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Mercury D4.2L Manual

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CA741
The product you have purchased comes with a limited warranty from Mercury Marine; the
terms of the warranty are set forth in the Warranty Sections of this manual. The warranty state-
ment contains a description of what is covered, what is not covered, the duration of coverage,
how to best obtain warranty coverage, important disclaimers and limitations of damages,
and other related information. Please review this important information.
CE344
The operator (driver) is responsible for the correct and safe operation of the boat, the
equipment aboard and the safety of all occupants aboard. We strongly recommend
that the operator read this Operation, Maintenance and Warranty Manual and
thoroughly understand the operational instructions for the power package and all
related accessories before the boat is used.
Diesel engine exhaust and some of its constituents are known to the state of
California to cause cancer, birth defects, and other reproductive harm.
The description and specifications contained herein were in effect at the time this guide was
approved for printing. Mercury Marine, whose policy is one of continuous improvement,
reserves the right to discontinue models at any time, or to change specifications or designs,
without notice and without incurring obligation.
1999, Mercury Marine
The following are registered trademarks of Brunswick Corporation:
Autoblend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser,
Mercury, Mercury Marine, Quicksilver, Ride-Guide, and Thruster.
Warranty Message
WARNING
WARNING
CALIFORNIA
PROPOSITION 65 WARNING
Mercury Marine Fond du Lac, Wisconsin, U.S.A.
Printed in U.S.A.

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Summary of Contents for Mercury D4.2L

  • Page 1: Page Warranty Message

    CA741 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty state- ment contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.

  • Page 2: Welcome

    CA753 WELCOME! You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.

  • Page 3: Identification Record

    CD474 Identification Record Please record the following information: Engine Model and Horsepower Engine Serial Number Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number Transmission Model (Inboard) Gear Ratio Transmission Serial Number Propeller Number Pitch Diameter Hull Identification Number (HIN) Purchase Date Boat Manufacturer Boat Model...

  • Page 4: Table Of Contents

    CD673 TABLE OF CONTENTS Page Warranty Message ............... . WELCOME! .
  • Page 5 ................Starting, Shifting and Stopping - D3.6L, D4.2L and D4.2L LD .

  • Page 6: Warranty Information

    CD54 Warranty Information CD55 Owner Warranty Registration UNITED STATES AND CANADA ONLY • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product. •...

  • Page 7: International Owner Registration

    CD56 International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim pro- gram for your area.

  • Page 8: Mercruiser Diesel Limited Warranty

    To validate the warranty, the “Warranty Registration Card”, included with each Product, must be prop- III. erly completed by the selling dealer and forwarded immediately after the sale to Mercury Marine (U.S.A. and Canada) or to a Marine Power International Branch, or Distributor Service Office (outside the U.S.A.
  • Page 9 Our sole and exclusive obligation under this warranty shall be limited to repairing a defective part or, at our option, refunding the purchase price or replacing such part or parts with new or Mercury certified remanufactured parts as shall be necessary to remedy any malfunction resulting from defects in mate- rial or workmanship as covered by this warranty.

  • Page 10: Warranty Coverage And Exclusion

    CD622 Warranty Coverage and Exclusion Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in mate- rial and workmanship. Installation errors, accidents normal wear and a variety of other causes that affect the product are not covered.

  • Page 11: Transferable Warranty

    • There is no charge for this service. Outside the United States and Canada, please contact the closest Mercury Marine Service Office, or the closest distributor in your country, for the transferable warranty procedure that would apply to you.
  • Page 12 CD594 THIS PAGE IS INTENTIONALLY BLANK...

  • Page 13: Read This Manual Thoroughly

    WARNING The use of accessories not manufactured or sold by Mercury Marine is not recommended for use with your MerCruiser unit. If your MerCruiser unit is equipped with an accessory not manufactured by Mercury Marine, be sure to read the Operation and Maintenance Manual for the accessory before operation.

  • Page 14: General Information

    CA619 General Information Lanyard Stop Switch 74608 The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from the operator’s position (as in accidental ejection from the operator’s position) to activate the switch. Some remote control units are equipped with a lanyard stop switch.
  • Page 15 While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut-down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat’s path as seriously as the boat would when under power.
  • Page 16 CA641 Courtesy of ABYC CA642 Courtesy of ABYC...

