Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
Page 2 Exhaust Gas Emissions Certification Number The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser® power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing.
Page 3: Read This Manual Thoroughly
We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
Page 4 NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. 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.
Page 5: Table Of Contents
How To Obtain Warranty Coverage....13 Mercury Product Protection Plan: United States and What Mercury Will Do........13 Canada..............3 What Is Not Covered........13 Mercury MerCruiser Limited Warranty Components Of The Emission Control System 13 (Gasoline‑Fueled Products Only) ......4 Disclaimers And Limitations......15 3‑Year Limited Warranty Against Corrosion....6 California Emission Control Warranty Statement.
Page 6 Starting and Stopping the Engine....47 Passenger Safety in Pontoon Boats and Deck Starting the Engine........47 Boats..............52 Stopping the Engine........48 Boats Having An Open Front Deck....53 Starting the Engine After It Has Been Stopped Boats With Front‑Mounted, Raised Pedestal While In Gear..........
Page 7 Power Trim Fluid...........80 Bravo One Propeller Installation..... 94 Checking............80 Bravo Two Propeller Removal......95 Filling..............81 Bravo Two Propeller Installation..... 95 Changing............81 Bravo Three Propeller Removal.....96 Battery..............81 Bravo Three Propeller Installation....97 Multiple EFI Engine Battery Precautions..82 Serpentine Drive Belt..........99 Cleaning the Flame Arrestor........82 Checking............99 Positive Crankcase Ventilation Valve (PCV)..83 Replacing Belt and/or Adjusting Tension..99...
Page 8 Engine Will Not Start or Is Hard to Start..135 Remote Control Is Difficult to Move, Has Engine Runs Rough, Misses, or Backfires. .135 Excessive Play, or Makes Unusual Sounds 136 Poor Performance........135 Steering Wheel Jerks or Is Difficult to Turn. 137 Excessive Engine Temperature....135 Power Trim Does Not Operate (Motor Does Not Insufficient Engine Temperature....136...
Page 9 Mercury Product Protection Plan: United States and What Is Not Covered ........13 Canada..............3 Components Of The Emission Control Mercury MerCruiser Limited Warranty (Gasoline- System ............13 Fueled Products Only) ......... 4 Disclaimers And Limitations ......15 3-Year Limited Warranty Against Corrosion..6...
Page 10: Warranty Registration: United States And Canada
A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.
Page 11: Transfer Of Warranty
Section 1 - Warranty The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use, and the selling distributor’s and dealer’s code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product.
Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)
One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after the original engine registration date. See your participating Mercury MerCruiser dealer for complete program details. Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)
Page 13 Section 1 - Warranty Conditions That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the pre‑delivery inspection process specified by Mercury Marine is completed and documented.
Page 14: 3-Year Limited Warranty Against Corrosion
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
Page 15: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines
This limited corrosion warranty provides coverage for four (4) years from either the date on which the MerCruiser SeaCore engine, transom, and sterndrive package is first sold or the date on which it is first put into service, whichever occurs first. The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
Page 16: Global Warranty Charts
Section 1 - Warranty This limited warranty does not cover the following: • Electrical system corrosion • Corrosion resulting from damage • Corrosion that causes purely cosmetic damage • Abuse or improper service • Corrosion to accessories, instruments, and steering systems •...
Page 17: Commercial Application Warranty Chart
Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...
Page 18: Government Application Warranty Chart
Section 1 - Warranty Government Application Warranty Chart Limited Corrosion Government Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...
Page 19: Mercury Installation Quality Certification Program 10 California Emissions Limited Warranty
California Emissions Limited Warranty NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 20: Duration Of Coverage
Duration Of Coverage NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model...
Page 21: How To Obtain Warranty Coverage
Section 1 - Warranty How To Obtain Warranty Coverage The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.
Page 22 Section 1 - Warranty Cold start enrichment system Intake valve(s) 2. Air Induction System Controlled hot air intake system Intake manifold Air filter Turbocharger systems Heat riser valve and assembly 3. Ignition System Spark plugs Magneto or electronic ignition system Spark advance/retard system Ignition coil and/or control module Ignition wires...
