Page 1 Name of engine family: EC Module H certificate number: number Vazer 100 1A035000 RCD‑H‑1 Vazer 100 ECT 1A035000 RCD‑H‑1 3.0 TKS 0W319169 RCD‑H‑1 3.0 MPI ECT 1A300000 RCD‑H‑1 4.3 TKS 0W319169 RCD‑H‑1 4.3 MPI 0W319169 RCD‑H‑1 4.3 MPI ECT 1A300000 RCD‑H‑1 SeaCore 4.3...
Page 2 Unique engine identification number: starting serial Name of engine family: EC Module H certificate number: number 377 MAG ECT 1A343300 RCD‑H‑1 496 MAG 0W319169 RCD‑H‑1 SeaCore 496 MAG 0W319169 RCD‑H‑1 496 MAG H.O. 0W319169 RCD‑H‑1 SeaCore 496 MAG H.O. 0W319169 RCD‑H‑1 496 MAG ECT 1A300000...
Page 3: Read This Manual Thoroughly
Engine Model and Horsepower Engine Serial Number Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number Transmission Model (Inboard) Gear Ratio Transmission Serial Number Propeller Number Pitch Diameter Hull Identification Number (HIN) Purchase Date Boat Manufacturer Boat Model Length The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser®...
Page 4 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 they warn of.
Page 5: Table Of Contents
Section 2 - Getting to Know Your Power Package Identification Information............22 Dual Engine Trim/Trailer............ 28 Identification..............22 Electrical System Overload Protection—3.0 MPI ECT.... 28 Alpha Sterndrive Decal Identification........ 22 Electrical System Overload Protection—3.0 TKS....31 Alpha Transom Serial Number......... 22 Audio, Visual, and Engine Warning Systems—3.0 MPI...
Page 6 Launching and Boat Operation..........40 Wave and Wake Jumping............44 Operation Chart..............40 Impact with Underwater Hazards........... 45 Starting and Stopping the Engine—3.0 MPI ECT....41 Drive Unit Impact Protection..........45 Starting and Stopping the Engine........41 Conditions Affecting Operation..........45 Starting the Engine............
Page 7 Section 6 - Storage Cold Weather or Extended Storage......... 96 Draining the 3.0 TKS Seawater System........ 102 Preparing Power Package for Storage—3.0 MPI ECT..96 Single Point Drain System..........102 Engine and Fuel System Preparation......96 Draining the Seawater Section of Models With Closed Preparing Power Package for Storage—3.0 TKS.....
Page 8 Poor Performance............112 Steering Wheel Jerks or Is Difficult to Turn....113 Troubleshooting Charts for 3.0 MPI ECT and 3.0 TKS..112 Power Trim Does Not Operate (Motor Does Not Excessive Engine Temperature........112 Operate)................ 113 Insufficient Engine Temperature........113 Power Trim Does Not Operate (Motor Operates but Low Engine Oil Pressure..........
Page 9: Section 1 - Warranty
Section 1 - Warranty Section 1 - Warranty Table of Contents Warranty Information and Policies.......... 2 What is Not Covered ..........11 Warranty Registration—United States and Canada..2 Expense of Claiming This Limited Warranty ..12 Warranty Registration—Outside the United States and Transfer of Warranty—Australia and New Zealand Policy Canada................
Page 10: Warranty Information And Policies
Section 1 - Warranty Warranty Information and Policies Warranty Registration—United States and Canada Outside United States and Canada ‑ Check with your local distributor. You may change your address on file with Mercury Marine at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.
Page 11: Mercury Installation Quality Certification Program
Section 1 - Warranty There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you. Mercury Installation Quality Certification Program 15502 Mercury MerCruiser products installed by a Mercury Installation Quality Certified Manufacturer are Installation Quality Certified products and may receive an additional one (1) year of limited warranty coverage.
Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)
Section 1 - Warranty Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only) Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only) What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following.
Page 13 Section 1 - Warranty What Mercury Marine Will Do Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury Marine product.
Page 14: 3-Year Limited Warranty Against Corrosion
Section 1 - Warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY.
Page 15: Emission Control Warranty Information-3.0 Tks
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: Owner Responsibility
Section 1 - Warranty ECI Label Standard of Compliance EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2009 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES Indicates a marine engine compliant with California CARB REFER TO THE OWNER'S MANUAL FOR MAINTENANCE exhaust emission regulations for 2009.
