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Mercury MerCruiser 5.7 TowSport MPI ECT Operation & Maintenance Manual

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5.7 TowSport MPI ECT
Mercury
MerCruiser
O P ERAT I O N
MAI N T EN AN C E
& W ARRAN T Y
M AN U A L

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Summary of Contents for Mercury MerCruiser 5.7 TowSport MPI ECT

  • Page 1 5.7 TowSport MPI ECT Mercury MerCruiser O P ERAT I O N MAI N T EN AN C E & W ARRAN T Y M AN U A L...

  • Page 2: Declaration Of Conformity-Mercury Mercruiser

    NOTE: The following applies to CE‑marked products only. Declaration of Conformity—Mercury MerCruiser This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser's instructions complies with the requirements of the following directives by meeting the associated standards, as amended:...

  • Page 3: Identification Record

    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 4: Warranty Message

    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 5 Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're Driven to Win are registered trademarks of Brunswick Corporation.

  • Page 6: Table Of Contents

    Outside the United States and Canada......3 Transfer of Warranty—Australia and New Zealand Mercury Installation Quality Certification Program....3 Policy................13 Mercury Product Protection Plan: United States and Global Warranty Charts............14 Canada................3 United States Warranty Chart—MerCruiser Gas and Mercury MerCruiser Warranty Coverage (Gasoline‑Fueled...
  • Page 7 Section 3 - On the Water Safe Boating Recommendations..........32 High‑Speed and High‑Performance Operation....... 36 Carbon Monoxide Exposure........... 33 Passenger Safety in Pontoon Boats and Deck Boats.... 36 Be Alert To Carbon Monoxide Poisoning......33 Boats Having an Open Front Deck........36 Stay Clear of Exhaust Areas..........
  • Page 8 Poor Performance............. 71 Steering Wheel Jerks or Is Difficult to Turn...... 72 Section 8 - Customer Assistance Information Owner Service Assistance............74 Contact Information for Mercury Marine Customer Service Local Repair Service............74 ................... 75 Service Away From Home..........74 Customer Service Literature............
  • Page 9 Page iv 90-8M0099728 NOVEMBER 2014...

  • Page 10: Section 1 - Warranty

    Outside the United States and Canada ....3 ..................13 Mercury Installation Quality Certification Program... 3 Global Warranty Charts............14 Mercury Product Protection Plan: United States and United States Warranty Chart—MerCruiser Gas and Canada................3 Diesel................14 Mercury MerCruiser Warranty Coverage Outside United States ...........

  • Page 11: Warranty Information

    Outside United States and Canada ‑ Check with your local distributor. You may change your address on file with Mercury Marine at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 12: Outside The United States And Canada

    See your participating Mercury MerCruiser dealer for complete program details. Mercury MerCruiser Warranty Coverage (Gasoline‑Fueled Products) WHAT IS COVERED: Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described in the warranty section of the owner's manual.
  • Page 13 CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the predelivery inspection process specified by Mercury Marine is completed and documented.

  • Page 14: Year Limited Warranty Against Corrosion

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.

  • Page 15: Emission Control Warranty Information

    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 16 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 17: Owner Responsibility

    U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three years or 480 hours of engine use whichever occurs first to the retail purchaser, that the engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations.

  • Page 18: California Emissions Limited Warranty

    California resident, to be free from defects in material or workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in the application of Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions identified below.

  • Page 19: California Emission Control Warranty Statement

    Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

  • Page 20: Warranty Policy-Australia And New Zealand

    What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.

  • Page 21: Transfer Of Coverage

    A list of dealers and their contact details is available at http://www.mercurymarine.com.au/home.aspx. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine at the address shown above. Mercury Marine will then arrange for the inspection and any covered repair. This Limited Warranty will not cover the purchaser for all related transportation charges and travel time.

  • Page 22: Expense Of Claiming This Limited Warranty

    There is no charge for this service. You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.

  • Page 23: Global Warranty Charts

    3 years H.O. MerCruiser Inboard 5.7 ‑ 6.2 ‑ 8.2 3 years 4 years 3 years Horizon Mercury Diesel Not available at time of Sterndrive and 2 years 3 years printing Inboard Outside United States For product purchased outside of United States, contact the distributor in your country, or the authorized Marine Power Service Center closest to you.

