Home

D1.7L DTI Diesel Engines - Alpha Models

1. 77300 CD562 Maintenance Aids 1 Power Steering System Quicksilver Power Trim and Steering Fluid or Dexron Il automatic transmission fluid ATP 2 All pivot points SAE 30W motor oil 3 Exposed Portion of Steering Cable and Propeller Shaft Quicksilver Special Lubricant 101 4 Sterndrive Unit Quicksilver Hi Performance Gear Lube 5 All Grease Fittings Quicksilver 2 4 C Marine Lubricant 6 Engine Coupler and Universal Joint Shaft Splines Quicksilver Engine Coupler Spline Grease 92 816391A4 7 All Exterior Surfaces Quicksilver Primer and Spray Paint as needed and Quicksilver Corrosion Guard 8 Power Trim System Quicksilver Power Trim and Steering Fluid or SAE 10W 30 motor oil 9 Crankcase Oil use ONLY specified engine oil Refer to Specifications 10 Closed Cooling System Coolant use ONLY specified engine coolant Refer to Specifications 11 Universal Joints Quicksilver U Joint and Gimbal Bearing Grease 92 828052A3 56 CD833 Maintenance Schedules Routine Maintenance Each Each Every Day Day Weekly Two Start End Months Check crankcase oil interval can be extended based on experi ence Check drive unit oil level trim pump oil level and power steering pump fluid level if equipped Check water pickups for debris or marine growth Check water strainer and clean if equipped Check coolant level If operating in salt brackish or polluted waters fl
2. CE406 Fuel System Absolute cleanliness is required for work on the fuel system fuel injection components have very close tolerances Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system FUEL TANK CLEANING AND FLUSHING IMPORTANT Diesel fuel should not be left in tank during winter storage as an accumulation of rust sludge and wax residue will form 1 Refer to boat manufacturer s instructions and clean fuel tank at specified intervals Unless specified otherwise flush and clean diesel fuel tank every 1000 hours or 5 years whichever occurs first CD654 HAND PUMP PRIMER 2 Aplunger type of hand pump primer is located on the fuel filter bracket and is used to 1 refill fuel system if system was run dry 2 refill fuel filter when changing filter or 3 to prime the fuel system if engine has not been run for a while To operate the hand pump primer move the plunger upper portion up and down as needed CD655 PRIMING FUEL SYSTEM 3 Prime engine if it has not been run for a while or if engine will not start Move the hand pump primer plunger up and down several times as previously outlined Attempt to start engine CD836 FILLING FUEL FILTER NOTE Follow this procedure after installing new filter or if fuel has been drained from filter checking for water 4 Loosen bleed screw on fuel filter bracket As previously outlined move plunger on ha
3. CD759 Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System 1 The Audio Warning System horn will sound if any of the following occur A Engine oil pressure too low B Cooling system temperature too high 2 If the Audio Warning System horn sounds while the engine is operating stop the engine immediately Investigate the cause and correct it if possible If the cause cannot be determined or corrected consult your Authorized Mercury MerCruiser Dealer Avoid engine or sterndrive damage Do not operate the engine once the Audio Warning System horn has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION The Audio Warning System will not protect the engine or sterndrive from damage It is designed to warn the operator that a problem has occurred 3 To test the Audio Warning System A Turn the ignition switch to the RUN position Do not start the engine B The horn will sound if the system is working correctly Once the engine is started the horn should not sound except to warn the operator that a problem has occurred CA31 MerCathode System 4 A 20 amp in line fuse is in the wire which connects to positive terminal on controller If fuse is blown defective the system will not operate 35 CD760 CD761 Electrical System Overload Protection If an electr
4. UN tf LIG EL CD805 Corrosion And Corrosion Protection INTERNAL COMPONENTS 1 There are anodes as part of the intercooler and heat exchanger systems which serve as sacrificial anodes These sacrificial anodes are installed in the seawater circuit to help avoid electrolytic corrosion caused by seawater There is one on the front and rear side of the heat exchanger and two on the intercooler Inspection and replacement interval will vary depending on the condition of seawater and mode of engine operation 2 Replace when eroded more than 50 Check at least once yearly NOTE Remove deposits from surface of anode before trying to determine amount of erosion A Length When New 32 mm 1 1 4 in B Diameter When New 15 mm 5 8 in 85 CD806 CD807 EXTERNAL COMPONENTS Whenever two or more dissimilar metals like those found on the sterndrive are submerged in a conductive solution such as 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 is known as galvanic corrosion ana if not controlled it will in time cause the need for replacement of power package components exposed to water IMPORTANT Replace sacrificial anodes if eroded 50 or more 1 Anodic Trim Tab serves as a sacrificial anode 2 Anodic Plate serves
5. Whichever Occurs First 8 Lubricate engine coupler every 50 hours if operated at idle for prolonged periods of time 58 Maintenance Schedules Continued Scheduled Maintenance Continued Every Every Every Every 200 300 500 1000 i hours hours hours hours First 50 hours or hours or hours Annually Annually Ore OFS ORD ONS years years years years t gt Check electrical system for loose damaged or corroded fasteners Check cooling system and exhaust system hose clamps for tightness Inspect both sys tems for damage or leaks Disassemble and inspect seawater pump and replace worn components Clean seawater section of closed cooling sys tem Clean inspect and test pressure cap Check anodes Replace coolant Every Every After 100 200 Inspect timing belt and pulleys Replace timing belt Check valve clearance Clean fuel tank Whichever Occurs First 59 CD782 AA PAA Tm Y DEI 74 WA E FAZ p ee 60 CD783 Checking Fluid Levels CRANKCASE OIL 1 Stop engine Allow approximately ten minutes for oil to drain into oil pan Boat must be at rest in water 2 Remove dipstick Wipe clean and reinstall fully into dipstick tube 3 Remove dipstick and observe oil level Oil must be between MIN and MAX marks on dipstick If necessary add oil as follows A MIN
6. CA408 Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect For this reason boats are normally equipped with a drain plug and or a bilge pump It is very important to check these items on a regular basis to ensure that the water level does not rise to come in contact with your power package Components on your engine will be damaged if submerged Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty CA17 Drive Unit Impact Protection The Power Trim hydraulic system is designed to provide impact protection for drive unit If a submerged object is struck while boat is moving forward the hydraulic system will cushion kick up of drive unit as it clears the object reducing damage to unit After drive unit has cleared object the hydraulic system allows drive unit to return to original operating position preventing loss of steering control and engine over speed Use extreme caution when operating in shallow water or where underwater objects are known to be present Use extreme care to prevent striking submerged objects while operating in REVERSE No impact protection is provided in REVERSE If drive unit should strike a submerged object stop engine as soon as possible and inspect drive unit for damage If damage is present or suspected boat should be taken to an Authorized Mercury MerCruiser Dealer for thor ough inspection and necessary repair Operating a dama
7. NY 5 JE CRUISELOG 6 32 CD842 a Instrumentation INSTRUMENTS The following is a brief explanation of instrumentation typically found on some boats The owner operator should be familiar with all instruments and their functions on the boat Because of the large variety of instrumentation and manufacturers you should have your boat dealer explain the particular gauges and normal readings that will appear on your style gauges Speedometer Indicates boat speed Tachometer Indicates engine rpm Oil Pressure Gauge Indicates engine oil pressure Battery Meter Indicates battery voltage Coolant Temperature Gauge Indicates engine operating temperature Fuel Gauge Indicates quantity of fuel in tank Power Trim Gauge Indicates drive unit angle trim UP OUT and DOWN IN Hour Meter Records engine running time oe N OO BO DN SWITCHES 9 Key Switch has three positions A OFF Inthe OFF position all electrical circuits are off and engine cannot be started If the engine is operating the Key Switch CANNOT be used to stop the engine The engine can only be stopped by using the engine Stop Switch while the Key Switch is in the RUN position No electrical circuit is operational when the Key Switch is turned to the OFF position B RUN In the RUN position all electrical circuits indicator lamps automatic preheating if equipped and all instruments are operational C START In the START position the
8. CA824 70564 CA825 Flushing Cooling System CA827 To prevent silt and or salt buildup in cooling system flush with freshwater after each use and prior to storage If flushing cooling system with boat in water raise drive unit to TRAILER position install flushing attachment and lower drive unit to full DOWN IN position If flushing cooling system with boat out of water remove propeller before proceeding If propeller is not removed observe the following precaution When flushing be certain the area around propeller is clear and no person or animal is standing nearby To avoid possible injury remove propeller 1 Install Quicksilver flushing attachment or equivalent over water intake openings in gear housing 2 Connect hose between flushing attachment and water source valve 3 With drive unit in normal operating position partially open water source valve about 1 2 maximum 4 Place drive in NEUTRAL idle speed position and start engine Avoid possible engine damage Do NOT run engine continuously at idle rpm e Do NOT run engine above 1500 rpm 5 Slowly advance throttle until engine reaches 1300 rpm 100 rpm 1 Watch temperature gauge on dash to ensure that engine does not overheat 6 Operate engine with drive in NEUTRAL for about 10 minutes or until discharge water is clear 7 Slowly return throttle to idle speed position 8 Stop engine 9 Shut off water and remove flushing attachment 84
9. CD816 Power Package Layup Continued Dealer should perform the remaining tasks prior to layup 12 After draining perform all checks inspections lubrication and fluid changes outlined in Maintenance Schedules 1 If boat is to remain in the water seacock if so equipped must remain closed until engine is to be re started to prevent water from flowing back into seawater cooling system If boat is not fitted with a sea cock water inlet hose must be disconnected and plugged to prevent water from flowing into cooling system and or boat 13 Close seacock if so equipped or disconnect and plug seawater inlet hose if boat is to remain in the water 14 Clean seawater strainer if equipped Refer to Cleaning Quicksilver Seawater Strainer 15 Clean engine and coat with Quicksilver Corrosion Guard 16 Lubricate all cables and linkages 17 Remove and store battery in a cool dry place Do not store on a concrete surface or on the ground Place on a dry wood board or a thick plastic base Refer to battery manufacturer s instructions CD72 1 Stern drive unit should be stored in full down position Universal Joint bellows may develop a set if unit is stored in raised position and may fail when unit is returned to service 18 Place stern drive unit in the full DOWN IN position 95 CD839 Power Package Recommissioning To prevent possible injury or damage to equipment do not install battery until al
10. Diameter Purchase Date Length The serial numbers are the manufacturer s keys to numerous engineering details which apply to your Mercury MerCruiser power package When contacting your Authorized Mercury MerCruiser Dealer about service always specify model and serial numbers SERIAL NUMBERS L ll SERIAL NUMBER BSO SAV Cert M146530015 CD840 TABLE OF CONTENTS Page Warranty Message sonia A DE 1 WELCOME tee eee See OEA Dd E 2 Identification Record u tds cre epa RA oc Fees nn kadre nie etn 3 Table ORCOS so ee iul aera A AN T pe ats 4 Warranty Information 6 Owner Warranty Registration nice rere ae aly RO Y Re ea 6 International Owner Registration ss u hete d ren ker a ek Eeg x b nde Ron s xe eR 7 Mercury MerCruiser Diesel Limited Warranty ee 8 Warranty Coverage and Exclusion ooocoooccconccc eee eee eee nennen nennen 10 Transferable Warranty 11 Read This Manual Thoroughly 12 General Information 13 Lanyard Stop SWIEN varar ed oe Sad ke SANAE ODE URP Aia 14 EXhaust Emlissio iS 22 21 an ae sight che sastre ra prada See 17 Wave And Wake Jumping 9 18 Impact With Underwater Hazards 2 2 2er zi 19 Sale BOATING Suggestions acc ar a haha i tele tl res lat ee as 20 Protecting People In The Water ois ss 2 en er a engl ie e Ri hee dU eds 21 High Speed And High Performance Boat Operation lluuussllssseeelseeees eere 21 Condit
11. mance and possible engine damage On the other hand operating an engine above the specified operating rpm range will cause higher than normal wear and or damage After initial propeller selection the following common problems may require that the propeller be changed to a lower pitch e Warmer weather and greater humidity cause an rpm loss e Operating in a higher elevation causes an rpm loss e Operating with a damaged propeller or dirty boat bottom causes an rpm loss Operating with increased load additional passengers pulling skiers etc For better acceleration such as is needed for water skiing use the next lower pitch propeller However do not operate at full throttle when using the lower pitch propeller but not pulling skiers 23 CA12 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide open throttle power of an engine Since air containing oxygen gets thinner as elevation increases the engine begins to starve for air Humidity barometric pressure and temperature do have a noticeable effect on the density of air Heat and humidity thin the air This condition can become particularly annoying when the propeller testing was done on a cool dry day Then later on a hot sultry day the boat doesn t seem to have the same performance Although some performance can be regained by dropping to a lower pitch propeller the basic problem still exists In some cases a gear ratio chan
12. Exhaust Pipe 12 Rear Engine Mount 13 Boat Transom Hull 14 Power Steering Cylinder Optional 54 77769 CD779 General Information Always disconnect battery cables from battery BEFORE working around electrical system components to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire This eliminates the engine wiring as a potential source of ignition 1 ENVIRONMENTAL HAZARD Discharge of oil or oil waste into the environment is restricted by law Do not spill oil or oil waste into the environment when using or servicing your boat Contain and dispose of oil or oil waste as defined by local authorities IMPORTANT Refer to Maintenance Schedules for complete listing of all routine and scheduled mainte nance to be performed Some listings can be done by owner operator while others should be performed by an Authorized Mercury MerCruiser Dealer Before attempting maintenance or repair procedures not covered in this manual it is recommended that a Mercury MerCruiser Service Manual s be purchased and read thoroughly NOTE Maintenance points are color coded for ease of identification See the decal on engine for identification 55 CD780 10
