The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.
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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 Manual included with the product. The Warranty Manual contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.
TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Features and Controls............... 2 Digital Throttle and Shift............. 6 Warning Horn Signals............2 Remote Controls..............6 Instrumentation..............2 Panel Mount Features............ 6 VesselView..............2 Console Mount Features..........7 SmartCraft Speedometer, Tachometer, and Digital Engine Electrical System Overload Protection....
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Engine Runs Rough, Misses, or Backfires...... 66 Free‑play, or Makes Unusual Sounds......67 Section 7 - Customer Assistance Information Owner Service Assistance............70 Contact Information for Mercury Marine Customer Service Local Repair Service............70 ..................71 Service Away From Home..........70 Customer Service Literature...........
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Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package Table of Contents Features and Controls............2 Digital Throttle and Shift..........6 Warning Horn Signals............2 Remote Controls.............. 6 Instrumentation..............2 Panel Mount Features ..........6 VesselView ..............
Section 1 - Getting to Know Your Power Package Features and Controls Warning Horn Signals When the key switch is turned to the on position, the horn will turn on for a moment as a test to indicate the horn is working. There are two types of warning horns to alert the operator of an active problem within the engine’s operating system.
Section 1 - Getting to Know Your Power Package • Coolant temperature • Oil pressure • Battery voltage • Fuel consumption • Engine operating hours SmartCraft tachometer and speedometer Tachometer Speedometer LCD display 50400 The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system. The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.
Section 1 - Getting to Know Your Power Package Switches Key switch Bilge blower switch (if equipped) 24735 Reference Switch Function Key switch Has four positions. "OFF." In the "OFF" position, all electrical circuits are off and the engine cannot be started. The engine is stopped when the key switch is turned to the "OFF"...
30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting, some fault codes are still being displayed, contact your authorized Mercury Diesel repair facility. Lanyard Stop Switch A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as may happen in an accidental ejection.
DTS Operator's Manual. Remote Controls Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description or demonstration of your remote control. Panel Mount Features Neutral lock button Throttle‑only button...
If the replacement fuse also blows, then the electrical overload has not been eliminated. Further checks must be made on the electrical system. Do not circumvent the electrical overload protection provided on fused circuits by installing a Contact your Mercury Diesel authorized repair facility. higher amperage fuse or shorting across the fuse block terminals.
Section 1 - Getting to Know Your Power Package After finding and correcting the cause of the overload, replace any open (blown) fuses. 27000 2.0 fuse panel Location on fuse panel Reference Fuse Protection (From Front of Engine) 20‑amp Unswitched power to helm Lower left 10‑amp Switched power to ECM...
Section 1 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.
Section 2 - On the Water Section 2 - On the Water Table of Contents Safe Boating Recommendations.......... 12 While Boat is in Operation ..........18 Carbon Monoxide Exposure..........13 While the Boat is Stationary ......... 18 Be Alert To Carbon Monoxide Poisoning ..... 13 High‑Speed and High‑Performance........
Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.
Section 2 - On the Water Be alert. • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed.
The power package must be equipped with a gear ratio and propeller that allows the engine to operate at wide open throttle (WOT) at the engine's rated speed (RPM). Use of Mercury Diesel engines in applications that do not meet specified operational parameters is not approved.
At temperatures of –20° C (–4° F) and below, use a coolant heater to improve cold starting. • If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for information about special cold weather equipment and precautions.
• Check all applicable items in the maintenance schedules and operation chart. • Perform any other necessary checks as indicated by your Mercury Diesel authorized repair facility or specified in your boat owner's and operation manual. Important Information—SmartStart IMPORTANT: This Mercury Diesel model is equipped with SmartStart. SmartStart performs all appropriate starting operations upon initial start switch activation.
Check the engine and the transmission, oil filter, oil lines, oil line connectors, and oil pan for leaks. Check the coolant hoses, heat exchanger connections, aftercooler, water pump, and drain fittings for leaks. Locate and correct any problems, or see your Mercury Diesel authorized repair facility if you are unable to determine the problem.
