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MerCruiser D3.6L/180 User Manual

Diesel engines, inboard models
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Summary of Contents for MerCruiser D3.6L/180

  • Page 2: Serial Numbers

    Exhaust Gas Emissions Certificate Number (Europe Only) Serial Numbers The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your MerCruiser power package. When contacting your Authorized MerCruiser Dealer about service, always specify model and serial numbers. THIS ENGINE CONFORMS TO INT’L...

  • Page 3: Table Of Contents

    ............Starting, Shifting and Stopping - D3.6L/180 and D4.2L/220 .
  • Page 4 ............Mercruiser Diesel Limited Warranty (continued) .

  • Page 5: Welcome

    The Operation and Maintenance Manual contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our MerCruiser products. We sincerely hope your boating will be pleasant! CONSUMER AFFAIRS DEPARTMENT...

  • Page 6: Read This Manual Thoroughly

    The use of accessories not manufactured or sold by Mercury Marine is not recommended for use with your MerCruiser unit. If your MerCruiser unit is equipped with an accessory not manufactured by Mercu- ry Marine, be sure to read the Operation and Maintenance Manual for the accessory before operation.

  • Page 7: Lanyard Stop Switch

    CA475 Lanyard Stop Switch 74608 Some boats come equipped with a lanyard stop switch. A lanyard stop switch can also be installed as an accessory. The purpose of this switch is to turn off the engine ignition whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch.
  • Page 8 CA400 Courtesy of ABYC...

  • Page 9: Exhaust Emissions

    CD327 Exhaust Emissions Be Alert To Carbon Monoxide Poisoning Carbon monoxide is produced in the exhaust fumes of all internal combustion engines, including the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories.

  • Page 10: Safe Boating Suggestions

    CA281 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course.

  • Page 11: Protecting People In The Water

    Never be under the influence of alcohol or drugs while boating (it is the law). They impair your judgment and greatly reduce your ability to react quickly. Know your boating area and avoid hazardous locations. Be alert. The operator of the boat is responsible by law to “maintain a proper lookout by sight (and hearing).” The operator must have an unobstructed view particularly to the front.

  • Page 12: Conditions Affecting Operation

    Conditions Affecting Operation Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: A. Shifting weight to rear (stern) will: Generally increases speed and engine RPM. At extremes, can cause boat to porpoise. Causes bow to bounce in choppy water. Increases danger of following wave splashing into boat when coming off plane.

  • Page 13: Propeller Selection

    Be sure that propeller being used does not allow engine to run against the governor, as a significant loss in performance will result. Engine RPM - Governor Limit Engine Recommended Operating RPM MIE Model Governor RPM Setting (Begins At: ) Range D3.6L/180 3600-3800 3830 D4.2L/220 3400-3600 3630 D2.8L D-Tronic...

  • Page 14: How Elevation And Climate Affect Performance

    CA12 How Elevation and Climate Affect Performance Elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxy- gen) gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a noticeable effect on the density of air.

  • Page 15: Operation And Maintenance

    IMPORTANT: Damage caused by improper application or failure to operate within the operational capability, or duty cycle, will not be covered by the MerCruiser Diesel Limited Warranty.

  • Page 16: Owner/Operator Responsibilities

    OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks, ensure that all lubrication and maintenance instruc- tions are complied with for safe operation, and return the unit to an Authorized MerCruiser Dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.

  • Page 17: Freezing Temperature And Cold Weather Operation

    It is very important to check these items on a regular basis to ensure that the water level does not rise to come in contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the MerCruiser Limited Warranty.

  • Page 18: Launching And Boat Operation Care

    Required After Submersion,” in this “Operation and Maintenance Manual.” CA18 Attention Required After Submersion Before recovery, contact an Authorized MerCruiser Dealer. After recovery, immediate service by an Authorized MerCruiser Dealer is required to prevent serious damage to power package. CA21 Stolen Power Package If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported.

  • Page 19: Replacement Service Parts

    Since marine engines must be capable of running at or near maximum RPM much of the time, special pistons, camshafts and other heavy-duty moving parts are required for long life and peak performance. These are but a few of the many special modifications that are required in MerCruiser marine engines to provide long life and dependable performance.

