Mercury MERCRUISER User Manual

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Page 1 Ignition‑protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031 Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust, when installed in a recreational craft, in accordance with the manufacturers supplied instructions, will meet the exhaust emissions requirements of the directive mentioned above.
Page 2: Read This Manual Thoroughly
At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations.
Page 3 Notice Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. These Safety Alerts alone cannot eliminate the hazards that they signal.
Page 5: Table Of Contents
Warranty Registration: Outside the United States and Canada. 2 California Emissions Limited Warranty........11 Transfer of Warranty..............2 What Is Covered..............12 Mercury Product Protection Plan: United States and Canada... 3 Duration Of Coverage............12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled How To Obtain Warranty Coverage........12 Products Only) ................3...
Page 6 Protecting People in the Water..........46 Conditions Affecting Operation..........49 While You Are Cruising............. 46 Weight Distribution (Passengers and Gear) Inside the While Boat Is Stationary........... 46 Boat.................49 High‑Speed and High‑Performance Operation....... 46 The Bottom of the Boat........... 49 Passenger Safety in Pontoon Boats and Deck Boats.... 46 Cavitation................
Page 7 Owner Service Assistance............. 122 Parts and Accessories Inquiries......... 122 Local Repair Service............122 Resolving a Problem............122 Service Away From Home..........122 Mercury Marine Service Offices........123 Stolen Power Package............. 122 Ordering Literature..............123 Attention Required after Submersion....... 122 United States and Canada..........123 Replacement Service Parts..........122...
Page 8 Page iv 90-864197076 NOVEMBER 2008...
Page 9: Section 1 - Warranty
....................2 California Emissions Limited Warranty......... 11 Transfer of Warranty............... 2 What Is Covered ............12 Mercury Product Protection Plan: United States and Canada Duration Of Coverage ........... 12 ....................3 How To Obtain Warranty Coverage ......12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled What Mercury Will Do ...........
Page 10: Warranty Registration: United States And Canada
Federal Boat Safety Act is required. You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax to Mercury MerCruiser’s warranty registration department with your name, old address, new address, and engine serial number.
Page 11: Mercury Product Protection Plan: United States And Canada
Mississauga, Canada, L5N 7W6 Fax 1-800-663-8334 Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the distributor closest to you.
Page 12 Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine.
Page 13: 3-Year Limited Warranty Against Corrosion
Improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product) • Improper service • 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 •...
Page 14: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines
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 15 This limited corrosion warranty provides coverage for four (4) years from either the date on which the MerCruiser SeaCore engine, transom, and sterndrive package is first sold or the date on which it is first put into service, whichever occurs first. The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
Page 16: Global Warranty Charts
Section 1 - Warranty Global Warranty Charts Warranty for Consumer Applications Standard Factory Limited Warranty by Certification Status of Boat Manufacturer Consumer Limited Engine Model Region Corrosion Warranty Installation Quality Not Certified Certified The Americas 1 year 3 years (excluding Brazil) 2 years 2 years Brazil...
Page 17: Warranty For Government Applications
Section 1 - Warranty Warranty for Government Applications Standard Factory Limited Warranty by Certification Status of Boat Manufacturer Government Limited Engine Model Region Corrosion Warranty Installation Quality Not Certified Certified The Americas 1 year 1 year 3 years (excluding Brazil) 2 years 2 years 2 years...
Page 18: Warranty For Commercial Applications
Section 1 - Warranty Warranty for Commercial Applications Standard Factory Limited Warranty by Certification Status of Boat Manufacturer Commercial Limited Engine Model Region Corrosion Warranty Installation Quality Not Certified Certified The Americas 1 year 1 year 1 year (excluding Brazil) 2 years 2 years 2 years...
Page 19: Mercury Installation Quality Certification Program
California Emissions Limited Warranty NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 20: What Is Covered
Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage.
