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MerCruiser D3.0L/150 Service Manual

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Service Manual Outline

SECTION 1 - Important Information

A - General Information

B - Maintenance

C - Troubleshooting

SECTION 2 - Removal and Installation

A - MCM (Stern Drive) Models

B - MIE (Inboard) Models

SECTION 3 - Engine

A - All Models

SECTION 4 - Electrical Systems

A - Starting System

B - Glow Plug System

C - Charging System

D - Instrumentation

E - Wiring Diagrams

SECTION 5 - Fuel System

A - Fuel Delivery Pump and Fuel Filter

B - Injection Pump

C - Fuel Injectors

SECTION 6 - Cooling System

A - Seawater Cooled Section

B - Closed Cooled Section

SECTION 7 - Intake and Exhaust System

A - Intercooler

B - Intake / Exhaust System

C - Turbocharger

SECTION 8 - Drive Systems

A - Hurth Down Angle Transmission

B - Hurth V-Drive Transmission

C - Propeller Shaft Models

SECTION 9 - Power Steering

A - Pump and Related Components

iv

90-806934 1194

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Summary of Contents for MerCruiser D3.0L/150

Page 1 Service Manual Outline SECTION 1 - Important Information A - General Information B - Maintenance C - Troubleshooting SECTION 2 - Removal and Installation A - MCM (Stern Drive) Models B - MIE (Inboard) Models SECTION 3 - Engine A - All Models SECTION 4 - Electrical Systems A - Starting System B - Glow Plug System...
Page 2 Notice We could not possibly know of and advise the service trade of all conceivable procedures by which a ser- Throughout this publication, “Dangers,” “Warnings” vice might be performed and of the possible hazards and “Cautions” are used to alert the mechanic to spe- and/or results of each method.
Page 3 Engine Mechanical Replacement Parts Components WARNING Many of the engine mechanical components are de- Electrical and fuel system components on Mer- signed for marine applications. Unlike automotive Cruiser Engines and Stern Drives are designed engines, marine engines are subjected to extended and manufactured to comply with U.S.
Page 4 In-Line Diesel Models Covered in This Manual MCM (Stern Drive) MODEL SERIAL NUMBER D3.0L/150 D0725150 and Above D3.6L/180 D0850125 and Above D4.2L/220 D0554730 and Above MIE (Inboard) MODEL SERIAL NUMBER D3.0L/150 D0725150 and Above D3.6L/180 D0850125 and Above D4.2L/220 D0554730 and Above NOTICE Refer to appropriate “Stern Drive Service Manual”...
Page 5 IMPORTANT INFORMATION 72000 GENERAL INFORMATION Note: Refer to the following Service Bulletins regarding this section. SB 97-13 Service/Repair of Electrical Test Equipment SB 96-13 Official Recall Notification Federal Boat Safety Act Commander 3000 Remote Control SB 96-5 Troubleshooting Shift Problems SB 95-2 Oildyne Trim Pump Adaptor Connectors SB 91-14 Replacement Trim Pump for the Prestolite Style Pump...
Page 6 Table of Contents Page Introduction ........1A-1 How to Use This Manual .
Page 7 Introduction Page Numbering Two number groups appear at the bottom of each This comprehensive overhaul and repair manual is page. Following is an example and description. designed as a service guide for the models previously listed. It provides specific information, including pro- cedures for disassembly, inspection, assembly and adjustment to enable dealers and service mechanics to repair and tune these engines.
Page 8 How to Read Parts Manual NOTE: The following is represen- tative of a page from a MerCruiser Parts Manual and is not intended to be an actual page from a specif- ic Parts Manual. 73287 CYLINDER BLOCK AND CAMSHAFT M0033-D8 REF.
Page 9 Directional References Engine Rotation Front of boat is bow; rear is stern. Starboard side is Engine rotation is determined by observing flywheel right side; port side is left side. In this maintenance rotation from the rear (stern end) of the engine looking manual, all directional references are given as they forward (toward water pump end).
Page 10 Use care during the first 20 hours of operation on new Cruiser Stern Drive Service Manual, or order publica- MerCruiser engines or possible engine failure may tion P/N 90-86144-92, “Everything you need to know occur. If a new engine has to be water-tested at full about propellers.”...
Page 11 Boat and Engine and reduces any porpoising (rhythmical bouncing) tendency. A slight hook is often built in by the man- Performance ufacturer. A hook also can be caused by incorrect trailering or storing the boat with support directly un- der the transom. Boat Bottom For maximum speed, a boat bottom should be as flat as possible in a fore-aft direction (longitudinally) for...
Page 12 Marine Fouling Weight distribution is not confined strictly to fore and aft locations, but also applies to lateral weight distri- Fouling is an unwanted build-up (usually animal-veg- bution. Uneven weight concentration to port or star- etable-derived) occurring on the boat’s bottom and board of the longitudinal centerline can produce a se- drive unit.
Page 13 It is the operator’s responsibility to operate within the operational capability, or duty cycle, will not be following recommended operational capability, or covered by the MerCruiser Diesel Limited duty cycle, as applicable to engine and installation: Warranty. •...
Page 14 IMPORTANT INFORMATION MAINTENANCE Note:Refer to the following Service Bulletin regarding this section. SB 91-7 New Engine Break-In Procedure for Diesel Engines INDEX...
Page 15 1B-23 Engine Initial Break-In Procedure ....1B-5 D3.0L/150 and D3.6L/150 Models ..1B-23 Engine 20-Hour Break-In Period ....
Page 16 Maintenance Schedule NOTE: Refer to appropriate Stern Drive Service WARNING Manual for information and procedures on stern drive Always disconnect battery cables from battery maintenance items listed. BEFORE working around electrical system com- ponents to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted.
Page 17 Maintenance Schedule (Continued) SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER REQUIRED SERVICE INTERVAL After First 20 Hours, But Not Later Than 50 Hours, of Op- 20-50 Hour Checkup (See NOTE 1.). eration After First 100 Hours of Operation or First Operating Retorque cylinder heads Season, Whichever Occurs First After 20-Hour Break-In Period, Then, for Pleasure-...
Page 18 Specifications Engine SPECIFICATION ITEM D3.0L/150 D3.6L/180 D4.2L/220 MCM (Stern Drive) 150 ( 112 ) 180 ( 134 ) 220 ( 164 ) Crankshaft Horse- Crankshaft Horse- power (Kilowatts) MIE (Inboard) 150 ( 112 ) 180 ( 134 ) 220 ( 164 )
Page 19 NOTICE All capacities are approximate fluid measures in U.S. Quarts (Litres). SPECIFICATION - MIE ( INBOARD ) ITEM ITEM D3.0L/150 D3.6L/180 D4.2L/220 Total Oil-filling Capacity 9-1/2 ( 9 ) 10-1/2 ( 10 ) 12-3/4 ( 12 ) from oil pan...
Page 20 After Break-in Period lowing RPMs: 1200 RPM, 2400 RPM and 3000 RPM. To help extend the life of your MerCruiser power 3. Run engine in gear for 3 minutes at each of the fol- package, the following recommendations should be lowing RPMs: 1500 RPM, 2800 RPM and 3400 considered;...
Page 21 20 Hour Checkup After 20 hours of operation, but no later than 50 hours, an Authorized MerCruiser Dealer should be contacted for the following services, checks, and adjustments. (Note: Some items may not apply to your specific power package.) The product owner is responsible for any charges. A copy of the dealer service work order must be kept by the product owner.
Page 22 Fluid Specifications Sulphur content of the above fuel is rated at 0.50% by weight, maximum (ASTM). Limits may vary in coun- tries outside of the United States. Diesel Fuel On intermittent use engines, high sulphur content die- sel fuel will greatly increase: •...
Page 23 We recommend the use of Quicksilver 4-Cycle Ma- rine Engine Oil, a specially blended 25W-40 SG/CD oil with Marine Additives. RECOMMENDED OILS FOR D3.0L/150 AND D3.6L/180 ALL TEMPERATURE OPERATION - USE 15W-40 CD AGIP SIGMA TURBO CHEVRON DELO 450 MOTOR OIL...
Page 24 Coolant for Closed Cooling System Checking Engine Oil Level/Filling IMPORTANT: ENGINE CRANKCASE OIL MUST CAUTION BE CHECKED AT INTERVALS SPECIFIED IN Alcohol or Methanol base antifreeze or plain wa- “MAINTENANCE SCHEDULE” CHART. It is nor- ter, are not recommended for use in fresh water mal for an engine to use a certain amount of oil in section of cooling system at any time.
Page 25 2. Remove dipstick and observe oil level. Oil must Changing Crankcase Oil and be between MIN and MAX marks on dipstick. If Oil Filter necessary, add oil as follows. IMPORTANT: Change oil when engine is warm from operation. Warm oil flows more freely, carry- ing away more impurities.
Page 26 6. Remove and discard oil filter and sealing ring. Maintaining Power Steering Coat sealing ring on new filter with oil and install Pump Fluid Level filter. Hand tighten only, do not use a filter wrench. With Engine Cold 1. Stop engine and position drive unit so that it is straight back.
Page 27 Filling and Bleeding Power Maintaining Transmission Steering System Fluid Level IMPORTANT: Power steering system must be IMPORTANT: To accurately check fluid level, en- filled exactly as explained in the following to be gine MUST BE run at 1500 RPM for 2 minutes im- sure that all air is bled from the system.
Page 28 Maintaining Power Trim 3. Observe oil level. Level must be up to, but not over, bottom of fill neck. Add Quicksilver Power Pump Oil Level Trim and Steering Fluid if required (or SAE 10W-30 motor oil if Quicksilver Power Trim and 1.
Page 29 Maintaining Closed Cooled 2. Periodically, to ensure that coolant recovery sys- tem is functioning properly, you should allow engine Section Coolant Level to cool and then slowly and carefully remove coolant tank cap. Coolant level must be to the bottom edge of 1.
Page 30 1. Allow engine to cool down. Slowly and carefully 5. Remove coolant recovery bottle from mounting remove pressure cap from coolant tank. bracket and pour out coolant. 2. Drain coolant from intake/exhaust manifold by 6. If required, clean system as outlined in “Cleaning opening the petcock.
Page 31 Filling Closed Cooling MCM Stern Drive Section NOTE: If flushing seawater cooling system with boat in water, raise drive unit to TRAILER position, install 1. Remove pressure cap from heat exchanger and flushing attachment and lower drive unit to full down/ fill section with Quicksilver Premixed Marine En- in position.
Page 32 MIE Inboard 3. Using an adaptor, connect a garden hose from a water tap to seawater pump inlet. CAUTION 4. Partially open water tap (approximately 1/2 maxi- mum). Do not use full water pressure. If boat is in the water, seacock (water inlet valve), if so equipped, must be closed until engine is to 5.
Page 33 Inspect Water Pickups Check/Clean Seawater Strainer Stern Drive Gear Housing 1. Visually inspect seawater strainer through glass top. Check water inlet area of gear housing to ensure that openings are clean and not obstructed. CAUTION When cleaning seawater strainer, close seacock, if so equipped.
Page 34 Fuel Filter Draining NOTICE Precautions Refer to “Precautions,” in this Fuel Filter section , BEFORE proceeding. WARNING Always disconnect battery cables from battery NOTE: To ensure complete draining, in warm weath- BEFORE working on fuel system to prevent fire. er, open the drain cock before starting daily opera- This eliminates the engine wiring as a potential tions.
Page 35 Filling Replacing NOTICE NOTICE Refer to “Precautions,” in this Fuel Filter Refer to “Precautions,” in this Fuel Filter section , BEFORE proceeding. section , BEFORE proceeding. NOTE: Follow this procedure after installing new filter 1. Turn water bleed valve counterclockwise (when or if fuel has been drained from filter checking for viewed from bottom of filter element) and remove water.
Page 36 Clean/Replace Air Filter 4. Wash element in warm water and detergent until clean. 1. Disconnect crankcase vent hose from end of air in- IMPORTANT: No treatment (such as partial oil sat- take screen housing. uration) is required or recommended on air clean- er foam element prior to use.
Page 37 Replace Drive Belts Alternator Belt Belt and Pulley Replacement Guidelines: NOTE: On some engines it may be necessary to re- • During belt assembly, do not force belt into pulley move other drive belts to gain access to a particular grooves by prying with a screwdriver, pry bar, etc.
Page 38 5. Install seawater pump inlet and outlet hoses. Power Steering Pump Belt Tighten hose clamps securely. D3.0L/150 AND D3.6L/150 MODELS 1. Loosen mounting and tensioning fasteners on power steering pump. 2. Turn tensioning bolt with pinion, to pivot pump and loosen belt.
Page 39 D4.2L/220 MODELS 4. Remove old power steering belt and install new belt. NOTE: On some engines it may be necessary to re- 5. Pivot the power steering pump to adjust belt. move other drive belts to gain access to a particular Approximately 3/16 in.
Page 40 Vacuum Pump Belt (Refer to SECTION 6A, Seawater Pump Removal.) D3.0L/150 AND D3.6L/150 MODELS IMPORTANT: There is an o-ring seal on the water pump. Ensure that it is in proper position before NOTE: On some engines it may be necessary to re- installing or securing the water pump.
Page 41 D4.2L/220 MODELS 4. Install new vacuum pump belt and adjust tension [3/16 in. (5 mm) deflection]. Torque mounting and tensioning screws to 15 lb. ft. (21 N·m). NOTE: On some engines it may be necessary to re- move other drive belts to gain access to a particular belt during replacement.
Page 42 Inspect/Replace Cooling REPLACEMENT System Sacrificial Anodes NOTE: Sacrificial anodes are available as an assem- bly. Replace both the plug and anode, if so desired. Coolant Tank / Heat Exchanger 1. Refer to “Inspection”, as previously outlined and Anode remove anode plug. Then: a.
Page 43 Intercooler Anode b. Clean interior threads of anode plug. c. Apply Loctite #242 to threads of new sacrifi- INSPECTION cial anode and install into anode plug. Tighten securely. The sacrificial anode is located on the top of the inter- d. Install new copper sealing washer. cooler.
Page 44 Check Battery Shift Cable Lubricate pivot points and guide contact surfaces with 1. Check battery connections to ensure they are SAE 30W motor oil. clean and tight. 2. Keep exterior surfaces of battery wiped clean with a water/baking soda solution. 3.
Page 45 ° F (0 C) or lower, observe the following precautions and instructions: NOTE: Refer to MerCruiser Stern Drive Service Man- ual for stern drive unit removal and installation. CAUTION Seawater (raw water) section of cooling system MUST BE COMPLETELY drained for winter stor- age or immediately after cold weather use, if the possibility of freezing temperatures exist.
Page 46 Saltwater Operation IMPORTANT: Observe the following information to ensure complete draining of cooling system. Seawater section must be flushed after each use. Re- • Engine must be as level as possible. fer to “Flushing Seawater Cooling System.” • A wire should be repeatedly inserted into all drain holes to ensure there are no obstruc- tions in passages.
Page 47 IMPORTANT: Closed cooling section must be IMPORTANT: This service should be performed kept filled year-round with specified coolant. by an authorized MerCruiser dealer. CAUTION The engine must be prepared for long storage pe- riods to prevent internal corrosion and severe damage.
Page 48 DRAINING INSTRUCTIONS 2. Do not open either of these two petcocks. They are in the closed cooling section. CAUTION If boat is to remain in the water, seacock, if so equipped, must be closed until engine is to be re- started to prevent water from flowing back into seawater cooling system.
Page 49 3. Remove the end covers from BOTH port and star- 4. Follow appropriate instructions “a” or “b”: board ends on upper and lower sections of heat a. On MCM (Stern Drive) Engines: Disconnect exchanger tank. Drain tank completely. Sponge- seawater outlet hose at aft end of power out or soak-up any water that remains in the bot- steering fluid cooler.
Page 50 Seal, and reinstall. Tighten securely. Install all hoses previously removed and tighten hose clamps securely. 73322 IMPORTANT: MerCruiser recommends that pro- a - Seawater Pump Outlet Hose pylene glycol antifreeze (nontoxic and biode- gradable, which makes it friendly to lakes and riv- 7.
Page 51 - Gasket e - Impeller 14. Start engine and run, AT IDLE SPEED, until anti- D3.0L/150 Seawater Pump Shown (All Similar) freeze mixture has been pumped into engine sea- water cooling system. Stop engine. IMPORTANT: Place a CAUTION TAG at instrument 15.
Page 52 - Gasket (Wide Surface on Cam Side) garage. d - Cover e - Cover Screws D3.0L/150 Seawater Pump Shown (All Similar) Recommissioning 2. Check that all cooling system hoses are in good condition and connected properly, hose clamps NOTICE are tight, and all petcocks and drain plugs are in- Refer to “Cold Weather or Extended Storage,”...
Page 53 6. Replace fuel filter as outlined previously in this CAUTION section. DO NOT operate engine without water flowing 7. For drive unit, refer to appropriate Stern Drive thru seawater pickup pump, as pump impeller Service Manual. may be damaged and subsequent overheating damage to engine or transmission may result.
Page 54 IMPORTANT INFORMATION TROUBLESHOOTING Note: Refer to the following Service Bulletin regarding this section: SB 96-9 MerCruiser Scan Tool INDEX...
Page 55 Table of Contents Page Engine Smoking (Blue) ..... . . 1C-12 NOTICE Engine Smoking (White) ..... . 1C-12 Exhaust Gas Temperature (High) .
Page 56 Precautions ticularly after storage. All fuel components in- cluding fuel tanks, whether plastic, metal or fiberglass, fuel lines, primers, fittings, and fuel fil- WARNING ters should be inspected for leakage, softening, Always disconnect battery cables from battery hardening, swelling or corrosion. Any sign of BEFORE working on fuel system to prevent fire or leakage or deterioration requires replacement explosion.
Page 57 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.
Page 58 Improper Full Throttle Engine RPM RPM Too High Cause Special Information 1. Propeller 1. Damaged; pitch too low; diameter too small; propeller hub slipping 2. 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.
Page 59 Engine Cranks Over but Will Not Start or Starts Hard Important Information Determine which engine system is causing the problem. To make an engine run, basic components - fuel, glow plugs, and compression - are required. If all three components are present, the engine should run. If any one of the three are missing, weak, or arriving at the wrong time the engine will not run.
Page 60 Fuel System (continued) Cause Special Information 12. Injection pump solenoid valve 13. Fuel supply pump 13. Low pump pressure Miscellaneous Cause Special Information 1. Low grade or stale fuel 2. Water in fuel 3. Incorrect starting procedure 3. Refer to Owners Manual 4.
Page 61 Engine Will Not Crank Over or Starter Inoperative (continued) 7. Faulty neutral start safety switch 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.
Page 62 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.
Page 63 Engine Runs Poorly at Idle Cause Special Information 1. Clogged air cleaner 2. Improper idle fuel mixture adjustment 3. Plugged fuel suction line or filter 4. Air leaks: suction side fuel line, water separating fuel filter or loose intake manifold 5.
