MerCruiser 6.2 MPI User Manual Download Page 4

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NOTICE

Indicates a situation which, if not avoided, could result in engine or major component

failure.

IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.

WARNING

The operator (driver) is responsible for the correct and safe operation of the boat, the

equipment aboard and the safety of all occupants aboard. We strongly recommend that

the operator read this Operation, Maintenance and Warranty Manual and thoroughly

understand the operational instructions for the power package and all related accessories

before the boat is used.

WARNING

The engine exhaust from this product contains chemicals known to the state of California

to cause cancer, birth defects or other reproductive harm.

Summary of Contents for 6.2 MPI

Page 1: ...x II ISO 8846 SAE J1171 SAE J1191 SAE J 2031 Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust when installed in a recreational craft in accordance with the manufacturers supplied instructions will meet the exhaust emissions requirements of the directive mentioned above This engine must not be put into service until the recreational craft in which it is to...

Page 2: ...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 Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 2007 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers...

Page 3: ...ime in order to verify and make a record of compliance with applicable standards and regulations All Mercury Marine product sold as new receives the applicable limited warranty coverage whether the engine participated in one of the test programs described above or not Read This Manual Thoroughly IMPORTANT If you don t understand any portion of this manual contact your dealer for a demonstration of...

Page 4: ...ver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used WARNING The engine exhaust from this product contains...

Page 5: ...ures Single Engine 20 Slim Binnacle Console Mount Features Single Engine 21 Console Mount Features Dual Engine 22 Synchronizing Dual Engines 22 Dual Helm Station Transfer 23 Synchronizing Dual Helms Prior To Station Transfer 24 Zero Effort Features 24 Electrical System Overload Protection 24 Audio Warning System 26 Testing The Audio Warning System 26 Engine Guardian Strategy 26 Transmission Guardi...

Page 6: ...Yourself Maintenance Suggestions 51 Inspection 51 Maintenance Schedule Inboard Models 52 Routine Maintenance 52 Scheduled Maintenance 52 Maintenance Log 53 Engine Oil 53 Checking 53 Filling 54 Changing Oil and Filter 55 Easy Engine Oil Drain System 55 Engine Oil Drain Pump 55 Changing Filter 56 Transmission Fluid 57 Checking While the Engine is Warm 57 Checking While Engine is Cold 57 Changing 57 ...

Page 7: ...TS Problems 94 Engine Guardian System 94 Starter Motor Will Not Crank Engine Or Cranks Slow 94 Engine Will Not Start or Is Hard to Start 95 Engine Runs Rough Misses or Backfires 95 Poor Performance 95 Excessive Engine Temperature 95 Insufficient Engine Temperature 96 Low Engine Oil Pressure 96 Battery Will Not Recharge 96 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Soun...

Page 8: ...Page iv 90 864197072 NOVEMBER 2007 ...

Page 9: ...cury Product Protection Plan United States and Canada 3 Mercury MerCruiser Limited Warranty Gasoline Fueled Products Only 4 3 Year Limited Warranty Against Corrosion 6 Global Warranty Charts 7 Consumer Application Warranty Chart 7 Commercial Application Warranty Chart 8 Government Application Warranty Chart 9 Mercury Installation Quality Certification Program 9 Emission Control Information Label 1...

Page 10: ...urned to him for warranty service The product warranty is not effective until the product is registered at the factory NOTE Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event that a safety recall notification under the Federal Boat Safety Act is required You may change your address at any time including at time of warranty clai...

Page 11: ...ing the warranty registration card and its relationship to warranty claim processing refer to the International Warranty See Table of Contents NOTE Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event of a safety recall notification under the Federal Boat Safety Act Transfer of Warranty The limited warranty is transferable to a s...

Page 12: ...fied installations Coverage for SeaCore Sterndrive Models The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations Coverage for Standard Models The Limited Warranty for Standard Models which do not include Sterndrive Models with Closed Cooling Inboard Models Scorpion 377 Models V...

Page 13: ...e purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange for the inspection and any covered repair The purchaser in that case shall pay for all related transportation charges and travel time If the service provided is not covered by this warranty the purchaser shall pay for all related labor and material and any other e...

Page 14: ...nt noncommercial use purchaser upon proper re registration of the product Warranty coverage is terminated for used product repossessed from a retail customer purchased at auction from a salvage yard or from an insurance company that obtained the product as a result of an insurance claim Condition That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail cu...

