Mercury Alpha Owner's Manual
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Mercury Alpha Owner's Manual

Gasoline engines
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Gasoline Engines - Alpha / Bravo Models
2001, Mercury Marine
90-860168003 201

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  • Page 1 INDEX  Gasoline Engines - Alpha / Bravo Models 2001, Mercury Marine 90-860168003 201...
  • Page 2 The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation.
  • Page 3 INDEX CA910 MERCRUISER Division of Mercury Marine Stillwater, OK, U.S.A. SPECIFICATIONS MODEL MCM 4.3LX/4.3LXH GEN + DISPLACEMENT ..262 CID IGNITION TIMING ..10 BTDC CYL. FIRING ORDER .
  • Page 4 INDEX CA961 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 5 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of...

  • Page 6: Table Of Contents

    ..... . Mercury MerCruiser Limited Warranty ....
  • Page 7 INDEX Page Operation Instrumentation ........Audio Warning System .

  • Page 8: Warranty Information

    INDEX CA455 Warranty Information 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 factory immediately upon sale of the new product. •...

  • Page 9: International Owner Registration

    INDEX 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.

  • Page 10: Mercury Mercruiser Limited Warranty

    Mercury MerCruiser One Year Limited Warranty (Gasoline Fueled Products Only) WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in ma- terial and workmanship during the period described below. DURATION OF COVERAGE This Limited Warranty provides coverage for either one (1) year from...
  • Page 11 WARRANTY COVERAGE Warranty coverage is available only to retail customers that pur- chase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented.
  • Page 12 Mercury dealer authorized to service the product. If purchas- er cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any cov- ered repair. Purchaser in that case shall pay for all related transporta- tion charges and/or travel time.
  • Page 13 No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforce- able against Mercury Marine.

  • Page 14: Year Limited Warranty Against Corrosion Failure

    3 Year Limited Warranty Against Corrosion (Worldwide) WHAT IS COVERED Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, tracker by Mercury Marine Outboard, MerCruiser Inboard or sterndrive engine (Product) will not be ren- dered inoperative as a direct result of corrosion for the period of time described below.
  • Page 15 WARRANTY COVERAGE Warranty coverage is available only to retail customers that pur- chase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed an documented.
  • Page 16 Mercury dealer authorized to service the product. If purchas- er cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any cov- ered repair. Purchaser in that case shall pay for all related transporta- tion charges and/or travel time.

  • Page 17: Transferable Warranty

    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 Attn: Warranty Registration Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 •...

  • Page 18: Mercury Product Protection Plan

    The optional Mercury Product Protection Plan is the only Factory Plan available for your engine. Two, three or four - year term plans can be purchased up to 12 months after the original engine registration date.
  • Page 19 INDEX CA961 THIS PAGE IS INTENTIONALLY BLANK...

  • Page 20: Read This Manual Thoroughly

    INDEX CA755 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARNINGS and CAUTIONS, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be...
  • Page 21 INDEX CAUTION CAUTION-Hazards or unsafe practices which could result in minor personal injury or product or property damage. IMPORTANT: - Indicates information or instructions that are necessary for proper operation and/or maintenance. WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard.

  • Page 22: General Information

    INDEX CC942 General Information Lanyard Stop Switch The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from the operator’s position (as in accidental ejection from the operator’s position) to activate the switch.

  • Page 23: Lanyard Stop Switch

    INDEX IMPORTANT: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator’s position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator’s position.
  • Page 24 INDEX CA619 Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: Occupants could be thrown forward due to unexpected loss of forward motion - a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller.

  • Page 25: Exhaust Emissions

    INDEX CA766 Exhaust Emissions CA641 Courtesy of ABYC CA767 Be Alert To Carbon Monoxide Poisoning Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories.
  • Page 26 INDEX CA642 Courtesy of ABYC CA643 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an unclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of...

  • Page 27: Wave And Wake Jumping

    INDEX CD543 Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re-enters the water.

  • Page 28: Impact With Underwater Hazards

    INDEX CD544 Impact With Underwater Hazards Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the sterndrive or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed.
  • Page 29 INDEX Keep in mind, one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles. After striking a submerged object, stop engine as soon as possible and inspect the sterndrive unit for any broken or loose parts.

  • Page 30: Operating With Low Water Inlets In Shallow Water

    INDEX CB795 Operating With Low Water Inlets In Shallow Water 76363 75827 CAUTION Serious engine damage could occur by failing to follow these instructions. Sand, silt or mud could be sucked into the water inlets restricting or shutting off the water supply to the engine. Extreme care should be exercised when operating a boat equipped with low water inlets (A) while maneuvering in shallow water.

  • Page 31: Drive Unit Impact Protection

    If drive unit should strike a submerged object, stop engine as soon as possible and inspect drive unit for damage. If damage is present or suspected, boat should be taken to an Authorized Mercury MerCruiser Dealer for thorough inspection and necessary repair.