13. Minimum oil level mark B MAX Maximum oil level mark NOTE Distance between marks is equivalent to approximately 1 0 liter 1 US quart 4 Remove oil filler cap Add specified oil to bring level up to but not over maximum oil level mark MAX on dipstick Reinstall oil filler cap NOTE It takes several minutes for the added oil to drain to the oil pan Wait approximately 10 minutes and check the level again after adding oil IMPORTANT Do not overfill crankcase oil CD482 DRIVE UNIT OIL NOTE Oil level will fluctuate during operation Oil level should be checked with cold engine before starting 5 Check gear lube monitor oil level Keep oil level at or near FULL line Check for water at bottom of monitor and or if oil appears to be discolored contact your Authorized Mercury MerCruiser Dealer immediately Both conditions may indicate a water leak somewhere in the drive unit IMPORTANT If more than 59 ml 2 fl oz of Quicksilver Gear Lube are required to fill drive unit a seal may be leaking Contact your Authorized Mercury MerCruiser Dealer for service Damage to unit may occur due to lack of lubrication CD270 POWER STEERING PUMP FLUID IMPORTANT If fluid is not visible in reservoir contact your Authorized Mercury MerCruiser Dealer Power steering fluid must be checked with engine off and drive unit pointed straight back Check with engine warm 6 Remove fill cap dipstick from reservoir Wipe clean and reinstall into rese
14. Your boat may be equipped with a Mercury Precision or Quicksilver remote control All controls may not have all features shown If boat is equipped with a remote control other than shown consult your dealer for a description and or demonstration of the control 1 Operation of the shift and throttle are controlled by the movement of the control handle A Single Control Handle Push the control handle forward from NEUTRAL with a quick firm motion to the first detent for FORWARD gear Continue pushing forward to increase speed and back to decrease speed Pull the control handle back from NEUTRAL with a quick firm motion to the first detent for REVERSE gear Con tinue pushing back to increase reverse speed B Dual Control Handles Shift and throttle are controlled by separate handles With throttle control at IDLE push shift control forward for FORWARD gear or pull back for REVERSE gear Then push the throttle control forward to increase speed 2 Neutral Release Lever Prevents accidental shift and throttle engagement Neutral lock button must be pushed IN to move the control handle out of NEUTRAL 3 Trim Tilt Button if Equipped Refer to Power Trim Operation 4 Lanyard Stop Switch Turns ignition OFF whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch Refer to the Lanyard Stop Switch safety explanation and Warning in the General Information Section 5 Lanyard
15. you possibly received substandard fuel with a low cetane rating Sulphur content of the above fuel is rated at 0 5096 by weight maximum ASTM Limits may vary in countries outside of the United States On intermittent use engines high sulphur content diesel fuel will greatly increase e Corrosion on metal parts e Deterioration of elastomer and plastic parts e Corrosion and extensive damage and excessive wear of internal engine parts particularly bearings e Starting and operating difficulties 46 CD769 Recommended Fuels IMPORTANT Mercury MerCruiser does not recommend to use Heavy Oil for your engine Heavy oil fuels causes hard starting and other various troubles such as premature wear of the injection pump plungers and injection nozzles resulting from the deposit of carbon residue and other contaminants JIS UAPANESE INDUSTRIAL STANDARD DIN DEUTSCHE INDUSTRIE NORMEN DIN 51601 SAE SOCIETY OF AUTOMOTIVE ENGINEERS No 2 D Based on SAE J 313C BS BRITISH STANDARD A 1 Based on BSEN 590 1197 CE16 Diesel Fuel In Cold Weather Unaltered diesel fuels thicken and gel in cold temperatures unless treated Virtually all diesel fuels are clima tized to allow their use in the particular region for that time of the year If it becomes necessary to further treat diesel fuel it is the owner operator s responsibility to add a commercial standard brand anti gel diesel fuel additive followi
16. Authorized Mercury MerCruiser Dealer immediately for shift cable adjustment 100 CA902 Steering Wheel Turns Hard Or Jerky Check all parts and fasteners if any are loose or Loose or missing steering fasteners or parts missing see Authorized Mercury MerCruiser Dealer immediately Contaminated power steering fluid Drain and replace CA453 Power Trim Does Not Operate Motor Doesn t Run Possible Cause Remedy Replace use Check all associated electrical connections and mos OOY ee on damage wires especially battery cables Clean and tighten 9 faulty connection Repair or replace wiring CA454 Power Trim Does Not Operate Motor Runs But Drive Unit Does Not Move Trim pump oil level low Fill pump with oil Drive unit binding in gimbal ring Check for obstruction 101 CA461 Owner Service Assistance Local Repair Service Always return your Mercury MerCruiser powered boat to your local Authorized Dealer should the need for service arise Only he has the factory trained mechanics knowledge special tools and equipment and the genuine Quicksilver parts and accessories to properly service your engine should the need occur He knows your engine best Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser stern drives and inboards Service Away From Home If you are away from your local dealer and the need arises for service contact the ne
17. Flush cooling system periodically preferably after each use 89 CD15 Miscellaneous Maintenance CD809 CA103 Battery 1 All lead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below battery manufacturer s specifications Refer to specific instructions and warnings accompanying your battery If this information is not available ob serve the following precautions when handling a battery Do not use jumper cables and a booster battery to start engine Do not recharge a weak battery in the boat Remove battery and recharge in a ventilated area away from fuel vapors sparks or flames Batteries contain acid which can cause severe burns Avoid contact with skin eyes and clothing Batteries also produce hydrogen and oxygen gasses when being charged This explosive gas escapes fill vent cell caps and may form an explosive atmosphere around the battery for several hours after it has been charged sparks or flames can ignite the gas and cause an explosion which may shatter the battery and could cause blindness or other serious injury Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte Hydrogen gases that escape from the battery during charging are explosive When charging batteries be sure area where batteries are located is well vented Battery electrolyte is a corrosive acid and should be handled with care If electrolyte
18. OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY CD622 Warranty Coverage and Exclusion Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in mate rial and workmanship Installation errors accidents normal wear and a variety of other causes that affect the product are not covered Warranty is limited to defects in material or workmanship but only when the consumer sale is made in the country to which distribution is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have WARRANTY DOES NOT APPLY TO THE FOLLOWING Minor adjustments or checks including checking fuel injection pump timing cleaning fuel injectors filters or adjusting belts controls and checking lubrication made in connection with normal services Damage caused by neglect lack of
19. Pressure Cap 20 Sacrificial Anode 21 Thermostat Housing 22 Engine Mount 23 Alternator 24 Serpentine Belt 25 Automatic Tensioner Pulley 26 Engine Water Circulating Pump Pulley 27 Crankshaft Pulley 28 Engine Plate Fixing bolt 29 Timing Cover Lower 52 CD777 PORT SIDE AND REAR VIEWS 1 Hose Engine To Heat Exchanger 2 Coolant Recovery Bottle 3 Hose 4 Gear Lube Monitor Bottle 5 Heat Exchanger 6 Heat Exchanger Coolant Pipe 7 Exhaust Elbow 8 Coolant Drain Plug 9 Sacrificial Anode 10 Seawater Drain Plug 11 Oil Pressure Gauge Sending Unit 12 Engine Coolant Drain Fitting 13 Intercooler 14 Sacrificial Anode 15 Intercooler To Intake Manifold Air Duct 16 Turbocharger 17 Starter Relay 18 Engine Oil Cooler 19 Starter Motor 20 Flywheel Housing 21 Seawater Inlet Fitting 22 Turbocharger To Intercooler Air Duct 53 CD778 STERNDRIVE AND TRANSOM VIEWS 1 Steering System 2 Transom Assembly 3 Sterndrive Unit 4 Antiventilation Plate 5 Power Trim Cylinder 6 Propeller 7 Seawater Intake Openings 8 Speedometer Pitot Tube 9 MerCathode Electrode Optional 10 Inner Transom Plate 11
20. Refer to the lanyard stop switch safety explanation and warning in the General Information Section 6 Throttle Friction Adjustment Console controls require cover removal for adjustment 7 Throttle Only Button Allows engine throttle advancement without shifting the engine This is done by disengaging the shift mechanism from the control handle The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position and should only be used to assist in starting the engine 37 CA768 38 CA418 Power Trim Power Trim allows the operator to adjust the drive angle while underway to provide the ideal boat angle for varying load and water conditions Also the Power Trim system Trailering feature allows the operator to raise and lower the drive unit for trailering beaching launching and low speed below 1200 rpm engine speed shallow water operation 1 Never trim the drive unit UP OUT using TRAILER switch while boat is underway at engine speeds above 1200 rpm Use extreme caution when operating with drive unit raised Severe damage to the drive unit may result if unit is raised beyond the gimbal ring support flanges at engine speeds above 1200 rpm 1 In most cases best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3 to 5 angle to the water 2 Trimming Drive Unit UP OUT Can e Generally incr
21. STEN Single Engine Trim TAI o da ciet Rot c e ette IQ DIS ACC Sew or end Ce epe rt ean Dual Engine Trim Traller a san me ER ERR RP Da restored Starting Shifting and Stopping ner Seen DE Oper athens rare D31 7 DTI ass ee een No e o n e sie Specifications Pile Requirements s as aut A u Au M M att an D Bade Pu eM DE Cx DU MIL ELENA Recommended Fuels s us vsert t Meade d oras EN PI Diesel Fuel In Gold Weather rs 24H feen Re Bea AU ka ARR a nahen Grankease Olle ricco scaena ios dri oci esee Erga to AE e o PIRE Ose sd Anti Freeze GCoolall cet ses eet RE E exe e kw RA RAE NA ACA e drue ARA eem ee Engine Specifications ad rs ee eae S QUU SUUS e xvii EA eii a ms Fud G3paeclliBS eu TS ET Seacock If Equipped a ni et Seawater Strainer If Equipped 22st x aire vee sake fat odo a pe can P o WE Maintenance Power Package Views 3 4 4 3421 esa barra a ed ie dee e dd General lnformation 2 23 een nenn Ben hen rer Bea near Ba ne lesen METI EA A en ee ansetter di ds NOE Maintenance Schedules manner een Checking Fluid Levels As ea re ee er ee Changing Lubricants and Fluids oia is ERA a AAA Air Gleatnelrs rar a tr da e arie teke Drive Balsa SR elle ru nel d lubrication re a A A A AA A ce E E A A EE a Be Propeller r le red SEE ET EE NE eae Flushing Goolm System aa ache d ds toe tec o eid tex eto aod annt dde ia Corrosion and Corrosion Protection lisse RR RII IRR rera Battery MEN Boom O
22. Uneven fuel injection amount between plungers Have inspected by an Authorized Mercury MerCruiser Dealer Cylinder compression pressure leakage Have inspected by an Authorized Mercury MerCruiser Dealer 98 CD821 Excessive Engine Temperature Posse ass Seacock closed or partially closed if equipped Clogged or improperly installed seawater strainer Drive belt loose or in poor condition Seawater pickups obstructed Coolant level low in closed cooling section Check for cause of low coolant level and repair Fill system with proper coolant solution Heat exchanger cores plugged with foreign material Clean seawater side of water water heat exchanger and seawater strainer Loss of pressure in closed cooling section Check for leaks Clean inspect and test pressure cap Closed cooling section dirty Fay seawater PER pump Seawater discharge restricted or plugged Seawater inlet hose kinked restricted CD822 Insufficient Engine Temperature Possible Cause Faully thermostat CD823 Turbocharger Noisy Or Rough Operation Possible Cause Poor lubrication low oil pressure at turbocharger Entry of foreign materials from intake or exhaust side Have inspected by an Authorized Mercury Rubbing of compressor or turbine impellers against MerCruiser Dealer housing Bearing failure 99 CD824 Low Engine Oil Pressure Faulty senders Have system checked by an Authorized Mercury MerCruiser Dealer Insufficient oi
23. acceptable types of anti freeze coolants are listed in the following table Refer to Maintenance Schedules for respective change intervals Description Part Number Quicksilver Premixed Marine Engine Coolant 92 813054A2 Fleetguard Compleat Product Number 91 50663 with DCA4 additive Obtain Locally 49 CD633 _ i Engine Specifications CD772 D1 7L DTI b ii Specification Sterndrive MCM escription D17L DTI Crankshaft Kilowatts Horsepower 89 5 120 Propeller Shaft Kilowatts Horsepower 86 5 116 4 Stroke 4 Cylinder Vertical In Line 4 Valves Per Cylinder Engine Type Dual Overhead Camshaft Direct Injection Turbocharged Intercooled Displacement 1 686 cu L 103 cid Engine Weight 225 kg 495 lb Firing Order 1 3 4 2 Maximum High Idle No Load rpm Idle rom in Neutral 3 725 750 rpm 79 kPa 0 8 bar 11 4 psi Minimum Oil Pressure 3 340 490 kPa 3 5 5 0 bar dal 49 71 psi Oil Temperature Peak 140 C 284 F Thermostat 82 95 C 180 203 F C F 3 39 in 1 Power rated in accordance with NMMA Procedure ISO 3046 Technically Identical to ICOMIA 28 83 2 Refer to Conditions Affecting Operation Propeller Selection for additional information 3 Engine at normal operating temperature 50 CD773 se Fluid Capacities ENGINE NOTICE Unit Of Measurement Liters U S Quarts All capacities are approximate fluid measures Total Oil Capacity 6 1 2 6 3
24. as a sacrificial anode 3 Block Is mounted to underside of gimbal housing and serves as a sacrificial anode 4 MerCathode System if equipped Electrode assembly replaces anodic block System should be tested to ensure adequate output Test should be made where boat is moored using Quicksilver Reference Electrode and Test Meter Contact your Authorized MerCruiser Dealer to arrange for this test 5 Anode Kit if so equipped Mounted to boat transom Acts as a sacrificial anode CD679 6 Trim Cylinder Anodes are mounted on each trim cylinder To replace the trim cylinder anodes A Remove two screws from anode B Clean mounting surfaces down to bare metal for proper contact C Install new anode Tighten screws securely CD808 7 Bearing Carrier Anode Alpha is located in front of the propeller between the front side of the propeller and the gear housing Refer to Propeller section in this manual for propeller removal and installation To replace the propeller anode Remove propeller B Remove two screws from anode C Clean mounting surfaces down to bare metal for proper contact D Install new anode Tighten screws securely E Reinstall propeller See Propeller Installation for proper tightening 87 CD362 CA168 In addition to the corrosion protection devices the following steps should be taken to inhibit corrosion IMPORTANT Corrosion damage that results from the improper application of anti fouling pain
25. etc Check shift and throttle control operation Check steering opera tion several minutes to allow the turbocharger and engine to cool Toggle STOP switch Down and hold until engine completely stops Turn key switch to OFF position Open fuel shut off valve if so equipped Turn battery switch OFF if so equipped Open seacock if so Close fuel shut off valve equipped if so equipped xl HO Do ae Close seacock if so engaged equipped Prime fuel injection sys Flush seawater cooling tem if necessary circuit if operating in saltwater area Pre lubricate turbochar ger and engine if neces sary Turn key switch to RUN and check that lights and indicator lamps come on Turn key switch to START after the indicator lamp for glow plugs if so equipped ceases Re lease key when engine starts Check that charge indica tor and oil pressure indica tor lamps cease after en gine starts Warm up engine at idle rpm for several minutes CD7 Specifications CD164 a Fuel Requirements Electrical system components on this engine are not external ignition protected DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT REF 33 CFR Failure to comply could result in fire explosion and or severe personal injury FIRE HAZARD Fuel leakage from any part of the fuel system
