Replacement Parts Warning; Inspection; Routine Maintenance; Start Of Season - Mercury TDI 4.2L Manual

Replacement Parts Warning

Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.

Inspection

Inspect your power package often and at regular intervals to help maintain operating performance and to identify potential
problems before they occur. The entire power package should be checked carefully, including all accessible engine parts.
1. Check for loose, damaged, or missing parts, hoses, and clamps; tighten or replace as necessary.
2. Check electrical connections and leads for damage.
3. Remove and inspect the propeller. If it is badly nicked, bent, or cracked, contact your Mercury Diesel–authorized repair
facility.
4. Repair nicks and corrosion damage on power package exterior finish. Contact your Mercury Diesel–authorized repair
facility.

Routine Maintenance

Start of Season

• Inspect the power package for leaks and damage.
• Inspect the accessory drive belts, hoses, and power steering pump (if applicable).
• Inspect the fuel injection pump drive belt condition.
• Verify that the seacock operates properly.
• Check the charge, connections, and condition of the battery. Charge or replace the battery as necessary.
• Check all fluid and lubricant levels, and adjust them as necessary.
• Inspect the anodes and replace them if they are 50% eroded.

Each Day Start

• Inspect the power package for leaks and damage.
• Check the engine oil level and adjust it as necessary.
• Check the engine coolant level and adjust it as necessary.
• Check the condition of the fuel filter. Drain water from the filter as necessary.
• Check the seawater strainer and clean it as necessary.
• Check the drive lubricant level (if applicable), and adjust it as necessary.
• Check the reverse‑gearbox lubricant level and adjust it as necessary, where applicable.
• Clean the gauges.
• Inspect the air filter for discoloration and contaminants.

Each Day End

• If operating in saltwater, brackish water, or polluted water, flush the seawater section of the cooling system.
• Drain any water from the fuel filter, if operating in freezing temperatures.

Weekly

• Inspect the power package for leaks and damage.
• Drain any water from the fuel filter.
• Check the trim pump fluid level, if applicable.
• Check the seawater inlets for debris or marine growth.
• Check and clean the seawater strainer.
• Inspect the anodes, and replace them if they are 50% eroded.
• Inspect the air filter for discoloration and contaminants.

End of Season

• Inspect the power package for leaks or damage.
90-8M0114081 DECEMBER 2015
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Section 4 - Maintenance
Page 35