Mercury Mercruiser Sterndrives D1.7L DTI In-Line Diesel 2000 2001 2002 2003 2004 2005 Factory Service Repair Manual + Wirings

Mercury Mercruiser Sterndrives D1.7L DTI In-Line Diesel 2000 2001 2002 2003 2004 2005 Factory Service Repair Manual + Wirings

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Mercury. 

537  Pages

MODEL YEAR:

2000, 2001, 2002, 2003, 2004, 2005

MODELS COVER:

D1.7L DTI        Serial.: OM055001 and Above

MANUAL COVERS:

SECTION 1 – Important Information

A – General Information

B – Maintenance

C – Troubleshooting

SECTION 2 – Removal and Installation

A – MCM (Sterndrive) Models

SECTION 3 – Engine

A – D1.7L DTI Engine Mechanical

SECTION 4 – Electrical System

A – Starting System

B – Charging System

C – Glow Plug System

D – Instrumentation

E – Wiring Diagrams

SECTION 5 – Fuel System

A – Fuel Filter

B – Fuel Injectors

C – Injection Pump

SECTION 6 – Cooling System

A – Closed Cooling

SECTION 7 – Intake and Exhaust System

A – Intercooler

B – Exhaust

C – Turbocharger

SECTION 8

A – Power Steering System

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

• Engine displacement: 1.7L (103 cubic inches).
• Cylinders: In-line 4-cylinder.
• Valves: 16 valves, DOHC (dual overhead camshafts).
• Power output: 120 horsepower (crankshaft-rated) at 4,400 rpm.
• Fuel system: Direct injection with a Bosch VE pump.
• Cooling: Closed circuit cooling (heat exchanger) to reduce corrosion.
• Aspiration: Turbocharged and intercooled. 

• Lightweight construction: The engine features a cast iron block and an alloy cylinder head. Its lighter weight, compared to petrol options of the time, helped to improve the planing efficiency of smaller boats.
• Efficient planing: The engine’s low-end power helped get boats onto a clean plane more quickly and maintain that plane at lower speeds, boosting fuel efficiency.
• Compact size: The D1.7L DTI is relatively compact, allowing for more space in the engine compartment.
• Emission compliance: With its turbo and intercooler, the engine met IMO (International Maritime Organization) diesel exhaust emission standards at the time. 

• Reliability concerns: According to JustAnswer, the Cummins-Mercruiser 1.7L engines of this era have faced some reliability issues and reports of frequent failures, particularly in the fuel system and turbocharger.
• Manufacturer support: For repairs, some sources indicate that manufacturer support may be limited due to the age of the engines. Sourcing quality replacement parts can also be a challenge.
• Corrosion and mounting: The engines may be susceptible to corrosion and mounting alignment issues, which can affect the performance of the outdrive.
• Diesel noise: As with many direct-injected diesels, the engine can produce a distinct “rattle” at lower RPMs, though it tends to quiet down at higher speeds.