Mercury 6.2L MPI Manual
  1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Engine
  5. 6.2L MPI
  6. Manual

Mercury 6.2L MPI Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to
ensure operating ease and durability.
With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read this manual.
The Operation and Maintenance Manual contains specific instructions for using and maintaining your product. 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 products. We sincerely hope your boating will be pleasant!
Mercury Marine, Fond du Lac, Wisconsin, U.S.A.
Name / function:
John Pfeifer, President,
Mercury Marine

Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your dealer. Your dealer can also provide a
demonstration of actual starting and operating procedures.
Notice
Throughout this publication, and on your power package, warnings, cautions, and notices, accompanied by the
International Hazard Symbol
particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions
while performing the service, plus common sense operation, are major accident prevention measures.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
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.
IMPORTANT: 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 and Maintenance
Manual and thoroughly understand the operational instructions for the power package and all related accessories before
the boat is used.
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.
Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury
Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to
change specifications or designs without notice and without incurring obligation.
!
, may be used to alert the installer and user to special instructions concerning a
WARNING
!
CAUTION
!
NOTICE
WARNING
!

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 6.2L MPI and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Mercury 6.2L MPI

Summary of Contents for Mercury 6.2L MPI

  • Page 1: Read This Manual Thoroughly

    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.
  • Page 2 At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Adaptive Speed Control (ASC)..........2 Operation..............11 Additional Operation Instructions for Joystick Piloting Sterndrive Adjustment..............11 (JPS)..................2 Special Digital Throttle and Shift (DTS) Features..... 12 Identification................2 Dock................
  • Page 4 Section 3 - Specifications Fuel Requirements..............36 4.5L MPI Engine Specifications........37 Fuel Ratings..............36 6.2L MPI Engine Specifications........38 Using Reformulated (Oxygenated) Gasoline (USA Only) Fluid Specifications..............38 ..................36 Engine................38 Gasoline Containing Alcohol..........36 Alpha Sterndrive.............. 39 Bu16 Butanol Fuel Blends..........
  • Page 5 Excessive Engine Temperature........101 Sterndrive Unit Does Not Move)........103 Section 7 - Customer Assistance Information Owner Service Assistance............. 106 Contact Information for Mercury Marine Customer Service Local Repair Service............106 ..................107 Service Away From Home..........106 Customer Service Literature..........107 Stolen Power Package.............
  • Page 6 Page iv 90-8M0128973 MAY 2017...
  • Page 7 Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package Table of Contents Adaptive Speed Control (ASC)..........2 Dual‑Handle Electronic Remote Control (ERC)— Additional Operation Instructions Joystick Piloting Operation and Adjustment..........11 Sterndrive (JPS)..............

  • Page 8: Adaptive Speed Control (Asc)

    Section 1 - Getting to Know Your Power Package Adaptive Speed Control (ASC) This power package utilizes Adaptive Speed Control (ASC) to maintain the engine RPM that is demanded at the remote control, regardless of the load change. As an example of how ASC functions, when the operator steers the boat into a hard turn or is navigating at a slow on‑plane speed in following seas when boat control is needed without a lot of speed, the propulsion control module will automatically adjust the engine to maintain the RPM without the operator changing the position of the remote control throttle handle.

  • Page 9: Alpha Sterndrive Serial Number

    Section 1 - Getting to Know Your Power Package Alpha Sterndrive Serial Number The drive serial number and the drive ratio are located on the port side of the sterndrive. 54406 Alpha sterndrive Alpha Transom Serial Number The Alpha transom serial number is stamped in the transom assembly decal. Transom Serial No.

  • Page 10: Bravo Sterndrive Serial Number And Identification

    Section 1 - Getting to Know Your Power Package Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port side of the sterndrive. 33533 Bravo sterndrive information on ground plate The serial number is also stamped on the driveshaft housing behind the back cover.

  • Page 11: Lanyard Stop Switch

    Section 1 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser dealers. 44425 Serial number location on gimbal housing 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.

  • Page 12: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition

    Section 1 - Getting to Know Your Power Package Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an emergency. WARNING If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat.

  • Page 13: System Link Digital Instruments

    Section 1 - Getting to Know Your Power Package • Fuel consumption • Engine operating hours SmartCraft tachometer and speedometer Tachometer Speedometer LCD display 50400 The SmartCraft instrument package also aids in identifying 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.

