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Mercury D1.7L DTI Alpha Operation, Maintenance And Warranty Manual

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CA741
The product you have purchased comes with a limited warranty from Mercury Marine; the
terms of the warranty are set forth in the Warranty Sections of this manual. The warranty state-
ment contains a description of what is covered, what is not covered, the duration of coverage,
how to best obtain warranty coverage, important disclaimers and limitations of damages,
and other related information. Please review this important information.
CE344
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.
Diesel engine exhaust and some of its constituents are known to the state of
California to cause cancer, birth defects, and other reproductive harm.
The description and specifications contained herein were in effect at the time this guide was
approved for printing. Mercury Marine, whose policy is one of continuous improvement,
reserves the right to discontinue models at any time, or to change specifications or designs,
without notice and without incurring obligation.
2001, Mercury Marine
The following are registered trademarks of Brunswick Corporation: Autoblend,
Jet-Prop, Mariner, Merc, MerCathode, Mercury MerCruiser, Mercury, Mercury
Marine, Quicksilver, RideGuide, and Thruster.
Warranty Message
WARNING
WARNING
CALIFORNIA
PROPOSITION 65 WARNING
Mercury Marine Fond du Lac, Wisconsin, U.S.A.
Printed in U.S.A.

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Summary of Contents for Mercury D1.7L DTI Alpha

  • Page 1: Page Warranty Message

    CA741 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty state- ment contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.

  • Page 2: Welcome

    The Operation, Maintenance and Warranty Manual contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleas- ant!

  • Page 3: Identification Record

    Exhaust Gas Emissions Certificate Number (Europe Only) 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.

  • Page 4: Table Of Contents

    ............. . . Mercury MerCruiser Diesel Limited Warranty .
  • Page 5 ..............Mercury Marine Service Offices .

  • Page 6: Warranty Information

    CD54 Warranty Information CD55 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. •...

  • Page 7: International Owner Registration

    CD56 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 pro- gram for your area.

  • Page 8: Mercury Mercruiser Diesel Limited Warranty

    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.
  • Page 9 (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, use of an accessory or part which damages the Mercury product and was not manufactured or sold by us, jet pump impellers and liners, operation with fuels,...

  • Page 10: Warranty Coverage And Exclusion

    CD622 Warranty Coverage and Exclusion Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in mate- rial and workmanship. Installation errors, accidents normal wear and a variety of other causes that affect the product are not covered.

  • Page 11: Transferable Warranty

    • There is no charge for this service. Outside the United States and Canada, please contact the closest Mercury Marine Service Office, or the closest distributor in your country, for the transferable warranty procedure that would apply to you.

  • Page 12: Read This Manual Thoroughly

    CD749 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 In- ternational HAZARD Symbol , may be used to alert the installer/user to special instructions concerning a partic- ular service or operation that may be hazardous if performed incorrectly or carelessly.

  • Page 13: General Information

    WARNING The use of accessories not manufactured or sold by Mercury Marine is not recommended for use with your Mercury MerCruiser unit. If your Mercury MerCruiser unit is equipped with an accessory not manufactured by Mercury Marine, be sure to read the Operation and Maintenance Manual for the accessory before operation.

  • Page 14: Lanyard Stop Switch

    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 15 While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut-down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat’s path as seriously as the boat would when under power.
  • Page 16 CA641 Courtesy of ABYC CA642 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, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories.

  • Page 18: Wave And Wake Jumping

    CD747 Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re-enters the water.

  • Page 19: Impact With Underwater Hazards

    CD830 Impact With Underwater Hazards Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the sterndrive or the boat bot- tom.

  • Page 20: 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 21: Protecting People In The Water

    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.

  • Page 22: Conditions Affecting Operation

    Conditions Affecting Operation Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: A. Shifting weight to rear (stern) will: • Generally increases speed and engine RPM. • At extremes, can cause boat to porpoise. •...

  • Page 23: Propeller Selection

    CD751 Propeller Selection IMPORTANT: Installed propeller must allow engine to run at the upper end of the specified throttle oper- ating revolutions per minute (rpm) range, with a normal load aboard the boat. 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(s).

