Service manual

ManualsBrandsMercury ManualsEngineD4.2L D-Tronic

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

Summary of content (878 pages)

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SERVICE MANUAL NUMBER 22 MARINE ENGINES IN-LINE DIESEL D2.8L D-Tronic . . . . . . . . Serial Number 0K000001 and Above D4.2L D-Tronic . . . . . . . . Serial Number 0K000001 and Above Printed in U.S.A.
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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.
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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.
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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.
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Models Covered in This Manual Sterndrive (MCM) Page iv Serial Number D2.8L D-Tronic 0K000001 and Above D4.2L D-Tronic 0K000001 and Above Inboard (MIE) Serial Number D2.8L D-Tronic 0K000001 and Above D4.
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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.
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IMPORTANT INFORMATION Section 1A - General Information Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual . . . . . . . . . . . . . . . Page Numbering . . . . . . . . . . . . . . . . . . . Engine Serial Number / Decal Locations . Operation / Duty Cycle . . . . . . . . . . . . . . . . . 1A-3 1A-3 1A-3 1A-4 1A-5 Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . 1A-6 Initial Break-In Procedure . . . . . . . . . . . .
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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 . . . . . . . . . . . . . . . . . . . . . . . . . .
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ENGINE Section 3A - Engine Mechanical Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Torque Specifications . . . . . . . . . . . . . . . . . . 3A-4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Special Tools (continued) . . . . . . . . . . . . 3A-7 Snap-On Tools . . . . . . . . . . . . . . . . . . . . . 3A-8 Kent-Moore Tools . . . . . . . . . . . . . . . . . . .
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ELECTRICAL SYSTEMS Section 4B - Charging System Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Replacement Parts Warning . . . . . . . . . . . . 4B-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Torque Specifications . . . . . . . . . . . . . . . . . . 4B-4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 4B-5 Lubricants/Sealers/Adhesives . . . . . . . . . . . 4B-5 Wire Color Code Abbreviations . . . . . . . . . . 4B-5 Precautions . . . . . .
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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 . . . . . . . .
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FUEL SYSTEM Section 5C - Fuel Injectors Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . .
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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 . . . . . . . . . . . . . . . . . . .
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COOLING SYSTEM Section 6A - Seawater Cooling System Torque Specifications . . . . . . . . . . . . . . . . . . 6A-3 Lubricants / Sealants / Adhesives . . . . . . . 6A-3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Seawater (Raw Water) System Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Seawater Pump Delivery Rates . . . . . . . 6A-4 Seawater Pickup Connections . . . . . . . . 6A-4 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . .
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INTAKE AND EXHAUST SYSTEM Section 7A - Intercooler Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Exploded Views . . . . . . . . . . . . . . . . . . . . . D2.8L Intercooler . . . . . . . . . . . . . . . . . D4.2L Intercooler . . . . . . . . . . . . . . . . . Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3 7A-3 7A-4 7A-4 7A-6 7A-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . .
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DRIVES Section 8A - ZF/Hurth Transmissions Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Operating Specifications . . . . . . . . . . . . . Ratios and Part Numbers . . . . . . . . . . . . Fluid Specifications . . . . . . . . . . . . . . . . . Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . .
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 IMPORTANT INFORMATION 1 Section 1A - General Information A Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual . . . . . . . . . . . . . . . Page Numbering . . . . . . . . . . . . . . . . . . . Engine Serial Number / Decal Locations . Operation / Duty Cycle . . . . . . . . . . . . . . . . . 90-860074-–1 FEBRUARY 2002 1A-3 1A-3 1A-3 1A-4 1A-5 Engine Break-In . . . . . . . . . . . . . . . . . . . . .
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 1A-2 90-860064--1 FEBRUARY 2002
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 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.
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 Engine Serial Number / Decal Locations a 71675 75301 d b 7332 75388 3 73929 a SERIAL NUMBER MAX 75298 RPM H P L B K W K G MARINE POWER EUROPE INC MADE IN ITALY BS M12O:11 3 93_ _ c 71688 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-4 90-860064--1 FEBRUARY 2
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 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).
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 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.
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 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.
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 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.
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK 90-860074-–1 FEBRUARY 2002 Page 1A-9
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GENERAL INFORMATION SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 1A-10 90-860064--1 FEBRUARY 2002
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MAINTENANCE SERVICE MANUAL NUMBER 22 IMPORTANT INFORMATION 1 Section 1B - Maintenance B Table of Contents 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 . .
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MAINTENANCE SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 1B-2 90-860074--1 FEBRUARY 2002
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MAINTENANCE SERVICE MANUAL NUMBER 22 Torque Specifications Description Nm lb-in.
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MAINTENANCE SERVICE MANUAL NUMBER 22 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 ) In-Line 4 Cylinder Diesel In-Line 6 Cylinder Diesel Engine Type 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.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Inboard (MIE) Engines Specification - Inboard (MIE) Description D2.8L D-Tronic D4.2L D-Tronic 123 ( 165 ) 186 ( 250 ) 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 Crankshaft Kilowatts (Horsepower) 1 Propeller Shaft Kilowatts (Horsepower) 1 Bore 94 mm ( 3.700 in. ) Stroke 100 mm ( 3.937 in.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Capacities NOTICE All capacities are approximate fluid measures. Engines NOTICE Unit Of Measurement: Liters (U.S. Quarts). D2.8L D-Tronic D4.2L D-Tronic 10 ( 8-1/2 ) 12 ( 12-3/4 ) 8 ( 6-1/2 ) 10 ( 10-3/4 ) Model Total Oil Capacity 1 Oil Pan Oil Drainage Oil Filter 1(1) Oil Cooler 1(1) Closed Cooling Circuit 1 11 ( 11-2/3 ) 13 ( 13-3/4 ) Always use dipstick to determine exact quantity of oil required Drives NOTICE Unit Of Measurement: Liters (U.S.
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MAINTENANCE SERVICE MANUAL NUMBER 22 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.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Sterndrive (MCM) Engines Routine Maintenance * Each Day Start Check crankcase oil (interval can be extended based on experience). If operating in salt, brackish or polluted waters, flush cooling system after each use. Each Day End Weekly Every Two Months D D Drain any water from fuel filter after each use (If operating in freezing temperatures). D Check drive unit oil level, trim pump oil level and power steering pump fluid level.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Sterndrive (MCM) Engines (Continued) Scheduled Maintenance * After First 20 hours Change crankcase oil and filter. Touch-up paint power package and spray with corrosion guard. Every Every Every Every 200 300 500 100 Every Every hours hours hours Annuhours or 2 5 or 3 or 3 or 5 ally Annually years years years years years z z z z D Every 1000 hours or 5 years z D D Change drive unit oil and retorque connection of gimbal ring to steering shaft.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Sterndrive (MCM) Engines (Continued) Scheduled Maintenance * (Continued) After First 20 hours Every Every Every Every 200 300 500 100 Every Every hours hours hours Annuhours or 2 5 or 3 or 3 or 5 ally Annually years years years years years z z z z Lubricate drive shaft U-joints and tailstock input and output bearings. D Inspect condition and tension of belts.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Inboard (MIE) Engines Routine Maintenance * Each Day Start Check crankcase oil (interval can be extended based on experience). If operating in salt, brackish or polluted waters, flush cooling system after each use. Each Day End Weekly Every Two Months D 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.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Inboard (MIE) Engines (Continued) Scheduled Maintenance * After First 20 hours Change crankcase oil and filter. Touch-up paint power package and spray with corrosion guard. Every Every Every 200 500 100 Every hours hours Annuhours or 2 or 3 or 5 ally Annually years years years z z z D Every 1000 hours Per or 5 OEM years z D D Change transmission fluid. D Replace fuel filter(s). D Check steering system and remote control for loose, missing or damaged parts.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Engine External Views Starboard Side View 2 1 3 4 6 5 7 8 9 10 15 11 14 13 12 78409 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 90-860074-
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MAINTENANCE SERVICE MANUAL NUMBER 22 Front View 1 2 16 3 4 5 15 6 14 13 12 11 7 10 9 8 78310 Typical In-Line D-Tronic Diesel 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 Page 1B-14 90-8600
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MAINTENANCE SERVICE MANUAL NUMBER 22 Port Side View 1 2 3 6 5 4 7 20 8 9 19 18 17 16 15 14 13 12 11 10 75298 Typical In-Line D-Tronic Diesel 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.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Rear View 1 2 3 7 4 5 6 74305 Typical In-Line D-Tronic Diesel 1 - Air Filter 2 - Turbocharger 3 - Exhaust Elbow 4 - Rear Engine Mount 5 - Engine Coupler 6 - Flywheel Housing (Rear Portion) 7 - Electrical Box Page 1B-16 90-860074--1 FEBRUARY 2002
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MAINTENANCE SERVICE MANUAL NUMBER 22 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.
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MAINTENANCE SERVICE MANUAL NUMBER 22 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.
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MAINTENANCE SERVICE MANUAL NUMBER 22 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.
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MAINTENANCE SERVICE MANUAL NUMBER 22 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. b b a 75297 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.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Fuel Precautions WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire. This eliminates the engine wiring as a potential source of ignition. WARNING FIRE HAZARD: Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death. Careful periodic inspection of entire fuel system is mandatory, particularly after storage.
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MAINTENANCE SERVICE MANUAL NUMBER 22 General Information Grade 2-D diesel fuel is required, meeting ASTM Standards D975 (or fuel rated Diesel DIN 51601) and having a minimum cetane rating of 45. The cetane number is a measure of the ignition quality of diesel fuel. Increasing the cetane number will not improve overall engine performance, but it may be necessary to raise the cetane rating for low temperature or high altitude use.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Fuel Filter PRECAUTIONS WARNING Be careful when draining, filling or replacing water separating fuel filter; diesel fuel is flammable. Ensure that the ignition key is OFF. Do NOT smoke or allow sources of open flame in the area while changing fuel system components. Wipe up any spilled fuel immediately. Do NOT allow fuel to come into contact with any hot surface which may cause it to ignite. WARNING Dispose of fuel-soaked rags, paper, etc.
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MAINTENANCE SERVICE MANUAL NUMBER 22 DRAINING NOTICE Refer to Precautions BEFORE proceeding. The filter can be drained of water and small dirt particles by opening the water drain cap (bleed valve). IMPORTANT: To ensure complete draining, in warm weather, open the drain cock before starting daily operations. In cold weather, when there is a possibility that the condensed water will freeze, drain the filter shortly after the end of daily operations.
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MAINTENANCE SERVICE MANUAL NUMBER 22 FILLING NOTICE Refer to Precautions BEFORE proceeding. Follow this procedure after installing a new filter or if fuel has been completely drained from the filter checking for water. NOTE: Place a suitable container under fuel filter to catch contaminated fuel and/or water 1. Loosen bleed screw on fuel filter bracket. 2. Move plunger knob on pump/primer up and down repeatedly, until an air free stream of fuel flows from bleed screw. Filter is full when this occurs.
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MAINTENANCE SERVICE MANUAL NUMBER 22 REMOVAL NOTICE Refer to Precautions BEFORE proceeding. NOTE: Place a suitable container under fuel filter to catch contaminated fuel and/or water 1. Twist locking ring by hand. Remove water separating fuel filter and sealing ring from mounting bracket. Do NOT use a filter wrench. a b 70161 75579 a - Locking Ring b - Filter Element IMPORTANT: Element cannot be cleaned and reused. It must be replaced. 2.
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MAINTENANCE SERVICE MANUAL NUMBER 22 INSTALLATION 1. Install O-ring and drain cap on new filter. a b 70160 a - O-ring Seal b - Drain Cap 2. Lubricate seal with clean engine oil. 3. Align filter to bracket. Twist locking ring by hand to secure filter to bracket. Do NOT use a filter wrench. a b c d a b c d 74731 - Filter Header - Locking Ring - Seal - Fuel Filter 4. Fill fuel filter as previously outlined.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Closed Cooling System Coolant Requirement CAUTION Alcohol or methanol based anti-freeze or plain water are not recommended for use in the closed cooling section of cooling system at any time. Because diesel engines are high compression engines and related higher engine operating temperatures are created, the closed cooling system and engine must remain as clean as possible to provide adequate engine cooling.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Checking Level 1. Coolant level must be between the bottom ADD mark and top FULL Hot mark on coolant recovery bottle with the engine at normal operating temperature. a c b 72520 a - Coolant Recovery Reservoir b - Bottom ADD Mark c - Top FULL Hot Mark 2. Add specified coolant to the coolant recovery bottle as required. WARNING Allow engine to cool before removing pressure cap.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Draining NOTICE For instructions on Draining Seawater Section refer to Cold Weather or Extended Storage in this SECTION 1B. IMPORTANT: Observe the following: w Insert a wire into drain holes to ensure that foreign material is not obstructing the drain holes. w Ensure engine is as level as possible to promote complete draining of cooling system. w Closed cooled section must be kept filled year round with recommended coolant.
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MAINTENANCE SERVICE MANUAL NUMBER 22 3. –Drain coolant from the engine block by opening the drain valve. a 76391 Typical a - Engine Block Drain Valve 4. After coolant has drained completely, securely close drain valves. 5. Empty the coolant recovery bottle. 6. If required, clean the closed cooled system. Refer to SECTION 6A. 7. Fill system with required coolant, as outlined in Filling.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Filling 1. Slowly fill with coolant through heat exchanger fill neck. 2. Continue filling until coolant level is at bottom of fill neck. CAUTION Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet during operation. 3. Supply cooling water to water inlet. 4. With the pressure cap off, start the engine and run at fast idle (1500-1800 rpm).
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MAINTENANCE SERVICE MANUAL NUMBER 22 Sacrificial Anodes Sacrificial anode locations: • Starboard, aft-side of the heat exchanger. • Top of the intercooler end cover. Removal 1. Allow the engine to cool. 2. Remove anode plugs and sacrificial anodes. a b c c 73326 73327 a - Heat Exchanger b - Intercooler End Cover c - Anode Plug And Sacrificial Anode Inspection 1. Replace anode assembly when deteriorated 50%. • Length When New - 19 mm (3/4 in.) • Diameter When New - 16 mm (5/8 in.) 2.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Disassembly NOTE: Sacrificial anodes are available as an assembly. Replace both the plug and anode, if so desired. 1. Unscrew sacrificial anode from anode plug by holding plug hex head and turning anode. a b 71367 a - Plug b - Anode Reassembly 1. Clean interior threads of anode plug. 2. Apply Loctite Pipe Sealant with Teflon to threads of new sacrificial anode and install into anode plug. Tighten securely. b a 71367 a - Plug b - Anode Installation 1.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Flushing Seawater System If engine is operated in salty, polluted or mineral-laden water, flush seawater section of cooling system (preferably after each use) to reduce corrosion and prevent the accumulation of deposits in the system. Thoroughly flush seawater section prior to storage. SternDrive (MCM) Models WARNING When flushing, be certain the area around propeller is clear and no one is standing nearby. To avoid possible injury, remove propeller. 1.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Inboard (MIE) Models WARNING When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid possible injury, remove propeller. CAUTION If boat is in the water, seacock (water inlet valve), if equipped, must be closed until engine is to be re-started, to prevent water from flowing into the boat and/or back into the cooling system.
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MAINTENANCE SERVICE MANUAL NUMBER 22 3. Using an adapter, connect a hose between the water inlet hose or connector fitting and a water tap. a b c 75299 a - Inlet Hose b - Adapter c - Hose To Water Tap 4. Partially open the water tap, approximately 1/2 maximum capacity. Do NOT use full water pressure. 5. Place the remote control in NEUTRAL, IDLE speed position, and start the engine. CAUTION Do NOT run engine above 1500 rpm when flushing.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Inspect Water Pickups SternDrive Gear Housing 1. Ensure that the gear housing water inlet holes are clean and not obstructed. a 73186 Typical a - Water Inlet Holes Inboard Though the Hull Pickup 1. Ensure that the seawater pickup water inlet holes (slots) are clean and not obstructed.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Lubrication Throttle Cable 1. Lubricate pivot points and guide contact surfaces with SAE 30W engine oil. b a 75332 Single Cable Shown (Dual Similar) a - Pivot Points b - Guide Contact Surfaces Shift Cable 1. Lubricate pivot points and guide contact surfaces with SAE 30W engine oil.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Engine Coupler / U-joint Shaft Splines NOTE: Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for sterndrive unit removal and installation, if necessary. IMPORTANT: These engines are equipped with a sealed engine coupler. The sealed coupler and the shaft splines can be lubricated without removing the sterndrive unit. 1.
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MAINTENANCE SERVICE MANUAL NUMBER 22 U-joints NOTE: Bravo Models - The crosses and the bearings on the sterndrive U-joint will need to be lubricated through the grease fittings. The sterndrive unit must be removed to grease these fittings. 1. Remove the sterndrive unit; refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for sterndrive unit removal and installation. 2.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Drive Shaft Extension Models 1. Apply 3-4 pumps of U-joint And Gimbal Bearing Grease to drive shaft grease fittings. a b 71346 71347 a - Transom End Fittings b - Engine End Fittings Sterndrive Unit and Transom Assembly 1. Apply approximately 8-10 pumps of U-joint And Gimbal Bearing Grease to the gimbal bearing.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Continuity Circuit The transom assembly and the sterndrive unit are equipped with ground circuit wires to ensure good electrical continuity between the engine, the transom assembly and the sterndrive components. Good continuity is essential for the Anode and the MerCathode System to function most effectively. 1. Inspect the following ground circuit components for loose connections, broken or fraying wires.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Continuity Circuit (continued) b a 22028 c a - Flywheel Housing Grounding Stud b - Ground Wire c - Inner Transom Plate Grounding Screw a 22755 b 22031 a - Gimbal Ring To Bell Housing Ground Wire b - Sterndrive Unit To Bell Housing Ground Plate a b 70575 22230 a - Driveshaft Housing To Gear Housing Anodic Plate b - Hydraulic Connector Block To Gimbal Housing Ground Washer b a 50383 22079 a - U-joint Bellows Ground Clip b - Exhaust Bellows Ground Clips
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SERVICE MANUAL NUMBER 22 MAINTENANCE MerCathode If the boat is equipped with a Quicksilver MerCathode System, the system should be tested to ensure that it is providing adequate output to protect the underwater metal parts on the boat. The test should be made where the boat is moored, using Quicksilver Reference Electrode and Test Meter. Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for testing procedures. Engine Mounts 1. Torque the rear engine mounts to 51 Nm (38 lb-ft).
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MAINTENANCE SERVICE MANUAL NUMBER 22 Power Steering Checking Fluid Level IMPORTANT: Use only Power Trim and Steering Fluid or automatic transmission fluid (ATF) Dexron III in power steering system. ENGINE WARM 1. Stop engine and center the sterndrive unit. 2. Remove the dipstick from the power steering fluid reservoir and observe the fluid level. 3. The fluid level should be between the full hot mark and the full cold mark on dipstick.
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MAINTENANCE SERVICE MANUAL NUMBER 22 ENGINE COLD 1. With engine stopped, center sterndrive unit. 2. Remove dipstick from power steering fluid reservoir and observe fluid level. 3. The level should be between the full cold mark and the bottom of the dipstick. d a c b 23162 73326 a b c d - Dipstick - Fluid Reservoir - Full Cold Mark - Bottom Of Dipstick 4.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Filling and Bleeding 1. With engine stopped, center sterndrive unit. 2. Remove dipstick from power steering reservoir. IMPORTANT: Use only Power Trim and Steering Fluid or Dexron III automatic transmission fluid (ATF) in power steering system. 3. Add fluid to bring the fluid level up to full cold mark on dipstick. IMPORTANT: All air must be removed from the system or fluid in pump may foam during operation and be discharged from pump reservoir.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Transmission Checking Fluid Level IMPORTANT: To accurately check fluid level, the engine must be operated at 1500 rpm for 2 minutes immediately prior to checking level. 1. Start engine and run at 1500 rpm for 2 minutes to fill all circuits, lines, and cooler. 2. For Hurth Transmissions IMPORTANT: Do NOT screw dipstick in; press it firmly in and remove to obtain an accurate reading. a. Stop the engine and quickly remove the dipstick to check level. b.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Power Trim Checking Fluid Level 1. Place sterndrive unit in full DOWN/IN position. IMPORTANT: Some trim pump reservoir fill caps have a small vent hole. Occasionally ensure vent is not restricted. 2. Unscrew reservoir cap. 3. Remove and discard cap plug if present. a b 73183 76631 a - Reservoir Cap b - Cap Plug 4. Observe oil level. Level must be up to, but not over, bottom edge of reservoir fill neck.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Filling 1. Add Power Trim and Steering Fluid or SAE 10W-30 engine oil to bring oil to proper level. 2. Install reservoir cap.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Gear Lube Monitor Checking Fluid Level NOTE: Fluid level in gear lube monitor will fluctuate during operation. Level should be checked with engine cold. 1. Check for water at bottom of monitor, or milky-tan appearance. Both conditions indicate a water leak somewhere in the sterndrive unit. Find and correct the cause. 2. Check gear lube monitor oil level. Keep oil level at or near “OPERATING RANGE (FULL)” line and never below the “ADD” line. Filling 1. Remove cap. 2.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Seawater Strainer 1. Visually inspect seawater strainer through glass top. CAUTION When cleaning seawater strainer, close seacock, if equipped. If boat is not equipped with a seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses. CAUTION Do NOT overtighten cover screws or cover will warp and leak. 2.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Air Filter Removal 1. Disconnect crankcase vent hose from end of air intake screen housing mounted on turbocharger inlet. a b 73323 Typical a - Intake Screen Housing b - Crankcase Vent Hose 2. Carefully remove air cleaner foam element from around air intake screen housing. b a 71267 a - Screen Housing b - Air Cleaner Element Inspection 1. Inspect the air cleaner element for tears or holes. 2.
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SERVICE MANUAL NUMBER 22 MAINTENANCE Cleaning 1. Wash air cleaner element in warm water and detergent until clean. IMPORTANT: No treatment (such as partial oil saturation) is required or recommended on air cleaner foam element prior to use. Use element clean and dry for proper filtration. 2. Allow air cleaner element to completely dry before use. Installation 1. Install air cleaner element around air intake screen. 2. Connect crankcase vent hose to end of intake screen housing.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Drive Belts General Information Belt and pulley replacement guidelines: Page 1B-56 • During belt assembly, do NOT force belt into pulley grooves by prying with a screwdriver, pry bar or similar. This will damage belt side cords, which will cause belt to turn over in pulley grooves, and result in complete destruction of belt. • Do NOT use belt dressing. • Always check condition of remaining belts. Replace belt if worn, cracked, grease-soaked or oil-soaked.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Inspection WARNING Avoid possible serious injury. Ensure engine is shut off and ignition key is removed before inspecting belts. 1. Visually inspect all drive belts for cracks, glazing, fraying or separation. 2. Check drive belts for proper tension by pressing midpoint between the pulleys on the longest belt span. Belts must not deflect more than 5 mm (3/16 in.).
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MAINTENANCE SERVICE MANUAL NUMBER 22 Alternator Belt NOTE: On some engines it may be necessary to remove other drive belts to gain access to a particular belt during replacement. Refer to appropriate sections for information concerning individual drive belts and proceed accordingly. CAUTION Before removing the seawater pump hoses, close the seacock, if equipped.
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MAINTENANCE SERVICE MANUAL NUMBER 22 7. Pivot the alternator. Adjust belt deflection to be 5 mm (3/16 in.) measured at midpoint between the pulleys on the longest belt span. 8. Torque tensioning and mounting bolts 28 Nm (21 lb-ft). a b c 74301 73521 Typical a - Deflection: 5 mm (3/16 in.) b - Tensioning Bolt c - Mounting Bolt 9. Install the seawater pump inlet and outlet hoses. 10. Open the seacock, if equipped.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Power Steering Pump Belt NOTE: On some engines it may be necessary to remove other drive belts to gain access to a particular belt during replacement. Refer to appropriate sections for information concerning individual drive belts and proceed accordingly. 1. Loosen the two mounting bolts and the tensioning bolt on power steering pump. 2. Pivot the power steering pump to loosen belt.
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MAINTENANCE SERVICE MANUAL NUMBER 22 4. Remove old belt. 5. Install new belt. 6. Pivot the power steering pump. Adjust belt deflection to be 5 mm (3/16 in.) measured at midpoint between the pulleys on the longest belt span. 7. Torque tensioning and mounting bolts to 21 Nm (15 lb-ft). c a a b 70113 73521 a - Mounting Bolts (1 Not Shown) b - Tensioning Bolt c - Deflection: 5 mm (3/16 in.) IMPORTANT: There is an o-ring seal on the seawater pump. 8.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Vacuum Pump Belt NOTE: On some engines it may be necessary to remove other drive belts to gain access to a particular belt during replacement. Refer to appropriate sections for information concerning individual drive belts and proceed accordingly. 1. Remove or loosen seawater pump nuts sufficiently to allow belt to pass between crankshaft balancer and water pump housing. NOTE: Refer to SECTION 6 - Seawater Pump Removal if necessary.
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MAINTENANCE SERVICE MANUAL NUMBER 22 6. Pivot the vacuum pump. Adjust belt deflection to be 5 mm (3/16 in.) measured at midpoint between the pulleys on the longest belt span. 7. Torque tensioning and mounting bolts to 21 Nm (15 lb-ft). c b a 74085 a - Mounting Bolt b - Tensioning Bolt c - Deflection: 5 mm (3/16 in.) IMPORTANT: There is an O-ring seal on the seawater pump. 8. Ensure that the O-ring seal is in the proper position before installing the seawater pump.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Battery 1. Ensure battery connections are clean and tight. 2. Keep exterior surfaces of battery wiped clean with a water/baking soda solution. 3. Ensure battery is securely fastened in place. 4. Refer to battery manufacturer’s recommendations for fluid level and charging. Charging System CAUTION Remove all battery cables from battery (before conducting the following check) to prevent accidentally causing a short circuit in the electrical system. 1.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Freezing Temperature and Cold Weather Operation IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to power package. Refer to the following and to Cold Weather or Extended Storage for related information and draining instructions.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Cold Weather or Extended Storage Power Package Layup IMPORTANT: Mercury MerCruiser strongly recommends that this service be performed by an Authorized Mercury MerCruiser Dealer. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. CAUTION The engine must be prepared for long storage periods to prevent internal corrosion and severe damage. CAUTION Overheating from insufficient cooling water will cause engine and drive system damage.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Draining IMPORTANT: Drain only the seawater section of the cooling system. Closed cooling section must be kept filled year-round with specified coolant. 1. Ensure that the engine is as level as possible to promote complete draining of the cooling system. CAUTION If boat is to remain in the water, seacock, if equipped, must be closed until engine is to be restarted to prevent water from flowing back into seawater cooling system.
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MAINTENANCE SERVICE MANUAL NUMBER 22 4. Remove the end covers from BOTH port and starboard ends on upper and lower sections of heat exchanger tank. 5. Drain tank completely. 6. Sponge out or soak up any water that remains in the bottom part of upper and lower heat exchanger sections, until all water passage tubes are completely free of standing water. CAUTION Avoid damage to heat exchanger and subsequent possible engine damage. Remove all water from heat exchanger sections.
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MAINTENANCE SERVICE MANUAL NUMBER 22 8. On Inboard (MIE) Engines: Disconnect seawater outlet hose at aft end of transmission fluid cooler. Lower hose and drain completely. a b 73335 Typical a - Transmission Fluid Cooler b - Seawater Hose 9. Remove the drain plug from the aft end cover of the intercooler. a b 74303 a - Drain Plug b - Intercooler 10. Remove seawater pump outlet hose from top of seawater pump and drain. a 75301 a - Seawater Pump Outlet Hose 11.
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MAINTENANCE SERVICE MANUAL NUMBER 22 12. Sterndrive (MCM) Only: Insert a small wire (repeatedly) to make sure that speedometer pitot tube, trim tab/anode cavity vent hole and trim tab/anode cavity drain passage are unobstructed and drained. b c a 71217 Typical Bravo Drive Unit a - Speedometer Pitot Tube b - Vent Hole c - Drain Passage 13. After seawater section of cooling system has been drained completely: a. Coat threads of intercooler drain plug with Perfect Seal and reinstall. Tighten securely. b.
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MAINTENANCE SERVICE MANUAL NUMBER 22 IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze (nontoxic and biodegradable, which makes it friendly to lakes and rivers) be used in seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer’s recommendations. 14. Fill a container with approximately 5.
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MAINTENANCE SERVICE MANUAL NUMBER 22 23. Remove seawater pump impeller for storage: a. Remove seawater pump cover mounting screws, and remove cover and gasket. b. Ease impeller off pump shaft with two screwdrivers. c. Reinstall cover for storage. NOTE: Pump shown removed for visual clarity only. b e c a d 71366 Typical a - Seawater Pump Housing b - Cover Screws c - Cover d - Gasket e - Impeller IMPORTANT: It is recommended that others be informed to NOT operate the engine. 24.
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MAINTENANCE SERVICE MANUAL NUMBER 22 Recommissioning NOTICE Refer to Cold Weather Extended Storage - Precautions, BEFORE proceeding. 1. Reinstall seawater pump components as follows: a. Place impeller in pump housing, turning clockwise while simultaneously pushing firmly inward onto pump shaft. NOTE: Use new gasket. Install in correct position - wide surface on side of cam. b. Install pump cover with new gasket in noted position. c. Install the seawater pump cover mounting screws. Tighten securely.
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MAINTENANCE SERVICE MANUAL NUMBER 22 2. Ensure that all cooling system hoses are in good condition, connected properly, and hose clamps are tight. Verify that all drain valves and drain plugs are installed and tight. 3. Inspect all drive belts. 4. Perform all lubrication and maintenance specified for completion Annually in Maintenance Schedule, except items that were performed at time of engine layup. 5. Fill fuel tanks with fresh diesel fuel. Old fuel should not be used.
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MAINTENANCE SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK 90-860074--1 FEBRUARY 2002 Page 1B-75
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MAINTENANCE SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 1B-76 90-860074--1 FEBRUARY 2002
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 IMPORTANT INFORMATION 1 SECTION 1C - Troubleshooting C Table of Contents 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 . . . . . . . . . . . . . . . . . . . . . .
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 1C-2 90-860074--1 FEBRUARY 2002
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Precautions WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system. WARNING Be careful when changing fuel system components; diesel fuel is flammable. Ensure that ignition key is OFF. Do NOT smoke or allow sources of spark or flame in the area while changing fuel system components. Wipe up any spilled fuel immediately.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 WARNING Make sure no fuel leaks exist before closing engine hatch. WARNING When running engine with boat out of water, be certain that area in vicinity of propeller is clear and that no person is standing nearby. As a precautionary measure, it is recommended that the propeller be removed. WARNING Do NOT leave helm unattended while performing idle speed adjustment. WARNING Safety glasses should be worn while working on fuel injection system.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Poor Boat Performance and/or Poor Maneuverability Symptom Cause 1. Bow too low 1. A. Improper drive unit trim angle B. Improper weight distribution C. Boat is underpowered D. Permanent or power hook in boat bottom E. False bottom full of water F. Improperly adjusted trim tabs (after planes) 2. Bow too high 2. A. Improper drive unit trim angle B. Propeller pitch too great C. Dirty boat bottom (marine growth) D. Poor running engine E.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Improper Full Throttle Engine RPM RPM Too High Cause Special Information 1. Operation 3. Unit trimmed out too far 2. Propeller 1. Damaged; pitch too low; diameter too small; propeller hub slipping 3. Boat 2. A. Water pickup or accessories mounted too close to propeller (ventilation) B. Keel located too close to propeller and/or too deep in the water (ventilation) C. Drive installed too high on transom D. Wrong gear ratio 4.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Engine Cranks Over But Will Not Start Or Starts Hard Electrical Cause 1. Battery, electrical connections, damaged wiring, Lanyard Stop Switch Special Information 1. Ensure ECM 5 Amp. fuse in electrical box is not defective (blown) 2. Ignition switch 3. Glow plugs (if equipped) inoperative 4. Injection timing 4. May crank over hard. Refer to SECTION 5A, 5D, and/or 5E for EDI diagnosis Fuel System Cause 1. Empty fuel tank Special Information 2.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Fuel System (continued) Page 1C-8 Cause 9. Fuel tank vent plugged Special Information 9. Engine will start initially. After a short time running, engine will stall and will not restart for a period of time. Can verify if it is a vent problem by running engine with filler cap loose. Filler cap will act as a vent. 10. Injection pump solenoid valve 10 Refer to SECTION 5. Check lanyard stop switch engaged or defective 11. Fuel supply pump 11.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Miscellaneous Cause Special Information 1. Low grade or stale fuel 2. Water in fuel 3. Incorrect starting procedure 3. Refer to Owners Manual 4. Internal mechanical damage (bent rods, etc.) 5. Low compression 5. Worn valves, rings, cylinder or head gasket 6. Valve timing incorrect 6. Timing gears improperly installed or cam slipped in drive gear 7.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Engine Will Not Crank Over or Starter Inoperative (continued) Cause 7. Faulty neutral start safety switch Special Information 7. Open circuit 8. Starter solenoid 9. Starter motor 10. Engine mechanical malfunction Glow Plugs Inoperative Cause Special Information 1. Battery discharged 2. Circuit breaker tripped 2. On dash or in electrical box 3. Poor battery connections 4. Glow plug(s) defective (burned out) 5. Relay defective or inoperative 5.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Charging System Inoperative Cause Special Information 1. Loose or broken drive belt 2. Engine rpm too low on initial start 2. Rev engine to 1500 rpm 3. Loose or corroded electrical connections 4. Faulty battery gauge 4. Best way to test is to replace gauge 5. Battery will not accept charge 5. Low electrolyte or failed battery 6. Faulty alternator or regulator 7.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Engine Operates Poorly at Idle Cause Special Information 1. Clogged air cleaner 2. Plugged fuel suction line or filter 3. Air leaks: suction side fuel line, water separating fuel filter or loose intake manifold 4. Water in fuel 4. Refer to SECTIONS 1B and 5A 5. Low grade or stale fuel 6. Fuel waxing or frozen water separating fuel filter (cold weather) 7. Valve timing 7. Cam slipped in drive gear 8. Restricted or plugged exhaust 9.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Engine Operates Poorly At High Rpm Cause Special Information 1. Refer to Poor Boat Performance And / Or Poor Maneuverability 2. Crankcase overfilled with oil 2. Check oil level with boat at rest in the water 3. Malfunction of anti-siphon valve (if equipped) 3. Restricting fuel supply 4. Plugged fuel tank vent 5. Low fuel supply 6. Clogged fuel filter 7. Low grade of fuel or water in the fuel 8. Obstructed or kinked fuel lines 9.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Poor Fuel Economy Cause Special Information 1. Fuel leaks 2. Operator habits 2. Prolonged idling; slow acceleration; failure to cut back on throttle once boat is on plane; boat over loaded; uneven weight distribution 3. Engine laboring 3. Bent, damaged, or wrong propeller. Water test boat for proper operating rpm at wide open throttle 4. Clogged air cleaner 5. Engine compartment sealed too tight 5. Not enough air for engine to operate properly 6.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Engine Smoking Black Smoke Cause Special Information 1. Overload 2. Restricted air cleaner and /or intercooler 3. Excessive fuel delivery 3. Refer to SECTION 5E for EDI diagnosis 4. Faulty injector(s) 4. Refer to SECTION 5C and / or 5E for EDI diagnosis 5. Restricted or plugged exhaust 6. Insufficient coolant temperature 7. Excessive idle time (injector coking) 9. Leaking head gaskets 10.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Blue Smoke Cause Special Information 1. Worn piston rings 1. Check compression 2. Sticking piston rings 2. Check compression 3. Crankcase overfilled - incorrect dipstick reading 4. Leaking head gaskets White Smoke Cause Special Information 1. Injection pump timing incorrect 1. Refer to SECTION 5D 2. Faulty injector(s) 2. Refer to SECTION 5C 3. Low compression 4. Plugged fuel suction line or filter 5.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Exhaust Gas Temperature High Cause Special Information 1. Excessive load 2. Injection pump timing incorrect 2. Refer to SECTION 5D 3. Faulty wastegate device Low Cause 1. Injection pump timing incorrect Special Information 1. Refer to SECTION 5D 2.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Turbocharger Ensure that troubles are not due to engine components, especially to injection system, before troubleshooting turbocharger and/or carrying out corrective action on turbocharger. Cause 1. Smoke from exhaust Special Information 1. A. Not enough air getting to engine air intake B. Clogged air filter C. Boost pressure too low D. Refer to Engine Smoking - Black, Blue and/or White 2. Loss of power 2. A. Not enough air getting to engine air intake B.
