Mercury 1.7 MI Manual

Diesel engine inboard models

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Page 1 INDEX...
Page 2 2003, Mercury Marine. The following are trademarks / service marks of Brunswick  Corporation: Alpha, Bravo, Flo-Torq, Merc, MerCathode, Mercury, Mercury Marine, Mercury MerCruiser, Mercury Precision Parts, Mercury Propellers, Mercury Product Protection, Quicksilver, RideGuide, SmartCraft and Zero Effort.
Page 3 INDEX CE459 WELCOME! You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.
Page 4 INDEX CD749 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARNINGS and CAUTIONS, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.
Page 5: Table Of Contents
Gear) Inside The Boat ....Operation Chart - 1.7 MI ....
Page 6 INDEX SECTION 4 - SPECIFICATIONS Fuel Requirements ..... Engine Oil ......Recommended Fuels .
Page 7 INDEX SECTION 6 - STORAGE Draining Instructions ....Cold Weather Or Extended Storage ..Preparing Your Power Package For Battery .
Page 8 INDEX NOTES: Page iv CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 9 INDEX SECTION 1 WARRANTY SECTION 1 - WARRANTY Table of Contents Warranty Information ....Warranty Policies ..... . . Owner Warranty Registration .
Page 10: Warranty Information
• You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax with you name, old address, new address, and engine serial number to Mercury MerCruiser’s warranty registration department.
Page 11: International Owner Registration
INDEX SECTION 1 WARRANTY International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.
Page 12: Warranty Policies
Cummins MerCruiser Diesel’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified re-manufactured parts, or refunding the purchase price of the Cummins MerCruiser Diesel product.
Page 13 INDEX SECTION 1 WARRANTY HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Cummins MerCruiser Diesel with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Cummins MerCruiser Diesel dealer / distributor authorized to service the product.
Page 14: Warranty Coverage And Exclusion
INDEX WARRANTY SECTION 1 CE552 Warranty Coverage and Exclusion Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes that affect the product are not covered. Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us.
Page 15 INDEX SECTION 1 WARRANTY • Use of other than Quicksilver replacement parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer’s • responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.
Page 16: Transferable Warranty
Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership. In the United States and Canada, mail to: Mercury Marine Attn: Warranty Registration Department W6250 Pioneer Road P.O.
Page 17 INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 - GETTING TO KNOW YOUR POWER PACKAGE Table of Contents Features And Controls ....Console Mounted .
Page 18: Section 2 - Getting To Know Your Power Package
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 0010 Features And Controls 0011 Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator’s position (as in accidental ejection from the operator’s position). 74608 Stop switch Lanyard...
Page 19 INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down.
Page 20: Instrumentation
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE CE478 Instrumentation INSTRUMENTS The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions on the boat. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings that will appear on your style gauges.
Page 21 INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE SWITCHES 77725 Typical switches Key switch Engine stop switch - push button Panel lights / audio test switch Key Switch - has 3 positions. 1. OFF - In the OFF position, all electrical circuits are off and engine cannot be started. If the engine is operating the key switch cannot be used to stop the engine.
Page 22 INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE CE479 ENGINE MONITORING FEATURES 77725 Charge indicator lamp Oil pressure warning lamp Preheat indicator lamp (not active on some late models equipped with a wait to start glow plug system) Coolant temperature warning lamp Water in fuel warning lamp The lamps function as follows, unless stated otherwise: Charge Indicator Lamp - indicates a problem with charging system if lamp illuminates...
Page 23: Remote Controls
GETTING TO KNOW YOUR POWER PACKAGE 0014 Remote Controls Your boat may be equipped with a 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 24: Console Mounted
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 0242.01 CONSOLE MOUNTED 79770 79769 Throttle only button Control handles Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position, and should only be used to assist in starting the engine.
Page 25: Electrical System Overload Protection
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE CE477 Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replacing the fuse or resetting the circuit breaker. NOTE: In an emergency, when the engine must be operated and the cause for the high current draw cannot be located and corrected, turn OFF or disconnect all accessories connected to the engine and instrumentation wiring.
Page 26: Audio Warning System
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE CE480 Audio Warning System Your Cummins MerCruiser Diesel power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine or transmission from damage. It is designed to warn the operator that a problem has occurred. The audio warning system will sound with a continuous alarm if one of the following occurs: •...
Page 27: Section 3 - On The Water
Gear) Inside The Boat ....Operation Chart - 1.7 MI ....
Page 28: Safe Boating Suggestions
INDEX ON THE WATER SECTION 3 CE554 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and also consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Cummins MerCruiser Diesel strongly recommends that all powerboat operators complete a boating safety course.
Page 29 INDEX ON THE WATER SECTION 3 • Watch for signs of weather change and avoid foul weather and rough-sea boating. Tell someone where you are going and when you expect to return. • • Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat.
Page 30: Be Alert To Carbon Monoxide Poisoning
INDEX ON THE WATER SECTION 3 • Know your boating area and avoid hazardous locations. 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.
Page 31: Good Ventilation
INDEX ON THE WATER SECTION 3 0024.01 GOOD VENTILATION Ventilate the passenger area by opening the side curtains or forward hatches to remove fumes. mc79553 Courtesy of ABYC Example of desired air flow through the boat 0025.01 POOR VENTILATION Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.
Page 32: Basic Boat Operation
INDEX ON THE WATER SECTION 3 0026 Basic Boat Operation 0027.1 Launching And Boat Operation Care CAUTION To avoid possible ingestion of water that can damage engine components: • Do not turn the ignition key off when the engine is above idle speed. w When launching your boat from a steep ramp, enter the water slowly.
Page 33 INDEX ON THE WATER SECTION 3 CE465 Duty Cycle Rating IMPORTANT: Damage caused by improper application or failure to operate the power package within the specified operating parameters, will not be covered by the Cummins MerCruiser Diesel Limited Warranty. It is the responsibility of the boat manufacturer and/or the installing dealer to ensure that the power package is properly applied.
Page 34: Operation Chart - 1.7 Mi
INDEX ON THE WATER SECTION 3 CE485 Operation Chart 1.7 MI STARTING AFTER WHILE STOPPING AND PROCEDURE STARTING UNDERWAY SHUT DOWN Frequently observe all Observe all gauges and gauges and indicator Shift remote control lever Open engine hatch. Air warning lights to check lights to monitor engine to neutral position.
Page 35: Starting, Shifting And Stopping
INDEX ON THE WATER SECTION 3 CE525 Starting, Shifting and Stopping WARNING Do not use volatile starting aids, such as ether, propane, or gasoline in the engine air intake system. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage.
Page 36 INDEX ON THE WATER SECTION 3 CE481 STARTING COLD ENGINE IMPORTANT: Check fluid levels before starting engine. Refer to Maintenance Schedule. 1. Turn on and operate the engine compartment bilge blower (if equipped) for five minutes. Or, open engine hatch to air out bilge before attempting to start engine. 2.
Page 37 INDEX ON THE WATER SECTION 3 CE482 ENGINE WARM UP CAUTION Improper or no warm-up of engine can seriously impair the life of your diesel engine. 1. After starting, ensure all instrumentation is functioning properly. Operate the engine at a fast idle (1000 to 1200 rpm) until engine temperature is within normal operating range. It is very important that any engine be warmed up before applying full load.
Page 38: Engine Shutdown (Stopping)
INDEX ON THE WATER SECTION 3 CE483 SHIFTING CAUTION Never attempt to shift the transmission unless the engine is at IDLE rpm. Damage to the transmission could occur. 1. To shift unit, ensure remote control/throttle lever is in NEUTRAL. Move control/shift lever forward to shift to FORWARD gear, or backward to shift to REVERSE.
Page 39 INDEX ON THE WATER SECTION 3 CE468 Freezing Temperature And Cold Weather Operation IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to prevent freezing damage to power package. Damage caused by freezing IS NOT covered by Cummins MerCruiser Diesel Limited Warranty. CAUTION Seawater (raw water) section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use, if the possibility of freezing...
Page 40 INDEX ON THE WATER SECTION 3 0032 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
