MerCruiser 496 MAG Owner's Manual
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MerCruiser 496 MAG Owner's Manual

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NOTE: The following applies to CE marked products only.
Declaration of Conformance – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury MerCruisers' instructions complies with the
requirements of the following directives by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Applicable Requirement
Owner's manual (A.2.5)
Openings in Hull, Deck and superstructure (A.3.4)
Handling characteristics (A.4)
Inboard Engine (A.5.1.1)
Fuel System (A.5.2)
Electrical System (A.5.3)
Steering system (A.5.4)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Ignition‑protected equipment (Annex II)
Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust, when installed in a
recreational craft, in accordance with the manufacturers supplied instructions, will meet the exhaust emissions
requirements of the directive mentioned above. This engine must not be put into service until the recreational craft in which
it is to be installed has been declared in conformity, if so required, with the relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion engine driven
devices ‑ Radio disturbance characteristics
Electrostatic discharge testing
The notified body responsible for surveillance of the quality system under Full Quality Assurance 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.
President ‑ Mercury MerCruiser, Stillwater, OK, USA
Regulatory contact:
Regulations and Product Safety Department
Mercury Marine
W6250 W. Pioneer Road
Fond du Lac, WI 54936
USA
Identification Record
Please record the following information:
ISO 10240
ISO 9093‑1; ISO 9093‑2
ISO 8665
ISO 15584; ISO 10088; ISO 7840; ISO 10133
ISO 10088; ISO 7840; ISO 8469
ISO 10133; ISO 8846
Applicable portions of: ISO 10592, ISO 8848 and ABYC
P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 8846; SAE J1171; SAE J1191; SAE J 2031
EN 50081‑1
EN 50082‑1
SAE J551 (CISPR 12)
EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3
Kevin Grodzki
Standards Applied

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Summary of Contents for MerCruiser 496 MAG

  • Page 1 Ignition‑protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031 Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust, when installed in a recreational craft, in accordance with the manufacturers supplied instructions, will meet the exhaust emissions requirements of the directive mentioned above.

  • Page 2: Read This Manual Thoroughly

    Boat Model Length 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. 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.
  • Page 3 Notice Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, 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.

  • Page 5: Table Of Contents

    Transfer of Warranty..............2 What Mercury Will Do............11 Mercury Product Protection Plan: United States and Canada... 3 What Is Not Covered............11 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Components Of The Emission Control System....12 Products Only) ................3 Disclaimers And Limitations..........13 3‑Year Limited Warranty Against Corrosion......5 Mercury Installation Quality Certification Program....13...
  • Page 6 Protecting People in the Water..........42 Conditions Affecting Operation..........45 While You Are Cruising............. 42 Weight Distribution (Passengers and Gear) Inside the While Boat Is Stationary........... 42 Boat.................45 High‑Speed and High‑Performance Operation....... 42 The Bottom of the Boat........... 45 Passenger Safety in Pontoon Boats and Deck Boats.... 43 Cavitation................
  • Page 7 General Information—Bravo Sterndrive......88 The Boat out of the Water—Alternative Water Pickups..91 Flushing Attachments........... 89 The Boat in the Water—Alternative Water Pickups..92 Sterndrive Water Pickups..........89 SeaCore Power Package Flushing Procedure....92 The Boat out of the Water—Bravo Sterndrive....89 Models Using The Sterndrive Water Pickup....
  • Page 8 Page iv 90-899883274 MARCH 2008...
  • Page 9 Mercury Product Protection Plan: United States and Canada What Is Not Covered ............ 11 ....................3 Components Of The Emission Control System .... 12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Disclaimers And Limitations ......... 13 Products Only) ............... 3 Mercury Installation Quality Certification Program....13 3‑Year Limited Warranty Against Corrosion......

  • Page 10: Warranty Registration: United States And Canada

    Federal Boat Safety Act is 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 to Mercury MerCruiser’s warranty registration department with your name, old address, new address, and engine serial number.

  • Page 11: Mercury Product Protection Plan: United States And Canada

    The optional Mercury Product Protection Plan is the only Factory Plan available for your engine. 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 12 Section 1 - Warranty Transfer of Coverage Unexpired warranty coverage can be transferred from one recreational‑use customer to a subsequent recreational‑use customer upon proper reregistration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial‑use customer.

