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Mercury MerCruiser 5.7 MPI User Manual

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NOTE: The following applies to CE marked products only.
Declaration of Conformance – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury
MerCruisers' instructions complies with the requirements of the following directives
by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Owner's manual (A.2.5)
Openings in Hull, Deck and superstructure (A.3.4) ISO 9093‑1; ISO 9093‑2
Handling characteristics (A.4)
Inboard Engine (A.5.1.1)
Fuel System (A.5.2)
Electrical System (A.5.3)
Steering system (A.5.4)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Ignition‑protected equipment (Annex II)
Mercury MerCruiser declares that our sterndrive or inboard engines without integral
exhaust, when installed in a recreational craft, in accordance with the manufacturers
supplied instructions, will meet the exhaust emissions requirements of the directive
mentioned above. This engine must not be put into service until the recreational craft
in which it is to be installed has been declared in conformity, if so required, with the
relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion engine
driven devices ‑ Radio disturbance characteristics
Electrostatic discharge testing
The notified body responsible for surveillance of the quality system under Full Quality Assurance
Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.
President ‑ Mercury Marine, Fond du Lac, WI USA
Applicable Requirement
Patrick C. Mackey
Standards Applied
ISO 10240
ISO 8665
ISO 15584; ISO 10088; ISO 7840; ISO 10133
ISO 10088; ISO 7840; ISO 8469
ISO 10133; ISO 8846
Applicable portions of: ISO 10592, ISO 8848 and
ABYC P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 8846; SAE J1171; SAE J1191; SAE J 2031
EN 50081‑1
EN 50082‑1
SAE J551 (CISPR 12)
EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3

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  • Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
  • Page 2 Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

  • Page 3: Read This Manual Thoroughly

    We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
  • Page 4 NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. 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.

  • Page 5: Table Of Contents

    Duration Of Coverage........11 Canada..............2 How To Obtain Warranty Coverage....12 Transfer of Warranty..........3 What Mercury Will Do........12 Mercury Product Protection Plan: United States and What Is Not Covered........12 Canada..............3 Components Of The Emission Control System 12 Mercury MerCruiser Limited Warranty Disclaimers And Limitations......14...
  • Page 6 Drain Plug and Bilge Pump......44 Boats Having An Open Front Deck....48 Basic Boat Operation (DTS Models)....44 Boats With Front‑Mounted, Raised Pedestal Launching and Boat Operation..... 44 Fishing Seats...........48 Operation Chart.......... 44 Wave and Wake Jumping........49 Starting and Stopping the Engine....45 Impact with Underwater Hazards......
  • Page 7 Section 8 - Customer Assistance Information Owner Service Assistance........104 Parts and Accessories Inquiries....105 Local Repair Service........104 Resolving a Problem........105 Service Away From Home......104 Mercury Marine Service Offices......105 Stolen Power Package........104 Ordering Literature..........106 Attention Required after Submersion....104 United States and Canada......106 Replacement Service Parts......104 Outside The United States and Canada..106...
  • Page 8 Page iv 90-899883173 DECEMBER 2007...

  • Page 9: Section 1 - Warranty

    Canada............2 What Mercury Will Do ........12 Transfer of Warranty..........3 What Is Not Covered ........12 Mercury Product Protection Plan: United States and Components Of The Emission Control Canada..............3 System ............12 Mercury MerCruiser Limited Warranty (Gasoline- Disclaimers And Limitations ......

  • Page 10: Warranty Registration: United States And Canada

    A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.

  • Page 11: Transfer Of Warranty

    To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address and engine serial number to Mercury Marine’s warranty registration department. In the United States mail to:...

  • Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)

    Only) Mercury MerCruiser Limited Warranty (Gasoline-Fueled Products Only) What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. Duration of Coverage Warranty Period for Recreational Use The warranty period begins on the date the product is first sold to a recreational‑use retail purchaser or the date on which the product is first put into service, whichever occurs first.
  • Page 13 Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine. Mercury Marine will then arrange for the inspection and any covered repair.

