mercruiser

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

4.3, 5.0 MPI & SEACORE 4.3, 5.0 MODELS INSTALLATION MANUALModels CoveredAlphaModels covered 4.3 MPI 5.0 MPI Serial Number 1A300000 and above

BravoModels covered 4.3 MPI 5.0 MPI SeaCore 4.3 SeaCore 5.0 1A300000 and above Serial Nnumber

NoticeNOTICE After completing installation, these instructions should be placed with the product for the owner's future use. NOTICE Predelivery preparation instructions must be performed before delivering boat to the product owner.

Notice to Boat Manufacturer/InstallerThroughout this publication, dangers, warnings, cautions, and notices, (accompanied by the International Hazard Symbol) are used to alert the manufacturer or installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.62006 for product safety information in product manuals, instructions, and other collateral materials. Observe Them Carefully! These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures.

! DANGERIndicates a hazardous situation which, if not avoided, will result in death or serious injury.

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2007 Mercury Marine

90-899883178 NOVEMBER 2007

! WARNINGIndicates a hazardous situation which, if not avoided, could result in death or serious injury.

! CAUTIONIndicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICEIndicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action. NOTE: Refer to the appropriate Mercury MerCruiser Product Applications Manual for application recommendations. This installation manual has been written and published by Mercury MerCruiser to aid the boat manufacturer (OEM) in the installation of the products described herein. It is assumed that these personnel are familiar with marine product installation. Furthermore, it is assumed that they are familiar with, if not trained in, the recommended installation procedures of Mercury MerCruiser product. We could not possibly know of or advise the marine trade of all conceivable installations and of the possible hazards and/or results of each installation. Therefore, the OEM is responsible for any installation that does not fulfil the requirements of this manual. It is the responsibility of the boat manufacturer to select the appropriate engine/transom/ drive package (including the correct gear ratio and propeller) for a given boat. Mercury MerCruiser recommends that any new or unique hull/power package combination be thoroughly water tested prior to sale, to verify that the boat performs as desired, and that the engine operates in the appropriate RPM range. It is recommended that a Mercury MerCruiser Product Application Engineer (PAE) be contacted for assistance. For assistance outside the United States, contact the local Mercury Marine office or authorized distributor. All information, illustrations and specifications contained in this manual are based on the latest product information available at time of publication. Mercury Marine reserves the right to make changes at any time without obligation. As required, revisions to this manual will be sent to all OEM boat companies.

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Manual Outline1 - Important Information 2 - Boat Construction 3 - Exhaust System 4 - Fuel System 5 - Cooling System 6 - Drive System and Engine Installation 7 - Electrical System 8 - Remote Controls 9 - Predelivery Preparation and Storage

Important Information

Boat Construction

Exhaust System

Fuel System

Cooling System

Drive System and Engine Installation

Electrical System

Remote Controls

Predelivery Preparation and Storage

1 2 3 4 5 6 7 8 9

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SECTION - 1

IMPORTANT INFORMATION

SECTION 1 - IMPORTANT INFORMATIONTable of ContentsTorque Specifications.............................................................................................................................................. 2 Quicksilver Products................................................................................................................................................ 2 Accessories ...................................................................................................................................................... 2 Remote Controls and Instrumentation for the DTS System.................................................................................... 3 Identification............................................................................................................................................................ 3 Serial Number Decal Placement.......................................................................................................................3 Bravo Sterndrive Serial Number and Identification...........................................................................................3 Bravo Transom Serial Number..........................................................................................................................4 Bravo Three Notice: Trimin Limit Insert.................................................................................................................. 5 Multiple Sterndrive Steering Tie Bar Arrangements................................................................................................ 5 Internal Power Steering With Internal Tie Bar Only ......................................................................................... 6 Internal Power Steering With Internal and External Tie Bar ............................................................................. 6 External Power Steering .................................................................................................................................. 6 External Power Steering With Low External Tie Bar ........................................................................................ 6 SeaCore Components and Castings....................................................................................................................... 6 Stainless Steel Fasteners........................................................................................................................................ 6 Corrosion Protection................................................................................................................................................ 7 Antifouling Paint..................................................................................................................................................... 7 Emission Control Information Label........................................................................................................................ 9 Owner Responsibility ...................................................................................................................................... 10 Star Label.............................................................................................................................................................. 10 Hang Tag............................................................................................................................................................... 11

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Lubricants, Sealants, AdhesivesTube Ref No.34

Description Special Lubricant 101

Where Used Threads of stainless steel fasteners

Part No. 92-802865Q02

Torque SpecificationsNOTE: Securely tighten all fasteners not listed below. NOTE: The propeller torque stated is a minimum torque value.Description Exhaust tube clamp Exhaust pipe bolts Exhaust blockoff plate bolts Bravo One propeller nut Bravo Two propeller nut Bravo Three front propeller nut Bravo Three rear propeller nut Rear engine mounting bolts Steering cable coupler nut Steering system pivot bolts Sterndrive unit fasteners Transom assembly fasteners Mounting clip screw Hose clamps Water inlet fitting bolts Water inlet blockoff screw Fuel inlet fitting Gen III Cool Fuel Module captured nut Battery stud Propeller shaft anode screw Nm 3 34 34 75 81 136 81 47 47 34 68 34 12.2 2 5 5 lbin. 26 108 26 45 45 lbft 25 25 55 60 100 60 35 35 25 50 25

Then align tabs with grooves Then align tabs with grooves

Finger tight + 13/4 to 21/4 turns with a wrench. Do not overtighten. 19 811 19 168 7191 168

Quicksilver ProductsAccessoriesQuicksilver gauges, remote controls, steering systems, propellers, and other accessories are available for this product. Mercury MerCruiser recommends the use of Quicksilver parts on all applications. Refer to Mercury Precision Parts Accessories Guide for a complete listing. This Guide is available from: Attn: Parts Department Mercury Marine W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 Outside of U.S.A., order through Distribution Center or Distributor.

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Remote Controls and Instrumentation for the DTS SystemThe Digital Throttle and Shift system (DTS) requires the use of specialized helm components, including a command module kit and electronic remote control. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

IdentificationSerial Number Decal PlacementThere are 3 sets of engine, transom assembly, and sterndrive serial number decal strips provided with each power package. One should be used for each of the following: Engine Specification Decal Warranty Registration Card Operation, Maintenance and Warranty Manual identification page Affix engine serial number decal to specification / serial number decal.

8331

aa - Specification/serial number decal

Bravo Sterndrive Serial Number and IdentificationThe sterndrive serial number, gear ratio, model number, and bar code is embedded in the ground plate located on the port side of the Bravo sterndrive.

a

b

c d

25906

a - Bar code b - Serial Number

c - Gear ratio d - Model number

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SECTION - 1

The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers.

a

25907

Bravo sterndrive serial number stamping a - Serial number stamping

Bravo Transom Serial NumberThe Bravo transom serial number is stamped in the Ubolt plate of the Bravo transom assembly.

a

25904

Bravo transom assembly Ubolt plate a - Transom assembly serial Number

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The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers.

a

25905

Gimbal housing with serial number stamping a - Transom assembly serial Number

Bravo Three Notice: Trimin Limit InsertNOTE: Bravo One, Two and Three Models are equipped with a trimin limit insert. It has been brought to our attention that some boats (predominantly deepVee heavy boats) will roll up on their side under certain, specific, operating conditions. The roll can be either to port or starboard and may be experienced while moving straight ahead, or while making a turn. The roll occurs most frequently at or near maximum speed, with the sterndrive unit trimmed at or near full trimin. While the boat will not roll completely over, the roll may be sufficient to unseat the operator or passengers, and thereby create an unsafe situation. The roll is caused by sternlift created from excessive sterndrive unit trimin. Under these extreme sternlift / bowdown conditions, instability can be created, which may cause the boat to roll. Weight distribution to the stern can reduce sternlift and, in some circumstances, help to control the condition. Weight distribution in the bow, port or starboard, may worsen the condition. The trimin limit insert reduces sternlift by preventing the sterndrive unit from reaching the last few degrees of full trim under. While this device should reduce the rolling tendency, it may not eliminate the tendency entirely. The need for this trimin limit insert, and its effectiveness, can only be determined through boat testing and is ultimately the responsibility of the boat manufacturer.

