TDI 3.0L Diesel Sterndrive Models
This sterndrive engine when installed in accordance to Mercury Marine's instructions complies with the requirements of
the following directives by meeting the associated standards, as amended:
Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC
Name of engine manufacturer: Volkswagen Antriebssysteme
90-8M0087070 1213
Declaration of Conformity—Mercury Diesel Sterndrive (VW)
Address: HMA‑E/1, PO 7962, Industriestraße Nord
Town: Salzgitter
Post Code: 38231
Country: Germany
Name of authorized representative: Brunswick Marine in EMEA Inc.
Address: Parc Industriel de Petit‑Rechain
Town: Verviers
Country: Belgium
Post Code:B‑4800
Name of notified body for exhaust emission assessment: International Marine Certification Institute (IMCI)
Address: Rue Abbé Cuypers 3
Town: Bruxelles
Post Code: B‑1040
Country: Belgium
ID Number: 0609
Town: Bruxelles
Post Code: B‑1040
Country: Belgium
☒ B+C
Conformity assessment module used for exhaust emissions:
ID Number: 0609
☐ B+D
☐ B+E
A☐
Conformity assessment module used for noise emissions:
☐ B+F
☐G
☐H
Aa ☒
G☐
H☐
Other Community Directives applied: Electromagnetic Compatibility Directive 2004/108/EC
Description of Engines and Essential Requirements
Engine Type
Fuel Type
Combustion Cycle
☒ z or sterndrive with integral exhaust
☒ Diesel
☒ 4 stroke
Identification of Engines Covered by This Declaration of Conformity
Name of engine model or engine
family:
Unique engine identification number(s) or engine
family code(s)
EC Type–examination
certificate or type‑approval
certificate number
TDI 2.5L 100/120
TDI 100‑5/TDI 100‑5 SE
EXVWM003
TDI 2.5L 140/150/165
TDI 150‑5/TDI 150‑5 D/TDI 165‑5
EXVWM004
TDI 3.0L 225/230/265
TDI 225‑6/TDI 230‑6/TDI 265‑6
EXVWM007
V6 TDI 100/230/260
TDI 3.0L 100/TDI 3.0L 230/TDI 3.0L 260
EXVWM007
TDI 4.2L 285/350
TDI 285‑8/TDI 350‑8
EXVWM008
V8 TDI 335/370
TDI 4.2L 335/TDI 4.2L 370
EXVWM008
© 2013 Mercury Marine
Address: Rue Abbé Cuypers 3
TDI 3.0L Diesel Sterndrive Models
Name of notified body for noise emission assessment: International Marine Certification Institute (IMCI)
Standards
Other normative document/
method
Technical file
B.1 engine identification
☐
☐
☒
B.2 exhaust emission requirements
☒*
☐
☐
B.3 durability
☐
☐
☒
B.4 owner's manual
☒
☐
☐
ISO 8665:2006
C.1 Noise emission levels
☒*
☐
☐
*EN ISO 14509
C.2 Owner's manual
☐
☒
☐
Owner's manual
Essential requirements
Please specify in more detail
(* = mandatory standard)
Annex 1.B—Exhaust Emissions
*EN ISO 8178‑1:1996
Annex 1.C—Noise Emissions
This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the engine
manufacturer that the engine(s) mentioned above complies (comply) with all applicable essential requirements in the way
specified.
Name / function:
Mark Schwabero, President
Mercury Marine
Signature and title:
Date and place of issue: June 6, 2013
Fond du Lac, Wisconsin, USA
Regulatory contact:
Regulations and Product Safety Department
Mercury Marine
W6250 W. Pioneer Road
Fond du Lac, WI 54936
USA
Identification Record
Please record the following information:
Engine Model and Horsepower
Engine Serial Number
Transom Assembly Serial Number (Sterndrive)
Gear Ratio
Sterndrive Unit Serial Number
Propeller Number
Pitch
Diameter
Hull Identification Number (HIN)
Boat Manufacturer
Purchase Date
Boat Model
Length
The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Diesel power
package. When contacting Mercury Marine about service, always specify model and serial numbers.
The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury
Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change
specifications or designs, without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, USA.
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure
operating ease and durability.
With proper care and maintenance, 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 Warranty Manual contains specific instructions for using and maintaining your product. We
suggest that this manual remain with the product for ready reference whenever you are on the water.
Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
Mercury MerCruiser
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 Warranty sections of this manual. The warranty statement contains a description of what is covered, what is not covered,
the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other
related information. Please review this important information.
Mercury Marine products are designed and manufactured to comply with our own high quality standards, applicable industry
standards and regulations, as well as certain emissions regulations. At Mercury Marine every engine is operated and tested
before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are
tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of
compliance with applicable standards and regulations. All Mercury Marine product, sold as new, receives the applicable limited
warranty coverage, whether the engine participated in one of the test programs described above or not.
Read This Manual Thoroughly
IMPORTANT: If you do not understand any portion of this manual, contact your dealer for a demonstration of actual starting
and operating procedures.
Notice
Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the
!
, may be used to alert the installer and user to special instructions concerning a particular
International Hazard Symbol
service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions while
performing the service, plus common sense operation, are major accident prevention measures.
!
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
!
WARNING
Indicates a hazardous situation which, if not avoided, could result in 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 or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.
NOTE: Indicates information that helps in the understanding of a particular step or action.
!
WARNING
The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all
occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and
thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.
!
WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or
other reproductive harm.
Copyright and Trademark Information
© MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the
Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick
Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.
TABLE OF CONTENTS
Section 1 - Warranty
Warranty Information................................................................. 2
Warranty Registration United States and Canada.............. 2
Outside United States and Canada................................ 2
Warranty Registration—Outside the United States and
Canada............................................................................... 2
Transfer of Warranty United States and Canada................ 2
Outside the United States and Canada.......................... 3
Diesel Duty‑Cycle Application Definitions .......................... 3
Emission Control Warranty Information..................................... 3
Important Information.......................................................... 3
U.S. EPA Emissions Limited Warranty............................... 3
Emission Control System Components.............................. 3
Warranty Policy—Diesel Models................................................ 4
TDI High‑Output Recreational Use Limited Warranty......... 4
TDI Light‑Duty Commercial Use Limited Warranty............. 5
3‑Year Limited Warranty Against Corrosion–Diesel Models
(Recreational Use Only)..................................................... 7
What Is Covered............................................................. 7
Duration of Coverage..................................................... 7
Conditions That Must Be Met to Obtain Warranty
Coverage........................................................................ 7
What Mercury Will Do..................................................... 7
How to Obtain Warranty Coverage................................. 7
What Is Not Covered...................................................... 8
Transfer of Warranty........................................................... 8
Warranty Policy—Australia and New Zealand........................... 8
MerCruiser Limited Warranty—Australia and New Zealand
Policy.................................................................................. 8
What is Covered............................................................. 9
Guarantees Under Australian Consumer Law................ 9
Duration of Coverage for This Limited Warranty............ 9
Warranty Period for Recreational Use............................ 9
Warranty Period for Commercial Use............................. 9
Transfer of Coverage...................................................... 9
Termination of Coverage................................................ 9
Conditions That Must Be Met to Obtain Warranty
Coverage ..................................................................... 10
What Mercury Will Do................................................... 10
How to Obtain Warranty Coverage Under This Limited
Warranty....................................................................... 10
What is Not Covered.................................................... 10
Expense of Claiming This Limited Warranty................. 11
Transfer of Warranty—Australia and New Zealand
Policy................................................................................ 11
Global Warranty Charts........................................................... 12
United States Warranty Chart—MerCruiser Gas and
Diesel................................................................................ 12
Outside United States................................................... 12
Canada Warranty Chart—MerCruiser Gas and Diesel..... 12
Outside Canada............................................................ 12
Australia and New Zealand Warranty Chart—MerCruiser
Gas and Diesel................................................................. 13
Outside Australia and New Zealand............................. 13
South Pacific Warranty Chart—MerCruiser Gas and
Diesel................................................................................ 13
Outside of the South Pacific......................................... 13
Asia Warranty Chart—MerCruiser Gas and Diesel.......... 13
Outside of Asia............................................................. 13
Europe and the Confederation of Independent States (CIS)
Warranty Charts—MerCruiser Gas and Diesel................. 13
Outside Europe and CIS............................................... 14
Middle‑East and Africa (excluding South Africa) Warranty
Charts—MerCruiser Gas and Diesel................................ 14
Outside Middle‑East and Africa.................................... 14
South Africa Warranty Charts—MerCruiser Gas and
Diesel................................................................................ 14
Outside South Africa..................................................... 14
Section 2 - Getting to Know Your Power Package
Engine Component List............................................................ 16
3.0 Liter TDI Front View Components.............................. 16
3.0 Liter TDI Starboard View Components....................... 16
3.0 Liter TDI Port View Components................................ 17
Features and Controls............................................................. 17
TDI 3.0 Liter Engine Features........................................... 17
Lanyard Stop Switch......................................................... 17
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition............................................ 18
Instrumentation................................................................. 19
VesselView................................................................... 19
SmartCraft Speedometer, Tachometer, and Digital
Gauges......................................................................... 19
System Link Digital Gauges......................................... 20
Power Trim....................................................................... 20
Single Engine Trim and Trailer..................................... 21
Dual Engine Trim and Trailer........................................ 21
Power Trim and MerCathode Overload Protection........... 21
Warning Horn Signals....................................................... 22
90-8M0087070
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Engine Guardian System.................................................. 23
Controls.................................................................................... 23
Switches........................................................................... 23
Emergency Stop Switch.................................................... 24
Remote Control................................................................. 24
Remote Control Function.............................................. 24
Digital Throttle and Shift................................................... 25
Electrical System Overload Protection..................................... 25
Fuses.................................................................................. 25
Vessel Adapter Assembly (VAA) Fuse Replacement........ 26
Identification............................................................................. 26
Serial Number Decal Placement....................................... 26
Engine Data Label Location.............................................. 27
Bravo Sterndrive Serial Number and Identification........... 28
Bravo Transom Serial Number......................................... 28
SeaCore Equipped Drives....................................................... 29
SeaCore Components and Castings................................ 29
Stainless Steel Fasteners................................................. 29
Page i
Emissions Information............................................................ 30
Exhaust Gas Emissions Certificate (Europe Only)........... 30
Owner Responsibility........................................................ 30
Section 3 - On The Water
Safe Boating Recommendations............................................ 32
Carbon Monoxide Exposure................................................... 33
Be Alert To Carbon Monoxide Poisoning.......................... 33
Stay Clear of Exhaust Areas............................................. 33
Good Ventilation .............................................................. 33
Poor Ventilation ............................................................... 34
Basic Boat Operation.............................................................. 34
Duty Cycle Rating............................................................. 34
Pleasure Duty Rating.................................................. 34
TDI Operation Chart............................................................... 36
Drain Plug and Bilge Pump.................................................... 36
Starting, Shifting, and Stopping.............................................. 36
Before Starting the Engine.............................................. 37
Starting a Cold Engine.................................................... 37
Engine Warm‑Up............................................................. 37
Starting a Warm Engine ................................................. 38
Shifting............................................................................ 38
Engine Shutdown (Stopping)........................................... 38
Starting the Engine After Stopped While in Gear............ 38
Trailering the Boat.................................................................. 38
Freezing Temperature and Cold Weather Operation............. 38
Protecting People In The Water............................................. 39
Protecting People in the Water........................................ 39
While You Are Cruising............................................... 39
While Boat Is Stationary.............................................. 39
High Speed and High Performance................................. 39
Passenger Safety in Pontoon Boats and Deck Boats..... 39
Boats Having an Open Front Deck............................. 40
Boats with Front‑Mounted, Raised‑Pedestal Fishing
Seats........................................................................... 40
Wave and Wake Jumping....................................................... 40
Impact with Underwater Hazards........................................... 41
Conditions Affecting Operation............................................... 41
Weight Distribution (Passengers and Gear) Inside the
Boat................................................................................. 41
Bottom of Boat................................................................. 41
Cavitation........................................................................ 42
Ventilation........................................................................ 42
Elevation and Climate..................................................... 42
Propeller Selection.......................................................... 42
Break‑In.................................................................................. 42
Initial Break‑In Procedure................................................ 42
Sterndrive 10‑Hour Break‑In Period (New or With
Replacement Gears)....................................................... 43
Engine Break‑In............................................................... 43
20‑Hour Break‑In Period............................................. 43
After the 20‑Hour Break‑In Period............................... 43
End of First Season Checkup.......................................... 43
Section 4 - Specifications
Fuel Requirements................................................................. 46
Nonferrous Metals and the Fuel System.......................... 46
Diesel Fuel in Cold Weather................................................... 46
Antifreeze/Coolant.................................................................. 46
Engine Oil .............................................................................. 47
Engine Specifications............................................................. 47
Fluid Specifications................................................................. 48
Engine Fluid Capacity..................................................... 48
Bravo Sterndrive Fluid Specifications—Diesel................ 48
Power Steering and Power Trim Fluids........................... 48
Approved Power Steering Fluids................................. 48
Approved Power Trim Fluids....................................... 48
Approved Paints..................................................................... 49
Section 5 - Maintenance
Owner and Operator Responsibilities..................................... 52
Dealer Responsibilities........................................................... 52
Maintenance........................................................................... 52
Replacement Parts Warning................................................... 53
Do‑It‑Yourself Maintenance Suggestions............................... 53
Inspection............................................................................... 53
Maintenance Schedule (Sterndrive Models)........................... 53
Routine Maintenance........................................................ 53
Each Day Start............................................................ 53
Each Day End............................................................. 53
Weekly........................................................................ 53
Every Two Months...................................................... 54
Scheduled Maintenance................................................... 54
Annually...................................................................... 54
Every 100 Hours or Annually (Whichever Occurs First)
.................................................................................... 54
Page ii
Every 200 Hours or Annually (Whichever Occurs First)
.................................................................................... 54
Every 500 Hours or 5 Years (Whichever Occurs First)
.................................................................................... 55
Every 1000 Hours or 5 Years (Whichever Occurs First)
.................................................................................... 55
Every 2000 Hours or 5 Years (Whichever Occurs First)... 55
Engine Oil............................................................................... 55
Checking the Engine Oil Level ....................................... 55
Adding Engine Oil............................................................ 55
Changing the Oil Filter..................................................... 56
Sterndrive Gear Lube............................................................. 58
Checking........................................................................... 58
Filling................................................................................ 58
Changing.......................................................................... 59
90-8M0087070
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Power Trim Fluid...................................................................... 62
Checking............................................................................ 62
Filling.................................................................................. 63
Changing............................................................................ 64
Power‑Assisted Steering Fluid................................................. 64
Checking............................................................................ 64
Filling.................................................................................. 64
Changing............................................................................ 65
Engine Coolant........................................................................ 65
Checking............................................................................ 65
Filling.................................................................................. 66
Changing............................................................................ 66
Replacing the Engine Coolant in the Closed‑Cooling
System..................................................................................... 67
Draining the Closed‑Cooling System................................ 67
Filling the Closed‑Cooling System.................................... 67
Air Filter Cleaning.................................................................... 69
Removal............................................................................. 69
Installation.......................................................................... 69
Water Separating Fuel Filter.................................................... 70
Draining.............................................................................. 70
Replacing........................................................................... 71
Filling.................................................................................. 71
Purging the Fuel System.......................................................... 72
Fuel System............................................................................. 72
Priming............................................................................... 72
Filling the Fuel System....................................................... 72
Winterization of Fuel System ............................................. 72
Seawater System..................................................................... 73
Seawater Pump Impeller Inspection................................. 73
Sterndrive Water Inlets Check.......................................... 73
Flushing and Draining the Seawater System.................... 74
Checking the Seawater Pickups....................................... 75
Cleaning the Seawater Strainer, if Equipped.................... 75
Corrosion Protection................................................................ 76
General Information.......................................................... 76
Engine Corrosion Protection Components....................... 76
Removal....................................................................... 76
Cleaning and Inspection............................................... 77
Installation.................................................................... 77
Maintaining Ground Circuit Continuity.............................. 78
MerCathode...................................................................... 80
Antifouling Paint................................................................ 80
Lubrication............................................................................... 81
Steering System............................................................... 81
Throttle Cable................................................................... 82
Shift Cable........................................................................ 83
Transom Assembly........................................................... 83
Propeller Shaft.................................................................. 83
Engine Coupler................................................................. 84
Driveshaft Extension Models............................................ 84
Maintaining Torques................................................................ 85
Gimbal Ring U‑bolt Nuts................................................... 85
Engine Mounts.................................................................. 86
Propellers................................................................................. 86
Bravo Sterndrive Propeller Removal................................ 86
Bravo One Models........................................................ 86
Bravo Two Models........................................................ 87
Bravo Three Models..................................................... 88
Bravo Sterndrive Propeller Installation............................. 89
Bravo One Models........................................................ 89
Bravo Three.................................................................. 90
Drive Belt................................................................................. 91
Drive Belt Failure Identification................................................ 91
Battery...................................................................................... 92
Battery Precautions for Multiple Engines................................. 93
Alternators.......................................................................... 93
Engine Control Unit (ECU)................................................. 93
Batteries............................................................................. 93
Battery Switches................................................................. 93
Battery Isolators................................................................. 93
Generators......................................................................... 93
Section 6 - Storage
Cold Weather (Freezing Temperature), Seasonal Storage, and
Extended Storage.................................................................... 96
Preparing Your Power Package for Seasonal or Extended
Storage............................................................................. 96
Seasonal Storage Instructions.......................................... 96
Extended Storage Instructions.......................................... 97
Battery Storage................................................................. 98
Recommissioning..................................................................... 98
Section 7 - Troubleshooting
Diagnosing Electronically Controlled Fuel System
Problems................................................................................ 100
Troubleshooting Charts.......................................................... 100
Starter Motor Will Not Crank Engine, or Cranks Slow.... 100
Engine Will Not Start, or Is Hard to Start........................ 100
Engine Runs Rough, Misses, or Backfires..................... 100
Poor Performance........................................................... 101
No Fuel or Faulty Fuel Supply........................................ 101
Engine Will Not Start, Starter Does Not Turn................. 101
Excessive Engine Temperature...................................... 101
90-8M0087070
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Insufficient Engine Temperature..................................... 102
Low Engine Oil Pressure................................................ 102
Battery Will Not Charge.................................................. 102
Remote Control Operates Hard, Binds, Has Excessive
Free‑play, or Makes Unusual Sounds............................ 102
Steering Wheel Turns Hard or Jerky.............................. 103
Power Trim Does Not Operate (Electric Motor Operates but
Sterndrive Unit Does Not Move)..................................... 103
Power Trim Does Not Operate (Electric Motor Does Not
Operate).......................................................................... 103
Page iii
Section 8 - Customer Assistance Information
Owner Service Assistance.................................................... 106
Local Repair Service....................................................... 106
Service Away From Home.............................................. 106
Stolen Power Package................................................... 106
Attention Required After Submersion............................. 106
Replacement Service Parts............................................ 106
Parts and Accessories Inquiries................................ 106
Resolving a Problem....................................................... 106
Contact Information for Mercury Marine Customer Service
........................................................................................ 107
Customer Service Literature................................................. 107
English Language........................................................... 107
Other Languages............................................................ 108
Ordering Literature............................................................... 108
United States and Canada.............................................. 108
Outside the United States and Canada.......................... 108
Section 9 - Maintenance Log
Maintenance Log.................................................................. 110
Page iv
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Section 1 - Warranty
Section 1 - Warranty
1
Table of Contents
Warranty Information.............................................................. 2
Warranty Registration United States and Canada........... 2
Outside United States and Canada ......................... 2
Warranty Registration—Outside the United States and
Canada............................................................................ 2
Transfer of Warranty United States and Canada............. 2
Outside the United States and Canada ................... 3
Diesel Duty‑Cycle Application Definitions ....................... 3
Emission Control Warranty Information.................................. 3
Important Information....................................................... 3
U.S. EPA Emissions Limited Warranty............................ 3
Emission Control System Components........................... 3
Warranty Policy—Diesel Models............................................ 4
TDI High‑Output Recreational Use Limited Warranty...... 4
TDI Light‑Duty Commercial Use Limited Warranty.......... 5
3‑Year Limited Warranty Against Corrosion–Diesel
Models (Recreational Use Only)...................................... 7
What Is Covered ...................................................... 7
Duration of Coverage .............................................. 7
Conditions That Must Be Met to Obtain Warranty
Coverage ................................................................. 7
What Mercury Will Do .............................................. 7
How to Obtain Warranty Coverage ......................... 7
What Is Not Covered ............................................... 8
Transfer of Warranty........................................................ 8
Warranty Policy—Australia and New Zealand........................ 8
MerCruiser Limited Warranty—Australia and New
Zealand Policy................................................................. 8
What is Covered ...................................................... 9
Guarantees Under Australian Consumer Law ......... 9
Duration of Coverage for This Limited Warranty ..... 9
Warranty Period for Recreational Use ..................... 9
Warranty Period for Commercial Use ...................... 9
Transfer of Coverage .............................................. 9
90-8M0087070
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DECEMBER 2013
Termination of Coverage ......................................... 9
Conditions That Must Be Met to Obtain Warranty
Coverage .............................................................. 10
What Mercury Will Do ............................................ 10
How to Obtain Warranty Coverage Under This
Limited Warranty ................................................... 10
What is Not Covered ............................................. 10
Expense of Claiming This Limited Warranty ......... 11
Transfer of Warranty—Australia and New Zealand Policy
....................................................................................... 11
Global Warranty Charts........................................................ 12
United States Warranty Chart—MerCruiser Gas and
Diesel............................................................................. 12
Outside United States ........................................... 12
Canada Warranty Chart—MerCruiser Gas and Diesel
....................................................................................... 12
Outside Canada .................................................... 12
Australia and New Zealand Warranty Chart—MerCruiser
Gas and Diesel.............................................................. 13
Outside Australia and New Zealand ...................... 13
South Pacific Warranty Chart—MerCruiser Gas and
Diesel............................................................................. 13
Outside of the South Pacific .................................. 13
Asia Warranty Chart—MerCruiser Gas and Diesel....... 13
Outside of Asia ...................................................... 13
Europe and the Confederation of Independent States
(CIS) Warranty Charts—MerCruiser Gas and Diesel.... 13
Outside Europe and CIS ....................................... 14
Middle‑East and Africa (excluding South Africa) Warranty
Charts—MerCruiser Gas and Diesel............................. 14
Outside Middle‑East and Africa ............................. 14
South Africa Warranty Charts—MerCruiser Gas and
Diesel............................................................................. 14
Outside South Africa ............................................. 14
Page 1
Section 1 - Warranty
Warranty Information
Warranty Registration United States and Canada
To be eligible for warranty coverage, the product must be registered with Mercury Marine.
At the time of sale, the selling dealer should complete the warranty registration and immediately submit it to Mercury Marine via
MercNET, e‑mail, or mail. Upon receipt of this warranty registration, Mercury Marine will record the registration.
A copy of the warranty registration should be provided to you by your selling dealer.
NOTE: Registration lists must be maintained by Mercury Marine and any dealer of Mercury Marine products sold in the United
States, should a safety recall notification under the Federal Safety Act be required.
You may change your registered address at any time, including at time of warranty claim, by calling Mercury Marine or sending
a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration
department. Your dealer can also process this change of information.
Mercury Marine
Attn: Warranty Registration Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax +1 920 907 6663
Outside United States and Canada
For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power
Service Center closest to you.
Warranty Registration—Outside the United States and Canada
1.
