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2003, Mercury Marine
1
Identification Record
2
WELCOME!
3
Read This Manual Thoroughly
4
SECTION 1 - WARRANTY
5
SECTION 4 - SPECIFICATIONS
6
SECTION 5 - MAINTENANCE
7
Warranty Information
10
WARRANTY
11
SECTION 1SECTION 1
11
Warranty Policies
12
WHAT IS NOT COVERED
13
DISCLAIMERS AND LIMITATIONS
13
WHAT IS COVERED
14
WHAT MERCURY WILL DO
14
WARRANTY SECTION 1
16
00000 was CD622
16
Transferable Warranty
18
Features And Controls
20
SECTION 2
21
Instrumentation
22
SWITCHES
23
ENGINE MONITORING FEATURES
24
Remote Controls
25
CONSOLE MOUNTED
26
Power Trim
28
SINGLE ENGINE TRIM/TRAILER
29
DUAL ENGINE TRIM/TRAILER
29
Audio Warning System
32
Emissions Information
33
SECTION 3 - ON THE WATER
35
Safe Boating Suggestions
36
ON THE WATER
37
SECTION 3
37
GOOD VENTILATION
39
POOR VENTILATION
39
Basic Boat Operation
40
Duty Cycle Rating
41
LIGHT DUTY RATING
42
GENERAL INFORMATION
44
BEFORE STARTING THE ENGINE
45
STARTING A COLD ENGINE
46
ENGINE WARM UP
47
STARTING A WARM ENGINE
47
SHIFTING
48
ENGINE SHUT-DOWN (STOPPING)
48
Trailering The Boat
53
Drain Plug and Bilge Pump
53
While You Are Cruising
54
While Boat Is Stationary
54
Wave And Wake Jumping
56
0035.1 with CMD change
57
Drive Unit Impact Protection
58
Bottom Of Boat
59
Cavitation
59
Ventilation
60
Elevation And Climate
60
Propeller Selection
61
Getting Started
62
20-Hour Break-In Period
63
After Break-In Period
64
End of First Season Checkup
64
Fuel Requirements
66
Diesel Fuel In Cold Weather
67
Anti-Freeze/Coolant
67
Engine Oil
68
Engine Specifications
69
D4.2L LD And D4.2L 230
70
D4.2L 300
72
Fluid Specifications
73
SPECIFICATIONS
74
SECTION 4
74
Dealer Responsibilities
76
Maintenance
77
0057 W CMD changes
78
Inspection
79
Maintenance Schedules
80
Routine Maintenance *
80
Scheduled Maintenance *
81
Maintenance Record
83
Changing Oil and Filter
86
00000 was CD919
88
Power Steering Pump Fluid
89
Checking
90
Changing
92
Drive Unit Oil
93
Power Trim Pump Fluid
97
SITUATION
99
RECOMMENDATIONS
99
Air Filter
100
Water Separating Fuel Filter
101
Replacing
102
MAINTENANCE
103
SECTION 5
103
Fuel System
106
Lubrication
108
Throttle Cable
110
Shift Cable
111
Engine Coupler
112
Removed)
113
Drive Shaft Extension Models
114
Propellers
115
Bravo Three
117
INSTALLATION
118
Drive Belts - All Engines
119
Power Steering Pump Belt
120
Corrosion Protection
121
Internal Components
125
INSPECTION
126
Painting Your Power Package
128
CE376 modified
129
Flushing The Seawater System
130
Dual Water Pick-Up Flush Gear
131
Case Seal Kit
131
91-881150Q1
131
Flushing Device 91-44357Q2
131
SECTION 6 - STORAGE
133
SECTION 6
134
0084 w / CMD
134
Draining Instructions
135
00000 was CD927 w / changes
140
Recommissioning
142
SECTION 7 - TROUBLESHOOTING
145
Diagnosing EDI Problems
146
Troubleshooting Charts
146
TROUBLESHOOTING
147
SECTION 7
147
Poor Performance
148
Excessive Engine Temperature
149
Low Engine Oil Pressure
150
Battery Will Not Charge
150
Unusual Sounds
150
0175 w / changes – CMD
151
0177 with CMD changes
151
Table of Contents
153
Owner Service Assistance
154
Replacement Service Parts
155
Resolving A Problem
156
Customer Service Literature
157
SECTION 8
158
Ordering Literature
159
00000 was CD851
160
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