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Mercury MR504LB3 Manual

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Declaration of Conformity for Recreational Craft Propulsion Engines with the
requirements of Directive 94/25/EC as amended by 2003/44/EC
This inboard engine, when installed in accordance with Mercury Marine's instructions, complies with the requirements of
the following directives by meeting the associated standards as amended:
Name of engine manufacturer: V M Motori, s.p.a.
Address: 29 Via Ferrarese
Town: Cento (FE)
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 (115/130 HP): T Ü V Product Service Gmbh
Address: 65 Ridlerstrasse
Town: Münich
Name of notified body for exhaust emission assessment (150/170 HP): International Marine Certification Institute
(IMCI)
Address: Rue Abbé Cuypers 3
Town: Bruxelles
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 model or engine
family:
2.0L 115/130
2.0L 150/170
Essential requirements
Annex I.B – Exhaust Emissions
B.1 Engine Identification
B.2 Exhaust Emission
Requirements
B.3 Durability
B.4 Owner's Manual
Annex I.C – Noise Emissions
Post Code: 44042
Post Code:B‑4800
Post Code: 80339
Post Code: B‑1040
Fuel Type:
☒
Unique engine identification number(s)
or engine family code(s)
MR504LB3/MR504LS3
MR504LH3/MR504LX3
Standards
☐
☒*
☐
☒
see the Declaration of Conformity for the craft in which the engine(s) has (have) been
Country: Belgium
Country: Germany
Country: Belgium
☒ B+C
☐ B+D
Combustion Cycle:
Diesel
☒
4 stroke
EC Type–examination certificate or
type‑approval certificate number
SB5 13 11 57278 013
EXVMMO001
Other
normative
Technical
document/
file
method
☐
☒
☐
☐
☐
☒
☐
☐
installed
Country: Italy
ID Number: 0123
ID Number: 0609
☐ B+E
☐ B+F
☐ G ☐ H
Please specify in more detail
(* = mandatory standard)
*EN ISO 8178‑1:1996
ISO 8665:2006

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  • Page 1 Declaration of Conformity for Recreational Craft Propulsion Engines with the requirements of Directive 94/25/EC as amended by 2003/44/EC This inboard engine, when installed in accordance with Mercury Marine’s instructions, complies with the requirements of the following directives by meeting the associated standards as amended: Name of engine manufacturer: V M Motori, s.p.a.
  • Page 2 Length Exhaust Gas Emissions Certification Number The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Diesel power package. When contacting Mercury Marine about service, always specify model and serial numbers. Descriptions and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policies are based on 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 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 5: Table Of Contents

    Canada................2 Canada Warranty Chart—MerCruiser Gas and Diesel..11 Transfer of Warranty............2 Outside Canada............11 Mercury Product Protection Plan: United States and Australia and New Zealand Warranty Chart—MerCruiser Canada................3 Gas and Diesel..............12 Emission Control Warranty Information........3 Outside Australia and New Zealand......
  • Page 6 High‑Speed and High‑Performance........32 Bottom of Boat..............34 Passenger Safety In Pontoon Boats And Deck Boats.... 32 Elevation and Climate............. 34 Boats Having An Open Front Deck........32 Propeller Selection............35 Boats With Front‑Mounted, Raised Pedestal Fishing Seats Getting Started............... 35 ..................
  • Page 7 Engine Runs Rough, Misses, or Backfires....... 78 Free‑play, or Makes Unusual Sounds......80 Section 8 - Customer Assistance Information Owner Service Assistance............82 Contact Information for Mercury Marine Customer Service Local Repair Service............82 ................... 83 Service Away From Home..........82 Customer Service Literature............
  • Page 8 Page iv 90-8M0089579 MARCH 2014...
  • Page 9 Outside United States ........... 11 Canada................2 Canada Warranty Chart—MerCruiser Gas and Diesel Transfer of Warranty............2 ..................11 Mercury Product Protection Plan: United States and Outside Canada ............ 11 Canada................3 Australia and New Zealand Warranty Chart—MerCruiser Emission Control Warranty Information........3 Gas and Diesel..............

  • Page 10: Warranty Information

    Outside United States and Canada ‑ Check with your local distributor. You may change your address on file with Mercury Marine at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 11: Mercury Product Protection Plan: United States And Canada

    The optional Mercury Product Protection Plan is the only factory authorized extended warranty plan available for your engine. See your participating Mercury MerCruiser dealer for complete program details.

