Not Sure About VW EGR Valve Health Look For These Symptoms
Mercury mercruiser marine engine in line diesel d2.8 l d-tronic service repair manual sn:0k000001 and above
1. 90- i
NUMBER 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
2. 90-860074--1 FEBRUARY 2002 Page i
Notice
Throughout this publication, Dangers, Warnings and Cautions (accompanied by the
International HAZARD Symbol ) are used to alert the mechanic to special instructions
concerning a particular service or operation that may be hazardous if performed incorrectly
or carelessly. OBSERVE THEM CAREFULLY!
These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus common sense operation,
are major accident prevention measures.
DANGER
Immediate hazards which will result in severe personal injury or death.
WARNING
Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
3. Page ii 90-860074--1 FEBRUARY 2002
Notice to Users of This Manual
This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
It is assumed that these personnel are familiar with marine product servicing procedures.
Furthermore, it is assumed that they have been trained in the recommended service
procedures of Mercury MerCruiser product, including the use of mechanics’ common hand
tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the marine trade of all conceivable procedures
and of the possible hazards and/or results of each method. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins, operation maintenance and warranty manuals and
installation manuals for other pertinent information concerning the products described in
this manual.
It should be kept in mind, while working on the product, that the electrical system is capable
of violent and damaging short circuits or severe electrical shocks. When performing any
work where electrical terminals could possibly be grounded or touched by the mechanic,
the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
It is important to note, during any maintenance procedure replacement fasteners must have
the same measurements and strength as those removed. Numbers on the heads of the
metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use
radial lines for this purpose, while most American nuts do not have strength markings.
Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal
injury. Therefore, fasteners removed should be saved for reuse in the same locations
whenever possible. Where the fasteners are not satisfactory for re-use, care should be
taken to select a replacement that matches the original.
4. 90-860074--1 FEBRUARY 2002 Page iii
Engine Mechanical Components
Many of the engine mechanical components are designed for marine applications. Unlike
automotive engines, marine engines are subjected to extended periods of heavy load
and wide open throttle operation and, therefore, require heavy-duty components. Special
marine engine parts have design and manufacturing specifications that are required to
provide long life and dependable performance. Marine engine parts also must be able to
resist the corrosive action of salt or brackish water that will rust or corrode standard
automotive parts within a short period of time.
Failure to use recommended Mercury / Quicksilver service replacement parts can result in
poor engine performance and/or durability, rapid corrosion of parts subjected to salt
water and possibly complete failure of the engine.
Replacement Parts
Use of parts other than the recommended service replacement parts, will void the warranty
on those parts that are damaged as a result.
WARNING
Electrical and fuel system components on Mercury MerCruiser Engines and Stern
Drives are designed and manufactured to comply with U.S. Coast Guard Rules
and Regulations to minimize risks of fire or explosion.
Use of replacement electrical or fuel system components, which do not comply to
these rules and regulations, could result in a fire or explosion hazard and should
be avoided.
When servicing the electrical and fuel systems, it is extremely important that all
components are properly installed and tightened. If not, any electrical component
opening would permit sparks to ignite fuel vapors from fuel system leaks, if they
existed.
