Mercury 1.7 MI Manual Download Page 235

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TROUBLESHOOTING

SECTION 7

CMD-3967823 / 90-865237030 OCTOBER 2003

Page 103

CE535

Engine Runs Rough, Misses And/Or Backfires

Possible Cause

Remedy

Idle speed too low.

Check idle speed and adjust, if necessary.

Clogged fuel or air filters.

Replace filters.

Stale or contaminated fuel.

If contaminated, drain tank. Fill with fresh

fuel.

Kinked or clogged fuel line or fuel tank

vent line.

Replace kinked lines or blow out lines with

compressed air to remove obstruction.

Air in fuel injection system.

Purge fuel injection system.

Injector / injector nozzle malfunction.

Have inspected by an authorized

Cummins MerCruiser Diesel dealer /

distributor.

Injection pump governor malfunction.

Have inspected by an authorized

Cummins MerCruiser Diesel dealer /

distributor.

INDEX

Summary of Contents for 1.7 MI

Page 1: ...2003 Mercury Marine CMD 3967823 90 865237030 1003 1 7 MI Diesel Engine Inboard Models INDEX...

Page 2: ...umber HIN Purchase Date 6 Boat Manufacturer Boat Model Length 7 Exhaust Gas Emissions Certificate Number Europe Only The description and specifications contained herein were in effect at the time this...

Page 3: ...is manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our Cummins MerCruiser Diesel products We sincerely hope your boating will be pleasa...

Page 4: ...nor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for proper operation and or maintenance CE458 WARNING The operator driver is respon...

Page 5: ...ions 20 Be Alert To Carbon Monoxide Poisoning 22 Good Ventilation 23 Poor Ventilation 23 Basic Boat Operation 24 Launching And Boat Operation Care 24 Duty Cycle Rating 25 Pleasure Duty Rating 25 Opera...

Page 6: ...illing 58 Changing 59 Transmission Fluid 62 Checking 62 Filling 63 Changing 64 Lubrication 66 Shift Cable 66 Throttle Cable 66 Engine Coolant 67 Checking 67 Filling 69 Changing 69 Water Separating Fue...

Page 7: ...ngine Oil Pressure 106 Battery Will Not Charge 107 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 107 SECTION 8 CUSTOMER ASSISTANCE INFORMATION Owner Service Assist...

Page 8: ...Page iv CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 9: ...ranty Information 2 Owner Warranty Registration 2 United States And Canada Only 2 International Owner Registration 3 Outside The United States And Canada 3 Warranty Policies 4 Recreational Use Diesel...

Page 10: ...ate of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service during this period present the temporary registration card to the dealer He will att...

Page 11: ...ice on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries...

Page 12: ...BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Cummins MerCruiser Diesel to distribute the product in the...

Page 13: ...y us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the product see the Operation Maintenance And Warranty Manual alteration or removal of pa...

Page 14: ...es Damage caused by neglect lack of maintenance accident abnormal operation improper installation or service or freezing temperatures Haul out launch towing charges removal and or replacement of boat...

Page 15: ...ter entering the engine via the air filter or exhaust system or submersion Also water in the starter motor Starter motors and or armatures or field coil assembly which are burned or where lead is thro...

Page 16: ...Warranty Registration Card and a copy of the bill of sale to show proof of ownership In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P...

Page 17: ...SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE Table of Contents Features And Controls 10 Lanyard Stop Switch 10 Instrumentation 12 Remote Controls 15 Panel Mounted 15 Console Mounted 16 Electrical Syst...

Page 18: ...ers releasing your grip on the steering wheel that is pulling in 1 direction consuming alcohol or drugs high speed boating maneuvers Some remote control units are equipped with a lanyard stop switch i...

Page 19: ...act with the boat hull and propeller from accidental ejection Personal injury or death could occur Always properly connect both ends of the lanyard stop switch Accidental or unintended activation of t...

Page 20: ...boat dealer explain the particular gauges and normal readings that will appear on your style gauges 77725 b c d 70514 a e g h 70519 f Typical a Speedometer b Tachometer c Oil pressure gauge d Battery...

Page 21: ...ating if equipped and all instruments are operational 3 START In the START position the engine can be started NOTE The key can only be removed in the OFF position Engine Stop Switch is used to stop th...

Page 22: ...timed preheat period begins when the key switch is turned to RUN The lamp stays on until the preheat period is complete The engine should be started only after the lamp goes out NOTE Some engines may...

Page 23: ...ol 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 en...

Page 24: ...djustment Screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed to adjust This will help prevent slipping of the remote control handle Turn s...

Page 25: ...reaker If the breaker remains open the electrical overload has not been eliminated Further checks must be made on the electrical system Contact your authorized Cummins MerCruiser Diesel dealer distrib...

Page 26: ...al oil pressure gauge Typical coolant temperature gauge 79753 Typical transmission fluid temperature switch CAUTION Operation of the engine after the audio warning system alarm has sounded could resul...

Page 27: ...Starting The Engine 27 Engine Shut down Stopping 30 Freezing Temperature And Cold Weather Operation 31 Drain Plug and Bilge Pump 31 Protecting People In The Water 32 While You Are Cruising 32 While Bo...

Page 28: ...s of Waterway Information booklet It lists regional sources of safety cruising and local navigation and is available at no charge by writing to Sources of Waterway Information National Marine Manufact...

Page 29: ...driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate Know your boat s operating...

Page 30: ...oat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be...

Page 31: ...etectors 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 an operating engine may be exposed to a h...

Page 32: ...ove idle speed w When launching your boat from a steep ramp enter the water slowly Do not use the lanyard stop switch to shut off the engine above idle speed When coming off plane if a large following...

