Mercury TDI 4.2L User Manual

Welcome

You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure operating ease and durability.

With proper care and maintenance, you will 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 products. We sincerely hope your boating will be pleasant! Mercury Marine, Fond du Lac, Wisconsin, U.S.A.

Name / function:

John Pfeifer, President, Mercury Marine

Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your dealer. Your dealer can also provide a demonstration of actual starting and operating procedures.

Notice

Throughout this publication, and on your power package, warnings, cautions, and notices, accompanied by the

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International Hazard Symbol !, may be used to alert the installer and 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

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates a situation which, if not avoided, could result in engine or major component failure.

IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.

IMPORTANT: 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.

WARNING

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

TDI 4.2L Diesel Sterndrive Models

The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.

Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation.

Warranty Message

The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual included with the product. The Warranty Manual contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.

Copyright and Trademark Information

Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.

Identification Records

Please record the following applicable information:

MerCruiser

Engine Model and Horsepower Engine Serial Number

Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number

Transmission Model (Inboard) Gear Ratio Transmission Serial Number

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number (Europe Only)

Section 1 - Getting to Know Your Power Package

Features and Controls............................................................... 2

TDI 4.2L Engine Description............................................... 2

Identification........................................................................ 2

Audio Warning System....................................................... 2

Testing the Audio Warning System................................ 3

Digital Throttle and Shift..................................................... 3

Instrumentation................................................................... 3

VesselView..................................................................... 3

SmartCraft Speedometer, Tachometer, and Digital

Gauges........................................................................... 3

System Link Digital Gauges........................................... 4

Controls...................................................................................... 5

Switches............................................................................. 5

Emergency Stop Switch...................................................... 6

Lanyard Stop Switch........................................................... 6

Keep the Lanyard Stop Switch and Lanyard Cord in

Good Operating Condition.............................................. 7

Section 2 - On The Water

Safe Boating Recommendations............................................. 16

Carbon Monoxide Exposure.................................................... 17

Be Alert To Carbon Monoxide Poisoning........................... 17

Stay Clear of Exhaust Areas.............................................. 17

Good Ventilation ................................................................ 17

Poor Ventilation ................................................................. 18

Duty Cycle................................................................................ 18

Basic Boat Operation......................................................... 18

Duty Cycle Rating......................................................... 18

Pleasure Duty Rating....................................................18

Basic Boat Operation............................................................... 19

Operation Chart................................................................ 19

Freezing Temperature and Cold Weather Operation....... 19

Drain Plug and Bilge Pump............................................... 20

Starting, Shifting, and Stopping............................................... 20

Before Starting the Engine................................................ 20

Starting a Cold Engine...................................................... 21

Engine Warm‑Up.............................................................. 21

Starting a Warm Engine ................................................... 21

Shifting.............................................................................. 22

Engine Shutdown (Stopping)............................................ 22

Starting the Engine After Stopped While in Gear............. 22

Trailering the Boat.................................................................... 22

Protecting People In The Water............................................... 22

Protecting People in the Water......................................... 22

Digital Throttle and Shift..................................................... 7

Engine Electrical System Overload Protection.......................... 7

Fuses....................................................................................7

Vessel Adapter Assembly Fuse Replacement..................... 8

Lanyard Stop Switch.................................................................. 8

Keep the Lanyard Stop Switch and Lanyard Cord in Good

Operating Condition............................................................. 9

Power Trim............................................................................... 10

Single‑Engine Trim and Trailer...........................................10

Dual‑Engine Trim and Trailer............................................. 11

Power Trim and MerCathode Overload Protection.................. 11

Emissions Information.............................................................. 12

Exhaust Gas Emissions Certificate (Europe Only)............. 12

Owner Responsibility..........................................................12

Engine Components................................................................ 13

While Boat is in Operation............................................ 22

While the Boat is Stationary......................................... 23

High Speed and High Performance.................................. 23

Passenger Safety in Pontoon Boats and Deck Boats....... 23

Boats Having an Open Front Deck............................... 23

Boats with Front‑Mounted, Raised‑Pedestal Fishing

Seats............................................................................ 23

Wave and Wake Jumping........................................................ 24

Impact with Underwater Hazards............................................. 24

Conditions Affecting Operation................................................ 25

Weight Distribution (Passengers and Gear) Inside the

Boat.................................................................................. 25

Bottom of Boat.................................................................. 25

Cavitation.......................................................................... 25

Ventilation......................................................................... 25

Elevation and Climate....................................................... 25

Propeller Selection............................................................ 26

Break‑In................................................................................... 26

Initial Break‑In Procedure................................................. 26

Sterndrive 10‑Hour Break‑In Period (New or With

Replacement Gears)......................................................... 26

Engine Break‑In................................................................ 26

20‑Hour Break‑In Period...............................................26

After the 20‑Hour Break‑In Period................................ 27

End of First Season Checkup........................................... 27

Section 3 - Specifications

Fuel Requirements................................................................... 30

Nonferrous Metals and the Fuel System............................ 30

Diesel Fuel in Cold Weather.................................................... 30

Antifreeze/Coolant................................................................... 30

Engine Oil ............................................................................... 31

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Engine Specifications............................................................... 31

Fluid Specifications.................................................................. 32

Engine............................................................................... 32

Bravo Sterndrive Fluid Specifications—Diesel................. 32

Power Steering and Power Trim Fluids........................... 32

Approved Power Steering Fluids.................................32

Section 4 - Maintenance

Approved Power Trim Fluids....................................... 32

Approved Paints..................................................................... 32

Owner and Operator Responsibilities..................................... 34

Dealer Responsibilities........................................................... 34

Maintenance........................................................................... 34

Replacement Parts Warning................................................... 35

Inspection............................................................................... 35

Routine Maintenance.............................................................. 35

Start of Season................................................................. 35

Each Day Start.................................................................. 35

Each Day End................................................................... 35

Weekly.............................................................................. 35

End of Season.................................................................. 35

Scheduled Maintenance......................................................... 36

Once a Year or Every 200 Operating Hours (Whichever

Occurs First)..................................................................... 36

Maintenance Notice.......................................................... 36

Every 5 Years or 500 Hours (Whichever Occurs First)..... 36

Every 5 Years or 1,000 Operating Hours (Whichever

Occurs First)..................................................................... 36

Every 5 Years or 2,000 Operating Hours (Whichever

Occurs First)..................................................................... 36

Engine Oil............................................................................... 36

Checking........................................................................... 37

Filling................................................................................ 37

Draining Using the Easy Drain System, if Equipped......... 37

Changing Oil and Filter..................................................... 38

Sterndrive Gear Lube............................................................. 39

Checking........................................................................... 39

Filling................................................................................ 39

Changing.......................................................................... 40

Power Trim Fluid.................................................................... 43

Checking........................................................................... 43

Filling................................................................................ 44

Changing.......................................................................... 45

Power Steering Fluid.............................................................. 45

Checking........................................................................... 45

Filling................................................................................ 45

Changing.......................................................................... 46

Engine Coolant....................................................................... 46

Checking the Coolant Level.............................................. 47

Adding Coolant................................................................. 47

Air Filter.................................................................................. 47

Removal............................................................................ 47

Inspection and Cleaning................................................... 47

Installation......................................................................... 48

Fuel Filter................................................................................ 48

Draining Water from the Filter........................................... 48

Replacing the Filter........................................................... 48

Purging the Fuel System........................................................ 49

Fuel System............................................................................ 49

Priming.............................................................................. 49

Fuel Tank Cleaning and Flushing..................................... 49

Seawater System................................................................... 49

Seawater Pump Impeller Inspection................................ 49

Sterndrive Water Inlets Check......................................... 50

Flushing and Draining the Seawater System.................. 51

Checking the Seawater Pickups...................................... 52

Cleaning the Seawater Strainer, if Equipped.................. 52

Corrosion Protection............................................................... 53

General Information......................................................... 53

Sacrificial Anode.............................................................. 53

Antifouling Paint.............................................................. 54

Lubrication.............................................................................. 54

Steering System.............................................................. 54

Throttle Cable.................................................................. 55

Shift Cable....................................................................... 55

Transom Assembly.......................................................... 55

Propeller Shaft................................................................. 55

Engine Coupler................................................................ 56

Driveshaft Extension Models........................................... 57

Maintaining Torques............................................................... 57

Gimbal Ring U‑bolt Nuts.................................................. 57

Engine Mounts................................................................ 58

Propellers............................................................................... 58

Bravo Sterndrive Propeller Removal............................... 58

Bravo One Models...................................................... 58

Bravo Two Models...................................................... 59

Bravo Three Models.................................................... 60

Bravo Sterndrive Propeller Installation............................ 61

Bravo One Models...................................................... 61

Bravo Three................................................................ 62

Drive Belts.............................................................................. 63

Drive Belt......................................................................... 63

Drive Belt Failure Identification........................................ 63

Battery.................................................................................... 64

Battery Precautions for Multiple Engines................................ 65

Alternators........................................................................ 65

Engine Control Unit (ECU)................................................ 65

Batteries............................................................................ 65

Battery Switches............................................................... 65

Battery Isolators................................................................ 65

Generators........................................................................ 65

Section 5 - Storage

Cold Weather (Freezing Temperature), Seasonal Storage, and

Extended Storage................................................................... 68

Preparing Your Power Package for Seasonal or Extended

Storage............................................................................ 68

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Seasonal Storage Instructions........................................ 68

Extended Storage Instructions........................................ 69

Battery Storage............................................................... 70

Recommissioning the Power Package................................... 70

Section 6 - Troubleshooting

Troubleshooting....................................................................... 72

Troubleshooting Charts............................................................ 72

Starter Motor Will Not Crank Engine, or Cranks Slow...... 72

Engine Will Not Start, or Is Hard to Start.......................... 72

Engine Runs Rough, Misses, or Backfires....................... 72

Poor Performance............................................................. 73

No Fuel or Faulty Fuel Supply.......................................... 73

Engine Will Not Start, Starter Does Not Turn................... 73

Excessive Engine Temperature........................................ 73

Insufficient Engine Temperature....................................... 74

Section 7 - Customer Assistance Information

Owner Service Assistance....................................................... 78

Local Repair Service.......................................................... 78

Service Away From Home..................................................78

Stolen Power Package....................................................... 78

Attention Required After Submersion................................. 78

Replacement Service Parts................................................ 78

Parts and Accessories Inquiries................................... 78

Resolving a Problem.......................................................... 78

Section 8 - Maintenance Log

Low Engine Oil Pressure.................................................. 74

Battery Will Not Charge.................................................... 74

Remote Control Operates Hard, Binds, Has Excessive

Free‑play, or Makes Unusual Sounds.............................. 74

Steering Wheel Turns Hard or Jerky................................ 74

Power Trim Does Not Operate (Electric Motor Operates but

Sterndrive Unit Does Not Move)....................................... 74

Power Trim Does Not Operate (Electric Motor Does Not

Operate)............................................................................ 75

Contact Information for Mercury Marine Customer Service

........................................................................................... 79

Customer Service Literature.................................................... 79

English Language.............................................................. 79

Other Languages................................................................80

Ordering Literature................................................................... 80

United States and Canada................................................. 80

Outside the United States and Canada.............................. 80

Scheduled Maintenance Log................................................... 82 Vessel Maintenance Notes...................................................... 83

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Section 1 - Getting to Know Your Power Package

Table of Contents

Features and Controls............................................................ 2

TDI 4.2L Engine Description............................................ 2

Identification.....................................................................2

Audio Warning System.................................................... 2

Testing the Audio Warning System ......................... 3

Digital Throttle and Shift.................................................. 3

Instrumentation................................................................ 3

VesselView .............................................................. 3

SmartCraft Speedometer, Tachometer, and Digital

Gauges .................................................................... 3

System Link Digital Gauges .................................... 4

Controls.................................................................................. 5

Switches.......................................................................... 5

Emergency Stop Switch...................................................6

Lanyard Stop Switch........................................................ 6

Keep the Lanyard Stop Switch and Lanyard Cord in

Good Operating Condition ....................................... 7

Digital Throttle and Shift.................................................. 7

Engine Electrical System Overload Protection....................... 7

Fuses .............................................................................. 7

Vessel Adapter Assembly Fuse Replacement ............... 8

Lanyard Stop Switch............................................................... 8

Keep the Lanyard Stop Switch and Lanyard Cord in

Good Operating Condition .............................................. 9

Power Trim........................................................................... 10

Single‑Engine Trim and Trailer ..................................... 10

Dual‑Engine Trim and Trailer ....................................... 11

Power Trim and MerCathode Overload Protection............... 11

Emissions Information.......................................................... 12

Exhaust Gas Emissions Certificate (Europe Only) ....... 12

Owner Responsibility .................................................... 12

Engine Components............................................................. 13

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Features and Controls

TDI 4.2L Engine Description

• Four‑stroke V8 diesel engine

• 4.2 liter displacement (252 cid)

• Common‑rail direct fuel injection

• Chain‑driven overhead‑cam hydraulic valvetrain

• Pressurized engine lubrication with replaceable oil filter

• Dry air filter

• Variable geometry turbochargers

• Twin cooling circuits, utilizing seawater cooling and closed‑circuit cooling Refer to Engine Specifications for additional details. Refer to Engine Components for the locations of engine components referenced in this manual.

Identification

The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.

Audio Warning System

Your Mercury Diesel power package may be equipped with an audio warning system. The audio warning system will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.

The audio warning system will sound with a continuous horn if one of the following occurs:

• The engine oil pressure is too low

• The coolant temperature is too hot

• Water in fuel

• Low coolant level

NOTICE

A continuous horn indicates a critical fault. Operating the engine during a critical fault can damage components. If the warning horn emits a continuous beep, do not operate the engine unless avoiding a hazardous situation.

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If the alarm sounds, stop the engine immediately if you are not in a hazardous situation. Investigate the cause and correct it, if possible. If you cannot determine the cause, consult your Mercury Diesel authorized repair facility.

Testing the Audio Warning System

1. Turn the ignition switch to the "RUN" or 1 position; do not start the engine.

2. Push the audio test switch toggle lever down and hold it.

3. Listen for the alarm. The alarm will sound if the system is functioning correctly.

Digital Throttle and Shift

Digital Throttle and Shift (DTS) operating instructions are provided in a separate manual. Refer to Mercury Diesel's SmartCraft and DTS Operator's Manual.

Instrumentation

VesselView

Your power package may be connected to a SmartCraft VesselView display. VesselView 7 is a comprehensive boat information center that can display information for up to four gasoline or diesel engines. It continuously monitors and reports basic operating data including detailed information such as seawater temperature and depth, trim status, boat speed and steering angle, and the status of fuel, oil, water, and waste tanks.

VesselView can be fully integrated with a vessel’s global positioning system (GPS) or other NMEA‑compatible device to provide up‑to‑the‑minute navigation, speed, and fuel‑to‑destination information.

VesselView 4 and 7 are equipped with a micro SD card port that allows an authorized OEM or dealership to import the personality configuration. It can also be use by the owner to import pictures or graphics. When more than one VesselView is used, either as a triple or quad‑engine application for multiple helms, the same mico SD card can be used to download those configurations.

VesselView

Refer to your VesselView operations manual for detailed instructions on how to operate this display.

SmartCraft Speedometer, Tachometer, and Digital Gauges

The SmartCraft instrument package augments the information provided by VesselView. The instrument package may display:

• Engine RPM

• Boat speed

• Coolant temperature

• Oil pressure

• Battery voltage

• Fuel consumption

• Engine operating hours

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Section 1 - Getting to Know Your Power Package

abc

37925

50400

SmartCraft tachometer and speedometer

a - Tachometer b - Speedometer c - LCD display

The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system. The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.

For basic operation information on the SmartCraft instrument package and for details on the warning functions monitored by the system, refer to the manual provided with your gauge package.

System Link Digital Gauges

Some instrumentation packages include gauges that augment the information provided by VesselView and the SmartCraft tachometer and speedometer. The owner and operator should be familiar with all the instruments and their functions on the boat. Have your boat dealer explain the gauges and normal readings that appear on your boat.

The following types of digital gauges may be included with your power package.

