27780 Mercury PULLER

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
B - De-ionized Water 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.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g03799358
Illustration 2 g03799340
Typical examples
Ensure that the area around Manifold (DEF Heater) (3), Diesel Exhaust Fluid (DEF) pump (4), Diesel Exhaust Fluid injector (5) and Diesel Exhaust Fluid (DEF) line (1), and Diesel Exhaust Fluid (DEF) line (2), and Diesel Exhaust Fluid (DEF) line (6) are clean and free dirt and debris. If necessary, use Tooling (B) and a suitable tool to clean the area around the DEF components.
Refer to the Original Equipment Manufacture (OEM) for the correct location of the manifold DEF heater (3), Diesel Exhaust Fluid (DEF) pump (4), and Diesel Exhaust Fluid injector (5). Refer to the OEM for the correct routing of the diesel exhaust fluid lines.
Disconnect the Original Equipment Manufacture (OEM) harness assemblies from harness assembly (7), harness assembly (8), and harness assembly (9) for the Diesel Exhaust Fluid (DEF) lines.
Make temporary marks on cable straps for installation purposes. Cut the cable straps. Ensure that all cable straps are removed.
Disconnect diesel exhaust fluid line (1) and diesel exhaust fluid line (2) from manifold DEF heater (3).
Use Tooling (A) to cap manifold DEF heater (3). Use Tooling (A) to plug diesel exhaust fluid line (1) and diesel exhaust fluid line (2).
Disconnect of the other end of diesel exhaust fluid line (1) and diesel exhaust fluid line (2) from DEF pump (4).
Use Tooling (A) to cap DEF pump (4). Use Tooling (A) to plug diesel exhaust fluid line (1) and diesel exhaust fluid line (2).
Disconnect diesel exhaust fluid line (6) from DEF injector (5) and DEF pump (4).
Use Tooling (A) to cap DEF injector (5). Use Tooling (A) to plug diesel exhaust fluid line (6) at both ends. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B - De-ionized Water 1
Ensure that all diesel exhaust fluid components are free from wear or damage. Replace any diesel exhaust fluid component that is worn or damaged.
Illustration 3 g03799358
Typical examples
Illustration 4 g03799340
Typical examples
Refer to the OEM for the correct routing of the diesel exhaust fluid lines.
Remove the caps from manifold DEF heater (3) and plug from DEF line (1) and DEF line (2).
Connect DEF line (1) and DEF line (2) to manifold DEF heater (3).
Remove the caps from DEF pump (4) and plugs from DEF line (1) and DEF line (2). Connect the DEF lines to the DEF pump. Ensure that the DEF lines are correctly orientated.
Remove cap from DEF line (6). Connect the DEF line to DEF pump (4).
Connect the OEM harness assemblies to harness assembly (7), harness assembly (8), and harness assembly (9) for the DEF lines.
Install new cable straps to the OEM harness assemblies for harness assembly (7) and harness assembly (8). Ensure that the cable straps are installed in the original positions. Note: Ensure that the cable straps meet OEM specification.
Prior to the installation of DEF supply line (6) to DEF injector (5), follow Step 9.a through Step 9.h in order to flush the DEF supply line.
Turn the battery disconnect switch to the ON position.
Connect the electronic service tool. Refer to Troubleshooting, "Electronic Service Tools" for the correct procedure.
Remove cap from DEF supply line (6). Place the open end of the DEF supply line in a suitable container, with a capacity greater than 2 L (0.44 Imp gal).
Select the DEF dosing system accuracy test. Refer to Troubleshooting, "DEF Dosing System Accuracy Test" for the correct procedure.
Hold DEF supply line (6) above the suitable container. Run the DEF dosing system accuracy test for maximum of 90 second. Ensure that the DEF supply line is not immersed in the DEF fluid in the suitable container.
Turn the battery disconnect switch to the OFF position.
Use Tooling (B) to clean any DEF fluid from the end of DEF supply line (6).
Remove the caps from DEF injector (5). Connect DEF supply line (6) to DEF injector (5).
Turn the battery disconnect switch to the ON position.
Use the electronic service tool to perform a pressure test on the DEF system and check for leaks. Refer to Troubleshooting, "DEF Dosing System Verification Test" for further information.
Turn