NUMBER 22
Printed in U.S.A. 90-860074--1 FEBRUARY 2002 ï›™ 2002, Mercury Marine
D2.8L D-Tronic Serial Number 0K000001 and Above . . . . . . . .
D4.2L D-Tronic Serial Number 0K000001 and Above . . . . . . . .
MARINE ENGINES
IN-LINE DIESEL
SERVICE
MANUAL
90-860074--1 FEBRUARY 2002 Page i
Notice
Throughout this publication, Dangers, Warnings and Cautions (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. 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
Immediate hazards which will result in severe personal injury or death.
WARNING
Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Page ii 90-860074--1 FEBRUARY 2002
Notice to Users of This Manual
This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
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 Mercury MerCruiser product, including the use of mechanics’ common hand
tools and the special Mercury Marine 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.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins, operation maintenance and warranty manuals and
installation manuals for other pertinent information concerning the products described in
this manual.
It should be kept in mind, while working on the product, that the electrical system is 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 re-use, care should be
taken to select a replacement that matches the original.
90-860074--1 FEBRUARY 2002 Page iii
Engine Mechanical Components
Many of the engine mechanical components are designed for marine applications. Unlike
automotive engines, marine engines are subjected to extended periods of heavy load
and wide open throttle operation and, therefore, require heavy-duty components. Special
marine engine parts have design and manufacturing specifications that are required to
provide long life and dependable performance. Marine engine parts also must be able to
resist the corrosive action of salt or brackish water that will rust or corrode standard
automotive parts within a short period of time.
Failure to use recommended Mercury / Quicksilver service replacement parts can result in
poor engine performance and/or durability, rapid corrosion of parts subjected to salt
water and possibly complete failure of the engine.
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.
WARNING
Electrical and fuel system components on Mercury MerCruiser Engines and Stern
Drives are designed and manufactured to comply with U.S. Coast Guard Rules
and Regulations to minimize risks of fire or explosion.
Use of replacement electrical or fuel system components, which do not comply to
these rules and regulations, could result in a fire or explosion hazard and should
be avoided.
When servicing the electrical and fuel systems, it is extremely important that all
components are properly installed and tightened. If not, any electrical component
opening would permit sparks to ignite fuel vapors from fuel system leaks, if they
existed.
Page iv 90-860074--1 FEBRUARY 2002
Models Covered in This Manual
Sterndrive (MCM) Serial Number
D2.8L D-Tronic 0K000001 and Above
D4.2L D-Tronic 0K000001 and Above
Inboard (MIE) Serial Number
D2.8L D-Tronic 0K000001 and Above
D4.2L D-Tronic 0K000001 and Above
1
2
3
4
5
6
7
8
Important Information
Removal And Installation
Engine Mechanical
Electrical System
Fuel System
Cooling System
Intake And Exhaust System
Drive System
9
Power Steering System
90-860074--1 FEBRUARY 2002 Page v
Service Manual Outline
Section 1 - Important Information
A - General Information
B - Maintenance
C - Troubleshooting
Section 2 - Removal and Installation
A - Sterndrive (MCM) Models
B - Inboard (MIE) Models
Section 3 - Engine Mechanical
A - D2.8L D-Tronic And D4.2L D-Tronic Engines
Section 4 - Electrical System
A - Starting System
B - Charging System
C - Glow Plug System (If Equipped)
D - Instrumentation
E - Wiring Diagrams
Section 5 - Fuel System
A - Description
B - Fuel Delivery Pump and Fuel Filter
C - Injectors
D - Injection Pump
E - EDI Diagnosis
Section 6 - Cooling System
A - Seawater Cooling System
B - Closed Cooling System
Section 7 - Intake And Exhaust System
A - Intercooler
B - Intake / Exhaust Manifold, Elbows and Risers
C - Turbocharger
Section 8 - Drive System
A - ZF / Hurth Transmissions
B - Propeller Shaft Models
Section 9 - Power Steering System
A - Pump And Related Components
Page vi 90-860074--1 FEBRUARY 2002
IMPORTANT INFORMATION
Section 1A - General Information
Introduction 1A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use This Manual 1A-3 . . . . . . . . . . . . . . .
Page Numbering 1A-3 . . . . . . . . . . . . . . . . . . .
