MerCruiser 3.0 MPI Owner's Manual
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MerCruiser 3.0 MPI Owner's 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
Owner's manual (A.2.5)
Openings in Hull, Deck and superstructure (A.3.4) ISO 9093‑1; ISO 9093‑2
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 Marine, Fond du Lac, WI USA
Applicable Requirement
Patrick C. Mackey
Standards Applied
ISO 10240
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

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Summary of Contents for MerCruiser 3.0 MPI

  • 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 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.

  • Page 3: Read This Manual Thoroughly

    Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant! Mercury MerCruiser Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty...
  • 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

    Mercury Product Protection Plan: United States and What Is Not Covered........12 Canada..............3 Components Of The Emission Control System 12 Mercury MerCruiser Limited Warranty Disclaimers And Limitations......14 (Gasoline‑Fueled Products Only) ......4 California Emission Control Warranty Statement. .14 3‑Year Limited Warranty Against Corrosion....6 Your Warranty Rights and Obligations.....14...
  • Page 6 Conditions Affecting Operation......42 Elevation and Climate........43 Weight Distribution (Passengers and Gear) Propeller Selection........43 Inside the Boat..........42 Getting Started............. 44 The Bottom of the Boat......... 42 20‑Hour Break‑In Period....... 44 Cavitation............42 After Break‑In Period........44 Ventilation............. 42 End of First Season Checkup....... 44 Section 4 - Specifications Fuel Requirements..........46 Engine Oil.............47...
  • Page 7 Section 6 - Storage Cold Weather or Extended Storage....... 86 Clearing Clogged Blue Drain Hoses....92 Preparing Power Package for Storage...86 Draining the Sterndrive........94 Engine and Fuel System Preparation..87 Battery Storage............95 Draining the Seawater System......88 Power Package Recommissioning......95 Single‑Point Drain System......88 Draining the Seawater Section of Models with Closed Cooling..........89...
  • Page 8 Page iv 90-899883272 MARCH 2008...

  • Page 9: Section 1 - Warranty

    Mercury Product Protection Plan: United States and Components Of The Emission Control Canada..............3 System ............12 Mercury MerCruiser Limited Warranty (Gasoline- Disclaimers And Limitations ......14 Fueled Products Only) ......... 4 California Emission Control Warranty Statement 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 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 is completed and documented.

  • 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: Global Warranty Charts

    Section 1 - Warranty This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty;...

  • Page 16: 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 Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...

  • Page 17: 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 Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...

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

    Section 1 - Warranty How To Obtain Warranty Coverage The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.
  • Page 21 Section 1 - Warranty Cold start enrichment system Intake valve(s) 2. Air Induction System Controlled hot air intake system Intake manifold Air filter Turbocharger systems Heat riser valve and assembly 3. Ignition System Spark plugs Magneto or electronic ignition system Spark advance/retard system Ignition coil and/or control module Ignition wires...

  • Page 22: Disclaimers And Limitations

    1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.

  • Page 23: Emission Control Information Label

    A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement.

  • Page 24: Owner Responsibility

    Beginning January 1, 2003, one Three‑Star or Four‑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 or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2007 and later exhaust emission standards.
  • Page 25 Section 1 - Warranty One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
  • Page 26 Section 1 - Warranty Notes: Page 18 90-899883272 MARCH 2008...

  • Page 27: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............20 Single Engine Trim/Trailer ......26 Alpha Sterndrive Decal Identification....20 Dual Engine Trim/Trailer ......27 Alpha Transom Serial Number......20 Electrical System Overload Protection....

  • 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. Alpha Sterndrive Decal Identification The Drive Serial No.

  • Page 29: Engine Serial Number Decal

    Section 2 - Getting to Know Your Power Package Engine Serial Number Decal The serial number decal is located on the aft portion of the starboard side of the block, near the starter motor. 32121 The engine, transom, and drive serial numbers are also located on the engine identification plate.

  • Page 30: Lanyard Stop Switch

    Section 2 - Getting to Know Your Power Package Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator's position (as in accidental ejection from the operator's position). 74608 Stop switch Clips to the operator...

