Diesel Engines - Inboard Models
 1997, Mercury Marine
Diesel Engines - Inboard Models
90-860096980 1197
CE290
Identification Record
Please record the following information that pertains to your power package:
1.
Engine Serial Number
Engine Model and Horsepower
2.
Transom Assembly Serial Number (Sterndrive)
Gear Ratio
Sterndrive Unit Serial Number
Transmission Model (Inboard)
Gear Ratio
Transmission Serial Number
3.
4.
Pitch
Propeller Number
Diameter
5.
Purchase Date
Hull Identification Number (HIN)
6.
Boat Manufacturer
Boat Model
Length
7.
Exhaust Gas Emissions Certificate Number (Europe Only)
Serial Numbers
The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your
MerCruiser power package. When contacting your Authorized MerCruiser Dealer about service, always
specify model and serial numbers.
1A (D-Tronic)
1A
71675
1A
3
7
71778
3
Serial Number
5
3
O_ ___ ___
THIS ENGINE
CONFORMS TO INT’L
BODENSEE SHIPPING
COMISSION STDS
CERT NO.
4
1B
M12 11 3 93 _
_
1B
7
71038
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, U.S.A.
Printed in U.S.A.
1997, Mercury Marine
The following are registered trademarks of Brunswick Corporation: Auto-blend, Jet-Prop, Mariner, Merc,
MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, Ride-Guide, and Thruster.
0
CE308
Table Of Contents
Page
Welcome! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Read This Manual Thoroughly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lanyard Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exhaust Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safe Boating Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Protecting People In The Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
While You Are Cruising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
While Boat Is Stationary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
High-Speed And High-Performance Boat Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conditions Affecting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Weight Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bottom Of Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
How Elevation and Climate Affect Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Recommended Operation / Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Owner/Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dealer Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Launching and Boat Operation Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Freezing Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drain Plug and Bilge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Attention Required After Submersion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Stolen Power Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacement Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Do-It-Yourself Maintenance Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diagnosing EDI Problems (If So Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Multiple EDI Engine Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Initial Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
20 Hour Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
After Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
End of First Season Checkup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
100 Hour Checkup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Seacock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Seawater Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Anti-Freeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Diesel Fuel In Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
D3.6L and D4.2L Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
D2.8L D-Tronic and D4.2L D-Tronic Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Quicksilver Instruments and Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical System Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Starting, Shifting and Stopping - D3.6L and D4.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operation Chart - D3.6L and D4.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Starting, Shifting and Stopping - D2.8L D-Tronic and D4.2L D-Tronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operation Chart - D2.8L D-Tronic and D4.2L D-Tronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Maintenance Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1
Page
Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Scheduled Maintenance That Can Be Performed By Owner / Operator . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Scheduled Maintenance That Should Be Performed By A Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Checking Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cleaning Quicksilver Seawater Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Shift Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Seawater Pump Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Flushing Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Flushing Seawater Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hand Pump/Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Priming Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Filling Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Filling (Bleeding) Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Draining Water Separating Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Replacing Water Separating Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Corrosion And Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Miscellaneous Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Bottom Of Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Antifouling Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Cold Weather Or Extended Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Power Package Layup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Battery Winter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Power Package Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Owner Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
International Owner Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Mercruiser Diesel Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Marine Power International Branch or Distributor Service Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Transferable Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Q-GUARD Product Protection Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Owner Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Local Repair Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Service Away From Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Parts And Accessories Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Resolving A Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Mercury Marine Service Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Customer Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
English Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Other Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Literature Order Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2
CA165
Welcome!
You have selected one of the finest marine power packages available. It incorporates numerous design features
to assure 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 and Maintenance 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 MerCruiser products. We sincerely hope your boating will be pleasant!
CONSUMER AFFAIRS DEPARTMENT
CA466
IMPORTANT: This manual contains basic Operation and Maintenance information for your MerCruiser
power package. If you desire to perform some of the maintenance items on your own, you should obtain
a copy of the “Maintenance Procedures” Manual for your particular power package. Information for
obtaining this manual is located at the back of this manual.
3
CD326
Read This Manual Thoroughly
IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION
OF ACTUAL STARTING AND OPERATING PROCEDURES.
NOTICE
Throughout this publication, and on your power package WARNINGS and CAUTIONS, accompanied by the International HAZARD Symbol ! , may be used to alert the installer/user to special instructions concerning a particular 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.
! WARNING
WARNING - Hazards or unsafe practices which could result in severe personal injury or death.
! CAUTION
CAUTION - Hazards or unsafe practices which could result in minor personal injury or product or property damage.
IMPORTANT: Indicates information or instructions that are necessary for proper operation and/or maintenance.
! 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
and Maintenance Manual and thoroughly understand the operational instructions for the power package
and all related accessories before the boat is used.
We strongly recommend that other occupants be instructed on proper starting and operation procedures so they will be prepared should they be required to operate the power package and boat in an
emergency.
! WARNING
The use of accessories not manufactured or sold by Mercury Marine is not recommended for use with
your MerCruiser unit. If your MerCruiser unit is equipped with an accessory not manufactured by Mercury Marine, be sure to read the Operation and Maintenance Manual for the accessory before operation.
If you haven’t been supplied with such a manual, contact your dealer or the manufacturer of the accessory to secure the applicable manual.
! WARNING
Electrical system components on this engine are not external ignition protected. DO NOT STORE OR
UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN
MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to
comply could result in fire, explosion and/or severe personal injury.
4
CA619
Lanyard Stop Switch
2
1
74608
The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from
the operator’s position (as in accidental ejection from the operator’s position) to activate the switch. Some remote
control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed on the dashboard
or side adjacent to the operator’s position.
The lanyard is a cord usually between 4 and 5 feet (1220 and 1524 mm) in length when stretched out with an
element on one end made to be inserted into the switch and a snap (2) on the other end for attaching to the
operator. The lanyard is coiled to make its at-rest condition as short as possible so as to minimize the likelihood
of lanyard entanglement with nearby objects. It is made as long as it is in its stretched condition to minimize the
likelihood of accidental activation should the operator choose to move around in an area close to the normal
operator’s position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator’s wrist or leg,
or tie a knot in the lanyard.
IMPORTANT: The purpose of a lanyard stop switch is to stop the engine when the operator moves far
enough away from the operator’s position to activate the switch. This would occur if the operator
accidentally falls overboard or moves within the boat a sufficient distance from the operator’s position.
Accidental ejections and falls overboard are more likely to occur in certain types of boats such as low
sided sport boats or bass boats, and high-performance boats. Accidental ejections and falls overboard
are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or
gunwale at planing speeds, standing at planing speeds, sitting on elevated fishing boat decks, operating
at planing speeds in shallow or obstacle-infested waters, releasing your grip on a steering wheel that
is pulling in one direction, drinking alcohol or consuming drugs, or daring, high-speed boat maneuvers.
While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some
distance depending upon the velocity and degree of any turn at shut-down. However, the boat will not complete
a full circle. 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 strongly recommend that other occupants be instructed on proper starting and operating procedures should
they be required to operate the engine in an emergency (e.g. if the operator is accidentally ejected).
5
! WARNING
Should the operator fall out of the boat, the possibility of serious injury or death from being run over by
the boat can be greatly reduced by stopping the engine immediately. Always properly connect both ends
of the stop switch lanyard to the stop switch and the operator.
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:
1 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 gear case or
propeller.
2 Loss of power and directional control in heavy seas, strong current or high winds.
3 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.
6
CA641
1
Courtesy of ABYC
CA620
Exhaust Emissions
Be Alert To Carbon Monoxide Poisoning
Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards,
sterndrives and inboard engines that propel boats, as well as the generators that power various boat
accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.
Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication,
include headache, dizziness, drowsiness, and nausea.
! WARNING
Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon
monoxide in sufficient concentration can lead to unconsciousness, brain damage or death.
GOOD VENTILATION
Ventilate passenger area, open side curtains, or forward hatches to remove fumes.
1 Example of desired air flow through the boat.
7
CA642
2A
2B
3A
3B
Courtesy of ABYC
CA643
POOR VENTILATION
Under certain running and/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 unclosed area of a
stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon
monoxide.
2 Examples of poor ventilation while boat is stationary:
A Running the engine when the boat is moored in a confined space.
B Mooring close to another boat that has its engine running.
3 Examples of poor ventilation while boat is moving:
A Running the boat with the trim angle of the bow too high.
B Running the boat with no forward hatches open (station wagon effect).
8
CA281
Safe Boating Suggestions
In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations
and restrictions, and consider the following suggestions.
• Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating
safety course. Courses are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2) The Power Squadron, (3) The Red Cross and (4) your state or provincial boating law enforcement agency. Inquiries may be
made to the Boating Hotline, 1-800-368-5647 or the Boat U.S. Foundation information number
1-800-336-BOAT.
We strongly recommend that all powerboat operators attend one of these courses.
You should also review the NMMA Sources of Waterway Information booklet. It lists regional sources of safety,
cruising and local navigation and is available at no charge by writing to:
Sources of Waterway Information
National Marine Manufacturers Association
410 N. Michigan Avenue
Chicago, IL 60611 U.S.A.
• Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs
are properly made.
• Check safety equipment on board. Here are suggestions of the types of safety equipment to carry when
boating:
(1) Approved fire extinguisher(s); paddle or oar.
(2) Signal devices: flashlight, rockets or flares, flag and whistle or horn.
(3) Spare propeller, thrust hubs and an appropriate wrench.
(4) Tools for necessary minor repairs; first aid kit and book.
(5) Anchor and extra anchor line; water-proof storage containers.
(6) Manual bilge pump and extra drain plugs; compass and map or chart of area.
(7) Spare operating equipment; batteries, bulbs, fuses, etc.
(8) Transistor radio
(9) Drinking water
• Know 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. Just 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, wearable-type life jacket (personal flotation device), correctly sized and readily accessible for every person on
board, 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 on board 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 capacity plate). When in doubt, contact your dealer or the boats manufacturer. Know your boat’s
operating and loading limitations.
• Make sure everyone in the boat is properly seated. Don’t allow anyone to sit or ride on any part of the boat
that was not intended for such use. This includes backs of seats, gunwales, transom, bow, decks, raised fishing seats, any rotating fishing seat; 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.
9
• Never be under the influence of alcohol or drugs while boating (it is the law). They impair your judgment
and greatly reduce your ability to react quickly.
• Know your boating area and avoid hazardous locations.
• 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 operators view when operating the boat above idle or planing transition speed. Watch “the
other guy,” the water and your wake.
• Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 25 miles per hour (40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet in front of you.
• Watch fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or down
skier on the operator’s side of the boat while returning to attend the skier. The operator 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.
CA282
Protecting People In The Water
While You Are Cruising
It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her
direction even at slow speed.
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 (coasting) and the drive unit is in neutral position, 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
Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near
your boat.
! WARNING
Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the person in the water is likely if contacted by a rotating propeller, a moving boat, a moving gear case, or any
solid device rigidly attached to a moving boat or gear case.
CA283
High-Speed And High-Performance Boat Operation
If your boat is considered 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 familiarization demonstration ride with your dealer or an operator experienced with your boat. For additional information,
obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-86168--3) from your dealer, distributor, or Mercury Marine.
10
CD3
Conditions Affecting Operation
CD4
Weight Distribution
Positioning of weight (passengers and gear) inside the boat has the following effects:
A. Shifting weight to rear (stern) will:
• Generally increases speed and engine RPM.
• At extremes, can cause boat to porpoise.
• Causes bow to bounce in choppy water.
• Increases danger of following wave splashing into boat when coming off plane.
B. Shifting weight to front (bow) will:
• Improves ease of planing on some boats.
• Improves rough water ride.
• At extremes, can cause boat to veer back and forth (bow steer).
CA8
Bottom Of Boat
To maintain maximum speed, the following conditions of the boat bottom should be observed.
A. Clean, free of barnacles and marine growth.
B. Free of distortion; nearly flat where it contacts the water.
C. Straight and smooth, fore and aft.
Marine vegetation may accumulate when boat is docked. This growth must be removed before operation; it may
clog water inlets and cause engine to over heat.
11
CE282
Propeller Selection
IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide-openthrottle revolutions per minute (RPM). Use an accurate service tachometer to verify engine operating
RPM.
It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the
correct propeller(s). Specified engine wide-open-throttle (WOT) and operating RPM range are listed in
“SPECIFICATIONS”.
IMPORTANT: The engines covered in this manual are equipped with a governor that limits engine RPM.
Be sure that propeller being used does not allow engine to run against the governor, as a significant loss
in performance will result.
Engine RPM - Governor Limit
MIE Model
Engine Recommended Operating RPM Range
Governed RPM Setting (Begins At: )
D3.6L
3600-3800
3830 ± 20
D4.2L
3400-3600
3630 ± 20
3600-3800
3875± 50
D2.8L D-Tronic
D4.2L D-Tronic
Select a propeller that will allow the engine power package to operate at or near the top of the recommended
wide-open-throttle operating RPM range with a normal load. Generally, there is a 100-150 RPM difference between 1 inch changes in propeller diameter or pitch.
