Mercury MerCruiser Axius SeaCore 350 MAG Manual Download

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Section 2 - Getting to Know Your Power Package

Notes:

Page 48

90-8M0050539

eng

MAY 2011

Summary of Contents for MerCruiser Axius SeaCore 350 MAG

Page 1: ...e 1322 Country Norway ID Number 0575 Conformity assessment module used for exhaust emissions B C B D B E B F G H Conformity assessment module used for noise emissions A Aa G H Other Community Directiv...

Page 2: ...tive document method technical file Please specify in more detail mandatory standard Annex 1 B Exhaust Emissions B 1 engine identification B 2 exhaust emission requirements EN ISO 8178 1 1996 B 3 dura...

Page 3: ...intenance you will thoroughly enjoy using this product for many boating seasons To ensure maximum performance and carefree use we ask that you thoroughly read this manual The Operation Maintenance and...

Page 4: ...n death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a situation which if not avoided could result in engine...

Page 5: ...al Operation Instructions for Axius Systems 22 Identification 22 Engine Serial Number Decal MPI 22 Alpha Sterndrive Decal Identification 22 Alpha Transom Serial Number 23 Bravo Sterndrive Serial Numbe...

Page 6: ...Conditions Affecting Operation 59 Weight Distribution Passengers and Gear Inside the Boat 59 The Bottom of the Boat 60 Cavitation 60 Ventilation 60 Elevation and Climate 60 Propeller Selection 60 Get...

Page 7: ...ing Fuel Filter 97 GEN II Models 97 Removal 97 Installation 98 GEN III Models 98 Removal 98 Installation 99 Lubrication 99 Steering System 99 Throttle Cable 101 Shift Cable Typical 101 Sterndrive U jo...

Page 8: ...ool Fuel Module 147 Battery Storage 148 Recommissioning the Power Package 148 Section 7 Troubleshooting Diagnosing EFI Problems 150 Diagnosing DTS Problems 150 Additional Operation Instructions for Ax...

Page 9: ...plications 10 Global Application Warranty Charts 350 377 MAG and SeaCore 350 377 MAG 10 Warranty for Consumer Applications 10 Warranty for Commercial Applications 11 Warranty for Government Applicatio...

Page 10: ...d Canada To ensure that your warranty coverage begins promptly your selling dealer should fill out the warranty registration card completely and mail it to the distributor responsible for administerin...

Page 11: ...boatbuilder customers who have achieved higher manufacturing standards It is the first and only comprehensive manufacturer installation certification program in the industry The program has three goa...

Page 12: ...Inboard Models and Vazer 100 Sterndrive Models The Limited Warranty for Horizon Inboard Models and Vazer 100 Models is four 4 years when installed by an Installation Quality Certified Installer or thr...

Page 13: ...oper maintenance What Mercury Marine Will Do Mercury Marine s sole and exclusive obligation under this warranty is limited to at our option repairing a defective part replacing such part or parts with...

Page 14: ...owing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this war...

Page 15: ...Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured How to Obtain Warranty Coverage The customer must p...

Page 16: ...sole and exclusive obligation under this warranty is limited to at our option repairing a corroded part replacing such part or parts with new or Mercury Marine certified remanufactured parts or refun...

Page 17: ...1 year 1 year SeaCore 350 MAG EC SeaCore 377 MAG EC The Americas excluding Brazil 3 years 4 years 4 years Brazil 2 years 2 years 2 years Europe Middle East Africa 3 years 4 years 4 years Australia Ne...

Page 18: ...MAG Warranty for Consumer Applications Engine Model Region Standard Factory Limited Warranty by Certification Status of Boat Manufacturer Consumer Limited Corrosion Warranty Not Certified Installation...

Page 19: ...MAG 377 MAG SeaCore 350 MAG SeaCore 377 MAG The Americas excluding Brazil 1 year 1 year 3 years Brazil 2 years 2 years 2 years Europe Middle East Africa 1 year or 500 hours 1 year or 500 hours 1 year...

Page 20: ...I Label Standard of Compliance REFER TO THE OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS FAMILY XXXXXXXXXXXX EMISSION CONTROLINFORMATION NOT FOR SALE IN CALIFORNIA THIS MARINE ENGINE...