Page 17: U.s. Epa Emissions Limited Warranty
Section 1 - Warranty U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three years or 480 hours of engine use whichever occurs first to the retail purchaser, that the engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations.
Page 18: Warranty Policy-Australia And New Zealand
Section 1 - Warranty Warranty Policy—Australia and New Zealand MerCruiser Limited Warranty—Australia and New Zealand Policy This Limited Warranty is given by Marine Power International Pty Ltd ACN 003 100 007 of 41–71 Bessemer Drive, Dandenong South, Victoria 3175 Australia (telephone (61) (3) 9791 5822), e‑mail: merc_info@mercmarine.com.
Page 19: Conditions That Must Be Met To Obtain Warranty Coverage
Section 1 - Warranty • Purchased from an insurance company that obtained the product as a result of an insurance claim • Purchased from a salvage yard • Repossession from a retail customer • Purchased at an auction Conditions That Must Be Met to Obtain Warranty Coverage Warranty coverage under this Limited Warranty 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 predelivery inspection process specified by Mercury Marine is completed and documented.
Page 20: Expense Of Claiming This Limited Warranty
Section 1 - Warranty • Alteration or removal of parts • Water entering the engine through the fuel intake, air intake, or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body •...
Page 21: Global Warranty Application Charts (3.0 Tks)
Section 1 - Warranty Global Warranty Application Charts (3.0 TKS) TKS Sterndrive Series Non‑Emissions Control (Recreational Use) Recreational Application: Standard Limited Warranty by Region and Boat Manufacturer All Engines (TKS) Non‑Installation Quality Certified Boat Installation Quality Certified Boat Region Manufacturer Manufacturer Americas 1 Year...
Page 22: Tks Sterndrive Series Non-Emissions Control (Government Use)
Section 1 - Warranty TKS Sterndrive Series Non‑Emissions Control (Government Use) Government Application: Standard Limited Warranty by Region and Boat Manufacturer All Engines (TKS) Non‑Installation Quality Certified Boat Installation Quality Certified Boat Region Manufacturer Manufacturer Americas 1 Year 1 Year (Excluding Brazil) Latin America 1 Year or 500 Hours...
Page 23: Tks Sterndrive Series Non-Emissions Control (Commercial Use-Corrosion)
Section 1 - Warranty TKS Sterndrive Series Non‑Emissions Control (Commercial Use—Corrosion) Commercial Application: Standard Limited Corrosion Warranty by Region for All Boat Manufacturers Region All Engines (TKS) Americas 1 Year (Excluding Brazil) Latin America 1 Year or 500 Hours Brazil 1 Year or 500 Hours Europe, CIS, South Africa 1 Year or 500 Hours...
Page 24: Global Warranty Application Charts (3.0 Mpi-Ect)
Section 1 - Warranty Global Warranty Application Charts (3.0 MPI–ECT) MPI Sterndrive Series with Emissions Control Technology (Recreational Use) Recreational Application: Standard Limited Warranty by Region and Boat Manufacturer All Engines (MPI) Non‑Installation Quality Certified Boat Installation Quality Certified Boat Region Manufacturer Manufacturer...
Page 25: Mpi Sterndrive Series With Emissions Control Technology (Government Use)
Section 1 - Warranty MPI Sterndrive Series with Emissions Control Technology (Government Use) Government Application: Standard Limited Warranty by Region and Boat Manufacturer All Engines (MPI) Non‑Installation Quality Certified Boat Installation Quality Certified Boat Region Manufacturer Manufacturer Americas 1 Year 1 Year (Excluding Brazil) Latin America...
Page 26: Mpi Sterndrive Series With Emissions Control Technology (Commercial Use-Corrosion)
Section 1 - Warranty MPI Sterndrive Series with Emissions Control Technology (Commercial Use—Corrosion) Commercial Application: Standard Limited Corrosion Warranty by Region for All Boat Manufacturers Region All Engines (MPI) Americas 1 Year (Excluding Brazil) Latin America 1 Year or 500 Hours Brazil 1 Year or 500 Hours Europe, CIS, South Africa...
Page 27: Hang Tag
Section 1 - Warranty The Star label will be affixed on the left side of the hull as shown. Recommended location Secondary location XX 1234 XX 32770 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 28 Section 1 - Warranty If in California, the dealer must place the hang tag in a visible location in the boat prior to displaying the boat. 43291 Hang tag front side Hang tag back side Page 20 90-8M0074347 OCTOBER 2012...
