Important Information, Maintenance, and Troubleshooting

Maintenance
Important Information, Maintenance, and

Troubleshooting
1
C
Section 1C - Maintenance
Table of Contents
Engine and Tune‑Up Specifications.................................. 1C-3 Sterndrive Gear Lube...................................................... 1C-18
Notes on Engine Specifications..................................1C-3 Checking...................................................................1C-18
4.3 MPI ECT............................................................... 1C-3 Filling........................................................................ 1C-19
Fluid Specifications............................................................1C-3 Visual Inspections............................................................1C-19
Engine........................................................................ 1C-3 Battery...................................................................... 1C-19
Power‑Assisted Steering and Power Trim Fluids....... 1C-4 Instruments...............................................................1C-19
Maintenance Intervals........................................................1C-4 Remote Control........................................................ 1C-19
Maintenance Schedules.................................................... 1C-4 Electrical System...................................................... 1C-19
Routine Maintenance..................................................1C-4 Exhaust System........................................................1C-20
Scheduled Maintenance............................................. 1C-5 Seawater Pump........................................................ 1C-20
Engine Oil.......................................................................... 1C-6 Steering System Lubrication............................................1C-20
Checking and Filling the Engine Oil............................1C-6 Corrosion Prevention ...................................................... 1C-21
Changing the Engine Oil and Filter.............................1C-7 Maintaining Ground Circuit Continuity...................... 1C-21
Power Trim Fluid................................................................1C-9 MerCathode..............................................................1C-24
Checking.....................................................................1C-9 Power Package Exterior Surfaces............................1C-24
Filling........................................................................ 1C-10 Seawater System.............................................................1C-24
Changing.................................................................. 1C-10 Cleaning the Seawater Strainer, If Equipped........... 1C-24
Flame Arrestor................................................................. 1C-11 Checking the Seawater Pickups...............................1C-25
Exploded View..........................................................1C-11 Draining the Seawater System........................................ 1C-25
IAC Muffler.......................................................................1C-11 Drain System Identification.......................................1C-26
Removal................................................................... 1C-11 Air Actuated Single‑Point Drain System................... 1C-27
Cleaning and Inspection........................................... 1C-12 Manual Single‑Point Drain System...........................1C-30
Installation................................................................ 1C-12 Manual Single‑Point Drain System with Plug........... 1C-31
Serpentine Drive Belt.......................................................1C-13 Three‑Point Manual Drain System........................... 1C-32
Sterndrive Models.....................................................1C-13 Flushing the Power Package (Alpha).............................. 1C-34
Closed‑Cooling System................................................... 1C-15 Flushing Attachments............................................... 1C-34
Checking Coolant Level............................................1C-15 Sterndrive Water Pickups......................................... 1C-34
Cleaning and Inspection........................................... 1C-16 Flushing the Power Package (Bravo).............................. 1C-35
Changing Coolant.....................................................1C-16 Flushing the Power Package....................................1C-35
Power‑Assisted Steering Fluid.........................................1C-16 SeaCore Power Package Flushing Procedure......... 1C-38
Changing.................................................................. 1C-18 Cold Weather or Extended Storage.................................1C-41
Compact Hydraulic Steering............................................ 1C-18 Preparing the Power Package for Storage............... 1C-42
System Check.......................................................... 1C-18 Power Package Recommissioning.................................. 1C-43
90-8M0041669 JANUARY 2014 Page 1C-1

Maintenance
Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
Extreme Grease Driveshaft U-joints and the tailstock input and output bearings 8M0071842
Quickstor Fuel Stabilizer Fuel system Obtain Locally
High Performance Gear
87 Gear lube monitor 92-858064K01
Lubricant
Steering cable grease fitting
95 2-4-C with PTFE 92-802859A 1
Exposed part of the steering cable
Power Trim and Steering Power trim pump
114 92-858074K01
Fluid Power-assisted steering system
Premium Plus 2-cycle TC-
115 Fuel system 92-858026K01
W3 Outboard Oil
120 Corrosion Guard Painted surfaces 92-802878 55
Extended Life Antifreeze/
122 Closed-cooling system 92-877770K1
Coolant
124 Quickstor Fuel Stabilizer Fuel system 92-8M0047932
Mercury 25W-40 Synthetic Oil filter sealing ring
139 92-8M0078629
Blend 4-Stroke Engine Oil All MerCruiser engines
Special Tools
Belt Tension Gauge SPX BT‑33‑73‑F
Measures serpentine belt deflection.
39451
Reference Electrode 91‑76675T 1
Senses and electrical current in the water when testing the MerCathode system.
Use to check hull potential.
9188
Flushing Device 91‑44357Q 2
Attaches to the water intakes; provides a water connection when flushing the
cooling system or operating the engine.
9192
Page 1C-2 90-8M0041669 JANUARY 2014

Maintenance
Dual Water Pick‑up Flush Gearcase Seal

91‑881150K 1
Kit
Blocks off the front water inlet holes on the dual water inlet gearcases.
9194
Engine and Tune‑Up Specifications

Notes on Engine Specifications
• Performance specifications are obtained and corrected in accordance with SAE J1228 (crankshaft power) and ISO 8665
(standard power).
• All measurements are taken with the engine at normal operating temperature.
• RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures.
• Oil pressure must be checked with the engine at normal operating temperature.
• Oil pressure specifications are for reference and may vary.
IMPORTANT: Do not mix spark plug types in an engine. All spark plugs should have the same part number.
4.3 MPI ECT

Crankshaft power 164 kW (220 hp)
Displacement 4.3 L (262 cid)
Hot 72 A
Alternator amperage
Cold 65 A
WOT 4400–4800
Rev limiter 4950
RPM
Idle in neutral 625 (not adjustable)
Idle in gear 650 (not adjustable)
At 2000 RPM 124 kPa (18 psi)
Minimum oil pressure
At idle 41 kPa (6 psi)
Seawater‑cooled models 60° C (140° F)
Thermostat
Models with closed cooling 77° C (170° F)
Timing at idle Not adjustable
Firing order 1‑6‑5‑4‑3‑2
Minimum battery rating 750 CCA, 950 MCA, 180 Ah
AC Platinum (AC 41‑993)
OEM
Spark plug type AC Platinum (AC 41‑101)
Service part NGK ITR4A15
Spark plug gap 1.5 mm (0.060 in.)
Emission control system Electronic control (PCM09), heated oxygen sensor (HO2S), catalyst
Fluid Specifications
Engine
IMPORTANT: It may be necessary to adjust the oil levels depending on the installation angle of the engine and the type of
cooling system (the heat exchanger and the fluid lines) on the engine.
NOTE: Measure the oil level with the boat in the water.
90-8M0041669 JANUARY 2014 Page 1C-3

Maintenance
NOTE: All capacities listed are approximate fluid measures.
Description Capacity Fluid Type

Engine oil (with filter) 3.3 L (3.5 US qt) Mercury 25W‑40 Synthetic Blend 4‑Stroke Engine Oil
Seawater‑cooling system
20 L (21 US qt) Propylene glycol and purified water
(winterization use only)
Mercury Extended Life Coolant/Antifreeze or extended‑life ethylene glycol
Closed‑cooling system 17.8 L (18.8 US qt)
5/100 coolant/antifreeze mixed 50/50 with purified water
Power‑Assisted Steering and Power Trim Fluids

Approved Power-Assisted Steering Fluids
Description Part Number
Power Trim and Steering Fluid 92‑858074K01
Approved Power Trim Fluids

Power Trim and Steering Fluid 92‑858074K01
SAE Engine Oil 10W‑30
Obtain locally
SAE Engine Oil 10W‑40
Maintenance Intervals
Maintenance intervals and the corresponding tasks to be performed, as shown in this schedule, are based on an average
boating application and environment. However, individual operating habits and personal maintenance preferences can have an
impact on the suggested intervals. Therefore, it is important that the boat owner and the servicing dealer discuss the
maintenance schedule and develop appropriate maintenance intervals to coincide with individual operating habits, the
environment, and maintenance requirements.
Maintenance Schedules
Routine Maintenance
IMPORTANT: Refer to the appropriate sterndrive service manual for the sterndrive maintenance schedule.
NOTE: Only perform maintenance that applies to your particular power package.
Task Interval Maintenance to Be Performed Procedure

