Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
Page 2 Exhaust Gas Emissions Certification Number The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser® power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing.
Page 3: Read This Manual Thoroughly
We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
Page 4 NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard.
Page 5: Table Of Contents
How To Obtain Warranty Coverage....13 Mercury Product Protection Plan: United States and What Mercury Will Do........14 Canada..............3 What Is Not Covered........14 Mercury MerCruiser Limited Warranty Components Of The Emission Control System 14 (Gasoline‑Fueled Products Only) ......4 Disclaimers And Limitations......15 3‑Year Limited Warranty Against Corrosion....6 California Emission Control Warranty Statement.
Page 6 Trailering the Boat.........46 Boats Having An Open Front Deck....51 Freezing Temperature Operation....46 Boats With Front‑Mounted, Raised Pedestal Drain Plug and Bilge Pump......47 Fishing Seats...........51 Basic Boat Operation (DTS Models)....47 Wave And Wake Jumping........51 Launching and Boat Operation..... 47 Impact With Underwater Hazards......52 Operation Chart..........
Page 7 Engine Coolant............73 Driveshaft Extension Models......90 Checking............73 Propellers..............90 Filling..............74 Propeller Repair..........90 Changing ............75 Alpha Propeller Removal........ 90 Drive Unit Oil............75 Alpha Propeller Installation......91 Checking............75 Bravo One Propeller Removal......92 Filling..............76 Bravo One Propeller Installation..... 92 Changing............77 Bravo Two Propeller Removal......93 Power Trim Fluid...........79 Bravo Two Propeller Installation.....
Page 8 Engine Guardian System........134 Battery Will Not Come Up On Charge....136 Starter Motor Will Not Crank Engine, Or Cranks Remote Control Operates Hard, Binds, Has Slow..............134 Excessive Free‑play Or Makes Unusual Engine Will Not Start Or Is Hard To Start...134 Sounds...............136 Engine Runs Rough, Misses And/Or Backfires.
Page 9 Mercury Product Protection Plan: United States and What Is Not Covered ........14 Canada..............3 Components Of The Emission Control System Mercury MerCruiser Limited Warranty (Gasoline- ..............14 Fueled Products Only) ......... 4 Disclaimers And Limitations ......15 3-Year Limited Warranty Against Corrosion..6...
Page 10: Warranty Registration: United States And Canada
A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.
Page 11: Transfer Of Warranty
Section 1 - Warranty The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use, and the selling distributor’s and dealer’s code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product.
Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)
One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after the original engine registration date. See your participating Mercury MerCruiser dealer for complete program details. Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)
Page 13 Section 1 - Warranty Termination of Coverage Warranty coverage is terminated for used product obtained in any of the following ways: • Repossession from a retail customer • Purchase at auction • Purchase from a salvage yard • Purchase from an insurance company that obtained the product as a result of an insurance claim Conditions That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the pre‑delivery inspection process specified by Mercury Marine...
Page 14: 3-Year Limited Warranty Against Corrosion
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
Page 15: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines
4-YEAR LIMITED CORROSION WARRANTY: SEACORE STERNDRIVE MODELS WITH GAS ENGINES What Is Covered Mercury Marine warrants that each new MerCruiser SeaCore engine, transom, and sterndrive package will not be rendered inoperative as a direct result of corrosion for the period of time described below.
Page 16: Global Warranty Charts
This limited corrosion warranty provides coverage for four (4) years from either the date on which the MerCruiser SeaCore engine, transom, and sterndrive package is first sold or the date on which it is first put into service, whichever occurs first. The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
Page 17: Consumer Application Warranty Chart
Section 1 - Warranty Consumer Application Warranty Chart Limited Corrosion Consumer Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion and Horizon...
Page 18: Commercial Application Warranty Chart
Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...
Page 19: Government Application Warranty Chart
Section 1 - Warranty Government Application Warranty Chart Limited Corrosion Government Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...
