P. 1
Mercruiser D7.3L Stern Drives - Manual_wiring

Mercruiser D7.3L Stern Drives - Manual_wiring

|Views: 687|Likes:
Published by Little Tomato

More info:

Published by: Little Tomato on Aug 15, 2011
Copyright:Attribution Non-commercial

Availability:

Read on Scribd mobile: iPhone, iPad and Android.
download as PDF, TXT or read online from Scribd
See more
See less

05/24/2012

pdf

text

original

Sections

  • WELCOME
  • Read This Manual Thoroughly
  • Lanyard Stop Switch
  • Safe Boating Suggestions
  • Protecting People In The Water
  • While You Are Cruising
  • While Boat Is Stationary
  • High-Speed And High-Performance Boat Operation
  • Conditions Affecting Operation
  • Weight Distribution
  • Bottom Of Boat
  • Cavitation
  • Ventilation
  • Propeller Selection
  • How Elevation And Climate Affect Performance
  • Important Information
  • Operation And Maintenance
  • RECOMMENDED OPERATION/DUTY CYCLE
  • OWNER/OPERATOR RESPONSIBILITIES
  • DEALER RESPONSIBILITIES
  • Freezing Temperature And Cold Weather Operation
  • Drive Unit Impact Protection
  • Launching and Boat Operation Care
  • Attention Required After Submersion
  • Trailering Boat
  • Stolen Power Package
  • Replacement Service Parts
  • Do-It-Yourself Maintenance Suggestions
  • Engine Break-In
  • INITIAL BREAK-IN PROCEDURE
  • 20-HOUR BREAK-IN PROCEDURE
  • 20-Hour Checkup
  • Specifications
  • Seacock
  • Seawater Strainer
  • Fuel Requirements
  • Diesel Fuel In Cold Weather
  • Crankcase Oil
  • Engine
  • Capacities
  • Operation
  • Quicksilver Instruments and Instrumentation
  • Electrical System Overload Protection
  • Mercathode System
  • Power Trim
  • Starting, Shifting and Stopping
  • Maintenance
  • Power Package Views
  • FRONT
  • PORT (LEFT) SIDE
  • General Maintenance Information
  • Maintenance Aids
  • Maintenance Schedules
  • Checking Fluids Levels
  • CRANKCASE OIL
  • POWER TRIM PUMP FLUID
  • POWER STEERING PUMP FLUID
  • ENGINE COOLANT
  • Changing Fluids
  • CRANKCASE OIL AND FILTER
  • DRIVE UNIT OIL
  • DRIVE UNIT GEAR LUBE MONITOR
  • Drive Belts
  • INSPECTION
  • TENSION
  • REPLACEMENT
  • Air Filter - Cleaning/Replacement
  • Lubrication
  • Cleaning Quicksilver Seawater Strainer
  • Flushing Seawater Cooling System
  • Seawater Pump Impeller
  • Flushing Fuel Tank
  • Fuel System
  • Corrosion And Corrosion Protection
  • Propeller
  • Miscellaneous Maintenance
  • Battery
  • Inspection And Maintenance
  • Cold Weather Or Extended Storage
  • Power Package Layup
  • DRAINING INSTRUCTIONS
  • Power Package Recommissioning
  • Troubleshooting
  • Diagrams
  • Water Flow Diagram
  • Engine Wiring Diagram
  • Quicksilver Instrumentation Wiring Diagram
  • MerCathode System Diagram
  • Power Trim System Diagram
  • Warranty Information
  • Owner Warranty Registration
  • International Owner Registration
  • Warranty Policy
  • Mercruiser Diesel Limited Warranty
  • Marine Power International Branch or Distributor Service Offices
  • Warranty Coverage
  • Transferable Warranty
  • Q-GUARD Product Protection Plan
  • Owner Service Assistance
  • Local Repair Service
  • Service Away from Home
  • Parts and Accessories Inquiries
  • Resolving a Problem
  • Service Centers
  • Customer Service Literature
  • GENERAL MAINTENANCE PARTS
  • Engine Parts
  • Drive Parts
  • LITERATURE ORDER FORM

OPERATION & MAINTENANCE MANUAL

D7.3L/270 Bravo Two and Bravo Three
©1995, Brunswick Corporation 90-823206960 595

CD1

Identification Record
PLEASE RECORD THE FOLLOWING INFORMATION: 1. Engine Model, Horsepower, and Serial Number 2. Transom Assembly Serial Number 3. Stern Drive Unit Serial Number and Gear Ratio 4. Propeller Number 5. Propeller Pitch 6. Hull Identification Number (HIN) 7. Boat Manufacturer
CD192

Purchase Date Boat Model Length

Serial Numbers
The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your MerCruiser® power package. When contacting your Authorized MerCruiser Dealer about service, always specify model and serial numbers.

8 1B
TYPE

SERIAL NUMBER

1A

2 3

6
BSO: M12 11 3 93 07 BRUNSWICK CORP. FOND DU LAC,WIS. 54935 U.S.A.

D7.3L / 270 TURBO AC
MOT. NO. 3000-3400 RPM PROPPING RANGE

1A

71936

1B

71935

BSO: M12 11 3 93 07

8

71930

4 5

ABC12345Z123

-19

48-12345

6
0

5

4

2,3

73929

CD275

TABLE OF CONTENTS
Page
Welcome! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Read This Manual Thoroughly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lanyard Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safe Boating Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Protecting People In The Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 While You Are Cruising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 While Boat Is Stationary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 High-Speed And High-Performance Boat Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Conditions Affecting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Weight Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bottom Of Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 How Elevation And Climate Affect Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Operation And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Recommended Operation/Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Owner/Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dealer Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Freezing Temperature And Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Drive Unit Impact Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Launching and Boat Operation Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Attention Required After Submersion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Trailering Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Stolen Power Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Replacement Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Do-It-Yourself Maintenance Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Initial Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 20-Hour Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 20-Hour Checkup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Seacock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Seawater Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Diesel Fuel In Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Required Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Quicksilver Instruments and Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Electrical System Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Mercathode System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Power Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Starting, Shifting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Power Package Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Port (Left) Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Maintenance Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Checking Fluids Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Drive Unit Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Power Trim Pump Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Power Steering Pump Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 International Owner Registration . . . . . . . . . . . . . 93 Transferable Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Mercruiser Diesel Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Q-GUARD Product Protection Plan . 69 Inspection And Maintenance . . . . . 73 Draining Instructions . . . . . . . . . 95 Parts and Accessories Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Quicksilver Instrumentation Wiring Diagram . . . . . . Jet-Prop. . . . . . . . . . . . . . . . . 55 Flushing Seawater Cooling System . . . . . . . . . 59 Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Owner Warranty Registration . . . . . . . . . . . . . . 78 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Owner Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Troubleshooting . . . . . . . . . . . . . . . . . . . . . Merc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Drive Parts . . . . . . Brunswick Corporation The following are registered trademarks of Brunswick Corporation: Autoblend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MerCruiser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Power Trim System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . Mariner. 69 Bottom Of Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Thruster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Owner’s Logbook . . . . . . . . . . . 55 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . 55 Flushing Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Cleaning Quicksilver Seawater Strainer . . . . . 98 General Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Crankcase Oil and Filter . . . . . . . . . . . . . . . . . . . 73 Power Package Layup (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MerCathode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. . . . . . . . . . . . . . . . . . . Ride-Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Engine Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 The description and specifications contained herein were in effect at the time this guide was approved for printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page Engine Coolant . 83 Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printed in U. . . . . . . . . . 45 Changing Fluids . . . . . . . . . . . . . . 49 Tension . . . . . . . . whose policy is one of continuous improvement. . 47 Drive Unit Oil . . . . . . . . . . . . . . . . . . . . . . . . Mercury Marine. . . . . . . . . . . . . . . . . . . . 57 Corrosion And Corrosion Protection . . . . . . . . . . . . . . 95 Service Centers . . . . . . . . . . . . . . . . . . . . . . . .Cleaning/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quicksilver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Literature Order Form . . . . . . . . . . . . . 95 Resolving a Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Marine Power International Branch or Distributor Service Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Drive Belts . . . . . . . . . . . 95 Local Repair Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Customer Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . without notice and without incurring obligation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reserves the right to discontinue models at any time. . . . . . . . or to change specifications or designs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Marine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Marine Fond du Lac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Miscellaneous Maintenance . . . . . . . . . . . . . . . . . . . 69 Cold Weather Or Extended Storage . . . 92 Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Service Away from Home . . . . . . . . . . . . 89 Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Seawater Pump Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ©1995. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 MerCathode System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Drive Unit Gear Lube Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Power Package Layup . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wisconsin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Power Package Layup (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Power Package Recommissioning . . . . . . . . . . . .

The Operation and Maintenance Manual contains specific instructions for using and maintaining your product. It incorporates numerous design features to assure operating ease and durability. We sincerely hope your boating will be pleasant! CONSUMER AFFAIRS DEPARTMENT 3 . we ask that you thoroughly read the Operation and Maintenance Manual which accompanies the product. We suggest that this manual remain with the product for ready reference whenever you are on the water. With proper care and maintenance.CE3 WELCOME You have selected one of the finest marine power packages available. you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use. Thank you for purchasing one of our MerCruiser products.

IMPORTANT: Indicates information or instructions that are necessary for proper operation and/or maintenance.Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION. ! WARNING The operator (driver) is responsible for the correct and safe operation of the boat. Observe them carefully.Hazards or unsafe practices which could result in minor personal injury or product or property damage.Hazards or unsafe practices which could result in severe personal injury or death. propeller. plus “common sense” operation. Shift the unit to neutral and shut off engine when your boat is near people in the water. We strongly recommend that the operator read this Operation and Maintenance Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used. even at slow speed. ! CAUTION CAUTION . We strongly recommend that other occupants be instructed on proper starting and operation procedures so they will be prepared should they be required to operate the power package and boat in an emergency. gear housing. are major accident prevention measures. CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. These “Safety Alerts” alone cannot eliminate the hazards that they signal. Serious injury is likely if a person in the water is struck by a moving boat. If you haven’t been supplied with such a manual. accompanied by the International HAZARD Symbol ! . 4 . Strict compliance with these special instructions while performing the service. the equipment aboard and the safety of all occupants aboard. and on your power package WARNINGS and CAUTIONS. or accessory rigidly attached to your boat or motor. NOTICE Throughout this publication. contact your dealer or the manufacturer of the accessory to secure the applicable manual. ! WARNING The use of accessories not manufactured or sold by Mercury Marine is not recommended for use with your MerCruiser unit. ! WARNING It is difficult for persons standing or floating in the water to move clear if they see a powerboat heading toward them. 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. be sure to read the Operation and Maintenance Manual for the accessory before operation. ! WARNING WARNING . If your MerCruiser unit is equipped with an accessory not manufactured by Mercury Marine.

or not to use. Loss of balance and falling forward of unstable boat passengers . and highperformance boats. drinking and driving. If for any reason it is desired to have a shorter functional lanyard. use. the boat will not complete a full circle. or not to use such a switch. This would occur if the operator falls or moves within the boat a sufficient distance from the operator’s position. A lanyard stop switch can also be installed as an accessory. Loss of power and directional control in heavy seas. strong current or high winds. standing at planing speeds. or daring. Loss of control when docking. the final decision of whether to use a lanyard stop switch rests with you. DISADVANTAGES: Inadvertent activation of the switch is also a possibility.CA280 Lanyard Stop Switch 2 1 74608 1 Some boats come equipped with a lanyard stop switch. The purpose of this switch is to turn off the engine ignition whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. Read the Safety Warning on this page and the following page before electing to install. operating at high speeds in shallow or obstacle-infested waters. This type of accident is most likely in certain types of boats such as low-sided boats. 5 . This could cause any. 2 The lanyard is a cord usually between 4 and 5 feet (1220 and 1524 mm) in length when stretched out with an element on one end made to be inserted into the switch and a metal snap on the other end for attaching to the operator. this may be accomplished by using up length in the way the lanyard and clip are attached to the operator (such as wrapping the lanyard around the operator’s wrist or leg) or by tying a simple knot in the lanyard. 2. of the following potentially hazardous situations: 1. high-speed boat maneuvers. It is also likely as a result of poor operating practices such as sitting on the back of the seat at planing speeds. While the boat is coasting. releasing your grip on a steering wheel that is pulling in one direction. ADVANTAGES: The purpose of a lanyard stop switch is to stop the engine ignition whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. it can cause injury to anyone in the boat’s path as seriously as the boat would when under power. We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine and boat in an emergency. a boat can continue to coast for some distance depending upon the velocity and degree of any turn at shut-down. As we cannot possibly know of and advise the boating public of all conceivable boat/motor types and/or poor operating practices. such a switch. ! WARNING The following advantages and disadvantages of a lanyard stop switch should be considered before electing to use. It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator’s position. or all. the owner/driver.a particular concern in bow rider type boats. While activation of the lanyard stop switch will result in immediate power shut-down. It is coiled to make its at rest condition as short as possible so as to minimize the likelihood of lanyard entanglement with nearby objects. 3. However.

Don’t allow anyone to sit or ride on any part of the boat that was not intended for such use. Foundation information number 1-800-336-BOAT. S. (2) The Power Squadron. Stop the engine whenever passengers are boarding. cruising and local navigation and is available at no charge by writing to: Sources of Waterway Information National Marine Manufacturers Association 410 N. Courses are offered in the U. batteries. familiarize yourself with local and other governmental boating regulations and restrictions. flag and whistle or horn. (8) Transistor radio (9) Drinking water • Know signs of weather change and avoid foul weather and rough-sea boating. This includes backs of seats. You should also review the NMMA Sources of Waterway Information booklet. plus a throwable cushion or ring. • Make sure everyone in the boat is properly seated. • Tell someone where you are going and when you expect to return.A. water-proof storage containers. When in doubt. fuses. compass and map or chart of area. • Know and obey all nautical rules and laws of the waterways. thrust hubs and an appropriate wrench. It lists regional sources of safety. anywhere that sudden unexpected acceleration.S. • Passenger boarding.S. Here are suggestions of the types of safety equipment to carry when boating: (1) Approved fire extinguisher(s). • Use personal flotation devices. • Perform safety checks and required maintenance. (4) Tools for necessary minor repairs. Instruct at least one person on board in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard. Coast Guard approved. gunwales. Federal Law requires that there be a U.S. 1-800-368-5647 or the Boat U. Boat operators should complete a boating safety course. • Prepare other boat operators.S. paddle or oar. (7) Spare operating equipment. Know your boat’s operating and loading limitations. bulbs. Inquiries may be made to the Boating Hotline. first aid kit and book. bow.A. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). decks. unloading or are near the back (stern) of the boat. by (1) The U. Coast Guard Auxiliary. Michigan Avenue Chicago. (5) Anchor and extra anchor line. sudden stopping. transom. contact your dealer or the boats manufacturer. (3) The Red Cross and (4) your state or provincial boating law enforcement agency. IL 60611 U. correctly sized and readily accessible for every person on board. We strongly advise that everyone wear a life jacket at all times while in the boat. 6 . wearabletype life jacket (personal flotation device).CA281 Safe Boating Suggestions In order to safely enjoy the waterways. any rotating fishing seat. Just shifting the drive unit into neutral is not sufficient. unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat. etc. • Check safety equipment on board. Follow a regular schedule and ensure that all repairs are properly made. raised fishing seats. • Do not overload your boat. (3) Spare propeller. (2) Signal devices: flashlight. rockets or flares. (6) Manual bilge pump and extra drain plugs. We strongly recommend that all powerboat operators attend one of these courses. and consider the following suggestions.

00 or (4) there is complete loss of the boat. A boating accident must be reported if (1) there is loss of life or probable loss of life. load. ! WARNING Stop your engine immediately whenever anyone in the water is near your boat. As an example. • Never drive your boat directly behind a water skier in case the skier falls. we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat. or any solid device rigidly attached to a moving boat or gear case. • Watch fallen skiers. Seek further assistance from local law enforcement. Watch “the other guy. your boat traveling at 25 miles per hour (40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet in front of you. CA282 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed. When using your boat for water skiing or similar activities. always keep a fallen or down skier on the operator’s side of the boat while returning to attend the skier. 7 . Whenever a boat is moving (coasting) and the drive unit is in neutral position. • Be alert. or fishing seats should block the operators view when operating the boat above idle or planing transition speed.• Never be under the influence of alcohol or drugs while boating (it is the law). The operator should always have the down skier in sight and never back up to the skier or anyone in the water. While Boat Is Stationary Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near your boat. No passengers. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. For additional information. (3) there is damage to boats or other property where the damage value exceeds $500. there is sufficient force by the water on the propeller to cause the propeller to rotate. Serious injury to the person in the water is likely if contacted by a rotating propeller.” the water and your wake.” The operator must have an unobstructed view particularly to the front. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. (2) there is personal injury requiring medical treatment beyond first aid. This neutral propeller rotation can cause serious injury. They impair your judgment and greatly reduce your ability to react quickly. distributor. • Report accidents. • Know your boating area and avoid hazardous locations. The operator of the boat is responsible by law to “maintain a proper lookout by sight (and hearing). obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-86168--3) from your dealer. a moving gear case. or Mercury Marine. a moving boat. CA283 High-Speed And High-Performance Boat Operation If your boat is considered a high-speed or high-performance boat with which you are unfamiliar.

