Mercury Mercruiser Tow Sport 5.7 MPI Manual

With gen iii cool fuel

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NOTE: The following applies to CE‑marked products only.

Declaration of Conformity—Mercury MerCruiser

This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser's instructions complies with the

requirements of the following directives by meeting the associated standards, as amended:

Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC

Name of engine manufacturer: Mercury Marine

Address: W6250 W. Pioneer Road, P.O. Box 1939

Town: Fond du Lac, WI

Name of Authorized Representative: Brunswick Marine in EMEA Inc.

Address: Parc Industriel de Petit‑Rechain

Town: Verviers

Name of Notified Body for exhaust emission assessment: Det Norske Veritas AS

Address: Veritasveien 1

Town: Hovik

Conformity assessment module used for exhaust emissions:

Other Community Directives applied: Electromagnetic Compatibility Directive 2004/108/EC

Description of Engines and Essential Requirements

Engine Type

☒ Inboard engine

Identification of Engines Covered by This Declaration of Conformity

Name of engine family

5.7 MPI

Horizon 5.7

5.7 MPI ECT

Horizon 5.7 ECT

6.2 MPI

Horizon 6.2

6.2 MPI ECT

Horizon 6.2 ECT

Tow Sports 5.7 MPI

Scorpion 350

Scorpion 377

Tow Sports 5.7 MPI ECT 1A090000

Scorpion 350 ECT

Scorpion 377 ECT

Horizon 8.1

8.1 H.O.

Horizon 8.2 ECT

8.2 H.O. ECT

Post Code: 54936‑1939

Post Code: 4800

Post Code: 1322

Country: Norway

Fuel Type

☒ Petrol

Unique engine identification number: starting serial number

0W307898

1A090000

0W307898

1A091600

0W307898

1A090000

1A091600

0W307898

1A350340

Country: USA

Country: Belgium

ID Number: 0575

☐ B+C

☐ B+D

☐ B+E

☐ B+F

Combustion Cycle

☒ 4 stroke

EC Module H certificate number

RCD‑H‑1

☐ G ☒ H

Table of Contents

Summary of Contents for Mercury Mercruiser Tow Sport 5.7 MPI

Page 1 NOTE: The following applies to CE‑marked products only. Declaration of Conformity—Mercury MerCruiser This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser's instructions complies with the requirements of the following directives by meeting the associated standards, as amended:...
Page 2 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.
Page 3: Read This Manual Thoroughly
At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are tested in a controlled and monitored environment for up to 10 hours of engine run time in order to verify and make a record of compliance with applicable standards and regulations.
Page 4 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 The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
Page 5: Table Of Contents
Tow Sports Series Non‑Emissions Control (Government Warranty Period for Commercial Use......9 Use—Corrosion)............... 15 Transfer of Coverage............9 Mercury Installation Quality Certification Program....15 Termination of Coverage..........9 Conditions That Must Be Met to Obtain Warranty Coverage ............... 9 Section 2 - Getting to Know Your Power Package Identification................
Page 6 Section 4 - Specifications Cruising RPM................. 34 Engine Specifications............. 35 Fuel Requirements..............34 Tow Sports 5.7 MPI With Gen III Cool Fuel, Without Fuel Ratings..............34 Emissions Control............35 Using Reformulated (Oxygenated) Gasolines (USA Only) Fluid Specifications............36 ..................34 Engine.................
Page 7 Steering Wheel Jerks or Is Difficult to Turn......76 Makes Unusual Sounds............76 Section 8 - Customer Assistance Information Owner Service Assistance............78 Contact Information for Mercury Marine Customer Service Local Repair Service............78 ................... 79 Service Away From Home..........78 Customer Service Literature............
Page 8 Page iv 90-8M0076545 NOVEMBER 2012...
Page 9: Section 1 - Warranty
Section 1 - Warranty Section 1 - Warranty Table of Contents Warranty Registration—Outside the United States and What Mercury Will Do ..........10 Canada................... 2 How to Obtain Warranty Coverage Under This Transfer of Warranty............... 2 Limited Warranty ........... 10 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled...
Page 10: Warranty Registration-Outside The United States And Canada
IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. It is our desire to have ALL products registered at the factory should it ever be necessary to contact you. Make sure your Mercury Marine distributor or Mercury Marine authorized dealer fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area.
Page 11 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.
Page 12: 3-Year Limited Warranty Against Corrosion