  • Page 14: Remote Controls (Non-Dts Models)

    Remote Controls (Non‑DTS Models) Remote Control Features—Non‑DTS Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control.

  • Page 15: Remote Controls (Dts Models)

    Remote Controls IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

  • Page 16: Special Digital Throttle And Shift (Dts) Features

    Section 1 - Getting to Know Your Power Package Trim switch (if equipped) ‑ When the power trim switch is activated on the ERC handle, the DTS command module senses a closed circuit for either up or down trim. The DTS command module formulates a signal and sends it to the PCM. The PCM closes the ground circuit to the up or down trim relay.

  • Page 17: Dual-Handle Electronic Remote Control (Erc)-Operation And Adjustment

    Section 1 - Getting to Know Your Power Package Item Control Function Trim control Raises and lowers the sterndrive for best efficiency, or for conditions such as shallow water, (handle) trailering, etc. Allows the operator to start or stop the engine without the use of the key switch. The key switch Stop/Start must be in the run position for the start/stop switch to function.

  • Page 18: Special Digital Throttle And Shift (Dts) Features

    Section 1 - Getting to Know Your Power Package Adjust to the tension desired. Detent tension adjustment screw Handle tension adjustment screw 51901 Special Digital Throttle and Shift (DTS) Features The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed features can operate simultaneously.

  • Page 19: Dock

    Section 1 - Getting to Know Your Power Package Item Control Function Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission into THROTTLE ONLY gear. – Decreases brightness settings for the CAN pad, VesselView, and SmartCraft gauges. 1 LEVER Enables the throttle and shift functions of both engines to be controlled by the port lever.

  • Page 20: Lever

    Section 1 - Getting to Know Your Power Package The neutral lights stop flashing and remain illuminated. The joystick can now be used. 1 Lever The joystick piloting system features the ability to command both engines with a single lever on a dual‑engine application. This feature simplifies engine management during rough sea conditions by allowing you to use a single lever to command both engines simultaneously.

  • Page 21: Transfer (Boats Equipped With Dual Helms)

    Section 1 - Getting to Know Your Power Package Transfer (Boats Equipped with Dual Helms) The TRANSFER button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on boats equipped with dual helms. Refer to Helm Transfer. 51858 TRANSFER button Helm Transfer...

  • Page 22: Power Trim

    Section 1 - 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 23: Single Engine Trim/Trailer

    Section 1 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
  • Page 24 Section 1 - Getting to Know Your Power Package The circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. 55033 All of the engine protection fuses are located at the front of the engine. To access the fuses, disengage the fuse holders from the electrical plate assembly.

  • Page 25: Visual And Audio Warning Systems

    Section 1 - Getting to Know Your Power Package A 90‑amp fuse located near the flame arrestor, protects the engine power harness if an electrical overload occurs. The fuse is translucent so it can be inspected if the fuse has failed and is open. 90‑amp fuse Hot stud 56871...

  • Page 26: Testing The Obd-M Malfunction Indicator Lamp (Mil)

    Section 1 - Getting to Know Your Power Package The service engine icon or MIL will provide a visual indication of a malfunction with the engine's emission control system and will remain illuminated while the OBD‑M fault is active. 47594 SC 1000 gauge and service engine light Testing the OBD-M Malfunction Indicator Lamp (MIL) Turn the ignition switch to the on position without cranking the engine.

  • Page 27: Testing The Audio Warning System

    Section 1 - Getting to Know Your Power Package Testing the Audio Warning System Turn the key switch to the on position without cranking the engine. Listen for the audio alarm. The alarm will sound if the system is functioning correctly. Guardian Strategy The MerCruiser Engine Guardian system reduces the potential for engine damage by restricting engine power when the PCM detects a potential problem.
  • Page 28 Section 1 - Getting to Know Your Power Package Notes: Page 22 90-8M0128973 MAY 2017...
  • Page 29 Section 2 - On the Water Section 2 - On the Water Table of Contents Additional Operation Instructions Joystick Piloting High‑Speed and High‑Performance Operation..... 29 Sterndrive (JPS)..............24 Passenger Safety in Pontoon Boats and Deck Boats..29 Safe Boating Recommendations.......... 24 Boats Having an Open Front Deck .......

  • Page 30: Additional Operation Instructions For Joystick Piloting Sterndrive (Jps)

    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.