  • Page 24: How Elevation And Climate Affect Performance

    CA12 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxygen) gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a noticeable effect on the density of air. Heat and humidity thin the air. This condition can become particularly annoying when the propeller testing was done on a cool, dry day.

  • Page 25: Important Information

    Pleasure duty rating applies to recreational planing craft used exclusively for pleasure and recreation. IMPORTANT: Damage caused by improper application or failure to operate within the operational capa- bility, or duty cycle, will not be covered by the Mercury MerCruiser Diesel Limited Warranty.
  • Page 26 OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks, ensure that all lubrication and maintenance instruc- tions are complied with for safe operation, and return the unit to an Authorized Mercury MerCruiser Dealer for a periodic checkup.

  • Page 27: Freezing Temperature And Cold Weather Operation

    If drive unit should strike a submerged object, stop engine as soon as possible and inspect drive unit for damage. If damage is present or suspected, boat should be taken to an Authorized Mercury MerCruiser Dealer for thor- ough inspection and necessary repair. Operating a damaged drive unit could cause additional damage to other parts of drive unit, or could affect control of boat.

  • Page 28: 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 number(s) 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 29: 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 30: Engine Break-In

    CD753 Engine Break-In INITIAL BREAK-IN PROCEDURE It is especially important that the following procedure be used on new diesel engines. This break-in procedure allows the proper seating of the pistons and rings, which greatly reduces the likelihood of problems. IMPORTANT: It is recommended that the boat not be accelerated hard until this procedure has been completed.

  • Page 31: Sterndrive Unit 10-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 32: Operation

    CD843 Operation 70515 70516 70514 70522 70522 70517 70518 70523 70520 70521 70519...

  • Page 33: Instrumentation

    CD842 Instrumentation INSTRUMENTS 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. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings that will appear on your style gauges.
  • Page 34 CD756 77359 CD757 ENGINE MONITORING FEATURES The appropriate light functions as follows: Preheat Indicator Lamp - indicates when the glow plugs, if equipped, are preheating the combustion chambers. When the engine is cold the timed preheat period begins when the key switch is turned to RUN. The light stays on until the preheat period is complete.

  • Page 35: Audio Warning System

    22444 CD759 Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System horn will sound if any of the following occur: Engine oil pressure too low. Cooling system temperature too high.

  • Page 36: Electrical System Overload Protection

    CD760 77121 71630 77360 CD761 Electrical System Overload Protection lf an electrical overload occurs, a fuse will blow or a circuit breaker will trip open. IMPORTANT: The cause must be found and corrected before replacing fuse or resetting circuit breaker. One 50 amp circuit breaker provide protection for engine wiring harness and instrumentation power lead.

  • Page 37: Remote Control Features

    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 38 CA768 ° 3 - 5...

  • Page 39: Power Trim

    CA418 Power Trim Power Trim allows the operator to adjust the drive angle, while underway, to provide the ideal boat angle for varying load and water conditions. Also, the Power Trim system “Trailering” feature allows the operator to raise and lower the drive unit for trailering, beaching, launching and low speed (below 1200 rpm engine speed), shallow water operation.

  • Page 40: Single Engine Trim / Trailer

    CB804 Single Engine Trim / Trailer Single engine applications will have a button that can be pressed to trim the drive unit up or down. To raise the drive unit for trailering, beaching, launching and low speed, (below 1200 rpm) shallow water operation push the trim button to raise the drive unit to the full UP / OUT position.

  • Page 41: Starting, Shifting And Stopping

    CD831 77312 CD764 Starting, Shifting and Stopping GENERAL INFORMATION WARNING Do not use volatile starting aids, such as Ether, Propane, or Gasoline in the engine air intake system. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage.
  • Page 42 Check oil pressure gauge immediately after engine starts. If oil pressure is not within specified range (Refer to Specifications), stop the engine, locate and correct the problem, or see your Authorized Mercury MerCruiser Dealer if you are unable to determine the problem. CAUTION Do not increase the engine speed until the oil pressure gauge indicates normal.
  • Page 43 Check for coolant leaks. Check coolant hoses and connection pipes of heat exchanger, fluid coolers, inter- cooler, water pump and drain fittings. Locate and correct any problems, or see your Authorized Mercury MerCruiser Dealer if you are unable to determine the problem.
  • Page 44 Once underway, engine oil pressure should be within the range listed in the engine specifications chart at maximum rpm, or wide-open-throttle. Stop the engine if oil pressure is not within this range. Locate and correct the problem, or see your Authorized Mercury MerCruiser Dealer if you are unable to determine the problem. CB575 IMPORTANT: Avoid stopping engine if the drive unit is in gear.

