Installation; Fuel Filter; Draining Water From The Filter; Replacing The Filter - Mercury TDI 4.2L Manual

Section 4 - Maintenance

Installation

1. Install the rubber side covers onto the air filter element.
2. Align the marks as shown by the arrows in the air filter mounting illustration.
3. Install the tension springs.
4. Install the large clamps onto the rubber side covers. Tighten the fasteners to retain the boots.
5. Place the small clamps onto the small openings on the rubber side covers.
6. Gently compress the rubber side covers toward the center of the air filter element and install the filter assembly onto the
turbocharger inlets.
7. Tighten the small clamps to retain the filter assembly.
8. Install the crankcase ventilation hoses.

Fuel Filter

Water entering the fuel injection system will cause corrosion and rusting of the injectors and other components, disabling the
fuel injection system. Check daily for water in the water‑separating fuel filter and have the engine inspected immediately if
there is evidence of water in the fuel system.
IMPORTANT: Use a suitable container to collect fuel. Clean up any spills immediately and dispose of fuel and old filters in a
safe manner in accordance with all local, federal, and international regulations.
This remote‑mounted fuel filter and lift pump assembly is equipped with a water‑in‑fuel sensor to alert the operator when water
is present in the filter. This filter needs to be replaced at specified intervals, refer to Routine Maintenance, or whenever water
is detected in the fuel, whichever occurs first.
d
c
b

Draining Water from the Filter

1. Place a suitable container under the fuel filter assembly.
2. Remove the drain plug from the bottom of the assembly.
3. Drain the filter until the fuel is clean in appearance.
4. Install the drain plug and tighten securely.

Replacing the Filter

Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
IMPORTANT: The fuel filter cannot be cleaned and reused. It must be replaced. Be sure to replace the filter with a filter of the
same specifications to eliminate possible damage to the fuel system components.
1. Disconnect both battery cables from the battery.
2. Disconnect the water‑in‑fuel sensor from the wiring harness.
3. Place a suitable container under the fuel filter assembly.
4. Remove the cannister from the assembly.
5. Pull up on the fuel filter to remove it from the cannister.
Page 48
e
a - Water‑in‑fuel sensor
b - Cannister nut (hidden)
c - Cannister
d - Fuel line fittings
d e - Power connector
a
52790
NOTICE
WARNING
!
90-8M0114081 DECEMBER 2015
eng