Mercury D2.8L D-Tronic Specifications Page 1

2003, Mercury Marine2.8 And 4.2 Diesel Sterndrive ModelsCMDĆ4081850 / 90Ć860094030 903

WARRANTY SECTION 1Page 2 CMD-4081850 / 90-860094030 SEPTEMBER 20030005Warranty InformationOwner Warranty RegistrationUNITED STATES AND CANADA ONLY•

MAINTENANCESECTION 5Page 92 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD648Air FilterCleaning1. Disconnect crankcase vent hose from end of

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 93 00000 was CD884 with CMD changesWater Separating Fuel FilterWARNINGBe careful

MAINTENANCESECTION 5Page 94 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD885 with step 1 f added, 2 E and ?CMD changesReplacing1. On D4.2L,

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 952. On D4.2L LD and D4.2L 230 Models:a. Remove and discard water separating fuel

MAINTENANCESECTION 5Page 96 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD882 using subsub only from mod , andFillingCD880 same text in new a

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 972. Move the plunger on the hand pump/primer up and down repeatedly, until an ai

MAINTENANCESECTION 5Page 98 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CE406 removed some subsubs to make usable hereFuel System00000 was CD

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 9900000 was CE406 removed some subsubs to make usable hereFuel Tank Cleaning And

MAINTENANCESECTION 5Page 100 CMD-4081850 / 90-860094030 SEPTEMBER 20030078Lubrication0148Steering SystemWARNINGDo NOT grease steering cable while ex

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1013. Lubricate the steering system pivot points.71904aAa-Steering system pivot p

WARRANTYSECTION 1SECTION 1CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 3International Owner RegistrationOUTSIDE THE UNITED STATES AND CANADA• It i

MAINTENANCESECTION 5Page 102 CMD-4081850 / 90-860094030 SEPTEMBER 20030079 with diesel graphics from mod cd920Throttle Cable1. Lubricate the pivot p

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1030080 modified graphicsShift Cable1. Lubricate the pivot points and the guide c

MAINTENANCESECTION 5Page 104 CMD-4081850 / 90-860094030 SEPTEMBER 20030149.01Sterndrive Unit and Transom Assembly1. Lubricate the gimbal bearing thr

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1050000 New from SM #28 section 1BSterndrive U-joint Cross Bearings And Shaft Spl

MAINTENANCESECTION 5Page 106 CMD-4081850 / 90-860094030 SEPTEMBER 20030151 modified to be consistent with other diesel statementsDrive Shaft Extensi

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1070152Propellers0157Bravo One and TwoREMOVALWARNINGAvoid Injury: Remote Control

MAINTENANCESECTION 5Page 108 CMD-4081850 / 90-860094030 SEPTEMBER 2003IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other d

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1090159.01Bravo ThreeREMOVALWARNINGAvoid Injury: Remote Control must be in NEUTRA

MAINTENANCESECTION 5Page 110 CMD-4081850 / 90-860094030 SEPTEMBER 20030160.01INSTALLATION77107fedcbaa-Rear propeller nutb-Rear propellerc-Rear prope

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1117. Install and torque the propeller nut. Check propeller at least every 20 hou

WARRANTY SECTION 1Page 4 CMD-4081850 / 90-860094030 SEPTEMBER 20030006 and CD854Warranty PoliciesRecreational Use Diesel Limited WarrantyWHAT IS COV

MAINTENANCESECTION 5Page 112 CMD-4081850 / 90-860094030 SEPTEMBER 2003Alternator Drive Belt and Engine Water Circulating Pump Belt, or Belts1. Inspe

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1130161.02Corrosion ProtectionWhenever 2 or more dissimilar metals (like those fo

MAINTENANCESECTION 5Page 114 CMD-4081850 / 90-860094030 SEPTEMBER 2003Ventilation Plate Anode - Is mounted on the front of the gearcase and serves

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 115Anode Kit (if equipped) - Mounted to boat transom. Acts as a sacrificial anode