A damaged propeller or gear housing. B. CA8 Bottom Of Boat To maintain maximum speed. CA10 Ventilation Ventilation is caused by surface air or exhaust gases which are introduced around the propeller resulting in propeller speedup and a reduction in boat speed. Bent propeller blade or damaged gear housing skew .CD3 Conditions Affecting Operation CD4 Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: A. B. B. Drive unit trimmed out too far. Cavitation can seriously erode the surface of the gear housing or propeller. C. B. Drive unit installed too high on transom. • At extremes. Marine vegetation may accumulate when boat is docked. C. which allows exhaust gases to escape between propeller and gear housing. Clean. Cavitation permits the propeller to speed up. Excessive ventilation is annoying and usually caused by: A. CA9 Cavitation Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater object. free of barnacles and marine growth. Free of distortion. A missing propeller diffuser ring. Raised burrs or sharp edges on propeller or gear housing. • At extremes. D. A. • Increases danger of following wave splashing into boat when coming off plane. Shifting weight to rear (stern) will: • Generally increases speed and engine RPM. This growth must be removed before operation. can cause boat to veer back and forth (bow steer). fore and aft. but the boat speed to reduce. Weeds or other debris snagged on propeller or gear housing. 8 . • Causes bow to bounce in choppy water. Shifting weight to front (bow) will: • Improves ease of planing on some boats. it may clog water inlets and cause engine to over heat. Straight and smooth. Common causes of cavitation are: A. such as a gear housing or propeller. can cause boat to porpoise. the following conditions of the boat bottom should be observed. nearly flat where it contacts the water. C. • Improves rough water ride.

• Operating with a damaged propeller or dirty boat bottom causes an RPM loss. do not operate at full throttle when using the lower pitch propeller but not pulling skiers. the following common problems may require that the propeller be changed to a lower pitch: • Warmer weather and greater humidity cause an RPM loss.CD266 Propeller Selection It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller(s). Generally. However. Engine RPM . etc. IMPORTANT: The engines covered in this manual are equipped with a governor that limits engine RPM. the propeller must be changed to prevent loss of performance and possible engine damage. such as is needed for water skiing. 9 . as a significant loss in performance will result. • Operating in a higher elevation causes an RPM loss. On the other hand. use the next lower pitch propeller. • Operating with increased load ( additional passengers. pulling skiers. Be sure that propeller being used does not allow engine to run against the governor. If full throttle operation is below the recommended range.Governor Limit MCM Model D7. there is a 200 RPM change between propeller pitches. operating an engine above the recommended operating RPM range will cause higher than normal wear and/or damage.) For better acceleration. caused by an excessive trim angle. High RPM. Specified engine wide-open-throttle (WOT) and operating RPM range are listed in “SPECIFICATIONS”.3L/270 Engine Recommended Operating RPM Range 3000-3400 Governor RPM Setting (Begins At: ) 3475 ± 50 Select a propeller that will allow the engine power package to operate at or near the top end of the recommended wide-open-throttle operating RPM range with a normal load. After initial propeller selection. should not be used in determining correct propeller selection.

barometric pressure and temperature do have a noticeable effect on the density of air. This. Nothing will regain this speed for the boater.CA12 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide-open-throttle power of an engine. can be somewhat regained by switching to a lowerpitch propeller that allows the engine to again run at recommended RPM. In some cases. this propeller will. it is essential that the engine be propped to allow it to operate at or near the top end of the recommended maximum RPM range at wideopen-throttle with a normal boat load. This condition can become particularly annoying when an engine is propped out on a cool. in effect. low barometric pressure and high humidity all combine to reduce the engine power. Humidity. This will result in further loss of horsepower at the propeller with another decrease in boat speed. In pointing out the practical consequences of weather effects. become too large. sultry day in August. This. Although some performance can be regained by dropping to a lower-pitch propeller. Since air (containing oxygen) gets thinner as elevation increases. as much as 2 or 3 miles per hour in some cases. dry day in spring and later. of course. in turn. Consequently. enhances overall reliability and durability of the engine. With the drop in available horsepower. is reflected in decreased boat speeds. but the coming of cool. doesn’t have its old zip. the engine begins to starve for air. Summer conditions of high temperature. an engine -. Not only does this allow the engine to develop full power. dry weather. however. the basic problem still exists. For boaters to realize optimum engine performance under changing weather conditions.running on a hot. a gear-ratio change to more reduction is possible and very beneficial. Heat and humidity thin the air.may encounter a loss of as much as 14% of the horsepower it would produce on a dry brisk spring or fall day. This secondary loss. on a hot. the engine operates at less than its recommended RPM. 10 . humid summer day -. but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging detonation.

but are not limited to: search and rescue craft. or recreational power boats in non-revenue applications. or boats with planing hulls where acceleration and top speed are of primary importance. Examples of Light Duty applications include. fire boats. IMPORTANT: Damage caused by improper application or failure to operate within the operational capability. 11 . and limited season fishing boats such as sport-fish charter boats.) Annual operating time is not to exceed 500 hours. Application to common commercial crafts having full-displacement or semi-displacement hulls exceeds the recommended operational capability. Light duty rating applies to planing boats where the use of full rated power at maximum rated RPM is limited (as stated above). NOTE: Pleasure duty rating applies to high performance-type boats. or duty cycle. or duty cycle.CD5 Important Information CD247 Operation And Maintenance RECOMMENDED OPERATION/DUTY CYCLE It is the operator’s responsibility to operate within the following recommended operational capability.) Operated at rated power and rated speed for short periods of time.) Operated such that full rated power at maximum rated RPM is limited to 10% of operating time and continuous cruising RPM is limited to 90% of Wide-Open-Throttle RPM (when propped within specified RPM range). fast patrol boats. 2. This rating is reserved for privately-owned yachts. dive boats. will not be covered by the MerCruiser Diesel Limited Warranty. or duty cycle. as applicable to engine and installation: • Pleasure Duty 1. • Light Duty 1.

Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such. a dealer’s responsibilities to the customer include predelivery inspection and preparation such as: • Make sure that the boat is properly equipped.CE7 OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks. • Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory (branch or distributor) immediately upon sale of the new product. • Explain and demonstrate the operation of the power package and boat. See your Authorized MerCruiser Dealer for service aids. ! CAUTION The injection pump lever Wide-Open-Throttle (W. and is factory set and sealed. make certain that the MerCruiser power package and other equipment are in proper operating condition. and will keep your overall operating expenses at a minimum. and return the unit to an Authorized MerCruiser Dealer for a periodic checkup. • Make all necessary adjustments for maximum efficiency.) Stop Screw adjusts the engine speed governor.T. the dealer should provide you with a copy of a Predelivery Inspection Checklist. Proper maintenance and care of your power package will assure optimum performance and dependability. Individual operating habits and usage contribute to the need for maintenance service. and resulting damages will not be covered by the limited warranty. • Prior to delivery. ensure that all lubrication and maintenance instructions are complied with for safe operation. Removal of the seal and/or readjustment of the governed speed is considered misuse of engine. • Familiarize the customer with the on-board equipment. are not considered defects in workmanship or material within the terms of the warranty.O. CA14 DEALER RESPONSIBILITIES In general. Readjusting the governed speed and operating above the specified RPM will cause extensive engine damage and/or failure. • At the time of delivery. 12 .

if the possibility of freezing temperatures exist. 13 . Fill fuel tank at end of daily operation to prevent condensation. it is recommended that you use the crankcase mounted coolant heater to improve cold starting. Use extreme care to prevent striking submerged objects while operating in REVERSE. • Be sure to use proper cold weather lubrication oil. If continued running is necessary. boat should be taken to an Authorized MerCruiser Dealer for thorough inspection and necessary repair. ! CAUTION Seawater (raw water) section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use. drain water from water separator. reducing damage to unit. do so at greatly reduced speeds. • At the end of each daily operation. CA17 Drive Unit Impact Protection The Power Trim hydraulic system is designed to provide impact protection for drive unit. • Use required permanent-type antifreeze solution to protect components against damage by freezing. No impact protection is provided in REVERSE. or could affect control of boat.CE8 Freezing Temperature And Cold Weather Operation IMPORTANT: If boat is operated during periods of freezing temperature. Use extreme caution when operating in shallow water or where underwater objects are known to be present. stop engine as soon as possible and inspect drive unit for damage. Check that all other electrical equipment is in optimum condition. and be sure the crankcase contains a sufficient amount. precautions must be taken to prevent freezing damage to power package. After drive unit has cleared object. In order to operate the engine in temperatures of 32° F (0° C) or lower. preventing loss of steering control and engine over speed. • At temperatures of –4° F (–20° C) and below. Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. COMPLETELY drain seawater section of cooling system to protect against damage by freezing. the hydraulic system will cushion kick-up of drive unit as it clears the object. IMPORTANT: Impact protection system cannot be designed to ensure total protection from impact damage under all conditions. observe the following instructions: • At the end of each daily operation. If drive unit should strike a submerged object. Refer to the following and to “Cold Weather or Extended Storage” for related information and draining instructions. If a submerged object is struck while boat is moving forward. the hydraulic system allows drive unit to return to original operating position. Operating a damaged drive unit could cause additional damage to other parts of drive unit. • If operating in arctic temperatures of –20° F (–29° C) or lower. If damage is present or suspected. if equipped. consult your dealer for information about special cold weather equipment and precautions. • Make certain that the battery is of sufficient size and is fully charged.

In any of these situations. immediately advise the local authorities and Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. When backing up rapidly.” CA18 Attention Required After Submersion • Before recovery. 14 . contact an Authorized MerCruiser Dealer. This may force water through the exhaust system into the cylinders. Refer to “Attention Required After Submersion. the same situation may occur as stated in the preceding paragraph. If adequate road clearance is a problem.” in this “Operation and Maintenance Manual.CA20 Launching and Boat Operation Care ! CAUTION During launching from a trailer. CA21 Stolen Power Package If your power package is stolen. stopping suddenly or backing up rapidly may cause a following wave to “swamp” the transom causing water to enter the cylinders through the exhaust system causing severe engine damage. The more weight on the transom. immediate service by an Authorized MerCruiser Dealer is required to prevent serious damage to power package. place drive unit in full trailer position and support with an optional trailer kit which is available from your Authorized MerCruiser Dealer. CA19 Trailering Boat Boat can be trailered with drive unit in up or down position. Adequate road clearance is required between road and gear housing skew when trailering with drive unit in down position. the boat may enter the water rapidly and at a steep angle. Slowing down rapidly. This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors. the more likely this is to occur. water entering the engine could cause severe damage to internal parts. if the unloading ramp is steep or the trailer bed must be tilted. • After recovery.

CE9 Replacement Service Parts Marine engines are expected to operate at or near full throttle for most of their life. The service manual outlines the correct procedures to follow. service center. CA23 Do-It-Yourself Maintenance Suggestions If you are one of those persons who likes to do-it-yourself. camshafts and other heavy-duty moving parts are required for long life and peak performance. 15 . he must examine you personally. These conditions require numerous special parts. A doctor can’t and won’t diagnose your illness by telephone. here are some suggestions for you. It is written for the trained mechanic. It is difficult for them to diagnose a problem over the telephone. or the factory to attempt for them to diagnose a problem or request the repair procedure. It may be a very simple adjustment to correct the problem. • There are special tools and equipment that are required to perform some repairs. such as your MerCruiser power package. so there may be procedures you don’t understand. They are also expected to operate in both fresh and saltwater environments. • This will cost you more than taking it to the dealer immediately upon having a problem. Do not attempt repairs if you do not understand the procedures. He has qualified factory-trained mechanics. • Your Authorized Dealer is there to service your power package. • If you attempt to service the product yourself. are highly technical pieces of machinery. You can cause damage to the product in excess of the cost a dealer would charge you. just as a mechanic must examine your power package. Have him winterize it in the fall and service It before the boating season. It is recommended you have the dealer do periodic maintenance checks on your power package. we suggest you order the service manual for that model. Do not attempt these repairs unless you have these special tools and/or equipment. Since marine engines must be capable of running at or near maximum RPM much of the time. the dealer’s mechanic must reassemble the components and test to determine the problem. • Do not attempt any repairs which are not covered in your Operation and Maintenance Manual accompanying your product unless you are aware of the precautions (“Cautions” and “Warnings”) and procedures required. This will reduce the possibility of any problems occurring during your boating season when you want trouble-free boating pleasure. These are but a few of the many special modifications that are required in MerCruiser marine engines to provide long life and dependable performance. as specifications are quite different from those of the standard automotive engine. if you partially disassemble an engine or drive assembly and are unable to repair it. Care should be exercised when replacing marine engine parts. Your safety is of our concern. • Also. • Do not telephone the dealer. • Present-day marine equipment. special pistons.

3. occasional operation at full throttle (5 minutes at a time maximum) is permissible. Shifting and Stopping” and start engine. Run engine in gear for 3 minutes at each of the following RPMs: 1800 RPM. This break-in procedure allows the proper seating of the pistons and rings. 3000 RPM and Maximum Rated Full-Throttle RPM. then. shift into gear as soon as possible after starting engine and advance throttle so that RPM is above 1500 (provided that conditions permit safe operation at this speed). During the next 10 hours. • DO NOT operate at full throttle until engine reaches normal operating temperature. If engine does not start. 2800 RPM and 3200 RPM. • OBSERVE INSTRUMENTS. • DO NOT operate at any one constant speed for extended periods. IMPORTANT: Never operate the starter motor longer than 15 seconds at a time. stop engine immediately and determine cause. 2. remove break in oil and replace oil filter. if an abnormal reading occurs. • AVOID full throttle acceleration from stopped position. Refer to “Starting. 2400 RPM and 3000 RPM. Fill crankcase with correct grade and viscosity oil. Correct break-in is essential to obtain minimum oil consumption and maximum engine performance. the following rules must be observed: • DO NOT operate engine below 1500 RPM for extended periods during the first 10 hours. Run engine in gear for 3 minutes at each of the following RPMs: 1200 RPM. which greatly reduces the likelihood of problems. During this period. • AT END OF 20-HOUR break-in period. It is normal for oil consumption to be somewhat high during the break-in period. to avoid overheating the starter motor. INITIAL BREAK-IN PROCEDURE IS AS FOLLOWS: 1. Run engine in gear for 3 minutes at each of the following RPMs: 1500 RPM. 16 . wait 1 minute to allow the starter motor to cool. repeat starting procedure. Add if necessary.CE10 Engine Break-In INITIAL BREAK-IN PROCEDURE It is especially important that the following procedure be used on new diesel engines. • FREQUENTLY CHECK crankcase oil and stern drive unit fluid levels. 4. IMPORTANT: It is recommended that the boat not be accelerated hard until this procedure has been completed. During this break-in period. Allow engine to idle until it has reached normal operating temperature. 20-HOUR BREAK-IN PROCEDURE IMPORTANT: The first 20 hours of operation is the engine break-in period. • DO NOT exceed 75% of full throttle during the first 10 hours except during engine Initial Break-In Procedure.

17 .74 N·m) (stern drive models only) Power steering system fluid (stern drive models only)* Drive unit lubricant level (stern drive models only)* Transmission fluid level (inboard models only)* Power trim pump oil level (stern drive models only)* ON-WATER TESTING (ENGINE RUNNING/OPERATING TEMPERATURE) . . ft.ft. but no later than 50 hours. check or adjust as indicated. that the product be taken to an authorized MerCruiser service dealer after 20 hours of operation. (47-54 N⋅m).) A copy of the dealer service work order must be kept. neutral and reverse Steering operation throughout range Power trim operation (stern drive models only) Maximum RPM in forward gear -. as evidence of the completion of this requirement. ft.CHECK OR ADJUST Not Applicable Completed Torque turbocharger fasteners [31 lb. coolant and exhaust leaks Remote control operation--forward. (42 N·m)] and exhaust manifold fasteners [24 lb. In these instances check the “Not Applicable” box provided. Check that rear engine mounts are torqued to 35-40 lb. ft.Use only factory approved coolant and fluids. shift and steering system fasteners tight and/or properly secured Drive mounting fasteners are tight Check that both front engine mount locknuts are tightened securely. oil.change propeller if necessary♦ AFTER-WATER TESTING .SERVICE Change crankcase oil and filter ♦ * . (stern drive models only) Drain fuel filter and check for water Check condition and tension of all drive belts Check closed cooling system coolant level * Retorque gimbal ring clamping bolt to 50 . (Note: Some items may not apply to your specific power package. check to ensure that tab washers are bent down over adjusting nuts. by product owner.CHECK OR ADJUST Idle RPM in forward gear♦ All gauges and indicator lamps proper readings♦ Fuel. and adjustments. Then.CE170 20-Hour Checkup It is a condition for the continuation of warranty. water. Service.55 lb.Refer to “Specifications . checks.Engine” Chart in this manual. (32 N·m)] (V-8 Diesel models only) Tighten cooling and exhaust system hose clamps Throttle. BEFORE RUNNING (ENGINE COLD) . (67 . for the following services.

