Mercury D4.2L D-Tronic

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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

Main Page

Fuel System15
- Default Chapter1
- Section 5E - Edi Diagnosis15
- Section 6A - Seawater Cooling System16
  - Section 6B - Closed Cooling System16
Important Information 121
- Table of Contents21
- Section 1A - General Information21
- How to Use this Manual23
- Introduction23
- Page Numbering23
- Engine Serial Number / Decal Locations24
- Operation / Duty Cycle25
- Engine Break-In26
- Initial Break-In Procedure26
- Mercury/Quicksilver Lubricants, Sealants and Adhesives27
Important Information 131
- Lubricants / Sealants / Adhesives33
- Special Tools33
- Tools33
- Torque Specifications33
- Engine Specifications34
  - Sterndrive (MCM) Engines34
  - Inboard (MIE) Engines35
- Capacities36
  - Engines36
  - Drives36
  - Transmissions36
- Maintenance Schedules37
  - Maintenance Intervals37
  - Sterndrive (MCM) Engines38
  - Inboard (MIE) Engines41
- Engine External Views43
  - Starboard Side View43
  - Front View44
  - Port Side View45
  - Rear View46
- Engine Oil47
  - Oil Level47
  - Changing Engine Oil and Oil Filter49
- Fuel51
  - Precautions51
  - General Information52
  - Diesel Fuel in Cold Weather52
  - Fuel Filter53
- Closed Cooling System58
  - Coolant Requirement58
  - Checking Level59
  - Draining60
  - Filling62
- Sacrificial Anodes63
  - Removal63
  - Inspection63
  - Disassembly64
  - Reassembly64
  - Installation64
- Flushing Seawater System65
  - Sterndrive (MCM) Models65
  - Inboard (MIE) Models66
- Inspect Water Pickups68
  - Sterndrive Gear Housing68
  - Inboard Though the Hull Pickup68
- Lubrication69
  - Throttle Cable69
  - Shift Cable69
  - Engine Coupler / U-Joint Shaft Splines 1B-4070
  - U-Joints71
  - Drive Shaft Extension Models72
  - Sterndrive Unit and Transom Assembly72
- Continuity Circuit73
- Continuity Circuit (Continued)74
- Electrical System75
- Engine Mounts75
- Mercathode75
- Power Steering76
  - Checking Fluid Level76
  - Filling and Bleeding78
- Transmission79
  - Checking Fluid Level79
- Power Trim80
  - Checking Fluid Level80
  - Filling81
- Gear Lube Monitor82
  - Checking Fluid Level82
  - Filling82
- Seawater Strainer83
- Air Filter84
  - Removal84
  - Inspection84
  - Cleaning85
  - Installation85
- Drive Belts86
  - General Information86
  - Inspection87
  - Engine Water Circulating Pump Belt87
  - Alternator Belt88
  - Power Steering Pump Belt90
  - Vacuum Pump Belt92
- Battery94
- Charging System94
- Corrosion and Corrosion Protection94
- Saltwater Operation94
- Freezing Temperature and Cold Weather Operation95
- Cold Weather or Extended Storage96
  - Power Package Layup96
  - Draining97
- Recommissioning103
Important Information 1107
- Precautions109
- Poor Boat Performance And/Or Poor Maneuverability111
- Improper Full Throttle Engine RPM112
  - RPM too High112
  - RPM too Low112
- Engine Cranks over but will Not Start or Starts Hard113
  - Electrical113
  - Fuel System113
  - Miscellaneous115
- Engine will Not Crank over or Starter Inoperative115
- Glow Plugs Inoperative116
- Charging System Inoperative117
- Noisy Alternator117
- Engine Operates Poorly at Idle118
- Engine Operates Poorly at High Rpm119
- Poor Fuel Economy120
- Engine Smoking121
  - Black Smoke121
  - Blue Smoke122
  - White Smoke122
- Exhaust Gas Temperature123
  - High123
  - Low123
- Turbocharger124
- Engine Noise125
  - Valve Cover Area126
