Mercury Sterndrive QSD 2.0 Manual

Mercury Sterndrive QSD 2.0 Manual

Diesel engine
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Declaration of Conformity for Recreational Craft Propulsion Engines with the
requirements of Directive 94/25/EC as amended by 2003/44/EC
(To be completed by manufacturer of inboard engines and z or sterndrive engines without integral exhaust)
Name of engine manufacturer: V M MOTORI, s.p.a.
Address: VIA FERRARESE, 29
Town: CENTO (FE)
Name of Authorized Representative: Brunswick Marine in EMEA Inc.
Address: Parc Industriel de Petit‑Rechain
Town: Verviers
Name of Notified Body for exhaust emission assessment: T Ü V PRODUCT SERVICE Gmbh
Address: RIDLERSTRASSE, 65
Town: MÜNICH
Name of Notified Body for noise emission assessment: International Marine Certification Institute (IMCI)
Address: Rue Abbé Cuypers 3
Town: Bruxelles
Conformity assessment module used for exhaust emissions:
Conformity assessment module used for noise emissions:
Other Community Directives applied: Electromagnetic Compatibility Directive 2004/108/EC
——————————————————————————————————————————————————
Description of Engines and Essential Requirements
Engine Type:
z or sterndrive with integral exhaust
IDENTIFICATION OF ENGINE(S) COVERED BY THIS DECLARATION OF CONFORMITY
Name of engine model or engine
family:
QSD 4.2L 350/320/270
QSD 2.8L 230/220/210/170
QSD 2.0L 170/150/130/115
Essential requirements
Annex I.B–Exhaust Emissions
B.1 engine identification
B.2 exhaust emission requirements
B.3 durability
B.4 owner's manual
Annex I.C–Noise Emissions
C.1 Noise emission levels
Post Code: 44042
Post Code: 4800
Post Code: 80339
Post Code: B‑1040
Unique engine identification
number(s) or engine family code(s)
MR706LX / MR706LH / MR706LS
MR704LX / MR704LY / MR704LH /
MR704LS
MR504LX / MR504LH / MR504LS /
MR504LB
Standards
☒*
Country: ITALY
Country: Belgium
Country: GERMANY
Country: Belgium
☒ B+C ☐ B+D ☐ B+E ☐ B+F ☐ G ☐ H
☐ A
☒ Aa
Fuel Type:
Diesel
EC Type–examination certificate or
type‑approval certificate number
SB5 06 08 57278 006
SB5 08 07 57278 008
SB5 07 07 57278 007
Other
normative
Technical
document/
file
method
*EN ISO 8178‑1:1996
ISO 8665:1995
*EN ISO 14509
ID Number: 0123
ID Number: 0609
☐ G
☐ H
Combustion Cycle:
4 stroke
Please specify in more detail
(* = mandatory standard)

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Summary of Contents for Mercury Sterndrive QSD 2.0

  • Page 1 Declaration of Conformity for Recreational Craft Propulsion Engines with the requirements of Directive 94/25/EC as amended by 2003/44/EC (To be completed by manufacturer of inboard engines and z or sterndrive engines without integral exhaust) Name of engine manufacturer: V M MOTORI, s.p.a. Address: VIA FERRARESE, 29 Town: CENTO (FE) Post Code: 44042...
  • Page 2 Length Exhaust Gas Emissions Certification Number The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Diesel power package. When contacting Mercury Marine about service, always specify model and serial numbers. Descriptions and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policies are based on 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 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty sections of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.
  • Page 5: Table Of Contents

    Conditions That Must Be Met to Obtain Warranty How to Obtain Warranty Coverage......... 5 Coverage................ 3 What Is Not Covered............5 What Mercury Marine Will Do......... 3 Transfer of Warranty............5 Section 2 - Getting to Know Your Power Package Identification................8 VesselView...............
  • Page 6 Bottom of Boat..............32 Sterndrive 10‑Hour Break‑In Period (New or With Cavitation................ 32 Replacement Gears)............34 Ventilation................ 33 Engine Break‑In............... 34 Elevation and Climate............. 33 20‑Hour Break‑In Period..........34 Propeller Selection............33 After the 20‑Hour Break‑In Period....... 34 Getting Started............... 33 End of First Season Checkup..........
  • Page 7 Engine Coupler..............94 Bravo Two Models............100 Driveshaft Extension Models..........94 Bravo Three Models........... 101 Sterndrive, Bellows, and Engine Alignment...... 95 Bravo Diesel Sterndrive Propeller Installation....102 Maintaining Torques..............97 Bravo One Models............102 Alpha Gimbal Ring Clamp Bolt......... 97 Bravo Two Models............
  • Page 8 Page iv 90-8M0069751 APRIL 2012...
  • Page 9: Section 1 - Warranty

    Conditions That Must Be Met to Obtain Warranty How to Obtain Warranty Coverage ......5 Coverage ..............3 What Is Not Covered ..........5 What Mercury Marine Will Do ........3 Transfer of Warranty............5 90-8M0069751 APRIL 2012 Page 1...
  • Page 10: Warranty Information

