Related Manuals for Mercury 3.0 MPI ECT
Summary of Contents for Mercury 3.0 MPI ECT
- Page 1 3.0 MPI ECT and 3.0 TKS Sterndrive Models O P ERAT I O N & M AI N T EN AN CE MAN U AL...
- Page 3 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 4 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual included with the product. The Warranty Manual contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.
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Page 5: Table Of Contents
Launching and Boat Operation..........20 Wave and Wake Jumping............24 Operation Chart..............20 Impact with Underwater Hazards..........24 Starting and Stopping the Engine—3.0 MPI ECT....21 Drive Unit Impact Protection..........25 Starting and Stopping the Engine........21 Conditions Affecting Operation..........25 Starting the Engine............ - Page 6 Section 4 - Maintenance General Information..............38 Checking and Filling............52 Owner/Operator Responsibilities........38 Changing the Oil and Filter..........52 Dealer Responsibilities............ 38 Power‑Assisted Steering Fluid—3.0 MPI ECT....... 53 Maintenance..............38 Checking................. 53 Do‑It‑Yourself Maintenance Suggestions......38 Filling................53 Inspection................ 39 Changing.................
- Page 7 Single Point Drain System..........80 Recommissioning the Power Package........85 Section 6 - Troubleshooting Troubleshooting Information and Charts Specifically for 3.0 MPI Troubleshooting Charts for 3.0 MPI ECT and 3.0 TKS.... 90 ECT..................88 Excessive Engine Temperature........90 Diagnosing EFI Problems..........88 Insufficient Engine Temperature........
- Page 8 Page iv 90-8M0113856 DECEMBER 2015...
- Page 9 Single Engine Trim/Trailer ..........9 Identification..............2 Dual Engine Trim/Trailer ..........9 Engine Serial Number Decal........... 2 Electrical System Overload Protection—3.0 MPI ECT... 9 Alpha Sterndrive Serial Number........3 Electrical System Overload Protection—3.0 TKS....12 Alpha Transom Serial Number........3 Visual and Audio Warning Systems (ECT)......
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Page 10: Identification Information
Section 1 - Getting to Know Your Power Package Identification Information 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 the aft portion of the starboard side of the block, near the starter motor. -
Page 11: 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 12: Lanyard Stop Switch
Section 1 - Getting to Know Your Power Package 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. The lanyard is connected to the operator's personal flotation device or wrist. A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist. -
Page 13: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition
Section 1 - Getting to Know Your Power Package Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard cord. -
Page 14: System Link Digital Instruments
Quantity of fuel in tank Remote Controls Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control. -
Page 15: Panel Mount Features
Section 1 - Getting to Know Your Power Package Panel Mount Features Neutral lock button Throttle only button Lanyard stop switch Control handle tension adjustment screw Control handle Trim/tilt button mc77019-1 Neutral lock button ‑ Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the control handle out of neutral. -
Page 16: Power Trim
Section 1 - Getting to Know Your Power Package Control handles ‑ Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear and continue pushing forward to increase speed. -
Page 17: Single Engine Trim/Trailer
Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only. Electrical System Overload Protection—3.0 MPI ECT An electrical overload will either open a fuse or open a circuit breaker. You must find and repair the source of the overload before replacing the fuse or resetting the circuit breaker. - Page 18 Section 1 - Getting to Know Your Power Package Four fuses protect the main power, fuel pump, ignition, and accessory circuits. Two 10‑amp fuses protect the O sensors. These fuses are located on the top of the engine, underneath the engine information plate. Fuse locations sensor fuses Main power, fuel pump, ignition, and accessory fuses...
- Page 19 Section 1 - Getting to Know Your Power Package A 15‑amp accessory fuse is located on the rear of the engine. This fuse protects the accessory circuits. 7524 Accessory fuse In the ignition switch "I" terminal lead, there may be a 20‑amp fuse that protects the electrical system. Check for an open fuse or open circuit breaker if you turn the ignition key to the start position and nothing happens.
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Page 20: Electrical System Overload Protection-3.0 Tks
Reset the circuit breaker. If the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your authorized Mercury MerCruiser dealer as soon as possible. Page 12... - Page 21 Section 1 - Getting to Know Your Power Package A circuit breaker protects the engine wiring harness and the instrumentation power lead. Reset the breaker by pushing the red button. 51185 Engine wiring harness and instrumentation circuit breaker A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.
- Page 22 Section 1 - 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 Ignition switch fuse—typical The power trim system is protected from overload by a 110‑amp fuse and a 20‑amp spade fuse on the power trim pump.
