Mercury mercruiser marine engine in line diesel d4.2 l d-tronic service repair manual sn：0k000001 and above

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

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.

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.

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.

Page iv 90-860074--1 FEBRUARY 2002
Models Covered in This Manual
Sterndrive (MCM) Serial Number
D2.8L D-Tronic 0K000001 and Above
Inboard (MIE) Serial Number

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

Page vi 90-860074--1 FEBRUARY 2002
IMPORTANT INFORMATION
Section 1A - General Information
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. . . . . . . . . . . . . . . . . . . . . . .
Section 1B - Maintenance
Torque Specifications 1B-3. . . . . . . . . . . . . . . . . .
Special Tools 1B-3. . . . . . . . . . . . . . . . . . . . . . . . .
Tools 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 1B-3. . . . . . .
Engine Specifications 1B-4. . . . . . . . . . . . . . . . . .
Sterndrive (MCM) Engines 1B-4. . . . . . . . . . .
Inboard (MIE) Engines 1B-5. . . . . . . . . . . . . .
Capacities 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engines 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Drives 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmissions 1B-6. . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedules 1B-7. . . . . . . . . . . . . . . .
Maintenance Intervals 1B-7. . . . . . . . . . . . . . .
Inboard (MIE) Engines 1B-11. . . . . . . . . . . . .
Engine External Views 1B-13. . . . . . . . . . . . . . . .
Starboard Side View 1B-13. . . . . . . . . . . . . . .
Front View 1B-14. . . . . . . . . . . . . . . . . . . . . . . .
Port Side View 1B-15. . . . . . . . . . . . . . . . . . . .
Rear View 1B-16. . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil 1B-17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level 1B-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Oil Filter 1B-19. . .
Fuel 1B-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions 1B-21. . . . . . . . . . . . . . . . . . . . . . .
General Information 1B-22. . . . . . . . . . . . . . . .
Diesel Fuel In Cold Weather 1B-22. . . . . . . .
Fuel Filter 1B-23. . . . . . . . . . . . . . . . . . . . . . . .
Closed Cooling System 1B-28. . . . . . . . . . . . . . .
Coolant Requirement 1B-28. . . . . . . . . . . . . .
Checking Level 1B-29. . . . . . . . . . . . . . . . . . . .
Draining 1B-30. . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 1B-32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sacrificial Anodes 1B-33. . . . . . . . . . . . . . . . . . . .
Removal 1B-33. . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . .
Sterndrive Unit and Transom
Assembly 1B-42. . . . . . . . . . . . . . . . . . . . . . . .
Continuity Circuit 1B-43. . . . . . . . . . . . . . . . . . . . .
Continuity Circuit (continued) 1B-44. . . . . . . . . .
MerCathode 1B-45. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounts 1B-45. . . . . . . . . . . . . . . . . . . . . . .
Electrical System 1B-45. . . . . . . . . . . . . . . . . . . . .
Power Steering 1B-46. . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 1B-46. . . . . . . . . . . . . . .
Filling and Bleeding 1B-48. . . . . . . . . . . . . . . .
Transmission 1B-49. . . . . . . . . . . . . . . . . . . . . . . .
Power Trim 1B-50. . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 1B-51. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Lube Monitor 1B-52. . . . . . . . . . . . . . . . . . .
Filling 1B-52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Strainer 1B-53. . . . . . . . . . . . . . . . . . . .
Air Filter 1B-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1B-54. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 1B-54. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 1B-55. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1B-55. . . . . . . . . . . . . . . . . . . . . . . .
Drive Belts 1B-56. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 1B-57. . . . . . . . . . . . . . . . . . . . . . . .
Engine Water Circulating Pump Belt 1B-57. .
Alternator Belt 1B-58. . . . . . . . . . . . . . . . . . . . .
Power Steering Pump Belt 1B-60. . . . . . . . . .
Vacuum Pump Belt 1B-62. . . . . . . . . . . . . . . .
Battery 1B-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1B-64. . . . . . . . . . . . . . . . . . . . .
Corrosion and Corrosion Protection 1B-64. . . . .
Saltwater Operation 1B-64. . . . . . . . . . . . . . . . . .
Freezing Temperature and Cold Weather
Operation 1B-65. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage 1B-66. . . . .
Power Package Layup 1B-66. . . . . . . . . . . . .
Draining 1B-67. . . . . . . . . . . . . . . . . . . . . . . . . .
Recommissioning 1B-73. . . . . . . . . . . . . . . . . . . .