  • Page 31: Carbon Monoxide Exposure

    Section 2 - On the Water Never operate a boat while under the influence of alcohol or drugs. It is the law. • Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly. Know your boating area and avoid hazardous locations. Be alert.

  • Page 32: Poor Ventilation

    Section 2 - On the Water Example of desired air flow through the boat: 43367 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 33: Starting And Stopping The Engine

    Section 2 - On the Water Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Check shift and throttle Turn battery switch on. Close fuel shut off valve. control operation. Close seacock, if Operate bilge blowers. Check steering operation. equipped.

  • Page 34: 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. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.

  • Page 35: Protecting People In The Water

    For additional information, refer to Hi‑Performance Boat Operation booklet (90‑849250R03) from your dealer, distributor, or Mercury Marine. Passenger Safety in Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers.

  • Page 36: Wave And Wake Jumping

    Section 2 - On the Water Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. mc79557-1 Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

  • Page 37: Drive Unit Impact Protection

    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 38: The Bottom Of The Boat

    Because of the many variables of boat design, only testing will determine the best propeller for a particular application. Available propellers are listed in the Mercury Precision Parts/Quicksilver Accessories Guide. Page 32...

  • Page 39: Engine Rpm Limiter

    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 40 Section 2 - On the Water Notes: Page 34 90-8M0128973 MAY 2017...
  • Page 41 Section 3 - Specifications Table of Contents Fuel Requirements............... 36 4.5L MPI Engine Specifications........37 Fuel Ratings ..............36 6.2L MPI Engine Specifications........38 Using Reformulated (Oxygenated) Gasoline (USA Only) Fluid Specifications............... 38 ..................36 Engine................38 Gasoline Containing Alcohol ........36 Alpha Sterndrive............

  • Page 42: Fuel Requirements

    Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).

  • Page 43: Engine Specifications

    Section 3 - Specifications If Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of recommendation. 1. Mercury/Quicksilver 25W‑40 Mineral NMMA FC‑W Catalyst Compatible. IMPORTANT: If you are servicing a catalyst engine, use the following oils for short periods of time only.

  • Page 44: L Mpi Engine 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.

  • Page 45: Alpha Sterndrive

    4.5L seawater cooling system 20 L (21 US qt) Propylene glycol and purified water (winterization use only) Mercury Extended Life Coolant Antifreeze or extended‑life 4.5L closed‑cooling system 14.2 L (15 US qt) ethylene glycol 5/100 antifreeze mixed 50/50 with purified water Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil,...
  • Page 46 Section 3 - Specifications Notes: Page 40 90-8M0128973 MAY 2017...
  • Page 47 Section 4 - Maintenance Section 4 - Maintenance Table of Contents Service Decals..............42 Fuel System Maintenance............ 59 Closed Cooling Service Decals ‑ Alpha and Bravo Drive Fuel System..............59 ..................42 Fuel Line Inspection............59 Bravo Standard Cooling Service Decal ......42 Water‑Separating Fuel Filter..........

  • Page 48: Service Decals

    Section 4 - Maintenance Service Decals Closed Cooling Service Decals ‑ Alpha and Bravo Drive Specifications Cooling system drain Serial numbers and maintenance identification colors Mercathode system diagnostic (where applicable) 54977 Bravo Standard Cooling Service Decal 54978 Bravo standard cooling service decal Page 42 90-8M0128973 MAY 2017...

  • Page 49: Alpha Standard Cooling Service Decal

    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 50: Do-It-Yourself Maintenance Suggestions

    Certain other items should be performed only by an authorized Mercury MerCruiser dealer. Before attempting maintenance or repair procedures not covered in this manual, we recommend that you purchase a Mercury MerCruiser service manual and read it thoroughly.

  • Page 51: After Each Use

    Section 4 - Maintenance • Check the lanyard stop switch After Each Use • Flush the engine with fresh water, brackish or saltwater use only Weekly Checks • Check the seawater inlets for marine growth • Clean the seawater strainer, if equipped •...

  • Page 52: Five Years Or 500 Hours

    Section 4 - Maintenance • Inspect the gimbal housing bellows and verify clamp tightness—dealer item • Inspect the gimbal bearing for roughness—dealer item • Lubricate the engine coupler—dealer item • Replace the vent valve on each exhaust elbow, port and starboard, if equipped—dealer item Five Years or 500 Hours •...

  • Page 53: Changing Oil And Filter

    Section 4 - Maintenance Remove the oil fill cap. 54969 4.5 liter oil fill cap Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. Check the oil level with the dipstick.

