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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 Tow Sports 5.7 MPI
Summary of Contents for MerCruiser Tow Sports 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
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 Conditions Affecting Operation......41 Elevation and Climate........42 Weight Distribution (Passengers and Gear) Getting Started............. 42 Inside the Boat..........41 20‑Hour Break‑In Period....... 42 The Bottom of the Boat......... 41 After Break‑In Period........43 Cavitation............42 End of First Season Checkup....... 43 Ventilation.............
- Page 7 Section 7 - Troubleshooting Diagnosing EFI Problems........86 Poor Performance..........87 Diagnosing DTS Problems........86 Excessive Engine Temperature.....87 Engine Guardian System........86 Insufficient Engine Temperature....88 Troubleshooting Charts.........86 Low Engine Oil Pressure........88 Starter Motor Will Not Crank Engine, or Cranks Battery Will Not Recharge......88 Slowly.............86 Remote Control Is Difficult to Move, Has Engine Will Not Start or Is Hard to Start..87...
- Page 8 Page iv 90-865253073 DECEMBER 2007...
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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: Section 1 - 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 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. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
- Page 26 Section 1 - Warranty Notes: Page 18 90-865253073 DECEMBER 2007...
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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 Remote Controls...........25 Engine Serial Number Decal......20 Panel Mount Features ......26 Transmissions..........20 Console Mount Features ......27 Velvet Drive Transmissions .... -
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: Zf Marine Transmissions
Section 2 - Getting to Know Your Power Package On the Velvet Drive 5000A and 5000V Transmissions the transmission identification plate indicates gear ratio, serial number and model. 7370 Velvet Drive 5000A ‑ 8 degree down‑angle transmission shown (5000V ‑ V‑drive similar) Transmission identification plate ZF MARINE TRANSMISSIONS On the ZF Marine 8 Degree Down‑Angle and V‑Drive Transmissions, the transmission... -
Page 30: Walter V-Drive Transmissions
Section 2 - Getting to Know Your Power Package WALTER V-DRIVE TRANSMISSIONS On the Walter V‑Drive Transmissions, the transmission identification plate indicates gear ratio, serial number, and model. 7452 Walter RV‑36 V‑drive Transmission identification plate Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator's position (as in accidental ejection from the operator's position). -
Page 31: Instrumentation
Section 2 - Getting to Know Your Power Package • consuming alcohol or drugs • high speed boating maneuvers 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 32: Digital Gauges
Section 2 - Getting to Know Your Power Package Your power package may be connected to a SmartCraft VesselView display. This display provides a single, easy‑to‑use source for real‑time information about a variety of vessel systems. The interactive VesselView display continuously monitors and reports information about speed and performance, trim angle, water temperature and depth, and other operating data. -
Page 33: Analog Gauges
Section 2 - Getting to Know Your Power Package The SmartCraft instrument package also aids in Engine Guardian diagnostics. The SmartCraft Instrument package displays critical engine alarm data and potential problems. Refer to the manual with your gauge package for the warning functions monitored by and basic operation of the SmartCraft instrument package. -
Page 34: 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 35: 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 36: Electrical System Overload Protection
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 37 Section 2 - Getting to Know Your Power Package Four fuses are located on the port side of the engine. These fuses protect the main power, fuel pump, ignition, and accessory circuits. 33214 Engine fuses Two 10 amp fuses protect the O (oxygen) sensors.
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Page 38: 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 39: Caution
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 40: Testing The Audio Warning System
Guardian restores engine power to normal. To avoid recurrence of the problem, contact an authorized Mercury MerCruiser dealer. 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. -
Page 41: Section 3 - On The Water
Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions........34 Passenger Safety in Pontoon Boats and Deck Boats Be Alert to Carbon Monoxide Poisoning..... 35 ................39 Good Ventilation ........... 35 Boats Having An Open Front Deck .... -
Page 42: 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 43: 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 44: 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 45: 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 46: 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 47: While Boat Is Stationary
Section 3 - On the Water Whenever a boat is moving (even coasting) and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury. While Boat Is Stationary WARNING A spinning propeller, a moving boat, or any solid device attached to the boat can cause... -
Page 48: Wave And Wake Jumping
Section 3 - On the Water Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. mc79557-1 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. -
Page 49: 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 50: Cavitation
Section 3 - On the Water Cavitation Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object such as a gear housing or a propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the gear housing or the propeller. -
Page 51: 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 52 Section 3 - On the Water Notes: Page 44 90-865253073 DECEMBER 2007...
