important information 1 b - · pdf file1b-0 - maintenance 90-823224--2 796 ... power steering...

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IMPORTANT INFORMATION

MAINTENANCE

1B-0 - MAINTENANCE 90-823224--2 796

Table of ContentsPage

Maintenance Schedule 1B-1. . . . . . . . . . . . . . . . . . . . Maintenance Intervals 1B-1. . . . . . . . . . . . . . . . . . To Be Done by Dealer 1B-2. . . . . . . . . . . . . . . . . .

Tune-Up Specifications 1B-4. . . . . . . . . . . . . . . . . . . MCM (Stern Drive) 1B-4. . . . . . . . . . . . . . . . . . . . . MIE (Inboard) 1B-5. . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Capacities 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . All Models 1B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-Hour Break-In Period 1B-7. . . . . . . . . . . . . . . . End of First Season Checkup 1B-7. . . . . . . . . . .

Fuel Specifications 1B-8. . . . . . . . . . . . . . . . . . . . . . . Fuel 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Oil 1B-9. . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Fluid 1B-10. . . . . . . . . . . . . . . . . . Transmission Fluid 1B-10. . . . . . . . . . . . . . . . . . . . Coolant for Closed Cooling System 1B-10. . . . .

Maintaining Crankcase Oil Level 1B-10. . . . . . . . . . Overfilled Engine Crankcase 1B-10. . . . . . . . . . . Checking Engine Oil Level/Filling 1B-10. . . . . . .

Changing Oil and Filter 1B-10. . . . . . . . . . . . . . . . . . . Maintaining Power Steering Pump Fluid Level 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With Engine Warm 1B-11. . . . . . . . . . . . . . . . . . . . With Engine Cold 1B-11. . . . . . . . . . . . . . . . . . . . .

Filling and Bleeding Power Steering System 1B-12Maintaining Closed Cooling Coolant Level 1B-13. . Flushing Cooling System 1B-13. . . . . . . . . . . . . . . . .

MCM (Stern Drive) 1B-13. . . . . . . . . . . . . . . . . . . . MIE (Inboard) 1B-15. . . . . . . . . . . . . . . . . . . . . . . .

Maintaining Transmission Fluid Level 1B-15. . . . . . Lubrication 1B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Cable 1B-16. . . . . . . . . . . . . . . . . . . . . . . . Shift Cable 1B-17. . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coupler/U-Joint Shaft Splines 1B-18. . . Drive Shaft Extension Models 1B-18. . . . . . . . . . Starter Motor 1B-19. . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather or Extended Storage 1B-19. . . . . . . . Precautions 1B-19. . . . . . . . . . . . . . . . . . . . . . . . . . Layup 1B-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining Instructions 1B-22. . . . . . . . . . . . . . . . . . Recommissioning 1B-34. . . . . . . . . . . . . . . . . . . . .

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Maintenance ScheduleMaintenance IntervalsMaintenance intervals and the tasks to be performed, as shown in this current schedule, or as found in a pre-viously printed schedules, are generally based on an average boating application and environment. However,individual operating habits and personal maintenance preferences can have an impact on the suggested inter-vals. In consideration of these factors, MerCruiser has adjusted some maintenance intervals and correspondingtasks to be performed. In some cases, this may allow for more individual tasks to be performed in a single visitto the serving dealer, rather than multiple visits. Therefore, it is very important that the boat owner and servicingdealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincidewith the individual operating habits, environment, and maintenance requirements.

Always disconnect battery cables from battery BEFORE working around electrical systems components to pre-vent injury to yourself and damage to electrical system should a wire be accidentally shorted.

SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR

NOTE: Only perform maintenance which applies to your particular power package.

Task Interval

Engine Crankcase Oil - Check level

W kl

Closed Cooling Coolant - Check level

W kl

Power Steering Fluid - Check level

W kl

Stern Drive Unit Oil - Check level

W klBattery - Check level and inspect for damage

WeeklyFuel Pump Sight Tube (If Equipped) - Check that nofuel is present

Weekly

Power Trim Pump Oil - Check level

Anodes - Inspect for erosion

Gear Housing Water Pickups - Check for marinegrowth or debris

Drive Belt(s) - Inspect condition and check tension Every 100 hours of operation or 120 days.Whichever occurs first.

Propeller Shaft - Lubricate Saltwater Use : Every 50 hours of operation or 60days, Whichever occurs first.

Power Package - Exterior Surfaces - Spray with rustpreventative

days, Whichever occurs first.Freshwater Use: Every 100 hours of operation or

120 days, Whichever occurs first.

Power Package Exterior Surfaces - Clean and paint Once a year

Cooling System - Flush seawater section Saltwater Use: After every use.

1B-2 - MAINTENANCE 90-823224--2 796

Maintenance Schedule (Continued)To Be Done by Dealer


Task Interval

Seawater Pickup Pump - Disassemble and inspect Whenever insufficient seawater flow is suspected. (If operating temperature exceeds normal range.)

Crankcase Oil and Filter Change

E d f fi b i

Ignition system - Clean and Inspect condition.

E d f fi b i

Flame Arrestor and Crankcase Ventilation Hose -Clean and Inspect.

E d f fi b i

Positive Crankcase Ventilation (PCV) Valve (If SoEquipped) - Change

E d f fi b i

Stern Drive unit Oil - Change

E d f fi b i

Gimbal Ring Clamping Screws - Retorque to 40 ft.lb. (54 N·m)

E d f fi b i

Rear Engine Mounts - Check torque to 30-40 ft. lb.(47-54 N·m)

E d f fi b i

Gimbal Bearing - Lubricate

E d f fi b i

Cooling System - Clean and Inspect

E d f fi b i

Engine Alignment - Check

E d f fi b iEngine Coupling Universal Joint Shaft Splines -Lubricate

End of first boating seasonand thereafter,

every100 hours of operationSteering System - Lubricate and inspect for loose,damage or missing parts.

every100 hours of operationor once yearly, whichever

occurs first.Electrical System - Check for loose or damaged

wiring.

occurs first.

Cooling System Hoses and Clamps - Inspect fordamage and deterioration. Check Clamps for

tightness.

Closed Cooling System Pressure Cap - Clean,inspect and test .

Continuity Circuit - Check components for looseconnections, broken or frayed wires.

Shift and Throttle Cable and Linkage - Lubricateand inspect for loose, damaged or missing parts

Engine Exhaust System - Inspect externally fordamage, deterioration and restrictions. Check for

tightness.

Ignition System - Check Timing and adjust asneeded.

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Maintenance Schedule (Continued)To Be Done by Dealer


Task Interval

Steering Head and Remote Control - Inspect andLubricate. End of first boating season and thereafter, every

100 hours of operation or once yearly whicheverCarburetor (If So Equipped) - Inspect and adjust. 100 hours of operation or once yearly, whicheveroccurs first.

Throttle Body (Fuel Injection Models) - Inspectoccurs first.

Fuel Filters - Replace

O Y

Quicksilver Mercathode System - Test output.

O YClosed Cooling Coolant - Test for Alkalinity Once a Year

Heat Exchanger - Clean seawater section.