Page 23: Components Of The Emission Control System 13 Disclaimers And Limitations
1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 24: Emission Control Information Label
A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement.
Page 25: Owner Responsibility
Beginning January 1, 2003, one Three‑Star or Four‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2007 and later exhaust emission standards.
Page 26 Section 1 - Warranty One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
Page 27: Section 2 - Getting To Know Your Power Package
Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............20 Console Mount Features - Single Engine..30 Engine Serial Number Decal MPI....20 Slim Binnacle Console Mount Features - Single Alpha Sterndrive Decal Identification....20 Engine............31 Alpha Transom Serial Number......21...
Page 28: Identification
Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal MPI The serial number decal is located on the engine cover.
Page 29: Alpha Transom Serial Number
Section 2 - Getting to Know Your Power Package Alpha Transom Serial Number The transom serial number is located on the top of the transom assembly. 25619 Alpha transom assembly serial number Bravo Sterndrive Serial Number and Identification The sterndrive serial number, gear ratio, model number, and bar code is embedded in the ground plate located on the port side of the Bravo sterndrive.
Page 30: Bravo Transom Serial Number
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers. 25907 Bravo sterndrive serial number stamping...
Page 31: Lanyard Stop Switch
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. 25905 Gimbal housing with serial number stamping Transom assembly serial Number...
Page 32: Instrumentation
Section 2 - Getting to Know Your Power Package The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.
Page 33: Digital Gauges
Section 2 - Getting to Know Your Power Package Your power package may be connected to a SmartCraft VesselView display. This display provides a single, easy‑to‑use source for real‑time information about a variety of vessel systems. The interactive VesselView display continuously monitors and reports information about speed and performance, trim angle, water temperature and depth, and other operating data.
Page 34: Analog Gauges
Section 2 - Getting to Know Your Power Package The SmartCraft instrument package also aids in Engine Guardian diagnostics. The SmartCraft Instrument package displays critical engine alarm data and potential problems. Refer to the manual with your gauge package for the warning functions monitored by and basic operation of the SmartCraft instrument package.
Page 35: Panel Mount Features
Section 2 - Getting to Know Your Power Package PANEL MOUNT FEATURES mc77019-1 Neutral lock button Control handle tension adjustment screw Throttle only button Control handle Lanyard stop switch Trim/tilt button Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the control handle out of neutral.
Page 36: Console Mount Features
Section 2 - Getting to Know Your Power Package CONSOLE MOUNT FEATURES mc79503-1 Throttle Only Button Power Trim Switch Control Handle Trailer Switch Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position.
Page 37: Panel Mount Features
Section 2 - Getting to Know Your Power Package Panel Mount Features 3409 Lanyard stop switch Control handle Shift lock Trim/tilt switch Throttle only button Start/stop button Detent tension adjustment screw Control handle friction adjustment screw Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.
Page 38: Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Console Mount Features ‑ Single Engine 3410 Control handle Trim/tilt switch Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 39: Slim Binnacle Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Slim Binnacle Console Mount Features ‑ Single Engine START STOP 14637 Control handle Trim/tilt switch Active light Neutral light Start/stop button Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 40: Console Mount Features- Dual Engine
Section 2 - Getting to Know Your Power Package Console Mount Features‑ Dual Engine SYNC ACTIVE THROTTLE ONLY STATION SELECT 3411 Trim/tilt switch Arrow trackpad Control handles Sync light Active light Throttle only/station select key Neutral light Detent tension adjustment Select key Control handle friction adjustment screw...
Page 41: Synchronizing Dual Engines
Section 2 - Getting to Know Your Power Package Synchronizing Dual Engines The auto synchronizing feature, when engaged, will automatically adjust the port engine speed to match the speed of the starboard engine. Synchronizing of engines will automatically engage when the speed of both engines are over 900 RPM for two seconds and remote control handles are positioned within 5°...