Page 41 INDEX ON THE WATER SECTION 3 0131.02 Passenger Safety Message - Pontoon And Deck Boats WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and coming in contact with the boat hull or propeller. Stay back from the front end of the deck and remain seated while the boat is in motion.
Page 42 INDEX ON THE WATER SECTION 3 0034.01 Wave And Wake Jumping mc79675 WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to a boat hand hold.
Page 43 INDEX ON THE WATER SECTION 3 0035.02 Impact With Underwater Hazards mc79680 Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the underwater drive components, rudder or the boat bottom.
Page 44: Elevation And Climate
INDEX ON THE WATER SECTION 3 0036 Conditions Affecting Operation Weight Distribution (Passengers And Gear) Inside The Boat Shifting weight to rear (stern): Generally increases speed and engine rpm • • Causes bow to bounce in choppy water Increases danger of following wave splashing into the boat when coming off plane •...
Page 45: Propeller Selection
INDEX ON THE WATER SECTION 3 CE464 Propeller Selection CAUTION The installed propeller must allow the engine to run at the Rated Engine rpm at WOT to avoid engine damage. Using a propeller that causes the engine to operate below the Rated Engine rpm can cause piston and/or valve damage (even if the engine is not operated at WOT).
Page 46: Getting Started
INDEX ON THE WATER SECTION 3 0042 Getting Started CE555 Engine Break-In INITIAL BREAK-IN PROCEDURE It is especially important that the following procedure be used on new diesel engines. This break-in procedure allows the proper seating of the pistons and rings, which greatly reduces the likelihood of problems.
Page 47: After Break-In Period
INDEX ON THE WATER SECTION 3 CE475 After Break-In Period To help extend the life of your Cummins MerCruiser Diesel power package, the following recommendations should be considered; Ensure that propeller allows the engine to operate at the specified Rated Engine •...
Page 48 INDEX ON THE WATER SECTION 3 NOTES: Page 40 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 49 INDEX SPECIFICATIONS SECTION 4 SECTION 4 - SPECIFICATIONS Table of Contents Fuel Requirements ..... Engine Oil ......Recommended Fuels .
Page 50: Fuel Requirements
INDEX SPECIFICATIONS SECTION 4 CD164 Fuel Requirements WARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury.
Page 51: Recommended Fuels
INDEX SPECIFICATIONS SECTION 4 CD888 Recommended Fuels CAUTION Avoid fuel system damage. Use of fuels not recommended by Cummins MerCruiser Diesel may cause hard-starting and other various troubles such as premature wear of the injection pump plungers and injection nozzles resulting from the deposit of carbon residue and other contaminants.
Page 52: Antifreeze/Coolant
INDEX SPECIFICATIONS SECTION 4 CE528 AntiFreeze/Coolant CAUTION Alcohol or Methanol base antifreeze or plain water are not recommended for use in closed cooling section of cooling system at any time. Because diesel engines are high compression engines and related higher engine operating temperatures are created, the closed cooling system and engine, including related cooling passages must remain as clean as possible to provide adequate engine cooling.
Page 53: Engine Oil
Engine crankcase Engine crankcase Obtain Locally Obtain Locally Wintershall Multi-Rekord Veedol Turbostar Wintershall VIiva 1 These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W-40 oil. CMD-3967823 / 90-865237030 OCTOBER 2003 Page 45...
Page 54: Engine Specifications
INDEX SPECIFICATIONS SECTION 4 CE486 Engine Specifications Specification - Inboard Description Description 1.7 MI 4 Stroke, 4 Cylinder, Vertical In-Line, 4 Valves Per Cylinder, Engine type Dual Overhead Camshaft, Direct Injection, Turbocharged, Intercooled Displacement 1.686 cubic liters (103 cid) Engine weight (approximate)
Page 55: Fluid Specifications
(heat exchanger and fluid lines). Capacity All models liters Fluid type Part Number (U.S. qts) 6-1/2 Engine Oil (With Mercury Diesel Engine Oil 92-877695K1 Filter) (6-3/4) Closed Cooling 8-3/4 (9-1/4) Marine Engine Coolant 92-813054A2 System Seawater Cooling...
Page 56 INDEX SPECIFICATIONS SECTION 4 NOTES: Page 48 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 57 INDEX SECTION 5 MAINTENANCE SECTION 5 - MAINTENANCE Table of Contents Owner/Operator Responsibilities ..Replacing ......Dealer Responsibilities .
Page 58: Owner/Operator Responsibilities
INDEX SECTION 5 MAINTENANCE CE466 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 Cummins MerCruiser Diesel 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: Maintenance
Before attempting maintenance or repair procedures not covered in this manual, it is recommended that the appropriate Cummins MerCruiser Diesel or Mercury MerCruiser Service Manual be purchased and read thoroughly. IMPORTANT: NOTE: Maintenance points are color coded for ease of identification. See the decal on engine for identification.
Page 60: Do-It-Yourself Maintenance Suggestions
INDEX SECTION 5 MAINTENANCE CE473 Do-It-Yourself Maintenance Suggestions Present-day marine equipment, such as your Cummins MerCruiser Diesel power package, are highly technical pieces of machinery. Special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic. If you are one of those persons who likes to do-it-yourself, here are some suggestions for you.
Page 61: Maintenance Schedules
INDEX SECTION 5 MAINTENANCE CE490 Maintenance Schedules Routine Maintenance Each Each Every Weekly Start Months Check the engine oil level (interval can be extended based on experience). Check the coolant level. Check the transmission fluid level. If operating in salt, brackish or polluted waters, flush the cooling system after each use.
Page 62: Scheduled Maintenance
INDEX SECTION 5 MAINTENANCE Maintenance Schedules (Continued) Scheduled Maintenance Every Every After First hours or hours or Annually Annually hours Change the engine oil and filter. Retorque the exhaust riser clamp. Change the transmission fluid. Check the steering system and the remote control for loose, missing or damaged parts.
Page 63 INDEX SECTION 5 MAINTENANCE Maintenance Schedules (Continued) Scheduled Maintenance Every Every Every Every 1000 hours hours hours hours or 2 or 5 or 5 or 3 years years years years Replace the coolant. Check the electrical system for loose, damaged, or corroded fasteners. Inspect the timing belt and pulleys.
Page 64: Maintenance Record
INDEX SECTION 5 MAINTENANCE 0166 Maintenance Record Hour Meter Maintenance Date Serviced By Reading Performed Page 56 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 65: Engine Oil
INDEX SECTION 5 MAINTENANCE 0062 Engine Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities.
Page 66: Filling
Fluid type Part Number (U.S. qts) Engine Oil (With 6-1/2 Mercury Diesel Engine Oil 92-877695K1 Filter) (6-3/4) Always use the dipstick to determine the exact quantity of oil or fluid required. 3. Install the oil fill cap. Page 58...
Page 67: Changing
INDEX SECTION 5 MAINTENANCE CE469 Changing Refer to the Maintenance Schedules for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only recommended engine oil. Refer to Specifications.
Page 68 INDEX SECTION 5 MAINTENANCE 7. Use a filter wrench or appropriate socket to remove the cartridge type oil filter. 8. Discard the old filter element. Discard the old O-rings from the top piece. 79740 Filter element O-rings Top piece 9. Install the three O-rings. Apply a coat of engine oil to the O-rings. Install the element on the top piece.
Page 69 INDEX SECTION 5 MAINTENANCE 12. Remove oil fill cap and refill engine with new oil. Refer to specifications for quantity and grade of oil. 13. Add specified oil to bring level up to, but not over, maximum oil level mark - MAX - on dipstick.
Page 70: Transmission Fluid
INDEX SECTION 5 MAINTENANCE CE493 Transmission Fluid Checking 1. Remove the dipstick. IMPORTANT: When checking the fluid level, rest the dipstick on top of the threaded housing hole. Do not screw the dipstick into the threaded housing hole. 2. Check the fluid level as indicated on the dipstick with the dipstick resting on the top of the threaded hole.
Page 71: Filling
INDEX SECTION 5 MAINTENANCE CE463 Filling 1. If necessary, add specified automatic transmission fluid through the dipstick threaded hole to bring the level up to the MAXIMUM mark on the dipstick. IMPORTANT: Use only specified Automatic Transmission Fluid (ATF). Í Í Í Í Í Í 79465 Dipstick Threaded hole...
Page 72: Changing
INDEX SECTION 5 MAINTENANCE CE496 Changing 1. Clean the exterior of the transmission around the fluid filter assembly. 2. Use a 6 mm allen wrench and remove the fluid filter assembly by turning the assembly nut counterclockwise and pulling at the same time. 79799 Fluid filter assembly Assembly nut...
Page 73 INDEX SECTION 5 MAINTENANCE 5. Remove and discard the filter element and the O-rings. 6. Coat the new O-rings with transmission fluid. 7. Install the new O-rings and filter element. 50975 27662 Filter Element Cover O-rings CAUTION Transmission fluid filter assembly must be properly seated to avoid fluid foaming and/or loss of fluid resulting in decreased efficiency and/or damage to transmission.
Page 74: Lubrication
INDEX SECTION 5 MAINTENANCE CE474 Lubrication Shift Cable 1. Lubricate the pivot points and the guide contact surfaces. 71374 Typical Pivot points Guide contact surfaces Description Where Used Part Number Pivot points, guide contact Engine Oil Obtain Locally surfaces Throttle Cable 1.
Page 75: Engine Coolant
INDEX SECTION 5 MAINTENANCE CE524 Engine Coolant Checking CAUTION Allow the engine to cool before removing the pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. After the engine has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off.