26. following procedure be used on new sterndrive units This break in procedure allows the proper seating of drive unit gears and related components which greatly reduces the likelihood of problems 1 Avoid full throttle starts 2 DO NOT operate at any one constant speed for extended periods of time 3 DO NOT exceed 75 of full throttle during the first 5 hours During the next 5 hours operate at intermittent full throttle 4 Drive unit should be shifted into forward gear a minimum of 10 times during break in with run in time at moderate rpm after each shift CA211 After Break In Period To help extend the life of your Mercury MerCruiser power package the following recommendations should be considered Use a propeller that allows the engine to operate at or near the top of the maximum rpm range See Specifications section when at full throttle with a normal boat load e Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at maximum full throttle RPM CA414 End of First Season Checkup At the end of the first season of operation an Authorized Mercury MerCruiser Dealer should be contacted to discuss and or perform various scheduled maintenance items If you are in an area where the product is operated continuously year round operation you should contact your dealer at the end of the first 100 hours of operation or once yearly whichever occurs first CD843 Operation 5 7
27. is spilled or splashed on any part of the body immediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible 90 CD810 CA104 Bottom Of Boat 2 To maintain maximum speed the following conditions of the boat bottom should be observed e Clean free of barnacles and marine growth Free of distortion nearly flat where it contacts water Straight and smooth fore and aft ANTIFOULING PAINTS 3 Refer to Antifouling Paint recommendations and related information on previous pages Refer to Corrosion And Corrosion Protection for additional information 91 CD44 Cold Weather Or Extended Storage CD811 CD829 Power Package Layup IMPORTANT Mercury MerCruiser strongly recommends that this service should be performed by an Authorized Mercury MerCruiser Dealer Damage caused by freezing IS NOT covered by the Mercury Mer Cruiser Limited Warranty The engine must be prepared for long storage periods to prevent internal corrosion and severe damage DO NOT operate engine without water flowing thru seawater pickup pump as pump impeller may be damaged and subsequent overheating damage to engine or drive unit may result IMPORTANT If boat has already been removed from water before starting engine a source of water must be supplied to water intake inlet openi
28. liners operation with fuels oils or lubricants which are not suitable for use with the product see the Operation Maintenance and Warranty Manual alteration or removal of parts or water entering the engine through the fuel intake air intake or exhaust system Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also expenses associated with the removal and or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty No individual or entity including Mercury Marine authorized dealers has been given authority by Mercury Marine to make any affirmation representation or warranty regarding the product other than those contained in this limited warranty and if made shall not be enforceable against Mercury Marine For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation Maintenance and Warranty Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES
29. maintenance accident abnormal operation improper installation or ser vice or freezing temperatures Haul out launch towing charges removal and or replacement of boat partitions or material because of boat design for necessary access to the product all related transportation charges and or travel time etc Reason able access must be provided to the product for warranty service Customer must deliver product to an Autho rized Dealer Additional service work requested by customer other than that necessary to satisfy the warranty obligation Labor performed by other than an Authorized Dealer may be covered only under following circumstances When performed on emergency basis providing there are no Authorized Dealers in area who can perform the work required or have no facilities to haul out etc and prior factory approval has been given to have the work performed at this facility All incidental and or consequential damages storage charges telephone or rental charges of any type in convenience or loss of time or income are the owner s responsibility Use of other than Quicksilver replacement parts when making warranty repairs Oils lubricants or fluids changed as a matter of normal maintenance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration Participating in or preparing for racing or other competitive activity Engine noise does not neces
30. no forward hatches open station wagon effect CD747 Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating However when this activity is done with sufficient speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat re enters the water The primary concern is the boat changing direction while in the midst of the jump In such case the landing may cause the boat to violently veer in a new direction Such a sharp change in direction 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 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 steer sharply to one side 1 Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake Avoid wave or wake jumping whenever possible Instruct all occupants that if a wake or wave jump occurs get low and hang on to any boat hand hold CD830 Impact With Underwater Hazards Reduce speed and proceed with caution whenever you re driving a boat in shallow water areas or in are
31. such a dealer written notice must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is requested in order to obtain coverage Vi VII VIII WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended rpm range see the Operation Maintenance and Warranty Manual operation of the product in a manner inconsistent with the recommended operation duty cycle section of the Operation Maintenance and Warranty Manual neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part which damages the Mercury product and was not manufactured or sold by us jet pump impellers and
32. the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury WHILE BOAT IS STATIONARY Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near your boat Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gear case or any solid device rigidly attached to a moving boat or gear case CC828 High Speed And High Performance Boat Operation If your boat is considered a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat For additional information obtain a copy of our Hi Performance Boat Operation booklet Part Number 90 849250 1 from your dealer distributor or Mercury Marine 21 CA7 Conditions Affecting Operation Weight Distribution Positioning of weight passengers and gear inside the boat has the following effects A Shifting weight to rear stern will e Generally increases speed and engine RPM e At extremes can cause boat to porpoise e Causes bow to bounce in choppy water e Increases danger of following wave splashing into boat when coming off
33. unable to determine the problem 1 Do not increase the engine speed until the oil pressure gauge indicates normal Shut the engine down if oil pressure does not register on the gauge within 20 to 30 seconds after start 42 CD766 ENGINE WARM UP Improper or no warm up of engine can seriously impair the life of your diesel engine 1 After starting check to ensure all instrumentation is functioning properly Run engine at 1 000 to 1 200 rpm until engine temperature is within normal operating range It is very important that any engine be warmed up before applying full load The warm up period provides time for the lubricating oil to establish a film between moving parts NOTE Engine warm up time during cold weather can be reduced by operating vessel at reduced engine speed Commence normal vessel operation when systems reach operating temperatures 2 After the engine has reached operating temperature A Oil pressure should be within range listed in the engine specifications chart Stop the engine if oil pressure is not within this range B Check the fuel system for leakage from the injection pump fuel pipes fuel filter and fuel lines C Check for oil leakage Check the engine and sterndrive unit for oil leakage Especially check the oil filter oil lines oil line connectors and oil pan D Check for coolant leaks Check coolant hoses and connection pipes of heat exchanger fluid coolers inter cooler water pump and drain
34. vent line kinked or clogged Replace kinked lines or blow out lines with compressed air to remove obstruction Air in fuel injection system Purge fuel injection system Glow plugs or glow plug system inoperative if Test and repair or replace components equipped Injector injector nozzle malfunction Have inspected by an Authorized Mercury MerCruiser Dealer Incorrect injection timing Have inspected by an Authorized Mercury MerCruiser Dealer 97 CD819 Engine Runs Rough Misses And Or Backfires Air in fuel injection system Purge fuel injection system Injector injector nozzle malfunction Have inspected by an Authorized Mercury MerCruiser Dealer Injection pump governor malfunction Have inspected by an Authorized Mercury MerCruiser Dealer CD820 Poor Performance Cracked kinked or clogged fuel line or fuel tank vent Replace line or remove line and blow out line with line compressed air to remove obstruction Stale or contaminated fuel If contaminated drain tank Fill with fresh fuel Boat bottom fouled or damaged Clean or repair as necessary Air in fuel injection system Purge fuel injection system Clogged fuel or air filters Replace filters Fuel leakage from overflow valve Have inspected by an Authorized Mercury MerCruiser Dealer Incorrect valve clearance adjustment Inspect and adjust valve clearance Deteriorated injection pump governor spring Have inspected by an Authorized Mercury MerCruiser Dealer
35. 103 CA463 Customer Service Literature English Language English language publications are available from Attn Publications Department Mercury Marine W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest Mercury Marine or Marine Power International Service Center for further information When ordering be sure to 1 List your product model year and serial number s 2 Check the literature and quantities you want 3 Enclose full remittance in check or money order NO C O D s CA781 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 caa781 Andre sprog Kontakt det n rmeste Mercury Marine eller Marine Power International servicecenter for oplysninger om hvor dan du kan anskaffe en Betjenings og vedligeholdelsesmanual p et andet sprog En liste med reservedels numre for andre sprog leveres sammen med din power pakke cab781 Andere talen Voor het verkrijgen van een Handleiding voor gebruik en onderhoud in andere talen dient u contact op te nemen met het dichtstbijzijnde internationale servicecentrum van Mercury Marine of Marine Power voor informatie hier over Een lijst met onderdeelnummers voor andere talen wordt bij uw motor
36. 4 Coolant Anti Freeze Capacity 8 3 4 9 1 4 1 Always use dipstick to determine exact quantity of oil required CD774 DRIVE NOTICE Unit Of Measurement Milliliters U S Fluid Ounces All capacities are approximate fluid measures Sterndrive Model Drive Unit Oil Capacity With Gear Lube Monitor Bottle 1892 64 CD775 Seacock If Equipped Seawater Strainer If Equipped Flow Rate 80 L min 21 US gal min Minimum Location Should be easily accessible installed in water inlet hose after seacock if equipped ina vibration ree location 51 CD10 Maintenance CD776 Power Package Views FRONT AND STARBOARD SIDE VIEWS X 0 lt Ed to Q ES 77121 1 Air cleaner 2 Oil Separator 3 Oil Filter 4 Nozzle Dust Cover 5 Oil Dipstick 6 Injection Pipe 7 Camshaft Cover 8 Primer Pump Water Separating Fuel Filter 9 Injection Pump 10 Injection Pump Bracket 11 Oil Drain Plug 12 Starter Motor 13 Shift Plate Assembly 14 Engine Plate 15 Engine Lifting Eye 16 Intercooler To Intake Manifold Air Duct 17 Timing Cover Upper 18 Seawater Drain Plug 19
37. CA741 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in the Warranty Sections of this manual The warranty state ment 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 CE344 The operator driver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm The description and specifications contained herein were in effect at the time this guide was approved for printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A 2001 Mercury Marine The following are registered trade
38. all the element on the top piece 8 Install the top piece with the new element into the oil filter housing 9 Turn the new cartridge until the sealing face is fitted against the gasket using the filter wrench or socket Torque to 25 Nm 18 lb ft NOTE Over tightening the cartridge will cause deformation of the cartridge and oil leakage 10 Remove oil fill cap and refill engine with new oil Refer to specifications for quantity and grade of oil 11 Add specified oil to bring level up to but not over maximum oil level mark MAX on dipstick 12 Reinstall oil filler cap IMPORTANT After oil change pre lubricate turbocharger and engine To do this hold the STOP switch engaged while you simultaneously turn the key switch to START position for 15 seconds This will rotate the starter motor and engine oil pump During this process the engine will not run because no fuel is injected Allow the starter motor to cool down for one minute and repeat the above described process To avoid overheating the starter motor do not engage the starter for more that 15 seconds 13 Pre lubricate the engine 14 Start and operate the engine for a few minutes Stop the engine and wait for about ten minutes 15 Remove oil dipstick Wipe clean and reinstall into dipstick tube 16 Remove dipstick and observe oil level If necessary add oil to bring level up to but not over MAX mark or between MIN and MAX marks on dipstick A Minimum oil level mark B Maximum
39. ard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard IMPORTANT The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator acci dentally falls overboard or moves within the boat a sufficient distance from the operator s position Acci dental ejections and falls overboard are more likely to occur in certain types of boats such as low sided sport boats or bass boats and high performance boats Accidental ejections and falls overboard are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or gun wale at planing speeds standing at planing speeds sitting on elevated fishing boat decks operating at planing speeds in shallow or obstacle infested waters releasing your grip on a steering wheel that is pulling in one direction drinking alcohol or consuming drugs or daring high speed boat maneuvers While activation of the lanyard stop switch will stop the engine immediately a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We strongly recommend that other occupants be instructed on proper starting and opera
