803079T 1 Mercruiser REPAIR KIT, Lower Gear

Table 1
Troubleshooting Test Steps Values Results
1. Extended Idle Times
A. Extended idle times will allow oil to pass into the exhaust system. Refer to Operation and Maintenance Manual, Operation Section.
Idle times
Result The idle times are extensive.
Reduce the idle times.
Proceed to Test Step 6.
Result The idle times are not extensive.
Proceed to Test Step 2.
2. Air Intake and Exhaust System
A. Check the air filter restriction indicator, if equipped.
B. Check the air intake and the exhaust system for the following defects:
Signs of dirt ingress
Blockages
Restrictions
Damage to the air intake and exhaust lines and hose
C. Check for ECM codes for inlet air restriction:
107-15: Engine Air Filter 1 Differential Pressure high - least severe (1)
107-16: Engine Air Filter 1 Differential Pressure high - moderate severity (2)
D. Check that the engine has not exceeded the service interval for the air cleaner element. Refer to Operation and Maintenance Manual.
Air intake and exhaust system
Result: The air filter restriction indicator has operated or the air filter is blocked.
Repair: Make sure that the air filter is clean and serviceable. If necessary, replace the air filter.
Result: The air intake or the exhaust system is blocked, restricted, or damaged.
Repair: Repair the air intake or the exhaust system, as required.
Result: A 107-15 or 107-16 code is active
Repair: Refer to Troubleshooting, Inlet Air is Restricted.
Result: The service interval for the air cleaner element has been exceeded.
Repair: Replace the air cleaner element. Refer to Operation and Maintenance Manual, Engine Air Cleaner Element - Replace.
Result: The air intake or the exhaust system is OK.
Proceed to Test Step 3.
3. Worn Valve Guide Seals or Faulty Valve Guide Seals
A. Inspect the valve guide seals for wear and for damage.
Valve guide seals
Result: The valve guide seals are damaged.
Repair: Replace the valve guide seals. Verify the repair.
Proceed to Test Step 6.
Result: The valve guide seals are not damaged.
Proceed to Test Step 4.
4. Worn Valve Guides
A. Inspect the valve guides for wear. Refer to the Specification manual for the maximum permissible wear of the valve guides.
Valve guides
Result: The valve guides are worn.
Repair: If necessary, recondition the cylinder head. Verify the repair.
Proceed to Test Step 6.
Result: The valve guides are not worn.
Proceed to Test Step 5.
5. Worn Piston Rings
A. Remove the pistons. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove".
B. Remove the piston rings from the pistons. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Disassemble"
C. Inspect the pistons and piston rings for wear or damage. Refer to the "Specifications" manual for further information.
Piston rings
Result The piston rings are worn.
Repair: Replace the piston rings. Verify the repair.
Proceed to Test Step 6.
Result The piston rings are not worn.
Contact the Dealer Solutions Network (DSN).
6. Check the Aftertreatment System for Oil
A. Remove excess oil from piping with a clean cloth.
B. Remove the Clean Emissions Module (CEM). Refer to Disassembly and Assembly, "Clean Emissions Module - Remove and Install".
C. Support the CEM over a suitable container with the exhaust inlet downwards. Leave the CEM to drain for 8 hours.
D. Check the quantity of drained oil in the container.
CEM
Result The volume of drained oil is greater than 0.3 L (0.31701 qt).
Repair: Install a replacement CEM. Refer to Disassembly and Assembly, "Clean Emissions Module - Remove and Install".
Return the unit to service.
Result The volume of drained oil is less than 0.3 L (0.31701 qt).
Proceed to Test Step 7.
7. Recover the Aftertreatment System
A. Clean any remaining oil from the piping and the CEM inlet with a clean cloth.
B. Install the Clean Emissions Module (CEM). Refer to Disassembly and Assembly, "Clean Emissions Module - Remove and Install".
C. Run the engine at high idle with no load for a minimum of 20 minutes.
D. Use the electronic service tool to perform the "Aftertreatment Recovery Procedure". While the procedure is progressing, check for smoke from the exhaust. Some smoke will be evident during the procedure. The smoke must dissipate before the procedure is completed.
CEM
Result: The "Aftertreatment Recovery Procedure" completes with a soot load of less than 80% and no smoke from the exhaust.
Proceed to Test Step 8
Result The "Aftertreatment Recovery Procedure" completes with a soot load of more than 80% or smoke from the exhaust.
Contact the Dealer Solutions Network (DSN).
8. Clean the Fuel System
A. Following the instructions on the bottle, add Cat Fuel System Cleaner (343-6210) to the fuel tank.
Electronic Unit Injectors
Return the unit to service, the fuel system will be cleaned during operation.