  • Page 54: Changing Filter

    Fluid Type 4.5L 4.25 L (4.5 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W® 6.2L 4.7 L (5 US qt) With the boat at rest in the water, start the engine, run the engine for three minutes, and check for leaks.

  • Page 55: Filling

    Warm range Cold range 54972 IMPORTANT: If fluid is not visible in the reservoir, contact your authorized Mercury MerCruiser dealer. Filling Remove the fill cap/dipstick and observe the level. Add the specified fluid to bring the fluid level up to the proper level.

  • Page 56: Filling

    Closed cooling system 92-877770K1 Check the antifreeze concentration for adequate freeze protection and correct if necessary. Refer to the Specifications section. Install the fill cap to the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Page 50 90-8M0128973 MAY 2017...

  • Page 57: Alpha Sterndrive Gear Lube

    IMPORTANT: If more than 59 ml (2 fl oz) of gear lubricant is required to fill the monitor, a seal may be leaking. Damage to the sterndrive unit may occur due to lack of lubrication. Contact your authorized Mercury MerCruiser dealer.

  • Page 58: Bravo Sterndrive Gear Lube

    Sterndrive unit 92-858064K01 IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit. Install the oil vent screw and sealing washer. Continue to pump gear lubricant into the drive through the oil fill and drain plug hole until the gear lubricant appears in the gear lube monitor.

  • Page 59: Filling

    Section 4 - Maintenance Check the gear lube level in the monitor bottle. Keep the gear lube level within the recommended operating range. Gear lube monitor cap Maximum range Minimum range 58362 Inspect the gear lube condition. If any water is visible in the bottom of the gear lube monitor, if water appears at the fill and drain plug hole, or if the gear lube appears discolored, there may be a water leak in the sterndrive.
  • Page 60 Lower the sterndrive unit so the propeller shaft is level. IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit. Fill the sterndrive unit through the oil fill and drain hole with specified gear lubricant until an air‑free stream of lubricant flows from the oil vent hole.

  • Page 61: Power Trim Fluid

    Auxiliary Batteries Mercury strongly recommends using at least group 27 or 31 type AGM batteries when load shedding devices are used in place of auxiliary batteries. Boats using JPS are typically large vessels with many DC loads and the minimum group 24 batteries will not be sufficient.

  • Page 62: Multiple Efi Engine Battery Precautions

    Section 4 - Maintenance Connect electrical components such as LVDs (low voltage disconnects), VSRs (voltage sensing relays), and ACRs (automatic closing relays) to an isolated auxiliary battery bank. Review ABYC regulations for power connection points. Multiple EFI Engine Battery Precautions Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on.
  • Page 63 Section 4 - Maintenance Lift up on the front of the second cover to disengage the cover from the front grommets. Pull the cover towards the front of the vessel to remove it from the two rear grommets. Front grommets Rear grommets 54984 Loosen the clamp securing the flame arrestor and remove the flame arrestor.

  • Page 64: Changing The Positive Crankcase Ventilation (Pcv) Valve

    NOTE: The PCV valve should be replaced with Mercury Mercruiser OEM parts to ensure compliance with emission regulations. Pull the PCV valve out of the starboard valve cover and remove from the hose.

  • Page 65: Fuel System Maintenance

    Section 4 - Maintenance Fuel System Maintenance Fuel System 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 66: Draining The Filter Housing

    Section 4 - Maintenance Slide the filter housing up to release it from the bracket. The fuel hoses have enough slack to remove the filter housing from the bracket. Bracket retainers Filter cover Red service cap 63676 Draining the Filter Housing WARNING Fuel is flammable and explosive.

  • Page 67: Lubrication

    Section 4 - 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 the steering cable does not have a grease fitting, the inner wire of the cable cannot be greased. If the steering cable has grease fittings, turn the steering wheel until the steering cable is fully retracted into the cable housing.

  • Page 68: Remote Control Cable Lubrication

    Lubricate the steering pin. Steering pin mc71904-1 Tube Ref No. Description Where Used Part No. Mercury 25W-40 Synthetic Blend Steering pin 92-8M0078629 4-Stroke Engine Oil On dual engine boats: Lubricate the tie bar pivot points. Tube Ref No. Description Where Used Part No.

