Mercury 2.8 EI 200 User manual

2004, Mercury Marine2.8 EI 200 Diesel Inboard Models CMDĆ4081877 / 90Ć865861040 304

0001.
Identification Record
The serial numbers are the manufacturer’s keys to numerous engineering details which apply
to your Cummins MerCruiser Dieselpower package. When contacting Cummins
MerCruiser Diesel (CMD) about service, always specify model and serial numbers.
2
1
7
1
1
79994
Please record the following information:
1.
Engine Model and Horsepower Engine Serial Number
2.
Transom Assembly Serial Number
(Sterndrive)
Gear
Ratio
Sterndrive Unit Serial
Number
3.
Transmission Model (Inboard) Gear
Ratio
Transmission Serial
Number
4.
Propeller Number Pitch Diameter
5.
Hull Identification Number (HIN) Purchase Date
6.
Boat Manufacturer Boat
Model
Length
7.
Exhaust Gas Emissions Certificate Number (Europe Only)
The description and specifications contained herein were in effect at the time this guide was approved
for printing. Cummins MerCruiser Diesel, 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.
2004, Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury
Precision Parts, Mercury Propellers, Marathon, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,
Pro Max, OptiMax, Sport–Jet, Cleaver, K–Planes, MerCathode, Quickleen, RideGuide, SmartCraft,
Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered
trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark
of Brunswick Corporation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.

0002.1 and CE459
WELCOME!
You have selected one of the finest marine power packages available. It incorporates
numerous design features to assure operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using this product for many
boating seasons. To ensure maximum performance and carefree use, we ask that you
thoroughly read this manual.
The Operation, Maintenance, and Warranty Manual contains specific instructions for using
and maintaining your product. We suggest that this manual remain with the product for ready
reference whenever you are on the water.
Thank you for purchasing one of our Cummins MerCruiser Diesel products. We sincerely
hope your boating will be pleasant!
Cummins MerCruiser Diesel
0003 with CMD
Warranty Message
The product you have purchased comes with a limited warranty from Cummins MerCruiser
Diesel; the terms of the warranty are set forth in the Warranty Sections of this manual. The
warranty statement contains a description of what is covered, what is not covered, the
duration of coverage, how to best obtain warranty coverage, important disclaimers and
limitations of damages and other related information. Please review this important
information.

0004
Read This Manual Thoroughly
IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A
DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES.
NOTICE
Throughout this publication, and on your power package, WARNINGS and CAUTIONS,
accompanied by the International Hazard Symbol !, may be used to alert the installer/user
to special instructions concerning a particular service or operation that may be hazardous if
performed incorrectly or carelessly. Observe them carefully.
These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance
with these special instructions while performing the service, plus common sense operation,
are major accident prevention measures.
WARNING
WARNING - Hazards or unsafe practices which could result in severe personal injury
or death.
CAUTION
CAUTION - Hazards or unsafe practices which could result in minor personal injury
or product or property damage.
IMPORTANT: - Indicates information or instructions that are necessary for proper
operation and/or maintenance.
0197 modified or CE461
WARNING
The operator (driver) is responsible for the correct and safe operation of the boat, the
equipment aboard and the safety of all occupants aboard. We strongly recommend
that the operator read this Operation, Maintenance and Warranty Manual and
thoroughly understand the operational instructions for the power package and all
related accessories before the boat is used.
We strongly recommend that other occupants be instructed on proper starting and
operation procedures so they will be prepared should they be required to operate the
power package and boat in an emergency.
WARNING
California Proposition 65 Warning
The engine exhaust from this product contains chemicals known to the state of
California to cause cancer, birth defects or other reproductive harm.
WARNING
Electrical system components on this engine are not external ignition protected. DO
NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES,
UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM
ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could result in fire, explo-
sion and/or severe personal injury.

