Mercury D2.8L D-Tronic Service Manual Download Page 376

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CHARGING SYSTEM

SERVICE MANUAL NUMBER 22

Page 4B-8

90-860074--1 FEBRUARY 2002

Charging System Components

The alternator system consists of the alternator, battery, the ignition switch and the wiring
which connects these components.

NOTE: The wire color codes vary between models and are not shown. Refer to SECTION
4E Wiring Diagrams for color code information.

75420

Typical

a -

Battery Meter

b -

Ignition Switch

c -

Harness Plug and Connector

d -

Alternator

e -

Circuit Breaker

f -

Starter Motor

g -

Ground Stud

h -

Battery

Summary of Contents for D2.8L D-Tronic

Page 1: ...BER 22 Printed in U S A 90 860074 1 FEBRUARY 2002 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 ...

Page 2: ......

Page 3: ...RVE 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 deat...

Page 4: ...es 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 perform...

Page 5: ...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 manufactu...

Page 6: ...RY 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 ...

Page 7: ...ine 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 ...

Page 8: ... 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...

Page 9: ... 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 INSTAL...

Page 10: ...cation 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 Ex...

Page 11: ...114 Rear Oil Seal 3A 116 Removal 3A 116 Installation 3A 117 Crankshaft and Main Bearings 3A 118 Removal 3A 118 Cleaning 3A 123 Inspection 3A 124 Installation 3A 127 Cylinder Liners 3A 136 Removal 3A 136 Identification 3A 137 Cleaning and Inspection 3A 138 Installation 3A 139 Flywheel Housing Coupler Drive Plate And Flywheel 3A 144 Exploded View 3A 144 Flywheel Housing 3A 148 Sterndrive MCM Coupler...

Page 12: ...icants Sealants Adhesives 4C 4 Special Tools 4C 4 Description 4C 4 Precautions 4C 4 Glow Plug Testing Prior to Removal 4C 5 Removal 4C 6 Cleaning 4C 7 Inspection 4C 7 Installation 4C 8 Glow Plug Actuator Relay and Auxiliary Relay 4C 9 Testing 4C 9 Removal 4C 10 Cleaning 4C 10 Inspection 4C 10 Installation 4C 10 Glow Plug Circuit Diagram 4C 11 ELECTRICAL SYSTEMS Section 4D Instrumentation Identific...

Page 13: ...ired 5A 6 Visual Physical Inspection 5A 6 Electrostatic Discharge Damage 5A 6 Diagnostic Information 5A 7 Terminology 5A 7 Electronic Control Module ECM and Sensors 5A 9 General Description 5A 9 Computers and Voltage Signals 5A 9 Analog Signals 5A 9 Analog Value Conditioning 5A 11 Digital Signals 5A 13 Engine Control Module ECM 5A 15 Speed Density System 5A 17 ECM Input and Sensor Descriptions 5A ...

Page 14: ...tification Number Location 5D 2 Specifications 5D 2 Injection Pump 5D 2 Timing 5D 3 Torque Specifications 5D 3 Special Tools 5D 3 Tools 5D 4 Special EDI Tools 5D 4 Kent Moore Tools 5D 4 Lubricants Sealants Adhesives 5D 4 Description 5D 5 Fuel Ratings 5D 6 Diesel Fuel in Cold Weather 5D 6 Repair and Service 5D 7 General Information 5D 7 Service Information 5D 7 Precautions 5D 9 Exploded View 5D 10 ...

Page 15: ... 5E 42 Battery Switched K15 5E 43 Microcontroller Fault 5E 44 ECM Reference Voltage u_ref 2 5v 5E 45 Main Relay 5E 46 Timing Actuator Timing Solenoid Valve 5E 48 Glow Plug Main Relay Glow Plug Relay Actuator If Equipped 5E 50 Glow Plug Auxiliary Relay If Equipped 5E 52 Glow Plug Lamp Glow Plug Display 5E 54 Glow Plug Lamp Glow Plug Display 5E 56 MIL Malfunction Indicator Lamp Diagnostic Lamp 5E 58...

Page 16: ...stem Specifications 6B 4 Capacity 6B 4 Thermostats 6B 4 Pressure Cap 6B 4 Coolant 6B 4 Torque Specifications 6B 5 Lubricants Sealants Adhesives 6B 5 Tools 6B 5 Special Tools 6B 5 Tools 6B 5 Diagrams and Exploded Views 6B 6 Coolant Flow Diagram 6B 6 Heat Exchanger Coolant Tank and Related Components 6B 8 Engine Water Circulating Pump 6B 10 Checking Coolant Level 6B 11 Testing Closed Cooling System ...

Page 17: ...terndrive MCM Exhaust System 7B 8 Locating And Installing The Inboard MIE Exhaust System 7B 9 Exhaust Pipe Sterndrive MCM 7B 11 Removal 7B 11 Cleaning 7B 11 Installation 7B 12 Intake Exhaust Manifold 7B 13 Removal 7B 13 Cleaning and Inspection 7B 14 Installation 7B 15 INTAKE AND EXHAUST SYSTEM Section 7C Turbocharger Identification 7C 3 Turbocharger Specifications 7C 3 Torque Specifications 7C 4 L...

Page 18: ...ontrol And Cables 8A 15 Transmission Shift Lever And Shift Cable Bracket 8A 15 Shift Cable Installation and Adjustment 8A 16 Pressure And Temperature Tests 8A 21 Transmission Repair 8A 21 DRIVES Section 8B Propeller Shaft Models Lubricants Sealants Adhesives 8B 2 Checks Made with Boat In Water 8B 3 Checks Made with Boat Out of Water and Shaft Installed 8B 5 Checks Made with Propeller Shaft Removed...

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Page 20: ...Page xviii 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 21: ...MATION Section 1A General Information Table of Contents 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 ...

Page 22: ...GENERAL INFORMATION SERVICE MANUAL NUMBER 22 Page 1A 2 90 860064 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 23: ...lers and service mechanics to repair and tune these engines Before attempting repairs it is suggested that the procedure first be read through to gain knowledge of the methods and tools used and the cautions and warnings required for safety How to Use This Manual This manual is divided into sections that represent major components and systems Some sections are further divided into parts that more ...

Page 24: ...b d 75301 73929 MARINE POWER EUROPE INC MADE IN ITALY SERIAL NUMBER MAX RPM H P L B K W K G a 71675 a c 71688 BS O M12 11 3 93_ _ Typical Sterndrive MCM Engine Shown Inboard MIE Similar a Serial Number Plate b Manufacturer s Serial Number Stamped in Block c Exhaust Gas Emissions Certificate Number Example d MerCruiser Specification Decal ...

Page 25: ...g boats such as sport fish charter boats Application to common commercial crafts having full displacement or semi displacement hulls exceeds the recommended operational capability or duty cycle IMPORTANT Damage caused by improper application or failure to operate within the operational capability or duty cycle will not be covered by the Mercury MerCruiser Diesel Limited Warranty PLEASURE DUTY RATI...

Page 26: ...t a time to avoid overheating the starter motor If engine does not start wait 1 minute to allow the starter motor to cool then repeat starting procedure 1 Refer to appropriate Starting Shifting and Stopping section in the Operation Maintenance and Warranty Manual provided with the product and start the engine Allow the engine to idle until it has reached normal operating temperature 2 Operate the ...

Page 27: ...Adhesive 1 5 oz 42 5 g tube N A 92 86166Q1 33 Loctite 680 Retaining Compound 10 ml tube N A 92 809833 34 Special Lubricant 101 8 oz 226 8 g tube 92 802865A1 92 802865Q1 42 U Joint and Gimbal Bearing Grease 92 802870A1 92 802870Q1 51 Loctite 222 Thread Locker 10 ml tube N A 92 809818 66 Loctite 242 Thread Locker 10 ml tube N A 92 809821 79 4 Cycle 25W40 Engine Oil 92 802837A1 92 802837Q1 82 Premium...

Page 28: ... N A 92 813054A2 123 Fuel System Treatment and Stabilizer Concentrate 16 oz 437 ml 92 802876A1 92 802876Q1 124 Heat Transfer Compound 1 5 oz 42 5 g tube N A 92 805701 1 125 Liquid Gasket N A 92 808137 126 T442 Sealant N A 92 862258 127 Loctite 5900 Ultra Black RTV Silicone Sealant 13 oz 371 g tube N A 92 809826 128 Loctite Gasket Remover 18 oz 532 ml spray can N A 92 809828 1 129 Sealer Kit Two Pa...

Page 29: ...SERVICE MANUAL NUMBER 22 GENERAL INFORMATION Page 1A 9 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 30: ...GENERAL INFORMATION SERVICE MANUAL NUMBER 22 Page 1A 10 90 860064 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 31: ...odels 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 4...

Page 32: ...MAINTENANCE SERVICE MANUAL NUMBER 22 Page 1B 2 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 33: ...ent 44357T 2 Reference Electrode and Test Meter 91 76675T1 Tools Description Part Number Water Tap Hose Adapter To Water Inlet Fitting Typical Hand operated Grease Gun Obtain Locally Lubricants Sealants Adhesives Description Part Number Mercury Diesel Engine Oil 92 877695K1 Liquid Neoprene 92 25711 3 Loctite 567 PST Pipe Sealant 92 809822 Engine Coupler Spline Grease 92 816391A4 U Joint and Gimbal...

Page 34: ...Pres 750 rpm 1 5 3 1 bar 152 310 kPa 22 45 psi Oil Pres sure 3800 rpm 3 5 5 6 bar 345 556 kPa 50 80 psi Oil Temperature 100 110 degrees C 212 230 degrees F Thermo Water 2 Total 1 at temperature 70 degrees C 160 degrees F stats 1 at temperature 82 degrees C 180 degrees F Oil 95 degrees C 203 degrees F Coolant Temperature 80 85 degrees C 176 185 degrees F Electrical System 12 volt Negative Ground Al...

Page 35: ... bar 152 310 kPa 22 45 psi Oil Pressure 3800 rpm 3 5 5 6 bar 345 556 kPa 50 80 psi Oil Temperature 100 110 degrees C 212 230 degrees F Water 2 Total 1 at temperature 70 degrees C 160 degrees F Thermostats 1 at temperature 82 degrees C 180 degrees F Oil 1 Total 95 degrees C 203 degrees F Coolant Temperature 80 85 degrees C 176 185 degrees F Electrical System 12 volt Negative Ground Alternator Ratin...

Page 36: ...determine exact quantity of oil required Drives NOTICE Unit Of Measurement Liters U S Quarts Item Specification Bravo One 2 6 2 75 Drive Unit Oil Capacity With Gear Lube Bravo Two 3 3 2 Monitor Bravo Three 2 9 3 Transmissions IMPORTANT It may be necessary to adjust oil levels depending on installation angle and cooling systems heat exchanger and fluid lines NOTICE Unit Of Measurement Liters U S Qu...

Page 37: ...s should be disconnected at the battery Maintenance Intervals Maintenance intervals and the tasks to be performed are generally based on an average boating application and environment However individual operating habits and personal maintenance preferences can have an impact on the suggested intervals In consideration of these factors Mercury MerCruiser has adjusted some maintenance intervals and ...

Page 38: ...ris or marine growth Check water strainer and clean Check coolant level D Inspect drive unit anodes and replace if 50 percent eroded D Check battery connections and fluid level D Lubricate propeller shaft and the retorque nut if operating in only freshwater this maintenance may be extended to every four months D Operating in Saltwater Only treat engine surface with corrosion guard D Clean air filt...

Page 39: ...ing to steering shaft D Replace fuel filter s D Check steering system and re mote control for loose missing or damaged parts Lubricate cables and linkages D Inspect U joints splines and bellows Check clamps Check engine alignment Lubricate U joints and splines D Lubricate gimbal bearing and engine coupler D Check continuity circuit for loose or damaged connections Test MerCathodeR unit output on B...

Page 40: ...ive shaft U joints and tailstock input and output bearings D Inspect condition and tension of belts D Check cooling system and ex haust system hose clamps for tightness Inspect both systems for damage or leaks D Disassemble and inspect seawa ter pump and replace worn com ponents D Clean seawater section of closed cooling system Clean inspect and test pressure cap Check anodes D Replace coolant D R...

Page 41: ...mperatures D Check transmission fluid D Check water pickups for debris or marine growth Check water strainer and clean Check coolant level D Check battery connections and fluid level D Clean air filter every 50 hours of operation D Operating in Saltwater Only treat engine surface with corrosion guard D Ensure that the gauges and the wiring connections are secure Clean the gauges 1 D Only perform m...

Page 42: ...ing or damaged parts Lubricate cables and linkages D Retorque engine mounts D Check electrical system for loose dam aged or corroded fasteners D Inspect condition and tension of belts D Check cooling system and exhaust sys tem hose clamps for tightness Inspect both systems for damage or leaks D Disassemble and inspect seawater pump and replace worn components D Clean seawater section of closed coo...

Page 43: ...6 7 8 9 13 15 Typical In Line D Tronic Diesel 1 Exhaust Riser or Elbow If Equipped 2 Intercooler Air Duct 3 Fluid Cooler 4 Shift Plate 5 Intercooler 6 Sacrificial Anode 7 Power Steering Fluid Reservoir 8 Thermostat Housing 9 Heat Exchanger 10 Engine Oil Cooler 11 Power Steering Pump 12 Front Engine Mount 13 Oil Pan 14 Starter Motor 15 Wastegate ...

Page 44: ... Line D Tronic Diesel 1 Sacrificial Anode 2 Pressure Cap 3 Heat Exchanger 4 Engine Oil Cooler 5 Seawater Pump Outlet Hose 6 Alternator 7 Seawater Pump Inlet Hose 8 Seawater Pump 9 Oil Pan 10 Crankshaft Pulley 11 Engine Water Circulating Pump Pulley 12 Power Steering Pump 13 Front Engine Mount 14 Oil Thermostat 15 Oil Filter 16 Exhaust Elbow ...

Page 45: ...ine Cover 3 Fuel Injector 4 Fuel Filter 5 Gear Lube Monitor 6 PCV Oil Separator 7 Air Filter 8 MerCathode Controller 9 Rear Engine Mount 10 Flywheel Housing Rear Portion 11 5 Amp ECM Fuse 12 Electrical Box 13 Engine Block Ground Stud 14 Fuel Delivery Pump 15 Oil Pan 16 Engine Control Module ECM 17 Throttle Position Sensor 18 Vibration Damper And Crankshaft Pulley 19 Seawater Pump 20 Heat Exchanger...

Page 46: ...R 22 Page 1B 16 90 860074 1 FEBRUARY 2002 Rear View 74305 1 2 3 4 5 6 7 Typical In Line D Tronic Diesel 1 Air Filter 2 Turbocharger 3 Exhaust Elbow 4 Rear Engine Mount 5 Engine Coupler 6 Flywheel Housing Rear Portion 7 Electrical Box ...

Page 47: ...HALL VIVA 1 These oils are approved by Mercury Marine and Marine Power Europe For all temperature operation use 15W 40 oil Oil Level OVERFILLED ENGINE CRANKCASE An overfilled crankcase can cause a fluctuation or drop in oil pressure on Mercury MerCruiser engines The over full condition results in the engine crankshaft splashing and agitating the oil causing it to become aerated The aerated oil cau...

Page 48: ...y or damage to oil dipstick and internal engine components Do NOT remove crankcase oil dipstick when engine is running Stop the engine completely before removing or inserting dipstick If it becomes necessary to check oil level during operation stop the engine and allow approximately 10 minutes for oil to drain into pan 6 Remove oil dipstick Wipe clean and install into dipstick tube 7 Remove dipsti...

Page 49: ...t engine and allow it to reach normal operating temperature 2 Stop the engine and allow approximately 10 minutes for oil to drain into oil pan 3 Remove threaded fitting from crankcase oil drain hose 4 Install crankcase oil pump 90265A2 onto threaded fitting of oil drain hose a b 75298 70571 a b c a Oil Drain Hose b Threaded Fitting c Crankcase Oil Pump 5 Pump oil out of crankcase into drain pan 6 ...

Page 50: ...o bring level up to but not over maximum oil level mark on dipstick 12 Install oil filler cap 13 Supply cooling water to water inlet 14 Start the engine and allow it to reach normal operating temperature IMPORTANT Always use dipstick to determine how much oil is required CAUTION Avoid possible injury or damage to oil dipstick and internal engine components Do NOT remove crankcase oil dipstick when...

Page 51: ...corrosion Any sign of leakage or deterioration requires replacement before further engine operation WARNING Electrical system components on this engine are not external ignition protected DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT REF 33 CFR Failure to comply could result in fire explosio...

Page 52: ...ard starting and other various troubles such as premature wear of the injection pump plungers and injection nozzles resulting from the deposit of carbon residue and other contaminants Sulphur content of the above fuel is rated at 0 50 by weight maximum ASTM Limits may vary in countries outside of the United States On intermittent use engines high sulphur content diesel fuel will greatly increase C...

Page 53: ...o contact with any hot sur face which may cause it to ignite WARNING Dispose of fuel soaked rags paper etc in an appropriate air tight fire retardant container Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death WARNING Make sure no fuel leaks exist before closing engine hatch CAUTION Absolute cleanliness is required for work on t...

Page 54: ...er when 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 fuel filter to catch contaminated fuel and or water 1 Using a suitable container to catch contaminated fuel and or water open drain cap at bottom of filter by turning the drain counterclockwise as viewed from the bottom of the filter 2...

Page 55: ...le container under fuel filter to catch contaminated fuel and or water 1 Loosen bleed screw on fuel filter bracket 2 Move plunger knob on pump primer up and down repeatedly until an air free stream of fuel flows from bleed screw Filter is full when this occurs 75301 a b a Plunger Knob b Bleed Screw 3 Securely tighten bleed screw 4 Supply cooling water to water inlet 5 Start the engine check for fu...

Page 56: ...fuel and or water 1 Twist locking ring by hand Remove water separating fuel filter and sealing ring from mounting bracket Do NOT use a filter wrench 70161 75579 a b a Locking Ring b Filter Element IMPORTANT Element cannot be cleaned and reused It must be replaced 2 Remove the drain cap and O ring from bottom of the existing filter Note position of O ring seal 3 Inspect and replace damaged componen...

Page 57: ...ain cap on new filter 70160 a b a O ring Seal b Drain Cap 2 Lubricate seal with clean engine oil 3 Align filter to bracket Twist locking ring by hand to secure filter to bracket Do NOT use a filter wrench 74731 a b c d a Filter Header b Locking Ring c Seal d Fuel Filter 4 Fill fuel filter as previously outlined ...

Page 58: ...n the system restricting the cooling system efficiency In addition additives and inhibitors introduced into acceptable coolant solutions will form a protective film on internal passages and provide protection against internal cooling system erosion The closed cooling section should be kept filled year round with an acceptable coolant solution Do NOT drain closed cooling section for storage this wi...

Page 59: ... specified coolant to the coolant recovery bottle as required WARNING Allow engine to cool before removing pressure cap Sudden loss of pressure could cause hot coolant to boil and discharge violently causing severe injury 3 Remove pressure cap 4 Coolant level must be to the bottom edge of the fill neck with the engine cool 75299 a a Fill Neck 5 If coolant is low check the coolant system for malfun...

Page 60: ...on is filled with an ethylene glycol anti freeze and water solution properly mixed to protect engine to lowest temperature to which it will be exposed w Do NOT use Propylene Glycol anti freeze in the closed cooled section of the engine WARNING Allow engine to cool before removing pressure cap Sudden loss of pressure could cause hot coolant to boil and discharge violently causing severe injury 1 Al...

Page 61: ...ne block by opening the drain valve 76391 a Typical a Engine Block Drain Valve 4 After coolant has drained completely securely close drain valves 5 Empty the coolant recovery bottle 6 If required clean the closed cooled system Refer to SECTION 6A 7 Fill system with required coolant as outlined in Filling ...

Page 62: ...idle 1500 1800 rpm Add coolant to heat exchanger as required to maintain coolant level 1 in 25 mm below fill neck 5 After engine has reached normal operating temperature thermostats are fully open and coolant level remains constant fill heat exchanger to bottom of fill neck 6 Install pressure cap 7 Observe engine temperature gauge to make sure that engine operating temperature is normal If gauge i...

Page 63: ...oval 1 Allow the engine to cool 2 Remove anode plugs and sacrificial anodes 73326 a 73327 b c c a Heat Exchanger b Intercooler End Cover c Anode Plug And Sacrificial Anode Inspection 1 Replace anode assembly when deteriorated 50 Length When New 19 mm 3 4 in Diameter When New 16 mm 5 8 in 2 Discard sealing washer 71368 c d e b a a Anode Plug b Sacrificial Anode c Length d Diameter e Sealing Washer ...

Page 64: ...Plug b Anode Reassembly 1 Clean interior threads of anode plug 2 Apply Loctite Pipe Sealant with Teflon to threads of new sacrificial anode and install into anode plug Tighten securely 71367 a b a Plug b Anode Installation 1 Install new sealing washer 2 Install anode plug with sacrificial anode and washer into heat exchanger or intercooler end cover Tighten securely 71368 a b a Plug And Anode b Se...

Page 65: ... Attachment or equivalent over water pickup openings in gear housing 2 Attach a hose between the flushing attachment and a water source 72012 a b a Flushing Attachment b Hose 3 Lower sterndrive unit to full DOWN IN position CAUTION Do NOT run engine above 1500 rpm when flushing Suction created by seawater pickup pump may collapse flushing hose causing engine to overheat 4 Partially open water tap ...

Page 66: ...oling system If boat is not fitted with a seacock water inlet hose must be disconnected and plugged to prevent water from flowing into the boat and or back into the cooling system As a precautionary measure attach a tag to the ignition switch or steering wheel of the boat with the warning Open seacock or reconnect water inlet hose before starting engine 1 If the boat is in the water close the seac...

Page 67: ...ngine at IDLE speed in NEUTRAL for 10 minutes or until discharge water is clear 7 Stop the engine 8 Shut off the water tap 9 Remove the hose and the adapter from the seawater pump connector fitting CAUTION If boat is in the water the seacock water inlet valve if equipped must remain closed until engine is to be re started to prevent water from flowing back into the cooling system and or the boat I...

Page 68: ...SternDrive Gear Housing 1 Ensure that the gear housing water inlet holes are clean and not obstructed 73186 a Typical a Water Inlet Holes Inboard Though the Hull Pickup 1 Ensure that the seawater pickup water inlet holes slots are clean and not obstructed 70355 a Typical a Water Inlet Holes Slots ...

Page 69: ...ith SAE 30W engine oil 75332 a b Single Cable Shown Dual Similar a Pivot Points b Guide Contact Surfaces Shift Cable 1 Lubricate pivot points and guide contact surfaces with SAE 30W engine oil 22245 a b a b a a 73587 a b Typical Sterndrive Model Shift Cable Typical Inboard Model Shift Cable and Transmission Linkage a Pivot Points b Guide Contact Surface ...

Page 70: ...th a sealed engine coupler The sealed coupler and the shaft splines can be lubricated without removing the sterndrive unit 1 Lubricate the engine coupler splines through the grease fittings on the coupler by applying approximately 8 10 pumps of Engine Coupler Spline Grease from a typical hand operated grease gun If the boat is operated at idle for prolonged periods of time the coupler should be lu...

Page 71: ...ove the sterndrive unit refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for sterndrive unit removal and installation 2 Apply U joint And Gimbal Bearing Grease Except on Bravo X Drives use Exxon Unirex EP2 Grease Obtain Locally from a typical hand operated grease gun until a small amount of grease begins to push out 3 Lubricate the U joint shaft splines using Engine Coupler Sp...

Page 72: ...ply 3 4 pumps of U joint And Gimbal Bearing Grease to drive shaft grease fittings 71346 71347 a b a Transom End Fittings b Engine End Fittings Sterndrive Unit and Transom Assembly 1 Apply approximately 8 10 pumps of U joint And Gimbal Bearing Grease to the gimbal bearing 70558 a a Gimbal Bearing b Hinge Pins ...

Page 73: ...omponents Good continuity is essential for the Anode and the MerCathode System to function most effectively 1 Inspect the following ground circuit components for loose connections broken or fraying wires 22028 a a Steering Lever Ground Wire 22650 77079 a b a Inner Transom Plate To Gimbal Housing Ground Wire b Driveshaft Housing To Gear Housing Ground Plate Inside Anode Cavity 77100 a b a Gimbal Ho...

Page 74: ...ound Wire c Inner Transom Plate Grounding Screw 22755 22031 a b a Gimbal Ring To Bell Housing Ground Wire b Sterndrive Unit To Bell Housing Ground Plate 70575 22230 a b a Driveshaft Housing To Gear Housing Anodic Plate b Hydraulic Connector Block To Gimbal Housing Ground Washer 50383 22079 b a a U joint Bellows Ground Clip b Exhaust Bellows Ground Clips ...

Page 75: ...r metal parts on the boat The test should be made where the boat is moored using Quicksilver Reference Electrode and Test Meter Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for testing procedures Engine Mounts 1 Torque the rear engine mounts to 51 Nm 38 lb ft Refer to SECTION 2 Electrical System NOTE Refer to SECTION 4 for specific procedures Inspect the entire electrical ...

Page 76: ...tick from the power steering fluid reservoir and observe the fluid level 3 The fluid level should be between the full hot mark and the full cold mark on dipstick 73326 d c 23162 a b a Dipstick b Fluid Reservoir c Full Hot Mark d Full Cold Mark 4 If the fluid level is below marks but fluid is visible in reservoir add fluid to bring the level up to the full hot mark on the dipstick Do NOT overfill 5...

Page 77: ... the full cold mark and the bottom of the dipstick 73326 c d 23162 a b a Dipstick b Fluid Reservoir c Full Cold Mark d Bottom Of Dipstick 4 If the fluid level is below the bottom of dipstick but fluid is still visible in the reservoir add required amount of fluid to bring level up to full cold mark on dipstick DO NOT overfill 5 If fluid is not visible in the reservoir a leak exists in the power st...

Page 78: ...urn the steering wheel at a moderate rate to end of travel in each direction pausing a few seconds at end of travel Do this a minimum of 5 complete cycles then recheck fluid level and add fluid if necessary 5 Install dipstick 6 Supply cooling water to water inlet 7 Start engine and operate at IDLE until engine reaches normal operating temperature During this time slowly turn steering wheel to end ...

Page 79: ... Transmissions IMPORTANT Do NOT screw dipstick in press it firmly in and remove to obtain an accurate reading a Stop the engine and quickly remove the dipstick to check level b If fluid is below top full line add Dexron III Automatic Transmission Fluid through dipstick hole Do NOT overfill c If fluid level is below minimum fluid level line check transmission case cooler and hoses for leaks 71383 a...

Page 80: ... IMPORTANT Some trim pump reservoir fill caps have a small vent hole Occasionally ensure vent is not restricted 2 Unscrew reservoir cap 3 Remove and discard cap plug if present 76631 73183 b a a Reservoir Cap b Cap Plug 4 Observe oil level Level must be up to but not over bottom edge of reservoir fill neck 77348 b a a Reservoir Fill Neck b Reservoir Cap ...

Page 81: ...ANUAL NUMBER 22 90 860074 1 FEBRUARY 2002 Page 1B 51 Filling 1 Add Power Trim and Steering Fluid or SAE 10W 30 engine oil to bring oil to proper level 2 Install reservoir cap 77348 b a a Reservoir Fill Neck b Reservoir Cap ...

Page 82: ...re in the sterndrive unit Find and correct the cause 2 Check gear lube monitor oil level Keep oil level at or near OPERATING RANGE FULL line and never below the ADD line Filling 1 Remove cap 2 Add High Performance Gear Lube to gear lube monitor as needed IMPORTANT If more than 57 grams 2 oz of High Performance Gear Lube are required to fill drive unit a seal may be leaking Damage to the unit may o...

Page 83: ...er will warp and leak 2 With engine off close seacock if equipped or remove and plug seawater inlet hose if no seacock exists 3 Remove screws washers and cover 4 Remove strainer drain plug and washer 5 Clean all debris from strainer housing flush both strainer and housing with clean water 6 Check gasket and replace when necessary if it leaks 7 Reinstall strainer drain plug and washer 8 Reattach co...

Page 84: ...Screen Housing b Crankcase Vent Hose 2 Carefully remove air cleaner foam element from around air intake screen housing 71267 a b a Screen Housing b Air Cleaner Element Inspection 1 Inspect the air cleaner element for tears or holes 2 Replace the air cleaner element according to maintenance schedules or if it is deteriorated or torn IMPORTANT Refer to Maintenance Schedules for replacement interval ...

Page 85: ...element clean and dry for proper filtration 2 Allow air cleaner element to completely dry before use Installation 1 Install air cleaner element around air intake screen 2 Connect crankcase vent hose to end of intake screen housing Tighten hose clamp securely IMPORTANT To prevent unfiltered air from entering the engine be certain that all of the air intake screen is covered by the foam element when...

Page 86: ...rn cracked grease soaked or oil soaked When replacing belt and pulley pulley alignment must be checked under tensioned condition brackets securely clamped A misalignment that can be detected by visual inspection is detrimental to belt performance Except for belts controlled by an automatic tensioner if a belt is disturbed for any reason it must be tensioned to the correct tension Replace pulleys i...

Page 87: ...specting belts 1 Visually inspect all drive belts for cracks glazing fraying or separation 2 Check drive belts for proper tension by pressing midpoint between the pulleys on the longest belt span Belts must not deflect more than 5 mm 3 16 in 71588 73190 a b a b 71588 Typical a Drive Belts b Deflection Measurement Engine Water Circulating Pump Belt Refer to Alternator Belt instructions ...

Page 88: ...g the seawater pump hoses close the seacock if equipped If boat is not equipped with a seacock remove and plug the seawater inlet hose to prevent a siphoning action that may occur allowing seawater to enter the boat 1 Close the seacock if equipped If boat is not equipped with a seacock remove and plug the seawater inlet hose 2 Remove seawater pump inlet and outlet hoses 78310 b a Typical a Inlet H...

Page 89: ...t between the pulleys on the longest belt span 8 Torque tensioning and mounting bolts 28 Nm 21 lb ft 73521 b 74301 a c Typical a Deflection 5 mm 3 16 in b Tensioning Bolt c Mounting Bolt 9 Install the seawater pump inlet and outlet hoses 10 Open the seacock if equipped If boat is not equipped with a seacock remove the plug and connect the seawater inlet hose ...

Page 90: ...on power steering pump 2 Pivot the power steering pump to loosen belt 70113 a a b a Mounting Bolts 1 Not Shown b Tensioning Bolt CAUTION Before removing the seawater pump close the seacock if equipped If boat is not equipped with a seacock remove and plug the seawater inlet hose to prevent a siphoning action that may occur allowing seawater to enter the boat 3 Remove or loosen seawater pump nuts s...

Page 91: ...b c a 73521 70113 a Mounting Bolts 1 Not Shown b Tensioning Bolt c Deflection 5 mm 3 16 in IMPORTANT There is an o ring seal on the seawater pump 8 Ensure that the o ring seal is in the proper position before installing the seawater pump Also ensure the pump and keyway align 9 Install the seawater pump 23161 70243 c b a a O ring b Key And Keyway c Hex Nut With Washer 10 Install the seawater pump i...

Page 92: ...idual drive belts and proceed accordingly 1 Remove or loosen seawater pump nuts sufficiently to allow belt to pass between crankshaft balancer and water pump housing NOTE Refer to SECTION 6 Seawater Pump Removal if necessary 23161 a a Hex Nuts With Washers 2 Loosen the vacuum pump mounting and tensioning bolts behind the bracket 74085 a b c a Mounting Bolt b Tensioning Bolt c Vacuum Pump Bracket 3...

Page 93: ...an 7 Torque tensioning and mounting bolts to 21 Nm 15 lb ft 74085 a b c a Mounting Bolt b Tensioning Bolt c Deflection 5 mm 3 16 in IMPORTANT There is an O ring seal on the seawater pump 8 Ensure that the O ring seal is in the proper position before installing the seawater pump Also ensure the pump and keyway align 9 Install the seawater pump 23161 70243 a c b a O ring b Keyway c Hex Nuts With Was...

Page 94: ... system for loose damaged or corroded connectors 2 Check wiring for frayed or worn insulation 3 Check alternator mounting bolts for adequate tightness 4 Check alternator drive belt for excessive wear cracks fraying and glazed surfaces Corrosion and Corrosion Protection 1 After first cleaning all surfaces check all metal surfaces and touch up with Paint 2 To maintain a protective coating on all met...

Page 95: ... boat As a precautionary measure attach a tag to the ignition switch or steering wheel of the boat with the warning Open seacock or reconnect water inlet hose before starting engine 1 At the end of operations each day COMPLETELY drain seawater section of the cooling system and the seawater strainer to protect against damage by freezing Refer to SECTION 1B 2 At the end of operation each day drain w...

Page 96: ... drive system damage Ensure that there is sufficient water always available at water inlet holes during operation IMPORTANT If boat has already been removed from water before starting engine a source of water must be supplied to water inlet holes Refer to Flushing Cooling System 1 Provide sufficient water supply to water inlet holes 2 Start the engine and operate until it reaches normal operating ...

Page 97: ...d with a seacock water inlet hose must be disconnected and plugged to prevent water from flowing into cooling system and or boat As a precautionary measure attach a tag to the ignition switch or steering wheel with the warning that the valve must be opened or the water inlet hose reconnected prior to starting the engine 2 Close seacock or disconnect and plug seawater inlet hose if boat is to remai...

Page 98: ...UTION Avoid damage to heat exchanger and subsequent possible engine damage Remove all water from heat exchanger sections Failure to do so could cause corrosion or freeze damage to heat exchanger water passage tubes 73322 73326 a b a b a Upper Section End Cover b Lower Section End Cover NOTE In the following it may be necessary to lower or bend the hoses to allow water to drain completely 7 On Ster...

Page 99: ...ain completely 73335 a b Typical a Transmission Fluid Cooler b Seawater Hose 9 Remove the drain plug from the aft end cover of the intercooler 74303 a b a Drain Plug b Intercooler 10 Remove seawater pump outlet hose from top of seawater pump and drain 75301 a a Seawater Pump Outlet Hose 11 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained ...

Page 100: ...b Vent Hole c Drain Passage 13 After seawater section of cooling system has been drained completely a Coat threads of intercooler drain plug with Perfect Seal and reinstall Tighten securely b Reconnect hoses Tighten hose clamps securely NOTE Renew end cover gaskets if worn or deteriorated c Install all four end cover gaskets and covers on the heat exchanger tank d Torque the end covers on the uppe...

Page 101: ...e exposed during cold weather or extended storage 15 Disconnect hose from seawater pump connector fitting Using an adaptor temporarily connect an appropriate length piece of hose to seawater pump and place the other end of the hose into container of coolant 75299 a b Typical a Inlet Hose b Connector Fitting 16 Start the engine and operate at IDLE speed until antifreeze mixture has been pumped into...

Page 102: ... c d e Typical a Seawater Pump Housing b Cover Screws c Cover d Gasket e Impeller IMPORTANT It is recommended that others be informed to NOT operate the engine 24 Place a CAUTION TAG at instrument panel and in engine compartment stating that the seawater pump is out Do NOT operate engine CAUTION Sterndrive unit should be stored in full DOWN IN position Universal Joint bellows may develop a set if ...

Page 103: ...housing turning clockwise while simultaneously pushing firmly inward onto pump shaft NOTE Use new gasket Install in correct position wide surface on side of cam b Install pump cover with new gasket in noted position c Install the seawater pump cover mounting screws Tighten securely NOTE Pump shown removed for visual clarity only 71366 a b c d e a a Impeller b Seawater Pump Housing c Gasket Wide Su...

Page 104: ...y terminal LAST If battery cables are reversed or connection order is reversed electrical system damage will result 8 Install a fully charged battery Clean the battery cable clamps and terminals Reconnect the cables see CAUTION listed above Secure each cable clamp when connecting Coat terminals with a battery terminal anti corrosion spray to help retard corrosion 9 Perform all checks on OPERATION ...

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Page 107: ...tes 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...

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Page 109: ... fuel filter base can crack casting and or cause a fuel leak Follow specific procedure given in SECTION 4 of this manual for all fuel line connections WARNING FIRE HAZARD Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death Careful periodic inspection of entire fuel system is mandatory particularly after storage All fuel components inclu...

Page 110: ...uld be worn while working on fuel injection system The fuel in jection pump will generate pressures in excess of 2000 psi 13790 kPa Use caution when removing injectors injector lines or bleeding air from injection system CAUTION Do NOT operate engine without water being supplied to seawater pickup pump on engine or pump impeller may be damaged and subsequent overheating damage to engine may result...

Page 111: ... Improper drive unit trim angle B Propeller pitch too great C Dirty boat bottom marine growth D Poor running engine E Improper weight distribution F Rocker in boat bottom G False bottom full of water H Improperly adjusted trim tabs after planes 3 Propeller ventilating 3 A Drive unit installed too high on transom B Dirty or rough boat bottom C Damaged propeller pitch too small diameter too small D ...

Page 112: ...cessories mounted too close to propeller venti lation B Keel located too close to propeller and or too deep in the water ventila tion C Drive installed too high on transom D Wrong gear ratio 4 Engine coupler slipping RPM Too Low Cause Special Information 1 Operation 3 Unit trimmed in too far 2 Propeller 1 Damaged pitch too great diameter too great 2 Boat 2 A Dirty or damaged bottom B Permanent or ...

Page 113: ...erative 4 Injection timing 4 May crank over hard Refer to SECTION 5A 5D and or 5E for EDI diagnosis Fuel System Cause Special Information 1 Empty fuel tank 2 Fuel shut off valve closed if equipped 3 Anti siphon valve stuck closed if equipped 3 Restricting fuel supply 4 Low grade stale fuel or water in fuel 5 Fuel waxing or frozen water separator cold weather 6 Plugged fuel suction line or filter 7...

Page 114: ... a short time running engine will stall and will not restart for a period of time Can verify if it is a vent problem by running engine with filler cap loose Filler cap will act as a vent 10 Injection pump solenoid valve 10 Refer to SECTION 5 Check lanyard stop switch engaged or defective 11 Fuel supply pump 11 Low supply pump pressure Refer to SECTION 5A 5D and or 5E for EDI diagnosis ...

Page 115: ...c 5 Low compression 5 Worn valves rings cylinder or head gasket 6 Valve timing incorrect 6 Timing gears improperly installed or cam slipped in drive gear 7 Restricted or plugged exhaust Engine Will Not Crank Over or Starter Inoperative Cause Special Information 1 Remote control lever not in neutral position 2 Battery charge low damaged wiring loose electrical connections 3 Circuit breaker tripped ...

Page 116: ...se Special Information 1 Battery discharged 2 Circuit breaker tripped 2 On dash or in electrical box 3 Poor battery connections 4 Glow plug s defective burned out 5 Relay defective or inoperative 5 Check Main or Auxiliary Relay in electrical box Refer to SECTION 4C and or 5E for EDI Diagnosis 6 Pre glow circuit of controller inoperative 6 In electrical box 7 ECT malfunction or inoperative 7 Refer ...

Page 117: ...nections 4 Faulty battery gauge 4 Best way to test is to replace gauge 5 Battery will not accept charge 5 Low electrolyte or failed battery 6 Faulty alternator or regulator 7 Refer to Charging System SECTION 4B for complete diagnostic procedures Noisy Alternator Cause Special Information 1 Loose mounting bolts 2 Drive belt 2 Worn frayed loose 3 Loose drive pulley 4 Worn or dirty bearings 5 Faulty ...

Page 118: ...6 Fuel waxing or frozen water separating fuel filter cold weather 7 Valve timing 7 Cam slipped in drive gear 8 Restricted or plugged exhaust 9 Injectors not functioning properly 9 Refer to SECTION 5E for EDI Diagnosis 10 Injection pump timing incorrect 10 Refer to SECTION 5E for EDI Diagnosis 11 Low compression 11 Also check for defective blown head gasket 12 Water leaking into cylinders 12 Defect...

Page 119: ...ion of anti siphon valve if equipped 3 Restricting fuel supply 4 Plugged fuel tank vent 5 Low fuel supply 6 Clogged fuel filter 7 Low grade of fuel or water in the fuel 8 Obstructed or kinked fuel lines 9 Injectors not functioning properly 9 Refer to SECTION 5C and or 5E for EDI Diagnosis 10 Engine overheating 10 Refer to Engine Overheats 11 Low compression 11 Worn valves rings cylinders etc 12 Re...

Page 120: ... boat for proper operating rpm at wide open throttle 4 Clogged air cleaner 5 Engine compartment sealed too tight 5 Not enough air for engine to operate properly 6 Boat bottom 6 Dirty marine growth hook rocker 7 Turbocharger malfunction 8 Improper fuel 9 Crankcase ventilation system not working 10 Engine operating too hot or too cold 11 Plugged or restricted exhaust 12 Engine 12 Low compression 13 ...