Page 42: Synchronizing Dual Helms Prior To Station Transfer
Section 2 - Getting to Know Your Power Package 3. Press throttle only/station select button once. The "ACTIVE" light will illuminate to indicate the remote control station is in control of the engine. SYNC ACTIVE ACTIVE THROTTLE THROTTLE ONLY ONLY STAT ION SELECT STATION SELECT 3433...
Page 43: Power Trim
Section 2 - Getting to Know Your Power Package Power Trim Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, low speed (below 1200 RPM engine speed) and shallow water operation.
Page 44: Single Engine Trim/Trailer
Section 2 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
Page 45 Section 2 - Getting to Know Your Power Package 3. Reset the breaker by pushing the yellow lever back into the housing. 22529 Yellow lever style circuit breaker Yellow lever Red test button A 90 amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.
Page 46 Section 2 - Getting to Know Your Power Package Two 10 amp fuses protect the O (oxygen) sensors. These are located at the rear of the engine, near the 14‑pin connector. 33177 A 15 amp accessory fuse protects the accessory circuits. This fuse is located on the rear of the engine.
Page 47 Section 2 - Getting to Know Your Power Package The power trim system is protected from overload by both a 110 amp fuse and a 20 amp spade fuse on the power trim pump. The trim pump may also have an in‑line circuit protection device in the power trim positive lead near the battery switch or battery connection.
Page 48: Audio Warning System
IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from damage. Your Mercury MerCruiser power package may be equipped with an audio warning system. Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.
Page 49: Obdm
If an OBDM fault is detected, the audio warning system sound with one five‑second horn, then one short, 1/2‑second horn every 60 seconds for certain faults related to the emissions or fuel system. See your authorized Mercury MerCruiser dealer for assistance. ½...
Page 50 Section 2 - Getting to Know Your Power Package As another example, Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage. Transmission Guardian monitors the clutch pack pressure in forward and reverse gears. If the transmission fluid pressure drops below a predetermined level, Transmission Guardian lowers the engine torque and speed to prevent clutch slippage.
Page 51: Section 3 - On The Water
Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions........44 While You Are Cruising ........ 52 Be Alert to Carbon Monoxide Poisoning..... 45 While Boat Is Stationary ....... 52 Good Ventilation ........... 45 High-Speed and High-Performance Operation Poor Ventilation ...........
Page 52: Safe Boating Suggestions
Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.
Page 53: Be Alert To Carbon Monoxide Poisoning
Section 3 - On the Water • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat;...
Page 54: Poor Ventilation
Section 3 - On the Water 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.
Page 55: Starting And Stopping The Engine
Section 3 - On the Water Operation Chart WHILE BEFORE STARTING AFTER STARTING AFTER STOPPING UNDERWAY Check shift and Turn battery switch on. throttle control Close fuel shut off valve. operation. Check steering Close seacock, if Operate bilge blowers. operation. equipped.
Page 56: Stopping The Engine
IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. Page 48 90-899883169 DECEMBER 2007...
Page 57: Drain Plug And Bilge Pump
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 58: Stopping The Engine
Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes. NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process.
Page 59: Throttle-Only Operation
IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. 90-899883169 DECEMBER 2007 Page 51...
Page 60: Drain Plug And Bilge Pump
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 61: Boats Having An Open Front Deck
Section 3 - On the Water Boats Having An Open Front Deck No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure. Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.
Page 62: Impact With Underwater Hazards
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Page 63: Drive Unit Impact Protection
Section 3 - On the Water Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object, reducing damage to the unit.
Page 64: Cavitation
Section 3 - On the Water • 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 the boat is docked. This growth must be removed before operation;...
Page 65: Getting Started
Change the engine oil and oil filter. Refer to Maintenance. End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of...
Page 66 Section 3 - On the Water Notes: Page 58 90-899883169 DECEMBER 2007...
Page 67 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........60 Engine............62 Fuel Ratings ..........60 Alpha Sterndrive..........62 Using Reformulated (Oxygenated) Gasoline Bravo Sterndrives..........63 (USA Only) ........... 60 Power-Assisted Steering and Power Trim Fluids Gasoline Containing Alcohol ......60 ..............63 Engine Oil............