  • Page 13: 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 14: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines

    4-YEAR LIMITED CORROSION WARRANTY: SEACORE STERNDRIVE MODELS WITH GAS ENGINES What Is Covered Mercury Marine warrants that each new MerCruiser SeaCore engine, transom, and sterndrive package will not be rendered inoperative as a direct result of corrosion for the period of time described below.

  • Page 15: Global Warranty Charts

    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: Consumer Application Warranty Chart

    Section 1 - Warranty Consumer Application Warranty Chart Limited Corrosion Consumer Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Vazer Vazer Standard Models, Standar Models Scorpio Standar Models Scorpio and and...

  • 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, Vazer Vazer Standard Models, Standar Models Scorpio Standar Models Scorpio and and...

  • Page 18: Government Application Warranty Chart

    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 19: 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 year products refers to products manufactured during calendar year 2003 This limited warranty provides coverage for the components of the emissions control systems.

  • Page 20: Components Of The Emission Control System

    Section 1 - Warranty Non‑warranty maintenance, replacement, or repair of emission control devices and systems may be performed by any marine engine repair establishment or individual. The use of non‑Mercury parts for non‑warranty maintenance or repairs will not be grounds for disallowing other warranty work. The use of add‑on (as defined at section 1900 (b)(1) and (b)(10) of Title 13 of the California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine.

  • Page 21: Disclaimers And Limitations

    Certified Manufacturer status and receive an additional one (1) year of Mercury limited factory warranty coverage on all MerCruiser‑powered boats that are registered on and after the boat builder's certification date for all worldwide registrations. Mercury has designated a section of our Website to promote the Installation Quality Certification Program and communicate its benefits to consumers.

  • Page 22: California Emission Control Warranty Statement

    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 23: Owner Responsibility

    Better Fuel Economy ‑ burns up to 30‑40 percent less gas and oil than conventional carbureted two‑stroke engines, saving money and resources. Longer Emission Warranty ‑ Protects consumer for worry free operation. Beginning January 1, 2003, one Three‑Star or Four‑Star label will be included with each factory‑certified Mercury MerCruiser engine. 90-899883274 MARCH 2008...
  • Page 24 Section 1 - Warranty 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 25: 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................. 18 Console Mount Features‑ Dual Engine......25 Engine Serial Number Decal......... 18 Synchronizing Dual Engines.......... 26 Bravo Sterndrive Serial Number and Identification..18 Dual Helm Station Transfer...........

  • Page 26: 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 The serial number decal is located on top of the engine.

  • Page 27: Bravo Transom Serial Number

    The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly. Bravo transom assembly U-bolt plate Transom assembly serial Number 25904 The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. Gimbal housing with serial number stamping...

  • Page 28: Instrumentation

    Section 2 - Getting to Know Your Power Package • standing at planing speeds • operating at planing speeds in shallow or obstacle infested waters • releasing your grip on the steering wheel that is pulling in one direction • consuming alcohol or drugs •...

  • Page 29: 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 30: Panel Mount Features

    Section 2 - Getting to Know Your Power Package Panel Mount Features Neutral lock button Throttle only button Lanyard stop switch Control handle tension adjustment screw Control handle Trim/tilt button mc77019-1 Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the control handle out of neutral.

  • Page 31: Zero Effort Features

    Section 2 - Getting to Know Your Power Package Control Handles - 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 and continue pushing forward to increase speed.

  • Page 32: Console Mount Features - Single Engine

    Section 2 - Getting to Know Your Power Package 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. Refer to Lanyard Stop Switch for information on the use of this switch. Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.

  • Page 33: Slim Binnacle Console Mount Features - Single Engine

    Section 2 - Getting to Know Your Power Package Slim Binnacle Console Mount Features ‑ Single Engine Control handle Trim/tilt switch Active light Neutral light Start/stop button Throttle only/station select key Detent tension adjustment Control handle friction adjustment START screw STOP 14637 Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.

  • Page 34: Synchronizing Dual Engines

    Section 2 - Getting to Know Your Power Package Arrow Trackpad - Navigates through System View on‑screen function messages. Sync Light - The sync light is illuminated when the RPM of the two engines are being synchronized by the DTS system. Throttle Only/Station Select Key - Allows engine throttle advancement without shifting the engine.

  • Page 35: Synchronizing Dual Helms Prior To Station Transfer

    Section 2 - Getting to Know Your Power Package Press throttle only/station select button once. The "ACTIVE" light will illuminate to indicate the remote control station is in control of the engine. Active light Throttle only/station select button SYNC ACTIVE ACTIVE THROTTLE THROTTLE...

