Power Package Recommissioning - Mercury D4.2L Manual

CD667

Power Package Recommissioning

To prevent possible injury or damage to equipment, do not install battery until all maintenance has
been performed on engine.
1
Check that all cooling system hoses are in good condition, connected properly, and hose clamps are tight.
2
Install seawater pump impeller. Place impeller in pump and press onto pump shaft firmly. Install pump cover,
with gasket, and tighten screws securely.
IMPORTANT: Use new gasket. Install in correct position - wide surface on side of cam.
A
Impeller
B
Gasket
C
Wide Surface
D
Cam
E
Cover and Screws
3
Replace fuel filter.
4
Bleed fuel system (see "Maintenance - Fuel System").
When installing battery, be sure to connect POSITIVE (+) battery cable to POSITIVE (+) battery terminal
FIRST, and NEGATIVE (–) battery cable to NEGATIVE (–) battery terminal LAST. It battery cables are
reversed, or connection order is reversed, electrical system damage will result.
5
Install fully-charged battery. Clean battery cable clamps and terminals and reconnect cables (see CAUTION
listed above). Secure each cable clamp when connecting. Coat terminals with a battery terminal anti-corrosion
spray to help retard corrosion.
6
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. This will rotate the start-
er motor and engine/oil pump. During this process the engine will not run because no fuel is injected.
Allow the starter motor to cool down for one minute and repeat the above described process. To avoid
overheating the starter motor, do not engage starter motor for more than 15 seconds each time.
7
Pre-lubricate the engine if necessary. Refer to above "Important" information. Start engine and closely ob-
serve instrumentation to make sure that all systems are functioning correctly.
8
Carefully inspect engine for fuel, oil, fluid, water and exhaust leaks.
9
Check steering system, shift and throttle control for proper operation.
WARNING
CAUTION
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