Drive Unit Bellows and Clamps - Inspect

Universal Joint Cross Bearings- InspectEnd of first boating season and thereafter, every200 hours of operation or once yearly, whicheveroccurs first.

Closed Cooling Coolant - Replace Every Two Years

1B-4 - MAINTENANCE 90-823224--2 796

Tune-Up Specifications

MCM (Stern Drive)

Model MCM 7.4LMCM 7.4LPT Bravo

Three

MCM 454Magnum

MCM 454EFI

MCM 502Magnum

MCM 502EFI

MagnumPropshaft RatingsHP (KW)

300 (224) 300 (224) 350 (261) 385 (287) 390 (291) 415 (309)

Number of Cylinders V-8

Displacement 454 C.I.D (7.4L) 502 C.I.D. (8.2L)

Bore/Stroke In. (mm) 4.25x4.00 (108x101.6) 4.47 x 4.00(113.5 x 101.6)

Compression Ratio 8.0:1 8.6:1

Compression Pressure 150 PSI (1034 kPa)

Idle RPM(in Forward Gear)

650 600 650 600

Max. RPM (at W.O.T.) 4200-4600 4600-5000

Oil Pressure(at 2000 RPM)

30-70 PSI (207-483 kPa)

Min. Oil Pressure(at Idle)

4 PSI (28 kPa)

Fuel Pump Pressure(at 1800 RPM)

3-7 PSI (21-48 kPa)

Fuel Rail Pressure(Running) (E.F.I. Only)

37 PSI(255 kPa)

37 PSI(255 kPa)

Electrical System 12 V Negative (–) Ground

Min. BatteryRequirements

450 cca575 mca

90A/h

650 cca,825 mca,or 150A/h

550 cca,700 mca or

120A/h

650 cca,825 mca,or 150A/h

Firing Order 1-8-4-3-6-5-7-2

Spark Plug Type AC MR43T/Champion RV15YC4/NGK BR6FS

Spark Plug Gap .035 in (0.9 mm)

Timing (at Idle RPM) 8 Degrees BTDC

Preliminary Idle Mixture 1 1/4 Turns 1 1/4 Turns

Thermostat 143° F(62° C)

160° F(71° C)

143° F(62° C)

160° F(71° C)

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MIE (Inboard)

Model MIE 7.4L MIE 454 EFI MIE 8.2L

Propshaft RatingsHP (KW)

310 (231) 395 (231) 400 (298)

Number of Cylinders V-8

Displacement 454 C.I.D (7.4L) 502 C.I.D. (8.2L)

Bore/Stroke 4.25x4.00 In. (108x101.6 mm) 4.47x4.00 (113.5x101.6)

Compression Ratio 8.0:1 8.6:1

Compression Pressure 150 PSI (1034 kPa) 150 PSI (1034 kPa)

Idle RPM (in Forward Gear)

650 600 600

Max. RPM (at W.O.T.) 4000-4400 4600-5000 4400-4800

Oil Pressure(at 2000 RPM)

30-70 PSI (207-483 kPa)

Min. Oil Pressure(at Idle)

4 PSI (28 kPa)

Fuel Pump Pressure(at 1800 RPM)

3-7 PSI (21-48 kPa) 3-7 PSI (21-48 kPa)

Fuel Rail Pressure(Running) (E.F.I. Only) 37 PSI (255 kPa)

Electrical System 12 V Negative (–) Ground

Min. BatteryRequirements

450 cca, 575 mca or90A/h

650 cca, 825 mca, or150A/h

550 cca, 700 mca or120A/h

Firing Order 1-8-4-3-6-5-7-2

Spark Plug Type AC MR43T/Champion RV15YC4/NGK BR6FS

Spark Plug Gap .035 in (0.9 mm)

Timing (at Idle RPM) 8 Degrees BTDC

Preliminary Idle Mixture 1-1/4 Turns 1-1/4 Turns

Thermostat 143°F(62° C)

160° F(71° C)

143°F(62° C)

72008

LH ROTATIONFRONT

Firing Order1-8-4-3-6-5-7-2

1B-6 - MAINTENANCE 90-823224--2 796

Fluid Capacities

NOTICE

All capacities are approximate fluid measures.

All capacities are U.S. Quarts (Litres).

MODEL MCM AND MIE 454 CID / 7.4L

MCM AND MIE 7.4L MPI

MCM AND MIE 502 CID / 8.2L

Crankcase Oil1 (With Filter) 7 (6.6) 7 (6.6)

Seawater Cooling System2 20 (19)

Closed Cooling System 28 (26.5) 1 18 (17) 2 18 (17) 2 28 (26.5) 2

1 Closed cooling system with manifolds included in coolant side of system.2 Closed cooling system without manifolds included in coolant side of system.

IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling sys-tems (heat exchanger and fluid lines).

MAKE AND MODEL CAPACITY QUARTS (LITRES) FLUID TYPE

Hurth 630A 3-1/4 (3)

D III A i T i i630V 4.25 (4.0)

Dexron III Automatic Transmission800A2 5-3/4 (5.5) Dexron III Automatic TransmissionFluid

800AM 4-2/5 (4.2)Fluid

Velvet Drive 1:1 2 (1.9)

NOTE: Always use dipstick to determine exact quantity of fluid required

NOTE: Seawater cooling system capacity information is for winterization use only

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All Models20-Hour Break-In PeriodIMPORTANT: The first 20 hours of operation isthe engine break-in period. Correct break-in isessential to obtain minimum oil consumptionand maximum engine performance. During thisbreak-in period, the following rules must beobserved:

• Do not operate below 1500 RPM for extendedperiods of time for first 10 hours. Shift into gear assoon as possible after starting and advancethrottle above 1500 RPM if conditions permitsafe operation.

• Do not operate at one speed consistently forextended periods.

• Do not exceed 3/4 throttle during first 10 hours.During next 10 hours, occasional operation at fullthrottle is permissible (5 minutes at a timemaximum).

• Avoid full throttle acceleration from IDLE speed.

• Do not operate at full throttle until engine reachesnormal operating temperature.

After Break-in PeriodTo help extend the life of your MerCruiser powerpackage, the following recommendations should beconsidered;

• Use a propeller that allows the engine to operateat or near the top of the maximum RPM range(See “Specifications” section) when at full throttlewith a normal boat load.

• Operation at 3/4 throttle setting or lower is recom-mended. Refrain from prolonged operation atmaximum (full throttle) RPM.

End of First Season CheckupAt the end of the first season of operation, anAuthorized MerCruiser Dealer should be contactedto discuss and/or perform various scheduledmaintenance items. If you are in an area where theproduct is operated continuously (year-roundoperation), you should contact your dealer at the endof the first 100 hours of operation, or once yearly,whichever occurs first.

1B-8 - MAINTENANCE 90-823224--2 796

Fuel Specifications

Fuel

! CAUTIONUse of improper gasoline can damage the engineseriously. Engine damage that results from useof improper gasoline is considered misuse of theengine and is not covered under MerCruiser War-ranty.