  • Page 17: Exhaust Emissions

    CA620 Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories.

  • Page 18: Wave And Wake Jumping

    CD543 Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re-enters the water.

  • Page 19: Impact With Underwater Hazards

    CD604 Impact With Underwater Hazards Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the sterndrive or the boat bot- tom.

  • Page 20: Safe Boating Suggestions

    CA476 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course.

  • Page 21: Protecting People In The Water

    For additional information, obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-849250--1) from your dealer, distributor, or Mercury Marine.

  • Page 22: Conditions Affecting Operation

    Conditions Affecting Operation Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: A. Shifting weight to rear (stern) will: • Generally increases speed and engine RPM. • At extremes, can cause boat to porpoise. •...

  • Page 23: Propeller Selection

    Engine Specified Operating Rpm Range (Begins At: ) D3.6L 3600-3800 3830± 20 D4.2L 3400-3600 3630± 20 D4.2L LD 3400-3600 3650± 50 D2.8L D-Tronic ± 3600-3800 3875± 50 D4.2L D-Tronic Select a propeller that will allow the engine power package to operate at or near the top end of the recommended wide-open-throttle operating rpm range with a normal load.

  • Page 24: How Elevation And Climate Affect Performance

    CD476 How Elevation And Climate Affect Performance NOTE: Engines equipped with EDI (D-Tronic engines) reduce the effects of changes in elevation and climate by automatically adjusting fuel flow for weather conditions and elevation. EDI engines however, do not compen- sate for increased loading or hull conditions. Generally, elevation has a very noticeable effect on the wide-open-throttle power of an engine.

  • Page 25: Important Information

    PLEASURE DUTY RATING • Engine Specified Operating rpm Range Model D4.2L and D4.2L LD 3400-3600 D3.6L, D2.8L D-Tronic, D4.2L D-Tronic 3600-3800 • Wide-Open-Throttle operation is limited to short periods of time. LIGHT DUTY RATING • Engine Specified Operating rpm Range Model D4.2L and D4.2L LD...
  • Page 26 CD478 OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks, ensure that all lubrication and maintenance instruc- tions are complied with for safe operation, and return the unit to an Authorized MerCruiser Dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.

  • Page 27: Freezing Temperature And Cold Weather Operation

    Freezing Temperature And Cold Weather Operation IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to prevent freezing damage to power package. Refer to the following and to “Cold Weather or Extended Storage” for related information and draining instructions. CAUTION Seawater (raw water) section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use, if the possibility of freezing temperatures exist.

  • Page 28: Launching And Boat Operation Care

    Stolen Power Package If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors.

  • Page 29: Do-It-Yourself Maintenance Suggestions

    CA772 Do-It-Yourself Maintenance Suggestions If you are one of those persons who likes to do-it-yourself, here are some suggestions for you. • Present-day marine equipment, such as your MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.

  • Page 30: Diagnosing Edi Problems (If So Equipped)

    CD329 Diagnosing EDI Problems (If So Equipped) Your Authorized MerCruiser Dealer has the proper service tools for diagnosing problems on Electronic Diesel Injection (EDI) Systems. The Electronic Control Module (ECM) on these engines have the ability to detect some problems with the system when they occur, and store a “Trouble Code” in the ECM’s memory. This code can then be read later by a service technician using a special diagnostic tool.

  • Page 31: Engine Break-In

    On D2.8L D-Tronic and D4.2L D-Tronic Engines: Proceed to Step 2. b. On D3.6L, D4.2L and D4.2L LD Engines Only: After a lengthy layup (several months or more) pre-lu- bricate the turbocharger and engine. To do this, hold the STOP switch toggle lever DOWN while you simulta- neously turn the key switch to START position for 15 seconds.

  • Page 32: Sterndrive Unit 10-Hour Break-In Period

    CD608 Sterndrive Unit 10-Hour Break-In Period It is especially important that the following procedure be used on new sterndrive units. This break-in procedure allows the proper seating of drive unit gears and related components, which greatly reduces the likelihood of problems.
  • Page 33 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 34 CD334 71856 71856 71856 72753 71856 73546 71856 71886 73547 71772...