90-860074--1 FEBRUARY 2002 Page vii
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
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 viii 90-860074--1 FEBRUARY 2002
ENGINE
Section 3A - Engine Mechanical
Identification 3A-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Tools 3A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 3A-6. . . . . . . . . . . . . . . . . . . . . . .
Special Tools (continued) 3A-7. . . . . . . . . . . .
Snap-On Tools 3A-8. . . . . . . . . . . . . . . . . . . . .
Kent-Moore Tools 3A-8. . . . . . . . . . . . . . . . . . .
Lubricants/Sealants/Adhesives 3A-9. . . . . . . . . .
Engine Specifications 3A-10. . . . . . . . . . . . . . . . .
Piston Rings 3A-10. . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner Diameter 3A-10. . . . . . . . . . . .
Cylinder Liner Protrusion 3A-11. . . . . . . . . . .
Head Gaskets 3A-11. . . . . . . . . . . . . . . . . . . . .
Cylinder Head 3A-11. . . . . . . . . . . . . . . . . . . . .
Oil Pump 3A-12. . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 3A-12. . . . . . . . . . . . . . . . . . . . . . . . .
Valve Lifter 3A-12. . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm 3A-13. . . . . . . . . . . . . . . . . . . . . . .
Valve Adjustment 3A-13. . . . . . . . . . . . . . . . . .
Valve 3A-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat 3A-13. . . . . . . . . . . . . . . . . . . . . . . .
Valve Guide 3A-14. . . . . . . . . . . . . . . . . . . . . . .
Valve Spring 3A-14. . . . . . . . . . . . . . . . . . . . . .
Crankshaft 3A-15. . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft (continued) 3A-16. . . . . . . . . . . . .
Connecting Rods 3A-17. . . . . . . . . . . . . . . . . .
Connecting Rod Crank Pin Bore 3A-17. . . . .
Connecting Rod Bushings 3A-17. . . . . . . . . .
Pistons 3A-17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel 3A-17. . . . . . . . . . . . . . . . . . . . . . . . .
Precautions 3A-18. . . . . . . . . . . . . . . . . . . . . . . . .
General Information 3A-19. . . . . . . . . . . . . . . . . .
Engine Rotation 3A-19. . . . . . . . . . . . . . . . . . .
Engine Firing Order 3A-19. . . . . . . . . . . . . . . .
Late Model Cylinder Head Gasket -
Torque Sequence and Specifications 3A-20
Early Model Cylinder Head Gasket -
Torque Sequence 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. . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-39. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Heads 3A-40. . . . . . . . . . . . . . . . . . . . . .
Exploded Views 3A-40. . . . . . . . . . . . . . . . . . .
Removal 3A-42. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3A-44. . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-44. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-45. . . . . . . . . . . . . . . . . . . . . . . .
Repair 3A-50. . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Plugs 3A-50. . . . . . . . . . . . . . . . . .
Assembly 3A-52. . . . . . . . . . . . . . . . . . . . . . . . .
Installation -
Using Early Model Gaskets 3A-55. . . . . . . . .
Installation -
Using Late Model Gaskets 3A-62. . . . . . . . .
Rocker Arm 3A-71. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3A-71. . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-71. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-71. . . . . . . . . . . . . . . . . . . . . . . .
Assembly 3A-72. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-73. . . . . . . . . . . . . . . . . . . . . . . .
Timing Gear Cover 3A-77. . . . . . . . . . . . . . . . . . .
Exploded View 3A-77. . . . . . . . . . . . . . . . . . . .
Removal 3A-78. . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-78. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-78. . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-79. . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 3A-81. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3A-81. . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-81. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-82. . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 3A-83. . . . . . . . . . . . . . . . . . . . . .
Installation 3A-83. . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Relief Valve 3A-84. . . . . . . . . . . . . .
Removal 3A-84. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3A-85. . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-85. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-86. . . . . . . . . . . . . . . . . . . . . . . .
Assembly 3A-86. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-87. . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Oil Pick-Up Tube Assembly 3A-88.
Removal 3A-88. . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-89. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-89. . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-89. . . . . . . . . . . . . . . . . . . . . . . .