  • Page 32: Safe Boating Suggestions

    INDEX CA476 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course.
  • Page 33 INDEX Anchor and extra anchor line; water-proof storage containers. Manual bilge pump and extra drain plugs; compass and map or chart of area. Spare operating equipment; batteries, bulbs, fuses, etc. Transistor radio. Drinking water. • Know signs of weather change and avoid foul weather and rough-sea boating.
  • Page 34 INDEX • Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat’s operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your dealer or the boats manufacturer.
  • Page 35 INDEX • Be alert. The operator of the boat is responsible by law to “maintain a proper lookout by sight (and hearing).” The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operators view when operating the boat above idle or planing transition speed.

  • Page 36: Protecting People In The Water

    INDEX 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. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 37: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-849250--1) from your dealer, distributor, or Mercury Marine.

  • Page 38: Conditions Affecting Operation

    INDEX CA958 Conditions Affecting Operation Weight Distribution (Passengers And Gear) Inside The Boat Shifting weight to rear (stern): • Generally increases speed and engine rpm. • At extremes, can cause boat to porpoise. • Causes bow to bounce in choppy water. •...
  • Page 39 INDEX Cavitation Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater object, such as a gear housing or propeller. Cavitation permits the propeller to speed up, but the boat speed to reduce. Cavitation can seriously erode the surface of the gear housing or propeller.

  • Page 40: Propeller Selection

    INDEX CB822 Propeller Selection IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide open throttle revolutions per minute (rpm). Use an accurate service tachometer to verify engine operating rpm. It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propellers.
  • Page 41 INDEX If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage.

  • Page 42: How Elevation And Climate Affect Performance

    INDEX CA960 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide open throttle power of an engine. Since air gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a noticeable effect on the density of air.
  • Page 43 INDEX For boaters to realize optimum engine performance under changing weather conditions, 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 WOT with a normal boat load. Not only does this allow the engine to develop full power, but equally important is the fact that the engine also will be operating in an rpm range that discourages detonation.

  • Page 44: Important Information

    Individual operating habits and usage contribute to the need for maintenance service. Proper maintenance and care of your power package will assure optimum performance and dependability, and will keep your overall operating expenses at a minimum. See your Authorized Mercury MerCruiser Dealer for service aids.
  • Page 45 • Make sure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency.

  • Page 46: Freezing Temperature Operation

    Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.

  • Page 47: Emissions Information (Europe Only)

    • Proper steps to maintain the engine within specifications. Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. IMPORTANT: The testing dealer or agency will be equipped with the appropriate test equipment and adapters for this engine.

  • Page 48: Trailering Boat

    “down” position. If adequate road clearance is a problem, place drive unit in full trailer position and support with an optional trailer kit which is available from your Authorized Mercury MerCruiser Dealer. CA20 Launching And Boat Operation Care...

  • Page 49: Stolen Power Package

    Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors.

  • Page 50: Do-It-Yourself Maintenance Suggestions

    These are but a few of the many special modifications that are required in Mercury MerCruiser marine engines to provide long life and dependable performance. CA872...
  • Page 51 INDEX • There are special tools and equipment that are required to perform some repairs. Do not attempt these repairs unless you have these special tools and/or equipment. You can cause damage to the product in excess of the cost a dealer would charge you.

  • Page 52: Multiple Efi Engine Battery Precautions

    INDEX CC1004 NOTE: All references to EFI models apply to EFI and MPI engines. CA782 Multiple EFI Engine Battery Precautions Situation Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on.

  • Page 53: Diagnosing Efi Problems (If Equipped)

    Diagnosing EFI Problems (If Equipped) NOTE: All references to EFI models apply to EFI and MPI engines. Your Authorized Mercury MerCruiser Dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a “Trouble Code”...

  • Page 54: 20-Hour Break-In Period

    INDEX CA413 20-Hour Break-In Period IMPORTANT: The first 20 hours of operation is the engine break-in period. Correct break-in is essential to obtain minimum oil consumption and maximum engine performance. During this break-in period, the following rules must be observed: •...

  • Page 55: After Break-In Period

    (full throttle) rpm. CA875 End of First Season Checkup At the end of the first season of operation, an Authorized Mercury MerCruiser Dealer should be contacted to discuss and/or perform various scheduled maintenance items. If you are in an area where...
  • Page 56 INDEX CA26 70515 70516 70514 70517 70523 70522 70518 70520 70521 70519...

  • Page 57: Operation

    INDEX CA470 Operation Instrumentation The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions on the boat. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings that will appear on your style gauges.
  • Page 58 INDEX CB218 70516 70518 76230...

  • Page 59: Audio Warning System

    INDEX CA963 Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The audio warning system alarm will sound if one of the following occur: Engine Oil Pressure Too Low Engine Temperature Too Hot...
  • Page 60 INDEX CB758 74898 76037 74907 75989...

