881260A 3 Mercury GEAR, Forward (29 Teeth)

Probable Causes
DEF tank filler cap
DEF gauge
DEF manifold
DEF leak
DEF quality
DEF line restriction
DEF pump/associated componentsRecommended Actions
Reference: Refer to the Disassembly and Assembly for the appropriate procedure for the removal and installation of components.
Table 2
Troubleshooting Test Steps Values Results
1. Check the Diesel Exhaust Fluid (DEF) Tank Filler Cap.
A. Clean dirt and debris from around the tank cap before removing the cap. Blockages can be caused by a build-up of dirt and debris around the cap.
Note : A blocked DEF filler cap can cause a 5392-31 or E1370 (2) code.
B. Remove and inspect the filler cap for blockages.
DEF Filler Cap
Result : A blockage was not found.
Proceed to Test Step 2.
Result : A blockage was found.
Repair : Rinse the cap gently with clean water or replace the cap. The cap contains a membrane so care must be taken not to damage the membrane. If the cap cannot be cleaned, replace the cap.
Proceed to Test Step 2.
2. Check the Diesel Exhaust Fluid (DEF) Gauge.
A. Turn the keyswitch to ON. Do not start the engine.
B. Check the current position of the DEF gauge.
C. Turn the keyswitch to OFF.
D. Clean dirt and debris from around the tank cap before removing the cap. Add or remove DEF from the DEF tank.
Note : Only use DEF that meets ISO 22241 quality standards.
E. Turn the keyswitch to ON. Do not start the engine.
F. Check for a change in the DEF gauge position.
DEF Gauge
Result : The gauge did not move by adding or removing DEF from the tank.
Proceed to Test Step 3.
Result : The gauge moved by adding or removing DEF from the tank.
Proceed to Test Step 4.
3. Check the Electrical Connection at the DEF Manifold.
A. Turn the keyswitch to OFF.
B. Inspect the electrical connections to the DEF manifold. Refer to Troubleshooting, "Electrical Connectors - Inspect" for further information.
C. Inspect the connections for corrosion or loose wires.
Electrical Connections
Result : The electrical connections are free of corrosion and loose wires.
Repair : Replace the DEF manifold.
Proceed to Test Step 11.
Result : The electrical connections are not free of corrosion or loose wires.
Repair : Make the necessary repairs.
Proceed to Test Step 11.
4. Inspect the DEF lines for leaks.
A. Turn the keyswitch to ON. Do not start the engine.
B. Connect to the "Aftertreatment Diesel Exhaust Fluid Controller #1" using Cat ET.
C. Navigate to "Diagnostics Tests".
D. Perform the "DEF Dosing System Verification Test" to pressurize the system.
Note: This test can take up to 30 minutes to complete.
E. Inspect all DEF lines from the tank to the DEF injector. Check for pinched, damaged, disconnected, or leaking lines.
F. Turn the keyswitch to OFF.
DEF lines
Result: A leaking or disconnected line was found.
Repair : Repair or replace the failed DEF line.
Proceed to Test Step 11.
Result: A leaking or disconnected line was not found.
Proceed to Test Step 5.
5. Check the Diesel Exhaust Fluid (DEF) quality.
A. Measure the DEF quality. Refer to Testing and Adjusting, "Diesel Exhaust Fluid Quality - Test" for the correct procedure.
DEF
Result : The DEF is not contaminated.
Proceed to Test Step 6.
Result : The DEF is contaminated.
Repair : Contact the Dealer Solutions Network (DSN) for further information.
Illustration 1 g03755436
(1) DEF Suction Line Connection on the Header Unit
Table 3
Troubleshooting Test Steps Values Results
6. Check for suction line restrictions.
A. Disconnect the suction line from the DEF manifold and DEF pump.
B. Inspect the suction line for obstructions or damage. Also, check that the line is connected in the proper locations.
Note : Possible obstructions are ice, DEF deposits, or debris.
Restrictions
Result: An obstruction or damage was found.
Repair : Flush the line with water or low-pressure air or replace the suction line.
Proceed to Test Step 11.
Result: An obstruction or damage was not found.
Repair : Reinstall the suction line.
Proceed to Test Step 7.
7. Check for Return Line Restrictions
A. Disconnect the return line from the DEF manifold and the DEF pump.
B. Inspect the return line and the return fitting for obstructions or damage. Check that the line is connected in the proper locations.
Note: Possible obstructions are ice, DEF deposits, or debris.
Restrictions
Result: An obstruction or damage was found.
Repair: Flush the line or connector with water or low-pressure air and/or replace the return line or fitting.
Proceed to Test Step 11.
Result: An obstruction or damage was not found.
Repair: Reinstall the return line.
Proceed to Test Step 8.
8. Check the DEF Manifold for Leaks
A. Turn the keyswitch to OFF.
B. Remove the DEF manifold from the DEF tank.
C. Inspect the suction pipe on the manifold for any leaks or cracks.
Result: A leak or crack was found.
Repair: Replace the DEF manifold.
Proceed to Test Step 11.
Result: A leak or crack was not found.
Repair: Reinstall the return line.
Proceed to Test Step 9.
9. Replace the DEF pump filters.
A. Turn the keyswitch to OFF.
B. Clean the area around the pump filters.
C. Replace the DEF pump suction line filter fitting. Tighten the new filter fitting to a torque of 4.5 N m (40 lb in).
D. Replace the DEF pump filter. Refer to Operation and Maintenance Manual, Diesel Exhaust Fluid Filter - Replace for the correct procedure.
E. Remove DEF tank header from the DEF tank.
F. Flush the DEF tank and replace the DEF filters. Refer to Testing and Adjusting , Diesel Exhaust Fluid Tank - Flush for the appropriate procedure.
DEF Pump and DEF Tank Filters
&nbs