Page 21: What Is Not Covered
California Code of Regulations) or modified parts not exempted by the California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a non‑exempted add‑on or modified part will not be covered.
Page 22: Disclaimers And Limitations
1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 23: Emission Control Information Label
Emission Control Information Label A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement.
Page 24: Emission Certification Star Label
All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2007 and later exhaust emission standards.
Page 25 Section 1 - Warranty One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
Page 26 Section 1 - Warranty Notes: Page 18 90-864197076 NOVEMBER 2008...
Page 27: Section 2 - Getting To Know Your Power Package
Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification................. 20 Slim Binnacle Console Mount Features ‑ Single Engine Engine Serial Number Decal MPI........20 ..................28 Alpha Sterndrive Decal Identification......20 Console Mount Features‑...
Page 28: Identification
Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal MPI The serial number decal is located on the engine cover.
Page 29: Alpha Transom Serial Number
Section 2 - Getting to Know Your Power Package Alpha Transom Serial Number The transom serial number is located on the top of the transom assembly. 25619 Alpha transom assembly serial number Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port side of the sterndrive.
Page 30: Bravo Transom Serial Number
The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly. Bravo transom assembly U-bolt plate Transom assembly serial Number 25904 The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. Gimbal housing with serial number stamping...
Page 31: Instrumentation
Section 2 - Getting to Know Your Power Package • sitting on the seat or gunwale at planing speeds • standing at planing speeds • operating at planing speeds in shallow or obstacle infested waters • releasing your grip on the steering wheel that is pulling in one direction •...
Page 32: Digital Gauges
Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure (requires a SmartCraft oil pressure sender kit), battery voltage, fuel consumption, and engine operating hours.
Page 33: Analog Gauges
Remote Controls (Non‑DTS Models) Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.
Page 34: Panel Mount Features
Section 2 - Getting to Know Your Power Package Panel Mount Features Neutral lock button Throttle only button Lanyard stop switch Control handle tension adjustment screw Control handle Trim/tilt button mc77019-1 Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the control handle out of neutral.
Page 35: Remote Controls (Dts Models)
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 36: Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Console Mount Features ‑ Single Engine Control handle Trim/tilt switch Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw 3410 Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 37: Console Mount Features- Dual Engine
Section 2 - Getting to Know Your Power Package Throttle Only/Station Select Key - Allows engine throttle advancement without shifting the engine. The throttle only/station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms.
Page 38: Dual Helm Station Transfer
Section 2 - Getting to Know Your Power Package Auto Synchronizing will stay engaged up to 95% throttle opening. The Sync light will turn on when the engines are synchronized. SYNC ACTIVE THROTTLE ONLY STAT ION SELECT 3434 To disengage, move one or both control handles until they are more than 5° apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%.
Page 39: Zero Effort Features
Section 2 - Getting to Know Your Power Package Zero Effort Features Shift ever Throttle lever Trim/tilt switch 5656 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.
Page 40: Single Engine Trim/Trailer
Section 2 - Getting to Know Your Power Package • Cause engine overheating if trimmed up/out to a point where any cooling water intake holes are above the water line mc78529 Trimming sterndrive unit down/in can: • Help the boat accelerate and plane off quicker •...
Page 41 Section 2 - Getting to Know Your Power Package Reset the breaker by pushing the yellow lever back into the housing. Yellow lever style circuit breaker Yellow lever Red test button 22529 A 90 amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs. mc74907-1 Four fuses, located on the port side of the engine, protect various electronic fuel injection (EFI) circuits.
Page 42 Section 2 - Getting to Know Your Power Package Two 10 amp fuses protect the O (oxygen) sensors. These are located at the rear of the engine, near the 14‑pin connector. 33177 A 15 amp accessory fuse protects the accessory circuits. This fuse is located on the rear of the engine. Cover 15 amp fuse Accessory harness...
