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Mercury 4.2 Diesel Operation & Maintenance Manual

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2.8 and 4.2 Diesel
Inboard Models
O P ERAT I O N &
M AI N T EN AN CE
MAN U AL

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Summary of Contents for Mercury 4.2 Diesel

  • Page 1 2.8 and 4.2 Diesel Inboard Models O P ERAT I O N & M AI N T EN AN CE MAN U AL...
  • Page 2 The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.
  • Page 3 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 Manual included with the product. The Warranty Manual 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 4: Table Of Contents

    TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Identification................2 SmartCraft Speedometer, Tachometer, and Digital Serial Number Decal............2 Gauges................6 Engine Data Label.............. 2 System Link Digital Gauges........... 7 ZF Marine Transmissions........... 3 Emergency Stop Switch............8 Technodrive Transmissions..........
  • Page 5 Section 4 - Maintenance Owner and Operator Responsibilities........32 Filling................50 Dealer Responsibilities............32 Fuel System................51 Maintenance................32 Priming................51 Do‑It‑Yourself Maintenance Suggestions....... 32 Filling (Bleeding).............. 51 Inspection................32 Fuel Tank Cleaning and Flushing........52 Maintenance Schedule............33 Seawater System..............52 Routine Maintenance............
  • Page 6 Section 7 - Customer Assistance Information Owner Service Assistance............76 Contact Information for Mercury Marine Customer Service Local Repair Service............76 ................... 77 Service Away From Home..........76 Customer Service Literature............ 77 Stolen Power Package............76 English Language.............. 77 Attention Required After Submersion......... 76 Other Languages..............
  • Page 7 Page iv 90-8M0113988 DECEMBER 2015...
  • Page 8 Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package Table of Contents Identification................2 SmartCraft Speedometer, Tachometer, and Digital Serial Number Decal............2 Gauges ..............6 Engine Data Label............2 System Link Digital Gauges ........7 ZF Marine Transmissions..........

  • Page 9: Identification

    Section 1 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.

  • Page 10: Zf Marine Transmissions

    Section 1 - Getting to Know Your Power Package ZF Marine Transmissions On the ZF Marine 63A 8° down‑angle and 63IV V‑drive transmissions, the transmission identification plate indicates gear ratio, serial number, and model. Typical ZF Marine down-angle transmission show (V-drive similar) Transmission identification plate 7449 Technodrive Transmissions...

  • Page 11: Switches

    Section 1 - Getting to Know Your Power Package NOTICE The sound from an audio warning horn indicates that a critical fault malfunction has occurred. Operating a power package with a critical fault can damage components. If the audio warning horn emits a sound, do not continue operations unless avoiding a hazardous situation.

  • Page 12: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition

    Section 1 - Getting to Know Your Power Package A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist. ATTACH LANYARD Lanyard cord clip Lanyard decal Lanyard stop switch 53910 Accidental ejections, such as falling overboard, are more likely to occur in: •...

  • Page 13: Instrumentation

    Section 1 - Getting to Know Your Power Package Before each use, inspect the lanyard cord to ensure that it is in good working condition and that there are no breaks, cuts, or wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard cords.

  • Page 14: System Link Digital Gauges

    Section 1 - Getting to Know Your Power Package SmartCraft tachometer and speedometer Tachometer Speedometer LCD display 50400 The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system. The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display. For basic operation information on the SmartCraft instrument package and for details on the warning functions monitored by the system, refer to the manual provided with your gauge package.

  • Page 15: Emergency Stop Switch

    Mercury Diesel repair facility. Remote Controls Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.

  • Page 16: Panel Mount Features

    Section 1 - Getting to Know Your Power Package Panel Mount Features Neutral lock button Throttle‑only button Lanyard stop switch Control handle tension adjustment screw Control handle Trim and tilt button mc77019-1 Neutral lock button. Prevents accidental shift and throttle engagement. The neutral lock button must be pushed into move the control handle out of neutral.

  • Page 17: Overload Protection-Upper Engine Circuit Breaker Panel

    If the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your Mercury Diesel authorized repair facility. Circuit breakers provide protection for the engine electrical system. The circuit breaker panel is located beneath a small access panel in the engine cover on top of the engine.