USA and Canada

Fuel having a posted pump Octane Rating of 87 (R +M) / 2 minimum. Premium gasoline [92 (R + M) / 2] isalso acceptable . DO NOT use leaded gasolines.Outside USA and Canada

Fuel having a posted pump Octane Rating of 92 RONminimum. Premium gasoline (98 RON) is also ac-ceptable. If unleaded is not available, use a majorbrand of leaded gasoline.

Gasolines containing alcohol, either methyl alcohol(methanol) or ethyl alcohol (ethanol) may cause in-creased:

• Corrosion of metal parts.

• Deterioration of elastomer and plastic parts.

• Fuel permeation through flexible fuel lines.

• Wear and damage of internal engine parts.

• Starting and operating difficulties.

Some of these adverse effects are due to the tenden-cy of gasolines containing alcohol to absorb moisturefrom the air, resulting in a phase of water and alcoholseparating from the gasoline in the fuel tank.

The adverse effects of alcohol are more severe withmethyl alcohol (methanol) and are worse with in-creasing alcohol content.

! WARNINGFire and Explosion Hazard: Fuel leakage fromany part of the fuel system can be a fire and ex-plosion hazard which can cause serious bodilyinjury or death. Careful periodic inspection of theentire fuel system is mandatory, particularly afterstorage. All fuel system components includingfuel tanks (whether plastic, metal or fiberglass),fuel lines, primer bulbs, fittings, fuel filters andcarburetors should be inspected for leakage,softening, hardening, swelling or corrosion. Any

sign of leakage or deterioration requires replace-ment before further engine operation.

Because of possible adverse effects of alcohol ingasoline, it is recommended that only alco-hol-free gasoline be used where possible. If onlyfuel containing alcohol is available, or if the pres-ence of alcohol is unknown, increased inspec-tion frequency for leaks and abnormalities is re-quired.

! WARNINGAvoid gasoline fire or explosion. Improper instal-lation of brass fittings or plugs into fuel pump orfuel filter base can crack casting and/or cause afuel leak.

IMPORTANT: When operating a MerCruiser en-gine on gasoline containing alcohol, storage ofgasoline in the fuel tank for long periods shouldbe avoided. Long periods of storage, common toboats, create unique problems. In cars, alco-hol-blend fuels normally are consumed beforethey can absorb enough moisture to causetrouble, but boats often sit idle long enough forphase separation to take place. In addition, inter-nal corrosion may take place during storage if al-cohol has washed protective oil films from inter-nal components.

GASOLINE / ALCOHOL BLENDS

Many new motor vehicle owner manuals are warningabout the potential damage from using gasoline con-taining alcohol, especially METHANOL. They citepossible fuel system damage and performance prob-lems. These are just two of the hazards that may becaused by alcohol. These same problems as well asthe additional safety risk of fire and explosion fromfuel system leaks apply to marine inboard engines.METHANOL is more severe in its bad effect than isETHANOL. Alcohol is also more severe in older en-gines since newer engines have materials which aremore resistant to alcohol.

EFFECTS OF GASOLINE / ALCOHOL BLENDSON MARINE ENGINES

Corrosion of metals may result from use of alco-hol-gasoline blends. Portable or permanently in-stalled fuel tanks of metal or fiberglass, fuel filters,fuel lines and float bowls may be affected by alcoholblended fuels. Many fiberglass fuel tanks are slowlydissolved by alcohol, leading immediately to filter andcarburetor plugging and eventually to tank failure.

Fuels containing alcohol will absorb moisture fromthe air. At first, this moisture will remain in solution,

MAINTENANCE - 1B-990-823224--2 796

but once the water content of the fuel has built up toabout one-half of one percent, it will separate out(phase separation), bringing the alcohol with it. Thisalcohol-water mixture settles to the bottom of the fueltank and if this mixture gets into the engine, the en-gine can be seriously damaged internally, as it maywash the protective film of oil off the bore of any cylin-der that it enters. Before the engine can be restarted,it is necessary to remove the separated alcohol andwater layer, flush out the fuel system with clean fueland remove and dry the spark plugs.

BOAT / MOTOR STORAGE

When operating a MerCruiser engine on gasolinecontaining alcohol, storage of gasoline in the fueltank for long periods of time should be avoided.

Long periods of storage, common to boats, createunique problems. In cars, gasoline/alcohol blendfuels normally are consumed before they can absorbenough moisture to cause trouble, but boats often sitidle long enough for phase separation to take place.In addition, internal corrosion may take place duringstorage if alcohol has washed protective oil films frominternal components.

WINTER STORAGE

If boat is to be placed in winter storage, carburetorsmust be run dry at idle RPM. Permanent fuel tanksshould be drained completely and Quicksilver Gaso-line Stabilizer and Conditioner added to any fuel re-maining in the tank. Portable fuel tanks should beemptied completely.

WARRANTY

Performance problems and fuel system or otherdamage resulting from the use of gasoline-alcoholblended fuels are not the responsibility of MerCruiserand will not be covered under our warranty.

CONTINUING EVALUATIONS

The effects of gasoline with ETHANOL and METHA-NOL are still being evaluated by the United StatesCoast Guard, the National Marine Manufacturers As-sociation (NMMA), Mercury Marine and other engineand boat manufacturers.

We have recommended pump posting of alcoholcontent of gasoline. Further we recommend usinggasoline known not to contain any METHANOL orETHANOL when possible.

TEST FOR ALCOHOL CONTENT IN GASOLINE

The following is an acceptable and widely used fieldprocedure for the detection of alcohol in gasoline.Use any small transparent bottle or tube that can becapped and is, or can be, provided with graduationsor a mark at about 1/3 full. A pencil mark on a piece ofadhesive tape may be used.

Procedure

1. Fill the container with water to the mark.

2. Add fuel almost to fill the container, leaving someair space, then cap the container. The propor-tions of fuel to water are not critical, but thereshould be 2 to 3 times as much fuel as water.

3. Shake container vigorously and allow it to sit up-right for 3 to 5 minutes . If the volume of waterappears to have increased, alcohol is present. Ifyou are not sure, there is no need for concern. Ifthe dividing line between water and fuel becomescloudy, use the middle of the cloudy band.

Crankcase OilTo help obtain optimum engine performance and toprovide maximum protection, we strongly recom-mend the use of Quicksilver 4-Cycle Marine EngineOil. If not available, a good grade, straight weight, de-tergent automotive oil of correct viscosity, with an APIclassification of SF or SG, may be used.

The following chart is a guide to crankcase oil selec-tion. Oil filter should always be changed with oil.

In those areas where recommended straight weightoil is not available, a multi-viscosity 20W-40 (SF orSG) or, as a second but less preferable choice,20W-50 (SF or SG) may be used.

IMPORTANT: The use of non-detergent oils, mul-ti-viscosity oils (other than 20W-40 or 20W-50),low quality oils or oils which contain solid addi-tives specifically are not recommended.

72010

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Power Steering FluidUse Quicksilver Power Trim and Steering Fluid, orautomatic transmission Fluid (ATF), Dexron, DexronII, Dexron IIl.