Page 33: ...ating applies to recreational planing craft used exclusively for pleasure and recreation Typical applications include pleasure craft such as sailboats ski boats runabouts speedboats and other planing...

Page 34: ...ntrol operation Engage the STOP switch and hold until engine completely stops Prime fuel injection system if necessary Turn key switch to OFF position Pre lubricate turbocharger and engine if necessar...

Page 35: ...77312 a a Stop lever BEFORE STARTING THE ENGINE CAUTION Overheating from insufficient cooling water will cause engine and drive system damage Ensure that there is sufficient water always available at...

Page 36: ...be started only after the five second wait to start period has ended NOTE The preheat devices glow plugs should operate at temperatures lower than 80 degrees C 176 degrees F An engine coolant temperat...

Page 37: ...il pressure should be within range listed in the engine specifications chart Stop the engine if oil pressure is not within this range b Check the fuel system for leaks from the injection pump fuel pip...

Page 38: ...mum rpm or wide open throttle Stop the engine if oil pressure is not within this range Locate and correct the problem or see your authorized Cummins MerCruiser Diesel dealer distributor if you are una...

Page 39: ...ent type antifreeze solution to protect components against damage by freezing Be sure to use proper cold weather lubrication oil and be sure the crankcase contains a sufficient amount Make certain tha...

Page 40: ...a boat is moving coasting in NEUTRAL IDLE there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury While Boat...

Page 41: ...them over the front of boat Falling over the front of the boat between the two pontoons will position them to come into contact with the drive unit 1 Boats having an open front deck a No one should e...

Page 42: ...f the water certain hazards arise particularly when the boat re enters the water The primary concern is the boat changing direction while in the midst of the jump In such cases the landing may cause t...

Page 43: ...ven out of the boat Impact damage to the underwater drive components rudder and or boat Keep in mind one of the most important things you can do to help reduce injury or impact damage in these situati...

Page 44: ...t bottom should be Clean free of barnacles and marine growth Free of distortion nearly flat where it contacts the water Straight and smooth fore and aft Marine vegetation may accumulate when the boat...

Page 45: ...device that limits engine rpm Be sure that propeller being used does not allow engine to run excessively against the governor as a significant loss in performance will result NOTE Use an accurate ser...

Page 46: ...in gear for 3 minutes at each of the following rpms 1700 rpm 3500 rpm and 4000 rpm 4 Operate the engine in gear for 3 minutes at each of the following rpms 2100 rpm 3500 rpm and Maximum Rated Full Th...

Page 47: ...nance Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at WOT rpm Change the oil and oil filter Refer to Specifications and Maintenance CE476 End of First Sea...

Page 48: ...ON THE WATER SECTION 3 Page 40 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 49: ...0 865237030 OCTOBER 2003 Page 41 SECTION 4 SPECIFICATIONS Table of Contents Fuel Requirements 42 Recommended Fuels 43 Diesel Fuel In Cold Weather 43 AntiFreeze Coolant 44 Engine Oil 45 Engine Specific...

Page 50: ...l is highly flammable and produces a significant risk to the user IMPORTANT Use of improper or water contaminated diesel fuel can damage your en gine seriously Use of improper fuel is considered misus...

Page 51: ...endation JIS JAPANESE INDUSTRIAL STANDARD No 2 DIN DEUTSCHE INDUSTRIE NORMEN DIN 51601 SAE SOCIETY OF AUTOMOTIVE ENGINEERS Based on SAE J 313C No 2 D BS BRITISH STANDARD Based on BSEN 590 1197 A 1 CE1...

Page 52: ...utions will form a protective film on internal passages and provide protection against internal cooling system erosion The closed cooling section should be kept filled year round with an acceptable an...

Page 53: ...a rating of HD SAE API CG 4 and CH 4 We strongly recommend the use of Description Where Used Part Number Mercury Diesel Engine Oil Engine crankcase 92 877695K1 This oil is a specially blended 15W 40...

Page 54: ...Camshaft Direct Injection Turbocharged Intercooled Displacement 1 686 cubic liters 103 cid Engine weight approximate 250 kg 550 lb Bore 79 mm 3 11 in Stroke 86 mm 3 39 in Th t t 82 95 180 203 1 Thermo...

Page 55: ...4 1 Mercury Diesel Engine Oil 92 877695K1 Closed Cooling System 8 3 4 9 1 4 Marine Engine Coolant 92 813054A2 Seawater Cooling System 2 6 1 2 6 3 4 Not Applicable Not Applicable 1 Always use the dips...

Page 56: ...SPECIFICATIONS SECTION 4 Page 48 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 57: ...ging 64 Lubrication 66 Shift Cable 66 Throttle Cable 66 Engine Coolant 67 Checking 67 Filling 69 Changing 69 Water Separating Fuel Filter 70 Draining 70 Replacing 72 Filling 74 Fuel System 75 Priming...

Page 58: ...imum performance and dependability and will keep your overall operating expenses at a minimum See your authorized Cummins MerCruiser Diesel dealer distributor for service aids CE467 Dealer Responsibil...

Page 59: ...itant IMPORTANT Refer to Maintenance Chart for complete listing of all scheduled maintenance to be performed Some listings can be done by owner operator while others should be performed by an authoriz...

Page 60: ...ine 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 off...

Page 61: ...he fuel filter after each use if operating in freezing temperatures D Check the water inlets for debris or marine growth Check the seawater strainer and clean D Check the battery connections and the f...

Page 62: ...arts Lubricate the cables and the linkages D Disassemble and inspect the seawater pump and replace the worn components D Touch up paint the power package and spray with corrosion guard D Inspect the c...

Page 63: ...or 5 years z Every 1000 hours or 5 years z Per OEM Replace the coolant D Check the electrical system for loose damaged or corroded fasteners D Inspect the timing belt and pulleys D Retorque the engine...