Page 43 Section 2 - Getting to Know Your Power Package The power trim system is protected from overload by both a 110 amp fuse and a 20 amp spade fuse on the power trim pump. The trim pump may also have an in‑line circuit protection device in the power trim positive lead near the battery switch or battery connection.
Page 44: Audio Warning System
IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from damage. Your Mercury MerCruiser power package may be equipped with an audio warning system. Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.
Page 45: Obdm
If an OBDM fault is detected, the audio warning system sound with one five‑second horn, then one short, 1/2‑second horn every 60 seconds for certain faults related to the emissions or fuel system. See your authorized Mercury MerCruiser dealer for assistance.
Page 46 Section 2 - Getting to Know Your Power Package Notes: Page 38 90-864197076 NOVEMBER 2008...
Page 47 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions............ 40 Drain Plug and Bilge Pump..........46 Be Alert to Carbon Monoxide Poisoning....... 41 Protecting People in the Water..........46 Good Ventilation ............41 While You Are Cruising ..........
Page 48: Safe Boating Suggestions
Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.
Page 49: Be Alert To Carbon Monoxide Poisoning
Section 3 - On the Water • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load or fishing seats should block the operators view when the boat is above idle or planing transition speed.
Page 50: Basic Boat Operation (Non-Dts Models)
Section 3 - On the Water Examples of poor ventilation while a boat is moving: Operating the boat with the trim angle of the bow too high Operating the boat with no mc79556-1 forward hatches open (station wagon effect) Basic Boat Operation (Non‑DTS Models) Launching and Boat Operation IMPORTANT: Install bilge drain plug prior to launching boat.
Page 51: Stopping The Engine
IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.
Page 52: Basic Boat Operation (Dts Models)
NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process.
Page 53: Stopping The Engine
Section 3 - On the Water Push the throttle‑only button and position the remote control handle or throttle lever to the 1/4 throttle position. Turn the ignition key to "start." Release key when the engine starts and allow the switch to return to the "on" position. If the engine does not start after step 5: Move the remote control handle.throttle lever to the full throttle position, then return to 1/4 throttle.
Page 54: 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. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.
Page 55: Boats With Front-Mounted, Raised Pedestal Fishing Seats
Section 3 - On the Water Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. mc79555-1 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.
Page 56: Impact With Underwater Hazards
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Page 57: Operating With Low Water Inlets In Shallow Water
Section 3 - On the Water Operating with Low Water Inlets in Shallow Water Low Water Inlets mc75827-1 NOTICE Operating in shallow water can cause severe engine damage due to clogged water inlets. Ensure that the water inlets on the gearcase do not ingest sand, silt, or other debris, which can restrict or stop cooling water supply to the engine.
Page 58: Elevation And Climate
Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After the Break‑In Period To help extend the life of your Mercury MerCruiser power package, follow these recommendations: •...
Page 59: End Of First Season Checkup
End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss 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 60 Section 3 - On the Water Notes: Page 52 90-864197076 NOVEMBER 2008...
Page 61: Section 4 - Specifications
Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 54 377 MAG, SeaCore 377 MAG........56 Fuel Ratings ..............54 Fluid Specifications............... 56 Using Reformulated (Oxygenated) Gasoline (USA Only) Engine................57 ..................54 Alpha Sterndrive............57 Gasoline Containing Alcohol ........
Page 62: Fuel Requirements
Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and are acceptable for use in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol.
Page 63: Engine Specifications
MerCruiser engines. Although these high‑phosphorus lubricants may allow acceptable engine performance, exposure over time will damage the catalyst. Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty.
Page 64: 377 Mag, Seacore 377 Mag
Section 4 - Specifications 224 kW (300 hp) Propshaft power 5.7 L (350 cid) Displacement 72 A Alternator amperage Cold 65 A 4800–5200 Rev limiter 5350 Idle in neutral At 2000 RPM 124 kPa (18 psi) Minimum oil pressure At idle 41 kPa (6 psi) Seawater‑cooled models 71°...
