6515 Mercruiser CYLINDER BLOCK ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
At temperatures lower than −15° C (5° F), care should be taken when removing the Diesel Exhaust Fluid (DEF) line connectors that are attached to the tank, pump, and injector. To limit possible damage to the DEF line connectors, carefully apply heat to the area of the DEF line connectors.
Care must be taken to ensure that fluids 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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Turn the battery disconnect switch to the OFF position.
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Illustration 1 g06140822
Remove diesel exhaust fluid line (1). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Use Tooling (A) to plug diesel exhaust fluid line (1) and the cap connection for the diesel exhaust fluid line.
Remove diesel exhaust fluid line (6). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Use Tooling (A) to plug diesel exhaust fluid line (6) and cap the connection for the diesel exhaust fluid line.
Remove the diesel exhaust fluid line (11) from the connection . Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Use Tooling (A) to plug diesel exhaust fluid line (11) and cap the connection for the diesel exhaust fluid line.
Loosen hose clamp (2) and hose clamp (4) for hose assembly (3).
Disconnect hose assembly (3) from manifold DEF heater and the diesel exhaust fluid pump.
Loosen hose clamp (7) and hose clamp (9). Disconnect hose assembly (8) from the manifold DEF heater and the diesel exhaust fluid pump.
Disconnect the hose assembly from connection (5). Refer to the Original Equipment Manufactures (OEM) for the correct procedure.
Use Tooling (A) to plug connection (5).
Remove solenoid valve (10). Refer to Disassembly and Assembly, "Solenoid Valve (DEF Heater Coolant) - Remove and Install" for the correct procedure.
Illustration 2 g03419414
Remove bolt (14) and bracket (13).
Disconnected harness assembly (17) from the diesel exhaust fluid pump.
Remove bolts (12), bolts (15), and bolts (17) from bracket (16).
Position bracket (18) away from the bracket for the diesel exhaust fluid pump.
Illustration 3 g03419415
Remove Allen head bolts (19) from cap (20).
Remove cap (20) from manifold (23).
Remove O-ring seal (21) (not shown) and O-ring seal (22) (not shown).
Remove bolts (24) from manifold (23).
Remove manifold (23) from the diesel exhaust fluid pump.
Use Tooling (A) to cap the connection on the diesel exhaust fluid pump.
Illustration 4 g03419524
Remove bolts (25) from diesel exhaust fluid pump (26). Support the weight of the diesel exhaust fluid pump as the bolts are removed.
Remove diesel exhaust fluid pump (26) from bracket (27).
If necessary, remove filter (28) (not shown). Refer to Operation and Maintenance Manual, "Diesel Emission Fluid (DEF) Filter - Clean/Replace" for the correct procedure.
Illustration 5 g06145649
If necessary, follow Step 28.a through Step 28.c to remove connections from diesel exhaust fluid pump (26).Note: The removal of the connections from the diesel exhaust fluid pump new connections must be installed to the diesel exhaust fluid pump.
Place identification marks on connections (29) and diesel exhaust fluid pump (26) for installation purpose. Remove the connections from the diesel exhaust fluid pump. Use suitable plugs to plug the open ports on the diesel exhaust fluid pump. Discard the connections.
Place identification marks on connection (30) and diesel exhaust fluid pump (26) for installation purpose. Remove the connection from the diesel exhaust fluid pump. Use suitable plugs to plug the open port on the diesel exhaust fluid pump. Discard the connection.Note: The connections are not interchangeable.
Place identification marks on connection (31), connection (32), and diesel exhaust fluid pump (26) for installation purpose. Remove the connections from the diesel exhaust fluid pump. Use suitable plugs to plug the open ports on the diesel exhaust fluid pump. Discard the connections.Note: The connections are not interchangeable.Installation Procedure
Table 2
Required Tools