OPERATION & MAINTENANCE MANUAL

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

CD1

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

Purchase Date Boat Model Length

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

8 1B
TYPE

SERIAL NUMBER

1A

2 3

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

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

1A

71936

1B

71935

BSO: M12 11 3 93 07

8

71930

4 5

ABC12345Z123

-19

48-12345

6
0

5

4

2,3

73929

CD275

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

1

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

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

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

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

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

The operator should always have the down skier in sight and never back up to the skier or anyone in the water.00 or (4) there is complete loss of the boat. load. No passengers. a moving boat. When using your boat for water skiing or similar activities. ! WARNING Stop your engine immediately whenever anyone in the water is near your boat. 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. • Know your boating area and avoid hazardous locations. CA283 High-Speed And High-Performance Boat Operation If your boat is considered a high-speed or high-performance boat with which you are unfamiliar. The operator of the boat is responsible by law to “maintain a proper lookout by sight (and hearing). or fishing seats should block the operators view when operating the boat above idle or planing transition speed. 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. 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. Whenever a boat is moving (coasting) and the drive unit is in neutral position. As an example. 7 . • Report accidents.” the water and your wake. 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. Watch “the other guy. For additional information. a moving gear case. Serious injury to the person in the water is likely if contacted by a rotating propeller. 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. • Never drive your boat directly behind a water skier in case the skier falls.” The operator must have an unobstructed view particularly to the front. • Be alert. obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-86168--3) from your dealer. or Mercury Marine. They impair your judgment and greatly reduce your ability to react quickly. This neutral propeller rotation can cause serious injury. A boating accident must be reported if (1) there is loss of life or probable loss of life. distributor. always keep a fallen or down skier on the operator’s side of the boat while returning to attend the skier. Seek further assistance from local law enforcement. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.• Never be under the influence of alcohol or drugs while boating (it is the law). • Watch fallen skiers. (3) there is damage to boats or other property where the damage value exceeds $500. or any solid device rigidly attached to a moving boat or gear case. there is sufficient force by the water on the propeller to cause the propeller to rotate. (2) there is personal injury requiring medical treatment beyond first aid.

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

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

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

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

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

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

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

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

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

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

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

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

( 104.210° F ( 77° . ( 106. or 180 Ah 12v.MCM (Stern Drive) D7. Series 28MT ) 170° . 20 .99° C ) 12-volt Negative ( . 2.7 bar (69 kPa) ] Minimum 40-70 PSI [ 2. 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.250° F ( 94° .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.4 kW 1 Power rated in accordance with NMMA Procedure . 950 mca.CD249 Engine DESCRIPTION Crankshaft Horsepower (Kilowatts) 1 SPECIFICATION .6v.121° C ) 170° F ( 77° C ) 230° F ( 110° C ) Coolant Temperature Electrical System Alternator Rating Recommended Battery Rating Starter ( Delco. in.3L ) 1-2-7-3-4-5-6-8 4.39 mm ) 4. (7.4. 14.8 bar ( 276-482 kPa ) ] 200° .18 in. 65A 750 cca.) Ground 949W.ISO 3046 (Technically Identical to ICOMIA 28-83).20 mm ) 19:1 Non-Adjustable (Hydraulic) 75 PSI ( 517 kPa ) 3475 ± 50 3400 675 ± 25 10 PSI [ 0.8 .11 in.

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. 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. special additives. 21 .3L/270 12 (11-1/3) 10 (9-1/2) 1 (1) 1 (1) 3.9) 26 (24-1/2) Bravo Two Bravo Three use dipstick to determine exact quantity of oil or fluid required.2 (3) 3 (2. Use of other coolant may cause fouling of the heat exchangers. and overheating of the engine. and purified water.

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

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

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

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

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

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

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

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

CD199 2 3 1 73976 6 5 4 73977 30 .

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

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

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

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

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

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

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 .

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

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

CD191

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

Change engine oil and filter.

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

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

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

Every 500 hours of operation

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

At least once yearly. Every 1000 hours of operation

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

41

CD33

b d

c a

3

71380

1,2

71771

4

71868

e

5
71930

70550

k

f i

l

J

71672

g
70979

h

6,7,8
42

70979

9 , 10

72187

CE44

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

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

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

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

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

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

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

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

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

43

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

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

CD218 f a c b c 3.8 72522 9 . 4.9 d e 70121 5 71930 71930 g 6 46 71930 7. 10 70550 . 6 70571 71377 8.

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

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

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

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

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

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

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

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

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

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

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

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

CD15 Miscellaneous Maintenance CD30 1 71088 2.3 71930 68 .

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

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

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

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

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

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

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

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

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

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

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

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

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

Coolant Temp.Drive Unit Oil Level 14.50 Amp Circuit Breaker 12.Warm-Up Timing Advance Sender 17.Injection Pump 3 .Wires Connected Together (Sealed and Protected) 13.Tachometer Magnetic Pickup 14 16.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 .Starter Slave Solenoid 9 . 8 ELECTRICAL BOX 74188 .Glow Plug Controller 10.Water-In-Fuel Sensor 8 . 84 10 11 12 9 See NOTE.Engine Coolant Temperature 15 Audio Warning Switch 18.Starter 6 .Trim Sender 15.Harness Connectors 7 .Engine Oil Pressure Audio 13 Warning Switch 20.Oil Pressure Sender 5 .Alternator 19.Glow Plug (8 Total) 4 .Battery NOTE: FOR CONNECTION ON MERCATHODE CONTROLLER.150 Amp Circuit Breaker 11 . Sender 2 .

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

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 .CD210 MerCathode System Diagram a b c a .

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

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

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

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

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

CD268

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

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CD61

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

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

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

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

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

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

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

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CD62

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

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

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

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

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

94

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

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

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

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

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

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

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