Mercury 350 Mag MPI Horizon Service Manual
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Mercury 350 Mag MPI Horizon Service Manual

Inboard horizon series
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Horizon Inboard Models
2001, Mercury Marine
90 861357002 101

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  • Page 1 Horizon Inboard Models  2001, Mercury Marine 90 861357002 101...

  • Page 2: Serial Numbers

    Boat Model Length Serial Numbers The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your Mercury MerCruiser power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing.
  • Page 3 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 statement 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.

  • Page 4: Table Of Contents

    ............Mercury MerCruiser Limited Warranty - Gasoline Engines .
  • Page 5 Page Maintenance Maintenance Aids ............... . Fluid Capacities .

  • Page 6: Warranty Information

    CA455 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product. • It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address.

  • Page 7: International Owner Registration

    International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.

  • Page 8: Mercury Mercruiser Limited Warranty - Gasoline Engines

    Our sole and exclusive obligation under this Warranty shall be limited to repairing a defective part, or at our option, refunding the purchase price or replacing such part or parts with new or Mercury certified remanufactured parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty.

  • Page 9: Mercury Mercruiser International Warranty - Gasoline Engines

    Product. Claim shall be made under this warranty by delivering the Product for inspection to a Mercury Mer- Cruiser dealer authorized to service the Product. If purchaser cannot deliver Product to such autho- rized dealer, he may give notice in writing to the Marine Power Service Center or distributor.

  • Page 10: Year Limited Warranty Against Corrosion Failure

    Mercury MerCruiser boating applications. In areas where Tri-Butyl-Tin-Adipate base paints are prohibited by law, copper base paints can be used on the boat hull and transom. Do not apply paint to the Mercury MerCruiser drive unit or transom assembly. In addition, care must be taken to avoid an electrical interconnection between the Mercury MerCruiser Product and the paint.

  • Page 11: Warranty Coverage

    CA458 Warranty Coverage The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The table explains some of the types of services that are not covered by warranty. Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship.

  • Page 12: Transferable Warranty

    The optional Mercury Product Protection Plan is the only Factory Plan available for your engine. Two, three or four - year term plans can be purchased up to 12 months after the original engine registration date.
  • Page 13 CA961 THIS PAGE IS INTENTIONALLY BLANK...

  • Page 14: Read This Manual Thoroughly

    CA755 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARNINGS and CAUTIONS, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.

  • Page 15: General Information

    CC942 General Information CA619 Lanyard Stop Switch 74608 The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from the operator’s position (as in accidental ejection from the operator’s position) to activate the switch. Some remote control units are equipped with a lanyard stop switch.
  • Page 16 CC670 Courtesy of ABYC...

  • Page 17: Exhaust Emissions

    CA620 Exhaust Emissions Be Alert To Carbon Monoxide Poisoning Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, stern drives and inboard engines that propel boats, as well as the generators that power various boat accessories.

  • Page 18: Safe Boating Suggestions

    CA476 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course.

  • Page 19: Protecting People In The Water

    • Make sure everyone in the boat is properly seated. Don’t allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes backs of seats, gunwales, transom, bow, decks, raised fishing seats, any rotating fishing seat;...

  • Page 20: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi-Performance Boat Operation booklet (Part Number 90-849250--1) from your dealer, distributor, or Mercury Marine. CA958 Conditions Affecting Operation...

  • Page 21: Propeller Selection

    CC1027 Propeller Selection IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide open throttle revolutions per minute (rpm). Use an accurate service tachometer to verify engine operating rpm. It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller.

  • Page 22: How Elevation And Climate Affect Performance

    OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks; to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an Authorized Mercury MerCruiser Dealer for a periodic checkup.

  • Page 23: Freezing Temperature Operation

    In general, a dealer’s responsibilities to the customer include predelivery inspection and preparation such as: • Make sure 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 24: Launching And Boat Operation Care

    Stolen Power Package If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors.

  • Page 25: Do-It-Yourself Maintenance Suggestions

    If you are one of those persons who likes to do-it-yourself, here are some suggestions for you. • 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 26: Multiple Efi Engine Battery Precautions

    NOTE: All references to EFI models apply to EFI and MPI engines. 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 27: 20-Hour Break-In Period

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

  • Page 28: Operation

    CC830 Operation CC831 70515 70514 70516 70517 70518 70519 70522 70523 70521 CC810 Instrumentation The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions on the boat. Speedometer - indicates boat speed.

  • Page 29: Audio Warning System

    HAZARDOUS SITUATION. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred. When the alarm sounds with the engine running, stop engine immediately. Investigate cause and correct it, if possible. If cause cannot be determined, consult your Authorized Mercury MerCruiser Dealer.
  • Page 30 CC882 74898 72852 70525 71585 77001 77498 77602...

  • Page 31: Electrical System Overload Protection

    CC1002 Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replacing fuse or resetting circuit breaker. A circuit breaker provides protection for engine wiring harness and instrumentation power lead. Reset by pushing RESET button IN.