Page 64: ...MAINTENANCE SECTION 5 Page 56 CMD 3967823 90 865237030 OCTOBER 2003 0166 Maintenance Record Date Hour Meter Reading Serviced By Maintenance Performed INDEX...

Page 65: ...ed by local authorities CE492 Checking 1 Stop the engine Allow approximately 10 minutes for oil to drain into oil pan The boat must be at rest in the water 2 Remove the dipstick Wipe clean and reinsta...

Page 66: ...ot over MAX mark on dipstick NOTE It takes several minutes for the added oil to drain to the oil pan Wait approximately 10 minutes and check the level again after adding oil All models Capacity liters...

Page 67: ...d engine oil Refer to Specifications 1 Start the engine and allow it to warm up to normal operating temperature 2 Stop the engine and allow some time for oil to drain into oil pan approximately 10 min...

Page 68: ...ply a coat of engine oil to the O rings Install the element on the top piece Description Where Used Part Number Engine oil Oil filter O rings Obtain Locally 10 Install the top piece with the new eleme...

Page 69: ...u simultaneously turn the key switch to the START position for 15 seconds Doing this together turns the engine without starting it b Repeat step a as needed Pre lubrication is complete when oil pressu...

Page 70: ...the level up to the MAXIMUM mark on the dipstick a b c d 79465 a Dipstick b Threaded hole c MAXIMUM Fluid Level d MINIMUM Fluid Level IMPORTANT To accurately check the fluid level the engine must be o...

Page 71: ...vel d MINIMUM Fluid Level Model Capacity liters U S qts Fluid type ZF Marine 25A 1 8 1 9 1 Dexron III Automatic Transmission Fluid or Equivalent 1 Always use the dipstick to determine the exact quanti...

Page 72: ...nd remove the fluid filter assembly by turning the assembly nut counterclockwise and pulling at the same time a b 79799 a Fluid filter assembly b Assembly nut 3 Push the hose of a suction pump through...

Page 73: ...ated to avoid fluid foaming and or loss of fluid resulting in decreased efficiency and or damage to transmission 8 Install the fluid filter assembly in the transmission cavity by turning clockwise and...

Page 74: ...cal a Pivot points b Guide contact surfaces Description Where Used Part Number A Engine Oil Pivot points guide contact surfaces Obtain Locally Throttle Cable 1 Lubricate the pivot points and the guide...

Page 75: ...ap from the heat exchanger and observe the coolant level 3 The coolant level in the heat exchanger should be at the bottom of the filler neck If coolant is low refer to Filling NOTE If no coolant is v...

Page 76: ...re Used Part Number Marine Engine Coolant 92 813054A2 Fleetguard Compleat Product 91 50663 with DCA4 Additive Closed cooling system Obtain Locally 8 If coolant level in coolant recovery bottle was low...

Page 77: ...leat Product 91 50663 with DCA4 Additive Closed cooling system Obtain Locally 5 Install the fill cap onto the coolant recovery bottle Changing Contact your authorized Cummins MerCruiser Diesel dealer...

Page 78: ...ON If water should enter the fuel injection system take unit to an authorized Cummins MerCruiser Diesel dealer distributor IMMEDIATELY so that corrosion and rusting of the injectors and other componen...

Page 79: ...drained or until fuel is clear in appearance b a 77121 a Priming pump 4 Close drain cap by turning clockwise Tighten securely 5 Fill the fuel filter Refer to Filling 6 After starting the engine check...

Page 80: ...eparating fuel filter and sealing ring from fuel filter bracket 2 Remove the drain cap from the filter by turning it counterclockwise Discard the used filter 77343 77128 77120 b c a c a a Water separa...

Page 81: ...tain Locally 6 Thread filter onto bracket until the sealing ring contacts bracket 7 Tighten the fuel filter an additional 2 3 of a turn with a filter wrench 8 Ensure that the bottom drain cap is secur...

Page 82: ...nd pump primer move the plunger upper portion up and down as needed 77343 b a a Fuel filter bracket b Hand pump primer NOTE Follow this procedure after installing new filter or if fuel has been draine...

Page 83: ...5 CE530 Fuel System Priming Prime the engine if it has not been operated for a while or if the engine will not start 1 Move the hand pump primer plunger up and down several times 77343 b a a Fuel filt...

Page 84: ...ntainer under fuel injection pump to catch fuel 4 Remove and plug boat fuel return hose from injection pump return fuel fitting CAUTION Avoid the risks of fuel leaking The injection pump fuel return v...

Page 85: ...e clamp 77343 a b a Fuel return hose b Hose clamp 8 Move plunger knob up and down several times until some added resistance is noticed when knob is moved 9 Check for fuel leaks 10 Dispose of waste fue...

Page 86: ...urs first CE497 Drive Belts All drive belts must be periodically inspected for tension and condition excessive wear cracks fraying or glazed surfaces If any drive belts need replacement or tension nee...

Page 87: ...that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 75130 a b c a Transverse crack b Longitudinal crack c Fraying 3 Check the operation of the automatic tensioner an...

Page 88: ...d debris There are no serviceable parts to the air cleaner Cleaning 1 Remove any debris present at openings 77132 a b a Air cleaner b Openings Checking 1 Ensure that the assembly is not cracked or dam...

Page 89: ...as part of the intercooler and heat exchanger systems which serve as sacrificial anodes These sacrificial anodes are installed in the seawater circuit to help avoid galvanic corrosion caused by seawa...

Page 90: ...1 Replace anode assembly when deteriorated 50 Length When New 32 mm 1 1 4 in Diameter When New 15 mm 5 8 in 2 Discard sealing washer c d e b a 71368 a Anode plug b Sacrificial anode c Length d Diamete...