Page 21: ...ion levels within prescribed certification standards The operator may not modify the engine in any manner that alters the horsepower or allows emissions levels to exceed factory specifications Califor...

Page 22: ...spection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay f...

Page 23: ...o cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage Select emission control parts from 2009 and later inboard or sterndrive engines are warranted for 3 years or 480 hour...

Page 24: ...em a Catalytic converter b Thermal reactor c Exhaust manifold d Exhaust valves 8 Miscellaneous items used in above systems a Hoses clamps fittings tubing sealing gaskets or devices and mounting hardwa...

Page 25: ...The Star label identifies that these engines meet the California Air Resources Board s Sterndrive and Inboard marine engine 2007 and later exhaust emission standards Engines meeting these standards ha...

Page 26: ...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...

Page 27: ...n 1 Warranty 90 8M0050539 eng MAY 2011 Page 19 If in California the dealer must place the hang tag in a visible location in the boat prior to displaying the boat 43291 Hang tag front side Hang tag bac...

Page 28: ...Section 1 Warranty Notes Page 20 90 8M0050539 eng MAY 2011...

Page 29: ...Console Mount Features Dual Engine 32 Synchronizing Dual Engines 32 Dual Helm Station Transfer 33 Synchronizing Dual Helms Prior To Station Transfer 33 Zero Effort Features 34 Dual Console Control wit...

Page 30: ...iser power package When contacting MerCruiser about service always specify model and serial numbers Engine Serial Number Decal MPI The serial number decal is located on the engine cover 25903 Serial n...

Page 31: ...serial number Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number gear ratio model number and bar code are embedded in the ground plate on the port side of the sterndr...

Page 32: ...rized MerCruiser Dealers Gimbal housing with serial number stamping a Transom assembly serial Number Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operato...

Page 33: ...erate 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 de...

Page 34: ...rim gauge Speedometer indicates boat speed Tachometer indicates engine RPM Oil pressure gauge indicates engine oil pressure Voltmeter indicates battery voltage Water temperature gauge indicates engine...

Page 35: ...lows 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...

Page 36: ...f g h i j 14671 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...

Page 37: ...r 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 from neutral with a quic...

Page 38: ...p switch b Control handle c Shift lock d Trim tilt switch e Throttle only button f Start stop button g Detent tension adjustment screw h Control handle friction adjustment screw Lanyard Stop Switch Tu...

Page 39: ...lm Station Transfer Detent Tension Adjustment Screw This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions cover must be removed...

Page 40: ...ve Light The active light is illuminated to show the remote control is active and ready for use Neutral Light The neutral light is illuminated when the engine is in neutral gear position NOTE Gear pos...

Page 41: ...ows the engine control to be transferred to the new station The control will automatically start adjusting engine RPM and gear position to match the control handle setting at the new station Adjust co...

Page 42: ...n Trim Tilt Switch Refer to Power Trim Dual Console Control with CAN Trackpad Features and Operation Dual Handle Console Control With CAN Trackpad Features and Operation 1 Operation of shift and throt...

Page 43: ...when throttle only is engaged Advance throttle to increase engine RPM To disengage return control handle to neutral position and press the throttle only button Engine RPM is limited to prevent engine...

Page 44: ...ing the TRANSFER button two times allows engine control to be transferred to a new helm When a helm transfer is initiated the control will automatically start adjusting engine RPM and gear position to...

Page 45: ...tion Trim Tilt Switch Refer to Power Trim Power Trim Power trim allows the operator to adjust the sterndrive angle while underway to provide the ideal boat angle for varying load and water conditions...

Page 46: ...sterndrive unit can be trimmed up out when engine speed is above 3500 RPM Dual Engine Trim Trailer NOTICE If using external tie bars raising or lowering the drives independently of each other can dam...

Page 47: ...by pushing the yellow lever back into the housing Yellow lever style circuit breaker a Yellow lever b Red test button A 90 amp fuse located on the large post of the starter solenoid protects the engi...

Page 48: ...4 pin connector 33177 A 15 amp accessory fuse protects the accessory circuits This fuse is located on the rear of the engine a Cover b 15 amp fuse c Accessory harness A 20 amp fuse may be located in t...