System Link digital gauges

Item Gauge Indicates a Oil pressure gauge Engine oil pressure b Voltmeter Battery voltage c Water temperature gauge Engine operating temperature d Fuel gauge Quantity of fuel in tank

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Controls

38160

28082

OFF

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Switches

Four‑Position Key Switch

NOTE: The key can only be removed with the key switch in the "OFF" position.

Dual‑Engine Start‑Stop Switch

Section 1 - Getting to Know Your Power Package

•

"OFF" ‑ In the "OFF" position, all electrical circuits are off. The engine will not operate with the key switch in the "OFF" position.

•

"ACC" ‑ In the "ACC" position, any accessories connected to the electrical circuits can be operated. The engine will not operate with the key switch in the "ACC" position.

•

"ON" ‑ In the "ON" position, all electrical circuits and instrumentation receive power. The engine can be started with an optional start‑stop switch.

•

"START" ‑ Turn the key to the start position and release to start the engine.

A start‑stop switch is optional equipment. The start‑stop switch works in conjunction with the key switch. There is one start‑stop switch for each engine. Each button on a multi‑engine start‑stop switch functions independently. The key switch must be in the "ON" position to start a stopped engine with the start‑stop switch. Pressing a start‑stop switch button when an engine is running will shut down the corresponding engine.

Bilge Blower Toggle Switch

Operates the bilge blower, if equipped.

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OFF

RUN

ATTACH LANYARD

Emergency Stop Switch

An emergency stop (E‑stop) switch is used to turn off the engines in an emergency situation, such as a person overboard or a tangled propeller. When activated, an E‑stop switch interrupts the power supply to the engine and transmission. If the boat is equipped with an E‑stop switch, the E‑stop switch turns off all of the engines.

Typical E-stop switch

Activation of an E‑stop switch stops the engine, or engines, immediately, but the boat can continue to coast for some distance depending upon the velocity and degree of any turn at shutdown. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

We recommend instructing other occupants on proper starting and operating procedures should they need to operate the engine in an emergency.

Accidental or unintended activation of the switch during normal operation is also possible, which can cause any or all of the following potentially hazardous situations:

• Occupants can be thrown forward due to unexpected loss of forward motion, and passengers in the front of the boat could be ejected over the bow and possibly struck by the propulsion or steering components.

• The operator can lose power and directional control in heavy seas, strong current, or high winds.

• The operator can lose control of the vessel when docking.

Restarting an engine using the key switch or start button after an E‑stop shutdown without first turning the key switch to the off position for at least 30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting, some fault codes are still being displayed, contact your authorized Mercury Diesel repair facility.

Lanyard Stop Switch

A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist.

A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.

a - Lanyard cord clip b - Lanyard decal c - Lanyard stop switch

Accidental ejections, such as falling overboard, are more likely to occur in:

• Low‑sided sport boats

• Bass boats

• High‑performance boats

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Section 1 - Getting to Know Your Power Package

Accidental ejections can also occur from:

• Poor operating practices

• Sitting on the seat or gunwale at planing speeds

• Standing at planing speeds

• Operating at planing speeds in shallow or obstacle‑infested waters

• Releasing your grip on the steering wheel

• Carelessness caused by consuming alcohol or drugs

• High‑speed boating maneuvers The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) long when stretched out, with an element on one end made

to be inserted into the switch, and a snap on the other end for attaching to the operator. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the operator's normal position. The operator can shorten the lanyard by wrapping the lanyard around his wrist, or by tying a knot in the lanyard.

Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance, depending upon its velocity. While the boat is coasting, it can cause injury to anyone in the boat's path as it would under power.

Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an emergency.

WARNING

If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard.

Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations:

• Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the

front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.

• Loss of power and directional control in heavy seas, strong current, or high winds.

• Loss of control when docking.

WARNING

Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.

Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition

Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.

Before each use, inspect the lanyard cord to ensure that it is in good working condition and that there are no breaks, cuts, or wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard cords.

Digital Throttle and Shift

Digital Throttle and Shift (DTS) operating instructions are provided in a separate manual. Refer to Mercury Diesel's SmartCraft and DTS Operator's Manual.

Engine Electrical System Overload Protection

Fuses

CAUTION

Failure to protect wiring with an appropriate fuse can damage the wiring and start a fire. When installing any accessories, we recommend using a Mercury accessory kit. Always use the appropriate fuse to protect wiring.

Individual circuits are protected by fuses. If an electrical overload occurs, a fuse will burn out. Find and correct the cause for the electrical overload before replacing the fuse.

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Two fuses are located on the top of the engine. Remove the engine cover to access these fuses. Be certain to replace an open fuse only with one of the same rating.

a - 15‑amp fuse b - 25‑amp fuse

The remaining fuses are located in the vessel adapter assembly (refer to your boat owner's manual for location) and on the rear side of the control unit of the individual instrumentation.

Vessel Adapter Assembly Fuse Replacement

NOTE: Refer to your boat owner's manual for the location of the vessel adapter assembly (VAA). The key for the VAA was provided along with the ignition keys.

1. Turn the ignition switch to the "OFF" position.

2. Unlock and open the cover of the vessel adapter assembly.

3. Determine which fuse belongs to the failed circuit using the illustration below.

a - Helm power 5‑amp fuse b - EFP 1‑amp fuse c - Feature A 1‑amp fuse d - T.15 5‑amp fuse e - Feature B 1‑amp fuse f - Main power 10‑amp fuse

4. Replace the blown fuse with a new fuse of the same rating.

5. Close and lock the cover of the VAA.

Lanyard Stop Switch

The purpose of a lanyard stop switch 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. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed as an accessory ‑ generally on the dashboard or side adjacent to the operator's position.

A decal near the lanyard stop switch is a visual reminder for the operator to attach the lanyard to their personal flotation device (PFD) or wrist.

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The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the 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.

a - Lanyard cord clip b - Lanyard decal c - Lanyard stop switch

Read the following Safety Information before proceeding. Important Safety Information: 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. Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables, bass boats, high performance boats, and light, sensitive handling fishing boats operated by a hand tiller. Falling overboard and accidental ejections 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 or tiller handle 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 (if the operator is accidentally ejected).

WARNING

Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations:

• Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the

front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller.

• Loss of power and directional control in heavy seas, strong current, or high winds.

• Loss of control when docking.

Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition

Before each use, check to ensure the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.

Before each use, visually inspect the lanyard cord to ensure it is in good working condition and that there are no breaks, cuts, or wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard cords.

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Section 1 - Getting to Know Your Power Package

Power Trim

Power trim allows the operator to adjust the sterndrive angle while underway to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive for trailering, beaching, launching, low‑speed (below 1200 RPM engine speed), and shallow water operation.

WARNING

Excessive trim can cause serious injury or death at high speeds, and single‑ram trim systems do not provide a trim‑out limiting device or trim indicator. Use caution when trimming with a single‑ram trim system and never trim out beyond the unit's side support flanges while the boat is underway or at engine speeds above 1200 RPM.

For best performance, trim the sterndrive so that the boat bottom is at a 3–5° angle to the water.

3 - 5

mc79528

Trimming the sterndrive up (out) can:

• Generally increase top speed

• Increase clearance over submerged objects or a shallow bottom

• Cause the boat to accelerate and plane off slower

• In excess, cause boat porpoising (bouncing) or propeller ventilation

• Cause engine overheating if trimmed up (out) to a point where any cooling water intake holes are above the water line

mc78529

Trimming the sterndrive down (in) can:

• Help the boat accelerate and plane off quicker

• Generally improve the ride in choppy water

• In most cases, reduce boat speed

• If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.

mc79530

Single‑Engine Trim and Trailer

Single engine applications have a button that can be pressed to trim the sterndrive unit up (out) or down (in).

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Section 1 - Getting to Know Your Power Package

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To raise the sterndrive for trailering, beaching, launching, low‑speed (below 1200 RPM), and shallow water operation push the trim button to raise the sterndrive to the full up (out) position.

Some controls also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only.

Dual‑Engine Trim and Trailer

NOTICE

If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering systems. If using an external tie bar, raise and lower all drives together as a unit.

Dual‑engine applications may have a single integral button to operate both sterndrives simultaneously or may have separate buttons for each sterndrive.

Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only.

Power Trim and MerCathode Overload Protection

If an electrical overload on the electrical system occurs, a fuse will open (blow). Find and correct the cause before replacing the fuse.

NOTE: If you must operate the engine in an emergency, turn off and disconnect all accessories from the engine and instrumentation wiring if you cannot find and correct the cause for the electrical overload or excessive current draw. Replace the fuse. If the fuse burns out, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your Mercury Diesel authorized repair facility.

1. The power trim system is protected from overload by a 110‑amp fuse and a 20‑amp in‑line fuse on the power trim pump.

a - 20‑amp in‑line fuse holder b - 110‑amp fuse

2. There are several different Quicksilver MerCathode systems available. Each has a fuse connected to the positive (+)

terminal on the controller. If the fuse is open (blown), the system will not operate, resulting in a loss of corrosion protection. Replace the fuse with one of the same amp rating.

a - MerCathode b - Red/purple wire c - Fuse

9208

90-8M0114081 eng DECEMBER 2015 Page 11

Section 1 - Getting to Know Your Power Package

xxxxxxxxx

x.x

x x

52250

xxxxxxxxx

Emissions Information

Exhaust Gas Emissions Certificate (Europe Only)

A tamper‑resistant label is affixed to the engine at time of manufacture. In addition to the required exhaust gas emissions certificate number, the label lists the engine serial number, engine family, maximum RPM, engine power, and weight. Note that the exhaust gas emissions certification will not affect the fit, function, or performance of the engines. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury Diesel about the availability of replacement decals before proceeding.

Owner Responsibility

The owner or operator is not to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission levels to exceed their predetermined factory specifications.

Page 12 90-8M0114081 eng DECEMBER 2015

Engine Components

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Section 1 - Getting to Know Your Power Package

a - Exhaust outlet b - Turbocharger c - Oil filter d - Engine oil filler cap e - Sacrificial anode (hidden) f - Intercooler g - Seawater pump h - Heat exchanger i - Starter

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Section 1 - Getting to Know Your Power Package

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a - Engine oil dipstick b - Coolant resevoir c - Coolant reservoir cap d - Ribbed V‑belt e - Alternator f - Fuses g - Air filter h - Fuel injection pump drive belt (hidden)

NOTE: The fuel injection pump drive belt is located at the rear of the engine and is protected by a cover. Refer to your Mercury Diesel–authorized repair facility for servicing.

i - Electronic control units

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Table of Contents

Section 2 - On The Water

Safe Boating Recommendations.......................................... 16

Carbon Monoxide Exposure................................................. 17

Be Alert To Carbon Monoxide Poisoning ..................... 17

Stay Clear of Exhaust Areas ........................................ 17

Good Ventilation .......................................................... 17

Poor Ventilation ........................................................... 18

Duty Cycle............................................................................ 18

Basic Boat Operation .................................................... 18

Duty Cycle Rating .................................................. 18

Pleasure Duty Rating ............................................ 18

Basic Boat Operation............................................................ 19

Operation Chart............................................................. 19

Freezing Temperature and Cold Weather Operation.... 19

Drain Plug and Bilge Pump............................................20

Starting, Shifting, and Stopping............................................ 20

Before Starting the Engine.............................................20

Starting a Cold Engine................................................... 21

Engine Warm‑Up........................................................... 21

Starting a Warm Engine ................................................21

Shifting........................................................................... 22

Engine Shutdown (Stopping)......................................... 22

Starting the Engine After Stopped While in Gear.......... 22

Trailering the Boat................................................................ 22

Protecting People In The Water........................................... 22

Protecting People in the Water...................................... 22

While Boat is in Operation ..................................... 22

While the Boat is Stationary .................................. 23

High Speed and High Performance............................... 23

Passenger Safety in Pontoon Boats and Deck Boats....23

Boats Having an Open Front Deck ........................ 23

Boats with Front‑Mounted, Raised‑Pedestal Fishing

Seats ..................................................................... 23

Wave and Wake Jumping..................................................... 24

Impact with Underwater Hazards......................................... 24

Conditions Affecting Operation............................................. 25

Weight Distribution (Passengers and Gear) Inside the

Boat............................................................................... 25

Bottom of Boat............................................................... 25

Cavitation....................................................................... 25

Ventilation...................................................................... 25

Elevation and Climate.................................................... 25

Propeller Selection.........................................................26

Break‑In................................................................................ 26

Initial Break‑In Procedure.............................................. 26

Sterndrive 10‑Hour Break‑In Period (New or With

Replacement Gears)......................................................26

Engine Break‑In............................................................. 26

20‑Hour Break‑In Period ....................................... 26

After the 20‑Hour Break‑In Period ......................... 27

End of First Season Checkup........................................ 27

90-8M0114081 eng DECEMBER 2015 Page 15

Section 2 - On The Water

Safe Boating Recommendations

To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions.

Know and obey all nautical rules and laws of the waterways.

• We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).

Perform safety checks and required maintenance.

• Follow a regular schedule and ensure that all repairs are properly made.

Check safety equipment onboard.

• Here are some suggestions of the types of safety equipment to carry when boating:

Approved fire extinguishers

Signal devices: flashlight, rockets or flares, flag, and whistle or horn

Tools necessary for minor repairs

Anchor and extra anchor line

Manual bilge pump and extra drain plugs

Drinking water

Radio

Paddle or oar

Spare propeller, thrust hubs, and an appropriate wrench

First aid kit and instructions

Waterproof storage containers

Spare operating equipment, batteries, bulbs, and fuses

Compass and map or chart of the area

Personal flotation device (one per person onboard)

Watch for signs of weather change and avoid foul weather and rough‑sea boating.

Tell someone where you are going and when you expect to return.

Passenger boarding.

• Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive unit into neutral is not sufficient.

Use personal flotation devices.

• Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.

Prepare other boat operators.

• Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard.

Do not overload your boat.

• Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer.

Ensure that everyone in the boat is properly seated.

• Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement.

Never operate a boat while under the influence of alcohol or drugs. It is the law.

• Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.

Know your boating area and avoid hazardous locations.

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Be alert.

• The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have

an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed. Watch out for others, the water, and your wake.

Never drive your boat directly behind a water skier.

• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.

Watch fallen skiers.

• When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the

boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

Report accidents.

• Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when

their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00, or 4) there is complete loss of the boat. Seek further assistance from local law enforcement.

Carbon Monoxide Exposure

Be Alert To Carbon Monoxide Poisoning

Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling CO.

Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include headache, dizziness, drowsiness, and nausea.

WARNING

Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide.

Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.

Stay Clear of Exhaust Areas

Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing). This dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the possibility of injury from the boat propeller.

Good Ventilation

Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat:

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Section 2 - On The Water

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43368

Poor Ventilation

Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.

Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

1. Examples of poor ventilation while the boat is stationary:

a - Operating the engine when the boat

is moored in a confined space

b - Mooring close to another boat that

has its engine operating

2. Examples of poor ventilation while the boat is moving:

a - Operating the boat with the

trim angle of the bow too high

b - Operating the boat with no

forward hatches open (station wagon effect)

Duty Cycle

Basic Boat Operation

IMPORTANT: Damage caused by improper application or failure to operate the power package within the specified operating parameters will not be covered by the Mercury Diesel Limited Warranty.

Duty Cycle Rating

It is the responsibility of the boat manufacturer or the installing dealer to ensure that the power package is properly applied. In all cases, the power package must be equipped with the gear ratio that allows the engine to operate at wide‑open throttle (WOT) at the rated engine RPM. The power package must also be applied in accordance with recommendations indicated in the appropriate applications manual. Use of Mercury Diesel engines in other than the applications indicated by the following information and in the appropriate applications manual requires written approval from an authorized Mercury Diesel application engineer.

Pleasure Duty Rating

The pleasure duty rating applies to recreational planing craft used exclusively for pleasure and recreation. Typical pleasure craft include sailboats, ski boats, runabouts, speedboats, and other planing hulls. Application must conform to the Pleasure Craft/Recreational duty cycle shown in the following table.

Page 18 90-8M0114081 eng DECEMBER 2015

Section 2 - On The Water

Engine speed (percent of WOT) 100 91 80 63 Idle

Engine power (percent of total) 100 75 50 25 0

(percent of total operating time)

Basic Boat Operation

Operation Chart

Starting Procedure

Open the engine hatch. Air out the bilge completely.

Turn the battery switch on, if equipped.

