MerCruiser Sterndrive 4.3 MPI User Manual
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MerCruiser Sterndrive 4.3 MPI User Manual

MerCruiser Sterndrive 4.3 MPI User Manual

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NOTE: The following applies to CE marked products only.
Declaration of Conformance – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury MerCruisers' instructions complies with the
requirements of the following directives by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Applicable Requirement
Owner's manual (A.2.5)
Openings in Hull, Deck and superstructure (A.3.4)
Handling characteristics (A.4)
Inboard Engine (A.5.1.1)
Fuel System (A.5.2)
Electrical System (A.5.3)
Steering system (A.5.4)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Ignition‑protected equipment (Annex II)
Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust, when installed in a
recreational craft, in accordance with the manufacturers supplied instructions, will meet the exhaust emissions
requirements of the directive mentioned above. This engine must not be put into service until the recreational craft in which
it is to be installed has been declared in conformity, if so required, with the relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion engine driven
devices ‑ Radio disturbance characteristics
Electrostatic discharge testing
The notified body responsible for surveillance of the quality system under Full Quality Assurance Module H of Directive
2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.
President ‑ Mercury MerCruiser, Stillwater, OK, USA
Regulatory contact:
Regulations and Product Safety Department
Mercury Marine
W6250 W. Pioneer Road
Fond du Lac, WI 54936
USA
Identification Record
Please record the following information:
ISO 10240
ISO 9093‑1; ISO 9093‑2
ISO 8665
ISO 15584; ISO 10088; ISO 7840; ISO 10133
ISO 10088; ISO 7840; ISO 8469
ISO 10133; ISO 8846
Applicable portions of: ISO 10592, ISO 8848 and ABYC
P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 8846; SAE J1171; SAE J1191; SAE J 2031
EN 50081‑1
EN 50082‑1
SAE J551 (CISPR 12)
EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3
Kevin Grodzki
Standards Applied

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

  • Page 2: Read This Manual Thoroughly

    Boat Model Length The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser® power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation.
  • Page 3 Notice Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. These Safety Alerts alone cannot eliminate the hazards that they signal.

  • Page 5: Table Of Contents

    Transfer of Warranty..............2 Duration of Coverage............11 Mercury Product Protection Plan: United States and Canada... 3 How to Obtain Warranty Coverage........12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled What Mercury Will Do............12 Products Only) ................3 What Is Not Covered............12 3‑Year Limited Warranty Against Corrosion......5 Disclaimers and Limitations..........12...
  • Page 6 Impact with Underwater Hazards........... 42 Ventilation................43 Drive Unit Impact Protection..........42 Elevation and Climate............. 44 Operating with Low Water Inlets in Shallow Water....43 Propeller Selection............44 Conditions Affecting Operation..........43 Getting Started............... 44 Weight Distribution (Passengers and Gear) Inside the 20‑Hour Break‑In Period..........
  • Page 7 Corrosion Information............81 Sterndrive Surface Care........... 85 Maintaining Ground Circuit Continuity......81 Flushing the Power Package........... 85 Anodes and MerCathode System Locations....81 Flushing Attachments........... 86 Checking the Quicksilver MerCathode System....82 Sterndrive Water Pickups..........87 Power Package Exterior Surfaces........83 Alternative Water Pickups..........
  • Page 8 Page iv 90-8M0053269 NOVEMBER 2010...
  • Page 9 Mercury Product Protection Plan: United States and Canada How to Obtain Warranty Coverage ....... 12 ....................3 What Mercury Will Do ........... 12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled What Is Not Covered ............ 12 Products Only) ............... 3 Disclaimers and Limitations .......... 12 3‑Year Limited Warranty Against Corrosion......

  • Page 10: Warranty Registration: United States And Canada

    Federal Boat Safety Act is required. You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax to Mercury MerCruiser’s warranty registration department with your name, old address, new address, and engine serial number.

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

    The optional Mercury Product Protection Plan is the only Factory Plan available for your engine. One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after the original engine registration date. See your participating Mercury MerCruiser dealer for complete program details. Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)
  • Page 12 Section 1 - Warranty Transfer of Coverage Unexpired warranty coverage can be transferred from one recreational‑use customer to a subsequent recreational‑use customer upon proper reregistration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial‑use customer.