If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of
performance and possible engine damage. On the other hand, operating an engine above the recommended
operating RPM range will cause higher than normal wear and/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 applicable to D-Tronic models).
• Operating in a higher elevation causes an RPM loss (not applicable to D-Tronic models).
• Operating with a damaged propeller or dirty boat bottom causes an RPM loss.
• Operating with increased load (additional passengers, pulling skiers, etc.).
For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. However, do not
operate at full throttle when using the lower pitch propeller but not pulling skiers.
12
CD476
How Elevation and Climate Affect Performance
NOTE: Engines equipped with EDI (D-Tronic engines) reduce the effects of changes in elevation and climate
by automatically adjusting fuel flow for weather conditions and elevation. EDI engines however, do not compensate for increased loading or hull conditions.
Generally, elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxygen) gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a noticeable effect on the density of air. Heat and humidity thin the air. This condition can become particularly annoying when an engine is propped out on a cool, dry day in spring and later, on
a hot, sultry day in August, doesn’t have its old zip.
Although some performance can be regained by dropping to a lower-pitch propeller, the basic problem still exists.
In some cases, a gear-ratio change to more reduction is possible and very beneficial.
Summer conditions of high temperature, low barometric pressure and high humidity all combine to reduce the
engine power. This, in turn, is reflected in decreased boat speeds, as much as 2 or 3 miles per hour in some
cases. Nothing will regain this speed for the boater, but the coming of cool, dry weather.
In pointing out the practical consequences of weather effects, an engine -- running on a hot, humid summer day
-- may encounter a loss of as much as 14% of the horsepower it would produce on a dry brisk spring or fall day.
With the drop in available horsepower, this propeller will, in effect, become too large. Consequently, the engine
operates at less than its recommended RPM. This will result in further loss of horsepower at the propeller with
another decrease in boat speed. This secondary loss, however, can be somewhat regained by switching to a
lower-pitch propeller that allows the engine to again run at recommended RPM.
For boaters to realize optimum engine performance under changing weather conditions, it is essential that the
engine be propped to allow it to operate at or near the top end of the recommended maximum RPM range at
wide-open-throttle with a normal boat load.
Not only does this allow the engine to develop full power, but equally important is the fact that the engine also
will be operating in an RPM range that discourages damaging detonation. This, of course, enhances overall reliability and durability of the engine.
13
CD247
Operation and Maintenance
RECOMMENDED OPERATION / DUTY CYCLE
It is the operator’s responsibility to operate within the following recommended operational capability, or duty
cycle, as applicable to engine and installation:
• Pleasure Duty 1.) Operated at rated power and rated speed for short periods of time.
• Light Duty 1.) Operated such that full rated power at maximum rated RPM is limited to 10% of operating time
and continuous cruising RPM is limited to 90% of Wide-Open-Throttle RPM (when propped within
specified RPM range).
2.) Annual operating time is not to exceed 500 hours.
NOTE: Pleasure duty rating applies to high performance-type boats, or boats with planing hulls where
acceleration and top speed are of primary importance. This rating is reserved for privately-owned yachts, or
recreational power boats in non-revenue applications.
Light duty rating applies to planing boats where the use of full rated power at maximum rated RPM is limited (as
stated above). Examples of Light Duty applications include, but are not limited to: search and rescue craft, fast
patrol boats, fire boats, dive boats, and limited season fishing boats such as sport-fish charter boats. Application
to common commercial crafts having full-displacement or semi-displacement hulls exceeds the recommended
operational capability, or duty cycle.
IMPORTANT: Damage caused by improper application or failure to operate within the operational
capability, or duty cycle, will not be covered by the MerCruiser Diesel Limited Warranty.
14
CD478
OWNER/OPERATOR RESPONSIBILITIES
It is the operator’s responsibility to perform all safety checks, ensure that all lubrication and maintenance instructions are complied with for safe operation, and return the unit to an Authorized MerCruiser Dealer for a periodic
checkup.
Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such,
are not considered defects in workmanship or material within 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 assure optimum performance and dependability, and
will keep your overall operating expenses at a minimum. See your Authorized MerCruiser Dealer for service aids.
! CAUTION
Except on the D-Tronic models, the injection pump lever Wide-Open-Throttle (W.O.T.) Stop Screw
adjusts the engine speed governor, and is factory set and sealed. Readjusting the governed speed and
operating above the specified RPM will cause extensive engine damage and/or failure. Removal of the
seal and/or readjustment of the governed speed is considered misuse of engine, and resulting damages
will not be covered by the limited warranty.
CA14
DEALER RESPONSIBILITIES
In general, a dealer’s responsibilities to the customer include predelivery inspection and preparation such as:
• Make sure that the boat is properly equipped.
• Prior to delivery, make certain that the MerCruiser power package and other equipment are in proper operating condition.
• Make all necessary adjustments for maximum efficiency.
• Familiarize the customer with the on-board equipment.
• Explain and demonstrate the operation of the power package and boat.
• At the time of delivery, the dealer should provide you with a copy of a Predelivery Inspection Checklist.
• Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory (branch
or distributor) immediately upon sale of the new product.
15
CA20
Launching and Boat Operation Care
! CAUTION
During launching from a trailer, if the unloading ramp is steep or the trailer bed must be tilted, the boat
may enter the water rapidly and at a steep angle. This may force water through the exhaust system into
the cylinders. The more weight on the transom, the more likely this is to occur.
Slowing down rapidly, stopping suddenly or backing up rapidly may cause a following wave to “swamp”
the transom causing water to enter the cylinders through the exhaust system causing severe engine
damage.
When backing up rapidly, the same situation may occur as stated in the preceding paragraph.
In any of these situations, water entering the engine could cause severe damage to internal parts. Refer to
“Attention Required After Submersion,” in this “Operation and Maintenance Manual.”
CA407
Freezing Temperature Operation
IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to
prevent freezing damage to power package. Damage caused by freezing IS NOT covered by MerCruiser
Limited Warranty.
CA408
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 and/or a bilge pump. It is very important to check these items on a regular basis to
ensure that the water level does not rise to come in contact with your power package. Components on your
engine will be damaged if submerged. Damage caused by submersion is not covered by the MerCruiser Limited
Warranty.
CA409
Attention Required After Submersion
• Before recovery, contact an Authorized MerCruiser Dealer.
• After recovery, immediate service by an Authorized MerCruiser Dealer is required to prevent serious damage
to power package.
CA21
Stolen Power Package
If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and
serial number(s) and to whom the recovery is to be reported. This “Stolen Motor” information is placed into a file
at Mercury Marine to aid authorities and dealers in recovery of stolen motors.
16
CE9
Replacement Service Parts
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. Care should
be exercised when replacing marine engine parts, as specifications are quite different from those of the standard
automotive engine.
Since marine engines must be capable of running at or near maximum RPM much of the time, special pistons,
camshafts and other heavy-duty moving parts are required for long life and peak performance.
These are but a few of the many special modifications that are required in MerCruiser marine engines to provide
long life and dependable performance.
CA410
Do-It-Yourself Maintenance Suggestions
If you are one of those persons who likes to do-it-yourself, here are some suggestions for you.
• Present-day marine equipment, such as your MerCruiser power package, are highly technical pieces of
machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are
more complex for the untrained mechanic.
• Do not attempt any repairs which are not covered in this manual unless you are aware of the precautions
(“Cautions” and “Warnings”) and procedures required. Your safety is of our concern.
• If you attempt to service the product yourself, we suggest you order the maintenance procedures manual for
that model. This manual outlines the correct procedures to follow. 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/or equipment. You can cause damage to the product in excess of
the cost a dealer would charge you.
• Also, if you partially disassemble an 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 request
the repair procedure. It is difficult for them to diagnose a problem over the telephone.
• Your Authorized Dealer is there to service your power package. They have qualified factory-trained
mechanics.
It is recommended you have the dealer 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.
17
CD329
Diagnosing EDI Problems (If So Equipped)
Your Authorized MerCruiser Dealer has the proper service tools for diagnosing problems on Electronic Diesel
Injection (EDI) Systems. The Electronic Control Module (ECM) on these engines have the ability to detect some
problems with the system when they occur, and store a “Trouble Code” in the ECM’s memory. This code can
then be read later by a service technician using a special diagnostic tool.
CA622
Multiple EDI Engine Battery Precautions
Situation
Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the
alternator is mounted on. When batteries for two different engines are connected, one alternator will supply all
of the charging current for both batteries. Normally, the other engine’s alternator will not be required to supply
any charging current.
EDI Electronic Control Module (ECM): The ECM 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 ECM’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 ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM
will reset itself. The engine will now run normally. This ECM shut down usually happens so fast that the engine
just appears to have an ignition miss.
Recommendations
Batteries: Boats with multi-engine EDI power packages require each engine be connected to its own battery.
This ensures that the engine’s Electronic Control Module (ECM) has a stable voltage source.
Battery Switches: Battery switches should always be positioned so each engine is running off its own battery.
DO NOT operate engines with switches in BOTH or ALL position. In an emergency, another engine’s battery
can be used to start an engine with a dead battery.
Battery Isolators: Isolators can be used to charge an auxiliary battery used only for accessories. Isolators
should not be used to charge the battery of another engine in the boat.
Generators: The generator’s battery should be considered another engine’s battery.
18
CD477
Engine 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.
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 engine does not start, wait 1 minute to allow the starter motor to cool; then, repeat starting procedure.
Initial Break-in Procedure Is As Follows:
1. Follow instructions “a” or “b”:
a. On D2.8L D-Tronic and D4.2L D-Tronic Engines: Proceed to Step2.
b. On D3.6L and D4.2L Engines Only: Pre-lubricate the turbocharger and engine. To do this, hold the
“STOP” switch toggle lever DOWN while you simultaneously turn the key switch to “START” position for 15
seconds. This will rotate the starter motor and engine/oil pump. During this process the engine will not run
because no fuel is injected. Allow the starter motor to cool down for one minute and repeat the above described process. To avoid overheating the starter motor, do not engage starter motor for more than 15 seconds each time.
2. Refer to appropriate “Starting, Shifting and Stopping” section and start engine. Allow engine to idle until it
has reached normal operating temperature.
3. Run engine in gear for 3 minutes at each of the following RPMs: 1200 RPM, 2400 RPM and 3000 RPM.
4. Run engine in gear for 3 minutes at each of the following RPMs: 1500 RPM, 2800 RPM and 3400 RPM.
5. Run engine in gear for 3 minutes at each of the following RPMs: 1800 RPM, 3000 RPM and Maximum Rated
Full-Throttle RPM.
CE11
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 engine below 1500 RPM for extended periods during the first 10 hours. During this period,
shift into gear as soon as possible after starting engine and advance throttle so that RPM is above 1500 (provided that conditions permit safe operation at this speed).
• DO NOT operate at any one constant speed for extended periods.
• DO NOT exceed 75% of full throttle during the first 10 hours except during engine Initial Break-In Procedure.
During the next 10 hours, occasional operation at full throttle (5 minutes at a time maximum) is permissible.
• AVOID full throttle acceleration from stopped position.
• DO NOT operate at full throttle until engine reaches normal operating temperature.
• OBSERVE INSTRUMENTS, if an abnormal reading occurs, stop engine immediately and determine cause.
• FREQUENTLY CHECK crankcase oil and transmission fluid levels. Add if necessary. It is normal for oil consumption to be somewhat high during the break-in period.
• AT END OF 20-HOUR break-in period, remove break in oil and replace oil filter. Fill crankcase with correct
grade and viscosity oil.
19
CA211
After Break-In Period
To help extend the life of your MerCruiser power package, the following recommendations should be considered;
• Use a propeller that allows the engine to operate at or near the top of the maximum RPM range (See
“Specifications” section) when at full throttle with a normal boat load.
• Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged operation at maximum (full
throttle) RPM.
CA414
End of First Season Checkup
At the end of the first season of operation, an Authorized MerCruiser Dealer should be contacted to discuss
and/or perform various scheduled maintenance items. If you are in an area where the product is operated
continuously (year-round operation), you should contact your dealer at the end of the first 100 hours of operation,
or once yearly, whichever occurs first.
CE299
100 Hour Checkup
It is a condition for the continuation of warranty, that the product be taken to an authorized MerCruiser service
dealer after the first 100 hours of operation, but no later than 150 hours, for cylinder head retorque service. A
copy of the dealer service work order must be kept, by the product owner, as evidence of compliance therewith.
20
CE13
Specifications
CD11
Seacock
Seacock (water inlet valve) used, must have an internal cross-sectional area equal to or greater than hose to
prevent restricting water flow. A 1-1/2 in. (38mm) brass ball or gate valve is minimum required.
Seacock should be installed in an area where it is easily accessible and supported adequately to prevent hose
fatigue.
CE14
Seawater Strainer
Seawater Strainer should be provided, and be of sufficient size to ensure that an adequate supply of water will
be maintained for cooling engine. A minimum flow rate of 40 gallons (150 litres) per minute is required.
Strainer should be installed in an area where it will be easily accessible for inspection and cleaning. Strainer
should be installed in water inlet hose after seacock to allow operator to shut off water inlet when cleaning
strainer.