Page 76 INDEX SECTION 5 MAINTENANCE 5. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle. 6. The coolant level should be between the ADD and FULL marks. 75301 Coolant recovery bottle 7. Add the specified coolant as necessary. Description Where Used Part Number...
Page 77: Filling
INDEX SECTION 5 MAINTENANCE Filling 1. If coolant is low in the heat exchanger, add specified coolant as necessary to bring the level up to the bottom of the fill neck. IMPORTANT: The pressure cap is correctly installed if it contacts locking tabs on the fill neck when tightened.
Page 78: Water Separating Fuel Filter
INDEX SECTION 5 MAINTENANCE CE494 Water Separating Fuel Filter WARNING Be careful when draining water separating fuel filter. Diesel fuel is flammable. Be sure ignition key is OFF. Do not allow fuel to contact any hot surfaces which may cause it to ignite. Do not allow sources of open flame in the area. Wipe up any spilled fuel immediately.
Page 79 INDEX SECTION 5 MAINTENANCE 3. Operate the priming pump up and down about 10 times until approximately 4 ml (2 fl oz) is drained or until fuel is clear in appearance. 77121 Priming pump 4. Close drain cap by turning clockwise. Tighten securely. 5.
Page 80: Replacing
INDEX SECTION 5 MAINTENANCE Replacing IMPORTANT: Element cannot be cleaned and reused. It must be replaced. 1. Remove water separating fuel filter and sealing ring from fuel filter bracket. 2. Remove the drain cap from the filter by turning it counterclockwise. Discard the used filter.
Page 81 INDEX SECTION 5 MAINTENANCE 4. Clean filter sealing surface on mounting bracket. 5. Coat sealing ring on new filter with clean motor oil. 77296 Typical mounting bracket and filter Filter sealing surface Sealing ring Description Where Used Part Number Engine oil Oil filter O-rings Obtain Locally 6.
Page 82: Filling
INDEX SECTION 5 MAINTENANCE Filling A plunger-type of hand pump/primer is located on the fuel filter bracket and is used to: Refill fuel filter when changing filter • • Refill fuel system if system was run dry • To prime the fuel system if engine has not been operated for a while. To operate the hand pump/primer, move the plunger (upper portion) up and down as needed.
Page 83: Fuel System
INDEX SECTION 5 MAINTENANCE CE530 Fuel System Priming Prime the engine if it has not been operated for a while or if the engine will not start. 1. Move the hand pump/primer plunger up and down several times. 77343 Fuel filter bracket Hand pump / primer 2.
Page 84: Purging Air
INDEX SECTION 5 MAINTENANCE Purging Air NOTE: Follow this procedure if fuel system was run dry or if part of fuel system was drained for a service function. 1. Fill the fuel filter. Refer to Filling. 2. Check filter and drain cap for fuel leaks. Ensure that bleed screw on fuel filter bracket is closed.
Page 85 INDEX SECTION 5 MAINTENANCE 6. Move plunger on hand pump/primer up and down repeatedly, until an air free stream of fuel flows from temporary hose. 77343 77761 Plunger Fuel from temporary hose 7. Remove temporary hose. Unplug and install boat fuel return hose on fitting. Securely tighten the hose clamp.
Page 86: Fuel Tank Cleaning And Flushing
INDEX SECTION 5 MAINTENANCE CE549 Fuel Tank Cleaning And Flushing IMPORTANT: Diesel fuel should not be left in tank during winter storage, as an accumulation of rust, sludge, and wax residue will form. Refer to boat manufacturer’s instructions and clean fuel tank at specified intervals. Unless specified otherwise, flush and clean diesel fuel tank every 1000 hours or 5 years, whichever occurs first.
Page 87 INDEX SECTION 5 MAINTENANCE 2. Inspect serpentine belt for proper tension and for the following: • Excessive wear • Cracks NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in direction of belt length) that join transverse cracks are NOT acceptable. •...
Page 88: Air Cleaner
INDEX SECTION 5 MAINTENANCE CE531 Air Cleaner The air cleaner is used to prevent the entry of rain water, seawater, and debris. There are no serviceable parts to the air cleaner. Cleaning 1. Remove any debris present at openings. 77132 Air cleaner Openings Checking...
Page 89: Corrosion Protection
INDEX SECTION 5 MAINTENANCE CE532 Corrosion Protection Whenever two or more dissimilar metals are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode.
Page 90: Inspection
INDEX SECTION 5 MAINTENANCE INSPECTION Inspection and replacement interval will vary depending on the condition of seawater and mode of engine operation. NOTE: Remove deposits from surface of anode before trying to determine amount of erosion. 1. Replace anode assembly when deteriorated 50%. •...
Page 91: Installation
INDEX SECTION 5 MAINTENANCE 3. Apply sealant to threads of new sacrificial anode and install into anode plug. Tighten securely. 71367 Plug Anode Description Where Used Part Number Loctite 567 PST Pipe Sealant Threads of anode plug 92-809822 INSTALLATION 1. Install new sealing washer. 2.
Page 92: Cleaning The Seawater Strainer, If Equipped
INDEX SECTION 5 MAINTENANCE CE551 Cleaning The Seawater Strainer, If Equipped 1. Visually inspect seawater strainer through glass top. CAUTION When cleaning seawater strainer, close seacock, if equipped. If boat is not equipped with a seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses.
Page 93: Flushing The Power Package
INDEX SECTION 5 MAINTENANCE CE533 Flushing The Power Package NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results. CAUTION Overheating from insufficient cooling water will cause engine and drive system damage.
Page 94 INDEX SECTION 5 MAINTENANCE 2. If flushing the engine with the boat out of the water: WARNING When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid possible injury, remove propeller. a. Remove the propeller. Refer to boat manufacturers’ instructions. b.
Page 95 INDEX SECTION 5 MAINTENANCE 4. Place the remote control in NEUTRAL, IDLE speed position and start the engine. CAUTION Do not run engine above 1500 rpm when flushing. Suction created by seawater pickup pump may collapse flushing hose, causing engine to overheat. 5.
Page 96: Seawater Pump Impeller
INDEX SECTION 5 MAINTENANCE CE495 Seawater Pump Impeller This maintenance should be performed by an authorized Cummins MerCruiser Diesel dealer / distributor. 1. Seawater pump impeller and impeller splines should be inspected for wear or damage at scheduled maintenance interval or whenever insufficient seawater flow is suspected (if operating temperature exceeds normal range).
Page 97: Miscellaneous Maintenance
INDEX SECTION 5 MAINTENANCE CA103 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use. Recharge every 30 to 45 days. or when specific gravity drops below battery manufacturer’s specifications. Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.
Page 98 INDEX SECTION 5 MAINTENANCE NOTES: Page 90 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 99 INDEX SECTION 6 STORAGE SECTION 6 - STORAGE Table of Contents Cold Weather Or Extended Storage ..Draining Instructions ....Preparing Your Power Package For Battery .
Page 100: Cold Weather Or Extended Storage
Cold Weather Or Extended Storage IMPORTANT: Cummins MerCruiser Diesel strongly recommends that this service should be performed by an authorized Cummins MerCruiser Diesel dealer / distributor. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. CAUTION...
Page 101: Storage
INDEX SECTION 6 STORAGE CE500 Draining Instructions CAUTION Ensure that the boat is out of the water or seacock is closed and bilge pump is operating before beginning procedure. Excess water in bilge can damage engine or cause boat to sink. CAUTION Do not operate engine with drain system open.
Page 102 INDEX STORAGE SECTION 6 5. Remove the drain plug from the lower part of the intercooler. 79115 Drain plug 6. Remove the drain plug, or the propeller shaft log seal (stuffing box) cooling hose if equipped, from the transmission fluid cooler. 79109 Drain plug, or cooling hose (not shown) Transmission fluid cooler...
Page 103 INDEX SECTION 6 STORAGE 9. Remove the seawater pump impeller for extended storage. a. Remove the seawater pump cover mounting screws. b. Remove the seawater pump cover and gasket. IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight.
Page 104: Battery
INDEX STORAGE SECTION 6 10. For additional assurance against freezing and corrosion fill the seawater cooling system with a mixture of propylene glycol antifreeze and tap water. a. Fill a container with approximately 5.6 liter (6 U.S. quarts) of propylene glycol antifreeze and tap water mixed to manufacturer’s recommendation to protect engine to the lowest temperature to which it will be exposed during the cold weather or extended storage.
Page 105: Power Package Recommissioning
INDEX SECTION 6 STORAGE CE502 Power Package Recommissioning NOTICE Refer to Cold Weather Or Extended Storage precautions, BEFORE proceeding. 1. Install the seawater pump impeller after ensuring that the splines are not worn and inspecting it for worn or damaged vanes. a.
Page 106 INDEX STORAGE SECTION 6 5. Perform all lubrication and maintenance specified for completion Annually in Section 5 - Maintenance Schedule, except items that were performed at time of engine layup. 6. Fill fuel tanks with fresh diesel fuel. Old fuel should not be used. Check fuel lines and connections for leaks and general condition.
Page 107 INDEX SECTION 6 STORAGE 10. Perform all checks on the Operation Chart in the Starting Procedure column. Refer to Section 3. CAUTION Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet openings during operation.
