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Mercury V-6 series, User Manual

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Mercury V-6 series User Manual Download Page 123

 121

CA462

Mercury Marine Service Offices

For assistance, call, fax, or write. Please include your daytime tele-
phone number with mail and fax correspondence.

Telephone

Fax

Mail

United States

(405) 743-6566

(405) 743-6570

MerCruiser
3003 N. Perkins Rd.
Stillwater, OK 74075

Canada

(905) 270-4481

(905) 270-4510

Mercury Marine Ltd.
1156 Dundas Hwy. E.
Mississauga, Ontario
Canada L4Y 2C2

Australia, Pacific

(61) (3) 791-5822

(61) (3) 793-5880

Mercury Marine Australia
132-140 Frankston Road
Dandenong, Victoria 3164
Australia

Europe, Middle East, Africa

(32) (87) 32 

•

 32 

•

11

(32) (87) 31 

•

 19 

•

 65

Marine Power - Europe, Inc.
Parc Industriel de Petit-Rechain
B-4800 Verviers
Belgium

Mexico, Central America, South America, Caribbean

(305) 385-9585

(305) 385-5507

Mercury Marine - Latin America
 & Caribbean
9010 S.W. 137th Ave.
Suite 226
Miami, FL 33186  U.S.A.

Japan

(81) 543/34-2500

(81) 543/34-2022

Mercury Marine - Japan
No. 27-2 Muramatsu Chisaki-Shinden
Shimizu City
Shizuoka Prefecture
Japan 424

Asia, Singapore

(65) 270-7680

(65) 270-7898

Marine Power International, Ltd.
Block 1002 Jalan Bukit Merah #07-08
Redhill Industrial Estate
JTC Flatted Factories
Singapore 0315

Summary of Contents for V-6 series

Page 1: ...Gasoline Engines Alpha Models 1998 Mercury Marine 90 860168985 1098...

Page 2: ...details which apply to your MerCruiser power package When contacting your Authorized MerCruiser Dealer about service always specify model and serial numbers The description and specifications contain...

Page 3: ...water OK U S A SPECIFICATIONS MODEL MCM 4 3LX 4 3LXH GEN DISPLACEMENT 262 CID IGNITION TIMING 10 BTDC CYL FIRING ORDER 1 6 5 4 3 2 SPARK PLUGS AC MR43LTS ENGINE ROTATION LH MAX W O T RPM 4400 4800 IDL...

Page 4: ...on 20 Operation And Maintenance 20 Freezing Temperature Operation 21 Drive Unit Impact Protection 21 Drain Plug and Bilge Pump 21 Emissions Information Europe Only 22 Attention Required After Submersi...

Page 5: ...Battery 94 Bottom Of Boat 95 Inspection And Maintenance 95 Cold Weather Or Extended Storage 96 Power Package Lay Up 96 Battery Winter Storage 96 Do It Yourself Maintenance 96 Power Package Recommissio...

Page 6: ...g will be pleasant Consumer Affairs Department CA741 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in the Wa...

Page 7: ...ions while performing the service plus common sense operation are major accident prevention measures WARNING WARNING Hazards or unsafe practices which could result in severe personal injury or death C...

Page 8: ...entanglement with nearby objects It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close t...

Page 9: ...ally ejected WARNING Should the operator fall out of the boat the possibility of seri ous injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately Alwa...

Page 10: ...8 CA641 1...

Page 11: ...is odorless colorless and tasteless Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication include headache dizziness drowsiness and nausea WARNING A...

Page 12: ...10 CA642 3A 3B Courtesy of ABYC 2A 2B...

Page 13: ...passengers in an unclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 2 Examples of poor ventilation while boat is stati...

Page 14: ...y 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 Manufacturers Associ...

Page 15: ...e 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 operatin...

Page 16: ...Watch fallen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend the skier The operator...

Page 17: ...allowing people to swim or be in the water near your boat WARNING Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if co...

Page 18: ...ing off plane Shifting weight to front bow will Improve ease of planing Improve rough water ride At extremes can cause boat to veer back and forth bow steer CA8 Bottom Of Boat To maintain maximum spee...

Page 19: ...nd the propeller resulting in propeller speedup and a reduction in boat speed Excessive ventilation is annoying and usually caused by A Drive unit trimmed out too far B A missing propeller diffuser ri...