All fuel components including fuel tanks. NOTE: If your engine suddenly becomes noisy after a fuel fill.CD7 Specifications CD11 Seacock Seacock (water inlet valve) used. A lower cetane number could cause hard starting and slower warm-up. and could increase engine noise and exhaust emissions. Any sign of leakage or deterioration requires replacement before further engine operation. This mixture of gasoline. fittings. Limits may vary in countries outside of the United States. IMPORTANT: Use of improper or water contaminated diesel fuel can damage your engine seriously. high sulphur content diesel fuel will greatly increase: • Corrosion on metal parts. or high altitude use. 18 . Careful periodic inspection of entire fuel system is mandatory. and excessive wear of internal engine parts. A minimum flow rate of 40 gallons (150 litres) per minute is required. soften. swelling or corrosion. Increasing the cetane number will not improve overall engine performance. A 1-1/2 in. CE14 Seawater Strainer Seawater Strainer should be provided. fuel lines. gasohol and/or alcohol be mixed with diesel fuel for any reason. Strainer should be installed in an area where it will be easily accessible for inspection and cleaning.50% by weight. • Corrosion and extensive damage. Sulphur content of the above fuel is rated at 0. metal or fiberglass. you possibly received substandard fuel with a low cetane rating. Use of improper fuel is considered misuse of engine. • Deterioration of elastomer and plastic parts. On intermittent use engines. The Cetane number is a measure of the ignition quality of diesel fuel. and having a minimum cetane rating of 45. and fuel filters should be inspected for leakage. (38mm) brass ball or gate valve is minimum required. and damage caused thereby will not be covered by warranty. Grade 2-D diesel fuel is required. maximum (ASTM). CE15 Fuel Requirements ! WARNING FIRE HAZARD: Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death. particularly bearings. and be of sufficient size to ensure that an adequate supply of water will be maintained for cooling engine. Strainer should be installed in water inlet hose after seacock to allow operator to shut off water inlet when cleaning strainer. but it may be necessary to raise the cetane rating for low temperature. primers. meeting ASTM Standards D975 (or fuel rated Diesel DIN 51601). particularly after storage. Seacock should be installed in an area where it is easily accessible and supported adequately to prevent hose fatigue. must have an internal cross-sectional area equal to or greater than hose to prevent restricting water flow. • Starting and operating difficulties. hardening. gasohol and/or alcohol with diesel fuel is highly flammable and produces a significant risk to the user. ! WARNING Under no circumstances should gasoline. whether plastic.

the engine requires engine oil with rating of HD-SAE-API-SG/CD. AGIP SIGMA TURBO SHELL MYRINA MOPAR MOBIL DELVAC 1400 SUPER TEXACO URSA SUPER TD WINTERSHALL MULTI-REKORD TOTAL RUBIA TIR VEEDOL TURBOBOSTAR WINTERSHALL VIVA 1 19 . unless treated. Virtually all diesel fuels are “climatized” to allow their use in the particular region for that time of the year. If it becomes necessary to further treat diesel fuel. it is the owner/operator’s responsibility to add a commercial “standard brand” “anti-gel” diesel fuel additive. exceed MlL-2104 D standards. a specially blended 25W-40 SG/CD oil with Marine Additives. following that product’s directions. and conforming to or exceeding military specifications of MIL-2104 D. RECOMMENDED OILS ALL TEMPERATURE OPERATION .USE 15W-40 CD These oils. We strongly recommend the use of QUICKSILVER 4-Cycle Marine Engine Oil.CE16 Diesel Fuel In Cold Weather Unaltered diesel fuels thicken and “gel” in cold temperatures. CE17 Crankcase Oil To help obtain optimum engine performance and to provide maximum protection. approved by Mercury Marine and Marine Power Europe. for all temperature operations.

950 mca.210° F ( 77° .250° F ( 94° . Series 28MT ) 170° .3L/270 270 (201) 238 (177) Propeller Shaft Horsepower (Kilowatts) 1 Engine Type Displacement Firing Order Bore Stroke Compression Ratio Valve Clearance Maximum Pressure Difference Between Cyl. 20 .8 bar ( 276-482 kPa ) ] 200° . 2.99° C ) 12-volt Negative ( .) Ground 949W. (7.8 .4. ( 106.18 in.3L ) 1-2-7-3-4-5-6-8 4. 65A 750 cca. or 180 Ah 12v.11 in.CD249 Engine DESCRIPTION Crankshaft Horsepower (Kilowatts) 1 SPECIFICATION .121° C ) 170° F ( 77° C ) 230° F ( 110° C ) Coolant Temperature Electrical System Alternator Rating Recommended Battery Rating Starter ( Delco. Maximum Governed RPM @ WOT Maximum RPM @ WOT Idle RPM in Forward Gear Oil Pressure Oil Temperature Thermostats: @ 650 RPM @ 3400 RPM Water: Oil: V-8 Cylinder Diesel 444 cu. 14.4 kW 1 Power rated in accordance with NMMA Procedure .39 mm ) 4.7 bar (69 kPa) ] Minimum 40-70 PSI [ 2.20 mm ) 19:1 Non-Adjustable (Hydraulic) 75 PSI ( 517 kPa ) 3475 ± 50 3400 675 ± 25 10 PSI [ 0. ( 104.6v.MCM (Stern Drive) D7. in.ISO 3046 (Technically Identical to ICOMIA 28-83).

21 . and overheating of the engine. and purified water. special additives. ITEM Total Oil-Filling Capacity1 From oil pan Oil D i Drainage: From oil filter From oil cooler Drive Unit Oil Capacity (With Gear Lube Monitor)1 Closed Cooling System 1 Always SPECIFICATION MCM (Stern Drive) D7.2 (3) 3 (2.9) 26 (24-1/2) Bravo Two Bravo Three use dipstick to determine exact quantity of oil or fluid required.3L/270 12 (11-1/3) 10 (9-1/2) 1 (1) 1 (1) 3.CD194 Capacities NOTE: All measurements are given in US Quarts (Liters). CE20 Required Coolant: Quicksilver Premixed Marine Engine Coolant IMPORTANT: This contains special low silicate ethylene glycol. Use of other coolant may cause fouling of the heat exchangers.

CD9 Operation CD16 1 71856 3 71856 2 71856 4 72753 5 71856 6 71856 7 71772 8 71886 22 .

23 . The green area on the gauge is the normal operating range.has three positions. The instrumentation shown is required for safe operation of boat and engine. all electrical circuits. if equipped with other than Quicksilver instrumentation. 4 Cruise Log (Engine Hour Meter) .indicates engine oil pressure. NOTE: Key can only be removed in the “OFF” position. 7 Audio Warning Buzzer Standard Features . Refer to “Specifications” for normal operating readings. Refer to “Specifications” for normal operating readings. automatic preheating and all instrumentation is operational. all electrical circuits are off and engine cannot be started. and if alternator and charging circuit are functioning properly.indicates battery voltage. In the “START” position the engine can be started.records engine running time.CD18 Quicksilver Instruments and Instrumentation Shown is the basic Quicksilver instrumentation and engine system monitor display for the Diesel Power Package. The engine is stopped when the key switch is turned to the “OFF” position. In the “RUN” position. or collectively mounted in the optional single panel available from Quicksilver. indicator lamps.indicates engine speed (RPM). Gauges and engine system monitor panel may be individually mounted. 6 Trim/Tilt Gauge .indicates engine coolant temperature. in the “OFF” position. 5 Voltmeter. 2 Tachometer .Buzzer sounds if: (1) Cooling system temperature too high (2) Oil pressure too low (3) Drive unit oil too low (4) Water is present in fuel filter 8 Key Switch . 1 Oil Pressure Gauge . Operator should become familiar with all instrumentation before operating the engines.indicates drive unit trim angle (“Up/Out” or “Down/In”). 3 Coolant Temperature Gauge . NOTE: Refer to manufacturer’s instructions and explanations about instrumentation.

light should go off.located in-line on key switch RED/PURPLE wire and protects the Instrumentation and wiring should an electrical overload occur. this may be an indication of low oil level in the gear lube monitor bottle.indicates a problem with charging system if lamp illuminates while engine is running.has three positions. When engine starts. Check “blown” (burned) fuse if key is turned to RUN or START and nothing happens. and then.Coolant Temperature Warning Lamp . 3 20 Amp Fuse and Holder . 24 .Charge Indicator Lamp .Preheat Indicator Lamp .Oil Pressure Warning Lamp . When the switch is toggled “DOWN” the audio warning buzzer will sound allowing the operator to perform a test of the audio warning buzzer.lights up when the glow plugs are preheating the combustion chambers. d . c .Water-In-Fuel Warning Lamp . The cause should be determined and corrected.indicates water is present in fuel filter and that fuel filter requires service. NOTE: The coolant temperature warning lamp is wired in a parallel circuit with the gear lube monitor bottle switch. If an overload occurs. b .indicates low engine oil pressure if lamp illuminates while engine is running. the fuse will burn out. With switch toggled “UP” the instrumentation lights are all illuminated.The appropriate light functions as follows: a . The timed preheat period begins when the key switch is turned on. After cause is corrected. IMPORTANT: Cause for overload must be determined and corrected before attempting to install new fuse or fuse failure will occur again. e .CE23 1 e d c b a 71891 2 CD171 71891 3 71722 1 Engine System Monitor Features . in the normal position all electrical circuits operate in a standard fashion (as described above). install new fuse and check systems to function. only when the engine is cold.indicates excessive engine coolant temperature if lamp illuminates while engine is running. The light stays on until the preheat period is complete. THE ENGINE CAN BE STARTED ONLY AFTER THE LIGHT GOES OUT. 2 Panel Lights/Audio Test Switch . If lamp illuminates while engine is running. Lamp will light when key switch is “ON” and engine is not running. and coolant temperature and coolant level are normal.

If an overload occurs. 4 The Power Trim system is protected from overload by 110 amp fuse and a 20 amp in-line fuse on Power Trim pump. 1 One 50 amp circuit breaker provides protection for engine wiring harness and instrumentation power lead. In an emergency. 2 One 150 amp circuit breaker provides protection for glow plug system and related engine wiring harness connections. If fuse is “blown” (defective). 3 When equipped with Quicksilver instrumentation and wiring a 20 amp fuse and holder is located in-line on key switch RED/PURPLE wire and protects the Instrumentation and wiring should an electrical overload occur. a fuse will blow or a circuit breaker will trip open. the system will not operate. when engine must be operated and cause for high current draw cannot be located and corrected. electrical overload has not been eliminated. Reset by pushing RESET button IN (from outside). Check “blown” (burned) fuse if key is turned to RUN or START and instruments do not work and/or if switches do not function. turn OFF or disconnect all accessories connected to engine and instrumentation wiring. 25 . Reset circuit breaker. If breaker remains open. Further checks must be made on glow plug system and/or electrical system. IMPORTANT: The cause must be found and corrected before replacing fuse or resetting circuit breaker. Further checks must be made on electrical system. If breaker remains open. CA31 Mercathode System 5 A 20 amp in-line fuse is in the wire which connects to positive (+) terminal on controller. the fuse will burn out.CD19 1 2 71863 4 71630 3 71722 71856 5 22444 CD20 Electrical System Overload Protection lf an electrical overload occurs. Reset by pushing RESET button IN (from outside). electrical overload has not been eliminated.

CD197 1 7 3 2 11 10 9 8 5 12 6 4 8 11 10 9 12 13 26 .

“Push” the control handle forward from “Neutral” with a quick firm motion to the first detent for “Forward” gear. 11 Power Trim Switch . The throttle only button can be depressed only when the remote control handle is in the “Neutral” position. 8 Control Handle(s) . 1 Neutral Lock Bar .Used to raise drive unit for trailering.This screw can be adjusted to “Increase” or “Decrease” the tension on the control handle (cover must be removed to adjust). This is done by disengaging the shift mechanism from the control handle. Turn screw “Clockwise” to increase tension and “Counterclockwise” to decrease tension. The throttle only button can be depressed only when the remote control handle is in the “Neutral” position.See “Power Trim” section for detailed power trim operating procedures. Adjust to tension desired.This screw can be adjusted to “Increase” or “Decrease” the tension on the control handle. consult your dealer for a description and/or demonstration of the control.Operation of the the shift and throttle are controlled by the movement of the control handle. 9 Throttle Only Button . See “Power Trim” for detailed trailer switch operation.Allows engine throttle advancement without shifting the engine.CD195 Remote Controls (Panel Mounted) Your boat may be equipped with one of many Quicksilver® remote controls available.See “Power Trim” section for detailed power trim operating procedures. all controls may not have all features shown. launching.Allows engine throttle advancement without shifting the engine. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. and should only be used to assist in starting the engine. Also. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. 13 Power Trim Adjustment Switches (Used on Three Button Trim Control Only) . NOTE: If boat is equipped with a remote control other than shown.Prevents accidental shift and throttle engagement. launching. “Push” the control handle forward from “Neutral” with a quick firm motion to the first detent for “Forward” gear. 10 Control Handle Tension Adjustment Screw . Also. NOTE: If boat is equipped with a remote control other than shown. breaching or shallow water operation. 12 Trailer Switch . 2 Throttle Only Button . See “Power Trim” for detailed trailer switch operation. all controls may not have all features shown. CD196 Remote Controls (Console Mounted) Your boat may be equipped with one of many Quicksilver® remote controls available. This will help prevent “Creep” of the remote control handle. 5 Lanyard Stop Switch . Neutral lock bar must be pulled “Up” to move the control handle out of neutral. 3 Power Trim Switch . consult your dealer for a description and/or demonstration of the control. Continue pushing back to increase speed. 6 Control Handle Tension Adjustment Screw . This is done by disengaging the shift mechanism from the control handle.See “Power Trim” for detailed power trim operating procedures. breaching or shallow water operation. Turn screw “Clockwise” to increase tension and “Counterclockwise” to decrease tension.Operation of the shift and throttle are controlled by the movement of the control handle. 7 Control Handle . 4 Trailer Switch .Used to raise drive unit for trailering. Continue pushing back to increase speed. and should only be used to assist in starting the engine. Adjust to tension desired. 27 . See “Lanyard Stop Switch” at the front of this manual for safety warning on the use of this switch. Pull the control handle back from “Neutral” with a quick firm motion to the first detent for “Reverse” gear. This will help prevent “Creep” of the remote control handle. Pull the control handle back from “Neutral” with a quick firm motion to the first detent for “Reverse” gear.Turns ignition “Off” whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. Continue pushing forward to increase speed. Continue pushing forward to increase speed.

CD198 4 1 2 3 71339 70537 3° – 5° 5 71338 28 .

cause boat “porpoising” (bouncing) or propeller ventilation. Generally increase top speed. consult your dealer for a description and/or demonstration of the control. the Power Trim system “Trailering” feature allows the operator to raise and lower the drive unit for trailering. Use extreme caution when operating with drive unit raised. ! CAUTION Never trim the drive unit UP/OUT using TRAILER switch while boat is underway at engine speeds above 1200 RPM. turn screw counterclockwise. 3 FRICTION Screw . or if a significant wave is encountered. to decrease. 4 DETENT Screw . All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Do not thread screw all the way out. 1 In most cases. reduce boat speed.adjusts control handle friction so motor speed can be set and driver does not have to hold handle. to provide the ideal boat angle for varying load and water conditions. best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3° to 5° angle to the water.allows engine RPM to be increased or decreased. Cause boat to accelerate and plane off slower. launching and low speed (below 1200 RPM engine speed). To increase tension. Move lever backward to shift to REVERSE gear. Turn screw clockwise to increase friction. while underway.CD217 Remote Controls (Two Lever) Your boat may be equipped with one of many Quicksilver® remote controls available. beaching. 2 Throttle Lever . Also. lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. Generally improve the ride in choppy water. In excess. 1 Shift Lever . Severe damage to the drive unit may result if unit is raised beyond the gimbal ring support flanges at engine speeds above 1200 RPM.controls the effort needed to move control handle out of NEUTRAL. ! CAUTION Never shift unit into or out of gear unless throttle lever is a idle RPM. Also. Move lever forward to shift to FORWARD gear.shifts unit into gear with full lever movement. NOTE: If boat is equipped with a remote control other than shown. IMPORTANT: Boats equipped with dual power packages may have both shift levers on one control and both throttle levers on the other control. Trimming Drive Unit UP/OUT Can: • • • • • • Lower the bow. CA284 Power Trim Power Trim allows the operator to adjust the drive angle. all controls may not have all features shown. turn screw clockwise. This can result in an unexpected turn in either direction called “bow steering” or “over steering” if any turn is attempted. Help the boat accelerate and plane off quicker. Cause engine overheating if trimmed UP/OUT to a point where any cooling water intake holes are above the water line. If in excess. 29 Trimming Drive Unit DOWN/IN Can: • • • • . Increase clearance over submerged objects or a shallow bottom. In most cases. shallow water operation. Lever in full vertical position shifts to NEUTRAL. Do not thread screw all the way out.