90-860074--1 FEBRUARY 2002 Page ix
ENGINE (continued)
Section 3A - Engine Mechanical (continued)
Adapter / Oil Thermostat 3A-91. . . . . . . . . . . . . .
Removal 3A-91. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3A-92. . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 3A-92. . . . . . . . . . . .
Testing 3A-92. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-93. . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 3A-95. . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded View 3A-95. . . . . . . . . . . . . . . . . . . .
Testing - Measuring Lobe Lift 3A-96. . . . . . . .
Removal 3A-96. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-98. . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-99. . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Bearings 3A-100. . . . . . . . . . . . . . . . . .
Inspection 3A-100. . . . . . . . . . . . . . . . . . . . . . .
Removal 3A-100. . . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-101. . . . . . . . . . . . . . . . . . . . . . .
Valve Lifters 3A-102. . . . . . . . . . . . . . . . . . . . . . . .
Removal 3A-102. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-103. . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-103. . . . . . . . . . . . . . . . . . . . . . .
Installation 3A-104. . . . . . . . . . . . . . . . . . . . . . .
Valve Push Rods 3A-105. . . . . . . . . . . . . . . . . . . .
Removal 3A-105. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 3A-105. . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-105. . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . .
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 / Inboard (MIE)
Drive Plate 3A-150. . . . . . . . . . . . . . . . . . . . . . .
Flywheel 3A-151. . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounts 3A-152. . . . . . . . . . . . . . . . . . . . . .
Front Mounts 3A-152. . . . . . . . . . . . . . . . . . . . .
MIE (Inboard) Transmission Mounts 3A-153.
Engine 20-Hour Break-In Period 3A-154. . . . . .
After Break-in Period 3A-154. . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS
Section 4A - Starting System
Specifications 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. . . . . . . . . . . . . . . . . . . . . .

Page x 90-860074--1 FEBRUARY 2002
ELECTRICAL SYSTEMS
Section 4B - Charging System
Identification 4B-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts Warning 4B-3. . . . . . . . . . . .
Specifications 4B-4. . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 4B-5. . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants/Sealers/Adhesives 4B-5. . . . . . . . . . .
Wire Color Code Abbreviations 4B-5. . . . . . . . . .
Precautions 4B-6. . . . . . . . . . . . . . . . . . . . . . . . . .
General 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 4B-17. . . . . . . . . . . . . . . . .
Installation 4B-18. . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Bracket 4B-18. . . . . . . . . . . . . . . . .
Alternator 4B-18. . . . . . . . . . . . . . . . . . . . . . . . .
Battery Isolators 4B-19. . . . . . . . . . . . . . . . . . . . . .
Dual Battery Charging Systems 4B-19. . . . .
Battery Isolator Diagram 4B-20. . . . . . . . . . . .
ELECTRICAL SYSTEMS
Section 4C - Glow Plug System
Identification 4C-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 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. . . . . . . . . . . . .
ELECTRICAL SYSTEMS
Section 4D - Instrumentation
Identification 4D-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Gauges 4D-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Panels 4D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 4D-4. . . . . . . . . . . . . . . . . . . . . . . . .
Tools 4D-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 4D-4. . . . . . .
Wire Color Abbreviations 4D-4. . . . . . . . . . . . . . .
Precautions 4D-5. . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 4D-6. . . . . . . . . . . . . . . . . . .
Special Information 4D-6. . . . . . . . . . . . . . . . . . . .
Tachometer 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 Fluid Temperature
Switch 4D-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Second Station Extension Harness 4D-26. . . . .
Remote Control / Neutral Start Safety
Circuit 4D-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Station 4D-29. . . . . . . . . . . . . . . . . . . .
Secondary Station 4D-30. . . . . . . . . . . . . . . . .