Check the engine oil level. (This interval may be extended based
Checking and Filling the Engine Oil
on experience with the product.)
Check the sterndrive gear lube level. Sterndrive Gear Lube ‑ Checking
Each day start Check the trim pump oil level. Power Trim Fluid ‑ Checking
Check the power‑assisted steering pump or the compact
Power‑Assisted Steering Fluid
hydraulic steering fluid level, depending on the steering system of
Compact Hydraulic Steering
your model.
Flushing the Power Package
If operating in saltwater, brackish water, or polluted water, flush (Alpha)
Each day end
the seawater section of the cooling system. Flushing the Power Package
(Bravo)
Check the water inlets for debris or marine growth. Checking the Seawater Pickups
Cleaning the Seawater Strainer, If
Check and clean the seawater strainer, if equipped.
Equipped
Weekly
On models with closed‑cooling, check the coolant level. Checking Coolant Level
Inspect the sterndrive anodes and replace any that are eroded Refer to the appropriate sterndrive
50% or more. service manual.
Page 1C-4 90-8M0041669 JANUARY 2014

Maintenance

Remove the propeller, lubricate the propeller shaft, and torque the
Refer to the appropriate sterndrive
nut. (If operating only in freshwater, this interval can be extended
service manual.
to every four months.)
If operating in saltwater, brackish water, or polluted water, apply
Every 2 months or Power Package Exterior Surfaces
Corrosion Guard to the power package.
50 hours of operation
Check the battery connections and condition. Visual Inspections ‑ Battery
Ensure that the gauges and the wiring connections are secure.
Clean the gauges. (If operating in saltwater, reduce this interval to Visual Inspections ‑ Instruments
every 25 hours or 30 days, whichever occurs first.)
Scheduled Maintenance
NOTE: Only perform maintenance that applies to your particular power package.

After the initial 20‑hour
Change the engine oil and filter. Changing the Engine Oil and Filter
break‑in period
Every 50 hours or 2
Bravo models operated at idle for prolonged periods of time:
months (whichever Refer to the Bravo service manual.
Lubricate the engine coupler.
occurs first)
Touch‑up the paint on the power package. Power Package Exterior Surfaces
Change the engine oil and filter. Changing the Engine Oil and Filter
Models with closed cooling: Check the coolant level and Checking Coolant Level
antifreeze concentration for adequate freeze protection. Section 6C ‑ Testing Coolant for
Correct if necessary. Alkalinity
Tighten the connection of the gimbal ring to the steering shaft
to specifications. Refer to the appropriate sterndrive
service manual.
Change the sterndrive gear lube.
Section 5B ‑ Water‑Separating Fuel
Replace the water‑separating fuel filter.
Filter
Check the steering system and the remote control for loose,
Every 100 hours or Visual Inspections ‑ Remote Control
missing, or damaged parts. Lubricate the cables and the
annually Steering System Lubrication
linkages.
(whichever occurs first)
Maintaining Ground Circuit
Check the continuity circuit for loose or damaged connections.
Continuity
Test the MerCathode unit output if equipped.
MerCathode
Clean the flame arrestor, IAC muffler, and the crankcase Flame Arrestor
ventilation hoses. IAC Muffler
Inspect the condition and the tension of the belts. Serpentine Drive Belt
Driveshaft extension models: Lubricate the driveshaft U‑joints
Use Extreme Grease.
and the tailstock input and output bearings.
Beginning 100 hours or 1 year after a satisfactory inspection
per instructions found in Every 300 hours or 3 years, inspect Visual Inspections ‑ Electrical
the condition of the spark plugs, spark plug wires, and the System
distributor cap and rotor. Replace as necessary.
Every 150 hours of
Bravo models: Lubricate the engine coupler. (Lubricate every
operation or annually Refer to the Bravo service manual.
50 hours if operated at idle for prolonged periods.)
(whichever occurs first)
90-8M0041669 JANUARY 2014 Page 1C-5

Maintenance

Check the engine mounts and tighten to specification if Section 2B ‑ Engine Installation and
necessary. Alignment
Check the electrical system for loose, damaged, or corroded
–
fasteners.
Inspect the condition of the spark plugs, spark plug wires, and
the distributor cap and rotor, if equipped. Replace as
Visual Inspections ‑ Electrical
necessary. If the condition of these components is satisfactory
System
at inspection, repeat the inspection every 100 hours or once a
year, whichever occurs first.
Check the cooling system and the exhaust system hose
clamps for tightness. Inspect both systems for damage or –
leaks.
Disassemble and inspect the seawater pump and replace worn
Visual Inspections ‑ Seawater Pump
components.
Every 300 hours or 3 Section 6C ‑ Heat Exchanger

years Models with closed cooling: Clean the seawater section of the Assembly
heat exchanger; clean, inspect, and test the pressure cap. Section 6C ‑ Pressure Cap
Maintenance and Testing
Inspect the exhaust system components.
If the package was equipped with water shutters (flapper Visual Inspections ‑ Exhaust System
valves), verify that they are not missing or worn.
Section 2B ‑ Engine Installation and
Check the engine alignment.
Alignment
Inspect the U‑joints, splines, and bellows, and check the
clamps.
Lubricate the U‑joint splines and cross bearing, if equipped
with a grease fitting. Refer to the appropriate sterndrive
service manual.
Inspect the gimbal bearing for roughness. Replace if
necessary.
Alpha models: Lubricate the engine coupler.
Replace the coolant/anitifreeze. Replace every two years if not
Every 5 years Changing Coolant
using extended‑life coolant/antifreeze.

Extreme Grease Driveshaft U-joints and the tailstock input and output bearings 8M0071842
Engine Oil
Checking and Filling the Engine Oil
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.
Oil Level—Overfilled
An overfilled crankcase (oil level too high) can cause a fluctuation or drop in oil pressure, and rocker arm clatter. This condition
results in the engine crankshaft splashing and agitating the oil, causing it to foam (become aerated). The aerated oil causes the
hydraulic valve lifters to bleed down. This, in turn, results in rocker arm clatter and loss of engine performance, due to the
valves not opening properly.
Care must be taken when checking the engine oil level. The oil level must be maintained between the minimum and maximum
marks on the dipstick. To avoid getting a false reading, adhere to the following procedures.
Page 1C-6 90-8M0041669 JANUARY 2014

Maintenance
Checking
1. Stop the engine. Allow approximately five minutes for the oil to drain into the oil pan. The boat must be at rest in the water.
2. Remove the dipstick. Wipe the oil from the dipstick.
NOTE: Ensure that the dipstick is installed with oil level indication marks facing the rear of the engine (flywheel end).
3. Install the dipstick fully into the dipstick tube. Wait one minute to allow trapped air to vent.
a - Engine oil dipstick handle

b - Maximum oil level mark
a c - Minimum oil level mark
53993
4. Remove the dipstick and observe the oil level. The oil level must be no higher than the maximum oil level mark and no
lower than the minimum oil level mark.
5. If the oil level is low, refer to Filling.
6. Install the dipstick into the dipstick tube.
Filling
IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid required.
1. Remove the oil fill cap from the oil fill tube.
45310
IMPORTANT: Do not overfill the engine with oil.

