MerCruiser Tow Sports 5.7 MPI User Manual Download Page 38

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Section 2 - Getting to Know Your Power Package

Page 30

90-865253073 DECEMBER 2007

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

A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical

system. Check for a failed fuse if the ignition key is turned to the "START" position and

nothing happens, and the circuit breaker is not tripped.

mc70525-1

Audio Warning System

IMPORTANT: The audio warning system alerts the operator that a problem has occurred.

It does not protect the engine from damage.
Your Mercury MerCruiser power package may be equipped with an audio warning system.

Most faults cause the warning horn circuit to activate. How the warning horn activates

depends on the severity of the problem.
There are three warning horn states:
• Caution
• Severe
• Onboard Diagnostic Marine (OBDM) fault

Summary of Contents for Tow Sports 5.7 MPI

Page 1: ...nt Annex 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 i...

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: ...etting to Know Your Power Package Identification 20 Engine Serial Number Decal 20 Transmissions 20 Velvet Drive Transmissions 20 ZF Marine Transmissions 21 Walter V Drive Transmissions 22 Lanyard Stop Switch 22 Instrumentation 23 VesselView 23 Digital Gauges 24 Analog Gauges 25 Remote Controls Non DTS Models 25 Remote Controls 25 Panel Mount Features 26 Console Mount Features 27 Zero Effort Featur...

Page 6: ...ine Oil Drain Pump 57 Changing the Oil Filter 58 Transmission Fluid 59 Checking While the Engine is Warm 59 Checking While Engine is Cold 59 Changing 59 Battery 59 Multiple EFI Engine Battery Precautions 60 Cleaning the Flame Arrestor 60 Positive Crankcase Ventilation Valve PCV 61 Changing 61 Cleaning The IAC Muffler 62 Water Separating Fuel Filter 63 GEN III Models 63 Removal 63 Installation 64 L...

Page 7: ...ature 88 Low Engine Oil Pressure 88 Battery Will Not Recharge 88 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 88 Steering Wheel Jerks or Is Difficult to Turn 89 Section 8 Customer Assistance Information Owner Service Assistance 92 Local Repair Service 92 Service Away From Home 92 Stolen Power Package 92 Attention Required after Submersion 92 Replacement Service Pa...

Page 8: ...Page iv 90 865253073 DECEMBER 2007 ...

Page 9: ...y Chart 7 Commercial Application Warranty Chart 8 Government Application Warranty Chart 9 Mercury Installation Quality Certification Program 9 California Emissions Limited Warranty 10 What Is Covered 10 Duration Of Coverage 11 How To Obtain Warranty Coverage 12 What Mercury Will Do 12 What Is Not Covered 12 Components Of The Emission Control System 12 Disclaimers And Limitations 14 California Emis...

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: ...Certification Program and communicate its benefits to consumers For a current list of MerCruiser powered boat brands that have earned Installation Quality Certification visit www mercurymarine com mercruiser_warranty California Emissions Limited Warranty NOTE Mercury Marine does not establish model years for the Mercury MerCruiser product line In order to comply with CARB warranty regulations and ...

Page 19: ...alendar year As an example 2003 model year products refers to products manufactured during calendar year 2003 This limited warranty provides coverage for the components of the emissions control systems Select emission control parts from model year 2003 2005 inboard or sterndrive engines are warranted for 2 years from either the date the product is first sold or first put into service whichever occ...

Page 20: ...nsistent with the recommended operation procedures neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part not manufactured or sold by us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the ...

Page 21: ...cation System a Oil pump and internal parts b Oil injector s c Oil meter 5 Positive Crankcase Ventilation PCV System a PCV Valve b Oil filler cap 6 Exhaust System a Exhaust manifold b Exhaust elbow c Intermediate exhaust elbow d Lower exhaust pipe e Tailpipe 7 Catalysts or Thermal Reactor System a Catalytic converter b Thermal reactor c Exhaust manifold d Exhaust valve s 8 Miscellaneous Items Used...

Page 22: ...so included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Mercury Marine will repair your inboard or sterndrive engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage For 2003 2008 spark ignition inboard and sterndrive marine engines Select emission control parts from model year1 2003 2008 inboard and...

Page 23: ...he 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 NOTE When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine the Declaration of Conformance applies Refer to the front page of this manual for further information EMISSION CON...

Page 24: ...nomy burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources 3 Longer Emission Warranty Protects consumer for worry free operation 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 ...

