Mercury 2.8 Diesel Operation & Maintenance Manual Download

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www.mercurymarine.com.au

41-71 Bessemer Drive

Dandenong South, Victoria 3175 Australia

www.mercurymarine.com

P.O. Box 1939

Fond du Lac, WI 54936-1939 USA

www.brunswick-marine.com

Parc Industriel de Petit-Rechain

B-4800 Verviers, Belgium

Printed in U.S.A.

90-8M0113987 NOVEMBER 2015

2.8 and 4.2 Diesel

Sterndrive Models

OPERATION &

MAINTENANCE

MANUAL

Summary of Contents for 2.8 Diesel

Page 1: ...mercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mercury Marine All rights reserved Printed in U S A 90 8...

Page 2: ......

Page 3: ...these special instructions while performing the service plus common sense operation are major accident prevention measures WARNING Indicates a hazardous situation which if not avoided could result in...

Page 4: ...erCruiser Mercury Mercury with Waves Logo Mercury Marine Mercury Precision Parts Mercury Propellers Mercury Racing MotorGuide OptiMax Quicksilver SeaCore Skyhook SmartCraft Sport Jet Verado VesselView...

Page 5: ...Launching 20 Duty Cycle Rating Requirements 20 High Output Rating 20 Operation Chart 21 Freezing Temperature and Cold Weather Operation 21 Drain Plug and Bilge Pump 22 Trailering the Boat 22 Starting...

Page 6: ...ith the Boat in the Water 66 Engine Seawater Pump Inspection 67 Replacing the Engine Coolant in the Closed Cooling System 67 Draining the Closed Cooling System 67 Filling the Closed Cooling System 68...

Page 7: ...or Jerky 106 Power Trim does not Operate Electric Motor Operates but Sterndrive does not Move 106 Power Trim Does Not Operate Electric Motor Does Not Operate 106 Section 7 Customer Assistance Informa...

Page 8: ...Page iv 90 8M0113987 eng DECEMBER 2015...

Page 9: ...6 Instrumentation 6 VesselView 6 SmartCraft Speedometer Tachometer and Digital Gauges 7 System Link Digital Gauges 7 Emergency Stop Switch 8 Remote Controls 8 Panel Mount Features 9 Console Mount Feat...

Page 10: ...rmance of the engine and neither boatbuilders nor dealers may remove the engine data label or the engine component it is affixed to before sale If modifications are necessary or the engine data label...

Page 11: ...ground plate on the port side of the sterndrive 33533 Bravo sterndrive information on ground plate The serial number is also stamped on the driveshaft housing behind the back cover This is used as a...

Page 12: ...case of any horn sounding the user should refer to the helm displays to understand the specific situation For the operator to view the fault code of the malfunction indicated and any recommended acti...

Page 13: ...ith the key switch There is one start stop switch for each engine Each button on a multi engine start stop switch functions independently The key switch must be in the run position to start a stopped...

Page 14: ...al or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward...

Page 15: ...Coolant temperature Oil pressure Battery voltage Fuel consumption Engine operating hours SmartCraft tachometer and speedometer a Tachometer b Speedometer c LCD display The SmartCraft instrument packa...

Page 16: ...arting and operating procedures should they need to operate the engine in an emergency Accidental or unintended activation of the switch during normal operation is also possible which can cause any or...

Page 17: ...Switch for information on the use of this switch Control handle The shift and throttle are controlled by the movement of the control handle Push the control handle forward from neutral with a quick fi...

Page 18: ...ile underway to provide the ideal boat angle for varying load and water conditions Also the trailering feature allows the operator to raise and lower the sterndrive for trailering beaching launching l...

Page 19: ...sly or may have separate buttons for each sterndrive Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only Trim without Key CAUTION The T...

Page 20: ...to SIM Upper right f 5 A Power diagnostic connector Lower right Overload Protection Port Side Power Distribution Box If an electrical overload occurs a fuse will burn out blow or a circuit breaker wi...

Page 21: ...otection A vessel integration panel VIP is typically mounted in the engine compartment The VIP contains three circuit breakers that help protect system wiring a Helm circuit breaker 10 A b Gear circui...

Page 22: ...to provide engine protection If Engine Guardian has been activated reduce the engine speed The problem will need to be identified and corrected The system must be reset before the engine will operate...

Page 23: ...lamp loads or both Galled fasteners may appear to torque properly but still have incorrect clamp loads Apply lubricant 2 4 C with PTFE or an equivalent on the threads of stainless steel fasteners duri...