MAINTENANCESECTION 5Page 116 CMD-4081850 / 90-860094030 SEPTEMBER 2003Propshaft Anode (Bravo Three Only) - is located in front of the propeller, bet

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 117Internal ComponentsSacrificial anode locations:• Starboard, aft-side of the he

MAINTENANCESECTION 5Page 118 CMD-4081850 / 90-860094030 SEPTEMBER 2003INSPECTIONNOTE: Remove deposits from surface of anode before trying to determi

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1193. Apply sealant to threads of new sacrificial anode and install into anode pl

MAINTENANCESECTION 5Page 120 CMD-4081850 / 90-860094030 SEPTEMBER 20030162 modified in step 2 to have the word tim removecPainting Your Power Packa

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 121CE376 modifiedCleaning The Seawater Strainer1. Visually inspect seawater strai

WARRANTYSECTION 1SECTION 1CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 5HOW TO OBTAIN WARRANTY COVERAGEThe customer must provide Mercury with a re

MAINTENANCESECTION 5Page 122 CMD-4081850 / 90-860094030 SEPTEMBER 2003Flushing The Seawater SystemSeawater section must be flushed after each operat

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1231. Ensure the area around propeller is clear and no one is standing nearby. To

MAINTENANCESECTION 5Page 124 CMD-4081850 / 90-860094030 SEPTEMBER 20033. Attach a hose between the flushing attachment and a water source.72012abTyp

6STORAGESECTION 6CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 125SECTION 6 - STORAGETable of ContentsCold Weather Or Extended Storage 126. . . . .

STORAGESECTION 6Page 126 CMD-4081850 / 90-860094030 SEPTEMBER 20030084 w / CMDCold Weather Or Extended StorageIMPORTANT: Cummins MerCruiser Diesel

STORAGESECTION 6CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 127CD665 w / changesDraining InstructionsIMPORTANT: Observe the following information

STORAGESECTION 6Page 128 CMD-4081850 / 90-860094030 SEPTEMBER 20035. Disconnect seawater outlet hose at aft end of power steering cooler. Lower hose

STORAGESECTION 6CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1297. Remove the seawater pump outlet hose from top of seawater pump. Drain the hose.

STORAGESECTION 6Page 130 CMD-4081850 / 90-860094030 SEPTEMBER 200310. Using a piece of wire, check water drain holes in sterndrive unit to ensure th

STORAGESECTION 6CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 13111. After seawater section of cooling system has been drained completely, coat thr

WARRANTY SECTION 1Page 6 CMD-4081850 / 90-860094030 SEPTEMBER 2003000000 was CD687Light Duty Commercial Use Diesel Limited WarrantyWHAT IS COVEREDMe

STORAGESECTION 6Page 132 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD927 w / changesIMPORTANT: Cummins MerCruiser Diesel recommends that pr

STORAGESECTION 6CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 13324. Remove the seawater pump impeller for storage:a. Remove the seawater pump cove

STORAGESECTION 6Page 134 CMD-4081850 / 90-860094030 SEPTEMBER 2003CD928 w / changesRecommissioningNOTICERefer to Cold Weather Extended Storage - Pre

STORAGESECTION 6CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1352. Ensure that all cooling system hoses are in good condition, connected properly,

7TROUBLESHOOTINGSECTION 7CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 137SECTION 7 - TROUBLESHOOTINGTable of ContentsDiagnosing EDI Problems 138.

TROUBLESHOOTINGSECTION 7Page 138 CMD-4081850 / 90-860094030 SEPTEMBER 20030102 changed to CMD and EDI not EFIDiagnosing EDI ProblemsYour authorized

TROUBLESHOOTINGSECTION 7CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 139Engine Will Not Start, Or Is Hard To StartPossible Cause RemedyLanyard sto

TROUBLESHOOTINGSECTION 7Page 140 CMD-4081850 / 90-860094030 SEPTEMBER 20030105 w / changes – EDI and CMDEngine Runs Rough, Misses And/Or BackfiresPo

TROUBLESHOOTINGSECTION 7CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1410107.2 with CMD changesExcessive Engine TemperaturePossible Cause RemedyWa