90-860074--1 FEBRUARY 2002 Page xi
ELECTRICAL SYSTEMS
Section 4E - Wiring Diagrams
Wire Color Abbreviations 4E-3. . . . . . . . . . . . . . .
Tools 4E-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 4E-3. . . . . . .
General Information 4E-3. . . . . . . . . . . . . . . . . . .
Sterndrive (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 Connectors 4E-26. . . . . .
Models With 21-Pin Deutsch t
Connector 4E-28. . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM
Section 5A - Description
Introduction 5A-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions 5A-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Procedure 5A-5. . . . . . . . . . . . . . . . . .
General Information 5A-6. . . . . . . . . . . . . . . . . . .
Basic Knowledge and Tools Required 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-18. .
Fuel Management 5A-26. . . . . . . . . . . . . . . . . . . .
Control 5A-26. . . . . . . . . . . . . . . . . . . . . . . . . . .
Modes Of Operation 5A-27. . . . . . . . . . . . . . .
Diagnosis and Testing 5A-30. . . . . . . . . . . . . . . .
ECM Reactions During Operation 5A-30. . . .
ECM Self-Diagnostics 5A-30. . . . . . . . . . . . . .
FUEL SYSTEM
Section 5B - Fuel Delivery Pump and Fuel Filter
Identification 5B-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Torque 5B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools 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 xii 90-860074--1 FEBRUARY 2002
FUEL SYSTEM
Section 5C - Fuel Injectors
Identification 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. . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM
Section 5D - Injection Pump
Identification 5D-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Code and Identification
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. . . . . . . . . . . . . . . . . . . . . . .
Fuel Injection Pump Removal 5D-11. . . . . . . . . .
Fuel Injection Pump Installation 5D-16. . . . . . . .
Installation With Engine Assembled 5D-16. .
Installation During Engine
Reassembly 5D-19. . . . . . . . . . . . . . . . . . . . . .
Fuel Injection Pump Timing 5D-23. . . . . . . . . . . .
Checking 5D-23. . . . . . . . . . . . . . . . . . . . . . . . .
Setting 5D-23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Engine - After Fuel Injection
Pump Installation and Timing 5D-28. . . . . . . . . .