Page 24: ...Section 1 Getting to Know Your Power Package Notes Page 16 90 8M0113987 eng DECEMBER 2015...

Page 25: ...Shifting 24 Engine Shut Down Stopping 24 Starting the Engine After Stopped While in Gear 24 Protecting People in the Water 24 While You Are Cruising 24 While Boat Is Stationary 24 High Speed and High...

Page 26: ...passengers are boarding unloading or are near the back stern of the boat Shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal law requires that there be a U S...

Page 27: ...urther assistance from local law enforcement Carbon Monoxide Exposure Be Alert To Carbon Monoxide Poisoning Carbon monoxide CO is a deadly gas that is present in the exhaust fumes of all internal comb...

Page 28: ...tion Information Launching IMPORTANT Install the bilge drain plug before launching the boat Duty Cycle Rating Requirements IMPORTANT Damage caused by incorrect application or failure to operate the po...

Page 29: ...ited Warranty NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage Drain the seawater section of the cooling system immediately after operation or be...

Page 30: ...ngine crankcase is filled to the correct level with the specified engine oil Refer to Section 4 Specifications Engine Oil Ensure all electrical connections are secure Check all items listed in Section...

Page 31: ...to Section 4 Specifications Engine Specifications Stop the engine if the oil pressure is not within the range specified b Check the fuel system for leakage from the injection pump fuel pipes fuel fil...

Page 32: ...ad operation can damage the turbocharger bearings Idle the engine for several minutes before shutdown 2 Operate the engine at idle speed for several minutes to allow the turbocharger and engine to coo...

Page 33: ...e front of the boat between the two pontoons will position them to be run over Boats Having An Open Front Deck No one should ever be on the deck in front of the rail while the boat is in motion Keep a...

Page 34: ...ard even out of the boat Impact damage to the underwater drive components rudder or boat Keep in mind that one of the most important things you can do to help reduce injury or impact damage in these s...

Page 35: ...propeller Bent propeller blade Raised burrs or sharp edges on the propeller Ventilation Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in prop...

Page 36: ...s been completed IMPORTANT Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor If the engine does not start wait one minute to allow the starter mot...

Page 37: ...indicated in the Maintenance Schedule Refer to Specifications and Maintenance Use a propeller that allows the engine to operate at the rated engine RPM when at full throttle with a fully loaded boat R...

Page 38: ...Section 2 On the Water Notes Page 30 90 8M0113987 eng DECEMBER 2015...

Page 39: ...iesel Fuel in Cold Weather 32 Antifreeze Coolant 32 Engine Oil 33 Engine Specifications 34 Fluid Specifications 34 Engine 34 2 8 34 4 2 34 Bravo Sterndrive Fluid Specifications Diesel 34 Power Assiste...

Page 40: ...NOTE If your engine suddenly becomes noisy after a fill up you possibly received substandard fuel with a low cetane rating On engines that use high sulphur content diesel fuel this will greatly increa...

Page 41: ...out knowing that they are compatible Refer to the coolant manufacturer s instructions The acceptable antifreeze coolants is listed in the following table Refer to Section 5 Maintenance for respective...

Page 42: ...Specifications IMPORTANT All capacities are approximate fluid measures Engine IMPORTANT You may need to adjust oil levels depending on the installation angle and cooling systems heat exchanger and flu...

Page 43: ...ption Part Number Power Trim and Steering Fluid 92 858074K01 Approved Power Trim Fluids Description Part Number Power Trim and Steering Fluid 92 858074K01 SAE Engine Oil 10W 30 Obtain locally SAE Engi...

Page 44: ...Section 3 Specifications Notes Page 36 90 8M0113987 eng DECEMBER 2015...

Page 45: ...ushing the Seawater System Sterndrive Models 64 With the Boat out of the Water 64 With the Boat in the Water 66 Engine Seawater Pump Inspection 67 Replacing the Engine Coolant in the Closed Cooling Sy...

Page 46: ...e engine compartment may be an irritant cause difficulty breathing or may ignite resulting in a fire or explosion Always ventilate the engine compartment before servicing the power package IMPORTANT R...

Page 47: ...ner or operator while others should be performed by a Mercury Diesel authorized repair facility Before attempting maintenance or repair procedures not covered in this manual we recommended that you pu...

Page 48: ...s Lubricate the engine coupler lubricate the engine coupler every 50 hours if operated at idle for prolonged periods of time Check the continuity circuit for loose or damaged connections If the boat i...

Page 49: ...engine speed is reduced NOTICE With the engine running the crankshaft journals or rod journals may strike and break the dipstick resulting in damage to internal engine components Stop the engine comp...