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Page 53: Section 4 - Specifications
Section 4 - Specifications Section 4 - Specifications Table of Contents Cruising RPM............46 Engine Oil............47 Fuel Requirements..........46 Engine Specifications......... 48 Fuel Ratings ..........46 Fluid Specifications..........48 Using Reformulated (Oxygenated) Gasoline Engine............48 (USA Only) ........... 46 Transmission..........49 Gasoline Containing Alcohol ...... -
Page 54: 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 55: Engine Oil
Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty. If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation, for short periods of time: 1. -
Page 56: Engine Specifications
NOTE: We do not recommend non‑detergent oils, multi‑viscosity oils (other than as specified), non FC‑W–rated synthetic oils, low‑quality oils, or oils that contain solid additives. Mercury MerCruiser Full-Synthetic Engine Oil, 20W-40, NMMA FC-W rated MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rated 4-cycle oil Other recognized brands of NMMA FC-W rated oils... -
Page 57: Transmission
Section 4 - Specifications All Models Capacity Fluid Type Mercury Full‑Synthetic MerCruiser Engine Engine oil (with filter) 4.25 L (4.50 US qt) Oil 20W‑40 Seawater cooling system (winterization use 20 L (21 US qt) Propylene glycol and purified water only) - Page 58 Section 4 - Specifications Notes: Page 50 90-865253073 DECEMBER 2007...
- Page 59 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......52 Battery..............59 Dealer Responsibilities........52 Multiple EFI Engine Battery Precautions..60 Maintenance............52 Cleaning the Flame Arrestor....... 60 Do-It-Yourself Maintenance Suggestions... 53 Positive Crankcase Ventilation Valve Inspection............53 (PCV) ............
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Page 60: 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 61: Do-It-Yourself Maintenance Suggestions
Transmission 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 62: Maintenance Schedule-Tow Sport Models
• Clean the flame arrestor, IAC muffler, and the crankcase ventilation hoses. Inspect the PCV valve, if equipped. To replace the IAC, contact your authorized Mercury MerCruiser dealer. • Inspect the condition and the tension of the belts. Page 54... -
Page 63: 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 Every 300 hours or 3 or once a year, whichever occurs first. -
Page 64: Filling
Section 5 - Maintenance 1. Stop the engine. Allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water. 2. Remove the dipstick, wipe clean, and reinstall fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent. -
Page 65: Changing Oil And Filter
Capacity Fluid Type 4.25 L Engine oil (with filter) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 (4.5 US qt) Changing Oil and Filter See Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage. -
Page 66: Changing The Oil Filter
NOTE: Adding 0.95 L (1 US qt) of engine oil raises the level from the add mark to the top of the OK range. All Models Capacity Fluid Type 4.25 L Engine oil (with filter) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 (4.50 US qt) Page 58 90-865253073 DECEMBER 2007... -
Page 67: Transmission Fluid
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. 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 68: 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 69: Positive Crankcase Ventilation Valve (Pcv)
10. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover. 11. Install the engine cover. Positive Crankcase Ventilation Valve (PCV) CHANGING IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. 90-865253073 DECEMBER 2007 Page 61... -
Page 70: Cleaning The Iac Muffler
Section 5 - Maintenance 1. Remove the PCV valve from the port valve cover. 33143 PCV valve (hose not shown) 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 71: Water-Separating Fuel Filter
Section 5 - Maintenance IMPORTANT: Do not get cleaner on electrical connections and do not use cleaner containing methyl ethyl ketone. 4. Clean the IAC muffler with warm water and a mild detergent. Replace if necessary. 5. Allow the IAC muffler to completely, then install. Water‑Separating Fuel Filter WARNING Fuel is flammable and explosive. -
Page 72: Installation
Section 5 - Maintenance 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 73: 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 Transmission Linkage IMPORTANT: The poppet ball must be centered in the detent hole for each F‑N‑R position. -
Page 74: Serpentine Drive Belt
5935 Pivot points Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Shift cable pivot points 92‑883725K01 Oil SAE25W‑40 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. -
Page 75: Replacing Belt And/Or Adjusting Tension
Section 5 - Maintenance • Glazed surfaces • Proper tension ‑ 13 mm (1/2 in.) deflection, with moderate thumb pressure, on the belt at the location that has the longest distance between two pulleys. mc75130-1 Replacing Belt and/or Adjusting Tension IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as before. -
Page 76: Flushing The Power Package-Tow Sports
Section 5 - Maintenance 7. While holding the adjustment stud at the correct belt tension, tighten the 16 mm (5/8 in.) locking nut. 6119 8 mm (1/16 in.) adjusting stud 16 mm (5/8 in.) locking nut 8. Operate the engine for a short period of time and recheck the belt adjustment. Flushing The Power Package—Tow Sports The Boat Out of the Water IMPORTANT: Flushing the power package is most effective when performed with the boat... - Page 77 Section 5 - Maintenance Proceed to step 3 2. All other models: Close the seacock, if equipped, and then disconnect the seawater inlet hose from the seawater pump inlet fitting.. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump and plug the hose.
