Mercury/Mariner Inboard 5.7 MPI ECT Manual
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Mercury/Mariner Inboard 5.7 MPI ECT Manual

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NOTE: The following applies to CE‑marked products only.
Declaration of Conformity—Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser's instructions complies with the
requirements of the following directives by meeting the associated standards, as amended:
Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC
Name of engine manufacturer: Mercury Marine
Address: W6250 W. Pioneer Road, P.O. Box 1939
Town: Fond du Lac, WI
Name of Authorized Representative: Brunswick Marine in EMEA Inc.
Address: Parc Industriel de Petit‑Rechain
Town: Verviers
Name of Notified Body for exhaust emission assessment: Det Norske Veritas AS
Address: Veritasveien 1
Town: Hovik
Conformity assessment module used for exhaust emissions:
Other Community Directives applied: Electromagnetic Compatibility Directive 2004/108/EC
Description of Engines and Essential Requirements
Engine Type
☒ Inboard engine
Identification of Engines Covered by This Declaration of Conformity
Name of engine family
5.7 MPI
Horizon 5.7
5.7 MPI ECT
Horizon 5.7 ECT
6.2 MPI
Horizon 6.2
6.2 MPI ECT
Horizon 6.2 ECT
Tow Sports 5.7 MPI
Scorpion 350
Scorpion 377
Tow Sports 5.7 MPI ECT 1A090000
Scorpion 350 ECT
Scorpion 377 ECT
Horizon 8.1
8.1 H.O.
Horizon 8.2 ECT
8.2 H.O. ECT
Post Code: 54936‑1939
Post Code: 4800
Post Code: 1322
Country: Norway
Fuel Type
☒ Petrol
Unique engine identification number: starting serial number
0W307898
0W307898
1A090000
1A090000
0W307898
0W307898
1A091600
1A091600
0W307898
0W307898
0W307898
1A090000
1A091600
0W307898
0W307898
1A350340
1A350340
Country: USA
Country: Belgium
ID Number: 0575
☐ B+C
☐ B+D
☐ B+E
☐ B+F
Combustion Cycle
☒ 4 stroke
EC Module H certificate number
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
☐ G ☒ H

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Summary of Contents for Mercury/Mariner Inboard 5.7 MPI ECT

  • Page 1 NOTE: The following applies to CE‑marked products only. Declaration of Conformity—Mercury MerCruiser This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser's instructions complies with the requirements of the following directives by meeting the associated standards, as amended: Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC Name of engine manufacturer: Mercury Marine Address: W6250 W.
  • Page 2 Other normative document/ Please specify in more detail Standards Technical file Essential requirements method (* = mandatory standard) Annex 1.B—Exhaust Emissions B.1 engine identification ☐ ☐ ☒ B.2 exhaust emission requirements ☒* ☐ ☐ * EN ISO 8178‑1:1996 B.3 durability ☐...

  • Page 3: Read This Manual Thoroughly

    Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, and #1 On the Water are registered trademarks of Brunswick Corporation.
  • Page 4 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. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used. WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 - Warranty Warranty Registration—United States and Canada....2 Transfer of Coverage............ 15 Warranty Registration—Outside the United States and Termination of Coverage..........15 Canada..................2 Conditions That Must Be Met to Obtain Warranty Transfer of Warranty..............2 Coverage ..............
  • Page 6 Horizon 5.7..............65 Engine Specifications—5.7, 6.2 MPI ECT, Horizon 5.7, 6.2 Horizon 6.2..............66 ECT Models................61 Fluid Specifications..............66 Inboard 5.7 MPI ECT............61 Engine................66 Inboard 6.2 MPI ECT............62 Transmission..............66 Section 5 - Maintenance Owner/Operator Responsibilities..........70 Maintenance................
  • Page 7 Inspection................. 71 Positive Crankcase Ventilation (PCV) Valve...... 79 Maintenance Schedule—Inboard Models........ 71 Changing..............79 Routine Maintenance............71 Cleaning the IAC Muffler............79 Scheduled Maintenance........... 71 Water‑Separating Fuel Filter............ 80 Maintenance Log..............72 Gen III Models..............80 Engine Oil................73 Removal............... 80 Checking................
  • Page 8 Section 9 - Checklists Predelivery Inspection (PDI)..........116 Customer Delivery Inspection (CDI)........117 Page iv 90-8M0074354 OCTOBER 2012...

