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1997-2002 MerCruiser D2.8L & D4.2L Diesel Repair Manual

This INSTANT DOWNLOAD 1997 1998 1999 2000 2001 2002 MerCruiser D2.8L D-Tronic & D4.2L D-Tronic in-line diesel engine service manual #22 was prepared primarily for professional technicians. However, adequate data is given for the majority of do-it-yourself mechanics and those performing repairs and maintenance procedures to your MerCruiser. This 1997-2002 MerCruiser repair manual was prepared to suite the needs of individuals who poses basic knowledge in electrical and mechanical concepts. For those without basic knowledge, you should avoid performing complicated repairs to the 1997-2002 MerCruiser equipment as it may render it unsafe. In any case, never attempt to service the 1997-2002 MerCruiser without the aid of a repair manual.


Sterndrive (MCM)

D2.8L D-Tronic - serial numbers 0K000001 and Above
D4.2L D-Tronic - serial numbers 0K000001 and Above

Inboard (MIE)

D2.8L D-Tronic - serial numbers 0k000001 and Above
D4.2L D-Tronic - serial numbers 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

This 1997-2002 MerCruiser manual will guide you through fundamentals of maintaining and repairing, step-by-step, to teach you what the factory trained technicians already know by heart. By applying the knowledge in this 1997-2002 MerCruiser repair manual, any owner should be able to make the right decisions about what they need to do to maintain and repair the 1997-2002 MerCruiser.

This 1997-2002 MerCruiser manual covers all aspects of repair. The manual covers part removal, disassembly, cleaning, assembly, installation procedures and much more. The manual contains all necessary illustrations, diagrams and specifications to guide the mechanic through any repair procedure. The 1997-2002 MerCruiser manual also contains an advanced troubleshooting guide to help diagnose and correct any problem.


Q. How do I obtain this manual?
A. Simply click on the download button, complete the payment and a download link is sent to your computer in seconds FOR INSTANT DOWNLOAD.

Q. Once I download the repair manual how long do I have access to the manual?
A. Once you download the manual you can store it on your computer forever and refer to it when maintenance and repair is necessary.

Q. How does the manual appear?
A. Once the manual has been downloaded it appears exactly the same as a repair manual you'd buy in stores. It includes every aspect of repair, step-by-step repair procedures, pictures, illustrations, diagrams, troubleshooting and specifications.

Q. Is the repair manual model and year specific?
A. YES! This is not a generic manual.

Q. Does my computer need special software to view the manual?
A. Your computer wont need any special software to view the manual. It is a simple PDF manual. All computers come with the necessary software already installed from the manufacture to view the manual.

Q. Will the download hurt my computer?
A. NO! This manual is 100 percent safe to download!
File Data

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File Size 12 megabytes
File Type PDF
Customer Rating
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