It is important that your selling dealer fills out the warranty registration card completely and mails it to the distributor or
Marine Power Service Center responsible for administering the warranty registration and claim program for your area.
2.
The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of
use and the selling distributor's and dealer's code number, name and address. The distributor or dealer also certifies that
you are the original purchaser and user of the product.
3.
A copy of the warranty registration card, designated as the purchaser's copy, must be given to you immediately after the
card has been completely filled out by the selling distributor or dealer. This card represents your factory registration
identification, and should be retained by you for future use when required. Should you ever require warranty service 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 forms.
4.
In some countries, the Marine Power Service Center will issue you a permanent (plastic) warranty registration card within
30 days after receiving the factory copy of the warranty registration card from your distributor or dealer. If you receive a
plastic warranty registration card, you may discard the purchaser's copy that you received from the distributor or dealer
when you purchased the product. Ask your distributor or dealer if this plastic card program applies to you.
5.
For further information concerning the warranty registration card and its relationship to Warranty Claim processing, refer to
the International Warranty. See Table of Contents.
IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. It is our desire to have
ALL products registered at the factory should it ever be necessary to contact you. Make sure your Mercury Marine distributor or
Mercury Marine authorized dealer fills out the warranty registration card immediately and sends the factory copy to the Marine
Power International Service Center for your area.
Transfer of Warranty United States and Canada
The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial applications.
To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s
name, address, and engine serial number to Mercury Marine’s warranty registration department. In the United States and
Canada, mail to:
Mercury Marine
Attn: Warranty Registration Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax +1 920 907 6663
Upon processing the transfer of warranty, Mercury Marine will record the new owner's information.
Page 2
90-8M0087070
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Section 1 - Warranty
There is no charge for this service.
Outside the United States and Canada
For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power
Service Center closest to you.
Diesel Duty‑Cycle Application Definitions
Continuous duty: This engine rating will allow for load factors above 65% and will allow the continuous use of full power.
Medium duty: This engine rating will allow for load factors up to 50% and is for applications that use full power for 33% of
engine run time (4 hours of full power for every 12 hours of engine run time) with the remainder at cruise speeds.
Recreational or light duty commercial: This engine rating will allow for load factors up to 40 percent and will allow for the
engine to use full power for 13% of engine run time (1 hour of full power for every 8 hours of engine run time) with the
remainder at cruise speeds.
Emission Control Warranty Information
Important Information
To identify the applicable emission control warranty coverage for a particular product, refer to the Emission Control
Information label affixed to the engine.
Engines designated as exempt from either Federal EPA or California emission control regulations are not covered by a
separate emission control component warranty. The product's Mercury MerCruiser manufacturer's warranty is not affected by
the engine's designation under Federal EPA or California emission control regulations.
For a list of typical emission control related engine components, refer to Emission Control System Components in the
warranty section of your owner's manual.
U.S. EPA Emissions Limited Warranty
Consistent with the obligations created by 40 CFR Part 1042, Subpart B, Mercury Marine provides an emission warranty of five
years or 500 hours of engine use whichever occurs first to the retail purchaser, that the engine is designed, built, and equipped
so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the engine is
free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations. This
emission‑related warranty covers all the components listed in the Emission Control System Components. Warranty claims may
be denied for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which
Mercury Marine has no responsibility.
Emission Control System Components
The emission‑related warranty covers all components whose failure would increase an engine's emission of any regulated
component including the following list of components:
1.
2.
3.
4.
Fuel metering system
a.
Pressure regulator or fuel injection system
b.
Cold start enrichment system
c.
Intake valves
Air induction system
a.
Intake manifold
b.
Turbocharger or supercharger systems
c.
Charge air cooler
Exhaust system
a.
Exhaust manifold
b.
Exhaust valves
Miscellaneous items used in above systems
a.
Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware
b.
Pulleys, belts, and idlers
c.
Vacuum, temperature, check and time sensitive valves and switches
d.
Sensors
e.
Electronic controls
NOTE: The EPA emission‑related warranty does not cover components whose failure would not increase an engine's
emissions on any regulated pollutant.
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Section 1 - Warranty
Warranty Policy—Diesel Models
TDI High‑Output Recreational Use Limited Warranty
WHAT IS COVERED: Mercury Marine warrants each new engine/drive package (product) to be free of defects in material and
workmanship during the period described following.
DURATION OF COVERAGE: The warranty period begins on the date the product is first sold to a recreational‑use retail
purchaser or the date on which the product is first put into service, whichever occurs first. This Limited Warranty provides
coverage for two (2) years of use. Commercial use of the product voids the warranty. Commercial use includes any work or
employment related use of the product, or any use of the product that generates income during any part of the warranty period,
even if the product is only occasionally used for such purposes. The repair or replacement of parts, or the performance of
service under this warranty does not extend the term of this warranty beyond its original expiration date. Unexpired warranty
coverage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper
registration of the product.
HIGH‑OUTPUT RATING: A High‑Output Rating applies to variable load applications where full power is limited to one (1)
hour out of every eight (8) hours of operation. Reduced power operation (the 7 hours out of 8 hours in which the engine is not
operated at full power) must be at or below cruise speed. Cruise speed is dependant on the engine's maximum engine rated
speed (RPM):
Full Power Engine Rated Speed (RPM)
Cruise Speed (RPM)
3500 RPM
3.0L (V6)
3100 RPM
4000 RPM
3.0L (V6)
3600 RPM
4200 RPM
4.2L (V8)
3800 RPM
This rating is for pleasure (noncommercial) applications that operate 500 hours or fewer per year.
CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail
customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale
occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Inaccurate warranty
registration information regarding recreational use, or subsequent change of use from recreational to commercial (unless
properly registered) may void the warranty at the sole discretion of Mercury Marine. Routine maintenance outlined in the
Operation, Maintenance and Warranty manual must be timely performed in order to obtain warranty coverage. Mercury Marine
reserves the right to make any warranty coverage contingent upon proof of proper 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 new or Mercury Marine certified remanufactured parts, or
refunding the purchase price of the Mercury Marine product. Mercury Marine 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: Warranty claims must be made through a Mercury Marine authorized repair
facility. The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the
product for warranty service. The purchaser shall not, unless requested by Mercury Marine, ship the product or parts of the
product directly to Mercury Marine.
TERMINATION OF COVERAGE: Warranty coverage may be terminated if:
•
The product was repossessed from a retail customer
•
Purchased at an auction
•
Purchased from a salvage yard
•
Purchased from an insurance company that obtained the product as a result of an insurance claim
•
Registered with incorrect information
WHAT IS NOT COVERED: This limited warranty does not cover the following:
•
Routine maintenance items
•
Adjustments
•
Normal wear and tear
•
Damage caused by abuse
•
Damage caused by abnormal use
•
Damage caused by the use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM
range (see the Operation, Maintenance and Warranty manual)
•
Damage caused by operating the product in a manner inconsistent with the recommended operation and duty cycle section
of the Operation, Maintenance and Warranty manual
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Section 1 - Warranty
•
Damage caused by neglect
•
Damage caused by an accident
•
Damage caused by submersion
•
Damage caused by improper installation (proper installation specifications and techniques are set forth in the installation
instructions for the product)
•
Damage caused by improper service
•
Damage caused by the use of an accessory or part that was not manufactured or sold by Mercury Marine and that
damages the Mercury product
•
Jet pump impellers and liners
•
Damage caused by the use of fuels, oils, or lubricants that are not suitable for use with the product
•
Alteration or removal of parts
•
Damage caused by water entering the engine through the fuel intake, air intake, or exhaust system or damage to the
product from insufficient cooling water caused by blockage of the cooling system by a foreign body
•
Damage caused by running the engine out of water
•
Mounting the engine too high on the transom
•
Damage caused by operating the boat with the engine overtrimmed
Use of the product for racing or other competitive activity, or operating with a racing‑type lower unit at any point, even by a
previous owner of the product, voids the warranty. Expenses related to haul‑out, launch, towing, 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 warranty. Also, expenses associated with the removal or replacement of boat
partitions or other material in order to gain access to the product are not covered by this warranty. No individual or entity,
including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation,
representation, or warranty regarding the product, other than those contained in this limited warranty. If such affirmation,
representation, or warranty is made, it shall not be enforceable against Mercury Marine.
DISCLAIMERS AND LIMITATIONS
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE
EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES
ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL
DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT
ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY
NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER
LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY.
TDI Light‑Duty Commercial Use Limited Warranty
WHAT IS COVERED: Mercury Marine warrants each new engine/drive package (product) to be free of defects in material and
workmanship during the period described following.
DURATION OF COVERAGE: The warranty period begins on the date the product is first sold to a light‑duty commercial‑use
retail purchaser or the date on which the product is first put into service, whichever occurs first. This Limited Warranty provides
coverage for one (1) year or the number of hours of use, whichever occurs first, specific for the product stated horsepower. The
repair or replacement of parts, or the performance of service under this warranty, does not extend the life of the warranty
beyond its original expiration date. Unexpired warranty coverage cannot be transferred.
LIGHT‑DUTY COMMERCIAL RATING: Applies to variable load applications where full power is limited to one (1) hour out of
every eight (8) hours of operation. Reduced power operation (the 7 hours out of 8 hours in which the engine is not operated at
full power) must be at or below cruise speed. Cruise speed is dependant on the engine's maximum engine rated speed (RPM):
Maximum Cruise Speed RPM
Maximum Hours Used
3.0L V6 100 hp (3000)
2600
1500
3.0L V6 230 hp (3500)
3100
1500
3.0L V6 230 hp (4000)
3600
1000
3.0L V6 260 hp (4000)
3600
1000
4.2L V8 335 hp (4200)
3800
1500
4.2L V8 370 hp (4200)
3800
1000
Engine Full Power Rated Speed (RPM)
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Section 1 - Warranty
COMMERCIAL USE: Commercial use is defined as any work or employment related use of this product, or any use of the
product which generates income, for any part of the warranty period, even if the product is only occasionally used for such
purposes. Light‑duty commercial use is not available in the United States.
Operation of the product in excess of the light‑duty commercial specifications will void the warranty.
CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Warranty coverage is available only to retail
customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale
occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Routine maintenance
outlined in the Operation, Maintenance and Warranty manual must be timely performed in order to obtain warranty coverage.
Mercury Marine reserves the right to make any warranty coverage contingent upon proof of proper 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 new or Mercury Marine certified remanufactured parts, or
refunding the purchase price of the Mercury Marine product. Mercury Marine 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: Warranty claims must be made through a Mercury Marine authorized repair
facility. The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the
product for warranty service. The purchaser shall not, unless requested by Mercury Marine, ship the product or parts of the
product directly to Mercury Marine.
TERMINATION OF COVERAGE: Warranty coverage may be terminated if:
•
The product was repossessed from a retail customer
•
Purchased at an auction
•
Purchased from a salvage yard
•
Purchased from an insurance company that obtained the product as a result of an insurance claim
•
Registered with incorrect information
WHAT IS NOT COVERED: This limited warranty does not cover the following:
•
Routine maintenance items
•
Adjustments
•
Normal wear and tear
•
Damage caused by abuse
•
Damage caused by abnormal use
•
Damage caused by the use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM
range (see the Operation, Maintenance and Warranty manual)
•
Damage caused by operating the product in a manner inconsistent with the recommended operation and duty cycle section
of the Operation, Maintenance and Warranty manual
•
Damage caused by neglect
•
Damage caused by an accident
•
Damage caused by submersion
•
Damage caused by improper installation (proper installation specifications and techniques are set forth in the installation
instructions for the product)
•
Damage caused by improper service
•
Damage caused by the use of an accessory or part that was not manufactured or sold by Mercury Marine and that
damages the Mercury product
•
Jet pump impellers and liners
•
Damage caused by the use of fuels, oils, or lubricants that are not suitable for use with the product
•
Alteration or removal of parts
•
Damage caused by water entering the engine through the fuel intake, air intake, or exhaust system or damage to the
product from insufficient cooling water caused by blockage of the cooling system by a foreign body
•
Damage caused by running the engine out of water
•
Mounting the engine too high on the transom
•
Damage caused by operating the boat with the engine overtrimmed
Page 6
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DECEMBER 2013
Section 1 - Warranty
Use of the product for racing or other competitive activity, or operating with a racing‑type lower unit at any point, even by a
previous owner of the product, voids the warranty. Expenses related to haul‑out, launch, towing, 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 warranty. Also, expenses associated with the removal or replacement of boat
partitions or other material in order to gain access to the product are not covered by this warranty. No individual or entity,
including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation,
representation, or warranty regarding the product, other than those contained in this limited warranty. If such affirmation,
representation, or warranty is made, it shall not be enforceable against Mercury Marine.
DISCLAIMERS AND LIMITATIONS
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE
EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES
ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL
DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT
ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY
NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER
LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY.
3‑Year Limited Warranty Against Corrosion–Diesel Models (Recreational Use Only)
What Is Covered
Mercury Marine warrants that each new recreational use engine/drive package (Product) will not be rendered inoperative as a
direct result of corrosion for the period of time described in the following:
Duration of Coverage
This limited corrosion warranty provides coverage for three (3) years from either the date the product is first sold, or the date on
which the product is first put into service, whichever occurs first. The repair and replacement of parts, or the performance of
service under this warranty does not extend the life of this warranty beyond its original expiration date. Unexpired warranty
coverage can be transferred to subsequent (noncommercial use) purchaser upon proper reregistration of the product. Warranty
coverage may be terminated for used product repossessed from a retail customer, purchased at an auction, from a salvage
yard, or from an insurance company that obtained the product as a result of an insurance claim.
Conditions That Must Be Met to Obtain Warranty Coverage
Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute
the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection
process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the
authorized dealer. Corrosion prevention devices specified in the Operation, Maintenance & Warranty manual must be in use on
the boat, and routine maintenance outlined in the Operation, Maintenance & Warranty manual must be timely performed
(including without limitation the replacement of sacrificial anodes, use of specified lubricants, and touch‑up of nicks and
scratches) in order to maintain warranty coverage. Mercury Marine reserves the right to make warranty coverage contingent
upon proof of proper maintenance.
What Mercury Will Do
Mercury's 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 refunding the purchase price of the Mercury
product. 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 provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty
service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the
product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange
for the inspection 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 for all related labor and material, and any other
expenses associated with that service. Purchaser shall not, unless requested by Mercury, ship the product or parts of the
product directly to Mercury. Proof of registered ownership must be presented to the dealer at the time warranty service is
requested in order to obtain coverage.
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Section 1 - Warranty
What Is Not Covered
This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes
purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; damage due to
marine growth; product sold with less than a one year limited product warranty; replacement parts (parts purchased by the
Customer); products used in a commercial application. Commercial use is defined as any work or employment related use of
the product, or any use of the product which generates income, for any part of warranty period, even if the product is only
occasionally used for such purposes.
DISCLAIMERS AND LIMITATIONS
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE
EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES
ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL
DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT
ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY
NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER
LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY.
Transfer of Warranty
The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial applications.
To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s
name, address and engine serial number to Mercury Marine’s Warranty Registration Department. In the United States and
Canada, mail to:
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax +1 920 907 6663
Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by
mail.
There is no charge for this service.
For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power
Service Center closest to you.
Warranty Policy—Australia and New Zealand
MerCruiser Limited Warranty—Australia and New Zealand Policy
This Limited Warranty is given by Marine Power International Pty Ltd ACN 003 100 007 of 41–71 Bessemer Drive, Dandenong
South, Victoria 3175 Australia (telephone (61) (3) 9791 5822), e‑mail: merc_info@mercmarine.com.
Page 8
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Section 1 - Warranty
What is Covered
Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below.
The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in
relation to the goods or services to which the warranty relates.
Guarantees Under Australian Consumer Law
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a
replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also
entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a
major failure.
Duration of Coverage for This Limited Warranty
You are only entitled to claim this Limited Warranty for defects which appear during the relevant warranty period (see the
following). Your claim must also be received by us before the warranty period expires.
MerCruiser Petrol Sterndrive and Inboard Engines
•
2‑year product warranty
•
3‑year corrosion warranty
•
1‑year/500 hours product warranty light commercial
MerCruiser SeaCore
•
3‑year product warranty
•
4‑year corrosion warranty
•
1‑year/500 hours product warranty light commercial
MerCruiser TowSport Engines
•
3‑year product warranty
•
3‑year corrosion warranty
•
1‑year/500 hours product warranty light commercial
MerCruiser Diesel
•
2‑year product warranty
•
3‑year corrosion warranty
•
1‑year/500 hours product warranty light commercial
Warranty Period for Recreational Use
The warranty period begins on the date the product is first sold to a recreational use retail purchaser or the date on which the
product is first put into service, whichever occurs first. The repair or replacement of parts or the performance of service under
this warranty does not extend the life of this limited warranty beyond its original expiration date. The warranty period is specific
to the model covered. Refer to your model for the base coverage period.
Warranty Period for Commercial Use
The warranty period begins on the date the product is first sold to a commercial use retail purchaser or the date on which the
product is first put into service, whichever occurs first. Commercial users of these products receive warranty coverage for either
one (1) year from the date of first retail sale or the accumulation of 500 hours of operation, whichever occurs first. Commercial
use is defined as any work related or employment related use of the product, or any use of the product that generates income
for any part of the warranty period, even if the product is only occasionally used for such purposes. The repair or replacement
of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration
date.
Transfer of Coverage
Unexpired warranty coverage can be transferred to a subsequent recreational use customer upon proper registration of the
product. Unexpired warranty coverage cannot be transferred either to or from a commercial use customer.
Termination of Coverage
Warranty coverage under this Limited Warranty is terminated for used product obtained in any of the following ways:
•
Purchased from an insurance company that obtained the product as a result of an insurance claim
•
Purchased from a salvage yard
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DECEMBER 2013
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Section 1 - Warranty
•
Repossession from a retail customer
•
Purchased at an auction
Conditions That Must Be Met to Obtain Warranty Coverage
Warranty coverage under this Limited Warranty is available only to retail customers that purchase from a dealer authorized by
Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the predelivery inspection
process specified by Mercury Marine is completed and documented. Warranty coverage becomes available upon proper
registration of the product by the authorized dealer. Inaccurate warranty registration information regarding recreational use or
subsequent change of use from recreational to commercial (unless properly registered) may void the warranty at the sole
discretion of Mercury Marine. Routine maintenance must be performed according to the maintenance schedule in the
Operation, Maintenance, and Warranty manual in order to obtain warranty coverage. Mercury Marine reserves the right to
make any warranty coverage contingent upon proof of proper maintenance.
What Mercury Will Do
Mercury Marine's sole and exclusive obligation under this Limited Warranty is limited to, at our option, repairing a defective part,
replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the
Mercury Marine product. Mercury Marine 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 Under This Limited Warranty
The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for
warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized
to service the product. A list of dealers and their contact details is available at http://www.mercurymarine.com.au/home.aspx. If
the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine at the address shown
above. Mercury Marine will then arrange for the inspection and any covered repair. This Limited Warranty will not cover the
purchaser for all related transportation charges and travel time. If the service provided is not covered by this limited warranty,
the purchaser shall pay for all related labor and material and any other expenses associated with that service, provided that a
consumer will not be obligated to pay where the service has been carried out to remedy a failure of an acceptable quality
guarantee which is binding on Mercury Marine under the Australian Consumer Law. The purchaser shall not, unless requested
by Mercury Marine, ship the product or parts of the product directly to Mercury Marine. Proof of registered ownership must be
presented to the dealer at the time warranty service is requested in order to obtain coverage under this Limited Warranty.
What is Not Covered
This limited warranty does not cover the following:
•
Operating the boat with the engine over trimmed
•
Routine maintenance items
•
Adjustments
•
Normal wear and tear
•
Damage caused by abuse
•
Abnormal use
•
Use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range. Refer to the
Operation, Maintenance, and Warranty manual.
•
Operation of the product in a manner inconsistent with the recommended operation and duty cycle section of the
Operation, Maintenance, and Warranty manual.
•
Neglect
•
Accident
•
Submersion
•
Improper installation (proper installation specifications and techniques are set forth in the installation instructions for the
product)
•
Improper service
•
Use of an accessory or part that was not manufactured or sold by Mercury Marine that causes damage to the Mercury
product
•
Jet pump impellers and liners
•
Operation with fuels, oils, or lubricants that are not suitable for use with the product. Refer to the Operation, Maintenance,
and Warranty manual.
•
Alteration or removal of parts
•
Water entering the engine through the fuel intake, air intake, or exhaust system or damage to the product from insufficient
cooling water caused by blockage of the cooling system by a foreign body
Page 10
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DECEMBER 2013
Section 1 - Warranty
•
Running the engine out of water
•
Mounting the engine too high on the transom
Use of the product for racing or other competitive activity, or operating with a racing‑type lower unit at any point, even by a
previous owner of the product, voids this limited warranty. Expenses related to haul‑out, launch, towing, 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 limited warranty. Also, expenses associated with the removal or replacement
of boat partitions or other material in order to gain access to the product are not covered by this limited warranty. No individual
or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation,
representation, or warranty regarding the product, other than those contained in this limited warranty. If such affirmation,
representation, or warranty is made, it shall not be enforceable against Mercury Marine.
Expense of Claiming This Limited Warranty
This Limited Warranty does not cover any expenses you may incur claiming the warranty.
DISCLAIMERS AND LIMITATIONS
EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS AND REMEDIES THAT A CONSUMER MAY HAVE
UNDER THE AUSTRALIAN CONSUMER LAW OR OTHER LAW IN RELATION TO WHICH THE PRODUCTS RELATE,
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE
EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES
ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL
DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS LIMITED WARRANTY.
Transfer of Warranty—Australia and New Zealand Policy
The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial applications.
To transfer the warranty to the subsequent owner, send or fax a copy of the Bill of Sale or Purchase Agreement, new owner’s
name, address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department. In Australia and
New Zealand, mail to:
Mercury Marine
Attn: Warranty Registration Department
Brunswick Asia Pacific Group
Private Bag 1420
Dandenong South, Victoria 3164
Australia
Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by
mail. There is no charge for this service.
You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a
letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty
Registration Department.
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DECEMBER 2013
Page 11
Section 1 - Warranty
Global Warranty Charts
United States Warranty Chart—MerCruiser Gas and Diesel
Product
Standard Limited
Warranty
Installation Quality
Certification Warranty
Standard Limited
Corrosion Warranty
MerCruiser
Sterndrive and
Inboard
1 year
2 years
3 years
MerCruiser
TowSport
2 years
3 years
3 years
MerCruiser
SeaCore
3 years
4 years
4 years
MerCruiser Inboard
5.7 ‑ 6.2 MPI, 8.2
H.O.
1 year
3 years
3 years
MerCruiser Inboard
5.7 ‑ 6.2 ‑ 8.2
horizon
3 years
4 years
3 years
Mercury Diesel
Sterndrive and
Inboard
2 years
Not available at time of
printing
3 years
Commercial Application
Contact the Marine Power
Service Center closest to
you
Outside United States
For product purchased outside of United States, contact the distributor in your country, or the authorized Marine Power Service
Center closest to you.
Canada Warranty Chart—MerCruiser Gas and Diesel
Product
Standard Limited
Warranty
Installation Quality
Certification Warranty
Standard Limited
Corrosion Warranty
MerCruiser
Sterndrive and
Inboard
1 year
2 years
3 years
MerCruiser
TowSport
2 years
3 years
3 years
MerCruiser
SeaCore
3 years
4 years
4 years
MerCruiser Inboard
5.7 ‑ 6.2 MPI, 8.2
H.O.