Page 121: ...verload 2 Restricted air cleaner and or intercooler 3 Excessive fuel delivery 3 Refer to SECTION 5E for EDI diagnosis 4 Faulty injector s 4 Refer to SECTION 5C and or 5E for EDI diagnosis 5 Restricted or plugged exhaust 6 Insufficient coolant temperature 7 Excessive idle time injector coking 9 Leaking head gaskets 10 Worn piston rings ...

Page 122: ...askets White Smoke Cause Special Information 1 Injection pump timing incorrect 1 Refer to SECTION 5D 2 Faulty injector s 2 Refer to SECTION 5C 3 Low compression 4 Plugged fuel suction line or filter 5 Air leaks suction side fuel line or water separating fuel filter 6 Questionable fuel quality 6 Low cetane 7 Restricted fuel return excessive return line pressure 8 Leaking head gaskets 9 Inoperative ...

Page 123: ...7 Exhaust Gas Temperature High Cause Special Information 1 Excessive load 2 Injection pump timing incorrect 2 Refer to SECTION 5D 3 Faulty wastegate device Low Cause Special Information 1 Injection pump timing incorrect 1 Refer to SECTION 5D 2 Excessive idling time light loads ...

Page 124: ... air cleaner C Boost pressure too low D Poor lubrication of turbocharger E Defective wastegate valve F Rubbing of compressor or turbine impellers against housing G Defective engine gaskets allowing air or fuel escape into exhaust or intake system 3 Unusual noises and vibrations at turbocharger 3 A Poor lubrication of turbocharger B Rubbing of compressor or turbine impellers against housing C Defec...

Page 125: ...ised 3 Try to isolate the noise to location in engine front to back top to bottom This can help determine which components are at fault 4 Sometimes noises can be caused by moving parts coming in contact with other components Examples are flywheel or coupler exhaust flappers rattling against exhaust pipe crankshaft striking pan pan baffle or dipstick tube rocker arm striking valve cover and loose f...

Page 126: ... lifter C Worn rocker arm D Bent push rod E Worn camshaft F Sticking valve Cylinder Area Location Possible Causes 1 Cylinder area may be confined to one cylinder or found in more than one cylinder timed to engine speed 1 A Sticking valve B Carbon build up C Connecting rod installed wrong D Bent connecting rod E Piston F Piston rings G Piston pin H Cylinder worn 2 Engine knocking 2 A Faulty injecto...

Page 127: ...ction pump C Fuel pump D Valve lifter camshaft wear E Cam bearings 2 Camshaft area center of engine timed to engine speed 2 A Fuel pump B Valve lifter camshaft wear C Cam bearings 3 Camshaft area rear of engine timed to engine speed 3 A Valve lifter camshaft wear B Cam bearings 4 Camshaft area throughout engine timed to engine speed 4 A Loss of oil pressure B Valve lifter camshaft wear C Cam beari...

Page 128: ...bearing D Main bearing 2 Crankshaft area center of engine timed to engine speed 2 A Crankshaft striking pan or pan baffle B Rod bearing C Main bearing 3 Crankshaft area rear of engine timed to engine speed 3 A Loose flywheel cover B Loose coupler or drive plate C Loose flywheel D Rod bearing E Main bearing 4 Crankshaft area throughout engine timed to engine speed 4 A Loss of oil pressure B Rod bea...

Page 129: ...ressure gauge in the boat 2 Check engine oil level with boat at rest in the water 2 Oil level should be between the ADD and FULL marks 3 Oil level in crankcase above FULL mark 3 May cause loss of engine rpm oil pressure gauge fluctuation drop in oil pressure and hydraulic valve lifter noise at high rpm 4 Oil level in crankcase below ADD mark 4 Low oil pressure oil pressure gauge fluctuation intern...

Page 130: ...ly The reason for the drop in oil pressure is that engine heat causes an expansion of the internal tolerances in the engine and also the oil will thin out somewhat from heat 7 Low engine oil pressure at idle after running at a high rpm 7 Refer to Number 5 and 6 preceding 8 Boats with dual engines 8 It is not uncommon to see different oil pressure readings between the two engines as long as both en...

Page 131: ...parts in oil pump air leak on suction side of oil pump or pickup oil tube 5 Oil leak can be internal or external 5 Oil passage plugs leaking cracked or porous cylinder block 6 Excessive bearing clearance 6 Cam bearings main bearings rod bearings High Oil Pressure IMPORTANT Oil pressure slightly higher than normal does not always indicate a problem Oil viscosity and weather conditions could cause h...

Page 132: ...e run engine with clean white paper on bilge floor locate oil leak s 3 Oil too thin 3 Oil diluted or wrong viscosity 4 Oil level too high 5 Drain holes in cylinder head plugged 5 Oil will flood valve guides 6 Defective valve stem seals if equipped 7 Worn valve stems or valve guides 8 Defective oil cooler if equipped 8 Crack in cooler tubes 9 Defective piston rings 9 Glazed scuffed worn stuck impro...

Page 133: ... environmental conditions If water is contained to cylinder s only it is usually entering through the intake system exhaust system or head gasket If the water is contained to crankcase only it is usually caused by a cracked or porous block a flooded bilge or condensation If the water is located in both the cylinder s and the crankcase it is usually caused by water in the cylinders getting past the...

Page 134: ... Improper engine or exhaust hose installation 3 Refer to exhaust specifications 4 Cracked exhaust manifold 5 Improper manifold to elbow gasket installation 6 Loose cylinder head bolts 7 Blown cylinder head gasket 7 Check for warped cylinder head or cylinder block 8 Cracked and leaking intercooler 8 Defective O rings or tubes 9 Porous or cracked casting 9 Check cylinder heads valve bridge cylinder ...

Page 135: ...lt 5 Clogged or improperly installed sea strainer 6 Loose hose connections between seawater pickup and seawater pump inlet 6 Pump will suck air pump may fail to prime or will force air bubbles into cooling system 7 Seawater inlet hose kinked or collapsed 7 Inlet hose must be wire reinforced to prevent collapsing and positioned to prevent kinks or restrictions 8 Seawater pickup clogged 9 Obstructio...

Page 136: ... Also refer to Engine Overheats Mechanical Mechanical Cause Special Information 1 Engine rpm below specifications at wide open throttle engine laboring 1 Damaged or wrong propeller growth on boat bottom false bottom full of water 2 Incorrect injection pump timing 2 Injection pump timing too far advanced or retarded 3 Seawater pump impeller slipping 4 Exhaust restriction 5 Valve timing off 5 Jumped...

Page 137: ...ring helm 5 Cable or helm partially frozen from corrosion or rust cable over lubricated improper cable installation 6 Binding in sterndrive unit 6 Refer to appropriate Mercury MerCruiser Sterndrive Service Manual 7 Restriction in hydraulic hoses 7 Causes a loss of pressure 8 Control valve not positioned properly not balanced properly or the mounting nut is loose 9 Mounting bracket adjusting screw ...

Page 138: ...ages 6 Stop nut adjusted improperly 6 Refer to appropriate Mercury Mer Cruiser Sterndrive Service Manual 7 Steering cables installed that do not meet ABYC standards 7 Refer to appropriate Mercury MerCruiser Sterndrive Service Manual Fluid Leaks Cause Special Information 1 Loose hose connections 1 Refer to SECTION 9A for bleeding instructions 2 Damaged hose 3 Oil leaking from top of pump 3 System o...

Page 139: ...gged or improperly installed sea strainer 4 Loose hose connections between seawater pickup and seawater pump inlet 4 Pump will draw in air pump may fail to prime or will force air bubbles into cooling system 5 Seawater inlet hose kinked or plugged 6 Seawater pickup plugged 7 Obstruction on boat bottom causing water turbulence 7 Obstruction will be in front of seawater pickup causing air bubbles to...

Page 140: ...o Number 7 2 Gears are shifted sluggishly 2 Lever travel of remote control is too short lever shift just short of minimum traveling distance 2 Lift remote control off if gears can be shifted by hand correct remote control 3 Clutch is slipping propeller speed too low as compared to engine speed 3 A Incorrect fluid used 3 A Drain and refill with correct fluid flush transmission while engine runs in ...

Page 141: ...ft B Disassemble transmission and input shaft replace bearing C Dished discs due to over heating of slipping clutch C Refer to Number 3 6 Shifting pressure too low 6 A Fluid filter dirty 6 A Replace fluid filter B Fluid level in transmission is too low B Fill with fluid check for fluid loss transmission cooler and pipelines lines for leaks also refer to steps Number 10 to Number 13 C Fluid pump is...

Page 142: ...ion B Refill with fluid C Fluid filter is dirty C Replace fluid filter D Fluid level in transmission is too low D Fill with fluid check for fluid loss in transmission cooler and pipelines lines for leaks also refer to steps 10 to 13 E Fluid pump is worn out E Replace control block together with fluid pump F Fitting key in input shaft for fluid pump drive is broken F Remove control block Replace fi...

Page 143: ... rings in input shaft Check control block and replace if damaged from faulty piston rings E Clutch is slipping E Refer to Number 3 F Clutch does not open completely due to worn clutch discs F Dismount transmission replace inner disc all faulty parts G Clutch does not open completely due to broken clutch cup springs G Disassemble transmission replace inner disc support and or clutch H Low water flo...

Page 144: ...ather B Shaft seal faulty B Disassemble transmission replace seal If seal location on input shaft is worn repair surface 12 Fluid leakage at venting filter 12 A Excessive fluid in transmission 12 A Pump out excessive fluid with commercial hand pump 13 Fluid leakage at joints or screw connections 13 A Bolts are not tight 13 A Tighten bolts to specified torque B Seals on bolts have been reused sever...

Page 145: ...ssion replace bearings concerned and other faulty parts D Beginning damage of gearings torsional vibrations running without fluid overload D Disassemble transmission remove faulty parts E Fluid baffle on transmission has come loose E Disassemble transmission attach baffle plate F Fluid suction pipe in transmission has come loose F Disassemble transmission fix fluid suction pipe 16 Chattering trans...

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Page 147: ...s Table of Contents 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 ...

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Page 149: ...ttle Cable End Guide Attaching Nut Tighten Nut Until It Contacts Flat Washer then Loosen Nut 1 2 Turn Remote Control Throttle and Shift Cable Barrel Attaching Nut Securely Rear Engine Mounts 51 37 Power Steering Fluid Hose Fittings at Control Valve 31 23 Sterndrive Unit Fasteners 68 50 Transom Assembly Fasteners 31 23 Seawater Pickup Inlet Fitting On Gimbal Housing 5 45 Drive Unit Gear Lube 90 Deg...

Page 150: ... prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant 7 Disconnect battery cables from battery 8 Disconnect battery cables from engine 9 Remove engine cover IMPORTANT Sterndrive unit must be removed prior to engine removal Refer to appropriate Mercury MerCruiser Sterndrive Service Manual 10 Remove sterndrive unit 11 Disconnect ex...

Page 151: ...ntaneously ignite and result in a fire hazard which could cause serious bodily injury or death 14 Close fuel shut off valve if equipped 15 Disconnect and suitably plug fuel lines to prevent fuel in tank from leaking into bilge 16 Disconnect throttle cable from engine NOTE After wires are disconnected be sure to loosen them from clamps or tie straps retaining them to engine or hoses 17 Disconnect t...

Page 152: ...at are connected to engine 25 Disconnect and suitably plug fluid hoses from power steering control valve on transom CAUTION DO NOT allow lifting sling to hook or compress engine components or damage will occur 26 Support engine with suitable sling through lifting eyes on engine 75298 c 78417 c b a Typical f Front Lifting Eye g Rear Lifting Eye h Suitable Sling 27 Remove front and rear engine mount...

Page 153: ... Ensure front mount adjusting nuts are positioned midway on studs so that adequate up and down adjustment exists for engine alignment 3 Lubricate coupler splines with Engine Coupler Spline Grease 75592 a Typical a Coupler Splines 4 Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended Refer to Removal for location of engine lifting eyes 5 Lift engine i...

Page 154: ...haust system DO NOT relieve hoist tension 22032 74298 IMPORTANT Engine attaching hardware must be installed in sequence shown 7 Install both rear engine mounting bolts and hardware as shown Torque to 47 54 Nm 35 40 lb ft 22032 a b c d e f g h a Rear Engine Mount b Inner Transom Plate Mount c Bolt d Washer e Spacer f Fiber Washer g Double Wound Lockwasher h Locknut Not Shown ...

Page 155: ...g can be crushed causing difficult or improper shifting 8 Set engine on stringers 9 Relieve hoist tension and disconnect sling from engine lifting eyes 10 Install a separate sling between front lifting eyes to help equalize load on hoist during alignment procedure 75331 a b a Sling In Starboard Lifting Eye b Sling In Port Lifting Eye 11 Attach a suitable hoist to the separate sling ...

Page 156: ...N To avoid damage to gimbal bearing engine coupler or alignment tool Do NOT attempt to force alignment tool Do NOT raise or lower engine with alignment tool inserted or partially inserted in gimbal bearing or engine coupler 12 Attempt to insert the solid end of the alignment tool through the gimbal bearing and into the engine coupler splines 70013 a b a a Alignment Tool Use Only Recommended Quicks...

Page 157: ... diameter of mount trunion MUST NOT extend over 19 mm 3 4 in from edge of mount bracket to centerline of mount stud b To Move Engine Left or Right Loosen trunion clamping bolts on both front mounts and move engine as necessary Do NOT over extend mount trunion Retighten locking nuts NOTE A small amount of side to side adjustment can be obtained from the slots on the engine mount pads 23161 g b c a ...

Page 158: ...O FINGERS all the way into and out of engine coupler splines Do not check by turning NOTE This may require tapping the sides of the tool Do NOT check by turning By greasing the splines you can identify which side has interference 71463 b c a 70013 76921 a Alignment Tool b Gimbal Bearing c Engine Coupler 15 Front engine mounts must rest on boat stringer Adjust front engine mounts if necessary 16 Re...

Page 159: ...ten ECM mounting bracket and front mount assembly to boat stringer using appropriate hardware lag bolts or through bolts etc 75301 a b c d a ECM Assembly Mounting Bracket b Front Port Engine Mount c Stringer d Slotted Hole For Raising Or Lowering ECM Assembly 18 Tighten both front mounts onto boat stringers using appropriate hardware 19 Recheck alignment with alignment tool Tool must enter coupler...

Page 160: ...ortion of mount with Perfect Seal if used in a saltwater environment to reduce rust and ease of serviceability 23161 a b c d e f g Typical a Locknut b Bracket c Mount Adjustment Nut d Lag Bolts e Clamp f Nuts g Clamp Spread Screw 21 Remove alignment tool 22 Remove chain sling from lifting eyes 23 Install sterndrive unit Refer to appropriate Mercury MerCruiser Sterndrive Service Manual ...

Page 161: ...ontrol valve as shown IMPORTANT Make hydraulic connections as quickly as possible to prevent oil leakage IMPORTANT Be careful not to cross thread or overtighten hose fittings 74045 74249 a b a Rear Fitting Pressure Hose b Front Fitting Return Hose 2 Tighten exhaust tube hose clamps securely 74298 a b Typical a Exhaust Tube b Hose Clamps 4 ...

Page 162: ...t attach any accessory ground wires to transom plate ground point 73567 a b c a Flywheel Housing Screw b Continuity Circuit Wire c Inner Transom Plate Grounding Screw 4 Connect any grounding wires and accessories that were connected to engine 5 Connect seawater inlet hose to engine water inlet fitting Tighten hose clamp securely 75299 a b Typical a Seawater Inlet Hose b Connector Fitting ...

Page 163: ...mp 7 Connect MerCathode wires to MerCathode controller mounted on engine Apply a thin coat of Liquid Neoprene to ALL electrical connections 71709 e 22232 a b c d a ORANGE Wire From Electrode On Transom Assembly b RED PURPLE Wire Connect other end To Positive Battery Terminal c BLACK Wire From Engine Harness d BROWN Wire From Electrode On Transom Assembly e Controller Assembly Location ...

Page 164: ...K BLK BLK a b a From Engine Harness b From Gimbal Housing 9 Mount the gear lube monitor in the engine bracket Secure with strap 10 Connect gear lube monitor wires to corresponding engine harness wires The TAN BLU wire connects to ORANGE engine harness wire BLACK wire connects to BLACK wire Ensure that bullet connectors are fully seated 75301 a b c Typical a Gear Lube Monitor b Strap c Bullet Conne...

Page 165: ...connector on side of electrical box 75301 75333 75337 e a b c f a b c d Standard And 21 Pin Deutscht Connections a Extension Harness From Instruments b Engine Harness and Connector End c Connector Collar d Location of Electrical Box e Electrical Box With Standard Connectors f Electrical Box With 21 Pin Deutscht Connector 12 After all wires are connected secure them with clamps or tie straps which ...

Page 166: ...while working on fuel system components Wipe up any spilled fuel imme diately Do NOT allow fuel to come into contact with any hot surface which may cause it to ignite 13 Connect flexible fuel line to inlet fitting on fuel pump Secure with hose clamp 75298 a b c a Fuel Line b Hose Clamp c Inlet Fitting 14 Connect flexible return fuel line to injection pump return line fitting Secure with hose clamp...

Page 167: ...TANT When installing throttle cables be sure that cables are routed in such a way as to avoid sharp bends and or contact with moving parts Do NOT fasten any items to throttle cables 1 Unless previously installed install throttle cable end guide anchor stud in middle hole of throttle position sensor lever 75301 a b a Throttle Position Sensor b Throttle Cable End Guide Anchor Stud Location 2 Place r...

Page 168: ... they bottom and loosen 1 2 turn a c b 75332 e d a d a Throttle Cable End Guide b Cable Barrel c Anchor Stud d Flat Washer and Locknut e Spacer If Required 8 Place remote control lever in full forward wide open throttle WOT position 9 Check to ensure throttle position sensor lever is contacting internal override spring Be certain that the cable is not causing the throttle position sensor to be ove...

Page 169: ...control lever is placed in FORWARD remote control is setup for RIGHT HAND RH propeller rotation b All Bravo One Two If shift cable end guide moves in direction B when control lever is placed in FORWARD remote control is setup for LEFT HAND LH propeller rotation 71656 A B All Bravo One Two c All Bravo Three Front propeller on drive unit is always LH Rotation and rear propeller is always RH Rotation...

Page 170: ...te control instructions 3 Loosen stud and move it to dimension as shown Re tighten stud 23345 a b a Stud b 76 mm 3 in Center of Pivot Bolt to Center of Stud 4 Install drive unit shift cable Tighten locknut until it contacts end guide then loosen 1 2 turn Insert cotter pin from the top and spread both ends 23345 a b c a Washers 2 b Locknut c Cotter Pin ...

Page 171: ...o NEUTRAL b Push in on shift cable end with enough pressure to remove play and mark position a on tube c Pull out on shift cable end with enough pressure to remove play and mark position b on tube d Measure distance between marks a and b and mark position c half way between marks a and b 22024 a b c c IMPORTANT Be sure to keep center mark c aligned with remote control shift cable end guide edge wh...

Page 172: ...om stud without first removing end guide anchor pin from shift lever and removing cable Attempting to bend shift cable to install or remove barrel will place undue stress on cable end guide and shift lever and damage to both could occur c Remove shift cable end guide from shift lever by removing anchor pin 23242 a b c e d a Remote Control Shift Cable End Guide b Anchor Pin c Backlash Center d Remo...

Page 173: ...ation All Bravo One And Two Models Forward slot in tool should fit over shift lever stud If slot does not fit over stud loosen shift lever stud and slide stud either direction until slot in tool fits over stud When adjustment is correct retighten stud 23242 a b c d RH Rotation All Bravo One Two Three 23242 d a b c LH Rotation All Bravo One And Two a Adjustment Tool b Barrel Retainer c Shift Lever ...

Page 174: ...gh clearance to operate This is necessary because the cables move up and down when the shift handle is moved If the control box is mounted too far back towards any fiberglass structure the cables will be interfered with this will cause very hard shifting NOTE The control box housing can be rotated in 30 increments to improve cable routing 74688 74689 Proper Cable Bend Improper Cable Bend 2 Ensure ...

Page 175: ... when the control box is installed in the side panel The cables must have room to move up and down when the control handle is shifted into either forward or reverse 7 Check to make sure that the engine was not set down on the intermediate shift cable during installation this will crush the inner cable tubing and cause improper and or stiff shifting 8 Do NOT fasten the shift cable with straps or cl...

Page 176: ...battery cables are connected apply a thin coat of Liquid Neoprene to the terminals c Be sure to slide rubber boot over the positive terminal after Liquid Neoprene dries 2 Connect battery cables to battery by FIRST connecting positive battery cable usually red to positive battery terminal Tighten clamp securely Then connect negative battery cable usually black to negative battery terminal Tighten c...

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Page 179: ...ble of Contents 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 180: ...INBOARD MIE MODELS SERVICE MANUAL NUMBER 22 Page 2B 2 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 181: ...lock 75 55 Transmission Mount Bracket to Transmission Housing 75 55 Rear Engine Mount Rubber Bushing Center Bolt 61 45 Engine Mount Locking Jam Nuts 80 59 Transmission Output Flange to Propeller Shaft Coupler Bolts 68 50 Remote Control Throttle and Shift Cable Barrel Attaching Nut Securely Remote Control Throttle and Shift Cable End Guide Attaching Nut Tighten Nut Until It Contacts Flat Washer the...

Page 182: ... which can cause serious bodily injury or death WARNING Be careful when working on fuel system components diesel fuel is flammable Ensure that the ignition key is OFF Do NOT smoke or allow sources of open flame in the area while changing fuel system components Wipe up any spilled fuel immediately Do NOT allow fuel to come into contact with any hot surface which may cause it to ignite WARNING Dispo...

Page 183: ... seawater inlet hose to prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses 11 Disconnect seawater inlet hose 12 Disconnect exhaust system hoses 13 Disconnect any grounding wires and accessories that are connected to engine 14 Disconnect coolant recovery bottle hose from heat exchanger 15 Disconnect propeller shaft coupler from transmission out...

Page 184: ...cur 16 Support engine with suitable sling through lifting eyes on engine 75298 c 71706 c b a Typical e Front Lifting Eye f Rear Lifting Eye g Suitable Sling 17 Remove front and rear engine mounting bolts Retain fasteners b b 75301 23161 a a Typical Front Mounts Shown All Similar a Starboard Mounting Bolt b Port Mounting Bolt 18 Carefully remove engine with transmission ...

Page 185: ...st be adjusted as explained in the following to center mount adjustment and establish a uniform height on all mounts Ensure that a All mounts are in the center of their up and down adjustment b Large diameter of mount trunnion extended no more than 19 mm 3 4 in c Each mount base is downward Tighten clamping screws and nuts slightly to prevent moving in or out Mounts must be free to pivot when inst...

Page 186: ...izontally If necessary loosen center bolt and turn bushing Torque to 41 61 Nm 30 45 lb ft 50688 a b c a Rubber Bushing b Slots c Bolt 3 Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended Refer to Removal for location of engine lifting eyes CAUTION Do NOT allow lifting sling to hook or compress engine components or damage will occur ...

Page 187: ...adjust engine position at this time IMPORTANT Engine bed must position engine so that a minimum of 6 mm 1 4 in up and down adjustment still exists on all 4 mounts after performing initial alignment This is necessary to allow for final engine alignment 74546 a b c Typical Transmission Shown a Propeller Shaft b Propeller Shaft Coupler c Transmission Output Flange 2 Ensure that all four mounts are st...

Page 188: ...ents to adjust engine position at this time IMPORTANT Engine bed must position engine so that a minimum of 6 mm 1 4 in up and down adjustment still exists on all 4 mounts after performing final alignment This is necessary to allow for final engine alignment 75534 a d c b Velvet Drive 50608 50608 a b c d c Hurth 630V a Propeller Shaft b Propeller Shaft Coupler c Transmission Output Flange d No Gap ...

Page 189: ...e parallel within 0 07 mm 0 003 in This applies to installations with solid couplings as well as flexible couplings 1 Ensure that mating surfaces on transmission output flange and propeller shaft coupler faces are clean and flat 2 Center propeller shaft in shaft log as follows a Push down and then lift shaft as far as it will move Then place shaft in the middle of the movement b Move shaft to port...

Page 190: ... flange Shoulder on propeller shaft coupler should engage recess on transmission output flange face with no resistance 72597 INCORRECT CORRECT INCORRECT NOTE Some propeller shaft couplers may not have a shoulder on mating face On these installations use a straight edge to check centerline alignment 72598 c b a d a Feeler Gauge b Transmission Coupling c Propeller Shaft d Straight Edge ...

Page 191: ...eller Shaft Coupler b Feeler Gauge c Transmission Output Flange d Check Point Intervals 5 If coupling centerlines are not aligned or if coupling faces are more than 0 07 mm 0 003 in out of parallel adjust engine mounts as follows a TO ADJUST ENGINE UP OR DOWN Loosen locking nut on mounts requiring adjustment and turn both front mount or rear mount adjusting nuts equally IMPORTANT Both front mount ...

Page 192: ... nuts to 68 Nm 50 lb ft NOTE A small amount of side to side adjustment can also be obtained from the slots on the engine mount pad front pads only Loosen lag bolts which fasten mounts to engine bed and move engine as required Tighten lag bolts securely IMPORTANT Large diameter of mount trunnion MUST NOT extend over 19 mm 3 4 in from mount brackets on any of the mounts 50687 a b 50687 a b Front Mou...

Page 193: ...cket holes directly over front port engine mount holes NOTE It may be necessary to lower or raise the ECM assembly and bracket depending upon the final configuration of the power package to position ECM on front mount 2 Fasten ECM mounting bracket and front mount assembly to boat stringer using appropriate hardware lag bolts or thru bolts etc 75301 a b c d a ECM Assembly Mounting Bracket b Front P...

Page 194: ...ic Grade 10 9 SAE Grade 8 or better with a shoulder grip length sufficient to pass through the mating face plane of couplers a All Couplings Without Propeller Shaft Set Screws Secure coupling together with bolts lockwashers and nuts Torque to 68 Nm 50 lb ft 50687 a b c d Hurth 8 Degree Down Angle Transmission Shown All Similar a Propeller Shaft Coupler b Bolts 4 c Lockwasher and Nut 4 d Transmissi...

Page 195: ...l Similar a Set Screw Location b Transfer Punch 2 Remove propeller shaft coupler and drill shallow dimples at locations marked with punch 3 Reinstall propeller shaft coupler and torque bolts to 68 Nm 50 lb ft Install set screws and tighten securely Safety wire set screws to ensure they Do NOT back out 50608 a b c d e Hurth V Drive Shown All Similar a Propeller Shaft Couple b Bolts 4 with Lockwashe...

Page 196: ...h hot spots on engine and avoid contact with moving parts 1 Connect instrument extension harness ends to engine harness ends Connector collar must be fully engaged and secure Tighten threaded connector collar of extension harness onto connector on side of electrical box 75301 75333 75337 e a b c f a b c d Harness Connections a Extension Harness From Instruments b Engine Harness and Connector End c...

Page 197: ... any hot surface which may cause it to ignite 3 Connect flexible fuel line to inlet fitting on fuel pump Secure with hose clamp 75298 a b c d a Fuel Line b Hose Clamp c Inlet Fitting d Fuel Pump 4 Connect flexible return fuel line to injection pump fuel return line fitting Secure with hose clamp 75579 a b c a Return Fuel Line b Return Fitting c Hose Clamp WARNING Dispose of fuel soaked rags paper ...

Page 198: ...ter lift muffler if equipped to exhaust system hose using at least two hose clamps at each connection Tighten hose clamps securely 7 Connect seawater inlet hose to seawater pump connector fitting Tighten hose clamp securely 75299 a b Typical a Seawater Inlet Hose b Connector Fitting 8 If removed previously connect seawater inlet hose to seawater strainer and tighten hose clamps securely 71362 a b ...

Page 199: ...ter solenoid terminal are free of paint and any other material that could cause a poor electrical connection b After battery cables are connected apply a thin coat of liquid neoprene to the terminals c Slide rubber boot over the positive terminal after liquid neoprene dries 2 Connect battery cables to battery by FIRST connecting positive battery cable usually red to positive battery terminal Tight...

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Page 201: ...ce 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 Installat...

Page 202: ...Installation 3A 105 Connecting Rod Piston Assembly 3A 106 Measuring Rod Bearing Clearance 3A 106 Removal 3A 107 Disassembly 3A 108 Cleaning 3A 109 Inspection 3A 109 Assembly 3A 113 Installation 3A 114 Rear Oil Seal 3A 116 Removal 3A 116 Installation 3A 117 Crankshaft and Main Bearings 3A 118 Removal 3A 118 Cleaning 3A 123 Inspection 3A 124 Installation 3A 127 Cylinder Liners 3A 136 Removal 3A 136 ...

Page 203: ...E INC MADE IN ITALY SERIAL NUMBER MAX RPM H P L B K W K G a Typical Sterndrive MCM Engine Shown Inboard MIE Similar a Serial Number Plate b Manufacturer s Serial Number The engine model and serial numbers are located on a sticker attached to the port side of the engine The manufacturer s serial number is stamped in the cylinder block ...

Page 204: ...lock M10x1 5 50 37 Rear Main Bearing Carrier Nut M8x1 25 27 5 20 Rear Portion M10x1 5 50 37 Flywheel 2 M12x1 25 110 81 Glow Plug 23 17 Idler Gear Mounting Screw M 8 x 1 25 27 5 20 1 Along with the application of conventional torque all D2 8L D Tronic and D4 2L D Tronic diesel engines will require cylinder head torque with a suitable wrench using a Torque Angle Gauge obtain locally Refer to Late Mo...

Page 205: ... Pan Screws M6x1 0 12 7 112 Oil Pressure Relief Valve Assembly 53 9 39 Oil Pump Screw M8x1 25 27 5 20 Oil Pick up Tube Screw 11 97 Oil Adapter Thermostat Housing Fitting 60 44 Power Steering Pump Mounting Bolt 21 15 Rocker Arm Support Flanged Nut M8x1 25 34 25 Timing Gear Cover M6x1 0 10 8 95 M8 10 8 95 Valve Cover M6x1 0 11 5 101 Vibration Damper Balancer M10x1 5 83 4 61 Water Manifold M6x1 0 11 ...

Page 206: ...502 Dial Indicator 91 58222A1 Flywheel Holder 91 801333506 Flywheel Seal Installer 91 801111260 Front Main Bearing and Camshaft Bearing Puller 91 801333508 Injection Pump Adaptor Tool 1 91 854220 Injection Pump Gear Puller 1 91 818372 Liner Gauge Bar Metric 2 91 801333509 Liner Gauge Bar SAE 3 91 814812A1 Graduated Disc Timing 4 91 801333500 Piston Ring Expander 91 24697 Support Block 91 814812A1 ...

Page 207: ...ification of this tool NOTE The 12 mm Triple Square special tool for cylinder head torque can be modified to allow the oil feed line to the rocker arms to remain installed during retorque of the cylinder heads 76067 a b d e f g h i k j c a 12 Point Triple Square b Modified Area c 12 8 mm 0 50 in Across Flats Hex d 12 8 mm 0 50 in e 11 9 mm 0 47 in f 37 6 mm 1 48 in g 66 6 mm 2 62 in h 24 4 mm 0 96...

Page 208: ...141 See Snap On Catalog for your regions distributor phone number Description Part Number Compression Gauge MT33B Torque Angle Gauge Degree Wheel Torquing TA360 Kent Moore Tools Kent Moore Tools Inc 29784 Little Mack Roseville MI 48066 Phone 313 774 9500 Description Part Number Valve Spring Compressor J 8062 Piston Ring Compressor J 8307 ...

Page 209: ...Y 2002 Page 3A 9 Lubricants Sealants Adhesives Description Part Number Loctite Master Gasket 92 12564 2 Loctite 271 Thread Locker 92 809819 Needle Bearing Assembly Lubricant 92 802868A1 Loctite 242 Loctite 620 Molykote Obtain Locally SAE 30W Engine Oil Loctite 290 ...

Page 210: ...ered 3 0 1181 Ring Thickness 2nd Compression 1 978 1 99 0779 0783 Oil Control 3 978 3 990 1566 1570 1st Compression 0 25 0 50 010 020 End Gap 2nd Compression 0 25 0 45 0098 0177 Oil Control 0 25 0 58 0098 0228 Ring to 1st Compression Not applicable Tapered Ring to Groove 2nd Compression 0 070 0 102 0027 0040 Clearance Oil Control 0 040 0 075 0016 0029 Cylinder Liner Diameter NOTE Measurements are ...

Page 211: ...d Gaskets IMPORTANT When replacing head gaskets observe the following If replacing only one head gasket use the same size gasket as was removed All head gaskets must be the same size on the same engine Piston Protrusion Above Cylinder Block Gasket Size To Be Used 0 63 0 74 024 029 1 42 0 56 0 73 0 82 028 032 1 52 0 60 0 83 0 92 031 037 1 62 0 64 Cylinder Head Description Measurement Height 89 95 9...

Page 212: ...d Gear Axial 0059 0098 0 15 0 25 Camshaft Description Measurement Exhaust 7 303 287 Lobe Lift Intake 7 019 276 Front 53 495 53 510 2 1061 2 1066 Journal Diameter Center 53 450 53 470 2 1043 2 1051 Rear 53 480 53 500 2 1055 2 1062 Front 0 030 0 095 0011 0037 Bearing Clear Center 0 070 0 140 0027 0055 ances Rear 0 040 0 110 0015 0043 Camshaft Thrust Plate Thickness 3 95 4 05 155 159 Valve Lifter Des...

Page 213: ...ydraulically Controlled Valve Valve Exhaust Intake Head Diameter 38 1 49 40 9 1 61 Stem Diameter 7 93 3122 7 95 3129 Face Width 2 64 2 99 1039 1177 3 57 3 85 1405 1515 Margin New 1 73 068 1 82 071 Margin After Grinding 1 30 051 Face Angle New 44 degrees 30 minutes 29 degrees 30 minutes Valve Seat Valve Exhaust Intake Seat Angle 45 degrees 30 degrees Seat Width 2 00 078 3 25 127 Seat Outer Diameter...

Page 214: ...REMENT mm in Valve Guide Valve Guide Exhaust Intake Maximum Clearance 0 093 0036 0 073 0028 Height Above Spring Counterbore 7 921 7 939 311 312 7 940 7 960 312 313 Valve Spring Valve Spring Height Pressure Free Standing 44 65 1 757 0 0 kg 0 lb Valve Closed 38 60 1 460 32 36 kg 71 79 lb Valve Open 28 20 1 110 92 5 96 2 kg 204 212 lb ...

Page 215: ...n Bearing Center 0 030 0 088 0012 0034 Clearance Rear 0 060 0 125 0024 0049 Front 63 060 63 080 2 4827 2 4835 Main Bearing Inside Center 63 050 63 093 2 4822 2 4840 Diameter Rear 70 060 70 110 2 7583 2 7602 Maximum Main Bearing Wear 0 1 0039 Connecting Rod Journal Outside Diameter 53 940 53 955 2 1236 2 1242 Connecting Rod Bearing Clearance 0 030 0 064 0011 0025 Connecting Rod Bearing Inside Diame...

Page 216: ... 005 2 479 2 4805 Main Journal Outside Center 63 005 63 020 2 4805 2 4810 Diameter Rear 79 985 80 000 3 1490 3 1496 Front 0 055 0 095 0022 0037 Main Bearing Center 0 030 0 088 0011 0034 Clearance Rear 0 045 085 0 0018 0 0033 Front 63 060 63 080 2 4827 2 4835 Main Bearing Inside Center 63 050 63 093 2 4822 2 4840 Diameter Rear 80 045 80 070 3 1514 3 1524 Maximum Main Bearing Wear 0 1 0039 Connectin...

Page 217: ... Crank Pin Bore Description Measurement Inner Diameter 57 563 57 582 2 2662 2 2670 Maximum Allowable Wear or Taper 0 02 0008 Connecting Rod Bushings Description Measurement Piston Pin Outer Diameter 29 990 29 996 1 1807 1 1809 Connecting Rod Bushing Inner Diame ter 30 035 30 050 1 1824 1 1830 Minimum and Maximum Clearance 0 039 0 060 0015 0023 Pistons Description Measurement Diameter Standard Clas...

Page 218: ...ls w The appropriate heat source should only be electric Heat source should be operated by a qualified person Follow all instructions of the manufacturer of the heat source The heat source should be checked each time it is used to ensure it is functioning properly w The thermometer used in the test should be a high temperature thermometer with a maximum reading of at least 1505 C 3005 F Under no c...

Page 219: ...edures of the cylinder block and cylinder heads only Refer to other sections for disassembly and assembly of various other components IMPORTANT Do NOT use any sealers or adhesives containing silicone Silicone can cause blockage in the cooling heat exchanger systems Engine Rotation NOTE Engine rotation is described when observed from the rear of the engine transmission end looking forward water pum...

Page 220: ...all 14 mm center bolt heads and threads with Molykote Lubricate the underside of all 12 mm side bolt heads and threads with clean engine oil SAE 30 W Position cylinder heads one at a time Install cylinder head end spacers formed spacer washers and bolts Temporarily finger tighten the bolts Hand tighten intake exhaust manifold to cylinder heads to align sides of cylinder heads Then recheck for prop...

Page 221: ... 3 2 1 5 6 7 30 Nm 22 lb ft b Second pass Engine Sequence Torque Angle D2 8L Center Bolts 3 2 1 4 5 8 9 10 7 6 65 Degrees D4 2L Center Bolts 11 12 13 14 10 9 8 4 3 2 1 5 6 7 65 Degrees c Third pass Engine Sequence Torque Angle D2 8L Center Bolts 3 2 1 4 5 8 9 10 7 6 65 Degrees D4 2L Center Bolts 11 12 13 14 10 9 8 4 3 2 1 5 6 7 65 Degrees 4 1 2 3 6 8 9 10 7 5 77114 2 1 5 6 7 8 9 10 11 12 13 14 3 4...

Page 222: ... 18 30 Nm 22 lb ft D4 2L Side Bolts 15 16 17 18 19 20 21 22 23 24 25 26 30 Nm 22 lb ft b Second pass Engine Sequence Torque Angle D2 8L Side Bolts 11 12 13 14 15 16 17 18 85 Degrees D4 2L Side Bolts 15 16 17 18 19 20 21 22 23 24 25 26 85 Degrees 11 12 13 14 15 16 17 18 77114 a 15 16 17 18 19 20 21 22 23 24 25 26 77113 b Side Bolt Torque Sequence Diagram a 4 Cylinder Engine b 6 Cylinder Engine ...

Page 223: ...utes at normal operating temperature 2 Let the engine cool down completely inoperative overnight if possible 3 One at a time loosen each center bolt and torque as indicated a First pass Engine Sequence Torque D2 8L Center Bolts 3 2 1 4 5 8 9 10 7 6 30 Nm 22 lb ft D4 2L Center Bolts 11 12 13 14 10 9 8 4 3 2 1 5 6 7 30 Nm 22 lb ft b Second pass Engine Sequence Torque Angle D2 8L Center Bolts 3 2 1 4...

Page 224: ...lt as indicated Engine Sequence Torque D2 8L Side Bolts 11 12 13 14 15 16 17 18 90 Nm 66 lb ft D4 2L Side Bolts 15 16 17 18 19 20 21 22 23 24 25 26 90 Nm 66 lb ft 15 16 17 18 19 20 21 22 23 24 25 26 77113 11 12 13 14 15 16 17 18 77114 b a Side Bolt Torque Sequence Diagram a D2 8L D Tronic Engine b D4 2L D Tronic Engine ...

Page 225: ...ghten the bolts Hand tighten intake exhaust manifold to cylinder heads to align sides of cylinder heads Then recheck for proper coverage of gaskets TORQUE PROCEDURE DURING ASSEMBLY 1 In sequence torque 14 mm bolts to 30 Nm 22 lb ft Repeat using same specification to ensure better preload 2 In sequence tighten each 14 mm bolt through an angle of 70 degrees 3 In sequence tighten each 14 mm bolt thro...

Page 226: ...ine at 2000 rpm for approximately 20 30 minutes at normal operating temperature 2 Let the engine cool down completely inoperative overnight if possible 3 In sequence and operating on only one bolt at a time loosen each 14 mm center bolt and then retorque to 30 Nm 22 lb ft Continue by tightening the bolt through an angle of 65 degrees and then through ANOTHER 65 degrees 130 degrees total 4 In seque...

Page 227: ...s first IMPORTANT Engine must be have been operated 100 hours or for one operating season whichever occurs first 1 Let engine cool down completely inoperative overnight if possible 2 In sequence and without loosening tighten 14 mm center bolts through an angle of 15 degrees 3 In sequence and without loosening tighten port and starboard 12 mm side bolts through an angle of 15 degrees 2 1 4 5 6 7 8 ...