  • Page 9: Section 1 - Warranty

    Section 1 - Warranty Section 1 - Warranty Table of Contents Warranty Registration—United States and Canada....2 Transfer of Coverage ..........15 Warranty Registration—Outside the United States and Termination of Coverage ........15 Canada................... 2 Conditions That Must Be Met to Obtain Warranty Transfer of Warranty...............

  • Page 10: Warranty Registration-United States And Canada

    Section 1 - Warranty Warranty Registration—United States and Canada Outside United States and Canada ‑ Check with your local distributor. You may change your address on file with Mercury Marine at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 11: Mercury Installation Quality Certification Program

    Section 1 - Warranty For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you. Mercury Installation Quality Certification Program 15502 Mercury MerCruiser products installed by a Mercury Installation Quality Certified Manufacturer are Installation Quality Certified products and may receive an additional one (1) year of limited warranty coverage.
  • Page 12 Section 1 - Warranty What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. Duration of Coverage Warranty Period for Recreational Use The warranty period begins on the date the product is first sold to a recreational‑use retail purchaser or the date on which the product is first put into service, whichever occurs first.
  • Page 13 Section 1 - Warranty What Mercury Marine Will Do Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury Marine product.

  • Page 14: 3-Year Limited Warranty Against Corrosion

    Section 1 - Warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY.

  • Page 15: Emission Control Warranty Information-5.7, 6.2 Mpi/Horizon Non-Ec Models

    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: Owner Responsibility

    Section 1 - Warranty ECI Label Standard of Compliance EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2009 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES Indicates a marine engine compliant with California CARB REFER TO THE OWNER'S MANUAL FOR MAINTENANCE exhaust emission regulations for 2009.

  • Page 17: U.s. Epa Emissions Limited Warranty

    Section 1 - Warranty U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three years or 480 hours of engine use whichever occurs first to the retail purchaser, that the engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations.

  • Page 18: Emission Control Warranty Information-5.7, 6.2 Mpi/Horizon Ec Models

    Section 1 - Warranty Emission Control Warranty Information—5.7, 6.2 MPI/Horizon EC Models Important Information To identify the applicable emission control warranty coverage for a particular product, refer to the Emission Control Information label affixed to the engine. Engines designated as exempt from either Federal EPA or California emission control regulations are not covered by a separate emission control component warranty.

  • Page 19: Owner Responsibility

    Section 1 - Warranty ECI Label Standard of Compliance EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2009 CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES Indicates a marine engine compliant with California CARB and REFER TO THE OWNER'S MANUAL FOR MAINTENANCE U.S.

  • Page 20: What Is Covered

    Section 1 - Warranty The California Air Resources Board has promulgated air emissions regulations for inboard and sterndrive engines. The regulations apply to all inboard and sterndrive engines that were manufactured for the 2003 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the components of the emission control system listed following), and further warrants that the inboard or sterndrive engine was designed, built, and equipped to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code.

  • Page 21: California Emission Control Warranty Statement

    Section 1 - Warranty Non‑warranty maintenance, replacement, or repair of emission control devices and systems may be performed by any marine engine repair establishment or individual. The use of non‑Mercury parts for nonwarranty maintenance or repairs will not be grounds for disallowing other warranty work. The use of add‑on (as defined at section 1900 (b)(1) and (b)(10) of Title 13 of the California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine.

  • Page 22: U.s. Epa Emissions Limited Warranty

    Section 1 - Warranty U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three years or 480 hours of engine use whichever occurs first to the retail purchaser, that the engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations.

  • Page 23: Warranty Policy-Australia And New Zealand

    Section 1 - Warranty Warranty Policy—Australia and New Zealand MerCruiser Limited Warranty—Australia and New Zealand Policy This Limited Warranty is given by Marine Power International Pty Ltd ACN 003 100 007 of 41–71 Bessemer Drive, Dandenong South, Victoria 3175 Australia (telephone (61) (3) 9791 5822), e‑mail: merc_info@mercmarine.com.

  • Page 24: Eng October 2012

    Section 1 - Warranty • Purchased from an insurance company that obtained the product as a result of an insurance claim • Purchased from a salvage yard • Repossession from a retail customer • Purchased at an auction Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty 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 predelivery inspection process specified by Mercury Marine is completed and documented.

  • Page 25: Section 1 - Warranty

    Section 1 - Warranty • Alteration or removal of parts • Water entering the engine through the fuel intake, air intake, or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body •...

