5007211 EVINRUDE Service Manual - English

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
B - De-ionized Water 1
Ensure that all adjustments and repairs that are carried out to the Diesel Exhaust Fluid (DEF) system are performed by authorized personnel that have the correct training.Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.
Care must be taken to ensure that Diesel Exhaust Fluid (DEF) for the system are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Ensure that the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information.
Refer to the Original Equipment Manufacture (OEM) for the location and removal of the diesel exhaust fluid tank.
Drain the coolant from the cooling system to a level below the solenoid valve, into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
Illustration 1 g06477172
Typical example
Ensure that the area around manifold DEF heater (2) is clean and free dirt and debris. If necessary, clean the area around the manifold DEF heater. Clean the area around the manifold DEF heater with Tooling (B) and a suitable tool for agitation.
Disconnect the Original Equipment Manufacture (OEM) harness assembly from harness assembly (3). Use Tooling (A) to cap the harness assembly.
Disconnect diesel exhaust fluid line (6) and diesel exhaust fluid line (7) from manifold DEF heater (2). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Make temporary marks on coolant fluid line (5), coolant fluid line (8), and note hose clamp positions for installation only.
Loosen hose clamp (4) and position away from manifold DEF heater (2). Disconnect coolant fluid line (5) from the manifold DEF heater. Use Tooling (A) to cap the connections and plug the coolant lines.Note: Discard the hose clamp.
Loosen hose clamp (9) and position away from manifold DEF heater (2). Disconnect coolant fluid line (8) from the manifold DEF heater. Use Tooling (A) to cap the connections and plug the coolant lines.Note: Discard the hose clamp.
Remove diesel exhaust fluid tank (1) from the mounting bracket.Installation Procedure
Ensure that all components are free from wear or damage. Replace any component that is worn or damaged.
Illustration 2 g06477172
Typical example
Install diesel exhaust fluid tank (1) onto the mounting bracket. Refer to the OEM for the correct installation procedure.
Install diesel exhaust fluid line (6) and diesel exhaust fluid line (7) to manifold DEF heater (2). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Position new hose clamp (4) onto coolant fluid line (5). Install coolant fluid line (5) to manifold DEF heater (2). Position hose clamp in position noted on removal. Tighten the hose clamp to a torque of 7 N m (62 lb in).Note: Ensure that the hose clamp is correctly orientated.
Position new hose clamp (9) onto coolant fluid line (8). Install coolant fluid line (8) to manifold DEF heater (2). Position hose clamp in position noted on removal. Tighten the hose clamp to a torque of 7 N m (62 lb in).Note: Ensure that the hose clamp is correctly orientated.
Remove the cap from harness assembly (3) and connect the OEM harness assembly.
Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Check" and Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure.
Turn the battery disconnect switch to the ON position.