Page 228: ... 8 9 D4 2L D Tronic Flow Diagram Shown D2 8L D Tronic Similar 1 Oil Pan 2 Oil Pump 3 Pressure Relief Valve 4 Oil Thermostat In Oil Filter Header 5 Oil Filter 6 Engine Oil Cooler Lower Portion of Heat Exchanger Coolant Tank 7 Rocker Arms 8 Camshaft Bearings 9 Piston Oil Jets 10 Crankshaft Main Bearing Carrier and Bearing 11 Turbocharger ...

Page 229: ...ring Failures 70436 a b c d Scratched By Dirt Lack Of Oil Improper Seating a Scratches b Dirt Imbedded Into Bearing Material c Overlay Wiped Out d Bright Polished Sections 70436 c a b Tapered Journal Radius Ride Fatigue Failure a Overlay Gone From Entire Surface b Radius Ride c Craters Or Pockets ...

Page 230: ...or bore and install Compression Tester Adapter Tool 91 881737 3 Torque the injector clamp to 24 Nm 18 lb ft 4 Connect gauge to Compression Adapter Tool and set gauge to zero 5 Ensure that battery is fully charged 6 Operate the starter The engine should be cranking at approximately 300 rpm Check compression gauge reading Compression should be 30 32 bar 435 464 psi Maximum pressure difference betwee...

Page 231: ...5504 a c b a Engine Cover b Retaining Screw and Hardware c Oil Fill Cap Cleaning 1 Clean the cover with warm soapy water 2 Air dry the cover Inspection 1 Inspect engine cover for cracks or deterioration 2 Inspect rubber isolation grommets for deterioration 3 Inspect hardware used with each grommet 4 Replace damaged parts Installation 1 Remove oil filler cap from engine to allow cover to be install...

Page 232: ...Cover b Vent Hose c Oil Fill Cap Extension Tube and Sealing Washer d Engine Cover Support Bar e Electrical Box Support Bracket 6 Remove fuel injectors as follows a Clean the area around the injectors and pipes b Remove injector fuel supply pipes c Remove injector fuel return pipe d Remove securing nut and injector nozzle hold down clamp NOTE To aid in removal of injectors it is sometimes helpful t...

Page 233: ... covers at the same time 8 Using a rubber mallet tap against side of valve cover to loosen 9 Lift the cover or covers from the heads 10 On 6 Cylinder Engines pull valve covers apart Discard the two old O rings on the connector between the valve covers Cleaning IMPORTANT Do NOT drop anything into cylinder head openings 1 Clean gasket material from cylinder heads 2 Remove old gasket material and cle...

Page 234: ...inder heads 3 Position the two longer screws through the electrical support bracket and spacers Install as shown 4 Install remaining screws 5 Torque valve cover screws evenly in a diagonal pattern to 11 5 Nm 101 lb in 6 Install plastic plugs into cylinder head screw holes 7 Install oil fill cap extension tube with sealing washer Tighten tube securely 75102 a b c d e f g h a Gasket b Valve Cover c ...

Page 235: ...maining screws Torque screws evenly in a diagonal pattern to 11 5 Nm 101 lb in 4 Install plastic plugs into cylinder head screw holes 5 Install oil fill cap extension tube with sealing washer on front valve cover as shown Install oil fill cap with sealing washer on aft valve cover Tighten both securely g 75103 b c d e f g h i j k a a c d a O ring b Connector c Gasket d Valve Cover e Screw M6 x 80 ...

Page 236: ...ANUAL NUMBER 22 Page 3A 36 90 860074 1 FEBRUARY 2002 3 Install engine cover support bar Torque screws to 27 5 Nm 20 lb ft 75374 a b c Typical a Vent Hose b Clamp c Engine Cover Support Bar 4 Install engine cover and oil fill cap ...

Page 237: ...g h i D2 8L D Tronic 75108 b d e a d e f h i b c g c D4 2L D Tronic a Hose Clamp b Banjo Bolt and Sealing Washer c Screws with Washers d Water Manifold e Vent Pipe To Turbocharger Fitting f Vent Hose To Heat Exchanger Fitting g Gasket End Cover or Manifold Pieces h Cylinder Head Gaskets i Hose and Clamp To Exhaust Manifold End Cover ...

Page 238: ...d Vent Pipe e Screws With Washers f Water Manifold Assembly 5 Using a rubber mallet tap against side of manifold to loosen Cleaning IMPORTANT Do NOT drop anything into cylinder head openings 1 Discard old sealing washers 2 Clean gasket material from cylinder heads and manifold flanges 3 Clean manifold pieces with solvent and dry with compressed air Inspection 1 Inspect sealing surfaces for deep ni...

Page 239: ...ypical End Cover b Gasket c Straight Edge Device d Bolts 4 Two Not Shown 3 Place new gaskets in position on cylinder heads NOTE A small amount of Loctite Master Gasket can be used to hold gaskets in place 4 Install water manifold while simultaneously positioning the water hose onto rear of manifold Torque screws with washers to 11 8 Nm 104 lb in in a diagonal pattern from centermost to outer ends ...

Page 240: ...L NUMBER 22 Page 3A 40 90 860074 1 FEBRUARY 2002 Cylinder Heads Exploded Views CYLINDER HEAD AND RELATED COMPONENTS 75101 2 1 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 20 75102 A B A B A 75103 21 22 23 24 25 26 27 28 29 30 31 27 ...

Page 241: ...h Depends on Location of Head 15 Plug Depends on Location of Head 16 Valve Cover Stud 17 Rocker Pedestal Stud 18 Rocker Pedestal 19 Rocker Arm 20 Rocker Arm Bushing 21 12 mm Cylinder Head Bolt 1 per head 22 12 mm Cylinder Head Bolt 1 per head 23 14 mm Cylinder Head Bolts 4 per head 24 Formed Spacer Washer Terminal Bridge 1 25 Formed Spacer Washer Terminal Bridge 1 26 Formed Spacer Washers Terminal...

Page 242: ...ition of the rocker arm assemblies and cylinder heads for reassembly 2 Remove rocker arm oil feed line banjo bolts with sealing washers Remove line from cylinder heads and from rear starboard of cylinder block 75103 a b b a Oil Feed Pipe b Banjo Bolts With Sealing Washers 3 Unscrew rocker arm retaining nuts 75387 a a Retaining Nuts 4 Remove the rocker arm assemblies by lifting upward 75511 a b a R...

Page 243: ...rting cylinder heads remove heads only when engine is cold 8 Take note of shape and location of formed spacer washers Starting at one end of the engine remove head bolts 75515 a a D4 2L D Tronic D2 8L D Tronic a Formed Spacer Washers 9 Using a rubber hammer tap on side of cylinder heads to loosen Remove the cylinder heads IMPORTANT Retain fuel Injectors with their original heads to aid in diagnosi...

Page 244: ...inal location 70272 a b 77175 a Typical Valve Spring Compressor b Valve Spring and Related Components Cleaning 1 Clean carbon from valves 2 Being careful not to damage aluminum heads clean all carbon from combustion chambers and valve ports 3 Clean gasket material from cylinder head mating surfaces 4 Thoroughly clean valve guides with valve guide cleaner 5 Wash cylinder head and components in clea...

Page 245: ...t valve springs for discoloration due to excessive heat 6 Inspect valve guides for cracks or chips 7 Inspect valve guide bores for seizure marks carbon deposits or scoring 8 Inspect valve guide height 9 Inspect valve spring keepers retainers and washer for wear distortion or cracks 10 Inspect for melting of aluminum by faulty fuel injectors 11 Inspect rocker arm support journals for scoring 12 Ins...

Page 246: ...ition it against the valve stem and close to the valve guide b While holding the valve head off of the seat by about 2 mm 1 16 in move valve stem back and forth in directions shown Compare stem clearance with specifications 70435 Valve Guide Exhaust Intake Maximum Clearance 0 093 mm 0036 in 0 073 mm 0028 in a b a Intake Valve Guide I D Measurement 7 99 8 00 mm 3145 3149 in b Exhaust Valve Guide I ...

Page 247: ... Surface to Seat 2 05 2 25 mm 080 088 in c Counterbore Inner Diameter Measurement Not Available At Time Of Printing d Seat Outer Diameter 39 mm 1 53 in e Seat Height 7 90 mm 311 in f Seat Width 2 00 mm 078 in g Seat Angle 60 Degrees Intake Valve Seat Specifications a Valve Recession Max 0 03 mm 001 in b Head Surface to Seat 2 17 2 37 mm 085 093 in c Counterbore Inner Diameter Measurement Not Avail...

Page 248: ... D Measurement 7 95 mm 3129 in b Face Width Measurement 3 57 3 85 mm 1405 1515 in c Margin After Grinding Measurement 1 82 mm 071 in d Face Angle 29 Degrees and 30 Minutes e Stem O D Measurement 7 93 mm 3122 in f Face Width Measurement 2 64 2 99 mm 1039 1177 in g Margin After Grinding Measurement 1 30 mm 051 in h Face Angle 44 Degrees and 30 Minutes ...

Page 249: ...the specified limit the valve spring must be replaced a b b a Free Standing Height Measurement 44 65 mm 1 757 in b Distortion Measurement Maximum 2 mm 079 5 64 in 3 Use a spring tester to measure the valve spring height under tension Replace spring if less than specified limit b a Closed Valve a Applied Pressure 32 36 kg 71 79 lb b Height Measurement 38 60 mm 1 460 in a b Open Valve a Applied Pres...

Page 250: ...that valve guide bores be free from carbon or dirt to insure proper centering of pilot in valve guide Machine valve seat angles to the following specifications Valve Seat Machine Angle Intake 30 degrees Exhaust 45 degrees VALVE SEAT REPLACEMENT 1 To replace the seats heat the head in an oven to 150 degrees C 300 degrees F Remove old seat Do NOT damage counterbore CAUTION To avoid distortion or mel...

Page 251: ...ves can be refaced to proper angle on a valve grinder thus insuring correct relation between cylinder head seat and valve mating surface Replace valves with excessive wear on stems or valves which are warped excessively When an excessively warped valve head is refaced a knife edge will be ground on part or all of the valve head due to amount of metal that must be removed to completely reface Knife...

Page 252: ...als over valve stem and push down on the seal until seated securely around top of guide 75386 a b a Valve Stem Seal b Seal Installed On Guide NOTE Grease may be used to hold keepers in place while releasing compressor tool 4 Install plate washer valve spring and retainer on valve stem Using valve spring compressor tool carefully compress spring and insert keepers into valve stem groove 70275 a b c...

Page 253: ...ng Cylinder Head Studs Lengths Vary CAUTION Head gasket thickness is very important on diesel engines If head gaskets are too thin the pistons will hit the valves or heads causing severe damage All head gaskets on one engine must be the same thickness or exhaust manifold and water manifold will not fit correctly When cylinder heads are removed for service but pistons and cylinder liners are not di...

Page 254: ... attached across liner as shown parallel to cylinder centerline 70277 a b c a Liner Gauge Bar b Dial Indicator c Liner 3 Set dial indicator to zero at point shown on cylinder block 75524 a a Dial Indicator Zero Point 4 Move dial indicator to point shown on piston Record measurement 75524 a a Measurement Point 5 Measure all piston heights and use largest reading to determine which gaskets to use fo...

Page 255: ...0 in gasket has two notches while the 1 62 mm 064 in gasket has one notch where indicated The 1 42 mm 056 in gasket is plain without notches 75516 a b c a 1 62 mm 064 in Gasket With One Notch b 1 52 mm 060 in Gasket With Two Notches c 1 42 mm 056 in Gasket Without Notches INSTALLATION 1 Before installing cylinder heads follow instructions a c a Clean out bolt holes in cylinder block Be certain no ...

Page 256: ...ds and underside of bolt heads of all 12 mm cylinder head bolts c Lubricate the threads and underside of bolt heads on all 14 mm cylinder head bolts with Molykote obtain locally d Place all parts on a clean surface or lint free shop cloth IMPORTANT Head gaskets must be installed DRY Do NOT use any sealer on gaskets IMPORTANT Install head gaskets ONLY as shown 3 Ensure head gaskets are installed as...

Page 257: ...HAND tightening 12 mm Cylinder Head Bolts as in the following steps CAUTION The following steps must be carried out properly to prevent misalignment of cylInder heads or head gaskets which could result in failure of the cylinder head gaskets or cylinder heads causing severe engine damage 5 Beginning with cylinder number 1 with gasket facing UP as previously shown install new cylinder head gasket a...

Page 258: ...or each cylinder head and corresponding cylinder proceeding in numerical order from cylinder number 1 8 Install all lubricated 14 mm cylinder head bolts including the proper formed spacer washers terminal bridges three types and cylinder head spacers for ends of first and last cylinder heads as shown in the following 75515 a a a a b b a a a Spacers First and Last Cylinder Head Ends b Formed Spacer...

Page 259: ...ronic 10 Temporarily install intake exhaust manifold without gaskets and FINGER tighten each nut with locking washer 11 Slightly loosen 12 mm and 14 mm bolts as needed to allow cylinder heads to ALIGN as you HAND tighten exhaust manifold nuts 12 HAND TIGHTEN all 14 mm and 12 mm cylinder head bolts in torque sequence 13 In torque sequence tighten 14 mm cylinder head bolts to 30 Nm 22 lb ft Refer to...

Page 260: ...quence Diagrams a D4 2L D Tronic b D2 8L D Tronic 18 Tighten each 14 mm bolt through ANOTHER 70 degrees following the same sequence CAUTION Avoid component or engine failure Cylinder heads require additional angular torque and conventional torque application after the first 20 30 minute run in and then after the first 100 hours or first operating season whichever occurs first 19 Remove exhaust man...

Page 261: ... ft Continue by tightening the bolt through an angle of 65 Degrees and then through ANOTHER 65 Degrees 130 Degrees total 2 In sequence and without loosening check torque on port and starboard 12 mm side bolts to be 90 N m 66 lb ft d Install valve covers CAUTION Avoid component or engine failure Cylinder heads require additional angular torque and conventional torque application after the first 100...

Page 262: ...as required for early model gaskets Description Gasket Thickness in mm D2 8L D Tronic 0 056 1 42 D2 8L D Tronic Serial Number 0L098059 Gasket seals all 4 cylinders 0 060 1 52 And Above 0 064 1 62 Description Gasket Thickness in mm 0 056 1 42 Gasket seals front 3 cylinders 0 060 1 52 D4 2L D Tronic 0 064 1 62 Serial Number 0L098232 And Above 0 056 1 42 And Above Gasket seals rear 3 cylinders 0 060 ...

Page 263: ...cylinder head bolts and washers including all formed spacer washers terminal bridges three types and cylinder head spacers for ends of first and last cylinder heads b Using clean SAE 30W engine oil lubricate the bolt threads and underside of bolt heads of all 12mm cylinder head bolts c Lubricate the threads and underside of bolt heads on all 14mm cylinder head bolts with Molykote obtain locally d ...

Page 264: ...igned 78143 a a b b a a D4 2L D Tronic Guide Pin Locations Shown D2 8L Similar a Guide Pin Bolt Hole Locations Two at each cylinder b Guide Pins Installed 7 Beginning with cylinder number 1 install a cylinder head over the guide pins 8 ONE AT A TIME remove Guide Pins and install the oiled 12mm cylinder head bolts with washers HAND tight Do NOT disturb head placement 9 Using a screwdriver install t...

Page 265: ...nds of first and last cylinder heads as shown in the following 75515 a a a a b b a a a Spacer s First and Last Cylinder Head Ends b Formed Spacer Washers Terminal Bridges Three Types 14 Lightly HAND tighten bolts in torque sequence 75515 2 1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 3 4 4 1 2 3 6 8 9 11 10 12 13 14 7 5 15 16 17 18 a b Torque Sequence Diagrams a D4 2L D Tronic 6 ...

Page 266: ...ily install exhaust manifold without gaskets and FINGER tighten each nut with locking washer 16 Slightly loosen 12 mm and 14 mm bolts as needed to allow cylinder heads to ALIGN as you HAND tighten exhaust manifold nuts 17 HAND TIGHTEN all 14 mm and 12 mm cylinder head bolts in torque sequence ...

Page 267: ...ngle D2 8L Center Bolts 3 2 1 4 5 8 9 10 7 6 65 Degrees D4 2L Center Bolts 11 12 13 14 10 9 8 4 3 2 1 5 6 7 65 Degrees c Third pass Engine Sequence Torque Angle D2 8L Center Bolts 3 2 1 4 5 8 9 10 7 6 65 Degrees D4 2L Center Bolts 11 12 13 14 10 9 8 4 3 2 1 5 6 7 65 Degrees 4 1 2 3 6 8 9 11 10 12 13 14 7 5 15 16 17 18 77114 a b D2 8L D Tronic Torque Sequence Diagram 2 1 5 6 7 8 9 10 11 12 13 14 15...

Page 268: ...19 20 21 22 23 24 25 26 30 Nm 22 lb ft b Second pass Engine Sequence Torque Angle D2 8L Side Bolts 11 12 13 14 15 16 17 18 85 Degrees D4 2L Side Bolts 15 16 17 18 19 20 21 22 23 24 25 26 85 Degrees 4 1 2 3 6 8 9 11 10 12 13 14 7 5 15 16 17 18 77114 a b D2 8L D Tronic Torque Sequence Diagram 2 1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 3 4 77113 a b D4 2L D Tronic Torque Sequenc...

Page 269: ... temperature 2 Let the engine cool down completely inoperative overnight if possible 3 One at a time loosen each center bolt and torque as indicated in a and b a First pass Engine Sequence Torque D2 8L Center Bolts 3 2 1 4 5 8 9 10 7 6 30 NM 22 lb ft D4 2L Center Bolts 11 12 13 14 10 9 8 4 3 2 1 5 6 7 30 NM 22 lb ft b Second pass Engine Sequence Torque Angle D2 8L Center Bolts 3 2 1 4 5 8 9 10 7 6...

Page 270: ...Engine Sequence Torque D2 8L Side Bolts 11 12 13 14 15 16 17 18 90 NM 66 lb ft D4 2L Side Bolts 15 16 17 18 19 20 21 22 23 24 25 26 90 NM 66 lb ft 11 12 13 14 15 16 17 18 77114 a D2 8L D Tronic Side Bolt Torque Sequence Diagram 15 16 17 18 19 20 21 22 23 24 25 26 77113 a D4 2L D Tronic Side Bolt Torque Sequence Diagram a Side Bolt Set ...

Page 271: ... to their position in the engine or label the parts in order for reassembly to the original location Cleaning 1 Wash all parts in cleaning solvent 2 Dry parts with compressed air Inspection 1 Inspect parts for excessive wear cracks or damage 2 Using a micrometer measure outside diameter of rocker arm support journals 75349 a a Rocker Arm Support Journal Outside Diameter Measurement 24 97 25 00 mm ...

Page 272: ... oil 1 Lubricate rocker arm bushings and support journals with SAE 30W engine oil 75349 a b a a Rocker Arm Bushings b Rocker Arm Support Journals 2 Install rocker arms on support Position as shown 75101 a b a Rocker Arms Positioned Correctly b Rocker Arm Support 3 Install strap Make sure strap is not spread open or valve cover will not fit 75101 a b a Rocker Arm Assembly b Strap ...

Page 273: ...ssary to establish TDC if not already known BEFORE installing the rocker arm assemblies 1 Remove 3 opposing retaining bolts from the vibration damper balancer 2 Using balancer bolts or suitable attach crankshaft tool 91 814827 to crankshaft balancer 70485 a a Crankshaft Tool 3 Align crankshaft and timing mark as follows a Temporarily insert a push rod into both cylinder number 1 lifters b Slowly r...

Page 274: ...ber 1 piston is at Top Dead Center TDC on its compression stroke at this point 75437 70281 a b a a TDC Notch On Pulley b Timing Cover Mark NOTE Some modification to the graduated disc tool may be required for use on some models 4 Attach graduated disc 91 801333500 to crankshaft pulley or tool Position the disc with Zero degrees as shown 78142 a b c a Graduated Disc b Crankshaft Tool c Zero Degrees...

Page 275: ...der in firing order up to TDC Firing Order D2 8L D Tronic 1 3 4 2 D4 2L D Tronic 1 5 3 6 2 4 INSTALLING THE ASSEMBLIES NOTE Screw plugs in glow plug holes or glow plugs if equipped may be removed to release compression when turning crankshaft 1 Rotate the crankshaft to place each cylinder at TDC before installing the assembly for that cylinder Refer to Establishing Top Dead Center TDC 2 Install va...

Page 276: ...rm sockets 75401 c a b Typical Cross Section View a Push Rod b Lifter Socket c Rocker Arm Socket 4 Install both flanged nuts on rocker arm support Torque evenly to 34 Nm 25 lb ft IMPORTANT No valve adjustment is required Valve lash is automatically set when rocker arm nuts are torqued as specified 5 Refer to appropriate procedures and reassemble remaining components ...

Page 277: ... 15 1 2 3 4 5 6 7 8 9 1 Cover 2 Gasket 3 Pin 2 4 Cover 5 Washer 6 Screw 1 7 Washer 1 8 Screw 13 9 Seal Apply Oil to Inner Lips of Seal Upon Installation 10 O ring 11 Crankshaft Pulley 12 Vibration Damper 13 Nut 14 Screw 6 15 Lockwasher 6 Description Part Number A Loctite Master Gasket 92 12564 2 B Clean SAE 30W engine Oil Obtain Locally ...

Page 278: ...pump 4 Install flywheel holding tool 91 801333506 5 Remove six allen head bolts and remove crankshaft vibration damper 6 Using a suitable socket remove the large crankshaft pulley nut 7 Using Puller 91 801333507 remove crankshaft pulley 8 Remove fasteners including one at alternator bracket and remove timing cover Note size and position of fasteners for reassembly Cleaning 1 Remove old gasket mate...

Page 279: ...Nm 95 lb in d Install the single M8 screw left mid point on cover with the serrated cupped washer Torque the screw to 10 8 Nm 95 lb in 4 Ensure that the crankshaft pulley woodruff key is installed 5 Ensure that the woodruff key remains in proper position and install the crankshaft pulley 6 Apply Loctite 222 Thread Locker to pulley nut threads 7 Install the pulley nut With flywheel holder tool 91 8...

Page 280: ... to 45 50 Nm 34 37 lb ft 75106 a b c d e f a Brace b Timing Cover c Screw d Washer e Spacer f Flange Nut 13 Tension the alternator belt power steering belt and vacuum pump belt if equipped Torque drive belt related mounting and tensioning bolts to specifications 14 Install seawater pump inlet hose and outlet hose Tighten hose clamps securely 15 Open the seacock if equipped or remove plug from seaw...

Page 281: ...mp Removal 1 Remove the timing gear cover 2 Remove the screws securing oil pump 70292 a b a Screws 3 b Oil Pump 3 Remove the oil pump from bore in block 70287 a a Oil Pump Cleaning 1 Dismantle and wash all parts in cleaning solvent 2 Put on safety glasses 3 Dry parts with compressed air ...

Page 282: ...n Maximum 0 500 mm 01968 in c Diameter of rotor housing 58 105 58 130 mm 2 287 2 288 in 70282 a b c d e a Rotor b Outer Rotor c Clearance Between Rotors d Clearance Between Housing and Outer Rotor e Diameter of Rotor Housing d Depth of rotor housing 32 403 32 406 mm 1 2757 1 2758 in e Axial clearance between pump driven gear and pump body 0 050 0 070 mm 002 003 in 2 If measurements are not within ...

Page 283: ... Install the bevelled end of the outer rotor towards the pump gear 2 Ensure that the rotor and gear coupling resists a rolling torque of 9 kgm 32 4 oz Installation 1 Install oil pump in cylinder block Torque screws to 27 5 Nm 20 lb ft 70292 a b a Screws 3 b Oil Pump 2 Install timing gear cover ...

Page 284: ...ean old gasket material from area around relief valve 3 Unscrew the valve assembly seat body from the crankcase using a suitable tool The tool should engage the two slots opposite each other on the edge of the valve assembly NOTE Locking compound is used during installation of the oil pressure relief valve assembly Area around the assembly may need to be heated to aid in removal 70298 a b c Typica...

Page 285: ...asses 3 Push cap in and hold Remove snap ring Release spring pressure slowly 70285 70284 a b c a Cap b Snap Ring c Valve Assembly Seat Body 4 Remove cap spring or springs and relief valve from bore of the valve assembly NOTE Some oil pressure relief valves have only one spring 70283 a b c d a Cap b Spring Inner Present If Dual Spring Equipped c Spring d Relief Valve Cleaning 1 Clean gaskets from c...

Page 286: ...t valve slides freely in seat body when coated with oil Assembly 1 Coat inside of oil pressure relief valve seat body bore with SAE 30W engine oil Liberally oil coat remaining components 2 Assemble valve spring s inner and outer springs if dual spring equipped and cap as shown Install parts into valve seat body 70284 70285 f a b c e d a Relief Valve b Spring Inner Present If Dual Spring Equipped c...

Page 287: ...ng complete oil pressure relief valve assembly Screw the complete assembly into the crankcase 70285 70298 a b a Valve Assembly b Apply Sealant to Threads 2 Using a suitable tool torque relief valve assembly to 53 9 Nm 39 lb ft 70298 a b c Typical a Example Of Suitable Tool b Valve Assembly c Slots 3 Install oil pan and related hardware ...

Page 288: ...ck up suction tube and oil pick up tube elbow to block NOTE This view is representative of all models Your specific pick up tube assembly may differ slightly in appearance 70288 a b c d Typical a Baffle b Oil Pick up Tube c Elbow d Inlet Strainer End 3 Remove old O ring from suction tube Remove old O ring from elbow on engines with two piece suction tube 70286 a b c a Pickup Tube b Elbow c O rings...

Page 289: ...Check all welds for leaks 3 Inspect oil pick up assembly for fatigue cracks or damage 4 Replace parts with those for your specific model Installation 1 On Engines With Two Piece Suction Tube a Renew O rings on oil pick up tube and elbow 70286 b a a b a O ring Oil Pick up Suction Tube b O ring Oil Pick up Suction Tube Elbow b Install elbow on oil pick up tube 2 On Engines With One Piece Suction Tub...

Page 290: ...ith baffle on cylinder block Torque screws to 11 Nm 97 lb in 4 Using a new gasket install oil pan and related hardware Torque oil pan screws evenly in a diagonal pattern to 12 7 Nm 112 lb in 70288 75107 b e a c d a Baffle b Oil Pick up Tube c Tube Elbow Except On One Piece Tube d Screws e Oil Pan and Related Hardware ...

Page 291: ...arks on hoses to assist in reassembly 3 Completely loosen hex head screw fitting retaining adapter to cylinder block 75385 a b c d b Typical a Oil Temperature Audio Warning Switch b Hose Fitting c Adapter Oil Thermostat d Screw Fitting 4 Lift adapter and screw fitting from engine Remove fitting and sealing washer 5 If not already accomplished remove old O ring from groove on adapter on underside w...

Page 292: ...e f a Thermostat b Spring c O ring Seal d Sealing Washer e Hex Head Plug f Adapter Oil Thermostat Cleaning and Inspection 2 Clean parts in solvent 3 Dry with compressed air 4 Inspect components for cracks or damage Replace as needed Refer to Testing to verify if thermostat is functional Testing NOTICE Read WARNING about testing in Precautions at the front of this SECTION before pro ceeding with te...

Page 293: ...ees C 212 degrees F pin should be extended approximately 5 7 mm 3 16 5 16 in more than when it was cold NOTE Thermostat shown removed from test water for visual clarity Do NOT handle until cool 71084 a a Thermostat Pin Extended 5 If pin does not extend push out thermostat is faulty and must be replaced Installation 1 Coat threads of hex head plug with Loctite Pipe Sealant with Teflon 2 Install the...

Page 294: ...nd connect oil hoses to adaptor Tighten fittings securely 7 Connect audio warning wire ring terminal to switch Tighten nut securely Coat terminals with Quicksilver Liquid Neoprene 75528 75385 a b e c d a f f c b a Adapter b Hex Head Fitting c Sealing Washer d O ring Seal e Oil Temperature Audio Warning Switch Connection f Hose Fitting 8 Fill engine to proper level with recommended engine oil 9 Sta...

Page 295: ...02 Page 3A 95 Camshaft Exploded View 75105 10 1 2 3 4 5 6 7 8 9 Typical Camshaft and Related Components 1 Bearings 2 Camshaft 3 Thrust Plate 4 Injection Pump Drive Gear 5 Crankshaft Drive Gear 6 Idler Gear 7 Camshaft Gear 8 Mounting Screw 9 Lockwasher 10 Woodruff Key ...

Page 296: ... manner IMPORTANT Camshaft replacement will be necessary if lobe dimensions are less than 0 05 mm 0019 in of the values indicated in the specification charts Removal 1 Turn crankshaft to cylinder number 1 TDC of its compression stroke 2 Remove a Timing Gear Cover b Fuel Pump IMPORTANT Place rocker arm assemblies push rods and lifters in a rack for reassembly in their original locations c Valve Pus...

Page 297: ...BRUARY 2002 Page 3A 97 5 Remove the idler gear If complete engine disassembly is required or if idler gear is worn or damaged IMPORTANT Mark retaining screws for reassembly in their original locations 70292 a b b a Idler Gear b Retaining Screw With Lockwasher ...

Page 298: ...al is needed upon reassembly gear must be heated in an oven to 180 200 degrees C 360 390 degrees F and pressed on the shaft After installing proper thrust plate and positioning the key press the gear until gear is tight against shoulder 6 Measure clearance between thrust plate and camshaft Camshaft assembly Clearance should be 0 030 0 095 mm 0012 0037 in Wear limit is 0 200 mm 0078 in If measured ...

Page 299: ... 16 mm 5 8 in will partially block oil gallery in cylinder block causing a lack of lubrication Be certain retainer screw c as shown is NOT longer than 16 mm 5 8 in 70293 a b d a b c d a Idler Gear b Retaining Screws with Lockwashers c Retaining Screw Must NOT Be Longer Than 16 mm 5 8 in d Marks Aligned Properly 2 Lubricate camshaft lobes with a mixture of 20 SAE 30W engine oil and 80 Needle Bearin...

Page 300: ...e engine assembly Camshaft Bearings Inspection With camshaft removed 1 Visually inspect bearings Renew if worn or damaged 2 Measure inner diameter of bearings Refer to specifications Renew bearings if not within specifications Removal NOTE Camshaft bearings can only be removed and installed with crankshaft removed 1 Using special tool 91 801333508 with appropriate hardware remove camshaft bearings...

Page 301: ...ign with drilled oil passages in cylinder block or severe engine damage will result 3 Align camshaft bearing oil feed holes with drilled oil passages in cylinder block 4 Using Special Tool 91 801333508 with appropriate hardware install new camshaft bearings 70354 a b c a Special Tool b Bearing c Oil Feed Hole MUST BE Aligned With Drilled Passages In Block 5 Check position of oil hole in each beari...

Page 302: ... ensure that the flat portions of the lifters are properly positioned in the retainers Removal 1 Remove engine cover 2 Remove valve covers IMPORTANT Place rocker arm assemblies push rods and lifters in a rack for reassembly in their original locations 3 Remove rocker arm assemblies and push rods IMPORTANT Lifters must be reassembled in the exact same position on the camshaft lobes so that the roll...

Page 303: ...ning 1 Wash all parts in cleaning solvent 2 Dry with compressed air Inspection 1 Inspect lifters carefully If any parts are damaged or worn the entire lifter assembly should be replaced Refer to Specifications 2 If outer lifter body wall is scuffed or worn inspect cylinder block lifter bore 3 If roller is worn or damaged inspect camshaft lobe 4 If push rod seat is scuffed or worn inspect push rod ...

Page 304: ...rior to disassembly 3 Install retainers around the square top of the lifters to prevent them from rotating 4 Install push rods Ensure push rods seat in lifter socket 75383 75103 a b c a Lifter b Retainer c Push Rod 5 Install rocker arm assemblies Torque nuts to 34 Nm 25 lb ft 6 Install valve cover s using new gaskets and new O rings on 6 cylinder connector piece Torque screws to 11 5 Nm 101 lb in ...

Page 305: ...ean oil passages of old oil and sludge 3 Dry parts with compressed air Inspection 1 Inspect all contact surfaces spherical tips for wear 2 Check run out straightness of each push rod 3 Replace all damaged or worn parts Installation IMPORTANT When installing lifters and rocker arms coat rocker arm bearing surface rocker arm and push rod ball and seat with engine oil 1 Install push rods in order of ...

Page 306: ...not within specifications replace or recondition crankshaft 5 Measure new or used bearing clearances with Plastigage or its equivalent as follows a Clean oil from crank pin b Install bearing in connecting rod c Place a piece of gauging plastic the full width of crank pin parallel to crankshaft d Install rod cap with bearing Torque bolts to 29 4 Nm 60 degrees 21 lb ft 60 degrees IMPORTANT Do NOT tu...

Page 307: ... surface with oil and install rod cap Torque to 29 4 Nm 60 degrees 21 lb ft 60 degrees Removal 1 Remove cylinder heads 2 Remove oil pan and oil pick up tube 3 Use a reamer to remove the ridge or any deposits from upper end of cylinder bore 4 Install crankshaft tool 91 814827 Turn crankshaft to gain access to connecting rod bolts NOTE Connecting rods are numbered similar to as shown Record the numb...

Page 308: ... soft jawed vise as shown 70290 2 Use Piston Ring Expander 91 24697 to remove the 2 compression rings 3 Using same tool remove lower oil control ring and spring 70291 a b a Lower Oil Control Ring b Spring 4 Remove snap rings retaining piston pin Push pin out of connecting rod and piston 70294 a b a Snap Ring b Piston Pin ...

Page 309: ...t Do NOT WIRE BRUSH ANY PART OF PISTON Clean ring grooves Make sure oil ring holes are clean 70229 a b a Ring Grooves b Oil Ring Holes Inspection CONNECTING ROD AND PIN 1 Wash connecting rods in cleaning solvent and dry with compressed air 2 Check for twisted or bent rods and inspect for nicks or cracks Replace damaged connecting rods 3 Measure connecting rod bushing I D and piston pin O D Replace...

Page 310: ...rence details 70296 a a Location for Class A Designation 1 Inspect piston for cracked ring lands skirts or pin bosses wavy worn ring lands scuffed or damaged skirts or eroded areas at top of piston Replace pistons which are damaged or show signs of excessive wear Refer to Step 6 following 2 Inspect grooves for nicks or burrs that might cause rings to hang up 3 Except on upper ring groove of piston...

Page 311: ...ing are typical in nature the first upper compression ring is trapezoidal tapered in design That is it has a 15 degree taper on both upper and lower surfaces Correspondingly the first compression ring groove is tapered 15 degrees on top and bottom Note also that the upper ring s edge parallel to cylinder liner is not a straight cut It is rounded or arced in design IMPORTANT Do NOT mistake these ta...

Page 312: ...CHECKING RING END GAP 1 Select rings comparable in size to piston being used 2 Slip compression ring in cylinder bore then press ring down into cylinder bore about 6 mm 1 4 in below ring travel Ensure that ring is square with cylinder wall 3 Measure gap between ends of ring with a feeler gauge as shown Refer to Specifications 70295 Checking Ring End Gap 4 If gap between ends of ring is below speci...

Page 313: ...necting rod with the combustion chamber recess aligned with rod numbers 70296 a b a Combustion Chamber Recess b Rod Numbers 3 Insert piston pin and install snap ring 4 Clamp in a soft jawed vise as shown 70290 NOTE Always install rings with ring markings facing the top of piston 5 Install spring in lower piston groove 6 Install oil control ring 7 Squeeze ring into groove to seat spring and check f...

Page 314: ...mpression ring in upper piston groove Installation 1 Before installing pistons into cylinders ring gaps must be positioned as follows a First compression ring trapezoidal gap 30 degrees to the right of combustion chamber recess b Second compression ring gap directly opposite the combustion chamber recess c Lower oil control ring gap 30 degrees to the left of combustion chamber recess a b c 78416 T...

Page 315: ...30W engine oil and 80 Needle Bearing Assembly Lubricant 7 Align connecting rod with crankshaft journal and tap on piston top until rod bearing contacts journal Do NOT scratch or nick crankshaft journal 8 Ensure that corresponding numbers on rod cap and connecting rod are the same and are on the same camshaft side 9 Install rod cap lubricate bolt threads with Needle Bearing Assembly Lubricant Torqu...

Page 316: ...ect ones for the engine The rear main oil seal rides on both the flywheel and the crankshaft thrust plate flywheel spacer Removal 1 Remove the flywheel housing rear portion 2 On Sterndrive MCM Models Remove the engine coupler 3 On Inboard MIE Models Remove the drive plate 4 Remove the six flywheel retaining bolts and the flywheel 5 Remove the thrust plate flywheel spacer IMPORTANT Do NOT damage ma...

Page 317: ...e certain there are no scratches nicks cracks or seizure marks on plate Renew plate if any are found Only minor grooves or indentations can be removed 4 Install new O ring into groove of thrust plate 70304 a b a Thrust Plate b O Ring 5 Install thrust plate with O ring towards crankshaft Tighten thrust plate retaining screw securely 6 Install the flywheel IMPORTANT Flywheel bolts may be used a maxi...

Page 318: ...and parts are the correct ones for the engine Removal 1 Remove the pistons 2 Remove the timing gear cover 3 Remove the camshaft and lifters 4 Remove the oil pump 5 Proceed as outlined REAR MAIN BEARING CARRIER AND BEARINGS 1 Remove the flywheel housing rear portion 2 On Sterndrive MCM Models Remove the engine coupler 3 On Inboard MIE Models Remove the drive plate 4 Remove the six flywheel retainin...

Page 319: ...BRUARY 2002 Page 3A 119 7 Mark position of rear main bearing carrier in relation to block 70302 a b c a Rear Main Bearing Carrier b Cylinder Block c Reference Mark 8 Remove the screw locking thrust plate to crankshaft 70302 a b a Locking Screw b Thrust Plate ...

Page 320: ...flywheel housing using only the nuts on the carrier 10 Tap evenly around the housing as shown The carrier and thrust plate will be pulled from the cylinder block 70303 a b c a Nuts On Carrier 6 b Flywheel Housing c Plastic Hammer 11 Remove nuts temporarily holding the flywheel housing to the rear bearing carrier and proceed to next appropriate section ...

Page 321: ...block 2 Remove main bearing oil feed locating screws which hold main bearing carriers in block 70305 a b c a Main Bearing Oil Feed Locating Screws b Special Locating Screw c Oil Sender 3 Install Crankshaft Installer Tool 91 801333504 over timing gear 70306 a b a Crankshaft Installer Tool b Timing Gear 4 Turn engine vertical with front facing down 5 Using a hoist and a suitable sling attached to cr...

Page 322: ...arts 1 After marking carriers remove bolts and separate carrier halves Remove carriers with bearings from crankshaft journals 70307 a b c a Bolts with Washers b Bearing Carrier c Main Bearings FRONT MAIN BEARING NOTE If bearings are being inspected prior to replacement refer to Inspection in this section before removing front main bearing If all bearings are being replaced proceed 1 Assemble Beari...

Page 323: ... 91 801333503 and Crankshaft Pulley Puller 91 801763590 onto timing gear as shown 2 Remove the timing gear 3 Remove the spacer if equipped 70309 a b c d a Gear Puller b Pulley Puller c Timing Gear d Spacer If Equipped Not Shown Cleaning 1 Immerse crankshaft in a solvent bath and clean 2 Put on safety glasses 3 Clear oil passages with compressed air 4 Dry with compressed air ...

Page 324: ...rfaces on front and rear ends or threaded areas of crankshaft ends are out of round worn or damaged 3 After a seizure over heating or grinding crankshaft must be Magnafluxed to verify no surface cracks are present NOTE It will be necessary to measure inner diameter of bearings in carriers and outer diameter of matching crankshaft journal to determine maximum clearance Refer to the following sectio...

Page 325: ...lves if removed b Observing marks made earlier assemble carriers Torque bolts with washers to 42 Nm 31 lb ft c Measure inner diameter of bearing as shown 70310 Measuring Inner Diameter Of Bearing d Measure outer diameter of matching crankshaft journal as shown 70311 Measuring Outer Diameter Of Journal e Calculate difference between measurement taken in step c and d clearance and refer to specifica...

Page 326: ...eck clearance of front main bearing a Measure crankshaft front main bearing journal b Measure I D of front main bearing in cylinder block as shown 70312 c Calculate difference between measurement taken in step a and b clearance and refer to specifications for maximum clearance TIMING GEAR 1 Ensure timing gear teeth are not worn or damaged 2 Remove slight indentations with a very fine grade Carboru...

Page 327: ...hole of new bearing 70313 a b a Oil Passage b Bearing Hole 2 Place new bearing on Puller Installer Tool 91 801333508 as shown Tool will install bearing to the correct depth Oil passage MUST BE aligned NOTE To aid installation retain bearing halves on tool with a rubber band or similar 70402 a b a Tool 91 801333508 b Bearing Halves On Tool ...