  - Cylinder Area126
  - Camshaft Area127
  - Crankshaft Area128
  - Miscellaneous129
- Oil Pressure129
  - Low Oil Pressure131
  - High Oil Pressure131
  - Excessive Oil Consumption132
- Water / Coolant in Engine133
  - Important Information133
  - Water / Coolant in Crankcase Oil133
  - Water / Coolant on Top Pistons134
- Engine Overheats135
  - Cooling System135
  - Mechanical136
- Power Steering137
  - Poor, Erratic or no Assist137
  - Noisy Pump138
  - Fluid Leaks138
- Insufficient Water Flow from Belt Driven Seawater Pump139
- ZF / Hurth Hydraulic Transmission140
Removal and Installation 2147
- Special Tools149
- Torque Specifications149
- Lubricants / Sealants / Adhesives150
- Removal150
- Installation153
  - Engine Installation / Alignment153
  - Engine Connections161
- Throttle Cable Installation and Adjustment167
- Shift Cable Installation and Adjustment169
- Troubleshooting Shift Problems174
- Battery Cables176
Removal and Installation 2179
- Torque Specifications181
- Removal182
  - Engine Removal182
- Installation185
  - Engine Installation and Initial Alignment185
- Engine Final Alignment189
- Engine Connections196
- Battery Cables199
- Shift Cable Installation and Adjustment199
- Throttle Cable Installation and Adjustment199
Engine201
- Identification203
- Torque Specifications204
- Tools206
  - Special Tools206
  - Special Tools (Continued)207
  - Snap-On Tools208
- Lubricants/Sealants/Adhesives209
- Engine Specifications210
  - Piston Rings210
  - Cylinder Liner Diameter210
  - Cylinder Liner Protrusion211
  - Head Gaskets211
  - Cylinder Head211
  - Oil Pump212
  - Camshaft212
  - Valve Lifter212
  - Rocker Arm213
  - Valve Adjustment213
  - Valve213
  - Valve Seat213
  - Valve Guide214
  - Valve Spring214
  - Crankshaft215
  - Crankshaft (Continued)216
  - Connecting Rods217
  - Connecting Rod Crank Pin Bore217
  - Connecting Rod Bushings217
  - Pistons217
  - Flywheel217
- Precautions218
- General Information219
  - Engine Rotation219
  - Engine Firing Order219
  - Late Model Cylinder Head Gasket220
  - Early Model Cylinder Head Gasket225
  - Lubrication System - All Models228
  - Examples of Bearing Failures229
  - Compression Testing Procedure230
- Engine Cover231
  - Removal231
  - Cleaning231
  - Inspection231
  - Installation231
- Valve Covers232
  - Removal232
  - Cleaning233
  - Inspection233
  - Installation234
- Water Manifold237
  - Exploded Views237
  - Removal238
  - Cleaning238
  - Inspection238
  - Installation239
- Cylinder Heads240
  - Exploded Views240
  - Removal242
  - Disassembly244
  - Cleaning244
  - Inspection245
  - Repair250
  - Expansion Plugs250
  - Assembly252
  - Installation - Using Early Model Gaskets255
  - Installation - Using Late Model Gaskets262
- Rocker Arm271
  - Removal271
  - Cleaning271
  - Inspection271
  - Assembly272
  - Installation273
- Timing Gear Cover277
  - Exploded View277
  - Removal278
  - Cleaning278
  - Inspection278
  - Installation279
- Oil Pump281
  - Removal281
  - Cleaning281
  - Inspection282
  - Reassembly283
  - Installation283
- Oil Pressure Relief Valve284
  - Removal284
  - Disassembly285
  - Cleaning285
  - Inspection286
  - Assembly286
  - Installation287
- Oil Pan and Oil Pick-Up Tube Assembly288
  - Removal288
  - Cleaning289
  - Inspection289
  - Installation289
- Adapter / Oil Thermostat291
  - Removal291
  - Disassembly292
  - Cleaning and Inspection292
  - Testing292
  - Installation293
- Camshaft295