Page 108 INDEX STORAGE SECTION 6 NOTES: Page 100 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 109 INDEX TROUBLESHOOTING SECTION 7 SECTION 7 - TROUBLESHOOTING Table of Contents Troubleshooting Charts ....Insufficient Engine Temperature ..Starter Motor Will Not Crank Engine, Or Turbocharger - Noisy Or Rough Cranks Slow .
Page 110: Section 7 - Troubleshooting
INDEX TROUBLESHOOTING SECTION 7 0103 Troubleshooting Charts Starter Motor Will Not Crank Engine, Or Cranks Slow Possible Cause Remedy Battery switch turned off. Turn switch on. Remote control not in neutral position. Position control lever in neutral. Check and reset circuit breaker or replace Open circuit breaker or blown fuse.
Page 111: Engine Runs Rough, Misses And/Or Backfires
INDEX TROUBLESHOOTING SECTION 7 CE535 Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Idle speed too low. Check idle speed and adjust, if necessary. Clogged fuel or air filters. Replace filters. If contaminated, drain tank. Fill with fresh Stale or contaminated fuel. fuel.
Page 112: Poor Performance
INDEX TROUBLESHOOTING SECTION 7 CE536 Poor Performance Possible Cause Remedy Inspect throttle cable and linkages for Throttle not fully open operation. Damaged or improper propeller Replace. Excessive bilge water Drain and check for cause of entry. Boat overloaded or load improperly Reduce load or redistribute load more distributed evenly.
Page 113: Excessive Engine Temperature
INDEX TROUBLESHOOTING SECTION 7 CE537 Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed. Open. Position hose to prevent kinking Seawater inlet hose kinked (restricted) (restriction). Use of improperly designed hose on inlet side of seawater pump allowing it to Replace hose with wire reinforced design.
Page 114: Turbocharger - Noisy Or Rough Operation
INDEX TROUBLESHOOTING SECTION 7 CE539 Turbocharger - Noisy Or Rough Operation Possible Cause Remedy Poor lubrication / low oil pressure at turbocharger. Entry of foreign materials from intake or Have inspected by an authorized exhaust side. Cummins MerCruiser Diesel dealer / Cummins MerCruiser Diesel dealer / distributor.
Page 115: Battery Will Not Charge
INDEX TROUBLESHOOTING SECTION 7 CE542 Battery Will Not Charge Possible Cause Remedy Excessive current draw from battery. Turn off non-essential accessories. Check all associated electrical connections and wires (especially battery Loose or dirty electrical connections or cables). Clean and tighten faulty damaged wiring.
Page 116 INDEX TROUBLESHOOTING SECTION 7 NOTES: Page 108 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 117 INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 SECTION 8 - CUSTOMER ASSISTANCE INFORMATION Table of Contents Owner Service Assistance ... . . Muut kielet ......Local Repair Service .
Page 118: Owner Service Assistance
INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 CE553 Owner Service Assistance Local Repair Service Always return your Cummins MerCruiser Diesel powered boat to your authorized dealer / distributor should the need for service arise. Only the dealer / distributor has the factory trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur.
Page 119: Replacement Service Parts
INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 CE472 Replacement Service Parts WARNING Electrical, ignition and fuel system components on Cummins MerCruiser Diesel en- gines and drive systems are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided.
Page 120: Resolving A Problem
INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 CE545 Resolving A Problem Satisfaction with your Cummins MerCruiser Diesel product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your authorized Cummins MerCruiser Diesel dealer / distributor. If additional assistance is required, take these steps: 1.
Page 121: Customer Service Literature
Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 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 122: Andere Sprachen
Para obtener un Manual de operación y mantenimiento en otro idioma, póngase en contacto con el centro de servicio más cercano de Mercury Marine o Marine Power International para recibir información. Con su conjunto motriz se entrega una lista de los números de pieza para los otros idiomas.
Page 123: Ordering Literature
United States and Canada For information on additional literature that is available for your particular Cummins MerCruiser Diesel power package and how to order that literature contact your nearest Cummins MerCruiser Diesel dealer / distributor or contact: Mercury Marine Telephone Mail Mercury Marine...
Page 124 INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 NOTES: Page 116 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 125 INDEX...
Page 126 2003, Mercury Marine. The following are trademarks / service marks of Brunswick  Corporation: Alpha, Bravo, Flo-Torq, Merc, MerCathode, Mercury, Mercury Marine, Mercury MerCruiser, Mercury Precision Parts, Mercury Propellers, Mercury Product Protection, Quicksilver, RideGuide, SmartCraft and Zero Effort.
Page 127 INDEX CE459 WELCOME! You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.
Page 128 INDEX CD749 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARNINGS and CAUTIONS, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.
Page 129 Gear) Inside The Boat ....Operation Chart - 1.7 MI ....
Page 130 INDEX SECTION 4 - SPECIFICATIONS Fuel Requirements ..... Engine Oil ......Recommended Fuels .
Page 131 INDEX SECTION 6 - STORAGE Draining Instructions ....Cold Weather Or Extended Storage ..Preparing Your Power Package For Battery .
Page 132 INDEX NOTES: Page iv CMD-3967823 / 90–865237030 OCTOBER 2003...
Page 133 INDEX SECTION 1 WARRANTY SECTION 1 - WARRANTY Table of Contents Warranty Information ....Warranty Policies ..... . . Owner Warranty Registration .
Page 134: Warranty Information
• You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax with you name, old address, new address, and engine serial number to Mercury MerCruiser’s warranty registration department.
Page 135: International Owner Registration
INDEX SECTION 1 WARRANTY International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.
Page 136: Warranty Policies
Cummins MerCruiser Diesel’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified re-manufactured parts, or refunding the purchase price of the Cummins MerCruiser Diesel product.
Page 137 INDEX SECTION 1 WARRANTY HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Cummins MerCruiser Diesel with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Cummins MerCruiser Diesel dealer / distributor authorized to service the product.
Page 138: Warranty Coverage And Exclusion
INDEX WARRANTY SECTION 1 CE552 Warranty Coverage and Exclusion Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes that affect the product are not covered. Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us.
Page 139 INDEX SECTION 1 WARRANTY • Use of other than Quicksilver replacement parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer’s • responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.
Page 140: Transferable Warranty
Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership. In the United States and Canada, mail to: Mercury Marine Attn: Warranty Registration Department W6250 Pioneer Road P.O.
Page 141 INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 - GETTING TO KNOW YOUR POWER PACKAGE Table of Contents Features And Controls ....Console Mounted .
Page 142: Features And Controls
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 0010 Features And Controls 0011 Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator’s position (as in accidental ejection from the operator’s position). 74608 Stop switch Lanyard...
Page 143 INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down.
Page 144: Instrumentation
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE CE478 Instrumentation INSTRUMENTS The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions on the boat. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings that will appear on your style gauges.
Page 145 INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE SWITCHES 77725 Typical switches Key switch Engine stop switch - push button Panel lights / audio test switch Key Switch - has 3 positions. 1. OFF - In the OFF position, all electrical circuits are off and engine cannot be started. If the engine is operating the key switch cannot be used to stop the engine.
Page 146 INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE CE479 ENGINE MONITORING FEATURES 77725 Charge indicator lamp Oil pressure warning lamp Preheat indicator lamp (not active on some late models equipped with a wait to start glow plug system) Coolant temperature warning lamp Water in fuel warning lamp The lamps function as follows, unless stated otherwise: Charge Indicator Lamp - indicates a problem with charging system if lamp illuminates...
Page 147: Remote Controls
GETTING TO KNOW YOUR POWER PACKAGE 0014 Remote Controls Your boat may be equipped with a 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 148: Console Mounted
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 0242.01 CONSOLE MOUNTED 79770 79769 Throttle only button Control handles Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position, and should only be used to assist in starting the engine.
Page 149: Electrical System Overload Protection
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE CE477 Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replacing the fuse or resetting the circuit breaker. NOTE: In an emergency, when the engine must be operated and the cause for the high current draw cannot be located and corrected, turn OFF or disconnect all accessories connected to the engine and instrumentation wiring.
