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

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

Thank you for purchasing one of our MerCruiser products. It incorporates numerous design features to assure operating ease and durability. 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. We suggest that this manual remain with the product for ready reference whenever you are on the water. We sincerely hope your boating will be pleasant! CONSUMER AFFAIRS DEPARTMENT 3 . The Operation and Maintenance Manual contains specific instructions for using and maintaining your product. we ask that you thoroughly read the Operation and Maintenance Manual which accompanies the product.

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

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. A lanyard stop switch can also be installed as an accessory. the boat will not complete a full circle. strong current or high winds. 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. 3. or not to use. or all. As we cannot possibly know of and advise the boating public of all conceivable boat/motor types and/or poor operating practices. the owner/driver. Loss of power and directional control in heavy seas. DISADVANTAGES: Inadvertent activation of the switch is also a possibility. 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. However. or daring. and highperformance boats. a boat can continue to coast for some distance depending upon the velocity and degree of any turn at shut-down.a particular concern in bow rider type boats. 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. This could cause any. use. 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. 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. While activation of the lanyard stop switch will result in immediate power shut-down. operating at high speeds in shallow or obstacle-infested waters. such a switch. it can cause injury to anyone in the boat’s path as seriously as the boat would when under power. 2. 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. high-speed boat maneuvers.CA280 Lanyard Stop Switch 2 1 74608 1 Some boats come equipped with a lanyard stop switch. ! WARNING The following advantages and disadvantages of a lanyard stop switch should be considered before electing to use. standing at planing speeds. releasing your grip on a steering wheel that is pulling in one direction. If for any reason it is desired to have a shorter functional lanyard. drinking and driving. Loss of balance and falling forward of unstable boat passengers . It is also likely as a result of poor operating practices such as sitting on the back of the seat at planing speeds. This type of accident is most likely in certain types of boats such as low-sided boats. Loss of control when docking. While the boat is coasting. the final decision of whether to use a lanyard stop switch rests with you. 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. 5 . of the following potentially hazardous situations: 1.

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

• Know your boating area and avoid hazardous locations. Seek further assistance from local law enforcement. ! WARNING Stop your engine immediately whenever anyone in the water is near your boat. • Watch fallen skiers. • Never drive your boat directly behind a water skier in case the skier falls. 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.” The operator must have an unobstructed view particularly to the front. As an example. No passengers. Serious injury to the person in the water is likely if contacted by a rotating propeller. or any solid device rigidly attached to a moving boat or gear case. or fishing seats should block the operators view when operating the boat above idle or planing transition speed. a moving gear case. obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-86168--3) from your dealer. 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.” the water and your wake. This neutral propeller rotation can cause serious injury. For additional information.• Never be under the influence of alcohol or drugs while boating (it is the law). a moving boat. The operator should always have the down skier in sight and never back up to the skier or anyone in the water. load. • Be alert. (2) there is personal injury requiring medical treatment beyond first aid. • Report accidents. 7 . (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. 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. 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. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. Whenever a boat is moving (coasting) and the drive unit is in neutral position. 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. Watch “the other guy. A boating accident must be reported if (1) there is loss of life or probable loss of life. always keep a fallen or down skier on the operator’s side of the boat while returning to attend the skier. The operator of the boat is responsible by law to “maintain a proper lookout by sight (and hearing).00 or (4) there is complete loss of the boat. or Mercury Marine. They impair your judgment and greatly reduce your ability to react quickly. distributor. When using your boat for water skiing or similar activities. 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.

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

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

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

or recreational power boats in non-revenue applications. • Light Duty 1.) Operated at rated power and rated speed for short periods of time. or boats with planing hulls where acceleration and top speed are of primary importance. will not be covered by the MerCruiser Diesel Limited Warranty. NOTE: Pleasure duty rating applies to high performance-type boats. 2. and limited season fishing boats such as sport-fish charter boats. IMPORTANT: Damage caused by improper application or failure to operate within the operational capability. dive boats. but are not limited to: search and rescue craft.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. Examples of Light Duty applications include. Light duty rating applies to planing boats where the use of full rated power at maximum rated RPM is limited (as stated above). fast patrol boats.) 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). as applicable to engine and installation: • Pleasure Duty 1. or duty cycle. 11 . fire boats. Application to common commercial crafts having full-displacement or semi-displacement hulls exceeds the recommended operational capability. or duty cycle. or duty cycle. This rating is reserved for privately-owned yachts.) Annual operating time is not to exceed 500 hours.