! WARNINGOn some boats, increased trimin range can cause handling problems at high speeds, resulting in personal injury or death. We recommend that only qualified personnel adjust the trimin limit inserts and test the boat for handling problems.

Multiple Sterndrive Steering Tie Bar ArrangementsWith multiple sterndrives you must select one of several possible steering systems.

NOTICEIncorrect tie bar installation can damage the drive and steering system. Do not let the tie bar contact other components during severe turning conditions. Always calculate sufficient turning clearances, observe recommended tie bar arrangements, and check for proper installation before operating the boat.

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Internal Power Steering With Internal Tie Bar OnlyAt the lower end of the performance spectrum, boats not capable of speeds in excess of 97 km/ h. (60 MPH), the basic internal tie bar is recommended. It connects the slave sterndrive to the sterndrive that is directly connected to the factory power steering output. This internal tie bar is available in a variety of lengths from the sterndrive manufacturer.

Internal Power Steering With Internal and External Tie BarAs a boat moves into the moderate performance range of 97113 km/h. (6070 MPH) or for a reduction in steering backlash, an external tie bar should be added. External tie bars are usually designed to attach at the aft power trim cylinder bosses. This location is an excellent choice because of its proximity to the propeller. HOWEVER, because of the potential overstress that can occur if one sterndrive is trimmed much differently than the other, a dual trim control kit (Part Number 90362A3) should be installed to limit this potential tilt differential to about 20 degrees. IMPORTANT: Mercury Marine does not recommend the use of an external tie bar ONLY with no internal tie bar when using the internal power steering system. This can cause excessive loads on the steering components on the sterndrive connected to the internal power steering system. These increased loads can damage the steering components, resulting in increased play in the steering of the boat.

External Power SteeringWhen boat speeds move past 113 km/h (70 MPH) or if additional steering backlash reduction is desired, external power steering is recommended. This normally will include an external tie bar mounted at the same general location as the power steering cylinders, which are generally attached at the top of the sterndrive's drive shaft housing. With this steering system, no internal tie bar should be used. These steering cylinders can be attached either inboard (between) or outboard of the sterndrives.

External Power Steering With Low External Tie BarFor the fastest boats, over 129 km/h (80 MPH) , or for the ultimate in steering backlash reduction, use external power steering, BUT (where mechanically possible) with the external tie bar mounted at the trim cylinder boss location (as previously described in "Internal Power Steering with Internal and External Tie Bar" statements). Again, this system does not use an internal tie bar.

SeaCore Components and CastingsMercury MerCruiser SeaCore power packages are equipped with additional stainless steel components and particular aluminum castings with special coatings. Do not replace SeaCore components with nonSeaCore. Use only the specified Mercury MerCruiser SeaCore components and castings on these power packages.

Stainless Steel FastenersSeaCore models are equipped with additional stainless steel fasteners to maximize corrosion resistance in salt water environments. Stainless steel fasteners are subject to galling when installed without lubrication. Galling can result in fastener destruction, improper clamp loads, or both. Galled fasteners may appear to torque properly, but still have incorrect clamp loads. Apply a lubricant, such as Special Lubricant 101 or an equivalent, on the threads of stainless steel fasteners during installation to avoid galling. Lubricate at least the first 8 mm (1/4 in.) of the threads before installation.Tube Ref No.34

Description Special Lubricant 101

Where Used Threads of stainless steel fasteners

Part No. 92-802865Q02

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Corrosion ProtectionMercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions or if using a stainless steel propeller, it is recommended that a Quicksilver AntiCorrosion Anode Kit and/or a MerCathode System with 2 additional transom mounted anode assemblies be installed (some models have a MerCathode System as standard equipment). A MerCathode Monitor also is available to allow the operator to check the operation of the MerCathode System with the push of a button. (Refer to Mercury Precision Parts Accessories Guide for part numbers.) Boats that are connected to AC shore power require additional protection to prevent destructive low voltage galvanic currents from passing through the shore power ground wire. A Quicksilver Galvanic Isolator can be installed to block the passage of these currents while still providing a path to ground for dangerous fault (shock) currents. (Refer to Mercury Precision Parts Accessories Guide for part number.) IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and anodes may be unable to handle the increased galvanic corrosion potential.

Antifouling PaintIMPORTANT: Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited warranty. Painting Boat Hull or Boat Transom: Antifouling paint may be applied to boat hull and boat transom but you must observe the following precautions: IMPORTANT: Do not paint anodes or pressure wash anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.

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SECTION - 1

IMPORTANT: If antifouling protection is required for boat hull or boat transom, copper base paint, if not prohibited by law, can be used. If using copper based antifouling paint, observe the following: Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (11/2 in.) UNPAINTED area on transom of the boat around these items.

a

b8107

a - Painted boat transom

b - Minimum 40 mm (11/2 in.) unpainted area around transom assembly

NOTE: Sterndrive unit and transom assembly can be painted with a good quality marine paint or an antifouling paint that DOES NOT contain copper or any other material that could conduct electrical current. Do not paint drain holes, anodes, MerCathode system or items specified by boat manufacturer.

NOTICEWashing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or highpressure washers to clean the MerCathode assembly.

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Do not wash the sterndrive unit with a power washer as this can damage the coating on the reference wire of the MerCathode assembly, if equipped, and increase corrosion.

c

a

ba - MerCathode reference electrode b - Do not paint c - Do not pressure wash6211

Emission Control Information LabelA tamperresistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement. Please note that the low emissions certification will not affect the fit, function, or performance of the engines. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.

NOTE: When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine, the Declaration of Conformance applies. Refer to the front page of this manual for further information.

EMISSION CONTROL INFORMATIONTHIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL # XXXXXXXX FAMILY XXXXXXXXXXXX STD. XX.X g/kW-hr D.O.M. DISPMMM YYYY

X.XL

0575

Emission Control LabelCalifornia EmissionsCompliant "SERIAL#"Engine Serial Number "FAMILY"Engine Family "STD."Emissions Standard "D.O.M."Date of Manufacture

31656

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SECTION - 1

"DISP"Piston Displacement

EMISSION CONTROL INFORMATION

NOT FOR SALE IN CALIFORNIAREFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL # XXXXXXXX FAMILY XXXXXXXXXXXX STD. XX.X g/kW-hr D.O.M. DISPMMM YYYY

X.XL31657

Emission Control LabelNot for Sale in California "SERIAL#"Engine Serial Number "FAMILY"Engine Family "STD."Emissions Standard "D.O.M."Date of Manufacture "DISP"Piston Displacement

Owner ResponsibilityThe operator must have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The operator may not modify the engine in any manner that alters the horsepower or allows emissions levels to exceed their factory specifications.