  • Page 45: Operation Chart - D1.7L Dti

    CD768 Operation Chart D1.7L DTI STARTING AFTER WHILE STOPPING & PROCEDURE STARTING UNDERWAY SHUT DOWN Observe all gauges and Frequently observe all Shift remote control lever Open engine hatch. Air warning lights to check gauges and indicator to neutral position. out bilge completely.

  • Page 46: Specifications

    Specifications CD164 Fuel Requirements WARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury.

  • Page 47: Recommended Fuels

    CD769 Recommended Fuels IMPORTANT: Mercury MerCruiser does not recommend to use “Heavy Oil” for your engine. Heavy oil fuels causes hard-starting and other various troubles such as premature wear of the injection pump plungers and injection nozzles resulting from the deposit of carbon residue and other contaminants.

  • Page 48: Crankcase Oil

    API CH-4, CF-4, CG-4,CF-2, SJ and SH oils. Other recommended oils: SHELL MYRINA TEXACO URSA SUPER TD VEEDOL TURBOSTAR MOPAR WINTERSHALL MULTI-REKORD WINTERSHALL VIVA 1 These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W-40 oil.

  • Page 49: Anti-Freeze/Coolant

    CD771 Anti-Freeze/Coolant CAUTION Alcohol or Methanol base antifreeze or plain water are not recommended for use in closed cooling section of cooling system at any time. Because diesel engines are high compression engines and related higher engine operating temperatures are created, the closed cooling system and engine, including related cooling passages must remain as clean as pos- sible to provide adequate engine cooling.

  • Page 50: Engine Specifications

    CD633 Engine Specifications CD772 D1.7L DTI Specification - Sterndrive (MCM) Description D1.7L DTI Crankshaft Kilowatts (Horsepower) 89.5 (120) Propeller Shaft Kilowatts (Horsepower) 86.5 (116) 4 Stroke, 4 Cylinder, Vertical In-Line, 4 Valves Per Cylinder, Dual Overhead Camshaft, Direct Engine Type Injection, Turbocharged, Intercooled Displacement...

  • Page 51: Fluid Capacities

    CD773 Fluid Capacities ENGINE NOTICE Unit Of Measurement: Liters (U.S. Quarts) All capacities are approximate fluid measures. Description Specification Total Oil Capacity 6-1/2 (6-3/4) Coolant (Anti-Freeze) Capacity 8-3/4 (9-1/4) Always use dipstick to determine exact quantity of oil required CD774 DRIVE NOTICE Unit Of Measurement: Milliliters (U.S.

  • Page 52: Maintenance

    CD10 Maintenance CD776 Power Package Views FRONT AND STARBOARD SIDE VIEWS 19 20 77121 Air cleaner Oil Separator Oil Filter Nozzle Dust Cover Oil Dipstick Injection Pipe Camshaft Cover Primer Pump / Water Separating Fuel Filter Injection Pump 10 - Injection Pump Bracket 11 - Oil Drain Plug...
  • Page 53 CD777 PORT SIDE AND REAR VIEWS 77122 Hose, Engine To Heat Exchanger Coolant Recovery Bottle Hose Gear Lube Monitor Bottle Heat Exchanger Heat Exchanger Coolant Pipe Exhaust Elbow Coolant Drain Plug Sacrificial Anode 10 - Seawater Drain Plug 11 - Oil Pressure Gauge Sending Unit 12 - Engine Coolant Drain Fitting...
  • Page 54 CD778 STERNDRIVE AND TRANSOM VIEWS 77769 Steering System Transom Assembly Sterndrive Unit Antiventilation Plate Power Trim Cylinder Propeller Seawater Intake Openings Speedometer Pitot Tube MerCathode Electrode (Optional) 10 - Inner Transom Plate 11 - Exhaust Pipe 12 - Rear Engine Mount 13 - Boat Transom / Hull 14 -...