40. arest Authorized Dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot obtain service contact the nearest Regional Service Center Outside the United States and Canada contact the nearest Marine Power International Service Center Parts And Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accessories should be directed to your local Authorized Dealer The dealer has the necessary information to order parts and accessories for you should he not have them in stock Only Authorized Dealers can purchase genuine Quicksilver parts and accessories from the factory Mercury Marine does not sell to unauthorized dealers or retail customers When inquiring on parts and accessories the dealer requires the motor model and serial number s to order the correct parts CB577 Resolving A Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us If you ever have a problem question or concern about your power package contact your dealer or any Authorized Mercury Mer Cruiser Dealership If additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will w
41. arning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine IMPORTANT Observe the following information to ensure complete draining of cooling system e Engine must be as level as possible e A wire should be repeatedly inserted into all drain holes to ensure there are no obstructions in pas sages 5 Ensure engine is as level as possible to ensure complete draining of cooling system 6 Close seacock if so equipped or disconnect and plug seawater inlet hose if boat is to remain in the water Avoid damage to heat exchanger and subsequent possible engine damage Remove all water from heat exchanger sections Failure to do so could cause corrosion or freeze damage to heat exchanger water passage tubes 7 Remove drain plug from front cover of heat exchanger 93 CD814 Power Package Layup Continued CD815 8 Remove drain plug from lower part of intercooler 9 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained 10 Ensure that gear housing water vent and drain holes speedometer pitot hole and trim tab cavity vent and drain holes are open and unobstructed Avoid water entering boat Do not unplug seawater inlet hose unless a seacock is present and it is closed 11 After seawater section of cooling system has been drained completely coat threads of drain plugs with Perfect Seal and reinstall Tighten securely 94
42. as where the waters are suspected of having underwater obstacles that could be struck by the sterndrive or the boat bot tom The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed Under these conditions boat speed should be kept to a minimum planing speed Striking a floating underwater object may result in an infinite number of situations Some of these situations could result in the following e The boat could move suddenly in a new direction Such a sharp change in direction or turn can cause occu pants to be thrown out of their seats or out of the boat e A rapid reduction in speed This will cause occupants to be thrown forward even out of the boat e Impact damage to the sterndrive and or boat Keep in mind one of the most important things you can do to help reduce injury or impact damage in these situa tions is control the boat speed Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles A ter striking a submerged object stop engine as soon as possible and inspect the sterndrive unit for any broken or loose parts If damage is present or suspected the power package should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractures transom fractures water leaks Operating a damaged sterndrive could caus
43. can be a fire hazard which can cause serious bodily injury or death Careful periodic inspection of entire fuel system is mandatory particularly after storage All fuel components including fuel tanks whether plastic metal or fiberglass fuel lines primers fittings and fuel filters should be inspected for leakage soften hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine operation IMPORTANT Use of improper or water contaminated diesel fuel can damage your engine seriously Use of improper fuel is considered misuse of engine and damage caused thereby will not be covered by war ranty Under no circumstances should gasoline gasohol and or alcohol be mixed with diesel fuel for any reason This mixture of gasoline gasohol and or alcohol with diesel fuel is highly flammable and produces a significant risk to the user Grade 2 D diesel fuel is required meeting ASTM Standards D975 or fuel rated Diesel DIN 51601 and having a minimum cetane rating of 45 The Cetane number is a measure of the ignition quality of diesel fuel Increasing the cetane number will not im prove overall engine performance but it may be necessary to raise the cetane rating for low temperature or high altitude use A lower cetane number could cause hard starting and slower warm up and could increase engine noise and exhaust emissions NOTE If your engine suddenly becomes noisy after a fuel fill
44. d CA746 REMOVAL 1 Place wood block between propeller blade and anti ventilation plate to prevent rotation Straighten bent tabs on tab washer 2 Turn propeller shaft nut counterclockwise to remove nut 3 Slide tab washer drive sleeve propeller and thrust hub off propeller shaft CA79 REPAIR Some damaged propellers can be repaired See your dealer CA774 INSTALLATION IMPORTANT If reusing tab washer carefully inspect tabs for cracks or other damage Replace tab washer if condition is questionable 4 Apply a liberal coat of one of the following Quicksilver lubricants to propeller shaft Anti Corrosion Grease Special Lubricant 101 or 2 4 C Marine Lubricant with Teflon 5 Slide thrust hub onto propeller shaft with stepped side toward propeller hub 6 Install Flo Torque II Drive Hub into propeller NOTE The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued 7 Align splines and place propeller on propeller shaft 8 Install drive sleeve and locking tab washer 9 Install propeller nut Tighten nut securely A minimum of 55 Ibs ft 75 N m torque is required Bend three tabs on tab washer down into grooves in spline washer After first use bend the three tabs straight retighten propeller nut to minimum 55 Ibs ft torque 75 N m Bend tabs back down into spline washer Check propeller at least after 20 hours of operation Do not operate with loose propeller 83
45. distributor deal er also certifies that you are the original purchaser and user of the product A copy of the Warranty Registration Card designated as the Purchaser s Copy MUST be given to you im mediately after the card has been completely filled out by the selling distributor dealer This card represents your factory registration identification and should be retained by you for future use when required Should you ever require warranty service on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registra tion Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distrib utor dealer If you receive a plastic Warranty Registration Card you may discard the Purchaser s Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you For further information concerning the Warranty Registration Card and its relationship to Warranty Claim pro cessing refer to the International Warranty Refer to Table of Contents IMPORTANT Registration lists must be maintained by the factory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it
46. e additional damage to other parts of the power package or could affect control of the boat If continued running is necessary do so at greatly reduced speeds t Avoid serious injury or death from loss of boat control Continued boating with major impact damage can result in sudden component failure with or without subsequent impacts Have the power package thoroughly inspected and any necessary repairs made CA476 Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulations and restrictions and consider the following suggestions e Know and obey all nautical rules and laws of the waterways Boat operators should complete a boating safety course Courses are offered in the U S A by 1 The U S Coast Guard Auxiliary 2 The Power Squad ron 3 The Red Cross and 4 your state or provincial boating law enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT We strongly recommend that all powerboat operators attend one of these courses You should also review the NMMA Sources of Waterway Information booklet It lists regional sources of safety cruising and local navigation and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Association 410 N Michigan Avenue Chicago IL 60611 U S A e Perform safety chec
47. e are some suggestions for you Present day marine equipment such as your Mercury MerCruiser power package are highly technical pieces of machinery Electronic ignition and special fuel delivery systems provide greater fuel economies but also are more complex for the untrained mechanic Do not attempt any repairs which are not covered in this manual unless you are aware of the precautions Cautions and Warnings and procedures required Your safety is of our concern If you attempt to service the product yourself we suggest you order the service manual for that model The service manual outlines the correct procedures to follow It is written for the trained mechanic so there may be procedures you don t understand Do not attempt repairs if you do not understand the procedures There are special tools and equipment that are required to perform some repairs Do not attempt these repairs unless you have these special tools and or equipment You can cause damage to the product in excess of the cost a dealer would charge you Also if you partially disassemble an engine or drive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagn
48. ease top speed e Increase clearance over submerged objects or a shallow bottom e Cause boat to accelerate and plane off slower e n excess cause boat porpoising bouncing or propeller ventilation e Cause engine overheating if trimmed UP OUT to a point where any cooling water intake holes are above the water line 3 Trimming Drive Unit DOWN IN Can e Help the boat accelerate and plane off quicker e Generally improve the ride in choppy water e n most cases reduce boat speed e f 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 39 CB804 Single Engine Trim Trailer Single engine applications will have a button that can be pressed to trim the drive unit up or down To raise the drive unit for trailering beaching launching and low speed below 1200 rpm shallow water operation push the trim button to raise the drive unit to the full UP OUT position Some controls also have a trailer button that trims the drive to a position suitable only for trailer purposes Dual Engine Trim Trailer 1 When lowering or raising sterndrives equipped with a dual engine tie bar kit the sterndrives must be raised or lowered evenly to prevent the tie bar from becoming twisted Failure t
49. elatin to form This gelatin will block engine and heat exchanger passages causing engine overheating The coolant if not premixed should be mixed before being added to the closed cooling system using a proper anti freeze together with deionized water Common tap water or softened water contains unwanted minerals which can leave large deposits in the system that restrict the cooling system efficiency In addition additives and inhibitors introduced into acceptable coolant solutions will form a protective film on internal passages and pro vide protection against internal cooling system erosion The closed cooling section should be kept filled year round with an acceptable anti freeze coolant solution Do not drain closed cooled section for storage as this will promote rusting of internal surfaces If engine will be exposed to freezing temperatures make sure that closed cooled section is filled with a properly mixed antifreeze coolant solution to protect engine and closed cooling system to lowest temperature to which they will be exposed IMPORTANT The anti freeze coolant used in these marine engines must be a low silicate ethylene glycol containing special additives and deionized purified water Using other types of engine coolant may cause fouling of the heat exchangers and overheating of the engine Do not combine different types of coolants without knowing that they are compatible Refer to the coolant manufacturer s instructions Some
50. engine can be started NOTE Key can only be removed in the OFF position 10 Engine Stop Switch is used to stop the engine This is done by electrically shutting off the fuel delivery system The switch toggle or push button is either toggled DOWN or pressed IN Engage and hold the stop switch until the engine stops completely Then turn the key switch to the OFF position A Toggle Switch B Push Button Switch 33 CD756 CD757 ENGINE MONITORING FEATURES 1 A 34 The appropriate light functions as follows Preheat Indicator Lamp indicates when the glow plugs if equipped are preheating the combustion chambers When the engine is cold the timed preheat period begins when the key switch is turned to RUN The light stays on until the preheat period is complete The engine can be started only after the light goes out Charge Indicator Lamp indicates a problem with charging system if lamp illuminates while engine is operating Lamp will be on when key switch is in RUN and engine is not operating When engine starts light should go off Oil Pressure Warning Lamp indicates low engine oil pressure if lamp illuminates while engine is operating Coolant Temperature Warning Lamp indicates excessive engine coolant temperature if lamp illuminates while engine is operating Water In Fuel Warning Lamp indicates water is present in fuel filter and that fuel filter requires service CD758 MERCATHODE ESAS
51. epeatedly on remote control handle until handle returns to the neutral detent position This may take several tries if the power package was operating above idle RPM when the engine stopped 4 After handle returns to the neutral detent position resume normal starting procedures CD341 ENGINE SHUT DOWN STOPPING 1 Place remote control lever in NEUTRAL Avoid damaging the turbocharger and engine Immediate engine shutdown stopping after high load operation may result in permanent turbocharger bearing damage Operate the engine at IDLE for sever al minutes before shut down 2 Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool 3 Toggle stop switch DOWN and hold until engine stops completely 4 Turn key switch to the OFF position 44 CD768 Operation Chart D1 7L DTI STARTING AFTER WHILE STOPPING amp PROCEDURE STARTING UNDERWAY SHUT DOWN Observe all gauges and Frequently observe all Open engine hatch Air warning lights to check gauges and indicator out bilge completely condition of engine If not lights to monitor engine normal stop engine condition Shift remote control lever to neutral position Run engine at idle speed Turn battery switch ON if so equipped Turn on and run engine compartment bilge blow er if so equipped for five minutes Check for leaks fuel oil water fluid etc Check for fuel oil water fluid and exhaust leaks
52. er or the manufacturer of the accessory to secure the applicable manual Electrical system components on this engine are not external ignition protected DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT REF 33 CFR Failure to comply could result in fire explosion and or severe personal injury CA619 Lanyard Stop Switch The purpose of a lanyard stop switch 1 is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch Some remote control units are equipped with a lanyard stop switch A lanyard stop switch can be installed on the dashboard or side adjacent to the operator s position The lanyard is a cord usually between 4 and 5 feet 1220 and 1524 mm in length when stretched out with an element on one end made to be inserted into the switch and a snap 2 on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible so as to minimize the likelihood of lanyard entanglement with nearby objects It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s position If it is desired to have a shorter lany