Page 150: Audio Warning System
INDEX SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE CE480 Audio Warning System Your Cummins MerCruiser Diesel power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine or transmission from damage. It is designed to warn the operator that a problem has occurred. The audio warning system will sound with a continuous alarm if one of the following occurs: •...
Page 151 Gear) Inside The Boat ....Operation Chart - 1.7 MI ....
Page 152: Safe Boating Suggestions
INDEX ON THE WATER SECTION 3 CE554 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and also consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Cummins MerCruiser Diesel strongly recommends that all powerboat operators complete a boating safety course.
Page 153 INDEX ON THE WATER SECTION 3 • Watch for signs of weather change and avoid foul weather and rough-sea boating. Tell someone where you are going and when you expect to return. • • Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat.
Page 154: Be Alert To Carbon Monoxide Poisoning
INDEX ON THE WATER SECTION 3 • Know your boating area and avoid hazardous locations. 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.
Page 155: Good Ventilation
INDEX ON THE WATER SECTION 3 0024.01 GOOD VENTILATION Ventilate the passenger area by opening the side curtains or forward hatches to remove fumes. mc79553 Courtesy of ABYC Example of desired air flow through the boat 0025.01 POOR VENTILATION Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.
Page 156: Basic Boat Operation
INDEX ON THE WATER SECTION 3 0026 Basic Boat Operation 0027.1 Launching And Boat Operation Care CAUTION To avoid possible ingestion of water that can damage engine components: • Do not turn the ignition key off when the engine is above idle speed. w When launching your boat from a steep ramp, enter the water slowly.
Page 157 INDEX ON THE WATER SECTION 3 CE465 Duty Cycle Rating IMPORTANT: Damage caused by improper application or failure to operate the power package within the specified operating parameters, will not be covered by the Cummins MerCruiser Diesel Limited Warranty. It is the responsibility of the boat manufacturer and/or the installing dealer to ensure that the power package is properly applied.
Page 158: Operation Chart - 1.7 Mi
INDEX ON THE WATER SECTION 3 CE485 Operation Chart 1.7 MI STARTING AFTER WHILE STOPPING AND PROCEDURE STARTING UNDERWAY SHUT DOWN Frequently observe all Observe all gauges and gauges and indicator Shift remote control lever Open engine hatch. Air warning lights to check lights to monitor engine to neutral position.
Page 159: Starting, Shifting And Stopping
INDEX ON THE WATER SECTION 3 CE525 Starting, Shifting and Stopping WARNING Do not use volatile starting aids, such as ether, propane, or gasoline in the engine air intake system. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage.
Page 160 INDEX ON THE WATER SECTION 3 CE481 STARTING COLD ENGINE IMPORTANT: Check fluid levels before starting engine. Refer to Maintenance Schedule. 1. Turn on and operate the engine compartment bilge blower (if equipped) for five minutes. Or, open engine hatch to air out bilge before attempting to start engine. 2.
Page 161 INDEX ON THE WATER SECTION 3 CE482 ENGINE WARM UP CAUTION Improper or no warm-up of engine can seriously impair the life of your diesel engine. 1. After starting, ensure all instrumentation is functioning properly. Operate the engine at a fast idle (1000 to 1200 rpm) until engine temperature is within normal operating range. It is very important that any engine be warmed up before applying full load.
Page 162: Engine Shutdown (Stopping)
INDEX ON THE WATER SECTION 3 CE483 SHIFTING CAUTION Never attempt to shift the transmission unless the engine is at IDLE rpm. Damage to the transmission could occur. 1. To shift unit, ensure remote control/throttle lever is in NEUTRAL. Move control/shift lever forward to shift to FORWARD gear, or backward to shift to REVERSE.
Page 163: Freezing Temperature And Cold Weather Operation
INDEX ON THE WATER SECTION 3 CE468 Freezing Temperature And Cold Weather Operation IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to prevent freezing damage to power package. Damage caused by freezing IS NOT covered by Cummins MerCruiser Diesel Limited Warranty. CAUTION Seawater (raw water) section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use, if the possibility of freezing...
Page 164: Protecting People In The Water
INDEX ON THE WATER SECTION 3 0032 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
Page 165: Passenger Safety Message - Pontoon And Deck Boats
INDEX ON THE WATER SECTION 3 0131.02 Passenger Safety Message - Pontoon And Deck Boats WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and coming in contact with the boat hull or propeller. Stay back from the front end of the deck and remain seated while the boat is in motion.
Page 166: Wave And Wake Jumping
INDEX ON THE WATER SECTION 3 0034.01 Wave And Wake Jumping mc79675 WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to a boat hand hold.
Page 167: Impact With Underwater Hazards
INDEX ON THE WATER SECTION 3 0035.02 Impact With Underwater Hazards mc79680 Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the underwater drive components, rudder or the boat bottom.
Page 168: Conditions Affecting Operation
INDEX ON THE WATER SECTION 3 0036 Conditions Affecting Operation Weight Distribution (Passengers And Gear) Inside The Boat Shifting weight to rear (stern): Generally increases speed and engine rpm • • Causes bow to bounce in choppy water Increases danger of following wave splashing into the boat when coming off plane •...
Page 169: Propeller Selection
INDEX ON THE WATER SECTION 3 CE464 Propeller Selection CAUTION The installed propeller must allow the engine to run at the Rated Engine rpm at WOT to avoid engine damage. Using a propeller that causes the engine to operate below the Rated Engine rpm can cause piston and/or valve damage (even if the engine is not operated at WOT).
Page 170: Getting Started
INDEX ON THE WATER SECTION 3 0042 Getting Started CE555 Engine Break-In INITIAL BREAK-IN PROCEDURE It is especially important that the following procedure be used on new diesel engines. This break-in procedure allows the proper seating of the pistons and rings, which greatly reduces the likelihood of problems.
Page 171: After Break-In Period
INDEX ON THE WATER SECTION 3 CE475 After Break-In Period To help extend the life of your Cummins MerCruiser Diesel power package, the following recommendations should be considered; Ensure that propeller allows the engine to operate at the specified Rated Engine •...
Page 172 INDEX ON THE WATER SECTION 3 NOTES: Page 40 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 173 INDEX SPECIFICATIONS SECTION 4 SECTION 4 - SPECIFICATIONS Table of Contents Fuel Requirements ..... Engine Oil ......Recommended Fuels .
Page 174: Fuel Requirements
INDEX SPECIFICATIONS SECTION 4 CD164 Fuel Requirements WARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury.
Page 175: Recommended Fuels
INDEX SPECIFICATIONS SECTION 4 CD888 Recommended Fuels CAUTION Avoid fuel system damage. Use of fuels not recommended by Cummins MerCruiser Diesel may cause hard-starting and other various troubles such as premature wear of the injection pump plungers and injection nozzles resulting from the deposit of carbon residue and other contaminants.
Page 176: Antifreeze/Coolant
INDEX SPECIFICATIONS SECTION 4 CE528 AntiFreeze/Coolant CAUTION Alcohol or Methanol base antifreeze or plain water are not recommended for use in closed cooling section of cooling system at any time. Because diesel engines are high compression engines and related higher engine operating temperatures are created, the closed cooling system and engine, including related cooling passages must remain as clean as possible to provide adequate engine cooling.
Page 177: Engine Oil
Engine crankcase Engine crankcase Obtain Locally Obtain Locally Wintershall Multi-Rekord Veedol Turbostar Wintershall VIiva 1 These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W-40 oil. CMD-3967823 / 90-865237030 OCTOBER 2003 Page 45...
Page 178: Engine Specifications
INDEX SPECIFICATIONS SECTION 4 CE486 Engine Specifications Specification - Inboard Description Description 1.7 MI 4 Stroke, 4 Cylinder, Vertical In-Line, 4 Valves Per Cylinder, Engine type Dual Overhead Camshaft, Direct Injection, Turbocharged, Intercooled Displacement 1.686 cubic liters (103 cid) Engine weight (approximate)
Page 179: Fluid Specifications
(heat exchanger and fluid lines). Capacity liters All models Fluid type Part Number (U.S. qts) 6-1/2 Engine Oil (With Mercury Diesel Engine Oil 92-877695K1 Filter) (6-3/4) Closed Cooling 8-3/4 (9-1/4) Marine Engine Coolant 92-813054A2 System Seawater Cooling...
Page 180 INDEX SPECIFICATIONS SECTION 4 NOTES: Page 48 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 181 INDEX SECTION 5 MAINTENANCE SECTION 5 - MAINTENANCE Table of Contents Owner/Operator Responsibilities ..Replacing ......Dealer Responsibilities .
Page 182: Owner/Operator Responsibilities
INDEX SECTION 5 MAINTENANCE CE466 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 Cummins MerCruiser Diesel 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 183: Maintenance
Before attempting maintenance or repair procedures not covered in this manual, it is recommended that the appropriate Cummins MerCruiser Diesel or Mercury MerCruiser Service Manual be purchased and read thoroughly. IMPORTANT: NOTE: Maintenance points are color coded for ease of identification. See the decal on engine for identification.
