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D3.6L/180 and D4.2L/220 Inboard Models

1. 63 Water Flow Diagrarm oe RE e Do mt e De an 63 ENGINE Wiring Diagram E 64 Quicksilver Instrumentation Wiring Diagram 65 Warranty Information A O ln Re 66 Owner Warranty Registration tandas Ether doit bla PO ESO Pp tido 66 International Owner Registration 67 Warranty A quc setis pda verd aec demus icto BY SEE dry rr ate tae 68 Mercruiser Diesel Limited Warranty 22 2 e ea 68 Marine Power International Branch or Distributor Service 5 70 Warranty Coverage 1 3 wm 71 Transferable Warranty E RRA AA A ARS 72 GsGuard Product Protection Plan zuo ie pio out seq ua Ue Sod b RO PU tela 72 Owner Service Assistance e e RE NE EIE OR Ux EN RAE Ede RR EAE EGO 73 local Repair SOMICC cogere tos RD SOS CD M MORIS 73 Service Away from ictus ir tm dime Sea 73 Parts and Accessories Inquiries eke een yea get YS 73 Resolving a Problem em a 73 75 Customer Service sponte a ptr ete tS e
2. RR RER SNC 4954944909 42 58 Cleaning Quicksilver Seawater Strainer NOTE Refer to manufacturers instructions if equipped with other than a Quicksilver seawater strainer ACAUTION When cleaning seawater strainer close seacock if so equipped If boat is not equipped with a seacock remove and plug seawater inlet hose to prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses 1 With engine off close seacock if so equipped or remove and plug seawater inlet hose Remove 2 screws and washers A and cover Remove strainer C and drain plug and washer D and clean any debris from strainer housing flush both strainer and housing E with clean water Check gasket F replace when necessary if it leaks Reinstall drain plug and washer Reattach cover with screws and washers Prior to starting engine open seacock if so equipped or remove plug from seawater inlet hose and reconnect Tighten hose clamps securely After starting engine check for leaks and or air in system which would indicate an external leak CE55 Lubrication SHIFT CABLE 2 Lubricate pivot points with SAE 30W motor oil CA73 THROTTLE CABLE 3 Lubricate pivot points with SAE 30W motor oil CB66 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer 4 Seawater pump impeller should be inspected whenever insufficient s
3. terea hard teh euet RS ato ed 43 Flushing Fuel Tank sos Sins eR Wes an A se PEN ER IG ea 43 Flushing Seawater Cooling System e senses Heese ea caer aoe eds oe eee ees eG ieee 45 FUG SYSIOIMW cios Macatee e een areas 47 PUB TA app T 47 Hand er Goda ED ee a 47 Priming FUSSION 47 A seses TEC TH 47 Filling Bleeding Fuel System ics a Rn aka 47 Draining Water Separating Fuel id en 47 Replacing Water Separating Fuel Filter 49 Corrosion And Corrosion Protection y a A 49 Internal Gomponenis siris act yet en ee a eerte eC a 49 Miscellaneous Maintenance RNA EA 51 rur A rec MC 51 Bottom Of sepen exe EE REPE Seige PER ERG A A a 51 Antifouling ac oo AE NN 51 Inspection And Maintenance boxe UR rae hoe xe RET Ex a uk REA 51 Cold Weather Or Extended Storage er eee we RLM OER 53 Power Package Layup 2e ee Doer e mae Ex Fase BOE qe DO RO 53 Draining lmSsiracHors 2 ee RN AA is E M bd 55 Power Package Recommissioning pp 59 Troubleshooting ER a ns Bees RAS hee 60 Diagrams
4. gral safety switch that allows starting engine in NEUTRAL only Also all controls may not have all features shown NOTE If boat is equipped with a remote control other than shown consult your dealer for a description and or demonstration of the control 1 Throttle Only Button Allows engine throttle advancement without shifting the engine This is done by disen gaging the shift mechanism from the control handle The throttle only button can be depressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 2 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the ten sion on the control handle cover must be removed to adjust This will help prevent Creep of the remote control handle Turn screw Clockwise to increase tension and Counterclockwise to decrease tension Adjust to tension desired 3 Control Handle s Operation of the the shift and throttle are controlled by the movement of the control handle Push the control handle forward from Neutral with a quick firm motion to the first detent for Forward gear Con tinue pushing forward to increase speed Pull the control handle back from Neutral with a quick firm motion to the first detent for Reverse gear Continue pushing back to increase speed 29 CD290 CD308 Starting And Stopping Do not use volat
5. D MR MTS 75 Owner s Logbook e eei ste uer TERRI Beale A ME ee 76 General Maihlenance Parls ee ene wr NE e ROM ER eas 80 Literature Order GOWN en Et Re erem Naeem dus Dna debes eS a 81 The description and specifications contained herein were in effect at the time this guide was approved for print ing 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 Printed in U S A Pond au Pag a 1995 Brunswick Corporation The following are registered trademarks of Brunswick Corporation Autoblend Jet Prop Mariner Merc MerCathode MerCruiser Mercury Mercury Marine Quicksil ver Ride Guide and Thruster CD163 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 en sure maximum performance and carefree use we ask that you thoroughly read the Operation and Maintenance Manual which accompanies the product The Operation and Maintenance Manual contains specific instructions for using and maintaining your product We suggest that t
6. Release key when engine starts Check that charge indica tor and oil pressure indica tor lamps go out AFTER engine starts Warm up engine at idle RPM for several minutes 32 CD10 Maintenance CE102 3 71893 CE39 General Maintenance Information Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire This elimi nates the engine wiring as a potential source of ignition IMPORTANT Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be per formed Some listings can be done by owner operator while others should be performed by an Authorized MerCruiser Dealer Before attempting maintenance or repair procedures not covered in this manual it is recommended that a MerCruiser Service Manual s be purchased and read thoroughly CE211 Aids 1 Hurth Hydraulic Transmission Model 630A 630V Dexron Ill automatic transmission fluid ATF Add fluid at dipstick hole 2 All pivot points SAE 30W motor oil 3 All Exterior Surfaces Quicksilver Primer and Spray Paint as needed and Quicksilver Corrosion Guard 4 Crankcase Oil API rating of CD required Refer to Specifications for list of approved oils 5 Closed Cooling System Coolant use ONLY Quicksilver
7. The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The table explains some of the types of services that are not covered by warranty Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship Installation errors accidents normal wear and a variety of other causes that affect the product are not covered Warranty is limited to defects in material or workmanship but only when the consumer sale is made in the country to which distribution is authorized by us Should you have any questions concerning warranty coverage contact your authorized dealer They will be pleased to answer any questions that you may have WARRANTY DOES NOT APPLY TO THE FOLLOWING Minor adjustments or checks including checking fuel injection pump timing cleaning fuel injectors filters or adjusting belts controls and checking lubrication made in connection with normal services Damage caused by neglect lack of maintenance accident abnormal operation improper installation or 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 Au
8. As a precautionary measure attach a tag to the ignition switch warning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine 1 Close seacock if so equipped or disconnect and plug seawater inlet hose Disconnect water inlet hose from seawater pickup pump connection Using appropriate flushing adaptor connect water hose between adaptor and water tap Partially open water tap about 1 2 maximum 2 Place remote control in NEUTRAL idle speed position and start engine Operate engine at idle speed in NEU TRAL for about 10 minutes or until discharge water is clear Stop engine Shut off water remove flushing adaptor from seawater pump inlet hose connection and reconnect water inlet hose Tighten hose clamp securely 3 The closed cooling section of cooling system that contains coolant does not need to be flushed Coolant is changed at specified intervals Refer to Maintenance Chart 45 CD294 CE61 Fuel System ACAUTION Absolute cleanliness is required for work on the fuel system since the injection pump and fuel injectors have very close tolerances Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system FUEL TANK IMPORTANT Diesel fuel should not be left in tank during winter storage as an accumulation of rust sludge and wax residue will form 1 Fuel tank should be cleaned at specified intervals Refer to boat
9. Belt Quicksilver Motor Oil Anti Corrosion Grease Storage Seal Corrosion Guard Spray CE189 Drive Parts D3 6L 180 MIE D4 2L 220 MIE 92 815869A12 92 815869A12 D3 6L 180 MIE D4 2L 220 MIE Transmission Filter 35 815419 35 815419 80 CC178 Literature Order Form Model Horsepower Serial Number Year Service Manual shows the complete assembly and disassembly of the engine or stern drive Parts Manual shows the exploded view of the engine or stern drive with corresponding part number Operation and maintenance manual Owner s Guide explains basic operation and maintenance Part Number Total Price Official Use Only Parts Manual Drive Only C 90 4 95 Mm mem Y PAY Manual Sa Sae Grand Total must be collected from customers in all states except AK AZ DE ID MT NV NH NY OR VT WV WY Orders Totaling up to 20 00 add 3 00 20 01 50 00 add 4 00 50 01 up Free 81 Please Return with Payment to Mercury Marine Attn Publications Dept P O Box 1939 Fond du Lac WI 54936 1939 Ship To Please Print or Type This is your Shipping Label Name Address City State Method of Payment No Cash or C O D Personal Check Cashiers Check 1 E E E Card Number Visa _ Master Signature Telephone Number 82 Month Year Expiration Date Date CAL
10. COUNTRIES Contact the Nearest Marine Power International Service Center The customer service representative will review all the facts involved If they feel some further action can be taken they will advise the Service Center They will contact your dealer to bring the problem to a satisfactory conclusion ALL SERVICE WORK IS DONE BY THE AUTHORIZED DEALER USING THE DEALER S FACILITIES OUR SERVICE CENTERS AND FACTORY DO NOT HAVE FACILITIES TO SERVICE OR REPAIR YOUR PRODUCT 74 CD278 E Service Centers UNITED STATES AUSTRALIA PACIFIC MerCruiser Marine Power International Pty Ltd 3003 N Perkins Road P B 1420 132 140 Frankston Road Stillwater OK 74075 2299 Dandenong Victoria 3164 Telephone 405 743 6566 Australia Fax 405 743 6570 Telephone 61 3 791 5822 Fax 61 3 791 5880 CANADA ASIA Mercury Marine Marine Power International Ltd 1156 Dundas Highway East Block 1002 Jalan Bukit Merah 07 08 Mississauga Ontario Redhill Industrial Estate L4Y 2C2 Canada JTC Flatted Factories Telephone 905 270 4481 Singapore 0315 Fax 905 270 4510 Telephone 65 270 7680 Fax 65 270 7898 MEXICO CENTRAL AMERICA SOUTH AMERICA CARIBBEAN JAPAN Marine Power International Marine Power International Japan 9350 SW 72nd St Sunset Dr No 27 2 Muramatsu Chisaki shinden Suite 100 Shimizu City Miami FL 33173 Shizuoka Prefecture U S A Japan 424 Telephone 305 596 9606 Telephone 81 543 34 2500 Fax 305 5
11. GRAY YEL GRN GREEN LT ORN ORANGE DRK PPL PURPLE TAN BLK 3 73603 65 CD54 Warranty Information CD55 Owner Warranty Registration UNITED STATES AND CANADA ONLY e ltisimportantthatyourselling dealer fills out the Warranty Registration Card completely and mails it to the facto ry immediately upon sale of the new product e Itidentifies 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 e Upon receipt of the Warranty Registration Card at the factory you will issued a plastic Owner Warranty Regis tration Card which is your only valid registration identification It must be presented to the servicing dealer should warranty service be required Warranty claims will not be accepted without presentation of this card A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service during this period present the temporary registration card to the dealer He will attach it to your warranty claim form Because of your selling dealer s continuing personal interest in your satisfaction the product should be returned to him for warranty s