  • Page 12: Emission Control Information Label

    Warranty Policy—Diesel Models High‑Output Recreational Use Limited Warranty WHAT IS COVERED: Mercury Marine warrants each new engine/drive package (Product) to be free of defects in material and workmanship during the period described following. DURATION OF COVERAGE: 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 CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: 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 predelivery inspection process is completed and documented.

  • Page 14: Light-Duty Commercial Use Limited Warranty

    CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: 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 predelivery inspection process is completed and documented.

  • Page 15: 3-Year Limited Warranty Against Corrosion-Diesel Models (Recreational Use Only)

    • Damage caused by improper service • Damage caused by the 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 •...

  • Page 16: Warranty Policy-Australia And New Zealand

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We 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.
  • Page 17 Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. A list of dealers and their contact details is available at http://www.mercurymarine.com.au/home.aspx.

  • Page 18: Transfer Of Warranty-Australia And New Zealand Policy

    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 19: Global Warranty Charts

    3 years H.O. MerCruiser Inboard 5.7 ‑ 6.2 ‑ 8.2 3 years 4 years 3 years Horizon Mercury Diesel Not available at time of Sterndrive and 2 years 3 years printing Inboard Outside United States For product purchased outside of United States, contact the distributor in your country, or the authorized Marine Power Service Center closest to you.

  • Page 20: Australia And New Zealand Warranty Chart-Mercruiser Gas And Diesel

    Contact the Marine Power Service Center closest to you MerCruiser TowSport 3 years 3 years Mercury Diesel Sterndrive 2 years 3 years and Inboard Outside Australia and New Zealand For product purchased outside of Australia and New Zealand, contact the distributor in your country, or the authorized Marine Power Service Center closest to you.

  • Page 21: Outside Europe And Cis

    Inboard Contact the Marine Power Horizon, Scorpion, 2 years 3 years 4 years Service Center closest to SeaCore Mercury Diesel Not available at time of Sterndrive and 1 year 3 years printing Inboard Outside Middle-East and Africa For products purchased outside of Middle‑East and Africa regions, contact the distributor in your country, or the Marine Power Service Center closest to you.
  • Page 22 Section 1 - WARRANTY Notes: Page 14 90-8M0089579 MARCH 2014...

  • Page 23: 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 Features and Controls............16 Digital Throttle and Shift..........20 Warning Horn Signals............ 16 Remote Controls............20 Instrumentation.............. 16 Panel Mount Features ........... 20 VesselView ............

  • Page 24: Features And Controls

    Section 2 - Getting to Know Your Power Package Features and Controls Warning Horn Signals When the key switch is turned to the on position, the horn will turn on for a moment as a test to indicate the horn is working. There are two types of warning horns to alert the operator of an active problem within the engine’s operating system.

  • Page 25: System Link Digital Gauges

    Section 2 - Getting to Know Your Power Package • Coolant temperature • Oil pressure • Battery voltage • Fuel consumption • Engine operating hours SmartCraft tachometer and speedometer Tachometer Speedometer LCD display 50400 The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system. The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.

  • Page 26: Switches

    Section 2 - Getting to Know Your Power Package Switches Key switch Bilge blower switch (if equipped) 24735 Reference Switch Function Key switch Has four positions. "OFF." In the "OFF" position, all electrical circuits are off and the engine cannot be started. The engine is stopped when the key switch is turned to the "OFF"...

  • Page 27: Lanyard Stop Switch

    30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting, some fault codes are still being displayed, contact your authorized Mercury Diesel repair facility. Lanyard Stop Switch A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as may happen in an accidental ejection.

  • Page 28: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition

    DTS Operator's Manual. Remote Controls Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description or demonstration of your remote control. Panel Mount Features Neutral lock button Throttle‑only button...

  • Page 29: Console Mount Features

    If the replacement fuse also blows, then the electrical overload has not been eliminated. Further checks must be made on the electrical system. Do not circumvent the electrical overload protection provided on fused circuits by installing a Contact your Mercury Diesel authorized repair facility. higher amperage fuse or shorting across the fuse block terminals.