  • Page 13: 3-Year Limited Warranty Against Corrosion

    Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.

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

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

  • Page 15: Global Warranty Charts

    This limited corrosion warranty provides coverage for four (4) years from either the date on which the MerCruiser SeaCore engine, transom, and sterndrive package is first sold or the date on which it is first put into service, whichever occurs first. The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.

  • Page 16: Consumer Application Warranty Chart

    Section 1 - Warranty Consumer Application Warranty Chart Limited Corrosion Consumer Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...

  • Page 17: Commercial Application Warranty Chart

    Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...

  • Page 18: 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 19: 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 20: How To Obtain Warranty Coverage

    Your Warranty Rights and Obligations 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: 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 22: 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 23 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 24 Section 1 - Warranty Notes: Page 16 90-8M0053269 NOVEMBER 2010...

  • Page 25: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification................. 18 Slim Binnacle Console Mount Features ‑ Single Engine Engine Serial Number Decal MPI........18 ..................24 Bravo Sterndrive Serial Number and Identification..18 Console Mount Features‑...

  • Page 26: Identification

    Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal MPI The serial number decal is located on the engine cover.

  • Page 27: Bravo Transom Serial Number

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

  • Page 28: Instrumentation

    Section 2 - Getting to Know Your Power Package • 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 29: Digital Gauges

    Section 2 - Getting to Know Your Power Package 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. The System View continuously monitors and reports information ranging from basic operating data to detailed vessel environment information.

  • Page 30: Panel Mount Features

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

  • Page 31: Remote Controls (Dts Models)

    Section 2 - Getting to Know Your Power Package Control Handles - Operation of the the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear and continue pushing forward to increase speed.

  • Page 32: Console Mount Features - Single Engine

    Section 2 - Getting to Know Your Power Package 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 33: 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 34: 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 35: 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 36: 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 37 Section 2 - Getting to Know Your Power Package 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 38: 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 39: Testing The Audio Warning System

    If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If you cannot determine the cause, contact your authorized Mercury MerCruiser dealer. Testing The Audio Warning System Turn the ignition switch to the "ON"...
  • Page 40 Section 2 - Getting to Know Your Power Package Notes: Page 32 90-8M0053269 NOVEMBER 2010...
  • Page 41 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions............ 34 Drain Plug and Bilge Pump..........40 Be Alert to Carbon Monoxide Poisoning....... 35 Protecting People in the Water..........40 Good Ventilation ............35 While You Are Cruising ..........

  • Page 42: Safe Boating Suggestions

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

  • Page 43: 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 44: 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 45: 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 46: 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 47: 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 48: 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 49: 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 50: 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 51: 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 52: Elevation And Climate

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

  • Page 53: 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 54 Section 3 - On The Water Notes: Page 46 90-8M0053269 NOVEMBER 2010...

  • Page 55: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 48 Fluid Specifications (MPI)............. 50 Fuel Ratings ..............48 Fluid Specifications............50 Using Reformulated (Oxygenated) Gasolines (USA Only) Engine................50 ..................48 Alpha Sterndrive............51 Gasolines Containing Alcohol ........48 Bravo Sterndrives............

  • Page 56: 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. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 57: Engine Specifications (Mpi)

    NOTE: The use of non‑detergent oils, multi‑viscosity oils (other than as specified), non FC‑W rated synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended. MerCruiser/ Quicksilver Synthetic Blend, NMMA FC-W rated, 4-cycle oil MerCruiser / Quicksilver 25W40 NMMA FC-W rated oil...

  • Page 58: Fluid Specifications (Mpi)

    Always use the dipstick to determine the exact quantity of oil or fluid required. 4.3L MPI Models Capacity Fluid Type Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil Engine oil (with filter) 3.8 liters (4 U.S. qt.) 25W‑40 Seawater cooling system 20 liters (21 U.S.