12. Item 7 MUST be disconnected and protected with at least two layers of electrical tape 64 186 Quicksilver Instrumentation Wiring Diagram 1 Oil Pressure 2 Tachometer 3 Wires Not Used See NOTE 1 4 Coolant Temperature 5 Voltmeter 6 Cruise Log Engine Hour Meter See NOTE 2 7 Engine System Monitor a PreHeat b Alternator 8 Light Switch and Audio Test 9 Stop Switch 10 Keyswitch 11 20 Amp Fuse and Holder 12 Audio Warning Buzzers 13 Spare Wires Not Used c Oil Pressure d Coolant Temp NOTE 1 Tape each wire separately with at least two layers of elec trical tape NOTE 2 May be wired to any PPL that is key switched and BLK PPL 2 TAN BLK LT BLU BLK GRY BRN WHT TAN BRN WHT PPL YEL RED pi TAN BLU RED PPL PPL TAN BLK e BLK WHT GRN TAN WHT BAN TAN BLK GRY 2 YEL RED 7 RED PPL 6 3 TAN BLU 4 BLU TAN BLK YEL er X9 e B TAN WHT 6 BLK 7 BRN WHT 10 BLK 8 BLK YEL 1 BLU TAN 2 WHT GRN 5 BRN 4 YEL RED LHM NVL NUD LHM PPL BLK YEL TAN BLK BLU TAN TAN BLK T 1 BLK BLACK RED BLU BLUE TAN BROWN WHT GRY
13. Premixed Marine Engine Coolant CE131 Maintenance Schedules Always disconnect battery cables from battery BEFORE working around electrical system components to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER OPERATOR REQUIRED SERVICE TIME Check engine oil level Check transmission fluid level Check closed coolant level Check water pickups for marine growth or debris Drain fuel filter Check Clean seawater strainer Before Operation Clean As Required Flush seawater section of cooling system Saltwater Use After Each Use Clean air filter Every 50 Hours of Operation or As Conditions Require Inspect condition and check tension Every 50 Hours of Operation or 60 Days of drive belts Whichever Occurs First fuel fil Every 100 Hours of Operation or Once A eplace fuel filter Year Whichever Occurs First fi Every 200 Hours of Operation or Once a filter ange air titg Year Whichever Occurs First Check Sacrificial Anode in heat exchang er Replace when over 50 eroded Before Operation Check Sacrificial Anode in intercooler Replace when over 50 eroded Once a Year Spray power package exterior surfaces with Quicksilver Corrosion Guard Clean and paint power package exterior surfaces Check battery fluid level Refer to Battery Manufacturer Specifications As Necessary 34 SCHEDULED MAINT
14. STOP switch toggle lever DOWN and hold in this position while you turn the key switch to START position Doing this TOGETHER turns the engine without starting it DO NOT engage starter for more than 15 sec onds allow at least one minute cool down time before re engaging starter for another 15 seconds Watch that starter does not overheat 39 184 73522 40 CD104 Air Filter Cleaning Replacement 1 Disconnect crankcase vent hose A from end of air cleaner Carefully remove air cleaner foam element from around air intake screen housing C mounted on turbocharger inlet Wash foam element in warm water and deter gent until clean ACAUTION Avoid potential fire hazards and personal injury or damage to polyester foam element Do not clean foam element in petroleum based solvents or cleaners IMPORTANT treatment such as partial oil saturation is required or recommended on air cleaner foam element prior to use Use element clean and dry for proper filtration Allow element to completely dry before use and install around air intake screen Replace the foam element if it is deteriorated or torn Refer to MAINTENANCE Maintenance Chart for replacement interval under normal condi tions IMPORTANT To prevent unfiltered air from entering the engine be certain that all of the air intake screen is covered by the foam element when installed CE183 Drive Belts Inspection Tension Replace
15. and sold to the consumer in a country to which distribution is authorized by the Company to be free from defects in material and workmanship This warranty shall apply only to pleasure craft and light duty craft applications This warranty shall become effective upon the date of sale to the first purchaser or user of the Product The warranty period for Pleasure Craft applications is one 1 year from date of sale to the first purchaser or user of the product The warranty period for Light Duty Craft applications is one 1 year from date of sale to the first purchaser or user of the product or the accumulation of 500 hours of engine operation whichever occurs first The unused period of the applicable warranty if any is transferable to subsequent purchasers If the law applicable in the Country State or Province where the product is sold prohibits limitation of warranty coverage to one 1 year then the warranty shall be the minimum period required by law For purposes of this warranty Pleasure Craft is defined as a recreational planing craft used only and exclusively for pleasure and recreation Light Duty Craft is defined as a planing hull vessel used in any law enforcement commercial or professional entertainment activity or used in any enterprise or venture in which revenue in any amount is generated directly or indirectly To validate the warranty the Warranty Registration Card included with each Product must be properly com plete
16. it will be exposed during cold weather or extended storage 4 Disconnect hose from seawater inlet side of seawater pump Connect an appropriate length piece of hose to seawater pump and place the other end of the hose into container of coolant 5 Start engine and run at idle speed until coolant mixture has been pumped into engine seawater system then stop engine 6 Reconnect water inlet hose to seawater pump 7 Clean engine and coat with Quicksilver Corrosion Guard 8 Lubricate all cables and linkages 9 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 10 Remove seawater pump impeller for storage as follows e Remove seawater pump cover mounting screws and remove cover A and gasket B e Ease impeller C off pump shaft with two screwdrivers e Reinstall cover for storage IMPORTANT Place a CAUTION TAG at instrument panel and in engine compartment stating that Seawa ter Pump Impeller is Out DO NOT Operate Engine 57 116 CD310 Power Package Recommissioning IMPORTANT This service should be performed by an Authorized MerCruiser Dealer To prevent possible injury or damage to equipment do not install battery until all maintenance has been performed on engine 1 Check that all cooling system hoses are in good condition connected properly and hose clamps are
17. operator read this Operation and Maintenance Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used We strongly recommend that other occupants be instructed on proper starting and operation procedures so they will be prepared should they be required to operate the power package and boat in an emergency It is difficult for persons standing or floating in the water to move clear if they see a powerboat heading toward them even at slow speed Shift the unit to neutral and shut off engine when your boat is near people in the water Serious injury is likely if a person in the water is struck by a moving boat gear housing propeller or accessory rigidly attached to your boat or motor The use of accessories not manufactured or sold by Mercury Marine is not recommended for use with your MerCruiser unit If your MerCruiser unit is equipped with an accessory not manufactured by Mercury Marine be sure to read the Operation and Maintenance Manual for the accessory before operation If you haven t been supplied with such a manual contact your dealer or the manufacturer of the accessory to secure the applicable manual Electrical system components on this engine are not external ignition protected DO NOT STORE OR UTI LIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT ref 33 CFR Failure
18. resolved to your satisfaction please follow these steps STEP ONE DISCUSS YOUR PROBLEM WITH ONE OF THE DEALERSHIP MANAGEMENT PERSONNEL Misunderstandings or complaints can be quickly solved by the dealer If you are unable to obtain satisfaction con tact the dealership s owner STEP TWO IF YOU REQUIRE ADDITIONAL ASSISTANCE TO RESOLVE YOUR CONCERN CONTACT YOUR NEAREST MERCRUISER SERVICE CENTER Provide the following important information e Your name address and telephone number e The model and serial number s e Your dealer s name and location Present hours of operation e Details of problem or complaint e Boat make and size e Propeller pitch and or part number e Normal use and approximate gross load 73 CD65 Please bear mind that the Service Centers resolve all problems through the dealership using the dealer s facilities equipment and personnel This is the reason we request you use the preceding steps in sequence when you have a problem or complaint Our experience has shown that this is the most expedient and successful procedure to follow to ensure satisfaction to our customers FOLLOW STEP THREE ONLY AFTER COMPLETING STEPS ONE AND TWO AND YOUR COMPLAINT HAS NOT BEEN RESOLVED STEP THREE CONTACT CONSUMER AFFAIRS DEPARTMENT UNITED STATES MerCruiser 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6515 CANADA Contact the Nearest Regional Service Center OTHER
19. seacock if so equipped or disconnect and plug seawater inlet hose if boat is to remain in the water 2 Remove the end covers and from BOTH port and starboard ends of upper and lower sections of heat ex changer tank Drain tank completely Sponge out or soak up any water that remains in the bottom part of each section until all water passage tubes are completely free of standing water ACAUTION 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 pas sage tubes NOTE In the following it may be necessary to lower or bend the hoses to allow water to drain completely 3 Disconnect seawater outlet hose B at aft end of power steering cooler Lower hose and drain completely 4 Remove the drain plug C from the aft end cover of the intercooler 5 Remove seawater pump outlet hose D from top of seawater pump and drain 6 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained ACAUTION Avoid water entering boat Do not unplug seawater inlet hose unless a seacock is present and itis closed 7 Remove hose s at seawater strainer and drain hose s completely Empty seawater strainer Refer to MAIN TENANCE SECTION Cleaning Quicksilver Seawater Strainer Reconnect hose s and tighten hose clamps se curely 8 After sea
20. to comply could result in fire explosion and or severe personal injury 4 280 Lanyard Stop Switch SINAN 1 Some boats come equipped with a lanyard stop switch A lanyard stop switch can also be installed as an acces sory The purpose of this switch is to turn off the engine ignition whenever the operator when attached to the lan yard moves far enough away from the operator s position to activate the switch 74608 2 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 metal snap on the other end for attaching to the operator It 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 posi tion If for any reason it is desired to have a shorter functional lanyard this may be accomplished by using up length in the way the lanyard and clip are attached to the operator such as wrapping the lanyard around the operator s wrist or leg or by tying a simple knot in the lanyard Read the Safety Warning on this page and the following page before electing to install use or not to use such a switc
21. 936 1939 Attn Warranty Registration Department 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 distributor in your country or the Marine Power International Service Center closest to you for the transferable warranty procedure that would apply to you Q GUARD Product Protection Plan UNITED STATES AND CANADA ONLY Certain Performance Products triple engine installations and commercial applications are excluded The Mercury Marine Q GUARD Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty The optional Q GUARD Product Protection Plan is the only Factory Plan available for your engine Two three or four year plans can be purchased up to 180 days after the original engine purchase date See your participating dealer for complete program details 72 CD63 Owner Service Assistance CD64 Local Repair Service Always return your MerCruiser powered boat to your local Authorized Dealer should the need for service arise Only he has the factory trained mechanics knowledge special tools and equipment and the genuine Quicksilver parts and accessories to properly service your engine should the need occur He knows yo
22. 96 3869 Fax 81 543 34 2022 EUROPE MIDDLE EAST AFRICA Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Telephone 0 87 32 32 11 32 87 31 19 65 Customer Service Literature English language publications are available from Mercury Marine Attn Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest 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 75 CD68 Owner s Logbook Operating Hours o tc o c 76 CD68 Owner s Logbook Operating Hours o tc o c 77 CD68 Owner s Logbook Operating Hours o tc o c 78 CD68 Owner s Logbook Operating Hours o tc o c 79 General 210 Engine Oil Filter Fuel Filter Air Filter Element Seawater Filter Impeller 160 Degrees Thermostats 180 Degrees Thermostat Housing Gasket Alternator
