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Mercury TDI 4.2L, Manual

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Summary of Contents for TDI 4.2L

Page 1: ...hese special instructions while performing the service plus common sense operation are major accident prevention measures WARNING Indicates a hazardous situation which if not avoided could result in d...

Page 2: ...erCruiser Mercury Mercury with Waves Logo Mercury Marine Mercury Precision Parts Mercury Propellers Mercury Racing MotorGuide OptiMax Quicksilver SeaCore Skyhook SmartCraft Sport Jet Verado VesselView...

Page 3: ...18 Pleasure Duty Rating 18 Basic Boat Operation 19 Operation Chart 19 Freezing Temperature and Cold Weather Operation 19 Drain Plug and Bilge Pump 20 Starting Shifting and Stopping 20 Before Starting...

Page 4: ...r from the Filter 48 Replacing the Filter 48 Purging the Fuel System 49 Fuel System 49 Priming 49 Fuel Tank Cleaning and Flushing 49 Seawater System 49 Seawater Pump Impeller Inspection 49 Sterndrive...

Page 5: ...eering Wheel Turns Hard or Jerky 74 Power Trim Does Not Operate Electric Motor Operates but Sterndrive Unit Does Not Move 74 Power Trim Does Not Operate Electric Motor Does Not Operate 75 Section 7 Cu...

Page 6: ...Page iv 90 8M0114081 eng DECEMBER 2015...

Page 7: ...Controls 5 Switches 5 Emergency Stop Switch 6 Lanyard Stop Switch 6 Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition 7 Digital Throttle and Shift 7 Engine Electrical System Ov...

Page 8: ...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 Audio...

Page 9: ...usly monitors and reports basic operating data including detailed information such as seawater temperature and depth trim status boat speed and steering angle and the status of fuel oil water and wast...

Page 10: ...system refer to the manual provided with your gauge package System Link Digital Gauges Some instrumentation packages include gauges that augment the information provided by VesselView and the SmartCra...

Page 11: ...ted with an optional start stop switch START Turn the key to the start position and release to start the engine NOTE The key can only be removed with the key switch in the OFF position Dual Engine Sta...

Page 12: ...rs in the front of the boat could be ejected over the bow and possibly struck by the propulsion or steering components The operator can lose power and directional control in heavy seas strong current...

Page 13: ...ion of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss o...

Page 14: ...er assembly 3 Determine which fuse belongs to the failed circuit using the illustration below a Helm power 5 amp fuse b EFP 1 amp fuse c Feature A 1 amp fuse d T 15 5 amp fuse e Feature B 1 amp fuse f...

Page 15: ...anyard stop switch will stop the engine immediately a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down However the boat will not complete a...

Page 16: ...he boat bottom is at a 3 5 angle to the water 3 5 mc79528 Trimming the sterndrive up out can Generally increase top speed Increase clearance over submerged objects or a shallow bottom Cause the boat t...

Page 17: ...and MerCathode Overload Protection If an electrical overload on the electrical system occurs a fuse will open blow Find and correct the cause before replacing the fuse NOTE If you must operate the en...

Page 18: ...and weight Note that the exhaust gas emissions certification will not affect the fit function or performance of the engines Boatbuilders and dealers may not remove the label or the part it is affixed...

Page 19: ...ckage 90 8M0114081 eng DECEMBER 2015 Page 13 Engine Components a Exhaust outlet b Turbocharger c Oil filter d Engine oil filler cap e Sacrificial anode hidden f Intercooler g Seawater pump h Heat exch...

Page 20: ...nt reservoir cap d Ribbed V belt e Alternator f Fuses g Air filter h Fuel injection pump drive belt hidden NOTE The fuel injection pump drive belt is located at the rear of the engine and is protected...

Page 21: ...tarting the Engine After Stopped While in Gear 22 Trailering the Boat 22 Protecting People In The Water 22 Protecting People in the Water 22 While Boat is in Operation 22 While the Boat is Stationary...