  • Page 31: Instrumentation

    Section 2 - Getting to Know Your Power Package Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: • Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.

  • Page 32: Remote Controls

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

  • Page 33: 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 34: Single Engine Trim/Trailer

    Section 2 - Getting to Know Your Power Package For best performance trim the sterndrive unit so that the boat bottom is at a 3‑5° angle to the water. 3 - 5 mc79528 Trimming sterndrive unit up/out can: • Generally increase top speed •...

  • Page 35: Dual Engine Trim/Trailer

    Reset the circuit breaker. If the breaker remains open, you have not eliminated the electrical overload and the electrical system requires further checks. Contact your authorized Mercury MerCruiser dealer. A circuit breaker protect the engine wiring harness and the instrumentation power lead. To test the circuit breaker, push the red button.
  • Page 36 Section 2 - Getting to Know Your Power Package Four fuses protect the main power, fuel pump, ignition, and accessory circuits. Two 10 amp fuses protect the O sensors. These are located on the top of the engine underneath the engine information plate.
  • Page 37 Section 2 - Getting to Know Your Power Package In the ignition switch "I" terminal lead, there may be a 20 amp fuse that protects the electrical system. Check for a failed fuse if you turn the ignition key to the "START" position and nothing happens, assuming the circuit breaker is not tripped.

  • Page 38: Audio Warning System

    IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from damage. Your Mercury MerCruiser power package may be equipped with an audio warning system. Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.

  • Page 39: Caution

    Severe IMPORTANT: If you experience a severe fault, contact your authorized Mercury MerCruiser dealer. If a severe fault is detected, the audio warning system will sound for six seconds, turn off for six seconds, then sound for six more seconds.

  • Page 40: Obdm

    Guardian restores engine power to normal. To avoid recurrence of the problem, contact an authorized Mercury MerCruiser dealer. As another example, Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage. Transmission Guardian monitors the clutch pack pressure in forward and reverse gears.

  • Page 41: Section 3 - On The Water

    Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions........34 Passenger Safety in Pontoon Boats and Deck Boats Be Alert to Carbon Monoxide Poisoning..... 35 ................39 Good Ventilation ........... 35 Boats Having An Open Front Deck ....

  • 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.

  • Page 43: Be Alert To Carbon Monoxide Poisoning

    Section 3 - On the Water • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat;...

  • Page 44: Poor Ventilation

    Section 3 - On the Water 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. Install one or more carbon monoxide detectors in your boat.

  • Page 45: Starting And Stopping The Engine

    Section 3 - On the Water Operation Chart WHILE BEFORE STARTING AFTER STARTING AFTER STOPPING UNDERWAY Check shift and Turn battery switch on. throttle control Close fuel shut off valve. operation. Check steering Close seacock, if Operate bilge blowers. operation. equipped.

  • Page 46: Stopping The Engine

    Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.

  • Page 47: Protecting People In The Water

    Section 3 - On the Water Protecting People in the Water While You Are Cruising It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 48: 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 49: 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 50: Drive Unit Impact Protection

    Section 3 - On the Water Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object, reducing damage to the unit.

  • Page 51: Elevation And Climate

    Section 3 - On the Water • Drive unit trimmed out too far. • A missing propeller diffuser ring. • A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing. • Drive unit installed too high on transom. Elevation and Climate Elevation and climate changes will affect the performance of your power package.

  • Page 52: Getting Started

    Change the engine oil and oil filter. Refer to Maintenance. 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...
  • Page 53 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........46 Engine Oil............47 Fuel Ratings ..........46 Engine Specifications......... 48 Using Reformulated (Oxygenated) Gasoline Fluid Specifications..........48 (USA Only) ........... 46 Sterndrives ........... 48 Gasoline Containing Alcohol ......46 Engine ............

  • Page 54: Fuel Requirements

    Reformulated gasoline is required in certain areas of the USA and are acceptable for use in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol.