  • Page 30: Vessel Integration Panel (Vip) Overload Protection

    Section 2 - Getting to Know Your Power Package After finding and correcting the cause of the overload, replace any open (blown) fuses. 27000 2.0 fuse panel Location on fuse panel Reference Fuse Protection (From Front of Engine) 20‑amp Unswitched power to helm Lower left 10‑amp Switched power to ECM...

  • Page 31: Identification

    Guardian will allow the engine to reach a normal operating RPM. Identification The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.

  • Page 32: Technodrive Transmissions

    Section 2 - Getting to Know Your Power Package The owner or operator is not to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission levels to exceed their predetermined factory specifications. Engine data label example Engine weight Engine power rating Maximum engine speed (RPM)
  • Page 33 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Recommendations.......... 26 While Boat is in Operation ..........32 Carbon Monoxide Exposure..........27 While the Boat is Stationary ......... 32 Be Alert To Carbon Monoxide Poisoning ..... 27 High‑Speed and High‑Performance........

  • Page 34: Safe Boating Recommendations

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

  • Page 35: Carbon Monoxide Exposure

    Section 3 - On the Water Be alert. • 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

    The power package must be equipped with a gear ratio and propeller that allows the engine to operate at wide open throttle (WOT) at the engine's rated speed (RPM). Use of Mercury Diesel engines in applications that do not meet specified operational parameters is not approved.

  • Page 37: Operation Chart

    At temperatures of –20° C (–4° F) and below, use a coolant heater to improve cold starting. • If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for information about special cold weather equipment and precautions.

  • Page 38: Drain Plug And Bilge Pump

    • Check all applicable items in the maintenance schedules and operation chart. • Perform any other necessary checks as indicated by your Mercury Diesel authorized repair facility or specified in your boat owner's and operation manual. Important Information—SmartStart IMPORTANT: This Mercury Diesel model is equipped with SmartStart. SmartStart performs all appropriate starting operations upon initial start switch activation.

  • Page 39: Engine Warm Up

    Check the engine and the transmission, oil filter, oil lines, oil line connectors, and oil pan for leaks. Check the coolant hoses, heat exchanger connections, aftercooler, water pump, and drain fittings for leaks. Locate and correct any problems, or see your Mercury Diesel authorized repair facility if you are unable to determine the problem.

  • Page 40: Protecting People In The Water

    If your boat is considered a high‑speed or high‑performance boat, we recommend that you never operate it at its high‑speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to the Hi‑Performance Boat Operation booklet from your Mercury Diesel authorized repair facility.

  • Page 41: Boats With Front-Mounted, Raised Pedestal Fishing Seats

    Section 3 - On the Water Boats With Front‑Mounted, Raised Pedestal Fishing Seats Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

  • Page 42: Conditions Affecting Operation

    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. Conditions Affecting Operation...

  • Page 43: Propeller Selection

    It is important to follow this procedure to properly break in the engine. IMPORTANT: Mercury Marine recommends that the boat not be accelerated hard until this procedure has been completed. IMPORTANT: Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool;...

  • Page 44: End Of First Season Checkup

    Section 3 - On the Water • Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged operation at wide‑open throttle RPM. End of First Season Checkup At the end of the first season of operation, contact an authorized repair facility to discuss or perform scheduled maintenance items.
  • Page 45 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 38 Engine Specifications............39 Nonferrous Metals and the Fuel System ...... 38 Fluid Specifications............... 40 Diesel Fuel in Cold Weather..........38 Engine................40 Antifreeze/Coolant..............38 Transmission..............40 Engine Oil................

  • Page 46: Fuel Requirements

    Mercury diesels are required to use Grade No. 2‑D ULSD (ultra‑low sulphur diesel) fuel meeting ASTM Standards D975 (or fuel rated Diesel DIN EN 590), and having a minimum cetane rating of 40.

  • Page 47: Engine Oil

    To optimize the performance of this engine in marine applications, Mercury strongly recommends the use of Quicksilver 5W‑30 Full Synthetic TDI Engine Oil. This oil meets international ACEA C3 specifications.

  • Page 48: Fluid Specifications

    *Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.
  • Page 49 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner and Operator Responsibilities........42 Removal................. 57 Dealer Responsibilities............42 Inspection..............58 Maintenance................. 42 Installation..............58 Do‑It‑Yourself Maintenance Suggestions......42 Water‑Separating Fuel Filter..........59 General Inspection............... 42 Draining................. 59 Engine Cover................

