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

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

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

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

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

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

” the water and your wake. 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. always keep a fallen or down skier on the operator’s side of the boat while returning to attend the skier. a moving boat. No passengers. Serious injury to the person in the water is likely if contacted by a rotating propeller. When using your boat for water skiing or similar activities. For additional information. 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. (2) there is personal injury requiring medical treatment beyond first aid. • Report accidents. 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. (3) there is damage to boats or other property where the damage value exceeds $500. or Mercury Marine. 7 . Seek further assistance from local law enforcement. A boating accident must be reported if (1) there is loss of life or probable loss of life.00 or (4) there is complete loss of the boat. • Watch fallen skiers. obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-86168--3) from your dealer. This neutral propeller rotation can cause serious injury. or fishing seats should block the operators view when operating the boat above idle or planing transition speed. 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. The operator should always have the down skier in sight and never back up to the skier or anyone in the water. load. a moving gear case. • Never drive your boat directly behind a water skier in case the skier falls. • Be alert. Watch “the other guy. there is sufficient force by the water on the propeller to cause the propeller to rotate.• Never be under the influence of alcohol or drugs while boating (it is the law). They impair your judgment and greatly reduce your ability to react quickly. • Know your boating area and avoid hazardous locations. ! WARNING Stop your engine immediately whenever anyone in the water is near your boat. 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. Whenever a boat is moving (coasting) and the drive unit is in neutral position. or any solid device rigidly attached to a moving boat or gear case. distributor. 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 operator of the boat is responsible by law to “maintain a proper lookout by sight (and hearing). As an example.” The operator must have an unobstructed view particularly to the front.

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

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

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

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

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

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

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

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

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

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

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

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

6v.MCM (Stern Drive) D7. 65A 750 cca.11 in.CD249 Engine DESCRIPTION Crankshaft Horsepower (Kilowatts) 1 SPECIFICATION .121° C ) 170° F ( 77° C ) 230° F ( 110° C ) Coolant Temperature Electrical System Alternator Rating Recommended Battery Rating Starter ( Delco.99° C ) 12-volt Negative ( . Series 28MT ) 170° . or 180 Ah 12v. in.8 bar ( 276-482 kPa ) ] 200° .3L ) 1-2-7-3-4-5-6-8 4. 14. 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.7 bar (69 kPa) ] Minimum 40-70 PSI [ 2.4 kW 1 Power rated in accordance with NMMA Procedure .) Ground 949W.210° F ( 77° .4. 20 . ( 106.20 mm ) 19:1 Non-Adjustable (Hydraulic) 75 PSI ( 517 kPa ) 3475 ± 50 3400 675 ± 25 10 PSI [ 0. 950 mca.8 .39 mm ) 4.3L/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.250° F ( 94° . 2.18 in. (7.ISO 3046 (Technically Identical to ICOMIA 28-83). ( 104.

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

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

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

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

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

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

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

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

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

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

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

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

Refer to “Specifications . or see your Authorized MerCruiser Dealer if you are unable to determine the problem.Crankcase Oil”. there is a hand pump/primer located on the engine to improve initial fuel supply. Shut the engine down if oil pressure does not register on the gauge within 20 to 30 seconds after start. Refer to “Maintenance . then. to avoid overheating the starter motor. 4 Check to ensure all instrumentation is functioning properly and indicating normal readings. ! 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. Priming Fuel System” and follow instructions given. If engine does not start. oil pressure should exceed 10 psi (69 kPa) minimum. CE30 STARTING COLD ENGINE IMPORTANT: Always check all fluid levels before starting engine. or Gasoline in the engine air intake system. wait 1 minute to allow the starter motor to cool. 1 Check all items listed in the MAINTENANCE CHART AND OPERATION CHART (Refer to “Table Of Contents”). If the oil pressure does not meet these minimum limits. • Check the air cleaner for proper installation of filter element. Within seconds after starting the engine. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage. stop the engine. or specified in your boat owner’s manual. 3 If engine has not been run for a period of time and will not readily start with the standard starting procedure. 1 Turn on and run engine compartment bilge blower (if so equipped) for five minutes. • Never operate the starter motor longer than 15 seconds at a time. Propane. such as Ether. as indicated by your dealer. NOTE: Engine can be started once preheat indicator lamp goes out. ! CAUTION Do not increase the engine speed until the oil pressure gauge indicates normal. 34 . 2 Perform any other necessary checks.Fuel System. Refer to Maintenance Chart. Lamp should be illuminated when engine is cold and will be off when preheat cycle is complete. Observe preheat indicator (glow plug) lamp. • Be sure engine crankcase is filled to correct level with the proper grade of oil for the prevailing temperature. • Be sure that all electrical connections are secure. Or. Check to ensure charge indicator and oil pressure warning lamps go out. IMPORTANT: As an added precaution. 2 Turn key switch to RUN position. Shifting and Stopping BEFORE STARTING THE ENGINE ! WARNING Do not use volatile starting aids. repeat starting procedure. 3 Turn key switch to START position.CE29 Starting. open engine hatch to air out bilge before attempting to start engine(s). Release key when engine starts and allow switch to return to RUN position. 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). locate and correct the problem.

