MerCruiser 3.0 TKS Owner's Manual

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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.
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.
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 Console Mount Features........19...
Page 6 Section 4 - Specifications Fuel Requirements..........38 Engine Oil.............39 Fuel Ratings.............38 Engine Specifications...........39 Using Reformulated (Oxygenated) Gasolines Fluid Specifications..........40 (USA Only)............38 Sterndrives............40 Gasolines Containing Alcohol......38 Engine..............40 Section 5 - Maintenance Owner/Operator Responsibilities......42 Positive Crankcase Ventilation Valve (PCV)... 55 Dealer Responsibilities.........42 Changing.............
Page 7 Preparing Power Package for Storage...76 Clearing Clogged Blue Drain Hoses....82 Engine and Fuel System Preparation..77 Draining the Sterndrive........83 Draining the Seawater System......78 Battery Storage............84 Single Point Drain System......78 Power Package Recommissioning......84 Draining the Seawater Section of Closed Cooled Models............80 Section 7 - Troubleshooting Starter Motor Will Not Crank Engine, Or Cranks...
Page 8 Page iv 90-860168070 AUGUST 2007...
Page 9: Section 1 - Warranty
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 90-860168070 AUGUST 2007...
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.
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 90-860168070 AUGUST 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 Console Mount Features ......19 Alpha Sterndrive Decal Identification....14 Electrical System Overload Protection-Carbureted Alpha Transom Serial Number......14 Engines...............
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. Alpha Sterndrive Decal Identification The Drive Serial No.
Page 23: Engine Serial Number Decal
Section 2 - Getting to Know Your Power Package Engine Serial Number Decal The serial number decal is located on the aft portion of the starboard side of the block, near the starter motor. 32121 The engine, transom, and drive serial numbers are also located on the engine identification plate.
Page 24: Lanyard Stop Switch
Section 2 - Getting to Know Your Power Package 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). 74608 Stop switch Clips to the operator...
Page 25: Instrumentation
Section 2 - Getting to Know Your Power Package Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: • Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.
Page 26: Remote Controls
Section 2 - Getting to Know Your Power Package Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.
Page 27: Console Mount Features
Section 2 - Getting to Know Your Power Package Console Mount Features mc79503-1 Throttle Only Button Power Trim Switch Control Handle Trailer Switch 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 28 Section 2 - Getting to Know Your Power Package 1. A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. The circuit breaker can be tested by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset the yellow lever after testing, or if tripped, by pushing the yellow lever back into the housing.
Page 29 Section 2 - Getting to Know Your Power Package 3. A 15 amp accessory fuse is located on the rear of the engine. This fuse protects the accessory circuits. A 20 amp fuse is located on the top of the engne to protect the TKS circuit.
Page 30: 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 31: 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 32: Single Engine Trim/Trailer
Section 2 - Getting to Know Your Power Package • Cause engine overheating if trimmed up/out to a point where any cooling water intake holes are above the water line mc78529 Trimming sterndrive unit down/in can: • Help the boat accelerate and plane off quicker •...
Page 33 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions........26 Passenger Safety in Pontoon Boats and Deck Boats Be Alert to Carbon Monoxide Poisoning..... 27 ................31 Good Ventilation ........... 27 Boats Having An Open Front Deck ....
Page 34: 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 35: 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 36: 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 37: Starting And Stopping The Engine
Section 3 - On the Water Operation Chart WHILE BEFORE STARTING AFTER STARTING AFTER STOPPING UNDERWAY Check shift and Turn battery switch on. throttle control Close fuel shut off valve. operation. Check steering Close seacock, if Operate bilge blowers. operation. equipped.
Page 38: Stopping The Engine
IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. Page 30 90-860168070 AUGUST 2007...
Page 39: Drain Plug And Bilge Pump
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 40: Boats Having An Open Front Deck
Section 3 - On the Water Boats Having An Open Front Deck No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure. Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.
Page 41: Impact With Underwater Hazards
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Page 42: Drive Unit Impact Protection
Section 3 - On the Water Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object, reducing damage to the unit.
Page 43: Elevation And Climate
Section 3 - On the Water • Drive unit trimmed out too far. • A missing propeller diffuser ring. • A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing. • Drive unit installed too high on transom. Elevation and Climate Elevation and climate changes will affect the performance of your power package.
Page 44: Getting Started
Transmission models). 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 45 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........38 Engine Oil............39 Fuel Ratings ..........38 Engine Specifications......... 39 Using Reformulated (Oxygenated) Gasolines Fluid Specifications..........40 (USA Only) ........... 38 Sterndrives ........... 40 Gasolines Containing Alcohol ...... 38 Engine ............
Page 46: Fuel Requirements
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 47: 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 48: Fluid Specifications
IMPORTANT: All capacities are approximate fluid measures. 3.0 TKS Capacity Fluid Type Mercury Full‑Synthetic MerCruiser 20W‑40, NMMA FC‑W rated Engine oil (with filter) 3.8 L (4 US qt) oil. Seawater cooling system 9 L (8.5 US qt) Propylene glycol and purified water...