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Page 23: Visual And Audio Warning Systems (Ect)
Section 1 - Getting to Know Your Power Package Visual and Audio Warning Systems (ECT) Service Engine Light and OBD‑M MIL Kit Boats powered by emissions control technology (ECT) catalyzed engines must be equipped with a SmartCraft‑enabled gauge capable of displaying the service engine icon, or a dash‑mounted service engine light. Malfunction indicator lamp (MIL) kits containing a dash‑mounted service engine light and a special harness that connects to the engine harness may be purchased separately. -
Page 24: Guardian Strategy
Audio Warning System—3.0 TKS Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The audio warning system will not protect the engine from damage. It is designed to warn the operator that a problem has occurred. - Page 25 Launching and Boat Operation..........20 Wave and Wake Jumping............. 24 Operation Chart ............20 Impact with Underwater Hazards......... 24 Starting and Stopping the Engine—3.0 MPI ECT....21 Drive Unit Impact Protection ......... 25 Starting and Stopping the Engine........21 Conditions Affecting Operation..........25 Starting the Engine ..........
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Page 26: Safe Boating Recommendations
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 27: Carbon Monoxide Exposure
Section 2 - On the Water Be alert. • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed. -
Page 28: Poor Ventilation
Section 2 - 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 29: Starting And Stopping The Engine-3.0 Mpi Ect
Section 2 - On the Water Starting and Stopping the Engine—3.0 MPI ECT 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. -
Page 30: 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 31: 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 32: 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 33: 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 34: Elevation And Climate
Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After Break‑In Period To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered; •... -
Page 35: End Of First Season Checkup
End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first. - Page 36 Section 2 - On the Water Notes: Page 28 90-8M0113856 DECEMBER 2015...
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Page 37: Section 3 - Specifications
Section 3 - Specifications Section 3 - Specifications Table of Contents Specifications—3.0 MPI ECT..........30 Engine ..............32 Engine Specifications—3.0 MPI ECT......30 Specifications—3.0 TKS............32 Fuel Requirements............30 Engine Specifications—3.0 TKS........32 Fuel Ratings ............30 Fuel Requirements............33 Using Reformulated (Oxygenated) Gasoline (USA Fuel Ratings ............ -
Page 38: Specifications-3.0 Mpi Ect
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 39: Gasoline Containing Alcohol
Bu16 Butanol Fuel Blends Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings). -
Page 40: Fluid Specifications
Section 3 - Specifications Use the following information for selecting the type of oil according to the order of preference. Mercury/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W Catalyst Compatible rated 4-cycle oil Mercury/Quicksilver 25W-40 Mineral NMMA FC-W Catalyst Compatible rated 4-cycle oil... -
Page 41: Fuel Requirements
The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings). -
Page 42: Engine Oil
Section 3 - Specifications IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing alcohol, do not store the gasoline in the fuel tank for long periods. Cars normally consume alcohol‑blend fuels before they can absorb enough moisture to cause trouble, boats often sit idle long enough for phase separation to take place. - Page 43 Compatible rated Seawater cooling system 9 L (8.5 US qt) Propylene glycol and purified water Mercury Extended Life Coolant Antifreeze or extended life ethylene glycol 5/100 Closed cooling system 9 L (8.5 US qt) antifreeze mixed 50/50 with purified water...
- Page 44 Section 3 - Specifications Notes: Page 36 90-8M0113856 DECEMBER 2015...