WARRANTYSECTION 1SECTION 1CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 7HOW TO OBTAIN WARRANTY COVERAGEThe customer must provide Mercury with a re

TROUBLESHOOTINGSECTION 7Page 142 CMD-4081850 / 90-860094030 SEPTEMBER 20030109 with CMD changesLow Engine Oil PressurePossible Cause RemedyFaulty se

TROUBLESHOOTINGSECTION 7CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1430175 w / changes – CMDSteering Wheel Turns Hard Or JerkyPossible Cause Rem

TROUBLESHOOTINGSECTION 7Page 144 CMD-4081850 / 90-860094030 SEPTEMBER 2003NOTES:

8CUSTOMER ASSISTANCE INFORMATIONSECTION 8CMD 4081850 / 90-860094030 SEPTEMBER 2003 Page 145SECTION 8 - CUSTOMER ASSISTANCE INFORMATIONTable of Conte

CUSTOMER ASSISTANCE INFORMATIONSECTION 8Page 146 CMD-4081850 / 90-860094030 SEPTEMBER 2003CD944 w/ CMD changesOwner Service AssistanceLocal Repair S

CUSTOMER ASSISTANCE INFORMATIONSECTION 8CMD 4081850 / 90-860094030 SEPTEMBER 2003 Page 1470117 – precaution only then CE472Replacement Service Parts

CUSTOMER ASSISTANCE INFORMATIONSECTION 8Page 148 CMD-4081850 / 90-860094030 SEPTEMBER 20030119 w / changes – see rev. bars or CD945Resolving A Probl

CUSTOMER ASSISTANCE INFORMATIONSECTION 8CMD 4081850 / 90-860094030 SEPTEMBER 2003 Page 1490121Customer Service LiteratureEnglish LanguageEnglish lan

CUSTOMER ASSISTANCE INFORMATIONSECTION 8Page 150 CMD-4081850 / 90-860094030 SEPTEMBER 2003Andere SprachenUm eine Betriebs– und Wartungsanleitung in

CUSTOMER ASSISTANCE INFORMATIONSECTION 8CMD 4081850 / 90-860094030 SEPTEMBER 2003 Page 1510122 w / changes – or see CD946 or see rev barsOrdering Li

WARRANTY SECTION 1Page 8 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD622Warranty Coverage and ExclusionKeep in mind that warranty covers re

75308CUSTOMER ASSISTANCE INFORMATIONSECTION 8Page 152 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD851

WARRANTYSECTION 1SECTION 1CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 9• Use of other than Quicksilver replacement parts when making warranty rep

WARRANTY SECTION 1Page 10 CMD-4081850 / 90-860094030 SEPTEMBER 20030008Transferable WarrantyThe product warranty is transferable to a subsequent pur

2GETTING TO KNOW YOUR POWER PACKAGESECTION 2CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 11SECTION 2 - GETTING TO KNOW YOUR POWERPACKAGETable of C

0001.Identification RecordThe serial numbers are the manufacturer’s keys to numerous engineering details which applyto your Cummins MerCruiser Diesel

GETTING TO KNOW YOUR POWER PACKAGESECTION 2Page 12 CMD-4081850 / 90-860094030 SEPTEMBER 20030010Features And Controls0011Lanyard Stop SwitchThe purp

GETTING TO KNOW YOUR POWER PACKAGESECTION 2CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 13Activation of the lanyard stop switch will stop the engi

GETTING TO KNOW YOUR POWER PACKAGESECTION 2Page 14 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was 0012.2InstrumentationINSTRUMENTSThe following

GETTING TO KNOW YOUR POWER PACKAGESECTION 2CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1500000 was part CD934 and CD860SWITCHES790767354770522ab

GETTING TO KNOW YOUR POWER PACKAGESECTION 2Page 16 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CE479 and CD860ENGINE MONITORING FEATURES77359

GETTING TO KNOW YOUR POWER PACKAGESECTION 2CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 170014Remote ControlsYour boat may be equipped with a Merc