53. er or gear housing which allows exhaust gases to escape between propeller and gear housing D Drive unit installed too high on transom 22 CD751 Propeller Selection IMPORTANT Installed propeller must allow engine to run at the upper end of the specified throttle oper ating revolutions per minute rpm range with a normal load aboard the boat Use an accurate service tachometer to verify engine operating rpm It is the responsibility of the boat manufacturer and or the selling dealer to equip the power package with the correct propeller s Specified engine wide open throttle WOT and operating rpm range are listed below and in Specifications IMPORTANT The engines covered in this manual depending upon the model are equipped with either a governor or a device that limits engine rpm Be sure that propeller being used does not allow engine to run against the governor or limiter as a significant loss in performance will result Engine Rpm Limits MCM Model Engine Specified Operating Rpm Range Rpm e rece Setting D1 7L DTI 4000 4400 4400 Select a propeller that will allow the engine power package to operate at or near the top end of the recommended wide open throttle operating rpm range with a normal load High rpm caused by an excessive trim angle should not be used in determining correct propeller selection If full throttle operation is below the specified range the propeller must be changed to prevent loss of perfor
54. etting underway CA72 SHIFT CABLE 6 Lubricate pivot points with SAE 30W motor oil 72 CD796 c a D 1 Omi JE EN CA73 THROTTLE CABLE 1 Lubricate pivot points with SAE 30W motor oil CA938 DRIVE UNIT AND TRANSOM ASSEMBLY 2 Lubricate gimbal bearing by applying approximately 8 10 pumps of grease from a typical hand operated grease gun using Quicksilver U Joint and Gimbal Bearing Grease A Alpha Models Lubricate hinge pins by applying a couple of pumps of grease from a typical hand operated grease gun using Quicksilver 2 4 C Marine Lubricant with Teflon 3 For propeller shaft lubrication see PROPELLER CB776 ENGINE COUPLER 4 Lubricate engine coupler splines through grease fitting on coupler by applying approximately 8 10 pumps of grease from a typical hand operated grease gun using Quicksilver Engine Coupler Spline Grease If boat is operated at idle for prolonged periods of time coupler should be lubricated every 50 hours CB777 DRIVE SHAFT EXTENSION MODELS 5 Lubricate drive shaft grease fittings at transom end by applying approximately 3 4 pumps of grease from a typical hand operated grease gun using Quicksilver U joint and Gimbal Bearing Grease 6 Lubricate drive shaft grease fittings at engine end by applying approximately 3 4 pumps of grease from a typical hand operated grease gun using Quicksilver U joint and Gimbal Bearing Grease 73 CD844
55. ever be necessary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the fac tory copy to the Marine Power International Service Center for your area CD685 Recreational Use Diesel Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for one 1 year from the date the product is first sold to a recreational use retail purchaser or the date on which the product is first put into service whichever occurs first Commercial use of the product voids the warranty Commercial use is defined as any work or employment related use of the product or any use of the product which generates income for any part of the warranty period even if the product is only occasionally used for such purposes The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred to a subsequent purchaser upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then onl
56. ey fastener and rotate Release and allow to glide back slowly Tensioner must return to it s initial position CHECKING POWER STEERING PUMP BELT 4 Inspect drive belt for proper tension and for the following e Excessive wear e Cracks e Fraying e Glazed surfaces e Proper tension Check tension by depressing upper strand of belt with moderate hand pressure at point shown Belt should move no more than 5 mm 3 16 in either way 71 CD795 yy I I nO CA524 Lubrication STEERING SYSTEM 1 If Steering Cable Has Grease Fittings Turn steering until steering cable is fully retracted into cable housing Apply approximately 3 pumps of grease from a typical hand operated grease gun Lubricate at fitting with 2 4 C Marine Lubricant with Teflon Do not grease steering cable while extended Hydraulic lock could occur and cause loss of steering control NOTE f steering cable does not have grease fitting inner wire of cable cannot be greased 2 Turn steering until steering cable fully extended Lubricate by applying a thin coat of Special Lubricant 101 on exposed part of cable 3 Lubricate steering system pivot points with SAE 30W motor oil 4 On dual engine boats Lubricate all pivot points including tie bar pivot points with SAE 30W motor oil 5 Upon first starting engine turn steering wheel several times to starboard and then port to ensure that the steering system operates properly before g
57. fittings 3 Locate and correct any problems or see your Authorized Mercury MerCruiser Dealer if you are unable to determine the problem CD767 STARTING WARM ENGINE 1 Turn on and run engine compartment bilge blower for five minutes if equipped Or open engine hatch to air out bilge before attempting to start engine s 2 Turn key switch to the RUN position 3 Turn key switch to START position and release when engine starts Ensure charge indicator and oil pressure warning lamps go off 4 Check to ensure all instrumentation is functioning properly and indicating normal readings 43 CE33 SHIFTING 1 Never attempt to shift unit unless engine is at idle RPM Damage to drive unit could occur 1 To shift unit be sure remote control throttle lever is in NEUTRAL Move control shift lever with a firm quick motion forward to shift to FORWARD gear or backward to shift to REVERSE After shifting drive unit advance throttle to desired setting 2 Once underway engine oil pressure should be within the range listed in the engine specifications chart at maximum rpm or wide open throttle Stop the engine if oil pressure is not within this range Locate and correct the problem or see your Authorized Mercury MerCruiser Dealer if you are unable to determine the problem CB575 IMPORTANT Avoid stopping engine if the drive unit is in gear If engine does stop with drive unit in gear refer to the following procedure 3 Push and pull r
58. ge to more reduction is possible and very beneficial Summer conditions of high temperature low barometric pressure and high humidity all combine to reduce the engine power This in turn is reflected in decreased boat speeds as much as 2 or 3 miles per hour in some cases Nothing will regain this speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day With the drop in available horsepower this propeller will in effect become too large Consequently the engine operates at less than its recommended rpm This will result in further loss of horsepower at the propeller with another decrease in boat speed This secondary loss however can be somewhat regained by switching to a lower pitch propeller that allows the engine to again run at recommended rpm For boaters to realize optimum engine performance under changing weather conditions it is essential that the engine be propped to allow it to operate at or near the top end of the recommended maximum rpm range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the engine also will be operating in an rpm range that discourages damaging detonation This of course enhances overall reliabili
59. ged drive unit could cause additional damage to other parts of drive unit or could affect control of boat If continued running is necessary do so at greatly reduced speeds IMPORTANT Impact protection system cannot be designed to ensure total protection from impact dam age under all conditions 27 CA20 Launching and Boat Operation Care During launching from a trailer if the unloading ramp is steep or the trailer bed must be tilted the boat may enter the water rapidly and at a steep angle This may force water through the exhaust system into the cylinders The more weight on the transom the more likely this is to occur Slowing down rapidly or stopping suddenly may cause a following wave to swamp the transom causing water to enter the cylinders through the exhaust system causing severe engine damage When backing up rapidly the same situation may occur as stated in the preceding paragraph In any of these situations water entering the engine could cause severe damage to internal parts Refer to Attention Required After Submersion CA409 Attention Required After Submersion e Before recovery contact an Authorized Mercury MerCruiser Dealer e After recovery immediate service by an Authorized Mercury MerCruiser Dealer is required to prevent serious damage to power package CA19 Trailering Boat Boat can be trailered with drive unit in up or down position Adequate road clearance is required between r
60. gnal Strict compliance with these special instructions while performing the service plus common sense operation are major accident prevention mea sures Hazards or unsafe practices which could result in severe personal injury or death Hazards or unsafe practices which could result in minor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for proper operation and or main tenance CD750 General Information The operator driver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used We strongly recommend that other occupants be instructed on proper starting and operation procedures so they will be prepared should they be required to operate the power package and boat in an emergency The use of accessories not manufactured or sold by Mercury Marine is not recommended for use with your Mercury MerCruiser unit If your Mercury MerCruiser unit is equipped with an accessory not manufactured by Mercury Marine be sure to read the Operation and Maintenance Manual for the accessory before operation If you haven t been supplied with such a manual contact your deal
61. he skier falls As an example your boat trav eling at 25 miles per hour 40 km hr in 5 seconds will overtake a fallen skier who was 200 feet in front of you e Watch fallen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water e Report accidents Boat operators are required by law to file a Boating Accident Report with their state boat ing 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 treat ment beyond first aid 3 there is damage to boats or other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement CA282 Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his her direction even at slow speed Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water Whenever a boat is moving coasting and the drive unit is in neutral position there is sufficient force by the water on
62. hold the STOP switch engaged while you simultaneously turn the key switch to START position for 15 seconds This will rotate the starter motor and engine oil pump During this pro cess the engine will not run because no fuel is injected Allow the starter motor to cool down for one minute and repeat the above described process To avoid overheating the starter motor do not engage starter motor for more than 15 seconds each time 7 Pre lubricate the engine if necessary Refer to above Important information 8 Start engine and closely observe instrumentation to make sure that all systems are functioning correctly 9 Carefully inspect engine for fuel oil fluid water and exhaust leaks 10 Check steering system shift and throttle control for proper operation 96 CA442 Troubleshooting Starter Motor Will Not Crank Engine Or Cranks Slow Battery switch turned off Remote control not in neutral position Open circuit breaker or blown fuse Check all electrical connections and wires especially battery cables Clean and tighten faulty connection Bad battery Test and replace if bad CD818 Engine Will Not Start Or Is Hard To Start Faulty electrical stop circuit Have Authorized Mercury MerCruiser Dealer service electric stop circuit Loose or dirty electrical connections or damaged wiring Clogged fuel filters Replace filters Stale or contaminated fuel If contaminated drain tank Fill with fresh fuel Fuel line or tank
63. ical overload occurs a fuse will blow or a circuit breaker will trip open IMPORTANT The cause must be found and corrected before replacing fuse or resetting circuit breaker 1 One 50 amp circuit breaker provide protection for engine wiring harness and instrumentation power lead Reset by pushing RESET button IN In an emergency when engine must be operated and cause for high current draw cannot be located and cor rected turn off or disconnect all accessories connected to engine and instrumentation wiring Reset circuit breaker If breaker remains open electrical overload has not been eliminated Further checks must be made on electrical system 2 When equipped with Quicksilver instrumentation and wiring a 20 amp fuse and holder is located in line on key switch power supply wire The fuse protects the instrumentation and wiring should an electrical overload occur If an overload occurs the fuse will burn out Check blown defective fuse if key is turned to RUN or START and instruments do not work and or if switches do not function IMPORTANT Cause for overload must be determined and corrected before attempting to install new fuse or fuse failure will occur again After cause is corrected install new fuse and check system to function 3 The Power Trim system is protected from overload by two fuses on the Power Trim pump A 110 amp B 20 amp in line 36 CA933 Remote Controls CD762 CD763 Remote Control Features
64. ified lubricant Refer to Propeller Installation if necessary Reinstall propeller and torque nut to 75 Nm 55 Ib ft MINIMUM 10 Recheck oil level after first use IMPORTANT Oil level in gear lube monitor will rise and fall during drive operation always check oil level when drive is cool and engine is shut down 69 CD792 CD793 Air Cleaner The air cleaner is used to prevent the entry of rain water seawater and debris No maintenance is required and there are no serviceable parts to the air cleaner 1 Ensure that the air cleaner is mounted clamped securely at all times Replace the assembly if is cracked or damaged Air cleaner B Clamp CD794 Drive Belts CHECKING SERPENTINE BELT Avoid possible serious injury Make sure engine is shut off and ignition key is removed before inspect ing belt 2 The various components are A Water Circulating Pump Pulley C Alternator Pulley B Automatic Tensioner Pulley D Crankshaft Pulley 3 Inspect drive belt for proper tension and for the following e Excessive wear e Cracks NOTE Minor transverse cracks across the belt width may be acceptable Longitudinal cracks in direction of belt length that join transverse cracks are NOT acceptable e Fraying e Glazed surfaces e Proper tension Check operation of the automatic tensioner and associated components Move tensioner pulley in direction of arrow position a suitable tool on pull
65. information on additional literature that is available for your particular MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Telephone Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54936 1939 920 929 5110 920 929 4894 Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular MerCruiser power package and how to order that literature 106 CD68 Owner s Logbook Operating Hours o o tc Lo c y o o c c o 107 CD68 Owner s Logbook Operating Hours a o tc Lo c o o c c o E 108 CD68 Owner s Logbook Operating Hours o o tc Lo c y o o c c o 109