Page 64 Engine Runs Poorly At High Rpm Cause Special Information 1. Also refer to “Poor Boat Performance” 1. See “Table of Contents” 2. Crankcase overfilled with oil 2. Check oil level with boat at rest in the water 3. Anti-siphon valve (if equipped) 3.
Page 65 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.
Page 66 Engine Smoking (Black) Cause Special Information 1. Overload 2. Clogged air cleaner Excessive fuel delivery 3. Refer to Section 5A 4. Faulty injector(s) Refer to Section 5C 5. Restricted or plugged exhaust 6. Insufficient coolant temperature Excessive idle time (slobber) 8.
Page 67 Engine Smoking (Blue) Cause Special Information 1. Insufficient load 1. Check propeller 2. Low fresh water temperature (faulty thermostat) 2. Check temperature of oil and water 3. Worn piston rings 3. Check compression 4. Sticking piston rings 4. Check compression 5.
Page 68 Exhaust Gas Temperature (High) Cause Special Information 1. Excessive load 2. Injection pump timing incorrect 2. Refer to Section 5B Wrong assembly - timing device - pressure regu- lating valve Exhaust Gas Temperature (Low) Cause Special Information 1. Injection pump timing incorrect 1.
Page 69 Turbocharger Make certain that troubles are not due to engine components, especially to injection system, before troubleshoot- ing turbocharger and/or carrying out corrective action on turbocharger. Cause Special Information 1. Smoke from exhaust 1. A. Not enough air getting to engine air intake B.
Page 70 Engine Noise IMPORTANT INFORMATION 4. Try to isolate the noise to location in engine: front to back, top to bottom. This can help determine No definite rule or test will positively determine source which components are at fault. of engine noise; therefore, use the following informa- tion only as a general guide to engine noise diagno- 5.
Page 71 Cylinder Area (continued) Location Possible Causes 2. Engine knocking 2. A. Faulty injector (white smoke) B. Worn delivery valve C. Wrong injection timing D. Incorrect valve clearance E. Loose pre-combustion chamber F. Tight piston pin Camshaft Area Location Possible Causes 1.
Page 72 Crankshaft Area Location Possible Causes 1. Crankshaft area, front of engine, timed to engine 1. A. Crankshaft timing gear speed B. Oil Pump C. Rod bearing D. Main bearing 2. Crankshaft area, center of engine, timed to 2. A. Crankshaft striking pan or pan baffle engine speed B.
Page 73 Oil Pressure Item Special Information 1. Measuring oil pressure 1. Use a good automotive oil pressure test gauge. Do not rely on the oil pressure gauge in the boat. 2. Check engine oil level with boat at rest in the 2.
Page 74 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;...
Page 75 Excessive Oil Consumption Cause Special Information 1. Normal consumption 1. One quart of oil consumed in 5-15 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.
Page 76 Water in Engine If water is contained to cylinder(s) only, it is usually en- tering through the intake system, exhaust system, or head gasket. IMPORTANT INFORMATION If the water is contained to crankcase only, it is usually IMPORTANT: First determine location of water in caused by a cracked or porous block, a flooded bilge, engine.
Page 77 Water On Top Pistons Cause Special Information 1. Rain water running onto air cleaner 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.
Page 78 Engine Overheats (Cooling System) (continued) Cause Special Information 6. Loose hose connections between seawater 6. Pump will suck air. Pump may fail to prime or will pickup and seawater pump inlet force air bubbles into cooling system. 7. Seawater inlet hose kinked or collapsed 7.
Page 79 Engine Overheats (Mechanical) Cause Special Information 1. Engine RPM below specifications at wide- 1. Damaged or wrong propeller; growth on boat open-throttle (engine laboring) bottom; false bottom full of water 2. Incorrect injection pump timing 2. Injection pump timing too far advanced or retarded 3.
Page 80 Power Steering Poor, Erratic, or No Assist Cause Special Information 1. Drive belt 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.
Page 81 Noisy Pump Cause Special Information Drive belt 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.
Page 82 Insufficient Water Flow From Belt Driven Seawater Pump Cause Special Information 1. Drive belt 1. Loose, worn or broken 2. Seawater shutoff valve partially or fully closed 3. Clogged or improperly installed sea strainer 4. Loose hose connections between seawater pick 4.
Page 83 Hurth Hydraulic Transmission Trouble Possible Cause Remedy 1. Transmission gears 1. A. Shifting lever loose 1. A. Tighten clamping screw on cannot be shifted shifting lever B. Remote control does not B. Lift remote control off, if gears permit lever travel required for can be shifted by hand, correct testing remote control...
Page 84 Hurth Hydraulic Transmission (continued) Trouble Possible Cause Remedy 6. Shifting pressure too low 6. A. Fluid filter dirty 6. A. Replace fluid filter B. Fluid level in transmission is B. Fill with fluid; check for fluid too low loss in transmission,cooler and pipelines lines for leaks also refer to steps 10 to 13 C.
Page 85 Hurth Hydraulic Transmission (continued) Trouble Possible Cause Remedy 8. Excessive fluid G. Clutch does not open G. Disassemble transmission, temperature completely due to broken replace inner disc support (continued) clutch cup springs and/or clutch H. Low water flow from sea pump H.
Page 86 Hurth Hydraulic Transmission (continued) Trouble Possible Cause Remedy 15. Transmission noise 15. A. Fluid level too low so that 15. A. Top off fluid to fill mark changes, becomes pump sucks in air louder B. Damage starting on flexible B. Replace flexible coupling. coupling due to wear or Check alignment between fatigue, possible due to...
Page 87 SB 96-1 Bravo Transom Assemblies for the 1996-1/2 Model Year SB 95-21 Bearing Cup Installation in the Bravo One Bearing Carrier SB 95-10 MerCruiser MCM D7.3L/270 Diesel Sterndrive Replacement SB 91-26 Bravo One Clutch SB 91-21 Drive Unit Gear Ratio Identification...
Page 88 Table of Contents Page Torque Specifications ......2A-1 Tools/Lubricants/Adhesives ....2A-1 Removal .
Page 89 Torque Specifications IMPORTANT: Listed below are the torque specifications for those fasteners which have a specific torque value. Tighten all other fasteners (not listed) securely. DESCRIPTION Lb. In. Lb. Ft. N·m Drive Unit Shift Cable or Power Shift Output Cable End Guide Tighten Nut Until It Bottoms Out Against Flat Attaching Nut Washer;...
Page 90 Removal 4. Loosen hose clamps, then disconnect and suit- ably plug fuel lines to prevent fuel in tank from leaking into bilge. IMPORTANT: Stern drive unit must be removed 5. Disconnect throttle cable from injection pump prior to engine removal. Refer to Stern Drive Ser- linkage on engine and retain locknuts and hard- vice Manual.
Page 91 Installation CAUTION DO NOT allow lifting sling to hook or compress engine components or damage will occur. Engine Preparation 15. Support engine with suitable sling, through lifting 1. Follow instructions “a” or “b”: eyes on engine and remove front and rear engine a.
Page 92 IMPORTANT: Engine attaching hardware must be 8. Remove rocker cover nut (and O-ring seal) near- installed in sequence shown. est pulley end of engine and install Engine Lifting Eye Tool 91-814412 as shown. Tighten securely, but do not overtighten. Attach chain and hook 6.
Page 93 - Clamp f - Nuts – Loosen to Move Bracket Side-to-Side g - Clamp Spread-Screw D3.0L/150. D3.6L/180, and D4.2L/220 6. Remove alignment tool if not already removed. 7. Remove Engine Lifting Eye Tool. Install rocker cover nut with new o-ring seal. Torque rocker nut to 84 lb.
Page 94 Engine Connections 4. Connect any grounding wires and accessories that were connected to engine. 1. Connect power steering hoses to control valve. 5. Connect seawater inlet hose to engine water inlet IMPORTANT: Make hydraulic connections as fitting. Tighten hose clamp securely. quickly as possible to prevent oil leakage.
Page 95 7. Connect MerCathode wires to MerCathode con- 9. Follow gear lube monitor bottle connection troller mounted on engine. Apply a thin coat of instructions “a” or “b”. In “a” and “b” the TAN/ Liquid Neoprene to ALL electrical connections. BLUE wire connects to BLACK/GREEN wire. BLACK wire connects to BLACK wire.
Page 96 b. Connect fuel return line to injection pump re- WARNING turn fitting and secure with hose clamps. Be careful when working on fuel system compo- nents; 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 changing fuel system components.
Page 97 Shift Cable Installation 3. Loosen stud and move it to dimension as shown. Retighten stud. and Adjustment NOTE: Shift Cable Adjustment Tool (91-12427) al- lows the shift cables to be installed and adjusted, with or without the stern drive attached. IMPORTANT: When installing shift cables, be sure that cables are routed in such a way as to avoid sharp bends and/or contact with moving...
Page 98 6. Locate center of remote control shift cable play CAUTION (backlash), or center of Power Shift output control DO NOT attempt to install or remove remote con- cable play (on engines with Power Shift). trol cable or Power Shift output cable barrel from a.
Page 99 10. Follow instructions “a” or “b”: a. On Engines WITHOUT Power Shift: Shift remote control lever into forward position. Place end of adjustment tool in barrel retainer. (1) Slot (as indicated )in tool should fit over shift lever stud. • RH ROTATION – ON BRAVO ONE AND TWO : Rear slot in tool should fit over shift lever stud.
Page 100 • RH ROTATION – ON BRAVO ONE AND TWO b. On Engines Equipped WITH Power Shift: Final adjustment of Power Shift Assembly MODELS: Rear slot in tool should fit over shift output cable at the shift plate cannot be ac- lever stud.
Page 101 Throttle Cable Installation 5. Check to ensure injector pump lever is contact- ing “W.O.T. Stop Screw,” DO NOT attempt to and Adjustment adjust screw (screw is sealed). Check to ensure that remote control and cable are providing proper output. IMPORTANT: When installing throttle cables, be sure that cables are routed in such a way as to avoid sharp bends and/or avoid contact with moving parts.
Page 102 Engine Idle Speed c. Tighten jam-nut while preventing screw (a) from turning. Adjustment WARNING DO NOT leave helm unattended while performing idle speed check. Boat MUST BE moving forward (not tied to the dock) when checking idle speed. Idle speed must not be lower than 750 RPM, in gear.
Page 103 REMOVAL AND INSTALLATION 73322 MIE (INBOARD) MODELS Index...
Page 104 Table of Contents Page Torque Specifications ......2B-1 Tools/Lubricants/Adhesives ..... 2B-1 Removal .
Page 105 Torque Specifications IMPORTANT: Listed below are the torque specifications for those fasteners which have a specific torque value. Tighten all other fasteners (not listed) securely. Fastener Location Lb. In. Lb. Ft. N·m Remote Control Throttle and Shift Cable Barrel Attaching Nut Securely Remote Control Throttle and Shift Cable End Guide Attaching Tighten Nut Until It Bottoms Out Against Flat...
Page 106 Removal 5. Disconnect throttle cable from injection pump and bracket anchor studs. Retain locknuts and hard- ware. Engine Removal 6. Disconnect shift cable(s) from transmission. CAUTION CAUTION Before removing seawater strainer hose, close seacock, if so equipped. If boat is not equipped It is good practice to ventilate the engine com- with a seacock, remove and plug seawater inlet partment prior to servicing any engine compo-...
Page 107 14. Remove front and rear engine mounting bolts. CAUTION Retain hardware. DO NOT allow lifting sling to hook or compress engine components or damage to them will occur. 13. Support engine with suitable sling, through lifting eyes on engine and remove front and rear engine mounting bolts.
Page 108 (3) Large diameter of mount trunnion ex- pended. Refer to “Removal” section for loca- tended no more than 3/4 in. (19 mm), as tion of lifting eyes. shown. (4) Each mount base is downward. Tighten CAUTION clamping screws and nuts slightly to pre- DO NOT allow lifting sling to hook or compress vent moving in or out.
Page 109 Engine Final Alignment 3. Check that coupling centerlines align, by butting propeller shaft coupler against transmission out- put flange. Shoulder on propeller shaft coupler CAUTION should engage recess on transmission output flange face with no resistance. To avoid vibration, noise and damage to trans- mission output shaft oil seal and bearings, en- gine must be properly aligned.
Page 110 4. Check for angular misalignment, by hand holding 5. If coupling centerlines are not aligned or if cou- coupling faces tightly together and checking for a pling faces are more than .003 in. (0.07 mm) out gap between coupling faces with a .003 in. of parallel, adjust engine mounts as follows: (0.07mm) feeler gauge at 90 intervals.
Page 111 b. TO MOVE ENGINE TO THE LEFT OR c. After engine has been properly aligned, se- RIGHT: Loosen clamping screw and nut on all cure mounts to stringers using appropriate four mount brackets; move engine to the left hardware. or right as necessary to obtain proper align- 6.
Page 112 b. Couplings with Propeller Shaft Engine Connections Screws: (1) If propeller shaft coupler has set screws, CAUTION remove set screws and mark (dimple) lo- cations using a transfer punch. It is good practice to ventilate the engine com- partment prior to servicing any engine compo- nents to remove any fuel vapors which may cause difficulty breathing or be an irritant.
Page 113 b. Connect fuel return line to injection pump re- WARNING turn fitting and secure with hose clamps. Be careful when working on fuel system compo- nents; 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 changing fuel system components.
Page 114 8. Connect seawater inlet hose to seawater pump 10. Connect coolant recovery bottle plastic hose to fitting. Tighten hose clamp securely. heat exchanger and secure with tubing clamp. 73331 71362 a - Seawater Pump Fitting b - Seawater Inlet Hose 70548 a - Plastic Tubing 9.
Page 115 Shift Cable Installation and WARNING Adjustment - Hurth Transmissions Avoid serious injury or property damage caused by improper shifting. Anchor stud for shift cable must be installed in the correct hole. NOTE: On models with other than Quicksilver shift cables refer to shift cable manufacturer’s instruc- 1.
Page 116 2. Place remote control shift lever, and transmis- IMPORTANT: Transmission is “fully” in gear sion shift lever, in neutral position. when shift lever comes to a stop, in either direc- tion. 3. Remove nuts and washers from shift cable at- taching studs.
Page 117 NOTE: To change cable approach direction on SINGLE CABLE - REAR ENTRY single or dual station installations, only the spacers/ bushings have to be switched to the opposite stud (the studs are identical). SINGLE CABLE - FORWARD ENTRY 73587 CABLE 73589 END GUIDE STUD...
Page 118 DUAL CABLE - FORWARD ENTRY DUAL CABLE - REAR ENTRY 73591 73590 CABLE BARREL CABLE STUD END GUIDE STUD CABLE CABLE END GUIDE BARREL STUD STUD 50073 71211 a - Cable End Guides b - Locknut and Washer (Tighten Until Bottomed, Then Back a - Cable End Guides Off One Full Turn) b - Locknut and Washer (Tighten Until Bottomed, Then Back...
Page 119 Throttle Cable Installation and Adjustment NOTE: On models equipped with other than Quick- silver Throttle Cables, attach and adjust throttle cables referring to cable manufacturer’s instructions. IMPORTANT: When installing throttle cables, be sure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts.
Page 120 4. Check to ensure injector pump lever is contact- 5. Place remote control lever in neutral/idle posi- ing “W.O.T. Stop Screw,” DO NOT attempt to tion and, if necessary, readjust throttle cable adjust screw (screw is sealed). Check to ensure barrel.
Page 121 ENGINE ALL MODELS - ENGINE Note: Refer to the following Service Bulletin regarding this section. SB 96-10 Piston Ring End Gap INDEX...
Page 122 ........3A-19 MerCruiser Diesel Service Tools ....
Page 123 Page Page Oil Seal (Rear Main) ......3A-51 Front Main Bearing ..... 3A-57 Removal .
Page 124 Main Bearing Carrier Locating Bolts (Banjo) Oil Pick-up Tube Rocker Arm Lock Nuts Drive Plate [MIE (Inboard) Engines] Adaptor Plate [MIE (Inboard) D3.0L/150 and D3.6L/180 Engines] Coupler [MCM (Stern Drive) Engines] Power Steering Pulley (on Crankshaft) Alternator Mounts Power Steering Pump Mounts...
Page 125 MT33B Flywheel Seal Installer 91-801111260 Note 2: For use on D3.0L/150 with VM S/N 70811 and up. Also for use on D3.6L/180 with VM 5/N 56945 and up. Note 3: For use on D4.2L/220. Note 4: For use with millimeter dial gauge.
Page 126 Engine Specifications UNIT OF MEASUREMENT in. (mm) MODEL D3.0L/150 D3.6L/180 D4.2L/220 Engine Type – In-Line Diesel 5 Cylinder 6 Cylinder 6 Cylinder Firing Order 1-2-4-5-3 1-5-3-6-2-4 1-5-3-6-2-4 Crankshaft Horsepower (Kilowatts) 150 (112) 180 (134) 220 (164) MCM (Stern Drive Models):...
Page 127 .017 - .020 .056 (1.42) PISTON RINGS (0.48 - 0.57) (0.43 - 0.52) .023 - .026 .021 - .024 .060 (1.52) D3.0L/150 and (0.58 - 0.67) (0.53 - 0.62) MODELS D4.2L/220 D3.6L/180 .027 - .030 .025 - .028 .064 (1.62) (0.68 - 0.77)
Page 128 VALVE SEAT SPECIFICATIONS ROCKER ARM SPECIFICATIONS Exhaust Intake .865 - .866 Journal Diameter (21.979 - 22.000) Seat Angle 45° 55° .867 - .868 Bushing I.D. .055 - .059 .047 - .051 Seat Width (22.020 - 22.041) (1.40 - 1.50) (1.20 - 1.30) Max.
Page 129 Max. difference in weight of connecting rods must not exceed Runout — Face .004 (0.10) 10 gr. in one engine. Runout — Bore .004 (0.10) PISTONS OIL PUMP D3.0L/150 and MODELS D4.2L/220 D3.6L/180 Rotor .006 (0.152) Class 3.6181 - 3.6185 3.6980 - 3.6984...
Page 130 Firing Order FLYWHEEL 1-5-3-6-2-4 D3.6L/180 and D4.2L/220 FLYWHEEL 50489 1-2-4-5-3 D3.0L/150 90-806934 1194 ENGINE - ALL MODELS - 3A-7 INDEX...
Page 131 71675 73321 Mercruiser Serial Number 70427 VM Serial Number a - MerCruiser Serial Number Plates b - VM Serial Number (Stamped in Block) c - Exhaust Gas Emissions Certificate Number (Example) 3A-8 - ENGINE - ALL MODELS 90-806934 1194 INDEX...
Page 132 - Cylinder Head With Radial Glow Plug Arrangement (Glow Plug Enters Side of Head At An Angle) Later model D3.0L/150 engines beginning with Serial b – Cylinder Head With Tangential Glow Plug Arrangement Number 0D725152 and above, D3.6L/180 engines...
Page 133 Engine Rotation PISTON RINGS and CONNECTING RODS The pistons have three rings, two compression and Engine rotation terminology, at times, has caused one oil control. The top compression ring is tapered confusion. To clarify, engine rotation is determined by and the second compression ring is stepped. The observing flywheel rotation from the rear (transmission or bottom ring, oil control, has a spring inside to help stern drive end) of the engine looking forward.
Page 134 6 - Engine Oil Cooler (Lower Portion of Heat Exchanger/Coolant Tank) 7 - Rocker Arms 8 - Camshaft Bearings 9 - Piston Oil Jets 10- Crankshaft Main Bearing Carrier and Bearing 11- Turbocharger D4.2L/220 Shown (D3.0L/150 and D3.6L/180 Similar) 90-806934 1194 ENGINE - ALL MODELS - 3A-11 INDEX...