Star LabelThe 4.3 models meet the California Air Resources Board's ThreeStar Sterndrive and Inboard marine engine 2003 exhaust emission standards. The ThreeStar label will be affixed on the left side of the hull as shown.

a

XX 1234 XX

b32973

a - Recommended location

b - Secondary location

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SECTION - 1 One Star - Low emission


mc79569-1

The onestar label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted twostroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

Two Stars - Very Low emission The twostar label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star LowEmission engines.

FO

IDA

mc79570-1

Three Stars - Ultra Low emission The threestar label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star Low Emission engines.

SS

A

D

mc79571-1

Four Stars - Super Ultra Low emission The Four Star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star Low Emission engines.

FN R

T

mc79572-1

Hang TagOn 4.3 models, the Dealer must mark the appropriate box on one hang tag to match the Star label affixed to the boat. The dealer is responsible for displaying the hang tag in a visible location on the boat on display in California. Failure to properly display the hang tag could result in a citation and possible fine to the dealer from the California Air Resources Board. If in California, the dealer must place the hang tag in a visible location in the boat prior to displaying the boat.

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NOTES:

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SECTION - 2

BOAT CONSTRUCTION

SECTION 2 - BOAT CONSTRUCTIONTable of ContentsBoat Construction.................................................................................................................................................... 2 Transom Thickness and Surface Plane............................................................................................................2 Transom Cutout.................................................................................................................................................2 Checking Transom Thickness...........................................................................................................................2 Engine Bed........................................................................................................................................................2

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BOAT CONSTRUCTION

SECTION - 2

Boat ConstructionTransom Thickness and Surface PlaneIMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts.Transom Specifications Thickness Between 51 57 mm (2 21/4 in.) for 203 mm (8 in.) to either side of the vertical center line Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.) Flatness Angle Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal dimensions) :Inner Surface Flat within 3 mm (1/8 in.) Outer Surface Flat within 2 mm (1/16 in.) 10 16 degrees

a

e d b d

ca - Transom thickness b - Inner surface c - Outer surface

7508

d - Transom plate coverage 203 mm (8 in.) from center e - Transom angle

Transom CutoutRefer to Section 6 - Drive System And Engine Mounting.

Checking Transom ThicknessRefer to Section 6 - Drive System And Engine Mounting.

Engine BedIMPORTANT: The finished boat stringer must position the front engine mount so that a minimum of 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer. This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer (structure) to obtain the 6 mm (1/4 in.) dimension.Description Difference between starboard and port engine mount Mount adjustment up and down (minimum) Specification 57.2 cm (221/2 in.) 6 mm (1/4 in.)

NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure that the front and rear mount locations in the vessel are parallel and in the same plane. This may be checked by tying a string from the left front mount location to the right rear mount location and another from right front to left rear. The strings should touch where they cross.

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SECTION - 3

EXHAUST SYSTEM

SECTION 3 - EXHAUST SYSTEMTable of ContentsExhaust System....................................................................................................................................................... 2 Important Information........................................................................................................................................2 Carbon Monoxide Poisoning.............................................................................................................................2 Good Ventilation ........................................................................................................................................ 2 Poor Ventilation ......................................................................................................................................... 3 Measuring Exhaust Elbow Height........................................................................................................................... 3 General Information...........................................................................................................................................3 Exhaust Angle Measurement ..................................................................................................................... 4 Boat Requirements............................................................................................................................................4 Loading Requirements......................................................................................................................................5 Loading the Boat with a Capacity Plate.............................................................................................................5 Example ..................................................................................................................................................... 6 Loading the BoatWithout a Capacity Plate....................................................................................................7 Example ..................................................................................................................................................... 8 Clear Hose Measurement Method..................................................................................................................10 Clear Hose Measurement Method from Seacock or Muffler Drain.................................................................. 11

3

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EXHAUST SYSTEM

SECTION - 3

Exhaust SystemImportant Information

NOTICEImproperly designing, installing, or modifying the engines exhaust system can introduce seawater or water from condensation into the combustion chambers, damaging the engine. The installing dealer or boat builder is responsible for proper installation of the exhaust system as explained in the installation instructions for the product. Engine damage resulting from water ingestion is not covered by the product warranty, unless the damage is the result of a defective part supplied by the engine manufacturer. The exhaust system must be installed in accordance with the information contained in this section to prevent water intrusion problems. Special care is required on the transom or hull exhaust applications, as these customdesigned exhaust systems can create a tuning effect that can cause water to be forced back into the engine. The instructions under Checking for Water Intrusion must be performed to ensure that water intrusion is not occurring. It is the boat manufacturer's responsibility for ensuring that water intrusion does not exist with their unique exhaust system. Engines with through propeller exhaust have been carefully designed and tested to avoid water intrusion problems and no additional testing is required. These applications require that only that exhaust elbow height be checked as outlined under Measuring Exhaust Elbow Height.

! WARNINGInstalling the exhaust system incorrectly can lead to serious injury or death. When installing or designing exhaust systems, follow all federal, state, and local boating and safety standards for the market in which the boat will be sold. Exhaust system design and installation can affect: Noise level. Performance. Water Intrusion. Carbon monoxide levels. Component longevity.

Carbon Monoxide PoisoningIMPORTANT: The following important information is covered in the owner's operation, maintenance and warranty manuals. You may also want to include this information in the boat owner's manual. 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. Carbon monoxide is a deadly gas that is odorless, colorless, and tasteless. Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea.

! WARNINGCarbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide.

GOOD VENTILATIONVentilate passenger area, open side curtains, or forward hatches to remove fumes.

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EXHAUST SYSTEM

1. Example of desired air flow through the boat.

mc79553-1

POOR VENTILATIONUnder certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install 1 or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near an operating engine may be exposed to a hazardous level of carbon monoxide. 1. Examples of poor ventilation while a boat is stationary:

aa - Operating the engine when the boat is moored in a confined space.

b

mc79554-1

b - Mooring close to another boat with its engine operating.

2. Examples of poor ventilation while a boat is moving:

aa - Operating the boat with the trim angle of the bow too high.

b

mc79556-1

b - Operating the boat with no forward hatches open (station wagon effect).

Measuring Exhaust Elbow HeightGeneral InformationThe height of the exhaust elbows must be within the dimensions specified to prevent water intrusion problems. Exhaust elbow risers must be installed, if needed, to obtain the proper exhaust elbow height and exhaust angle. Risers are limited to 152.4 mm (6 in.) on all 4.3 and 5.0 models. Measurement must be taken with the boat in the water. Load the boat as outlined to simulate the maximum loading conditions likely to be encountered in normal operation. IMPORTANT: Exhaust elbow height is measured to the waterline inside of the water lift muffler (instead of the water line outside of the boat) on applications so equipped. Refer to Water Lift Muffler. IMPORTANT: Load distribution recommendations are the responsibility of the boat manufacturer. Any load distribution conditions that will affect the exhaust system must be clearly communicated to the operator in the owner's manual. For example, the number of people that can be located on the swim platform simultaneously should be included in the manual if this could pose a problem. Measurements under all loading conditions must be within the following specifications.Minimum Exhaust Elbow Height Model 4.3, 5.0 MPI and SeaCore 4.3, 5.0 Models Specifications 330 mm (13 in.)