  • Page 26: Global Warranty Application Charts (5.7, 6.2/Mpi/Horizon/Non-Ect)

    Section 1 - Warranty Global Warranty Application Charts (5.7, 6.2/MPI/Horizon/Non‑ECT) Inboard Series Non‑Emissions Control (Recreational Use) Recreational Application: Standard Limited Warranty by Region and Boat Manufacturer Non‑Installation Quality Certified Boat Installation Quality Certified Boat Manufacturer Manufacturer Region Horizon Horizon Americas 3 Years 4 Years (Excluding Brazil)

  • Page 27: Inboard Series Non-Emissions Control (Government Use)

    Section 1 - Warranty Inboard Series Non‑Emissions Control (Government Use) Government Application: Standard Limited Warranty by Region and Boat Manufacturer Non‑Installation Quality Certified Boat Installation Quality Certified Boat Manufacturer Manufacturer Region Horizon Horizon Americas 1 Year 1 Year (Excluding Brazil) Latin America 1 Year or 500 Hours 1 Year or 500 Hours...

  • Page 28: Inboard Series Non-Emissions Control (Commercial Use-Corrosion)

    Section 1 - Warranty Inboard Series Non‑Emissions Control (Commercial Use—Corrosion) Commercial Application: Standard Limited Corrosion Warranty by Region for All Boat Manufacturers Region Horizon Americas 1 Year (Excluding Brazil) Latin America 1 Year or 500 Hours 1 Year or 500 Hours Brazil 1 Year or 500 Hours 1 Year or 500 Hours...

  • Page 29: Global Warranty Application Charts (5.7, 6.2/Mpi/Horizon/Ect)

    Section 1 - Warranty Global Warranty Application Charts (5.7, 6.2/MPI/Horizon/ECT) Inboard Series with Emissions Control Technology (Recreational Use) Recreational Application: Standard Limited Warranty by Region and Boat Manufacturer Non‑Installation Quality Certified Boat Installation Quality Certified Boat Manufacturer Manufacturer Region Horizon High Output Horizon High Output...

  • Page 30: Inboard Series With Emissions Control Technology (Commercial Use)

    Section 1 - Warranty Inboard Series with Emissions Control Technology (Commercial Use) Commercial: Standard Limited Warranty by Region and Boat Manufacturer Non‑Installation Quality Certified Boat Installation Quality Certified Boat Manufacturer Manufacturer Region Horizon High Output Horizon High Output Americas (Excluding 1 Year 1 Year 1 Year...

  • Page 31: Inboard Series With Emissions Control Technology (Government Use)

    Section 1 - Warranty Inboard Series with Emissions Control Technology (Government Use) Government Application: Standard Limited Warranty by Region and Boat Manufacturer Non‑Installation Quality Certified Boat Installation Quality Certified Boat Manufacturer Manufacturer Region Horizon High Output Horizon High Output Americas (Excluding 1 Year 1 Year...

  • Page 32: Inboard Series With Emissions Control Technology (Commercial Use-Corrosion)

    Section 1 - Warranty Inboard Series with Emissions Control Technology (Commercial Use—Corrosion) Commercial Application: Standard Limited Corrosion Warranty by Region for All Boat Manufacturers Region Horizon High Output Americas 1 Year 1 Year (Excluding Brazil) Latin America 1 Year or 500 Hours 1 Year or 500 Hours 1 Year or 500 Hours Brazil...

  • Page 33: Hang Tag

    Section 1 - Warranty The Star label will be affixed on the left side of the hull as shown. Recommended location Secondary location XX 1234 XX 32770 One Star ‑ Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards.
  • Page 34 Section 1 - Warranty If in California, the dealer must place the hang tag in a visible location in the boat prior to displaying the boat. 43291 Hang tag front side Hang tag back side Page 26 90-8M0074354 OCTOBER 2012...

  • Page 35: 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................. 28 Dual Helm Station Transfer........... 37 Engine Serial Number Decal......... 28 Synchronizing Dual Helms Prior To Station Transfer Transmissions..............

  • Page 36: Identification

    Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer'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 37: Zf Marine Transmissions

    Section 2 - Getting to Know Your Power Package ZF Marine Transmissions On the ZF Marine 8 Degree Down‑Angle and V‑Drive Transmissions, the transmission identification plate indicates gear ratio, serial number, and model. Typical ZF Marine down-angle transmission shown (V-drive similar) Transmission identification plate 7449 Walter V-Drive Transmissions...