    Warranty Registration United States and Canada To be eligible for warranty coverage, the product must be registered with Mercury Marine. At the time of sale, the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET, E‑mail, or mail. Upon receipt of this warranty registration, Mercury Marine will record the registration.
  • Page 11: High-Output Rating

    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 Mercury Marine specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
  • Page 12: 3-Year Limited Warranty Against Corrosion-Diesel Models (Recreational Use Only)

    Section 1 - Warranty • Use of an accessory or part that was not manufactured or sold by Mercury Marine and that damages the Mercury product • Jet pump impellers and liners • Operation with fuels, oils, or lubricants that are not suitable for use with the product (see the Operation, Maintenance &...
  • Page 13: How To Obtain Warranty Coverage

    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, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair.
  • Page 14 Section 1 - Warranty Notes: Page 6 90-8M0069751 APRIL 2012...
  • Page 15: 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................8 VesselView..............14 Serial Number Decal............8 System Tachometer or Speedometer......14 Data Label Location............8 Features And Controls............15 Engine Data Label............
  • Page 16: Identification

    Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.
  • Page 17: Alpha Sterndrive Decal Identification

    Section 2 - Getting to Know Your Power Package The owner or operator is not to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission levels to exceed their predetermined factory specifications. Example QSD engine data label CE logo Engine weight Engine power rating...
  • Page 18: Bravo Sterndrive Serial Number And Identification

    Section 2 - Getting to Know Your Power Package Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port side of the sterndrive. 33533 Bravo sterndrive information on ground plate The serial number is also stamped as a permanent reference on the sterndrive casting inside the back cover.
  • Page 19: Instrumentation-Qsd Sterndrive Models

    Instrumentation—QSD Sterndrive Models Digital Gauges A Mercury Marine SmartCraft instrument package may be provided with this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, battery voltage, fuel consumption, and engine operating hours.
  • Page 20: Vesselview (If Equipped)

    Section 2 - Getting to Know Your Power Package The following types of gauges may be included with your power package. 26019 Typical gauges Reference Gauge Function Oil pressure gauge Indicates engine oil pressure. Battery meter Indicates battery voltage. Coolant temperature gauge Indicates engine operating temperature.
  • Page 21: Switches

    Section 2 - Getting to Know Your Power Package Switches Key switch Bilge blower switch (if equipped) 24735 Reference Switch Function Key switch Has four positions. "OFF." In the "OFF" position, all electrical circuits are off and the engine cannot be started. The engine is stopped when the key switch is turned to the "OFF"...
  • Page 22: Engine Monitoring Features

    Audio Warning System Your Mercury Marine power package is equipped with an audio warning system. The audio warning system monitors critical components and informs the operator when a malfunction has occurred. The warning system is not capable of protecting the power package from damage caused by a malfunction.
  • Page 23: Features And Controls

    30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting, some fault codes are still being displayed, contact your authorized Mercury Diesel repair facility. 90-8M0069751...
  • Page 24: Lanyard Stop Switch

    Digital Throttle and Shift Applications For Digital Throttle and Shift (DTS) applications and electronic remote control (ERC) operation refer to the Mercury Marine SmartCraft and DTS Owner's Manual.
  • Page 25: Remote Controls

    Section 2 - Getting to Know Your Power Package Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote control. All controls may not have all features shown. Consult your dealer for a description or demonstration of your remote control.
  • Page 26: Power Trim

    Section 2 - Getting to Know Your Power Package 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 27: Single-Engine Trim And Trailer

    If the replacement fuse also blows then the electrical overload has not been eliminated. Further checks must be made on the electrical system. Do not circumvent the electrical overload protection provided on fused circuits by installing a Contact your Mercury Diesel authorized repair facility. higher amperage fuse or shorting across the fuse block terminals.
  • Page 28: Vessel Integration Panel (Vip) Overload Protection

    Replace the fuse. If the fuse burns out, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your Mercury Diesel authorized repair facility. Page 20...
  • Page 29 Section 2 - Getting to Know Your Power Package The power trim system is protected from overload by a 110‑amp fuse and a 20‑amp in‑line fuse on the power trim pump. 20‑amp in‑line fuse holder 110‑amp fuse 9208 The Quicksilver three‑button power trim control panel, if equipped, is protected from overload by a 20‑amp in‑line fuse. 20‑amp in‑line fuse The Quicksilver MerCathode System, if equipped, has a 20‑amp in‑line fuse in the wire that connects to the positive (+) terminal on the controller.
  • Page 30 Section 2 - Getting to Know Your Power Package Notes: Page 22 90-8M0069751 APRIL 2012...
  • Page 31 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions............ 24 High‑Speed and High‑Performance....... 30 Be Alert to Carbon Monoxide Poisoning....... 25 Passenger Safety In Pontoon Boats And Deck Boats... 30 Good Ventilation ............25 Boats Having An Open Front Deck .......
  • Page 32: Safe Boating Suggestions