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EXHAUST SYSTEM Minimum Exhaust Hose Slope Model 4.3, 5.0 MPI and SeaCore 4.3, 5.0 Models

SECTION - 3

Specification within 45.7 cm (18 Specification for the remainder of in.) of the engine system (if applicable) 10 3

If the exhaust elbow height or exhaust angle is insufficient, modify the exhaust system or install the appropriate exhaust riser. Refer to the appropriate Mercury Precision Parts and Accessory Guide for part numbers. The maximum exhaust riser height is specified in the table below.Riser Options Model 4.3, 5.0 MPI and SeaCore 4.3, 5.0 Models Low 76 mm (3 in.) and 43 mm (1.7 in.) Medium 76 mm (3 in.) and 43 mm (1.7 in.) High 152 mm (6 in.)

EXHAUST ANGLE MEASUREMENTMeasure the exhaust angle of each section of the exhaust system using an inclinometer as shown in the diagram below. Begin the measurement at the exhaust elbow outlet continuing along each section to the exhaust exit point of the boat. All exhaust angle measurements must be performed with the boat at rest in the water. Perform the first set of measurements without a load in the boat. Perform the second set of measurements with the boat fully loaded. See Loading Requirements.

c a

b18582

Typical Exhaust a - Inclinometer b - Exhaust hose or tube

c - Minimum 305 mm (12 in.)

Boat RequirementsIMPORTANT: Consider the following requirements before performing the exhaust elbow waterline height measurement. No prototype hulls or light layup hulls should be considered. Any measurement performed on nonproduction boats, prototype hulls, or light layup hulls could be inaccurate and could result in product damage. All boats that display a CE certification capacity plate must use the maximum capacity as stated on the CE certification capacity plate to perform the exhaust elbow waterline measurement. All boats that only display the US Coast Guard (USCG) capacity plate must use the maximum capacity as stated on the USCG capacity plate to perform the exhaust elbow waterline measurement.

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EXHAUST SYSTEM

For boats that do not have a capacity plate, the maximum capacity load is the number of persons that can sit on designated seating plus cargo excluding cabin space. Measurements used for official Mercury MerCruiser audit at the OEM boat builder must be performed on current production boats. No prototype hulls or light layup hulls will be considered for official audit purposes. Measurements used for official Mercury MerCruiser audit at OEM boat builders must use the CE certification maximum load for any boat model that will be sold outside of the United States.

Loading Requirements1. Fill the fuel tanks, fresh water tanks or holding tanks, ballast tanks, and heater tanks to simulate fully loaded condition. 2. Weights can be used to simulate these load conditions if desired. Place weights in the corresponding area for which the load is being replaced. Refer to the following conversions. 1 U.S. gallon of water = 8.3 lb. 1 liter of water = 1 kg 1 U.S. gallon of gasoline = 6 lb. 1 liter of gasoline = 0.72 kg 3. For the purpose of MerCruiser waterline height measurements: One person is equivalent to 74.84 kg (165 lb.) Cargo per person is equivalent to 11.34 kg (25 lb.) 4. Add weight for any additional boat options: extra battery, battery charger, tower, arch, generator, ballast tanks, ballast sacks, television, carpet, anchor, stereo/entertainment equipment, washer/dryer, safe, etc. 5. If a swim platform is an option, the swim platform must be installed for the waterline height measurement. Use the following guide to determine the correct swim platform load: a. Boats less than 8.84 m (29 ft.) long, not including boats that are 8.84 m (29 ft.) long, must add the maximum rated swim platform weight capacity to the swim platform. b. Boats less than 8.84 m (29 ft.) long, not including boats that are 8.84 m (29 ft.) long that do not have a maximum rated swim platform weight capacity, must add181.45 Kg (400 lb.) to the swim platform . c. Boats 8.84 m (29 ft.) long and greater than 8.84 m (29 ft.) long, must add the maximum rated swim platform weight capacity to the swim platform. d. Boats 8.84 m (29 ft.) long and greater than 8.84 m (29 ft.) long, that do not have a maximum rated swim platform weight capacity must add 226.80 kg (500 lb.) to the swim platform.

Loading the Boat with a Capacity PlateFor boats with a capacity plate, use the maximum load for persons and gear as listed on the capacity plate to determine the number of persons to place onto the boat for exhaust elbow waterline height measurements. IMPORTANT: Use 20 inches for average passenger seat width when measuring bench seating. Round up or down at 0.5 to obtain a whole person. See the examples listed below. 48 in. (bench seat length) 20 in. (seat width) = 2.4 persons. 2.4 persons rounded down = 2 persons. 55 in. (bench seat length) 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons. 1. Take the maximum capacity weight as listed on the capacity plate (XXXX lb. Persons, Gear) and subtract the swim platform load, if applicable. 2. Next divide the weight by 74.84 kg (165 lb.) per person. This gives the whole number and remainder of 74.84 kg (165 lb.) persons to load onto the boat.

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3. Put the remainder of a person in the next available seat. See Boat loading diagram.

24860

24861

CE Capacity Plate

USCG Capacity Plate

IMPORTANT: If there is not enough seating for the number of people, treat the leftover weight as cargo. Load cargo weight onto the boat before loading passenger weight. 4. If applicable, load cargo (leftover persons weight) onto the boat. Distribute cargo as described below. IMPORTANT: If the boat configuration does not allow for aft, center, and bow storage, choose the storage application from the Optional Cargo Distribution table that best applies to your boat configuration.Preferred Cargo Distribution Aft storage 25% Center storage 50% Optional Cargo Distribution Aft storage 25% None 50% None 100% None Center storage 75% 75% None 100% None None Bow storage None 25% 50% None None 100% Bow storage 25%

5. Perform the first measurement with the swim platform loaded and the person taking the waterline measurement on the boat. 6. Load the swim platform if equipped. 7. Measure the exhaust elbow waterline height. IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat. 8. Load a person weight into a seat, and measure the exhaust elbow waterline height after each person weight is loaded onto the boat. Repeat until a person weight is is loaded into each seat in that row. 9. Continue the process moving forward toward the bow of the boat to the next row of seats until a person weight is loaded into each seat.

NOTE: The total weight loaded onto the boat must not exceed the maximum capacity displayed on the capacity plate. NOTE: The following example is provided as a reference.

EXAMPLENOTE: This example uses a boat that is less than 8.84 m (29 ft.) long, not including a boat that is 8.84 m (29 ft.) long that does not have a maximum rated swim platform weight capacity, and must add 181.45 Kg (400 lb.) to the swim platform NOTE: Use 0.50 lb. as the break point to round up or down to obtain a whole pound.