Page 20: Mercury Installation Quality Certification Program 11 California Emissions Limited Warranty
California Emissions Limited Warranty NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 21: Duration Of Coverage
Duration Of Coverage NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model...
Page 22: What Mercury Will Do
Section 1 - Warranty What Mercury Will Do Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our expense and at our option, repairing or replacing defective parts with new or Mercury Marine certified re‑manufactured parts, or refunding the purchase price of the Mercury product.
Page 23: Components Of The Emission Control System 14 Disclaimers And Limitations
1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 24: Manufacturer's Warranty Coverage
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, FEL (emission level), date of manufacture (month, year), and the engine displacement.
Page 25: Owner Responsibility
Beginning January 1, 2003, one Three‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating. The Three‑Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission standards.
Page 26 Section 1 - Warranty The Three‑Star label will be affixed on the left side of the hull as shown. XX 1234 XX mc79531 Recommended location Secondary location 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.
Page 27: Section 2 - Getting To Know Your Power Package
Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............20 Console Mount Features - Single Engine..29 Engine Serial Number Decal MPI....20 Slim Binnacle Console Mount Features - Single Bravo Sterndrive Serial Number and Engine............30 Identification..........20...
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: Bravo Transom Serial Number
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers. 25907 Bravo sterndrive serial number stamping...
Page 30: Lanyard Stop Switch
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. 25905 Gimbal housing with serial number stamping Transom assembly serial Number...
Page 31: Instrumentation
Section 2 - Getting to Know Your Power Package The lanyard is a cord usually between 122 and 152 cm (4 and 5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.
Page 32: Digital Gauges
Section 2 - Getting to Know Your Power Package Your power package may be connected to the Mercury SC5000 SmartCraft System View display. The display monitors and reports information ranging from basic operating data to engine alarm data. The SC5000 System View Display is a comprehensive boat information center. System View allows the boat operator to receive a wealth of critical operational information, displayed clearly and instantly at the helm on the LCD display.
Page 33: Analog Gauges
Section 2 - Getting to Know Your Power Package Analog Gauges The following is a brief explanation of the instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings for your boat.
Page 34: Panel Mount Features
Section 2 - Getting to Know Your Power Package PANEL MOUNT FEATURES mc77019-1 Neutral lock button Control handle tension adjustment screw Throttle only button Control handle Lanyard stop switch Trim/tilt button Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the control handle out of neutral.
Page 35: Console Mount Features
Section 2 - Getting to Know Your Power Package CONSOLE MOUNT FEATURES mc79503-1 Throttle Only Button Power Trim Switch Control Handle Trailer Switch Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position.
Page 36: Panel Mount Features
Section 2 - Getting to Know Your Power Package Panel Mount Features 3409 Lanyard stop switch Control handle Shift lock Trim/tilt switch Throttle only button Start/stop button Detent tension adjustment screw Control handle friction adjustment screw Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.
Page 37: Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Console Mount Features ‑ Single Engine 3410 Control handle Trim/tilt switch Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 38: Engine
Section 2 - Getting to Know Your Power Package Slim Binnacle Console Mount Features ‑ Single Engine START STOP 14637 Control handle Trim/tilt switch Active light Neutral light Start/stop button Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 39: Console Mount Features- Dual Engine
Section 2 - Getting to Know Your Power Package Console Mount Features‑ Dual Engine SYNC ACTIVE THROTTLE ONLY STATION SELECT 3411 Trim/tilt switch Arrow trackpad Control handles Sync light Active light Throttle only/station select key Neutral light Detent tension adjustment Select key Control handle friction adjustment screw...
Page 40: Synchronizing Dual Engines
Section 2 - Getting to Know Your Power Package Synchronizing Dual Engines The auto synchronizing feature, when engaged, will automatically adjust the port engine speed to match the speed of the starboard engine. Synchronizing of engines will automatically engage when the speed of both engines are over 900 RPM for two seconds and remote control handles are positioned within 5°...