CD199 2 3 1 73976 6 5 4 73977 30 .

CB188 POWER TRIM OPERATION . 31 . Should this happen.PANEL MOUNT REMOTE CONTROL IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel.CONSOLE MOUNT REMOTE CONTROL (SINGLE ENGINE VERSION) 4 Trailer Position: Press button until drive unit reaches desired height. 1 Trailer Position: Press button until drive unit reaches desired height. 6 Lower Drive Unit: Press DOWN on Trim switch until drive unit reaches desired position. 2 Trim Up/Out: Press UP on Trim switch until drive unit reaches desired trim position. 3 Lower Drive Unit: Press DOWN on Trim switch until drive unit reaches desired position. CB189 POWER TRIM OPERATION . 5 Trim Up/Out: Press UP on Trim switch until drive unit reaches desired trim position. release button and allow motor to cool for about one minute. Circuit breaker will reset and Power Trim operation may be resumed. an internal circuit breaker will open and pump will stop.

CD200 2A 1 2B 73979 4 1 73978 3 5 70540 6 70540 7 70540 32 .

Using these “Fine Tune Switches”. an internal circuit breaker will open and pump will stop.used to contol both drive units from the handle. CB193 POWER TRIM OPERATION . 3 Three Button Trim Control (Trim Adjustment Switches) .CA285 POWER TRIM OPERATION . Circuit breaker will reset and Power Trim operation may be resumed. 2 Two Button Trim Control (Dual Buttons in Handle) . 7 Trim Drive Unit IN/DOWN: Press IN button until drive unit reaches desired trim position. Forward Trim Button . in the trailering position. 5 Trailer Position: Simultaneously press the UP button (top) along with the UP/OUT button (center) until drive unit reaches desired trailer position. release button(s) and allow motor to cool for about one minute. an internal circuit breaker will open and pump will stop. set each drive unit to the desired trim angle.Press button until drive unit reaches desired height for trailering drive units. stern drives must be lowered evenly to prevent tie bar from becoming twisted. 6 Trim Drive Unit UP/OUT: Press center UP/OUT button until drive unit reaches desired trim position. Press down on button(s) to trim drive unit DOWN/IN.DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL (TWO BUTTON AND THREE BUTTON VERSIONS) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel. Should this happen. release button and allow motor to cool for about one minute. A.Used to trim the port drive unit. 1 Trailer Button (Both Versions) . Failure to lower stern drives evenly may result in tie bar or stern drive(s) damage. ! CAUTION When lowering or raising stern drives equipped with a dual engine tie bar kit. 33 .used to trim both drives simultaneously after drives have been fine-tuned as described above.THREE BUTTON TRIM PANEL (USED ON MODELS WITH TWO-LEVER CONTROL) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel. Press UP on button(s) to trim drive unit UP/OUT.With a single integral trim button in the handle to control two drive units simultaneously. 4 Three Button Trim Control (Single Trim Switch in Handle) . Circuit breaker will reset and Power Trim operation may be resumed. Rear Trim Button . these two switches control the “Fine Tune” adjustment of each drive unit. Should this happen. Then use the single trim switch in the handle to control the trim of both drive units simultaneously.Used to trim the starboard drive unit. B.

34 . 2 Turn key switch to RUN position. then. 2 Perform any other necessary checks. wait 1 minute to allow the starter motor to cool. NOTE: Engine can be started once preheat indicator lamp goes out. Propane. to avoid overheating the starter motor. 3 Turn key switch to START position. such as Ether. stop the engine. oil pressure should exceed 10 psi (69 kPa) minimum. the following steps must be observed before starting: • Do not start engine without water being supplied to seawater pickup pump (to prevent pump or engine damage). or see your Authorized MerCruiser Dealer if you are unable to determine the problem. Refer to “Maintenance . Within seconds after starting the engine. • Be sure engine crankcase is filled to correct level with the proper grade of oil for the prevailing temperature. • Check the air cleaner for proper installation of filter element. If engine does not start. Check to ensure charge indicator and oil pressure warning lamps go out. • Never operate the starter motor longer than 15 seconds at a time. or specified in your boat owner’s manual. locate and correct the problem. ! CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant. open engine hatch to air out bilge before attempting to start engine(s). Refer to “Specifications . there is a hand pump/primer located on the engine to improve initial fuel supply. CE30 STARTING COLD ENGINE IMPORTANT: Always check all fluid levels before starting engine. Shifting and Stopping BEFORE STARTING THE ENGINE ! WARNING Do not use volatile starting aids. Or. ! CAUTION Do not increase the engine speed until the oil pressure gauge indicates normal. Priming Fuel System” and follow instructions given. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage. 1 Check all items listed in the MAINTENANCE CHART AND OPERATION CHART (Refer to “Table Of Contents”). 1 Turn on and run engine compartment bilge blower (if so equipped) for five minutes. IMPORTANT: As an added precaution. Lamp should be illuminated when engine is cold and will be off when preheat cycle is complete. as indicated by your dealer.CE29 Starting. Refer to Maintenance Chart. or Gasoline in the engine air intake system. If the oil pressure does not meet these minimum limits. 4 Check to ensure all instrumentation is functioning properly and indicating normal readings.Crankcase Oil”.Fuel System. • Be sure that all electrical connections are secure. Observe preheat indicator (glow plug) lamp. Release key when engine starts and allow switch to return to RUN position. 3 If engine has not been run for a period of time and will not readily start with the standard starting procedure. repeat starting procedure. Shut the engine down if oil pressure does not register on the gauge within 20 to 30 seconds after start.

or see your Authorized MerCruiser Dealer if you are unable to determine the problem. or see your Authorized MerCruiser Dealer if you are unable to determine the problem. 3 Turn key switch to the “OFF” position.CE31 ENGINE WARM UP ! CAUTION Improper or no warm-up of engine can seriously impair the Iife of your diesel engine. Check to ensure glow plug preheat lamp is not illuminated. be sure remote control/throttle lever is in NEUTRAL. 4 Check to ensure all instrumentation is functioning properly and indicating normal readings. Damage to drive unit could occur. 3. 2.” 2 Run engine at idle speed for several minutes to allow engine to cool down. Stop the engine if oil pressure is not within this range. CE32 STARTING WARM ENGINE 1 Turn on and run engine compartment bilge blower for five minutes (if so equipped). The warm-up period provides time for the lubricating oil to establish a film between moving parts. open engine hatch to air out bilge before attempting to start engine(s). Move control/shift lever with a firm. Turn key to start position. or see your Authorized MerCruiser Dealer if you are unable to determine the problem. CE34 ENGINE SHUT-DOWN (STOPPING) 1 Place remote control lever in “Neutral. Commence normal vessel operation when systems reach operating temperatures. to release clutch from gear. Check to ensure charge indicator and oil pressure warning lamps go out. 1. advance throttle to desired setting. It is very important that any engine be warmed up before applying full load. Stop the engine if oil pressure is not within this range. Run engine at idle RPM until engine temperature is within normal operating range. Locate and correct the problem. or Wide-Open-Throttle. 1 After starting. Pull/push remote control handle to neutral-lock position (it will be necessary to exert force to move handle). engine oil pressure should be within the range listed in the engine specifications chart at maximum RPM. Locate and correct the problem. NOTE: Engine warm-up time during cold weather can be reduced by operating vessel at reduced engine speed. momentarily. 2 Turn key switch to the “RUN” position. 2 Once underway. oil pressure should be within range listed in the engine specifications chart. Resume normal starting procedure. quick motion forward to shift to FORWARD gear. Stop the engine if oil pressure is not within this range. or backward to shift to REVERSE. After shifting drive unit. CE33 SHIFTING ! CAUTION Never attempt to shift unit unless engine is at idle RPM. 2 After the engine has reached operating temperature. Locate and correct the problem. check to ensure all instrumentation is functioning properly. CB13 IMPORTANT: Starting procedure if engine is shut-off or stops with drive unit in gear. 35 . 1 To shift unit. 3 Turn key switch to the “START” position and release when engine fires. Oil pressure should be within the range listed in the engine specifications chart. Or.

stop engine. to release clutch from gear. Flush seawater cooling circuit. Release key when engine starts. momentarily. WHILE UNDERWAY Frequently observe all gauges and indicator lights to monitor engine condition.fuel. Pull/push remote control handle to neutral-lock position (it will be necessary to exert force to move handle).CE35 OPERATION CHART STARTING PROCEDURE Open engine hatch. for five minutes. Check for leaks . Turn key switch to START. Warm-up engine at idle RPM for several minutes. Turn on and run engine compartment bilge blower. Resume normal starting procedure. and exhaust leaks. 3. if so equipped. water. Turn key to start position. if so equipped. if so equipped. oil. If not normal. Check shift and throttle control operation. 1. IMPORTANT: Starting procedure if engine is shut-off or stops with drive unit in gear. Open fuel shutoff valve. Close seacock. 36 . if so equipped. Check that charge indicator and oil pressure indicator lamps go out AFTER engine starts. Air out bilge completely. if so equipped. AFTER STARTING Observe all gauges and warning lights to check condition of engine. 2. Open seacock. Run engine at idle speed several minutes to allow it to cool down. if so equipped. Check for fuel. if so equipped. Prime fuel injection system. Turn key switch to “RUN” and check that lights and indicator lamps come on. Turn key switch to OFF position. fluid. etc. CB13 Turn battery switch OFF. Check steering operation. Close fuel shutoff valve. fluid. oil. Turn battery switch ON. water. if operating in saltwater area. STOPPING & SHUT DOWN Shift remote control lever to neutral position. AFTER preheater indicator lamp has gone out. etc. if necessary.

CD10 Maintenance CD25 Power Package Views FRONT w x a b c v u t s r f q p o n g m h l a b c d e f g h i j k l mn o p q r s t u v wx Heat Exchanger/Coolant Tank Cap k Engine Water Circulating Pump and Pulley Sacrificial Anode (On Heat Exchanger) Heat Exchanger/Coolant Tank Alternator Port Exhaust Manifold Seawater Pump and Pulley Engine Water Circulating Pump Belt Crankshaft Pulley Oil Pan Oil Pan Drain Plug Vacuum Pump/Seawater Pump Belt Starter Starboard Front Engine Mount Vacuum Pump Fuel Delivery Pump Water Separating Fuel Filter Power Steering Pump and Pulley Fuel Distribution Block and Hand Pump/Primer (Starboard Side) Engine Oil Dipstick Heat Exchanger Seawater Cooling (Raw Water) Drain Plug Heat Exchanger Closed Cooling (Fresh Water) Drain Plug Engine Oil Cooler Sacrificial Anode (On Engine Oil Cooler) d e i J 71929 37 .

CD27 PORT (LEFT) SIDE u t s r q v w x a b p c o n m l 71930 d k J a b c d e f g h i j k l mn o p q r s t u v wx Steering System Transom Assembly Stern Drive Unit Antiventilation Plate Power Trim Cylinder Speedometer Pitot Tube MerCathode Electrode Rear Engine Mount Exhaust Manifold Oil Pan Oil Pan Drain Plug Front Engine Mount Seawater Pump and Pulley Crankshaft Pulley Alternator Sacrificial Anode (On Heat Exchanger) Heat Exchanger/Coolant Tank Heat Exchanger/Coolant Tank Cap Engine Oil Filter Aftercooler Engine Oil Fill Cap (Port) Air Filter Turbocharger Exhaust Elbow i h g f e 71930 38 .

9 Crankcase Oil . 3 Exposed Portion of Steering Cable and Propeller Shaft .CD28 2 10 1 2 3 4 6 7 8 7 9 5 71930 CE39 General Maintenance Information ! WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system. and Quicksilver Corrosion Guard. or SAE 10W-30 motor oil.Quicksilver U-Joint and Gimbal Bearing Grease.Quicksilver Hi-Performance Gear Lube. while others should be performed by an Authorized MerCruiser Dealer. IMPORTANT: Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed. 6 Engine Coupler and Universal Joint Shaft Splines . This eliminates the engine wiring as a potential source of ignition. it is recommended that a MerCruiser Service Manual(s) be purchased and read thoroughly.Quicksilver Power Trim and Steering Fluid. CD267 Maintenance Aids 1 Power Steering System . (Refer to “Specifications” for list of approved oils. 2 All pivot points . 5 Universal Joints . or Dexron III automatic transmission fluid (ATF).API rating of CD required.Quicksilver Engine Coupler Spline Grease (92-816391A4) 7 All Exterior Surfaces .) 10 Closed Cooling System Coolant . ! WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire. Some listings can be done by owner/operator. Before attempting maintenance or repair procedures not covered in this manual.SAE 30W motor oil. 8 Power Trim System . as needed. 39 .Quicksilver Power Trim and Steering Fluid.Quicksilver Special Lubricant 101.use ONLY Quicksilver Premixed Marine Engine Coolant. 4 Stern Drive Unit .Quicksilver Primer and Spray Paint.

Check closed coolant level.Inspect for erosion TIME Before Use Before Use/Clean As Required Weekly or As Required (Replace when over 50% eroded) Cooling System .replace.clean. Power Trim Pump Oil .spray with Quicksilver Corrosion Guard.change. Sacrificial Anode (in heat exchanger) check (replace when over 50% eroded).check for marine growth or debris. Check battery fluid level.inspect condition and check tensions. Freshwater use: Every 100 hours of operation or 120 days. Sacrificial Anode (in engine oil cooler) .clean and paint. Power Package Exterior Surfaces . Check/clean seawater strainer.lubricate Fuel Filter . SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER/OPERATOR REQUIRED SERVICE Check engine oil level. Drive Belts .check (replace when over 50% eroded).Whichever Occurs First Every 200 Hours of Use. Power Package Exterior Surfaces . Whichever Occurs First. As Necessary Refer to Battery Manufacturer Specifications 40 . Air Filter . Propeller Shaft . Every 100 Hours of Use or 120 Days . Drain fuel filter. Drive Unit Alloy Anodes . Whichever Occurs First.check level Check power steering fluid Saltwater Use: After Each Use Every 50 Hours of Use Every 50 Hours of Use.CD31 Maintenance Schedules ! WARNING Always disconnect battery cables from battery BEFORE working around electrical system components to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted.flush seawater section. Check drive unit gear lube monitor. Water Pickups . or as conditions require Every 50 Hours of Use or 60 Days Whichever Occurs First Saltwater use: Every 50 hours of operation or 60 days. or Yearly Whichever Occurs First Once a Year Air Filter .

CD191

SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER REQUIRED SERVICE 20-Hour Checkup (See NOTE.) TIME After first 20 Hours, But not later than 50 hours of operation After 20-Hour Break-In Period, Then, for Pleasurecraft Use: Every 100 Hours of Use or 120 Days Whichever Occurs First; and for Light Duty Use: Every 50 Hours of Use or 60 Days - Whichever Occurs First Every 50 hours of operation or 60 days, Whichever Occurs First. Every 100 hours of operation Once a year Every 100 hours of operation or 120 days whichever occurs first

Change engine oil and filter.

Lubricate Engine Coupling, Universal Joint Shaft Splines. Check engine alignment and mounting hardware. Check and adjust idle RPM. Change Stern Drive Unit Oil including gear lube monitor oil. Retorque Gimbal Ring Clamping U-Bolt to 50-55 lb. ft. (67-74 N·m). Rear Engine Mounts - Check torque to 35 - 40 lb.ft. (47-54 N⋅m) Clean, inspect and test closed cooling system pressure cap. Replace coolant (using only Quicksilver Premixed Marine Engine Coolant). Clean heat exchangers. Lubricate Universal Joint Cross Bearings. Clean intercooler core. Replace drive belts. Inspect cooling system hoses and clamps. Externally inspect exhaust system and clamps. Inspect shift/throttle cables and linkage and lubricate. Check electrical system for loose or damaged wiring. Lubricate Transom Gimbal Bearing. Lubricate and inspect Steering System for loose, damaged or missing parts. Ground Wire Circuit continuity - check components for loose connections, broken or frayed wires. Disassemble and inspect Seawater Pump. Clean fuel tank.

Every 100 hours of operation or once a year, whichever occurs first

Every 200 hours of operation or once a year, whichever occurs first

Every 500 hours of operation

Saltwater use: Every 50 hours of operation or 60 days, Whichever Occurs First. Freshwater use: Every 100 hours of operation or 120 days, Whichever Occurs First.

At least once yearly. Every 1000 hours of operation

NOTE : For a list of 20-Hour Checkup maintenance items to be performed, see “IMPORTANT INFORMATION” section of this manual.

41

CD33

b d

c a

3

71380

1,2

71771

4

71868

e

5
71930

70550

k

f i

l

J

71672

g
70979

h

6,7,8
42

70979

9 , 10

72187

CE44

Checking Fluids Levels
CRANKCASE OIL 1 Check engine oil daily before first start-up.