1 year
3 years
3 years
MerCruiser Inboard
5.7 ‑ 6.2 ‑ 8.2
horizon
3 years
4 years
3 years
Mercury Diesel
Sterndrive and
Inboard
2 years
Not available at time of
printing
3 years
Commercial Application
Contact the Marine Power
Service Center closest to
you
Outside Canada
For product purchased outside of Canada, contact the distributor in your country, or the authorized Marine Power Service
Center closest to you.
Page 12
90-8M0087070
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DECEMBER 2013
Section 1 - Warranty
Australia and New Zealand Warranty Chart—MerCruiser Gas and Diesel
Product
Standard Limited Warranty
Standard Limited
Corrosion Warranty
MerCruiser Sterndrive and
Inboard
2 years
3 years
MerCruiser SeaCore
3 years
4 years
MerCruiser TowSport
3 years
3 years
Mercury Diesel Sterndrive
and Inboard
2 years
3 years
Commercial Application
Contact the Marine Power Service
Center closest to you
Outside Australia and New Zealand
For product purchased outside of Australia and New Zealand, contact the distributor in your country, or the authorized Marine
Power Service Center closest to you.
South Pacific Warranty Chart—MerCruiser Gas and Diesel
Product
Standard Limited
Warranty
Standard Limited
Corrosion Warranty
MerCruiser Sterndrive and
Inboard
2 years
3 years
Mercury Diesel Sterndrive
and Inboard
2 years
3 years
Commercial Application
Contact the Marine Power Service Center
closest to you
Outside of the South Pacific
For product purchased outside of the South Pacific, contact the distributor in your country, or the authorized Marine Power
Service Center closest to you.
Asia Warranty Chart—MerCruiser Gas and Diesel
Product
Standard Limited
Warranty
Standard Limited
Corrosion Warranty
MerCruiser Gasoline
Sterndrive and Inboard
1 year
3 years
Mercury Diesel Sterndrive
and Inboard
1 year
3 years
Commercial Application
Contact the Marine Power Service Center
closest to you
Outside of Asia
For product purchased outside of the Asian region, contact the distributor in your country, or the Marine Power Service Center
closest to you.
Europe and the Confederation of Independent States (CIS) Warranty Charts—MerCruiser Gas
and Diesel
Product
Standard Limited
Warranty
Installation Quality
Certification Warranty
Standard Limited
Corrosion Warranty
MerCruiser
Sterndrive and
Inboard
2 years
3 years
3 years
Horizon, Scorpion,
SeaCore
3 years
4 years
3 years
Mercury Diesel
Sterndrive and
Inboard
2 years
Not available at time of
printing
3 years
90-8M0087070
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DECEMBER 2013
Commercial Application
Contact the Marine Power
Service Center closest to
you
Page 13
Section 1 - Warranty
Outside Europe and CIS
For products purchased outside of Europe and CIS regions, contact the distributor in your country, or the Marine Power Service
Center closest to you.
Middle‑East and Africa (excluding South Africa) Warranty Charts—MerCruiser Gas and Diesel
Product
Standard Limited
Warranty
Installation Quality
Certification Warranty
Standard Limited
Corrosion Warranty
MerCruiser
Sterndrive and
Inboard
1 year
2 years
3 years
Horizon, Scorpion,
SeaCore
2 years
3 years
4 years
Mercury Diesel
Sterndrive and
Inboard
1 year
Not available at time of
printing
3 years
Commercial Application
Contact the Marine Power
Service Center closest to
you
Outside Middle-East and Africa
For products purchased outside of Middle‑East and Africa regions, contact the distributor in your country, or the Marine Power
Service Center closest to you.
South Africa Warranty Charts—MerCruiser Gas and Diesel
Product
Standard Limited
Warranty
Installation Quality
Certification Warranty
Standard Limited
Corrosion Warranty
MerCruiser
Sterndrive and
Inboard
1 year
2 years
3 years
Horizon, Scorpion,
SeaCore
2 years
3 years
4 years
Mercury Diesel
Sterndrive and
Inboard
1 year
Not available at time of
printing
3 years
Commercial Application
Contact the Marine Power
Service Center closest to
you
Outside South Africa
For products purchased outside of South Africa, contact the distributor in your country, or the Marine Power Service Center
closest to you.
Page 14
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Section 2 - Getting to Know Your Power Package
Section 2 - Getting to Know Your Power Package
Table of Contents
Engine Component List........................................................ 16
3.0 Liter TDI Front View Components........................... 16
3.0 Liter TDI Starboard View Components.................... 16
3.0 Liter TDI Port View Components............................. 17
Features and Controls.......................................................... 17
TDI 3.0 Liter Engine Features........................................ 17
Lanyard Stop Switch...................................................... 17
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition ..................................... 18
Instrumentation.............................................................. 19
VesselView ............................................................ 19
SmartCraft Speedometer, Tachometer, and Digital
Gauges .................................................................. 19
System Link Digital Gauges .................................. 20
Power Trim.................................................................... 20
Single Engine Trim and Trailer .............................. 21
Dual Engine Trim and Trailer ................................ 21
Power Trim and MerCathode Overload Protection........ 21
Warning Horn Signals.................................................... 22
Engine Guardian System............................................... 23
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Controls................................................................................ 23
Switches........................................................................ 23
Emergency Stop Switch................................................. 24
Remote Control.............................................................. 24
Remote Control Function ...................................... 24
Digital Throttle and Shift................................................ 25
Electrical System Overload Protection................................. 25
Fuses ............................................................................ 25
Vessel Adapter Assembly (VAA) Fuse Replacement ... 26
Identification......................................................................... 26
Serial Number Decal Placement.................................... 26
Engine Data Label Location........................................... 27
Bravo Sterndrive Serial Number and Identification........ 28
Bravo Transom Serial Number...................................... 28
SeaCore Equipped Drives.................................................... 29
SeaCore Components and Castings............................. 29
Stainless Steel Fasteners.............................................. 29
Emissions Information.......................................................... 30
Exhaust Gas Emissions Certificate (Europe Only) ....... 30
Owner Responsibility .................................................... 30
2
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Section 2 - Getting to Know Your Power Package
Engine Component List
3.0 Liter TDI Front View Components
b
c
a
d
e
abcdef-
p
ghij-
f
k-
o
n
lmnop-
g
Gear lubrication monitor
Engine control module cover
Engine oil dipstick
Engine coolant expansion
tank
Power steering oil reservoir
Charge air cooler
(intercooler)
Sacrificial anode
Seawater inlet connection
Seawater pump
Seawater‑cooling system
drain screw
Closed‑cooling system drain
screw
Heat exchanger
Alternator
Water‑in‑fuel sensor
Fuel filter with water sensor
Manual fuel primer
h
m
i
j
l
k
52237
3.0 Liter TDI Starboard View Components
i
k
j
a
b
h
abcdefghijk-
Engine control module cover
Gear lubrication monitor
Manual fuel primer
Fuel filter with water sensor
Water‑in‑fuel sensor
Motor mount
Starter
Air filter
Turbocharger
Oil filter
Oil fill cap
c
d
g
f
Page 16
e
52238
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DECEMBER 2013
Section 2 - Getting to Know Your Power Package
3.0 Liter TDI Port View Components
a
m
b
c
l
d
abcdefghijkl-
k
j
m-
Oil filter
Air filter
Turbocharger
Exhaust pipe
Seawater‑cooling drain screw
Power steering/gearbox oil
cooler
Motor mount
Power steering pump
Charge air cooler (intercooler)
Oil fill cap
Power steering oil reservoir
Engine coolant expansion
tank
Engine control module cover
i
h
g
f
e
52239
Features and Controls
TDI 3.0 Liter Engine Features
The Mercury Diesel 3.0 Liter 6‑cylinder engine has the following features:
•
Four‑stroke diesel engine
•
Common‑rail direct injection
•
6 cylinders (90° V angle)
•
3.0 liter displacement (183.1 cid)
•
Crankshaft mounted on four bearings
•
4 valves per cylinder
•
Hydraulically adjusted bucket tappets
•
Forced‑feed circulatory engine lubrication with geared oil pump and replaceable oil filter in main flow
•
Dry air filter
•
Turbocharged with variable turbine geometry
•
Two separate cooling circuits
•
Seawater‑cooled circuit runs through the oil cooler, the main heat exchanger, and the exhaust manifold.
•
Closed‑cooling circuit runs coolant as a closed pressurized system through the engine block, oil cooler, exhaust
collector, and after reaching the operating temperature, through the main heat exchanger.
Refer to Specifications for additional details.
Lanyard Stop Switch
A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as
may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist.
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Section 2 - Getting to Know Your Power Package
A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.
ATTACH LANYARD
a - Lanyard cord clip
b - Lanyard decal
c - Lanyard stop switch
RUN
b
OFF
a
c
53910
Accidental ejections, such as falling overboard, are more likely to occur in:
•
Low‑sided sport boats
•
Bass boats
•
High‑performance boats
Accidental ejections can also occur from:
•
Poor operating practices
•
Sitting on the seat or gunwale at planing speeds
•
Standing at planing speeds
•
Operating at planing speeds in shallow or obstacle‑infested waters
•
Releasing your grip on the steering wheel
•
Carelessness caused by consuming alcohol or drugs
•
High‑speed boating maneuvers
The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) long when stretched out, with an element on one end made
to be inserted into the switch, and a snap on the other end for attaching to the operator. The lanyard is coiled to make its at‑rest
condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is
made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the
operator's normal position. The operator can shorten the lanyard by wrapping the lanyard around his wrist, or by tying a knot in
the lanyard.
Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance,
depending upon its velocity. While the boat is coasting, it can cause injury to anyone in the boat's path as it would under power.
Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an
emergency.
!
WARNING
If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being
struck by the boat. Always properly connect the operator to the stop switch using a lanyard.
Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of
the following potentially hazardous situations:
•
Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the
front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.
•
Loss of power and directional control in heavy seas, strong current, or high winds.
•
Loss of control when docking.
!
WARNING
Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat
operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.
Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition
Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard
cord. If the engine does not stop, have the switch repaired before operating the boat.
Before each use, inspect the lanyard cord to ensure that it is in good working condition and that there are no breaks, cuts, or
wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard
cords.
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Section 2 - Getting to Know Your Power Package
Instrumentation
VesselView
Your power package may be connected to a SmartCraft VesselView display. VesselView 7 is a comprehensive boat
information center that can display information for up to four gasoline or diesel engines. It continuously monitors and reports
basic operating data including detailed information such as seawater temperature and depth, trim status, boat speed and
steering angle, and the status of fuel, oil, water, and waste tanks.
VesselView can be fully integrated with a vessel’s global positioning system (GPS) or other NMEA‑compatible device to provide
up‑to‑the‑minute navigation, speed, and fuel‑to‑destination information.
VesselView 4 and 7 are equipped with a micro SD card port that allows an authorized OEM or dealership to import the
personality configuration. It can also be use by the owner to import pictures or graphics. When more than one VesselView is
used, either as a triple or quad‑engine application for multiple helms, the same mico SD card can be used to download those
configurations.
52421
VesselView
Refer to your VesselView operations manual for detailed instructions on how to operate this display.
SmartCraft Speedometer, Tachometer, and Digital Gauges
The SmartCraft instrument package augments the information provided by VesselView. The instrument package may display:
•
Engine RPM
•
Boat speed
•
Coolant temperature
•
Oil pressure
•
Battery voltage
•
Fuel consumption
•
Engine operating hours
b
a
c
SmartCraft tachometer and speedometer
a - Tachometer
b - Speedometer
c - LCD display
50400
The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system.
The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.
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Section 2 - Getting to Know Your Power Package
For basic operation information on the SmartCraft instrument package and for details on the warning functions monitored by the
system, refer to the manual provided with your gauge package.
System Link Digital Gauges
Some instrumentation packages include gauges that augment the information provided by VesselView and the SmartCraft
tachometer and speedometer. The owner and operator should be familiar with all the instruments and their functions on the
boat. Have your boat dealer explain the gauges and normal readings that appear on your boat.
The following types of digital gauges may be included with your power package.
a
b
c
d
37925
System Link digital gauges
Item
Gauge
Indicates
a
Oil pressure gauge
Engine oil pressure
b
Voltmeter
Battery voltage
c
Water temperature gauge
Engine operating temperature
d
Fuel gauge
Quantity of fuel in tank
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. Also, the trailering feature allows the operator to raise and lower the sterndrive for trailering, beaching,
launching, low‑speed (below 1200 RPM engine speed), and shallow water operation.
!
WARNING
Excessive trim can cause serious injury or death at high speeds, and single‑ram trim systems do not provide a trim‑out
limiting device or trim indicator. Use caution when trimming with a single‑ram trim system and never trim out beyond the unit's
side support flanges while the boat is underway or at engine speeds above 1200 RPM.
For best performance trim the sterndrive so that the boat bottom is at a 3–5° angle to the water.
3-5
mc79528
Trimming the sterndrive up (out) can:
•
Generally increase top speed
•
Increase clearance over submerged objects or a shallow bottom
•
Cause the boat to accelerate and plane off slower
•
In excess, cause boat porpoising (bouncing) or propeller ventilation
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Section 2 - Getting to Know Your Power Package
•
Cause engine overheating if trimmed up (out) to a point where any cooling water intake holes are above the water line
mc78529
Trimming the sterndrive down (in) can:
•
Help the boat accelerate and plane off quicker
•
Generally improve the ride in choppy water
•
In most cases, reduce boat speed
•
If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane.
This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a
significant wave is encountered.
mc79530
Single Engine Trim and Trailer
Single engine applications have a button that can be pressed to trim the sterndrive unit up (out) or down (in).
To raise the sterndrive for trailering, beaching, launching, low‑speed (below 1200 RPM), and shallow water operation push the
trim button to raise the sterndrive to the full up (out) position.
Some controls also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only.
Dual Engine Trim and Trailer
NOTICE
If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering
systems. If using an external tie bar, raise and lower all drives together as a unit.
Dual engine applications may have a single integral button to operate both sterndrives simultaneously or may have separate
buttons for each sterndrive.
Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only.
Power Trim and MerCathode Overload Protection
If an electrical overload on the electrical system occurs, a fuse will open (blow). Find and correct the cause before replacing the
fuse.
NOTE: If you must operate the engine in an emergency, turn off and disconnect all accessories from the engine and
instrumentation wiring if you cannot find and correct the cause for the electrical overload or excessive current draw. Replace
the fuse. If the fuse burns out, the electrical overload has not been eliminated. Further checks must be made on the electrical
system. Contact your Mercury Diesel authorized repair facility.
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Section 2 - Getting to Know Your Power Package
1.
The power trim system is protected from overload by a 110‑amp fuse and a 20‑amp in‑line fuse on the power trim pump.
a - 20‑amp in‑line fuse holder
b - 110‑amp fuse
a
b
2.
9208
There are several different Quicksilver MerCathode systems available. Each has a fuse connected to the positive (+)
terminal on the controller. If the fuse is open (blown), the system will not operate, resulting in a loss of corrosion protection.
Replace the fuse with one of the same amp rating.
a
a - MerCathode
b - Red/purple wire
c - Fuse
c
b
50534
Warning Horn Signals
When the key switch is turned to the on position, the horn will turn on for a moment as a test to indicate the horn is working.
There are two types of warning horns to alert the operator of an active problem within the engine’s operating system.
1.
Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian
system may engage and protect the engine by limiting power. You should return to port immediately and contact your
servicing dealer.
2.
Intermittent short beeps for six seconds: Indicates a noncritical engine condition. This condition does not require
immediate attention. You may continue using your boat, however, depending on the nature of the problem, the engine’s
power may be limited by the Engine Guardian system to protect the engine. You should contact your servicing dealer at
your earliest convenience.
It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and
restart it, the horn will sound again, one time, if the fault is still present.
A few of the noncritical conditions indicated by the intermittent short beeps for six seconds can be corrected by the operator.
These operator correctable conditions are as follows:
•
Water in the fuel filter. Refer to Maintenance – Water Separating Fuel Filter.
•
Cooling system (water pressure or engine temperature) problem. Stop the engine and check the water intake holes in the
lower unit for obstruction.
•
Low engine oil level. Refer to Fuel and Oil – Checking and Adding Engine Oil.
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Section 2 - Getting to Know Your Power Package
Engine Guardian System
The Engine Guardian system monitors the critical sensors on the engine for any early indications of problems. Engine Guardian
is functional whenever your engine is operating, so you never have to be concerned about whether or not you are protected.
The system will respond to a problem by sounding the warning horn for six seconds and/or reducing engine power in order to
provide engine protection.
If Engine Guardian has been activated, reduce the engine speed. The problem will need to be identified and corrected. The
system must be reset before the engine will operate at higher speeds. Moving the throttle lever back to the idle position will
reset the Engine Guardian system. If the Engine Guardian system has determined the reset has not corrected the problem,
Engine Guardian will remain activated, limiting the throttle. The problem must be identified and corrected before Engine
Guardian will allow the engine to reach a normal operating RPM.
Controls
Switches
Four‑Position Key Switch
•
"OFF" ‑ In the "OFF" position, all electrical circuits are off. The engine will not operate
with the key switch in the "OFF" position.
•
"ACC" ‑ In the "ACC" position, any accessories connected to the electrical circuits can
be operated. The engine will not operate with the key switch in the "ACC" position.
•
"ON" ‑ In the "ON" position, all electrical circuits and instrumentation receive power. The
engine can be started with an optional start‑stop switch.
•
"START" ‑ Turn the key to the start position and release to start the engine.
NOTE: The key can only be removed with the key switch in the "OFF" position.
38160
Dual‑Engine Start‑Stop Switch
A start‑stop switch is optional equipment. The start‑stop switch works in conjunction
with the key switch. There is one start‑stop switch for each engine. Each button on a
multi‑engine start‑stop switch functions independently. The key switch must be in the
run position to start a stopped engine with the start‑stop switch. Pressing a start‑stop
switch button when an engine is running will shut down the corresponding engine.
28082
Bilge Blower Toggle Switch
Operates the bilge blower, if equipped.
ON
OFF
38277
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Section 2 - Getting to Know Your Power Package
Emergency Stop Switch
An emergency stop (E‑stop) switch is used to turn off the engines in an emergency situation, such as a person overboard or a
tangled propeller. When activated, an E‑stop switch interrupts the power supply to the engine and transmission. If the boat is
equipped with an E‑stop switch, the E‑stop switch turns off all of the engines.
35308
Typical E-stop switch
Activation of an E‑stop switch stops the engine, or engines, immediately, but the boat can continue to coast for some distance
depending upon the velocity and degree of any turn at shutdown. While the boat is coasting, it can cause injury to anyone in the
boat's path as seriously as the boat would when under power.
We recommend instructing other occupants on proper starting and operating procedures should they need to operate the
engine in an emergency.
Accidental or unintended activation of the switch during normal operation is also possible, which can cause any or all of the
following potentially hazardous situations:
•
Occupants can be thrown forward due to unexpected loss of forward motion, and passengers in the front of the boat could
be ejected over the bow and possibly struck by the propulsion or steering components.
•
The operator can lose power and directional control in heavy seas, strong current, or high winds.
•
The operator can lose control of the vessel when docking.
Restarting an engine using the key switch or start button after an E‑stop shutdown without first turning the key switch to the off
position for at least 30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous
situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting, some
fault codes are still being displayed, contact your authorized Mercury Diesel repair facility.
Remote Control
Remote Control Function
Operation of the throttle and shift are controlled by the movement of the control handle. Push the control handle forward from
neutral with a quick firm motion to the first detent for forward gear. Continue pushing forward to increase the engine RPM. Pull
the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pulling back to
increase the engine RPM.
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Section 2 - Getting to Know Your Power Package
The remote control handle must be in the neutral position to start the engine.
a
c
abcd-
d
Neutral
Increase engine RPM
Forward gear
Reverse gear
b
b
51014
Digital Throttle and Shift
Digital Throttle and Shift (DTS) operating instructions are provided in a separate manual. Refer to Mercury Diesel's SmartCraft
and DTS Operator's Manual.
Electrical System Overload Protection
!
CAUTION
Failure to protect wiring with an appropriate fuse can damage the wiring and start a fire. When installing any accessories, we
recommend using a Mercury accessory kit. Always use the appropriate fuse to protect wiring.
Fuses
Fuses protect individual circuits from an overload. If an electrical overload occurs, a fuse will burn out. Find and correct the
cause for the electrical overload before replacing the fuse. Always replace a burned out fuse with a fuse that is the same
current rating. Never install a higher current rated fuse.
a
b
Identifying a burned out fuse
a - Good fuse
b - Burned out fuse
28619
Two fuses are located on the engine. To access these fuses, remove the two screws securing the engine control module cover.
Be certain to replace an open fuse only with one of the same current rating.
The remaining fuses are located in the vessel adapter assembly (refer to your boat owner's manual for location) and on the rear
side of the control unit of the individual instrumentation.
Engine Control Module
a - 25‑amp fuse
b - 15‑amp fuse
b
a
52530
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Section 2 - Getting to Know Your Power Package
Vessel Adapter Assembly (VAA) Fuse Replacement
NOTE: Refer to your boat owner's manual for the location of the vessel adapter assembly (VAA). The key for the VAA was
provided along with the ignition keys.
1. Verify the ignition key is off and the lanyard switch is off.
2. Insert the key into the lock and turn it 1/4 turn to the right to unlock it.
Vessel adapter assembly
a - Locked
b - Unlocked
a
b
52444
3.
Lift the cover. A decal on the cover identifies components and fuses inside the VAA.
abcdef-
f
e
d
c
Helm power 5‑amp fuse
EFP 1‑amp fuse
Feature A 1‑amp fuse
T.15 5‑amp fuse
Feature B 1‑amp fuse
Main power 10‑amp fuse
b
a
52510
4.
Replace the open fuse with a new fuse of the same current rating.
5.
Close and lock the cover to prevent water intrusion and an accidental short circuit.
Identification
Serial Number Decal Placement
Three sets of engine, transom assembly, and sterndrive serial number decal strips are provided with each power package. One
set should be used for each of the following:
•
Engine specification decal
•
Warranty registration card
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Section 2 - Getting to Know Your Power Package
•
Operation, Maintenance, and Warranty Manual identification page.
25986
Engine specification and serial number decal
Engine Data Label Location
The engine data label is located on top of the electrical box.
a
a - Engine data label (not seen—on top of the
electrical box)
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Section 2 - Getting to Know Your Power Package
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 sterndrive.
33533
Bravo sterndrive information on ground plate
The serial number is also stamped as a permanent reference on the sterndrive casting inside the back cover.
33534
Bravo sterndrive serial number stamping
Bravo Transom Serial Number
The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly.
Bravo transom assembly U-bolt plate
a - Transom assembly serial number
a
51170
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Section 2 - Getting to Know Your Power Package
The serial number is also stamped on the gimbal housing. This is used as a permanent reference for Mercury Diesel authorized
repair facilities.
Gimbal housing with serial
number stamping
a - Transom assembly serial
number
a
25905
SeaCore Equipped Drives
SeaCore Components and Castings
Mercury MerCruiser SeaCore power packages are equipped with additional stainless steel components and particular
aluminum castings with special coatings. Do not replace SeaCore components with non‑SeaCore. Use only the specified
Mercury MerCruiser SeaCore components and castings on these power packages.
Stainless Steel Fasteners
SeaCore models are equipped with additional stainless steel fasteners to maximize corrosion resistance in saltwater
environments.