  • Page 50: Owner And 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 a Mercury Diesel authorized repair facility for a periodic checkup.

  • Page 51: Engine Cover

    Section 5 - Maintenance Remove and inspect the propeller. If badly nicked, bent, or cracked, contact your Mercury Diesel authorized repair facility. Repair nicks and corrosion damage on power package exterior finish. Contact your Mercury Diesel authorized repair facility. NOTE: A small panel in the engine cover allows access to the engine fuse panel, the engine oil fill cap, and the engine oil dipstick without removing the entire engine cover.
  • Page 52 Section 5 - Maintenance • Check the engine oil level. (This interval can be extended based on operator experience with the product.) Each day start • Check the engine coolant level. • Check the transmission oil level. • If operating in saltwater, brackish water, or polluted water, flush the seawater section of the cooling system after each use.

  • Page 53: Scheduled Maintenance

    Check the engine to propeller shaft alignment. Engine Oil Specifications To optimize the performance of this engine in marine applications, Mercury strongly recommends the use of Quicksilver 5W‑30 Full Synthetic TDI Engine Oil. This oil meets international ACEA C3 specifications. Engine Oil 2.0L...

  • Page 54: Checking

    Section 5 - Maintenance Checking engine oil level must be done carefully. The oil level must be maintained between the minimum and the maximum oil level mark on the dipstick. To ensure that you are not getting a false reading, observe the following before checking the oil level.

  • Page 55: Changing Oil And Filter

    Section 5 - Maintenance Remove the oil fill cap. 2.0L engine oil service Engine cover with access panel removed Engine oil fill cap Engine oil dipstick 27986 Add the specified oil to bring the oil level up to, but not over, the maximum mark on the dipstick. Engine Oil 2.0L System Capacity...
  • Page 56 Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Loctite 567 PST Pipe Sealant Drain plug threads 92-809822 Tighten the oil filter housing drain plug to the specified torque. Engine Coolant Oil Cooler Description lb‑in. lb‑ft Drain plug –...

  • Page 57: Tm 345 Technodrive Transmission Fluid

    If the oil level is low, add transmission oil to bring the level up to the maximum mark on the dipstick. See Filling. NOTE: If the transmission oil level was extremely low, see your local Mercury Diesel authorized repair facility.

  • Page 58: Filling

    Section 5 - Maintenance Filling If necessary, add the specified transmission oil through the dipstick receptacle to bring the level up to the maximum mark on the dipstick. Minimum oil level Maximum oil level Dipstick 27922 NOTE: Always use the dipstick to determine the quantity of oil required. Model Capacity Fluid type...

  • Page 59: Tm 485-A Technodrive Transmission Fluid

    Section 5 - Maintenance Loosen the retaining nut. 27978 Transmission oil filter retaining nut Remove the filter element. Clean the oil filter element using the cleaning solvent. Tube Ref No. Description Where Used Part No. Cleaning solvent Transmission filter element Obtain Locally 10.

  • Page 60: Add Fluid

    If the fluid level is low, add transmission fluid to bring the level up to the maximum mark on the dipstick. See Add Fluid. NOTE: If the transmission fluid level was extremely low, see your local Mercury Diesel authorized repair facility.

  • Page 61: Change Fluid

    Section 5 - Maintenance Change Fluid 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 62 Section 5 - Maintenance Remove the filter element. Filter element 24618 Clean the filter element with a mild cleaning solvent, obtained locally. 10. Lubricate the O‑rings with SAE Engine Oil 30W. Tube Ref No. Description Where Used Part No. SAE Engine Oil 30W Transmission filter element O-ring Obtain Locally 11.

  • Page 63: Engine Coolant

    Section 5 - Maintenance 13. Tighten the assembly nut to the specified torque. Assembly nut Securing tab 24621 Description lb‑in. lb‑ft Assembly nut 5–8 48–72 – 14. Fill the transmission to the proper level with the specified fluid. See Add Fluid. Engine Coolant CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns.

  • Page 64: Draining The Closed-Cooling System

    11. Remove the pressure cap and add coolant to the specified level. 12. Install and securely tighten the pressure cap. Draining the Closed‑Cooling System IMPORTANT: Due to the complex nature of this service Mercury Diesel strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law.