Page 68: Fuel Requirements
Reformulated gasoline is required in certain areas of the USA and are acceptable for use in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol.
Page 69: Engine Oil
Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty. If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation, for short periods of time: 1.
Page 70: Engine Specifications
RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures. Oil pressure must be checked with the engine at normal operating temperature. Models 5.0 MPI and SeaCore 5.0 Power 194 kW (260 hp) Number of cylinders Displacement 5.0 L (305 cid)
Page 71: Bravo Sterndrives
Section 4 - Specifications Bravo Sterndrives NOTE: Oil capacity includes gear lube monitor. Model Capacity Fluid Type Bravo One 2736 mL (92‑1/2 oz) Bravo Two 3209 mL (108‑1/2 oz) High Performance Gear Lubricant Bravo Three (single seawater pickup) 2972 mL (100‑1/2 oz) Bravo Three (dual seawater pickup) 2736 mL (92‑1/2 oz) Power‑Assisted Steering and Power Trim Fluids...
Page 72 Section 4 - Specifications Notes: Page 64 90-899883169 DECEMBER 2007...
Page 73 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......67 Lubrication............88 Dealer Responsibilities........67 Steering System..........88 Maintenance............67 Throttle Cable..........89 Do-It-Yourself Maintenance Suggestions... 68 Shift Cable - Typical........90 Inspection............68 Sterndrive Unit and Transom Assembly..90 Maintenance Schedule—Sterndrive Models..
Page 74 Section 5 - Maintenance Page 66 90-899883169 DECEMBER 2007...
Page 75: Owner/Operator Responsibilities
• Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •...
Page 76: Do-It-Yourself Maintenance Suggestions
Gear lube oil Do‑It‑Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.
Page 77: Maintenance Schedule-Sterndrive Models
Section 5 - Maintenance Maintenance Schedule—Sterndrive Models Routine Maintenance NOTE: Only perform maintenance that applies to your particular power package. Task Interval Maintenance to Be Performed • Check the engine oil level. (You can extend this interval based on experience with the product.) •...
Page 78: Maintenance Log
• Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase ventilation hoses. Inspect the PCV valve, if equipped. NOTE: On MerCruiser V6 models, the PCV valve is a non‑serviceable, internal component of the valve cover assembly. • Inspect the condition and the tension of the belts.
Page 79: Engine Oil
Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat.
Page 80: Filling
2. Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. Recheck oil level. 3. Replace the fill cap. Engine Model Engine Oil Capacity Fluid type All Models 4.25 L (4.50 US qt) Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40 Page 72 90-899883169 DECEMBER 2007...
Page 81: Changing Oil And Filter
Section 5 - Maintenance Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
Page 82: Changing Filter
Section 5 - Maintenance 4. Insert the hose end of the crankcase oil pump onto an appropriate container and, using the handle, pump until the crankcase is empty. 5. Remove the pump. 6. Install the dipstick. CHANGING FILTER 1. Remove and discard oil filter. 33201 Oil filter 2.
Page 83: Filling
Power steering pump Cold range Warm range 3. Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling 1. Remove the fill cap/dipstick and observe the level. 2. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.
Page 84: Filling
Heat exchanger cap 2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. 3. Install the cap onto the heat exchanger.
Page 85: Changing
Refer to the Specifications section. 4. Install the fill cap to the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Drive Unit Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law.
Page 86: Filling
If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.
Page 87: December
IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air‑free stream of...
Page 88: Power Trim Fluid
Section 5 - Maintenance Tube Ref No. Description Where Used Part No. High Performance Gear Sterndrive unit 92-858064K01 Lubricant IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in sterndrive unit. 8. Install the oil vent screw and sealing washer. IMPORTANT: Filling is not complete until the gear lubricant appears in the gear lube monitor 9.
Page 89: Filling
3. Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.
Page 90: Multiple Efi Engine Battery Precautions
Section 5 - Maintenance Multiple EFI Engine Battery Precautions Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for 2 different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine's alternator will not be required to supply any charging current.
