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Mercury D4.2L D-Tronic manuals

Owner’s manuals and user’s guides for Engine Mercury D4.2L D-Tronic.
We providing 2 pdf manuals Mercury D4.2L D-Tronic for download free by document types: Service Manual, User Manual


Mercury D4.2L D-Tronic Service Manual (878 pages)


Brand: Mercury | Category: Engine | Size: 12.39 MB |

 

Table of contents

NUMBER 22

1

Engine Mechanical Components

5

Models Covered in This Manual

6

Service Manual Outline

7

ENGINE (continued)

11

ELECTRICAL SYSTEMS

11

FUEL SYSTEM

13

COOLING SYSTEM

16

INTAKE AND EXHAUST SYSTEM

17

POWER STEERING

18

Page 1A-2

22

90-860064--1 FEBRUARY 2002

22

Introduction

23

How to Use This Manual

23

Page 1A-4

24

Operation / Duty Cycle

25

Engine Break-In

26

Description Container Size

27

Mercury Part

27

Quicksilver Part

27

Page 1A-9

29

90-860074-–1 FEBRUARY 2002

29

Page 1A-10

30

Inboard (MIE) Engines

35

Capacities

36

Maintenance Schedules

37

Sterndrive (MCM) Engines

38

Routine Maintenance *

38

Scheduled Maintenance *

39

Engine External Views

43

Front View

44

Port Side View

45

Rear View

46

Engine Oil

47

Diesel Fuel In Cold Weather

52

Fuel Filter

53

Closed Cooling System

58

Checking Level

59

Draining

60

Sacrificial Anodes

63

Flushing Seawater System

65

Inspect Water Pickups

68

Lubrication

69

U-joints

71

Drive Shaft Extension Models

72

Continuity Circuit

73

MerCathode

75

Electrical System

75

ENGINE COLD

77

Filling and Bleeding

78

Transmission

79

Power Trim

80

2. Install reservoir cap

81

Gear Lube Monitor

82

Air Filter

84

Drive Belts

86

Alternator Belt

88

Power Steering Pump Belt

90

Vacuum Pump Belt

92

Charging System

94

Saltwater Operation

94

Power Package Layup

96

MAINTENANCE

101

SERVICE MANUAL NUMBER 22

101

Recommissioning

103

IMPORTANT INFORMATION

107

Precautions

109

TROUBLESHOOTING

111

RPM Too High

112

RPM Too Low

112

Electrical

113

Fuel System

113

Fuel System (continued)

114

Miscellaneous

115

(continued)

116

Glow Plugs Inoperative

116

Charging System Inoperative

117

Noisy Alternator

117

Poor Fuel Economy

120

Engine Smoking

121

Blue Smoke

122

White Smoke

122

Exhaust Gas Temperature

123

Turbocharger

124

Engine Noise

125

Valve Cover Area

126

Cylinder Area

126

Camshaft Area

127

Crankshaft Area

128

Oil Pressure

129

Oil Pressure (continued)

130

Low Oil Pressure

131

High Oil Pressure

131

Excessive Oil Consumption

132

Water / Coolant in Engine

133

Engine Overheats

135

Cooling System (continued)

136

Mechanical

136

Power Steering

137

Noisy Pump

138

Fluid Leaks

138

REMOVAL AND INSTALLATION

147

STERNDRIVE (MCM) MODELS

148

Torque Specifications

149

Special Tools

149

Installation

153

70013 76921

158

Engine Connections

161

Battery Cables

176

Lubricants/Sealants/Adhesives

181

Engine Removal

182

INBOARD (MIE) MODELS

183

Engine Final Alignment

189

INCORRECT

190

Table of Contents

201

Table of Contents (continued)

202

Identification

203

ENGINE MECHANICAL

205

Special Tools (continued)

207

Snap-On Tools

208

Kent-Moore Tools

208

Engine Specifications

210

Cylinder Liner Protrusion

211

Head Gaskets

211

Cylinder Head

211

Oil Pump

212

Camshaft

212

Valve Lifter

212

Rocker Arm

213

Valve Adjustment

213

Valve Seat

213

Valve Guide

214

Valve Spring

214

Crankshaft

215

Crankshaft (continued)

216

Connecting Rods

217

Connecting Rod Crank Pin Bore

217

Connecting Rod Bushings

217

Flywheel

217

General Information

219

Examples of Bearing Failures

229

Compression Testing Procedure

230

Engine Cover

231

Valve Covers

232

Cleaning

233

Inspection

233

Water Manifold

237

Cylinder Heads

240

Disassembly

244

Open Valve

249

Expansion Plugs

250

Assembly

252

Timing Gear Cover

277

Reassembly

283

Oil Pressure Relief Valve

284

Adapter / Oil Thermostat

291

Cleaning and Inspection

292

Testing - Measuring Lobe Lift

296

Camshaft Bearings

300

Valve Lifters

302

Valve Push Rods

305

Rear Oil Seal

316

Crankshaft and Main Bearings

318

Cylinder Liners

336

Exploded View

344

Flywheel Housing

348

Engine Mounts

352

After Break-in Period

354

ELECTRICAL SYSTEM

357

Specifications

359

Replacement Parts

360

Starting System Components

360

STARTING SYSTEM

361

Starter Motor

363

Solenoid Switch

364

Electrical Systems

369

Replacement Parts Warning

371

Wire Color Code Abbreviations

373

CHARGING SYSTEM

375

Charging System Components

376

Circuitry Test

378

Output Circuit

379

Excitation Circuit

380

Sensing Circuit

381

Current Output Test

382

Alternator

385

Alternator Bracket

385

Battery Isolators

387

Battery Isolator Diagram

388

Description

394

GLOW PLUG SYSTEM

395

Glow Plug Circuit Diagram

401

Wire Color Abbreviations

406

Special Information

408

INSTRUMENTATION

409

CRUISELOG (ENGINE HOUR METER)