2. Add the specified engine oil to bring the level up to, but not over, the maximum fill line on the dipstick.
Engine Oil Capacity Fluid type

3.3 L (3.5 US qt) Mercury 25W‑40 Synthetic Blend 4‑Stroke Engine Oil
NOTE: The volume from the minimum to the maximum fill line is 0.60 L (0.63 US qt).
3. Confirm that the engine oil level is now up to, but not over, the maximum fill line on the dipstick.
4. Install the oil fill cap.
Changing the Engine Oil and Filter

Refer to the maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage.
90-8M0041669 JANUARY 2014 Page 1C-7

Maintenance
IMPORTANT: Change the engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more
impurities. Use only recommended engine oil (refer to Specifications).
Draining Using a Crankcase Oil Pump

1. Loosen the oil filter to vent the system.
2. Remove the dipstick.
3. Tighten the oil pump threaded fitting onto the dipstick tube threaded fitting.
a b a - Typical oil pump

b - Oil drain hose
c - Dipstick tube
c
52338
4. Insert the end of the hose on the oil pump into an appropriate container and, using the handle, pump until the crankcase is
empty.
5. Remove the pump.
6. Install the dipstick.
Changing the Oil Filter

1. Remove and discard the oil filter.
45311
Engine oil filter
2. Using a clean, lint‑free cloth, wipe the old oil and debris from the filter mounting flange.
3. Apply clean engine oil to the sealing ring on the new filter.

Mercury 25W-40
139 Synthetic Blend 4-Stroke Oil filter sealing ring 92-8M0078629
Engine Oil
4. Install the oil filter. Tighten the filter securely following the filter manufacturer's instructions. Do not overtighten.
Page 1C-8 90-8M0041669 JANUARY 2014

Maintenance
5. Remove the oil fill cap.
45310
Oil fill cap

IMPORTANT: Always use the dipstick to determine exactly how much oil is required.
6. Add the specified engine oil to bring the level up to the minimum oil fill mark on the dipstick.

Mercury 25W-40
139 Synthetic Blend 4-Stroke All MerCruiser engines 92-8M0078629
Engine Oil
7. With the boat at rest in the water, remove the dipstick and check the oil level. Add the specified engine oil to bring the level
up to, but not over, the maximum oil fill mark on the dipstick.
NOTE: Adding 0.60 L (0.63 US qt) of engine oil will raise the level from the minimum oil fill mark to the maximum oil fill
mark.
8. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine immediately if leaks exist. Check
the installation.
9. Allow approximately five minutes for the oil to drain into the oil pan.
10. With the boat at rest in the water, remove the dipstick and check the oil level.
Power Trim Fluid

Checking
IMPORTANT: Check the fluid level with the sterndrive unit in the full down (in) position only.
1. Place the sterndrive unit in full down (in) position.
2. Observe the fluid level. The fluid level must be between the "MIN" and "MAX" lines on the reservoir.
a b
7876
a - Reservoir
b - "MIN" and "MAX" lines
3. Fill as necessary with the specified fluid. Refer to Filling.
90-8M0041669 JANUARY 2014 Page 1C-9

Maintenance

Power Trim and Steering
114 Power trim pump 92-858074K01
Fluid
Filling
1. If the fluid level is below the "MIN" line, the specified fluid must be added.
2. Remove the fill cap from the reservoir.
NOTE: The fill cap is vented.
b Power trim pump reservoir shows the oil level is below

a
the "MIN" line
a - Fill cap assembly
b - Fill cap installed
50212
3. Add the specified fluid until the fluid level is between the "MIN" and "MAX" lines on the reservoir.
a b
7876
a - Reservoir
b - "MIN" and "MAX" lines

114 Power trim pump 92-858074K01
Fluid
4. Install the fill cap.
Changing
Power trim fluid does not require changing unless it becomes contaminated with water or debris.
1. Remove the contaminated power trim fluid from the power trim pump reservoir.
2. Fill the power trim pump reservoir to the proper level with the appropriate power trim fluid. Refer to Filling.
3. Raise and lower the sterndrive 6–10 times to cycle the power trim fluid, and to purge contaminants from the system.
4. Repeat the above process until the power trim fluid is no longer contaminated.
Page 1C-10 90-8M0041669 JANUARY 2014

Maintenance
Flame Arrestor
Exploded View
a- Breather tubing
b- Engine cover
c- M6 nut (3)
d- Cover mount bracket
c e- Flame‑arrestor‑bracket‑to‑oil‑fill‑tube screw
f- Flame arrestor
b d g- Special stud (3)
e
a
52507
Removal
1. Remove the engine cover.
2. Remove the breather tubing from the fitting on the flame arrestor.
3. Remove the three M6 nuts that secure the flame arrestor to the special studs.
4. Remove the flame‑arrestor‑bracket‑to‑oil‑fill‑tube screw, and remove the flame arrestor bracket.
5. Remove the flame arrestor from the throttle body and the special studs.
Cleaning and Inspection

1. Clean the flame arrestor with warm water and a mild detergent. Allow the flame arrestor to air dry completely before use.
2. Inspect the flame arrestor for holes, cracks, or deterioration. Replace if necessary.
3. Clean the breather tubing with warm water and a mild detergent. Dry with compressed air or allow to air dry completely.
4. Inspect the breather tubing for cracks or deterioration. Replace if necessary.
Installation
1. Slide the flame arrestor onto the throttle body and the three special studs.
2. Position the flame arrestor bracket over the flame arrestor and secure it to the oil fill tube with the
flame‑arrestor‑bracket‑to‑oil‑fill‑tube screw. Tighten the screw to the specified torque.
Description Nm lb‑in. lb‑ft

Flame‑arrestor‑bracket‑to‑oil‑fill‑tube screw 2.8 25 –
3. Secure the flame arrestor bracket to the three special studs with three M6 nuts. Tighten the nuts to the specified torque.

M6 nuts 2.8 25 –
4. Attach the breather tubing to the flame arrestor.
5. Attach the engine cover.
IAC Muffler
Removal
NOTE: On all ECT models, except models equipped with DTS, the IAC is located on the outside of the throttle body utilizing an
adapter manifold. Models equipped with DTS do not have a separate IAC valve and muffler.
1. Remove the engine cover.
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Maintenance
2. Locate the IAC adapter manifold and muffler.
b IAC muffler in adapter manifold—typical engine

a a - IAC muffler
b - Adapter manifold
39411
3. Remove the IAC muffler from the slot in the adapter using needle‑nose pliers. Note the orientation of the muffler in the slot.
IAC muffler in adapter

b
manifold—typical
engine
a - IAC muffler
b - Adapter slot
49071

1. Inspect the IAC muffler for holes, cracks, or deterioration. Replace if damaged
2. Clean the muffler with warm water and mild detergent. Replace if necessary.
3. Allow the muffler to air dry completely before use.
Installation
1. Using needle‑nose pliers, insert the IAC muffler in the slot of the adapter at the same orientation as noted during removal.
IAC muffler in adapter manifold—typical

a engine
a - Needle‑nose pliers
b - IAC muffler in adapter slot
b
49089
Page 1C-12 90-8M0041669 JANUARY 2014

Maintenance
2. To avoid unwanted noise (whistle‑sounds), ensure that no gaps exist between the muffler and any openings in the
housing's air intake.
d a- IAC muffler
b- Housing
c c- No gap—vertically
d- No gap—horizontally
49070
3. Install the engine cover.
Serpentine Drive Belt

! WARNING
Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition
key before adjusting tension or inspecting belts.
IMPORTANT: The brackets and washers on the three idler pulleys must be in a certain order or the serpentine belt will come
off. All pulleys are referenced as though you were standing in front of the engine looking at the belt.
Sterndrive Models
d a d a
b b
a
f f
6117
c
c
e 6116
With a seawater pump Without a seawater pump

a - Idler pulley
b - Water circulating pump pulley
c - Crankshaft pulley
d - Alternator pulley
e - Seawater pump pulley
f - Power steering pump pulley
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Maintenance
Second Engine on a Dual Engine Installation
a a
b b
c c
a
d d
50286
e 50285
With a seawater pump and without a power steering pump Without a seawater pump and without a power steering pump
a - Idler pulley
b - Alternator pulley
c - Water circulating pump pulley
d - Crankshaft pulley
e - Seawater pump pulley
Checking
Inspect the drive belt for the following:
• Excessive wear
• Cracks
NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt
length) that join transverse cracks are NOT acceptable.
mc75130-1
• Fraying
• Glazed surfaces
• Proper tension—13 mm (1/2 in.) deflection, with moderate thumb pressure, on the belt at the location that has the longest
distance between two pulleys
Replacing Belt or Adjusting Tension

IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as before.
NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys.
1. Loosen the 16 mm (5/8 in.) locking nut on the adjustment stud.
2. Turn the adjustment stud and loosen the belt.
3. If a new serpentine drive belt is required, remove the old belt, and install a new belt onto the pulleys.
4. Put a wrench on the adjustment stud 16 mm (5/8 in.) locking nut.
5. Use an 8 mm (5/16 in.) socket and tighten the adjusting stud to adjust the belt deflection.
6. Using one of the two methods following, check for correct deflection.
a. Push down with moderate thumb pressure on the longest stretch of belt. Proper deflection is 13 mm (1/2 in.).
Page 1C-14 90-8M0041669 JANUARY 2014

Maintenance
b. Attach the belt tension gauge to the belt. The gauge has different ranges for new and used belts.
a - Serpentine belt
a b - SPX belt tension gauge
49019

7. While holding the adjustment stud at the correct belt tension, tighten the 16 mm (5/8 in.) locking nut.
a - 8 mm (5/16 in.) adjusting stud

a
b - 16 mm (5/8 in.) locking nut
b
49020

Locking nut 29 22
8. Operate the engine for a short period of time and recheck the belt adjustment.
Closed‑Cooling System
Checking Coolant Level
! CAUTION
A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow
the engine to cool down before removing the coolant pressure cap.
1. Remove the cap from the heat exchanger and observe the fluid level.
2. The coolant level in the heat exchanger should be at the bottom of the filler neck.
IMPORTANT: When reinstalling the pressure cap, tighten it until it seats on the filler neck.
3. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle.
4. The coolant level should be between the "ADD" and "FULL" marks.
6102
90-8M0041669 JANUARY 2014 Page 1C-15

Maintenance
5. Add the specified fluid as necessary.

Extended Life Antifreeze/
122 Closed-cooling system 92-877770K1
Coolant

NOTE: Refer to Section 6C.
1. Ensure that all hose clamps are tight and connections are secure.
2. Inspect the entire system for damage or leaks.
3. Clean the seawater section.
4. Clean, inspect and test the pressure cap.
Changing Coolant
The coolant should be changed periodically based on the use of the specified coolant; refer to the Maintenance Schedules for
the interval. For the coolant changing procedures, refer to Section 6C.
Power‑Assisted Steering Fluid

Checking
Engine at Normal Operating Temperature
1. Stop the engine.
2. Center the sterndrive.
3. Remove the fill cap/dipstick from the power‑assisted steering pump and note the fluid level.
a - Fill cap/dipstick
a
a b - Power‑assisted steering pump
b
48953
4. The fluid level should be between the "HOT" mark and the "ADD" mark on the dipstick.
b c a - "ADD" mark
a b - "HOT" mark
c - "FULL COLD" mark
48955
5. If the fluid level is below the "ADD" mark, but fluid is still visible in the pump reservoir, add the required amount of specified
fluid through the fill cap opening to bring the level up to the "HOT" mark on the dipstick. Do not overfill.

114 Power-assisted steering system 92-858074K01
Fluid
6. If fluid is not visible in the reservoir, a leak exists in the power‑assisted steering system. Find the cause and correct.
Page 1C-16 90-8M0041669 JANUARY 2014

Maintenance
Engine Cold
1. With the engine stopped, center the sterndrive.
2. Remove the fill cap/dipstick from the power‑assisted steering pump and note the fluid level.
3. The fluid level should be between the "FULL COLD" mark and the bottom of the dipstick.
b c a - "ADD" mark
a b - "HOT" mark
48955
4. If the fluid level is below the bottom of the dipstick, but fluid is still visible in the pump reservoir, add the required amount of
specified fluid through the fill cap opening to bring the level up to the "FULL COLD" mark on the dipstick. Do not overfill.
5. If fluid is not visible in the reservoir, a leak exists in the power‑assisted steering system. Find the cause and correct it.
Filling and Bleeding

IMPORTANT: The power‑assisted steering system must be filled exactly as explained to ensure that all air is bled from the
system. All air must be removed or fluid in the pump may foam during operation and be discharged from the pump reservoir.
Foamy fluid may also cause the power‑assisted steering system to become spongy, which may result in poor boat control.
1. With the engine stopped, center the sterndrive.
2. Remove the fill cap/dipstick from the power‑assisted steering pump.
IMPORTANT: Use only specified fluid in the power‑assisted steering system.
3. Add the specified fluid, as required, to bring the level up to the appropriate mark on the dipstick depending on the fluid
temperature.

114 Power-assisted steering system 92-858074K01
Fluid
4. Turn the steering wheel back and forth to the end of travel in each direction several times.
5. Recheck the fluid level and add fluid, if necessary.
6. Install the fill cap/dipstick. Tighten securely.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
7. Supply cooling water to the engine.
8. Start the engine and operate at fast idle (1300 RPM) until the engine reaches normal operating temperature. During this
time, turn the steering wheel back and forth to the end of travel in each direction several times.
9. Center the sterndrive and stop the engine.
10. Remove the fill cap/dipstick from the pump.
11. Allow any foam in the pump reservoir to disperse.
12. Check the fluid level and add fluid, as required, to bring the level up to the "HOT" mark on the dipstick. Do not overfill.
b c a - "ADD" mark
a b - "HOT" mark
48955
90-8M0041669 JANUARY 2014 Page 1C-17

Maintenance
13. Reinstall the fill cap/dipstick. Tighten securely.

IMPORTANT: The drive unit must be centered and the power‑assisted steering fluid must be hot to accurately check the
fluid level.
14. If the fluid is still foamy (in step 10), repeat steps 7–13 until the fluid does not foam and the level remains constant.
Changing
Power‑assisted steering fluid does not require changing unless it becomes contaminated. Refer to Section 8A ‑
Power‑Assisted Steering Pump and Related Components.
Compact Hydraulic Steering

Complete instructions are listed in Section 8B ‑ Compact Hydraulic Steering.
! WARNING
Failure to fill the system properly can damage steering components, causing serious injury or death from loss of boat control.
Completely retract the cylinder rod before checking or adding hydraulic fluid.
Setting the Fluid Level

The system must be filled and purged as outlined in Section 8B ‑ Compact Hydraulic Steering before setting the fluid level.
1. Ensure that the cylinder rod is fully retracted.
2. With the filler tube screwed into the helm filler plug hole, fill the tube approximately half full of air‑free hydraulic fluid.
3. Open the starboard bleeder valve and slowly turn the steering wheel clockwise until the fluid level in the filler tube is at the
top of the plastic filler fitting. Continue turning steering wheel clockwise ¼ turn more, and then stop. Close the bleeder
valve.
4. Remove the filler tube. The fluid level should be at the bottom of the filler hole. Install the vent/fill plug.
Maintaining the Fluid Level

To maintain proper fluid level, observe the following:
• Do not allow the fluid level to drop more than 6 mm (1/4 in.) below the bottom of the filler hole.
• Check the fluid level periodically.
System Check
After filling, purging, and setting the fluid level the system must be checked for proper connections, possible leaks, and
complete purging of air.
IMPORTANT: In the following procedure, turn the wheel with enough force to exceed the pressure relief valve in the helm. This
action should not harm the helm or the system.
1. Turn the steering wheel (any wheel on a multi‑steering station) very hard to port to pressurize the system.
2. While maintaining pressure, check all port fittings and hose connections. Ensure that there are no leaks. If leaks are
present, correct them before using.
3. Turn steering wheel (any wheel on multi‑steering station) very hard to starboard to pressurize system.
4. While maintaining pressure, check all starboard fittings and hose connections. Ensure that there are no leaks. If leaks are
present, correct them before using.
NOTE: Observing a significant drop in the fluid level at the helm while performing the system check may mean you are
compressing air. Further filling and purging would be required.
5. If no leaks are present, the system is ready for service.
Sterndrive Gear Lube

Checking
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.
NOTE: The oil level fluctuates during operation, so check with the engine cold before starting.
1. Check the gear lube oil level. Keep the oil level within the recommended operating range.
Page 1C-18 90-8M0041669 JANUARY 2014

Maintenance
2. Inspect the gear lube oil in the monitor for any condition that may indicate a problem in the sterndrive. Some conditions that
indicate a problem are:
a. Water is visible at the bottom of the gear lube monitor.
b. The gear lube appears milky.
c. The gear lube smells burned and looks dark.
d. Metal particles are present in the gear lube.
43200
Gear lube monitor
Filling
New installations may require as much as 470 mL (16 fl oz) of gear lube added to the monitor bottle during the break‑in period
(20 hours of running time). It is important to monitor and maintain the gear lube level during the break‑in period.
NOTE: If filling the entire sterndrive, refer to the appropriate sterndrive service manual.
1. Remove the gear lube monitor cap.
2. Fill the monitor with high performance gear lubricant until the fluid level is in the operating range. Do not overfill.

