Service Manual #48 QSD 2.0 Liter Diesel Engines
Sterndrive Serial Numbers: 88201000 and Above Inboard Serial Numbers: 88200000 and Above
Manual Outline 1 - Important Information A - General Information B - Maintenance C - Troubleshooting 2 - Removal And Installation A - Sterndrive Models B - Inboard Models 3 - Engine Mechanical A - QSD 2.0 Engines 4 - Electrical System A - Starting System B - Charging System C - Instrumentation D - Wiring Diagrams 5 - Fuel System A - Component Description B - Fuel Filter Assembly C - Common Rail and Fuel Lines D - Fuel Injectors E - High Pressure Fuel Pump F - ECS Diagnostics G - ECS Repair 6 - Cooling System A - Closed-Cooling System
Important Information
Removal And Installation
Engine Mechanical
Electrical System
Fuel System
Cooling System
Intake and Exhaust System
Drive System
Power-Assisted Steering System
1 2 3 4 5 6 7 8 9
7 - Intake and Exhaust System A - Intake Manifold and Aftercooler Assembly B - Exhaust Manifold and Elbow C - Turbocharger 8 - Drive System A - Technodrive Transmissions B - Propeller Shaft Models 9 - Power-Assisted Steering System A - Power-Assisted Steering Pump and Related Components
Page v
General Information
Important Information
1
A
Section 1A - General Information
Table of Contents Introduction......................................................1A-2 How To Use This Manual.................................1A-2 Engine Serial Number and Decal Locations .........................................................................1A-2 Identification..............................................1A-2 Serial Number Decal.................................1A-2 Engine Data Plate Location......................1A-3 Engine Data Plate.....................................1A-3
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Emissions Information..............................1A-4 Operation—Duty Cycle....................................1A-4 Duty Cycle Rating.....................................1A-4 High Output Rating...................................1A-4 Engine Break‑In...............................................1A-5 20‑Hour Break‑In Period...........................1A-5 After the 20‑Hour Break‑In Period............1A-5
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General Information
Introduction This comprehensive overhaul and repair manual is designed as a service guide for the MerCruiser and Cummins MerCruiser Diesel models listed earlier. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment, to enable dealers and service mechanics to repair these products. Before attempting repairs, read through the procedures to understand the methods and tools used and the cautions and warnings required for safety.
How To Use This Manual This manual is divided into sections, which represent major components and systems. Some sections are further divided into parts that more fully describe the component. Refer to the Service Manual Outline following Models Covered in this manual for section titles.
Engine Serial Number and Decal Locations Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to you Cummins MerCruiser Diesel power package. When contacting Cummins MerCruiser Diesel (CMD) about service, always specify model and serial numbers.
Serial Number Decal The serial number decal is located on the engine and indicates the engine's CMD serial number, transom serial number, drive serial number, and the fill cap color codes for engine fluids.
25986
Serial number decal
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General Information
Engine Data Plate Location The engine data plate is on the front of the engine. The data plate lists important identification and emissions certification information.
28074
Location of QSD 2.0 engine data plate
Engine Data Plate A tamper‑resistant engine data plate is affixed to the engine at the time of manufacture by Cummins MerCruiser Diesel. It contains important exhaust gas emissions information. Please note that the engine data plate will not affect the fit, function, or performance of the engine and neither boatbuilders nor dealers may remove the engine data plate or the engine component it is affixed to before sale. If modifications are necessary or the engine data plate is damaged contact Cummins MerCruiser Diesel about the availability of a replacement. The owner or operator is not to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission levels to exceed their predetermined factory specifications.
a
c
b
d e f g h j
i abcdef-
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Typical engine data plate Engine serial number Cummins MerCruiser Diesel model information Emissions certification information Fuel rate Rated operation engine speed Governed engine speed
k ghijk-
25401
Minimum idle speed Engine power rating Engine weight Emissions data Manufacturer model number, IMO type, liters per cylinder
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General Information
Emissions Information EXHAUST GAS EMISSIONS CERTIFICATE A tamper‑resistant exhaust gas emission label is affixed to the engine's integrated exhaust manifold and expansion tank assembly at the time of manufacture by Cummins MerCruiser Diesel. Please note that the exhaust gas emissions certification will not affect the fit, function, or performance of the engine. Neither boatbuilders nor dealers may remove the exhaust gas emission label or the part it is affixed to before sale. If modifications require the removal or cause damage to the exhaust gas emission label, contact Cummins MerCruiser Diesel about the availability of a replacement before proceeding.