  • Page 18: Overload Protection-Port Side Power Distribution Box

    After finding and correcting the cause of the overload, connect the starting battery and turn the ignition switch to the run position. The circuit breaker should automatically reset. If a circuit breaker fails to reset, contact your Mercury Diesel authorized...

  • Page 19: Vessel Integration Panel (Vip) Overload Protection

    Section 1 - Getting to Know Your Power Package Circuit Protection Circuit Breaker Rating Key unswitched power to helm 20 A Switched power to ECM 10 A Key switch to ECM 10 A Switched power to ECM 15 A ECM switched power to SIM 15 A Power—diagnostic connector Vessel Integration Panel (VIP) Overload Protection...
  • Page 20 Section 2 - On the Water Section 2 - On the Water Table of Contents Safe Boating Recommendations.......... 14 Engine Shut Down (Stopping)........20 Carbon Monoxide Exposure..........15 Protecting People in the Water..........20 Be Alert To Carbon Monoxide Poisoning ..... 15 While Boat is in Operation ........

  • Page 21: Safe Boating Recommendations

    Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.

  • Page 22: Carbon Monoxide Exposure

    Section 2 - On the Water Be alert. • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed.

  • Page 23: Poor Ventilation

    The power package must be equipped with a gear ratio and propeller that allows the engine to operate at wide open throttle (WOT) at the engine's rated speed (RPM). Use of Mercury Diesel engines in applications that do not meet specified operational parameters is not approved.

  • Page 24: Operation Chart

    At temperatures of –20° C (–4° F) and below, use a coolant heater to improve cold starting. • If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for information about special cold weather equipment and precautions.

  • Page 25: Drain Plug And Bilge Pump

    • Check all applicable items in the maintenance schedules and operation chart. • Perform any other necessary checks as indicated by your Mercury Diesel authorized repair facility or specified in your boat owner's and operation manual. Important Information – SmartStart IMPORTANT: This power package is equipped with SmartStart.

  • Page 26: Engine Warm Up

    Check the engine and the transmission, oil filter, oil lines, oil line connectors, and oil pan for leaks. Check the coolant hoses, heat exchanger connections, aftercooler, water pump, and drain fittings for leaks. Locate and correct any problems, or see your Mercury Diesel authorized repair facility if you are unable to determine the problem.

  • Page 27: Engine Shut Down (Stopping)

    If your boat is considered a high‑speed or high‑performance boat, we recommend that you never operate it at its high‑speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to the Hi‑Performance Boat Operation booklet from your Mercury Diesel authorized repair facility.

  • Page 28: Boats With Front-Mounted, Raised Pedestal Fishing Seats

    Section 2 - On the Water Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. mc79555-1 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.

  • Page 29: Impact With Underwater Hazards

    Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Conditions Affecting Operation...

  • Page 30: Elevation And Climate

    It is important to follow this procedure to properly break in the engine. IMPORTANT: Mercury Marine recommends that the boat not be accelerated hard until this procedure has been completed. IMPORTANT: Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool;...

  • Page 31: After The 20-Hour Break-In Period

    Check the engine oil level frequently. Add oil as needed. High oil consumption is normal during the break‑in period. After the 20-Hour Break-In Period To help extend the life of your power package, Mercury Marine recommends the following: • Change the engine oil and filter and the transmission fluid at the interval indicated in the Maintenance Schedule. Refer to Specifications and Maintenance.

  • Page 32: Section 3 - Specifications

    Section 3 - Specifications Section 3 - Specifications Table of Contents Fuel Requirements............... 26 Engine................28 Diesel Fuel in Cold Weather..........26 2.8 ................. 28 Antifreeze/Coolant..............26 4.2 ................. 28 Engine Oil................27 Transmission..............28 Engine Specifications............28 Approved Paints..............28 Fluid Specifications...............

  • Page 33: Fuel Requirements

    Mercury diesels are required to use grade 2–D ULSD (ultra‑low sulphur diesel) fuel meeting ASTM Standards D975 (or fuel rated Diesel DIN EN 590), and having a minimum cetane rating of 51.