GETTING TO KNOW YOUR POWER PACKAGESECTION 2Page 18 CMD-4081850 / 90-860094030 SEPTEMBER 20030016.01CONSOLE MOUNTEDCAUTIONAvoid possible boat and pow

GETTING TO KNOW YOUR POWER PACKAGESECTION 2CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 190017.02CONSOLE MOUNTED77971abcdeabbcdea-Throttle only bu

GETTING TO KNOW YOUR POWER PACKAGESECTION 2Page 20 CMD-4081850 / 90-860094030 SEPTEMBER 20030169Power TrimPower Trim allows the operator to adjust t

GETTING TO KNOW YOUR POWER PACKAGESECTION 2CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 21Trimming sterndrive unit DOWN/IN can:• Help the boat acc

0002.1 and CE459WELCOME!You have selected one of the finest marine power packages available. It incorporatesnumerous design features to assure operati

GETTING TO KNOW YOUR POWER PACKAGESECTION 2Page 22 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was 0018.01 w / CMD changeElectrical System Overlo

GETTING TO KNOW YOUR POWER PACKAGESECTION 2CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 2300000 was 0172.014. The Power Trim System is protected f

GETTING TO KNOW YOUR POWER PACKAGESECTION 2Page 24 CMD-4081850 / 90-860094030 SEPTEMBER 20030020.03 w changes – CMDAudio Warning SystemYour Cummins

GETTING TO KNOW YOUR POWER PACKAGESECTION 2CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 2500000 was 0220.0Emissions InformationExhaust Gas Emissio

GETTING TO KNOW YOUR POWER PACKAGESECTION 2Page 26 CMD-4081850 / 90-860094030 SEPTEMBER 2003NOTES:

3ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 27SECTION 3 - ON THE WATERTable of ContentsSafe Boating Suggestions 28. . . .

ON THE WATERSECTION 3Page 28 CMD-4081850 / 90-860094030 SEPTEMBER 20030022 w / CMD changesSafe Boating SuggestionsIn order to safely enjoy the water

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 29• Watch for signs of weather change and avoid foul weather and rough-seaboati

ON THE WATERSECTION 3Page 30 CMD-4081850 / 90-860094030 SEPTEMBER 2003• Know your boating area and avoid hazardous locations.• Be alert. The operato

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 310024GOOD VENTILATIONVentilate the passenger area, open the side curtains or f

0004Read This Manual ThoroughlyIF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR ADEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES

ON THE WATERSECTION 3Page 32 CMD-4081850 / 90-860094030 SEPTEMBER 20030026Basic Boat Operation0027.1Launching And Boat Operation CareCAUTIONTo avoid

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 33CD908Duty Cycle RatingIMPORTANT: Damage caused by improper application or fai

ON THE WATERSECTION 3Page 34 CMD-4081850 / 90-860094030 SEPTEMBER 2003LIGHT DUTY RATINGIt is the operator’s responsibility to operate within the fol

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 35000000 was 0028.3 and CD694 – changed 4th row last column to be “Engage STOP

ON THE WATERSECTION 3Page 36 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was 0029 and CD913Starting, Shifting and Stopping - D4.2L, D4.2L LD and

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 37Mechanical Engine Stop Lever - located on the injection pump of all engines e

ON THE WATERSECTION 3Page 38 CMD-4081850 / 90-860094030 SEPTEMBER 2003CDSTARTING A COLD ENGINEIMPORTANT: Always check all fluid levels before starti

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 39CEENGINE WARM UPCAUTIONImproper or no warm-up of engine can seriously impair

ON THE WATERSECTION 3Page 40 CMD-4081850 / 90-860094030 SEPTEMBER 2003CE33SHIFTINGCAUTIONNever attempt to shift unit unless engine is at idle rpm. D

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 41CD864Operation Chart - D2.8L D-Tronic, D4.2L D-Tronic and D4.2LSTARTINGPROCED

CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page iSECTION 1 - WARRANTYWarranty Information 2. . . . . . . . . . . . . . . . . . . . Owner Warranty Reg