Stainless steel fasteners are subject to galling when installed without lubrication. Galling can result in fastener destruction,
improper clamp loads, or both. Galled fasteners may appear to torque properly, but still have incorrect clamp loads.
Apply lubricant 2‑4‑C with PTFE or an equivalent, on the threads of stainless steel fasteners during installation to avoid galling.
Lubricate at least the first 8 mm (1/4 in.) of the threads before installation.
Tube Ref No.
2-4-C with PTFE
95
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Description
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DECEMBER 2013
Where Used
Part No.
Threads of stainless steel fasteners
92-802859A 1
Page 29
Section 2 - Getting to Know Your Power Package
Emissions Information
Exhaust Gas Emissions Certificate (Europe Only)
xxxxxxxxx
x.x
A tamper‑resistant label is affixed to the engine at time of manufacture. In addition to the required exhaust gas emissions
certificate number, the label lists the engine serial number, engine family, maximum RPM, engine power, and weight. Note that
the exhaust gas emissions certification will not affect the fit, function, or performance of the engines. Boatbuilders and dealers
may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury Diesel about the
availability of replacement decals before proceeding.
xxxxxxxxx
xx
52250
Owner Responsibility
The owner or operator is not to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission
levels to exceed their predetermined factory specifications.
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Section 3 - On The Water
Section 3 - On The Water
Table of Contents
Safe Boating Recommendations.......................................... 32
Carbon Monoxide Exposure................................................. 33
Be Alert To Carbon Monoxide Poisoning ..................... 33
Stay Clear of Exhaust Areas ........................................ 33
Good Ventilation .......................................................... 33
Poor Ventilation ........................................................... 34
Basic Boat Operation............................................................ 34
Duty Cycle Rating ......................................................... 34
Pleasure Duty Rating ............................................ 34
TDI Operation Chart............................................................. 36
Drain Plug and Bilge Pump.................................................. 36
Starting, Shifting, and Stopping............................................ 36
Before Starting the Engine............................................. 37
Starting a Cold Engine................................................... 37
Engine Warm‑Up........................................................... 37
Starting a Warm Engine ................................................ 38
Shifting........................................................................... 38
Engine Shutdown (Stopping)......................................... 38
Starting the Engine After Stopped While in Gear.......... 38
Trailering the Boat................................................................ 38
Freezing Temperature and Cold Weather Operation........... 38
Protecting People In The Water........................................... 39
Protecting People in the Water...................................... 39
While You Are Cruising ......................................... 39
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While Boat Is Stationary ........................................ 39
High Speed and High Performance............................... 39
Passenger Safety in Pontoon Boats and Deck Boats.... 39
Boats Having an Open Front Deck ........................ 40
Boats with Front‑Mounted, Raised‑Pedestal Fishing
Seats ..................................................................... 40
Wave and Wake Jumping..................................................... 40
Impact with Underwater Hazards......................................... 41
Conditions Affecting Operation............................................. 41
Weight Distribution (Passengers and Gear) Inside the
Boat............................................................................... 41
Bottom of Boat............................................................... 41
Cavitation....................................................................... 42
Ventilation...................................................................... 42
Elevation and Climate.................................................... 42
Propeller Selection......................................................... 42
Break‑In................................................................................ 42
Initial Break‑In Procedure.............................................. 42
Sterndrive 10‑Hour Break‑In Period (New or With
Replacement Gears)...................................................... 43
Engine Break‑In............................................................. 43
20‑Hour Break‑In Period ....................................... 43
After the 20‑Hour Break‑In Period ......................... 43
End of First Season Checkup........................................ 43
3
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Section 3 - On The Water
Safe Boating Recommendations
To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions
and consider the following suggestions.
Know and obey all nautical rules and laws of the waterways.
•
We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary,
the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For
more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).
Perform safety checks and required maintenance.
•
Follow a regular schedule and ensure that all repairs are properly made.
Check safety equipment onboard.
•
Here are some suggestions of the types of safety equipment to carry when boating:
Approved fire extinguishers
Signal devices: flashlight, rockets or flares, flag, and whistle or horn
Tools necessary for minor repairs
Anchor and extra anchor line
Manual bilge pump and extra drain plugs
Drinking water
Radio
Paddle or oar
Spare propeller, thrust hubs, and an appropriate wrench
First aid kit and instructions
Waterproof storage containers
Spare operating equipment, batteries, bulbs, and fuses
Compass and map or chart of the area
Personal flotation device (one per person onboard)
Watch for signs of weather change and avoid foul weather and rough‑sea boating.
Tell someone where you are going and when you expect to return.
Passenger boarding.
•
Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive
unit into neutral is not sufficient.
Use personal flotation devices.
•
Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and
readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life
jacket at all times while in the boat.
Prepare other boat operators.
•
Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the 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's capacity plate). Know your
boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your
authorized Mercury Marine dealer or the boat manufacturer.
Ensure that everyone in the boat is properly seated.
•
Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of
seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride
anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat
movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat
and are in it before any boat movement.
Never operate a boat while under the influence of alcohol or drugs. It is the law.
•
Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.
Know your boating area and avoid hazardous locations.
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Be alert.
•
The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have
an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when
the boat is above idle or planing transition speed. Watch out for others, the water, and your wake.
Never drive your boat directly behind a water skier.
•
Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.
Watch fallen skiers.
•
When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the
boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to
the skier or anyone in the water.
Report accidents.
•
Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when
their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable
loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other
property where the damage 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 deadly gas that is present in the exhaust fumes of all internal combustion engines, including the
engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless,
but if you can smell or taste engine exhaust, you are inhaling CO.
Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include
headache, dizziness, drowsiness, and nausea.
!
WARNING
Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage,
or death. Avoid exposure to carbon monoxide.
Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.
Stay Clear of Exhaust Areas
41127
Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines
are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While
underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing). This
dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the
possibility of injury from the boat propeller.
Good Ventilation
Ventilate the passenger area, open side curtains or forward hatches to remove fumes.
Example of desired air flow through the boat:
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Poor Ventilation
Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient
ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors 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 a running engine may be exposed to a hazardous level of carbon monoxide.
1.
Examples of poor ventilation while the boat is stationary:
a
a - Operating the engine when the boat
is moored in a confined space
b - Mooring close to another boat that
has its engine operating
b
21626
2.
Examples of poor ventilation while the boat is moving:
a
b
43368
a - Operating the boat with the
trim angle of the bow too
high
b - Operating the boat with no
forward hatches open
(station wagon effect)
Basic Boat Operation
IMPORTANT: Always check to ensure the bilge drain plug is installed before launching the boat.
Duty Cycle Rating
IMPORTANT: Damage caused by improper application or failure to operate the power package within the specified operating
parameters will not be covered by the Mercury Diesel Limited Warranty.
It is the responsibility of the boat manufacturer or the installing dealer to ensure that the power package is properly applied. In
all cases, the power package must be equipped with the gear ratio that allows the engine to operate at wide‑open throttle
(WOT) at the rated engine RPM. The power package must also be applied in accordance with recommendations indicated in
the appropriate applications manual. Use of Mercury Diesel engines in other than the applications indicated by the following
information and in the appropriate applications manual requires written approval from an authorized Mercury Diesel application
engineer.
Pleasure Duty Rating
The pleasure duty rating 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 hulls. Application must conform to
the Pleasure Craft/Recreational duty cycle shown (EPA Mode Number Cycle 5 Duty Cycle).
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Section 3 - On The Water
EPA Mode Number
Cycle 5
DUTY CYCLE
1
2
3
4
5
Engine speed (percent of WOT)
100
91
80
63
Idle
Engine power (percent of total)
100
75
50
25
0
Time at given mode
(percent of total operating time)
8
13
17
32
30
1
2
5
3
4
90-8M0087070
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MODES
Chart showing full power operation is limited to a maximum of 1 of 12 hours
1 - Mode 1: 1.0 hour (8%)
2 - Mode 2: 1.5 hours (13%)
3 - Mode 3: 2.0 hours (17%)
4 - Mode 4: 4.0 hours (32%)
5 - Mode 5: 3.5 hours (30%)
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Section 3 - On The Water
TDI Operation Chart
Starting Procedure
After Starting
While Underway
Stopping and Shutdown
Open the engine hatch. Air
out the bilge completely.
Observe all gauges and
indicator lamps to check the
condition of the engine. If not
normal, stop the engine.
Frequently observe all
gauges and indicator lamps
to monitor engine condition.
Shift the remote control lever
to the neutral position.
Listen for the audio alarm.
Run the engine at idle‑RPM
for several minutes to allow
the turbocharger and engine
to cool.
Turn the battery switch on, if Check for fuel, oil, water, fluid,
equipped.
and exhaust leaks, etc.
Turn on and run the engine
compartment bilge blower, if
equipped, for five minutes.
Check the shift and throttle
control operation.
Turn the key switch to the off
position.
Check for leaks: fuel, oil,
water, fluid, etc.
Check the steering operation.
Turn the battery switch off, if
equipped.
Open the fuel shut‑off valve,
if equipped.
Close the fuel shut‑off valve,
if equipped.
Open the seacock, if
equipped.
Close the seacock, if
equipped.
Prime the fuel injection
system, if necessary.
Flush the seawater cooling
circuit, if operating in
saltwater, brackish water, or
polluted water.
Turn the key switch to the
run position and check that
the lights and indicator
lamps come on.
Turn the key switch to the
start position. Release the
key when the engine starts.
Check that the charge
indicator and oil pressure
indicator lamps are off after
engine starts.
Verify there are no faults.
Warm‑up the engine at a
fast idle‑RPM for several
minutes.
Drain Plug and Bilge Pump
The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a
drain plug or a bilge pump. It is very important to check these items on a regular basis to ensure that the water level does not
come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by
submersion is not covered by the warranty.
Starting, Shifting, and Stopping
!
WARNING
Vapors can ignite and cause an explosion, resulting in engine damage or severe personal injury. Do not use volatile starting
aids such as ether, propane, or gasoline in the engine air intake system.
!
WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire
or explosion. Always ventilate the engine compartment before servicing the power package.
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Section 3 - On The Water
Before Starting the Engine
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
IMPORTANT: Observe the following before starting:
•
Provide water to the seawater pickup pump.
•
Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the
engine does not start, wait one minute to allow the starter motor to cool; then, repeat the starting procedure.
•
Ensure that the engine crankcase is filled to the correct level with the proper grade of oil for the prevailing
temperature. Refer to Specifications—Engine Oil.
•
Ensure that all electrical connections are secure.
•
Check all items listed in the Maintenance Schedule and Operation Chart.
•
Perform any other necessary checks as indicated by your Mercury Diesel authorized repair facility or specified in
your boat owner’s manual.
Starting a Cold Engine
IMPORTANT: Check the fluid levels before starting the engine. Refer to Maintenance.
1.
Turn on and run the engine compartment bilge blower (if equipped) for five minutes. Or, open the engine hatch to air out
the bilge before attempting to start the engine.
2.
Place the sterndrive in the full down (in) position.
3.
Place the control handle in neutral.
4.
5.
NOTE: The fuel delivery pump is equipped with a priming lever to assist in filling the fuel filter or fuel system. The fuel
delivery pump priming lever can be moved up and down repeatedly in the event that the hand pump and primer plunger on
the fuel filter header is not used to fill the system.
If the engine has not been run for a period of time and will not readily start with the standard starting procedure, use the
hand pump and primer plunger located on the fuel filter header. Move the primer plunger (or the priming lever on the fuel
delivery pump) up and down four or five strokes. Attempt to start the engine following the normal procedure.
Turn the key switch to the "RUN" position. Observe the indicator lamp for the glow plugs, if equipped. When the cylinder
temperature is great enough to sustain combustion, the indicator lamp will go off and the engine can be started.
NOTICE
Engaging the starter motor while the engine is operating can damage the starter motor or flywheel. Do not engage the starter
motor continually for longer than 15 seconds. Do not engage the starter motor when the engine is operating.
6.
Turn the key switch to the "START" position. Release the key and allow the switch to return to the "RUN" position when the
engine starts.
IMPORTANT: Within seconds after starting the engine, the oil pressure should exceed 10 psi (69 kPa) minimum. If the oil
pressure does not meet these minimum limits, stop the engine then locate and correct the problem. If you are unable to
determine the problem, see your Mercury Diesel authorized repair facility.
7.
Ensure that the charge indicator and oil pressure warning lamps are off.
8.
Ensure that all instrumentation is functioning properly and indicating normal readings.
Engine Warm‑Up
1.
After starting the engine, verify that all instrumentation is functioning properly.
2.
Operate the engine at 1000–1200 RPM until the engine temperature is within the normal operating range. It is important
that any engine be warmed up before applying full load. The warm‑up period provides time for the lubricating oil to
establish a film between moving parts.
NOTICE
Engine wear caused by increased friction and limited oil flow is greatest when an engine is cold. Decrease engine wear by
allowing the engine coolant temperature to reach normal operating range before hard acceleration or applying full throttle.
3.
After the engine has reached operating temperature:
a.
The oil pressure should be within the range specified. Refer to Specifications—Engine Specifications. Stop the
engine if the oil pressure is not within the range specified.
b.
Check the fuel system for leakage from the injection pump, fuel pipes, fuel filter, or fuel lines.
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Section 3 - On The Water
4.
c.
Check the engine and drive system for oil leakage. Specifically inspect the oil filter, oil lines, oil line connectors, and
oil pan.
d.
Check for coolant leaks. Check the coolant hoses and connection pipes of the heat exchanger, fluid coolers,
aftercooler, water pump, and drain fittings for leaks.
Correct any problems found, or see your Mercury Diesel‑authorized repair facility if you are unable to determine the
problem.
Starting a Warm Engine
1.
Run the engine compartment bilge blower for five minutes. Otherwise, open the engine hatch to air out the bilge before
attempting to start the engine.
2.
Place the remote control handle in neutral.
3.
Turn the key switch to the "RUN" position.
4.
Turn the key switch to the "START" position and release the key when the engine starts. Ensure that the charge indicator
and oil pressure warning lamps turn off.
5.
Ensure that all the instrumentation functions properly and indicates normal readings.
Shifting
NOTICE
Shifting into gear at engine speeds above idle will damage the gearcase. Shifting into gear when the engine is not running
can misalign the clutch, preventing proper shifting. Always shift the gearcase into gear when the engine is operating at idle. If
you must shift while the engine is not operating, rotate the propeller shaft in the appropriate direction during shifting.
1.
Ensure that the remote control shift lever is in Neutral.
2.
To shift the sterndrive, move the remote control shift lever with a firm, quick motion forward to shift to forward gear, or
backward to shift to reverse.
3.
After shifting the sterndrive, advance the throttle to the desired setting.
IMPORTANT: Avoid stopping the engine if the sterndrive is in gear. If the engine does stop with the sterndrive in gear, see
the following procedure:
4.
Push and pull repeatedly on the remote control handle until the handle returns to the neutral detent position. This may take
several tries if the power package was operating above idle RPM when the engine stopped.
5.
After the handle returns to the neutral detent position, resume normal starting procedures.
Engine Shutdown (Stopping)
1.
Place the remote control lever in neutral.
NOTICE
Immediately stopping the engine after high load operation can damage the turbocharger bearings. Idle the engine for several
minutes before shutdown.
2.
Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool.
3.
Turn key switch to the "OFF" position.
Starting the Engine After Stopped While in Gear
IMPORTANT: Avoid stopping the engine if the sterndrive is in gear. If the engine does stop with the sterndrive in gear, see the
following procedure:
1.
Push and pull repeatedly on the remote control handle until the handle returns to the neutral detent position. This may take
several tries if the power package was operating above idle RPM when the engine stopped.
2.
After the handle returns to the neutral detent position, resume normal starting procedures.
Trailering the Boat
Your boat can be trailered with the sterndrive in the up (out) or down (in) position. Adequate clearance is required between the
road and sterndrive when transporting.
If adequate road clearance is a problem, place the sterndrive in full trailer position and support it with an optional trailer kit,
which is available from your Mercury Marine authorized repair facility.
Freezing Temperature and Cold Weather Operation
IMPORTANT: If the boat is operated during periods of freezing temperature, take precautions to prevent freezing damage to
the power package. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.
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Section 3 - On The Water
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open
the seacock or unplug and connect the water inlet hose before starting the engine.
In order to operate the engine in temperatures of 0° C (32° F) or lower, observe the following instructions:
•
At the end of each daily operation, completely drain the seawater section of the cooling system to protect against damage
by freezing.
•
At the end of each daily operation, drain the water from the water separator, if equipped. Fill the fuel tank at the end of daily
operation to prevent condensation.
•
Use the required permanent‑type antifreeze solution to protect components against damage by freezing.
•
Use proper cold weather lubrication oil; ensure that the crankcase contains a sufficient amount.
•
Make certain that the battery is of sufficient size and is fully charged. Check that all other electrical equipment is in
optimum condition.
•
At temperatures of –20° C (–4° F) and below, use a coolant heater and a marine application bilge air heater to improve cold
starting.
•
If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for
information about special cold weather equipment and precautions.
Refer to Section 6 for cold weather or extended storage related information.
Protecting People In The Water
While You Are Cruising
It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds.
21604
Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
Whenever a boat is moving (even coasting) and the gear shift is in neutral, 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 Is Stationary
!
WARNING
A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
Stop the engine immediately whenever anyone in the 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
If your boat is a high‑speed or high performance boat with which you are unfamiliar, we recommend that you never operate it at
its high‑speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator
experienced with your boat. For additional information, refer to the High Performance Boat Operation booklet
(90‑849250‑R2) from your authorized Mercury Diesel repair facility.
Passenger Safety in Pontoon Boats and Deck Boats
Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats
other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a
large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat.
Falling over the front of the boat between the two pontoons will position them to be run over.
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Section 3 - On The Water
Boats Having an Open Front Deck
No one should ever be on the deck in front of the rail while the boat is in motion. Keep all passengers behind the front rail or
enclosure.
Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their
legs caught by a wave and pulled into the water.
mc79555-1
!
WARNING
Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.
Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.
Boats with Front-Mounted, Raised-Pedestal Fishing Seats
Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats
designated for traveling at faster speeds.
Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.
mc79557-1
Wave and Wake Jumping
!
WARNING
Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave
or wake jumping whenever possible.
mc79680-1
Operating recreational boats over waves and wakes is a natural part of boating. However, 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
reenters the water.
The primary concern is the boat changing direction while in the midst of the jump. In such cases the landing may cause the
boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their
seats or out of the boat.
There is another less common hazardous result from allowing your boat to launch off of a wave or wake. If the bow of your boat
pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an
instant. This will bring the boat nearly to a stop in an instant and can send the occupants flying forward. The boat may also veer
sharply to one side.
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Section 3 - On The Water
Impact with Underwater Hazards
Reduce speed and proceed with caution when operating in shallow water or in areas where the waters are suspected of having
underwater obstacles that could be struck by the drive components, rudder, or the boat bottom.
mc79679-1
IMPORTANT: To help reduce injury or impact damage from striking a floating or underwater object, control the boat speed.
Under these conditions, boat speed should be kept to a maximum of 24 to 40 km/h (15 to 25 mph).
The following demonstrate some, but not all, examples of what can happen if the boat strikes an object:
•
The boat could move suddenly in a new direction. A sharp change in direction or turn can throw occupants out of their
seats or out of the boat.
•
A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat.
•
Impact damage to the underwater drive components, rudder, or boat.
Keep in mind that one of the most important things you can do to help reduce injury or impact damage in these situations is
control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have
underwater obstacles.
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose
parts. If damage is present or suspected, the power package should be taken to a Mercury Diesel‑authorized repair facility for a
thorough inspection and any necessary repair.
The boat should be checked for hull fractures, transom fractures, and water leaks.
Operating with damaged drive components, rudder, or boat bottom could cause damage to other parts of the power package,
or could affect control of the boat. If continued operation is necessary, do so at greatly reduced speeds.
!
WARNING
Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel
experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.
Conditions Affecting Operation
Weight Distribution (Passengers and Gear) Inside the Boat
Shifting weight to the rear (stern):
•
Generally increases speed and engine RPM
•
Causes bow to bounce in choppy water
•
Increases danger of following wave splashing into the boat when coming off plane
•
At extremes, can cause the boat to porpoise
Shifting weight to the front (bow):
•
Improves ease of planing
•
Improves rough‑water ride
•
At extremes, can cause the boat to veer back and forth (bow steer)
Bottom of Boat
To maintain maximum speed, ensure that the boat bottom is:
•
Clean, free of barnacles and marine growth
•
Free of distortion, nearly flat where it contacts water
•
Straight and smooth, fore and aft
Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog water
inlets and cause the engine to overheat.
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Section 3 - On The Water
Cavitation
Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object, such as a gear housing or a
propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the
gear housing or the propeller. Common causes of cavitation are:
•
Weeds or other debris snagged on the propeller
•
Bent propeller blade
•
Raised burrs or sharp edges on the propeller
Ventilation
Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed‑up
and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to
continue, eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:
•
The drive unit being trimmed out too far
•
A missing propeller diffuser ring
•
A damaged propeller or gear housing, that allows exhaust gases to escape between the propeller and gear housing
•
The drive unit installed too high on transom
Elevation and Climate
Elevation and climate changes affect the performance of your power package. Loss of performance can be caused by:
•
High elevations
•
High temperatures
•
Low barometric pressures
•
High humidity
For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to
allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your
normal boating weather conditions.
In most cases, the recommended RPM can be achieved by changing to a lower pitch propeller.
Propeller Selection
NOTICE
Operating the engine with the wrong propeller installed can limit power, increase fuel consumption, overheat the engine, or
cause internal powerhead damage. Choose a propeller that allows the engine to operate at the specified wide open throttle
RPM.
It is the responsibility of the boat manufacturer and the selling dealer to equip the power package with the correct propellers.
IMPORTANT: Be sure that the propeller being used does not allow the engine to run against the limiter, as a significant loss in
performance will result.
NOTE: Use an accurate service tachometer to verify RPM.
Select a propeller that will allow the engine power package to operate at the rated engine RPM with a full load.
If full‑throttle operation is below the rated engine RPM, the propeller must be changed to prevent loss of performance and
possible engine damage. On the other hand, operating an engine above the rated engine RPM will cause higher than normal
wear or damage.
After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch:
•
Warmer weather and greater humidity cause an RPM loss (not as significant on these models).
•
Operating in a higher elevation causes an RPM loss (not as significant on these models).
•
Operating with a damaged propeller or dirty boat bottom causes an RPM loss.
•
Operating with increased load (additional passengers, pulling skiers).
For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do not operate at full throttle
when using the lower pitch propeller but not pulling skiers.
Break‑In
Initial Break‑In Procedure
It is especially important that the following procedure be used on new diesel engines. This break‑in procedure allows the proper
seating of the pistons and rings, which greatly reduces the likelihood of problems.
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Section 3 - On The Water
IMPORTANT: It is recommended that the boat not be accelerated hard until this procedure has been completed.
IMPORTANT: Never operate the starter motor longer than 15‑seconds at a time to avoid overheating the starter motor. If the
engine does not start, wait approximately 60‑seconds to allow the starter motor to cool; then, repeat the starting procedure.
1.
See the appropriate Starting, Shifting, and Stopping section, and start the engine. Operate the engine at a fast idle until
it has reached normal operating temperature.
2.
Operate the engine in gear for three‑minutes at : 1200 RPM, 2400 RPM, and 3000 RPM.
3.