Page 29: Section 2 - Getting To Know Your Power Package
Electrical System Overload Protection—3.0 MPI ECT..28 Alpha Sterndrive Decal Identification......22 Electrical System Overload Protection—3.0 TKS....31 Alpha Transom Serial Number........22 Audio, Visual, and Engine Warning Systems—3.0 MPI ECT Engine Serial Number Decal......... 23 ....................33 Lanyard Stop Switch............. 23 Audio Warning System..........
Page 30: Identification Information
Section 2 - Getting to Know Your Power Package Identification Information Identification The serial numbers are the manufacturer'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 number is located on the port side of the Alpha sterndrive.
Page 31: 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. Engine serial number Transom serial number Drive serial number...
Page 32: Instrumentation
Section 2 - Getting to Know Your Power Package • consuming alcohol or drugs • high‑speed boating maneuvers The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) 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 33: Smartcraft Speedometer And Tachometer Digital Gauges
Section 2 - Getting to Know Your Power Package Refer to your VesselView operations manual for detailed instructions on how to operate this display. SmartCraft Speedometer and Tachometer Digital Gauges The SmartCraft instrument package, if equipped, augments the information provided by VesselView. The instrument package may display: •...
Page 34: Remote Controls
Section 2 - Getting to Know Your Power Package Remote Controls Your boat may be equipped with 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. Panel Mount Features Neutral lock button Throttle only button...
Page 35: Power Trim
Section 2 - Getting to Know Your Power Package 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: Single Engine Trim/Trailer
Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only. Electrical System Overload Protection—3.0 MPI ECT An electrical overload will either open a fuse or open a circuit breaker. You must find and repair the source of the overload before replacing the fuse or resetting the circuit breaker.
Page 37 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 fuses are located on the top of the engine, underneath the engine information plate. Fuse locations sensor fuses Main power, fuel pump, ignition, and accessory fuses...
Page 38 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 an open fuse or open circuit breaker if you turn the ignition key to the "START" position and nothing happens. mc70525-1 Ignition switch fuse—typical The power trim system is protected from overload by a 110‑amp fuse and a 20‑amp spade fuse on the power trim pump.
Page 39: Electrical System Overload Protection-3.0 Tks
Section 2 - Getting to Know Your Power Package The three‑button power trim control panel is protected by a 20‑amp in‑line fuse. mc70527-1 Power trim control panel fuse The MerCathode system has a 5‑amp fuse, which connects to the positive (+) terminal on the controller. If the fuse is open, the system will not operate, resulting in a loss of corrosion protection.
Page 40 Section 2 - Getting to Know Your Power Package A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs. mc74907-1 Engine wiring harness fuse A 15‑amp accessory fuse is located on the rear of the engine. This fuse protects the accessory circuits. A 20‑amp fuse is located on the top of the engine to protect the TKS circuit.
Page 41: Audio, Visual, And Engine Warning Systems-3.0 Mpi Ect
MerCathode Red/purple wire 5‑amp fuse 50534 Audio, Visual, and Engine Warning Systems—3.0 MPI ECT Audio Warning System IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from damage. 90-8M0074347...
Page 42: Caution
Section 2 - Getting to Know Your Power Package The 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. There are two warning horn states: •...
Page 43: Testing The Obd-M Malfunction Indicator Lamp (Mil)
Section 2 - Getting to Know Your Power Package The service engine icon or MIL will provide a visual indication of a malfunction with the engine's emission control system and will remain illuminated while the OBD‑M fault is active. 47594 SC 1000 gauge and service engine light Testing the OBD-M Malfunction Indicator Lamp (MIL) Turn the ignition switch to the on position without cranking the engine.
Page 44 Section 2 - Getting to Know Your Power Package Listen for the audio alarm. The alarm will sound if the system is functioning correctly. Page 36 90-8M0074347 OCTOBER 2012...
Page 45 Launching and Boat Operation..........40 Wave and Wake Jumping............. 44 Operation Chart ............40 Impact with Underwater Hazards......... 45 Starting and Stopping the Engine—3.0 MPI ECT....41 Drive Unit Impact Protection ......... 45 Starting and Stopping the Engine........41 Conditions Affecting Operation..........45 Starting the Engine ..........
Page 46: Safe Boating Suggestions
Section 3 - On the Water Safe Boating Suggestions To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions. Know and obey all nautical rules and laws of the waterways. •...