Page 65: Engine
Seawater cooling system (winterization 20 L (21 US qt) Propylene glycol and purified water use only) Mercury Extended Life Coolant Antifreeze or extended life Closed cooling system 18 L (19 US qt) ethylene glycol 5/100 antifreeze mixed 50/50 with purified water Alpha Sterndrive NOTE: Oil capacity includes gear lube monitor.
Page 66 Section 4 - Specifications Notes: Page 58 90-864197076 NOVEMBER 2008...
Page 67 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 60 Installation ............. 75 Dealer Responsibilities............60 Lubrication................76 Maintenance................. 60 Steering System............76 Do‑It‑Yourself Maintenance Suggestions......60 Throttle Cable..............77 Inspection................61 Shift Cable ‑ Typical............78 Maintenance Schedule—Sterndrive Models......
Page 68: Owner/Operator Responsibilities
It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Mercury MerCruiser dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.
Page 69: 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 70: Maintenance Log
• Lubricate the U‑joint splines and cross bearing, if equipped with a grease fitting. • Inspect the gimbel bearing for roughness. Replace if necessary. See your certified Mercury MerCruiser dealer. • Vazer models, Alpha models, and 496 MAG Bravo models only: Lubricate the engine coupler.
Page 71: Engine Oil
Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil Checking NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.
Page 72: Filling
Fluid type All Models 4.25 L (4.50 US qt) Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40 Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
Page 73: Changing Filter
Proper fluid level with engine cold should be within the cold range. Power steering pump Cold range Warm range 33202 Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. 90-864197076 NOVEMBER 2008 Page 65...
Page 74: 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 75: Filling
92-877770K1 Coolant Check the antifreeze concentration for adequate freeze protection and correct if necessary. Refer to the Specifications section. Install the fill cap to the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. 90-864197076 NOVEMBER 2008 Page 67...
Page 76: Drive Unit Oil
Check the gear lube oil level. Keep the oil level within the recommended operating range. If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately.
Page 77 IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air‑free stream of lubricant flows from oil vent hole.
Page 78: Power Trim Fluid
Section 5 - Maintenance 10. Fill the monitor so that the oil level is in the operating range. Do not overfill. Ensure that the rubber gasket is inside the cap and install. Do not overtighten. NOTE: Oil capacity includes gear lube monitor. Model Capacity Fluid Type...
Page 79: Changing
Section 5 - Maintenance Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.
Page 80: Positive Crankcase Ventilation Valve (Pcv)
10. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover. 11. Install the engine cover. Positive Crankcase Ventilation Valve (PCV) Changing NOTE: We recommend the use of Mercury MerCruiser replacement parts to ensure compliance with emission regulations. Page 72 90-864197076 NOVEMBER 2008...
Page 81: Cleaning The Iac Muffler
Section 5 - Maintenance 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. Install a new PCV valve in the valve cover and reconnect the hose. Ensure that the PCV valve is tightly seated in the valve cover.
Page 82: 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 83: Gen Iii Models
Removal Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Disconnect the Cool Fuel Module harness from the engine wiring harness.
Page 84: 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 85: Throttle Cable
Lubricate the steering pin. Steering pin mc71904-1 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Steering pin 92‑883725K01 SAE25W‑40 On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.
Page 86: Shift Cable - Typical
Guide contact surfaces mc79736 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Shift cable pivot points & 92‑883725K01 SAE25W‑40 guide contact surfaces Sterndrive Unit and Transom Assembly Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun.
Page 87: Sterndrive U-Joint Shaft Splines And O-Rings (Sterndrive Unit Removed)
Section 5 - Maintenance Sterndrive U‑joint Shaft Splines And O‑rings (Sterndrive Unit Removed) Coat sterndrive U‑joint O‑rings and driveshaft splines with grease. Driveshaft splines U‑joint O‑rings (3) 8591 Tube Ref No. Description Where Used Part No. Engine Coupler Spline Driveshaft splines and U-joint O-rings 92-802869A 1 Grease For propeller shaft lubrication, refer to Propellers.