Operate the engine in gear for three‑minutes at: 1500 RPM, 2800 RPM, and 3400 RPM.
4.
Operate the engine in gear for three‑minutes at : 1800 RPM, 3000 RPM, and maximum rated full throttle RPM.
Sterndrive 10‑Hour Break‑In Period (New or With Replacement Gears)
It is important that the following procedure be used on new sterndrives and rebuilt sterndrives with new replacement gears. This
break‑in procedure allows the proper seating of the sterndrive gears and related components, which greatly reduces the
likelihood of problems.
•
Avoid full‑throttle starts.
•
Do not operate at any constant speed for an extended period of time.
•
Do not exceed 75% throttle during the first five‑hours. During the next five‑hours, operate at intermittent full throttle.
•
The sterndrive should be shifted into forward gear a minimum of 10 times during break‑in, with run‑in time at moderate
RPM after each shift.
Engine Break‑In
20-Hour Break-In Period
IMPORTANT: The first 20 hours of operation is the engine break‑in period. Correct break‑in is essential to obtain minimum oil
consumption and maximum engine performance. During this break‑in period, the following rules must be observed:
•
Do not operate below 1500 RPM for extended periods of time for 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 any constant speed for an extended period of time.
•
Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occasional operation at full throttle is
permissible (in five‑minute intervals).
•
Avoid full‑throttle acceleration from an idle.
•
Do not operate at full‑throttle until the engine reaches normal operating temperature.
•
Check engine oil level frequently. Add oil as needed. High oil consumption is normal during the break‑in period.
•
At the end of the 20‑hour break‑in period, change the engine oil and filter as specified. Refer to Specifications and
Maintenance.
After the 20-Hour Break-In Period
To help extend the life of the power package, Mercury Diesel recommends the following:
•
Select a propeller that functions efficiently throughout the recommended engine powerband for a fully‑loaded boat. Refer to
Specifications and Maintenance.
•
Never operate at wide‑open throttle for prolonged periods. Operation at 3/4 throttle and below is recommeneded.
End of First Season Checkup
At the end of the first season of operation, contact an authorized Mercury Diesel repair facility regarding scheduled
maintenance items. If the product is operated on a continuous, or year‑round basis, contact the dealer at the end of the first 100
hours of operation or once yearly, whichever occurs first.
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Section 3 - On The Water
Notes:
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Section 4 - Specifications
Section 4 - Specifications
Table of Contents
Fuel Requirements............................................................... 46
Nonferrous Metals and the Fuel System ...................... 46
Diesel Fuel in Cold Weather................................................. 46
Antifreeze/Coolant................................................................ 46
Engine Oil ............................................................................ 47
Engine Specifications........................................................... 47
Fluid Specifications............................................................... 48
Engine Fluid Capacity.................................................... 48
Bravo Sterndrive Fluid Specifications—Diesel.............. 48
Power Steering and Power Trim Fluids......................... 48
Approved Power Steering Fluids ........................... 48
Approved Power Trim Fluids ................................. 48
Approved Paints................................................................... 49
4
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Section 4 - Specifications
Fuel Requirements
!
WARNING
Failure to comply with regulations can result in injury from fire or explosion. Electrical system components on this engine are
not rated as external ignition–protected (EIP). Do not store or use gasoline on boats equipped with these engines, unless
provisions have been made to exclude gasoline vapors from the engine compartment (REF: 33 CFR).
!
WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system
components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or
deterioration requires replacement before further engine operation.
!
WARNING
This engine requires diesel fuel. Mixing gasoline, gasohol, or alcohol and diesel fuel can cause serious injury or death due to
fire or explosion. Never mix gasoline, gasohol, or alcohol with diesel fuel.
IMPORTANT: Use of improper or water‑contaminated diesel fuel can seriously damage your engine. Use of improper fuel is
considered misuse of the engine, and damage caused thereby will not be covered by the warranty.
Mercury diesels are required to use Grade No. 2‑D ULSD (ultra‑low sulphur diesel) fuel meeting ASTM Standards D975 (or fuel
rated Diesel DIN EN 590), and having a minimum cetane rating of 40.
BIODIESEL: The blend of diesel fuel used may not contain more than 7% biodiesel fuel. Use of LSD or blends of ULSD fuel
containing more than 7% biodiesel fuel may result in fuel system degradation, injection nozzle clogging, hard starting,
increased oil change intervals, or excessive exhaust smoke.
The cetane number is a measure of the ignition quality of diesel fuel. Increasing the cetane number will not improve overall
engine performance, but it may be necessary to raise the cetane rating for low‑temperature or high‑altitude use. A lower cetane
number could cause hard starting and slower warm‑up, and could increase engine noise and exhaust emissions.
NOTE: If your engine suddenly becomes noisy after a fill‑up, you possibly received substandard fuel with a low cetane rating.
On intermittent‑use engines, high sulphur content diesel fuel will greatly increase:
•
Corrosion on metal parts
•
Deterioration of elastomer and plastic parts
•
Excessive wear of internal engine parts, particularly bearings, and corrosion and extensive damage to other engine parts
•
Difficulty starting and operating the engine
Nonferrous Metals and the Fuel System
Nonferrous metals must not be used in the fuel system components. The use of items such as copper lines, brass nipples, or
galvanized tanks may result in an engine power loss or a failure of the injection nozzles.
Diesel Fuel in Cold Weather
Unaltered diesel fuels thicken and gel in cold temperatures unless treated. Virtually all diesel fuels are climatized to allow their
use in the particular region for that time of the year. If it becomes necessary to further treat diesel fuel, it is the owner/operator's
responsibility to add a commercial standard brand of anti‑gel diesel fuel additive, following that product's directions.
Antifreeze/Coolant
NOTICE
Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed
cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be
exposed.
Diesel engines are high‑compression engines that operate at higher temperatures than typical insternal combustion engines.
Therefore, the closed‑cooling system and engine, including related cooling passages, must remain as clean as possible to
provide adequate engine cooling. To ensure proper cooling, we recommend filling the closed‑cooling section of the cooling
system with a low silicate formula of ethylene glycol antifreeze in a solution with deionized water. Common tap water or
softened water contains unwanted minerals that can leave large deposits in the system that restrict the cooling system
efficiency. A low silicate formula prevents the antifreeze from separating and forming a silicate gelatin. This gelatin can block
passages in the engine and heat exchanger, causing the engine to overheat.
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Section 4 - Specifications
Only premixed, coolant should be added to the closed‑cooling system. Additives and inhibitors introduced into acceptable
coolant solutions will form a protective film on the internal passages and provide protection against internal cooling system
erosion.
Do not drain the closed‑cooling section for storage. The closed‑cooling section should be kept filled year‑round with an
acceptable antifreeze/coolant solution to avoid rust forming on the internal surfaces. If the engine will be exposed to freezing
temperatures, ensure that the closed‑cooling section is filled with a properly mixed antifreeze/coolant solution to protect the
engine and closed‑cooling system to the lowest temperature to which they will be exposed.
NOTE: It is recommended that a 50/50 solution of coolant (antifreeze) and deionized, purified water be used. A 50/50 solution
will provide freeze protection to –35° C (–31° F). Decreasing the solution to 40/60 will provide freeze protection to –25° C
(–13° F). Even in the warmest climates, never decrease the solution below 40/60. Increasing the solution to 60/40 will provide
freeze protection to –50° C (–58° F).
IMPORTANT: The antifreeze/coolant used in these marine engines must be a low silicate ethylene glycol, containing special
additives, and deionized, purified water. Using other types of engine coolant may cause fouling of the heat exchangers and
overheating of the engine. Do not combine different types of coolants without knowing that they are compatible. Refer to the
coolant manufacturer's instructions.
The acceptable antifreeze/coolants is listed in the following table. Refer to Section 5 ‑ Maintenance for respective change
intervals.
Description
Availability
Part Number
Marine Engine Coolant
Worldwide
8M0078028
Engine Oil
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.
Engine oil must be 5W‑30 viscosity, and meet VW Standard 504 00/507 00.
We strongly recommend the use of:
Description
Where Used
Part Number
5W‑30 (1 L)
Engine crankcase
8M0069603
5W‑30 (4 L)
Engine crankcase
8M0069602
Engine Specifications
Description
Specifications
Engine type
90° V6 cylinder diesel
Displacement
3.0 L (183.1 cid)
Engine weight
330 kg (727.5 lb)
Firing order
1‑4‑2‑5‑3‑6
Bore
83 mm (3.267 in.)
Stroke
91.4 mm (3.598 in.)
Rated engine RPM
4000
Idle RPM in neutral (engine at normal operating temperature)
Rated engine horsepower
Charge air pressure
at 4000 RPM
230
171.5 kw (230.0 hp)
260
193.8 kw (260.0 hp)
230
1 bar (14.5 psi)
260
1.5 bar (21.7 psi)
Oil pressure (minimum)
Thermostat temperature
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DECEMBER 2013
640 RPM (idle)
1.8 bar (26.0 psi)
2000 RPM
4.0 bar (58.0 psi)
Water
70 °C (158 °F)
Page 47
Section 4 - Specifications
Description
Specifications
Twin circuit cooling system:
Closed‑cooling system with separate expansion tank,
thermostat controlled
Heat exchange system cooled with a seawater/freshwater
impeller pump
Cooling system type
Overpressure valve opening
1.4–1.6 bar (20.3–23.2 psi)
Coolant temperature (maximum)
105 °C (221 °F)
Coolant specification
50% water and 50% antifreeze (lilac colored)
Oil temperature (maximum)
135 °C (275 °F)
Oil volume difference between minimum and maximum
markings on the dipstick
1.3 L (1.4 US qt)
Electrical system
12‑volt negative (–) ground
Alternator rating
2160 W, 12 V
Recommended battery rating*
750 CCA, 950 MCA, or 180 mAh
*Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are
the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do
not meet Mercury Marine battery requirements.
Fluid Specifications
Engine Fluid Capacity
IMPORTANT: It may be necessary to adjust the fluid levels depending on installation angle and cooling systems (heat
exchanger and fluid lines).
All models
Capacity
Fluid type
Engine oil with filter
8.0 L (8.45 US qt)
5W‑30
8M0069602
Closed cooling
system
9.0 L (9.5 US qt)
Marine Engine Coolant
(lilac colored)
8M0070979
Part Number
Bravo Sterndrive Fluid Specifications—Diesel
Sterndrive Model
Fluid Capacity includes the Sterndrive and
the Gear Lube Monitor
Bravo One X Diesel
2736 ml (92.5 oz)
Bravo Two X Diesel
3209 ml (108.5 oz)
Bravo Three X Diesel
2972 ml (100.5 oz)
Fluid Type
Fluid Part Number
High Performance Gear Lubricant
92‑858064K01
Power Steering and Power Trim Fluids
Approved Power Steering Fluids
Description
Part Number
Power Trim and Steering Fluid
92‑802880A1
Dextron III Automatic Transmission Fluid
Obtain Locally
Approved Power Trim Fluids
Description
Part Number
Power Trim and Steering Fluid
92‑802880A1
SAE Engine Oil 30W
Obtain locally
SAE Engine Oil 40W
Obtain locally
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Section 4 - Specifications
Approved Paints
Description
Part Number
Mercury Light Gray Primer
92‑802878 52
Mercury Phantom Black
92‑802878Q 1
Mercury Diesel White
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8M0071082
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Section 4 - Specifications
Notes:
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Section 5 - Maintenance
Section 5 - Maintenance
Table of Contents
Owner and Operator Responsibilities................................... 52
Dealer Responsibilities......................................................... 52
Maintenance......................................................................... 52
Replacement Parts Warning................................................. 53
Do‑It‑Yourself Maintenance Suggestions............................. 53
Inspection............................................................................. 53
Maintenance Schedule (Sterndrive Models)......................... 53
Routine Maintenance .................................................... 53
Each Day Start ...................................................... 53
Each Day End ....................................................... 53
Weekly ................................................................... 53
Every Two Months ................................................. 54
Scheduled Maintenance ............................................... 54
Annually ................................................................. 54
Every 100 Hours or Annually (Whichever Occurs
First) ...................................................................... 54
Every 200 Hours or Annually (Whichever Occurs
First) ...................................................................... 54
Every 500 Hours or 5 Years (Whichever Occurs
First) ...................................................................... 55
Every 1000 Hours or 5 Years (Whichever Occurs
First) ...................................................................... 55
Every 2000 Hours or 5 Years (Whichever Occurs First)
...................................................................................... 55
Engine Oil............................................................................. 55
Checking the Engine Oil Level ...................................... 55
Adding Engine Oil.......................................................... 55
Changing the Oil Filter................................................... 56
Sterndrive Gear Lube........................................................... 58
Checking ....................................................................... 58
Filling ............................................................................ 58
Changing ...................................................................... 59
Power Trim Fluid.................................................................. 62
Checking ....................................................................... 62
Filling ............................................................................ 63
Changing ...................................................................... 64
Power‑Assisted Steering Fluid............................................. 64
Checking ....................................................................... 64
Filling ............................................................................ 64
Changing ...................................................................... 65
Engine Coolant..................................................................... 65
Checking ....................................................................... 65
Filling ............................................................................ 66
Changing ...................................................................... 66
Replacing the Engine Coolant in the Closed‑Cooling System
.............................................................................................. 67
Draining the Closed‑Cooling System............................. 67
Filling the Closed‑Cooling System................................. 67
Air Filter Cleaning................................................................. 69
Removal ....................................................................... 69
Installation .................................................................... 69
Water Separating Fuel Filter................................................. 70
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Draining ........................................................................ 70
Replacing ...................................................................... 71
Filling ............................................................................ 71
Purging the Fuel System...................................................... 72
Fuel System.......................................................................... 72
Priming ......................................................................... 72
Filling the Fuel System ................................................. 72
Winterization of Fuel System ....................................... 72
Seawater System................................................................. 73
Seawater Pump Impeller Inspection.............................. 73
Sterndrive Water Inlets Check....................................... 73
Flushing and Draining the Seawater System................. 74
Checking the Seawater Pickups.................................... 75
Cleaning the Seawater Strainer, if Equipped................. 75
Corrosion Protection............................................................. 76
General Information....................................................... 76
Engine Corrosion Protection Components.................... 76
Removal ................................................................ 76
Cleaning and Inspection ........................................ 77
Installation ............................................................. 77
Maintaining Ground Circuit Continuity........................... 78
MerCathode................................................................... 80
Antifouling Paint............................................................. 80
Lubrication............................................................................ 81
Steering System............................................................ 81
Throttle Cable................................................................ 82
Shift Cable..................................................................... 83
Transom Assembly........................................................ 83
Propeller Shaft............................................................... 83
Engine Coupler.............................................................. 84
Driveshaft Extension Models......................................... 84
Maintaining Torques............................................................. 85
Gimbal Ring U‑bolt Nuts................................................ 85
Engine Mounts............................................................... 86
Propellers............................................................................. 86
Bravo Sterndrive Propeller Removal............................. 86
Bravo One Models ................................................. 86
Bravo Two Models ................................................. 87
Bravo Three Models .............................................. 88
Bravo Sterndrive Propeller Installation.......................... 89
Bravo One Models ................................................. 89
Bravo Three ........................................................... 90
Drive Belt.............................................................................. 91
Drive Belt Failure Identification............................................. 91
Battery.................................................................................. 92
Battery Precautions for Multiple Engines.............................. 93
Alternators .................................................................... 93
Engine Control Unit (ECU) ........................................... 93
Batteries ....................................................................... 93
Battery Switches ........................................................... 93
Battery Isolators ............................................................ 93
Generators .................................................................... 93
5
Page 51
Section 5 - Maintenance
Owner and Operator Responsibilities
It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are
complied with for safe operation, and to return the unit to a Mercury Diesel–authorized repair facility for a periodic checkup.
Normal maintenance service and replacement parts are the responsibility of the owner or operator and are not covered by the
terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.
Proper maintenance and care of your power package will ensure optimum performance and dependability and will keep your
overall operating expenses at a minimum. See your Mercury Diesel–authorized repair facility for service aids.
Dealer Responsibilities
In general, a dealer's responsibilities to the customer include predelivery inspection and preparation:
•
Before delivery, making certain that the Mercury Diesel power package is in proper operating condition.
•
Making all necessary adjustments for maximum efficiency.
•
Explaining and demonstrating the operation of the power package and the boat.
•
Providing a copy of the Predelivery Inspection Checklist.
•
Filling out the Warranty Registration Card completely and mailing it to the factory immediately upon sale of the new
product. All power packages must be registered for warranty purposes.
Maintenance
!
WARNING
Neglect or improper maintenance, repairs, or inspections of the power package can result in product damage or serious injury
or death. Perform all procedures as described in this manual. If you are not familiar with proper maintenance or service
procedures, consign the work to an authorized Mercury Marine dealer.
!
WARNING
Accidental engine starting can cause serious injury or death. Remove the key from the ignition switch and engage the lanyard
stop or E‑stop switch to prevent the engine from starting when performing service or maintenance on the power package.
!
WARNING
Engine components and fluids are hot and can cause serious injury or death. Allow the engine to cool before removing any
components or opening any fluid hoses.
!
WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
!
WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire
or explosion. Always ventilate the engine compartment before servicing the power package.
IMPORTANT: Refer to Maintenance Schedule for a complete listing of all scheduled maintenance to be performed. Some
tasks can be done by the owner or operator, while others should be performed by an authorized Mercury Diesel repair facility.
Before attempting maintenance or repair procedures not covered in this manual, we recommended that you purchase the
appropriate Mercury Diesel service manual and read it thoroughly.
Before performing any maintenance on your Mercury Diesel engine:
•
Protect yourself with suitable work clothing and personal protection equipment.
•
Stop the engine, remove the ignition key, and press the emergency stop switch.
•
Move the throttle to the neutral position.
•
Allow the engine to cool.
•
Ventilate the engine compartment for at least five minutes before beginning work.
•
Disconnect the battery, if servicing any electrical components. Always disconnect the negative (–) lead first and reconnect
it last.
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Section 5 - Maintenance
Replacement Parts Warning
!
WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
Do‑It‑Yourself Maintenance Suggestions
Present‑day marine equipment, such as your Mercury Diesel power package, are highly technical pieces of machinery. Special
fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.
If you are one of those persons who likes to do it yourself, here are some suggestions for you.
•
Do not attempt any repairs unless you are aware of the Cautions, Warnings, and procedures required. Your safety is our
concern.
•
If you attempt to service the product yourself, we suggest you order the service manual for that model. The service manual
outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you do not
understand. Do not attempt repairs if you do not understand the procedures.
•
There are special tools and equipment that are required to perform some repairs. Do not attempt these repairs unless you
have these special tools and equipment. You can cause damage to the product in excess of the cost a dealer would
charge you.
•
Also, if you partially disassemble an engine or drive assembly and are unable to repair it, the dealer's mechanic must
reassemble the components and test to determine the problem. This will cost you more than taking it to the dealer
immediately upon having a problem. It may be a very simple adjustment to correct the problem.
•
Do not telephone the dealer, service office, or the factory to attempt for them to diagnose a problem or to request the repair
procedure. It is difficult for them to diagnose a problem over the telephone.
Your local Mercury Diesel authorized repair facility is there to service your power package. They have qualified factory‑trained
mechanics.
It is recommended you have the Mercury Diesel authorized repair facility do periodic maintenance checks on your power
package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of any
problems occurring during your boating season when you want trouble‑free boating pleasure.
Inspection
Inspect your power package often and at regular intervals to help maintain operating performance and to identify potential
problems before they occur. The entire power package should be checked carefully, including all accessible engine parts.
1.
Check for loose, damaged, or missing parts, hoses, and clamps; tighten or replace as necessary.
2.
Check electrical connections and leads for damage.
3.
Remove and inspect the propeller. If it is badly nicked, bent, or cracked, contact your Mercury Diesel–authorized repair
facility.
4.
Repair nicks and corrosion damage on power package exterior finish. Contact your Mercury Diesel–authorized repair
facility.
Maintenance Schedule (Sterndrive Models)
Routine Maintenance
Each Day Start
•
Check the engine oil level.
•
Check the engine coolant level.
•
Check the power‑assisted steering fluid level.
•
Check the sterndrive gear lubricant level in the gear lube monitor.
Each Day End
•
If operating in saltwater, brackish water, or polluted water, flush the seawater section of the cooling system after each use.
•
Drain any water from the fuel filter after each use if operating in freezing temperatures.
Weekly
•
Drain any water from the fuel filter.
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Section 5 - Maintenance
•
Check the trim pump fluid level.
•
Check the seawater inlets for debris or marine growth.
•
Check and clean the seawater strainer.
•
Inspect the anodes and replace if they are 50% eroded.
•
Inspect the air filter.
Every Two Months
•
Check the battery connections and fluid level.
•
Lubricate the propeller shaft and torque the propeller nut (if operating in only freshwater, this maintenance may be
extended to every four months).
•
Spray the engine surfaces with Corrosion Guard if operating in saltwater, brackish water, or polluted waters.
Tube Ref No.
120
Description
Corrosion Guard
Where Used
Part No.
Engine surfaces
92-802878 55
•
Inspect the air filter every two months or every 20 hours, whichever occurs first.
•
Ensure that the gauges and the wiring connections are secure. Clean the gauges every two months or every 50 hours,
whichever occurs first. If operating in saltwater, the interval is reduced to every 25 hours or 30 days whichever occurs first.
Scheduled Maintenance
Annually
Touch up the power package with paint and spray with Corrosion Guard.
Tube Ref No.
120
Description
Corrosion Guard
Where Used
Part No.
Engine surfaces
92-802878 55
Every 100 Hours or Annually (Whichever Occurs First)
•
Change the sterndrive gear lube.
•
Torque the gimbal ring U‑bolt locknuts.
•
Check the steering system and the remote control for loose, missing, or damaged parts. Lubricate the cables and linkages.
•
Inspect the sterndrive U‑joints and lubricate the splines. Inspect the bellows, the exhaust tube, and check the clamps for
tightness.
•
Inspect the gimbal bearing and lubricate the engine coupler every 50 hours if operated at idle for prolonged periods of time.
•
Check the continuity circuit for loose or damaged connections. If equipped with MerCathode, test the unit output. See your
authorized dealer.
•
Check the electrical system for loose, damaged, or corroded fasteners.
•
Driveshaft extension models: Inspect the driveshaft U‑joints, transom end (tailstock) bearings, and engine end (output)
bearings for wear. See your authorized dealer.
•
Lubricate the throttle and shift linkage if applicable.
Every 200 Hours or Annually (Whichever Occurs First)
•
Visual inspection for leaks.
•
Change the engine oil and filter.
•
Replace the fuel water separator filter.
•
Check the power steering fluid level.
•
Check the closed cooling fluid condition and level.
•
Inspect the air filter element and clean if necessary.
•
Check the condition of the alternator and power steering pump ribbed V‑belt.
•
Check the condition of the fuel injection pump belt. See your authorized dealer.
•
Clean the seawater filter.
•
Inspect the seawater pump and replace the impeller if necessary. See your authorized dealer.
•
Inspect the sacrificial anode and replace if necessary.
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Section 5 - Maintenance
Every 500 Hours or 5 Years (Whichever Occurs First)
•
Replace the turbocharger outlet air temperature sensor.
•
Inspect and clean the turbocharger intercooler core as required.
Every 1000 Hours or 5 Years (Whichever Occurs First)
•
Clean the fuel tank.
•
Inspect and clean, as required, the pipe bundles of the heat exchanger.
Every 2000 Hours or 5 Years (Whichever Occurs First)
Replace the fuel injection pump belt. See your authorized dealer.