Page 49: ...wer trim positive lead near the battery switch or battery connection a 20 amp spade fuse b 110 amp fuse A power harness connected to the engine starting battery minimizes voltage drop to the electrica...

Page 50: ...rn 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 ch...

Page 51: ...n fuse if the ignition key is turned to the START position and nothing happens and circuit breaker is not tripped mc70525 1 5 The power trim system is protected from overload by a 110 amp fuse and a 2...

Page 52: ...ts to the engine harness may be purchased separately The service engine icon or MIL will provide a visual indication of a malfunction with the engine s emission control system and will remain illumina...

Page 53: ...engine power when the PCM detects a potential problem Below are some examples of what Engine Guardian monitors Oil pressure Engine overspeed Exhaust manifold temperature IMPORTANT Guardian can reduce...

Page 54: ...e audio warning system sounds for six seconds turns off for six seconds and sounds for six more seconds Then the audio warning system sounds for two half second intervals every sixty seconds a Horn on...

Page 55: ...f the water inlet becomes partially blocked Engine Guardian Strategy will reduce the available power level of the engine to help prevent damage from decreased water flow to the engine If the debris pa...

Page 56: ...Section 2 Getting to Know Your Power Package Notes Page 48 90 8M0050539 eng MAY 2011...

Page 57: ...peration Chart 54 Starting and Stopping the Engine 55 Starting the Engine 55 Stopping the Engine 56 Throttle Only Operation 56 Trailering the Boat 56 Freezing Temperature Operation 56 Drain Plug and B...

Page 58: ...d foul weather and rough sea boating Tell someone where you are going and when you expect to return Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back s...

Page 59: ...value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement Carbon Monoxide Exposure Be Alert To Carbon Monoxide Poisoning Carbon monoxide CO is a...

Page 60: ...ed in a confined space b Mooring close to another boat that has its engine operating 2 Examples of poor ventilation while the boat is moving a Operating the boat with the trim angle of the bow too hig...

Page 61: ...e 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 u...

Page 62: ...drive unit in the up or down position Adequate clearance is required between the road and sterndrive when transporting If adequate road clearance is a problem place the sterndrive unit in full trailer...

Page 63: ...incorporates push button starting Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts SmartStart completely controls the starting proce...

Page 64: ...control can shift the engine or transmission at speeds greater than idle causing unexpected boat movement which may result in injury death or property damage due to loss of boat control Always place...

Page 65: ...water is near your boat Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat High Speed and High Performance Operation If your boat is considered...

Page 66: ...r when this activity is done with enough speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat re enters the water The primary concern...

Page 67: ...ntinued operation is necessary do so at greatly reduced speeds WARNING Operating a boat or engine with impact damage can result in product damage serious injury or death If the vessel experiences any...

Page 68: ...surface If allowed to continue eventual blade failure breakage will occur Excessive ventilation is usually caused by Drive unit trimmed out too far A missing propeller diffuser ring A damaged propell...

Page 69: ...for the first 10 hours Shift into gear as soon as possible after starting and advance the throttle above 1500 rpm if conditions permit safe operation Do not operate at one speed consistently for exte...

Page 70: ...Section 3 On the Water Notes Page 62 90 8M0050539 eng MAY 2011...

Page 71: ...377 MAG ECT 66 350 377 MAG and SeaCore 350 377 MAG Specifications 66 Fuel Requirements 66 Fuel Ratings 66 Using Reformulated Oxygenated Gasolines USA Only 67 Gasolines Containing Alcohol 67 Engine Oi...

Page 72: ...from the air causing the water and the alcohol to separate from the gasoline in the fuel tank IMPORTANT The fuel system components on your Mercury MerCruiser engine will withstand up to 10 alcohol co...

Page 73: ...pecified non FC W rated synthetic oils low quality oils or oils that contain solid additives Mercury Full Synthetic MerCruiser Engine Oil 20W 40 NMMA FC W rated MerCruiser Quicksilver 25W 40 Synthetic...

