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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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Related Manuals for MerCruiser 5.7 MPI
Summary of Contents for MerCruiser 5.7 MPI
- 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 Exhaust Gas Emissions Certification Number 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
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 pleasant! - 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
Government Application Warranty Chart....9 Mercury Product Protection Plan: United States and Mercury Installation Quality Certification Program. .9 Canada..............3 Emission Control Information Label.......10 Mercury MerCruiser Limited Warranty Owner Responsibility........11 (Gasoline‑Fueled Products Only) ......4 Section 2 - Getting to Know Your Power Package Identification............14 Slim Binnacle Console Mount Features ‑... - Page 6 Passenger Safety in Pontoon Boats and Deck The Bottom of the Boat......... 40 Boats..............38 Cavitation............40 Boats Having An Open Front Deck....38 Ventilation............. 41 Boats With Front‑Mounted, Raised Pedestal Elevation and Climate........41 Fishing Seats...........38 Getting Started............. 41 Wave and Wake Jumping........39 20‑Hour Break‑In Period.......
- Page 7 Drain System Identification......76 Boat out of the Water........84 Air Actuated Single Point Drain System..76 Three‑Point Manual Drain System....85 Manual Single Point Drain System....77 Boat in the Water.........85 Three Point Manual Drain System....77 Boat out of the Water........86 Multi‑Point Drain (MPD) System....78 Multi‑Point Drain (MPD) System....87 Air‑Actuated Single‑Point Drain System..
- Page 8 Page iv 90-864197072 NOVEMBER 2007...
- Page 9 Government Application Warranty Chart ..9 Mercury Product Protection Plan: United States and Mercury Installation Quality Certification Program Canada..............3 ................9 Mercury MerCruiser Limited Warranty (Gasoline- Emission Control Information Label....10 Fueled Products Only) ......... 4 Owner Responsibility ........11 90-864197072 NOVEMBER 2007...
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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: 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 19: Owner Responsibility
Section 1 - Warranty NOTE: When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine, the Declaration of Conformance applies. Refer to the front page of this manual for further information. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION... - Page 20 Section 1 - Warranty Notes: Page 12 90-864197072 NOVEMBER 2007...
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Page 21: 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............14 Slim Binnacle Console Mount Features - Single Engine Serial Number Decal......14 Engine............21 Lanyard Stop Switch........... 14 Console Mount Features- Dual Engine..22 Instrumentation........... -
Page 22: 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 23: 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 24: Analog Gauges
Section 2 - Getting to Know Your Power Package SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a constant speed with an engine speed between 500 and 1200 RPM. 26238 SmartCraft gauges Tachometer LCD system view display Speedometer The SmartCraft instrument package also aids in Engine Guardian diagnostics. -
Page 25: Remote Controls (Non-Dts Models)
Section 2 - Getting to Know Your Power Package Reference Gauge Function Fuel gauge Indicates quantity of fuel in tank. Hour meter Records engine operating time. Bilge blower switch Operates the bilge blower. Ignition switch Allows the operator to start and stop engine. Remote Controls (Non‑DTS Models) Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. -
Page 26: 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 27: 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 28: 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. 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). -
Page 29: 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 30: 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 31: 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 STAT ION 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 32: Synchronizing Dual Helms Prior To Station Transfer
Section 2 - Getting to Know Your Power Package SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER Pressing the station select button and holding it in allows the boat operator 10 seconds to match up the control handle settings at the new station with the handle settings that are at the old (to be inactive) station. - Page 33 Section 2 - Getting to Know Your Power Package 1. A circuit breaker protects the engine wiring harness and the instrumentation power lead. Test the circuit breaker by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset after testing, or if tripped, by pushing the yellow lever back into the housing.
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Page 34: Audio Warning System
Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred. -
Page 35: Transmission Guardian Strategy
Transmission Guardian Strategy IMPORTANT: Boat speed could be reduced to idle and may not respond to the throttle. 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. - Page 36 Section 2 - Getting to Know Your Power Package Notes: Page 28 90-864197072 NOVEMBER 2007...