66. installatie geleverd cac781 Muut kielet Saadaksesi Kaytt6 ja huolto ohjekirjoja muilla kielill ota yhteys l himp n Mercury Marine tai Marine Power International huoltokeskukseen josta saat l hempi tietoja Moottorisi mukana seuraa monikielinen varaosa numeroluettelo 104 cad781 Autres langues Pour obtenir un Manuel d utilisation et d entretien dans une autre langue contactez le centre de service apr s vente international Mercury Marine ou Marine Power le plus proche pour toute information Une liste des num ros de pi ces en d autres langues accompagne votre bloc moteur cae781 Andere Sprachen Um eine Betriebs und Wartungsanleitung in einer anderen Sprache zu erhalten wenden Sie sich an das n chste Mercury Marine oder Marine Power International Service Center Eine Liste mit Teilenummern f r Fremdsprachen ist im Lieferumfang Ihres Motors enthalten caf781 Altre lingue Per ottenere il manuale di funzionamento e manutenzione in altra lingua contattate il centro assistenza interna zionale Mercury Marine o Marine Power pi vicino In dotazione con il gruppo motore viene fornito l elenco dei codici prodotto dei componenti venduti all estero cag781 Andre spr k Ytterligere informasjon om bruks og vedlikeholdsh ndbok p andre spr k kan f s ved henvendelse til naermeste internasjonale servicecenter for Mercury Marine eller Marine Power En liste over delenumre for andre spr k folger med aggrega
67. ions Affecting Operation 22 Weight Distribution xi r drakk Site wate r d ep ne lo ste 22 Bottom COT Boat RE ea mae SS on a at ele e a A AR ARUM paa ie a aT 22 Cavitation lt r aban sd Rees beds ethene SEE 22 NOTATION ura RN are Wee ek ae ater ee er care EE ea in Bh eee OT ge 22 Propeller Selection x2 52 e A Diet win e and Sons lo t elc fn eda isa 23 How Elevation And Climate Affect Performance ooooccocccccccnonnr eee tenes 24 Important Information 25 Operation and Maintenance 0 25 Freezing Temperature And Cold Weather Operation 9 27 Drain Plug and Bilge Pump u su a Aron os RENE o ESEL TER 27 Drive Unit Impact Protection 0 27 Launching and Boat Operation Care vasse sad cae ee ae see 28 Attention Required After Submersion 3 innere Rem x RO a ears 28 E BOSE oco sois A ae 28 Stolen Power Package VL PA SATT SAN e LE 28 Replacement Service Parts 7 28 Do It Yourself Maintenance Suggestions 9 29 Engine Break In sc cess ia an pe a ET RO E Rage ee Swed ida 30 Sterndrive Unit 10 Hour Break In Period 0 31 After Break In Period s werd sedvane et fak teehee Rend gea p ges esi ei eed 31 End of First Season Checkup a a he 31 Operation Instrumentation tar a 4er AR eds Audio Warning System pp Mercathode System epa belinda VO is a Roel A Ree ds ed Electrical System Overload Protection 0 R mote Gonrol FealUle8 anne ade Net ea Races IHR e icit ee iq e la Power Tim sr co EPOR GRE hese DER RES OR RR RR E Ee Ru ie bar RIEF
68. ives and inboard engines that propel boats as well as the generators that power various boat accessories Carbon monoxide is a deadly gas that is odorless colorless and tasteless Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication include headache dizziness drowsiness and nausea Avoid the combination of a running engine and poor ventilation Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness brain damage or death GOOD VENTILATION Ventilate passenger area open side curtains or forward hatches to remove fumes 1 Example of desired air flow through the boat CA643 POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an unclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide 2 Examples of poor ventilation while boat is stationary A Running the engine when the boat is moored in a confined space B Mooring close to another boat that has its engine running 3 Examples of poor ventilation while boat is moving A Running the boat with the trim angle of the bow too high B Running the boat with
69. ks and required maintenance Follow a regular schedule and ensure that all repairs are properly made e Check safety equipment on board Here are suggestions of the types of safety equipment to carry when boating 1 Approved fire extinguisher s paddle or oar 2 Signal devices flashlight rockets or flares flag and whistle or horn 3 Spare propeller thrust hubs and an appropriate wrench 4 Tools for necessary minor repairs first aid kit and book 5 Anchor and extra anchor line water proof storage containers 6 Manual bilge pump and extra drain plugs compass and map or chart of area 7 Spare operating equipment batteries bulbs fuses etc 8 Transistor radio 9 Drinking water e Know signs of weather change and avoid foul weather and rough sea boating Tell someone where you are going and when you expect to return e Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back stern of the boat Just shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal Law requires that there be a U S Coast Guard approved wear able type life jacket personal flotation device correctly sized and readily accessible for every person on board plus a throwable cushion or ring We strongly advise that everyone wear a life jacket at all times while in the boat Prepare other boat operators Instruct at least one person on board in
70. l in crankcase Check and add oil Excessive oil in crankcase causing it to become Check and remove required amount of oil Check for cause of excessive oil improper filling bad fuel pump etc Diluted or improper viscosity oil Change oil and oil filter using correct grade and viscosity oil Determine cause for dilution excessive idling faulty fuel pump etc aerated CD826 Battery Will Not Come Up On Charge Possible Cause Remedy Excessive current draw from battery Turn off non essential accessories Loose or dirty electrical connections or damaged Check all associated electrical connections and wiring wires especially battery cables Clean and tighten faulty connections Repair or replace damaged wiring Alternator drive belt loose or in poor condition Replace serpentine belt and or check automatic tensioner Unacceptable battery condition Test battery CD825 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle linkage Lubricate fasteners Loose or missing shift and throttle linkage fasteners Check all linkages If any are loose or missing see Authorized Mercury MerCruiser Dealer immediately Obstruction in shift or throttle linkages Remove obstruction Shift or throttle cable kinked Straighten cable or have dealer replace cable if damaged beyond repair Improper shift cable adjustment See
71. l maintenance has been performed on engine 1 Check that all cooling system hoses are in good condition connected properly and hose clamps are tight 2 Replace fuel filter 3 Bleed fuel system Refer to Maintenance Fuel System When installing battery be sure to connect POSITIVE battery cable to POSITIVE battery terminal FIRST and NEGATIVE battery cable to NEGATIVE battery terminal LAST It battery cables are reversed or connection order is reversed electrical system damage will result 4 Install fully charged battery Clean battery cable clamps and terminals and reconnect cables see CAUTION listed above Secure each cable clamp when connecting Coat terminals with a battery terminal anti corrosion spray to help retard corrosion 5 Perform all checks on Operation Chart in the Starting Procedure column DO NOT operate engine without water flowing thru seawater pickup pump as pump impeller may be damaged and subsequent overheating damage to engine or drive unit may result IMPORTANT If boat has already been removed from water before starting engine a source of water must be supplied to water intake inlet openings Follow all warnings and flushing attachment proce dures stated in FLUSHING COOLING SYSTEM 6 Supply cooling water to water intake inlet openings on sterndrive IMPORTANT After not having been operated for two months or longer it is necessary to pre lubricate the engine To do this
72. ly 15 minutes before adding coolant then with the engine running add coolant slowly Adding cold coolant to a hot engine may crack the cylinder head or crankcase Never use water alone 3 Periodically to ensure that coolant recovery system is functioning properly you should allow engine to cool and then slowly and carefully remove coolant tank cap Coolant level must be to the bottom edge of the tank filler neck If coolant is low add specified coolant as necessary to bring up to proper level Refer to items 1 and 2 above CD620 POWER TRIM PUMP FLUID Power trim pump fluid level must be checked with the drive unit in the full DOWN IN position 4 New trim pumps have a shipping cap plug in the reservoir fill neck Ensure that this cap plug has been removed Remove and discard cap plug if present 5 Remove reservoir cap and observe oil level Level must be up to but not over the bottom edge of fill neck Add Quicksilver Power Trim and Steering Fluid or use SAE 10W 30 or 10W 40 motor oil if available as necessary to bring oil to proper level Replace reservoir cap Reservoir Fill Neck B Reservoir Cap 63 CD834 64 CD835 Changing Lubricants and Fluids See Maintenance Schedules for change interval Lubricants should be changed before placing boat in storage Power Trim or Power Steering fluids do not require changing Coolant in closed cooling s
73. marks of Brunswick Corporation Autoblend Jet Prop Mariner Merc MerCathode Mercury MerCruiser Mercury Mercury Marine Quicksilver RideGuide and Thruster Printed in U S A D1 7L DTI Diesel Engines Alpha Models 20363600 201 2001 Mercury Marine CA753 WELCOME You have selected one of the finest marine power packages available It incorporates numerous design features to assure operating ease and durability With proper care and maintenance you will thoroughly enjoy using this product for many boating seasons To ensure maximum performance and carefree use we ask that you thoroughly read this manual The Operation Maintenance and Warranty Manual contains specific instructions for using and maintaining your product We suggest that this manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our Mercury MerCruiser products We sincerely hope your boating will be pleas ant CONSUMER AFFAIRS DEPARTMENT CD748 Identification Record Please record the following information 4 Engine Model and Horsepower 2 Transom Assembly Serial Number Sterndrive Gear Ratio 3 Transmission Model Inboard Gear Ratio 4 Propeller Number Pitch 5 Hull Identification Number HIN 6 Boat Manufacturer Boat Model 7 Exhaust Gas Emissions Certificate Number Europe Only Serial Numbers Engine Serial Number Sterndrive Unit Serial Number Transmission Serial Number
74. nd 4000 rpm Run engine in gear for 3 minutes at each of the following roms 2100 rpm 3500 rpm and Maximum Rated Full Throttle rpm CD828 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 e DONOT operate engine below 1500 RPM for extended periods during the first 10 hours During this period shift into gear as soon as possible after starting engine and advance throttle so that rom is above 1500 pro vided that conditions permit safe operation at this speed e DONOT operate at any one constant speed for extended periods e DONOT exceed 75 of full throttle during the first 10 hours except during engine Initial Break In Procedure During the next 10 hours occasional operation at full throttle 5 minutes at a time maximum is permissible e AVOID full throttle acceleration from stopped position e DO NOT operate at full throttle until engine reaches normal operating temperature e OBSERVE INSTRUMENTS if an abnormal reading occurs stop engine immediately and determine cause e FREQUENTLY CHECK crankcase oil and sterndrive unit fluid levels Add if necessary It is normal for oil con sumption to be somewhat high during the break in period 30 CD608 Sterndrive Unit 10 Hour Break In Period It is especially important that the
75. nd pump primer up and down repeatedly until an air free stream of fuel flows from bleed screw Filter is full when this occurs 5 Tighten bleed screw 6 Operate the priming pump several times Check for fuel leakage 75 CD837 CD838 FILLING BLEEDING FUEL SYSTEM NOTE Follow this procedure if fuel system was run dry or if part of fuel system was drained for a service function 1 Fill fuel filter as outlined previously 2 Place a suitable container under fuel injection pump to catch fuel 3 Remove and plug boat fuel return hose from injection pump return fuel fitting Avoid the risks of fuel leaking The injection pump fuel return valve a special hollow bolt uses sealing washers to prevent fuel from leaking Replace the sealing washers if leaking 4 Temporarily install a length of fuel hose on return fuel fitting Avoid disturbing special hollow bolt and sealing washers A Return Fuel Fitting B Temporary Hose C Hollow Bolt and Sealing Washers 5 Move plunger on hand pump primer up and down repeatedly until an air free stream of fuel flows from temporary hose 6 Remove temporary hose Unplug and install boat return fuel hose on fitting Clamp hose 7 Move plunger knob up and down several times until some added resistance is noticed when knob is moved 8 Check for fuel leaks 9 Dispose of waste fuel as defined by local authorities 10 Start engine check for fuel leaks If leaks e
76. ng expenses at a minimum See your Authorized Mercury MerCruiser Dealer for service aids 1 The injection pump lever Wide Open Throttle WOT Stop Screw adjusts the engine speed governor and is factory set and sealed Readjusting the governed speed and operating above the specified RPM will cause extensive engine damage and or failure Removal of the seal and or readjustment of the governed speed is considered misuse of engine and resulting damages will not be covered by the limited warranty CA14 DEALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include predelivery inspection and preparation such as e Make sure that the boat is properly equipped e Prior to delivery make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition e Make all necessary adjustments for maximum efficiency e Familiarize the customer with the on board equipment e Explain and demonstrate the operation of the power package and boat e Atthe time of delivery the dealer should provide you with a copy of a Predelivery Inspection Checklist e Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory branch or distributor immediately upon sale of the new product 26 CE8 Freezing Temperature And Cold Weather Operation IMPORTANT If boat is operated during periods of freezing temperature precautions must be taken to prevent f
77. ng that product s directions 47 CD770 Crankcase Oil To help obtain optimum engine performance and to provide maximum protection the engine requires engine oil with a rating of HD SAE API CG 4 CH 4 SH and Su We strongly recommend the use of MERCURY DIESEL ENGINE OIL This oil is a specially blended 15W 40 oil with Marine Additives for all temperature operation It exceeds requirements for API CH 4 CF 4 CG 4 CF 2 SJ and SH oils Other recommended oils SHELL MYRINA TEXACO URSA SUPER TD VEEDOL TURBOSTAR MOPAR WINTERSHALL MULTI REKORD WINTERSHALL VIVA 1 These oils are approved by Mercury Marine and Marine Power Europe For all temperature operation use 15W 40 oil CD771 Anti Freeze Coolant 1 Alcohol or Methanol base antifreeze or plain water are not recommended for use in closed cooling section of cooling system at any time Because diesel engines are high compression engines and related higher engine operating temperatures are created the closed cooling system and engine including related cooling passages must remain as clean as pos sible to provide adequate engine cooling This can only be assured by using the proper anti freeze water additives and inhibitors lt is recommended that the closed cooled section of the cooling system be filled with a low silicate formula of ethylene glycol antifreeze in solution with deionized water A low silicate formula prevents antifreeze separation which causes a silicate g