• Improper service • Use of an accessory or part that was not manufactured or sold by Mercury Marine and that damages the Mercury product • Jet pump impellers and liners • Operation with fuels, oils, or lubricants that are not suitable for use with the product (see the Operation, Maintenance &...
Page 13: Emission Control Warranty Information
Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
Page 14: Emission Control Information Label
A tamper‑resistant emission control information (ECI) label is affixed to the engine in a visible location at the time of manufacture by Mercury MerCruiser. Please note that the low emissions certification will not affect the fit, function, or performance of the engine. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.
Page 15: Owner Responsibility
U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three years or 480 hours of engine use whichever occurs first to the retail purchaser, that the engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations.
Page 16: Warranty Policy-Australia And New Zealand
What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.
Page 17: Warranty Period For Recreational Use
Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the predelivery inspection process specified by Mercury Marine is completed and documented.
Page 18: What Mercury Will Do
A list of dealers and their contact details is available at http://www.mercurymarine.com.au/home.aspx. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine at the address shown above. Mercury Marine will then arrange for the inspection and any covered repair. This Limited Warranty will not cover the purchaser for all related transportation charges and travel time.
Page 19: Expense Of Claiming This Limited Warranty
There is no charge for this service. You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.
Page 20: Global Warranty Application Charts
Section 1 - Warranty Global Warranty Application Charts Tow Sports Series Non‑Emissions Control (Recreational Use) Recreational Application: Standard Limited Warranty by Region and Boat Manufacturer Non‑Installation Quality Certified Boat Installation Quality Certified Boat Manufacturer Manufacturer Region Scorpion Scorpion Americas (Excluding 2 Years 2 Years 3 Years...
Page 21: Tow Sports Series Non-Emissions Control (Commercial Use)
Section 1 - Warranty Tow Sports Series Non‑Emissions Control (Commercial Use) Commercial Application: Standard Limited Warranty by Region and Boat Manufacturer Non‑Installation Quality Certified Boat Installation Quality Certified Boat Manufacturer Manufacturer Region Scorpion Scorpion Americas (Excluding 1 Year 1 Year 1 Year 1 Year Brazil)
Page 22: Tow Sports Series Non-Emissions Control (Government Use)
Section 1 - Warranty Tow Sports Series Non‑Emissions Control (Government Use) Government Application: Standard Limited Warranty by Region and Boat Manufacturer Non‑Installation Quality Certified Boat Installation Quality Certified Boat Manufacturer Manufacturer Region Scorpion Scorpion Americas (Excluding 1 Year 1 Year 1 Year 1 Year Brazil)
Page 23: Tow Sports Series Non-Emissions Control (Commercial Use-Corrosion)
1 Year or 500 Hours South Pacific 1 Year or 500 Hours 1 Year or 500 Hours Other Asian Regions 1 Year or 500 Hours 1 Year or 500 Hours Mercury Installation Quality Certification Program 15502 90-8M0076545 NOVEMBER 2012 Page 15...
Page 24 Boatbuilders that successfully complete the program and meet all certification requirements earn Installation Quality System Certified Manufacturer status and receive an additional one (1) year of Mercury limited factory warranty coverage on all MerCruiser‑powered boats that are registered on and after the boatbuilder's certification date for all worldwide registrations.
Page 25: 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................. 18 Remote Controls............20 Engine Serial Number Decal......... 18 Panel Mount Features........... 20 Lanyard Stop Switch............. 18 Electrical System Overload Protection......... 21 Instrumentation..............
Page 26: Identification
Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer'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 27: Instrumentation
Instrumentation 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 28: 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 29: Electrical System Overload Protection
Section 2 - Getting to Know Your Power Package Neutral lock button – Prevents accidental shift and throttle engagement. Neutral lock button must be pushed in to move the control handle out of neutral. Throttle only button – Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle.
Page 30: Audio Warning System
Audio Warning System Your Mercury MerCruiser power package may be equipped with an audio warning system. The audio warning system will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