23. AUTION During launching from a trailer if the unloading ramp is steep or the trailer bed must be tilted the boat may enter the water rapidly and at a steep angle This may force water through the exhaust system into the cylinders The more weight on the transom the more likely this is to occur Slowing down rapidly stopping suddenly or backing up rapidly may cause a following wave to swamp the transom causing water to enter the cylinders through the exhaust system causing severe engine dam age 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 Atten tion Required After Submersion in this Operation and Maintenance Manual CA18 Attention Required After Submersion Before recovery contact an Authorized MerCruiser Dealer e After recovery immediate service by an Authorized MerCruiser Dealer is required to prevent serious damage to power package CA21 Stolen Power Package If your power package is stolen immediately advise the local authorities and Mercury Marine of the model and serial number s and to whom the recovery is to be reported This Stolen Motor information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors CE9 Replacement Service Parts Marine engines are expected to operate at or near
24. ENANCE PERFORMED BY DEALER REQUIRED SERVICE TIME 20 Hour Checkup See NOTE 1 After First 20 Hours but Not Later Than 50 Hours of Operation After First 100 Hours of Operation or First Oper ating Season Whichever Occurs First After 20 Hour Break In Period then for Pleasurecraft Use Every 100 Hours of Use or 120 Days Whichever Occurs First and for Light Duty Use Every 50 Hours of Use or 60 Days Whichever Occurs First Retorque cylinder heads Change engine oil and filter Check engine alignment and mounting Malware Every 100 Hours of Operation Change transmission fluid Clean inspect and test closed cooling sys Every 100 Hours of Operation or Once a tem pressure cap Year Whichever Occurs First Check and adjust idle RPM Replace coolant using only Quicksilver Premixed Marine Engine Coolant Every 200 Hours of Operation or Once a Year Whichever Occurs First Clean heat exchangers Clean aftercooler core Every 500 Hours of Operation Replace drive belts Inspect cooling system hoses and clamps Externally inspect exhaust system and clamps Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Inspect shift throttle cables and linkage Freshwater use Every 100 Hours of Operation and lubricate or 120 Days Whichever Occurs First Check electrical system for loose or dam aged wiring Clean fuel tank Every 1000 Hours of Operation Disassemble and inspect s
25. IFORNIA 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
26. NENTS 2 There are anodes as part of the intercooler and heat exchanger systems which serve as sacrificial anodes Replace when eroded more than 5096 check at least once yearly Length When New 3 4 in 19mm B Diameter When New 5 8 in 15mm 50 126 I D lt AN CA103 Miscellaneous Maintenance Battery 1 Alllead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below battery manufacturer s specifications Refer to specific instructions and warnings accompanying your battery If this information is not available observe the following precautions when handling a battery 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 Hy drogen gases that escape f
27. ON OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSIONS 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 69 CD278 Marine Power International Branch or Distributor Service Offices INTERNATIONAL HEADQUARTERS Marine Power International Division of Brunswick Corporation P O Box 1939 Fond du Lac WI 54936 1939 USA Telephone 414 929 5000 EUROPE MIDDLE EAST AFRICA Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Telephone 0 87 32 32 11 Fax 32 87 31 19 65 LATIN AMERICA CARIBBEAN Marine Power International 9350 SW 72nd St Sunset Dr Suite 100 Miami FL 33173 U S A Telephone 305 596 9606 Fax 305 596 3869 70 AUSTRALIA Marine Power International Pty Ltd P B 1420 132 140 Frankston Road Dandenong Victoria 3164 Australia Telephone 61 3 791 5822 Fax 61 3 791 5880 ASIA PACIFIC Marine Power International Ltd Block 1002 Jalan Bukit Merah 07 08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone 65 270 7680 Fax 65 270 7898 JAPAN Marine Power International Japan No 27 2 Muramatsu Chisaki shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone 81 543 34 2500 Fax 81 543 34 2022 CD279 Warranty Coverage
28. OPERATION 8 MANUAL D3 6L 180 and D4 2L 220 Inboard Models 1995 Brunswick Corporation 90 821069960 795 CE93 Identification Record PLEASE RECORD THE FOLLOWING INFORMATION 1 Engine Model Horsepower and Serial Number 2 Transom Models Transmission Serial Number 3 Propeller Number Pitch Diameter 4 Hull Identification Number HIN Purchase Date 5 Boat Manufacturer Boat Model Length 6 Exhaust Gas Emissions Certificate Number CE173 Serial Numbers The serial numbers are the manufacturer s keys to numerous engineering details which apply to your MerCruiser power package When contacting your Authorized MerCruiser Dealer about service always specify model and serial numbers merCruvrer D4 2L 220 TURBO AC ae rover email M NCHEN TvpE HSW 630A 16 ABC12345Z123 MOT TMIN Getr Nr IO 3500 ia 1 56 iB 158 SYSTEM_PATENT NO MADE IN WEST GERMANY MADE IN BELGIUM 1139 THIS ENGINE CONFORMS TO INT L BODENSEE SHIPPING COMISSION STDS CERT NO 11393 __ 9 73565 3 HH 217 Table Of Contents Page WEEGOMEN tea teu tore a a ee 3 Head This Manual Thoroughly nasse er a a SEA E EAE SR 4 Eariyare aer a eos A MU 5 Safe Bo
29. ORMANCE TOTAL RUBIA TIR CENTURY SHPD ESSO HESSOL TURBODIESEL VALVOLINE SUPER HD LD 213 DESCRIPTION MIE Inboard DALE Crankshaft Horsepower Kilowatts 220 164 Maximum WOT RPM 3800 3600 ale in Forward Gear 750 RPM 22 36 PSI 1 5 2 5 bar 152 248 kPa Oil Pressure 3600 RPM 50 58 PSI 3 5 4 bar 345 400 kPa F C Water 1 at temperature Thermostats EOS AL IEIMPETSRTE TSS 1807 8870 Bosch 1 Power rated in accordance with Procedure ISO 3046 Technically Identical to 28 83 20 182 NX Capacities NOTE All measurements given in US Quarts Liters SPECIFICATION DESCRIPTION MIE Inboard D3 6L 180 D4 2L 220 Total Oil Filling Capacity 10 1 2 10 12 3 4 eve From oil cooler oil cooler 2 Transmission Hurth 8 Down Transmission Huth8 amp amp DownAngle 1 4 1 4 4 Transmission Hurth V Drive ss 5 4 3 4 Closed Cooling Circuit 12 3 4 12 13 3 4 13 1Always use dipstick to determine exact quantity of oil or fluid required CE20 Required Coolant Quicksilver Premixed Marine Engine Coolant IMPORTANT This contains special low silicate ethylene glycol special additives and purified water Use of other coolant may cause fouling of the heat exchangers and overheating of the engine 21 132 Quartz Cruiselog 22 21 Operation CE98 Quick
30. RTING AFTER WHILE STOPPING amp PROCEDURE STARTING UNDERWAY SHUT DOWN Open engine hatch Air out bilge completely 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 Check steering opera water fluid etc tion Open fuel shut off valve if so equipped Open seacock if so equipped Check that mechanical engine stop lever is not engaged Prime fuel injection sys tem if necessary Shift remote control lever to neutral position Observe all gauges and Frequently observe all warning lights to check gauges and indicator condition of engine If not lights to monitor engine normal stop engine condition Check for fuel oil water fluid and exhaust leaks etc Check shift and throttle control operation Run engine at idle speed several minutes to allow it to cool down Toggle STOP switch Down and hold until engine completely stops Turn key switch to OFF position Turn battery switch off if so equipped Close fuel shut off valve if so equipped Close seacock if so equipped Flush seawater cooling circuit if operating in saltwater area Pre lubricate turbochar ger and engine if neces Turn key switch to RUN and check that lights and indicator lamps come on key switch START AFTER heater indicator lamp has gone out
31. age Refer to the following and to Cold Weather or Extended Storage for related information and draining instructions Damage caused by freezing IS NOT covered by the Mer Cruiser Limited Warranty ACAUTION Seawater raw water section of cooling system MUST BE COMPLETELY drained for winter storage or im mediately 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 Atthe end of each daily operation COMPLETELY drain seawater section of cooling system to protect against damage by freezing At the 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 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 f operating in arctic temperatures of 20 F 29 C or lower consult your dealer for information about special cold weather equipment and precautions 20 Launching and Boat Operation Care AC
32. age uit Ace Pa a Ee AM EE MM a T A oe AMA du a MR HE 14 Replacement Sence Paris ee ee OM De r 14 Do It Yourself Maintenance Suggestions 15 Engine Break Iri EA ere Re net 16 Initial Break In Procedure Rr en rer 16 20 Four Break iN Period ote anne Da pu a px Raps 16 20 Flour Checkup a a Ea Rd ME ge ode RE RR 17 E 18 ee 18 Seawater STEAM aaa a td qup ERU cM a E ERE 18 Fuel Requirements IE 18 Diesel Fuel In Gold Weather IR ee ale ate E EUR 19 Grankoase Oll ba et onte d eon Pip ia as Sere Mima 19 os ped 20 ET 21 Required Coolants nen ae 21 Operation aeaee a e AAE TAAS E EE E SE DE AS EIE a Gr toe LM M E 23 Quicksilver Instruments and Instrumentation 23 Electrical System Overload Protection pp 25 Starting And SIOPPING i aes aaae aren age mps BRA RE 30 Starting Gold Eph abel pua Be beo e Me gate BEA eked ae Bee 31 Starting Warm Eng
33. al navigation and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Association 410 N Michigan Avenue Chicago IL 60611 U S A Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made e Check safety equipment on board Here are suggestions of the types of safety equipment to carry when boat ing 1 Approved fire extinguisher s paddle or oar 2 Signal devices flashlight rockets or flares flag and whistle or horn 3 Spare propeller thrust hubs and an appropriate wrench 4 Tools for necessary minor repairs first aid kit and book 5 Anchor and extra anchor line water proof storage containers 6 Manual bilge pump and extra drain plugs compass and map or chart of area 7 Spare operating equipment batteries bulbs fuses etc 8 Transistor radio 9 Drinking water Know signs of weather change and avoid foul weather and rough sea boating e Tell someone where you are going and when you expect to return Passenger boarding Stop the engine whenever passengers are boarding unloading or are near the back stern of the boat Just shifting the drive unit into neutral is not sufficient e Use personal flotation devices Federal Law requires that there be a U S Coast Guard approved wearable type life jacket personal flotation device correctly sized and readily accessible for e
34. asohol and or alcohol with diesel fuel is highly flammable and produces a sig nificant risk to the user Grade 2 D diesel fuel is required meeting ASTM Standards D975 or fuel rated Diesel DIN 51601 and having a minimum cetane rating of 45 The Cetane number is a measure of the ignition quality of diesel fuel Increasing the cetane number will not improve overall engine performance but it may be necessary to raise the cetane rating for low temperature or high altitude use Alower cetane number could cause hard starting and slower warm up and could increase engine noise and exhaust emissions NOTE If your engine suddenly becomes noisy after a fuel fill you possibly received substandard fuel with a low cetane rating Sulphur content of the above fuel is rated at 0 5096 by weight maximum ASTM Limits may vary in countries out side of the United States 18 On intermittent use engines high sulphur content diesel fuel will greatly increase Corrosion on metal parts Deterioration of elastomer and plastic parts Corrosion and extensive damage and excessive wear of internal engine parts particularly bearings e Starting and operating difficulties 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 tre