  • Page 14: 3-Year Limited Warranty Against Corrosion

    Also, expenses associated with the removal or replacement of boat partitions or other material in order to gain access to the product are not covered by this warranty. No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation, or warranty regarding the product, other than those contained in this limited warranty.

  • Page 15: Global Warranty Charts

    Section 1 - Warranty This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty;...

  • Page 16: Commercial Application Warranty Chart

    Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...

  • Page 17: Government Application Warranty Chart

    500 hours 500 hours 500 hours 500 hours 500 hours Pacific, Australia, Zealand) NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies Mercury Installation Quality Certification Program 15502 90-899883173 DECEMBER 2007 Page 9...

  • Page 18: California Emissions Limited Warranty

    The regulations apply to all inboard and sterndrive engines that were manufactured for the 2003 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the...

  • Page 19: Duration Of Coverage

    Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions identified below. The cost to diagnose a warranty failure is covered under the warranty (if the warranty claim is approved).

  • Page 20: How To Obtain Warranty Coverage

    Mercury Marine and Mercury will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.
  • Page 21 Section 1 - Warranty Cold start enrichment system Intake valve(s) 2. Air Induction System Controlled hot air intake system Intake manifold Air filter Turbocharger systems Heat riser valve and assembly 3. Ignition System Spark plugs Magneto or electronic ignition system Spark advance/retard system Ignition coil and/or control module Ignition wires...

  • Page 22: Disclaimers And Limitations

    1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.

  • Page 23: Emission Control Information Label

    Section 1 - Warranty You are responsible for presenting your inboard or sterndrive engine to a Mercury Marine dealer authorized to service the product as soon as a problem exists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.

  • Page 24: Owner Responsibility

    Beginning January 1, 2003, one Three‑Star or Four‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2007 and later exhaust emission standards.
  • Page 25 Section 1 - Warranty One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
  • Page 26 Section 1 - Warranty Notes: Page 18 90-899883173 DECEMBER 2007...

  • Page 27: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............20 Panel Mount Features........28 Engine Serial Number Decal......20 Console Mount Features - Single Engine..29 Transmissions..........20 Slim Binnacle Console Mount Features - Single Velvet Drive Transmissions ....

  • Page 28: Identification

    Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal The serial number decal is located on top of the engine.

  • Page 29: Zf Marine Transmissions

    Section 2 - Getting to Know Your Power Package On the Velvet Drive 5000A and 5000V Transmissions the transmission identification plate indicates gear ratio, serial number and model. 7370 Velvet Drive 5000A ‑ 8 degree down‑angle transmission shown (5000V ‑ V‑drive similar) Transmission identification plate ZF MARINE TRANSMISSIONS On the ZF Marine 8 Degree Down‑Angle and V‑Drive Transmissions, the transmission...

  • Page 30: Walter V-Drive Transmissions

    Section 2 - Getting to Know Your Power Package WALTER V-DRIVE TRANSMISSIONS On the Walter V‑Drive Transmissions, the transmission identification plate indicates gear ratio, serial number, and model. 7452 Walter RV‑36 V‑drive Transmission identification plate Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator's position (as in accidental ejection from the operator's position).

  • Page 31: Instrumentation

    Section 2 - Getting to Know Your Power Package • consuming alcohol or drugs • high speed boating maneuvers The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.

  • Page 32: Digital Gauges

    Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure (requires a SmartCraft oil pressure sender kit), battery voltage, fuel consumption, and engine operating hours.

  • Page 33: Analog Gauges

    Remote Controls (Non‑DTS Models) Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.

  • Page 34: Panel Mount Features

    Section 2 - Getting to Know Your Power Package PANEL MOUNT FEATURES 17355 Neutral lock button Control handle tension adjustment screw Throttle only button Control handle Lanyard stop switch Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed in to move the control handle out of neutral.

  • Page 35: Console Mount Features

    Section 2 - Getting to Know Your Power Package CONSOLE MOUNT FEATURES 17356 Throttle Only Button Control Handle Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position.