  • Page 34: Engine Oil

    Shell Myrina Mopar Texaco Ursa Super TD Engine crankcase Obtain Locally Wintershall Multi‑Rekord Veedol Turbostar Wintershall VIiva 1 These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W40 oil. 90-8M0113988 DECEMBER 2015 Page 27...

  • Page 35: Engine Specifications

    Part Number Engine oil (with filter) 8.9 (9.4) 15W40 4‑cycle Diesel Engine Oil 92‑858042K01 Closed cooling system 11 (11.6) Mercury Extended Life Antifreeze 92‑877770K1 All models Capacity liters (US qt) Fluid Type Part Number Engine oil (with filter) 13.8 (14.6) 15W40 4‑cycle Diesel Engine Oil...
  • Page 36 Section 3 - Specifications Description Part Number Mercury Phantom Black 92‑802878Q1 90-8M0113988 DECEMBER 2015 Page 29...
  • Page 37 Section 3 - Specifications Notes: Page 30 90-8M0113988 DECEMBER 2015...
  • Page 38 Section 4 - Maintenance Section 4 - Maintenance Table of Contents Owner and Operator Responsibilities........32 Filling................50 Dealer Responsibilities............32 Fuel System................51 Maintenance................. 32 Priming................51 Do‑It‑Yourself Maintenance Suggestions......32 Filling (Bleeding)............51 Inspection................32 Fuel Tank Cleaning and Flushing........52 Maintenance Schedule............

  • Page 39: Owner And Operator Responsibilities

    It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation, and to return the unit to a Mercury Diesel authorized repair facility for a periodic checkup.

  • Page 40: Maintenance Schedule

    Section 4 - Maintenance Remove and inspect the propeller. If the propeller is badly nicked, bent, or cracked, contact your Mercury Diesel authorized repair facility. Repair nicks and corrosion damage on power package exterior finish. Contact your Mercury Diesel authorized repair facility.

  • Page 41: Scheduled Maintenance

    Section 4 - Maintenance • Check the engine oil level. (This interval can be extended based on operator experience with the product.) Each day start • Check the engine coolant level. • Check the transmission oil level. • If operating in saltwater, brackish water, or polluted water, flush the seawater section of the cooling system after each use.

  • Page 42: Engine Oil

    Section 4 - Maintenance Engine Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

  • Page 43: Changing Oil And Filter

    Section 4 - Maintenance Capacity Fluid Type Engine oil (with filter) 8.9 L (9.4 U.S. qt) 4‑Cycle 15W40 Marine Engine Oil Capacity Fluid Type Engine oil (with filter) 13.8 L (14.6 U.S. qt) 4‑Cycle 15W40 Marine Engine Oil IMPORTANT: Always use the dipstick to determine the amount of oil required to refill the engine oil. Install the oil fill cap.

  • Page 44: Zf Marine Transmission Fluid

    Section 4 - Maintenance 11. Disconnect and discard the old filter element. Discard the old O‑ring from the top piece. Typical Top piece O‑ring Filter element 16603 12. Install the new O‑ring. Apply lubricant to the O‑ring. Tube Ref No. Description Where Used Part No.

  • Page 45: Add Fluid

    If the fluid level is low, add transmission fluid to bring the level up to the maximum mark on the dipstick. Refer to Add Fluid. NOTE: If the transmission fluid level was extremely low, see your local Mercury Diesel authorized repair facility. Install the dipstick.
  • Page 46 Section 4 - Maintenance Use a 6 mm Allen wrench and remove the fluid filter assembly by turning the assembly nut counterclockwise and pulling at the same time. Assembly nut Fluid filter assembly 13163 Push the hose of a suction pump through the suction pipe and down to the bottom of the housing. Pump the fluid from the housing into a suitable container.

  • Page 47: Technodrive Transmission Fluid

    If the fluid level is low, add transmission fluid to bring the level up to the maximum mark on the dipstick. See Add Fluid. NOTE: If the transmission fluid level was extremely low, see your local Mercury Diesel authorized repair facility.