5. Page iv 90-860074--1 FEBRUARY 2002
Models Covered in This Manual
Sterndrive (MCM) Serial Number
D2.8L D-Tronic 0K000001 and Above
D4.2L D-Tronic 0K000001 and Above
Inboard (MIE) Serial Number
D2.8L D-Tronic 0K000001 and Above
D4.2L D-Tronic 0K000001 and Above
6. 1
2
3
4
5
6
7
8
Important Information
Removal And Installation
Engine Mechanical
Electrical System
Fuel System
Cooling System
Intake And Exhaust System
Drive System
9Power Steering System
90-860074--1 FEBRUARY 2002 Page v
Service Manual Outline
Section 1 - Important Information
A - General Information
B - Maintenance
C - Troubleshooting
Section 2 - Removal and Installation
A - Sterndrive (MCM) Models
B - Inboard (MIE) Models
Section 3 - Engine Mechanical
A - D2.8L D-Tronic And D4.2L D-Tronic Engines
Section 4 - Electrical System
A - Starting System
B - Charging System
C - Glow Plug System (If Equipped)
D - Instrumentation
E - Wiring Diagrams
Section 5 - Fuel System
A - Description
B - Fuel Delivery Pump and Fuel Filter
C - Injectors
D - Injection Pump
E - EDI Diagnosis
Section 6 - Cooling System
A - Seawater Cooling System
B - Closed Cooling System
Section 7 - Intake And Exhaust System
A - Intercooler
B - Intake / Exhaust Manifold, Elbows and Risers
C - Turbocharger
Section 8 - Drive System
A - ZF / Hurth Transmissions
B - Propeller Shaft Models
Section 9 - Power Steering System
A - Pump And Related Components
21. GENERAL INFORMATION SERVICE MANUAL NUMBER 22
Page 1A-2 90-860064--1 FEBRUARY 2002
THIS PAGE IS INTENTIONALLY BLANK
22. SERVICE MANUAL NUMBER 22 GENERAL INFORMATION
Page 1A-390-860074-–1 FEBRUARY 2002
NOTICE
For information and procedures on Troubleshooting, refer to SECTION 1C.
NOTICE
Refer to appropriate Sterndrive Service Manual for transom assembly and sterndrive unit repair.
Introduction
This comprehensive overhaul and repair manual is designed as a service guide for the
models previously listed. It provides specific information, including procedures for
disassembly, inspection, assembly and adjustment to enable dealers 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 fully describe the component.
Page Numbering
Two number groups appear at the bottom of each page. The following is an example and
description.
a b c d e f g
90-860074--1 FEBRUARY 2002Page 1A-3
a - Section Number
b - Section Part
c - Page Number
d - Manual Number
e - Revision Number 1
f - Month Printed
g - Year Printed
23. GENERAL INFORMATION SERVICE MANUAL NUMBER 22
Page 1A-4 90-860064--1 FEBRUARY 2002
Engine Serial Number / Decal Locations
75298
7332
3 75388
b
d
75301
73929
MARINE POWER
EUROPE INC
MADE IN ITALY
SERIAL NUMBER
MAX
RPM
H
P
L
B
K
W
K
G
a
71675a
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
24. SERVICE MANUAL NUMBER 22 GENERAL INFORMATION
Page 1A-590-860074-–1 FEBRUARY 2002
Operation / Duty Cycle
It is the operator’s responsibility to operate within the following specified operational
capability, or duty cycle, as applicable to engine and installation:
NOTE:
Pleasure duty rating applies to recreational planing craft used exclusively for pleasure and
recreation.
Light duty rating applies to planing boats where the use of full rated power at maximum rated
rpm is limited (as stated above). Examples of Light Duty applications include, but are not
limited to: search and rescue craft, fast patrol boats, fire boats, dive boats, and limited
season fishing 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 RATING / DUTY CYCLE
D2.8L D-Tronic and D4.2L D-Tronic
Specified Operating RPM Range 3600 - 3800
Wide Open Throttle (WOT)
Operation
Limited to short periods of time.
LIGHT DUTY RATING / DUTY CYCLE
D2.8L D-Tronic and D4.2L D-Tronic
Specified Operating RPM Range 3600-3800
Wide Open Throttle (WOT)
Operation
Limited to less that 10% of operating time.
Continuous cruising RPM
Limited to 90% or less of wide open throttle
RPM
Annual operating time Not to exceed 500 hours
25. GENERAL INFORMATION SERVICE MANUAL NUMBER 22
Page 1A-6 90-860064--1 FEBRUARY 2002
Engine Break-In
Initial Break-In Procedure
The following procedure must be used on new and rebuilt diesel engines. This break-in
procedure allows the proper seating of the pistons and rings, which greatly reduces the
likelihood of problems.
