At 3hr 45min it was the longest best-of-three match this year, the ATP said, eclipsing the 3hr 38min played by Rafael Nadal and Stefanos Tsitsipas in the Barcelona final in April.
Zverev advanced to the fourth round, coming from behind in both sets to beat two time Olympic gold medal winner Murray 6-4, 7-6 (7/4)
Indian Wells 2021: Murray rallies to beat Alcaraz; Swiatek donates prize money on World Mental Health Day
Andy Murray will next face either third-seeded Alexander Zverev or American Jenson Brooksby.
Indian Wells Masters: Emma Raducanu loses in straight sets to Aliaksandra Sasnovich; Andy Murray advances
Raducanu lost 6-2, 6-4 in the second round, ending her 10-match winning streak that began in New York. She received a wild-card into the combined ATP and WTA tournament in the Southern California desert.
Murray had asked for help on social media earlier, saying he'd left his tennis shoes -- which were stinky after a day of practice in the California desert -- underneath his car to dry out overnight only to find them vanished when he returned in the morning.
Murray, who is preparing for the Indian Wells, left his tennis shoes underneath his car to dry out overnight — but they had vanished when he returned in the morning. His wedding ring was tied to his footwear.
San Diego Open: Casper Ruud knocks Andy Murray out; Denis Shapovalov claws back to beat Taylor Fritz
The match was even at 5-all but turned when Murray, a three-time Grand Slam champion and former No 1-ranked player who is now 109th, allowed the first set to slip away entirely and also fell behind early in the second by dropping five consecutive games.
Poland's Hurkacz, who beat Roger Federer on his way to the Wimbledon semi-finals in July, won 7-6 (7/4), 6-3.
Murray, now ranked at 113, swept to a convincing 6-3, 6-3 victory over Vasek Pospisil, his fifth win against the Canadian in six meetings.
The Scot, 34, won seven straight games en route to a 4-6, 6-3, 6-2 comeback victory in two hours and 24 minutes.
Murray, now down at 116 in the world, lost to 158th-ranked Roman Safiullin of Russia, 6-2, 4-6, 6-1.
Murray, who underwent right hip surgery in 2017 and again 2019, lost in five sets to third-ranked Stefanos Tsitsipas in the first round in New York, where the Scot won the third of his major titles in 2012.
The Greek third seed was stunned by 18-year-old Spaniard Carlos Alcaraz 6-3, 4-6, 7-6 (7/2), 0-6, 7-6 (7/5) in a third-round match at Arthur Ashe Stadium, Tsitsipas having never reached the last 16 at the US Open.
US Open 2021: Victoria Azarenka says it is 'a bit bizarre that fans have to be vaccinated and players are not'
Azarenka, a two-time Australian Open winner and three-time US Open runner-up from Belarus, told fans after her victory Wednesday she was glad they were all vaccinated for the deadly virus, a requirement mandated by New York City officials.
Australian Open organisers are hoping players can avoid the hard hotel quarantine and other restrictions they endured in 2021 due to rising vaccination rates in the general public in Australia.
On court, Murray used the word "cheating" for Stefanos Tsitsipas. At his news conference, he called it "nonsense" and said he "lost respect" for the Greek, who was the runner-up at the French Open in June and is seeded No 3 in New York.
US Open 2021: Andy Murray says he has 'lost respect' for Stefanos Tsitsipas for delaying tactics in first-round clash
Murray barely greeted Tsitsipas at the net after the Greek third seed's delays, including medical timeouts and bathroom breaks to disrupt Murray's rhythm.
US Open 2021: Stefanos Tsitsipas beats Andy Murray in five-set first-round thriller; Halep, Stephens progress to second round
Tsitsipas defeated the 112th-ranked British star 2-6, 7-6 (9/7), 3-6, 6-3, 6-4 in an atmosphere more like an intense second-week showdown than a curtain-raiser for the fortnight.
Tsitsipas is set for a first career matchup against Murray, a 34-year-old Scotsman who won the 2012 US Open and the 2013 and 2016 Wimbledon crowns as well as 2012 and 2016 Olympic gold medals.
Tiafoe advances to the third round of the hardcourt tournament where he will face either Thiago Monteiro or Eduardo Nava.