Turn on and run the engine compartment bilge blower, if equipped, for five minutes.

Check for leaks: fuel, oil, water, fluid, etc.

Open the fuel shut‑off valve, if equipped.

Open the seacock, if equipped.

Prime the fuel injection system, if necessary.

Turn the key switch to "START" position. Release the key when the engine starts.

Warm‑up the engine at a fast idle‑RPM for several minutes.

EPA Mode Number

Cycle 5

Duty Cycle

Time at given mode

Chart showing full power operation is limited to a maximum of 1 of 12 hours

14584

After Starting While Underway Stopping and Shut Down Observe all instrumentation to

monitor the condition of the engine. If not normal, stop the engine.

Check for fuel, oil, water, fluid, and exhaust leaks, etc.

Check shift and throttle control operation.

Check steering operation.

1 - Mode 1: 1.0 hour (8%) 2 - Mode 2: 1.5 hours (13%) 3 - Mode 3: 2.0 hours (17%) 4 - Mode 4: 4.0 hours (32%) 5 - Mode 5: 3.5 hours (30%)

Frequently review all instrumentation to monitor engine condition.

Listen for the audio alarm.

1 2 3 4 5

8 13 17 32 30

Modes

Shift the remote control lever to the neutral position.

Run the engine at idle‑RPM for several minutes to allow the turbocharger and engine to cool.

Turn the key switch to "OFF" position.

Turn the battery switch off, if equipped.

Close the fuel shut‑off valve, if equipped.

Close the seacock, if equipped.

Flush the seawater cooling circuit, if operating in saltwater, brackish water, or polluted water.

Freezing Temperature and Cold Weather Operation

IMPORTANT: If the boat is operated during periods of freezing temperature, take precautions to prevent freezing damage to the power package. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.

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Section 2 - On The Water

NOTICE

Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system. If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.

NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and connect the water inlet hose before starting the engine.

In order to operate the engine in temperatures of 0° C (32° F) or lower, observe the following instructions:

• At the end of each daily operation, completely drain the seawater section of the cooling system to protect against damage by freezing.

• At the end of each daily operation, drain the water from the water separator, if equipped. Fill the fuel tank at the end of daily operation to prevent condensation.

• Use the required permanent‑type antifreeze solution to protect components against damage by freezing.

• Use proper cold weather lubrication oil; ensure that the crankcase contains a sufficient amount.

• Make certain that the battery is of sufficient size and is fully charged. Check that all other electrical equipment is in optimum condition.

• At temperatures of –20° C (–4° F) and below, use a coolant heater and a marine application bilge air heater to improve cold starting.

• If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for information about special cold weather equipment and precautions.

Refer to Section 6 for cold weather or extended storage related information.

Drain Plug and Bilge Pump

The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a drain plug or a bilge pump. It is very important to check these items on a regular basis to ensure that the water level does not come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the warranty.

Starting, Shifting, and Stopping

WARNING

Vapors can ignite and cause an explosion, resulting in engine damage or severe personal injury. Do not use volatile starting aids such as ether, propane, or gasoline in the engine air intake system.

WARNING

Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire or explosion. Always ventilate the engine compartment before servicing the power package.

Before Starting the Engine

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

IMPORTANT: Observe the following before starting:

• Verify seawater pickup is open.

• Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool; then, repeat the starting procedure.

• Ensure that the engine crankcase is filled to the correct level with the proper grade of oil for the prevailing temperature. Refer to Specifications—Engine Oil.

• Ensure that all electrical connections are secure.

•

Check all items listed in the maintenance schedules and Operation Chart.

• Perform any other necessary checks as indicated by your Mercury Diesel authorized repair facility or specified in your boat owner’s manual.

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Section 2 - On The Water

Starting a Cold Engine

IMPORTANT: Check the fluid levels before starting the engine. Refer to the Maintenance Schedule. Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool; then, repeat the starting procedure.

1. Run the engine compartment bilge blower for five minutes, or open the engine hatch to air out the bilge before attempting

to start the engine.

2. Place the sterndrive in the full down (in) position.

3. Place the control handle in neutral.

4. If the engine has not been run for a long period of time and will not readily start with the standard starting procedure,

proceed as follows.

5. Turn the ignition switch to the "ON" position and the fuel pump will run for five seconds. Turn the ignition switch to the

"OFF" position and wait for five seconds. repeat this step six times.

6. Start the engine.

IMPORTANT: Within seconds after starting the engine, the oil pressure should exceed a minimum of 10 psi (69 kPa). If the oil pressure is below the minimum specification, stop the engine then locate and correct the problem. If you are unable to determine the problem, see your Mercury Diesel‑authorized repair facility.

NOTICE

Engaging the starter motor while the engine is operating can damage the starter motor or flywheel. Do not engage the starter motor continually for longer than 15 seconds. Do not engage the starter motor when the engine is operating.

7. Verify that the charge indicator and oil pressure warning lamps are off.

8. Verify that all instrumentation is functioning properly and indicating normal readings.

9. Allow the engine to reach a normal operating temperature before demanding power from the engine.

Engine Warm‑Up

1. After starting the engine, verify that all instrumentation is functioning properly.

2. Operate the engine at 1000–1200 RPM until the engine temperature is within the normal operating range. It is important

that any engine be warmed up before applying full load. The warm‑up period provides time for the lubricating oil to establish a film between moving parts.

NOTICE

Engine wear caused by increased friction and limited oil flow is greatest when an engine is cold. Decrease engine wear by allowing the engine coolant temperature to reach normal operating range before hard acceleration or applying full throttle.

3. After the engine has reached operating temperature:

The oil pressure should be within the range specified. Refer to Specifications—Engine Specifications. Stop the

engine if the oil pressure is not within the range specified. b. Check the fuel system for leakage from the injection pump, fuel pipes, fuel filter, or fuel lines. c. Check the engine and drive system for oil leakage. Specifically inspect the oil filter, oil lines, oil line connectors, and

oil pan. d. Check for coolant leaks. Check the coolant hoses and connection pipes of the heat exchanger, fluid coolers,

aftercooler, water pump, and drain fittings for leaks.

4. Correct any problems found, or see your Mercury Diesel‑authorized repair facility if you are unable to determine the problem.

Starting a Warm Engine

1. Run the engine compartment bilge blower for five minutes, or open the engine hatch to air out the bilge before attempting to start the engine.

2. Move the remote control handle to the "NEUTRAL" position.

3. Turn the key switch to the "ON" position.

4. Turn the key switch to the "START" position and release the key when the engine starts. Verify that the charge indicator and oil pressure warning lamps turn off.

5. Verify that the instrumentation functions properly and normal readings are indicated.

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Section 2 - On The Water

21604

Shifting

NOTICE

Shifting into gear at engine speeds above idle will damage the gearcase. Shifting into gear when the engine is not running can misalign the clutch, preventing proper shifting. Always shift the gearcase into gear when the engine is operating at idle. If you must shift while the engine is not operating, rotate the propeller shaft in the appropriate direction during shifting.

1. Verify that the remote control shift lever is in neutral.

2. To shift the sterndrive, move the remote control shift lever with a firm, quick motion forward to shift to forward gear, or backward to shift into reverse.

3. After shifting the sterndrive, advance the throttle to the desired setting. IMPORTANT: Avoid stopping the engine if the sterndrive is in gear. If the engine does stop with the sterndrive in gear, proceed to steps 4 and 5:

4. Push and pull repeatedly on the remote control handle until the handle returns to the neutral detent position. This may take several tries if the power package was operating above idle RPM when the engine stopped.

5. After the handle returns to the neutral detent position, resume normal starting procedures.

Engine Shutdown (Stopping)

1. Place the remote control lever in neutral.

NOTICE

Immediately stopping the engine after high load operation can damage the turbocharger bearings. Idle the engine for several minutes before shutdown.

2. Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool.

3. Turn the key switch to the "OFF" position or press the start‑stop switch button if equipped.

Starting the Engine After Stopped While in Gear

IMPORTANT: Avoid stopping the engine if the sterndrive is in gear. If the engine does stop with the sterndrive in gear, see the following procedure:

1. Push and pull repeatedly on the remote control handle until the handle returns to the neutral detent position. This may take several tries if the power package was operating above idle RPM when the engine stopped.

2. After the handle returns to the neutral detent position, resume normal starting procedures.

Trailering the Boat

Your boat can be trailered with the sterndrive unit in the up or down position. Adequate clearance is required between the road and sterndrive when transporting.

If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit, available at your Mercury Diesel authorized repair facility.

Protecting People In The Water

While Boat is in Operation

People in the water cannot take quick action to avoid a boat heading in their direction.

Approach slowly and exercise extreme caution when boating in areas where people may be in the water. When a boat is moving and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the

propeller to rotate. This neutral propeller rotation can cause serious injury.

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Section 2 - On The Water

While the Boat is Stationary

WARNING

A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers. Stop the engine immediately whenever anyone in the water is near your boat.

Shift into neutral and shut down the engine before allowing people in the water near the boat.

High Speed and High Performance

If your boat is a high‑speed or high performance boat with which you are unfamiliar, we recommend that you never operate it at its high‑speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to the High Performance Boat Operation booklet (90‑849250‑R2) from your authorized Mercury Diesel repair facility.

Passenger Safety in Pontoon Boats and Deck Boats

Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat. Falling over the front of the boat between the two pontoons will position them to be run over.

Boats Having an Open Front Deck

No one should ever be on the deck in front of the rail while the boat is in motion. Keep all passengers behind the front rail or enclosure.

Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.

mc79555-1

WARNING

Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.

Boats with Front-Mounted, Raised-Pedestal Fishing Seats

Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds.

Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

mc79557-1

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Section 2 - On The Water

Wave and Wake Jumping

WARNING

Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

mc79680-1

Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with enough speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat reenters the water.

The primary concern is the boat changing direction while in the midst of the jump. In such cases the landing may cause the boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat.

There is another less common hazardous result from allowing your boat to launch off of a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat nearly to a stop in an instant and can send the occupants flying forward. The boat may also veer sharply to one side.

Impact with Underwater Hazards

Reduce speed and proceed with caution when operating in shallow water or in areas where the waters are suspected of having underwater obstacles that could be struck by the drive components, rudder, or the boat bottom.

mc79679-1

IMPORTANT: To help reduce injury or impact damage from striking a floating or underwater object, control the boat speed. Under these conditions, boat speed should be kept to a maximum of 24 to 40 km/h (15 to 25 mph).

The following demonstrate some, but not all, examples of what can happen if the boat strikes an object:

• The boat could move suddenly in a new direction. A sharp change in direction or turn can throw occupants out of their seats or out of the boat.

• A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat.

• Impact damage to the underwater drive components, rudder, or boat.

Keep in mind that one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles.

After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to a Mercury Diesel‑authorized repair facility for a thorough inspection and any necessary repair.

The boat should be checked for hull fractures, transom fractures, and water leaks. Operating with damaged drive components, rudder, or boat bottom could cause damage to other parts of the power package,

or could affect control of the boat. If continued operation is necessary, do so at greatly reduced speeds.

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Section 2 - On The Water

WARNING

Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.

Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat

Shifting weight to the rear (stern):

• Generally increases speed and engine RPM

• Causes bow to bounce in choppy water

• Increases danger of following wave splashing into the boat when coming off plane

• At extremes, can cause the boat to porpoise

Shifting weight to the front (bow):

• Improves ease of planing

• Improves rough‑water ride

• At extremes, can cause the boat to veer back and forth (bow steer)

Bottom of Boat

To maintain maximum speed, ensure that the boat bottom is:

• Clean, free of barnacles and marine growth

• Free of distortion, nearly flat where it contacts water

• Straight and smooth, fore and aft Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog water

inlets and cause the engine to overheat.

Cavitation

Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object, such as a gear housing or a propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the gear housing or the propeller. Common causes of cavitation are:

• Weeds or other debris snagged on the propeller

• Bent propeller blade

• Raised burrs or sharp edges on the propeller

Ventilation

Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed‑up and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to continue, eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:

• The drive unit being trimmed out too far

• A missing propeller diffuser ring

• A damaged propeller or gear housing, that allows exhaust gases to escape between the propeller and gear housing

• The drive unit installed too high on transom

Elevation and Climate

Elevation and climate changes affect the performance of your power package. Loss of performance can be caused by:

• High elevations

• High temperatures

• Low barometric pressures

• High humidity For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to

allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your normal boating weather conditions.

In most cases, the recommended RPM can be achieved by changing to a lower pitch propeller.

90-8M0114081 eng DECEMBER 2015 Page 25

Section 2 - On The Water

Propeller Selection

NOTICE

Operating the engine with the wrong propeller installed can limit power, increase fuel consumption, overheat the engine, or cause internal powerhead damage. Choose a propeller that allows the engine to operate at the specified wide open throttle RPM.

It is the responsibility of the boat manufacturer and the selling dealer to equip the power package with the correct propellers. IMPORTANT: Be sure that the propeller being used does not allow the engine to run against the limiter, as a significant loss in

performance will result.

NOTE: Use an accurate service tachometer to verify RPM.

Select a propeller that will allow the engine power package to operate at the rated engine RPM with a full load. If full‑throttle operation is below the rated engine RPM, the propeller must be changed to prevent loss of performance and

possible engine damage. On the other hand, operating an engine above the rated engine RPM will cause higher than normal wear or damage.

After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch:

• Warmer weather and greater humidity cause an RPM loss (not as significant on these models).

• Operating in a higher elevation causes an RPM loss (not as significant on these models).

• Operating with a damaged propeller or dirty boat bottom causes an RPM loss.

• Operating with increased load (additional passengers, pulling skiers).

For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do not operate at full throttle when using the lower pitch propeller but not pulling skiers.

Break‑In

Initial Break‑In Procedure

It is especially important that the following procedure be used on new diesel engines. This break‑in procedure allows the proper seating of the pistons and rings, which greatly reduces the likelihood of problems.

IMPORTANT: It is recommended that the boat not be accelerated hard until this procedure has been completed. IMPORTANT: Never operate the starter motor longer than 15‑seconds at a time to avoid overheating the starter motor. If the engine does not start, wait approximately 60‑seconds to allow the starter motor to cool; then, repeat the starting procedure.

See the appropriate Starting, Shifting, and Stopping section, and start the engine. Operate the engine at a fast idle until it has reached normal operating temperature.

2. Operate the engine in gear for three‑minutes at : 1200 RPM, 2400 RPM, and 3000 RPM.

3. Operate the engine in gear for three‑minutes at: 1500 RPM, 2800 RPM, and 3400 RPM.

4. Operate the engine in gear for three‑minutes at : 1800 RPM, 3000 RPM, and maximum rated full throttle RPM.

Sterndrive 10‑Hour Break‑In Period (New or With Replacement Gears)

It is important that the following procedure be used on new sterndrives and rebuilt sterndrives with new replacement gears. This break‑in procedure allows the proper seating of the sterndrive gears and related components, which greatly reduces the likelihood of problems.

• Avoid full‑throttle starts.

• Do not operate at any constant speed for an extended period of time.

• Do not exceed 75% throttle during the first five‑hours. During the next five‑hours, operate at intermittent full throttle.

• The sterndrive should be shifted into forward gear a minimum of 10 times during break‑in, with run‑in time at moderate RPM after each shift.

Engine Break‑In

20-Hour Break-In Period

IMPORTANT: The first 20 hours of operation is the engine break‑in period. Correct break‑in is essential to obtain minimum oil consumption and maximum engine performance. During this break‑in period, the following rules must be observed:

• Do not operate below 1500 RPM for extended periods of time for the first 10 hours. Shift into gear as soon as possible after starting, and advance the throttle above 1500 RPM if conditions permit safe operation.

• Do not operate at any constant speed for an extended period of time.

• Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occasional operation at full throttle is permissible (in five‑minute intervals).

Page 26 90-8M0114081 eng DECEMBER 2015

Section 2 - On The Water

• Avoid full‑throttle acceleration from an idle.

• Do not operate at full‑throttle until the engine reaches normal operating temperature.

• Check engine oil level frequently. Add oil as needed. High oil consumption is normal during the break‑in period.

•

At the end of the 20‑hour break‑in period, change the engine oil and filter as specified. Refer to Specifications and Maintenance.