NOTE: If it becomes necessary to check oil level during operation, stop engine and allow 5 minutes for oil to drain into pan. 2 Remove dipstick a . Wipe clean and reinstall into dipstick tube.

3 Remove dipstick and observe oil level. Oil must be between marks b and c on dipstick.
b - MAXIMUM Oil Level - top line. Fill to this level; do not overfill. c - MINIMUM Oil Level - Do not allow oil level to drop below this line.

4 If necessary, add oil as follows: Remove oil filler cap d (starboard oil filler cap is shown on opposite page port similar). Add specified oil to bring level up to, but not over, “MAXIMUM” mark on dipstick. Reinstall oil filler cap.
CD34

DRIVE UNIT OIL 5 Check gear lube monitor oil level; keep oil level at or near “Fill” line e . Check for water at bottom of monitor, and/or if oil appears a milky-tan, contact your Authorized MerCruiser Dealer immediately; both conditions indicate a water leak somewhere in the drive unit. IMPORTANT: If more than 2 fl. oz.. (59 ml) of Quicksilver High Performance Gear Lube are required to fill gear lube monitor, a seal may be leaking. Contact your Authorized MerCruiser Dealer for service. Damage to drive unit may occur due to lack of lubrication.
CD35

POWER TRIM PUMP FLUID Power trim pump fluid level must be checked with the drive unit in the full “Down/In” position.

6 New trim pumps have a shipping “cap plug” f in the reservoir fill neck g . Remove fill cap h from reservoir
and check to ensure that this “cap plug” is NOT present in filler neck. Remove and discard “cap plug” if present. 7 Remove fill cap and observe oil level. Level must be up to, but not over, the bottom edge of fill neck. IMPORTANT: Fill cap has a small hole i in it which acts as a vent. Frequently check that vent is open and unrestricted. 8 Add Quicksilver Power Trim and Steering Fluid if available, as necessary, to bring oil to proper level or use SAE 10W-30 or 10W-40 motor oil. Install fill cap.
CD270

POWER STEERING PUMP FLUID IMPORTANT: If fluid is not visible in reservoir, contact your Authorized MerCruiser Dealer. Power steering fluid must be checked with engine off and drive unit pointed straight back. Check with engine warm.

9 Remove fill cap/dipstick J from reservoir. Wipe clean and reinstall into reservoir.. 10 Remove fill cap/dipstick and observe fluid level. Fluid must be between marks k and l on fill cap/dipstick.
k - MAXIMUM – “FULL HOT” Fluid Level - top line. Fill to this level when fluid is hot; do not overfill. - MINIMUM – “FULL COLD” Fluid Level - Fill to this level when fluid is cold. Do not allow fluid to drop below this level. 11 If necessary, add Quicksilver Power Trim and Steering Fluid or, if Quicksilver Power Trim and Steering Fluid is not available, use Dexron III, to bring fluid to proper level. Replace fill cap/dipstick. l

43

CD37 1 71381 71929 c a b 2 44 73254 3 72714 .

45 .CE45 ENGINE COOLANT 1 Check coolant level in coolant recovery bottle. add coolant slowly. the tank cap maintains pressure on the coolant tank. To have cap tested. • Also. If coolant is low. add coolant as necessary to bring up to proper level. • Inspect coolant tank cap gaskets c for damage and replace if necessary. let the engine cool for approximately 15 minutes before adding coolant. Refer to “Specifications” for proper coolant. you should allow engine to cool and then slowly and carefully remove coolant tank cap a . 3 If coolant level was low: • Inspect coolant recovery system for leaks. It may not be holding pressure properly. Adding cold coolant to a hot engine may crack the cylinder head or crankcase. causing severe burns. ! CAUTION If the coolant should get extremely low and the engine very hot. contact your Authorized MerCruiser Dealer. Coolant level must be to the bottom edge of the tank filler neck b . ! WARNING Do not remove coolant tank cap when engine is hot. with the engine running. Add specified coolant as required. then. Never use water alone. NOTE: Coolant recovery system is considered to be functioning properly when coolant level in heat exchanger/ coolant tank remains at bottom edge of its filler neck. to ensure that coolant recovery system is functioning properly. 2 Periodically. Coolant may discharge violently.

8 72522 9 . 4.CD218 f a c b c 3.9 d e 70121 5 71930 71930 g 6 46 71930 7. 6 70571 71377 8. 10 70550 .

7 Place drive unit in full trim limit (out) position. Quickly install sealing washer and OIL FILL/DRAIN screw. IMPORTANT: Keep oil level as near the high level mark as possible. Lubricate O-ring on monitor neck with stern drive oil. DO NOT OVERFILL! CB49 DRIVE UNIT OIL IMPORTANT: Use only Quicksilver High Performance Gear Lube in drive unit. 8 Remove OIL VENT screw and sealing washer. Install oil dipstick. Coat sealing ring on new filter with oil and install filter. Never operate an engine with oil level below low level mark. Coolant in closed cooling system should be changed at specified intervals by your Authorized MerCruiser Dealer. Fill drive unit. Hand tighten only. 11 Recheck oil level after first use. IMPORTANT: Oil level in monitor will rise and fall during drive operation. Inspect cap seal – check for leaks. Lubricate O-ring seal after every cap removal using drive oil. Use dipstick to determine exactly how much oil is required. Warm oil flows more freely. NOTE: Oil dipstick may be located on either port or starboard side of engine depending on type of installation. do not over tighten. and tighten securely. 2 Stop engine and allow some time for oil to drain into oil pan (approximately 5 minutes). 47 . Use only recommended motor oil (see SPECIFICATIONS). or if oil appears milky tan. 5 Remove and discard oil filter d and sealing ring e (not visible in picture). remove OIL FILL/DRAIN SCREW and sealing washer. with Specified Gear Lube until an air-free stream of lubricant flows from OIL VENT hole. install cap. Clean monitor thoroughly. When crankcase is empty. Lower drive unit so anti-ventilation plate is level. Replace O-ring seal when necessary. IMPORTANT: When refilling engine with oil always use dipstick to determine how much oil is required. Power Trim or Power Steering fluids do not require changing. Allow oil to drain completely. 6 Remove oil fill cap (port oil filler cap g is shown on opposite page . to ensure ease of installation and removal of cap. Remove tube from OIL FILL/DRAIN hole. do not use a filter wrench. CRANKCASE OIL AND FILTER IMPORTANT: Change oil when engine is warm from operation. IMPORTANT: If any water drained from OIL FILL/DRAIN hole. 10 Fill monitor to “FILL” mark. 3 Remove oil dipstick a and install crankcase oil pump b (Quicksilver Part Number 90265A2) onto threaded fitting c of oil dipstick tube. 4 Pump oil out of crankcase into drain pan. drive unit is leaking and should be checked immediately by your Authorized MerCruiser Dealer.CD67 Changing Fluids See MAINTENANCE CHART for lubricant change interval. CD73 DRIVE UNIT GEAR LUBE MONITOR Change oil in gear lube monitor when changing drive unit oil. always check oil level when drive is cool and engine is shut down. Lubricant should be changed before placing boat in storage. When oil starts to run out the vent hole (Monitor circuit completely filled). Tighten securely.starboard cap is f in upper drawing) and refill engine to proper level with new oil (refer to “Specifications” for quantity and grade of oil). carrying away more impurities. remove pump. reinstall OIL VENT screw and sealing washer. Location is similar in any case. 1 Start engine and allow it to warm up to normal operating temperature. through OIL FILL/DRAIN hole. 9 Fill gear lube monitor with Specified Gear Lube.

CD39 c 1 2 73190 b d 4 71976 3 a 73257 e g f h 6 71967 5 71975 48 .

INSPECTION ! WARNING Make sure engine is shut off and ignition key is removed before inspecting belts or pulleys. the pulley alignment must be checked under tensioned condition (brackets securely clamped). Engine Water Circulating Pump Belt(s) Refer to alternator and seawater pump drive belt instructions. When tension is correct. retighten all fasteners securely. Remove old belt and install new belt. see your Authorized MerCruiser Dealer. do not force belt(s) into pulley grooves by prying with a screwdriver. Move power steering pump. Adjust belt tension. This will damage belt side cords which will cause belt(s) to turn over in pulley grooves and result in complete destruction of belt(s). Adjust belt tension. NOTE: Refer to “Drive Belts . Remove old belt and install new belt. CD40 Power Steering Pump Belt 5 Loosen mounting bolt e and tensioning bolt f . Move vacuum pump. Perform an inspection of the following belts: • Alternator Belt • Power Steering Pump Belt • Vacuum Pump Belt (If So Equipped) • Seawater Pump Belt 2 Check belt tension by depressing upper strand of belt(s) at point shown. retighten all fasteners securely. CE51 TENSION 1 All drive belts must be periodically inspected for tension and condition. for information on belt tensioning.CE50 Drive Belts If any drive belts or pulleys need replacement or drive belt tension needs adjustment. cracked. etc. CE52 REPLACEMENT NOTE: During belt replacement. • Replace pulleys if worn. Vacuum Pump Belt (If So Equipped) 6 Loosen mounting bolt g and tensioning bolt h . Alternator Belt 3 Loosen mounting bolt a and tensioning bolt b . IMPORTANT: Observe the following drive belt and pulley guidelines: • Do not use belt dressing. grease or oil soaked. Adjust belt tension. 49 .Replacement” as follows. pry bar. Always check condition of remaining belts. When tension is correct. Adjust belt tension. it must be correctly tensioned prior to operation. When tension is correct. Remove old belt and install new belt. Seawater Pump Belt 4 Loosen mounting bolt c and tensioning bolt d . Approximately 1/2 inch (13 mm) deflection should be measured at midpoint between the pulleys on the longest span. or clean if still suitable for service. Remove old belt and install new belt. Move alternator. • When replacing a belt. Move seawater pump. • Replace a belt if worn. retighten all fasteners securely. • If a belt is disturbed for any reason. A misalignment that can be detected by visual inspection is detrimental to the belt performance. retighten all fasteners securely. When tension is correct.

CD271 d a b 2 71903 c 73189 1 3 74044 71901 4 71904 5 70556 5 71955 50 .

or damage to polyester foam element. with SAE 30W motor oil. Align breather tube hole opening in element and air intake screen.CD66 Air Filter . Allow element to completely dry before use. ! CAUTION Avoid potential fire hazards and personal injury. including tie bar pivot points. Wash foam element in warm water and detergent until clean. CA286 Lubrication STEERING SYSTEM 2 If Steering Cable Has Grease Fittings: With cable fully retracted into cable housing. Use element clean and dry for proper filtration. Insert metal crankcase breather tube into opening.“Maintenance Chart” for replacement interval under normal conditions. Hydraulic lock could occur and cause loss of steering control. 4 Lubricate steering system pivot points with SAE 30W motor oil. Carefully remove air cleaner foam element c from around air intake screen housing d mounted on turbocharger inlet. Do not clean foam element in petroleum based solvents or cleaners. inner wire of cable cannot be greased. CE135 SHIFT CABLE AND THROTTLE CABLE 5 Lubricate pivot points with SAE 30W motor oil.) IMPORTANT: To prevent unfiltered air from entering the engine be certain that all of the air intake screen is covered by the foam element when installed. lubricate fitting with 2-4-C Marine Lubricant with Teflon. IMPORTANT: No treatment (such as partial oil saturation) is required or recommended on air cleaner foam element prior to use. lubricate all pivot points. Replace the foam element if it is deteriorated or torn. NOTE: If steering cable does not have grease fitting. 3 With steering cable fully extended lubricate exposed part of cable with Special Lubricant 101. Install around air intake screen. 51 .Cleaning/Replacement 1 Withdraw metal crankcase breather tube a inserted through foam and air intake screen of air cleaner (Note: It may be necessary to flex the rubber hose b sufficiently to allow pulling the tube from air filter. (Refer to MAINTENANCE . ! WARNING Do not grease steering cable while extended.). On dual engine boats.

CD272 3 1 70558 73346 4 5 71346 71347 52 .

IMPORTANT: Stern drive must be removed to lubricate U-joints. see PROPELLER. P/N 92-816391A4. at transom end. at engine end. 53 . Contact your Authorized MerCruiser Dealer for this service. 2 For propeller shaft lubrication. Contact your authorized MerCruiser dealer for this service. CB56 ENGINE COUPLER 3 Lubricate engine coupler splines with Quicksilver Engine Coupler Spline Grease 92-816391A4. Failure to do this will result in a broken fitting if drive unit is removed. CB330 DRIVE SHAFT EXTENSION MODELS 4 Lubricate drive shaft grease fittings. ! CAUTION Speedometer water hose must be disconnected from drive unit BEFORE removing drive unit.CB355 DRIVE UNIT AND TRANSOM ASSEMBLY 1 Lubricate gimbal bearing with Quicksilver U-joint and Gimbal Bearing Grease. 5 Lubricate drive shaft grease fittings. universal joints are greased with Quicksilver U-joint and Gimbal Bearing Grease. with U-Joint and Gimbal Bearing Grease. NOTE: Engine coupling and shaft splines are greased with Quicksilver Engine Coupler Spline Grease. with U-Joint and Gimbal Bearing Grease.

4 72055 54 .CD175 a b c f 1 e 70355 1 70062 1 d 71362 5 h 73254 3 71930 70565 4 71353 6 71871 g h 7 71444 2.

be certain the area around propeller is clear. Place remote control in NEUTRAL. Stop engine. raise drive unit to TRAILER position. flush both strainer and housing e with clean water. and clean any debris from strainer housing. Prior to starting engine. for about 10 minutes. CE56 Flushing Fuel Tank 7 Flush and clean diesel fuel tank (every 1000 hours. ! CAUTION Watch temperature gauge on dash to ensure that engine does not overheat. install flushing attachment and lower drive unit to full down/in position. partially open water tap (about 1/2 maximum). NOTE: If flushing cooling system with boat in water. and/or air in system (which would indicate an external leak). 3 Connect hose h between flushing attachment and water tap. Tighten hose clamps securely. 1 With engine off. shut off water and remove flushing attachment. remove and plug seawater inlet hose to prevent a siphoning action that may occur. Reattach cover with screws and washers. After starting engine. if so equipped. Refer to “Maintenance Chart. flush with tap water at specified Intervals. Remove 2 screws and washers a . in NEUTRAL. Check gasket f . allowing seawater to flow from the drain holes or removed hoses. Coolant is changed at specified intervals. Reinstall drain plug and washer. CD172 Flushing Seawater Cooling System To prevent silt and/or salt buildup in the seawater circuit of cooling system. 4 With drive unit in normal operating position. or remove plug from seawater inlet hose and reconnect. Remove strainer c . close seacock. 5 The closed section of cooling system that contains coolant does not need to be flushed. causing engine to overheat. remove propeller. ! CAUTION Do not run engine above 1500 RPM when flushing.replace when necessary (if it leaks). 2 Install Quicksilver flushing attachment g (or equivalent) over water intake openings in gear housing. check for leaks. and cover b . idle speed positron and start engine. To avoid possible injury. open seacock if so equipped. Suction created by seawater pickup pump may collapse flushing hose. close seacock if so equipped. and drain plug and washer d . ! WARNING When flushing. or until discharge water is clear. If boat is not equipped with a seacock. Operate engine at idle speed. 55 .” CB66 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer. 6 Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected (if operating temperature exceeds normal range). maximum) following boat manufacturer’s instructions. and no one is standing nearby. ! CAUTION When cleaning seawater strainer.CE58 Cleaning Quicksilver Seawater Strainer NOTE: Refer to manufacturers instructions if equipped with other than a Quicksilver seawater strainer. or remove and plug seawater inlet hose.

CD43 a 1 71444 2 b 71868 71967 71974 d c f e 3 56 71967 4 71967 .

move plunger on hand pump/primer up and down repeatedly. CE63 PRIMING FUEL SYSTEM Prime engine if it has not been run for a while or if engine will not start. etc. 3 Remove protective cap c from bleeder valve d on fuel filter header flange. 1 Fuel tank should be cleaned at specified intervals. Diesel fuel is flammable. CE64 FILLING FUEL FILTER / BLEEDING FUEL SYSTEM NOTE: Follow this procedure after installing new filter or if fuel has been drained from filter while checking for water. Drain until fuel is clear in appearance. Move the hand pump/primer plunger up and down several times as previously outlined. NOTE: To ensure complete draining. Dispose of fuel soaked rags. Do not allow sources of open flame in the area. Filter is full when this occurs.CE61 Fuel System ! CAUTION Absolute cleanliness is required for work on the fuel system. knurled portion) up and down as needed. Wipe up any spilled fuel immediately. Do not allow fuel to contact any hot surfaces which may cause it to ignite. Be sure ignition key is OFF. Release bleeder valve and install protective cap. In cold weather. As previously outlined. Also. To operate the hand pump/primer. FUEL TANK IMPORTANT: Diesel fuel should not be left in tank during winter storage. as an accumulation of rust. in an appropriate air tight. since the injection pump and fuel injectors have very close tolerances. Close drain cock by turning counterclockwise (as viewed from the bottom of the filter). Open the drain cock by turning the drain clockwise (as viewed from the bottom of the filter). Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death. 57 . Refer to boat manufacturer’s instructions. 4 The filter e can be drained of water and small dirt particles by opening the drain cock f at bottom of filter. Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system. or (3) to prime the fuel system if engine has not been run for a while. Push in on bleeder valve core and hold open. Attempt to start engine. Tighten securely. move the plunger (upper. until an air-free stream of fuel flows from bleeder valve. drain the filter shortly after the end of daily operations. Fill fuel filter as previously outlined. CE65 DRAINING WATER SEPARATING FUEL FILTER ! WARNING Be careful when draining water separating fuel filter. sludge and wax residue will form. CE62 HAND PUMP/PRIMER 2 A plunger-type of hand pump/primer a is located on the fuel distribution block b (on starboard exhaust manifold forward end) and is used to: (1) refill fuel system if system was run dry. in warm weather open the drain cock before starting daily operations. where there is a possibility that the condensed water will freeze. fire retardant container. paper. (2) refill fuel filter when changing filter. follow this procedure if fuel system was run dry or if part of fuel system was drained for a service function.