Page 41: Synchronizing Dual Helms Prior To Station Transfer
Section 2 - Getting to Know Your Power Package 3. Press throttle only/station select button once. The "ACTIVE" light will illuminate to indicate the remote control station is in control of the engine. SYNC ACTIVE ACTIVE THROTTLE THROTTLE ONLY ONLY STATION SELECT STATION SELECT 3433...
Page 42: Power Trim
Section 2 - Getting to Know Your Power Package Power Trim Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, low speed (below 1200 RPM engine speed) and shallow water operation.
Page 43: Single Engine Trim/Trailer
Section 2 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
Page 44 Section 2 - Getting to Know Your Power Package 1. A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. The circuit breaker can be tested by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset the yellow lever after testing, or if tripped, by pushing the yellow lever back into the housing.
Page 45 Section 2 - Getting to Know Your Power Package 4. A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for blown fuse if the ignition key is turned to the "START" position and nothing happens (and circuit breaker is not tripped).
Page 46: Audio Warning System
Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
Page 47: Warning Horn Signals
Section 2 - Getting to Know Your Power Package Also the Engine Guardian Strategy will reduce engine power to 90 percent of maximum if any sensor on the power package fails. For example, if the water inlet becomes partially blocked, Engine Guardian Strategy will reduce the available power level of the engine to help prevent damage from decreased water flow to the engine.
Page 48 Section 2 - Getting to Know Your Power Package Notes: Page 40 90-864195070 JUNE 2007...
Page 49 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........42 While You Are Cruising ........ 50 Be Alert To Carbon Monoxide Poisoning... 43 While Boat Is Stationary ....... 50 Good Ventilation ........... 44 High-Speed And High-Performance Boat Operation Poor Ventilation ...........
Page 50: Safe Boating Suggestions
Know and obey all nautical rules and laws of the waterways. • Mercury MerCruiser 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 51: Be Alert To Carbon Monoxide Poisoning
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 52: Good Ventilation
Section 3 - On The Water Good Ventilation Ventilate the passenger area, open the side curtains or forward hatches to remove fumes. 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.
Page 53: Starting And Stopping The Engine
Section 3 - On The Water Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Close seacock, if Operate bilge blowers. Check steering operation. equipped. Flush cooling system if in Open fuel shut off valve. saltwater. Open seacock, if Drain bilge.
Page 54: Stopping The Engine
IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. Page 46 90-864195070 JUNE 2007...
Page 55: Drain Plug And Bilge Pump
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 56: Stopping The Engine
Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes. NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process.
Page 57: Throttle Only Operation
If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit which is available from your authorized Mercury MerCruiser dealer. 90-864195070 JUNE 2007 Page 49...
Page 58: Freezing Temperature Operation
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 59: Passenger Safety In Pontoon Boats And Deck Boats
Section 3 - On The Water Passenger Safety In Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed.
Page 60: 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 61: Drive Unit Impact Protection
Section 3 - On The Water WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protection for the sterndrive unit.
Page 62: Bottom Of Boat
Section 3 - On The Water • Improves ease of planing • Improves rough water ride • At extremes, can cause the boat to veer back and forth (bow steer) Bottom Of Boat To maintain maximum speed, the boat bottom should be: •...
Page 63: Propeller Selection
Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After Break‑In Period To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered; 90-864195070 JUNE 2007...
Page 64: 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 65: Section 4 - Specifications
Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........58 Fluid Specifications........60 Fuel Ratings ..........58 Engine............60 Using Reformulated (Oxygenated) Gasolines Alpha Sterndrive..........61 (USA Only) ........... 58 Bravo Sterndrives..........61 Gasolines Containing Alcohol ...... 58 Power-Assisted Steering and Power Trim Fluids Engine Oil............
Page 66: Fuel Requirements
The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand.
Page 67: Engine Oil
To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of the following oils listed in the order of recommendation: 1. MerCruiser / Quicksilver Synthetic Blend, NMMA FC‑W rated, 4 cycle oil. 2. MerCruiser / Quicksilver 25W40 NMMA FC‑W rated oil.