After the 20-Hour Break-In Period

To help extend the life of the power package, Mercury Diesel recommends the following:

• Select a propeller that functions efficiently throughout the recommended engine powerband for a fully‑loaded boat. Refer to

Specifications and Maintenance.

• Never operate at wide‑open throttle for prolonged periods. Operation at 3/4 throttle and below is recommeneded.

End of First Season Checkup

At the end of the first season of operation, contact an authorized Mercury Diesel repair facility regarding scheduled maintenance items. If the product is operated on a continuous, or year‑round basis, contact the dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.

90-8M0114081 eng DECEMBER 2015 Page 27

Section 2 - On The Water

Notes:

Page 28 90-8M0114081 eng DECEMBER 2015

Table of Contents

Section 3 - Specifications

Fuel Requirements............................................................... 30

Nonferrous Metals and the Fuel System ...................... 30

Diesel Fuel in Cold Weather................................................. 30

Antifreeze/Coolant................................................................ 30

Engine Oil ............................................................................ 31

Engine Specifications........................................................... 31

Fluid Specifications............................................................... 32

Engine............................................................................32

Bravo Sterndrive Fluid Specifications—Diesel.............. 32

Power Steering and Power Trim Fluids......................... 32

Approved Power Steering Fluids ........................... 32

Approved Power Trim Fluids ................................. 32

Approved Paints................................................................... 32

90-8M0114081 eng DECEMBER 2015 Page 29

Section 3 - Specifications

Fuel Requirements

WARNING

Failure to comply with regulations can result in injury from fire or explosion. Electrical system components on this engine are not rated as external ignition–protected (EIP). Do not store or use gasoline on boats equipped with these engines, unless provisions have been made to exclude gasoline vapors from the engine compartment (REF: 33 CFR).

WARNING

Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation.

WARNING

This engine requires diesel fuel. Mixing gasoline, gasohol, or alcohol and diesel fuel can cause serious injury or death due to fire or explosion. Never mix gasoline, gasohol, or alcohol with diesel fuel.

IMPORTANT: Use of improper or water‑contaminated diesel fuel can seriously damage your engine. Use of improper fuel is considered misuse of the engine, and damage caused thereby will not be covered by the warranty.

Mercury diesels are required to use Grade No. 2‑D ULSD (ultra‑low sulphur diesel) fuel meeting ASTM Standards D975 (or fuel rated Diesel DIN EN 590), and having a minimum cetane rating of 40.

BIODIESEL: The blend of diesel fuel used may not contain more than 7% biodiesel fuel. Use of LSD or blends of ULSD fuel containing more than 7% biodiesel fuel may result in fuel system degradation, injection nozzle clogging, hard starting, increased oil change intervals, or excessive exhaust smoke.

The cetane number is a measure of the ignition quality of diesel fuel. Increasing the cetane number will not improve overall engine performance, but it may be necessary to raise the cetane rating for low‑temperature or high‑altitude use. A lower cetane number could cause hard starting and slower warm‑up, and could increase engine noise and exhaust emissions.

NOTE: If your engine suddenly becomes noisy after a fill‑up, you possibly received substandard fuel with a low cetane rating.

On intermittent‑use engines, high sulphur content diesel fuel will greatly increase:

• Corrosion on metal parts

• Deterioration of elastomer and plastic parts

• Excessive wear of internal engine parts, particularly bearings, and corrosion and extensive damage to other engine parts

• Difficulty starting and operating the engine

Nonferrous Metals and the Fuel System

Nonferrous metals must not be used in the fuel system components. The use of items such as copper lines, brass nipples, or galvanized tanks may result in an engine power loss or a failure of the injection nozzles.

Diesel Fuel in Cold Weather

Unaltered diesel fuels thicken and gel in cold temperatures unless treated. Virtually all diesel fuels are climatized to allow their use in the particular region for that time of the year. If it becomes necessary to further treat diesel fuel, it is the owner/operator's responsibility to add a commercial standard brand of antigel diesel fuel additive, following that product's directions.

Antifreeze/Coolant

NOTICE

Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed.

Diesel engines are high‑compression engines that operate at higher temperatures than typical insternal combustion engines. Therefore, the closed‑cooling system and engine, including related cooling passages, must remain as clean as possible to provide adequate engine cooling. To ensure proper cooling, we recommend filling the closed‑cooling section of the cooling system with a low silicate formula of ethylene glycol antifreeze in a solution with deionized water. Common tap water or softened water contains unwanted minerals that can leave large deposits in the system that restrict the cooling system efficiency. A low silicate formula prevents the antifreeze from separating and forming a silicate gelatin. This gelatin can block passages in the engine and heat exchanger, causing the engine to overheat.

Page 30 90-8M0114081 eng DECEMBER 2015

Section 3 - Specifications

Only premixed, coolant should be added to the closed‑cooling system. Additives and inhibitors introduced into acceptable coolant solutions will form a protective film on the internal passages and provide protection against internal cooling system erosion.

Do not drain the closed‑cooling section for storage. The closed‑cooling section should be kept filled year‑round with an acceptable antifreeze/coolant solution to avoid rust forming on the internal surfaces. If the engine will be exposed to freezing temperatures, ensure that the closed‑cooling section is filled with a properly mixed antifreeze/coolant solution to protect the engine and closed‑cooling system to the lowest temperature to which they will be exposed.

NOTE: It is recommended that a 50/50 solution of coolant (antifreeze) and deionized, purified water be used. A 50/50 solution will provide freeze protection to –35° C (–31° F). Decreasing the solution to 40/60 will provide freeze protection to –25° C (–13° F). Even in the warmest climates, never decrease the solution below 40/60. Increasing the solution to 60/40 will provide freeze protection to –50° C (–58° F).

IMPORTANT: The antifreeze/coolant used in these marine engines must be a low silicate ethylene glycol, containing special additives, and deionized, purified water. Using other types of engine coolant may cause fouling of the heat exchangers and overheating of the engine. Do not combine different types of coolants without knowing that they are compatible. Refer to the coolant manufacturer's instructions.

The acceptable antifreeze/coolants is listed in the following table. Refer to Section 5 ‑ Maintenance for respective change intervals.

Description

Marine Engine Coolant Worldwide 8M0078028

Availability Part Number

Engine Oil

NOTICE

Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,

coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing

the disposal or recycling of waste, and contain and dispose of fluids as required.

Engine oil must be 5W‑30 viscosity, and meet VW Standard 504 00/507 00. We strongly recommend the use of:

Description

5W‑30 (1 L) Engine crankcase 8M0069603

5W‑30 (4 L) Engine crankcase 8M0069602

Where Used Part Number

Engine Specifications

Description Engine type V8 diesel Displacement 4.2 L (252 cid) Firing order 1‑5‑4‑8‑6‑3‑7‑2 Bore 83.0 mm (3.27 in.) Stroke 95.5 mm (3.75 in.) Rated engine RPM (refer to Conditions Affecting Operation

—Propeller Selection for additional information) Idle RPM in neutral (engine at normal operating temperature) 650 RPM

Oil pressure at any engine temperature

Thermostat Water 70° C (158° F) Coolant temperature 70–85° C (158–185° F) Electrical system 12‑volt negative (–) ground Battery* 750 CCA, 950 MCA, or 180 mAh Alternator 120 A

750 RPM 152–310 kPa (22–45 psi)

3800 RPM 345–556 kPa (50–80 psi)

Refer to Performance Curve and Data Sheet TDI (available

at www.mercurymarine.com/engines/diesel/)

Specification

*Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and Reserve Capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.

90-8M0114081 eng DECEMBER 2015 Page 31

Section 3 - Specifications

Fluid Specifications

IMPORTANT: All capacities are approximate fluid measures.

Engine

IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines).

All models Capacity Fluid Type Part Number

Engine oil (with filter) 9.5 L (10.0 US qt)

Closed‑cooling system 15.0 L (15.8 US qt) Marine Engine Coolant 8M0078028 Hydraulic oil Hydraulic oil 858075K01

Bravo Sterndrive Fluid Specifications—Diesel

Fluid Capacity includes the

Sterndrive Model

Bravo One XR 2736 ml (92‑1/2 oz) Bravo Three XR 2972 ml (100‑1/2 oz)

Sterndrive and the Gear

Lube Monitor

Power Steering and Power Trim Fluids

Approved Power Steering Fluids

5W‑30 4‑cycle Diesel Engine Oil (1 L) 8M0069603 5W‑30 4‑cycle Diesel Engine Oil (4 L) 8M0069602

Fluid Type Fluid Part Number

High Performance Gear

Lubricant

92‑802854A1

Description Power Trim and Steering Fluid 92‑802880A1 Dextron III Automatic Transmission Fluid Obtain Locally

Part Number

Approved Power Trim Fluids

Description Power Trim and Steering Fluid 92‑802880A1 SAE Engine Oil 30W Obtain locally SAE Engine Oil 40W Obtain locally

Part Number

Approved Paints

Description Mercury Light Gray Primer 92‑802878 52 Mercury Phantom Black 92‑802878Q 1 Diesel White 8M0071082

Part Number

Page 32 90-8M0114081 eng DECEMBER 2015

Table of Contents

Section 4 - Maintenance

Owner and Operator Responsibilities................................... 34

Dealer Responsibilities......................................................... 34

Maintenance......................................................................... 34

Replacement Parts Warning................................................. 35

Inspection............................................................................. 35

Routine Maintenance............................................................ 35

Start of Season ............................................................. 35

Each Day Start ............................................................. 35

Each Day End ............................................................... 35

Weekly .......................................................................... 35

End of Season .............................................................. 35

Scheduled Maintenance....................................................... 36

Once a Year or Every 200 Operating Hours (Whichever

Occurs First) ................................................................. 36

Maintenance Notice ...................................................... 36

Every 5 Years or 500 Hours (Whichever Occurs First)

...................................................................................... 36

Every 5 Years or 1,000 Operating Hours (Whichever

Occurs First) ................................................................. 36

Every 5 Years or 2,000 Operating Hours (Whichever

Occurs First) ................................................................. 36

Engine Oil............................................................................. 36

Checking ....................................................................... 37

Filling ............................................................................ 37

Draining Using the Easy Drain System, if Equipped .... 37

Changing Oil and Filter ................................................. 38

Sterndrive Gear Lube........................................................... 39

Checking ....................................................................... 39

Filling ............................................................................ 39

Changing ...................................................................... 40

Power Trim Fluid.................................................................. 43

Checking ....................................................................... 43

Filling ............................................................................ 44

Changing ...................................................................... 45

Power Steering Fluid............................................................ 45

Checking ....................................................................... 45

Filling ............................................................................ 45

Changing ...................................................................... 46

Engine Coolant..................................................................... 46

Checking the Coolant Level .......................................... 47

Adding Coolant ............................................................. 47

Air Filter................................................................................ 47

Removal ....................................................................... 47

Inspection and Cleaning ............................................... 47

Installation .................................................................... 48

Fuel Filter.............................................................................. 48

Draining Water from the Filter ...................................... 48

Replacing the Filter ....................................................... 48

Purging the Fuel System...................................................... 49

Fuel System.......................................................................... 49

Priming ......................................................................... 49

Fuel Tank Cleaning and Flushing ................................. 49

Seawater System................................................................. 49

Seawater Pump Impeller Inspection.............................. 49

Sterndrive Water Inlets Check....................................... 50

Flushing and Draining the Seawater System.................51

Checking the Seawater Pickups.................................... 52

Cleaning the Seawater Strainer, if Equipped................. 52

Corrosion Protection............................................................. 53

General Information....................................................... 53

Sacrificial Anode............................................................ 53

Antifouling Paint............................................................. 54

Lubrication............................................................................ 54

Steering System............................................................ 54

Throttle Cable................................................................ 55

Shift Cable..................................................................... 55

Transom Assembly........................................................ 55

Propeller Shaft............................................................... 55

Engine Coupler.............................................................. 56

Driveshaft Extension Models......................................... 57

Maintaining Torques............................................................. 57

Gimbal Ring U‑bolt Nuts................................................ 57

Engine Mounts............................................................... 58

Propellers............................................................................. 58

Bravo Sterndrive Propeller Removal............................. 58

Bravo One Models ................................................. 58

Bravo Two Models ................................................. 59

Bravo Three Models .............................................. 60

Bravo Sterndrive Propeller Installation.......................... 61

Bravo One Models ................................................. 61

Bravo Three ........................................................... 62

Drive Belts............................................................................ 63

Drive Belt....................................................................... 63

Drive Belt Failure Identification...................................... 63

Battery.................................................................................. 64

Battery Precautions for Multiple Engines.............................. 65

Alternators .................................................................... 65

Engine Control Unit (ECU) ........................................... 65

Batteries ....................................................................... 65

Battery Switches ........................................................... 65

Battery Isolators ............................................................ 65

Generators .................................................................... 65

90-8M0114081 eng DECEMBER 2015 Page 33

Section 4 - Maintenance

Owner and Operator Responsibilities

It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation, and to return the unit to a Mercury Diesel–authorized repair facility for a periodic checkup.

Normal maintenance service and replacement parts are the responsibility of the owner or operator and are not covered by the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of your power package will ensure optimum performance and dependability and will keep your overall operating expenses at a minimum. See your Mercury Diesel–authorized repair facility for service aids.

Dealer Responsibilities

Below is a list of Mercury Diesel dealer predelivery inspection and preparation responsibilities:

• Verify that the power package is in proper operating condition.

• Make any necessary adjustments for maximum efficiency.

• Explain and demonstrate the operation of the power package and the boat.

• Provide a copy of the Predelivery Inspection Checklist.

• Fill out the warranty registration card completely and mail it to the factory immediately upon sale of the new product. All power packages must be registered for warranty purposes.

Maintenance

WARNING

Neglect or improper maintenance, repairs, or inspections of the power package can result in product damage or serious injury or death. Perform all procedures as described in this manual. If you are not familiar with proper maintenance or service procedures, consign the work to an authorized Mercury Marine dealer.

WARNING

Accidental engine starting can cause serious injury or death. Remove the key from the ignition switch and engage the lanyard stop or E‑stop switch to prevent the engine from starting when performing service or maintenance on the power package.

WARNING

Engine components and fluids are hot and can cause serious injury or death. Allow the engine to cool before removing any components or opening any fluid hoses.

WARNING

Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components.

WARNING

IMPORTANT: Refer to Maintenance Schedule for a complete listing of all scheduled maintenance to be performed. Some tasks can be done by the owner or operator, while others should be performed by an authorized Mercury Diesel repair facility. Before attempting maintenance or repair procedures not covered in this manual, we recommended that you purchase the appropriate Mercury Diesel service manual and read it thoroughly.

Before performing any maintenance on your Mercury Diesel engine:

• Protect yourself with suitable work clothing and personal protection equipment.

• Stop the engine, remove the ignition key, and press the emergency stop switch.

• Move the throttle to the neutral position.

• Allow the engine to cool.

• Ventilate the engine compartment for at least five minutes before beginning work.

• Disconnect the battery, if servicing any electrical components. Always disconnect the negative (–) lead first and reconnect it last.

Page 34 90-8M0114081 eng DECEMBER 2015

Section 4 - Maintenance

Replacement Parts Warning

WARNING

Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.

Inspection

Inspect your power package often and at regular intervals to help maintain operating performance and to identify potential problems before they occur. The entire power package should be checked carefully, including all accessible engine parts.

1. Check for loose, damaged, or missing parts, hoses, and clamps; tighten or replace as necessary.

2. Check electrical connections and leads for damage.

3. Remove and inspect the propeller. If it is badly nicked, bent, or cracked, contact your Mercury Diesel–authorized repair

facility.

4. Repair nicks and corrosion damage on power package exterior finish. Contact your Mercury Diesel–authorized repair

facility.

Routine Maintenance

Start of Season

• Inspect the power package for leaks and damage.

• Inspect the accessory drive belts, hoses, and power steering pump (if applicable).

• Inspect the fuel injection pump drive belt condition.

• Verify that the seacock operates properly.

• Check the charge, connections, and condition of the battery. Charge or replace the battery as necessary.

• Check all fluid and lubricant levels, and adjust them as necessary.

• Inspect the anodes and replace them if they are 50% eroded.

Each Day Start

• Inspect the power package for leaks and damage.

• Check the engine oil level and adjust it as necessary.

• Check the engine coolant level and adjust it as necessary.