Page 50: ...ing temperature 2 Stop the engine and allow some time for the oil to drain into the oil pan approximately five minutes 3 Remove the fitting from the end of crankcase oil drain hose 4 Install the crank...

Page 51: ...15 Turn the oil filter top piece until the sealing surface contacts the housing Torque the top piece using an appropriate socket a Top piece b Oil filter housing Description Nm lb in lb ft Oil filter...

Page 52: ...f more than 59 ml 2 fl oz of High Performance Gear Lube is required to fill the gear lube monitor a seal may be leaking Damage to the sterndrive may occur due to lack of lubrication Contact your Mercu...

Page 53: ...to Propellers 5 Bravo One Models a Lower the sterndrive to the full down in position b Remove the gear lube fill and drain plug and sealing washer c Drain the gear lube into a suitable container a Fil...

Page 54: ...Mercury Quicksilver High Performance Gear Lube in the sterndrive 10 Install the vent plug and sealing washer 11 Continue to pump gear lube into the drive through the fill and drain plug hole until the...

Page 55: ...8 60 16 Install the sterndrive propeller Refer to Propellers 17 Recheck the gear lube level at the gear lube monitor after the first use Refer to Checking IMPORTANT The gear lube level in the gear lu...

Page 56: ...he specified fluid See Filling Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim pump 92 858074K01 Filling 1 If the fluid level is below the MIN line the specifie...

Page 57: ...T Use only Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid ATF in the power assisted steering system IMPORTANT Running the pump dry will damage the pump Always che...

Page 58: ...the engine to cool down before removing the coolant pressure cap Check Coolant IMPORTANT When possible check the engine coolant before starting the engine 1 Allow the engine to cool 2 Remove the pres...

Page 59: ...val See Replacing the Engine Coolant in the Closed Cooling System 2 8 Air Filter Removal IMPORTANT Keep gear lube monitor bottle in an upright position to prevent fluid from spilling NOTE It is not ne...

Page 60: ...RTANT Treatment such as partial oil saturation is not required and is not recommended on the foam element before use The foam element must be clean and dry for proper filtration 1 Install the air filt...

Page 61: ...housing c Turbocharger d Clamp 3 Remove the air filter element from the air filter housing a Air filter housing b Air filter element Inspection 1 The air filter cannot be cleaned Replace the air filt...

Page 62: ...ING Fuel is flammable and explosive Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area whi...

Page 63: ...n cold weather where there is a possibility that the condensed water will freeze drain the filter shortly after the end of daily operations NOTE Place a suitable container under the fuel filter to cat...

Page 64: ...g drain cap and use it on the new filter Be sure to replace the O ring on the drain cap 4 Remove the drain cap and O ring seal from the bottom of the existing fuel filter Note the position of the O ri...

Page 65: ...13 Connect the battery cables 14 Start and operate the engine Check the filter connection for fuel leaks If leaks exist recheck filter installation If leaks continue stop the engine immediately and c...

Page 66: ...Fuel System Priming Prime the engine if it has not been run for an extended period or if the engine will not start 1 Move the hand pump and primer plunger up and down several times as previously outl...

Page 67: ...to ensure complete draining of the cooling system Drain the seawater system of the power package before cold weather freezing temperature seasonal storage or extended storage IMPORTANT The boat must...

Page 68: ...he seawater inlet hose from the connector on the seawater pump hose and drain 2 8 4 2 a Seawater inlet hose b Connector c Seawater pump hose 7 Repeatedly clean out the drain holes using a stiff piece...

Page 69: ...No 19 Perfect Seal Drain plug or fitting threads 92 34227Q02 10 Connect all hoses Tighten the hose clamps Sterndrive Water Inlets Check 1 Obtain a piece of wire the appropriate size to insert into th...

Page 70: ...the water supply from the seawater pump water inlet or seacock when performing service or maintenance on the cooling system 1 With the engine off close the seacock if equipped or remove and plug the s...

Page 71: ...the engine or causing the boat to sink Do not overtighten the cover screws or the cover may warp and introduce seawater into the bilge 5 For metal seawater strainers a Install the strainer drain plug...

Page 72: ...results we recommend flushing the seawater system after each outing After each operation in saltwater and before storage the seawater cooling system must be flushed With the Boat out of the Water 1 Lo...

Page 73: ...b Hose IMPORTANT Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through hull or through transom water inlet need a supply of cooling water available to both the...