Page 15: ...rands Region Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Vazer Standard Models and and Models with Closed Cooling SeaCore USA and Canada 1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years Latin America 1 year 3 years 1 year 1 year 2 years 4 years 2 years 2 years 3 years 4 years Mex...

Page 16: ...1 year 1 year 1 year Europe 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand ...

Page 17: ...or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 h...

Page 18: ...s that successfully complete the program and meet all certification requirements earn Installation Quality System Certified Manufacturer status and receive an additional one 1 year of Mercury limited factory warranty coverage on all MerCruiser powered boats that are registered on and after the boat builder s certification date for all worldwide registrations Mercury has designated a section of our...

Page 19: ...ant SERIAL Engine Serial Number FAMILY Engine Family STD Emissions Standard D O M Date of Manufacture DISP Piston Displacement EMISSION CONTROL INFORMATION REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL FAMILY STD D O M DISP 31657 XXXXXXXXXXXX XX X g kW hr XXXXXXXX X XL MMM YYYY NOT FOR SALE IN CALIFORNIA Emission Control Label Not for Sale in California SERIAL Engin...

Page 20: ...Section 1 Warranty Notes Page 12 90 864197072 NOVEMBER 2007 ...

Page 21: ...tures 18 Zero Effort Features 18 Remote Controls DTS Models 19 Remote Controls 19 Panel Mount Features 19 Console Mount Features Single Engine 20 Slim Binnacle Console Mount Features Single Engine 21 Console Mount Features Dual Engine 22 Synchronizing Dual Engines 22 Dual Helm Station Transfer 23 Synchronizing Dual Helms Prior To Station Transfer 24 Zero Effort Features 24 Electrical System Overlo...

Page 22: ...witch 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 RUN a b c a Stop switch b Lanyard c Clips to the operator Accidental ejections such as falling overboard are more likely to occur in low sided sport boats bass boats high performance boats Accidental ejections can ...

Page 23: ...e required to operate the engine in an emergency e g if the operator is accidentally ejected WARNING If the operator falls out of the boat stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat Always properly connect the operator to the stop switch using a lanyard Accidental or unintended activation of the switch during normal operation is a...

Page 24: ...raft instrument package Analog Gauges The following is a brief explanation of the instrumentation typically found on some boats The owner operator should be familiar with all instruments and their functions Because of the large variety of instrumentation and manufacturers you should have your boat dealer explain the particular gauges and normal readings for your boat L H OIL C H TEMP 0 1 2 3 4 5 6...

Page 25: ...cement 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 Lanyard Stop Switch Turns the ignition off whenever the operator when attached to the lanyard moves far enough away from the operat...

Page 26: ...n to the first detent for forward gear and continue pushing forward to increase speed Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed Control Handle Tension Adjustment Screw not visible This screw is used to adjust the effort required to move the remote control handle Refer to instructions provided ...

Page 27: ... system works with specialized helm components such as a command module kit and electronic remote control Consult your dealer for a description and or demonstration of your remote control Panel Mount Features 17358 c d e b a f g a Lanyard stop switch b Control handle c Shift lock d Trim tilt switch e Throttle only button f Detent tension adjustment screw g Control handle friction adjustment screw ...

Page 28: ...lect key e Arrow trackpad f Throttle only station select key g Detent tension adjustment h Control handle friction adjustment screw Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear Continue pushing forward to increase speed Pull the contr...

Page 29: ...ward to increase speed Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed Active Light The active light is illuminated to show the remote control is active and ready for use Neutral Light The neutral light is illuminated when the engine is in neutral gear position Start Stop Button Allows the boat oper...

Page 30: ...tion messages Sync Light The sync light is illuminated when the RPM of the two engines are being synchronized by the DTS system Throttle Only Station Select Key Allows engine throttle advancement without shifting the engine The throttle only station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms Re...

Page 31: ...lm transfer should only be performed while engine is in neutral NOTE Idle position is preferred when doing a station transfer If conditions do not allow the remote control to be placed at idle position a station transfer can be done while in gear NOTE Pressing and releasing station select button at new station allows the engine control to be transferred to the new station The control will automati...

Page 32: ...on Shift into neutral by moving the shift lever to its center position Shift into forward by moving the shift lever to its forward position Throttle Lever Throttle functions are controlled by the movement of the throttle lever Increase the RPM by moving the throttle lever forward Achieve Wide Open Throttle WOT by placing the throttle lever in its full forward position Decrease RPM by moving the th...