  • Page 35: Operation

    NOTE: Key can only be removed in the OFF position. D3.6L, D4.2L and D4.2L LD - If engine is running the key switch cannot be used to stop engine. The engine can only be stopped by using the Engine Stop Switch, while the Key Switch is in the RUN position. No electri- cal circuit is operational when the key switch is turned to the OFF position.
  • Page 36 The light stays on until the preheat period is complete. The timed preheat period begins when the key switch is turned on, and then, only when the engine is cold. On D3.6L and D4.2L models, the engine can be started only after the light goes out.

  • Page 37: Electrical System Overload Protection

    CD636 74703 71630 73546 22444 CD495 Electrical System Overload Protection lf an electrical overload occurs, a fuse will blow or a circuit breaker will trip open. IMPORTANT: The cause must be found and corrected before replacing fuse or resetting circuit breaker. Two 60 amp circuit breakers provide protection for engine wiring harness and instrumentation power lead.
  • Page 38 CD197...

  • Page 39: Remote Controls

    CD195 Remote Controls (Panel Mounted)  Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown.
  • Page 40 CD552 71339 70537...
  • Page 41 CD217 Remote Controls (Two Lever)  Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown.
  • Page 42 CD553 ° 3 - 5...

  • Page 43: Power Trim

    CA35 Power Trim  The Power Trim system allows operator to raise and lower drive unit for trailering, beaching, launching and shallow water operation. Power Trim also allows operator to adjust drive unit angle, while underway, to provide ideal boat angle for varying load and water conditions. In most cases, best overall performance is obtained with drive unit adjusted so boat will run at a 3°...
  • Page 44 CD199 73976 73977...
  • Page 45 CB188 POWER TRIM OPERATION - PANEL MOUNT REMOTE CONTROL IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an inter- nal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute.
  • Page 46 CD200 73979 73978 70540 70540 70540...
  • Page 47 CA627 POWER TRIM OPERATION - DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL (TWO BUTTON AND THREE BUTTON VERSIONS) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an inter- nal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute.
  • Page 48 CD599 71386 76378...

  • Page 49: Starting, Shifting And Stopping - D3.6L, D4.2L And D4.2L Ld

    Cold Start Assist: On D3.6L and D4.2L models, a Cold Start Lever located on the injection pump is used to aid in starting when the temperature is below 50° F (10° C). This is done by moving lever in direction shown. Lever should be reset as soon as engine starts and idles smoothly.
  • Page 50 On D3.6L and D4.2L only, set “Cold Start Lever” if temperature is below 50° F (10° C). After a lengthy layup (several months or more) pre-lubricate the turbocharger and engine. To do this, hold the STOP switch toggle lever DOWN while you simultaneously turn the key switch to START position for 15 se- conds.
  • Page 51 CD340 STARTING WARM ENGINE Turn on and run engine compartment bilge blower for five minutes (if so equipped). Or, open engine hatch to air out bilge before attempting to start engine(s). Turn key switch to the RUN position. Turn key switch to START position and release when engine fires. Check to ensure charge indicator and oil pressure warning lamps go out.

  • Page 52: Operation Chart - D3.6L, D4.2L And D4.2L Ld

    CD630 Operation Chart D3.6L, D4.2L and D4.2L LD STARTING AFTER WHILE STOPPING & PROCEDURE STARTING UNDERWAY SHUT DOWN Observe all gauges and Frequently observe all Shift remote control lever Open engine hatch. Air warning lights to check gauges and indicator to neutral position.

  • Page 53: Starting, Shifting And Stopping - D2.8L D-Tronic And D4.2L D-Tronic

    • Check the air cleaner for proper installation of filter element. Check all items listed in the Maintenance Schedules and Operation Chart - D2.8L D-Tronic and D4.2L D-Tron- ic (refer to “Table Of Contents”). Perform any other necessary checks, as indicated by your dealer, or specified in your boat owner’s manual.
  • Page 54 CE298 STARTING COLD ENGINE IMPORTANT: Always check all fluid levels before starting engine. Refer to Maintenance Chart. Turn on and run engine compartment bilge blower (if so equipped) for five minutes. Or, open engine hatch to air out bilge before attempting to start engine(s). If engine has not been run for a period of time and will not readily start with the standard starting procedure, there is a hand pump/primer knob located on the fuel filter header.
  • Page 55 CE32 STARTING WARM ENGINE Turn on and run engine compartment bilge blower for five minutes (if so equipped). Or, open engine hatch to air out bilge before attempting to start engine(s). Turn key switch to the RUN position. Check to ensure glow plug preheat lamp is not illuminated. Turn key switch to the START position and release when engine fires.