Page 184: Do-It-Yourself Maintenance Suggestions
INDEX SECTION 5 MAINTENANCE CE473 Do-It-Yourself Maintenance Suggestions Present-day marine equipment, such as your Cummins MerCruiser Diesel power package, are highly technical pieces of machinery. Special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic. If you are one of those persons who likes to do-it-yourself, here are some suggestions for you.
Page 185: Maintenance Schedules
INDEX SECTION 5 MAINTENANCE CE490 Maintenance Schedules Routine Maintenance Each Each Every Weekly Start Months Check the engine oil level (interval can be extended based on experience). Check the coolant level. Check the transmission fluid level. If operating in salt, brackish or polluted waters, flush the cooling system after each use.
Page 186: Scheduled Maintenance
INDEX SECTION 5 MAINTENANCE Maintenance Schedules (Continued) Scheduled Maintenance Every Every After First hours or hours or Annually Annually hours Change the engine oil and filter. Retorque the exhaust riser clamp. Change the transmission fluid. Check the steering system and the remote control for loose, missing or damaged parts.
Page 187 INDEX SECTION 5 MAINTENANCE Maintenance Schedules (Continued) Scheduled Maintenance Every Every Every Every 1000 hours hours hours hours or 2 or 5 or 5 or 3 years years years years Replace the coolant. Check the electrical system for loose, damaged, or corroded fasteners. Inspect the timing belt and pulleys.
Page 188: Maintenance Record
INDEX SECTION 5 MAINTENANCE 0166 Maintenance Record Hour Meter Maintenance Date Serviced By Reading Performed Page 56 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 189: Engine Oil
INDEX SECTION 5 MAINTENANCE 0062 Engine Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities.
Page 190: Filling
Fluid type Part Number (U.S. qts) 6-1/2 Engine Oil (With Mercury Diesel Engine Oil 92-877695K1 Filter) (6-3/4) Always use the dipstick to determine the exact quantity of oil or fluid required. 3. Install the oil fill cap. Page 58...
Page 191: Changing
INDEX SECTION 5 MAINTENANCE CE469 Changing Refer to the Maintenance Schedules for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only recommended engine oil. Refer to Specifications.
Page 192 INDEX SECTION 5 MAINTENANCE 7. Use a filter wrench or appropriate socket to remove the cartridge type oil filter. 8. Discard the old filter element. Discard the old O-rings from the top piece. 79740 Filter element O-rings Top piece 9. Install the three O-rings. Apply a coat of engine oil to the O-rings. Install the element on the top piece.
Page 193 INDEX SECTION 5 MAINTENANCE 12. Remove oil fill cap and refill engine with new oil. Refer to specifications for quantity and grade of oil. 13. Add specified oil to bring level up to, but not over, maximum oil level mark - MAX - on dipstick.
Page 194: Transmission Fluid
INDEX SECTION 5 MAINTENANCE CE493 Transmission Fluid Checking 1. Remove the dipstick. IMPORTANT: When checking the fluid level, rest the dipstick on top of the threaded housing hole. Do not screw the dipstick into the threaded housing hole. 2. Check the fluid level as indicated on the dipstick with the dipstick resting on the top of the threaded hole.
Page 195: Filling
INDEX SECTION 5 MAINTENANCE CE463 Filling 1. If necessary, add specified automatic transmission fluid through the dipstick threaded hole to bring the level up to the MAXIMUM mark on the dipstick. IMPORTANT: Use only specified Automatic Transmission Fluid (ATF). Í Í Í Í Í Í 79465 Dipstick Threaded hole...
Page 196: Changing
INDEX SECTION 5 MAINTENANCE CE496 Changing 1. Clean the exterior of the transmission around the fluid filter assembly. 2. Use a 6 mm allen wrench and remove the fluid filter assembly by turning the assembly nut counterclockwise and pulling at the same time. 79799 Fluid filter assembly Assembly nut...
Page 197 INDEX SECTION 5 MAINTENANCE 5. Remove and discard the filter element and the O-rings. 6. Coat the new O-rings with transmission fluid. 7. Install the new O-rings and filter element. 50975 27662 Filter Element Cover O-rings CAUTION Transmission fluid filter assembly must be properly seated to avoid fluid foaming and/or loss of fluid resulting in decreased efficiency and/or damage to transmission.
Page 198: Lubrication
INDEX SECTION 5 MAINTENANCE CE474 Lubrication Shift Cable 1. Lubricate the pivot points and the guide contact surfaces. 71374 Typical Pivot points Guide contact surfaces Description Where Used Part Number Pivot points, guide contact Engine Oil Obtain Locally surfaces Throttle Cable 1.
Page 199: Engine Coolant
INDEX SECTION 5 MAINTENANCE CE524 Engine Coolant Checking CAUTION Allow the engine to cool before removing the pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. After the engine has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off.
Page 200 INDEX SECTION 5 MAINTENANCE 5. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle. 6. The coolant level should be between the ADD and FULL marks. 75301 Coolant recovery bottle 7. Add the specified coolant as necessary. Description Where Used Part Number...
Page 201: Filling
INDEX SECTION 5 MAINTENANCE Filling 1. If coolant is low in the heat exchanger, add specified coolant as necessary to bring the level up to the bottom of the fill neck. IMPORTANT: The pressure cap is correctly installed if it contacts locking tabs on the fill neck when tightened.
Page 202: Water Separating Fuel Filter
INDEX SECTION 5 MAINTENANCE CE494 Water Separating Fuel Filter WARNING Be careful when draining water separating fuel filter. Diesel fuel is flammable. Be sure ignition key is OFF. Do not allow fuel to contact any hot surfaces which may cause it to ignite. Do not allow sources of open flame in the area. Wipe up any spilled fuel immediately.
Page 203 INDEX SECTION 5 MAINTENANCE 3. Operate the priming pump up and down about 10 times until approximately 4 ml (2 fl oz) is drained or until fuel is clear in appearance. 77121 Priming pump 4. Close drain cap by turning clockwise. Tighten securely. 5.
Page 204: Replacing
INDEX SECTION 5 MAINTENANCE Replacing IMPORTANT: Element cannot be cleaned and reused. It must be replaced. 1. Remove water separating fuel filter and sealing ring from fuel filter bracket. 2. Remove the drain cap from the filter by turning it counterclockwise. Discard the used filter.
Page 205 INDEX SECTION 5 MAINTENANCE 4. Clean filter sealing surface on mounting bracket. 5. Coat sealing ring on new filter with clean motor oil. 77296 Typical mounting bracket and filter Filter sealing surface Sealing ring Description Where Used Part Number Engine oil Oil filter O-rings Obtain Locally 6.
Page 206: Filling
INDEX SECTION 5 MAINTENANCE Filling A plunger-type of hand pump/primer is located on the fuel filter bracket and is used to: Refill fuel filter when changing filter • • Refill fuel system if system was run dry • To prime the fuel system if engine has not been operated for a while. To operate the hand pump/primer, move the plunger (upper portion) up and down as needed.
Page 207: Fuel System
INDEX SECTION 5 MAINTENANCE CE530 Fuel System Priming Prime the engine if it has not been operated for a while or if the engine will not start. 1. Move the hand pump/primer plunger up and down several times. 77343 Fuel filter bracket Hand pump / primer 2.
Page 208: Purging Air
INDEX SECTION 5 MAINTENANCE Purging Air NOTE: Follow this procedure if fuel system was run dry or if part of fuel system was drained for a service function. 1. Fill the fuel filter. Refer to Filling. 2. Check filter and drain cap for fuel leaks. Ensure that bleed screw on fuel filter bracket is closed.
Page 209 INDEX SECTION 5 MAINTENANCE 6. Move plunger on hand pump/primer up and down repeatedly, until an air free stream of fuel flows from temporary hose. 77343 77761 Plunger Fuel from temporary hose 7. Remove temporary hose. Unplug and install boat fuel return hose on fitting. Securely tighten the hose clamp.
Page 210: Fuel Tank Cleaning And Flushing
INDEX SECTION 5 MAINTENANCE CE549 Fuel Tank Cleaning And Flushing IMPORTANT: Diesel fuel should not be left in tank during winter storage, as an accumulation of rust, sludge, and wax residue will form. Refer to boat manufacturer’s instructions and clean fuel tank at specified intervals. Unless specified otherwise, flush and clean diesel fuel tank every 1000 hours or 5 years, whichever occurs first.
Page 211 INDEX SECTION 5 MAINTENANCE 2. Inspect serpentine belt for proper tension and for the following: • Excessive wear • Cracks NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in direction of belt length) that join transverse cracks are NOT acceptable. •...
Page 212: Air Cleaner
INDEX SECTION 5 MAINTENANCE CE531 Air Cleaner The air cleaner is used to prevent the entry of rain water, seawater, and debris. There are no serviceable parts to the air cleaner. Cleaning 1. Remove any debris present at openings. 77132 Air cleaner Openings Checking...
Page 213: Corrosion Protection
INDEX SECTION 5 MAINTENANCE CE532 Corrosion Protection Whenever two or more dissimilar metals are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode.
Page 214: Inspection
INDEX SECTION 5 MAINTENANCE INSPECTION Inspection and replacement interval will vary depending on the condition of seawater and mode of engine operation. NOTE: Remove deposits from surface of anode before trying to determine amount of erosion. 1. Replace anode assembly when deteriorated 50%. •...
Page 215: Installation