35. at diesel fuel it is the owner operator s responsibility to add a commercial standard brand anti gel diesel fuel additive following that product s directions CD243 Crankcase To help obtain optimum engine performance and to provide maximum protection the engine requires engine oil with rating of HD SAE API SG CD and conforming to or exceeding military specifications of MIL 2104 D We strongly recommend the use of QUICKSILVER 4 Cycle Marine Engine a specially blended 25W 40 SG CD oil with Marine Additives for all temperature operations RECOMMENDED OILS FOR D4 2L 220 ENGINES ALL TEMPERATURE OPERATION USE 15W 40 CD These oils approved by Mercury Marine and Marine Power Europe exceed MIL 2104 D standards AGIP SIGMA TURBO MOBIL DELVAC 1400 SUPER TOTAL RUBIA TIR SHELL MYRINA TEXACO URSA SUPER TD VEEDOL TURBOBOSTAR MOPAR WINTERSHALL MULTI REKORD WINTERSHALL VIVA 1 RECOMMENDED OILS FOR D3 6L 180 ENGINES ALL TEMPERATURE OPERATION USE 15W 40 CD These oils approved by Mercury Marine and Marine Power Europe exceed MIL 2104 D standards AGIP SIGMA TURBO CHEVRON DELO 450 MOTOR OIL FANAL INDOL X ARAL OL P 327 MULTIGRADE FINA KAPP LDO AUTOL VALVE SHP DEUSOL TURBOMAX FUCHS TITAN TRUCK 1540 AVIATICON TURBO DIVINOL MULTIMAX EXTRA GULF SUPERFLEET SPECIAL BP VANELLUS C3 EXTRA DUKCHAMS HYPERGRADE IP TAURUS M CALTEX RPM DELO 450 OIL ECUBSOL OIL CD PLUS MOBIL DELVAC 1400 SUPER CASTROL TURBOMAX ELF MULTIPERF
36. ating Suggestions y sun A Protecting People In The Water re 7 While You Are octobre nte ee cee Sto E Rogie 7 While Boat Is Stationary is Rea EEG Ri Rx RE ROSE ee ee ne 7 High Speed And High Performance Boat Operation 7 Conditions Affecting Operation 8 Weight Gis cle deser en Mace 8 Or BEATS re a 8 Propeller Selection nonn ie Ce ciu Md M ME rn Eu dac a idt E bes 9 How Elevation and Climate Affect Performance 10 Important Information csv REPRE a a a REGENT nn 11 Operation and Maintenance coros ae ee la 11 Recommended Operation Duty 11 Owner Operator Responsibilities 12 Dealer Responsibilities wu mer cavit egre eae eu mete a En 12 Freezing Temperature And Cold Weather 13 Launching and Boat Operation Care pp 14 Attention Required After Submersion 14 Stolen Power Pack
37. be pulled Up to move the control handle out of neutral 2 Throttle Only Button Allows engine throttle advancement without shifting the engine This is done by disen gaging the shift mechanism from the control handle The throttle only button can be depressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 3 Lanyard Stop Switch Turns ignition Off whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch See Lanyard Stop Switch at the front of this manual for safety warning on the use of this switch 4 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the ten sion on the control handle This will help prevent Creep of the remote control handle Turn screw Clockwise to increase tension and Counterclockwise to decrease tension Adjust to tension desired 5 Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from Neutral with a quick firm motion to the first detent for Forward gear Continue pushing forward to increase speed Pull the control handle back from Neutral with a quick firm motion to the first detent for Reverse gear Continue pushing back to increase speed CE158 Remote Controls Two Lev
38. cator lamp is not lighted 5 Turn key switch to START position and release when engine fires Check to ensure charge indicator and oil pressure warning lamps go out CAUTION Improper or no warm up of engine can seriously impair the life of your diesel engine 6 Run engine at Idle RPM until engine temperature is within normal operating range CAUTION Never attempt to shift unit unless engine is at idle RPM Damage to drive unit could occur 7 Check to ensure all instrumentation is functioning properly and indicating normal readings STARTING WARM ENGINE 1 Turn on and run engine compartment bilge blower for five minutes if so equipped Or open engine hatch to air out bilge before attempting to start engine s 2 Turn key switch to the RUN position 3 Turn key switch to START position and release when engine fires Check to ensure charge indicator and oil pressure warning lamps go out CAUTION Improper or no warm up of engine can seriously impair the life of your diesel engine 4 Check to ensure all instrumentation is functioning properly and indicating normal readings ENGINE SHUT DOWN 1 Place remote control lever in Neutral 2 Run engine at idle speed for several minutes to allow engine to cool down 3 Toggle STOP switch Down and hold until engine stops completely 4 Turn key switch to the OFF position 31 160 STA
39. ck for water in water separating fuel filter before startup daily ACAUTION If water should enter the fuel injection system take unit to Authorized 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 ap propriate 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 Replace as follows Remove and discard water separating fuel filter A and sealing ring B from mounting bracket C Coat sealing ring on new filter with clean motor oil Thread filter onto bracket and tighten securely by hand Do not use a filter wrench Check that bottom drain cap D is securely tightened Fill fuel filter as explained previously Make sure no leaks exist before closing engine hatch e Startand run engine Check filter connection for fuel leaks If leaks exist recheck filter installation If leaks con tinue stop engine immediately and contact your Authorized MerCruiser Dealer CD119 Corrosion And Corrosion Protection INTERNAL COMPO
40. d by the selling dealer and forwarded immediately after the sale to Mercury Marine U S A and Canada or to a Marine Power International Branch or Distributor Service Office outside the U S A and Canada Purchaser must provide proof of purchase and substantiate the original date of sale by presenting to the dealer authorized to service the Product the original purchaser s copy of the Warranty Registration Card or the Owner Warranty Registration Card If either of these items is not available purchaser must provide a copy of the original purchaser s of Sale Sales Contract for the Product to be serviced Warranty claims will not be accepted by the dealer until the original date of sale and Product serial number can be verified It is a condition for the continuation of this warranty that the Product be taken to an authorized MerCruiser Service Dealer after 20 hours of engine operation but not later than 50 hours for required checks and adjustments A copy of the dealer service work order must be retained as evidence of the completion of this requirement Since this warranty applies to defects in material or workmanship it does not apply to normal wear adjustments tune ups or to damage caused by 1 Neglect lack of maintenance accident abnormal operation improper installation or service 2 Use of a propeller not properly suited to application boat load or failure to follow instructions in applicable service and warranty inf
41. date of purchase and to use the information on the card to prepare the warranty claim form s e n some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor dealer If you receive a plastic Warranty Registration Card you may discard the Purchaser s Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you For further information concerning the Warranty Registration Card and its relationship to Warranty Claim 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 ever be necessary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the facto ry copy to the Marine Power International Service Center for your area 67 CD212 Mer VI 68 Warranty Policy cruiser Diesel Limited Warranty We warrant each new production MerCruiser Diesel Stern Drive Power Package Inboard Engine and Accessories attached thereto hereafter referred to as Product manufactured by MerCruiser hereafter referred to as the Company
42. e 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 en gine be propped to allow it to operate at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging detonation This of course enhances overall reliability and durability of the engine CE6 Important Information CD247 Operation and Maintenance RECOMMENDED OPERATION DUTY CYCLE It is the operator s responsibility to operate within the following recommended operational capability or duty cycle as applicable to engine and installation e Pleasure Duty 1 Operated at rated power and rated speed for short periods of time e Light Duty 1 Operated such that full rated power at maximum rated RPM is limited to 10 of operating time and continuous cruising RPM is limited to 90 of Wide Open Throttle RPM when propped within specified RPM range 2 Annual operating time is not to exceed 500 hours NOTE Pleasure duty rating applies to high performance type boats or boats with planing hulls where acceleration and top speed are of primary importance This rating is reserved for privatel
43. e used on new diesel engines This break in procedure al lows 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 com pleted IMPORTANT Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor If engine does not start wait 1 minute to allow the starter motor to cool then repeat starting procedure Initial Break in Procedure Is As Follows 1 Pre lubricate the turbocharger and engine To do this hold the STOP switch toggle lever DOWN while you simultaneously turn the key switch to START position for 15 seconds This will rotate the starter motor and engine oil pump During this process the engine will not run because no fuel is injected Allow the starter motor to cool down for one minute and repeat the above described process To avoid overheating the starter motor do not engage starter motor for more than 15 seconds each time 2 Referto Starting Shifting and Stopping and start engine Allow engine to idle until it has reached normal oper ating temperature 3 Run engine in gear for 3 minutes at each of the following RPMs 1200 RPM 2400 RPM and 3000 RPM Run engine in gear for 3 minutes at each of the following RPMs 1500 RPM 2800 RPM and 3400 RPM Run engine in gear for 3 minutes at each of the following RPMs 1800 RPM 3000 RPM and Max
44. e 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 tempera ture do have a noticeable effect on the density of air Heat and humidity thin the air This condition can become particularly annoying when an engine is propped out on a cool dry day in spring and later on a hot sultry day in August doesn t have its old zip Although some performance can be regained by dropping to a lower pitch propeller the basic problem still exists In some cases a gear ratio change to more reduction is possible and very beneficial Summer conditions of high temperature low barometric pressure and high humidity all combine to reduce the en gine 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 b
45. eawater flow is suspected if operating temperature exceeds normal range 56 Flushing Fuel Tank 5 Flush and clean diesel fuel tank every 1000 hours maximum following boat manufacturer s instructions 43 110 CE111 Flushing Seawater Cooling System To prevent silt and or salt buildup the seawater circuit of cooling system flush with freshwater at specified Inter vals ACAUTION When flushing seawater cooling system close seacock if so equipped If boat is not equipped with a sea cock remove and plug seawater inlet hose to prevent a siphoning action that may occur allowing seawa ter to flow from the drain holes or removed hoses When flushing be certain the area around propeller is clear and no one is standing nearby To avoid possi ble injury remove propeller ACAUTION Do not run engine above 1500 RPM when flushing Suction created by seawater pickup pump may collapse flushing hose causing engine to overheat ACAUTION Watch temperature gauge on dash to ensure that engine does not overheat ACAUTION If boat is in the water or is to remain in the water seacock if so equipped must be closed until engine is to be restarted to prevent contaminated water from flowing back into cooling system If boat is not fitted with a seacock water inlet hose must be disconnected and plugged to prevent contaminated water from flowing into cooling system and or boat
46. eawater pump At Least Once Yearly NOTE 1 For a list of 20 Hour Checkup maintenance items to be performed see IMPORTANT INFORMATION section of this manual 35 104 CD94 Checking Fluid Levels CRANKCASE OIL ACAUTION Avoid possible injury or damage to oil dipstick and internal engine components Do not remove crankcase oil dipstick when engine is running Stop the engine completely before removing or inserting dipstick Check engine oil daily before first start up If it becomes necessary to check oil level during operation stop engine and allow 5 minutes for oil to drain into pan 1 Remove dipstick Wipe clean and reinstall into dipstick tube 2 Remove dipstick and observe oil level Oil must be between MIN and MAX marks on dipstick If necessary add oil as follows 3 Remove oil filler cap Add specified oil to bring level up to but not over MAX mark on dipstick Reinstall oil filler cap CD166 ENGINE COOLANT 4 Before starting engine check coolant level in coolant recovery bottle Coolant level must be between the ADD and FULL marks on front of bottle If level is low remove fill cap from coolant recovery bottle and add specified coolant as required Refer to Specifications for proper coolant Do not remove coolant tank cap when engine is hot Coolant may discharge violently causing severe burns 5 If coolant level in coolant recovery bottle was low e Inspect coo
