> — merCruiser SERVICE MANUAL Number 1 Stern Drive Units and Marine Engines Book 1 of 2 Sections 1 thru 5Notice to Users of This Manual This service manual has been written and published by the service department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or sim- ilar products manufactured and marketed by Mercury Marine. That they have been trained in the recom- mended servicing procedures of these products which includes the use of mechanics common hand toolsand the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses service procedure and/or tool, which is not recom- mended by the manufacturer, first must completely satisfy himself that neither his nor the product's safety will be endangered by the service procedure selected All information, illustrations and specifications con- tained in this manual are based on the latest product information available at time of publication. It should be kept in mind, while working on the pro- duct, that the electrical system and ignition system is capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. ‘Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started It is important to note that, during any maintenance procedure, replacement fasteners must nave the same measurements and strength as those removed, whether metric or customary. (Numbers on the heads of the metric bolts and on surfaces of metric nuts indi- cate their strength. Customary bolts use radial lines for this purpose, while most customary nuts do not have strength markings. Mismatched or incorrect fasteners, can result in damage or malfuction, or possibly per- sonal injury. Therefore, fasteners removed should be ‘saved for re-use in the same locations whenever possi- ble. Where the fasteners are not satisfactory forre-use, ‘care should be taken to select a replacement that matches the original.Replacement Parts AWARNING Electrical, ignition and fuel system components on MerCruiser Engines and Stern Drives are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided. When servicing the electrical, ignition and fuel sys- tems, itis extremely important that all components are properly installed and tightened. If not, any electrical ‘orignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed. Engine Mechanical Components Many of the engine mechanical components are de- signed for marine applications. Unlike automotive engines, marine engines are subjected to extended Periods of heavy load and wide-open-throttle opera- tion, therefore, require heavy-duty components. Spe- cial marine engine parts have design and manufactur ing specifications which are required to provide long life and dependable performance. Marine engine parts also must be able to resist the corrosive action of salt or brackish water that will rust or corrode standard auto- motive parts within a short period of time. Failure to use recommended Quicksilver service re- placement parts can result in poor engine performance and/or durabiltiy, rapid corrosion of parts subjected to salt water and possibly complete failure of the engine. Use of parts other than recommended service replace- ment parts will void the warranty on those parts which are damaged as a result of the use of other than recommended partsMODELS COVERED IN THIS MANUAL MERCRUISER STERN DRIVE ENGINES (MCM) TRANSOM ASSEMBLY AND STERN DRIVE UNITS [Model Serial Number Model Serial Number IMCM 60 All MCO_ All MOM 80 All MCI All MCM 90 All MCIAB/C All MoM 110 All MCIA/BIC E-2 All IMCM 120 3770640 and below MC 80 All IMM 140 (6 Cyl) All MC 90 All IMOM 140 (4 Cyl.) 3771644 and below MC 120 3780849 and below MM 150 All MC 140 "3780849 and below _ MCM 160 All MC 160 All MoM 165 3774864 and below MC 165, 3780849 and below IMCM 888 3777489 and below MC 688 784374 and below MOM 190 (V-8) All MOM 215 H All MGM 200 (6 Cyl All MOM 215 E L All MCM 215 All MC TR [3787239 and below IMCM 225 (G.M.) __All MCI All MOM 225TR (Ford) 379774 and below MC II All MCM 250 (827 CID) 4767999 and below MGM 255TR (Ford) 3838787 and below IMM 270 All MGM 310 All IMCM 325 All MCM 390 AL MERCRUISER INBOARD ENGINES (MIE) Model Serial Number MIE 30 All MIE SS All MIE 215, Al MIE 225 (GM) All MIE 225 (Ford) 3750507 and below. MIE 250 (827 CID) 4767999 and below, MIE 255 (Ford) 3899487 and below MIE 270, All MIE 325 All MIE 300, AllMODELS COVERED IN THIS MANUAL MERCRUISER STERN DRIVE ENGINES (MCM) TRANSOM ASSEMBLY AND STERN DRIVE UNITS [Model Serial Number Model Serial Number IMCM 60 All MCO_ All MOM 80 All MCI All MCM 90 All MCIAB/C All MoM 110 All MCIA/BIC E-2 All IMCM 120 3770640 and below MC 80 All IMM 140 (6 Cyl) All MC 90 All IMOM 140 (4 Cyl.) 3771644 and below MC 120 3780849 and below MM 150 All MC 140 "3780849 and below _ MCM 160 All MC 160 All MoM 165 3774864 and below MC 165, 3780849 and below IMCM 888 3777489 and below MC 688 784374 and below MOM 190 (V-8) All MOM 215 H All MGM 200 (6 Cyl All MOM 215 E L All MCM 215 All MC TR [3787239 and below IMCM 225 (G.M.) __All MCI All MOM 225TR (Ford) 379774 and below MC II All MCM 250 (827 CID) 4767999 and below MGM 255TR (Ford) 3838787 and below IMM 270 All MGM 310 All IMCM 325 All MCM 390 AL MERCRUISER INBOARD ENGINES (MIE) Model Serial Number MIE 30 All MIE SS All MIE 215, Al MIE 225 (GM) All MIE 225 (Ford) 3750507 and below. MIE 250 (827 CID) 4767999 and below, MIE 255 (Ford) 3899487 and below MIE 270, All MIE 325 All MIE 300, AllMERCRUISER SERVICE MANUAL OUTLINE SECTION NO 1 General Information 2 Removal-Installation-Alignment 3 Electrical System 4 Fuel Systems 5 Engine 6 