Page 135 Bearing Failures Scratches Bright (Polished) Overlay Dirt Sections Wiped Out 70436 Imbedded SCRATCHED IMPROPER into Bearing LACK OF OIL Material BY DIRT SEATING Radius Ride Overlay Gone Craters or Pockets 70436 from Entire Surface TAPERED RADIUS FATIGUE FAILURE JOURNAL RIDE Compression Testing 4.
Page 136 Engine Mounts MIE (Inboard) Transmission Mounts Front Mount Positions The front motor mounts can be installed two ways as shown by the following photos. Be sure and mark the mounts before removing them from engine block. Front Mount Standard Position 27035 Hydraulic Transmission Mount Components Standard Mount Position...
Page 137 - Drive Plate Housing b - Drive Plate c - Adaptor Plate (D3.0L/150 and D3.6L/180 Engines Only) MCM (Stern Drive) Engine Coupler And Flywheel Housing NOTE: Some engines are equipped with a solid (Single Stage) coupler, in place of the “Dual Stage” coupler found on others.
Page 138 Rocker Covers 5. Clean gaskets from rocker covers and cylinder heads. Do not drop anything into cylinder head openings. Removal Installation 1. Remove retaining screw. Remove oil separator and O-ring seal from rear rocker cover. 1. Install 4 new O-rings on connectors before pushing rocker covers together.
Page 139 Water Manifold Installation 1. Use a new gasket and install end cover on man- Removal ifold pieces. Torque screws with washers to 84 lb. 1. Follow instructions “a,” “b” and “c”: in. (10 N·m). a. Loosen hose clamp at rear of water manifold. 2.
Page 140 Cylinder Heads 3. Take note of shape and location of thick head bolt washers. Starting at one end of the engine, remove head bolts. Removal IMPORTANT: To avoid distorting cylinder heads, remove only when engine is cold. IMPORTANT: Retain fuel Injectors with their original heads to aid in diagnosis of problems.
Page 141 Disassembly Cleaning 1. Using valve spring compressor, carefully remove 1. Being careful not to damage aluminum heads, keepers, retainers, and springs. Place valves in clean carbon deposits and gasket material from numbered rack according to their position in the combustion chambers and sealing surfaces. engine.
Page 142 Repair 1. Heat head in oven to 300_ F (150_ C). Remove old seat. Do not damage counterbore. NOTE: Heads are identified by a code stamped on CAUTION flange as shown. To avoid distortion or melting of aluminum heads, DO NOT use a torch to replace valve seats. 2.
Page 143 INTAKE VALVE SEAT SPECIFICATIONS MEASURING VALVE GUIDE WEAR 1. Insert new valve into guide. 2. Using dial gauge as shown, measure amount of play valve stem has by moving stem back and forth against gauge. Measure as close to guide as possible.
Page 144 VALVE GUIDE REPLACEMENT refaced, a knife edge will be ground on part or all of the valve head, due to amount of metal that must be 1. Heat head in oven to 185_ F (85_ C). Using a suit- removed to completely reface. Knife edges lead to able drift, drive out old guide from underside of head.
Page 145 VALVE SPRING SPECIFICATIONS Assembly 1. Lubricate valve guides and valve stems with S.A.E. 30W Oil. 2. Install each valve in the port from which it was removed or to which it was fitted. a - Height Measurement: 1.70 [1-45/64] in. (43.20mm) NOTE: Valve stem seals are not used on intake or Free Standing exhaust valves.
Page 146 3. Set dial indicator to zero at point shown on engine CAUTION block. Head gasket thickness is very important on Diesel engines. If head gaskets are too thin, the pistons will hit the valves or heads, causing severe damage. All head gaskets on one engine must be the same thickness or exhaust manifold and water manifold will not fit correctly.
Page 147 HEAD GASKET IDENTIFICATION c. Lubricate the threads and underside of bolt heads on all 14mm cylinder head bolts with NOTE: All engines use the same cylinder head Molykote (obtain locally). gaskets in one of three thickness as previously determined and shown following. d.
Page 148 3. Using a screwdriver install two (2) Cylinder Head 4. Beginning with cylinder Number One, with pre- Guide Pins 91-801333501, into 12mm bolt holes chamber seal facing UP (as previously shown) in engine block at cylinder Number One location, install new cylinder head gasket and cylinder as shown.
Page 149 TORQUE SEQUENCE DIAGRAMS D3.0L/150 (5 Cylinder) 50529 D3.6L/180 and D4.2L/220 (6 Cylinder) 3A-26 - ENGINE - ALL MODELS 90-806934 1194 INDEX...
Page 150 7. Install all lubricated 14mm cylinder head bolts, in- 13. Tighten each 14mm bolt through ANOTHER 70 cluding the proper formed spacer-washers (ter- Degrees following the same sequence. minal bridges, three types) and cylinder head 14. In sequence tighten port and starboard 12mm cyl- spacers, for ends of first and last cylinder heads, inder head bolts to 22 lb.
Page 151 23. AFTER COMPLETE ENGINE ASSEMBLY AND 24. AFTER 100 HOURS, OR THE FIRST OPERAT- INSTALLATION, follow these additional cylinder ING SEASON, WHICHEVER OCCURS FIRST, head angular torque instructions: follow instructions “a” – “e”: a. Run engine at idle until water temperature a.
Page 152 Rocker Arm 2. Lubricate rocker arm bushings and support jour- nals with S.A.E. 30W Oil. Repair 1. Using a micrometer, measure outside diameter (O. D.) of rocker arm support journals. 70274 a - Rocker Arm Bushings 70274 b - Rocker Arm Support Journals 3.
Page 153 Be sure to keep hands, feet, and clothing away from moving engine parts. 1. Follow instructions “a” or “b”: a. On D3.0L/150 and D3.6L/180 Models: If so equipped, remove power steering belt and drive pulley with flange. Remove 3 opposing balancer (vibration damper) retaining bolts from crankshaft pulley.
Page 154 7. Remove rocker arm covers. 1. Follow instructions “a” or “b”: 8. Loosen locknuts on both rocker arm adjusting a. On D3.0L/150 and D3.6L/180 Models: If so screws of number 1 cylinder. equipped, remove power steering belt. Re- 9. Insert a .012 in. (0.30mm) feeler gauge between move three allen-head bolts from vibration valve stem and rocker arm.
Page 155 8. Follow instructions “a” or “b”: Installation a. On D3.0L/150 and D3.6L/180 Models: 1. Check to see that crankshaft O-ring seal between Remove lower cover to gain access to a timing gear and pulleys is still in place and in timing gear cover screw.
Page 156 5. Follow instructions “a” or “b”: NOTE: Oil pump bearing arrangement in this picture may differ slightly from your model. Picture is a. On D3.0L/150 and D3.6L/180 Models: representative of all models. Install vibration damper, and if so equipped, install power steering pulley flange using damper bolts.
Page 157 Inspection 2. If oil pump has ball bearing, lubricate with 2-4-C Marine Lubricant. (Some models have a sealed 1. Using a feeler gauge, measure clearance bearing arrangement; no lubrication is possible.) between rotor and housing. Maximum clearance is .006 in. (0.152mm). 70282 a - Rotor b - Housing...
Page 158 Oil Pressure Relief Valve 4. If spring(s) is/are broken or valve is badly worn or sticking in bore, replace complete valve assembly. Removal NOTE: Bore may need to be heated before removal from engine block. 1. Remove oil pan. Clean gaskets from engine block and pan flanges.
Page 159 Oil Pick-Up Tube Assembly Installation 1. Renew O-rings on oil pick-up tube and elbow. Removal 1. Remove oil pan. Clean old gasket from engine block and oil pan flange. 2. Remove screws retaining baffle, oil pick-up (suction) tube, and oil pick-up (suction) tube elbow to block.
Page 160 Oil Thermostat 4. Lift oil filter head and fitting from engine. Remove fitting with sealing washer. Removal 1. Using a suitable container to catch oil, remove oil filter. 2. Disconnect TAN/WHT wire from oil temperature audio warning switch. 71082 a - Oil Filter Head b - O-Ring Seal c - Hex Head Fitting d - Sealing Washer...
Page 161 Testing WARNING WARNING The following test involves the use of electricity and intense heat. Failure to follow appropriate Always wear safety glasses when using com- procedures or warnings can cause burns or pressed air. shock which can result in severe personal injury or death.
Page 162 5. Pin must begin to extend (push up) as shown, 3. If not already accomplished, remove old O-ring when water temperature reaches 195° F (90° C). from groove on oil filter head (on underside of At 212° F (100° C) pin should be extended filter head when mounted).
Page 163 6. Coat sealing washer of new oil filter with 8. Pre-lubricate engine and turbocharger. To do this, Quicksilver 4-Cycle Marine Engine Oil or move the “STOP” switch toggle lever DOWN and 15W-40CD engine oil and install. Hand tighten, hold in this position while you turn the key switch do not use a filter wrench.
Page 164 IMPORTANT: Engine must be turned upside down Inspection so lifters will drop away from camshaft. 1. In addition to measuring lobe lift, in the course of 4. Remove camshaft flange mounting screws and general overhaul, inspect the following (refer to lockwashers.
Page 165 Installation 2. Lubricate camshaft lobes with a mixture of 20% S.A.E. 30W engine oil and 80% Needle Bearing BEFORE installation of camshaft, consider the Lubricant 92-42649A1. following: 3. Lubricate camshaft bearings with S.A.E. 30W D Inspect camshaft bearings. Replace as needed. engine oil.
Page 166 Camshaft Bearings Installation 1. Clean camshaft bearing bores in cylinder block Inspection with solvent and blow out with compressed air. Be sure drilled oil passages are clean. With camshaft removed: IMPORTANT: Oil feed holes in bearings MUST 1. Visually inspect bearings. Renew if worn or align with drilled oil passages in engine block or damaged.
Page 167 Valve Lifters (Tappets) Cleaning and Inspection Thoroughly clean all parts in cleaning solvent and CAUTION inspect them carefully. If any parts are damaged or worn, camshaft and lifters should be replaced. If outer If the camshaft is replaced, the valve lifters lifter body wall is scuffed or worn, inspect cylinder (tappets) must also be replaced or serious block lifter bore.
Page 168 Valve Push Rods 2. Turn crankshaft to gain access to connecting rod bolts. Removal 3. One cylinder at a time, remove rod caps and inspect bearings. (Refer to “Bearing Failure” IMPORTANT: Place rocker arms, rocker arm pictures at front of section.) components and push rods in a rack or holder for reinstallation in the same locations.
Page 169 Removal 2. Use Piston Ring Expander 91-24697 to remove 2 top compression rings. 1. Remove cylinder heads. 3. Using same tool, remove lower (oil control) ring 2. Remove oil pan and oil pick-up tube. and spring. 3. Use a reamer to remove the ridge or any deposits from upper end of cylinder bore.
Page 170 Cleaning and Inspection PISTONS: CAUTION CONNECTING ROD and PIN: For D3.0L/150 and D3.6L/180 engines, pistons are 1. Wash connecting rods in cleaning solvent and dry provided in two standard sizes and correspond to with compressed air. the tolerance classes: Class A or Class B. For 2.
Page 171 2. Inspect piston for cracked ring lands, skirts or pin 6. Proper clearance of piston ring in its piston ring bosses, wavy worn ring lands, scuffed or damaged groove is very important to provide proper ring skirts or eroded areas at top of piston. Replace action and reduce wear.
Page 172 Assembly 1. Coat inside of connecting rod bushing, piston pin bore, and piston pin with S.A.E. 30W engine oil. 2. Assemble piston to connecting rod with the combustion chamber recess aligned with rod numbers. a - Tapered Compression Ring b - “Scraper” Compression Ring c - Oil Control Ring d - Ring Clearance 70296...
Page 173 CAUTION numbers on connecting rod must face injector and camshaft side of the engine. For D3.0L/150 and D3.6L/180 engines, pistons are 4. Turn crankshaft to position crank pin away from provided in two standard sizes and correspond to cylinder so connecting rod will not damage it the tolerance classes: Class A or Class B.
Page 174 7. Align connecting rod with crank pin and tap on 2. CAREFULLY pry out old seal using a suitable piston top until rod bearing contacts crank pin. Do device. not scratch or nick crank pin. 8. Install rod cap, lubricate bolt threads with Quick- silver Needle Bearing Assembly Lubricant 92-825265A1, and torque to 61 lb.
Page 175 1. Remove flywheel housing assembly (rear portion). 2. Follow instructions “a” or “b”: a. On MIE Models: Remove drive plate from adaptor plate (D3.0L/150 and D3.6L/180 only) and/or flywheel. b. On MCM Models: Remove engine coupler from flywheel. NOTE: Refer to “Flywheel Related Components”.
Page 176 3. Remove the six flywheel retaining bolts and the 5. Mark position of rear main bearing carrier in flywheel. relation to block. 70361 a - Flywheel Retaining Bolts (6) b - Flywheel 70302 4. Remove 9 bolts and 6 nuts (with respective a - Rear Main Bearing Carrier washers) retaining flywheel housing.
Page 177 7. To assist in removing bearing carrier, temporarily Crankshaft reinstall flywheel housing using only the nuts on 1. Remove main bearing oil feed locating screws the carrier. By tapping evenly, around the housing (which hold main bearing carriers in block). Note as shown, the carrier and thrust plate will be position of oil sender in engine block.
Page 178 4. Using a hoist and suitable sling attached to Front Main Bearing crankshaft, lift crank out of block. NOTE: If bearings are being inspected prior to re- placement, refer to “INSPECTION,” in this section, Main Bearing Carriers and Bearings: before removing front main bearing. If all bearings are being replaced proceed.
Page 179 TIMING GEAR (CRANKSHAFT): MAIN BEARINGS (MEASUREMENT) NOTE: Replace gear only if worn or damaged. 1. Inspect bearings. Refer to “Bearing Failures.” 1. Install Crankshaft Gear Puller 91-801333503 2. To check clearance of center main bearings: onto crankshaft and gear, as shown. a.
Page 180 3. Measure rear main bearing clearance in the same Installation manner as the center main bearings (no FRONT MAIN BEARING assembly of carrier is required). 1. Align oil passage with hole of new bearing. 4. To check clearance of front main bearing: a.
Page 181 MAIN BEARING CARRIERS AND BEARINGS 4. Be certain all carriers are positioned so that piston oil jet faces FRONT of engIne, as 1. Install new bearing shells into matching carrier shown, when installing on journal. Install halves. matching carrier halves (marked earlier) on 2.
Page 182 5. Follow instructions “a” or “b”: FULLY (to avoid damaging carrier threads) into bearing carriers. Where previously noted, install a. On D3.0L/150 and D3.6L/180 Models: Turn locating screw for oil sending unit (after removing all bearing carriers so “arrows” face up as...
Page 183 REAR MAIN BEARING CARRIER 3. Install standard size thrust washers into front (crankshaft) side of carrier. (Use Quicksilver 1. Refer to Oil Seal (Rear Main) – “Installation” and Needle Bearing Lubricant to help keep washers install new seal in carrier. Lubricate lips of seal positioned.) with clean motor oil.
Page 184 5. Lubricate crankshaft journal and bearing with 7. Install thrust plate with O-ring towards crankshaft. clean engine oil. Install rear main bearing carrier Tighten retaining screw securely. into engine block, align marks previously made. 8. Install new O-ring into groove of flywheel housing Always be certain lubrication holes on block and as shown.
Page 185 CRANKSHAFT END-PLAY (AXIAL) CLEARANCE 2. Remove plate from Cylinder Liner Puller 91-801333502. 1. Attach Dial Indicator 91-58222A1 to engine block to check installed crankshaft end-play (axial) clearance. Reading can be taken off of counter weight as shown. Move crankshaft fore and aft in block to obtain reading.
Page 186 Class B. Failure to use only the Class (A or B) liner designated for your engine, with matching Class A or B piston, will result in severe engine damage. 1. On D3.0L/150 and D3.6L/180 Engines: As shown in the following, inspect underside of liner for tolerance class identification reference mark (a small radial line).
Page 187 CYLINDER LINER (BLOCK) BORES Installation 1. Thoroughly clean the engine block with suitable Cylinder liners on all engines are required to protrude solvent and blow dry with compressed air. Inspect (or rise above the surface of the block) .00004 - .0023 for cracks or flaws.
Page 188 b. Using a precision depth gauge measure and d. Remove liner and install shim selected and record the amount of recess (depth below refit liner. block surface) of each liner as shown. e. Measure protrusion. Adjust using alternate shim if required. 70476 a - Liner Recess (Depth of Liner in Block) b - Cylinder Liner...
Page 189 - Red O-Ring using liner gauge bar 91-184812A1 (S.A.E.) or 91-801333509 (Metric) and appropriate dial D3.0L/150 and D3.6L/180 Engine Liners with One gauge as shown. If not as specified, adjust Upper and Three Lower O-Rings protrusion as previously outlined until each liner is protruded .0004 - .0023 in.
Page 190 7. Lubricate LOWER centering collars in engine 9. Install liners in block, being careful not to damage block (those areas where lower liner O-rings seal O-rings or distort shim. Hold liners securely in against the bore) with Needle Bearing Lubricant position with head bolts, cylindrical spacers 92-42649A1 or clean engine oil as shown.
Page 191 Battery and Battery Cable Requirements for MerCruiser ..D-Tronic Diesels SB 91-1 New Battery and Battery Cable Requirements for MerCruiser ..Products INDEX...
Page 192 Table Of Contents Page Starter Identification Number Location ... 4A-1 Starter Motor Specifications ....4A-1 Sealants –...
Page 193 Starter Identification Number Replacement Parts Location 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, 70809 explosion and/or severe personal injury.
Page 194 Battery Cables CAUTION 1. Select proper size positive (+) and negative (–) To prevent damage to the electrical system be battery cables, using chart. Battery should be sure to adhere to the following: located as close to engine as possible. a.
Page 195 Storage Starting Circuit Description a. Remove battery and clean exterior. This is a general description of the positive (+12V) current flow thru the starting circuit. b. Check fluid level and fill if low. c. Cover terminals and bolts with light coat of The starter used on the diesel engine is a high torque grease.
Page 196 Starting System Components Note 4 BLK/YEL 1 Note 3 7 YEL/RED 6 RED/PUR Note 1 Note 1 Note 2 Note 2 (–) Note 3 73846 1 - Ignition (Start) Switch Note 1 : Wire routing on MIE (Inboard) engine and/or 2 - 20 Ampere Fuse instrument harness.
Page 197 Starter – Exploded View 50185 a - Solenoid j - Armature b - Drive Gear Housing k - Brush c - Shift Lever l - Brush Holder Frame d - Snap Ring m - End Frame e - Retainer n - Shims f - Drive Gear o - C-Clip Assembly...
Page 198 Periodic Inspection Solenoid Switch Starter motor and solenoid are completely enclosed REMOVAL in the drive housing to prevent entrance of moisture 1. Remove starter motor as previously outlined. and dirt. However, periodic inspection is required. 2. Remove nut as shown, from field coil wire. a.
Page 199 4. Slide solenoid plunger off shift fork. 2. Install solenoid to starter with 3 screws. Tighten securely. 70812 a - Solenoid Retaining Screws (3) 3. Place field coil wire on terminal and secure with 70814 70813 hex nut. a - Solenoid Plunger b - Shift Fork INSTALLATION 1.
Page 200 Starter Motor Disassembly 4. Remove end frame. 1. Remove solenoid as outlined previously. 2. Remove cap screws and cap. 70816 a - End Frame 70814 a - Cap Screws 5. Remove field frame and brush holder from drive b - Cap gear housing.