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SERVICE MANUAL NUMBER 22 TROUBLESHOOTING Engine Noise No definite rule or test will positively determine source of engine noise; therefore, use the following information only as a general guide to engine noise diagnosis. 1. Use a timing light to determine if noise is timed with engine speed or one-half engine speed. Noises timed with engine speed are related to crankshaft, rods, pistons, piston pins, and flywheel. Noises timed to one-half engine speed are valve train related. 2.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Valve Cover Area Location 1. Valve cover area, timed to one-half engine speed, noise could be confined to one cylinder or may be found in any multitude of cylinders Possible Cause 1. A. Rocker arm striking valve cover B. Hydraulic lifter C. Worn rocker arm D. Bent push rod E. Worn camshaft F. Sticking valve Cylinder Area Location 1. Cylinder area, may be confined to one cylinder or found in more than one cylinder, timed to engine speed Possible Causes 1. A.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Camshaft Area Location 1. Camshaft area, front of engine, timed to engine speed Possible Causes 1. A. Camshaft timing gear B. Injection pump C. Fuel pump D. Valve lifter - camshaft wear E. Cam bearings 2. Camshaft area, center of engine, timed to engine speed 2. A. Fuel pump B. Valve lifter - camshaft wear C. Cam bearings 3. Camshaft area, rear of engine, timed to engine speed 3. A. Valve lifter - camshaft wear B. Cam bearings 4.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Crankshaft Area Location Possible Causes 1. Crankshaft area, front of engine, timed 1. A. Crankshaft timing gear to engine speed B. Oil Pump C. Rod bearing D. Main bearing 2. Crankshaft area, center of engine, timed to engine speed 2. A. Crankshaft striking pan or pan baffle B. Rod bearing C. Main bearing 3. Crankshaft area, rear of engine, timed to engine speed 3. A. Loose flywheel cover B. Loose coupler or drive plate C. Loose flywheel D. Rod bearing E.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Miscellaneous Location 1. Hissing Possible Causes A. Leaking exhaust (manifolds or pipes) B. Loose cylinder heads C. Blown head gasket 2. Whistle 2. A. Vacuum leak B. Dry or tight bearing in an accessory 3. Squeaks or squeals 3. A. Drive belt slipping B. Dry or tight bearing in an accessory C. Parts rubbing together Oil Pressure Item 1. Measuring oil pressure Special Information 1. Use a good automotive oil pressure test gauge.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Oil Pressure (continued) Item Page 1C-24 Special Information 6. Low engine oil pressure at idle 6. With modern engines and engine oils, low oil pressure readings at idle do not necessarily mean there is a problem. If valve lifters are not noisy at idle, there is a sufficient volume of oil to lubricate all internal moving parts properly.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Low Oil Pressure Cause Special Information 1. Low oil level in crankcase 2. Defective oil pressure gauge and/or sender 2. Verify with an automotive test gauge. 3. Thin or diluted oil 3. Oil broken down; contains water or fuel; wrong viscosity; engine running too hot or too cold; excessive idling in cold water (condensation) 4. Oil pump 4.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Excessive Oil Consumption NOTE: One quart of oil consumed in 15 hours of operation at WOT, especially in a new or rebuilt engine, is normal Cause Special Information 1. Normal consumption 1. One quart of oil consumed in 15 hours of operation at wide-open-throttle (especially in a new or rebuilt engine) is normal 2. Oil leaks 2. Clean bilge, run engine with clean white paper on bilge floor, locate oil leak(s) 3. Oil too thin 3.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Water / Coolant in Engine Important Information IMPORTANT: First determine location of water in engine. This information can be of great help when trying to determine where the water came from and how it got into the engine. The three most common problems are water on top of pistons, water in crankcase oil, water in crankcase oil and on top of pistons.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Water / Coolant On Top Pistons Cause 1. Rain water running onto air cleaner Special Information 1. Hatch cover 2. Backwash through the exhaust system 3. Improper engine or exhaust hose installation 3. Refer to exhaust specifications 4. Cracked exhaust manifold 5. Improper manifold to elbow gasket installation 6. Loose cylinder head bolts Page 1C-28 7. Blown cylinder head gasket 7. Check for warped cylinder head or cylinder block 8.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Engine Overheats Cooling System Cause Special Information IMPORTANT: The first step is to verify if the engine is actually overheating or if the temperature gauge or sender is faulty 1. Seacock (seawater shut off valve) partially or fully closed (if equipped) 2. Low coolant level 3. Antifreeze incorrect type or not mixed properly 3. Use low silicate type with special additives 4. Loose or broken drive belt 5. Clogged or improperly installed sea strainer 6.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Cooling System (continued) Cause Special Information 13. Obstruction in cooling system such as casting flash, sand, rust, salt, etc. 13. Refer to water flow diagram for engine type being serviced 14. Engine water circulating pump defective 18. Heat exchanger core or tubes plugged 15. Also refer to Engine Overheats (Mechanical) Mechanical Cause Special Information 1. Engine rpm below specifications at wide-open-throttle (engine laboring) 1.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Power Steering Poor, Erratic or No Assist Cause 1. Drive belt Special Information 1. Worn, broken or out of adjustment 2. Low fluid level 3. Air in system 3. Air leak in lines, pump, or air from installation. Refer to SECTION 9A for bleeding procedure. 4. Leaking hoses 4. Refer to SECTION 9A for bleeding procedure. 5. Steering cables and/or steering helm 5.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Noisy Pump Cause 1 Drive belt Special Information 1. Check belt tension 2. Low fluid level 3. Air in fluid 3. Air leak in lines, pump, or air form installation 4. Faulty Pump 4. Use stethoscope to listen for noise in pump 5. Restricted fluid passages 5. Kinks or debris in hoses or debris in passages 6. Stop nut adjusted improperly 6. Refer to appropriate Mercury MerCruiser Sterndrive Service Manual 7.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 Insufficient Water Flow From Belt Driven Seawater Pump Cause 1. Drive belt Special Information 1. Loose, worn or broken 2. Seawater shut off valve partially or fully closed 3. Clogged or improperly installed sea strainer 4. Loose hose connections between seawater pickup and seawater pump inlet 4. Pump will draw in air, pump may fail to prime or will force air bubbles into cooling system 5. Seawater inlet hose kinked or plugged 6. Seawater pickup plugged 7.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 ZF / Hurth Hydraulic Transmission Trouble 1. Transmission gears cannot be shifted Page 1C-34 Possible Cause 1. A. Shifting lever loose Remedy 1. A. Tighten clamping screw on shifting lever B. Remote control does not permit lever travel required for testing B. Lift remote control off, if gears can be shifted by hand, correct remote control C. Remote control faulty C. Repair remote control D. No shifting pressure available D. Refer to Number 7 2.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 ZF / Hurth Hydraulic Transmission (continued) Trouble Possible Cause Remedy 4. Transmission is blocked 4. A. Medium piston ring in input shaft in control block is faulty 4. A. Remove control block, replace piston ring, replace control block if worn 5. Output shaft turns in neutral position 5. A. Rotary slide valve in control block is worn 5. A. Replace control block 6. Shifting pressure too low 90-860074--1 FEBRUARY 2002 B.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 ZF / Hurth Hydraulic Transmission (continued) Trouble 7. No shifting pressure Possible Cause 7. A. Direction of engine 7. A. Replace with L.H. rotation does not agree rotation engine with arrow on transmission B. No fluid in transmission B. Refill with fluid C. Fluid filter is dirty C. Replace fluid filter D. Fluid level in transmission is too low D.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 ZF / Hurth Hydraulic Transmission (continued) Trouble 8. Excessive fluid temperature Possible Cause 8. A. Excessive fluid in transmission 8. A. Remove excessive fluid with commercial fluid pump B. Fluid cooler is dirty on water side B. Remove coolant lines and clean fluid cooler on water side C. Worn fluid pump in control block C. Replace control block and fluid pump D. Faulty piston rings in input shaft in control block D.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 ZF / Hurth Hydraulic Transmission (continued) Trouble 10. Fluid leakage at input shaft Possible Cause 10. A. Breather clogged by paint or dirt B. Shaft seal faulty 11. Fluid leakage at output shaft 11. A. Breather clogged by paint or dirt B. Shaft seal faulty 10. A. Remove dirt or paint from breather B. Disassemble transmission, replace seal. If seal location on input shaft is worn repair surface 11. A. Remove dirt or paint from breather B.
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TROUBLESHOOTING SERVICE MANUAL NUMBER 22 ZF / Hurth Hydraulic Transmission (continued) Trouble 15. Transmission noise changes, becomes louder Possible Cause Remedy 15. A. Fluid level too low so that pump sucks in air 15. A. Top off fluid to fill mark B. Damage starting on flexible coupling due to wear or fatigue, possible due to misalignment between engine and transmission B. Replace flexible coupling. Check alignment between engine and transmission C.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS REMOVAL AND INSTALLATION Section 2A - Sterndrive (MCM) Models Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . 2A-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Lubricants / Sealants / Adhesives . . . . . . . 2A-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7 Engine Installation / Alignment . . . . . . .
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS NOTICE For information and procedures on Troubleshooting, refer to SECTION 1C. Torque Specifications Description Nm Drive Unit Shift Cable or Power Shift Output Cable End Guide Attaching Nut Tighten Nut Until It Contacts Flat Washer; then, Loosen Nut 1/2 Turn Remote Control Throttle Cable End Guide Attaching Nut Tighten Nut Until It Contacts Flat Washer; then, Loosen Nut 1/2 Turn Remote Control Throttle and Shift Cable Barrel Attaching Nut lb-in.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 Lubricants / Sealants / Adhesives Description Part Number Liquid Neoprene Perfect Seal 92-25711--2 92-34227--1 Engine Coupler Spline Grease 91-816391A4 Battery Terminal Sealant Obtain Locally Removal CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant. 7. Disconnect battery cables from battery. 8.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS WARNING FIRE HAZARD: Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death. WARNING Be careful when working on fuel system components; diesel fuel is flammable. Be sure that the ignition key is OFF. Do NOT smoke or allow sources of open flame in the area while working on fuel system components. Wipe up any spilled fuel immediately.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 21. Disconnect exhaust system hoses. 22. Remove both shift cables from shift plate. 23. On Engines With Power Shift: Disconnect vacuum hose from power shift cylinder. 24. Disconnect any grounding wires and accessories that are connected to engine. 25. Disconnect and suitably plug fluid hoses from power steering control valve on transom. CAUTION DO NOT allow lifting sling to hook or compress engine components or damage will occur. 26.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS Installation Engine Installation / Alignment 1. On Engines Where Engine Mounts WERE NOT Disturbed: Proceed to Step 3. 2. On Engines Where Engine Mounts WERE Disturbed: Ensure front mount adjusting nuts are positioned midway on studs so that adequate up and down adjustment exists for engine alignment. 3. Lubricate coupler splines with Engine Coupler Spline Grease. a 75592 Typical a - Coupler Splines 4.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 6. Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust system. DO NOT relieve hoist tension. 22032 74298 IMPORTANT: Engine attaching hardware must be installed in sequence shown. 7. Install both rear engine mounting bolts and hardware as shown. Torque to 47-54 Nm (35-40 lb-ft).
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS CAUTION When lowering engine into position Do NOT set engine on shift cable. Shift cable outer casing can be crushed causing difficult or improper shifting. 8. Set engine on stringers. 9. Relieve hoist tension and disconnect sling from engine lifting eyes. 10. Install a separate sling between front lifting eyes to help equalize load on hoist during alignment procedure. a b 75331 a - Sling In Starboard Lifting Eye b - Sling In Port Lifting Eye 11.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 CAUTION Do NOT use an alignment tool from another manufacturer. Alignment tools other than Quicksilver Alignment Tool, may cause improper alignment and damage to gimbal bearing and/or engine coupler. CAUTION To avoid damage to gimbal bearing, engine coupler, or alignment tool: • Do NOT attempt to force alignment tool! • Do NOT raise or lower engine with alignment tool inserted (or partially inserted) in gimbal bearing or engine coupler. 12.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS 13. If the alignment tool does not fit, remove it and carefully adjust engine mounts as necessary: a. To Adjust Engine Up or Down: Loosen locknut on mounts. Turn adjusting nuts as necessary. Retighten locknuts. IMPORTANT: Large diameter of mount trunion MUST NOT extend over 19 mm (3/4 in.) from edge of mount bracket to centerline of mount stud. b. To Move Engine Left or Right: Loosen trunion clamping bolts on both front mounts and move engine as necessary.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 14. Attempt to insert the solid end of the alignment tool. a. Repeat step 13. and 14. until the alignment tool installs easily (SLIDES FREELY WITH TWO FINGERS) all the way into and out of engine coupler splines. Do not check by turning. NOTE: This may require tapping the sides of the tool. Do NOT check by turning. By greasing the splines you can identify which side has interference.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS 17. On port front mount do as follows: a. Position ECM assembly mounting bracket holes directly over front, port engine mount holes. NOTE: It may be necessary to lower, or raise, the ECM assembly and bracket in slotted hole, depending upon the final configuration of the power package, to position ECM on front mount. b. Fasten ECM mounting bracket and front mount assembly to boat stringer using appropriate hardware (lag bolts or through bolts etc.).
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 20. When alignment is correct, tighten locknuts and jam nuts securely. NOTE: Coat both nuts and threaded portion of mount with Perfect Seal if used in a saltwater environment to reduce rust and ease of serviceability. f a g b e c d 23161 Typical a - Locknut b - Bracket c - Mount Adjustment Nut d - Lag Bolts e - Clamp f - Nuts g - Clamp Spread-Screw 21. Remove alignment tool. 22. Remove chain sling from lifting eyes. 23. Install sterndrive unit.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS Engine Connections 1. Connect power steering hoses to control valve as shown. IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil leakage. IMPORTANT: Be careful not to cross-thread or overtighten hose fittings. a b 74045 74249 a - Rear Fitting (Pressure Hose) b - Front Fitting (Return Hose) 2. Tighten exhaust tube hose clamps securely.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 3. Connect continuity circuit wire from engine to transom assembly. Tighten screw securely. IMPORTANT: Do not attach any accessory ground (–) wires to transom plate ground point. c a b 73567 a - Flywheel Housing Screw b - Continuity Circuit Wire c - Inner Transom Plate Grounding Screw 4. Connect any grounding wires and accessories that were connected to engine. 5. Connect seawater inlet hose to engine water inlet fitting. Tighten hose clamp securely.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS 6. Connect coolant recovery bottle hose to heat exchanger and secure with clamp. b a 70548 a - Hose b - Clamp 7. Connect MerCathode wires to MerCathode controller mounted on engine. Apply a thin coat of Liquid Neoprene to ALL electrical connections.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 8. Connect the trim position sender bullet connectors, from the gimbal housing, to the engine harness. b a BLU/BLK BLK BLK/WHT BLK 24841 a - From Engine Harness b - From Gimbal Housing 9. Mount the gear lube monitor in the engine bracket. Secure with strap. 10. Connect gear lube monitor wires to corresponding engine harness wires. The TAN/BLU wire connects to ORANGE engine harness wire. BLACK wire connects to BLACK wire.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS 11. Connect instrument extension harness ends to engine harness ends. Connector collars must be fully engaged and secure. Tighten threaded connector collar of extension harness onto connector on side of electrical box.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 WARNING Be careful when working on fuel system components; diesel fuel is flammable. Be sure that the ignition key is OFF. Do NOT smoke or allow sources of open flame in the area while working on fuel system components. Wipe up any spilled fuel immediately. Do NOT allow fuel to come into contact with any hot surface which may cause it to ignite. 13. Connect flexible fuel line to inlet fitting on fuel pump. Secure with hose clamp.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS WARNING Dispose of fuel-soaked rags, paper, etc., in an appropriate air tight, fire retardant container. Fuel-soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death. 15. On Engines with Power Shift: Attach vacuum hose from power shift cylinder to vacuum pump fitting. Tighten hose clamp securely.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 4. Install the cable end guide on the throttle lever, then push cable barrel end lightly toward throttle lever end. This will place a slight preload on the shift cable to avoid slack in the cable when moving remote control lever. 5. Adjust barrel on throttle cable to align with stud in anchor bracket. Ensure the hole in the barrel positions the cable as shown. 6. Install the cable and secure with hardware as shown. 7.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS Shift Cable Installation and Adjustment NOTE: Shift Cable Adjustment Tool (91-12427) allows the shift cables to be installed and adjusted, with or without the sterndrive attached. IMPORTANT: The direction of propeller rotation (RH or LH) for this drive unit is determined by the following method. 1. Determine desired propeller rotation according to a., b., or c.: a.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 2. Install shift cable into remote control. Refer to appropriate remote control instructions. 3. Loosen stud and move it to dimension as shown. Re-tighten stud. b a 23345 a - Stud b - 76 mm (3 in.) - Center of Pivot Bolt to Center of Stud 4. Install drive unit shift cable. Tighten locknut until it contacts end guide, then loosen 1/2 turn. Insert cotter pin from the top and spread both ends.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS 5. Place adjustment tool over drive unit shift cable. Hold tool in place, using a piece of tape over the barrel retainer. 23242 a. Shift remote control to NEUTRAL. b. Push in on shift cable end with enough pressure to remove play, and mark position “a” on tube. c. Pull out on shift cable end with enough pressure to remove play, and mark position “b” on tube. d.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 6. Adjust remote control shift cable as follows: a. Temporarily install shift cable end guide into shift lever, and insert anchor pin. b. Adjust shift cable barrel so that hole in barrel centers with vertical centerline of stud. Ensure that backlash center mark is aligned with edge of control cable end guide.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS 8. Remove adjustment tool. 9. Shift remote control lever into full forward position. Place end of adjustment tool in barrel retainer. Rh Rotation - All Bravo One, Two, And Three Models: Rear slot in tool should fit over shift lever stud. Lh Rotation - All Bravo One And Two Models: Forward slot in tool should fit over shift lever stud. If slot does not fit over stud, loosen shift lever stud and slide stud either direction, until slot in tool fits over stud.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 Troubleshooting Shift Problems NOTE: The following information is provide to assist an installer in troubleshooting, if hard shifting or chucking/racheting is encountered when shifting into forward gear. 1. When installing the control box in the side panel of the boat, ensure that the cables have enough clearance to operate. This is necessary because the cables move up and down when the shift handle is moved.
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SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) MODELS 3. Before installing the shift cable into the control box, extend the stainless rod eye end of the cable and grease it with 2-4-C Marine Lubricant with Teflon. Move it back and forth to allow even distribution of the grease. 22005 4. Do not strap or clamp the control cables to any other cables or rigid structure within 9 m (3 ft) of the control box. 5. Ensure that the cable is not permanently kinked. 6.
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STERNDRIVE (MCM) MODELS SERVICE MANUAL NUMBER 22 Battery Cables 1. Connect battery cables to engine: a. Make sure that grounding stud and starter solenoid terminal are free of paint and any other material that could cause a poor electrical connection. b. After battery cables are connected, apply a thin coat of Liquid Neoprene to the terminals. c. Be sure to slide rubber boot over the positive (+) terminal after Liquid Neoprene dries. 2.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 REMOVAL AND INSTALLATION Section 2B - Inboard (MIE) Models Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . Tools/Lubricants/Adhesives . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Installation and Initial Alignment . . . . . . . . . . . . . . . . . . . . . . .
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 NOTICE For information and procedures on Troubleshooting, refer to SECTION 1C.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 Removal Engine Removal CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant. 3. Disconnect battery cables from battery. 4. Disconnect battery cables from engine. 5. Disconnect extension harness connector plug from engine harness connector.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 8. Disconnect throttle cable from engine. 9. Disconnect shift cable from transmission. 10. Close seacock if equipped, or disconnect and plug seawater inlet hose, if boat is to remain in the water. CAUTION Before removing seawater inlet hose, close seacock, if equipped. If boat is not equipped with a seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses. 11.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 CAUTION Do NOT allow lifting sling to hook or compress engine components or damage will occur. 16. Support engine with suitable sling through lifting eyes on engine. c c b a 71706 75298 Typical e-Front Lifting Eye f-Rear Lifting Eye g-Suitable Sling 17. Remove front and rear engine mounting bolts. Retain fasteners. a b a 23161 b 75301 Typical Front Mounts Shown (All Similar) a-Starboard Mounting Bolt b-Port Mounting Bolt 18.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 Installation Engine Installation and Initial Alignment 1. Engine mount or mount adjustment WAS NOT DISTURBED during engine service: Proceed to following Step 3. 2. Engine mount or mount adjustment WAS DISTURBED during engine service: IMPORTANT: Engine mounts must be adjusted, as explained in the following, to center mount adjustment and establish a uniform height on all mounts. Ensure that: a. All mounts are in the center of their up-and-down adjustment. b.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 d. Ensure rear engine mount rubber bushings are positioned so that slots in bushing are positioned horizontally. If necessary, loosen center bolt and turn bushing. Torque to 41-61 Nm (30-45 lb-ft). b c a 50688 a-Rubber Bushing b-Slots c-Bolt 3. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended. Refer to Removal for location of engine lifting eyes.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 MODELS WITH 8° DOWN ANGLE TRANSMISSIONS 1. Lift engine into boat and position on engine bed so that transmission output flange and propeller shaft coupler are visibly aligned (no gap can be seen between coupling faces when butted together). Adjust engine bed height if necessary to obtain proper alignment. Do NOT use mount adjustments to adjust engine position at this time. IMPORTANT: Engine bed must position engine so that a minimum of 6 mm (1/4 in.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 MODELS WITH V-DRIVE TRANSMISSIONS 1. Lift engine into boat and position so that enough propeller shaft protrudes through transmission and output flange for propeller shaft coupler to be attached. Then install coupler and position engine (no gap can be seen between coupling faces when butted together). Adjust engine bed height if necessary to obtain proper alignment. Do NOT use mount adjustments to adjust engine position at this time.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 Engine Final Alignment CAUTION To avoid vibration, noise and damage to transmission output shaft oil seal and bearings, engine must be properly aligned. IMPORTANT: Engine alignment MUST BE RECHECKED with boat in the water, fuel tanks filled and with a normal load on board. Engine must be aligned so that transmission output flange and propeller shaft coupler centerlines are aligned and coupling faces are parallel within 0.07 mm (0.003 in.).
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 3. Ensure that coupling centerlines align, by butting propeller shaft coupler against transmission output flange. Shoulder on propeller shaft coupler should engage recess on transmission output flange face with no resistance. INCORRECT CORRECT 72597 INCORRECT NOTE: Some propeller shaft couplers may not have a shoulder on mating face. On these installations, use a straight edge to check centerline alignment.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 4. Check for angular misalignment, by hand holding coupling faces tightly together and checking for a gap between coupling faces with a 0.07 mm (0.003 in.) feeler gauge at 90 degree intervals. b a c a c b d d 50688 Typical Down Angle Transmission (All Similar) 50608 Typical V-Drive a-Propeller Shaft Coupler b-Feeler Gauge c-Transmission Output Flange d-Check Point Intervals 5.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 b. TO MOVE ENGINE TO THE LEFT OR RIGHT: Loosen clamping screw and nut on all four mount brackets; move engine to the left or right as necessary to obtain proper alignment. Torque clamping screws and nuts to 68 Nm (50 lb-ft). NOTE: A small amount of side-to-side adjustment can also be obtained from the slots on the engine mount pad (front pads only). Loosen lag bolts (which fasten mounts to engine bed) and move engine, as required. Tighten lag bolts securely.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 c. After engine has been properly aligned, relieve hoist tension entirely. Secure mounts to stringers using appropriate hardware. On port front mount do as follows: (1.) Position ECM assembly mounting bracket holes directly over front, port engine mount holes. NOTE: It may be necessary to lower, or raise, the ECM assembly and bracket, depending upon the final configuration of the power package, to position ECM on front mount. (2.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 6. Connect propeller shaft coupler to transmission output flange following instructions a. or b.: IMPORTANT: All coupler bolts must be Metric Grade 10.9 (SAE Grade 8) or better, with a shoulder (grip length) sufficient to pass through the mating face plane of couplers. a. All Couplings Without Propeller Shaft Set Screws: Secure coupling together with bolts, lockwashers and nuts. Torque to 68 Nm (50 lb-ft).
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 b. Couplings with Propeller Shaft Set Screws: (1.) If propeller shaft coupler has set screws, remove set screws and mark (dimple) locations using a transfer punch. b a 50609 Hurth V-Drive Shown (All Similar) a-Set Screw Location b-Transfer Punch (2.) Remove propeller shaft coupler and drill shallow dimples at locations marked with punch. (3.) Reinstall propeller shaft coupler and torque bolts to 68 Nm (50 lb-ft). Install set screws and tighten securely.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 Engine Connections CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant. IMPORTANT: When routing all wire harnesses and hoses, ensure they are routed and secured to avoid coming in contact with hot spots on engine and avoid contact with moving parts. 1. Connect instrument extension harness ends to engine harness ends.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 WARNING Be careful when working on fuel system components; diesel fuel is flammable. Ensure that the ignition key is OFF. Do NOT smoke or allow sources of open flame in the area while changing fuel system components. Wipe up any spilled fuel immediately. Do NOT allow fuel to come into contact with any hot surface which may cause it to ignite. 3. Connect flexible fuel line to inlet fitting on fuel pump. Secure with hose clamp.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 5. After all wires are connected secure them with clamps or tie straps, which may have been retaining them to engine or hoses prior to removal. 6. Connect exhaust elbow, riser or water lift muffler, if equipped, to exhaust system hose using at least two hose clamps at each connection. Tighten hose clamps securely. 7. Connect seawater inlet hose to seawater pump connector fitting. Tighten hose clamp securely.
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INBOARD (MIE) MODELS SERVICE MANUAL NUMBER 22 9. Connect coolant recovery bottle hose to heat exchanger and secure with clamp. b a 70548 a-Hose b-Clamp Throttle Cable Installation and Adjustment Refer to SECTION 2A. Shift Cable Installation And Adjustment Refer to SECTION 8A. Battery Cables 1. Connect battery cables to engine: a. Make sure that grounding stud and starter solenoid terminal are free of paint and any other material that could cause a poor electrical connection. b.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 ENGINE Section 3A - Engine Mechanical Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Torque Specifications . . . . . . . . . . . . . . . . . . 3A-4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Special Tools (continued) . . . . . . . . . . . . 3A-7 Snap-On Tools . . . . . . . . . . . . . . . . . . . . . 3A-8 Kent-Moore Tools .
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Table of Contents (continued) Adapter / Oil Thermostat . . . . . . . . . . . . . . 3A-91 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3A-91 Disassembly . . . . . . . . . . . . . . . . . . . . . . 3A-92 Cleaning and Inspection . . . . . . . . . . . . 3A-92 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-92 Installation . . . . . . . . . . . . . . . . . . . . . . . . 3A-93 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Identification b a 7332 75388 3 SERIAL NUMBER MAX RPM H P L B 75298 K W K G MARINE POWER EUROPE INC MADE IN ITALY Typical Sterndrive (MCM) Engine Shown - Inboard (MIE) Similar a - Serial Number Plate b - Manufacturer’s Serial Number The engine model and serial numbers are located on a sticker attached to the port side of the engine. The manufacturer’s serial number is stamped in the cylinder block.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Torque Specifications Description Nm Alternator Bracket Bolt M12x1.75 Alternator Brace To Timing Cover lb-in. lb-ft 68.6 50 45-50 34-37 Camshaft Flange Mounting Screw M8x1.25 27.5 20 Connecting Rod Bolt M11x1 29.4 + 60 21 + 60 degrees degrees 196.2 144 Crankshaft Pulley Nut 3 M24x1.5 Cylinder Head Bolts 14mm Dia. 2 See 1. 12mm Dia. 2 Engine Mount M10x1.5 68.6 50 To Block M10x1.5 50 37 Rear Main Bearing Carrier Nut M8x1.25 27.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Torque Specifications (Continued) Description Main Bearing Carrier Halves Bolt 1 Nm lb-in. lb-ft M10x1.5 44.1 32 Main Bearing Carrier Locating Hollow Bolt M14x1.5 53.9 39 Inboard (MIE) Drive Plate 72 53 Sterndrive MCM Coupler 30 22 57 Oil Drain Plug M22x1.25 78.5 Oil Pan Screws M6x1.0 12.7 Oil Pressure Relief Valve Assembly Oil Pump Screw M8x1.25 112 53.9 39 27.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Tools Special Tools Description Part Number Compression Tester Adaptor 91-881737 Crankshaft Pulley Puller 91-801333507 Crankshaft Gear Puller 91-801333503 Crankshaft Installer 91-801333504 Crankshaft Tool (Rotating) 91-814827 Cylinder Head Guide Pin 91-801333501 Cylinder Liner Puller 91-801333502 Dial Indicator 91-58222A1 Flywheel Holder 91-801333506 Flywheel Seal Installer 91-801111260 Front Main Bearing and Camshaft Bearing Puller 91-8013
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Special Tools (continued) Description Part Number Cylinder Head Service Tool Kit (For Special Cylinder Head Bolts) 5 806563A1 5 : Refer to the following special information about modification of this tool. NOTE: The 12 mm Triple Square special tool for cylinder head torque can be modified to allow the oil feed line to the rocker arms to remain installed during retorque of the cylinder heads.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Snap-On Tools Snap-On Tools 2801 80th Street Kenosha, WI 53141 See Snap-On Catalog for your regions distributor phone number. Description Part Number Compression Gauge MT33B Torque Angle Gauge (Degree Wheel Torquing) TA360 Kent-Moore Tools Kent-Moore Tools, Inc.
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SERVICE MANUAL NUMBER 22 ENGINE MECHANICAL Lubricants/Sealants/Adhesives Description Part Number Loctite Master Gasket 92-12564-2 Loctite 271 Thread Locker 92-809819 Needle Bearing Assembly Lubricant 92-802868A1 Loctite 242 Loctite 620 Molykote Obtain Locally SAE 30W Engine Oil Loctite 290 90-860074--1 FEBRUARY 2002 Page 3A-9
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Specifications IMPORTANT: Specifications are for all models, unless otherwise listed. NOTICE UNIT OF MEASUREMENT: mm (in.) Piston Rings Description Groove Width Ring Thickness End Gap Ring to Groove Clearance Measurement 1st Compression (Tapered) 3.0 (.1181) 2nd Compression 2.06 - 2.08 (.0811 - .0818) Oil Control 4.03 - 4.05 (.1586 - .1594) 1st Compression (Tapered) 3.0 (.1181) 2nd Compression 1.978 - 1.99 (.0779 - .0783) Oil Control 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Specifications (continued) NOTICE UNIT OF MEASUREMENT: mm (in.) Cylinder Liner Protrusion Liner Recess BELOW Block (Without Shim) Shim to Be Used (Thickness) 0.14 - 0.09 (.0055 - .0035) 0.15 (.0059) 0.19 - 0.14 (.0074 - .0055) 0.20 (.0078) 0.22 - 0.17 (.0086 - .0066) 0.23 (.0090) Liner Protrusion ABOVE Block (With Shim) 0.01 - 0.06 (.0004 - .
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Specifications (continued) NOTICE UNIT OF MEASUREMENT: mm (in.) Oil Pump Description Measurement External Rotor End Float and Internal Rotor End Float External Rotor Clearance to Housing Clearance Between Pump Support and Gear (Axial) 0.030 - 0.087 (.0011 - .0034) 0.13 - 0.23 (.005 - .009) .0059 - .0098 (0.15 - 0.25) Camshaft Description Lobe Lift Journal Diameter Bearing Clearances Measurement Exhaust 7.303 (.287) Intake 7.019 ( .
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Specifications (continued) NOTICE UNIT OF MEASUREMENT: mm (in.) Rocker Arm Description Measurement Journal Diameter 24.97 - 25.00 (.983 - .984) Bushing lnner Diameter 25.021 - 25.020 (.985 - .985) Maximum Clearance 0.062 (.002) Valve Adjustment Valve Clearance Exhaust Intake Hydraulically Controlled Valve Valve Exhaust Intake Head Diameter 38 (1.49) 40.9 (1.61) Stem Diameter 7.93 (.3122) 7.95 (.3129) Face Width Margin (New) 2.64 - 2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Specifications (continued) NOTICE UNIT OF MEASUREMENT: mm (in.) Valve Guide Valve Guide Maximum Clearance Height Above Spring Counterbore Exhaust Intake 0.093 ( .0036 ) 0.073 ( .0028 ) 7.921 - 7.939 (.311 - .312) 7.940 - 7.960 (.312 - .313) Valve Spring Page 3A-14 Valve Spring Height Pressure Free Standing 44.65 (1.757) 0.0 kg (0 lb) Valve Closed 38.60 (1.460) 32 - 36 kg (71 - 79 lb) Valve Open 28.20 (1.110) 92.5 - 96.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Specifications (continued) NOTICE UNIT OF MEASUREMENT: mm (in.) Crankshaft D2.8L D-TRONIC - SERIAL NUMBER 0L098203 AND BELOW, AND D4.2 L D-TRONIC - SERIAL NUMBER 0L099524 AND BELOW Measurement Description Main Journal Outside Diameter Main Bearing Clearance Main Bearing Inside Diameter Front 62.985 - 63.005 (2.4797 - 2.4805) Center 63.005 - 63.020 (2.4805 - 2.4810) Rear 69.985 - 70.000 (2.7553 - 2.7559) Front 0.055 - 0.095 (.0022 - .
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Specifications (continued) NOTICE UNIT OF MEASUREMENT: mm (in.) Crankshaft (continued) D2.8L D-TRONIC - SERIAL NUMBER 0L098204 AND ABOVE, AND D4.2 L D-TRONIC - SERIAL NUMBER 0L099525 AND ABOVE IMPORTANT: The engines included in this serial number range had dimensional changes to the crankshaft, rear main bearing, rear main bearing carrier, thrust washers, O-ring seal, flywheel thrust spacer and flywheel seal.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Specifications (continued) NOTICE UNIT OF MEASUREMENT: mm (in.) Connecting Rods Description Measurement Weight 1 1250 grams (44.09 ounces) 1 : All service connecting rods are median weight and class. Connecting Rod Crank Pin Bore Description Measurement Inner Diameter 57.563 - 57.582 (2.2662 - 2.2670) Maximum Allowable Wear or Taper 0.02 (.0008) Connecting Rod Bushings Description Measurement Piston Pin Outer Diameter 29.990 - 29.996 (1.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Precautions WARNING Always wear safety glasses when using compressed air. WARNING Some tests in this SECTION involve the use of electricity and intense heat. Failure to follow appropriate procedures or warnings can cause burns or shock which can result in severe personal injury or death.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 General Information Some repairs, that are listed in this section, must be completed with engine removed from boat. Engine removal depends upon type of repair and boat design. Place engine on repair stand for major repairs. NOTE: This section contains disassembly and assembly procedures of the cylinder block and cylinder heads only. Refer to other sections for disassembly and assembly of various other components.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Late Model Cylinder Head Gasket - Torque Sequence and Specifications IMPORTANT: Cylinder head bolts may be installed as many as three times, and then must be replaced. Replace bolts if any doubt exists. IMPORTANT: Observe the following assembly notes: • Lubricate the underside of all 14 mm center bolt heads and threads with Molykote. • Lubricate the underside of all 12 mm side bolt heads and threads with clean engine oil (SAE 30 W).
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 TORQUE PROCEDURE DURING ASSEMBLY 3. Torque the center bolt set as indicated. a. First pass: Engine Sequence Torque D2.8L Center Bolts 3-2-1-4-5-8-9-10-7-6 30 Nm (22 lb-ft) D4.2L Center Bolts 11-12-13-14-10-9-8-4-3-2-1-5-6-7 30 Nm (22 lb-ft) Engine Sequence Torque Angle D2.8L Center Bolts 3-2-1-4-5-8-9-10-7-6 + 65 Degrees D4.2L Center Bolts 11-12-13-14-10-9-8-4-3-2-1-5-6-7 + 65 Degrees Engine Sequence Torque Angle D2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 4. Torque the side bolt set as indicated. a. First pass: Engine Sequence Torque D2.8L Side Bolts 11-12-13-14-15-16-17-18 30 Nm (22 lb-ft) D4.2L Side Bolts 15-16-17-18-19-20-21-22-23-24-25-26 30 Nm (22 lb-ft) Engine Sequence Torque Angle D2.8L Side Bolts 11-12-13-14-15-16-17-18 + 85 Degrees D4.2L Side Bolts 15-16-17-18-19-20-21-22-23-24-25-26 + 85 Degrees b.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 TORQUE PROCEDURE AFTER 20-30 MINUTE BREAK-IN CAUTION Avoid component or engine failure. Cylinder heads require additional angular torque and conventional torque application after the first 20-30 minute break-in. 1. Operate the engine at idle until water temperature reaches 70 degrees C (158 degrees F.). Then operate the engine at 2000 rpm for approximately 20-30 minutes at normal operating temperature. 2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 4. Without loosening, torque each side bolt as indicated. Engine Sequence Torque D2.8L Side Bolts 11-12-13-14-15-16-17-18 90 Nm (66 lb-ft) D4.2L Side Bolts 15-16-17-18-19-20-21-22-23-24-25-26 90 Nm (66 lb-ft) 15 a 11 16 12 17 13 18 14 77114 b 21 22 23 24 15 16 17 18 25 19 26 20 77113 Side Bolt Torque Sequence Diagram a - D2.8L D-Tronic Engine b - D4.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Early Model Cylinder Head Gasket - Torque Sequence and Specifications IMPORTANT: Cylinder head bolts may be installed as many as three times, and then must be replaced. Replace if any doubt exists. IMPORTANT: Observe the following assembly notes: • Lubricate the underside of all 14 mm (center) bolt heads and threads with Molykote. Lubricate the underside of all 12 mm (side) bolt heads and threads with clean SAE 30 W engine oil.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 TORQUE PROCEDURE AFTER 20-30 MINUTE BREAK-IN CAUTION Avoid component or engine failure. Cylinder heads require additional angular torque and conventional torque application after the first 20-30 minute break-in and then, after the first 100 hours or first operating season whichever occurs first. 1. Operate the engine at idle until water temperature reaches 70 degrees C (158 degrees F.).
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 TORQUE PROCEDURE AFTER 100 HOURS OF OPERATION, OR FIRST OPERATING SEASON, WHICHEVER OCCURS FIRST CAUTION Avoid component or engine failure. Cylinder heads require additional angular torque and conventional torque application after the first 100 hours or first operating season, whichever occurs first. IMPORTANT: Engine must be have been operated 100 hours or for one operating season, whichever occurs first. 1.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Lubrication System - All Models 7 6 4 8 9 5 3 10 2 11 1 73721 D4.2L D-Tronic Flow Diagram Shown (D2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Examples of Bearing Failures b a Scratched By Dirt a b c d c Lack Of Oil d 70436 Improper Seating - Scratches - Dirt Imbedded Into Bearing Material - Overlay Wiped Out - Bright (Polished) Sections b a c 70436 Tapered Journal Radius Ride Fatigue Failure a - Overlay Gone From Entire Surface b - Radius Ride c - Craters Or Pockets 90-860074--1 FEBRUARY 2002 Page 3A-29
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Compression Testing Procedure Periodically check engine compression pressure. Lowering of pressure causes loss of power, greater fuel consumption, smoke at the exhaust, low acceleration, unsteady slow idle, difficulty in starting and bearing seizure because of engine overheating. 1. Refer to SECTION 5C - Fuel Injectors, and while observing precautions listed, remove all fuel injectors.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Cover Removal 1. Remove the four cover retaining screws and hardware. 2. Remove oil filler cap to allow cover to be removed. 3. Lift cover from engine. 4. To protect engine, temporarily install oil filler cap during service work. c a b 75504 a - Engine Cover b - Retaining Screw and Hardware c - Oil Fill Cap Cleaning 1. Clean the cover with warm soapy water. 2. Air dry the cover. Inspection 1. Inspect engine cover for cracks or deterioration. 2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Valve Covers Removal 1. Remove engine cover. 2. Remove vent hose. 3. Remove oil fill cap extension tube and sealing washer. 4. Remove engine cover support bar. 5. Remove electrical box support bracket. c d a e b 75374 Typical a - Valve Cover b - Vent Hose c - Oil Fill Cap Extension Tube and Sealing Washer d - Engine Cover Support Bar e - Electrical Box Support Bracket 6. Remove fuel injectors as follows: a. Clean the area around the injectors and pipes. b.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 e. Withdraw the injectors. c d b a 75336 Typical a - Supply Pipes b - Return Pipe c - Clamp d - Injector 7. Remove the screws retaining the valve cover to the cylinder head. NOTE: The two screws holding the electrical box support bracket to the valve cover are 8 mm (approx. 5/16 in.) longer than the other screws. Do NOT mix fasteners. IMPORTANT: On 6 cylinder engines remove both covers at the same time. 8.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation 1. Follow instructions a. or b.: NOTE: A small amount of Loctite Master Gasket can be used to hold gaskets on valve covers. a. On D2.8L D-Tronic Engines: (1.) Install valve cover gaskets. (2.) Install valve covers on cylinder heads. (3.) Position the two longer screws through the electrical support bracket and spacers. Install as shown. (4.) Install remaining screws (5.) Torque valve cover screws evenly in a diagonal pattern to 11.5 Nm (101 lb-in.).