Transmission FluidVelvet Drive - 10 wt. tractor hydraulic fluid meetingthe C-3/TO-2 specification (preferably Mobil 424,Chevron, or Citgo).

Hurth - Automatic transmission fluid (ATF) Dexron IIor Dexron IIl.

Coolant for Closed Cooling System

! CAUTIONAlcohol or Methanol base antifreeze or plain wa-ter, are not recommended for use in fresh watersection of cooling system at any time.

We recommend that the coolant section of closedcooling system be filled with Quicksilver Pre-MixedEngine Coolant. In areas where the possibility offreezing does not exist, it is permissible to use a solu-tion of rust inhibitor and water (mixed to manufactur-er’s recommendations).

MerCruiser V-8 engines can use any type of perma-nent antifreeze or any brand antifreeze solution thatmeets GM specification 1825M.

Maintaining Crankcase OilLevel

Overfilled Engine CrankcaseOverfilled crankcases (oil level being too high ) cancause a fluctuation or drop in oil pressure and rockerarm “clatter” on MerCruiser engines. The over-fullcondition results in the engine crankshaft splashingand agitating the oil, causing it to foam (become aer-ated). The aerated oil causes the hydraulic valve lift-ers to “bleed down.” This, in turn, results in rockerarm “clatter” and loss of engine performance, due tothe valves not opening properly.

Care must be taken when checking engine oil level.Oil level must be maintained between the ADD markand the FULL mark on the dipstick. To ensure that

you are not getting a “false reading,” make sure thefollowing steps are done before checking the oil level.

• Boat “at rest” in the water, or

• If boat is on a trailer, raise or lower bow until theboat is setting at the approximate angle that itwould be if setting “at rest” in the water.

• Allow sufficient time for oil to drain into the crank-case if engine has just been run or oil has justbeen added.

Checking Engine Oil Level/FillingIMPORTANT: ENGINE CRANKCASE OIL MUSTBE CHECKED AT INTERVALS SPECIFIED IN“MAINTENANCE SCHEDULE” CHART. It is nor-mal for an engine to use a certain amount of oilin the process of lubrication and cooling of theengine. The amount of oil consumption is greatlydependent upon engine speed, with consump-tion being highest at wide-open-throttle and de-creasing substantially as engine speed is re-duced.

1. Stop engine and allow boat to come to a rest.

2. Allow oil to drain back into oil pan - approximately5 minutes.

3. Remove dipstick. Wipe clean and reinstall. Pushdipstick all the way into dipstick tube.

4. Remove dipstick and note the oil level.

5. Oil level must be between the FULL and ADDmarks.

6. If oil level is below ADD mark, proceed to Steps7 and 8.

7. Remove oil filler cap from valve rocker arm cover.

8. Add required amount of oil to bring level up to, butnot over, the FULL mark on dipstick.

Changing Oil and Filter1. Start engine and run until it reaches normal oper-

ating temperatures.

IMPORTANT: Change oil when engine is warmfrom operation, as it flows more freely, carryingaway more impurities.

2. Stop engine.

3. Remove drain plug from oil pan or from oil drainhose.

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NOTE: If drain plug is not accessible because of boatconstruction, oil may be removed through dipsticktube, using a Quicksilver Crankcase Oil Pump. (SeeQuicksilver Accessory Guide.)

4. After oil has drained completely, reinstall drainplug (if removed) and tighten securely.

5. Remove and discard oil filter and its sealing ring.

6. Coat sealing ring on new filter with engine oil, andinstall. Tighten filter securely (following filter man-ufacturer’s instructions). Do not over-tighten.

7. Fill crankcase with oil.

8. Start engine and check for leaks.

Maintaining Power SteeringPump Fluid Level

With Engine Warm1. Stop engine and position drive unit so that it is

straight back.

2. Remove fill cap/dipstick from power steeringpump and note fluid level.

72517

b a

a - Fill Cap / Dipstickb - Power Steering Pump

3. Level should be between the FULL HOT markand ADD mark on dipstick.

72518

a

a - Proper Fluid Level with Engine Warm

4. If level is below ADD mark, but fluid is still visiblein pump reservoir, add required amount of Quick-silver Power Trim and Steering Fluid or automatictransmission fluid (ATF), Dexron, or Dexron II,through fill cap opening, to bring level up to FULLHOT mark on dipstick. DO NOT OVERFILL.

5. If fluid is not visible in reservoir, a leak exists in thepower steering system. Find cause and correct.

With Engine Cold1. With engine stopped, position drive unit so that it

is straight back.

2. Remove fill cap/dipstick from power steeringpump and note fluid level.

3. Level should be between FULL COLD mark andbottom of dipstick.

72519

a

a - Proper Fluid Level with Engine Cold

1B-12 - MAINTENANCE 90-823224--2 796

4. If level is below bottom of dipstick, but fluid is stillvisible in pump reservoir, add required amount ofQuicksilver Power Trim and Steering Fluid or au-tomatic transmission fluid (ATF), Dexron DexronII, or Dexron III, through fill cap opening, to bringlevel up to FULL COLD mark on dipstick. DONOT OVERFILL.

If fluid is not visible in reservoir, a leak exists in thepower steering system. Find cause and correct.

Filling and Bleeding PowerSteering SystemIMPORTANT: Power steering system must befilled exactly as explained in the following to besure that all air is bled from the system. All airmust be removed, or fluid in pump may foam dur-ing operation and be discharged from pump res-ervoir. Foamy fluid also may cause power steer-ing system to become spongy, which may resultin poor boat control.

1. With engine stopped, position drive unit so that itis straight back. Remove fill cap/dipstick frompower steering pump. Add Quicksilver PowerTrim and Steering Fluid or automatic transmis-sion fluid (ATF), Dexron, Dexron II or Dexron III,as required, to bring level up to FULL COLD markon dipstick.

IMPORTANT: Use only Quicksilver Power Trimand Steering Fluid or automatic transmissionfluid (ATF), Dexron, Dexron II or Dexron IIl in pow-er steering system.

2. Turn steering wheel back and forth to end of trav-el in each direction several times, then recheckfluid level and add fluid, if necessary.

3. Install vented fill cap.

! CAUTIONDO NOT operate engine without water beingsupplied to seawater pickup pump, or pump im-peller may be damaged and subsequent over-heating damage to engine may result.

4. Start engine and run at fast idle (1000-1500RPM) until engine reaches normal operatingtemperature. During this time, turn steeringwheel back and forth to end of travel in each di-rection several times.

5. Position drive unit so that it is straight back andstop engine. Remove fill cap from pump. Allowany foam in pump reservoir to disperse, thencheck fluid level and add fluid, as required, tobring level up to FULL HOT mark on dipstick. DONOT OVERFILL. Reinstall fill cap securely.

IMPORTANT: Drive unit must be positionedstraight back and power steering fluid must behot to accurately check fluid level.