CD17 f 2 d 71967 71870 c b 71929 1 a 73187 e h g i 2 58 2 73191 73192 .

Example of deteriorated anode needing replacement. If leaks exist. 59 . Check for water in water separating fuel filter before startup. Tighten securely. paper. daily. If leaks continue. Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death. recheck filter installation. Remove fuel filter c (with sealing ring) from mounting bracket and discard. take unit to an Authorized MerCruiser Dealer IMMEDIATELY. Thread filter onto bracket fitting and tighten securely by hand. in an appropriate air tight. check at least once yearly. Remove (unscrew) drain bowl assembly b (with sealing ring) from bottom of filter using a suitable tool. which serve as sacrificial anodes.2 in. Fill and bleed fuel filter as explained previously.CE67 REPLACING WATER SEPARATING FUEL FILTER ! WARNING Be careful when changing water separating fuel filter. Do not allow fuel to contact any hot surfaces which may cause it to ignite. CE68 Corrosion And Corrosion Protection INTERNAL COMPONENTS 2 There is an anode installed in the top-port (left) side of the heat exchanger e and in the top-starboard (right) end of the engine oil cooler f . stop engine immediately and contact your Authorized MerCruiser Dealer.Length When New . (51 mm) h . ! WARNING Make sure no leaks exist before closing engine hatch. ! CAUTION Any water entering the fuel injection system will disable the system. Wipe up any spilled fuel immediately. Start and run engine. Check that bottom drain cock is securely tightened. 1 Remove and replace water separating fuel filter as follows: Disconnect electrical connector from water sensor a located on bottom of filter. Install drain bowl assembly b to bottom of filter.1/2 in. g . etc. (13 mm) i .Diameter When New . so that corrosion and rusting of the injectors and other components can be avoided. Be sure ignition key is OFF. Check filter connection for fuel leaks. Replace when eroded more than 50% . Do not use a filter wrench. Connect electrical connector to water sensor a located on bottom of filter. Coat sealing ring d on new filter with clean motor oil. Dispose of fuel soaked rags. Diesel fuel is flammable. Do no tallow sources of open flame in the area. ! CAUTION If water should enter the fuel injection system. fire retardant container.

CD206 a c c d b 6 72029 71804 5 71966 2 70055 71176 1 3 4 73919 70578 70577 60 .

61 .are mounted on each trim cylinder.are located in the splash plate. b . Unthread attaching screw and remove universal anodic plate.Install new anodes and tighten securely. Remove plug from drive shaft housing to access attaching screw and insert 1/2 inch socket.serves as a sacrificial anode. Replace as required. To replace the trim cylinder anodes: a . Acts as a sacrificial anode. Unscrew both attaching screws and remove. IMPORTANT: Replace sacrificial anodes if eroded 50% or more. just above the propellers. to erode.CD205 EXTERNAL COMPONENTS Whenever two or more dissimilar metals (like those found on the stern drive) are submerged in a conductive solution. Test should be made where boat is moored. Install a new anodic plate and tighten securely. or water with a high mineral content. 3 MerCathode System . CB385 NOTE: Bravo Three models are equipped with one or two propeller anodes at location shown. or anodic. To replace the propeller anodes: c . This is known as galvanic corrosion and.should be tested to ensure adequate output. Do not remove screw. The electrical current flow causes the metal that is most chemically active.serves as a sacrificial anode. Install new anodic plate and tighten screw securely.Mounted to boat transom. 4 Anode Kit (if so equipped) . a chemical reaction takes place causing electrical current to flow between metals. Contact your Authorized MerCruiser Dealer to arrange for this test. CA163 5 Trim Cylinder Anodes .Install new anodes and tighten securely. 2 Anodic Plate . d .Remove the bolts that secure the anodes to the splash plate.Remove two screws from each anode. 1 Universal Anodic Plate . Install plug. polluted water. it will in time cause the need for replacement of power package components exposed to water. if not controlled. CB162 6 Propeller Anodes (Bravo Three Model) . using Quicksilver Reference Electrode and Test Meter. such as saltwater.

CD202 1 71176 3 2 62 .

or MerCathode System and the paint by allowing a minimum of 1-1/2 in. IMPORTANT: If anti-fouling protection is required for boat hull or boat transom. (40mm) UNPAINTED area on transom of the boat around these items. 4 Spray power package components on inside of boat every 2-3 weeks with Quicksilver Corrosion Guard to protect finish from dulling and corrosion. should be kept well lubricated. observe the following: 2 Avoid any electrical interconnection between the MerCruiser Product. can be used. Anodic Blocks. Do not paint drain holes. and items specified by boat manufacturer. 5 All lubrication points. MerCathode system. preferably after each use. 6 Flush cooling system periodically. If using copper or tin based anti-fouling paints. shift and throttle linkages. copper or tin base paints. especially steering system. as this will render them ineffective as galvanic corrosion inhibitors. or any other material that could conduct electrical current. 3 Painting Drive Unit or Transom Assembly: Drive unit and transom assembly should be painted with a good quality marine paint or an anti-fouling paint that DOES NOT contain copper. tin. 1 Painting Boat Hull or Boat Transom: Antifouling paint may be applied to boat hull and boat transom but you must observe the following precautions: IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and anode. 63 . if not prohibited by law. External power package components may also be sprayed. the following steps should be taken to inhibit corrosion: IMPORTANT: Corrosion damage that results from the improper application of anti-fouling paint will not be covered by the limited warranty.CA168 In addition to the corrosion protection devices. anodes.

CD207 2 70561 5 7 72239 64 .

A minimum of 55 lbs. 65 . (75 N·m) torque is required. propeller and thrust hub off propeller shaft. Slide propeller and thrust hub off propeller shaft. 3 Slide tab washer. continuity washer. splint washer. CB157 REMOVAL (BRAVO THREE) 4 Place wood block between propeller blades and anti-ventilation plate to prevent rotation. Slide propeller and thrust hub off propeller shaft. Turn front propeller shaft nut counterclockwise to remove nut. CD201 REMOVAL (BRAVO TWO) 1 Place wood block between propeller blade and anti-ventilation plate to prevent rotation.CA77 Propeller ! WARNING Remote Control must be in NEUTRAL and ignition key removed from switch before removing and/or installing propeller. ! WARNING Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut. ! CAUTION Periodically check propeller nut for tightness during boating season. Straighten bent tabs on tab washer. 5 6 7 8 Turn aft propeller shaft nut counterclockwise to remove nut. 2 Turn propeller shaft nut counterclockwise to remove nut. ft.

CD204 1 2 3 4 5 70561 6 7 8 9 10 11 12 72239 66 .

See your dealer. 9 Install propeller nut. Check propeller at least after 20 hours of operation. ft. splint washer and tab washer onto shaft. Do not operate with loose propeller. 2-4-C Marine Lubricant with Teflon. torque (75 N. 5 Install propeller nut. Tighten nut securely.m) torque is required. Check propeller at least after 20 hours of operation. 11 Align splines and place propeller on propeller shaft. Special Lubricant 101. ft. After first use. (136 N·m) torque is required. retighten propeller nut to minimum 55 lbs. CD273 INSTALLATION (BRAVO TWO) IMPORTANT: If reusing tab washer. bend the three tabs straight. 10 Slide aft thrust hub onto propeller shaft. CB345 INSTALLATION (BRAVO THREE) 6 Apply a liberal coat of one of the following Quicksilver lubricants to both propeller shafts: Special Lubricant 101. Tighten nut securely. 3 Align splines and place propeller and thrust hub on propeller shaft. A minimum of 100 lbs. Do not operate with loose propeller. (81 N·m) torque is required. 7 Slide forward thrust hub onto propeller shaft. with tappered side toward propeller hub (Toward end of shaft). 8 Align splines and place propeller on propeller shaft. Do not operate with loose propeller. Bend three tabs on tab washer down into grooves in splint washer. 67 .carefully inspect tabs for cracks or other damage. 2 Slide thrust hub into propeller hub. Tighten nut securely. Replace tab washer if condition is questionable. Bend tabs back down into splint washer Check propeller at least after 20 hours of operation. A minimum of 55 lbs. (75 N. A minimum of 60 lbs. or Anti-Corrosion Grease. ft. with stepped side toward propeller hub. with tappered side toward propeller hub (Toward end of shaft). ft.m). 1 Apply a liberal coat of one of the following Quicksilver lubricants to propeller shaft: Anti-Corrosion Grease.CA79 REPAIR Some damaged propellers can be repaired. or 2-4-C Marine Lubricant with Teflon. 12 Install propeller nut. 4 Place continuity washer.

3 71930 68 .CD15 Miscellaneous Maintenance CD30 1 71088 2.

free of barnacles and marine growth. Free of distortion. ! WARNING Batteries contain acid which can cause severe burns . be sure area where batteries are located. and correct potential problems before they occur. ! WARNING Do not use jumper cables and a booster battery to start engine. 69 . lf electrolyte is spilled or splashed on any part of the body. If badly nicked. sparks or flames can ignite the gas and cause an explosion which may shatter the battery and could cause blindness or other serious injury. • Remove and inspect propeller. Hydrogen gases that escape from the battery during charging are explosive. Refer to CORROSION AND CORROSION PROTECTION for additional information. tighten or replace as required. • Flush seawater cooling circuit periodically (preferably after each use). see your dealer.CA103 Battery 1 All lead acid batteries discharge when not in use. External power package components may also be sprayed. • Check for loose. Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte. • All lubrication points (especially steering system. When charging batteries. sparks or flames. CA104 Bottom Of Boat 2 • • • To maintain maximum speed. Recharge every 30 to 45 days. CE70 Inspection And Maintenance 3 Inspect and/or maintain the following: • Inspect power package often. immediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible. eyes and clothing Batteries also produce hydrogen and oxygen gasses when being charged. If this information is not available. Use Quicksilver spray paints . or when specific gravity drops below battery manufacturer’s specifications. damaged or missing parts. hoses and clamps. Straight and smooth fore and aft. and may form an explosive atmosphere around the battery for several hours after it has been charged. Antifouling Paints Refer to Antifouling Paint recommendations and related information on previous pages. Battery electrolyte is a corrosive acid and should be handled with care. Refer to specific instructions and warnings accompanying your battery. The entire power package should be checked carefully including all accessible engine parts.Avoid contact with skin. • Repair nicks and corrosion damage on power package exterior finish. to help maintain its top operating performance. bent or cracked. • Spray power package components on inside of boat every 2-3 weeks with Quicksilver Corrosion Guard to protect finish from dulling and corrosion. Do not recharge a weak battery in the boat. and at regular intervals. the following conditions the boat bottom should be observed: Clean. Remove battery and recharge in a ventilated area away from fuel vapors.see your Authorized MerCruiser Dealer. shift and throttle linkages) should be kept well lubricated. is well-vented. nearly flat where it contacts water. This explosive gas escapes fill/vent cell caps. observe the following precautions when handling a battery.

CD44 Cold Weather Or Extended Storage CD45 1 71962 71930 2 70 73254 2 71864 .

NOTE: Refer to the following pages for continuation of specific draining instructions. 71 . 1 Start engine and run until it reaches normal operating temperature. ! WARNING Do not remove coolant cap when engine is hot .coolant may discharge violently. They are in the closed cooling section. Start engine and run for about 15 minutes.CE72 Power Package Layup IMPORTANT: This service should be performed by an Authorized MerCruiser Dealer. before starting engine a source of water must be supplied to water intake (inlet) openings. IMPORTANT: If boat has already been removed from water. IMPORTANT: Drain seawater section of closed cooling system only. Check for oil leaks. IMPORTANT: Closed cooling section must be kept filled year-round with the specified coolant. ! CAUTION The engine must be prepared for long storage periods to prevent internal corrosion and severe damage. 2 Do not remove or drain the inside plug on bottom of the heat exchanger or either of the two drain plugs on the cylinder block [one port and one starboard]. as pump impeller may be damaged and subsequent overheating damage to engine or transmission may result. Change oil and filter. IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine. ! CAUTION DO NOT operate engine without water flowing thru seawater pickup pump. Stop engine. Follow all warnings and flushing attachment procedures stated in “FLUSHING COOLING SYSTEM”.

8 71962 71930 7 71930 d e f 72186 4.8 6 g 71362 72 .8 c 2.CD66 b a 2.3.8 73254 71870 2.3.8 71865 5.3.

Do this until entire system is drained. water inlet hose must be disconnected and plugged to prevent water from flowing into cooling system and/or boat. if so equipped. c . NOTE: Only the port aftercooler side cover is shown. If boat is not fitted with a seacock. Remove drain plug g and empty seawater strainer. attach a tag to the ignition switch or steering wheel with the warning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine. Do not unplug seawater inlet hose unless a seacock is present and it is closed. Tighten clamps securely. 5 Disconnect seawater outlet hose e at aft end of power steering cooler. if boat is to remain in the water. 8 After seawater section of cooling system has been drained completely. 1 Close seacock. propeller plate cavity vent hole and drain passages are unobstructed and open. if so equipped. IMPORTANT: Observe the following information to ensure complete draining of cooling system: • Engine must be as level as possible. 73 . Tighten securely. Lower hose and drain completely. 2 Remove the following drain plugs: a . seacock. must remain closed until engine is to be restarted to prevent water from flowing back into seawater cooling system.tighten hose clamps securely. or disconnect and plug seawater inlet hose.The drain plug on the lower side of the engine oil cooler. Install drain plug and tighten securely. 6 Remove hose(s) f at seawater strainer and drain hose(s) completely. 4 Remove seawater pump outlet hose d from top of seawater pump and drain. • A wire should be repeatedly inserted into all drain holes to ensure there are no obstructions in passages.CD46 Power Package Layup (Continued) Drain seawater section of cooling system and prepare for cold weather or extended storage following these procedures: DRAINING INSTRUCTIONS ! CAUTION If boat is to remain in the water.The aftercooler drain plugs located on the starboard and port aftercooler side covers. coat threads of drain plugs with Perfect Seal and reinstall. As a precautionary measure. 3 Repeatedly clean out drain holes using a stiff piece of wire. Connect hose to seawater pump outlet (top) and hose at exhaust elbow. Starboard is similar. Reconnect hoses . ! CAUTION Avoid water entering boat. 7 Make sure that the speedometer pitot tube.The outer-most drain plug located on the bottom of the heat exchanger b .

CD47 a 71929 b 10 f 71976 10 74 c d e g 71871 71872 .

Connect an appropriate length piece of hose to seawater pump and place the other end of the hose into container of coolant. 2 Clean seawater strainer (refer to MAINTENANCE SECTION).S. quarts (5-1/2L) of antifreeze and tap water mixed to manufacturer’s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage.” CD72 ! CAUTION Stern drive unit should be stored in full “down” position. perform all checks. dry place. Remove the three seawater pump cover mounting screws. 11 Place stern drive unit in the full “down” position. and location of O-ring in groove on housing. 6 Clean engine and coat with Quicksilver Corrosion Guard. 7 Lubricate all cables and linkages. 8 Remove and store battery in a cool. 10 Remove seawater pump and components as follows: • Remove seawater pump mounting bolt a and tensioning bolt b . for storage. then stop engine. IMPORTANT: Place a CAUTION TAG at instrument panel and in engine compartment stating that “Seawater Pump is Out .) 9 Disconnect water inlet adaptor and hose from seawater pump. check local laws about disposal of the antifreeze solution after use. which makes it friendly to lakes and rivers) be used in seawater section of the cooling system for cold weather or extended storage. 3 Fill a container with approximately 6 U. Be careful not to damage pump impeller. 75 . Also. Be certain to follow the propylene glycol manufacturer’s recommendations. Universal Joint bellows may develop a “set” if unit is stored in raised position and may fail when unit is returned to service. and plate e . • Take notice of O-ring f . • Make matching marks on pump cover and pump housing prior to disassembly (to aid in reassembly later). • Ease impeller g out of pump body with two screwdrivers. except for the impeller. or on the ground Place on a dry. IMPORTANT: MerCruiser recommends that propylene glycol antifreeze (nontoxic and biodegradable. • Reassemble the components. gasket d . Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Remove seawater pump. 5 Start engine and run at idle speed until coolant mixture has been pumped into engine seawater system. 4 Disconnect hose from seawater inlet side of seawater pump. wood board or a thick plastic base (Refer to battery manufacturer’s instructions.DO NOT Operate Engine.CE76 Power Package Layup (Continued) Dealer should perform these remaining tasks prior to layup: 1 After draining. Do not store on a concrete surface. inspections. lubrication and fluid changes outlined in MAINTENANCE CHART. Remove cover (with pulley and shaft) c .