    Mercury Marine strongly recommends that all powerboat operators complete a boating safety course. Courses are offered in the U.S.A. by the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency.
  • Page 33: Be Alert To Carbon Monoxide Poisoning

    IMPORTANT: Install the bilge drain plug before launching the boat. Duty Cycle Rating Requirements IMPORTANT: Damage caused by incorrect application or failure to operate the power package within the specified operating parameters will not be covered by the Mercury Marine Limited Warranty. 90-8M0069751 APRIL 2012...
  • Page 34: High-Output Rating

    The power package must be equipped with a gear ratio and propeller that allows the engine to operate at wide open throttle (WOT) at the engine's rated speed (RPM). Use of Mercury Diesel engines in applications that do not meet specified operational parameters is not approved.
  • Page 35: Starting, Shifting, And Stopping

    Ensure that all electrical connections are secure. • Check all items listed in the Maintenance Schedules and Operation Chart. • Perform any other necessary checks as indicated by your Mercury Diesel authorized repair facility or specified in your boat owner’s manual. Starting a Cold Engine WARNING A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
  • Page 36: Engine Warm Up

    Check the engine and the transmission, oil filter, oil lines, oil line connectors, and oil pan for leaks. Check the coolant hoses, heat exchanger connections, aftercooler, water pump, and drain fittings for leaks. Locate and correct any problems, or see your Mercury Diesel authorized repair facility if you are unable to determine the problem.
  • Page 37: Starting The Engine After Stopped While In Gear

    At temperatures of –20° C (–4° F) and below, use a coolant heater to improve cold starting. • If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for information about special cold weather equipment and precautions.
  • Page 38: Protecting People In The Water

    If your boat is considered a high‑speed or high‑performance boat, we recommend that you never operate it at its high‑speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to the Hi‑Performance Boat Operation booklet from your Mercury Diesel authorized repair facility.
  • Page 39: Wave And Wake Jumping

    Section 3 - On the Water Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. mc79557-1 Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.
  • Page 40: Sterndrive Impact Protection

    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 Diesel repair facility for a thorough inspection and any necessary repair.
  • Page 41: Ventilation

    It is important to follow this procedure to properly break in the engine. IMPORTANT: Mercury Marine recommends that the boat not be accelerated hard until this procedure has been completed. IMPORTANT: Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool;...
  • Page 42: Sterndrive 10-Hour Break-In Period (New Or With Replacement Gears)

    Check the engine oil level frequently. Add oil as needed. High oil consumption is normal during the break‑in period. After the 20-Hour Break-In Period To help extend the life of your power package, Mercury Marine recommends the following: • Change the engine oil and filter and the transmission fluid at the interval indicated in the Maintenance Schedule. Refer to Specifications and Maintenance.
  • Page 43 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 36 Engine................38 Recommended Fuels............36 QSD 2.0 ..............38 Diesel Fuel in Cold Weather..........36 Alpha Sterndrive Fluid Specifications......39 Coolant (Antifreeze).............. 37 Bravo Sterndrive Fluid Specifications—Diesel....39 Engine Oil................
  • Page 44: Fuel Requirements

    Section 4 - Specifications Fuel Requirements WARNING Failure to comply with regulations can result in injury from fire or explosion. Electrical system components on this engine are not rated as external ignition–protected (EIP). Do not store or use gasoline on boats equipped with these engines, unless provisions have been made to exclude gasoline vapors from the engine compartment (REF: 33 CFR).
  • Page 45: Coolant (Antifreeze)

    We strongly recommend the use of: Description Where Used Part Number Mercury 4‑ Cycle 15W40 Marine Engine Oil Engine crankcase 92‑877695K1 This oil is a specially blended 15W40 oil with marine additives for all–temperature operation. It exceeds requirements for API CF‑2, CF‑4, CG‑4 and CH‑4 oils.
  • Page 46: Engine Specifications

    Texaco Ursa Super TD Engine crankcase Obtain Locally Wintershall Multi‑Rekord Veedol Turbostar Wintershall VIiva 1 These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W40 oil. Engine Specifications Specifications Description QSD 2.0 Engine type In‑line 4‑cylinder diesel...
  • Page 47: Alpha Sterndrive Fluid Specifications

    All Applications Description Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W‑30 Obtain locally SAE Engine Oil 10W‑40 Approved Paints Description Part Number Marine Cloud White 8M0071082 Mercury Light Gray Primer 92‑80287852 90-8M0069751 APRIL 2012 Page 39...
  • Page 48 Section 4 - Specifications Description Part Number Mercury Phantom Black 92‑802878Q1 Page 40 90-8M0069751 APRIL 2012...
  • Page 49 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner and Operator Responsibilities........42 Fuel Tank Cleaning and Flushing........70 Dealer Responsibilities............42 Seawater System..............70 Maintenance................. 42 Draining the Seawater System........70 Do‑It‑Yourself Maintenance Suggestions......42 Sterndrive Water Inlets Check........72 General Inspection...............
  • Page 50: Owner And 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 a Mercury Diesel authorized repair facility for a periodic checkup.
  • Page 51: Engine Cover

