859732 Mercury PLUG

Table 2
Required Service Tools
Part Number Description
441-0451 Kit - Test Reference: Refer to the appropriate Disassembly and Assembly procedure for removal or installation of components.
Table 3
Troubleshooting Test Steps Values Results
1. Determine the Code.
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM).
B. Download the "Warranty Report" from the Aftertreatment ECM before performing any troubleshooting or clearing any diagnostic trouble codes.
C. Determine the diagnostic trouble code that is active.
Diagnostic Code
Result : A E1410 (2) or 4364-2 code is active or logged.
Proceed to Test Step 2.
Result : For all codes other than a E1410 (2) or 4364-2, proceed to Test Step 3.
2. Check the NOx Sensors for Proper Installation.
A. Turn the keyswitch to OFF.
B. Verify that the sensors are located in the correct position.
Note : The "Engine Out NOx" sensor wiring has a black sheath. The "Tailpipe Out NOx" sensor wiring has a gray sheath.
C. If the sensors are installed in the wrong positions, install the sensors in the correct positions. Refer to Special Instruction, REHS8151 for the correct handling procedures.
D. Perform a "Aftertreatment System Functional Test" using Cat ET.
NOx Sensors
Result : The "Aftertreatment System Functional Test" completed successfully.
Return the unit to service.
Result : The "Aftertreatment System Functional Test" did not complete successfully and other codes were logged.
Repair : Troubleshoot the logged codes.
3. 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 and the concentration is not within the acceptable range.
Repair : Drain the DEF from the tank. Refill the tank with DEF that meets ISO 22241 quality standards.
Proceed to Test Step 14.
Result: The DEF is not contaminated and the concentration is within the acceptable range.
Proceed to Test Step 4.
Result : The DEF is contaminated.
Repair : Contact the DSN for further information.
4. Determine the DEF Quality Sensor Installation Status
A. Use Cat ET to check the status of the configuration parameter "Aftertreatment #1 DEF Quality Sensor Installation Status".
Parameter
Result : "Aftertreatment #1 DEF Quality Sensor Installation Status" is set to "Installed".
Proceed to Test Step 5.
Result : "Aftertreatment #1 DEF Quality Sensor Installation Status" is set to "Not Installed" or is not listed.
Proceed to Test Step 6.
5. Determine the Diagnostic Code
A. Connect Cat ET
B. Determine the code that is active.
Code
Result : An E1365 (2), 3516–16, E1364 (2), or 3516–18 code is active or logged.
Repair : Replace the DEF tank header assembly.
Proceed to Test Step 14.
Result : An E1309 (2) or 4364–18 code is active or logged.
Proceed to Test Step 6.
6. Inspect All of the DEF Lines for Leaks.
A. Turn the keyswitch to ON. Do not start the engine.
B. Connect to the "Diesel Exhaust Fluid Controller #1 ECM" in Cat ET.
C. Perform the "DEF Dosing System Verification Test" in order to pressurize the system. Refer to Troubleshooting, "Cat ET Service Features" for more information.
D. Visually inspect all DEF lines from the tank to the DEF injector. Look for pinched, damaged, or disconnected lines.
E. Inspect the lines for leakage.
F. Turn the keyswitch to OFF.
DEF Lines
Result : The lines are leaking, damaged, pinched, or disconnected.
Repair : Make the necessary repairs.
Proceed to Test Step 14.
Result : The lines are not leaking, damaged, pinched, or disconnected.
Proceed to Test Step 7.
7. Perform an "Aftertreatment NOx Sensor Functional Test".
A. Start the engine.
B. Connect to the "Engine #1 Aftertreatment Control ECM" using Cat ET.
C. Perform an "Aftertreatment NOx Sensor Functional Test".
Aftertreatment NOx Sensor Functional Test
Result : The test completed successfully.
Proceed to Test Step 8.
Result : The test did not complete successfully. A failed NOx sensor was detected.
Repair : Replace the failed NOx sensor. Refer to Special Instruction, REHS8151 for the correct handling instructions.
Proceed to Test Step 14.
8. Perform a "DEF Dosing System Accuracy Test".
A. Perform a "DEF Dosing System Accuracy Test" using Cat ET. Refer to Testing and Adjusting, "Aftertreatment SCR System Dosing Test" for the correct procedure.
DEF Dosing System Accuracy Test
Result : The quantity collected is within specifications.
Repair : Re-install the DEF injector.
Proceed to Test Step 12.
Result: The quantity collected is below specifications.
Proceed to Test Step 9.
Result : The quantity collected is above specifications. A failed DEF injector has been detected.
Repair : Replace the DEF injector.
Proceed to Test Step 14.
9. Check the DEF Pressure Line.
A. Turn the keyswitch to OFF. Allow 2 minutes to elapse before proceeding.
B. Remove the DEF pressure line between the DEF pump and the DEF injector.
C. Inspect the line for obstructions. Flush the line with water or low-pressure air, if necessary. Possible obstructions are ice, DEF deposits, or debris.
DEF Pressure Line
Result : An obstruction was found.
Repair : Flush the line or replace the line.
Proceed to Test Step 11.
Result : There are no obstructions.
Repair : Reinstall the line.
Proceed to Test Step 10.
10. Replace the DEF injector.
A. Turn the keyswitch to OFF.
B. Remove the DEF injector.
Note : Do not install the injector until Step 11 has been completed.
DEF Injector
Result: The DEF injector was connected to the DEF pressure line and the electrical connector.
Proceed to Test Step 11.
11. Perform a "DEF Dosing System Accuracy Test".
A. Perform a "DEF Dosing System Accuracy Test" using Cat ET. Refer to Testing and Adjusting, "Aftertreatment SCR System Dosing Test" for the correct procedure.
DEF Dosing System Accuracy Test
Result : The quantity collected is within specifications.
Repair : Install the DEF injector.
Proceed to Test Step 14.
Result : The quantity collected is below specifications.
Repair : Replace the DEF pump. Install the DEF injector.
Proceed to Test Step 14.
12. Check for Exhaust Leaks.
A. Start the engine.
B. Check the exhaust system for leaks or damage.
C. Check all exhaust connections from the turbo outlet to