Page 328: ...he gear in a suitable oven to 180 200 degrees C 356 392 degrees F 2 Ensure timing reference dots are facing the FRONT of the engine 3 Ensure crankshaft keyway and woodruff key are aligned 4 On early models install the timing gear On later models or if replacing the early gear install the new spacer and timing gear 70309 a b a Timing Gear b Spacer If Equipped Not shown MAIN BEARING CARRIERS AND BEA...

Page 329: ...heck the rear main bearing carrier oil jet and stake marks 70382 a b c a Bearing Carrier b Piston Oil Jet Location c Stake Peen Marks 3 Ensure that all carriers are positioned so that piston oil jet faces FRONT of engIne as shown when installing on journal Install matching carrier halves marked earlier on crankshaft journals in their original locations Lubricate bolts and washers with clean engine...

Page 330: ...olykote 75389 a b a Brush Dipped In Molykote b Main Bearing Bore 2 Install Crankshaft Installation Tool 91 801333504 on front gear to protect front main bearing 70404 a a Tool 91 801333504 3 Position engine crankcase horizontal with oil pan flange facing up 4 Carefully insert crankshaft with main bearing carriers attached into cylinder block ...

Page 331: ...Install new sealing washers on all main bearing carrier locating hollow bolts and HAND THREAD CAREFULLY to avoid damaging carrier threads into bearing carriers Where previously noted install locating bolt for oil sending unit after removing sending unit and adaptor nozzle from bolt to allow torquing Torque all bolts to 53 9 Nm 39 lb ft 70386 a b b a Carrier Locating Hollow Bolts b Sealing Washer s...

Page 332: ... carrier where bearing tab aligns 1 Using a suitable mandrel press bearing out of carrier 2 When pressing new bearing into carrier bearing tab and notch in carrier MUST BE aligned as shown 70382 a b a Bearing Tab b Notch In Carrier REAR MAIN BEARING CARRIER 1 Refer to Rear Oil Seal Installation and install new seal in carrier 70406 a b a Rear Main Oil Seal b Rear Main Bearing Carrier ...

Page 333: ...keep washers positioned 70407 a a Thrust Washers Standard Size Flywheel Side 3 Install standard size thrust washers into front crankshaft side of carrier Use Quicksilver Needle Bearing Lubricant to help keep washers positioned 70408 a a Thrust washers Standard Size Front Crankshaft Side 4 Install new O ring into groove around carrier Coat with clean engine oil to assist during installation 70408 a...

Page 334: ...ylinder block align marks previously made Always be certain lubrication holes on block and carrier align especially when or if marks are not present 70409 a b a Rear Main Bearing Carrier b Marks Aligned 6 Install new O ring into groove of thrust plate crankshaft side 70304 a b a Thrust Plate b O ring 7 Install thrust plate with O ring towards crankshaft Tighten retaining screw securely ...

Page 335: ... threads of flywheel bolts with clean engine oil and install flywheel Torque bolts to 110 Nm 81 lb ft CRANKSHAFT END PLAY AXIAL CLEARANCE 1 Attach Dial Indicator 91 58222A1 to cylinder block to check installed crankshaft end play axial clearance Reading can be taken off of counter weight as shown Move crankshaft fore and aft in block to obtain reading Clearance should be 0 121 0 323 mm 005 013 in ...

Page 336: ...ylinder Liner Puller Tool b Plate IMPORTANT Mark liners in a suitable fashion as to the cylinder number to avoid mismatching to pistons upon reassembly and orientation in block reference to prechamber bore of head 3 Install puller tool into cylinder and attach plate to tool at bottom of liner Remove liner s as shown Note location of shim between liner and crankcase bore relief Also note O rings on...

Page 337: ...Class A piston will result in severe engine damage 1 As shown in the following inspect underside of liner for tolerance class identification reference mark a small radial line NO MARK should be present The liner is a standard size Class A liner 2 If a MARK is present the liner is a size Class B liner and is NOT for use on D Tronic engines 3 Refer to specifications Liner I D for exact dimensions 70...

Page 338: ...r to specifications 4 When cylinder liner wear is within specifications light honing of the liner bore is allowed Replace if liners are not within specifications CYLINDER BLOCK LINER BORES 1 Thoroughly clean the cylinder block with suitable solvent and blow dry with compressed air Inspect for cracks or flaws 2 Check cylinder head mating surfaces of block and area around cylinder liner bores for ab...

Page 339: ...AUTION Ensure cylinder liners are fully seated in block in the following instructions or incorrect measurements will occur causing engine performance problems or severe engine damage NOTE Liners will spin freely in bore when the block and liner are completely clean and ready for assembly a Unless being replaced install liners in same cylinder block bore as marked or noted upon disassembly WITHOUT ...

Page 340: ...sed Protrusion ABOVE Block Without Shim Thickness ABOVE Block With Shim 0 14 0 09 0 15 0055 0035 0059 0 19 0 14 0 20 0 01 0 06 0074 0055 0078 0004 0023 0 22 0 17 0 23 0086 0066 0090 d Remove liner and install shim selected and refit liner e Measure protrusion Adjust using alternate shim if required 70475 a b c d a Cylinder Liner Protrusion Height Above Block Surface b Cylinder Liner c Cylinder Blo...

Page 341: ...ner b Suitable Bolt c Formed Spacer Washer 3 Recheck liners for proper amount of protrusion using liner gauge bar 91 184812A1 SAE or 91 801333509 Metric and appropriate dial gauge as shown If not as specified adjust protrusion as previously outlined until each liner is protruded 0 01 0 06mm 0004 0023 in above block 75551 4 Remove liners in order keeping appropriate shims matched to liners ...

Page 342: ...Shim b Black O Rings 2 c Brown O Ring 1 6 Lubricate LOWER centering collars in cylinder block those areas where lower liner O rings seal against the bore with Needle Bearing Lubricant 92 42649A1 or clean engine oil as shown IMPORTANT Do NOT lubricate upper bore area NOTE Liner shown fitted ONLY for visual clarity Do NOT install liners in this step 50491 a a Lubricate This Area Of Cylinder Block Lo...

Page 343: ...NLY 8 Install liners in block being careful not to damage O rings or distort shim Hold liners securely in position with suitable bolts and head bolt formed spacer washers as shown Torque bolts to 50 Nm 37 lb ft Allow Loctite to dry Do NOT release liners for approximately 1 1 2 to 2 hours 75015 a b c a Liner b Suitable Bolt c Formed Spacer Washer 9 Once again verify cylinder liner protrusion and ma...

Page 344: ... Housing Coupler Drive Plate And Flywheel Exploded View STERNDRIVE MCM MODELS NOTE Some engines are equipped with a solid Single Stage coupler in place of the Dual Stage coupler found on others 4 10 20 22 24 11 14 15 16 23 25 3 2 1 5 6 9 8 7 12 13 73791 19 18 B B B A 26 21 17 B 27 28 29 30 ...

Page 345: ...Washer and Lockwasher 15 Turbocharger Mounting Screw 2 16 Screw Flat Washer and Lockwasher 9 17 Flywheel Ring Gear 18 Thrust Plate Guide Ring O ring Seal 19 Set Screw and Thrust Plate Guide Ring 20 Flywheel With Ring Gear 21 Flywheel Bolt 6 22 RPM Speed Sensor 23 Wave Washer and Allen Head Screw 24 O ring Seal 25 Starter Stud Washer and Nut 26 Flywheel Housing 27 Lockwasher 6 mm 28 Screw M6 x 1 x ...

Page 346: ...ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Page 3A 146 90 860074 1 FEBRUARY 2002 INBOARD MIE MODELS 1 2 3 4 5 6 8 10 11 13 14 15 16 17 18 19 20 21 22 23 9 7 12 B A ...

Page 347: ...Screws 8 Flywheel 9 Set Screw 10 Thrust Plate Guide Ring 11 Guide Ring O ring 12 Ring Gear 13 Turbocharger Screw 14 Lockwasher 15 Washer 16 Turbocharger Bracket 17 Screw and Washer 18 Flywheel Housing To Cylinder Block Screw 19 RPM Speed Sensor 20 Wave Washer and Allen Head Screw 21 Starter Stud Washer and Nut 22 O ring for Flywheel Housing 23 Flywheel Housing Description Part Number A Clean SAE 3...

Page 348: ...ect ones for the engine Flywheel Housing REMOVAL 1 Remove the starter 2 Remove rear portion of flywheel housing 3 On Sterndrive MCM Models Remove engine coupler 4 On Inboard MIE Models Remove drive plate 5 Remove the six flywheel retaining bolts and the flywheel 6 Remove 9 bolts and 6 nuts with respective washers retaining flywheel housing 7 Disconnect and remove the rpm speed sensor 8 Remove flyw...

Page 349: ...torque the 6 rear main bearing carrier nuts with washers to 27 Nm 20 lb ft IMPORTANT Flywheel bolts may be used a maximum of 3 times within the prescribed torque limits 3 Lubricate threads of flywheel bolts with clean engine oil and install flywheel Torque bolts to 110 Nm 81 lb ft 4 On Sterndrive MCM Models Install engine coupler Apply Loctite 271 to threads and torque bolts to 30 Nm 22 lb ft 5 On...

Page 350: ...CM Models Remove engine coupler 3 On Inboard MIE Models Remove drive plate INSPECTION 1 Inspect splines in drive plate or coupler for wear 2 On Sterndrive MCM Models with two stage couplers the first stage piece of the coupler can be replaced Remove as necessary 78383 a b a Two Stage Coupler Assembly b Coupler First Stage Piece 3 Inspect drive plate or coupler for warping 4 Replace as necessary ...

Page 351: ...r Apply Loctite 271 to bolt threads Torque bolts to 30 Nm 22 lb ft 3 On Inboard MIE Models Install drive plate Apply Loctite 271 to bolt threads Torque bolts to 72 Nm 53 lb ft 4 Install rear portion of flywheel housing Torque bolts to 50 Nm 37 lb ft 5 Install other components previously removed Flywheel REMOVAL Refer to Flywheel Housing in this SECTION 3A CLEANING 1 Clean mating surfaces of flywhe...

Page 352: ...number breaks if a front mount is being replaced Only use the late front mounts on engines with the early serial numbers if the rear bushing are also replaced The front engine mounts can be installed two ways Mark the mounts before removing them from cylinder block to ensure installation in same location 50533 a b c b Front Mount Standard Position NOTE Reverse mount pad on front mounts by loosenin...

Page 353: ... Page 3A 153 MIE Inboard Transmission Mounts 27035 a b c d e f g Transmission Mount Components a Base b Housing c Bushing d Trunion Pin e Snap Ring f Bracket g Clamping Bolt 50533 a b 27035 a b a b Standard Mount Position Alternate Mount Position a Mount Bracket b Bolts ...

Page 354: ...ion at full throttle 5 minutes at a time maximum is permissible 4 AVOID full throttle accelerations from stopped position 5 Do NOT operate at full throttle until engine reaches normal operating temperature 6 OBSERVE INSTRUMENTATION carefully If an abnormal reading occurs stop engine immediately and determine cause 7 FREQUENTLY CHECK crankcase oil level and add oil if necessary It is normal for oil...

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Page 357: ...ontents Identification 4A 3 Specifications 4A 3 Torque Specifications 4A 3 Lubricants Sealants Adhesives 4A 3 Replacement Parts 4A 4 Starting System Components 4A 4 Inspection 4A 6 Periodic Inspection 4A 6 Testing Voltage 4A 6 Removal 4A 7 Starter Motor 4A 7 Solenoid Switch 4A 8 Installation 4A 9 Solenoid Switch 4A 9 Starter Motor 4A 10 ...

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Page 359: ...motor must never be used for more than 15 seconds at any one time Cranking should not be repeated without a pause of at least 2 minutes to permit the heat to escape Description Specification I D Number 0 001 362 3 Engine Rotation Left Hand Counterclockwise Minimum Required Cranking Battery Size 4 and 6 cylinder 750 cca 950 mca or 180 Ah No Load Test 11 5 Volts 125 Amps At 7000 rpm Torque Specifica...

Page 360: ...protected Do NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT REF 33 CFR Failure to comply could result in fire explosion and or severe personal injury Starting System Components 1 2 3 23 53 46 24 42 5 6 7 8 4 9 10 13 11 86 30 87 85 86 87 85 30 30 50 15 12 3 3 2 1 Typical ...

Page 361: ...ctrical Box 5 Circuit Breaker 6 Circuit Breaker 7 Start Relay 8 Main Relay 9 ECM Fuel System Harness Connector at Electrical Box 10 ECM 11 Battery 12 Starter 13 Electronic Shut Off Solenoid 1 Wire routing on Sterndrive MCM engine and instrument harness with Neutral Safety Switch located in remote control 2 Wire routing on Inboard MIE engine and instrument harness with Neutral Safety Switch located...

Page 362: ...T Voltage below 9 5 causes excessive heat build up which can damage the starter motor and weld the starter solenoid contacts together 1 Ensure that battery is fully charged 2 Connect voltmeter positive lead to the terminal on the starter solenoid 3 Connect voltmeter negative lead to the starter motor case Ensure that there is good metal contact to prevent a false voltage reading 4 Crank engine for...

Page 363: ...l system components to prevent injury to yourself or damage to electrical system 1 Disconnect battery cables from battery 2 Disconnect wires from starter 3 Remove starter mounting nuts and lockwashers 4 Pull starter motor away from flywheel and remove from engine 70810 a b c d a Battery Cable b RED Wire c YELLOW RED Solenoid Wire d Mounting Nuts with Lockwashers 2 Total One Not Shown ...

Page 364: ... Switch 1 Remove starter motor 2 Remove nut from the field wire on the solenoid 70811 a a Field Wire Nut 3 Remove screws retaining solenoid 70812 a a Screws 4 Slide solenoid plunger off shift lever 70813 70814 a b a Solenoid Plunger b Shift Lever 5 Remove solenoid from starter assembly ...

Page 365: ...ricant with Teflon to the shift lever and sliding portion of the pinion 2 Slide solenoid plunger onto shift lever 70833 a b c a Solenoid Plunger b Shift Lever c Drive Gear 3 Install solenoid screws and tighten securely 70812 a a Solenoid Screws 4 Install nut on the field wire terminal and tighten securely 70811 a b a Field Coil Wire b Hex Nut ...

Page 366: ...installation 2 Position starter motor on engine 3 Install lockwashers and nuts Torque nuts to 68 Nm 50 lb ft 70810 a a a Lockwasher and Nut 1 Not Shown 4 Connect wires to starter solenoid 70810 a b c a RED Wire b YELLOW RED Solenoid Wire c Positive Battery Cable 5 Coat terminals with Liquid Neoprene sealer 6 Slide rubber boot over positive terminal connection 7 Connect battery cables to battery ...

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Page 369: ...4B 6 Electronic Diesel Injection EDI Electrical System Precautions 4B 6 Battery Precautions Multiple EDI Engines 4B 7 Charging System Components 4B 8 Inspection 4B 9 Troubleshooting Tests Alternator on Engine 4B 10 Circuitry Test 4B 10 Output Circuit 4B 11 Excitation Circuit 4B 12 Sensing Circuit 4B 13 Current Output Test 4B 14 Exploded View 4B 16 Removal 4B 17 Alternator 4B 17 Alternator Bracket ...

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Page 371: ...Location Not Shown in This View d P AC Terminal e L2 Terminal f B Terminal Replacement Parts Warning WARNING Electrical ignition and fuel system components on your Mercury MerCruiser are designed and manufactured to comply with U S Coast Guard Rules and Regula tions to minimize risks of fire and explosion Use of replacement electrical ignition or fuel system components which do not comply with the...

Page 372: ...t 13 9 14 7 Volts Condenser Capacity 5 MFD V Belt Tension 5 mm 3 16 In 1 1 Depress belt with thumb at midway point between circulating pump pulley and alternator Torque Specifications Description Nm lb in lb ft Pulley Nut 58 33 Alternator Brace to Alternator 28 20 Alternator Brace to Engine Block 41 30 Alternator to Mounting Bracket 48 35 Alternator Mounting Bracket to Engine Block 41 30 ...

Page 373: ...tion Kit 91 31229A5 Universal Puller Plate 91 37241 Multi Meter DVA Tester 91 99750A1 Ammeter 0 70 Obtain Locally Lubricants Sealers Adhesives Description Part Number Liquid Neoprene 92 25711 1 Wire Color Code Abbreviations BLK Black PUR or PPL Purple BLU Blue RED Red BRN Brown TAN Tan GRY Gray WHT White GRN Green YEL Yellow ORN Orange LIT or LT Light PNK Pink DRK Dark ...

Page 374: ...m battery before working on the charging system wWhen installing battery connect battery cables to battery by FIRST installing positive battery cable end on positive battery terminal Tighten clamp se curely THEN install negative battery cable end on negative battery termi nal Tighten clamp securely wIf a charger or booster battery is to be used connect it in parallel with existing battery positive...

Page 375: ...tage spike in the engine s electrical system In either case the ECM could shut off When the voltage returns to the range that the ECM requires the ECM will reset itself The engine will now operate normally This ECM shut down usually happens so fast that the engine just seems to have misfired RECOMMENDATIONS Batteries Boats with multi engine EDI power packages require each engine be connected to it...

Page 376: ...ry the ignition switch and the wiring which connects these components NOTE The wire color codes vary between models and are not shown Refer to SECTION 4E Wiring Diagrams for color code information 75420 a b c d e f g h Typical a Battery Meter b Ignition Switch c Harness Plug and Connector d Alternator e Circuit Breaker f Starter Motor g Ground Stud h Battery ...

Page 377: ...t injury to yourself or damage to electrical system 1 Inspect entire alternator system for corroded or loose connectors 2 Check wiring for frayed or worn insulation 3 Check alternator drive belt for excessive wear cracks fraying and glazed surfaces Also check drive belt tension and adjust if necessary as explained under Drive Belt Tension Adjustment 4 Check alternator mounting bolts for adequate t...

Page 378: ...ngine at too low a speed for extended periods of time 2 Check physical condition and state of charge of battery Battery MUST BE at least 75 1 230 specific gravity of fully charged to obtain valid results in the following tests If not charge battery before testing system 3 Inspect entire alternator system wiring for defects Check all connections for tightness and cleanliness particularly battery ca...

Page 379: ...low 13 8 volts 4 Connect positive voltmeter lead to alternator output terminal 5 Connect negative lead to a ground terminal on alternator 6 Wiggle engine wiring harness while observing voltmeter Meter should indicate approximate battery voltage and should not vary If no reading is obtained or if reading varies check alternator output circuit for loose or dirty connections or damaged wiring 72784 a...

Page 380: ...PURPLE lead from regulator Connect positive voltmeter lead to PURPLE lead and negative voltmeter leads to ground Test 2 If voltmeter now indicates approximate battery voltage voltage regulator is defective and the alternator must be replaced If no voltage is indicated check excitation circuit for loose or dirty connections or damaged wiring 4 If reading is between 75 and 1 1 volts rotor field circ...

Page 381: ...sitive voltmeter lead to RED or GREEN lead and negative voltmeter lead to ground terminal 3 Voltmeter should indicate battery voltage If battery voltage is not present check sensing circuit for loose or dirty connection or damaged wiring 72786 a b c d e a Output Wire BLUE b Excitation Wire PURPLE c Sensing Wire RED or GREEN d Voltmeter 0 20 Volts e Ground ...

Page 382: ... positive side of ammeter toward output terminal 3 Reconnect negative battery cable 4 Turn on all accessories and turn ignition switch to RUN position and allow glow plug system to operate through one cycle Turn switch to OFF position Turn off accessories 5 Start engine and adjust engine speed to 1500 2000 rpm Quickly observe ammeter Reading should be at least 30 amps 6 If reading is low stop engi...

Page 383: ... terminal and negative voltmeter lead to negative terminal 2 Start engine and operate at fast idle until engine reaches normal operating temperature Adjust engine speed to 1500 2000 rpm and observe voltmeter for highest reading Reading should be between 13 9 and 14 7 volts 3 If reading is high check for a loose or dirty regulator ground lead connection If connection is good and sensing circuit che...

Page 384: ...r 1 Shown Some Models May Have 1 Upper and 1 Lower Spacer 4 Bracket 5 Screw and Lockwasher M14 6 Mounting Bolt M8 7 Mounting Nut M8 8 Alternator Brace 9 Alternator Brace Spacer 10 Brace Bolt Washers and Nut M10 11 Tensioning Bolt Lockwasher and Flat Washer 12 Pulley Lockwasher and Nut 13 Alternator V Belt Description Part Number A Liquid Neoprene 92 25711 1 ...

Page 385: ...t bracket screw 4 Remove the drive belt 5 Remove the alternator brace attaching bolt and washer 6 Remove the alternator mounting bolt washer and nut 78310 a b c a Alternator Brace b Brace Bolt c Alternator Mounting Bolt 7 Remove the alternator Alternator Bracket 1 Remove the alternator 2 Remove the bracket mounting bolts Note the position of the spacer or of the upper and lower spacers 3 Remove th...

Page 386: ...ts Torque the bolts to 41 Nm 30 lb ft 3 Install the alternator Alternator 1 Position the alternator in the mounting bracket 2 Install the mounting bolt 3 Position spacer if equipped and fasten the alternator brace to the alternator 4 Position the alternator drive belt on the pulleys and adjust the tension 5 Torque the alternator brace to alternator bolt to 28 Nm 20 lb ft 6 Torque the alternator br...

Page 387: ... system The auxiliary battery is primarily used as a power source for various accessories installed on the boat The battery isolator will allow the alternator to charge both the cranking and auxiliary batteries at the same time while preventing accessories con nected to the auxiliary battery from drawing power from the cranking battery Mercury Marine does not manufacture any battery isolator syste...

Page 388: ...attery Isolator Diagram 72934 1 2 2 2 A B B 2 1 BLK B RED 2 2 a b c d e 1 Typical Alternator a Isolator b Alternator c Starter d Cranking Battery e Auxiliary Battery 1 BLUE Wire From Alternator Battery Terminal 2 8 Gauge Minimum 1 Sufficient Gauge Wire Spliced To Connect As Shown ...

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Page 391: ...s 4C 3 Torque Specifications 4C 4 Lubricants Sealants Adhesives 4C 4 Special Tools 4C 4 Description 4C 4 Precautions 4C 4 Glow Plug Testing Prior to Removal 4C 5 Removal 4C 6 Cleaning 4C 7 Inspection 4C 7 Installation 4C 8 Glow Plug Actuator Relay and Auxiliary Relay 4C 9 Testing 4C 9 Removal 4C 10 Cleaning 4C 10 Inspection 4C 10 Installation 4C 10 Glow Plug Circuit Diagram 4C 11 ...

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Page 393: ...ug Diameter and Thread M12 x 1 25 Nominal Voltage 11 Volts Current Draw after 30 Seconds of Operation 7 5 9 5 Amps Preheat Time and Afterglow Time Controlled by ECM Voltage drop with test current after 30 seconds 0 63 0 77 Volt D4 2L D TRONIC ENGINE Description Specification Glow Plug Diameter and Thread M12 x 1 25 Nominal Voltage 11 Volts Current Draw after 30 Seconds of Operation 7 5 9 5 Amps Pr...

Page 394: ...12 volts depends directly on the tempera ture of the engine coolant as determined by the ECT sensor and the altitude of the engine as sensed by the BARO pressure sensor located inside the ECM The ignition OFF time in which the engine can be restarted without the preheat cycle is about 20 seconds When the ignition switch is turned ON a preheat indicator lamp will illuminate indicating that the syst...

Page 395: ...1 Remove hex nut and washer from glow plug terminal 12 Remove voltage supply wire 13 Remove glow plug connecting wire from glow plug terminal 77940 a c b a Voltage Supply Wire b Glow Plug Terminal c Glow Plug Connecting Wire 14 Connect ohmmeter between engine ground and glow plug terminal Continuity should exist If no continuity exists glow plug is faulty ...

Page 396: ...al 3 Remove voltage supply wire 4 Remove glow plug connecting wire from glow plug terminal 77940 a c b a Voltage Supply Wire b Glow Plug Terminal c Glow Plug Connecting Wire IMPORTANT Avoid contaminating cylinders Clean any corrosion or debris away from around glow plug before removal 5 Clean any dirt away from around glow plug and opening in cylinder head 6 Remove glow plug ...

Page 397: ...rea 4 Clean the glow plug threaded areas seat and heating element tip Inspection 1 With glow plug removed connect ohmmeter between glow plug terminal and glow plug external threads Continuity should exist If no continuity exists glow plug is faulty 2 Connect a VOM and check resistance between glow plug terminal and glow plug external threads Refer to Specifications for value 73198 a b Typical a Te...

Page 398: ...d could contact the cylinder head which is grounded Be certain ring terminal is isolated to the glow plug terminal 3 Attach connecting wire to glow plug terminal Ensure that the voltage supply wire is present where previously removed Supply wire must not contact the cylinder head when installed 77940 c b a Typical a Contact Areas b Voltage Supply Wire Ring Terminal End c Connecting Wire 4 Coat all...

Page 399: ...ug Actuator Relay NOTE The relay numbers can be found on the bottom of the relay Terminal 30 is connected to battery voltage through a circuit breaker Terminal 86 is connected to terminal 30 Terminal 87 is connected a circuit is formed to terminal 30 in the energized ON position Terminal 87 then supplies battery voltage to one half of the engines glow plugs and to the glow Plug Auxiliary Relay Ter...

Page 400: ...cloth 2 Clean terminals with a suitable cleaner Inspection 1 Look for evidence of any physical damage to base or connector surfaces of relays 2 Visually inspect electrical pins of ECT for straightness and no corrosion 3 Visually inspect connectors on the wiring harness for corrosion and for terminals that may have backed out of the harness Installation 1 Insert electrical connector onto relay 2 At...

Page 401: ... BRN BLK YEL BRN BRN BRN BRN BLU YEL BRN RED YEL RED YEL RED BLU YEL a b b c d e f g h a Glow Plug s Dashed Lines Indicate Not Present on Four Cylinder Models b ECM Circuit Path to Glow Plug Indicator Lamp c ECM Supplied Ground Path to Actuator Relay d Starter Positive Terminal Battery e Glow Plug Actuator Relay f Glow Plug Auxiliary Relay g Circuit Breaker 60 Amp h Circuit Breaker 60 Amp ...

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Page 403: ...r 4D 6 QSI Series Gauge Lighting Options 4D 7 Gauges 4D 8 Removal 4D 8 Testing 4D 8 Installation 4D 11 Senders 4D 11 Oil Pressure 4D 11 Water Temperature Primary Station 4D 13 Primary Station Switches 4D 15 Ignition Key Switch 4D 15 Audio Warning Test and Panel Light Switch 4D 17 Audio Warning System 4D 19 Alarm 4D 19 Oil Pressure Switch 4D 20 Water Temperature Switch Sender 4D 21 Transmission Flu...

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Page 405: ...MENTS NOTE One of three distinct series of Quicksilver gauges may be installed Aside from different gauge face appearances and styling the back of the gauges and wiring connections are different 72965 Typical QSI Series 77333 Typical Admiral Series Back of Flagship Series Similar Panels QUICKSILVER INSTRUMENTS 73546 a b Typical Quicksilver Instrumentation a Gauges b Engine System Monitor Panel ...

Page 406: ...ally Diesel Timing Tool or suitable service tachometer Obtain Locally Tools Kent Moore Tools Kent Moore Tools Inc 29784 Little Mack Roseville MI 48066 Phone 313 774 9500 Description Part Number Connector Test Adapter Kit J 35616 A Lubricants Sealants Adhesives Description Part Number Liquid Neoprene 92 25711 3 Loctite Pipe Sealant with Teflon Obtain Locally Wire Color Abbreviations BLK Black PUR o...

Page 407: ...asses The appropriate heat source should only be electric Heat source should be operated by a qualified person Follow all instructions of the manufacturer of the heat source The heat source should be checked each time it is used to ensure it is functioning properly The thermometer used in the test should be a high temperature thermometer with a maximum reading of at least 150 C 300 F Under no circ...

Page 408: ...charged Circuit breaker is closed All wires in circuit are connected All connections are tight and corrosion free Connectors are fully engaged CAUTION Avoid short circuits It may be necessary to remove instrument panel or Engine System Monitor panel from dashboard to gain access to instruments and switches Do not allow wires to come in contact with metal or other wires Special Information Tachomet...

Page 409: ...nel Lights Audio Test switch IMPORTANT Light socket must be removed from gauge and turned when adjusting lighting option to desired setting Turning socket while still installed in gauge could result in damage to gauge or socket NOTE For different lighting effects colored sleeves are available through the Quicksilver Accessories and can be assembled to the bulb 72969 a b 72968 a Separate Instrument...

Page 410: ... wires from back of gauge 3 Disconnect light socket wiring if separate 4 Remove holding strap and remove gauge Testing OIL PRESSURE AND WATER TEMPERATURE 1 Turn ignition switch to the OFF position 2 Remove signal wire from terminal SEND S 72819 a a Sender Wire Lead 3 Turn ignition switch to the RUN position Gauge being tested must be at position A 73288 a a Typical a Needle at Position A 4 Turn ig...

Page 411: ... 73289 a a Typical a Needle at Position B CRUISELOG ENGINE HOUR METER 1 Remove cables from battery and fully charge battery 2 Remove wires from back of gauge 3 Connect positive jumper lead from battery to gauge terminal 12 V 4 Connect negative jumper lead from battery to gauge terminal GND ground 72815 72750 5 Observe gauge run indicator on face of gauge If indicator is turning the gauge is operab...

Page 412: ...m a 12 Volt power source or battery to gauge terminal I or 12 V 72750 a b a Volt Meter b 12 Volt Power Source 5 Check gauge reading if not indicating battery voltage as shown replace gauge 73290 a Typical a Needle Indicating Battery Voltage TACHOMETER 1 If the gauge is not accurate be certain the switch on the back of the tachometer is set properly Refer to Special Information Tachometer 2 Replace...

Page 413: ...l 4 Connect other wires to gauge as shown in SECTION 4E Wiring Diagrams 5 Install gauge light socket 6 Coat all terminals with liquid neoprene 7 Reconnect battery cables to battery Senders NOTE Refer to SECTION 5 for information on the Engine Coolant Temperature ECT switch Oil Pressure REMOVAL 1 Remove harness wire from sender 2 Using a suitable wrench to hold the adaptor fitting to prevent loosen...

Page 414: ...ing a suitable T fitting arrangement with the existing sender and adaptor or fitting 3 Connect an ohmmeter between sender terminal and sender case NOTE Sender shown removed for visual clarity 74281 a b c 72936 70686 a a Oil Pressure Sender b Adaptor Fitting c Manual Pressure Gauge Installation Location 4 Check the resistance values of the sender at pressures as shown and verified on manual gauge w...

Page 415: ... 75298 a b c Typical a Harness Wiring b Water Temperature Sender c Sealing Washer 3 Counter hold the adaptor with a separate wrench 4 Remove the sender and sealing washer TESTING IMPORTANT Use the following test to determine the accuracy of the Water Tempera ture Sender gauge circuit If gauge indicates NO temperature when running engine refer to the SECTION 1C Troubleshooting NOTICE Read WARNING a...

Page 416: ...serve temperature on thermometer 4 As temperature rises ohmmeter readings must be within the ranges specified for each temperature 70688 a b c d e a Suitable Container b Thermometer c Heat Source d Water Temperature Sender e Ohmmeter Leads Test Temperature Ohms Reading 60 Degrees C 140 Degrees F 121 147 90 Degrees C 194 Degrees F 47 55 100 Degrees C 212 Degrees F 36 41 NOTE While sand cools you ma...

Page 417: ...prene to the terminals 5 Refill closed cooling system Primary Station Switches IMPORTANT Disconnect battery cables from battery before testing switches with wires still connected to switches IMPORTANT The decal or decals on the side of the toggle switches with the arrow and the word UP refer to the position of the switch when installed on the panel Ignition Key Switch REMOVAL 1 Disconnect battery ...

Page 418: ...terminals B to I There should be no continuity between terminal S and any other terminals 4 With key switch in the START continuity will exist between terminals B to I and B to S 5 Terminals are to make contact at angles shown and to stay in contact condition as switch is rotated toward the START position 6 If ignition key switch tests bad unscrew or unsolder wire connections and remove switch Tes...

Page 419: ... from back of switch TESTING 1 With switch lever toggled DOWN to its spring loaded AUDIO TEST position continuity should exist between terminal numbers 1 and 2 as indicated by decals If no continuity exists replace switch 2 With switch lever toggled UP to the panel light ON position continuity should exist between terminal numbers 4 and 5 as indicated by decals If no continuity exists replace swit...

Page 420: ...86 UP a b 1 2 3 4 5 6 73369 ÉÉ ÉÉ ÉÉ 87 805675 UP 1 2 3 c c d e f a b a Audio Test Panel Light Switch b Spring Loaded Audio Test Portion Direction of Movement DOWN When Installed c Terminal Number d Terminal e Jam Nut f Locking Washer g Engine System Monitor Panel h Hex Nut D2 8L D Tronic and D4 2L D Tronic Harness Wire Connect To Terminal Number WHITE RED And WHITE YELLOW OR 1 TAN WHITE And TAN B...

Page 421: ...an audio warning alarm can be tested by holding the toggle lever of the Audio Test switch on the Engine System Monitor Panel DOWN momentarily with the key switch in the RUN position If the alarm sounds it is operable Alarm WARNING The following test involves the use of electricity Failure to follow appropriate procedures can cause burns or shock which can result in severe personal injury or death ...

Page 422: ...al and switch case negative With the engine stopped the meter should indicate full continuity NOTE Sender shown removed for visual clarity 74446 70686 b c a Typical a Oil Pressure Audio Warning Switch b Harness Wire c Continuity Meter And Connection Points Oil Pressure kPa psi Switch Condition 0 0 Closed 31 52 4 5 7 5 Open INSTALLATION 1 Coat threads of switch with Loctite Pipe Sealant with Teflon...

Page 423: ...open REMOVAL 1 Drain the closed cooling system 2 Remove harness wiring from temperature switch sender located behind the electrical box bracket and accessible through a hole in the bracket as shown 3 Counter hold the adaptor with a separate wrench 4 Remove the sender and sealing washer 75298 a b c Typical a Harness Wiring b Water Temperature Switch Sender c Sealing Washer ...

Page 424: ...TICE Read WARNING about switch and sender testing in Precautions at front of this section before proceeding with tests 3 To test switch circuit for closing alarm ON as if coolant temperature rises above operating specifications follow instructions a g a Remove the switch sender b Refer to top view of switch sender in Step 1 and using suitable jumper leads connect alarm terminal to switch terminal ...

Page 425: ...lose alarm ON within the range of temperatures indicated in chart below Test Temperature Switch Condition 102 106 Degrees C 215 220 Degrees F Closed g Turn heat source OFF Allow sand and components to cool INSTALLATION 1 Apply Perfect Seal to threads of switch sender 2 Counter hold the adaptor with a separate wrench and install the switch sender and sealing washer 3 Torque the switch sender to the...

Page 426: ...move the switch and sealing washer 72770 a b Typical Transmission a Transmission Fluid Temperature Switch with Sealing Washer b Harness Wires TESTING 1 With the transmission COLD connect one lead of an ohmmeter to one terminal of the transmission switch Connect the other lead of ohmmeter to other terminal NOTE Switch shown removed for visual clarity only 72771 a b a Ohmmeter Leads b Transmission F...

Page 427: ...d e a Suitable Container b Thermometer c Heat Source d Transmission Fluid Temperature Switch e Ohmmeter Leads f Audio Warning Buzzer With Jumper Lead Test Temperature Switch Condition 126 138 Degrees C 258 282 Degrees F Closed 103 117 Degrees C 218 242 Degrees F Open 6 Turn heat source off Allow sand to cool Note thermometer reading to ensure switch opens at specified temperature while cooling 7 R...

Page 428: ... and secure 6 Connect second station instrument harness to Y box or Y harness connector tagged or titled 2nd STATION 7 Connect primary station instrument harness to Y box or Y harness connector tagged or titled MAIN STATION 8 Connect extension harnesses from engine harness to Y box or Y harness connector 9 Secure harnesses to boat at least every 460 mm 18 in using appropriate fasteners 77223 a b c...

Page 429: ...HARNESS CONNECTIONS 75305 76057 75871 a c d 75884 b e f g 1 2 3 4 5 6 Sterndrive Shown Inboard Similar a Second 2nd Station Instrumentation b Second Station Instrument Harness c Primary Station Instrument Harness d Primary MAIN Station Instrumentation e Y Box Harness f Extension Harness g To Engine ...

Page 430: ... WIRING HARNESS CONNECTIONS a c d 77223 b e f g Typical a Primary MAIN PANEL Station Instrumentation and Harness b Primary Station Extension Harness c Second 2nd PANEL Station Instrumentation and Harness d Second Station Extension Harness e Y Harness f Extension ENGINE Harness g To Engine ...

Page 431: ...ion while a sterndrive or transmission is in a gear STERNDRIVE MCM MODELS Ensure neutral start safety circuit remote control connections are made before use IMPORTANT The two bullet connectors on primary station harness YEL RED wire as shipped from the factory have to be disconnected and reconnected to Neutral Start Safety Circuit wires from the remote control 1 Disconnect the two YEL RED bullet c...

Page 432: ...T wire must be disconnected After doing so connect female YEL WHT terminal and male YEL RED terminal to Neutral Start Safety Circuit wires from remote control Leave the other two connectors disconnected 1 Disconnect the two bullet connectors on the YEL RED wire 2 Disconnect the two bullet connectors on the YEL WHT wire 3 Connect female YEL WHT terminal and male YEL RED terminal to neutral start sa...

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Page 435: ...ive MCM Models 4E 4 Engine Wiring Starting and Charging System 4E 4 ECM and Fuel System Wiring 4E 8 Quicksilver Instrumentation Wiring 4E 10 Power Trim System Wiring Diagram 4E 14 MerCathode System Wiring Diagram 4E 15 Inboard MIE Models 4E 16 Engine Wiring Starting and Charging System 4E 16 ECM and Fuel System Wiring 4E 20 Quicksilver Primary Instrumentation Wiring 4E 22 Models With Early Connect...

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Page 437: ...ark Special Tools Description Part Number DMT 2000A Tachometer Multi Meter Kit 91 854009A3 Tools Kent Moore Tools Kent Moore Tools Inc 29784 Little Mack Roseville MI 48066 Phone 313 774 9500 Description Part Number DVOM J 34029 A or Equivalent Lubricants Sealants Adhesives Description Part Number Liquid Neoprene 92 25711 2 General Information NOTE If using other than Quicksilver instrumentation an...

Page 438: ... BLK W G BRN B P EX S L2 RED RED RED BLK RED PNK BRN BLK YEL BLK BLK BLK BLK BLK BLK BLK BLK BLK ORN ORN ORN LT BLU GRY WHT GRY GRY WHT RED BLK RED PPL BLK RED RED RED RED RED RED RED RED RED BLU PPL PPL PPL PPL BRN BRN BRN BRN BRN BRN BRN BRN PPL BLK PPL BRN BRN BRN BLK BLK RED GRN WHT RED RED PPL PPL PPL PPL BRN BRN BLK ORN ORN ORN BLK RED BLK YEL YEL BLU BLK BLU BLK GRN RED PNK BRN WHT PNK PPL ...

Page 439: ...ne Harness Connector 24 5 Amp Fuse 1 Wires to trim pump 2 Wires to MerCathode electrode ECM FUEL SYSTEM HARNESS CONNECTOR NOTE Refer to Item Number on Electrical Box from preceding page Terminal Number Wire Color Code Terminal Number Wire Color Code Terminal Number Wire Color Code 1 PNK 5 BRN BLK 9 RED 2 BRN WHT 6 YEL BLK 10 BLK 3 BLU BLK 7 GRN 11 BLK 4 PPL 8 RED ENGINE HARNESS CONNECTOR NOTE Refe...

Page 440: ...BRN BLK BLK RED GRN WHT RED RED RED RED RED BRN BLK ORN ORN BLK RED BLK YEL RED YEL RED BLU BWN BLU BWN PPL YEL PPL YEL 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 TAN 24 GRN 1 2 BRN BRN BRN B P EX S L2 BLK GRN BLU PPL PPL 18 PPL GRN BRN BRN GRN PPL YEL BRN YEL WHT GRN RED GRY BLK TAN WHT TAN WHT TAN WHT BRN BRN PPL TAN BLK TAN BLK TAN BLK TAN RED LT BLU TAN BLU TAN BLK PPL WHT PPL WHT ...