CD535
Anti-Freeze/Coolant
! CAUTION
Alcohol or Methanol base antifreeze or plain water are not recommended for use in closed cooling section of cooling system at any time.
Because diesel engines are high compression engines and related higher engine operating temperatures are
created, the closed cooling system and engine, including related cooling passages must remain as clean as possible to provide adequate engine cooling. This can only be assured by using the proper anti-freeze, water, additives
and inhibitors. It is recommended that the closed cooled section of the cooling system be filled with a low, or no,
silicate formula of ethylene glycol antifreeze in solution with deionized water. A low silicate formula prevents antifreeze separation which causes a silicate gelatin to form. This gelatin will block engine and heat exchanger passages causing engine overheating.
The coolant, if not premixed, should be mixed before being added to the closed cooling system using a proper
anti-freeze together with deionized water. Common tap water or softened water contains unwanted minerals
which can leave large deposits in the system that restrict the cooling system efficiency. In addition, additives and
inhibitors introduced into acceptable coolant solutions will form a protective film on internal passages and provide protection against internal cooling system erosion.
The closed cooling section should be kept filled year-round with an acceptable anti/freeze/coolant solution. Do
not drain closed cooled section for storage, as this will promote rusting of internal surfaces. If engine will be exposed to freezing temperatures, make sure that closed cooled section is filled with a properly mixed antifreeze/
coolant solution, to protect engine and closed cooling system to lowest temperature to which they will be exposed.
IMPORTANT: The anti-freeze/coolant used in these marine engines must be a low (or no) 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.
Some acceptable types of anti-freeze/coolants are listed in the following table. Refer to “Maintenance Schedules”
for respective change intervals.
DESCRIPTION
Quicksilver Premixed Marine Engine Coolant
Extended Life Anti-Freeze/Coolant
Fleetguard Complete
PART NUMBER
92-813054A2
Obtain Locally
21
CD164
Fuel Requirements
! WARNING
Electrical system components on this engine are not external ignition protected. DO NOT STORE OR
UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN
MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to
comply could result in fire, explosion and/or severe personal injury.
! WARNING
FIRE HAZARD: Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death. Careful periodic inspection of entire fuel system is mandatory, particularly
after storage. All fuel components including fuel tanks, whether plastic, metal or fiberglass, fuel lines,
primers, fittings, and fuel filters should be inspected for leakage, soften, hardening, swelling or corrosion. Any sign of leakage or deterioration requires replacement before further engine operation.
IMPORTANT: Use of improper or water contaminated diesel fuel can damage your engine seriously. Use
of improper fuel is considered misuse of engine, and damage caused thereby will not be covered by warranty.
! WARNING
Under no circumstances should gasoline, gasohol and/or alcohol be mixed with diesel fuel for any reason. This mixture of gasoline, gasohol and/or alcohol with diesel fuel is highly flammable and produces
a significant risk to the user.
Grade 2-D diesel fuel is required, meeting ASTM Standards D975 (or fuel rated Diesel DIN 51601), and having
a minimum cetane rating of 45.
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 fuel fill, you possibly received substandard fuel with a
low cetane rating.
Sulphur content of the above fuel is rated at 0.50% by weight, maximum (ASTM). Limits may vary in countries
outside of the United States.
On intermittent use engines, high sulphur content diesel fuel will greatly increase:
• Corrosion on metal parts.
• Deterioration of elastomer and plastic parts.
• Corrosion and extensive damage, and excessive wear of internal engine parts, particularly bearings.
• Starting and operating difficulties.
22
CE16
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” “anti-gel” diesel fuel
additive, following that product’s directions.
CE284
Crankcase Oil
To help obtain optimum engine performance and to provide maximum protection, the engine requires engine
oil with a rating of HD-SAE-API SH, CF/CF-2.
We strongly recommend the use of QUICKSILVER 4-Cycle Marine Engine Oil, a specially blended 25W-40
SH, CF/CF-2 oil with Marine Additives, for all temperature operations.
The following oils, approved by Mercury Marine and Marine Power Europe, exceed MlL-2104 D standards. For
all temperature operation use 15W-40 oil.
RECOMMENDED OILS FOR D4.2L, D2.8L D-TRONIC AND D4.2L D-TRONIC ENGINES
AGIP SIGMA TURBO
MOBIL DELVAC 1400 SUPER
TOTAL RUBIA TIR
SHELL MYRINA
TEXACO URSA SUPER TD
VEEDOL TURBOBOSTAR
MOPAR
WINTERSHALL MULTI-REKORD
WINTERSHALL VIVA 1
RECOMMENDED OILS FOR D3.6L ENGINES
AGIP SIGMA TURBO
ARAL OL P 327
CHEVRON DELO 450 MOTOR OIL
MULTIGRADE
FANAL INDOL X
FINA KAPP LDO
AUTOL VALVE-SHP
DEUSOL TURBOMAX
FUCHS TITAN TRUCK 1540
AVIATICON TURBO
DIVINOL MULTIMAX EXTRA
GULF SUPERFLEET SPECIAL
BP VANELLUS C3 EXTRA
DUKCHAMS HYPERGRADE
IP TAURUS M
CALTEX RPM DELO 450 OIL
ECUBSOL OIL CD PLUS
MOBIL DELVAC 1400 SUPER
CASTROL TURBOMAX
ELF MULTIPERFORMANCE
TOTAL RUBIA TIR
CENTURY SHPD
ESSO HESSOL TURBODIESEL
VALVOLINE SUPER HD LD
23
CE285
Engine Specifications
D3.6L AND D4.2L MODELS
SPECIFICATION - MIE ( Inboard )
DESCRIPTION
Crankshaft Horsepower (Kilowatts)
1
Propeller Shaft Horsepower (Kilowatts)
1
Engine Type
D3.6L
D4.2L
180 ( 134 )
220 ( 164 )
180 ( 134 )
210 ( 156 )
In-Line 6 Cylinder Diesel
Displacement
219 cu. in. ( 3.6 L )
254 cu. in. ( 4.2 L )
1-5-3-6-2-4
1-5-3-6-2-4
Bore
3.622 in. ( 92mm )
3.700 in. ( 94 mm )
Stroke
3.543 in. ( 90mm )
3.937 in. ( 100 mm )
22 : 1
21.5 : 1
Firing Order
Compression Ratio
Valve Clearance ( Intake / Exhaust )
.012 in. ( 0.30 mm )
Maximum Pressure Difference Between Cyl.
72 PSI ( 500 kPa )
Maximum High Idle No Load RPM
Governed RPM Setting (Begins At:)
Rated RPM At Wide-Open-Throttle
2
Idle RPM in Forward Gear
Oil Pressure:
4200 ± 50
3830 ± 20
3630 ± 20
3800
3600
700
750 RPM
3600 - 3800 RPM
Oil Temperature
Thermostats:
4300 ± 50
22-36 PSI [ 1.5 - 2.5 bar ( 152-248 kPa ) ]
50-58 PSI [ 3.5 - 4 bar ( 345-400 kPa ) ]
212° - 230° F ( 100° - 110° C )
Water: ( 2 Total ) 1 at temp. :
1 at temp. :
160° F ( 70° C )
Oil: ( 1 Total )
195° F ( 90°
195
90 C )
180° F ( 82° C )
Coolant Temperature
176° - 185° F ( 80° - 85° C )
Electrical System
12-volt Negative ( - ) Ground
Alternator Rating
949W, 14.6v, 65A
Recommended Battery Capacity Rating
Starter
750 cca, 950 mca, or 180Ah
12v, 2.7 kW
1
Power rated in accordance with NMMA Procedure - ISO 3046 (Technically Identical to ICOMIA 28-83).
2
Refer to “Conditions Affecting Operation - Propeller Selection” for additional information.
24
CE286
D2.8L D-TRONIC AND D4.2L D-TRONIC MODELS
DESCRIPTION
SPECIFICATION - MIE (Inboard)
D2.8L D-Tronic
D4.2L D-Tronic
165 (123)
250 (186)
160 (119)
240 (179)
Engine Type
In-Line 4 Cylinder
Diesel
In-Line 6 Cylinder
Diesel
Displacement
169 cu. in. ( 2.8 L )
254 cu. in. ( 4.2 L )
1-3-4-2
1-5-3-6-2-4
Crankshaft Horsepower (Kilowatts)
1
Propeller Shaft Horsepower (Kilowatts) 1
Firing Order
Bore
3.700 in. ( 94mm )
Stroke
3.937 in. ( 100 mm )
Compression Ratio
16.5:1
Valve Clearance - Intake / Exhaust
Hydraulic
Maximum Pressure Difference Between Cyl.
4200 ± 50
Maximum High Idle No Load RPM
Governed RPM Setting (Begins At:)
Rated RPM at Wide-Open-Throttle
2
Low Idle RPM
Oil Pressure:
3875 ± 50
3800
700
750 RPM
22-45 PSI [ 1.5 - 3.1 bar ( 152-310 kPa ) ]
3800 RPM
50-80 PSI [ 3.5 - 5.6 bar ( 345-556 kPa ) ]
Oil Temperature
Thermostats:
72 PSI ( 500 kPa )
212° - 230° F ( 100° - 110° C )
Water: ( 2 Total ) 1 at temp. :
1 at temp. :
160° F ( 70° C )
Oil: ( 1 Total )
203° F ( 95° C )
180° F ( 82° C )
Coolant Temperature
176° - 185° F ( 80° - 85° C )
Electrical System
12-volt Negative ( – ) Ground
Alternator Rating
949W, 14.6v, 65A
Recommended Battery Rating
Starter
750 cca, 950 mca, or 180 Ah
12v, 2.7 kW
1
Power rated in accordance with NMMA Procedure - ISO 3046 (Technically Identical to ICOMIA 28-83).
2
Refer to “Conditions Affecting Operation - Propeller Selection” for additional information.
25
CE230
1
3
71856
2
4
71856
71856
5
71856
7A
73547
72753
73546
6
71772
8
26
7B
73547
CE21
Operation
CE287
Quicksilver Instruments and Instrumentation
Shown is the basic Quicksilver instrumentation and engine system monitor display for the Diesel Power Package. The instrumentation shown is required for safe operation of boat and engine. Operator should become familiar with all instrumentation before operating the engines.
Gauges and engine system monitor panel may be individually mounted, or collectively mounted in the optional
single panel available from Quicksilver.
NOTE: Refer to manufacturer’s instructions and explanations about instrumentation, if equipped with other than
Quicksilver instrumentation.
1 Oil Pressure Gauge - indicates engine oil pressure. Refer to “Specifications” for normal operating readings.
2 Tachometer - indicates engine speed (RPM).
3 Coolant Temperature Gauge - indicates engine coolant temperature. Refer to “Specifications” for normal
operating readings.
4 Cruise Log (Engine Hour Meter) - records engine running time.
5 Voltmeter- indicates battery voltage, and if alternator and charging circuit are functioning properly. The green
area on the gauge is the normal operating range.
6 Audio Warning Buzzer Standard Features - Buzzer sounds if:
(1) Cooling system temperature too high
(2) Oil pressure is too low
(3) Transmission fluid temperature is excessive
7 Key Switch - has three positions. In the “OFF” position, all electrical circuits are off and engine cannot be
started. In the “RUN” position, all electrical circuits, indicator lamps, automatic preheating (if so equipped) and
all instruments are operational. In the “START” position the engine can be started.
NOTE: Key can only be removed in the “OFF” position.
A D3.6L and D4.2L - If engine is running the key switch cannot be used to stop engine. The engine can only
be stopped by using the Engine Stop Switch, while the Key Switch is in the “RUN” position. No electrical circuit
is operational when the key switch is turned to the “OFF” position.
B D2.8L D-Tronic and D4.2L D-Tronic - The engine is stopped when the key switch is turned to the “OFF” position.
8 Engine Stop Switch - D3.6L and D4.2L - is used to stop the engine. This is done by electrically shutting off
fuel delivery system. Stop Switch is toggled “DOWN” and held until engine stops completely. Then, key switch
can be turned to the “OFF” position.
27
CD491
E
D
C
B
A
1
2
3
71722
71891
71891
CE288
1 Engine System Monitor Features - The appropriate light functions as follows:
A Preheat Indicator Lamp - lights up when the glow plugs, if so equipped, are preheating the combustion chambers. The light stays on until the preheat period is complete. The timed preheat period begins when the key
switch is turned on, and then, only when the engine is cold. On D3.6L and D4.2L models, the engine can be
started only after the light goes out.
B Charge Indicator Lamp - indicates a problem with charging system if lamp illuminates while engine is running.
Lamp will light when key switch is “ON” and engine is not running. When engine starts, light should go off.
C Oil Pressure Warning Lamp - indicates low engine oil pressure if lamp illuminates while engine is running.
D Coolant Temperature Warning Lamp - indicates excessive engine coolant temperature if lamp illuminates
while engine is running, or transmission fluid temperature is too high (See the following note).