  • Page 36: Single Engine Trim/Trailer

    Section 2 - Getting to Know Your Power Package For best performance trim the sterndrive unit so that the boat bottom is at a 3‑5° angle to the water. 3 - 5 mc79528 Trimming sterndrive unit up/out can: • Generally increase top speed •...

  • Page 37: Dual Engine Trim/Trailer

    Section 2 - Getting to Know Your Power Package Dual Engine Trim/Trailer NOTICE If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering systems. If using an external tie bar, raise and lower all drives together as a unit. Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have separate buttons for each sterndrive unit.
  • Page 38 Section 2 - Getting to Know Your Power Package A 90 amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs. mc74907-1 Four fuses, located on the port side of the engine, protect various electronic fuel injection (EFI) circuits. mc77602-1 Four fuses protect the main power, fuel pump, ignition, and accessory circuits.
  • Page 39 Section 2 - Getting to Know Your Power Package A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for an open fuse if the engine does not start, and the circuit breaker is not tripped. mc70525-1 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.

  • Page 40: 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 41: 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.
  • Page 42 Section 2 - Getting to Know Your Power Package Notes: Page 34 90-899883274 MARCH 2008...
  • Page 43 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions............ 36 Drain Plug and Bilge Pump..........42 Be Alert to Carbon Monoxide Poisoning....... 37 Protecting People in the Water..........42 Good Ventilation ............37 While You Are Cruising ..........

  • Page 44: 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. Ensure that everyone in the boat is properly seated.

  • Page 45: Be Alert To Carbon Monoxide Poisoning

    Section 3 - On the Water • 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 should block the operators view when the boat is above idle or planing transition speed.

  • Page 46: Basic Boat Operation (Non-Dts Models)

    Section 3 - On the Water Examples of poor ventilation while a boat is moving: Operating the boat with the trim angle of the bow too high Operating the boat with no mc79556-1 forward hatches open (station wagon effect) Basic Boat Operation (Non‑DTS Models) Launching and Boat Operation IMPORTANT: Install the bilge drain plug prior to launching the boat.

  • Page 47: Stopping The Engine

    Freezing Temperature 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. 90-899883274 MARCH 2008...

  • Page 48: Drain Plug And Bilge Pump

    It is very important to check these items on a regular basis to ensure that the water level does not come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty. Basic Boat Operation (DTS Models) Launching and Boat Operation IMPORTANT: Install the bilge drain plug prior to launching the boat.

  • Page 49: Stopping The Engine

    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 50: Trailering The Boat

    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. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.

  • Page 51: Passenger Safety In Pontoon Boats And Deck Boats

    Section 3 - On the Water Passenger Safety in Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat.

  • Page 52: 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 53: Operating With Low Water Inlets In Shallow Water

    Section 3 - On the Water Operating with Low Water Inlets in Shallow Water Low Water Inlets mc75827-1 NOTICE Operating in shallow water can cause severe engine damage due to clogged water inlets. Ensure that the water inlets on the gearcase do not ingest sand, silt, or other debris, which can restrict or stop cooling water supply to the engine.

  • Page 54: Elevation And Climate

    Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After Break‑In Period To help extend the life of your Mercury MerCruiser power package, follow these recommendations: •...

  • Page 55: End Of First Season Checkup

    End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss 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 the first 100 hours of operation or once yearly, whichever occurs first.
  • Page 56 Section 3 - On the Water Notes: Page 48 90-899883274 MARCH 2008...

  • Page 57: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 50 Fluid Specifications............... 52 Fuel Ratings ..............50 Engine................52 Using Reformulated (Oxygenated) Gasoline (USA Only) Bravo Sterndrives............52 ..................50 Power‑Assisted Steering and Power Trim Fluids..52 Gasoline Containing Alcohol ........

  • Page 58: Fuel Requirements

    Using Reformulated (Oxygenated) Gasoline (USA Only) 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 59: Engine Specifications

    MerCruiser engines. Although these high‑phosphorus lubricants may allow acceptable engine performance, exposure over time will damage the catalyst. Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty.

  • Page 60: Fluid Specifications

    All Models Capacity Fluid Type Engine oil (with filter) 8.5 L (9 US qt) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 Seawater cooling system (winterization 20 L (21 US qt) Propylene glycol and purified water use only) Mercury Extended Life Coolant Antifreeze or extended life ethylene...