ON THE WATERSECTION 3Page 42 CMD-4081850 / 90-860094030 SEPTEMBER 2003CD863 with changes to Engine Oil one bullet pointStarting, Shifting and Stopp

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 43CE w changes in all except list 1 and 2STARTING A COLD ENGINEIMPORTANT: Alway

ON THE WATERSECTION 3Page 44 CMD-4081850 / 90-860094030 SEPTEMBER 2003CESTARTING A WARM ENGINE1. Turn on and run engine compartment bilge blower for

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 450173Starting Engine After Stopped While In GearIMPORTANT: Avoid stopping the

ON THE WATERSECTION 3Page 46 CMD-4081850 / 90-860094030 SEPTEMBER 20030032Protecting People In The WaterWhile You Are CruisingIt is very difficult f

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 470131 w/ changes to align text and graphicsPassenger Safety Message - Pontoon

ON THE WATERSECTION 3Page 48 CMD-4081850 / 90-860094030 SEPTEMBER 20030034Wave And Wake JumpingWARNINGAvoid serious injury or death from being throw

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 490035.1 with CMD changeImpact With Underwater HazardsReduce speed and proceed

ON THE WATERSECTION 3Page 50 CMD-4081850 / 90-860094030 SEPTEMBER 20030132Drive Unit Impact ProtectionThe power trim hydraulic system is designed to

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 510036Conditions Affecting OperationWeight Distribution (Passengers And Gear) I

Page ii CMD-4081850 / 90-860094030 SEPTEMBER 2003SECTION 3 - ON THE WATERSafe Boating Suggestions 28. . . . . . . . . . . . . . Be Alert To Carbon M

ON THE WATERSECTION 3Page 52 CMD-4081850 / 90-860094030 SEPTEMBER 20030134VentilationVentilation is caused by surface air or exhaust gases that are

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 530040 and CE464Propeller SelectionCAUTIONThe installed propeller must allow th

ON THE WATERSECTION 3Page 54 CMD-4081850 / 90-860094030 SEPTEMBER 20030042Getting StartedCD912Initial Break-In ProcedureIt is especially important t

ON THE WATERSECTION 39CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 55CD608Sterndrive Unit 10-Hour Break-In PeriodIt is especially important that t

ON THE WATERSECTION 3Page 56 CMD-4081850 / 90-860094030 SEPTEMBER 20030043 w / changes – CMD and remove lasst bullet, see CE475After Break-In Period

4SPECIFICATIONSSECTION 4CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 57SECTION 4 - SPECIFICATIONSTable of ContentsFuel Requirements 58. . . . . .

SPECIFICATIONSSECTION 4Page 58 CMD-4081850 / 90-860094030 SEPTEMBER 2003CD164Fuel RequirementsWARNINGElectrical system components on this engine are

SPECIFICATIONSSECTION 4CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 59CE16Diesel Fuel In Cold WeatherUnaltered diesel fuels thicken and “gel” in c

SPECIFICATIONSSECTION 4Page 60 CMD-4081850 / 90-860094030 SEPTEMBER 2003CD865 w changes in tableEngine OilCAUTIONENVIRONMENTAL HAZARD! Discharge of

SPECIFICATIONSSECTION 4CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 6100000 was CD731Engine SpecificationsD4.2LDescriptionSpecification - Sterndri

CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page iiiSECTION 5 - MAINTENANCEOwner/Operator Responsibilities 68. . . . . . . . Dealer Responsibilities 6

SPECIFICATIONSSECTION 4Page 62 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD936D4.2L LD And D4.2L 230DescriptionSpecification - SterndriveDe

SPECIFICATIONSSECTION 4CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 6300000 was CD866D2.8L D-Tronic and D4.2L D-TronicDescriptionSpecification - S

SPECIFICATIONSSECTION 4Page 64 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD867D4.2L 300DescriptionSpecification - SterndriveDescriptionD4.2

SPECIFICATIONSSECTION 4CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 650051.02Fluid SpecificationsIMPORTANT: All capacities are approximate fluid m

SPECIFICATIONSSECTION 4Page 66 CMD-4081850 / 90-860094030 SEPTEMBER 2003NOTES:

5MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 67SECTION 5 - MAINTENANCETable of ContentsOwner/Operator Responsibilities 68. .

