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Mercury 4.3 MPI SeaCore Operation & Maintenance Manual

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4.3, 5.0 MPI
SeaCore Models
( ECT )
O PERAT I O N &
MAI N T EN AN C E
MAN U AL

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Summary of Contents for Mercury 4.3 MPI SeaCore

  • Page 1 4.3, 5.0 MPI SeaCore Models ( ECT ) O PERAT I O N & MAI N T EN AN C E MAN U AL...
  • Page 3 The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. 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 4 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 Manual included with the product. The Warranty Manual 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

    TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Additional Operation Instructions for Axius Systems ....2 Operation..............11 Identification................2 Adjustment..............11 Engine Serial Number ............2 Special Digital Throttle and Shift (DTS) Features..... 12 Alpha Sterndrive Serial Number......... 2 Dock................
  • Page 6 Section 3 - Specifications Fuel Requirements..............38 5.0 MPI ECT and SeaCore 5.0 ECT....... 40 Fuel Ratings..............38 Fluid Specifications..............40 Using Reformulated (Oxygenated) Gasoline (USA Only). 38 Engine................40 Gasoline Containing Alcohol..........38 Alpha Sterndrive.............. 41 Bu16 Butanol Fuel Blends.......... 38 Bravo Sterndrives............
  • Page 7 Excessive Engine Temperature........107 Sterndrive Unit Does Not Move)........109 Section 7 - Customer Assistance Information Owner Service Assistance............. 112 Contact Information for Mercury Marine Customer Service Local Repair Service............112 ..................113 Service Away From Home..........112 Customer Service Literature..........113 Stolen Power Package.............
  • Page 8 Page iv 90-8M0113859 DECEMBER 2015...
  • Page 9 Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package Table of Contents Additional Operation Instructions for Axius Systems ..... 2 Operation ............... 11 Identification................2 Adjustment ............11 Engine Serial Number ............. 2 Special Digital Throttle and Shift (DTS) Features..

  • Page 10: Additional Operation Instructions For Axius Systems

    Section 1 - Getting to Know Your Power Package Additional Operation Instructions for Axius Systems If your boat has DTS engines equipped with an Axius system, refer also to the Axius Operation Manual included with the boat. Identification The serial numbers are the manufacturer's keys to numerous engineering details which apply to your MerCruiser power package.

  • Page 11: Alpha Transom Serial Number

    Section 1 - Getting to Know Your Power Package Alpha Transom Serial Number The Alpha transom serial number is stamped in the transom assembly decal. Transom Serial No. 53651 The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser dealers.

  • Page 12: Bravo Transom Serial Number

    Section 1 - Getting to Know Your Power Package The serial number is also stamped on the driveshaft housing behind the back cover. This is used as a permanent reference for authorized MerCruiser dealers. 44426 Bravo sterndrive serial number stamping Bravo Transom Serial Number The Bravo transom serial number is stamped in the transom assembly decal.

  • Page 13: Lanyard Stop Switch

    Section 1 - Getting to Know Your Power Package Lanyard Stop Switch A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist. A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.

  • Page 14: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition

    Section 1 - Getting to Know Your Power Package Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard cord.

  • Page 15: System Link Digital Instruments

    Section 1 - Getting to Know Your Power Package • Engine operating hours SmartCraft tachometer and speedometer Tachometer Speedometer LCD display 50400 The SmartCraft instrument package also aids in identifying fault codes associated with the engine audio warning system. The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.

  • Page 16: Remote Controls (Non-Dts Models)

    Remote Controls (Non‑DTS Models) Remote Control Features—Non‑DTS Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control.

  • Page 17: Remote Controls (Dts Models)

    Remote Controls IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

  • Page 18: Special Digital Throttle And Shift (Dts) Features

    Section 1 - Getting to Know Your Power Package Trim switch (if equipped) ‑ When the power trim switch is activated on the ERC handle, the DTS command module senses a closed circuit for either up or down trim. The DTS command module formulates a signal and sends it to the PCM. The PCM closes the ground circuit to the up or down trim relay.