  • Page 55: General Information

    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(s) be purchased and read thoroughly.

  • Page 56: Maintenance Aids

    CD780 5, 6 77300 CD562 Maintenance Aids Power Steering System - Quicksilver Power Trim and Steering Fluid, or Dexron II automatic transmission fluid (ATF). All pivot points - SAE 30W motor oil. Exposed Portion of Steering Cable and Propeller Shaft - Quicksilver Special Lubricant 101. Sterndrive Unit - Quicksilver Hi-Performance Gear Lube.

  • Page 57: Maintenance Schedules

    CD833 Maintenance Schedules Routine Maintenance Each Each Every Weekly Start Months Check crankcase oil (interval can be extended based on experi- ence). Check drive unit oil level, trim pump oil level, and power steering pump fluid level if equipped. Check water pickups for debris or marine growth. Check water strainer and clean, if equipped.
  • Page 58 Maintenance Schedules (Continued) Scheduled Maintenance Every Every Every Every Every Every 1000 After hours hours hours hours first 50 hours or hours or or 2 or 3 or 5 or 5 hours Annually Annually years years years years Change crankcase oil and filter. Retorque exhaust riser clamp.
  • Page 59 Maintenance Schedules (Continued) Scheduled Maintenance (Continued) Every Every Every Every Every Every 1000 After hours hours hours hours First 50 hours or hours or or 2 or 3 or 5 or 5 hours Annually Annually years years years years Retorque engine mounts. Check electrical system for loose, damaged or corroded fasteners.
  • Page 60 CD782 71380 77343 77241 77335 70546...

  • Page 61: Checking Fluid Levels

    Check gear lube monitor oil level. Keep oil level at or near FULL line. Check for water at bottom of monitor and/or if oil appears to be discolored, contact your Authorized Mercury MerCruiser Dealer immediately. Both conditions may indicate a water leak somewhere in the drive unit.
  • Page 62 CD784 72714 77334 70979 77348...
  • Page 63 • Also, the tank cap maintains pressure on the coolant tank. It may not be holding pressure properly. To have cap tested, contact your Authorized Mercury MerCruiser Dealer. CAUTION If the coolant should get extremely low and the engine very hot, let the engine cool for approximately 15 minutes before adding coolant;...
  • Page 64 CD834 70571 77353 77343...

  • Page 65: Changing Lubricants And Fluids

    See Maintenance Schedules for change interval. Lubricants should be changed before placing boat in storage. Power Trim or Power Steering fluids do not require changing. Coolant in closed cooling system should be changed at specified intervals by your Authorized Mercury MerCruiser Dealer.
  • Page 66 CD788 77244 77242 71380 77314...
  • Page 67 CD841 CRANKCASE OIL AND FILTER (CONTINUED) Use a filter wrench or appropriate socket to remove the cartridge type oil filter. Discard the old filter element. Discard the old O-rings from the top piece. Filter Element O-Rings Top Piece Install the three O-rings. Apply a coat of engine oil to the O-rings. Install the element on the top piece. Install the top piece with the new element into the oil filter housing.
  • Page 68 CD790 77335 70021 74302 70569...
  • Page 69 IMPORTANT: If any water drained from OIL FILL/DRAIN hole, or if oil appears discolored, drive unit is leaking and should be checked immediately by your Authorized Mercury MerCruiser Dealer. Lower drive unit so propeller shaft is level. Fill drive unit, through OIL FILL/DRAIN hole, with specified gear lube until an air-free stream of lubricant flows from OIL VENT hole.
  • Page 70 CD792 77132 75130 77139 77321...

  • Page 71: Air Cleaner

    CD793 Air Cleaner The air cleaner is used to prevent the entry of rain water, seawater, and debris. No maintenance is required and there are no serviceable parts to the air cleaner. Ensure that the air cleaner is mounted (clamped) securely at all times. Replace the assembly if is cracked or damaged.

