Mercury D4.2L User Manual

CA741
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 Sections of this manual. The warranty state-
ment 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. Please review this important information.
CE344
WARNING
The operator (driver) is responsible for the correct and safe operation of the boat, the
equipment aboard and the safety of all occupants aboard. We strongly recommend
that the operator read this Operation, Maintenance and Warranty Manual and
thoroughly understand the operational instructions for the power package and all
related accessories before the boat is used.
WARNING
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to the state of
California to cause cancer, birth defects, and other reproductive harm.
The description and specifications contained herein were in effect at the time this guide was
approved for printing. Mercury Marine, whose policy is one of continuous improvement,
reserves the right to discontinue models at any time, or to change specifications or designs,
without notice and without incurring obligation.
Mercury Marine Fond du Lac, Wisconsin, U.S.A.
Printed in U.S.A.
1999, Mercury Marine
The following are registered trademarks of Brunswick Corporation:
Autoblend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser,
Mercury, Mercury Marine, Quicksilver, Ride-Guide, and Thruster.
Diesel Engines - Bravo Models
1999, Mercury Marine 90Ć860094990 1099

Mercury D4.2L Specifications

General

Fuel Type	Diesel
Horsepower	350 - 370 hp
Torque	568 - 598 lb-ft
Displacement	4.2L
Bore x Stroke	84 mm x 95 mm
Cooling System	Liquid-cooled

Summary

Warranty Information and Registration

Owner Warranty Registration Process

Details on registering the product for warranty in the US and Canada.

Mercruiser Diesel Limited Warranty Policy

Warranty Coverage and Exclusions

Manual Usage and Safety Precautions

Read This Manual Thoroughly

Importance of understanding manual warnings and cautions for safety.

Understanding Warning and Caution Symbols

Explanation of warning symbols and important notes for operation.

Exhaust Emissions and Carbon Monoxide Safety

Carbon Monoxide Poisoning Awareness

Warning about carbon monoxide hazards, symptoms, and prevention.

Wave and Wake Jumping Hazards and Safety

Safety During Wave/Wake Jumping

Safety advice to avoid injury during wave or wake jumping.

Impact with Underwater Hazards and Safety

Reducing Injury from Underwater Impacts

Precautions and consequences of striking underwater objects.

Water Safety and High-Performance Operation

Protecting People in the Water

Safety measures when people are in the water near the boat.

Important Operation and Maintenance Information

Recommended Operation Duty Cycles

Recommended operation duty cycles for pleasure and light duty ratings.

Owner and Dealer Responsibilities

Owner/Operator Responsibilities

Operator's duties for safety, maintenance, and dealer checks.

Cold Weather Operation and System Protection

Preventing Freezing Damage

Precautions to prevent freezing damage to the power package.

Boat Operation Care and Storage Procedures

Attention Required After Submersion

Immediate steps required after the power package is submerged.

Engine Break-In Procedures

Initial Engine Break-In Procedure

Procedure for the initial break-in of new diesel engines.

20-Hour Break-In Period Rules

Rules for the first 20 hours of operation for optimal break-in.

Operation: Engine Instruments and Controls

Quicksilver Instruments and Gauges

Engine Starting, Shifting, and Stopping (D3.6L/D4.2L)

Before Starting the Engine

Engine Starting and Warm-Up Procedures

Starting a Cold Engine

Steps for starting a cold engine and warm-up procedures.

Engine Warm Up Importance

Engine Operation: Starting, Shifting, and Stopping

Starting a Warm Engine

Steps for starting a warm engine.

Shifting the Drive Unit

Engine Shut-Down Procedure

Engine Starting, Shifting, and Stopping (D-Tronic)

Before Starting D-Tronic Engines

D-Tronic Engine Starting and Warm-Up

Starting a Cold D-Tronic Engine

Steps for starting a cold D-Tronic engine and warm-up.

D-Tronic Engine Warm Up Importance

D-Tronic Engine Operation: Starting, Shifting, and Stopping

Starting a Warm D-Tronic Engine

Steps for starting a warm D-Tronic engine.

Shifting D-Tronic Drive Unit

D-Tronic Engine Shut-Down

Fuel Requirements and Safety Warnings

Maintenance Overview and Aids

Routine Maintenance Schedules

Daily, Weekly, and Monthly Maintenance

Daily, weekly, and monthly routine maintenance tasks.

Scheduled Maintenance Intervals (Part 1)

Scheduled Maintenance Tasks (Post 20/100 Hours)

Maintenance tasks based on hours or years of operation.

Scheduled Maintenance Intervals (Part 2)

Scheduled Maintenance Tasks (Annual/2+ Years)

Further scheduled maintenance tasks based on intervals.

Fuel System Maintenance and Procedures

Fuel Tank Cleaning and Flushing

Power Package Recommissioning Steps

Troubleshooting Engine Starting Issues

Starter Motor Problems

Possible causes and remedies for starter motor issues.

Engine Will Not Start or Is Hard To Start

Possible causes and remedies for starting problems.

Troubleshooting Engine Performance Issues

Engine Runs Rough, Misses, or Backfires

Possible causes and remedies for rough running engines.

Poor Engine Performance Causes

Possible causes and remedies for poor engine performance.

Troubleshooting Engine Temperature Issues

Excessive Engine Temperature

Possible causes and remedies for overheating engines.

Insufficient Engine Temperature

Possible causes and remedies for engines running too cool.

Troubleshooting Oil, Battery, and Control Issues

Low Engine Oil Pressure

Possible causes and remedies for low engine oil pressure.

Battery Charging Problems

Possible causes and remedies for battery charging issues.

Remote Control Operation Issues

Troubleshooting for remote control issues.

Troubleshooting Steering and Power Trim Systems

Steering Wheel Turns Hard or Jerky

Possible causes and remedies for hard or jerky steering.

Power Trim System Malfunctions

Troubleshooting steps for power trim system issues.

Owner Service Assistance

Local Repair Service Recommendations

Service Away From Home

Resolving Product Problems

Steps to take to resolve issues with the product.