  • Page 69: Driveshaft U-Joint Splines And O-Rings (Sterndrive Unit Removed)

    Section 4 - Maintenance Driveshaft U‑joint Splines and O‑Rings (Sterndrive Unit Removed) Apply grease to the driveshaft U‑joint splines and O‑rings. Driveshaft U‑joint splines O‑rings (3) 8591 Tube Ref No. Description Where Used Part No. Extreme Grease Driveshaft U-joint splines and O-rings 8M0071842 For propeller shaft lubrication, refer to Propellers.

  • Page 70: Driveshaft Extension Models

    Tube Ref No. Description Where Used Part No. Transom end grease fitting, engine end grease fitting, driveshaft grease Extreme Grease 8M0071842 fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Page 64 90-8M0128973 MAY 2017...

  • Page 71: Alpha Or Bravo One Propeller Removal

    Section 4 - Maintenance Alpha or Bravo One 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 72: Bravo Two Propeller Removal

    Section 4 - Maintenance Bravo Two 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 73: Bravo Three Propeller Removal

    Turn the front propeller nut 70 mm (2‑3/4 in.) counterclockwise to remove the nut. Slide the propeller and thrust hub off the propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Rear propeller nut...

  • Page 74: Bravo Three Propeller Installation

    Section 4 - Maintenance Bravo Three Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. Rear propeller nut Rear propeller Rear propeller thrust hub...

  • Page 75: Serpentine Drive Belt

    Section 4 - Maintenance 11. Apply Loctite 271 Threadlocker onto the propeller shaft anode screw threads. Propeller Rear propeller nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer 5303 Tube Ref No. Description Where Used Part No. Loctite 271 Threadlocker Propeller shaft anode screw threads 92-809819...

  • Page 76: Serpentine Belt Failure Identification

    Section 4 - Maintenance Without a seawater pump Alternator pulley Water circulating pump pulley Crankshaft pulley Belt tensioner Power steering pump pulley 55045 Serpentine Belt Failure Identification Appearance Description Cause Solution Replace the belt and Abrasion Belt is in contact with an object. Each side of the belt appears inspect for contact with an Can be caused by improper belt...

  • Page 77: Checking

    Section 4 - Maintenance Appearance Description Cause Solution Chunk‑out can happen when Chunk‑out Pieces or chunks of rubber several cracks in one area move Replace the belt material have broken off the belt. parallel to the cord line. Heat, age, immediately.

  • Page 78: Replacing

    The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer. Maintaining Ground Circuit Continuity The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the engine, transom assembly, and sterndrive components.

  • Page 79: Sterndrive Corrosion Protection Components

    Section 4 - Maintenance Sterndrive Corrosion Protection Components To help control the effects of galvanic corrosion, sterndrives come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection, refer to the Marine Corrosion Protection Guide.
  • Page 80 Section 4 - Maintenance Do not pressure‑wash the MerCathode assembly, if equipped. Doing so will damage the coating on the reference electrode wire and decrease the corrosion protection. MerCathode mounted to the underside of the gimbal housing, if equipped MerCathode reference electrode, if equipped Do not paint Do not pressure wash...

  • Page 81: Mercathode System Battery Requirements

    Flush the cooling system periodically, preferably after each use. MerCathode System Battery Requirements The Mercury MerCruiser MerCathode system requires a minimum battery charge of 12.6 volts at all times to maintain functionality. Boats equipped with a MerCathode system that use shore power, and are not run for a long period of time, must use a battery charger to maintain a minimum battery charge of 12.6 volts or above.

  • Page 82: Mercathode Control Module

    Refer to MerCathode Theory of Operation for a thorough explanation on the state of protection the MerCathode is providing and whether or not the system requires inspection by an authorized Mercury MerCruiser dealer. Closed cooling...

  • Page 83: Do Not Use Caustic Cleaning Chemicals

    The system is not operating correctly. Contact your local second sensed reference electrode voltage in Mercury Service dealer for assistance. excess of 1.4 V. The reference voltage is outside of the 1 flash per 4 normal, expected range: either above 1.04 V...

  • Page 84: Sterndrive Surface Care

    Maintain a complete paint covering on the sterndrive. • Check the finish regularly. Prime and paint nicks and scratches using Mercury enamel paint and touch up paint. Use only tin‑based antifouling paint or its equivalent on or near aluminum surfaces below the waterline.