Page 31: Engine Guardian Strategy
Section 2 - Getting to Know Your Power Package Engine Guardian Strategy IMPORTANT: Boat speed could be reduced to idle and may not respond to the throttle. Engine Guardian strategy is designed to help reduce the potential for engine damage by reducing engine power when a potential problem is sensed by the ECM.
Page 32 Section 2 - Getting to Know Your Power Package Notes: Page 24 90-8M0076545 NOVEMBER 2012...
Page 33 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions............ 26 While You Are Cruising ..........30 Carbon Monoxide Exposure..........27 While Boat Is Stationary ..........30 Be Alert To Carbon Monoxide Poisoning ..... 27 High‑Speed and High‑Performance Operation.....
Page 34: 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. Ensure that everyone in the boat is properly seated.
Page 35: Carbon Monoxide Exposure
Section 3 - On The Water • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed.
Page 36: Poor Ventilation
Section 3 - On The Water Poor Ventilation Under certain running or wind 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. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.
Page 37: Starting And Stopping The Engine
Freezing Temperature Operation IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. 90-8M0076545 NOVEMBER 2012...
Page 38: Drain Plug And Bilge Pump
It is very important to check these items on a regular basis to ensure that the water level does not come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty. Protecting People in the Water While You Are Cruising It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds.
Page 39: Impact With Underwater Hazards
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Page 40: Cavitation
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 41 Section 4 - Specifications Section 4 - Specifications Table of Contents Cruising RPM............... 34 Engine Specifications............35 Fuel Requirements............... 34 Tow Sports 5.7 MPI With Gen III Cool Fuel, Without Fuel Ratings ..............34 Emissions Control............35 Using Reformulated (Oxygenated) Gasolines (USA Only) Fluid Specifications............
Page 42: Cruising Rpm
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 boat's fuel system components (fuel tanks, fuel lines, and fittings).
Page 43: Engine Oil
All MerCruiser engines Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA FC‑W rated If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation: Mercury/Quicksilver 25W‑40 Synthetic Blend, NMMA FC‑W–rated 4‑cycle MerCruiser oil Mercury/Quicksilver 25W‑40, NMMA FC‑W–rated 4‑cycle MerCruiser oil...
Page 44: Fluid Specifications
Section 4 - Specifications 235 kW (315 hp) Propshaft power 5.7 L (350 cid) Displacement 72 A Alternator amperage Cold 65 A 4800–5200 Rev limiter 5350 Idle in neutral At 2000 RPM 124 kPa (18 psi) Minimum oil pressure At idle 41 kPa (6 psi) Seawater‑cooled models 71°...
Page 45: Transmission
Section 4 - Specifications Transmission Model Capacity Fluid Type 5000A 2.8 Liter (3 U.S. Quart) Dexron lll Automatic Transmission Fluid 5000V 3.3 Liter (3.5 U.S. Quart) Dexron lll Automatic Transmission Fluid 1.7 Liter (1.75 U.S. Quart) Dexron lll Automatic Transmission Fluid 71C In‑Line 71C Gear Reduction 2.8 Liter (3 U.S.
Page 46 Section 4 - Specifications Notes: Page 38 90-8M0076545 NOVEMBER 2012...
Page 47: Section 5 - Maintenance
Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 40 Changing ..............46 Dealer Responsibilities............40 Cleaning the Flame Arrestor..........47 Maintenance................. 40 Positive Crankcase Ventilation Valve (PCV) ....47 Do‑It‑Yourself Maintenance Suggestions......40 Changing ............... 47 Inspection................
Page 48: 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. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.
Page 49: Inspection
Check plug leads and electrical leads for damage. • Remove and inspect the propeller. If badly nicked, bent, or cracked, contact your authorized Mercury MerCruiser dealer. • Repair nicks and corrosion damage on power package exterior finish. Contact your authorized Mercury MerCruiser dealer.
Page 50: Maintenance Log
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Touch up the paint on the power package. • Change the engine oil and filter. • Change the transmission fluid (Transmission Models). • Replace the water‑separating fuel filter element. Every 100 hours or annually •...
Page 51: Engine Oil
Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil 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 52: Filling
Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. Recheck oil level. Replace the fill cap. Tow Sports 5.7 MPI Capacity Fluid Type 4.25 L Engine oil (with filter) Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40 (4.5 US qt) Page 44 90-8M0076545 NOVEMBER 2012...