  • Page 36: Remote Controls (Dts Models)

    IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

  • Page 37: Console Mount Features - Single Engine

    Section 2 - Getting to Know Your Power Package Throttle Only Button - Allows engine throttle advancement without shifting the engine. The throttle only button can be depressed only when the remote control is in the neutral position, and should only be used to assist in starting or warming up the engine. Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions (cover must be removed).

  • Page 38: Engine

    Section 2 - Getting to Know Your Power Package Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension. Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed).

  • Page 39: Console Mount Features- Dual Engine

    Section 2 - Getting to Know Your Power Package Console Mount Features‑ Dual Engine SYNC ACTIVE THROTTLE ONLY STATION SELECT 17365 Control handles Sync light Active light Throttle only/station select key Neutral light Detent tension adjustment Select key Control handle friction adjustment screw Arrow trackpad Control Handle - Operation of the shift and throttle are controlled by the movement of the...

  • Page 40: Dual Helm Station Transfer

    Section 2 - Getting to Know Your Power Package Auto Synchronizing will stay engaged up to 95% throttle opening. The Sync light will turn on when the engines are synchronized. SYNC ACTIVE THROTTLE ONLY STAT ION SELECT 3434 To disengage, move one or both control handles until they are more than 5° apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%.

  • Page 41: Synchronizing Dual Helms Prior To Station Transfer

    Section 2 - Getting to Know Your Power Package SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER Pressing the station select button and holding it in allows the boat operator 10 seconds to match up the control handle settings at the new station with the handle settings that are at the old (to be inactive) station.
  • Page 42 Section 2 - Getting to Know Your Power Package A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. Test the circuit breaker by pushing the red button. If the circuit breaker is functioning properly, the yellow lever appears. Push the yellow lever into the housing to reset the circuit breaker.
  • Page 43 Section 2 - Getting to Know Your Power Package Two 10 amp fuses protect the O (oxygen) sensors. These are located at the rear of the engine, near the 14‑pin connector. 33177 Oxygen sensor fuses A 15 amp accessory fuse protects the accessory circuits. 32206 Fuse cover 15 amp fuse...

  • Page 44: Audio Warning System

    IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from damage. Your Mercury MerCruiser power package may be equipped with an audio warning system. Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.

  • Page 45: Obdm

    If an OBDM fault is detected, the audio warning system sound with one five‑second horn, then one short, 1/2‑second horn every 60 seconds for certain faults related to the emissions or fuel system. See your authorized Mercury MerCruiser dealer for assistance. ½...
  • Page 46 Section 2 - Getting to Know Your Power Package As another example, Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage. Transmission Guardian monitors the clutch pack pressure in forward and reverse gears. If the transmission fluid pressure drops below a predetermined level, Transmission Guardian lowers the engine torque and speed to prevent clutch slippage.

  • Page 47: Section 3 - On The Water

    Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions........40 While You Are Cruising ........ 47 Be Alert to Carbon Monoxide Poisoning..... 41 While Boat Is Stationary ....... 47 Good Ventilation ........... 41 High-Speed and High-Performance Operation Poor Ventilation ...........

  • Page 48: Safe Boating Suggestions

    Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.

  • Page 49: Be Alert To Carbon Monoxide Poisoning

    Section 3 - On the Water • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat;...

  • Page 50: Poor Ventilation

    Section 3 - On the Water 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.

  • Page 51: Starting And Stopping The Engine

    Section 3 - On the Water Operation Chart WHILE BEFORE STARTING AFTER STARTING AFTER STOPPING UNDERWAY Flush cooling system if in Open fuel shut off valve. saltwater. Open seacock, if equipped. Drain bilge. Close the drain system. Check the engine oil. Perform all other checks specified by your dealer and/or boat builder.

  • Page 52: Stopping The Engine

    Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.

  • Page 53: Starting And Stopping The Engine

    Section 3 - On the Water Operation Chart WHILE BEFORE STARTING AFTER STARTING AFTER STOPPING UNDERWAY Check shift and throttle Turn battery switch on. Close fuel shut off valve. control operation. Check steering Close seacock, if Operate bilge blowers. operation. equipped.

