Mercury MerCruiser Horizon 8.2 ECT Manual
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Mercury MerCruiser Horizon 8.2 ECT Manual

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

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  • 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 MerCruisers’ instructions complies with the requirements of the following directives by meeting the associated standards, as amended:...
  • Page 2 The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation.
  • 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 WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used. WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

  • Page 5: Table Of Contents

    Duration of Coverage........... 11 Mercury Installation Quality Certification Program..... 3 How to Obtain Warranty Coverage....... 12 Mercury Product Protection Plan: United States and Canada... 4 What Mercury Will Do........... 12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled What Is Not Covered............ 12 Products Only) ................
  • Page 6 Elevation and Climate............. 41 After Break‑In Period............42 Getting Started............... 42 End of First Season Checkup.......... 42 20‑Hour Break‑In Period..........42 Section 4 - Specifications Cruising RPM................. 44 Engine Specifications............. 45 Fuel Requirements..............44 Horizon 8.2 ECT and 8.2 H.O. ECT........ 45 Fuel Ratings..............
  • Page 7 Makes Unusual Sounds............ 78 Section 8 - Customer Assistance Information Owner Service Assistance............80 Resolving a Problem............80 Local Repair Service............80 Contact Information for Mercury Marine Customer Service Service Away From Home..........80 ................... 81 Stolen Power Package............80 Ordering Literature..............81 Attention Required After Submersion.........
  • Page 8 Page iv 90-8M0061999 MAY 2012...
  • Page 9 Duration of Coverage ..........11 Mercury Installation Quality Certification Program....3 How to Obtain Warranty Coverage ....... 12 Mercury Product Protection Plan: United States and Canada What Mercury Will Do ..........12 ....................4 What Is Not Covered ..........12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled...

  • Page 10: Warranty Registration: United States And Canada

    Federal Boat Safety Act is required. You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax to Mercury MerCruiser’s warranty registration department with your name, old address, new address, and engine serial number.

  • Page 11: Mercury Installation Quality Certification Program

    Mississauga, Canada, L5N 7W6 Fax 1-800-663-8334 Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the distributor closest to you.

  • Page 12: Mercury Product Protection Plan: United States And Canada

    Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only) Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only) What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. Duration of Coverage Warranty Period for Recreational Use The warranty period begins on the date the product is first sold to a recreational‑use retail purchaser or the date on which...
  • Page 13 Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine.

  • Page 14: 3-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 (see the Operation, Maintenance &...
  • Page 15 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 Mercury Marine specified predelivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 16: Global Application Warranty Charts

    Section 1 - Warranty Global Application Warranty Charts Warranty for Consumer Applications Standard Factory Limited Warranty by Consumer Certification Status of Boat Manufacturer Engine Model Region Limited Corrosion Installation Quality Warranty Not Certified Certified 1 year 2 years 3 years The Americas (excluding Brazil) 2 years 2 years...

  • Page 17: Warranty For Government Applications

    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 before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.
  • Page 18 Section 1 - Warranty ECI Label Standard of Compliance EMISSION CONTROL INFORMATION NOT FOR SALE IN CALIFORNIA THIS MARINE ENGINE COMPLIES WITH U.S. EPA EXHAUST REGULATIONS FOR 2009 Indicates a marine engine compliant with United States EPA REFER TO THE OWNER'S MANUAL FOR MAINTENANCE exhaust emission regulations for 2009.

  • Page 19: Owner Responsibility

    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 20: How To Obtain Warranty Coverage

    What Mercury Will Do Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our expense and at our option, repairing or replacing defective parts with new or Mercury Marine certified re‑manufactured parts, or refunding the purchase price of the Mercury product.

  • Page 21: Manufacturer's Warranty Coverage

    Mercury Marine recommends that you retain all receipts covering maintenance on your inboard or sterndrive engine, but Mercury Marine cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

  • Page 22: Emission Certification Star Label

    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 23: Hang Tag

    Section 1 - Warranty 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. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
  • Page 24 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 16 90-8M0061999 MAY 2012...