Drive Systems 7 Accessories 8 Specifications 8 Tools SECTION HEADING Part A - General Information Part B- Tuneup Part C- Lubrication Part A - MerCruiser 80-80-90 Part B - MerCruiserI Part C - MerCruiser I Early Part 0 - MerCruiser IL Transom Part E - MerCruiser I Part F = MerCruiser 215H Part G - MerCruiser 215E Part J - MerCruiser I-TR Drive Unit Part A - Starting System Part B - Ignition System Part G- Alternator System Part D- instrumentations Part E- Wiring Diagrams Part A - Fuel Pumps Part B - Carburetors Part A - Engine Mechanical, In-Line GM Part B - Engine Mechanical, In-Line 60-80-90 Part C - Engine Mechanical, V-8 GM Part D - Engine Mechanical. V-8 Ford Part A - MerCruiser 60-80-90 and MerCruiserT Part B- MerCruiser IT Part C - MerCruiser 215 Part D - MerCruiser II Part E - Direct Drive Transmission Part F - MerCruiser I-TR Drive Unit Part G - MerCruiser I-TR Transmission Part A Power Tilt & Trim Part B - Steering System Part C - Remote Controls Part D - Cooling Part E - General AccessoriesMERCRUISER "SECTION 1 qa 2 WACROAN RD Binypunce v's a 54321 g 9525! BOL eSAS 326457 8 Zs 6 INERL AP GENERAL INFORMATIONHow to Use This Manus Page Numbering Dvectional Reerences 3 Engine Rotation Terminology Engine Sori Number ‘Sern Drive Serial Numbers 2 Fluthing Cooing System Bee Winter Storage - Marine Engines Returning Engine to Service Winter Storage - Stern Orive Unites “Tut Pin Adjustment Power Tit Operation 22... Power Trim Operation Predgniton and Detonation. Tim Ta eee eeeee MerCeuisr Fuel System Electrical Insalation Comoression Test : Spark Plugs Ignition System TABLE of CONTENTS Page re) 1A2 1A 1A AAS jaaz 10.13 1aas 1016 aa rato 1420 1021 a2 181 1e4 ilies Carburetor Adjustment Throttie Cable Adjustments Fuel Puro Pressure Text Battery and Battery Cables Valve Adjustment Mechanical Litters : A Monifold . Crankcae Ventilation z MerCruiser Lubricant and Maintenance Chart ‘Stern Drive Lubvient Capacitor +.» ‘uicksiser Engine Cleaner Lubeiane Guns ther Merine Lubricants Engine Lubrication te See it Fiter 29.8 Components Stern Drive Lubrication (Checking Lubricant Love Draining and Filing Devs Uni Points ot Lubrication a 188 seat teat 1812 1842 18.412 1ca 102 103 14 rca 165 167 107 168 ico 1e2 retSECTION 1- GENERAL INFORMATION ITIERL RUIGER, PART A - GENERAL INFORMATIONINDEX Page Howto Use This Manual aaa Page Numbering aaa Directional References 3 1A2 Engine Rotation Terminology oe 1a2 si 1a ROE 19. AIRS MerCruiser 80 and 90 at 1A8 Mercruiser 120:140-160.165.295 |. ee ane MerCruiser 886:216-226ILTR and 2551-7 sas MerCruiser 25... saa Iooard Engines : A aaa Stern Drive Serial Numbers.» a teens, MercruisrZand "0" LI 105, MorCruiser 888 . fiihas MerCruiser IE »*, % ool. HRT Mer Cruiser 111215225007 and 26617 4A5; Flushing Cooling System tas. ‘MerCruiser 600-0 and 4 snd Cylinder Engines (Except 200) and 888 ie 1a6 ‘MerCruiser 200 and 8Cylinder Engines (Except BSB) =| 1A Wintar Storage -Marina Emines = 1a MerCruiser 60-80-90 HAT MerCruiser 110 theu 165.0. Tha BEvlinder Engines Lee Taso Returning Engine 0 Service «=... asa Winter storago stern Drive Units |) f4aaa Mercruiser ets 888 1aas MorCruisr IEIL22SIL-TR ond 2560-7 | Diliaag: Tike Pin Adjustment 2 sera eae MerCruiser 0 and TE 1435 Power Tit Operation 5 : 136 Boat a Rent Sae 1a46 Boat Underway é case Power Tim Operation é tas? Yellowhite-Grean Buttons Panat sss. 1aa7 Red. Fed/Green thie Buttons Panel lock Buttons Panel and Trim Switches Mounted fn Remote Control eeeiar7, Indieaor Readjustment oo rane Pre-gnition and Detonation fos t1aae Prelgnition 1a19 Detonation K Doi laaag. Tim Tab. en es 1420 Removal anc Repiacenent 1020 Adjustment 2 eae Mercruiser Fuel System ei tes sTAat Fuel Tank-Cautions 1a21 Fuel Lines-Lenath aa Sizes Diaz lccwies! Inealaton raatGENERAL INFORMATION HOW TO USE THIS MANUAL ‘This comprehensive overhaul and repair manual is designed for SECTIONS are separated by dividers (heavier color paper) mechanics to use asa reference guide. which enable the user to quickly locate any desired SECTION ‘The menual is divided into SECTIONS which represent major 1A table of contents, which lists major subjects and page components and ystems. Following are the SECTIONS which ‘numbers, is printed on the reverse side of each SECTION ‘compose this manual: divider. Section Section Heading i General Information ‘The SECTIONS are further divided into PARTS. Each PART 2 Removal, Installation and Alignment has a colored title page which is the same color as the 3 Electrical Systems SECTION divider. An index for the particular PART is printed 4 Fuel Systems the ttle page. 6 Engine ‘ 8 Drive Systems 7 Accessories XAMPLE: To find “Integral Charging System”, turn to 8 Specifications electrical Systems” divider. The table of contents on the 8 Tools back side of the divider indicates that “Integral Charging 10 Flat Rate Manual/Service Bulletins Syatem’” is located in PART C, “Alternator System”, Page (Dealers Only) C13. PAGE NUMBERING ‘Two number groups appear at the bottom of each page. The ‘example, below, is self explanatory Example: ELECTRICAL SYSTEM - 30-5 Publication Date Section Description (January 1973, Revision 1) Section Number Part of Section Letter Page Number vor GENERAL INFORMATION - 14sDIRECTIONAL REFERENCES Front of boat is bow; rear is stern. Starhoard side is right side: STARBOARD port side is left side. In this maintenance manual, all (aicu) directional references are given as they appear when view boat from stern, looking toward bow. (Pigury |) APT or STERN (REAR) Figure 