  • Page 19: Dual-Handle Electronic Remote Control (Erc)-Operation And Adjustment

    Section 1 - Getting to Know Your Power Package Item Control Function Trim control Raises and lowers the sterndrive for best efficiency, or for conditions such as shallow water, (handle) trailering, etc. Allows the operator to start or stop the engine without the use of the key switch. The key switch Stop/Start must be in the run position for the start/stop switch to function.

  • Page 20: Special Digital Throttle And Shift (Dts) Features

    Section 1 - Getting to Know Your Power Package Adjust to the tension desired. Detent tension adjustment screw Handle tension adjustment screw 51901 Special Digital Throttle and Shift (DTS) Features The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed features can operate simultaneously.

  • Page 21: Dock

    Section 1 - Getting to Know Your Power Package Item Control Function "+" Increases brightness settings for CAN pad, VesselView and SmartCraft gauges. Allows the boat operator to increase engine RPM for warm‑up without shifting the "THROTTLE ONLY" transmission into gear. "–"...

  • Page 22: Lever

    Section 1 - Getting to Know Your Power Package Press the "THROTTLE ONLY" button. The button light will turn off. The neutral lights stop flashing and remain illuminated. The joystick can now be used. 1 Lever The outboard joystick system features the ability to command both engines with a single lever on a dual‑engine application. This feature simplifies engine management during rough sea conditions by allowing you to use a single lever to command both engines simultaneously.

  • Page 23: Transfer (Boats Equipped With Dual Helms)

    Section 1 - Getting to Know Your Power Package Transfer (Boats equipped with dual helms) The "TRANSFER" button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on boats equipped with dual helms. Refer to Helm Transfer. 51858 "TRANSFER"...

  • Page 24: Power Trim

    Section 1 - Getting to Know Your Power Package Shift lever ‑ Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its forward position.

  • Page 25: Single Engine Trim/Trailer

    Section 1 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
  • Page 26 Section 1 - 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 90-amp fuse Four fuses, located on the port side of the engine, protect various electronic fuel injection (EFI) circuits. 33214 Engine fuses—5.0 MPI ECT 45307...
  • Page 27 Section 1 - Getting to Know Your Power Package Two 10‑amp fuses protect the O (oxygen) sensors. These are located at the rear of the engine, near the 14‑pin connector. 33177 Oxygen sensor fuses—5.0 MPI ECT 45308 Oxygen sensor fuses—4.3 MPI ECT cover removed for clarity A 15‑amp accessory fuse protects the accessory circuits.
  • Page 28 Section 1 - Getting to Know Your Power Package The power trim system is protected from overload by both a 110‑amp fuse and a 20‑amp spade fuse on the power trim pump. The trim pump may also have an in‑line circuit protection device in the power trim positive lead near the battery switch or battery connection.

  • Page 29: Visual And Audio Warning Systems

    Section 1 - Getting to Know Your Power Package The MerCathode system has a 5‑amp fuse that connects to the positive (+) terminal on the controller. If the fuse is open, the system will not operate, resulting in a loss of corrosion protection. MerCathode Red/purple wire 5‑amp fuse...

  • Page 30: Caution

    Section 1 - Getting to Know Your Power Package Caution If a caution state is detected, the audio warning system will sound for six one‑second intervals. Horn (on or off) Time (in seconds) 33402 Critical If a critical state is detected, the audio warning system sounds for six seconds and then turns off. Horn (on or off) Time (in seconds) 53403...
  • Page 31 Section 2 - On the Water Section 2 - On the Water Table of Contents Additional Operation Instructions for Axius Systems ... 24 Drain Plug and Bilge Pump..........31 Safe Boating Recommendations.......... 24 Protecting People in the Water..........31 Carbon Monoxide Exposure..........25 While You Are Cruising ..........

  • Page 32: Additional Operation Instructions For Axius Systems

    Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.

  • Page 33: Carbon Monoxide Exposure

    Section 2 - On the Water Never operate a boat while under the influence of alcohol or drugs. It is the law. • Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly. Know your boating area and avoid hazardous locations. Be alert.