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1. Maximum load (persons and gear) from capacity plate swim platform load = remaining weight to be placed in the boat. 1100 lb. 400 lb. = 700 lb. 2. Remaining weight to be placed in the boat MerCruiser person weight = number of persons to load onto the boat 700 lb. 165 lb. = 4.24 persons 3. Total number of persons number of whole persons = remaining persons 4.24 persons 4 persons = 0.24 remaining persons 4. Remainder persons MerCruiser person weight = remainder MerCruiser person weight 0.24 165 lb. = 40 lb. IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat. 5. Using the totals in this example, load four 165lb. persons and one 40lb. person onto boat seating with 400 lb. on the swim platform. 400 lb. + 165 lb. = 565 lb. 565 lb. + 165 lb. = 730 lb. 730 lb. + 165 lb. = 895 lb. 895 lb. + 165 lb. = 1060 lb. 1060 lb. + 40 lb. = 1100 lb.

d a b c

e

f24862

Boat loading diagram a - Swim platform load b - MerCruiser person weight (one) c - MerCruiser person weight (two)

d - MerCruiser person weight (three) e - MerCruiser person weight (four) f - Remainder MerCruiser person weight (five)

Loading the BoatWithout a Capacity PlateFor boats that do not display a capacity plate, the number of persons to be loaded onto the boat for measuring purposes is the number of persons that can sit on designated seating excluding cabin space. An additional weight of 25 lb. per person is to be added to the boat before loading passenger weight onto the boat. IMPORTANT: Use 20 inches for average passenger seat width when measuring bench seating. Round up or down at 0.5 to obtain a whole person. See the examples below. 48 in. (bench seat length) 20 in. (seat width) = 2.4 persons. 2.4 persons rounded down = 2 persons. 55 in. (bench seat length) 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons. 1. Total number of persons that can sit on designated seating excluding cabin space MerCruiser person weight = maximum passenger load for measurement.

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Number of persons 165 lb. (MerCruiser person weight) = XXXX lb. maximum passenger load. 2. Maximum passenger load from the calculation above swim platform load if applicable. 3. Divide the weight by 165 lb. per person. This gives the number of 165lb. persons to load onto the boat. Round up to next whole number. See Example 3. IMPORTANT: To account for cargo, add a weight of 25 lb. per person to the boat before loading passenger weight onto the boat. 4. Calculate the cargo by multiplying 25 lb. by the number of persons that can sit on designated seating excluding cabin space. See Example. 5. Load the cargo onto the boat. Distribute cargo as described below. IMPORTANT: If the boat configuration does not allow for aft, center, and bow storage, choose the storage application from the Optional Cargo Distribution table that best applies to your boat configuration.Preferred Cargo Distribution Aft storage 25% Center storage 50% Optional Cargo Distribution Aft storage 25% None 50% None 100% None Center storage 75% 75% None 100% None None Bow storage None 25% 50% None None 100% Bow storage 25%

6. Perform the first measurement with the swim platform loaded and the person measuring the waterline on the boat. 7. Load the swim platform if equipped. 8. Measure the exhaust elbow waterline height. IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat. 9. Load a person weight into a seat, and measure the exhaust elbow waterline height after each person weight is loaded onto the boat. Repeat until a person weight is is loaded into each seat in that row. 10. Continue the process moving forward toward the bow of the boat to the next row of seats until a person weight is loaded into each seat.

EXAMPLENOTE: The following example is provided as a reference. This example uses a boat that is 8.84 m (29 ft.) long and greater than 8.84 m (29 ft.) long, that does not have a maximum rated swim platform weight capacity, and must add 226.80 Kg (500 lb.) to the swim platform .

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IMPORTANT: The Designated Seating Diagram following illustrates the number of passengers that can sit on designated seating excluding cabin space.

6 9 2 1 3 4 5 7 824863

Designated Seating Diagram This example uses 9 persons as the maximum passenger load.

NOTE: Use 0.50 lb. as the break point to round up or down to obtain a whole pound. 1. To determine the maximum cargo load multiply the maximum passenger load by the maximum cargo weight per passenger. 9 passengers 25 lb. = 225 lb. 2. To determine the preferred cargo distribution for aft, center, and bow storage: a. To determine the maximum aft storage cargo weight, multiply the maximum cargo weight by 25% 3. To determine the maximum center storage cargo weight, multiply the maximum cargo weight by 50% a. 225 lb. 50% = 112.50 lb. b. 112.50 lb. rounded up = 113 lb. 4. To determine the maximum bow storage cargo weight, multiply the maximum cargo weight by 25% 225 lb. 25% = 56.25 lb. 56.25 lb. rounded down = 56 lb. 5. To determine the maximum number of passengers to load onto the boat, multiply 9 passengers by 165 lb. (MerCruiser person weight) to get a 1485 lb. (total passenger load) 9 passengers 165 lb. = 1485 lb. 6. Subtract the swim platform load from the total passenger load to get the remaining weight to be placed in the boat. 1485 lb. 500 lb. = 985 lb. 7. Divide the remaining weight to be placed onto the boat by the MerCruiser person weight to get the maximum number of passengers to load onto the boat. 985 lb. 165 lb. = 5.9 passengers 5.90 passengers rounded up = 6 passengers 8. Using the totals in this example load 56 lb. cargo in the aft storage, 113 lb. cargo in the center storage, and 56 lb. cargo in the bow storage onto the boat before adding passenger weight. Then, load six 165 lb. passengers, onto the boat with 500 lb. on the swim platform. 500 lb. + 225 lb. = 725 lb. 725 lb. + 165 lb. = 890 lb. 890 lb. + 165 lb. = 1055 lb. 1055 lb. + 165 lb. = 1220 lb. 1220 lb. + 165 lb. = 1385 lb. 1385 lb. + 165 lb. = 1550 lb.

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1550 lb. + 165 lb. = 1715 lb.

g a c b d h e f24864

i

j

Cargo, swim platform, and passenger weight loading diagram a - Swim platform load f - MerCruiser person weight (five) b - MerCruiser person weight (one) g - MerCruiser person weight (six) c - MerCruiser person weight (two) h - Aft storage d - MerCruiser person weight (three) i - Center storage e - MerCruiser person weight (four) j - Bow storage

Clear Hose Measurement Method1. Obtain an 810 mm (5/163/8 in.) ID (inner diameter) clear hose approximately 4.5 m (15 ft.) long. Install a metal fitting or a weight on one end of the hose to keep that end of the hose below the waterline. The fitting or weight must not restrict water from filling the clear hose.

b b a c

24865

a - Clear hose b - Fitting

c - Unrestricted opening

IMPORTANT: On engines equipped with more than one exhaust elbow, perform the exhaust elbow waterline height measurement on the side that sits lower in the water. 2. Put the weighted end of the clear hose over the side of the boat (port or starboard) that is sitting lower in the water. 3. Submerge the clear hose until completely filled with water. 4. Place a finger over the open end of the clear hose before removing it from the water. 5. Coil the excess clear hose into the bottom of the boat bilge. Keep the coil of clear hose below the waterline. 6. Keeping the clear hose in line with the engine's exhaust elbow, lift the end of the clear hose up to the highest point of the exhaust elbow.

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7. Slowly take the finger off of the end of the clear hose to let the water level stabilize. The water will seek the level of the water outside of the boat. Keep the clear hose close to the exhaust elbow and as vertical as possible.

b

c a d8340

e

9142

a - Waterline b - Top of exhaust elbow c - Clear hose

d - Weight e - Measurement, waterline to top of exhaust elbow

Clear Hose Measurement Method from Seacock or Muffler DrainIMPORTANT: Measure the exhaust elbow height to the waterline inside of the water lift muffler (instead of the water line outside of the boat) on applications so equipped. IMPORTANT: The engine must have been operated previously to fill the muffler with water. IMPORTANT: On engines equipped with more than one exhaust elbow, perform the exhaust elbow waterline height measurement on the side that sits lower in the water. 1. Attach a clear hose to the muffler drain point or seacock drain point. 2. Start the engine to fill the muffler and hose. 3. If attached to the seacock drain, open the seacock. 4. Route the remainder of the hose toward the engine's exhaust manifold and elbow. Ensure that this open end section of the hose is as vertical as possible from the boat's bilge to the top of the exhaust elbow. 5. Coil excess hose in the bilge of the boat, keeping it below the water line. 6. Lower the open end of the hose and siphon water until it starts to come out of the hose. Put a finger over the hose and lift open end until it is at the top of the exhaust elbow. 7. Slowly take the finger off of the end of the hose to let the water level stabilize. The water will seek the level of the water outside the boat. Keep the hose close to the exhaust elbow and as vertical as possible.