Page 53: Changing Oil And Filter
Section 5 - Maintenance Changing Oil and Filter Refer to the Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
Page 54: Changing Filter
Fluid Type 4.25 L Engine oil (with filter) Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40 (4.5 US qt) Start the engine, run the engine for three minutes, and check for leaks. Stop the engine. Allow approximately five minutes for the oil to drain into the oil pan. The boat must be at rest in the water.
Page 55: Cleaning The Flame Arrestor
Positive Crankcase Ventilation Valve (PCV) Changing NOTE: We recommend the use of Mercury MerCruiser replacement parts to ensure compliance with emission regulations. NOTE: On V6 models the PCV valve is non‑serviceable and is an internal component of the valve cover.
Page 56: Water-Separating Fuel Filter (Mpi)
Section 5 - Maintenance Remove the PCV valve from the port valve cover. PCV valve Hose mc71925-1 Disconnect the PCV valve from the hose and discard the valve. Install a new PCV valve in the valve cover and reconnect the hose. Ensure that the PCV valve is tightly seated in the valve cover.
Page 57: Gen Iii Models
Removal Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Disconnect the Cool Fuel Module harness from the engine wiring harness.
Page 58: Lubrication
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 Lubricate the pivot points and the guide contact surfaces.
Page 59: Serpentine Drive Belt
Section 5 - Maintenance Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Detent ball and shift lever 92‑883725K01 SAE25W‑40 holes Lubricate the shift cable pivot points. Pivot points 5935 Tube Ref. No. Description Where Used Part No.
Page 60: Replacing Belt And/Or Adjusting Tension
Section 5 - Maintenance • Proper tension ‑ 13 mm (1/2 in.) deflection, with moderate thumb pressure, on the belt at the location that has the longest distance between two pulleys. mc75130-1 Replacing Belt and/or Adjusting Tension IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as before. NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys.
Page 61 Section 5 - Maintenance Models with Walter V‑drive transmissions: Disconnect water inlet hose from the transmission fitting. Using appropriate connector, connect water hose to water source. Proceed to Step 3. 6091 All other models: Using appropriate connector, connect the flushing hose from the water source to the water inlet hose (upper hose) of the seawater pickup pump.
Page 62: Battery
Section 5 - Maintenance All other models: Using appropriate connector, connect the flushing hose from the water to the water inlet hose (upper hose) of the seawater pickup pump. Proceed to Step 3. 6092 Open the water source completely. Place remote control in neutral, idle speed position, and start engine. Operate engine at idle speed, in neutral, for about 10 minutes or until discharge water is clear.
Page 63 Section 5 - Maintenance Batteries: Boats with multiengine EFI power packages require each engine be connected to its own battery. This ensures that the engine's ECM has a stable voltage source. Battery switches: Battery switches should always be positioned so each engine is operating off of its own battery. Do not operate engines with switches in both or all position.
Page 64 Section 5 - Maintenance Notes: Page 56 90-8M0076545 NOVEMBER 2012...
Page 65 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........58 Manual Single‑Point Drain System........ 65 Preparing Power Package for Storage......58 Boat in the Water ........... 65 Engine and Fuel System Preparation ....58 Boat Out of the Water ..........
Page 66: Cold Weather Or Extended Storage
If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): Fuel tanks should be drained as low as possible and Mercury/Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank.
Page 67: Draining The Seawater System
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. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
Page 68: Manual Single-Point Drain System
Section 6 - Storage Scorpion models Blue air pump Air manifold Green indicators Blue drain plug locations 21125 Manual Single-Point Drain System 6128 Blue handle Blue drain plug location Three-Point Manual Drain System Blue drain plug 6126 Page 60 90-8M0076545 NOVEMBER 2012...
Page 69: Multipoint Drain (Mpd) System
Section 6 - Storage Multipoint Drain (MPD) System Side of cylinder block Bottom of exhaust manifolds 6129 6130 Water circulating pump hose Fuel cooler to thermostat housing Check valve (if equipped) 6131 Air Actuated Single‑Point Drain System Boat in the Water NOTE: This procedure is written for the air pump that is attached to the engine.