  - Exploded View295
  - Testing - Measuring Lobe Lift296
  - Removal296
  - Inspection298
  - Installation299
- Camshaft Bearings300
  - Inspection300
  - Removal300
  - Installation301
- Valve Lifters302
  - Removal302
  - Cleaning303
  - Inspection303
  - Installation304
- Valve Push Rods305
  - Removal305
  - Cleaning305
  - Inspection305
  - Installation305
- Connecting Rod / Piston Assembly306
  - Measuring Rod Bearing Clearance306
  - Removal307
  - Disassembly308
  - Cleaning309
  - Inspection309
  - Assembly313
  - Installation314
- Rear Oil Seal316
  - Removal316
  - Installation317
- Crankshaft and Main Bearings318
  - Removal318
  - Cleaning323
  - Inspection324
  - Installation327
- Cylinder Liners336
  - Removal336
  - Identification337
  - Cleaning and Inspection338
  - Installation339
- Flywheel Housing, Coupler / Drive Plate and Flywheel344
  - Exploded View344
  - Flywheel Housing348
  - Sterndrive (MCM) Coupler / Inboard (MIE) Drive Plate350
  - Flywheel351
- Engine Mounts352
  - Front Mounts352
  - MIE (Inboard) Transmission Mounts353
- After Break-In Period354
- Engine 20-Hour Break-In Period354
Electrical System357
- Identification359
- Lubricants / Sealants / Adhesives359
- Specifications359
- Torque Specifications359
- Replacement Parts360
- Starting System Components360
- Inspection362
- Periodic Inspection362
  - Testing Voltage362
- Removal363
  - Starter Motor363
- Installation365
  - Solenoid Switch365
  - Starter Motor366
Electrical Systems369
- Identification371
- Replacement Parts Warning371
- Specifications372
- Lubricants/Sealers/Adhesives373
- Special Tools373
- Wire Color Code Abbreviations373
- Precautions374
- Charging System Components376
- Inspection377
- Circuitry Test378
- Troubleshooting Tests (Alternator on Engine)378
- Removal385
  - Alternator385
  - Alternator Bracket385
- Installation386
  - Alternator Bracket386
  - Alternator386
- Battery Isolators387
  - Dual Battery Charging Systems387
  - Battery Isolator Diagram388
Electrical Systems391
- Identification393
- Specifications393
- Description394
- Lubricants / Sealants / Adhesives394
- Precautions394
- Special Tools394
- Torque Specifications394
- Glow Plug Testing (Prior to Removal)395
- Removal396
- Cleaning397
- Inspection397
- Installation398
- Glow Plug Actuator Relay and Auxiliary Relay399
- Glow Plug Circuit Diagram401
Electrical Systems403
- Identification405
  - Gauges405
  - Panels405
- Lubricants / Sealants / Adhesives406
- Special Tools406
- Tools406
- Wire Color Abbreviations406
- Precautions407
- General Information408
- Special Information408
  - Tachometer408
  - QSI Series Gauge Lighting Options409
- Gauges410
- Senders413
  - Oil Pressure413
  - Water Temperature - Primary Station415
- Primary Station Switches417
  - Ignition Key Switch417
  - Audio Warning Test and Panel Light Switch419
- Audio Warning System421
- Second Station Extension Harness428
- Remote Control / Neutral Start Safety Circuit431
  - Primary Station431
  - Secondary Station432
Electrical Systems435
- General Information437
- Lubricants / Sealants / Adhesives437
- Tools437
- Wire Color Abbreviations437
- Sterndrive (MCM) Models438
- Mercathode System Wiring Diagram449
- Engine Wiring - Starting and Charging System - Page 1 of 4450
- Inboard (MIE) Models450
- ECM and Fuel System Wiring - Page 1 of 2454
- Quicksilver Primary Instrumentation Wiring - Page 1 of 4456
- Connector459
Fuel System467
- Introduction469