  • Page 54: Stopping The Engine

    Section 3 - On the Water Turn the ignition key to "start." Release key when the engine starts and allow the switch to return to the "on" position. 6. If the engine does not start after step 5: Move the remote control handle.throttle lever to the full throttle position, then return to 1/4 throttle.

  • Page 55: Freezing Temperature Operation

    Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.

  • Page 56: High-Speed And High-Performance Operation

    For additional information, refer to Hi-Performance Boat Operation booklet (90‑849250‑R2) from your dealer, distributor or Mercury Marine. Passenger Safety in Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers.

  • Page 57: Wave And Wake Jumping

    Section 3 - On the Water Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. mc79680-1 Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with enough speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the water.

  • Page 58: Conditions Affecting Operation

    WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.

  • Page 59: Ventilation

    Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After Break‑In Period To help extend the life of your Mercury MerCruiser power package, follow these recommendations: •...

  • Page 60: End Of First Season Checkup

    End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.

  • Page 61: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Cruising RPM............54 Engine Oil............55 Fuel Requirements..........54 Engine Specifications......... 56 Fuel Ratings ..........54 Fluid Specifications..........57 Using Reformulated (Oxygenated) Gasoline Engine............57 (USA Only) ........... 54 Transmission..........57 Gasoline Containing Alcohol ......

  • Page 62: Cruising Rpm

    Reformulated gasoline is required in certain areas of the USA and are acceptable for use in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol.

  • Page 63: Engine Oil

    Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty. If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation, for short periods of time: 1.

  • Page 64: Engine Specifications

    NOTE: We do not recommend non‑detergent oils, multi‑viscosity oils (other than as specified), non FC‑W–rated synthetic oils, low‑quality oils, or oils that contain solid additives. Mercury MerCruiser Full-Synthetic Engine Oil, 20W-40, NMMA FC-W rated MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rated 4-cycle oil Other recognized brands of NMMA FC-W rated oils...

  • Page 65: Fluid Specifications

    Seawater cooling system (winterization use 20 L (21 US qt) Propylene glycol and purified water only) Mercury Extended Life Coolant Antifreeze Closed cooling system 18 L (19 US qt) or extended life ethylene glycol 5/100 antifreeze mixed 50/50 with purified water...
  • Page 66 Section 4 - Specifications Notes: Page 58 90-899883173 DECEMBER 2007...
  • Page 67 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......60 Changing ............70 Dealer Responsibilities........60 Battery..............70 Maintenance............60 Multiple EFI Engine Battery Precautions..70 Do-It-Yourself Maintenance Suggestions... 61 Cleaning the Flame Arrestor....... 71 Inspection............61 Positive Crankcase Ventilation Valve Maintenance Schedule—Inboard Models...

  • Page 68: Owner/Operator Responsibilities

    • Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •...

  • Page 69: Do-It-Yourself Maintenance Suggestions

    Transmission Do‑It‑Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.

  • Page 70: Maintenance Schedule-Inboard Models

    Section 5 - Maintenance Maintenance Schedule—Inboard Models Routine Maintenance NOTE: Only perform maintenance that applies to your particular power package. Task Interval Maintenance to Be Performed • Check the engine oil level. You can extend this interval based on experience with the product.

  • Page 71: Maintenance Log

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Check the engine mounts for tightness and tighten to specifications if necessary. • Inspect the condition of the spark plugs, spark plug wires, and the distributor cap and rotor, if equipped. Replace as necessary. If the condition of these components is satisfactory at inspection, repeat inspection every 100 hours or once a year, whichever occurs first.

  • Page 72: Engine Oil

    Section 5 - Maintenance Engine Oil Checking 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 into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

  • Page 73: Changing Oil And Filter

    Capacity Fluid Type 4.25 L Engine oil (with filter) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 (4.5 US qt) Changing Oil and Filter See Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage.

  • Page 74: Engine Oil Drain Pump

    Section 5 - Maintenance 4. Pull tether through the bilge drain. 7284 Bilge drain plug Oil drain hose plug Tether Oil drain hose Clip Bilge drain flange 5. Place the oil drain hose in a suitable container. 6. Remove the drain plug from the oil drain hose. 7.