  • Page 34: Poor Ventilation

    Section 2 - On the Water Example of desired air flow through the boat: 43367 Poor Ventilation Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

  • Page 35: Starting And Stopping The Engine

    Section 2 - On the Water Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Check shift and throttle Turn battery switch on. Close fuel shut off valve. control operation. Close seacock, if Operate bilge blowers. Check steering operation. equipped.

  • Page 36: Starting The Engine After It Has Been Stopped While In Gear

    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 37: Starting And Stopping The Engine

    Section 2 - On the Water Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Check shift and throttle Turn battery switch on. Close fuel shut off valve. control operation. Close seacock, if Operate bilge blowers. Check steering operation. equipped.

  • Page 38: 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. Page 30...

  • Page 39: 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. Protecting People in the Water While You Are Cruising It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds.

  • Page 40: Boats With Front-Mounted, Raised Pedestal Fishing Seats

    Section 2 - On the Water Boats With Front‑Mounted, Raised Pedestal Fishing Seats Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

  • Page 41: Drive Unit 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 MerCruiser dealer for a thorough inspection and necessary repair.

  • Page 42: The Bottom Of The Boat

    Section 2 - On the Water • Improves ease of planing • Improves rough water ride • At extremes, can cause the boat to veer back and forth (bow steer) The Bottom of the Boat To maintain maximum speed, the boat bottom should be: •...

  • Page 43: Engine Rpm Limiter

    End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
  • Page 44 Section 2 - On the Water Notes: Page 36 90-8M0113859 DECEMBER 2015...
  • Page 45 Section 3 - Specifications Section 3 - Specifications Table of Contents Fuel Requirements............... 38 4.3 MPI ECT ..............39 Fuel Ratings ..............38 5.0 MPI ECT and SeaCore 5.0 ECT......40 Using Reformulated (Oxygenated) Gasoline (USA Only) Fluid Specifications............... 40 ..................

  • Page 46: Fuel Requirements

    Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).

  • Page 47: Engine Specifications

    Section 3 - Specifications If Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of recommendation. 1. Mercury/Quicksilver 25W‑40 Mineral NMMA FC‑W Catalyst Compatible. IMPORTANT: If you are servicing a catalyst engine, use the following oils for short periods of time only.

  • Page 48: Mpi Ect And Seacore 5.0 Ect

    Section 3 - Specifications Seawater cooled 60 °C (140 °F) Thermostat Closed cooling 77 °C (170 °F) 1‑6‑5‑4‑3‑2 Firing order Non‑DTS models 750 CCA, 950 MCA, 180 Ah Minimum battery rating Factory installed AC Platinum (AC 41‑101) Spark plug type Service NGK (ITAR4A15) 1.5 mm (0.060 in.)

  • Page 49: Alpha Sterndrive

    20 L (21 US qt) 20 L (21 US qt) Propylene glycol and purified water (winterization use only) Mercury Extended Life Coolant Antifreeze Closed cooling system 17.8 L (18.8 US qt) 19 L (20 US qt) or extended‑life ethylene glycol 5/100...
  • Page 50 Section 3 - Specifications Notes: Page 42 90-8M0113859 DECEMBER 2015...
  • Page 51 Section 4 - Maintenance Section 4 - Maintenance Table of Contents Additional Operation Instructions for Axius Systems ... 44 Installation ............. 62 Owner/Operator Responsibilities.......... 44 Gen III Models............... 63 Dealer Responsibilities............44 Removal ..............63 Maintenance................. 44 Installation ............. 63 Do‑It‑Yourself Maintenance Suggestions......

  • Page 52: Additional Operation Instructions For Axius Systems

    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 53: 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 54: Scheduled Maintenance

    • Lubricate the U‑joint splines and cross bearing, if equipped with a grease fitting. • Inspect the gimbal bearing for roughness. Replace if necessary. See your certified Mercury MerCruiser dealer. • Alpha models and Bravo models: Lubricate the engine coupler.

  • Page 55: Engine Oil

    Section 4 - Maintenance 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 56: Filling

    Section 4 - Maintenance Filling IMPORTANT: Do not overfill the engine with oil. IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid required. Remove the oil fill cap. 45310 4.3 ECT oil fill cap 33210 5.0 ECT oil fill cap Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.