  • Page 38: Instrumentation

    Section 2 - Getting to Know Your Power Package • poor operating practices • sitting on the seat or gunwale at planing speeds • standing at planing speeds • operating at planing speeds in shallow or obstacle infested waters • releasing your grip on the steering wheel that is pulling in one direction •...

  • Page 39: Digital Gauges

    Section 2 - Getting to Know Your Power Package Your power package may be connected to a SmartCraft VesselView display. This display provides a single, easy‑to‑use source for real‑time information about a variety of vessel systems. The interactive VesselView display continuously monitors and reports information about speed and performance, trim angle, water temperature and depth, and other operating data.

  • Page 40: 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 41: Console Mount Features

    Section 2 - Getting to Know Your Power Package Neutral lock button ‑ Prevents accidental shift and throttle engagement. Neutral lock button must be pushed in to move the control handle out of neutral. Throttle only button ‑ Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle.

  • Page 42: Remote Controls (Dts Models)

    Section 2 - Getting to Know Your Power Package Shift lever ‑ Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its forward position.

  • Page 43: Console Mount Features - Single Engine

    Section 2 - Getting to Know Your Power Package Console Mount Features ‑ Single Engine Control handle Trim/tilt switch Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw 3410 Control handle ‑...

  • Page 44: Console Mount Features - Dual Engine

    Section 2 - Getting to Know Your Power Package NOTE: Gear position is determined by sensing the position of the shift actuator on the engine, not the position of the gear switch. Stop/start button ‑ Allows the boat operator to start or stop the engine without using the ignition key. Throttle only/station select key ‑...

  • Page 45: 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 STATION 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 46: Zero Effort Features

    Section 2 - Getting to Know Your Power Package Zero Effort Features Shift lever Throttle lever Trim/tilt switch 5656 Shift lever ‑ Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position.

  • Page 47: Synchronizing Engines

    Section 2 - Getting to Know Your Power Package Troll button ‑ Pressing the "TROLL" button activates troll control. The troll control feature allows the boat operator to set the engine speed for slow speed cruising or maneuvering. To activate, move the control handles into forward detent and press the button.

  • Page 48: Helm Transfer

    Section 2 - Getting to Know Your Power Package Press the "SYNC" button on the CAN trackpad to turn auto synchronization on or off. When the sync LED is yellow, the "SYNC" button has been pressed, but the conditions are not right for auto synchronization to engage. When the sync LED turns red, engine synchronization has been engaged.

  • Page 49: Zero Effort Features

    Section 2 - Getting to Know Your Power Package Zero Effort Features Shift lever Throttle lever Trim/tilt switch 5656 Shift lever ‑ Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position.
  • Page 50 Section 2 - Getting to Know Your Power Package A 90‑amp fuse located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs. mc74907-1 Four fuses located on the port side of the engine protect the main power, fuel pump, ignition, and accessory circuits. 33214 Engine fuses Two 10‑amp fuses protect the O...

  • Page 51: Electrical System Overload Protection

    Section 2 - Getting to Know Your Power Package A 15‑amp accessory fuse protects the accessory circuits. Fuse cover 15‑amp fuse Power harness 32206 A power harness, connected to the engine starting battery, minimizes voltage drop to the electrical system. This harness is protected by a 5‑amp fuse.
  • Page 52 Section 2 - Getting to Know Your Power Package A circuit breaker protects the engine wiring harness and the instrumentation power lead. Push the red button to reset the circuit breaker. 51185 A 90‑amp fuse located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.

  • Page 53: Visual And Audio Warning Systems

    Section 2 - Getting to Know Your Power Package A 20‑amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for an open fuse or open circuit breaker if the ignition key is turned to the "START" position and nothing happens. mc70525-1 Visual and Audio Warning Systems Service Engine Light and OBD‑M MIL Kit...

  • Page 54: Caution

    Section 2 - Getting to Know Your Power Package Caution If a caution state is detected, the audio warning system will sound for six one‑second intervals. Horn (on or off) Time (in seconds) 33402 Below are some examples of a caution state: •...

  • Page 55: Section 3 - On The Water

    Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions............ 48 Drain Plug and Bilge Pump..........54 Carbon Monoxide Exposure..........49 Protecting People in the Water..........54 Be Alert To Carbon Monoxide Poisoning ..... 49 While You Are Cruising ..........