NOTE: The audio warning buzzers are wired in a parallel circuit. If a buzzer sounds while engine is running,
check coolant temperature and coolant level or this may be an indication of excessive transmission temperature.
The cause should be determined and corrected.
E Malfunction Indicator Lamp (MIL) D2.8L D-Tronic and D4.2L D-Tronic Only - additional lamp indicates when
a problem exists that requires service if lamp illuminates while engine is running.
2 Panel Lights/Audio Test Switch - has three positions; in the normal position all electrical circuits operate
in a standard fashion (as described above). With switch toggled “UP” the instrumentation lights are all illuminated. When the switch is toggled “DOWN” the audio warning buzzer will sound allowing the operator to perform
a test of the audio warning buzzer.
3 20 Amp Fuse and Holder - located in-line on key switch power supply wire and protects the Instrumentation
and wiring should an electrical overload occur. If an overload occurs, the fuse will burn out. Check “blown”
(burned) fuse if key is turned to RUN or START and nothing happens.
IMPORTANT: Cause for overload must be determined and corrected before attempting to install new
fuse or fuse failure will occur again.
After cause is corrected, install new fuse and check systems to function.
28
CE312
2
73546
71856
1
75301
CE289
Electrical System Overload Protection
If an electrical overload occurs, a fuse will blow or a circuit breaker will trip open.
IMPORTANT: The cause must be found and corrected before replacing fuse or resetting circuit breaker.
1 Two 60 amp circuit breakers provide protection for engine wiring harness and instrumentation power lead.
Reset by pushing RESET button IN (on outside).
In an emergency, when engine must be operated and cause for high current draw cannot be located and corrected, turn OFF or disconnect all accessories connected to engine and instrumentation wiring. Reset circuit
breaker. If breaker remains open, electrical overload has not been eliminated. Further checks must be made on
electrical system.
2 When equipped with Quicksilver instrumentation and wiring a 20 amp fuse and holder is located in-line on
key switch power supply wire and protects the Instrumentation and wiring should an electrical overload occur.
If an overload occurs, the fuse will burn out. Check “blown” (burned) fuse if key is turned to RUN or START and
instruments do not work and/or if switches do not function.
29
CE143
1
5
2
3
73866
4
9
7
6
8
70537
71339
30
CE157
Remote Controls (Panel Mounted)
Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an
integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features
shown.
NOTE: If boat is equipped with a remote control other than shown, consult your dealer for a description and/or
demonstration of the control.
1 Neutral Lock Bar - Prevents accidental shift and throttle engagement. Neutral lock bar must be pulled “Up”
to move the control handle out of neutral.
2 Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the
remote control handle is in the “Neutral” position, and should only be used to assist in starting the engine.
3 Lanyard Stop Switch - Turns ignition “Off” whenever the operator (when attached to the lanyard) moves far
enough away from the operator’s position to activate the switch. See “Lanyard Stop Switch” at the front of this
manual for safety warning on the use of this switch.
4 Control Handle Tension Adjustment Screw - This screw can be adjusted to “Increase” or “Decrease” the
tension on the control handle. This will help prevent “Creep” of the remote control handle. Turn screw “Clockwise”
to increase tension and “Counterclockwise” to decrease tension. Adjust to tension desired.
5 Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
“Push” the control handle forward from “Neutral” with a quick firm motion to the first detent for “Forward” gear.
Continue pushing forward to increase speed. Pull the control handle back from “Neutral” with a quick firm motion
to the first detent for “Reverse” gear. Continue pushing back to increase speed.
CE158
Remote Controls (Two Lever)
Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an
integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features
shown.
NOTE: If boat is equipped with a remote control other than shown, consult your dealer for a description and/or
demonstration of the control.
6 Shift Lever - shifts unit into gear with full lever movement. Move lever forward to shift to FORWARD gear.
Move lever backward to shift to REVERSE gear. Lever in full vertical position shifts to NEUTRAL.
! CAUTION
Never shift unit into or out of gear unless throttle lever is at idle RPM.
7 Throttle Lever - allows engine RPM to be increased or decreased.
8 FRICTION Screw - adjusts control handle friction so motor speed can be set and driver does not have to hold
handle.
Turn screw clockwise to increase friction. Do not thread screw all the way out.
9 DETENT Screw - controls the effort needed to move control handle out of NEUTRAL. To increase tension,
turn screw clockwise; to decrease, turn screw counterclockwise. Do not thread screw all the way out.
IMPORTANT: Boats equipped with dual power packages may have both shift levers on one control and
both throttle levers on the other control.
31
CC200
3
2
1
3
2
1
32
CE159
Remote Controls (Console Mounted)
Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an
integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features
shown.
NOTE: If boat is equipped with a remote control other than shown, consult your dealer for a description and/or
demonstration of the control.
1 Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the
remote control handle is in the “Neutral” position, and should only be used to assist in starting the engine.
2 Control Handle Tension Adjustment Screw - This screw can be adjusted to “Increase” or “Decrease” the
tension on the control handle (cover must be removed to adjust). This will help prevent “Creep” of the remote
control handle. Turn screw “Clockwise” to increase tension and “Counterclockwise” to decrease tension. Adjust
to tension desired.
3 Control Handle(s) - Operation of the the shift and throttle 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 speed. Pull the control handle back from “Neutral” with a quick firm motion
to the first detent for “Reverse” gear. Continue pushing back to increase speed.
33
CE295
2
1
71386
3
75654
CD480
Starting, Shifting and Stopping - D3.6L and D4.2L
NOTE: Does not include engines equipped with D-Tronic fuel injection.
! WARNING
Do not use volatile starting aids, such as Ether, Propane, or Gasoline in the engine air intake system.
Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury
and engine damage.
! CAUTION
It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant.
1 Cold Start Lever - located on the injection pump is used to aid in starting when the temperature is below 50°
F (10° C). This is done by moving lever in direction shown. Lever should be reset as soon as engine starts and
idles smoothly.
2 Mechanical Engine Stop Lever - located on the injection pump is used to manually shut off engine by cutting
off the fuel supply. It can be engaged by moving the lever in the direction shown.
BEFORE STARTING THE ENGINE
IMPORTANT: As an added precaution, the following steps must be observed before starting:
• Do not start engine without water being supplied to seawater pickup pump (to prevent pump or engine damage).
• Never operate the starter motor longer than 15 seconds at a time, to avoid overheating the starter motor. If engine does not start, wait 1 minute to allow the starter motor to cool; then, repeat starting procedure.
• Be sure engine crankcase is filled to correct level with the proper grade of oil for the prevailing temperature. Refer to “Specifications - Crankcase Oil”.
• Be sure that all electrical connections are secure.
• Check the air cleaner for proper installation of filter element.
3 Check all items listed in the MAINTENANCE SCHEDULES and OPERATION CHART - D3.6L and D4.2L.
Refer to “Table Of Contents”.
4 Perform any other necessary checks, as indicated by your dealer, or specified in your boat owner’s manual.
34
CD339
STARTING COLD ENGINE
IMPORTANT: Always check all fluid levels before starting engine. Refer to Maintenance Chart.
1 Turn on and run engine compartment bilge blower (if so equipped) for five minutes. Or, open engine hatch
to air out bilge before attempting to start engine(s).
2 Set “Cold Start Lever” if temperature is below 50° F (10° C).
NOTE: Reset when engine idles smoothly.
3 If engine has not been run for a period of time and will not readily start with the standard starting procedure,
there is a hand pump/primer knob located on the fuel filter header. Move knob up and down four or five strokes.
4 Pre-lubricate engine, if required. To do this, hold the “STOP” switch toggle lever DOWN while you simultaneously turn the key switch to “START” position for 15 seconds. This will rotate the starter motor and engine/oil
pump. During this process the engine will not run because no fuel is injected. Allow the starter motor to cool down
for one minute and repeat the above described process. To avoid overheating the starter motor, do not engage
starter motor for more than 15 seconds each time. Refer to “Before Starting the Engine” as previously outlined.
5 Turn key switch to the “RUN” position. Observe indicator lamp for glow plugs. When cylinder temperature is
great enough to sustain combustion, the indicator lamp will cease to be lighted and the engine can be started.
6 Turn key switch to “START” position and release when engine fires. Check to ensure charge indicator and
oil pressure warning lamps go out.
! CAUTION
Improper or no warm-up of engine can seriously impair the Iife of your diesel engine.
7 Run engine at Idle RPM until engine temperature is within normal operating range.
! CAUTION
Never attempt to shift unit unless engine is at idle RPM. Damage to drive unit could occur.
8 Check to ensure all instrumentation is functioning properly and indicating normal readings.
CE31
ENGINE WARM UP
! CAUTION
Improper or no warm-up of engine can seriously impair the Iife of your diesel engine.
9 After starting, check to ensure all instrumentation is functioning properly. Run engine at idle RPM until engine
temperature is within normal operating range. It is very 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.
NOTE: Engine warm-up time during cold weather can be reduced by operating vessel at reduced engine speed.
Commence normal vessel operation when systems reach operating temperatures.
10 After the engine has reached operating temperature, oil pressure should be within range listed in the engine
specifications chart. Stop the engine if oil pressure is not within this range. Locate and correct the problem, or
see your Authorized MerCruiser Dealer if you are unable to determine the problem.
35
CD340
STARTING WARM ENGINE
1 Turn on and run engine compartment bilge blower for five minutes (if so equipped). Or, open engine hatch
to air out bilge before attempting to start engine(s).
2 Turn key switch to the “RUN” position.
3 Turn key switch to “START” position and release when engine fires. Check to ensure charge indicator and
oil pressure warning lamps go out.
! CAUTION
Improper or no warm-up of engine can seriously impair the Iife of your diesel engine.
4 Check to ensure all instrumentation is functioning properly and indicating normal readings.
CE33
SHIFTING
! CAUTION
Never attempt to shift unit unless engine is at idle RPM. Damage to drive unit could occur.
1 To shift unit, be sure remote control/throttle lever is in NEUTRAL. Move control/shift lever with a firm, quick
motion forward to shift to FORWARD gear, or backward to shift to REVERSE. After shifting drive unit, advance
throttle to desired setting.
2 Once underway, engine oil pressure should be within the range listed in the engine specifications chart at
maximum RPM, or Wide-Open-Throttle. Stop the engine if oil pressure is not within this range. Locate and correct the problem, or see your Authorized MerCruiser Dealer if you are unable to determine the problem.
CB575
IMPORTANT: Avoid stopping engine if the drive unit is in gear. If engine does stop with drive unit in gear,
refer to the following procedure:
3 Push and pull repeatedly on remote control handle until 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.
4 After handle returns to the neutral detent position,resume normal starting procedures.
CD341
ENGINE SHUT-DOWN (STOPPING)
5 Place remote control lever in “Neutral.”
! CAUTION
Avoid damaging the turbocharger and engine. Immediate engine shutdown (stopping) after high load
operation may resulting in permanent turbocharger bearing damage. Operate the engine at IDLE for several minutes before shut-down.
6 Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool.
7 Toggle STOP switch “Down” and hold, until engine stops completely.
8 Turn key switch to the “OFF” position.
36
CD496
Operation Chart - D3.6L and D4.2L
STARTING
PROCEDURE
AFTER
STARTING
WHILE
UNDERWAY
STOPPING &
SHUT DOWN
Open engine hatch. Air
out bilge completely.
Observe all gauges and
warning lights to check
condition of engine. If not
normal, stop engine.
Frequently observe all
gauges and indicator
lights to monitor engine
condition.
Shift remote control lever
to neutral position.
Turn battery switch ON,
if so equipped.
Check for fuel, oil, water,
fluid, and exhaust leaks,
etc.
Run engine at idle speed
several minutes to allow
the turbocharger and
engine to cool.
Turn on and run engine
compartment bilge blower, if so equipped, for five
minutes.
Check shift and throttle
control operation.
Toggle STOP switch
“Down” and hold, until
engine completely
stops.
Check for leaks - fuel, oil,
water, fluid, etc.
Check steering operation.
Turn key switch to OFF
position.
Open fuel shut-off valve,
if so equipped.
Turn battery switch OFF,
if so equipped.
Open seacock, if so
equipped.
Close fuel shut-off valve,
if so equipped.
Check that mechanical
engine-stop lever is not
engaged.
Close seacock, if so
equipped.
Prime fuel injection system, if necessary.
Flush seawater cooling
circuit, if operating in
saltwater area.
Pre-lubricate turbocharger and engine, if necessary.
Turn key switch to “RUN”
and check that lights and
indicator lamps come
on.
Turn key switch to
START, after the indicator lamp for glow
plugs (if so equipped)
ceases. Release key
when engine starts.
Check that charge indicator and oil pressure indicator lamps cease AFTER
engine starts.
Warm-up engine at idle
RPM for several minutes.
37
CE296
1
75301
75654
CE297
Starting, Shifting and Stopping - D2.8L D-Tronic and D4.2L D-Tronic
! WARNING
Do not use volatile starting aids, such as Ether, Propane, or Gasoline in the engine air intake system.
Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury
and engine damage.
! CAUTION
It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant.