Page 88: Driveshaft Extension Models
Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
Page 89: Bravo One Propeller Removal
Section 5 - Maintenance IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. Propeller shaft Thrust hub Flo‑Torq II drive hub Propeller Drive sleeve Locking tab washer Propeller nut 6215 Apply a liberal coat of one of the following lubricants to the propeller shaft.
Page 90: Bravo Two Propeller Removal
Section 5 - Maintenance IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. Propeller shaft Thrust hub Flo‑Torq II drive hub Propeller Drive sleeve Locking tab washer Propeller nut 6215 Slide thrust hub onto propeller shaft, with stepped side toward propeller hub.
Page 91: Bravo Two Propeller Installation
Section 5 - Maintenance Bravo Two Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage.
Page 92: Bravo Three Propeller Installation
Slide propeller and thrust hub off propeller shaft. Turn front propeller shaft nut 70 mm (2‑3/4 in.) counterclockwise to remove nut. Slide propeller and thrust hub off propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Rear propeller nut Rear propeller...
Page 93 Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Special Lubricant 101 Propeller shaft 92-802865Q02 Anti-Corrosion Grease Propeller shaft 92-802867Q 1 2-4-C Marine Lubricant Propeller shaft 92-802859A 1 with Teflon Align splines and place propeller on propeller shaft. Install and torque the propeller nut.
Page 94: Serpentine Drive Belt
Section 5 - Maintenance Serpentine Drive Belt WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts. 6117 6116 With a seawater pump Without a seawater pump Idler pulley Water circulating pump pulley...
Page 95: Corrosion Protection
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 96: Checking The Quicksilver Mercathode System
Checking the Quicksilver MerCathode System The MerCathode system should be tested to ensure adequate output. Perform the test where boat is moored, using the reference electrode and test meter. Contact your authorized Mercury MerCruiser dealer for service and information . Page 88...
Page 97: Power Package Exterior Surfaces
Clean the entire power package. External surfaces that have become bare should be repainted with the recommended primer and spray paint at recommended intervals. Description Part Number Mercury Light Gray Primer 92‑802878 52 Painted surfaces Mercury Phantom Black 92‑802878Q 1 Boat Bottom Care To achieve maximum performance and fuel economy, the boat bottom must be kept clean.
Page 98 If you are using copper based anti‑fouling paint, observe the following precaution: • Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) UNPAINTED area on transom of the boat around these items.
Page 99: 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 anti–fouling paint or its equivalent on or near aluminum surfaces below the waterline.
Page 100: 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 101: 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 102: 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 103: Alternative Water Pickups
Section 5 - Maintenance If there is not a hose running to the transom, refer to Alternative Water Pickups. 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 104: Seacore Power Package Flushing Procedure
Section 5 - 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 105 Section 5 - Maintenance NOTE: Engines with the sterndrive water inlet blocked off at the gimbal housing: Refer to Alternative Water Pickups. WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
Page 106 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 107 Section 5 - Maintenance 20. Insert the dust cover in the flush socket on the engine. Dust cover installed in the flush socket Dust cover Flush socket 18490 IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If unit is to be stored out of the water, open the seacock.
Page 108 Section 5 - Maintenance Notes: Page 100 90-864197076 NOVEMBER 2008...
Page 109 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........102 Boat in the Water ..........106 Preparing Power Package for Storage......102 Boat out of the Water .......... 108 Engine and Fuel System Preparation ....102 Manual Single‑Point Drain System (Alpha)....
Page 110: Cold Weather Or Extended Storage
If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): Fuel tanks should be drained as low as possible and Mercury/Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank.
Page 111: 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. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
Page 112: Air Actuated Single Point Drain System
Section 6 - Storage Air Actuated Single Point Drain System 33144 33150 Closed-cooled models Seawater-cooled models Blue drain plug location Blue air pump Air manifold Green indicators Manual Single Point Drain System (Alpha) 6128 Blue handle Blue drain plug location Page 104 90-864197076 NOVEMBER 2008...