  • Page 61: Electrical System Overload Protection

    INDEX CB775 Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replacing fuse or resetting circuit breaker. A circuit breaker provides protection for engine wiring harness and instrumentation power lead.
  • Page 62 INDEX CB654 70525 70526 70527 70528...
  • Page 63 INDEX CA941 A 20 amp fuse may be located in ignition switch “I” terminal lead to protect electrical system. Check for blown fuse if key is turned to START and nothing happens (and circuit breaker is not tripped). The Power Trim System is protected from overload by 110 amp fuse and a 20 amp in-line fuse on Power Trim pump.

  • Page 64: Remote Controls

    77443 CC998 Remote Control Features Your boat may be equipped with a Mercury Precision or Quicksilver remote control. All controls may not have all features shown. If boat is equipped with a remote control other than shown, consult your dealer for a description and/or demonstration of the control.
  • Page 65 INDEX Neutral Release Lever - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed IN to move the control handle out of NEUTRAL. Trim/Tilt Button(if Equipped) - Refer to Power Trim Operation. Lanyard Stop Switch - Turns ignition OFF whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch.
  • Page 66 INDEX CA768 ° 3 - 5...

  • Page 67: Power Trim

    INDEX CA418 Power Trim Power Trim allows the operator to adjust the drive angle, while underway, to provide the ideal boat angle for varying load and water conditions. Also, the Power Trim system “Trailering” feature allows the operator to raise and lower the drive unit for trailering, beaching, launching and low speed (below 1200 rpm engine speed), shallow water operation.
  • Page 68 INDEX • In most cases, reduce boat speed. • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called “bow steering”...

  • Page 69: Starting, Shifting And Stopping

    INDEX CA757 Starting, Shifting And Stopping WARNING Before starting engine, operate bilge blower for at least five minutes to remove any explosive fumes from engine compart- ment. If boat is not equipped with a bilge blower, open engine hatch and leave open while starting engine. CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel va-...
  • Page 70 INDEX Refer to A or B as appropriate for your model. A Carbureted Engine - Push THROTTLE ONLY button and position throttle setting as follows: COLD ENGINE - Move control/throttle lever to full throttle, then return to about 1/4 throttle. In extreme cold it may be necessary to pump lever more than once.
  • Page 71 INDEX After engine has warmed up, check water temperature gauge to ensure that engine temperature is not abnormally high. If it is, stop engine immediately and determine cause. Be sure charging system is functioning correctly. Observe power package for fuel, oil, water and exhaust leaks. To shift drive unit, return control/throttle lever to NEUTRAL.
  • Page 72 INDEX CB575 IMPORTANT: Avoid stopping engine if the drive unit is in gear. If engine does stop with drive unit in gear, refer to the following procedure: Push and pull repeatedly on remote control handle until han- dle returns to the neutral detent position. This may take several tries if the power package was operating above idle RPM when the engine stopped.

  • Page 73: Operation Chart

    INDEX CA971 Operation Chart BEFORE AFTER WHILE AFTER STARTING STARTING UNDERWAY STOPPING Open engine Observe all Observe all Turn ignition hatch. gauges to gauges to key to OFF. check check condition of condition of engine. If not engine. If not normal, stop normal, stop engine.

  • Page 74: Specifications

    FUEL RATINGS Mercury MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows: USA and Canada - having a posted pump Octane Rating of 87 (R+M)/2 minimum.
  • Page 75 The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat’s fuel system will withstand.
  • Page 76 IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long periods of storage,...

  • Page 77: Seacock Size Recommendation

    INDEX CB789 FUEL SYSTEM ADDITIVES (V6 AND 5.0L/305 CID MODELS) To maximize the life of valves and valve seats on your Mercury MerCruiser engine, Quicksilver Valve Lubricant (92-826259A12) regularly. CC540 Seacock Size Recommendation Seacock used must have an internal cross-sectional area equal to or greater than hose to prevent restricting waterflow.
  • Page 78 INDEX IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other than Quicksilver 25W-40 or a good quality 20W-40 or 20W-50), synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended. The chart below is a guide to crankcase oil selection. The oil filter should always be changed when changing engine oil.

  • Page 79: Engine

    Measured using an accurate service tachometer with engine at normal operating temperature. A special procedure must be followed to check or adjust timing. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure.

  • Page 80: Engine Specifications

    A special procedure must be followed to check or adjust timing. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure. A special procedure must be followed to adjust idle rpm. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure.
  • Page 81 A special procedure must be followed to check or adjust timing. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure. A special procedure must be followed to adjust idle rpm. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure.
  • Page 82 A special procedure must be followed to check or adjust timing. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure. A special procedure must be followed to adjust idle rpm. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure.
  • Page 83 Measured using an accurate service tachometer with engine at normal operating temperature. A special procedure must be followed to check or adjust timing. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure. Idle speed on EFI models is not adjustable.
  • Page 84 Measured using an accurate service tachometer with engine at normal operating temperature. A special procedure must be followed to check or adjust timing. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure. Idle speed on EFI models is not adjustable. Idle speed on EFI models is not adjustable.