Page 70 Section 6 - Storage Pull the lever on the air pump (vertical) to lock the pump on the fitting. Actuator fitting Green indicators Manual release valve Air pump Lever (locking) 8293 Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.
Page 71: Boat Out Of The Water
12. Remove the 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 72 Section 6 - Storage Pull the lever on the air pump (vertical) to lock the pump on the fitting. Actuator fitting Green indicators Manual release valve Air pump Lever (locking) 8293 Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.
Page 73: Manual Single-Point Drain System
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 74: Boat Out Of The Water
Section 6 - Storage Immediately remove the blue drain plug from the side of the thermostat housing. This must be removed within 30 seconds to properly vent the cooling system. Blue handle Blue drain plug location 6136 Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually.
Page 75: Three-Point Manual Drain System
Section 6 - Storage Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually. Drain location ‑ orange or red Blue drain plug 6137 Allow the system to drain for a minimum of five minutes. We recommend leaving the plugs out while transporting the boat or performing other maintenance to ensure that all water is drained.
Page 76: Boat Out Of The Water
Section 6 - Storage Remove the two blue drain plugs from the seawater pickup pump (front, starboard side). Blue drain plugs 6140 Verify that water is draining from each opening. 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 77 Section 6 - Storage Bottom of exhaust manifolds Cylinder block drain plug Exhaust manifold drain plug 6129 Water‑circulating pump hose Drain plug 6143 Fuel‑cooler‑to‑thermostat‑housing hose Drain plug 6144 Check valve Drain plug (if equipped) 6131 90-8M0076545 NOVEMBER 2012 Page 69...
Page 78: Boat In The Water
Section 6 - Storage On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...
Page 79: Draining Water From The Gen Iii Cool Fuel Module
Draining Water from the Gen III Cool Fuel Module Mercury MerCruiser recommends draining the Gen III Cool Fuel Module if it is equipped with a drain plug. Remove the drain plug from the Gen III Cool Fuel Module and allow the water to completely drain from the module.
Page 80: Battery Storage
Section 6 - Storage Place the O‑ring on the drain plug and install the drain plug in the module drain hole. Tighten the drain plug to finger‑tight. Gen III Cool Fuel Module Fuel in‑line fitting Drain plug O‑ring 43648 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.
Page 81: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems............. 74 Excessive Engine Temperature..........75 Diagnosing DTS Problems........... 74 Insufficient Engine Temperature........... 75 Engine Guardian System............74 Low Engine Oil Pressure............76 Starter Motor Will Not Crank Engine, or Cranks Slow..74 Battery Will Not Recharge............
Page 82: Diagnosing Efi Problems
Diagnosing DTS Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on digital throttle and shift (DTS) systems. The electronic control module (ECM)/propulsion control module (PCM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM/PCMs memory.
Page 83: Engine Runs Rough, Misses, Or Backfires
Clean the flame arrestor. Faulty ignition system component. Service ignition system. Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer. EFI system fault. Have EFI system checked by an authorized Mercury MerCruiser dealer. Poor Performance...
Page 84: Low Engine Oil Pressure
Check all linkages. If any are loose or missing, see authorized Loose or missing shift and throttle linkages. Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury MerCruiser dealer Shift or throttle cable kinked. replace cable if damaged beyond repair.
Page 85: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance............ 78 Contact Information for Mercury Marine Customer Local Repair Service ............ 78 Service ................. 79 Service Away From Home ..........78 Customer Service Literature..........79 Stolen Power Package ..........
Page 86: Owner Service Assistance
If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.
Page 87: Contact Information For Mercury Marine Customer Service
Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: 90-8M0076545...
Page 88: Other Languages
Enclose full remittance in check or money order (NO COD). Other Languages To obtain an Operation, 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.

This manual is also suitable for:

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Mercury Mercruiser Tow Sport 5.7 MPI Manual

Section 3 - on the Water

Section 7 - Troubleshooting

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