High Performance Gear
87 Gear lube monitor 92-858064K01
Lubricant
3. Replace the cap.
Visual Inspections
Battery
NOTE: Refer to the manufacturer's instructions.
1. Ensure that the battery connections are secure.
2. Check the fluid level.
Instruments
1. Ensure that all gauges are properly secured. Tighten the mounting bracket nuts, if they are loose. Do not overtighten.
2. Ensure that all gauge and wiring connections are tight and insulated where necessary.
IMPORTANT: The gauge may be scored or damaged if wiped with abrasive material such as sand, saline or detergent
compounds or washed with solvents such as trichloroethylene and turpentine.
3. Clean the gauges with fresh water to remove sand and salt deposits. Wipe with a soft cloth moistened with water.
Remote Control
1. Inspect the remote controls.
2. Ensure that there are no loose, missing, or damaged components.
3. Repair or replace, as necessary.
Electrical System
NOTE: Refer to Section 4 for specific procedures.
1. Inspect the spark plugs.
90-8M0041669 JANUARY 2014 Page 1C-19

Maintenance
2. Inspect the spark plug wires.
3. Inspect the distributor cap.
4. Inspect the entire electrical system for loose, damaged, or corroded fasteners.
5. Repair or replace as necessary.
Exhaust System
NOTE: Refer to Section 7.
1. Ensure that all hose clamps are tight and connections are secure.
2. Inspect the entire system for damage or leaks.
3. Repair or replace as necessary.
Seawater Pump
NOTE: Refer to Section 6A.
Inspect the seawater pump components. Replace as necessary.
Steering System Lubrication

! WARNING
Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely
retract the end of the steering cable before applying lubricant.
Lubricate the steering system as follows.

1. If the steering cable has a grease fitting:
a. Turn the steering wheel until the steering cable is fully retracted into the cable housing.
b. Apply approximately three pumps of grease from a typical hand‑operated grease gun to the steering cable grease
fitting.
a - Steering cable grease fitting
6221

95 2-4-C with PTFE Steering cable grease fitting 92-802859A 1
NOTE: If the steering cable does not have a grease fitting, the cable's inner wire cannot be greased.
Page 1C-20 90-8M0041669 JANUARY 2014

Maintenance
2. Turn the steering wheel until the steering cable is fully extended. Lightly lubricate the exposed part of the cable with 2‑4‑C.
a - Extended steering cable
6222

95 2-4-C with PTFE Exposed part of the steering cable 92-802859A 1
3. Lubricate the steering system pivot points with clean engine oil.
a - Steering system pivot points
mc71904-1
4. On dual‑engine boats: Lubricate the tie bar pivot points with clean engine oil.
5. Upon first starting the engine and before getting underway, turn the steering wheel several times to starboard and then to
port to ensure that the steering system operates properly.
Corrosion Prevention
Refer to the Mercury Precision Parts / Marine Corrosion Protection Guide (90‑881813003).
Maintaining Ground Circuit Continuity

The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the
engine, transom assembly, and sterndrive components. Good continuity is essential for the anode and the MerCathode system
to function effectively.
Inspect all ground circuit components for loose connections and broken or fraying wires.
90-8M0041669 JANUARY 2014 Page 1C-21

Maintenance
Models equipped with a separate ground wire must have the wire connected between the engine flywheel housing and the
transom plate.
a - Engine flywheel housing bolt

b b - Ground wire
a c - Inner transom plate grounding screw
c 7007
Models equipped with a transom harness must connect its ground wire to the grounding screw on the gimbal housing.
a b a - Gimbal housing grounding screw

b - Transom harness ground wire to
engine harness
c - Transom plate grounding stud and nut
d - Grounding wire gimbal housing to
transom plate
d
c
37462
a b a - Steering lever
b - Torx® screw
c - Continuity wire
50215
Page 1C-22 90-8M0041669 JANUARY 2014

Maintenance
a b c Bravo model shown, Alpha similar

a - Trim‑cylinder‑to‑gimbal‑ring
ground wire (2)
b - Gimbal‑housing‑to‑gimbal‑ring
ground wire
c - Gimbal‑ring‑to‑bell‑housing
ground wire
d - Screw
d
50216
a b c a - MerCathode
b - Continuity washers
c - Hydraulic manifold
b 50217
c b
37513 37632
Bravo sterndrive shown, Alpha sterndrive similar Ground washer shown inside anode cavity
a - Sterndrive of Bravo Three gear housing, other models
b - Ground washer similar
c - Ground plate (later model)
90-8M0041669 JANUARY 2014 Page 1C-23

Maintenance
a b c
50218
a - U‑joint bellows ground clip

b - Exhaust bellows ground clip
c - Exhaust tube ground clip
MerCathode
If the boat is equipped with a MerCathode system, the system should be tested to ensure that it is providing adequate output to
protect the underwater metal parts on the boat. The test should be made with the boat moored, using a reference electrode and
test meter.
Reference Electrode 91‑76675T 1
Refer to the appropriate Mercury MerCruiser sterndrive service manual for testing procedures.
Power Package Exterior Surfaces

1. Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for
proper application.

120 Corrosion Guard Painted surfaces 92-802878 55
2. Clean the entire power package. External surfaces that have become bare should be repainted with the recommended
primer and spray paint at recommended intervals.

Mercury Light Gray Primer 92‑802878 52
Painted surfaces
Mercury Phantom Black 92‑802878Q 1
Seawater System
Cleaning the Seawater Strainer, If Equipped
NOTICE
An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat,
causing damage or sinking the boat. Always close the water supply from the seawater pump, water inlet, or seacock when
performing service or maintenance on the cooling system.
1. With the engine off, close the seacock, if equipped, or remove and plug the seawater inlet hose.
2. Remove the screws, washers, and cover.
3. Remove the strainer, drain plug, and sealing washer.
4. Clean all the debris from the strainer housing. Flush both the strainer and housing with clean water.
5. Check the cover gasket and replace when damaged or if it leaks.
6. Reinstall the strainer, drain plug, and sealing washer.
! CAUTION
Seawater leaking from the seawater strainer could cause excess water in the bilge, damaging the engine or causing the boat
to sink. Do not overtighten the cover screws, or the cover may warp and introduce seawater into the bilge.
Page 1C-24 90-8M0041669 JANUARY 2014

Maintenance
7. Install the seal and cover using the screws and washers. Do not overtighten the cover screws.
a a- Screws and washers

b- Cover with glass
c- Strainer
b d- Housing
f e- Drain plug and sealing washer
f- Seal
d
e
12863
8. Open the seacock, if equipped, or remove the plug and reconnect the seawater inlet hose.
9. Upon first starting the engine, check for leaks or air in the system that would indicate an external leak.
Checking the Seawater Pickups

Ensure that the water inlet holes for the seawater pickup are clean and unobstructed.
a
a
16776
Typical through-the-hull seawater pickup Typical through-the-transom seawater pickup

a - Water inlet holes
Draining the Seawater System

! CAUTION
Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat
from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational
before draining. Do not operate the engine with the drain system open.
IMPORTANT: Only drain the seawater section of the closed cooling system.
IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system.
Your power package is equipped with a drain system. Refer to Drain System Identification to determine which instructions
apply to your power package.
IMPORTANT: The engine must not be operating at any point during the draining procedure.
90-8M0041669 JANUARY 2014 Page 1C-25