  • Page 85: Maintenance

    Authorized Mercury MerCruiser Dealer. Before attempting maintenance or repair procedures not covered in this manual, it is recommended that a Mercury MerCruiser Service Manual be purchased and read thoroughly. NOTE: Maintenance points are color coded for ease of identification.

  • Page 86: Fluid Capacities

    INDEX Power Trim System - Quicksilver Power Trim and Steering Fluid, or SAE 10W-30 motor oil. Crankcase Oil - Quicksilver 4-Cycle Marine Engine Oil (Refer to Specifications for alternatives and oil recommendations for varying ambient temperatures.) Closed Cooling System Coolant - Extended Life Ethylene Glycol 5/100 Antifreeze/Coolant mixed 50/50 with purified water.
  • Page 87 2 Seawater Cooling System capacity information is for winterization use only. IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines). Sterndrive Alpha Bravo Bravo Bravo Black- Sterndrive Model...

  • Page 88: Maintenance Chart

    INDEX CA951 Gas Sterndrive Routine Maintenance * Each Day Each Day Every Two Weekly Start Months Check crankcase oil (interval can be extended based on experi- ence). If operating in salt, brackish or polluted waters, flush cooling system after each use. Check drive unit oil level, trim pump oil level and power steering pump fluid level.
  • Page 89 INDEX Gas Sterndrive (Continued) Scheduled Maintenance * Every Every Every Every 2 Every 5 Annually Years Years Hours or Hours or Hours or Annually 3 Years 3 Years Touch-up paint power package and spray with corrosion guard. Change crankcase oil and filter. Change drive unit oil and retorque connection of gimbal ring to steering shaft.
  • Page 90 INDEX Gas Sterndrive(Continued) Scheduled Maintenance * (Continued) Every Every Every Every 2 Every 5 Annually Years Years Hours or Hours or Hours or Annually 3 Years 3 Years Clean flame arrestor and crankcase ventilation hoses. Replace PCV valve. Check electrical system for loose, damaged or corroded fasteners.

  • Page 91: Checking Fluids

    INDEX 76386 74766 76385 CB819 Checking Fluid Levels CHECKING CRANKCASE OIL Stop engine. Allow approximately five minutes for oil to drain into oil pan. Boat must be at rest in water. Remove dipstick. Wipe clean and reinstall fully into dipstick tube. Remove dipstick and observe oil level.
  • Page 92 CA886 CHECKING POWER STEERING PUMP FLUID Stop engine and position drive unit straight back. Remove FILLCAP/DIPSTICK and observe level. Add specified fluid if required. Reinstall FILLCAP/DIPSTICK. IMPORTANT: If fluid is not visible in pump, contact your Authorized Mercury MerCruiser Dealer.
  • Page 93 Coolant level must be at top of reservoir filler neck. If coolant is low, inspect gasket in cap for damage and replace if necessary. To have cap tested, contact your Authorized Mercury MerCruiser Dealer. Inspect coolant recovery system for leaks.
  • Page 94 If any water is visible at the bottom of monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your Authorized Mercury MerCruiser Dealer immediately. Both conditions may indicate a water leak somewhere in the drive unit.

  • Page 95: Fuel Pump Sight Tube Inspection 3.0L Models

    3.0L Models The engine fuel pump is equipped with a sight tube which gives visible evidence of a ruptured fuel pump diaphragm. If fuel is visible in tube, fuel pump should be replaced by your Authorized Mercury MerCruiser Dealer immediately.
  • Page 96 INDEX CA857 70571 74767 74766...

  • Page 97: Changing Fluids

    INDEX CB820 Changing Fluids Refer to Maintenance for change interval. Crankcase oil should be changed before placing boat in storage. Power Trim or Power Steering fluids do not require changing. Changing Crankcase Oil and Filter IMPORTANT: Change crankcase oil when engine is warm from operation.
  • Page 98 INDEX CB688 50132 70568 76230 72522 77106...
  • Page 99 Remove pump from OIL FILL/DRAIN hole. Quickly install sealing washer and OIL FILL/DRAIN screw. Tighten securely. Bravo One and Alpha Models: Grease propeller shaft heavily, with specified lubricant (Refer to Propeller Installation). Reinstall propeller and torque nut to 55 lb-ft (75 Nm) MINIMUM.
  • Page 100 INDEX CA961 THIS PAGE IS INTENTIONALLY BLANK...

  • Page 101: Changing Water Separating Fuel Filter

    INDEX CA968 Changing Water Separating Fuel Filter WARNING Avoid Fire or Explosion: Fuel injection system is pressurized during operation. Use care when removing water separating fuel filter. Fuel could spray on hot engine causing fire or explo- sion. Allow engine to cool down before attempting to remove the water separating fuel filter in the following procedure.
  • Page 102 INDEX CA518 1, 5 75034 74812 3, 7 70573...
  • Page 103 Start and run engine. Check filter connection for gasoline leaks. If leaks exist. recheck filter installation. If leaks continue, stop engine immediately and contact your Authorized Mercury MerCruiser Dealer. Install cover pieces around fuel filter. Be certain top part of cover latches to lower part.
  • Page 104 INDEX CA921 75142 72806 76360...