78. ngs Follow all warnings and flushing attachment proce dures stated in FLUSHING COOLING SYSTEM 1 Supply cooling water to water intake inlet openings on sterndrive 2 Start engine and run until it reaches normal operating temperature Stop engine Change oil and filter Start engine and run for about 15 minutes Check for oil leaks 3 Flush cooling system Refer to Flushing Cooling System procedure shown earlier in this manual IMPORTANT Closed cooling section must be kept filled year round with the specified coolant IMPORTANT Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine IMPORTANT Drain seawater section of closed cooling system only 4 Do not remove this drain plug It is in the closed cooling circuit NOTE Refer to the following pages for continuation of specific draining instructions CD812 Power Package Layup Continued CD813 Drain seawater section of cooling system and prepare for cold weather or extended storage following these pro cedures DRAINING INSTRUCTIONS If boat is to remain in the water seacock if so equipped must remain closed until engine is to be restarted to prevent water from flowing back into seawater cooling system If boat is not fitted with a seacock water inlet hose must be disconnected and plugged to prevent water from flowing into cooling system and or boat As a precautionary measure attach a tag to the ignition switch or steering wheel with the w
79. o raise or lower stern drives evenly may result in tie bar or sterndrive damage Dual engine applications may have a single integral button to operate both drive units simultaneously or may have separate buttons for each drive unit Some controls also have a trailer button that trims the drives to a position suitable for trailer purposes only 40 CD764 Starting Shifting and Stopping GENERAL INFORMATION Do not use volatile starting aids such as Ether Propane or Gasoline in the engine air intake system Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant 1 A Mechanical Engine Stop Lever is located on the injection pump It is used to manually shut off the engine by mechanically cutting off the fuel supply It can be engaged by moving the lever in the direction shown by the arrow BEFORE STARTING THE ENGINE DO NOT operate engine without water flowing thru seawater pickup pump as pump impeller may be damaged and subsequent overheating damage to engine or drive unit may result IMPORTANT As an added precaution the following steps must be observed before starting e Do not start engine without water being supplied to seawater pickup pump to prevent p
80. oad and gear housing skew when trailering with drive unit in down position If adequate road clearance is a problem place drive unit in full trailer position and support with an optional trailer kit which is available from your Authorized Mercury MerCruiser Dealer CA21 Stolen Power Package If your power package is stolen immediately advise the local authorities and Mercury Marine of the model and serial number s and to whom the recovery is to be reported This Stolen Motor information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors CE9 Replacement Service Parts Marine engines are expected to operate at or near full throttle for most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard automotive engine Since marine engines must be capable of running at or near maximum RPM much of the time special pistons camshafts and other heavy duty moving parts are required for long life and peak performance These are but a few of the many special modifications that are required in Mercury MerCruiser marine engines to provide long life and dependable performance 28 CA772 Do It Yourself Maintenance Suggestions If you are one of those persons who likes to do it yourself her
81. oducts used for commercial applications DIRECT SALE BY OWNER e The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership In the United States and Canada mail to Attn Warranty Registration Department Mercury Marine W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 e Anew Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file e There is no charge for this service Outside the United States and Canada please contact the closest Mercury Marine Service Office or the closest distributor in your country for the transferable warranty procedure that would apply to you CD749 Read This Manual Thoroughly IF YOU DON T UNDERSTAND ANY PORTION CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES NOTICE Throughout this publication and on your power package WARNINGS and CAUTIONS accompanied by the In ternational HAZARD Symbol may be used to alert the installer user to special instructions concerning a partic ular 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 si
82. of preheat cycle 5 Turn key switch to RUN position to activate the glow plugs Preheat cycle usually lasts 10 to 15 seconds Observe preheat indicator glow plug lamp Lamp should be illuminated when engine cylinder temperature is too low to sustain combustion Engine can be started once preheat indicator lamp goes off NOTE The engine should be started only after the lamp goes off IMPORTANT After starting the key switch should NOT be returned to the OFF position during engine operation If the starter switch is in the OFF position and the engine is operating the battery will not be charged audio warning alarms will not be operational in the event of trouble and accessories may not operate 6 Turn key switch to START position Release key when the engine starts Allow switch to return to RUN position Do not operate the engine with the switch in the OFF position without first shutting down the engine using the engine stop switch 1 Do not attempt to engage the starter while the engine is running as this will lead to starter pinion and ring gear damage 7 Ensure all instrumentation is functioning properly and indicating normal readings Ensure charge indicator and oil pressure warning lamps go off Check oil pressure gauge immediately after engine starts If oil pressure is not within specified range Refer to Specifications stop the engine locate and correct the problem or see your Authorized Mercury MerCruiser Dealer if you are
83. oil level mark IMPORTANT When refilling engine with oil always use dipstick to determine how much oil is required 1 Do not overfill the engine with oil Too much engine oil will cause excessive oil consumption and higher oil temperature 17 Start engine and check for leaks 67 CD790 74302 CD791 DRIVE UNIT OIL 1 Remove gear lube monitor from bracket 2 Empty contents into suitable container 3 Install monitor in bracket 4 Place drive unit in full trim limit UP OUT position remove OIL FILL DRAIN SCREW and sealing washer and drain oil 5 Remove OIL VENT screw and sealing washer Allow oil to drain completely IMPORTANT If any water drained from OIL FILL DRAIN hole or if oil appears discolored drive unit is leaking and should be checked immediately by your Authorized Mercury MerCruiser Dealer 6 Lower drive unit so propeller shaft is level Fill drive unit through OIL FILL DRAIN hole with specified gear lube until an air free stream of lubricant flows from OIL VENT hole IMPORTANT Use only Quicksilver High Performance Gear Lube in drive unit 7 Install OIL VENT screw and sealing washer 8 Continue to fill until gear lube appears in the gear lube monitor A Fill monitor to FULL mark Lubricate O ring on neck with sterndrive oil Install cap do not overtighten B Quickly install sealing washer and OIL FILL DRAIN screw Tighten securely 9 Remove propeller and grease propeller shaft heavily with spec
84. om of the filter approximately 5 turns 4 Operate the priming pump up and down about 10 times until approximately 4 ml 2 fl 0z is drained or until fuel is clear in appearance 5 Close drain cap by turning clockwise Tighten securely Fill fuel filter as previously outlined 6 After starting the engine check to see that there is no fuel leak from the drain cap IMPORTANT If fuel filter requires frequent draining have the fuel tank drained to remove the water 79 CD802 CD803 REPLACING WATER SEPARATING FUEL FILTER Any water entering the fuel injection system will disable the system Check for water in water separating fuel filter before startup daily If water should enter the fuel injection system take unit to an Authorized Mercury MerCruiser Dealer IMMEDIATELY so that corrosion and rusting of the injectors and other components can be avoided Be careful when changing water separating fuel filter Diesel fuel is flammable Be sure ignition key is OFF Do not allow fuel to contact any hot surfaces which may cause it to ignite Do no tallow sources of open flame in the area Wipe up any spilled fuel immediately Dispose of fuel soaked rags paper etc in an appropriate air tight fire retardant container Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death IMPORTANT Element cannot be cleaned and reused It mus
85. ork with you and your dealership to resolve all problems The following information will be needed by the service office ij K e Your name and address e Daytime telephone number e Model and serial number for your power package EXTRA e The name and address of your dealership HELP e Nature of problem Mercury Marine Service Offices are listed on the next page 102 CA915 Mercury Marine Service Offices For assistance call fax or write Please include your daytime telephone number with mail and fax correspondence Mail E Mercury MerCruiser 405 743 6566 405 743 6570 3003 N Perkins Rd Stillwater OK 74075 Mercury Marine Ltd 905 567 MERC 6372 905 567 8515 2395 Meadowpine Blvd Mississauga Ontario Canada L5N 7W6 Australia Pacific Mercury Marine Australia 61 3 9791 5822 61 3 9793 5880 132 140 Frankston Road Dandenong Victoria 3164 Australia Europe Middle East Africa Marine Power Europe Inc 32 87 32 e 32 11 32 87 31 19 65 Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mexico Central America South America Caribbean Mercury Marine Latin America 305 385 9585 805 385 5507 amp Caribbean 9010 S W 137th Ave Suite 226 Miami FL 33186 U S A Mercury Marine Japan 81 53 426 2500 81 53 423 2510 283 1 Anshin cho Hamamatsu Shizuoka 435 0005 Japan Asia Singapore Mercury Marine Singapore 5466160 5467789 72 Loyang Way Singapore 508762
86. ose a problem or request the repair procedure It is difficult for them to diagnose a problem over the telephone Your Authorized Dealer is there to service your power package They have qualified factory trained mechanics It is recommended you have the dealer do periodic maintenance checks on your power package Have them winterize it in the fall and service it before the boating season This will reduce the possibility of any problems occurring during your boating season when you want trouble free boating pleasure 29 CD753 Engine Break In INITIAL BREAK IN PROCEDURE It is especially important that the following procedure be used on new diesel engines This break in procedure allows the proper seating of the pistons and rings which greatly reduces the likelihood of problems IMPORTANT It is recommended that the boat not be accelerated hard until this procedure has been completed IMPORTANT Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor If engine does not start wait 1 minute to allow the starter motor to cool then repeat start ing procedure 1 Refer to appropriate Starting Shifting and Stopping section and start engine Allow engine to idle until it has reached normal operating temperature Run engine in gear for 3 minutes at each of the following roms 1400 rpm 2800 rpm and 3500 rpm Run engine in gear for 3 minutes at each of the following roms 1700 rpm 3500 rpm a
87. plane B Shifting weight to front bow will e Improve ease of planing on some boats e Improve rough water ride e At extremes can cause boat to veer back and forth bow steer CA8 Bottom Of Boat To maintain maximum speed the following conditions of the boat bottom should be observed A Clean free of barnacles and marine growth B Free of distortion nearly flat where it contacts the water C Straight and smooth fore and aft Marine vegetation may accumulate when boat is docked This growth must be removed before operation it may clog water inlets and cause engine to overheat CA9 lt Cavitation Cavitation occurs when water flow cannot follow the contour of a fast moving underwater object such as a gear housing or propeller Cavitation permits the propeller to speed up but the boat speed to reduce Cavitation can seriously erode the surface of the gear housing or propeller Common causes of cavitation are A Weeds or other debris snagged on propeller or gear housing B Bent propeller blade or damaged gear housing skew C Raised burrs or sharp edges on propeller or gear housing CA10 Ventilation Ventilation is caused by surface air or exhaust gases which are introduced around the propeller resulting in pro peller speedup and a reduction in boat speed Excessive ventilation is annoying and usually caused by A Drive unit trimmed out too far B A missing propeller diffuser ring C A damaged propell
88. pted without presentation of this card A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being pro cessed Should your product need service during this period present the temporary registration card to the dealer He will attach it to your warranty claim form Because of your selling dealer s continuing personal interest in your satisfaction the product should be re turned to him for warranty service If your plastic card is not received within 30 days from date of new product sale please contact your selling dealer The product warranty is not effective until the product is registered at the factory NOTICE Registration lists must be maintained by factory and dealer on marine products sold in the United States should notification under the federal boat safety act be required CD56 International Owner Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim pro gram for your area The Warranty Registration Card identifies your name and address product model and serial number s date of sale type of use and the selling distributors dealer s code number name and address The
89. r Boats 6 22 ente ok eub s Rue c MM EE tk oy Seba ie Re e Cold Weather or Extended Storage Power Package Layup Leger antistes iet ua RAET Draining Inst ueteris rss a doe he p daa PE Power Package Recommissioning 2 Sk deksel eed e eee do eda DAGE Troubleshooting Owner Service Assistance local Repair Servite EN EE Service Away From Home ss GEN Parts And Accessories Inquiries ara ee rec ee v A LO GAY x KE Resolving A Problems Sen as ee En ee ee Mercury Marine Service Offices ato solaris ern e ae ee ee Customer Service Literature 9 Ordening ETeratules es Dori ts Gr ASS NS SSE Owner s Logbook 102 102 102 103 104 106 107 CD54 Warranty Information CD55 Owner Warranty Registration UNITED STATES AND CANADA ONLY It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product It identifies name and address of the original purchaser product model and serial number s date of sale type of use and selling dealer s code name and address The dealer also certifies that you are the original purchaser and user of the product Upon receipt of the Warranty Registration Card at the factory you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification It must be presented to the servicing deal er should warranty service be required Warranty claims will not be acce
90. reezing damage to power package Refer to the following and to Cold Weather or Extended Storage for related information and draining instructions Seawater raw water section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use if the possibility of freezing temperatures exist Failure to comply may result in trapped water causing freeze and or corrosion damage to engine In order to operate the engine in temperatures of 32 F 0 C or lower observe the following instructions e Atthe end of each daily operation COMPLETELY drain seawater section of cooling system to protect against damage by freezing e Atthe end of each daily operation drain water from water separator if equipped Fill fuel tank at end of daily operation to prevent condensation e Use required permanent type antifreeze solution to protect components against damage by freezing e Be sure to use proper cold weather lubrication oil and be sure the crankcase contains a sufficient amount e Make certain that the battery is of sufficient size and is fully charged Check that all other electrical equipment is in optimum condition e At temperatures of 4 F 20 C and below it is recommended that you use a coolant heater to improve cold starting e f operating in arctic temperatures of 20 F 29 C or lower consult your dealer for information about spe cial cold weather equipment and precautions