1. Directional Reference (FRONT) Ler) ENGINE ROTATION TERMINOLOGY Engine rotation is determined by observing crankshaft rotation Taboard engines can be either loft or right hand rotation, from the rear of engine looking forward. Do not rely on propeller rotation, as propeller rotation is not All MerCruiser stern drive engines are left hand rotation, necessarily, the same as engine rotation 142. GENERAL INFORMATION wartENGINE SERIAL NUMBER IMPORTANT: Serial numbers are the manufacturer's key to mumerous engineering details applicable to the engine. When ordering parts, accessories and tools, or when corresponding with the manufacturer or dealer in regard to ‘Service matters, always specify engine serial number. MERCRUISER 60 located on left side of engine block above oil Figure 3. MerCruiser 80 and 90 Serial No. Location var MERCRUISER 80 and 90 Serial number is located on reat left side of engine block under intake manifold. (Figure 3) MERCRUISER 120-140-160-165-225 Serial number is located on tear right side of engine block above starter motor. (Figure 4) Figure 4. MerCruiser 120-140-160-165-200-225 Serial No. Location MERCRUISER 888-.215-225IL-TR and 25811-TR Serial number is located on rear top of cylinder block between intake manifold and flywheel housing. (Figure 5) Figure 5. MerCruiser 888-218-225IL-TR and 2551-7R Serial No. Location cer RAL INFORMATION -183MERCRUISER 325 INBOARD ENGINES ial number is located at rear of engine on fly wheel housing, Figure 6) 03622 03665, Figure 6. MerCruiser 325 Serial No. Location Figure 7. Inboard Engine Serial No. Location 1844 GENERAL INFORMATION 173R1STERN DRIVE SERIAL NUMBERS IMPORTANT: Serial numbers are the manufacturer's key to numerous engineering details applicable to the unit When ordering parts, accessories and tools, or when corresponding with the manufacturer or dealer in regard to ervice matters, always specify stern drive serial number. NOTE: A pressure-sensitive decal is enclosed with the stern drive, Decal should be placed on side of engine cylinder head rocker cover. MERCRUISER I and “The serial number of MerCruiser I and “O” Stern Drive Units are located as follows 1. Beneath MerCruiser decal embossing on either side of drive SL ead shaft housing. (Figure 1) ee 2. On drive shaft housing to bell housing mounting flange. Decal (Figure 1) 3, On and under MerCruiser decal on either side of driveshaft housing. (Figure 1) MERCRUISER 888 Stern drive unit serial number is stamped on drive shaft Serial No. hhousing under MerCruiser decal on either side of bousing. (Pigure 2) Serial number also is on the 888 decal on rear of drive shaft housing. (Figure 2) MERCRUISER IL in drive unit serial number is stamped on serial plate on front of steering lever housing. (Figure 3) MERCRUISER TIL215-22511-TR and 25510-TR Stern Drive Unit serial number is embossed on the MerCruiser ecal (located on left or right side of drive unit). This numb ‘ko is stamped on drive shaft housing, directly under MerCruiser decal. (Figure 4) Figure 4, MerCruiser 1E215-2251L-TR and 2551-TR. v7aR: [ERAL INFORMATION - 14SFLUSHING COOLING SYSTEM MERCRUISER 60-80-90 and 4 and 6-CYLINDER ENGINES (Except 200) and 888 NOTE: When engine is operated in salt or silt water, it és recommended to flush engine with fresh water periodically and before storage. CAUTION: Engine must be operated while flushing To prevent damage to water pump impeller, attach Flush-Test Device direetly over intake holes in gear housing strut to provide cooling water at this point. (Figure 1) DO NOT OPERATE above idle speed while flushing with Flush-Test Deviee. See your local dealer for this deviee. MerCruiser 888 engines with FRESH WATER COOLING are equipped with seawater pump (located ‘on engine) in addition to seawater pump in drive unit. Cooling water MUST BE supplied to BOTH pumps to prevent damage to water pumps" impellers. Figure 1. Flush Test Device WARNING! Whey Gudling, Be civ Wat Sree 2 Partially open water tap. DO NOT tse fall city water sicinity of propeller is dear and thal no person i pressure tag oat, rel pase inky, Ser one 3. Shift into neutral gear and run engine at 500600 RPM to cx z circulate water until engine reaches normal operating fo remove propeller sa precautionary measure 5 perating 3 Paes F temperature. Watch water temperature gauge to prevent overheating. Flush until dcharged water is lear THEN 1. Install Flashefet Device, Connect garden hose between it STOP ENGINE: and water tap A. Close water sp and remove Flash Test Deve. MERCRUISER 200 and 8-CYLINDER ENGINES (Except 888) NOTE: When engine is operated in salt water, flush it with 2. Remove ho: fresh water periodically and before storage. If engine is ‘flushed while boat is in water, water imtake must have a sea water cock installed between water pickup and pump inlet. e clamp and hose from water pump inlet, CAUTION: Do not operate engine without cooling water flowing through water pump, oF neoprene water pump impellers will become damaged. 3 Connect length of hose to pump inlet and city water tap. Partially open tap. Do not use full eity water pressure. 