Engine Serial Number / Decal Locations 1A-4 .
Operation / Duty Cycle 1A-5 . . . . . . . . . . . . . . . . .
Engine Break-In 1A-6 . . . . . . . . . . . . . . . . . . . . . . .
Initial Break-In Procedure 1A-6 . . . . . . . . . . . .
Mercury/Quicksilver Lubricants, Sealants
And Adhesives 1A-7 . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION
Section 1B - Maintenance
Torque Specifications 1B-3 . . . . . . . . . . . . . . . . . .
Special Tools 1B-3 . . . . . . . . . . . . . . . . . . . . . . . . .
Tools 1B-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 1B-3 . . . . . . .
Engine Specifications 1B-4 . . . . . . . . . . . . . . . . . .
Sterndrive (MCM) Engines 1B-4 . . . . . . . . . . .
Inboard (MIE) Engines 1B-5 . . . . . . . . . . . . . .
Capacities 1B-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engines 1B-6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drives 1B-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmissions 1B-6 . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedules 1B-7 . . . . . . . . . . . . . . . .
Maintenance Intervals 1B-7 . . . . . . . . . . . . . . .
Sterndrive (MCM) Engines 1B-8 . . . . . . . . . . .
Inboard (MIE) Engines 1B-11 . . . . . . . . . . . . .
Engine External Views 1B-13 . . . . . . . . . . . . . . . .
Starboard Side View 1B-13 . . . . . . . . . . . . . . .
Front View 1B-14 . . . . . . . . . . . . . . . . . . . . . . . .
Port Side View 1B-15 . . . . . . . . . . . . . . . . . . . .
Rear View 1B-16 . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil 1B-17 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level 1B-17 . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Oil Filter 1B-19 . . .
Fuel 1B-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions 1B-21 . . . . . . . . . . . . . . . . . . . . . . .
General Information 1B-22 . . . . . . . . . . . . . . . .
Diesel Fuel In Cold Weather 1B-22 . . . . . . . .
Fuel Filter 1B-23 . . . . . . . . . . . . . . . . . . . . . . . .
Closed Cooling System 1B-28 . . . . . . . . . . . . . . .
Coolant Requirement 1B-28 . . . . . . . . . . . . . .
Checking Level 1B-29 . . . . . . . . . . . . . . . . . . . .
Draining 1B-30 . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 1B-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sacrificial Anodes 1B-33 . . . . . . . . . . . . . . . . . . . .
Removal 1B-33 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 1B-33 . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 1B-34 . . . . . . . . . . . . . . . . . . . . . .
Reassembly 1B-34 . . . . . . . . . . . . . . . . . . . . . .
Installation 1B-34 . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Seawater System 1B-35 . . . . . . . . . . . .
SternDrive (MCM) Models 1B-35 . . . . . . . . . .
Inboard (MIE) Models 1B-36 . . . . . . . . . . . . . .
Inspect Water Pickups 1B-38 . . . . . . . . . . . . . . . .
SternDrive Gear Housing 1B-38 . . . . . . . . . . .
Inboard Though the Hull Pickup 1B-38 . . . . .
Lubrication 1B-39 . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable 1B-39 . . . . . . . . . . . . . . . . . . . . .
Shift Cable 1B-39 . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coupler / U-joint Shaft Splines 1B-40
U-joints 1B-41 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Extension Models 1B-42 . . . . . . .
Sterndrive Unit and Transom
Assembly 1B-42 . . . . . . . . . . . . . . . . . . . . . . . .
Continuity Circuit 1B-43 . . . . . . . . . . . . . . . . . . . . .
Continuity Circuit (continued) 1B-44 . . . . . . . . . .
MerCathode 1B-45 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounts 1B-45 . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 1B-45 . . . . . . . . . . . . . . . . . . . . .
Power Steering 1B-46 . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 1B-46 . . . . . . . . . . . . . . .
Filling and Bleeding 1B-48 . . . . . . . . . . . . . . . .
Transmission 1B-49 . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 1B-49 . . . . . . . . . . . . . . .
Power Trim 1B-50 . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 1B-50 . . . . . . . . . . . . . . .
Filling 1B-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Lube Monitor 1B-52 . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 1B-52 . . . . . . . . . . . . . . .