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 b. On D4.2L D-Tronic Engines: (1.) Install 2 new O-rings on connector before pushing valve covers together. Push covers together. (2.) Install valve cover gaskets. (3.) Position the two longer screws through the electrical support bracket and spacers. Install as shown. Install remaining screws Torque screws evenly in a diagonal pattern to 11.5 Nm (101 lb-in.). (4.) Install plastic plugs into cylinder head screw holes. (5.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 3. Install engine cover support bar. Torque screws to 27.5 Nm (20 lb-ft). c a b 75374 Typical a - Vent Hose b - Clamp c - Engine Cover Support Bar 4. Install engine cover and oil fill cap.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Water Manifold Exploded Views f a e b c b d i g h c 75440 D2.8L D-Tronic f a b e b d h e d i c g c 75108 D4.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Removal 1. Drain engine coolant. 2. Loosen hose clamp at rear of water manifold. 3. Remove banjo bolts, pipes and vent hoses. 4. Remove retaining screws and washers. b c b d e a f e 75108 Typical a - Hose Clamp b - Banjo Bolt And Sealing Washers c - Vent Hose d - Vent Pipe e - Screws With Washers f - Water Manifold Assembly 5. Using a rubber mallet, tap against side of manifold to loosen.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation 1. Use a new gasket and install end cover on manifold pieces. Torque screws with washers to 11.8 Nm (104 lb-in.). 2. Align manifold pieces with a straight edge device and torque screws to 11.8 Nm (104 lb-in.). IMPORTANT: When replacing the gasket between manifold pieces, align flanges using a straight edge as shown. b a b d b c 75108 70660 Typical a - Typical End Cover b - Gasket c - Straight Edge Device d - Bolts (4, Two Not Shown) 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Cylinder Heads Exploded Views CYLINDER HEAD AND RELATED COMPONENTS 20 19 1 A 2 18 3 4 17 5 16 6 7 15 8 9 14 31 8 30 10 13 11 12 75103 22 B 75101 23 A 24 27 25 B A 26 21 28 27 Page 3A-40 29 75102 90-860074--1 FEBRUARY 2002
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SERVICE MANUAL NUMBER 22 ENGINE MECHANICAL CYLINDER HEAD AND RELATED COMPONENTS (CONTINUED) 1 - Rocker Pedestal Nut 2 - Valve Cone (Keeper 2) 3 - Spring Retainer 4 - Valve Spring 5 - Plate Washer 6 - Valve Guide (Standard, or 0.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Removal IMPORTANT: Mark the location of each rocker arm assembly and cylinder head to ensure that they are reassembled in the same location. 1. Mark the position of the rocker arm assemblies and cylinder heads for reassembly. 2. Remove rocker arm oil feed line banjo bolts with sealing washers. Remove line from cylinder heads and from rear (starboard) of cylinder block. b a 75103 b a - Oil Feed Pipe b - Banjo Bolts With Sealing Washers 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 5. Withdraw the valve push rods. Store them so as to place them back in their original locations upon reassembly. 6. Remove the water manifold. 7. Remove the intake / exhaust manifold. IMPORTANT: To avoid distorting cylinder heads, remove heads only when engine is cold. 8. Take note of shape and location of formed spacer washers. Starting at one end of the engine, remove head bolts. a a 75515 D4.2L D-Tronic D2.8L D-Tronic a - Formed Spacer Washers 9.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Disassembly 1. Using valve spring compressor, carefully remove keepers, retainers, springs and spring plates. Place valves in numbered rack according to their position in the engine or label the parts in order for reassembly to the original location. a b 77175 70272 a - Typical Valve Spring Compressor b - Valve Spring and Related Components Cleaning 1. Clean carbon from valves. 2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Inspection GENERAL 1. Inspect expansion plugs for leakage or damage. 2. Inspect glow plug seats for damage. 1. Inspect injector seats for damage. 2. Inspect all gasket surfaces for deep grooves or pitting. 3. Inspect valve seats for cracks, excessive wear and looseness in counterbore. 4. Inspect valves for cracks, excessive wear or bent stems. 5. Inspect valve springs for discoloration due to excessive heat. 6. Inspect valve guides for cracks or chips. 7.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 VALVE GUIDES 1. Remove valve stem seals. 2. Insert new valve into guide. 3. Measure valve stem clearance as follows: a. Attach a dial indicator to cylinder head. Position it against the valve stem and close to the valve guide. b. While holding the valve head off of the seat by about 2 mm (1/16 in.), move valve stem back and forth in directions shown. Compare stem clearance with specifications. 70435 Valve Guide Maximum Clearance b Exhaust Intake 0.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 VALVE SEATS 1. Measure exhaust and intake valve seats. Refer to valve seat specifications. 2. If measured values are not as specified repair or replace the valve seats. d a g e b f c 50351 Exhaust Valve Seat Specifications a - Valve Recession (Max.): 0.03 mm (.001 in.) b - Head Surface to Seat: 2.05 -2.25 mm (.080 - .088 in.) c - Counterbore Inner Diameter: (Measurement Not Available At Time Of Printing) d - Seat Outer Diameter: 39 mm (1.53 in.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 VALVES a e b d c 41 mm Intake Valve a b c d e f g h Page 3A-48 h f g 38 mm Exhaust Valve - Stem O. D. Measurement: 7.95 mm(.3129 in.) - Face Width Measurement: 3.57 - 3.85 mm (.1405 - .1515 in.) - Margin (After Grinding) Measurement: 1.82 mm (.071 in.) - Face Angle : 29 Degrees and 30 Minutes - Stem O. D. Measurement: 7.93 mm (.3122 in.) - Face Width Measurement: 2.64 - 2.99 mm (.1039 - .1177 in.) - Margin (After Grinding) Measurement: 1.30 mm (.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 VALVE SPRINGS 1. Use a vernier caliper to measure the valve spring free height. Replace spring if less than specified limit. 2. Measure the springs distortion. If the measured value exceeds the specified limit, the valve spring must be replaced. b a b a - Free Standing Height Measurement: 44.65 mm (1.757 in.) b - Distortion Measurement: Maximum 2 mm (.079 [5/64] in.) 3. Use a spring tester to measure the valve spring height under tension.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Repair Expansion Plugs 1. Apply Loctite 290 to outer diameter of expansion plugs. 2. Install plugs flush to outer surface of cylinder head. a a 75101 a - Expansion Plugs VALVE SEAT RECONDITIONING Several different types of equipment are available for reconditioning valve seats. Equipment manufacturer’s recommendations should be followed carefully to attain proper results.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 VALVE GUIDE REPLACEMENT 1. Remove valve stem seals. 2. Heat head in oven to 85 degrees C (185 degrees F). Using a suitable drift, drive out old guide from underside of head. CAUTION To avoid distortion or melting of aluminum heads, Do NOT use a torch to replace valve guides. 3. With head temperature at 85 degrees C (185 degrees F), press new guide in to obtain measurement as shown. a c b a - Spring Seat Counterbore b - Intake Guide Height Measurement: 7.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Assembly VALVES NOTE: Valve stem seals are used on intake and exhaust valves. 1. Lubricate valve guides and valve stems with clean SAE 30W engine oil. 2. Install each valve in the port from which it was removed or to which it was fitted. 3. Install valve guide seals over valve stem and push down on the seal until seated securely around top of guide.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 CYLINDER HEAD STUDS IMPORTANT: All long cylinder head studs are not the same length. Some studs are longer than others and are used for attaching accessories. These studs must be in the correct location before exhaust manifold is installed. When replacing cylinder heads, remove studs and install in new head in same location. a 70273 a - Long Cylinder Head Studs (Lengths Vary) CAUTION Head gasket thickness is very important on diesel engines.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 DETERMINING HEAD GASKET THICKNESS 1. Use dial indicator 91-58222A1 and liner gauge bar 91-801333509 to measure piston height above the cylinder block with piston at Top Dead Center. 2. Place liner gauge bar with dial indicator attached, across liner as shown (parallel to cylinder centerline). b a c 70277 a - Liner Gauge Bar b - Dial Indicator c - Liner 3. Set dial indicator to zero at point shown on cylinder block. a 75524 a - Dial Indicator Zero Point 4.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation - Using Early Model Gaskets HEAD GASKET IDENTIFICATION NOTE: All engines with early model gaskets (head gasket fits a single-cylinder) use the same type of cylinder head gaskets in one of three thickness as previously determined and shown following. The 1.52 mm (.060 in.) gasket has two notches while the 1.62 mm (.064 in.) gasket has one notch where indicated. The 1.42 mm (.056 in.) gasket is plain, without notches. a b c 75516 a - 1.62 mm (.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 2. Prepare hardware following instructions a. - d.: IMPORTANT: Cylinder head bolts may be installed as many as three times, and then must be replaced with new bolts. Replace if any doubt exists. a. Thoroughly clean all cylinder head bolts and washers, including all formed spacer-washers (terminal bridges, three types) and cylinder head spacers (for ends of first and last cylinder heads). b.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 IMPORTANT: There is limited space between the cylinder heads after installation. IF all heads were removed, start installation with cylinder number 1 and proceed in numerical order. Ensure that when placed on cylinder block each head and corresponding gasket are properly positioned.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 6. ONE AT A TIME, remove Guide Pins and install oiled 12 mm cylinder head bolts with washers HAND tight. Do NOT disturb head placement. 7. Repeat Steps 5. and 6., for each cylinder head and corresponding cylinder, proceeding in numerical order from cylinder number 1. 8.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 9. Lightly HAND tighten bolts in torque sequence. 21 22 23 24 25 1 13 3 11 5 14 2 12 4 10 6 7 8 19 20 15 16 17 18 a 9 26 15 1 16 17 3 9 18 7 5 10 2 4 11 8 12 13 6 14 b 75515 Torque Sequence Diagrams a - D4.2L D-Tronic b - D2.8L D-Tronic 10. Temporarily install intake / exhaust manifold without gaskets and FINGER-tighten each nut with locking washer. 11.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 14. Following the same sequence tighten each 14 mm bolt through an angle of 70 degrees using a Torque Angle Gauge. 15. In sequence tighten PORT and STARBOARD 12mm cylinder head bolts to 30 Nm (22 lb-ft). 16. In sequence tighten only the STARBOARD 12mm cylinder head bolts through an angle of 85 ± 5 degrees using a Torque Angle Gauge. 17. In sequence tighten only the PORT 12mm cylinder head bolts through an angle of 85 ± 5 degrees using a Torque Angle Gauge.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 24. AFTER COMPLETE ENGINE ASSEMBLY AND INSTALLATION, follow these additional cylinder head angular torque instructions: a. Operate engine at idle until water temperature reaches 70° C (158° F) and then operate engine at 2000 rpm for approximately 20-30 minutes at operating temperatures. Let the engine cool down completely (inoperative overnight, if possible). b. Remove valve covers. c. Retorque the cylinder head bolts, as follows: (1.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation - Using Late Model Gaskets NOTE: Early model D2.8L D-Tronic and D4.2L D-Tronic diesel engines can be retrofitted with late model cylinder head gaskets if the cylinder head spacers (for ends of first and last cylinder heads) are replaced with new size spacers.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 INSTALLATION 1. Before installing the cylinder heads, follow instructions “a” - “c”: a. Clean out bolt holes in cylinder block. Be certain no contaminants (dirt, old oil or coolant) remain in holes. b. Clean gasket surfaces on block and heads. c. Oil the cylinder bores with Quicksilver 4 cycle engine oil. 2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 4. Using a screwdriver install two Cylinder Head Guide Pins (91-801333501) into 12 mm bolt holes in cylinder block at cylinder number 1 location. 5. On D2.8L D-Tronic Engines: Using a screwdriver install two Cylinder Head Guide Pins into 12 mm bolt holes in gasket and cylinder block at cylinder number 4 location. These pins will keep the gasket aligned. 6. On D4.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 13. Install all lubricated 14 mm cylinder head bolts, including the proper formed spacer-washers (terminal bridges, three types) and cylinder head spacers, for ends of first and last cylinder heads, as shown in the following. b a a a a b a a 75515 a - Spacer(s). First and Last Cylinder Head Ends b - Formed Spacer-Washers (Terminal Bridges, Three Types) 14. Lightly HAND tighten bolts in torque sequence.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 15. Temporarily install exhaust manifold without gaskets and FINGER-tighten each nut with locking washer. 16. Slightly loosen 12 mm and 14 mm bolts as needed, to allow cylinder heads to ALIGN as you HAND tighten exhaust manifold nuts. 17. HAND TIGHTEN all 14 mm and 12 mm cylinder head bolts in torque sequence.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 18. Torque the center bolt set as indicated. a. First pass: Engine Sequence Torque D2.8L Center Bolts 3-2-1-4-5-8-9-10-7-6 30 Nm (22 lb-ft) D4.2L Center Bolts 11-12-13-14-10-9-8-4-3-2-1-5-6-7 30 Nm (22 lb-ft) Engine Sequence Torque Angle D2.8L Center Bolts 3-2-1-4-5-8-9-10-7-6 + 65 Degrees D4.2L Center Bolts 11-12-13-14-10-9-8-4-3-2-1-5-6-7 + 65 Degrees Engine Sequence Torque Angle D2.8L Center Bolts 3-2-1-4-5-8-9-10-7-6 + 65 Degrees D4.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 19. Torque the side bolt set as indicated. a. First pass: Engine Sequence Torque D2.8L Side Bolts 11-12-13-14-15-16-17-18 30 Nm (22 lb-ft) D4.2L Side Bolts 15-16-17-18-19-20-21-22-23-24-25-26 30 Nm (22 lb-ft) Engine Sequence Torque Angle D2.8L Side Bolts 11-12-13-14-15-16-17-18 + 85 Degrees D4.2L Side Bolts 15-16-17-18-19-20-21-22-23-24-25-26 + 85 Degrees b.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 TORQUE PROCEDURE AFTER 20-30 MINUTE BREAK-IN CAUTION Avoid component or engine failure. Cylinder heads require additional angular torque and conventional torque application after the first 20-30 minute break-in. 1. Operate the engine at idle until water temperature reaches 70 degrees C (158 degrees F.). Then operate the engine at 2000 rpm for approximately 20-30 minutes at normal operating temperature. 2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 4. Without loosening, torque each side bolt as indicated. Engine Sequence Torque D2.8L Side Bolts 11-12-13-14-15-16-17-18 90 NM (66 lb-ft) D4.2L Side Bolts 15-16-17-18-19-20-21-22-23-24-25-26 90 NM (66 lb-ft) 15 16 17 18 a 11 12 13 77114 14 D2.8L D-Tronic Side Bolt Torque Sequence Diagram 21 22 23 24 25 26 a 15 16 17 18 19 20 77113 D4.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Rocker Arm Removal NOTE: When servicing the rocker arms of only one cylinder, bring that cylinder to TDC before removing rocker arms. When servicing all rocker arms, bring cylinder number 1 piston up to TDC before removing rocker arms. 1. Remove valve arm covers. IMPORTANT: Rocker arm assemblies and push rods must be reassembled in their original locations. 2. Remove rocker arm assemblies and push rods.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Assembly IMPORTANT: When installing rocker arms and valve push rods, coat bearing surfaces with engine oil. 1. Lubricate rocker arm bushings and support journals with SAE 30W engine oil. b a a 75349 a - Rocker Arm Bushings b - Rocker Arm Support Journals 2. Install rocker arms on support. Position as shown. a b 75101 a - Rocker Arms (Positioned Correctly) b - Rocker Arm Support 3. Install strap.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation ESTABLISHING TOP DEAD CENTER (TDC) NOTE: Screw plugs in glow plug holes or glow plugs, if equipped, may be removed to release compression when turning crankshaft. Rocker arm assemblies should be installed when each cylinder is at TDC to avoid damaging the valve train components. If the position of the crankshaft has moved since parts were removed, it may be necessary to establish TDC, if not already known, BEFORE installing the rocker arm assemblies.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 c. Continue to rotate engine CLOCKWISE until the notch on the pulley aligns with mark on timing gear cover. Cylinder number 1 piston is at Top Dead Center (TDC) on its compression stroke at this point. b a a 70281 75437 a - TDC Notch On Pulley b - Timing Cover Mark NOTE: Some modification to the graduated disc tool may be required for use on some models. 4. Attach graduated disc 91-801333500 to crankshaft pulley or tool.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 5. Using wire, make a pointer and attach it to a suitable location on engine. Align wire pointer to Zero (“0”) as shown. a 70664 a - Wire Pointer 6. Using crankshaft tool, turn crankshaft clockwise as needed (6 cylinder - 120 degrees or 4 cylinder - 180 degrees) to bring next cylinder in firing order up to TDC. Firing Order D2.8L D-Tronic 1-3-4-2 D4.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 3. Install rocker assembly onto studs. Simultaneously align valve push rods with rocker arm sockets. c a b 75401 Typical Cross-Section View a - Push Rod b - Lifter Socket c - Rocker Arm Socket 4. Install both flanged nuts on rocker arm support. Torque evenly to 34 Nm (25 lb-ft). IMPORTANT: No valve adjustment is required. Valve lash is automatically set when rocker arm nuts are torqued as specified. 5.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Timing Gear Cover Exploded View 4 5 1 2 A 3 6 7 11 12 9 10 13 B 14 8 15 73778 1 - Cover 2 - Gasket 3 - Pin (2) 4 - Cover 5 - Washer 6 - Screw (1) 7 - Washer (1) 8 - Screw (13) 9 - Seal (Apply Oil to Inner Lips of Seal Upon Installation) 10 - O-ring 11 - Crankshaft Pulley 12 - Vibration Damper 13 - Nut 14 - Screw (6) 15 - Lockwasher (6) Description A Loctite Master Gasket B Clean SAE 30W engine Oil 90-860074--1 FEBRUARY 2002 Part Number 92-12564-2
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Removal 1. If equipped, remove power steering pump and vacuum pump belt. 2. Remove alternator belt and upper alternator bracket screw, spacer and hardware from timing gear cover. CAUTION When removing seawater hoses or seawater pump, close seacock, if equipped. If boat is not equipped with a seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses and enter boat. 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation NOTE: While timing cover is removed renew O-ring if crankshaft and pulleys show signs of oil leakage from center. 1. Ensure that the crankshaft O-ring seal between timing gear and crankshaft pulley is still in place and in good condition. 2. Coat new timing gear cover gasket with Loctite Master Gasket. Install gasket on engine. 3. Install the timing cover as follows: a. Lightly lubricate the timing cover seal with clean SAE 30W engine oil. b.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 10. Remove flywheel holder tool. 11. Install seawater pump using a new O-ring seal. 12. Install alternator brace to timing cover, using the bolt, washer, spacer and nut removed during disassembly. Torque nut to 45-50 Nm (34-37 lb-ft). f d a c e b 75106 a b c d e f - Brace - Timing Cover - Screw - Washer - Spacer - Flange Nut 13. Tension the alternator belt, power steering belt, and vacuum pump belt, if equipped.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Oil Pump Removal 1. Remove the timing gear cover. 2. Remove the screws securing oil pump. a b 70292 a - Screws (3) b - Oil Pump 3. Remove the oil pump from bore in block. a 70287 a - Oil Pump Cleaning 1. Dismantle and wash all parts in cleaning solvent. 2. Put on safety glasses. 3. Dry parts with compressed air.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Inspection 1. Using appropriate gauging devices, measure the following: a. Clearance between rotors. Maximum: 0.152 mm (.006 in.). b. Clearance between housing and outer rotor: 0.105 - 0.106 mm (.00413 - .00417 in.). Maximum: 0.500 mm (.01968 in.). c. Diameter of rotor housing: 58.105 - 58.130 mm (2.287 - 2.288 in.).
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Reassembly 1. Install the bevelled end of the outer rotor towards the pump gear. 2. Ensure that the rotor and gear coupling resists a rolling torque of 9 kgm (32.4 oz.). Installation 1. Install oil pump in cylinder block. Torque screws to 27.5 Nm (20 lb-ft). a b 70292 a - Screws (3) b - Oil Pump 2. Install timing gear cover.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Oil Pressure Relief Valve The oil pressure relief valve (oil pressure regulator valve) is installed vertically in the underside of the crankcase. Removal 1. Remove oil pan. 2. Clean old gasket material from area around relief valve. 3. Unscrew the valve assembly seat/body from the crankcase using a suitable tool. The tool should engage the two slots opposite each other on the edge of the valve assembly.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Disassembly 1. Lock the pressure relief valve assembly in a soft-jawed vise. WARNING Use caution when removing or installing snap-ring. There is high spring pressure against cap. Wear safety glasses. 2. Put on safety glasses. 3. Push cap in and hold. Remove snap-ring. Release spring pressure slowly. a b c 70284 70285 a - Cap b - Snap-Ring c - Valve Assembly (Seat/Body) 4. Remove cap, spring or springs, and relief valve from bore of the valve assembly.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Inspection 1. Replace complete valve assembly if spring is broken. 2. Replace complete valve assembly if valve is badly worn or sticking in bore. 3. The valve can be lapped into its seat using a grinding paste, if necessary to restore pressure. 4. Ensure that valve slides freely in seat/body when coated with oil. Assembly 1. Coat inside of oil pressure relief valve seat/body bore with SAE 30W engine oil. Liberally oil coat remaining components. 2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation 1. Apply Loctite 242 to threads when replacing complete oil pressure relief valve assembly. Screw the complete assembly into the crankcase. b 70285 a 70298 a - Valve Assembly b - Apply Sealant to Threads 2. Using a suitable tool, torque relief valve assembly to 53.9 Nm (39 lb-ft). a c b 70298 Typical a - Example Of Suitable Tool b - Valve Assembly c - Slots 3. Install oil pan and related hardware.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Oil Pan and Oil Pick-Up Tube Assembly Removal 1. Disconnect oil drain tube from oil pan. Remove oil pan. 2. Remove screws retaining baffle, oil pick-up (suction) tube, and oil pick-up tube elbow to block. NOTE: This view is representative of all models. Your specific pick-up tube assembly may differ slightly in appearance. a b d c 70288 Typical a - Baffle b - Oil Pick-up Tube c - Elbow d - Inlet (Strainer End) 3. Remove old O-ring from suction tube.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Cleaning 1. Wash all parts in cleaning solvent and dry with compressed air. 2. Clean old gasket from cylinder block and oil pan flange. Inspection 1. Inspect the oil pan for fatigue cracks. 2. Check all welds for leaks. 3. Inspect oil pick-up assembly for fatigue cracks or damage. 4. Replace parts with those for your specific model. Installation 1. On Engines With Two Piece Suction Tube: a. Renew O-rings on oil pick-up tube and elbow.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 3. Install oil pick-up tube assembly, with baffle, on cylinder block. Torque screws to 11 Nm (97 lb-in.). 4. Using a new gasket, install oil pan and related hardware. Torque oil pan screws evenly, in a diagonal pattern, to 12.7 Nm (112 lb-in.).
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Adapter / Oil Thermostat Removal 1. Disconnect wire from oil temperature audio warning switch. 2. Using a suitable container to catch oil, completely loosen hose fittings retaining oil lines to adapter / oil thermostat. Make matching marks on hoses to assist in reassembly. 3. Completely loosen hex head screw fitting retaining adapter to cylinder block.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 6. Refer to appropriate procedures to continue engine disassembly if rebuilding, or proceed if only oil thermostat or adapter and related parts are being serviced. Disassembly 1. Remove hex head plug with sealing washer, O-ring, spring and thermostat from filter head. a b f a b c d e f c d e 75528 - Thermostat - Spring - O-ring Seal - Sealing Washer - Hex Head Plug - Adapter / Oil Thermostat Cleaning and Inspection 2. Clean parts in solvent. 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 2. Observe the preceding precautions and place thermostat in container of water. Water must cover thermostat. Suspend a thermometer in the water. Do NOT allow thermometer to touch the bottom of the pan. 3. Heat water and observe thermostat pin. 4. Pin must begin to extend (push up) as shown, when water temperature reaches 90 degrees C (195 degrees F.). At 100 degrees C (212 degrees F.) pin should be extended approximately 5-7 mm (3/16 - 5/16 in.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 3. Install large hex head fitting with new sealing washer through adapter. 4. Install a new O-ring in adapter groove where it seats on block. 5. Install adapter and torque the fitting to 44 lb-ft (60 Nm). 6. Observe markings made earlier and connect oil hoses to adaptor. Tighten fittings securely. 7. Connect audio warning wire ring terminal to switch. Tighten nut securely. Coat terminals with Quicksilver Liquid Neoprene.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Camshaft Exploded View 1 9 6 7 10 8 2 3 4 5 75105 Typical Camshaft and Related Components 1 - Bearings 2 - Camshaft 3 - Thrust Plate 4 - Injection Pump Drive Gear 5 - Crankshaft Drive Gear 6 - Idler Gear 7 - Camshaft Gear 8 - Mounting Screw 9 - Lockwasher 10 - Woodruff Key 90-860074--1 FEBRUARY 2002 Page 3A-95
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Testing - Measuring Lobe Lift 1. Remove all rocker arm assemblies. 2. Secure dial indicator 91-58222A1 to head so indicator plunger rests inside push rod cup. 3. Turn crankshaft so camshaft lobe is at the bottom of its travel and zero dial indicator. 4. Turn crankshaft two complete revolutions while reading dial indicator. Refer to specifications. 5. Measure all lobes of camshaft in the same manner.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 5. Remove the idler gear If complete engine disassembly is required, or if idler gear is worn or damaged. IMPORTANT: Mark retaining screws for reassembly in their original locations.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Inspection 1. Measure camshaft shaft run-out. 2. Measure lobe lift. If lobe lift is less than specified limit, the camshaft must be replaced. 3. Measure camshaft journal dimensions. 4. Inspect camshaft bearings. Replace as needed. Refer to Camshaft Bearings. 5. Inspect valve lifters and push rods. Replace if needed. IMPORTANT: Camshaft gear is a press-fit on shaft.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation 1. Install idler gear, if previously removed, so marks align with crankshaft gear as shown. Torque screws to 27 Nm (20 lb-ft). CAUTION Avoid possible severe engine damage. Installation of a screw longer than 16 mm (5/8 in.) will partially block oil gallery in cylinder block causing a lack of lubrication. Be certain retainer screw “c” as shown, is NOT longer than 16 mm (5/8 in.).
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 5. Align camshaft gear marks with idler gear marks as shown. Torque camshaft flange mounting screws to 27.5 Nm (20 lb-ft). c a b d 70289 a b c d - Camshaft Gear - Idler Gear - Marks Aligned Properly - Mounting Screws With Lockwashers 6. Complete the engine assembly. Camshaft Bearings Inspection With camshaft removed: 1. Visually inspect bearings. Renew if worn or damaged. 2. Measure inner diameter of bearings. Refer to specifications.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation 1. Clean camshaft bearing bores in cylinder block with solvent and blow out with compressed air. Ensure drilled oil passages are clean. 2. Lubricate outer surface of new camshaft bearings with engine oil to ease installation. CAUTION Avoid engine damage. Oil feed holes in bearings MUST align with drilled oil passages in cylinder block or severe engine damage will result. 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Valve Lifters CAUTION If the camshaft is replaced, the valve lifters (roller tappets) must also be replaced or serious component failure and engine damage could result. The hydraulically operated roller-tipped valve lifters are held in position and prevented from rotation by special retainers. There is one retainer for each head.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 6. Remove lifters, being certain to keep them in order. a d b 75383 c 75103 a b c d - Push Rod - Retainer - Lifter - Roller Cleaning 1. Wash all parts in cleaning solvent. 2. Dry with compressed air. Inspection 1. Inspect lifters carefully. If any parts are damaged or worn, the entire lifter assembly should be replaced. Refer to Specifications. 2. If outer lifter body wall is scuffed or worn, inspect cylinder block lifter bore. 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation IMPORTANT: Do NOT install used valve lifters if a new camshaft has been installed. 1. Before installIng lifters, coat entire valve lifter with engine oil. Pour an additive containing EP lube over lifters and camshaft lobes if all are new. 2. Install lifters in bores in order of removal. Align matching marks made prior to disassembly. 3. Install retainers around the square top of the lifters to prevent them from rotating. 4. Install push rods.
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SERVICE MANUAL NUMBER 22 ENGINE MECHANICAL Valve Push Rods Removal 1. As previously outlined, remove valve covers. IMPORTANT: Keep rocker arms, rocker arm components, valve push rod and hydraulic lifter from each valve together as a matched set. Mark or store them so they can be reinstalled in the same location later. 2. Remove rocker arm assemblies. 3. Lift push rod from seat in lifter cup. Cleaning 1. Clean all parts with solvent. 2. Clean oil passages of old oil and sludge. 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Connecting Rod / Piston Assembly Measuring Rod Bearing Clearance 1. Remove oil pan and oil pick-up tube assembly. 2. Turn crankshaft to gain access to connecting rod bolts. 3. One cylinder at a time, remove rod caps and inspect bearings. Refer to Bearing Failure. 4. Measure crank pin with a micrometer for out-of-round, taper, or excessive wear. If not within specifications, replace or recondition crankshaft. 5.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 6. If clearance exceeds specifications, on used bearings, replace bearings and recheck clearance. With new bearings, if correct clearance is not possible, recheck crank pin (journal) dimensions. If new bearings and replacement (or reconditioned crankshaft) will not yield proper measurement, it will be necessary to remove connecting rod/piston assembly (refer to following section) to check dimension of connecting rod crank pin bore. 7.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Disassembly 1. Clamp connecting rod in a soft jawed vise as shown. 70290 2. Use Piston Ring Expander 91-24697 to remove the 2 compression rings. 3. Using same tool, remove lower (oil control) ring and spring. a b 70291 a - Lower (Oil Control) Ring b - Spring 4. Remove snap rings retaining piston pin. Push pin out of connecting rod and piston.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Cleaning 1. Clean all parts with solvent. 2. Clean oil passages of old oil and sludge. 3. Put on safety glasses. 4. Dry parts with compressed air. 5. Clean varnish from piston skirts and pins with a suitable cleaning solvent. Do NOT WIRE BRUSH ANY PART OF PISTON. Clean ring grooves. Make sure oil ring holes are clean. a b 70229 a - Ring Grooves b - Oil Ring Holes Inspection CONNECTING ROD AND PIN 1.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 4. Measure connecting rod crank pin bore with a dial bore gauge or inside micrometer for out-of-round or excessive wear. Crank pin bore must be 57.563-57.582 mm (2.2662-2.2670 in.). Replace connecting rod if measurement exceeds allowable dimension by 0.02 mm (.0008 in.). a 70397 a - Rod Crank Pin Bore PISTONS IMPORTANT: The D-Tronic Engines should have only Class A pistons.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 4. Measure piston outer diameter about 13 mm (1/2 in.) from bottom of skirt. a 70229 a - Outer Diameter Measurement Point - 13 mm (1/2 in.) 5. Proper clearance of piston ring in its piston ring groove is very important to provide proper ring action and reduce wear. Keep in mind that while the second (scraper) compression ring and the oil control ring are typical in nature, the first (upper) compression ring is “trapezoidal” (tapered) in design.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 As always, when fitting serviceable or new rings, clearances between all ring and groove surfaces should be measured. Refer to Specifications. a b c a b c d d - First Compression Ring - Second Compression Ring - Oil Control Ring - Ring Clearance CHECKING RING END GAP 1. Select rings comparable in size to piston being used. 2. Slip compression ring in cylinder bore, then press ring down into cylinder bore about 6 mm (1/4 in.) below ring travel.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Assembly 1. Coat inside of connecting rod bushing, piston pin bore, and piston pin with SAE 30W engine oil. 2. Assemble piston to connecting rod with the combustion chamber recess aligned with rod numbers. a b 70296 a - Combustion Chamber Recess b - Rod Numbers 3. Insert piston pin and install snap ring. 4. Clamp in a soft jawed vise as shown. 70290 NOTE: Always install rings with ring markings facing the top of piston. 5.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 8. Using Piston Ring Expander 91-24697, install the second compression ring in the center piston groove. Scraper side of ring must face bottom of piston. a 70299 a - Scraper Side Toward Bottom Of Piston IMPORTANT: On all engines the word - TOP - appears on the upper surface of the first compression ring, and MUST FACE UP. 9. Using piston ring expander, install first compression ring in upper piston groove. Installation 1.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 IMPORTANT: The combustion chamber recess and numbers on connecting rod must face injector and camshaft side of the engine. 4. Turn crankshaft to position crank pin away from cylinder so connecting rod will not damage it during installation. 5. Using ring compressor, install piston by tapping on piston-top with a suitable device. a 70300 a - Ring Compressor 6. Insert bearing shells into connecting rod and matching rod cap.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Rear Oil Seal IMPORTANT: The later, D2.8L D-Tronic - serial number 0L098204 and above and D4.2L D-Tronic - serial number 0L099525 and above, engines had dimensional changes to the crankshaft, rear main bearing, rear main bearing carrier, thrust washers, O-ring seal, thrust plate (flywheel spacer) and flywheel seal. Ensure by serial number that the specifications and parts are the correct ones for the engine.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation IMPORTANT: Do NOT attempt to install rear main seal using a hammer or mallet. Damage to the seal or rear main bearing carrier could result. The seal is made of special compounds, Do NOT touch or handle the lips of the seal. 1. Lubricate outer surfaces of seal with clean engine oil. 2. Install new seal in carrier using tool 91-801111260 which will evenly PRESS the seal into position. Seal will stop (bottom-out) when seated.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Crankshaft and Main Bearings IMPORTANT: The later, D2.8L D-Tronic - serial number 0L098204 and above and D4.2L D-Tronic - serial number 0L099525 and above, engines had dimensional changes to the crankshaft, rear main bearing, rear main bearing carrier, thrust washers, O-ring seal, thrust plate (flywheel spacer) and flywheel seal. Ensure by serial number that the specifications and parts are the correct ones for the engine. Removal 1. Remove the pistons. 2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 7. Mark position of rear main bearing carrier in relation to block. a b c 70302 a - Rear Main Bearing Carrier b - Cylinder Block c - Reference Mark 8. Remove the screw locking thrust plate to crankshaft.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 9. To assist in removing the bearing carrier, temporarily reinstall the flywheel housing using only the nuts on the carrier. 10. Tap evenly around the housing as shown. The carrier and thrust plate will be pulled from the cylinder block. c a b 70303 a - Nuts On Carrier (6) b - Flywheel Housing c - Plastic Hammer 11. Remove nuts temporarily holding the flywheel housing to the rear bearing carrier, and proceed to next appropriate section.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 CRANKSHAFT AND MAIN BEARING CARRIERS 1. For proper installation during reassembly, note position of special locating screw retaining oil sender in cylinder block. 2. Remove main bearing oil feed locating screws which hold main bearing carriers in block. c b a 70305 a - Main Bearing Oil Feed Locating Screws b - Special Locating Screw c - Oil Sender 3. Install Crankshaft Installer Tool 91-801333504 over timing gear.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 MAIN BEARING CARRIERS AND BEARINGS IMPORTANT: Before removing bearing carriers from crankshaft, number or mark them according to journal upon which they are fitted. Also make matching marks on both bearing carrier halves for correct reassembly. Do NOT mix parts. 1. After marking carriers, remove bolts and separate carrier halves. Remove carriers with bearings from crankshaft journals.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 TIMING GEAR NOTE: Replace timing gear only if worn or damaged. 1. Install Crankshaft Gear Puller 91-801333503 and Crankshaft Pulley Puller 91-801763590 onto timing gear, as shown. 2. Remove the timing gear. 3. Remove the spacer if equipped. a b d c 70309 a b c d - Gear Puller - Pulley Puller - Timing Gear - Spacer, If Equipped (Not Shown) Cleaning 1. Immerse crankshaft in a solvent bath and clean. 2. Put on safety glasses. 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Inspection CRANKSHAFT 1. Visually inspect crankshaft for scratches, nicks, cracks and seizure marks. Replace if damaged. IMPORTANT: No material may be removed, either by hand or machine grinding, from thrust faces of crankshaft. 2. Replace crankshaft if machined surfaces on front and rear ends or threaded areas of crankshaft ends are out-of-round, worn or damaged. 3.
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SERVICE MANUAL NUMBER 22 ENGINE MECHANICAL MAIN BEARINGS (MEASUREMENT) 1. Inspect bearings. Refer to Examples of Bearing Failures. 2. To check clearance of center main bearings: a. Install bearings in original carrier halves, if removed. b. Observing marks made earlier, assemble carriers. Torque bolts with washers to 42 Nm (31 lb-ft). c. Measure inner diameter of bearing as shown. 70310 Measuring Inner Diameter Of Bearing d. Measure outer diameter of matching crankshaft journal as shown.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 3. Measure rear main bearing clearance in the same manner as the center main bearings (no assembly of carrier is required). 4. To check clearance of front main bearing: a. Measure crankshaft front main bearing journal. b. Measure I.D. of front main bearing in cylinder block as shown. 70312 c. Calculate difference between measurement taken in step a. and b. (clearance) and refer to specifications for maximum clearance. TIMING GEAR 1.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation FRONT MAIN BEARING 1. Align oil passage with hole of new bearing. b a 70313 a - Oil Passage b - Bearing Hole 2. Place new bearing on Puller/Installer Tool 91-801333508 as shown. Tool will install bearing to the correct depth. Oil passage MUST BE aligned. NOTE: To aid installation retain bearing halves on tool with a rubber band or similar.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 TIMING GEAR IMPORTANT: The early model crankshaft gear has been superseded to a new gear. A spacer is required behind the new gear to install. Description D2.8L D-Tronic D4.2L D-Tronic Serial Numbers Breaks: for engines 0L344916 And Above 0L344986 and Above using late model gear and spacer 1. Warm the gear in a suitable oven to 180 - 200 degrees C (356 - 392 degrees F.). 2. Ensure timing reference dots are facing the FRONT of the engine. 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 IMPORTANT: Piston oil jet MUST FACE FRONT (pulley end) of engine when installed. a. Identify piston oil jet location on all main bearing carriers. b. If not already accomplished, stake (peen) each oil jet in its bore in three places. Especially check the rear main bearing carrier oil jet and stake marks. a c b 70382 a - Bearing Carrier b - Piston Oil Jet Location c - Stake (Peen) Marks 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 CRANKSHAFT 1. Lubricate main bearing bores in crankcase with Molykote. b a 75389 a - Brush Dipped In Molykote b - Main Bearing Bore 2. Install Crankshaft Installation Tool 91-801333504 on front gear to protect front main bearing. a 70404 a - Tool 91-801333504 3. Position engine crankcase horizontal with oil pan flange facing up. 4. Carefully insert crankshaft, with main bearing carriers attached, into cylinder block.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 5. Rotate all bearing carriers so that the ROUND hole through the casting faces as shown, toward oil pan flange. Ensure that piston oil jets are directed toward FRONT of engine. a 70434 a - Bearing Carrier ROUND Hole 6. Install new sealing washers on all main bearing carrier locating hollow bolts and HAND THREAD CAREFULLY (to avoid damaging carrier threads) into bearing carriers.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 REAR MAIN BEARING IMPORTANT: Be certain to press bearing so as to prevent damage to notch arrangement in carrier where bearing tab aligns. 1. Using a suitable mandrel press bearing out of carrier. 2. When pressing new bearing into carrier, bearing tab and notch in carrier MUST BE aligned as shown. b a 70382 a - Bearing Tab b - Notch In Carrier REAR MAIN BEARING CARRIER 1. Refer to Rear Oil Seal - Installation and install new seal in carrier.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 2. Install standard size thrust washers into flywheel side of carrier as shown. (Use Quicksilver Needle Bearing Lubricant to help keep washers positioned.) a 70407 a - Thrust Washers (Standard Size), Flywheel Side 3. Install standard size thrust washers into front (crankshaft) side of carrier. (Use Quicksilver Needle Bearing Lubricant to help keep washers positioned.) a 70408 a - Thrust washers (Standard Size), Front (Crankshaft) Side 4.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 5. Lubricate crankshaft journal and bearing with clean engine oil. Install rear main bearing carrier into cylinder block, align marks previously made. Always be certain lubrication holes on block and carrier align, especially when or if marks are not present. b a 70409 a - Rear Main Bearing Carrier b - Marks Aligned 6. Install new O-ring into groove of thrust plate (crankshaft side). a b 70304 a - Thrust Plate b - O-ring 7.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 8. Install new O-ring into groove of flywheel housing as shown. a 70410 a - O-ring 9. Install flywheel housing. Torque the 9 bolts with washers to 50 Nm (37 lb-ft). Then, torque the 6 rear main bearing carrier nuts with washers to 27 Nm (20 lb-ft). IMPORTANT: Flywheel bolts may be used a maximum of 3 times within the prescribed torque limits. 10. Lubricate threads of flywheel bolts with clean engine oil and install flywheel. Torque bolts to 110 Nm (81 lb-ft).