  • Page 48: Add Fluid

    Section 4 - Maintenance Add Fluid If necessary, add specified transmission fluid through the dipstick threaded hole to bring the level up to the maximum mark on the dipstick. Dipstick Maximum fluid level Minimum fluid level 24604 NOTE: Always use the dipstick to determine the quantity of oil or fluid required. Model Capacity Fluid type...
  • Page 49 Section 4 - Maintenance Clean the exterior of the transmission around the fluid filter assembly. Loosen the assembly nut, and rotate the securing tab in the direction shown. Assembly nut Securing tab 24608 Remove the filter element. Filter element 24618 Clean the filter element with a mild cleaning solvent, obtained locally.

  • Page 50: Engine Coolant

    Section 4 - Maintenance 11. Reinstall the filter element. Filter element O‑ring 24620 NOTICE Improper installation of the transmission fluid filter assembly may cause the fluid to foam or leak out, resulting in decreased efficiency and damage to the transmission. Properly seat the transmission fluid filter during installation. 12.

  • Page 51: Filling

    Inspect the gasket in the pressure cap for damage and replace if necessary. The pressure cap maintains pressure on the cooling system and may not be holding pressure properly. To have the cap tested, contact your Mercury Diesel authorized repair facility. Add the specified coolant as necessary. Refer to Add Coolant.

  • Page 52: Changing

    Section 4 - Maintenance Changing Change (replace) the engine coolant at the prescribed interval. See Replacing the Engine Coolant in the Closed‑Cooling System. 2.8 Air Filter Removal Remove the retaining nut from the air filter cover. Remove the air filter cover. NOTE: It is not necessary to remove the air filter bracket mounted on the turbocharger inlet.

  • Page 53: Inspection

    Section 4 - Maintenance Loosen the clamp and remove the air filter housing from the turbocharger inlet. Oil separator vent hose Air filter housing Turbocharger Clamp 25881 Remove the air filter element from the air filter housing Air filter housing Air filter element 25893 Inspection...

  • Page 54: Installation

    Section 4 - Maintenance Installation Slide the filter element into the air filter housing. Ensure that the element is seated fully into the air filter housing. Air filter housing Air filter element 25893 NOTE: The warning labels on the air filter housing must be visible after the air filter housing is installed. Install the air filter housing on to the turbocharger inlet.

  • Page 55: Draining

    Section 4 - Maintenance The engine‑mounted water‑separating fuel filter is equipped with a water‑in‑fuel (WIF) sensor that should alert the operator when water is present in the filter. This fuel filter needs to be replaced at specified intervals or whenever water is detected in the fuel, whichever comes first.
  • Page 56 Section 4 - Maintenance Remove the water‑separating fuel filter and sealing ring from the mounting bracket. Do not use a filter wrench. Typical Water‑separating fuel filter 23459 NOTE: It may be necessary to keep the existing drain cap and use it on the new filter. Be sure to replace the O‑ring on the drain cap.

  • Page 57: Filling

    13. Connect the battery cables. 14. Start and operate the engine. Check the filter connection for fuel leaks. If leaks exist, recheck the filter installation. If leaks continue, stop the engine immediately and contact your Mercury Diesel authorized repair facility. Filling A type of hand pump and primer plunger is located on the fuel filter bracket and is used to •...

  • Page 58: Fuel System

    Section 4 - Maintenance Loosen the air vent (bleed) screw on the fuel filter bracket. Typical Air vent screw 23469 Move the primer plunger up and down repeatedly. The filter is full when an air‑free stream of fuel flows from the air vent screw.

  • Page 59: Fuel Tank Cleaning And Flushing

    Section 4 - Maintenance Fuel Tank Cleaning and Flushing IMPORTANT: Diesel fuel should not be left in the tank during winter storage, as an accumulation of rust, sludge, and wax residue will form. Refer to the boat manufacturer's instructions and clean the fuel tank at specified intervals. Unless specified otherwise, flush and clean the diesel fuel tank every 1000 hours or five years, whichever occurs first.
  • Page 60 Section 4 - Maintenance NOTE: In the following steps, the hoses may require lowering or bending to allow seawater to drain completely. Disconnect the seawater inlet hose from the connector on the seawater pump hose and drain. 23649 23480 Seawater inlet hose Connector Seawater pump hose Repeatedly clean out the drain holes using a stiff piece of wire until the seawater section is completely drained.