MAINTENANCESECTION 5Page 68 CMD-4081850 / 90-860094030 SEPTEMBER 20030054 W /CMD changesOwner/Operator ResponsibilitiesIt is the operator’s responsi

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 690056.1 w/ CMD changesMaintenanceWARNINGAvoid injury or death and power package

MAINTENANCESECTION 5Page 70 CMD-4081850 / 90-860094030 SEPTEMBER 20030057 W CMD changesDo-It-Yourself Maintenance SuggestionsPresent-day marine equi

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 710058 W / CMD changesInspectionInspect your power package often, and at regular

Page iv CMD-4081850 / 90-860094030 SEPTEMBER 2003SECTION 6 - STORAGECold Weather Or Extended Storage 126. . . . . Preparing Your Power Package For S

MAINTENANCESECTION 5Page 72 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD937Maintenance SchedulesRoutine Maintenance *EachDayStartEachDayEnd

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 73Maintenance Schedules (Continued)Scheduled Maintenance *AfterFirst20hoursAnnual

MAINTENANCESECTION 5Page 74 CMD-4081850 / 90-860094030 SEPTEMBER 2003Maintenance Schedules (Continued)Scheduled Maintenance * (Continued)Every2years

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 750166Maintenance RecordDateHour MeterReadingServiced ByMaintenancePerformed

MAINTENANCESECTION 5Page 76 CMD-4081850 / 90-860094030 SEPTEMBER 20030062Engine OilCAUTIONENVIRONMENTAL HAZARD! Discharge of oil or oil waste into t

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 77CD917FillingIMPORTANT: Do not overfill the engine with oil.1. Remove oil filler

MAINTENANCESECTION 5Page 78 CMD-4081850 / 90-860094030 SEPTEMBER 20030065Changing Oil and FilterRefer to the Maintenance schedule for the change int

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 796. Remove and discard oil filter and sealing ring.7. Coat sealing ring on new f

MAINTENANCESECTION 5Page 80 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was CD919D4.2L LD1. Start engine and allow it to warm up to normal operat

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 810139.2 / w changes or see CD939Power Steering Pump FluidChecking1. Stop the eng

1WARRANTYSECTION 1SECTION 1CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 1SECTION 1 - WARRANTYTable of ContentsWarranty Information 2. . . . . . .

MAINTENANCESECTION 5Page 82 CMD-4081850 / 90-860094030 SEPTEMBER 20030071.2Engine Coolant - Closed Cooled Models OnlyCD166 / CD918CheckingCAUTIONAll

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 834. With the engine at normal operating temperature, check the coolant level in

MAINTENANCESECTION 5Page 84 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was 0072 / and CD166Filling1. If coolant is low in the heat exchanger, ad

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 8500000 was 0142.01 w / CMD changesDrive Unit OilCAUTIONENVIRONMENTAL HAZARD! Dis

MAINTENANCESECTION 5Page 86 CMD-4081850 / 90-860094030 SEPTEMBER 20030143 w / CMD changesFillingIMPORTANT: If more than 59 ml (2 fl. oz.) of Quicksi

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 874. Bravo One Models: Remove the propeller, place the sterndrive unit in full tr

MAINTENANCESECTION 5Page 88 CMD-4081850 / 90-860094030 SEPTEMBER 2003IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil app

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 890145 w / changes – see rev barsPower Trim Pump FluidChecking1. Place the sternd

MAINTENANCESECTION 5Page 90 CMD-4081850 / 90-860094030 SEPTEMBER 200300000 was 0146 see rev. barsFilling1. Remove the fill cap from the reservoir.2.

MAINTENANCESECTION 5CMD-4081850 / 90-860094030 SEPTEMBER 2003 Page 9100000 was CE335Multiple EDI Engine Battery PrecautionsSITUATIONAlternators: Alt