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8. The measurement between the water in the hose and the top of the exhaust elbow is the exhaust elbow height. The maximum riser height is 15.2 cm (6 in.).

a

b24866

Typical vertical water lift muffler a - Minimum exhaust elbow height with b - Clear hose for measuring waterline maximum load

a

b

24867

Typical horizontal water lift muffler a - Minimum exhaust elbow height with b - Clear hose for measuring waterline maximum load

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SECTION - 4

FUEL SYSTEM

SECTION 4 - FUEL SYSTEMTable of ContentsFuel Delivery System .............................................................................................................................................. 2 California Regulations for 2007LowPermeation Fuel Hose..........................................................................2 Fuel Lines and Fittings......................................................................................................................................2 Fuel Delivery System .......................................................................................................................................3 Special Information About Electric Fuel Pumps ......................................................................................... 4

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Fuel Delivery SystemCalifornia Regulations for 2007LowPermeation Fuel HoseCalifornia Regulations for New 2007 and Later Spark-Ignition Inboard/Sterndrive Pleasurecraft (3) Requirements of engine manufacturers and boat manufacturers under Option 2 and using Low Permeation Fuel Line Hose: (A) Each manufacturer that chooses Option 2 must provide written instructions, as part of the installation materials provided to purchasers of the engine, to use Low Permeation fuel Line Hose for the primary Fuel line connecting the fuel tank to the engine of any boat that is manufactured for sale, sold, or offered for sale in California, or that is introduced, delivered or imported into California for introduction into commerce. (B) Each boat manufactured must install Low Permeation Fuel Line Hose for the primary Fuel line connecting the fuel tank to the engine of any boat that is manufactured for sale, sold, or offered for sale in California that uses an engine from a manufacturer that chooses Option 2. Low Permeation Fuel Line Hose is USCG Type A115, defined as not exceeding 15 g/m/24 h with CE10 fuel at 23 C as specified in SAE J 1527Marine Fuel Hoses.

Fuel Lines and FittingsWe recommended that you measure the exact route and length of the fuel lines before the first installation of the engine to prevent problems later in connecting them to the engine. Only a few points related to function and safety are listed here. Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines. Use fuel lines that are Coast Guard approved USCG Type A1. The U.S. boating standards and regulations specify the sole use of USCG Type A1 fuel lines in the engine compartment or in any location in the boat where a break in the line could result in a discharge of 150 cc (5 oz.) of fuel in 2 minutes. Ensure that the fuel pickup is at least 25 mm (1 in.) from the bottom of fuel tank to prevent picking up impurities. Using a digital vacuum gauge, measure the vacuum at the engine's fuel inlet. The maximum measured vacuum at the engine's fuel inlet must not exceed 6.9 kPa (2 in. Hg) throughout engine operating range. IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today's fuels. It can also cause poor engine performance because of fuel starvation. Follow the minimum fuel line diameter specification listed below.Description Minimum fuel line diameter on singleengine gasoline installations Minimum fuel line diameter on multiengine gasoline installations with single pickup and line Specification 10 mm (3/8 in.) 13 mm ( in.) ID or larger

On multi-engine gasoline installations, use a fuel pickup and fuel tank supply line for each engine. If a single pickup and line is used, the line must be 13 mm ( in.) ID or larger. On installations that require long lines or numerous fittings, use the fuel lines and fittings with an ID greater than 10 mm (3/8 in.). Use the Engine Compartment/Fuel System Pressure and Temperature Test to determine if the fuel pressure and temperature are within an acceptable range. If the temperature is excessive, reduce the fuel line length, reduce the number of fittings or insulate the components. Refer to the Engine Compartment/Fuel System Pressure and Temperature Test in the Mercury MerCruiser Product Applications Manual. Route the fuel lines as low as possible in the engine compartment to keep them in the coolest region. Temperature increases significantly with increased engine compartment height.

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Route the slope of the fuel line as consistent as possible to avoid high spots that can trap vapor and contribute to vapor locking problems. Ensure that the holes where the fuel lines run through the bulkheads are carefully rounded off or protected with grommets to prevent damage from vibration and chafing. Keep the fuel line free of stress and firmly secured to prevent vibration and chafing. Secure the fuel line with clamps that will not pinch or kink the line. Do not route the fuel line with sharp bends. Use a flexible fuel line to connect the fuel supply line to the fuel inlet fitting on the engine. The flexable line will absorb deflection between the engine and the hull structure when the engine is running. Keep all the fuel lines well secured. IMPORTANT: If the engine is equipped with a boost pump, an inline filter must be installed between the fuel tank and the boost pump. This filter is provided with the engine package. The 100 Vazer model is equipped with a fuel prefilter already installed on the engine. Do not install a inline fuel filter on Vazer models. The fuel delivery system must be designed to deliver the fuel to the engine with minimal restriction and at the lowest temperature. Gasoline is extremely sensitive to vaporizing if placed under a vacuum (low pressure) and exposed to moderate or high temperatures. This is particularly true if winter blend fuels with a high RVP (Reid Vapor Pressure) are encountered in warmer temperature areas. Excessive restriction in the fuel delivery system may cause a condition known as vapor locking. This typically occurs after the engine has been operated at high RPM and then shut off and allowed to sit for 15 minutes to 2 hours. During this time the engine heat soaks, causing the temperature of the fuel system to increase. Upon restart, the combination of heat and vacuum in the fuel system causes the fuel to vaporize. The fuel system cannot handle this vapor and therefore, fuel starvation results when the boater attempts to resume operation. Depending upon the degree of vapor locking, this can range from a hesitation or bog when accelerating to a complete stalling of the engine. To minimize the potential for this problem, the guidelines should be observed to limit fuel delivery restriction to 6.9 kPa (2 in. Hg) or less and fuel inlet temperature to 44 C (110 F) or less. The fuel delivery system is an integral part of the boat. Mercury MerCruiser makes no attempt in this manual to cover all aspects of design and integration of the fuel delivery system, due to a broad range of possible configurations and the numerous regulations and standards that cover this area. The applicable standards and regulations for the markets where your product will be sold should be observed, along with any information from the fuel system component manufacturers. The following general guidelines are provided:

! WARNINGImproper boat design and construction may result in serious injury or death. Adhere to all applicable marine regulations (United States Coast Guard [USCG], European Union Recreational Craft Directive [EURCD], etc.) and the standards they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards Organization [ISO], etc.) when designing and constructing the boat and other components, such as the engine compartment, fuel delivery system, or exhaust system. The main concern of a boat's fuel system is safety; this must be achieved through a technically sound installation and constant inspection. The fuel system, from the filler pipe to the fuel pump, is the same in principle for all boats. The fuel tank is an integrated component of the boat. Refer to the special information on service and maintenance, which you have received from the tank manufacturer. Only a few points related to function and safety are listed here [Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]: All connections should be on the upper side of the tank.