Page 22: ...passengers are boarding unloading or are near the back stern of the boat Shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal law requires that there be a U S...

Page 23: ...urther assistance from local law enforcement Carbon Monoxide Exposure Be Alert To Carbon Monoxide Poisoning Carbon monoxide CO is a deadly gas that is present in the exhaust fumes of all internal comb...

Page 24: ...per application or failure to operate the power package within the specified operating parameters will not be covered by the Mercury Diesel Limited Warranty Duty Cycle Rating It is the responsibility...

Page 25: ...d exhaust leaks etc Listen for the audio alarm Run the engine at idle RPM for several minutes to allow the turbocharger and engine to cool Turn on and run the engine compartment bilge blower if equipp...

Page 26: ...d weather equipment and precautions Refer to Section 6 for cold weather or extended storage related information Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for wat...

Page 27: ...erating temperature before demanding power from the engine Engine Warm Up 1 After starting the engine verify that all instrumentation is functioning properly 2 Operate the engine at 1000 1200 RPM unti...

Page 28: ...e engine for several minutes before shutdown 2 Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool 3 Turn the key switch to the OFF position or press the...

Page 29: ...eling faster than idle speed A sudden reduction in boat speed such as plunging into a large wave or wake a sudden throttle reduction or a sharp change of boat direction could throw them over the front...

Page 30: ...obstacles that could be struck by the drive components rudder or the boat bottom mc79679 1 IMPORTANT To help reduce injury or impact damage from striking a floating or underwater object control the bo...

Page 31: ...or a propeller Cavitation increases propeller speed while reducing boat speed Cavitation can seriously erode the surface of the gear housing or the propeller Common causes of cavitation are Weeds or o...

Page 32: ...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...

Page 33: ...p extend the life of the power package Mercury Diesel recommends the following Select a propeller that functions efficiently throughout the recommended engine powerband for a fully loaded boat Refer t...

Page 34: ...Section 2 On The Water Notes Page 28 90 8M0114081 eng DECEMBER 2015...

Page 35: ...rous Metals and the Fuel System 30 Diesel Fuel in Cold Weather 30 Antifreeze Coolant 30 Engine Oil 31 Engine Specifications 31 Fluid Specifications 32 Engine 32 Bravo Sterndrive Fluid Specifications D...

Page 36: ...s NOTE If your engine suddenly becomes noisy after a fill up you possibly received substandard fuel with a low cetane rating On intermittent use engines high sulphur content diesel fuel will greatly i...

Page 37: ...ructions The acceptable antifreeze coolants is listed in the following table Refer to Section 5 Maintenance for respective change intervals Description Availability Part Number Marine Engine Coolant W...

Page 38: ...075K01 Bravo Sterndrive Fluid Specifications Diesel Sterndrive Model Fluid Capacity includes the Sterndrive and the Gear Lube Monitor Fluid Type Fluid Part Number Bravo One XR 2736 ml 92 1 2 oz High P...

Page 39: ...Air Filter 47 Removal 47 Inspection and Cleaning 47 Installation 48 Fuel Filter 48 Draining Water from the Filter 48 Replacing the Filter 48 Purging the Fuel System 49 Fuel System 49 Priming 49 Fuel...

Page 40: ...WARNING Accidental engine starting can cause serious injury or death Remove the key from the ignition switch and engage the lanyard stop or E stop switch to prevent the engine from starting when perf...

Page 41: ...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 ne...

Page 42: ...and clean the seawater strainer Inspect the seawater pump and change the impeller as necessary Inspect the anodes and replace them if they are 50 eroded Verify that the gauges and the wiring connectio...

Page 43: ...the oil level The oil level must be between the indicator marks on the dipstick If necessary add oil as follows Dipstick indicator marks a Do not add oil b Safe operating range c Add oil Filling IMPOR...

Page 44: ...e only the recommended engine oil Refer to Specifications 1 Start and run the engine until normal operating temperature is achieved 2 Stop the engine and wait approximately five minutes for the oil to...