  • Page 32: Remote Controls

    Remote Control Features Your boat may be equipped with a Mercury Precision or Quicksilver remote control. All controls may not have all features shown. If boat is equipped with a remote control other than shown, consult your dealer for a description and/or demonstration of the control.
  • Page 33 CC1036 Kiekhaefer Remote Control Features Consult your dealer for a description and/or demonstration of other remote controls. Shift Control Handle - Push the control handle forward from NEUTRAL with a quick firm motion for FORWARD gear. Pull the control handle back from NEUTRAL with a quick firm motion for REVERSE gear. CAUTION On Dual Engine Applications: Both shift control handles should be moved simultaneously into the same gear.

  • Page 34: Starting, Shifting And Stopping

    CC995 Starting, Shifting And Stopping WARNING Before starting engine, operate bilge blower for at least five minutes to remove any explosive fumes from engine compartment. If boat is not equipped with a bilge blower, open engine hatch and leave open while starting engine. CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant.

  • Page 35: 8.1L Engine Guardian Strategy

    CC829 CAUTION To avoid possible ingestion of water that can damage engine components: • Do not turn the ignition key off when the engine is running above idle speed. • Do not use the lanyard stop switch to shut off the engine above idle speed. •...

  • Page 36: Operation Chart

    CH50 Operation Chart BEFORE STARTING WHILE AFTER STOPPING UNDERWAY Observe all gauges to monitor engine Open engine hatch. Turn battery switch OFF, if equipped. condition. If not normal, stop engine. Check engine oil level. Listen for audio warning horn signifying Close fuel shutoff valve, if equipped.

  • Page 37: Specifications

    The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat’s fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boats fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 38: Seacock Size Recommendation

    IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long periods of storage, common to boats, create unique problems.

  • Page 39: Engine Specifications

    Power Rated in Accordance with NMMA (National Marine Manufacturers’ Association) rating procedures. Measured using an accurate service tachometer, with engine at normal operating temperature. A special procedure must be followed to check or adjust timing. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure.

  • Page 40: Maintenance

    Some listings can be done by owner/operator, while others should be performed by an Authorized Mercury MerCruiser Dealer. Before attempting maintenance or repair procedures not covered in this manual, it is recommended that a Mercury MerCruiser Service Manual be purchased and read thoroughly.
  • Page 41 Transmission NOTICE Measurements: U.S. Quarts (Liters) All capacities are approximate fluid measures. Make and Model Capacity Fluid Type Velvet Drive Mobil 424 or 71C In-Line 1-1/2 (1.33) Dexron III Automatic Transmission Fluid 72 Series V Drive 3 (2.75) Do Not Mix! 5000A 2-3/4 (2.6) Dexron III Automatic Transmission Fluid...

  • Page 42: Maintenance Chart

    Gas Inboard (Continued) Scheduled Maintenance * Every Every Every Every Every 1000 Every Every Annu- hours hours hours hours hours or ally or 3 or 3 or 5 or 5 Annually years years years years years years Touch-up paint power package and spray with corrosion guard.
  • Page 43 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 44 CH37 70547 71419 76385 75540 77631...

  • Page 45: Checking Fluid Levels

    Checking Fluid Levels CAUTION Mercury MerCruiser recommends that the crankcase oil be checked BEFORE starting the engine. If it is necessary to check the oil level after starting the engine, stop engine and allow a minimum of 10 minutes for the oil to drain back into the oil pan.
  • Page 46 CA514 70571 74767 74766 77631...

  • Page 47: Changing Fluids

    CC989 Changing Fluids Refer to Maintenance for change interval. Crankcase oil should be changed before placing boat in storage. Changing Crankcase Oil and Filter CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat.
  • Page 48 CC1011 70573 77629...

  • Page 49: Changing Water Separating Fuel Filter

    Do not use a filter wrench. Start and operate engine. Check water separating fuel filter connection for gasoline leaks. If leaks exist, stop engine immediately and recheck filter installation. If leaks continue, contact your Authorized Mercury MerCruiser Dealer.
  • Page 50 CH40 76360 76365 70573...

  • Page 51: Cleaning Flame Arrestor And Related Components

    CH41 Cleaning Flame Arrestor and Related Components WARNING Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Be careful when cleaning flame arrestor and crankcase ventilation hoses; ensure that igni- tion is OFF. DO NOT smoke or allow sources of spark or open flame in area when cleaning flame arres- tor and crankcase ventilation hoses.
  • Page 52 CH42 74941 77597 50946 71457...

  • Page 53: Lubrication

    Velvet Drive Marine and Industrial Transmissions 200Theodore Rice Boulevard Industrial Park New Bedford, MA 02745 U.S.A. CC846 To obtain service and/or parts literature for your ZF/Hurth transmission, contact: Mercury Marine Publications Department P.O. Box 1939 Fond du Lac, WI 54936-1939...
  • Page 54 CC886 74073 75637 75423...

  • Page 55: Flushing Cooling System - 350 Mag Mpi Only

    CH49 Flushing Cooling System – 350 MAG MPI Only NOTE: Flushing is needed only for saltwater applications. Flushing is recommended after each outing for best results. CAUTION Do NOT start engine at any point in this procedure. If boat is in the water, starting engine during this procedure will pull in seawater.