    IMPORTANT: See Maintenance Schedule for a complete listing of all scheduled maintenance to be performed. Some listings can be done by the owner or operator, while others should be performed by a Mercury Diesel authorized repair facility. Before attempting maintenance or repair procedures not covered in this manual we recommended that you purchase the appropriate Mercury Diesel or Mercury MerCruiser Alpha Sterndrive Service Manuals, and read thoroughly.
  • Page 52: Scheduled Maintenance-Alpha And Bravo Models

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Check the engine oil level (This task interval can be extended based on operator experience with the product). • Check the engine coolant level. Each day start • Check the power‑assisted steering fluid level. •...
  • Page 53: Maintenance Log

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Change the engine oil and filter. • Change the sterndrive gear lube. • Torque the gimbal ring U‑bolt locknuts. • Replace the fuel filters. • Check the steering system and the remote control for loose, missing, or damaged parts. Lubricate the cables and linkages.
  • Page 54 Section 5 - Maintenance Date Maintenance Performed Engine Hours Page 46 90-8M0069751 APRIL 2012...
  • Page 55: Engine Oil

    Part No. 15W40 4-cycle Diesel Engine crankcase 92-858042K01 Engine Oil Other recommended oils are listed in the following table. These oils are approved by Mercury Diesel and Marine Power Europe. Shell Myrina Texaco Ursa Super TD Veedol Turbostar Mopar Wintershall Multi‑Rekord Wintershall Viva 1 For all‑temperature operation use 15W‑40 oil.
  • Page 56: Filling

    Section 5 - Maintenance Remove the dipstick. Wipe clean and reinstall into the dipstick tube. QSD 2.0L engine oil service Engine cover with access panel removed Engine oil fill cap Engine oil dipstick 27986 Remove the dipstick and observe the oil level. The oil level must be between the marks on the dipstick. If necessary, add oil.
  • Page 57: Changing Oil And Filter

    Section 5 - Maintenance Add the specified oil to bring the oil level up to, but not over, the maximum mark on the dipstick. Coolant oil cooler Seawater oil cooler 33988 Engine Coolant Oil Cooler QSD 2.0 System Capacity Fluid Type Part Number Engine oil (with filter) 5.85 L (6.20 US qt)
  • Page 58 Section 5 - Maintenance Crankcase oil pump 91‑90265A 5 Aids in the removal of engine oil without draining the crankcase. 11591 Pump the oil out of the crankcase into a drain pan. Remove the oil filter housing drain plug and drain the oil into an appropriate container. 33987 Engine coolant oil cooler Seawater oil cooler...
  • Page 59 Section 5 - Maintenance 12. Remove and discard the old filter element. Discard the old cover O‑ring. 33986 Engine coolant oil cooler Seawater oil cooler Oil filter cover O‑ring Filter element 13. Apply sealant to the threads of the oil filter housing drain plug and install. 33987 Engine coolant oil cooler Seawater oil cooler...
  • Page 60: Alpha Sterndrive Gear Lube

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. 15W40 4-cycle Diesel Oil filter O-rings 92-858042K01 Engine Oil 16. Push the filter element into the cover until it is locked. Listen for a click. 33986 Engine coolant oil cooler Seawater oil cooler Oil filter cover O‑ring...
  • Page 61: Filling

    IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lube is required to fill the gear lube monitor, a seal may be leaking. Damage to the sterndrive may occur due to lack of lubrication. Contact your Mercury Diesel authorized repair facility.
  • Page 62: Changing

    Section 5 - Maintenance Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap. Do not overtighten. Gear lube monitor cap 19962 NOTE: When filling the entire sterndrive, Refer to Changing . Changing Remove the gear lube monitor from the bracket. Retaining bracket Gear lube monitor 25339...
  • Page 63 IMPORTANT: If any water drained from the gear lube fill and drain hole, or if the oil appears milky, the sterndrive is leaking and should be checked immediately by your Mercury Diesel authorized repair facility. Lower the sterndrive so that the propeller shaft is level. Fill the sterndrive through the gear lube fill and drain hole, with the specified gear lubricant until an air‑free stream of lubricant flows from gear lube vent hole.
  • Page 64: Bravo Sterndrive Gear Lube

    IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lube is required to fill the gear lube monitor, a seal may be leaking. Damage to the sterndrive may occur due to lack of lubrication. Contact your Mercury Diesel authorized repair facility .
  • Page 65: Changing

    Section 5 - Maintenance Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap. Do not overtighten. Gear lube monitor cap 19962 NOTE: When filling the entire sterndrive, see Changing . Changing Remove the gear lube monitor from the bracket. Gear lube monitor bracket Gear lube monitor and cap Retaining strap...
  • Page 66 IMPORTANT: If any water drains from the fill and drain plug hole, or if the gear lube appears milky, the sterndrive is leaking and should be checked immediately by your Mercury Diesel authorized repair facility. Lower the sterndrive so that the propeller shaft is level.
  • Page 67 Section 5 - Maintenance 12. Fill the gear lube monitor so that the gear lube level is in the operating range. Do not overfill. Gear lube monitor Gear lube level at the "ADD" mark Gear lube level at the "OPERATING RANGE" mark Gear lube monitor cap 19947 Fluid Capacity includes...
  • Page 68: Power Trim Fluid