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Cylinder Liners Removal 1. Remove components as needed, including pistons. 2. Remove plate from Cylinder Liner Puller 91-801333502. b a 70412 a - Cylinder Liner Puller Tool b - Plate IMPORTANT: Mark liners in a suitable fashion as to the cylinder number (to avoid mismatching to pistons upon reassembly) and orientation in block (reference to prechamber bore of head). 3. Install puller tool into cylinder and attach plate to tool at bottom of liner.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Identification CAUTION For D-Tronic Engines the cylinder liners are provided in one standard size and correspond to the tolerance class: Class A. Failure to use only the Class A liner designated for your engine, with matching Class A piston, will result in severe engine damage. 1. As shown in the following, inspect underside of liner for tolerance class identification reference mark (a small radial line). NO MARK should be present.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Cleaning and Inspection CYLINDER LINERS 1. Clean liners, especially at areas as shown, and where O-rings fit. a 70414 a - Areas for Special Cleanliness 2. Check liners for abnormal wear or cracks. Replace as needed with those parts for your specific model. 3. Measure liners for out-of-round or taper with a dial or bore gauge, taking readings at three different vertical positions and at opposite sides of the liner bore. Refer to specifications. 4.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Installation Cylinder liners on all engines are required to protrude (or rise above the surface of the block) 0.01 - 0.06 mm (.0004 - .0023 in.). By using one of three shims available (placed between the liner flange and the block during installation of liner) it is possible to obtain the correct protrusion. 1. To determine the correct shim thickness needed for each liner follow instructions a. - e.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 c. Refer to the following chart to determine and select the shim thickness required: Liner Recess BELOW Block (Without Shim) Shim To Be Used (Thickness) 0.14 - 0.09 (.0055 - .0035) 0.15 (.0059) 0.19 - 0.14 (.0074 - .0055) 0.20 (.0078) 0.22 - 0.17 (.0086 - .0066) 0.23 (.0090) Liner Protrusion ABOVE Block (With Shim) 0.01 - 0.06 (.0004 - .0023) d. Remove liner and install shim selected and refit liner. e. Measure protrusion.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 2. Tighten liners, with appropriate shims, to 30 Nm (22 lb-ft) and formed spacer-washers as shown. c b a 75015 a - Liner b - Suitable Bolt c - Formed, Spacer-Washer 3. Recheck-liners for proper amount of protrusion using liner gauge bar 91-184812A1 (SAE) or 91-801333509 (Metric) and appropriate dial gauge as shown. If not as specified, adjust protrusion as previously outlined until each liner is protruded 0.01 0.06mm (.0004 - .0023 in.) above block.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 5. Install two BLACK O-rings in the grooves near the neck of the liner and one BROWN O-ring in groove at the bottom, as shown. b c a 70416 a - Shim b - Black O-Rings (2) c - Brown O-Ring (1) 6. Lubricate LOWER centering collars in cylinder block (those areas where lower liner O-rings seal against the bore) with Needle Bearing Lubricant 92-42649A1 or clean engine oil as shown. IMPORTANT: Do NOT lubricate upper bore area.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 7. Apply Loctite Master Gasket 92-12564--1 or Loctite 620 (obtain locally) to liner surfaces AS SHOWN. IMPORTANT: Do NOT apply Loctite to shim or shim contact surfaces. a 70414 a - Loctite Applied To These Areas ONLY 8. Install liners in block, being careful not to damage O-rings or distort shim. Hold liners securely in position with suitable bolts and head bolt formed, spacer-washers as shown. Torque bolts to 50 Nm (37 lb-ft). Allow Loctite to dry.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Flywheel Housing, Coupler / Drive Plate And Flywheel Exploded View STERNDRIVE (MCM) MODELS NOTE: Some engines are equipped with a solid (Single Stage) coupler, in place of the Dual Stage coupler found on others.
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SERVICE MANUAL NUMBER 22 ENGINE MECHANICAL STERNDRIVE (MCM ) MODELS (CONTINUED) 1 - Continuity Wire 2 - Washer 3 - Screw 4 - Rear Portion of Flywheel Housing - Sterndrive (MCM) 5 - Screw 6 - Lockwasher 7 - Grease Fitting 8 - Bravo Coupler Assembly 9 - Screw (6) 10 - Washer (6) 11 - Second Stage Coupler 12 - Screw and Washer 13 - Turbocharger Bracket 14 - Flat Washer and Lockwasher 15 - Turbocharger Mounting Screw (2) 16 - Screw, Flat Washer and Lockwasher (9) 17 - Flywheel Ring Gear 18 - Thrust Plate / Gu
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 INBOARD (MIE) MODELS 3 B 6 5 4 2 A 16 17 1 15 8 14 7 13 12 11 18 10 21 9 19 22 23 Page 3A-146 20 90-860074--1 FEBRUARY 2002
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SERVICE MANUAL NUMBER 22 ENGINE MECHANICAL INBOARD (MIE) MODELS (CONTINUED) 1 - Screw 2 - Washer 3 - Rear Portion of Flywheel Housing - Inboard (MIE) 4 - Drive Plate Screw 5 - Washer 6 - Typical Early Drive Plate (Later Plate Not Shown) 7 - Flywheel Screws 8 - Flywheel 9 - Set Screw 10 - Thrust Plate / Guide Ring 11 - Guide Ring O-ring 12 - Ring Gear 13 - Turbocharger Screw 14 - Lockwasher 15 - Washer 16 - Turbocharger Bracket 17 - Screw and Washer 18 - Flywheel Housing To Cylinder Block Screw 19 - RPM Sp
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 IMPORTANT: The later, D2.8L D-Tronic - serial number 0L098204 and above and D4.2L D-Tronic - serial number 0L099525 and above, engines had dimensional changes to the crankshaft, rear main bearing, rear main bearing carrier, thrust washers, O-ring seal, thrust plate (flywheel spacer) and flywheel seal. Ensure by serial number that the specifications and parts are the correct ones for the engine. Flywheel Housing REMOVAL 1. Remove the starter. 2.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 INSPECTION 1. Visually inspect rear portion of flywheel housing and flywheel housing for cracks, holes, and excessive wear. 2. Inspect O-ring on rpm speed sensor. 3. Replace if necessary. INSTALLATION 1. Install new O-ring into groove of flywheel housing. a 70410 a - O-ring IMPORTANT: Flywheel housing fasteners and hardware must be installed from where removed. 2. Install flywheel housing. Torque the 9 bolts with washers to 50 Nm (37 lb-ft).
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Sterndrive (MCM) Coupler / Inboard (MIE) Drive Plate REMOVAL 1. Remove rear portion of flywheel housing. 2. On Sterndrive (MCM) Models: Remove engine coupler. 3. On Inboard (MIE) Models: Remove drive plate. INSPECTION 1. Inspect splines in drive plate or coupler for wear. 2. On Sterndrive (MCM) Models with two-stage couplers: the first stage piece of the coupler can be replaced. Remove as necessary.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 INSTALLATION 1. On Sterndrive (MCM) Models with two-stage couplers: a. Install first stage piece if being replaced. b. Apply Loctite 271 to threads and torque 6M bolts with lockwashers to 16 Nm (12 lb-ft). b c a 78383 a - Two Stage Coupler Assembly b - Coupler (First Stage Piece) c - 6M Bolts With Lockwashers 2. On Sterndrive (MCM) Models: Install engine coupler. Apply Loctite 271 to bolt threads. Torque bolts to 30 Nm (22 lb-ft). 3.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine Mounts Front Mounts IMPORTANT: There are two different types of mounts being used on the D2.8L D-Tronic. Serial numbers 0L343125 and below use an early front mount. Serial numbers 0L343126 and above use a later front mount. Follow these serial number breaks if a front mount is being replaced. Only use the late front mounts on engines with the early serial numbers if the rear bushing are also replaced. The front engine mounts can be installed two ways.
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 MIE (Inboard) Transmission Mounts e f d c g a b 27035 Transmission Mount Components a - Base b - Housing c - Bushing d - Trunion (Pin) e - Snap Ring f - Bracket g - Clamping Bolt a a b b 27035 50533 Standard Mount Position Alternate Mount Position a - Mount Bracket b - Bolts 90-860074--1 FEBRUARY 2002 Page 3A-153
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ENGINE MECHANICAL SERVICE MANUAL NUMBER 22 Engine 20-Hour Break-In Period The first 20 hours of operation is the engine (new or rebuilt) break-in period. During this period, it is extremely important that the engine is operated as outlined in the following. 1. Do NOT operate engine below 1500 rpm for extended periods of time during the first 10 hours.
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STARTING SYSTEM SERVICE MANUAL NUMBER 22 ELECTRICAL SYSTEM Section 4A - Starting System Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . Starting System Components . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . .
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STARTING SYSTEM SERVICE MANUAL NUMBER 22 Identification a 70809 a - Identification Number Location On Starter Specifications IMPORTANT: The starter motor is designed to operate under great overload and produce a high horsepower for its size. It can do this only for a short time, since considerable heat accumulates and can cause serious damage. For this reason, the cranking motor must never be used for more than 15 seconds at any one time.
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STARTING SYSTEM SERVICE MANUAL NUMBER 22 Replacement Parts WARNING Electrical system components on this engine are not external ignition protected. Do NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR) Failure to comply could result in fire, explosion and/or severe personal injury Starting System Components 30 15 50 3 2 1 9 4 2. 3. 10 1.
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SERVICE MANUAL NUMBER 22 STARTING SYSTEM Starting System Components (continued) 1 - Ignition (Start) Switch, (Start/Stop) 2 - 20 Ampere Fuse 3 - Remote Control Neutral Safety Switch [MCM (Sterndrive)] 4 - Instrument/ Extension Harness Connector at Electrical Box 5 - Circuit Breaker 6 - Circuit Breaker 7 - Start Relay 8 - Main Relay 9 - ECM / Fuel System Harness Connector at Electrical Box 10 - ECM 11 - Battery 12 - Starter 13 - Electronic Shut-Off Solenoid 1.
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STARTING SYSTEM SERVICE MANUAL NUMBER 22 Inspection Periodic Inspection Starter motor with solenoid is completely enclosed when mounted to the drive housing to prevent entrance of moisture and dirt. However, periodic inspection is required. 1. Inspect terminals for corrosion and loose connections. 2. Inspect wiring for frayed and worn insulation. 3. Ensure that mounting nuts are tight. 4. Ensure that mounting surfaces under the starter motor and the mounting bolts are free of paint and corrosion.
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STARTING SYSTEM SERVICE MANUAL NUMBER 22 Removal Starter Motor WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system. 1. Disconnect battery cables from battery. 2. Disconnect wires from starter. 3. Remove starter mounting nuts and lockwashers. 4. Pull starter motor away from flywheel and remove from engine.
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STARTING SYSTEM SERVICE MANUAL NUMBER 22 Solenoid Switch 1. Remove starter motor. 2. Remove nut from the field wire on the solenoid. a 70811 a - Field Wire Nut 3. Remove screws retaining solenoid. a 70812 a - Screws 4. Slide solenoid plunger off shift lever. a b 70814 70813 a - Solenoid Plunger b - Shift Lever 5. Remove solenoid from starter assembly.
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STARTING SYSTEM SERVICE MANUAL NUMBER 22 Installation Solenoid Switch 1. Apply a light coat 2-4-C Marine Lubricant with Teflon to the shift lever and sliding portion of the pinion. 2. Slide solenoid plunger onto shift lever. b c a 70833 a - Solenoid Plunger b - Shift Lever c - Drive Gear 3. Install solenoid screws and tighten securely. a 70812 a - Solenoid Screws 4. Install nut on the field wire terminal and tighten securely.
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STARTING SYSTEM SERVICE MANUAL NUMBER 22 Starter Motor 1. Apply a light coat of 2-4-C Marine Lubricant With Teflon to mounting surfaces and fasteners prior to installation. 2. Position starter motor on engine. 3. Install lockwashers and nuts. Torque nuts to 68 Nm (50 lb-ft). a a 70810 a - Lockwasher and Nut (1 Not Shown) 4. Connect wires to starter solenoid. a c b 70810 a - RED Wire b - YELLOW/RED Solenoid Wire c - Positive (+) Battery Cable 5. Coat terminals with Liquid Neoprene sealer. 6.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Electrical Systems Section 4B - Charging System Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives . . . . . . . . . Wire Color Code Abbreviations . . . . . . . . Precautions . . . . . . .
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 NOTICE For information and procedures on Troubleshooting, refer to SECTION 1C.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Specifications Description Specification Excitation Circuit 1.3-2.5 Volts Current Output 65 Ampere Voltage Output 13.9-14.7 Volts Condenser Capacity .5 MFD 5 mm (3/16 In.) 1 V-Belt Tension 1 : Depress belt with thumb at midway point between circulating pump pulley and alternator. Torque Specifications Page 4B-4 Description Nm lb-in.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Special Tools Description Part Number Magneto Analyzer 91-76032 Bearing Removal and Installation Kit 91-31229A5 Universal Puller Plate 91-37241 Multi-Meter / DVA Tester 91-99750A1 Ammeter (0-70) Obtain Locally Lubricants / Sealers / Adhesives Description Part Number Liquid Neoprene 92-25711--1 Wire Color Code Abbreviations BLK BLU BRN GRY GRN ORN PNK 90-860074--1 FEBRUARY 2002 Black Blue Brown Gray Green Orange Pink PUR or PPL RED TAN WHT YEL LIT
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Precautions General CAUTION The following precautions MUST BE observed when working on the charging system. Failure to observe these precautions may result in serious damage to the alternator or charging system. wDo NOT attempt to polarize the alternator. wDo NOT short across or ground any of the terminals on the alternator, except as specifically instructed in the Troubleshooting Tests.
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SERVICE MANUAL NUMBER 22 CHARGING SYSTEM Battery Precautions - Multiple EDI Engines SITUATION Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for two different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine’s alternator will not be required to supply any charging current.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Charging System Components The alternator system consists of the alternator, battery, the ignition switch and the wiring which connects these components. NOTE: The wire color codes vary between models and are not shown. Refer to SECTION 4E Wiring Diagrams for color code information.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Inspection CAUTION Always disconnect battery cables from battery before working around the electrical system components to prevent injury to yourself or damage to electrical system. 1. Inspect entire alternator system for corroded or loose connectors. 2. Check wiring for frayed or worn insulation. 3. Check alternator drive belt for excessive wear, cracks, fraying and glazed surfaces.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Troubleshooting Tests (Alternator on Engine) Use the following tests in conjunction with the Troubleshooting in SECTION 1C. Before proceeding with the tests, however, perform the following checks to eliminate possible problem areas. Also observe Precautions, preceding, to prevent damage to alternator system. 1.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Output Circuit 1. Ensure battery is fully charged with the hydrometer test. 2. Start the engine and increase rpm to approximately 1500 rpm. 3. Check voltage reading. the voltage should be between 13.8 and 14.2 volts. If the reading is below 13,8 volts: 4. Connect positive (+) voltmeter lead to alternator output terminal. 5. Connect negative (–) lead to a ground terminal on alternator. 6. Wiggle engine wiring harness while observing voltmeter.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Excitation Circuit 1. Connect positive (+) voltmeter lead to tie strap/terminal on alternator and negative (–) lead to a ground terminal on alternator (Test 1). 2. Turn ignition switch to RUN position and note voltmeter reading. Reading should be 1.3 to 2.5 volts. 3. If no reading is obtained, an opening exists in alternator excitation lead or in excitation circuit of regulator. Unplug PURPLE lead from regulator.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Sensing Circuit 1. Unplug RED or GREEN lead from voltage regulator. 2. Connect positive (+) voltmeter lead to RED or GREEN lead and negative (–) voltmeter lead to ground terminal. 3. Voltmeter should indicate battery voltage. If battery voltage is not present, check sensing circuit for loose or dirty connection or damaged wiring.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Current Output Test Perform this test to check if alternator is capable of producing rated current output, using a 0-80 amp DC ammeter. WARNING Ensure engine compartment is well-ventilated and that there are no gasoline vapors present (during the test) to prevent the possibility of an explosion and/or a fire, should a spark occur. 1. Disconnect negative (–) battery cable from battery. 2.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Perform this test to determine if voltage regulator is operating correctly, using a 0-20 volt DC voltmeter. IMPORTANT: Battery MUST BE fully charged (1.260 or above specific gravity) to obtain proper voltage reading in this test. If necessary, charge battery with a battery charger or allow engine to operate a sufficient length of time to fully charge battery before taking reading. 1.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Exploded View 8 9 10 11 A 13 2 3 4 12 1 3 5 7 6 74467 1 - Key 2 - Alternator 3 - Spacer (1 Shown, Some Models May Have 1 Upper and 1 Lower Spacer) 4 - Bracket 5 - Screw and Lockwasher (M14) 6 - Mounting Bolt (M8) 7 - Mounting Nut (M8) 8 - Alternator Brace 9 - Alternator Brace Spacer 10 - Brace Bolt, Washers and Nut (M10) 11 - Tensioning Bolt, Lockwasher and Flat Washer 12 - Pulley, Lockwasher and Nut 13 - Alternator V-Belt Description A Liquid Neoprene
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Removal Alternator 1. Disconnect battery cables from battery. 2. Disconnect wiring harness from alternator. 3. Loosen alternator support bracket screw. 4. Remove the drive belt. 5. Remove the alternator brace attaching bolt and washer. 6. Remove the alternator mounting bolt, washer and nut. a b c 78310 a - Alternator Brace b - Brace Bolt c - Alternator Mounting Bolt 7. Remove the alternator. Alternator Bracket 1. Remove the alternator. 2.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Installation Alternator Bracket IMPORTANT: If the mounting bracket has been removed, refer to the Exploded View. Be certain that the mounting spacer and proper length brace spacer are in position for the appropriate engine. 1. Position the spacer, or spacers, between the bracket and the engine block. 2. Install the bracket mounting bolts. Torque the bolts to 41 Nm (30 lb-ft). 3. Install the alternator. Alternator 1. Position the alternator in the mounting bracket.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 8. Reconnect the wiring harness to the alternator. Coat terminals with liquid neoprene. d c e b a 72838 a b c d e - Excitation Wire - PURPLE - Sensing Wire - RED or GREEN - Ground Wire - BLACK - Output Wire - BLUE - Charge Indicator Lamp Lead - BROWN 9. Connect battery cables to battery. Battery Isolators Dual Battery Charging Systems NOTE: Mercury MerCruiser engines equipped with a 3-wire, belt driven alternator, can use a battery isolator.
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CHARGING SYSTEM SERVICE MANUAL NUMBER 22 Battery Isolator Diagram a A B2 2 B1 2 2 2 1. 1 b c (–) RED B+ 2 BLK e d 72934 Typical Alternator a - Isolator b - Alternator c - Starter d - Cranking Battery e - Auxiliary Battery 1 - BLUE Wire From Alternator Battery Terminal 2 - 8 Gauge Minimum 1. Page 4B-20 Sufficient Gauge Wire Spliced To Connect As Shown.
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GLOW PLUG SYSTEM SERVICE MANUAL NUMBER 22 ELECTRICAL SYSTEMS Section 4C - Glow Plug System Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . .
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SERVICE MANUAL NUMBER 22 GLOW PLUG SYSTEM Identification 75496 D2.8L D-Tronic and D4.2L D-Tronic Glow Plug Specifications NOTE: Glow plug system will work only when engine temperature is below 50 degrees C (22 degrees F.). D2.8L D-TRONIC ENGINE Description Glow Plug Diameter and Thread Nominal Voltage Current Draw after 30 Seconds of Operation Preheat Time and Afterglow Time Voltage drop, with test current after 30 seconds Specification M12 x 1.25 11 Volts 7.5 - 9.5 Amps Controlled by ECM 0.63 - 0.
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GLOW PLUG SYSTEM SERVICE MANUAL NUMBER 22 Torque Specifications NOTE: Securely tighten all fasteners not listed below. Description Nm Glow Plug 23 lb-in. lb-ft 17 Lubricants / Sealants / Adhesives Description Part Number Liquid Neoprene 92-25711--3 Special Tools Description Part Number Volt / Ohm Meter 91-93572 Description The D-Tronic engines are not equipped with glow plugs as standard equipment. Description and operation are explained in case the optional kit is installed.
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GLOW PLUG SYSTEM SERVICE MANUAL NUMBER 22 Glow Plug Testing (Prior to Removal) 10. Disconnect battery cables from battery. 11. Remove hex nut and washer from glow plug terminal. 12. Remove voltage supply wire. 13. Remove glow plug connecting wire from glow plug terminal. c b a 77940 a - Voltage Supply Wire b - Glow Plug Terminal c - Glow Plug Connecting Wire 14. Connect ohmmeter between engine ground and glow plug terminal. Continuity should exist. If no continuity exists, glow plug is faulty.
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GLOW PLUG SYSTEM SERVICE MANUAL NUMBER 22 Removal 1. Disconnect battery cables from battery. 2. Remove hex nut and washer from glow plug terminal. 3. Remove voltage supply wire. 4. Remove glow plug connecting wire from glow plug terminal. c b a 77940 a - Voltage Supply Wire b - Glow Plug Terminal c - Glow Plug Connecting Wire IMPORTANT: Avoid contaminating cylinders. Clean any corrosion or debris away from around glow plug before removal. 5.
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GLOW PLUG SYSTEM SERVICE MANUAL NUMBER 22 Cleaning 1. Clean contact area of connecting wire ring terminals. 2. Clean the power supply wire terminal end. 3. Clean cylinder head glow plug seat area. 4. Clean the glow plug threaded areas, seat and heating element (tip). Inspection 1. With glow plug removed, connect ohmmeter between glow plug terminal (+) and glow plug external (–) threads. Continuity should exist. If no continuity exists, glow plug is faulty. 2.
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GLOW PLUG SYSTEM SERVICE MANUAL NUMBER 22 Installation 1. Install glow plug. Torque to 23 Nm (17 lb-ft). 2. Ensure contact areas are clean. CAUTION Avoid shorting electrical circuits. Some voltage supply wire ring terminal ends are large and could contact the cylinder head which is grounded (–). Be certain ring terminal is isolated to the glow plug terminal. 3. Attach connecting wire to glow plug terminal. Ensure that the voltage supply wire is present where previously removed.
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GLOW PLUG SYSTEM SERVICE MANUAL NUMBER 22 Glow Plug Actuator Relay and Auxiliary Relay For more information on circuit description and testing refer to SECTION 5E - Diagnostic Circuit Checks. Testing 1. Ensure battery is fully charged. 2. Check the following before testing relays: a. All wires in circuit are connected. b. Plug-in connectors are fully engaged. c. All connections are corrosion free. d. Engine Coolant Temperature switch appears to be present and in usable condition. e.
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GLOW PLUG SYSTEM SERVICE MANUAL NUMBER 22 Removal 1. Remove electrical box cover. 2. Detach relay from inside of electrical box. 3. Disconnect electrical harness connector and remove relay. Cleaning 1. Clean exterior with a dry cloth. 2. Clean terminals with a suitable cleaner. Inspection 1. Look for evidence of any physical damage to base or connector surfaces of relays. 2. Visually inspect electrical pins of ECT for straightness and no corrosion. 3.
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GLOW PLUG SYSTEM SERVICE MANUAL NUMBER 22 Glow Plug Circuit Diagram NOTE: For additional information refer to SECTION 5E.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 ELECTRICAL SYSTEMS Section 4D - Instrumentation Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-3 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-3 Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 4D-4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-4 Lubricants / Sealants / Adhesives . . . . . . .
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 NOTICE For information and procedures on Troubleshooting refer to SECTION 1C. Identification Gauges QUICKSILVER INSTRUMENTS NOTE: One of three distinct series of Quicksilver gauges may be installed. Aside from different gauge face appearances and styling, the back of the gauges and wiring connections are different.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Special Tools Description Part Number MultiMeter 91-99750A1 DMT 2000A Digital MultiMeter 91-854009A2 Equipment for performing tests (suitable container, thermometer, suitable heat source, sandblasting sand or equivalent and a 12 volt Obtain Locally power source) Diesel Timing Tool or suitable service tachometer Obtain Locally Tools Kent-Moore Tools Kent-Moore Tools, Inc.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Precautions WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system. CAUTION Avoid short circuits. It may be necessary to remove instrument panel from dashboard to gain access to instruments and switches. Do not allow wires to come in contact with metal or other wires. WARNING Switch and sender testing involves the use of intense heat.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 General Information IMPORTANT: If all instruments appear suspect, an electrical overload may have occurred. A fuse may be defective or a circuit breaker may be tripped open. The cause must be found and corrected before replacing fuse or resetting circuit breaker. IMPORTANT: If all instruments appear suspect, check the main harness or electrical connector to ensure good contact. Before testing individual instruments, check the following: • Battery is fully charged.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 QSI Series Gauge Lighting Options These gauges are equipped with optional illumination lighting. Light bulb socket can be removed and contacts can be aligned to be used with ignition switch lighting circuit +12 V or separate instrumentation lighting circuit LT. Standard position on diesel products is for use with the separate Panel Lights/Audio Test switch.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Gauges IMPORTANT: If testing proves a gauge to be defective, it must be replaced as there is no repair available. Removal 1. Disconnect battery cables. 2. Remove wires from back of gauge. 3. Disconnect light socket wiring, if separate. 4. Remove holding strap and remove gauge. Testing OIL PRESSURE AND WATER TEMPERATURE 1. Turn ignition switch to the “OFF” position. 2. Remove signal wire from terminal SEND (“S”). a 72819 a - Sender Wire Lead 3.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 5. Connect jumper wire from terminal G (GND) to terminal SEND (“S”). a 72748 a - Jumper Wire 6. Turn ignition switch to the “RUN” position. Gauge being tested must be at position B. a a 73289 Typical a - Needle at Position B CRUISELOG (ENGINE HOUR METER) 1. Remove cables from battery and fully charge battery. 2. Remove wires from back of gauge. 3. Connect positive (+) jumper lead from battery to gauge terminal + (12 V). 4.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 VOLT METER GAUGE 1. Remove cables from battery and fully charge battery. 2. Remove wires from back of gauge. 3. Connect negative (–) jumper lead from battery to gauge terminal G (GND). 4. Connect positive (+) jumper lead from a 12 Volt power source, or battery, to gauge terminal I or +12 V. b a 72750 a - Volt Meter b - 12 Volt Power Source 5. Check gauge reading; if not indicating battery voltage, as shown, replace gauge.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Installation 1. Position gauge assembly in appropriate mounting hole. 2. Install holding strap and nuts. Tighten nuts evenly and securely. IMPORTANT: Do not distort case or bracket by over tightening. 3. Connect ground wire to ground terminal, if gauge is not mounted in metal panel. 4. Connect other wires to gauge as shown in SECTION 4E - Wiring Diagrams. 5. Install gauge light socket. 6. Coat all terminals with liquid neoprene. 7.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 TESTING IMPORTANT: Use the following test procedure for checking accuracy of oil pressure sender only. If oil pressure gauge indicates zero oil pressure, refer to SECTION 1C - Troubleshooting. 1. Remove harness wire from sender. Temporarily insulate the wire to avoid a possible short circuit. 2.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Water Temperature - Primary Station REMOVAL 1. Drain the closed cooling system. 2. Remove harness wiring from temperature switch located behind the electrical box bracket and accessible through a hole in the bracket, as shown. b c a 75298 Typical a - Harness Wiring b - Water Temperature Sender c - Sealing Washer 3. Counter-hold the adaptor with a separate wrench. 4. Remove the sender and sealing washer.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 1. Connect an ohmmeter between sender terminal G and switch hex (case) for ground (–) as shown. 70686 2. Using a suitable container, thermometer and heat source, suspend the sender with tip in sand. 3. Heat sand and observe temperature on thermometer. 4. As temperature rises, ohmmeter readings must be within the ranges specified for each temperature.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 INSTALLATION 1. Apply Perfect Seal to threads of sender. 2. Counter-hold the adaptor with a separate wrench and install the sender and sealing washer. 3. Torque the temperature sender to the adapter. Maximum torque is 25 Nm (18 lb-ft). Do NOT overtorque. 4. Connect harness wiring. Apply liquid neoprene to the terminals. 5. Refill closed cooling system.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 TESTING 1. Before testing key switch, check all fuses and/or circuit breakers in electrical circuit that could prevent operation of starter. IMPORTANT: Disconnect battery cables from battery before testing ignition key switch with wires still connected to switch. 2. Disconnect battery cables from battery, if proceeding to test switch with wires still connected. With key switch in the “OFF” position, there should be no continuity between switch terminals. 3.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Audio Warning Test and Panel Light Switch The switch provided for the audio warning test and panel (dash) lights is a three-position toggle switch. It must be wired and installed correctly to provide proper operation of the systems. REMOVAL 1. Remove hex nut retaining switch to Engine System Monitor Panel. 2. Remove wires from back of switch. TESTING 1.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 INSTALLATION 1. Using screws provided, connect the listed color coded wires to numbered switch terminals as shown. 2. Install switch in Engine System Monitor panel. Tighten hex nut securely to prevent switch from turning in its mounting hole. Do NOT overtighten.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Audio Warning System The Audio Warning System is divided into two separate circuits. Both circuits have an individual audio warning alarm that does NOT include any time delay. One circuit consists of the engine water temperature switch and related wiring.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Oil Pressure Switch TESTING When the engine is stopped the switch is normally closed. 1. Remove the harness wire from the switch. Insulate to avoid possible short circuit. 2. Connect continuity meter between switch terminal and switch case (negative –). With the engine stopped the meter should indicate full continuity. NOTE: Sender shown removed for visual clarity.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Water Temperature Switch / Sender When the engine is COLD the audio warning circuit is normally open. REMOVAL 1. Drain the closed cooling system. 2. Remove harness wiring from temperature switch / sender located behind the electrical box bracket and accessible through a hole in the bracket, as shown. 3. Counter-hold the adaptor with a separate wrench. 4. Remove the sender and sealing washer.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 TESTING 1. With engine COLD, remove wiring from switch/sender terminals. Note position on switch/sender for terminal referred to as W. b a 78189 Top View a - Water Temperature Switch/Sender b - Terminal W - Audio Warning Switch Circuit 2. Refer to the proceeding and connect a continuity meter between switch terminal W and sender hex case. a. No continuity should exist. b. If continuity exists, replace sender.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 e. Heat sand and observe temperature on thermometer. e d b 71772 a c 70758 a b c d e f f. - Suitable Container - Thermometer - Heat Source - Water Temperature Switch/Sender - 12 Volt Power Source and Jumper Leads - Audio Warning Alarm With Jumper Lead Replace switch / sender if it does not close (alarm ON ) within the range of temperatures indicated in chart below. Test Temperature Switch Condition 102 - 106 Degrees C (215 - 220 Degrees F.) Closed g.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Transmission Fluid Temperature Switch When the transmission is COLD or at a temperature less than as shown (refer to Testing - Test Temperature Chart), the switch is open. REMOVAL 1. Disconnect harness wires at switch. 2. Remove the switch and sealing washer. b a 72770 Typical Transmission a - Transmission Fluid Temperature Switch with Sealing Washer b - Harness Wires TESTING 1.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 NOTICE Read WARNING about switch and sender testing in Precautions at front of this section before proceeding with tests. 3. With an ohmmeter connected as in Step 1., use a suitable container, thermometer and heat source and suspend sender with tip in sand. 4. Heat sand and observe thermometer. 5. As temperature rises, switch will close and ohmmeter will indicate continuity. Refer to chart below for specifications.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Second Station Extension Harness 5. Connect and tighten threaded collars of instrument extension harnesses to second station instrument harness ends. IMPORTANT: When routing any wiring harness ensure that the harnesses do not rub or get pinched. NOTE: Refer to Wiring Diagrams - Wiring Harness Connections. IMPORTANT: Connectors must be fully engaged and secure. 6.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 EARLY MODEL WIRING HARNESS CONNECTIONS d 1 2 3 6 5 4 b a c 75305 76057 e 75871 f g 75884 Sterndrive Shown, Inboard Similar a - Second (2nd) Station Instrumentation b - Second Station Instrument Harness c - Primary Station Instrument Harness d - Primary (MAIN) Station Instrumentation e - Y-Box (Harness) f - Extension Harness g - To Engine 90-860074--1 FEBRUARY 2002 Page 4D-27
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 LATE MODEL WIRING HARNESS CONNECTIONS c d b a e f g 77223 Typical a - Primary (MAIN PANEL) Station Instrumentation and Harness b - Primary Station Extension Harness c - Second (2nd PANEL) Station Instrumentation and Harness d - Second Station Extension Harness e - Y-Harness f - Extension (“ENGINE”) Harness g - To Engine Page 4D-28 90-860074--1 FEBRUARY 2002
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Remote Control / Neutral Start Safety Circuit Primary Station WARNING Avoid injury or property damage. Starting an engine while the sterndrive unit or transmission is in gear could cause severe injury to people or animals in or near the boat, or property damage due to unexpected operation.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 Secondary Station WARNING Avoid injury or property damage. Starting an engine while the sterndrive unit or transmission is in gear could cause severe injury to people or animals in or near the boat, or property damage due to unexpected operation. Special circuitry and switches are necessary and must be used to prevent accidental starter engagement and subsequent engine operation while a sterndrive or transmission is in a gear.
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INSTRUMENTATION SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 4D-32 90-860074--1 FEBRUARY 2002
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 ELECTRICAL SYSTEMS Section 4E - Wiring Diagrams Table of Contents 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 . . . . . . . . . . . . . . . . . . . . . . . . .
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 4E-2 90-860074--1 FEBRUARY 2002
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Wire Color Abbreviations BLK BLU BRN GRY GRN ORN PNK Black Blue Brown Gray Green Orange Pink PUR or PPL RED TAN WHT YEL LIT or LT DRK Purple Red Tan White Yellow Light Dark Special Tools Description Part Number DMT 2000A Tachometer / Multi-Meter Kit 91-854009A3 Tools Kent-Moore Tools Kent-Moore Tools, Inc.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Sterndrive (MCM) Models Engine Wiring - Starting and Charging System - Page 1 of 4 BLK BLK RED 1. RED YEL 4 BLK 11 RED/BLK RED RED RED WHT LT.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Engine Wiring - Starting and Charging System - Page 2 of 4 1 - ECM / Fuel System Harness Connector 2 - Electrical Box 3 - Main Relay 4 - Start Relay 5 - Glow Plug Relay (Optional) 6 - Glow Plug Relay (Optional) 7 - 60 Amp. Circuit Breaker 8 - 60 Amp.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Engine Wiring - Starting and Charging System - Page 3 of 4 S G X M D P K L J F C H W A 2 3 4 5 6 7 8 9 10 11 12 1 TAN/BLK RED 11 BLK BLK BLK BLK RED/BLK 8 10 9 BLK RED RED GRN LT.BLU TAN 7 BLK BLK PPL/WHT RED/BLK GRN/WHT BLK BLK YEL/RED BLU 4 RED BLK BRN BLU 6 GRN/WHT RED/PPL RED PPL BRN 1.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Engine Wiring - Starting and Charging System - Page 4 of 4 1 - ECM / Fuel System Harness Connector 2 - Electrical Box 3 - Main Relay 4 - Start Relay 5 - Glow Plug Relay (Optional) 6 - Glow Plug Relay (Optional) 7 - 60 Amp. Circuit Breaker 8 - 60 Amp.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 ECM and Fuel System Wiring - Page 1 of 2 BLU/BLK BLU/BLK BLK/YEL BRN/BLK BLK/YEL RED RED BLU/WHT BLU 7 14 WHT/BLK 29 33 GRN/WHT 49 64 GRN/WHT 5 GRN/WHT 4 YEL 53 BLU 51 65 55 BRN 21 15 ORN/WHT PNK 38 57 YEL/PNK RED BLK/PUR GRN PPL/BLK ORN BRN/RED WHT/BLK 50 37 RED RED BRN/BLK GRN GRN 40 42 68 61 GRN/RED 45 46 23 24 26 1 BLU/YEL RED RED RED YEL 41 BLU/WHT BLU/BLK GRN BLU/WHT BRN/WHT 2 WHT/YEL GRN/RED GRN/BLK BRN
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 ECM and Fuel System Wiring - Page 2 of 2 1 2 3 4 5 6 7 8 9 - ECM (Electronic Control Module) / Fuel System Connector - ECM - Engine-Speed Sensor - Throttle Position Sensor - Engine Coolant Temperature Sensor (ECT to ECM) - Electronic Distributor Injection Pump - Electronic Shut Off Solenoid (ELAB) - Manifold Absolute Pressure Sensor (MAP) - Number 1 Cylinder Fuel Injector with Needle Motion Sensor (NBF) ECM / FUEL SYSTEM HARNESS CONNECTOR NOTE: Refer to Item Numb
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Quicksilver Instrumentation Wiring - Page 1 of 4 1 2 3 PUR 4 PUR BRN/WHT BLK 5 GRY 6 7 8 BLU/TAN BLK GRY BLK TAN/WHT BRN RED GRN BLK BLK LT.BLU 1 TAN GRY RED PUR BLK TAN/BLK BRN/WHT WHT/RED TAN/WHT PUR PUR BLK PUR BLK BLK BLK TAN WHT/YEL BRN RED RED BLU/TAN BRN/WHT YEL/RED YEL/RED BRN/WHT BLK LT.BLU RED RED 14 15 16 PUR TAN/BLK BRN 12 13 PUR 11 13 PUR LT.