  • Page 65: Air Filter

    25768 Ensure that the coolant has drained completely. If required, clean the closed‑cooling system. See your local Mercury Diesel authorized repair facility. Install and tighten the engine coolant drain plug. Install the water‑separating fuel filter. Refer to Water‑Separating Fuel Filter ‑ Replacing.

  • Page 66: Inspection

    Section 5 - Maintenance Loosen the clamp and remove the air filter housing from the turbocharger inlet. Air filter housing on engine Oil separator vent hose clamp Air filter element Air filter housing clamp 53217 Remove the air filter element from the air filter housing. Air filter element Air filter housing 53215...

  • Page 67: Water-Separating Fuel Filter

    Section 5 - Maintenance Install the oil separator vent hose. Oil separator vent hose clamp Air filter element Air filter housing clamp 53217 Tighten the oil separator vent hose clamp to the specified torque. Description lb‑in. lb‑ft Oil separator vent hose clamp –...

  • Page 68: Replacing

    Section 5 - Maintenance Open the drain by turning the drain cap counterclockwise (as viewed from the bottom of the filter) until fuel starts draining. Do not remove the drain cap. Typical water-separating fuel filter WIF sensor wire connection Filter Drain cap 23318 Drain until the fuel is clear in appearance.
  • Page 69 Section 5 - Maintenance Remove the drain cap and O‑ring seal from the bottom of the existing fuel filter. Note the position of the O‑ring seal. Typical Drain cap O‑ring seal 24566 Discard the used filter and O‑ring seal as defined by local authorities. Install the O‑ring and drain cap on the new water‑separating fuel filter.

  • Page 70: Filling

    13. Connect the battery cables. 14. Start and operate the engine. Check the filter connection for fuel leaks. If leaks exist, recheck the filter installation. If leaks continue, stop the engine immediately and contact your Mercury Diesel authorized repair facility. Filling A type of hand pump and primer plunger is located on the fuel filter bracket and is used to •...

  • Page 71: Fuel System

    Section 5 - Maintenance Move the primer plunger up and down repeatedly. The filter is full when an air‑free stream of fuel flows from the air vent screw. Typical Air vent screw Primer plunger 23468 Securely tighten the air vent screw. Typical Air vent screw 23469...

  • Page 72: Fuel Tank Cleaning And Flushing

    Section 5 - Maintenance Fuel Tank Cleaning and Flushing IMPORTANT: Diesel fuel should not be left in the tank during winter storage, as an accumulation of rust, sludge, and wax residue will form. Refer to the boat manufacturer's instructions and clean the fuel tank at specified intervals. Unless specified otherwise, flush and clean the diesel fuel tank every 1000 hours or five years, whichever occurs first.

  • Page 73: Checking The Seawater Pickups

    Section 5 - Maintenance A small diameter wire bore brush or stiff piece of wire can be used to clear the seawater drain valve of any debris. Disconnect the seawater inlet hose from the connector on the seawater pump. Seawater pump inlet Seawater pump Seawater pump outlet Fuel cooler (if equipped)

  • Page 74: Cleaning The Seawater Strainer

    Section 5 - Maintenance Cleaning the Seawater Strainer NOTE: Visually inspect the seawater strainer through its clear cover. NOTICE An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat, causing damage or sinking the boat. Always close the water supply from the seawater pump, water inlet, or seacock when performing service or maintenance on the cooling system.

  • Page 75: Engine Seawater Pump Inspection

    Engine Seawater Pump Inspection IMPORTANT: Mercury strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Remove and inspect the engine seawater pump at the interval specified in the Maintenance Schedule. See your Mercury Diesel authorized repair facility.

  • Page 76: Engine Corrosion Protection Components

    Section 5 - Maintenance IMPORTANT: Replace sacrificial anodes if eroded 50% or more. Mercury strongly recommends avoiding the use of anodes from other manufacturers. Refer to your Mercury Diesel authorized repair facility for additional information. Engine Corrosion Protection Components The engine is equipped with a sacrificial anode located in the end cover of the engine aftercooler to assist in protecting the engine and the seawater cooling system from corrosion.