Page 68: Fluid Specifications (Mpi)
Capacity Fluid Type Mercury/Quicksilver Synthetic Blend Engine oil (with filter) 3.8 liters (4 U.S. qt.) MerCruiser Engine Oil 25W‑40 Seawater cooling system (winterization use 20 liters (21 U.S. qt.) Propylene Glycol and Purified Water only) Mercury Extended Life Coolant/ Antifreeze or Extended Life Ethylene Closed cooling system 19 liters (20 U.S.
Page 69: Alpha Sterndrive
Fluid Type (includes Horizon) Models Mercury/Quicksilver Synthetic Blend Engine oil (with filter) 4.25 liters (4.5 U.S. qt.) MerCruiser Engine Oil 25W‑40 Seawater cooling system (winterization 20 liters (21 U.S. qt.) Propylene Glycol and Purified Water use only) Mercury Extended Life Coolant/...
Page 70 Section 4 - Specifications Notes: Page 62 90-864195070 JUNE 2007...
Page 71 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......65 Positive Crankcase Ventilation Valve (PCV) Dealer Responsibilities........65 ..............82 Maintenance............65 Changing ..........82 Do It Yourself Maintenance Suggestions... 66 Water-Separating Fuel Filter (MPI)..... 82 Inspection............
Page 72 Section 5 - Maintenance Alternative Water Pickups ....108 Models Using The Sterndrive Water Pickup The SeaCore Power Package Flushing ............. 109 Procedure............109 Page 64 90-864195070 JUNE 2007...
Page 73: Owner/Operator Responsibilities
• Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •...
Page 74: Do It Yourself Maintenance Suggestions
Transmission (Inboard models only) Do It Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.
Page 75: Maintenance Schedule - Sterndrive Models
Scheduled Maintenance NOTE: Only perform maintenance which applies to your particular power package. AFTER THE INITIAL 20 HOUR BREAK-IN PERIOD To help extend the life of your Mercury MerCruiser power package, we reccommend the following: • Change the engine oil and filter •...
Page 76: Every 200 Hours Or 3 Years
Section 5 - Maintenance • Driveshaft extension models: Lubricate the driveshaft U‑joints, and tailstock input and output bearings. EVERY 200 HOURS OR 3 YEARS • Inspect the U‑joints, the splines and the bellows. Check the clamps. Check the engine alignment. Lubricate the U‑joint splines and cross bearing, if equipped with a grease fitting.
Page 77: Engine Oil
Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat.
Page 78: Changing Oil And Filter
Fluid type 4.3L (262 cid) 3.8 liters (4 U.S. qt.) 5.0L (305 cid) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W‑40 4.25 liters (4.5 U.S. qt.) 5.7L (350 cid) Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage.
Page 79: Engine Oil Drain Pump
Section 5 - Maintenance 1. Loosen the oil filter to vent the system. 7284 Bilge drain plug Oil drain hose plug Tether Oil drain hose Clip Bilge drain flange 2. Remove the bilge drain plug. 3. Pull tether through the bilge drain. 4.
Page 80: Changing Filter
3.8 liters (4 U.S. qt.) Mercury/Quicksilver Synthetic Blend 5.0 MPI, 350 MAG MPI, MX 6.2 MPI MerCruiser Engine Oil 25W‑40 4.25 liters (4.5 U.S. qt.) 5.7L (350 cid) 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.
Page 81: Filling
Power steering pump Warm range Cold range 3. Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling 1. Remove the fill cap/dipstick and observe the level. 2. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.
Page 82: Filling
Heat exchanger cap 2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. 3. Install the cap onto the heat exchanger.
Page 83: Changing
92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Drive Unit Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat.
Page 84: Filling
If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.
Page 85: Changing
Section 5 - Maintenance Changing 1. Remove the gear lube monitor from the bracket. 6109 Gear lube monitor 2. Empty the contents into a suitable container. 3. Install the gear lube monitor in the bracket. 4. Bravo One Models: Remove the propeller, lower the sterndrive unit to the full down/ in position, remove the oil fill/drain screw and sealing washer and drain the oil.