• Check the condition of the fuel filter. Drain water from the filter as necessary.

• Check the seawater strainer and clean it as necessary.

• Check the drive lubricant level (if applicable), and adjust it as necessary.

• Check the reverse‑gearbox lubricant level and adjust it as necessary, where applicable.

• Clean the gauges.

• Inspect the air filter for discoloration and contaminants.

Each Day End

• If operating in saltwater, brackish water, or polluted water, flush the seawater section of the cooling system.

• Drain any water from the fuel filter, if operating in freezing temperatures.

Weekly

• Inspect the power package for leaks and damage.

• Drain any water from the fuel filter.

• Check the trim pump fluid level, if applicable.

• Check the seawater inlets for debris or marine growth.

• Check and clean the seawater strainer.

• Inspect the anodes, and replace them if they are 50% eroded.

• Inspect the air filter for discoloration and contaminants.

End of Season

• Inspect the power package for leaks or damage.

90-8M0114081 eng DECEMBER 2015 Page 35

Section 4 - Maintenance

• Change the engine oil and filter.

• Check the coolant level and adjust it as necessary.

• Check the seawater pump impeller and replace it as necessary.

• Check the air filter element and clean it as necessary.

• Check and clean the seawater strainer.

• Inspect the anodes and replace them if they are 50% eroded.

• Clean the engine and replace worn or damaged components.

• Flush, drain, and winterize the seawater cooling system, if the climate requires it.

• Fill the fuel tank with fresh fuel.

Scheduled Maintenance

Once a Year or Every 200 Operating Hours (Whichever Occurs First)

• Inspect the power package for leaks and damage.

• Check the charge, connections, and condition of the battery. Charge or replace the battery as necessary.

• Change the engine oil and filter element.

• Drain any water and change the fuel filter.

• Check the power steering hydraulic oil level (if applicable), and adjust it as necessary.

• Inspect the coolant level and adjust it as necessary.

• Inspect the air filter element and clean it as necessary.

• Inspect the accessory drive belts, hoses, and power steering pump, where applicable.

• Inspect the fuel injection pump drive belt condition.

• Inspect and clean the seawater strainer.

• Inspect the seawater pump and change the impeller as necessary.

• Inspect the anodes and replace them if they are 50% eroded.

• Verify that the gauges and the wiring connections are secure.

Maintenance Notice

IMPORTANT: Due to the risk of damaging equipment if they are performed incorrectly, we highly recommended that the following scheduled maintenance items be performed only by a Mercury Diesel authorized repair facility.

Every 5 Years or 500 Hours (Whichever Occurs First)

In addition to the Once–a–Year or Every 200 Operating Hours interval:

• Clean the intercooler core.

Every 5 Years or 1,000 Operating Hours (Whichever Occurs First)

In addition to the Once–a– Year or Every 200 Operating Hours interval:

• Clean the fuel tank.

• Check the heat exchanger pipe bundles. Remove and clean them as necessary:

Every 5 Years or 2,000 Operating Hours (Whichever Occurs First)

In addition to the Once–a–Year or Every 200 Operating Hours and Every 5 Years or 1,000 Operating Hours intervals:

• Replace the fuel injection pump drive belt.

Engine Oil

NOTICE

Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

Page 36 90-8M0114081 eng DECEMBER 2015

Section 4 - Maintenance

50505

50504

Checking

NOTICE

With the engine running, the crankshaft journals or rod journals may strike and break the dipstick, resulting in damage to internal engine components. Stop the engine completely before removing or inserting the dipstick.

1. If it becomes necessary to check the engine oil level during operation, stop the engine and allow five minutes for the oil to

drain into the pan.

2. Remove the dipstick, wipe it clean, and insert the dipstick back into the dipstick tube.

3. Remove the dipstick and check the oil level. The oil level must be between the indicator marks on the dipstick. If

necessary, add oil as follows.

Dipstick indicator marks

a - Do not add oil b - Safe operating range c - Add oil

Filling

IMPORTANT: Do not overfill the engine with oil. When filling the engine with oil always use the dipstick to determine how much oil is required.

1. Remove the oil fill cap.

Oil fill cap

2. Add oil to bring the level up to, but not over, the maximum mark on the dipstick.

Description Engine oil (with filter) 9.5 L (10.0 US qt) SAE 5W‑30 meeting VW Spec 50700

3. Install the oil fill cap.

Capacity Fluid Type

Draining Using the Easy Drain System, if Equipped

NOTE: The boat must be out of the water to perform this procedure.

1. Remove the boat from the water.

90-8M0114081 eng DECEMBER 2015 Page 37

Section 4 - Maintenance

7284

50509

2. Loosen the oil filter to vent the oil system.

a - Bilge drain plug b - Tether c - Clip d - Oil drain hose plug e - Oil drain hose f - Bilge drain flange

3. Remove the bilge drain plug.

4. Pull the tether through the bilge drain.

5. Place the oil drain hose in a suitable container.

6. Remove the drain plug from the oil drain hose.

7. After the oil has drained completely, install the drain plug in the oil drain hose.

8. Push the oil drain hose through bilge drain and install the bilge drain plug.

Changing Oil and Filter

Refer to the Maintenance Schedule for the change interval. You should change the engine oil before placing the boat in storage.

IMPORTANT: Change the engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only the recommended engine oil. Refer to Specifications.

1. Start and run the engine until normal operating temperature is achieved.

2. Stop the engine and wait approximately five minutes for the oil to drain into the oil pan.

3. Drain the oil from the engine into a suitable container. Dispose of all waste oil as directed by local authorities.

4. Place a suitable container under the oil filter housing to contain any oil leakage that may occur. Use an appropriate socket to loosen the oil filter protective cap.

5. Remove the protective cap and filter element.

Oil filter and housing

a - Protective cap b - O‑ring (large) c - Filter element d - Transfer tube O‑ring (small) e - Oil filter housing

6. Disconnect and discard the old filter element.

7. Discard the old O‑ring from the protective cap.

8. Apply a small amount of engine oil to the large O‑ring and install the O‑ring in the protective cap.

9. Apply a small amount of engine oil to the small O‑ring and install it onto the filter element transfer tube.

Page 38 90-8M0114081 eng DECEMBER 2015

Section 4 - Maintenance

10. Push the filter element onto the protective cap until it is locked. Listen for a click.

11. Install the protective cap with the new filter element into the oil filter housing. IMPORTANT: When installing the filter element into the oil filter housing, be sure to align the transfer tube on the filter element with the orifice in the bottom of the filter housing to avoid damaging the filter element. IMPORTANT: Overtightening the protective cap will cause deformation resulting in oil leakage.

12. Thread the protective cap into the filter housing until the sealing surface contacts the housing. Tighten the protective cap to the specified torque.

Description Nm lb‑in. lb‑ft Protective cap 35 – 25.8

13.

Remove the oil fill cap and fill the engine with new oil. Refer to Filling. IMPORTANT: When filling the engine with oil, always use the dipstick to determine how much oil is required.

14. Start the engine and check for leaks.

Sterndrive Gear Lube

NOTICE

Checking

NOTE: The gear lube level will fluctuate during operation. The gear lube level should be checked with the engine cold, before starting.

Check the gear lube monitor to determine the gear lube level. Keep the gear lube level within the recommended operating range. Refer to Filling.

Gear lube level shown is at the correct operating range

a - "ADD" mark

b - "OPERATING RANGE" mark

19948

Filling

IMPORTANT: If more than 59 ml (2 fl oz) of High Performance Gear Lube is required to fill the gear lube monitor, a seal may be leaking. Damage to the sterndrive may occur due to lack of lubrication. Contact your Mercury Diesel–authorized repair facility.

1. If the gear lube level is below or near the "ADD" mark, the specified gear lube must be added.

2. Remove the gear lube monitor cap.

90-8M0114081 eng DECEMBER 2015 Page 39

Section 4 - Maintenance

3. Fill the gear lube monitor with the specified gear lube so that the gear lube level is in the operating range. Do not overfill.

Gear lube monitor

a - Gear lube level at the "ADD" mark b - Gear lube level at the "OPERATING RANGE" mark c - Gear lube monitor cap

19947

Tube Ref No. Description Where Used Part No.

4. Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap. Do not overtighten.

NOTE: When filling the entire sterndrive, refer to

High Performance Gear Lube Gear lube monitor 92-858064K01

a - Gear lube monitor cap

19962

Changing

1. Remove the gear lube monitor from the bracket.

5500

2. Empty the contents of the gear lube monitor into a suitable container.

3. Install the gear lube monitor in the bracket.

Bravo One X Models:

a. Remove the propeller. b. Lower the sterndrive to the full down (in) position. c. Remove the gear lube fill and drain plug and sealing washer.

a - Gear lube monitor bracket b - Gear lube monitor and cap c - Retaining strap

Page 40 90-8M0114081 eng DECEMBER 2015

d. Drain the gear lube into a suitable container.

mc79506-1

a - Fill and drain plug b - Sealing washer

Bravo Three X Models:

a. Place the sterndrive in full trim limit out position. b. Remove the fill and drain plug and sealing washer. c. Drain the gear lube into a suitable container.

Section 4 - Maintenance

14621

Bravo Two X

a - Fill and drain plug b - Sealing washer

6. Remove the vent plug and sealing washer. Allow the gear lube to drain completely.

19066

IMPORTANT: If any water drains from the fill and drain plug hole, or if the gear lube appears milky, the sterndrive is leaking and should be checked immediately by your Mercury Diesel–authorized repair facility.

7. Lower the sterndrive so that the propeller shaft is level.

8. Fill the sterndrive through the fill and drain plug hole with the specified gear lube until an air‑free stream of lube flows from

the vent plug hole. IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lube in the sterndrive.

Bravo Three X

a - Vent plug b - Sealing washer

19777

Tube Ref No.

90-8M0114081 eng DECEMBER 2015 Page 41

High Performance Gear Lube Sterndrive unit 92-858064K01

Description Where Used Part No.

Section 4 - Maintenance

9. Install the vent plug and sealing washer.

10. Continue to pump gear lube into the drive through the fill and drain plug hole until the gear lube appears in the gear lube monitor.

11. Fill the gear lube monitor so that the gear lube level is in the operating range. Do not overfill.

Gear lube monitor

a - Gear lube level at the "ADD" mark b - Gear lube level at the "OPERATING RANGE" mark c - Gear lube monitor cap

19947

Fluid Capacity includes

Sterndrive Model

Bravo One X Diesel Bravo One XR

Bravo Three X Diesel Bravo Three XR

12. Ensure that the rubber gasket is inside the gear lube monitor cap and install. Do not overtighten.

the Sterndrive and the

Gear Lube Monitor

2736 ml (92‑1/2 oz)

2972 ml (100‑1/2 oz)

a - Gear lube monitor cap

Fluid Type Fluid Part Number

High Performance Gear

Lube

92‑802854A1

19962

13. Remove the pump from the sterndrive fill and drain plug hole.

Page 42 90-8M0114081 eng DECEMBER 2015

Section 4 - Maintenance

mc79506-1

14. Quickly install the sealing washer and the fill and drain plug. Tighten the plug to the specified torque.

14621

All Bravo models shown

a - Fill and drain plug b - Sealing washer

19777

Description Nm lb‑in lb‑ft Fill and drain plug 6.8 60 —

15.

Install the sterndrive propeller. Refer to Propellers.

16.

Check the level of the gear lube monitor after the first use. Refer to Maintaining Fluid Levels. IMPORTANT: The gear lube monitor level will change while the product is in use. Always check the gear lube level when the sterndrive is cool and the engine is not running.

Power Trim Fluid

Checking

IMPORTANT: Check the fluid level with the sterndrive in the full down (in) position only.

1. Place the sterndrive in full down (in) position.

90-8M0114081 eng DECEMBER 2015 Page 43

Section 4 - Maintenance

7701

2. Observe the fluid level. The fluid level must be between the "MIN" and "MAX" lines on the reservoir.

a - Reservoir b - "MIN" and "MAX" lines

Fill as necessary with the specified fluid. Refer to Filling.

Tube Ref No. Description Where Used Part No.

114

Power Trim and Steering Fluid Power trim pump 92-858074K01

Filling

1. If the fluid level is below the "MIN" line, the specified fluid must be added.

2. Remove the fill cap from the reservoir.

NOTE: The fill cap is vented.

7876

Power trim pump reservoir shows the

fluid level is below "MIN" line

a - Fill cap assembly b - Fill cap installed

Page 44 90-8M0114081 eng DECEMBER 2015

3. Add the specified fluid to bring the fluid level to within the "MIN" and "MAX" lines on the reservoir.

52308

Section 4 - Maintenance

a - Reservoir b - "MIN" and "MAX" lines

Tube Ref No. Description Where Used Part No.

114

4. Install the fill cap.

Power Trim and Steering Fluid Power trim pump 92-858074K01

7876

Changing

Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your Mercury Diesel authorized repair facility.

Power Steering Fluid

The power steering fluid level should be checked at regular intervals. IMPORTANT: Do not leave the steering wheel at full lock longer than 15 seconds with the engine running. The power steering

fluid will heat up considerably when the steering wheel is at full lock and could damage the power steering system. When the steering wheel is at full lock, power steering pump noise will increase as the pump is under full load and the engine idle RPM will be reduced momentarily.

Checking

1. Center the sterndrive and stop the engine.

2. Remove the fill cap and dipstick from the fluid reservoir and observe the level.

a - Fill cap b - Power steering fluid reservoir

IMPORTANT: If fluid is not visible in the fluid reservoir, see your Mercury Diesel–authorized repair facility.

Filling

1. Remove the fill cap/dipstick and wipe it with a clean cloth.

90-8M0114081 eng DECEMBER 2015 Page 45

Section 4 - Maintenance

50641

50698

2. Screw the fill cap/dipstick completely into the power steering fluid reservoir.

3. Remove the fill cap/dipstick from the reservoir and observe the fluid level.

•

If the fluid level is within range a, no fluid should be added.

•

If the fluid level is within range b, fluid may be added but should not exceed the maximum level in range a.

•

If the oil level is within range c, fluid must be added. There is sufficient fluid when the fluid level is within range b.

NOTE: If high steering loads are going to be encountered for a prolonged period of operation (10–12 hours), the fluid level should be at least in the middle of the min/max markings of the dipstick.

a - No fluid required b -

Oil may be added, but do not exceed above range a

c -

Oil must be added, but do not exceed above range a

4. Add the specified fluid to bring the fluid level up to the proper level.

Tube Ref No.

114

5. Install the fill cap/dipstick.

Power Trim and Steering Fluid Power-assisted steering system 92-858074K01

Dexron III Automatic Transmission Fluid

Description Where Used Part No.

Power-assisted steering system Obtain Locally

Changing

Power‑assisted steering fluid does not require changing unless it becomes contaminated. See your Mercury Diesel‑authorized repair facility.

Engine Coolant

CAUTION

A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap.

a - Coolant minimum level ("min" mark) b - Coolant maximum level

For proper engine operation, the coolant must always be maintained at the correct level within the closed‑cooling system. With the engine cold, the level should always be between the minimum and maximum level marks on the coolant expansion tank.

The coolant level is monitored by a sensor. The display window on the tachometer will warn the user of a low coolant level condition. An audible warning will also sound. A visual inspection of the coolant level within the coolant expansion tank should be performed regularly.

Page 46 90-8M0114081 eng DECEMBER 2015

Section 4 - Maintenance

50470

Checking the Coolant Level

IMPORTANT: Check the engine coolant before starting the engine.

1. Allow the engine to cool.

2. Verify that the coolant level is above the "min" mark on the coolant expansion tank.

3. If the coolant level is below the "min" mark: a. Inspect the closed‑cooling system for leaks. If any leaks are found, contact your Mercury Diesel authorized repair

facility for further diagnosis and repair.

Refer to Adding Coolant and add the specified coolant as necessary.

Adding Coolant

1. Allow the engine to cool.

2. Cover the cap on the coolant expansion tank with a cloth and carefully remove the cap (counterclockwise).

IMPORTANT: If the specified coolant is not immediately available, add only water and restore the proper coolant/water ratio with the specified coolant as soon as possible. Do not add any coolant other than the specified coolant.

3. Add the specified coolant as necessary to bring the level to the minimum level ("min" mark) but no higher than the coolant

maximum level.