  • Page 57: Changing Filter

    Section 4 - Maintenance Install the oil pump onto the dipstick tube. Typical oil pump Dipstick tube Oil drain hose mc70571-1 Insert the hose end of the crankcase oil pump onto an appropriate container and, using the handle, pump until the crankcase is empty.

  • Page 58: Power Steering Fluid

    Warm range 46013 Fill to the "FULL" line with the specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling Remove the fill cap/dipstick and observe the level. Add the specified fluid to bring the fluid level up to the proper level.

  • Page 59: Filling

    Heat exchanger cap The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. Install the cap onto the heat exchanger. IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the filler neck.

  • Page 60: Changing

    Install the fill cap to the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Alpha Sterndrive Gear Lube 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 61: Filling

    IMPORTANT: If more than 59 ml (2 fl oz) of gear lubricant is required to fill the monitor, a seal may be leaking. Damage to the sterndrive unit may occur due to lack of lubrication. Contact your authorized Mercury MerCruiser dealer.
  • Page 62 Sterndrive unit 92-858064K01 IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit. Install the oil vent screw and sealing washer. Continue to pump gear lubricant into the drive through the oil fill and drain plug hole until the gear lubricant appears in the gear lube monitor.

  • Page 63: Bravo Sterndrive Gear Lube

    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.
  • Page 64 Lower the sterndrive unit so the propeller shaft is level. IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit. Fill the sterndrive unit through the oil fill and drain hole with specified gear lubricant until an air‑free stream of lubricant flows from the oil vent hole.

  • Page 65: Power Trim Fluid

    Part No. Power Trim and Steering Fluid Power trim pump 92-858074K01 Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. 90-8M0113859 DECEMBER 2015 Page 57...

  • Page 66: Battery

    Auxiliary Batteries Mercury strongly recommends using at least a group 27 or 31 type AGM batteries when load shedding devices are used in place of auxiliary batteries. Boats using Axius are typically large vessels with many DC loads and the minimum group 24 batteries will not be sufficient.
  • Page 67 Section 4 - Maintenance 4.3 ECT models: Holding the edges of the engine cover, lift straight up, sliding the four engine cover pegs, near the outer corners of the cover, out of the cover grommets. Keep the engine cover level to avoid breaking the pegs. 4.3 ECT engine cover—shown under the cover Engine cover legs Engine cover grommets...

  • Page 68: Positive Crankcase Ventilation (Pcv) Valve

    Section 4 - Maintenance Description lb‑in. lb‑ft Flame arrestor bracket nut – 10. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover. 11. Install the engine cover. 4.3 ECT models: Holding the edges of the engine cover, position the four engine cover legs, near the outer corners of the cover, over the center holes in the cover grommets.

  • Page 69: Changing

    Section 4 - Maintenance Changing NOTE: We recommend the use of Mercury MerCruiser replacement parts to ensure compliance with emission regulations. Remove the PCV valve from the port valve cover. PCV valve (hose not shown) 33143 Disconnect the PCV valve from the hose and discard the valve.

  • Page 70: Water-Separating Fuel Filter (Mpi)

    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 the fuel supply valve, if equipped. Wrap the water‑separating fuel filter with a cloth to help catch any fuel spills or spray.

  • Page 71: 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 the fuel supply valve, if equipped. Disconnect the Cool Fuel Module harness from the engine wiring harness.

  • Page 72: 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 73: Throttle Cable

    Lubricate the steering pin. Steering pin mc71904-1 Tube Ref No. Description Where Used Part No. Mercury 25W-40 Synthetic Blend Steering pin 92-8M0078629 4-Stroke Engine Oil On dual engine boats: Lubricate the tie bar pivot points. Tube Ref No. Description Where Used Part No.

  • Page 74: Shift Plate Control Cable Lubrication

    43662 Tube Ref No. Description Where Used Part No. Mercury 25W-40 Synthetic Blend Shift cable pivot points and guide contact surfaces 92-8M0078629 4-Stroke Engine Oil Driveshaft U‑joint Splines and O‑Rings (Sterndrive Unit Removed) Apply grease to the driveshaft U‑joint splines and O‑rings.

