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MerCruiser D4.2L/220 User Manual

MerCruiser D4.2L/220
80 pages
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Diesel Engines - Inboard Models
1996, Mercury Marine 90-860096970 996

Table of Contents

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MerCruiser D4.2L/220 Specifications

General IconGeneral
Engine TypeInboard
Horsepower220 hp
Displacement4.2L
Fuel TypeDiesel
Fuel SystemDirect Injection
Cooling SystemClosed cooling

Summary

Read This Manual Thoroughly

Safety Alerts

Understand WARNINGS and CAUTIONS for safe operation and to prevent injury or death.

Lanyard Stop Switch

Exhaust Emissions

Be Alert To Carbon Monoxide Poisoning

Carbon monoxide is a deadly gas; symptoms include headache, dizziness, nausea.

Safe Boating Suggestions

Protecting People In The Water

While You Are Cruising

Exercise caution at slow speeds; neutral gear can still cause propeller rotation.

While Boat Is Stationary

Shut off engine before allowing people in water near the boat.

High-Speed And High-Performance Boat Operation

Propeller Selection

Operation and Maintenance

Freezing Temperature And Cold Weather Operation

Launching and Boat Operation Care

Attention Required After Submersion

Contact dealer before recovery and seek immediate service after recovery.

Replacement Service Parts

Engine Break-In

Initial Break-In Procedure

Procedure for seating pistons and rings for new diesel engines.

20 HOUR BREAK-IN PERIOD

Rules for the first 20 hours of operation to ensure oil consumption and performance.

Specifications

Crankcase Oil

Engine Specifications (D3.6L/180 and D4.2L/220)

Engine Specifications (D2.8L D-Tronic and D4.2L D-Tronic)

Operation

Engine System Monitor Features

Electrical System Overload Protection

Starting, Shifting and Stopping - D3.6L/180 and D4.2L/220

Pre-Starting Checks

Essential checks before starting the engine for safety and damage prevention.

Starting and Warm-up Procedures

Starting a Cold Engine

Procedure for starting a cold engine, including pre-lubrication and glow plugs.

Engine Warm-Up

Importance of warming up the engine to normal operating temperature.

Engine Operation Procedures

Starting a Warm Engine

Procedure for starting a warm engine, checking instrumentation.

Shifting Gears

Instructions for shifting into forward and reverse gears at idle RPM.

Engine Shut-Down (Stopping)

Procedure for safely shutting down the engine, including turbocharger cool-down.

D-Tronic Engine Operation

Starting Procedure

Pre-starting checks and procedure for D-Tronic engines.

D-Tronic Starting and Warm-up

Starting a Cold D-Tronic Engine

Procedure for starting cold D-Tronic engines, including glow plug checks.

D-Tronic Engine Warm-Up

Warm-up process for D-Tronic engines to ensure proper oil film.

D-Tronic Operation Procedures

Starting a Warm D-Tronic Engine

Procedure for starting warm D-Tronic engines, checking instrumentation.

D-Tronic Engine Shut-Down

Procedure for shutting down D-Tronic engines, including cool-down.

Maintenance

Maintenance Schedules

Scheduled Maintenance That Should Be Performed By A Dealer

Engine Coolant

Seawater System Maintenance

Flushing Seawater Cooling System

Fuel System

Replacing Water Separating Fuel Filter

Miscellaneous Maintenance

Cold Weather and Storage Procedures

Troubleshooting

Starter Motor Issues

Possible causes and remedies for starter motor not cranking or cranking slowly.

Engine Running Problems

Causes and remedies for engine running rough, missing, or backfiring.

Excessive Engine Temperature

Causes and remedies for engine overheating.

Oil Pressure and Charging Problems

Causes and remedies for low oil pressure and battery charging issues.

Starting Difficulties

Possible causes and remedies for engine not starting or starting hard.

Performance Issues

Causes and remedies for poor engine performance.

Warranty Information

Warranty Policy and Coverage

Mercruiser Diesel Limited Warranty

Details of the limited warranty for pleasure and light-duty craft applications.

Warranty Coverage

Owner Service Assistance

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