Page 86 IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air‑free stream of...
Page 87: Power Trim Fluid
Section 5 - Maintenance Model Capacity Fluid Type Alpha One 1892 ml (64 oz.) Bravo One 2736 ml (92‑1/2 oz.) High Performance Gear Lubricant Bravo Two 3209 ml (108‑1/2 oz.) Bravo Three 2972 ml (100‑1/2 oz.) 11. Remove the pump from the oil fill/drain hole. Quickly install the sealing washer and oil fill/drain screw.
Page 88: Changing
Section 5 - Maintenance 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 89: Cleaning The Flame Arrestor
Section 5 - Maintenance Cleaning The Flame Arrestor WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.
Page 90: Positive Crankcase Ventilation Valve (Pcv)
Section 5 - Maintenance Positive Crankcase Ventilation Valve (PCV) CHANGING IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. NOTE: On V6 models the PCV valve is non‑serviceable and is an internal component of the valve cover.
Page 91: Gen Ii Models
Sealing ring REMOVAL 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped. 3. Wrap the water‑separating fuel filter with a cloth to help catch any fuel spills or spray.
Page 92: Gen Iii Models
O‑ring REMOVAL 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped. 3. Disconnect the Cool Fuel Module harness from the engine wiring harness.
Page 93: Installation
10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication Steering System...
Page 94 Section 5 - Maintenance 1. If Steering Cable Has Grease Fittings: Turn steering wheel until steering cable is fully retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand‑operated grease gun. 6221 Steering cable grease fitting Tube Ref No.
Page 95: Throttle Cable
3. Lubricate the steering pin. mc71904-1 Steering pin Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Steering pin 92‑883725K01 Oil SAE25W‑40 4. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.
Page 96: Shift Cable - Typical
Pivot points Guide contact surfaces Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Shift cable pivot points & guide 92‑883725K01 Oil SAE25W‑40 contact surfaces Sterndrive Unit and Transom Assembly 1. Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun.
Page 97: Sterndrive U-Joint Shaft Splines And O-Rings (Sterndrive Unit Removed)
Section 5 - Maintenance Sterndrive U‑joint Shaft Splines And O‑rings (Sterndrive Unit Removed) 1. Coat sterndrive U‑joint O‑rings and driveshaft splines with grease. 8591 Driveshaft splines U‑joint O‑rings (3) Tube Ref No. Description Where Used Part No. Driveshaft splines and U-joint Engine Coupler Spline Grease 92-802869A1 O-rings...
Page 98: Driveshaft Extension Models
92-802870A1 Grease driveshaft grease fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
Page 99: Alpha Propeller Installation
Section 5 - Maintenance Alpha Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage.
Page 100: Bravo One Propeller Removal
Section 5 - Maintenance 7. Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller.
Page 101: Bravo Two Propeller Removal
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 with Propeller shaft 92-802859A1 Teflon 3. Install Flo‑Torq II Drive Hub into propeller. NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued.
Page 102: Bravo Three 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. 14946 Propeller shaft Propeller nut Thrust hub Spline washer Propeller Tab washer 1. Slide thrust hub into propeller hub with stepped side toward propeller hub. 2.
Page 103 6. Turn front propeller shaft nut 70 mm (2‑3/4 in.) counterclockwise to remove nut. 7. Slide propeller and thrust hub off propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 5304 Rear propeller nut...
Page 104: Bravo Three Propeller Installation
Section 5 - 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. 5304 Rear propeller nut Front propeller thrust hub...
Page 105 Section 5 - Maintenance 8. Install the propeller shaft anode over the propeller shaft nut. 9. Place the flat washer onto the propeller shaft anode screw. 10. Place the star washer onto the propeller shaft anode screw. 11. If a propeller shaft anode is reinstalled, apply Loctite Threadlocker 271 to the threads of the propeller shaft anode screw.
Page 106: 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 Alternator pulley...