Page 91: ...1368 a b a Sealing washer b Anode plug 3 Unplug and connect seawater inlet hose or open seacock if equipped CAUTION Avoid seawater pump impeller damage Do not operate the engine without cooling water...

Page 92: ...ews or cover will warp and leak 2 With engine off close seacock if equipped or remove and plug seawater inlet hose if no seacock exists 3 Remove screws washers and cover 4 Remove strainer drain plug a...

Page 93: ...water inlet during engine operation CAUTION If flushing with the boat in the water seawater can flow into the engine causing engine damage Water inlet must be closed when flushing the engine 1 If flus...

Page 94: ...manufacturers instructions b Using an appropriate adapter connect the flushing hose from a water tap to the seawater inlet hose on the seawater pickup pump inlet 79463 a b c d a Adapter b Flushing hos...

Page 95: ...ten the hose clamps securely 79464 a b a Adapter b Seawater pump inlet hose CAUTION If boat is in the water seacock must remain closed until engine is to be re started to prevent water from flowing ba...

Page 96: ...an authorized Cummins MerCruiser Diesel dealer distributor 1 Seawater pump impeller and impeller splines should be inspected for wear or damage at scheduled maintenance interval or whenever insufficie...

Page 97: ...ot recharge a weak battery in the boat Remove battery and recharge in a ventilated area away from fuel vapors sparks or flames WARNING Batteries contain acid which can cause severe burns Avoid contact...

Page 98: ...MAINTENANCE SECTION 5 Page 90 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 99: ...823 90 865237030 OCTOBER 2003 Page 91 SECTION 6 STORAGE Table of Contents Cold Weather Or Extended Storage 92 Preparing Your Power Package For Storage 92 Draining Instructions 93 Battery 96 Power Pack...

Page 100: ...for cold weather or extended storage Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Follow the propylene glycol manufacturer s recom...

Page 101: ...d be drained before flushing or prior to extended or cold weather storage IMPORTANT The boat must not be operating at any point during this procedure 1 Turn on bilge pump if the boat is in the water 2...

Page 102: ...om the transmission fluid cooler 79109 a b a Drain plug or cooling hose not shown b Transmission fluid cooler 7 Repeatedly clean out drain holes using a stiff piece of wire Do this until the entire se...

Page 103: ...d by prolonged exposure to direct sunlight c Remove the pump impeller and store away from direct sunlight d Reinstall the seawater pump cover for storage a b 79743 a Seawater pump cover b Cover mounti...

Page 104: ...le funnel slowly pour the propylene glycol antifreeze mixture through the anode plug opening and into the seawater system until system is full d Install the anode plug Tighten securely 11 Clean the ou...

Page 105: ...g c Install the seawater pump impeller into the housing by turning clockwise while simul taneously pushing inward d Install a new O ring on the seawater pump e Install the seawater pump cover f Instal...

Page 106: ...hen installing battery connect POSITIVE battery cable to POSITIVE battery terminal FIRST and NEGATIVE battery cable to NEGATIVE battery terminal LAST If battery cables are reversed or connection order...

Page 107: ...st one minute cool down time before engaging the starter for another 15 seconds 12 After having not been operated for 2 months or longer it is necessary to pre lubricate the turbocharger and engine a...

Page 108: ...STORAGE SECTION 6 Page 100 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 109: ...Engine Will Not Start Or Is Hard To Start 102 Engine Runs Rough Misses And Or Backfires 103 Poor Performance 104 Excessive Engine Temperature 105 Insufficient Engine Temperature 105 Turbocharger Noisy...

Page 110: ...roper starting procedure Read starting procedure Empty fuel tank or fuel shut off valve closed Fill tank or open valve Faulty electrical stop circuit Have an authorized Cummins MerCruiser Diesel deale...

Page 111: ...l If contaminated drain tank Fill with fresh fuel Kinked or clogged fuel line or fuel tank vent line Replace kinked lines or blow out lines with compressed air to remove obstruction Air in fuel inject...

Page 112: ...operly distributed Reduce load or redistribute load more evenly Boat bottom fouled or damaged Clean or repair as necessary Air in fuel injection system Purge fuel injection system Clogged fuel or air...

Page 113: ...ized Cummins MerCruiser Diesel dealer distributor Coolant level low in closed cooling section Check for cause of low coolant level and repair Fill system with proper coolant solution Heat exchanger co...

Page 114: ...g in white smoke and burning smell from turbocharger area This is usually normal and occurs mostly during the first hour of engine operation If the problem persists have inspected by an authorized Cum...

Page 115: ...ry condition Test battery CE543 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle linkage fastener...

Page 116: ...TROUBLESHOOTING SECTION 7 Page 108 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 117: ...After Submersion 110 Replacement Service Parts 111 Parts And Accessories Inquiries 111 Resolving A Problem 112 Customer Service Literature 113 English Language 113 Other Languages 113 Andre sprog 113...

Page 118: ...ntact the nearest authorized Cummins MerCruiser Diesel dealer distributor Refer to the Yellow Pages of the telephone directory or by using the service locator on the Cummins website www Cummins com If...

Page 119: ...tions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard automotive engine Since marine engines...

Page 120: ...ld you have a question concern or problem that cannot be resolved by your dealership please contact your local distributor of Cummins MerCruiser Diesel products for assistance The distributor will wor...

Page 121: ...te Mercury Marine eller Marine Power International servicecenter for oplysninger om hvordan du kan anskaffe en Betjenings og vedligeholdelsesmanual p et andet sprog En liste med reservedelsnumre for a...