Page 49 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......42 Changing ..........55 Dealer Responsibilities........42 Changing the Water-Separating Fuel Filter..55 Maintenance............42 Fuel Pump Sight Tube Inspection...... 56 Do-It-Yourself Maintenance Suggestions... 43 Lubrication............57 Inspection............
Page 50: 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 51: 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 52: Maintenance Schedules
• Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase ventilation hoses. Inspect the PCV valve, if equipped. NOTE: On MerCruiser V6 models, the PCV valve is a non‑serviceable, internal component of the valve cover assembly. • Inspect the condition and the tension of the belts.
Page 53: Maintenance Log
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Inspect the U‑joints, the splines, and the bellows. Check the clamps. • Check the engine alignment. • Lubricate the U‑joint splines and cross bearing, if equipped with grease Every 200 hours or 3 fittings.
Page 54: Sealed Carburetor Mixture Screw
Section 5 - Maintenance Sealed Carburetor Mixture Screw IMPORTANT: Changing the mixture setting on this engine can affect the exhaust emissions level and void the emissions certification. Do not adjust or remove the mixture settings or remove the mixture screw seals. See your authorized Mercury dealer or emissions testing agency.
Page 55: Changing Oil And Filter
Capacity Fluid Type 3.0 TKS 3.8 L (4 US qt) Mercury Full‑Synthetic MerCruiser Oil 20W‑40 Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
Page 56: Engine Oil Drain Pump
3.0 TKS 3.8 L (4 US qt) Mercury Full‑Synthetic MerCruiser Oil 20W‑40 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The boat must be at rest in the water.
Page 57: Filling
Warm range dipstick Cold range 3. Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling 1. Remove the fill cap/dipstick and observe the level. 2. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.
Page 58: Filling
Thermostat housing cap 2. The coolant level in the thermostat housing 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 thermostat housing.
Page 59: Changing
If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.
Page 60: Changing
Oil vent screw Sealing washer IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. Page 52 90-860168070 AUGUST 2007...
Page 61: Power Trim Fluid
Section 5 - Maintenance 6. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air‑free stream of lubricant flows from oil vent hole. Tube Ref No.
Page 62: Filling
3. Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. 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 63: Positive Crankcase Ventilation Valve (Pcv)
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. 90-860168070 AUGUST 2007...
Page 64: Fuel Pump Sight Tube Inspection
Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop the engine immediately and contact your authorized Mercury MerCruiser dealer. Fuel Pump Sight Tube Inspection 1. The engine fuel pump is equipped with a sight tube which gives visible evidence of a ruptured fuel pump diaphram.
Page 65: Lubrication
Section 5 - Maintenance Lubrication Steering System WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased. 1.
Page 66: Manual Steering System
3. Lubricate the steering pin. mc71904-1 Steering pin Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Steering pin 92‑883725K01 Oil SAE25W‑40 4. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.
Page 67: Throttle Cable
7169 Pivot points Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Throttle cable pivot points & 92‑883725K01 Oil SAE25W‑40 guide contact surfaces Shift Cable ‑ Typical 1. Lubricate the pivot points and the guide contact surfaces.
Page 68: Sterndrive Unit And Transom Assembly
Section 5 - Maintenance Sterndrive Unit and Transom Assembly 1. Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun. mc77068-1 Gimbal bearing grease fitting Tube Ref No. Description Where Used Part No. U-joint and Gimbal Bearing Gimbal bearing 92-802870A1 Grease...
Page 69: Driveshaft Extension Models
Section 5 - Maintenance NOTE: If the boat is operated at idle for prolonged periods of time, coupler should be lubricated in the Alpha Models ‑ every 150 hours. 6213 Alpha drive coupler Engine coupler grease fitting Tube Ref No. Description Where Used Part No.
Page 70: Propellers
Section 5 - Maintenance Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
Page 71: Drive Belts
Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shaft 92-802867Q 1 2-4-C Marine Lubricant with Propeller shaft 92-802859A1 Teflon 2. Slide thrust hub onto propeller shaft, with stepped side toward propeller hub. 3. Install Flo‑Torq II Drive Hub into propeller. NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued.
Page 72: Replacing - Front Mount Models
Section 5 - Maintenance Replacing ‑ Front Mount Models POWER STEERING PUMP DRIVE BELT, IF EQUIPPED 1. Loosen power steering pump attaching bolts and mounting bolts. 2. Pivot power steering pump toward engine, as required, until belt can be removed. 3.
Page 73: Alternator Belt
Your boat comes equipped with through the sterndrive water pickups. See Sterndrive Water Pickups (following) for the flushing procedure. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Alpha engines with the sterndrive water inlet blocked off at the gimbal...