BEFORE STARTING THE ENGINE
IMPORTANT: As an added precaution, the following steps must be observed before starting:
• Do not start engine without water being supplied to seawater pickup pump (to prevent pump or engine damage).
• Never operate the starter motor longer than 15 seconds at a time, to avoid overheating the starter motor. If engine does not start, wait 1 minute to allow the starter motor to cool; then, repeat starting procedure.
• Be sure engine crankcase is filled to correct level with the proper grade of oil for the prevailing temperature. Refer to “Specifications - Crankcase Oil”.
• Be sure that all electrical connections are secure.
• Check the air cleaner for proper installation of filter element.
1 Check all items listed in the MAINTENANCE SCHEDULES and OPERATION CHART - D2.8L D-Tronic and
D4.2L D-Tronic (Refer to “Table Of Contents”).
2 Perform any other necessary checks, as indicated by your dealer, or specified in your boat owner’s manual.
38
CE298
STARTING COLD ENGINE
IMPORTANT: Always check all fluid levels before starting engine. Refer to Maintenance Chart.
1 Turn on and run engine compartment bilge blower (if so equipped) for five minutes. Or, open engine hatch
to air out bilge before attempting to start engine(s).
2 If engine has not been run for a period of time and will not readily start with the standard starting procedure,
there is a hand pump/primer knob located on the fuel filter header. Move knob up and down four or five strokes.
Attempt to start engine following normal procedure.
3 Turn key switch to the “RUN” position. Observe indicator lamp for glow plugs, if so equipped. When cylinder
temperature is great enough to sustain combustion, the indicator lamp will cease to be lighted and the engine
can be started.
4 Turn key switch to START position. Release key when engine starts and allow switch to return to RUN position.
5 Check to ensure all instrumentation is functioning properly and indicating normal readings. Check to ensure
charge indicator and oil pressure warning lamps go out. Within seconds after starting the engine, oil pressure
should exceed 10 psi (69 kPa) minimum. If the oil pressure does not meet these minimum limits, stop the engine,
locate and correct the problem, or see your Authorized MerCruiser Dealer if you are unable to determine the
problem.
! CAUTION
Do not increase the engine speed until the oil pressure gauge indicates normal. Shut the engine down
if oil pressure does not register on the gauge within 20 to 30 seconds after start.
CE31
ENGINE WARM UP
! CAUTION
Improper or no warm-up of engine can seriously impair the Iife of your diesel engine.
1 After starting, check to ensure all instrumentation is functioning properly. Run engine at idle RPM until engine
temperature is within normal operating range. It is very 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.
NOTE: Engine warm-up time during cold weather can be reduced by operating vessel at reduced engine speed.
Commence normal vessel operation when systems reach operating temperatures.
2 After the engine has reached operating temperature, oil pressure should be within range listed in the engine
specifications chart. Stop the engine if oil pressure is not within this range. Locate and correct the problem, or
see your Authorized MerCruiser Dealer if you are unable to determine the problem.
39
CE32
STARTING WARM ENGINE
1 Turn on and run engine compartment bilge blower for five minutes (if so equipped). Or, open engine hatch
to air out bilge before attempting to start engine(s).
2 Turn key switch to the “RUN” position. Check to ensure glow plug preheat lamp is not illuminated.
3 Turn key switch to the “START” position and release when engine fires. Check to ensure charge indicator and
oil pressure warning lamps go out.
4 Check to ensure all instrumentation is functioning properly and indicating normal readings. Oil pressure
should be within the range listed in the engine specifications chart. Stop the engine if oil pressure is not within
this range. Locate and correct the problem, or see your Authorized MerCruiser Dealer if you are unable to determine the problem.
CE33
SHIFTING
! CAUTION
Never attempt to shift unit unless engine is at idle RPM. Damage to drive unit could occur.
5 To shift unit, be sure remote control/throttle lever is in NEUTRAL. Move control/shift lever with a firm, quick
motion forward to shift to FORWARD gear, or backward to shift to REVERSE. After shifting drive unit, advance
throttle to desired setting.
6 Once underway, engine oil pressure should be within the range listed in the engine specifications chart at
maximum RPM, or Wide-Open-Throttle. Stop the engine if oil pressure is not within this range. Locate and correct the problem, or see your Authorized MerCruiser Dealer if you are unable to determine the problem.
CB575
IMPORTANT: Avoid stopping engine if the drive unit is in gear. If engine does stop with drive unit in gear,
refer to the following procedure:
7 Push and pull repeatedly on remote control handle until 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.
8 After handle returns to the neutral detent position,resume normal starting procedures.
CD366
ENGINE SHUT-DOWN (STOPPING)
9 Place remote control lever in “Neutral.”
! CAUTION
Avoid damaging the turbocharger and engine. Immediate engine shutdown (stopping) after high load
operation may resulting in permanent turbocharger bearing damage. Operate the engine at IDLE for several minutes before shut-down.
10 Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool.
11 Turn key switch to the “OFF” position.
40
CD346
Operation Chart - D2.8L D-Tronic and D4.2L D-Tronic
STARTING
PROCEDURE
AFTER
STARTING
WHILE
UNDERWAY
STOPPING &
SHUT DOWN
Open engine hatch. Air
out bilge completely.
Observe all gauges and
warning lights to check
condition of engine. If
not normal, stop engine.
Frequently observe all
gauges and indicator
lights to monitor engine
condition.
Shift remote control lever to neutral position.
Turn battery switch ON,
if so equipped.
Check for fuel, oil, water,
fluid, and exhaust leaks,
etc.
Run engine at idle speed
several minutes to allow
the turbocharger and
engine to cool.
Turn on and run engine
compartment bilge blower, if so equipped, for five
minutes.
Check shift and throttle
control operation.
Turn key switch to OFF
position.
Check for leaks - fuel,
oil, water, fluid, etc.
Check steering operation.
Turn battery switch, if so
equipped, to OFF.
Open fuel shutoff valve,
if so equipped.
Close fuel shutoff valve,
if so equipped.
Open seacock, if so
equipped.
Close seacock, if so
equipped.
Prime fuel injection system, if necessary.
Flush seawater cooling
circuit, if operating in saltwater area.
Turn key switch to
“RUN” and check that
lights and indicator
lamps come on.
Turn key switch to START,
after the indicator lamp for
glow plugs (if so equipped)
ceases. Release key
when engine starts.
Check
that
charge
indicator and oil pressure
indicator lamps cease
AFTER engine starts.
Warm-up engine at idle
RPM for several minutes.
41
CD10
Maintenance
CE102
5
2
4
1
2
4
3
71893
CE303
General Information
! WARNING
Always disconnect battery cables from battery before working around electrical system components
to prevent injury to yourself or damage to electrical system.
! WARNING
Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire. This
eliminates the engine wiring as a potential source of ignition.
IMPORTANT: Refer to MAINTENANCE SCHEDULES for complete listing of all scheduled maintenance
to be performed. Some listings can be done by owner/operator, while others should be performed by
an Authorized MerCruiser Dealer. Before attempting maintenance or repair procedures not covered in
this manual, it is recommended that a MerCruiser Maintenance Procedures Manual or Service Manual
be purchased and read thoroughly.
NOTE: Maintenance points are color coded for ease of identification. See the decal on engine for identification.
CE291
Maintenance Aids
1 Hurth and Velvet Drive Transmissions - Dexron III automatic transmission fluid (ATF). Add fluid at dipstick hole.
2 All pivot points - SAE 30W motor oil.
3 All Exterior Surfaces - Quicksilver Primer and Spray Paint, as needed, and Quicksilver Corrosion Guard.
4 Crankcase Oil - API rating of SH, CF/CF-2 required. (Refer to “Specifications” for list of approved oils.)
5 Closed Cooling System Coolant - use only recommended engine coolant. Refer to “Engine Coolant.”
42
CE235
Maintenance Schedules
! WARNING
Always disconnect battery cables from battery BEFORE working around electrical system components
to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted.
SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR
NOTE: Only perform maintenance which applies to your particular power package.
Task
Engine Crankcase Oil - Check level.
Fuel Filter - Drain
Seawater Strainer - Check / Clean
Water Pickups - Check for marine growth or debris.
Interval
Before Use
Before Use and Whenever Insufficient Seawater
Suspected
operating
temperature
Flow is Sus
ected (if o
erating tem
erature
exceeds normal range.)
Closed Cooling Coolant - Check level.
Transmission Fluid - Check level
Weekly
Battery - Check level and inspect for damage.
Air Filter - Clean
Every 50 hours of operation or as conditions require.
Drive Belts (All) - Inspect condition and check tension. Every
y 100 hours of operation or 120 days,
y whichever
occurs first.
Fuel Filter - Replace.
Saltwater Use: Every 50 hours of operation or 60
Power Package Exterior Surfaces - Spray with rust days, whichever occurs first.
Freshwater Use: Every 100 hours of operation or 120
preventative.
days, whichever occurs first.
Sacrificial Anode (in intercooler) – Check and replace
when over 50% eroded.
Sacrificial Anode (in heat exchanger) – Check and
replace when over 50% eroded.
Once a year
Power Package Exterior Surfaces - Clean and paint.
Cooling System - Flush seawater section.
Saltwater Use: After every use.
43
CE333
SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED BY A DEALER
NOTE: Only perform maintenance which applies to your particular power package.
Task
Interval
Seawater Pickup Pump - Disassemble and inspect.
Whenever insufficient seawater flow is suspected, if
operating temperature exceeds normal range.
Cylinder Heads - Retorque.
After First 100 Hours of Operation, but Not Later Than
150 Hours of Operation.
Crankcase Oil and Filter - Change.
After 20-Hour Break-In Period, then, for
Pleasurecraft Use: Every 100 Hours of Use or 120
Days, Whichever Occurs First ; and for Light Duty
Use: Every 50 Hours of Use or 60 Days, Whichever
Occurs First
Flame Arrestor and Crankcase Ventilation Hose Clean and inspect.
Transmission Fluid - Change.
Cooling System - Clean and inspect.
Engine Alignment - Check.
Electrical System - Check for loose or damaged
wiring.
Cooling System Hoses and Clamps - Inspect for
damage and deterioration. Check clamps for End of first boating season and thereafter, every100
hours of operation or once yearly, whichever occurs
tightness.
first
first.
Closed Cooling System Pressure Cap - Clean,
inspect and test .
Engine Exhaust System - Inspect externally for
damage, deterioration and restrictions. Check for
tightness.
Shift and Throttle Cable and Linkage - Lubricate and
inspect for loose, damaged or missing parts.
Steering Head and Remote Control - Inspect and
lubricate.
Fuel Filter(s) - Replace.
Closed Cooling Coolant - Test for Alkalinity
Once a Year
Heat Exchanger - Clean seawater section.
Clean Aftercooler Core.
Every 500 Hours Of Operation.
Clean Fuel Tank.
Every 1000 Hours Of Operation.
Closed Cooling
Replace.
44
System
Anti-Freeze/Coolant
- Every Two Years Or 200 Hours Of Operation,
Whichever Occurs First.
THIS PAGE IS INTENTIONALLY BLANK
45
CE292
2
71380
1
71382
3B
3A
75301
73322
B
4
B
A
71383
46
5
73250
A
CD481
Checking Fluid Levels
CRANKCASE OIL
! CAUTION
Avoid possible injury or damage to oil dipstick and internal engine components. Do not remove crankcase oil dipstick when engine is running. Stop the engine completely before removing or inserting dipstick.
Check engine oil daily before first start-up.
If it becomes necessary to check oil level during operation, stop engine and allow 5 minutes for oil to drain into
pan.
1 Remove dipstick. Wipe clean and reinstall into dipstick tube.
2 Remove dipstick and observe oil level. Oil must be between MIN and MAX marks on dipstick. If necessary,
add oil as follows.
3 Remove oil filler cap. Add specified oil to bring level up to, but not over, “MAX” mark on dipstick. Reinstall oil
filler cap.
A D3.6L and D4.2L
B D2.8L D-Tronic and D4.2L D-Tronic
CE293
TRANSMISSION FLUID
4 Hurth Transmissions - Dipstick has neoprene seal - twist and pull to remove. Push handle down and seat fully;
to check fluid level. Fluid must be between marks A and B on dipstick.
A MAXIMUM Fluid Level - top line. Fill to this level; do not overfill.
B MINIMUM Fluid Level - do not allow fluid level to drop below this line.
5 Velvet Drive Transmissions - Dipstick has neoprene seal - twist and pull to remove. Push handle down and
seat fully; to check fluid level. Fluid must be between marks A (“FULL HOT” mark) and B on dipstick.
A MAXIMUM Fluid Level (FULL HOT) - top line. Fill to this level; do not overfill.
B MINIMUM Fluid Level - do not allow fluid level to drop below this line.
47
CE294
1
71381
73322
2
72714
3
73320
48
CD166
ENGINE COOLANT
1 Before starting engine, check coolant level in coolant recovery bottle. Coolant level must be between the
“ADD” and “FULL” marks (on front of bottle). If level is low, remove fill cap from coolant recovery bottle and add
specified coolant as required. Refer to “Specifications” for proper coolant.