IMPORTANT: It is recommended that the boat not be accelerated hard until this
procedure has been completed.
IMPORTANT: Never operate the starter motor longer than 15 seconds at 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 engine in gear for 3 minutes at each of the following rpms: 1200 rpm, 2400
rpm and 3000 rpm.
3. Operate the engine in gear for 3 minutes at each of the following rpms: 1500 rpm, 2800
rpm and 3400 rpm.
4. Operate the engine in gear for 3 minutes at each of the following rpms: 1800 rpm, 3000
rpm and WOT.
26. SERVICE MANUAL NUMBER 22 GENERAL INFORMATION
Page 1A-790-860074-–1 FEBRUARY 2002
Mercury/Quicksilver Lubricants, Sealants And Adhesives
Tube
Ref. #
Description Container Size
Mercury Part
Number
Quicksilver Part
Number
4
Needle Bearing Assy.
Lubricant
8 oz (226.8 g) tube N/A 92-802868A1
6 Dielectric Grease 8 oz (226.8 g) can N/A 92-823506-1
7
Loctite 271 - Thread
Locker
10 ml tube N/A 92-809819
9
Loctite 567 PST Pipe
Sealant
50 ml tube N/A 92-809822
12
Loctite Master Gasket
Kit
N/A 92-12564-2
14
2 Cycle Premium
Outboard Oil
1 US qt (0.94 L) 92-802813A1 92-802813Q1
19 Perfect Seal 16 oz (0.45 kg) can N/A 92-34227-1
25 Liquid Neoprene 8 oz (226.8 g) can N/A 92-25711-3
27 Bellows 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 Gear
Lubricant
1 US qt (0.94 L) 92-802846A1 92-802846Q1
87
High Performance
Gear Lube
1 US qt (0.94 L) 92-802854A1 92-802854Q1
91
Engine Coupler
Spline Grease
14 oz (0.39 kg)
cartridge
92-802869A1 92-802869Q1
94
Anti-Corrosion
Grease
8 oz (226.8 g) tube 92-802867A1 92-802867Q1
95 2-4-C with Teflon 8 oz (226.8 g) tube 92-802859A1 92-802859Q1
110
4 Stroke 10W30
Outboard Oil
1 US qt (0.94 L) 92-802833A1 92-802833Q1
114
Power Trim &
Steering Fluid
8 oz (226.8 g) 92-802880A1 92-802880Q1
27. GENERAL INFORMATION SERVICE MANUAL NUMBER 22
Page 1A-8 90-860064--1 FEBRUARY 2002
Tube
Ref. #
Description Container Size
Mercury Part
Number
Quicksilver Part
Number
115
Premium Plus 2 Cycle
TC-W3 Outboard Oil
1 US qt (0.94 L) 92-802824A1 92-802824Q1
116
RTV 587 Silicone
Sealer
3 oz (85.05 g) N/A 92-809825
117 Loctite 7649 Primer N 4.5 oz (127.57 g) N/A 92-809824
118
Storage Seal Rust
Inhibitor
12 oz (325 ml) spray
can
92-802878-56 92-802878Q56
119 Corrosion Guard
12 oz (325 ml) spray
can
92-802878 55 92-802878Q55
120
15W40 4-cycle Diesel
Engine Oil
1.06 US gal.(4 L) 92-877695K1 92-877695Q1
121
Extended Life
Antifreeze/Coolant
1 US gal. (3.78 L) 92-877770K1 92-877770K1
122
Marine Engine
Coolant
1.33 US gal. (5 L) 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 Part
Epoxy
N/A 92-65150 1
Dexron III Automatic
Transmission Fluid
Obtain Locally Obtain Locally
Loctite 592 Obtain Locally Obtain Locally
Loctite Quick Tite Obtain Locally Obtain Locally
Isopropyl Alcohol Obtain Locally Obtain Locally
Hot Glue Obtain Locally Obtain Locally
