Mercury Mercruiser Service Manual Engines in line diesel D2.8L/ D4.2L D-Tronic

Mercury Mercruiser Service Manual Engines in line diesel D2.8L/ D4.2L D-Tronic
Mercury Mercruiser Engines in line diesel D2.8L/ D4.2L D-Tronic

Service Manual MARINE ENGINES IN-LINE DIESEL
D2.8L D-Tronic Serial Number 0K000001 and Above
D4.2L D-Tronic Serial Number 0K000001 and Above

Service Manual Outline
Section 1 - Important Information
A - General Information
B - Maintenance
C - Troubleshooting
Section 2 - Removal and Installation
A - Sterndrive (MCM) Models
B - Inboard (MIE) Models
Section 3 - Engine Mechanical
A - D2.8L D-Tronic And D4.2L D-Tronic Engines
Section 4 - Electrical System
A - Starting System
B - Charging System
C - Glow Plug System (If Equipped)
D - Instrumentation
E - Wiring Diagrams
Section 5 - Fuel System
A - Description
B - Fuel Delivery Pump and Fuel Filter
C - Injectors
D - Injection Pump
E - EDI Diagnosis
Section 6 - Cooling System
A - Seawater Cooling System
B - Closed Cooling System
Section 7 - Intake And Exhaust System
A - Intercooler
B - Intake / Exhaust Manifold, Elbows and Risers
C - Turbocharger
Section 8 - Drive System
A - ZF / Hurth Transmissions
B - Propeller Shaft Models
Section 9 - Power Steering System
A - Pump And Related Components

Mercury Mercruiser Initial Break-In Procedure
The following procedure must be used on new and rebuilt diesel engines. This break-in procedure allows the proper seating of the pistons and rings, which greatly reduces the likelihood of problems.

  1. Refer to appropriate Starting, Shifting and Stopping section in the Operation, Maintenance and Warranty Manual provided with the product and start the engine. Allow the engine to idle until it has reached normal operating temperature.
  2. Operate the engine in gear for 3 minutes at each of the following rpms: 1200 rpm, 2400 rpm and 3000 rpm.
  3. Operate the engine in gear for 3 minutes at each of the following rpms: 1500 rpm, 2800 rpm and 3400 rpm.
  4. Operate the engine in gear for 3 minutes at each of the following rpms: 1800 rpm, 3000 rpm and WOT.