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The drain plug at the lowest point on the tank serves to permit the removal of water and sediment. The tank breather pipe must have an inner diameter of at least 13 mm (1/2 in.) and must be fitted with a swan neck to prevent water from entering the tank. It is recommended that the exact route and length of the fuel lines be established at the first installation of the engine to prevent problems later in connecting them to the engine. All fuel lines must be well secured. The holes where the lines run through the bulkheads should be carefully rounded off or protected with rubber grommets. This prevents damage to the lines from abrasion. The following, but not limited to the following, additional fuel connection related points, applying to all engines unless otherwise stated, must be considered [Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]: 1. Fuel pickup should be at least 25 mm (1 in.) from the bottom of fuel tank to prevent picking up impurities. 2. Using a digital vacuum gauge, measure the vacuum at the engine's fuel inlet. The maximum measured vacuum at the engine's fuel inlet must not exceed 6.9 kPa (2 in. Hg) through out engine operating range. IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today's fuels. It can also cause poor engine performance because of fuel starvation. 3. Use fuel lines that are Coast Guard approved (USCG Type A1).Description Minimum fuel line diameter on singleengine gasoline installations Minimum fuel line diameter on multiengine gasoline installations with single pickup and line Specification 10 mm (3/8 in.) 13 mm ( in.) ID or larger

4. On multi-engine gasoline installations, use a fuel pickup and fuel tank supply line for each engine. If a single pickup and line is used, the line must be 13 mm ( in.) ID or larger. 5. On installations that require long lines or numerous fittings, use the fuel lines and fittings with an ID greater than 10 mm (3/8 in.). 6. Install the fuel lines so they are free of stress and firmly secured to prevent vibration and/or chafing. 7. Avoided sharp bends in the fuel lines. 8. Use a flexible fuel line to the fuel inlet fitting on the engine to absorb deflection when engine is running.

SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS

! WARNINGImproper boat design and construction may result in serious injury or death. Adhere to all applicable marine regulations (United States Coast Guard [USCG], European Union Recreational Craft Directive [EURCD], etc.) and the standards they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards Organization [ISO], etc.) when designing and constructing the boat and other components, such as the engine compartment, fuel delivery system, or exhaust system. The installation of additional filters may cause: Fuel vapor locking. Difficult warmstarting. Piston detonation due to lean fuel mixture. Poor driveability.

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SECTION - 5

COOLING SYSTEM

SECTION 5 - COOLING SYSTEMTable of ContentsGeneral Information................................................................................................................................................. 2 Seawater Supply System........................................................................................................................................ 2 Seawater Supply Hose......................................................................................................................................2 Seawater Inlet Hose..........................................................................................................................................2 ThroughHull Seawater Pickup System............................................................................................................. 3 Seawater Pickup...............................................................................................................................................4 Seacock.............................................................................................................................................................5 Sea Strainer......................................................................................................................................................6 Sterndrives With Closed Cooling Engines............................................................................................................... 7 Bravo Models with Closed Cooling.................................................................................................................... 7 SeaCore Models................................................................................................................................................7 SeaCore Bravo One and Bravo Three Models .......................................................................................... 7 SeaCore Bravo Two Models ...................................................................................................................... 7 Seawater Pickups for SeaCore Sterndrive Engine Models ....................................................................... 8 Installing the YFitting........................................................................................................................................9 Installing the Seawater Supply Hose.................................................................................................................9 Closed Cooling...................................................................................................................................................... 10 Description......................................................................................................................................................10 Antifreeze Recommendations.........................................................................................................................10 Coolant Recovery System...............................................................................................................................11 Hot Water Heater Hose Connections MPI Models ............................................................................................. 11 Supply Hose Connection ................................................................................................................................ 12 Return Hose Connection ................................................................................................................................ 13 Water Flow Diagrams............................................................................................................................................ 14 V6 and V8.....................................................................................................................................................14 V8 Bravo Models With Closed Cooling and Risers ................................................................................ 14 V6 Alpha Models With Closed Cooling and Risers ................................................................................. 15 V8 Bravo Models With Closed Cooling ................................................................................................... 16 V6 Sterndrive Models With Closed Cooling ............................................................................................ 17 V6 Bravo MPD Models With Seawater Cooling ...................................................................................... 18 V8 Bravo MPD Models With Seawater Cooling ...................................................................................... 19 V8 Bravo Models With Seawater Cooling (Except MPD Models) ........................................................... 20 V6 Bravo Models With Seawater Cooling (Except MPD Models) ........................................................... 21 V6 and V8 Alpha MPD Models With Seawater Cooling ........................................................................ 22 V6 and V8 Alpha Models With Seawater Cooling (Except MPD Models) ............................................. 23

5

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Lubricant, Sealant, AdhesivesTube Ref No.9 116

Description Loctite 567 PST Pipe Sealant RTV 587 Ultra Blue Silicone Sealer

Where Used

Part No.

Hose fitting threads and plastic plug threads 92-809822 Sealing surfaces and screw shaft 92-809825

General InformationMercury MerCruiser engines have either a seawater cooling system or a closed cooling system. Seawater cooling systems are sometimes called raw water cooling or standard cooling, while closed cooling systems are sometimes called fresh water cooling. On engines with seawater cooling, the engine is cooled entirely by the seawater in which the boat is being operated. Closed cooling systems use a combination of fresh water (antifreeze and water) and seawater for cooling. Both types of systems are designed to keep the engine operating temperature at approximately 71 degrees C (160 degrees F) for optimum performance, fuel economy and durability. (Refer to cooling system flow diagrams at end of section.) To monitor the cooling system, a temperature switch is incorporated into the audio warning system, which alerts the operator of an abnormal condition if the temperature exceeds approximately 93 degrees C (200 degrees F). A temperature sender is also employed to operate a temperature gauge at the dash. On dual helm applications, this sender must be replaced with a dual station sender to obtain the proper temperature reading at both stations. Refer to the Instrumentation and Controls section for more information. The cooling system must receive a sufficient amount of seawater under all operating conditions to operate properly. The design and installation of the seawater supply system is the boat manufacturer's responsibility. Cooling system components must be constructed, sized, and installed in accordance with the following guidelines.

NOTICEWithout sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

Seawater Supply SystemSeawater Supply HoseSeawater Supply Hose Specifications Seawater inlet hose Seawater pickup Seacock (ABYC requirement) Sea strainer (optional) Low restriction with 32 mm (11/4 in.) connections 32 mm (11/4 in.) I.D. (wire reinforced)

Seawater Inlet Hose A reinforced hose capable of supporting 10 in. Hg vacuum must be used to prevent the seawater inlet hose from collapsing from pump suction. The hose should be oil and seawater resistant. Use the shortest hose length possible with the least number of bends to minimize restriction. All connections must be secured with a hose clamp.

