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NOTE: The following applies to CE marked products only.
Declaration of Conformance – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury
MerCruisers' instructions complies with the requirements of the following directives
by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Owner's manual (A.2.5)
Openings in Hull, Deck and superstructure (A.3.4) ISO 9093‑1; ISO 9093‑2
Handling characteristics (A.4)
Inboard Engine (A.5.1.1)
Fuel System (A.5.2)
Electrical System (A.5.3)
Steering system (A.5.4)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Ignition‑protected equipment (Annex II)
Mercury MerCruiser declares that our sterndrive or inboard engines without integral
exhaust, when installed in a recreational craft, in accordance with the manufacturers
supplied instructions, will meet the exhaust emissions requirements of the directive
mentioned above. This engine must not be put into service until the recreational craft
in which it is to be installed has been declared in conformity, if so required, with the
relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion engine
driven devices ‑ Radio disturbance characteristics
Electrostatic discharge testing
The notified body responsible for surveillance of the quality system under Full Quality Assurance
Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.
President ‑ Mercury Marine, Fond du Lac, WI USA
Applicable Requirement
Patrick C. Mackey
Standards Applied
ISO 10240
ISO 8665
ISO 15584; ISO 10088; ISO 7840; ISO 10133
ISO 10088; ISO 7840; ISO 8469
ISO 10133; ISO 8846
Applicable portions of: ISO 10592, ISO 8848 and
ABYC P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 8846; SAE J1171; SAE J1191; SAE J 2031
EN 50081‑1
EN 50082‑1
SAE J551 (CISPR 12)
EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3
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Table of Contents
Troubleshooting
Related Manuals for MerCruiser 8.1 H.O.
Summary of Contents for MerCruiser 8.1 H.O.
- Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
- Page 2 Length The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser® power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing.
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Page 3: Read This Manual Thoroughly
Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant! Mercury MerCruiser 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... - Page 4 NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard.
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Page 5: Table Of Contents
Mercury Product Protection Plan: United States and What Is Not Covered........12 Canada..............3 Components Of The Emission Control System 12 Mercury MerCruiser Limited Warranty Disclaimers And Limitations......14 (Gasoline‑Fueled Products Only) ......4 California Emission Control Warranty Statement. .14 3‑Year Limited Warranty Against Corrosion....6 Your Warranty Rights and Obligations.....14... - Page 6 Drain Plug and Bilge Pump......42 Boats Having An Open Front Deck....46 Basic Boat Operation (DTS Models)....42 Boats With Front‑Mounted, Raised Pedestal Launching and Boat Operation..... 42 Fishing Seats...........47 Operation Chart.......... 43 Wave and Wake Jumping........47 Starting and Stopping the Engine....43 Impact with Underwater Hazards......
- Page 7 Section 6 - Storage Cold Weather or Extended Storage....... 78 Boat in the Water.........81 Preparing Power Package for Storage...78 Boat out of the Water........83 Engine and Fuel System Preparation..79 Manual Drain System........85 Draining the Seawater System......80 Boat in the Water.........85 Drain System Identification......
- Page 8 Page iv 90-899883273 MARCH 2008...
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Page 9: Section 1 - Warranty
Mercury Product Protection Plan: United States and Components Of The Emission Control Canada..............3 System ............12 Mercury MerCruiser Limited Warranty (Gasoline- Disclaimers And Limitations ......14 Fueled Products Only) ......... 4 California Emission Control Warranty Statement 3-Year Limited Warranty Against Corrosion..6 ................ -
Page 10: Warranty Registration: United States And Canada
A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer. -
Page 11: Transfer Of Warranty
Section 1 - Warranty The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use, and the selling distributor’s and dealer’s code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product. -
Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)
One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after the original engine registration date. See your participating Mercury MerCruiser dealer for complete program details. Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only) - Page 13 Section 1 - Warranty Conditions That Must Be Met in Order 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 pre‑delivery inspection process specified by Mercury Marine is completed and documented.
