of DEF fluid will help you keep your truck in tip-top shape.

Best of all, DEF is available in different sizes and is projected to become more available. From individual containers to bulk DEF supply options, whatever your need may be, we’re likely to see the use of DEF for heavy-duty diesel vehicles grow over the next decade (VerifiedMarketResearch.com, 2024).

Reaching out to your local mechanic and diesel truck provider will help you find the DEF supply best suited for your needs.

Quick tips about diesel exhaust fluid

Two men talking- one in a forklift and one outside the forklift

If you’re looking to purchase or already have DEF containers, the following tips can ensure you make the most of your diesel exhaust fluid purchase:

Did you know?

Did you know that spending money on preventive maintenance may be your best dollar spent for your fleet? DEF fluid or not, the average cost to maintain a commercial truck ranges from $15,00 to $18,000 a year.

As part of your preventive maintenance, ask your fleet repair shop about reducing breakdowns and improving vehicle longevity with the help of technicians who know how to handle diesel exhaust fluid. Learn more fun facts about diesel vehicles on our Instagram page here!

Have DEF-powered diesel trucks? We do DEF repairs and maintenance

An aerial-style picture of the Equipment Experts team with their trucks

We can all play our role in reducing harmful emissions from diesel vehicles by being more informed about harmful exhaust emissions. To reduce NOx emissions, diesel exhaust fluid is a must.

Fleet managers, if you’re looking to reduce harmful emissions from diesel engines, you’ll definitely want to look into DEF and SCR technology.

At Equipment Experts, we offer fleet management support and a slew of diesel truck repair services to keep your heavy-duty diesel equipment in tip-top shape. For more than 20 years, we’ve been Tacoma, Washington’s go-to diesel truck repair shop.

Our 12-bay facility is conveniently located where the I-5 and Highway 512 meet. Thus, whether you live in the Tacoma, Washington area or beyond, don’t hesitate to contact us anytime for all your fleet repair and diesel-related needs.

A friendly technician would be happy to help you. Until then, be well!

Frequently asked questions (FAQ) about diesel exhaust fuel

A picture of an Equipment Experts Inc. employee standing in front of a truck

1. How often should I top off DEF fluid?

To start, two and a half gallons of diesel exhaust fluid should last you about 800 miles on the road. In other words, for every 50 gallons of diesel fuel, you should budget for one gallon of DEF.

2. What happens if I run out of DEF fluid?

The Environmental Protection Agency (EPA) specifies that all diesel vehicles must come with staged warning systems and/or gauges to tell drivers how close their DEF system is to empty. Whether your vehicle slows down to five miles per hour or less, or your engine’s power reduces, if you don’t replace your DEF fluid, your diesel vehicle will eventually not start.

Also, check with your local diesel in-shop repair team on your DEF with every preventive maintenance service. Doing so will ensure you don’t run out of DEF or risk doing extra repair work.

3. How harmful and dangerous is DEF?

The good news is that DEF is not toxic, flammable, or polluting as a liquid. This liquid is safe to handle, store, and transport.

But, you should keep DEF out of sunlight and extreme temperatures to maintain its quality and shelf life.

Equipment Experts Fleet Services

Don't forget to share this post!
For in-depth knowledge, you can read our industry leading E-Book, a step-by-step guide on Managing Your Fleet.
READ NOW
Read also...
Does My Truck Need a Transmission Inspection? Need to Know Info
What's Forced Regeneration for Diesel Particulate Filters (DPF)?
What's the Average MPG for Semi Trucks (Tips for Improvement)?