  • Page 105: Cleaning Flame Arrestor And Related Components

    INDEX CA806 Cleaning Flame Arrestor and Related Components WARNING Avoid gasoline fire or explosion. Gasoline is extremely flam- mable and highly explosive under certain conditions. Be care- ful when cleaning flame arrestor and crankcase ventilation hoses: Be sure that ignition is OFF. DO NOT smoke or allow sources of spark or open flame in area when cleaning flame arrestor and crankcase ventilation hoses.
  • Page 106 INDEX CA922 71903 71359 74941 71901 71480 71904 71357 75454...

  • Page 107: Lubrication

    INDEX CA524 Lubrication Steering System If Steering Cable Has Grease Fittings: Turn steering until steering cable is fully retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand-operated grease gun. Lubricate at fitting with 2-4-C Marine Lubricant with Teflon.
  • Page 108 INDEX CA930 77044 77068 71569 71346 71347...

  • Page 109: Drive Shaft Extension Models

    Quicksilver U-Joint and Gimbal Bearing Grease. A Alpha Models - Lubricate hinge pins by applying a couple of pumps of grease from a typical hand-operated grease gun using Quicksilver 2-4-C Marine Lubricant with Teflon.

  • Page 110: Propeller

    INDEX CA634 76910 CA816 Propeller Alpha WARNING Avoid Injury: Remote Control must be in NEUTRAL and igni- tion key removed from switch before removing and/or install- ing propeller. WARNING Avoid Injury: 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.
  • Page 111 INDEX CA746 REMOVAL Place wood block between propeller blade and anti-ventilation plate to prevent rotation. Straighten bent tabs on tab washer. Turn propeller shaft nut counterclockwise to remove nut. Slide tab washer, drive sleeve, propeller and thrust hub off propeller shaft. CA79 REPAIR Some damaged propellers can be repaired.
  • Page 112 INDEX CA634 76910 CA774 INSTALLATION IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. Apply a liberal coat of one of the following Quicksilver lubricants to propeller shaft: Anti-Corrosion Grease, Special Lubricant 101, or 2-4-C Marine Lubricant with Teflon.
  • Page 113 INDEX NOTE: The drive sleeve is tapered and will slide fully into the propel- ler as the nut is tightened and properly torqued. Align splines and place propeller on propeller shaft. Install drive sleeve and locking tab washer. Install propeller nut. Tighten nut securely. A minimum of 55 lbs. ft. (75 N·m) torque is required.
  • Page 114 INDEX CB422 BRAVO ONE 76910 70561 BRAVO TWO...
  • Page 115 INDEX CA817 Propellers Bravo One and Two WARNING Avoid Injury: Remote Control must be in NEUTRAL and igni- tion key removed from switch before removing and/or install- ing propeller. WARNING Avoid Injury: 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.
  • Page 116 INDEX CB423 BRAVO ONE 76910 BRAVO TWO 70561...
  • Page 117 INDEX CA818 INSTALLATION IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. Apply a liberal coat of one of the following Quicksilver lubricants to propeller shaft: Anti-Corrosion Grease, Special Lubricant 101, or 2-4-C Marine Lubricant with Teflon.
  • Page 118 INDEX 77107 Propellers Bravo Three WARNING Avoid Injury: Remote Control must be in NEUTRAL and igni- tion key removed from switch before removing and/or install- ing propeller. WARNING Avoid Injury: 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.
  • Page 119 INDEX CAUTION Avoid Injury: Periodically check propeller nut for tightness ⋅ during boating season. A minimum of 55 lbs. ft. (75 N torque is required. REMOVAL (BRAVO THREE DRIVE) Place wood block between propeller blades and anti-ventilation plate to prevent rotation. Turn aft propeller shaft nut (1-7/16 in.
  • Page 120 INDEX CB150 77107 CA820 INSTALLATION Apply a liberal coat of one of the following Quicksilver lubricants to both propeller shafts: Special Lubricant 101, 2-4-C Marine Lubri- cant with Teflon, or Anti-Corrosion Grease. Slide forward thrust hub onto propeller shaft, with tapered side to- ward propeller hub (toward end of shaft).
  • Page 121 INDEX Install propeller nut. Tighten nut securely. A minimum of 100 lbs. ft. (136 N·m) torque is required. Check propeller at least after 20 hours of operation. Do not operate with loose propeller. Slide aft thrust hub onto propeller shaft, with tapered side toward propeller hub (toward end of shaft).
  • Page 122 INDEX CA529 71428 50633 50633...