Page 201 6. Remove hex nut, wave washer and bolt. Then, lift 8. Pry snap ring out of groove and remove. Slide armature, drive gear assembly and shift lever retainer, drive assembly and bushing plate from from drive gear housing. armature. 70821 a - Snap Ring 70819 b - Retainer...
Page 202 Armature Tests LOOSE ELECTRICAL CONNECTIONS open soldered connection armature TEST for SHORTS commutator leads is found during inspection, resolder with rosin flux. Check armature for shorts by placing on growler and holding hack saw blade over armature core while IMPORTANT: NEVER USE ACID FLUX ON rotating armature.
Page 203 TEST FOR GROUND Starter Motor Reassembly IMPORTANT: Be sure that positive brushes and 1. Brush Replacement. leads do not contact field frame assembly during a. Make 4 brush fixtures out of stiff wire (wire test, or false reading will result. coat hanger) as shown.
Page 204 c. Install new brush leads to holes located in 2. Assemble components on armature as follows: brush holder frame, and fasten to field coil a. Lubricate drive end of shaft with SAE 10W with screws and hex nuts provided with new Oil.
Page 205 c. Install a universal puller plate on drive gear 4. Lubricate bushing in drive gear housing with one assembly. Place in arbor press as shown. drop of SAE 10W oil. DO NOT over-lubricate. Install armature shaft into drive gear housing, Compress snap-ring into groove using a pair engaging shift lever into drive gear assembly as of pliers while lightly pressing down on end of...
Page 206 6. Install studs into drive gear housing. 8. Remove the 4 brush (holding) fixtures. 9. Lubricate end frame bushing with one drop of SAE 10W Oil. DO NOT over-lubricate. Install end frame on armature as shown. Tighten hex nuts securely. 70817 a - Studs 7.
Page 207 12. Install rubber seal and cap. Tighten screws Starter Motor Installation securely. 1. Install starter motor to bell-housing with lock washers and hex nuts. Tighten 50 lb. ft. (68 N⋅m). 2. Connect wires to solenoid as shown. Tighten securely. 3. Coat terminals with Quicksilver Liquid Neoprene. 4.
Page 208 ELECTRICAL SYSTEMS 73198 GLOW PLUG SYSTEM Index...
Page 209 ....... . . 4B-1 D3.0L/150 Engines ....
Page 210 Identification Specifications General 5 CYLINDER IN-LINE DIESEL ENGINES NOTE: Glow Plug System will work only when engine temperature is below 122 F (50 C). DESCRIPTION SPECIFICATION Glow Plug Diameter M12 x 1.25 and Thread Nominal Voltage 11 Volts Current Draw after 30 7.5 –...
Page 211 6 CYLINDER IN-LINE DIESEL ENGINES Glow Plugs DESCRIPTION SPECIFICATION Glow Plug Diameter Testing M12 x 1.25 and Thread WARNING Nominal Voltage 11 Volts Current Draw after 30 Always disconnect battery cables from battery before 7.5 – 9.5 Amps Seconds of Operation working around electrical system components to pre- 7 Seconds at 12 volts vent injury to yourself or damage to the electrical sys-...
Page 212 Removal Installation 1. Clean seat area and install glow plug. Torque to specifications. WARNING 2. Install electrical connections or connectors on Always disconnect battery cables from battery before glow plug terminals. (See note.) working around electrical system components to pre- vent injury to yourself or damage to the electrical sys- NOTE: Be certain contact area of connecting bridge tem.
Page 213 Water Temperature Switch Removal 1. Refer to SECTION 6B and drain coolant from Testing closed cooling system into a suitable container. 1. Before testing observe the following to obtain 2. Unplug the wiring harness connector. proper results: 3. Remove the sender and sealing washer. a.
Page 214 Pre-Glow Relay and Power Closed cooling system is cold, below approximately 122 F. (50 C). Relay System Circuit breakers on electrical box are not open (tripped). Refer to “Glow Plug Circuit” information for diagrams and test procedures. Fuse at instrument panel is not defective (blown).
Page 215 - Circuit Breaker (60 Amp) i - Circuit Breaker (60 Amp) j - Power Relay k - Slave Relay l - Power Relay Connector m- Pre-Glow Relay Connector D3.0L/150, D3.6L/180 and D4.2L/220 Engines Index 4B-6 - GLOW PLUG SYSTEM 90-806934 1194...
Page 216 Testing NOTE: Location of Test Points are given on the pre- vious page. STEP 1 Using an ohmmeter (R x1 Scale), check for con- tinuity between : Test Point 1 and Ground Point 2 to Ground No Continuity: No Continuity: BLACK Ground Wire is open Wire is open.
Page 217 ELECTRICAL SYSTEMS 72078 CHARGING SYSTEM Index...
Page 218 Table of Contents Page Page Identification ....... . 4C-1 Prestolite 65 Amp Mando 65 Amp Alternator Replacement Parts Warning .
Page 219 Mando 65 Amp Alternator Replacement Parts Warning WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufac- tured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explo- sion. Use of replacement electrical, ignition or fuel sys-...
Page 220 Torque Specifications A 3-phase stator is mounted directly over the rotor pole pieces and between two end frames. It consists of three windings wound 120 degrees electrically out- TORQUE DESCRIPTION DESCRIPTION of-phase on the inside of a laminated core. The wind- Lb.
Page 221 Precautions System Components The following precautions MUST BE observed when The alternator system consists of the alternator, bat- working on the alternator system. Failure to observe tery, the ignition switch and the wiring which connects these precautions may result in serious damage to these components.
Page 222 Alternator Circuits - Typical STARTER AUXILIARY BATTERY MAIN BATTERY 74146 Index 4C-4 - CHARGING SYSTEM 90-806934 1194...
Page 223 Battery isolators allow the addition of an auxiliary (se- CAUTION cond) battery to the MerCruiser electrical system. Remove all battery cables from battery (before The auxiliary battery is primarily used as a power source for various accessories installed on the boat.
Page 224 Drive Belt Tension Troubleshooting Tests Adjustment (Alternator on Engine) Use the following tests in conjunction with the “Trou- bleshooting” in Section 1. Before proceeding with the Alternator tests, however, perform the following checks to elimi- nate possible problem areas. Also observe “Precau- 1.
Page 225 2. Wiggle engine wiring harness while observing 5. If reading is between 6.0 and 7.0 volts, rotor field voltmeter. Meter should indicate approximate circuit probably is open. Remove regulator and in- battery voltage and should not vary. If no reading spect for worn brushes or dirty slip rings.
Page 226 3. Voltmeter should indicate battery voltage. If bat- 6. If reading is low, stop engine and connect a jump- tery voltage is not present, check sensing circuit er wire between alternator output terminal and (RED/PURPLE lead) for loose or dirty connection regulator terminal.
Page 227 3. If reading is high, check for a loose or dirty regula- 5. If a voltmeter reading of 14.5 volts or above is now tor ground lead connection. If connection is good obtained, voltage regulator is faulty and must be (and sensing circuit checked out good in “Circuit- replaced.
Page 228 Exploded View 72276 1 - Screw (3) 15- Rectifier Assembly 2 - Nut (9) 16- Flat Washer 3 - Flat Washer (4) 17- Screw 4 - Sensing Wire (RED/PURPLE) 18- Stator 5 - Excitation Wire (PURPLE) 19- Rotor and Slip Rings 6 - Cover 20- Retaining Plate 7 - Tie Strap...
Page 229 Disassembly 4. Remove two brush/regulator attaching screws and remove brush/regulator assembly. IMPORTANT: The following instructions are for complete disassembly and overhaul of the alter- nator. In many cases, however, complete disas- sembly of alternator is not required and, in those cases, it is necessary only to perform the opera- tions required to repair or replace the faulty part.
Page 230 7. Separate rear end frame and stator assembly 9. Turn end frame over (stator upward) and remove from front end frame and rotor assembly using one Phillips head screw which secures rectifiers two thin blade screwdrivers (positioned 180 de- to end frame. grees apart from one another) at the locations shown.
Page 231 IMPORTANT: With alternator disassembled to 13. Remove the three Phillips head screws and lock- this point, stator, rectifier, diodes, and rotor may washers which secure the front bearing retaining be tested, as explained under “Component Test- plate. ing,” following. IMPORTANT: DO NOT clamp vise on rotor pole pieces when removing pulley nut (in next step), as pole pieces may be distorted.
Page 232 Cleaning and Inspection Component Testing 1. Clean all parts with a clean, soft cloth. DO NOT ROTOR use solvent, or electrical components may be damaged. 1. Test rotor field circuit for opens, shorts or high re- sistance (Test 1), using an ohmmeter (set on R x1 2.
Page 233 d. If reading is low, a short exists in the field cir- a. Connect one lead of ohmmeter to one of the cuit. Inspect slip rings to be sure that they are stator leads and the other lead to stator frame. not bent and touching outer slip ring.
Page 234 RECTIFIER AND DIODE ASSEMBLY CAUTION NOTE: Failure of any component in tests following DO NOT use a test instrument with more than a 12 will require replacement of entire rectifier assembly. volt source (in the following test), as rectifier may be damaged.
Page 235 6. Connect one lead of an ohmmeter (set on R x1) Reassembly to the common side of the diode and the other 1. Install new front bearing into front end frame bear- lead to the other side, of one of the three diodes. ing bore using an arbor press.
Page 236 5. Assemble stator to rectifier by soldering the three 8. Position rear end frame and stator assembly over leads to the three rectifier terminals. front end frame and rotor assembly and align scribe marks on each (scribed during disassem- bly). Hand-press end frames together, then install four screws.
Page 237 10. Install brush/regulator assembly in rear end 12. Install cover with one Phillips head screw and two frame cavity and secure with two mounting nuts. Install two leads with nuts. screws, as shown. Tighten screws securely. Re- move drill bit to release brushes against slip rings. 72963 a - Phillips Head Screw b - Nuts (4)
Page 238 Installation 6. Connect negative battery cable to battery. IMPORTANT: If the mounting bracket has been re- moved, refer to the diagram at the bottom of this page. Be certain that the mounting spacer and proper length brace spacer are in position for the appropriate engines as indicated.
Page 239 WARNING Pulley Nut 35-50 (48-68) Electrical, ignition and fuel system components on your MerCruiser are designed and manufac- Front Bearing Screws 25-35 tured to comply with U.S. Coast Guard Rules and (2.8-3.9) Regulations to minimize risks of fire and explo- sion.
Page 240 When current is supplied to the rotor field winding, 4. NEVER disconnect regulator lead from alternator and the rotor is turned, the movement of the magnetic regulator terminal when the alternator is being fields created induces an alternating current into the driven by the engine.
Page 241 Alternator Circuits -Typical STARTER AUXILIARY BATTERY MAIN BATTERY 74147 Index 90-806934 1194 CHARGING SYSTEM - 4C-23...
Page 242 Battery isolators allow the addition of an auxiliary (se- CAUTION cond) battery to the MerCruiser electrical system. Remove all battery cables from battery (before The auxiliary battery is primarily used as a power source for various accessories installed on the boat.
Page 243 Drive Belt Tension Troubleshooting Tests Adjustment (Alternator on Engine) Use the following tests in conjunction with the “Trou- bleshooting” in Section 1. Before proceeding with the Alternator tests, however, perform the following checks to elimi- nate possible problem areas. Also observe “Precau- 1.
Page 244 2. If voltage output does not fall within specifica- OPEN DIODE-TRIO TEST tions, alternator should be tested for probable 1. With ignition on and engine not running, check for cause and disassembled for repair. battery voltage at alternator output terminal (Test 1) and 1.5 to 3.0 volts at regulator terminal (Test 73081 a - Output Wire - ORANGE...
Page 245 CURRENT OUTPUT TEST 7. If reading is now within specifications, diodes are faulty. Disassemble alternator and replace recti- Perform this test to check if alternator is capable of fier as explained under “Alternator Repair,” producing rated current output, using a 0-50 amp DC following, to determine if fault is in regulator or ammeter.
Page 246 OPEN REGULATOR TEST IMPORTANT: This test requires removal of regu- lator. CAUTION To prevent electrical system damage and/or sparks, disconnect battery cables at battery. 1. Remove insulator cap from regulator terminal. 73086 2. With ignition switch in the “RUN” position and en- a - Field Terminal (Green Wire) gine not running, check for battery voltage at al- b - Regulator Terminal...
Page 247 Exploded View PURPLE BLACK GREEN BROWN 73106 1 - Regulator and Leads 18- Nut 2 - Screws (4) 19- Washer 3 - Insulator Cap 20- Insulating Washer 4 - Nuts (6) 21- Insulator 5 - Washers (3) 22- Negative Rectifier 6 - Condenser 23- Positive Rectifier/Diode-Trio 7 - Insulating Washer...
Page 248 Disassembly 3. Disconnect regulator leads from terminals on rear end frame. Remove four regulator attaching screws, then pull regulator away from rear end 1. Using an oversized V-belt to protect the pulley, frame and disconnect field lead. clamp alternator in vise as shown. Remove pulley nut and lockwasher.
Page 249 Cleaning and Inspection CAUTION 1. Clean all parts with a clean, soft cloth. Do not use Do not insert screwdriver blades deeper than 1/16 solvent, or electrical components may be dam- in. (1.5 mm) to avoid damaging stator windings. aged. 2.
Page 250 Front Bearing Slip Rings/Rear Bearing Removal Removal 1. Remove snap ring. 1. Unsolder wires and carefully unwind them from slip ring terminals. 2. Use an arbor press to remove bearing from hous- ing. IMPORTANT: Do not damage rotor wires when re- moving slip rings or bearing.
Page 251 Installation IMPORTANT: Press on the center of slip rings only. Do not bend terminals or pinch wires. 1. Press new rear bearing all the way onto rotor shaft (until inner race contacts shoulder) with an arbor 3. Using an arbor press, install slip rings. Press on press and a bearing driver that contacts inner center of slip rings until they contact shoulder of bearing race only, as shown.
Page 252 Component Testing c. If reading is high or infinite (no meter move- ment), high resistance or an open exists in the field circuit. Check for poor connections be- tween field winding leads and slip ring termi- Rotor nals. If cause for open or high resistance can- not be found, connect ohmmeter directly to 1.
Page 253 Stator 3. A short in the stator is difficult to detect without special equipment, because of the low windings resistance. If all other electrical components test IMPORTANT: Stator leads MUST BE discon- out good, and alternator fails to produce rated nected from rectifiers and diode-trio for this test.
Page 254 2. Using an ohmmeter (set on R x1 scale), check for 4. Replace assembly if any of the rectifiers is continuity between rectifier terminal and heat shorted or open. sink. Reverse ohmmeter leads and recheck. Con- tinuity should be observed in one direction (polar- ity) only.
Page 255 Condenser 3. Position rear end frame and stator assembly with insulators over front end frame and rotor assem- 1. Using Magneto Analyzer (P/N 91-76032) and ac- bly. Align scribe marks on each (scribed during companying instructions, perform the following disassembly). Hand press end frames together, condenser tests: then install four screws.
Page 256 5. Attach field lead to brush assembly. Install regula- 7. Install spacer, woodruff key, fan, pulley, lock- tor and felt gasket to rear end frame. Install four washer and nut. screws and tighten securely. Reconnect regulator terminal leads to appropriate stud on rear end frame.
Page 257 8 - Brace Bolt, Washer and Nut 9 - Brace Spacer - Two Lengths : - .873 in. (22.5 mm) Long on D3.0L/150 and D3.6L/180 Engines - .440 in. (11 mm) Long on D4.2L/220 Engines 10- Tensioning Screw, Lockwasher and Flat Washers...
Page 258 ELECTRICAL SYSTEMS 73288 INSTRUMENTATION Index...
Page 259 Table of Contents Page Page Wiring Colors for MerCruiser Diesels ... . 4D-1 Stop Switch .......
Page 260 Wiring Colors for MerCruiser Diesels Where Used Color Code Color Code Primary Usage Secondary Usage Black All Grounds Black/Yellow Engine Stop Blue Instrument Lighting Blue/Black Glow Plug Wait Switch Blue/Tan Oil / Water Alarms Blue/White Glow Plugs Glow Plug Wait Lamp...
Page 261 Identification - Gauges If all instruments appear suspect, check the main harness or electrical connector to ensure good contact. Before testing individual instruments, check the following: All wires in circuit are connected. Plug in connectors are fully engaged. Battery is fully charged. All connections are tight and corrosion free.
Page 262 Gauge Special Information Lighting Options QSI SERIES These gauges are equipped with optional illumination lighting. Light bulb socket can be removed and con- tacts can be aligned to be used with ignition switch lighting circuit +12 V or separate instrumentation lighting circuit LT.
Page 263 3. Turn ignition switch to RUN. Gauge being tested Volt Meter Gauge must be at position A. TESTING 1. Remove cables from battery and fully charge bat- tery. Remove wires from back of gauge. 2. Connect negative (–) jumper lead from battery to gauge terminal G (GND).
Page 264 Tachometer Switch Setting Engine Pulses Switch Model Per Revolution Position D3.0L/150, D3.6L/180 and D4.2L/220 NOTE: Refer to “Tachometer Special Information” as discussed earlier, if using an alternator driven tachometer. 2. If properly set and still inaccurate, connect a die- sel timing tool or suitable service tachometer to engine and compare readings.
Page 265 Senders NOTE: Sender shown removed for visual clarity only. Oil Pressure REMOVAL 1. Remove LIGHT BLUE wire from sender. 2. Using a suitable wrench to hold the adaptor fitting (to prevent loosening of main bearing locating screw), unscrew the sender. 72936 70686 74281...
Page 266 Water Temperature - Primary Station TESTING IMPORTANT: Use the following test to determine REMOVAL the accuracy of the Water Temperature Sender gauge circuit. If gauge indicates NO temperature 1. Drain coolant from closed cooling system into a when running engine refer to the “TROUBLE- suitable container, as outlined in SECTION 6B.
Page 267 d. Turn heat source “OFF”. Allow sand and com- WARNING ponents to cool. The following test involves the use of intense NOTE: While sand cools you may recheck ohmmeter heat. Failure to follow appropriate procedures or readings. warnings can cause burns which can result in se- vere personal injury.
Page 268 Water Temperature - Second Station WARNING The following test involves the use of intense REMOVAL heat. Failure to follow appropriate procedures or warnings can cause burns which can result in se- 1. Drain coolant from closed cooling system into a vere personal injury.
Page 269 1. Follow these instructions: INSTALLATION 1. Apply Loctite Pipe Sealant with Teflon to threads a. With an ohmmeter connected as shown fol- of sender and install. Tighten securely. lowing and using a suitable container, ther- 2. Refill closed cooling system with approved cool- mometer and heat source, suspend sender ant as outlined in SECTION 6B.