  • Page 72: Lubrication

    CD795 71903 71904 71357 70373 CA524 Lubrication STEERING SYSTEM If Steering Cable Has Grease Fittings: Turn steering until steering cable is fully retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand-operated grease gun. Lubricate at fitting with 2-4-C Marine Lubricant with Teflon.
  • Page 73 CD796 77312 77044 77068 73346 71346 71347 CA73 THROTTLE CABLE Lubricate pivot points with SAE 30W motor oil. CA938 DRIVE UNIT AND TRANSOM ASSEMBLY Lubricate gimbal bearing by applying approximately 8-10 pumps of grease from a typical hand-operated grease gun using Quicksilver U-Joint and Gimbal Bearing Grease. Alpha Models - Lubricate hinge pins by applying a couple of pumps of grease from a typical hand-operated grease gun using Quicksilver 2-4-C Marine Lubricant with Teflon.
  • Page 74 CD844 71444 77381 77343...

  • Page 75: Fuel System

    CE406 Fuel System CAUTION Absolute cleanliness is required for work on the fuel system, fuel injection components have very close tolerances. Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system. FUEL TANK CLEANING AND FLUSHING IMPORTANT: Diesel fuel should not be left in tank during winter storage, as an accumulation of rust, sludge and wax residue will form.
  • Page 76 CD837 77761 77343...
  • Page 77 Start engine, check for fuel leaks. If leaks exist stop engine immediately. Recheck installation. NOTE: In some circumstances, it may be necessary to bleed (purge air) from the injectors if the engine does not readily start. Refer to an Authorized Mercury MerCruiser Dealer.
  • Page 78 CD800 77121 77161 77162...
  • Page 79 CD801 DRAINING WATER SEPARATING FUEL FILTER WARNING Be careful when draining water separating fuel filter. Diesel fuel is flammable. Be sure ignition key is OFF. Do not allow fuel to contact any hot surfaces which may cause it to ignite. Do not allow sources of open flame in the area.
  • Page 80 CD802 77128 77343 77128 77296...
  • Page 81 Any water entering the fuel injection system will disable the system. Check for water in water separating fuel filter before startup, daily. CAUTION If water should enter the fuel injection system, take unit to an Authorized Mercury MerCruiser Dealer IMMEDIATELY, so that corrosion and rusting of the injectors and other components can be avoided. WARNING Be careful when changing water separating fuel filter.
  • Page 82 CA634 76910 CA634 76910...

  • Page 83: Propeller

    CA816 Propeller ALPHA WARNING Avoid Injury: Remote Control must be in NEUTRAL and ignition key removed from switch before re- moving and/or installing propeller. WARNING Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut.

  • Page 84: Flushing Cooling System

    CA824 70564 CA825 Flushing Cooling System CA827 To prevent silt and/or salt buildup in cooling system, flush with freshwater after each use and prior to storage. If flushing cooling system with boat in water, raise drive unit to TRAILER position, install flushing attachment and lower drive unit to full DOWN/IN position.

  • Page 85: Corrosion And Corrosion Protection

    CD804 77334 77304 71368 71367 77122 CD805 Corrosion And Corrosion Protection INTERNAL COMPONENTS There are anodes as part of the intercooler and heat exchanger systems, which serve as sacrificial anodes. These sacrificial anodes are installed in the seawater circuit to help avoid electrolytic corrosion caused by seawater.
  • Page 86 CD806 70134 71957 72032 70576 71176 70055 70577 70578...
  • Page 87 CD807 EXTERNAL COMPONENTS Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged in a conductive solution, such as saltwater, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode.
  • Page 88 CD362 71176...
  • Page 89 If using copper or tin based anti-fouling paints, observe the following: Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1-1/2 in.) UNPAINTED area on transom of the boat around these items.

  • Page 90: Battery

    CD15 Miscellaneous Maintenance CD809 71088 CA103 Battery All lead acid batteries discharge when not in use. Recharge every 30 to 45 days. or when specific gravity drops below battery manufacturer’s specifications. Refer to specific instructions and warnings accompanying your battery. If this information is not available, ob- serve the following precautions when handling a battery.

