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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

39 mm ) 4. 65A 750 cca. 14.8 bar ( 276-482 kPa ) ] 200° .250° F ( 94° . ( 104.CD249 Engine DESCRIPTION Crankshaft Horsepower (Kilowatts) 1 SPECIFICATION .7 bar (69 kPa) ] Minimum 40-70 PSI [ 2.ISO 3046 (Technically Identical to ICOMIA 28-83).210° F ( 77° .3L/270 270 (201) 238 (177) Propeller Shaft Horsepower (Kilowatts) 1 Engine Type Displacement Firing Order Bore Stroke Compression Ratio Valve Clearance Maximum Pressure Difference Between Cyl. in.4 kW 1 Power rated in accordance with NMMA Procedure .99° C ) 12-volt Negative ( .3L ) 1-2-7-3-4-5-6-8 4.20 mm ) 19:1 Non-Adjustable (Hydraulic) 75 PSI ( 517 kPa ) 3475 ± 50 3400 675 ± 25 10 PSI [ 0.4.MCM (Stern Drive) D7. (7.18 in. Series 28MT ) 170° .11 in. or 180 Ah 12v.8 .6v. ( 106. 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.121° C ) 170° F ( 77° C ) 230° F ( 110° C ) Coolant Temperature Electrical System Alternator Rating Recommended Battery Rating Starter ( Delco.) Ground 949W. 950 mca. 20 . 2.

2 (3) 3 (2. and purified water.CD194 Capacities NOTE: All measurements are given in US Quarts (Liters). CE20 Required Coolant: Quicksilver Premixed Marine Engine Coolant IMPORTANT: This contains special low silicate ethylene glycol. Use of other coolant may cause fouling of the heat exchangers. 21 . special additives. and overheating of the engine. 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) D7.9) 26 (24-1/2) Bravo Two Bravo Three use dipstick to determine exact quantity of oil or fluid required.3L/270 12 (11-1/3) 10 (9-1/2) 1 (1) 1 (1) 3.

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

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

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

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

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

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

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

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

CD199 2 3 1 73976 6 5 4 73977 30 .

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

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

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

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

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

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

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 .

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

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

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 .

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

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

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

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

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

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

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

CD272 3 1 70558 73346 4 5 71346 71347 52 .

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

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.

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

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

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

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

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

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

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

CD202 1 71176 3 2 62 .

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

CD207 2 70561 5 7 72239 64 .

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

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

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

CD15 Miscellaneous Maintenance CD30 1 71088 2.3 71930 68 .

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

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

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

3.3.8 73254 71870 2.8 71865 5.8 c 2.8 71962 71930 7 71930 d e f 72186 4.CD66 b a 2.8 6 g 71362 72 .3.

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

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

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

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

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

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

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

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

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

• Replace and/or adjust. Repair or replace wiring. • Check all associated electrical connections and wires (especially battery cables). • Lubricate. Clean and tighten faulty connection. Power Trim Does Not Operate (Electric Motor Runs But Drive Unit Does Not Move) Possible Cause Remedy • Pump oil level low • Drive unit binding in gimbal ring • Fill pump with oil. 82 . • Lubricate. • Loose or missing steering fasteners or parts • Contaminated power steering fluid Power Trim Does Not Operate (Electric Motor Does Not Run) Possible Cause Remedy • Blown Fuse • Loose or dirty electrical connections or damaged wiring • Replace fuse. see Authorized MerCruiser Dealer immediately. If any are loose or • missing.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. • Check all parts and fasteners. Drain and replace. • Check for obstruction.

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

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 . 8 ELECTRICAL BOX 74188 .Alternator 19. 84 10 11 12 9 See NOTE.Injection Pump 3 .Harness Connectors 7 .Glow Plug (8 Total) 4 .Glow Plug Controller 10.Starter Slave Solenoid 9 .Battery NOTE: FOR CONNECTION ON MERCATHODE CONTROLLER.Oil Pressure Sender 5 .Coolant Temp.Wires Connected Together (Sealed and Protected) 13.Warm-Up Timing Advance Sender 17.Starter 6 .Drive Unit Oil Level 14. Sender 2 .Engine Oil Pressure Audio 13 Warning Switch 20.50 Amp Circuit Breaker 12.Engine Coolant Temperature 15 Audio Warning Switch 18.150 Amp Circuit Breaker 11 .Trim Sender 15.Tachometer Magnetic Pickup 14 16.

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

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

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

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

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

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

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

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

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

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

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

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 .

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

shows the complete assembly and disassembly of the engine or stern drive. ID. NV.01 . 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.00 $30.explains basic operation and maintenance.00.shows the exploded view of the engine or stern drive with corresponding part number.00 $30.00 Sub-Total Total Price * must be collected from customers in all states except: AK. add $3. Free Sales Tax * Ship/Hand** Grand Total 103 .01 . Parts Manual .00 50.00 $4. add $4. DE. IA.95 $4.CC178 LITERATURE ORDER FORM Model _______________ Horsepower______________Serial Number______________ Year_________ Service Manual .up.00.00 20.95 $5. WV. MI. MT.$50. ME. Price Each $30. NY. Operation and maintenance manual (Owner’s Guide) . NH. VT. AZ. HI. OR. WY ** Orders Totaling: up to $20.

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. Box 1939 Fond du Lac.O.) Personal Check Cashiers Check Money Order Month/Year Card Number Expiration Date Visa Master Card Signature Date ( ) Telephone Number 104 . P.Please Return with Payment to: Mercury Marine Attn: Publications Dept.D.