Page 91: Positive Crankcase Ventilation Valve (Pcv)
10. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover. 11. Install the engine cover. Positive Crankcase Ventilation Valve (PCV) CHANGING IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. 90-899883169 DECEMBER 2007 Page 83...
Page 92: Cleaning The Iac Muffler
Section 5 - Maintenance 1. Remove the PCV valve from the port valve cover. 33143 PCV valve (hose not shown) 2. Disconnect the PCV valve from the hose and discard the valve. 3. Install a new PCV valve in the valve cover and reconnect the hose. 4.
Page 93: Water-Separating Fuel Filter (Mpi)
Sealing ring REMOVAL 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close the fuel supply valve, if equipped. 3. Wrap the water‑separating fuel filter with a cloth to help catch any fuel spills or spray.
Page 94: Gen Iii Models
Cool Fuel Module filter reservoir Filter assembly retaining screw O‑ring REMOVAL 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Page 86 90-899883169 DECEMBER 2007...
Page 95: Installation
10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. 90-899883169 DECEMBER 2007 Page 87...
Page 96: Lubrication
Section 5 - Maintenance Lubrication Steering System WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased. 1.
Page 97: Throttle Cable
3. Lubricate the steering pin. mc71904-1 Steering pin Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Steering pin 92‑883725K01 Oil SAE25W‑40 4. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.
Page 98: Shift Cable - Typical
Pivot points Guide contact surfaces Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Shift cable pivot points & guide 92‑883725K01 Oil SAE25W‑40 contact surfaces Sterndrive Unit and Transom Assembly 1. Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun.
Page 99: Sterndrive U-Joint Shaft Splines And O-Rings (Sterndrive Unit Removed)
Section 5 - Maintenance Sterndrive U‑joint Shaft Splines And O‑rings (Sterndrive Unit Removed) 1. Coat sterndrive U‑joint O‑rings and driveshaft splines with grease. 8591 Driveshaft splines U‑joint O‑rings (3) Tube Ref No. Description Where Used Part No. Driveshaft splines and U-joint Engine Coupler Spline Grease 92-802869A 1 O-rings...
Page 100: Driveshaft Extension Models
92-802870A1 Grease driveshaft grease fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
Page 101: Alpha Propeller Installation
Section 5 - Maintenance Alpha Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage.
Page 102: Bravo One Propeller Removal
Section 5 - Maintenance Bravo One Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
Page 103: Bravo Two Propeller Removal
Section 5 - Maintenance NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued. 4. Align splines and place propeller on propeller shaft. 5. Install drive sleeve and locking tab washer. 6.
Page 104: Bravo Three Propeller Removal
Section 5 - Maintenance 1. Slide thrust hub into propeller hub with stepped side toward propeller hub. 2. Apply a liberal coat of one of the following lubricants to the propeller shaft. Tube Ref No. Description Where Used Part No. Special Lubricant 101 Propeller shaft 92-802865Q02...
Page 105: Bravo Three Propeller Installation
6. Turn front propeller shaft nut 70 mm (2‑3/4 in.) counterclockwise to remove nut. 7. Slide propeller and thrust hub off propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 5304 Rear propeller nut...
Page 106 Section 5 - Maintenance 2. Apply a liberal coat of one of the following lubricants to the propeller shaft. Tube Ref No. Description Where Used Part No. Special Lubricant 101 Propeller shaft 92-802865Q02 Anti-Corrosion Grease Propeller shaft 92-802867Q 1 2-4-C Marine Lubricant with Propeller shaft 92-802859A 1 Teflon...
Page 107: Serpentine Drive Belt
Section 5 - Maintenance Description llb‑in. lb‑ft Propeller shaft anode screw 38 mm (0.3125‑18 x 1.5 in.) long – Serpentine Drive Belt WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts. 6117 6116 With a seawater pump...
Page 108 Section 5 - Maintenance NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys. 1. Loosen the 16 mm (5/8 in.) locking nut on the adjustment stud. 2. Turn the adjustment stud and loosen the belt. 3.