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Page 14: 3-Year Limited Warranty Against Corrosion
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below. -
Page 15: Global Warranty Charts
Section 1 - Warranty This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty;... -
Page 16: Commercial Application Warranty Chart
Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and... -
Page 17: Government Application Warranty Chart
Section 1 - Warranty Government Application Warranty Chart Limited Corrosion Government Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and... -
Page 18: California Emissions Limited Warranty
California Emissions Limited Warranty NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003. -
Page 19: Duration Of Coverage
Duration Of Coverage NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model... -
Page 20: How To Obtain Warranty Coverage
Section 1 - Warranty How To Obtain Warranty Coverage The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair. - Page 21 Section 1 - Warranty Cold start enrichment system Intake valve(s) 2. Air Induction System Controlled hot air intake system Intake manifold Air filter Turbocharger systems Heat riser valve and assembly 3. Ignition System Spark plugs Magneto or electronic ignition system Spark advance/retard system Ignition coil and/or control module Ignition wires...
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Page 22: Disclaimers And Limitations
1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003. -
Page 23: Emission Control Information Label
A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement. -
Page 24: Owner Responsibility
Beginning January 1, 2003, one Three‑Star or Four‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2007 and later exhaust emission standards. - Page 25 Section 1 - Warranty The Star label will be affixed on the left side of the hull as shown. XX 1234 XX 32770 Recommended location Secondary location One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards.
- Page 26 Section 1 - Warranty Notes: Page 18 90-899883273 MARCH 2008...
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Page 27: Section 2 - Getting To Know Your Power Package
Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............20 Console Mount Features- Dual Engine..29 Engine Serial Number Decal......20 Synchronizing Dual Engines......29 Lanyard Stop Switch........... 20 Dual Helm Station Transfer......30 Instrumentation........... -
Page 28: Identification
Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal The serial number decal is located on top of the engine. -
Page 29: Instrumentation
Section 2 - Getting to Know Your Power Package The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator. -
Page 30: Digital Gauges
Section 2 - Getting to Know Your Power Package When the system detects a problem with the engine or system, the System View displays alarm messages to alert the operator to the potential problem. If the problem can cause immediate engine damage, the engine's Guardian system responds to the problem by limiting engine power. -
Page 31: Analog Gauges
Section 2 - Getting to Know Your Power Package Analog Gauges The following is a brief explanation of the instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings for your boat. -
Page 32: Panel Mount Features
Section 2 - Getting to Know Your Power Package PANEL MOUNT FEATURES 17355 Neutral lock button Control handle tension adjustment screw Throttle only button Control handle Lanyard stop switch Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed in to move the control handle out of neutral. -
Page 33: Console Mount Features
Section 2 - Getting to Know Your Power Package CONSOLE MOUNT FEATURES 17356 Throttle Only Button Control Handle Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position. -
Page 34: Remote Controls (Dts Models)
Section 2 - Getting to Know Your Power Package Throttle Lever - Throttle functions are controlled by the movement of the throttle lever. Increase the RPM by moving the throttle lever forward. Achieve Wide Open Throttle (WOT) by placing the throttle lever in its full forward position. Decrease RPM by moving the throttle lever back. -
Page 35: Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Throttle Only Button - Allows engine throttle advancement without shifting the engine. The throttle only button can be depressed only when the remote control is in the neutral position, and should only be used to assist in starting or warming up the engine. Start/Stop Button - Allows the boat operator to start or stop the engine without using the ignition key. -
Page 36: Slim Binnacle Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension. Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed). -
Page 37: Console Mount Features- Dual Engine
Section 2 - Getting to Know Your Power Package Console Mount Features‑ Dual Engine SYNC ACTIVE THROTTLE ONLY STATION SELECT 17365 Control handles Sync light Active light Throttle only/station select key Neutral light Detent tension adjustment Select key Control handle friction adjustment screw Arrow trackpad Control Handle - Operation of the shift and throttle are controlled by the movement of the... -
Page 38: Dual Helm Station Transfer
Section 2 - Getting to Know Your Power Package Auto Synchronizing will stay engaged up to 95% throttle opening. The Sync light will turn on when the engines are synchronized. SYNC ACTIVE THROTTLE ONLY STATION SELECT 3434 To disengage, move one or both control handles until they are more than 5° apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%. -
Page 39: Synchronizing Dual Helms Prior To Station Transfer
Reset the circuit breaker. If the breaker remains open, you have not eliminated the electrical overload and the electrical system requires further checks. Contact your authorized Mercury MerCruiser dealer. The circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. - Page 40 Section 2 - Getting to Know Your Power Package 3. Reset the breaker by pushing the yellow lever back into the housing. 22529 Yellow lever style circuit breaker‑typical Yellow lever‑shown tripped Red test button A 90 amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.