- Precautions470
  - Testing Procedure471
- General Information472
- Electronic Control Module (ECM) and Sensors475
- Fuel Management492
  - Control492
  - Modes of Operation493
- Diagnosis and Testing496
  - ECM Reactions During Operation496
  - ECM Self-Diagnostics496
Fuel Systems501
- Identification503
- Lubricants / Sealants / Adhesives503
- Specifications503
- Tools503
- Torque503
- Precautions504
- Exploded View506
- Fuel Delivery Pump, Fuel Filter and Related Components506
  - Testing508
- Removal510
- Installation511
- Water Separating Fuel Filter513
  - Removal513
  - Installation513
- Water Drain Valve Operation515
- Purging Air from the Fuel System516
Fuel System519
- Identification521
- Specifications521
- Torque521
- Precautions523
- Description524
- Fuel Injector (Cutaway View)525
- Exploded View526
- Injector Test (Engine Misfiring)527
- Removal528
- Inspection530
- Testing530
- Installation531
- Purging Air from Fuel Injectors (Bleeding)534
Fuel System537
- Identification538
  - Pump Code and Identification Number Location538
- Specifications538
  - Injection Pump538
  - Timing539
- Special Tools539
- Torque Specifications539
- Precautions541
- Description542
- Diesel Fuel in Cold Weather543
- Fuel Ratings543
- Repair and Service544
- Exploded View546
- Fuel Injection Pump Removal547
- Fuel Injection Pump Installation552
  - Installation with Engine Assembled552
  - Installation During Engine Reassembly555
- Fuel Injection Pump Timing559
  - Checking559
  - Setting559
- Starting Engine - after Fuel Injection Pump Installation and Timing564
Fuel Systems569
- General Information570
- Diagnostic Information575
- ECM Input and Sensor Diagram583
- ECM Connector Pin Layout584
- Connector Chart585
- Map (Manifold Air Pressure) Sensor588
  - ECT (Engine Coolant Temperature) Sensor590
- Iat (Intake Air Temperature) Sensor598
Cooling System683
- Lubricants / Sealants / Adhesives685
- Torque Specifications685
- Seawater (Raw Water) System Specifications686
  - Seawater Pump Delivery Rates686
  - Seawater Pickup Connections686
- Seawater Pickup Connection687
- Seawater Strainer688
- Exploded View - Seawater Pumps689
  - D2.8L D-Tronic689
  - D4.2L D-Tronic690
- Seawater Flow Diagram692
  - Seawater Pump694
- Exploded View709
- General Information713
- Oil / Power Steering / Transmission Fluid Coolers713
- Exploded View714
- Location of Coolers715
- Cleaning Without Removal716
- Inspection before Removal716
- Engine Oil Cooler717
- Power Steering722
- Transmission Fluid Cooler724
Cooling Systems729
- Specifications732
  - Pressure Cap732
- Diagrams and Exploded Views734
- Checking Coolant Level739
- Testing Closed Cooling System740
- Coolant Change Interval745
- Coolant Requirement745
- Draining Closed Cooling System745
- Cleaning Closed Cooling System747
  - Using a Cleaner747
- Flushing the Closed Cooling System748
  - Filling the Closed Cooling System749
Intake and Exhaust System785
- Exploded Views788
- Locating and Installing the Sterndrive (MCM) Exhaust System792
Drives839
- Specifications842
- Lubricants / Sealants / Adhesives843
- Important Information844
  - Transmission / Propeller Rotation845
- Transmission Removal850
- Transmission Installation851
- Shift Control and Cables853
  - Transmission Shift Lever and Shift Cable Bracket853
  - Shift Cable Installation and Adjustment854
- Pressure and Temperature Tests859
- Transmission Repair859

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