    Section 5 - Maintenance Description lb–in. lb–ft Fill and drain plug – 16. Install the sterndrive propeller. See Propellers. 17. Recheck the gear lube level at the gear lube monitor after the first use. See Checking. IMPORTANT: The gear lube level in the gear lube monitor will rise and fall during sterndrive operation; always check the gear lube level when the sterndrive is cool and the engine is shut down.
  • Page 69: Changing

    Fluid Install the fill cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your Mercury Diesel authorized repair facility. Power‑Assisted Steering Fluid IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid (ATF) in the power‑assisted steering system.
  • Page 70: Filling

    Section 5 - Maintenance IMPORTANT: If fluid is not visible in the fluid reservoir, see your Mercury Diesel authorized repair facility. Filling Remove the fill cap and dipstick and observe the fluid level. Add the specified fluid to bring the fluid level up to the proper level.
  • Page 71: Filling

    14142 The pressure cap maintains pressure on the cooling system and may not be holding pressure properly. To have the cap tested, contact your Mercury Diesel authorized repair facility. Add the specified coolant as necessary. See Filling. IMPORTANT: When installing the pressure cap, be sure to tighten it securely to prevent coolant loss.
  • Page 72: Air Filter

    Section 5 - Maintenance Air Filter Removal Loosen the clamp and remove the oil separator vent hose. Loosen the clamp and remove the air filter housing from the turbocharger inlet. Air filter housing installed on engine Air filter housing Oil separator vent hose Air intake retaining clamp 25357 Remove the air filter element from the air filter housing...
  • Page 73: Water-Separating Fuel Filter

    Section 5 - Maintenance Slide the filter element into the air filter housing. Ensure that the element is seated fully into the air filter housing. Air filter housing Air filter element 25893 NOTE: The warning labels on the air filter housing must be visible after the air filter housing is installed. Install the air filter housing on to the turbocharger inlet.
  • Page 74: Draining

    Section 5 - Maintenance IMPORTANT: Use a suitable container to collect fuel. Clean up any spills immediately and dispose of fuel in a safe manner in accordance with all local, federal, and international regulations. The engine‑mounted water‑separating fuel filter is equipped with a water‑in‑fuel (WIF) sensor that should alert the operator when water is present in the filter.
  • Page 75 Section 5 - Maintenance Remove the water‑separating fuel filter and sealing ring from the mounting bracket. Do not use a filter wrench. Typical Water‑separating fuel filter 23459 NOTE: It may be necessary to keep the existing drain cap and use it on the new filter. Be sure to replace the O‑ring on the drain cap.
  • Page 76: Filling

    13. Connect the battery cables. 14. Start and operate the engine. Check the filter connection for fuel leaks. If leaks exist, recheck the filter installation. If leaks continue, stop the engine immediately and contact your Mercury Diesel authorized repair facility. Filling A type of hand pump and primer plunger is located on the fuel filter bracket and is used to •...
  • Page 77: Fuel System

    Section 5 - Maintenance Loosen the air vent (bleed) screw on the fuel filter bracket. Typical Air vent screw 23469 Move the primer plunger up and down repeatedly. The filter is full when an air‑free stream of fuel flows from the air vent screw.
  • Page 78: Filling (Bleeding)

    Section 5 - Maintenance Move the primer plunger up and down repeatedly. Fuel priming pump 25985 Attempt to start the engine. Filling (Bleeding) NOTE: Follow this procedure if the fuel system was run dry or if part of the fuel system was drained for a service function. See Water Separating Fuel Filter ‑...
  • Page 79 Section 5 - Maintenance If the boat is to remain in the water, turn on the bilge pump, close the seacock (if equipped), or disconnect and plug the seawater inlet hose. 25667 Typical seacock installation Make the engine as level as possible to ensure complete draining of the seawater system. Attach a temporary drain hose to the barbed fitting of the seawater drain valve.
  • Page 80: Sterndrive Water Inlets Check

    Section 5 - Maintenance On models equipped with a seawater strainer, remove the hoses at the seawater strainer and drain them completely. Drain and empty the seawater strainer. Reconnect the hoses and tighten the hose clamps securely. Typical Seawater inlet Seawater outlet Seawater strainer cover 25831...
  • Page 81: Checking The Seawater Pickups