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Page 41: Audio Warning System
32777 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 42: Testing The Audio Warning System
IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from damage. Your Mercury MerCruiser power package may be equipped with an audio warning system. Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem. -
Page 43: Obdm
If an OBDM fault is detected, the audio warning system sound with one five‑second horn, then one short, 1/2‑second horn every 60 seconds for certain faults related to the emissions or fuel system. See your authorized Mercury MerCruiser dealer for assistance. ½... - Page 44 Section 2 - Getting to Know Your Power Package As another example, Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage. Transmission Guardian monitors the clutch pack pressure in forward and reverse gears. If the transmission fluid pressure drops below a predetermined level, Transmission Guardian lowers the engine torque and speed to prevent clutch slippage.
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Page 45: Section 3 - On The Water
Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions........38 Protecting People in the Water......46 Be Alert to Carbon Monoxide Poisoning..... 39 While You Are Cruising ........ 46 Good Ventilation ........... 39 While Boat Is Stationary ....... -
Page 46: Safe Boating Suggestions
Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer. -
Page 47: Be Alert To Carbon Monoxide Poisoning
Section 3 - On the Water • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat;... -
Page 48: Poor Ventilation
Section 3 - On the Water 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. -
Page 49: Operation Chart
Section 3 - On the Water OPERATION CHART Operation Chart WHILE BEFORE STARTING AFTER STARTING AFTER STOPPING UNDERWAY Observe all gauges to Observe all gauges check condition of to check condition of Turn ignition key to the Install bilge drain plug. engine. -
Page 50: Stopping The Engine
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty. -
Page 51: Operation Chart
Section 3 - On the Water • Do not turn the key off when the engine is above idle speed. • Do not use the lanyard stop switch to shut off the engine when operating above idle speed. • Enter the water slowly when launching your boat from a steep ramp. •... -
Page 52: Stopping The Engine
Section 3 - On the Water NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process. -
Page 53: Throttle-Only Operation
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty. -
Page 54: Protecting People In The Water
Section 3 - On the Water 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. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. -
Page 55: Boats With Front-Mounted, Raised Pedestal Fishing Seats
Section 3 - On the Water Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. mc79555-1 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. -
Page 56: 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 57: The Bottom Of The Boat
Section 3 - On the Water • Generally increases speed and engine RPM • Causes bow to bounce in choppy water • Increases danger of following wave splashing into the boat when coming off plane • At extremes, can cause the boat to porpoise Shifting weight to front (bow): •... -
Page 58: After Break-In Period
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 59 Section 4 - Specifications Section 4 - Specifications Table of Contents Cruising RPM............52 Engine Oil............53 Fuel Requirements..........52 Engine Specifications......... 54 Fuel Ratings ..........52 Fluid Specifications..........54 Using Reformulated (Oxygenated) Gasoline Engine............54 (USA Only) ........... 52 Transmission..........55 Gasoline Containing Alcohol ......