4. Place remote eontrol handle in neutral position and start engine. Be sure that no one is near propeller. Operate engine at 300 to 600 RPM in neutral gear to circulate water until engine reaches normal operating temperature 5. Check that water is being discharged out exhaust outlets and watch water temperature gause on instrument panel to provent overheating 6. Allow engine to un until discharged water is clear 7. Stop engine and remove flushing hos. Fasten water intake line securely to pump inlet with hose clamp. (Figu Open sea water cock, 1. Clos: sea water cock (if fushed while boat isin water) 1A6 GENERAL INFORMATION v79R1WINTER STORAGE - MARINE ENGINES vlinder blocks suffer horizontal cracks when water freezes in the block. These freeze cracks are caused by failure to drain the cylinder block and exhaust manifold for winter storaze in anticipation of freezing weather. Four and 6-cylinder blocks ‘rack on sides of the engine.just below the core plugs or along the upper edge below the cylinder head Bight-ylinder blocks usually crack in the area near the WARNING: Do not operate engine without cooling water flowing through water pump, or water pump will be damaged. 1. Run engine unt) normal operating temperature is reached, then shut down. 2. Drain engine oil and replace ol filter. 3, Refill erankease with fresh SAE 30 MS oil. Add 8 ounces of Quicksilver 4-Cyele Engine Oil Supplement (C-92-33365, 16 ounce [.473 liter] can) to oil 4. Shut fuel supply off at fuel tank. 5. Remove flame arrestor and start engine. With engine running at fast idle (800-1200 RPM), slowly pour 4 ounces (IIB liter) of Quicksilver Storage Seal (C-9228143) or if not available, 4 ounces of SAE 30 MS oil (for MerCruiser 80 and 90 and 8 ounces of oil for MerCruiser 60) into carburetor throat while engine is running fuel out of ‘Carburetor, fuel pump and lines. Stall engine by pouring last two (2) ounces of oil rapidly into carburetor. WARNING: Be aure that engine compartment is well ventilated ~ and that there are no gasoline vapors present during this operation ~ to prevent a potential fire hazard 6. Remove spark plugs and squirt one ounce of Quicksilver Storage Seal or SAE 30 MS oil into each eylinder. Crank engine for 13 seconds with starter to coat cylinder w Disconnect battery leads, remove battery and store as specified by battery manufacturer. Clean and service battery supports, container and cables as required. 8. Condition oF replace spark plugs. Remove excess oil from round spark plug holes end install plugs 9, lean flame arrestor and reinstall 10. Drain all gasoline from fuel tank. LL. Replace fue! filter 12, Remove rocker arm cover. If condensation has collected in cover compartment, carefully wipe away all traces of bilswater mixture. Liberally coat valve mechanism and inside of cover with Quicksilver Storage Seal or SAE 30 MS oil. Reinstall cover, using new gasket. 13.0n 80 and 90 engine, the cooling system is self-draining thru a check valve which is located on the right, rear side fof the engine block, next to hydraulic pump. (Figure 1) To pe sure that valve is not plugged with foreign material, which could prevent. cooling. s fom draining, proceed as follows for 80 and 90 engine ‘4. Position bow of boat so that it is higher than stern Rear of engine must be lower than froat to provide complete draining, v73R1 MERCRUISER 60-80-90 hhydraulie lifters or below the intake manifold in the valley of the block. If freezing feilure is indicated or water is found in the erankease, remove the intake manifold to check these NOTE: For elosed cooling system maintenance, refer to Section 7D “Cooling” hose clamp on hose “A” in Figure 1 and we hose from check valve c. Insert a short length of wire into valve to be sure that valve is not plugged d._ Remove plug from rear of manifold. (Figure 3) fe Allow water to drain completely. Reinstall hose and plug. 1d. For MerCruiser 60 engine, remove exhaust manifold elbow ‘and cylinder bloek drain plugs and allow all water to drain Out. One plug is located in exhaust manifold elbow toward Front and one plug is located in cylinder block on front of cagine. (Figure 2,3 or 4) Both plugs must be removed to ‘drain completely. Reinstall drain plugs and tighten secure: ty eo that cooling system will he operable when engine is returned to service, See “Returning Engine to Servie following. For draining closed cooling system, refer to tion 7D “Accessor Figure 2. Drain Plug MerCruiser 60 ENERAL INFORMATION = 18-7Figure 4. Manifold Drain Plug - MerCruiser 90 MERCRUISER 110 thru 165 WARNING: Do not operate engine without cooling water flowing through water pump, or water pump will be damaged. 1. Run engine sufficiently to bring it up to normal operating temperature, then shut down and drain erankease com pletely and remove oi filter. 2. Refill erankease with fresh SAE 30 MS oil and add one pint (473 liter) can of Quicksilver 4Cyele Engine Oil Supplement (C-92-33365) to crankease oil at this time and install new oil filter. 8. Shut gasoline supply off at fuel tank. 4. Restart engine and operate for a few minutes at fast idle G00 to 1200 RPM) to be sure that new oil is being well-circulated and that new oil filter cartridge is properly sealed. Stop and recheck oil level to be sure that lovel is still at “FULL” mark on dipstick. Add oll if necessary WARNING: Be sure engine compartment is well ventilated — and that there are no gasoline vapors present during this operation ~ to prevent @ potential fire hazard. 5. Remove flame arrestor and fog internal surfaces of induetion system by restarting engine and running at fast idle (800 to 1200 RPM) while slowly pouring Quicksilver Storage Seal 8143) or, if not available, pour approximately one cup of SAE 30 MS oil into carburetor during the time that the engine is running gasoline out of the carburetor, fuel pump and fuel lines, Stall engine by pouring last two (2) ounces of oil rapidly into carburetor. 