Description Marine Engine Coolant Closed‑cooling system 8M0078028

4. Install the cap and tighten securely to prevent coolant loss.

Where Used Part Number

Air Filter

Removal

1. Remove the crankcase ventilation hoses.

2. Remove the small clamps from the turbocharger inlets.

3. Remove the large clamps from the air filter.

4. Remove the tension springs from the air filter assembly.

5. Remove the rubber side covers from the air filter element.

a - Crankcase ventilation hoses b - Small clamps c - Large clamps d - Tension springs e - Rubber side covers

Air filter mounting

Inspection and Cleaning

Do not use fuel, thinner, or other cleaning agents for cleaning the air filter element. Use only the recommended products in the cleaning kit. Failure to use the correct products can damage the air filter element.

1. Inspect the air filter for damage.

2. Using compressed air, not exceeding 2.0 bar (29 psi), blow debris from the air filter from the inside, toward the outside of

the filter.

3. For cleaning the air filter, purchase K&N® filter recharging kit 99‑5050. Follow the procedures contained in recharging kit.

4. Replace the air filter as needed.

90-8M0114081 eng DECEMBER 2015 Page 47

NOTICE

Section 4 - Maintenance

52790

Installation

1. Install the rubber side covers onto the air filter element.

2. Align the marks as shown by the arrows in the air filter mounting illustration.

3. Install the tension springs.

4. Install the large clamps onto the rubber side covers. Tighten the fasteners to retain the boots.

5. Place the small clamps onto the small openings on the rubber side covers.

6. Gently compress the rubber side covers toward the center of the air filter element and install the filter assembly onto the turbocharger inlets.

7. Tighten the small clamps to retain the filter assembly.

8. Install the crankcase ventilation hoses.

Fuel Filter

NOTICE

Water entering the fuel injection system will cause corrosion and rusting of the injectors and other components, disabling the fuel injection system. Check daily for water in the water‑separating fuel filter and have the engine inspected immediately if there is evidence of water in the fuel system.

IMPORTANT: Use a suitable container to collect fuel. Clean up any spills immediately and dispose of fuel and old filters in a safe manner in accordance with all local, federal, and international regulations.

This remote‑mounted fuel filter and lift pump assembly is equipped with a water‑in‑fuel sensor to alert the operator when water is present in the filter. This filter needs to be replaced at specified intervals, refer to Routine Maintenance, or whenever water is detected in the fuel, whichever occurs first.

a - Water‑in‑fuel sensor b - Cannister nut (hidden) c - Cannister d - Fuel line fittings e - Power connector

Draining Water from the Filter

1. Place a suitable container under the fuel filter assembly.

2. Remove the drain plug from the bottom of the assembly.

3. Drain the filter until the fuel is clean in appearance.

4. Install the drain plug and tighten securely.

Replacing the Filter

WARNING

IMPORTANT: The fuel filter cannot be cleaned and reused. It must be replaced. Be sure to replace the filter with a filter of the same specifications to eliminate possible damage to the fuel system components.

1. Disconnect both battery cables from the battery.

2. Disconnect the water‑in‑fuel sensor from the wiring harness.

3. Place a suitable container under the fuel filter assembly.

4. Remove the cannister from the assembly.

5. Pull up on the fuel filter to remove it from the cannister.

Page 48 90-8M0114081 eng DECEMBER 2015

Section 4 - Maintenance

6. Replace the O‑ring.

7. Insert the new fuel filter into the cannister. The filter will snap into place.

8. Lubricate the new O‑ring around the cannister with clean diesel fuel.

NOTE: Do not fill the canister with fuel.

9. Install the cannister onto the upper portion of the fuel filter assembly and hand‑tighten it.

10. Connect the water‑in‑fuel sensor to the wiring harness.

11. Connect the battery cables to the battery, connecting the negative (–) cable last.

12. Ensure the fuel tank is filled with fuel.

13. Turn the ignition switch to the "ON" position. The fuel pump will run for five seconds. Turn the ignition switch to the "OFF"

position and wait five seconds. Repeat this step six times.

14. Start the engine and let it idle for approximately 20‑30 seconds then shut the engine off.

15. Wait a few seconds and repeat step 13 two more times.

16. Check fuel filter and connections for leaks.

IMPORTANT: If leaks exist, check the connections and verify that all connections and the cannister are properly seated. If leaks continue, stop the engine immediately and contact your Mercury Diesel–authorized repair facility.

Purging the Fuel System

WARNING

The fuel injection pump generates pressure in excess of 13790 kPa (2000 psi), which is high enough to penetrate or cut the skin. Do not use your fingers to feel for fuel leaks and wear personal protective equipment when servicing the fuel system.

NOTE: It is possible that the engine will not start if the fuel system has not been completely purged of air.

1. Ensure that the fuel tank is filled with fuel.

2. Turn the ignition switch to the "ON" position. The fuel pump will run for five seconds. Turn the ignition switch to the "OFF"

position and wait five seconds. Repeat this step six times.

3. Start the engine and let it idle for approximately 20–30 seconds, then shut the engine off.

4. Wait a few seconds and repeat step 3 two more times.

Fuel System

Priming

NOTE: Follow this procedure if the fuel system was run dry or if part of the fuel system was drained for a service function.

1. Turn the ignition switch to the "ON" position and the fuel pump will run for five seconds. Turn the ignition switch to the

"OFF" position and wait five seconds. Repeat this step six times.

2. Start the engine.

Fuel Tank Cleaning and Flushing

IMPORTANT: Diesel fuel should not be left in the tank during winter storage, as an accumulation of rust, sludge and wax residue will form.

Refer to the boat manufacturer's instructions and clean the fuel tank at specified intervals. Unless specified otherwise, flush and clean the diesel fuel tank every 1000 hours or five years, whichever occurs first.

Seawater System

Seawater Pump Impeller Inspection

The seawater pump impeller must be inspected (and replaced, if necessary) at the interval specified by the maintenance schedule. It is recommended this task be performed at a Mercury Diesel–authorized repair facility.

1. Close the seacock.

90-8M0114081 eng DECEMBER 2015 Page 49

Section 4 - Maintenance

50717

50720

2. Remove the four screws on the front side of the seawater pump and remove the cover. Discard the O‑ring.

Seawater pump cover screws

3. Mark the direction of rotation of the impeller and remove the protective cap from the middle of the impeller.

a - Seawater pump b - Impeller c - Protective cap d - O‑ring e - Cover f - Screw (4)

4. Use a suitable puller to remove the impeller from the impeller shaft.

5. Inspect the impeller for damage. The impeller must be replaced if there are any signs of damage.

NOTE: Keep an extra impeller onboard the boat at all times.

6. Lubricate the impeller with silicone spray or glycerine.

7. Push the impeller onto the shaft and press the protective cap into the impeller.

8. Insert a new O‑ring into its groove.

9. Install the cover onto the housing and secure the cover with the four screws. Tighten the screws to the specified torque.

Description Seawater pump cover screws 4.0 35.4 –

10. Open the seacock.

11. Start the engine and check the cooling system for leaks.

Nm lb‑in. lb‑ft

Sterndrive Water Inlets Check

1. Obtain a piece of wire the appropriate size to insert into the water inlets holes.

2. Insert the wire in and out of the sterndrive water inlets to ensure that they are open and to remove debris or marine growth. Do not scrape the sterndrive paint.

Page 50 90-8M0114081 eng DECEMBER 2015

Section 4 - Maintenance

22495

50672

3. Remove the wire from the sterndrive and retain for periodic water inlet checks.

a - Dual water pickup water inlets b - Side pickup water inlets

Flushing and Draining the Seawater System

1. Close the seacock.

2. Open and clean the seawater filter.

3. Fill the seawater filter with fresh water and operate the engine at idle.

IMPORTANT: Keep the seawater filter filled with fresh water while the engine is running.

4. Operate the engine until the water draining from the engine runs clear to ensure that all sludge and salt residues are

flushed away.

5. Switch off the engine.

6. Replace the cover on the seawater filter.

7. Attach a suitable hose to the seawater‑cooling system drain screw.

Heat exchanger drain screws

a - Closed‑cooling system drain screw b - Seawater‑cooling system drain screw

8. Open the drain screw and allow the water to drain into a suitable container.

9. When the draining is complete, remove the hose and close the drain screw.

10. Be certain to open the seacock prior to boat operation.

90-8M0114081 eng DECEMBER 2015 Page 51

Section 4 - Maintenance

Checking the Seawater Pickups

Verify that the water inlet holes for the seawater pickup are clean and unobstructed.

16776

Typical through-the-hull seawater pickup Typical through-the-transom seawater pickup

a - Water inlet holes

Cleaning the Seawater Strainer, if Equipped

NOTICE

An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat, causing damage or sinking the boat. Always close the water supply from the seawater pump, water inlet, or seacock when performing service or maintenance on the cooling system.

1. With the engine off, close the seacock, if equipped, or remove and plug the seawater inlet hose.

2. Remove the screws, washers, and cover.

3. Remove the strainer, drain plug, and sealing washer.

4. Clean all the debris from the strainer housing. Flush both the strainer and housing with clean water.

5. Check the cover gasket and replace when damaged or if it leaks.

6. Reinstall the strainer, drain plug, and sealing washer.

CAUTION

Seawater leaking from the seawater strainer could cause excess water in the bilge, damaging the engine or causing the boat to sink. Do not overtighten the cover screws, or the cover may warp and introduce seawater into the bilge.

Page 52 90-8M0114081 eng DECEMBER 2015

7. Install the seal and cover using the screws and washers. Do not overtighten the cover screws.

50723

Section 4 - Maintenance

a - Screws and washers b - Cover with glass c - Strainer d - Housing e - Drain plug and sealing washer f - Seal

12863

8. Open the seacock, if equipped, or remove the plug and reconnect the seawater inlet hose.

9. Upon first starting the engine, check for leaks or air in the system that would indicate an external leak.

Corrosion Protection

General Information

When two or more dissimilar metals are submerged in a conductive solution of saltwater, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This erosion is known as galvanic corrosion and, if it is not controlled, it will eventually cause the need for replacement of power package components exposed to water.

To help control the effects of galvanic corrosion, Mercury Diesel power packages come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection refer to the Marine Corrosion Protection Guide.

IMPORTANT: Replace sacrificial anodes if they are eroded 50% or more. Mercury Diesel strongly recommends avoiding the use of anodes from other manufacturers. Refer to your Mercury Diesel–authorized repair facility for additional information.

Sacrificial Anode

The sacrificial anode in the cooling system must be checked as specified by the maintenance schedule. The anode is located at the back of the charge air cooler.

a - Sacrificial anode b - Length of a new anode = 20 mm

(0.79 in.)

c - Back of the charge air cooler

1. Close the seacock.

2. Place a suitable container capable of holding approximately 2–2.5 L (2.1–2.6 US qt) of liquid in a position to capture the escaping seawater.

3. Remove the sacrificial anode.

4. Inspect the anode. If the anode is less than 10 mm (0.39 in.), it has eroded more than 50% and must be replaced.

90-8M0114081 eng DECEMBER 2015 Page 53

Section 4 - Maintenance

5. Install the anode into the back of the charge air cooler.

6. Open the seacock.

7. Start the engine and check for leaks.

Antifouling Paint

IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint is not covered by the limited warranty.

In some areas it may be advisable to paint the bottom of the boat to help prevent marine growth. Contact a Mercury Diesel authorized repair facility for recommendations for your boat.

Lubrication

Steering System

WARNING

Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant.

NOTE: If the steering cable does not have a grease fitting, the inner wire of the cable cannot be greased.

If the steering cable has grease fittings, turn the steering wheel until the steering cable is fully retracted into the cable housing. Apply approximately three pumps of grease from a typical hand‑operated grease gun.

a - Steering cable grease fitting

6221

Tube Ref No. Description Where Used Part No.

2. Turn the steering wheel until the steering cable is fully extended. Lightly lubricate the exposed part of the cable.

2-4-C with PTFE Steering cable grease fitting 92-802859A 1

a - Extended steering cable

6222

Tube Ref No. Description Where Used Part No.

Page 54 90-8M0114081 eng DECEMBER 2015

2-4-C with PTFE Steering cable 92-802859A 1

3. Lubricate the steering pin.

a - Steering pin

mc71904-1

Tube Ref. No. Description Where Used Part No.

Synthetic Blend MerCruiser Engine Oil SAE25W‑40

4. On dual engine boats: Lubricate the tie bar pivot points.

Section 4 - Maintenance

Steering pin 8M0078630

Tube Ref. No.

Synthetic Blend MerCruiser Engine Oil SAE25W‑40

5. Upon first starting the engine, turn the steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway.

Description Where Used Part No.

Tie bar pivot points 8M0078630

Throttle Cable

The throttle‑control system for the TDI 4.2L engine is electronic and requires no maintenance. See your Mercury Diesel authorized repair facility for diagnosis or repair.

Shift Cable

The shift‑control system for the TDI 4.2L engine is electronic and requires no maintenance. See your Mercury Diesel authorized repair facility for diagnosis or repair.

Transom Assembly

Lubricate the gimbal bearing by applying approximately 8–10 pumps of grease from a typical hand‑operated grease gun.

a - Gimbal bearing grease insert

19979

Tube Ref No. Description Where Used Part No.

Extreme Grease Gimbel bearing grease insert 8M0071842

Propeller Shaft

NOTE: Refer to

Lubricate the sterndrive propeller shaft by applying a coating of one of the following lubricants to the propeller shaft.

90-8M0114081 eng DECEMBER 2015 Page 55

Propeller Removal

Section 4 - Maintenance

52519

• Apply a generous coating of one of the following lubricants to the propeller shaft.

a - Propeller shaft

Tube Ref No. Description Where Used Part No.

Extreme Grease Propeller shaft 8M0071842

20335

2-4-C with PTFE Propeller shaft 92-802859A 1

Engine Coupler

IMPORTANT: These engines are equipped with a sealed engine coupler. The sealed coupler and the shaft splines can be lubricated without removing the sterndrive unit.

Lubricate the engine coupler splines through the grease fitting on the coupler by applying approximately 8–10 pumps of Extreme Grease from a typical hand‑operated grease gun.

NOTE: On Bravo equipped models, if the boat is operated at idle for prolonged periods, the coupler should be lubricated every 50 hours.

Coupler shown separated for clarity

Tube Ref No. Description Where Used Part No.

Extreme Grease Engine coupler and shaft splines 8M0071842

Page 56 90-8M0114081 eng DECEMBER 2015

Section 4 - Maintenance

17014

Driveshaft Extension Models

1. Lubricate the transom end grease fitting and engine end grease fitting by applying approximately 10–12 pumps of grease from a typical hand‑operated grease gun.

2. Lubricate the driveshaft grease fittings by applying approximately 3–4 pumps of grease from a typical hand‑operated grease gun.

a - Driveshaft grease fittings b - Transom end grease fitting c - Engine end grease fitting

Tube Ref No. Description Where Used Part No.

Extreme Grease

Transom end grease fitting, engine end grease fitting, driveshaft grease

Maintaining Torques

Gimbal Ring U‑bolt Nuts

NOTE: The gimbal ring is a component of the transom assembly.

Tighten the gimbal ring U‑bolt nuts to the specified torque.

19624

fittings

a - Transom assembly b - Gimbal ring U‑bolt nuts

8M0071842

Description Nm lb‑in. lb‑ft Gimbal ring U‑bolt nuts for 3/8 in. U‑bolt 72 – 53 Gimbal ring U‑bolt nuts for 7/16 in. U‑bolt 95 – 70

90-8M0114081 eng DECEMBER 2015 Page 57

Section 4 - Maintenance

4750

Engine Mounts

Loosen the rear engine mount bolts 1 to 1‑1/2 turns. Tighten the rear engine mount bolts to the specified torque.

a - Rear engine mount b - Transom plate mount c - Rear engine mount bolt

Description Nm lb‑in. lb‑ft Rear engine mount bolts 51 – 38

19622

Propellers

Bravo Sterndrive Propeller Removal

WARNING

Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

Bravo One Models

1. Straighten the bent tabs of the tab washer on the propeller shaft.

a - Propeller b - Tab washer c - Drive sleeve adapter d - Tab bent down e - Propeller nut

Page 58 90-8M0114081 eng DECEMBER 2015

2. Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate.

