421087 Volvo.Penta Gear

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 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.
Refer to the Original Equipment Manufacture (OEM) for the location of the DEF pump.
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.
Illustration 1 g03727625
Ensure that the area around DEF fluid pump (1) is clean and free dirt and debris. If necessary, clean the area around the DEF injector. Clean the area around the DEF fluid pump with Tooling (B) and a suitable tool.
Disconnect harness assembly (3) from Original Equipment Manufacture (OEM) harness assembly (4).
Make temporary marks on DEF lines for installation purposes. Remove the DEF line from connection (5) and the DEF line from connection (6) from DEF fluid pump (1). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Use Tooling (A) to plug the DEF lines. Tooling (A) to cap connection (5) and connection (6).
Remove bolts (7) from DEF pump (1). Support the weight of the DEF pump as the bolts are removed. Remove the DEF pump.
If necessary, remove DEF filter (2) (not shown). Refer to Operation and Maintenance Manual, "Diesel Exhaust Fluid Filter - Clean/Replace" for the correct procedure. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A - Capping Kit 1
B - De-ionized Water 1
Ensure that the DEF pump is free from wear or damage. Replace the DEF pump as an assembly if any component of the DEF pump is not free from wear or damage.
Illustration 2 g03727625
If necessary, install a new DEF filter (2) (not shown). Refer to Operation and Maintenance Manual, "Diesel Exhaust Fluid Filter - Clean/Replace" for the correct procedure.
Install DEF pump (1) and install bolts (7) to diesel exhaust fluid pump. Support the weight of the DEF pump as the bolts are installed. Tighten the bolts to a torque of 16 N m (142 lb in).
Remove plugs from the DEF lines. Remove the caps from connection (5) and connection (6).
Install the DEF line to connection (5) and the DEF line to connection (6). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. Note: Ensure that the DEF lines are connected into the correct positions.
Connect harness assembly (3) to OEM harness assembly (4).
Illustration 3 g03741895
Typical example
After the installation of the DEF lines on to the DEF pump. Follow Step 7.a through Step 7.k in order to flush DEF supply line (8) at DEF injector (9).
Ensure that the area around DEF injector (9) is clean and free dirt and debris. If necessary, clean the area around the DEF injector. Clean the area around the DEF injector with Tooling (B) and a suitable tool.
Disconnect DEF line (8) from DEF injector (9).
Use Tooling (A) to cap DEF injector (9) and DEF line (8).
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 the DEF supply line. 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 the DEF supply line 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 the DEF supply line.
Remove the caps from DEF injector (9). Connect DEF supply line (8) to the DEF injector.
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 the battery disconnect switch to the OFF position. Disconnect the electronic service tool.
Turn the battery disconnect switch to the ON position.