Page 47: Carbon Monoxide Exposure
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 operator's view when the boat is above idle or planing transition speed.
Page 48: Poor Ventilation
Section 3 - On the Water Poor Ventilation Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.
Page 49: Starting And Stopping The Engine-3.0 Mpi Ect
Listen for the audio warning alarm to sound when the ignition switch is in the "ON" position. Starting and Stopping the Engine—3.0 MPI ECT Starting and Stopping the Engine NOTE: Only perform those functions applicable to your power package. Starting the Engine Check all items listed in the Operation Chart.
Page 50: Stopping The Engine
Section 3 - On the Water Stopping the Engine Move the remote control handle to neutral/idle and allow the engine to slow to idle speed. If engine has been operated at high speed for a long period of time, allow the engine to cool at idle speed for 3–5 minutes. Turn ignition key to the "OFF"...
Page 51: Throttle Only Operation
Section 3 - On the Water Throttle Only Operation Refer to Remote Controls section for remote control features. Move the control lever to the idle/neutral position. Depress and hold the throttle only button, and move the control lever to the idle/forward or idle/reverse position. Advancing the control lever beyond the idle/forward or idle/reverse position will cause engine speed to increase.
Page 52: 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. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.
Page 53: Impact With Underwater Hazards
Section 3 - On the Water There is another less common hazardous result from allowing your boat to launch off of a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant.
Page 54: The Bottom Of The Boat
Section 3 - On the Water • Causes bow to bounce in choppy water • Increases danger of following wave splashing into the boat when coming off plane • At extremes, can cause the boat to porpoise Shifting weight to front (bow): •...
Page 55: Getting Started-3.0 Mpi Ect
For better acceleration, such as is needed for waterskiing, use the next lower pitch propeller. When not pulling skiers, do not operate at full throttle when using the lower pitch propeller. Getting Started—3.0 MPI ECT 20‑Hour Break‑In Period IMPORTANT: The first 20 hours of operation is the engine break‑in period. Correct break‑in is essential to obtain minimum oil consumption and maximum engine performance.
Page 56: End Of First Season Checkup
Section 3 - On the Water 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 57: Section 4 - Specifications
Section 4 - Specifications Section 4 - Specifications Table of Contents Specifications—3.0 MPI ECT..........50 Specifications—3.0 TKS............52 Engine Specifications—3.0 MPI ECT......50 Engine Specifications—3.0 TKS........52 Fuel Requirements............50 Fuel Requirements............53 Fuel Ratings ............50 Fuel Ratings ............53...
Page 58: Specifications-3.0 Mpi Ect
Section 4 - Specifications Specifications—3.0 MPI ECT Engine Specifications—3.0 MPI ECT NOTE: Performance specifications are obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power. All measurements are taken with the engine at normal operating temperature. RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures.
Page 59: Gasoline Containing Alcohol
Section 4 - Specifications Gasoline Containing Alcohol If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), be aware of possible adverse effects. These adverse effects are more severe with methanol and worsen according to the percentage of alcohol in the fuel. Alcohol in gasoline can absorb moisture from the air, causing the water and the alcohol to separate from the gasoline in the fuel tank.
Page 60: Fluid Specifications
Section 4 - Specifications NOTE: We do not recommend nondetergent oils, multi‑viscosity oils (other than as specified), non FC‑W–rated synthetic oils, low‑quality oils, or oils that contain solid additives. Mercury Full-Synthetic MerCruiser Engine Oil, 20W-40, NMMA FC-W rated MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rated 4-cycle MerCruiser oil Mercury/Quicksilver 25W-40, NMMA FC-W rated 4-cycle MerCruiser oil Other recognized brands of NMMA FC-W rated oils SAE40W...
Page 61: Fuel Requirements
Section 4 - Specifications At 2000 RPM 207 kPa (30 psi) Minimum oil pressure At idle 28 kPa (4 psi) Seawater‑cooled models 71° C (160° F) Thermostat Models with closed cooling 2° ATDC Timing at idle 1‑3‑4‑2 Firing order 375 CCA, 475 MCA, 90 Ah Minimum battery rating AC MR43LTS Champion RS12YC...
Page 62: Engine Oil
Section 4 - Specifications IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing alcohol, do not store the gasoline in the fuel tank for long periods. Cars normally consume alcohol‑blend fuels before they can absorb enough moisture to cause trouble, boats often sit idle long enough for phase separation to take place.
