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

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Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your MERCURY. Read and print pages, or copy the entire manual to your hard drive.

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SKU: N/A Categories: Watercrafts/Boats, Mercury

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

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Mercury. Read and print pages, or copy the entire manual to your hard drive.

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

The Mercury MerCruiser D1.7L DTI is a 1.7-liter inline-four, 16-valve turbocharged and intercooled direct-injected diesel engine. Based on an Isuzu design, this engine was paired with a Mercury Alpha drive and was offered during the 2000–2005 model years.

Engine specifications

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.

Design and performance characteristics

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.

Potential issues and considerations

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.