47. ed at specified intervals by your Authorized MerCruiser Dealer CRANKCASE OIL AND FILTER IMPORTANT Change oil when engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended motor oil see SPECIFICATIONS Start engine and allow it to warm up to normal operating temperature Stop engine and allow some time for oil to drain into oil pan approximately 5 minutes Remove fitting A from end of crankcase oil drain hose B laying on top of engine Install crankcase oil pump A Quicksilver Part Number 90265A2 onto threaded fitting B of oil drain hose 5 Pump oil out of crankcase into drain pan When crankcase is empty remove pump and reinstall crankcase oil drain hose fitting Tighten securely 6 Remove anddiscard oil filter and sealing ring Coat sealing ring on new filter with oil and install filter Hand tighten only do not use a filter wrench 7 Remove oil fill cap and refill engine with new oil refer to Specifications for quantity and grade of oil hk OND IMPORTANT When refilling engine with oil always use dipstick to determine how much oil is required ACAUTION Avoid possible injury or damage to oil dipstick and internal engine components Do not remove crankcase oil dipstick when engine is running Stop the engine completely before removing or inserting dipstick IMPORTANT After oil change pre lubricate turbocharger and engine To do this move the
48. er Your boat may be equipped with one of many Quicksilver remote controls available All controls feature an inte gral safety switch that allows starting engine in NEUTRAL only Also all controls may not have all features shown NOTE If boat is equipped with a remote control other than shown consult your dealer for a description and or demonstration of the control 6 Shift Lever shifts unit into gear with full lever movement Move lever forward to shift to FORWARD gear Move lever backward to shift to REVERSE gear Lever in full vertical position shifts to NEUTRAL ACAUTION Never shift unit into or out of gear unless throttle lever is at idle RPM 7 Throttle Lever allows engine RPM to be increased or decreased 8 FRICTION Screw adjusts control handle friction so motor speed can be set and driver does not have to hold handle Turn screw clockwise to increase friction Do not thread screw all the way out 9 DETENT Screw controls the effort needed to move control handle out of NEUTRAL To increase tension turn screw clockwise to decrease turn screw counterclockwise Do not thread screw all the way out IMPORTANT Boats equipped with dual power packages may have both shift levers on one control and both throttle levers on the other control 27 CC200 159 Remote Controls Console Mounted Your boat may be equipped with one of many Quicksilver remote controls available All controls feature an inte
49. er minute is required Strainer should be installed in an area where it will be easily accessible for inspection and cleaning Strainer should be installed in water inlet hose after seacock to allow operator to shut off water inlet when cleaning strainer CE15 Fuel Requirements Electrical system components on this engine are not external ignition protected DO NOT STORE OR UTI LIZE 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 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 g
50. ervice e fyour plastic card is not received within 30 days from date of new product sale please contact your selling deal er e The product warranty is not effective until the product is registered at the factory e 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 66 CD56 International Owner Registration OUTSIDE THE UNITED STATES AND CANADA ltisimportantthat your selling dealer fills out the Warranty Registration Card completely and mails it to the dis tributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area e The Warranty Registration Card identifies your name and address product model and serial number s date of sale type of use and the selling distributors dealer s code number name and address The distributor dealer also certifies that you are the original purchaser and user of the product Acopy ofthe Warranty Registration Card designated as the Purchaser s Copy MUST be given to you immedi ately 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
51. est Marine Power International Branch or Distribu tor Service Office outside the U S A and Canada We shall then arrange for the inspection and repair pro vided such service is covered under this warranty Purchaser shall pay for all related transportation charges and or travel time If the service is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Any Product or parts shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid Our obligation under this warranty shall be limited to repairing a defective part or at our option refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this warranty The repair or replacement of parts or the performance of service under this warranty does not extend the period of this warranty beyond its original expiration date We reserve the right to improve the design of any Product without assuming any obligation to modify any Product previously manufactured ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANT Y WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IM PLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY SOME STATES OR COUNTHIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSI
52. fore replacing fuse or resetting circuit breaker 1 Two 60 amp circuit breakers provide protection for engine wiring harness and instrumentation power lead set by pushing RESET button IN on outside In an emergency when engine must be operated and cause for high current draw cannot be located and corrected turn OFF or disconnect all accessories connected to engine and instrumentation wiring Reset circuit breaker If breaker remains open electrical overload has not been eliminated Further checks must be made on electrical system 2 When equipped with Quicksilver instrumentation and wiring a 20 amp fuse and holder is located in line on key switch RED PURPLE wire and protects the Instrumentation and wiring should an electrical overload occur If an overload occurs the fuse will burn out Check blown burned fuse if key is turned to RUN or START and instru ments do not work and or if switches do not function 25 143 157 Remote Controls Panel Mounted Your boat may be equipped with one of many Quicksilver remote controls available All controls feature an inte gral safety switch that allows starting engine in NEUTRAL only Also all controls may not have all features shown NOTE If boat is equipped with a remote control other than shown consult your dealer for a description and or demonstration of the control 1 Neutral Lock Bar Prevents accidental shift and throttle engagement Neutral lock bar must
53. full throttle for most of their life They are also expected to oper ate 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 auto motive engine Since marine engines must be capable of running at or near maximum RPM much of the time special pistons camshafts and other heavy duty moving parts are required for long life and peak performance These are but a few of the many special modifications that are required in MerCruiser marine engines to provide long life and dependable performance 23 Do It Yourself Maintenance Suggestions If you are one of those persons who likes to do it yourself here are some suggestions for you Present day marine equipment such as your MerCruiser power package are highly technical pieces of machin ery Do not attempt any repairs which are not covered in your Operation and Maintenance Manual accompanying your product 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 ser vice 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 understa
54. g 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 As we cannot possibly know of and advise the boating public of all conceivable boat motor types and or poor operating practices the final decision of whether to use a lanyard stop switch rests with you the own er driver We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine and boat in an emergency 281 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 loc
55. h The following advantages and disadvantages of a lanyard stop switch should be considered before elect ing to use or not to use such a switch ADVANTAGES The purpose of a lanyard stop switch is to stop the engine ignition whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch This would occur if the operator falls or moves within the boat a sufficient distance from the operator s position This type of accident is most likely in certain types of boats such as low sided boats and high performance boats It is also likely as a result of poor operating practices such as sitting on the back of the seat at planing speeds standing at planing speeds operating at high speeds in shallow or obstacle in fested waters releasing your grip on a steering wheel that is pulling in one direction drinking and driving or daring high speed boat maneuvers DISADVANTAGES Inadvertent activation of the switch is also a possibility This could cause any or all of the following potentially hazardous situations 1 Loss of balance and falling forward of unstable boat passengers a particular concern in bow rider type boats 2 Loss of power and directional control in heavy seas strong current or high winds 3 Loss of control when docking While activation of the lanyard stop switch will result in immediate power shut down a boat can continue to coast for some distance dependin
56. he following note NOTE The coolant temperature warning lamp is wired in a parallel circuit with the transmission temperature switch If lamp illuminates while engine is running and coolant temperature and coolant level are normal this may be an indication of excessive transmission temperature The cause should be determined and corrected 2 Panel Lights Audio Test Switch has three positions in the normal position all electrical circuits operate in a standard fashion as described above With switch toggled UP the instrumentation lights are all illuminated When the switch is toggled DOWN the audio warning buzzer will sound allowing the operator to perform a test of the audio warning buzzer 3 20 Fuse and Holder located in line on key switch RED PURPLE wire and protects the Instrumentation and wiring should an electrical overload occur If an overload occurs the fuse will burn out Check blown burned fuse if key is turned to RUN or START and nothing happens IMPORTANT Cause for overload must be determined and corrected before attempting to install new fuse or fuse failure will occur again After cause is corrected install new fuse and check systems to function 24 100 RED PPL 73546 71856 CE101 Electrical System Overload Protection If an electrical overload occurs a fuse will blow or a circuit breaker will trip open IMPORTANT The cause must be found and corrected be
57. his manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our MerCruiser products We sincerely hope your boating will be pleasant CONSUMER AFFAIRS DEPARTMENT 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 Inter national HAZARD Symbol may be used to alert the installer user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe them carefully These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these special in structions while performing the service plus common sense operation are major accident prevention measures WARNING Hazards or unsafe practices which could result in severe personal injury or death ACAUTION CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for proper operation and or mainte nance 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