  • Page 56: Flushing Cooling System - 8.1 S Horizon Only

    CC1014 CH48 Flushing Cooling System – 8.1 S Horizon Only WARNING When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid possible injury, remove propeller. CAUTION Do not run engine above 1500 rpm when flushing. Suction created by seawater pickup pump may col- lapse flushing hose, causing engine to overheat.

  • Page 57: Serpentine Drive Belt

    Check the tension of the serpentine drive belt. If there is more than 1/4 in. (6 mm) deflection, the tension needs adjustment. See your Authorized Mercury MerCruiser Dealer to have the tension adjusted or belt replaced. Idler Pulley Circulating Pump Pulley...

  • Page 58: Battery

    Check plug leads and electrical leads for damage. Remove and inspect propeller. If badly nicked, bent or cracked, see your Authorized Mercury MerCruiser Dealer. Repair nicks and corrosion damage on power package exterior finish. Use Quicksilver spray paints - see your...

  • Page 59: Cold Weather Or Extended Storage

    Cold Weather Or Extended Storage Power Package Lay Up IMPORTANT: Mercury MerCruiser strongly recommends that this service be performed by an Authorized Mercury MerCruiser Dealer. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. WARNING Avoid Fire or Explosion: Ensure that engine compartment is well ventilated and no gasoline vapors are present during the following operation to prevent a potential fire hazard.
  • Page 60 Allow engine to cool down. Remove the water separating fuel filter. Refer to Changing Water Separating Fuel Filter. Pour out a small amount of fuel into a suitable container, then add approximately 2 fluid ounces (60 ml) of Quicksilver 2-Cycle Outboard Oil to fuel in the water separating fuel filter. Reinstall water separating fuel filter.

  • Page 61: Draining Instructions

    Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. CAUTION...
  • Page 62 CC1017 77638 77516 71515 77512...
  • Page 63 CC1024 SINGLE POINT DRAIN SYSTEM CAUTION Freeze damage can occur if operating where temperatures are below 32° F. Use Manual Drain System to ensure heat exchanger is completely drained. NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used.

  • Page 64: Battery Winter Storage

    CA115 Battery Winter Storage Follow battery manufacturer’s instructions for storage. CC1026 Power Package Recommissioning WARNING To prevent possible injury or damage to equipment, do not install battery until all maintenance has been performed on engine. CAUTION Refer to FLUSHING COOLING SYSTEM before starting engine. Verify that all cooling system hoses are connected and tight and all drain plugs are installed and tight.

  • Page 65: Troubleshooting

    Fuel line or tank vent line kinked or clogged. compressed air to remove obstruction. Have EFI System checked by an Authorized EFI System Fault. Mercury MerCruiser Dealer. Faulty wire connections. Check wire connections. CC1033 Engine RPM Decreases, Will Not Rise Above 2000 RPM...

  • Page 66: Poor Performance

    Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy EFI Models: Have EFI system checked by an Idle speed too low. Authorized Mercury MerCruiser Dealer. Ignition System fault. Service ignition system. Clogged fuel filter. Replace filter. Stale or contaminated fuel.

  • Page 67: Excessive Engine Temperature

    C1028 Excessive Engine Temperature Possible Cause Remedy Water Inlet valve closed (If Equipped). Open valve completely. Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups obstructed. Remove obstruction. Faulty thermostat. Replace. Check for cause of low coolant level and repair. Fill Coolant level low in closed cooling system.

  • Page 68: Battery Will Not Come Up On Charge

    Lubricate. fasteners. Check all throttle linkages. If any are loose or Loose or missing shift and throttle linkages. missing, see Authorized Mercury MerCruiser Dealer immediately. Obstruction in shift or throttle linkages. Remove obstruction. Straighten cable or have dealer replace cable if Shift or throttle cable kinked.

  • Page 69: Owner Service Assistance

    Only Authorized Dealers can purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When inquiring on parts and accessories, the dealer requires the motor model and serial number(s) to order the correct parts.

  • Page 70: Resolving A Problem

    CA904 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 Mer- Cruiser Dealership.

  • Page 71: Mercury Marine Service Offices

    (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 B-4800 Verviers Belgium Mexico, Central America, South America, Caribbean Mercury Marine - Latin America & Caribbean 9010 S.W. 137th Ave. (305) 385-9585 (305) 385-5507 Suite 226 Miami, FL 33186 U.S.A.

  • Page 72: Customer Service Literature

    Other Languages To obtain an Operation and Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
  • Page 73 Altre lingue Per ottenere il manuale di funzionamento e manutenzione in altra lingua, contattate il centro assistenza internazionale Mercury Marine o Marine Power più vicino. In dotazione con il gruppo motore, viene fornito l’elenco dei codici prodotto dei componenti venduti all’estero.

  • Page 74: Ordering Literature

    Model __________ Horsepower__________ Serial Number_____________ Year_______ United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact: Mercury Marine Telephone...

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