  • Page 24: Australia And New Zealand Warranty Chart-Mercruiser Gas And Diesel

    Contact the Marine Power Service Center closest to you MerCruiser TowSport 3 years 3 years Mercury Diesel Sterndrive 2 years 3 years and Inboard Outside Australia and New Zealand For product purchased outside of Australia and New Zealand, contact the distributor in your country, or the authorized Marine Power Service Center closest to you.

  • Page 25: Outside Europe And Cis

    Beginning January 1, 2003, one Three‑Star or Four‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's sterndrive and inboard marine engine 2007 and later exhaust emission standards.

  • Page 26: Hang Tag

    Section 1 - Warranty The Star label will be affixed on the left side of the hull as shown. Recommended location Secondary location XX 1234 XX 32770 One Star ‑ Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards.
  • Page 27 Section 1 - Warranty If in California, the dealer must place the hang tag in a visible location in the boat prior to displaying the boat. 43291 Hang tag front side Hang tag back side Page 18 90-8M0099728 NOVEMBER 2014...
  • Page 28 Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification................. 20 Remote Controls............25 Engine Serial Number ........... 20 Panel Mount Features ........... 25 Transmissions..............20 Console Mount Features ........25 Velvet Drive Transmissions ........

  • Page 29: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number The serial number is located in two places on the engine.

  • Page 30: Zf Marine Transmissions

    Section 2 - Getting to Know Your Power Package On the Velvet Drive 5000A and 5000V Transmissions the transmission identification plate indicates gear ratio, serial number and model. Velvet Drive 5000A - 8 degree down-angle transmission shown (5000V - V-drive similar) Transmission identification plate 7370 ZF Marine Transmissions...

  • Page 31: Lanyard Stop Switch

    Section 2 - Getting to Know Your Power Package Lanyard Stop Switch A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist. A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.

  • Page 32: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition

    Card reader door 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 33: 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 500 and 1200 RPM. SmartCraft gauges Tachometer Speedometer LCD system view display 26238 The SmartCraft instrument package also aids in Engine Guardian diagnostics.

  • Page 34: Remote Controls (Non-Dts Models)

    Remote Controls (Non‑DTS Models) Remote Controls Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control. Panel Mount Features...

  • Page 35: Electrical System Overload Protection

    Section 2 - Getting to Know Your Power Package 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.
  • Page 36 Section 2 - Getting to Know Your Power Package Four fuses located on the port side of the engine protect the main power, fuel pump, ignition, and accessory circuits. 33214 Engine fuses Two 10‑amp fuses protect the O (oxygen) sensors. These are located at the rear of the engine, near the 14‑pin connector. 33177 Oxygen sensor fuses A 15‑amp accessory fuse protects the accessory circuits.

  • Page 37: Visual And Audio Warning Systems

    Section 2 - Getting to Know Your Power Package A power harness, connected to the engine starting battery, minimizes voltage drop to the electrical system. This harness is protected by a 5‑amp fuse. This connection is located at the rear of the engine, near the 14‑pin connector. 33179 Visual and Audio Warning Systems Service Engine Light and OBD‑M MIL Kit...

  • Page 38: Caution

    Section 2 - Getting to Know Your Power Package Caution If a caution state is detected, the audio warning system will sound for six one‑second intervals. Horn (on or off) Time (in seconds) 33402 Critical If a critical state is detected, the audio warning system sounds for six seconds and then turns off. Horn (on or off) Time (in seconds) 53403...
  • Page 39 Section 2 - Getting to Know Your Power Package Notes: Page 30 90-8M0099728 NOVEMBER 2014...
  • Page 40 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Recommendations.......... 32 High‑Speed and High‑Performance Operation..... 36 Carbon Monoxide Exposure..........33 Passenger Safety in Pontoon Boats and Deck Boats..36 Be Alert To Carbon Monoxide Poisoning ..... 33 Boats Having an Open Front Deck .......

  • Page 41: Safe Boating Recommendations

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

  • Page 42: Carbon Monoxide Exposure

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

  • Page 43: 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 44: Starting The Engine

    IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.