Page 33: ...ll appear Reset after testing or if tripped by pushing the yellow lever back into the housing b a 22529 Yellow lever style circuit breaker typical a Yellow lever shown tripped b Red test button 2 A 90 amp fuse is located on the large post of the starter solenoid This fuse protects the engine wiring harness if an electrical overload occurs mc74907 1 3 Four fuses are located on the port side of the ...

Page 34: ...curs Transmission fluid temperature too hot Transmission pressure too low NOTICE A continuous horn indicates a critical fault Operating the engine during a critical fault can damage components If the warning horn emits a continuous beep do not operate the engine unless avoiding a hazardous situation If the alarm sounds stop the engine immediately Investigate cause and correct it if possible If the...

Page 35: ...ottle Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage Transmission Guardian monitors the clutch pack pressure in forward and reverse gears If the transmission fluid pressure drops below a predetermined level Transmission Guardian lowers the engine torque and speed to prevent clutch slippage To avoid possible recurrence of the problem you should cont...

Page 36: ...Section 2 Getting to Know Your Power Package Notes Page 28 90 864197072 NOVEMBER 2007 ...

Page 37: ...topping the Engine 35 Starting the Engine 35 Stopping the Engine 36 Throttle Only Operation 36 Freezing Temperature Operation 37 Drain Plug and Bilge Pump 37 Protecting People in the Water 37 While You Are Cruising 37 While Boat Is Stationary 37 High Speed and High Performance Operation 38 Passenger Safety in Pontoon Boats and Deck Boats 38 Boats Having An Open Front Deck 38 Boats With Front Mount...

Page 38: ... instructions Water proof storage containers Spare operating equipment batteries bulbs and fuses Compass and map or chart of the area Personal flotation device 1 per person on board 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 unloadin...

Page 39: ...or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involv...

Page 40: ...perating 2 Examples of poor ventilation while a boat is moving mc79556 1 a b a Operating the boat with the trim angle of the bow too high b Operating the boat with no forward hatches open station wagon effect Basic Boat Operation Non DTS Models Launching and Boat Operation IMPORTANT Install bilge drain plug prior to launching boat OPERATION CHART Operation Chart BEFORE STARTING AFTER STARTING WHIL...

Page 41: ... engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five minutes 3 Turn ignition key to START Release key when engine starts and allow switch to return to ON position Allow engine to warm up 6 10 minutes on first start of the day 4 If engine does not start after 3 attempts a Pus...

Page 42: ...le reverse position without pressing the throttle only button will shift the unit into the chosen gear Freezing Temperature Operation IMPORTANT If the boat is operated during periods of freezing temperature precautions must be taken to prevent freeze damage to the power package Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty Drain Plug and Bilge Pump The engine comp...

Page 43: ... fumes contained in the engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five minutes NOTE MerCruiser DTS models are equipped with SmartStart The SmartStart feature incorporates push button starting Rather than holding the start button or key switch to start the engine and the...

Page 44: ...e ignition key switch to the START position then release immediately The control system will recognize that the engine is running and will stop the engine The control system will remain active Moving the ignition key switch to the START position again will issue a start request to the control system and the control system will start the engine if appropriate d Activate the lanyard stop switch if e...

Page 45: ... 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 For this reason boats are normally equipped with a drain plug and or a bilge pump It is very important to check these items on a regular basis to ensure that the water level does not...

Page 46: ...sudden throttle reduction or a sharp change of boat direction could throw them over the front of boat Falling over the front of the boat between the two pontoons will position them to be run over Boats Having An Open Front Deck No one should ever be on the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could ...

Page 47: ...te under the water surface and submarine for an instant This will bring the boat nearly to a stop in an instant and can send the occupants flying forward The boat may also veer sharply to one side Impact with Underwater Hazards Reduce speed and proceed with caution whenever you re driving a boat in shallow water or in areas where the waters are suspected of having underwater obstacles that could b...

Page 48: ... inspect and repair the vessel or power package 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 At extremes can cause the boat to porpoise Shifting weight to front bow Impr...

Page 49: ...ded RPM can be achieved by changing to a lower pitch propeller Getting Started 20 Hour Break In Period IMPORTANT The first 20 hours of operation is the engine break in period Correct break in is essential to obtain minimum oil consumption and maximum engine performance During this break in period the following rules must be observed Do not operate below 1500 RPM for extended periods of time for th...