Filling 1B-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Strainer 1B-53 . . . . . . . . . . . . . . . . . . . .
Air Filter 1B-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1B-54 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 1B-54 . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 1B-55 . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1B-55 . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belts 1B-56 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 1B-56 . . . . . . . . . . . . . . . .
Inspection 1B-57 . . . . . . . . . . . . . . . . . . . . . . . .
Engine Water Circulating Pump Belt 1B-57 . .
Alternator Belt 1B-58 . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump Belt 1B-60 . . . . . . . . . .
Vacuum Pump Belt 1B-62 . . . . . . . . . . . . . . . .
Battery 1B-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1B-64 . . . . . . . . . . . . . . . . . . . . .
Corrosion and Corrosion Protection 1B-64 . . . . .
Saltwater Operation 1B-64 . . . . . . . . . . . . . . . . . .
Freezing Temperature and Cold Weather
Operation 1B-65 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage 1B-66 . . . . .
Power Package Layup 1B-66 . . . . . . . . . . . . .
Draining 1B-67 . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommissioning 1B-73 . . . . . . . . . . . . . . . . . . . .
90-860074--1 FEBRUARY 2002 Page vii
IMPORTANT INFORMATION
SECTION 1C - Troubleshooting
Precautions 1C-3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Poor Boat Performance and/or Poor
Maneuverability 1C-5 . . . . . . . . . . . . . . . . . . . . . .
Improper Full Throttle Engine RPM 1C-6 . . . . . .
RPM Too High 1C-6 . . . . . . . . . . . . . . . . . . . . .
RPM Too Low 1C-6 . . . . . . . . . . . . . . . . . . . . . .
Engine Cranks Over But Will Not Start Or
Starts Hard 1C-7 . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 1C-7 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 1C-7 . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous 1C-9 . . . . . . . . . . . . . . . . . . . . . .
Engine Will Not Crank Over or Starter
Inoperative 1C-9 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plugs Inoperative 1C-10 . . . . . . . . . . . . . . .
Charging System Inoperative 1C-11 . . . . . . . . . .
Noisy Alternator 1C-11 . . . . . . . . . . . . . . . . . . . . . .
Engine Operates Poorly at Idle 1C-12 . . . . . . . . .
Engine Operates Poorly At High Rpm 1C-13 . . .
Poor Fuel Economy 1C-14 . . . . . . . . . . . . . . . . . .
Engine Smoking 1C-15 . . . . . . . . . . . . . . . . . . . . .
Black Smoke 1C-15 . . . . . . . . . . . . . . . . . . . . . .
Blue Smoke 1C-16 . . . . . . . . . . . . . . . . . . . . . . .
White Smoke 1C-16 . . . . . . . . . . . . . . . . . . . . .
Exhaust Gas Temperature 1C-17 . . . . . . . . . . . . .
High 1C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low 1C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger 1C-18 . . . . . . . . . . . . . . . . . . . . . . . .
Engine Noise 1C-19 . . . . . . . . . . . . . . . . . . . . . . . .
Valve Cover Area 1C-20 . . . . . . . . . . . . . . . . . .
Cylinder Area 1C-20 . . . . . . . . . . . . . . . . . . . . .
Camshaft Area 1C-21 . . . . . . . . . . . . . . . . . . . .
Crankshaft Area 1C-22 . . . . . . . . . . . . . . . . . . .
Miscellaneous 1C-23 . . . . . . . . . . . . . . . . . . . . .
Oil Pressure 1C-23 . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure 1C-25 . . . . . . . . . . . . . . . . . .
High Oil Pressure 1C-25 . . . . . . . . . . . . . . . . . .
Excessive Oil Consumption 1C-26 . . . . . . . . .
Water / Coolant in Engine 1C-27 . . . . . . . . . . . . .
Important Information 1C-27 . . . . . . . . . . . . . .
Water / Coolant In Crankcase Oil 1C-27 . . . .
Water / Coolant On Top Pistons 1C-28 . . . . .
Engine Overheats 1C-29 . . . . . . . . . . . . . . . . . . . .
Cooling System 1C-29 . . . . . . . . . . . . . . . . . . .