411

VOLT METER GAUGE

412

TACHOMETER

412

+ 100 rpm

412

Primary Station Switches

417

INSTALLATION

420

87-805675

420

Audio Warning System

421

Oil Pressure Switch

422

Primary Station

431

Secondary Station

432

Sterndrive (MCM) Models

438

WIRING DIAGRAMS

439

Inboard (MIE) Models

450

Models With Early Connectors

460

Testing Procedure

471

Diagnostic Information

473

Terminology

473

General Description

475

Computers and Voltage Signals

475

Analog Signals

475

Analog Value Conditioning

477

Digital Signals

479

Engine Control Module (ECM)

481

Speed Density System

483

DESCRIPTION

485

Fuel Management

492

Modes Of Operation

493

Diagnosis and Testing

496

FUEL SYSTEMS

501

Obtain Locally

507

Water Separating Fuel Filter

513

Water Drain Valve Operation

515

EFEP60H Nozzle Tester

522

0 681 200 502

522

Fuel Injector (Cutaway View)

525

FUEL INJECTORS

527

Special EDI Tools

540

Fuel Ratings

543

Diesel Fuel in Cold Weather

543

Repair and Service

544

Testing Information

545

Fuel Injection Pump Removal

547

INJECTION PUMP

549

Timing for instructions

554

Fuel Injection Pump Timing

559

TESTING FUEL RETURN PRESSURE

567

Visual/Physical Inspection

571

Service Precautions

573

Abbreviations (continued)

576

ECM Self-Diagnosis

576

Malfunction Indicator Lamp

577

Reading Codes

578

EDI DIAGNOSIS

579

Clearing Codes

581

ECM Input and Sensor Diagram

583

ECM Connector Pin Layout

584

Connector Chart

585

Connector Chart (continued)

586

Fuel Temperature Sensor

592

RPM (Engine Speed) Sensor

594

Battery Voltage

610

Battery (Switched K15)

611

Microcontroller Fault

612

Main Relay

614

7533675336

632

Trouble Codes

636

Display Terminology

637

IMPORTANT PRELIMINARY CHECKS

642

INTERMITTENTS

643

(A) Verify that the drive /

646

Repair Procedures

661

System Components

664

Fuel Injection Pump Repair

666

Wiring Harness Service

667

HARNESS VIEWS

669

Throttle Position (TP) Sensor

678

Instrumented Injector

680

Engine RPM Speed Sensor

680

Idle Speed Setting Circuit

681

Seawater Pump Delivery Rates

686

Seawater Pickup Connections

686

Seawater Pickup Connection

687

Seawater Strainer

688

D2.8L D-Tronic

689

D4.2L D-Tronic

690

SEAWATER COOLING SYSTEM

691

Seawater Flow Diagram

692

Seawater Pump

694

Location of Coolers

715

Inspection Before Removal

716

Cleaning Without Removal

716

Engine Oil Cooler

717

Transmission Fluid Cooler

724

COOLING SYSTEMS

729

CLOSED COOLING SYSTEM

731

Diagrams and Exploded Views

734

Engine Water Circulating Pump

738

Checking Coolant Level

739

Testing Closed Cooling System

740

Pressure Cap Rating

741

Amount of Pressure

741

Applied to Closed

741

Cooling System

741

Testing Pressure Cap

743

Coolant Change Interval

745

Coolant Requirement

745

Using A Cleaner

747

Thermostats

750

Heat Exchanger

754

Water Circulating Pump

759

Coolant Manifold

761

Corrosion Protection

761

Exploded Views

766

D2.8L Intercooler (continued)

767

D4.2L Intercooler

768

D4.2L Intercooler (continued)

769

Intercooler

770

INTERCOOLER

777

MANIFOLDS, ELBOWS AND RISERS

789

Inboard (MIE) Exhaust Systems

790

Intake / Exhaust Manifold

797

INTAKE / EXHAUST SYSTEM

803

Turbocharger Specifications

805

TURBOCHARGER

809

REMOVING EXHAUST ELBOW

813

REMOVING TURBOCHARGER UNIT

815

Boost Pressure Control

830

CLEANING

831

Wastegate

835

ZF / HURTH TRANSMISSIONS

843

Important Information

844

Transmission Fluid

846

Changing

847

10. Check the fluid level

849

Transmission Removal

850

Transmission Installation

851

Shift Control And Cables

853

Transmission Repair

859

DRIVE SYSTEMS

861

PROPELLER SHAFT MODELS

863

POWER STEERING SYSTEM

869

Related Components

872

Power Steering Pump

873

PUMP AND RELATED COMPONENTS

875

SERVICE MANUAL NUMBER 22

875

Checking Fluid Level

876

Mercury D4.2L D-Tronic User Manual (33 pages)


Brand: Mercury | Category: Engine | Size: 9.23 MB |

 

Table of contents

INSTRUMENTS

1

INSTRUMENTS

10




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