6. If fluid is still foamy (in Step 5), repeat Steps 4 and5 until fluid does not foam and level remains con-stant.

MAINTENANCE - 1B-1390-823224--2 796

Maintaining Closed CoolingCoolant Level

! WARNINGAllow engine to cool down before removing pres-sure cap. Sudden loss of pressure could causehot coolant to boil and discharge violently. Afterengine has cooled, turn cap 1/4 turn to allow anypressure to escape slowly, then push down andturn cap all the way off.

1. Coolant level in heat exchanger should be full (tobottom of filler neck).

IMPORTANT: When reinstalling pressure cap, besure to tighten it until it contacts stop on fillerneck.

2. Coolant level should be between the ADD andFULL marks on coolant recovery reservoir withthe engine at normal operating temperature.

72520

a

a - Coolant Recovery Reservoir

Flushing Cooling SystemIf engine is operated in salty, polluted, or mineral-lad-en water, flush cooling system (preferably after eachuse) to reduce corrosion and prevent the accumula-tion of deposits in the system. Thoroughly flush cool-ing system prior to storage.

MCM (Stern Drive)

BOAT OUT OF WATER

1. Install flushing attachment over water pickupholes in gear housing as shown.

2. Attach a garden hose between the flushing at-tachment and a water tap.

72693

a

b

a - Flushing Attachmentb - Hose

! WARNINGWhen flushing, be certain the area around pro-peller is clear, and no one is standing nearby. Toavoid possible injury, remove propeller.

! CAUTIONDo not run engine above 1500 RPM when flush-ing. Suction created by seawater pickup pumpmay collapse flushing hose, causing engine tooverheat.

1B-14 - MAINTENANCE 90-823224--2 796

! CAUTIONWatch temperature gauge on dash to ensure thatengine does not overheat.

3. Partially open water tap (approximately 1/2 maxi-mum capacity). DO NOT use full water pressure.

4. Place remote control in neutral, idle speed posi-tion, and start engine.

5. Operate engine at idle speed in neutral for 10minutes, or until discharge water is clear, thenstop engine.

6. Shut off water tap. Remove garden hose andflushing attachment.

BOAT IN WATER

1. Raise drive unit to full UP position.

2. Install flushing attachment over water pickupholes in gear housing as shown.

3. Attach a garden hose between the flushing at-tachment and a water tap.

72693

a

b

a - Flushing Attachmentb - Hose

4. Lower drive unit to full IN position.



5. Partially open water tap (approximately 1/2 maxi-mum capacity). DO NOT use full water pressure.

6. Place remote control in neutral, idle speed posi-tion, and start engine.

7. Operate engine at idle speed in neutral for 10minutes, then stop engine.

8. Shut off water tap.

9. Raise drive unit to full UP position.

10. Remove garden hose and flushing attachment.

MAINTENANCE - 1B-1590-823224--2 796

MIE (Inboard)

! CAUTIONIf boat is in the water, seacock, if so equipped,must remain closed until engine is to bere-started, to prevent water from flowing backinto cooling system and/or boat. If boat is notfitted with a seacock, water inlet hose must be leftdisconnected and plugged (to prevent waterfrom flowing back into cooling system and/orboat). As a precautionary measure, attach a tagto the ignition switch or steering wheel of theboat with the warning: Open seacock or recon-nect water inlet hose before starting engine.

IMPORTANT: If a seacock is to be installed forthis purpose, valve used must have an internalcross-sectional area equal to or greater than wa-ter inlet hose to prevent restricting water flowduring normal operation. A 1-1/4 in. (32 mm), orlarger, brass ball valve or gate valve is recom-mended.

1. If boat is in water, close seacock, if so equipped,or disconnect and plug seawater inlet hose toprevent seawater from entering boat.

2. Remove inlet hose from seawater pickup pump.

3. Using an adaptor, connect a garden hose from awater tap to seawater pump inlet.

4. Partially open water tap (approximately 1/3 maxi-mum). Do not use full water pressure.

5. Place the remote control lever in neutral positionand start engine.

! WARNINGWhen flushing, be certain the area around pro-peller is clear, and no one is standing nearby. Toavoid possible injury, remove propeller.



6. Operate engine at idle speed in neutral for 10minutes, or until discharge water is clear. Stopengine.

7. Shut off water tap. Remove garden hose andadaptor from pump inlet and reconnect water in-let hose. Be sure to tighten hose clamp securely.

IMPORTANT: If boat is in the water, do not openwater inlet valve until engine is to be restarted toprevent contaminated water from flowing backinto engine. If boat is not fitted with a valve, leavewater inlet hose disconnected and plugged.

Maintaining TransmissionFluid LevelIMPORTANT: Be sure to push dipstick all the waydown into dipstick tube when checking fluidlevel.

1. Remove dipstick to check transmission fluid lev-el. Fluid level may be over the full mark becausefluid from the cooler and lines has drained backinto the transmission. If fluid level is low, add thespecified fluid through the dipstick hole until fullmark on dipstick is reached. DO NOT OVER-FILL.

72527

Hurth

1B-16 - MAINTENANCE 90-823224--2 796

72526

Velvet Drive

IMPORTANT: To accurately check fluid level, en-gine MUST BE run at 1500 RPM for 2 minutes im-mediately prior to checking level.

2. Start engine and run at 1500 RPM for 2 minutesto fill all circuits, lines, and cooler.

3. Stop engine and quickly check level before fluiddrains back into transmission. Add fluid if neces-sary.

4. If fluid level is extremely low, check transmissioncase, cooler, and hoses for leaks.

IMPORTANT: Velvet Drive - transmission - use 10wt. tractor hydraulic fluid meeting the C-3/TO-2specification (preferably Mobil 423, Chevron, orCitgo).

Hurth transmission - use Dexron II or Dexron IIIautomatic transmission fluid (ATF).

Lubrication

Throttle Cable

MODELS WITH 4 BARREL CARBURETOR

72014

b

a

a - Pivot Pointsb - Guide Contact Surface

MODELS WITH THROTTLE BODY FUELINJECTION

75038

a

a

b


MAINTENANCE - 1B-1790-823224--2 796

MODELS WITH MULTI-PORT FUEL INJECTION

72791b

a

a


Shift Cable

72016

b

a

a

a

b

MCM Models - Typical Shift Cablea - Pivot Pointsb - Guide Contact Surface

MIE MODEL TYPICAL SHIFT CABLE ANDTRANSMISSION LINKAGE

71208

a

a

b

Hurtha - Pivot Pointsb - Guide Contact Surface

72528

a

a

b

Velvet Drivea - Pivot Pointsb - Guide Contact Surface

1B-18 - MAINTENANCE 90-823224--2 796

Engine Coupler/U-Joint Shaft SplinesNOTE: Engine coupler and shaft splines are greasedwith Quicksilver Engine Coupler Spline Grease,92-816391A4; universal joints are greased withQuicksilver 2-4-C Marine Lubricant.

NOTE: Refer to MerCruiser Stern Drive ServiceManual for stern drive unit removal and installation,if necessary.

IMPORTANT: Stern Drive Unit does not have to beremoved to grease coupler.