  • Page 55: Engine Oil

    IMPORTANT: Lubrication requirements for catalyzed engines differ from the requirements for non‑catalyzed engines. Some marine‑grade lubricants contain high levels of phosphorus, which can damage the catalyst system on MerCruiser engines. Although these high‑phosphorus lubricants may allow acceptable engine performance, exposure over time will damage the catalyst.

  • Page 56: Engine Specifications

    IMPORTANT: All capacities are approximate fluid measures. 3.0 MPI Capacity Fluid Type Mercury Full‑Synthetic MerCruiser 20W‑40, NMMA FC‑W rated Engine oil (with filter) 3.8 L (4 US qt) oil. Seawater cooling system 9 L (8.5 US qt) Propylene glycol and purified water...
  • Page 57 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......50 Changing ..........63 Dealer Responsibilities........50 Cleaning the IAC Muffler........64 Maintenance............50 Changing the Water-Separating Fuel Filter..65 Do-It-Yourself Maintenance Suggestions... 51 Inspecting the Fuel Pump Sight Tube....66 Inspection............

  • Page 58: 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 59: 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 60: Maintenance Schedule-Sterndrive Models

    Section 5 - Maintenance Maintenance Schedule—Sterndrive Models Routine Maintenance NOTE: Only perform maintenance that applies to your particular power package. Task Interval Maintenance to Be Performed • Check the engine oil level. (You can extend this interval based on experience with the product.) •...

  • Page 61: Maintenance Log

    • Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase ventilation hoses. Inspect the PCV valve, if equipped. NOTE: On MerCruiser V6 models, the PCV valve is a non‑serviceable, internal component of the valve cover assembly. • Inspect the condition and the tension of the belts.

  • Page 62: Engine Oil

    Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil Checking and Filling 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 63: Changing Oil And Filter

    Capacity Fluid Type 3.0 MPI 3.8 L (4 US qt) Mercury Full‑Synthetic MerCruiser Oil 20W‑40 5. Replace the fill cap. Changing Oil and Filter See Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage.

  • Page 64: Engine Oil Drain Pump

    Section 5 - Maintenance 4. Pull tether through the bilge drain. 7284 Bilge drain plug Oil drain hose plug Tether Oil drain hose Clip Bilge drain flange 5. Place the oil drain hose in a suitable container. 6. Remove the drain plug from the oil drain hose. 7.

  • Page 65: Power-Assisted Steering Fluid

    Cold full mark Warm full mark 3. Add the specified fluid if required. Refer to Filling. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling 1. Remove the fill cap and dipstick and observe the fluid level.

  • Page 66: Changing

    2. The coolant level in the thermostat housing should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. 3. Check the antifreeze concentration for adequate freeze protection and correct if necessary.

  • Page 67: Filling

    Section 5 - Maintenance 5. With the engine at normal operating temperature, check that the coolant level in the coolant recovery bottle is between the "ADD" and "FULL" marks. 6102 6. Add the specified fluid as necessary. Tube Ref No. Description Where Used Part No.

  • Page 68: Changing

    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 69 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. 6. 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 70: Power Trim Fluid

    Power Trim and Steering Fluid Power trim pump 92-858074K01 3. Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Page 62 90-899883272 MARCH 2008...

  • Page 71: Cleaning The Flame Arrestor

    Positive Crankcase Ventilation Valve (PCV) CHANGING IMPORTANT: You cannot clean the PCV valve. Replace the PCV valve if it is defective or sticking. To ensure compliance with emission regulations, use only Mercury MerCruiser replacement parts. 1. Remove the engine information plate.

  • Page 72: Cleaning The Iac Muffler

    Section 5 - Maintenance 2. Remove the PCV valve. 32608 PCV valve Crankcase ventilation hose return fitting 3. If inspecting the valve with the engine stopped: Disconnect the PCV valve from the hose. Shake the PCV valve. If you hear a metallic rattle, the valve is functional. If you do not hear the rattle, replace the valve.

  • Page 73: Changing The Water-Separating Fuel Filter

    Section 5 - Maintenance 2. Remove the IAC muffler from the slot in the air valve plate using needle‑nosed pliers. 32180 IAC muffler location 3. Inspect the muffler for holes, cracks, or deterioration. Replace if damaged. IMPORTANT: Do not use a cleaner tains methyl ethyl ketone and do not use cleaner on electrical connections.