Page 45: ...ne and check for leaks Sterndrive Gear Lube 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...

Page 46: ...re that the rubber gasket is inside the gear lube monitor cap and install the cap Do not overtighten a Gear lube monitor cap NOTE When filling the entire sterndrive refer to Changing Changing 1 Remove...

Page 47: ...Vent plug b Sealing washer IMPORTANT If any water drains from the fill and drain plug hole or if the gear lube appears milky the sterndrive is leaking and should be checked immediately by your Mercury...

Page 48: ...r lube level at the ADD mark b Gear lube level at the OPERATING RANGE mark c Gear lube monitor cap Sterndrive Model Fluid Capacity includes the Sterndrive and the Gear Lube Monitor Fluid Type Fluid Pa...

Page 49: ...terndrive propeller Refer to Propellers 16 Check the level of the gear lube monitor after the first use Refer to Maintaining Fluid Levels IMPORTANT The gear lube monitor level will change while the pr...

Page 50: ...specified fluid Refer to Filling Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim pump 92 858074K01 Filling 1 If the fluid level is below the MIN line the speci...

Page 51: ...MPORTANT Do not leave the steering wheel at full lock longer than 15 seconds with the engine running The power steering fluid will heat up considerably when the steering wheel is at full lock and coul...

Page 52: ...ower Trim and Steering Fluid Power assisted steering system 92 858074K01 28 Dexron III Automatic Transmission Fluid Power assisted steering system Obtain Locally 5 Install the fill cap dipstick Changi...

Page 53: ...k but no higher than the coolant maximum level Description Where Used Part Number Marine Engine Coolant Closed cooling system 8M0078028 4 Install the cap and tighten securely to prevent coolant loss A...

Page 54: ...uipped 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 d...

Page 55: ...wear personal protective equipment when servicing the fuel system NOTE It is possible that the engine will not start if the fuel system has not been completely purged of air 1 Ensure that the fuel ta...

Page 56: ...ller onboard the boat at all times 6 Lubricate the impeller with silicone spray or glycerine 7 Push the impeller onto the shaft and press the protective cap into the impeller 8 Insert a new O ring int...

Page 57: ...er while the engine is running 4 Operate the engine until the water draining from the engine runs clear to ensure that all sludge and salt residues are flushed away 5 Switch off the engine 6 Replace t...

Page 58: ...water inlet or seacock when performing service or maintenance on the cooling system 1 With the engine off close the seacock if equipped or remove and plug the seawater inlet hose 2 Remove the screws...

Page 59: ...ge components exposed to water To help control the effects of galvanic corrosion Mercury Diesel power packages come with several sacrificial anodes and other corrosion protection devices For a more co...

Page 60: ...jury or death from loss of boat control Completely retract the end of the steering cable before applying lubricant NOTE If the steering cable does not have a grease fitting the inner wire of the cable...

Page 61: ...throttle control system for the TDI 4 2L engine is electronic and requires no maintenance See your Mercury Diesel authorized repair facility for diagnosis or repair Shift Cable The shift control syste...

Page 62: ...e coupler The sealed coupler and the shaft splines can be lubricated without removing the sterndrive unit Lubricate the engine coupler splines through the grease fitting on the coupler by applying app...

Page 63: ...eshaft grease fittings b Transom end grease fitting c Engine end grease fitting Tube Ref No Description Where Used Part No Extreme Grease Transom end grease fitting engine end grease fitting driveshaf...

Page 64: ...oval WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in...

Page 65: ...e models a Propeller shaft splines b Forward thrust hub c Flo Torque II drive hub d Propeller e Drive sleeve adapter f Tab washer g Propeller nut Bravo Two Models 1 Straighten the bent tabs of the tab...

Page 66: ...aft anode screw e Flat washer f Star washer 4 Turn the aft propeller shaft nut counterclockwise to remove the nut 5 Slide the propeller and thrust hub off of the propeller shaft 6 Using the propeller...