! WARNING
Do not remove coolant tank cap when engine is hot. Coolant may discharge violently, causing severe
burns.
2 If coolant level in coolant recovery bottle was low:
• Inspect coolant recovery system for leaks.
• Inspect coolant tank cap gaskets for damage and replace if necessary.
• Also, the tank cap maintains pressure on the coolant tank. It may not be holding pressure properly. To have
cap tested, contact your Authorized MerCruiser Dealer.
! CAUTION
If the coolant should get extremely low and the engine very hot, let the engine cool for approximately
15 minutes before adding coolant; then, with the engine running, add coolant slowly. Adding cold coolant to a hot engine may crack the cylinder head or crankcase. Never use water alone.
3 Periodically, to ensure that coolant recovery system is functioning properly, you should allow engine to cool
and then slowly and carefully remove coolant tank cap. Coolant level must be to the bottom edge of the tank filler
neck. If coolant is low, add specified coolant as necessary to bring up to proper level. Refer to items 1 and 2
above.
49
CE301
2
3
2
71374
71261
71780
1
1
70355
3
70062
75332
A
B
F
C
4
73522
E
D
1
50
71362
4
71366
CE58
Cleaning Quicksilver Seawater Strainer
NOTE: Refer to manufacturers instructions if equipped with other than a Quicksilver seawater strainer.
! CAUTION
When cleaning seawater strainer, close seacock, if so equipped. If boat is not equipped with a seacock,
remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater
to flow from the drain holes or removed hoses.
1 With engine off, close seacock if so equipped, or remove and plug seawater inlet hose. Remove 2 screws
and washers (A), and cover (B). Remove strainer (C), and drain plug and washer (D), and clean any debris from
strainer housing; flush both strainer and housing (E) with clean water. Check gasket (F) - replace when necessary (if it leaks). Reinstall drain plug and washer. Reattach cover with screws and washers. Prior to starting engine, open seacock if so equipped, or remove plug from seawater inlet hose and reconnect. Tighten hose clamps
securely. After starting engine, check for leaks, and/or air in system (which would indicate an external leak).
CE55
Lubrication
SHIFT CABLE
2 Lubricate pivot points with SAE 30W motor oil.
CA73
THROTTLE CABLE
3 Lubricate pivot points with SAE 30W motor oil .
CB66
Seawater Pump Impeller
This maintenance should be performed by an Authorized MerCruiser Dealer.
4 Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected (if operating
temperature exceeds normal range).
CE56
Flushing Fuel Tank
5 Flush and clean diesel fuel tank (every 1000 hours, maximum) following boat manufacturer’s instructions.
51
CE110
1,2
1,2
70355
73522
1,2
70062
3
52
73320
CE302
Flushing Seawater Cooling System
To prevent silt and/or salt buildup in the seawater circuit of cooling system, flush with freshwater at specified Intervals.
! CAUTION
When flushing seawater cooling system, close seacock, if so equipped. If boat is not equipped with a
seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing
seawater to flow from the drain holes or removed hoses.
! WARNING
When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid
possible injury, remove propeller.
! CAUTION
Do not run engine above 1500 RPM when flushing. Suction created by seawater pickup pump may collapse flushing hose, causing engine to overheat.
! CAUTION
Watch temperature gauge on dash to ensure that engine does not overheat.
! CAUTION
If boat is in the water, or is to remain in the water, seacock, if so equipped, must be closed until engine
is to be restarted, to prevent contaminated water from flowing back into cooling system. If boat is not
fitted with a seacock, water inlet hose must be disconnected and plugged to prevent contaminated water
from flowing into cooling system and/or boat. As a precautionary measure, attach a tag to the ignition
switch warning that the seacock must be opened or the water inlet hose reconnected prior to starting
the engine.
1 Close seacock, if so equipped, or disconnect and plug seawater inlet hose. Disconnect water inlet hose from
seawater pickup pump connection. Using appropriate flushing adaptor, connect water hose between adaptor
and water tap. Partially open water tap (about 1/2 maximum).
2 Place remote control in NEUTRAL, idle speed position and start engine. Operate engine at idle speed, in
NEUTRAL, for about 10 minutes, or until discharge water is clear. Stop engine. Shut off water, remove flushing
adaptor from seawater pump inlet hose connection and reconnect water inlet hose. Tighten hose clamp securely.
3 The closed cooling section of cooling system that contains coolant does not need to be flushed. Coolant is
changed at specified intervals. Refer to “Maintenance Schedules.”
53
CD394
2
3
1
71444
74726
a
b
4
54
71371
5
74726
CE61
Fuel System
! CAUTION
Absolute cleanliness is required for work on the fuel system, since the injection pump and fuel injectors
have very close tolerances. Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system.
FUEL TANK
IMPORTANT: Diesel fuel should not be left in tank during winter storage, as an accumulation of rust,
sludge and wax residue will form.
1 Fuel tank should be cleaned at specified intervals. Refer to boat manufacturer’s instructions.
CD283
HAND PUMP/PRIMER
2 A plunger-type of hand pump/primer is located on the fuel filter bracket and is used to: (1) refill fuel system
if system was run dry; (2) refill fuel filter when changing filter; or (3) to prime the fuel system if engine has not
been run for a while. To operate the hand pump/primer, move the plunger (upper portion) up and down as needed.
CE63
PRIMING FUEL SYSTEM
Prime engine if it has not been run for a while or if engine will not start. Move the hand pump/primer plunger up
and down several times as previously outlined. Attempt to start engine.
CD284
FILLING FUEL FILTER
NOTE: Follow this procedure after installing new filter or if fuel has been drained from filter checking for water.
3 Loosen bleed screw on fuel filter bracket. As previously outlined, move plunger on hand pump/primer up and
down repeatedly, until an air free stream of fuel flows from bleed screw. Filter is full when this occurs. Tighten
bleed screw.
CD504
FILLING (BLEEDING) FUEL SYSTEM
NOTE: Follow this procedure if fuel system was run dry or if part of fuel system was drained for a service function.
Fill fuel system up to the point that fuel filter is full following previous procedure (Filling Fuel Filter); then, ensure
that bleed screw on fuel filter bracket is closed.
4 On D3.6L and D4.2L Only: Loosen, DO NOT REMOVE, bleed screw on fuel injection pump (located between
fuel line connection fittings on injection pump). Continue to repeatedly move plunger on hand pump/primer, until
an air-free stream of fuel flows from injection pump bleed screw. Tighten bleed screw.
CD286
DRAINING WATER SEPARATING FUEL FILTER
! WARNING
Be careful when draining water separating fuel filter. Diesel fuel is flammable. Be sure ignition key is OFF.
Do not allow fuel to contact any hot surfaces which may cause it to ignite. Do not allow sources of open
flame in the area. Wipe up any spilled fuel immediately. Dispose of fuel soaked rags, paper, etc. in an
appropriate air tight, fire retardant container. Fuel soaked items may spontaneously ignite and result in
a fire hazard which could cause serious bodily injury or death.
5 The filter (A) can be drained of water and small dirt particles by opening drain cock at bottom of filter. Open
by turning the drain (B) counterclockwise (as viewed from the bottom of the filter). Drain until fuel is clear in appearance. Close drain by turning clockwise. Tighten securely. Fill fuel filter as previously outlined.
NOTE: To ensure complete draining, in warm weather open the water bleed valve 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.
55
CD483
C
A
D
B
2
1
74731
74732
A
B
2
71367
2
73327
2
56
71368
CD484
REPLACING WATER SEPARATING FUEL FILTER
! CAUTION
Any water entering the fuel injection system will disable the system. Check for water in water separating
fuel filter before startup, daily.
! CAUTION
If water should enter the fuel injection system, take unit to an Authorized MerCruiser Dealer
IMMEDIATELY, so that corrosion and rusting of the injectors and other components can be avoided.
! WARNING
Be careful when changing water separating fuel filter. Diesel fuel is flammable. Be sure ignition key is
OFF. Do not allow fuel to contact any hot surfaces which may cause it to ignite. Do no tallow sources
of open flame in the area. Wipe up any spilled fuel immediately. Dispose of fuel soaked rags, paper, etc.
in an appropriate air tight, fire retardant container. Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death.
1 Replace as follows:
A Twist locking ring by hand. Remove water separating fuel filter and sealing ring from mounting bracket.
Do not use a filter wrench.
B Remove the drain cap and O-ring from bottom of the existing filter. Install on new filter.
C Coat sealing ring on new filter with clean motor oil.
D Align filter to bracket. Twist locking ring by hand to secure filter to bracket. Do not use a filter wrench.
E Check that bottom drain cap is securely tightened. Fill fuel filter as explained previously. Check filter and
drain cap for fuel leaks.
! WARNING
Make sure no leaks exist before closing engine hatch.
F Start and run engine. Check filter connection for fuel leaks. If leaks exist stop engine immediately. Recheck
filter installation. Contact your Authorized MerCruiser Dealer if leaks continue.
CD119
Corrosion And Corrosion Protection
INTERNAL COMPONENTS
2 There are anodes as part of the intercooler and heat exchanger systems, which serves as a sacrificial anodes.
Replace when eroded more than 50%; check at least once yearly.
A Length When New - 3/4 in. (19mm)
B Diameter When New - 5/8 in. (15mm)
57
CE126
1
71088
2,3,4
73565
58
CA103
Miscellaneous Maintenance
Battery
1 All lead acid batteries discharge when not in use. Recharge every 30 to 45 days. or when specific gravity drops
below battery manufacturer’s specifications.
Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.
! WARNING
Do not use jumper cables and a booster battery to start engine. Do not recharge a weak battery in the
boat. Remove battery and recharge in a ventilated area away from fuel vapors, sparks or flames.
! WARNING
Batteries contain acid which can cause severe burns - Avoid contact with skin, eyes and clothing Batteries also produce hydrogen and oxygen gasses when being charged. This explosive gas escapes fill/vent
cell caps, and may form an explosive atmosphere around the battery for several hours after it has been
charged; sparks or flames can ignite the gas and cause an explosion which may shatter the battery and
could cause blindness or other serious injury.
Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte.
Hydrogen gases that escape from the battery during charging are explosive. When charging batteries,
be sure area where batteries are located, is well-vented. Battery electrolyte is a corrosive acid and
should be handled with care. lf electrolyte is spilled or splashed on any part of the body, immediately
flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible.
CE281
Bottom Of Boat
2 To maintain maximum speed, the following conditions regarding the boat bottom should be observed:
• Clean, free of barnacles and marine growth.
• Free of distortion, nearly flat where it contacts water.
• Straight and smooth fore and aft.
CC72
Antifouling Paints
3 Antifouling Paint - In some areas it may be advisable to paint bottom of boat to help prevent marine growth.
See your dealer for recommendations for your boat.
CE70
Inspection And Maintenance
4 Inspect and/or maintain the following:
• Inspect power package often, and at regular intervals, to help maintain its top operating performance, and
correct potential problems before they occur. The entire power package should be checked carefully including
all accessible engine parts.
• Check for loose, damaged or missing parts, hoses and clamps; tighten or replace as required.
• Remove and inspect propeller. If badly nicked, bent or cracked, see your dealer.
• Repair nicks and corrosion damage on power package exterior finish. Use Quicksilver spray paints - see your
Authorized MerCruiser Dealer.
• Spray power package components on inside of boat every 2-3 weeks with Quicksilver Corrosion Guard to
protect finish from dulling and corrosion. External power package components may also be sprayed.
• All lubrication points (especially steering system, shift and throttle linkages) should be kept well lubricated.
• Flush seawater cooling circuit periodically (preferably after each use).
59
CA639
Cold Weather Or Extended Storage
Power Package Layup
IMPORTANT: MerCruiser strongly recommends that this service should be performed by an Authorized
MerCruiser Dealer. Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty.
CA115
Battery Winter Storage
Follow battery manufacturer’s instructions for storage.
CD486
Power Package Recommissioning
! WARNING
To prevent possible injury or damage to equipment, do not install battery until all maintenance has been
performed on engine.
1 Check that all cooling system hoses are in good condition, connected properly, and hose clamps are tight.
2 Install seawater pump impeller, as follows:.
IMPORTANT: Use new gasket. Install in correct position - wide surface on side with cam.
• Place impeller in pump and press onto pump shaft firmly.
• Install pump cover, with gasket, and tighten screws securely.
3 Replace fuel filter.
4 Bleed fuel system (see “MAINTENANCE - Fuel System”).
! CAUTION
When installing battery, be sure to connect POSITIVE (+) battery cable to POSITIVE (+) battery terminal
FIRST, and NEGATIVE (–) battery cable to NEGATIVE (–) battery terminal LAST. It battery cables are reversed, or connection order is reversed, electrical system damage will result.
5 Install fully-charged battery. Clean battery cable clamps and terminals and reconnect cables (see CAUTION
listed above). Secure each cable clamp when connecting. Coat terminals with a battery terminal anti-corrosion
spray to help retard corrosion.