Engine Oil
Checking the Engine Oil Level
NOTICE
With the engine running, the crankshaft journals or rod journals may strike and break the dipstick, resulting in damage to
internal engine components. Stop the engine completely before removing or inserting the dipstick.
1.
Stop the engine and allow five minutes for the oil to drain into the pan.
2.
Remove the dipstick, wipe it clean, and install it into the dipstick tube. Verify that the dipstick is completely inserted into the
tube.
52253
3.
Remove the dipstick and observe the oil level. The oil level must be between the marks on the dipstick. If necessary, add
oil.
a - No oil required
b - Oil may be added but not to exceed range "a"
c - Oil must be added but not to exceed range "a"
a
b
c
50584
Adding Engine Oil
IMPORTANT: When filling or adding oil to the engine, always use the dipstick to determine how much oil is required. Do not
overfill the engine with oil.
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Section 5 - Maintenance
1.
Remove the oil fill cap.
a - Oil fill cap
a
50583
2.
Add the specified oil to bring the oil level up to, but not over, the maximum mark on the dipstick.
a - No oil required
b - Oil may be added but not to exceed range "a"
c - Oil must be added but not to exceed range "a"
a
b
c
50584
NOTE: If the engine will be running for an extended period of time (10–12 hours), the oil level must be in the middle of the
MIN and MAX markings indicated on the dipstick.
3.0 L TDI
Fluid Type
Capacity
5W‑30 that meets VW 504
00/507 00 specifications
8.0 Liter (8.45 US qt)
Volume difference between the minimum and maximum markings
on the dipstick
1.3 Liter (1.4 US qt)
Engine oil (with filter)
3.
Install the oil fill cap.
Changing the Oil Filter
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.
Refer to the Maintenance Schedule for the change interval. You should change the engine oil before placing the boat in
storage.
IMPORTANT: Change the engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more
impurities. Use only recommended engine oil. Refer to Specifications.
1.
Remove the top engine cover.
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Section 5 - Maintenance
2.
Remove the cover of the oil filter so that the return valve opens, allowing the oil to return to the oil sump.
a - Oil filter cover
a
50598
3.
Separate the oil filter element from the oil filter cover.
4.
Clean the cover with a clean cloth.
5.
Replace the sealing O‑rings.
6.
Apply clean oil to the new sealing O‑rings.
a
c
abcd-
b
Filter cover
O‑ring
Oil filter element
Pin with O‑ring
d
50601
7.
Install the new oil filter element into the filter housing.
IMPORTANT: When installing the oil filter element, ensure that the pin on the lower end of the filter element is aligned with
the hole in the housing.
a - Hole
a
50609
8.
9.
Install the cover onto the filter element. Tighten the cover to the specified torque.
Description
Nm
lb‑in.
lb‑ft
Oil filter element cover
35
–
25.8
Clean up any spilled oil and dispose of as directed by local authorities.
10. Remove the oil fill cap and add the required amount of oil to the engine.
IMPORTANT: When adding oil to the engine, always use the dipstick to determine how much oil is required.
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Section 5 - Maintenance
Sterndrive Gear Lube
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.
Checking
NOTE: The gear lube level will fluctuate during operation. The gear lube level should be checked with the engine cold, before
starting.
Check the gear lube monitor to determine the gear lube level. Keep the gear lube level within the recommended operating
range. Refer to Filling.
Gear lube level shown is at the correct operating range
a - "ADD" mark
b - "OPERATING RANGE" mark
b
a
19948
Filling
IMPORTANT: If more than 59 ml (2 fl oz) of High Performance Gear Lube is required to fill the gear lube monitor, a seal may be
leaking. Damage to the sterndrive may occur due to lack of lubrication. Contact your Mercury Diesel–authorized repair facility.
1.
If the gear lube level is below or near the "ADD" mark, the specified gear lube must be added.
2.
Remove the gear lube monitor cap.
3.
Fill the gear lube monitor with the specified gear lube so that the gear lube level is in the operating range. Do not overfill.
Gear lube monitor
a - Gear lube level at the "ADD" mark
b - Gear lube level at the "OPERATING RANGE" mark
c - Gear lube monitor cap
c
b
a
19947
Tube Ref No.
87
4.
Description
High Performance Gear Lube
Where Used
Part No.
Gear lube monitor
92-858064K01
Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap. Do not overtighten.
a
a - Gear lube monitor cap
19962
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Section 5 - Maintenance
NOTE: When filling the entire sterndrive, refer to Changing.
Changing
1.
Remove the gear lube monitor from the bracket.
a
a - Gear lube monitor bracket
b - Gear lube monitor and cap
c - Retaining strap
b
c
5500
2.
Empty the contents of the gear lube monitor into a suitable container.
3.
Install the gear lube monitor in the bracket.
4.
Bravo One X Models:
a.
Remove the propeller.
b.
Lower the sterndrive to the full down (in) position.
c.
Remove the gear lube fill and drain plug and the sealing washers.
d.
Drain the gear lube into a suitable container.
a - Fill and drain plug
b - Sealing washer
a
b
5.
mc79506-1
Bravo Three X Models:
a.
Place the sterndrive in the full trim limit out position.
b.
Remove the fill and drain plug and the sealing washers.
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Section 5 - Maintenance
c.
Drain the gear lube into a suitable container.
b
b
a
a
19777
14621
Bravo Two X
a - Fill and drain plug
b - Sealing washer
6.
Bravo Three X
Remove the vent plug and sealing washer. Allow the gear lube to drain completely.
a - Vent plug
b - Sealing washer
a b
19066
IMPORTANT: If any water drains from the fill and drain plug hole, or if the gear lube appears milky, the sterndrive is
leaking and should be checked immediately by your Mercury Diesel–authorized repair facility.
7.
Lower the sterndrive so that the propeller shaft is level.
8.
Fill the sterndrive through the fill and drain plug hole with the specified gear lube until an air‑free stream of lube flows from
the vent plug hole.
IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lube in the sterndrive.
Tube Ref No.
87
9.
Description
High Performance Gear Lube
Where Used
Part No.
Sterndrive unit
92-858064K01
Install the vent plug and sealing washer.
10. Continue to pump gear lube into the drive through the fill and drain plug hole until the gear lube appears in the gear lube
monitor.
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Section 5 - Maintenance
11. Fill the gear lube monitor so that the gear lube level is in the operating range. Do not overfill.
Gear lube monitor
a - Gear lube level at the "ADD" mark
b - Gear lube level at the "OPERATING RANGE" mark
c - Gear lube monitor cap
c
b
a
19947
Fluid Capacity includes
the Sterndrive and the
Gear Lube Monitor
Sterndrive Model
Bravo One X Diesel
Bravo One XR
2736 ml (92.5 oz)
Bravo Two X Diesel
3209 ml (108.5 oz)
Bravo Three X Diesel
Bravo Three XR
2972 ml (100.5 oz)
Fluid Type
Fluid Part Number
High Performance Gear
Lube
92‑802854A1
12. Ensure that the rubber gasket is inside the gear lube monitor cap and install. Do not overtighten.
a
a - Gear lube monitor cap
19962
13. Remove the pump from the sterndrive fill and drain plug hole.
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Section 5 - Maintenance
14. Quickly install the sealing washer and the fill and drain plug. Tighten the plug to the specified torque.
a
b
a
mc79506-1
b
14621
All Bravo models shown
a - Fill and drain plug
b - Sealing washer
b
a
19777
Description
Nm
lb‑in
lb‑ft
Fill and drain plug
6.8
60
—
15. Install the sterndrive propeller. Refer to Propellers.
16. Check the level of the gear lube monitor after the first use.
IMPORTANT: The gear lube monitor level will change while the product is in use. Always check the gear lube level when the
sterndrive is cool and the engine is not running.
Power Trim Fluid
Checking
IMPORTANT: Check the fluid level with the sterndrive in the full down (in) position only.
1.
Place the sterndrive in full down (in) position.
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Section 5 - Maintenance
2.
Observe the fluid level. The fluid level must be between the "MIN" and "MAX" lines on the reservoir.
a
b
7876
a - Reservoir
b - "MIN" and "MAX" lines
3.
Fill as necessary with the specified fluid. Refer to Filling.
Tube Ref No.
114
Description
Power Trim and Steering Fluid
Where Used
Part No.
Power trim pump
92-858074K01
Filling
1.
If the fluid level is below the "MIN" line, the specified fluid must be added.
2.
Remove the fill cap from the reservoir.
NOTE: Fill cap is vented.
a
b
Power trim pump reservoir shows the
fluid level is below "MIN" line
a - Fill cap assembly
b - Fill cap installed
7701
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Section 5 - Maintenance
3.
Add the specified fluid to bring the fluid level to within the "MIN" and "MAX" lines on the reservoir.
a
b
7876
a - Reservoir
b - "MIN" and "MAX" lines
Tube Ref No.
114
4.
Description
Power Trim and Steering Fluid
Where Used
Part No.
Power trim pump
92-858074K01
Install the fill cap.
Changing
Power trim fluid does not require changing unless it becomes contaminated with water or debris.
Power‑Assisted Steering Fluid
The power steering fluid level should be checked at regular intervals.
IMPORTANT: Do not leave the steering wheel at full lock for longer than 15 seconds with the engine running. The power
steering fluid will heat up considerably when the steering wheel is at full lock and could cause damage to the power steering
system.
When the steering wheel is at full lock, power steering pump noise will increase as the pump is under full load and the engine
idle RPM will be reduced momentarily.
Checking
1.
Center the sterndrive and stop the engine.
2.
Remove the fill cap and dipstick from the fluid reservoir and observe the level.
52257
IMPORTANT: If fluid is not visible in the fluid reservoir, see your Mercury Diesel authorized repair facility.
Filling
1.
Remove the fill cap/dipstick and wipe it with a clean cloth.
2.
Install the fill cap/dipstick completely into the power steering fluid reservoir.
3.
Remove the fill cap/dipstick from the reservoir and observe the fluid level.
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Section 5 - Maintenance
•
If the fluid level is within range , no fluid should be added.
•
If the fluid level is within range "b", fluid may be added but should not exceed the maximum level in range "a".
•
If the oil level is within range "c", fluid must be added. There is sufficient fluid when the fluid level is within range "b".
NOTE: If high steering loads are expected for a prolonged period of operation (10–12 hours), the fluid level should be
in the middle of the min/max markings of the dipstick.
a - No fluid required
b - Oil may be added, but do not exceed range "a"
c - Oil must be added, but do not exceed above "a"
a
b
c
50641
4.
Add the specified fluid to bring the fluid level up to the proper level.
Tube Ref No.
28
5.
Description
Dexron III Automatic
Transmission Fluid
Where Used
Part No.
Power-assisted steering system
Obtain Locally
Install the fill cap/dipstick.
Changing
Power‑assisted steering fluid does not require changing unless it becomes contaminated. See your Mercury Diesel authorized
repair facility.
Engine Coolant
!
CAUTION
A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow
the engine to cool down before removing the coolant pressure cap.
Checking
IMPORTANT: Check the engine coolant before starting the engine.
1.
Stop the engine and allow the engine to cool.
2.
Remove the pressure cap from the coolant expansion tank.
3.
The coolant level must be above the minimum mark and below the maximum mark on the coolant expansion tank.
a
a - Pressure cap
b - Maximum mark
c - Minimum mark
b
c
52258
IMPORTANT: The coolant level is monitored by a sensor. If the coolant level is low, a fault will be recorded, indicated on a
SmartCraft gage, and a warning tone will be activated.
4.
If the coolant level is low:
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Section 5 - Maintenance
a.
Inspect the coolant recovery system for leaks.
b.
Inspect the O‑ring in the pressure cap for damage and replace if necessary.
c
c.
a - Pressure cap
b - Over pressure valve
c - O‑ring
b
a
50656
The pressure cap maintains pressure on the cooling system and may not be holding pressure properly. To have the
cap tested, contact your Mercury Diesel authorized repair facility.
d. Refer to Filling and add the specified coolant as necessary.
IMPORTANT: When installing the pressure cap, be sure to tighten it securely until it clicks to prevent coolant loss.
5.
If the coolant level is correct, install the pressure cap and tighten securely until it clicks.
Filling
1.
Allow the engine to cool.
2.
Remove the pressure cap from the coolant expansion tank.
3.
If the coolant is low in the coolant expansion tank, add the specified coolant as necessary to bring the level between the
minimum mark and the maximum mark.
a
a - Pressure cap
b - Maximum mark
c - Minimum mark
b
c
52258
Description
Marine Engine Coolant
Capacity
Part Number
9.0 Liter (9.5 US qt)
8M0070979
IMPORTANT: When installing the pressure cap, be sure to tighten it securely until the cap clicks to prevent coolant loss.
4.
Install the pressure cap. Tighten it securely until the cap clicks.
Changing
Change (replace) the engine coolant at the prescribed interval. Refer to Replacing the Engine Coolant in the Closed
Cooling System.
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Section 5 - Maintenance
Replacing the Engine Coolant in the Closed‑Cooling System
Draining the Closed‑Cooling System
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.
NOTE: For instructions on draining the seawater section, refer to Flushing and Draining the Seawater System in this section.
IMPORTANT: Observe the following points:
•
Ensure that the engine is as level as possible to promote complete draining of the cooling system.
•
The closed‑cooling section must be filled year‑round with the required coolant. If the engine will be exposed to freezing
temperatures, ensure that the closed‑cooling section is filled with a solution of ethylene glycol antifreeze and water properly
mixed to protect the engine to the lowest temperature to which it will be exposed.
•
Do not use propylene glycol antifreeze in the closed‑cooling section of the engine.
!
CAUTION
A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow
the engine to cool down before removing the coolant pressure cap.
1.
Allow the engine to cool.
2.
Remove the pressure cap from the expansion tank coolant reservoir.
3.
Loosen the closed cooling heat exchanger drain screw approximately two turns, and allow the contents to drain into an
appropriate container.
a - Closed‑cooling system drain screw
b - Seawater system drain screw
a
b
50672
4.
If required, clean the closed‑cooling system. See your Mercury Diesel authorized repair facility.
5.
Fill the system with the specified coolant. Refer to Filling the Closed‑Cooling System.
Filling the Closed‑Cooling System
IMPORTANT: Use only the specified coolant.
Description
Marine Engine Coolant
1.
Capacity
Part Number
9.0 Liter (9.5 US qt)
8M0070979
Verify that the closed‑cooling heat exchanger drain screw is tight.
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Section 5 - Maintenance
2.
Remove the pressure cap from the expansion tank coolant reservoir.
a
a - Pressure cap
b - Maximum mark
c - Minimum mark
b
c
52258
3.
Slowly add the coolant to the expansion tank. Allow the entrapped air to escape.
4.
When coolant cannot be added, supply the seawater pump with water.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
5.
Do not install the pressure cap. Start and operate the engine at idle for approximately two minutes.
6.
Add coolant if necessary to maintain the coolant at the specified level on the expansion tank.
7.
Allow the engine to warm up,
8.
Add coolant if necessary to maintain the coolant at the specified level on the expansion tank.
9.
Inspect the O‑ring in the pressure cap for damage and replace if necessary.
b
a
c
a - Pressure cap
b - Over pressure valve
c - O‑ring
50656
10. Install the pressure cap after the engine has reached normal operating temperature (with the thermostat fully open) and the
coolant level remains constant.
11. Observe the temperature gauge and check the engine for coolant leaks. If the temperature gauge indicates the presence of
excessive temperature or coolant is leaking, stop the engine immediately and inspect for the cause.
12. After the first operation, allow the engine to cool.
13. Remove the pressure cap and add the specified coolant to the level indicated on the expansion tank.
14. Install and securely tighten the pressure cap.
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Section 5 - Maintenance
Air Filter Cleaning
Removal
1.
Loosen the screw securing the air filter to the intake manifold and remove the air filter.
b
a
a - Air filter
b - Screw
c - Intake manifold
c
50680
!
CAUTION
Using compressed air can cause serious injury. Always wear eye protection when working with compressed air to prevent
injury from ruptured hoses or flying debris.
2.
Use compressed air to blow out the filter from the inside towards the outside. Do not exceed the air pressure specification.
b
a - Air filter
b - Compressed air nozzle
a
50675
Air Filter Cleaning
Maximum air pressure
2.0 bar (29 psi)
IMPORTANT: Do not use petroleum products for cleaning the air filter as the filter element may be damaged.
3.
For cleaning the air filter, purchase K&N® filter recharging kit 99‑5050. Follow the procedures contained in the recharging
kit.
Installation
1.
Install the air filter onto the intake manifold.
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Section 5 - Maintenance
2.
Tighten the air filter attaching screw securely.
a
b
a - Air filter
b - Screw
c - Intake manifold
c
50680
Water Separating Fuel 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 the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
NOTICE
Water entering the fuel injection system will cause corrosion and rusting of the injectors and other components, disabling the
fuel injection system. Check daily for water in the water‑separating fuel filter and have the engine inspected immediately if
there is evidence of water in the fuel system.
IMPORTANT: Use a suitable container to collect fuel. Clean up any spills immediately and dispose of fuel in a safe manner in
accordance with all local, federal, and international regulations.
The engine‑mounted water separating fine element fuel filter is equipped with a water‑in‑fuel sensor that should alert the
operator when water is present in the filter. This fuel filter needs to be replaced at specified intervals or whenever water is
detected in the fuel, whichever comes first.
The operator may be alerted that the water‑in‑fuel sensor has detected water in the fuel, if the boat is equipped with the proper
instrumentation:
•
Instrument notification (if equipped)
•
Indicator lamp (if equipped)
When the engine is equipped with a remote mounted primary filter, it should be drained or replaced at specified intervals, or
whenever water is detected in the engine mounted fuel filter.
Draining
The engine‑mounted water separating fuel filter can be drained of water and sediment by removing the water‑in‑fuel sending
unit located on the bottom of the filter.
NOTE: To ensure complete draining in warm weather, drain the filter before starting daily operations. In cold weather, where
there is a possibility that the condensed water will freeze, drain the filter shortly after the end of daily operations.
NOTE: Place a suitable container under the fuel filter to catch contaminated fuel or water. Dispose of fuel and old filters in a
safe manner in accordance with all local, federal, and international regulations.
1. Place a suitable container under the water separating fine element fuel filter.
2. Disconnect the water‑in‑fuel sensor harness connector.
3. Remove the water‑in‑fuel sensor from the bottom of the filter.
4. Unscrew the bleed screw.
5. Drain the filter until the fuel is free of debris and water.
6. Install the water‑in‑fuel sensor and tighten securely.
7. Connect the water‑in‑fuel harness connector.
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Section 5 - Maintenance
8.
Install the bleed screw and tighten securely.
9.
Push on the primer pump on top of the fuel filter until increased resistance is felt. Increased resistance will indicate the fuel
system has been filled with fuel.
a
abcd-
b
Primer pump
Bleed screw
Fine element fuel filter
Water‑in‑fuel sensor
c
d
52259
Replacing
!
WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
IMPORTANT: The fine element fuel filter cannot be cleaned and reused. It must be replaced.
1.
Disconnect both battery cables from the battery.
2.
Disconnect the water‑in‑fuel sensor harness connector.
3.
Place a suitable container under the water separating fine element fuel filter.
4.
Unscrew the fine element fuel filter and empty the fuel contents into the container.
5.
Remove the water‑in‑fuel sensor and O‑ring from the fuel filter.
6.
Install the water‑in‑fuel sensor with O‑ring into the new fuel filter. Tighten securely.
7.
Fill the new fuel filter with clean diesel fuel.
8.
Apply clean diesel fuel to the new fuel filter sealing O‑ring.
9.
Install the new fine element fuel filter onto the filter bracket and tighten by hand.
NOTE: After replacing the fine element fuel filter and filling it with fuel, it is not necessary to bleed the fuel system.
10. Connect the water‑in‑fuel sensor harness connector.
11. After changing the fine element fuel filter, push on the primer pump on the filter housing until increased resistance is felt.
The fuel system has then been filled.
12. Visually check the fuel system for leaks.
13. Connect the battery cables.
14. Start and operate the engine. Check the filter connection for fuel leaks. If leaks exist, recheck filter installation. If leaks
continue, stop the engine immediately and contact your Mercury Diesel authorized repair facility.
Filling
A plunger‑type of primer pump is located on the fuel filter bracket and is used to:
•
Fill the fuel filter when draining or changing the fine element fuel filter.
•
Fill the fuel system on the engine if the system was run dry.
•
Prime the fuel system if the engine has not been run for an extended period.
NOTE: Follow this procedure after installing a new filter if it has not been prefilled or if the fuel has been drained from the filter
when checking for water.
1. Loosen the bleed screw on the fuel filter bracket.
2. Move the primer pump up and down repeatedly until the filter is full and the stream of fuel flowing from the bleed screw
contains no air bubbles.
90-8M0087070
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DECEMBER 2013
Page 71
Section 5 - Maintenance
3.
Securely tighten the bleed screw.
a
abcd-
b
Primer pump
Bleed screw
Fine element fuel filter
Water‑in‑fuel sensor
c
d
52259
Purging the Fuel System
IMPORTANT: The fuel line must be purged before the engine is put into operation.
1.
Loosen the bleed screw on top of the fuel filter bracket.
2.
Use a suitable container to collect fuel while purging the system. Clean up any spills immediately and dispose of the fuel in
a safe manner according with all local, federal, and international regulations.
3.
Move the hand pump on top of the fuel filter bracket up and down repeatedly. The filter is full when an air‑free stream of
fuel flows from the bleed screw port.
a
a - Hand pump
b - Bleed screw and seal
b
50886
4.
Install the bleed screw with the seal and securely tighten.
Fuel System
Priming
Prime the engine if it has not been run for an extended period or if the engine will not start.
1.
Move the hand pump/primer plunger on the fine element fuel filter bracket up and down several times.
2.
Start the engine.
Filling the Fuel System
NOTE: Follow this procedure if the fuel system was run dry or if part of the fuel system was drained for a service function.
1. Move the hand pump/primer plunger on the fine element fuel filter bracket up and down several times to fill the fuel filter.
2. Check the filter for fuel leaks. Ensure that the bleed screw on the fuel filter bracket is closed.
Winterization of Fuel System
1.
Fill the fuel tank to prevent condensation from forming.
2.
Inspect the fuel system for leaks.
3.
Drain the water from the circulation filter.
Page 72
90-8M0087070
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DECEMBER 2013
Section 5 - Maintenance
4.
Replace the fine element fuel filter.
Seawater System
Seawater Pump Impeller Inspection
The seawater pump impeller must be inspected (and replaced, if necessary) at the interval specified by the maintenance
schedule. It is recommended this task be performed at a Mercury Diesel–authorized repair facility.
1.
Close the seacock.
2.
Remove the four screws on the front side of the seawater pump and remove the cover. Discard the O‑ring.
50717
Seawater pump cover screws
3.
Mark the direction of rotation of the impeller and remove the protective cap from the middle of the impeller.
a
b
c
d
e
f
abcdef-
Seawater pump
Impeller
Protective cap
O‑ring
Cover
Screw (4)
50720
4.
Use a suitable puller to remove the impeller from the impeller shaft.
5.
Inspect the impeller for damage. The impeller must be replaced if there are any signs of damage.
6.
7.
8.
9.
NOTE: Keep an extra impeller onboard the boat at all times.
Lubricate the impeller with silicone spray or glycerine.
Push the impeller onto the shaft and press the protective cap into the impeller.
Insert a new O‑ring into its groove.