Page 50: ...ce ZF Transmission models 1 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 1 Requ...

Page 51: ...ion 4 Specifications Table of Contents Cruising RPM 44 Fuel Requirements 44 Fuel Ratings 44 Using Reformulated Oxygenated Gasolines USA Only 44 Gasolines Containing Alcohol 44 Engine Oil 45 Engine Specifications 46 Fluid Specifications 46 Engine 46 Transmission 47 4 ...

Page 52: ... USA and Canada having a posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also acceptable If unleaded gasoline is not available use a major brand of leaded gasoline Using Reformulated Oxygenated Gasolines USA Only This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels is Alcohol Ethanol or Ether MTBE or ETBE If Ethanol is t...

Page 53: ...taining alcohol do not store the gasoline in the fuel tank for long periods Whereas cars normally consume alcohol blend fuels before they can absorb enough moisture to cause trouble boats often sit idle long enough for phase separation to take place In addition internal corrosion may take place during storage if alcohol has washed protective oil films from internal components Engine Oil To help ob...

Page 54: ...24 kW 300 hp 239 kW 320 hp Displacement 5 7 L 350 cid 6 2 L 377 cid Specified WOT RPM range 4600 5000 4800 5200 Idle RPM in neutral 600 Minimum oil pressure at idle 41 kPa 6 psi Thermostat seawater cooled models 71 C 160 F Thermostat closed cooled models 77 C 170 F Timing at idle Not adjustable Firing order 1 8 4 3 6 5 7 2 Electrical system 12 V negative ground Alternator rating 65 A Minimum batte...

Page 55: ... qt 71C In Line 1 66 L 1 75 US qt Dexron III Automatic Transmission Fluid 71C Gear Reduction 2 84 L 3 00 US qt 71C Remote V Drive 1 66 L 1 75 US qt 72C In Line 1 66 L 1 75 US qt Dexron III Automatic Transmission Fluid 72C Gear Reduction 1 66 L 1 75 US qt 72C Remote V Drive 1 66 L 1 75 US qt 72C V Drive 3 79 L 4 00 US qt 63A 4 00 L 4 5 US qt Dexron III Automatic Transmission Fluid 63V 4 00 L 4 5 US...

Page 56: ...Section 4 Specifications Notes Page 48 90 864197072 NOVEMBER 2007 ...

Page 57: ...ain Pump 55 Changing Filter 56 Transmission Fluid 57 Checking While the Engine is Warm 57 Checking While Engine is Cold 57 Changing 57 Engine Coolant 57 Checking 57 Filling 58 Changing 59 Cleaning the Flame Arrestor 59 Positive Crankcase Ventilation Valve PCV 60 Changing 60 Water Separating Fuel Filter 61 GEN III Models 62 Removal 62 Installation 63 Lubrication 63 Throttle Cable 63 Transmission Li...

Page 58: ...y Familiarize the customer with the on board equipment Explain and demonstrate the operation of the power package and boat Provide you with a copy of a Predelivery Inspection Checklist Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product Maintenance WARNING Performing service or maintenance without first d...

Page 59: ...n engine or drive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagnose a problem or to request...

Page 60: ...il and filter Change the engine oil and filter Change the transmission fluid and filter ZF Marine requires changing the transmission fluid and filter maintain warranty Every 100 hours or annually whichever occurs first Touch up the paint on the power package Change the engine oil and filter Change the transmission fluid ZF Transmission Models Replace the water separating fuel filter element Clean ...

Page 61: ...OTICE Discharge of oil coolant or other engine drive fluids into the environment is restricted by law Use caution not to spill oil coolant or other fluids into the environment when using or servicing your boat Be aware of the local restrictions governing the disposal or recycling of waste and contain and dispose of fluids as required Checking 1 Stop the engine Allow approximately 5 minutes for the...

Page 62: ...l level Oil level must be between full or OK range and add Reinstall dipstick into dipstick tube Filling IMPORTANT Do not overfill the engine with oil IMPORTANT Always use the dipstick to determine the exact quantity of oil or fluid required 1 Remove oil fill cap a 6077 a Oil fill cap IMPORTANT Add the specified engine oil to bring the level up to but not over the full or OK range mark on the dips...