Page 25: ... marine engine 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low emission A SS D mc79571 1 The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust em...

Page 26: ...Section 1 Warranty Notes Page 18 90 865253073 DECEMBER 2007 ...

Page 27: ...s 20 ZF Marine Transmissions 21 Walter V Drive Transmissions 22 Lanyard Stop Switch 22 Instrumentation 23 VesselView 23 Digital Gauges 24 Analog Gauges 25 Remote Controls Non DTS Models 25 Remote Controls 25 Panel Mount Features 26 Console Mount Features 27 Zero Effort Features 27 Electrical System Overload Protection 28 Audio Warning System 30 Caution 31 Severe 31 OBDM 31 Testing The Audio Warnin...

Page 28: ...ial number is also stamped in the engine block Transmissions VELVET DRIVE TRANSMISSIONS On Velvet Drive In Line and V Drive Transmissions 71C 72C 72C V Drive with or without Walter transmissions the gear ratio in forward gear is marked on transmission identification plate Transmission output shaft rotation and propeller rotation required in forward gear is indicated on a decal on transmission case...

Page 29: ...d model 7370 a Velvet Drive 5000A 8 degree down angle transmission shown 5000V V drive similar a Transmission identification plate ZF MARINE TRANSMISSIONS On the ZF Marine 8 Degree Down Angle and V Drive Transmissions the transmission identification plate indicates gear ratio serial number and model a 7449 Typical ZF Marine down angle transmission shown V drive similar a Transmission identificatio...

Page 30: ...he 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 also occur from poor operating practices sitting on the seat or gunwale at ...

Page 31: ...boat would when under power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be 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 p...

Page 32: ...n VesselView may also be connected to other vessel systems such as GPS generators and cabin environmental controls This comprehensive vessel integration allows the operator to monitor and control a wide range of vessel systems from a single convenient display Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product A few of the functions the instrument packag...

Page 33: ...adings for your boat L H OIL C H TEMP 0 1 2 3 4 5 6 7 8 R P M X 1000 MPH KPH 10 20 30 40 50 60 70 80 30 40 50 60 70 80 90 100 120 110 10 16 BATT 0 4 4 4 FUEL CRUISELOG 0 0 0 0 0 a b c d e f g h i 17352 Reference Gauge Function a Speedometer Indicates boat speed b Tachometer Indicates engine RPM c Oil pressure gauge Indicates engine oil pressure d Voltmeter Indicates battery voltage e Coolant tempe...

Page 34: ...t 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 operator s position to activate the switch Refer to Lanyard Stop Switch for information on the use of this switch Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward ...

Page 35: ...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 36: ...t 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 Reset the circuit breaker If the breaker remains open the electrical overload has not been eliminated Further checks must be made on the electrical system Contact your authorized dea...

Page 37: ...uses protect the main power fuel pump ignition and accessory circuits 33214 Engine fuses Two 10 amp fuses protect the O2 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 a b c 32206 a Fuse cover b 15 amp fuse c Power harness ...

Page 38: ...trical system Check for a failed fuse if the ignition key is turned to the START position and nothing happens and the circuit breaker is not tripped mc70525 1 Audio Warning System IMPORTANT The audio warning system alerts the operator that a problem has occurred It does not protect the engine from damage Your Mercury MerCruiser power package may be equipped with an audio warning system Most faults...

Page 39: ... severe fault is detected the audio warning system will sound for six seconds turn off for six seconds then sound for six more seconds 33403 a ON ON 6 6 6 OFF b a Horn on or off b Time in seconds Below are some examples of a severe fault Engine oil pressure is too low Engine temperature is too hot Seawater pressure is too low Transmission pressure is low select models OBDM If an OBDM fault is dete...

Page 40: ...lt for diagnostics For example if the water inlet becomes partially blocked Guardian reduces the available power level of the engine to help prevent damage from decreased water flow to the engine If the debris passes through and full water flow is restored Guardian restores engine power to normal To avoid recurrence of the problem contact an authorized Mercury MerCruiser dealer As another example ...

Page 41: ...Drain Plug and Bilge Pump 38 Protecting People in the Water 38 While You Are Cruising 38 While Boat Is Stationary 39 High Speed and High Performance Operation 39 Passenger Safety in Pontoon Boats and Deck Boats 39 Boats Having An Open Front Deck 39 Boats With Front Mounted Raised Pedestal Fishing Seats 39 Wave and Wake Jumping 40 Impact with Underwater Hazards 40 Conditions Affecting Operation 41 ...