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

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

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

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

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

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

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

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

ISO 3046 (Technically Identical to ICOMIA 28-83). or 180 Ah 12v.8 .250° F ( 94° .99° C ) 12-volt Negative ( .4. 950 mca.11 in. 20 . Series 28MT ) 170° . (7.3L/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. in. 14.CD249 Engine DESCRIPTION Crankshaft Horsepower (Kilowatts) 1 SPECIFICATION .8 bar ( 276-482 kPa ) ] 200° .7 bar (69 kPa) ] Minimum 40-70 PSI [ 2.18 in. 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.MCM (Stern Drive) D7. 65A 750 cca.) Ground 949W.3L ) 1-2-7-3-4-5-6-8 4. 2.6v. ( 106.39 mm ) 4.210° F ( 77° . ( 104.4 kW 1 Power rated in accordance with NMMA Procedure .121° C ) 170° F ( 77° C ) 230° F ( 110° C ) Coolant Temperature Electrical System Alternator Rating Recommended Battery Rating Starter ( Delco.20 mm ) 19:1 Non-Adjustable (Hydraulic) 75 PSI ( 517 kPa ) 3475 ± 50 3400 675 ± 25 10 PSI [ 0.

Use of other coolant may cause fouling of the heat exchangers.CD194 Capacities NOTE: All measurements are given in US Quarts (Liters).9) 26 (24-1/2) Bravo Two Bravo Three use dipstick to determine exact quantity of oil or fluid required. 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. and overheating of the engine. 21 . and purified water.3L/270 12 (11-1/3) 10 (9-1/2) 1 (1) 1 (1) 3. CE20 Required Coolant: Quicksilver Premixed Marine Engine Coolant IMPORTANT: This contains special low silicate ethylene glycol. special additives.

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

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

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

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

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

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

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

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

CD199 2 3 1 73976 6 5 4 73977 30 .

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

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

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

Propane. 4 Check to ensure all instrumentation is functioning properly and indicating normal readings. 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). Priming Fuel System” and follow instructions given. 3 Turn key switch to START position. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage. Release key when engine starts and allow switch to return to RUN position. as indicated by your dealer. Refer to “Specifications . Refer to Maintenance Chart. • Be sure engine crankcase is filled to correct level with the proper grade of oil for the prevailing temperature. 3 If engine has not been run for a period of time and will not readily start with the standard starting procedure. Shifting and Stopping BEFORE STARTING THE ENGINE ! WARNING Do not use volatile starting aids. to avoid overheating the starter motor. such as Ether. 1 Check all items listed in the MAINTENANCE CHART AND OPERATION CHART (Refer to “Table Of Contents”). IMPORTANT: As an added precaution. 34 . wait 1 minute to allow the starter motor to cool.CE29 Starting. there is a hand pump/primer located on the engine to improve initial fuel supply. Within seconds after starting the engine. CE30 STARTING COLD ENGINE IMPORTANT: Always check all fluid levels before starting engine. locate and correct the problem. ! CAUTION Do not increase the engine speed until the oil pressure gauge indicates normal. • Never operate the starter motor longer than 15 seconds at a time. Observe preheat indicator (glow plug) lamp. If engine does not start. Or. or Gasoline in the engine air intake system. stop the engine. NOTE: Engine can be started once preheat indicator lamp goes out. repeat starting procedure. open engine hatch to air out bilge before attempting to start engine(s).Crankcase Oil”. 2 Perform any other necessary checks. Shut the engine down if oil pressure does not register on the gauge within 20 to 30 seconds after start. If the oil pressure does not meet these minimum limits. 1 Turn on and run engine compartment bilge blower (if so equipped) for five minutes. ! 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. or specified in your boat owner’s manual.Fuel System. then. Check to ensure charge indicator and oil pressure warning lamps go out. • Check the air cleaner for proper installation of filter element. • Be sure that all electrical connections are secure. Refer to “Maintenance . Lamp should be illuminated when engine is cold and will be off when preheat cycle is complete. 2 Turn key switch to RUN position. or see your Authorized MerCruiser Dealer if you are unable to determine the problem.

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

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

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 .

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

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

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

10 70550 . 4. 6 70571 71377 8.8 72522 9 .CD218 f a c b c 3.9 d e 70121 5 71930 71930 g 6 46 71930 7.

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

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

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

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

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

CD272 3 1 70558 73346 4 5 71346 71347 52 .

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

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.