90-860074--1 FEBRUARY 2002 Page xiii
FUEL SYSTEM
Section 5E - EDI Diagnosis
General Information 5E-2. . . . . . . . . . . . . . . . . . .
Introduction 5E-2. . . . . . . . . . . . . . . . . . . . . . . .
Basic Knowledge and Tools Required 5E-2.
Visual/Physical Inspection 5E-3. . . . . . . . . . .
Electrostatic Discharge Damage 5E-3. . . . . .
Special Tools 5E-4. . . . . . . . . . . . . . . . . . . . . . .
Special EDI Tools 5E-4. . . . . . . . . . . . . . . . . . .
Kent-Moore Tools 5E-4. . . . . . . . . . . . . . . . . . .
Service Precautions 5E-5. . . . . . . . . . . . . . . . .
Diagnostic Information 5E-7. . . . . . . . . . . . . . . . .
Abbreviations 5E-7. . . . . . . . . . . . . . . . . . . . . .
ECM Self-Diagnosis 5E-8. . . . . . . . . . . . . . . .
Malfunction Indicator Lamp 5E-9. . . . . . . . . .
Intermittent Problems and
Malfunction Indicator Lamp 5E-10. . . . . . . . .
Reading Codes 5E-10. . . . . . . . . . . . . . . . . . . .
Clearing Codes 5E-13. . . . . . . . . . . . . . . . . . . .
Diagnosis of Driveability Concerns 5E-14. . .
ECM Input and Sensor Diagram 5E-15. . . . . . . .
ECM Connector Pin Layout 5E-16. . . . . . . . . . . .
Connector Chart 5E-17. . . . . . . . . . . . . . . . . . . . .
MAP (Manifold Air Pressure) Sensor 5E-20.
ECT (Engine Coolant Temperature)
Sensor 5E-22. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Temperature Sensor 5E-24. . . . . . . . . . .
RPM (Engine Speed) Sensor 5E-26. . . . . . . .
BARO (Atmospheric Pressure)
Sensor 5E-28. . . . . . . . . . . . . . . . . . . . . . . . . .
IAT (Intake Air Temperature) Sensor 5E-30.
Instrumented Injector
(Needle Movement Sensor) 5E-32. . . . . . . .
Fuel Quantity Actuator
(Pump Actuator) 5E-34. . . . . . . . . . . . . . . . . .
Fuel Quantity Sensor
(Control Sleeve Position Sensor) 5E-36. . . .
Timing Fault
(Timing Advance Regulation) 5E-38. . . . . . .
TP (Throttle Position)
Sensor / Low Idle 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 Indicator Lamp
(Diagnostic Lamp)] 5E-58. . . . . . . . . . . . . . . .
MIL [Malfunction Indicator Lamp
(Diagnostic Lamp)] 5E-60. . . . . . . . . . . . . . . .
Fuel Shut Off Valve [EAB
(Electrical Shut Off)] 5E-62. . . . . . . . . . . . . . .
EEPROM Fault (EEPROM and
Configuration) 5E-64. . . . . . . . . . . . . . . . . . . .
RPM Signal From Injector
(Secondary Engine Speed Sensor) 5E-66. .
Troubleshooting For EDI Systems 5E-68. . . . . .
Trouble Codes 5E-68. . . . . . . . . . . . . . . . . . . .
Display Terminology 5E-69. . . . . . . . . . . . . . .
Troubleshooting Charts 5E-74. . . . . . . . . . . . .
Repair Procedures 5E-93. . . . . . . . . . . . . . . . . . .
Service Precautions 5E-93. . . . . . . . . . . . . . . .
Replacement Parts Warning 5E-94. . . . . . . .
Torque Specifications 5E-95. . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 5E-95. . . .
System Components 5E-96. . . . . . . . . . . . . . .
Fuel Injection Pump Repair 5E-98. . . . . . . . .
Wiring Harness Service 5E-99. . . . . . . . . . . .
Relay, Module and Sensor Servicing
(On-Board Service) 5E-102. . . . . . . . . . . . . . . . .
Precautions 5E-102. . . . . . . . . . . . . . . . . . . . . .
Main Relay 5E-102. . . . . . . . . . . . . . . . . . . . . .
ECM (Electronic Control Module) 5E-104. . .
ECT (Engine Coolant Temperature)
Sensor 5E-106. . . . . . . . . . . . . . . . . . . . . . . . .
MAP (Manifold Absolute Pressure) /
IAT (Intake Air Temperature) Sensor 5E-108
Throttle Position (TP) Sensor 5E-110. . . . . . .
Instrumented Injector 5E-112. . . . . . . . . . . . . .
Engine RPM Speed Sensor 5E-112. . . . . . . .
Idle Speed Setting Circuit 5E-113. . . . . . . . . .

Page xiv 90-860074--1 FEBRUARY 2002
COOLING SYSTEM
Section 6A - Seawater Cooling System
Tools 6A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater (Raw Water) System
Specifications 6A-4. . . . . . . . . . . . . . . . . . . . . . . .
Seawater Pump Delivery Rates 6A-4. . . . . . .
Seawater Pickup Connections 6A-4. . . . . . . .
Precautions 6A-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Pickup Connection 6A-5. . . . . . . . . . .
Seacock 6A-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. . . . . . . . . . . . . . . .
Exploded View 6A-32. . . . . . . . . . . . . . . . . . . .
Location of Coolers 6A-33. . . . . . . . . . . . . . . .
Inspection Before Removal 6A-34. . . . . . . . .
Cleaning Without Removal 6A-34. . . . . . . . . .
Engine Oil Cooler 6A-35. . . . . . . . . . . . . . . . . .
Power Steering 6A-40. . . . . . . . . . . . . . . . . . . .
Transmission Fluid Cooler 6A-42. . . . . . . . . .
Installation 6A-43. . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM
Section 6B - Closed Cooling System
Capacity 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostats 6B-4. . . . . . . . . . . . . . . . . . . . . . .
Pressure Cap 6B-4. . . . . . . . . . . . . . . . . . . . . .
Coolant 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
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 6B-12. . . . . . . .
Testing Coolant 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-21. . . . .
Thermostats 6B-22. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6B-22. . . . . . . . . . . . . . . . . . . . . . . . .
Testing 6B-23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B-25. . . . . . . . . . . . . . . . . . . . . . . .
Heat Exchanger 6B-26. . . . . . . . . . . . . . . . . . . . . .
Testing 6B-26. . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair 6B-26. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6B-27. . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 6B-28. . . . . . . . . . . .
Installation 6B-29. . . . . . . . . . . . . . . . . . . . . . . .
Water Circulating Pump 6B-31. . . . . . . . . . . . . . .
Removal 6B-31. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B-32. . . . . . . . . . . . . . . . . . . . . . . .
Coolant Manifold 6B-33. . . . . . . . . . . . . . . . . . . . .
Corrosion Protection 6B-33. . . . . . . . . . . . . . . . . .
Auxiliary Hot Water Heater Connections 6B-33.