Page 20: ...elow the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating RPM range will...

Page 21: ...s speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a hot humid summer day may encounter a loss of as much as 1...

Page 22: ...mum performance and dependability and will keep your overall operating expenses at a minimum See your Authorized MerCruiser Dealer for service aids CA14 DEALER RESPONSIBILITIES In general a dealer s r...

Page 23: ...g in REVERSE No impact protection is provided in REVERSE If drive unit should strike a submerged object stop engine as soon as possible and inspect drive unit for damage If damage is present or suspec...

Page 24: ...r or agency will be equipped with the appropriate test equipment and adapters for this engine Refer to Emissions Testing procedure found later in this manual CA409 Attention Required After Submersion...

Page 25: ...n this instance water may enter the cylinders through the exhaust system When backing up rapidly the same situation may occur as stated in the preceding paragraph In any of these situations water ente...

Page 26: ...for most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine...

Page 27: ...ot attempt these repairs unless you have these special tools and or equipment You can cause damage to the product in excess of the cost a dealer would charge you Also if you partially disassemble an e...

Page 28: ...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 29: ...tore a Trouble Code in the ECM s memory This code can then be read later by a service technician using a special diagnostic tool CA624 Water Separating Fuel Filter CAUTION The electric fuel pump and f...

Page 30: ...as possible after starting and advance throttle above 1500 RPM if conditions permit safe operation Do not operate at one speed consistently for extended periods Do not exceed 3 4 throttle during firs...

Page 31: ...ation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at maximum full throttle RPM CA414 End of First Season Checkup At the end of the first season of operation an Aut...

Page 32: ...30 CA26 70514 70515 70516 70523 70517 70522 70518 70521 70520 70519 1 2 3 4 5 6 7 8 9 10...

Page 33: ...ear on your style gauges 1 Speedometer Indicates boat speed 2 Tachometer Indicates engine RPM 3 Oil Pressure Gauge Indicates engine oil pressure 4 Battery Meter Indicates battery voltage 5 Water Tempe...

Page 34: ...32 CB218 70516 1 2 3 71987 70518...

Page 35: ...sition without cranking the en gine The horn will sound if the system is working correctly CAUTION Avoid engine damage Do not operate engine once the buzzer has sounded EXCEPT TO AVOID A HAZARDOUS SIT...

Page 36: ...34 CA756 74898 1A 74907 2 3 4 76037 1B...

Page 37: ...iring harness if an electrical overload occurs 3 On EFI Models A 90 Amp fuse is located on the large post of the starter solenoid This fuse is designed to protect the engine wiring harness if an elect...

Page 38: ...36 CA697 70528 70527 70526 9 7 8 5A 5B 5C 5 70525 6...

Page 39: ...blown fuse if key is turned to START and nothing happens and circuit breaker if equipped is not tripped CA482 7 The Power Trim System is protected from overload by 110 amp fuse and a 20 amp in line f...

Page 40: ...38 CB181 1 4 5 2 3 6 7...

Page 41: ...ng procedures 4 Trailer Switch Used to raise drive unit for trailering launching breaching or shallow water operation See Power Trim for detailed trailer switch operation 5 Lanyard Stop Switch Turns i...

Page 42: ...40 CB183 1 4 2 6 3 2 4 3 1 6 5 5...

Page 43: ...ressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 3 Control Handle Tension Adjustment Screw This screw can be adjusted to I...

Page 44: ...42 CB185 3 4 70537 71339 1 2...

Page 45: ...be increased or decreased 3 FRICTION Screw adjusts control handle friction so motor speed can be set and driver does not have to hold handle Turn screw clockwise to increase friction Do not thread sc...

Page 46: ...71338 1 3 TO 5 DEGREES 44 CA34...

Page 47: ...performance is obtained with the drive unit adjusted so the boat bottom will run at a 3 to 5 angle to the water Trimming Drive Unit UP OUT Can Generally increase top speed Increase clearance over subm...

Page 48: ...46 CB187 1 3 2 6 4 5 73976 73977...

Page 49: ...er Position Press button until drive unit reaches desired height 2 Trim Up Out Press UP on Trim switch until drive unit reaches desired trim position 3 Lower Drive Unit Press DOWN on Trim switch until...

