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D4.2L/220
MerCruiser D4.2L/220 User Manual
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Diesel Engines - Inboard Models
1996, Mercury Marine
90-860096970 996
2
Table of Contents
Serial Numbers
2
Table of Contents
3
Welcome
5
Read this Manual Thoroughly
6
Lanyard Stop Switch
7
Exhaust Emissions
9
Be Alert to Carbon Monoxide Poisoning
9
Poor Ventilation
9
Good Ventilation
9
Safe Boating Suggestions
10
Protecting People in the Water
11
While You Are Cruising
11
While Boat Is Stationary
11
High-Speed and High-Performance Boat Operation
11
Conditions Affecting Operation
12
Weight Distribution
12
Bottom of Boat
12
Propeller Selection
13
How Elevation and Climate Affect Performance
14
Operation and Maintenance
15
Recommended Operation/Duty Cycle
15
Owner/Operator Responsibilities
16
Dealer Responsibilities
16
Freezing Temperature and Cold Weather Operation
17
Drain Plug and Bilge Pump
17
Launching and Boat Operation Care
18
Attention Required after Submersion
18
Stolen Power Package
18
Replacement Service Parts
19
Do-It-Yourself Maintenance Suggestions
19
Diagnosing Problems of EDI (if so Equipped)
19
Engine Break-In
20
Initial Break-In Procedure
20
20 Hour Break-In Period
20
After Break-In Period
21
End of First Season Checkup
21
Specifications
22
Seacock
22
Seawater Strainer
22
Fuel Requirements
22
Diesel Fuel in Cold Weather
23
Crankcase Oil
23
Engine Specifications
24
Operation
27
Quicksilver Instruments and Instrumentation
27
Electrical System Overload Protection
29
Starting, Shifting and Stopping - D3.6L/180 and D4.2L/220
34
Operation Chart - D3.6L/180 and D4.2L/220
37
Starting, Shifting and Stopping - D2.8L D-Tronic and D4.2L D-Tronic
38
Operation Chart - D2.8L D-Tronic and D4.2L D-Tronic
41
General Maintenance Information
42
Maintenance Aids
42
Maintenance Schedules
43
Scheduled Maintenance that Should be Performed by a Dealer
44
Checking Fluid Levels
47
Crankcase Oil
47
Transmission Fluid
47
Engine Coolant
49
Cleaning Quicksilver Seawater Strainer
51
Lubrication
51
Shift Cable
51
Throttle Cable
51
Seawater Pump Impeller
51
Flushing Fuel Tank
51
Flushing Seawater Cooling System
53
Fuel System
55
Fuel Tank
55
Hand Pump/Primer
55
Priming Fuel System
55
Filling Fuel Filter
55
Filling (Bleeding) Fuel System
55
Draining Water Separating Fuel Filter
55
Replacing Water Separating Fuel Filter
57
Corrosion and Corrosion Protection
57
Internal Components
57
Miscellaneous Maintenance
59
Battery
59
Bottom of Boat
59
Antifouling Paints
59
Inspection and Maintenance
59
Cold Weather or Extended Storage
60
Power Package Layup
60
Battery Winter Storage
60
Power Package Recommissioning
60
Troubleshooting
61
Starter Motor will Not Crank Engine, or Cranks It very Slowly
61
Engine will Not Start, or Is Hard to Start
61
Engine Runs Rough, Misses And/Or Backfires
62
Poor Performance
62
Excessive Engine Temperature
63
Insufficient Engine Temperature
63
Low Engine Oil Pressure
64
Battery will Not Come up on Charge
64
Remote Control Operates Hard, Binds, Has Excessive Free-Play or Makes Unusual Sounds
64
Warranty Information
65
Owner Warranty Registration
65
International Owner Registration
66
Warranty Policy
67
Mercruiser Diesel Limited Warranty
67
Mercruiser Diesel Limited Warranty (Continued)
68
Marine Power International Branch or Distributor Service Offices
69
Warranty Coverage
70
Transferable Warranty
71
Q-GUARD Product Protection Plan
71
Owner Service Assistance
72
Local Repair Service
72
Service Away from Home
72
Parts and Accessories Inquiries
72
Resolving a Problem
72
Mercury Marine Service Offices
73
Customer Service Literature
74
English Language
74
Other Languages
74
Literature Order Form
77
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MerCruiser D4.2L/220 Specifications
General
Engine Type
Inboard
Horsepower
220 hp
Displacement
4.2L
Fuel Type
Diesel
Fuel System
Direct Injection
Cooling System
Closed cooling
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