INDEX SECTION 5 MAINTENANCE 3. Apply sealant to threads of new sacrificial anode and install into anode plug. Tighten securely. 71367 Plug Anode Description Where Used Part Number Loctite 567 PST Pipe Sealant Threads of anode plug 92-809822 INSTALLATION 1. Install new sealing washer. 2.
Page 216: Cleaning The Seawater Strainer, If Equipped
INDEX SECTION 5 MAINTENANCE CE551 Cleaning The Seawater Strainer, If Equipped 1. Visually inspect seawater strainer through glass top. CAUTION When cleaning seawater strainer, close seacock, if equipped. If boat is not equipped with a seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses.
Page 217: Flushing The Power Package
INDEX SECTION 5 MAINTENANCE CE533 Flushing The Power Package NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results. CAUTION Overheating from insufficient cooling water will cause engine and drive system damage.
Page 218 INDEX SECTION 5 MAINTENANCE 2. If flushing the engine with the boat out of the water: WARNING When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid possible injury, remove propeller. a. Remove the propeller. Refer to boat manufacturers’ instructions. b.
Page 219 INDEX SECTION 5 MAINTENANCE 4. Place the remote control in NEUTRAL, IDLE speed position and start the engine. CAUTION Do not run engine above 1500 rpm when flushing. Suction created by seawater pickup pump may collapse flushing hose, causing engine to overheat. 5.
Page 220: Seawater Pump Impeller
INDEX SECTION 5 MAINTENANCE CE495 Seawater Pump Impeller This maintenance should be performed by an authorized Cummins MerCruiser Diesel dealer / distributor. 1. Seawater pump impeller and impeller splines should be inspected for wear or damage at scheduled maintenance interval or whenever insufficient seawater flow is suspected (if operating temperature exceeds normal range).
Page 221: Miscellaneous Maintenance
INDEX SECTION 5 MAINTENANCE CA103 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use. Recharge every 30 to 45 days. or when specific gravity drops below battery manufacturer’s specifications. Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.
Page 222 INDEX SECTION 5 MAINTENANCE NOTES: Page 90 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 223 INDEX SECTION 6 STORAGE SECTION 6 - STORAGE Table of Contents Cold Weather Or Extended Storage ..Draining Instructions ....Preparing Your Power Package For Battery .
Page 224: Cold Weather Or Extended Storage
IMPORTANT: Cummins MerCruiser Diesel strongly recommends that this service should be performed by an authorized Cummins MerCruiser Diesel dealer / distributor. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. CAUTION Seawater section of cooling system MUST BE COMPLETELY drained for winter storage, or immediately after cold weather use, if the possibility of freezing temperatures exist.
Page 225: Draining Instructions
INDEX SECTION 6 STORAGE CE500 Draining Instructions CAUTION Ensure that the boat is out of the water or seacock is closed and bilge pump is operating before beginning procedure. Excess water in bilge can damage engine or cause boat to sink. CAUTION Do not operate engine with drain system open.
Page 226 INDEX STORAGE SECTION 6 5. Remove the drain plug from the lower part of the intercooler. 79115 Drain plug 6. Remove the drain plug, or the propeller shaft log seal (stuffing box) cooling hose if equipped, from the transmission fluid cooler. 79109 Drain plug, or cooling hose (not shown) Transmission fluid cooler...
Page 227 INDEX SECTION 6 STORAGE 9. Remove the seawater pump impeller for extended storage. a. Remove the seawater pump cover mounting screws. b. Remove the seawater pump cover and gasket. IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight.
Page 228: Battery
INDEX STORAGE SECTION 6 10. For additional assurance against freezing and corrosion fill the seawater cooling system with a mixture of propylene glycol antifreeze and tap water. a. Fill a container with approximately 5.6 liter (6 U.S. quarts) of propylene glycol anti- freeze and tap water mixed to manufacturer’s recommendation to protect engine to the lowest temperature to which it will be exposed during the cold weather or ex- tended storage.
Page 229: Power Package Recommissioning
INDEX SECTION 6 STORAGE CE502 Power Package Recommissioning NOTICE Refer to Cold Weather Or Extended Storage precautions, BEFORE proceeding. 1. Install the seawater pump impeller after ensuring that the splines are not worn and inspecting it for worn or damaged vanes. a.
Page 230 INDEX STORAGE SECTION 6 5. Perform all lubrication and maintenance specified for completion Annually in Section 5 - Maintenance Schedule, except items that were performed at time of engine layup. 6. Fill fuel tanks with fresh diesel fuel. Old fuel should not be used. Check fuel lines and connections for leaks and general condition.
Page 231 INDEX SECTION 6 STORAGE 10. Perform all checks on the Operation Chart in the Starting Procedure column. Refer to Section 3. CAUTION Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet openings during operation.
Page 232 INDEX STORAGE SECTION 6 NOTES: Page 100 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 233 INDEX TROUBLESHOOTING SECTION 7 SECTION 7 - TROUBLESHOOTING Table of Contents Troubleshooting Charts ....Insufficient Engine Temperature ..Starter Motor Will Not Crank Engine, Or Turbocharger - Noisy Or Rough Cranks Slow .
Page 234: Troubleshooting Charts
INDEX TROUBLESHOOTING SECTION 7 0103 Troubleshooting Charts Starter Motor Will Not Crank Engine, Or Cranks Slow Possible Cause Remedy Battery switch turned off. Turn switch on. Remote control not in neutral position. Position control lever in neutral. Check and reset circuit breaker or replace Open circuit breaker or blown fuse.
Page 235: Engine Runs Rough, Misses And/Or Backfires
INDEX TROUBLESHOOTING SECTION 7 CE535 Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Idle speed too low. Check idle speed and adjust, if necessary. Clogged fuel or air filters. Replace filters. If contaminated, drain tank. Fill with fresh Stale or contaminated fuel. fuel.
Page 236: Poor Performance
INDEX TROUBLESHOOTING SECTION 7 CE536 Poor Performance Possible Cause Remedy Inspect throttle cable and linkages for Throttle not fully open operation. Damaged or improper propeller Replace. Excessive bilge water Drain and check for cause of entry. Boat overloaded or load improperly Reduce load or redistribute load more distributed evenly.
Page 237: Excessive Engine Temperature
INDEX TROUBLESHOOTING SECTION 7 CE537 Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed. Open. Position hose to prevent kinking Seawater inlet hose kinked (restricted) (restriction). Use of improperly designed hose on inlet side of seawater pump allowing it to Replace hose with wire reinforced design.
Page 238: Turbocharger - Noisy Or Rough Operation
INDEX TROUBLESHOOTING SECTION 7 CE539 Turbocharger - Noisy Or Rough Operation Possible Cause Remedy Poor lubrication / low oil pressure at turbocharger. Entry of foreign materials from intake or Have inspected by an authorized exhaust side. Cummins MerCruiser Diesel dealer / Cummins MerCruiser Diesel dealer / distributor.
Page 239: Battery Will Not Charge
INDEX TROUBLESHOOTING SECTION 7 CE542 Battery Will Not Charge Possible Cause Remedy Excessive current draw from battery. Turn off non-essential accessories. Check all associated electrical connections and wires (especially battery Loose or dirty electrical connections or cables). Clean and tighten faulty damaged wiring.
Page 240 INDEX TROUBLESHOOTING SECTION 7 NOTES: Page 108 CMD-3967823 / 90-865237030 OCTOBER 2003...
Page 241 INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 SECTION 8 - CUSTOMER ASSISTANCE INFORMATION Table of Contents Owner Service Assistance ... . . Muut kielet ......Local Repair Service .
Page 242: Owner Service Assistance
INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 CE553 Owner Service Assistance Local Repair Service Always return your Cummins MerCruiser Diesel powered boat to your authorized dealer / distributor should the need for service arise. Only the dealer / distributor has the factory trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur.
Page 243: Replacement Service Parts
INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 CE472 Replacement Service Parts WARNING Electrical, ignition and fuel system components on Cummins MerCruiser Diesel en- gines and drive systems are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided.
Page 244: Resolving A Problem
INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 CE545 Resolving A Problem Satisfaction with your Cummins MerCruiser Diesel product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your authorized Cummins MerCruiser Diesel dealer / distributor. If additional assistance is required, take these steps: 1.
Page 245: Customer Service Literature
Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 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 246: Andere Sprachen
Para obtener un Manual de operación y mantenimiento en otro idioma, póngase en contacto con el centro de servicio más cercano de Mercury Marine o Marine Power International para recibir información. Con su conjunto motriz se entrega una lista de los números de pieza para los otros idiomas.
Page 247: Ordering Literature
United States and Canada For information on additional literature that is available for your particular Cummins MerCruiser Diesel power package and how to order that literature contact your nearest Cummins MerCruiser Diesel dealer / distributor or contact: Mercury Marine Telephone Mail Mercury Marine Attn: Publications Department (920) 929–5110...
Page 248 INDEX CUSTOMER ASSISTANCE INFORMATION SECTION 8 NOTES: Page 116 CMD-3967823 / 90-865237030 OCTOBER 2003...