  • Page 91: Bottom Of Boat

    CD810 È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È È...

  • Page 92: Cold Weather Or Extended Storage

    CD829 Power Package Layup IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an Authorized Mercury MerCruiser Dealer. Damage caused by freezing IS NOT covered by the Mercury Mer- Cruiser Limited Warranty. CAUTION The engine must be prepared for long storage periods to prevent internal corrosion and severe damage.

  • Page 93: Draining Instructions

    CD812 Power Package Layup (Continued) 77144 CD813 Drain seawater section of cooling system and prepare for cold weather or extended storage following these pro- cedures: DRAINING INSTRUCTIONS CAUTION If boat is to remain in the water, seacock, if so equipped, must remain closed until engine is to be restarted to prevent water from flowing back into seawater cooling system.
  • Page 94 CD814 Power Package Layup (Continued) 77143 71217 CD815 Remove drain plug from lower part of intercooler. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. Ensure that gear housing water vent and drain holes, speedometer pitot hole and trim tab cavity vent and drain holes are open and unobstructed.
  • Page 95 CD816 Power Package Layup (Continued) Dealer should perform the remaining tasks prior to layup: After draining, perform all checks, inspections, lubrication and fluid changes outlined in Maintenance Schedules. CAUTION If boat is to remain in the water, seacock, if so equipped, must remain closed until engine is to be re- started to prevent water from flowing back into seawater cooling system.

  • Page 96: Power Package Recommissioning

    CD839 Power Package Recommissioning WARNING To prevent possible injury or damage to equipment, do not install battery until all maintenance has been performed on engine. Check that all cooling system hoses are in good condition, connected properly, and hose clamps are tight. Replace fuel filter.

  • Page 97: Troubleshooting

    Empty fuel tank or fuel shutoff valve closed Fill tank or open valve. Throttle not operating properly Check throttle for freedom of movement. Faulty electrical stop-circuit Have Authorized Mercury MerCruiser Dealer service electric stop-circuit. Clogged fuel filters Replace filters. Stale or contaminated fuel If contaminated, drain tank.

  • Page 98: Poor Performance

    Air in fuel injection system Purge fuel injection system. Injector / injector nozzle malfunction Have inspected by an Authorized Mercury MerCruiser Dealer. Injection pump governor malfunction Have inspected by an Authorized Mercury MerCruiser Dealer.

  • Page 99: Excessive Engine Temperature

    Remedy Poor lubrication / low oil pressure at turbocharger Entry of foreign materials from intake or exhaust side Have inspected by an Authorized Mercury Have inspected by an Authorized Mercury MerCruiser Dealer. Rubbing of compressor or turbine impellers against housing...

  • Page 100: Low Engine Oil Pressure

    CD824 Low Engine Oil Pressure Possible Cause Remedy Faulty senders Have system checked by an Authorized Mercury MerCruiser Dealer. Insufficient oil in crankcase Check and add oil. Excessive oil in crankcase (causing it to become Check and remove required amount of oil. Check for...

  • Page 101: Steering Wheel Turns Hard Or Jerky

    Replace and/or adjust. Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners if any are loose or Loose or missing steering fasteners or parts. missing, see Authorized Mercury MerCruiser Dealer immediately. Contaminated power steering fluid. Drain and replace. CA453 Power Trim Does Not Operate (Motor Doesn’t Run)

  • Page 102: Owner Service Assistance

    CB577 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 103: Mercury Marine Service Offices

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

  • Page 104: Customer Service Literature

    CA781 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 105 Per ottenere il manuale di funzionamento e manutenzione in altra lingua, contattate il centro assistenza interna- zionale 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 106: Ordering Literature

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

  • Page 107: Owner's Logbook

    CD68 Owner’s Logbook Operating Date Maintenance and Repair Hours...
  • Page 108 CD68 Owner’s Logbook Operating Date Maintenance and Repair Hours...
  • Page 109 CD68 Owner’s Logbook Operating Date Maintenance and Repair Hours...

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