Page 50: ...48 CB190 4 2A 1 1 2B 3 73978 73979...

Page 51: ...ntil drive unit reaches desired height for trailering drive units 2 Two Button Trim Control Dual Buttons in Handle used to control both drive units from the handle Press UP on button s to trim drive u...

Page 52: ...50 CB192 70540 70540 70540 1 2 3...

Page 53: ...release button s and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed 1 Trailer Position Simultaneously press the UP button top along with th...

Page 54: ...unit unless engine is at Idle RPM Perform the following as appropriate 1 Check all items listed in OPERATION CHART 2 Perform any other necessary checks as indicated by your dealer or specified in you...

Page 55: ...IFICATIONS stop engine immediately and determine cause 9 If engine is cold run engine for 1 or 2 minutes at fast idle 1000 1500 RPM 10After engine has warmed up check water temperature gauge to ensure...

Page 56: ...minimize the wave action against the stern of the boat Do not come off plane quickly shift into reverse and shut off engine CB575 IMPORTANT Avoid stopping engine if the drive unit is in gear If engine...

Page 57: ...n battery switch ON if so equipped Check for fuel oil water fluid and exhaust leaks etc Turn battery switch OFF if so equipped Operate bilge blowers if so equipped Check shift and throttle control ope...

Page 58: ...oline CA291 USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The two types of oxygenates used in these fuels is Alcohol Ethanol or Ether M...

Page 59: ...fuel lines fittings fuel filters and carbure tors fuel injection components should be inspected for leak age softening hardening swelling or corrosion Any sign of leakage or deterioration requires rep...

Page 60: ...ation of SH CF CF 2 may be used In those areas where Quicksilver 4 Cycle 25W 40 Marine Engine Oil or a recommended straight weight oil are not available a multi viscosity 20W 40 or as a second but les...

Page 61: ...or 2 ATDC5 Firing Order 1 3 4 2 Electrical System 12 Volt Negative Ground Alternator Rating 55 Amps Recommended Battery Rating Minimum 375 cca 475 mca 90 Ah 1 Power Rated in Accordance with NMMA Nati...

Page 62: ...ed in Accordance with NMMA National Marine Manufacturers Associa tion rating procedures 2 Power Rated in Accordance with BSO SAV rating procedures This rating proce dure is used to certify that the en...

Page 63: ...MMA National Marine Manufacturers Associa tion rating procedures 2 Power Rated in Accordance with BSO SAV rating procedures This rating proce dure is used to certify that the engine complies with Stag...

Page 64: ...20 Ah 1 Power Rated in Accordance with NMMA National Marine Manufacturers Associa tion rating procedures 2 Power Rated in Accordance with BSO SAV rating procedures This rating proce dure is used to ce...

Page 65: ...decal on engine for identification Maintenance Aids 1 Power Steering System Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid ATF 2 Propeller Shaft Quicksilver Speci...

Page 66: ...rval Engine Crankcase Oil Check level Closed Cooling Coolant Check level Power Steering Fluid Check level Sterndrive Unit Oil Check level Battery Check level and inspect for damage Weekly Fuel Pump Si...

Page 67: ...s of operation or 120 days whichever occurs first Propeller Shaft Lubricate Saltwater Use Every 50 hours of operation or 60 days Power Package Exterior Surfaces Spray with rust preventative 60 y which...

Page 68: ...Filter Change Ignition system Clean and inspect condition Flame Arrestor and Crankcase Ventilation Hose Clean and inspect Positive Crankcase Ventilation PCV Valve If Equipped Change End of first boat...

Page 69: ...em Hoses and Clamps Inspect for damage and deterioration Check clamps for tightness End of first boating season and Continuity Circuit Check components for loose connections broken or frayed wires End...

Page 70: ...nit Bellows and Clamps Inspect Engine Alignment Check End of first boating season and thereafter Saltwater Use Every 300 Engine Coupling Universal Joint Shaft Splines Lubricate Saltwater Use Every 300...

Page 71: ...THIS PAGE IS INTENTIONALLY BLANK 69 CA175...

Page 72: ...70 CA431 2 3 4 4 5 70543 74766 70547 70546 74764 6 71340 75028 1...