Install the cover onto the housing and secure the cover with the four screws. Tighten the screws to the specified torque.
Description
Nm
lb‑in.
lb‑ft
Seawater pump cover screws
4.0
35.4
–
10. Open the seacock.
11. Start the engine and check the cooling system for leaks.
Sterndrive Water Inlets Check
1.
Obtain a piece of wire the appropriate size to insert into the water inlets holes.
2.
Insert the wire in and out of the sterndrive water inlets to ensure that they are open and to remove debris or marine growth.
Do not scrape the sterndrive paint.
90-8M0087070
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DECEMBER 2013
Page 73
Section 5 - Maintenance
3.
Remove the wire from the sterndrive and retain for periodic water inlet checks.
a - Dual water pickup water inlets
b - Side pickup water inlets
a
b
22495
Flushing and Draining the Seawater System
1.
Close the seacock.
2.
Open and clean the seawater filter.
3.
Fill the seawater filter with fresh water and operate the engine at idle.
IMPORTANT: Keep the seawater filter filled with fresh water while the engine is running.
4.
Operate the engine until the water draining from the engine runs clear to ensure that all sludge and salt residues are
flushed away.
5.
Switch off the engine.
6.
Replace the cover on the seawater filter.
7.
Attach a suitable hose to the seawater‑cooling system drain screw.
Heat exchanger drain screws
a - Closed‑cooling system drain screw
b - Seawater‑cooling system drain screw
a
b
50672
8.
Open the drain screw and allow the water to drain into a suitable container.
9.
When the draining is complete, remove the hose and close the drain screw.
10. Be certain to open the seacock prior to boat operation.
Page 74
90-8M0087070
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DECEMBER 2013
Section 5 - Maintenance
Checking the Seawater Pickups
Verify the water inlet holes for the seawater pickup are clean and unobstructed.
a
a
16776
Typical through-the-hull seawater pickup
a - Water inlet holes
Typical through-the-transom seawater pickup
Cleaning the Seawater Strainer, if Equipped
NOTICE
An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat,
causing damage or sinking the boat. Always close the water supply from the seawater pump, water inlet, or seacock when
performing service or maintenance on the cooling system.
1.
With the engine off, close the seacock, if equipped, or remove and plug the seawater inlet hose.
2.
Remove the screws, washers, and cover.
3.
Remove the strainer, drain plug, and sealing washer.
4.
Clean all the debris from the strainer housing. Flush both the strainer and housing with clean water.
5.
Check the cover gasket and replace when damaged or if it leaks.
6.
Reinstall the strainer, drain plug, and sealing washer.
!
CAUTION
Seawater leaking from the seawater strainer could cause excess water in the bilge, damaging the engine or causing the boat
to sink. Do not overtighten the cover screws, or the cover may warp and introduce seawater into the bilge.
90-8M0087070
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DECEMBER 2013
Page 75
Section 5 - Maintenance
7.
Install the seal and cover using the screws and washers. Do not overtighten the cover screws.
a
abcdef-
b
f
Screws and washers
Cover with glass
Strainer
Housing
Drain plug and sealing washer
Seal
c
d
e
12863
8.
Open the seacock, if equipped, or remove the plug and reconnect the seawater inlet hose.
9.
Upon first starting the engine, check for leaks or air in the system that would indicate an external leak.
Corrosion Protection
General Information
When two or more dissimilar metals are submerged in a conductive solution of saltwater, polluted water, or water with a high
mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow
causes the metal that is most chemically active, or anodic, to erode. This erosion is known as galvanic corrosion and, if it is not
controlled, it will eventually cause the need for replacement of power package components exposed to water.
To help control the effects of galvanic corrosion, Mercury Diesel power packages come with several sacrificial anodes and
other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection refer to the
Marine Corrosion Protection Guide.
IMPORTANT: Replace sacrificial anodes if they are eroded 50% or more. Mercury Diesel strongly recommends avoiding the
use of anodes from other manufacturers. Refer to your Mercury Diesel–authorized repair facility for additional information.
Engine Corrosion Protection Components
The engine is equipped with a sacrificial anode located on the intercooler end cover to assist in protecting the engine and the
seawater cooling system from corrosion.
Removal
1.
Allow the engine to cool.
NOTICE
Failure to close the seawater inlet or seacock when removing or replacing the anode plugs can lead to water damage. Close
the seacock or remove and plug the seawater inlet hose to prevent water from entering the anode plug holes.
2.
With the engine off, close the seacock, if equipped, or remove and plug the seawater inlet hose.
3.
Drain the seawater system. Refer to Flushing and Draining the Seawater System.
Page 76
90-8M0087070
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DECEMBER 2013
Section 5 - Maintenance
4.
Remove the anode assembly.
d
abcd-
a
Intercooler
Anode plug
Anode length 20 mm (0.79 in.)
Gear lubrication monitor (sterndrive
only)
c
b
54639
Cleaning and Inspection
Inspection and replacement interval will vary according to the condition of the seawater and the mode of engine operation.
NOTE: Use sandpaper, fiber brush, or cleaning pad, remove the deposits from the surface of the anode before trying to
determine the amount of erosion. Do not use a mild steel brush which might leave deposits that could accelerate corrosion.
1. Remove the deposits.
2. Inspect and measure the anode. Compare the measurements to the specifications for a new sacrificial anode and replace
the anode assembly when deteriorated 50%.
NOTE: Sacrificial anodes are available only as an assembly. Replace both the plug and anode as a unit.
abcde-
Anode plug
Sacrificial anode
Length
Diameter
Sealing washer
Sacrificial anode measurements (new)
3.
Length
20.0 mm (0.79 in.)
Diameter
9.9 mm (0.390 in.)
Discard the sealing washer.
Installation
1.
Install a new sealing washer on the anode assembly.
b
a - Anode assembly
b - Sealing washer
a
50843
90-8M0087070
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DECEMBER 2013
Page 77
Section 5 - Maintenance
2.
Install the anode assembly with the washer into the intercooler end cover and tighten securely.
a - Anode
a
50781
3.
Unplug and connect the seawater inlet hose, or open the seacock if equipped.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
4.
Ensure that the seawater pickup pump is supplied cooling water.
5.
Start the engine and check for leaks.
Maintaining Ground Circuit Continuity
The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the
engine, transom assembly, and sterndrive components. Good continuity is essential for the anode and the MerCathode system
to function effectively.
Inspect all ground circuit components for loose connections and broken or fraying wires.
Models equipped with a separate ground wire must have the wire connected between the engine flywheel housing and the
transom plate.
a - Engine flywheel housing bolt
b - Ground wire
c - Inner transom plate grounding screw
b
a
c
Page 78
7007
90-8M0087070
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DECEMBER 2013
Section 5 - Maintenance
Models equipped with a transom harness must connect its ground wire to the grounding screw on the gimbal housing.
b
a
a - Gimbal housing grounding screw
b - Transom harness ground wire to
engine harness
c - Transom plate grounding stud and nut
d - Grounding wire gimbal housing to
transom plate
d
c
37462
a
b
a - Steering lever
b - Torx® screw
c - Continuity wire
c
50215
a
c
b
Bravo model shown, Alpha similar
a - Trim‑cylinder‑to‑gimbal‑ring
ground wire (2)
b - Gimbal‑housing‑to‑gimbal‑ring
ground wire
c - Gimbal‑ring‑to‑bell‑housing
ground wire
d - Screw
d
50216
a
c
b
b
90-8M0087070
eng
DECEMBER 2013
a - MerCathode
b - Continuity washers
c - Hydraulic manifold
50217
Page 79
Section 5 - Maintenance
a
c
b
37513
37632
Ground washer shown inside anode cavity
of Bravo Three gear housing, other models
similar
Bravo sterndrive shown, Alpha sterndrive similar
a - Sterndrive
b - Ground washer
c - Ground plate (later model)
a
b
c
50218
a - U‑joint bellows ground clip
b - Exhaust bellows ground clip
c - Exhaust tube ground clip
MerCathode
If the boat is equipped with a MerCathode system, the system should be tested to ensure that it is providing adequate output to
protect the underwater metal parts on the boat. The test should be made where the boat is moored, using a Reference
Electrode and Test Meter.
91‑76675T 1
Reference Electrode
Senses and electrical current in the water when testing the MerCathode system. Use to check hull
potential.
9188
Refer to the appropriate Mercury MerCruiser sterndrive service manual for testing procedures.
Antifouling Paint
IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint is not covered by the limited
warranty.
In some areas it may be advisable to paint the bottom of the boat to help prevent marine growth. Contact a Mercury Diesel
authorized repair facility for recommendations for your boat.
Page 80
90-8M0087070
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DECEMBER 2013
Section 5 - Maintenance
Lubrication
Steering System
!
WARNING
Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely
retract the end of the steering cable before applying lubricant.
NOTE: If the steering cable does not have a grease fitting, the inner wire of the cable cannot be greased.
1. If the steering cable has grease fittings, turn the steering wheel until the steering cable is fully retracted into the cable
housing. Apply approximately three pumps of grease from a typical hand‑operated grease gun.
a - Steering cable grease fitting
a
6221
Tube Ref No.
2-4-C with PTFE
95
2.
Description
Where Used
Part No.
Steering cable grease fitting
92-802859A 1
Turn the steering wheel until the steering cable is fully extended. Lightly lubricate the exposed part of the cable.
a - Extended steering cable
a
6222
Tube Ref No.
95
90-8M0087070
eng
Description
2-4-C with PTFE
DECEMBER 2013
Where Used
Part No.
Steering cable
92-802859A 1
Page 81
Section 5 - Maintenance
3.
Lubricate the steering pin.
a - Steering pin
a
mc71904-1
Tube Ref. No.
Description
Where Used
Part No.
Steering pin
92‑883725K01
Where Used
Part No.
Tie bar pivot points
92‑883725K01
Synthetic Blend MerCruiser Engine Oil
SAE25W‑40
4.
On dual engine boats: Lubricate the tie bar pivot points.
Tube Ref. No.
Description
Synthetic Blend MerCruiser Engine Oil
SAE25W‑40
5.
Upon first starting the engine, turn the steering wheel several times to starboard and then port to ensure that the steering
system operates properly before getting underway.
Throttle Cable
Lubricate the pin and throttle cable surfaces with oil.
a
b
Throttle cable lubrication
a - Pin
b - Throttle cable
52809
Tube Ref No.
80
Page 82
Description
SAE Engine Oil 30W
Where Used
Part No.
Ball pin and throttle cable end contact surfaces
Obtain Locally
90-8M0087070
eng
DECEMBER 2013
Section 5 - Maintenance
Shift Cable
1.
Lubricate the pivot points and guide contact surfaces.
a
a
a
20261
b
Typical sterndrive model shift cable
a - Pivot points
b - Guide contact surface
Tube Ref No.
80
Description
SAE Engine Oil 30W
Where Used
Part No.
Shift cable pivot points and guide contact surfaces
Obtain Locally
Transom Assembly
Lubricate the gimbal bearing by applying approximately 8–10 pumps of grease from a typical hand‑operated grease gun.
a - Gimbal bearing grease insert
a
19979
Tube Ref No.
Description
Extreme Grease
Where Used
Part No.
Gimbel bearing grease insert
8M0071842
Propeller Shaft
NOTE: Refer to Propeller Removal.
Lubricate the sterndrive propeller shaft by applying a coating of one of the following lubricants to the propeller shaft.
90-8M0087070
eng
DECEMBER 2013
Page 83
Section 5 - Maintenance
•
Apply a generous coating of one of the following lubricants to the propeller shaft.
a
a
20335
a - Propeller shaft
Tube Ref No.
95
Description
Where Used
Part No.
Extreme Grease
Propeller shaft
8M0071842
2-4-C with PTFE
Propeller shaft
92-802859A 1
Engine Coupler
IMPORTANT: These engines are equipped with a sealed engine coupler. The sealed coupler and the shaft splines can be
lubricated without removing the sterndrive unit.
1.
Lubricate the engine coupler splines through the grease fitting on the coupler by applying approximately 8‑10 pumps of
Extreme Grease from a typical hand‑operated grease gun.
NOTE: If the boat is operated at idle for prolonged periods of time, the coupler should be lubricated on Bravo models every
50 hours.
Coupler shown separated for clarity
a - Grease fitting
a
Tube Ref No.
20861
Description
Extreme Grease
Where Used
Part No.
Engine coupler and shaft splines
8M0071842
Driveshaft Extension Models
1.
Lubricate the transom end grease fitting and engine end grease fitting by applying approximately 10–12 pumps of grease
from a typical hand‑operated grease gun.
Page 84
90-8M0087070
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DECEMBER 2013
Section 5 - Maintenance
2.
Lubricate the driveshaft grease fittings by applying approximately 3–4 pumps of grease from a typical hand‑operated
grease gun.
c
b
a
a
17014
a - Driveshaft grease fittings
b - Transom end grease fitting
c - Engine end grease fitting
Tube Ref No.
Description
Extreme Grease
Where Used
Part No.
Transom end grease fitting, engine end grease fitting, driveshaft grease
fittings
8M0071842
Maintaining Torques
Gimbal Ring U‑bolt Nuts
NOTE: The gimbal ring is a component of the transom assembly.
Tighten the gimbal ring U‑bolts to the specified torque.
a - Transom assembly
b - Gimbal ring U‑bolt nuts
b
a
19624
Description
Nm
lb‑in.
lb‑ft
Gimbal ring U‑bolt nuts for 3/8 in. U‑bolt
72
–
53
Gimbal ring U‑bolt nuts for 7/16 in. U‑bolt
95
–
70
90-8M0087070
eng
DECEMBER 2013
Page 85
Section 5 - Maintenance
Engine Mounts
Loosen the rear engine mount bolts 1 to 1‑1/2 turns. Tighten the rear engine mount bolts to the specified torque.
a - Rear engine mount
b - Transom plate mount
c - Rear engine mount bolt
a
c
b
19622
Description
Nm
lb‑in.
lb‑ft
Rear engine mount bolts
51
–
38
Propellers
Bravo Sterndrive 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 propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the
engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
Bravo One Models
1.
Straighten the bent tabs of the tab washer on the propeller shaft.
b
c
a
d
e
abcde-
Propeller
Tab washer
Drive sleeve adapter
Tab bent down
Propeller nut
4750
Page 86
90-8M0087070
eng
DECEMBER 2013
Section 5 - Maintenance
2.
Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate.
a - Wood block
b - Propeller
c - Propeller nut under socket
3.
Turn the propeller shaft nut counterclockwise and remove the nut.
4.
Slide the propeller and the attaching hardware from the propeller shaft.
d
e
a
b
f
g
Bravo One models
a - Propeller shaft splines
b - Forward thrust hub
c - Flo‑Torque II drive hub
d - Propeller
e - Drive sleeve adapter
f - Tab washer
g - Propeller nut
c
5301
Bravo Two Models
1.
Straighten the bent tabs of the tab washer on the propeller shaft.
b
c
a
d
e
abcde-
Propeller
Tab washer
Drive sleeve adapter
Tab bent down
Propeller nut
4750
2.
Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate.
a - Wood block
b - Propeller
c - Propeller nut under socket
3.
Turn the propeller shaft nut counterclockwise to remove the nut.
90-8M0087070
eng
DECEMBER 2013
Page 87
Section 5 - Maintenance
4.
Slide the propeller and attaching hardware from the propeller shaft.
c
d
f
a
b
e
Bravo Two
a - Propeller shaft splines
b - Forward thrust hub
c - Propeller
d - Spline washer
e - Tab washer
f - Propeller nut
8566
Bravo Three Models
1.
Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate.
2.
Remove the bolt and washers securing the propeller shaft anode.
3.
Remove the propeller shaft anode.
a
b
c
abcdef-
Propeller
Propeller shaft nut
Propeller shaft anode
Propeller shaft anode screw
Flat washer
Star washer
d
e
f
19058
4.
Turn the aft propeller shaft nut counterclockwise to remove the nut.
5.
Slide the propeller and thrust hub off of the propeller shaft.
6.
Using the propeller nut tool, turn the front propeller shaft nut counterclockwise and remove the nut.
91‑805457T 1
Propeller Nut Tool
Aids in the removal and installation of the front propeller nut.
10677
7.
Slide the propeller and the thrust hub off the propeller shaft.
e
f
b
i
g h
c
d
a
j
5304
Page 88
Bravo Three
a - Aft propeller nut
b - Aft propeller
c - Aft propeller thrust hub
d - Front propeller nut
e - Front propeller
f - Front propeller thrust hub
g - Propeller shaft anode screw
h - Flat washer
i - Star washer
j - Propeller shaft anode
90-8M0087070
eng
DECEMBER 2013
Section 5 - Maintenance
Bravo Sterndrive Propeller Installation
!
WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the
engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
a - Wood block
b - Propeller
c - Propeller nut under socket
Bravo One Models
IMPORTANT: Use the correct rotation propeller. The propeller rotation must match the direction of rotation of the propeller
shaft.
1.
Liberally coat the propeller shaft spline with one of the following lubricants.
Tube Ref No.
95
Description
Where Used
Part No.
2-4-C with PTFE
Propeller shaft splines
92-802859A 1
Extreme Grease
Propeller shaft splines
8M0071842
2.
Install the propeller with the attaching hardware as shown.
3.
Tighten the propeller nut to the specified torque.
d
e
a
b
f
g
Typical Bravo One models
a - Propeller shaft splines
b - Forward thrust hub
c - Flo‑Torque II drive hub
d - Propeller
e - Drive sleeve adapter
f - Tab washer
g - Propeller nut
c
5301
NOTE: The propeller torque stated is a minimum torque value.
Description
Bravo One propeller nut
4.
Nm
lb‑in.
lb‑ft
75
–
55
Then align tabs with grooves
Models equipped with the tab washer: Continue to tighten the propeller nut until the three tabs on the tab washer align
with the grooves on the spline washer.
90-8M0087070
eng
DECEMBER 2013
Page 89
Section 5 - Maintenance
5.
Bend the three tabs down into the grooves.
b
c
a
d
e
abcde-
Propeller
Tab washer
Drive sleeve adapter
Tab bent down
Propeller nut
4750
Bravo Three
1.
Liberally coat the propeller shaft spline with one of the following lubricants.
Tube Ref No.
95
Description
Where Used
Part No.
2-4-C with PTFE
Propeller shaft splines
92-802859A 1
Extreme Grease
Propeller shaft splines
8M0071842
2.
Slide the forward thrust hub onto the propeller shaft with the tapered side toward the propeller hub.
3.
Align splines and place front propeller on propeller shaft.
4.
Install the front propeller locknut and tighten to the specified torque using the propeller nut tool.
91‑805457T 1
Propeller Nut Tool
Aids in the removal and installation of the front propeller nut.
10677
Description
Nm
lb‑in.
lb‑ft
Bravo Three front propeller nut
136
–
100
5.
Slide the aft thrust hub onto the propeller shaft with the tapered side toward the propeller hub.
6.
Align the splines and install the aft propeller.
7.
Install the propeller nut and torque.
NOTE: The propeller torque stated is a minimum torque value.
Page 90
Description
Nm
lb‑in.
lb‑ft
Bravo Three rear propeller nut
81
–
60
90-8M0087070
eng
DECEMBER 2013
Section 5 - Maintenance
8.
Install the propeller shaft anode and secure with the screw. Tighten the screw to the specified torque.
e
f
b
i
g h
c
d
a
j
5304
Bravo Three
a - Rear propeller nut
b - Rear propeller
c - Rear propeller thrust hub
d - Front propeller nut
e - Front propeller
f - Front propeller thrust hub
g - Propeller shaft anode screw
h - Flat washer
i - Star washer
j - Propeller shaft anode
Description
Nm
lb‑in.
lb‑ft
Propeller shaft anode screw
19
168
–
Drive Belt
All drive belts must be periodically inspected for tension and condition. Turn the engine off and remove the ignition key before
inspecting for excessive wear, cracks, fraying, and glazed surfaces.
!
WARNING
Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition
key before inspecting the belts.
In the event that the drive belt requires replacement, it is recommended that the drive belt replacement be performed by a
Mercury Diesel–authorized repair facility.
Drive Belt Failure Identification
Appearance
Description
Cause
Solution
Abrasion
Each side of the belt appears
shiny or glazed. Severe
condition: Fabric is exposed.
The belt is in contact with an
object. This can be caused by
improper belt tension or tensioner
failure.
Replace the belt and
inspect its route for
contact with another
object. Verify that the belt
tensioner is functioning.
Pilling
Belt material is sheared off from
the ribs and builds up in the belt
grooves.
There are a number of causes
including lack of tension,
misalignment, worn pulleys, or a
combination of these factors.
When pilling leads to belt
noise or excess vibration,
the belt should be
replaced.
40791
40794
90-8M0087070
eng
DECEMBER 2013
Page 91
Section 5 - Maintenance
Appearance
Description
Cause
Improper installation
The belt ribs begin separating
from the joined strands. If left
unattended, the cover will often
separate, causing the belt to
unravel.
Solution
Improper belt installation is a
common cause of premature
failure. One of the outermost belt
ribs is placed outside the pulley
groove, causing a belt rib to run
without a supporting or aligning
pulley groove.
40795
The belt should be
replaced immediately.
Ensure all ribs of the
replacement belt fit into
the pulley grooves.
Operate the engine.
Then, with the engine off
and the battery
disconnected, inspect the
belt for proper installation.
Misalignment
Sidewalls of the belt may appear
glazed or the edge‑cord may
Pulley misalignment. Misalignment
become frayed and the ribs are
forces the belt to kink or twist while
removed. A noticeable noise
running, causing premature wear.
may result. In severe cases, the
belt can jump off the pulley.
Replace the belt and
verify the alignment of the
pulley.
Chunk‑out
Pieces or chunks of rubber
material have broken off the
belt. When chunk‑out has
occurred, a belt can fail at any
moment.
Chunk‑out can happen when
several cracks in one area move
parallel to the cord line. Heat, age,
and stress are the primary
contributors.
Replace the belt
immediately.
Uneven rib wear
The belt shows damage to the
side with the possibility of
breaks in the tensile cord or
jagged edged ribs.
A foreign object in the pulley can
cause uneven wear and cut into
the belt.
Replace the belt and
inspect all pulleys for
foreign objects or
damage.
Cracking
Small visible cracks along the
length of a rib or ribs.
Continuous exposure to high
temperatures, the stress of
bending around the pulley leads to
cracking. Cracks begin on the ribs
and grow into the cord line. If three
or more cracks appear in a
three‑inch section of a belt, 80% of
the life is gone.
Replace the belt
immediately.
40796
40797
40799
40800
Battery
Refer to the specific instructions and warnings accompanying your battery. If this information is not available, observe the
following precautions when handling a battery.
!
WARNING
Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious
injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away
from sparks or flames.
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Section 5 - Maintenance
!
WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause
severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.
Battery Precautions for Multiple Engines
Alternators
Alternators are designed to charge a single battery that supplies electrical power to the individual engine on which the
alternator is mounted. Connect only one battery to one alternator. Do not connect two batteries to the same alternator unless a
battery isolator is used.
Engine Control Unit (ECU)
The engine control unit requires a stable voltage source. During multiple–engine operation, an onboard electrical device may
cause a sudden drain of voltage at the engine's battery. The voltage may go below the ECU's minimum required voltage. Also,
the alternator on the other engine may now start charging. This could cause a voltage spike in the engine's electrical system.
In either case, the ECU could shut off. When the voltage returns to the range that the ECU requires, the ECU will reset itself.