  • Page 45: Protecting People In The Water

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

  • Page 46: 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 47: 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 48: 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 49 Section 3 - On the Water Notes: Page 40 90-8M0099728 NOVEMBER 2014...
  • Page 50 Section 4 - Specifications Section 4 - Specifications Table of Contents Cruising RPM............... 42 Engine Oil................43 Fuel Requirements............... 42 Engine Specifications............43 Fuel Ratings ..............42 TowSport 5.7 MPI EC............ 43 Using Reformulated (Oxygenated) Gasoline (USA Only) Fluid Specifications............... 44 ..................

  • Page 51: Section 4 - Specifications

    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 52: Engine Oil

    Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty. If Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of recommendation.

  • Page 53: Fluid Specifications

    IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid required. All Models Capacity Fluid Type Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Engine oil (with filter) 4.25 L (4.50 US qt) Oil, NMMA FC‑W Seawater cooling system (winterization use...
  • Page 54 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 46 Multiple EFI Engine Battery Precautions....... 51 Dealer Responsibilities............46 Cleaning the Flame Arrestor..........51 Maintenance................. 46 Positive Crankcase Ventilation (PCV) Valve ....52 Do‑It‑Yourself Maintenance Suggestions......46 Changing ...............

  • Page 55: 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 56: 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 57: Section 5 - Maintenance

    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 and filter (ZF transmission models). • Replace the water‑separating fuel filter element. Every 100 hours or •...

  • Page 58: Oil Level-Overfilled

    All Models Capacity Fluid Type 4.25 L Engine oil (with filter) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W (4.5 US qt) Engine Oil Drain Pump Loosen the oil filter to vent the system. Remove the dipstick. Install the oil pump onto the dipstick tube.

  • Page 59: Changing The Oil Filter

    Fluid Type 4.25 L Engine oil (with filter) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W (4.50 US qt) Start the engine and operate for three minutes, checking for leaks. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water.

  • Page 60: Battery

    Section 5 - Maintenance Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery. WARNING Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion.

  • Page 61: Positive Crankcase Ventilation (Pcv) Valve

    Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover. Install the engine cover. Positive Crankcase Ventilation (PCV) Valve Changing NOTE: We recommend the use of Mercury MerCruiser replacement parts to ensure compliance with emission regulations. Page 52 90-8M0099728 NOVEMBER 2014...

  • Page 62: Cleaning The Iac Muffler

    Section 5 - Maintenance Remove the PCV valve from the port valve cover. 33143 PCV valve (hose not shown) Disconnect the PCV valve from the hose and discard the valve. Install a new PCV valve in the valve cover and reconnect the hose. Ensure that the PCV valve is tightly seated in the valve cover.

  • Page 63: Water-Separating Fuel Filter

    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 the fuel supply valve, if equipped. Disconnect the Cool Fuel Module harness from the engine wiring harness.

  • Page 64: Installation

    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. Lubrication Throttle Cable Lubricate the pivot points and the guide contact surfaces.
  • Page 65 Section 5 - Maintenance Lubricate the detent ball and the holes in the shift lever. In-line transmission Detent ball and holes 5934 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Detent ball and shift lever 92‑883725K01 SAE25W‑40 holes...

  • Page 66: Serpentine Drive Belt

    Section 5 - Maintenance Serpentine Drive Belt WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts. Idler pulley Circulating pump pulley Crankshaft pulley Alternator pulley Seawater pump pulley...

  • Page 67: Flushing The Power Package-Towsports

    Section 5 - Maintenance Attach the belt tension gauge to the belt. The gauge has different ranges for new and used belts. Belt tension gauge Serpentine belt 14980 While holding the adjustment stud at the correct belt tension, tighten the 16 mm (5/8 in.) locking nut. 8 mm (5/16 in.) adjusting stud 16 mm (5/8 in.) locking nut 6119...

  • Page 68: The Boat In The Water

    Section 5 - Maintenance All other models: Close the seacock, if equipped, and then disconnect the seawater inlet hose from the seawater pump inlet fitting. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump and plug the hose. 10839 Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.
  • Page 69 Section 5 - Maintenance Close the seacock, if equipped, and then disconnect the seawater inlet hose from the transmission seawater inlet fitting. NOTICE Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage. Close the seacock before disconnecting the seawater inlet hose.
  • Page 70 Section 5 - Maintenance NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM (±...
  • Page 71 Section 5 - Maintenance Notes: Page 62 90-8M0099728 NOVEMBER 2014...
  • Page 72 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........64 Three‑Point Manual Drain System......... 66 Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 64 Boat in the Water ........... 66 Fuel Containing Alcohol..........64 Boat Out of the Water ..........67 Preparing Power Package for Storage—MPI Models..

