9648 1 Mercury REPAIR KIT

Table 2
Required Tools
Tool Part Number Part Description Qty
A 431-7087 Test Kit (Refractometer) 1 Complete the procedure in the order in which the steps are listed.
Table 3
Troubleshooting Test Steps Values Results
1. Check for Other Active Diagnostic Codes
A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Check for active diagnostic codes
Diagnostic trouble code
Result: There is at least one other active diagnostic code
Repair: Troubleshoot all other active diagnostic codes before continuing with this procedure.
Refer to Troubleshooting, "Diagnostic Trouble Codes" for further information.
Result: A 4364-17 code is active or logged.
Proceed to Test Step 2.
2. Check the NOx Sensors for Correct Installation
A. Check the color of the wire insulation between the NOx sensor probe and the NOx sensor controller for the engine-out NOx sensor and the tailpipe-out NOx sensor.
The wire insulation for the engine-out NOx sensor is black
The wire insulation for the tailpipe-out NOx sensor is gray.
Engine-out NOx sensor insulation is black.
Tailpipe-out NOx sensor insulation is gray.
Result: The NOx sensors are not installed in the correct positions.
Repair: Install the NOx sensors in the correct positions.
Refer to Disassembly and Assembly, Nitrogen Oxide Sensor - Remove and Install.
Result: The NOx sensors are installed in the correct positions.
Proceed to Test Step 3.
3. Check the NOx Concentration Levels From Each NOx Sensor
A. Establish communication between the electronic service tool and the ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Start the engine. Allow the coolant and the exhaust to reach normal operating temperatures. Wait for the DEF dosing system to enter normal dosing mode.
C. Go to the "Status" screen on the electronic service tool.
Make a note of the values for the following parameters:
"Aftertreatment #1 Intake NOx Level"
"Aftertreatment #1 Outlet #1 NOx Level"
NOx Sensor Check
Proceed to Test Step 4.
Result: The "Aftertreatment #1 Intake NOx Level" is less than the "Aftertreatment #1 Outlet #1 NOx Level". Both levels are less than 5000 ppm.
The NOx concentration levels are implausible. The NOx sensors may be installed in the incorrect position in the exhaust.
Repair: Confirm the NOx sensor installation and wiring. Refer to Troubleshooting, NOx Sensor - Test.
Result: At least one of the NOx sensor concentration levels is equal to or greater than 5000 ppm.
The NOx concentration levels are implausible.
Repair: Inspect the NOx sensors. Refer to Troubleshooting, NOx Sensor - Test.
Result: The "Aftertreatment #1 Intake NOx Level" is greater than or equal to the "Aftertreatment #1 Outlet #1 NOx Level". Both values are lower than 5000 ppm.
The NOx concentration levels are plausible.
Proceed to Test Step 4.
4. Check the DEF Quality
A. Use Tooling A to measure the Diesel Exhaust Fluid (DEF) quality.
Refer to Systems Operation, Testing and Adjusting, "Diesel Exhaust Fluid Quality - Test" for the correct procedure.
DEF quality standards
Result: The DEF quality is not within the acceptable range.
Repair: Drain the DEF fluid from the tank. Refill the tank with DEF that meets ISO 22241 quality standards.
Result: The DEF quality is within the acceptable range.
Proceed to Test Step 5.
5. Inspect All the DEF Lines for Leaks
A. Turn the keyswitch to the ON position. Do not start the engine.
B. Use the electronic service tool to perform the "DEF Dosing System Verification Test" to pressurize the system. Refer to Troubleshooting, "Service Tool Features" for more information.
C. Visually inspect all DEF lines from the DEF tank to the DEF injector. Look for pinched, damaged, or disconnected lines.
D. Inspect the lines for leakage.
E. Turn the keyswitch to the OFF position.
Leaks
Result: The lines are leaking, damaged, pinched, or disconnected.
Repair: Make the necessary repairs.
Result: The lines are not leaking, damaged, pinched, or disconnected.
Proceed to Test Step 6.
6. Exhaust System
A. Inspect the exhaust system for leaks and/or restrictions. Refer to Systems Operation, Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".
B. Check the exhaust system for leaks or damage.
C. Check all exhaust connections from the turbo outlet to the SCR outlet (tailpipe outlet).
D. Check for damage to the exhaust system insulation.
Exhaust leaks
Result: Exhaust leaks are found.
Repair: Repair or replace the component that is causing an exhaust leak.
Result: The exhaust system is restricted with white deposits.
Repair: Refer to Troubleshooting, "Exhaust System Contains DEF Deposits".
Result: The exhaust system is OK.
Proceed to Test Step 7.
7. Perform the "DEF Dosing System Accuracy Test"
A. Perform the "DEF Dosing System Accuracy Test". Refer to Systems Operation, Testing and Adjusting, "Aftertreatment SCR System Dosing Test" for the correct procedure.
DEF dosing
Result: The quantity collected is not within the acceptable range.
Repair: Replace the DEF injector. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install".
Result: The quantity collected is within the desired range.
Proceed to Test Step 8.
8. Check the DEF Pressure Line
A. Turn the keyswitch to the OFF position for 2 minutes.
B. Remove the DEF pressure line between the DEF pump and the DEF injector.
C. Check for ice, urea deposits, or debris in the DEF pressure line.
Restrictions, obstructions, or leaks
Result: There are restrictions in the DEF pressure line.
Remove the restrictions or replace the DEF pressure line.
Result: There are no restrictions or leaks in the lines.
Proceed to Test Step 9.
9. Check the Engine Breather System
A. Ensure that the crankcase breather filter has been replaced according to the maintenance interval schedule. Refer to Operation and Maintenance Manual, "Engine Crankcase Breather Element - Replace".
B. Check for correct operation of the crankcase pressure relief valve. Refer to Troubleshooting, "Crankcase Breather Ejects Oil".
Breather System
Result: Fault found in the engine breather system.
Repair: Make any necessary repairs.
Result: The engine breather system is OK.
Contact the Dealer Solutions Network (DSN).