  • Page 56: Safe Boating Suggestions

    Section 3 - On the Water Safe Boating Suggestions To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions. Know and obey all nautical rules and laws of the waterways. •...

  • Page 57: Carbon Monoxide Exposure

    Section 3 - On the Water • 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.

  • Page 58: Poor Ventilation

    Section 3 - On the Water Poor Ventilation Under certain running or wind 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. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

  • Page 59: Starting And Stopping The Engine

    Section 3 - On the Water Starting and Stopping the Engine NOTE: Only perform those functions applicable to your power package. Starting the Engine Check all items listed in the Operation Chart. Place the remote control handle in neutral. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.

  • Page 60: Basic Boat Operation (Dts Models)

    Section 3 - On the Water Basic Boat Operation (DTS Models) Launching and Boat Operation IMPORTANT: Install bilge drain plug prior to launching boat. Operation Chart Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Observe all gauges to Observe all gauges to check condition of Turn ignition key to the...

  • Page 61: 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. 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. Turn the ignition key to "START."...

  • Page 62: Freezing Temperature Operation

    Section 3 - On the Water Freezing Temperature Operation 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. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.

  • Page 63: Boats With Front-Mounted, Raised Pedestal Fishing Seats

    Section 3 - On the Water WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion. 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.

  • Page 64: Conditions Affecting Operation

    Section 3 - On the Water IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed. Under these conditions, boat speed should be kept to a maximum speed of 24–40 km/h (15–25 mph).

  • Page 65: Ventilation

    Section 3 - On the Water Ventilation Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed‑up and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to continue, eventual blade failure (breakage) will occur.
  • Page 66 Section 3 - On the Water Notes: Page 58 90-8M0074354 OCTOBER 2012...

  • Page 67: Section 4 - Specifications

    Engine Oil................61 Horizon 5.7..............65 Engine Specifications—5.7, 6.2 MPI ECT, Horizon 5.7, 6.2 Horizon 6.2..............66 ECT Models................61 Fluid Specifications............... 66 Inboard 5.7 MPI ECT............. 61 Engine................66 Inboard 6.2 MPI ECT............. 62 Transmission..............66 90-8M0074354 OCTOBER 2012...

  • Page 68: Cruising Rpm-All Models

    Section 4 - Specifications Cruising RPM—All Models Material and design advancements allow modern inboard engines operate at higher engine speeds than their predecessors. Increased RPM significantly increases the horsepower of these new engines and is a critical part of performance and efficiency. The materials and design of the new engines allow these higher speeds without durability penalty.

  • Page 69: Engine Oil

    32878 Engine Specifications—5.7, 6.2 MPI ECT, Horizon 5.7, 6.2 ECT Models Inboard 5.7 MPI ECT NOTE: Performance specifications are obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power. All measurements are taken with the engine at normal operating temperature.

  • Page 70: Inboard 6.2 Mpi Ect

    Section 4 - Specifications 72 A Alternator amperage Cold 65 A 4600–5000 Rev limiter 5150 Idle in neutral At 2000 RPM 124 kPa (18 psi) Minimum oil pressure At idle 41 kPa (6 psi) Seawater‑cooled models 71° C (160° F) Thermostat MPI models with Closed Cooling 77°...

  • Page 71: Horizon 5.7 Ect

    Section 4 - Specifications Horizon 5.7 ECT NOTE: Performance specifications are obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power. All measurements are taken with the engine at normal operating temperature. RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures. Oil pressure must be checked with the engine at normal operating temperature.

  • Page 72: Engine Specifications-5.7, 6.2 Mpi, Horizon 5.7, 6.2 Models

    Section 4 - Specifications 1‑8‑4‑3‑6‑5‑7‑2 Firing order Non‑DTS models 750 CCA, 950 MCA, 180 Ah Minimum battery rating DTS models 800 CCA, 1000 MCA, 190 Ah AC Platinum (AC 41‑993) Spark plug type AC Platinum (AC 41‑101) 1.5 mm (0.060 in.) Spark plug gap Electronic control (PCM‑09), heated oxygen sensor Emission control system...

  • Page 73: Horizon 5.7

    Section 4 - Specifications 72 A Alternator amperage Cold 65 A 4600–5000 Rev limiter 5150 Idle in neutral At 2000 RPM 124 kPa (18 psi) Minimum oil pressure At idle 41 kPa (6 psi) Seawater‑cooled models 71° C (160° F) Thermostat MPI models with closed cooling 77°...