If your boat is considered a high‑speed or high‑performance boat, 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. For additional information, refer to the Hi‑Performance Boat Operation booklet from your Mercury Diesel authorized repair facility.
Section 2 - On the Water Boats With Front‑Mounted, Raised Pedestal Fishing Seats Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.
Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Conditions Affecting Operation...
It is important to follow this procedure to properly break in the engine. IMPORTANT: Mercury Marine recommends that the boat not be accelerated hard until this procedure has been completed. IMPORTANT: Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool;...
Section 2 - On the Water • Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged operation at wide‑open throttle RPM. End of First Season Checkup At the end of the first season of operation, contact an authorized repair facility to discuss or perform scheduled maintenance items.
Mercury diesels are required to use grade 2–D ULSD (ultra‑low sulphur diesel) fuel meeting ASTM Standards D975 (or fuel rated Diesel DIN EN 590), and having a minimum cetane rating of 51.
To optimize the performance of this engine in marine applications, Mercury strongly recommends the use of Quicksilver 5W‑30 Full Synthetic TDI Engine Oil. This oil meets international ACEA C3 specifications.
*Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.
It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation, and to return the unit to a Mercury Diesel authorized repair facility for a periodic checkup.
Section 4 - Maintenance Remove and inspect the propeller. If badly nicked, bent, or cracked, contact your Mercury Diesel authorized repair facility. Repair nicks and corrosion damage on power package exterior finish. Contact your Mercury Diesel authorized repair facility. NOTE: A small panel in the engine cover allows access to the engine fuse panel, the engine oil fill cap, and the engine oil dipstick without removing the entire engine cover.
Section 4 - Maintenance • Check the engine oil level. (This interval can be extended based on operator experience with the product.) Each day start • Check the engine coolant level. • Check the transmission oil level. • If operating in saltwater, brackish water, or polluted water, flush the seawater section of the cooling system after each use.
Section 4 - Maintenance Engine Oil Specifications To optimize the performance of this engine in marine applications, Mercury strongly recommends the use of Quicksilver 5W‑30 Full Synthetic TDI Engine Oil. This oil meets international ACEA C3 specifications. Engine Oil 2.0L...
Section 4 - Maintenance Remove the dipstick and observe the oil level. The oil level must be between the marks on the dipstick. If necessary, add oil. Refer to Filling. Engine oil level markings Dipstick Minimum operating level Full mark and maximum operating level 14624 Install engine oil dipstick.
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Section 4 - Maintenance Discard the oil filter and O‑ring. Drain plug Oil filter cover O‑ring Oil filter 53087 Apply sealant to the threads of the oil filter housing drain plug and install. Tube Ref No. Description Where Used Part No. Loctite 567 PST Pipe Sealant Drain plug threads 92-809822...
Section 4 - Maintenance 13. Locate the crankcase oil drain hose and remove the cap. 53365 14. Install the crankcase oil pump (order separately) onto the crankcase oil drain hose. Crankcase Oil Pump 91‑ 802889Q 1 Aids in the removal of engine oil without draining the crankcase. 11591 15.
If the oil level is low, add transmission oil to bring the level up to the maximum mark on the dipstick. See Filling. NOTE: If the transmission oil level was extremely low, see your local Mercury Diesel authorized repair facility.
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Section 4 - Maintenance Remove the transmission oil drain plug and drain the transmission into a suitable container. 27977 Transmission drain plug Contain and dispose of the oil and oil waste according to applicable regulations. Reinstall the transmission oil drain plug. Tighten the drain plug to the specified torque.
If the fluid level is low, add transmission fluid to bring the level up to the maximum mark on the dipstick. See Add Fluid. NOTE: If the transmission fluid level was extremely low, see your local Mercury Diesel authorized repair facility.