Page 122: ...er um Manual de Opera o e Manuten o em outro idioma contate o Centro de Servi o Internacional de Marine Power Pot ncia Marinha ou a Mercury Marine mais pr xima para obter informa es Uma lista de n mer...

Page 123: ...Cummins MerCruiser Diesel power package and how to order that literature contact your nearest Cummins MerCruiser Diesel dealer distributor or contact Mercury Marine Telephone Fax Mail 920 929 5110 920...

Page 124: ...CUSTOMER ASSISTANCE INFORMATION SECTION 8 Page 116 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 125: ...2003 Mercury Marine CMD 3967823 90 865237030 1003 1 7 MI Diesel Engine Inboard Models INDEX...

Page 126: ...umber HIN Purchase Date 6 Boat Manufacturer Boat Model Length 7 Exhaust Gas Emissions Certificate Number Europe Only The description and specifications contained herein were in effect at the time this...

Page 127: ...is manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our Cummins MerCruiser Diesel products We sincerely hope your boating will be pleasa...

Page 128: ...nor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for proper operation and or maintenance CE458 WARNING The operator driver is respon...

Page 129: ...ions 20 Be Alert To Carbon Monoxide Poisoning 22 Good Ventilation 23 Poor Ventilation 23 Basic Boat Operation 24 Launching And Boat Operation Care 24 Duty Cycle Rating 25 Pleasure Duty Rating 25 Opera...

Page 130: ...illing 58 Changing 59 Transmission Fluid 62 Checking 62 Filling 63 Changing 64 Lubrication 66 Shift Cable 66 Throttle Cable 66 Engine Coolant 67 Checking 67 Filling 69 Changing 69 Water Separating Fue...

Page 131: ...ngine Oil Pressure 106 Battery Will Not Charge 107 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 107 SECTION 8 CUSTOMER ASSISTANCE INFORMATION Owner Service Assist...

Page 132: ...Page iv CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 133: ...ranty Information 2 Owner Warranty Registration 2 United States And Canada Only 2 International Owner Registration 3 Outside The United States And Canada 3 Warranty Policies 4 Recreational Use Diesel...

Page 134: ...ate of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service during this period present the temporary registration card to the dealer He will att...

Page 135: ...ice on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries...

Page 136: ...BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Cummins MerCruiser Diesel to distribute the product in the...

Page 137: ...y us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the product see the Operation Maintenance And Warranty Manual alteration or removal of pa...

Page 138: ...es Damage caused by neglect lack of maintenance accident abnormal operation improper installation or service or freezing temperatures Haul out launch towing charges removal and or replacement of boat...

Page 139: ...ter entering the engine via the air filter or exhaust system or submersion Also water in the starter motor Starter motors and or armatures or field coil assembly which are burned or where lead is thro...

Page 140: ...Warranty Registration Card and a copy of the bill of sale to show proof of ownership In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P...

Page 141: ...SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE Table of Contents Features And Controls 10 Lanyard Stop Switch 10 Instrumentation 12 Remote Controls 15 Panel Mounted 15 Console Mounted 16 Electrical Syst...

Page 142: ...ers releasing your grip on the steering wheel that is pulling in 1 direction consuming alcohol or drugs high speed boating maneuvers Some remote control units are equipped with a lanyard stop switch i...

Page 143: ...act with the boat hull and propeller from accidental ejection Personal injury or death could occur Always properly connect both ends of the lanyard stop switch Accidental or unintended activation of t...

Page 144: ...boat dealer explain the particular gauges and normal readings that will appear on your style gauges 77725 b c d 70514 a e g h 70519 f Typical a Speedometer b Tachometer c Oil pressure gauge d Battery...

Page 145: ...ating if equipped and all instruments are operational 3 START In the START position the engine can be started NOTE The key can only be removed in the OFF position Engine Stop Switch is used to stop th...

Page 146: ...timed preheat period begins when the key switch is turned to RUN The lamp stays on until the preheat period is complete The engine should be started only after the lamp goes out NOTE Some engines may...

Page 147: ...ol 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 en...

Page 148: ...djustment Screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed to adjust This will help prevent slipping of the remote control handle Turn s...

Page 149: ...reaker If the breaker remains open the electrical overload has not been eliminated Further checks must be made on the electrical system Contact your authorized Cummins MerCruiser Diesel dealer distrib...

Page 150: ...al oil pressure gauge Typical coolant temperature gauge 79753 Typical transmission fluid temperature switch CAUTION Operation of the engine after the audio warning system alarm has sounded could resul...

Page 151: ...Starting The Engine 27 Engine Shut down Stopping 30 Freezing Temperature And Cold Weather Operation 31 Drain Plug and Bilge Pump 31 Protecting People In The Water 32 While You Are Cruising 32 While Bo...

Page 152: ...s of Waterway Information booklet It lists regional sources of safety cruising and local navigation and is available at no charge by writing to Sources of Waterway Information National Marine Manufact...

Page 153: ...driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate Know your boat s operating...

Page 154: ...oat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be...

Page 155: ...etectors 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 an operating engine may be exposed to a h...

Page 156: ...ove idle speed w When launching your boat from a steep ramp enter the water slowly Do not use the lanyard stop switch to shut off the engine above idle speed When coming off plane if a large following...

Page 157: ...ating applies to recreational planing craft used exclusively for pleasure and recreation Typical applications include pleasure craft such as sailboats ski boats runabouts speedboats and other planing...

Page 158: ...ntrol operation Engage the STOP switch and hold until engine completely stops Prime fuel injection system if necessary Turn key switch to OFF position Pre lubricate turbocharger and engine if necessar...

Page 159: ...77312 a a Stop lever BEFORE STARTING THE ENGINE CAUTION Overheating from insufficient cooling water will cause engine and drive system damage Ensure that there is sufficient water always available at...