  • Page 123: Drive Belts

    INDEX CA839 Drive Belts WARNING Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belts. V-Belts (3.0L Model) CHECKING Inspect the alternator and power steering pump drive belts for the following: • •...
  • Page 124 INDEX D Loosen the alternator as outlined below. Remove and replace the alternator belt. E Replace the spacer block between the bracket assembly and the engine block. Install the two screws using the flat and lock wash- ers removed previously. Torque the two screws to 21 lb. ft. (28 N·m).
  • Page 125 INDEX CA961 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 126 INDEX CA948 76503 76338 75130...
  • Page 127 INDEX CA947 Serpentine Drive Belt WARNING Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belt. The various components are: Idler Pulley Alternator Pulley Circulating Pump Pulley Seawater Pump Pulley Crankshaft Pulley Power Steering Pulley CHECKING Inspect drive belt for proper tension and for the following:...
  • Page 128 INDEX CA928 REPLACING AND / OR ADJUSTING TENSION IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as before. Remove drive belt as follows: NOTE: The upper, left (port) idler pulley is the belt adjustment pulley. A Loosen 5/8 in.
  • Page 129 INDEX CA961 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 130 INDEX CA925 73919 71176 70577 70576 70578 70575...

  • Page 131: Corrosion And Corrosion Protection

    Test should be made where boat is moored, using Quicksilver Reference Electrode and Test Meter. Contact your Authorized Mercury MerCruiser Dealer to arrange for this test. Anode Kit (if equipped) - Mounted to boat transom. Acts as a sacrificial anode.
  • Page 132 C Install new anode. Tighten screws securely. CA969 Bearing Carrier Anode (Alpha and Bravo One) - is located in front of the propeller, between the front side of the propeller and the gear housing. Refer to Propeller section in this manual for propeller removal and installation.
  • Page 133 INDEX D Install new anode. Tighten screws securely. E Reinstall propeller. See Propeller Installation for proper tighten- ing. Bearing Carrier Anode - is located in front of the propeller, between the front side of the propeller and the gear housing. Refer to Propeller section in this manual for propeller removal and installation.
  • Page 134 INDEX Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 1-1/2 in. (40 mm) UNPAINTED area on transom of the boat around these items. Painting Drive Unit or Transom Assembly: Drive unit and...
  • Page 135 INDEX CA961 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 136 INDEX CA97 “SEE CAUTION” 71918 71925...

  • Page 137: Emissions (Europe Only)

    Remove PCV valve from port valve cover. Disconnect it from the hose and discard valve. Install new PCV valve in valve cover and reconnect hose. Ensure valve is tightly seated in valve cover. Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations.
  • Page 138 INDEX CA637 75319 71926 75324...

  • Page 139: Emissions Testing

    Proper engine tuning procedures to ensure these features remain in good operating order. • Proper steps to maintain the engine within specifications. Use only Mercury MerCruiser replacement parts to ensure com- pliance with emission regulations. CA638 Installing Test Probes IMPORTANT: The testing dealer or agency will be equipped with the appropriate test equipment and adapters for this engine.

  • Page 140: Battery

    INDEX CA478 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use. Recharge every 30 to 45 days, or when specific gravity drops below battery manufacturer’s specifications. Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.

  • Page 141: Inspection And Maintenance

    Check plug leads and electrical leads for damage. Remove and inspect propeller. If badly nicked, bent or cracked, see your Authorized Mercury Mercruiser Dealer. Repair nicks and corrosion damage on power package exterior finish. Use Quicksilver spray paints - see your Authorized Mercury MerCruiser Dealer.

  • Page 142: Cold Weather Or Extended Storage

    Cold Weather Or Extended Storage Power Package Lay Up IMPORTANT: Mercury MerCruiser Strongly recommends that this service should be performed by an Authorized Mercury MerCruiser Dealer. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. WARNING...
  • Page 143 INDEX IMPORTANT: Before starting engine, a water source must be attached to the seawater intake openings in gear housing, and/or seawater pickup pump. Follow all warnings, and flushing attachments procedures stated, in Flushing Cooling System. CAUTION Sterndrive unit should be stored in full DOWN position. Uni- versal Joint bellows may develop a set if unit is stored in raised position and may fail when unit is returned to service.
  • Page 144 INDEX CA575 Power Package Lay Up (continued) CARBURETED MODELS 75844 WARNING Avoid Fire or Explosion: Be sure engine compartment is well ventilated and no gasoline vapors are present during the fol- lowing operation. Close the fuel shut-off valve, if so equipped. If no fuel shut off valve is present, a suitable method must be employed to STOP the flow of fuel from the fuel tank to the engine before proceeding.
  • Page 145 INDEX CA576 Power Package Lay Up (continued) EFI MODELS WITH COOL FUEL SYSTEM WARNING Avoid Fire or Explosion: Be sure engine compartment is well ventilated and no gasoline vapors are present during the fol- lowing operation. WARNING Avoid Fire or Explosion: Fuel injection system is pressurized during operation.
  • Page 146 INDEX 77108 Prepare fuel system for extended storage as follows: A Allow engine to cool down. B Depress latch and remove (slide down) the lower filter cover. C Remove the water separating fuel filter. D Pour out a small amount of fuel into a suitable container, then add approximately 2 fluid ounces (60 ml) of Quicksilver 2-Cycle Out- board Oil to fuel in the water separating fuel filter.