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SERVICE MANUAL NUMBER 22 WIRING DIAGRAMS Quicksilver Instrumentation Wiring - Page 2 of 4 1 - Oil Pressure Gauge 2 - Tachometer Gauge 3 - Trim Gauge 4 - Engine Coolant Temperature Gauge 5 - Voltmeter Gauge 6 - Cruise Log (Engine Hour Meter) 7 - Engine System Monitor Panel a - Preheat Indicator Lamp b - Charge Indicator Lamp c - Oil Pressure Warning Lamp / Low Gear Lube Monitor Level Lamp d - Coolant High Temperature Lamp e - Malfunction Indicator Lamp 8 - Panel Lights/Audio Warning Test Switch 9 - Key Swi
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Quicksilver Instrumentation Wiring - Page 3 of 4 GRY TAN TAN BRN/WHT PPL/ORN TAN/WHT PPL BLU BRN/WHT YEL 18 GRY BLU 1 PPL TAN/BLK BLK RED BRN BLK/YEL GRY YEL/RED GRN TAN/WHT YEL BLK 2 3 TAN BLU/TAN BLK/YEL X U W V F 3.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Quicksilver Instrumentation Wiring - Page 4 Of 4 1 - Voltmeter Gauge 2 - Tachometer Gauge 3 - Water Temperature Gauge 4 - Oil Pressure Gauge 5 - Trim Position Gauge 6 - Engine System Monitor Panel 7 - Malfunction Indicator Lamp (Check Engine) 8 - Coolant High Temperature 9 - Oil Pressure Warning Lamp / Low Gear Lube Monitor Level Lamp 10 - Charge Indicator Lamp 11 - Preheat Indicator Lamp 12 - Panel Lights/Audio Warning Test Switch 13 - Key Switch 14 - Neutral Star
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Power Trim System Wiring Diagram a b c d e f g h - 20 Amp Fuse - Ground Bolt (Floor Mount) - UP Solenoid - 110 Amp Fuse - DOWN Solenoid - Trailer Switch - Neutral Switch To Instrument Wiring Harness - Trim Limit Switch b a c d f e g h BLK BLU BRN GRY GRN ORN PNK PUR RED TAN WHT YEL LT OR LIT DRK = = = = = = = = = = = = = = BLACK BLUE BROWN GRAY GREEN ORANGE PINK PURPLE RED TAN WHITE YELLOW LIGHT DARK 73962 Page 4E-14 90-860074--1 FEBRUARY 2002
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 MerCathode System Wiring Diagram a - Controller b - 20 Amp Fuse c - Electrode a b c BLK BLU BRN GRY GRN ORN PNK PUR RED TAN WHT YEL LT OR LIT DRK = = = = = = = = = = = = = = BLACK BLUE BROWN GRAY GREEN ORANGE PINK PURPLE RED TAN WHITE YELLOW LIGHT DARK 73596 90-860074--1 FEBRUARY 2002 Page 4E-15
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Inboard (MIE) Models Engine Wiring - Starting and Charging System - Page 1 of 4 3 RED BLK BLK RED GRN GRN/WHT BLU/BLK 2 RED BLK YEL 4 PPL BLK RED/BLK BLK 8 10 9 1. 22 RED/BLK PPL/WHT RED RED 7 LT.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Engine Wiring - Starting and Charging System - Page 2 of 4 1 - ECM / Fuel System Harness Connector 2 - Electrical Box 3 - Main Relay 4 - Start Relay 5 - Glow Plug Relay (Optional) 6 - Glow Plug Relay (Optional) 7 - 60 AMP Circuit Breaker 8 - 60 AMP Circuit Breaker 9 - 12 Volt Battery 10 - Engine Ground Stud 11 - Starter 12 - Engine Coolant Temperature Sender 13 - Glow Plugs (If Equipped) 14 - Alternator 15 - Transmission Neutral Safety Switch 16 - Transmission Tem
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Engine Wiring - Starting and Charging System - Page 3 of 4 23 R E S G X M D P K L J F C H W A B T N V U 1 21 2 3 4 5 6 7 8 9 10 11 12 1 BLK BLU/BLK BLK RED/BLK 8 10 9 1. 11 BLK RED RED GRN LT.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Engine Wiring - Starting and Charging System - Page 3 of 4 1 - ECM / Fuel System Harness Connector 2 - Electrical Box 3 - Main Relay 4 - Start Relay 5 - Glow Plug Relay (Optional) 6 - Glow Plug Relay (Optional) 7 - 60 AMP Circuit Breaker 8 - 60 AMP Circuit Breaker 9 - 12 Volt Battery 10 - Engine Ground Stud 11 - Wires Not Used On This Model 12 - Wires Not Used On This Model 13 - Transmission Neutral Safety Switch 14 - Transmission Temperature Switch 15 - Engine Co
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 ECM and Fuel System Wiring - Page 1 of 2 BLU/BLK BLU/BLK BLK/YEL BRN/BLK BLK/YEL RED RED BLU 33 GRN/WHT 49 64 GRN/WHT 5 GRN/WHT 4 YEL 53 BLU 51 GRN 65 8 55 BRN 21 15 ORN/WHT PNK 38 57 YEL/PNK YEL RED RED RED RED RED BLK/PUR GRN PPL/BLK ORN BRN/RED WHT/BLK BLU/BLK 41 50 RED RED RED GRN/BLK WHT/YEL GRN BLU/WHT BRN/WHT 2 40 WHT 42 68 61 GRN/RED 45 46 23 24 26 1 BLK ORN BLK BLK BLK BLU/YEL BRN WHT 2 BLU/YEL 14 WH
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 ECM and Fuel System Wiring - Page 2 of 2 1 2 3 4 5 6 7 8 9 - ECM (Electronic Control Module) / Fuel System Connector - ECM - Engine-Speed Sensor - Throttle Position Sensor - Engine Coolant Temperature Sensor (ECT to ECM) - Electronic Distributor Injection Pump - Electronic Shut-Off Solenoid (ELAB) - Manifold Absolute Pressure Sensor (MAP) - Number 1 Cylinder Fuel Injector with Needle Motion Sensor (NBF) ECM / FUEL SYSTEM HARNESS CONNECTOR NOTE: Refer to Item Numb
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Quicksilver Primary Instrumentation Wiring - Page 1 of 4 1 2 3 PUR 4 PUR BRN/WHT BLK 5 GRY 6 7 8 BLU/TAN BLK GRY BLK TAN/WHT BRN RED GRN BLK BLK LT.BLU 1 TAN GRY RED PUR BLK TAN/BLK BRN/WHT WHT/RED TAN/WHT PUR PUR BLK PUR BLK BLK BLK TAN WHT/YEL BRN RED RED BLU/TAN BRN/WHT YEL/RED YEL/RED BRN/WHT BLK LT.BLU RED RED 14 15 16 PUR TAN/BLK BRN 12 13 PUR 11 13 PUR LT.
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SERVICE MANUAL NUMBER 22 WIRING DIAGRAMS Quicksilver Primary Instrumentation Wiring - Page 2 of 4 1 - Oil Pressure Gauge 2 - Tachometer Gauge 3 - Wires Not Used On This Model 4 - Engine Coolant Temperature Gauge 5 - Voltmeter Gauge 6 - Cruise Log (Engine Hour Meter) 7 - Engine System Monitor Panel a - Preheat Indicator Lamp b - Charge Indicator Lamp c - Oil Pressure Warning Lamp / Low Gear Lube Monitor Level Lamp d - Coolant High Temperature Lamp e - Malfunction Indicator Lamp 8 - Panel Lights/Audio Warni
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Quicksilver Primary Instrumentation Wiring - Page 3 of 4 BLK/YEL 1.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Quicksilver Primary Instrumentation Wiring - Page 4 Of 4 Later Model D2.8L D-Tronic and D4.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Quicksilver Second Station Instrumentation Wiring Models With Early Connectors STERNDRIVE (MCM) - SECOND STATION INSTRUMENTATION 1 2 PUR 4 PUR BRN/WHT BLK 5 GRY 6 7 8 9 BLU/TAN BLK BLK BLK BLK BLK BLK 1 BLK GRY PUR PUR LT.BLU TAN RED PUR 30 86 TAN/BLK BRN/WHT 85 87 BLK PUR ORN BLK BLK BLK BLK TAN PUR BRN ORN PUR ORN GRN 15 PUR BRN/WHT YEL/RED BRN Bullet connectors shown.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 INBOARD (MIE) - SECOND STATION INSTRUMENTATION 1 PUR BRN/WHT BLK GRY 6 7 8 BLU/TAN BLK BRN/WHT YEL/RED BRN ORN BLK BLK BLK TAN GRN BLK BLK 1 TAN GRY BLK PUR PUR PUR LT.BLU BLK BRN/WHT YEL/RED PUR 30 86 TAN/BLK ORN 85 RED BLK PUR BLK BRN ORN PUR BLK RED RED GRY BLK BRN TAN/BLK 14 LT.BLU 10 11 12 13 14 15 16 BRN/WHT LT.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 Models With 21-Pin Deutscht Connector STERNDRIVE (MCM) - SECOND STATION INSTRUMENTATION GRY TAN TAN 18 TAN/WHT PPL BLU BRN/WHT YEL PPL/ORN GRY BLU BRN/WHT 1 PPL TAN/BLK BLK RED BRN BLK/YEL GRY YEL/RED GRN TAN/WHT YEL BLK PPL 2 3 GRN/RED G A H B X TAN BLU/TAN W V F U 3.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 STERNDRIVE (MCM) - SECOND STATION INSTRUMENTATION - PAGE 2 OF 2 1 - Voltmeter Gauge 2 - Tachometer Gauge 3 - Water Temperature Gauge 4 - Oil Pressure Gauge 5 - Trim Position Gauge 6 - Engine System Monitor Panel 7 - Malfunction Indicator Lamp (Check Engine) 8 - Coolant High Temperature 9 - Oil Pressure Warning Lamp / Low Gear Lube Monitor Level Lamp 10 - Charge Indicator Lamp 11 - Preheat Indicator Lamp 12 - Panel Lights/Audio Warning Test Switch 13 - Stop Switch 1
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 INBOARD (MIE) - SECOND STATION INSTRUMENTATION GRY TAN TAN BRN/WHT 18 TAN/WHT PPL BLU BRN/WHT YEL PPL/ORN GRY BLU 1 PPL TAN/BLK BLK RED BRN BLK/YEL GRY YEL/RED GRN TAN/WHT YEL BLK PPL 2 2. TAN BLU/TAN BLK/YEL V U W T F X S 3 GRN/RED G A H B D E P R TAN/BLK J BLUE/TAN PPL/ORN RED K N L C M BRN YEL/WHT RED/YEL 4 BLU RED/YEL YEL/WHT 1.
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WIRING DIAGRAMS SERVICE MANUAL NUMBER 22 INBOARD (MIE) - SECOND STATION INSTRUMENTATION - PAGE 2 OF 2 1 - Voltmeter Gauge 2 - Tachometer Gauge 3 - Water Temperature Gauge 4 - Oil Pressure Gauge 5 - Wires Not Used On This Model.
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DESCRIPTION SERVICE MANUAL NUMBER 22 FUEL SYSTEM Section 5A - Description Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Procedure . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . Basic Knowledge and Tools Required . Visual/Physical Inspection . . . . . . . . . . . Electrostatic Discharge Damage . . . . . . Diagnostic Information . . . . . . . . . . .
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SERVICE MANUAL NUMBER 22 DESCRIPTION Introduction The following information has been prepared for effective service and diagnosis of the Mercury MerCruiser Electronic Diesel Injection (EDI) system. All information, illustrations and specifications contained herein are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice.
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DESCRIPTION SERVICE MANUAL NUMBER 22 Precautions CAUTION To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: proper service and repair are important to the safety of the service technician and the safe, reliable operation of all Mercury MerCruiser Electronic Diesel Injection (EDI) equipped engines. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
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DESCRIPTION SERVICE MANUAL NUMBER 22 Testing Procedure 5. When a test light is specified, a low-power test light must be used. DO NOT use a high-wattage test light. While a particular brand of test light is not suggested, a simple test, as shown below, on any test light will ensure it to be safe for system circuit testing: a. Connect an accurate ammeter (such as the high impedance digital multimeter) in series with the test light being tested, and power the test light/ammeter circuit with the battery. b.
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DESCRIPTION SERVICE MANUAL NUMBER 22 General Information Basic Knowledge and Tools Required To use the information in this manual most effectively, a general understanding of basic electrical circuits and circuit testing tools is required. You should be familiar with wiring diagrams; the meaning of volts, ohms and amperes; the basic theories of electricity and understand what happens in an open or shorted wire. To perform system diagnosis, several special tools and equipment are required.
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DESCRIPTION SERVICE MANUAL NUMBER 22 Diagnostic Information The diagnostic information and functional checks contained in SECTION 5E of this manual are designed to locate a faulty circuit or component through logic based on the process of elimination. The information was prepared with the requirement that the system functioned correctly at the time of assembly and that there are no multiple failures.
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DESCRIPTION SERVICE MANUAL NUMBER 22 ABBREVIATIONS (CONTINUED) Page 5A-8 kPa Kilopascal KV Kilovolts LDF MAP or Boost Pressure Sensor LGS Low Idle Switch MAP Manifold Absolute Pressure MIL Malfunction Indicator Lamp msec Millisecond mV Millivolt NBF Instrumented Injector N/C Normally Closed N/O Normally Open PID Packet of Informational Data PROM Programmable Read Only Memory RAM Random Access Memory REF HI Reference High REF LO Reference Low ROM Read Only Memory SRC Si
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SERVICE MANUAL NUMBER 22 DESCRIPTION Electronic Control Module (ECM) and Sensors General Description The Mercury MerCruiser Electronic Diesel Injection (EDI) system is equipped with a computer that provides the operator with state-of-the-art control of fuel delivery. Computers use voltage to send and receive information. Computers and Voltage Signals Voltage is electrical pressure. Voltage does not flow in circuits. Instead, voltage causes current. Current does the real work in electrical circuits.
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DESCRIPTION SERVICE MANUAL NUMBER 22 SENSORS WITH MORE THAN TWO-WIRES (MAP / IAT AND TP) As an example, the following figure shows a schematic representation of a 3-wire sensor. All 3-wire sensors have a reference voltage, a ground and a variable wiper. The lead coming off of the wiper will be the signal to the Engine Control Module (ECM). As this wiper position changes, the signal voltage returned to the computer also changes.
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SERVICE MANUAL NUMBER 22 DESCRIPTION Analog Value Conditioning The analog value conditioning is subdivided into two parts: sampling the analog signals and scaling and checking the raw values.
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DESCRIPTION SERVICE MANUAL NUMBER 22 ANALOG VALUE EVALUATION To process the raw values there are three different loop frames: speed-synchronous (speed interrupt-synchronous up to a max of 6 ms), fast time-synchronous (20 ms) and slow time-synchronous (100 ms). To evaluate the analog signals, the raw values are checked and converted. Checking consists of a signal range check (SRC). Upon exceeding the valid signal range, a default value is used for the raw values.
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SERVICE MANUAL NUMBER 22 DESCRIPTION Digital Signals GENERAL The computer uses digital signals in a code that contains only ones and zeros. The high voltage of the digital signal represents a one (1), and no voltage represents a zero (0). Each zero and each one is called a bit of information, or just a bit. Eight bits together are called a word. A word, therefore, contains some combination of eight binary code bits: eight ones, eight zeros, five ones and three zeros, and so on.
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DESCRIPTION SERVICE MANUAL NUMBER 22 SWITCH TYPES Switched inputs (also known as discretes) to the computer can cause one bit to change, resulting in information being communicated to the computer. Switched inputs can come in two types: they are pull-up and pull-down types. Both types will be discussed. With a pull-up type switch, the ECM will sense a voltage when the switch is CLOSED. With the pull-down switch, the ECM recognizes the voltage when the switch is OPEN.
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DESCRIPTION SERVICE MANUAL NUMBER 22 Engine Control Module (ECM) The Engine Control Module (ECM) is the control center of the fuel injection system. It constantly monitors information from various sensors, and controls the systems that affect engine performance. The ECM also performs a diagnostic function check of the system. It can recognize operational problems and store a code or codes, which identify the problem areas to aid the technician in making repairs. 75301 D2.8L D-Tronic and D4.
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DESCRIPTION SERVICE MANUAL NUMBER 22 ECM FUNCTION The ECM supplies 4.9 volts (generally rounded to 5 volts, in conversation) or 12 volts to power various sensors or switches. This is done through resistances in the ECM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low.
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SERVICE MANUAL NUMBER 22 DESCRIPTION Speed Density System The Electronic Diesel Injection (EDI) system is a speed and air density system. The system is based on speed/density fuel management. Three specific data sensors provide the ECM with the basic information for the fuel management portion of its operation. That is, three specific signals to the ECM establish the engine speed and air density factors: the Engine rpm Sensor, Intake Air Sensor and the Manifold Absolute Pressure Sensor.
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DESCRIPTION SERVICE MANUAL NUMBER 22 ECM Input and Sensor Descriptions The following shows the sensors, switches, and other inputs used by the ECM to output control the various systems. Although we will not cover them all in great detail, there will be a brief description of each.
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DESCRIPTION SERVICE MANUAL NUMBER 22 INSTRUMENTED INJECTOR [NEEDLE MOVEMENT SENSOR (NBF)] The injector timing reference is supplied to the ECM by way of the Instrumented Injector (Needle Movement Sensor) in the cylinder number 1 injector. This position variable type input creates the timing signal for the ECM. This signal is used for a number of control and testing functions within the ECM.
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DESCRIPTION SERVICE MANUAL NUMBER 22 ENGINE COOLANT TEMPERATURE (ECT) SENSOR The Engine Coolant Temperature (ECT) Sensor is a thermistor (a resistor which changes value based on temperature) immersed in the engine coolant stream. Low coolant temperature produces a high resistance, while high temperature causes low resistance. b c a 75341 a - ECT Sensor b - Harness Connector c - Locking Tab The ECM supplies a fixed current to the ECT through a resistor in the ECM and measures the voltage.
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DESCRIPTION SERVICE MANUAL NUMBER 22 INTAKE AIR TEMPERATURE AND MANIFOLD PRESSURE SENSOR ASSEMBLY Intake Air Temperature (IAT) Sensor The Intake Air Temperature (IAT) sensor and MAP sensor form an assembly. The IAT portion of the assembly is a thermistor (a resistor which changes value based on temperature). Low temperature produces a high resistance, while high temperature causes a low resistance.
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DESCRIPTION SERVICE MANUAL NUMBER 22 Manifold Absolute Pressure (MAP) Sensor The Manifold Absolute Pressure (MAP) sensor is a pressure transducer that measures the changes in the intake manifold pressure. The pressure changes as a result of engine load and speed change, and the MAP sensor converts this to a voltage output.
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DESCRIPTION SERVICE MANUAL NUMBER 22 FUEL QUANTITY ACTUATOR AND SENSOR Inside the electronic diesel pump the solenoid actuator (rotary actuator) for injected fuel quantity control engages with the control collar through a shaft. Similar to the mechanically governed fuel injection pump, the cutoff ports are opened or closed depending upon the control collar’s position. The injected fuel quantity can be infinitely varied between zero and maximum (e.g., for cold starting).
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DESCRIPTION SERVICE MANUAL NUMBER 22 FUEL TEMPERATURE SENSOR The Fuel Temperature Sensor is a thermistor (a resistor which changes value based on temperature) immersed in the fuel inside the upper chamber of the fuel pump. It is not a serviceable item. Low fuel temperature produces a high resistance, while high temperature causes low resistance. The ECM supplies a fixed current to the pump through a resistor in the ECM and measures the voltage.
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DESCRIPTION SERVICE MANUAL NUMBER 22 THROTTLE POSITION (TP) SENSOR The Throttle Position (TP) Sensor is a potentiometer connected to the throttle cable. The TP has one end connected to 5 volts from the ECM and the other to ECM ground. A third wire is connected to the ECM to measure the voltage from the TP. As the throttle cable is operated, the angle of the wiper inside the TP body is changed: the voltage output of the TP also changes.
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DESCRIPTION SERVICE MANUAL NUMBER 22 Fuel Management Control As stated previously, the Electronic Diesel Injection (EDI) is controlled by an Engine Control Module (ECM). This module is the nerve/decision center of the system. It uses all the information it gathers to manage and deliver increased fuel economy and maximum engine performance. The EDI system has been designed so that the ECM controls the injected quantity and timing by the ECM.
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SERVICE MANUAL NUMBER 22 DESCRIPTION Modes Of Operation PREHEATING THE GLOW PLUGS (IF EQUIPPED) The operation of the glow plugs and the glow plug preheating on-time is controlled by the ECM. The time period during which the glow plugs are ON (supplied 12 volts) depends directly on the temperature of the engine coolant (coolant temperature sensor) and the altitude of the engine. The altitude is determined by the BARO Barometric Absolute pressure sensor located inside the ECM.
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DESCRIPTION SERVICE MANUAL NUMBER 22 ENGINE SPEED CHANGES The ECM adjusts the engine operating strategy during acceleration and deceleration in order to avoid unstable operating conditions such as jerkiness and roughness. FUEL FLOW PROPORTIONING The ECM uses information from the Throttle Position sensor and the Engine rpm Speed sensor along with the strategies in its memory to determine the proper fuel quantity to be injected into the engine.
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SERVICE MANUAL NUMBER 22 DESCRIPTION INJECTOR TIMING REGULATION Determining the proper fuel injection point (timing) depends on the quantity of fuel, engine rpm and coolant temperature. The ECM controls the timing using the signal from the number one instrumented injector and corrects the timing to the nominal timing rate. Timing is changed by modulating the pressure in the upper (high pressure) chamber communicating with the pump body through the Timing Solenoid Valve.
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DESCRIPTION SERVICE MANUAL NUMBER 22 Diagnosis and Testing NOTICE For more information on diagnosis and testing refer to SECTION 5E. ECM Reactions During Operation The ECM is capable of performing diagnostic checks within the electronic diesel fuel injection system. When the ECM senses a problem in the system it will identify the problem(s) by storing fault code number(s) in its memory.
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SERVICE MANUAL NUMBER 22 DESCRIPTION MALFUNCTION INDICATOR LAMP The Engine System Monitor Panel provided in the factory instrumentation package is equipped with a Malfunction Indicator Lamp (MIL). The MIL is a lamp with a check mark (n) on the colored lens. • It informs the operator and service technician that a problem has occurred and that the vessel is in need of service as soon as reasonably possible. • It displays Codes stored by the ECM which help the technician diagnose system problems.
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DESCRIPTION SERVICE MANUAL NUMBER 22 INTERMITTENT PROBLEMS AND MALFUNCTION INDICATOR LAMP In the case of an intermittent problem, the Malfunction Indicator Lamp will light for ten seconds and then will go out. However, the corresponding code will be stored in the memory of the ECM. When unexpected codes appear during the code reading process, one can assume that these codes were set by an intermittent malfunction and could be helpful in diagnosing the system. An intermittent code may or may not reset.
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DESCRIPTION SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 5A-34 90-860074--1 FEBRUARY 2002
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 FUEL SYSTEMS Section 5B - Fuel Delivery Pump and Fuel Filter Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . .
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Identification 70163 D2.8L D-Tronic and D4.2L D-Tronic Fuel Delivery Pump Specifications Description D2.8L D-Tronic And D4.2L D-Tronic Fuel Flow per Minute 80 Liters (85 U. S. Qts.) at 2500 rpm Delivery Pressure Supply Restriction Measured at 2500 rpm; no load. Return Pressure 14 - 34 kPa (2-5 psi) 20.261 kPa (6 in. Hg) 13.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Precautions WARNING ALWAYS disconnect battery cables from battery BEFORE working on fuel system to prevent fire. This eliminates the engine wiring as a potential source of ignition. WARNING FIRE HAZARD: Be careful when changing fuel system components; diesel fuel is flammable. Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death. Ensure that ignition key is OFF.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 WARNING FIRE HAZARD: Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death. Careful periodic inspection of entire fuel system is mandatory, particularly after storage. All fuel components including fuel tanks, whether plastic, metal or fiberglass, fuel lines, primers, fittings and fuel filters should be inspected for leakage, softening, hardening, swelling or corrosion.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Exploded View Fuel Delivery Pump, Fuel Filter and Related Components 22 21 3 2 4 12 A 5 9 8 11 10 7 6 20 13 9 10 16 10 1 17 9 18 19 14 15 75406 Page 5B-6 90-860074--1 FEBRUARY 2002
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SERVICE MANUAL NUMBER 22 FUEL DELIVERY PUMP AND FUEL FILTER 1 - Fuel Pump 2 - Screw 3 - Lockwasher 4 - Filter Bracket 5 - Fuel Filter 6 - O-ring 7 - Drain Cap 8 - Pipe, Pump-To-Filter Header 9 - Hollow Bolt (3) 10 - Sealing Washer 11 - Pipe, Filter Header-To-Injection Pump 12 - Nut 13 - Fuel Pump Cover 14 - Diaphragm 15 - Diaphragm Spring 16 - O-ring 17 - Stud (2) 18 - Lockwasher (2) 19 - Nut (2) 20 - Fuel Inlet Fitting 21 - Elbow Fittings 22 - Bracket Description Part Number A 30W Engine Oil Obtain Lo
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Testing IMPORTANT: Avoid a decrease in engine performance. Restrictions of either fuel supply or fuel return circuits will adversely affect engine performance. TESTING FUEL DELIVERY PUMP PRESSURE 3. Remove the bleeder valve from the filter header. 4. Install a suitable barbed , tappered fitting with a short section of fuel hose connected. 5. Attach a suitable 0-100 kPa (0-15 PSI) pressure gauge to this hose.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 TESTING FUEL SYSTEM RESTRICTION TO DELIVERY PUMP 1. Install a suitable vacuum gauge to the inlet side of fuel delivery pump. 2. If measured value is greater than specified, repair as needed.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Removal 1. Disconnect battery cables from battery. 2. Remove fuel supply hose. Plug hose to prevent fuel from leaking into boat. a b 75298 Typical d - Fuel Delivery Pump e - Fuel Supply Hose 3. Remove the hollow bolt from the fuel outlet pipe. Discard sealing washers. 4. Remove the fuel pump. Discard the O-ring seal.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Installation 1. Using 2 new sealing washers on hollow bolt, attach fuel inlet fitting to fuel pump as shown. 2. Tighten hollow bolt securely. c c b a 75298 a - Hollow Bolt b - Sealing Washer c - Fuel Inlet Fitting 3. Using a new O-ring, install the fuel pump on the engine block. Temporarily hand tighten the mounting nuts.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 4. Using 2 new sealing washers on hollow bolt, attach fuel outlet pipe to fuel pump. 5. Torque fuel pump mounting nuts securely. 6. Tighten fuel outlet pipe hollow bolt securely. 7. Connect fuel supply hose. Tighten hose clamp securely.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Water Separating Fuel Filter Removal 1. Disconnect battery cables from battery. NOTE: Use a suitable container to catch excess fuel. 2. Twist locking ring by hand. Remove water separating fuel filter and sealing ring from mounting bracket. Do NOT use a filter wrench. IMPORTANT: Element cannot be cleaned and reused. It must be replaced. 3. Remove the drain cap and O-ring from bottom of the existing filter. Note position of O-ring seal.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 2. Lubricate fuel filter seal with clean 30W engine oil. Align filter to bracket. Twist locking ring by hand to secure filter to bracket. Do NOT use a filter wrench. a b c d 74731 a b c d - Filter Header - Locking Ring - Sealing Ring (Lubricate) - Water Separating Fuel Filter NOTE: Place a suitable container under fuel filter to catch excess fuel. 3. Loosen bleed screw on fuel filter bracket. 4.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Water Drain Valve Operation The fuel filter can be drained of water and small dirt particles without removal of filter. NOTE: To ensure complete draining, in warm weather open the water bleed valve before starting daily operations. In cold weather, where there is a possibility that the condensed water will freeze, drain the filter shortly after the end of daily operations. 1.
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FUEL DELIVERY PUMP AND FUEL FILTER SERVICE MANUAL NUMBER 22 Purging Air From The Fuel System CAUTION Absolute cleanliness is required for work on the fuel system, since the injection pump and fuel injectors have very close tolerances. Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 FUEL SYSTEM Section 5C - Fuel Injectors Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Precautions . . . . . . . .
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Identification The Bosch injector for Direct Injected D-Tronic engines can be identified as shown. 75339 Instrumented Injector Shown (Non-Instrumented Injector Similar) Specifications Description Specification Manufacturer Robert Bosch Corporation Injector Type D2.8L D-Tronic D4.2L D-Tronic Opening Pressure (New Injector) Spray Angle Spray Hole Diameter Multi-Orifice, Hole-Type Nozzle 27,000 kPa (3915 psi) 157 Degrees 0.25 mm (.001 in.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Tools Bosch EFEP60H Nozzle Tester 0 681 200 502 Description: Robert Bosch Corporation 2800 South 25th Avenue Broadview, IL 60153 Mailing Address: P.O.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Precautions WARNING ALWAYS disconnect battery cables from battery BEFORE working on fuel system to prevent fire. This eliminates the engine wiring as a potential source of ignition. WARNING FIRE HAZARD: Be careful when changing fuel system components; diesel fuel is flammable. Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death. Ensure that ignition key is OFF.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Description In the EDI fuel injection system, the injectors (with their nozzles in the particular nozzle holders) are an important connection between the electronically controlled injection pump and the engine. The injectors job includes the following: • Meter the injected fuel. • Manage and prepare the fuel spray in the cylinder. • Set the rate of fuel discharge. • Close-off the injection system from the combustion process taking place inside each cylinder.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Fuel Injector (Cutaway View) 1 3 2 4 5 6 7 6 8 7 5 9 10 11 12 75104 75439 Instrumented Injector (Needle Motion Sensor) Shown (Non-Instrumented Similar) 1 - Holder Body 2 - Adjusting Spindle 3 - Contact Lug 4 - Sensor Coil 5 - Pressure Adjustment Shim 6 - Pressure Spring 7 - Pressure Spindle 8 - Guide 9 - Spring Support 10 - Stop Sleeve 11 - Intermediate Disc 12 - Nozzle Retaining Nut 90-860074--1 FEBRUARY 2002 Page 5C-7
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Exploded View 4 6 24 5 26 25 3 2 23 22 1 12 11 23 9 10 8 7 23 22 23 17 21 17 16 15 14 19 20 19 13 73911 18 1 - Injector / Instrumented Injector (Cylinder Number 1 Only) 2 - Nozzle Gasket 3 - O-ring 4 - Nut (M8) 5 - Washer (If Equipped) 6 - Injector Clamp 7 - Injection Pipe (Cylinder #1) 8 - Injection Pipe (Cylinder #2) 9 - Injection Pipe (Cylinder #3) 10 - Injection Pipe (Cylinder #4) 11 - Injection Pipe (Cylinder #5 - D4.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 NOTICE Read Precautions at front of this SECTION before proceeding. Injector Test (Engine Misfiring) 7. Supply cooling water to seawater inlet holes. 8. Put on safety glasses. 9. With the engine operating at idle, carefully loosen injector pipe sleeve nut at injectors, one cylinder at a time. a. If idle rpm changes, injector is operating. b. If idle rpm does not change, injector may be faulty. a 17 mm 70148 Typical a - Sleeve Nut At Injector 10.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Removal 1. Remove engine cover. 2. Clean dirt from around fuel injector fittings and pipes. IMPORTANT: Ensure that each pipe adapter is counterheld with a second wrench when removing the return pipe hollow bolts. 3. Counterhold fuel return pipe adapter and remove the fuel return pipe hollow bolts. Discard sealing washers. 4. Remove fuel return pipe.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 CAUTION Do NOT bend fuel injection pipes. Bending may cause metal to flake off inside pipes, causing injectors or injection pump to malfunction. 7. Remove fuel injection pipes from injection pump and injectors. 8. Remove flanged hex nut and washer (some engines may not have washers installed). 9. Remove injector clamp. Retain all components.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Inspection 1. Remove any injector seals that may have stayed in the head. Do NOT gouge or nick seat. 2. Ensure that cylinder head injector bores are clean. Testing WARNING Test fluid from the injection nozzle tester will spray out under great pressure. It can easily puncture a person’s skin. Keep your hands away from the injection nozzle tester at all times. Mercury MerCruiser recommends using the EFEP60H nozzle tester from the Robert Bosch Corporation.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Installation 1. Place new copper sealing washer on injector seat as shown. IMPORTANT: Make certain the sealing washer is centered in the bore, and fully seated on the head. a a 70146 Typical a - Copper Sealing Washer 2. Install new O-ring seal on injector. Lubricate seal with a light coat of 30W engine oil. 3. Point fuel return pipe adaptor away from valve cover and install injector. Ensure seal is not damaged during installation. 4. Install injector clamp nut.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 5. Install fuel injection pipes . Tighten sleeve nuts to 17 Nm (156 lb-in.). a b 75583 a - High Pressure Fuel Line b - Sleeve Nut 6. Using 2 new sealing washers for each hollow bolt, install fuel return pipe on injector adapters. IMPORTANT: Ensure that each pipe adapter is counterheld with a second wrench when installing the return pipe hollow bolts. 7. Counterhold fuel return pipe adapter and tighten hollow bolts securely.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 8. Using 2 new sealing washers for the hollow bolt, install fuel return pipe line on injection pump connector. Tighten hollow bolt securely. a b c 73911 75583 Typical a - Fuel Return Pipe b - Hollow Bolts c - Sealing Washers (Two Per Hollow Bolt and Fitting) 9. Refer to Purging Air From Fuel Injectors (Bleeding) to operate the engine and check for fuel leaks. Repair as needed. 10. Install the engine cover.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 Purging Air From Fuel Injectors (Bleeding) In most cases the design of the EDI System will prevent needing to purge air from the fuel lines and injectors. Draining and replacing the water separating fuel filter should include purging air from the new filter, but not usually from the fuel lines, injectors or system. CAUTION Overheating from insufficient cooling water will cause engine and drive system damage.
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FUEL INJECTORS SERVICE MANUAL NUMBER 22 WARNING Avoid injury. Fuel pressure is high enough to penetrate the skin. Do NOT use your fingers to feel for fuel leaks at fittings. 7. Start the engine. 8. Check for fuel leaks while waiting for engine to reach normal operating temperature. Immediately stop the engine if leaks exist. 9. Recheck the installation. 10. Start the engine. 11. Allow the engine to reach normal operating temperature.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 FUEL SYSTEM Section 5D - Injection Pump Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Code and Identification Number Location . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pump . . . . . . . . . . . . . . . . . . . . . Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . Special Tools . .
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INJECTION PUMP SERVICE MANUAL NUMBER 22 NOTICE Refer to SECTION 5A and 5E for additional information on the EDI Fuel System and the Fuel Injection Pump. Identification Pump Code and Identification Number Location a 75409 a - Identification Plate Engine - MCM and MIE Pump Code and Identification Number D2.8L D-Tronic Code:VE 4/12 E 1900 LV1857 L718 Bosch Part Number: 0 460 424 ___ (Quicksilver Part Number: 854213) D4.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Timing IMPORTANT: The following conditions must be met before injection pump timing is changed or set: • Dial Gauge mounted and set on pump. • Notch on crankshaft damper, or power steering pulley, aligns with timing mark on gear housing cover (0 Degrees - TDC). • Number 1 Piston at TDC. Model Setting D2.8L D-Tronic - MCM and MIE 0.60 - 0.65 mm (0.023 - 0.025 in.) D4.2L D-Tronic - MCM and MIE 1.74 - 1.76 mm (0.068 - 0.069 in.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Tools Special EDI Tools Tool Name Description Part Number EFI / EDI Scan Tool (Rinda Technologies 1) Displays problem codes stored in the ECM. It also allows monitoring of various circuits and components in the fuel injection system. Allows for test firing injectors. 94050M (English) 94055M (Multi-Language) Quicksilver Diagnostic Blink Code Tool Flashes light to display problem codes. 91-854221 1: Rinda Technologies, 4563 N. Elston Ave.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Precautions WARNING Electrical system components on this engine are not external ignition protected. Do NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (ref: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury. WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Description Mercury MerCruiser EDI Diesel Engines use the Bosch, Type VE, Distributor Fuel Injection Pump with an electronic governor and integral timing device. The pump is mounted on the port side of the engine and is driven by the camshaft gear. The pump is formed basically by an electrical (upper) part and a mechanical (lower) part.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Fuel Ratings WARNING Under no circumstances should gasoline be mixed with diesel fuel for any reason. This mixture of gasoline and diesel fuel is highly flammable and produces a significant risk to the user. IMPORTANT: Use of improper or water contaminated diesel fuel can damage the engine seriously. Use of improper fuel is considered misuse of engine, and damage caused thereby will not be covered by warranty.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Repair and Service General Information The Robert Bosch Corporation has a network of authorized Bosch Service Dealers throughout the world to service their products. The electronically controlled EDI pump and injectors must be sent to an authorized Bosch Service Center. When shipping an injection pump to a service center for adjustments or repairs, the fuel return line hollow bolt must accompany the unit.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Testing Information 14. When a test light is specified, a low-power test light must be used. Do NOT use a high-wattage test light. While a particular brand of test light is not suggested, a simple test, as shown below, on any test light will ensure it to be safe for system circuit testing: a.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Exploded View 12 1 2 A 8 13 12 14 6 11 9 7 10 73911 3 4 5 15 75437 27 - Injection Pump 28 - Gasket 29 - Stud (M8 x 30) 30 - Washer 31 - Nut 32 - Key 33 - Lockwasher 34 - Nut 35 - Electric Fuel Shut-Off Device 36 - Washer 37 - Nut 38 - Sealing Washer 39 - Banjo bolt (M14 x 1.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Fuel Injection Pump Removal WARNING Safety glasses should be worn while working on fuel injection system. The fuel injection pump will generate pressures in excess of 27000 kPa (3900 psi). Use caution when removing injectors, injector lines or bleeding air from injection system. 1. Remove the hex-head plug in cylinder number 1 glow plug hole, or remove cylinder number 1 cylinder glow plug, if equipped.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 6. The TDC notch is on the pulley aft edge of the larger drive pulleys. Align notch to timing marks on gear cover for TDC number 1 cylinder. b a a 75437 70281 Typical a - TDC Notch On Pulley b - Timing Cover Mark 7. Disconnect battery cables. 8. Using a suitable device remove threaded, round injection pump gear cover by turning cover COUNTERCLOCKWISE. a 70761 a - Cover (Pin-Type or Hex-Head) 9. Remove injection pump gear nut and lockwasher.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 10. With central bolt of gear puller tool backed out, install tool into timing cover. Puller will hold gear against timing cover while pump is removed. NOTE: Gear puller tool screws into timing cover. a c b 22217 70770 a - Timing Cover b - Gear Puller Tool c - Central Bolt 11. Remove the throttle cable and throttle cable bracket. 12. Disconnect the ECM 68 pin connector and TP sensor connector.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 16. Remove the fuel supply line between the pump and filter flange. 17. Remove the fuel return hose from connector. Plug the hose after removal to prevent a fuel leak. 18. Remove the injector fuel return pipe from pump. Discard old sealing washers. a b a c a d 73911 c b 75579 a b c d - Supply Line (Filter to Pump) - Return Hose - Connector - Return Pipe (Injectors to Pump) 19. Unclamp injection pipes.