Page 74: ...77 cid Alternator amperage Hot 72 A Cold 65 A RPM WOT 4800 5200 Rev limiter 5350 Idle in neutral 550 Minimum oil pressure At 2000 RPM 124 kPa 18 psi At idle 41 kPa 6 psi Thermostat Seawater cooled mod...

Page 75: ...r or plastic parts Fuel permeation through the rubber fuel lines Difficulty starting and operating the engine WARNING Fuel leakage is a fire or explosion hazard which can cause serious injury or death...

Page 76: ...erating 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 tempera...

Page 77: ...160 F MPI models with closed cooling 77 C 170 F Timing at idle Not Adjustable Firing order 1 8 4 3 6 5 7 2 Minimum battery rating Non DTS models 750 CCA 950 MCA 180 Ah DTS models 800 CCA 1000 MCA 190...

Page 78: ...udes gear lube monitor Model Capacity Fluid Type Alpha One 1892 mL 64 oz High Performance Gear Lubricant Bravo Sterndrives NOTE Oil capacity includes gear lube monitor Model Capacity Fluid Type Bravo...

Page 79: ...ging 93 Battery 93 Multiple EFI Engine Battery Precautions 93 Scheduled Maintenance Specifically for 350 377 MAG ECT and SeaCore 350 377 MAG ECT 93 Cleaning the Flame Arrestor 93 Positive Crankcase Ve...

Page 80: ...ing the Power Package Bravo 116 General Information 116 Flushing the Power Package 116 Flushing Attachments 116 Sterndrive Water Pickups 117 Alternative Water Pickups 118 SeaCore Power Package Flushin...

Page 81: ...elling 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 withou...

Page 82: ...help maintain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all accessible engine parts Check for loose...

Page 83: ...annually whichever occurs first Touch up the paint on the power package Change the engine oil and filter Change the sterndrive gear lube If the condition of the spark plugs spark plug wires and the di...

Page 84: ...ine coupler Every 5 years Replace the coolant anitifreeze Replace every two years if not using extended life coolant antifreeze Maintenance Schedules 350 377 MAG and SeaCore 350 377 MAG Routine Mainte...

Page 85: ...ricate the engine coupler every 50 hours if operated at idle for prolonged periods of time Every 100 hours of operation or annually whichever occurs first Touch up the paint on the power package Chang...

Page 86: ...n of the closed cooling system Clean inspect and test the pressure cap Inspect the exhaust system components If the package was equipped with water shutters flapper valves verify that they are not mis...

Page 87: ...an and reinstall fully into the dipstick tube Wait 60 seconds to allow trapped air to vent NOTE Ensure that dipstick is installed with oil level indication marks facing the rear of the engine flywheel...

Page 88: ...and using the handle pump until the crankcase is empty 5 Remove the pump 6 Install the dipstick Changing Filter 1 Remove and discard oil filter 33201 Oil filter 2 Coat sealing ring on new filter with...

Page 89: ...indication marks facing the rear of the engine flywheel end a Dipstick tube IMPORTANT Add the specified engine oil to bring the level up to but not over the full or OK range mark on the dipstick 3 Rem...

Page 90: ...empty 5 Remove the pump 6 Install the dipstick Changing Filter 1 Remove and discard oil filter a Oil filter 2 Coat sealing ring on new filter with engine oil and install 3 Tighten oil filter securely...

Page 91: ...pecified fluid IMPORTANT If fluid is not visible in pump contact your authorized Mercury MerCruiser dealer Filling 1 Remove the fill cap dipstick and observe the level 2 Add Quicksilver Power Trim and...

Page 92: ...ission Fluid ATF to bring the fluid level up to the proper level Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power steering system 92 858074K01 3 Reinstall the fill ca...

Page 93: ...ant level in the coolant recovery bottle 5 The coolant level should be between the ADD and FULL marks 6102 6 Add the specified fluid as necessary Tube Ref No Description Where Used Part No 122 Extende...

Page 94: ...freeze Coolant Closed cooling system 92 877770K1 3 Check the antifreeze concentration for adequate freeze protection and correct if necessary Refer to the Specifications section 4 Install the fill cap...

Page 95: ...engine to overheat resulting in engine damage Minimize the possibility of trapping air when initially filling the closed cooling system by positioning the boat so that the front of the engine is highe...