- Page 37 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........30 While You Are Cruising ........ 37 Be Alert to Carbon Monoxide Poisoning..... 31 While Boat Is Stationary ....... 37 Good Ventilation ........... 31 High-Speed and High-Performance Operation Poor Ventilation ...........
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Page 38: 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 39: 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 40: 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 41: Starting And Stopping The Engine
Section 3 - On The Water Operation Chart WHILE BEFORE STARTING AFTER STARTING AFTER STOPPING UNDERWAY Flush cooling system if in Open fuel shut off valve. saltwater. Open seacock, if equipped. Drain bilge. Close the drain system. Check the engine oil. Perform all other checks specified by your dealer and/or boat builder. -
Page 42: 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 43: Starting And Stopping The Engine
Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes. 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 44: Stopping The Engine
Section 3 - On The Water Turn the ignition key to "start." Release key when the engine starts and allow the switch to return to the "on" position. 6. If the engine does not start after step 5: Move the remote control handle.throttle lever to the full throttle position, then return to 1/4 throttle. -
Page 45: Freezing Temperature Operation
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty. -
Page 46: High-Speed And High-Performance Operation
Section 3 - On The Water Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat. High‑Speed and High‑Performance Operation If your boat is considered a high‑speed or high‑performance boat with which you are unfamiliar, 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. -
Page 47: Wave And Wake Jumping
Section 3 - On The Water Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. mc79680-1 Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with enough 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 48: Conditions Affecting Operation
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 49: Ventilation
Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After Break‑In Period To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered; •... -
Page 50: End Of First Season Checkup
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 51: Section 4 - Specifications
Section 4 - Specifications Section 4 - Specifications Table of Contents Cruising RPM............44 Engine Oil............45 Fuel Requirements..........44 Engine Specifications......... 46 Fuel Ratings ..........44 Fluid Specifications..........46 Using Reformulated (Oxygenated) Gasolines Engine ............46 (USA Only) ........... 44 Transmission .......... -
Page 52: Cruising Rpm
The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. -
Page 53: Engine Oil
All MerCruiser engines Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA FC‑W rated If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation: 1. Mercury/Quicksilver 25W‑40 Synthetic Blend, NMMA FC‑W–rated 4‑cycle MerCruiser 2. -
Page 54: Engine Specifications
IMPORTANT: All capacities are approximate fluid measures. All Models Capacity Fluid Type Engine oil (with filter) 4.25 L (4.5 US qt) Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40 Seawater cooling system 20 L (21 US qt) Propylene glycol and purified water Page 46 90-864197072 NOVEMBER 2007... -
Page 55: Transmission
Section 4 - Specifications All Models Capacity Fluid Type Mercury Extended Life Coolant Antifreeze or extended life Closed cooling system 19 L (20 US qt) ethylene glycol 5/100 antifreeze mixed 50/50 with purified water Transmission Model Capaci Fluid Type 5000A 2.84 L (3.00 US qt) Dexron III Automatic Transmission Fluid 5000V... - Page 56 Section 4 - Specifications Notes: Page 48 90-864197072 NOVEMBER 2007...
- Page 57 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......50 Filling ............58 Dealer Responsibilities........50 Changing ............. 59 Maintenance............50 Cleaning the Flame Arrestor....... 59 Do-It-Yourself Maintenance Suggestions... 51 Positive Crankcase Ventilation Valve Inspection............51 (PCV) ............