Maintenance
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used
in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure that the propylene glycol
antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol
manufacturer's recommendations.
Drain System Identification

Air Actuated Single-Point Drain System
c d Models with closed cooling
a - Heat exchanger
b b - Blue drain plug
c - Air pump
d - Air manifold
b 54110
Manual Single-Point Drain System
a b a
54111 54112
a - Blue drain plug (vent) a - Blue drain plug

b - Blue handle b - Drain
Manual Single-Point Drain System with Plug
54480
Blue drain plug
Page 1C-26 90-8M0041669 JANUARY 2014

Maintenance
Three-Point Manual Drain System
a - Blue drain plug (3)
a
a 6126
Air Actuated Single‑Point Drain System

Boat in the Water
NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used.
1. Close the seacock (if equipped) or remove and plug the water inlet hose.
2. Remove the air pump from the engine.
3. Ensure that the lever on top of the pump is flush with the handle (horizontal).
4. Install the air pump on the actuator fitting.
5. Pull the lever on the air pump (vertical) to lock the pump on the fitting.
6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side
will begin draining before the starboard side.
c e Air manifold and pump

a - Actuator fitting
b - Green indicators
c - Manual release valve
d - Air pump
a e - Lever (locking)
d
8293
b
90-8M0041669 JANUARY 2014 Page 1C-27

Maintenance
7. Immediately remove the blue drain plug from the heat exchanger. This must be removed within 30 seconds to properly
vent the cooling system.
c d a- Heat exchanger
b- Blue drain plug
b c- Air pump
d- Air manifold
b 54110
8. Verify that water is draining from each opening. If not, use the Three‑Point Manual Drain System instructions.
a - Port side drain location

b - Starboard side drain location
b 6133
9. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.
10. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do not allow the
engine to start.
11. Reinstall the blue drain plug in the heat exchanger.
12. Remove the air pump from the air manifold and return it to the mounting bracket.
NOTE: Mercury recommends leaving the drain system open while transporting the boat or while performing other
maintenance. This helps ensure that all water is drained.
13. Before launching the boat, pull on the manual release valve. Verify that the green indicators are no longer extended.
a - Green indicators
a
6135
14. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Page 1C-28 90-8M0041669 JANUARY 2014

Maintenance
Boat Out of the Water

NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used.
1. Place the boat on a level surface to ensure complete draining of the system.
2. Remove the air pump from the engine.
3. Ensure that the lever on top of the pump is flush with the handle (horizontal).
4. Install the air pump on the actuator fitting.
5. Pull the lever on the air pump (vertical) to lock the pump on the fitting.
6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side
will begin draining before the starboard side.
c e a- Actuator fitting
b- Green indicators
c- Manual release valve
d- Air pump
e- Lever (locking)
a
d
8293
b
7. Verify that water is draining from each opening. If not, use the Three‑Point Manual Drain System instructions.
a - Port side drain location

b - Starboard side drain location
b 6133
8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.
9. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do not allow the
engine to start.
10. Remove the air pump from the air manifold and return it to the mounting bracket.
NOTE: Mercury recommends leaving the drain system open while transporting the boat or while performing other
maintenance. This helps ensure that all water is drained.
90-8M0041669 JANUARY 2014 Page 1C-29

Maintenance
11. Before launching the boat, pull the manual release valve on the air manifold. Verify that the green indicators are no longer
extended.
a - Green indicators
a
6135
Manual Single‑Point Drain System

Boat in the Water
2. Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that
the drain system is open. Do not force the handle as this will create new threads.
3. Immediately remove the blue drain plug from the thermostat housing. This must be removed within 30 seconds to properly
vent the cooling system.
a - Blue drain plug (vent)

b - Blue handle
a b
54111
4. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and
drain it manually.
a - Blue drain plug

b - Drain
a
54112
5. Allow the system to drain for a minimum of five minutes. We recommend leaving the drain system open while transporting
the boat or performing other maintenance.
6. Reinstall the blue drain plug in the thermostat housing.
7. Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug, if removed. The
handle is fully seated when no red is visible. Do not overtighten the handle, as this action will create new threads.
8. Open the seacock (if equipped) or unplug and reconnect the water inlet hose before operating the engine.
Page 1C-30 90-8M0041669 JANUARY 2014

Maintenance

2. Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that
the drain system is open. Do not overtighten the handle, as this action will create new threads.
a - Blue handle
6141
3. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and
drain manually.
a - Blue drain plug

b - Drain
a
54112
4. Allow the system to drain for a minimum of five minutes. We recommend leaving the plugs out while transporting the boat
or performing other maintenance to ensure that all water is drained.
5. Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug, if removed. The
handle is fully seated when no red is visible. Do not overtighten the handle, as this action will create new threads.
Manual Single‑Point Drain System with Plug

Boat in the Water
2. Remove the blue drain plug from the drain fitting (lower front, port side).
54480
Blue drain plug
90-8M0041669 JANUARY 2014 Page 1C-31

Maintenance
3. To properly vent the cooling system, remove the blue drain plug from the thermostat housing within 30 seconds.
a - Blue drain plug
50336
4. Verify that water is draining.
the boat or performing other maintenance to ensure that all water is drained.
6. Before launching the boat or starting the engine, close the drain system by installing the two blue drain plugs.

2. Remove the blue drain plug.
54480
Blue drain plug
3. Verify that water is draining from the opening.

5. Before launching the boat or starting the engine, close the drain system by installing the blue drain plug.
Three‑Point Manual Drain System

Boat in the Water
NOTE: Use this procedure if your engine is not equipped with an air actuated single‑point drain system or if the air actuated
single‑point drain system fails.
2. Remove the blue drain plug from the distribution housing (lower front, port side).
a - Blue drain plug

b - Drain
a
54112
Page 1C-32 90-8M0041669 JANUARY 2014

Maintenance
3. To properly vent the cooling system, remove the blue drain plug from the thermostat housing within 30 seconds.
a - Blue drain plug
50336
4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).
a - Blue drain plugs (2)
a 6140
5. Verify that water is draining from each opening.

7. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow
the engine to start.
8. Before launching the boat or starting the engine, close the drain system by installing the four blue drain plugs.

NOTE: Use this procedure if your engine is not equipped with an air actuated single‑point drain system or if the air actuated
single‑point drain system fails.
2. Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup
pump (front, starboard side).
a a
6142
a - Blue drain plug (3)
3. Verify that water is draining from each opening.

5. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow
the engine to start.
90-8M0041669 JANUARY 2014 Page 1C-33

Maintenance
6. Before launching the boat or starting the engine, close the drain system by installing the three blue drain plugs.
Flushing the Power Package (Alpha)

Your boat comes equipped with through‑the‑sterndrive water pickups. Refer to Sterndrive Water Pickups for the flushing
procedure.
IMPORTANT: Alpha engines that have the sterndrive water inlet blocked off at the gimbal housing and use a through‑the‑hull
water inlet need a supply of cooling water available to both the sterndrive and the engine during operation.
Flushing Attachments
Sterndrive Water Pickups

This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment.
49818
Side pickup
NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications. Flushing is recommended after
each outing for best results.
NOTICE
Flushing the engine with the boat in the water can cause seawater to flow into the engine, resulting in engine damage. Close
the seacock before flushing the engine. Keep the seacock closed until starting the engine.
1. On seawater cooled models: Proceed to step 5 or step 6.