Page 270 TESTING Stop Switch The “STOP” switch is a single-pole, momentarily 1. Before testing key switch, check all fuses and/or “closed” switch, provided for stopping the engine. circuit breakers in electrical circuit which could This is done by electrically shutting off the fuel deliv- prevent operation of starter.
Page 271 INSTALLATION Audio Warning Test and Panel Light Switch 1. Using screws provided, install wires to appropri- ate switch terminals as shown in chart. The switch provided for the audio warning test and 2. Make sure that all connections are secure. Seal panel (dash) lights is a three-position toggle switch.
Page 272 3. Install switch in Engine System Monitor panel. TESTING Tighten hex nut securely to prevent switch from 1. Toggle switch lever to its spring loaded START turning in its mounting hole. DO NOT overtigh- position. ten. É É 2. Continuity should exist between terminal num- É...
Page 273 Stop Switch Terminal Number and/or Connection The “STOP” switch, provided for stopping the engine Location at this second station, is a single-pole, momentarily PURPLE (PPL) “closed” switch. BLACK/YEL- REMOVAL (BLK/YEL) 1. Remove hex nut retaining switch to Engine Sys- tem Monitor Panel. Note 1.: Wire is sta-strapped to instrument harness near connector collar.
Page 274 Buzzer NOTE: Sender shown removed for visual clarity only. WARNING The following test involves the use of electricity. Failure to follow appropriate procedures can cause burns or shock which can result in severe personal injury or death. TESTING 1. If buzzer does not sound: a.
Page 275 Water Temperature Switch/Sender TESTING 1. With engine COLD, remove wiring block from When engine is COLD audio warning circuit is nor- switch/sender terminals. Note position on switch/ mally open. sender for terminal referred to as “W” REMOVAL 1. Drain coolant from closed cooling system into a suitable container, as outlined in SECTION 6B.
Page 276 c. Using suitable container, thermometer and WARNING heat source, suspend switch with tip in sand. The following test involves the use of intense d. Heat sand and observe temperature on heat. Failure to follow appropriate procedures or thermometer. warnings can cause burns which can result in se- vere personal injury.
Page 277 Transmission Fluid Temperature TESTING Switch 1. With transmission COLD, connect one lead of an ohmmeter to one terminal of transmission switch. When transmission is COLD or at a temperature less Connect the other lead of ohmmeter to other ter- than as shown (See “Test Temperature Chart”follow- minal.
Page 278 c. As temperature rises, switch will close and WARNING ohmmeter will indicate continuity. Refer to The following test involves the use of intense chart below for specifications. heat. Failure to follow appropriate procedures or warnings can cause burns which can result in se- vere personal injury.
Page 279 ELECTRICAL SYSTEMS WIRING DIAGRAMS Note:Refer to the following Service Bulletin regarding this section. SB 96-2 Water In Fuel Module (WIF) Warning Light INDEX...
Page 280 ..4E -3 MIE - D3.0L/150, D3.6L/180 and D4.2L/220 - Mando Alternator ......
Page 281 Wiring Colors for MerCruiser Diesel Where Used Color Code Primary Usage Secondary Usage Black All Grounds Black/Yellow Engine Stop Blue Instrument Lighting Blue/Black Glow Plug Wait Switch Blue/Tan Glow Plug Wait Lamp Blue/White Glow Plugs Brown Alternator Charge Lamp Reference Electrode-MerCathode...
Page 282 See NOTE 4. BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE MCM - D3.0L/150, D3.6L/180 PPL = PURPLE RED = RED and D4.2L/220 - Mando Alternator TAN = TAN WHT = WHITE YEL = YELLOW...
Page 283 MCM - D3.0L/150, D3.6L/180 BLK = BLACK See NOTE 4. BLU = BLUE and D4.2L/220 - Prestolite Alternator BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PPL = PURPLE RED = RED TAN = TAN WHT = WHITE...
Page 284 MIE - D3.0L/150, D3.6L/180 and See NOTE 3. BLK = BLACK D4.2L/220 - Mando Alternator BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PPL = PURPLE RED = RED TAN = TAN WHT = WHITE...
Page 285 MIE - D3.0L/150, D3.6L/180 and D4.2L/220 - Prestolite Alternator See NOTE 3. Electrical Box See NOTE 1. See NOTE 1. See NOTE 2. BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE...
Page 286 Quicksilver Instrumentation MCM - D3.0L/150, D3.6L/150 and D4.2L/220 1 - Oil Pressure 8 - Light Switch and Audio Test 2 - Tachometer 9 - Stop Switch 3 - Trim Gauge 10- Keyswitch 4 - Coolant Temperature 11- 20-Amp Fuse and Holder...
Page 287 MIE - D3.0L/150, D3.6L/180 and D4.2L/220 1 - Oil Pressure 8 - Light Switch and Audio Test 2 - Tachometer 9 - Stop Switch 3 - Wires Not Used 10- Keyswitch (See NOTE 1.) 11- 20-Amp Fuse and Holder 4 - Coolant Temperature...
Page 288 MCM - Second Station Instrumentation 1 - Oil Pressure (See NOTE 4.) 8 - Stop Switch 2 - Tachometer 9 - Start Switch 3 - Trim Gauge (See NOTE 4.) 10- 20-Amp Fuse and Holder 4 - Wire(s) Not Used 11- Audio Warning Buzzers (See NOTE 1.) 12- Spare Wires - (Not Used)
Page 289 MIE - Second Station Instrumentation 1 - Oil Pressure 5 - Engine System Monitor (See NOTE 4.) 6 - Light Switch and Audio Test 2 - Tachometer 7 - Stop Switch 3 - Wire(s) Not Used 8 - Start Switch (See NOTE 1.) 9 - 20-Amp Fuse and Holder 4 - Voltmeter...
Page 290 Wiring Harness Connections MCM - Wiring Harness Connections (Standard) Secondary Station Primary Station See Note. See Note. a - “Y” Harness b - “T” Harness c - Extension Harnesses (Primary to Secondary Instrumentation) d - Extension Harnesses (To Engine) Note: Connect these wires together with a screw and nut.
Page 291 MCM - Wiring Harness Connections (Optional) Secondary Station Primary Station a - “Y” Harness b - “T” Harness c - Extension Harnesses (Primary to Secondary Instrumentation) d - Extension Harnesses (To Engine) Note: Connect these wires together with a screw and nut.
Page 292 MIE - Wiring Harness Connections Secondary Station Primary Station See Note. See Note. a - “Y” Harness b - “T” Harness c - Extension Harnesses (Primary to Secondary Instrumentation) d - Extension Harnesses (To Engine) Note: Connect these wires together with a screw and nut.
Page 293 FUEL SYSTEMS 74475 FUEL DELIVERY PUMP and FUEL FILTER Note:Refer to the following Service Bulletins regarding this section. SB 95-16 Low Sulfur Diesel Fuels SB 95-9 Diesel Fuel Filters and Fuel Additives INDEX...
Page 294 Table Of Contents Page Identification ....... . 5A-1 Fuel Pump Specifications .
Page 295 Identification General Fuel Pump and Filter Description The fuel delivery pump is of the diaphragm type and is mounted on the side of the engine block. It is operated by the camshaft, and on all models is equipped with an external lever to assist in priming the injection pump and purging air from fuel system.
Page 296 Fuel Lines WARNING WARNING Dispose of fuel soaked rags, paper, etc. in an appropriate air tight, fire retardant container. Boating industry standards (NMMA, ABYC, etc.) Fuel soaked items may spontaneously ignite and federal standards and Coast Guard regulations result in a fire hazard which could cause serious must be adhered to when installing fuel delivery bodily injury or death.
Page 297 Exploded View - Fuel Pump and Fuel Filter 74475 1 - Bracket 20- Fuel Inlet Fitting 2 - Screw 21- Fuel Pump Cover (Removed for visual clarity 3 - Lockwasher of Items 19 - 20.) 4 - Nut 22- Diaphragm 5 - Fuel Filter 23- Diaphragm Spring 6 - O-Ring...
Page 298 Fuel Pump Removal 3. Remove banjo bolt at fuel filter. Discard sealing washers. WARNING ALWAYS disconnect battery cables from battery BEFORE working on fuel system to prevent fire or explosion. 1. Disconnect battery cables from battery. 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.
Page 299 Fuel Pump Repair 3. Remove cover exposing pump diaphragms and one-way valves. DISASSEMBLY 1. Remove banjo bolts and fuel lines. Discard sealing washers. 70194 a - Pump Diaphragms b - One-Way Valves 4. Remove one-way valve carrier from cover. 70162 a - Banjo Bolts, with Sealing Washers b - Fuel Lines 2.
Page 300 5. Remove from cover and inspect O-ring and 7. Remove spacer from between diaphragms. spacer for damage. 70165 70166 a - Spacer b - Diaphragms 8. Clean parts in solvent. Dry with compressed air. ASSEMBLY 1. Install spacer between diaphragms. 70168 a - Cover b - O-ring...
Page 301 2. Place spring on rod and install in pump housing. 4. Install one-way valve carrier in cover, as shown. Push in and turn diaphragm 1/4 turn to hold in place. 70164 a - One-Way Valve Carrier b - Cover 5. Install cover on pump housing in position as noted or marked during disassembly.
Page 302 6. Align holes in cover, diaphragm, spacer, and 2. Using a new O-ring, install fuel pump on engine housing. Install screws and tighten securely. block. Tighten mounting nuts securely. 3. Using 2 new sealing washers on banjo bolt, attach fuel line to filter mount. Tighten all banjo bolts securely.
Page 303 Water Separating Fuel Filter IMPORTANT: Element cannot be cleaned and reused. It must be replaced. Replacement 3. Turn water bleed valve counterclockwise and re- move from old filter. Install it on new filter turning clockwise. Tighten securely. (Note position of O- WARNING ring seal.) ALWAYS disconnect battery cables from battery...
Page 304 5. Follow instructions “a” - “c”: Water Bleed Valve Operation 1. Using a suitable container to catch water, push NOTE: Place a suitable container under fuel filter to water bleed valve in (UP), as shown. catch excess fuel. a. Loosen bleed screw (on header flange). b.
Page 305 Purging Air from Fuel System 2. Loosen bleed screw on injection pump. - Priming Injection Pump 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 73321 Make sure that no fuel leaks exist, before closing...
Page 306 FUEL SYSTEM 50397 INJECTION PUMP Index...
Page 307 Table Of Contents Page Identification ....... . 5B-1 Pump Code and I.D. Number Location .
Page 308 Pump Code and I.D. Number Location Engine - MCM Pump Code and Identification and MIE Number Code: VE 5/11F 1900 L179 Bosch Part Number: D3.0L/150 0460 415007 (Quicksilver Part Number: 801763706) Code: VE 6/11F 1900 L178 Bosch Part Number: D3.6L/180...
Page 309 This reduces exhaust smoke at low engine RPM. Note 1 : For use on D3.0L/150 and D3.6L/180 engines. The timing-advance device advances timing up to 24 Note 2 : For use on D4.2L/220 engines.
Page 310 Precautions WARNING FIRE HAZARD: Fuel leakage from any part of the WARNING fuel system can be a fire hazard which can cause serious bodily injury or death. Careful periodic Electrical system components on this engine are inspection of entire fuel system is mandatory, not external ignition protected.
Page 311 Fuel Requirements Diesel Fuel in Cold Weather WARNING WARNING Under should gasoline be Under should gasoline be mixed with diesel fuel for any reason. This mixture mixed with diesel fuel for any reason. This mixture of gasoline and diesel fuel is highly flammable and of gasoline and diesel fuel is highly flammable and produces a significant risk to the user.
Page 312 Exploded Views - Injection Pump and Related Components 73911 1 - Injection Pump 25- Plain Washer, Lockwasher and Nut (3 of each) 2 - Lever 26- Boost Pressure Tube 3 - Gasket 27- Banjo Bolt and Sealing Washers 4 - Traction Rod 28- Clamp 5 - Ball Pin 29- Screw, Lockwasher and Nut (1 of each)
Page 313 70485 1. Follow instructions “a” or “b”: a. On MCM (Stern Drive) D3.0L/150 and a - Crankshaft Tool 91-814827 D3.6L/180 Engines: 3. Remove oil fill cap from valve cover. (1) Remove power steering belt.
Page 314 4. Look through oil fill cap hole into the valve cover, NOTE: Seawater pump shown removed for visual while using a suitable inspection light. Proceed clarity only. as follows: a. Slowly rotate engine CLOCKWISE (looking from water pump end toward flywheel end) while watching the first rocker arm and valve (front-most is Number 1 cylinder’s intake valve).
Page 315 IMPORTANT: Banjo bolts, used to hold fuel inlet CAUTION and return lines to injection pump, are calibrated Do not bend fuel injector lines. Bending may and MUST remain with pump in their original location. cause metal to flake off inside lines, causing injectors or injection pump to malfunction.
Page 316 11. Remove injection pump gear nut and lockwasher. instructions “a” or “b”: 12. With central bolt of tool backed out, install a. On D3.0L/150 and D3.6L/180 Engines: appropriate injection pump gear puller tool (refer Remove 4 hex nuts and cover.
Page 317 15. Paying special attention to key, carefully remove pump and place aside. Back central bolt out of puller tool. NOTE: If key does fall into engine, on D3.0L/150 and D3.6L/180 engines remove lower cover of timing cover as shown following. Pour oil into pump opening to attempt to flush key out lower opening.
Page 318 4. Remove any pump backlash by rotating shaft 7. Using a heavy grease to hold in place, install in- COUNTERCLOCKWISE (facing unit) until resis- jection pump key in pump shaft slot. Be certain tance is felt. key is positioned properly. Keyway will be at 11 o’clock position as shown.
Page 319 Installation During Engine Reassembly 4. Using a suitable gauge wire, make a pointer and being careful not to damage mating surfaces attach to a suitable location on the block. Align 1. Install flywheel holder tool and install crankshaft wire pointer to zero degrees (“0”) as shown. pulley.
Page 320 6. Using a heavy grease to hold in place install 8. Remove gear. injection pump key in pump slot. Temporarily 9. Install injection pump using new gasket. Install install gear on injection pump shaft (Do not hex nuts with flat washers and lockwashers secure gear at this time).
Page 321 10. Be certain injection pump key is properly Fuel Injection Pump Timing positioned. Apply heavy grease to hold key in slot Checking Timing of pump. IMPORTANT: Due to a change in production On completely assembled and/or installed engines, Engines with VM Serial Number 56945 and up and for the purpose of “checking”...
Page 322 2. Be certain cold start lever is positioned as shown. 4. Watch dial indicator needle and SLOWLY rotate the crankshaft COUNTERCLOCKWISE (viewed from water pump end looking toward flywheel) toward 0 until dial indicator STOPS moving. 5. Set the dial indicator to Zero [ 0 in. 0.00 mm) ], as shown.
Page 323 7. AT THIS MOMENT, the dial indicator should read CAUTION 0.34 in. (0.88 mm). If not, loosen the injection Keep injectors and injection pump fittings clean. pump mounting nuts and rotate the pump in ei- ther direction to obtain the correct specifications. Do not allow dirt to enter fittings when installing lines.
Page 324 12. Install throttle cable(s) following these instruc- tions: IMPORTANT: When installing throttle cable(s), be sure 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. a.
Page 325 (screw is sealed). 15. Follow instructions “a” or “b”: Check to ensure that remote control and a. On D3.0l/150 and D3.6L/180 Engines: cable are providing proper output. (1) Install the flange, if so equipped, to which the power steering pulley mounts.
Page 326 c. Move fuel pump lever UP and DOWN CAUTION repeatedly, until an air free stream of fuel When installing battery, be sure to connect flows from bleed screw. POSITIVE (+) battery cable to POSITIVE (+) battery terminal FIRST, and NEGATIVE (–) battery cable to NEGATIVE (–) battery terminal LAST.
Page 327 IMPORTANT: After lengthy repairs or lay-up b. Tighten each fuel line fitting when fuel (several months) it is necessary to pre-lubricate appears at fitting until all fittings are the turbo-charger. To do this, move the “STOP” tightened. switch toggle lever DOWN and hold in this NOTE: Engine may start during this operation.
Page 328 FUEL SYSTEMS 50442 FUEL INJECTORS Index...
Page 329 Table Of Contents Page Index ........5C-0 Identification .
Page 330 Identification Description The Bosch throttling pintle-type injector nozzle can The D3.0L/150, D3.6L/180 and D4.2L/220 diesel be identified as shown. engines use a throttle pintle type injector nozzle. This type of nozzle is used with a turbulence chamber (prechamber), which is located in the cylinder head.
Page 331 Due to fuel injector design changes the 530 D-TA, 636 D-TA, D183 and D219 Model fuel injector MUST NOT be used in a D254, D3.0L/150, D3.6L/180 or a CAUTION D4.2L/220 engine under any conditions. However, the new-style D254 or a D4.2L/220 fuel injector DO NOT operate engine without cooling water CAN BE used in all engines as a replacement.
Page 332 Fuel Injectors 5. Remove clamping shoe after removing hex nut and lockwasher. Remove spacer. Retain all components. Removal CAUTION Keep injectors and injection pump fittings clean. Do not allow dirt to enter fittings when removing or installing lines. Dirt will cause injectors or injection pump to malfunction.
Page 333 Testing CAUTION Mercury Marine recommends the EFEP60H nozzle Do not bend fuel injector lines. Bending may tester from the Robert Bosch Corporation. Follow cause metal to flake off inside lines, causing instructions with injector tester for checking nozzle injectors or injection pump to malfunction. opening pressure and spray pattern.
Page 334 2. Install injector with fuel return hole facing rocker 4. Install clamping shoe around flat sides of fuel arms. injector as shown. Install lockwasher and hex nut. Tighten to 20 lb. ft. (27 N·m 70144 a - Clamping Shoe b - Lockwasher 70145 c - Hex Nut a - Fuel Return Hole...
Page 335 6. Using 2 new sealing washers for each banjo bolt, 2. Wear safety glasses when bleeding air from in- install fuel-return line. Tighten banjo bolts jector lines. Slightly loosen each injector fuel line securely. fitting. Use starter motor to crank engine, while observing injectors.
Page 336 Injector Test (Engine Misfiring) WARNING Safety glasses should be worn while working on fuel injection system. The fuel injection pump will generate pressures in excess of 2000 P.S.I. (13790 kPa). Use caution when removing injectors, injector lines, or bleeding air from injection system.
Page 337 COOLING SYSTEM SEAWATER SYSTEM Note:Refer to the following Service Bulletin regarding this section. SB 97-2 MerCruiser MCM/MIE Inline Diesel Heat Exchanger End Cover Torque INDEX...
Page 338 6A-2 Exploded Views and Diagrams ....6A-3 D3.0L/150 and D3.6L/180 Seawater Pump ..6A-3 D4.2L/220 Seawater Pump ....
Page 339 Fleetguard Restore CC2610 Specifications Seawater Pump Seawater Pickup Connection D3.0L/150 AND D3.6L/180 ENGINES Seawater Pickup and Hose: Water pickup must be large enough to permit sufficient water flow to engine Seawater Pump Delivery Rates seawater pickup pump for adequate engine cooling.
Page 340 (Minimum) hose fatigue. 30 U.S. Gal. per min. D3.0L/150 and D3.6L/180 (114 L per min.) To prevent restricting water flow seacock used must have an internal cross-sectional area (equal to or 40 U.S. Gal. per min.
Page 341 Exploded Views and Diagrams D3.0L/150 and D3.6L/180 Seawater Pump 73947 1 - Pump Housing Lubricant/Sealant Application Points 2 - Screw 3 - Housing Pin Shell Alvania No. 2 (See NOTE.) 4 - Ball Bearing 5 - Spacer Loctite Master Gasket...
Page 342 D4.2L/220 Seawater Pump 73946 1 - Pump Housing Lubricant/Sealant Application Points 2 - Screw 3 - Cover Loctite Master Gasket 4 - Gasket 5 - Impeller Torque Specifications 6 - Cam (Apply Sealer Indicated to Back-Side) 7 - Thrust Washer (Align Notch with Housing Pin) Tighten Securely 8 - Retaining Ring 9 - Spacer...
