68956 Mercury COVER, GEAR HOUSING

Introduction
The following special instructions must be used to test for a crack in the Diesel Particulate Filter (DPF). Do not perform any procedure that is outlined in this Special Instruction until you have read and understand the information that is contained in this document.Required Tools
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     380-5200     Tool Kit     1    
B     366-7782     Attenuator     1    Testing Procedure
Perform a "Manual Diesel Particulate Filter Regeneration" using the electronic service tool.
After the manual DPF regeneration is complete, operate the engine at 1800 rpm for a MINIMUM of 20 minutes to stabilize the DPF temperatures.Note: The engine must maintain a steady speed for the entire duration of the test.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Illustration 1 g02597531
Typical example (1) DPF Outlet Cap (2) Filter Paper (3) Hose Assembly (4) Air Pump
Illustration 2 g03655197
Typical example
Stop the engine. Disconnect harness assembly from both soot antennae. Remove outlet soot antenna (5). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Illustration 3 g03655207
Typical example
Install Tooling (B) between the inlet and outlet soot antenna connections. Refer to illustration 3.
Illustration 4 g02599418
Typical example (6) Filter Paper
Install the filter in the fitting, refer to Illustration 4. Install the fitting in the DPF outlet port where the outlet soot antenna was installed. The filter must be installed in less than 10 minutes after the engine has shut down.
Turn the vacuum pump ON.
Disable automatic regeneration in the electronic service tool.
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Disabled". The check engine light and an active diagnostic trouble code will be present.
Start the engine. Operate the engine at 1800 rpm for 15 minutes.Note: The engine must maintain a steady speed for the entire duration of the test.
Stop the engine. Remove the filter assembly within 25 minutes. Use proper personal protective equipment to remove the filter assembly.
Allow the filter assembly time to cool down before disassembly.
Carefully disassemble the filter assembly to prevent contamination. Tip the fitting down on a clean surface to remove the filter paper. Handle the filter paper with clean hands and only by the edges.
Illustration 5 g02597796
Typical example
Compare the stained area in the center of the filter paper to the color coded sheet provided. Refer to Illustration 5.
If the shade is equal to or darker than the "Color Code Sheet", then replace the DPF. Refer to Special Instruction, "Diesel Particulate Filter (DPF) Maintenance on Tier 4 Products Equipped with a Diesel Particulate Filter".
If the shade is lighter than the "Color Code Sheet", then the DPF can continue in service.
Enable the Automatic regeneration in the electronic service tool.
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Not - Disabled". The check engine light will go off unless other diagnostic trouble codes are active.
Remove Tooling (B). Install outlet soot antenna (5). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure. Connect harness assembly to both soot antennae.
Perform a soot sensor calibration. Select "Service", "Calibration", "Soot loading sensor calibration".
A regeneration will be performed to reset soot level and will calibrate the soot sensor.
Return the unit to service.
Clean the items in Tooling (A) with a suitable cleaning solution after each application to prevent contamination.