Page 73: ...AP DIPSTICK and observe level Add specified fluid if required Reinstall FILLCAP DIPSTICK IMPORTANT If fluid is not visible in pump contact your Authorized MerCruiser Dealer CA477 CHECKING ENGINE COOLA...

Page 74: ...72 CA763 70979 70551 71425 3 2A 2B 75028 1...

Page 75: ...ue to lack of lubrication Contact your Authorized MerCruiser Dealer for service CB763 CHECKING POWER TRIM PUMP FLUID Place drive unit in full down in position 2 Remove fill cap from reservoir and obse...

Page 76: ...74 CA473 75492 2...

Page 77: ...ating when removing propeller nut CAUTION Avoid Injury Periodically check propeller nut for tightness during boating season A minimum of 55 lbs ft 75 N m torque is required CA746 REMOVAL 1 Place wood...

Page 78: ...76 CA634 4 5 6 7 8 75492 9...

Page 79: ...into propeller NOTE The drive sleeve is tapered and will slide fully into the propel ler as the nut is tightened and properly torqued 7 Align splines and place propeller on propeller shaft 8 Install...

Page 80: ...78 CA202 1 2 3 70565 71353 70564...

Page 81: ...lush with freshwater at specified intervals CB672 If flushing cooling system with boat in water raise drive unit to TRAILER position install flushing attachment and lower drive unit to full DOWN IN po...

Page 82: ...80 CA150 1 2 71428...

Page 83: ...mp drive belt if so equipped If any drive belts need replacement or tension needs adjustment see your Authorized MerCruiser Dealer 1 Alternator Drive Belt Inspect drive belt for excessive wear or dama...

Page 84: ...82 CA436 2 3 A B C D E A B C D E A 1 1...

Page 85: ...ustment idler pulley on models without closed cooling This location is between the power steering pump and alternator pulleys on models with closed cooling 1 Check the tension of the serpentine drive...

Page 86: ...84 CA204 71335 70578 70577 70576 70033 4 2 3 5 1 73919...

Page 87: ...se the need for replacement of power package components exposed to water IMPORTANT Replace sacrificial anodes if eroded 50 or more 1 Universal Anodic Plate serves as a sacrificial anode 2 Anodic Plate...

Page 88: ...86 CA162 71958 71957 1 2...

Page 89: ...ounted on each trim cylinder CA646 2 Bearing Carrier Anode is located in front of the propeller between the front side of the propeller and the gear housing Refer to Propeller section in this manual f...

Page 90: ...88 CA93 1 2 71176 3...

Page 91: ...bserve the following 2 Avoid any electrical interconnection between the MerCruiser Product Anodic Blocks or MerCathode System and the paint by allowing a minimum of 1 1 2 in 40mm UNPAINTED area on tra...

Page 92: ...90 CA97 1 71925 71918 SEE CAUTION...

Page 93: ...ture setting on this engine could affect the exhaust emissions level thus voiding the emissions certification These seals should only be removed by an authorized dealer or emissions testing agency CA9...

Page 94: ...92 CA637 75319 75324 71926 1 2A 2B 3 C...

Page 95: ...ipped with the appropriate test equipment and adapters for this engine The test probes should be installed as follows 1 Remove plugs from both exhaust elbows 2 Install exhaust elbow adapter fittings a...

Page 96: ...in eyes and clothing Batteries also produce hydrogen and oxygen gases when being charged This explo sive gas escapes fill vent cell caps and may form an explosive atmosphere around the battery for sev...

Page 97: ...n CA105 Inspection And Maintenance Inspect power package often and at regular intervals to help maintain its top operating performance and correct potential problems before they occur The entire power...

Page 98: ...IS NOT covered by the MerCruiser Limited Warranty CA115 Battery Winter Storage Follow battery manufacturer s instructions for storage CA645 Do It Yourself Maintenance If you desire to perform your ow...

Page 99: ...d battery Clean battery cable clamps and terminals and reconnect cables see CAUTION listed above Tighten each cable clamp securely when connecting 3 Coat terminal connections with a battery terminal a...

Page 100: ...control not in neutral position Position control lever in neutral Open circuit breaker or blown fuse Check and reset circuit breaker or replace fuse Loose or dirty electrical connections or damaged wi...