6 Perform all checks on OPERATION CHART in the STARTING PROCEDURE column.
IMPORTANT: On D3.6L and D4.2L Engines: After not having been operated for two months or longer,
it is necessary to pre-lubricate the engine. To do this, hold the “STOP” switch toggle lever DOWN while
you simultaneously turn the key switch to “START” position for 15 seconds. This will rotate the starter
motor and engine/oil pump. During this process the engine will not run because no fuel is injected. Allow
the starter motor to cool down for one minute and repeat the above described process. To avoid overheating the starter motor, do not engage starter motor for more than 15 seconds each time.
7 Pre-lubricate the engine if necessary. Refer to above “Important” information. Start engine and closely observe instrumentation to make sure that all systems are functioning correctly.
8 Carefully inspect engine for fuel, oil, fluid, water and exhaust leaks.
9 Check steering system, shift and throttle control for proper operation.
60
CD49
Troubleshooting
CD361
Starter Motor Will Not Crank Engine, Or Cranks It Very Slowly
Possible Cause
• Battery switch turned off
Remedy
• 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 dam-
• Check all electrical connections and wires (especially
aged wiring
• Bad battery
battery cables). Clean and tighten faulty connection.
• Test and replace if bad.
Engine Will Not Start, Or Is Hard To Start
Possible Cause
• Improper starting procedure
Remedy
• Read starting procedure.
• Empty fuel tank or fuel shutoff valve closed
• Faulty mechanical fuel delivery pump
• Fill tank or open valve.
• Have pump replaced by an Authorized Mer-
• Throttle not operating properly
• Faulty electrical stop-circuit
Cruiser Dealer, if fuel is present.
• Check throttle for freedom of movement.
• Have Authorized MerCruiser Dealer service
• Clogged fuel filters
electric stop-circuit.
• Replace filters.
• Stale or contaminated fuel
• If contaminated, drain tank. Fill with fresh fuel.
• Fuel line or tank vent line kinked or
• Replace kinked lines or blow out lines with
clogged
compressed air to remove obstruction.
• Air in fuel injection system
• Purge fuel injection system.
• Glow-plugs or glow-plug system inoperative,
• Test, and repair or replace components
if so equipped
• EDI System fault.
• Have EDI System checked by an Authorized
MerCruiser Dealer.
61
Engine Runs Rough, Misses And/Or Backfires
Possible Cause
Remedy
• Throttle not operating properly
• Check throttle linkages for binding or an obstruction.
• Idle speed too low
• Check idle speed and adjust, if necessary.
• Clogged fuel or air filters
• Replace filters.
• Stale or contaminated fuel
• If contaminated, drain tank. Fill with fresh fuel.
• Kinked or clogged fuel line or fuel tank
• Replace kinked line or blow out line with com-
vent line
pressed air to remove obstruction.
• Air in fuel injection system
• Purge fuel injection system.
• EDI System fault.
• Have EDI System checked by an Authorized
MerCruiser Dealer.
Poor Performance
Possible Cause
• Throttle not fully open
Remedy
• Inspect throttle cable and linkages for operation.
• Damaged or improper propeller
• Replace.
• Excessive bilge water
• Boat overloaded or load improperly dis-
• Drain and check for cause of entry.
• Reduce load or redistribute load more evenly.
tributed
• Boat bottom fouled or damaged
• Clean or repair as necessary.
• EDI System fault.
• Have EDI System checked by an Authorized
MerCruiser Dealer.
62
Excessive Engine Temperature
Possible Cause
• Seacock closed, if so equipped
• Open.
• Drive belt loose or in poor condition
• Replace and/or adjust belt.
• Seawater pickups obstructed
• Remove obstruction.
• Faulty thermostat
• Replace.
• Coolant level low in closed cooling
• Check for cause of low coolant level and repair.
section
• Heat exchanger cores plugged with
foreign material
• Loss of pressure in closed cooling
section
Remedy
Fill system with proper coolant solution.
• Clean seawater side of water/water
heat exchanger, and seawater strainer.
• Check for leaks. Clean, inspect and test pressure cap.
• Closed cooling section dirty
• Clean and flush.
• Faulty seawater pickup pump
• Repair.
• Seawater discharge restricted or plugged
• Clean exhaust elbow.
• Seawater inlet hose kinked (restricted)
• Position hose to prevent kinking (restriction).
• Use of improperly designed hose on inlet side
• Replace hose with wire reinforced design.
of seawater pump allowing it to collapse
Insufficient Engine Temperature
Possible Cause
• Faulty thermostats
Remedy
• Replace.
63
Low Engine Oil Pressure
Possible Cause
• Faulty senders
Remedy
• Have system checked by an Authorized
MerCruiser Dealer.
• Insufficient oil in crankcase
• Check and add oil.
• Excessive oil in crankcase (causing it to
• Check and remove required amount of oil.
become aerated)
• Diluted or improper viscosity oil
Check for cause of excessive oil (improper
filling, bad fuel pump, etc.).
• Change oil and oil filter, using correct grade
and viscosity oil. Determine cause for dilution
(excessive idling, faulty fuel pump, etc.).
Battery Will Not Come Up On Charge
Possible Cause
• Excessive current draw from battery
Remedy
• Turn off non-essential accessories.
• Loose or dirty electrical connections or
• Check all associated electrical connections and
damaged wiring
wires (especially battery cables). Clean and tighten faulty connections. Repair or replace damaged
wiring.
• Alternator drive belt loose or in poor condition
• Replace and/or adjust.
• Unacceptable battery condition
• Test battery.
Remote Control Operates Hard, Binds, Has Excessive Free-play Or Makes Unusual Sounds
Possible Cause
• Insufficient lubrication on shift and throttle
linkage fasteners
• Lubricate.
• Loose or missing shift and throttle linkage
• Check all linkages. If any are loose or missing, see
fasteners
Remedy
Authorized MerCruiser Dealer immediately.
• Obstruction in shift or throttle linkages
• Remove obstruction.
• Shift or throttle cable kinked
• Straighten cable, or have dealer replace
cable if damaged beyond repair.
• Improper shift cable adjustment.
• See Authorized MerCruiser Dealer immediately for shift cable adjustment .
• Vacuum leak at shift cylinder, hose or fittings
of Power Shift Assembly, if so equipped
64
• Repair cut, pinched, or kinked hose or faulty
shift cylinder.
CD54
Warranty Information
CD55
Owner Warranty Registration
UNITED STATES AND CANADA ONLY
• It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the
•
•
•
•
•
factory immediately upon sale of the new product.
It identifies name and address of the original purchaser, product model and serial number(s), date of sale,
type of use and selling dealer’s code, name and address. The dealer also certifies that you are the original
purchaser and user of the product.
Upon receipt of the Warranty Registration Card at the factory, you will be issued a plastic Owner Warranty
Registration Card which is your only valid registration identification. It must be presented to the servicing dealer should warranty service be required. Warranty claims will not be accepted without presentation of this card.
A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It
is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service during this period, present the temporary registration card to the
dealer. He will attach it to your warranty claim form.
Because of your selling dealer’s continuing personal interest in your satisfaction, the product should be returned to him for warranty service.
If your plastic card is not received within 30 days from date of new product sale, please contact your selling
dealer.
The product warranty is not effective until the product is registered at the factory.
•
• NOTICE: Registration lists must be maintained by factory and dealer on marine products sold in the United
States, should notification under the federal boat safety act be required.
65
CD56
International Owner Registration
OUTSIDE THE UNITED STATES AND CANADA
• 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/claim program for your area.
The Warranty Registration Card identifies your name and address, product model and serial number(s), date
of sale, type of use and the selling distributors/dealer’s code number, name and address. The distributor/dealer also certifies that you are the original purchaser and user of the product.
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/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 form(s).
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/dealer If you receive a plastic Warranty Registration Card, you may discard the “Purchaser’s Copy” that
you received from the distributor/dealer when you purchased the product. Ask your distributor/dealer if this
plastic card program applies to you.
For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing, refer to the “International Warranty.” Refer to “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 dealer/distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area.
66
CD488
Warranty Policy
Mercruiser Diesel Limited Warranty
I. We warrant each new production MerCruiser Diesel Sterndrive Power Package, Inboard Engine and
Accessories attached thereto (hereafter referred to as “Product”), manufactured by MerCruiser (hereafter
referred to as the “Company”), to be free from defects in material and workmanship, but only when the
customer purchases or obtains predelivery service from a Dealer authorized by us to distribute MerCruiser
Product in the country in which the sale or predelivery service occurred. This warranty shall apply only to
pleasure craft and light-duty craft applications.
II. This warranty shall become effective upon the date of sale to the first purchaser or user of the Product. The
warranty period for Pleasure Craft applications is one (1) year from date of sale to the first purchaser or
user of the product. The warranty period for Light-Duty Craft applications is one (1) year from date of sale
to the first purchaser or user of the product, or the accumulation of 500 hours of engine operation, whichever
occurs first. The unused period of the applicable warranty, if any, is transferable to subsequent purchasers.
If the law applicable in the Country, State or Province where the product is sold prohibits limitation of
warranty coverage to one (1) year, then the warranty shall be the minimum period required by law. For
purposes of this warranty Pleasure Craft is defined as a recreational planing craft used only and exclusively
for pleasure and recreation. Light-Duty Craft is defined as a planing hull vessel used in any law
enforcement, commercial, or professional entertainment activity, or used in any enterprise or venture in
which revenue in any amount is generated directly or indirectly.
III. To validate the warranty, the “Warranty Registration Card”, included with each Product, must be properly
completed by the selling dealer and forwarded immediately after the sale to Mercury Marine (U.S.A. and
Canada) or to a Marine Power International Branch, or Distributor Service Office (outside the U.S.A. and
Canada).
IV. Purchaser must provide proof of purchase and substantiate the original date of sale by presenting to the
dealer, authorized to service the Product, the original purchaser’s copy of the “Warranty Registration Card”
or the “Owner Warranty Registration Card”. If either of these items is not available, purchaser must provide
a copy of the original purchaser’s “Bill of Sale” (Sales Contract) for the Product to be serviced. Warranty
claims will not be accepted by the dealer until the original date of sale and Product serial number can be
verified.
V. It is a condition for the continuation of this warranty that the Product be taken to an authorized MerCruiser
Service Dealer, after 100 hours of engine operation, but not later than 150 hours, for required checks and
adjustments. A copy of the dealer service work order must be retained as evidence of the completion of
this requirement.
VI. Since this warranty applies to defects in material or workmanship, it does not apply to normal wear,
adjustments, tune-ups or to damage caused by: 1) Neglect, lack of maintenance, accident, abnormal
operation, improper installation or service; 2) Use of a propeller not properly suited to application/boat load
or, failure to follow instructions in applicable service and warranty information manuals or operation and
maintenance manual; 3) Use of an accessory or part not manufactured or sold by us; 4) Operation with
fuels, oils, lubricants or coolants/coolant additives which are not suitable for use with the Product or
recommended by us; 5) Participating in or preparing for racing or other competitive activity or operating with
racing type lower unit; 6) Alteration or removal of parts; 7) Water entering engine cylinder/s through the
exhaust system or air intake system; 8) Use of product in a full-displacement or semi-displacement hull
vessel; or 9) Use or operation of the product in a manner inconsistent with the “Recommended
Operation/Duty Cycle” section of the Operation and Maintenance Manual.
67
CD213
Mercruiser Diesel Limited Warranty (continued)
VII. Reasonable access must be provided to the Product for warranty service. This warranty will not apply to:
1) Haul-out, launch, towing and storage charges, telephone or rental charges of any type, inconvenience,
or loss of time or income, or other consequential damages; or 2) Removal and/or replacement of boat partitions or material because of boat design for necessary access to the Product.
VIII. Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer
authorized to service the Product. If purchaser cannot deliver Product to such authorized dealer, he may
give notice in writing to the Company (U.S.A. and Canada) or the nearest Marine Power International
Branch or Distributor Service Office (outside the U.S.A. and Canada). We shall then arrange for the inspection and repair, provided such service is covered under this warranty. Purchaser shall pay for all related
transportation charges and/or travel time. If the service is not covered by this warranty, purchaser shall pay
for all related labor and material, and any other expenses associated with that service. Any Product or parts
shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid.
IX. Our obligation under this warranty shall be limited to repairing a defective part or, at our option, refunding
the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting
from defects in material or workmanship as covered by this warranty. The repair or replacement of parts,
or the performance of service, under this warranty, does not extend the period of this warranty beyond its
original expiration date. We reserve the right to improve the design of any Product without assuming any
obligation to modify any Product previously manufactured.
X. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY.
WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY. IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY. SOME STATES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE
LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU.
XI. 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.
68
CD278
Marine Power International Branch or Distributor Service Offices
INTERNATIONAL HEADQUARTERS
AUSTRALIA
Marine Power International
Division of Brunswick Corporation
P.O. Box 1939
Fond du Lac, Wl 54936-1939
USA
Telephone: (414) 929-5000
Marine Power International Pty. Ltd.