Page 63 Using the Engine Oil Drain Pump ......65 Alternator Belt ..........81 Changing the Oil Filter........... 65 Replacing ‑ Side Mount Models ......81 Power‑Assisted Steering Fluid—3.0 MPI ECT..... 66 Power Steering Pump Drive Belt, if equipped Checking................ 66 ............... 81 Filling................
Page 64: General Information
Section 5 - Maintenance General Information 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 65: Inspection
Do not adjust or remove the mixture settings or remove the mixture screw seals. See your authorized Mercury dealer or emissions testing agency. Maintenance Schedules—3.0 MPI ECT Routine Maintenance NOTE: Only perform maintenance that applies to your particular power package.
Page 66: Scheduled Maintenance
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Remove the propeller and lubricate the propeller shaft and torque the nut. (If operating only in freshwater, you can extend the interval to every four months.) • If operating in saltwater, brackish water, or polluted water, apply Corrosion Guard to the power package.
Page 67: Maintenance Schedules-3.0 Tks
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Check the engine mounts for tightness and torque if necessary. • Check the electrical system for loose, damaged, or corroded fasteners. • Inspect the condition of the spark plugs, spark plug wires, and the distributor cap and rotor, if equipped.
Page 68: Scheduled Maintenance
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Remove the propeller and lubricate the propeller shaft and torque the nut. (If operating only in freshwater, you can extend the interval to every four months.) • If operating in saltwater, brackish water, or polluted water, apply Corrosion Guard to the power package.
Page 69: Maintenance Log
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Check the engine mounts for tightness and torque if necessary. • Check the electrical system for loose, damaged, or corroded fasteners. • Inspect the condition of the spark plugs, spark plug wires, and the distributor cap and rotor, if equipped.
Page 70: Engine Oil-3.0 Mpi Ect
Section 5 - Maintenance Engine Oil—3.0 MPI ECT 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. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.
Page 71: Using The Engine Oil Drain Pump
Section 5 - Maintenance IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only recommended engine oil (refer to the Specifications section). Using the Engine Oil Drain Pump Loosen the oil filter to vent the system.
Page 72: Checking And Filling
Section 5 - Maintenance Checking and Filling Stop the engine. Allow approximately five minutes for the oil to drain into the oil pan. The boat must be at rest in the water. IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid required. Remove the dipstick, wipe clean, and install fully into the dipstick tube.
Page 73: Using The Engine Oil Drain Pump
Section 5 - Maintenance Pull the tether through the bilge drain. 7284 Bilge drain plug Tether Clip Oil drain hose plug Oil drain hose Bilge drain flange Place the oil drain hose in a suitable container. Remove the drain plug from the oil drain hose. Loosen the oil filter to vent the system.
Page 74: Power-Assisted Steering Fluid-3.0 Mpi Ect
Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water. Check the oil level and add more if necessary. Power‑Assisted Steering Fluid—3.0 MPI ECT Checking Stop the engine and center the sterndrive unit.
Page 75: Filling
Changing Power steering fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Engine Coolant—3.0 MPI ECT Checking CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap.
Page 76: Filling
Section 5 - Maintenance Remove the cap from the thermostat housing and observe the fluid level. 32637 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.
Page 77: Changing
Section 5 - Maintenance NOTICE Air trapped in the closed cooling system can cause the engine to overheat, resulting in engine damage. Minimize the possibility of trapping air when initially filling the closed cooling system by positioning the boat so that the front of the engine is higher than the rear of the engine.
Page 78: Filling
Section 5 - Maintenance The coolant level should be between the "ADD" and "FULL" marks. 6102 Add the specified fluid as necessary. Tube Ref No. Description Where Used Part No. Extended Life Antifreeze/ Closed Cooling System 92-877770K1 Coolant Filling NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine.
Page 79: Checking
47638 Gear lube monitor bottle location Typical 3.0 TKS Typical 3.0 MPI ECT Keep the gear lube level within the recommended operating range. If the gear lube level is below or near the "ADD" mark, refer to Filling. Gear lube level at "ADD" mark Gear lube level at "OPERATING RANGE"...
Page 80: Changing
Section 5 - Maintenance Tube Ref No. Description Where Used Part No. High Performance Gear Gear lube monitor 92-858064K01 Lubricant Ensure that the rubber gasket is inside the cap and install. Do not over tighten. NOTE: When filling the entire sterndrive unit refer to Changing . Changing Remove the gear lube monitor from the bracket.