  • Page 74: Horizon 6.2

    Section 4 - Specifications Horizon 6.2 NOTE: Performance specifications are obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power. All measurements are taken with the engine at normal operating temperature. RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures. Oil pressure must be checked with the engine at normal operating temperature.
  • Page 75 Section 4 - Specifications Model Capacity Fluid Type 72C In‑Line 1.66 L (1.75 US qt) 72C Gear Reduction 1.66 L (1.75 US qt) Dexron III Automatic Transmission Fluid 72C Remote V‑Drive 1.66 L (1.75 US qt) 72C V‑Drive 3.79 L (4.00 US qt) 4.00 L (4.5 US qt) Dexron III Automatic Transmission Fluid 4.00 L (4.5 US qt)
  • Page 76 Section 4 - Specifications Notes: Page 68 90-8M0074354 OCTOBER 2012...

  • Page 77: Section 5 - Maintenance

    Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 70 Changing ..............77 Dealer Responsibilities............70 Cleaning the Flame Arrestor..........78 Maintenance................. 70 Positive Crankcase Ventilation (PCV) Valve ....79 Do‑It‑Yourself Maintenance Suggestions......70 Changing ............... 79 Inspection................

  • Page 78: Owner/Operator Responsibilities

    Section 5 - Maintenance Owner/Operator Responsibilities 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 an authorized Mercury MerCruiser dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.

  • Page 79: Inspection

    Section 5 - Maintenance • If you attempt to service the product yourself, we suggest you order the service manual for that model. The service manual outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you don't understand.

  • Page 80: Maintenance Log

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Touch up the paint on the power package. • Change the engine oil and filter. • Change the transmission fluid (ZF Transmission Models). • If the condition of the spark plugs, spark plug wires, and the distributor cap and rotor was satisfactory at the initial inspection (as listed in Every 300 hours or 3 years), inspect the condition of these components.

  • Page 81: Engine Oil

    Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil Checking NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

  • Page 82: Changing Oil And Filter

    Section 5 - Maintenance Remove oil fill cap. 33140 Oil fill cap—5.7, 6.2 MPI ECT, Horizon 5.7, 6.2 ECT models Oil fill cap—5.7, 6.2 MPI, Horizon 5.7, 6.2 models Oil fill cap 6077 Add the specified engine oil to bring the level up to, but not over, the "FULL" or "OK" range mark on the dipstick. Recheck oil level.

  • Page 83: Changing The Oil Filter

    Section 5 - Maintenance Install the oil pump onto the dipstick tube. Typical oil pump Dipstick tube Oil drain hose mc70571-1 Insert the hose end of the crankcase oil pump onto an appropriate container and, using the handle, pump until the crankcase is empty.

  • Page 84: Transmission Fluid

    Section 5 - Maintenance Transmission Fluid Checking While the Engine is Warm Velvet Drive transmissions ‑ Stop the engine and immediately check fluid level by turning T‑handle counterclockwise, to remove dipstick. Fluid level should be up to full mark. If low, add specified fluid through dipstick tube on transmissions. ZF Marine transmissions ‑...

  • Page 85: Filling

    Section 5 - Maintenance The coolant level should be between the "ADD" and "FULL" marks. 6102 Add the specified fluid as necessary. Tube Ref No. Description Where Used Part No. Extended Life Antifreeze/ Closed Cooling System 92-877770K1 Coolant Filling NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine.

  • Page 86: Cleaning The Flame Arrestor

    Section 5 - Maintenance Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors.

  • Page 87: Positive Crankcase Ventilation (Pcv) Valve

    Section 5 - Maintenance Positive Crankcase Ventilation (PCV) Valve Changing NOTE: We recommend the use of Mercury MerCruiser replacement parts to ensure compliance with emission regulations. Remove the PCV valve from the port valve cover. PCV valve (hose not shown) 33143 Disconnect the PCV valve from the hose and discard the valve.

  • Page 88: Water-Separating Fuel Filter

    Section 5 - Maintenance Clean the IAC muffler with warm water and a mild detergent. Replace if necessary. Allow the IAC muffler to dry completely, and then install. 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.

  • Page 89: Installation

    Section 5 - Maintenance Remove the filter cup from the filter cap by grasping the filter cap and rotating it in a clockwise direction while holding the filter cup stationary. 10. Remove the used water‑separating fuel filter element from the filter cup, place it in a clean, approved container. 11.