Page 160: ...be started only after the five second wait to start period has ended NOTE The preheat devices glow plugs should operate at temperatures lower than 80 degrees C 176 degrees F An engine coolant temperat...

Page 161: ...il pressure should be within range listed in the engine specifications chart Stop the engine if oil pressure is not within this range b Check the fuel system for leaks from the injection pump fuel pip...

Page 162: ...mum rpm or wide open throttle Stop the engine if oil pressure is not within this range Locate and correct the problem or see your authorized Cummins MerCruiser Diesel dealer distributor if you are una...

Page 163: ...ent type antifreeze solution to protect components against damage by freezing Be sure to use proper cold weather lubrication oil and be sure the crankcase contains a sufficient amount Make certain tha...

Page 164: ...a boat is moving coasting in NEUTRAL IDLE there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury While Boat...

Page 165: ...them over the front of boat Falling over the front of the boat between the two pontoons will position them to come into contact with the drive unit 1 Boats having an open front deck a No one should e...

Page 166: ...f the water certain hazards arise particularly when the boat re enters the water The primary concern is the boat changing direction while in the midst of the jump In such cases the landing may cause t...

Page 167: ...ven out of the boat Impact damage to the underwater drive components rudder and or boat Keep in mind one of the most important things you can do to help reduce injury or impact damage in these situati...

Page 168: ...t bottom should be Clean free of barnacles and marine growth Free of distortion nearly flat where it contacts the water Straight and smooth fore and aft Marine vegetation may accumulate when the boat...

Page 169: ...device that limits engine rpm Be sure that propeller being used does not allow engine to run excessively against the governor as a significant loss in performance will result NOTE Use an accurate ser...

Page 170: ...in gear for 3 minutes at each of the following rpms 1700 rpm 3500 rpm and 4000 rpm 4 Operate the engine in gear for 3 minutes at each of the following rpms 2100 rpm 3500 rpm and Maximum Rated Full Th...

Page 171: ...nance Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at WOT rpm Change the oil and oil filter Refer to Specifications and Maintenance CE476 End of First Sea...

Page 172: ...ON THE WATER SECTION 3 Page 40 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 173: ...0 865237030 OCTOBER 2003 Page 41 SECTION 4 SPECIFICATIONS Table of Contents Fuel Requirements 42 Recommended Fuels 43 Diesel Fuel In Cold Weather 43 AntiFreeze Coolant 44 Engine Oil 45 Engine Specific...

Page 174: ...l is highly flammable and produces a significant risk to the user IMPORTANT Use of improper or water contaminated diesel fuel can damage your en gine seriously Use of improper fuel is considered misus...

Page 175: ...ndation JIS JAPANESE INDUSTRIAL STAN DARD No 2 DIN DEUTSCHE INDUSTRIE NOR MEN DIN 51601 SAE SOCIETY OF AUTOMOTIVE ENGINEERS Based on SAE J 313C No 2 D BS BRITISH STANDARD Based on BSEN 590 1197 A 1 CE...

Page 176: ...utions will form a protective film on internal passages and provide protection against internal cooling system erosion The closed cooling section should be kept filled year round with an acceptable an...

Page 177: ...a rating of HD SAE API CG 4 and CH 4 We strongly recommend the use of Description Where Used Part Number Mercury Diesel Engine Oil Engine crankcase 92 877695K1 This oil is a specially blended 15W 40...

Page 178: ...Camshaft Direct Injection Turbocharged Intercooled Displacement 1 686 cubic liters 103 cid Engine weight approximate 250 kg 550 lb Bore 79 mm 3 11 in Stroke 86 mm 3 39 in Th t t 82 95 180 203 1 Thermo...

Page 179: ...4 1 Mercury Diesel Engine Oil 92 877695K1 Closed Cooling System 8 3 4 9 1 4 Marine Engine Coolant 92 813054A2 Seawater Cooling System 2 6 1 2 6 3 4 Not Applicable Not Applicable 1 Always use the dips...

Page 180: ...SPECIFICATIONS SECTION 4 Page 48 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 181: ...ging 64 Lubrication 66 Shift Cable 66 Throttle Cable 66 Engine Coolant 67 Checking 67 Filling 69 Changing 69 Water Separating Fuel Filter 70 Draining 70 Replacing 72 Filling 74 Fuel System 75 Priming...

Page 182: ...imum performance and dependability and will keep your overall operating expenses at a minimum See your authorized Cummins MerCruiser Diesel dealer distributor for service aids CE467 Dealer Responsibil...

Page 183: ...itant IMPORTANT Refer to Maintenance Chart for complete listing of all scheduled maintenance to be performed Some listings can be done by owner operator while others should be performed by an authoriz...

Page 184: ...ine 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 off...

Page 185: ...he fuel filter after each use if operating in freezing temperatures D Check the water inlets for debris or marine growth Check the seawater strainer and clean D Check the battery connections and the f...

Page 186: ...arts Lubricate the cables and the linkages D Disassemble and inspect the seawater pump and replace the worn components D Touch up paint the power package and spray with corrosion guard D Inspect the c...

Page 187: ...or 5 years z Every 1000 hours or 5 years z Per OEM Replace the coolant D Check the electrical system for loose damaged or corroded fasteners D Inspect the timing belt and pulleys D Retorque the engine...

Page 188: ...MAINTENANCE SECTION 5 Page 56 CMD 3967823 90 865237030 OCTOBER 2003 0166 Maintenance Record Date Hour Meter Reading Serviced By Maintenance Performed INDEX...

Page 189: ...ed by local authorities CE492 Checking 1 Stop the engine Allow approximately 10 minutes for oil to drain into oil pan The boat must be at rest in the water 2 Remove the dipstick Wipe clean and reinsta...