Page 109: Corrosion Protection
The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer and refer to the Mercury Precision Parts / Marine Corrosion Protection Guide (90‑881813003).
Page 110: System
The MerCathode system should be tested to ensure adequate output. Perform the test where boat is moored, using the reference electrode and test meter. Contact your authorized Mercury MerCruiser dealer for service and information . Page 102 90-899883169 DECEMBER 2007...
Page 111: Power Package Exterior Surfaces
Section 5 - Maintenance Reference Electrode 91‑76675T 1 Senses and electrical current in the water when testing the MerCathode system. Use to check hull potential. 9188 Power Package Exterior Surfaces 1. Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for proper application.
Page 112 • Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) UNPAINTED area on transom of the boat around these items.
Page 113: Sterndrive Surface Care
Section 5 - Maintenance Do not power‑wash a sterndrive that has a MerCathode assembly. Doing so can damage the coating on the reference wire of the MerCathode assembly and increase corrosion. 21563 Reference electrode Anode plate Sterndrive Surface Care 21083 Standard Bravo sterndrive Sacrificial trim cylinder anode Stainless steel hoses...
Page 114: Flushing The Power Package (Alpha)
Your boat comes equipped with through the sterndrive water pickups. See Sterndrive Water Pickups (following) for the flushing procedure. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Alpha engines with the sterndrive water inlet blocked off at the gimbal...
Page 115: Sterndrive Water Pickups
Section 5 - Maintenance Sterndrive Water Pickups This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment (44357Q 2). 5773 Side Pickup NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications.
Page 116: Flushing The Power Package (Bravo)
Flushing the Power Package (Bravo) General Information Your authorized Mercury MerCruiser dealer can explain how to properly flush your power package. Flushing the Power Package The boat can be equipped with a combination of any of three different types of water pickups: through the hull, through the transom, and through the sterndrive.
Page 117: Flushing Attachments
Section 5 - Maintenance FLUSHING ATTACHMENTS 21514 21515 Flushing attachments for dual water pickup Flushing attachments for side water pickup Flushing device Hose attachment Dual water pickup flush gearcase seal kit Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.
Page 118: Sterndrive Water Pickups
Section 5 - Maintenance STERNDRIVE WATER PICKUPS There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side water pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side water pickups require the flushing attachment (44357Q 2).
Page 119: Alternative Water Pickups
Section 5 - Maintenance WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
Page 120 Section 5 - Maintenance WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
Page 121: Seacore Power Package Flushing Procedure
Section 5 - Maintenance 14. Shut off the water and remove flushing attachments. 15. If the boat is out of the water, install the water inlet hose to the aft side of the seawater pump. Tighten the hose clamp securely. 16.
Page 122 Section 5 - Maintenance 5. Remove the quick‑connect fitting from the parts bag supplied with the engine. 6. Attach the quick‑connect fitting to a water hose. 18487 Quick connect fitting (water hose Water hose end) 7. Snap the quick‑connect fitting with the water hose into the flush socket on the engine. 18489 Water hose Flush socket...
Page 123 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. 25900 Quick‑connect fitting stored in the boat Quick‑connect fitting (water hose end)
Page 124 Section 5 - Maintenance 20. Insert the dust cover in the flush socket on the engine. 18490 Dust cover installed in the flush socket Dust cover Flush socket IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage.
Page 125 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....118 Boat in the Water ......... 122 Preparing Power Package for Storage..118 Boat out of the Water ......124 Engine and Fuel System Preparation . . 119 Manual Single-Point Drain System (Alpha) Draining the Seawater System......
Page 126: Cold Weather Or Extended Storage
Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage.
Page 127: Engine And Fuel System Preparation
Section 6 - Storage 10. For additional assurance against freezing and rust, after draining, fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.
Page 128: Draining The Seawater System
Identification to determine which instructions apply to your power package. IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage.