CMD-4081877 / 90-865861040 MARCH 2004 Page i
SECTION 1 - WARRANTY
Warranty Information 2. . . . . . . . . . . . . . . . . . . .
Owner Warranty Registration 2. . . . . . . . . . . .
United States And Canada Only 2. . . . . .
International Owner Registration 3. . . . . . . . .
Outside The United States And
Canada 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Policies 4. . . . . . . . . . . . . . . . . . . . . . .
Recreational Use Diesel Limited
Warranty 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What Is Covered 4. . . . . . . . . . . . . . . . . . . .
Duration Of Coverage 4. . . . . . . . . . . . . . .
Conditions That Must Be Met In Order
To Obtain Warranty Coverage 4. . . . . . . .
What Cummins Mercruiser Diesel Will
Do 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How To Obtain Warranty Coverage 5. . . .
What Is Not Covered 5. . . . . . . . . . . . . . . .
Disclaimers And Limitations 5. . . . . . . . . .
Warranty Coverage and Exclusion 6. . . . . . .
Warranty Does Not Apply To The
Following: 6. . . . . . . . . . . . . . . . . . . . . . . . .
Transferable Warranty 8. . . . . . . . . . . . . . . . . . .
Direct Sale By Owner 8. . . . . . . . . . . . . . . . . .
SECTION 2 - GETTING TO KNOW YOUR POWER
PACKAGE
Features And Controls 10. . . . . . . . . . . . . . . . .
Lanyard Stop Switch 10. . . . . . . . . . . . . . . . . .
Instrumentation 12. . . . . . . . . . . . . . . . . . . . . . .
Remote Controls 15. . . . . . . . . . . . . . . . . . . . .
Panel Mounted 15. . . . . . . . . . . . . . . . . . . .
Console Mounted 16. . . . . . . . . . . . . . . . . .
Electrical System Overload Protection 17. . .
Audio Warning System 18. . . . . . . . . . . . . . . .
Testing The Audio Warning System 18. . .
Emissions Information 19. . . . . . . . . . . . . . . . .
Exhaust Gas Emissions Certificate
(Europe Only) 19. . . . . . . . . . . . . . . . . . . . . . .
Owner Responsibility 19. . . . . . . . . . . . . . . . . .

Page ii CMD-4081877 / 90-865861040 MARCH 2004
SECTION 3 - ON THE WATER
Safe Boating Suggestions 22. . . . . . . . . . . . . .
Be Alert To Carbon Monoxide
Poisoning 24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Good Ventilation 25. . . . . . . . . . . . . . . . . . .
Poor Ventilation 25. . . . . . . . . . . . . . . . . . . .
Basic Boat Operation 26. . . . . . . . . . . . . . . . . . .
Launching And Boat Operation Care 26. . . .
Duty Cycle Rating 27. . . . . . . . . . . . . . . . . . . .
Pleasure Duty Rating 27. . . . . . . . . . . . . . .
Operation Chart - 2.8 EI 200 28. . . . . . . . . . .
Starting, Shifting and Stopping -
2.8 EI 200 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Starting The Engine 29. . . . . . . . . .
Starting A Cold Engine 30. . . . . . . . . . . . . .
Engine Warm Up 30. . . . . . . . . . . . . . . . . . .
Engine Shut-Down (Stopping) 31. . . . . . .
Freezing Temperature And Cold
Weather Operation 32. . . . . . . . . . . . . . . . . . .
Drain Plug and Bilge Pump 32. . . . . . . . . . . .
Protecting People In The Water 33. . . . . . . . .
While You Are Cruising 33. . . . . . . . . . . . . . . .
While Boat Is Stationary 33. . . . . . . . . . . . . . .
High-Speed And High-Performance
Boat Operation 33. . . . . . . . . . . . . . . . . . . . . . . .
Passenger Safety Message - Pontoon
And Deck Boats 34. . . . . . . . . . . . . . . . . . . . . . .
Wave And Wake Jumping 35. . . . . . . . . . . . . . .
Impact With Underwater Hazards 36. . . . . . . .
Conditions Affecting Operation 37. . . . . . . . .
Weight Distribution (Passengers And
Gear) Inside The Boat 37. . . . . . . . . . . . . . . .
Bottom Of Boat 37. . . . . . . . . . . . . . . . . . . . . . .
Elevation And Climate 37. . . . . . . . . . . . . . . . .
Propeller Selection 38. . . . . . . . . . . . . . . . . . . .
Getting Started 39. . . . . . . . . . . . . . . . . . . . . . . . .
Initial Break-In Procedure 39. . . . . . . . . . . . . .
20-Hour Break-In Period 39. . . . . . . . . . . . . . .
After Break-In Period 40. . . . . . . . . . . . . . . . . .
End of First Season Checkup 40. . . . . . . . . .
SECTION 4 - SPECIFICATIONS
Fuel Requirements 42. . . . . . . . . . . . . . . . . . . . .
Diesel Fuel In Cold Weather 43. . . . . . . . . . . . .
AntiFreeze/Coolant 43. . . . . . . . . . . . . . . . . . . . .
Engine Oil 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 46. . . . . . . . . . . . . . . . . .
2.8 EI 200 46. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Specifications 47. . . . . . . . . . . . . . . . . . . .