  • Page 56: Operation Chart - D2.8L D-Tronic And D4.2L D-Tronic

    CD346 Operation Chart - D2.8L D-Tronic and D4.2L D-Tronic STARTING AFTER WHILE STOPPING & PROCEDURE STARTING UNDERWAY SHUT DOWN Observe all gauges and Frequently observe all Open engine hatch. Air Shift remote control le- warning lights to check gauges and indicator out bilge completely.

  • Page 57: Specifications

    Specifications CD11 Seacock Seacock (water inlet valve) used, must have an internal cross-sectional area equal to or greater than hose to prevent restricting water flow. A 1-1/2 in. (38mm) brass ball or gate valve is minimum required. Seacock should be installed in an area where it is easily accessible and supported adequately to prevent hose fatigue.

  • Page 58: Fuel Requirements

    CD164 Fuel Requirements WARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury.

  • Page 59: Diesel Fuel In Cold Weather

    We strongly recommend the use of QUICKSILVER 4-Cycle Marine Engine Oil, a specially blended 25W-40 SH, CF/CF-2 oil with Marine Additives, for all temperature operations. The following oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W-40 oil.

  • Page 60: Engine Specifications

    CD633 Engine Specifications D3.6L AND D4.2L Specification - Sterndrive (MCM) Description D3.6L D4.2L Crankshaft Horsepower (Kilowatts) 180 (134) 220 (164) Propeller Shaft Horsepower (Kilowatts) 170 (127) 200 (149) Engine Type In-Line 6 Cylinder Diesel Displacement 219 cu. in. ( 3.6 L ) 254 cu.
  • Page 61 CD634 D2.8L D-TRONIC AND D4.2L D-TRONIC Specification - Sterndrive (MCM) Description D2.8L D-Tronic D4.2L D-Tronic Crankshaft Horsepower (Kilowatts) 165 ( 123 ) 250 ( 186 ) Propeller Shaft Horsepower (Kilowatts) 150 ( 112 ) 225 ( 168 ) In-Line 4 Cylinder...
  • Page 62 CD635 D4.2L LD Specification - Sterndrive (MCM) Description D4.2L LD Crankshaft Horsepower (Kilowatts) 200 (149) Propeller Shaft Horsepower (Kilowatts) 180 (134) In-Line 6 Cylinder Engine Type Diesel Displacement 254 cu. in. ( 4.2 L ) Firing Order 1 - 5 - 3 - 6 - 2 - 4 Bore 3.700 in.

  • Page 63: Fluid Capacities

    12-3/4 ( 12 ) 13-3/4 ( 13 ) Always use dipstick to determine exact quantity of oil required D4.2L D-Tronic Model D2.8L D-Tronic and D4.2L LD Total Oil Capacity 8-1/2 ( 10 ) 12-3/4 ( 12 ) Oil Pan 6-1/2 ( 8 )

  • Page 64: Maintenance

    CD10 Maintenance CD301 5, 6 74298 CE303 General Information WARNING Always disconnect battery cables from battery BEFORE working around electrical system components to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted. WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire. This eliminates the engine wiring as a potential source of ignition.

  • Page 65: Maintenance Schedules

    CD637 Maintenance Schedules Routine Maintenance Each Each Every Weekly Start Months Check crankcase oil (interval can be extended based on experi- ence). If operating in salt, brackish or polluted waters, flush cooling system after each use. Drain any water from fuel filter after each use (If operating in freez- ing temperatures).

  • Page 66: Scheduled Maintenance

    Maintenance Schedules (Continued) Scheduled Maintenance Every Every Every Every Every 1000 After After Every Every hours hours hours hours First First Annu- hours or or 3 or 3 or 5 or 5 ally Annually years years hours hours years years years years Change crankcase oil and...
  • Page 67 Maintenance Schedules (Continued) Scheduled Maintenance (Continued) Every Every Every Every Every 1000 After After Every Every hours hours hours hours First First Annu- hours or or 3 or 3 or 5 or 5 ally Annually years years hours hours years years years years...
  • Page 68 CD638 71382 71380 74302 76394 75301 73322 71442 75297...

