54168 Mercruiser GUIDE

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
Ensure that all adjustments and repairs that are carried out to the Diesel Emission 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 Emission 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.
Illustration 1 g03726978
Remove flexible exhaust pipe (1). Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.
Disconnect the harness assembly from exhaust temperature sensor (2).
Disconnect harness assembly (4) from Diesel Emission Fluid (DEF) injector (3). Use Tooling (A) to cap the harness assembly and the DEF injector.
Remove Diesel Emission Fluid (DEF) line (5) and diesel emission fluid line (6) from the DEF injector (3). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Use Tooling (A) to caps DEF injector (3).
Use Tooling (A) plug diesel emission fluid line (5) and diesel emission fluid line (6).
Illustration 2 g03726980
Remove the Original Equipment Manufacture (OEM) exhaust tube assembly (7) from Clean Emissions Module (CEM) (12). Refer to the OEM for the correct procedure.
Disconnect the harness assembly from exhaust temperature sensor (8).
Attach a suitable lifting device to the assembly of CEM (12).
Remove bolts (10) and bolts (11) from CEM (12). Use the suitable lifting device to remove the CEM from the bracket. Installation Procedure
Ensure that all components are clean and free from wear and damage. If necessary, replace the CEM as an assembly. The assembly of the CEM will be supplied with mounting brackets. The orientation of the CEM to the brackets will be preset. The clamps retaining the CEM to the bracket should not be loosened or removed.
Illustration 3 g03726980
Attach a suitable lifting device to the assembly of CEM (12).
Use the suitable lifting device to install CEM (12) to the bracket. Install bolts (10) and bolts (11) to CEM (12). Tighten the bolts to a torque of 44 N m (32 lb ft).
Remove the suitable lifting device from CEM (12).
Connect the harness assembly to exhaust temperature sensor (8).
Install the Original Equipment Manufacture (OEM) exhaust tube assembly (7) to Clean Emissions Module CEM (12). Refer to the OEM for the correct procedure.
Illustration 4 g03726978
Install flexible exhaust pipe (1). Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.
Connect the harness assembly to exhaust temperature sensor (2).
Remove the cap the harness assembly (4) and DEF injector (3). Connect the harness assembly to the DEF injector.
Remove the caps from DEF injector (3) and diesel emission fluid line (5) and diesel emission fluid line (6). Connect the diesel emission fluid lines to the DEF injector. Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.