Page 96: ...r lubricant is required to fill the monitor a seal may be leaking Damage to the sterndrive unit may occur due to lack of lubrication Contact your authorized Mercury MerCruiser dealer 1 Remove the gear...

Page 97: ...Ref No Description Where Used Part No 87 High Performance Gear Lubricant Sterndrive unit 92 858064K01 IMPORTANT Use only Mercury Quicksilver High Performance Gear Lubricant in sterndrive unit 7 Instal...

Page 98: ...monitor Filling New installations may require as much as 470 mL 16 fl oz of gear lube added to the monitor bottle during the break in period 20 hours of running time It is important to monitor and ma...

Page 99: ...ling washer IMPORTANT If any water drains from the unit or if the fluid appears milky the sterndrive unit is leaking See your authorized Mercury MerCruiser dealer 7 Lower the sterndrive unit so the pr...

Page 100: ...the propeller Refer to Propellers 15 Check the oil level after the first use IMPORTANT Oil level in the gear lube monitor rises and falls during operation Always check the oil level when the sterndri...

Page 101: ...ther engine may now start charging This could cause a voltage spike in the engine s electrical system In either case the ECM could shut off When the voltage returns to the range that the ECM requires...

Page 102: ...ith 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...

Page 103: ...icing 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 muffl...

Page 104: ...emove the flame arrestor a Engine cover knob b Engine cover c Nuts flame arrestor d Cover mount bracket e Flame arrestor f Crankcase ventilation hose 4 Clean the flame arrestor with warm water and a m...

Page 105: ...Filter WARNING Fuel is flammable and explosive Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in t...

Page 106: ...nents will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 5 Supply cooling water to the engine 6 Start the engine Check for gasoline leaks around...

Page 107: ...place 4 Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel and align the screws retained in the filter cap with the screw holes in the Cool Fuel Module Tighten...

Page 108: ...pecial Lubricant 101 Steering cable grease fitting 92 802865Q02 2 Turn steering wheel until steering cable fully extended Lightly lubricate the exposed part of cable a Extended steering cable Tube Ref...

Page 109: ...Cable 1 Lubricate the pivot points and the guide contact surfaces a Pivot points b Guide contact surfaces Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Th...

Page 110: ...ated at idle for prolonged periods of time coupler should be lubricated Bravo Models every 50 hours Alpha Models every 150 hours Alpha drive coupler Bravo drive coupler a Grease fitting Tube Ref No De...

Page 111: ...ruiser dealer Alpha Propeller Removal 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 p...

Page 112: ...nimum 75 55 7 Bend three tabs on the tab washer down into the grooves in spline washer After the first use bend the three tabs straight and retorque the propeller nut Bend tabs back down into spline w...

Page 113: ...er nut minimum 75 55 IMPORTANT The propeller torque stated is a minimum torque value Some special use propellers may have a different torque value Use the installation information provided with the pr...

Page 114: ...Lubricant with Teflon Propeller shaft 92 802859A 1 3 Align splines and place propeller on propeller shaft 4 Install spline washer and tab washer 5 Install and torque the propeller nut Description Nm...

Page 115: ...eller f Front propeller thrust hub g Propeller shaft anode screw h Flat washer i Star washer j Propeller shaft anode Bravo Three Propeller Installation NOTICE Operating the engine with a loose propell...

Page 116: ...t Check propeller at least every 20 hours of operation and retorque as needed Description Nm lb in lb ft Aft propeller nut 81 60 8 Install the propeller shaft anode over the propeller shaft nut 9 Plac...

Page 117: ...acceptable Longitudinal cracks in the direction of belt length that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 13 mm 1 2 in deflection with moderate thumb pressu...

Page 118: ...contact your authorized Mercury MerCruiser dealer and refer to the Mercury Precision Parts Marine Corrosion Protection Guide 90 881813003 Maintaining Ground Circuit Continuity The transom assembly and...

Page 119: ...sing The MerCathode controler is mounted on the engine or on the boat transom The controler harness connects to the electrode harness 20340 Anode kit if equipped Mounted to the boat transom 20341 Trim...