  • Page 69: Checking Fluid Levels

    Remove oil filler cap. Add specified oil to bring level up to, but not over, MAX mark on dipstick. Reinstall oil filler cap. D3.6L and D4.2L D2.8L D-Tronic and D4.2L D-Tronic D4.2L LD CD482 DRIVE UNIT OIL NOTE: Oil level will fluctuate during operation.
  • Page 70 CD640 72714 71381 73320 70979 73184...
  • Page 71 CD166 ENGINE COOLANT Before starting engine, check coolant level in coolant recovery bottle. Coolant level must be between the “ADD” and “FULL” marks (on front of bottle). If level is low, remove fill cap from coolant recovery bottle and add specified coolant as required.
  • Page 72 CD641 70571 73322 75301 75298 74725...

  • Page 73: Changing Fluids

    Power Trim or Power Steering fluids do not require changing. Coolant in closed cooling system should be changed at specified intervals by your Authorized Mercury MerCruiser Dealer. CRANKCASE OIL AND FILTER - D3.6L, D4.2L, D2.8L D-TRONIC AND D4.2L D-TRONIC IMPORTANT: Change oil when engine is warm from operation.
  • Page 74 CD643 76379 75297 76394...
  • Page 75 CD644 CRANKCASE OIL AND FILTER - D4.2L LD IMPORTANT: Change oil when engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only recommended motor oil (refer to “Specifications”). Start engine and allow it to warm up to normal operating temperature.
  • Page 76 CD645 74302 70121 75301 74732 76380 70581 70568 72522...
  • Page 77 Remove gear lube monitor bottle from bracket. Empty contents into suitable container. Install monitor in bracket. D3.6L and D4.2L D2.8L D-Tronic and D4.2L D-Tronic D4.2L LD Bravo One Models: Remove propeller, place drive unit in full DOWN/IN position, remove OIL FILL/DRAIN SCREW and sealing washer, and drain oil.
  • Page 78 CD647 71267 74301 71588 70113 74085...

  • Page 79: Air Filter Cleaning/Replacement

    All drive belts must be periodically inspected for tension and condition (excessive wear, cracks, fraying, or glazed surfaces). If any drive belts need replacement or tension needs adjustment, see your Authorized Mercury MerCruiser Dealer. IMPORTANT: On models with dual-row pulleys and dual belts always inspect both belts. Never renew just one of the two belts driving the alternator and engine water circulating pump.
  • Page 80 CD650 70355 70062 73320 74301 71443 74095...

  • Page 81: Drive Belts - D3.6L Engines

    CD651 Drive Belts - D3.6L Engines WARNING Make sure engine is shut off and ignition key is removed before inspecting belts. All drive belts must be periodically inspected for tension and condition (excessive wear, cracks, fraying, or glazed surfaces). Alternator Belt/Water Circulating Pump Belt Power Steering Pump Belt Vacuum Pump Belt (If so equipped) Check belt tension by depressing belt, with moderate hand pressure, at points shown.
  • Page 82 CD652 71903 71904 75332 71901 76405 74732 70558 70094 71346 73346 71347...

  • Page 83: Lubrication

    Lubricate pivot points with SAE 30W motor oil. CD674 THROTTLE CABLE Lubricate pivot points with SAE 30W motor oil. D2.8L D-Tronic and D4.2L D-Tronic D3.6L, D4.2L and D4.2L LD CA525 DRIVE UNIT AND TRANSOM ASSEMBLY Lubricate gimbal bearing by applying approximately 8-10 pumps of grease from a typical hand-operated grease gun using Quicksilver U-Joint and Gimbal Bearing Grease.
  • Page 84 CD304 70062 70355 71362 70565 71353 74733 72055 73320...

  • Page 85: Cleaning Quicksilver Seawater Strainer

    CE376 Cleaning Quicksilver Seawater Strainer NOTE: Refer to manufacturers instructions if equipped with other than a Quicksilver seawater strainer. CAUTION When cleaning seawater strainer, close seacock, if so equipped. If boat is not equipped with a seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses.
  • Page 86 CD653 71444 74726 76390 71371 76379...