188 - GENERAL INFORMATION 10 1. Figure 6. Drain Plugs - 120 Model Replace fuel filter Drain all gcoline from fuel tank. Release and inspect alternator and water pump drive belt, Replace if necessary. Reinstall ina loose position. Remove manifold and cylinder block drain plugs. Plugs are located a: shown in Figure 5 or 6. All plugs must be removed to drain completely When draining the engine's cooling system, it is necessary that the bow of the boat be higher than the stern, or water may remain trapped in the cylinder block and exhaust ‘manifold. It also is advisable to insert a short piece of wire in the drain holes to be sure that sand, silt or other foreign material is not partially blocking the drain hole. If the fengine is not completely drained, the trapped water may freeze and cause severe damage to the engine. For draining closed cooling system, refer to “Accessories” Section 7D. Reinstall drain plags and tighten securely so that cooling system will be operable when engine is returned to service. Inspect all water hoses for cracks and deterioration and serviee them as required. For additional insurance against freezing and rust, it is recommended that the cooling system be filled with a solution of permanent anti-freeae and water. Solution should be mixed to the antifreeze manufacturer's recom. mended proportion for the lowest temperature to which engine will be exposed while in storage NOTE: Refer to. Figures 7-8-9 to determine which exhaust manifold and water distribution black is on engine.stem with anticrerze as follows: A. Engine Equipped as in Figure 7 1) Remove water intake hose from elbow in manifold body and insert plug in elbow. 2) Remove water outlet hove from relief valve body. 3) Install hose on water distribution block in inverted |. (Figure 7) 4 fe solution into neck on distribution block until solution rises in neck on reli valve body. 5) Replace hose on relief valve body Figure 7. Filling with Anti-Freeze B. Engine Equipped as in Figure & 1) Remove water intake hose from elbow in manifold body and insert plugin elbow. 2) Remove hose between distribution block and relief valve hody 3) Pour antifreeze solution into neck on distribution block until colution rises in neck on relief valve body. 4) Replace hose between distribution block and relief salve body eae Figure 8. Filling with Anti-Freeze vari C._ Engine Equipped as in Figure 9 1) Remove water distribution block cover and thermo- stat. 2) Remove hose from front end cap on manifold. 3) Pour anti-freeze solution into opening in water ution block until cylinder block, head and manifold sce full Reinstall thermostat, using a new hose to manifold end cap. et, and connect Figure 9. Filling with Anti-Freeze 13. Remove spark plugs from each cylinder and aquirt one (1) ounce (.03 liter) of Quicksilver Storage Seal ((-92-20143) for SAE 30 MS oil into each cylinder. Be sure to pull high tension lead out of distributor and ground wire while cranking. With spark plugs removed, crank engine for at least 15 seconds with starter to assure a good coating of oil ‘on evlinder walls. Remove excess oil from around spark plug holes and lightly lubricate spark plug threads. 14, Remove and clean flame arrestor and replace 15. Remove battery and service as specified by manufacturer. supports, containers and cables lean and service batte as required. 16. Remove yalve rocker arm cover and ins mechanism for worn or damaged parts. If condensation has foceurred in rocker arm cover compartment, carefully wipe away all traces of oil-water mixture, then liberally coat -chanism and inside of cover with Quicksilver sal (C-92-28143) or SAE 30 MS oil. Reinstall new gasket. 17. Remove oil filler eap and thoroughly clean and re-i 18. Clean outside of engine and spray Quicksilver Rust and Gorrosion Preventive (C-92-29152) on exterior surfaces of 0 leave a very ligh coat cil on exterior surfaces of ct valve train engine or wipe down with of Storage Seal or SAE 30 Mi ne to prevent direct exposure to weather ‘engine. Cover elements GENERAL INFORMATION - 1498—CYLINDER ENGINES WARNING: Do not operate engine without cooling water flowing through water pump, or water pump will be damaged. 1. Drain engine oil and replace il filter. 2. Refill erankease with fresh SAE 30 MS oil and one pint (473 liter) can of Quicksilver 4.Cyele Engine Oil Supple- ment (C:92.33365). Shut gasoline supply off at fuel tank. Remove flame arrestor and fog intemal surfaces of induction system by restarting engine and running at fast idle (800 to 1200 RPM), while slowly pourinz Quicksilver Storage Seal (C-92.28143) or, if not available, approxi imately one cup of SAE 30 MS oil into carburetor during the time that the engine is running gasoline out of the carburetor, fuel pur fuel lines. Stall engine by Pouring last two (2) ounces of ail rapidly into carhuretor. WARNING: Be sure that engine compartment is well ventilated - and that there are no gasoline vapors present during this operation ~ to. prevent engine fire. 5. Disconnect battery. 6. Drain all soline from fuel tan 7. Release and inspect alternator and water pump drive belt Replae if necessary. Reinstall in a loose position. 