  • Page 25: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification................. 18 Dual‑Handle Console Control With CAN Trackpad: Information Decal............18 Features and Operation..........24 Smartphone Link............18 Synchronizing Engines..........25 Serial Number Decal Strips...........

  • Page 26: Identification

    Section 2 - Getting to Know Your Power Package Identification Serial numbers are the manufacture's key to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify the engine model and serial number. Information Decal The information decal is located on the top of the engine coolant reservoir.

  • Page 27: Lanyard Stop Switch

    Section 2 - Getting to Know Your Power Package • Operation, Maintenance, and Warranty Manual identification page. Information decal Serial number decal (applied to the information decal) 50422 The engine serial number is also stamped into a plaque located on the engine block. Flywheel housing cover Engine serial number stamp Engine block...

  • Page 28: Instrumentation

    650–1200 Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure (requires a SmartCraft oil pressure sender kit), battery voltage, fuel consumption, and engine operating hours.

  • Page 29: Analog Gauges

    Section 2 - Getting to Know Your Power Package SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a constant speed with an engine speed between the specified RPM range. SmartCraft gauges Tachometer Speedometer LCD system view display 26238 The SmartCraft instrument package also aids in Engine Guardian diagnostics.

  • Page 30: Remote Controls

    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 31: Console Mount Features - Single Engine

    Section 2 - Getting to Know Your Power Package Console Mount Features ‑ Single Engine 17359 Control handle Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle ‑ 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.

  • Page 32: Dual Console Control With Can Trackpad Features And Operation

    Section 2 - Getting to Know Your Power Package Control Handle ‑ 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. Continue pushing forward to increase speed.

  • Page 33: Synchronizing Engines

    Section 2 - Getting to Know Your Power Package Throttle only button ‑ Allows the boat operator to increase engine RPM for warm‑up, without shifting the engine into gear. To engage throttle only, move the control handle into the neutral position. Press the throttle only button and move the control handle ahead to the forward detent.

  • Page 34: Helm Transfer

    Section 2 - Getting to Know Your Power Package To disengage the auto synchronization feature, press the "SYNC" button. NEUTRAL TROLL SYNC TRANSFER THROTTLE ONLY 22590 Helm Transfer WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear.
  • Page 35 Section 2 - Getting to Know Your Power Package NOTE: The circuit breaker is located at the starboard rear of the engine in the electrical center. 50370 Circuit breaker Red test button Yellow lever Finger A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.
  • Page 36 Section 2 - Getting to Know Your Power Package A 15‑amp accessory fuse protects the accessory circuits. This fuse is located on the rear of the engine. Fuse cover 15‑amp fuse Accessory harness 32206 The emissions control system is protected by a 5‑amp fuse located in the power harness. 5‑amp fuse Positive battery terminal (Harness lead with fuse) Negative battery terminal...

  • Page 37: Visual And Audio Warning Systems

    IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from damage. The Mercury MerCruiser power package may be equipped with an audio warning system. Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.

  • Page 38: Caution

    Severe IMPORTANT: Operators are advised to contact an authorized Mercury MerCruiser dealer if a severe fault is activated. If a severe state is detected, the audio warning system sounds for six seconds, turns off for six seconds, and sounds for six more seconds.
  • Page 39 Section 2 - Getting to Know Your Power Package Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage. Transmission Guardian monitors the clutch pack pressure in forward and reverse gears. If the transmission fluid pressure drops below a predetermined level, Transmission Guardian lowers the engine torque and speed to prevent clutch slippage.
  • Page 40 Section 2 - Getting to Know Your Power Package Notes: Page 32 90-8M0061999 MAY 2012...
  • Page 41 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions............ 34 High‑Speed and High‑Performance Operation..... 39 Carbon Monoxide Exposure..........35 Passenger Safety in Pontoon Boats and Deck Boats..39 Be Alert To Carbon Monoxide Poisoning ..... 35 Boats Having an Open Front Deck .......

  • Page 42: Safe Boating Suggestions

    Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.

  • Page 43: Carbon Monoxide Exposure

    Section 3 - On the Water • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed.