The engine will now run normally. This ECU shutdown usually happens so fast that the engine just appears to have an ignition
miss.
Batteries
Boats with multiple–engine electronic–control power packages require that each engine be connected to its own battery,
ensuring that the engine control unit has a stable voltage source.
Battery Switches
Battery switches should always be positioned so that each engine is operating off of its own battery. Do not operate engines
with switches in the both or all position. In an emergency, another engine's battery can be used to start an engine with a dead
battery.
Battery Isolators
Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should not be used to
charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose.
Generators
The generator's battery should be considered another engine's battery.
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Section 5 - Maintenance
Notes:
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Section 6 - Storage
Section 6 - Storage
Table of Contents
Cold Weather (Freezing Temperature), Seasonal Storage,
and Extended Storage.......................................................... 96
Preparing Your Power Package for Seasonal or
Extended Storage.......................................................... 96
Seasonal Storage Instructions....................................... 96
Extended Storage Instructions....................................... 97
Battery Storage.............................................................. 98
Recommissioning................................................................. 98
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Section 6 - Storage
Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage
IMPORTANT: Mercury Diesel strongly recommends that this service be performed by a Mercury Diesel–authorized repair
facility. Damage caused by freezing is not covered by the Mercury Diesel Limited Warranty.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open
the seacock or unplug and reconnect the water inlet hose before starting the engine.
You should consider a boat is in storage whenever it is not in operation. The amount of time that the power package is not
operated may be for a brief period, such as during a day, overnight, for a season, or for an extended period of time. Certain
precautions and procedures must be observed to protect the power package from freeze damage, corrosion damage, or both
types of damage during storage.
Freeze damage can happen when water trapped in the seawater cooling system freezes. For example, after operating the boat,
exposure to freezing temperatures for even a brief period of time could result in freeze damage.
Corrosion damage is the result of saltwater, polluted water, or water with a high mineral content trapped in the seawater cooling
system. Saltwater should not stay in an engine's cooling system for even a brief storage time; drain and flush the seawater
cooling system after each outing.
Cold weather operation refers to operating the boat whenever the possibility of freezing temperatures exists. Likewise, cold
weather (freezing temperature) storage refers to whenever the boat is not being operated and the possibility of freezing
temperatures exists. The seawater section of the cooling system must be completely drained immediately after operation.
Seasonal storage refers to when the boat is not being operated for one month or more. The length of time varies depending on
the geographic location of the boat in storage. Seasonal storage precautions and procedures include all of the steps for cold
weather (freezing temperature) storage and some additional steps that must be taken when storage will last longer than the
short time of cold weather (freezing temperature) storage.
Extended storage means storage for a period of time that may last for several seasons or longer. Extended storage precautions
and procedures include all of the steps for cold weather (freezing temperature) storage and seasonal storage plus some
additional steps.
Refer to the specific procedures in this section related to the conditions and the length of storage for your application.
Preparing Your Power Package for Seasonal or Extended Storage
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
IMPORTANT: If the boat has already been removed from the water, supply water to the water inlet holes before starting the
engine. Follow all warnings and flushing attachment procedures stated in Flushing the Seawater System.
1.
Supply cooling water to the water inlet holes or seawater pump inlet.
2.
Start the engine and operate until it reaches normal operating temperature.
3.
Stop the engine.
4.
Change the engine oil and filter.
5.
Start the engine and run for about 15 minutes. Check for oil leaks.
6.
Flush the seawater cooling system. Refer to Flushing the Seawater System.
7.
Change the sterndrive gear oil.
Seasonal Storage Instructions
1.
Read all precautions and perform all procedures found in Preparing Your Power Package for Seasonal or Extended
Storage.
2.
Read all precautions and perform all procedures found in Flushing and Draining the Seawater System and drain the
seawater section of the cooling system.
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Section 6 - Storage
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
IMPORTANT: Mercury Diesel recommends that propylene glycol antifreeze be used in the seawater section of the cooling
system for cold weather (freezing temperature), seasonal storage, or extended storage. Make sure that the propylene
glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene
glycol manufacturer's recommendations.
3.
Fill a container with approximately 5.6 Liter (6.0 US qt) of propylene glycol antifreeze and tap water mixed to
manufacturer's recommendation to provide –73.3 °C (–100 °F) protection to the engine.
4.
Disconnect the seawater inlet hose from the seawater pump. Using an adapter, if required, temporarily connect an
appropriate length piece of hose to the seawater pump and place the other end of the hose into the container of propylene
glycol antifreeze and tap water.
a
a - Seawater pump
b - Container of propylene glycol
antifreeze and tap water
b
50893
5.
6.
7.
8.
NOTE: Discharge of propylene glycol antifreeze into the environment may be restricted by law. Dispose of propylene glycol
antifreeze in accordance with federal, state, and local laws and guidelines.
Start the engine and operate at idle speed until the antifreeze mixture has been pumped into the engine seawater cooling
system.
Stop the engine.
Remove the temporary hose from the seawater pump.
Clean the outside of the engine and repaint any areas required with primer and spray paint. After the paint has dried, coat
the engine with the specified corrosion inhibiting oil or equivalent.
Description
9.
Where Used
Part Number
Corrosion Guard
Outside of engine, transom assembly, and
sterndrive
92‑802878‑55
Light gray primer paint
Outside of engine, transom assembly, and
sterndrive
92‑802878‑52
Phantom black paint
Transom assembly and sterndrive
92‑802878‑1
Diesel white paint
Outside of engine
92‑8M0071082
Your Mercury Diesel–authorized repair facility should now perform all checks, inspections, lubrications, and fluid changes
outlined in Maintenance Schedules.
NOTICE
The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when
returned to service and allowing water to enter the boat. Store the sterndrive in the full down position.
10. Place the sterndrive in the full down (in) position.
11. Follow the battery manufacturer's instructions for storage and store the battery.
Extended Storage Instructions
IMPORTANT: Mercury Diesel strongly recommends that this service be performed by an Mercury Diesel–authorized repair
facility.
1.
Read all precautions and perform all procedures found in Preparing Your Power Package for Seasonal or Extended
Storage.
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Page 97
Section 6 - Storage
2.
Read all precautions and perform all procedures found in Flushing and Draining the Seawater System.
3.
Read all precautions and perform all procedures found in Seasonal Storage Instructions.
4.
Remove the seawater pump impeller and store away from direct sunlight. See a Mercury Diesel–authorized repair facility
for additional information and service.
IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight.
5.
Place a caution tag at the instrument panel and in the engine compartment stating that the seawater pump is out and not to
operate the engine.
Battery Storage
Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully
charged and in good operating condition. It should be clean and free of leaks. Follow the battery manufacturer's instructions for
storage.
Recommissioning
NOTE: Discharge of propylene glycol antifreeze into the environment may be restricted by law. Contain and dispose of
propylene glycol antifreeze in accordance with federal, state, and local laws and guidelines.
1. On engines that were prepared for extended storage, refer to a Mercury Diesel authorized repair facility and have the
seawater pump impeller installed, if it was removed for storage.
2. On engines that were prepared for cold weather (freezing temperature), seasonal, or extended storage, drain the
propylene glycol antifreeze into a suitable container. Refer to Flushing and Draining the Seawater System. Dispose of
the propylene glycol antifreeze in accordance with federal, state, and local laws and guidelines.
3. Ensure that all cooling system hoses are in good condition, connected properly, and clamped tightly. Verify that all drain
valves and drain plugs are installed and tight.
4. Inspect all drive belts.
5. Perform all lubrication and maintenance specified for completion according to Annually in Maintenance Schedules,
except items that were performed at time of engine storage.
6. Fill the fuel tanks with fresh diesel fuel. Do not use old fuel. Check the general condition of the fuel lines and inspect the
connections for leaks.
7. Replace the water‑separating fuel filter or filters (some engines may have more than one).
!
CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage
the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.
8.
Install a fully charged battery. Clean the battery cable clamps and terminals. Reconnect the cables (see the CAUTION
listed above). Secure each cable clamp when connecting. Coat terminals with a battery terminal anti‑corrosion spray to
help retard corrosion.
9.
Perform all checks in the Starting Procedure column found in the Operation Chart. See the On the Water section.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
10. Supply cooling water to the water inlet openings.
11. Start the engine and closely observe instrumentation. Ensure that all systems are functioning correctly.
12. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks.
13. Check the steering system, shift, and throttle control for proper operation.
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Section 7 - Troubleshooting
Section 7 - Troubleshooting
Table of Contents
Diagnosing Electronically Controlled Fuel System Problems
............................................................................................ 100
Troubleshooting Charts...................................................... 100
Starter Motor Will Not Crank Engine, or Cranks Slow. 100
Engine Will Not Start, or Is Hard to Start..................... 100
Engine Runs Rough, Misses, or Backfires.................. 100
Poor Performance........................................................ 101
No Fuel or Faulty Fuel Supply..................................... 101
Engine Will Not Start, Starter Does Not Turn.............. 101
Excessive Engine Temperature................................... 101
Insufficient Engine Temperature.................................. 102
Low Engine Oil Pressure............................................. 102
Battery Will Not Charge............................................... 102
Remote Control Operates Hard, Binds, Has Excessive
Free‑play, or Makes Unusual Sounds......................... 102
Steering Wheel Turns Hard or Jerky........................... 103
Power Trim Does Not Operate (Electric Motor Operates
but Sterndrive Unit Does Not Move)............................ 103
Power Trim Does Not Operate (Electric Motor Does Not
Operate)....................................................................... 103
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Section 7 - Troubleshooting
Diagnosing Electronically Controlled Fuel System Problems
Your Mercury Diesel authorized repair facility has the proper service tools for diagnosing problems on electronically controlled
fuel systems. The engine control module on these engines has the ability to detect some problems with the system when they
occur, and store a trouble code in the control module's memory. This code can then be read later by a service technician using
a special diagnostic tool.
Troubleshooting Charts
Starter Motor Will Not Crank Engine, or Cranks Slow
Possible Cause
Remedy
Battery switch turned off.
Turn switch on.
Remote 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
wiring.
Check all electrical connections and wires (especially battery
cables). Clean and tighten faulty connection.
Bad battery.
Test and replace if bad.
Engine Will Not Start, or Is Hard to Start
Possible Cause
Remedy
Lanyard stop switch activated.
Check lanyard stop switch.
Improper starting procedure.
Read starting procedure.
Empty fuel tank or fuel shut off valve closed.
Fill tank or open valve.
Faulty mechanical fuel delivery pump.
Have pump replaced by a Mercury Diesel–authorized repair facility if
fuel is present.
Throttle not operating properly.
Check the throttle for freedom of movement.
Faulty electrical stop‑circuit.
Have a Mercury Diesel–authorized repair facility service the electrical
stop circuit.
Clogged fuel filters.
Replace the filters.
Stale or contaminated fuel.
Drain tank. Fill with fresh fuel.
Fuel line or tank vent line kinked or clogged.
Replace kinked lines or blow out the lines with compressed air to
remove obstruction.
Air in fuel injection system.
Purge fuel injection system.
Faulty wire connections.
Check wire connections.
Glow plugs or glow plug system inoperative, if
equipped.
Have a Mercury Diesel–authorized repair facility service the glow plug
system.
Electronic fuel system fault.
Have the electronic fuel system checked by a Mercury Diesel–
authorized repair facility.
Engine Runs Rough, Misses, or Backfires
Remedy
Possible Cause
Throttle not operating properly.
Check the throttle for binding or an obstruction.
Idle speed too low.
Check idle speed and adjust, if necessary.
Clogged fuel or air filters.
Replace the filters.
Stale or contaminated fuel.
Drain tank and 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 system.
Purge fuel injection system.
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Section 7 - Troubleshooting
Possible Cause
Electronic fuel system faulty.
Remedy
Have electronic system checked by a Mercury Diesel–authorized repair
facility.
Poor Performance
Possible Cause
Remedy
Throttle not fully open.
Inspect throttle cable and linkages for proper operation.
Damaged or improper propeller.
Replace propeller. See a Mercury Diesel–authorized repair facility.
Excessive bilge water.
Drain and check for cause of entry.
Boat overloaded or improperly distributed.
Reduce load or redistribute more evenly.
Boat bottom fouled or damaged.
Clean or repair as necessary.
Electronic fuel system fault.
Have electronic fuel system checked by a Mercury Diesel–authorized
repair facility.
Faulty turbocharger outlet air temperature sensor. Replace.
No Fuel or Faulty Fuel Supply
Possible Cause
Remedy
The fuel cock is closed.
Open the fuel cock.
There is no fuel in the tank.
Fill the tank. Refer to Purging the Fuel System.
The fuel tank is dirty.
Clean the fuel tank.
The fuel lines are clogged.
Check the lines and clean them if necessary.
The water level in the circulation filter (if equipped) is too high.
Drain the water from the circulation filter.
The circulation filter (if equipped) is clogged.
Clean the circulation filter or replace it if necessary.
The water level is too high in the fuel filter.
Drain the water from the fuel filter.
The fuel filter is clogged.
Replace the fuel filter.
Engine Will Not Start, Starter Does Not Turn
Possible Cause
Remedy
The throttle lever is not in the neutral position.
Move the throttle lever into neutral.
The neutral switch in the gearbox does not output a signal.
Check the operation of the neutral switch.
The lanyard stop switch is activated.
Reset the lanyard stop switch.
The ignition is switched off.
Switch on the ignition.
The battery is discharged or defective.
Check the battery and charge it. Replace the battery if
necessary.
The starter connections are loose or corroded.
Check the connections and clean or replace if necessary.
The connections to the ignition or starter switch are loose or
corroded.
Check the connections and clean or replace if necessary.
There is air inside the fuel system.
Refer to Purging the Fuel System. Contact an authorized
Mercury Diesel repair facility for assistance.
Excessive Engine Temperature
Remedy
Possible Cause
Water inlet or seacock closed.
Open.
Drive belt loose or in poor condition.
Replace or adjust belt.
Seawater pickups or sea strainer obstructed.
Remove obstruction.
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Section 7 - Troubleshooting
Possible Cause
Remedy
Faulty thermostat.
Replace. See a Mercury Diesel–authorized repair facility.
Coolant level low in closed–cooling section.
Check for cause of low coolant level and repair. Fill system with
proper coolant solution.
Heat exchanger cores plugged with foreign material.
Clean heat exchanger. See a Mercury Diesel–authorized repair
facility.
Loss of pressure in closed–cooling section.
Check for leaks. Clean, inspect, and test pressure cap. See a
Mercury Diesel–authorized repair facility.
Faulty seawater pickup pump.
Repair. See a Mercury Diesel–authorized repair facility.
Seawater discharge restricted or plugged.
Clean exhaust elbows. See a Mercury Diesel–authorized repair
facility.
Seawater inlet hose kinked (restricted).
Position hose to prevent kinking (restriction).
Use of improperly designed hose on inlet side of
seawater pump allowing it to collapse.
Replace hose with wire reinforced design.
Insufficient Engine Temperature
Possible Cause
Faulty thermostats.
Remedy
Replace. See a Mercury Diesel–authorized repair facility.
Low Engine Oil Pressure
Possible Cause
Remedy
Faulty senders.
Have the system checked by a Mercury Diesel–authorized repair facility.
Insufficient amount of oil in the crankcase.
Check and add oil as required.
Excessive oil in crankcase (causing it to
become aerated).
Check and remove the required amount of oil. Check for cause of excessive oil
(improper filling).
Diluted or improper viscosity oil.
Change oil and oil filter. Use the correct grade and viscosity oil. Determine the
cause for dilution (excessive idling).
Battery Will Not Charge
Possible Cause
Excessive current draw from battery.
Remedy
Turn off nonessential accessories.
Check all associated electrical connections and wires (especially
Loose or dirty electrical connections or damaged wiring. battery cables). Clean and tighten faulty connections. Repair or
replace damaged wiring.
Alternator drive belt loose or in poor condition.
Replace or adjust.
Unacceptable battery condition.
Test battery.
Remote Control Operates Hard, Binds, Has Excessive Free‑play, or Makes Unusual Sounds
Remedy
Possible Cause
Insufficient lubrication on shift and throttle linkage
fasteners.
Lubricate.
Obstruction in the shift or throttle linkages.
Remove the obstruction.
Loose or missing shift and throttle linkages.
Check all throttle and shift linkages. If any are loose or missing, see a
Mercury Diesel–authorized repair facility immediately.
Shift or throttle cable kinked.
Straighten cable or have a Mercury Diesel–authorized repair facility
replace cable if damaged beyond repair.
Improper shift cable adjustment.
Have adjustment checked by a Mercury Diesel–authorized repair facility.
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Section 7 - Troubleshooting
Steering Wheel Turns Hard or Jerky
Possible Cause
Remedy
Low power steering pump fluid level.
Check for leak. Refill the system with fluid.
Drive belt loose or in poor condition.
Replace and/or adjust.
Insufficient lubrication on the steering components. Lubricate.
Loose or missing steering fasteners or parts.
Check all parts and fasteners; if any are loose or missing, see a Mercury
Diesel–authorized repair facility immediately.
Contaminated power steering fluid.
See a Mercury Diesel–authorized repair facility.
Power Trim Does Not Operate (Electric Motor Operates but Sterndrive Unit Does Not Move)
Possible Cause
Remedy
The trim pump oil level is low.
Fill the trim pump with oil.
The drive unit is binding in the gimbal ring.
Check for obstruction. See a Mercury Diesel–authorized repair facility.
Power Trim Does Not Operate (Electric Motor Does Not Operate)
Possible Cause
Remedy
Blown fuse.
Replace the fuse.
Loose or dirty electrical connections or
damaged wiring.
Check all the associated electrical connections and the wires (especially the
battery cables). Clean and tighten the faulty connection. Repair or replace the
wiring.
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Section 7 - Troubleshooting
Notes:
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Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information
Table of Contents
Owner Service Assistance.................................................. 106
Local Repair Service .................................................. 106
Service Away From Home .......................................... 106
Stolen Power Package ............................................... 106
Attention Required After Submersion ......................... 106
Replacement Service Parts ........................................ 106
Parts and Accessories Inquiries .......................... 106
Resolving a Problem .................................................. 106
Contact Information for Mercury Marine Customer
Service ....................................................................... 107
Customer Service Literature............................................... 107
English Language ....................................................... 107
Other Languages ........................................................ 108
Ordering Literature............................................................. 108
United States and Canada ......................................... 108
Outside the United States and Canada ...................... 108
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Section 8 - Customer Assistance Information
Owner Service Assistance
Local Repair Service
If you need service for your Mercury MerCruiser‑powered boat, take it to your authorized dealer. Only authorized dealers
specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine
Quicksilver parts and accessories to properly service your engine.
NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser
sterndrives and inboards.
Service Away From Home
If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. If, for any reason,
you cannot obtain service, contact the nearest regional service center. Outside the United States and Canada, contact the
nearest Marine Power International service center.
Stolen Power Package
If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers
and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities
and dealers in recovery of stolen power packages.
Attention Required After Submersion
1.
2.
Before recovery, contact an authorized Mercury MerCruiser dealer.
After recovery, immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of
serious engine damage.
Replacement Service Parts
!
WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
Marine engines are expected to operate at or near full throttle for 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 specifications are different from those of the standard automotive engine. For example, one of the most
important special replacement parts is the cylinder head gasket. Marine engines cannot use steel‑type automotive head
gaskets because saltwater is highly corrosive. A marine engine head gasket uses special materials to resist corrosion.
Because marine engines must be capable of running at or near maximum RPM much of the time, they also have special valve
springs, valve lifters, pistons, bearings, camshafts, and other heavy‑duty moving parts.
Mercury MerCruiser marine engines have other special modifications to provide long life and dependable performance.
Parts and Accessories Inquiries
Direct any inquiries concerning Quicksilver replacement parts and accessories to your local authorized dealer. The dealer has
the necessary information to order parts and accessories for you. Only authorized dealers can purchase genuine Quicksilver
parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When
inquiring about parts and accessories, the dealer requires the engine model and serial numbers to order the correct parts.
Resolving a Problem
Satisfaction with your Mercury MerCruiser product is important to your dealer and to us. If you ever have a problem, question,
or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If you need
additional assistance:
1. Talk with the dealership's sales manager or service manager. Contact the owner of the dealership if the sales manager and
service manager have been unable to resolve the problem.
2. If your question, concern, or problem cannot be resolved by your dealership, please contact a Mercury Marine Service
Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.
The following information will be needed by Customer Service:
•
Your name and address
•
Daytime telephone number
•
Model and serial numbers for your power package
•
The name and address of your dealership
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Section 8 - Customer Assistance Information
•
Nature of the problem
Contact Information for Mercury Marine Customer Service
For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence.
United States, Canada
Telephone
English +1 920 929 5040
Français +1 905 636 4751
Fax
English +1 920 929 5893
Français +1 905 636 1704
Website
www.mercurymarine.com
Mercury Marine
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
Australia, Pacific
Telephone
+61 3 9791 5822
Fax
+61 3 9706 7228
Brunswick Asia Pacific Group
41–71 Bessemer Drive
Dandenong South, Victoria 3175
Australia
Europe, Middle East, Africa
Telephone
+32 87 32 32 11
Fax
+32 87 31 19 65
Brunswick Marine Europe
Parc Industriel de Petit-Rechain
B-4800 Verviers,
Belgium
Mexico, Central America, South America, Caribbean
Telephone
+1 954 744 3500
Fax
+1 954 744 3535
Mercury Marine
11650 Interchange Circle North
Miramar, FL 33025
U.S.A.
Japan
Telephone
+072 233 8888
Fax
+072 233 8833
Kisaka Co., Ltd.
4-130 Kannabecho Sakai-shi Sakai-ku
5900984 Osaka,
Japan
Asia, Singapore
Telephone
+65 65466160
Fax
+65 65467789
Brunswick Asia Pacific Group
T/A Mercury Marine Singapore Pte Ltd
29 Loyang Drive
Singapore, 508944
Customer Service Literature
English Language
English language publications are available from:
Mercury Marine
Attn: Publications Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939
Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for
further information.
When ordering be sure to:
•
List your product, model, year, and serial numbers.
•
Check the literature and quantities you want.
•
Enclose full remittance in check or money order (NO COD).
90-8M0087070
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Page 107
Section 8 - Customer Assistance Information
Other Languages
To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine
Power International Service Center for information. A list of part numbers for other languages is provided with your power
package.
Ordering Literature
Before ordering literature, have the following information about your power package available:
Model
Serial Number
Horsepower
Year
United States and Canada
For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact:
Mercury Marine
Telephone
Fax
Mail
(920) 929‑5110
(USA only)
(920) 929‑4894
(USA only)
Mercury Marine
Attn: Publications Department
P.O. Box 1939
Fond du Lac, WI 54935-1939
Outside the United States and Canada
Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular
power package.
Submit the following
order form with payment
to:
Mercury Marine
Attn: Publications Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
Ship To: (Copy this form and print or type–This is your shipping label)
Name
Address
City, State, Province
ZIP or postal code
Country
Quantity
Page 108
Item
Stock Number
Price
Total
.
.
.
.
.
.
.
.
.
.
Total Due
.
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Section 9 - Maintenance Log
Section 9 - Maintenance Log
Table of Contents
Maintenance Log................................................................ 110
9
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DECEMBER 2013
Page 109
Section 9 - Maintenance Log
Maintenance Log
Record all maintenance performed on your power package here. Be sure to save all work orders and receipts.
Date
Page 110
Maintenance Performed
Engine Hours
90-8M0087070
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DECEMBER 2013
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