Page 113: Three Point Manual Drain System
Section 6 - Storage Three Point Manual Drain System Blue drain plug 6126 Multi-Point Drain (MPD) System Side of cylinder block Bottom of exhaust manifolds 6129 33155 Fuel cooler to thermostat housing Check valve (if equipped) 6131 90-864197076 NOVEMBER 2008 Page 105...
Page 114: Air Actuated Single Point Drain System
Section 6 - Storage Air Actuated Single Point Drain System Boat in the Water NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. Close the seacock (if equipped) or remove and plug the water inlet hose. Remove the air pump from the engine.
Page 115 Section 6 - Storage Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger. This must be removed within 30 seconds to properly vent the cooling system. 33144 33150 Closed Cooled Models Seawater Cooled Models Blue drain plug location Blue air pump Air manifold...
Page 116: 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 117 Section 6 - Storage Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side. 33144 33150 Closed Cooled Models Seawater Cooled Models Blue drain plug location Blue air pump Air manifold...
Page 118: Manual Single-Point Drain System (Alpha)
Section 6 - Storage 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. 12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.
Page 119: Boat Out Of The Water
Section 6 - Storage Allow the system to drain for a minimum of five minutes. We recommend leaving the drain system open while transporting the boat or performing other maintenance. Reinstall the blue drain plug in the thermostat housing. Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug, if removed. The handle is fully seated when no red is visible.
Page 120: Boat Out Of The Water
Section 6 - Storage Remove the blue drain plug from the distribution housing (lower front, port side). Blue drain plug 6138 To properly vent the cooling system, remove the blue drain plug from the side of the thermostat housing within 30 seconds. Blue drain plug location 6139 Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).
Page 121: Battery Storage
Section 6 - Storage Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side). 6142 Blue drain plug Verify that water is draining from each opening. Allow the system to drain for a minimum of five minutes.
Page 122 Section 6 - Storage Notes: Page 114 90-864197076 NOVEMBER 2008...
Page 123 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........... 116 Low Engine Oil Pressure..........118 Diagnosing DTS Problems..........116 Battery Will Not Recharge........... 118 Engine Guardian System............ 116 Remote Control Is Difficult to Move, Has Excessive Play, Troubleshooting Charts............
Page 124: Diagnosing Efi Problems
Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.
Page 125: Engine Runs Rough, Misses, Or Backfires
Clean Flame Arrestor. Faulty ignition system component. Service ignition system. Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer. EFI System fault. Have EFI System checked by an authorized Mercury MerCruiser dealer. Poor Performance Possible Cause Remedy Throttle not fully open.
Page 126: Low Engine Oil Pressure
Check all throttle linkages. If any are loose or missing, see authorized Loose or missing shift and throttle linkages. Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury MerCruiser dealer Shift or throttle cable kinked. replace cable if damaged beyond repair.
Page 127: Power Trim Does Not Operate
Section 7 - Troubleshooting Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low. Fill pump with oil. Drive unit binding in gimbal ring. Check for obstruction. 90-864197076 NOVEMBER 2008 Page 119...
Page 128 Section 7 - Troubleshooting Notes: Page 120 90-864197076 NOVEMBER 2008...
Page 129: Section 8 - Customer Assistance Information
Parts and Accessories Inquiries ......122 Local Repair Service ..........122 Resolving a Problem ..........122 Service Away From Home .......... 122 Mercury Marine Service Offices ......... 123 Stolen Power Package ..........122 Ordering Literature............. 123 Attention Required after Submersion ......122 United States and Canada .........
Page 130: Owner Service Assistance
If your power package is stolen, immediately advise 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 131: Mercury Marine Service Offices
• Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P.O. Box 1939...
Page 132: Outside The United States And Canada
Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature. Please return with payment to:...

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