  • Page 85: Important Information About Flushing Procedures

    Choosing the correct flushing procedure for your engine will depend on the engine model, and in some cases the marine hardware and cooling system water supply features provided by the boat manufacturer. Contact your authorized Mercury MerCruiser dealer for information about the best flushing procedure for your engine and boat model.

  • Page 86: Alpha Models With Closed Cooling

    Section 4 - Maintenance Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 5773 Side pickup NOTE: Flushing is required for salty, brackish, mineral‑laden, or polluted water applications. Flush the engine after each outing for best results.

  • Page 87: Sterndrive Water Pickups

    Section 4 - Maintenance IMPORTANT: Installations using block off plates at the gimbal housing that use a through‑the‑hull or through‑the‑transom pickup still require a supply of cooling water for both the sterndrive and the engine during operation. Sterndrive Water Pickups This sterndrive is equipped with side water inlets.

  • Page 88: Flushing The Power Package-Bravo Models

    Section 4 - 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. 11.

  • Page 89: Sterndrive Water Pickups

    Sterndrive Water Pickups There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side water pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side water pickups require the flushing attachment (44357Q 2).

  • Page 90: Alternative Water Pickups

    Section 4 - Maintenance If flushing the cooling system with the boat out of the water: 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 91: Seacore Power Package Flushing Procedure

    Section 4 - Maintenance Remove the seawater inlet hose from the seawater pump at the location shown. Plug the hose to prevent water from siphoning into the engine or boat. 55049 Seawater inlet hose connection Use a suitable adapter to connect the flushing hose from the water source to the water inlet of the seawater pump. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
  • Page 92 Section 4 - 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 93 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. 63788 Quick-connect fitting: store on the boat, NOT the engine 19.
  • Page 94 Section 4 - Maintenance Notes: Page 88 90-8M0128973 MAY 2017...

  • Page 95: Section 5 - Storage

    Section 5 - Storage Section 5 - Storage Table of Contents Draining the Seawater System..........90 Cold Weather or Extended Storage........95 Draining the Raw Water..........90 Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 95 Air Actuated Single‑Point Drain System—Closed Cooling Fuel Containing Alcohol..........95 ..................

  • Page 96: Draining The Seawater System

    IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the raw water section of the cooling system during freezing temperatures or for extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
  • Page 97 Section 5 - Storage IMPORTANT: If water does not drain from the distribution housing when both green indicators are extended, remove the blue plug on the distribution housing. Distribution housing water drain Blue plugs 55101 Check to ensure water drains out of the seawater pump housing. IMPORTANT: If water does not drain from the seawater pump housing when both green indicators are extended, remove the blue plugs on the seawater pump housing.

  • Page 98: Air Actuated Single-Point Drain System (Bravo Standard Cooling)

    Section 5 - Storage 16. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Green indicators 6135 17. Open the seacock, if equipped, or unplug and connect the water inlet hose prior to operating the engine. Air Actuated Single‑Point Drain System (Bravo Standard Cooling) The following instructions apply to draining procedures performed on engines in vessels that are in the water.
  • Page 99 Section 5 - Storage Install the air pump on the actuator fitting. Pull the lever on the air pump (vertical) to lock the pump onto the fitting. Actuator fitting Green indicators Manual release valve Air pump Lever (locking) 8293 Pump air into the system until both green indicators extend out of the actuator assembly. Water should begin to drain out of the distribution housing.

  • Page 100: Manual Single-Point Drain System (Alpha Standard Cooling)

    15. Install the blue plug on the heat exchanger and tighten securely. 16. Mercury MerCruiser recommends the drain system remain open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained. 17. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

  • Page 101: Cold Weather Or Extended Storage

    If ethanol is used in the gasoline in your area, refer to Fuel Containing Alcohol. Fuels for your Mercury Marine engine may contain up to 10% of ethanol or ether. Fuel Containing Alcohol Fuels containing either methanol (methyl alcohol) or ethanol (ethyl alcohol) may cause certain adverse effects.

  • Page 102: Preparing Power Package For Storage-Mpi Models

    Section 5 - Storage The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 103: Engine And Fuel System Preparation

    Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation. Check the antifreeze concentration where applicable. Refer to the Specifications section. Before adding Mercury Quickstor Fuel Stabilizer to the fuel in the tank, determine the type of fuel that is in the fuel tanks and proceed with the following: Vessels using fuel without alcohol—fill the vessel fuel tanks with fresh gasoline that does not contain alcohol and add...