IN THE UNITED STATES, THIS ENGINE IS CATEGORIZED AS A RECREATIONAL ENGINE UNDER 40 CFR PART 94.
INSTALLATION OF THIS ENGINE IN ANY NON-RECREATIONAL VESSEL IS A VIOLATION OF FEDERAL LAW SUBJECT TO PENALTY
4937335 25387
Exhaust gas emission label
OWNER RESPONSIBILITY Neither the owner nor operator is to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission levels to exceed their predetermined factory specifications.
Operation—Duty Cycle Duty Cycle Rating IMPORTANT: Damage caused by improper application or failure to operate the power package within the specified operating parameters will not be covered by the Cummins MerCruiser Diesel Limited Warranty. The boat manufacturer or the installing dealer is responsible for ensuring that the power package is applied in accordance with recommendations indicated in the appropriate Cummins MerCruiser Diesel applications manual. In all cases, the power package must be equipped with a gear ratio and propeller that allows the engine to operate at wide open throttle (WOT) at the rated engine RPM. The power package must also be applied Use of Cummins MerCruiser Diesel engines in applications other than those indicated by the following information or the appropriate application manual is not approved.
High Output Rating High Output Rating applies to variable load applications where full power is limited to one (1) hour out of every eight (8) hours of operation. Reduced load operation occurs when engine RPM is at least 200 RPM below the engine's maximum rated RPM for applications rated at or below 3000 RPM and at least 400 RPM below the engine's maximum rated RPM for applications rated above 3000 RPM. This rating is for pleasure (non‑revenue generating) applications that operate 500 hours or less per year. Page 1A-4
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General Information
Engine Break‑In 20‑Hour Break‑In Period IMPORTANT: The first 20 hours of operation are a break‑in period for the engine. Correct break‑in is essential to obtain minimum oil consumption and maximum engine performance. During this break‑in period, observe the following rules: • Do not operate below 1500 RPM for extended periods of time during the first 10 hours. Advance the throttle above 1500 RPM as soon as conditions permit safe operation. • Do not consistently operate at one speed for extended periods. • Do not exceed 3/4 throttle during the first 10 hours, during the next 10 hours do not operate at full throttle for more than five minutes at a time. • Do not accelerate at full‑throttle from idle speed. • Do not operate at full throttle until the engine reaches normal operating temperature. • High oil consumption is normal during the break‑in period. Frequently check the engine oil level.
After the 20‑Hour Break‑In Period To help extend the life of your power package, Cummins MerCruiser Diesel recommends: • Changing the engine oil and filter, and the transmission fluid on inboard models, at the interval indicated in the Maintenance Schedule. • •
Using a propeller that allows the engine to operate at the rated engine RPM when at full throttle with a maximum boat load. Operating at 3/4 throttle or lower. See the duty cycle information listed in Section 1A: Operation—Duty Cycle.