Page 63: ...y recommended engine oil refer to Specifications EASY ENGINE OIL DRAIN SYSTEM NOTE Boat must be out of water to perform this procedure 1 Loosen the oil filter to vent the system 2 Remove the bilge drain plug 3 Pull tether through the bilge drain f e d c b a 7284 a Binge drain plug b Tether c Clip d Oil drain hose plug e Oil drain hose f Bilge drain flange 4 Place the oil drain hose in a suitable c...

Page 64: ...e oil and install 3 Tighten oil filter securely following filter manufacturer s instructions Do not overtighten 4 Remove oil fill cap IMPORTANT Always use dipstick to determine exactly how much oil is required 5 Add recommended engine oil to bring level up to the bottom of the OK range on the dipstick 6 With the boat at rest in the water check the oil level and add specified fluid to bring the oil...

Page 65: ...he dipstick to check the level If the fluid is below the top full line add the specified fluid through the breather elbow Do not overfill Reinstall the dipstick with the cap fully seated Checking While Engine is Cold NOTE Cold fluid level check To ease checking the fluid level the dipstick can be marked or scribed with a cold level mark 1 Follow the procedure for the warm fluid level check then al...

Page 66: ... until it seats on the filler neck 4 With the engine at normal operating temperature check the coolant level in the coolant recovery bottle 5 The coolant level should be between the ADD and FULL marks 6102 6 Add the specified fluid as necessary Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 Filling NOTICE Using propylene glycol ant...

Page 67: ...t recovery bottle 2 Fill to the FULL line with the specified coolant Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 3 Install the fill cap onto the coolant recovery bottle Changing Contact your authorized Mercury MerCruiser dealer Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive Ensure the key switch is off and t...

Page 68: ...d a mild detergent Dry with compressed air or allow to air dry completely 8 Inspect the crankcase ventilation hose for cracks or deterioration Replace if necessary 9 Install the flame arrestor and flame arrestor bracket Torque the flame arrestor bracket nuts Description Nm lb in lb ft Flame arrestor bracket nut 12 106 10 Connect the crankcase ventilation hose to the fitting on the flame arrestor a...

Page 69: ...h is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately CAUTION Failure to release pressure from the fuel system will result in ...

Page 70: ...off position 6 Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module Do not remove the filter assembly retaining screws from the filter cap 7 Unseat the filter assembly by grasping the filter assembly handle and pulling upward Do not remove the filter assembly from the Cool Fuel Module at this time 8 Allow any fuel that may be in the filter assembly to...

Page 71: ...uel Module and torque each filter assembly retaining screw Description Nm lb in lb ft Filter assembly retaining screw 6 53 6 Open fuel supply valve if equipped 7 Reconnect the Cool Fuel Module harness to the engine wiring harness 8 Properly ventilate the engine compartment NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide...

Page 72: ...ntered in the detent hole for each F N R position 1 Lubricate the detent ball and the holes in the shift lever a 5934 In Line Transmission Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Detent ball and shift lever holes 92 883725K01 2 Lubricate the shift cable pivot points a a 5935 a Pivot points Tube Ref No Description Where Used Part No Synthetic Blend...

Page 73: ...on of belt length that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 13 mm 1 2 in deflection with moderate thumb pressure on the belt at the location that has the longest distance between two pulleys mc75130 1 Replacing Belt and or Adjusting Tension IMPORTANT If a belt is to be reused it should be installed in the same direction of rotation as before NOTE Belt de...

Page 74: ... the correct belt tension tighten the 16 mm 5 8 in locking nut a b 6119 a 8 mm 1 16 in adjusting stud b 16 mm 5 8 in locking nut 8 Operate the engine for a short period of time and recheck the belt adjustment Flushing The Power Package Horizon Models NOTE Flushing is needed only for salty brackish mineral laden or polluted water applications Flushing is recommended after each outing for best resul...

Page 75: ...is not operating will result in water collecting in the exhaust system damaging the engine Do not supply flush water for more than 15 seconds without the engine operating 11 Turn off water source within 15 seconds of shutting off engine 12 Disconnect the quick connect fitting and water hose from the flush socket on the engine by pressing the release button on the flush socket 13 Attach to the next...

Page 76: ...n plate 1 Models with Walter V Drive Transmissions a Close the seacock if equipped and then disconnect the seawater inlet hose from the transmission seawater inlet fitting b If not equipped with a seacock disconnect the seawater inlet hose from the transmission seawater inlet fitting and plug the seawater inlet hose 6091 c Using appropriate connector connect the flushing water hose to the transmis...