5301

4750

a - Wood block b - Propeller c - Propeller nut under socket

3. Turn the propeller shaft nut counterclockwise and remove the nut.

4. Slide the propeller and the attaching hardware from the propeller shaft.

Bravo One models

a - Propeller shaft splines b - Forward thrust hub c - Flo‑Torque II drive hub d - Propeller e - Drive sleeve adapter f - Tab washer g - Propeller nut

Section 4 - Maintenance

Bravo Two Models

1. Straighten the bent tabs of the tab washer on the propeller shaft.

a - Propeller b - Tab washer c - Drive sleeve adapter d - Tab bent down e - Propeller nut

2. Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate.

Wood block

a b - Propeller c - Propeller nut under socket

3. Turn the propeller shaft nut counterclockwise to remove the nut.

90-8M0114081 eng DECEMBER 2015 Page 59

Section 4 - Maintenance

10677

4. Slide the propeller and attaching hardware from the propeller shaft.

8566

Bravo Two

a - Propeller shaft splines b - Forward thrust hub c - Propeller d - Spline washer e - Tab washer f - Propeller nut

Bravo Three Models

1. Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate.

2. Remove the bolt and washers securing the propeller shaft anode.

3. Remove the propeller shaft anode.

a - Propeller b - Propeller shaft nut c - Propeller shaft anode d - Propeller shaft anode screw

e - Flat washer f - Star washer

4. Turn the aft propeller shaft nut counterclockwise to remove the nut.

5. Slide the propeller and thrust hub off of the propeller shaft.

6. Using the propeller nut tool, turn the front propeller shaft nut counterclockwise and remove the nut.

Propeller Nut Tool

Aids in the removal and installation of the front propeller nut.

7. Slide the propeller and the thrust hub off the propeller shaft.

19058

5304

91‑805457T 1

Bravo Three

a - Aft propeller nut b - Aft propeller c - Aft propeller thrust hub d - Front propeller nut e - Front propeller f - Front propeller thrust hub g - Propeller shaft anode screw h - Flat washer i - Star washer j - Propeller shaft anode

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Section 4 - Maintenance

5301

Bravo Sterndrive Propeller Installation

WARNING

a - Wood block b - Propeller c - Propeller nut under socket

Bravo One Models

IMPORTANT: Use the correct rotation propeller. The propeller rotation must match the direction of rotation of the propeller shaft.

1. Liberally coat the propeller shaft spline with one of the following lubricants.

Tube Ref No. Description Where Used Part No.

2. Install the propeller with the attaching hardware as shown.

3. Tighten the propeller nut to the specified torque.

2-4-C with PTFE Propeller shaft splines 92-802859A 1

Extreme Grease Propeller shaft splines 8M0071842

Typical Bravo One models

a - Propeller shaft splines b - Forward thrust hub c - Flo‑Torque II drive hub d - Propeller e - Drive sleeve adapter f - Tab washer g - Propeller nut

NOTE: The propeller torque stated is a minimum torque value.

Description

Bravo One propeller nut

Models equipped with the tab washer: Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer.

Nm lb‑in. lb‑ft

75 – 55

Then align tabs with grooves

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Section 4 - Maintenance

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4750

5. Bend the three tabs down into the grooves.

a - Propeller b - Tab washer c - Drive sleeve adapter d - Tab bent down e - Propeller nut

Bravo Three

1. Liberally coat the propeller shaft spline with one of the following lubricants.

Tube Ref No. Description Where Used Part No.

2. Slide the forward thrust hub onto the propeller shaft with the tapered side toward the propeller hub.

3. Align splines and place front propeller on propeller shaft.

4. Install the front propeller locknut and tighten to the specified torque using the propeller nut tool.

2-4-C with PTFE Propeller shaft splines 92-802859A 1

Extreme Grease Propeller shaft splines 8M0071842

Propeller Nut Tool

Aids in the removal and installation of the front propeller nut.

91‑805457T 1

Description Nm lb‑in. lb‑ft Bravo Three front propeller nut 136 – 100

5. Slide the aft thrust hub onto the propeller shaft with the tapered side toward the propeller hub.

6. Align the splines and install the aft propeller.

7. Install the propeller nut and torque.

NOTE: The propeller torque stated is a minimum torque value.

Description

Nm lb‑in. lb‑ft

Bravo Three rear propeller nut 81 – 60

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Section 4 - Maintenance

40791

40794

8. Install the propeller shaft anode and secure with the screw. Tighten the screw to the specified torque.

5304

Description Nm lb‑in. lb‑ft Propeller shaft anode screw 19 168 –

Bravo Three

a - Rear propeller nut b - Rear propeller c - Rear propeller thrust hub d - Front propeller nut e - Front propeller f - Front propeller thrust hub g - Propeller shaft anode screw h - Flat washer i - Star washer j - Propeller shaft anode

Drive Belts

Drive Belt

All drive belts must be periodically inspected for tension and condition. Turn the engine off and remove the ignition key before inspecting for excessive wear, cracks, fraying, and glazed surfaces.

WARNING

Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before inspecting the belts.

In the event that the drive belt requires replacement, it is recommended that the drive belt replacement be performed by a Mercury Diesel–authorized repair facility.

Drive Belt Failure Identification

Appearance

Abrasion

Each side of the belt appears shiny or glazed. Severe condition: Fabric is exposed.

Pilling

Belt material is sheared off from the ribs and builds up in the belt grooves.

Description Cause Solution

Replace the belt and The belt is in contact with an object. This can be caused by improper belt tension or tensioner failure.

There are a number of causes including lack of tension, misalignment, worn pulleys, or a combination of these factors.

inspect its route for

contact with another

object. Verify that the belt

tensioner is functioning.

When pilling leads to belt

noise or excess vibration,

the belt should be

replaced.

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Section 4 - Maintenance

40795

40796

40797

40799

40800

Appearance Description Cause Solution

Improper installation

The belt ribs begin separating from the joined strands. If left unattended, the cover will often separate, causing the belt to unravel.

Misalignment

Sidewalls of the belt may appear glazed or the edge‑cord may become frayed and the ribs are removed. A noticeable noise may result. In severe cases, the belt can jump off the pulley.

Improper belt installation is a common cause of premature failure. One of the outermost belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove.

Pulley misalignment. Misalignment forces the belt to kink or twist while running, causing premature wear.

The belt should be replaced immediately. Ensure all ribs of the replacement belt fit into the pulley grooves. Operate the engine. Then, with the engine off and the battery disconnected, inspect the belt for proper installation.

Replace the belt and verify the alignment of the pulley.

Chunk‑out

Pieces or chunks of rubber material have broken off the belt. When chunk‑out has occurred, a belt can fail at any moment.

Uneven rib wear

The belt shows damage to the side with the possibility of breaks in the tensile cord or jagged edged ribs.

Cracking

Small visible cracks along the length of a rib or ribs.

Chunk‑out can happen when several cracks in one area move parallel to the cord line. Heat, age, and stress are the primary contributors.

A foreign object in the pulley can cause uneven wear and cut into the belt.

Continuous exposure to high temperatures, the stress of bending around the pulley leads to cracking. Cracks begin on the ribs and grow into the cord line. If three or more cracks appear in a three‑inch section of a belt, 80% of the life is gone.

Replace the belt immediately.

Replace the belt and inspect all pulleys for foreign objects or damage.

Replace the belt immediately.

Battery

Refer to the specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.

WARNING

Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away from sparks or flames.

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Section 4 - Maintenance

WARNING

An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.

Battery Precautions for Multiple Engines

Alternators

Alternators are designed to charge a single battery that supplies electrical power to the individual engine on which the alternator is mounted. Connect only one battery to one alternator. Do not connect two batteries to the same alternator battery isolator is used.

Engine Control Unit (ECU)

The engine control unit requires a stable voltage source. During multiple–engine operation, an onboard electrical device may cause a sudden drain of voltage at the engine's battery. The voltage may go below the ECU's minimum required voltage. Also, the alternator on the other engine may now start charging. This could cause a voltage spike in the engine's electrical system.

In either case, the ECU could shut off. When the voltage returns to the range that the ECU requires, the ECU will reset itself. The engine will now run normally. This ECU shutdown usually happens so fast that the engine just appears to have an ignition miss.

Batteries

Boats with multiple–engine electronic–control power packages require that each engine be connected to its own battery, ensuring that the engine control unit has a stable voltage source.

Battery Switches

Battery switches should always be positioned so that each engine is operating off of its own battery. Do not operate engines with switches in the both or all position. In an emergency, another engine's battery can be used to start an engine with a dead battery.

unless a

Battery Isolators

Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose.

Generators

The generator's battery should be considered another engine's battery.

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Section 4 - Maintenance

Notes:

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Table of Contents

Section 5 - Storage

Cold Weather (Freezing Temperature), Seasonal Storage,

and Extended Storage.......................................................... 68

Preparing Your Power Package for Seasonal or

Extended Storage.......................................................... 68

Seasonal Storage Instructions....................................... 68

Extended Storage Instructions.......................................69

Battery Storage.............................................................. 70

Recommissioning the Power Package................................. 70

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Section 5 - Storage

Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage

IMPORTANT: Mercury Diesel strongly recommends that this service be performed by a Mercury Diesel–authorized repair facility. Damage caused by freezing is not covered by the Mercury Diesel Limited Warranty.

NOTICE

NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine.

You should consider a boat is in storage whenever it is not in operation. The amount of time that the power package is not operated may be for a brief period, such as during a day, overnight, for a season, or for an extended period of time. Certain precautions and procedures must be observed to protect the power package from freeze damage, corrosion damage, or both types of damage during storage.

Freeze damage can happen when water trapped in the seawater cooling system freezes. For example, after operating the boat, exposure to freezing temperatures for even a brief period of time could result in freeze damage.

Corrosion damage is the result of saltwater, polluted water, or water with a high mineral content trapped in the seawater cooling system. Saltwater should not stay in an engine's cooling system for even a brief storage time; drain and flush the seawater cooling system after each outing.

Cold weather operation refers to operating the boat whenever the possibility of freezing temperatures exists. Likewise, cold weather (freezing temperature) storage refers to whenever the boat is not being operated and the possibility of freezing temperatures exists. The seawater section of the cooling system must be completely drained immediately after operation.

Seasonal storage refers to when the boat is not being operated for one month or more. The length of time varies depending on the geographic location of the boat in storage. Seasonal storage precautions and procedures include all of the steps for cold weather (freezing temperature) storage and some additional steps that must be taken when storage will last longer than the short time of cold weather (freezing temperature) storage.

Extended storage means storage for a period of time that may last for several seasons or longer. Extended storage precautions and procedures include all of the steps for cold weather (freezing temperature) storage and seasonal storage plus some additional steps.

Refer to the specific procedures in this section related to the conditions and the length of storage for your application.

Preparing Your Power Package for Seasonal or Extended Storage

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

IMPORTANT: If the boat has already been removed from the water, supply water to the water inlet holes before starting the engine. Follow all warnings and flushing attachment procedures stated in Flushing the Seawater System.

1. Supply cooling water to the water inlet holes or seawater pump inlet.

2. Start the engine and operate until it reaches normal operating temperature.

3. Stop the engine.

4. Change the engine oil and filter.

5. Start the engine and run for about 15 minutes. Check for oil leaks.

Flush the seawater cooling system. Refer to Flushing the Seawater System.

7. Change the sterndrive gear oil.

Seasonal Storage Instructions

Read all precautions and perform all procedures found in Preparing Your Power Package for Seasonal or Extended Storage.

Read all precautions and perform all procedures found in Flushing and Draining the Seawater System and drain the seawater section of the cooling system.

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NOTICE

IMPORTANT: Mercury Diesel recommends that propylene glycol antifreeze be used in the seawater section of the cooling system for cold weather (freezing temperature), seasonal storage, or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.

3. Fill a container with approximately 5.6 Liter (6.0 US qt) of propylene glycol antifreeze and tap water mixed to manufacturer's recommendation to provide –73.3 °C (–100 °F) protection to the engine.

4. Disconnect the seawater inlet hose from the seawater pump. Using an adapter, if required, temporarily connect an appropriate length piece of hose to the seawater pump and place the other end of the hose into the container of propylene glycol antifreeze and tap water.

a - Seawater pump b - Container of propylene glycol

antifreeze and tap water

NOTE: Discharge of propylene glycol antifreeze into the environment may be restricted by law. Dispose of propylene glycol antifreeze in accordance with federal, state, and local laws and guidelines.

5. Start the engine and operate at idle speed until the antifreeze mixture has been pumped into the engine seawater cooling system.

6. Stop the engine.

7. Remove the temporary hose from the seawater pump.

8. Clean the outside of the engine and repaint any areas required with primer and spray paint. After the paint has dried, coat the engine with the specified corrosion inhibiting oil or equivalent.

Description

Corrosion Guard

Light gray primer paint

Phantom black paint Transom assembly and sterndrive 92‑802878‑1 Diesel white paint Outside of engine 92‑8M0071082

9. Your Mercury Diesel–authorized repair facility should now perform all checks, inspections, lubrications, and fluid changes outlined in Maintenance Schedules.

Outside of engine, transom assembly, and sterndrive

Where Used Part Number

92‑802878‑55

92‑802878‑52

NOTICE

The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position.

10. Place the sterndrive in the full down (in) position.

11. Follow the battery manufacturer's instructions for storage and store the battery.

Extended Storage Instructions

IMPORTANT: Mercury Diesel strongly recommends that this service be performed by an Mercury Diesel–authorized repair facility.

Read all precautions and perform all procedures found in Preparing Your Power Package for Seasonal or Extended Storage.

Read all precautions and perform all procedures found in Flushing and Draining the Seawater System.

90-8M0114081 eng DECEMBER 2015 Page 69

Section 5 - Storage

Read all precautions and perform all procedures found in Seasonal Storage Instructions.

4. Remove the seawater pump impeller and store away from direct sunlight. See a Mercury Diesel–authorized repair facility for additional information and service. IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight.

5. Place a caution tag at the instrument panel and in the engine compartment stating that the seawater pump is out and not to operate the engine.

Battery Storage

Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition. It should be clean and free of leaks. Follow the battery manufacturer's instructions for storage.

Recommissioning the Power Package

1. Ensure that all cooling system hoses are connected properly and the hose clamps are tight.

CAUTION

Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.

2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect the cables. Tighten each cable clamp securely when connecting.

3. Coat the terminal connections with a battery terminal anticorrosion agent.

Perform all the checks in the Before Starting column of the Operation Chart.

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

5. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly.

6. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks.

7. Inspect the steering system, shift and throttle control for proper operation.

Page 70 90-8M0114081 eng DECEMBER 2015

Table of Contents

Section 6 - Troubleshooting

Troubleshooting.................................................................... 72

Troubleshooting Charts........................................................ 72

Starter Motor Will Not Crank Engine, or Cranks Slow... 72

Engine Will Not Start, or Is Hard to Start....................... 72

Engine Runs Rough, Misses, or Backfires.................... 72

Poor Performance..........................................................73

No Fuel or Faulty Fuel Supply....................................... 73

Engine Will Not Start, Starter Does Not Turn................ 73

Excessive Engine Temperature..................................... 73

Insufficient Engine Temperature.................................... 74

Low Engine Oil Pressure............................................... 74

Battery Will Not Charge................................................. 74

Remote Control Operates Hard, Binds, Has Excessive

Free‑play, or Makes Unusual Sounds........................... 74

Steering Wheel Turns Hard or Jerky............................. 74

Power Trim Does Not Operate (Electric Motor Operates

but Sterndrive Unit Does Not Move).............................. 74

Power Trim Does Not Operate (Electric Motor Does Not

Operate).........................................................................75

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Section 6 - Troubleshooting

Troubleshooting

The broad network of Mercury Diesel service partners with trained professionals, modern equipment, and all of the required special tools is available to you for the care and service of your Mercury Diesel engine. If repairs must be made, the engine should be brought to an authorized Mercury Diesel repair facility. However, if you experience starting or running problems while on the water, the following troubleshooting charts can help you remedy some simple problems.

Troubleshooting Charts

Starter Motor Will Not Crank Engine, or Cranks Slow

Possible Cause Remedy Battery switch turned off. Turn switch on. Remote control not in neutral position. Position control lever in neutral. Open circuit breaker or blown fuse. Check and reset circuit breaker or replace fuse.

