Section 4 - Maintenance - Mercury TDI 4.2L Manual

Table of Contents
Owner and Operator Responsibilities................................... 34
Dealer Responsibilities......................................................... 34
Maintenance......................................................................... 34
Replacement Parts Warning................................................. 35
Inspection............................................................................. 35
Routine Maintenance............................................................ 35
Start of Season ............................................................. 35
Each Day Start ............................................................. 35
Each Day End ............................................................... 35
Weekly .......................................................................... 35
End of Season .............................................................. 35
Scheduled Maintenance....................................................... 36
Once a Year or Every 200 Operating Hours (Whichever
Occurs First) ................................................................. 36
Maintenance Notice ...................................................... 36
Every 5 Years or 500 Hours (Whichever Occurs First)
...................................................................................... 36
Every 5 Years or 1,000 Operating Hours (Whichever
Occurs First) ................................................................. 36
Every 5 Years or 2,000 Operating Hours (Whichever
Occurs First) ................................................................. 36
Engine Oil............................................................................. 36
Checking ....................................................................... 37
Filling ............................................................................ 37
Draining Using the Easy Drain System, if Equipped .... 37
Changing Oil and Filter ................................................. 38
Sterndrive Gear Lube........................................................... 39
Checking ....................................................................... 39
Filling ............................................................................ 39
Changing ...................................................................... 40
Power Trim Fluid.................................................................. 43
Checking ....................................................................... 43
Filling ............................................................................ 44
Changing ...................................................................... 45
Power Steering Fluid............................................................ 45
Checking ....................................................................... 45
Filling ............................................................................ 45
Changing ...................................................................... 46
Engine Coolant..................................................................... 46
Checking the Coolant Level .......................................... 47
Adding Coolant ............................................................. 47
Air Filter................................................................................ 47
Removal ....................................................................... 47
Inspection and Cleaning ............................................... 47
Installation .................................................................... 48
Fuel Filter.............................................................................. 48
90-8M0114081 DECEMBER 2015
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Section 4 - Maintenance

Purging the Fuel System...................................................... 49
Fuel System.......................................................................... 49
Seawater System................................................................. 49
Corrosion Protection............................................................. 53
Lubrication............................................................................ 54
Maintaining Torques............................................................. 57
Propellers............................................................................. 58
Drive Belts............................................................................ 63
Battery.................................................................................. 64
Battery Precautions for Multiple Engines.............................. 65
Draining Water from the Filter ...................................... 48
Replacing the Filter ....................................................... 48
Priming ......................................................................... 49
Fuel Tank Cleaning and Flushing ................................. 49
Seawater Pump Impeller Inspection.............................. 49
Sterndrive Water Inlets Check....................................... 50
Flushing and Draining the Seawater System................. 51
Checking the Seawater Pickups.................................... 52
Cleaning the Seawater Strainer, if Equipped................. 52
General Information....................................................... 53
Sacrificial Anode............................................................ 53
Antifouling Paint............................................................. 54
Steering System............................................................ 54
Throttle Cable................................................................ 55
Shift Cable..................................................................... 55
Transom Assembly........................................................ 55
Propeller Shaft............................................................... 55
Engine Coupler.............................................................. 56
Driveshaft Extension Models......................................... 57
Gimbal Ring U-bolt Nuts................................................ 57
Engine Mounts............................................................... 58
Bravo Sterndrive Propeller Removal............................. 58
Bravo One Models ................................................. 58
Bravo Two Models ................................................. 59
Bravo Three Models .............................................. 60
Bravo Sterndrive Propeller Installation.......................... 61
Bravo One Models ................................................. 61
Bravo Three ........................................................... 62
Drive Belt....................................................................... 63
Drive Belt Failure Identification...................................... 63
Alternators .................................................................... 65
Engine Control Unit (ECU) ........................................... 65
Batteries ....................................................................... 65
Battery Switches ........................................................... 65
Battery Isolators ............................................................ 65
Generators .................................................................... 65
Section 4 - Maintenance
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