Page 441: ...oined With Screw and Nut 27 Idle Speed Setting Circuit 1 Wires to trim pump 2 Wires to MerCathode electrode ECM FUEL SYSTEM HARNESS CONNECTOR NOTE Refer to Item Number 1 on Electrical Box from preceding page Terminal Number Wire Color Code Terminal Number Wire Color Code Terminal Number Wire Color Code 1 PNK 5 BRN BLK 9 RED 2 BRN WHT 6 YEL BLK 10 BLK 3 BLU BWN 7 GRN 11 BLK 4 PPL 8 RED ENGINE HARNE...

Page 442: ...ED BLU BLK BLU BLK BRN BLK GRN BLK WHT YEL BLU WHT BLU WHT GRN YEL PNK ORN WHT GRN RED GRN RED GRN RED BLK BLK BLK RED RED RED RED RED RED RED WHT BLU YEL GRN YEL BLU PNK WHT RED BRN BLK 1 2 1 2 WHT RED BRN WHT ORN WHT BLU RED GRN GRN BLU YEL BLU YEL RED ORN ORN ORN RED RED BRN BLU WHT BLU RED RED BLU WHT BRN BRN PPL WHT BRN WHT BLK WHT BLK WHT BLK WHT BLK BLK PUR BLK PUR BLK PUR BLK PUR PPL BLK B...

Page 443: ...Electrical Box from preceding page Terminal Number Wire Color Code Terminal Number Wire Color Code Terminal Number Wire Color Code 1 PNK 5 BRN BLK 9 RED 2 BRN WHT 6 BLK YEL 10 BLK 3 BLU BLK 7 WHT RED 11 BLK 4 GRN RED 8 RED 12 RED ORN ECM CONNECTOR NOTE Refer to Item Number 2 connected to ECM from preceding page Terminal Number Wire Color Code Terminal Number Wire Color Code Terminal Number Wire Co...

Page 444: ...UR PUR PUR PUR PUR GRN GRN GRN GRN PUR PUR PUR B I S TAN BLK YEL RED RED RED BLK YEL RED YEL RED WHT YEL WHT RED YEL RED YEL RED BRN BLU TAN BLU TAN GRY GRY GRY TAN BLK TAN BLK TAN BLK TAN BLK LT BLU LT BLU BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BRN WHT BRN WHT TAN TAN TAN TAN RED BRN BRN BRN GRN GRN ORN RED BLK BRN PUR PUR PUR PUR GRN GRN YEL RED YEL RED BRN WHT BRN WHT RED BLK b a e d c 1 2 3 4...

Page 445: ...st Switch 9 Key Switch 10 20 Amp Fuse 11 Audio Warning Alarms Oil Pressure and Engine Coolant Temperature 12 Neutral Start Safety Circuit For Sterndrive MCM Remote Control 13 Instrument Harness Connector 1 Bullet connectors shown Alternately if equipped connect wires together with ring terminals using screws and hex nuts Apply Liquid Neoprene to connec tions and slide rubber sleeves over connectio...

Page 446: ...T BLU BLU BLU PPL BLK GRN TAN TAN TAN GRY GRY BRN BRN TAN BLK BLK TAN WHT PPL ORN RED BRN BLU TAN PPL WHT PPL ORN YEL RED YEL RED RED YEL RED YEL 76908 GRY YEL BLK BLK PPL GRN 19 20 21 1 2 3 4 5 6 13 14 15 UP YEL BLK PPL WHT PPL PPL PPL 87 30 86 85 BRN BLU TAN GRN YEL RED 17 16 ORN PPL PPL BLK YEL BRN WHT BLU TAN PPL BLK PPL PPL TAN WHT TAN BLK TAN WHT TAN WHT TAN BLK TAN BLK PPL TAN BLK PPL TAN W...

Page 447: ... Deutscht 19 Fuel Gauge Optional 20 Connector Without Relay Relay To Be Installed if Second Station Equipped 21 Connector Jumper If Single Station Only 22 20 Amp Fuse 23 Audio Warning Delay Relay During Pre Heat 24 Diode Pack 1 Bullet connectors shown Alternately if equipped connect wires together with ring terminals using screws and hex nuts Apply Liquid Neoprene to connec tions and slide rubber ...

Page 448: ...W LT OR LIT LIGHT DRK DARK b c d e f g h a WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Page 4E 14 90 860074 1 FEBRUARY 2002 Power Trim System Wiring Diagram a 20 Amp Fuse b Ground Bolt Floor Mount c UP Solenoid d 110 Amp Fuse e DOWN Solenoid f Trailer Switch g Neutral Switch To Instrument Wiring Harness h Trim Limit Switch ...

Page 449: ...GRN GREEN ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LT OR LIT LIGHT DRK DARK WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 90 860074 1 FEBRUARY 2002 Page 4E 15 MerCathode System Wiring Diagram a Controller b 20 Amp Fuse c Electrode ...

Page 450: ...ED RED BLK RED PNK BRN BLK YEL BLK BLK BLK BLK BLK BLK BLK BLK ORN ORN ORN LT BLU GRY WHT GRY GRY WHT RED BLK BLK RED RED RED RED RED RED RED RED RED BLU PPL PPL PPL PPL BRN BRN BRN BRN BRN BRN BRN BRN PPL PPL BRN BRN BRN BLK BLK RED GRN WHT RED RED PPL PPL PPL PPL BRN BRN BLK ORN ORN ORN BLK RED BLK YEL YEL BLU BLK BLU BLK GRN RED PNK BRN WHT PNK PPL BLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 451: ...parated Not used on this model Tape each wire separately with at least two layers of electrical tape ECM FUEL SYSTEM HARNESS CONNECTOR NOTE Refer to Item Number 1 on Electrical Box from preceding page Terminal Number Wire Color Code Terminal Number Wire Color Code Terminal Number Wire Color Code 1 PNK 5 BRN BLK 9 RED 2 BRN WHT 6 YEL BLK 10 BLK 3 BLU BLK 7 GRN 11 BLK 4 PPL 8 RED ENGINE HARNESS CONN...

Page 452: ... RED RED RED RED BRN BLK ORN ORN BLK RED BLK YEL RED YEL RED BLU BLK BLU BLK PPL YEL PPL YEL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 TAN GRN 1 BRN BRN BRN B P EX S L2 BLK GRN BLU PPL PPL 18 PPL GRN BRN BRN GRN PPL YEL BRN YEL WHT GRN RED GRY BLK TAN WHT TAN WHT TAN WHT BRN BRN PPL TAN BLK TAN BLK TAN BLK TAN RED LT BLU TAN BLU TAN BLK PPL WHT PPL WHT TAN BLK BRN BRN BRN BLK BLK BLK B...

Page 453: ... separated Not used on this model Tape each wire separately with at least two layers of electrical tape ECM FUEL SYSTEM HARNESS CONNECTOR NOTE Refer to Item Number 1 on Electrical Box from preceding page Terminal Number Wire Color Code Terminal Number Wire Color Code Terminal Number Wire Color Code 1 PNK 5 BRN BLK 9 RED 2 BRN WHT 6 YEL BLK 10 BLK 3 BLU BLK 7 GRN 11 BLK 4 PPL 8 RED 12 RED ORN ENGIN...

Page 454: ... WHT GRN WHT BLU RED BLU BLK BLU BLK BRN BLK GRN BLK WHT YEL BLU WHT BLU WHT GRN YEL PNK ORN WHT GRN RED GRN RED GRN RED BLK BLK BLK RED RED RED RED RED RED RED WHT BLU YEL GRN YEL BLU PNK WHT RED BRN BLK 1 2 1 2 WHT RED BRN WHT ORN WHT BLU RED GRN GRN BLU YEL BLU YEL RED ORN ORN ORN RED RED BRN BLU WHT BLU RED RED BLU WHT BRN BRN PPL WHT BRN WHT BLK WHT BLK WHT BLK WHT BLK BLK PUR BLK PUR BLK PUR...

Page 455: ...Electrical Box from preceding page Terminal Number Wire Color Code Terminal Number Wire Color Code Terminal Number Wire Color Code 1 PNK 5 BRN BLK 9 RED 2 BRN WHT 6 BLK YEL 10 BLK 3 BLU BLK 7 WHT RED 11 BLK 4 GRN RED 8 RED 12 RED ORN ECM CONNECTOR NOTE Refer to Item Number 2 connected on ECM from preceding page Terminal Number Wire Color Code Terminal Number Wire Color Code Terminal Number Wire Co...

Page 456: ...R PUR PUR GRN GRN GRN GRN PUR PUR PUR B I S TAN BLK YEL RED RED RED BLK YEL RED YEL RED WHT YEL WHT RED YEL RED YEL RED BRN BLU TAN BLU TAN GRY GRY GRY TAN BLK TAN BLK TAN BLK TAN BLK LT BLU LT BLU BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BRN WHT BRN WHT TAN TAN TAN TAN RED BRN BRN BRN GRN GRN RED BLK BRN PUR PUR PUR PUR GRN GRN YEL RED YEL RED BRN WHT BRN WHT RED BLK b a e d c 1 2 3 4 5 6 1 2 3 4 ...

Page 457: ... Panel Lights Audio Warning Test Switch 9 Key Switch 10 20 Amp Fuse 11 Audio Warning Horns Oil Pressure and Engine Coolant Temperature 12 Neutral Start Safety Circuit Refer To Transmission Neutral Start Safety Switch Circuit On Inboard Models 13 Instrument Harness Connector Standard 1 Keep wires separated Not used on this model Tape each wire separately with at least two layers of electrical tape ...

Page 458: ...AN WHT PPL ORN RED BRN BLU TAN PPL WHT PPL ORN YEL RED YEL RED YEL RED YEL RED 76908 GRY YEL BLK BLK PPL GRN BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN ORANGE PPL PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW PNK PINK LT LIGHT DRK DARK 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 22 UP S B I YEL BLK PPL WHT PPL PPL PPL 87 30 86 85 BRN BLU TAN GRN YEL RED 17 16 ORN PPL PPL BLK YEL BRN WHT BLU T...

Page 459: ...fety Switch Circuit On Inboard Models 15 Spare Wires Optional Hour Meter Gauge 16 Audio Warning Horn Oil 17 Audio Warning Horn Temperature 18 Instrument Harness Connector 21 Pin Deutscht 19 Fuel Gauge Optional 20 Connector With Relay If Second Station Equipped 21 Connector Jumper If Single Station Only 22 20 Amp Fuse 23 Audio Warning Delay Relay During Pre Heat 24 Diode Pack 1 Keep wires separated...

Page 460: ...y Liquid Neoprene to connections and slide rubber sleeves over connections 76057 YEL RED YEL RED 2 3 4 7 1 5 6 8 9 10 11 BRN BLK 13 14 15 16 12 ORN PUR PUR BLK GRY BLU TAN LT BLU TAN ORN BRN WHT BLK BLK BLK BLK BLK PUR PUR PUR PUR PUR GRN GRN GRN GRN GRN PUR BLK PUR TAN BRN WHT BRN WHT ORN RED PUR GRN BLU TAN BRN BLK BLK BLK BLK PUR BRN WHT BLK BLK BLK BLK BLK PUR PUR PUR PUR GRN GRN GRN GRN PUR P...

Page 461: ...BLK PUR PUR PUR PUR PUR GRN GRN GRN GRN GRN PUR BLK PUR TAN BRN WHT BRN WHT ORN RED PUR GRN BLU TAN BRN BLK BLK BLK BLK PUR BRN WHT BLK BLK BLK BLK BLK PUR PUR PUR PUR GRN GRN GRN GRN PUR PUR PUR TAN BLK YEL RED RED RED BLK YEL RED YEL RED WHT YEL WHT YEL WHT RED WHT RED YEL RED YEL RED BLU TAN BLU TAN GRY GRY GRY TAN BLK TAN BLK TAN BLK TAN BLK LT BLU LT BLU BLK BLK BLK BLK BLK BLK BLK BLK BLK BL...

Page 462: ...RN YEL YEL BRN WHT BRN WHT BRN WHT BLU BLU BLU PPL BLK GRN TAN TAN TAN GRY GRY BRN BRN TAN BLK BLK TAN WHT PPL ORN RED BRN BLU TAN PPL WHT PPL YEL RED YEL RED RED YEL RED YEL 76907 GRY YEL BLK BLK PPL GRN 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 UP BLK PPL WHT PPL PPL PPL 87 30 86 85 BRN BLU TAN GRN YEL RED 17 16 PPL PPL BLK YEL BRN WHT BLU TAN PPL BLK PPL PPL TAN WHT TAN BLK TAN WHT TAN WHT T...

Page 463: ...res Not Used 20 Connector Without Relay 21 Connector Jumper 22 20 Amp Fuse 23 Audio Warning Delay Relay During Pre Heat 24 Diode Pack 25 Neutral Start Safety Circuit Sterndrive MCM Remote Control 1 Bullet connectors shown Alternately if equipped connect wires together with ring terminals using screws and hex nuts Apply Liquid Neoprene to connec tions and slide rubber sleeves over connections 2 Kee...

Page 464: ... WHT BRN WHT BRN WHT BLU BLU BLU PPL BLK GRN TAN TAN TAN GRY GRY BRN BRN TAN BLK BLK TAN WHT PPL ORN RED BRN BLU TAN PPL WHT PPL YEL RED YEL RED RED YEL RED YEL 76907 GRY YEL BLK BLK PPL GRN 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 UP BLK PPL WHT PPL PPL PPL 87 30 86 85 BRN BLU TAN GRN YEL RED 17 16 PPL PPL BLK YEL BRN WHT BLU TAN PPL BLK PPL PPL TAN WHT TAN BLK TAN WHT TAN WHT TAN BLK TAN BLK...

Page 465: ...ning Horn Temperature 18 Instrument Harness Connector Deutscht 19 Fuel Gauge Wires Not Used 20 Connector Without Relay 21 Connector Jumper 22 20 Amp Fuse 23 Audio Warning Delay Relay During Pre Heat 24 Diode Pack 25 Neutral Start Safety Circuit Refer To Transmission Neutral Start Safety Switch Circuit On Inboard Models 1 Keep wires separated Not used on this model Tape each wire separately with at...

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Page 467: ... Discharge Damage 5A 6 Diagnostic Information 5A 7 Terminology 5A 7 Electronic Control Module ECM and Sensors 5A 9 General Description 5A 9 Computers and Voltage Signals 5A 9 Analog Signals 5A 9 Analog Value Conditioning 5A 11 Digital Signals 5A 13 Engine Control Module ECM 5A 15 Speed Density System 5A 17 ECM Input and Sensor Descriptions 5A 18 Fuel Management 5A 26 Control 5A 26 Modes Of Operati...

Page 468: ...DESCRIPTION SERVICE MANUAL NUMBER 22 Page 5A 2 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 469: ...on illustrations and specifications contained herein are based on the latest product information available at the time of publication approval The right is reserved to make changes at any time without notice An understanding of the material contained in this manual and in subsequent publications issued when necessary will assist service personnel in properly maintaining the quality to which Mercur...

Page 470: ...epair may damage the engine or render it unsafe It is also important to understand that these Cautions and Notes are not exhaustive because it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions The following requirements must be observed when working on EDI equipped engines Before removing any ECM Engine Control Module syste...

Page 471: ...gital multimeter in series with the test light being tested and power the test light ammeter circuit with the battery b If the ammeter indicates LESS than 3 10 amp current flow 3 A or 300 mA the test light is SAFE to use c If the ammeter indicates MORE than 3 10 amp current flow 3 A or 300 mA the test light is NOT SAFE to use a b c f Amp Meter g Test Light h 12 Volt Battery NOTE Using a test light...

Page 472: ...ne compartment for proper connections burned or chafed spots pinched wires or contact with sharp edges or hot exhaust manifolds This visual physical inspection is very important It must be done carefully and thoroughly Electrostatic Discharge Damage Electronic components used in control systems are often designed to carry very low voltage and are very susceptible to damage caused by electrostatic ...

Page 473: ...e are no multiple failures Terminology ABBREVIATIONS ADF MAP Manifold Atmospheric Pressure Sensor BARO Barometric Pressure BAT Battery Positive Terminal Battery or System Voltage B Battery Positive CKT Circuit CONN Connector CYL Cylinder DEG Degrees DIAG Diagnostic DLC Data Link Connector DTC Diagnostic Trouble Code DVOM Digital Volt Ohmmeter ECM Engine Control Module ECT Engine Coolant Temperatur...

Page 474: ...L Malfunction Indicator Lamp msec Millisecond mV Millivolt NBF Instrumented Injector N C Normally Closed N O Normally Open PID Packet of Informational Data PROM Programmable Read Only Memory RAM Random Access Memory REF HI Reference High REF LO Reference Low ROM Read Only Memory SRC Signal Range Check SW Switch TACH Tachometer TERM Terminal TP Throttle Position Sensor V Volts VAC Vacuum WOT Wide O...

Page 475: ...can send information by changing levels changing waveform shape or changing the speed at which the signal switches from one level to another Computers use voltage signals to communicate with one another The different sections inside computers also use voltage signals to communicate with each other There are two kinds of voltage signals analog and digital Both of these are used in computer systems ...

Page 476: ... this wiper position changes the signal voltage returned to the computer also changes 3 Wire Sensor TWO WIRE SENSORS ECT The following figure is the schematic of a 2 wire type sensor This sensor is basically a variable resistor in series with a fixed known resistor within the computer By knowing the values of the input voltage and the voltage drop across the known resistor the value of the variabl...

Page 477: ...perature Intake manifold pressure boost pressure Atmospheric pressure Throttle Position TP Instrumented Injector Needle movement TP current Reference voltage Battery voltage ANALOG VALUE SAMPLING Sampling saves the results of the periodic analog digital conversion as raw values The stored values are evaluated at a later time In addition to periodic signal sampling there is also an active speed syn...

Page 478: ... for evaluating the TP sensor and MAP sensor These signals have a supply voltage through which the raw value is scaled In case of TP sensor failure such as a SRC defect on supply voltage a default value for fuel quantity calculation would be substituted by the ECM The engine would only be capable of a default set speed of 800 rpm The ECM is programmed to respond appropriately to variations from ot...

Page 479: ...gine rpm at a lower level Although the computer uses 8 bit digital codes internally and when talking to another computer each bit can have a meaning PROCESSING THE DIGITAL INPUTS The digital inputs are centrally read processed and distributed throughout the system The first input message indicates the raw electrical conditions a special internal message indicates the logical validity checked condi...

Page 480: ...s the voltage when the switch is OPEN Discretes can also be used to inform a computer of FREQUENCY information PULSE COUNTERS For the computer to determine frequency information from a switched input the computer must measure the time between voltage pulses As a number of pulses are recorded in a set amount of time the computer can calculate the frequency The meaning of the frequency number can ha...

Page 481: ...des which identify the problem areas to aid the technician in making repairs 75301 D2 8L D Tronic and D4 2L D Tronic Engine Control Module ECM The ECM is supplied voltage from the key switch through a 5 ampere fuse and holder located in the electrical box on the port side of the engine If the fuse is defective blown certain systems will not function properly As an example the engine may crank but ...

Page 482: ...readings MEMORY There are three types of memory storage within the ECM ROM RAM and EEPROM ROM Read Only Memory ROM is a permanent memory that is physically soldered to the circuit boards within the ECM The ROM contains the overall control programs Once the ROM is programmed it cannot be changed The ROM memory is non erasable and does not need power to be retained RAM Random Access Memory RAM is th...

Page 483: ... IAT sensor is a thermistor that changes its resistance depending on the air temperature When the temperature is low the resistance is high and when the temperature is high the resistance is low The Manifold Absolute Pressure MAP sensor circuit is a sensor that monitors the changes in intake manifold pressure which results from changes in engine loads These pressure changes are supplied to the ECM...

Page 484: ...brief description of each Sensors ECM Actuat ors Number 1 Cylinder Fuel Injector Injected fuel Fuel Injector Needle motion sensor Injected fuel quantity Electronic ally controlled fuel fuel injection Temperature sensors water air fuel Engine shut off pump Fuel Quantity and Micro and Timing Sensor for control collar position processors Start of injection Engine rpm Speed sensor Starting control Glo...

Page 485: ...tion variable type input creates the timing signal for the ECM This signal is used for a number of control and testing functions within the ECM 75339 a b c Instrumented Injector a Instrumented Injector b Electrical Harness Connector c Locking Tab A failure in the Instrumented Injector circuit should set Code P1201 or P1725 Display of these codes indicates a failure in the sensor circuit so proper ...

Page 486: ...or b Harness Connector c Locking Tab The ECM supplies a fixed current to the ECT through a resistor in the ECM and measures the voltage The voltage will be high when the engine is cold and low when the engine is hot By measuring the voltage the ECM knows the engine coolant temperature Engine coolant temperature affects most systems the ECM controls A failure in the ECT circuit should set Code P011...

Page 487: ...a thermistor a resistor which changes value based on temperature Low temperature produces a high resistance while high temperature causes a low resistance 75340 a b c a IAT Sensor b Harness Connector c Locking Tab The ECM supplies a fixed current to the sensor through a resistor in the ECM and measures the voltage The ECM voltage will be high when the intake air is cold and low when the intake man...

Page 488: ...As the manifold pressure changes the electrical resistance of the MAP sensor also changes By monitoring the sensor output voltage the ECM knows the manifold pressure A higher pressure low vacuum high voltage requires more fuel while a lower pressure higher vacuum low voltage requires less fuel The ECM uses the MAP sensor to control fuel delivery and injection timing A closed throttle position on e...

Page 489: ...een zero and maximum e g for cold starting Using an angle sensor potentiometer called the Fuel Quantity Sensor the rotary actuator s angle of rotation and thus the position of the control collar are reported back to the ECM and used to determine the injected fuel quantity as a function of engine speed When no voltage is applied to the actuator its return springs reduce the injection quantity to ze...

Page 490: ...rcuit should set Code P0180 Remember this code indicates a failure in the fuel temperature sensor circuit so proper use of the chart will lead to either repairing a wiring problem or determining the failure is the fuel pump However it is not suggested that the pump be replaced for this failure unless the customer complains of related driveability problems ENGINE RPM SPEED SENSOR The Engine rpm Spe...

Page 491: ...that at wide open throttle WOT the output voltage should be near 4 5 volts By monitoring the output voltage from the TP sensor the ECM can determine fuel delivery based on the throttle position operator demand 75336 a b a TP Sensor b Electrical Connector Failures that might occur with the TP sensor are TP sensor out of range SRC High or Low Low idle switch defective TP sensor supply voltage incorr...

Page 492: ...the injected quantity and timing by the ECM This electronic control allows the ECM to maintain optimum engine performance and the lowest exhaust emissions possible Recall that the EDI system uses inputs from sensors to make decisions on the quantity of fuel and amount of pump timing advance or retard allowed In order for the ECM to properly calculate advance it must always know the engine speed Th...

Page 493: ...nformation The ECM sets the fuel injection timing based on the signal from the coolant temperature sensor ENGINE OPERATION During engine operation the ECM calculates the fuel flow rate based on signals from the throttle position sensor and Engine rpm Speed sensor This information is then sent to the injection pump which regulates the rate of the fuel flowing into the cylinders of the engines The i...

Page 494: ...ine operation control function particularly during acceleration and deceleration ELECTRONIC INJECTION PUMP The electronic injection pump with its upper chambers high pressure and lower chamber low pressure pump and actuators are the same as the mechanically controlled injector pump The pump interior pressure is dependent upon pump speed Similar to the mechanical timing device this pressure is appl...

Page 495: ...turned to the tank The position of the Timing Solenoid Valve piston is actually determined by the difference in the pressure acting on the face of the piston The position of the injection timing adjustment piston also determines the position of the piston in its valve seat Rotating the bearing ring changes the piston valve seat phasing compared to the position of the rotating cam disk This advance...

Page 496: ...ere are two recommended methods of retrieving fault codes from the ECM 1 Scan Tool 2 Blink Code Tool ECM Self Diagnostics The ECM performs a continual self diagnosis on certain control functions This diagnostic capability is complemented by the diagnostic procedures contained in this manual The ECM s language for communicating the source of a malfunction is a system of diagnostic codes The codes a...

Page 497: ...stic system has detected a problem If the problem is corrected the light will go out in most cases after ten seconds but a code will remain stored in the ECM When the lamp remains ON while the engine is operating or when a malfunction is suspected due to a driveability problem an EDI Diagnostic Circuit Check must be performed These checks will expose malfunctions which may not be detected if other...

Page 498: ...M When unexpected codes appear during the code reading process one can assume that these codes were set by an intermittent malfunction and could be helpful in diagnosing the system An intermittent code may or may not reset IF IT IS AN INTERMITTENT FAILURE A DIAGNOSTIC CODE CHART IS NOT USED Consult the Diagnostic Help section following the Circuit Description information Troubleshooting also cover...

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Page 501: ...Identification 5B 3 Specifications 5B 3 Torque 5B 3 Tools 5B 3 Lubricants Sealants Adhesives 5B 3 Precautions 5B 4 Exploded View 5B 6 Fuel Delivery Pump Fuel Filter and Related Components 5B 6 Testing 5B 8 Removal 5B 10 Installation 5B 11 Water Separating Fuel Filter 5B 13 Removal 5B 13 Installation 5B 13 Water Drain Valve Operation 5B 15 Purging Air From The Fuel System 5B 16 ...

Page 502: ...FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Page 5B 2 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 503: ... S Qts at 2500 rpm Delivery Pressure Measured at 2500 14 34 kPa 2 5 psi Supply Restriction Measured at 2500 rpm no load 20 261 kPa 6 in Hg Return Pressure 13 78 kPa 2 psi Torque Description Nm lb in lb ft Filter Header To Bracket Nut 32 24 Pump To Block Nut 24 18 Fuel Filter Hand tighten only Tools DESCRIPTION PART NUMBER Fuel Pressure Gauge 0 103 35 kPa 0 15 psi Obtain Locally Lubricants Sealants...

Page 504: ...to ignite WARNING FIRE HAZARD Wipe up any spilled fuel immediately Dispose of rags appropriately Dispose of fuel soaked rags paper etc in an appropriate air tight fire retardant container Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death WARNING Avoid diesel fuel fire or explosion Improper installation of brass fittings or plugs...

Page 505: ...fuel lines primers fittings and fuel filters should be inspected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine operation WARNING Make sure that no fuel leaks exist before closing engine hatch CAUTION Do NOT operate engine without cooling water being supplied to seawater pickup pump or pump impeller will be dama...

Page 506: ... AND FUEL FILTER SERVICE MANUAL NUMBER 22 Page 5B 6 90 860074 1 FEBRUARY 2002 Exploded View Fuel Delivery Pump Fuel Filter and Related Components 75406 1 2 3 4 6 5 7 8 9 9 9 10 10 10 11 12 20 15 16 17 18 19 21 A 13 14 22 ...

Page 507: ...5 Fuel Filter 6 O ring 7 Drain Cap 8 Pipe Pump To Filter Header 9 Hollow Bolt 3 10 Sealing Washer 11 Pipe Filter Header To Injection Pump 12 Nut 13 Fuel Pump Cover 14 Diaphragm 15 Diaphragm Spring 16 O ring 17 Stud 2 18 Lockwasher 2 19 Nut 2 20 Fuel Inlet Fitting 21 Elbow Fittings 22 Bracket Description Part Number A 30W Engine Oil Obtain Locally ...

Page 508: ...ect engine performance TESTING FUEL DELIVERY PUMP PRESSURE 3 Remove the bleeder valve from the filter header 4 Install a suitable barbed tappered fitting with a short section of fuel hose connected 5 Attach a suitable 0 100 kPa 0 15 PSI pressure gauge to this hose 71967 74726 Testing Delivery Pressure c Bleeder Valve d Suitable Barbed Fitting e Pressure Gauge 6 If the measured value is not within ...

Page 509: ... 9 TESTING FUEL SYSTEM RESTRICTION TO DELIVERY PUMP 1 Install a suitable vacuum gauge to the inlet side of fuel delivery pump 2 If measured value is greater than specified repair as needed 71967 75298 a b c Testing Restriction a Inlet Fitting b Suitable Vacuum Gauge c Fuel Supply From Fuel Tank ...

Page 510: ...Remove fuel supply hose Plug hose to prevent fuel from leaking into boat 75298 a b Typical d Fuel Delivery Pump e Fuel Supply Hose 3 Remove the hollow bolt from the fuel outlet pipe Discard sealing washers 4 Remove the fuel pump Discard the O ring seal 75298 a b b a b c d e Typical a Hollow Bolt b Sealing Washer c Lockwasher d Mounting Nut e O ring ...

Page 511: ...w sealing washers on hollow bolt attach fuel inlet fitting to fuel pump as shown 2 Tighten hollow bolt securely 75298 a c b c a Hollow Bolt b Sealing Washer c Fuel Inlet Fitting 3 Using a new O ring install the fuel pump on the engine block Temporarily hand tighten the mounting nuts a b c 75298 a O ring b Lockwasher c Nut ...

Page 512: ...g washers on hollow bolt attach fuel outlet pipe to fuel pump 5 Torque fuel pump mounting nuts securely 6 Tighten fuel outlet pipe hollow bolt securely 7 Connect fuel supply hose Tighten hose clamp securely d a b b c f e 75298 a Hollow Bolt b Sealing Washer c Fuel Outlet Pipe d Mounting Nut e Clamp f Fuel Supply Hose ...

Page 513: ...el filter and sealing ring from mounting bracket Do NOT use a filter wrench IMPORTANT Element cannot be cleaned and reused It must be replaced 3 Remove the drain cap and O ring from bottom of the existing filter Note position of O ring seal Inspect and replace damaged components 70161 75579 b a c d a Locking Ring b Filter Element c Drain Cap d O ring 4 Discard filter and sealing ring Installation ...

Page 514: ...Sealing Ring Lubricate d Water Separating Fuel Filter NOTE Place a suitable container under fuel filter to catch excess fuel 3 Loosen bleed screw on fuel filter bracket 4 Move plunger on hand pump primer up and down repeatedly until an air free stream of fuel flows from bleed screw Filter is full when this occurs 5 Tighten bleed screw 74726 a b a Pump Primer Knob b Bleed Screw 6 Connect battery ca...

Page 515: ...tarting daily operations In cold weather where there is a possibility that the condensed water will freeze drain the filter shortly after the end of daily operations 1 Using a suitable container to catch contaminated fuel and or water open drain cap at bottom of filter by turning the drain counterclockwise as viewed from the bottom of the filter 2 Drain until fuel is clear in appearance 74726 a b ...

Page 516: ...stem In most cases the design of the EDI System will prevent needing to purge the fuel injection pump itself However should it become necessary to purge air from the fuel injection pump proceed as follows NOTE Place suitable container under the fuel filter and injection pump to catch excess fuel 1 Bleed air from the water separating fuel filter 2 Loosen the bleed screw on injection pump 3 Move plu...

Page 517: ...FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 90 860074 1 FEBRUARY 2002 Page 5B 17 THIS PAGE IS INTENTIONALLY BLANK ...

Page 518: ...FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Page 5B 18 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 519: ...dentification 5C 3 Specifications 5C 3 Torque 5C 3 Tools 5C 4 Bosch 5C 4 Lubricants Sealants Adhesives 5C 4 Precautions 5C 5 Description 5C 6 Fuel Injector Cutaway View 5C 7 Exploded View 5C 8 Injector Test Engine Misfiring 5C 9 Removal 5C 10 Inspection 5C 12 Testing 5C 12 Installation 5C 13 Purging Air From Fuel Injectors Bleeding 5C 16 ...

Page 520: ...FUEL INJECTORS SERVICE MANUAL NUMBER 22 Page 5C 2 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 521: ...rumented Injector Similar Specifications Description Specification Manufacturer Robert Bosch Corporation D2 8L D Tronic Injector Type D4 2L D Tronic Multi Orifice Hole Type Nozzle Opening Pressure New Injector 27 000 kPa 3915 psi Spray Angle 157 Degrees Spray Hole Diameter 0 25 mm 001 in Torque Description Nm lb in lb ft Injector Clamp Nut 24 18 Injection Pipe Sleeve Nut 17 156 Injection Pipe Clam...

Page 522: ... Bosch EFEP60H Nozzle Tester 0 681 200 502 Description Robert Bosch Corporation 2800 South 25th Avenue Broadview IL 60153 Mailing Address P O Box 4601 North Suburban IL 60197 Phone 312 865 5200 74442 Lubricants Sealants Adhesives Description Part Number 30W Engine Oil Obtain Locally ...

Page 523: ...el leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death Careful periodic inspection of entire fuel system is mandatory particularly after storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines primers fittings and fuel filters should be inspected for leakage softening hardening swelling or corrosion An...

Page 524: ...the previous throttling pintle nozzles the hole type nozzle must be installed in a given position The spray holes are at different angles in the nozzle body and must be correctly aligned with regard to the combustion chamber The nozzle has a specially shaped end or nozzle cone into which the needle of the injector seats Two precisely sized and matched pressure springs hold the needle seated The sp...

Page 525: ...10 11 12 1 2 3 4 5 6 7 8 9 6 7 5 Instrumented Injector Needle Motion Sensor Shown Non Instrumented Similar 1 Holder Body 2 Adjusting Spindle 3 Contact Lug 4 Sensor Coil 5 Pressure Adjustment Shim 6 Pressure Spring 7 Pressure Spindle 8 Guide 9 Spring Support 10 Stop Sleeve 11 Intermediate Disc 12 Nozzle Retaining Nut ...

Page 526: ...Equipped 6 Injector Clamp 7 Injection Pipe Cylinder 1 8 Injection Pipe Cylinder 2 9 Injection Pipe Cylinder 3 10 Injection Pipe Cylinder 4 11 Injection Pipe Cylinder 5 D4 2L D Tronic Only 12 Injection Pipe Cylinder 6 D4 2L D Tronic Only 13 Clamp 14 Clamp 15 Clamp 16 Hollow Bolt 17 Sealing Washer 18 Hollow Bolt M14 x 1 5 19 Sealing Washer 20 Fuel Return Fitting 21 Return Fuel Connector 22 Hollow Bo...

Page 527: ...ith the engine operating at idle carefully loosen injector pipe sleeve nut at injectors one cylinder at a time a If idle rpm changes injector is operating b If idle rpm does not change injector may be faulty 70148 17 mm a Typical a Sleeve Nut At Injector 10 Check all injectors one at a time 11 Stop engine Replace injector or injectors as necessary 12 If engine continues to misfire check for mechan...

Page 528: ...rn pipe hollow bolts 3 Counterhold fuel return pipe adapter and remove the fuel return pipe hollow bolts Discard sealing washers 4 Remove fuel return pipe b c a d d d c e 73911 Typical a Return Pipe Adapter b Fuel Return Pipe c Hollow Bolts d Sealing Washers e Return Fuel Connector On Injection Pump 5 Loosen fuel injection pipe clamps 6 Loosen fuel injection pipe sleeve nuts a b 73911 a 75583 b a ...

Page 529: ...ector clamp Retain all components 75584 a b a b a Flanged Hex Nut or Hex Nut and Washer If Equipped b Clamp CAUTION To prevent injector nozzle from rusting wet parts with diesel fuel before handling NOTE To assist in removal rotate the injector slightly clockwise and counter clockwise to break any seal formed by paint or corrosion Repeat for each injector if required 10 Withdraw the fuel injector ...

Page 530: ... with injector tester for checking nozzle opening pressure and spray pattern IMPORTANT Mercury Marine does not recommend fuel injectors be disassembled for service If an injector tester is not available substitute a new injector for any injectors thought to be faulty 74442 EFEP60H Nozzle Tester 1 Put on safety glasses 2 Use a nozzle tester to check the injection nozzle opening pressure and the spr...

Page 531: ...146 a a Typical a Copper Sealing Washer 2 Install new O ring seal on injector Lubricate seal with a light coat of 30W engine oil 3 Point fuel return pipe adaptor away from valve cover and install injector Ensure seal is not damaged during installation 4 Install injector clamp nut Torque nut to 24 Nm 18 lb ft 73911 75584 b e a b c d d e a Fuel Injector b Fuel Return Pipe Adaptor c O ring d Clamp e ...

Page 532: ...new sealing washers for each hollow bolt install fuel return pipe on injector adapters IMPORTANT Ensure that each pipe adapter is counterheld with a second wrench when installing the return pipe hollow bolts 7 Counterhold fuel return pipe adapter and tighten hollow bolts securely 73911 75583 a b c a b c c Typical a Fuel Return Pipe b Hollow Bolts c Sealing Washers Two Per Hollow Bolt and Fitting d...

Page 533: ...l fuel return pipe line on injection pump connector Tighten hollow bolt securely 73911 75583 a b c Typical a Fuel Return Pipe b Hollow Bolts c Sealing Washers Two Per Hollow Bolt and Fitting 9 Refer to Purging Air From Fuel Injectors Bleeding to operate the engine and check for fuel leaks Repair as needed 10 Install the engine cover ...

Page 534: ... Ensure that there is sufficient water always available at water inlet holes during operation 1 Supply cooling water to water inlet CAUTION To prevent damage to starter motor Do NOT use for more than 15 seconds at one time Allow at least 2 minutes for starter motor to cool before reusing 2 Put on safety glasses 3 Slightly loosen each injection pipe sleeve nut 4 Crank the engine with the starter mo...

Page 535: ...stallation 10 Start the engine 11 Allow the engine to reach normal operating temperature Check for fuel leaks at injection pump and injectors by placing a piece of paper near the sleeve nuts or pipes to be checked The paper should show fuel spray if leaks are present Do NOT use your fingers to feel for leaks Watch for fuel spray on paper 12 Repair as needed NOTE It is sometimes helpful to use comp...

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Page 537: ...oore Tools 5D 4 Lubricants Sealants Adhesives 5D 4 Precautions 5D 5 Description 5D 6 Fuel Ratings 5D 7 Diesel Fuel in Cold Weather 5D 7 Repair and Service 5D 8 General Information 5D 8 Service Information 5D 8 Testing Information 5D 9 Exploded View 5D 10 Fuel Injection Pump Removal 5D 11 Fuel Injection Pump Installation 5D 16 Installation With Engine Assembled 5D 16 Installation During Engine Reas...

Page 538: ...e and Identification Number D2 8L D Tronic Code VE 4 12 E 1900 LV1857 L718 Bosch Part Number 0 460 424 ___ Quicksilver Part Number 854213 D4 2L D Tronic Code VE 4 12 E 1900 LV1848 L719 Bosch Part Number 0 460 424 ___ Quicksilver Part Number 854134 Specifications Injection Pump Description Manufacturer Robert Bosch Corporation Type of Injection Pump Distributor Type VE Ejection Pressure at Fuel Inj...

Page 539: ... D Tronic MCM and MIE 0 60 0 65 mm 0 023 0 025 in D4 2L D Tronic MCM and MIE 1 74 1 76 mm 0 068 0 069 in Torque Specifications NOTE Securely tighten all fasteners not listed below Description Nm lb in lb ft Pump Mounting Nuts 30 22 Pump Gear 88 64 Fuel Line Sleeve Nut High Pressure 18 156 Special Tools Description Part Number Graduated Disc 1 91 801333500 Injection Pump Gear Puller 91 818372 Crank...

Page 540: ...t Moore Tools Kent Moore Tools Inc 29784 Little Mack Roseville MI 48066 Phone 313 774 9500 Description Part Number High Impedance Multimeter DVM 1 Minimum 10 megohm input impedance required on all voltage ranges As ammeter accurately measures low value current flow As ohmmeter reads 0 200 ohms 2 20 200 kΩ 2 20 mΩ J 34029 A or Equivalent Unpowered Test Light 2 Used to check circuit wiring short to ...

Page 541: ...fuel system is mandatory particularly after storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines primers fittings and fuel filters should be inspected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine operation WARNING Be careful when changing fuel system components diesel...

Page 542: ...puts from various sensors to make decisions on the quantity of fuel and amount of pump timing advance or retard allowed During engine operation the ECM calculates the fuel flow rate based on signals from the Throttle Position sensor and Engine rpm speed sensor This information is then sent to the injection pump which regulates the rate of the fuel flowing into the cylinders of the engine The injec...

Page 543: ...igh altitude use Sulphur content of the above fuel is rated at 0 50 by weight maximum ASTM Limits may vary in countries outside of the United States On intermittent use engines high sulphur content diesel fuel will greatly increase Corrosion of metal parts Deterioration of elastomer and plastic parts Corrosion and extensive damage and excessive wear of internal engine parts particularly bearings S...

Page 544: ...nt disconnect the negative battery cable Never start the engine without the battery cable terminal ends being solidly connected Never separate the battery from the on board electrical system while the engine is operating Never separate the battery feed wire from the charging system while the engine is operating When charging the battery disconnect it from the boat s electrical system Ensure that a...

Page 545: ...ital multimeter in series with the test light being tested and power the test light ammeter circuit with the battery b If the ammeter indicates LESS than 3 10 amp current flow 0 3 amp or 300 mA the test light is SAFE to use c If the ammeter indicates MORE than 3 10 amp current flow 0 3 amp or 300 mA the test light is NOT SAFE to use a b c a Amp Meter b Test Light c 12 Volt Battery NOTE Using a tes...