72529

a

b

MCM Modelsa - Quicksilver Engine Coupler Spline Greaseb - Grease Fitting(s) Use Grease Fitting If Drive Is Installed

72531

a

a

a

Typical Bravo Drivea - Quicksilver Engine Coupler Spline Grease

Drive Shaft Extension Models

72018

a

a

Transom Enda - Lubrication Points

72028

a

a

Engine Enda - Lubrication Points

MAINTENANCE - 1B-1990-823224--2 796

Starter Motor

MIE MODELS

! WARNINGWhen performing the following procedure, besure to observe the following:

• Be sure that engine compartment is well venti-lated and that no gasoline vapors are presentto avoid the possibility of a fire.

• Be sure to ground coil high-tension wire toblock. Failure to ground coil wire may causedamage to ignition coil in addition to being asafety hazard.

• Stay clear of all moving parts.

1. Remove ignition coil high-tension wire from dis-tributor cap tower and ground it to engine blockwith jumper wire. While cranking engine withstarter motor, lubricate starter motor front bush-ing through oil cover with motor oil or its equiva-lent. Reinstall coil high-tension wire.

2. Remove plastic plug from flywheel housing. Lu-bricate starter motor shaft with motor oil throughhole in flywheel housing. Reinstall plastic plug.

72019

a

a

a - Lubrication Points

Cold Weather or ExtendedStorage

Precautions

! WARNINGBE CAREFUL while working on fuel system; gas-oline is extremely flammable and highly explo-sive under certain conditions. Be sure that igni-tion key is OFF and do not smoke or allowsources of spark and/or open flames in the area.

! WARNINGTo prevent a potential fire hazard, be sure that en-gine compartment is well ventilated and thatthere are no gasoline vapors present duringstarting or fogging of engine.

! CAUTIONDO NOT operate engine without cooling waterbeing supplied to seawater pickup pump or waterpump impeller will be damaged and subsequentoverheating damage to engine may result.

! CAUTIONSeawater (Raw-water) section of cooling systemMUST BE COMPLETELY drained for winter stor-age, or immediately after cold weather use, if thepossibility of freezing temperatures exists. Fail-ure to comply may result in trapped water caus-ing freeze and/or corrosion damage to engine.

! CAUTIONIf boat is in the water, seacock (water inlet valve),if so equipped, must be left closed until engine isto be re-started, to prevent water from flowingback into cooling system and/or boat. If boat isnot fitted with a seacock, water inlet hose mustbe left disconnected and plugged (to prevent wa-ter from flowing back into cooling system and/orboat). As a precautionary measure, attach a tagto the ignition switch or steering wheel of theboat with the warning: Open seacock or recon-nect water inlet hose before starting engine.

1B-20 - MAINTENANCE 90-823224--2 796

IMPORTANT: Observe the following informationto ensure complete draining of cooling system.

• Engine must be as level as possible.

• A wire should be repeatedly inserted into alldrain holes to ensure there are no obstruc-tions in passages. Remove petcock, if neces-sary, to insert wire completely into drain hole.

IMPORTANT: To prevent threads in manifolds, el-bows and cylinder blocks from rusting out dur-ing storage, reinstall plugs using QuicksilverPerfect Seal on threads. Never leave drain plugsout during storage.

! CAUTIONStern drive unit should be stored in full “down”position. Universal Joint bellows may develop a“set” if unit is stored in raised position and mayfail when unit is returned to service.

NOTE: If possible, place a container under drainsand hoses to prevent water from draining into boat.

! CAUTIONIf engine is equipped with Closed Cooling Sys-tem, Closed Cooling section must be kept filledwith a solution of ethylene glycol antifreeze andwater (mix antifreeze to manufacturer’s recom-mended proportions to protect engine to lowesttemperature to which it will be exposed). DO NOTUSE PROPYLENE GLYCOL antifreeze in closedcooling section. Seawater section, however,must be drained completely.

! CAUTIONA discharged battery can be damaged by freez-ing.

Layup

NOTICE

Refer to “Cold Weather or Extended Storage,”“Precautions,” in this section, BEFORE proceed-ing.

1. Fill fuel tank(s) with fresh gasoline that does notcontain alcohol and a sufficient amount of Quick-silver Gasoline Stabilizer and Conditioner to treatthe gasoline.

IMPORTANT: If boat is to be placed in storage(with fuel containing alcohol in fuel tanks), car-buretors or vapor separator tanks must be rundry at idle RPM. Fuel tanks should be drainedcompletely and Quicksilver Gasoline Stabilizerand Conditioner added to any fuel remaining inthe tank. Also, refer to “Fuel Specifications,” seeTable of Contents.

2. Replace all fuel filters

3. Start engine and check for fuel leaks.

4. Run engine sufficiently to heat it to normal operat-ing temperature; shut off engine and change oiland filter.

5. If boat has been operated in salty, polluted or min-eral-laden waters, flush cooling system.

6. Prepare fuel system for extended storage as fol-lows:

a. For engines with carburetors:

Remove flame arrestor assembly and restartengine. While operating engine at fast idle(1000-1500 RPM), fog internal surfaces of in-duction system and combustion chambers bysquirting approximately 8 ounces (227grams) of Quicksilver Storage Seal or SAE20W engine oil into carburetor bores. Stallengine by squirting last 2 ounces (57 grams)of Storage Seal or oil rapidly into carburetor.Turn ignition to OFF.

b. For fuel injected engines with VST:

! WARNINGFuel injection system is pressurized. A specialprocedure must be used to remove this pressurebefore removing the plug from vapor separatortank. DO NOT attempt to remove plug withouthaving pressure removed. Fuel could spray onhot engine causing fire or explosion.

MAINTENANCE - 1B-2190-823224--2 796

(1) Relieve fuel pressure from system. Referto “Fuel Pressure Relief Procedure” inSection 5C.

(2) Remove plug from top of vapor separatortank.

(3) Add approximately 1 fluid ounce (30 ml)of Quicksilver 2-Cycle Outboard Oil tofuel in the vapor separator tank.

(4) Shut off the fuel supply to the engine’sfuel pump.

(5) Start engine and run at idle speed until thevapor separator tank and fuel injectionsystem is empty.

(6) Reinstall the plug in top of vapor separa-tor tank.

c. For fuel injected engines with Cool Fuelsystem:

(1) Fill fuel tank(s) with fresh gasoline (thatdoes not contain alcohol) and a sufficientamount of Quicksilver Gasoline Stabilizerfor Marine Engines to treat gasoline. Fol-low instructions on container.

(2) If boat is to be placed in storage withfuel containing alcohol in fuel tanks (iffuel without alcohol is not available):Fuel tanks should be drained completelyand Quicksilver Gasoline Stabilizer forMarine Engines added to any fuel re-maining in the tank. Refer to “FUEL RE-QUIREMENTS” for additional informa-tion.

(3) Prepare fuel system for extended storageas follows:

(4) Allow engine to cool down.

(5) Remove the water separating fuel filter.

(6) Pour out a small amount of fuel into a suit-able container, then add approximately 2fluid ounces (60 ml) of Quicksilver2-Cycle Outboard Oil to fuel in the waterseparating fuel filter.

(7) Install water separating fuel filter.

(8) Shut off the fuel supply to the engine.