Loose or dirty electrical connections or damaged wiring.

Bad battery. Test and replace if bad.

Engine Will Not Start, or Is Hard to Start

Check all electrical connections and wires (especially battery cables). Clean and tighten faulty connection.

Possible Cause Lanyard stop switch activated. Check lanyard stop switch. Improper starting procedure. Read starting procedure. Empty fuel tank or fuel shut off valve closed. Fill tank or open valve.

Faulty mechanical fuel delivery pump.

Throttle not operating properly. Check the throttle for freedom of movement.

Faulty electrical stop‑circuit.

Clogged fuel filters. Replace the filters. Stale or contaminated fuel. Drain tank. Fill with fresh fuel.

Fuel line or tank vent line kinked or clogged.

Air in fuel injection system. Purge fuel injection system. Faulty wire connections. Check wire connections. Glow plugs or glow plug system inoperative, if

equipped.

Electronic fuel system fault.

Have pump replaced by a Mercury Diesel–authorized repair facility if fuel is present.

Have a Mercury Diesel–authorized repair facility service the electrical stop circuit.

Replace kinked lines or blow out the lines with compressed air to remove obstruction.

Have a Mercury Diesel–authorized repair facility service the glow plug system.

Have the electronic fuel system checked by a Mercury Diesel– authorized repair facility.

Remedy

Engine Runs Rough, Misses, or Backfires

Possible Cause Throttle not operating properly. Check the throttle for binding or an obstruction. Idle speed too low. Check idle speed and adjust, if necessary. Clogged fuel or air filters. Replace the filters. Stale or contaminated fuel. Drain tank and fill with fresh fuel.

Kinked or clogged fuel line or fuel tank vent line.

Air in fuel system. Purge fuel injection system.

Electronic fuel system faulty.

Replace kinked lines or blow out lines with compressed air to remove obstruction.

Have electronic system checked by a Mercury Diesel–authorized repair facility.

Remedy

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Section 6 - Troubleshooting

Poor Performance

Possible Cause Remedy Throttle not fully open. Inspect throttle cable and linkages for proper operation. Damaged or improper propeller. Replace propeller. See a Mercury Diesel–authorized repair facility. Excessive bilge water. Drain and check for cause of entry. Boat overloaded or improperly distributed. Reduce load or redistribute more evenly. Boat bottom fouled or damaged. Clean or repair as necessary.

Electronic fuel system fault.

Have electronic fuel system checked by a Mercury Diesel–authorized repair facility.

No Fuel or Faulty Fuel Supply

Possible Cause The fuel cock is closed. Open the fuel cock. There is no fuel in the tank. The fuel tank is dirty. Clean the fuel tank. The fuel lines are clogged. Check the lines and clean them if necessary. The water level in the circulation filter (if equipped) is too high. Drain the water from the circulation filter. The circulation filter (if equipped) is clogged. Clean the circulation filter or replace it if necessary. The water level is too high in the fuel filter. Drain the water from the fuel filter. The fuel filter is clogged. Replace the fuel filter.

Remedy

Fill the tank. Refer to Purging the Fuel System.

Engine Will Not Start, Starter Does Not Turn

Possible Cause The throttle lever is not in the neutral position. Move the throttle lever into neutral. The neutral switch in the gearbox does not output a signal. Check the operation of the neutral switch. The lanyard stop switch is activated. Reset the lanyard stop switch. The ignition is switched off. Switch on the ignition.

The battery is discharged or defective.

The starter connections are loose or corroded. Check the connections and clean or replace if necessary. The connections to the ignition or starter switch are loose or

corroded.

There is air inside the fuel system.

Remedy

Check the battery and charge it. Replace the battery if necessary.

Check the connections and clean or replace if necessary.

Refer to Purging the Fuel System. Contact an authorized Mercury Diesel repair facility for assistance.

Excessive Engine Temperature

Possible Cause Water inlet or seacock closed. Open. Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups or sea strainer obstructed. Remove obstruction. Faulty thermostat. Replace. See a Mercury Diesel–authorized repair facility.

Coolant level low in closed–cooling section.

Heat exchanger cores plugged with foreign material.

Loss of pressure in closed–cooling section.

Faulty seawater pickup pump. Repair. See a Mercury Diesel–authorized repair facility.

Seawater discharge restricted or plugged.

90-8M0114081 eng DECEMBER 2015 Page 73

Check for cause of low coolant level and repair. Fill system with proper coolant solution.

Clean heat exchanger. See a Mercury Diesel–authorized repair facility.

Check for leaks. Clean, inspect, and test pressure cap. See a Mercury Diesel–authorized repair facility.

Clean exhaust elbows. See a Mercury Diesel–authorized repair facility.

Remedy

Section 6 - Troubleshooting

Possible Cause Remedy Seawater inlet hose kinked (restricted). Position hose to prevent kinking (restriction). Use of improperly designed hose on inlet side of

seawater pump allowing it to collapse.

Replace hose with wire reinforced design.

Insufficient Engine Temperature

Possible Cause Remedy

Faulty thermostats. Replace. See a Mercury Diesel–authorized repair facility.

Low Engine Oil Pressure

Possible Cause Remedy Faulty senders. Have the system checked by a Mercury Diesel–authorized repair facility. Insufficient amount of oil in the crankcase. Check and add oil as required. Excessive oil in crankcase (causing it to

become aerated).

Diluted or improper viscosity oil.

Check and remove the required amount of oil. Check for cause of excessive oil (improper filling).

Change oil and oil filter. Use the correct grade and viscosity oil. Determine the cause for dilution (excessive idling).

Battery Will Not Charge

Possible Cause

Excessive current draw from battery. Turn off nonessential accessories.

Check all associated electrical connections and wires (especially

Loose or dirty electrical connections or damaged wiring.

Alternator drive belt loose or in poor condition. Replace or adjust. Unacceptable battery condition. Test battery.

battery cables). Clean and tighten faulty connections. Repair or replace damaged wiring.

Remedy

Remote Control Operates Hard, Binds, Has Excessive Free‑play, or Makes Unusual Sounds

Possible Cause

Insufficient lubrication on shift and throttle linkage fasteners.

Obstruction in the shift or throttle linkages. Remove the obstruction.

Loose or missing shift and throttle linkages.

Shift or throttle cable kinked.

Improper shift cable adjustment. Have adjustment checked by a Mercury Diesel–authorized repair facility.

Lubricate.

Check all throttle and shift linkages. If any are loose or missing, see a Mercury Diesel–authorized repair facility immediately.

Straighten cable or have a Mercury Diesel–authorized repair facility replace cable if damaged beyond repair.

Remedy

Steering Wheel Turns Hard or Jerky

Possible Cause Low power steering pump fluid level. Check for leak. Refill the system with fluid. Drive belt loose or in poor condition. Replace and/or adjust. Insufficient lubrication on the steering components. Lubricate.

Loose or missing steering fasteners or parts.

Contaminated power steering fluid. See a Mercury Diesel–authorized repair facility.

Check all parts and fasteners; if any are loose or missing, see a Mercury Diesel–authorized repair facility immediately.

Remedy

Power Trim Does Not Operate (Electric Motor Operates but Sterndrive Unit Does Not Move)

Possible Cause

The trim pump oil level is low. Fill the trim pump with oil.

Page 74 90-8M0114081 eng DECEMBER 2015

Remedy

Section 6 - Troubleshooting

Possible Cause Remedy

The drive unit is binding in the gimbal ring. Check for obstruction. See a Mercury Diesel–authorized repair facility.

Power Trim Does Not Operate (Electric Motor Does Not Operate)

Possible Cause Remedy

Blown fuse. Replace the fuse.

Loose or dirty electrical connections or damaged wiring.

Check all the associated electrical connections and the wires (especially the battery cables). Clean and tighten the faulty connection. Repair or replace the wiring.

90-8M0114081 eng DECEMBER 2015 Page 75

Section 6 - Troubleshooting

Notes:

Page 76 90-8M0114081 eng DECEMBER 2015

Section 7 - Customer Assistance Information

Table of Contents

Section 7 - Customer Assistance Information

Owner Service Assistance.................................................... 78

Local Repair Service .................................................... 78

Service Away From Home ............................................ 78

Stolen Power Package ................................................. 78

Attention Required After Submersion ........................... 78

Replacement Service Parts .......................................... 78

Parts and Accessories Inquiries ............................ 78

Resolving a Problem .................................................... 78

Contact Information for Mercury Marine Customer

Service ......................................................................... 79

Customer Service Literature................................................. 79

English Language ......................................................... 79

Other Languages .......................................................... 80

Ordering Literature............................................................... 80

United States and Canada ........................................... 80

Outside the United States and Canada ........................ 80

90-8M0114081 eng DECEMBER 2015 Page 77

Section 7 - Customer Assistance Information

Owner Service Assistance

Local Repair Service

If you need service for your Mercury MerCruiser‑powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine.

NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser sterndrives and inboards.

Service Away From Home

If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. If, for any reason, you cannot obtain service, contact the nearest regional service center. Outside the United States and Canada, contact the nearest Marine Power International service center.

Stolen Power Package

If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

Attention Required After Submersion

1. Before recovery, contact an authorized Mercury MerCruiser dealer.

2. After recovery, immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of serious engine damage.

Replacement Service Parts

WARNING

Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in both fresh and saltwater environments. These conditions require numerous special parts. Exercise care when replacing marine engine parts because specifications are different from those of the standard automotive engine. For example, one of the most important special replacement parts is the cylinder head gasket. Marine engines cannot use steel‑type automotive head gaskets because saltwater is highly corrosive. A marine engine head gasket uses special materials to resist corrosion.

Because marine engines must be capable of running at or near maximum RPM much of the time, they also have special valve springs, valve lifters, pistons, bearings, camshafts, and other heavy‑duty moving parts.

Mercury MerCruiser marine engines have other special modifications to provide long life and dependable performance.

Parts and Accessories Inquiries

Direct any inquiries concerning Quicksilver replacement parts and accessories to your local authorized dealer. The dealer has the necessary information to order parts and accessories for you. Only authorized dealers can purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When inquiring about parts and accessories, the dealer requires the engine model and serial numbers to order the correct parts.

Resolving a Problem

Satisfaction with your Mercury MerCruiser product is important to your dealer and to us. If you ever have a problem, question, or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If you need additional assistance:

1. Talk with the dealership's sales manager or service manager. Contact the owner of the dealership if the sales manager and service manager have been unable to resolve the problem.

2. If your question, concern, or problem cannot be resolved by your dealership, please contact a Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.

The following information will be needed by Customer Service:

• Your name and address

• Daytime telephone number

• Model and serial numbers for your power package

• The name and address of your dealership

Page 78 90-8M0114081 eng DECEMBER 2015

Section 7 - Customer Assistance Information

• Nature of the problem

Contact Information for Mercury Marine Customer Service

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

United States, Canada

Telephone

Fax

Website www.mercurymarine.com

Australia, Pacific Telephone +61 3 9791 5822 Brunswick Asia Pacific Group

Fax +61 3 9706 7228

Europe, Middle East, Africa Telephone +32 87 32 32 11 Brunswick Marine Europe

Fax +32 87 31 19 65

English +1 920 929 5040 Français +1 905 636 4751

English +1 920 929 5893 Français +1 905 636 1704

41–71 Bessemer Drive Dandenong South, Victoria 3175 Australia

Parc Industriel de Petit-Rechain B-4800 Verviers, Belgium

Mercury Marine W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939

Mexico, Central America, South America, Caribbean Telephone +1 954 744 3500 Mercury Marine

11650 Interchange Circle North

Fax +1 954 744 3535

Japan Telephone +072 233 8888 Kisaka Co., Ltd.

4-130 Kannabecho Sakai-shi Sakai-ku

Fax +072 233 8833

Asia, Singapore Telephone +65 65466160 Brunswick Asia Pacific Group

Fax +65 65467789

5900984 Osaka, Japan

T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore, 508944

Miramar, FL 33025 U.S.A.

Customer Service Literature

English Language

English language publications are available from: Mercury Marine Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 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:

• List your product, model, year, and serial numbers.

• Check the literature and quantities you want.

• Enclose full remittance in check or money order (NO COD).

90-8M0114081 eng DECEMBER 2015 Page 79

Section 7 - Customer Assistance Information

Other Languages

To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.

Ordering Literature

Before ordering literature, have the following information about your power package available:

Model Serial Number Horsepower Year

United States and Canada

For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact:

Mercury Marine

Telephone Fax Mail

Mercury Marine

(920) 929‑5110

(USA only)

Outside the United States and Canada

Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package.

(920) 929‑4894

(USA only)

Attn: Publications Department

P.O. Box 1939

Fond du Lac, WI 54936-1939

Mercury Marine Submit the following order form with payment to:

Ship To: (Copy this form and print or type–This is your shipping label)

Name

Address

City, State, Province

ZIP or postal code

Country

Quantity Item Stock Number Price Total

Attn: Publications Department

W6250 Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54936-1939

. . . . . . . . . .

Total Due .

Page 80 90-8M0114081 eng DECEMBER 2015

Section 8 - Maintenance Log

Table of Contents

Scheduled Maintenance Log................................................ 82 Vessel Maintenance Notes................................................... 83

90-8M0114081 eng DECEMBER 2015 Page 81

Section 8 - Maintenance Log

Scheduled Maintenance Log

Actual Hours Service Notes

Dealer Name

Actual Hours Service Notes

Dealer Name

Actual Hours Service Notes

Dealer Name

100 Hours

Signature

200 Hours

Signature

300 Hours

Signature

Date

Actual Hours Service Notes

Dealer Name

Actual Hours Service Notes

Dealer Name

Actual Hours Service Notes

Dealer Name

400 Hours

Signature

500 Hours

Signature

600 Hours

Signature

Date

Page 82 90-8M0114081 eng DECEMBER 2015

Section 8 - Maintenance Log

Vessel Maintenance Notes

Record all general maintenance performed on your power package here. Save all work orders and receipts.

Date

Engine

Hours

Maintenance Completed Servicing Dealer

90-8M0114081 eng DECEMBER 2015 Page 83

Mercury TDI 4.2L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Welcome

Read This Manual Thoroughly

Notice

TDI 4.2L Diesel Sterndrive Models

Warranty Message

Copyright and Trademark Information

Identification Records

TABLE OF CONTENTS

Features and Controls

TDI 4.2L Engine Description

Identification

Audio Warning System

Testing the Audio Warning System

Digital Throttle and Shift

Instrumentation

VesselView

SmartCraft Speedometer, Tachometer, and Digital Gauges

System Link Digital Gauges

Controls

Switches

Emergency Stop Switch

Lanyard Stop Switch

Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition

Digital Throttle and Shift

Engine Electrical System Overload Protection

Fuses

Vessel Adapter Assembly Fuse Replacement

Lanyard Stop Switch

Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition

Power Trim

Power Trim and MerCathode Overload Protection

Emissions Information

Exhaust Gas Emissions Certificate (Europe Only)

Owner Responsibility

Engine Components

Safe Boating Recommendations

Carbon Monoxide Exposure

Be Alert To Carbon Monoxide Poisoning

Stay Clear of Exhaust Areas

Good Ventilation

Poor Ventilation

Duty Cycle

Basic Boat Operation

Basic Boat Operation

Operation Chart

Freezing Temperature and Cold Weather Operation

Drain Plug and Bilge Pump

Starting, Shifting, and Stopping

Before Starting the Engine

Starting a Cold Engine

Starting a Warm Engine

Shifting

Engine Shutdown (Stopping)

Starting the Engine After Stopped While in Gear

Trailering the Boat

Protecting People In The Water

High Speed and High Performance

Passenger Safety in Pontoon Boats and Deck Boats

Boats Having an Open Front Deck

Boats with Front-Mounted, Raised-Pedestal Fishing Seats

Wave and Wake Jumping

Impact with Underwater Hazards

Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat

Bottom of Boat

Cavitation

Ventilation

Elevation and Climate

Propeller Selection

20-Hour Break-In Period

After the 20-Hour Break-In Period

End of First Season Checkup

Fuel Requirements

Nonferrous Metals and the Fuel System

Diesel Fuel in Cold Weather

Antifreeze/Coolant