  • Page 61: Approved Power Trim Fluids

    Section 4 - Specifications Approved Power Trim Fluids Description Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W‑30 Obtain locally SAE Engine Oil 10W‑40 90-899883274 MARCH 2008 Page 53...
  • Page 62 Section 4 - Specifications Notes: Page 54 90-899883274 MARCH 2008...
  • Page 63 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 56 Throttle Cable..............72 Dealer Responsibilities............56 Shift Cable ‑ Typical............73 Maintenance................. 56 Sterndrive Unit and Transom Assembly......73 Do‑It‑Yourself Maintenance Suggestions......56 Sterndrive U‑joint Shaft Splines And O‑rings (Sterndrive Inspection................

  • Page 64: Owner/Operator Responsibilities

    It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Mercury 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.

  • Page 65: Inspection

    Check plug leads and electrical leads for damage. • Remove and inspect the propeller. If badly nicked, bent or cracked, contact your authorized Mercury MerCruiser dealer. • Repair nicks and corrosion damage on power package exterior finish. Contact your authorized Mercury MerCruiser dealer.

  • Page 66: 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 67: Engine Oil

    Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil Checking 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. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

  • Page 68: Filling

    Fluid Type Engine oil (with filter) 8.5 L (9 US qt) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 Check the oil level and replace the fill cap. Changing Oil and Filter See Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage.

  • Page 69: Engine Oil Drain Pump

    Section 5 - Maintenance Remove the drain plug from the oil drain hose. After oil has drained completely, install the drain plug in the oil drain hose. Push the hose through bilge drain and install the plug. Replace the engine oil filter. See Changing the Oil Filter. Engine Oil Drain Pump Loosen the oil filter to vent the system.

  • Page 70: Power-Assisted Steering Fluid

    Stop the engine and center the sterndrive unit. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Remove the fill cap from the power steering pump reservoir and observe the level. The oil level must be at the lower mark when the engine is cold and at the upper mark when the engine is warm.

  • Page 71: Engine Coolant

    Section 5 - Maintenance Engine Coolant Checking CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle.

  • Page 72: Changing

    Inspect the lubricant condition. If any water is visible at the bottom of the gear lube monitor, if water appears at the fill and drain plug hole, or if the gear lube appears discolored, contact your authorized Mercury MerCruiser dealer immediately. These conditions can indicate a water leak in the sterndrive.

  • Page 73: Changing

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. High Performance Gear Gear lube monitor 92-858064K01 Lubricant Replace the cap. Changing Remove the gear lube monitor from the bracket. Empty the contents into a suitable container. Install the gear lube monitor in the bracket. Bravo One Models: Remove the propeller.

  • Page 74: Power Trim Fluid

    IMPORTANT: If any water drains from the unit, or if the fluid appears milky, the sterndrive unit is leaking. See your authorized Mercury MerCruiser dealer. Lower the sterndrive unit so the propeller shaft is level. IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in sterndrive unit.

  • Page 75: Filling

    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 76: Cleaning The Flame Arrestor

    Section 5 - Maintenance EFI Electronic Control Module (ECM): The ECM requires a stable voltage source. During multiple engine operation, an onboard electrical device may cause a sudden drain of voltage at the engine's battery. The voltage may go below the ECM's minimum required voltage.

  • Page 77: Water-Separating Fuel Filter

    Section 5 - Maintenance Remove the IAC muffler from the slot in the air valve plate using needle‑nosed pliers. Air valve plate IAC muffler location 31654 Inspect the muffler for holes, cracks, or deterioration. Replace if damaged. IMPORTANT: Do not use a cleaner that contains methyl ethyl ketone and do not use cleaner on electrical connections. Clean the muffler with warm water and mild detergent.

  • Page 78: Gen Iii Models

    Removal Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Disconnect the Cool Fuel Module harness from the engine wiring harness.

  • Page 79: Lubrication

    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. Lubrication...

  • Page 80: Throttle Cable

    Lubricate the steering pin. Steering pin mc71904-1 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Steering pin 92‑883725K01 SAE25W‑40 On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.

  • Page 81: Shift Cable - Typical

    Guide contact surfaces mc79736 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Shift cable pivot points & 92‑883725K01 SAE25W‑40 guide contact surfaces Sterndrive Unit and Transom Assembly Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun.