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Page 60: Cruising Rpm
Reformulated gasoline is required in certain areas of the USA and are acceptable for use in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol. -
Page 61: Engine Oil
IMPORTANT: Lubrication requirements for catalyzed engines differ from the requirements for non‑catalyzed engines. Some marine‑grade lubricants contain high levels of phosphorus, which can damage the catalyst system on MerCruiser engines. Although these high‑phosphorus lubricants may allow acceptable engine performance, exposure over time will damage the catalyst. -
Page 62: Engine Specifications
FC‑W–rated synthetic oils, low‑quality oils, or oils that contain solid additives. Mercury Full-Synthetic MerCruiser Engine Oil, 20W-40, NMMA FC-W rated MerCruiser/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 Other recognized brands of NMMA FC-W rated oils... -
Page 63: Transmission
Section 4 - Specifications All Models Capacity Fluid Type Mercury Full‑Synthetic MerCruiser Engine Oil Engine oil (with filter) 8.5 L (9 US qt) 20W‑40 Seawater cooling system (winterization use 20 L (21 US qt) Propylene glycol and purified water only) - Page 64 Section 4 - Specifications Notes: Page 56 90-899883273 MARCH 2008...
- Page 65 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......58 Battery..............66 Dealer Responsibilities........58 Multiple EFI Engine Battery Precautions..66 Maintenance............58 Cleaning the Flame Arrestor....... 67 Do-It-Yourself Maintenance Suggestions... 59 Cleaning the IAC Muffler (Non-DTS Models Only) Inspection............
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Page 66: Owner/Operator Responsibilities
• Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •... -
Page 67: Do-It-Yourself Maintenance Suggestions
Transmission (inboard models only) Do‑It‑Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic. -
Page 68: Maintenance Schedule-Inboard Models
• Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase ventilation hoses. Inspect the PCV valve, if equipped. NOTE: On MerCruiser V6 models, the PCV valve is a non‑serviceable, internal component of the valve cover assembly. • Inspect the condition and the tension of the belts. -
Page 69: Maintenance Log
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Check the engine mounts for tightness and tighten to specifications if necessary. • Inspect the condition of the spark plugs, spark plug wires, and the distributor cap and rotor, if equipped. Replace as necessary. If the condition of these components is satisfactory at inspection, repeat inspection every 100 hours or once a year, whichever occurs first. -
Page 70: Engine Oil
Section 5 - Maintenance Engine Oil Checking NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required. -
Page 71: Changing Oil And Filter
Fluid Type Engine oil (with filter) 8.5 L (9 US qt) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 3. Check the oil level and replace the fill cap. Changing Oil and Filter See Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage. -
Page 72: Changing The Oil Filter
Engine oil (with filter) 8.5 L (9 US qt) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 8. Start the engine and operate for three minutes, checking for leaks. 9. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water. -
Page 73: Changing
2. Remove the dipstick, wipe clean and reinsert. 3. Remove the dipstick, observe the fluid level and mark the cold fluid level. 4. Reinstall the dipstick, tighten the T‑handle securely. Do not overtighten. Changing Contact your authorized Mercury MerCruiser dealer. Engine Coolant Checking CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. -
Page 74: Changing
Refer to the Specifications section. 4. Install the fill cap to the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery. -
Page 75: Cleaning The Flame Arrestor
Section 5 - Maintenance EFI Electronic Control Module (ECM): The ECM requires 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 go below the ECM's minimum required voltage. -
Page 76: Cleaning The Iac Muffler (Non-Dts Models Only)
Section 5 - Maintenance 3. Clean the flame arrestor with solvent and dry with compressed air or set aside and allow to air dry completely. 4. Install the flame arrestor and tighten the clamp. 5. Install the engine cover. Cleaning the IAC Muffler (Non‑DTS Models Only) WARNING Fuel is flammable and explosive. -
Page 77: Water-Separating Fuel Filter
O‑ring REMOVAL 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped. 3. Disconnect the Cool Fuel Module harness from the engine wiring harness. -
Page 78: Installation
10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Page 70 90-899883273 MARCH 2008... -
Page 79: Lubrication
Pivot points Guide contact surfaces Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Throttle cable pivot points & 92‑883725K01 Oil SAE25W‑40 guide contact surfaces Shift Cable ‑ Typical 1. Lubricate the pivot points and the guide contact surfaces. -
Page 80: Driveshaft Extension Models
Section 5 - Maintenance NOTE: If the boat is operated at idle for prolonged periods of time, coupler should be lubricated every 50 hours. 6212 Bravo drive coupler Grease fitting Tube Ref No. Description Where Used Part No. Engine Coupler Spline Grease Coupler 92-802869A 1 NOTE: The coupler and shaft splines can be lubricated without removing the sterndrive... -
Page 81: Serpentine Drive Belt
Section 5 - Maintenance Serpentine Drive Belt Belt Routing WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before inspecting the belts. 8119 Idler pulley Alternator pulley Water circulating pump pulley Seawater pump pulley Crankshaft pulley... -
Page 82: Replacing
Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the cast stops. See your authorized MerCruiser dealer for service if these conditions exist. -
Page 83: The Boat In The Water-Inboard Models
Section 5 - Maintenance 1. Close the seacock, if equipped, then disconnect the seawater inlet hose from the seawater pump. 2. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump and immediately plug the hose. 3. - Page 84 Section 5 - Maintenance 3. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump. NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the engine.