  • Page 87: Fuel System

    On D3.6L, D4.2L and D4.2L LD Only: Loosen, DO NOT REMOVE, bleed screw on fuel injection pump (lo- cated between fuel line connection fittings on injection pump). Continue to repeatedly move plunger on hand...
  • Page 88 CD658 76379 74726 74726...
  • Page 89 Close drain by turning clockwise. Tighten securely. Fill fuel filter as previously outlined. D3.6L and D4.2L Models. D2.8L D-Tronic, D4.2L D-Tronic and D4.2L LD Models. NOTE: To ensure complete draining, in warm weather open the water bleed valve before starting daily opera- tions.
  • Page 90 CD660 76114 74731 76379...
  • Page 91 Make sure no leaks exist before closing engine hatch. All Models: Start and run engine. Check filter connection for fuel leaks. If leaks exist, recheck filter installa- tion. If leaks continue, stop engine immediately and contact your Authorized Mercury MerCruiser Dealer.
  • Page 92 CD677 73522 71366 75492 BRAVO ONE 71560 BRAVO TWO 70561...

  • Page 93: Seawater Pump Impeller

    CB66 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer. Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected (if operating temperature exceeds normal range). CB421 Propellers (Bravo One and Two) WARNING Avoid Injury: Remote Control must be in NEUTRAL and ignition key removed from switch before re- moving and/or installing propeller.
  • Page 94 CB722 75492 BRAVO ONE BRAVO TWO 70561...
  • Page 95 CD513 INSTALLATION (BRAVO ONE AND TWO) Apply a liberal coat of one of the following Quicksilver lubricants to propeller shaft: Anti-Corrosion Grease, Special Lubricant 101, or 2-4-C Marine Lubricant with Teflon. Slide thrust hub into propeller hub, with stepped side toward propeller hub. Bravo One: Install Flo-Torq II Drive Hub with drive sleeve.
  • Page 96 CD355 72239 72239...
  • Page 97 CD356 Propellers (Bravo Three) WARNING Avoid Injury: Remote Control must be in NEUTRAL and ignition key removed from switch before removing and/or installing propellers. WARNING Avoid Injury: Place a block of wood between splash-plate and propellers to protect hands from propeller blades and to prevent propellers from rotating when removing propeller nuts.
  • Page 98 CD662 74732 71367 73327 71368...

  • Page 99: Corrosion And Corrosion Protection

    CD119 Corrosion And Corrosion Protection INTERNAL COMPONENTS There are anodes as part of the intercooler and heat exchanger systems, which serves as a sacrificial anodes. Replace when eroded more than 50%; check at least once yearly. Length When New - 3/4 in. (19mm) Diameter When New - 5/8 in.
  • Page 100 CD231 73919 72032 71966 71176 70577 70578 70055...
  • Page 101 CD205 EXTERNAL COMPONENTS Whenever two or more dissimilar metals (like those found on the stern drive) are submerged in a conductive solution, such as saltwater, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemi- cally active, or anodic, to erode.
  • Page 102 CD362 71176...
  • Page 103 CA168 In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion: IMPORTANT: Corrosion damage that results from the improper application of anti-fouling paint will not be covered by the limited warranty. Painting Boat Hull or Boat Transom: Antifouling paint may be applied to boat hull and boat transom but you must observe the following precautions: IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.
  • Page 104 CD363 71088 È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È...

  • Page 105: Battery

    CD15 Miscellaneous Maintenance CA103 Battery All lead acid batteries discharge when not in use. Recharge every 30 to 45 days. or when specific gravity drops below battery manufacturer’s specifications Refer to specific instructions and warnings accompanying your battery. If this information is not available, ob- serve the following precautions when handling a battery.
  • Page 106 CD663 76391 74732 74725 71364 76391...

  • Page 107: Cold Weather Or Extended Storage

    CD44 Cold Weather Or Extended Storage CA115 Battery Winter Storage Follow battery manufacturer’s instructions for storage. CD280 Power Package Layup IMPORTANT: MerCruiser strongly recommends that this service should be performed by an Authorized MerCruiser Dealer. Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty. CAUTION The engine must be prepared for long storage periods to prevent internal corrosion and severe dam- age.
  • Page 108 CD664 74732 74732 73322 73322 71217 74303 71362...