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Page 1A-5
Maintenance
Important Information
1
B
Section 1B - Maintenance
Table of Contents Maintenance Tools...........................................1B-4 Engine Specifications.......................................1B-3 Capacities........................................................1B-5 Fluid Specifications...................................1B-5 Engine.......................................................1B-5 Alpha Sterndrive Fluid Specifications.......1B-5 Bravo Serial Numbers Below 0W240000 ..................................................................1B-5 Bravo Serial Numbers Above 0W240000 ..................................................................1B-5 Power‑Assisted Steering and Power Trim Fluids........................................................1B-5 TM345 Transmission................................1B-6 Maintenance Intervals......................................1B-6 Maintenance Schedule—Sterndrive Models .........................................................................1B-6 Routine Maintenance................................1B-6 Scheduled Maintenance...........................1B-7 Maintenance Schedule—Inboard Models........1B-8 Routine Maintenance................................1B-8 Scheduled Maintenance...........................1B-8 QSD 2.0 External Engine Views....................1B-10 Front View...............................................1B-10 Starboard Side View...............................1B-11 Rear View...............................................1B-12 Port Side View........................................1B-13 Top View.................................................1B-14 Engine Oil......................................................1B-15 Specifications..........................................1B-15 Oil Level—Overfilled...............................1B-16 Checking.................................................1B-16 Filling......................................................1B-17 Changing Oil and Filter...........................1B-18 Technodrive Transmission Fluid....................1B-21 Checking.................................................1B-21 Filling......................................................1B-22 Changing................................................1B-22 Power‑Assisted Steering Fluid.......................1B-23 Checking.................................................1B-23 Filling......................................................1B-24 Changing................................................1B-24 Closed‑Cooling System.................................1B-25 Engine Coolant.......................................1B-25 Checking.................................................1B-25 Filling......................................................1B-26 90-866942 JANUARY 2008
Changing................................................1B-26 Draining the Closed Cooling System......1B-26 Filling the Closed Cooling System..........1B-28 Battery............................................................1B-29 Fuel System...................................................1B-30 Fuel Requirements.................................1B-30 Recommended Fuels..............................1B-30 Diesel Fuel In Cold Weather...................1B-31 Priming....................................................1B-31 Filling (Bleeding).....................................1B-31 Fuel Tank Cleaning and Flushing...........1B-31 Water‑Separating Fuel Filter..........................1B-32 Draining..................................................1B-32 Replacing................................................1B-33 Filling......................................................1B-36 Air Filter..........................................................1B-38 Removal..................................................1B-38 Inspection...............................................1B-38 Installation...............................................1B-38 Seawater Pump Inspection............................1B-39 Alpha Sterndrive Block‑off Plate.............1B-39 Sterndrive Seawater Pump Inspection. . .1B-40 Engine Seawater Pump Inspection.........1B-40 Seawater System...........................................1B-40 Alpha Sterndrive Block‑off Plate.............1B-40 Bravo Sterndrive Block‑off Plate.............1B-40 Draining the Seawater System...............1B-40 Alpha Sterndrive Water Inlets Check......1B-42 Bravo Sterndrive Water Inlets Check......1B-43 Checking the Seawater Pickups.............1B-44 Cleaning the Seawater Strainer..............1B-44 Flushing the Seawater System—Alpha Models....................................................1B-46 Flushing the Seawater System—Bravo Models....................................................1B-48 Corrosion Protection–General........................1B-50 Engine Corrosion Protection Components ................................................................1B-50 Sterndrive Corrosion Protection Components ................................................................1B-53 MerCathode............................................1B-55 Painting Your Power Package................1B-55 Corrosion Protection, Alpha Sterndrive..........1B-56 General Information................................1B-56 Page 1B-1
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Maintenance
Alpha Sterndrive Continuity Circuit Inspection .................................................................1B-56 Corrosion Protection, Bravo Sterndrive...........1B-56 General Information.................................1B-56 Continuity Circuit—Bravo Sterndrive.......1B-57 Lubrication.......................................................1B-60 Steering System.......................................1B-60 Throttle Cable..........................................1B-61 Shift Cable...............................................1B-62 Transom Assembly..................................1B-62 Engine Coupler........................................1B-62 Sterndrive U‑joint Cross Bearings and Shaft Splines (Sterndrive Unit Removed)..........1B-63 Propeller Shaft.........................................1B-64 Maintaining Torques........................................1B-64 Transom Gimbal Ring Clamp Bolt...........1B-64 Engine Mounts.........................................1B-65 Electrical System.............................................1B-65 QSD 2.0 Drive Belts........................................1B-65 Power Assisted Steering Pump Belt–Sterndrive Only.................................................................1B-66
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Inspection.................................................1B-66 Driveshaft Extension Models...................1B-67 Adjustment...............................................1B-67 Removal...................................................1B-68 Installation................................................1B-68 Serpentine Belt................................................1B-70 Inspection.................................................1B-70 Adjustment...............................................1B-71 Removal...................................................1B-71 Installation................................................1B-72 Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage......................1B-74 Cold Weather (Freezing Temperature) Storage .................................................................1B-75 Preparing Your Power Package for Seasonal or Extended Storage....................................1B-75 Seasonal Storage Instructions.................1B-76 Extended Storage Instructions.................1B-77 Battery......................................................1B-77 Recommissioning.....................................1B-78
