Mercury D4.2L D-Tronic Service Manual

90-860074--1 FEBRUARY 2002 Page vii
IMPORTANT INFORMATION
SECTION 1C - Troubleshooting
Precautions 1C-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Poor Boat Performance and/or Poor
Maneuverability 1C-5. . . . . . . . . . . . . . . . . . . . . .
Improper Full Throttle Engine RPM 1C-6. . . . . .
RPM Too High 1C-6. . . . . . . . . . . . . . . . . . . . .
RPM Too Low 1C-6. . . . . . . . . . . . . . . . . . . . . .
Engine Cranks Over But Will Not Start Or
Starts Hard 1C-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 1C-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 1C-7. . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous 1C-9. . . . . . . . . . . . . . . . . . . . . .
Engine Will Not Crank Over or Starter
Inoperative 1C-9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plugs Inoperative 1C-10. . . . . . . . . . . . . . .
Charging System Inoperative 1C-11. . . . . . . . . .
Noisy Alternator 1C-11. . . . . . . . . . . . . . . . . . . . . .
Engine Operates Poorly at Idle 1C-12. . . . . . . . .
Engine Operates 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 Consumption 1C-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 INSTALLATION
Section 2A - Sterndrive (MCM) Models
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. . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
Section 2B - Inboard (MIE) Models
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. . . . . . . . . . . . . . . . . . . .

Mercury D4.2L D-Tronic Specifications

General

Brand	Mercury
Model	D4.2L D-Tronic
Category	Engine
Language	English