Page 67: ...opeller shaft 1 Liberally coat the propeller shaft spline with one of the following lubricants Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Propeller shaft splines 92 802859A 1 Extrem...

Page 68: ...ered side toward the propeller hub 3 Align splines and place front propeller on propeller shaft 4 Install the front propeller locknut and tighten to the specified torque using the propeller nut tool P...

Page 69: ...or death Turn off the engine and remove the ignition key before inspecting the belts In the event that the drive belt requires replacement it is recommended that the drive belt replacement be perform...

Page 70: ...broken off the belt When chunk out has occurred a belt can fail at any moment Chunk out can happen when several cracks in one area move parallel to the cord line Heat age and stress are the primary co...

Page 71: ...art charging This could cause a voltage spike in the engine s electrical system In either case the ECU could shut off When the voltage returns to the range that the ECU requires the ECU will reset its...

Page 72: ...Section 4 Maintenance Notes Page 66 90 8M0114081 eng DECEMBER 2015...

Page 73: ...le of Contents Cold Weather Freezing Temperature Seasonal Storage and Extended Storage 68 Preparing Your Power Package for Seasonal or Extended Storage 68 Seasonal Storage Instructions 68 Extended Sto...

Page 74: ...ewise cold weather freezing temperature storage refers to whenever the boat is not being operated and the possibility of freezing temperatures exists The seawater section of the cooling system must be...

Page 75: ...ted by law Dispose of propylene glycol antifreeze in accordance with federal state and local laws and guidelines 5 Start the engine and operate at idle speed until the antifreeze mixture has been pump...

Page 76: ...re that all cooling system hoses are connected properly and the hose clamps are tight CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical sho...

Page 77: ...or Performance 73 No Fuel or Faulty Fuel Supply 73 Engine Will Not Start Starter Does Not Turn 73 Excessive Engine Temperature 73 Insufficient Engine Temperature 74 Low Engine Oil Pressure 74 Battery...

Page 78: ...hanical fuel delivery pump Have pump replaced by a Mercury Diesel authorized repair facility if fuel is present Throttle not operating properly Check the throttle for freedom of movement Faulty electr...

Page 79: ...utral The neutral switch in the gearbox does not output a signal Check the operation of the neutral switch The lanyard stop switch is activated Reset the lanyard stop switch The ignition is switched o...

Page 80: ...iring Alternator drive belt loose or in poor condition Replace or adjust Unacceptable battery condition Test battery Remote Control Operates Hard Binds Has Excessive Free play or Makes Unusual Sounds...

Page 81: ...ury Diesel authorized repair facility Power Trim Does Not Operate Electric Motor Does Not Operate Possible Cause Remedy Blown fuse Replace the fuse Loose or dirty electrical connections or damaged wir...

Page 82: ...Section 6 Troubleshooting Notes Page 76 90 8M0114081 eng DECEMBER 2015...

Page 83: ...rvice Away From Home 78 Stolen Power Package 78 Attention Required After Submersion 78 Replacement Service Parts 78 Parts and Accessories Inquiries 78 Resolving a Problem 78 Contact Information for Me...

Page 84: ...in both fresh and saltwater environments These conditions require numerous special parts Exercise care when replacing marine engine parts because specifications are different from those of the standa...

Page 85: ...rviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 1 954 744 3535 Japan...

Page 86: ...Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Depar...

Page 87: ...Section 8 Maintenance Log 90 8M0114081 eng DECEMBER 2015 Page 81 Section 8 Maintenance Log Table of Contents Scheduled Maintenance Log 82 Vessel Maintenance Notes 83 8...

Page 88: ...me 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 Signa...

Page 89: ...g 90 8M0114081 eng DECEMBER 2015 Page 83 Vessel Maintenance Notes Record all general maintenance performed on your power package here Save all work orders and receipts Date Engine Hours Maintenance Co...

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