Mercury Diesel 3.0L TDI Tier III Reference manual

Mercury Diesel
Service Bulletin
Bulletin No. 2014-68
OEM No. 2014-66
Circulate to: Sales Manager Accounting Service Manager Technician Parts Manager
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
2014-68 NOVEMBER 2014 © 2015 Mercury Marine Page 1 / 12
Official Recall Notification United States Federal Boat Safety Act
—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
Models Affected
Models Covered Serial Number
Mercury Diesel 3.0L TDI Tier III engines All
Scope
Worldwide
Situation
Mercury Diesel has identified a situation whereby the oil supply line to the turbocharger could loosen. This issue may affect all
engines, regardless of engine run‑time or service history. Loosening of the oil supply line can allow engine oil to leak onto hot
engine components and can cause an odor, smoke, and possibly a fire.
Inspection
Engines reworked by the factory or by an authorized dealer will have a mark indicating that the rework has been performed.
With the engine removed from the shipping container, or installed in a boat the rework identification will be a green dot placed
to the left of the serial number decal.
57251
Green dot showing that rework has been performed

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
Page 2 / 12 © 2015 Mercury Marine NOVEMBER 2014 2014-68
Solution
1. Order 8M0100488.
57371
ab
c
d
d
e
f
g
h
8M0100488 Oil line kit
Ref. Qty. Description
a 1 Replacement oil line
b 1 Oil filter canister protective cover
c 1 Oil line port protective plug
d 2 Seals
e 1 O‑ring
f 1 Banjo bolt
g 1 Oil line flange retention screw
h 1 Screw for antirotation bracket
NS 1 Oil filter
NOTICE
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage
the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.
2. Disconnect the engine's starting battery.

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
2014-68 NOVEMBER 2014 © 2015 Mercury Marine Page 3 / 12
3. Remove the engine cover.
Component locations
a - Oil filter, shown capped (refer to following steps)
b - Turbocharger oil line
c - Fuel metering valve connector
d - Oil line retainer flange and retaining screw (not
visible, but located beneath fuel lines)
e - Turbocharger oil line banjo bolt
f - Antirotation screw
4. Remove the banjo bolt securing the oil supply line to the turbocharger.
57252
Banjo bolt being removed
57351
a
b
b
c
d
e
f

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
Page 4 / 12 © 2015 Mercury Marine NOVEMBER 2014 2014-68
5. Disconnect the fuel metering valve connector, and secure the connector out of the way.
57254
Fuel metering valve connector
6. Remove the T30 screw, which secures the oil supply line retaining flange to the cylinder block.
57257
Remove the T30 screw from the oil supply line retaining flange
7. Remove the engine oil filter.

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
2014-68 NOVEMBER 2014 © 2015 Mercury Marine Page 5 / 12
8. Cap the engine oil filter canister with the cap supplied in the kit.
57259
Oil filter canister capped
9. Remove the fuel line and return fuel line from the fuel line retainer, and spread the lines apart.
57260
Remove the fuel lines from the retainer
57350
Spread the fuel lines apart to gain access to the oil supply line

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
Page 6 / 12 © 2015 Mercury Marine NOVEMBER 2014 2014-68
10. Remove the turbocharger oil supply line from the cylinder block.
a. To protect the engine from contamination by dirt or paint particles when installing the new line, a plug is included in
the kit to close off the port. Using a flexible claw pickup tool, insert the supplied plug into the oil line port, as shown as
soon as the oil line has been moved sufficiently out of the way.
57365
Oil line port with components removed for clarity
57364
Plug being lowered

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
2014-68 NOVEMBER 2014 © 2015 Mercury Marine Page 7 / 12
b. As you are picking the line straight up, begin to rotate the line at the top of the oil supply line towards the middle of the
engine.
57361
c. This rotation and lifting will place the flange of the oil supply line even with the top of the oil filter canister and the main
fuel supply line. Some manipulation of the fuel supply line may be needed during this step.
57362
11. Remove the oil supply line from the engine by maneuvering the flange of the oil supply line between the oil filter canister,
injection pump, and fuel supply lines.
57363