    Section 5 - Maintenance Bravo sterndrive dual pickup water inlet locations Dual water pickup water inlets Side pickup water inlets 22495 Checking the Seawater Pickups Ensure that the water inlet holes for the seawater pickup are clean and not obstructed. 16776 Typical through-hull seawater pickup Typical through-transom seawater pickup...
  • Page 82 Section 5 - Maintenance Remove the seawater strainer cover by turning it counterclockwise by hand. Seawater inlet Seawater outlet Seawater strainer cover 25831 Remove the strainer from the strainer housing and clean out any debris. Flush the strainer with clean water. Clean out any debris from the strainer housing and flush with clean water.
  • Page 83: Flushing The Seawater System-Alpha Sterndrives

    Flushing the Seawater System—Alpha Sterndrives IMPORTANT: Your Mercury Alpha sterndrive power package has the sterndrive‑to‑engine seawater supply port blocked off at the gimbal housing and uses an alternative seawater inlet to supply cooling water for the engine. When flushing the seawater system a supply of cooling water must be provided to both the sterndrive and the engine during operation.
  • Page 84 Section 5 - Maintenance Install the appropriate flushing attachment over the water inlet holes in the gear housing. 5773 Alpha Sterndrive Side Pickup Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 Lower the sterndrive to full down position.
  • Page 85: Flushing The Seawater System-Bravo Sterndrives

    Section 5 - Maintenance Connect a second flushing hose from a water tap to the seawater inlet hose connector or to the seawater pump inlet using an appropriate adapter. Seawater pump inlet Seawater pump Seawater pump outlet Fuel cooler (if equipped) 25668 With the sterndrive in the normal operating position, partially open both the sterndrive and engine flushing water supplies (about 1/2 maximum flow).
  • Page 86 Section 5 - Maintenance Close the seacock, if equipped, or disconnect and plug the seawater inlet hose. 13171 Seacock Seawater inlet hose Plug Raise the sterndrive to trailer position. Install the appropriate flushing attachment over the water inlet holes in the gear housing. 21514 21515 Flushing attachments for dual water pickup...
  • Page 87 Section 5 - Maintenance Dual Water Pick‑up Flush Gearcase Seal 91‑881150K 1 Blocks off the front water inlet holes on the dual water inlet gearcases. 9194 Lower the sterndrive to full down position. If flushing the seawater system with the boat out of the water: Lower sterndrive to full down position.
  • Page 88: Engine Seawater Pump Inspection

    Mercury Diesel authorized repair facility. Replacing the Engine Coolant Draining the Closed‑Cooling System IMPORTANT: Due to the complex nature of this service Mercury Diesel strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. 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 89: Filling The Closed Cooling System

    25768 Ensure that the coolant has drained completely. If required, clean the closed cooling system. See your local Mercury Diesel authorized repair facility. Install and tighten the engine coolant drain plug. Reinstall the water–separating fuel filter. Refer to Water–Separating Fuel Filter, Replacing.
  • Page 90: Corrosion Protection

    To help control the effects of galvanic corrosion, Mercury power packages come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection refer to the Marine Corrosion Protection Guide.
  • Page 91: Cleaning And Inspection

    Section 5 - Maintenance NOTICE Failure to close the seawater inlet or seacock when removing or replacing the anode plugs can lead to water damage. Close the seacock or remove and plug the seawater inlet hose to prevent water from entering the anode plug holes. With the engine off, close the seacock, if equipped, or remove and plug the seawater inlet hose.
  • Page 92: Installation

    Section 5 - Maintenance Installation Install a new sealing washer on the anode assembly (anode plug with the sacrificial anode). Anode assembly Sealing washer 19227 Install the anode assembly and washer into the aftercooler end cover. Tighten securely. 25583 Seawater system anode assembly location Unplug and connect the seawater inlet hose, or open the seacock if equipped.
  • Page 93: Sterndrive Corrosion Protection Components

    Section 5 - Maintenance Sterndrive Corrosion Protection Components To help control the effects of galvanic corrosion, Mercury Diesel sterndrives come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection, refer to the Marine Corrosion Protection Guide.
  • Page 94 MerCathode System—The electrode assembly, if equipped, replaces the anode block. The system should be tested to ensure adequate output. Perform the test when the boat is moored, using a Quicksilver reference electrode and test meter. Contact your Mercury Diesel authorized repair facility. Page 86...
  • Page 95 Section 5 - Maintenance Description Location Figure Alpha sterndrive Mounted on the underside of the lower gearcase. gearcase anodic plate 22405 Bravo sterndrive Mounted on the underside of the lower gearcase. gearcase anode plate 20336 Alpha and Bravo sterndrive Mounted on the front of the gearcase. ventilation plate anode 20338 Alpha and Bravo sterndrive...
  • Page 96: Alpha Sterndrive Continuity Circuit Inspection

    Section 5 - Maintenance Alpha Sterndrive Continuity Circuit Inspection The transom assembly and sterndrive unit are equipped with ground‑circuit wires to ensure good electrical continuity between the engine, transom assembly, and sterndrive components. Good continuity to a ground is essential for the anode and MerCathode system to function most effectively.
  • Page 97 Section 5 - Maintenance Inspect the gimbal housing ground wires for loose connections, broken connectors, or frayed wiring. Gimbal housing–to–gimbal ring ground wire Gimbal housing–to–trim cylinder ground wires 7006 Inspect the flywheel housing grounding stud, ground wire, and the inner transom plate grounding screw for loose connections, broken connectors, or frayed wiring.
  • Page 98: Mercathode