8 Remove cooling system drain plugs. Drain plogs are located as shown in Figure 10 or 11 All drain plugs must be removed to drain engine complete ly. When draining MerCruiser 888, 215, 225 and 255, engine must be level to prevent water from being trapped in eylinder block end manifolds. When draining all other V8 engines, the front of the engine should be higher than the rear to prevent water from being trapped in the eylinder block and manifolds. It also is advisable to insert a short piece of wire in the drain holes to be sure that foreign material is not partially blocking hole and prevent- ing water from draining completely 9. Remove water intake hose from sea water pump and allow water to drain. Reinstall hose. Remove circulating pump, hose and allow water to drain. Reinstall hose. For draining closed cooling system, refer to “Accessories” Section 7D. 18.10 -GENERAL INFORMATION osas Figure 11. Engine Oil Cooler and Transmission Oil Cooler Drain Plug- 325 Model 10. Reinstall drain plugs and tighten securely so that cooling system will function when engine is returned to service. 11. Inspect all water hoses for cracks and deterioration and replace them if required. 12. Remove spark plugs and squirt one (1) ounce of Quiek silver Storage Seal (C92-28143) or SAE 30 MS oil into each cylinder. With spark plugs removed, erank engine for at least 15 seconds with starter to assure good coating of oil on eylinder walls. Pull high tension lead out of distributor and ground wire while cranking. Remove excess cil from around spark plug holes and lightly lubricate spark plug threads. 3. Service spark plugs. See Section 3 “Ignition” 14, Remove and clean flame arrestor and replace 5. Remove battery and service as specified by manufacturer. Clean and service battery supports, containers and cable as required 16. Replace Fuel pump inlet filter 17. Remove valve rocker arm covers. If condensation has ccurred in rocker arm cover compartment, carefully wipe away all traces of oil-water mixture, then liberally coat valve mechanism and inside of cover with Quicksilver 28143) or SAE 30 MS oil. Reinstall 18.Clean outside of engine and spray Quicksilver Rust and Corrosion Preventive (C:92.29152) on exterior surfaces of 1¢ oF wipe down with rag to leave a very light coat Storage Seal or SAE 30 MS cil an exterior surfaces of 19. For additional insurance against freeving and rust, itis recommended that the cooling system he filled with a Solution solution of permanent anti-reere and water. should be mixed to the anti-freeze manulzcturer’s recom: mended proportion for the lowest temperature to which engine will be exposed while in storage. Fill cooling system as follows: (Figure 12 or 13) a. Loosen hose clamps, which fasten hoses to front manifold end eaps, and remove hoses. b. Remove screws, which fasten thermostat housing cover to housing, and remove cover. Remove thermostat from housing d. Pour anti-freeze solution into thermostat housing until level comes up to top, 17aR104579 Figure 12. Filling MerCruiser 888-215-2251E-TR and 2551ETR with Anti-Freeze ©. Pour antifreeze solution into opening on each mani- fold end cap until level comes up to top of end cap. xy to remove plugs from exhaust manifold (one in each manifold). (Figure 14) Pour anti-freeze solution in each manifold Figure 13. Filling MerCruiser 225-250-325 with Anti-Freeze tuntil solution is visible. Coat threads on plugs with 2 thread sealing compound and reinstall plugs. Remove hove which runs from lower water metering housing to engine block water pump. (Pigure 15) Pour antiireeze olution into hose until solution is visible in hose Reinstall hose and 1 2 Place new gasket 0 thermostat and cover. h. Connect hoses to manifold end caps. thermostat housing and install 20. Drain stern drive unit Tubricant and refill with new Super-Duty Gear Lubricant (C.9252650). 1. Lubricate deive unit upper pivot pin 22. Lubricate steering cable var on Figure 14. Plug Removed from V-8 Engines 23. Remove propeller, apply AntiCorrosion Grease (C.92-45134A1) to propeller shaft and reinstall 24, Wipe exterior of stem drive unit clean and spray with Quicksilver Corrosion and Rust Preventive (C-92-29152). 25. Store stern drive unit in the normal operating pos may develop a “cet”, if unit is The universal joint stored in a tlted-up pos when unit is returned t Service”, following. ion, and result in bellows failure Figure 15. Hose Removed from Lower Water Metering Housing ILTR TRANSMISSION DRAIN INSTRUCTIONS In order to prevent damage to transmission oil cooler from MerCruiser 22511-TR and 2551L-TR Engines, freesing water one of the following p dures must be followed. 1. Filloil cooler with antifreeze as follows 1. On engines with Power Steering, remove Power Steer xr drain plug, Remove transmission cooler outlet hose from exhaust elbow and pour anti-freeze GENERAL INFORMATION 18.11into hose (a small funnel may be used) until anti-freeze appears at Power Steering oil cooler. Reinstall Power Steering cooler drain plug and attach hose. b. Engines without Power Steering: Remove transmission cooler inlet hose from seawater pump and pour antifreeze into cooler outlet hose until anti-freeze appears at seawater pump end of oil cooler hove, Reattach hoses. RETURNING ENGINE TO SERVICE 1. Install battery, being sure that it is in a fully-changed condition. Clean and lightly lubricate termina 2. Drain anti-freeze, if you desire to save it. 3. Cheek cooling system to he sure all hoses are properly attached. NOTE: On 4 and 6-cylinder engines, which have been filled with anti-freeze solution, be sure to remove plug 1A12-GENERAL INFORMATION 6 from water intoke elbow in manifold and reinstall hose. Readjust drive belt tension, as outlined in “Tune-up” Section I Check engine alignment heck engine, stem drive unit and Power Trim pump oil levels. Check engine mount fasteners. VaRWINTER STORAGE - STERN DRIVE UNITS It is recommended that the stern drive unit be stored in normal operating position. If the unit is stored in the “tilt-up” position, the bellows may develop a “set” which would result qh premature failure when the units retumed to service. MERCRUISER I-thru-888 Be sure that water drain holes in gear housing are open. Drain stern drive lubricant and refill with Super-Duty Gear Lubricant (C-92-$0229-1), Refer to “Draining and Filling Drive Unit”, Section 1C. Figure 1. Drain Plug Locations 3. Lubricate following parts with Multipurpose Quicksilver Inbriant (C-92-49588) 2 Ride-Guide steering cable b. Pivot socket of steering arm. €. Universal joint shaft splines and engine coupling splines. Drive unit upper and lower pivot pins. Drive unit hinge pins. Gimbal bearing, if applicable. 