CMD-4081877 / 90-865861040 MARCH 2004 Page iii
SECTION 5 - MAINTENANCE
Owner/Operator Responsibilities 50. . . .
Dealer Responsibilities 50. . . . . . . . . . . . . . . . .
Maintenance 51. . . . . . . . . . . . . . . . . . . . . . . . . . .
Do-It-Yourself Maintenance
Suggestions 52. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 52. . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedules 53. . . . . . . . . . . . . . .
Routine Maintenance 53. . . . . . . . . . . . . . . . . .
Scheduled Maintenance 54. . . . . . . . . . . . . . .
Maintenance Record 55. . . . . . . . . . . . . . . . . .
Engine Oil 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking 57. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Oil and Filter 59. . . . . . . . . . . . . . . .
2.8 ES 200 59. . . . . . . . . . . . . . . . . . . . . . . .
Transmission Fluid 61. . . . . . . . . . . . . . . . . . . . .
Checking 61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing 63. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant 65. . . . . . . . . . . . . . . . . . . . . . . .
Checking 65. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing 67. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement 68. . . . . . . . . . . . . . . . . . . . . . . . .
Water Separating Fuel Filter 69. . . . . . . . . . . .
Draining 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing 71. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 74. . . . . . . . . . . . . . . . . . . . . . .
Priming 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling (Bleeding) 74. . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Cleaning And Flushing 74. . . . . . .
Lubrication 75. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable 75. . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable 75. . . . . . . . . . . . . . . . . . . . . . . .
Drive Belts 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Serpentine Belt 76. . . . . . . . . . . . . .
Corrosion Protection 78. . . . . . . . . . . . . . . . . . .
Antifouling Paints 78. . . . . . . . . . . . . . . . . . . . .
Internal Components 78. . . . . . . . . . . . . . . . . .
Removal 78. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 79. . . . . . . . . . . . . . . . . . . . . . . . .
Repair 79. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 80. . . . . . . . . . . . . . . . . . . . . . . .
Seawater System 80. . . . . . . . . . . . . . . . . . . . . . .
Draining The Seawater System 80. . . . . . . . .
Cleaning The Seawater Strainer, If
Equipped 83. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing The Seawater System 84. . . . . . . . .
Checking The Water Pickups 86. . . . . . . . . . .
Though The Hull Or Through The
Transom Pickups 86. . . . . . . . . . . . . . . . . .
Battery 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiple Electronic Control Engine
Battery Precautions 87. . . . . . . . . . . . . . . . . .
Situation 87. . . . . . . . . . . . . . . . . . . . . . . . . .
Recommendations 87. . . . . . . . . . . . . . . . .