Page 81: Power Trim Fluid
Section 5 - Maintenance 10. Ensure that the rubber gasket is inside the cap and install. Do not over tighten. "ADD" mark "OPERATING RANGE" mark 19948 NOTE: Oil capacity includes the gear lube monitor. Model Capacity Fluid Type High Performance Gear Alpha One 1892 ml (64 oz) Lubricant...
Page 82: Changing
Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Scheduled Maintenance Procedures Specifically for 3.0 MPI ECT Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start.
Page 83: Changing The Water-Separating Fuel Filter
Section 5 - Maintenance Remove the IAC muffler from the slot in the air valve plate using needle‑nosed pliers. IAC muffler location 32180 Inspect the muffler for holes, cracks, or deterioration. Replace if damaged. IMPORTANT: Do not use a cleaner that contains methyl ethyl ketone on the IAC or on electrical connections. Clean the muffler with warm water and mild detergent.
Page 84: Inspecting The Fuel Pump Sight Tube
Section 5 - Maintenance Inspecting the Fuel Pump Sight Tube The engine fuel pump sight tube gives you visual evidence of a fuel leak in the fuel pump diaphram. If fuel is ever visible in the tube, see your authorized Mercury MerCruiser dealer to replace the fuel pump. 32555 Fuel pump sight tube Drive Belts...
Page 85: Replacing Belts On Front Mount Models
Section 5 - Maintenance Replacing Belts on Front Mount Models Power steering belt Alternator belt Alternator Spacer block Crank position sensor 32557 Power Steering Pump Drive Belt Loosen power steering pump attaching bolts and mounting bolts. Pivot power steering pump toward engine, as required, until belt can be removed. Install new drive belt on pulleys.
Page 86: Alternator Belt
Section 5 - Maintenance Alternator Belt Remove power steering pump drive belt, if equipped. Loosen the alternator. Remove and replace the alternator belt. Install the power steering belt, if equipped. Move the power steering brace to its original position and adjust tension of both drive belts.
Page 87: Positive Crankcase Ventilation Valve (Pcv)
Section 5 - Maintenance 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. Remove the PCV valve.
Page 88: Fuel Pump Sight Tube Inspection
Section 5 - Maintenance Supply cooling water to the engine. 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 the engine immediately and contact your authorized Mercury MerCruiser dealer.
Page 89: Alternator Belt
Section 5 - Maintenance Install new drive belt on pulleys. Adjust tension. Power steering belt Spacer block Alternator Alternator belt 7172 Description Deflection 6 mm ( 1/4 inches) Alternator Belt Remove the power steering belt, if equipped. Remove the two port side, front engine mount bracket assembly screws and washers. Remove the spacer block between the bracket assembly and the engine block.
Page 90: Alternator Belt
Section 5 - Maintenance Description Deflection 6 mm ( 1/4 inches) Alternator Belt Remove power steering pump drive belt, if equipped. Loosen the alternator. Remove and replace the alternator belt. Install power steering belt, if equipped. Move the power steering brace to its original position and adjust tension of both drive belts.
Page 91: Manual Steering System
Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Special Lubricant 101 Steering cable 802859A1 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.
Page 92: Throttle Cable-3.0 Mpi Ect
Section 5 - Maintenance Throttle Cable—3.0 MPI ECT Lubricate the pivot points and the guide contact surfaces with oil. Pivot points Guide contact surfaces 32586 Throttle Cable—3.0 TKS Lubricate the pivot points and the guide contact surfaces. Pivot points 7169 Tube Ref.
Page 93: Shift Cable - Typical
Section 5 - Maintenance Shift Cable ‑ Typical Lubricate the pivot points and the guide contact surfaces. Pivot points Guide contact surfaces mc79736 Tube Ref. No. Description Where Used Part No. Shift cable pivot points and Synthetic Blend MerCruiser Engine Oil SAE25W‑40 92‑883725K01 guide contact surfaces Sterndrive U‑joint Shaft Splines and O‑rings (Sterndrive Unit Removed)
Page 94: Driveshaft Extension Models
Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Engine Coupler Spline Coupler 8M0071842 Grease NOTE: Alpha Models ‑ Your power package is equipped with a sealed engine coupler and Perm‑a‑Lube U‑joints. The sealed coupler and shaft splines can be lubricated without removing the sterndrive unit. The Perm‑a‑Lube U‑joints do not require lubrication.