  • Page 61: Checking The Seawater Pickups

    Section 4 - Maintenance Checking the Seawater Pickups Ensure that the water inlet holes for the seawater pickup are clean and not obstructed. 16776 Typical through-hull seawater pickup Typical through-transom seawater pickup Water inlet holes Cleaning the Seawater Strainer, if Equipped NOTICE An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat, causing damage or sinking the boat.
  • Page 62 Section 4 - Maintenance Clean any debris from the strainer housing. Flush both the strainer and housing with clean water. Inspect the cover gasket and replace if damaged. Strainer cove Strainer basket Seal 37287 CAUTION Seawater leaking from the seawater strainer could cause excess water in the bilge, damaging the engine or causing the boat to sink.

  • Page 63: Flushing The Seawater System-Inboard Models

    Section 4 - Maintenance Screw the strainer cover on. Strainer cove Strainer basket Seal 37287 Open the seacock, if equipped, or remove the plug and reconnect the seawater inlet hose. Upon first starting the engine, check for leaks or air in the system that would indicate an external leak. Flushing the Seawater System—Inboard Models Flushing the seawater system with fresh water is needed only for applications operating in saltwater, brackish water, polluted water, or water with a high mineral content to avoid salt or silt buildup.

  • Page 64: With The Boat In The Water

    Section 4 - Maintenance NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. Operate the engine at idle speed in neutral for about 10 minutes, or until the discharge water is clear.

  • Page 65: Engine Seawater Pump Inspection

    Engine Seawater Pump Inspection IMPORTANT: Mercury strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Remove and inspect the engine seawater pump at the interval specified in the Maintenance Schedule. See your Mercury Diesel authorized repair facility.

  • Page 66: Filling The Closed-Cooling System

    After the coolant has drained completely, install the intake and exhaust manifold drain plug, the heat exchanger drain plug, and the engine block drain plug. Tighten all drain plugs securely. If required, clean the closed‑cooling system. See your local Mercury Diesel authorized repair facility. Fill the system with the specified coolant. Refer to Filling the Closed Cooling System.

  • Page 67: Corrosion Protection

    To help control the effects of galvanic corrosion, Mercury power packages come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection refer to the Marine Corrosion Protection Guide.

  • Page 68: Cleaning And Inspection

    Section 4 - Maintenance Remove the anode assembly (anode plug and the sacrificial anode) from the top of the aftercooler end cover. Aftercooler end cover Anode assembly 23266 Remove the anode assembly (anode plug and the sacrificial anode) from the aft end of the fluid cooler. Typical engine Anode assembly Fluid cooler...

  • Page 69: Installation

    Section 4 - Maintenance Sacrificial anode measurements (new) Length 19 mm ( 3/4 in.) Diameter 16 mm ( 5/8 in.) Discard the sealing washer. Installation Install a new sealing washer on the anode assembly (anode plug with the sacrificial anode). Anode assembly Sealing washer 19227...

  • Page 70: Antifouling Paint

    IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint is not covered by the limited warranty. In some areas it may be advisable to paint the bottom of the boat to help prevent marine growth. Contact a Mercury Diesel authorized repair facility for recommendations for your boat.

  • Page 71: Drive Belts

    Section 4 - Maintenance Drive Belts Drive Belt All drive belts must be periodically inspected for tension and condition, such as excessive wear, cracks, fraying, or glazed surfaces. WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts.

  • Page 72: Replacement

    Section 4 - Maintenance Rotate the automatic tensioner in the direction of the arrow. Automatic tensioner Release slot 23256 Release the automatic tensioner and allow it to glide back slowly. The automatic tensioner must return to the initial position and hold tension on the serpentine belt. Replacement IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as when first used.

  • Page 73: Battery

    Section 4 - Maintenance Battery Refer to the specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery. WARNING Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion.