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

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

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

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

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

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

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shift and throttle linkages. 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. observe the following: 2 Avoid any electrical interconnection between the MerCruiser Product. preferably after each use. Do not paint drain holes. especially steering system. as this will render them ineffective as galvanic corrosion inhibitors. should be kept well lubricated. or any other material that could conduct electrical current. anodes.CA168 In addition to the corrosion protection devices. can be used. 5 All lubrication points. IMPORTANT: If anti-fouling protection is required for boat hull or boat transom. 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. External power package components may also be sprayed. tin. copper or tin base paints. (40mm) UNPAINTED area on transom of the boat around these items. 63 . Anodic Blocks. or MerCathode System and the paint by allowing a minimum of 1-1/2 in. if not prohibited by law. 4 Spray power package components on inside of boat every 2-3 weeks with Quicksilver Corrosion Guard to protect finish from dulling and corrosion. If using copper or tin based anti-fouling paints. 6 Flush cooling system periodically. 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. MerCathode system. and items specified by boat manufacturer.

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

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

CD15 Miscellaneous Maintenance CD30 1 71088 2.3 71930 68 .

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

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

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

8 73254 71870 2.8 c 2.8 6 g 71362 72 .CD66 b a 2.8 71962 71930 7 71930 d e f 72186 4.8 71865 5.3.3.3.

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

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

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

• Have Authorized MerCruiser Dealer service electric stop-circuit. • Test. • Air in fuel injection system • Glow-plugs or glow-plug system inoperative • Purge fuel injection system. if fuel is present. Engine Will Not Start. • Position control lever in neutral. Fill with fresh fuel. • Check and reset circuit breaker or replace fuse. • Replace kinked lines or blow out lines with compressed air to remove obstruction. and repair or replace components 78 . • Have pump replaced by an Authorized MerCruiser Dealer. • 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. • Check throttle for freedom of movement. 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. Or Is Hard To Start Possible Cause • Improper starting procedure Remedy • Read starting procedure. Clean and tighten faulty connection. drain tank.CD49 Troubleshooting CD76 Starter Motor Will Not Crank Engine. • If contaminated. • Bad battery • Test and replace if bad. • Check all electrical connections and wires (especially battery cables). • Replace filters.

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

faulty fuel pump. Low Engine Oil Pressure Possible Cause • Insufficient oil in crankcase Remedy • Check and add oil. • Check and remove required amount of oil. • Clean exhaust elbow. and seawater strainer. 80 . • Excessive oil in crankcase (causing it to become aerated) • Diluted or improper viscosity oil • Change oil and oil filter. inspect and test pressure cap. Determine cause for dilution (excessive idling. • Remove obstruction. • Repair. • Replace hose with wire reinforced design. Check for cause of excessive oil (improper filling. • 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.). • Position hose to prevent kinking (restriction). Insufficient Engine Temperature Possible Cause • Faulty thermostats Remedy • Replace.Excessive Engine Temperature Possible Cause • Seacock closed. • Check for cause of low coolant level and repair. • Loss of pressure in closed cooling section • Check for leaks. • Replace and/or adjust belt. if so equipped Remedy • Open. etc. etc. using correct grade and viscosity oil. • Replace. bad fuel pump. Fill system with proper coolant solution. • 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. Clean.).

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

• Lubricate. • 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. 82 . Repair or replace wiring. Drain and replace. • Replace and/or adjust. • Check all parts and fasteners.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. see Authorized MerCruiser Dealer immediately. • Check for obstruction. If any are loose or • missing. • Check all associated electrical connections and wires (especially battery cables). • Lubricate. 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. Clean and tighten faulty connection.

Power Steering Fluid Cooler 8 .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 .Heat Exchanger (Seawater Circuit) 7 .Engine Oil Cooler 6 .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 .Seawater Outlet (Exhaust) 10.Seawater Pump 4 .Seawater Outlet (Thru-Gimbal Housing) ABCDEFGH- CLOSED COOLING CIRCUIT (COOLANT) Circulating Pump .Seawater Strainer 3 .Exhaust Pipe Water Jacket 9 .Seawater Inlet 2 .Aftercooler 5 .

Warm-Up Timing Advance Sender 17.Injection Pump 3 .Glow Plug (8 Total) 4 .Wires Connected Together (Sealed and Protected) 13. 8 ELECTRICAL BOX 74188 .Engine Oil Pressure Audio 13 Warning Switch 20.Battery NOTE: FOR CONNECTION ON MERCATHODE CONTROLLER.150 Amp Circuit Breaker 11 .Starter Slave Solenoid 9 .Tachometer Magnetic Pickup 14 16.Water-In-Fuel Sensor 8 .50 Amp Circuit Breaker 12.Harness Connectors 7 .Starter 6 .Engine Coolant Temperature 15 Audio Warning Switch 18.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 .Coolant Temp.Alternator 19.Trim Sender 15. 84 10 11 12 9 See NOTE.Drive Unit Oil Level 14.Oil Pressure Sender 5 .Glow Plug Controller 10. Sender 2 .