4, Lubricate universal joint bearings with Universal Joint Lubricant (C-92-58209). Remove propeller, apply Perfect Seal No. (C:52-34227-1) to propeller shait and reinstall. 6. Lubricate shift lock shaft with SAE 30 oil, if applicable. 7. Check bellows condition. Replace if necessary MERCRUISER II-II-215-22511-TR and 255! 1. Check and refill stern drive unit with Super-Duty Quicksilver Gear Lubricant (C-92-52650) before storage. Refer to “Draining and Filling Drive Unit” Section 1, Part c. 2. Lubricate the various MerCruiser Stern Drive components wwith Quicksilver Multipurpose Lubricant (C:92-49588) and Lubrieant Gun (C-91-30500) thra grease lttings: wart 02736 Figure 2. Drain Plug Location 8. Check water pump impeller. Replace if impeller is worn, hardened or set. 9. Check condition of drive unit painted surfaces. Clean and paint metal surfaces that have become exposed. 5 Jtera drive exterior with Corrosion and Rust Preventive (€92-2915212). If applicable, also spray underside of tant in area around reverse locks. 10. At this time, before installing drive unit, check engine ment as explained in Seotion 2. -TR 1. Inside boat location a. Ride-Guide steering eable end next to hand nut. bb. Inner transom mounting plate 1) Leftside at base of erank uit 2) Right side top for crank ring gear. fe. Inside steering lever housing’ for steering lever shat. GENERAL INFORMATION - 1813,2. Outside of boat 4. Gimbal housing upper and lower pivot pin. Tilt pins on both sides of gimbal housing. 3. Lubricate universal joint bearings with Universal Joint Lubricant (C-92-58229-1). 4. Check bellows condition and replace if necessary. 5. Before installing drive unit, check engine alignment as explained in Section 2. 6. Remove propeller, apply Perfect Seal No. 4 (C-92-84227-1) or a waterproof-type lubricant to propeller 14:14. GENERAL INFORMATION shaft and reinstall propeller. (Refer to “Drive Unit” Section 6) = Wipe exterior of stern drive unit clean and spray with Corrosion and Rust Preventive (C-92-29152-12). Also spray underside of unit in area around reverse locks. Store ster drive unit in the normal operating position. The universal joint bellows may develop a “set”, if unit is stored in a tited-up position, and result in bellows failure ‘when unitis returned to service. vaR1TILT PIN ADJUSTMENT MERCRUISER O-I and IL Holes are provided in the gimbal ring to permit changing location of tilt lock pin for proper adjustment of tilt angle. Tilt angle of stern drive unit on transom should be set so anti-cavitation plate (Figure 1) is about parallel with bottom ‘Of boat. Speed of boats, with conter of gravity located forward, sometimes may he improved by tilting unit out one pin hole. This will tend to raise bow and reduce wetted Surface. If unit is tilted in, hoat will ride with bow down, ‘wetting more of the bottom and reducing speed, but generally improving operation in rough water. Operation with excessive tilt out may induce cavitation or cause porpoising of the host It is, therefore, preferable to level boat by proper loading rather than by extreme adjustment of tilt angle. 173k ef oy GENERAL INFORMATION 18.15POWER TILT OPERATION The MerCruiser Full Power Tilt is actuated by switches ‘mounted in control panel. (Figure 2) Stem drive unit may be raised or lowered when engine is running or stopped. Remote control must be in nentral or forward gear position hefore raising drive unit. Key switch in control panel must be in “On position to raise or lower stern drive un MERCRUISER re rs ears Figure 2. Control Panel Switehes To raise drive unit, depress top of ro switch in. To lower drive unit, depr switch and hold switch in. Reverse lock hook release lever ‘must be in “Lock” position at all times when operating boat. ‘Tilt angle adjustment stud may be positioned in gimbal ring holes, as required, for proper trim when underway. Reler to “Tilt Pin Adjustment”, preceding IMPORTANT: When drive unit reaches the limit of its upward and downward travel and stops moving, rocker switch should be released. Pump motor is equipped with an overload entout that will open and, thereby. stop pump motor if rocker switch remains depressed more than 10 seconds after drive unit reaches the end of its travel. If cextout should open, do not depress rocker switeh for one 1A:18-GENERAL INFORMATION ‘minute. After this period of tim unit may be operated. BOAT at REST Raising Drive Unit - Place remote control lever in neutral or forward position. Turn control panel key switch to “On” position Push top of rocker switch in and hold until drive unit has tilted up amount desired or reaches end of travel ‘Turn control panel key svriteh to “Off” position. Lowering Drive Unit ‘Turn control panel key switch to “On” postion, Push bottom of rocker switch in and hold until drive unit reaches end of travel and reverse lock hooks latch, 3. Turn control panel key switch to “OF” position IMPORTANT: Because of presence of the special alloy “trim-tab” at rear base of drive shaft housing, it is recommended that stem drive unit be left in operating position. If trim tab is out-of-water (as when tilted up) it ‘cannot function as a galvanie corrosion inhibitor. BOAT UNDERWAY Raising Drive Ui L. Place remote control lever is position (500-600 RPM). 