    Use to check hull potential. 9188 Refer to the appropriate Mercury MerCruiser sterndrive service manual for testing procedures. Painting Your Power Package IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint will not be covered by the limited warranty.
  • Page 99: Lubrication

    Section 5 - Maintenance • Avoid any electrical interconnection between the paint and the Mercury MerCruiser product, anodic blocks, or MerCathode system by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on the transom of the boat around these items.
  • Page 100 Section 5 - Maintenance Turn the steering wheel until the steering cable is fully extended. Lightly lubricate the exposed part of the cable. Extended steering cable 6222 Tube Ref No. Description Where Used Part No. Special Lubricant 101 Steering cable 92-802865Q02 Lubricate the steering pin.
  • Page 101: Throttle Cable

    Section 5 - Maintenance Throttle Cable Lubricate the pivot points and guide contact surfaces. Pivot points Guide contact surfaces 23643 Tube Ref No. Description Where Used Part No. SAE Engine Oil 30W Throttle cable pivot points and guide contact surfaces Obtain Locally Shift Cable Lubricate the pivot points and guide contact surfaces.
  • Page 102: Transom Assembly

    Section 5 - Maintenance Transom Assembly Lubricate the gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun. Gimbal bearing grease insert 19979 Tube Ref No. Description Where Used Part No. U-joint and Gimbal Gimbal bearing grease insert 92-802870A1 Bearing Grease Engine Coupler...
  • Page 103: Sterndrive, Bellows, And Engine Alignment

    Sterndrive, Bellows, and Engine Alignment NOTE: Have your Mercury Diesel authorized repair facility perform the maintenance procedures listed, or refer to the appropriate Mercury MerCruiser Alpha Sterndrive Service Manual . Lubricate the sterndrive U‑joint O‑rings and driveshaft splines.
  • Page 104 Section 5 - Maintenance 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, See Propellers. Inspect the U‑joint bellows for cracks or other signs of deterioration. Ensure that the bellows clamps are tight. Rotate the bell housing in the upward and side‑to‑side directions to inspect the exhaust bellows, shift cable bellows, and clamps.
  • Page 105: Maintaining Torques

    Section 5 - Maintenance Check the engine alignment. 7936 Alignment tool End of alignment tool to insert through gimbal housing assembly Gimbal bearing Engine coupler Maintaining Torques Alpha Gimbal Ring Clamp Bolt NOTE: The gimbal ring is a component of the transom assembly. Torque the gimbal ring clamp bolts.
  • Page 106: Engine Mounts

    Section 5 - Maintenance Tighten the gimbal ring U‑bolt nuts to specification. Transom assembly Gimbal ring U‑bolt nuts 19624 Description lb–in. lb–ft Gimbal ring U‑bolt nuts for 3/8 in. U‑bolt – Gimbal ring U‑bolt nuts for 7/16 in. U‑bolt – Engine Mounts Loosen the rear engine mount bolts 1 to 1‑1/2 turns.
  • Page 107: Alpha Propeller Installation

    Section 5 - Maintenance Turn propeller shaft nut counterclockwise to remove nut. Slide tab washer, drive sleeve, propeller and thrust hub off propeller shaft. 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.
  • Page 108: Bravo One Models

    Section 5 - Maintenance Bravo One 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 sterndrive's anti‑ventilation plate. Wood block Propeller Propeller nut under socket...
  • Page 109: Bravo Three Models

    Section 5 - Maintenance Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate. Wood block Propeller Propeller nut under socket Turn the propeller shaft nut counterclockwise to remove the nut. Slide the propeller and attaching hardware from the propeller shaft. Bravo Two Propeller shaft splines Forward thrust hub...
  • Page 110: Bravo Diesel Sterndrive Propeller Installation

    Section 5 - Maintenance Slide the propeller and the thrust hub off the propeller shaft. Bravo Three Aft propeller nut Aft propeller Aft propeller thrust hub Front propeller nut Front propeller Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer Propeller shaft anode 5304...
  • Page 111: Bravo Two Models

    Section 5 - Maintenance Torque the propeller nut. Typical Bravo One models Propeller shaft splines Forward thrust hub Flo‑Torque II drive hub Propeller Drive sleeve adapter Tab washer Propeller nut 5301 NOTE: The propeller torque stated is a minimum torque value. Description lb–in.
  • Page 112: 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 Then align tabs with groves Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer.
  • Page 113: Drive Belts

    Section 5 - Maintenance Description lb–in. lb–ft Bravo Three front propeller nut – Slide the aft thrust hub onto the propeller shaft with the tapered side toward the propeller hub. Align the splines and install the aft propeller. Install the propeller nut and torque. NOTE: The propeller torque stated is a minimum torque value.
  • Page 114: Power-Assisted Steering Pump Belt Inspection