  • Page 147: Draining Instructions

    Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. Ensure engine is as level as possible to ensure complete draining of cooling system.
  • Page 148 INDEX 75432 75081 Remove drain plugs from the following locations, if equipped: A Port and starboard side of cylinder block. B Bottom of exhaust manifolds. C Starboard side Y-fitting. D Fuel cooler. E Port seawater pipe. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained.
  • Page 149 INDEX 76038 71216 CA897 NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. Models equipped with circulating pump hose drain plug: Remove drain plug. Models without circulating pump hose drain plug: Loosen hose clamps and disconnect hose from circulating pump. Allow water to drain.
  • Page 150 INDEX IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
  • Page 151 Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. IMPORTANT: Closed cooling section must be kept filled year-round with recommended coolant. If engine will be...
  • Page 152 INDEX CA795 3A 2 75039 73581 71515 71170 71216...
  • Page 153 INDEX CA796 IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine. Ensure engine is as level as possible to ensure complete draining of cooling system. Remove drain plug(s) from bottom of exhaust manifold(s). Remove drain plug from A or B, depending on model: A Fuel cooler.
  • Page 154 INDEX CA797 76242 76243 76244 76244...

  • Page 155: L Single Point Drain

    INDEX CA854 3.0L Single Point Drain CAUTION Ensure bilge pump is operating before beginning procedures. Excess water in bilge can damage engine or cause boat to sink. CAUTION Allow engine to cool down before disconnecting blue drain hoses. Engine water temperature can exceed 160° F ( 71° C). CAUTION Do not operate engine with blue drain hoses disconnected.
  • Page 156 INDEX Clearing Clogged Blue Drain Hoses 76287 BOAT IN WATER CAUTION Allow engine to cool down before disconnecting blue drain hoses. Engine water temperature can exceed 160° F ( 71° C). CAUTION Ensure bilge pump is operating before beginning procedures. Excess water in bilge can damage engine or cause boat to sink.
  • Page 157 Steps 7 - 9 in 3.0L Single Point Drain. The unit will need to be serviced by an authorized Mercury MerCruiser dealer. If water is draining, return to Step 4 of 3.0L Single Point Drain.
  • Page 158 INDEX Clearing Clogged Blue Drain Hoses (continued) 72693 Engine Running Attach UNCLOGGED blue drain hose to the bracket, leaving the CLOGGED blue drain hose disconnected. Install flushing attachment over water pickup holes (A) in gear housing as shown. Attach a hose between the flushing attachment and a water supply.
  • Page 159 Steps 7 - 9 in 3.0L Single Point Drain. The unit will need to be serviced by an authorized Mercury MerCruiser dealer. If water is draining, return to Step 3 of 3.0L Single Point Drain.

  • Page 160: Flushing Cooling System

    INDEX CA799 76287 CA825 Flushing Cooling System CA801 3.0L Single Point Drain If engine is operated in salty or brackish water, flush cooling system (preferably after each use) to reduce corrosion and prevent the accumulation of deposits in the system. Thoroughly flush cooling system prior to storage.
  • Page 161 INDEX Fully open the water supply and allow it to run for 10 minutes. Turn off the water supply. Disconnect the water hose adapter from the blue drain hose and the water hose. Pull T-handle until the quick connect fittings on the blue drain hoses are within reach.
  • Page 162 INDEX CA824 70564 CA800 All Other Models CA827 To prevent silt and/or salt buildup in cooling system, flush with freshwater after each use and prior to storage. If flushing cooling system with boat in water, raise drive unit to TRAILER position, install flushing attachment and lower drive unit to full DOWN/IN position.

  • Page 163: Battery Winter Storage

    INDEX Install Quicksilver flushing attachment (or equivalent) over water intake openings in gear housing. Connect hose between flushing attachment and water source valve. With drive unit in normal operating position, partially open water source valve (about 1/2 maximum). Place drive in NEUTRAL, idle speed position and start engine. CAUTION Avoid possible engine damage.

  • Page 164: Power Package Recommissioning

    INDEX CA116 Power Package Recommissioning WARNING To prevent possible injury or damage to equipment, do not in- stall battery until all maintenance has been performed on en- gine. Check that all cooling system hoses are connected properly and hose clamps are tight. CAUTION When installing battery, be sure to connect NEGATIVE (–) bat- tery cable to NEGATIVE (–) battery terminal and POSITIVE (+)
  • Page 165 INDEX Perform all checks in Operation Chart in the BEFORE STARTING column. CAUTION Refer to FLUSHING COOLING SYSTEM before starting en- gine. Start engine and closely observe instrumentation to make sure that all systems are functioning correctly. Carefully inspect engine for fuel, oil, fluid, water and exhaust leaks.