Page 120: ...Care To achieve maximum performance and fuel economy the boat bottom must be kept clean Accumulation of marine growth or other foreign matter can greatly reduce boat speed and increase fuel consumptio...

Page 121: ...in unpainted area around transom assembly NOTE Sterndrive and transom assembly can be painted with a good marine paint or an anti fouling paint that DOES NOT contain copper or any other material that...

Page 122: ...nt Tube Ref No Description Where Used Part No 25 Liquid Neoprene All electrical connections 92 25711 3 Inspect the sacrificial trim tab or anode plate if equipped at regular intervals and replace it b...

Page 123: ...the sterndrive seawater inlet blocked supply water to the sterndrive and to the engine See Alternative Water Pickups 2 On models using the sterndrive water pickups for water supply proceed to Step 3 o...

Page 124: ...e the seawater inlet hose from the thermostat housing and plug the hose to prevent water from siphoning into the boat This prevents seawater from contaminating the engine flush 15 Tag the ignition swi...

Page 125: ...ions Flushing is recommended after each outing for best results NOTICE Flushing the engine with the boat in the water can cause seawater to flow into the engine resulting in engine damage Close the se...

Page 126: ...ive in neutral for about 10 minutes or until discharge water is clear 12 Slowly return throttle to idle speed position 13 Stop engine 14 Shut off water and remove flushing attachment 15 Remove the sea...

Page 127: ...rol in neutral idle speed position and start 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...

Page 128: ...ropeller 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 pr...

Page 129: ...ther components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 11 Operate the engine at idle speed in neutral gear Do not exceed 1200 RPM 12...

Page 130: ...air during engine operation causing an overheating problem Damages due to engine overheating are not covered by Mercury MerCruiser Warranty Quick connect fitting stored in the boat a Quick connect fi...

Page 131: ...Boat out of the Water 133 Three Point Manual Drain System 133 Boat in the Water 133 Boat out of the Water 134 Draining the Sterndrive 135 Draining the Seawater System 350 377 MAG and SeaCore 350 377 M...

Page 132: ...Stabilizer for Marine Engines added to any fuel remaining in the tank Refer to Fuel Requirements for additional information 4 Flush the cooling system Refer to the Maintenance section 5 Supply cooling...

Page 133: ...engine s fuel system to become completely dry 7 Replace the water separating fuel filter element Refer to Section 5 Draining the Seawater System 350 377 MAG ECT and SeaCore 350 MAG ECT Draining the Se...

Page 134: ...Single Point Drain System Closed cooled models Seawater cooled models a Blue drain plug location b Blue air pump c Air manifold d Green indicators Manual Single Point Drain System Alpha a Blue handle...

Page 135: ...Three Point Manual Drain System a Blue drain plug Multi Point Drain MPD System a Side of cylinder block b Bottom of exhaust manifolds 33155 Fuel cooler to thermostat housing a Check valve if equipped...

Page 136: ...emove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pull lever on air pump vertical to lo...

Page 137: ...ndicators 8 Verify that water is draining from each opening If not use the Three Point Manual Drain System instructions a Port side drain location b Starboard side drain location 9 Allow the system to...

Page 138: ...pen the seacock if equipped or unplug and reconnect the water inlet hose prior to operating the engine Boat out of the Water NOTE This procedure is written for the air pump that is attached to the eng...

Page 139: ...tors 7 Verify that water is draining from each opening If not use the Three Point Manual Drain System instructions a Port side drain location b Starboard side drain location 8 Allow the system to drai...

Page 140: ...r remove and plug the water inlet hose 2 Rotate the blue handle counterclockwise until it stops approximately two turns The red on the handle shaft indicates that the drain system is open Do not force...

Page 141: ...dicates that the drain system is open Do not overtighten the handle as this action will create new threads a Blue handle 3 Visually verify that water is draining If water does not drain remove the blu...

Page 142: ...drain system open while transporting the boat or performing other maintenance to ensure that all water is drained 7 Crank the engine over slightly with starter motor to purge any water trapped in the...

Page 143: ...y installing the three blue drain plugs Draining the Sterndrive NOTE This procedure is needed only for salty brackish mineral laden or polluted water applications and for freezing temperatures or exte...