Mechanical 1C-30 . . . . . . . . . . . . . . . . . . . . . . .
Power Steering 1C-31 . . . . . . . . . . . . . . . . . . . . . .
Poor, Erratic or No Assist 1C-31 . . . . . . . . . . .
Noisy Pump 1C-32 . . . . . . . . . . . . . . . . . . . . . . .
Fluid Leaks 1C-32 . . . . . . . . . . . . . . . . . . . . . . .
Insufficient Water Flow From Belt Driven
Seawater Pump 1C-33 . . . . . . . . . . . . . . . . . . . . .
ZF / Hurth Hydraulic Transmission 1C-34 . . . . . .
REMOVAL AND INSTALLATION
Section 2A - Sterndrive (MCM) Models
Torque Specifications 2A-3 . . . . . . . . . . . . . . . . . .
Special Tools 2A-3 . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 2A-4 . . . . . . .
Removal 2A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 2A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Installation / Alignment 2A-7 . . . . . . .
Engine Connections 2A-15 . . . . . . . . . . . . . . .
Throttle Cable Installation and
Adjustment 2A-21 . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation and
Adjustment 2A-23 . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Shift Problems 2A-28 . . . . . .
Battery Cables 2A-30 . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
Section 2B - Inboard (MIE) Models
Torque Specifications 2B-3 . . . . . . . . . . . . . . . . . .
Tools/Lubricants/Adhesives 2B-3 . . . . . . . . . . . . .
Removal 2B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Removal 2B-4 . . . . . . . . . . . . . . . . . . . .
Installation 2B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Installation and Initial
Alignment 2B-7 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Final Alignment 2B-11 . . . . . . . . . . . . .
Engine Connections 2B-18 . . . . . . . . . . . . . . .
Throttle Cable Installation and
Adjustment 2B-21 . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation And
Adjustment 2B-21 . . . . . . . . . . . . . . . . . . . . . . .
Battery Cables 2B-21 . . . . . . . . . . . . . . . . . . . .
Page viii 90-860074--1 FEBRUARY 2002
ENGINE
Section 3A - Engine Mechanical
Identification 3A-3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 3A-4 . . . . . . . . . . . . . . . . . .
Tools 3A-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 3A-6 . . . . . . . . . . . . . . . . . . . . . . .
Special Tools (continued) 3A-7 . . . . . . . . . . . .
Snap-On Tools 3A-8 . . . . . . . . . . . . . . . . . . . . .
Kent-Moore Tools 3A-8 . . . . . . . . . . . . . . . . . . .
Lubricants/Sealants/Adhesives 3A-9 . . . . . . . . . .
Engine Specifications 3A-10 . . . . . . . . . . . . . . . . .
Piston Rings 3A-10 . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner Diameter 3A-10 . . . . . . . . . . . .
Cylinder Liner Protrusion 3A-11 . . . . . . . . . . .
Head Gaskets 3A-11 . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 3A-11 . . . . . . . . . . . . . . . . . . . . .
Oil Pump 3A-12 . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 3A-12 . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lifter 3A-12 . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm 3A-13 . . . . . . . . . . . . . . . . . . . . . . .
Valve Adjustment 3A-13 . . . . . . . . . . . . . . . . . .
Valve 3A-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat 3A-13 . . . . . . . . . . . . . . . . . . . . . . . .
Valve Guide 3A-14 . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring 3A-14 . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 3A-15 . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft (continued) 3A-16 . . . . . . . . . . . . .
Connecting Rods 3A-17 . . . . . . . . . . . . . . . . . .
Connecting Rod Crank Pin Bore 3A-17 . . . . .
Connecting Rod Bushings 3A-17 . . . . . . . . . .
Pistons 3A-17 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel 3A-17 . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions 3A-18 . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 3A-19 . . . . . . . . . . . . . . . . . .
Engine Rotation 3A-19 . . . . . . . . . . . . . . . . . . .
Engine Firing Order 3A-19 . . . . . . . . . . . . . . . .
Late Model Cylinder Head Gasket -
Torque Sequence and Specifications 3A-20
Early Model Cylinder Head Gasket -
Torque Sequence and Specifications 3A-25
Lubrication System - All Models 3A-28 . . . . .