Page 190: ...ot over MAX mark on dipstick NOTE It takes several minutes for the added oil to drain to the oil pan Wait approximately 10 minutes and check the level again after adding oil All models Capacity liters...

Page 191: ...d engine oil Refer to Specifications 1 Start the engine and allow it to warm up to normal operating temperature 2 Stop the engine and allow some time for oil to drain into oil pan approximately 10 min...

Page 192: ...ply a coat of engine oil to the O rings Install the element on the top piece Description Where Used Part Number Engine oil Oil filter O rings Obtain Locally 10 Install the top piece with the new eleme...

Page 193: ...u simultaneously turn the key switch to the START position for 15 seconds Doing this together turns the engine without starting it b Repeat step a as needed Pre lubrication is complete when oil pressu...

Page 194: ...the level up to the MAXIMUM mark on the dipstick a b c d 79465 a Dipstick b Threaded hole c MAXIMUM Fluid Level d MINIMUM Fluid Level IMPORTANT To accurately check the fluid level the engine must be o...

Page 195: ...vel d MINIMUM Fluid Level Model Capacity liters U S qts Fluid type ZF Marine 25A 1 8 1 9 1 Dexron III Automatic Transmission Fluid or Equivalent 1 Always use the dipstick to determine the exact quanti...

Page 196: ...nd remove the fluid filter assembly by turning the assembly nut counterclockwise and pulling at the same time a b 79799 a Fluid filter assembly b Assembly nut 3 Push the hose of a suction pump through...

Page 197: ...ated to avoid fluid foaming and or loss of fluid resulting in decreased efficiency and or damage to transmission 8 Install the fluid filter assembly in the transmission cavity by turning clockwise and...

Page 198: ...cal a Pivot points b Guide contact surfaces Description Where Used Part Number A Engine Oil Pivot points guide contact surfaces Obtain Locally Throttle Cable 1 Lubricate the pivot points and the guide...

Page 199: ...ap from the heat exchanger and observe the coolant level 3 The coolant level in the heat exchanger should be at the bottom of the filler neck If coolant is low refer to Filling NOTE If no coolant is v...

Page 200: ...re Used Part Number Marine Engine Coolant 92 813054A2 Fleetguard Compleat Product 91 50663 with DCA4 Additive Closed cooling system Obtain Locally 8 If coolant level in coolant recovery bottle was low...

Page 201: ...leat Product 91 50663 with DCA4 Additive Closed cooling system Obtain Locally 5 Install the fill cap onto the coolant recovery bottle Changing Contact your authorized Cummins MerCruiser Diesel dealer...

Page 202: ...ON If water should enter the fuel injection system take unit to an authorized Cummins MerCruiser Diesel dealer distributor IMMEDIATELY so that corrosion and rusting of the injectors and other componen...

Page 203: ...drained or until fuel is clear in appearance b a 77121 a Priming pump 4 Close drain cap by turning clockwise Tighten securely 5 Fill the fuel filter Refer to Filling 6 After starting the engine check...

Page 204: ...eparating fuel filter and sealing ring from fuel filter bracket 2 Remove the drain cap from the filter by turning it counterclockwise Discard the used filter 77343 77128 77120 b c a c a a Water separa...

Page 205: ...tain Locally 6 Thread filter onto bracket until the sealing ring contacts bracket 7 Tighten the fuel filter an additional 2 3 of a turn with a filter wrench 8 Ensure that the bottom drain cap is secur...

Page 206: ...nd pump primer move the plunger upper portion up and down as needed 77343 b a a Fuel filter bracket b Hand pump primer NOTE Follow this procedure after installing new filter or if fuel has been draine...

Page 207: ...5 CE530 Fuel System Priming Prime the engine if it has not been operated for a while or if the engine will not start 1 Move the hand pump primer plunger up and down several times 77343 b a a Fuel filt...

Page 208: ...ntainer under fuel injection pump to catch fuel 4 Remove and plug boat fuel return hose from injection pump return fuel fitting CAUTION Avoid the risks of fuel leaking The injection pump fuel return v...

Page 209: ...e clamp 77343 a b a Fuel return hose b Hose clamp 8 Move plunger knob up and down several times until some added resistance is noticed when knob is moved 9 Check for fuel leaks 10 Dispose of waste fue...

Page 210: ...urs first CE497 Drive Belts All drive belts must be periodically inspected for tension and condition excessive wear cracks fraying or glazed surfaces If any drive belts need replacement or tension nee...

Page 211: ...that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 75130 a b c a Transverse crack b Longitudinal crack c Fraying 3 Check the operation of the automatic tensioner an...

Page 212: ...d debris There are no serviceable parts to the air cleaner Cleaning 1 Remove any debris present at openings 77132 a b a Air cleaner b Openings Checking 1 Ensure that the assembly is not cracked or dam...

Page 213: ...as part of the intercooler and heat exchanger systems which serve as sacrificial anodes These sacrificial anodes are installed in the seawater circuit to help avoid galvanic corrosion caused by seawa...

Page 214: ...1 Replace anode assembly when deteriorated 50 Length When New 32 mm 1 1 4 in Diameter When New 15 mm 5 8 in 2 Discard sealing washer c d e b a 71368 a Anode plug b Sacrificial anode c Length d Diamete...

Page 215: ...1368 a b a Sealing washer b Anode plug 3 Unplug and connect seawater inlet hose or open seacock if equipped CAUTION Avoid seawater pump impeller damage Do not operate the engine without cooling water...

Page 216: ...screws or cover will warp and leak 2 With engine off close seacock if equipped or remove and plug seawater inlet hose if no seacock exists 3 Remove screws washers and cover 4 Remove strainer drain pl...

