Mercury MerCruiser 6.2 Inboard MPI DTS 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

5.7 Horizon

5.7 MPI ECT

5.7 Horizon ECT

6.2 MPI

6.2 Horizon

6.2 MPI ECT

6.2 Horizon ECT

6.2 MPI (300, 350)

6.2 MPI ECT (300, 350)

6.2 TowSport MPI (320, 370)

6.2 TowSport MPI ECT (320, 370) 2A000000

5.7 TowSport MPI

Scorpion 350

Scorpion 377

5.7 TowSport MPI ECT

Scorpion 350 ECT

Scorpion 377 ECT

8.2 Horizon

Post Code: 54936‑1939

Post Code: B‑4800

Post Code: 1322

Country: Norway

Fuel Type

☒ Petrol

Unique engine identification number: starting serial

number

2A000000

Country: USA

Country: Belgium

ID Number: 0575

☐ B+C

☐ B+D

☐ B+E

Combustion Cycle

☒ 4 stroke

EC Module H certificate number

RCD‑H‑1 R1

☐ B+F

☐ G ☒ H

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June 11, 2025

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Summary of Contents for Mercury MerCruiser 6.2 Inboard MPI DTS

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:...
Page 2 Directives. Name and function: Signature John Pfeifer President, Mercury Marine, Fond du Lac, WI, USA Date and place of issue: April 15, 2014 Fond du Lac, Wisconsin, USA Regulatory contact:...
Page 3 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 4 Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. 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, #1 On the...
Page 5: Table Of Contents
Outside the United States and Canada......3 Transfer of Warranty—Australia and New Zealand Mercury Installation Quality Certification Program....3 Policy................13 Mercury Product Protection Plan: United States and Global Warranty Charts............14 Canada................4 United States Warranty Chart—MerCruiser Gas and Mercury MerCruiser Warranty Coverage (Gasoline‑Fueled...
Page 6 Section 3 - On the Water Safe Boating Recommendations..........36 High‑Speed and High‑Performance Operation....... 40 Carbon Monoxide Exposure........... 37 Passenger Safety in Pontoon Boats and Deck Boats.... 41 Be Alert To Carbon Monoxide Poisoning......37 Boats Having an Open Front Deck........41 Stay Clear of Exhaust Areas..........
Page 7 Steering Wheel Jerks or Is Difficult to Turn...... 80 Poor Performance............. 79 Section 8 - Customer Assistance Information Owner Service Assistance............82 Contact Information for Mercury Marine Customer Service Local Repair Service............82 ................... 83 Service Away From Home..........82 Customer Service Literature............
Page 8 Page iv 90-8M0099741 JUNE 2015...
Page 9: Section 1 - Warranty
Outside the United States and Canada ....3 ..................13 Mercury Installation Quality Certification Program... 3 Global Warranty Charts............14 Mercury Product Protection Plan: United States and United States Warranty Chart—MerCruiser Gas and Canada................4 Diesel................14 Mercury MerCruiser Warranty Coverage Outside United States ...........
Page 10: Warranty Information
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: Outside The United States And Canada
Boatbuilders that successfully complete the program and meet all certification requirements earn Installation Quality System Certified Manufacturer status and receive an additional one (1) year of Mercury limited factory warranty coverage on all MerCruiser‑powered boats that are registered on and after the boatbuilder's certification date for all worldwide registrations.
Page 12: Mercury Product Protection Plan: United States And Canada
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the predelivery inspection process specified by Mercury Marine is completed and documented.
Page 13: Year Limited Warranty Against Corrosion
• Improper service • Use of an accessory or part that was not manufactured or sold by Mercury Marine and that damages the Mercury product • Jet pump impellers and liners • Operation with fuels, oils, or lubricants that are not suitable for use with the product. Refer to the Specifications section.
Page 14: Emission Control Warranty Information
Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
Page 15: Emission Control Information Label
A tamper‑resistant emission control information (ECI) label is affixed to the engine in a visible location at the time of manufacture by Mercury MerCruiser. Please note that the low emissions certification will not affect the fit, function, or performance of the engine. Boatbuilders and dealers may not remove the label or the part it is affixed to. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.
Page 16: U.s. Epa Emissions Limited 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 17: California Emissions Limited Warranty
California resident, to be free from defects in material or workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions identified below.
Page 18: California Emission Control Warranty Statement
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. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.
Page 19: Guarantees Under Australian Consumer Law
Section 1 - Warranty Guarantees Under Australian Consumer Law Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
Page 20: Conditions That Must Be Met To Obtain Warranty Coverage
A list of dealers and their contact details is available at http://www.mercurymarine.com.au/home.aspx. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine at the address shown above. Mercury Marine will then arrange for the inspection and any covered repair. This Limited Warranty will not cover the purchaser for all related transportation charges and travel time.