  • Page 77: Installation

    IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint is not covered by the limited warranty. In some areas it may be advisable to paint the bottom of the boat to help prevent marine growth. Contact a Mercury Diesel authorized repair facility for recommendations for your boat.

  • Page 78: Shift Cable

    2.0L front cover removed Serpentine belt Power‑assisted steering belt (sterndrive only) 25603 Serpentine Belt Inspection Should the serpentine belt need replacement, consult your Mercury Diesel authorized repair facility. Inspect the serpentine belt for proper tension and for the following: • Excessive wear •...

  • Page 79: Battery

    See your Mercury Diesel authorized dealer for all of your repair needs. There is no adjustment available for the serpentine belt. If the belt becomes loose or noisy, it has worn out and must be replaced.
  • Page 80 Section 5 - Maintenance Engine Control Module (ECM) and Vessel Integration Panel (VIP). The ECM and VIP require a stable voltage source. During multiple engine operation, an onboard electrical device may cause a sudden drain of voltage at the engine's battery. The voltage may drop below the ECM or VIP minimum voltage requirements.

  • Page 81: Section 6 - Storage

    Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather (Freezing Temperature), Seasonal Storage, Seasonal Storage............75 and Extended Storage............74 Extended Storage Instructions........76 Cold Weather (Freezing Temperature) Storage.... 74 Battery................76 Preparing Your Power Package for Seasonal or Recommissioning..............

  • Page 82: Cold Weather (Freezing Temperature), Seasonal Storage, And Extended Storage

    Section 6 - Storage Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage IMPORTANT: Mercury Marine strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.

  • Page 83: Seasonal Storage

    Description Where Used Part Number Corrosion Guard 92‑802878‑55 Light gray primer Outside of engine 92‑802878‑52 Marine Cloud White paint 8M0071082 Mercury Phantom Black Shift plate and air filter housing 92‑802878Q1 90-8M0089579 MARCH 2014 Page 75...

  • Page 84: Extended Storage Instructions

    Read all precautions and perform all procedures found in Seasonal Storage Instructions. IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight. Remove the seawater pump impeller and store away from direct sunlight. Refer to a Mercury Diesel authorized repair facility for additional information and service.
  • Page 85 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing Electronically Controlled Fuel System Problems Poor Performance............79 ....................78 Incorrect Engine Temperature........79 Troubleshooting Charts............78 Low Engine Oil Pressure..........79 Starter Motor Will Not Crank Engine, or Cranks Slow... 78 Battery Will Not Charge..........

  • Page 86: Diagnosing Electronically Controlled Fuel System Problems

    Diagnosing Electronically Controlled Fuel System Problems A Mercury Diesel authorized repair facility has the proper service tools for diagnosing problems on electronically controlled fuel systems. The engine control module (ECM) on these engines has the ability to detect problems with the system when they occur, and store a trouble code in the ECM's memory.

  • Page 87: Poor Performance

    Boat overloaded or improperly distributed. Reduce load or redistribute more evenly. Boat bottom fouled or damaged. Clean or repair as necessary. Have electronic fuel system checked by a Mercury Diesel authorized repair Electronic fuel system fault. facility. Electronically controlled turbocharger fault...

  • Page 88: Remote Control Operates Hard, Binds, Has Excessive Free-Play, Or Makes Unusual Sounds

    Obstruction in the shift or throttle linkages. Remove the obstruction. Check all throttle linkages. If any are loose or missing, see a Mercury Loose or missing shift and throttle linkages. Diesel authorized repair facility immediately. Straighten cable or have a Mercury Diesel authorized repair facility Shift or throttle cable kinked.
  • Page 89 Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance............ 82 Contact Information for Mercury Marine Customer Local Repair Service ............ 82 Service ................. 83 Service Away From Home ..........82 Customer Service Literature..........83 Stolen Power Package ..........

  • Page 90: 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 91: Contact Information For Mercury Marine Customer Service

    Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 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: •...

  • Page 92: Other Languages

    Section 8 - Customer Assistance Information 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.
  • Page 93 Section 9 - Maintenance Log Section 9 - Maintenance Log Table of Contents Maintenance Log..............86 90-8M0089579 MARCH 2014 Page 85...
  • Page 94 Section 9 - Maintenance Log Maintenance Log Record all maintenance performed on your power package here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours Page 86 90-8M0089579 MARCH 2014...

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