CD48 b 71871 e 1 d a c 71871 f g 71929 1 76 71976 .

Tension drive belt. 5 Fill up with fresh diesel fuel. do not install battery until all maintenance has been performed on engine. Tighten securely. 9 Carefully inspect engine for fuel. fluid. 8 Start engine and closely observe instrumentation to make sure that all systems are functioning correctly. 4 Bleed fuel system (see “MAINTENANCE . • Place impeller a in pump housing. Align matching marks made prior to disassembly. 1 Reinstall seawater pump components and pump as follows: NOTE: Use new gasket and O-ring. Install in correct position. or connection order is reversed. 2 Check that all cooling system hoses are in good condition. connected properly. IMPORTANT: Avoid starter motor overheating. Secure each cable clamp when connecting. Coat terminals with a battery terminal anti-corrosion spray to help retard corrosion. Check fuel lines and connections for leaks and general condition. water and exhaust leaks.FUEL SYSTEM”). • Install pump plate c . Tighten fasteners securely. • Engage pump shaft key in impeller keyway and install seawater pump cover e . and hose clamps are tight.CE78 Power Package Recommissioning IMPORTANT: This service should be performed by an Authorized MerCruiser Dealer. ! CAUTION When installing battery. 6 Install fully-charged battery. allow at least one minute cool-down time before re-engaging starter for another 15 seconds. and NEGATIVE (–) battery cable to NEGATIVE (–) battery terminal LAST. shift and throttle control for proper operation. • Install new O-ring b in groove on housing. Clean battery cable clamps and terminals and reconnect cables (see CAUTION listed above). 3 Replace fuel filter. ! WARNING To prevent possible injury or damage to equipment. • Install the three seawater pump cover mounting screws. Old fuel should not be used. • Install pump on engine using mounting bolt f and tensioning bolt g with hardware. It battery cables are reversed. oil. 77 . 7 Perform all checks on OPERATION CHART in the STARTING PROCEDURE column. be sure to connect POSITIVE (+) battery cable to POSITIVE (+) battery terminal FIRST. electrical system damage will result. 10 Check steering system. DO NOT engage starter for more than 15 seconds. with new gasket d in position as shown.

• Replace kinked lines or blow out lines with compressed air to remove obstruction. if fuel is present. drain tank. Fill with fresh fuel. • Check throttle for freedom of movement. • Air in fuel injection system • Glow-plugs or glow-plug system inoperative • Purge fuel injection system. Or Cranks It Very Slowly Possible Cause Remedy • Battery switch turned off • Remote control not in neutral position • Open circuit breaker or blown fuse • Loose or dirty electrical connections or damaged wiring • Turn switch on. Engine Will Not Start. • If contaminated. Clean and tighten faulty connection. • Test. Or Is Hard To Start Possible Cause • Improper starting procedure Remedy • Read starting procedure. • Bad battery • Test and replace if bad. • Check and reset circuit breaker or replace fuse.CD49 Troubleshooting CD76 Starter Motor Will Not Crank Engine. • Have Authorized MerCruiser Dealer service electric stop-circuit. • Replace filters. • Check all electrical connections and wires (especially battery cables). • Position control lever in neutral. • Empty fuel tank or fuel shutoff valve closed • Faulty fuel pump • Throttle not operating properly • Faulty electrical stop-circuit • Clogged fuel filters • Stale or contaminated fuel • Fuel line or tank vent line kinked or clogged • Fill tank or open valve. and repair or replace components 78 . • Have pump replaced by an Authorized MerCruiser Dealer.

Misses And/Or Backfires Possible Cause • Throttle not operating properly Remedy • Check throttle linkages for binding or an obstruction. • If contaminated. • Idle speed too low • Clogged fuel or air filters • Stale or contaminated fuel • Kinked or clogged fuel line or fuel tank vent line • Check idle speed and adjust. drain tank. • Replace kinked line or blow out line with compressed air to remove obstruction. if necessary. • Damaged or improper propeller • Excessive bilge water • Boat overloaded or load improperly dis• Boat bottom fouled or damaged • Aneroid device improperly adjusted tributed • Replace. • Air in fuel injection system • Purge fuel injection system. • Drain and check for cause of entry. Poor Performance Possible Cause • Throttle not fully open Remedy • Inspect throttle cable and linkages for operation.Engine Runs Rough. Fill with fresh fuel. 79 . • Replace filters. • Reduce load or redistribute load more evenly. • Clean or repair as necessary. • Adjust aneroid device.

• Replace. • Remove obstruction. if so equipped Remedy • Open. Determine cause for dilution (excessive idling. • Clean exhaust elbow. faulty fuel pump.). • Check and remove required amount of oil. using correct grade and viscosity oil. • Position hose to prevent kinking (restriction). Insufficient Engine Temperature Possible Cause • Faulty thermostats Remedy • Replace. • Drive belt loose or in poor condition • Seawater pickups obstructed • Faulty thermostat • Coolant level low in closed cooling section • Heat exchanger cores plugged with foreign material • Clean seawater side of water/water heat exchanger. 80 . • Loss of pressure in closed cooling section • Check for leaks. Check for cause of excessive oil (improper filling. • Check for cause of low coolant level and repair. • Closed cooling section dirty • Faulty seawater pickup pump • Seawater discharge restricted or plugged • Seawater inlet hose kinked (restricted) • Use of improperly designed hose on inlet side of seawater pump allowing it to collapse • Clean and flush. • Replace and/or adjust belt.Excessive Engine Temperature Possible Cause • Seacock closed. • Excessive oil in crankcase (causing it to become aerated) • Diluted or improper viscosity oil • Change oil and oil filter. • Replace hose with wire reinforced design. and seawater strainer. • Repair. etc. Clean. etc. bad fuel pump. Low Engine Oil Pressure Possible Cause • Insufficient oil in crankcase Remedy • Check and add oil. Fill system with proper coolant solution.). inspect and test pressure cap.

• Loose or missing shift and throttle linkage fasteners • Obstruction in shift or throttle linkages • Shift or throttle cable kinked • Improper shift cable adjustment. • Replace and/or adjust. • Straighten cable. • Alternator drive belt loose or in poor condition • Unacceptable battery condition • Test battery. Binds. • Repair cut. Clean and tighten faulty connections. pinched. • Vacuum leak at shift cylinder. • Loose or dirty electrical connections or damaged wiring • Check all associated electrical connections and wires (especially battery cables). Remote Control Operates Hard. hose or fittings of Power Shift Assembly • Remove obstruction. 81 . • Check all linkages. or have dealer replace cable if damaged beyond repair. see Authorized MerCruiser Dealer immediately. Repair or replace damaged wiring. Has Excessive Free-play Or Makes Unusual Sounds Possible Cause • Insufficient lubrication on shift and throttle linkage fasteners Remedy • Lubricate. If any are loose or missing. or kinked hose or faulty shift cylinder.Battery Will Not Come Up On Charge Possible Cause • Excessive current draw from battery Remedy • Turn off non-essential accessories. • See Authorized MerCruiser Dealer immediately for shift cable adjustment .

see Authorized MerCruiser Dealer immediately. • Loose or missing steering fasteners or parts • Contaminated power steering fluid Power Trim Does Not Operate (Electric Motor Does Not Run) Possible Cause Remedy • Blown Fuse • Loose or dirty electrical connections or damaged wiring • Replace fuse. • Check for obstruction. • Lubricate. • Check all associated electrical connections and wires (especially battery cables). Repair or replace wiring. • Lubricate. • Replace and/or adjust. • Check all parts and fasteners. Drain and replace. If any are loose or • missing. Clean and tighten faulty connection.CD130 Steering Wheel Turns Hard Or Jerky Possible Cause Remedy • Low power steering pump fluid level • Drive belt loose or in poor condition • Insufficient lubrication on steering system • components Insufficient lubrication on transom gimbal housing assembly and swivel shaft • Refill system with fluid. Power Trim Does Not Operate (Electric Motor Runs But Drive Unit Does Not Move) Possible Cause Remedy • Pump oil level low • Drive unit binding in gimbal ring • Fill pump with oil. 82 .

Aftercooler 5 .Seawater Outlet (Thru-Gimbal Housing) ABCDEFGH- CLOSED COOLING CIRCUIT (COOLANT) Circulating Pump .Closed Coolant Exhaust Manifolds Engine Crankcase Cylinder Heads Turbocharger Thermostat Bypass Heat Exchanger (Closed Cooling Circuit) FLOW OF: a – Engine Air b – Engine Oil c – Power Steering Fluid 71875 83 .Seawater Pump 4 .Power Steering Fluid Cooler 8 .Seawater Strainer 3 .Heat Exchanger (Seawater Circuit) 7 .Exhaust Pipe Water Jacket 9 .Seawater Inlet 2 .Seawater Outlet (Exhaust) 10.CD50 Diagrams CD208 Water Flow Diagram a 3 2 4 6 H 8 7 5 c b 1 9 10 B D E C F G D B A SEAWATER COOLING CIRCUIT (RAW WATER) 1 .Engine Oil Cooler 6 .

Warm-Up Timing Advance Sender 17.Engine Coolant Temperature 15 Audio Warning Switch 18.Tachometer Magnetic Pickup 14 16.Injection Pump 3 .Starter Slave Solenoid 9 . 84 10 11 12 9 See NOTE.Starter 6 . Sender 2 .Harness Connectors 7 .Oil Pressure Sender 5 .Glow Plug Controller 10.150 Amp Circuit Breaker 11 .Engine Oil Pressure Audio 13 Warning Switch 20. 8 ELECTRICAL BOX 74188 .Glow Plug (8 Total) 4 .Battery NOTE: FOR CONNECTION ON MERCATHODE CONTROLLER.Drive Unit Oil Level 14.Wires Connected Together (Sealed and Protected) 13.CD274 Engine Wiring Diagram b 1 2 a BRN (4) TAN/BLK (3) BLU/BLK (2) GRN/WHT (1) NOT USED TAN/WHT (5) WHT/GRN (6) NOT USED BLK (1) LT BLU (8) GRY (2) NOT USED 19 3 TAN (3) BRN/WHT (10) RED/WHT (4) PPL (5) YEL/RED (7) RED/PPL (6) 2 3 1 8 7 6 4 5 10 4 3 4 5 6 2 1 5 a b 6 18 BLK BLU BRN GRY GRN ORN PNK PPL RED TAN WHT YEL LT DRK = = = = = = = = = = = = = = BLACK BLUE BROWN GRAY GREEN ORANGE PINK PURPLE RED TAN WHITE YELLOW LIGHT DARK 74159 17 16 7 20 1 .50 Amp Circuit Breaker 12.Coolant Temp.Alternator 19.Trim Sender 15.Water-In-Fuel Sensor 8 .

20-Amp Fuse and Holder 10. - 1 2 13 12 3 4 14 5 UP 6 a. Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection. b.-Alternator. and BLK.-Coolant Temperature.Light Switch and Audio Test 8 .) 14.CD209 Quicksilver Instrumentation Wiring Diagram 1 2 3 4 5 6 Voltmeter Tachometer Coolant Temperature Oil Pressure Trim Gauge Engine System Monitor. c. e. a. NOTE 2: Tape each wire separately with at least two layers of electrical tape.-Water In Fuel b.Audio Warning Buzzers 12.Keyswitch 9 . 11 a 8 7 6 10 5 1 2 3 4 1 2 7 See NOTE 3.Wires Not Used (See Note 2. 7 9 S B I b 6 8 5 4 3 8 a LT BLU (8) YEL/RED (7) BLK (1) GRY (2) BRN/WHT (10) TAN (3) RED/WHT (4) PPL (5) b WHT/GRN (6) BLK (7) TAN/WHT (5) BLK (8) BRN (4) BLK BLU BRN GRY GRN ORN PNK = = = = = = = BLACK BLUE BROWN GRAY GREEN ORANGE PINK PPL RED TAN WHT YEL LT DRK = = = = = = = PURPLE RED TAN WHITE YELLOW LIGHT DARK 73852 RED/PPL (6) GRN/WHT (1) TAN/BLK (3) BLU/BLK (2) 85 . NOTE 3: Connect Wires Together with Screw and Hew Nut.) NOTE 1: May be wired to any PPL (that is key switched).Cruise Log (Engine Hour Meter) (See Note 1.-Oil Pressure d. d.Wait-To-Start Relay 13. 10 e. c.-Preheat 7 .Water-In-Fuel Module 11.

Controller b .20 Amp Fuse c .Electrode BLK = BLU = BRN = GRY = GRN= ORN= PNK = PUR = RED = TAN = WHT= YEL = LIT = DRK = Black Blue Brown Gray Green Orange Pink Purple Red Tan White Yellow Light Dark 73596 86 .CD210 MerCathode System Diagram a b c a .

CD211 Power Trim System Diagram BLK = BLU = BRN = GRY = GRN= ORN= PNK = PUR = RED = TAN = WHT= YEL = LIT = DRK = BLACK BLUE BROWN GRAY GREEN ORANGE PINK PURPLE RED TAN WHITE YELLOW LIGHT DARK b a c d f e g h a b c d e f g h 20 Amp Fuse Ground Bolt (Floor Mount) “UP” Solenoid 110 Amp Fuse “DOWN” Solenoid To Trailer Switch Neutral Switch to Instrument Wiring Harness Trim Limit Switch 73962 87 .

Because of your selling dealer’s continuing personal interest in your satisfaction. type of use and selling dealer’s code. product model and serial number(s). should notification under the Federal Boat Safety Act be required.CD54 Warranty Information CD55 Owner Warranty Registration UNITED STATES AND CANADA ONLY • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the facto• • • ry immediately upon sale of the new product. If your plastic card is not received within 30 days from date of new product sale. The product warranty is not effective until the product is registered at the factory. Upon receipt of the Warranty Registration Card at the factory. It must be presented to the servicing dealer should warranty service be required. the product should be returned to him for warranty service. please contact your selling dealer. States. you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification. The dealer also certifies that you are the original purchaser and user of the product. • • • • NOTICE: Registration lists must be maintained by factory and dealer on marine products sold in the United 88 . present the temporary registration card to the dealer. He will attach it to your warranty claim form. name and address. It identifies name and address of the original purchaser. date of sale. A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service during this period. Warranty claims will not be accepted without presentation of this card.

It is our desire to have ALL products registered at the factory should it ever be necessary to contact you.CD56 International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area. • A copy of the Warranty Registration Card. your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form(s). product model and serial number(s). The distributor/dealer also certifies that you are the original purchaser and user of the product. name and address. refer to the “International Warranty. date of sale. • The Warranty Registration Card identifies your name and address. the Marine Power Service Center will issue you a permanent (plastic) Warranty Registration Card within 30 days after receiving the “Factory Copy” of the Warranty Registration Card from your distributor/ dealer If you receive a plastic Warranty Registration Card.” Refer to “Table of Contents. Make sure your dealer/distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area. you may discard the “Purchaser’s Copy” that you received from the distributor/dealer when you purchased the product. • In some countries. This card represents your factory registration identification. • For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing. type of use and the selling distributors/dealer’s code number. 89 . designated as the “Purchaser’s Copy”. Ask your distributor/dealer if this plastic card program applies to you. and should be retained by you for future use when required Should you ever require warranty service on this product.” IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. MUST be given to you immediately after the card has been completely filled out by the selling distributor/dealer.