Page 107: Corrosion Protection
The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer and refer to the Mercury Precision Parts / Marine Corrosion Protection Guide (90‑881813003).
Page 108: Maintaining Ground Circuit Continuity
Section 5 - Maintenance 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. Good continuity is essential for the MerCathode System to function effectively.
Page 109: System
The MerCathode system should be tested to ensure adequate output. Perform the test where boat is moored, using the reference electrode and test meter. Contact your authorized Mercury MerCruiser dealer for service and information . 90-864195070 JUNE 2007 Page 101...
Page 110: Power Package Exterior Surfaces
Section 5 - Maintenance Reference Electrode 91‑76675T 1 Senses and electrical current in the water when testing the MerCathode system. Use to check hull potential. 9188 Power Package Exterior Surfaces 1. Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for proper application.
Page 111 • 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 112: Sterndrive Surface Care
Section 5 - Maintenance Do not power‑wash a sterndrive that has a MerCathode assembly. Doing so can damage the coating on the reference wire of the MerCathode assembly and increase corrosion. 21563 Reference electrode Anode plate Sterndrive Surface Care 21083 Standard Bravo sterndrive Sacrificial trim cylinder anode Stainless steel hoses...
Page 113: Flushing The Power Package
The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Bravo models equipped with closed cooling require dual water pickups and must be equipped with a through‑hull or through‑transom pickup in addition to the...
Page 114: Sterndrive Water Pickups
9194 STERNDRIVE WATER PICKUPS There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side pickups require the flushing attachment (44357Q 2).
Page 115 Section 5 - Maintenance 3. On Bravo closed cooled models using the sterndrive seawater inlet and a through-hull or through-transom alternative water pickup: Flushing water will need to be supplied to only the sterndrive by taking the following steps to block, or disconnect and block, the hose from the alternative seawater pickup pump inlet Y‑fitting.
Page 116: Alternative Water Pickups
Section 5 - Maintenance ALTERNATIVE WATER PICKUPS IMPORTANT: Two water sources are needed for this procedure. NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through‑hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation.
Page 117: The Seacore Power Package Flushing Procedure
Section 5 - Maintenance 8. Place the remote control in neutral idle speed position and start engine. NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.
Page 118 Section 5 - Maintenance 2. Close the seacock, if equipped. 18510 For visual clarity, the secock shown is not installed Hose fitting to engine Handle (closed position) Seacock To water source pickup attachment 3. If equipped with an alternative water pickup and not equipped with a seacock, disconnect the water hose from the alternative water pickup and plug both ends, excluding the Bravo sterndrive.
Page 119 Section 5 - Maintenance 7. Snap the quick‑connect fitting with the water hose into the flush socket on the engine. 18489 Water hose Flush socket Quick‑connect fitting (water hose end) 8. Open the water source of the water hose to a full flow. 9.
Page 120 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. 25900 Quick‑connect fitting stored in the boat Quick‑connect fitting (water hose end)
Page 121 Section 5 - Maintenance 20. Insert the dust cover in the flush socket on the engine. 18490 Dust cover installed in the flush socket Dust cover Flush socket IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage.
Page 122 Section 5 - Maintenance Notes: Page 114 90-864195070 JUNE 2007...
Page 123 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....116 Boat out of the Water ......122 Preparing Power Package for Storage..116 Manual Single Point Drain System....124 Engine and Fuel System Preparation . . 117 Boat in the Water .........
Page 124: Cold Weather Or Extended Storage
Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage.
Page 125: Engine And Fuel System Preparation
Section 6 - Storage NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
Page 126: Draining The Seawater System
Section 6 - Storage 3. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not equipped with a fuel shut off valve. 4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting. IMPORTANT: Supply cooling water to the engine.
Page 127: Drain System Identification
Section 6 - Storage Drain System Identification AIR ACTUATED SINGLE POINT DRAIN SYSTEM 6125 6124 Closed Cooled Models Seawater Cooled Models Blue drain plug location Air manifold Blue air pump Green indicators MANUAL SINGLE POINT DRAIN SYSTEM 6128 Blue handle Blue drain plug location THREE POINT MANUAL DRAIN SYSTEM 6126...
