Cummins MerCruiser QSD 2.0 Diesel Engines Service Repair Ma

Page i Models Covered Sterndrive Models Covered Serial Number QSD 2.0 Sterndrive 88201000 and Above Inboard Models Covered Serial Number QSD 2.0 Inboard 88200000 and Above Notice To Users Of This Manual Throughout this publication, dangers, warnings, cautions, and notices, (accompanied by the International HAZARD Symbol ! ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006 for product safety information in product manuals, instructions, and other collateral materials. OBSERVE THEM CAREFULLY! These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures. ! DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. ! CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. This manual has been written and published by the Service Department of Cummins MerCruiser Diesel to aid our dealers’ mechanics and company service personnel when servicing the products described herein. We reserve the right to make changes to this manual without prior notification. © 2007, Mercury Marine

Page ii Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation. It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of Cummins MerCruiser Diesel Power Products, including the use of mechanics’ common hand tools and the special Cummins MerCruiser Diesel or recommended tools from other suppliers. We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. Refer to dealer service bulletins, operation maintenance and warranty manuals and installation manuals for other pertinent information concerning the products described in this manual. Work Precautions It should be kept in mind, while working on the product, that the electrical systems are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches the original. Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to ground as soon as possible. Replacement Parts Use of parts other than the recommended service replacement parts, will void the warranty on those parts that are damaged as a result.

Page iii ! WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components. Cleanliness And Care Of Product A Cummins MerCruiser Diesel Power Product is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of a mm/ in. When any product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

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Page v Manual Outline 1 - Important Information A - General Information B - Maintenance C - Troubleshooting 2 - Removal And Installation A - Sterndrive Models B - Inboard Models 3 - Engine Mechanical A - QSD 2.0 Engines 4 - Electrical System A - Starting System B - Charging System C - Instrumentation D - Wiring Diagrams 5 - Fuel System A - Component Description B - Fuel Filter Assembly C - Common Rail and Fuel Lines D - Fuel Injectors E - High Pressure Fuel Pump F - ECS Diagnostics G - ECS Repair 6 - Cooling System A - Closed-Cooling System 7 - Intake and Exhaust System A - Intake Manifold and Aftercooler Assembly B - Exhaust Manifold and Elbow C - Turbocharger 8 - Drive System A - Technodrive Transmissions B - Propeller Shaft Models 9 - Power-Assisted Steering System A - Power-Assisted Steering Pump and Related Components Important Information 1 Removal And Installation 2 Engine Mechanical 3 Electrical System 4 Fuel System 5 Cooling System 6 Intake and Exhaust System 7 Drive System 8 Power-Assisted Steering System 9

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General Information 90-866942 JANUARY 2008 Page 1A-1 1 A Important Information Section 1A - General Information Table of Contents Introduction......................................................1A-2 How To Use This Manual.................................1A-2 Engine Serial Number and Decal Locations .........................................................................1A-2 Identification..............................................1A-2 Serial Number Decal.................................1A-2 Engine Data Plate Location......................1A-3 Engine Data Plate.....................................1A-3 Emissions Information..............................1A-4 Operation—Duty Cycle....................................1A-4 Duty Cycle Rating.....................................1A-4 High Output Rating...................................1A-4 Engine Break‑In...............................................1A-5 20‑Hour Break‑In Period...........................1A-5 After the 20‑Hour Break‑In Period............1A-5

General Information Page 1A-2 90-866942 JANUARY 2008 Introduction This comprehensive overhaul and repair manual is designed as a service guide for the MerCruiser and Cummins MerCruiser Diesel models listed earlier. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment, to enable dealers and service mechanics to repair these products. Before attempting repairs, read through the procedures to understand the methods and tools used and the cautions and warnings required for safety. How To Use This Manual This manual is divided into sections, which represent major components and systems. Some sections are further divided into parts that more fully describe the component. Refer to the Service Manual Outline following Models Covered in this manual for section titles. Engine Serial Number and Decal Locations Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to you Cummins MerCruiser Diesel power package. When contacting Cummins MerCruiser Diesel (CMD) about service, always specify model and serial numbers. Serial Number Decal The serial number decal is located on the engine and indicates the engine's CMD serial number, transom serial number, drive serial number, and the fill cap color codes for engine fluids. 25986 Serial number decal

General Information 90-866942 JANUARY 2008 Page 1A-3 Engine Data Plate Location The engine data plate is on the front of the engine. The data plate lists important identification and emissions certification information. 28074 Location of QSD 2.0 engine data plate Engine Data Plate A tamper‑resistant engine data plate is affixed to the engine at the time of manufacture by Cummins MerCruiser Diesel. It contains important exhaust gas emissions information. Please note that the engine data plate will not affect the fit, function, or performance of the engine and neither boatbuilders nor dealers may remove the engine data plate or the engine component it is affixed to before sale. If modifications are necessary or the engine data plate is damaged contact Cummins MerCruiser Diesel about the availability of a replacement. The owner or operator is not to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission levels to exceed their predetermined factory specifications. 25401 c b a d e f g h i j k Typical engine data plate a - Engine serial number b - Cummins MerCruiser Diesel model information c - Emissions certification information d - Fuel rate e - Rated operation engine speed f - Governed engine speed g - Minimum idle speed h - Engine power rating i - Engine weight j - Emissions data k - Manufacturer model number, IMO type, liters per cylinder

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Cummins MerCruiser QSD 2.0 Diesel Engines Service Repair Ma

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