Page 343 Water Flow Diagram 71954 SEAWATER COOLING CIRCUIT CLOSED COOLING CIRCUIT (RAW WATER) (FRESH WATER/COOLANT) 1 - Seawater Inlet - a - Circulating Pump - Closed Coolant Thru Drive - MCM (Stern Drive) b - Engine Block - Upper Section of Liners Thru Hull - MIE (Inboard) c - Water Manifold 2 - Seacock (If So Equipped)
Page 344 Seawater Pump Repair Removal DISASSEMBLY 1. Clamp pump in vise as shown. Remove 6 cover CAUTION screws. If boat is in water while working on seawater pump, when removing seawater inlet hose, 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 enter boat.
Page 345 4. Follow instructions “a” or “b”: (2) Remove spacer (washer) from shaft. a. On D3.0L/150 and D3.6L/180 pumps: Re- move internal snap ring from pump body. 70695 a - Spacer (Washer) 70628 5. Using a soft hammer, tap shaft and bearing assembly out of pump housing.
Page 346 (if visible), or suitably mark each bearing, to ensure installation in original position if reused. a. On D3.0L/150 and D3.6L/180 pumps: Us- ing an arbor press and suitable hardware, re- move one bearing at a time from pump shaft to avoid damaging spacer.
Page 347 9. Follow instructions “a” or “b”: NOTE: Although different in appearance the front seal will press out like a normal seal. a. On D3.0L/150 and D3.6L/180 pumps: Us- ing a suitable tool, remove two seals, one O- ring, and one flat washer from pump housing.
Page 348 12. Replace all parts that do not conform to standards. ASSEMBLY 1. Follow instructions “a” or “b”: a. On D3.0L/150 and D3.6L/180 pumps: IMPORTANT: In the following steps press on inner races of bearings ONLY. Do not crush spacer. (1) Using an arbor press, install first bearing against shoulder of pump shaft beginning from splined end.
Page 349 3. Install rear seal following instructions “a” or “b”: 4. Install thrust washer into pump housing. Align washer notch with pin in housing. a. On D3.0L/150 and D3.6L/180 pumps: Install O-ring into bearing side of housing. Using a suitable tool, install seal (lip facing out –...
Page 350 6. Follow instructions “a” or “b”: 8. Follow instructions “a” or “b”: a. On D3.0L/150 and D3.6L/180 pumps: a. On D3.0L/150 and D3.6L/180 pumps: Install internal snap ring into pump body IMPORTANT: It is recommended that Shell groove. Alvania No. 2 grease be used when packing seals and bearings in the following steps.
Page 351 9. Hold pump housing in soft-jaw vise. Install 11. Install gasket and cover. Tighten screws evenly impeller into housing by turning clockwise while in a diagonal pattern. Tighten securely. simultaneously pushing inward as shown. 70624 Typical Pump and Impeller Shown 10.
Page 352 Installation 3. Install pump on timing gear cover studs. Tighten hex nuts with washers securely. 1. Install O-ring on pump housing shoulder. 70423 70628 a - O-ring Typical Pump Shown 2. Turn pump shaft in direction shown to align drive slot with camshaft.
Page 353 4. Install inlet and outlet hoses. Tighten hose Sea Strainer clamps securely. Exploded View 70636 a - Inlet Hose b - Outlet Hose c - Hose Clamps Typical Pump and Hoses Shown 5. Open seacock, if so equipped, or remove plug from seawater inlet hose and reconnect hose.
Page 354 Removal b. Models Without Seacock: (1) If not equipped with seacock, disconnect seawater inlet hose, from seawater CAUTION strainer inlet. If boat is in water while working on seawater (2) Quickly plug seawater inlet hose. strainer, 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...
Page 355 Installation 3. Check drain plug and lens cover bolts. Tighten securely. Do not overtighten cover bolts or cover IMPORTANT: Mount seawater strainer in a may warp and leak water into boat. 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.
Page 356 CAUTION Seawater cooling system MUST BE completely drained for storage, or trapped water may cause freeze and/or corrosion damage to engine and/or components. CAUTION If boat is in the water, seacock (if so equipped) MUST BE left closed until engine is to be 73522 restarted, to prevent water from flowing back into a - Transmission Fluid Cooler...
Page 357 Remove cooler with J-clamp. IMPORTANT: MerCruiser does not recommend the immersion of oil/power steering/ transmis- sion fluid coolers in cleaning solutions. If back- flushing of the problem cooler does not satisfac- torily clear the passages replacement of the cooler is recommended.
Page 358 ENGINE OIL COOLER c. Disconnect seawater and closed cooling hoses as required to allow removal of heat exchanger, as shown following. 1. Refer to SECTION 1B – Maintenance, “Cold Weather Extended Storage, Draining d. Disconnect turbocharger coolant vent hose Instructions” (and precautions in this section) on upper-port side of expansion tank.
Page 359 TRANSMISSION FLUID COOLER Installation 1. Refer to Section 1B – Maintenance, “Cold POWER STEERING Weather Extended Storage, Draining Instructions” (and precautions in this section) 1. Follow instructions “a” – “c”: and drain the seawater system, if not already a. Install cooler with J-clamp into connecting accomplished.
Page 360 ENGINE OIL COOLER e. Install the two large screw clamps retaining the heat exchanger to the port and starboard 1. Follow instructions “a” – “e”: brackets. NOTE: Prior to installing the heat exchanger, put a Reconnect turbocharger coolant vent hose . small amount of petroleum jelly on the brackets and Tighten hose clamp securely.
Page 361 TRANSMISSION FLUID COOLER 2. Open seacock if so equipped, or unplug seawater inlet hose and reconnect. Tighten hose 1. Follow instructions “a” – “c” : clamps securely. a. If cooler is being replaced, coat threads of 3. Start engine. Run briefly (to fill cooler) and check 90°...
Page 362 COOLING SYSTEMS 73793 CLOSED COOLING SYSTEM Index...
Page 363 6B-20 Engine Water Circulating Pumps ... . . 6B-5 D3.0L/150 and D3.6L/180 Engines ..6B-5 D4.2L/220 Engines ..... .
Page 364 Engine coolant pro- U.S. Gal. (L) vides protection down to –33 F. ( –38 C). Model (Approximate) IMPORTANT: Quicksilver Premixed Marine En- D3.0L/150 11.5 (11) gine Coolant contains special low silicate ethy- D3.6L/180 12.5 (12) lene glycol, special additives, and purified water.
Page 365 Lubricants / Sealants Special Tools DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER Quicksilver 2-4-C Marine Lubri- Pink Litmus Paper Obtain Locally 92-825407A2 cant Thermostat Tester Obtain Locally Special Lubricant 101 92-13872A1 Heat Exchanger Cleaning Brush Obtain Locally Quicksilver Perfect Seal 92-34227--1 Loctite Master Gasket 92-12564--1 Gasket Sealer...
Page 366 Exploded Views and Diagrams Water Flow Diagram 71954 SEAWATER COOLING CIRCUIT CLOSED COOLING CIRCUIT (RAW WATER) (FRESH WATER/COOLANT) 1 - Seawater Inlet - a - Circulating Pump - Closed Coolant Thru Drive - MCM (Stern Drive) b - Engine Block - Upper Section of Liners Thru Hull - MIE (Inboard) c - Water Manifold 2 - Seacock (If So Equipped)
Page 367 Heat Exchanger / Coolant Tank, Water Manifold, and Related Components 73793 73793 1 - Heat Exchanger / Coolant Tank 21- Hose and Clamps (To Exhaust Manifold End Cover) 2 - Circulating Pump-to-Heat Exchanger Hose 22- Hose (To Heat Exchanger Fitting) 3 - Thermostat Housing-to-Heat Exchanger Hose 4 - Pressure Cap - Hose Connection to Turbocharger Banjo Fitting...
Page 368 Engine Water Circulating Pumps Sea Strainer D3.0L/150 AND D3.6L/180 ENGINES 73944 1 - Water Circulating Pump (With Pulley) 2 - Gasket 3 - Stud(s) 4 - Hex Nuts with Washers Torque Specifications 72673 22 lb. ft. (30 N·m) 1 - Screws and Washers 2 - Cover D4.2L/220 ENGINES...
Page 369 Description Maintaining Coolant Level The closed cooling system is composed of two sepa- Before starting engine each day, check to ensure that rate sub-systems; the seawater system (Discussed coolant is visible in coolant recovery bottle. in SECTION 6A.) and the closed cooling system. The If coolant is not visible, check coolant (fresh water) heat from the closed cooling system is absorbed by section of cooling system (including coolant recovery...
Page 370 Changing (Replacing) WARNING Coolant DO NOT remove coolant pressure cap when the engine is hot - coolant may discharge violently, causing severe burns. Coolant Requirement CAUTION CAUTION If the coolant should get extremely low and the engine very hot, let the engine cool for approxi- Alcohol or methanol base antifreeze or plain wa- mately 15 minutes before adding coolant;...
Page 371 Draining Closed Cooling properly mixed to protect engine to lowest tem- perature to which it will be exposed. Section IMPORTANT: Do not use Propylene Glycol Anti- freeze in the closed cooled section of the engine. WARNING 1. Allow engine to cool down. Remove pressure cap Allow engine to cool before removing pressure from coolant tank.
Page 372 Cleaning Closed Cooling c. Attach tap water hose to adaptor. d. Follow instructions “(1)” or “(2)”: Section (1) On engines with Auxiliary Hot Water Cooling System Cleaners Heaters: Proceed to “e”. (2) On engines without Auxiliary Hot Wa- 1. Drain coolant from engine as previously outlined. ter Heaters: Open cylinder block drain NOTE: Properly dispose of old coolant.
Page 373 Filling Closed Cooling Coolant in closed cooling (fresh water) section should be changed every two years and should be checked Section for alkalinity at least once between change intervals. To check coolant for alkalinity, proceed as follows: 1. Remove pressure cap from heat exchanger and 1.
Page 374 If needle in gauge vibrates, c. At Higher Speeds (3200 - 3800 on compression or combustion is leaking into D3.0L/150 and D3.6L/180 Engines or 3200 closed cooled section from a leak in the com- - 3600 on D4.2L/220 Engines): Normal op- bustion chamber.
Page 375 Testing Pressure Cap Pressure cap is designed to maintain a pressure of approximately its rated capacity (refer to “Specifica- tions”) in closed cooled section once engine has at- tained operating temperature. Cap should be cleaned, inspected and pressure-tested at regular tune-up intervals or whenever cap is suspected of maintaining improper pressure as follows: WARNING...
Page 376 Thermostats IMPORTANT: Do not allow old gasket material or debris inside, which might foul cooling system passages. Removal Testing 1. Refer to “Draining Closed Cooling Section” as previously outlined, and drain coolant. 1. Clean thermostats in soap and water to remove 2.
Page 377 IMPORTANT: Refer to specifications and note Heat Exchanger that the two thermostats have different opening temperatures. Testing 5. Continue to heat water until a temperature 25 F (14 C) above opening temperature is obtained. Thermostat valve must be completely OPEN at FOR INTERNAL LEAK: this temperature.
Page 378 Removal Remove combination heat exchanger and engine oil cooler. 1. Refer to SECTION 1B – Maintenance, “Cold Weather Extended Storage, Draining Instructions” (and precautions in this section) and drain the seawater system, if not already accomplished. 2. Refer to previously outlined “Draining Closed Cooling Section”...
Page 379 Installation d. Install the two large screw clamps retaining the heat exchanger to the port and starboard 1. Follow instructions “a” – “e”: brackets. NOTE: Prior to installing the heat exchanger, put a e. Reconnect turbocharger coolant vent hose . small amount of petroleum jelly on the brackets and Tighten hose clamp securely.
Page 380 - Water Circulating Pump Fasteners holes, corrosion or other damage. Inspect pump D4.2L/220 Pump Shown (D3.0L/150 impeller for cracks and erosion. Replace com- D3.6L/180 Similar) plete pump, if any damage exists. 3. Check impeller shaft and bearings for excessive 4.
Page 381 Water Manifold Installation 1. Be certain mating surfaces of water manifold sections are clean and free of all old gasket Removal material. Machined surfaces must not have nicks or gouges, or coolant leaks may result. 1. Refer to instructions in Changing (Replace) Cool- ant - “Draining Coolant”...
Page 382 3. Install new gaskets on cylinder head/manifold Corrosion Protection studs. There are anodes as part of the heat exchanger and 4. Slide water manifold assembly on studs. Install intercooler system, which serve as sacrificial anodes. lockwashers and nuts. Torque nuts evenly in a Replace when eroded more than 50%;...
Page 383 Auxiliary Hot Water Heater Connections 72037 71898 72038 a - Plug, Rear Cover (Allen-Head or Hex-Head) f - Sealing Washer, (Existing) b - Sealing Washer, (Existing) g - Hose Coupler Fitting (From Kit) c - Hose Coupler Fitting (From Kit) h - Sealing Washer (From Kit) d - Sealing Washer (From Kit) i - Supply Hose...
Page 384 INTAKE AND EXHAUST SYSTEM INTERCOOLER Index...
Page 385 ....... 7A-2 D3.0L/150 and D3.6L/180 Intercooler ..
Page 386 (sometimes referred to as an “aftercooler” Water Temperature or “air cooler”) to cool the intake air before it enters Sender the cylinders. On D3.0L/150 and D3.6L/180 engines Turbocharger Pressure the intercooler housing has a separate intake duct Tighten Securely Fitting retained with screws on the outer side.
Page 387 Exploded Views D3.0L/150 and D3.6L/180 Intercooler a - Radiator Insert (Heat Exchanger Core) b - Intercooler Housing c - Intake Duct d - Front Cover e - Rear Cover f - O-ring (3 On Some Engines, 4 On Others Equipped With Plate)
Page 388 D4.2/220 Intercooler) 70903 70904 a - Radiator Insert (Heat Exchanger Core) b - Intercooler Housing c - Intake Duct d - Gasket (6) e - Front Cover f - Rear Cover g - O-ring (3 On Some Engines, 4 On Others Equipped With Plate) h - Plate (On Some Engines) i - Anode...
Page 389 70912 a - Intercooler b - Rear Cover c - Drain Plug With Sealing Washer D3.0L/150 and D3.6L/180 Engines 70913 a - Banjo Bolt With Sealing Washers b - Boost Pressure Tube D4.2L/220 Boost...
Page 390 5. Loosen hose clamps and disconnect seawater hoses from intercooler-to-heat exchanger and a. On D4.2L/220 Engines: Proceed to step 7 from seawater pump-to-intercooler. following. b. On D3.0L/150 and D3.6L/180 Engines: Re- move intake duct from side of intercooler housing. 70919 a - Intercooler Housing...
Page 391 1. Follow instructions “a” or “b”: a. On D3.0L/150 and D3.6L/180 Engines: (1) Remove front and rear covers. Note posi- 70920 tion of plate and O-rings.
Page 392 b. On D4.2L/220 Engines: (3) Remove front cover and O-ring. (1) Remove intake duct from rear of inter- cooler. 70907 a - Intercooler Housing b - Front Cover c - O-ring (4) Slide radiator insert out front of intercool- er housing. Note position of O-ring. 70931 a - Intercooler Housing b - Intake Duct...
Page 393 5. Clean and paint exterior surfaces as required to prevent corrosion. 70926 Assembly D3.0L/150 and D3.6L/180 Intercooler IMPORTANT: Do not roll or twist O-ring(s) when installing around radiator insert in the following. 1. Install O-ring on radiator insert against front flange.
Page 394 3. Place O-ring into groove of front cover. Fasten to 5. Following instructions “a” or “b”: housing using 4 allen-head screws and wave a. On intercoolers WITHOUT plate and washers. Torque to 30 lb. ft. (40 N·m). second O-ring: Proceed to step 6. b.
Page 395 7. Follow instructions “a” or “b”: 3. Install intercooler housing. Install hex nuts (10 on five cylinder, and 12 on six cylinder) with lock- a. On D3.0L/150 and D3.6L/180 Engines: washers and torque to 24 lb. ft. (32 N·m). Proceed to the following “Installation” instruc- tions.
Page 396 4. Follow instructions “a” or “b”: 5. Securely tighten hose clamp at turbocharger-to- intake duct hose as shown. a. On D4.2L/220 Engines: Proceed to step 5. b. On D3.0L/150 and D3.6L/180 Engines: (1) Apply Loctite 514 sealer to intake duct flange. a - Intake Duct...
Page 397 7. Install seawater hoses from seawater pump-to- CAUTION intercooler and from intercooler-to-heat ex- DO NOT operate an engine without water flowing changer. Securely tighten all hose clamps.. through seawater pickup pump, as pump impel- ler may be damaged and subsequent overheat- ing damage to engine, transmission or stern drive unit may result.
Page 398 INTAKE AND EXHAUST SYSTEM 28085 INTAKE / EXHAUST SYSTEM Index...
Page 399 ....... 7B-1 D3.0L/150 and D3.6L/180 Intake/Exhaust Manifold ........
Page 400 Additionally, on D4.2L/220 engines the exhaust Hose Clamps manifold includes a flange for mounting a turbo boost wastegate and valve assembly. Exploded View D3.0L/150 and D3.6L/180 Intake/Exhaust Manifold See NOTE. 1 - Exhaust Manifold 2 - Stud(s) 3 - Welch Plug...
Page 401 D4.2L/220 Intake/Exhaust Manifold See NOTE. 28085 1 - Exhaust Manifold, With Wastegate Flange 2 - Stud(s) 3 - Welch Plug 4 - Gasket(s) 5 - Drain Cock 6 - Screw 7 - Cover 8 - Water Temperature Sender With Sealing Washer NOTE: Later engines have the water temperature switch/sender mounted on the last cylinder head (closest to the flywheel).
Page 402 9 - Oval Exhaust Pipe (A Round Exhaust Pipe is used on Riser Equipped Engines to match Riser outlet.) 10- Screw and Lockwasher (4) 11- D4.2L/220 Exhaust Riser Assembly (D3.0L/150 and D3.6L/180 are similar.) 12- Round Exhaust Pipe for Exhaust Riser Equipped D4.2L/220 Engines (No Water Shutter Assembly)
Page 403 Torque Specifications 7 - Short Exhaust Hose (If So Equipped) Tighten all fasteners securely. 8 - Exhaust Pipe Oval-to-Round Adaptor (If So Equipped) 9 - D4.2L/220 Exhaust Riser Assembly (D3.0L/150 and D3.6L/180 are similar.) Typical Index 7B-4 – INTAKE/EXHAUST SYSTEM...
Page 404 Representative View of Complete Exhaust System – Inboard (Use diagrams for parts identification only.) 70902 a - Exhaust Elbow With Gasket and Clamp b - Hose c - Outlet With Water Shutter and Flapper d - Water Lift Muffler e - Oval-to-Round Adaptor (On Some Engines) Typical Index 90-806934 1194...
Page 405 Damage or More caused by water in the engine will not be covered by MerCruiser Warranty, unless this damage is the result of defective part(s). Determine if an exhaust riser kit or a water lift muffler...
Page 406 Determine if an exhaust riser kit or a water lift 3. System must not cause excessive back pres- muffler kit is required, by taking measurements (a) sure when measured at exhaust elbow outlets. and (b), with boat at rest in the water and maximum Back pressure MUST NOT exceed a 39-1/2 in.
Page 407 Exhaust Pipe - Stern Drive Installation IMPORTANT: Exhaust pipe and gimbal housing Removal assembly mating surfaces must be clean and IMPORTANT: Engine must be removed to gain free of nicks and scratches. O-ring must be access to exhaust pipe. Refer to Section 2A for properly seated in groove, or water and exhaust engine removal and installation.
Page 408 Exhaust Manifold 7. Remove nuts and lockwashers (6 cylinder has 24, and 5 cylinder has 20). Removal 1. Remove heat exchanger assembly as outlined in Section 6B. 2. Remove intercooler housing as outlined in Section 7A. 3. Remove wastegate and valve as outlined in Section 7C, if so equipped.
Page 409 Installation NOTE: Later engines have a hex head plug in place of the temperature switch/sender. 1. Be certain mating surfaces of cylinder heads are clean and free of all old gasket material. Machined surfaces must not have nicks or gouges, or water and exhaust leaks may result. 2.
Page 410 INTAKE/EXHAUST SYSTEM TURBOCHARGER Index...
Page 411 Table Of Contents Page Identification ........7C-1 Torque Specifications .