  • Page 109: Draining Instructions

    Disconnect seawater outlet hose at aft end of power steering cooler. Lower hose and drain completely. Remove the drain plug from the aft end cover of the intercooler. NOTE: D4.2L engine intercooler drain plug shown, all models similar. Remove seawater pump outlet hose from top of seawater pump and drain.
  • Page 110 CD675 74733 71366 71366...
  • Page 111 Close seacock, if so equipped, or disconnect and plug seawater inlet hose, if boat is to remain in the water. Clean seawater strainer (refer to “Cleaning Quicksilver Seawater Strainer”). IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in seawater section of the cooling system for cold weather or extended storage.
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  • Page 113: Power Package Recommissioning

    Perform all checks on Operation Chart in the Starting Procedure column. IMPORTANT: On D3.6L, D4.2L and D4.2L LD Engines: After not having been operated for two months or longer, it is necessary to pre-lubricate the engine. To do this, hold the STOP switch toggle lever DOWN while you simultaneously turn the key switch to START position for 15 seconds.

  • Page 114: Troubleshooting

    CD49 Troubleshooting CD361 Starter Motor Will Not Crank Engine, Or Cranks It Very Slowly Possible Cause Remedy • • Battery switch turned off Turn switch on. • • Remote control not in neutral position Position control lever in neutral. • •...

  • Page 115: Poor Performance

    Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy • • Throttle not operating properly Check throttle linkages for binding or an obstruction. • • Idle speed too low Check idle speed and adjust, if necessary. • • Clogged fuel or air filters Replace filters.

  • Page 116: Excessive Engine Temperature

    Excessive Engine Temperature Possible Cause Remedy • • Seacock closed, if so equipped Open. • • Drive belt loose or in poor condition Replace and/or adjust belt. • • Seawater pickups obstructed Remove obstruction. • • Faulty thermostat Replace. • •...

  • Page 117: Low Engine Oil Pressure

    Low Engine Oil Pressure Possible Cause Remedy • • Faulty senders Have system checked by an Authorized MerCruiser Dealer. • • Insufficient oil in crankcase Check and add oil. • • Excessive oil in crankcase (causing it to Check and remove required amount of oil. become aerated) Check for cause of excessive oil (improper filling, bad fuel pump, etc.).

  • Page 118: Steering Wheel Turns Hard Or Jerky

    CD130 Steering Wheel Turns Hard Or Jerky Possible Cause Remedy • • Low power steering pump fluid level Refill system with fluid. • • Drive belt loose or in poor condition Replace and/or adjust. • • Insufficient lubrication on steering system Lubricate.
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  • Page 120: Owner Service Assistance

    Only Authorized Dealers can purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When inquiring on parts and accessories, the dealer requires the motor model and serial number(s) to order the correct parts.

  • Page 121: Mercury Marine Service Offices

    (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 Parc Industriel de Petit-Rechain B-4800 Verviers Belgium Mexico, Central America, South America, Caribbean Mercury Marine - Latin America (305) 385-9585 (305) 385-5507 & Caribbean 9010 S.W. 137th Ave. Suite 226 Miami, FL 33186 U.S.A.

  • Page 122: Customer Service Literature

    CA781 Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
  • Page 123 Per ottenere il manuale di funzionamento e manutenzione in altra lingua, contattate il centro assistenza interna- zionale Mercury Marine o Marine Power più vicino. In dotazione con il gruppo motore, viene fornito l’elenco dei codici prodotto dei componenti venduti all’estero.

  • Page 124: Ordering Literature

    Serial Number_____________ Year_______ United States and Canada For information on additional literature that is available for your particular MerCruiser power package and how to order that literature contact your nearest dealer or contact: Mercury Marine Telephone Mail Mercury Marine Attn: Publications Department...

  • Page 125: Owner's Logbook

    CD68 Owner’s Logbook Operating Date Maintenance and Repair Hours...
  • Page 126 CD68 Owner’s Logbook Operating Date Maintenance and Repair Hours...
  • Page 127 CD68 Owner’s Logbook Operating Date Maintenance and Repair Hours...
  • Page 128 75308...

This manual is also suitable for:

D3.6lD4.2l ldD2.8l d-tronicBravo series

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