NOTE: Models with closed cooling are equipped with a heat exchanger on the engine.
2. If flushing the cooling system with the boat in the water:
a. Raise the sterndrive to trailer position.
b. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
a a - Flushing attachment
b - Hose connector
21515
c. Lower the sterndrive to the full down/in position.
3. If flushing the cooling system with the boat out of the water:
Page 1C-34 90-8M0041669 JANUARY 2014

Maintenance
a. Lower the sterndrive to the full down/in position.
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the
engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
b. Remove the propeller.
c. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
a a - Flushing attachment
b - Hose connector
21515
4. Connect the hose between the flushing attachment and the water source.
5. With the sterndrive in the normal operating position, open the water source completely.
6. Place the remote control in the neutral idle speed position and start the engine.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat
the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.
7. Press the throttle‑only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
8. Observe the water temperature gauge to ensure that the engine is operating in the normal range.
9. Operate the engine with the sterndrive in neutral for about 10 minutes or until the discharge water is clear.
10. Slowly return the throttle to the idle speed position.
11. Stop the engine.
12. Shut off the water and remove the hose and flushing attachment.
13. If the boat is to be stored in the water: After the flush procedure is completed, remove the seawater inlet hose from the
thermostat housing and plug the hose to prevent water from siphoning into the boat. This prevents seawater from
contaminating the engine flush.
14. Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating the
engine.
Flushing the Power Package (Bravo)

Flushing the Power Package
The boat can be equipped with a combination of any of three different types of water pickups: through‑the‑hull,
through‑the‑transom, and through‑the‑sterndrive. The flushing procedures for these systems are separated into two categories:
sterndrive water pickups and alternative water pickups.
IMPORTANT: Engines that require dual water pickups require a through‑the‑hull or through‑the‑transom pickup in addition to
the sterndrive water inlets.
IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through‑the‑hull or
through‑the‑transom pickup need a supply of cooling water available to both the sterndrive and to the engine during operation.
90-8M0041669 JANUARY 2014 Page 1C-35

Maintenance
Flushing Attachments
a a
b b
c
21514 21515
Flushing attachments for dual water pickup Flushing attachments for side water pickup
a - Flushing device
b - Hose attachment
c - Dual water pickup flush gearcase seal kit

Dual Water Pick‑up Flush Gearcase Seal
91‑881150K 1
Kit
Sterndrive Water Pickups

There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water and side water pickups. Dual
water pickups require the flushing device and the flush gearcase seal kit. Side water pickups require the flushing device.
5752
5773
Dual water pickup Side water pickup
NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after
NOTICE
Flushing the engine with the boat in the water can cause seawater to flow into the engine, resulting in engine damage. Close
the seacock before flushing the engine. Keep the seacock closed until starting the engine.
1. On models with the sterndrive seawater inlet blocked, supply water to the sterndrive and to the engine. Refer to
Alternative Water Pickups.
Page 1C-36 90-8M0041669 JANUARY 2014

Maintenance
2. On models using the sterndrive seawater inlet and a through‑the‑hull or through‑the‑transom alternative water pickup,
supply water to only the sterndrive by taking the following steps to block, or disconnect and block, the hose from the
alternative seawater pickup pump inlet Y‑fitting.
a. If equipped with a seacock, close the seacock in the hose from the alternative water pickup.
b. If not equipped with a seacock, disconnect the hose from the alternative water pickup and plug both ends.
c. If there is not a hose running to the transom, refer to Alternative Water Pickups.
3. On models using the sterndrive water pickups for water supply: proceed to step 4 or step 5.
a. Raise the sterndrive to trailer position.
c. Lower sterndrive to full down (in) position.
a. Lower the sterndrive to full down (in) position.
! WARNING
b. Remove propeller.
6. Connect hose between flushing attachment and water source.
7. With the sterndrive in normal operating position, fully open the water source.
8. Place the remote control in the neutral idle speed position and start the engine.
NOTICE
9. Press the throttle‑only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
11. Operate the engine with the sterndrive in neutral for about 10 minutes or until the discharge water is clear.
12. Slowly return the throttle to idle speed position.
14. Shut off the water and remove the flushing attachment.
15. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the
engine.
16. Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating the
engine.
Alternative Water Pickups

IMPORTANT: Two water sources are needed for this procedure.
NOTE: Flushing is needed only for salty, brackish, mineral‑laden or polluted water applications. Flushing is recommended after
IMPORTANT: Models with the sterndrive water inlet blocked off at the gimbal housing and using a through‑hull water inlet need
a supply of cooling water available to both the sterndrive and to the engine during operation.
a. Raise the sterndrive to the trailer position.
c. Lower the sterndrive unit to the full down (in) position.
a. Lower the sterndrive to the full down (in) position.
90-8M0041669 JANUARY 2014 Page 1C-37

Maintenance
! WARNING
b. Remove the propeller. Refer to the appropriate sterndrive service manual for details.
3. Connect a hose between the flushing attachment and a water source.
4. Close the seacock, if equipped, to prevent water from siphoning into the engine or boat.
5. Remove the seawater inlet hose from the seawater pump at the location shown. Plug the hose to prevent water from
siphoning into the engine or boat.
33208
Seawater inlet hose connection
6. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.
NOTICE
7. With the sterndrive in normal operating position, open the water source fully.
8. Place the remote control in neutral idle speed position and start engine.
NOTICE
9. Slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
11. Operate the engine with the sterndrive in neutral for about 10 minutes or until discharge water is clear.
12. Slowly return the throttle to the idle speed position.
14. Shut off the water and remove the flushing attachments.
15. If the boat is out of the water, install the water inlet hose to the aft side of the seawater pump. Tighten the hose clamp
securely.
16. If the boat is in the water, tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be
reconnected prior to operating the engine.
SeaCore Power Package Flushing Procedure

NOTE: Flushing is needed only for salt, brackish, mineral‑laden or polluted water applications. Flushing is recommended after
Page 1C-38 90-8M0041669 JANUARY 2014

Maintenance
IMPORTANT: Flushing the SeaCore power package with the boat and sterndrive in the water is less effective. Flushing the
SeaCore power package is most effective when performed with the boat and sterndrive out of the water, such as on a boat lift
or trailer.
Models Using the Sterndrive Water Pickup

IMPORTANT: The system is designed to flush the Bravo sterndrive and the engine with one water source. Do not block or
remove the inlet water hose from the sterndrive to the engine.
NOTE: Engines with the sterndrive water inlet blocked off at the gimbal housing: refer to Alternative Water Pickups.
! WARNING
IMPORTANT: Do not allow the engine to pull air or seawater from alternative water pickup sources during the flushing
procedure. If equipped, ensure that all alternative water inlet hoses are plugged at both ends.
1. Remove the boat from the water.
2. Close the seacock, if equipped.
For visual clarity, the seacock shown is not installed

c a - Hose fitting to engine
b - Seacock
c - Handle (closed position)
d - To water source pickup attachment
a b d
18510
3. If equipped with an alternative water pickup and not equipped with a seacock, disconnect the water hose from the
alternative water pickup and plug both ends, excluding the Bravo sterndrive.
4. Ensure that the inlet water hose from the sterndrive to the engine is connected.
5. Remove the quick‑connect fitting from the parts bag supplied with the engine.
6. Attach the quick‑connect fitting to a water hose.
a a - Quick connect fitting (water hose end)

b
b - Water hose
18487
90-8M0041669 JANUARY 2014 Page 1C-39

Maintenance
7. Snap the quick‑connect fitting with the water hose into the flush socket on the engine.
a - Water hose
b - Quick‑connect fitting (water hose end)
a
c - Flush socket
18489
8. Open the water source of the water hose to a full flow.