Page 129: Three Point Manual Drain System
Section 6 - Storage MANUAL SINGLE POINT DRAIN SYSTEM (ALPHA) 6128 Blue handle Blue drain plug location THREE POINT MANUAL DRAIN SYSTEM 6126 Blue drain plug MULTI-POINT DRAIN (MPD) SYSTEM 6129 Side of cylinder block Bottom of exhaust manifolds 90-899883169 DECEMBER 2007 Page 121...
Page 130: Air Actuated Single Point Drain System
Section 6 - Storage 33155 Fuel cooler to thermostat housing 6131 Check valve (if equipped) Air Actuated Single Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used.
Page 131 12. Remove the air pump from the air manifold and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
Page 132: Boat Out Of The Water
Section 6 - Storage 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Page 133 10. Remove the air pump from the air manifold and return it to the mounting bracket. 11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
Page 134: Boat In The Water
Section 6 - Storage 12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators Manual Single‑Point Drain System (Alpha) BOAT IN THE WATER 1. Close the seacock (if equipped) or remove and plug the water inlet hose. 2.
Page 135: Boat Out Of The Water
Section 6 - Storage 4. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually. 33152 Blue drain plug Drain location ‑ orange or red 5. Allow the system to drain for a minimum of five minutes. We recommend leaving the drain system open while transporting the boat or performing other maintenance.
Page 136: Three-Point Manual Drain System
Section 6 - Storage 3. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually. 33152 Blue drain plug Drain location ‑ orange or red 4. Allow the system to drain for a minimum of five minutes. We recommend leaving the plugs out while transporting the boat or performing other maintenance to ensure that all water is drained.
Page 137: Section 6 - Storage
Section 6 - Storage 3. To properly vent the cooling system, remove the blue drain plug from the side of the thermostat housing within 30 seconds. 6139 Blue drain plug location 4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side). 6140 Blue drain plugs 5.
Page 138: Battery Storage
Section 6 - Storage 2. Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side). 6142 Blue drain plug 3. Verify that water is draining from each opening. 4.
Page 139 Section 6 - Storage 7. Inspect the steering system, shift and throttle control for proper operation. 90-899883169 DECEMBER 2007 Page 131...
Page 140 Section 6 - Storage Notes: Page 132 90-899883169 DECEMBER 2007...
Page 141: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems......... 134 Low Engine Oil Pressure......136 Diagnosing DTS Problems....... 134 Battery Will Not Recharge......136 Engine Guardian System........134 Remote Control Is Difficult to Move, Has Troubleshooting Charts........134 Excessive Play, or Makes Unusual Sounds Starter Motor Will Not Crank Engine, or Cranks ..............136...
Page 142: Diagnosing Efi Problems
Section 7 - Troubleshooting Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.
Page 143: Engine Will Not Start Or Is Hard To Start
Boat bottom fouled or damaged. Clean or repair as necessary. Ignition problem. See Engine Runs Rough, Misses or Backfires. Engine overheating. See Excessive Engine Temperature. Have EFI System checked by an authorized Mercury MerCruiser EFI System fault dealer. Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed.
Page 144: Insufficient Engine Temperature
Check all throttle linkages. If any are loose or missing, Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair. Page 136 90-899883169 DECEMBER 2007...
Page 145: Power Trim Does Not Operate (Motor Does Not Operate)
Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners if any are loose or missing, Loose or missing steering fasteners or parts. see authorized Mercury MerCruiser dealer immediately. Contaminated power steering fluid. See authorized Mercury MerCruiser dealer. Power Trim Does Not Operate (Motor Does Not Operate)
Page 146 Section 7 - Troubleshooting Notes: Page 138 90-899883169 DECEMBER 2007...
Page 147: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 140 Parts and Accessories Inquiries ... 141 Local Repair Service ........140 Resolving a Problem ........141 Service Away From Home ......140 Mercury Marine Service Offices ....
Page 148: Owner Service Assistance
Owner Service Assistance Local Repair Service If you need service for your Mercury MerCruiser–powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine.
Page 149: Parts And Accessories Inquiries
Resolving a Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership.
Page 150: Ordering Literature
• Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P.O. Box 1939...

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