  • Page 59: Alpha Sterndrive

    5.0 MPI, 350 MAG MPI, MX 6.2 MPI (includes Capacity Fluid Type Horizon) Models 4.25 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Engine oil (with filter) (4.5 U.S. qt.) Oil 25W‑40 Seawater cooling system (winterization use 20 liters (21 U.S. qt.)
  • Page 60 Section 4 - Specifications Notes: Page 52 90-8M0053269 NOVEMBER 2010...
  • Page 61 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 54 Changing ............... 67 Dealer Responsibilities............54 Water‑Separating Fuel Filter (MPI)........67 Maintenance................. 54 Water‑Separating Fuel Filter.......... 67 Do‑It‑Yourself Maintenance Suggestions......54 GEN II Models............... 68 Inspection................55 Removal ..............

  • Page 62: 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 63: 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 64: Every 100 Hours Or Annually (Whichever Occurs First)

    Section 5 - Maintenance Every 100 Hours or Annually (Whichever Occurs First) • Touch‑up the paint on the power package. • Change the crankcase oil and filter. • Change the drive unit oil • Retorque the connection of the gimbal ring to the steering shaft. •...

  • Page 65: 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. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

  • Page 66: 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 67: Changing Filter

    Engine Model Engine Oil Capacity Fluid type 4.3L MPI 3.8 liters (4 U.S. qt.) Mercury/Quicksilver Synthetic Blend MerCruiser 5.0 MPI, 350 MAG MPI, MX 6.2 MPI 5.7L Engine Oil 25W‑40 4.25 liters (4.5 U.S. qt.) (350 cid) Start the engine, run the engine for three minutes, and check for leaks. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan.

  • Page 68: Filling

    Warm range 6100 Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling Remove the fill cap/dipstick and observe the level. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.

  • Page 69: Filling

    Fill to the "FULL" line with the specified coolant. Tube Ref No. Description Where Used Part No. Extended Life Antifreeze/ Closed Cooling System 92-877770K1 Coolant Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. 90-8M0053269 NOVEMBER 2010 Page 61...

  • Page 70: 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 71: Changing

    Section 5 - Maintenance Changing Remove the gear lube monitor from the bracket. Gear lube monitor 6109 Empty the contents into a suitable container. Install the gear lube monitor in the bracket. 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 72: Power Trim Fluid

    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 73: Filling

    Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.

  • Page 74: Cleaning The Flame Arrestor

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

  • Page 75: Positive Crankcase Ventilation Valve (Pcv)

    Positive Crankcase Ventilation Valve (PCV) Changing NOTE: We recommend the use of 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 76: Gen Ii Models

    Removal Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close the fuel supply valve, if equipped. Wrap the water‑separating fuel filter with a cloth to help catch any fuel spills or spray.

  • Page 77: 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 78: 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 79: 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 80: 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 81: 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 82: 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 83: 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 84: 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 85: 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 86: 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 87 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 88: 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 89: Corrosion Protection

    This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer and refer to the Mercury Precision Parts / Marine Corrosion Protection Guide (90‑881813003).

  • Page 90: 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 82...

  • Page 91: Power Package Exterior Surfaces

    Section 5 - Maintenance Reference Electrode 91‑76675T 1 Senses and electrical current in the water when testing the MerCathode system. Use to check hull potential. 9188 Power Package Exterior Surfaces Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for proper application.
  • Page 92 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 93: Sterndrive Surface Care

    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 sterndrive water inlets.

  • Page 94: Flushing Attachments

    Section 5 - Maintenance Flushing Attachments 21514 21515 Flushing attachments for dual water pickup Flushing attachments for side water pickup Flushing device Hose attachment Dual water pickup flush gearcase seal kit Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

  • Page 95: Sterndrive Water Pickups

    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 96: Alternative Water Pickups

    Section 5 - Maintenance 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. Depress the throttle‑only button and slowly advance the throttle until the engine reaches 1300 RPM (±...

  • Page 97: Seacore Power Package Flushing Procedure

    Section 5 - Maintenance NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. With sterndrive in normal operating position, open the water source fully. Place the remote control in neutral idle speed position and start engine.
  • Page 98 Section 5 - Maintenance 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. Ensure that the inlet water hose from the sterndrive to the engine is connected. Remove the quick‑connect fitting from the parts bag supplied with the engine.
  • Page 99 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 100 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 101: Section 6 - Storage

    Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........94 Boat out of the Water ..........99 Preparing Power Package for Storage......94 Manual Single‑Point Drain System......101 Engine and Fuel System Preparation ....95 Boat in the Water ..........