For purposes of this warranty Pleasure Craft is defined as a recreational planing craft used only and exclusively for pleasure and recreation. IV. 7) Water entering engine cylinder/s through the exhaust system or air intake system. tune-ups or to damage caused by: 1) Neglect. The unused period of the applicable warranty. Since this warranty applies to defects in material or workmanship. Warranty claims will not be accepted by the dealer until the original date of sale and Product serial number can be verified. We warrant each new production MerCruiser Diesel Stern Drive Power Package. 90 . accident. or Distributor Service Office (outside the U. whichever occurs first. and sold to the consumer in a country to which distribution is authorized by the Company. it does not apply to normal wear. Light-Duty Craft is defined as a planing hull vessel used in any law enforcement. is transferable to subsequent purchasers. if any. The warranty period for Light-Duty Craft applications is one (1) year from date of sale to the first purchaser or user of the product.A. the “Warranty Registration Card”. oils. then the warranty shall be the minimum period required by law. included with each Product. A copy of the dealer service work order must be retained as evidence of the completion of this requirement. This warranty shall apply only to pleasure craft and light-duty craft applications. must be properly com- pleted by the selling dealer and forwarded immediately after the sale to Mercury Marine (U. 5) Participating in or preparing for racing or other competitive activity or operating with racing type lower unit. 2) Use of a propeller not properly suited to application/boat load or. If either of these items is not available. This warranty shall become effective upon the date of sale to the first purchaser or user of the Product. lubricants or coolants/coolant additives which are not suitable for use with the Product or recommended by us. authorized to service the Product. or used in any enterprise or venture in which revenue in any amount is generated directly or indirectly. lack of maintenance. adjustments. II. and Canada). 4) Operation with fuels. 8) Use of product in a full-displacement or semi-displacement hull vessel. 3) Use of an accessory or part not manufactured or sold by us. State or Province where the product is sold prohibits limitation of warranty coverage to one (1) year. It is a condition for the continuation of this warranty that the Product be taken to an authorized MerCruiser Service Dealer. Purchaser must provide proof of purchase and substantiate the original date of sale by presenting to the dealer. V. or professional entertainment activity. improper installation or service. after 20 hours of engine operation. abnormal operation. To validate the warranty. failure to follow instructions in applicable service and warranty information manuals or operation and maintenance manual. and Canada) or to a Marine Power International Branch. but not later than 50 hours. If the law applicable in the Country. or the accumulation of 500 hours of engine operation. 6) Alteration or removal of parts. the original purchaser’s copy of the “Warranty Registration Card” or the “Owner Warranty Registration Card”. manufactured by MerCruiser (hereafter referred to as the “Company”). or 9) Use or operation of the product in a manner inconsistent with the “Recommended Operation/Duty Cycle” section of the Operation and Maintenance Manual. III.S. purchaser must provide a copy of the original purchaser’s “Bill of Sale” (Sales Contract) for the Product to be serviced. Inboard Engine and Accessories attached thereto (hereafter referred to as “Product”). commercial.CD212 Warranty Policy Mercruiser Diesel Limited Warranty I.S. VI.A. The warranty period for Pleasure Craft applications is one (1) year from date of sale to the first purchaser or user of the product. for required checks and adjustments. to be free from defects in material and workmanship.

and any other expenses associated with that service. We shall then arrange for the inspection and repair. The repair or replacement of parts. Purchaser shall pay for all related transportation charges and/or travel time. Any Product or parts shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid. X. If purchaser cannot deliver Product to such authorized dealer. he may give notice in writing to the Company (U. provided such service is covered under this warranty. launch. We reserve the right to improve the design of any Product without assuming any obligation to modify any Product previously manufactured. telephone or rental charges of any type. If the service is not covered by this warranty. XI.A.CD213 Mercruiser Diesel Limited Warranty (continued) VII. and Canada). or loss of time or income. refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this warranty. SOME STATES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES. or the performance of service. Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer autho- rized to service the Product. towing and storage charges. inconvenience. IX. Our obligation under this warranty shall be limited to repairing a defective part or. at our option.S. Reasonable access must be provided to the Product for warranty service. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY. does not extend the period of this warranty beyond its original expiration date.S. and Canada) or the nearest Marine Power International Branch or Distributor Service Office (outside the U. 91 . WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY. SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU.A. purchaser shall pay for all related labor and material. or 2) Removal and/or replacement of boat partitions or material because of boat design for necessary access to the Product. under this warranty. VIII. IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY. This warranty will not apply to: 1) Haul-out. This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state and country to country. or other consequential damages.

CD268

Marine Power International Branch or Distributor Service Offices
INTERNATIONAL HEADQUARTERS Marine Power International Division of Brunswick Corporation P.O. Box 1939 Fond du Lac, Wl 54936-1939 USA Telephone: (414) 929-5000 EUROPE, MIDDLE EAST, AFRICA Marine Power Europe, Inc. Parc Industriel de Petit-Rechain B-4822 Verviers Belgium Telephone (0) 87 / 32 • 32 • 11 Fax (32) (87) 31 • 19 • 65 LATIN AMERICA, CARIBBEAN Marine Power International 9350 SW 72nd St. (Sunset Dr.) Suite 100 Miami, FL 33173 U.S.A. Telephone (305) 596-9606 Fax (305) 596-3869 AUSTRALIA Marine Power International Pty. Ltd. P.B. 1420, 132-140 Frankston Road Dandenong, Victoria 3164 Australia Telephone (61) (3) 791-5822 Fax (61) (3) 791-5880 ASIA / PACIFIC Marine Power International, Ltd. Block 1002 Jalan Bukit Merah #07-08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone (65) 270-7680 Fax (65) 270-7898 JAPAN Marine Power International - Japan No. 27-2 Muramatsu Chisaki-shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone (81) 543/34-2500 Fax (81) 543/34-2022

92

CD61

Warranty Coverage
The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The table explains some of the types of services that are not covered by warranty. Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents normal wear and a variety of other causes that affect the product are not covered. Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us. Should you have any questions concerning warranty coverage contact your authorized dealer. They will be pleased to answer any questions that you may have.
WARRANTY DOES NOT APPLY TO THE FOLLOWING:

• Minor adjustments and tune-ups, including checking, cleaning or adjusting spark plugs, ignition components,
carburetor settings, filters, belts, controls, and checking lubrication made in connection with normal services. • Damage caused by neglect, lack of maintenance, accident abnormal operation or improper installation or service. • Haul-out, launch, towing charges; removal and/or replacement of boat partitions or material because of boat design for necessary access to the product; all related transportation charges and/or travel time, etc. Reasonable access must be provided to the product for warranty service. Customer must deliver product to an Authorized Dealer. • Additional service work requested by customer other than that necessary to satisfy the warranty obligation.

• Labor performed by other than an Authorized Dealer may be covered only under following circumstances: When
performed on emergency basis (providing there are no Authorized Dealers in area who can perform the work required or have no facilities to haul out, etc., and prior factory approval has been given to have the work performed at this facility). • All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner’s responsibility. • Use of other than Quicksilver replacement parts when making warranty repairs.

• Oils, lubricants or fluids changed as a matter of normal maintenance is customer’s responsibility unless loss
or contamination of same is caused by product failure that would be eligible for warranty consideration. • Participating in or preparing for racing or other competitive activity.

• Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal
engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty. • Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard.

• Water entering the engine via the carburetor or exhaust system or submersion Also water in the starter motor. • Starter motors and/or armatures or field coil assembly, which are burned, or where lead is thrown out of commutator because of excess cranking. • Valve or valve seat grinding required because wear.

• Failure of any parts caused by lack of cooling water, which results from starting power package out of water,
foreign material blocking inlets or power package being mounted too high. • Use of fuels and lubricants which are not suitable for use with or on the product. Refer to your Operation and Maintenance Manual. • Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. Failures which are not related to the use of those parts or accessories, are covered under warranty, if they otherwise meet the terms of the limited warranty for that product.

93

CD62

Transferable Warranty
The product warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications.

DIRECT SALE BY OWNER • The second owner can be registered as the new owner and retain the unused portion of the limited warranty
by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership. In the United States and Canada, mail to: Mercury Marine W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, Wl 54936-1939 Attn: Warranty Registration Department

• A new Owner Warranty Registration Card will be issued with the new owner’s name and address. Registration
records will be changed on the factory computer registration file.

• There is no charge for this service.
Outside the United States and Canada, please contact the distributor in your country, or the Marine Power International Service Center closest to you, for the transferable warranty procedure that would apply to you.

Q-GUARD Product Protection Plan
UNITED STATES AND CANADA ONLY
(Certain Performance Products, triple engine installations, and commercial applications are excluded) The Mercury Marine Q-GUARD Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty. The optional Q-GUARD Product Protection Plan is the only Factory Plan available for your engine. Two, three or four-year plans can be purchased up to 180 days after the original engine purchase date. See your participating dealer for complete program details.

94

Mercury Marine does not sell to unauthorized dealers or retail customers. Boat make and size. the dealer requires the motor model and serial number(s) to order the correct parts.IF YOU REQUIRE ADDITIONAL ASSISTANCE TO RESOLVE YOUR CONCERN. Only Authorized Dealers can purchase genuine Quicksilver parts and accessories from the factory. contact the nearest Marine Power International Service Center. If for any reason. The dealer has all the necessary information to order parts and accessories for you should he not have them in stock. Only he has the factory-trained mechanics. lf you are unable to obtain satisfaction. Outside the United States and Canada. He knows your engine best. special tools and equipment and the genuine Quicksilver parts and accessories∗ to properly service your engine should the need occur. Normal use and approximate gross load. power package and trailer. Should there be a misunderstanding. Provide the following important information: • • • • • • • • Your name. Any problems with service sales.CD63 Owner Service Assistance CD64 Local Repair Service Always return your MerCruiser powered boat to your local Authorized Dealer. Resolving a Problem Your satisfaction and goodwill are of primary importance to your dealer and to Mercury Marine. contact the nearest Regional Service Center. should the need for service arise. or if your problem has not been resolved to your satisfaction please follow these steps: STEP ONE .DISCUSS YOUR PROBLEM WITH ONE OF THE DEALERSHIP MANAGEMENT PERSONNEL. you cannot obtain service. warranty or operation of your MerCruiser power package will be resolved by your dealer. The model and serial number(s). address and telephone number. Present hours of operation. Details of problem or complaint. ∗Quicksilver parts and accessories are engineered and built specifically for MerCruiser stern drives and inboards. contact the dealership’s owner. Parts and Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accessories should be directed to your local Authorized Dealer. 95 . STEP TWO . Refer to the Yellow Pages of the telephone directory. When inquiring on parts and accessories. Service Away from Home If you are away from your local dealer and the need arises for service. Misunderstandings or complaints can be quickly solved by the dealer. He also is your primary source of information on your boat. Propeller pitch and/or part number. contact the nearest Authorized Dealer. CONTACT YOUR NEAREST MERCRUISER SERVICE CENTER. Your dealer’s name and location. knowledge.

they will advise the Service Center. FOLLOW STEP THREE ONLY AFTER COMPLETING STEPS ONE AND TWO AND YOUR COMPLAINT HAS NOT BEEN RESOLVED.CONTACT CONSUMER AFFAIRS DEPARTMENT UNITED STATES: MerCruiser 3003 N. OUR SERVICE CENTERS AND FACTORY DO NOT HAVE FACILITIES TO SERVICE OR REPAIR YOUR PRODUCT. ALL SERVICE WORK IS DONE BY THE AUTHORIZED DEALER USING THE DEALER’S FACILITIES. STEP THREE .CD65 Please bear in mind that the Service Centers resolve all problems through the dealership using the dealer’s facilities equipment and personnel. This is the reason we request you use the preceding steps in sequence when you have a problem or complaint. They will contact your dealer to bring the problem to a satisfactory conclusion. If they feel some further action can be taken. 96 . Perkins Road Stillwater. Our experience has shown that this is the most expedient and successful procedure to follow to ensure satisfaction to our customers. OK 74075-2299 Telephone (405) 743-6515 CANADA: Contact the Nearest Regional Service Center OTHER COUNTRIES: Contact the Nearest Marine Power International Service Center The customer service representative will review all the facts involved.

Ltd. Enclose full remittance in check or money order (NO C. 2. 3. Inc. Box 1939 Fond du Lac.B. FL 33173 U. Perkins Road Stillwater. Check the literature and quantities you want. CARIBBEAN Marine Power International 9350 SW 72nd St. Wl 54936-1939 Outside the United States and Canada. model. PACIFIC Marine Power International Pty. When ordering be sure to: 1.S.’s).D. contact the nearest Marine Power International Service Center for further information. Ontario L4Y 2C2 Canada Telephone (905) 270-4481 Fax (905) 270-4510 MEXICO. (Sunset Dr. Ltd. P. Telephone (305) 596-9606 Fax (305) 596-3869 EUROPE. 1420. MIDDLE EAST. 97 .CE199 Service Centers UNITED STATES MerCruiser 3003 N.O. OK 74075-2299 Telephone (405) 743-6566 Fax (405) 743-6570 CANADA Mercury Marine 1156 Dundas Highway East Mississauga. Parc Industriel de Petit-Rechain B-4822 Verviers Belgium Telephone (0) 87 / 32 • 32 • 11 Fax (32) (87) 31 • 19 • 65 AUSTRALIA.A. List your product. AFRICA Marine Power Europe.O. 27-2 Muramatsu Chisaki-shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone (81) 543/34-2500 Fax (81) 543/34-2022 Customer Service Literature English language publications are available from: Mercury Marine Attn: Publications Department W6250 West Pioneer Road P. Victoria 3164 Australia Telephone (61) (3) 791-5822 Fax (61) (3) 791-5880 ASIA Marine Power International. Block 1002 Jalan Bukit Merah #07-08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone (65) 270-7680 Fax (65) 270-7898 JAPAN Marine Power International .) Suite 100 Miami.Japan No. year and serial number(s). CENTRAL AMERICA. SOUTH AMERICA. 132-140 Frankston Road Dandenong.

CD68 Owner’s Logbook Date Maintenance and Repair Operating Hours 98 .

CD68 Owner’s Logbook Date Maintenance and Repair Operating Hours 99 .

CD68 Owner’s Logbook Date Maintenance and Repair Operating Hours 100 .

3L/270 35-805809 80828 38-816171 801763855 808136 27-805806 57-806170 57-806160 57-806851 92-816096A12 92-78376A6 92-86145A12 92-815869A12 101 .CD269 GENERAL MAINTENANCE PARTS Engine Parts DESCRIPTION Oil Filter Air Filter Sea Water Filter Water Separating Fuel Filter Thermostat Thermostat Gaskets Alternator Belt Power Steering Belt Water Pump Belt Quicksilver Motor Oil Anti-Corrosion Grease Storage Seal Corrosion Guard Spray MCM D7.

Anodic Plate Anodic Plate (Front Propeller) Anodic Plate (Rear Propeller) Universal Anodic Plate Trim Cylinder Anodes Gimbal Housing Anode Bearing Carrier Anode Drain Screw Drain Screw O-Ring Vent Screw Vent Screw O-Ring Bell Housing to D.H.H.Drive Parts DESCRIPTION Front Propeller Nut Rear Propeller Nut Propeller Nut Front Thrust Hub Rear Thrust Hub Thrust Hub D.S.S. Seal Drive Mounting O-Ring Trim Pump 20 Amp Fuse Trim Pump 10 Amp Fuse 2-4-C Marine Lubricant with Teflon U-Joint and Gimbal Bearing Grease Engine Coupler Spline Grease High Performance Gear Lube Touch Up Spray Paint 10-14834A1 25-805726 10-79953 25-805726 16755 25-45710 88-79091 88-79023A10 92-825407A3 92-828052A2 92-816391A4 92-816026A1 92-78373-12 76214A5 806190A1 821631A1 806190A1 821631A1 806188A1 10-14834A1 25-805726 10-79953 25-805726 16755 25-45710 88-79091 88-79023A10 92-825407A3 92-828052A2 92-816391A4 92-816026A1 92-78373-12 55074T 821630A1 821630A1 76214A5 76214--4 11-54034 11-805100T 11-805101T Bravo Two Bravo Three 11-805092 11-805093 102 .

OR. Free Sales Tax * Ship/Hand** Grand Total 103 . AZ.01 . Price Each $30. add $4.00.00.$50.00 $4. ID. NY. WV.shows the complete assembly and disassembly of the engine or stern drive.00 $30.00 50.00 Sub-Total Total Price * must be collected from customers in all states except: AK. WY ** Orders Totaling: up to $20. HI.01 . NV. Parts Manual . ME.shows the exploded view of the engine or stern drive with corresponding part number.95 $4. DE. Manual Service Manual: Engine Service Manual: Drive Service Manual: Remote Control Parts Manual: Engine Only Parts Manual: Drive Only Operation and Maintenance Manual 909090909090- Part Number (Official Use Only) Qty. MT. NH. IA.95 $5.up. Operation and maintenance manual (Owner’s Guide) .explains basic operation and maintenance.00 $30. MI.00 20.CC178 LITERATURE ORDER FORM Model _______________ Horsepower______________Serial Number______________ Year_________ Service Manual . VT. add $3.

Box 1939 Fond du Lac.Please Return with Payment to: Mercury Marine Attn: Publications Dept.O. WI 54936-1939 Ship To: (Please Print or Type .This is your Shipping Label) Name Address City State Zip Method of Payment: (No Cash or C.O.D. P.) Personal Check Cashiers Check Money Order Month/Year Card Number Expiration Date Visa Master Card Signature Date ( ) Telephone Number 104 .

You're Reading a Free Preview

Download
scribd
/*********** DO NOT ALTER ANYTHING BELOW THIS LINE ! ************/ var s_code=s.t();if(s_code)document.write(s_code)//-->