Page 144: ...Core 350 377 MAG Draining the Seawater System CAUTION Water can enter the bilge when the drain system is open damaging the engine or causing the boat to sink Remove the boat from the water or close th...

Page 145: ...Single Point Drain System a Blue handle b Blue drain plug location Three Point Manual Drain System a Blue drain plug Multi Point Drain MPD System a Side of cylinder block b Bottom of exhaust manifold...

Page 146: ...remove and plug the water inlet hose 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting...

Page 147: ...ide 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 slight...

Page 148: ...OTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Place the boat on a lever surface to ensure complete draining of system 2 Remove the...

Page 149: ...rain 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 wat...

Page 150: ...water does not drain remove the blue drain plug from the distribution housing and drain manually a Drain location orange or red b Blue drain plug 5 Allow the system to drain for a minimum of five minu...

Page 151: ...leaving the plugs out while transporting the boat or performing other maintenance to ensure that all water is drained 5 Close the drain system by rotating the blue handle clockwise until it stops or i...

Page 152: ...ck if equipped or unplug and reconnect the water inlet hose prior 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...

Page 153: ...locations It may be necessary to clean out the drain holes using a stiff piece of wire Do no until the entire system is drained a Port and starboard side of cylinder block b Bottom of exhaust manifol...

Page 154: ...a Hose clamps b Blue drain plugs 4 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 5 After the cooling system...

Page 155: ...o the lowest temperature to which it will be exposed during freezing temperatures or extended storage IMPORTANT Mercury MerCruiser requires that propylene glycol antifreeze mixed to the manufacturers...

Page 156: ...connect 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...

Page 157: ...Slowly150 Engine Will Not Start or Is Hard to Start 150 Engine Runs Rough Misses or Backfires 151 Poor Performance 151 Excessive Engine Temperature 151 Insufficient Engine Temperature 151 Low Engine...

Page 158: ...Guardian System has been activated reduce throttle speed The horn will turn off when throttle speed is within the allowable limit Consult an authorized Mercury MerCruiser dealer for assistance Trouble...

Page 159: ...r redistribute load more evenly Flame arrestor dirty Clean the flame arrestor Boat bottom fouled or damaged Clean or repair as necessary Ignition problem See Engine Runs Rough Misses or Backfires Engi...

Page 160: ...inkage fasteners Lubricate Obstruction in shift or throttle linkages Remove obstruction Loose or missing shift and throttle linkages Check all throttle linkages If any are loose or missing see authori...

Page 161: ...8M0050539 eng MAY 2011 Page 153 Power Trim Does Not Operate Motor Operates but Sterndrive Unit Does Not Move Possible Cause Remedy Trim pump oil level low Fill pump with oil Drive unit binding in gimb...

Page 162: ...Section 7 Troubleshooting Notes Page 154 90 8M0050539 eng MAY 2011...

Page 163: ...6 Local Repair Service 156 Service Away From Home 156 Stolen Power Package 156 Attention Required After Submersion 156 Replacement Service Parts 156 Parts and Accessories Inquiries 156 Resolving a Pro...

Page 164: ...r most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Exercise care when replacing marine engine parts because...

Page 165: ...alia 32 87 32 32 11 32 87 31 19 65 Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium 954 744 3500 954 744 3535 Mercury Marine Latin America Caribbean 11650 Interchange C...

Page 166: ...for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature Print or type your mailing address which be used as yo...

Page 167: ...Section 9 Checklists 90 8M0050539 eng MAY 2011 Page 159 Section 9 Checklists Table of Contents Predelivery Inspection PDI 160 Customer Delivery Inspection CDI 162 9...

Page 168: ...s tight Battery of proper rating fully charged secured with protective covers in place All electrical connections tight Exhaust system hose clamps tight All fuel connections tight Correct propeller se...

Page 169: ...Acceleration from idle RPM is normal WOT________ RPM within specification in forward gear EC models run two full operating cycles key on off to WOT with engine at normal operating temperature while mo...

Page 170: ...Warranty provide and explain the limited warranty to the customer Explain dealer services Explain the optional Mercury Product Protection Plan North America only Operation of equipment explain and de...

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