  • Page 74: Inspecting The Fuel Pump Sight Tube

    Inspecting the Fuel Pump Sight Tube The engine fuel pump sight tube gives you visual evidence of a fuel leak. If fuel is ever visible in the tube, see your authorized Mercury MerCruiser dealer to replace the fuel pump. 32555...

  • Page 75: Lubrication

    Section 5 - Maintenance Lubrication Steering System WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased. 1.

  • Page 76: Manual Steering System

    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 77: Throttle Cable

    1. Lubricate the pivot points and the guide contact surfaces. mc79736 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 90-899883272 MARCH 2008 Page 69...

  • Page 78: Sterndrive Unit And Transom Assembly

    Section 5 - Maintenance Sterndrive Unit and Transom Assembly 1. Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun. mc77068-1 Gimbal bearing grease fitting Tube Ref No. Description Where Used Part No. U-joint and Gimbal Bearing Gimbal bearing 92-802870A1 Grease...

  • Page 79: Driveshaft Extension Models

    Section 5 - Maintenance NOTE: If the boat is operated at idle for prolonged periods of time, coupler should be lubricated in the Alpha Models ‑ every 150 hours. 6213 Alpha drive coupler Engine coupler grease fitting Tube Ref No. Description Where Used Part No.

  • Page 80: Propellers

    Section 5 - Maintenance 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 81: Drive Belts

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shaft 92-802867Q 1 2-4-C Marine Lubricant with Propeller shaft 92-802859A 1 Teflon 2. Slide thrust hub onto propeller shaft, with stepped side toward propeller hub. 3.

  • Page 82: Replacing Belts On Front Mount Models

    Section 5 - Maintenance Replacing Belts on Front Mount Models 32557 Power steering belt Spacer block Alternator belt Crank position sensor Alternator POWER STEERING PUMP DRIVE BELT 1. Loosen power steering pump attaching bolts and mounting bolts. 2. Pivot power steering pump toward engine, as required, until belt can be removed. 3.

  • Page 83: Replacing Belts On Side Mount Models

    Your boat comes equipped with through the sterndrive water pickups. See Sterndrive Water Pickups (following) for the flushing procedure. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Alpha engines with the sterndrive water inlet blocked off at the gimbal...

  • Page 84: Sterndrive Water Pickups

    Section 5 - Maintenance Sterndrive Water Pickups This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment (44357Q 2). 5773 Side Pickup NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications.

  • Page 85: Battery

    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. 7.

  • Page 86: Corrosion Protection

    Section 5 - Maintenance Corrosion Protection NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or high‑pressure washers to clean the MerCathode assembly. 6211 MerCathode reference electrode Do not pressure wash Do not paint Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged...
  • Page 87 Section 5 - Maintenance Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.), it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System...
  • Page 88 MerCathode System ‑ Electrode assembly replaces Anodic block. System should be tested to ensure adequate output. The test should be performed where boat is moored, using Quicksilver Reference Electrode and Test Meter. Contact your authorized Mercury MerCruiser dealer. Page 80 90-899883272 MARCH 2008...
  • Page 89 Section 5 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. 6206 MerCathode controller MerCathode assembly Anode Kit (if equipped) ‑ Mounted to the boat transom. 5642 Trim Cylinder Anodes ‑ Mounted on each trim cylinder. 7460 Trim cylinder anodes 90-899883272 MARCH 2008...

  • Page 90: Painting Your Power Package

    Section 5 - Maintenance Bearing Carrier Anode (Alpha) ‑ Located in front of the propeller, between the front side of the propeller and the gear housing. 7461 Bearing carrier anode Screws In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion: 1.

  • Page 91: March

    Section 5 - Maintenance • Avoid any 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 92 Section 5 - Maintenance Notes: Page 84 90-899883272 MARCH 2008...
  • Page 93 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....86 Clearing Clogged Blue Drain Hoses.....92 Preparing Power Package for Storage..86 Draining the Sterndrive.........94 Engine and Fuel System Preparation ..87 Battery Storage........... 95 Draining the Seawater System......