Page 74: Sterndrive Water Pickups
Section 5 - Maintenance Sterndrive Water Pickups This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment (44357Q 2). 5773 Side Pickup NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications.
Page 75: Battery
Section 5 - Maintenance NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. 7.
Page 76: Corrosion Protection
Section 5 - Maintenance Corrosion Protection NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or high‑pressure washers to clean the MerCathode assembly. 6211 MerCathode reference electrode Do not pressure wash Do not paint Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged...
Page 77 Section 5 - Maintenance Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.), it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System...
Page 78 MerCathode System ‑ Electrode assembly replaces Anodic block. System should be tested to ensure adequate output. The test should be performed where boat is moored, using Quicksilver Reference Electrode and Test Meter. Contact your authorized Mercury MerCruiser dealer. Page 70 90-860168070 AUGUST 2007...
Page 79 Section 5 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. 6206 MerCathode controller MerCathode assembly Anode Kit (if equipped) ‑ Mounted to the boat transom. 5642 Trim Cylinder Anodes ‑ Mounted on each trim cylinder. 7460 Trim cylinder anodes 90-860168070 AUGUST 2007...
Page 80: Painting Your Power Package
Section 5 - Maintenance Bearing Carrier Anode (Alpha) ‑ Located in front of the propeller, between the front side of the propeller and the gear housing. 7461 Bearing carrier anode Screws In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion: 1.
Page 81: August
Section 5 - Maintenance • Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items.
Page 82 Section 5 - Maintenance Notes: Page 74 90-860168070 AUGUST 2007...
Page 83: Section 6 - Storage
Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....76 Clearing Clogged Blue Drain Hoses.....82 Preparing Power Package for Storage..76 Draining the Sterndrive.........83 Engine and Fuel System Preparation ..77 Battery Storage........... 84 Draining the Seawater System......
Page 84: Preparing Power Package For 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 85: Engine And Fuel System Preparation
Section 6 - Storage NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
Page 86: Draining The Seawater System
Corrosion Guard Outside of engine 92-802878 55 8. For sterndrive unit lay‑up, refer to appropriate Mercury MerCruiser sterndrive service manual. 9. Replace the fuel filter. Refer to the Maintenance section for proper procedure. 10. Change the oil and oil filter.
Page 87 Section 6 - Storage 1. If draining with the boat in the water, close the seacock (if equipped) or remove and plug the water inlet hose. If draining with the boat out of the water, place the boat on a level surface to ensure complete draining of the system.
Page 88: Draining The Seawater Section Of Closed Cooled Models
Section 6 - Storage Draining the Seawater Section of Closed Cooled Models NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
Page 89 Section 6 - Storage 4. Remove and lower the hose from the water inlet to the power steering cooler (if equipped), or the water inlet to the heat exchanger. 7327 Power steering cooler, if equipped Water inlet to heat exchanger hose 5.
Page 90: Clearing Clogged Blue Drain Hoses
Section 6 - Storage 7. After the cooling system has been drained completely, apply sealant to the aft heat exchanger plug. 7184 Heat exchanger drain plug Tube Ref No. Description Where Used Part No. Perfect Seal Aft heat exchanger plug 92-34227 1 8.
Page 91: Draining The Sterndrive
The unit will need to be serviced by an authorized Mercury MerCruiser dealer. Pull the T‑handle until the quick connect fittings on the blue drain hoses are within reach.
Page 92: Battery Storage
Section 6 - Storage 1. Insert a small wire repeatedly to make sure that vent holes, water drain holes, and passages are unobstructed and open. 6146 Sterndrive Water Drain Holes Speedometer pitot tube Gear housing water drain hole (one each at port and starboard) Trim tab cavity vent hole Gear housing cavity vent hole Trim tab cavity drain passage...
Page 93 Section 6 - Storage NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 5. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly.
Page 94 Section 6 - Storage Notes: Page 86 90-860168070 AUGUST 2007...
Page 95: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Starter Motor Will Not Crank Engine, Or Cranks Battery Will Not Recharge........89 Slow..............88 Remote Control Is Difficult to Move, Has Excessive Engine Will Not Start Or Is Hard To Start... 88 Play, or Makes Unusual Sounds......
Page 96: Starter Motor Will Not Crank Engine, Or Cranks Slow
Section 7 - Troubleshooting Starter Motor Will Not Crank Engine, Or Cranks Slow Possible Cause Remedy Battery switch turned off. Turn the switch on. Remote control not in neutral position. Position the control lever in neutral. Open circuit breaker or blown fuse. Check and reset the circuit breaker or replace fuse.
Page 97: Excessive Engine Temperature
Clean or repair as necessary. See Engine Runs Rough, Misses or Backfires. Ignition problem. Engine overheating. See Excessive Engine Temperature. Running rich. Have authorized Mercury MerCruiser dealer check and repair. Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed. Open.
Page 98: 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 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...

MerCruiser 3.0 TKS Owner's Manual

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Section 5 - Maintenance

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