  • Page 73: Cold Weather Or Extended Storage

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

  • Page 74: Special Fuel Mix

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

  • Page 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: Boat Out Of The Water

    Draining Water from the Gen III Cool Fuel Module Mercury MerCruiser recommends draining the Gen III Cool Fuel Module if it is equipped with a drain plug. Remove the drain plug from the Gen III Cool Fuel Module and allow the water to completely drain from the module.

  • Page 77: Battery Storage

    Section 6 - Storage Place the O‑ring on the drain plug and install the drain plug in the module drain hole. Tighten the drain plug to finger‑tight. Gen III Cool Fuel Module Fuel in‑line fitting Drain plug O‑ring 43648 Battery Storage Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition.
  • Page 78 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems............. 70 Excessive Engine Temperature........71 Engine Guardian System............70 Insufficient Engine Temperature........71 Troubleshooting Charts............70 Low Engine Oil Pressure..........72 Starter Motor Will Not Crank Engine, or Cranks Slowly Battery Will Not Recharge..........

  • Page 79: Section 7 - Troubleshooting

    Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on electronic fuel injection (EFI) systems. The engine control module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECMs memory.

  • Page 80: Excessive Engine Temperature

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

  • Page 81: Low Engine Oil Pressure

    Steering Wheel Jerks or Is Difficult to Turn Possible Cause Remedy Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners if any are loose or missing, see authorized Loose or missing steering fasteners or parts. Mercury MerCruiser dealer immediately. Page 72 90-8M0099728 NOVEMBER 2014...
  • Page 82 Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance............ 74 Contact Information for Mercury Marine Customer Local Repair Service ............ 74 Service ................. 75 Service Away From Home ..........74 Customer Service Literature..........75 Stolen Power Package ..........

  • Page 83: Section 8 - Customer Assistance Information

    If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

  • Page 84: Contact Information For Mercury Marine Customer Service

    Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: •...

  • Page 85: Other Languages

    Section 8 - Customer Assistance Information Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
  • Page 86 Section 9 - Checklists Section 9 - Checklists Table of Contents Predelivery Inspection (PDI)..........78 Customer Delivery Inspection (CDI)........79 90-8M0099728 NOVEMBER 2014 Page 77...

  • Page 87: Section 9 - Checklists

    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 88: Customer Delivery Inspection (Cdi)

    Approve the external appearance of the product (paint, cowl, decals, etc.) ⃞ Warranty—provide and explain the limited warranty to the customer. Explain dealer services. ⃞ ⃞ Explain the optional Mercury Product Protection Plan (North America only) Operation of equipment—explain and demonstrate: ⃞ E‑stop switch/lanyard stop switch operation (all helms) ⃞...
  • Page 89 Section 9 - Checklists Completed Item ⃞ ⃞ Functions of SmartCraft accessories (if applicable) ⃞ Off‑season storage and maintenance schedule ⃞ Engine (starting, stopping, shifting, using throttle) ⃞ Boat (lights, battery switch location, fuses/breakers) ⃞ ⃞ Trailer (if applicable) Registration: ⃞...
  • Page 90 Section 10 - Maintenance Log Section 10 - Maintenance Log Table of Contents Scheduled Maintenance Log..........82 Vessel Maintenance Notes........... 83 90-8M0099728 NOVEMBER 2014 Page 81...

  • Page 91: Section 10 - Maintenance Log

    Section 10 - Maintenance Log Scheduled Maintenance Log 100 Hours Actual Hours Service Notes Dealer Name Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name...

  • Page 92: Vessel Maintenance Notes

    Section 10 - Maintenance Log Vessel Maintenance Notes Record all general maintenance performed on your power package here. Save all work orders and receipts. Engine Date Maintenance Completed Servicing Dealer Hours 90-8M0099728 NOVEMBER 2014 Page 83...