90-860074--1 FEBRUARY 2002 Page xv
INTAKE AND EXHAUST SYSTEM
Section 7A - Intercooler
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. . . . . . . . . . . . . . . . . . . . . . .
Section 7B - Manifolds, Elbows And Risers
Torque 7B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 7B-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded Views 7B-4. . . . . . . . . . . . . . . . . . . . . . .
Typical 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. . . . . . . . . . . . . .
Removal 7B-13. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7B-15. . . . . . . . . . . . . . . . . . . . . . . .
Section 7C - Turbocharger
Identification 7C-3. . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger Specifications 7C-3. . . . . . . . . .
Torque Specifications 7C-4. . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 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. . . . . . . . . . . . . .
Exhaust Pipe 7C-28. . . . . . . . . . . . . . . . . . . . .
Valve 7C-31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wastegate 7C-33. . . . . . . . . . . . . . . . . . . . . . .

Page xvi 90-860074--1 FEBRUARY 2002
DRIVES
Section 8A - ZF/Hurth Transmissions
Specifications 8A-4. . . . . . . . . . . . . . . . . . . . . . . . .
Operating Specifications 8A-4. . . . . . . . . . . . .
Ratios and Part Numbers 8A-4. . . . . . . . . . . .
Fluid Specifications 8A-4. . . . . . . . . . . . . . . . .
Torque 8A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools 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 Installation and
Adjustment 8A-16. . . . . . . . . . . . . . . . . . . . . . .
Pressure And Temperature Tests 8A-21. . . . . . .
Transmission Repair 8A-21. . . . . . . . . . . . . . . . . .
DRIVES
Section 8B - Propeller Shaft Models
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING
Section 9A - Pump And Related Components
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. . . . . . . . . . . . . . . . . . . .

90-860074--1 FEBRUARY 2002 Page xvii
THIS PAGE IS INTENTIONALLY BLANK

Page xviii 90-860074--1 FEBRUARY 2002

1
A
SERVICE MANUAL NUMBER 22 GENERAL INFORMATION
Page 1A-190-860074-–1 FEBRUARY 2002
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. . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION SERVICE MANUAL NUMBER 22
Page 1A-2 90-860064--1 FEBRUARY 2002

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

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

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

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.
rpm and 3400 rpm.
rpm and WOT.

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

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
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
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
Cyanacrylate
Adhesive
3M Permabond
#3M08155