Loctite 609 Obtain Locally Obtain Locally
Loctite 405 Obtain Locally Obtain Locally
Cyanacrylate
Adhesive
Obtain Locally Obtain Locally
3M Permabond
#3M08155
Obtain Locally Obtain Locally
Loctite 262 Obtain Locally Obtain Locally
28. SERVICE MANUAL NUMBER 22 GENERAL INFORMATION
Page 1A-990-860074-–1 FEBRUARY 2002
THIS PAGE IS INTENTIONALLY BLANK
29. GENERAL INFORMATION SERVICE MANUAL NUMBER 22
Page 1A-10 90-860064--1 FEBRUARY 2002
THIS PAGE IS INTENTIONALLY BLANK
31. MAINTENANCE SERVICE MANUAL NUMBER 22
Page 1B-2 90-860074--1 FEBRUARY 2002
THIS PAGE IS INTENTIONALLY BLANK
32. MAINTENANCESERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002 Page 1B-3
Torque Specifications
Description Nm lb-in. lb-ft
Rear Engine Mounts 51 38
Alternator Tensioning Or Mounting Bolt 28 21
Power Steering Tensioning Or Mounting Bolt 21 15
Vacuum Pump Tensioning Or Mounting Bolt 21 15
Heat Exchanger End Covers
Upper 14-15
120-
132
Lower 11
108-
120
Special Tools
Description Part Number
Crankcase Oil Pump 90265A2
Flushing Attachment 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 Bearing Grease 1 92-828052A2
2-4-C Marine Lubricant With Teflon 92-802861Q1
Exxon Unirex EP2 Grease Obtain Locally
SAE 30W Engine Oil Obtain Locally
1 Except on Bravo X Drive U-joint crosses and bearings - use Exxon Unirex EP2 Grease.
33. MAINTENANCE SERVICE MANUAL NUMBER 22
Page 1B-4 90-860074--1 FEBRUARY 2002
Engine Specifications
Sterndrive (MCM) Engines
Specification - Sterndrive (MCM)
Description
D2.8L D-Tronic D4.2L D-Tronic
Crankshaft Kilowatts (Horsepower) 1 123 ( 165 ) 186 ( 250 )
Propeller Shaft Kilowatts (Horsepower) 1 112 ( 150 ) 168 ( 225 )
Engine Type
In-Line 4 Cylinder
Diesel
In-Line 6 Cylinder
Diesel
Displacement 2.8 liter (169 cu. in.) 4.2 liter (254 cu. in.)
Firing Order 1 - 3 - 4 - 2 1 - 5 - 3 - 6 - 2 - 4
Bore 94 mm ( 3.700 in. )
Stroke 100 mm ( 3.937 in. )
Compression Ratio 16.5:1
Valve Clearance - Intake / Exhaust Hydraulic
Maximum Pressure Difference Between
Cylinders
500 kPa ( 72 psi )
Maximum High Idle No Load rpm 4200 ± 50
Governed rpm Setting (Begins At:) 3850 ± 50
Rated rpm at Wide-Open-Throttle 2 3800
700 3
Low Idle rpm
600 4
Oil 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
Alternator Rating 949W, 14.6v, 65 Amp.
Recommended Battery Rating 750 cca, 950 mca, or 180 Ah
Starter 12v, 2.7 kW
1 Power rated in accordance with NMMA Procedure - ISO 3046 (Technically Identical to ICOMIA
28-83).
2 Refer to Conditions Affecting Operation - Propeller Selection for additional information.
3 Mercury Serial Number 0L343084 and Below on D2.8L D-Tronic Engines. Mercury Serial Number
0L343703 and Below on D4.2L D-Tronic Engines.
4 Mercury Serial Number 0L343085 and Above on D2.8L D-Tronic Engines. Mercury Serial Number
0L343704 and Above on D4.2L D-Tronic Engines.
34. MAINTENANCESERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002 Page 1B-5
Inboard (MIE) Engines
Specification - Inboard (MIE)
Description
D2.8L D-Tronic D4.2L D-Tronic
Crankshaft Kilowatts (Horsepower) 1 123 ( 165 ) 186 ( 250 )
Propeller Shaft Kilowatts (Horsepower) 1 119 ( 160 ) 179 ( 240 )
Engine Type
In-Line 4 Cylinder
Diesel
In-Line 6 Cylinder
Diesel
Displacement
2.8 liter
169 cu. in.
4.2 liter (254 cu. in.)
Firing Order 1 - 3 - 4 - 2 1 - 5 - 3 - 6 - 2 - 4
Bore 94 mm ( 3.700 in. )
Stroke 100 mm ( 3.937 in. )
Compression Ratio 16.5:1
Valve Clearance - Intake / Exhaust Hydraulic
Maximum Pressure Difference Between
Cylinders
500 kPa ( 72 psi )
Maximum High Idle No Load rpm 4200 ± 50
Governed rpm Setting (Begins At:) 3850 ± 50
Rated rpm at Wide Open Throttle 2 3800
700 3
Low Idle rpm
600 4
750 rpm 1.5 - 3.1 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 Rating 949W, 14.6v, 65 Amp.
Recommended Battery Rating 750 cca / 950 mca / 180 Ah
Starter 12v, 2.7 kW
1 Power rated in accordance with NMMA Procedure - ISO 3046 (Technically Identical to ICOMIA
28-83).
2 Refer to “Conditions Affecting Operation - Propeller Selection” for additional information.
3 Mercury Serial Number 0L343084 and Below on D2.8L D-Tronic Engines. Mercury Serial Number
0L343703 and Below on D4.2L D-Tronic Engines.
4 Mercury Serial Number 0L343085 and Above on D2.8L D-Tronic Engines. Mercury Serial Number
0L343704 and Above on D4.2L D-Tronic Engines.
35. MAINTENANCE SERVICE MANUAL NUMBER 22
Page 1B-6 90-860074--1 FEBRUARY 2002
Capacities
NOTICE
All capacities are approximate fluid measures.
Engines
NOTICE
Unit Of Measurement: Liters (U.S. Quarts).
Model
D2.8L
D-Tronic
D4.2L
D-Tronic
Total Oil Capacity 1 10 ( 8-1/2 ) 12 ( 12-3/4 )
Oil Pan 8 ( 6-1/2 ) 10 ( 10-3/4 )
Oil Drainage Oil Filter 1 ( 1 )
Oil Cooler 1 ( 1 )
Closed Cooling Circuit 11 ( 11-2/3 ) 13 ( 13-3/4 )
1 Always use dipstick to 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. Quarts).
Make And Model Specification1 Fluid Type
Hurth 630A 3 (3-1/4) Dexron III Automatic
630V 4 (4-1/2)
Dexron III Automatic
Transmission Fluid
1 Always use dipstick to determine exact quantity of oil required
36. MAINTENANCESERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002 Page 1B-7
NOTICE
For information and procedures on Troubleshooting refer to SECTION 1C.
Maintenance Schedules
NOTE: Refer to appropriate Mercury MerCruiser Sterndrive Service Manual for information
and procedures on sterndrive maintenance.
WARNING
Avoid injury or death, product damage, fire or explosion. The electrical system is
capable of violent and damaging short circuits or severe electrical shocks. When
performing any activity where any electrical terminals could possibly be grounded
or touched, the battery cables 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
corresponding tasks. In some cases, this may allow for more tasks to be performed in a
single visit to the dealer, rather than multiple visits. Therefore, it is very important that the
boat owner and servicing dealer discuss the Maintenance Schedule and develop
appropriate maintenance intervals to coincide with individual operating habits, the
environment and maintenance requirements.
37. MAINTENANCE SERVICE MANUAL NUMBER 22
Page 1B-8 90-860074--1 FEBRUARY 2002
Sterndrive (MCM) Engines
Routine Maintenance *
Each
Day
Start
Each
Day
End
Weekly
Every
Two
Months
Check crankcase oil (interval can be extended based on experi-
ence).