Page 21: Expense Of Claiming This Limited Warranty
There is no charge for this service. You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.
Page 22: Global Warranty Charts
3 years H.O. MerCruiser Inboard 5.7 ‑ 6.2 ‑ 8.2 3 years 4 years 3 years Horizon Mercury Diesel Not available at time of Sterndrive and 2 years 3 years printing Inboard Outside United States For product purchased outside of United States, contact the distributor in your country, or the authorized Marine Power Service Center closest to you.
Page 23: Australia And New Zealand Warranty Chart-Mercruiser Gas And Diesel
Contact the Marine Power Service Center closest to you MerCruiser TowSport 3 years 3 years Mercury Diesel Sterndrive 2 years 3 years and Inboard Outside Australia and New Zealand For product purchased outside of Australia and New Zealand, contact the distributor in your country, or the authorized Marine Power Service Center closest to you.
Page 24: Outside Europe And Cis
Beginning January 1, 2003, one Three‑Star or Four‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's sterndrive and inboard marine engine 2007 and later exhaust emission standards.
Page 25: 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 26 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 18 90-8M0099741 JUNE 2015...
Page 27: 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 Adaptive Speed Control (ASC)..........20 Operation ............... 25 Identification................. 20 Adjustment ............26 Engine Serial Number............ 20 Special Digital Throttle and Shift (DTS) Features..27 Transmissions..............
Page 28: Adaptive Speed Control (Asc)
Section 2 - 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 29: Transmissions
Section 2 - Getting to Know Your Power Package Transmissions ZF Marine Transmissions On the ZF Marine 63 series transmissions, the identification plate lists the gear ratio, serial number, and model. 58645 Model 63A shown, others similar 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 30: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition
Section 2 - 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 31: System Link Digital Instruments
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 32: Dts Slim Binnacle Single Handle Console Features And Operation
Section 2 - Getting to Know Your Power Package DTS Slim Binnacle Single Handle Console Features and Operation Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear.
Page 33: Special Digital Throttle And Shift (Dts) Features
Section 2 - Getting to Know Your Power Package Special Digital Throttle and Shift (DTS) Features The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. STOP/ START DOCK TRANSFER THROTTLE - ONLY 58648 Slim binnacle ERC Item Control Function...
Page 34: Adjustment
Section 2 - Getting to Know Your Power Package NOTE: In certain modes, the gear position is determined by the electronic shift control (ESC), not the position of the ERC levers. When using the joystick or while in Skyhook, the computer controls the shifting in and out of gears even though the handles are in neutral.
Page 35: Special Digital Throttle And Shift (Dts) Features
Section 2 - Getting to Know Your Power Package 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. 58650 Dual engine ERC Item Control...
Page 36: Dock
Section 2 - Getting to Know Your Power Package Dock Dock mode is available with joystick operation and remote control lever operation. Dock mode reduces throttle capacity to approximately 70% of normal joystick throttle demand, allowing finer control of engine power in close quarter situations. If more power is needed for vessel maneuvering when environmental conditions require more thrust, use the electronic remote control levers.
Page 37: Lever
Section 2 - Getting to Know Your Power Package 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 38: Transfer (Boats Equipped With Dual Helms)
Section 2 - 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 39 Section 2 - Getting to Know Your Power Package To access the circuit breaker and fuses, remove the outside engine cover. Pull the outside engine cover up to remove it from the four rubber mount grommets. 58358 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.
Page 40: Visual And Audio Warning Systems
Section 2 - 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 41: Testing The Obd-M Malfunction Indicator Lamp (Mil)
Section 2 - 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 42: Testing The Audio Warning System
Section 2 - 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 43 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Recommendations.......... 36 High‑Speed and High‑Performance Operation..... 40 Carbon Monoxide Exposure..........37 Passenger Safety in Pontoon Boats and Deck Boats..41 Be Alert To Carbon Monoxide Poisoning ..... 37 Boats Having an Open Front Deck .......
Page 44: 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 45: Carbon Monoxide Exposure
Section 3 - 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 46: 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 47: Starting And Stopping The Engine
Section 3 - On the Water Starting and Stopping the Engine 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. Provide a sufficient supply of water to the water inlets during operation.