Page 546: ...2 12 14 15 27 Injection Pump 28 Gasket 29 Stud M8 x 30 30 Washer 31 Nut 32 Key 33 Lockwasher 34 Nut 35 Electric Fuel Shut Off Device 36 Washer 37 Nut 38 Sealing Washer 39 Banjo bolt M14 x 1 5 40 Return Fuel Connector 41 Keyway Orientation During Install All Settings At TDC Cylinder 1 Description Part Number A Perfect Seal 92 25711 3 ...

Page 547: ... diesel fuel vapors may be expelled from cylinder openings causing breathing difficulty or injury Do NOT crank the engine using the ignition key switch when establishing Top Dead Center TDC of a cylinder because the engine could start unexpectedly Use a suitable remote starter switch As an added safety measure remove the key from the ignition switch to prevent start up 3 Position a piece of thin p...

Page 548: ...or TDC number 1 cylinder 75437 70281 a b a Typical a TDC Notch On Pulley b Timing Cover Mark 7 Disconnect battery cables 8 Using a suitable device remove threaded round injection pump gear cover by turning cover COUNTERCLOCKWISE 70761 a a Cover Pin Type or Hex Head 9 Remove injection pump gear nut and lockwasher Do NOT allow crankshaft to rotate 22217 70770 a b a Gear b Nut and Lockwasher ...

Page 549: ...P sensor connector The ECM has a slide to lock catch on it and the TP sensor connector is a twist to lock 13 Remove three allen head screws retaining the port engine lifting eye and heat exchanger bracket to the timing cover 14 Remove the two ECM bracket lower isolator flanged nuts 15 Lift the ECM ECM bracket and engine lifting eye from the engine IMPORTANT Hollow bolts used to hold fuel inlet and...

Page 550: ... washers 75579 a b c d c b a a 73911 a Supply Line Filter to Pump b Return Hose c Connector d Return Pipe Injectors to Pump 19 Unclamp injection pipes CAUTION Keep injectors and injection pump fittings clean Do NOT allow dirt to enter fittings when removing lines Dirt will cause injectors or injection pump to malfunction 20 Loosen injection pipe sleeve nuts 21 Remove high pressure fuel injection p...

Page 551: ...te IMPORTANT The injection pump shaft and gear use a key to stay in alignment Be careful not to drop the key into the engine when removing pump 27 Paying special attention to the key to avoid dropping it into the engine carefully remove the pump and place it aside IMPORTANT Put suitable protective covers shipping plugs or similar over the injection pump fuel ports to avoid contamination 28 Back th...

Page 552: ...n stroke and timing marks are aligned 1 Ensure pump gear is held in the same position as when pump was removed This should be cylinder number 1 TDC 2 Rotate shaft to align keyway with cylinder number 1 injector port NOTE To rotate shaft temporarily install original shaft nut and a suitable jam nut Do NOT damage pump shaft threads with improper nuts or overtightening 70420 Typical a Shaft Keyway 3 ...

Page 553: ...on 9 Ensure the key is positioned properly IMPORTANT Do NOT drop key into engine If key is dropped into engine the key must be removed before operation of the engine 10 Insert pump shaft into gear being careful not to dislodge key Do NOT turn pump shaft from 11 o clock position Rotate pump body in slotted holes to align key with gear slot 11 Install pump to cylinder block hex nuts with flat washer...

Page 554: ...e 5D 18 90 860074 1 FEBRUARY 2002 15 Rotate pump to end of adjustment slot travel in direction shown 70422 a Typical a Direction To Rotate 16 Timing of the injection pump MUST BE accomplished Refer to Fuel Injection Pump Timing for instructions ...

Page 555: ...the crankshaft in the direction of rotation numerous revolutions to align the crankshaft gear idler gear and camshaft gear alignment marks Refer to SECTION 3A Camshaft and verify alignment to establish cylinder number 1 Top Dead Center on compression stroke in the following steps 3 Ensure cylinder number 1 piston is at TDC of its compression stroke and timing marks are aligned 4 Attach the graduat...

Page 556: ...Degree Mark 7 Using a heavy grease to hold key in place install injection pump key in pump slot 8 Temporarily install gear on injection pump shaft Do NOT secure gear at this time 9 Rotate shaft to align keyway with cylinder number 1 injector port 10 Remove any pump backlash by rotating gear COUNTERCLOCKWISE when facing pump until resistance is felt 11 Ensure keyway is at approximately the 11 o clo...

Page 557: ...alant to a new injection pump gasket 14 Install new gasket on pump mounting studs 70768 a b a Gasket b Pump Mounting Studs 15 Install pump to cylinder block 16 Install hex nuts with flat washers and lockwashers Temporarily only finger tighten the nuts 17 Rotate pump to end of adjustment slot travel in direction shown 70422 b a Typical a Hex Nuts With Flat Washers And Lockwashers 3 Total b Directio...

Page 558: ...stall gear on injection pump shaft using whichever key slot on gear that allows gear to be installed the easiest 20 Using a new lockwasher install gear on shaft with hex nut Torque to 88 Nm 64 lb ft 22217 70424 a b c a Gear b New Lockwasher c Hex Nut 21 Timing of the injection pump MUST BE accomplished Refer to Fuel Injection Pump Timing in this section for instructions ...

Page 559: ...outlined and accomplish steps in that section dealing with installation of crankshaft tool graduated disc positioning of crankshaft and removal of parts to gain access to rear of fuel injection pump and vent screw Setting 1 Establish that the engine is on TDC of the Number One Cylinder 2 Remove vent screw and sealing washer from rear of injection pump NOTE Pump shown removed for visual clarity 754...

Page 560: ... 2 54 mm 0 10 in NOTE Adaptor tool 854220 is designed to use on EDI engines 70430 a b a Suitable Adaptor Tool b Dial Gauge Preloaded 4 Watch dial indicator needle and SLOWLY rotate the crankshaft COUNTERCLOCKWISE viewed from water pump end looking toward flywheel until dial indicator STOPS moving 5 Set the dial indicator to zero 0 as shown 70431 a a Dial Indicator ...

Page 561: ...The dial indicator follows this rotational movement of crankshaft and STOPS when the cylinder number 1 piston is at TDC when the crankshaft is not turned further 7 AT THIS MOMENT the dial indicator should show the specified timing setting If not loosen the injection pump mounting nuts and rotate the pump slightly in the appropriate direction to obtain the setting Model Setting D2 8L D Tronic MCM a...

Page 562: ...lean Do NOT allow dirt to enter fittings when installing Dirt will cause injectors or injection pump to malfunction CAUTION Do NOT bend fuel injector pipes Bending may cause metal to flake off inside causing injectors or injection pump to malfunction 10 During Engine Reassembly Continue engine reassembly Refer to following instructions after all other necessary engine reassembly steps are complete...

Page 563: ... Return Pipe Injectors to Pump NOTE Refer to the Exploded Views in SECTION 5C and to those in this section in the following 15 Position the ECM ECM bracket and engine lifting eye on the engine 16 Install the ECM bracket lower isolator flanged nuts Tighten nuts securely 17 Install three allen head screws retaining the port engine lifting eye and heat exchanger bracket to the timing cover Torque scr...

Page 564: ...ng belt if equipped and optional belts if equipped Starting Engine After Fuel Injection Pump Installation and Timing Generally purging air from the system is only needed after draining and replacing the water separating fuel filter or purging a new filter of air In most cases the design of the EDI System will prevent needing to purge the Fuel Injection Pump itself After installing the fuel injecti...

Page 565: ...s necessary to purge air from the fuel injection pump proceed as follows NOTE Place suitable container under fuel filter and injection pump to catch excess fuel 5 Bleed air from Water Separating Fuel Filter 6 Loosen bleed screw on injection pump 7 Move plunger on hand pump primer up and down repeatedly until an air free stream of fuel flows from bleed screw 71371 a b c a Injection Pump b Bleed Scr...

Page 566: ... THE ENGINE STARTS Operate engine at idle Check all fuel connections for fuel leaks If leaks exist stop engine and refer to following Step 13 and correct as needed 12 IF THE ENGINE WILL NOT START Air will have to be bled from injector lines Follow these instructions a Wear safety glasses when bleeding air from injection pipes Slightly loosen each injection pipe sleeve nut Turn ignition key switch ...

Page 567: ...g and sleeve nuts when checking for fuel leaks 15 Allow engine to reach operating temperature Once again check for leaks as previously outlined and correct as needed WARNING Dispose of fuel soaked rags paper etc in an appropriate air tight fire retardant container Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death WARNING Make su...

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Page 569: ...le Switch 5E 40 Battery Voltage 5E 42 Battery Switched K15 5E 43 Microcontroller Fault 5E 44 ECM Reference Voltage u_ref 2 5v 5E 45 Main Relay 5E 46 Timing Actuator Timing Solenoid Valve 5E 48 Glow Plug Main Relay Glow Plug Relay Actuator If Equipped 5E 50 Glow Plug Auxiliary Relay If Equipped 5E 52 Glow Plug Lamp Glow Plug Display 5E 54 Glow Plug Lamp Glow Plug Display 5E 56 MIL Malfunction Indic...

Page 570: ... service or repair may damage the engine or render it unsafe It is also important to understand that these Cautions and Notes are not exhaustive because it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions Introduction The following pages been prepared for effective diagnosis of the Mercury MerCruiser Electronic Diesel Inje...

Page 571: ...low voltage and are very susceptible to damage caused by electrostatic discharge It is possible for less than 100 volts of static electricity to cause damage to some electronic components By comparison it takes as much as 4 000 volts for a person to even feel the effect of a static discharge There are several ways for a person to become statically charged The most common methods of charging are by...

Page 572: ...blem codes 91 854221 1 Rinda Technologies 4563 N Elston Ave Chicago IL 60630 Phone 312 736 6633 Kent Moore Tools Kent Moore Tools Inc 29784 Little Mack Roseville MI 48066 Phone 313 774 9500 Description Part Number High Impedance Multimeter DVM 1 Minimum 10 megohm input impedance required on all voltage ranges As ammeter accurately measures low value current flow As ohmmeter reads 0 200 ohms 2 20 2...

Page 573: ... boat s electrical system Ensure that all cable harnesses are connected solidly and that battery connections are thoroughly clean Never connect or disconnect the wiring harness at the ECM when the ignition is switched ON Before attempting any electric arc welding disconnect the battery leads and the ECM connectors When steam cleaning engines Do NOT direct the steam cleaning nozzle at ECM system co...

Page 574: ...ltimeter in series with the test light being tested and power the test light ammeter circuit with the battery b If the ammeter indicates LESS than 3 10 amp current flow 3 A or 300 mA the test light is SAFE to use c If the ammeter indicates MORE than 3 10 amp current flow 3 A or 300 mA the test light is NOT SAFE to use a b c d Amp meter e Test Light f 12 Volt Battery NOTE Using a test light with 10...

Page 575: ...ultiple failures Abbreviations ADF Atmospheric Pressure Sensor See BARO BARO Barometric Pressure BAT Battery Positive Terminal Battery or System Voltage B Battery Positive CKT Circuit CONN Connector CYL Cylinder DEG Degrees DIAG Diagnostic DLC Data Link Connector DTC Diagnostic Trouble Code DVOM Digital Volt Ohmmeter ECM Engine Control Module ECT Engine Coolant Temperature EEPROM Electronic Erasab...

Page 576: ...H Tachometer TERM Terminal TP Throttle Position Sensor V Volts VAC Vacuum WOT Wide Open Throttle ECM Self Diagnosis The ECM performs a continual self diagnosis on certain control functions This diagnostic capability is complemented by the diagnostic procedures contained in this manual The ECM s language for communicating the source of a malfunction is a system of diagnostic codes The codes are fou...

Page 577: ...diagnostic system has detected a problem If the problem goes away the light will go out in most cases after ten seconds but a code will remain stored in the ECM When the lamp remains ON while the engine is operating or when a malfunction is suspected due to a driveability problem an EDI Diagnostic Circuit Check must be performed These checks will expose malfunctions which may not be detected if ot...

Page 578: ...iagnostic code discussion Troubleshooting The EDI System also covers the topic of Intermittents A physical inspection of the applicable sub system most often will resolve the problem Reading Codes The provision for communicating with the ECM is the Data Link Connector DLC connector It is part of the EDI engine wiring harness and is a 4 pin connector of which only 3 pins are currently being used Th...

Page 579: ...s representing the second blink code number pause for 2 5 seconds 4 flashes of 0 5 seconds at 0 5 second intervals representing the third blink code number pause for 2 5 seconds 4 flashes of 0 5 seconds at 0 5 second intervals representing the forth blink code number pause for 2 5 seconds flash for 2 5 seconds indicating end of the code NOTE The Malfunction Indicator Lamp MIL on the engine monitor...

Page 580: ...lluminates momentarily or when the engine driveability is momentarily poor If the problem seems to be related to certain parameters that can be checked on the scan tool they should be checked while operating the vessel If there does not seem to be any correlation between the problem and any specific circuit the scan tool can be checked on each position watching for a period of time to see if there...

Page 581: ...ation be tween the Tool and the ECM 6 Press the button for longer than 2 5 seconds to interrupt the diagnostic procedure 7 Press the button again for longer than 2 5 seconds to start the ECM checking for codes 8 See that the 4444 Code meaning no trouble codes present is displayed 9 If codes are still present refer to appropriate Troubleshooting and or Diagnostic informa tion 10 Each time the Blink...

Page 582: ...out of range sensor may be suspected Because of the unique design of the EDI system fail safes have been incorporated into the ECM to replace a sensed value with a default value in the case of a sensor malfunction or sensor wiring concern By allowing this to occur limited engine performance is restored until the vessel is repaired A basic understanding of sensor operation is necessary in order to ...

Page 583: ... be a brief description of each Sensors ECM Actuators Number 1 Cylinder Injected fuel Fuel Injector Needle motion sensor Injected fuel quantity Electronically controlled fuel injection Temperature sensors water air fuel Engine shut off fuel injection pump Fuel Quantity and Timing Micro Sensor for control collar position processors Start of injection Engine speed sensor Starting control Glow contro...

Page 584: ...ch appear shaded represent pins not utilized in the Marine application The white squares indicate pins that are currently used and have corresponding wires connected when the harness is attached to the ECM Refer to Connector Chart for additional information 1 2 7 8 3 4 5 6 9 10 15 16 11 12 13 14 18 19 17 20 22 21 24 29 30 25 26 27 28 31 32 37 38 33 34 35 36 40 41 39 42 44 45 43 46 47 52 53 48 49 5...

Page 585: ...n incorrect diagnosis of the problem Wire Color Diagnostic Trouble ECM Pin Circuit Designation Wire Color Abbreviation Trouble Codes ScanTool 1 Battery Minus BLK P1600 2 Engine Speed sensor signal output BRN BLK P1735 3 Glowplug Indicator Lamp BLK YEL P1645 4 Fuel Quantity Actuator GRN WHT twisted pair P1220 5 Fuel Quantity Actuator GRN WHT twisted pair P1220 6 Unused 7 Fuel Quantity Control Sleev...

Page 586: ...attery Minus BLK P1600 25 Unused 26 Malfunction Indicator Lamp MIL BRN WHT P1650 27 Unused 28 Unused 29 Control Sleeve Position Sensor GRN P1225 30 Unused 31 Unused 32 Unused 33 Analog Ground ECT Injection Pump BRN PUR P0115 34 Unused 35 Unused 36 Unused 37 1 Idle rpm Increase Signal RED ORN 38 Switched battery 15 Ignition PNK P1605 39 Unused 40 MAP Sensor Signal WHT YEL P0105 41 5 Volt Output GRN...

Page 587: ... control side BLU BLK P1635 51 Solenoid Valve for Timing BLU P1630 52 Fuel Quantity Sensor Measure Coil BLU YEL P1225 53 Electric Shut Off Device YEL P1660 54 Unused 55 a Throttle Position Sensor Ground b MAP IAT Sensor Ground a BLU WHT b BLU WHT a P1515 b P1110 56 Unused 57 TP Sensor 5 Volt PNK YEL P1515 58 Unused 59 Unused 60 Unused 61 K Line GRN RED 62 Unused 63 Fuel Temperature Sender BLU RED ...

Page 588: ...ressure changes as a result of engine load and speed change and the MAP sensor converts this to a voltage output signal from the assembly NOTE Sometimes this component may be referred to as a boost pressure sensor due to the presence of a turbocharger The ECM sends a 5 volt reference signal to the MAP sensor As the manifold pressure changes the electrical resistance of the MAP sensor also changes ...

Page 589: ...g seal causing improper signal Will cause high amount of smoke Bent terminal or pin at the MAP connection or ECM Defective MAP or ECM MAP failure influences engine performance as follows FUEL QUANTITY ACTUATION Maximum engine rpm is 70 of the normal operating range 45 of fuel quantity reduction NOTE Failure of the MAP and IAT sensor at the same time will limit engine performance to 60 maximum of t...

Page 590: ...causes low resistance The ECM supplies a 5 volt signal to the ECT through a resistor in the ECM and measures the voltage The voltage will be high when the engine is cold and low when the engine is hot By measuring the voltage the ECM knows the engine coolant temperature Engine coolant temperature affects most systems the ECM controls The voltage received at the ECM will determine operation of the ...

Page 591: ...0 104 0 120 3 0 DIAGNOSTIC HELP Verify the following Open or short in the CKT Pin 14 or CKT Pin 33 Bent terminal or pin at the ECT or ECM Defective ECT or ECM ECT failure influences engine performance as follows FUEL QUANTITY ACTUATION Maximum engine rpm is 80 of the normal operating range 35 of fuel quantity reduction LOW IDLE SETPOINT VALUE The engine operates at 850 rpm for the first 300 second...

Page 592: ...UIT DESCRIPTION The Fuel Temperature Sensor is a thermistor a resistor which changes value based on temperature Low temperature produces a high resistance while high temperature causes a low resistance The ECM supplies a 5 volt signal to the sensor through a resistor in the ECM and measures the voltage The ECM voltage will be high when the fuel temperature is cold and low when the fuel temperature...

Page 593: ...following Open or short in the CKT Pin 33 or CKT Pin 63 Bent terminal or pin at the fuel pump connector or ECM Defective fuel injection pump temperature sensor circuit or ECM Fuel Temperature Sensor failure influences engine performance as follows FUEL QUANTITY ACTUATION No fuel quantity correction can occur as a function of fuel temperature When sensor is functioning the engine has the same perfo...

Page 594: ...RCUIT DESCRIPTION The rpm Engine Speed Sensor is an induction type pulse generator which mounts close the leading edge of the flywheel Four notches drilling serve to sense the engine speed The resulting change in magnetic flux induces an AC voltage signal which is evaluated by the ECM The ECM processes the signal to establish TDC and the crankshaft position relative to TDC A failure in the rpm sen...

Page 595: ...EMENT 1000 1000 ohm DIAGNOSTIC HELP Verify the following Open or short in the CKT Pin 8 or CKT Pin 21 Bent pin at the 3 terminal connector or ECM Sensor mounting is improper Defective rpm sensor or ECM RPM Sensor failure influences engine performance as follows The engine will not start If the engine speed sensor fails during starting procedures The MIL Malfunction Indicator Lamp IS NOT illuminate...

Page 596: ...OFF b a 75336 a b a ECM b BARO Atomosheric Pressure Sensor CIRCUIT DESCRIPTION The BARO Atmospheric Pressure Sensor is inside the ECM It is not serviceable or replaceable individually The complete ECM must be replaced to repair a faulty BARO sensor A failure in the BARO sensor circuit should set a Code P1105 CKT PIN NAME Not Applicable BARO Atmospheric Pressure Sensor ...

Page 597: ... inside the ECM and are not serviceable DIAGNOSTIC HELP BARO Sensor failure influences engine performance as follows The engine behavior does not change noticeably when the engine is operated at or near sea level It is acceptable to operate the engine with this failure unless there is a complaint If the engine is most frequently operated at high altitude elevation higher than 4900 ft 1500 m it is ...

Page 598: ...SCRIPTION The IAT sensor and MAP Manifold Absolute Pressure sensor form an assembly The IAT portion of the assembly is a thermistor a resistor which changes value based on temperature Low temperature produces a high resistance while high temperature causes a low resistance The ECM supplies a 5 volt signal to the sensor through a resistor in the ECM and measures the voltage The ECM voltage will be ...

Page 599: ... 390 3 79 4 190 20 67 1 2 270 2 500 2 730 30 85 1 1 528 1 692 1 856 40 104 1 1 059 1 170 1 281 50 122 1 0 748 0 826 0 904 60 140 1 0 538 0 594 0 650 80 175 1 0 2902 0 3224 0 3546 100 212 1 0 1641 0 1852 0 2063 120 247 1 0 0970 0 1116 0 1262 DIAGNOSTIC HELP Verify the following Open or short in the CKT Pin 55 or CKT Pin 64 Bent pin at the ECT or ECM Defective ECT or ECM IAT failure influences engin...

Page 600: ...upplied to the ECM by way of the Instrumented Injector Needle Movement Sensor or referred to sometimes as NBF installed in the Number 1 Cylinder injector This position variable type input device creates the timing signal for the ECM This signal is used for a number of control and testing functions within the ECM A failure in the Instrumented Injector circuit should set Scan Code P1201 Display of t...

Page 601: ... Open or short in the CKT Pin 11 or CKT Pin 12 Defective sensor Defective ECM Instrumented Injector failure influences engine performance as follows FUEL QUANTITY ACTUATION Maximum engine rpm is 80 of the normal operating range 35 of fuel quantity reduction LOW IDLE SETPOINT VALUE The engine operates at 850 rpm for the first 72 seconds after engine start up and then goes to 700 rpm normal idle TIM...

Page 602: ... quantity control engages with the control collar through a shaft Similar to the mechanically governed fuel injection pump the cutoff ports are opened or closed depending upon the control collar s position The injected fuel quantity can be infinitely varied between zero and maximum e g for cold starting When no voltage is applied to the actuator its return springs reduce the injection quantity to ...

Page 603: ...nplugged and key ON Measure between terminals 5 and 7 of the harness side connector CURRENT VOLTS MINIMUM MAXIMUM MEASUREMENT 12 Battery Voltage DIAGNOSTIC HELP Verify the following Open or short in the CKT Pins 4 5 49 or CKT Pins 23 45 68 Improper terminals or pins at the 7 terminal connector or ECM Defective fuel injection pump Defective ECM Failure of the Fuel Quantity Actuator influences engin...

Page 604: ...antity engages with the control collar through a shaft Similar to the mechanically governed fuel injection pump the cutoff ports are opened or closed depending upon the control collar s position The injected fuel quantity can be infinitely varied between zero and maximum e g for cold starting Using this Fuel Quantity Sensor an angle sensor or potentiometer the fuel quantity actuator s angle of rot...

Page 605: ...connector unplugged and key ON Measure between terminals 3 and 5 of the harness side connector CURRENT VOLTS MINIMUM MAXIMUM MEASUREMENT 5 0 0 DIAGNOSTIC HELP Verify the following Open or short in the CKT Pin 5 CKT Pin 7 or CKT Pin 52 Improper terminals or pins at the 7 terminal connector or ECM Defective fuel injection pump Defective ECM Failure of the Fuel Quantity Sensor influences engine perfo...

Page 606: ...epends on the quantity of fuel engine rpm and coolant temperature The ECM controls the timing using the signal from the number one instrumented injector and corrects the timing to the nominal timing rate Adjustment of pressure is carried out by an electric Timing Solenoid Valve which the ECM operates When the actuated timing advance timing governing is different from the setpoint ECM stored inform...

Page 607: ...connector with the connector unplugged and key ON Measure between terminal1 and engine ground CURRENT VOLTS MINIMUM MAXIMUM MEASUREMENT 12 Battery Voltage DIAGNOSTIC HELP Verify the following Open or short in the CKT Pins 23 45 68 or CKT Pin 51 Improper terminals or pins at the 2 terminal connector or ECM Defective fuel injection pump Defective ECM Failure of the timing governing solenoid valve in...

Page 608: ...output voltage will vary through the range from idle to WOT Also at closed throttle the Low Idle Switch sometimes referred to as LGS is activated This confirms to the ECM that the TP is at the closed throttle position As the throttle position changes the output increases so that at WOT the output voltage should be near 4 5 volts By monitoring the output voltage from the TP sensor the ECM can deter...

Page 609: ...connector plugged in and key ON CURRENT VOLTS MINIMUM MAXIMUM MEASUREMENT 5 With the key OFF and the 7 terminal connector unplugged verify the TP sensor potentiometer resistance between terminals 1 and 4 of the sensor connector CONDITION RESISTANCE Ohm MINIMUM MAXIMUM MEASUREMENT TP at Idle Position 1050 100 TP at WOT Position 1650 100 DIAGNOSTIC HELP Verify the following Open or short in the CKT ...

Page 610: ...ing If the battery voltage drops below 6 9 volts the fuel quantity actuator begins to work improperly The ECM stops working when the battery voltage drops below 6 volts However the diagnostic system will not recognize a low voltage problem The only error recognized by the ECM is if the battery voltage is too high above 20 volts DIAGNOSTIC HELP Verify the following Alternator drive belt or belt ten...

Page 611: ... RUN position However the ignition switch is not monitored by the ECM Instead evaluation of the unverified terminal 15 is carried out by the ECM If the ECM detects 0 volt at CKT Pin 38 it sets the trouble code DIAGNOSTIC HELP Verify the following Open in CKT Pin 38 from ignition switch Improper terminals or pins at the electrical box terminal connectors or ECM Defective ignition switch Internal EC...

Page 612: ...tor Lamp OFF 75343 CIRCUIT DESCRIPTION As part of self diagnosis the ECM is capable of determining if failures have occurred to circuits within the ECM If defects exists the ECM sets this code DIAGNOSTIC HELP Verify the following Replace the ECM Recognition by the ECM of Microprocessor Fault influences engine performance as follows No loss of power ...

Page 613: ... 75343 CIRCUIT DESCRIPTION As part of self diagnosis the ECM is capable of determining if failures have occurred to the reference voltage circuits within the ECM If defects exists the ECM sets a Scan Code 161A DIAGNOSTIC HELP Verify the following Replace the ECM Recognition by the ECM of a Reference Voltage fault influences engine performance as follows No loss of power ...

Page 614: ...had given the shut off command After Run not completely finished then there has been a control unit defect Over the defect validity check The defect main relay switched off too early is reported during the next control unit initialization If a signal change from Battery Switched K15 occurs and the functions for after run test has ended with a complete error storage then the main relay is shut off ...

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Page 616: ...djusting the pressure in the upper high pressure chamber to injector opening pressure at the correct instant timing Adjustment of pressure is carried out by an electric Timing Solenoid Valve which the ECM operates The solenoid valve is closed if power 12 volts is removed With the valve fully closed no voltage pressure increases start of injection is advanced With the solenoid valve permanently ope...

Page 617: ...connector with the connector unplugged and key ON Measure between terminal1 and engine ground CURRENT VOLTS MINIMUM MAXIMUM MEASUREMENT 12 Battery Voltage DIAGNOSTIC HELP Verify the following Open or short in the CKT Pins 23 45 68 or CKT Pin 51 Improper terminals or pins at the 2 terminal connector or ECM Defective fuel injection pump Defective ECM Failure of the timing governing solenoid valve in...

Page 618: ...e Glow Plug Auxiliary Relay are inside the electrical box of the engine The ECM determines if when and for how long a period the glow plug relays should be activated based on coolant temperature information from the ECT This processing by the ECM is done before during and after the engine is started It is the relay that controls the large amount of amperes needed by the glow plugs Concurrent with ...

Page 619: ... YEL Wire at glow plug indicator lamp on the Engine Monitor Panel Verify supply voltage from circuit breakers to relays with relay connector unplugged and key ON Measure CURRENT VOLTS GLOW PLUG RELAY CONNECTOR NUMBER 12 30 12 86 DIAGNOSTIC HELP Verify the following Open or short in the CKT Pin 50 or CKT Pins 1 Improper terminals or pins at the electrical box relay connector or ECM Defective circui...

Page 620: ...The ECM determines if when and for how long a period the glow plugs relays should be activated based on coolant temperature information from the ECT This processing by the ECM is done before during and after the engine is started It is the relay that controls the large amount of amperes needed by the glow plugs Concurrent with supplying power to half of the glow plugs the Glow Plug Relay Actuator ...

Page 621: ...ged and key ON Measure CURRENT VOLTS GLOW PLUG AUXILIARY RELAY CON NECTOR NUMBER 12 30 Verify supply voltage from Glow Plug Relay Actuator with relay connector unplugged and key ON Measure CURRENT VOLTS GLOW PLUG AUXILIARY RELAY CON NECTOR NUMBER 12 86 DIAGNOSTIC HELP Verify the following Open or short in wiring between glow plug relays Improper terminals or pins at the electrical box relay connec...

Page 622: ... BLK YEL b c d e a a Electrical Box b Pin 6 of Instrumentation Harness 16 Pin Connector c Pin 6 of ECM 11 Pin Harness Connector d Glow Plug Lamp e Instrument Panel f ECM Supplied Ground Circuit CIRCUIT DESCRIPTION The Glow Plug Lamp wait to start is controlled by the ECM The lamp is supplied 12 volts with the key in the ON RUN position A ground path is closed when the ECM is operating the relays f...

Page 623: ...ply voltage from key switch terminal 15 with key ON Measure CURRENT VOLTS GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 12 PNK DIAGNOSTIC HELP Verify the following Open or short in wiring between instrument panel and ECM Improper terminals or pins at the electrical box harness connectors or ECM Defective bulb Defective bulb socket Defective ECM Failure of the Glow Plug Lamp circuit does not influence e...

Page 624: ...BLK ORN ORN YEL RED BLU BLK PPL YEL PPL YEL TAN GRN PPL YEL GRY BLK K PPL PPL a b c f a Electrical Box b Pin K of Instrumentation Harness 21 Pin Connector c Pin 6 of ECM 12 Pin Harness Connector d Glow Plug Lamp e Instrument Panel f ECM Supplied Ground Circuit CIRCUIT DESCRIPTION The Glow Plug Lamp is controlled by the ECM The lamp is supplied 12 volts with the key in the ON RUN position A ground ...

Page 625: ...ply voltage from key switch terminal 15 with key ON Measure CURRENT VOLTS GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 12 PUR DIAGNOSTIC HELP Verify the following Open or short in wiring between instrument panel and ECM Improper terminals or pins at the electrical box harness connectors or ECM Defective bulb Defective bulb socket Defective ECM Failure of the Glow Plug Lamp circuit does not influence e...

Page 626: ...ectrical Box b Pin 2 of Instrumentation Harness 16 Pin Connector c Pin 2 of ECM 11 Pin Harness Connector d MIL e Instrument Panel f ECM Supplied Ground Circuit CIRCUIT DESCRIPTION The MIL Malfunction Indicator Lamp is controlled by the ECM The lamp is supplied 12 volts with the key in the ON RUN position A ground path is closed when the ECM determines that a malfunction trouble code has occurred T...

Page 627: ...fy supply voltage from key switch terminal 15 with key ON Measure CURRENT VOLTS GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 12 PNK DIAGNOSTIC HELP Verify the following Open or short in wiring between instrument panel and ECM Improper terminals or pins at the electrical box harness connectors or ECM Defective bulb Defective bulb socket Defective ECM Failure of the MIL circuit does not influence engine...

Page 628: ...TAN GRN PPL YEL GRY BLK M PPL PPL a b c f BRN WHT YEL a Electrical Box b Pin M of Instrumentation Harness 21 Pin Connector c Pin 2 of ECM 12 Pin Harness Connector d MIL e Instrument Panel f ECM Supplied Ground Circuit CIRCUIT DESCRIPTION The MIL Malfunction Indicator Lamp is controlled by the ECM The lamp is supplied 12 volts with the key in the ON RUN position A ground path is closed when the ECM...

Page 629: ...fy supply voltage from key switch terminal 15 with key ON Measure CURRENT VOLTS GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 12 PUR DIAGNOSTIC HELP Verify the following Open or short in wiring between instrument panel and ECM Improper terminals or pins at the electrical box harness connectors or ECM Defective bulb Defective bulb socket Defective ECM Failure of the MIL circuit does not influence engine...

Page 630: ...lectrical Shut Off This valve is a redundant method of stopping the engine In case of a defect in a part or parts of the EDI system which would prevent the engine from stopping the ECM can energize this valve to positively stop the flow of fuel This valve is similar as on the previous Indirect Injection systems but is controlled by the ECM A 12 volt current is supplied to CKT Pin 53 which energize...

Page 631: ... Ohm MINIMUM MAXIMUM MEASUREMENT 7 5 0 5 DIAGNOSTIC HELP Verify the following Open or short in the CKT Pin 53 Improper terminals or pins at the device connection or ECM Defective fuel shut off valve Defective ECM Failure of the fuel shut off valve or circuit influences engine performance as follows If the valve failed previously the engine will not start If there is a plausibility error the engine...

Page 632: ...rcuits should set a Scan Code P1680 DIAGNOSTIC AIDS An intermittent Code P1680 may be caused by a bad cell in the EEPROM that is sensitive to temperature changes If the EEPROM failed more than once but is intermittent replace ECM An intermittent problem may be caused by a poor or corroded connection rubbed through wire connection a wire that is broken inside the insulation or a corroded wire Any c...

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Page 634: ...ymbol for Shield Cable CIRCUIT DESCRIPTION A secondary engine speed sensor signal called rpm Signal From Injector is supplied to the ECM by way of the Instrumented Injector in the Number 1 Cylinder When functioning for the ECM circuitry as the Secondary Speed Sensor a failure in this circuit will set a Scan Code P1725 Display of this code indicates a failure in the sensor circuit so proper diagnos...

Page 635: ...following Open or short in the CKT Pin 11 or CKT Pin 12 Defective sensor Defective ECM It is possible to have this failure when the two terminals in the Instrumented Injector connector are reversed Failure of the rpm Signal From Injector influences engine performance as follows FUEL QUANTITY ACTUATION Maximum engine rpm is 80 of the normal operating range 35 of fuel quantity reduction TIMING ADVAN...

Page 636: ...umented Injector P1220 1223 Fuel Quantity Actuator P1225 1222 Fuel Quantity Sensor P1230 1321 Timing Fault P1515 1144 TP Sensor Low Idle Switch P1600 1233 Battery Voltage P1605 1232 Battery Switched K15 P1615 1311 Microcontroller Fault P161A 1234 ECM Reference Voltage P1625 1231 Main Relay P1635 None Glow Plug Main Relay If Equipped P1640 None Glow Plug Auxiliary Relay If Equipped P1645 None Glow ...

Page 637: ...Possible Cause P0105 P1515 PICK UP SRC LOW EXCEEDED Check for open circuit in signal from ECM P0105 P1515 PICK UP SRC HIGH EXCEEDED Check for short circuit in signal from ECM P0105 P1515 SUPPLY SRC LOW EXCEEDED Check for open circuit P0105 P1515 SUPPLY SRC HIGH EXCEEDED Check for short circuit P0105 P1515 PLAUSIBILITY WITH LDF ADF The difference between the MAP and BARO sensor signals has exceeded...

Page 638: ...25 P1725 STATIC PLAUSIBILITY This fault occurs when the instrumented injector signal speed is more than a specified amount but the rpm sensor is less than a specific amount Check both circuits P1220 PERSISTENT NEGATIVE GOVERNOR DEVIATION WARM When the engine is warm and the monitored fuel quantity is greater at a preset engine speed than the real position of the fuel quantity actuator Check wiring...

Page 639: ... engine is cold and the monitored fuel quantity is less at a preset engine speed than the real position of the fuel quantity actuator Check wiring first If connections are OK the pump itself should be replaced P1225 START POSITION NOT ATTAINED The fuel quantity sensor has indicated to the ECM that the fuel quantity actuator was not at the set point value during an ECM controlled start position tes...

Page 640: ... instrumented injector circuit and injection pump P1515 PWG PLAUSIBILITY WITH LGS A fault has been indicated in the TP sensor most likely in the low idle switch circuit Check these circuits P1515 PWG PLAUSIBILITY WITH POTENTIOMETER A fault has been indicated in the TP sensor most likely in the TP sensor circuit Check these circuits P1515 PWG PLAUSIBILITY WITH BRE Not applicable to marine EDI Shoul...

Page 641: ... shut off command Replace the ECM P1625 SHUTS OFF TOO LATE The main relay shut off AFTER the ECM gave the shut off command Replace the ECM P1635 GENERAL PLAUSIBILITY ERROR Not recognized by Marine ECM application P1660 POWER STAGE DEFECT An error was saved at ignition OFF when the shut off valve P1660 PLAUSIBILITY IN AFTER RUN OFF when the shut off valve circuit was tested Check the circuit and va...

Page 642: ...K Several of the symptom procedures call for a careful visual physical check The importance of this step cannot be stressed too strongly It can lead to cor recting a problem without further checks and can save valuable time These checks should include 1 ECM grounds and sensors for being clean tight and in their proper locations 2 Fuel lines or hoses for splits kinks and proper connections Check th...

Page 643: ...connectors All connector terminals and connectors in problem circuit should be carefully reformed or replaced to insure proper contact tension 3 Poor terminal to wire connection crimping An intermittent may be caused by 1 Electrical system interference caused by a sharp electrical surge Normally the problem will occur when the faulty component is operated 2 Improper installation of electrical opti...

Page 644: ...attery charge low 6 No voltage to starter solenoid 7 Solenoid or starter motor inoperative 1 Remove the starter motor Check for broken flywheel teeth or a broken starting motor spring 2 Rotate the engine to check for rotational resistance 3 Clean and tighten connections Reapply Liquid Neoprene when required 4 Check starter relay supply voltage and proper operation of neutral safety switch if equip...

Page 645: ...operating properly 8 Worn or inoperative injection pump 9 Camshaft out of time 1 kit fuel supply 2 Check for loose wires and verify that the fuel shutdown solenoid and fuel shutdown solenoid relay is functioning 3 Remove the obstruction 4 Drain fuel water separator and replace fuel filter 5 Check fuel inlet restriction Correct cause 6 Check fuel flow bleed fuel system 7 Check replace bad or improp...

Page 646: ...Throttle cable loose or damaged 1 The fuel shutoff solenoid control must be in the run position Ensure proper procedure is being used 2 A Verify that the drive transmission is not engaged B Check the battery starting motor and look for loose or corroded wiring connections 3 Scan Verify system is working Repair replace inoperative parts 4 Verify glow plugs system is working Repair replace inoperati...

Page 647: ...er 2 Check fuel screen 3 Check replace improperly operating injectors 4 Scan Repair Replace components as needed 5 Scan Check Time the pump 6 Check compression to identify the problem ROUGH IDLE IRREGULARLY FIRING OR ENGINE SHAKING 1 If engine is cold glow plug relay on glow plug s defective 2 Idle speed fuel quantity too low for the accessories 3 Engine mounts damaged or lose 4 High pressure fuel...

Page 648: ...rating 1 Correct leaks in the high pressure lines fittings injectors sealing washers or delivery valves 2 Check the flow through the filter and bleed the system Locate and eliminate the air source 3 Verify by operating the engine with clean fuel from a temporary supply tank Check for presence of gasoline Replace fuel water separator filter 4 Check for a bent push rod or damaged roller lifter Repla...

Page 649: ...ontaminated fuel 1 Verify system is working Repair replace inoperative parts 2 Verify system is working Repair replace inoperative parts 3 Adjust the idle speed 4 Visually check for exhaust restriction and inspect the air intake Repair replace restricting parts 5 Check flow through the filter and bleed the system Locate and eliminate the source 6 Verify by inspecting the fuel filter Clean the syst...

Page 650: ...ED 1 Engine overload 2 Improperly operating tachometer 3 Throttle linkage worn or incorrectly adjusted 4 Inadequate fuel supply 5 Air fuel controls leak 6 Improperly operating injection pump 7 Incorrect ECM part number 1 Verify high idle speed without load Investigate operation to ensure correct gear is being used 2 Verify engine speed with hand tachometer correct as required 3 Adjust linkage for ...

Page 651: ... correct oil level 3 Check for added loading from accessories or driven units brakes dragging and other changes in vehicle loading Repair replace as needed 4 Check for leaks and obstructions Tighter the fittings Repair or replace the pump if Scan Check determines pump is not functioning 5 Inspect replace air cleaner element Look for other restrictions 6 Check the flow through the filter to locate ...

Page 652: ...or improperly operating injectors 7 Incorrect injection pump timing 8 Improperly operating injection pump 1 Check correct leaks in hoses gaskets intercooler and around mounting capscrews or through holes in the cooler end covers 2 Check correct leaks in the manifold or turbocharger gaskets If manifold is cracked replace manifold 3 Inspect replace turbocharger 4 Check wastegate operation 5 Check fo...