58. ile starting aids such as Ether Propane or Gasoline in the engine air intake system Ex plosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage ACAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to re move any fuel vapors which may cause difficulty breathing or be an irritant IMPORTANT Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor If engine does not start wait 1 minute to allow the starter motor to cool then repeat starting procedure IMPORTANT After not having been operated for two months or longer it is necessary to pre lubricate the engine To do this hold the STOP switch toggle lever DOWN while you simultaneously turn the key switch to START position for 15 seconds This will rotate the starter motor and engine oil pump During this process the engine will not run because no fuel is injected Allow the starter motor to cool down for one minute and repeatthe above described process To avoid overheating the starter motor do notengage starter motor for more than 15 seconds each time 1 Pre lubricate engine and turbocharger if necessary Refer to above Important information NOTE There are remote cable kits available for use with the cold start lever See your authorized MerCruiser Dealer for these kits 2 Cold Start Lever
59. imum Rated Full Throttle RPM CE11 20 HOUR BREAK IN PERIOD IMPORTANT The first 20 hours of operation is the engine break in period Correct break in is essential to obtain minimum oil consumption and maximum engine performance During this break in period the following rules must be observed DO NOT operate engine below 1500 RPM for extended periods during the first 10 hours During this period shift into gear as soon as possible after starting engine and advance throttle so that RPM is above 1500 pro vided that conditions permit safe operation at this speed DO NOT operate at any one constant speed for extended periods DO NOT exceed 75 of full throttle during the first 10 hours except during engine Initial Break In Procedure During the next 10 hours occasional operation at full throttle 5 minutes at a time maximum is permissible AVOID full throttle acceleration from stopped position DO NOT operate at full throttle until engine reaches normal operating temperature OBSERVE INSTRUMENTS if an abnormal reading occurs stop engine immediately and determine cause FREQUENTLY CHECK crankcase oil and transmission fluid levels Add if necessary It is normal for oil con sumption to be somewhat high during the break in period AT END OF 20 HOUR break in period remove break in oil and replace oil filter Fill crankcase with correct grade and viscosity oil 16 170 20 Hour Checkup It is a conditio
60. ine ass ate n CER nsu 31 bd o eA CR hoa A Site NR bete Nise doe ol dd ps ne he 31 Op ratioMm Ghari d s an esaa a cuts S Rade ate ae ie I lave Ma Br Ree 32 General Maintenance Information enr ae Ges Eu Eae ren 33 Maintenance Aids eer a Ux Vu hd x X A E eie Peres eee A E ee 33 Maintenance Schedules 4 34 Checking Fluid Levels i penri eh re E RE AA gei o 37 Crankease OIL EU A PUE IMEEM 37 Engine COGAN ar dete icd a ute en aes Ge di ACG edges a Ies Feud Ipsae 37 Transmisor o oe dud e x s SC RIDE Mu 37 handing Fluids n Es Lp TS dto erts ditare aos S esa es c sedie c Maa 39 Grankcase Oil and Filter econ ere RC tea E Re a 39 Air Filter Cleaning Replacement 58588 qe Ben e bouis eli e DS ma 41 Drive Belts Inspection Tension Replacement 41 Cleaning Quicksilver Seawater 43 EUDACANOA oe eite gee ature Deets Seite eal eee oes 43 Shit Cablen E re PP er er 43 AI tier 43 Seawater Pump Impeller ar vote e
61. inue to repeatedly move plunger hand pump primer until an air free stream of fuel flows from injection pump bleed screw Tighten bleed screw CD286 DRAINING WATER SEPARATING FUEL FILTER 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 ap propriate air tight fire retardant container Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death 5 The filter A can be drained of water and small dirt particles by opening drain cock at bottom of filter Open by turning the drain B counterclockwise as viewed from the bottom of the filter Drain until fuel is clear in appear ance Close drain by turning clockwise Tighten securely Fill fuel filter as previously outlined NOTE To ensure complete draining in warm weather open the water bleed valve before starting daily operations In cold weather where there is a possibility that the condensed water will freeze drain the filter shortly after the end of daily operations 47 CD295 48 CD117 REPLACING WATER SEPARATING FUEL FILTER ACAUTION Any water entering the fuel injection system will disable the system Che
62. l Cooler e Turbocharger 6 Heat Exchanger Seawater Circuit f Exhaust Manifold 7 Transmission Fluid Cooler g Thermostat 8 Exhaust Pipe Water Jacket 9 Seawater Outlet Exhaust 71954 63 185 Engine Wiring Diagram Electrical See 3 BLK GRY RED PPL PPL See NOTE 1 See NOTE 1 a E WHTGRN e y Ex See NOTE 2 BLK BLACK BLU BLUE BRN BROWN 5 GRN GREEN ORN ORANGE PPL PURPLE RED RED as 1 Water Temperature Sender Audio TAN TAN Warning Switch ELE vue 2 Transmission Fluid Temperature Audio LT LIGHT Warning Switch DRK DARK 3 Transmission Neutral Safety Start Switch 4 Starter 5 Oil Pressure Switch Audio Warning 6 Oil Pressure Sender 7 Tachometer Magnetic Pickup 8 Audio Warning Delay Relay 9 Power Relay 10 Start Relay 11 Pre Glow Relay 12 60 Amp Circuit Breaker 13 60 Amp Circuit Breaker 14 Engine Ground Negative 15 Fuel Injection Pump TAN BLK 3 WHT GRN 5 BLU TAN 2 NOT USED BLK YEL 1 NOT USED NOT USED NOTE 1 Wires Not Used On MIE Engines 16 Glow Plugs NOTE 2 Spare Wire Not Used 17 Fuel Solenoid 74327 NOTE 3 GRAY wire may be connected to alternator AC terminal for tachometer signal If 18 Alternator connected in this manner the GRAY and BLACK wire terminal ends at the Magnetic Pickup 19 Battery
63. l filter using correct grade and viscosity oil Determine cause for dilution excessive idling faulty fuel pump etc Battery Will Not Come Up On Charge Possible Cause Remedy Excessive current draw from battery e Turn off non essential accessories Loose or dirty electrical connections or Check all associated electrical connections and wire damaged wiring especially battery cables Clean and tighten fault connections Repair or replace damaged wiring Alternator drive belt loose or in poor condition e Replace and or adjust Unacceptable battery condition e Test battery Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle Lubricate linkage fasteners Loose or missing shift and throttle linkage Check all linkages If any are loose or missing see fasteners Authorized MerCruiser Dealer immediately Obstruction in shift or throttle linkages Remove obstruction Shift or throttle cable kinked Straighten cable or have dealer replace cable if damaged beyond repair CD50 Diagrams CD131 Water Flow Diagram Ua SEAWATER COOLING CIRCUIT CLOSED COOLING CIRCUIT RAW WATER COOLANT 1 Seawater Inlet Thru Hull a Circulating Pump Closed Coolant 2 Seawater Strainer b Engine Block Upper Section of Liners 3 Seawater Pump c Water Manifold 4 Intercooler d Cylinder Heads 5 Engine Oi
64. lant 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 MerCruiser Dealer ACAUTION If the coolant should get extremely low and the engine very hot let the engine cool for approximately 15 minutes before adding coolant then with the engine running add coolant slowly Adding cold coolant to a hot engine may crack the cylinder head or crankcase Never use water alone 6 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 CE46 TRANSMISSION FLUID 7 Dipstick has neoprene seal twist and pull to remove Push handle down and seat fully to check fluid level Fluid must be between marks A and B on dipstick A MAXIMUM Fluid Level top line Fill to this level do not overfill B MINIMUM Fluid Level do not allow fluid level to drop below this line 37 218 CE214 0 Changing Fluids See MAINTENANCE CHART for lubricant change interval Lubricant should be changed before placing boat in storage Coolant in closed cooling system should be chang
65. located on the injection pump is used to aid in starting when the temperature is below 50 F 10 C This is done by moving lever in direction shown Lever should be reset as soon as engine starts and idles smoothly 3 If engine has not been run for a period of time and will not readily start with the standard starting procedure there is a hand pump primer lever located on the fuel pump Move lever on fuel pump up and down four or five strokes Attempt to start engine following normal procedure 4 Mechanical Engine Stop Lever located on the injection pump is used to manually shut off engine by cutting off the fuel supply It can be engaged by moving the lever in the direction shown 30 CD309 STARTING COLD ENGINE IMPORTANT Always check all fluid levels before starting engine Refer to Maintenance Chart 1 Turn on and run engine compartment bilge blower if so equipped for five minutes Or open engine hatch to air out bilge before attempting to start engine S 2 Pre lubricate engine if required Refer to Starting Shifting and Stopping as previously outlined 3 Set Cold Start Lever if temperature is below 50 F 10 Reset when engine idles smoothly 4 Turn key switch to the RUN position and observe preheat indicator lamp When cylinder temperature is great enough to sustain combustion the preheat lamp will cease to be lighted and the engine can be started NOTE Engine can be started when the preheat indi
66. lty electrical stop circuit Have Authorized MerCruiser Dealer service electric stop circuit Clogged fuel filters Replace filters Stale or contaminated fuel If contaminated drain tank Fill with fresh fuel Fuel line or tank vent line kinked or Replace kinked lines or blow out lines with clogged compressed air to remove obstruction Air in fuel injection system Purge fuel injection system Glow plugs or glow plug system inoperative Test and repair or replace components Engine Runs Rough Misses And Or Backfires Possible Cause Remedy Throttle not operating properly Check throttle linkages for binding or an obstruction Idle speed too low Check idle speed and adjust if necessary Clogged fuel or air filters Replace filters Stale or contaminated fuel If contaminated drain tank Fill with fresh fuel Kinked or clogged fuel line or fuel tank Replace kinked line or blow out line with com vent line pressed air to remove obstruction Air in fuel injection system Purge fuel injection system 79 Troubleshooting Poor Performance Possible Cause Remedy Throttle not fully open Inspect throttle cable and linkages for operation Damaged or improper propeller Replace Excessive bilge water Drain and check for cause of entry Boat overloaded or load improperly dis Reduce load or redistribute load more evenly tributed Boat bottom fouled or damaged Clean or repair as necessary Aneroid device improperly adjusted If Adj
67. manufacturer s instructions CD283 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 CE63 PRIMING FUEL SYSTEM Prime engine if it has not been run for a while or if engine will not start Move the hand pump primer plunger up and down several times as previously outlined Attempt to start engine CD284 FILLING FUEL FILTER NOTE Follow this procedure after installing new filter or if fuel has been drained from filter checking for water 3 Loosen bleed screw on fuel filter bracket As previously outlined move plunger on hand pump primer up and down repeatedly until an air free stream of fuel flows from bleed screw Filter is full when this occurs Tighten bleed screw CD285 FILLING BLEEDING FUEL SYSTEM NOTE Follow this procedure if fuel system was run dry or if part of fuel system was drained for a service function Fill fuel system up to the point that fuel filter is full following previous procedure Filling Fuel Filter then ensure that bleed screw on fuel filter bracket is closed 4 Loosen DO NOT REMOVE bleed screw on fuel injection pump located between fuel line connection fittings on injection pump Cont
68. me caution any time you are boating in an area where there might be people in the water Whenever a boat is moving coasting and the drive unit is in neutral position there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury While Boat Is Stationary Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near your boat Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gear case or any solid device rigidly attached to a moving boat or gear case CA283 High Speed And High Performance Boat Operation If your boat is considered a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat For additional information obtain a copy of our Hi Performance Boat Operation booklet Part Number 90 86168 3 from your dealer distributor or Mercury Marine CD3 Conditions Affecting Operation CD4 Weight Distribution Positioning of weight passengers and gear inside the boat has the following effects Shifting weight to rear stern