D
If operating in salt, brackish or polluted waters, flush cooling sys-
tem after each use.
D
Drain any water from fuel filter after each use (If operating in freez-
ing temperatures).
D
Check drive unit oil level, trim pump oil level and power steering
pump fluid level.
D
Check water pickups for debris 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 filter every 50 hours of operation. D
Ensure that the gauges and the wiring connections are secure.
Clean the gauges.1 D
* Only perform maintenance which applies to your particular power package.
1 Or every 50 hours, whichever occurs first. If operating in saltwater, interval is reduced to every 25 hours or 30 days
whichever occurs first
38. MAINTENANCESERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002 Page 1B-9
Sterndrive (MCM) Engines (Continued)
Scheduled Maintenance *
After
First
20
hours
Annu-
ally
Every
100
hours or
Annually
z
Every
200
hours
or 3
years
z
Every
300
hours
or 3
years
z
Every
2
years
Every
5
years
Every
500
hours
or 5
years
z
Every
1000
hours
or 5
years
z
Change crankcase oil and filter. D D
Touch-up paint power package
and spray with corrosion guard.
D
Change drive unit oil and
retorque connection of gimbal
ring 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
Bravo Models.
D
Retorque engine mounts. D
Check electrical system for loose,
damaged or corroded fasteners.
D
* Only perform maintenance which applies to your particular power package.
z Whichever Occurs First
* Lubricate engine coupler every 50 hours if operated at idle for prolonged periods of time.
39. MAINTENANCE SERVICE MANUAL NUMBER 22
Page 1B-10 90-860074--1 FEBRUARY 2002
Sterndrive (MCM) Engines (Continued)
Scheduled Maintenance * (Continued)
After
First
20
hours
Annu-
ally
Every
100
hours or
Annually
z
Every
200
hours
or 3
years
z
Every
300
hours
or 3
years
z
Every
2
years
Every
5
years
Every
500
hours
or 5
years
z
Every
1000
hours
or 5
years
z
Lubricate drive 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
Replace air filter. D
Clean aftercooler core. D
Clean fuel tank. D
* Only perform maintenance which applies to your particular power package.
z Whichever Occurs First
40. MAINTENANCESERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002 Page 1B-11
Inboard (MIE) Engines
Routine Maintenance *
Each
Day
Start
Each
Day
End
Weekly
Every
Two
Months
Check crankcase oil (interval can be extended based on experi-
ence).
D
If operating in salt, brackish or polluted waters, flush cooling sys-
tem after each use.
D
Drain any water from fuel filter after each use (if operating in
freezing temperatures).
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 maintenance which applies to your particular power package.
1 Or every 50 hours, whichever occurs first. If operating in saltwater, interval is reduced to every 25 hours or 30 days
whichever occurs first
41. MAINTENANCE SERVICE MANUAL NUMBER 22
Page 1B-12 90-860074--1 FEBRUARY 2002
Inboard (MIE) Engines (Continued)
Scheduled Maintenance *
After
First
20
hours
Annu-
ally
Every
100
hours or
Annually
z
Every
200
hours
or 3
years
z
Every
2
years
Every
500
hours
or 5
years
z
Every
1000
hours
or 5
years
z
Per
OEM
Change crankcase oil and filter. D D
Touch-up paint power package and
spray with corrosion guard.
D
Change transmission fluid. D
Replace fuel filter(s). D
Check steering system and remote
control for loose, missing 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 cooling
system. Clean, inspect and test pressure
cap. Check anodes on diesel models.
D
Replace coolant. D
Replace air filter. D
Clean aftercooler core. D
Clean fuel tank. D
Check engine-to-propeller shaft align-
ment.