Page 74: ...hull pickup a Remove the adapter from the seawater pump inlet hose connection b Reconnect the seawater inlet hose Tighten the hose clamps securely With the Boat in the Water NOTICE Disconnecting the s...

Page 75: ...ngine Coolant in the Closed Cooling System Draining the Closed Cooling System NOTICE Discharge of oil coolant or other engine drive fluids into the environment is restricted by law Use caution not to...

Page 76: ...t has drained completely install the intake and exhaust manifold drain plug the heat exchanger drain plug and the engine block drain plug Tighten all drain plugs securely 7 If required clean the close...

Page 77: ...rks if marked 9 Install and securely tighten the pressure cap Corrosion Protection General Information Whenever two or more dissimilar metals such as those found on this power package are submerged in...

Page 78: ...and the mode of engine operation NOTE Using sandpaper fiber brush or cleaning pad remove the deposits from the surface of the anode before trying to determine the amount of erosion Do not use a mild...

Page 79: ...g with the sacrificial anode a Anode assembly b Sealing washer 2 Install the anode assembly and washer into the aftercooler end cover Tighten securely a Aftercooler end cover b Anode assembly 3 On 4 2...

Page 80: ...a more comprehensive explanation of corrosion and corrosion protection refer to the Marine Corrosion Protection Guide Typical single sterndrive a Anode Alpha models MerCathode Bravo models b Ventilat...

Page 81: ...Replace sacrificial anodes if eroded 50 or more The following sacrificial anodes are installed at different locations on your power package These anodes help protect against galvanic corrosion by sacr...

Page 82: ...rcase 20338 Alpha and Bravo sterndrive trim cylinder anodes Mounted on each of the trim cylinders 20342 Alpha and Bravo sterndrive bearing carrier anode Located in front of the propeller between the f...

Page 83: ...ical continuity between the engine transom assembly and sterndrive components Good continuity to a ground is essential for the anode and MerCathode system to function effectively 1 Inspect the steerin...

Page 84: ...late cavity a Ground plate inside anode cavity 5 Inspect the gimbal housing ground wires for loose connections broken connectors or frayed wiring a Gimbal housing to gimbal ring ground wire b Gimbal h...

Page 85: ...und clip for loose or faulty connections Exhaust tube ground clip shown U joint bellows ground clips similar a Exhaust tube ground clip MerCathode If the boat is equipped with a MerCathode system the...

Page 86: ...ling paint to the boat hull and transom However observe the following IMPORTANT Do not paint anodes or MerCathode System reference electrode and anode Paint will render them ineffective as inhibitors...

Page 87: ...om Black Bare metal 92 802878 1 Spray all electrical connections with sealant Tube Ref No Description Where Used Part No 25 Liquid Neoprene All electrical connections 92 25711 3 Inspect the sacrificia...

Page 88: ...Part No 95 2 4 C with PTFE Steering cable grease fitting 92 802859A 1 2 Turn the steering wheel until the steering cable is fully extended Lightly lubricate the exposed part of the cable a Extended st...

Page 89: ...erway Throttle Cable 1 Lubricate the pivot points and guide contact surfaces a Pivot points b Guide contact surfaces Tube Ref No Description Where Used Part No 80 SAE Engine Oil 30W Throttle cable piv...

Page 90: ...emoving the sterndrive Lubricate the engine coupler splines through the grease fitting on the coupler by applying approximately 8 10 pumps of Extreme Grease from a typical hand operated grease gun NOT...

Page 91: ...aft grease fittings 8M0071842 Sterndrive Bellows and Engine Alignment IMPORTANT Have your Mercury Diesel authorized repair facility perform the maintenance procedures listed or refer to the appropriat...

Page 92: ...a U joint bellow b Exhaust tube c Bell housing d Gimbal ring e Gimbal housing f Shift cable bellows 4 Check the engine alignment a Alignment tool b End of alignment tool to insert through gimbal housi...

Page 93: ...s a Rear engine mount b Transom plate mount c Rear engine mount bolt Description Nm lb in lb ft Rear engine mounts 47 35 Propellers Bravo Sterndrive Propeller Removal WARNING Rotating propellers can c...

Page 94: ...ller c Propeller nut under socket 3 Turn the propeller shaft nut counterclockwise and remove the nut 4 Slide the propeller and the attaching hardware from the propeller shaft Bravo One models a Propel...

Page 95: ...Place a block of wood between the propeller blade and the sterndrive s anti ventilation plate 2 Remove the bolt and washers securing the propeller shaft anode 3 Remove the propeller shaft anode a Prop...