  • Page 20: Engine Break-In

    On D2.8L D-Tronic and D4.2L D-Tronic Engines: Proceed to Step2. b. On D3.6L/180 and D4.2L/220 Engines Only: Pre-lubricate the turbocharger and engine. To do this, hold the “STOP” switch toggle lever DOWN while you simultaneously turn the key switch to “START”...

  • Page 21: After Break-In Period

    End of First Season Checkup At the end of the first season of operation, an Authorized MerCruiser Dealer should be contacted to discuss and/or perform various scheduled maintenance items. If you are in an area where the product is operated continuously (year-round operation), you should contact your dealer at the end of the first 100 hours of operation, or once yearly, whichever occurs first.

  • Page 22: Specifications

    CE13 Specifications CD11 Seacock Seacock (water inlet valve) used, must have an internal cross-sectional area equal to or greater than hose to prevent restricting water flow. A 1-1/2 in. (38mm) brass ball or gate valve is minimum required. Seacock should be installed in an area where it is easily accessible and supported adequately to prevent hose fatigue.

  • Page 23: Diesel Fuel In Cold Weather

    VEEDOL TURBOBOSTAR MOPAR WINTERSHALL MULTI-REKORD WINTERSHALL VIVA 1 RECOMMENDED OILS FOR D3.6L/180 ENGINES ALL TEMPERATURE OPERATION - USE 15W-40 These oils, approved by Mercury Marine and Marine Power Europe, exceed MlL-2104 D standards. AGIP SIGMA TURBO CHEVRON DELO 450 MOTOR OIL...

  • Page 24: Engine Specifications

    CE228 Engine Specifications (D3.6L/180 and D4.2L/220) SPECIFICATION MIE ( Inboard ) DESCRIPTION D3.6L/180 D4.2L/220 Crankshaft Horsepower (Kilowatts) 180 ( 134 ) 220 ( 164 ) Propeller Shaft Horsepower (Kilowatts) 180 ( 134 ) 210 ( 156 ) Engine Type In-Line 6 Cylinder Diesel Displacement 219 cu.
  • Page 25 CE229 Engine Specifications (D2.8L D-Tronic and D4.2L D-Tronic) SPECIFICATION MIE (Inboard) DESCRIPTION D2.8L D-Tronic D4.2L D-Tronic Crankshaft Horsepower (Kilowatts) 165 (123) 250 (186) Propeller Shaft Horsepower (Kilowatts) 160 (119) 240 (179) In-Line 4 Cylinder In-Line 6 Cylinder Engine Type Diesel Diesel Displacement 169 cu.
  • Page 26 CE230 71856 71856 71856 71856 72753 73546 73547 71772 73547...

  • Page 27: Operation

    NOTE: Key can only be removed in the “OFF” position. D3.6L/180 and D4.2L/220 - If engine is running the key switch cannot be used to stop engine. The engine can only be stopped by using the Engine Stop Switch, while the Key Switch is in the “RUN” position. No electri- cal circuit is operational when the key switch is turned to the “OFF”...
  • Page 28 CD336 71891 71891 71722 CE232 Engine System Monitor Features - The appropriate light functions as follows: Preheat Indicator Lamp - lights up when the glow plugs, if so equipped, are preheating the combustion cham- bers. The light stays on until the preheat period is complete. The timed preheat period begins when the key switch is turned on, and then, only when the engine is cold.

  • Page 29: Electrical System Overload Protection

    Check “blown” (burned) fuse if key is turned to RUN or START and instruments do not work and/or if switches do not function. D3.6L/180 and D4.2L/220 Engines – RED/PURPLE Wire with fuse. D2.8L D-Tronic and D4.2L D-Tronic – RED Wire with fuse.
  • Page 30 CE143 73866 70537 71339...
  • Page 31 CE157 Remote Controls (Panel Mounted) Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown.
  • Page 32 CC200...
  • Page 33 CE159 Remote Controls (Console Mounted) Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown.