  • Page 90: Lubrication

    Section 5 - Maintenance Battery switches: Battery switches should always be positioned so each engine is operating off of its own battery. Do not operate engines with switches in both or all position. In an emergency, another engine's battery can be used to start an engine with a dead battery.

  • Page 91: Serpentine Drive Belt

    Section 5 - Maintenance Lubricate the shift cable pivot points. Pivot points 5935 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Shift cable pivot points 92‑883725K01 SAE25W‑40 Serpentine Drive Belt WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts.

  • Page 92: Replacing Belt And/Or Adjusting Tension

    Section 5 - Maintenance • Proper tension ‑ 13 mm (1/2 in.) deflection, with moderate thumb pressure, on the belt at the location that has the longest distance between two pulleys. mc75130-1 Replacing Belt and/or Adjusting Tension IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as before. NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys.

  • Page 93: The Boat Out Of The Water

    Section 5 - Maintenance 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. 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.
  • Page 94 Section 5 - Maintenance 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 95: The Boat In The Water

    Section 5 - Maintenance Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM). Observe the water temperature gauge to ensure that the engine is operating in the normal range. Operate the engine with the transmission in neutral for a minimum of 10 minutes. For power packages operated in salty, brackish, mineral‑laden, or polluted water: Continue to operate the engine until the discharge water is clear.
  • Page 96 Section 5 - Maintenance If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump inlet fitting and immediately plug the seawater inlet hose to prevent water from siphoning into the engine or boat. 10839 Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump. Proceed to step 3.
  • Page 97 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........90 Manual Single‑Point Drain System........ 98 Preparing Power Package for Storage......90 Boat in the Water ........... 98 Engine and Fuel System Preparation ....90 Boat Out of the Water ..........

  • Page 98: 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 99: Draining The Seawater System

    Section 6 - Storage NOTICE Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation. In a 23 Liter (6 US gal) remote fuel tank mix: 19 Liter (5 US gal) regular unleaded 87 octane (90 RON) gasoline 1.89 Liter (2 US qt) Premium Plus 2‑Cycle TC‑W3 Outboard Oil 150 ml (5 oz) Fuel System Treatment and Stabilizer or 30 ml (1 oz) Fuel System Treatment and Stabilizer Concentrate...

  • Page 100: Drain System Identification

    Section 6 - Storage Drain System Identification Air Actuated Single-Point Drain System 6124 6125 Closed cooling models Seawater cooled models Blue drain plug location Blue air pump Air manifold Green indicators Scorpion models Blue air pump Air manifold Green indicators Blue drain plug locations 21125 Manual Single-Point Drain System...

  • Page 101: Three-Point Manual Drain System

    Section 6 - Storage Three-Point Manual Drain System Blue drain plug 6126 Multipoint Drain (MPD) System Side of cylinder block Bottom of exhaust manifolds 6129 6130 Water circulating pump hose Fuel cooler to thermostat housing 90-8M0074354 OCTOBER 2012 Page 93...

  • Page 102: Air Actuated Single-Point Drain System

    Section 6 - Storage Check valve (if equipped) 6131 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. Close the seacock (if equipped) or remove and plug the water inlet hose.
  • Page 103 Section 6 - Storage Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger. This must be removed within 30 seconds to properly vent the cooling system. 6124 6125 Closed cooling models Seawater cooled models Blue drain plug location Blue air pump Air manifold...

  • Page 104: Boat Out Of The Water

    Section 6 - Storage 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Green indicators 6135 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine. Boat Out of the Water NOTE: This procedure is written for the air pump that is attached to the engine.
  • Page 105 Section 6 - Storage Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side. 6124 6125 Closed cooling models Seawater cooled models Blue drain plug location Blue air pump Air manifold...

  • Page 106: Manual Single-Point Drain System

    Section 6 - Storage 12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Green indicators 6135 Manual Single‑Point Drain System Boat in the Water Close the seacock (if equipped) or remove and plug the water inlet hose. Rotate the blue handle counterclockwise until it stops (approximately two turns).

  • Page 107: Boat Out Of The Water

    Section 6 - Storage Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug, if removed. The handle is fully seated when no red is visible. Do not overtighten the handle, as this action will create new threads. Open the seacock (if equipped) or unplug and reconnect the water inlet hose before operating the engine.