P. B. 1420, 132-140 Frankston Road
Dandenong, Victoria 3164
Australia
Telephone (61) (3) 791-5822
Fax (61) (3) 791-5880
EUROPE, MIDDLE EAST, AFRICA
ASIA / PACIFIC
Marine Power Europe, Inc.
Parc Industriel de Petit-Rechain
B-4800 Verviers
Belgium
Telephone (0) 87 / 32 • 32 • 11
Fax (32) (87) 31 • 19 • 65
Marine Power International, Ltd.
Block 1002 Jalan Bukit Merah #07-08
Redhill Industrial Estate
JTC Flatted Factories
Singapore 0315
Telephone (65) 270-7680
Fax (65) 270-7898
LATIN AMERICA, CARIBBEAN
JAPAN
Marine Power International
9350 SW 72nd St. (Sunset Dr.)
Suite 100
Miami, FL 33173
U.S.A.
Telephone (305) 596-9606
Fax (305) 596-3869
Marine Power International - Japan
No. 27-2 Muramatsu Chisaki-shinden
Shimizu City
Shizuoka Prefecture
Japan 424
Telephone (81) 543/34-2500
Fax (81) 543/34-2022
69
CD279
Warranty Coverage
The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The table explains some of the types of services that are not covered by warranty.
Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents normal wear and a variety of other causes that affect the
product are not covered.
Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country
to which distribution is authorized by us.
Should you have any questions concerning warranty coverage contact your authorized dealer. They will be
pleased to answer any questions that you may have.
WARRANTY DOES NOT APPLY TO THE FOLLOWING:
• Minor adjustments or checks, including checking fuel injection pump timing, cleaning fuel injectors, filters, or
adjusting belts, controls, and checking lubrication made in connection with normal services.
• Damage caused by neglect, lack of maintenance, accident, abnormal operation, improper installation or service, or freezing temperatures.
• Haul-out, launch, towing charges; removal and/or replacement of boat partitions or material because of boat
design for necessary access to the product; all related transportation charges and/or travel time, etc. Reasonable access must be provided to the product for warranty service. Customer must deliver product to an Authorized Dealer.
• Additional service work requested by customer other than that necessary to satisfy the warranty obligation.
• Labor performed by other than an Authorized Dealer may be covered only under following circumstances:
When performed on emergency basis (providing there are no Authorized Dealers in area who can perform
the work required or have no facilities to haul out, etc., and prior factory approval has been given to have the
work performed at this facility).
• All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner’s responsibility.
• Use of other than Quicksilver replacement parts when making warranty repairs.
• Oils, lubricants or fluids changed as a matter of normal maintenance is customer’s responsibility unless loss
or contamination of same is caused by product failure that would be eligible for warranty consideration.
• Participating in or preparing for racing or other competitive activity.
• Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal
engine condition which could result in a failure, condition responsible for noise should be corrected under the
warranty.
• Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard.
• Water entering the engine via the air filter or exhaust system or submersion. Also, water in the starter motor.
• Starter motors and/or armatures or field coil assembly, which are burned, or where lead is thrown out of commutator because of excess cranking.
• Valve or valve seat grinding required because wear.
• Failure of any parts caused by lack of cooling water, which results from starting power package out of water,
foreign material blocking inlets or power package being mounted too high.
• Use of fuels and lubricants which are not suitable for use with or on the product. Refer to your Operation and
Maintenance Manual.
• Our limited warranty does not apply to any damage to our products caused by the installation or use of parts
and accessories which are not manufactured or sold by us. Failures which are not related to the use of those
parts or accessories, are covered under warranty, if they otherwise meet the terms of the limited warranty for
that product.
70
CD62
Transferable Warranty
The product 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.
DIRECT SALE BY OWNER
• The second owner can be registered as the new owner and retain the unused portion of the limited warranty
by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show
proof of ownership. In the United States and Canada, mail to:
Mercury Marine
W6250 West Pioneer Road
P.O. Box 1939
Fond du Lac, Wl 54936-1939
Attn: Warranty Registration Department
• A new Owner Warranty Registration Card will be issued with the new owner’s name and address. Registration
records will be changed on the factory computer registration file.
• There is no charge for this service.
Outside the United States and Canada, please contact the distributor in your country, or the Marine Power International Service Center closest to you, for the transferable warranty procedure that would apply
to you.
Q-GUARD Product Protection Plan
UNITED STATES AND CANADA ONLY
(Certain Performance Products, triple engine installations, and commercial applications are excluded)
The Mercury Marine Q-GUARD Product Protection Plan provides coverage against unexpected mechanical and
electrical breakdowns that may occur beyond the standard limited warranty.
The optional Q-GUARD Product Protection Plan is the only Factory Plan available for your engine.
Two, three or four-year plans can be purchased up to 180 days after the original engine purchase date.
See your participating dealer for complete program details.
71
CA461
Owner Service Assistance
Local Repair Service
Always return your MerCruiser powered boat to your local Authorized Dealer, should the need for service arise.
Only he has the factory trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver
parts and accessories* to properly service your engine should the need occur. He knows your engine best.
* Quicksilver parts and accessories are engineered and built by Mercury Marine, specifically for MerCruiser
stern drives 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.
Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the
nearest Regional Service Center. Outside the United States and Canada, contact the nearest Marine Power
International Service Center.
Parts And Accessories Inquiries
All inquiries concerning Quicksilver replacement parts and accessories should be directed to your local
Authorized Dealer. The dealer has the necessary information to order parts and accessories for you should he
not have them in stock. 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 on parts
and accessories, the dealer requires the motor model and serial number(s) to order the correct parts.
CB577
Resolving A Problem
Satisfaction with your MerCruiser product is very 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 MerCruiser Dealership.
If additional assistance is required, take these steps.
1 Talk with the dealership’s sales manager or service manager. If this has already been
done, then contact the owner of the dealership.
2 Should you have a question, concern or problem that cannot be resolved by your dealership, please contact Mercury Marine Service Office for assistance. Mercury Marine will
work with you and your dealership to resolve all problems.
The following information will be needed
by the service office:
• Your name and address
• Daytime telephone number
• Model and serial number for your power package
• The name and address of your dealership
• Nature of problem
Mercury Marine Service Offices are listed on the next page.
72
EXTRA
HELP
CA462
Mercury Marine Service Offices
For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence.
Telephone
Fax
Mail
United States
(405) 743-6566
(405) 743-6570
MerCruiser
3003 N. Perkins Rd.
Stillwater, OK 74075
(905) 270-4481
(905) 270-4510
Mercury Marine Ltd.
1156 Dundas Hwy. E.
Mississauga, Ontario
Canada L4Y 2C2
Canada
Australia, Pacific
(61) (3) 791-5822
(61) (3) 793-5880
Mercury Marine Australia
132-140 Frankston Road
Dandenong,Victoria 3164
Australia
Europe, Middle East, Africa
(32) (87) 32 • 32 • 11
(32) (87) 31 • 19 • 65
Marine Power - Europe, Inc.
Parc Industriel de Petit-Rechain
B-4800 Verviers
Belgium
(305) 385-5507
Mercury Marine - Latin America
& Caribbean
9010 S.W. 137th Ave.
Suite 226
Miami, Fl 33186 U.S.A.
Mexico, Central America, South America, Caribbean
(305) 385-9585
Japan
(81) 543/34-2500
(81) 543/34-2022
Mercury Marine - Japan
No. 27-2 Muramatsu Chisaki-Shinden
Shimizu City
Shizuoka Prefecture
Japan 424
(65) 270-7898
Marine Power International, Ltd.
Block 1002 Jalan Bukit Merah #07-08
Redhill Industrial Estate
JTC Flatted Factories
Singapore 0315
Asia, Singapore
(65) 270-7680
73
CA463
Customer Service Literature
English Language
English language publications are available from:
Mercury Marine
Attn: Publications Department
W6250 West Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
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:
1. List your product, model, year and serial number(s).
2. Check the literature and quantities you want.
3. Enclose full remittance in check or money order (NO C.O.D.’s).
CA464
Other Languages
To obtain an Operation and Maintenance Manual or Maintenance Procedures Manual in another language,
contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part
numbers for other languages is provided with your power package.
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Andre sprog
Kontakt det nærmeste Mercury Marine eller Marine Power International service center for oplysninger om hvordan du kan anskaffe en Betjenings– og vedligeholdelsesmanual eller en manual med vedligeholdelsesprocedurer på et andet sprog. En liste med reservedelsnumre for andre sprog leveres sammen med din power–pakke.
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Andere talen
Voor het verkrijgen van een Handleiding voor gebruik en onderhoud of een Onderhoudshandleiding in andere
talen dient u contact op te nemen met het dichtstbijzijnde internationale servicecentrum van Mercury Marine of
Marine Power voor informatie hierover. Een lijst met onderdeelnummers voor andere talen wordt bij uw motorinstallatie geleverd.
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Muut kielet
Saadaksesi Käyttö– ja huolto–ohjekirjoja muilla kielillä, ota yhteys lähimpään Mercury Marine tai Marine Power
International huoltokeskukseen, josta saat lähempiä tietoja. Moottorisi mukana seuraa monikielinen varaosanumeroluettelo.
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Autres langues
Pour obtenir un Manuel d’utilisation et d’entretien ou un Manuel d’entretien dans une autre langue, contactez
le centre de service après–vente international Mercury Marine ou Marine Power le plus proche pour toute information. Une liste des numéros de pièces en d’autres langues accompagne votre bloc–moteur.
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Andere Sprachen
Um eine Betriebs– und Wartungsanleitung oder ein Handbuch der Wartungsverfahren in einer anderen Sprache
zu erhalten, wenden Sie sich an das nächste Mercury Marine oder Marine Power International Service Center.
Eine Liste mit Teilenummern für Fremdsprachen ist im Lieferumfang Ihres Motors enthalten.
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Altre lingue
Per ottenere il manuale di funzionamento e manutenzione o il manuale delle procedure di manutenzione in altra
lingua, contattate il centro assistenza internazionale Mercury Marine o Marine Power più vicino. In dotazione
con il gruppo motore, viene fornito l’elenco dei codici prodotto dei componenti venduti all’estero.
Andre språk
Ytterligere informasjon om bruks– og vedlikeholdshåndbok eller servicehåndbok på andre språk kan fås ved
henvendelse til nærmeste internasjonale servicecenter for Mercury Marine eller Marine Power. En liste over
delenumre for andre språk følger med aggregatet.
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Outros Idiomas
Para obter um Manual de Operação e Manutenção ou um Manual de Procedimentos de Manutenção em outro
idioma, contate o Centro de Serviço Internacional de “Marine Power” (Potência Marinha) ou a Mercury Marine
mais próxima para obter informações. Uma lista de números de referência para outros idiomas é fornecida com
o seu pacote de propulsão.
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Otros idiomas
Para obtener un Manual de operación y mantenimiento o un Manual de procedimientos en otro idioma, póngase
en contacto con el centro de servicio más cercano de Mercury Marine o Marine Power International para recibir
información. Con su conjunto motriz se entrega una lista de los números de pieza para los otros idiomas.
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Andra språk
För att få Instruktions– och underhållsböcker på andra språk, kontakta närmaste Mercury Marine eller Marine
Power International servicecenter, som kan ge ytterligare information. En förteckning över artikelnummer på andra språk medföljer ditt kraftpaket.
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Literature Order Form
Model __________ Horsepower__________
Serial Number__________ Year_____
Operation and Maintenance Manual (Owner’s Guide) - explains basic operation and maintenance.
Maintenance Procedure Manual - explains basic do-it-yourself maintenance procedures.
Service Manual - shows the complete assembly and disassembly of the engine or stern drive.
Parts Manual - shows the exploded view of the engine or stern drive with corresponding part number.
Part
Number
Manual
Qty.
Price Each
Total Price
(Official Use Only)
Service Manual:
Engine
90-
$30.00
Service Manual:
Drive
90-
$30.00
Service Manual:
Remote Control
90-
$30.00
Parts Manual:
Engine Only
90-
$4.95
Parts Manual:
Drive Only
90-
$4.95
Operation and Maintenance Manual 90-
$5.00
Maintenance Procedure Manual
$15.00
90-
* must be collected from customers in all states except:
AK, AZ, DE, HI, ID, IA, ME, MI, MT, NV, NH, NY, OR, VT, WV, WY
** Orders Totaling: up
u to $20.00, add $3.00
SubTotal
Sales Tax *
20.01 - $50.00, add $4.00
Ship/Hand**
50.01 - up, Free
Grand Total
77
Please Return with Payment to:
Mercury Marine
Attn: Publications Dept.
P.O. Box 1939
Fond du Lac, WI 54936-1939
Ship To: (Please Print or Type - This is your Shipping Label)
Name
Address
City
State
Zip
METHOD OF PAYMENT: (NO CASH OR C.O.D.)
Personal Check
Cashiers Check
Visa
Master Card
Card Number
Signature
(
)
Telephone Number
78
Money Order
Month/Year
Expiration Date
Date
75308
79
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
80
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