  • Page 34: Starting, Shifting And Stopping - D3.6L/180 And D4.2L/220

    Be sure that all electrical connections are secure. Check the air cleaner for proper installation of filter element. Check all items listed in the MAINTENANCE SCHEDULES and OPERATION CHART - D3.6L/180 and D4.2L/220. Refer to “Table Of Contents”. Perform any other necessary checks, as indicated by your dealer, or specified in your boat owner’s manual.
  • Page 35 After the engine has reached operating temperature, oil pressure should be within range listed in the engine specifications chart. Stop the engine if oil pressure is not within this range. Locate and correct the problem, or see your Authorized MerCruiser Dealer if you are unable to determine the problem.
  • Page 36 Once underway, engine oil pressure should be within the range listed in the engine specifications chart at maximum RPM, or Wide-Open-Throttle. Stop the engine if oil pressure is not within this range. Locate and cor- rect the problem, or see your Authorized MerCruiser Dealer if you are unable to determine the problem. CB575 IMPORTANT: Avoid stopping engine if the drive unit is in gear.

  • Page 37: Operation Chart - D3.6L/180 And D4.2L/220

    CD342 Operation Chart - D3.6L/180 and D4.2L/220 STARTING AFTER WHILE STOPPING & PROCEDURE STARTING UNDERWAY SHUT DOWN Observe all gauges and Frequently observe all Shift remote control lever Open engine hatch. Air warning lights to check gauges and indicator to neutral position.

  • Page 38: Starting, Shifting And Stopping - D2.8L D-Tronic And D4.2L D-Tronic

    CD343 74726 75301 CD344 Starting, Shifting and Stopping - D2.8L D-Tronic and D4.2L D-Tronic WARNING Do not use volatile starting aids, such as Ether, Propane, or Gasoline in the engine air intake system. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage.
  • Page 39 Within seconds after starting the engine, oil pressure should exceed 10 psi (69 kPa) minimum. If the oil pressure does not meet these minimum limits, stop the engine, locate and correct the problem, or see your Authorized MerCruiser Dealer if you are unable to determine the problem.
  • Page 40 Stop the engine if oil pressure is not within this range. Locate and correct the problem, or see your Authorized MerCruiser Dealer if you are unable to deter- mine the problem.

  • Page 41: Operation Chart - D2.8L D-Tronic And D4.2L D-Tronic

    CD346 Operation Chart - D2.8L D-Tronic and D4.2L D-Tronic STARTING AFTER WHILE STOPPING & PROCEDURE STARTING UNDERWAY SHUT DOWN Observe all gauges and Frequently observe all Open engine hatch. Air Shift remote control le- warning lights to check gauges and indicator out bilge completely.

  • Page 42: General Maintenance Information

    Some listings can be done by owner/operator, while others should be performed by an Au- thorized MerCruiser Dealer. Before attempting maintenance or repair procedures not covered in this manual, it is recommended that a MerCruiser Service Manual(s) be purchased and read thoroughly. CE211 Maintenance Aids Hurth Hydraulic Transmission, Model 630A or 630V - Dexron III automatic transmission fluid (ATF).

  • Page 43: Maintenance Schedules

    CE235 Maintenance Schedules WARNING Always disconnect battery cables from battery BEFORE working around electrical system components to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted. SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR NOTE: Only perform maintenance which applies to your particular power package.

  • Page 44: Scheduled Maintenance That Should Be Performed By A Dealer

    CE236 Scheduled Maintenance That Should Be Performed By A Dealer NOTE: Only perform maintenance which applies to your particular power package. Task Interval Whenever insufficient seawater flow is suspected, if Seawater Pickup Pump - Disassemble and inspect. operating temperature exceeds normal range. After First 100 Hours of Operation or First Operating Retorque cylinder heads.
  • Page 45 CA175 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 46 CE237 71382 71380 73322 75301 71383...

