91
CD661
REPLACING WATER SEPARATING FUEL FILTER
CAUTION
Any water entering the fuel injection system will disable the system. Check for water in water
separating fuel filter before startup, daily.
CAUTION
If water should enter the fuel injection system, take unit to an Authorized MerCruiser Dealer
IMMEDIATELY, so that corrosion and rusting of the injectors and other components can be avoided.
WARNING
Be careful when changing water separating fuel filter. Diesel fuel is flammable. Be sure ignition key is
OFF. Do not allow fuel to contact any hot surfaces which may cause it to ignite. Do no tallow sources
of open flame in the area. Wipe up any spilled fuel immediately. Dispose of fuel soaked rags, paper,
etc. in an appropriate air tight, fire retardant container. Fuel soaked items may spontaneously ignite
and result in a fire hazard which could cause serious bodily injury or death.
1 On D3.6L, D4.2L, D2.8L D-Tronic and D4.2L D-Tronic Models:
A Twist locking ring by hand. Remove water separating fuel filter and sealing ring from mounting bracket. Do
not use a filter wrench.
B Remove the drain cap and O-ring from bottom of the existing filter. Install on new filter.
C Coat sealing ring on new filter with clean motor oil.
D Align filter to bracket. Twist locking ring by hand to secure filter to bracket. Do not use a filter wrench.
E Check that bottom drain cap is securely tightened. Fill fuel filter as explained previously. Check filter and drain
cap for fuel leaks.
2 On D4.2L LD Models:
A Remove and discard water separating fuel filter and sealing ring from mounting bracket.
B Coat sealing ring on new filter with clean motor oil.
C Thread filter onto bracket and tighten securely by hand. Do not use a filter wrench.
D Check that bottom drain cap is securely tightened. Fill fuel filter as explained previously. Check filter and drain
cap for fuel leaks.
WARNING
Make sure no leaks exist before closing engine hatch.
3 All Models: Start and run engine. Check filter connection for fuel leaks. If leaks exist, recheck filter installa-
tion. If leaks continue, stop engine immediately and contact your Authorized Mercury MerCruiser Dealer.
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