Page 101: ...retor Models Check choke linkages for freedom of movement Engine flooded Do not attempt to start engine for at least 5 minutes Refer to Starting Procedures Faulty ignition system component Service ign...

Page 102: ...g or an obstruction Faulty ignition system component Service ignition system Clogged fuel filter Replace filter Stale or contaminated fuel If contaminated drain tank Fill with fresh fuel Kinked or clo...

Page 103: ...EFI System checked CA447 Excessive Engine Temperature Possible Cause Remedy Seacock closed Open Drive belt loose or in poor condition Replace or adjust belt Seawater pickups obstructed Remove obstruc...

Page 104: ...Change oil and oil filter using correct grade and viscosity oil Determine cause for dilution excessive idling faulty fuel pump etc CA450 Battery Will Not Come Up On Charge Possible Cause Remedy Exces...

Page 105: ...inkages Remove obstruction Shift or throttle cable kinked Straighten cable or have dealer replace cable if damaged beyond repair CA452 Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low powe...

Page 106: ...ged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring CA454 Power Trim Does Not Operate Motor Runs But...

Page 107: ...anty claims will not be accepted without presentation of this card A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from...

Page 108: ...aler 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 the Marine Power Service Ce...

Page 109: ...e this warranty applies to defects in material and workmanship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of maintenance accident ab normal opera...

Page 110: ...epted without presentation of the Warranty Registration Card VI Our obligation under this Warranty shall be limited to repairing a defective part or at our option refunding the purchase price or repla...

Page 111: ...al worn parts ad justments tune ups or to damage caused by 1 Neglect lack of maintenance accident abnormal operation or im proper installation or service 2 Use of an accessory or part not manufactured...

Page 112: ...nty purchaser shall pay for all re lated labor and material and any other expenses asso ciated with that service Any Product or parts shipped by purchaser for inspection or repair must be shipped with...

Page 113: ...sly manufactured VII ALL INCIDENTAL AND OR CONSEQUENTIAL DAM AGES ARE EXCLUDED FROM THIS WARRANTY WAR RANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WAR RANTIES ARE LIM...

Page 114: ...nt of sacrificial anodes specified lubrication and touch up of nicks and scratches have been implemented on a timely basis 2 Recommended corrosion prevention devices have been employed details below I...

Page 115: ...ts and you may also have other legal rights which vary from state to state or country to country VI Other details of this warranty are contained in paragraphs IV V and VI of the United States and Cana...

Page 116: ...that results from the improper application of copper base paint will not be covered by this limited warranty TRANSFER OF WARRANTY This Limited Warranty is transferable to subsequent purchasers for th...

Page 117: ...ted by customer other than that necessary to satisfy the warranty obligation Labor performed by other than an Authorized Dealer may be covered only under following circumstances When performed on emer...

Page 118: ...where lead is thrown out of commutator because of excess cranking Valve or valve seat grinding required because of wear Failure of any parts caused by lack of cooling water which results from starting...

Page 119: ...nd 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 West Pioneer Road P O Box 1939 Fond du Lac W...

Page 120: ...ection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty The optional Q Guard Product Protection Plan is the only Facto...

Page 121: ...Authorized Dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot obtain service contact the nearest Regional Service Center Outside the United States and Canada con...

Page 122: ...this has already been done then contact the owner of the dealer ship 2 Should you have a question concern or problem that cannot be resolved by your deal ership please contact Mercury Marine Ser vice...

Page 123: ...ankston Road Dandenong Victoria 3164 Australia Europe Middle East Africa 32 87 32 32 11 32 87 31 19 65 Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mexico Central A...

Page 124: ...se full remittance in check or money order NO C O D s CA464 Other Languages To obtain an Operation and Maintenance Manual or Maintenance Procedures Manual in another language contact the nearest Mercu...

Page 125: ...en tretien dans une autre langue contactez le centre de service apr s vente international Mercury Marine ou Marine Power le plus proche pour toute information Une liste des num ros de pi ces en d autr...

Page 126: ...obter informa es Uma lis ta de n meros de refer ncia para outros idiomas fornecida com o seu pacote de propuls o caj464 Otros idiomas Para obtener un Manual de operaci n y mantenimiento o un Manual de...

Page 127: ...or your particular MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine Attn Publ...

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