Page 48: 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 49: Passenger Safety In Pontoon Boats And Deck Boats
Section 3 - On the Water Passenger Safety in Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.
Page 50: Impact With Underwater Hazards
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Page 51: Cavitation
Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After the Break‑In Period To help extend the life of your Mercury MerCruiser power package, follow these recommendations: •...
Page 52: 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 53 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 46 Engine Oil................46 Fuel Ratings ..............46 6.2 MPI Inboard Engine Specifications......... 47 Using Reformulated (Oxygenated) Gasoline (USA Only) Fluid Specifications............... 48 ..................46 Engine................48 Gasoline Containing Alcohol ........
Page 54: 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 MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol.
Page 55: Mpi Inboard Engine Specifications
Section 4 - 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 56: Fluid 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 57 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 50 Filling................57 Dealer Responsibilities............50 Changing ..............58 Maintenance................. 50 Flame Arrestor..............58 Do‑It‑Yourself Maintenance Suggestions......50 Fuel System Maintenance............ 59 Inspection................51 Fuel System..............59 Maintenance Schedule—Inboard Models......
Page 58: 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 59: Inspection
Check plug leads and electrical leads for damage. • Remove and inspect the propeller. If badly nicked, bent, or cracked, contact your authorized Mercury MerCruiser dealer. • Repair nicks and corrosion damage on power package exterior finish. Contact your authorized Mercury MerCruiser dealer.
Page 60: Engine Oil
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Touch up the paint on the power package. • Change the engine oil and filter. • If the condition of the spark plugs, spark plug wires was satisfactory at the initial inspection (as listed in Every 300 hours or 3 years), inspect the condition of these components every year and replace as necessary.
Page 61: Oil Level-Overfilled
Section 5 - Maintenance Remove the dipstick, wipe it clean, and install it fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent. Remove the dipstick. 58400 V-drive model shown 58402 In-line drive model shown Inspect the dipstick for the oil level reading. The oil should be between the ADD mark and the FULL or OK range mark on the dipstick.
Page 62: Engine Oil Drain Pump
Capacity Fluid Type Engine oil (with filter) 4.7 L (5 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Engine Oil Drain Pump Loosen the oil filter to vent the system. Remove the dipstick. Install the oil pump onto the dipstick tube.
Page 63: Changing The Oil Filter
Engine oil (with filter) 4.7 L (5 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Start the engine and operate for three minutes while checking for leaks. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water.
Page 64: Checking The Fluid Level When Hot
Install the dipstick and tighten the T‑handle securely. Do not overtighten. Checking the Fluid Level When Hot The process for checking the fluid level when hot is the same as checking the fluid level before operation. Changing Contact your authorized Mercury MerCruiser dealer. Transmission Filter Inspection/Replacement Engine Coolant Checking CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns.
Page 65: Filling
Heat exchanger cap The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. Install the cap onto the heat exchanger. IMPORTANT: When installing the cap, be sure to tighten it until it seats on the filler neck.
Page 66: Changing
Install the fill cap to the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. 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 67: Fuel System Maintenance
Section 5 - Maintenance Loosen the clamp securing the flame arrestor and remove the flame arrestor. Flame arrestor Clamp securing the flame arrestor 58395 Clean the flame arrestor with warm water and a mild detergent. Inspect the flame arrestor for holes, cracks, or deterioration. Replace if necessary. Allow the flame arrestor to air dry completely before use.
Page 68: Draining The Filter Housing
Section 5 - Maintenance Locate the water‑separating fuel filter on the starboard front side of the engine. 58365 Remove the red service cap. Place a rag or towel around the fuel filter housing to prevent the fuel from leaking or spraying. Use the fuel filter removal/installation tool or the shaft of a screwdriver between the lugs on the filter cover and turn the fuel filter cover counterclockwise to loosen it.
Page 69: Fuel Filter Inspection
Section 5 - Maintenance Tip the filter housing and remove the filter cover to drain the fluid into an approved container. Dispose of the fuel according to local regulations. 58367 Fuel Filter Inspection The fuel filter is an important component in the fuel delivery system and should be inspected for debris or degradation every 100 hours of operation.
Page 70: Serpentine Drive Belt
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 71: Checking