  • Page 75: Engine Coupler

    Tube Ref No. Description Where Used Part No. Transom end grease fitting, engine end grease fitting, driveshaft grease Extreme Grease 8M0071842 fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 90-8M0113859 DECEMBER 2015 Page 67...

  • Page 76: Alpha Or Bravo One Propeller Removal

    Section 4 - Maintenance Alpha or Bravo One Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 77: Bravo Two Propeller Removal

    Section 4 - Maintenance Bravo Two 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 78: Bravo Three Propeller Removal

    Turn the front propeller nut 70 mm (2‑3/4 in.) counterclockwise to remove the nut. Slide the propeller and thrust hub off the propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Rear propeller nut...

  • Page 79: Bravo Three Propeller Installation

    Section 4 - Maintenance Bravo Three 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. Rear propeller nut Rear propeller Rear propeller thrust hub...

  • Page 80: Serpentine Drive Belt

    Section 4 - Maintenance 11. Apply Loctite 271 Threadlocker onto the propeller shaft anode screw threads. Propeller Rear propeller nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer 5303 Tube Ref No. Description Where Used Part No. Loctite 271 Threadlocker Propeller shaft anode screw threads 92-809819...

  • Page 81: Replacing Belt And/Or Adjusting Tension

    Section 4 - Maintenance • Cracks NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are not acceptable. • Fraying • Glazed surfaces • Proper tension ‑ 13 mm (1/2 in.) deflection, with moderate thumb pressure, on the belt at the location that has the longest distance between two pulleys.

  • Page 82: Corrosion Protection

    The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer. Maintaining Ground Circuit Continuity The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the engine, transom assembly, and sterndrive components.
  • Page 83 Section 4 - Maintenance NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or high‑pressure washers to clean the MerCathode assembly. Do not pressure‑wash the MerCathode assembly, if equipped. Doing so will damage the coating on the reference electrode wire and decrease the corrosion protection.

  • Page 84: Mercathode System Battery Requirements

    Flush the cooling system periodically, preferably after each use. MerCathode System Battery Requirements The Mercury MerCruiser MerCathode system requires a minimum battery charge of 12.6 volts at all times to maintain functionality. Boats equipped with a MerCathode system that use shore power, and are not run for a long period of time, must use a battery charger to maintain a minimum battery charge of 12.6 volts or above.

  • Page 85: Power Package Exterior Surfaces

    The system is not operating correctly. Contact your local second sensed reference electrode voltage in Mercury Service dealer for assistance. excess of 1.4 V. The reference voltage is outside of the 1 flash per 4 normal, expected range: either above 1.04 V...

  • Page 86: Sterndrive Surface Care

    Maintain a complete paint covering on the sterndrive. • Check the finish regularly. Prime and paint nicks and scratches using Mercury enamel paint and touch up paint. Use only tin‑based antifouling paint or its equivalent on or near aluminum surfaces below the waterline.

  • Page 87: Important Information About Flushing Procedures

    Choosing the correct flushing procedure for your engine will depend on the engine model, and in some cases the marine hardware and cooling system water supply features provided by the boat manufacturer. Contact your authorized Mercury MerCruiser dealer for information about the best flushing procedure for your engine and boat model.

  • Page 88: Flushing Attachments

    9192 Sterndrive Water Pickups This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment (44357Q 5773 Side pickup NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications. Flushing is recommended after each outing for best results.

  • Page 89: Flushing The Power Package (Bravo)

    Flushing the Power Package (Bravo) General Information Your authorized Mercury MerCruiser dealer can explain how to properly flush your power package. Flushing the Power Package The boat can be equipped with a combination of any of three different types of water pickups: through‑the‑hull, through‑the‑transom, and through‑the‑sterndrive.

  • Page 90: Sterndrive Water Pickups

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

  • Page 91: Alternative Water Pickups

    Section 4 - Maintenance On models using the sterndrive water pickups for water supply: proceed to Step 4. or Step 5. If flushing the cooling system with the boat in the water: Raise sterndrive to trailer position. Install the appropriate flushing attachment over the water inlet holes in the gear housing. Lower sterndrive to full down (in) position.