D
* Only perform maintenance which applies to your particular power package.
z Whichever Occurs First
42. MAINTENANCESERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002 Page 1B-13
Engine External Views
Starboard Side View
78409
10
11
12
14
1 2 3 4
5 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
46. MAINTENANCESERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002 Page 1B-17
Engine Oil
CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is
restricted by law. Do NOT spill oil or oil waste into the environment when using or
servicing your boat. Contain and dispose of oil or oil waste as defined by local
authorities.
To help obtain optimum engine performance and to provide maximum protection, the engine
requires engine oil with a rating of HD-SAE-API CG-4 and CH-4.
We strongly recommend the use of:
MERCURY DIESEL ENGINE OIL QUICKSILVER HEAVY DUTY ENGINE OIL
These oils are both specially blended 15W-40 oil with Marine Additives, for all temperature
operation. They both exceed requirements for API CH-4, CF-4, CG-4 and CF-2 oils.
Other recommended oils:
SHELL MYRINA TEXACO URSA SUPER TD VEEDOL TURBOSTAR
MOPAR WINTERSHALL MULTI-REKORD WINTERSHALL 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 causes a loss of engine
performance and an increase in crankcase backpressure. An extreme overfill condition
could result in large amounts of oil being drawn into the intake.
Care must be taken when checking engine oil level. Oil level must be maintained between
the minimum oil level mark and the maximum mark on the dipstick. To ensure that you are
not getting a false reading, observe the following before checking the oil level.
• Boat at rest in the water, or if boat is on a trailer, raise or lower bow until the boat is
setting like it does at rest in the water.
• Allow ten minutes for oil to drain into the oil pan if engine has just been operated or
oil has just been added.
47. MAINTENANCE SERVICE MANUAL NUMBER 22
Page 1B-18 90-860074--1 FEBRUARY 2002
CHECKING / FILLING
IMPORTANT: Engine crankcase oil must be checked at intervals specified in
Maintenance Schedule. It is normal for an engine to use a certain amount of oil in the
process of lubricating and cooling the engine. The amount of oil consumed is greatly
dependent upon engine speed, with consumption being highest at WOT and
decreasing substantially as engine speed is reduced.
5. Check engine oil daily before first start-up.
CAUTION
Avoid possible injury, 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 dipstick and observe oil level. Oil must be between marks on dipstick.
71380
71382
a bc
75732
a - Oil Dipstick
b - Minimum Oil Level Mark
c - Maximum Oil Level Mark
8. If oil level is low, remove oil filler cap. Add specified oil to bring level up to, but not over,
maximum oil level mark on dipstick.
75301
a
a - Oil Filler Cap
9. Install oil filler cap.
48. MAINTENANCESERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002 Page 1B-19
Changing Engine Oil and Oil Filter
IMPORTANT: Change oil when engine is warm from operation. Warm oil flows more
freely, carrying away more impurities. Use only recommended engine oil (see
Specifications).
1. Start 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
ab
c
a - Oil Drain Hose
b - Threaded Fitting
c - Crankcase Oil Pump
5. Pump oil out of crankcase into drain pan.
6. Remove crankcase oil pump.
7. Install threaded fitting on crankcase oil drain hose.
49. MAINTENANCE SERVICE MANUAL NUMBER 22
Page 1B-20 90-860074--1 FEBRUARY 2002
8. Remove and discard oil filter and seal.
9. Coat seal on new filter with engine oil and install filter. Hand tighten only, do NOT use
a filter wrench.
75297
bb
a
b
a - Oil Filter
b - Seal
10. Remove oil fill cap and refill engine with new engine oil.
CAUTION
Do NOT overfill the engine with oil. Too much engine oil will cause a loss of engine
performance and an increase in crankcase back-pressure.
11. Add specified oil to 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 engine is running. Stop the engine
completely before removing or inserting dipstick.
15. Stop engine and allow approximately 10 minutes for oil to drain into oil pan.
16. Remove dipstick and observe oil level. Oil must be between the marks on the dipstick.
17. Start engine and check for leaks.
50. Thank you very much
for your reading.
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