Page 653: ...11 Piston rings not sealing blue smoke 1 Refer to troubleshooting for coolant temperature below normal refer to Cooling System Inspect glow plugs for proper operation 2 Use proper starting procedures 3 Check fuel supply pressure and inlet restriction 4 Scan Check pump timing 5 Inspect change air filter Look for other restriction Check charge air cooler for obstructions 6 Check correct leaks in the...

Page 654: ...gine air inlet to remove oxygen supply The engine air inlet is on the port side on the flywheel end of the engine The fire extinguisher must be directed at this location for emergency shutdown conditions CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT SHUT OFF 1 Fuel shutoff solenoid inoperative 2 Engine operating on fumes drawn into the air intake 3 Fuel injection pump and or Fuel Shut Off V...

Page 655: ...ant level Add coolant if necessary Locate and correct the source Off the coolant loss refer to Group Cooling 2 Replace cap with the correct rating for the system 3 Check replace belt or belt tensioner 4 Verify that the gauge and temperature sensor are accurate Replace gauge sensor if bad 5 Remove obstruction restriction 6 Check and replace the thermostat 7 A Make sure the fill rate is not being ex...

Page 656: ...ipping plugs remain in cooler 7 Worn oil pump 8 Suction tube loose or seal leaking 9 Loose main bearing cap 10 Worn bearings or wrong bearings installed 11 Oil jet under piston bad fit into main carrier 1 A Check and fill with clean engine oil B Check for a severe external oil leak that could reduce the pressure 2 Verify the correct oil is being used Check for oil dilution Refer to Contaminated Lu...

Page 657: ...TING OIL LOSS 1 External leaks 2 Crankcase being overfilled 3 Incorrect oil specification or viscosity 4 Oil Cooler leak 5 High blow by forcing oil out the breather 6 Turbocharger leaking oil to the air intake 7 Piston rings not sealing oil being consumed by the engine 1 Visually inspect for oil leaks Repair as required 2 Verify that the correct dipstick and or correctly marked dipstick is being u...

Page 658: ...ne load rating is not being exceeded 4 Scan check injection pump timing 5 Check and replace inoperative Injector EXCESSIVE VIBRATION 1 Loose or broken engine mounts 2 Damaged or improperly operating accessories 3 Improperly operating vibration damper 4 Worn or damaged alternator bearing 5 Flywheel housing misaligned 6 Loose or broken power component 7 Worn or unbalanced drive line components 1 Rep...

Page 659: ...moke Engine Diagnosis Performance 3 Make sure the push rods are not bent and rocker levers are not severely worn Replace Bent or severely worn pads 4 Check turbocharger impeller and turbine wheel for housing contact Repair replace as required 5 Visually inspect and measure gear backlash Replace gears as required 6 Check replace rod and main bearings ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING...

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Page 661: ...eful periodic inspection of entire fuel system is mandatory particularly after storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines primers fittings and fuel filters should be inspected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine operation WARNING Be careful when cha...

Page 662: ...at ing damage to engine may result IMPORTANT The following information MUST BE adhered to when working on the fuel system Always keep a dry chemical fire extinguisher at the work area Do NOT replace fuel pipe with fuel hose Do NOT attempt any repair to the fuel system until instructions and illustrations relating to that repair are thoroughly understood Observe all Precautions and Notes Replacemen...

Page 663: ... IAT Sensor 3 5 31 ECT Sensor Reducer Fitting To Cylinder Head 24 3 18 TP Sensor 6 7 60 ECM Bracket To Isolator Mounts 19 168 ECM To Bracket 8 72 RPM Sensor 6 7 60 ECT Sensor To Reducer Fitting Tapered Threads Tighten Securely Lubricants Sealants Adhesives Description Part Number Liquid Neoprene 92 25711 3 Loctite 567 PST Pipe Sealant 92 809822 Loctite 242 Thread Locker 92 809821 ...

Page 664: ...EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Page 5E 96 90 860074 1 FEBRUARY 2002 System Components 75301 75339 75341 75340 75311 75336 75395 1 2 3 4 5 13 14 15 16 9 10 12 75395 6 75336 75336 73911 11 7 8 ...

Page 665: ...4 ECT Sensor 45 Engine Speed Sensor 46 Electrical Box 47 Data Link Connector DLC 48 Instrument Harness Connector 49 Engine Harness Connector 50 Main Relay 51 Start Relay 52 Circuit Breakers 53 Glow Plug Relays If Equipped 54 Electric Shut Off Solenoid 55 Injection Pump 56 ECM Standard Calibration Or Bodensee Complieant Calibration Available 57 TP Sensor ...

Page 666: ...ust be sent to an authorized Bosch Service Center When shipping an injection pump to a service center for adjustments or repairs the fuel return line hollow bolt must accompany the unit The hollow bolt incorporates a sized orifice is calibrated for proper pressure which is matched to the pump The pump cannot be properly adjusted without the matched orifice Contact the Bosch distributor nearest you...

Page 667: ...ants on the contact mating surfaces Incomplete mating of the connector halves during assembly or during subsequent troubleshooting procedures Tendency for connectors to come apart due to vibration and or temperature cycling Terminals not fully seated in the connector body Inadequate terminal crimps to the wire Wire harnesses should be replaced with proper part number harnesses When signal wires ar...

Page 668: ...he male and female terminals together A secondary lock holds the seal and terminal into the connector When diagnosing open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors Merely wiggling a connector on a sensor or in the wiring harness may locate the open circuit condition This should always be considered when an open circuit ...

Page 669: ...74 1 FEBRUARY 2002 Page 5E 101 HARNESS VIEWS 75300 U D E R S V W X H B G F C A N P L T K M J a b Instrument Harness And Connector a Early model 16 Pin Standard Connector b Late Model 21 Pin Deutscht Connector 75395 Engine Harness And Electrical Box ...

Page 670: ...rminal Do NOT reconnect the negative battery cable until the module or sensor removed has been re installed with secure connections IMPORTANT Modules and sensors are electrical devices easily damaged by contact with liquid cleaners or solvents Clean with a dry cloth unless specifically directed to do otherwise Main Relay REMOVAL 1 Remove electrical box cover 2 Detach main relay from inside of elec...

Page 671: ...t connectors on the wiring harness for corrosion and for terminals that may have backed out of the harness TESTING NOTE The relay numbers can be found on the bottom of the relay 1 The following information applies to operations tests of this relay Terminal 30 is connected to battery voltage through a circuit breaker Terminal 87 is connected a circuit is formed to terminal 30 in the energized ON po...

Page 672: ...in order to meet Bodensee emission requirements in twin installations Ensure any replacement ECM is the correct part REMOVAL 1 Slide the locking top of the connector aside and disconnect the 68 pin electrical connec tor from the engine control module ECM 2 Remove ECM from electrical bracket Retain hardware NOTE A taller ECM bracket is used on D Tronic engines with V Drive Transmissions 75298 a b c...

Page 673: ... obvious damage 2 Visually inspect electrical pins of ECM for straightness and no corrosion 3 Visually inspect connectors on the wiring harness for corrosion and terminals that may have backed of the harness INSTALLATION 1 Mount new ECM to electrical bracket Torque bolts and flanged nuts to specifications 2 Connect and lock the 68 pin electrical connector to the ECM 75298 a b c a Electrical Bracke...

Page 674: ...tion of the EDI system 1 Refer to SECTION 6B and drain coolant 2 Disconnect electrical connector from ECT Engine Coolant Temperature sensor NOTE The ECT is mounted in a reducer fitting that is installed in the head 3 Stabilize the reducer fitting with a separate tool and remove the ECT 75579 a b c Typical a Reducer Fitting b ECT Sensor c Connector CLEANING 1 Clean sensor with a dry cloth 2 Remove ...

Page 675: ...d terminals that may have backed of the harness INSTALLATION 1 Install reducer fitting if removed previously Replace the sealing washer Torque the re ducer to specifications 2 Apply Loctite 567 PST Pipe Sealant to the threads of ECT Install the ECT and tighten securely 3 Connect electrical connector to ECT 75579 a b c 75341 d b c Typical a Reducer Fitting b ECT Sensor c Connector d Sealing Washer ...

Page 676: ...ng coolant pipe 3 Remove sensor from intercooler housing 75582 a b c d a MAP IAT Sensor b Electrical Connector c Intercooler d J clip CLEANING 1 Clean sensor with a dry cloth 2 Clean harness connector INSPECTION 1 Look for evidence of any physical damage to base or connector surfaces of the sensor 2 Visually inspect electrical pins of sensor for straightness and no corrosion 3 Visually inspect con...

Page 677: ...o plenum using screws Insert upper screw through J clip for coolant pipe and then through the sensor to the intercooler Torque screws to specifica tions 3 Attach and lock the engine harness electrical connector to the MAP IAT sensor 75582 75410 a b c d e a MAP IAT Sensor b Electrical Connector c Lock d Screw e J clip TESTING Refer to Diagnostic Circuit Checks for information and procedures ...

Page 678: ... 3 Remove TP from ECM bracket 75332 a b c c a ECM Bracket b TP Sensor c Allen Head Screw and Flanged Nut 2 Required CLEANING 1 Clean sensor with a dry cloth 2 Clean harness connector INSPECTION 1 Look for evidence of any physical damage to base or connector surfaces of the ECT 2 Visually inspect electrical pins of ECT for straightness and no corrosion 3 Visually inspect connectors on the wiring ha...

Page 679: ...ine harness 3 Install throttle cable Refer to SECTION 2 4 Tighten throttle cable locknuts until they bottom and loosen 1 2 turn 75332 a b c d e d a Throttle Cable End Guide b Cable Barrel c Anchor Stud d Flat Washer And Locknut e Spacer If Required 5 Connect the battery cables Start the engine and check the TP sensor output voltage It should be 0 4 0 8 V at idle and 4 5 V at WOT Refer to Testing D...

Page 680: ...b Allen Head Screw c Adapter If Equipped d Flywheel Housing CLEANING 1 Clean sensor and connector with a dry cloth 2 Clean harness connector INSPECTION 1 Look for evidence of any physical damage to sensor surfaces and tip of sensor 2 Visually inspect connectors for corrosion and terminals that may have backed out of the harness 3 Inspect O ring seal for damage INSTALLATION 1 Install new O ring on ...

Page 681: ... of the Main Relay When the wires are connected the engine idle speed should be 700 rpm If the wires are disconnected the idle speed should be 600 rpm Determine the best idle speed for the power package and application Set the idle speed circuit accordingly INSPECTION 1 Visually inspect connectors for corrosion if wires are connected 2 Visually inspect for terminals that may have backed out of the...

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Page 683: ...6 Seawater Strainer 6A 6 Exploded View Seawater Pumps 6A 7 D2 8L D Tronic 6A 7 D4 2L D Tronic 6A 8 Seawater Flow Diagram 6A 10 Seawater Pump 6A 12 Removal 6A 12 Disassembly 6A 13 Cleaning 6A 17 Inspection 6A 18 Assembly 6A 19 Installation 6A 25 Seawater Strainer 6A 27 Exploded View 6A 27 Removal 6A 28 Installation 6A 30 Oil Power Steering Transmission Fluid Coolers 6A 31 General Information 6A 31 ...

Page 684: ...SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Page 6A 2 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 685: ...t Exchanger End Covers Upper 14 15 120 132 Lower 11 108 120 Port Heat Exchanger Bracket 30 22 J clamp to Exhaust Manifold 32 24 Lubricants Sealants Adhesives Description Part Number Loctite Master Gasket 92 12564 1 U joint and Gimbal Bearing Grease 92 802870A1 Petroleum Jelly Loctite Pipe Sealant With Teflon Obtain Locally Tools Schaefer Brush Manufacturing Company 117 West Walker Street Milwaukee...

Page 686: ...s SEAWATER PICKUP HOSE Description D2 8L D Tronic D4 2L D Tronic Seawater Pickup Hose Diameter 38 mm 1 1 2 in Minimum SEACOCK WATER INLET VALVE Description D2 8L D Tronic D4 2L D Tronic Seacock Size Internal Cross Sectional Area 38 mm 1 1 2 in Minimum SEAWATER STRAINER Description D2 8L D Tronic D4 2L D Tronic Seawater Strainer Flow Requirement 150 liter 40 U S Gallons Minimum Per Minute THROUGH T...

Page 687: ...pened or the water inlet hose reconnected prior to start ing the engine IMPORTANT A wire should be repeatedly inserted into drain holes to ensure that for eign material is not obstructing the drain holes IMPORTANT To prevent threads from rusting out during storage reinstall plugs us ing Perfect Seal on threads NEVER leave drain plugs out after cleaning or during storage Seawater Pickup Connection ...

Page 688: ...e boat is in the water Install seacock in an area where it will be easily accessible and support adequately to prevent hose fatigue To prevent restricting water flow seacock used must have an internal cross sectional area equal to or greater than hose Refer to Specifications 70355 b c a Through The Hull Components Shown All Similar a Wire Reinforced Hose b Seacock c Seawater Pickup Seawater Strain...

Page 689: ... 13 14 15 16 17 18 8 9 A A 58 Pump Housing 59 Screw 60 Housing Pin 61 Ball Bearing 62 Bearing Spacer 63 Snap Ring 64 Shaft 65 Thrust Washer 66 Lip Seal 67 Slinger 68 Spacer 69 Primary Lip Seal 70 Cam 71 Impeller 72 Spline Plug 73 Gasket 74 Cover 75 Screw 76 O Ring 77 Nut With Washer 4 Washers Not Shown Description Part Number A Loctite Master Gasket 92 12564 2 ...

Page 690: ... 9 15 A A 1 Pump Housing 2 Screw 3 Cover 4 Gasket 5 Impeller and Spline Plug 6 Cam Apply Sealer Indicated to Back Side 7 Thrust Washer Align Notch with Housing Pin 8 Retaining Ring 9 Spacer 10 Seal 11 Oil Seal 12 Screw 13 Sealed Ball Bearing 14 Shaft 15 O ring 16 Lockwasher 4 17 Nut 4 Description Part Number A Loctite Master Gasket 92 12564 2 ...

Page 691: ...SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 90 860074 1 FEBRUARY 2002 Page 6A 9 THIS PAGE IS INTENTIONALLY BLANK ...

Page 692: ...SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Page 6A 10 90 860074 1 FEBRUARY 2002 Seawater Flow Diagram 75 a b e g f d c 10 9 8 5 1 3 2 4 7 6 Typical All Engines ...

Page 693: ...Seawater Strainer 4 Seawater Pump 5 Intercooler 6 Engine Oil Cooler 7 Heat Exchanger 8 Fluid Cooler Power Steering Fluid Sterndrive Transmission Fluid Inboard 9 Exhaust Pipe Water Jacket 10 Seawater Outlet Exhaust Engine Components a Thermostat Housing and Thermostats b Circulating Pump Closed Coolant c Engine Block Upper Section of Liners d Cylinder Heads e Water Manifold f Turbocharger g Exhaust...

Page 694: ...d plug seawater inlet hose to prevent a siphoning action that may occur allowing seawater to enter boat 1 Close seacock if equipped or remove and plug seawater pump inlet hose 2 Loosen the 6 seawater pump cover screws to drain water into a suitable container Remove outlet hose 75299 c a b c d Typical a Inlet Hose b Connector Fitting c Cover Screws 6 d Outlet Hose 3 Remove the 4 hex nuts with lockw...

Page 695: ...RUARY 2002 Page 6A 13 Disassembly 1 Clamp the pump in a vise 2 Remove the 6 cover screws 70625 a Typical a Cover Screws 3 Using 2 screwdrivers carefully remove the impeller 70626 4 On D2 8L D Tronic pumps Remove internal snap ring from pump body 70628 a a Snap Ring ...

Page 696: ...n D4 2L D Tronic pumps a Remove external retaining ring from pump shaft 70694 a a External Retaining Ring b Remove spacer from shaft 70695 a a Spacer 6 Using a soft faced hammer tap shaft and bearing assembly out of pump housing 70638 b a Typical a Shaft and Bearing Assembly b Pump Housing ...

Page 697: ...one bearing at a time from pump shaft to avoid damaging spacer Press off toward splines of shaft and on inner race of bearings only 70635 a b c a Bearing s b Spacer c Pump Shaft 8 On D4 2L D Tronic pumps Using an arbor press and suitable hardware remove one bearing at a time from pump shaft spacer is machined as part of shaft Press one bearing off toward splines of shaft and the other opposite Pre...

Page 698: ... Typical Pump and Cam a Screw b Cam 10 Remove thrust washer from its position on locating pin in pump housing a 70631 Typical Pump and Thrust Washer a Thrust Washer 11 On D2 8L D Tronic pumps Using a suitable tool remove two lipseals one spacer and one slinger ring from pump housing Notice positioning 70637 a b c d a Primary Lipseal b Spacer c Slinger Ring d Lipseal ...

Page 699: ...Housing b Using a suitable tool press front seal assembly out front of pump housing from rear NOTE Although different in appearance the front seal will press out like a normal seal b a c a Front Seal b Pump Housing c Rear Seal Cleaning WARNING Always wear safety glasses when using compressed air 1 Clean metal parts in solvent and dry with compressed air 2 After cleaning apply a coat of light engin...

Page 700: ...ngine oil 3 Inspect seals from bearing housing 4 Inspect pump shaft for grooves in surface where seals contact shaft 5 Inspect drive key on shaft 6 Inspect surface where bearings contact shaft for evidence of inner races turning on shaft 7 Inspect impeller splines and shaft splines 8 Inspect pump body 9 Inspect cam for scratches or gouging 10 Inspect pump impeller for wear on sides and tips of bla...

Page 701: ...from splined end b Install plastic spacer and press second bearing on shaft in positions shown 70634 b c a a First Bearing b Spacer Plastic c Second Bearing 2 On D4 2L D Tronic pumps IMPORTANT In the following steps press on inner races of bearings ONLY a Using an arbor press install rear bearing against shoulder of spacer Press from rear of shaft b Press front bearing against shoulder of spacer P...

Page 702: ...uitable tool install impeller primary lipseal lip facing out back of seal visible b a 70629 a Rubber Washer Installed First Not Shown In This View b Impeller Primary Seal 4 On D4 2L D Tronic pumps Install impeller primary seal assembly using a suitable tool Plastic collar around lip MUST face impeller 70630 a b b a a Impeller Primary Seal b Plastic Collar Around Lip ...

Page 703: ...install rear seal lip facing front of pump back of seal visible 70629 a b a O ring b Rear Seal 6 On D4 2L D Tronic pumps Using a suitable tool install rear seal lip facing out back of seal visible 70444 a a Rear Seal 7 Install thrust washer into pump housing Align washer notch with pin in housing 70630 c b a Typical Pump and Thrust Washer a Thrust Washer b Washer Notch c Housing Pin ...

Page 704: ...screw securely Remove excess sealant and allow to dry before continuing assembly 70633 b c b 70638 Typical Pump and Cam a Sealant b Cam c Screw 10 Coat lips of seals in pump housing with U Joint and Gimbal Bearing Grease 11 Install shaft and bearing assembly into housing as shown 12 Tap lightly with soft faced hammer if needed to seat assembly 70638 Typical Pump and Shaft With Bearings ...

Page 705: ...14 On D4 2L D Tronic pumps a Install spacer washer on shaft next to front seal assembly b Install external retaining ring into groove of shaft 70694 c a b a Front Seal Assembly b Spacer Washer c External Retaining Ring 15 Hold pump housing in soft jaw vise Install impeller into housing by turning clockwise while simultaneously pushing inward as shown 70624 Typical Pump and Impeller ...

Page 706: ...rubber button seal into end of impeller 70627 a b a Rubber Button Seal b Impeller 17 Install gasket wide surface on cam side and cover Tighten screws evenly in a diagonal pattern Tighten securely 70625 70625 c a c a b b Typical Pump and Cover a Cover b Gasket Wide Surface On Cam Side c Screws 6 ...

Page 707: ... FEBRUARY 2002 Page 6A 25 Installation 1 Install O ring on pump housing shoulder 70628 a Typical Pump a O ring 2 Turn pump shaft in direction shown to align pump keyway with camshaft key 70442 b 70628 a Typical Pump and Camshaft End a Pump Keyway b Camshaft Key ...

Page 708: ...0423 23161 a b Typical Pump Installation a Studs b Hex Nuts With Washers 4 Install seawater inlet and outlet hoses Tighten hose clamps securely 70636 c c b a Typical Pump and Hoses a Inlet Hose b Outlet Hose c Hose Clamps 5 Open seacock if equipped or remove plug from seawater inlet hose and reconnect hose Tighten hose clamps securely 6 Start engine 7 Check for leaks ...

Page 709: ... 90 860074 1 FEBRUARY 2002 Page 6A 27 Seawater Strainer Exploded View b h a f d c g 78157 1 2 3 4 5 6 7 8 8 Typical 1 Drain Plug and Gasket 2 Filter Housing 3 Filter Element 4 O ring Seal 5 Clear Lens 6 Lens Cover 7 Nozzle 2 8 Cover Screw with Washer ...

Page 710: ...seawater inlet hose to pre vent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses and enter the boat IMPORTANT Be certain engine is OFF and cooling system is cold 1 Models Equipped With A Seacock a Close seacock seawater inlet valve if equipped 70355 a a Seacock Seawater inlet valve 1 Disconnect seawater inlet hose from seawater strainer 50226 a b a ...

Page 711: ...uipped with seacock disconnect seawater inlet hose from seawater strain er inlet b Quickly plug seawater inlet hose 70062 b c d a a Inlet Hose b Strainer c Strainer Inlet d Suitable Plug 3 Remove seawater outlet hose Drain into a suitable container 70062 a b a Outlet Hose b Strainer 4 Remove mounting bolts 5 Remove strainer ...

Page 712: ... seawater strainer Ensure the following Arrow flow direction must point towards seawater pump Tighten mounting bolts securely 50226 c c a b a Strainer b Arrow c Mounting Bolt Hole 2 Install seawater inlet and outlet hoses Use 2 hose clamps on each hose connection Tighten clamps securely 50226 c c a b a Inlet Hose b Strainer c Hose Clamps 2 Each 3 Check drain plug and lens cover bolts Tighten secur...

Page 713: ...ipped with more than one During engine operation contaminants within the seawater such as salt silt or lime collect on the inside of the tubes thus reducing heat transfer and greatly decreasing cooler heat exchanger efficiency It is therefore recommended that the seawater coolers be cleaned periodically according to Maintenance Schedules chart in SECTION 1B or whenever decreased cooling efficiency...

Page 714: ... MANUAL NUMBER 22 Page 6A 32 90 860074 1 FEBRUARY 2002 Exploded View 78386 1 2 3 1 D4 2L Inboard MIE Early Design 2 D2 8L D Tronic And D4 2L D Tronic Sterndrive MCM Design 3 D2 8L D Tronic And D4 2L D Tronic Inboard MIE Later Design ...

Page 715: ...tion of Coolers Refer to the following for location of oil power steering and transmission fluid coolers b 75393 a b 75297 c Typical Sterndrive MCM Model a Fluid Cooler D4 2L b Engine Oil Cooler c Fluid Cooler D2 8L 75301 a b 73522 Typical Inboard MIE Model a Fluid Cooler b Engine Oil Cooler ...

Page 716: ...Refer to Cold Weather or Extended Storage Draining Instructions in SECTION 1B and Precautions in this section BEFORE proceeding 1 Drain the seawater system 2 On coolers a Remove hoses from both ends of cooler to be cleaned b Temporarily attach a suitable hose to inlet end of cooler and place end of hose in a suitable container to catch water in the following c Attach a suitable adaptor to the outl...

Page 717: ...r system 2 Drain the closed cooling system 3 Obtain clean suitable devices and plug hoses in following instructions to avoid loss of engine oil 4 Mark port and starboard oil hoses to aid in reassembly 5 Disconnect oil lines from oil cooler fittings near each end of oil cooler on heat exchanger Quickly plug the lines NOTE Components shown removed for visual clarity b a c a Engine Oil Cooler Heat Ex...

Page 718: ...from fitting on upper port side of heat exchanger expansion tank 8 Remove the two large screw clamps retaining the heat exchanger to the port and starboard brackets 9 Remove the heat exchanger and engine oil cooler NOTE If the oil cooler is to be replaced it will be necessary to replace the complete heat exchanger assembly 74484 b b a a c a a a Engine Oil Cooler Heat Exchanger and Related Componen...

Page 719: ...of petroleum jelly on the heat exchanger brackets and hose ends to ease installation 1 Install the heat exchanger and engine oil cooler 2 Make all necessary seawater and closed cooling hose connections Tighten hose clamps securely 74484 b b a a a a a Engine Oil Cooler Heat Exchanger and Related Components a Hoses b Clamps ...

Page 720: ...oolant recovery bottle hose 5 Install the two large screw clamps retaining the heat exchanger to the port and starboard brackets 6 Reconnect turbocharger coolant vent hose 74487 75297 c d a c b d e f Engine Oil Cooler Heat Exchanger and Related a Heat Exchanger Oil Cooler b Starboard Oil Line And Fitting c Port Oil Line And Fitting d Turbocharger Coolant Vent Hose e Coolant Recovery Bottle Hose f ...

Page 721: ...olutions If backflushing and or wire brushing of the problem cooler does not satisfactorily clear the passages replacement of the cooler is recommended If passages are still obstructed a Clean tubes in heat exchanger and coolers by operating a suitable wire brush of the proper size through each tube 71724 a a Wire Brush Sized to Fit Passages b Rinse out heat exchanger and cooler tubes with tap wat...

Page 722: ...rk fore and aft fluid hoses to aid in reassembly NOTE Obtain two clean suitable devices and plug hoses in following instructions to avoid loss of fluid 4 Using a suitable container to catch excess fluid disconnect fluid hoses Plug hoses quickly 5 Remove fasteners from clamps retaining cooler 6 Remove cooler with J clamp 75594 75393 a e f e d c b d Typical Power Steering Cooler Installation a D4 2L...

Page 723: ... Tighten fluid hose clamps securely 75594 75393 e g f e a d b c Typical Power Steering Cooler Installation a D4 2L D Tronic Cooler b Forward Fluid Hose From Reservoir c Aft Fluid Hose To Pump d Seawater Hose From Heat Exchanger e Seawater Hose To Exhaust Elbow Or Riser f J clamp And Nut g D2 8L D Tronic Cooler 4 Refer to SECTION 1B and refill power steering reservoir 5 Open seacock or unplug seawa...

Page 724: ...llowing instructions to avoid loss of fluid 4 Using a suitable container to catch excess fluid disconnect fluid hoses Plug hoses quickly 5 Remove fasteners from clamps retaining cooler 6 Remove transmission fluid cooler 7 If cooler is to be replaced note position of transmission fluid hose connectors Remove and retain the connectors NOTE Some early model fluid hose connectors are 90 degree elbow c...

Page 725: ...own a Transmission Fluid Cooler b Connectors 2 Install transmission fluid cooler on intake exhaust manifold or bracket Secure with clamps and fasteners Torque manifold nuts to 32 Nm 24 lb ft 3 Connect transmission fluid hoses to cooler in positions noted on disassembly Tighten hose clamps securely f d d e c f b b a 73522 Typical Transmission Fluid Cooler Installation Shown a Fluid Cooler b Seawate...

Page 726: ...inlet hose and reconnect Tighten hose clamps securely 5 Start engine Operate briefly to fill cooler 6 Check for leaks 7 Stop engine IMPORTANT Use only ATF Automatic Transmission Fluid such as Dexron III 8 Quickly check transmission fluid level Fluid should be between MIN and MAX marks on dipstick 9 Fill transmission to proper level ...

Page 727: ...SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 90 860074 1 FEBRUARY 2002 Page 6A 45 THIS PAGE IS INTENTIONALLY BLANK ...

Page 728: ...SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Page 6A 46 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 729: ...oolant for Alkalinity 6B 12 Pressure Testing System 6B 12 Testing for Cylinder Head Gasket Leak 6B 14 Testing Pressure Cap 6B 15 Coolant Change Interval 6B 17 Coolant Requirement 6B 17 Draining Closed Cooling System 6B 17 Cleaning Closed Cooling System 6B 19 Using A Cleaner 6B 19 Heat Exchanger and Cooler Cleaning 6B 19 Flushing The Closed Cooling System 6B 20 Filling The Closed Cooling System 6B ...

Page 730: ...CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Page 6B 2 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 731: ...ater Cooling System or Draining Seawater Section refer to SECTION 1B Maintenance NOTICE For information on other heat exchangers cooled by seawater refer to SECTION 6A Seawater Cooling System Oil Power Steering Transmission Fluid Coolers NOTICE For information on Oil Filter Head and Oil Thermostat refer to SECTION 3A Engine Mechanical Oil Thermostat ...

Page 732: ...e is present Pressure Cap Description Operating Pressure D2 8L D Tronic D4 2L D Tronic 97 kPa 14 psi 1 1 Must hold rated pressure for 30 seconds without going below 76 kPa 11 psi Coolant IMPORTANT Use only Mercury MerCruiser specified coolant Use of other coolant may cause fouling of the heat exchangers and overheating of the engine These specified premixed formulas require no mixing with water or...

Page 733: ...er End Cover Bolt 12 14 108 120 Lubricants Sealants Adhesives Description Part Number 2 4 C Marine Lubricant With Teflon 92 802859A Special Lubricant 101 92 802865A1 Perfect Seal 92 34227 1 Loctite Master Gasket 92 12564 2 Loctite Pipe Sealant with Teflon Obtain Locally Tools Special Tools Description Part Number Cooling System Cleaner 91 814825 Fleetguard Restore CC2610 Obtain Locally Tools Descr...

Page 734: ...CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Page 6B 6 90 860074 1 FEBRUARY 2002 Diagrams and Exploded Views Coolant Flow Diagram 75351 g f e d c b a h Closed Cooling Circuit Fresh Water Coolant ...

Page 735: ...074 1 FEBRUARY 2002 Page 6B 7 Coolant Flow Diagram continued g Circulating Pump Closed Coolant h Engine Block Upper Section Of Liners i Cylinder Heads j Water Manifold k Turbocharger l Exhaust Manifold m Thermostat Housing And Thermostats n Heat Exchanger ...

Page 736: ... MANUAL NUMBER 22 Page 6B 8 90 860074 1 FEBRUARY 2002 Heat Exchanger Coolant Tank and Related Components 78387 DECAL 8 1 2 3 4 B 3 20 11 18 19 14 15 16 A A 11 24 D C 21 8 6 7 5 B 9 13 10 12 13 10 23 23 26 78273 17 11 27 22 28 11 25 ...

Page 737: ... Housing Cover 15 Stud M6 x 75 mm 3 in Long 1 16 Lockwasher 17 Engine Cover Mount Threaded Spacer Nut 1 18 Thermostat Housing To Heat Exchanger Hose 19 Screw with Lockwasher M8 x 100 mm 3 15 16 in Long 2 20 Screw with Lockwasher M8 x 60 mm x 2 23 64 in Long 2 21 Pressure Cap 22 Heat Exchanger Coolant Tank 23 Hose Clamp 2 24 Circulating Pump to Heat Exchanger Hose 25 Drain Screw and Sealing Washer ...

Page 738: ...860074 1 FEBRUARY 2002 Engine Water Circulating Pump 73948 4 1 2 3 A B 5 1 Water Circulating Pump 2 Screws With Washers 3 Gasket 4 Pulley 5 Screws With Washers Description Nm lb in lb ft A Engine Water Circulating Pump Screw 30 22 B Water Pump Pulley Screw 8 5 72 ...

Page 739: ...lant recovery system for leaks and repair as necessary Refill coolant section with required coolant solution If coolant is visible start engine and operate until it reaches normal operating temperature then recheck coolant level in coolant recovery bottle Coolant level MUST BE between the Add and Full marks on front of bottle If level is low remove fill cap from coolant recovery bottle and add nee...

Page 740: ... Coolant Pressure Testing System WARNING Allow engine to cool before removing pressure cap Sudden loss of pressure could cause hot coolant to boil and discharge violently After engine has cooled turn cap 1 4 turn to allow any pressure to escape slowly then push down and turn cap all the way off If coolant section of closed cooled system is suspected of leaking or not holding sufficient pressure an...

Page 741: ...rnally and it probably is due to one or more of the following Loose cylinder head bolts or damaged gasket Loose turbocharger bolts or damaged gasket Loose exhaust elbow or damaged gasket Cracked or porous cylinder head or block Cracked or porous exhaust manifold 10 Proceed as follows until location of internal leak is found a Start engine Pressurize system to previously specified amount and observ...

Page 742: ...ine is operating a During Idle and Warm Up Some coolant and or air will leave the reservoir b During Cruising Speed 2800 3200 rpm Coolant and or air leaving the reservoir should stop after approximately five minutes of operation at a steady rpm A leaking head gasket will produce air bubbling through the U going to the coolant recovery bottle The frequency and size of the bubbles will depend on the...

Page 743: ... removing pressure cap Sudden loss of pressure could cause hot coolant to boil and discharge violently After engine has cooled turn cap 1 4 turn to allow any pressure to escape slowly then push down and turn cap all the way off 1 Carefully remove pressure cap from reservoir or heat exchanger 2 Wash cap with clean water to remove any deposits or debris from sealing surfaces 3 Inspect gasket if used...

Page 744: ...a b a b a Filler Neck b Cam Lock Flange 7 Using a cooling system pressure tester similar to one shown test cap to ensure that it releases at proper pressure and does not leak Refer to instructions which accompany tester for correct test procedure Cap must relieve pressure at 97 kPa 14 psi and must hold rated pressure for 30 seconds without going below 76 kPa 11 psi Replace cap if measured values a...

Page 745: ...cting the drain holes w Ensure that the engine is as level as possible to promote complete draining of cooling system w If engine will be exposed to freezing temperatures make sure closed cooling section is filled with an ethylene glycol antifreeze and water solution properly mixed to protect engine to lowest temperature to which it will be exposed w Closed cooling section must be kept filled year...

Page 746: ... turn cap all the way off of heat exchanger coolant tank 2 Drain coolant from intake exhaust manifold by opening the drain valve 3 Drain coolant from the engine block by opening the drain valve 4 After coolant has drained completely securely close drain valves 5 Empty coolant recovery bottle 6 If required clean system Refer to Cleaning Closed Cooling System 7 Fill system with required coolant 7136...

Page 747: ...d one liter of Cooling System Cleaner 92 814825 or add Fleetgaurd Restore CC2610 to cooling system following the manufacturer s instructions 3 Fill the cooling system with tap water to within 13 19 mm 1 2 3 4 in of bottom of filler neck 4 Install pressure cap NOTE During system cleaning leave auxiliary heater if equipped connected to engine Otherwise the engine will be contaminated when the heater...

Page 748: ...hose from water source to adapter 5 On engines with Auxiliary Hot Water Heater Proceed to step 7 6 On engines without Auxiliary Hot Water Heater Open cylinder block drain valves 7 Run tap water through system until discharge water is clean NOTE Catch expelled water in a suitable container and dispose of properly 8 Shut off water tap 9 Remove tap water hose and adapter 10 Install large hex plug wit...

Page 749: ...recommended coolant solution to heat exchanger as required to maintain coolant level 25 mm 1 in below filler neck 3 After engine has reached normal operating temperature thermostats are fully open and coolant level remains constant fill heat exchanger to bottom of filler neck 4 Observe engine temperature gauge to make sure that engine operating temperature is normal IMPORTANT If gauge indicates ex...

Page 750: ...ger 3 Remove thermostat housing cover screws and washers including the cover spacer NOTE Components shown removed for visual clarity only It is not necessary to remove the housing itself 73973 a b c d e f a Hose and Clamps b Thermostat Housing Cover c Screws and Washers 5 d Stud e Washer f Spacer For Engine Cover 4 Remove housing cover IMPORTANT Do NOT allow old gasket material or debris inside wh...

Page 751: ...or debris 2 Inspect thermostats for corrosion or other visible damage 3 If thermostats are suspected of producing insufficient engine temperature check thermostats for leaks by holding them up to lighted background Light leaking around the thermostat valve indicates that thermostat is not closing completely and should be replaced A few light leaks at one or two points around the valve perimeter is...

Page 752: ... Thermostat IMPORTANT Refer to specifications and note that the two thermostats have different opening temperatures 5 Continue to heat water until a temperature 14 degrees C 25 degrees F above opening temperature is obtained Thermostat valve must be completely OPEN at this temperature 6 Unplug tester and allow water to cool to a temperature 5 degrees C 10 degrees F below specified opening temperat...

Page 753: ...ct Seal to both sides of the new thermostat housing gasket 3 Install the new gasket 4 Install thermostat housing cover 5 Torque the housing cover screws and nut evenly to 16 Nm 132 lb in in a diagonal pattern 78274 a b b c d e A a Housing Cover b Thermostat 2 Different Temperatures c Gasket d Screw With Washer 5 e Engine Cover Mount Threaded Spacer Nut 1 6 Connect hoses 7 Fill the closed cooling s...

Page 754: ...the tubes in the exchanger Closed cooling coolant flows AROUND the tubes 1 Remove end caps and inspect for any blockage in the seawater circuit weeds etc 2 Remove closed cooling circuit hoses and inspect the tubes just inside the fittings Because the complete heat exchanger cannot be inspected the heat exchanger should be replaced if blockage is suspected Repair IMPORTANT Braze with BCUP 2 rod or ...

Page 755: ... loss of engine oil 3 Disconnect oil lines from oil cooler fittings near each end of oil cooler on heat exchanger Quickly plug lines NOTE Components shown removed for visual clarity a 75301 c b a Heat Exchanger With Oil Cooler b Starboard Oil Line And Fitting c Port Oil Line And Fitting 4 Disconnect seawater and closed cooling hoses as required to allow removal of heat exchanger 5 Disconnect turbo...

Page 756: ...ssary to replace the complete assembly Cleaning and Inspection 1 Clean water passages in heat exchanger by inserting a suitable sized wire brush on a proper length rod into each passage 2 Put on safety glasses 3 Blow loose particles out of and from between water passages using compressed air 4 Provided the passages for seawater are acceptably clean and free of debris clean the exterior of the heat...

Page 757: ... combination heat exchanger and engine oil cooler 3 Make all necessary seawater and closed cooling hose connections 74484 b b a a a a A a Engine Oil Cooler Heat Exchanger and Related Components a Hoses b Clamps 4 Unplug and install port and starboard oil lines to fittings near each end of oil cooler b a 75301 75297 b c c a a Engine Oil Cooler b Starboard Oil Line And Fitting c Port Oil Line And Fi...

Page 758: ...ect coolant recovery bottle hose 7 Reconnect turbocharger coolant vent hose 74487 a d c b a Heat Exchanger Oil Cooler b Large Screw Clamps Or Automatic Tension Clamps Not Shown c Coolant Recovery Bottle Hose d Turbocharger Coolant Vent Hose 8 Fill the closed cooling system 9 Open seacock if equipped or unplug and reconnect seawater inlet hose 10 Pre lube the turbocharger and engine 11 Start the en...

Page 759: ... pump hoses 6 Remove the pump 7 Discard gasket 78273 a b c Typical a Water Circulating Pump b Gasket c Nuts Cleaning and Inspection 1 Remove all traces of old gasket material from water circulating pump body 2 Remove all traces of old gasket material from engine block do NOT allow debris inside which might foul cooling system passages 3 Inspect pump for blockage cracks sand holes corrosion or othe...

Page 760: ... c Nuts 5 Install the heat exchanger 6 Install and tension drive belts NOTE On all models check belt tension by depressing upper strand of belt at center point between pulleys Belt must not deflect more than 5 mm 3 16 in 7 Fill the closed cooling system 8 Unplug and connect seawater inlet hose or open the seacock 9 Ensure seawater pickup pump is supplied cooling water 10 Start the engine 11 Test t...

Page 761: ... Auxiliary Hot Water Heater Connections 72037 72038 71898 a b c d e f g h j i k Auxiliary Hot Water Heater Adaptor Kit On A Typical Engine a Allen Head Plug Rear Cover b Sealing Washer c Hose Coupler Fitting d Sealing Washer e Plug On Closed Coolant Tank Heat Exchanger f Sealing Washer g Hose Coupler Fitting h Sealing Washer i Supply Hose j Return Hose k Heater ...

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Page 763: ...AUST SYSTEM Section 7A Intercooler Table of Contents Torque Specifications 7A 3 Lubricants Sealants Adhesives 7A 3 Exploded Views 7A 4 D2 8L Intercooler 7A 4 D4 2L Intercooler 7A 6 Intercooler 7A 8 Removal 7A 8 Disassembly 7A 11 Cleaning and Inspection 7A 13 Assembly 7A 14 Installation 7A 17 ...

Page 764: ...INTERCOOLER SERVICE MANUAL NUMBER 22 Page 7A 2 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 765: ...pecifications Description Nm lb in lb ft Intake Duct Screw Rear All Models 10 84 Side D21 8L D Tronic Only 10 84 End Cover Screw 40 30 Anode Plug 13 120 Intercooler Housing Nut 32 24 Lubricants Sealants Adhesives Description Part Number Loctite 514 92 75505 1 Perfect Seal 92 34227 1 ...