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Maintenance
Engine Specifications Specifications
Description
QSD 2.0
Engine type
In‑line 4‑cylinder diesel
Induction Type
Turbocharged and aftercooled 16‑Valve
Displacement
2.0 L (122 c.i.d.)
Firing order
1, 3, 4, 2
Bore
83 mm (3.700 in.)
Stroke
92 mm (3.622 in.)
Rated engine RPM (see Conditions Affecting Operation— Refer to CMD's Marine Performance Curves Propeller Selection for additional information). And Data Sheet (www.cmdmarine.com) Idle RPM in neutral (engine at normal operating temperature).
700 RPM
Oil pressure at idle
240kPa, (2.4 bar), (35 psi)
Oil pressure at 4000 RPM
660kPa, (6.6 bar), (95 psi)
Thermostats (water)
83° C (181° F)
Thermostats (oil)
95° C (203° F)
Coolant temperature
80–85° C (176–185° F)
Electrical system
12‑volt negative (–) ground
Alternator rating
14#, 110 A
Recommended battery rating
750 CCA, 950 MCA, or 180 Ah
Lubricant, Sealant, Adhesives Tube Ref No.
Description Cleaning solvent
28
Dexron III Automatic Transmission Fluid
34
Special Lubricant 101
42
80
91
Part No. Obtain Locally
Power-assisted steering system
Obtain Locally
Steering cable grease fitting Steering cable Gimbal bearing grease insert U-joint and Gimbal Transom end grease fitting, engine end grease fitting, Bearing Grease driveshaft grease fittings Transmission filter element O-ring Water-separating fuel filter sealing ring SAE engine oil 30W Throttle cable pivot points and guide contact surfaces Shift cable pivot points and guide contact surfaces Coupler Engine Coupler Spline Grease Driveshaft splines
114
Power Trim and Steering Fluid
121
15W40 4-cycle Diesel Engine Oil
123
Marine Engine Coolant (Only available in Europe)
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Where Used Transmission filter element Closed cooling system Gray sterndrive U-joint cross bearings on Bravo X Sterndrive units
92-802865Q02 92-802870A1
Obtain Locally
92-802869A 1
Power-assisted steering pump
92-858074K01
Engine crankcase Oil filter O-rings
92-858042K01
Closed cooling system
92-813054A2
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Maintenance
Special Tools Flushing Device
91‑44357Q 2
Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.
9192
Dual Water Pick‑up Flush Gearcase Seal Kit
91‑881150K 1
Blocks off the front water inlet holes on the dual water inlet gearcases. 9194
Crankcase oil pump
91‑90265A 5
Aids in the removal of engine oil without draining the crankcase.
11591
Reference Electrode
91‑76675T 1
Senses and electrical current in the water when testing the MerCathode system. Use to check hull potential. 9188
Maintenance Tools Part Number
Description Water supply hose adapter (to Water Inlet Fitting)
Obtain Locally
Hand‑operated grease gun
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Flushing Device
91‑44357Q 2
Dual Water Pick‑up Flush Gearcase Seal Kit
91‑881150K 1
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Maintenance
Capacities Fluid Specifications IMPORTANT: All capacities are approximate fluid measures.