Page 1A-990-860074-–1 FEBRUARY 2002

Page 1A-10 90-860064--1 FEBRUARY 2002

1
B
MAINTENANCESERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002 Page 1B-1
Section 1B - Maintenance
Table of Contents
Special Tools 1B-3. . . . . . . . . . . . . . . . . . . . . . . . .
Tools 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1B-4. . . . . . . . . . . . . . . . . .
Inboard (MIE) Engines 1B-5. . . . . . . . . . . . . .
Capacities 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engines 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Drives 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmissions 1B-6. . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedules 1B-7. . . . . . . . . . . . . . . .
Maintenance Intervals 1B-7. . . . . . . . . . . . . . .
Inboard (MIE) Engines 1B-11. . . . . . . . . . . . .
Engine External Views 1B-13. . . . . . . . . . . . . . . .
Starboard Side View 1B-13. . . . . . . . . . . . . . .
Front View 1B-14. . . . . . . . . . . . . . . . . . . . . . . .
Port Side View 1B-15. . . . . . . . . . . . . . . . . . . .
Rear View 1B-16. . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil 1B-17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level 1B-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Oil Filter 1B-19. . .
Fuel 1B-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions 1B-21. . . . . . . . . . . . . . . . . . . . . . .
Diesel Fuel In Cold Weather 1B-22. . . . . . . .
Fuel Filter 1B-23. . . . . . . . . . . . . . . . . . . . . . . .
Closed Cooling System 1B-28. . . . . . . . . . . . . . .
Coolant Requirement 1B-28. . . . . . . . . . . . . .
Checking Level 1B-29. . . . . . . . . . . . . . . . . . . .
Draining 1B-30. . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 1B-32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sacrificial Anodes 1B-33. . . . . . . . . . . . . . . . . . . .
Removal 1B-33. . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . .
Sterndrive Unit and Transom
Assembly 1B-42. . . . . . . . . . . . . . . . . . . . . . . .
Continuity Circuit 1B-43. . . . . . . . . . . . . . . . . . . . .
Continuity Circuit (continued) 1B-44. . . . . . . . . .
MerCathode 1B-45. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounts 1B-45. . . . . . . . . . . . . . . . . . . . . . .
Electrical System 1B-45. . . . . . . . . . . . . . . . . . . . .
Power Steering 1B-46. . . . . . . . . . . . . . . . . . . . . .
Filling and Bleeding 1B-48. . . . . . . . . . . . . . . .
Transmission 1B-49. . . . . . . . . . . . . . . . . . . . . . . .
Power Trim 1B-50. . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 1B-51. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Lube Monitor 1B-52. . . . . . . . . . . . . . . . . . .
Filling 1B-52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Strainer 1B-53. . . . . . . . . . . . . . . . . . . .
Air Filter 1B-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1B-54. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 1B-54. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 1B-55. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1B-55. . . . . . . . . . . . . . . . . . . . . . . .
Drive Belts 1B-56. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 1B-57. . . . . . . . . . . . . . . . . . . . . . . .
Engine Water Circulating Pump Belt 1B-57. .
Alternator Belt 1B-58. . . . . . . . . . . . . . . . . . . . .
Power Steering Pump Belt 1B-60. . . . . . . . . .
Vacuum Pump Belt 1B-62. . . . . . . . . . . . . . . .
Battery 1B-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1B-64. . . . . . . . . . . . . . . . . . . . .
Corrosion and Corrosion Protection 1B-64. . . . .
Saltwater Operation 1B-64. . . . . . . . . . . . . . . . . .
Freezing Temperature and Cold Weather
Operation 1B-65. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage 1B-66. . . . .
Power Package Layup 1B-66. . . . . . . . . . . . .
Draining 1B-67. . . . . . . . . . . . . . . . . . . . . . . . . .
Recommissioning 1B-73. . . . . . . . . . . . . . . . . . . .

MAINTENANCE SERVICE MANUAL NUMBER 22
Page 1B-2 90-860074--1 FEBRUARY 2002

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
Water Tap Hose Adapter To Water Inlet Fitting
Typical Hand-operated Grease Gun
Obtain Locally
Lubricants / Sealants / Adhesives
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.

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.

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.

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
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
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

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.

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

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
z Whichever Occurs First
* Lubricate engine coupler every 50 hours if operated at idle for prolonged periods of time.

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

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
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

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

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

Page 1B-14 90-860074--1 FEBRUARY 2002
Front View
1
10
11
12
13
14
2
3
4
5
6
7
8
9
15
16
78310
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

90-860074--1 FEBRUARY 2002 Page 1B-15
Port Side View
75298
1012
13
15
16
1 2 3
4 5
6
7
8
9
14
17
18
19
11
20
1 - Oil Fill Cap
2 - Engine 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 1B-16 90-860074--1 FEBRUARY 2002
Rear View
74305
1
2
3
4
5
6
7
1 - Air Filter
2 - Turbocharger
3 - Exhaust Elbow
4 - Rear Engine Mount
5 - Engine Coupler
6 - Flywheel Housing (Rear Portion)
7 - Electrical Box

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.

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.

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.

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.

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Mercury mercruiser marine engine in line diesel d4.2 l d-tronic service repair manual sn：0k000001 and above