91. rvoir 7 Remove fill cap dipstick from reservoir and observe fluid level Fluid must be between marks A and B on fill cap dipstick A MAXIMUM FULL HOT Fluid Level top Line Fill to this level when fluid is hot Do not overfill B MINIMUM FULL COLD Fluid Level Fill to this level when fluid is cold Do not allow fluid to drop below this level 8 If necessary add Quicksilver Power Trim and Steering Fluid or if Quicksilver Power Trim and Steering Fluid is not available use Dexron III to bring fluid to proper level Replace fill cap dipstick CD785 ENGINE COOLANT 1 Before starting engine check coolant level in coolant recovery bottle Coolant level must be between the MIN and MAX marks on front of bottle If level is low remove fill cap from coolant recovery bottle and add specified coolant as required Refer to Specifications for proper coolant Do not remove coolant tank cap when engine is hot Coolant may discharge violently causing severe burns 2 If coolant level in coolant recovery bottle was low e Inspect coolant recovery system for leaks e Inspect coolant tank cap gaskets for damage and replace if necessary e Also the tank cap maintains pressure on the coolant tank It may not be holding pressure properly To have cap tested contact your Authorized Mercury MerCruiser Dealer If the coolant should get extremely low and the engine very hot let the engine cool for approximate
92. sarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard Water entering the engine via the air filter or exhaust system or submersion Also water in the starter motor Starter motors and or armatures or field coil assembly which are burned or where lead is thrown out of com mutator because of excess cranking Valve or valve seat grinding required because wear Failure of any parts caused by lack of cooling water which results from starting power package out of water foreign material blocking inlets or power package being mounted too high Use of fuels and lubricants which are not suitable for use with or on the product Refer to your Operation and Maintenance Manual Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product CE350 Transferable Warranty The product warranty is transferable to a subsequent purchaser but only for the remainder of the unused portion of the limited warranty This will not apply to pr
93. t be replaced Remove water separating fuel filter and sealing ring from fuel filter bracket Remove the drain cap from the filter by turning it counterclockwise Discard the used filter Install the O ring and drain cap on the new fuel filter Tighten drain cap Clean filter sealing surface on mounting bracket Coat sealing ring on new filter with clean motor oil Thread filter onto bracket until the sealing ring contacts bracket Tighten the fuel filter an additional 2 3 of a turn with a filter wrench ON OO BON Ensure bottom drain cap is securely tightened Fill fuel filter as explained previously Check filter and drain cap for fuel leaks Make sure no leaks exist before closing engine hatch 9 Start and run engine Check filter connection for fuel leaks If leaks exist recheck filter installation If leaks continue stop engine immediately and contact your Authorized Mercury MerCruiser Dealer CA634 76910 CA634 76910 CA816 Propeller ALPHA Avoid Injury Remote Control must be in NEUTRAL and ignition key removed from switch before re moving and or installing propeller Avoid Injury Place a block of wood between anti ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut 1 Avoid Injury Periodically check propeller nut for tightness during boating season A minimum of 55 Ibs ft 75 N m torque is require
94. t will not be covered by the limited warranty 1 Painting Boat Hull or Boat Transom Antifouling paint may be applied to boat hull and boat transom but you must observe the following precautions IMPORTANT DO NOT paint anodes or MerCathode System reference electrode and anode as this will render them ineffective as galvanic corrosion inhibitors IMPORTANT If anti fouling protection is required for boat hull or boat transom copper or tin base paints if not prohibited by law can be used If using copper or tin based anti fouling paints observe the following 2 Avoid any electrical interconnection between the Mercury MerCruiser Product Anodic Blocks or MerCathode System and the paint by allowing a minimum of 40 mm 1 1 2 in UNPAINTED area on transom of the boat around these items 3 Painting Drive Unit or Transom Assembly Drive unit and transom assembly should be painted with a good quality marine paint or an anti fouling paint that DOES NOT contain copper tin or any other material that could conduct electrical current Do not paint drain holes anodes MerCathode system and items specified by boat manufacturer 4 Spray power package components on inside of boat every 2 3 weeks with Quicksilver Corrosion Guard to protect finish from dulling and corrosion External power package components may also be sprayed 5 All lubrication points especially steering system shift and throttle linkages should be kept well lubricated 6
95. tet cah781 Outros Idiomas Para obter um Manual de Operac o e Manutenc o em outro idioma contate o Centro de Servico Internacional de Marine Power Pot ncia Marinha ou a Mercury Marine mais pr xima para obter informacdes Uma lista de n meros de refer ncia para outros idiomas fornecida com o seu pacote de propuls o caj781 Otros idiomas Para obtener un Manual de operaci n y mantenimiento en otro idioma p ngase en contacto con el centro de servicio m s cercano de Mercury Marine o Marine Power International para recibir informaci n Con su conjunto motriz se entrega una lista de los n meros de pieza para los otros idiomas cak781 Andra spr k F r att f Instruktions och underh llsb cker p andra spr k kontakta n rmaste Mercury Marine eller Marine Power International servicecenter som kan ge ytterligare information En f rteckning ver artikelnummer p an dra spr k medf ljer ditt kraftpaket CAm781 Alhes yAwooeg Tia va axroxmoete Eva Eyye pi o Aertovpylas xar Zuvimpnons oe CA yAoooa ETIKOLVMVNOTE UE TO mAnoveotepo AucOv c K vtpo X pBus ths Mercury Marine y mc Marine Power yia n npopopies To TAXETO voyvoc 005 OVVOSEVETAL ANO EVAV KUTA OYVO APLOUDV MAPAYYEALAS yira ec YAMOOES 105 CA752 Ordering Literature Before ordering literature please have the following information about your power package available Model Horsepower Serial Number Year United States and Canada For
96. the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate When in doubt contact your dealer or the boats manufacturer Know your boat s operating and loading limitations e Make sure everyone in the boat is properly seated Don t allow anyone to sit or ride on any part of the boat that was not intended for such use This includes backs of seats gunwales transom bow decks raised fishing seats any rotating fishing seat anywhere that sudden unexpected acceleration sudden stopping unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat 20 e Never be under the influence of alcohol or drugs while boating it is the law They impair your judgment and greatly reduce your ability to react quickly e Know your boating area and avoid hazardous locations e Be alert The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passengers load or fishing seats should block the operators view when operating the boat above idle or planing transition speed Watch the other guy the water and your wake e Never drive your boat directly behind a water skier in case t
97. ting procedures should they be required to operate the engine in an emergency e g if the operator is accidentally ejected Should the operator fall out of the boat the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately Always properly connect both ends of the stop switch lanyard to the stop switch and the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations 1 Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller 2 Loss of power and directional control in heavy seas strong current or high winds 3 Loss of control when docking 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 CA641 Courtesy of ABYC CA642 Courtesy of ABYC CA620 Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards sterndr
98. ty and durability of the engine 24 CD5 Important Information CD832 Operation and Maintenance OPERATION DUTY CYCLE It is the operator s responsibility to operate within the following specified operational capability or duty cycle as applicable to engine and installation PLEASURE DUTY RATING e Engine Specified Operating Rpm Range D1 7L DTI 4000 4400 e Wide Open Throttle operation is limited to short periods of time NOTE Pleasure duty rating applies to recreational planing craft used exclusively for pleasure and recreation IMPORTANT Damage caused by improper application or failure to operate within the operational capa bility or duty cycle will not be covered by the Mercury MerCruiser Diesel Limited Warranty 25 GE OWNER OPERATOR RESPONSIBILITIES It is the operator s responsibility to perform all safety checks ensure that all lubrication and maintenance instruc tions are complied with for safe operation and return the unit to an Authorized Mercury MerCruiser Dealer for a periodic checkup Normal maintenance service and replacement parts are the responsibility of the owner operator and as such are not considered defects in workmanship or material within the terms of the warranty Individual operating hab its and usage contribute to the need for maintenance service Proper maintenance and care of your power package will assure optimum performance and dependability and will Keep your overall operati
99. ump or engine damage Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor If engine does not start wait 1 minute to allow the starter motor to cool then repeat starting procedure e Be sure engine crankcase is filled to correct level with the proper grade of oil for the prevailing tem perature Refer to Specifications Crankcase Oil e Be sure that all electrical connections are secure 2 Check all items listed in the Maintenance Schedules and Operation Chart 3 Perform any other necessary checks as indicated by your dealer or specified in your boat owner s manual 41 CD765 STARTING COLD ENGINE IMPORTANT Check fluid levels before starting engine Refer to Maintenance Schedule 1 Turn on and run engine compartment bilge blower if equipped for five minutes Or open engine hatch to air out bilge before attempting to start engine s 2 Place drive unit in full DOWN IN position 3 Place control handle in NEUTRAL 4 If engine has not been run for a period of time and will not readily start with the standard starting procedure there is a hand pump primer located on the engine to improve initial fuel supply Refer to Maintenance Fuel System Priming Fuel System and follow instructions given NOTE The preheat devices glow plugs should operate at temperatures lower than 0 C 82 F An engine coolant temperature sensor will automatically control activation and duration
100. ush cooling system after each use Drain any water from fuel filter after each use If operating in freez ing temperatures Inspect drive unit anodes and replace if 50 percent eroded Check battery connections and fluid level Lubricate propeller shaft and the retorque nut if operating in only freshwater this maintenance may be extended to every four months Operating in Saltwater Only treat engine surface with corrosion guard 57 Maintenance Schedules Continued Scheduled Maintenance Every Every Every Every 200 300 500 1000 hours hours hours hours or2 o3 or5 or5 Every Every After 100 200 first 50 hours or hours or hours Annually Annually years years years years p m SS EE Retorque exhaust riser clamp exhaust riser Er III M drive unit oil and retorque a of gimbal ring to LT shaft Replace fuel filter s fuel filter s III NNI steering Lem and remote control u loose missing or damaged parts Lubricate cables and linkages Inspect U joints splines and bellows Check clamps Check engine alignment Lubricate U joints and splines Lubricate hinge pins gimbal bearing and engine coupler 8 Check continuity circuit for loose or damaged connections Test MerCathode unit output if equipped Drain condensation from intercooler Lubricate driveshaft U joints and tailstock input and output bearings Touch up paint power package and spray with corrosion guard
101. xist stop engine immediately Recheck installation NOTE In some circumstances it may be necessary to bleed purge air from the injectors ifthe engine does not readily start Refer to an Authorized Mercury MerCruiser Dealer 77 CD800 77121 CD801 DRAINING WATER SEPARATING FUEL FILTER Be careful when draining water separating fuel filter Diesel fuel is flammable Be sure ignition key is OFF Do not allow fuel to contact any hot surfaces which may cause it to ignite Do not allow sources of open flame in the area Wipe up any spilled fuel immediately Dispose of fuel soaked rags paper etc in an appropriate air tight fire retardant container Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death NOTE To ensure complete draining in warm weather open the drain cap water bleed valve before starting daily operations In cold weather where there is a possibility that the condensed water will freeze drain the filter shortly after the end of daily operations 1 The filter can be drained of water and small dirt particles by opening drain cap at bottom of filter 2 Place a small container at the end of a drain hose beneath the drain cap on the filter 3 Open by turning the drain cap counterclockwise as viewed from the bott
102. y after the Mercury Marine specified pre delivery inspection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Inaccurate warranty registration information regarding recreational use or subsequent change of use from recreational to commercial may void the warranty at the sole discretion of Mercury Marine Routine maintenance outlined in the Operation Maintenance and Warranty Manual must be timely performed in order to obtain warranty coverage If this maintenance is performed by the retail customer Mercury Marine reserves the right to make future warranty coverage contingent on proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing a defective part replacing such part or parts with new or Mercury Marine certified re manufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to
103. ystem should be changed at specified intervals by your Authorized Mercury MerCruiser Dealer CRANKCASE OIL AND FILTER IMPORTANT Change crankcase oil when engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended motor oil refer to Specifications 1 Start engine and allow it to warm up to normal operating temperature 2 Stop engine and allow some time for oil to drain into oil pan approximately 10 minutes 3 Install crankcase oil pump Push adapter onto dipstick tube and attach pump A Dipstick tube B Quicksilver Hose Oil Pump Adapter Quicksilver P N 32 863642 C Quicksilver Crankcase Oil Pump Quicksilver P N 802889A1 Eid oil out of crankcase into drain pan When crankcase is empty remove pump and adapter Install oil ENVIRONMENTAL HAZARD Discharge of oil or oil waste into the environment is restricted by law Do not spill oil or oil waste into the environment when using or servicing your boat Contain and dispose of oil or oil waste as defined by local authorities 65 CD788 CD841 CRANKCASE OIL AND FILTER CONTINUED 5 Use a filter wrench or appropriate socket to remove the cartridge type oil filter 6 Discard the old filter element Discard the old O rings from the top piece A Filter Element B O Rings C Top Piece 7 Install the three O rings Apply a coat of engine oil to the O rings Inst

D1.7L DTI Diesel Engines - Alpha Models

Contents

Download Pdf Manuals

Related Search

Related Contents