Page 412 Sealants 70076 a - Identification Number Location Loctite 514 92-75505-1 Gasket Sealer 92-72592-1 Turbocharger Specifications Model D3.0L/150 D3.6L/180 D4.2L/220 Manufacturer Kuhnle, Kopp and Kaush K26 2664 GA 10.71 K26 2664 GA 12.71 K26 2964 MNA 8.72 Part Number...
Page 413 On D3.0L/150 and D3.6L/180 Engines: Turbo reduced. pressure, or boost, is limited by engine RPM. On D4.2L/220 Engines: Turbo pressure is limited by a boost pressure control valve (commonly called a “wastegate”)
Page 414 Exploded Views Turbocharger And Related Components 73941 1 - Turbocharger Torque Specifications 2 - Gasket 18 lb. ft. (24 N·m) 3 - Clamp 4 - Gasket 5 - Exhaust Elbow, or Riser (Not Shown) 6 - Oil Drain Pipe 7 - Double Banjo Bolt with Sealing Washer 8 - Coolant Vent Hose (Connection shown as dashed line.) 9 - Hose Fittings, At Water Manifold 10- Hose Fitting for Hose to Heat Exchanger...
Page 415 Boost Pressure Control (Wastegate) Components Typical MCM (Stern Drive) D4.2L/220 Components Shown - [MIE (Inboard) Similar] 73940 1 - Wastegate Torque Specifications 2 - Wastegate-to-Exhaust Manifold Gasket 18 lb. ft. (24 N·m) 3 - Wastegate Exhaust Pipe, MCM Shown (MIE Similar) 4 - Gasket (2) 5 - Hex Nut and Lockwasher (4) 6 - Heat Shield Blanket (For Exhaust Pipe)
Page 416 IMPORTANT: Before suspecting the turbocharger D3.0L/150 D3.6L/180 Engines: for engine running problems, the fuel injection Maximum boost should be between 12.5 - 16 psi system and engine mechanicals (valves, cam- (82.7 - 110.3 kPa) at 3800 RPM. shaft, etc.) must be in good working order.
Page 417 Removal 4. Follow instructions “a” or “b”: a. On D3.0L/150 and D3.6L/180 Engines: Proceed to Step 5. WARNING b. On D4.2L/220 Engines: Always disconnect battery cables from battery (1) Loosen spring retaining heat-shield blan- before working around electrIcal system compo- ket around wastegate exhaust pipe.
Page 418 6. Loosen exhaust elbow, or riser, clamp. Remove 3. Remove oil feed pipe and banjo bolt from coolant elbow gasket and clamp. vent pipe at turbocharger as shown. Loosen air filter and turbocharger-to-intake duct hose clamps. 73632 73941 70989 70987 a - Turbocharger-to-Intake Duct Hose Clamp a - Clamp b - Oil Feed Pipe...
Page 419 “a” or “b”: screws as shown, and MerCathode controller bracket if so equipped (not shown in the follow- a. On D3.0L/150 and D3.6L/180 Engines: ing). Remove turbocharger unit. Remove intake duct from side of intercooler housing. (Refer to SECTION 7A - Intercooler, for instructions on removal.)
Page 420 NOTE: If the exhaust housing cannot easily be Cleaning removed by hand, tap on it carefully all around using IMPORTANT: Never use a caustic cleaning solu- a plastic hammer and carefully remove it in the tion, as it may attack aluminum. Also, never use following.
Page 421 RADIAL (SIDE) PLAY – MEASURING 2. Follow instructions “a” or “b”: 1. With turbocharger held in vise, attach dial indica- a. On D3.0L/150 and D3.6L/180 Engines: tor as shown in following. (1) Being certain surfaces are clean of old 2. Move turbine shaft in direction shown. Maximum gasket material or debris, install a new radial (side) play is .0165 in.
Page 422 b. On D4.2L/220 Engines: Installation (1) Being certain surfaces are clean, install a IMPORTANT: When installing turbocharger, it new O-ring in groove of drain/spacer may be necessary to turn intake and exhaust flange where it meets bearing housing of housings to line up with intake air duct and ex- turbocharger.
Page 423 4. Follow instructions “a” or “b”: 5. Follow instructions “a” - “d”: a. On D3.0L/150 and D3.6L/180 Engines: Re- a. Using new sealing washers on banjo bolt, move hex nuts from spacer (previously install coolant vent line to turbocharger ex- installed finger tight).
Page 424 6. If previously only the intake duct of intercooler was removed, follow instructions “a” or “b”: a. On D3.0L/150 and D3.6L/180 Engines: (1) Clean sealing flanges of intercooler housing and intake duct. Do not nick or gouge the surfaces.
Page 425 - Exhaust Riser f - Exhaust Hose 9. Follow instructions “a” or “b”: g - Exhaust Hose Clamp (4) a. On D3.0L/150 and D3.6L/180 Engines: h - Exhaust Pipe Typical Installations Shown (1) Using a new gasket, install exhaust el- bow, or exhaust riser if so equipped, as shown.
Page 426 b. On D4.2L/220 Engines: (3) Install seawater hose from fluid cooler-to- exhaust elbow, or riser if so equipped. (1) Install exhaust elbow, or riser, using new Tighten hose clamp securely. gaskets on exhaust elbow and wastegate exhaust pipe flange as shown, Align (4) Position exhaust hose as shown.
Page 427 10. Fill closed cooling system at this time according Exhaust Pipe to instructions in Section 6B - Closed Cooling System, “Filling Closed Cooling System.” INSPECTION 11. Connect battery cables to battery by FIRST 1. Loosen spring retaining heat shield blanket installing positive (+) battery cable end on around wastegate exhaust pipe as shown.
Page 428 REMOVAL 3. Using hex nuts or screws, with lockwashers, install wastegate exhaust pipe as shown. Tighten 1. Refer to “Removing Exhaust Elbow” as previous- fasteners securely. ly outlined and remove exhaust elbow. 2. Remove two remaining hex nuts, or screws, and lockwashers on wastegate exhaust pipe as shown.
Page 429 Valve 2. Remove allen-head screws and washers retain- ing valve to wastegate. Remove valve. REMOVAL 1. Follow instructions “a” - “c”: a. Remove banjo bolt with sealing washers (2) from pressure line on bottom of intercooler housing as shown. b. Remove banjo bolt with sealing washers (2) from pressure line on valve as shown.
Page 430 Wastegate INSTALLATION 1. Clean all traces of old gasket material from ex- REMOVAL haust manifold flange where shown. 1. Remove the following, as previously outlined: Exhaust elbow Wastegate exhaust pipe Wastegate valve 2. Remove the four fasteners with lockwashers re- taining wastegate to exhaust manifold as shown.
Page 431 3. Following instructions previously outlined, install: Wastegate valve Wastegate exhaust pipe Exhaust elbow or riser 4. Pre-lubricate turbocharger and engine. To do this, move the “STOP” switch toggle lever DOWN and hold in this position while you turn the key switch to “START” position. Doing this TOGETHER turns the engine without starting it.
Page 432 DRIVE SYSTEMS 25280 HURTH DOWN ANGLE TRANSMISSION Note:Refer to the following Service Bulletins regarding this section. SB 99-5 Proper Oil Fill Level On Velvet Drive Transmissions SB 98-15 Shift Cable Measurements For Transmissions SB 96-16 Hurth V-Drive Output Flange Torque SB 96-11 Hurth Transmissions SB 95-24 Hurth Marine Gear Distributors SB 95-23 Velvet Drvie Distributors...
Page 433 Table of Contents Page Page Identification ....... . 8A-1 Reassembly .
Page 434 Identification Tools/Lubricants/Sealants The transmission identification plate is located on the DESCRIPTION PART NUMBER top rear of the transmission. Tapered Roller Bearing 91-813950 Inner Race Puller Tapered Roller Bearing 91-813951 Outer Race Puller Pressure Plate Removal 91-813952 Tool Reversing Clutch Tapered Roller Bearing 91-813953 Inner Race Puller Plate Mandrel-Input Shaft Seal...
Page 435 Specifications General The Hurth transmission is a “full power reversing” Transmission Fluid Specification transmission, allowing a standard (LH rotation) en- gine to be used for both rotations. Propeller rotation is determined by shift cable attachment at the remote DESCRIPTION SPECIFICATION control.
Page 436 Shift Cable Installation and IMPORTANT: Check that shift lever is positioned ° approximately 10 aft of vertical when in the neu- Adjustment tral detent position and that the distance (“c”) between studs in the following is set at 7-1/8 in. These Hurth transmissions are full reversing trans- (318mm).
Page 437 3. Locate center of remote control and control shift IMPORTANT: Transmission is “fully” in gear cable play (backlash), as follows: when shift lever comes to a stop, in either direc- tion. a. Check that remote control is in neutral posi- tion.
Page 438 NOTE: To change cable approach direction on single or dual station installations, only the spacers/bush- ings have to be switched to the opposite stud (the studs are identical). 73587 73589 71972 71210 a - Cable End Guide b - Spacer (As Required) a - Cable End Guide c - Elastic Stop Nut and Washer b - Spacer (As Required)
Page 439 73591 73590 CABLE BARREL STUD CABLE END GUIDE STUD 50073 71211 a - Cable End Guide(s) b - Spacer c - Elastic Stop Nut and Washer a - Cable End Guides d - Bushing(s) b - Locknut and Washer (Tighten Until Bottomed, Then Back Off e - Cable Barrel(s) [Position(s) Only Indicated In Lower One Full Turn) Drawing]...
Page 440 Checking Transmission Draining Transmission Fluid Level 1. Clean the exterior of transmission before disas- sembly. IMPORTANT: Use only specified transmission 2. Remove oil filter from housing by turning (coun- fluid (see “Specifications”). terclockwise) and pulling at the same time. Check transmission fluid before starting engine each day, as follows: 1.
Page 441 Filling Transmission 3. Start engine and run for two minutes to fill system with fluid. IMPORTANT: Use only Automatic Transmission 4. Stop engine and check fluid level. Fluid should be Fluid (ATF) as recommended in “Specifications.” between min. and max. lines on dipstick. 1.
Page 442 Transmission Removal Transmission Installation 1. Disconnect wires from neutral safety switch and 1. Coat splines on input shaft with Quicksilver En- audio warning temperature switch. gine Coupler Spline Grease. 2. Disconnect fluid cooler hoses. Appropriately la- bel hose “Port” and “Starboard”. 50686 71044 a - Neutral Safety Switch...
Page 443 3. Reconnect fluid cooler hoses. Securely tighten OIL FILTER AND DIPSTICK hose fittings. 1. Remove oil filter from housing by turning T-handle counterclockwise and pulling at the same time. 4. Connect wires to neutral safety switch and to audio warning temperature switch. Coat connec- tions on neutral safety switch with Quicksilver Liquid Neoprene.
Page 444 3. Remove filter element from cover and inspect 5. Remove dipstick by turning counterclockwise and O-rings for wear. Replace if necessary. pulling at the same time. 50975 a - O-Rings 4. Push hose of suction pump through suction pipe and down to the bottom of the housing. Pump fluid from housing.
Page 445 BREATHER VALVE OUTPUT FLANGE 1. Remove breather valve. Clean with suitable 1. Remove bolt, washer and O-ring. cleaner, allow to dry and coat with oil. 71049 71048 a - Breather Valve MOUNTS 1. Remove mounts from transmission housing. In- spect mounts for damage and replace if neces- sary.
Page 446 2. Reinstall bolt and remove flange using appropri- CONTROL BLOCK ate puller. 1. Remove hex head bolts. 27661 a - Hex Head Bolts (6) 2. Remove control block and gasket from housing. 71051 27666 71052 a - Bolt b - Flange c - Puller 90-806934 1194 HURTH DOWN ANGLE TRANSMISSION - 8A-13...
Page 447 2. Remove input side of housing. Be sure to locate CAUTION and save locator pins. Be careful not to allow dirt to enter control block from front side. 3. Cover openings in control block with a protective cloth. 27665 71053 a - Locator Pins a - Openings 3.
Page 448 4. Remove intermediate shaft assembly. 6. Remove output shaft assembly. 71055 71058 5. Remove baffle plate as follows: a. Bend tabs up away from screws. BEARING, GEAR AND SEAL INSPECTION b. Remove screws, then remove baffle plate. 1. Inspect all tapered roller bearings, the piston rings on the input shaft and all gears for wear.
Page 449 SEALS b. Remove screws and hold-down plate. 1. Remove suction pipe seal as follows: c. Remove suction pipe by pulling downward out of seal. 71060 a - Screws b - Hold-Down Plate 27666 d. Remove seal from top side. a - Seal a.
Page 450 2. Remove input shaft seal using appropriate man- TAPERED ROLLER BEARING CUPS drel. IMPORTANT: Do not remove tapered roller bear- ing cups unless replacing tapered roller bear- ings. Bearing and cup must be replaced as a set. IMPORTANT: Do not mix up shims under cups on the input housing side.
Page 451 b. Pull bearing cup from housing using tool as TAPERED ROLLER BEARINGS shown. CAUTION Gears should never be removed from intermedi- ate shaft or output shaft, as this will affect proper gear alignment. 1. Remove tapered roller bearings from intermedi- ate shaft and output shaft by using a universal puller plate and pressing bearings off.
Page 452 REVERSING CLUTCH, GEARS AND TAPERED b. Tighten jaws onto bearing by turning on ROLLER BEARINGS knurled part of tool. Tighten assembly. 1. Remove tapered roller bearing from splined end of input shaft using special tool as follows: a. Place tool over tapered roller bearing. Ensure jaws of tool will be pulling on bottom edge of rollers and NOT on the cage.
Page 453 2. Remove butting ring from splined end of input 4. Remove needle bearings. shaft by installing special tool as shown and lightly tapping upward on tool. 27673 a - Special Tool b - Butting Ring 27680 3. Remove butting ring and gear assembly. 5.
Page 454 6. Remove tapered roller bearing, butting ring and 1. Position snap ring compression tool on clutch as- gear from piston end of shaft using special tool as sembly so that compression screws are centered shown. Press all components off at the same over slots in clutch housing.
Page 455 NOTE: For ease of reassembly, end disc and snap IMPORTANT: Thrust discs have a wave pattern. ring should not be removed from tool unless their con- These discs must be reinstalled in a specific pat- dition is questionable. tern when reassembled. Make note of notches in thrust disc tabs, and how they are arranged.
Page 456 3. Remove discs. Reassembly CLUTCH DISCS IMPORTANT: Thrust discs have a wave pattern. These discs must be reinstalled in a specific man- ner as explained following. 27680 50248 1. Arrange thrust discs and inner discs as shown. 4. Inspect thrust discs and inner discs for wear. Re- Ensure notches on thrust disc tabs are aligned as place if there is any questionable wear.
Page 457 2. Install discs in clutch housing. 4. If end disc and snap ring were removed from tool, reinstall as follows: a. Loosen all compression screws on tool. 27677 a - Compression Screws b. Place snap ring into groove in end disc and compress by hand so that compression dogs will hold in on snap ring.
Page 458 c. Tighten compression screws evenly to com- 5. Tap lightly around top of tool until end disc bot- pletely compress snap ring into end disc. toms. Loosen compression screws and remove tool. 27677 a - End Disc b - Compression Screws d.
Page 459 6. Double check that snap ring has been properly GEAR ASSEMBLY seated by prying up lightly on end disc. 1. Reinstall gear assembly. Twist gear assembly from side to side to allow splines to engage with inner discs. Ensure all inner discs are engaged with splines by observing through slots in clutch housing.
Page 460 TAPERED ROLLER BEARING 3. Reinstall piston rings on input shaft. Ensure ends of rings are coupled as shown. Then position WARNING rings so that ends are staggered so no two are aligned. Do not touch bearing once it has been heated. Se- vere burns could result.
Page 461 INTERMEDIATE SHAFT OUTPUT SHAFT WARNING WARNING Do not touch bearing once it has been heated. Se- Do not touch bearing once it has been heated. Se- vere burns could result. Use special protective vere burns could result. Use special protective gloves to handle bearing.
Page 462 PREASSEMBLY OF OUTPUT HALF OF HOUSING WARNING IMPORTANT: If tapered roller bearing cups were Use care in handling housing once it has been removed, ensure output shaft seal IS NOT in heated. Severe burns could result. Use special place, as it will be necessary to heat housing prior protective gloves to handle housing.
Page 463 Output Shaft Seal 2. Reinstall suction pipe. Place one drop of Quicksil- ver Loctite 8831 or Type A on screw threads. 1. If bearing were not replaced and no shimming Then secure suction pipe down with retainer is required, push new seal onto special mandrel. plate.
Page 464 3. Install baffle plate. Apply one drop of Quicksilver 5. Install input shaft. Ensure all gears mesh as Loctite 8831 or Type A to screws. Tighten screws shown. securely and bend tabs down over screws. 71057 a - Tabs b - Screws c - Baffle Plate 4.
Page 465 PREASSEMBLY OF INPUT HALF OF HOUSING WARNING 1. Install breather valve (DO NOT overtighten). Use care in handling housing once it has been heated. Severe burns could result. Use special protective gloves to handle housing. 3. Heat each tapered roller bearing cup bore with a torch lamp.
Page 466 4. Install input half of housing onto output half. En- b. Mount dial indicator on input shaft. Turn input sure locator pins are in place. Install bolts and shaft several times to seat bearing. lockwashers and torque to 36 lb. ft. (49 N·m). 71064 27685 c.
Page 467 IMPORTANT: The following step should be done e. Make note of reading. The bearing clearance very carefully to obtain the actual bearing clear- measured PLUS the preload required is equal ance. Avoid bumping the input shaft and turn to the amount of shim thickness to be ADD- very slowly on the special tool knob.
Page 468 Intermediate Shaft Preload d. Zero dial indicator. 1. Measure bearing clearance as follows: a. Remove hex plug from housing. 71065 27685 b. Screw special bolt with nut into intermediate IMPORTANT: The following step should be done shaft and tighten snugly. Turn nut up until it very carefully, to obtain the actual bearing clear- touches bolt head.
Page 469 Make note of the reading. The bearing clear- Output Shaft Preload ance measured PLUS the preload required is 1. Measure the bearing clearance as follows: equal to the amount of shim thickness to be a. Install flange washer and bolt. Tighten snugly. ADDED.
Page 470 IMPORTANT: The following step should be done 2. When thickness of shims to be ADDED has been very carefully to obtain the actual bearing clear- determined, the input half of housing must again ance. Pry up gently and evenly to lift shaft. Shaft be removed.
Page 471 b. Pull bearing cup from housing as shown. WARNING Use care in handling housing once it has been heated. Severe burns could result. Use special protective gloves to handle housing. 5. Heat each tapered roller bearing cup bore with a torch lamp.
Page 472 Final Assembly 4. Install bolts and lockwashers and torque to 36 lb. ft. (49 N·m). INPUT SHAFT SEAL 1. Push new seal onto special mandrel. Ensure seal will be positioned with lip of seal facing inward. Drive seal uniformly into bore of housing to the point that it is countersunk .040 in.
Page 473 CONTROL BLOCK FLUID FILTER 1. Ensure piston rings are in place and the key is in 1. Coat new O-rings with ATF. keyway. Align key on shaft with keyway in control block. 2. Install new gasket between control block and housing.
Page 474 DIPSTICK 4. Install O-ring into flange and coat with ATF. 1. Coat sealing ring on dipstick with ATF. 5. Install washer and bolt. Torque to 63 lb. ft. (85 N·m). 2. Install dipstick into transmission and tighten by pressing down and turning clockwise at the same time.
Page 475 FILLING WITH TRANSMISSION FLUID IMPORTANT: Use only ATF (Automatic Transmis- sion Fluid), such as Dexron II-D. 1. Fill transmission to proper level, through fluid filter cavity. (Refer to “Transmission Fluid Capacity”.) 2. Install filter as follows: a. Align flat spot on filter with flat surface inside of housing.