  • Page 108: Boat Out Of The Water

    Section 6 - Storage Remove the blue drain plug from the distribution housing (lower front, port side). Blue drain plug 6138 To properly vent the cooling system, remove the blue drain plug from the side of the thermostat housing within 30 seconds. Blue drain plug location 6139 Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).

  • Page 109: Multipoint Drain (Mpd) System

    Section 6 - Storage Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side). 6142 Blue drain plug Verify that water is draining from each opening. Allow the system to drain for a minimum of five minutes.
  • Page 110 Section 6 - Storage Water‑circulating pump hose Drain plug 6143 Fuel‑cooler‑to‑thermostat‑housing hose Drain plug 6144 Check valve Drain plug (if equipped) 6131 Page 102 90-8M0074354 OCTOBER 2012...

  • Page 111: Boat In The Water

    Section 6 - Storage On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...

  • Page 112: Draining Water From The Gen Iii Cool Fuel Module

    Section 6 - Storage Fuel‑cooler‑to‑thermostat‑housing hose Drain plug 6144 Check valve Drain plug (if equipped) 6131 On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...

  • Page 113: Battery Storage

    Section 6 - Storage Place the O‑ring on the drain plug and install the drain plug in the module drain hole. Tighten the drain plug to finger‑tight. Gen III Cool Fuel Module Fuel in‑line fitting Drain plug O‑ring 43648 Battery Storage Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition.
  • Page 114 Section 6 - Storage Notes: Page 106 90-8M0074354 OCTOBER 2012...
  • Page 115 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........... 108 Poor Performance............109 Diagnosing DTS Problems..........108 Excessive Engine Temperature........109 Engine Guardian System............ 108 Insufficient Engine Temperature........109 Troubleshooting Charts............108 Low Engine Oil Pressure..........110 Starter Motor Will Not Crank Engine, or Cranks Slowly Battery Will Not Recharge...........

  • Page 116: 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 ECMs memory.

  • Page 117: Engine Runs Rough, Misses, Or Backfires

    Section 7 - Troubleshooting Engine Runs Rough, Misses, or Backfires Possible Cause Remedy Clogged fuel filter. Replace filter. Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel. Replace kinked lines or blow out lines with compressed air to remove Kinked or clogged fuel line or fuel tank vent line.

  • Page 118: Low Engine Oil Pressure

    Section 7 - Troubleshooting Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase. Check and add oil. Excessive oil in crankcase (causing it to Check and remove required amount of oil. Check for cause of excessive oil become aerated). (improper filling).

  • Page 119: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance..........112 Contact Information for Mercury Marine Customer Local Repair Service ..........112 Service ............... 113 Service Away From Home .......... 112 Customer Service Literature..........113 Stolen Power Package ..........

  • Page 120: Owner Service Assistance

    Section 8 - Customer Assistance Information 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 121: Contact Information For Mercury Marine Customer Service

    Section 8 - Customer Assistance Information • Model and serial numbers for your power package • The name and address of your dealership • Nature of the problem Contact Information for Mercury Marine Customer Service For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English +1 920 929 5040 Mercury Marine...

  • Page 122: Other Languages

    Section 8 - Customer Assistance Information • List your product, model, year, and serial numbers. • Check the literature and quantities you want. • Enclose full remittance in check or money order (NO COD). 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.
  • Page 123 Section 9 - Checklists Section 9 - Checklists Table of Contents Predelivery Inspection (PDI)..........116 Customer Delivery Inspection (CDI)........117 90-8M0074354 OCTOBER 2012 Page 115...
  • Page 124 Section 9 - Checklists Predelivery Inspection (PDI) IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual. Perform these tasks before the Customer Delivery Inspection (CDI). Check/ Item Adjust...
  • Page 125 Section 9 - Checklists Predelivery Inspection Checklist, Continued Check/ Item Adjust On‑the‑Water Test ⃞ ⃞ Engine alignment (Inboard models only) ⃞ Starter neutral safety switch operation ⃞ E‑stop switch/lanyard stop switch operation (all helms) ⃞ Seawater pump operation ⃞ Operation of instruments ⃞...
  • Page 126 Section 9 - Checklists Completed Item ⃞ ⃞ Functions of SmartCraft accessories (if applicable) ⃞ Off‑season storage and maintenance schedule ⃞ Engine (starting, stopping, shifting, using throttle) ⃞ Boat (lights, battery switch location, fuses/breakers) ⃞ ⃞ Trailer (if applicable) Registration: ⃞...

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