Page 95: 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 the tab washer, carefully inspect tabs for cracks or other damage.
Page 96: Flushing Attachments
Section 5 - Maintenance Flushing Attachments Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 Sterndrive Water Pickups This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment (44357Q 5773 Side Pickup NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications.
Page 97: Battery
Section 5 - Maintenance With sterndrive in normal operating position, open the water source completely. Place the remote control in the 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.
Page 98 Section 5 - Maintenance Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals.
Page 99 Section 5 - Maintenance The following sacrificial anodes are installed at different locations on your power package. These anodes help protect against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the metal components on the power package. Gearcase Anodic Plate ‑...
Page 100 Section 5 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. MerCathode controller MerCathode assembly 6206 Anode Kit (if equipped) ‑ Mounted to the boat transom. 5642 Trim Cylinder Anodes ‑ Mounted on each trim cylinder. Trim cylinder anodes 7460 Bearing Carrier Anode (Alpha) ‑...
Page 101: Painting Your Power Package
Section 5 - Maintenance In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion: Paint your power package, refer to Painting Your Power Package. Spray power package components on inside of boat annually with Corrosion Guard to protect finish from dulling and corrosion.
Page 102 Section 5 - Maintenance Notes: Page 94 90-8M0074347 OCTOBER 2012...
Page 103 Engine and Fuel System Preparation ....98 Draining the Sterndrive............107 Draining the Seawater System..........99 Battery Storage..............107 Draining the 3.0 MPI ECT Seawater System....... 99 Recommissioning the Power Package....... 107 Single‑Point Drain System..........99 Draining the Seawater Section of Models with Closed Cooling.................
Page 104: Cold Weather Or Extended Storage
Be certain to follow the propylene glycol manufacturer's recommendations. Preparing Power Package for Storage—3.0 MPI ECT Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline.
Page 105: Preparing Power Package For Storage-3.0 Tks
Section 6 - Storage NOTICE Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation. In a 23 liter (6 US gal.) remote fuel tank mix: 19 liter (5 US gal.) regular unleaded 87 octane (90 RON) gasoline 1.89 liter (2 US qt.) Premium Plus 2‑Cycle TC‑W3 Outboard Oil 150 ml (5 oz) Fuel System Treatment and Stabilizer or 30 ml (1 oz) Fuel System Treatment and Stabilizer Concentrate...
Page 106: Engine And Fuel System Preparation
Section 6 - Storage NOTICE The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position. 11.
Page 107: Draining The Seawater System
IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system. IMPORTANT: The engine must not be operating at any point during the draining procedure. Draining the 3.0 MPI ECT Seawater System Single‑Point Drain System CAUTION Disconnecting the blue drain hoses can cause serious burns due to hot water.
Page 108: Draining The Seawater Section Of Models With Closed Cooling
Section 6 - Storage Draining the Seawater Section of Models with Closed Cooling 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. 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 109 Section 6 - Storage 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 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.
Page 110: Draining The 3.0 Tks Seawater System
Section 6 - Storage Crank the engine over slightly with the starter motor to purge any water trapped in seawater pickup pump. Do not allow the engine to start. After the cooling system has drained completely, apply sealant to the aft heat exchanger plug. Aft heat exchanger drain plug 7184 Tube Ref No.
Page 111: Draining The Seawater Section Of Models With Closed Cooling
Section 6 - Storage Pull the T‑handle until the hose guide is in contact with the quick connect fittings. T‑handle Hose guide 7183 Push down on the T‑handle to force the blue drain hoses below their connection points on the block. Ensure water is draining from blue drain hoses.
Page 112 Section 6 - Storage Bottom of exhaust manifold. Exhaust manifold drain plug 7186 Clean out the drain holes with a stiff piece of wire until the entire system is drained. NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. Remove and lower the hose from the water inlet to the power steering cooler (if equipped), or the water inlet to the heat exchanger.
Page 113: Clearing Clogged Blue Drain Hoses
Section 6 - Storage Ensure the gear housing water vent and drain holes, speedometer pitot hole, and trim tab cavity vent and drain holes are open and unobstructed. Gear housing vent holes Trim tab cavity drain holes Gear housing drain hole Speedometer pitot hole 7329 Crank the engine over slightly with the starter motor to purge any water trapped in seawater pickup pump.
Page 114 Section 6 - Storage 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. Flushing attachment 7358 Flushing Device 91‑44357Q 2...