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Page 78: The Boat In The Water
Section 5 - Maintenance 12. Immediately shut off the supply water and remove the flushing attachment. 13. Install the water inlet hose to the seawater inlet of the seawater pump or V‑Drive water inlet. 14. Tighten hose clamp securely. 15. Attach to the next engine, if equipped, and repeat procedure. The Boat In the Water IMPORTANT: Flushing the power package is most effective when performed with the boat out of the water. - Page 79 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 seawater pump inlet fitting and immediately plug the seawater inlet hose to prevent water from siphoning into the engine or boat.
- Page 80 Section 5 - Maintenance 11. Stop the engine. 12. Immediately shut off the water supply and remove the flushing attachment. 13. Remove the flushing connector from the water inlet. 14. Tag the ignition switch with an appropriate tag requiring the seacock to be opened or the seawater inlet hose to be reconnected prior to operating the engine.
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Page 81: Section 6 - Storage
Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....74 Air Actuated Single Point Drain System..77 Preparing Power Package for Storage..74 Boat in the Water ........77 Engine and Fuel System Preparation ..75 Boat out of 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 9. 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: Three Point Manual Drain System
Section 6 - Storage THREE POINT MANUAL DRAIN SYSTEM 6126 Blue drain plug Air Actuated Single Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the blue air pump that is attached to the engine. However, any air source can be used. 1. - Page 86 12. Remove the blue 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 87: 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 88 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.
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Page 89: Three-Point Manual Drain System
Section 6 - Storage 12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators Three‑Point Manual Drain System BOAT IN THE WATER NOTE: Use this procedure if your engine is not equipped with an air‑actuated single‑point drain system or if the air‑actuated single point drain system fails. -
Page 90: Boat Out Of The Water
Section 6 - Storage 4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side). 6140 Blue drain plugs 5. Verify that water is draining from each opening. 6. Allow the system to drain for a minimum of five minutes. We recommend leaving the drain system open while transporting the boat or performing other maintenance to ensure that all water is drained. -
Page 91: Battery Storage
Section 6 - Storage Battery Storage Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition. It should be clean and free of leaks. - Page 92 Section 6 - Storage Notes: Page 84 90-865253073 DECEMBER 2007...
- Page 93 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........86 Excessive Engine Temperature....87 Diagnosing DTS Problems......... 86 Insufficient Engine Temperature....88 Engine Guardian System........86 Low Engine Oil Pressure.......88 Troubleshooting Charts........86 Battery Will Not Recharge......88 Starter Motor Will Not Crank Engine, or Cranks Remote Control Is Difficult to Move, Has Slowly............86...
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Page 94: 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 95: 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 96: 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 88 90-865253073 DECEMBER 2007... -
Page 97: 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. 90-865253073 DECEMBER 2007... - Page 98 Section 7 - Troubleshooting Notes: Page 90 90-865253073 DECEMBER 2007...
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Page 99: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........92 Parts and Accessories Inquiries ..... 93 Local Repair Service ........92 Resolving a Problem ........93 Service Away From Home ......92 Mercury Marine Service Offices .... -
Page 100: 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 101: 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 102: 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...