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Page 58: 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 59: 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 60: Maintenance Schedule-Inboard Models
• Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase annually ventilation hoses. Inspect the PCV valve, if equipped. On MerCruiser V6 (whichever occurs first) models, the PCV valve is a non‑serviceable, internal component of the valve cover assembly. -
Page 61: Maintenance Log
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Replace the coolant/anitifreeze. Replace every two years if not using Every 5 years extended‑life coolant/antifreeze. Maintenance Log Record all maintenance performed on your power package here. Be sure to save all work orders and receipts. -
Page 62: Filling
Section 5 - Maintenance NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the engine (flywheel end). 6076 Dipstick tube IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. -
Page 63: Changing Oil And Filter
Capacity Fluid Type 4.25 L Engine oil (with filter) Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40 (4.5 US qt) Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage. -
Page 64: Changing Filter
NOTE: Adding 0.95 L (1 US qt) of engine oil will raise the level from the add mark to the top of the OK range. 5.7, 6.2 MPI and Horizon 5.7, 6.2 Capacity Fluid Type 4.25 L Engine oil (with filter) Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40 (4.5 US qt) Page 56 90-864197072 NOVEMBER 2007... -
Page 65: Transmission Fluid
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 66: Filling
Heat exchanger cap 2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. 3. Install the cap onto the heat exchanger. -
Page 67: Changing
92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. -
Page 68: Positive Crankcase Ventilation Valve (Pcv)
11. Install the engine cover. Positive Crankcase Ventilation Valve (PCV) CHANGING IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. NOTE: On V6 models the PCV valve is non‑serviceable and is an internal component of the valve cover. -
Page 69: Water-Separating Fuel Filter
Section 5 - Maintenance 1. Remove the PCV valve from the port valve cover. mc71925-1 PCV valve Hose 2. Disconnect the PCV valve from the hose and discard the valve. 3. Install a new PCV valve in the valve cover and reconnect the hose. 4. -
Page 70: Gen Iii Models
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 71: 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. Lubrication Throttle Cable 1. -
Page 72: Transmission Linkage
Section 5 - Maintenance Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Throttle cable pivot points & 92‑883725K01 Oil SAE25W‑40 guide contact surfaces Transmission Linkage IMPORTANT: The poppet ball must be centered in the detent hole for each F‑N‑R position. -
Page 73: Serpentine Drive Belt
Section 5 - Maintenance Serpentine Drive Belt WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts. 6089 Idler pulley Alternator pulley Circulating pump pulley Seawater pump pulley Crankshaft pulley... -
Page 74: Flushing The Power Package
Section 5 - Maintenance 5. Use a 8 mm (5/16 in.) socket and tighten adjusting the stud to adjust the belt deflection. 6. Using one of the 2 methods following, check for correct deflection. Push down with moderate thumb pressure on the longest stretch of belt. Proper deflection is 13 mm (1/2 in.). -
Page 75: The Boat Out Of The Water
Section 5 - Maintenance NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the engine. Do not supply flush water for more than 15 seconds without the engine operating. 4. Snap the quick connect fitting and the water hose into the flush socket on the engine. 6090 Quick connect fitting 5. - Page 76 Section 5 - Maintenance IMPORTANT: Flushing is needed If the engine package has been operated in salty, brackish, mineral‑laden or polluted water. For best results flushing is recommended after each outing and before cold weather and extended storage. WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
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Page 77: The Boat In The Water
Section 5 - Maintenance NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the engine. Do not supply flush water for more than 15 seconds without the engine operating. 3. Completely open the water source to provide maximum water supply. 4. - Page 78 Section 5 - Maintenance NOTICE Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage. Close the seacock before disconnecting the seawater inlet hose. Plug the seawater inlet hose immediately after disconnecting it. If not equipped with a seacock, disconnect the seawater inlet hose from the transmission seawater inlet fitting and immediately plug the seawater inlet hose to prevent water from siphoning into the engine or boat.
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Page 79: Battery
Section 5 - Maintenance NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the engine. Do not supply flush water for more than 15 seconds without the engine operating. 3. Completely open the water source to provide maximum water supply. 4. -
Page 80: Multiple Efi Engine Battery Precautions
Section 5 - Maintenance Multiple EFI Engine Battery Precautions Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for 2 different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine's alternator will not be required to supply any charging current. -
Page 81: Section 6 - Storage
Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....74 Boat out of the Water ......81 Preparing Power Package for Storage..74 Manual Single-Point Drain System....83 Engine and Fuel System Preparation ..75 Boat in the Water ........ -
Page 82: 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 83: Engine And Fuel System Preparation
Section 6 - Storage 8. 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 84: 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 85: Manual Single Point Drain System
Section 6 - Storage 21125 Scorpion Models Blue air pump Green indicators Air manifold Blue drain plug locations MANUAL SINGLE POINT DRAIN SYSTEM 6128 Blue handle Blue drain plug location THREE POINT MANUAL DRAIN SYSTEM 6126 Blue drain plug 90-864197072 NOVEMBER 2007 Page 77... -
Page 86: Multi-Point Drain (Mpd) System
Section 6 - Storage MULTI-POINT DRAIN (MPD) SYSTEM 6129 Side of cylinder block Bottom of exhaust manifolds 6130 Water circulating pump hose Fuel cooler to thermostat housing 6131 Check valve (if equipped) Air‑Actuated Single‑Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. - Page 87 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.