Page 115: Draining The Sterndrive
Section 6 - Storage 14. If water is draining from the blue drain hose, continue with Step 4 of Single Point Drain System. Draining the Sterndrive NOTE: This procedure is needed only for salty, brackish, mineral‑laden, or polluted water applications; and for freezing temperatures or extended storage.
Page 116 Section 6 - Storage 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. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks.
Page 117: Section 7 - Troubleshooting
Table of Contents Troubleshooting Information and Charts Specifically for 3.0 Poor Performance............112 MPI ECT................110 Troubleshooting Charts for 3.0 MPI ECT and 3.0 TKS..112 Diagnosing EFI Problems..........110 Excessive Engine Temperature........112 Engine Guardian System..........110 Insufficient Engine Temperature........113 Starter Motor Will Not Crank Engine, or Cranks Slowly Low Engine Oil Pressure..........
Page 118: Troubleshooting Information And Charts Specifically For 3.0 Mpi Ect
Section 7 - Troubleshooting Troubleshooting Information and Charts Specifically for 3.0 MPI ECT 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 ECMs memory.
Page 119: Engine Runs Rough, Misses, Or Backfires
Section 7 - Troubleshooting Engine Runs Rough, Misses, or Backfires Possible Cause Remedy Clogged fuel filter. Replace filter. Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel. Replace kinked lines or blow out lines with compressed air to remove Kinked or clogged fuel line or fuel tank vent line.
Page 120: Engine Runs Rough, Misses, Or Backfires
See Engine Runs Rough, Misses, or Backfires. Engine overheating. See Excessive Engine Temperature. Running rich. Have authorized Mercury MerCruiser dealer check and repair. Troubleshooting Charts for 3.0 MPI ECT and 3.0 TKS Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed.
Page 121: Insufficient Engine Temperature
Section 7 - Troubleshooting Insufficient Engine Temperature Possible Cause Remedy Faulty thermostat. Replace. Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase. Check and add oil. Excessive oil in crankcase (causing it to Check and remove required amount of oil. Check for cause of excessive oil become aerated).
Page 122: Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move)
Section 7 - Troubleshooting Possible Cause Remedy Loose or dirty electrical Check all associated electrical connections and wires (especially battery cables). Clean and connections or damaged tighten faulty connection. Repair or replace wiring. wiring. Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low.
Page 123: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance..........116 Contact Information for Mercury Marine Customer Local Repair Service ..........116 Service ............... 117 Service Away From Home .......... 116 Customer Service Literature..........117 Stolen Power Package ..........
Page 124: Owner Service Assistance
Section 8 - Customer Assistance Information 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 125: Contact Information For Mercury Marine Customer Service
Section 8 - Customer Assistance Information • Model and serial numbers for your power package • The name and address of your dealership • Nature of the problem Contact Information for Mercury Marine Customer Service For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English +1 920 929 5040 Mercury Marine...
Page 126: Other Languages
Section 8 - Customer Assistance Information • List your product, model, year, and serial numbers. • Check the literature and quantities you want. • Enclose full remittance in check or money order (NO COD). Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information.
Page 127: Section 9 - Checklists
Section 9 - Checklists Section 9 - Checklists Table of Contents Predelivery Inspection (PDI)..........120 Customer Delivery Inspection (CDI)........121 90-8M0074347 OCTOBER 2012 Page 119...
Page 128: Predelivery Inspection (Pdi)
Section 9 - Checklists Predelivery Inspection (PDI) IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual. Perform these tasks before the Customer Delivery Inspection (CDI). Check/ Item Adjust...
Page 129: Customer Delivery Inspection (Cdi)
Section 9 - Checklists Predelivery Inspection Checklist, Continued Check/ Item Adjust On‑the‑Water Test ⃞ ⃞ Engine alignment (Inboard models only) ⃞ Starter neutral safety switch operation ⃞ E‑stop switch/lanyard stop switch operation (all helms) ⃞ Seawater pump operation ⃞ Operation of instruments ⃞...
Page 130 Section 9 - Checklists Completed Item ⃞ ⃞ Functions of SmartCraft accessories (if applicable) ⃞ Off‑season storage and maintenance schedule ⃞ Engine (starting, stopping, shifting, using throttle) ⃞ Boat (lights, battery switch location, fuses/breakers) ⃞ ⃞ Trailer (if applicable) Registration: ⃞...

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