Page 128: Multi-Point Drain (Mpd) System
Section 6 - Storage MULTI-POINT DRAIN (MPD) SYSTEM 6129 Side of cylinder block Bottom of exhaust manifolds 6130 Water circulating pump hose Fuel cooler to thermostat housing 6131 Check valve (if equipped) Air Actuated Single Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine.
Page 129: Section 6 - Storage
Section 6 - Storage 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump Green indicators Lever (locking) Manual release valve 6. Pump air into the system until both green indicators extend and water drains from both sides of the engine.
Page 130: 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 131 Section 6 - Storage 3. Ensure that the lever on top of the pump is flush with the handle (horizontal). 4. Install the air pump on the actuator fitting. 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump...
Page 132: Manual Single Point Drain System
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 133: Boat Out Of The Water
6137 Drain location ‑ orange or red Blue drain plug 5. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. 6. Reinstall the blue drain plug in the thermostat housing.
Page 134: Three Point Manual Drain System
Drain location ‑ orange or red Blue drain plug 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 135 Blue drain plugs 5. Verify that water is draining from each opening. 6. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 136: Boat Out Of The Water
Blue drain plug 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 137 Section 6 - Storage Water circulating pump hose 6143 Drain plug Fuel cooler to thermostat housing hose 6144 Drain plug Check valve 6131 Drain plug (if equipped) 90-864195070 JUNE 2007 Page 129...
Page 138: Draining The Sterndrive
Section 6 - Storage 3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...
Page 139: Battery Storage
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage.
Page 140 Section 6 - Storage Notes: Page 132 90-864195070 JUNE 2007...
Page 141: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems......... 134 Low Engine Oil Pressure........136 Diagnosing DTS Problems....... 134 Battery Will Not Come Up On Charge....136 Engine Guardian System........134 Remote Control Operates Hard, Binds, Has Starter Motor Will Not Crank Engine, Or Cranks Excessive Free-play Or Makes Unusual Sounds Slow..............
Page 142: Diagnosing Efi Problems
Section 7 - Troubleshooting Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.
Page 143: Engine Runs Rough, Misses And/Or Backfires
Section 7 - Troubleshooting Possible Cause Remedy Have EFI System checked by an authorized Mercury EFI system fault. MerCruiser dealer. Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Clogged fuel filter. Replace filter. Stale or contaminated fuel. If contaminated, drain tank. Fill with fresh fuel.
Page 144: Insufficient Engine Temperature
Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair. Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level.
Page 145: Power Trim Does Not Operate (Motor Does Not Operate)
Section 7 - Troubleshooting Power Trim Does Not Operate (Motor Does Not Operate) Possible Cause Remedy Replace fuse. Fuses may be located near the dash trim switch, at the trim pump, in the positive (red) Blown fuse. power trim battery lead near the battery switch, or a combination of these.
Page 146 Section 7 - Troubleshooting Notes: Page 138 90-864195070 JUNE 2007...
Page 147: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 140 Parts And Accessories Inquiries ..141 Local Repair Service ........140 Resolving A Problem ........141 Service Away From Home ......140 Mercury Marine Service Offices ....
Page 148: Owner Service Assistance
These are but a few of the many special modifications that are required in Mercury MerCruiser marine engines to provide long life and dependable performance. 1. Quicksilver parts and accessories are engineered and built by Mercury Marine, specifically for Mercury MerCruiser sterndrives and inboards.
Page 149: Parts And Accessories Inquiries
Resolving A Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If additional assistance is required, take these steps: 1.
Page 150: Ordering Literature
• Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P.O. Box 1939...

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MerCruiser Sterndrive 4.3 MPI User Manual

Section 3 - on the Water

Section 4 - Specifications

Section 5 - Maintenance

Section 7 - Troubleshooting

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