2. Turn control panel key switeh to “On” position. 3. Push top of rocker switch in and hold until drive unit has tilted up amount desired. (Figure 1) weutral or forward gear idle NOTE: Tilt unit is intended for shallow weter operation at low throttle settings. Do not ran at high speed with drive unit tilted out beyond gimbal ring tlt pin flanges, as drive init has no side thrust support when tilted this high. While running, do not tilt unit so high that water intake holes in gear housing strut are lifted out of the water. This would result in overheating of the engine, as indicated by water temperature gauge on instrument panel. A water pressure gauge can be installed on the dash to give afasterindication of loss of water pressure from tilting too high. Serious engine damage may result from overheating. IMPORTANT: When operating boat with unit tilted up, it is nevessary that control panel key isleft in “On” position, Safety Lilt switch on stern drive unit will not function when control panel key switch is in “On” position and engine will not stop running when drive unit tts up, Lowering Drive Unit 1. Push bottom of rocker switeh in and hold until drive unit reaches end of travel and reverse lock hooks latch. (Figure » 2. Turn control panel key switeh to “Of” position. IMPORTANT: Be sure to turn key “Of” for normal operation so that safety tilt switch on stem drive unit will function and engine will stop if drive unit strikes an underwater abject. 173R1POWER TRIM OPERATION (Yellow-White-Green Buttons Panel) NOTE: Remote control lever must be in “Neutral” or “Forward” position when operating Power Trim. Power Trim is actuated by push buttor ‘control panel. TRIMMING BOAT L. Trimming Out: Press green “Out” button (Figure 3) until drive unit moves to properly trim boat. Cutout switch will stop drive unit from moving out beyond gimbal ring flanges. ‘Trimming In; Press white “In” button (Figure 3) until drive unit moves to properly trim boat or until drive reaches end of downward travel itches mounted in TRAILERING BOAT Raise drive unit for trailering or launching by placing remote control lever in “Neutral” or “Forward” and pressing yellow “{ip” button on control. (Figure 3) Push trim “In button to lower drive uni Meee spe enced > POWER TRIM OPERATION (Red-Red/Green-White Buttons Panel, Black Buttons Panel and Trim Switches Mounted in Remote Control) CAUTION: When using Power Trim om some boats, operation at extreme “in” or “Out™ positions greatly inereases steering torque, and steering becomes diff- cult. Stern drive unit should be trimmed to a safe ‘operating angle to provide easy steering. r. oe mm oasis Figure 4. Push Button Switches in Control Lever MerCruiser 215-225IE-TR and 2551-TR vart NOTE: For initial installation and adjustment of trim sender and gouge, refer to the appropriate drive in Section 6 Power ‘Trim is actuated by push button switches mounted in control lever (Figure 4) or in trim control panel (Figure 5). Red-Red/Green-White button panel operates the same and is the same clectrially as Black buttons panel shown in Figure 4. Operate Power Trim only in neutral or forward gear TRIMMING BOAT 1. Trimming Ont: Press “Up” button (Figure 4) until drive unit moves to properly trim boat. If control panel is used ¢ press “Lp/Out™ button. Cutout switch will Stop drive unit from moving out beyond flanges. Trinring In: Prose “In” button (Figure 4 or 5) until drive {nit moves to propedly trim boat or antl deve eaches end of doveniard travel imball ring TRAILERING BOAT 1. Control Lever: Raise drive unit for tralering or launching by placing remote control lever in "Neutral" or “Forward and pressing “Trailer” button on control. (Figure 4) Push GENERAL INFORMATION - 18.17trim “In” button on lever to lower drive unit. Control Panel: Raise drive unit for trailering or launching by shifting control to “Neutral” or “Forward” and presing “Up” and “Up/Out” buttons simultaneously. (Figure 5) Push trim “In” button to lower drive unit Raise or lower drive with these buttons for shallow water operation at reduced throttle CAUTION: Do not run at high speed with drive unit ‘out beyond gimbal ring flanges, as drive unit will have xo side thrust support. Exercise caution when operat- ing at extreme angles in shallow water. Figure 6. Indicator Readjustment NOTE: If button is held depressed after drive end of upward travel, an overload cutout switch will open and pump motor will stop. To prevent eutout from ‘opening, it is recommended that buttons) be released when drive unit reaches end of upward travel. If eutout should open, do not depress switches for approximately fone minute. After this period of time, extout will close and vnit may be operated. INDICATOR READJUSTMENT If unit was fully extended into the “Up” trailer position, it be necessary to reset the indieator by operating “In button. Hold until indicator needle (Figure 6) reaches hottom Figure 5. Black Buttons Trim Control Panet °°" of green are TAB. GENERAL INFORMATION 173R1