  • Page 47: Checking Fluid Levels

    Remove dipstick and observe oil level. Oil must be between MIN and MAX marks on dipstick. If necessary, add oil as follows. Remove oil filler cap. Add specified oil to bring level up to, but not over, “MAX” mark on dipstick. Reinstall oil filler cap. D3.6L/180 and D4.2L/220 D2.8L D-Tronic and D4.2L D-Tronic CE46 TRANSMISSION FLUID Dipstick has neoprene seal - twist and pull to remove.
  • Page 48 71381 73322 72714 73320...

  • Page 49: Engine Coolant

    Inspect coolant tank cap gaskets for damage and replace if necessary. Also, the tank cap maintains pressure on the coolant tank. It may not be holding pressure properly. To have cap tested, contact your Authorized MerCruiser Dealer. CAUTION If the coolant should get extremely low and the engine very hot, let the engine cool for approximately 15 minutes before adding coolant;...
  • Page 50 CE162 71374 71261 70062 70355 73522 71366 71362 71444...

  • Page 51: Cleaning Quicksilver Seawater Strainer

    Lubricate pivot points with SAE 30W motor oil . CB66 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer. Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected (if operating temperature exceeds normal range).
  • Page 52 CE110 1 , 2 73522 1 , 2 1 , 2 70355 70062 73320...

  • Page 53: Flushing Seawater Cooling System

    CE111 Flushing Seawater Cooling System To prevent silt and/or salt buildup in the seawater circuit of cooling system, flush with freshwater at specified Inter- vals. CAUTION When flushing seawater cooling system, close seacock, if so 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.
  • Page 54 CD294 74726 71444 71371 74726...

  • Page 55: Fuel System

    CE61 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 func- tion of the fuel injection system. FUEL TANK IMPORTANT: Diesel fuel should not be left in tank during winter storage, as an accumulation of rust, sludge and wax residue will form.
  • Page 56 CD357 74731 74732 71367 73327 71368...

  • Page 57: Replacing Water Separating Fuel Filter

    Make sure no leaks exist before closing engine hatch. Start and run engine. Check filter connection for fuel leaks. If leaks exist, recheck filter installation. If leaks continue, stop engine immediately and contact your Authorized MerCruiser Dealer. CD119 Corrosion And Corrosion Protection INTERNAL COMPONENTS There are anodes as part of the intercooler and heat exchanger systems, which serves as a sacrificial anodes.
  • Page 58 CE126 71088 2 , 3 , 4 73565...

  • Page 59: Miscellaneous Maintenance

    Remove and inspect propeller. If badly nicked, bent or cracked, see your dealer. Repair nicks and corrosion damage on power package exterior finish. Use Quicksilver spray paints - see your Authorized MerCruiser Dealer. Spray power package components on inside of boat every 2-3 weeks with Quicksilver Corrosion Guard to protect finish from dulling and corrosion.

  • Page 60: Cold Weather Or Extended Storage

    Perform all checks on OPERATION CHART in the STARTING PROCEDURE column. IMPORTANT: On D3.6L/180 and D4.2L/220 Engines: After not having been operated for two months or longer, it is necessary to pre-lubricate the engine. To do this, hold the “STOP” switch toggle lever DOWN while you simultaneously turn the key switch to “START”...

  • Page 61: Troubleshooting

    Have pump replaced by an Authorized Mer- Cruiser Dealer, if fuel is present. Throttle not operating properly Check throttle for freedom of movement. Faulty electrical stop-circuit Have Authorized MerCruiser Dealer service electric stop-circuit. Clogged fuel filters Replace filters. Stale or contaminated fuel If contaminated, drain tank.

  • Page 62: Engine Runs Rough, Misses And/Or Backfires

    Air in fuel injection system Purge fuel injection system. Have EDI System checked by an Authorized EDI System fault. MerCruiser Dealer. Poor Performance Possible Cause Remedy Throttle not fully open Inspect throttle cable and linkages for operation.

  • Page 63: Excessive Engine Temperature

    Excessive Engine Temperature Possible Cause Remedy Seacock closed, if so equipped Open. Drive belt loose or in poor condition Replace and/or adjust belt. Seawater pickups obstructed Remove obstruction. Faulty thermostat Replace. Coolant level low in closed cooling Check for cause of low coolant level and repair. section Fill system with proper coolant solution.