  • Page 92: Seacore Power Package Flushing Procedure

    Section 4 - Maintenance Remove the seawater inlet hose from the seawater pump at the location shown. Plug the hose to prevent water from siphoning into the engine or boat. 33208 Seawater inlet hose connection Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
  • Page 93 Section 4 - 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 94 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 95 Section 4 - 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 96 Section 4 - Maintenance Notes: Page 88 90-8M0113859 DECEMBER 2015...
  • Page 97 Section 5 - Storage Section 5 - Storage Table of Contents Cold Weather or Extended Storage........90 Multipoint Drain (MPD) System ......94 Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 90 Air Actuated Single‑Point Drain System......95 Fuel Containing Alcohol..........90 Boat in the Water ........... 95 Preparing Power Package for Storage—MPI Models..

  • Page 98: Cold Weather Or Extended Storage

    (phase) of the water/alcohol from the gasoline in the fuel tank. The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 99: Special Fuel Mix

    Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation. Check the antifreeze concentration where applicable. Refer to the Specifications section. Before adding Mercury Quickstor Fuel Stabilizer to the fuel in the tank, determine the type of fuel that is in the fuel tanks and proceed with the following: Vessels using fuel without alcohol—fill the vessel fuel tanks with fresh gasoline that does not contain alcohol and add...

  • Page 100: Draining The Seawater System

    IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.

  • Page 101: Manual Single-Point Drain System, Seawater Cooled Models

    Section 5 - Storage Seawater cooled models—Non-catalyst shown, catalyzed similar Blue drain plug location Air manifold Green indicators 43766 Manual Single-Point Drain System, Seawater cooled models 6128 Non-ECT shown, ECT similar Blue handle Blue drain plug location 4.3 ECT Single-Point Drain System with Plug 45951 Blue drain plug 90-8M0113859...

  • Page 102: Three-Point Manual Drain System, Seawater Cooled

    Section 5 - Storage Three-Point Manual Drain System, Seawater cooled Note two plugs on seawater pump Blue drain plug 6126 Multipoint Drain (MPD) System Side of cylinder block (port and starboard) Bottom of exhaust manifolds (port and starboard) 6129 33155 Fuel cooler to thermostat housing Check valve (if equipped) 6131...

  • Page 103: Air Actuated Single-Point Drain System

    Section 5 - Storage Air Actuated Single‑Point Drain System Boat in the Water NOTE: This procedure is written for the air pump that is included with the engine. However, any air source can be used. Close the seacock (if equipped) or remove and plug the water inlet hose. Remove the blue air pump from the engine.

  • Page 104: Boat Out Of The Water

    12. Remove the air pump from the air manifold and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
  • Page 105 Section 5 - Storage Ensure that the lever on top of the pump is flush with the handle (horizontal). Install the air pump on the actuator fitting. Pull the lever on the air pump (vertical) to lock the pump onto the fitting. Actuator fitting Green indicators Manual release valve...

  • Page 106: Manual Single-Point Drain System (Alpha)

    10. Remove the air pump from the air manifold and return it to the mounting bracket. 11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

  • Page 107: Boat Out Of The Water

    Section 5 - Storage 5.0 MPI ECT—Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open. Do not force the handle as this will create new threads. 4.3 MPI ECT and 5.0 MPI ECT—Immediately remove the blue drain plug from the side of the thermostat housing.
  • Page 108 Section 5 - Storage • 4.3 MPI ECT—Remove the blue plug at the distribution housing at the lower front right corner of the engine. 45951 4.3 MPI ECT • 5.0 MPI ECT—Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open.

  • Page 109: Three-Point Manual Drain System-Seawater Cooled

    Section 5 - Storage Three‑Point Manual Drain System—Seawater Cooled Boat in the Water NOTE: Use this procedure if your engine is not equipped with an air actuated single‑point drain system or if the air actuated single‑point drain system fails. Close the seacock (if equipped) or remove and plug the water inlet hose. Remove the blue drain plug from the distribution housing (lower front, port side).