Page 217: ...water inlet during engine operation CAUTION If flushing with the boat in the water seawater can flow into the engine causing engine damage Water inlet must be closed when flushing the engine 1 If flus...

Page 218: ...manufacturers instructions b Using an appropriate adapter connect the flushing hose from a water tap to the seawater inlet hose on the seawater pickup pump inlet 79463 a b c d a Adapter b Flushing hos...

Page 219: ...ten the hose clamps securely 79464 a b a Adapter b Seawater pump inlet hose CAUTION If boat is in the water seacock must remain closed until engine is to be re started to prevent water from flowing ba...

Page 220: ...an authorized Cummins MerCruiser Diesel dealer distributor 1 Seawater pump impeller and impeller splines should be inspected for wear or damage at scheduled maintenance interval or whenever insufficie...

Page 221: ...ot recharge a weak battery in the boat Remove battery and recharge in a ventilated area away from fuel vapors sparks or flames WARNING Batteries contain acid which can cause severe burns Avoid contact...

Page 222: ...MAINTENANCE SECTION 5 Page 90 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 223: ...823 90 865237030 OCTOBER 2003 Page 91 SECTION 6 STORAGE Table of Contents Cold Weather Or Extended Storage 92 Preparing Your Power Package For Storage 92 Draining Instructions 93 Battery 96 Power Pack...

Page 224: ...for cold weather or extended storage Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Follow the propylene glycol manufacturer s recom...

Page 225: ...d be drained before flushing or prior to extended or cold weather storage IMPORTANT The boat must not be operating at any point during this procedure 1 Turn on bilge pump if the boat is in the water 2...

Page 226: ...om the transmission fluid cooler 79109 a b a Drain plug or cooling hose not shown b Transmission fluid cooler 7 Repeatedly clean out drain holes using a stiff piece of wire Do this until the entire se...

Page 227: ...d by prolonged exposure to direct sunlight c Remove the pump impeller and store away from direct sunlight d Reinstall the seawater pump cover for storage a b 79743 a Seawater pump cover b Cover mounti...

Page 228: ...ble funnel slowly pour the propylene glycol antifreeze mixture through the anode plug opening and into the seawater system until system is full d Install the anode plug Tighten securely 11 Clean the o...

Page 229: ...g c Install the seawater pump impeller into the housing by turning clockwise while simul taneously pushing inward d Install a new O ring on the seawater pump e Install the seawater pump cover f Instal...

Page 230: ...hen installing battery connect POSITIVE battery cable to POSITIVE battery terminal FIRST and NEGATIVE battery cable to NEGATIVE battery terminal LAST If battery cables are reversed or connection order...

Page 231: ...st one minute cool down time before engaging the starter for another 15 seconds 12 After having not been operated for 2 months or longer it is necessary to pre lubricate the turbocharger and engine a...

Page 232: ...STORAGE SECTION 6 Page 100 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 233: ...Engine Will Not Start Or Is Hard To Start 102 Engine Runs Rough Misses And Or Backfires 103 Poor Performance 104 Excessive Engine Temperature 105 Insufficient Engine Temperature 105 Turbocharger Noisy...

Page 234: ...roper starting procedure Read starting procedure Empty fuel tank or fuel shut off valve closed Fill tank or open valve Faulty electrical stop circuit Have an authorized Cummins MerCruiser Diesel deale...

Page 235: ...l If contaminated drain tank Fill with fresh fuel Kinked or clogged fuel line or fuel tank vent line Replace kinked lines or blow out lines with compressed air to remove obstruction Air in fuel inject...

Page 236: ...operly distributed Reduce load or redistribute load more evenly Boat bottom fouled or damaged Clean or repair as necessary Air in fuel injection system Purge fuel injection system Clogged fuel or air...

Page 237: ...ized Cummins MerCruiser Diesel dealer distributor Coolant level low in closed cooling section Check for cause of low coolant level and repair Fill system with proper coolant solution Heat exchanger co...

Page 238: ...g in white smoke and burning smell from turbocharger area This is usually normal and occurs mostly during the first hour of engine operation If the problem persists have inspected by an authorized Cum...

Page 239: ...ry condition Test battery CE543 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle linkage fastener...

Page 240: ...TROUBLESHOOTING SECTION 7 Page 108 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

Page 241: ...After Submersion 110 Replacement Service Parts 111 Parts And Accessories Inquiries 111 Resolving A Problem 112 Customer Service Literature 113 English Language 113 Other Languages 113 Andre sprog 113...

Page 242: ...ntact the nearest authorized Cummins MerCruiser Diesel dealer distributor Refer to the Yellow Pages of the telephone directory or by using the service locator on the Cummins website www Cummins com If...

Page 243: ...tions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard automotive engine Since marine engines...

Page 244: ...ld you have a question concern or problem that cannot be resolved by your dealership please contact your local distributor of Cummins MerCruiser Diesel products for assistance The distributor will wor...

Page 245: ...te Mercury Marine eller Marine Power International servicecenter for oplysninger om hvordan du kan anskaffe en Betjenings og vedligeholdelsesmanual p et andet sprog En liste med reservedelsnumre for a...

Page 246: ...er um Manual de Opera o e Manuten o em outro idioma contate o Centro de Servi o Internacional de Marine Power Pot ncia Marinha ou a Mercury Marine mais pr xima para obter informa es Uma lista de n mer...

Page 247: ...Cummins MerCruiser Diesel power package and how to order that literature contact your nearest Cummins MerCruiser Diesel dealer distributor or contact Mercury Marine Telephone Fax Mail 920 929 5110 920...

Page 248: ...CUSTOMER ASSISTANCE INFORMATION SECTION 8 Page 116 CMD 3967823 90 865237030 OCTOBER 2003 NOTES INDEX...

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