Mercury 1.7 MI Manual

Section 1 - Warranty

Section 1 - Warranty 1

Warranty Information

Warranty Policies

Transferable Warranty

Section 2 - Getting to Know Your Power Package 2

Features and Controls

Features and Controls

Section 3 - on the Water

Safe Boating Suggestions

Basic Boat Operation

Safe Boating Suggestions

Basic Boat Operation

Getting Started

Section 4 - Specifications

Fuel Requirements

Diesel Fuel in Cold Weather

Antifreeze/Coolant

Engine Oil

Engine Specifications

Section 5 - Maintenance

Owner/Operator Responsibilities

Dealer Responsibilities

Maintenance

Maintenance

Engine Oil

Transmission Fluid

Lubrication

Engine Coolant

Water Separating Fuel Filter

Fuel System

Drive Belts

Air Cleaner

Corrosion Protection

Cleaning the Seawater Strainer, if Equipped

Flushing the Power Package

Seawater Pump Impeller

Miscellaneous Maintenance

Section 6 - Storage

Cold Weather or Extended Storage

Power Package Recommissioning

Section 7 - Troubleshooting

Troubleshooting Charts

Section 7 - Troubleshooting

Section 8 - Customer Assistance Information

Owner Service Assistance

Customer Service Literature

Ordering Literature

Section 1 - Warranty 1

Warranty Information

Warranty Policies

Transferable Warranty

Section 2 - Getting to Know Your Power Package 2

Section 3 - on the Water

Safe Boating Suggestions

Basic Boat Operation

Protecting People in the Water

Passenger Safety Message - Pontoon and Deck Boats

Wave and Wake Jumping

Impact with Underwater Hazards

Conditions Affecting Operation

Getting Started

Section 4 - Specifications

Section 5 - Maintenance

Owner/Operator Responsibilities

Dealer Responsibilities

Maintenance

Engine Oil

Transmission Fluid

Lubrication

Engine Coolant

Water Separating Fuel Filter

Fuel System

Drive Belts

Air Cleaner

Corrosion Protection

Cleaning the Seawater Strainer, if Equipped

Flushing the Power Package

Seawater Pump Impeller