Mercury D4.2L D-Tronic

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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22

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.

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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