  • Page 44: 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 45: Starting And Stopping The Engine

    Section 3 - On the Water Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Close the drain system. Check the engine oil. Perform all other checks specified by your dealer and/or boat builder. Listen for Audio Warning Alarm to sound when the ignition switch is in the "ON"...

  • Page 46: Throttle Only 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 47: Protecting People In The Water

    For additional information, refer to Hi‑Performance Boat Operation booklet (90‑849250‑R03) 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 48: Wave And Wake Jumping

    Section 3 - 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 49: Conditions Affecting Operation

    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 50: Getting Started

    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 51 Section 4 - Specifications Section 4 - Specifications Table of Contents Cruising RPM............... 44 Engine Oil................45 Fuel Requirements............... 44 Engine Specifications............45 Fuel Ratings ..............44 Horizon 8.2 ECT and 8.2 H.O. ECT....... 45 Using Reformulated (Oxygenated) Gasoline (USA Only) Fluid Specifications...............

  • Page 52: Cruising Rpm

    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 53: Engine Oil

    Section 4 - 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 54: Fluid Specifications

    Seawater cooling system 20 L (21 US qt) Propylene glycol and purified water (winterization use only) Mercury Extended Life Antifreeze/Coolant or extended life Closed cooling system 17.4 L (18.4 US qt) ethylene glycol 5/100 antifreeze mixed 50/50 with purified water...
  • Page 55 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 48 Checking Coolant Level..........55 Dealer Responsibilities............48 ................55 Maintenance................. 48 Filling the Closed Cooling System......... 55 Do‑It‑Yourself Maintenance Suggestions......48 Draining................. 56 Inspection................49 Cleaning................. 56 Maintenance Schedule—Inboard Models......

  • Page 56: 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 57: 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 58: Maintenance Log

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

  • Page 59: Engine Oil

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

  • Page 60: Changing Oil And Filter

    Fluid Type Engine oil (with filter) 6.5 L (7 US qt) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 Check the oil level and replace the fill cap. Changing Oil and Filter Refer to Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage.

  • Page 61: Changing The Oil Filter

    Engine oil (with filter) 6.5 L (7 US qt) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 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 62: Checking While Engine Is Cold

    4.3 L (4.5 US qt) Dexron III Automatic Transmission Fluid 5.7 L (6 US qt) Changing Contact your authorized Mercury MerCruiser dealer. Closed Cooling System Coolant Requirement NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed.

  • Page 63: Checking Coolant Level

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Extended Life Antifreeze/ Closed cooling system 92-877770K1 Coolant Checking Coolant Level 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: Draining

    "FULL" mark, repeat the warm‑up/cool‑down cycle, and check the coolant level again. Maintain the coolant level in the reservoir at or near the "FULL" mark with the engine cold. Draining Contact your authorized Mercury MerCruiser dealer. Cleaning Contact your authorized Mercury MerCruiser dealer.

  • Page 65: Cleaning The Flame Arrester

    Section 5 - Maintenance Cleaning the Flame Arrester 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: Water-Separating Fuel Filter

    Inspect the PCV valve and replace if necessary. Install the PCV valve into the intake manifold. Ensure that the PCV valve is tightly seated into the intake manifold. We recommend the use of Mercury MerCruiser replacement parts. Water‑Separating Fuel Filter WARNING Fuel is flammable and explosive.

  • Page 67: Gen Iii Models

    Removal Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Disconnect the Cool Fuel Module harness from the engine wiring harness.

  • Page 68: Serpentine Drive Belt

    10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Serpentine Drive Belt...

  • Page 69: Replacing

    Section 5 - Maintenance 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. 21062 Replacing IMPORTANT: If reusing a belt, install it in the same direction of rotation as before. The belt tensioner operates within the limits of movement provided by the cast stops when the belt length and geometry are correct.

  • Page 70: Flushing The Seawater System-Inboard Models

    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. 50920 Deflection measurement point Description Deflection 13 mm (½ in.) Flushing the Seawater System—Inboard Models The Boat Out of the Water—Inboard Models IMPORTANT: Flushing the power package is most effective when performed with the boat out of the water.