  • Page 166: Troubleshooting

    INDEX CA442 Troubleshooting Starter Motor Will Not Crank Engine, Or Cranks Slow Possible Cause Remedy Battery switch turned off. Turn switch on. Remote control not in neutral Position control lever in neutral. position. Open circuit breaker or blown Check and reset circuit breaker fuse.
  • Page 167 Read starting procedure. Empty fuel tank or fuel shutoff Fill tank or open valve. valve closed. 3.0L: Check sight tube for fuel. Have Authorized Mercury Faulty fuel pump. MerCruiser Dealer replace pump, if fuel is present. Carburetor Models: Check Choke not operating properly.
  • Page 168 Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy EFI Models: Have EFI system Idle speed too low. checked by an Authorized Mercury MerCruiser Dealer. Carburetor Models: Check Choke not operating properly. choke linkages for binding or an obstruction. Faulty ignition system Service ignition system.

  • Page 169: Poor Performance

    Clean or repair as necessary. damaged. Flame Arrestor dirty. Clean Flame Arrestor. See Engine Runs Rough, Ignition or carburetion problem. Misses or Backfires. See Excessive Engine Engine overheating. Temperature. Have EFI System checked by EFI System fault (If Equipped). an Authorized Mercury MerCruiser Dealer.

  • Page 170: Excessive Engine Temperature

    INDEX CA447 Excessive Engine Temperature Possible Cause Remedy Seacock closed. Open. Drive belt loose or in poor Replace or adjust belt. condition. Seawater pickups obstructed. Remove obstruction. Faulty thermostat. Replace. Check for cause of low coolant Coolant level low in closed level and repair.

  • Page 171: Insufficient Engine Temperature

    INDEX CA448 Insufficient Engine Temperature Possible Cause Remedy Faulty Thermostat. Replace. CA449 Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase. Check and add oil. Check and remove required Excessive oil in crankcase amount of oil. Check for cause (causing it to become aerated).

  • Page 172: Battery Will Not Come Up On Charge

    Check all throttle linkages. If Loose or missing shift and any are loose or missing, see throttle linkages. Authorized Mercury MerCruiser Dealer immediately. Obstruction in shift or throttle Remove obstruction. linkages. Straighten cable or have dealer Shift or throttle cable kinked.

  • Page 173: Steering Wheel Turns Hard Or Jerky

    Replace and/or adjust. condition. Insufficient lubrication on Lubricate. steering components. Check all parts and fasteners if Loose or missing steering any are loose or missing, see fasteners or parts. Authorized Mercury MerCruiser Dealer immediately. Contaminated power steering Drain and replace. fluid.
  • Page 174 INDEX CA453 Power Trim Does Not Operate (Motor Doesn’t Run) Possible Cause Remedy Blown fuse. Replace fuse. Check all associated electrical connections and wires Loose or dirty electrical (especially battery cables). connections or damaged Clean and tighten faulty wiring. connection. Repair or replace wiring.

  • Page 175: Owner Service Assistance

    CA903 Owner Service Assistance Local Repair Service Always return your Mercury MerCruiser powered boat to your local Authorized Dealer, should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur.

  • Page 176: Resolving A Problem

    • Your name and address • Daytime telephone number • Model and serial numbers for your power package • The name and address of your dealership • Nature of problem Mercury Marine Service Offices are listed on the next page.

  • Page 177: Mercury Marine Service Offices

    (32) (87) 32 • 32 • (32) (87) 31 • 19 • Parc Industriel de Petit-Rechain B-4800 Verviers Belgium Mexico, Central America, South America, Caribbean Mercury Marine - Latin America (305) 385-9585 (305) 385-5507 & Caribbean 9010 S.W. 137th Ave. Suite 226 Miami, FL 33186 U.S.A.

  • Page 178: Customer Service Literature

    Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
  • Page 179 Andere Sprachen Um eine Betriebs– und Wartungsanleitung in einer anderen Sprache zu erhalten, wenden Sie sich an das nächste Mercury Marine oder Marine Power International Service Center. Eine Liste mit Teilenummern für Fremdsprachen ist im Lieferumfang Ihres Motors enthalten.
  • Page 180 Gia na apoktÞsete Ýna Egxeiρßdio Leitouρgßaj kai SuntÞρhshj se Üllh glþssa, epikoinwnÞste me to plhsiÝsteρo DieqnÝj KÝntρo SÝρbij thj Mercury Marine Þ thj Marine Power gia plhρofoρßej. To pakÝto isxýoj saj sunodeýetai apü Ýnan katÜlogo aρiqmþn paρaggelßaj gia Üllej glþssej.

  • Page 181: Ordering Literature

    Model __________ Horsepower__________ Serial Number_____________ Year_______ United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact: Mercury Marine Telephone...

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