  • Page 82: 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) Coat sterndrive U‑joint O‑rings and driveshaft splines with grease. Driveshaft splines U‑joint O‑rings (3) 8591 Tube Ref No. Description Where Used Part No. Engine Coupler Spline Driveshaft splines and U-joint O-rings 92-802869A 1 Grease For propeller shaft lubrication, refer to Propellers.

  • Page 83: Propellers

    Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Bravo Sterndrive 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 84 Section 5 - Maintenance Place a block of wood between the propeller blade and the sterndrives anti‑ventilation plate. Wood block Propeller Propeller nut under socket 4826 Turn the propeller shaft nut counterclockwise and remove the nut. Slide the propeller and the attaching hardware from the propeller shaft. Bravo One models Propeller shaft splines Forward thrust hub...

  • Page 85: Bravo Two Models

    Section 5 - Maintenance Bravo Two Models Straighten the bent tabs of the tab washer on the propeller shaft. Prop Tab washer Drive sleeve adapter Tab bent down Propeller nut 4750 Place a block of wood between the propeller blade and the sterndrives anti‑ventilation plate. Wood block Propeller Propeller nut under socket...
  • Page 86 Section 5 - Maintenance Remove the propeller shaft anode. Propeller Propeller shaft nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer 19058 Turn aft propeller shaft nut counterclockwise to remove nut. Slide propeller and thrust hub off propeller shaft. Use the Propeller Nut Tool, turn the front propeller shaft nut counterclockwise and remove the nut.

  • Page 87: Bravo Sterndrive Propeller Installation

    Section 5 - Maintenance Bravo Sterndrive Propeller Installation 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 88: Bravo Two Models

    Section 5 - Maintenance Bravo One XR models Propeller shaft Propeller hub insert with snubbers Propeller Thick washer Washer Washer Propeller nut 19816 NOTE: The propeller torque stated is a minimum torque value. Description lb. in. lb. ft. Bravo One propeller nut –...

  • Page 89: Bravo Three

    Section 5 - Maintenance Torque the propeller nut. Bravo Two Propeller shaft splines Forward thrust hub Propeller Spline washer Tab washer Propeller nut 8566 NOTE: The propeller torque stated is a minimum torque value. Description lb. in. lb. ft. Bravo Two propeller nut –...

  • Page 90: Serpentine Drive Belt

    Section 5 - Maintenance Description lb. in. lb. ft. Bravo Three front propeller nut – Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub Align splines and install aft propeller. Install propeller nut and torque. Description lb.

  • Page 91: Replacing

    If the tensioner contacts either of the cast stops during operation, check the mounting brackets and the belt length. Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the cast stops. See your authorized MerCruiser dealer for service if these conditions exist. CAUTION Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage.

  • Page 92: Corrosion Protection

    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 93: Checking The Quicksilver Mercathode System

    Checking the Quicksilver MerCathode 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 . 90-899883274 MARCH 2008...

  • Page 94: 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 Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for proper application.
  • Page 95 If you are using copper based anti‑fouling paint, observe the following precaution: • 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 96: Sterndrive Surface Care

    Section 5 - Maintenance Sterndrive Surface Care Standard Bravo sterndrive Sacrificial trim cylinder anode Sacrificial anodic plate Steering lever ground wire Ground wire between the gimbal ring and bell housing Stainless steel hoses Ground wire between the gimbal housing and trim cylinder Ground wire between the gimbal ring and gimbal housing 21083 We recommend the following maintenance items to help keep your sterndrive corrosion‑free:...

  • Page 97: Flushing Attachments

    Sterndrive Water Pickups There are three types of water pickups available on Mercury MerCruiser sterndrives: low water, dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), low water pickups require the flushing attachment (849996T 1), and side pickups require the flushing attachment (44357Q 2).

  • Page 98: The Boat In The Water-Bravo Sterndrive

    13. Stop the engine. 14. Immediately shut off the supply water and remove the flushing attachment. 15. Install the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual. The Boat in the Water—Bravo Sterndrive IMPORTANT: Flushing the power package is most effective when performed with the boat and sterndrive out of the water.

  • Page 99: The Boat Out Of The Water-Alternative Water Pickups

    Place a block of wood between the propeller blade and the anti‑ventilation plate. Remove the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual. Close the seacock, if equipped.