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SERVICE MANUAL NUMBER 22 INJECTION PUMP NOTE: If necessary, refer to SECTION 5E for description and location of electrical items. 22. Disconnect the Fuel Shut Off Solenoid wire. 23. Disconnect the Fuel Quantity Actuator/Sensor connector. 24. Disconnect the Fuel Timing Solenoid Valve connector. 25. Remove the three injection pump mounting nuts and washers. 26. Slowly turn central bolt of gear puller tool CLOCKWISE until pump and gear separate.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Fuel Injection Pump Installation Installation With Engine Assembled IMPORTANT: If engine has been disturbed, or must be rotated before installing injection pump take care not to wedge pump gear in gear housing while turning crankshaft. 1. Ensure cylinder number 1 piston is at top dead center (TDC) of its compression stroke and timing marks are aligned. 1. Ensure pump gear is held in the same position as when pump was removed. This should be cylinder number 1 TDC. 2.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 4. Being careful not to disturb shaft alignment, remove nuts temporarily installed to rotate shaft. 5. Apply Perfect Seal sealant to a new injection pump gasket. 6. Install new gasket on pump mounting studs. 7. Ensure pump gear upper keyway is positioned approximately as shown. c a b 70768 a - Gasket b - Pump Mounting Studs c - Pump Gear Upper Keyway 8. Install injection pump key in pump shaft keyway. Apply heavy grease to hold key in position. 9.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 15. Rotate pump to end of adjustment slot travel in direction shown. a 70422 Typical a - Direction To Rotate 16. Timing of the injection pump MUST BE accomplished. Refer to Fuel Injection Pump Timing for instructions.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Installation During Engine Reassembly 1. Temporarily install crankshaft pulley, if removed previously. 2. Attach Crankshaft Tool 91-814827 if necessary. CAUTION To avoid severe engine damage the engine MUST BE set on cylinder number 1 COMPRESSION STROKE at Top Dead Center (TDC) before proceeding.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 5. Using a suitable gauge of wire, make a wire pointer. Attach the pointer to a suitable location on the block. Do NOT damage the mating surfaces 6. Align wire pointer to zero degrees (0) as shown. a 70419 b a - Wire Pointer b - Zero (0) Degree Mark 7. Using a heavy grease to hold key in place, install injection pump key in pump slot. 8. Temporarily install gear on injection pump shaft. Do NOT secure gear at this time. 9.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 12. Being careful not to disturb shaft alignment, remove gear. Ensure injection pump key is properly positioned. 13. Apply Perfect Seal sealant to a new injection pump gasket. 14. Install new gasket on pump mounting studs. a b 70768 a - Gasket b - Pump Mounting Studs 15. Install pump to cylinder block. 16. Install hex nuts with flat washers and lockwashers. Temporarily only finger-tighten the nuts. 17.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 18. Ensure injection pump key is properly positioned. IMPORTANT: Do NOT force gear on shaft. 19. Install gear on injection pump shaft, using whichever key slot on gear that allows gear to be installed the easiest. 20. Using a new lockwasher, install gear on shaft with hex nut. Torque to 88 Nm (64 lb-ft). b a c 22217 70424 a - Gear b - New Lockwasher c - Hex Nut 21. Timing of the injection pump MUST BE accomplished.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 Fuel Injection Pump Timing Checking On completely assembled and/or installed engines, and for the purpose of checking fuel injection pump timing refer to instructions previously outlined and accomplish steps, in that section, dealing with installation of crankshaft tool, graduated disc, positioning of crankshaft and removal of parts to gain access to rear of fuel injection pump and vent screw. Setting 1.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 3. Install adaptor tool and dial gauge as shown. Pre-load the dial indicator with at least 2.54 mm (0.10 in.). NOTE: Adaptor tool 854220 is designed to use on EDI engines. a b 70430 a - Suitable Adaptor Tool b - Dial Gauge - Preloaded 4. Watch dial indicator needle and SLOWLY rotate the crankshaft COUNTERCLOCKWISE (viewed from water pump end looking toward flywheel) until dial indicator STOPS moving. 5. Set the dial indicator to zero (0) as shown.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 6. SLOWLY rotate crankshaft CLOCKWISE (viewed from water pump end looking toward flywheel) until 0 Degrees (engine Top Dead Center) is indicated on graduated disc as shown (or until notch on crankshaft damper, or power steering pulley, aligns with timing mark on gear housing cover). 70432 NOTE: The dial indicator follows this rotational movement of crankshaft and STOPS when the cylinder number 1 piston is at TDC, when the crankshaft is not turned further. 7.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 CAUTION Dial gauge indication MUST NOT be allowed to change when mounting nuts are tightened. Failure to maintain setting will result in engine damage. 8. Torque the three injection pump mounting nuts to 27.5 Nm (20 lb-ft). 9. Remove dial gauge and adaptor. Reinstall fuel injection pump vent screw using new sealing washer. Tighten securely. CAUTION Keep injectors and injection pump pipes and fittings clean. Do NOT allow dirt to enter fittings when installing.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 IMPORTANT: Hollow bolts used to hold fuel inlet and return pipes to injection pump are calibrated and MUST remain with pump in their original location. IMPORTANT: Use new sealing washers on hollow bolts to prevent leaks. 12. Install the fuel supply pipe between the pump and filter flange. 13. Unplug and install the fuel return hose to the connector. 14. Install the injector fuel return pipe to the pump.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 21. Install throttle cables. Refer to SECTION 2A - Throttle Cable Installation and Adjustment. IMPORTANT: When installing throttle cables, ensure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. Do NOT fasten any items to throttle cables. 22. Remove graduated disc and adaptor ring, crankshaft tool and wire pointer from front of engine. Install the three balancer screws previously removed.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 4. Continue moving the plunger on hand pump/primer up and down repeatedly until resistance is felt. This should have filled the fuel injection pump. However, should the engine not start and it becomes necessary to purge air from the fuel injection pump, proceed as follows. NOTE: Place suitable container under fuel filter and injection pump to catch excess fuel. 5. Bleed air from Water Separating Fuel Filter. 6. Loosen bleed screw on injection pump. 7.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 9. Install a fully charged battery. CAUTION To prevent damage to starter motor, Do NOT operate starter for more than 15 seconds at one time. Allow at least 2 minutes for starter motor to cool before reusing. 10. Attempt to start the engine. WARNING Safety glasses should be worn while working on fuel injection system. The fuel injection pump will generate pressures in excess of 13790 kPa (2000 psi).
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INJECTION PUMP SERVICE MANUAL NUMBER 22 13. Check for fuel leaks at injection pump and injectors using a piece of paper placed near the suspect fitting or sleeve nut to be checked. The paper should show leaks if present. Do NOT use your fingers to feel for leaks! Watch for fuel spray on paper. Repair as needed. 14. Retest until certain no leaks are present.
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INJECTION PUMP SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 5D-32 90-860074--1 FEBRUARY 2002
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 FUEL SYSTEMS Section 5E - EDI Diagnosis Table of Contents 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 . . . . . . . . . . . . . . . . . . .
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 General Information CAUTION To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: proper service and repair are important to the safety of the service technician and the safe, reliable operation of all Mercury MerCruiser Electronic Diesel Injection (EDI) equipped engines. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
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SERVICE MANUAL NUMBER 22 EDI DIAGNOSIS Visual/Physical Inspection A careful visual and physical inspection must be performed as part of any diagnostic procedure. This can often lead to fixing a problem without further steps. Inspect all hoses for correct routing, pinches, cuts, or disconnects. Inspect hoses that are difficult to see. Inspect all the wires in the engine compartment for proper connections, burned or chafed spots, pinched wires, or contact with sharp edges or hot exhaust manifolds.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Special Tools Tool Name DMT 2000A Description Part Number Tachometer / Multi-Meter Kit - High Impedance Multimeter 91-854009A3 Special EDI Tools Tool Name Description Part Number EFI / EDI Scan Tool (Rinda Technologies 1) Displays problem codes stored in the ECM. It also allows monitoring of various circuits and components in the fuel injection system. Allows for test firing injectors.
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SERVICE MANUAL NUMBER 22 EDI DIAGNOSIS Service Precautions Observe the following when working on EDI equipped engines: • Before removing any ECM system component, disconnect the negative battery cable. • Never start the engine without the battery cable terminal ends being solidly connected. • Never separate the battery from the on-board electrical system while the engine is operating. • Never separate the battery feed wire from the charging system while the engine is operating.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 3. When a test light is specified, a low-power test light must be used. Do NOT use a highwattage test light. While a particular brand of test light is not suggested, a simple test, as shown below, on any test light will ensure it to be safe for system circuit testing: a. Connect an accurate ammeter (such as the high impedance digital multimeter) in series with the test light being tested, and power the test light/ammeter circuit with the battery. b.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Diagnostic Information The diagnostic information and functional checks in this manual are designed to locate a faulty circuit or component through logic based on the process of elimination. The information was prepared with the requirement that the system functioned correctly at the time of assembly and that there are no multiple failures.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Abbreviations (continued) KV Kilovolts LDF Boost Pressure Sensor (See MAP) LGS Low Idle Switch MAP Manifold Absolute Pressure MIL Malfunction Indicator Lamp msec Millisecond NBF Instrumented Injector N/C Normally Closed N/O Normally Open PID Packet of Informational Data PROM Programmable Read Only Memory PWG Throttle Position Sensor RAM Random Access Memory REF HI Reference High REF LO Reference Low ROM Read Only Memory SRC Signal Ran
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SERVICE MANUAL NUMBER 22 EDI DIAGNOSIS Malfunction Indicator Lamp The Engine System Monitor Panel provided in the factory instrumentation package is equipped with a Malfunction Indicator Lamp (MIL). The MIL is a lamp with a check mark (n) on the colored lens. • It informs the operator and service technician that a problem has occurred and that the vessel is in need of service as soon as reasonably possible. • It displays Codes stored by the ECM which help the technician diagnose system problems.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Intermittent Problems and Malfunction Indicator Lamp In the case of an intermittent problem, the Malfunction Indicator Lamp will light for ten seconds and then will go out. However, the corresponding code will be stored in the memory of the ECM. When unexpected codes appear during the code reading process, one can assume that these codes were set by an intermittent malfunction and could be helpful in diagnosing the system. An intermittent code may or may not reset.
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SERVICE MANUAL NUMBER 22 EDI DIAGNOSIS BLINK CODE TOOL 1. Install diagnostic Blink Code Tool (BCT) connector into the cavity of the DLC connector. 2. Switch the key ON. Keep the key ON for all diagnostic work. 3. Press the button on the BCT for 2.5 - 5.0 seconds. 4. When the button is released the BCT lamp will start to flash an output sequence which begins with a long blink followed by four groups of shorter blinks. 5. If there are no fault codes stored, the code 4 4 4 4 will be blinked out.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 SCAN CODE TOOL IMPORTANT: If a scan tool is used to read the codes, follow the manufacturer’s instructions. The ECM can communicate a variety of information through the DLC connector. This data is transmitted at a high frequency which requires a scan tool for interpretation.
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SERVICE MANUAL NUMBER 22 EDI DIAGNOSIS Clearing Codes IMPORTANT: To avoid improper tool functions, Ensure the battery is fully charged. BLINK CODE TOOL 1. Connect BCT (Blink Code Tool), if not already connected. 2. Make certain the ignition key is in the OFF position. 3. Press the button on the Diagnostic Code Tool, and hold it depressed. 4. Switch the key to ON while continuing to press the Tool button for between 2.5 and 5 seconds. 5. When the button on the Tool is released the 0000 Code should be seen.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Diagnosis of Driveability Concerns If a driveability concern still exists after following the diagnostic circuit checks and reviewing Troubleshooting, an out-of-range sensor may be suspected. Because of the unique design of the EDI system, fail-safes have been incorporated into the ECM to replace a sensed value with a default value in the case of a sensor malfunction or sensor wiring concern.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 ECM Input and Sensor Diagram The following shows the sensors, switches, other inputs and outputs used by the ECM to control its various systems. Although we will not cover them all in great detail, there will be a brief description of each.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 ECM Connector Pin Layout All related wiring attaches to the ECM with one 68 pin wiring harness connector. This connector is represented by the following diagram. The numbered squares represent a pin and its relative location in the cavity of the ECM. Those numbered squares which appear shaded represent pins not utilized in the Marine application.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Connector Chart The following chart will aid in identification and diagnosis of wiring circuits that are attached to the ECM through the 68 pin connector. CAUTION AVOID loss of engine operation or wiring damage. Serious electrical damage could result from improper probing of wires and connectors. Do NOT damage wires, connectors or electrical system. NOTE: Clear each code after disconnecting and reconnecting each sensor.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Connector Chart (continued) ECM Pin Page 5E-18 Wire Color Abbreviation 18 Unused - - 19 Unused - - 20 Unused - - 21 Engine Speed Sensor (Digital) BRN/RED P0725 22 Unused - - 23 Battery Feed RED P1600 24 Battery Minus BLK P1600 25 Unused - - 26 Malfunction Indicator Lamp (MIL) BRN/WHT P1650 27 Unused - - 28 Unused - - 29 Control Sleeve Position Sensor GRN P1225 30 Unused - - 31 Unused - - 32 Unused - - 33
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Connector Chart (continued) ECM Pin Circuit Designation Wire Color Abbreviation Diagnostic Trouble Codes DTC(s) ScanTool - - 44 Unused 45 Battery Feed RED P1600 46 Battery Minus BLK P1600 47 Unused - - 48 Unused - - 49 Fuel Quantity Actuator GRN/WHT P1220 50 Glow Plug Relay (control side) BLU/BLK P1635 51 Solenoid Valve for Timing BLU P1630 52 Fuel Quantity Sensor (Measure Coil) BLU/YEL P1225 53 Electric Shut Off Device YEL
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 MAP (Manifold Air Pressure) Sensor Scan Code: P0105 Blink Code: 2222 Malfunction Indicator Lamp: ON 40 41 64 55 4 3 2 1 a GRN/BLK 64 b GRN WHT/YEL 41 c 40 d BLU/WHT 55 e f a b c d e f 75340 - MAP / IAT Sensor Assembly - IAT Signal - 5 Volt Reference Signal - MAP Signal - Sensor Ground - To Throttle Position Sensor CIRCUIT DESCRIPTION: The MAP (Manifold Air Pressure) sensor and IAT (Intake Air Temperature) sensor form an assembly.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION: Verify continuity between the following pins: ECM 68 PIN CONNECTOR 4 TERMINAL CONNECTOR AT ECT 40 4 41 3 55 1 DIAGNOSTIC HELP: Verify the following: • Open or short in the CKT Pin 40, CKT Pin 41 or CKT Pin 55 will cause low amount of smoke. • Assembly loose on manifold or a damaged O-ring seal, causing improper signal. Will cause high amount of smoke. • Bent terminal or pin at the MAP connection or ECM. • Defective MAP or ECM.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 ECT (Engine Coolant Temperature) Sensor Scan Code: P0115 Blink Code: 1113 Malfunction Indicator Lamp: ON a b 1 2 14 c 33 WHT/BRN 14 d BRN/PUR 33 e f 75341 a b c d e f - ECT Sensor - ECT Connector - ECT Signal - 5 Volt Reference Signal - Sensor Ground - To Injection Pump CIRCUIT DESCRIPTION: The ECT (Engine Coolant Temperature) Sensor is a thermistor (a resistor which changes value based on temperature) immersed in the engine coolant stream.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION: Verify continuity between the following pins: ECM 68 PIN CONNECTOR 2 TERMINAL CONNECTOR AT ECT 14 1 33 2 Verify the sensor resistance between the two ECT sensor terminals as a function of temperatures: NOTE: Stabilization time before each measurement should be at least 10 minutes in water. TEMPERATURE °C (°F) RESISTANCE (kOhm) MAXIMUM MEASUREMENT Current (mA) –30 (–22) 22.2 - 31.8 0.2 –10 (13) 8.29 - 10.61 0.4 20 (67) 2.28 - 2.72 1.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Fuel Temperature Sensor Scan Code: P0180 Blink Code: 3333 Malfunction Indicator Lamp: OFF ECM c BLU/RED a 6 7 d 33 1 5 4 BRN/PUR b 63 2 3 75409 75565 a b c d - Fuel Temperature Sensor (Inside Fuel Injection Pump) - 5 Volt Reference Signal - Fuel Temperature Sensor Signal - Sensor Ground CIRCUIT DESCRIPTION: The Fuel Temperature Sensor is a thermistor (a resistor which changes value based on temperature).
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR 7 TERMINAL CONNECTOR AT FUEL INJECTION PUMP 33 5 63 6 Verify the sensor resistance between terminals 5 and 6 of the injection pump connector as a function of temperatures: TEMPERATURE °C° (F) RESISTANCE (kOhm) –10 (13) 8.29 - 10.61 20 (67) 2.28 - 2.72 50 (122) 0.751 - 0.901 80 (175) 0.291 - 0.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 RPM (Engine Speed) Sensor P0725 Blink Code: 1131 Malfunction Indicator Lamp: ON 123 Scan Code: 2 b 3 e ECM 1 WHT BRN/RED 8 21 c d a 75311 a b c d e - RPM (Engine Speed) Sensor - Harness Connector - Sensor ECM Input Signal - Sensor Ground (–) - Symbol for Shield Cable CIRCUIT DESCRIPTION: The rpm (Engine Speed) Sensor is an induction-type pulse generator which mounts close the leading edge of the flywheel.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR 3 TERMINAL CONNECTOR 8 2 21 1 and 3 (3 is shield wire) 21 3 (shield wire) Verify the resistance between terminals 1 and 2 of the sensor: RESISTANCE (Ohm) MAXIMUM MEASUREMENT 1000 1000 ohm DIAGNOSTIC HELP: Verify the following: • Open or short in the CKT Pin 8 or CKT Pin 21. • Bent pin at the 3 terminal connector or ECM. • Sensor mounting is improper.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 BARO (Atmospheric Pressure) Sensor Scan Code: P1105 Blink Code: 1121 Malfunction Indicator Lamp: OFF b a 75336 a - ECM b - BARO (Atomosheric Pressure) Sensor CIRCUIT DESCRIPTION: The BARO (Atmospheric Pressure) Sensor is inside the ECM. It is not serviceable or replaceable individually. The complete ECM must be replaced to repair a faulty BARO sensor. A failure in the BARO sensor circuit should set a Code P1105.
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SERVICE MANUAL NUMBER 22 EDI DIAGNOSIS TEST DESCRIPTION Verify failure using either the Blink Code Tool and/or Scan Tool. There are no individual circuits to be tested. All BARO sensor circuits are inside the ECM and are not serviceable. DIAGNOSTIC HELP: BARO Sensor failure influences engine performance as follows: • The engine behavior does not change noticeably when the engine is operated at or near sea level. It is acceptable to operate the engine with this failure, unless there is a complaint.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 IAT (Intake Air Temperature) Sensor Blink Code: 1112 Malfunction Indicator Lamp: ON 40 41 64 55 P1110 4 3 2 1 Scan Code: GRN/BLK 64 GRN 41 WHT/YEL a BLU/WHT f a b c d e f 40 55 b c d e 75340 - IAT / MAP Sensor Assembly - IAT Signal - 5 Volt Reference Signal - MAP Signal - Sensor Ground - To Throttle Position Sensor CIRCUIT DESCRIPTION: The IAT sensor and MAP (Manifold Absolute Pressure) sensor form an assembly.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION: Verify continuity between the following pins: ECM 68 PIN CONNECTOR 4 TERMINAL CONNECTOR AT MAP 55 1 64 2 Verify the sensor resistance between the two IAT sensor terminals as a function of temperature: NOTE: Stabilization time before each measurement should be at least 10 minutes in test medium. TEMPERATURE °F (°C) MINIMUM RESISTANCE (kOhm) TYPICAL RESISTANCE (kOhm) MAXIMUM RESISTANCE (kOhm) –40 (–40) 1 39.18 48.55 57.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Instrumented Injector (Needle Movement Sensor) Scan Code: P1201 Blink Code: 1132 Malfunction Indicator Lamp: ON b a 2 1 2 e ECM 1 BRN 11 d WHT 12 c 75339 a b c d e - Instrumented Injector (Needle Movement Sensor) - Harness Connector - Sensor ECM Signal - Sensor Ground (–) - Symbol for Shield Cable CIRCUIT DESCRIPTION: The injector timing reference is supplied to the ECM by way of the Instrumented Injector (Needle Movement Sensor, or referred to so
PAGE 601
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR 2 TERMINAL CONNECTOR 11 2 (is shield wire, also) 12 1 Verify the sensor resistance between terminals 1 and 2 of the sensor: RESISTANCE (Ohm) MINIMUM / MAXIMUM MEASUREMENT 100 90 - 110 DIAGNOSTIC HELP: Verify the following: • Open or short in the CKT Pin 11 or CKT Pin 12. • Defective sensor. • Defective ECM.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Fuel Quantity Actuator (Pump Actuator) Scan Code: P1220 Blink Code: 1223 Malfunction Indicator Lamp: ON ECM b 75409 6 5 4 2 c 45 c RED 68 c GRN/WHT 4 d GRN/WHT 5 d GRN/WHT 49 d 7 1 23 RED RED a b RED e 3 75565 a b c d e - Fuel Quantity Actuator (Inside Injection Pump) - Harness Connector - Battery Supply Voltage To Sensor From ECM - Sensor Ground (–) - Twisted Wire Pair CIRCUIT DESCRIPTION: Inside the electronic diesel pump the Fu
PAGE 603
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR 7 TERMINAL CONNECTOR 4 / 5 / 49 4 23 / 45 / 68 7 Verify the actuators resistance between terminals 4 and 7 of the injection pump connector: RESISTANCE (Ohm) MINIMUM / MAXIMUM MEASUREMENT 1 ± 0.3 Verify supply voltage to injection pump with the 7 terminal connector unplugged and key ON.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Fuel Quantity Sensor (Control Sleeve Position Sensor) Scan Code: P1225 Blink Code: 1222 Malfunction Indicator Lamp: ON b ECM a 6 b 7 29 c BLU/YEL 52 d ORN 7 e BRN/PUR 33 f 1 5 4 GRN 2 3 75565 a b c d e f - Fuel Quantity Sensor (Control Sleeve Position Sensor) - Fuel Quantity Sensor Connector - Control Sleeve Position Sensor - Fuel Quantity Sensor (Measure Coil) - Control Sleeve Position Sensor Signal - Analog Ground (–) CIRCUIT DESCRIPTION
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR 7 TERMINAL CONNECTOR 29 1 52 2 7 3 33 5 Verify the actuators resistance between terminals 1 and 2 of the injection pump connector: RESISTANCE (Ohm) MINIMUM / MAXIMUM MEASUREMENT 11.3 ± 0.3 Verify supply voltage to injection pump with the 7 terminal connector unplugged and key ON.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Timing Fault (Timing Advance Regulation) Scan Code: P1230 Blink Code: 1321 Malfunction Indicator Lamp: OFF ECM a BLU b 12 c 2 d 51 RED 68 e RED 45 e RED 23 e 1 75409 a b c d e - Fuel Injection Pump - Timing Solenoid Valve - Harness Connector - Sensor Ground (–) - Battery Supply Voltage (1 of 3) CIRCUIT DESCRIPTION: Determining the proper fuel injection point (timing) depends on the quantity of fuel, engine rpm and coolant temperature.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR 2 TERMINAL CONNECTOR 23 / 45 / 68 1 51 2 Verify the solenoid valves resistance between terminals 1 and 2 of the connector: RESISTANCE (Ohm) MINIMUM / MAXIMUM MEASUREMENT 15 ± 0.0 Verify supply voltage to solenoid valve terminal connector with the connector unplugged and key ON.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TP (Throttle Position) Sensor / Low Idle Switch Scan Code: P1515 Blink Code: 1144 Malfunction Indicator Lamp: ON ECM a b 6 7 1 g 5 4 ORN/WHT 15 c PNK/YEL 57 d BLU/WHT 55 e BRN/RED 65 f 2 3 BLK b 1 75565 a b c d e f g - TP Sensor - Harness Connector - TP Sensor Signal - 5 Volt Reference Signal - Sensor Ground (–) - Battery Supply Voltage - To MAP/IAT Sensor CIRCUIT DESCRIPTION: The TP (Throttle Position) sensor translates throttle positi
PAGE 609
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION NOTE: Constant voltage may be observed at the very first part and the very last part of the TP’s rotation. Verify continuity between the following: ECM 68 PIN CONNECTOR 7 TERMINAL CONNECTOR 15 1 57 2 55 4 65 5 1 6 Verify supply voltage to TP sensor with the 7 terminal connector unplugged and key ON.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Battery Voltage Scan Code: P1600 Blink Code: 1233 Malfunction Indicator Lamp: OFF 72965 CIRCUIT DESCRIPTION: If battery voltage drops below 9 volts the Instrumented Injector (needle movement sensor) stops working. If the battery voltage drops below 6 - 9 volts the fuel quantity actuator begins to work improperly. The ECM stops working when the battery voltage drops below 6 volts. However, the diagnostic system will not recognize a low voltage problem.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Battery (Switched K15) Scan Code: P1605 Blink Code: 1232 Malfunction Indicator Lamp: ON/OFF 75343 CIRCUIT DESCRIPTION: Battery voltage is supplied to the ECM through several circuits. The ignition switch terminal 15 (sometimes called K15) is energized when the key is switched to the ON / RUN position. However, the ignition switch is not monitored by the ECM. Instead, evaluation of the unverified terminal 15 is carried out by the ECM.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Microcontroller Fault Scan Code: P1615 Blink Code: 1311 Malfunction Indicator Lamp: OFF 75343 CIRCUIT DESCRIPTION: As part of self-diagnosis the ECM is capable of determining if failures have occurred to circuits within the ECM. If defects exists the ECM sets this code. DIAGNOSTIC HELP: Verify the following: • Replace the ECM. Recognition by the ECM of Microprocessor Fault influences engine performance as follows: • Page 5E-44 No loss of power.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 ECM Reference Voltage (u_ref - 2.5v) Scan Code: P161A Blink Code: 1234 Malfunction Indicator Lamp: OFF 75343 CIRCUIT DESCRIPTION: As part of self-diagnosis the ECM is capable of determining if failures have occurred to the reference voltage circuits within the ECM. If defects exists the ECM sets a Scan Code 161A. DIAGNOSTIC HELP: Verify the following: • Replace the ECM.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Main Relay Scan Code: P1625 Blink Code: 1231 Malfunction Indicator Lamp: OFF ECM b f c e d WHT/RED RED 42 g 23 h 75342 a b c d e f g h - Electrical box - Battery 12 Volt To Circuit Breaker - Circuit Breaker - Main Relay - 11 Terminal ECM Harness Connector on Electrical Box - 11 Terminal Connector - Ground (–) CKT Pin 42 for Relay - 12 Volt Power Supply to ECM CIRCUIT DESCRIPTION: The Main Relay test monitors whether the power supply was shut off too e
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK 90-860074--1 FEBRUARY 2002 Page 5E-47
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Timing Actuator (Timing Solenoid Valve) Scan Code: P1630 Blink Code: 1214 Malfunction Indicator Lamp: OFF ECM a BLU b 12 c a b c d e 2 d 51 RED 68 e RED 45 e RED 23 e 1 75409 - Fuel Injection Pump - Timing Solenoid Valve - Harness Connector - Sensor Ground (–) - Battery Supply Voltage (1 of 3) CIRCUIT DESCRIPTION: Determining the proper fuel injection point (timing) depends on the quantity of fuel, engine rpm and coolant temperature.
PAGE 617
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR 2 TERMINAL CONNECTOR 23 / 45 / 68 1 51 2 Verify the solenoid valves resistance between terminals 1 and 2 of the connector: RESISTANCE (Ohm) MINIMUM / MAXIMUM MEASUREMENT 15 ± 0.0 Verify supply voltage to solenoid valve terminal connector with the connector unplugged and key ON.
PAGE 618
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Glow Plug Main Relay (Glow Plug Relay Actuator), If Equipped Scan Code: 1635 Blink Code: No recognition by ECM.
PAGE 619
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION NOTE: The relay terminal numbers can be found on the bottom of the relay. Verify continuity between the following: ECM 68 PIN CONNECTOR GLOW PLUG RELAY CONNECTOR / TERMINAL NUMBER 50 85 Verify continuity between the following: ECM 68 PIN CONNECTOR INSTRUMENT PANEL TERMINAL 3 BLK/YEL Wire at glow plug indicator lamp on the Engine Monitor Panel Verify supply voltage from circuit breakers to relays with relay connector unplugged and key ON.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Glow Plug Auxiliary Relay, If Equipped Scan Code: P1640 Blink Code: No recognition by ECM.
PAGE 621
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION NOTE: The relay terminal numbers can be found on the bottom of the relay. Verify continuity between the following with relay connectors unplugged and key OFF. Measure: GLOW PLUG RELAY CONNECTOR / TERMINAL NUMBER GLOW PLUG AUXILIARY RELAY CONNECTOR / TERMINAL NUMBER 87 86 Verify supply voltage from circuit breaker to Glow Plug Auxiliary Relay with relay connector unplugged and key ON.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Glow Plug Lamp (Glow Plug Display) MODELS WITH EARLY (16 PIN) CONNECTOR NOTE: Functional only if the engine is equipped with a Glow Plug System.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 3 BLK/YEL Verify supply voltage from key switch terminal 15 with key ON. Measure: CURRENT (VOLTS) GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 12 PNK DIAGNOSTIC HELP: Verify the following: • Open or short in wiring between instrument panel and ECM. • Improper terminals or pins at the electrical box harness connectors or ECM.
PAGE 624
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Glow Plug Lamp (Glow Plug Display) MODELS WITH LATE (21 PIN) CONNECTOR NOTE: Functional only if the engine is equipped with a Glow Plug System.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 3 BLU/TAN Verify supply voltage from key switch terminal 15 with key ON. Measure: CURRENT (VOLTS) GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 12 PUR DIAGNOSTIC HELP: Verify the following: • Open or short in wiring between instrument panel and ECM. • Improper terminals or pins at the electrical box harness connectors or ECM.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 MIL [Malfunction Indicator Lamp (Diagnostic Lamp)] MODELS WITH EARLY (16 PIN) CONNECTOR Scan Code: P1650 Blink Code: 1242 Malfunction Indicator Lamp: OFF e d a 75305 BRN/WHT BRN/WHT ECM b c 26 BRN/WHT 75476 a b c d e f - Electrical Box - Pin 2 of Instrumentation Harness 16 Pin Connector - Pin 2 of ECM 11 Pin Harness Connector - MIL - Instrument Panel - ECM Supplied Ground Circuit CIRCUIT DESCRIPTION: The MIL (Malfunction Indicator Lamp) is controlled
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 26 BRN/WHT Verify supply voltage from key switch terminal 15 with key ON. Measure: CURRENT (VOLTS) GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 12 PNK DIAGNOSTIC HELP: Verify the following: • Open or short in wiring between instrument panel and ECM. • Improper terminals or pins at the electrical box harness connectors or ECM.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 MIL [Malfunction Indicator Lamp (Diagnostic Lamp)] MODELS WITH LATE (21 PIN) CONNECTOR Scan Code: P1650 Blink Code: 1242 Malfunction Indicator Lamp: OFF 1 a 2 3 PPL/YEL M b BLK ORN d ORN PPL e RED BLK GRY PPL TAN 75305 YEL BRN ECM RED YEL 2 BLU/TAN YEL/RED PPL BLU/BLK PPL/YEL c GRN RED BLK RED BLK BRN/WHT 26 f RED 75476 a b c d e f - Electrical Box - Pin M of Instrumentation Harness 21 Pin Connector - Pin 2 of ECM 12 Pin Harness
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 26 BRN/WHT Verify supply voltage from key switch terminal 15 with key ON. Measure: CURRENT (VOLTS) GLOW PLUG BULB SOCKET WIRE AT DASH PANEL 12 PUR DIAGNOSTIC HELP: Verify the following: • Open or short in wiring between instrument panel and ECM. • Improper terminals or pins at the electrical box harness connectors or ECM.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Fuel Shut Off Valve [EAB (Electrical Shut Off)] Scan Code: P1660 Blink Code: 1221 Malfunction Indicator Lamp: ON ECM b a YEL 53 c 75409 a - Fuel Injection Pump b - Fuel Shut Off Valve c - ECM Controlled12 Volt Power Supply CIRCUIT DESCRIPTION: As a safety feature the engine is equipped with a Fuel Shut Off Valve (Electrical Shut Off). This valve is a redundant method of stopping the engine.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR DEVICE TERMINAL 53 Electrical Fuel Shut Off Verify supply voltage to fuel shut off valve terminal with the wire disconnected and key ON. Measure between the wire and the engine ground (–). Current should be present for the first 25 seconds only, and then cease, unless there is a failure.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 EEPROM Fault (EEPROM and Configuration) Scan Code: P1680 Blink Code: 1313 Malfunction Indicator Lamp: OFF 75336 a - ECM (Engine Control Module) CIRCUIT DESCRIPTION The EEPROM Fault code may appear as a result of a calibration failure in the ECM. At startup the defect memory is read out from the EEPROM and interpreted. Thus a determination is made concerning how many entries are filed in the defect memory.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK 90-860074--1 FEBRUARY 2002 Page 5E-65
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 RPM Signal From Injector (Secondary Engine Speed Sensor) Scan Code: P1725 Blink Code: 3332 Malfunction Indicator Lamp: ON a 12 b 2 e ECM 1 BRN 11 d WHT 12 c 75339 a b c d e - Instrumented Injector (Needle Movement Sensor) - Harness Connector - Sensor ECM Signal - Sensor Ground (–) - Symbol for Shield Cable CIRCUIT DESCRIPTION: A secondary engine speed sensor signal called rpm Signal From Injector, is supplied to the ECM by way of the Instrumented
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 TEST DESCRIPTION Verify continuity between the following: ECM 68 PIN CONNECTOR 2 TERMINAL CONNECTOR 11 2 (is shield wire, also) 12 1 Verify the sensor resistance between terminals 1 and 2 of the sensor: RESISTANCE (Ohm) MINIMUM - MAXIMUM MEASUREMENT 100 90 - 110 DIAGNOSTIC HELP: Verify the following: • Open or short in the CKT Pin 11 or CKT Pin 12. • Defective sensor. • Defective ECM.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting For EDI Systems Trouble Codes Code Number Page 5E-68 Code Description Scan Code Number Blink Code Number P0105 2222 MAP Sensor P0115 1113 ECT Sensor P0180 3333 Fuel Temp.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Display Terminology In addition to displaying trouble codes and their description, the Scan Tool is capable of supplying Extended Information. This information is designed to assist the technician in more readily resolving the cause of a listed Trouble Code. Refer to “Diagnostic Circuit Check” information and procedures. Although not all displayed information needs further explanation (e.g.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Display Terminology (Continued) Related to Scan Tool Code Explanation / Possible Cause PLAUSIBILITY WITH LDF Problem most likely to be found in MAP circuit. Example: boost pressure equals atmospheric pressure but rpms are high.) Check wiring. P0725, P1725 DYNAMIC PLAUSIBILITY The rpm sensor or instrumented injector have indicated a fault while the engine was operating (that is, over a period of time).