Page 42: ... 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 43: ...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 44: ...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 45: ... 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 46: ...ntrol lever to the idle neutral position Moving the control lever from the idle neutral position to the idle forward or idle 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...

Page 47: ...toon Boats and Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed A sudden reduction in boat speed such as plunging into a large wave or wake a sudden throttle reduction or a sharp change of boat direction could throw them over the front of boat Falling o...

Page 48: ... while in the midst of the jump In such cases the landing may cause the boat to violently veer in a new direction Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat There is another less common hazardous result from allowing your boat to launch off of a wave or wake If the bow of your boat pitches down far enough while airborne upon wate...

Page 49: ...uiser dealer for a thorough inspection and necessary repair The boat should be checked for hull fractures transom fractures and water leaks Operating with damaged underwater drive components rudder or boat bottom could cause additional damage to other parts of the power package or could affect control of the boat If continued operation is necessary do so at greatly reduced speeds WARNING Operating...

Page 50: ...ce of your power package Loss of performance can be caused by Higher elevations Higher temperatures Low barometric pressures High humidity For you to have optimum engine performance under changing weather conditions it is essential that the engine be propped to allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your normal boating w...

Page 51: ...rottle or lower Refrain from prolonged operation at wide open throttle RPM Change the engine oil and oil filter Refer to Maintenance Change the transmission oil and filter Refer to Maintenance 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 a...

Page 52: ...Section 3 On the Water Notes Page 44 90 865253073 DECEMBER 2007 ...

Page 53: ...tion 4 Specifications Table of Contents Cruising RPM 46 Fuel Requirements 46 Fuel Ratings 46 Using Reformulated Oxygenated Gasoline USA Only 46 Gasoline Containing Alcohol 46 Engine Oil 47 Engine Specifications 48 Fluid Specifications 48 Engine 48 Transmission 49 4 ...

Page 54: ...mum Premium gasoline 92 R M 2 Octane is also acceptable Do not use leaded gasoline Outside USA and Canada 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 Gasoline USA Only Reformulated gasoline is required in certain areas of the USA and are acceptable f...

Page 55: ...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 maintain optimum engine performance and to provide maximum protection we recommend the following oil Application Recommended Oil All MerCruiser engines with Emissions Control Mercury MerCruiser Full Synthetic E...

Page 56: ...are taken with the engine at normal operating temperature RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures Oil pressure must be checked with the engine at normal operating temperature Model Tow Sports 5 7 MPI Power 235 kW 315 hp Displacement 5 7 L 350 cid Specified WOT RPM range 4600 5000 Idle RPM in neutral 600 Minimum oil pressure at idl...

Page 57: ...nsmission Model Capaci Fluid Type 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 45C Tow Sports 1 90 L 64 oz Dexron III Automatic...

Page 58: ...Section 4 Specifications Notes Page 50 90 865253073 DECEMBER 2007 ...

Page 59: ...Engine Oil Drain Pump 57 Changing the Oil Filter 58 Transmission Fluid 59 Checking While the Engine is Warm 59 Checking While Engine is Cold 59 Changing 59 Battery 59 Multiple EFI Engine Battery Precautions 60 Cleaning the Flame Arrestor 60 Positive Crankcase Ventilation Valve PCV 61 Changing 61 Cleaning The IAC Muffler 62 Water Separating Fuel Filter 63 GEN III Models 63 Removal 63 Installation 6...

Page 60: ...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 61: ...re 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 the repair procedure It is diff...

Page 62: ... saltwater reduce this interval to every 25 hours or 30 days whichever occurs first Scheduled Maintenance NOTE Only perform maintenance that applies to your particular power package Task Interval Maintenance to Be Performed After the initial 20 hour break in period Change the engine oil and filter Change the engine oil and filter Change the transmission fluid and filter ZF Marine requires changing...

Page 63: ... system hose clamps for tightness Inspect both systems for damage or leaks Disassemble and inspect the seawater pump and replace worn components Inspect the exhaust system components If the package was equipped with water shutters flapper valves verify that they are not missing or worn Maintenance Log Record all maintenance performed on your power package here Be sure to save all work orders and r...