Page 476 Functional Test 1. Connect a pressure gauge and thermometer to fluid pump at locations shown. 50686 a - Pressure Gauge (M10x1 Thread) - Remove Plug b - Thermometer (3/8 In. Thread) - Remove Temperature Sender 2. Perform functional tests as shown in chart follow- ing.
Page 477 DRIVE SYSTEMS 72959 HURTH V-DRIVE TRANSMISSION Index...
Page 478 Table of Contents Page Page Identification ........8B-1 Reassembly .
Page 479 Identification Torque Specifications The transmission identification plate is located on the TORQUE top rear of the transmission. DESCRIPTION DESCRIPTION Lb. Ft. Transmission Housing Halves Bolts and Nuts Control Block to Housing Bolts Output Flange to Output Shaft Mounts Transmission to Flywheel Housing Specifications DESCRIPTION...
Page 480 Tools/Lubricants/Sealants General The Hurth transmission is a “full power reversing” DESCRIPTION PART NUMBER transmission, allowing a standard (LH rotation) en- Tapered Roller Bearing gine to be used for both rotations. Propeller rotation 91-813950 Inner Race Puller is determined by shift cable attachment at the remote control.
Page 481 Shift Cable Installation and IMPORTANT: Check that shift lever is positioned approximately 10 aft of vertical when in the neu- Adjustment tral detent position and that the distance (“c”) These Hurth transmissions are full reversing trans- between studs in the following is set at 7-1/8 in. missions.
Page 482 3. Locate center of remote control and control shift 6. Place remote control shift lever in forward gear cable play (backlash), as follows: position. Check to ensure transmission is fully in gear, as follows: a. Check that remote control is in neutral posi- tion.
Page 483 10. Reattach locknut and washer to cable barrel stud. Tighten until they bottom out. Tighten securely, but do not overtighten. NOTE: To change cable approach direction on single or dual station installations, only the spacers/ bushings have to be switched to the opposite stud (the studs are identical).
Page 484 73591 73590 CABLE BARREL STUD CABLE END GUIDE STUD 50073 71211 a - Cable End Guide(s) b - Spacer c - Elastic Stop Nut and Washer a - Cable End Guides d - Bushing(s) b - Locknut and Washer (Tighten Until Bottomed, Then Back e - Cable Barrel(s) [Position(s) Only Indicated In Lower Drawing] One Full Turn)
Page 485 Checking Transmission Draining Transmission Fluid Level 1. Clean the exterior of transmission before disas- sembly. IMPORTANT: Use only specified transmission 2. Remove oil filter from housing by turning (coun- fluid (see “Lubricants/Sealants”). terclockwise) and pulling at the same time. Check transmission fluid before starting engine each day, as follows: 1.
Page 486 Filling Transmission b. Push down until cover is fully seated (top of cover flush with housing), then, Turn T-handle IMPORTANT: Use only Automatic Transmission clockwise until tight. Fluid (ATF) as recommended in “Tool/Lubricants/ Sealants.” 1. Fill transmission to proper level, through oil filter cavity.
Page 487 Transmission Removal Transmission Installation 1. Disconnect wires from neutral safety switch and 1. Coat splines on input shaft with Quicksilver En- audio warning temperature switch. gine Coupler Spline Grease. 2. Disconnect fluid cooler hoses. Appropriately la- bel hose “Port” and “Starboard”. 71044 50686 a - Input Shaft...
Page 488 3. Connect wires to neutral safety switch and to au- 2. Remove cover and filter element from transmis- dio warning temperature switch. Coat connec- sion. tions on neutral safety switch with Quicksilver Liq- uid Neoprene. 27662 3. Remove filter element from cover and inspect 50686 O-rings for wear.
Page 489 5. Remove dipstick by turning (counterclockwise) BREATHER VALVE and pulling at the same time. 1. Remove breather valve. Clean with suitable cleaner, allow to dry and coat with oil. 71048 a - Breather Valve MOUNTS 1. Remove mounts from transmission housing. In- 27661 spect mounts for damage and replace if neces- 6.
Page 490 OUTPUT FLANGE 2. Turn four remaining bolts out until they just con- tact flange puller plate. Then continue to turn bolts 1. Remove four bolts as shown and loosen but DO out evenly (to push on puller plate) to remove NOT remove four remaining bolts.
Page 491 CONTROL BLOCK CAUTION 1. Remove hex head bolts. Be careful not to allow dirt to enter control block from front side. 3. Cover openings in control block with a protective cloth. 27661 a - Hex Socket Head Bolts (6) 27665 2.
Page 492 2. Remove input side of housing. Be sure to locate 4. Remove intermediate shaft assembly. and save locator pins. 73021 5. Remove reversing shaft assembly. 73019 a - Locator Pins 3. Remove input shaft assembly. 73022 73020 Index 8B-14 - HURTH V-DRIVE TRANSMISSION 90-806934 1194...
Page 493 6. Remove output shaft assembly. SEALS 1. Remove suction pipe seal as follows: 73023 27666 a - Seal BEARING, GEAR AND SEAL INSPECTION 1. Inspect all tapered roller bearings, the piston rings on the input shaft and all gears for wear. If a.
Page 494 b. Remove screws and hold down plate. 2. Remove input shaft seal using appropriate man- drel. c. Remove suction pipe by pulling downward out of seal. 27670 a - Seal 3. Remove output shaft seals using appropriate mandrel. 73025 a - Screws b - Hold Down Plate d.
Page 495 TAPERED ROLLER BEARING CUPS b. Pull bearing cup from housing using tool as shown. IMPORTANT: Do not remove tapered roller bear- ing cups unless replacing tapered roller bear- ings. Bearing and cup must be replaced as a set. IMPORTANT: Do not mix up shims under cups on the input housing side.
Page 496 TAPERED ROLLER BEARINGS REVERSING CLUTCH, GEARS AND TAPERED ROLLER BEARINGS IMPORTANT: Bearings and gear on output shaft are not replaceable. Replace output shaft, gear 1. Remove tapered roller bearing from splined end and bearings as a complete assembly only. of input shaft using special tool as follows: a.
Page 497 b. Tighten jaws onto bearing by turning on 2. Remove butting ring from splined end of input knurled part of tool. Tighten assembly. shaft by installing special tool as shown and lightly tapping upward on tool. 27673 a - Special Tool b - Butting Ring 27671 3.
Page 498 4. Remove needle bearings. 6. Remove tapered roller bearing, butting ring and gear from piston end of shaft using special tool as shown. Press all components off at the same time. Then, remove needle bearings. 27673 27680 CLUTCH DISCS NOTE: Discs on both sides of clutch are removed in 5.
Page 499 1. Position snap ring compression tool on clutch as- NOTE: For ease of reassembly, end disc and snap ring should not be removed from tool unless their con- sembly so that compression screws are centered over slots in clutch housing. dition is questionable.
Page 500 IMPORTANT: Thrust discs have a wave pattern. 3. Remove discs. These discs must be reinstalled in a specific pat- tern, when reassembled. Make note of notches in thrust disc tabs, and how they are arranged. 50248 27680 4. Inspect thrust discs and inner discs for wear. Re- place if there is any questionable wear.
Page 501 Reassembly 2. Install discs in clutch housing. CLUTCH DISCS IMPORTANT: Thrust discs have a wave pattern. These discs must be reinstalled in a specific man- ner as explained following. 27680 50248 1. Arrange thrust discs and inner discs as shown. 3.
Page 502 4. If end disc and snap ring were removed from tool, c. Tighten compression screws evenly to com- reinstall as follows: pletely compress snap ring into end disc. a. Loosen all compression screws on tool. 27677 a - Compression Screws 27677 b.
Page 503 5. Tap lightly around top of tool until end disc bot- 6. Double check that snap ring has been properly toms. Loosen compression screws and remove seated by prying up lightly on end disc. tool. 27679 7. Reinstall discs on opposite side of clutch in same manner.
Page 504 GEAR ASSEMBLY TAPERED ROLLER BEARING 1. Reinstall gear assembly. Twist gear assembly WARNING from side to side to allow splines to engage with Do not touch bearing once it has been heated. Severe inner discs. Ensure all inner discs are engaged burns could result.
Page 505 2. Install tapered roller bearing on opposite end of CAUTION shaft in the same manner. Use care in reinstalling piston rings on input shaft. Piston rings are brittle and may snap if REVERSING SHAFT spread too far open. WARNING 3. Reinstall piston rings on input shaft. Ensure ends Do not touch bearing once it has been heated.
Page 506 PREASSEMBLY OF OUTPUT HALF OF WARNING HOUSING Use care in handling housing, once it is heated with IMPORTANT: If tapered roller bearing cups were torch lamp. Severe burns could result. Use special removed, ensure output shaft seal IS NOT in protective gloves when handling housing.
Page 507 Output Shaft Seal Suction Pipe 1. Reinstall suction pipe seal in bottom of oil filter 1. If bearing were not replaced and no shimming bore. Coat seal with ATF. is required, push new seal onto special mandrel. Ensure seal will be positioned with lip of seal fac- ing inward.
Page 508 Shafts 4. Install intermediate shaft. 1. Coat tapered roller bearings with ATF. 2. Install output shaft. 73021 5. Install input shaft. Ensure all gears mesh as shown. 73023 3. Install reversing shaft. 73020 73022 73031 Index 8B-30 - HURTH V-DRIVE TRANSMISSION 90-806934 1194...
Page 509 PREASSEMBLY OF INPUT HALF OF HOUSING WARNING Use care in handling housing once it has been heated with a torch lamp. Severe burns could result. Use spe- 1. Install breather valve (do not over-tighten). cial protective gloves when handling housing. 2.
Page 510 3. Install input half of housing onto output half. En- b. Mount dial indicator on input shaft. Turn input sure locator pins are in place. Install bolts and shaft several times to seat bearing. lockwashers and torque to 36 lb. ft. (49 N·m). 73033 a - Bolts and Lockwashers 27685...
Page 511 IMPORTANT: The following step should be done e. Make note of reading. The bearing clearance very carefully to obtain the actual bearing clear- measured PLUS the preload required is equal ance. Avoid bumping the input shaft and turn to the amount of shim thickness to be ADD- very slowly on the special tool knob.
Page 512 Intermediate Shaft Preload d. Zero dial indicator. 1. Measure bearing clearance as follows: a. Remove hex plug from housing. 73034 27685 b. Screw special bolt with nut into intermediate shaft and tighten snugly. Turn nut up until it IMPORTANT: The following step should be done touches bolt head.
Page 513 Make note of the reading. The bearing clear- OUTPUT SHAFT PRELOAD ance measured PLUS the preload required is 1. Measure the bearing clearance as follows: equal to the amount of shim thickness to be a. Install flange with bolts and washers. Tighten ADDED.
Page 514 IMPORTANT: The following step should be done 2. When thickness of shims to be ADDED has been very carefully to obtain the actual bearing clear- determined, the input half of housing must again ance. Pry up gently and evenly to lift shaft. Shaft be removed.
Page 515 b. Pull bearing cup from housing as shown. WARNING Use care in handling housing once it has been heated. Severe burns could result. Use special protective gloves to handle housing. 5. Heat each tapered roller bearing cup bore with a torch lamp.
Page 516 Final Assembly 2. Coat lips of seals on input and output shafts with ATF. INPUT SHAFT SEAL 3. Apply a thin layer of Loctite 515 Sealer to ma- chined surfaces on housing halves. Reinstall in- 1. Push new seal onto special mandrel. Ensure seal put half of housing.
Page 517 5. Double check to ensure that there is no shaft 4. Coat each hex socket head bolt with a drop of clearance on all three shafts. Refer back to pre- Quicksilver Loctite 8831 or Type A. Secure con- vious steps if necessary, and use dial indicator. trol block to housing with bolts and lockwashers.
Page 518 2. Reassemble filter assembly as shown. DO NOT OUTPUT FLANGE tighten and compress upper O-ring. 1. Install locator pins into output shaft. 72805 73017 a - O-Ring a - Locator Pins (4) 2. Install flange on output shaft. Apply Loctite 8831 DIPSTICK or Type A to threads of bolts and torque to 14 lb.
Page 519 FILLING WITH TRANSMISSION FLUID IMPORTANT: Use only ATF (Automatic Transmis- sion Fluid), such as Dexron II-D. 1. Fill transmission to proper level, through fluid filter cavity. (Refer to “Capacity.”) 2. Install filter as follows: a. Bring flat spot on filter into agreement with flat surface inside of housing.
Page 520 Functional Test 1. Connect a pressure gauge and thermometer to fluid pump at locations shown. 50686 a - Pressure Gauge (M10x1 Thread) - Remove Plug b - Thermometer (3/8 In. Thread) - Remove Temperature Sender 2. Perform functional tests as shown in chart following. Refer to “Specifications” for correct readings. Tests to Be Carried Out: 1.
Page 521 DRIVE SYSTEMS PROPELLER SHAFT MODELS Index...
Page 522 Table of Contents Page Torque Specifications ..... 8C-1 Tools/Lubricants/Sealants ....8C-1 Propeller Shaft (MIE Model) .
Page 523 Torque Specifications TORQUE DESCRIPTION DESCRIPTION Lb. Ft. Propeller Shaft Coupling to Coupling Housing (MIE Model) Coupling Set Screws (If so equipped) Securely (See NOTE. ) NOTE: Safety wire set screws if so equipped Tools/Lubricants/Sealants DESCRIPTION PART NUMBER Quicksilver 2-4-C Marine Lubricant 92-86154A1 Quicksilver Engine Coupler Spline Grease 92-8166391A4...
Page 524 3. Check output coupling flange of transmission. 7. Tighten set screws securely. Safety wire set- screws, if so equipped. 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.
Page 525 3. Check the diameter of all propeller blades. If not Checks Made with Propeller Shaft the same, repair propeller. Removed from Boat 1. Check propeller shaft for straightness. Check at three or four places. If dial indicator deflects over .004 in. (0.1 mm), replace shaft. a - V-Blocks b - Dial Indicator a - Metal Straight Edge (Held to Rudder with C-Clamp)
Page 526 POWER STEERING SYSTEM 71034 PUMPS AND RELATED COMPONENTS Note:Refer to the following Service Bulletins regarding this section. SB 96-8 Brass Power Steering Hose Coupling SB 95-8 MerCruiser Steering Recommendations INDEX...
Page 527 ..... 9A-2 Unit, “Steering Systems”. D3.0L/150 and D3.6L/180 Engines ..9A-2 D4.2L/220 Engines .
Page 528 Torque Specifications Description TORQUE The power steering system utilizes an engine-driven DESCRIPTION Lb. Ft. N⋅m hydraulic pump that supplies fluid flow and pressure by means of hoses to a control valve that, in turn, con- Front bracket trols fluid flow and pressure to-and-from a booster Rear Brace cylinder.
Page 529 Exploded Views Power Steering Pumps D3.0L/150 AND D3.6L/180 ENGINES 71034 1 - Pump Torque Specifications 2 - Pulley 3 - Tensioning Bolt 24 lb. ft. (32 N·m) 4 - Pinion For Tensioning Nut 5 - Tensioning Nut 15 lb. ft. (21 N·m)
Page 530 Power Steering Pumps (continued) D4.2L/220 ENGINES 71035 1 - Pump Torque Specifications 2 - Pulley 3 - Tensioning Screw 15 lb. ft. (21 N·m) 4 - Mounting Screw 5 - Bushing 6 - Fluid Pressure Hose 7 - Fluid Reservoir Hose 8 - Hose Clamp 9 - Bracket 90-806934 1194...
Page 531 Related Components ALL ENGINES 71034 1 - Fluid Reservoir Tank Lubricant/Sealant Application Points 2 - Hose Clamp (2) 3 - Clamping Screw Quicksilver Power Trim and Steering . . 4 - Support Fluid - 92-90100, or Automatic Transmis 5 - Supply Hose sion Fluid - Dexron, Dexron II, Dexron II -D 6 - Pressure Hose - Obtain Locally...
Page 532 4. Drain power steering fluid from pump into a suit- able container. DO NOT reuse fluid. 5. Following instructions “a” or “b”. a. On D4.2L/220 Pumps: Proceed to Step 5. b. On D3.0L/150, D3.6L/180 Pumps: (1) Remove and retain front bracket and 26441 screws.
Page 533 Do not tighten presently. 74481 2. Follow instructions “a” or “b”: a. D4.2L/220 Pumps: Proceed to Step 3. 26441 b. D3.0L/150, D3.6L/180 Pumps: a - Reservoir Hose (1) Install new O-ring onto adaptor and install b - Hose Clamp c - Pressure Hose adaptor into new pump.
Page 534 “a” or “b”: attach with fasteners and hardware retained pre- a. On D3.0L/150, D3.6L 180 Pumps: Turn ten- viously, as shown. sioning bolt with pinion to adjust belt. Torque mounting nut and tensioning nut 15 lb.
Page 535 For more information on power steering system components refer appropriate MerCruiser Stern Drive Service Manual. 23162 2. Add Quicksilver Power Trim and Steering Fluid or Dexron ATF to bring fluid up to the correct level. 9A-8 - PUMPS AND RELATED COMPONENTS...
Page 536 POWER STEERING SYSTEM 71034 PUMPS AND RELATED COMPONENTS...
Page 537 Power Steering Pumps ..... 10A-2 Unit, “Steering Systems”. D3.0L/150 and D3.6L/180 Engines ..10A-2 D4.2L/220 Engines .
Page 538 Torque Specifications Description The power steering system utilizes an engine-driven TORQUE hydraulic pump that supplies fluid flow and pressure DESCRIPTION DESCRIPTION Lb. Ft. by means of hoses to a control valve that, in turn, con- Front bracket trols fluid flow and pressure to-and-from a booster cylinder.
Page 539 Exploded Views Power Steering Pumps D3.0L/150 AND D3.6L/180 ENGINES 71034 1 - Pump Torque Specifications 2 - Pulley 3 - Tensioning Bolt 24 lb. ft. (32 N·m) 4 - Pinion For Tensioning Nut 5 - Tensioning Nut 15 lb. ft. (21 N·m)
Page 540 Power Steering Pumps (continued) D4.2L/220 ENGINES 71035 1 - Pump Torque Specifications 2 - Pulley 3 - Tensioning Screw 15 lb. ft. (21 N·m) 4 - Mounting Screw 5 - Bushing 6 - Fluid Pressure Hose 7 - Fluid Reservoir Hose 8 - Hose Clamp 9 - Bracket 90-806934 1194...
Page 541 Related Components ALL ENGINES 71034 1 - Fluid Reservoir Tank Lubricant/Sealant Application Points 2 - Hose Clamp (2) 3 - Clamping Screw Quicksilver Power Trim and Steering 4 - Support Fluid - 92-90100, or Automatic Transmission Fluid - 5 - Supply Hose Dexron, Dexron II, Dexron II -D - Obtain Locally 6 - Pressure Hose 7 - Return Hose (From Transom)
Page 542 Power Steering Pump D3.0L/150, D3.6L/180 Removal CAUTION Disconnect Battery cables at battery to prevent engine rotation and injury while working on pump. 1. Remove vacuum pump belt (see Section 1B “Maintenance.”) 70113 2. Remove and retain bolts or screws, lockwashers, hardware and nuts as shown.
Page 543 (screw head will bottom out). 5. Following instructions “a” or “b”. a. On D4.2L/220 Pumps: Proceed to Step 5. b. On D3.0L/150, D3.6L/180 Pumps: 1. Remove and retain front bracket and screws. 2. Remove and retain rear brace and screws.
Page 544 6. Position drive belt in pulley groove and tension belt following instructions “a” or “b”: a. On D3.0L/150, D3.6L 180 Pumps: Turn ten- sioning bolt with pinion to adjust belt. Torque mounting nut and tensioning nut 15 lb. ft. (21 N·m).
Page 545 NOTE: On All Models: Check belt tension by de- Maintaining Power Steering pressing upper strand of belt at center point between Pump Fluid Level pulleys. Belt must not deflect more than 3/16 in. (5mm). IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid, or Dexron II automatic trans- mission fluid (ATF), in power steering system.
Page 546 (using suitable adaptor), connected to hose, or hoses attached to water NOTICE tap.. For more information on power steering system components refer appropriate MerCruiser Stern Drive Service Manual. 90-806934 1194 PUMPS AND RELATED COMPONENTS - 10A-9...

This manual is also suitable for:

D3.6l/180 D4.2l/220