Page 77: ...clear 10 Slowly return the throttle to idle speed position NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system damaging the engine Do not supply flush water for more than 15 seconds without the engine operating 11 Stop the engine 12 Immediately shut off the supply water and remove the flushing attachment 13 Install the water inlet hose to the s...

Page 78: ...the transmission seawater inlet fitting d Proceed to step 3 2 All other models a Close the seacock if equipped and then disconnect the seawater inlet hose from the seawater pump 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 Plug the seawater inlet hose immediat...

Page 79: ... return the throttle to idle speed position NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system damaging the engine Do not supply flush water for more than 15 seconds without the engine operating 11 Stop the engine 12 Immediately shut off the water supply and remove the flushing attachment 13 Remove the flushing connector from the water inlet 1...

Page 80: ...em In either case the ECM could shut off When the voltage returns to the range that the ECM requires the ECM will reset itself and the engine will operate normally The ECM shuts off and resets itself so quickly that the engine may only seem to have an ignition miss Batteries Boats with multi engine EFI power packages require each engine be connected to its own battery This ensures that the engine ...

Page 81: ...n System 76 Manual Single Point Drain System 77 Three Point Manual Drain System 77 Multi Point Drain MPD System 78 Air Actuated Single Point Drain System 78 Boat in the Water 78 Boat out of the Water 81 Manual Single Point Drain System 83 Boat in the Water 83 Boat out of the Water 84 Three Point Manual Drain System 85 Boat in the Water 85 Boat out of the Water 86 Multi Point Drain MPD System 87 Bo...

Page 82: ...lene glycol manufacturer s recommendations Preparing Power Package for Storage 1 Fill the fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline Follow instructions on the container 2 If the boat is to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alcohol is n...

Page 83: ...fore servicing the power package 1 In a 23 liter 6 U S gal remote fuel tank mix a 19 liter 5 U S gal regular unleaded 87 octain 90 RON gasoline b 1 89 liter 2 U S qts Premium Plus 2 Cycle TC W3 Outboard Oil c 150 ml 5 ounces Fuel System Treatment and Stabilizer or 30 ml 1 ounce Fuel System Treatment and Stabilizer Concentrate Tube Ref No Description Where Used Part No 115 Premium Plus 2 cycle TC W...

Page 84: ...ain system Refer to Drain System Identification to determine which instructions apply to your power package 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 st...

Page 85: ... 21125 a b c d d Scorpion Models a Blue air pump b Air manifold c Green indicators d Blue drain plug locations MANUAL SINGLE POINT DRAIN SYSTEM b a b 6128 a Blue handle b Blue drain plug location THREE POINT MANUAL DRAIN SYSTEM a a 6126 a Blue drain plug ...

Page 86: ...using a 6131 a Check valve if equipped Air Actuated Single Point Drain System BOAT IN THE WATER NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4...

Page 87: ... green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side 7 Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger This must be removed within 30 seconds to properly vent the cooling system 6124 a b c d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug lo...

Page 88: ... drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 10 Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump Do not allow engine to start 11 Reinstall the blue drain plug in the thermostat housing or heat exchanger 12 Remove the air pump from the air manifold and return it to the mounting bracket 13 Mercur...

Page 89: ... WATER NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Place the boat on a lever surface to ensure complete draining of system 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pull lever on air pump vertical to lock...

Page 90: ...a b c d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump c Air manifold d Green indicators 21125 a b c d d Scorpion Models a Blue air pump b Air manifold c Green indicators d Blue drain plug locations 7 Verify that water is draining from each opening If not use the Three Point Manual Drain System instructions a 6133 b a Port side drain location b ...

Page 91: ...helps ensure that all water is drained 12 Before launching the boat pull up on the manual release valve Verify that the green indicators are no longer extended a 6135 a Green indicators Manual Single Point Drain System BOAT IN THE WATER 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Rotate the blue handle counterclockwise until it stops approximately two turns The red on...

Page 92: ...lose the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug if removed The handle is fully seated when no red is visible Do not overtighten the handle as this action will create new threads 8 Open the seacock if equipped or unplug and reconnect the water inlet hose before operating the engine BOAT OUT OF THE WATER 1 Place the boat on a level surface t...

Page 93: ...ater is drained 5 Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug The handle is fully seated when no red is visible Do not overtighten handle as this action will create new threads Three Point Manual Drain System BOAT IN THE WATER NOTE Use this procedure if your engine is not equipped with an air actuated single point drain system or if...