Page 64: ...the dipstick reading which should indicate a level between the full or OK mark and the ADD mark Reinstall the dipstick into the dipstick tube If the oil level is low refer to Filling Filling IMPORTANT Do not overfill the engine with oil Always use the dipstick to determine the exact quantity of oil or fluid required 1 Remove oil fill cap 33140 Oil fill cap IMPORTANT Add the specified engine oil to...

Page 65: ...e boat must be out of water to perform this procedure 1 Loosen the oil filter to vent the system 2 Allow sufficient time for the oil to drain from the filter down into the engine block 3 Remove the bilge drain plug 4 Pull tether through the bilge drain f e d c b a 7284 a Bilge drain plug b Tether c Clip d Oil drain hose plug e Oil drain hose f Bilge drain flange 5 Place the oil drain hose in a sui...

Page 66: ...ing ring on the new filter with engine oil 3 Install and tighten the oil filter securely following the filter manufacturer s instructions Do not overtighten 4 Remove oil fill cap 5 Use the dipstick to determine the amount of engine oil required Replace the dipstick 6 Add the required amount of the recommended oil to bring the level up to the bottom of the OK range on the dipstick 7 With the boat a...

Page 67: ...d 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 allow the boat to sit overnight IMPORTANT Be sure to push the dipstick all the way down into the dipstick tube when checking the fluid level 2 Remove the dipstick wipe clean and reinsert 3 Remove the dipstick observe the fluid level ...

Page 68: ...Boats with multi engine EFI power packages require each engine be connected to its own battery This ensures that the engine s ECM has a stable voltage source Battery Switches Battery switches should always be positioned so each engine is operating off of its own battery Do not operate engines with switches in both or all position In an emergency another engine s battery can be used to start an eng...

Page 69: ... the crankcase ventilation hose with warm water and 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 venti...

Page 70: ...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 NOTE The IAC muffler may be installed in the throttle body or in the IAC adapter Locate y...

Page 71: ...ervicing 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 fuel spraying out which can cause a fire or explosion Allow the engine to cool completely and release all fuel pressure before servicing any pa...

Page 72: ... filter element into the filter cup Push the element into the cup until completely seated 2 Install new O ring on the filter cup 3 Attach the filter cap to the filter cup by grasping the filter cap and rotating it in a counter clockwise direction while holding the filter cup stationary until the filter cap locks securely into place 4 Install the fuel filter assembly slowly into the Cool Fuel Modul...

Page 73: ...thetic Blend MerCruiser Engine Oil SAE25W 40 Throttle cable pivot points guide contact surfaces 92 883725K01 Transmission Linkage IMPORTANT The poppet ball must be centered 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 Dete...

Page 74: ...ning may cause serious injury or death Turn off the engine and remove the ignition key before adjusting tension or inspecting belts b a c d e 6089 a Idler pulley b Circulating pump pulley c Crankshaft pulley d Alternator pulley e Seawater pump pulley Checking 1 Inspect the drive belt for proper tension and for the following Excessive wear Cracks NOTE Minor transverse cracks across the belt width m...

Page 75: ... on the adjustment stud 2 Turn the adjustment stud and loosen the belt 3 If a new serpentine drive belt is required remove the old belt and install a new belt onto the pulleys 4 Put a wrench on the adjustment stud 16 mm 5 8 in locking nut 5 Use a 8 mm 5 16 in socket and tighten adjusting the stud to adjust the belt deflection 6 Using one of the 2 methods following check for correct deflection a Pu...

Page 76: ...er each outing and before cold weather and extended storage WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ven...

Page 77: ...tion 5 Immediately start the engine 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 6 Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM 100 RPM 7 Observe th...

Page 78: ...e seacock before disconnecting the seawater inlet hose Plug the seawater inlet hose immediately after disconnecting it 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 NOTICE Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage Close the...

Page 79: ...ter source to provide maximum water supply 4 Place the remote control in the neutral idle speed position 5 Immediately start the engine 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 6 Depress the throttl...

Page 80: ...ly and remove the flushing attachment 13 Remove the flushing connector from the water inlet 14 Tag the ignition switch with an appropriate tag requiring the seacock to be opened or the seawater inlet hose to be reconnected prior to operating the engine 15 Repeat the flushing procedure on the next engine if equipped ...