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Page 45: Section 4 - Maintenance
Table of Contents General Information.............. 38 Checking and Filling............52 Owner/Operator Responsibilities........38 Changing the Oil and Filter..........52 Dealer Responsibilities..........38 Power‑Assisted Steering Fluid—3.0 MPI ECT..... 53 Maintenance..............38 Checking................ 53 Do‑It‑Yourself Maintenance Suggestions...... 38 Filling................53 Inspection..............39 Changing............... -
Page 46: General Information
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 47: Inspection
IMPORTANT: Changing the mixture setting on this engine can affect the exhaust emissions level and void the emissions certification. Do not adjust or remove the mixture settings or remove the mixture screw seals. See your authorized Mercury dealer or emissions testing agency. -
Page 48: Scheduled Maintenance
Inspect the U‑joints, the splines, the bellows, and check the clamps. • Lubricate the U‑joint splines and cross bearing, if equipped with a grease fitting. • Inspect the gimbal bearing for roughness. Replace if necessary. See your certified Mercury MerCruiser dealer. • Lubricate the engine coupler. -
Page 49: Scheduled Maintenance Procedures Specifically For 3.0 Mpi Ect
Replace the coolant/antifreeze. Replace every two years if not using extended‑life coolant/ Every 5 years antifreeze. Scheduled Maintenance Procedures Specifically for 3.0 MPI ECT 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. -
Page 50: Inspecting The Fuel Pump Sight Tube
Inspecting the Fuel Pump Sight Tube The engine fuel pump sight tube gives you visual evidence of a fuel leak in the fuel pump diaphram. If fuel is ever visible in the tube, see your authorized Mercury MerCruiser dealer to replace the fuel pump. 32555... -
Page 51: Drive Belts
Section 4 - Maintenance Drive Belts 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. Power steering pump pulley Water circulating pump pulley Crankshaft pulley Alternator pulley 7170... -
Page 52: Replacing Belts On Side Mount Models
Section 4 - Maintenance Description Specification Crankshaft position sensor air gap 0.64–1.02 mm (0.024–0.040 in.) Tighten the two spacer block bolts. If necessary, you can loosen the crankshaft position sensor bolts to move the sensor into position. Tighten all bolts to the specified torque. Description lb‑in. -
Page 53: Scheduled Maintenance
Section 4 - Maintenance Task Interval Maintenance to Be Performed • Check the water inlets for debris or marine growth. • Check and clean the seawater strainer, if equipped. Weekly • Check the coolant level. • Inspect the sterndrive anodes and replace if eroded 50% or more. •... -
Page 54: Scheduled Maintenance Procedures Specifically For 3.0 Tks
Inspect the U‑joints, the splines, the bellows, and check the clamps. • Lubricate the U‑joint splines and cross bearing, if equipped with a grease fitting. • Inspect the gimbal bearing for roughness. Replace if necessary. See your certified Mercury MerCruiser dealer. • Lubricate the engine coupler. -
Page 55: Positive Crankcase Ventilation Valve (Pcv)
The engine fuel pump is equipped with a sight tube which gives visible evidence of a ruptured fuel pump diaphram. IMPORTANT: If fuel is visible in tube, the fuel pump should be replaced by your Authorized Mercury MerCruiser Dealer immediately. -
Page 56: Drive Belts
Section 4 - Maintenance Drive Belts 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. Power steering pump pulley Water circulating pump pulley Crankshaft pulley Alternator pulley 7170... -
Page 57: Replacing - Side Mount Models
Section 4 - Maintenance Remove the spacer block between the bracket assembly and the engine block. It may be necessary to tape gently on the spacer to allow removal. Loosen the alternator. Remove and replace the alternator belt. Replace the spacer block between the bracket assembly and the engine block. Install the two screws using the flat and lockwashers removed previously. -
Page 58: Engine Oil-3.0 Mpi Ect
10. Start the engine and check for leaks around the fuel filter assembly. If leaks exist, stop the engine immediately, check the filter installation, clean spilled fuel, and properly ventilate the engine compartment. If leaks continue, stop the engine immediately and contact your authorized Mercury MerCruiser dealer. Engine Oil—3.0 MPI ECT... -
Page 59: Changing The Oil And Filter
IMPORTANT: Do not overfill the engine with oil. 32610 Oil fill cap Engine Model Capacity Fluid Type Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Catalyst 3.0 MPI 3.8 L (4 US qt) Compatible rated Replace the fill cap. Changing the Oil and Filter IMPORTANT: Change the engine oil when the engine is warm from operation. -
Page 60: Engine Oil-3.0 Tks
IMPORTANT: Do not overfill the engine with oil. Oil fill cap 7519 Engine Model Capacity Fluid Type Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Catalyst 3.0 TKS 3.8 L (4 US qt) Compatible rated Install the dipstick into the dipstick tube. Install the oil fill cap. -
Page 61: Power-Assisted Steering Fluid-3.0 Mpi Ect
Cold full mark 32553 Add the specified fluid if required. Refer to Filling. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling Remove the fill cap and dipstick and observe the fluid level. 90-8M0113856... -
Page 62: Changing
Warm range 7158 Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling Remove the fill cap/dipstick and observe the level. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level. -
Page 63: Engine Coolant-3.0 Mpi Ect
Section 4 - Maintenance Engine Coolant—3.0 MPI ECT Checking CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap. -
Page 64: Filling