    Cracks • Fiber fraying • Glazed surfaces Replace the belt if worn or damaged it must be replaced. See your Mercury Diesel authorized repair facility. Power–assisted steering stretch belt Power–assisted steering pump pulley Crankshaft pulley 25604 There is no adjustment available for the power‑assisted steering pump stretch‑belt. If the belt becomes loose or noisy, it has worn out and must be replaced.
  • Page 115: Battery

    See your Mercury Diesel authorized dealer for all of your repair needs. There is no adjustment available for the serpentine belt. If the belt becomes loose or noisy, it has worn out and must be replaced.
  • Page 116 Section 5 - Maintenance Battery Switches. Battery switches should always be positioned so that each engine is operating off of its own battery. Do not operate engines with switches in the both or all position. In an emergency, another engine's battery can be used to start an engine with a dead battery.
  • Page 117 Section 6 - Storage Section 6 - Storage Table of Contents Cold‑Weather, Seasonal, and Extended Storage....110 Seasonal Storage Instructions........111 Cold Weather (Freezing Temperature), Seasonal Extended Storage Instructions........112 Storage, and Extended Storage........110 Battery................. 112 Cold Weather (Freezing Temperature) Storage..110 Recommissioning...............
  • Page 118: Cold-Weather, Seasonal, And Extended Storage

    Cold‑Weather, Seasonal, and Extended Storage Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage IMPORTANT: Mercury recommends this service be performed by a Mercury Diesel authorized repair facility. Damage caused by freezing is not covered by the Mercury Limited Warranty.
  • Page 119: Preparing Your Power Package For Seasonal Or Extended Storage

    If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged. IMPORTANT: Mercury Marine recommends the use of propylene glycol antifreeze in the seawater section of the cooling system for cold weather (freezing temperature), seasonal storage, or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
  • Page 120: Extended Storage Instructions

    Read all precautions and perform all procedures found in Seasonal Storage Instructions. IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight. Remove the seawater pump impeller and store away from direct sunlight. Refer to a Mercury Diesel authorized repair facility for additional information and service.
  • Page 121 Section 6 - Storage Install a fully charged battery. Clean the battery cable clamps and terminals. Reconnect the cables (refer to the CAUTION listed above). Secure each cable clamp when connecting. Coat terminals with a battery terminal anti‑corrosion spray to help retard corrosion.
  • Page 122 Section 6 - Storage Notes: Page 114 90-8M0069751 APRIL 2012...
  • Page 123 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing Electronically Controlled Fuel System Problems Battery Will Not Charge..........117 .................... 116 Remote Control Operates Hard, Binds, Has Excessive Troubleshooting Charts............116 Free‑play, or Makes Unusual Sounds......118 Starter Motor Will Not Crank Engine, or Cranks Slow.
  • Page 124: Diagnosing Electronically Controlled Fuel System Problems

    Diagnosing Electronically Controlled Fuel System Problems A Mercury Diesel authorized repair facility has the proper service tools for diagnosing problems on electronically controlled fuel systems. The engine control module (ECM) on these engines has the ability to detect problems with the system when they occur, and store a trouble code in the ECM's memory.
  • Page 125: Poor Performance

    Boat overloaded or improperly distributed. Reduce load or redistribute more evenly. Boat bottom fouled or damaged. Clean or repair as necessary. Have electronic fuel system checked by a Mercury Diesel authorized repair Electronic fuel system fault. facility. Incorrect Engine Temperature...
  • Page 126: Remote Control Operates Hard, Binds, Has Excessive Free-Play, Or Makes Unusual Sounds

    Drive belt loose or in poor condition. Replace or adjust. Insufficient lubrication on the steering components. Lubricate. Check all parts and fasteners; if any are loose or missing, see a Mercury Loose or missing steering fasteners or parts. Diesel authorized repair facility immediately.
  • Page 127 Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance..........120 Muut kielet ..............121 Local Repair Service ..........120 Autres langues ............121 Service Away From Home .......... 120 Andere Sprachen ............121 Stolen Power Package ..........
  • Page 128: Owner Service Assistance

    If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model number, serial number and to whom the recovery is to be reported. This information is filed at Mercury Marine to aid authorities, dealers and distributors in the recovery process.
  • Page 129: Customer Service Literature

    Pour obtenir un Manuel d'utilisation et d'entretien dans une autre langue, contactez le centre de service après‑vente international Mercury Marine ou Marine Power le plus proche pour toute information. Une liste des numéros de pièces en d'autres langues accompagne votre bloc‑moteur.
  • Page 130: Otros Idiomas

    Para obtener un Manual de operación y mantenimiento en otro idioma, póngase en contacto con el centro de servicio más cercano de Mercury Marine o Marine Power International para recibir información. Con su conjunto motriz se entrega una lista de los números de pieza para los otros idiomas.
  • Page 131 Section 8 - Customer Assistance Information Quantity Item Stock Number Price Total Total Due 90-8M0069751 APRIL 2012 Page 123...

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