Section 4 - Maintenance Add Fluid If necessary, add specified transmission fluid through the dipstick threaded hole to bring the level up to the maximum mark on the dipstick. Dipstick Maximum fluid level Minimum fluid level 24604 NOTE: Always use the dipstick to determine the quantity of oil or fluid required. Model Capacity Fluid type...
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Section 4 - Maintenance Clean the exterior of the transmission around the fluid filter assembly. Loosen the assembly nut, and rotate the securing tab in the direction shown. Assembly nut Securing tab 24608 Remove the filter element. Filter element 24618 Clean the filter element with a mild cleaning solvent, obtained locally.
Section 4 - Maintenance 11. Reinstall the filter element. Filter element O‑ring 24620 NOTICE Improper installation of the transmission fluid filter assembly may cause the fluid to foam or leak out, resulting in decreased efficiency and damage to the transmission. Properly seat the transmission fluid filter during installation. 12.
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The pressure cap maintains pressure on the cooling system and may not be holding pressure properly. To have the cap tested, contact your Mercury Diesel authorized repair facility. Slowly add the coolant within 25 mm (1 in.) of the top of the expansion tank filler neck.
11. Remove the pressure cap and add coolant to the specified level. 12. Install and securely tighten the pressure cap. Draining the Closed‑Cooling System IMPORTANT: Due to the complex nature of this service Mercury Diesel strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law.
25768 Ensure that the coolant has drained completely. If required, clean the closed‑cooling system. See your local Mercury Diesel authorized repair facility. Install and tighten the engine coolant drain plug. Install the water‑separating fuel filter. Refer to Water‑Separating Fuel Filter, Replacing.
Section 4 - Maintenance Remove the air filter element from the air filter housing. Air filter element Air filter housing 53215 Inspection The air filter cannot be cleaned. Replace the air filter if it is dirty or contaminated. Replace the air filter if the foam element is deteriorated or torn. Replace the air filter at the recommended interval.
Section 4 - Maintenance Tighten the oil separator vent hose clamp to the specified torque. Description lb‑in. lb‑ft Oil separator vent hose clamp – Water‑Separating Fuel Filter WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start.
Section 4 - Maintenance Fill the fuel filter. See Filling. Replacing WARNING Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components.
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13. Connect the battery cables. 14. Start and operate the engine. Check the filter connection for fuel leaks. If leaks exist, recheck the filter installation. If leaks continue, stop the engine immediately and contact your Mercury Diesel authorized repair facility. 90-8M0113986...
Section 4 - Maintenance Filling A type of hand pump and primer plunger is located on the fuel filter bracket and is used to • Refill the fuel filter when draining or changing the filter. • Refill the fuel system on the engine if the system was run dry. •...
Section 4 - Maintenance Fuel System Priming Prime the engine if it has not been run for an extended period or if the engine will not start. Move the primer plunger up and down repeatedly. Fuel priming pump 25985 Attempt to start the engine. Filling (Bleeding) NOTE: Follow this procedure if the fuel system was run dry or if part of the fuel system was drained for a service function.
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Section 4 - Maintenance If the boat is to remain in the water, turn on the bilge pump, close the seacock (if equipped), or disconnect and plug the seawater inlet hose. 25667 Typical seacock installation Make the engine as level as possible to ensure complete draining of the seawater system. Attach a temporary drain hose to the barbed fitting of the seawater drain valve.
Section 4 - Maintenance On models equipped with a seawater strainer, remove the hoses at the seawater strainer and drain them completely. Drain and empty the seawater strainer. Connect the hoses and tighten the hose clamps securely. Typical Seawater inlet Seawater outlet Seawater strainer cover 25831...
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Section 4 - 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 the boat is in the water, ensure that the engine is off and close the seacock, if equipped, or remove and plug the seawater inlet hose.
Engine Seawater Pump Inspection IMPORTANT: Mercury strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Remove and inspect the engine seawater pump at the interval specified in the Maintenance Schedule. See your Mercury Diesel authorized repair facility.