  • Page 110: Draining Water From The Gen Iii Cool Fuel Module

    Draining Water from the Gen III Cool Fuel Module Mercury MerCruiser recommends draining the Gen III Cool Fuel Module if it is equipped with a drain plug. Remove the drain plug from the Gen III Cool Fuel Module and allow the water to completely drain from the module.
  • Page 111 Section 5 - Storage Coat the terminal connections with a battery terminal anticorrosion agent. Perform all the checks in the Operation Chart. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.
  • Page 112 Section 5 - Storage Notes: Page 104 90-8M0113859 DECEMBER 2015...
  • Page 113 Section 6 - Troubleshooting Section 6 - Troubleshooting Table of Contents Diagnosing EFI Problems........... 106 Insufficient Engine Temperature........107 Diagnosing DTS Problems..........106 Low Engine Oil Pressure..........108 Additional Operation Instructions for Axius Systems ..106 Battery Will Not Recharge........... 108 Engine Guardian System............

  • Page 114: Diagnosing Efi Problems

    Diagnosing DTS Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on digital throttle and shift (DTS) systems. The engine control module (ECM)/propulsion control module (PCM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM/PCMs memory.

  • Page 115: Engine Runs Rough, Misses, Or Backfires

    Clean the 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...

  • Page 116: Low Engine Oil Pressure

    Check all 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 117: Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move)

    Section 6 - 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. 90-8M0113859 DECEMBER 2015 Page 109...
  • Page 118 Section 6 - Troubleshooting Notes: Page 110 90-8M0113859 DECEMBER 2015...

  • Page 119: Section 7 - Customer Assistance Information

    Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance..........112 Contact Information for Mercury Marine Customer Local Repair Service ..........112 Service ............... 113 Service Away From Home .......... 112 Customer Service Literature..........113 Stolen Power Package ..........

  • Page 120: Owner Service Assistance

    If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

  • Page 121: Contact Information For Mercury Marine Customer Service

    Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: •...

  • Page 122: Other Languages

    Enclose full remittance in check or money order (NO COD). Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.

  • Page 123: Section 8 - Checklists

    Section 8 - Checklists Section 8 - Checklists Table of Contents Predelivery Inspection (PDI)..........116 Customer Delivery Inspection (CDI)........117 90-8M0113859 DECEMBER 2015 Page 115...

  • Page 124: Predelivery Inspection (Pdi)

    Section 8 - Checklists Predelivery Inspection (PDI) IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual. Perform these tasks before the Customer Delivery Inspection (CDI). Check/ Item Adjust...

  • Page 125: Customer Delivery Inspection (Cdi)

    Approve the external appearance of the product (paint, cowl, decals, etc.) ⃞ Warranty—provide and explain the limited warranty to the customer. Explain dealer services. ⃞ ⃞ Explain the optional Mercury Product Protection Plan (North America only) Operation of equipment—explain and demonstrate: ⃞ E‑stop switch/lanyard stop switch operation (all helms) ⃞...
  • Page 126 Section 8 - Checklists Completed Item ⃞ ⃞ Functions of SmartCraft accessories (if applicable) ⃞ Off‑season storage and maintenance schedule ⃞ Engine (starting, stopping, shifting, using throttle) ⃞ Boat (lights, battery switch location, fuses/breakers) ⃞ ⃞ Trailer (if applicable) Registration: ⃞...

  • Page 127: Section 9 - Maintenance Log

    Section 9 - Maintenance Log Section 9 - Maintenance Log Table of Contents Scheduled Maintenance Log..........120 Vessel Maintenance Notes..........121 90-8M0113859 DECEMBER 2015 Page 119...

  • Page 128: Scheduled Maintenance Log

    Section 9 - Maintenance Log Scheduled Maintenance Log 100 Hours Actual Hours Service Notes Dealer Name Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name...

  • Page 129: Vessel Maintenance Notes

    Section 9 - Maintenance Log Vessel Maintenance Notes Record all general maintenance performed on your power package here. Save all work orders and receipts. Engine Date Maintenance Completed Servicing Dealer Hours 90-8M0113859 DECEMBER 2015 Page 121...
  • Page 131 Parc Industriel de Petit-Rechain 41-71 Bessemer Drive P.O. Box 1939 B-4800 Verviers, Belgium Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA © Mercury Marine. All rights reserved. 90-8M0113859 NOVEMBER 2015 Printed in U.S.A.

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