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. Engine Coolant—3.0 TKS Checking CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap. -
Page 65: Filling
92-877770K1 Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Alpha Sterndrive Gear Lube 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. -
Page 66: Filling
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 67: Changing
Sterndrive unit 92-858064K01 IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in 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 gear lubricant appears in the gear lube monitor. -
Page 68: Power Trim Fluid
Section 4 - Maintenance 10. Ensure that the rubber gasket is inside the cap and install. Do not over tighten. "ADD" mark "OPERATING RANGE" mark 19948 NOTE: Oil capacity includes the gear lube monitor. Model Capacity Fluid Type High Performance Gear Alpha One 1892 ml (64 oz) Lubricant... -
Page 69: Changing
92-858074K01 Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. 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. -
Page 70: Throttle Cable-3.0 Mpi Ect
After starting the engine, turn the steering wheel several times to port and starboard to ensure that the steering system operates properly before getting underway. Throttle Cable—3.0 MPI ECT Lubricate the pivot points and the guide contact surfaces with oil. -
Page 71: Throttle Cable-3.0 Tks
Section 4 - Maintenance Throttle Cable—3.0 TKS Lubricate the pivot points and the guide contact surfaces. Pivot points 7169 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Throttle cable pivot points & 92‑883725K01 SAE25W‑40 guide contact surfaces Shift Plate Control Cable Lubrication Lubricate the points shown in the following illustration with oil at least once a year, more often if the product is operated in saltwater. -
Page 72: Driveshaft U-Joint Splines And O-Rings
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 73: Propellers
Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. -
Page 74: Flushing The Power Package
Your boat comes equipped with through the sterndrive water pickups. See Sterndrive Water Pickups (following) for the flushing procedure. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Alpha engines with the sterndrive water inlet blocked off at the gimbal housing, and using a through the hull... -
Page 75: Sterndrive Water Pickups
Section 4 - Maintenance Sterndrive Water Pickups This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment (44357Q 5773 Side Pickup NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications. Flushing is recommended after each outing for best results. -
Page 76: Battery
Section 4 - Maintenance 12. This step is only required if the boat is to be stored in the water. After the flush procedure is completed, remove the seawater inlet hose from the thermostat housing and plug the hose to prevent water from siphoning into the boat. This prevents seawater from contaminating the engine flush. - Page 77 Section 4 - Maintenance Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.), it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System be installed (some models have a MerCathode System as standard equipment).
- Page 78 MerCathode System ‑ Electrode assembly replaces Anodic block. System should be tested to ensure adequate output. The test should be performed where boat is moored, using Quicksilver Reference Electrode and Test Meter. Contact your authorized Mercury MerCruiser dealer. Page 70...
- Page 79 Section 4 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. MerCathode controller MerCathode assembly 6206 Anode Kit (if equipped) ‑ Mounted to the boat transom. 5642 Trim Cylinder Anodes ‑ Mounted on each trim cylinder. Trim cylinder anodes 7460 Bearing Carrier Anode (Alpha) ‑...
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Page 80: Painting Your Power Package
If using copper or tin based anti‑fouling paints, observe the following: • Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items. -
Page 81: Section 5 - Storage
Clearing Clogged Blue Drain Hoses........83 Engine and Fuel System Preparation ....76 Draining the Sterndrive............85 Draining the Seawater System..........77 Battery Storage..............85 Draining the 3.0 MPI ECT Seawater System....... 77 Recommissioning the Power Package......... 85 90-8M0113856 DECEMBER 2015 Page 73... -
Page 82: Cold Weather Or Extended Storage
(phase) of the water/alcohol from the gasoline in the fuel tank. 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 83: Special Fuel Mix
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 84: Engine And Fuel System Preparation
Always ventilate the engine compartment before servicing the power package. 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 85: Draining The Seawater System
IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system. IMPORTANT: The engine must not be operating at any point during the draining procedure. Draining the 3.0 MPI ECT Seawater System Single‑Point Drain System CAUTION Disconnecting the blue drain hoses can cause serious burns due to hot water. -
Page 86: Draining The Seawater Section Of Models With Closed Cooling
Section 5 - Storage Leave the blue drain hoses disconnected until all water drains from the engine. Pull the T‑handle until the quick connect fittings on the blue drain hoses are within reach. Install the quick connect fittings on the bracket. Pull on the blue drain hoses to ensure they are firmly connected. 10. - Page 87 Section 5 - Storage Remove and lower the hose connecting the water inlet to the power steering cooler, or the water inlet to the heat exchanger. 32651 Power steering cooler Water inlet to heat exchanger hose Ensure that the speedometer pitot hole, gear housing water vent and drain holes, and trim tab cavity vent and drain holes are open and unobstructed.