  • Page 104: Recommissioning The Power Package

    Section 5 - Storage Recommissioning the Power Package Ensure that all cooling system hoses are connected properly and hose clamps are tight. CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system.

  • Page 105: Section 6 - Troubleshooting

    Section 6 - Troubleshooting Section 6 - Troubleshooting Table of Contents Diagnosing EFI Problems........... 100 Insufficient Engine Temperature........101 Diagnosing DTS Problems..........100 Low Engine Oil Pressure..........101 Additional Operation Instructions Joystick Piloting Battery Will Not Recharge........... 102 Sterndrive (JPS)..............100 Remote Control Is Difficult to Move, Has Excessive Play, Engine Guardian System............

  • Page 106: Diagnosing Efi Problems

    Diagnosing DTS Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on digital throttle and shift (DTS) systems. The propulsion control module (PCM) has the ability to detect problems with the system when they occur, and store a trouble code.

  • Page 107: Engine Runs Rough, Misses, Or Backfires

    Clean the flame arrestor. Faulty ignition system component. Service ignition system. Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer. EFI system fault. Have EFI system checked by an authorized Mercury MerCruiser dealer. Poor Performance...

  • Page 108: Battery Will Not Recharge

    DTS trackpad. If the light is on, put the handles in neutral and push the button to disengage. Check your Mercury‑approved MFD to see if cruise control is enabled. Disable cruise control. The ERC lever controls the engines, but they do not Check for damage to the propeller, and change the propeller if reach wide‑open throttle.

  • Page 109: Steering Wheel Jerks Or Is Difficult To Turn

    Check all parts and fasteners. If any are loose or missing, see authorized Loose or missing steering fasteners or parts. Mercury MerCruiser dealer immediately. Contaminated power steering fluid. See authorized Mercury MerCruiser dealer. Power Trim Does Not Operate (Motor Does Not Operate) Possible Cause Remedy Replace fuse.
  • Page 110 Section 6 - Troubleshooting Notes: Page 104 90-8M0128973 MAY 2017...

  • Page 111: Section 7 - Customer Assistance Information

    Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance..........106 Contact Information for Mercury Marine Customer Local Repair Service ..........106 Service ............... 107 Service Away From Home .......... 106 Customer Service Literature..........107 Stolen Power Package ..........

  • Page 112: Owner Service Assistance

    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.

  • Page 113: Contact Information For Mercury Marine Customer Service

    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: •...

  • Page 114: Other Languages

    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.
  • Page 115 Section 8 - Checklists Section 8 - Checklists Table of Contents Predelivery Inspection (PDI)..........110 Customer Delivery Inspection (CDI)........111 90-8M0128973 MAY 2017 Page 109...

  • Page 116: Predelivery Inspection (Pdi)

    Section 8 - Checklists Predelivery Inspection (PDI) IMPORTANT: This checklist is for packages that are not equipped with joystick piloting. For engine packages equipped with joystick piloting, use the checklist included with the joystick piloting operation manual. Perform these tasks before the Customer Delivery Inspection (CDI). Check/ Item Adjust...

  • Page 117: Customer Delivery Inspection (Cdi)

    Approve the external appearance of the product (paint, cowl, decals, etc.) ⃞ Warranty—provide and explain the limited warranty to the customer. Explain dealer services. ⃞ ⃞ Explain the optional Mercury Product Protection Plan (North America only) Operation of equipment—explain and demonstrate: ⃞ E‑stop switch/lanyard stop switch operation (all helms) ⃞...
  • Page 118 Section 8 - Checklists N/A Completed Item ⃞ Boat (lights, battery switch location, fuses/breakers) ⃞ ⃞ Trailer (if applicable) Registration: ⃞ Complete and submit warranty registration—provide the customer with a copy Page 112 90-8M0128973 MAY 2017...

  • Page 119: Section 9 - Maintenance Log

    Section 9 - Maintenance Log Section 9 - Maintenance Log Table of Contents Scheduled Maintenance Log..........114 Vessel Maintenance Notes..........115 90-8M0128973 MAY 2017 Page 113...

  • Page 120: Scheduled Maintenance Log

    Section 9 - 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...

  • Page 121: Vessel Maintenance Notes

    Section 9 - 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 90-8M0128973 MAY 2017 Page 115...

This manual is also suitable for:

4.5l

Table of Contents

Save PDF