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
Page 8 / 12 © 2015 Mercury Marine NOVEMBER 2014 2014-68
12. Assemble the new oil supply O‑ring onto the new oil supply line. Do not apply oil to the O‑ring. Doing so may introduce
contaminants.
57264
O-ring installed on oil line
13. Reinstall the oil supply line onto the engine. As with removal of the old line, it may be necessary to rotate the line during
installation. Install the oil supply line from the engine by maneuvering the flange of the oil supply line between the oil filter
canister, injection pump, and fuel supply lines.
IMPORTANT: Do not remove the oil port plug until it is necessary to attach the oil line. Contaminants may have been
loosened while maneuvering the oil line.
a - Mechanical fingers maintaining position of port plug
while the oil line is being maneuvered
b - Turbocharger oil line being installed
14. Using the mechanical fingers, secure the oil line flange to the engine with the retained screw. Hand‑tighten the screw.
57369
b
b
a
57366

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
2014-68 NOVEMBER 2014 © 2015 Mercury Marine Page 9 / 12
15. Install a new banjo bolt with washers, and hand‑tighten it.
57265
16. Install the M6 antirotation fastener, and hand‑tighten it.
57372
Antirotation screw
17. Tighten the screw to secure the oil supply line flange to the cylinder block to the specified torque.

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
Page 10 / 12 © 2015 Mercury Marine NOVEMBER 2014 2014-68
Description Nm lb‑in. lb‑ft
Screw to secure oil supply line flange 10 88.5 –
57370
18. Tighten the banjo bolt to the specified torque.
Description Nm lb‑in. lb‑ft
Banjo bolt 20 177 –
57269
19. Tighten the M6 antirotation fastener to the specified torque.

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
2014-68 NOVEMBER 2014 © 2015 Mercury Marine Page 11 / 12
Description Nm lb‑in. lb‑ft
M6 antirotation fastener 10 88.5 –
57367
20. Reconnect the fuel line retainer.
57270
21. Install a new engine oil filter, and tighten the cap to the specified torque.

Official Recall Notification United States Federal Boat Safety Act—Mercury Diesel 3.0L Tier III Turbocharger Oil Supply Line
Update
THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.
This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.
Page 12 / 12 © 2015 Mercury Marine NOVEMBER 2014 2014-68
Description Nm lb‑in. lb‑ft
Engine oil filter cap 35 – 26
57271
22. Reconnect the fuel metering valve connector.
23. Drain the engine oil, and refill the sump with specified engine oil.
! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage
the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.
24. Reconnect the battery. Refer to your service guide for the proper procedure.
25. Test run to check for engine oil leaks.
26. Mark the engine with a green paint dot to indicate that the new oil line has been installed.
27. Reinstall the engine cover.
Owner Notification
A letter will be sent to every registered owner of an affected product. The letter will advise the owner to contact any Mercury
Diesel dealer for the repair. As a selling or servicing dealer, you should also contact your customers to make them aware of this
recall and to schedule an appointment for this repair. A copy of the letter is included with this service bulletin for your reference.
Parts Required
Qty. Description Part Number
1 Oil line kit 8M0100488
Warranty
United States and Canada: Mercury Marine will credit the dealer for the cost of parts and labor. Submit a warranty claim
through your normal warranty‑processing channel, listing:
• Engine serial number
• Labor: 1.5 hour
• Warranty flat rate code: SB10 and SB05
• Qty. 1, Oil line kit ‑ P/N 8M0100488
• Part code: 361
• Fail code: 00
Outside the United States and Canada: Follow instructions issued by your local office or by your distributor.

Official Notification of Federal Boat Safety Act Recall
Dear Customer,
Thank you for the purchase of your Mercury Diesel power package.
Mercury Diesel is dedicated to providing superior product reliability and
customer satisfaction. As part of our commitment to superior customer
satisfaction we have determined that your power package must be recalled
under the Federal Boat Safety Act so an update can be performed.
What is the condition?
Your power packagemust have the turbocharger oil supply line updated. A
loose connection on the oil supply line to the turbocharger may allow
engine oil to come in contact with hot engine components. This may cause
an odor, smoke, and possibly a fire.
What will Mercury Marine do?
We have provided instructions to our dealers on the upgrade to be
performed to these engines. This update will be performed at no charge to
you.
What should you do?
Contact your Mercury Diesel dealer to arrange a service appointment. When
scheduling your service appointment, mention Mercury Diesel Service
Bulletin 2014-68.
Please present this notice to your Mercury Diesel dealer when you bring
your vessel in for servicing.
What if you have other questions or if you no longer own this engine?
Please contact your Mercury Diesel dealer or call Mercury Diesel Customer
Service at 920-929-5040 between 7:30 am and 5:30 pm CST.
We have sent this notice in the interest of your continued satisfaction with
our product, and we sincerely regret any inconvenience this may cause you.
Thank you for boating with Mercury Marine.
Mercury Marine Service