Cummins MerCruiser OSD 4.2 270 HP Factory Service & Work Shop Manual

Page i Models Covered Sterndrive Models Covered Serial Number QSD 2.8 Sterndrive 170 HP 88300400 ‑ 88304999 QSD 2.8 Sterndrive 200 HP 88305400 ‑ 88309999 QSD 2.8 Sterndrive 230 HP 88310400 ‑ 88314999 QSD 4.2 Sterndrive 270 HP 88401000 ‑ 88404999 QSD 4.2 Sterndrive 320 HP 88406000 ‑ 88415999 QSD 4.2 Sterndrive 350 HP 88417000 ‑ 88419999 Inboard Models Covered Serial Number QSD 2.8 Inboard 170 HP 88300000 ‑ 88300399 QSD 2.8 Inboard 200 HP 88305000 ‑ 88305399 QSD 2.8 Inboard 230 HP 88310000 ‑ 88310399 QSD 4.2 Inboard 270 HP 88400000 ‑ 88400999 QSD 4.2 Inboard 320 HP 88405000 ‑ 88405999 QSD 4.2 Inboard 350 HP 88416000 ‑ 88416999 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.

Page ii 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 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.

Page iii 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. ! 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 2.8 and 4.2 Diesel 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 - Aftercooler B - Elbows, Risers, Intake and Exhaust Manifold C - Turbocharger 8 - Drive System A - ZF Marine Transmissions B - Technodrive Transmissions C - 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 CMD-4082040 / 90-866941 NOVEMBER 2007 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 Engine Dataplate......................................1A-2 Serial Number Decal.................................1A-3 Operation—Duty Cycle....................................1A-3 Duty Cycle Rating.....................................1A-3 High Output Rating...................................1A-3 Engine Break‑In...............................................1A-3 20‑Hour Break‑In Period...........................1A-3 After the 20‑Hour Break‑In Period............1A-4

General Information Page 1A-2 CMD-4082040 / 90-866941 NOVEMBER 2007 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 Engine Dataplate 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 dataplate 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

General Information CMD-4082040 / 90-866941 NOVEMBER 2007 Page 1A-3 Serial Number Decal The serial number decal is located on top of the engine on the aft end of the intercooler. 32623 Serial number and maintenance color code decal Operation—Duty Cycle Duty Cycle Rating IMPORTANT: Damage caused by improper application or failure to operate the power package within the specified operating parameters will not be covered by the Cummins MerCruiser Diesel Limited Warranty. The boat manufacturer or the installing dealer is responsible for ensuring that the power package is applied in accordance with recommendations indicated in the appropriate Cummins MerCruiser Diesel applications manual. In all cases, the power package must be equipped with a gear ratio and propeller that allows the engine to operate at wide open throttle (WOT) at the rated engine RPM. The power package must also be applied Use of Cummins MerCruiser Diesel engines in applications other than those indicated by the following information or the appropriate application manual is not approved. High Output Rating High Output Rating applies to variable load applications where full power is limited to one (1) hour out of every eight (8) hours of operation. Reduced load operation occurs when engine RPM is at least 200 RPM below the engine's maximum rated RPM for applications rated at or below 3000 RPM and at least 400 RPM below the engine's maximum rated RPM for applications rated above 3000 RPM. This rating is for pleasure (non‑revenue generating) applications that operate 500 hours or less per year. Engine Break‑In 20‑Hour Break‑In Period IMPORTANT: The first 20 hours of operation are a break‑in period for the engine. Correct break‑in is essential to obtain minimum oil consumption and maximum engine performance. During this break‑in period, observe the following rules: • Do not operate below 1500 RPM for extended periods of time during the first 10 hours. Advance the throttle above 1500 RPM as soon as conditions permit safe operation. • Do not consistently operate at one speed for extended periods. • Do not exceed 3/4 throttle during the first 10 hours, during the next 10 hours do not operate at full throttle for more than five minutes at a time. • Do not accelerate at full‑throttle from idle speed. • Do not operate at full throttle until the engine reaches normal operating temperature. • High oil consumption is normal during the break‑in period. Frequently check the engine oil level.

Cummins MerCruiser OSD 4.2 270 HP Factory Service & Work Shop Manual

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