Page 81: ...ystem Preparation 75 Draining the Seawater System 76 Drain System Identification 76 Air Actuated Single Point Drain System 76 Three Point Manual Drain System 77 Air Actuated Single Point Drain System 77 Boat in the Water 77 Boat out of the Water 79 Three Point Manual Drain System 81 Boat in the Water 81 Boat out of the Water 82 Battery Storage 83 Power Package Recommissioning 83 6 ...

Page 82: ...ecommendations 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 not available Fuel tanks shou...

Page 83: ...g out of fuel can damage catalyst components Do not allow the fuel tanks to become empty during operation 1 In a 23 liter 6 US gal remote fuel tank mix a 19 liter 5 US gal regular unleaded 87 octane 90 RON gasoline b 1 89 liter 2 US qt Premium Plus 2 Cycle TC W3 Outboard Oil c 150 ml 5 oz Fuel System Treatment and Stabilizer or 30 ml 1 oz Fuel System Treatment and Stabilizer Concentrate Tube Ref N...

Page 84: ...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 storage Make sure that the p...

Page 85: ... plug the water inlet hose 2 Remove the blue 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 pump on the fitting 8293 b d e a c a Actuator fitting b Green indicators c Manual release valve d Blue air pump e Lever locking 6 Pump air into the system until b...

Page 86: ...em instructions a b 6133 a Port side drain location b Starboard side drain location 9 Allow the system to 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 he...

Page 87: ...R NOTE This procedure is written for the blue 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 blue 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...

Page 88: ...t use the Three Point Manual Drain System instructions a b 6133 a Port side drain location b Starboard side drain location 8 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 9 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump Do not allow engine to start 10 Remove the air pump from th...

Page 89: ...ure if your engine is not equipped with an air actuated single point drain system or if the air actuated single point drain system fails 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Remove the blue drain plug from the distribution housing lower front port side 6138 a a Blue drain plug 3 To properly vent the cooling system remove the blue drain plug from the side of the...

Page 90: ...or to operating the engine BOAT OUT OF THE WATER NOTE Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails 1 Place the boat on a level surface to ensure complete draining of the system 2 Remove three blue drain plugs one from the distribution housing lower front port side and two from the seawater pickup pump fro...

Page 91: ...onnect the negative battery cable first and connect it last 2 Install a fully charged battery Clean the battery cable clamps and terminals and reconnect cables Tighten each cable clamp securely when connecting 3 Coat the terminal connections with a battery terminal anti corrosion agent 4 Perform all the checks in the before starting column of the Operation Chart NOTICE Without sufficient cooling w...

Page 92: ...Section 6 Storage Notes Page 84 90 865253073 DECEMBER 2007 ...

Page 93: ...arter Motor Will Not Crank Engine or Cranks Slowly 86 Engine Will Not Start or Is Hard to Start 87 Engine Runs Rough Misses or Backfires 87 Poor Performance 87 Excessive Engine Temperature 87 Insufficient Engine Temperature 88 Low Engine Oil Pressure 88 Battery Will Not Recharge 88 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 88 Steering Wheel Jerks or Is Difficul...

Page 94: ...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 speed is within the allowable limit Consult an authorized Mercur...

Page 95: ...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 Performance Possible Cause Remedy T...

Page 96: ...r improper viscosity oil Change oil and oil filter using correct grade and viscosity oil Determine cause for dilution excessive idling Battery Will Not Recharge Possible Cause Remedy Excessive current draw from battery Turn off non essential accessories Alternator drive belt loose or in poor condition Replace and or adjust Unacceptable battery condition Test battery replace if necessary Loose or d...

Page 97: ...eak Refill system with fluid Drive belt loose or in poor condition Replace and or adjust Insufficient lubrication on steering components Lubricate Loose or missing steering fasteners or parts Check all parts and fasteners if any are loose or missing see authorized Mercury MerCruiser dealer immediately Contaminated power steering fluid See authorized Mercury MerCruiser dealer ...

Page 98: ...Section 7 Troubleshooting Notes Page 90 90 865253073 DECEMBER 2007 ...

Page 99: ...rvice Assistance 92 Local Repair Service 92 Service Away From Home 92 Stolen Power Package 92 Attention Required after Submersion 92 Replacement Service Parts 92 Parts and Accessories Inquiries 93 Resolving a Problem 93 Mercury Marine Service Offices 93 Ordering Literature 94 United States and Canada 94 Outside The United States and Canada 94 8 ...

Page 100: ...ct 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 e...

Page 101: ...t 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 an...

Page 102: ...ted 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 f...

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