69. ment If any drive belts need replacement or tension needs adjustment see your Authorized MerCruiser Dealer Make sure engine is shut off and ignition key is removed before inspecting belts 2 All drive belts must be periodically inspected for tension and condition excessive wear or damage NOTE D4 2L 220 engine shown D3 6L 180 similar Perform an inspection of the following belt A Alternator Belt Water Circulating Pump Belt 3 Check belt tension by depressing upper strand of belt s at point shown Approximately 3 16 inch 5 mm deflec tion should be measured at midpoint between the pulleys on the longest span ALTERNATOR BELT ACAUTION When replacing alternator belt close seacock if so equipped If boat is not equipped with a seacock re move and plug seawater inlet hose to prevent a siphoning action that may occur allowing seawater to flow from drain holes or removed hoses 4 Close seacock if so equipped or plug seawater inlet hose Remove seawater hoses at seawater pump 5 Loosen mounting bolt A Loosen nut and tensioning bolt B Move alternator Remove old belt and install new belt Adjust belt tension refer to item 3 When tension is correct retighten all fasteners securely Reconnect sea water hoses to seawater pump Tighten hose clamps securely Open seacock ifso equipped or remove plug from seawater inlet hose and reconnect hose Tighten hose clamps securely 4 162 PAGO AV O
70. motors and or armatures or field coil assembly which are burned or where lead is thrown out of commu tator 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 71 CD62 Transferable Warranty The product warranty is transferable to a subsequent purchaser but only for the remainder of the unused portion of the limited warranty This will not apply to products used for commercial applications DIRECT SALE BY OWNER 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 Mercury Marine W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54
71. n for the continuation of warranty that the product be taken to an authorized MerCruiser service deal er after 20 hours of operation but no later than 50 hours for the following services checks and adjustments Note Some items may not apply to your specific power package In these instances check the Not Applicable box provided A copy of the dealer service work order must be kept by product owner as evidence of the comple tion of this requirement Service check or adjust as indicated BEFORE RUNNING ENGINE COLD CHECK OR ADJUST Not Applicable Completed Torque turbocharger fasteners 31 Ib ft 42 N m and exhaust manifold fasteners 24 Ib ft 32 N m V 8 Diesel models only Tighten cooling and exhaust system hose clamps Throttle shift and steering system fasteners tight and or properly secured Drive mounting fasteners are tight Check that both front engine mount locknuts are tightened securely Then check to ensure that tab washers are bent down over adjusting nuts Check that rear engine mounts are torqued to 35 40 Ib ft 47 54 N m stern drive models only Drain fuel filter and check for water Check condition and tension of all drive belts Check closed cooling system coolant level Retorque gimbal ring clamping bolt to 50 55 Ib ft 67 74 N m stern drive models only Power steering system fluid stern drive models only Drive unit lubricant level stern drive models onl
72. nd 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 center or the factory to attempt for them to diagnose a problem or request the repair procedure It is difficult for them to diagnose a problem over the telephone A doctor can t and won t diagnose your illness by telephone he must examine you personally just as a mechanic must examine your power package Your Authorized Dealer is there to service your power package He has qualified factory trained mechanics It is recommended you have the dealer do periodic maintenance checks on your power package Have him winter ize 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 212 Engine Break In INITIAL BREAK IN PROCEDURE It is especially important that the following procedure b
73. ormation manuals or operation and maintenance manual 3 Use of an accessory or part not manufactured or sold by us 4 Operation with fuels oils lubricants or coolants coolant additives which are not suitable for use with the Product or recommended by us 5 Participating in or preparing for racing or other competitive activity or operating with racing type lower unit 6 Alteration or removal of parts 7 Water entering engine cylinder s through the exhaust system or air intake system 8 Use of product in a full displacement or semi displacement hull vessel or 9 Use or operation of the product in a manner inconsistent with the Recommended Operation Duty Cycle section of the Operation and Maintenance Manual CD213 Mercruiser Diesel Limited Warranty continued VII VIII XI Reasonable access must be provided to the Product for warranty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other consequential damages or 2 Removal and or replacement of boat partitions or material because of boat design for necessary access to the Product Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer autho rized to service the Product If purchaser cannot deliver Product to such authorized dealer he may give notice in writing to the Company U S A and Canada or the near
74. ould block the operators view when operating the boat above idle or planing transition speed Watch the other guy the water and your wake Never drive your boat directly behind a water skier in case the skier falls As an example your boat travel ing 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 Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal injury requiring medical treatment beyond first aid 3 there is damage to boats or other property where the damage value exceeds 500 00 or 4 there is complete loss of the boat Seek further assistance from local law enforcement CA282 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his her direction even at slow speed Always slow down and exercise extre
75. r Spray power package components on inside of boat every 2 3 weeks with Quicksilver Corrosion Guard to pro tect finish from dulling and corrosion External power package components may also be sprayed All lubrication points especially steering system shift and throttle linkages should be kept well lubricated Flush seawater cooling circuit periodically preferably after each use 215 CD44 Cold Weather Or Extended Storage CD280 Power Package Layup IMPORTANT MerCruiser strongly recommends that this service should be performed by an Authorized MerCruiser Dealer Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty ACAUTION The engine must be prepared for long storage periods to prevent internal corrosion and severe damage 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 procedures stated in FLUSHING COOLING SYSTEM ACAUTION DO NOT operate engine without water flowing thru seawater pickup pump as pump impeller may be dam aged and subsequent overheating damage to engine or drive unit may result 1 Start engine and run until it reaches normal operating temperature Stop engine Change oil and filter Start en gine and run for about 15 minutes Check for oil leaks Do not remove coolant cap when engine is hot coolant ma
76. rical circuits indicator lamps automatic preheating and all instrumentation is operational In the START position the engine can be started Also if engine is running the key switch cannot be used to stop engine The engine can only be stopped by using the Engine Stop Switch 8 Engine Stop Switch is used to stop the engine This is done by electrically shutting off the fuel delivery system Stop switch is toggled DOWN and held until engine stops completely NOTE Key can only be removed in the OFF position 23 CD139 CE99 1 Engine System Monitor Features The appropriate light functions as follows A Preheat Indicator Lamp lights up when the glow plugs are preheating the combustion chambers The light stays on until the preheat period is complete The timed preheat period begins when the key switch is turned on and then only when the engine is cold THE ENGINE CAN BE STARTED ONLY AFTER THE LIGHT GOES OUT B Charge Indicator Lamp indicates a problem with charging system if lamp illuminates while engine is running Lamp will light when key switch is ON and engine is not running When engine starts light should go off C Oil Pressure Warning Lamp indicates low engine oil pressure if lamp illuminates while engine is running D Coolant Temperature Warning Lamp indicates excessive engine coolant temperature if lamp illuminates while engine is running or transmission fluid temperature is too high See t
77. rom 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 is spilled or splashed on any part of the body immediately flush the ex posed area with liberal amounts of water and obtain medical aid as soon as possible CA104 Bottom Of Boat 2 To maintain maximum speed the following conditions regarding the boat bottom should be observed Clean free of barnacles and marine growth Free of distortion nearly flat where it contacts water Straight and smooth fore and aft CC72 Antifouling Paints 3 Antifouling Paint In some areas it may be advisable to paint bottom of boat to help prevent marine growth See your dealer for recommendations for your boat CE70 Inspection And Maintenance 4 Inspect and or maintain the following e Inspect power package often and at regular intervals to help maintain its top operating performance and cor rect potential problems before they occur The entire power package should be checked carefully including all accessible engine parts Check for loose damaged or missing parts hoses and clamps tighten or replace as required Remove and inspect propeller If badly nicked bent or cracked see your dealer Repair nicks and corrosion damage on power package exterior finish Use Quicksilver spray paints see your Authorized MerCruiser Deale
78. s a significant loss in performance will result Engine RPM Governor Limit MIE Model Engine Recommended Operating RPM Range Governor RPM Setting Begins At D3 6L 180 3600 3800 3830 D4 2L 220 3400 3600 3630 Select a propeller that will allow the engine power package to operate at or near the top of the recommended wide open throttle operating RPM range with a normal load Generally there is a 100 150 RPM difference between 1 inch changes in propeller diameter or pitch If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating RPM range will cause higher than normal wear and or damage After initial propeller selection the following common problems may require that the propeller be changed to a low er 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 e Operating with increased load additional passengers pulling skiers etc For better acceleration such as is needed for water skiing use the next lower pitch propeller However do not operate at full throttle when using the lower pitch propeller but not pulling skiers 12 How Elevation and Climate Affect Performance Elevation has a very noticeable effect on th
79. silver Instruments and Instrumentation Shown is the basic Quicksilver instrumentation and engine system monitor display for the Diesel Power Package The instrumentation shown is required for safe operation of boat and engine Operator should become familiar with all instrumentation before operating the engines Gauges and engine system monitor panel may be individually mounted or collectively mounted in the optional single panel available from Quicksilver NOTE Refer to manufacturer s instructions and explanations about instrumentation if equipped with other than Quicksilver instrumentation 1 Oil Pressure Gauge indicates engine oil pressure Refer to Specifications for normal operating readings 2 Tachometer indicates engine speed RPM 3 Coolant Temperature Gauge indicates engine coolant temperature Refer to Specifications for normal oper ating readings 4 Cruise Log Engine Hour Meter records engine running time 5 Voltmeter indicates battery voltage and if alternator and charging circuit are functioning properly The green area on the gauge is the normal operating range 6 Audio Warning Buzzer Standard Features Buzzer sounds if 1 Cooling system temperature too high 2 Oil pressure is too low 3 Transmission fluid temperature is excessive 7 Key Switch has three positions in the OFF position all electrical circuits are off and engine cannot be started In the RUN position all elect
80. tho rized Dealer Additional service work requested by customer other than that necessary to satisfy the warranty obligation Labor performed by otherthan 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 per formed at this facility All incidental and or consequential damages storage charges telephone or rental charges of any type incon venience or loss of time or income are the owner s responsibility Use of other than Quicksilver replacement parts when making warranty repairs Oils lubricants or fluids changed as a matter of normal maintenance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration Participating in or preparing for racing or other competitive activity Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard Water entering the engine via the air filter or exhaust system or submersion Also water in the starter motor Starter