  • Page 75: Changing The Oil Filter

    Fluid Type 4.25 L Engine oil (with filter) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 (4.50 US qt) 8. Start the engine and operate for three minutes, checking for leaks. 9. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water.

  • Page 76: Checking While Engine Is Cold

    Heat exchanger cap 2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. 3. Install the cap onto the heat exchanger.

  • Page 77: Filling

    Section 5 - Maintenance 5. The coolant level should be between the "ADD" and "FULL" marks. 6102 6. Add the specified fluid as necessary. Tube Ref No. Description Where Used Part No. Extended Life Antifreeze/ Closed Cooling System 92-877770K1 Coolant Filling NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling...

  • Page 78: Changing

    Section 5 - Maintenance Changing Contact your authorized Mercury MerCruiser dealer. Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery. WARNING Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion.

  • Page 79: Cleaning The Flame Arrestor

    Section 5 - Maintenance Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.

  • Page 80: Positive Crankcase Ventilation Valve (Pcv)

    Section 5 - Maintenance 11. Install the engine cover. Positive Crankcase Ventilation Valve (PCV) CHANGING IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. 1. Remove the PCV valve from the port valve cover. 33143 PCV valve (hose not shown) 2.

  • Page 81: Water-Separating Fuel Filter

    Section 5 - Maintenance 2. Remove the IAC muffler. 33269 IAC muffler installed in the IAC adapter 3. Inspect the IAC muffler for holes, cracks, or deterioration. Replace the IAC muffler if damaged. IMPORTANT: Do not get cleaner on electrical connections and do not use cleaner containing methyl ethyl ketone.

  • Page 82: Gen Iii Models

    O‑ring REMOVAL 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped. 3. Disconnect the Cool Fuel Module harness from the engine wiring harness.

  • Page 83: Installation

    10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication Throttle Cable 1.

  • Page 84: Transmission Linkage

    Section 5 - Maintenance Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Throttle cable pivot points & 92‑883725K01 Oil SAE25W‑40 guide contact surfaces Transmission Linkage IMPORTANT: The poppet ball must be centered in the detent hole for each F‑N‑R position. 1.

  • Page 85: Serpentine Drive Belt

    Section 5 - Maintenance Serpentine Drive Belt WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts. 6089 Idler pulley Alternator pulley Circulating pump pulley Seawater pump pulley Crankshaft pulley...

  • Page 86: Flushing The Power Package

    Section 5 - Maintenance 5. Use a 8 mm (5/16 in.) socket and tighten adjusting the stud to adjust the belt deflection. 6. Using one of the 2 methods following, check for correct deflection. Push down with moderate thumb pressure on the longest stretch of belt. Proper deflection is 13 mm (1/2 in.).
  • Page 87 Section 5 - Maintenance NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the engine. Do not supply flush water for more than 15 seconds without the engine operating. 4. Snap the quick connect fitting and the water hose into the flush socket on the engine. 33389 V‑drive shown (inline similar) 5.

  • Page 88: The Boat Out Of The Water

    Section 5 - Maintenance The Boat Out of the Water IMPORTANT: Flushing the power package is most effective when performed with the boat out of the water. IMPORTANT: Flushing is needed If the engine package has been operated in salty, brackish, mineral‑laden or polluted water.

  • Page 89: The Boat In The Water

    Section 5 - Maintenance Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump. Proceed to step 3. NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the engine.
  • Page 90 Section 5 - Maintenance IMPORTANT: Flushing is needed If the engine package has been operated in salty, brackish, mineral‑laden or polluted water. For best results flushing is recommended after each outing and before cold weather and extended storage. NOTICE Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage.
  • Page 91 Section 5 - Maintenance If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump inlet fitting and immediately plug the seawater inlet hose to prevent water from siphoning into the engine or boat. 10839 Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.
  • Page 92 Section 5 - Maintenance 14. Tag the ignition switch with an appropriate tag requiring the seacock to be opened or the seawater inlet hose to be reconnected prior to operating the engine. 15. Repeat the flushing procedure on the next engine, if equipped. Page 84 90-899883173 DECEMBER 2007...
  • Page 93 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....86 Air Actuated Single Point Drain System..89 Preparing Power Package for Storage..86 Boat in the Water ........89 Engine and Fuel System Preparation ..87 Boat out of the Water ......