Page 96: ...gine from starting Place a block of wood between the propeller blade and the anti ventilation plate a Wood block b Propeller c Propeller nut under socket Bravo One Models IMPORTANT Use the correct rot...

Page 97: ...opeller shaft splines 92 802859A 1 Extreme Grease Propeller shaft splines 8M0071842 2 Slide the forward thrust hub onto the propeller shaft with the tapered side toward the propeller hub 3 Align splin...

Page 98: ...fraying or glazed surfaces WARNING Inspecting the belts with the engine running may cause serious injury or death Turn off the engine and remove the ignition key before adjusting tension or inspectin...

Page 99: ...ensioner must return to the initial position and hold tension on the serpentine belt Replacement IMPORTANT If a belt is to be reused it should be installed in the same direction of rotation as when fi...

Page 100: ...point shown The belt must correspond to the specifications in the following table 2 8 shown 4 2 similar a Power steering pump belt Power assisted steering drive belt tension Belt deflection with moder...

Page 101: ...in lb ft Power assisted steering pump mounting bolts 21 15 Replacement 1 Remove the serpentine belt See Serpentine Belt 2 Loosen the power assisted steering pump mounting bolts 2 8 shown 4 2 similar a...

Page 102: ...damage from fire or explosion Remove the battery from the boat and recharge in a ventilated area away from sparks or flames WARNING An operating or charging battery produces gas that can ignite and ex...

Page 103: ...ctronic Control Module ECM has a stable voltage source Battery Switches Battery switches should always be positioned so that each engine is operating off of its own battery Do not operate engines with...

Page 104: ...Section 4 Maintenance Notes Page 96 90 8M0113987 eng DECEMBER 2015...

Page 105: ...nts Cold Weather Freezing Temperature Seasonal Storage and Extended Storage 98 Cold Weather Freezing Temperature Storage 98 Preparing Your Power Package for Seasonal or Extended Storage 98 Seasonal St...

Page 106: ...for one month or more The length of time varies depending on the geographic location of the boat in storage Seasonal storage precautions and procedures include all of the steps for cold weather freezi...

Page 107: ...ylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 3 Fill a container with approxim...

Page 108: ...guidelines 1 On engines prepared for extended storage have a Mercury Diesel authorized repair facility install the seawater pump impeller if it was removed for storage 2 On engines that were prepared...

Page 109: ...on 5 Storage 90 8M0113987 eng DECEMBER 2015 Page 101 12 Carefully inspect the engine for fuel oil fluid water and exhaust leaks 13 Check the steering system shift and throttle control for proper opera...

Page 110: ...Section 5 Storage Notes Page 102 90 8M0113987 eng DECEMBER 2015...

Page 111: ...l Not Start or Is Hard to Start 104 Engine Runs Rough Misses or Backfires 104 Poor Performance 104 Incorrect Engine Temperature 105 Low Engine Oil Pressure 105 Battery Will Not Charge 105 Remote Contr...

Page 112: ...ment Faulty electrical stop circuit Have a Mercury Diesel authorized repair facility service the electrical stop circuit Clogged fuel filters Replace fuel filters Stale or contaminated fuel Drain tank...

Page 113: ...kinking restriction Use of improperly designed hose on inlet side of seawater pump allowing it to collapse Replace hose with wire reinforced design Faulty thermostats Replace See a Mercury Diesel aut...

Page 114: ...ers or parts Check all parts and fasteners if any are loose or missing see a Mercury Diesel authorized repair facility immediately Contaminated power steering fluid See a Mercury Diesel authorized rep...

Page 115: ...Away From Home 108 Stolen Power Package 108 Attention Required After Submersion 108 Replacement Service Parts 108 Parts and Accessories Inquiries 108 Resolving a Problem 108 Contact Information for M...

Page 116: ...in both fresh and saltwater environments These conditions require numerous special parts Exercise care when replacing marine engine parts because specifications are different from those of the standa...

Page 117: ...rviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 1 954 744 3535 Japan...

Page 118: ...r Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Depa...

Page 119: ...Section 8 Maintenance Log 90 8M0113987 eng DECEMBER 2015 Page 111 Section 8 Maintenance Log Table of Contents Scheduled Maintenance Log 112 Vessel Maintenance Notes 113 8...

Page 120: ...me Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name Signa...

Page 121: ...90 8M0113987 eng DECEMBER 2015 Page 113 Vessel Maintenance Notes Record all general maintenance performed on your power package here Save all work orders and receipts Date Engine Hours Maintenance Co...

Page 122: ......

Page 123: ...mercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mercury Marine All rights reserved Printed in U S A 90 8...

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