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Display Terminology (Continued) Related to Scan Tool Code P1220 P1220 P1225 P1225 90-860074--1 FEBRUARY 2002 Displayed Extended Information As Shown On Scan Tool Explanation / Possible Cause PERSISTENT NEGATIVE GOVERNOR DEVIATION (COLD) When the engine is cold and the monitored fuel quantity is greater at a preset engine speed than the real position of the fuel quantity actuator. Check wiring first. If connections are OK, the pump itself should be replaced.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Display Terminology (Continued) Related to Scan Tool Code Displayed Extended Information As Shown On Scan Tool Explanation / Possible Cause POSITIVE GOVERNOR DEVIATION Control of injection timing is occurring at a greater frequency than the programmed control values. Check the instrumented injector circuit and injection pump. NEGATIVE GOVERNOR DEVIATION Control of injection timing is occurring at a lesser frequency than the programmed control values.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Display Terminology (Continued) Related to Scan Tool Code Displayed Extended Information As Shown On Scan Tool P1615 RECOVERY HAS OCCURRED P1615 PREPARE ACTUATOR FOR GATE ARRAY FUEL QUANTITY STOP P1615 REDUNDANT OVERRUN MONITORING P1615 GATE ARRAY FUEL QUANTITY STOP P1615 GATE ARRAY MONITORING P1615 GATE ARRAY REPROGRAMMING Explanation / Possible Cause Clear the code(s) and start the engine. If the same fault occurs at each start, replace the ECM.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts IMPORTANT PRELIMINARY CHECKS BEFORE USING THIS SECTION Before using this section you should have determined that: 1. The ECM is operating correctly. 2. There are no diagnostic trouble codes (DTC) stored. SYMPTOM Verify the customer complaint, and locate the correct symptom. Check the items indicated under that symptom. VISUAL/PHYSICAL CHECK Several of the symptom procedures call for a careful visual/physical check.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) INTERMITTENTS Definition: Problem occurs randomly. May or may not store a Diagnostic Trouble Code (DTC). Do NOT use the diagnostic trouble code charts for intermittent problems, unless instructed to do so. If a fault is intermittent, incorrect use of diagnostic trouble code charts may result in replacement of good parts. Most intermittent problems are caused by faulty electrical connections or wiring.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES 1. Starting motor operating, but not cranking the engine. 2. Crankshaft rotation restricted. 3. Starting circuit connections loose or corroded. 4. Neutral safety switch or starter relay inoperative. 5. Battery charge low. ENGINE WILL NOT CRANK OR 6. No voltage to starter CRANKS solenoid. SLOWLY 7. Solenoid or starter motor inoperative. CORRECTION 1. Remove the starter motor.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES 1. No fuel in supply tank. 1. kit fuel supply. 2. Fuel Shut Off Valve not operating. 2. Check for loose wires and verify that the fuel shutdown solenoid and fuel shutdown solenoid relay is functioning. 3. Air intake or exhaust plugged. 4. Fuel filter plugged. 5. Excessive fuel inlet restriction. ENGINE CRANKS BUT WILL NOT START NO SMOKE CORRECTION 6.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES CORRECTION 1. Incorrect starting procedure. 2. 3. 4. 5. 6. ENGINE HARD TO START, OR WILL NOT START, SMOKE FROM EXHAUST. 7. 1. The fuel shutoff solenoid control must be in the run Cranking speed too slow. position. Ensure proper Glow Plug Actuating Relay or procedure is being used. Auxiliary Relay defective. 2. (A) Verify that the drive / One or more glow plugs transmission is not engaged. defective.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES 1. Contaminated fuel. 2. Fuel screen plugged. 3. One or more injectors worn or not operating properly. ENGINE HARD TO START, OR WILL NOT START, SMOKE FROM EXHAUST. 4. Malfunctioning, worn or inoperative injection pump. 5. Injection pump out of time or Timing Fault. 6. Engine compression low. CORRECTION 1. Verify by operating the engine with clean fuel from a temporary tank.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES CORRECTION 1. Fuel injection lines leaking. 2. 3. 4. 5. 1. Correct leaks in the high pressure lines, fittings, Air in the fuel or the fuel supply injectors sealing washers or is inadequate. delivery valves. Contaminated fuel. 2. Check the flow through the Incorrect valve operation. filter and bleed the system. Locate and eliminate the air Injection pump timing source. incorrect. operating 3.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES CORRECTION 1. Glow plug relay(s) defective. 2. 3. 4. 5. 6. ENGINE STARTS, BUT 7. WILL NOT KEEP OPERATING 1. Verify system is working. Repair/replace inoperative One or more glow plugs parts. defective. 2. Verify system is working. Idle speed / fuel quantity too Repair/replace inoperative low for the accessories. parts. Intake air or exhaust system 3. Adjust the idle speed. restricted. 4.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION SURGING (SPEED CHANGE) POSSIBLE CAUSES CORRECTION 1. If the condition occurs at idle, 1. Adjust the idle speed. the idle speed is set too low for 2. Inspect/correct leaks in the the accessories. high pressure fines. Fittings 2. High pressure fuel leak. and delivery valve sealing washers. 3. One or more injectors worn or not operating properly. 3. Check/replace the inoperative injector 4.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES CORRECTION 1. Throttle cable not moving to full throttle. 1. Check/correct for stop-to-stop travel. 2. High oil level. 2. Check/correct oil level. 3. Engine overloaded. 3. Check for added loading from accessories or driven units, brakes dragging and other changes in vehicle loading. Repair/replace as needed. 4.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES 1. Air leak between the turbocharger and the intercooler. 2. Exhaust leak at the manifold or turbocharger. 1. Check/correct leaks in hoses, gaskets, intercooler and around mounting capscrews or through holes in the cooler end covers. 4. Wastegate operation. 2. Check/correct leaks in the manifold or turbocharger gaskets. If manifold is cracked, replace manifold. 5. Valve not operating 3.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES CORRECTION 1. Engine operating too cold 1. Refer to troubleshooting for (white smoke). coolant temperature below normal (refer to Cooling 2. Improper starting procedure System). Inspect glow plugs (white smoke). for proper operation. 3. Fuel supply inadequate. 2. Use proper starting 4. Injection pump timing. procedures. 5. inadequate intake air. 3. Check fuel supply pressure and inlet restriction. 6.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) WARNING In case of engine runaway due to flammable fumes from gasoline spills or turbocharger oil leaks being sucked into the engine, shut off engine ignition switch first then use a C02 fire extinguisher and direct the spray near the engine air inlet to remove oxygen supply. The engine air inlet is on the port side on the flywheel end of the engine.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES 1. Low coolant level. 2. Incorrect/improperly operating pressure cap. 3. Loose drive belt on water pump. 4. Improperly operating temperature sensor / gauge 5. Obstructed or restricted seawater pump inlet. 6. Improperly operating. incorrect or no thermostat. 7. Air in the cooling system. 8. Inoperative water pump. 9. Incorrect injection pump timing. COOLANT TEMPERATURE ABOVE NORMAL 10.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES CORRECTION 1. Incorrect thermostat or 1. Check and replace Contamination in thermostat. thermostat. COOLANT TEMPERATURE BELOW NORMAL 2. Temperature sensor or gauge inoperative. 3. Coolant not flowing by temperature sensor. 1. Low oil level. 2. Oil viscosity thin. diluted or wrong specification. 3. Improperly operating pressure switch/gauge. 4. Relief valve stuck open. 5. Plugged oil filter. 6.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION LUBRICATING OIL PRESSURE TOO HIGH POSSIBLE CAUSES CORRECTION 1. Pressure switch/gauge not 1. Verify the pressure switch is operating properly. functioning correctly. If not, replace switch/gauge. 2. Engine operating too cold. 2. Refer to “Coolant 3. Oil viscosity too thick. Temperature Below Normal.” 4. Oil pressure relief valve stuck 3. Make sure the Correct oil closed or binding.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION POSSIBLE CAUSES 1. Air in the fuel system. COMPRESSION KNOCKS CORRECTION 1. Bleed the fuel system. 2. Poor quality fuel or 2. Verify by operating from a water/gasoline contaminated temporary tank with good fuel. fuel. Clean and flush the fuel supply tanks. Replace 3. Engine overloaded. fuel/water separator. 4. Incorrect injection pump 3. Verify the engine load rating timing. is not being exceeded. 5.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Troubleshooting Charts (Continued) CONDITION EXCESSIVE ENGINE NOISES POSSIBLE CAUSES CORRECTION 1. Drive belt squeal, insufficient 1. Inspect the drive belt. Check tension or abnormally high drive belt tension. loading. 2. Refer to Excessive Exhaust 2. Intake air or exhaust leaks. smoke (Engine Diagnosis Performance). 3. Excessive valve lash. 3. Make sure the push rods are 4. Turbocharger noise. not bent and rocker levers are 5. Gear train noise.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 5E-92 90-860074--1 FEBRUARY 2002
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Repair Procedures Service Precautions WARNING Electrical system components on this engine are not external ignition protected. Do NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (ref: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 WARNING Make sure no fuel leaks exist, before closing engine hatch. CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant. CAUTION Fuel pressure MUST BE relieved before servicing high pressure components in the fuel system.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Torque Specifications NOTE: Securely tighten all fasteners not listed below. Description Nm lb-in. MAP / IAT Sensor 3.5 31 ECT Sensor Reducer Fitting To Cylinder Head 24.3 TP Sensor 6.7 60 ECM Bracket To Isolator Mounts 19 168 ECM To Bracket 8 72 6.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 System Components 75340 75341 2 3 75339 1 4 75311 75301 16 5 14 75336 13 73911 15 75336 12 6 75395 11 7 8 10 9 75336 75395 Page 5E-96 90-860074--1 FEBRUARY 2002
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SERVICE MANUAL NUMBER 22 EDI DIAGNOSIS System Component List 42 - Instrumented Injector (#1 Cylinder) 43 - MAP/IAT Sensor 44 - ECT Sensor 45 - Engine Speed Sensor 46 - Electrical Box 47 - Data Link Connector (DLC) 48 - Instrument Harness Connector 49 - Engine Harness Connector 50 - Main Relay 51 - Start Relay 52 - Circuit Breakers 53 - Glow Plug Relays (If Equipped) 54 - Electric Shut Off Solenoid 55 - Injection Pump 56 - ECM (Standard Calibration, Or Bodensee Complieant Calibration Available) 57 - TP Sen
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Fuel Injection Pump Repair The Robert Bosch Corporation has a network of authorized Bosch Service Dealers throughout the world to service their products. The pump and injectors must be sent to an authorized Bosch Service Center. When shipping an injection pump to a service center for adjustments or repairs, the fuel return line hollow bolt must accompany the unit.
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SERVICE MANUAL NUMBER 22 EDI DIAGNOSIS Wiring Harness Service GENERAL INFORMATION Marine engine control circuits contain many special design features not found in standard land vehicle wiring. Environmental protection is used extensively to protect electrical contacts. Proper splicing methods must be used when making repairs. The proper operation of low amperage input/output circuits depends upon good continuity between circuit connectors.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 WIRE REPAIR 1. Locate damaged wire. 2. Remove insulation as required. 73048 3. Splice two wires together using a splice clip. Solder with rosin core solder. 73048 4. Cover splice with heat shrink sleeve to insulate from other wires. 73048 CONNECTOR SERVICE Most connectors in the engine compartment are protected against moisture and dirt which could create oxidation and deposits on the terminals.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 HARNESS VIEWS a b K J L C M N G A H B U W V F X D E T P R S 75300 Instrument Harness And Connector a - Early model 16 Pin Standard Connector b - Late Model 21 Pin Deutscht Connector 75395 Engine Harness And Electrical Box 90-860074--1 FEBRUARY 2002 Page 5E-101
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Relay, Module and Sensor Servicing (On-Board Service) Precautions WARNING BEFORE attempting to disconnect and remove any module or sensor, check to make sure that the engine ignition system is OFF. Then disconnect the negative (–) battery cable from the terminal. Do NOT reconnect the negative (–) battery cable until the module or sensor removed has been re-installed with secure connections.
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SERVICE MANUAL NUMBER 22 EDI DIAGNOSIS CLEANING IMPORTANT: The main relay is an electrical component. Do NOT soak in any liquid cleaner or solvent; damage may result. 1. Clean exterior with a dry cloth. 2. Clean terminals with a suitable cleaner. INSPECTION 1. Look for evidence of any physical damage to base or connector surfaces of relay. 2. Visually inspect electrical pins of ECT for straightness and no corrosion. 3.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 ECM (Electronic Control Module) NOTICE Refer to Service Precautions, in Repair Procedures, BEFORE proceeding. IMPORTANT: The ECM is a sensitive electrical device, subject to electrostatic damage. Therefore, take care not to touch connector pins when removing, cleaning or installing the module. IMPORTANT: An ECM with derated calibration is used for the D4.2L D-tronic in order to meet Bodensee emission requirements in twin-installations.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 INSPECTION NOTE: The ECM is a sealed electrical component. If a Scan check has shown it to be defective, replace the unit with another ECM having the same part number and service number as the original. 1. Inspect outer surfaces for any obvious damage 2. Visually inspect electrical pins of ECM for straightness and no corrosion. 3. Visually inspect connectors on the wiring harness for corrosion and terminals that may have backed of the harness. INSTALLATION 1.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 ECT (Engine Coolant Temperature) Sensor NOTICE Refer to Service Precautions in Repair Procedures, BEFORE proceeding. REMOVAL NOTE: Handle the ECT carefully as any damage to it will affect operation of the EDI system. 1. Refer to SECTION 6B and drain coolant. 2. Disconnect electrical connector from ECT (Engine Coolant Temperature) sensor. NOTE: The ECT is mounted in a reducer fitting that is installed in the head. 3.
PAGE 675
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 INSPECTION 1. Look for evidence of any physical damage to base or connector surfaces of the ECT. 2. Visually inspect electrical pins of ECT for straightness and no corrosion. 3. Visually inspect connectors on the wiring harness for corrosion and terminals that may have backed of the harness. INSTALLATION 1. Install reducer fitting, if removed previously. Replace the sealing washer. Torque the reducer to specifications. 2.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 MAP (Manifold Absolute Pressure) / IAT (Intake Air Temperature) Sensor NOTICE Refer to Service Precautions, in Repair Procedures, BEFORE proceeding. REMOVAL 1. Disconnect electrical connector from the MAP / IAT sensor. 2. Remove screws from sensor and J-clip retaining coolant pipe. 3. Remove sensor from intercooler housing. d a c a b c d b 75582 - MAP/IAT Sensor - Electrical Connector - Intercooler - J-clip CLEANING 1. Clean sensor with a dry cloth. 2.
PAGE 677
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 INSTALLATION 1. Install new O-ring on MAP/IAT sensor. b a 75408 a - O-ring b - MAP/IAT Sensor 2. Install MAP/IAT sensor to plenum using screws. Insert upper screw through J-clip for coolant pipe and then through the sensor to the intercooler. Torque screws to specifications. 3. Attach and lock the engine harness electrical connector to the MAP/IAT sensor.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Throttle Position (TP) Sensor NOTICE Refer to Service Precautions in Repair Procedures, BEFORE proceeding. REMOVAL 1. Disconnect throttle cable. 2. Disconnect TP electrical connector from engine harness. 3. Remove TP from ECM bracket. c a b c 75332 a - ECM Bracket b - TP Sensor c - Allen Head Screw and Flanged Nut (2 Required) CLEANING 1. Clean sensor with a dry cloth. 2. Clean harness connector. INSPECTION 1.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 INSTALLATION 1. Install TP sensor to ECM bracket using allen head screws with flanged nuts. Torque screws to specifications. 2. Connect sensor to engine harness. 3. Install throttle cable. Refer to SECTION 2. 4. Tighten throttle cable locknuts until they bottom and loosen 1/2 turn. b a d c d e 75332 a b c d e - Throttle Cable End Guide - Cable Barrel - Anchor Stud - Flat Washer And Locknut - Spacer (If Required) 5. Connect the battery cables.
PAGE 680
EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Instrumented Injector Refer to SECTION 5C for information and procedures. Engine RPM Speed Sensor REMOVAL 1. Disconnect rpm Sensor from harness. 2. Remove screw retaining sensor to flywheel housing or adapter piece if equipped. 3. Withdraw sensor from housing. a b c d 75377 a b c d - Engine RPM Speed Sensor - Allen Head Screw - Adapter (If Equipped) - Flywheel Housing CLEANING 1. Clean sensor and connector with a dry cloth. 2. Clean harness connector.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 Idle Speed Setting Circuit 12 RED/ORN RED/ORN 77611 An electrical circuit, using two RED/ORANGE wires inside the electrical box, has been added to allow for a 100 rpm increase in the base idle speed signal from the ECM. This is called the Idle Speed Setting Circuit. Locate the RED/ORANGE wire male and female bullet connector ends. One wire end is from terminal 12 of the ECM / Fuel System Harness connector and the other is from terminal 87 of the Main Relay.
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EDI DIAGNOSIS SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 5E-114 90-860074--1 FEBRUARY 2002
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 COOLING SYSTEM Section 6A - Seawater Cooling System Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . 6A-3 Lubricants / Sealants / Adhesives . . . . . . . 6A-3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Seawater (Raw Water) System Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Seawater Pump Delivery Rates . . . . . . . 6A-4 Seawater Pickup Connections . . . . . . . .
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 6A-2 90-860074--1 FEBRUARY 2002
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 NOTICE For instructions on Cleaning Seawater Strainer, Flushing Seawater Cooling System or Draining Seawater Section refer to SECTION 1B. Torque Specifications Description Nm lb-in.
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Seawater (Raw Water) System Specifications Seawater Pump Delivery Rates Description Engine rpm Liters (U.S. Gallons) Per Minute 2000 60 (16) 3000 87 (23) 3800 109 (29) 2000 71 (19) 3000 98 (26) 3800 114-1/2 (30-1/2) D2.8L D-Tronic D4.2L D-Tronic Seawater Pickup Connections SEAWATER PICKUP HOSE Description D2.8L D-Tronic D4.2L D-Tronic Seawater Pickup Hose Diameter 38 mm (1-1/2 in.) Minimum SEACOCK (WATER INLET VALVE) Description D2.
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Precautions IMPORTANT: If the possibility of freezing exists, seawater section, and associated heat exchangers, MUST BE drained to prevent freeze damage to cooling system and engine. Seawater section also should be drained if boat is to be stored for an extended period of time, to prevent corrosion damage.
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Seacock If a seacock is being used, it must be installed between water pickup and seawater pickup pump (or seawater strainer), to allow operator to shut off the seawater in case of a leak or when boat is not in use. This will also allow the operator to flush or drain the engine, or clean the sea strainer while boat is in the water. Install seacock in an area where it will be easily accessible and support adequately to prevent hose fatigue.
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Exploded View - Seawater Pumps D2.
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 D4.
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Seawater Flow Diagram 9 10 f 8 5 g a e d b c 2 6 7 1 4 3 Typical - All Engines Page 6A-10 90-860074--1 FEBRUARY 2002 75
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SERVICE MANUAL NUMBER 22 SEAWATER COOLING SYSTEM Seawater Cooling Circuit (Raw Water) 1 - Seawater Inlet Through Drive - Sterndrive Through Hull - Inboard 2 - Seacock (If Equipped) 3 - Seawater Strainer 4 - Seawater Pump 5 - Intercooler 6 - Engine Oil Cooler 7 - Heat Exchanger 8 - Fluid Cooler Power Steering Fluid - Sterndrive Transmission Fluid - Inboard 9 - Exhaust Pipe Water Jacket 10 - Seawater Outlet (Exhaust) Engine Components a - Thermostat Housing and Thermostats b - Circulating Pump - Closed Cool
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Seawater Pump Removal CAUTION If boat is in water while working on seawater pump, when removing seawater inlet hose, close seacock, if equipped. If boat is not equipped with a seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater to enter boat. 1. Close seacock if equipped, or remove and plug seawater pump inlet hose. 2. Loosen the 6 seawater pump cover screws to drain water into a suitable container.
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Disassembly 1. Clamp the pump in a vise. 2. Remove the 6 cover screws. a 70625 Typical a - Cover Screws 3. Using 2 screwdrivers, carefully remove the impeller. 70626 4. On D2.8L D-Tronic pumps: Remove internal snap ring from pump body.
PAGE 696
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 5. On D4.2L D-Tronic pumps: a. Remove external retaining ring from pump shaft. a 70694 a - External Retaining Ring b. Remove spacer from shaft. a 70695 a - Spacer 6. Using a soft faced hammer, tap shaft and bearing assembly out of pump housing.
PAGE 697
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 IMPORTANT: Take note of factory markings on bearings (if visible), or suitably mark each bearing, to ensure installation in original position if reused. 7. On D2.8L D-Tronic pumps: Using an arbor press and suitable hardware, remove one bearing at a time from pump shaft to avoid damaging spacer. Press off toward splines of shaft and on inner race of bearings only. a c b 70635 a - Bearing(s) b - Spacer c - Pump Shaft 8. On D4.
PAGE 698
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 9. Remove screw from between inlet and outlet to allow cam removal. b a 70638 70632 Typical Pump and Cam a - Screw b - Cam 10. Remove thrust washer from its position on locating pin in pump housing. a 70631 Typical Pump and Thrust Washer a - Thrust Washer 11. On D2.8L D-Tronic pumps: Using a suitable tool, remove two lipseals, one spacer, and one slinger ring from pump housing. Notice positioning.
PAGE 699
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 12. On D4.2L D-Tronic pumps: a. Being careful not to gouge or nick pump housing, remove rear seal by inserting a screwdriver through holes in pump housing and carefully pry (push). c a b 70697 a - Screwdriver b - Rear Seal c - Pump Housing b. Using a suitable tool, press front seal assembly out front of pump housing from rear. NOTE: Although different in appearance the front seal will press out like a normal seal.
PAGE 700
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Inspection 1. Inspect bearing housing. Examine surfaces (where bearings contact housing) for evidence of bearing outer racers turning in housing. 2. Inspect bearings for worn or defective condition. Examine sealed bearings for evidence of loss of factory grease, or evidence of internal contamination by engine oil. 3. Inspect seals from bearing housing. 4. Inspect pump shaft for grooves in surface where seals contact shaft. 5. Inspect drive key on shaft. 6.
PAGE 701
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Assembly 1. On D2.8L D-Tronic pumps: IMPORTANT: In the following steps press on inner races of bearings ONLY. Do NOT crush spacer. a. Using an arbor press, install first bearing against shoulder of pump shaft beginning from splined end. b. Install plastic spacer and press second bearing on shaft, in positions shown. b c a 70634 a - First Bearing b - Spacer (Plastic) c - Second Bearing 2. On D4.
PAGE 702
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 3. On D2.8L D-Tronic pumps: Install spacer into impeller side of housing. Using a suitable tool, install impeller primary lipseal (lip facing out - back of seal visible). a b 70629 a - Rubber Washer (Installed First, Not Shown In This View) b - Impeller Primary Seal 4. On D4.2L D-Tronic pumps: Install impeller primary seal assembly using a suitable tool. Plastic collar around lip MUST face impeller.
PAGE 703
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 5. On D2.8L D-Tronic pumps:Install slinger ring into bearing side of housing. Using a suitable tool, install rear seal (lip facing front of pump - back of seal visible). b a 70629 a - O-ring b - Rear Seal 6. On D4.2L D-Tronic pumps: Using a suitable tool, install rear seal (lip facing out - back of seal visible). a 70444 a - Rear Seal 7. Install thrust washer into pump housing. Align washer notch with pin in housing.
PAGE 704
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 8. Coat backside of cam with Loctite Master Gasket sealant. 9. Install cam in housing as shown. Tighten screw securely. Remove excess sealant and allow to dry before continuing assembly. b c 70638 b 70633 Typical Pump and Cam a - Sealant b - Cam c - Screw 10. Coat lips of seals in pump housing with U-Joint and Gimbal Bearing Grease. 11. Install shaft and bearing assembly into housing as shown. 12.
PAGE 705
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 13. On D2.8L D-Tronic pumps: Install internal snap ring into pump body groove. a 70628 a - Snap Ring 14. On D4.2L D-Tronic pumps: a. Install spacer (washer) on shaft next to front seal assembly. b. Install external retaining ring into groove of shaft. c a b 70694 a - Front Seal Assembly b - Spacer (Washer) c - External Retaining Ring 15. Hold pump housing in soft-jaw vise.
PAGE 706
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 16. Push rubber button seal into end of impeller. a b 70627 a - Rubber Button Seal b - Impeller 17. Install gasket (wide surface on cam side) and cover. Tighten screws evenly in a diagonal pattern. Tighten securely.
PAGE 707
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Installation 1. Install O-ring on pump housing shoulder. a 70628 Typical Pump a - O-ring 2. Turn pump shaft in direction shown to align pump keyway with camshaft key.
PAGE 708
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 3. Install pump on timing gear cover studs. Tighten hex nuts with washers securely. a b 23161 70423 Typical Pump Installation a - Studs b - Hex Nuts With Washers 4. Install seawater inlet and outlet hoses. Tighten hose clamps securely. c b a c 70636 Typical Pump and Hoses a - Inlet Hose b - Outlet Hose c - Hose Clamps 5. Open seacock, if equipped, or remove plug from seawater inlet hose and reconnect hose. Tighten hose clamps securely. 6.
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Seawater Strainer Exploded View 7 h 6f 5 4 d c3 8 2 b a1 g 8 78157 Typical 1 - Drain Plug and Gasket 2 - Filter Housing 3 - Filter Element 4 - O-ring Seal 5 - Clear Lens 6 - Lens Cover 7 - Nozzle (2) 8 - Cover Screw with Washer 90-860074--1 FEBRUARY 2002 Page 6A-27
PAGE 710
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Removal CAUTION If boat is in water while working on seawater strainer, close seacock, if equipped. If boat is not equipped with a seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses and enter the boat. IMPORTANT: Be certain engine is OFF and cooling system is cold. 1. Models Equipped With A Seacock: a. Close seacock (seawater inlet valve), if equipped.
PAGE 711
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 2. Models Without A Seacock: a. If not equipped with seacock, disconnect seawater inlet hose, from seawater strainer inlet. b. Quickly plug seawater inlet hose. b a b c d c a d 70062 - Inlet Hose - Strainer - Strainer Inlet - Suitable Plug 3. Remove seawater outlet hose. Drain into a suitable container. a b 70062 a - Outlet Hose b - Strainer 4. Remove mounting bolts. 5. Remove strainer.
PAGE 712
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Installation IMPORTANT: Mount seawater strainer in a vibration-free location. Never mount it on the engine or transmission. Hoses must not be kinked or allowed to come in contact with hot or moving engine or transmission parts. 1. Mount seawater strainer. Ensure the following: • Arrow (flow direction) must point towards seawater pump. • Tighten mounting bolts securely. b a c c 50226 a - Strainer b - Arrow c - Mounting Bolt Hole 2.
PAGE 713
SERVICE MANUAL NUMBER 22 SEAWATER COOLING SYSTEM Oil / Power Steering / Transmission Fluid Coolers General Information Cooling efficiency of an engine and components is greatly dependent upon heat transfer through the tubes within the coolers (heat exchanger or exchangers, if equipped with more than one).
PAGE 714
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Exploded View 1 2 3 78386 1 - D4.2L Inboard (MIE) Early Design 2 - D2.8L D-Tronic And D4.2L D-Tronic Sterndrive (MCM) Design 3 - D2.8L D-Tronic And D4.
PAGE 715
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Location of Coolers Refer to the following for location of oil, power steering and transmission fluid coolers. a b c 75393 75297 Typical Sterndrive (MCM) Model a - Fluid Cooler (D4.2L) b - Engine Oil Cooler c - Fluid Cooler (D2.
PAGE 716
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Inspection Before Removal NOTICE Refer to Cold Weather or Extended Storage, Draining Instructions in SECTION 1B and Precautions in this section, BEFORE proceeding. 1. Drain the seawater system. 2. Remove hose clamp or end cover from INLET end of the appropriate coolers. Refer to Seawater Flow Diagrams. 3. Inspect the passages. Clean if needed. 4. Refit hose or end cover. Torque end cover to specification or securely tighten hose clamp.
PAGE 717
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Engine Oil Cooler REMOVAL NOTICE Refer to Cold Weather or Extended Storage, Draining Instructions in SECTION 1B and Precautions in this section, BEFORE proceeding. 1. Drain the seawater system. 2. Drain the closed cooling system. 3. Obtain clean, suitable devices and plug hoses in following instructions to avoid loss of engine oil. 4. Mark port and starboard oil hoses to aid in reassembly. 5.
PAGE 718
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 6. Disconnect seawater and closed cooling hoses as required to allow removal of heat exchanger and engine oil cooler. 7. Disconnect turbocharger coolant vent hose from fitting on upper-port side of heat exchanger expansion tank. 8. Remove the two large screw clamps retaining the heat exchanger to the port and starboard brackets. 9. Remove the heat exchanger and engine oil cooler.
PAGE 719
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 INSTALLATION 1. Apply a small amount of petroleum jelly on the heat exchanger brackets and hose ends to ease installation. 1. Install the heat exchanger and engine oil cooler. 2. Make all necessary seawater and closed cooling hose connections. Tighten hose clamps securely.
PAGE 720
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 3. Unplug and install port and starboard oil lines, as marked upon disassembly, to fittings near each end of oil cooler. 4. Reconnect coolant recovery bottle hose. 5. Install the two large screw clamps retaining the heat exchanger to the port and starboard brackets. 6. Reconnect turbocharger coolant vent hose.
PAGE 721
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 7. Inspect cooler / exchanger passages. • If passages are clear: Reconnect seawater hoses and tighten hose clamps securely. IMPORTANT: Mercury MerCruiser does not recommend the immersion of oil/power steering/ transmission fluid coolers in cleaning solutions. If backflushing and/or wire brushing of the problem cooler does not satisfactorily clear the passages replacement of the cooler is recommended. • If passages are still obstructed: a.
PAGE 722
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Power Steering REMOVAL NOTICE Refer to Cold Weather or Extended Storage, Draining Instructions in SECTION 1B-Maintenance and Precautions in this section, BEFORE proceeding. 1. Drain the seawater system. 2. Disconnect seawater hoses from fluid cooler. 3. Mark fore and aft fluid hoses to aid in reassembly. NOTE: Obtain two clean, suitable devices and plug hoses in following instructions to avoid loss of fluid. 4.
PAGE 723
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 INSTALLATION 1. Install J-clamp and cooler onto exhaust manifold stud. Torque to 24 lb-ft (32 Nm). 2. Install connecting seawater hoses. Position fittings as shown and tighten seawater hose clamps. 3. Remove plugs from power steering fluid hoses and connect to fittings as marked on disassembly. Tighten fluid hose clamps securely. f e a d c b 75594 e g 75393 Typical Power Steering Cooler Installation a - D4.
PAGE 724
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Transmission Fluid Cooler REMOVAL NOTICE Refer to Cold Weather or Extended Storage, Draining Instructions in SECTION 1B and Precautions in this section, BEFORE proceeding. 1. Drain the seawater system. 2. Disconnect seawater hoses from fluid cooler. 3. Mark fore and aft fluid hoses to aid in reassembly. NOTE: Obtain clean, suitable devices and plug hoses in following instructions to avoid loss of fluid. 4.
PAGE 725
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 Installation 1. Coat threads of fluid hose connectors with Loctite Pipe Sealant with Teflon and install on cooler in positions noted on disassembly. a b Typical Transmission Fluid Cooler Shown a - Transmission Fluid Cooler b - Connectors 2. Install transmission fluid cooler on intake/exhaust manifold or bracket. Secure with clamps and fasteners. Torque manifold nuts to 32 Nm (24 lb-ft). 3.
PAGE 726
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 4. Open seacock if equipped, or unplug seawater inlet hose and reconnect. Tighten hose clamps securely. 5. Start engine. Operate briefly to fill cooler. 6. Check for leaks. 7. Stop engine. IMPORTANT: Use only ATF (Automatic Transmission Fluid), such as Dexron III. 8. Quickly check transmission fluid level. Fluid should be between MIN and MAX marks on dipstick. 9. Fill transmission to proper level.
PAGE 727
SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK 90-860074--1 FEBRUARY 2002 Page 6A-45
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SEAWATER COOLING SYSTEM SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 6A-46 90-860074--1 FEBRUARY 2002
PAGE 729
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 COOLING SYSTEMS Section 6B - Closed Cooling System Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Thermostats . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Pressure Cap . . . . . . . . . . . . . . . . . . . . . . 6B-4 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Torque Specifications . . . . . . . . . . . . . . . . . .
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CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 6B-2 90-860074--1 FEBRUARY 2002
PAGE 731
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 NOTICE For instructions on Cleaning Seawater Strainer, Flushing Seawater Cooling System or Draining Seawater Section refer to SECTION 1B - Maintenance. NOTICE For information on other heat exchangers cooled by seawater refer to SECTION 6A Seawater Cooling System, Oil / Power Steering / Transmission Fluid Coolers. NOTICE For information on Oil Filter Head and Oil Thermostat refer to SECTION 3A - Engine Mechanical, Oil Thermostat.
PAGE 732
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Specifications Capacity Liters (U.S. Quarts) Approximate Description D2.8L D-Tronic 11 (11-2/3) D4.2L D-Tronic 13 (13-3/4) Thermostats Description Operating Temperature D2.8L D-Tronic 1 at 70 Degrees C (160 Degrees F), and 1 at 82 Degrees C (180 Degrees F) D4.2L D-Tronic IMPORTANT: It is not necessary to position either thermostat in a certain location within the thermostat housing.
PAGE 733
SERVICE MANUAL NUMBER 22 CLOSED COOLING SYSTEM Torque Specifications Description Nm lb-in. Engine Water Circulating Pump Screw 30 Thermostat Housing Cover 16 Heat Exchanger Bracket / Thermostat Housing 30 Water Pump Pulley Screw 8.
PAGE 734
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Diagrams and Exploded Views Coolant Flow Diagram e d g f c b a h 75351 Closed Cooling Circuit (Fresh Water / Coolant) Page 6B-6 90-860074--1 FEBRUARY 2002
PAGE 735
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Coolant Flow Diagram (continued) g h i j k l m n - Circulating Pump - Closed Coolant - Engine Block - Upper Section Of Liners - Cylinder Heads - Water Manifold - Turbocharger - Exhaust Manifold - Thermostat Housing And Thermostats - Heat Exchanger 90-860074-1 FEBRUARY 2002 Page 6B-7
PAGE 736
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Heat Exchanger / Coolant Tank and Related Components B 17 16 2 14 13 18 B 1 15 3 4 13 11 12 10 11 9 3 5 11 6 19 A 7 11 20 A 8 10 28 27 78273 21 22 C 25 DEC AL 26 D 23 24 23 78387 Page 6B-8 90-860074--1 FEBRUARY 2002
PAGE 737
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Heat Exchanger / Coolant Tank and Related Components (continued) 1 - Screw, M6x78 mm (5) 2 - Lockwasher (6) 3 - Hose Clamp 4 - Thermostat Housing To Heat Exchanger Hose 5 - Engine Lifting Eye 6 - Screw, M10 x 35 mm (1-3/8 in.
PAGE 738
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Engine Water Circulating Pump 3 1 4 B 5 2 A 1 2 3 4 5 Page 6B-10 73948 - Water Circulating Pump - Screws With Washers - Gasket - Pulley - Screws With Washers Description Nm A Engine Water Circulating Pump Screw 30 B Water Pump Pulley Screw 8.5 lb-in.
PAGE 739
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Checking Coolant Level CAUTION Alcohol or methanol base antifreeze or plain water are not recommended for use in cooling system at any time. Before starting engine each day, check to ensure that coolant is visible in coolant recovery bottle. WARNING Do NOT remove coolant pressure cap when the engine is hot - coolant may discharge violently, causing severe burns. Let the engine cool before removing the pressure cap.
PAGE 740
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Testing Closed Cooling System Testing Coolant for Alkalinity WARNING Allow engine to cool before removing pressure cap as sudden loss of pressure could cause hot coolant to boil and discharge violently. After engine has cooled, turn cap 1/4 turn to allow any pressure to escape slowly, then push down and turn cap all the way off. Coolant in closed cooling (fresh water) section should be changed every two years.
PAGE 741
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 5. Attach an automotive-type cooling system pressure tester to filler neck and pressurize closed cooling system to amount specified in following chart, based on pressure cap rating for your engine. Pressure Cap Rating Amount of Pressure Applied to Closed Cooling System 97 kPa (14 psi) 137 kPa (20 psi) 6. Observe gauge reading for approximately two minutes; pressure should not drop during this time.
PAGE 742
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Testing for Cylinder Head Gasket Leak A leaking head gasket will cause combustion gas to be forced into the cooling system. The mixture of coolant and tiny air bubbles is a poor heat conductor and will overheat an engine quickly. Compression tests or cooling system pressure check normally will not detect the leak because the test pressure is far below the combustion pressures which cause the leak. An effective test follows.
PAGE 743
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Testing Pressure Cap Pressure cap is designed to maintain a pressure of approximately its rated capacity (refer to Specifications) in closed cooled section once engine has attained operating temperature. Cap should be cleaned, inspected and pressure-tested at regular tune-up intervals or whenever cap is suspected of maintaining improper pressure. WARNING Allow engine to cool before removing pressure cap.
PAGE 744
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 6. Examine lower inside sealing surface in filler neck to ensure that it is perfectly smooth and free of debris. Also, inspect cam lock flanges on sides of filler neck to ensure that they are not bent. a b 72715 a - Filler Neck b - Cam Lock Flange 7. Using a cooling system pressure tester similar to one shown, test cap to ensure that it releases at proper pressure and does not leak. Refer to instructions which accompany tester for correct test procedure.
PAGE 745
SERVICE MANUAL NUMBER 22 CLOSED COOLING SYSTEM Coolant Change Interval Refer to SECTION 1B. Coolant Requirement Refer to SECTION 1B. Draining Closed Cooling System IMPORTANT: Observe the following: w Insert a wire into drain holes to ensure that foreign material is not obstructing the drain holes. w Ensure that the engine is as level as possible to promote complete draining of cooling system.
PAGE 746
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 WARNING Allow engine to cool before removing pressure cap. Sudden loss of pressure could cause hot coolant to boil and discharge violently causing severe injury. 1. Allow engine to cool. After engine has cooled, turn pressure cap 1/4 turn to allow any pressure to escape slowly, then push down and turn cap all the way off of heat exchanger/coolant tank. 2. Drain coolant from intake/exhaust manifold by opening the drain valve. 3.
PAGE 747
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Cleaning Closed Cooling System The closed cooling section of the cooling system should be cleaned according to the Maintenance Schedules in SECTION 1B, or whenever decreased cooling efficiency is experienced. A good grade automotive cooling system cleaning solution may be used to remove rust, scale or other foreign material. Always follow manufacturer’s instructions for the cleaner.
PAGE 748
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Flushing The Closed Cooling System 1. Remove thermostat housing cover. 2. Remove the thermostats and temporarily install housing cover. Torque housing cover screws to 16 Nm (132 lb-in.). 3. Remove large hex plug from exhaust manifold rear cover. Then, install an adapter to this opening, suitable for connecting a tap water hose. NOTE: On engines equipped with auxiliary hot water heater, remove heater hose from fitting (in place of hex plug).
PAGE 749
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Filling The Closed Cooling System 1. Remove pressure cap from heat exchanger and fill section with specified coolant until coolant level is 25 mm (1 in.) below filler neck. CAUTION Avoid seawater pickup pump impeller damage and subsequent overheating damage to sterndrive unit. DO NOT operate engine without water being supplied to seawater pickup pump. 2. With pressure cap off, start engine and operate at fast idle (1500-1800 rpm).
PAGE 750
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Thermostats Removal 1. Refer to Draining Instructions as previously outlined, and drain coolant. 2. Remove closed cooling system hose between thermostat housing and heat exchanger. 3. Remove thermostat housing cover screws and washers, including the cover spacer. NOTE: Components shown removed for visual clarity only. It is not necessary to remove the housing itself.
PAGE 751
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 6. Remove thermostats. a b d c 73973 a - Thermostat Housing Cover b - Thermostat(s) c - Gasket Testing 1. Clean thermostats in soap and water to remove any deposits or debris. 2. Inspect thermostats for corrosion or other visible damage. 3. If thermostats are suspected of producing insufficient engine temperature, check thermostats for leaks by holding them up to lighted background.
PAGE 752
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 4. Following the manufacturers recommendations for usage, check opening and closing temperature. The thermostat opens when it drops off of thread using a tester. Thermostat must open at specified temperature stamped on thermostat. b a c 72675 Typical Thermostat Tester In Use a - Thermometer b - Nylon String c - Thermostat IMPORTANT: Refer to specifications and note that the two thermostats have different opening temperatures. 5.
PAGE 753
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Installation NOTE: Always install the thermostats before the gasket. Regardless of position, ensure that 1 thermostat is a 70 degrees C (160 degrees F) thermostat and 1 is an 82 degrees C (180 degrees F) thermostat. 1. Install thermostats. NOTE: Always use a new thermostat housing gasket. 2. Apply Perfect Seal to both sides of the new thermostat housing gasket. 3. Install the new gasket. 4. Install thermostat housing cover. 5.
PAGE 754
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Heat Exchanger NOTICE Refer to Cold Weather or Extended Storage, Draining Instructions in SECTION 1B and Precautions in this section, BEFORE proceeding. Testing INTERNAL LEAK An internal leak will cause coolant to go into the seawater system when pressure is put on the closed cooling circuit. 1. Remove top seawater (inlet) hose from the exchanger. Do NOT drain the exchanger. 2.
PAGE 755
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Removal NOTICE Refer to Cold Weather or Extended Storage, Draining Instructions in SECTION 1B and Precautions in this section, BEFORE proceeding. 1. Drain the seawater system. 2. Drain the closed cooling system. NOTE: In the following instructions, obtain clean, suitable devices and plug hoses to avoid loss of engine oil. 3. Disconnect oil lines from oil cooler fittings near each end of oil cooler on heat exchanger. Quickly plug lines.
PAGE 756
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 7. Remove combination heat exchanger and engine oil cooler. b a a a b c a a 74484 Heat Exchanger / Engine Oil Cooler and Related Components a - Hoses b - Clamps c - Coolant Vent Hose Fitting 8. If either the closed cooling section or oil cooler portion of the heat exchanger are defective, it will be necessary to replace the complete assembly. Cleaning and Inspection 1.
PAGE 757
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Installation 1. Apply a small amount of petroleum jelly on the brackets and hose ends to ease installation. 2. Install the combination heat exchanger and engine oil cooler. 3. Make all necessary seawater and closed cooling hose connections. b a A a a b a a 74484 Engine Oil Cooler / Heat Exchanger and Related Components a - Hoses b - Clamps 4. Unplug and install port and starboard oil lines to fittings near each end of oil cooler.
PAGE 758
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 5. Install the two large screw clamps retaining the heat exchanger to the port and starboard brackets. NOTE: There is a new style clamp to be used on the D2.8L D-Tronics that uses an automatic spring tensioner. This clamp will replace the earlier clamps. 6. Reconnect coolant recovery bottle hose. 7. Reconnect turbocharger coolant vent hose.
PAGE 759
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Water Circulating Pump NOTICE Refer to Cold Weather or Extended Storage, Draining Instructions in SECTION 1B and Precautions in this section, BEFORE proceeding. IMPORTANT: Water circulating pump on D4.2L engines is a larger volume pump and does NOT interchange with circulating pumps on D2.8L engines. Removal 1. Drain the seawater system. 2. Drain the closed cooling system. 3. Remove the heat exchanger. 4. Remove alternator drive belts. 5.
PAGE 760
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Installation 1. Apply Loctite Master Gasket to both sides of new gasket and position on engine block. 2. Install water circulating pump. 3. Connect water circulating pump hoses. 4. Torque nuts evenly to 30 Nm (22 lb-ft), in a diagonal pattern. b a c 78273 Typical a - Water Circulating Pump b - Gasket c - Nuts 5. Install the heat exchanger. 6. Install and tension drive belts.