Section 5 - Maintenance Appearance Description Cause Solution The belt life has been severely limited and Improper belt installation is a should be replaced Improper install common cause of premature immediately. Ensure all The belt ribs begin separating failure. One of the outermost belt ribs of the replacement from the joined strands.
Page 72: Replacing
Section 5 - Maintenance • Fraying • Glazed surfaces • Proper tension Use moderate thumb pressure on the belt at the location with the longest distance between two pulleys. Description Deflection 13 mm (1/2 in.) NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are not acceptable.
Page 73: Flushing The Power Package-Models With A Flushing Attachment
Section 5 - Maintenance NOTE: Proper tension is a measurement of deflection with moderate thumb pressure on the belt at the location that has the longest distance between two pulleys. Description Deflection 13 mm (½ in.) Flushing the Power Package—Models with a Flushing Attachment NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications.
Page 74 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. Quick-connect fitting stored in the boat Quick‑connect fitting (water hose end)
Page 75 Section 5 - Maintenance 16. Insert the dust cover in the flush socket on the engine. Dust cover installed in the flush socket Dust cover Flush socket 18490 17. Remove the plugs from the water hose and connect to the fittings. Tighten the hose clamps securely. 18.
Page 76 Section 5 - Maintenance Notes: Page 68 90-8M0099741 JUNE 2015...
Page 77 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........70 Draining the Seawater System..........72 Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 70 Draining the Raw Water..........72 Fuel Containing Alcohol..........70 Air Actuated Single‑Point Drain System (Closed Cooling, Preparing Power Package for Storage—MPI Models..
Page 78: 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 79: 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 80: Towsport And Inboard Transmissions Extended Storage
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 81 Section 6 - Storage 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. Check to ensure water drains out of the distribution housing.
Page 82 Section 6 - Storage 10. There are power packages that require specific drain plugs removed because the engine angle is greater than the air actuated drain system allows for proper draining of the system. Remove the blue plugs shown in the following illustrations. 58423 Port side view 58765...
Page 83: Battery Storage
Section 6 - Storage 17. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Green indicators 6135 18. Open the seacock, if equipped, or unplug and connect the water inlet hose prior to operating the engine. 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 84 Section 6 - Storage Notes: Page 76 90-8M0099741 JUNE 2015...
Page 85 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems............. 78 Poor Performance............79 Diagnosing DTS Problems........... 78 Excessive Engine Temperature........79 Engine Guardian System............78 Insufficient Engine Temperature........79 Troubleshooting Charts............78 Low Engine Oil Pressure..........80 Starter Motor Will Not Crank Engine, or Cranks Slowly Battery Will Not Recharge..........
Page 86: 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 engine control module (ECM)/propulsion control module (PCM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM/PCMs memory.
Page 87: 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 88: Low Engine Oil Pressure
Steering Wheel Jerks or Is Difficult to Turn Possible Cause Remedy Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners if any are loose or missing, see authorized Loose or missing steering fasteners or parts. Mercury MerCruiser dealer immediately. Page 80 90-8M0099741 JUNE 2015...
Page 89 Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance............ 82 Contact Information for Mercury Marine Customer Local Repair Service ............ 82 Service ................. 83 Service Away From Home ..........82 Customer Service Literature..........83 Stolen Power Package ..........
Page 90: 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 91: 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 92: Other Languages
Section 8 - 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 93: Section 9 - Checklists
Section 9 - Checklists Section 9 - Checklists Table of Contents Predelivery Inspection (PDI)..........86 Customer Delivery Inspection (CDI)........87 90-8M0099741 JUNE 2015 Page 85...
Page 94: Predelivery Inspection (Pdi)
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 95: 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 96 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: ⃞...
Page 97: Section 10 - Maintenance Log
Section 10 - Maintenance Log Section 10 - Maintenance Log Table of Contents Scheduled Maintenance Log..........90 Vessel Maintenance Notes........... 91 90-8M0099741 JUNE 2015 Page 89...
Page 98: Scheduled Maintenance Log
Section 10 - 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 99: Vessel Maintenance Notes
Section 10 - 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 90-8M0099741 JUNE 2015 Page 91...

Mercury MerCruiser 6.2 Inboard MPI DTS Manual

Section 5 - Maintenance

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