  • Page 71: The Boat In The Water-Inboard Models

    Section 5 - Maintenance Operate the engine with the transmission in neutral for a minimum of 10 minutes. 10. For power packages operated in salty, brackish, mineral‑laden, or polluted water: Continue to operate the engine until the discharge water is clear. 11.
  • Page 72 Section 5 - Maintenance Notes: Page 64 90-8M0061999 MAY 2012...
  • Page 73 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........66 Boat in the Water ........... 68 Preparing Power Package for Storage......66 Boat Out of the Water ..........70 Engine and Fuel System Preparation ....66 Manual Drain System............

  • Page 74: Cold Weather Or Extended Storage

    Preparing Power Package for Storage Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount of Mercury/Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline. Follow instructions on the container. Check the antifreeze concentration. Refer to the Specifications section.

  • Page 75: 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 seawater section of the cooling system for freezing temperatures or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.

  • Page 76: Drain System Identification

    Section 6 - Storage Drain System Identification Air-Actuated Single-Point Drain System Manual pressure release valve Threaded cap for air connection Green indicators 43070 Starboard side air‑actuated drain location Port side air‑actuated drain location 50411 Manual Drain System Starboard side blue drain plugs Port side blue drain plug...
  • Page 77 12. Remove the air pump from the air connection and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

  • Page 78: Boat Out Of The Water

    Section 6 - Storage 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Manual release valve pull ring Threaded cap on air connection Green indicators 43558 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine. Boat Out of the Water NOTE: This procedure is written for the air pump that is attached to the engine.

  • Page 79: Manual Drain System

    11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

  • Page 80: Boat Out Of The Water

    Verify that water is draining from each opening. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.

  • Page 81: Battery Storage

    Section 6 - Storage Place the O‑ring on the drain plug and apply Perfect Seal to the threads. Install the drain plug in the module drain hole. Tighten the drain plug to finger‑tight. Gen 3 Cool Fuel Module Drain plug O‑ring 50410 Tube Ref No.
  • Page 82 Section 6 - Storage Notes: Page 74 90-8M0061999 MAY 2012...

  • Page 83: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems............. 76 Poor Performance............77 Diagnosing DTS Problems........... 76 Excessive Engine Temperature........77 Engine Guardian System............76 Insufficient Engine Temperature........77 Troubleshooting Charts............76 Low Engine Oil Pressure..........78 Starter Motor Will Not Crank Engine, or Cranks Slowly Battery Will Not Recharge..........

  • Page 84: 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 Electronic 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/PCM's memory.

  • Page 85: Engine Runs Rough, Misses, Or Backfires

    Clean 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 Possible Cause Remedy Throttle not fully open.

  • Page 86: Low Engine Oil Pressure

    Check all throttle linkages. If any are loose or missing, see Loose or missing shift and throttle linkages. authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury MerCruiser dealer Shift or throttle cable kinked. replace cable if damaged beyond repair.
  • Page 87 Table of Contents Owner Service Assistance............ 80 Resolving a Problem ............ 80 Local Repair Service ............ 80 Contact Information for Mercury Marine Customer Service Away From Home ..........80 Service ................. 81 Stolen Power Package ..........80 Ordering Literature............... 81 Attention Required After Submersion ......

  • Page 88: Owner Service Assistance

    If your power package is stolen, immediately advise 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 89: Contact Information For Mercury Marine Customer Service

    • Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact us at: Mercury Marine Publications P.O. Box 1939...

  • Page 90: Outside The United States And Canada

    Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature. Print or type your mailing address, which be used as your shipping label, and include your order and payment. Mail to:...

  • Page 91: Section 9 - Checklists

    Section 9 - Checklists Section 9 - Checklists Table of Contents Predelivery Inspection (PDI)..........84 Customer Delivery Inspection (CDI)........85 90-8M0061999 MAY 2012 Page 83...

  • Page 92: 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 93: Customer Delivery Inspection (Cdi)

    ⃞ 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 94 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: ⃞...

This manual is also suitable for:

Mercruiser 8.2 h.o. ect

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