- Page 85 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....78 Air Actuated Single Point Drain System..81 Preparing Power Package for Storage..78 Boat in the Water ........81 Engine and Fuel System Preparation ..79 Boat out of the Water ......
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Page 86: Cold Weather Or Extended Storage
Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. -
Page 87: Engine And Fuel System Preparation
Section 6 - Storage 10. For additional assurance against freezing and rust, after draining, fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage. -
Page 88: Draining The Seawater System
Identification to determine which instructions apply to your power package. IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. -
Page 89: Manual Drain System
Section 6 - Storage 17254 Port side drain location Starboard side drain location MANUAL DRAIN SYSTEM 17255 Blue drain plug locations 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. However, any air source can be used. - Page 90 Section 6 - Storage 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump Green indicators Lever (locking) Manual release valve 6. Pump air into the system until both green indicators extend and water drains from both sides of the engine.
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Page 91: Boat Out Of The Water
11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. 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 92 Section 6 - Storage 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump Green indicators Lever (locking) Manual release valve 6. Pump air into the system until both green indicators extend and water drains from both sides of the engine.
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Page 93: Manual Drain System
11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. 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 94: Boat Out Of The Water
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained. -
Page 95: Battery Storage
Section 6 - Storage 6. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 7. Prior to launching the boat or starting the engine, close the drain system by installing the two blue drain plugs. - Page 96 Section 6 - Storage Notes: Page 88 90-899883273 MARCH 2008...
- Page 97 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........90 Excessive Engine Temperature....91 Diagnosing DTS Problems......... 90 Insufficient Engine Temperature....92 Engine Guardian System........90 Low Engine Oil Pressure.......92 Troubleshooting Charts........90 Battery Will Not Recharge......92 Starter Motor Will Not Crank Engine, or Cranks Remote Control Is Difficult to Move, Has Slowly............90...
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Page 98: Diagnosing Efi Problems
Section 7 - Troubleshooting Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory. -
Page 99: Engine Will Not Start Or Is Hard To Start
Boat bottom fouled or damaged. Clean or repair as necessary. Ignition problem. See Engine Runs Rough, Misses or Backfires. Engine overheating. See Excessive Engine Temperature. Have EFI System checked by an authorized Mercury MerCruiser EFI System fault dealer. Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed. -
Page 100: Insufficient Engine Temperature
Check all throttle linkages. If any are loose or missing, Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair. Page 92 90-899883273 MARCH 2008... -
Page 101: Steering Wheel Jerks Or Is Difficult To Turn
Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners if any are loose or missing, Loose or missing steering fasteners or parts. see authorized Mercury MerCruiser dealer immediately. Contaminated power steering fluid. See authorized Mercury MerCruiser dealer. 90-899883273 MARCH 2008... - Page 102 Section 7 - Troubleshooting Notes: Page 94 90-899883273 MARCH 2008...
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Page 103: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........96 Parts and Accessories Inquiries ..... 97 Local Repair Service ........96 Resolving a Problem ........97 Service Away From Home ......96 Mercury Marine Service Offices .... -
Page 104: Owner Service Assistance
Owner Service Assistance Local Repair Service If you need service for your Mercury MerCruiser–powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine. -
Page 105: Parts And Accessories Inquiries
Resolving a Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. -
Page 106: Ordering Literature
• Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P.O. Box 1939...