  • Page 64: Low Engine Oil Pressure

    Straighten cable, or have dealer replace cable if damaged beyond repair. Improper shift cable adjustment. See Authorized MerCruiser Dealer immedi- ately for shift cable adjustment . Vacuum leak at shift cylinder, hose or fittings Repair cut, pinched, or kinked hose or faulty of Power Shift Assembly, if so equipped shift cylinder.

  • Page 65: Warranty Information

    CD54 Warranty Information CD55 Owner Warranty Registration UNITED STATES AND CANADA ONLY It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product. It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address.

  • Page 66: International Owner Registration

    CD56 International Owner Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim pro- gram for your area.

  • Page 67: Warranty Policy

    Product serial number can be verified. It is a condition for the continuation of this warranty that the Product be taken to an authorized MerCruiser Service Dealer, after 20 hours of engine operation, but not later than 50 hours, for required checks and adjustments.

  • Page 68: Mercruiser Diesel Limited Warranty (Continued)

    2) Removal and/or replacement of boat parti- tions or material because of boat design for necessary access to the Product. Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer VIII.

  • Page 69: Marine Power International Branch Or Distributor Service Offices

    CD278 Marine Power International Branch or Distributor Service Offices INTERNATIONAL HEADQUARTERS AUSTRALIA Marine Power International Marine Power International Pty. Ltd. Division of Brunswick Corporation P. B. 1420, 132-140 Frankston Road P.O. Box 1939 Dandenong, Victoria 3164 Fond du Lac, Wl 54936-1939 Australia Telephone (61) (3) 791-5822 Telephone: (414) 929-5000...

  • Page 70: Warranty Coverage

    CD279 Warranty Coverage The purpose of this section is to help eliminate some of the more common misunderstandings regarding warran- ty coverage. The table explains some of the types of services that are not covered by warranty. Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in mate- rial and workmanship.

  • Page 71: Transferable Warranty

    CD62 Transferable Warranty The product warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. DIRECT SALE BY OWNER The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership.

  • Page 72: Owner Service Assistance

    CB577 Resolving A Problem Satisfaction with your MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any Authorized MerCruiser Dealership. If additional assistance is required, take these steps.

  • Page 73: Mercury Marine Service Offices

    Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspon- dence. Telephone Mail United States MerCruiser (405) 743-6566 (405) 743-6570 3003 N. Perkins Rd. Stillwater, OK 74075 Canada Mercury Marine Ltd.

  • Page 74: Customer Service Literature

    CA463 Customer Service Literature English Language English language publications are available from: Mercury Marine Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information.
  • Page 75 cae464 Andere Sprachen Um eine Betriebs– und Wartungsanleitung oder ein Handbuch der Wartungsverfahren in einer anderen Sprache zu erhalten, wenden Sie sich an das nächste Mercury Marine oder Marine Power International Service Center. Eine Liste mit Teilenummern für Fremdsprachen ist im Lieferumfang Ihres Motors enthalten. caf464 Altre lingue Per ottenere il manuale di funzionamento e manutenzione o il manuale delle procedure di manutenzione in altra...
  • Page 76 THIS PAGE IS INTENTIONALLY BLANK...

  • Page 77: Literature Order Form

    CA465 Literature Order Form Model __________ Horsepower__________ Serial Number__________ Year_____ Operation and Maintenance Manual (Owner’s Guide) - explains basic operation and maintenance. Maintenance Procedure Manual - explains basic do-it-yourself maintenance procedures. Service Manual - shows the complete assembly and disassembly of the engine or stern drive. Parts Manual - shows the exploded view of the engine or stern drive with corresponding part number.
  • Page 78 Please Return with Payment to: Mercury Marine Attn: Publications Dept. P.O. Box 1939 Fond du Lac, WI 54936-1939 Ship To: (Please Print or Type - This is your Shipping Label) Name Address City State METHOD OF PAYMENT: (NO CASH OR C.O.D.) Personal Check Cashiers Check Money Order...
  • Page 79 75308...
  • Page 80 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

This manual is also suitable for:

D4.2l/220D2.8l d-tronicD4.2l d-tronic

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