  • Page 102: Cold Weather Or Extended Storage

    Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures.

  • Page 103: Engine And Fuel System Preparation

    Section 6 - Storage Engine and Fuel System Preparation WARNING Fuel is flammable and explosive. Ensure that 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. Keep the work area well ventilated and avoid prolonged exposure to vapors.

  • Page 104: Drain System Identification

    Section 6 - Storage Drain System Identification Air Actuated Single Point Drain System 6124 6125 Closed Cooled Models Seawater Cooled Models Blue drain plug location Blue air pump Air manifold Green indicators Manual Single Point Drain System 6128 Blue handle Blue drain plug location Three Point Manual Drain System Blue drain plug...

  • Page 105: Multi-Point Drain (Mpd) System

    Section 6 - Storage Multi-Point Drain (MPD) System Side of cylinder block Bottom of exhaust manifolds 6129 6130 Water circulating pump hose Fuel cooler to thermostat housing Check valve (if equipped) 6131 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 106 Section 6 - Storage Pull lever on air pump (vertical) to lock pump on the fitting. Actuator fitting Green indicators Manual release valve Air pump Lever (locking) 8293 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.

  • Page 107: Boat Out Of The Water

    Section 6 - Storage 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. 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.
  • Page 108 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 109: Manual Single-Point Drain System

    Section 6 - Storage Manual Single‑Point Drain System Boat in the Water Close the seacock (if equipped) or remove and plug the water inlet hose. Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open.

  • Page 110: Three-Point Manual Drain System

    Section 6 - Storage Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open. Do not overtighten the handle, as this action will create new threads. Blue handle 6141 Visually verify that water is draining.

  • Page 111: Boat Out Of The Water

    Section 6 - Storage 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). Blue drain plugs 6140 Verify that water is draining from each opening.

  • Page 112: Multi-Point Drain (Mpd) System

    Section 6 - Storage Multi‑Point Drain (MPD) System Place the boat on a level surface to ensure complete draining of the system. Remove the blue drain plugs from the following locations. It may be necessary to clean out the drain holes using a stiff piece of wire.

  • Page 113: Draining The Sterndrive

    Section 6 - Storage Check valve Drain plug (if equipped) 6131 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 114: Battery Storage

    IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
  • Page 115 Section 6 - Storage Carefully inspect the engine for fuel, oil, fluid, water and exhaust leaks. Inspect the steering system, shift and throttle control for proper operation. 90-8M0053269 NOVEMBER 2010 Page 107...
  • Page 116 Section 6 - Storage Notes: Page 108 90-8M0053269 NOVEMBER 2010...

  • Page 117: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........... 110 Low Engine Oil Pressure............ 112 Diagnosing DTS Problems..........110 Battery Will Not Recharge..........112 Engine Guardian System............ 110 Remote Control Is Difficult to Move, Has Excessive Play, or Starter Motor Will Not Crank Engine, Or Cranks Slow..

  • Page 118: 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 119: 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 120: 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 121: Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move)

    Section 7 - Troubleshooting Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low. Fill pump with oil. Drive unit binding in gimbal ring. Check for obstruction. 90-8M0053269 NOVEMBER 2010 Page 113...
  • Page 122 Section 7 - Troubleshooting Notes: Page 114 90-8M0053269 NOVEMBER 2010...

  • Page 123: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance..........116 Parts and Accessories Inquiries ......116 Local Repair Service ..........116 Resolving a Problem ..........116 Service Away From Home .......... 116 Mercury Marine Service Offices .........

  • Page 124: Owner Service Assistance

    Resolving a Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If you need additional assistance: Talk with the dealership's sales manager or service manager.

  • Page 125: 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 us at: Mercury Marine Publications P.O. Box 1939...

  • Page 126: 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. Print or type your mailing address, which be used as your shipping label, and include your order and payment. Mail to:...

This manual is also suitable for:

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