Engine IMPORTANT: If necessary, adjust fluid levels depending on installation angle, heat exchanger, and fluid lines used. Always check the proper indicator to determine the exact quantity of oil or fluid required.
QSD 2.0 All Models Engine oil (with filter)
Closed cooling system
System Capacity
Fluid Type
Part Number
6.00 L (6.30 US qt.)
15W40 4‑cycle Diesel Engine Oil
92‑877695K1
Marine Engine Coolant (Only available in Europe)
92‑813054A2
Fleetguard Compleat with DCA4 Fleetguard Part Number: CC2825 Container size: 3.75 liter (1.00 gal.)
Obtain locally
7.50 L (8.00 US qt.)
Alpha Sterndrive Fluid Specifications NOTE: Oil capacity includes gear lube monitor. Model
Capacity
Fluid Type
Alpha One
1892 ml (64 oz)
High Performance Gear Lubricant
Bravo Serial Numbers Below 0W240000 NOTE: Oil capacity includes gear lube monitor. Models
Capacity
Bravo One
2602 ml (88 fl oz)
Bravo Two
3076 ml (104 fl oz)
Bravo Three
2839 ml (96 fl oz)
Fluid Type High performance gear lubricant
Bravo Serial Numbers Above 0W240000 NOTE: Oil capacity includes gear lube monitor. Models
Capacity
Bravo One
2736 ml (92.5 fl oz)
Bravo Two
3209 ml (108.5 fl oz)
Bravo Three
Side water pick‑up
2972 ml (100.5 fl oz)
Dual water pick‑up
2736 ml (92.5 oz)
Fluid Type High performance gear lubricant
Power‑Assisted Steering and Power Trim Fluids APPROVED POWER-ASSISTED STEERING FLUIDS Description Power Trim and Steering Fluid
Part Number 92‑858074K01
APPROVED POWER TRIM FLUIDS Description Power Trim and Steering Fluid
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Part Number 92‑858074K01
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Maintenance Description
Part Number
SAE Engine Oil 10W‑30
Obtain locally
SAE Engine Oil 10W‑40
TM345 Transmission NOTE: Capacities are for the transmission only and do not include the fluid cooler or fluid cooler hose capacities. Model
Capacity
Technodrive TM345
Fluid type
1.6 liters (2.7 qt.)
Class CD SAE 20 or Class CD SAE 30 engine oil
Part Number Obtain Locally
Maintenance Intervals NOTE: Refer to appropriate Mercury MerCruiser Sterndrive Service Manual for information and procedures on Sterndrive Maintenance.
! WARNING Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components. Maintenance intervals and the corresponding tasks, as shown in this schedule or found in a previous schedule, are based on an average boating application and environment. However, factors such as individual operating habits and personal maintenance preferences can impact the suggested intervals. In consideration of these factors, Cummins MerCruiser Diesel has adjusted some maintenance intervals and corresponding tasks. In some cases, more tasks are scheduled to be performed in a single visit to the servicing facility. Therefore, the boat owner and servicing dealer should discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide with individual operating habits, operating environments, and maintenance requirements. Always disconnect battery cables from the battery before working around electrical system components to prevent injury to yourself and damage to the electrical system should a wire be accidentally shorted.
Maintenance Schedule—Sterndrive Models Routine Maintenance NOTE: Perform only the maintenance tasks that apply to your particular power package. Task Interval
Each day start
Each day end
Page 1B-6
Maintenance to Be Performed •
Check the engine oil level. (You may extend this interval based on operator experience with the product.)
•
Check the engine coolant level.
•
Check the power‑assisted steering fluid level.
•
Check the sterndrive gear lube level in the gear lube monitor.
•
If operating in saltwater, brackish water, or polluted water, flush the seawater section of the cooling system after each use.
•
Drain any water from the primary fuel filter after each use. (Drain all water from both fuel filters if operating in freezing temperatures.)
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