Page 766: ...INTERCOOLER SERVICE MANUAL NUMBER 22 Page 7A 4 90 860074 1 FEBRUARY 2002 Exploded Views D2 8L Intercooler 75619 b c 10 11 13 14 15 16 2 3 4 5 6 7 8 9 7 7 A A B C D A A 1 B 15 12 ...

Page 767: ...ed With Plate 3 On Others 8 Plate If Equipped 9 Anode 10 Anode Plug With Sealing Washer 11 Drain Plug With Sealing Washer 12 Rear Intake Duct Screw and Washer 13 Gasket 14 Intake Duct Screw 15 End Cover Screw 16 Nut and Washer Description Part Number A Loctite 514 Obtain Locally Description Nm lb in lb ft Intake Duct Screw Rear All Models 10 84 A Side D21 8L D Tronic Only 10 84 B End Cover Screw 4...

Page 768: ...INTERCOOLER SERVICE MANUAL NUMBER 22 Page 7A 6 90 860074 1 FEBRUARY 2002 D4 2L Intercooler 11 c 70904 10 11 12 13 15 1 2 3 4 5 6 7 8 9 7 7 14 13 A 16 B C D A B ...

Page 769: ...Equipped 9 Anode 10 Anode Plug With Sealing Washer 11 Drain Plug With Sealing Washer Not Shown In This View 12 Intake Duct Screw 4 13 Cover Screws 14 Stud 2 Lengths 15 Engine Cover Spacer 16 Intercooler Housing Nut LUBRICANT SEALANTS ADHESIVES Description Part Number A Loctite 514 Obtain Locally TORQUE Description Nm lb in lb ft Intake Duct Screw Rear All Models 10 84 A Side D21 8L D Tronic Only 1...

Page 770: ...e seawater system 16 Disconnect MAP IAT sensor Remove J clamp for coolant vent hose b a 75582 a MAP IAT Sensor Connector b J clamp 17 On Sterndrive Engines a Remove sterndrive shift bracket b Remove engine lifting eye bracket from intercooler end cover 75300 a b Sterndrive MCM Engine a Shift Bracket b Engine Lifting Eye Bracket ...

Page 771: ...er of intercooler 75621 a b 70912 c b Sterndrive Shown Inboard Similar a Intercooler b Rear Cover c Drain Plug With Sealing Washer 19 Remove hollow bolt and sealing washers from wastegate valve pressure line 70916 73940 a a b b Sterndrive Shown Inboard Similar a Wastegate Valve Pressure Line b Hollow Bolt With Sealing Washers ...

Page 772: ...lamps and disconnect seawater hoses from intercooler to heat exchanger and from seawater pump to intercooler 75298 b a a Seawater Pump To Intercooler Hose b Intercooler To Heat Exchanger Hose 21 Loosen hose clamp at turbocharger as shown 70918 a c b Typical a Hose b Hose Clamp c Turbocharger ...

Page 773: ...p anything into intake ports or severe engine damage could occur 23 Using a magnet to remove all lockwashers from studs where hex nuts were removed 24 Remove intercooler and housing Disassembly CAUTION Whenever intercooler is disassembled or radiator insert removed from intercooler ALL O ring seals must be replaced to prevent seawater from leaking into intake air duct and manifold which could resu...

Page 774: ...ed plate and second O ring position 70906 a b c d Typical a Intercooler Housing b Rear Cover c O ring Two If Equipped d Plate 3 Remove front cover and O ring 70907 c a b a Intercooler Housing b Front Cover c O ring 4 Slide radiator insert out front of intercooler housing Note position of O ring 70905 a b a Radiator Insert b O Ring ...

Page 775: ... sealant from flanges Do NOT nick or gouge the surfaces which would cause intake or water leaks 75619 b a D2 8L Engine Intercooler Housing and Intake Duct a Side Intake Duct b Intercooler Housing 3 Use a 4 4 mm 11 64 in diameter by 610 mm 24 in long rod to clean out radiator insert tubes or take to a radiator shop for cleaning 4 Inspect each part for cracks or other damage which would render it un...

Page 776: ...diator Insert Front Flange b O ring 2 Install radiator insert into intercooler housing Align insert passages as shown 70933 70926 b c a c b a D4 2L D Tronic D2 8L D Tronic a Housing b Radiator Insert c Alignment Reference Mark 3 Place O ring into groove of front cover Fasten to housing using 4 allen head screws and wave washers Torque to 40 Nm 30 lb ft 70908 70926 c a a b Typical a Front Cover b O...

Page 777: ...te and second O ring Proceed to next step 6 On intercoolers WITH plate and second O ring a Install plate on rear of intercooler b Install second O ring around radiator insert and against plate 70928 a b Typical a Plate b O ring Second One Required 7 Using the 4 allen head screws and wave washers install rear cover Torque to 40 Nm 30 lb ft Install drain plug with new sealing washer 70912 c b a Typi...

Page 778: ...L D Tronic Similar a Intercooler Housing Side Intake Duct On D2 8L Engines b Intake Duct Rear Intake Duct On D2 8L Engines c Allen Head Screws and Wave Washers 10 On D2 8L D Tronic Engines a If the side intake duct of the intercooler housing was removed for cleaning and inspection apply Loctite 514 sealer on mating surfaces b Assemble using screws with washers Torque screws to 10 Nm 84 lb in 75619...

Page 779: ...stall new intake port gaskets 70881 c a b Typical a Manifold b Intake Ports c Intake Port Gaskets 2 Install intercooler housing 3 Install hex nuts with lockwashers and torque to 32 Nm 24 lb ft 70916 70921 b a c a c Typical a Intercooler Intercooler Housing b Exhaust Intake Manifold c Hex Nuts ...

Page 780: ...ke duct hose as shown 70918 d b a c Typical a Hose b Hose Clamp c Turbocharger d Intake Duct 5 Connect wastegate valve pressure line using the hollow bolt with two new sealing washers as shown Tighten securely 70916 73940 a a b b Sterndrive Shown Inboard Similar a Wastegate Valve Pressure Line b Hollow Bolt With Sealing Washers ...

Page 781: ...ger Tighten Hose clamps securely 75298 b a a Seawater Pump to Intercooler Hose b Intercooler to Heat Exchanger Hose 7 On Sterndrive MCM Engines a Install sterndrive shift bracket onto side of intercooler Tighten screws securely b Install engine lifting eye bracket onto intercooler end cover Tighten screws securely 75300 a b a Shift Bracket b Engine Lifting Eye Bracket ...

Page 782: ...t overheating damage to engine transmission or sterndrive unit may result CAUTION Watch temperature gauge on dash to ensure that engine does not overheat 9 Upon first operating engine after repair or service of intake system and or intercooler observe temperature gauge for normal engine operating temperatures and be certain to check for leaks Stop engine IMMEDIATELY in the event of leaking or over...

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Page 785: ...ypical Intake Exhaust Manifold 7B 4 Sterndrive MCM Exhaust Systems 7B 5 Inboard MIE Exhaust Systems 7B 6 Representative View of Complete Inboard Exhaust System 7B 7 Locating and Installing The Sterndrive MCM Exhaust System 7B 8 Locating And Installing The Inboard MIE Exhaust System 7B 9 Exhaust Pipe Sterndrive MCM 7B 11 Removal 7B 11 Cleaning 7B 11 Installation 7B 12 Intake Exhaust Manifold 7B 13 ...

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Page 787: ...in Locally Description All diesel engines covered in this manual use an exhaust manifold which incorporates air passages for both intake and exhaust in a single unit Fresh water from the closed cooling system is pumped by the engine water circulating pump through the combined intake and exhaust manifold when the engine is operating When reference is made to the exhaust manifold keep in mind that i...

Page 788: ...ical Intake Exhaust Manifold 28085 2 5 3 4 6 9 8 12 1 4 7 11 13 11 10 1 Intake Exhaust Manifold With Wastegate Flange 2 Stud 3 Welch Plug 4 Gasket s 5 Drain Valve 6 Plug With Washer 7 Cover 8 Plug With Washer If Equipped 9 Cover Screw With Lock Washer 10 Nut 11 Flange Nut 12 Gasket 13 Turbocharger Flange Nut ...

Page 789: ...ndrive MCM Exhaust Systems 71704 73942 1 2 3 4 5 6 7 8 9 4 Typical 1 Exhaust Riser 2 Clamp 3 Gasket 4 Hose Clamps 5 Exhaust Hose 6 Round Exhaust Pipe For Exhaust Riser Equipped Engines No Water Shutter Assembly 7 Screw And Lockwasher 4 8 Wastegate Exhaust Pipe And Gaskets 9 Heat Shield Blanket ...

Page 790: ... 12 1 Exhaust Elbow Design 1 2 Connector 3 Plug 4 Clamp 5 Gasket 6 Hose Clamps 7 Short Exhaust Hose If Equipped 8 Exhaust Pipe Oval To Round Adapter If Equipped 9 Wastegate Exhaust Pipe Gaskets And Hardware 10 Exhaust Elbow Design 2 11 Wastegate Exhaust Pipe Gaskets And Hardware 12 Heat Shield Blanket 13 Exhaust Probe Hole 14 Round To Round Adapter If Equipped ...

Page 791: ... 7 Representative View of Complete Inboard Exhaust System NOTE Use diagrams for parts identification only a c e b a b d b c 73942 e 70902 Typical a Exhaust Elbow With Gasket And Clamp b Hose c Outlet With Water Shutter And Flapper d Water Lift Muffler e Oval To Round Adapter If Equipped ...

Page 792: ...mage is the result of defective parts Determine if an exhaust riser kit or a water lift muffler kit is required by taking measurements a and b with boat at rest in the water and maximum load aboard Subtract b from a to find c If c is less than specified in chart an exhaust riser kit must be installed The Sterndrive MCM engine is equipped with a factory installed exhaust riser Verify that the riser...

Page 793: ...del c a Minus b All Models c Must Be 279 mm 11 in or More 73592 c a b c d Typical Inboard MIE Engine a From Waterline To Top Of Transom b From Highest Point On Exhaust Elbow To Top Of Transom c From a minus b d Waterline At Rest Additional information 1 If an exhaust riser or a water lift muffler kit is NOT required The exhaust outlet for routing exhaust to outside of boat must be located so that ...

Page 794: ...e f g b Typical Continuously Sloping Exhaust Line a Exhaust Elbow b Measurement 379 mm 11 in Minimum c Exhaust Hose Or Pipe Slope to Specifications d Muffler e Exhaust Outlet Internal Shutter f Exhaust Flapper Valve g Waterline 71775 d e a c d e f g b Typical Waterlift Muffler Exhaust System a Exhaust Elbow b Vent Line 6 mm 1 4 in c Water Lift Muffler d Exhaust Hose e Drain Cock f Transom g Waterl...

Page 795: ...ckwashers retaining the exhaust pipe to the gimbal housing 2 Remove the exhaust pipe 3 Remove the O ring seal and discard 24841 b a a a Bolts And Thick Lockwashers 4 b Exhaust Pipe Cleaning IMPORTANT Exhaust pipe and gimbal housing assembly mating surfaces must be clean and free of nicks and scratches O ring must be properly seated in groove or water and exhaust may leak into boat 1 Clean the mati...

Page 796: ...l Housing Exhaust Pipe Similar b O ring 2 Hold exhaust pipe in position Install the four thick washers and bolts Torque evenly in a diagonal pattern to 30 Nm 23 lb ft 3 Lubricate the inside of large end of exhaust hose with a soap and water solution Slide hose over exhaust pipe and install two hose clamps Tighten hose clamps securely 24841 c d a a a Exhaust Pipe b Bolts And Thick Lockwashers 4 c H...

Page 797: ...ORE proceeding 1 Drain seawater cooling system 2 Drain closed cooling system 3 Remove heat exchanger assembly 4 Remove intercooler housing 5 Remove wastegate and valve 6 Remove turbocharger 7 Remove shift bracket fluid cooler and hoses if equipped 8 Loosen hose clamp on rear cover to rear of water manifold strip hose 70881 70882 b c d a b Typical a Exhaust Manifold b Rear Cover c Hose Clamp d Hose...

Page 798: ...ign material Passages must be clean for efficient cooling 4 If more thorough inspection is desired pipe plugs may be removed from exhaust manifold and exhaust elbow IMPORTANT If plugs are removed coat threads with Perfect Seal before reinstalling 5 Check for cracks 6 Ensure mating surfaces of cylinder heads are clean and free of all old gasket material 7 To test manifold body for leaks block off p...

Page 799: ...cket clamps and fluid cooler with hoses where removed previously 4 Install intake exhaust manifold flange nuts or lockwashers and nuts Torque nuts evenly in a diagonal pattern to 32 Nm 24 lb ft 5 Install hose clamp on rear cover to rear of manifold strip elbow hose Tighten securely 70882 b c d 70881 e a b f f Typical a Exhaust Manifold b Rear Cover c Hose Clamp d Hose Rear Cover To Rear Manifold S...

Page 800: ...CE MANUAL NUMBER 22 Page 7B 16 90 860074 1 FEBRUARY 2002 6 Install turbocharger 7 Install wastegate and valve 8 Install intercooler housing 9 Install heat exchanger assembly 10 Fill closed cooling system 11 Start engine Check for leaks ...

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Page 803: ...esives 7C 4 Description 7C 5 Turbocharger 7C 5 Wastegate 7C 5 Exploded Views 7C 6 Turbocharger And Related Components 7C 6 Boost Pressure Control Wastegate Components 7C 8 Turbocharger 7C 9 Testing Turbocharger Boost Pressure 7C 9 Checking Turbine Bearings Assembled 7C 10 Removal 7C 11 Disassembly 7C 15 Cleaning 7C 17 Inspection 7C 18 Assembly 7C 19 Installation 7C 21 Boost Pressure Control 7C 28 ...

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Page 805: ...L D Tronic D4 2L D Tronic Manufacturer KKK Kuhnle Kopp and Kaush Part KKK K24 2467GxA6 71 K26 2967MxA8 72 Part Number Quicksilver 854212 854128 Maximum turbine shaft axial end play 0 15 mm 0 0059 in Maximum turbine shaft radial side play 0 42 mm 0 0165 in Maximum Boost 100 124 kPa 14 5 18 psi Engine rpm when boost starts 1600 1800 1500 1800 Wastegate Equipped Equipped ...

Page 806: ...ription lb ft Nm Turbocharger Mounting Nuts 18 24 Clamping Plate Nuts or Screws 22 30 Wastegate to Exhaust Manifold Mounting Nuts 18 24 Valve to Wastegate Screws Tighten Securely Equally in a diagonal pattern Lubricants Sealants Adhesives Description P N Loctite 514 92 75505 1 Gasket Sealer 92 72592 1 ...

Page 807: ...m Turbocharger pressure is limited by a boost pressure control valve commonly called a was tegate is mounted on the combined exhaust intake manifold Wastegate When used in combination with the turbocharger a higher torque output even at low engine speeds is obtained and allows the engine a wider operating speed range The function of the wastegate is to limit the boost pressure generated by the tur...

Page 808: ...URBOCHARGER SERVICE MANUAL NUMBER 22 Page 7C 6 90 860074 1 FEBRUARY 2002 Exploded Views Turbocharger And Related Components 73941 10 11 6 23 7 22 12 21 15 16 1 17 20 12 7 18 2 9 14 5 4 3 20 19 13 19 8 24 ...

Page 809: ...ipe Plug 1 4 in x 18 22 Oil Drain Pipe 23 Hollow Bolt with Sealing Washer 24 Coolant Vent Pipe and Hose 25 Fitting At Water Manifold 26 Seawater Hose Fitting Cast Into MCM Riser 27 Turbocharger to Intake Duct Hose 28 Hose Clamps 29 Oil Feed Pipe 30 Gasket 31 Spacer 32 O ring 33 Connector 34 Sealing Washer 35 Turbocharger Support Bracket and Fasteners 36 Plug 37 Inboard MIE Exhaust Elbow Design 1 3...

Page 810: ...stegate 2 Wastegate to Exhaust Manifold Gasket 3 Typical Inboard Wastegate Exhaust Pipe 4 Gasket 2 5 Hex Nut and Lockwasher 4 6 Heat Shield Blanket For Exhaust Pipe 7 Boost Pressure Valve 8 Boost Pressure Line 9 Hollow Bolt and Sealing Washers at Exhaust Manifold 10 Hollow Bolt and Sealing Washers at Valve 11 Typical Sterndrive Wastegate Exhaust Pipe 12 Stud M8 x 20 mm ...

Page 811: ...perature Engine air cleaner should be clean or replaced if not clean 1 Remove plug screw with sealing washer from intercooler housing as shown 70904 73334 a b Typical a Plug Screw With Sealing Washer b Intercooler Housing 2 Install a 0 172 4 kPa 0 25 psi pressure gauge into intercooler where plug was removed in Step 1 3 Start engine and watch pressure gauge On All Engines Maximum boost should be b...

Page 812: ...ine impeller by hand to see that it turns smoothly If not turbine bearings or impeller problems exist 3 Using a feeler gauge as shown check clearance between turbine blades and housing at two locations opposite one another The difference in the two readings is the radial play Maximum radial play is 0 42 mm 0 0165 in 70984 Checking Turbine Blade Clearance 4 Check if turbine blades are rubbing on ho...

Page 813: ...e to electrical system REMOVING EXHAUST ELBOW 1 Disconnect battery cables from battery terminals 2 Loosen hose clamp and disconnect seawater hose at turbocharger exhaust elbow or riser Drain seawater into a suitable container 50665 a b Typical a Hose Clamp b Seawater Hose 3 Loosen exhaust elbow hose clamps as shown 74298 a c b Sterndrive D4 2L With Riser Shown All Similar a Hose Clamps b Exhaust E...

Page 814: ...t elbow 70986 a b c d Typical a Spring Blanket Retainer b Heat Shield Blanket c Hex Nuts With Lockwashers d Wastegate Exhaust Pipe 6 Make matching marks on exhaust elbow or riser and turbocharger housing for alignment during reassembly 7 Loosen exhaust elbow or riser clamp Remove elbow gasket and clamp 70987 73941 73632 b c a d d Typical Exhaust Elbow Similar With Riser a Matching Marks b Clamp c ...

Page 815: ...r as previously outlined 3 Remove lifting eye bracket 70988 a b Typical a Bracket Lifting Eye b Screws 4 Remove oil feed pipe and hollow bolt from coolant vent pipe at turbocharger as shown Loosen air filter and turbocharger to intake duct hose clamps 70989 a c b d Typical a Intake Duct Hose Clamp b Oil Feed Pipe c Hollow Bolt With Sealing Washers d Air Filter Clamp ...

Page 816: ...s To gain access to turbocharger mounting nuts re move intake duct from rear of intercooler housing Refer to SECTION 7A Intercool er IMPORTANT In the event that turbocharger mounting nuts are corroded or otherwise resist loosening in the following it may become necessary to completely remove the intercooler housing to gain a more suitable access to mounting nuts Refer to SECTION 7A Intercooler for...

Page 817: ...acket b Screw With Washer 2 Disassembly 1 Make matching marks on the exhaust housing and bearing housing to aid alignment in reassembly 2 Remove 6 hex nuts or hex screws and the 3 clamping plates shown 70993 c b e d a a Matching Marks b Hex Nuts or Hex Screws 6 Total 2 Not Shown In This View c Clamping Plates 3 Total One Not Shown In This View d Exhaust Housing e Bearing Housing ...

Page 818: ...ammer and carefully remove it in the following IMPORTANT Be careful not to damage the turbine impeller when removing exhaust housing 3 Remove exhaust housing as shown 70994 b c a a Exhaust Housing b Bearing Housing c Turbine Impeller 4 Inspect turbine blades If blades are rubbing against housing the bearings are worn Replace turbocharger 70994 b a a Turbine b Inspect Edges of Blades ...

Page 819: ...assembled parts for burning abrasion carbon deposits gas and oil leakage CAUTION Always wear safety glasses when using compressed air to protect from hose rupturing or flying debris WARNING When using compressed air to dry components Do NOT spin turbine or allow turbine to spin since no oil is being provided to the bearings and could result in damage to the bearings 2 Thoroughly clean all the part...

Page 820: ... turbine shaft in direction shown Maximum axial play end play is 0 15 mm 0 0059 in 3 If measured value is greater than specified replace the turbocharger 70995 a Measuring Axial End Play RADIAL SIDE PLAY MEASURING 1 With turbocharger held in vise attach dial indicator as shown in following 2 Move turbine shaft in direction shown Maximum radial side play is 0 42 mm 0 0165 in 3 If measured value is ...

Page 821: ... tighten hex nuts or screws Do NOT tighten securely at this time 70993 c a d e a Matching Marks b Exhaust Housing c Bearing Housing d Clamping Plates 3 Total One Not Shown e Hex Nuts or Hex Screws 6 Total 2 Not Shown 2 Follow instructions a or b a On Engines With Gasket Seals 1 Being certain surfaces are clean of old gasket material or debris install a new gasket on bearing housing oil drain space...

Page 822: ...flange where it meets bearing housing of turbocharger 2 Assemble spacer with bracket attached as shown Tighten hex nuts finger tight at this time 70998 a b c d a b a O ring Now Shown In Assembled View b Spacer Oil Drain c Support Bracket d Hex Nut 3 Position exhaust housing and bearing housing with intake housing as shown 70999 b a a Exhaust Housing b Bearing Housing With Intake Housing ...

Page 823: ...ket install turbocharger on exhaust manifold as shown Tighten nuts to 24 Nm 18 lb ft 70991 b a a Gasket Exhaust Manifold to Turbocharger b Nut 4 Total 2 Not Shown 2 Install support bracket screws with washers as shown Tighten screws securely 70992 b a a Screws With Washers b Support Bracket 3 Tighten the six hex nuts or hex screws on D4 2L on clamping plates of exhaust housing to bearing housing t...

Page 824: ...ew gasket install drain pipe Tighten hex nuts securely 71000 c c d b a a Spacer b Hex Nuts c Gasket d Oil Drain Pipe 5 On Engines With O ring Seal Remove hex nuts from spacer previously installed finger tight Using a new O ring positioned in spacer groove install drain pipe Tighten hex nuts with lockwashers securely 70990 c d b a a Spacer b Hex Nuts c O ring d Oil Drain Pipe ...

Page 825: ... surfaces and using a new gasket install oil feed pipe as shown Tighten screws securely 8 Install turbocharger to intake duct hose as shown Tighten hose clamp at turbocharger securely 9 Fit air filter to turbocharger and tighten clamp securely 70989 a b c d f g e h i Typical All Similar a Sealing Washers b Hollow Bolt c Coolant Vent Line d Turbocharger Exhaust Housing e Gasket f Oil Feed Pipe g Sc...

Page 826: ...a tion 10 Clean sealing flanges of intercooler housing and intake duct Do NOT nick or gouge the surfaces a Apply Loctite 514 sealer to intake duct flange on intercooler as shown 70931 a b c D4 2L Shown D2 8L Similar a Intercooler Housing b Intake Duct c Flange Apply Sealer Here 11 Install intake duct on intercooler as shown Torque four allen head screws with wave washers to 10 Nm 7 lb ft NOTE Inte...

Page 827: ...hers 13 As shown tighten turbocharger to intake duct hose clamp securely 70918 a c b d Typical a Hose b Hose Clamp c Turbocharger d Intake Duct 14 Install exhaust elbow or riser using new gaskets on exhaust elbow and wastegate exhaust pipe flange as shown Align studs on elbow or riser with holes in wastegate exhaust pipe Simultaneously align with exhaust pipe Tighten exhaust elbow clamp securely ...

Page 828: ...Tighten fasteners securely and wrap with heat shield blanket Fasten spring to retain blanket 71001 73941 73632 a c e e c b d c d f b g h Typical Without Riser a Gasket Exhaust Elbow b Gasket Wastegate Exhaust Pipe To Elbow Or Riser c Exhaust Elbow d Wastegate Exhaust Pipe e Clamp Exhaust Elbow f Hex Nut g Heat Shield Blanket h Spring ...

Page 829: ...Cooler c Clamp Seawater Hose d Exhaust Hose e Clamp Exhaust Hose f Exhaust Pipe 18 Fill closed cooling system at this time according to instructions in SECTION 6B Closed Cooling System Filling Closed Cooling System 19 Connect battery cables to battery by FIRST installing positive battery cable end on positive battery terminal Tighten clamp securely THEN install negative battery cable end on negati...

Page 830: ...o yourself or damage to electrical system Exhaust Pipe INSPECTION 1 Loosen spring retaining heat shield blanket around wastegate exhaust pipe as shown 71002 a b c d Typical Assembly Shown a Retaining Spring b Blanket Heat Shield c Wastegate Exhaust Pipe d Gasket 2 Visually examine pipe and convolutions for signs of cracking or leakage Also examine gaskets for signs of leakage Repair as needed Refe...

Page 831: ...rs on wastegate exhaust pipe as shown 71004 b a c Typical Pipe Shown a Hex Nut or Screws With Lockwashers 2 b Wastegate Exhaust Pipe c Wastegate 3 Remove wastegate exhaust pipe CLEANING 1 Clean old gasket material from wastegate mating surfaces and pipe if to be reused being careful not to distort pipe or crack it Do NOT allow debris to enter wastegate opening ...

Page 832: ...r screws with lockwashers install wastegate exhaust pipe Tighten fasteners securely 71004 b c a Typical a Gasket b Wastegate Exhaust Pipe c Hex Nuts With Lockwashers 3 Install turbocharger exhaust elbow Refer to Turbocharger Installation as previously outlined and accomplish appropriate instructions regarding installation of exhaust elbow or riser ...

Page 833: ...th sealing washers from pressure line on bottom of intercooler housing as shown 2 Remove the two hollow bolt with sealing washers from pressure line on valve as shown 3 Remove pressure line 75297 70917 c d f b a b e Typical a Hollow Bolts b Sealing Washers 2 Each c Pressure Line d Intercooler Housing e Wastegate f Valve ...

Page 834: ...ng on valve toward front of engine and install on wastegate using allen head screws and washers In equal amounts tighten screws securely 2 Install pressure line on valve using hollow bolt with new sealing washers Finger tighten 3 Install hollow bolt with new sealing washers on pressure line at exhaust manifold Finger tighten 4 Tighten both hollow bolts securely Do NOT overtighten 5 Start engine an...

Page 835: ...the wastegate exhaust pipe 4 Remove the wastegate valve 5 Remove the four fasteners with lockwashers retaining wastegate to exhaust manifold 71005 a c b Typical a Hex Nuts Or Screws With Lockwashers 4 b Wastegate c Exhaust Manifold CLEANING 1 Clean all traces of old gasket material from exhaust manifold flange 71006 2 Clean old gasket material from wastegate ...

Page 836: ...aust manifold as shown Securely tighten the four fasteners with lockwashers 2 Install the wastegate valve 3 Install the wastegate exhaust pipe 4 Install the exhaust elbow or riser 71005 a b c Typical a Wastegate b Gasket c Hex Nuts Or Screws With Lockwashers 4 5 Start the engine and check for leaks 6 Test turbocharger boost pressure ...

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Page 839: ...ubricants Sealants Adhesives 8A 5 Important Information 8A 6 Engine 8A 6 Transmission 8A 6 Propeller 8A 6 Transmission Propeller Rotation 8A 7 Transmission Fluid Level 8A 8 Checking 8A 8 Filling 8A 9 Changing 8A 9 Transmission Removal 8A 12 Transmission Inspection 8A 13 Transmission Installation 8A 13 Shift Control And Cables 8A 15 Transmission Shift Lever And Shift Cable Bracket 8A 15 Shift Cable...

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Page 841: ...UMBER 22 90 860074 1 FEBRUARY 2002 Page 8A 3 Identification The transmission identification plate is located on the top rear of the transmission 72959 a 77626 Typical ZF Hurth Transmission Identification Plate a Serial Number And Gear Ratio ...

Page 842: ...tios and Part Numbers 630A Ratio Normal ZF Hurth Model Number Mercury Marine Part Number 1 5 1 863744T2 2 0 1 863744T3 2 5 1 HSW630A 863744T4 2 7 1 863744T5 630V Ratio Normal ZF Hurth Model Number Mercury Marine Part Number 1 55 1 863745T2 2 0 1 HSW630V 863745T3 2 5 1 863745T4 1Ratio may be rounded off in some cases Fluid Specifications NOTICE Unit Of Measurement Liters U S Quarts All capacities a...

Page 843: ...sing 25 18 Output Flange 18 14 Mounts Transmission To Flywheel Housing 61 45 Tools Description Part Number Thermometer 3 8 NPT Thread 18 to 132 C 0 270 F Pressure Gauge 0 500 psi 1 8 NPT Obtain Locally Lubricants Sealants Adhesives Description Part Number Quicksilver Engine Coupler Spline Grease 92 816391A4 Quicksilver Liquid Neoprene 92 25711 3 Loctite Type A Loctite 515 Obtain Locally ...

Page 844: ... 1000 rpm Free wheeling of one propeller in a twin engine boat at trolling speeds will not cause damage to the transmission however boat operation above trolling speed should be avoided Ensure that proper fluid level exists before free wheeling propeller Always replace fluid cooler and hoses after a transmission failure or prior to installing a new or rebuilt transmission Metallic particles from a...

Page 845: ...for direction desired c 25506 a b d e b Hurth 630A or 800A 8 Down Angle Transmissions 72959 72959 a b c d e b Hurth 630V V Drive Transmissions a Direction Of Shift Lever Engagement Toward Flywheel b Engine Transmission Input Shaft Rotation Direction LH c Transmission Output Propeller Shaft Rotation Direction LH d Direction Of Shift Lever Engagement Away From Flywheel e Transmission Output Propelle...

Page 846: ...ission from the cooler and cooler lines 1 When the transmission is at operating temperature place selector lever in NEUTRAL 2 Shut off engine 3 Remove dipstick and wipe clean IMPORTANT Do not screw dipstick in press it firmly in and remove 4 Immediately insert clean dipstick remove and read fluid level 5 Add or remove fluid as necessary until the fluid is at the required mark TRANSMISSION COLD NOT...

Page 847: ...n fluid 1 Remove dipstick 2 Fill transmission through dipstick tube 3 Replace dipstick and recheck level 77564 a a Dipstick Tube Changing 1 Clean the exterior of the transmission around the fluid filter assembly 2 Use a 6 mm allen wrench and remove the fluid filter assembly from the transmission by turning counterclockwise and pulling at the same time 27666 ...

Page 848: ...3013 a a Drain Plug 630V Only 4 630A Only Push the hose of a suction pump through the suction pipe and down to the bottom of the housing and remove the fluid NOTE The maximum outside diameter of the suction hose is 16 mm 5 8 in 71043 5 Remove and discard the filter element and the O rings 6 Coat new O rings with transmission fluid 7 Install new O rings and filter element 50975 a b c a Filter Eleme...

Page 849: ...L NUMBER 22 90 860074 1 FEBRUARY 2002 Page 8A 11 8 Install the fluid filter assembly in the transmission cavity by turning clockwise and pushing at the same time 27662 9 Fill the transmission with specified fluid 10 Check the fluid level ...

Page 850: ...om transmission output flange 10 Remove the four rear engine mount to engine bed fasteners and hardware 11 Support rear part of engine using a suitable hoist or wooden blocks under flywheel hous ing 12 Support transmission with a hoist or by other suitable means through the lifting eye on the transmission case 13 Remove port and starboard rear mount brackets with base and trunnion from transmis si...

Page 851: ...h attaching hardware Torque transmission to flywheel housing fasteners to 61 Nm 45 lb ft Remove hoist 4 Install rear mount brackets to transmission Torque fasteners and hardware to 61 Nm 45 lb ft 5 Using hoist raise engine and transmission to remove blocks if employed Lower assembly to engine bed Securely tighten the four rear engine mount to engine bed fasteners with hardware Relieve hoist tensio...

Page 852: ...shift cables Refer to Shift Cable Installation And Adjustment 12 Refer to SECTION 2B and check engine final alignment 13 After final engine and coupler alignment has been properly set with boat in the water connect propeller shaft coupler to transmission output flange with bolts lockwashers and nuts Torque to 68 Nm 50 lb ft IMPORTANT Be certain to torque trunnion clamping fasteners on engine mount...

Page 853: ... b Shift Cable Anchor Stud Location For Quicksilver Shift Cables 2 On bracket with two anchor location holes Ensure that anchor stud is installed in the hole marked 630 WARNING Avoid serious personal injury or property damage caused by improper shifting Anchor stud for shift cable must be installed in the correct hole when using bracket with two anchor location holes 71020 71041 a a b b c c Shift ...

Page 854: ...ift Lever b Shift Lever In Neutral Detent c Dimension Between Studs 181 mm 7 1 8 In d Clamping Bolt CAUTION Avoid severe transmission damage All ZF Hurth Transmissions require Standard Left Hand rotation engines NEVER connect a ZF Hurth Transmission to a Right Hand rotation engine IMPORTANT Transmission propeller rotation is determined by the shift cable instal lation in the remote control Right h...

Page 855: ... center of remote control and control shift cable play backlash as follows a Ensure that remote control is in neutral position b Push in on control cable end with enough pressure to remove play and mark position a on tube c Pull out on control cable end with enough effort to remove play and mark position b on tube d Measure distance between marks a and b and mark position c halfway between marks a...

Page 856: ...s time 8 Follow instructions a or b a If transmission shift lever will position properly in one gear but not in the other re check shift cable adjustment b If transmission shift lever will not position properly in both gears move transmission shift lever stud from top hole in shift lever to bottom hole and recheck for proper posi tioning If proper positioning is still not obtained the remote contr...

Page 857: ...l 72955 71210 e b c d b a f g h Typical Single Cable Installation Forward Approach a Cable End Guide b Locknut and Washer c Spacer Fits Over Bushings d Bushing e Cable Barrel f Spacers Fits Over Stud g Cable Barrel Stud h Cable End Guide Stud 72957 50229 a b f b c d e g h Typical Single Cable Installation Rear Approach a Cable End Guide b Locknut And Washer c Spacer Fits Over Bushings d Bushing e ...

Page 858: ...le End Guide b Locknut And Washer c Spacer Fits Over Bushings d Bushing e Cable Barrel f Spacers Fits Over Stud g Cable Barrel Stud h Cable End Guide Stud 72960 50073 e b d a b d g h Typical Dual Cable Installation Rear Approach a Cable End Guide b Locknut And Washer c Spacer Fits Over Bushings d Bushing e Cable Barrel f Spacers Fits Over Stud g Cable Barrel Stud h Cable End Guide Stud ...

Page 859: ...cation 5 Check for leaks Transmission Repair Mercury Marine stocks a limited number of replacement parts for these transmissions ZF Marine has a network of distributors throughout the world to service their product These distributors in turn have a dealer network to service the transmissions Also service manuals for each transmission can be obtained from ZF Marine For the location of your closest ...

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Page 861: ...02 Page 8B 1 DRIVE SYSTEMS Section 8B Propeller Shaft Models Table of Contents Lubricants Sealants Adhesives 8B 2 Checks Made with Boat In Water 8B 3 Checks Made with Boat Out of Water and Shaft Installed 8B 5 Checks Made with Propeller Shaft Removed from Boat 8B 7 Strut 8B 7 ...

Page 862: ... ft Propeller Shaft Coupling to Coupling Housing MIE 68 50 Coupling Set Screws If Equipped Securely See NOTE NOTE Safety wire set screws if equipped Lubricants Sealants Adhesives Description Part Number 2 4 C Marine Lubricant 92 86154A1 Engine Coupler Spline Grease 92 8166391A 4 Loctite 8831 92 823089 1 Loctite 290 Obtain Locally ...

Page 863: ...upling 2 Check fit of coupling to propeller shaft following instructions a or b a Straight Bore Type 1 Loosen set screws 2 Try to move coupling by hand The bore of the coupling should be a semi press fit to shaft 3 Check shaft for wear If worn replacement of shaft may be necessary If shaft is not worn try another coupling b Tapered Bore Type 1 Check nut on shaft for tightness 2 If nut was loose re...

Page 864: ...ide Diameter Of A Typical Drive System Checking Coupling Face Of A Typical Drive System 4 If there is greater than 0 076 mm 0 003 in movement in Step 3 replace output cou pling 5 Replace damaged parts and realign engine as outlined 6 Torque propeller shaft coupling and transmission coupling output flange to 68 Nm 50 lb ft 7 Tighten set screws securely Safety wire set screws if equipped ...

Page 865: ...ey d Mark the shaft behind the propeller then remove propeller e Install the key and propeller Make sure propeller still lines up with mark This ensur es that key is not oversize and holding the tapers apart Retighten propeller nut f Ensure key is not sticking out of propeller 2 Check for propeller shaft being bent behind the strut a b a Metal Straight Edge Held to Rudder with C Clamp Position Cor...

Page 866: ...ades are the same pitch and that propeller is properly seated on shaft Rotate propeller at least one complete turn and check at three different points on blades Repair or replace if necessary NOTE Hold metal straight edge to rudder with a C clamp or equivalent a b c a Metal Straight Edge b Rudder c Propeller Blades ...

Page 867: ... a b c a V Blocks b Dial Indicator c Shaft 2 Ensure that bore of coupling is 90 degrees from coupling flange Rotate at least one complete turn Replace coupling if needle moves a b c d a V Blocks b Dial Indicator c Coupling Flange d Shaft Against Block to Prevent Fore and Aft Movement Strut Refer to boat manufacturer s service manual for alignment and replacement Normally the shaft should be center...

Page 868: ...PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 22 Page 8B 8 90 860074 1 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK ...

Page 869: ...M Section 9A Pump And Related Components Table of Contents Torque Specifications 9A 2 Lubricants Sealants Adhesives 9A 2 Description 9A 2 Exploded Views 9A 3 Power Steering Pump 9A 3 Related Components 9A 4 Power Steering Pump 9A 5 Removal 9A 5 Installation 9A 6 Checking Fluid Level 9A 8 Filling and Bleeding 9A 8 ...

Page 870: ...Nm lb in lb ft Front bracket Rear Brace 32 24 Mounting And Tensioning Bolt 21 15 Lubricants Sealants Adhesives Description Part Number Quicksilver Power Trim and Steering Fluid 92 90100 Automatic Transmission Fluid Dexron III Obtain Locally Description IMPORTANT Power Steering Pumps are considered non repairable units and are intended to be removed and replaced with new units ...

Page 871: ...2 90 860074 1 FEBRUARY 2002 Page 9A 3 Exploded Views Power Steering Pump 71035 1 2 3 4 6 4 9 7 8 5 1 Pump 2 Pulley 3 Tensioning Bolt Lockwasher And Flat Washer 4 Mounting Bolt 5 Bushing 6 Fluid Pressure Hose 7 Fluid Reservoir Hose 8 Hose Clamp 9 Bracket ...

Page 872: ...60074 1 FEBRUARY 2002 Related Components ALL ENGINES 71034 9 6 7 1 8 2 5 3 4 78418 1 Fluid Reservoir Tank 2 Hose Clamp 2 3 Fluid Reservoir Support 4 Bracket 5 Supply Hose 6 Pressure Hose 7 Return Hose From Transom 8 Return Hose From Cooler 9 Power Steering Fluid Cooler ...

Page 873: ...oning Bolt Lockwasher And Flat Washer 3 Lower pump down to gain access to hose connections Remove hoses and adaptor as shown Using clean suitable plugs quickly plug hoses to limit loss of fluid NOTE If possible lift pump above power steering reservoir and then remove hoses to mini mize fluid loss 4 Drain power steering fluid from pump into a suitable container Do NOT reuse fluid 5 Using a suitable...

Page 874: ...sing a suitable screw push install pulley onto shaft until pulley face is flush as shown with shaft end screw head will bottom out 74481 2 Install reservoir hose and pressure hose to pump as shown Temporarily hand tighten only a b c d e 78418 a Reservoir Hose b Hose Clamp c Pressure Hose d O ring e Fitting ...

Page 875: ...e and tension belt Belt must not deflect more than 5 mm 3 16 in Move or pry power steering pump to tension belt Torque mounting bolts and tensioning bolt to 21 Nm 15 lb ft NOTE On all models power steering drive pulley is behind crankshaft front pulley 6 If not already accomplished drain fluid from power steering reservoir into a suitable con tainer Do NOT reuse old fluid Dispose of properly 7 Fil...

Page 876: ...2 Page 9A 8 90 860074 1 FEBRUARY 2002 Checking Fluid Level Refer to SECTION 1B Filling and Bleeding Refer to SECTION 1B NOTICE For more information on power steering system and components refer to appropriate Mercury MerCruiser Sterndrive Service Manual ...

Page 877: ...PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 90 860074 1 FEBRUARY 2002 Page 9A 9 THIS PAGE IS INTENTIONALLY BLANK ...

Page 878: ...PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 Page 9A 10 90 860074 1 FEBRUARY 2002 ...

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Mercury D2.8L D-Tronic, Service Manual

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