  • Page 100: The Boat In The Water-Alternative Water Pickups

    15. Immediately shut off the supply water and remove the flushing attachment. 16. Install the water inlet hose to the seawater inlet of the seawater pump. Tighten the hose clamp securely. 17. Install the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual. The Boat in the Water—Alternative Water Pickups IMPORTANT: Flushing the power package is most effective when performed with the boat and sterndrive out of the water.
  • Page 101 Section 5 - Maintenance NOTE: Engines with the sterndrive water inlet blocked off at the gimbal housing: Refer to Alternative Water Pickups. 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 102 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. Quick-connect fitting stored in the boat Quick‑connect fitting (water hose end)
  • Page 103 Section 5 - Maintenance 20. Insert the dust cover in the flush socket on the engine. Dust cover installed in the flush socket Dust cover Flush socket 18490 IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If unit is to be stored out of the water, open the seacock.
  • Page 104 Section 5 - Maintenance Notes: Page 96 90-899883274 MARCH 2008...

  • Page 105: Section 6 - Storage

    Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........98 Boat in the Water ..........100 Preparing Power Package for Storage......98 Boat out of the Water .......... 102 Engine and Fuel System Preparation ....98 Manual Drain System..........

  • Page 106: Cold Weather Or Extended 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. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures.

  • Page 107: Draining The Seawater System

    Section 6 - Storage NOTICE Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation. In a 23 liter (6 US gal.) remote fuel tank mix: 19 liter (5 US gal.) regular unleaded 87 octane (90 RON) gasoline 1.89 liter (2 US qt.) Premium Plus 2‑Cycle TC‑W3 Outboard Oil 150 ml (5 oz) Fuel System Treatment and Stabilizer or 30 ml (1 oz) Fuel System Treatment and Stabilizer Concentrate Tube Ref No.

  • Page 108: Drain System Identification

    Section 6 - Storage Drain System Identification Air Actuated Single Point Drain System Actuator fitting Green indicators Manual release valve 8294 Port side drain location Starboard side drain location 17254 Manual Drain System Blue drain plug locations 17255 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.
  • Page 109 11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. 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 110: Boat Out Of The Water

    Section 6 - Storage 13. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Green indicators 6135 14. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine. Boat out of the Water NOTE: This procedure is written for the air pump that is attached to the engine.
  • Page 111 11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. 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 112: Manual Drain System

    Verify that water is draining from each opening. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.

  • Page 113: Battery Storage

    IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
  • Page 114 Section 6 - Storage Carefully inspect the engine for fuel, oil, fluid, water and exhaust leaks. Inspect the steering system, shift and throttle control for proper operation. Page 106 90-899883274 MARCH 2008...

  • Page 115: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........... 108 Insufficient Engine Temperature........109 Diagnosing DTS Problems..........108 Low Engine Oil Pressure..........110 Engine Guardian System............ 108 Battery Will Not Recharge........... 110 Troubleshooting Charts............108 Remote Control Is Difficult to Move, Has Excessive Play, Starter Motor Will Not Crank Engine, or Cranks Slowly or Makes Unusual Sounds...........

  • Page 116: Diagnosing Efi Problems

    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 117: Engine Runs Rough, Misses, Or Backfires

    Clean Flame Arrestor. Faulty ignition system component. Service ignition system. Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer. EFI System fault. Have EFI System checked by an authorized Mercury MerCruiser dealer. Poor Performance Possible Cause Remedy Throttle not fully open.

  • Page 118: Low Engine Oil Pressure

    Check all throttle linkages. If any are loose or missing, see authorized Loose or missing shift and throttle linkages. Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury MerCruiser dealer Shift or throttle cable kinked. replace cable if damaged beyond repair.

  • Page 119: Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move)

    Section 7 - Troubleshooting Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low. Fill pump with oil. Drive unit binding in gimbal ring. Check for obstruction. 90-899883274 MARCH 2008 Page 111...
  • Page 120 Section 7 - Troubleshooting Notes: Page 112 90-899883274 MARCH 2008...

  • Page 121: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance..........114 Parts and Accessories Inquiries ......114 Local Repair Service ..........114 Resolving a Problem ..........114 Service Away From Home .......... 114 Mercury Marine Service Offices .........

  • Page 122: Owner Service Assistance

    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. If you need additional assistance: Talk with the dealership's sales manager or service manager.

  • Page 123: Mercury Marine Service Offices

    • 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...

  • Page 124: Outside The United States And Canada

    Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature. Please return with payment to:...

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