Page 94: ...rting the boat or performing other maintenance to ensure that all water is drained 7 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 8 Before launching the boat or starting the engine close the drain system by installing the four blue drain plugs 9 Open the seacock if equipped or unplug and reconnect the wate...

Page 95: ...r slightly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 6 Before launching the boat or starting the engine close the drain system by installing the three blue drain plugs Multi Point Drain MPD System BOAT OUT OF THE WATER 1 Place the boat on a level surface to ensure complete draining of the system 2 Remove the blue drain plugs from the...

Page 96: ...ion 6 Storage Page 88 90 864197072 NOVEMBER 2007 c Water circulating pump hose a 6143 a Drain plug d Fuel cooler to thermostat housing hose a 6144 a Drain plug e Check valve a 6131 a Drain plug if equipped ...

Page 97: ...kup pump Do not allow the engine to start 5 After the cooling system has been drained completely install the drain plugs reconnect the hoses and tighten all hose clamps securely BOAT IN THE WATER 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Remove the blue drain plugs from the following locations If necessary clean out the drain holes using a stiff piece of wire Do so ...

Page 98: ...ion 6 Storage Page 90 90 864197072 NOVEMBER 2007 c Water circulating pump hose a 6143 a Drain plug d Fuel cooler to thermostat housing hose a 6144 a Drain plug e Check valve a 6131 a Drain plug if equipped ...

Page 99: ...ctions for storage Power Package Recommissioning 1 Ensure that all cooling system hoses are connected properly and hose clamps are tight CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system Always disconnect the negative battery cable first and connect it last 2 Install a fully charged battery Clean...

Page 100: ...Section 6 Storage Notes Page 92 90 864197072 NOVEMBER 2007 ...

Page 101: ...Will Not Crank Engine Or Cranks Slow 94 Engine Will Not Start or Is Hard to Start 95 Engine Runs Rough Misses or Backfires 95 Poor Performance 95 Excessive Engine Temperature 95 Insufficient Engine Temperature 96 Low Engine Oil Pressure 96 Battery Will Not Recharge 96 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 97 Steering Wheel Jerks or Is Difficult to Turn 97 7...

Page 102: ...ian using a special diagnostic tool Engine Guardian System The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems The system will respond to a problem by emitting a continuous beep and or reducing engine power in order to provide engine protection If Guardian System has been activated reduce throttle speed The horn will turn off when throttle s...

Page 103: ...logged fuel line or fuel tank vent line Replace kinked lines or blow out lines with compressed air to remove obstruction Flame Arrestor dirty Clean Flame Arrestor Faulty ignition system component Service ignition system Idle speed too low Have EFI system checked by an authorized Mercury MerCruiser dealer EFI System fault Have EFI System checked by an authorized Mercury MerCruiser dealer Poor Perfo...

Page 104: ...ble Cause Remedy Faulty thermostat Replace Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase Check and add oil Excessive oil in crankcase causing it to become aerated Check and remove required amount of oil Check for cause of excessive oil improper filling Diluted or improper viscosity oil Change oil and oil filter using correct grade and viscosity oil Determine cause for...

Page 105: ...er immediately Shift or throttle cable kinked Straighten cable or have authorized Mercury MerCruiser dealer replace cable if damaged beyond repair Steering Wheel Jerks or Is Difficult to Turn Possible Cause Remedy Low power steering pump fluid level Check for leak Refill system with fluid Drive belt loose or in poor condition Replace and or adjust Insufficient lubrication on steering components Lu...

Page 106: ...Section 7 Troubleshooting Notes Page 98 90 864197072 NOVEMBER 2007 ...

Page 107: ...Assistance 100 Local Repair Service 100 Service Away From Home 100 Stolen Power Package 100 Attention Required after Submersion 100 Replacement Service Parts 100 Parts and Accessories Inquiries 101 Resolving a Problem 101 Mercury Marine Service Offices 101 Ordering Literature 102 United States and Canada 102 Outside The United States and Canada 102 8 ...

Page 108: ...act an authorized Mercury MerCruiser dealer 2 After recovery immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of serious engine damage Replacement Service Parts WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or ...

Page 109: ...ct the owner of the dealership if the sales manager and service manager have been unable to resolve the problem 2 If your question concern or problem cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the Service Office Your name a...

Page 110: ...ited States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P O Box 1939 Fond du Lac WI 54936 1939 920 929 5110 Fax 920 929 4894 Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center ...

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