Examples of Bearing Failures 3A-29 . . . . . . .
Compression Testing Procedure 3A-30 . . . . .
Engine Cover 3A-31 . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3A-31 . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-31 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-31 . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-31 . . . . . . . . . . . . . . . . . . . . . . . .
Valve Covers 3A-32 . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3A-32 . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-33 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-33 . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-34 . . . . . . . . . . . . . . . . . . . . . . . .
Water Manifold 3A-37 . . . . . . . . . . . . . . . . . . . . . . .
Exploded Views 3A-37 . . . . . . . . . . . . . . . . . . .
Removal 3A-38 . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-38 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-38 . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-39 . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Heads 3A-40 . . . . . . . . . . . . . . . . . . . . . .
Exploded Views 3A-40 . . . . . . . . . . . . . . . . . . .
Removal 3A-42 . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3A-44 . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-44 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-45 . . . . . . . . . . . . . . . . . . . . . . . .
Repair 3A-50 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Plugs 3A-50 . . . . . . . . . . . . . . . . . .
Assembly 3A-52 . . . . . . . . . . . . . . . . . . . . . . . . .
Installation -
Using Early Model Gaskets 3A-55 . . . . . . . . .
Installation -
Using Late Model Gaskets 3A-62 . . . . . . . . .
Rocker Arm 3A-71 . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3A-71 . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-71 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-71 . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 3A-72 . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-73 . . . . . . . . . . . . . . . . . . . . . . . .
Timing Gear Cover 3A-77 . . . . . . . . . . . . . . . . . . .
Exploded View 3A-77 . . . . . . . . . . . . . . . . . . . .
Removal 3A-78 . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-78 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-78 . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-79 . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 3A-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3A-81 . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-81 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-82 . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 3A-83 . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-83 . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Relief Valve 3A-84 . . . . . . . . . . . . . .
Removal 3A-84 . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3A-85 . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-85 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-86 . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 3A-86 . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-87 . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Oil Pick-Up Tube Assembly 3A-88 .
Removal 3A-88 . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-89 . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-89 . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-89 . . . . . . . . . . . . . . . . . . . . . . . .
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Mercury Mercruiser Marine Engines #22 IN-LINE Diesel D-Tronic 2.8L & 4.2L Service Repair Manual
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Description
This service repair manual is the ultimate guide for the Mercury Mercruiser Marine Engines IN-LINE Diesel D-Tronic 2.8L & 4.2L. It encompasses comprehensive service and repair procedures, including assembling, disassembling, and wiring diagrams.
Models Covered in This Manual:
- Sterndrive (MCM) Serial Number
- D2.8L D-Tronic 0K000001 and Above
- D4.2L D-Tronic 0K000001 and Above
- Inboard (MIE) Serial Number
- D2.8L D-Tronic 0K000001 and Above
- D4.2L D-Tronic 0K000001 and Above
This manual covers the following:
- Section 1 - Important Information
- A - General Information
- B - Maintenance
- C - Troubleshooting
- Section 2 - Removal and Installation
- A - Sterndrive (MCM) Models
- B - Inboard (MIE) Models
- Section 3 - Engine Mechanical
- A - D2.8L D-Tronic And D4.2L D-Tronic Engines
- Section 4 - Electrical System
- A - Starting System
- B - Charging System
- C - Glow Plug System (If Equipped)
- D - Instrumentation
- E - Wiring Diagrams
- Section 5 - Fuel System
- A - Description
- B - Fuel Delivery Pump and Fuel Filter
- C - Injectors
- D - Injection Pump
- E - EDI Diagnosis
- Section 6 - Cooling System
- A - Seawater Cooling System
- B - Closed Cooling System
- Section 7 - Intake And Exhaust System
- A - Intercooler
- B - Intake / Exhaust Manifold, Elbows and Risers
- C - Turbocharger
- Section 8 - Drive System
- A - ZF / Hurth Transmissions
- B - Propeller Shaft Models
- Section 9 - Power Steering System
- A - Pump And Related Components
This manual is available in high-quality format, with all pages printable. It is instantly accessible without any shipping costs or the need to wait for a CD-ROM.
File Format: PDF
Language: English
Compatible: All Versions of Windows & Mac
Requirements: Adobe Reader