(9) Start and run engine at idle speed for twominutes.

(10) Stop engine, remove and discard newwater separating fuel filter and in line fuelfilter.

(11) Install new filters.

(12) Close fuel shut-off valve, if so equipped.

7. Close fuel shutoff valve, if so equipped.

8. Clean flame arrestor and crankcase ventilationhoses and reinstall.

9. Lubricate all items outlined in “Lubrication.”

10. Drain seawater section of cooling system, as out-lined in “Draining Instructions” following.

11. Closed Cooling System Models: Test coolantto ensure that it will withstand lowest temperatureexpected during storage.

12. Service batteries.

13. Clean outside of engine and repaint any areas re-quired with Quicksilver Primer and Spray Paint.After paint has dried, spray Quicksilver Corrosionand Rust Preventive Type II or wipe down withQuicksilver Storage Seal or SAE 20W engine oil.

14. For drive unit, refer to appropriate stern drivemanual.

1B-22 - MAINTENANCE 90-823224--2 796

Draining Instructions

DRAINING SEAWATER (RAW-WATER) COOLEDMODELS

NOTICERefer to “Cold Weather or Extended

Storage,” “Precautions,” in this section,BEFORE proceeding.

MCM (Stern Drive) Models:

1. Engine must be as level as possible to ensurecomplete draining of cooling system.

2. Remove drain plugs (port and starboard) fromcylinder block.

74130a

Starboard Side Shown (Port Similar)a - Drain Plug

3. Repeatedly clean out drain holes using a stiffpiece of wire. Do this until entire system isdrained.

NOTE: It may be necessary to lift, bend, or lowerhoses to allow water to drain completely when hosesare disconnected.

4. Remove hose or drain plug from bottom of portand starboard exhaust manifolds.

NOTE: With the engine level, sufficient draining ofmanifolds will occur when the hose or drain plug is re-moved from the elbow in the exhaust manifold.

a

Engine with Drain Plug In Exhaust Manifolda - Bottom Hose, Exhaust Manifold To Thermostat Housing

74130b


MAINTENANCE - 1B-2390-823224--2 796

5. Remove the engine water circulating pump hoseas shown.

72587

a

a - Hose, Water Circulating Pump To Thermostat Housing

6. On 7.4L and 454 Magnum Engines: Removethe oil/power steering fluid cooler seawater hose,as shown.

72925

a

a - Hose, Seawater Pump To Cooler

7. On Cool Fuel Models or Carbureted modelswit port side water tube: Remove the drainscrew from the fuel cooler.

75018

b

a

a - Cool Fuel Modelb - Carbureted Model

1B-24 - MAINTENANCE 90-823224--2 796

8. On 502 Engines: Remove the oil/power steeringfluid cooler seawater hoses, as shown.

72926a

a - Hose, Seawater Pump To Cooler

70585

b

a - Hose, Oil / Power Steering Cooler To Heat Exchanger

a. Remove seawater pump inlet hose as shown.

70346

b

a

Engines With Combination Seawater / Mechani-cal Fuel Pumpa - Seawater Pickup Pumpb - Inlet Hose

a

b

72352

Engines WIth Cool Fuel Systema - Seawater Inlet Hoseb - Hose To Cooler

MAINTENANCE - 1B-2590-823224--2 796

9. Insert a small wire (repeatedly) to make sure thatspeedometer pitot tube, trim tab cavity vent hole,and trim tab cavity drain passage are unob-structed and drained.

71217

b

ca

Typical Bravo Drive Unita - Speedometer Pitot Tubeb - Trim Tab Cavity Vent Holec - Trim Tab Cavity Drain Passage

a. Crank engine over slightly with starter motorto purge any water trapped in seawater pick-up pump. DO NOT ALLOW ENGINE TOSTART.

b. After cooling system has been drained com-pletely, coat threads of drain plugs withQuicksilver Perfect Seal. Install all drainplugs and tighten securely. Reconnect allhoses and tighten all hose clamps securely.

IMPORTANT: MerCruiser recommends that pro-pylene glycol antifreeze (nontoxic and biode-gradable, which makes it friendly to lakes and riv-ers) be used in sea-water section of the coolingsystem for cold weather or extended storage.Make sure that the propylene glycol antifreezecontains a rust inhibitor and is recommended foruse in marine engines. Be certain to follow thepropylene glycol manufacturer’s recommenda-tions.

10. For additional assurance against freezing andrust, remove the thermostat cover and thermo-stat. Fill the engine seawater cooling system witha mixture of antifreeze and tap water mixed tomanufacturer’s recommendation to protect en-gine to the lowest temperature to which it will beexposed during cold weather or extended stor-age. Using a new gasket, reinstall thermostat andcover. Tighten cover bolts to 30 lb. ft. (41 N·m).

NOTE: Hoses shown removed only to indicate flow.Do not remove hoses.

72589

b

c

d

ef

g

a

a - Coverb - Gasketc - Spacerd - Thermostate - O-Ringf - Housingg - Fill Here

1B-26 - MAINTENANCE 90-823224--2 796

MIE (Inboard) Models:




2. Remove drain plugs (port and starboard) fromcylinder block.

74130

a




4. Remove hose or drain cock from bottom of portand starboard exhaust manifolds.

NOTE: With the engine level, sufficient draining ofmanifolds will occur when exhaust manifold-to-ther-mostat housing hoses or drain cocks are removed.

NOTE: Some engines may be equipped with drainplugs in the elbows on exhaust manifolds. Removedrain plugs only.

a

72609

Engine With Drain Plugs In Exhaust Manifoldsa - Bottom Hose, Exhaust Manifold To Thermostat Housing

74130

a

Starboard Shown (Port Similar)a - Drain Plug

MAINTENANCE - 1B-2790-823224--2 796

5. Remove the engine water circulating pump hoseas shown.

72587

a

a - Hose, Water Circulating Pump To Thermostat Housing

6. Remove hose from the seawater pump, asshown.

70346a

b

Engines With Combination Seawater / Mechani-cal Fuel Pumpa - Seawater Pickup Pumpb - Hose, Seawater Inlet

a

b

72352

Engines WIth Cool Fuel Systema - Seawater Inlet Hoseb - Hose To Cooler

7. Remove the transmission fluid cooler hose asshown.

72721

a

71782a

Typical Transmission Fluid Cooler Locationsa - Hose

1B-28 - MAINTENANCE 90-823224--2 796

8. Crank engine over slightly with starter motor topurge any water trapped in seawater pickuppump. DO NOT ALLOW ENGINE TO START.

9. After cooling system has been drained complete-ly, coat threads of drain plugs with QuicksilverPerfect Seal. Install all drain plugs and tighten se-curely. Reconnect all hoses and tighten all hoseclamps securely.

IMPORTANT: MerCruiser recommends that pro-pylene glycol antifreeze (nontoxic and biode-gradable, which makes it friendly to lakes and riv-ers) be used in sea-water section of the coolingsystem for cold weather or extended storage.Make sure that the propylene glycol antifreezecontains a rust inhibitor and is recommended foruse in marine engines. Be certain to follow thepropylene glycol manufacturer’s recommenda-tions.

