MerCruiser 8.1 H.O. User Manual
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MerCruiser 8.1 H.O. User Manual

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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 MerCruiser, Stillwater, OK, USA
Applicable Requirement
Kevin Grodzki
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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  • Page 1 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. Kevin Grodzki President ‑ Mercury MerCruiser, Stillwater, OK, 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.

  • 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.

  • Page 5: Table Of Contents

    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) ‑ USA & Canada (For other countries please refer to the chart) ..4 Section 2 - Getting to Know Your Power Package Identification............14...
  • 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 Power Package Recommissioning......77 Section 7 - Troubleshooting Diagnosing EFI Problems........80 Excessive Engine Temperature......81 Diagnosing DTS Problems........80 Insufficient Engine Temperature......82 Engine Guardian System........80 Low Engine Oil Pressure........82 Starter Motor Will Not Crank Engine, Or Cranks Battery Will Not Recharge........82 Slow...............80 Remote Control Is Difficult to Move, Has Excessive Engine Will Not Start or Is Hard to Start....81...
  • Page 8 Page iv 90-864841070 OCTOBER 2007...

  • Page 9: Section 1 - Warranty

    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) - USA & Canada (For other Owner Responsibility ........11 countries please refer to the chart) ...... 4...

  • 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) - Usa & Canada (For Other Countries Please Refer To The Chart)

    Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only) ‑ USA & Canada (For other countries please refer to the chart) MERCURY MERCRUISER LIMITED WARRANTY (GASOLINE-FUELED PRODUCTS ONLY) - USA & Canada (For other countries please refer to the chart) What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following.
  • 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.

  • 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 Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...

  • 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 Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...

  • 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 90-864841070 OCTOBER 2007...

  • 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 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 25: 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 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. Start/Stop Button - Allows the boat operator to start or stop the engine without using the ignition key.

  • Page 29: 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: 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 3. Reset the breaker by pushing the yellow lever back into the housing. 22529 Yellow lever style circuit breaker Yellow lever 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.

  • 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: Testing The Audio Warning System

    If the warning horn emits a continuous beep, do not operate the engine unless avoiding a hazardous situation. If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If the cause cannot be determined, contact your authorized Mercury MerCruiser dealer. Testing The Audio Warning System 1.

  • Page 36: Warning Horn Signals

    Section 2 - Getting to Know Your Power Package Warning Horn Signals Most faults will cause the warning horn circuit to activate. How the warning horn activates depends on how serious the problem is. There are four warning horn states: •...

  • Page 37: Section 3 - On The Water

    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 ...........

  • 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, follow these recommendations: •...

  • 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..........47 Using Reformulated (Oxygenated) Gasolines Transmission ..........47 (USA Only) ........... 44 Engine ............

  • 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

    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 55: Fluid Specifications

    (heat exchanger and fluid lines). All Models Capacity Fluid Type Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA Engine oil (with filter) 8.5 L (9 US qt) FC‑W rated Seawater cooling system 20 L (21 US qt) Propylene glycol and purified water Mercury Extended Life Coolant Antifreeze or extended‑life...
  • Page 56 Section 4 - Specifications Notes: Page 48 90-864841070 OCTOBER 2007...

  • Page 57: Section 5 - Maintenance

    Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......50 Changing ............57 Dealer Responsibilities........50 Engine Coolant........... 57 Maintenance............50 Checking ............57 Do-It-Yourself Maintenance Suggestions... 51 Filling ............58 Inspection............51 Changing ............. 58 Maintenance Schedule—Inboard Models...

  • 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). 8480 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

    3. Replace the fill cap. All Models Capacity Fluid Type Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA Engine oil (with filter) 8.5 L (9 US qt) FC‑W rated 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

    All Models Capacity Fluid Type Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA Engine oil (with filter) 8.5 L (9 US qt) FC‑W rated 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.

  • Page 65: Checking While Engine Is Cold

    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

    Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately. 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.
  • Page 67 Section 5 - Maintenance 5. Turn key switch to off position. 6. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module. Do not remove the filter assembly retaining screws from the filter cap. 8837 Cool Fuel Module Fuel filter element...

  • Page 68: Cleaning The Flame Arrestor

    21. 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. Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive.

  • Page 69: 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. 8119 Idler pulley Alternator pulley Water circulating pump pulley Seawater pump pulley Crankshaft pulley...
  • Page 70 Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the limits. See your authorized MerCruiser dealer for service if these conditions exist. CAUTION Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage.

  • Page 71: Flushing The Seawater System-Inboard Models

    Section 5 - Maintenance 3. Use a breaker bar and appropriate socket to position the tensioner back to the engine running location and slide the belt over the tensioner pulley. Slowly relieve the tensioner to the belt. 8117 Breaker bar with arrow in direction of movement to reposition in tension. Breaker bar Flushing the Seawater System—Inboard Models The Boat out of the Water—Inboard Models...

  • Page 72: The Boat In The Water-Inboard Models

    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. Completely open the water source to provide maximum water supply. 5.

  • Page 73: Battery

    Section 5 - Maintenance 4. Completely open the water source to provide maximum water supply. 5. Place the remote control in the neutral idle speed position. 6. Immediately start the engine. NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine.
  • Page 74 Section 5 - Maintenance In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself, and the engine will operate normally. The ECM shuts off and resets itself so quickly that the engine may only seem to have an ignition miss. Batteries: Boats with multi‑engine EFI power packages require each engine be connected to its own battery.

  • Page 75: Section 6 - Storage

    Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....68 Air Actuated Single Point Drain System..71 Preparing Power Package for Storage..68 Boat in the Water ........71 Engine and Fuel System Preparation ..69 Boat out of the Water ......

  • Page 76: 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 77: 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 78: 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 79: 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 80 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 81: 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 82 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 83: 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 84: 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 85: 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 86: October

    Section 6 - Storage Notes: Page 78 90-864841070 OCTOBER 2007...

  • Page 87: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........80 Excessive Engine Temperature......81 Diagnosing DTS Problems......... 80 Insufficient Engine Temperature......82 Engine Guardian System........80 Low Engine Oil Pressure........82 Starter Motor Will Not Crank Engine, Or Cranks Battery Will Not Recharge........

  • Page 88: 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 89: 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 90: 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 91: 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 92 Section 7 - Troubleshooting Notes: Page 84 90-864841070 OCTOBER 2007...

  • Page 93: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........86 Parts and Accessories Inquiries ..... 87 Local Repair Service ........86 Resolving a Problem ........87 Service Away From Home ......86 Mercury Marine Service Offices ....

  • Page 94: 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 95: 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 96: 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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