  • Page 94: Cold Weather Or Extended Storage

    Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage.

  • Page 95: Engine And Fuel System Preparation

    Section 6 - Storage 10. For additional assurance against freezing and rust, after draining, fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.

  • Page 96: Draining The Seawater System

    Identification to determine which instructions apply to your power package. IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage.

  • Page 97: Three Point Manual Drain System

    Section 6 - Storage THREE POINT MANUAL DRAIN SYSTEM 6126 Blue drain plug Air Actuated Single Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the blue air pump that is attached to the engine. However, any air source can be used. 1.
  • Page 98 12. Remove the blue air pump from the air manifold and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

  • Page 99: Boat Out Of The Water

    Section 6 - Storage 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
  • Page 100 10. Remove the air pump from the air manifold and return it to the mounting bracket. 11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

  • Page 101: Three-Point Manual Drain System

    Section 6 - Storage 12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators Three‑Point Manual Drain System BOAT IN THE WATER NOTE: Use this procedure if your engine is not equipped with an air‑actuated single‑point drain system or if the air‑actuated single point drain system fails.

  • Page 102: Boat Out Of The Water

    Section 6 - Storage 4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side). 6140 Blue drain plugs 5. Verify that water is draining from each opening. 6. Allow the system to drain for a minimum of five minutes. We recommend leaving the drain system open while transporting the boat or performing other maintenance to ensure that all water is drained.

  • Page 103: Battery Storage

    Section 6 - Storage Battery Storage Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition. It should be clean and free of leaks.
  • Page 104 Section 6 - Storage Notes: Page 96 90-899883173 DECEMBER 2007...
  • Page 105 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........98 Excessive Engine Temperature....99 Diagnosing DTS Problems......... 98 Insufficient Engine Temperature....100 Engine Guardian System........98 Low Engine Oil Pressure......100 Troubleshooting Charts........98 Battery Will Not Recharge......100 Starter Motor Will Not Crank Engine, or Cranks Remote Control Is Difficult to Move, Has Slowly............98...

  • Page 106: Diagnosing Efi Problems

    Section 7 - Troubleshooting Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.

  • Page 107: Engine Will Not Start Or Is Hard To Start

    Boat bottom fouled or damaged. Clean or repair as necessary. Ignition problem. See Engine Runs Rough, Misses or Backfires. Engine overheating. See Excessive Engine Temperature. Have EFI System checked by an authorized Mercury MerCruiser EFI System fault dealer. Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed.

  • Page 108: Insufficient Engine Temperature

    Check all throttle linkages. If any are loose or missing, Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair.

  • Page 109: Steering Wheel Jerks Or Is Difficult To Turn

    Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners if any are loose or missing, Loose or missing steering fasteners or parts. see authorized Mercury MerCruiser dealer immediately. Contaminated power steering fluid. See authorized Mercury MerCruiser dealer. 90-899883173 DECEMBER 2007...
  • Page 110 Section 7 - Troubleshooting Notes: Page 102 90-899883173 DECEMBER 2007...

  • Page 111: Section 8 - Customer Assistance Information

    Parts and Accessories Inquiries ... 105 Local Repair Service ........104 Resolving a Problem ........105 Service Away From Home ......104 Mercury Marine Service Offices ....105 Stolen Power Package ....... 104 Ordering Literature..........106 Attention Required after Submersion ..104 United States and Canada ......

  • Page 112: Owner Service Assistance

    Owner Service Assistance Local Repair Service If you need service for your Mercury MerCruiser–powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine.

  • Page 113: Parts And Accessories Inquiries

    Resolving a Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership.

  • Page 114: Ordering Literature

    Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature. Please return with payment to:...

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