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

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

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 .

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

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

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 .

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

CD218 f a c b c 3. 10 70550 .8 72522 9 .9 d e 70121 5 71930 71930 g 6 46 71930 7. 4. 6 70571 71377 8.

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

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

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

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

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

CD272 3 1 70558 73346 4 5 71346 71347 52 .

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

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.

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

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

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

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

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

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

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

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

CD15 Miscellaneous Maintenance CD30 1 71088 2.3 71930 68 .

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

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

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

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

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

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

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

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

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

Drain and replace. Clean and tighten faulty connection. 82 . • Replace and/or adjust. • Check for obstruction.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. • 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. • Lubricate. Repair or replace wiring. • Loose or missing steering fasteners or parts • Contaminated power steering fluid Power Trim Does Not Operate (Electric Motor Does Not Run) Possible Cause Remedy • Blown Fuse • Loose or dirty electrical connections or damaged wiring • Replace fuse. • Check all associated electrical connections and wires (especially battery cables). If any are loose or • missing. • Check all parts and fasteners. see Authorized MerCruiser Dealer immediately.

Seawater Outlet (Exhaust) 10.Exhaust Pipe Water Jacket 9 .Seawater Outlet (Thru-Gimbal Housing) ABCDEFGH- CLOSED COOLING CIRCUIT (COOLANT) Circulating Pump .Power Steering Fluid Cooler 8 .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 Pump 4 .Heat Exchanger (Seawater Circuit) 7 .Closed Coolant Exhaust Manifolds Engine Crankcase Cylinder Heads Turbocharger Thermostat Bypass Heat Exchanger (Closed Cooling Circuit) FLOW OF: a – Engine Air b – Engine Oil c – Power Steering Fluid 71875 83 .Seawater Strainer 3 .Engine Oil Cooler 6 .Aftercooler 5 .Seawater Inlet 2 .

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

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

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

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

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

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

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

CD268

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

92

CD61

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

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

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

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

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

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

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

93

CD62

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

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

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

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

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

94

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

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

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

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 .

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 D7.3L/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 .

S.Drive Parts DESCRIPTION Front Propeller Nut Rear Propeller Nut Propeller Nut Front Thrust Hub Rear Thrust Hub Thrust Hub D. Anodic Plate Anodic Plate (Front Propeller) Anodic Plate (Rear Propeller) Universal Anodic Plate Trim Cylinder Anodes Gimbal Housing Anode Bearing Carrier Anode Drain Screw Drain Screw O-Ring Vent Screw Vent Screw O-Ring Bell Housing to D.H.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 .H.

00.explains basic operation and maintenance. VT.95 $4. HI. Free Sales Tax * Ship/Hand** Grand Total 103 .00 $4. ME. Operation and maintenance manual (Owner’s Guide) .95 $5. DE.shows the exploded view of the engine or stern drive with corresponding part number.$50.00 $30.CC178 LITERATURE ORDER FORM Model _______________ Horsepower______________Serial Number______________ Year_________ Service Manual .00. NV. IA.00 Sub-Total Total Price * must be collected from customers in all states except: AK.00 20. MI. WV. WY ** Orders Totaling: up to $20. Parts Manual . Price Each $30. MT. 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 . OR.shows the complete assembly and disassembly of the engine or stern drive. NY.01 . add $4.up. NH. add $3.00 50. ID. AZ.00 $30.

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

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