81. tight 2 Install seawater pump impeller as follows NOTE D4 2L 220 engine and pump shown D3 6L 180 similar Pump shown removed for visual clarity only IMPORTANT Use new gasket Install in correct position wide surface D on side of cam Place impeller in pump and press onto pump shaft firmly Install pump cover B with gasket C and tighten screws securely Replace fuel filter Bleed fuel system see MAINTENANCE FUEL SYSTEM A CAUTION When installing battery be sure to connect POSITIVE battery cable to POSITIVE battery terminal FIRST and NEGATIVE battery cable to NEGATIVE battery terminal LAST It battery cables are re versed or connection order is reversed electrical system damage will result 5 Install fully charged battery Clean battery cable clamps and terminals and reconnect cables see CAUTION listed above Secure each cable clamp when connecting Coat terminals with a battery terminal anti corrosion spray to help retard corrosion 6 Perform all checks on OPERATION CHART in the STARTING PROCEDURE column IMPORTANT After not having been operated for two months or longer it is necessary to pre lubricate the engine To do this hold the STOP switch toggle lever DOWN while you simultaneously turn the key switch to START position for 15 seconds This will rotate the starter motor and engine oil pump During this process the engine will not run because no f
82. uel 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 the above Important Information Start engine and closely ob serve instrumentation to make sure that all systems are functioning correctly 8 Carefully inspect engine for fuel oil fluid water and exhaust leaks 9 Check steering system shift and throttle control for proper operation 59 79 60 Troubleshooting Starter Motor Will Not Crank Engine Or Cranks It Very Slowly Possible Cause Remedy Battery switch turned off Turn switch on Remote control not in neutral position e Position control lever in neutral Open circuit breaker or blown fuse Check and reset circuit breaker or replace fuse Loose or dirty electrical connections or dam Check all electrical connections and wires especially aged wiring battery cables Clean and tighten faulty connection Bad battery Test and replace if bad Engine Will Not Start Or Is Hard To Start Possible Cause Remedy Improper starting procedure Read starting procedure Empty fuel tank or fuel shutoff valve closed Fill tank or open valve Faulty fuel pump Have pump replaced by an Authorized Mer Cruiser Dealer if fuel is present Throttle not operating properly Check throttle for freedom of movement Fau
83. ur Authorized MerCruiser Dealer for service aids ACAUTION The injection pump lever Wide Open Throttle W O T Stop Screw adjusts the engine speed governor and is factory set and sealed Readjusting the governed speed and operating above the specified RPM will cause extensive engine damage and or failure Removal of the seal and or readjustment of the governed speed is considered misuse of engine and resulting damages will not be covered by the limited warranty CA14 DEALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include predelivery inspection and preparation such as e Make sure that the boat is properly equipped Prior to delivery make certain that the MerCruiser power package and other equipment are in proper operating condition Make all necessary adjustments for maximum efficiency Familiarize the customer with the on board equipment e Explain and demonstrate the operation of the power package and boat At the time of delivery the dealer should provide you with 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 CD281 Freezing Temperature And Cold Weather Operation IMPORTANT If boatis operated during periods of freezing temperature precautions must be taken to pre vent freezing damage to power pack
84. ur engine best Quicksilver parts and accessories are engineered and built specifically for MerCruiser stern drives and inboards Service Away from Home If you are away from your local dealer and the need arises for service contact the nearest Authorized Dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot obtain service contact the nearest Regional Service Center Outside the United States and Canada contact the nearest Marine Power International Service Center Parts and Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accessories should be directed to your local Authorized Dealer The dealer has all 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 Resolving a Problem Your satisfaction and goodwill are of primary importance to your dealer and to Mercury Marine Any problems with service sales warranty or operation of your MerCruiser power package will be resolved by your dealer He also is your primary source of information on your boat power package and trailer Should there be a misunderstanding or if your problem has not been
85. ust aneroid device so equipped Possible Cause Remedy Seacock closed if so equipped Open e Drive belt loose or in poor condition Replace and or adjust belt Seawater pickups obstructed Remove obstruction e Faulty thermostat Replace Coolant level low in closed cooling Check for cause of low coolant level and repair section Fill system with proper coolant solution Heat exchanger cores plugged with Clean seawater side of water water foreign material heat exchanger and seawater strainer e Loss of pressure in closed cooling Check for leaks Clean inspect and test pres section sure Cap Closed cooling section dirty Clean and flush Faulty seawater pickup pump Repair Seawater discharge restricted or plugged Clean exhaust elbow Seawater inlet hose kinked restricted Position hose to prevent kinking restriction Use of improperly designed hose on inlet side Replace hose with wire reinforced design of seawater pump allowing it to collapse Insufficient Engine Temperature Possible Cause e Faulty thermostat e Replace 61 79 62 Troubleshooting Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase e Check and add oil Excessive oil in crankcase causing it to Check and remove required amount of oil become aerated Check for cause of excessive oil improper filling bad fuel pump etc Diluted or improper viscosity oil Change oil and oi
86. very 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 e Prepare other boat operators Instruct at least one person on board in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate When in doubt contact your dealer or the boats manufacturer Know your boat s oper ating 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 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 Bealert 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 sh
87. water section of cooling system has been drained completely coat threads of intercooler drain plug with Perfect Seal and reinstall Tighten securely Reconnect hoses Tighten hose clamps securely Install all four end covers two As and two 5 on the heat exchanger tank Renew end cover gaskets if worn or deteriorated Torque the end covers on the upper heat exchanger section to 16 Ib ft 22 N m Torque the end covers on the lower heat exchanger section to 96 Ib 11 N m 55 115 CD127 Power Package Layup Continued Dealer should perform the remaining tasks prior to layup 1 After draining perform all checks inspections lubrication and fluid changes outlined in MAINTENANCE CHART 2 Clean seawater strainer refer to MAINTENANCE SECTION IMPORTANT MerCruiser recommends that propylene glycol antifreeze nontoxic and biodegradable which makes it friendly to lakes and rivers be used in seawater section of the cooling system for cold weather or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s rec ommendations Also check local laws about disposal of the antifreeze solution after use 3 Fill a container with approximately 6 U S quarts 5 6L of antifreeze and tap water mixed to manufacturer s recommendation to protect engine to the lowest temperature to which
88. will Generally increases speed and engine RPM At extremes can cause boat to porpoise Causes bow to bounce in choppy water Increases danger of following wave splashing into boat when coming off plane Shifting weight to front bow will Improves ease of planing on some boats Improves rough water ride At extremes can cause boat to veer back and forth bow steer CA8 Bottom Of Boat To maintain maximum speed the following conditions of the boat bottom should be observed A B C Clean free of barnacles and marine growth Free of distortion nearly flat where it contacts the water Straight and smooth fore and aft Marine vegetation may accumulate when boat is docked This growth must be removed before operation it may clog water inlets and cause engine to over heat 209 Propeller Selection IMPORTANT Installed propeller must allow engine to run at its specified maximum wide open throttle revolutions per minute RPM Use an accurate service tachometer to verify engine operating RPM Itis the responsibility of the boat manufacturer and or the selling dealer to equip the power package with the correct propeller s Specified engine wide open throttle WOT and operating RPM range are listed in SPECIFI CATIONS IMPORTANT The engines covered in this manual are equipped with a governor that limits engine RPM Be sure that propeller being used does not allow engine to run against the governor a
89. y Transmission fluid level inboard models only Power trim pump oil level stern drive models only ON WATER TESTING ENGINE RUNNING OPERATING TEMPERATURE CHECK OR ADJUST Adjust idle RPM in forward gear4 All gauges and indicator lamps proper readings 6 Fuel oil water coolant and exhaust leaks Remote control operation forward neutral and reverse Steering operation throughout range Power trim operation stern drive models only Maximum RPM in forward gear change propeller if necessary AFTER WATER TESTING SERVICE Change crankcase oil and filter Refer to Specifications Engine Chart in this manual Use only factory approved coolant and fluids Specifications Seacock water inlet valve used must have an internal cross sectional area equal to or greater than hose to pre vent restricting water flow A 1 1 2 in 88mm brass ball or gate valve is minimum required Seacock should be installed in an area where it is easily accessible and supported adequately to prevent hose fatigue CE14 Seawater Strainer Seawater Strainer should be provided and be of sufficient size to ensure that an adequate supply of water will be maintained for cooling engine A minimum flow rate of 40 gallons 150 litres p
90. y discharge violently 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 2 Do not open either of these two petcocks They are in the closed cooling circuit NOTE Refer to the following pages for continuation of specific draining instructions 53 216 164 Power Package Layup Continued Drain seawater section of cooling system and prepare for cold weather or extended storage following these proce dures DRAINING INSTRUCTIONS ACAUTION 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 notfitted with 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 warning 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 A wire should be repeatedly inserted into all drain holes to ensure there are no obstructions in pas sages 1 Close
91. y owned yachts or recreational power boats in non revenue applications Light duty rating applies to planing boats where the use of full rated power at maximum rated RPM is limited as stated above Examples of Light Duty applications include but are not limited to search and rescue craft fast patrol boats fire boats dive boats and limited season fishing boats such as sport fish charter boats Application to common commercial crafts having full displacement or semi displacement hulls exceeds the recommended operational capability or duty cycle IMPORTANT Damage caused by improper application or failure to operate within the operational capability or duty cycle will not be covered by the MerCruiser Diesel Limited Warranty CE7 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 MerCruiser Dealer for a periodic checkup Normal maintenance service and replacement parts are the responsibility of the owner operator and as such are not considered defects in workmanship or material within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your power package will assure optimum performance and dependability and will keep your overall operating expenses at a minimum See yo

D3.6L/180 and D4.2L/220 Inboard Models

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