  • Page 74: Section 5 - Storage

    Section 5 - Storage Section 5 - Storage Table of Contents Cold Weather (Freezing Temperature), Seasonal Storage, Seasonal Storage............69 and Extended Storage............68 Extended Storage Instructions........70 Cold Weather (Freezing Temperature) Storage.... 68 Battery................70 Preparing Your Power Package for Seasonal or Recommissioning..............

  • Page 75: Cold Weather (Freezing Temperature), Seasonal Storage, And Extended Storage

    Section 5 - Storage Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage IMPORTANT: Mercury Marine strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.

  • Page 76: Seasonal Storage

    Description Where Used Part Number Corrosion Guard 92‑802878‑55 Light gray primer Outside of engine 92‑802878‑52 Mercury Diesel White 8M0108939 Mercury Phantom Black Shift plate and air filter housing 92‑802878Q1 90-8M0113988 DECEMBER 2015 Page 69...

  • Page 77: Extended Storage Instructions

    Read all precautions and perform all procedures found in Seasonal Storage Instructions. IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight. Remove the seawater pump impeller and store away from direct sunlight. Refer to a Mercury Diesel authorized repair facility for additional information and service.

  • Page 78: Section 6 - Troubleshooting

    Section 6 - Troubleshooting Section 6 - Troubleshooting Table of Contents Diagnosing Electronically Controlled Fuel System Problems Poor Performance............72 ....................72 Incorrect Engine Temperature........73 Troubleshooting Charts............72 Low Engine Oil Pressure..........73 Starter Motor Will Not Crank Engine, or Cranks Slow... 72 Battery Will Not Charge..........

  • Page 79: Diagnosing Electronically Controlled Fuel System Problems

    Diagnosing Electronically Controlled Fuel System Problems A Mercury Diesel authorized repair facility has the proper service tools for diagnosing problems on electronically controlled fuel systems. The engine control module (ECM) on these engines has the ability to detect problems with the system when they occur, and store a trouble code in the ECM's memory.

  • Page 80: Incorrect Engine Temperature

    Obstruction in the shift or throttle linkages. Remove the obstruction. Check all throttle linkages. If any are loose or missing, see a Mercury Loose or missing shift and throttle linkages. Diesel authorized repair facility immediately. Straighten cable or have a Mercury Diesel authorized repair facility Shift or throttle cable kinked.
  • Page 81 Section 6 - Troubleshooting Possible Cause Remedy Improper shift cable adjustment. Have adjustment checked by a Mercury Diesel authorized repair facility. Page 74 90-8M0113988 DECEMBER 2015...
  • Page 82 Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance............ 76 Contact Information for Mercury Marine Customer Local Repair Service ............ 76 Service ................. 77 Service Away From Home ..........76 Customer Service Literature..........77 Stolen Power Package ..........

  • Page 83: Owner Service Assistance

    If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

  • Page 84: Contact Information For Mercury Marine Customer Service

    Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: •...

  • Page 85: Other Languages

    Section 7 - Customer Assistance Information 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 86: Section 8 - Maintenance Log

    Section 8 - Maintenance Log Section 8 - Maintenance Log Table of Contents Scheduled Maintenance Log..........80 Vessel Maintenance Notes........... 81 90-8M0113988 DECEMBER 2015 Page 79...

  • Page 87: Scheduled Maintenance Log

    Section 8 - Maintenance Log Scheduled Maintenance Log 100 Hours Actual Hours Service Notes Dealer Name Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name...

  • Page 88: Vessel Maintenance Notes

    Section 8 - Maintenance Log Vessel Maintenance Notes Record all general maintenance performed on your power package here. Save all work orders and receipts. Engine Date Maintenance Completed Servicing Dealer Hours 90-8M0113988 DECEMBER 2015 Page 81...
  • Page 89 Parc Industriel de Petit-Rechain 41-71 Bessemer Drive P.O. Box 1939 B-4800 Verviers, Belgium Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA © Mercury Marine. All rights reserved. 90-8M0113988 NOVEMBER 2015 Printed in U.S.A.

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