  • Page 94: 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 95: Engine And Fuel System Preparation

    Section 6 - Storage 10. For additional assurance against freezing and rust, after draining, fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.

  • Page 96: Draining The Seawater System

    Section 6 - Storage Draining the Seawater System CAUTION Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining.

  • Page 97: Draining The Seawater Section Of Models With Closed Cooling

    Section 6 - Storage 3. Push the quick connect fitting release buttons and remove the blue drain hoses from the bracket. 32559 Release button (to engine block) Blue drain hoses T‑handle Hose guide Release button (to exhaust manifold) 4. Pull the T‑handle until the hose guide is in contact with the quick connect fittings. 5.
  • Page 98 Section 6 - Storage 1. If draining with the boat in the water, close the seacock (if equipped) or remove and plug the water inlet hose. If draining with the boat out of the water, place the boat on a level surface to ensure complete draining of the system.
  • Page 99 Section 6 - Storage 4. Remove and lower the hose connecting the water inlet to the power steering cooler, or the water inlet to the heat exchanger. 32651 Power steering cooler Water inlet to heat exchanger hose 90-899883272 MARCH 2008 Page 91...

  • Page 100: Clearing Clogged Blue Drain Hoses

    Section 6 - Storage 5. Ensure that the speedometer pitot hole, gear housing water vent and drain holes, and trim tab cavity vent and drain holes are open and unobstructed. 7329 Gear housing vent holes Gear housing drain hole Trim tab cavity drain holes Speedometer pitot hole 6.
  • Page 101 Section 6 - Storage 3. Ensure the clogged blue drain hose is in the correct position below its connection point on the block. 4. Turn on the bilge pump and supply water to the water inlets. If the boat is out of the water, install the flushing attachment and open the water source fully to provide maximum water flow.

  • Page 102: Draining The Sterndrive

    The unit will need to be serviced by an authorized Mercury MerCruiser dealer. Pull the T‑handle until the quick connect fittings on the blue drain hoses are within reach.

  • Page 103: Battery Storage

    Section 6 - Storage Battery Storage Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition. It should be clean and free of leaks.
  • Page 104 Section 6 - Storage Notes: Page 96 90-899883272 MARCH 2008...

  • Page 105: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........98 Battery Will Not Recharge......100 Engine Guardian System........98 Remote Control Is Difficult to Move, Has Troubleshooting Charts........98 Excessive Play, or Makes Unusual Sounds Starter Motor Will Not Crank Engine, or Cranks ..............100 Slowly............98 Steering Wheel Jerks or Is Difficult to Turn...

  • Page 106: 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 107: Engine Runs Rough, Misses, Or Backfires

    Boat bottom fouled or damaged. Clean or repair as necessary. Ignition problem. See Engine Runs Rough, Misses or Backfires. Engine overheating. See Excessive Engine Temperature. Have EFI System checked by an authorized Mercury MerCruiser EFI System fault dealer. Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed.

  • Page 108: Low Engine Oil Pressure

    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 Jerks or Is Difficult to Turn Possible Cause Remedy Low power steering pump fluid level.

  • Page 109: Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move)

    Section 7 - Troubleshooting Possible Cause Remedy Check all associated electrical connections and wires Loose or dirty electrical connections or damaged (especially battery cables). Clean and tighten faulty wiring. connection. Repair or replace wiring. Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low.
  • Page 110 Section 7 - Troubleshooting Notes: Page 102 90-899883272 MARCH 2008...

  • Page 111: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 104 Parts and Accessories Inquiries ... 105 Local Repair Service ........104 Resolving a Problem ........105 Service Away From Home ......104 Mercury Marine Service Offices ....

  • Page 112: Owner Service Assistance

    Owner Service Assistance Local Repair Service If you need service for your Mercury MerCruiser–powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine.

  • Page 113: 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.

  • Page 114: 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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