10. For additional assurance against freezing andrust, remove the thermostat cover and thermo-stat. Fill the engine seawater cooling system witha mixture of antifreeze and tap water mixed tomanufacturer’s recommendation to protect en-gine to the lowest temperature to which it will beexposed during cold weather or extended stor-age. Using a new gasket, reinstall thermostat andcover. Tighten cover bolts to 30 lb. ft. (41 N·m).

NOTE: Hoses shown removed only to indicate flow.Do not remove hoses.

72589

b

c

d

ef

g

a

d

e

g

f

c

a - Coverb - Gasketc - Spacerd - Thermostate - O-Ringf - Housingg - Fill Here

MAINTENANCE - 1B-2990-823224--2 796

DRAINING SEAWATER SECTION OF CLOSEDCOOLING (COOLANT) MODELS

MCM (Stern Drive) Models:




2. Remove drain plug from heat exchanger.

70583

a

a - Heat Exchangerb - Drain Plug



4. Remove hose from engine oil/power steeringfluid cooler as shown.

70584a

7.4L/454 Magnum Enginea - Hose, Oil Cooler To Heat Exchanger

70585

a

502 Magnum Enginea - Hose, Oil Cooler To Heat Exchanger

1B-30 - MAINTENANCE 90-823224--2 796

5. Remove seawater pump inlet hose as shown.

71170b

a

Engines With Combination Seawater / Mechani-cal Fuel Pumpa - Seawater Inlet Hoseb - Hose To Cooler

a

b

72352

Engines With Cool Fuel Systema - Seawater Inlet Hoseb - Hose To Cooler

6. Follow instructions “a” or “b”:

a. On Engines Without Risers: Disconnect“T”-fitting-to-heat exchanger hose from heatexchanger.

70586

a

Typical Engine Without Risers Showna - Hose, Heat Exchanger To T-Fitting

b. On Engines With 3 in. (76 mm) or 6 in. (152mm) Risers And Hoses Routed to RiserFitting Pointed Toward Flywheel End: Re-move heat exchanger-to-riser hose from portand starboard riser and remove heat exchan-ger-to-“T” fitting hose from heat exchang-er.

70588a

b

c

Typical Engine With Risers Showna - Hose, Heat Exchanger To Port Riserb - Hose, Heat Exchanger To Starboard Riserc - Hose, Heat Exchanger To T-Fitting

MAINTENANCE - 1B-3190-823224--2 796

7. On Bravo Drive Equipped Models: Insert asmall wire (repeatedly) to make sure that speed-ometer pitot tube, trim tab cavity vent hole, andtrim tab cavity drain passage are unobstructedand drained.

71217

b

ca

Typical Bravo Drive Unita - Speedometer Pitot Tubeb - Trim Tab Cavity Vent Holec - Trim Tab Cavity Drain Passage

8. Crank engine over slightly with starter motor topurge any water trapped in seawater pickuppump. DO NOT ALLOW ENGINE TO START.

9. After seawater section of cooling system hasbeen drained completely, coat threads of drainplugs with Quicksilver Perfect Seal. Install alldrain plugs and tighten securely. Reconnect allhoses and tighten all hose clamps securely.

MIE (Inboard) Models





2. On Engines Without Risers: Disconnect portand starboard heat exchanger-to-exhaust elbowhoses and lower to drain.

71504

b

a

Typical Engine Without Risersa - Hose, To Starboard Exhaust Elbowb - Hose, To Port Exhaust Elbow

1B-32 - MAINTENANCE 90-823224--2 796

3. On Engines with 3 in. (76 mm) or 6 in. (152mm) Risers: Remove heat exchanger-to-riserhose from port and starboard riser.

71507

a

Typical Engine With 3 in. (76mm) Riser [Star-board Similar; 6 in. (152mm) Risers Similar]a - Hose, Heat Exchanger To Riser Fitting

4. Disconnect and lower oil cooler-to-heat exchang-er hose from oil cooler, as appropriate on your en-gine.

71782

a

7.4L Engine With Rear Mounted Heat Exchanger(Velvet Drive In-Line and V-Drive Transmissions)a - Hose, Oil Cooler To Heat Exchanger

NOTE: Engine oil cooler is mounted beneath rearmounted heat exchanger tank.

71447

a

7.4L Engine With Rear Mounted Heat Exchanger(Hurth Transmission)a - Hose, Oil Cooler To Heat Exchanger

71517

a

7.4L / 8.2L Engine With Front Mounted Heat Ex-changera - Hose, Oil Cooler To Heat Exchanger

MAINTENANCE - 1B-3390-823224--2 796

5. Remove the transmission fluid cooler hose, asappropriate on your engine, to drain hose andcooler.

71782

a

7.4L Engine With Rear Mounted Heat Exchanger(Velvet Drive In-Line and V-Drive Transmissions)a - Hose, Transmission Cooler To Oil Cooler

72721

a

Typical Hurth Transmissiona - Hose, Transmission Fluid Cooler

6. Remove seawater pump inlet hose as shown.

71170

b

a

Engines Combination Seawater Pump / Mechani-cal Fuel Pumpa - Seawater Inlet Hoseb - Hose To Cooler

a

b

72352

Engines With Cool Fuel Systema - Seawater Inlet Hoseb - Hose To Cooler

7. Crank engine over SLIGHTLY, with starter motor,to purge any water trapped in seawater pickuppump. DO NOT ALLOW ENGINE TO START.

8. After seawater section of cooling system hasbeen drained completely, coat threads of drainplugs with Quicksilver Perfect Seal. Install alldrain plugs and tighten securely. Reconnect allhoses and tighten all hose clamps securely.

1B-34 - MAINTENANCE 90-823224--2 796

Recommissioning



1. Check that all cooling system hoses are con-nected and tight and all petcocks and drain plugsare installed and tight.

2. Inspect all drive belts.

3. Perform all lubrication and maintenance speci-fied for completion “At Least Once Yearly” inmaintenance chart, except items which were per-formed at time of engine layup.

4. For drive unit, refer to appropriate stern drivemanual.

! CAUTIONWhen installing battery (in next step), be sure toconnect positive battery cable to positive (+) ter-minal and negative (grounded) battery cable tonegative (–) battery terminal. If battery cables arereversed, damage to electrical system WILL re-sult.

5. Install fully charged battery. Clean battery cableclamps and terminals to help retard corrosion.

6. Start engine and closely observe instrumentationto ensure that all systems are functioning proper-ly.

7. Carefully inspect entire engine for fuel, oil, waterand exhaust leaks.

8. Check fuel pump sight tube.

9. Check steering system and shift and throttle con-trols for proper operation.

THIS PAGE IS INTENTIONALLY BLANK TOALLOW FOR CORRECTIONS OR ADDITIONS

AT A LATER DATE

MAINTENANCE - 1B-3590-823224--2 796

THIS PAGE IS INTENTIONALLY BLANK TOALLOW FOR CORRECTIONS OR ADDITIONS

AT A LATER DATE

1B-36 - MAINTENANCE 90-823224--2 796

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