Section 4 - Maintenance Remove the anode assembly (anode plug, sealing washer, and the sacrificial anode) from the aftercooler end cover. 53216 Seawater system anode assembly location Cleaning and Inspection NOTE: Use sandpaper, fiber brush, or a cleaning pad to remove the deposits from the surface of the anode before trying to determine the amount of erosion.
IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint is not covered by the limited warranty. In some areas it may be advisable to paint the bottom of the boat to help prevent marine growth. Contact a Mercury Diesel authorized repair facility for recommendations for your boat.
Stretch‑belt service and maintenance procedures differ from standard accessory drive belts. Should the power‑assisted steering pump stretch‑belt need replacement, consult your Mercury Diesel authorized repair facility. Inspect the power–assisted steering stretch‑belt for the following: •...
Section 4 - Maintenance Replace the belt if worn or damaged it must be replaced. See your Mercury Diesel authorized repair facility. Power–assisted steering stretch belt Power–assisted steering pump pulley Crankshaft pulley 25604 There is no adjustment available for the power‑assisted steering pump stretch‑belt. If the belt becomes loose or noisy, it has worn out and must be replaced.
See your Mercury Diesel authorized dealer for all of your repair needs. There is no adjustment available for the serpentine belt. If the belt becomes loose or noisy, it has worn out and must be replaced.
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Section 4 - Maintenance Battery Switches. Battery switches should always be positioned so that each engine is operating off of its own battery. Do not operate engines with switches in the both or all position. In an emergency, another engine's battery can be used to start an engine with a dead battery.
Section 5 - Storage Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage IMPORTANT: Mercury Marine strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.
Description Where Used Part Number Corrosion Guard 92‑802878‑55 Light gray primer Outside of engine 92‑802878‑52 Mercury Diesel White 8M0108939 Mercury Phantom Black Shift plate and air filter housing 92‑802878Q1 90-8M0113986 DECEMBER 2015 Page 63...
Read all precautions and perform all procedures found in Seasonal Storage Instructions. IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight. Remove the seawater pump impeller and store away from direct sunlight. Refer to a Mercury Diesel authorized repair facility for additional information and service.
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Section 6 - Troubleshooting Section 6 - Troubleshooting Table of Contents Diagnosing Electronically Controlled Fuel System Problems Poor Performance............66 ....................66 Incorrect Engine Temperature........67 Troubleshooting Charts............66 Low Engine Oil Pressure..........67 Starter Motor Will Not Crank Engine, or Cranks Slow... 66 Battery Will Not Charge..........
Diagnosing Electronically Controlled Fuel System Problems A Mercury Diesel authorized repair facility has the proper service tools for diagnosing problems on electronically controlled fuel systems. The engine control module (ECM) on these engines has the ability to detect problems with the system when they occur, and store a trouble code in the ECM's memory.
Obstruction in the shift or throttle linkages. Remove the obstruction. Check all throttle linkages. If any are loose or missing, see a Mercury Loose or missing shift and throttle linkages. Diesel authorized repair facility immediately. Straighten cable or have a Mercury Diesel authorized repair facility Shift or throttle cable kinked.
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Section 6 - Troubleshooting Possible Cause Remedy Improper shift cable adjustment. Have adjustment checked by a Mercury Diesel authorized repair facility. Page 68 90-8M0113986 DECEMBER 2015...
Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance............ 70 Contact Information for Mercury Marine Customer Local Repair Service ............ 70 Service ................. 71 Service Away From Home ..........70 Customer Service Literature..........71 Stolen Power Package ..........
If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.
Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: •...
Section 7 - Customer Assistance Information Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
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Section 8 - Maintenance Log Scheduled Maintenance Log 100 Hours Actual Hours Service Notes Dealer Name Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name...
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Section 8 - Maintenance Log Vessel Maintenance Notes Record all general maintenance performed on your power package here. Save all work orders and receipts. Engine Date Maintenance Completed Servicing Dealer Hours 90-8M0113986 DECEMBER 2015 Page 75...
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