PAGE 761
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 Coolant Manifold Refer to SECTION 3A. Corrosion Protection Refer to SECTION 1B.
PAGE 762
CLOSED COOLING SYSTEM SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 6B-34 90-860074--1 FEBRUARY 2002
PAGE 763
INTERCOOLER SERVICE MANUAL NUMBER 22 INTAKE AND EXHAUST SYSTEM Section 7A - Intercooler Table of Contents Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Exploded Views . . . . . . . . . . . . . . . . . . . . . D2.8L Intercooler . . . . . . . . . . . . . . . . . D4.2L Intercooler . . . . . . . . . . . . . . . . . Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3 7A-3 7A-4 7A-4 7A-6 7A-8 Removal . . . . . . . . . . . . . . . . . . . .
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INTERCOOLER SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 7A-2 90-860074--1 FEBRUARY 2002
PAGE 765
INTERCOOLER SERVICE MANUAL NUMBER 22 Torque Specifications Description Nm lb-in. Rear - (All Models) 10 84 Side (D21.
PAGE 766
INTERCOOLER SERVICE MANUAL NUMBER 22 Exploded Views D2.
PAGE 767
INTERCOOLER SERVICE MANUAL NUMBER 22 D2.
PAGE 768
INTERCOOLER SERVICE MANUAL NUMBER 22 D4.
PAGE 769
INTERCOOLER SERVICE MANUAL NUMBER 22 D4.
PAGE 770
INTERCOOLER SERVICE MANUAL NUMBER 22 Intercooler Removal 14. Remove engine cover. 15. Drain the seawater system. 16. Disconnect MAP/IAT sensor. Remove J-clamp for coolant vent hose. b a 75582 a - MAP/IAT Sensor Connector b - J-clamp 17. On Sterndrive Engines: a. Remove sterndrive shift bracket. b. Remove engine lifting eye bracket from intercooler end cover.
PAGE 771
INTERCOOLER SERVICE MANUAL NUMBER 22 18. Remove drain plug and sealing washer from rear cover of intercooler. a b b c 70912 75621 Sterndrive Shown (Inboard Similar) a - Intercooler b - Rear Cover c - Drain Plug With Sealing Washer 19. Remove hollow bolt and sealing washers from wastegate valve pressure line.
PAGE 772
INTERCOOLER SERVICE MANUAL NUMBER 22 20. Loosen hose clamps and disconnect seawater hoses from intercooler-to-heat exchanger and from seawater pump-to-intercooler. b a 75298 a - Seawater Pump To Intercooler Hose b - Intercooler To Heat Exchanger Hose 21. Loosen hose clamp at turbocharger as shown.
PAGE 773
INTERCOOLER SERVICE MANUAL NUMBER 22 22. Remove hex nuts retaining intercooler housing flanges to exhaust / intake manifold studs. a a c c b 70916 70921 Typical a - Intercooler/Intercooler Housing b - Exhaust/Intake Manifold c - Hex Nuts CAUTION Remove ALL washers from studs BEFORE lifting off intercooler and intercooler housing. Do NOT drop anything into intake ports or severe engine damage could occur. 23. Using a magnet to remove all lockwashers from studs where hex nuts were removed. 24.
PAGE 774
INTERCOOLER SERVICE MANUAL NUMBER 22 2. Remove rear cover. Note position of O-ring, and if equipped, plate and second O-ring position. a d b c 70906 Typical a - Intercooler Housing b - Rear Cover c - O-ring (Two - If Equipped) d - Plate 3. Remove front cover and O-ring. c a b 70907 a - Intercooler Housing b - Front Cover c - O-ring 4. Slide radiator insert out front of intercooler housing. Note position of O-ring.
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INTERCOOLER SERVICE MANUAL NUMBER 22 Cleaning and Inspection 1. Clean old gasket material and sealant from flanges. Do NOT nick or gouge the surfaces which would cause intake or water leaks. 2. On D2.8L Engines: Depending on service requirement and/or to allow for a complete cleaning and inspection, separate (remove) side intake duct from intercooler housing. Clean old gasket material and sealant from flanges. Do NOT nick or gouge the surfaces which would cause intake or water leaks. a b 75619 D2.
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INTERCOOLER SERVICE MANUAL NUMBER 22 Assembly IMPORTANT: Do NOT roll or twist O-ring(s) when installing. 1. Install O-ring on radiator insert against front flange. a b 70925 Typical Radiator Insert Shown a - Radiator Insert (Front Flange) b - O-ring 2. Install radiator insert into intercooler housing. Align insert passages as shown. a a b b c c 70933 D4.2L D-Tronic 70926 D2.8L D-Tronic a - Housing b - Radiator Insert c - Alignment Reference Mark 3. Place O-ring into groove of front cover.
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INTERCOOLER SERVICE MANUAL NUMBER 22 IMPORTANT: Do NOT roll or twist O-ring(s) when installing. 4. Install O-ring on rear of intercooler housing. b 70927 a Typical a - O-ring b - Rear of Intercooler Housing 5. On intercoolers WITHOUT plate and second O-ring: Proceed to next step. 6. On intercoolers WITH plate and second O-ring: a. Install plate on rear of intercooler. b. Install second O-ring around radiator insert and against plate. a b 70928 Typical a - Plate b - O-ring (Second One Required) 7.
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INTERCOOLER SERVICE MANUAL NUMBER 22 8. Apply Loctite 514 sealer on intake duct-to-intercooler housing mating surface. On D2.8L D-Tronic engines apply sealer to side intake duct mating surface. 9. Using 4 allen-head screws and wave washers, install intake duct. Torque to 40 Nm (30 lb-ft). a b c 70929 D4.2L D-Tronic Shown (D2.8L D-Tronic Similar) a - Intercooler Housing (Side Intake Duct On D2.8L Engines) b - Intake Duct (Rear Intake Duct On D2.8L Engines) c - Allen-Head Screws and Wave Washers 10.
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INTERCOOLER SERVICE MANUAL NUMBER 22 Installation 1. Install new intake port gaskets. c b a 70881 Typical a - Manifold b - Intake Ports c - Intake Port Gaskets 2. Install intercooler housing. 3. Install hex nuts with lockwashers and torque to 32 Nm (24 lb-ft).
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INTERCOOLER SERVICE MANUAL NUMBER 22 4. Securely tighten hose clamp at turbocharger-to-intake duct hose as shown. d b a c 70918 Typical a - Hose b - Hose Clamp c - Turbocharger d - Intake Duct 5. Connect wastegate valve pressure line using the hollow bolt with two new sealing washers as shown. Tighten securely.
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INTERCOOLER SERVICE MANUAL NUMBER 22 6. Install seawater hoses from seawater pump-to-intercooler and from intercooler-to-heat exchanger. Tighten Hose clamps securely. b a 75298 a - Seawater Pump-to-Intercooler Hose b - Intercooler-to-Heat Exchanger Hose 7. On Sterndrive (MCM) Engines: a. Install sterndrive shift bracket onto side of intercooler. Tighten screws securely. b. Install engine lifting eye bracket onto intercooler end cover. Tighten screws securely.
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INTERCOOLER SERVICE MANUAL NUMBER 22 8. Install engine cover. CAUTION Do NOT operate an engine without water flowing through seawater pickup pump, as pump impeller may be damaged and subsequent overheating damage to engine, transmission or sterndrive unit may result. CAUTION Watch temperature gauge on dash to ensure that engine does not overheat. 9.
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INTERCOOLER SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 7A-22 90-860074--1 FEBRUARY 2002
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 INTAKE AND EXHAUST SYSTEM Section 7B - Manifolds, Elbows And Risers Table of Contents Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded Views . . . . . . . . . . . . . . . . . . . . . . . Typical Intake / Exhaust Manifold . . . . . Sterndrive (MCM) Exhaust Systems . . . Inboard (MIE) Exhaust Systems . . . . . .
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SERVICE MANUAL NUMBER 22 MANIFOLDS, ELBOWS AND RISERS Torque Description Nm lb-in.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Exploded Views Typical Intake / Exhaust Manifold 12 1 4 11 3 11 13 5 4 7 2 10 8 9 6 28085 1 - Intake / Exhaust Manifold, With Wastegate Flange 2 - Stud 3 - Welch Plug 4 - Gasket(s) 5 - Drain Valve 6 - Plug With Washer 7 - Cover 8 - Plug With Washer, If Equipped 9 - Cover Screw With Lock Washer 10 - Nut 11 - Flange Nut 12 - Gasket 13 - Turbocharger Flange Nut Page 7B-4 90-860074--1 FEBRUARY 2002
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Sterndrive (MCM) Exhaust Systems 8 2 3 1 9 71704 4 5 4 6 7 73942 Typical 1 - Exhaust Riser 2 - Clamp 3 - Gasket 4 - Hose Clamps 5 - Exhaust Hose 6 - Round Exhaust Pipe For Exhaust Riser Equipped Engines (No Water Shutter Assembly) 7 - Screw And Lockwasher (4) 8 - Wastegate Exhaust Pipe And Gaskets 9 - Heat Shield Blanket 90-860074--1 FEBRUARY 2002 Page 7B-5
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Inboard (MIE) Exhaust Systems 11 10 3 12 2 6 4 12 5 7 6 9 7 8 1 6 70902 73942 1 - Exhaust Elbow (Design 1) 2 - Connector 3 - Plug 4 - Clamp 5 - Gasket 6 - Hose Clamps 7 - Short Exhaust Hose (If Equipped) 8 - Exhaust Pipe Oval-To-Round Adapter (If Equipped) 9 - Wastegate Exhaust Pipe, Gaskets And Hardware 10 - Exhaust Elbow (Design 2) 11 - Wastegate Exhaust Pipe, Gaskets And Hardware 12 - Heat Shield Blanket 13 - Exhaust Probe Hole 14 - R
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Representative View of Complete Inboard Exhaust System NOTE: (Use diagrams for parts identification only.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Locating and Installing The Sterndrive (MCM) Exhaust System IMPORTANT: It is the responsibility of the boat manufacturer, or installing dealer, to properly locate the engine and install the exhaust system. Improper installation may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Locating And Installing The Inboard (MIE) Exhaust System IMPORTANT: It is the responsibility of the boat manufacturer, or installing dealer, to properly locate the engine and install the exhaust system. Improper installation may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 5. System must not cause excessive back pressure when measured at exhaust elbow outlets. Back pressure MUST NOT exceed a 1000 mm (39-1/2 in.) water column, or 76 mm (3 in.) of mercury when measured with a mercury manometer [approximately 10.3 kPa (1-1/2 psi)]. Minimum exhaust hose size is 102 mm (4 in.). e dd c a f b g 71774 Typical Continuously Sloping Exhaust Line a - Exhaust Elbow b - Measurement - 379 mm (11 in.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Exhaust Pipe - Sterndrive (MCM) Removal IMPORTANT: Engine must be removed to gain access to exhaust pipe. Refer to SECTION 2A for engine removal and installation. 1. Remove the 4 bolts and thick lockwashers retaining the exhaust pipe to the gimbal housing. 2. Remove the exhaust pipe. 3. Remove the O-ring seal and discard.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Installation 1. Install new O-ring. Be certain it is seated properly in groove of gimbal housing. b a 22030 a - Mating Surface (Gimbal Housing, Exhaust Pipe Similar) b - O-ring 2. Hold exhaust pipe in position. Install the four thick washers and bolts. Torque evenly in a diagonal pattern to 30 Nm (23 lb-ft). 3. Lubricate the inside of large end of exhaust hose with a soap and water solution. Slide hose over exhaust pipe and install two hose clamps.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Intake / Exhaust Manifold Removal NOTICE Refer to Cold Weather or Extended Storage, Draining Instructions in SECTION 1B and Precautions in this section, BEFORE proceeding. 1. Drain seawater cooling system. 2. Drain closed cooling system. 3. Remove heat exchanger assembly. 4. Remove intercooler housing. 5. Remove wastegate and valve. 6. Remove turbocharger. 7. Remove shift bracket, fluid cooler and hoses, if equipped. 8.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 9. Remove remaining intake / exhaust manifold flange nuts or nuts and lockwashers. a 70881 Typical a - Flange Nuts Or Nuts And Lockwashers Cleaning and Inspection 1. Clean gasket material from all surfaces and wash parts in solvent. 2. Inspect all parts carefully. Machined surfaces must be clean and free of all marks and deep scratches, or water and exhaust leaks may result. 3. Check water passages for foreign material.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 Installation 1. Install new intake / exhaust manifold gaskets. a b 70883 Typical a - Manifold Studs b - Gaskets 2. Install intake / exhaust manifold on studs. 3. Position shift bracket, clamps and fluid cooler with hoses, where removed previously. 4. Install intake / exhaust manifold flange nuts or lockwashers and nuts. Torque nuts evenly in a diagonal pattern to 32 Nm (24 lb-ft). 5.
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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 22 6. Install turbocharger 7. Install wastegate and valve. 8. Install intercooler housing 9. Install heat exchanger assembly. 10. Fill closed cooling system. 11. Start engine. Check for leaks.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 INTAKE / EXHAUST SYSTEM Section 7C - Turbocharger Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger Specifications . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger . . . . . . . . . . . . . . . . . . . . Wastegate . . . . . . . . . . . . . . . . . . . . . . . Exploded Views . . . .
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Identification a 70076 a - Identification Number Location Turbocharger Specifications Model Manufacturer Part Number KKK Quicksilver D2.8L D-Tronic D4.2L D-Tronic KKK - Kuhnle, Kopp and Kaush K24-2467GxA6.71 K26-2967MxA8.72 854212 854128 Maximum turbine shaft axial (end) play 0.15 mm (0.0059 in.) Maximum turbine shaft radial (side) play 0.42 mm (0.0165 in.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Torque Specifications Description lb-ft Nm Turbocharger Mounting Nuts 18 24 Clamping Plate Nuts or Screws 22 30 Wastegate-to-Exhaust Manifold Mounting Nuts 18 24 Valve-to-Wastegate Screws Tighten Securely (Equally, in a diagonal pattern.
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SERVICE MANUAL NUMBER 22 TURBOCHARGER Description Turbocharger All diesel engines covered in this manual are equipped with a turbocharger to boost intake pressure resulting in increased horsepower. In one casing on the turbocharger housing exhaust gases are used to spin the turbine up to 100,000 rpm. The compressor, which is installed on the same shaft but in a separate casing, draws in filtered air, compresses it, and delivers it to the engine through an intake duct and intercooler.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Exploded Views Turbocharger And Related Components 14 13 9 6 3 17 15 19 11 20 19 5 2 18 1 16 4 10 20 7 12 8 21 22 12 7 24 23 73941 Page 7C-6 90-860074--1 FEBRUARY 2002
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SERVICE MANUAL NUMBER 22 TURBOCHARGER Turbocharger And Related Components (continued) 15 - Turbocharger 16 - Gasket 17 - Stud (4 x M10x30 mm) 18 - Clamp 19 - Gasket 20 - Sterndrive (MCM) Exhaust Riser (If Equipped) 21 - Pipe Plug, 1/4 in.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Boost Pressure Control (Wastegate) Components 4 12 2 4 8 9 11 5 1 10 12 3 6 12 4 7 4 73940 1 - Wastegate 2 - Wastegate-to-Exhaust Manifold Gasket 3 - Typical Inboard Wastegate Exhaust Pipe 4 - Gasket (2) 5 - Hex Nut and Lockwasher (4) 6 - Heat Shield Blanket (For Exhaust Pipe) 7 - Boost Pressure Valve 8 - Boost Pressure Line 9 - Hollow Bolt and Sealing Washers (at Exhaust Manifold) 10 - Hollow Bolt and Sealing Washers (at Valve) 11 - Typical Sterndrive Was
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Turbocharger IMPORTANT: Before suspecting the turbocharger for engine operating problems, the fuel injection system and engine mechanicals (valves, camshaft, etc.) must be in good working order. Testing Turbocharger Boost Pressure CAUTION Safety glasses, gloves and protective clothing should be worn while testing turbocharger boost pressure, to protect against pressurized air being released by a leak or rupture of a hose which could cause injury.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Checking Turbine Bearings (Assembled) 1. Refer to the following pages for Turbocharger - Removal and remove exhaust elbow as outlined for your engine. 2. Rotate the turbine impeller by hand to see that it turns smoothly. If not, turbine bearings or impeller problems exist. 3. Using a feeler gauge as shown, check clearance between turbine blades and housing at two locations opposite one another. The difference in the two readings is the radial play.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Removal WARNING Always disconnect battery cables from battery before working around electrIcal system components to prevent injury to yourself or damage to electrical system. REMOVING EXHAUST ELBOW 1. Disconnect battery cables from battery terminals. 2. Loosen hose clamp and disconnect seawater hose at turbocharger exhaust elbow or riser. Drain seawater into a suitable container. a b 50665 Typical a - Hose Clamp b - Seawater Hose 3.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 4. Loosen spring retaining heat-shield blanket around wastegate exhaust pipe. 5. Remove fasteners and lockwashers retaining wastegate exhaust pipe to exhaust elbow. d c b a 70986 Typical a - Spring (Blanket Retainer) b - Heat-Shield Blanket c - Hex Nuts With Lockwashers d - Wastegate Exhaust Pipe 6. Make matching marks on exhaust elbow or riser and turbocharger housing, for alignment during reassembly. 7. Loosen exhaust elbow, or riser, clamp.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 REMOVING TURBOCHARGER UNIT 1. Drain the closed cooling system. 2. Remove exhaust elbow or riser as previously outlined. 3. Remove lifting eye bracket. a b 70988 Typical a - Bracket, Lifting Eye b - Screws 4. Remove oil feed pipe and hollow bolt from coolant vent pipe at turbocharger as shown. Loosen air filter and turbocharger-to-intake duct hose clamps.
PAGE 816
TURBOCHARGER SERVICE MANUAL NUMBER 22 5. Remove oil drain pipe on bottom of turbocharger as shown. a b 70990 a - Oil Drain Pipe b - Hex Nuts With Lockwashers 6. Follow instructions a. or b.: a. On D2.8L D-Tronic Engines: Remove intake duct from side of intercooler housing. (Refer to SECTION 7A - Intercooler, for instructions on removal.) b. On D4.2L D-Tronic Engines:To gain access to turbocharger mounting nuts, remove intake duct from rear of intercooler housing. (Refer to SECTION 7A - Intercooler.
PAGE 817
TURBOCHARGER SERVICE MANUAL NUMBER 22 8. Remove the two support bracket mounting screws as shown. Remove turbocharger unit. b a 70992 a - Support Bracket b - Screw With Washer (2) Disassembly 1. Make matching marks on the exhaust housing and bearing housing to aid alignment in reassembly. 2. Remove 6 hex nuts or hex screws and the 3 clamping plates shown.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 NOTE: If the exhaust housing cannot easily be removed by hand, tap on it carefully all around using a plastic hammer and carefully remove it in the following. IMPORTANT: Be careful not to damage the turbine impeller when removing exhaust housing. 3. Remove exhaust housing as shown. c a b 70994 a - Exhaust Housing b - Bearing Housing c - Turbine Impeller 4. Inspect turbine blades. If blades are rubbing against housing, the bearings are worn. Replace turbocharger.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Cleaning IMPORTANT: Never use a caustic cleaning solution, as it may attack aluminum. Also, never use a wire brush which could damage impeller or mating surfaces. 1. BEFORE cleaning, inspect the disassembled parts for burning, abrasion, carbon deposits, gas and oil leakage. CAUTION Always wear safety glasses when using compressed air to protect from hose rupturing or flying debris.
PAGE 820
TURBOCHARGER SERVICE MANUAL NUMBER 22 Inspection IMPORTANT: If turbine shaft bearing axial or radial play is excessive, replace turbocharger. AXIAL (END) PLAY - MEASURING 1. With turbocharger held in vise, attach dial indicator as shown following. 2. Move turbine shaft in direction shown. Maximum axial play (end play) is 0.15 mm (0.0059 in.). 3. If measured value is greater than specified, replace the turbocharger. 70995 a. Measuring Axial (End) Play RADIAL (SIDE) PLAY - MEASURING 1.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Assembly IMPORTANT: When installing a new turbocharger, it may be necessary to turn intake, bearing, and/or exhaust housings to allow mounting bracket to be bolted to engine. 1. While aligning matching marks, assemble exhaust housing and bearing housing together. Install clamping plates and finger-tighten hex nuts or screws. Do NOT tighten securely at this time.
PAGE 822
TURBOCHARGER SERVICE MANUAL NUMBER 22 b. On Engines With O-Ring Seals: (1.) Being certain surfaces are clean, install a new O-ring in groove of drain/spacer flange where it meets bearing housing of turbocharger. (2.) Assemble spacer with bracket attached as shown. Tighten hex nuts finger-tight at this time. a a b d c 70998 b a b c d - O-ring (Now Shown In Assembled View) - Spacer (Oil Drain) - Support Bracket - Hex Nut 3. Position exhaust housing and bearing housing (with intake housing) as shown.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Installation IMPORTANT: When installing turbocharger, it may be necessary to turn intake and exhaust housings to line up with intake air duct and exhaust manifolds on engine. 1. Using a new gasket, install turbocharger on exhaust manifold as shown. Tighten nuts to 24 Nm (18 lb-ft). a b 70991 a - Gasket, Exhaust Manifold-to-Turbocharger b - Nut (4 Total - 2 Not Shown) 2. Install support bracket screws with washers as shown. Tighten screws securely.
PAGE 824
TURBOCHARGER SERVICE MANUAL NUMBER 22 4. On Engines With Gasket Seal: Remove hex nuts from spacer (previously installed finger-tight). Using a new gasket, install drain pipe. Tighten hex nuts securely. c a d c b 71000 a b c d - Spacer - Hex Nuts - Gasket - Oil Drain Pipe 5. On Engines With O-ring Seal: Remove hex nuts from spacer (previously installed finger-tight). Using a new O-ring positioned in spacer groove, install drain pipe. Tighten hex nuts with lockwashers securely.
PAGE 825
TURBOCHARGER SERVICE MANUAL NUMBER 22 6. Using new sealing washers on hollow bolt, install coolant vent line to turbocharger exhaust housing as shown. Tighten hollow bolt securely. 7. Clean sealing surfaces and using a new gasket, install oil feed pipe as shown. Tighten screws securely. 8. Install turbocharger-to-intake duct hose as shown. Tighten hose clamp at turbocharger securely. 9. Fit air filter to turbocharger and tighten clamp securely.
PAGE 826
TURBOCHARGER SERVICE MANUAL NUMBER 22 IMPORTANT: If it became necessary to remove the entire intercooler housing from the intake/exhaust manifold during disassembly (to gain better access to turbocharger mounting nuts) refer to SECTION 7A - Intercooler, at this time for proper installation. 10. Clean sealing flanges of intercooler housing and intake duct. Do NOT nick or gouge the surfaces. a. Apply Loctite 514 sealer to intake duct flange on intercooler as shown. a c b 70931 D4.2L Shown (D2.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 12. Install lifting eye bracket as shown. Tighten screws securely. a b 70988 Typical a - Bracket, Lifting Eye b - Screws With Washers 13. As shown, tighten turbocharger-to-intake duct hose clamp securely. d b a c 70918 Typical a - Hose b - Hose Clamp c - Turbocharger d - Intake Duct 14. Install exhaust elbow, or riser, using new gaskets on exhaust elbow and wastegate exhaust pipe flange as shown.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 15. Install hex nuts and washers on wastegate exhaust pipe. Tighten fasteners securely and wrap with heat shield blanket. Fasten spring to retain blanket.
PAGE 829
TURBOCHARGER SERVICE MANUAL NUMBER 22 16. Install seawater hose from fluid cooler-to-exhaust elbow, or riser if equipped. Tighten hose clamp securely. 17. Position exhaust hose as shown. Tighten hose clamps securely. a c b d e f 75297 Typical Riser Installation a - Exhaust Riser b - Seawater Hose From Fluid Cooler c - Clamp, Seawater Hose d - Exhaust Hose e - Clamp, Exhaust Hose f - Exhaust Pipe 18.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Boost Pressure Control WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system. Exhaust Pipe INSPECTION 1. Loosen spring retaining heat shield blanket around wastegate exhaust pipe as shown. b c d 71002 a Typical Assembly Shown a - Retaining Spring b - Blanket, Heat Shield c - Wastegate Exhaust Pipe d - Gasket 2.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 REMOVAL 1. Remove exhaust elbow. 2. Remove two remaining hex nuts, or screws and lockwashers on wastegate exhaust pipe as shown. c a b 71004 Typical Pipe Shown a - Hex Nut or Screws, With Lockwashers (2) b - Wastegate Exhaust Pipe c - Wastegate 3. Remove wastegate exhaust pipe. CLEANING 1. Clean old gasket material from wastegate mating surfaces and pipe (if to be reused), being careful not to distort pipe or crack it.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 INSTALLATION 1. Install new gasket on wastegate flange. 2. Using hex nuts or screws, with lockwashers, install wastegate exhaust pipe. Tighten fasteners securely. c a b 71004 Typical a - Gasket b - Wastegate Exhaust Pipe c - Hex Nuts With Lockwashers 3. Install turbocharger exhaust elbow. Refer to Turbocharger - Installation as previously outlined, and accomplish appropriate instructions regarding installation of exhaust elbow or riser.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 Valve REMOVAL 1. Remove the two hollow bolt with sealing washers from pressure line on bottom of intercooler housing as shown. 2. Remove the two hollow bolt with sealing washers from pressure line on valve as shown. 3. Remove pressure line.
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TURBOCHARGER SERVICE MANUAL NUMBER 22 4. Remove screws and washers retaining valve to wastegate. 5. Remove the valve. a 70983 Typical a - Screws With Washers (3 Total - Two Not Shown) b - Valve c - Wastegate INSTALLATION 1. Position pressure line fitting on valve toward front of engine and install on wastegate using allen-head screws and washers. In equal amounts, tighten screws securely. 2. Install pressure line on valve using hollow bolt with new sealing washers. Finger-tighten. 3.
PAGE 835
TURBOCHARGER SERVICE MANUAL NUMBER 22 Wastegate REMOVAL 1. Drain closed cooling system. 2. Remove the exhaust elbow. 3. Remove the wastegate exhaust pipe. 4. Remove the wastegate valve. 5. Remove the four fasteners with lockwashers retaining wastegate to exhaust manifold. c a b 71005 Typical a - Hex Nuts Or Screws, With Lockwashers (4) b - Wastegate c - Exhaust Manifold CLEANING 1. Clean all traces of old gasket material from exhaust manifold flange. 71006 2.
PAGE 836
TURBOCHARGER SERVICE MANUAL NUMBER 22 INSTALLATION 1. Using a new gasket install wastegate on exhaust manifold as shown. Securely tighten the four fasteners with lockwashers. 2. Install the wastegate valve. 3. Install the wastegate exhaust pipe. 4. Install the exhaust elbow or riser. a b c 71005 Typical a - Wastegate b - Gasket c - Hex Nuts Or Screws, With Lockwashers (4) 5. Start the engine and check for leaks. 6. Test turbocharger boost pressure.
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ZF / HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 22 DRIVES Section 8A - ZF / Hurth Transmissions Table of Contents Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Operating Specifications . . . . . . . . . . . . . Ratios and Part Numbers . . . . . . . . . . . . Fluid Specifications . . . . . . . . . . . . . . . . . Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . .
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ZF / HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 22 Identification The transmission identification plate is located on the top rear of the transmission.
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ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 Specifications Operating Specifications Description Specification Shifting Pressure At 2000 rpm 21.5-23.5 bar (312-341 psi) Operating Temperature 54-79 degrees C (130-175 degrees F) Temperature Switch Settings + / – 10 degrees Open Close 87.8 degrees C (190 degrees F) 110 degrees C (230 degrees F) Ratios and Part Numbers 630A Ratio (Normal) ZF / Hurth Model Number 1.5:1 2.0:1 2.
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SERVICE MANUAL NUMBER 22 ZF / HURTH TRANSMISSIONS Torque Description Nm Transmission Housing Halves Bolts and Nuts 49 36 Control Block-To-Housing 25 18 Output Flange 18 14 61 45 Mounts Transmission To Flywheel Housing lb-in.
PAGE 844
ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 Important Information Engine All current production engines are left hand rotation. Engine rotation is described when observed from the rear of the engine (transmission end) looking forward (water pump end). Installed angle of Inboard (MIE) engine should not exceed a maximum of 18 degrees with respect to the water line. Transmission Transmission gear ratio is marked on transmission identification plate, which is located on the top of transmission.
PAGE 845
ZF / HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 22 Transmission / Propeller Rotation The ZF / Hurth transmissions are full power reversing transmissions, allowing a standard LH rotation engine to be used for both propeller rotations. Propeller rotation is determined by shift cable attachment at the remote control. Use correct rotation propeller and shift cable hook up for direction desired.
PAGE 846
ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 Transmission Fluid IMPORTANT: Use only specified transmission fluid. IMPORTANT: The fluid level dipstick is located on the port side of transmission. Checking Level TRANSMISSION WARM The transmission should be at operating temperature 54-79 degrees C (130-175 degrees F) to get an accurate fluid level reading. Fluid will expand when heated. Fluid will drain back from the cooler. Expansion and drain-back can significantly affect fluid level.
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ZF / HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 22 Filling If transmission fluid level is low, fill with specified transmission fluid. 1. Remove dipstick. 2. Fill transmission through dipstick tube. 3. Replace dipstick and recheck level. a 77564 a - Dipstick Tube Changing 1. Clean the exterior of the transmission around the fluid filter assembly. 2. Use a 6 mm allen wrench and remove the fluid filter assembly from the transmission by turning counterclockwise and pulling at the same time.
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ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 3. 630V Only: Remove the drain plug from the transmission and allow the fluid to drain. Reinstall the drain plug and tighten securely. a 73013 a - Drain Plug (630V Only) 4. 630A Only: Push the hose of a suction pump through the suction pipe and down to the bottom of the housing and remove the fluid. NOTE: The maximum outside diameter of the suction hose is 16 mm (5/8 in.). 71043 5. Remove and discard the filter element and the O-rings. 6.
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SERVICE MANUAL NUMBER 22 ZF / HURTH TRANSMISSIONS 8. Install the fluid filter assembly in the transmission cavity by turning clockwise and pushing at the same time. 27662 9. Fill the transmission with specified fluid. 10. Check the fluid level.
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ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 Transmission Removal 1. Disconnect negative battery cable. 2. If required, drain transmission fluid. NOTE: Fluid cooler should be removed with transmission. 3. Disconnect seawater hoses from transmission fluid cooler. 4. Remove fluid cooler and lines from bracket. 5. Disconnect shift cable from transmission. 6. Disconnect wires from neutral start safety switch. 7. Disconnect wires from transmission fluid temperature switch. 8.
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ZF / HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 22 Transmission Installation 1. Apply Engine Coupler Spline Grease to transmission input shaft splines and engine drive plate splines. a 71044 a - Input Shaft 2. Using a suitable hoist, position transmission in boat and align transmission splines with drive plate splines. 3. Slide transmission into place and secure with attaching hardware. Torque transmission to flywheel housing fasteners to 61 Nm (45 lb-ft). Remove hoist. 4.
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ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 7. Connect seawater hoses to transmission fluid cooler and tighten hose clamps securely. 8. Connect wires to neutral safety switch and to audio warning temperature switch. Coat connections on neutral safety switch with Liquid Neoprene. 9. Connect wires to neutral start safety switch. 10. Connect wires to transmission fluid temperature switch.
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ZF / HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 22 Shift Control And Cables Transmission Shift Lever And Shift Cable Bracket 1. The shift lever has two holes as illustrated. Ensure that the shift cable anchor stud is installed in the top hole when using Quicksilver Remote Control cables. b a 77520 a - Shift Lever b - Shift Cable Anchor Stud Location (For Quicksilver Shift Cables) 2. On bracket with two anchor location holes: Ensure that anchor stud is installed in the hole marked “630.
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ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 Shift Cable Installation And Adjustment IMPORTANT: Ensure that shift lever is positioned approximately 10 degrees aft of vertical as shown when in the neutral detent position. Also, ensure that the distance between studs in the following is set at 181 mm (7-1/8 in.). If necessary, loosen clamping bolt and position lever so that dimension “c” is as shown when in the neutral detent position, and retighten clamping bolt.
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ZF / HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 22 IMPORTANT: When installing shift cables, ensure that cables are routed to avoid sharp bends and/or contact with moving parts. Do NOT fasten any items to shift cables. NOTE: On models with other than Quicksilver shift cables refer to the shift cable manufacturer’s instructions. 1. Place remote control shift lever and transmission shift lever in neutral position. 2. Remove nuts and washers from shift cable attaching studs. 3.
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ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 6. Place remote control shift lever in forward gear position. Ensure transmission is fully in gear, as follows: a. Hold shift lever in position. b. Carefully slide shift cable off of anchor points. c. Attempt to move shift lever further. d. Temporarily install shift cable. Do NOT secure at this time. 7. Place remote control shift lever in reverse gear position. Again ensure transmission is fully in gear as follows: a. Hold shift lever in position. b.
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ZF / HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 22 NOTE: To change cable approach direction on single or dual station installations, only the spacer/bushings have to be switched to the opposite stud. The studs are identical.
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ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 d e g b h c a 71211 72956 b Typical Dual Cable Installation- Forward Approach a - Cable End Guide a - Cable End Guide b - Locknut And Washer c - Spacer (Fits Over Bushings) d - Bushing e - Cable Barrel f - Spacers (Fits Over Stud) g - Cable Barrel Stud h - Cable End Guide Stud d g b e a h 50073 d 72960 b Typical Dual Cable Installation- Rear Approach a - Cable End Guide b - Locknut And Washer c - Spacer (Fits Over Bushings) d - Bushing e -
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ZF / HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 22 Pressure And Temperature Tests 1. Remove pressure service port plug from Port A. 2. Connect a pressure gauge to Port A. 3. Remove temperature sender and install thermocouple at Port B. b a 50686 a - Port A b - Port B 4. Ensure that fluid temperature and shifting pressure meet specification. 5. Check for leaks. Transmission Repair Mercury Marine stocks a limited number of replacement parts for these transmissions.
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ZF / HURTH TRASNSMISSIONS SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 8A-22 90-860074--1 FEBRUARY 2002
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PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 22 DRIVE SYSTEMS Section 8B - Propeller Shaft Models Table of Contents Lubricants / Sealants / Adhesives . . . . . . . 8B-2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 22 Torque Specifications Description Nm Propeller Shaft Coupling to Coupling Housing (MIE) 68 Coupling Set Screws (If Equipped) lb-in. lb-ft 50 Securely (See NOTE.) NOTE: Safety wire set screws, if equipped.
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PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 22 NOTICE The following information can be used as a guide for determining vibration problems on boats powered by inboard engines (MIE Engines). For installation, alignment and repairs to shafts,struts,shaft logs and rudders, refer to boat manufacturer’s service manual. If boat is equipped with V-Drive or a remote mounted V-Drive refer to boat manufacturer’s service manual. For MIE engine installation and alignment, refer to SECTION 2B.
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PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 22 3. Check output coupling flange of transmission. Rotate at least one complete turn. Checking Coupling Outside Diameter Of A Typical Drive System Checking Coupling Face Of A Typical Drive System 4. If there is greater than 0.076 mm (0.003 in.) movement in Step 3, replace output coupling. 5. Replace damaged parts and realign engine as outlined. 6. Torque propeller shaft coupling and transmission coupling (output flange) to 68 Nm (50 lb-ft). 7.
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PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 22 Checks Made with Boat Out of Water and Shaft Installed Possible causes for vibration may be propeller shaft, propeller to shaft fit or propeller. All three can be checked by using the rudder, a strong metal straight edge and a C-clamp. 1. Check installation of propeller to shaft. a. Remove propeller. b. Check for chipped or cracked keyway in propeller on shaft without key. c. Install propeller on shaft without key. d.
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PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 22 4. Ensure that all propeller blades are the same pitch and that propeller is properly seated on shaft. Rotate propeller at least one complete turn and check at three different points on blades. Repair or replace if necessary. NOTE: Hold metal straight edge to rudder with a C-clamp or equivalent.
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PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 22 Checks Made with Propeller Shaft Removed from Boat 1. Check propeller shaft for straightness. Rotate at least one complete turn and check at three or four places. If dial indicator deflects over 0.1 mm (0.004 in.), replace shaft. b c a a - V-Blocks b - Dial Indicator c - Shaft 2. Ensure that bore of coupling is 90 degrees from coupling flange. Rotate at least one complete turn. Replace coupling if needle moves.
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PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 22 THIS PAGE IS INTENTIONALLY BLANK Page 8B-8 90-860074--1 FEBRUARY 2002
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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 POWER STEERING SYSTEM Section 9A - Pump And Related Components Table of Contents Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded Views . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump . . . . . . . . . . . . . . . Related Components . . . . . . . . . . . . . . . .
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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 Torque Specifications NOTE: Securely tighten all fasteners not listed below. Description Front bracket Rear Brace Mounting And Tensioning Bolt Nm lb-in.
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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 Exploded Views Power Steering Pump 7 9 8 6 5 4 4 3 1 2 71035 1 2 3 4 5 6 7 8 9 - Pump - Pulley - Tensioning Bolt, Lockwasher And Flat Washer - Mounting Bolt - Bushing - Fluid Pressure Hose - Fluid Reservoir Hose - Hose Clamp - Bracket 90-860074--1 FEBRUARY 2002 Page 9A-3
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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 Related Components ALL ENGINES 9 8 3 7 1 2 6 4 78418 5 71034 1 2 3 4 5 6 7 8 9 Page 9A-4 - Fluid Reservoir Tank - Hose Clamp (2) - Fluid Reservoir Support - Bracket - Supply Hose - Pressure Hose - Return Hose (From Transom) - Return Hose (From Cooler) - Power Steering Fluid Cooler 90-860074--1 FEBRUARY 2002
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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 Power Steering Pump Removal CAUTION Disconnect Battery cables at battery to prevent engine rotation and injury while working on pump. 1. Remove vacuum pump belt, if equipped. 2. Remove and retain mounting and tensioning bolts and hardware. a b 70113 Typical a - Mounting Bolts (One With A Bushing Not Shown In This View) b - Tensioning Bolt, Lockwasher And Flat Washer 3. Lower pump down to gain access to hose connections.
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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 Installation 1. Using a suitable screw, push (install) pulley onto shaft until pulley face is flush, as shown, with shaft end (screw head will bottom out). 74481 2. Install reservoir hose and pressure hose to pump as shown. Temporarily hand tighten only.
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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 3. Place hoses appropriately between oil filter and pump mounting bracket, lift pump into place and attach with fasteners and hardware retained previously, as shown. a c a b 70113 a - Mounting Bolt With Washer (One Not Shown - Shown In Inset With Bushing) b - Tensioning Bolt, Lockwasher and Flat Washer c - Bushing 4. Tighten reservoir hose clamp securely. Tighten pressure hose fitting securely. Do NOT overtighten. 5.
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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 22 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.
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SERVICE MANUAL NUMBER 22 PUMP AND RELATED COMPONENTS THIS PAGE IS INTENTIONALLY BLANK 90-860074--1 FEBRUARY 2002 Page 9A-9
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PUMP AND RELATED COMPONENTS Page 9A-10 SERVICE MANUAL NUMBER 22 90-860074--1 FEBRUARY 2002