-Water In Fuel b.Audio Warning Buzzers 12.Light Switch and Audio Test 8 . Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection.-Alternator. 10 e.) NOTE 1: May be wired to any PPL (that is key switched). c.Keyswitch 9 . d.20-Amp Fuse and Holder 10. NOTE 2: Tape each wire separately with at least two layers of electrical tape. - 1 2 13 12 3 4 14 5 UP 6 a. a. b. 11 a 8 7 6 10 5 1 2 3 4 1 2 7 See NOTE 3.Cruise Log (Engine Hour Meter) (See Note 1. c.) 14.-Coolant Temperature.CD209 Quicksilver Instrumentation Wiring Diagram 1 2 3 4 5 6 Voltmeter Tachometer Coolant Temperature Oil Pressure Trim Gauge Engine System Monitor. e. 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 .-Oil Pressure d.-Preheat 7 .Wait-To-Start Relay 13. and BLK. NOTE 3: Connect Wires Together with Screw and Hew Nut.Wires Not Used (See Note 2.Water-In-Fuel Module 11.

CD210 MerCathode System Diagram a b c a .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 .Controller b .20 Amp Fuse c .

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 .

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

” IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. • A copy of the Warranty Registration Card.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. 89 . MUST be given to you immediately after the card has been completely filled out by the selling distributor/dealer. • The Warranty Registration Card identifies your name and address. • In some countries. 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. Ask your distributor/dealer if this plastic card program applies to you. 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. name and address. designated as the “Purchaser’s Copy”. you may discard the “Purchaser’s Copy” that you received from the distributor/dealer when you purchased the product.” Refer to “Table of Contents. date of sale. The distributor/dealer also certifies that you are the original purchaser and user of the product. It is our desire to have ALL products registered at the factory should it ever be necessary to contact you. product model and serial number(s). This card represents your factory registration identification. • For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing. and should be retained by you for future use when required Should you ever require warranty service on this product. refer to the “International Warranty. 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). type of use and the selling distributors/dealer’s code number.

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

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

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

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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.

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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

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

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

97 . contact the nearest Marine Power International Service Center for further information.CE199 Service Centers UNITED STATES MerCruiser 3003 N. When ordering be sure to: 1. (Sunset Dr. Check the literature and quantities you want.B. 1420. Ltd. Perkins Road Stillwater.O. Ontario L4Y 2C2 Canada Telephone (905) 270-4481 Fax (905) 270-4510 MEXICO.O. Wl 54936-1939 Outside the United States and Canada.Japan No. P. 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 .D. Parc Industriel de Petit-Rechain B-4822 Verviers Belgium Telephone (0) 87 / 32 • 32 • 11 Fax (32) (87) 31 • 19 • 65 AUSTRALIA. Inc. Box 1939 Fond du Lac.) Suite 100 Miami. 3.S. MIDDLE EAST. Telephone (305) 596-9606 Fax (305) 596-3869 EUROPE. OK 74075-2299 Telephone (405) 743-6566 Fax (405) 743-6570 CANADA Mercury Marine 1156 Dundas Highway East Mississauga. 2. 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. model. Enclose full remittance in check or money order (NO C. List your product.’s). FL 33173 U. CARIBBEAN Marine Power International 9350 SW 72nd St. PACIFIC Marine Power International Pty. SOUTH AMERICA. AFRICA Marine Power Europe. CENTRAL AMERICA.A. Ltd. year and serial number(s). 132-140 Frankston Road Dandenong. Victoria 3164 Australia Telephone (61) (3) 791-5822 Fax (61) (3) 791-5880 ASIA Marine Power International.

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.

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 . 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.Drive Parts DESCRIPTION Front Propeller Nut Rear Propeller Nut Propeller Nut Front Thrust Hub Rear Thrust Hub Thrust Hub D.S.H.H.

NH. ID. ME.shows the exploded view of the engine or stern drive with corresponding part number.up. WV. MI. HI. NV. OR. NY. 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.01 .00 Sub-Total Total Price * must be collected from customers in all states except: AK. MT. add $3.95 $5. DE. Parts Manual . Operation and maintenance manual (Owner’s Guide) .00 $30. Free Sales Tax * Ship/Hand** Grand Total 103 .01 .$50. add $4. AZ.00.CC178 LITERATURE ORDER FORM Model _______________ Horsepower______________Serial Number______________ Year_________ Service Manual .shows the complete assembly and disassembly of the engine or stern drive.00 $30.00 $4. WY ** Orders Totaling: up to $20.00 20.explains basic operation and maintenance.95 $4. Price Each $30. VT.00 50. IA.00.

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

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