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Page 88: Draining The 3.0 Tks Seawater System
Section 5 - Storage Crank the engine over slightly with the starter motor to purge any water trapped in seawater pickup pump. Do not allow the engine to start. After the cooling system has drained completely, apply sealant to the aft heat exchanger plug. Aft heat exchanger drain plug 7184 Tube Ref No. -
Page 89: Draining The Seawater Section Of Models With Closed Cooling
Section 5 - Storage Pull the T‑handle until the hose guide is in contact with the quick connect fittings. T‑handle Hose guide 7183 Push down on the T‑handle to force the blue drain hoses below their connection points on the block. Ensure water is draining from blue drain hoses. - Page 90 Section 5 - Storage Bottom of exhaust manifold. Exhaust manifold drain plug 7186 Clean out the drain holes with a stiff piece of wire until the entire system is drained. NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. Remove and lower the hose from the water inlet to the power steering cooler (if equipped), or the water inlet to the heat exchanger.
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Page 91: Clearing Clogged Blue Drain Hoses
Section 5 - Storage Ensure the gear housing water vent and drain holes, speedometer pitot hole, and trim tab cavity vent and drain holes are open and unobstructed. Gear housing vent holes Trim tab cavity drain holes Gear housing drain hole Speedometer pitot hole 7329 Crank the engine over slightly with the starter motor to purge any water trapped in seawater pickup pump. - Page 92 13. Check for water draining from the blue drain hose. If the blue drain hose is still clogged, shut off the bilge pump and reattach the blue drain hoses following the steps below. The unit will need to be serviced by an authorized Mercury MerCruiser dealer.
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Page 93: Draining The Sterndrive
Section 5 - Storage 14. If water is draining from the blue drain hose, continue with Step 4 of Single Point Drain System. Draining the Sterndrive NOTE: This procedure is needed only for salty, brackish, mineral‑laden, or polluted water applications; and for freezing temperatures or extended storage. - Page 94 Section 5 - Storage Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks. Inspect the steering system, shift and throttle control for proper operation. Page 86 90-8M0113856 DECEMBER 2015...
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Page 95: Section 6 - Troubleshooting
Section 6 - Troubleshooting Section 6 - Troubleshooting Table of Contents Troubleshooting Information and Charts Specifically for 3.0 Troubleshooting Charts for 3.0 MPI ECT and 3.0 TKS..90 MPI ECT................88 Excessive Engine Temperature........90 Diagnosing EFI Problems..........88 Insufficient Engine Temperature........91 Engine Guardian System.......... -
Page 96: Troubleshooting Information And Charts Specifically For 3.0 Mpi Ect
Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on electronic fuel injection (EFI) systems. The engine 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 97: 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 98: Engine Runs Rough, Misses, Or Backfires
See Engine Runs Rough, Misses, or Backfires. Engine overheating. See Excessive Engine Temperature. Running rich. Have authorized Mercury MerCruiser dealer check and repair. Troubleshooting Charts for 3.0 MPI ECT and 3.0 TKS Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed. -
Page 99: Insufficient Engine Temperature
Check all linkages. If any are loose or missing, see authorized Loose or missing shift and throttle linkages. Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury MerCruiser dealer Shift or throttle cable kinked. replace cable if damaged beyond repair. -
Page 100: Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move)
Section 6 - Troubleshooting Possible Cause Remedy Loose or dirty electrical Check all associated electrical connections and wires (especially battery cables). Clean and connections or damaged tighten faulty connection. Repair or replace wiring. wiring. Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low. -
Page 101: Section 7 - Customer Assistance Information
Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance............ 94 Contact Information for Mercury Marine Customer Local Repair Service ............ 94 Service ................. 95 Service Away From Home ..........94 Customer Service Literature..........95 Stolen Power Package .......... -
Page 102: 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 103: 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 104: Other Languages
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. A list of part numbers for other languages is provided with your power package. -
Page 105: Section 8 - Checklists
Section 8 - Checklists Section 8 - Checklists Table of Contents Predelivery Inspection (PDI)..........98 Customer Delivery Inspection (CDI)........99 90-8M0113856 DECEMBER 2015 Page 97... -
Page 106: Predelivery Inspection (Pdi)
Section 8 - 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 107: 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 108 Section 8 - 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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Page 109: Section 9 - Maintenance Log
Section 9 - Maintenance Log Section 9 - Maintenance Log Table of Contents Scheduled Maintenance Log..........102 Vessel Maintenance Notes..........103 90-8M0113856 DECEMBER 2015 Page 101... -
Page 110: 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 111: 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 90-8M0113856 DECEMBER 2015 Page 103... - Page 113 Parc Industriel de Petit-Rechain 41-71 Bessemer Drive P.O. Box 1939 B-4800 Verviers, Belgium Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA © Mercury Marine. All rights reserved. 90-8M0113856 NOVEMBER 2015 Printed in U.S.A.