9. Allow the water to flush the sterndrive for 30 seconds.
10. Place the remote control in neutral idle speed position and start the engine.
NOTICE
11. Operate the engine at idle speed in neutral gear. Do not exceed 1200 RPM.
12. Monitor the engine temperature while operating the engine.
13. Flush the engine for 5 to 10 minutes or until discharge water is clear.
14. Shut off the engine.
15. Allow the water to flush the sterndrive for 10 seconds.
16. Turn off the water source.
17. Disconnect the quick‑connect fitting and water hose from the flush socket on the engine by pressing the release button on
the flush socket.
a - Quick‑connect fitting (water hose end)

a b - Flush socket release button
18488
Page 1C-40 90-8M0041669 JANUARY 2014

Maintenance
18. Remove the quick‑connect fitting from the water hose.
a a - Quick‑connect fitting (water hose end)

b
b - Water hose
18487
19. Retain the quick‑connect fitting with the water hose end for repeated use by storing it separately in a storage compartment
on the boat for easy access.
IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater
pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not
covered by Mercury MerCruiser Warranty.
a Quick-connect fitting stored in the boat

a - Quick‑connect fitting (water hose end)
25900
20. Insert the dust cover in the flush socket on the engine.
a Dust cover installed in the flush socket

a - Dust cover
b - Flush socket
b
18490
IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If unit is to be
stored out of the water, open the seacock.
21. Open the seacock, if equipped, or reconnect the alternative water inlet source prior to operating the engine.
Cold Weather or Extended Storage

IMPORTANT: Mercury MerCruiser strongly recommends that this service be performed by an authorized Mercury MerCruiser
dealer. Damage caused by freezing temperatures is not covered by the Mercury MerCruiser Limited Warranty.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open
the seacock or unplug and reconnect the water inlet hose before starting the engine.
90-8M0041669 JANUARY 2014 Page 1C-41

Maintenance
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used
in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure that the propylene glycol
antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol
manufacturer's recommendations.
Preparing the Power Package for Storage

1. Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount of Mercury Quickstor Fuel
Stabilizer to treat the gasoline. Follow the instructions on the container.

124 Quickstor Fuel Stabilizer Fuel system 92-8M0047932
2. If the boat is to be placed in storage with fuel containing alcohol in the fuel tanks (if fuel without alcohol is not available):
drain the fuel tanks as low as possible and add Mercury Quickstor Fuel Stabilizer to any fuel remaining in the tank. Refer to
Section 1A ‑ Fuel Requirements for additional information.
3. Flush the seawater‑cooling system. Refer to Flushing the Power Package (Alpha) or Flushing the Power Package
(Bravo).
IMPORTANT: In order to run the engine as required in the remainder of the storage preparation procedure, water must be
supplied to the engine as described in the flushing procedure.
4. Provide sufficient cooling water to the engine as in the previous step.
5. Operate the engine sufficiently to bring it up to normal operating temperature and allow fuel with Mercury Quickstor Fuel
Stabilizer to circulate through the fuel system.
6. Shut off the engine.
7. Change the oil and oil filter.
8. Prepare the engine and fuel system for storage. Refer to Engine and Fuel System Preparation.
9. Drain the engine seawater‑cooling system. Refer to Draining the Seawater System.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
10. Sterndrive models: Ensure that the sterndrive vent holes, water drain holes, and passages are unobstructed and open.
11. For additional assurance against freezing and rust, after draining, fill the seawater‑cooling system with propylene glycol
mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during
freezing temperatures or extended storage.
NOTICE
The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when
returned to service and allowing water to enter the boat. Store the sterndrive in the full down position.
12. Sterndrive models: Store the boat with the drive unit in the full down/in position.
13. Store the battery according to the manufacturer's instructions.
Engine and Fuel System Preparation
! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire
or explosion. Always ventilate the engine compartment before servicing the power package.
1. In a 23 L (6 US gal) remote fuel tank mix:

a. 19 L (5 US gal) Regular unleaded 87 octane (90 RON) gasoline
Page 1C-42 90-8M0041669 JANUARY 2014

Maintenance
b. 1.89 L (2 US qts) Premium Plus 2‑Cycle TC‑W3 Outboard Oil

c. 150 mL (5.0 fl oz) Quickstor Fuel Stabilizer

Premium Plus 2-cycle TC-
115 Fuel system 92-858026K01
W3 Outboard Oil
Quickstor Fuel Stabilizer Fuel system Obtain Locally
2. Allow the engine to cool down.
IMPORTANT: Immediately wipe up any fuel spills or sprays.
3. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not equipped with a fuel shut off valve.
4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting.
5. Supply sufficient cooling water to the engine. Refer to the appropriate Flushing the Power Package procedure.
NOTICE
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation.
6. Start and operate the engine at 1300 RPM for five minutes.
7. After operating the engine for the specified time, slowly return the throttle to idle RPM and shut the engine off.
IMPORTANT: Ensure that some fogging mixture remains in the engine. Do not allow the engine's fuel system to become
completely dry.
8. Replace the water separating fuel filter element. Refer to Section 5 for the proper procedure.
Power Package Recommissioning

1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.
! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage
the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.
2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect the cables. Tighten each cable
clamp securely.
3. Coat the terminal connections with a battery terminal sealant.

Battery Terminal Sealant Battery terminal connections Obtain Locally
4. Perform the following prior to starting the engine:
a. Install the bilge drain plug.
b. Open the engine hatch.
c. Turn the battery switch on.
d. Operate the bilge blowers.
e. Open the fuel shut‑off valve.
f. Open the seacock, if equipped.
g. Close the drain system.
h. Check the engine oil.
i. Listen for the audio warning alarm to sound when the ignition switch is moved to the "ON" position.
NOTICE
5. Start the engine and closely observe the instrumentation to ensure that all systems are functioning correctly.
6. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks.
7. Inspect the steering system, shift, and throttle control for proper operation.
90-8M0041669 JANUARY 2014 Page 1C-43

Maintenance
Notes:
Page 1C-44 90-8M0041669 JANUARY 2014

Important Information, Maintenance, and Troubleshooting

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Maintenance

Important Information, Maintenance, and

90-8M0041669 JANUARY 2014 Page 1C-1

Lubricants, Sealants, Adhesives

Measures serpentine belt deflection.

Reference Electrode 91‑76675T 1

Flushing Device 91‑44357Q 2

Page 1C-2 90-8M0041669 JANUARY 2014

Dual Water Pick‑up Flush Gearcase Seal

Engine and Tune‑Up Specifications

4.3 MPI ECT

90-8M0041669 JANUARY 2014 Page 1C-3

Description Capacity Fluid Type

Power‑Assisted Steering and Power Trim Fluids

Approved Power Trim Fluids

Task Interval Maintenance to Be Performed Procedure

Page 1C-4 90-8M0041669 JANUARY 2014

Task Interval Maintenance to Be Performed Procedure

Task Interval Maintenance to Be Performed Procedure

90-8M0041669 JANUARY 2014 Page 1C-5

Task Interval Maintenance to Be Performed Procedure

Every 300 hours or 3 Section 6C ‑ Heat Exchanger

Tube Ref No. Description Where Used Part No.

Page 1C-6 90-8M0041669 JANUARY 2014

a - Engine oil dipstick handle

IMPORTANT: Do not overfill the engine with oil.

Engine Oil Capacity Fluid type

Changing the Engine Oil and Filter

90-8M0041669 JANUARY 2014 Page 1C-7

Draining Using a Crankcase Oil Pump

a b a - Typical oil pump

Changing the Oil Filter

Engine oil filter

Tube Ref No. Description Where Used Part No.

Page 1C-8 90-8M0041669 JANUARY 2014

5. Remove the oil fill cap.

Oil fill cap

Tube Ref No. Description Where Used Part No.

Power Trim Fluid

3. Fill as necessary with the specified fluid. Refer to Filling.

90-8M0041669 JANUARY 2014 Page 1C-9

Tube Ref No. Description Where Used Part No.

b Power trim pump reservoir shows the oil level is below

Tube Ref No. Description Where Used Part No.

Page 1C-10 90-8M0041669 JANUARY 2014

Cleaning and Inspection

Description Nm lb‑in. lb‑ft

Description Nm lb‑in. lb‑ft

90-8M0041669 JANUARY 2014 Page 1C-11

b IAC muffler in adapter manifold—typical engine

IAC muffler in adapter

Cleaning and Inspection

IAC muffler in adapter manifold—typical

Page 1C-12 90-8M0041669 JANUARY 2014

Serpentine Drive Belt

With a seawater pump Without a seawater pump

90-8M0041669 JANUARY 2014 Page 1C-13

Second Engine on a Dual Engine Installation

Belt Tension Gauge SPX BT‑33‑73‑F

Replacing Belt or Adjusting Tension

Page 1C-14 90-8M0041669 JANUARY 2014

Belt Tension Gauge SPX BT‑33‑73‑F

a - 8 mm (5/16 in.) adjusting stud