- Page 88 12. Remove the air pump from the air manifold and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
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Page 89: Boat Out Of The Water
Section 6 - Storage 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine. - Page 90 Section 6 - Storage 6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side. 6125 6124 Closed Cooled Models Seawater Cooled Models Blue drain plug location Air manifold Blue air pump...
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Page 91: Manual Single-Point Drain System
10. Remove the air pump from the air manifold and return it to the mounting bracket. 11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained. -
Page 92: Boat Out Of The Water
Section 6 - Storage 4. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually. 6137 Drain location ‑ orange or red Blue drain plug 5. Allow the system to drain for a minimum of five minutes. We recommend leaving the drain system open while transporting the boat or performing other maintenance. -
Page 93: Three-Point Manual Drain System
Section 6 - Storage 3. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually. 6137 Drain location ‑ orange or red Blue drain plug 4. Allow the system to drain for a minimum of five minutes. We recommend leaving the plugs out while transporting the boat or performing other maintenance to ensure that all water is drained. -
Page 94: Boat Out Of The Water
Section 6 - Storage 3. To properly vent the cooling system, remove the blue drain plug from the side of the thermostat housing within 30 seconds. 6139 Blue drain plug location 4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side). 6140 Blue drain plugs 5. -
Page 95: Multi-Point Drain (Mpd) System
Section 6 - Storage 2. Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side). 6142 Blue drain plug 3. Verify that water is draining from each opening. 4. - Page 96 Section 6 - Storage Water‑circulating pump hose 6143 Drain plug Fuel‑cooler‑to‑thermostat‑housing hose 6144 Drain plug Check valve 6131 Drain plug (if equipped) Page 88 90-864197072 NOVEMBER 2007...
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Page 97: Boat In The Water
Section 6 - Storage 3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs... - Page 98 Section 6 - Storage Water‑circulating pump hose 6143 Drain plug Fuel‑cooler‑to‑thermostat‑housing hose 6144 Drain plug Check valve 6131 Drain plug (if equipped) Page 90 90-864197072 NOVEMBER 2007...
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Page 99: Battery Storage
Section 6 - Storage 3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs... - Page 100 Section 6 - Storage Notes: Page 92 90-864197072 NOVEMBER 2007...
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Page 101: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........94 Excessive Engine Temperature......95 Diagnosing DTS Problems......... 94 Insufficient Engine Temperature......96 Engine Guardian System........94 Low Engine Oil Pressure........96 Starter Motor Will Not Crank Engine, Or Cranks Battery Will Not Recharge........ -
Page 102: 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 103: 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 104: Insufficient Engine Temperature
Section 7 - Troubleshooting Possible Cause Remedy Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups or sea strainer obstructed. Remove obstruction. Faulty thermostat. Replace. Coolant level (if equipped) low in closed cooling Check for cause of low coolant level and repair. Fill section. -
Page 105: Remote Control Is Difficult To Move, Has Excessive Play, Or Makes Unusual Sounds
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. Steering Wheel Jerks or Is Difficult to Turn Possible Cause Remedy Low power steering pump fluid level. - Page 106 Section 7 - Troubleshooting Notes: Page 98 90-864197072 NOVEMBER 2007...
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Page 107: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 100 Parts and Accessories Inquiries ... 101 Local Repair Service ........100 Resolving a Problem ........101 Service Away From Home ......100 Mercury Marine Service Offices .... -
Page 108: 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 109: 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 110: 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...
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