Page iv CMD-4081877 / 90-865861040 MARCH 2004
SECTION 6 - STORAGE AND RECOMMISSIONING
Cold Weather (Freezing Temperature),
Seasonal, And Extended Storage 90. . . . . . .
Cold Weather (Freezing Temperature)
Storage 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing Your Power Package For
Seasonal or Extended Storage 91. . . . . . . . .
Seasonal Storage Instructions 92. . . . . . . . . .
Extended Storage Instructions 93. . . . . . . . . .
Recommissioning 94. . . . . . . . . . . . . . . . . . . . . .
SECTION 7 - TROUBLESHOOTING
Diagnosing Electronically Controlled Fuel
System Problems 98. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Charts 98. . . . . . . . . . . . . . . .
Starter Motor Will Not Crank Engine,
Or Cranks Slow 98. . . . . . . . . . . . . . . . . . . . . .
Engine Will Not Start, Or Is Hard To
Start 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Runs Rough, Misses And/Or
Backfires 100. . . . . . . . . . . . . . . . . . . . . . . . . . .
Poor Performance 100. . . . . . . . . . . . . . . . . . .
Excessive Engine Temperature 101. . . . . . . .
Insufficient Engine Temperature 101. . . . . . .
Low Engine Oil Pressure 102. . . . . . . . . . . . .
Battery Will Not Charge 102. . . . . . . . . . . . . . .
Remote Control Operates Hard, Binds,
Has Excessive Free-play Or Makes
Unusual Sounds 102. . . . . . . . . . . . . . . . . . . .
SECTION 8 - CUSTOMER ASSISTANCE INFORMATION
Owner Service Assistance 104. . . . . . . . . . . . .
Local Repair Service 104. . . . . . . . . . . . . . . . .
Service Away From Home 104. . . . . . . . . . . .
Stolen Power Package 104. . . . . . . . . . . . . . .
Attention Required After Submersion 104. . .
Replacement Service Parts 105. . . . . . . . . . .
Parts And Accessories Inquiries 105. . . . . . .
Resolving A Problem 106. . . . . . . . . . . . . . . . .
Customer Service Literature 107. . . . . . . . . . .
English Language 107. . . . . . . . . . . . . . . . . . .
Other Languages 107. . . . . . . . . . . . . . . . . . . .
Andre sprog 107. . . . . . . . . . . . . . . . . . . . . . . . .
Andere talen 107. . . . . . . . . . . . . . . . . . . . . . . .
Muut kielet 107. . . . . . . . . . . . . . . . . . . . . . . . . .
Autres langues 107. . . . . . . . . . . . . . . . . . . . . .
Andere Sprachen 108. . . . . . . . . . . . . . . . . . . .
Altre lingue 108. . . . . . . . . . . . . . . . . . . . . . . . .
Andre språk 108. . . . . . . . . . . . . . . . . . . . . . . . .
Outros Idiomas 108. . . . . . . . . . . . . . . . . . . . . .
Otros idiomas 108. . . . . . . . . . . . . . . . . . . . . . .
Andra språk 108. . . . . . . . . . . . . . . . . . . . . . . . .
Allej glþssej 108. . . . . . . . . . . . . . . . . . . . . .
Ordering Literature 109. . . . . . . . . . . . . . . . . . . .
United States and Canada 109. . . . . . . . . . . .
Outside The United States and
Canada 109. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
WARRANTY
SECTION 1SECTION 1
CMD-4081877 / 90-865861040 MARCH 2004 Page 1
SECTION 1 - WARRANTY
Table of Contents
Warranty Information 2. . . . . . . . . . . . . . . . . . . .
Owner Warranty Registration 2. . . . . . . . . . . .
United States And Canada Only 2. . . . . .
International Owner Registration 3. . . . . . . . .
Outside The United States And
Canada 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Policies 4. . . . . . . . . . . . . . . . . . . . . . .
Recreational Use Diesel Limited
Warranty 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What Is Covered 4. . . . . . . . . . . . . . . . . . . .
Duration Of Coverage 4. . . . . . . . . . . . . . .
Conditions That Must Be Met In Order
To Obtain Warranty Coverage 4. . . . . . . .
What Cummins Mercruiser Diesel Will
Do 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How To Obtain Warranty Coverage 5. . . .
What Is Not Covered 5. . . . . . . . . . . . . . . .
DISCLAIMERS AND LIMITATIONS 5. . . .
Warranty Coverage and Exclusion 6. . . . . . .
Warranty Does Not Apply To The
Following: 6. . . . . . . . . . . . . . . . . . . . . . . . .
Transferable Warranty 8. . . . . . . . . . . . . . . . . . .
Direct Sale By Owner 8. . . . . . . . . . . . . . . . . .

WARRANTY SECTION 1
Page 2 CMD-4081877 / 90-865861040 MARCH 2004
0005
Warranty Information
Owner Warranty Registration
UNITED STATES AND CANADA ONLY
•It is important that your selling dealer fills out the Warranty Registration Card
completely and mails it to the factory immediately upon sale of the new product.
•It identifies name and address of the original purchaser, product model and serial
number(s), date of sale, type of use and selling dealer’s code, name and address.
The dealer also certifies that you are the original purchaser and user of the product.
•Upon receipt of the Warranty Registration Card at the factory, you will be issued a
plastic Owner Warranty Registration Card which is your only valid registration
identification. It must be presented to the servicing dealer should warranty service be
required. Warranty claims will not be accepted without presentation of this card.
•A temporary Owner Warranty Registration Card will be presented to you when you
purchase the product. It is valid only for 30 days from date of sale while your plastic
Owner Warranty Registration Card is being processed. Should your product need
service during this period, present the temporary registration card to the dealer. He
will attach it to your warranty claim form.
•Because of your selling dealer’s continuing personal interest in your satisfaction, the
product should be returned to him for warranty service.
•If your plastic card is not received within 30 days from date of new product sale,
please contact your selling dealer.
•The product warranty is not effective until the product is registered at the factory.
•NOTICE: Registration lists must be maintained by factory and dealer on marine
products sold in the United States, should notification under the Federal Boat Safety
Act be required.
•You may change your address at any time, including at time of warranty claim, by
calling Mercury MerCruiser or sending a letter or fax with you name, old address,
new address, and engine serial number to Mercury MerCruiser’s warranty
registration department. Your dealer can also process this change of information.
Mercury Marine
Attn: Warranty Registration Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939
Phone: [phone]
Fax: [phone]