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COOLING SYSTEM

Fasten hose as appropriate to maintain proper routing and to prevent chafing or contact with other moving parts.

a

a

7638

9361

Typical composite seawater pickup pump a - Seawater inlet hose connection

Typical brass seawater pickup pump

ThroughHull Seawater Pickup SystemIMPORTANT: Seawater hose used must be wire reinforced to avoid collapsing hose when suction is created by seawater pump impeller.

g

c f b e b d a7924

b

Typical installation shown with a through the hull seawater pickup a - Quicksilver seawater pickup and e - Seawater hose to engine seacock f - Seawater pump hose connector (if b - Hose clamp equipped) c - Seawater hose to seawater strainer g - Below seawater pump level d - Quicksilver seawater strainer IMPORTANT: Do not install the seawater pickup directly in line with the propeller, as the pickup may create turbulence and allow air to flow into the propeller slipstream. This will cause propeller ventilation and will adversely affect boat performance. IMPORTANT: Make gradual bends in the seawater hoses to avoid kinks. Hoses must not come in contact with steering system components, engine coupler, or drive shaft.

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The seawater pickup must be large enough to permit sufficient seawater flow to engine seawater pickup pump for adequate engine cooling. The seawater pickup also must supply a positive head while underway. The seawater pickup should be located as close to the seawater pump inlet as possible and in an area where an uninterrupted, solid stream of seawater will flow past when the boat is underway.

Seawater PickupEither a throughtransom or throughhull seawater pickup can be used. Select pickup location to minimize seawater inlet hose length while providing an optimum location for seawater pickup. The location should be in an area that will provide a solid, airfree flow of seawater under all operating conditions. Avoid areas with a disturbed seawater flow, such as those behind or in close proximity to the propeller. Locations that are too far forward or outboard should also be avoided as these are prone to aeration problems at high boat trim angles and in turns. Check for aeration as outlined under Seawater Supply Test. IMPORTANT: Do not install the seawater pickup directly in line with the propeller, as pickup may create turbulence and allow air to flow into the propeller slipstream. This will cause propeller ventilation and will adversely affect boat performance. Openings in seawater pickup should be approximately 3 mm (1/8 in.) maximum to prevent larger debris from entering and clogging the cooling system. IMPORTANT: Use a seawater strainer if the seawater pickup openings exceed 3 mm (1/8 in.). Provisions should be made to minimize galvanic corrosion, given the hull material being used and the composition of the surrounding components. Some industry standards and regulations also require that the pickup be connected into the boat's bonding system to minimize stray current corrosion. Refer to applicable standards and regulations for more details. IMPORTANT: External seawater pickup must have an integral seacock.

7532

Typical seacock

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b a g c

d

e

f

h i jTypical transom pickup abcdeHose fitting Nut (4) Gasket Oring (4) Washer (4)Description Loctite 567 PST Pipe Sealant Description RTV 587 Ultra Blue Silicone Sealer7558

fghij-

Screw (4) Plastic plug Pickup Screen Screw (2)Part No. 92-809822 Part No. 92-809825

Tube Ref No.9

Where Used Hose fitting threads and plastic plug threads Where Used Sealing surfaces and screw shaft

Tube Ref No.116

SeacockThe ABYC and other industry standards and regulations require the use of a seacock on certain types of applications to stop the entry of seawater in the event of a leak in the cooling system. Refer to applicable standards and regulations for specific requirements. The seacock also allows the seawater to be shut off when servicing the engine.

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The seacock must provide minimum restriction to seawater flow (see Specifications). A ball valve or gate valve is recommended. The ball valve is most common and is typically equipped with a lever type handle that operates in a 90 degree arc. This design gives a clear indication of whether the valve is open or shut. Industry standards and requirements typically require that the seacock be rigidly attached to the hull at the seawater pickup. Seacock location should be readily accessible for quick, easy operation.

7532

Typical seacock

Sea StrainerA sea strainer is recommended if the boat is to be operated in an area with a high debris content. The strainer must be sized to minimize restriction (See Specifications) and to provide a reasonable service interval. Locate the strainer in an area that will be easily accessible for servicing. If the boat is not equipped with a seacock, the strainer should be located above the seawaterline to prevent seawater entry into boat when servicing. The strainer must have provision to allow draining in freezing temperature periods.

7533

Typical Sea Strainer

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Sterndrives With Closed Cooling EnginesBravo Models with Closed CoolingNOTE: Closed cooled Bravo models require a through the hull or through the transom pickup in addition to the sterndrive water inlets in order to meet the minimum flow specifications. When additional water inlets are used, a Yfitting is installed to the engine seawater pump.

a

c b d8485

Dual seawater pickup for Bravo closed cooled engines a - Engine seawater pump c - Y fitting port to Bravo drive b - Hose from seawater pump inlet port d - Yfitting port to additional water inlet to Yfitting Models operated above the fiftieth parallel of the northern hemisphere or below the fiftieth parallel of the southern hemisphere do not require the dual seawater pickup with a bravo sterndrive on closed cooling models. Remove the Yfitting at the seawater pump inlet. Install a seawater suppy hose that meets MerCuiser specifications. Cut the hose to fit from the transom inlet fitting to the seawater pump inlet.

SeaCore ModelsSome SeaCore models do not require a throughthehull or throughthetransom seawater pickup to meet the minimum flow specifications. See the chart, Seawater Pickups for SeaCore Sterndrive Engine Models.

SEACORE BRAVO ONE AND BRAVO THREE MODELSThe SeaCore Bravo One and Bravo Three engine packages do not require a throughthehull or throughthetransom seawater pickup in addition to the sterndrive water pickups if: The sterndrive gearcase has dual water pickups. The boat is capable of 64 km/h (40 MPH) with the boat fully loaded and operated within the specified operating range.

NOTE: When not installing the throughthehull or throughthetransom seawater pickup, see Installing the Seawater Supply Hose.

SEACORE BRAVO TWO MODELSThe SeaCore Bravo Two engine packages must have a throughthehull or throughthetransom seawater pickup in addition to the sterndrive side water pickups. Install the Yfitting at the engine's seawater pump inlet. See Installing the Y-Fitting.

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SEAWATER PICKUPS FOR SEACORE STERNDRIVE ENGINE MODELSSeawater Pickups for SeaCore Sterndrive Engine Models Boat speed with the boat fully loaded and operated within the specified operating range SeaCore Bravo has side water pickup SeaCore Bravo has dual water pickup Throughthehull or throughthetransom seawater pickup

64 km/h (40 MPH) or greater

Not required See Installing the Seawater Supply Hose30180

Less than 64 km/h (40 MPH)3018130180

Required See Installing the Y-Fitting

64 km/h (40 MPH) or greater

Required See Installing the Y-Fitting30181

Greater or Less than 64 km/h (40 MPH) Models operated above the fiftieth parallel of the northern hemisphere or below the fiftieth parallel of the southern hemisphere.

Not required See Installing the Seawater Supply Hose3018130180

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Installing the YFittingEngine models that require a throughthehull or throughthetransom seawater pickup, require a Yfitting at the engine seawater pump inlet port. The Yfitting directs the seawater from the sterndrive and throughthehull or throughthetransom seawater pickup to the engine's seawater pump to meet the minimum flow specifications.

a

c b dabcd8485

Typical Yfitting installation Engine seawater pump Hose 101.6 mm (4 in.) from seawater pump inlet to Yfitting port Yfitting port to water inlet at transom Yfitting port to throughthehull or throughthetransom seawater pickup

NOTE: For models not factory equipped with a Yfitting, refer to Mercury Parts Catalog, Closed Cooling Systems (Bravo) to order the specified Yfitting, seawater supply bulk hose, and hose clamps that meets MerCruiser specifications. 1. Cut a 101.6 mm (4 in.) leneth piece of the supply hose and install it to the seawater pump inlet and the Yfitting port. 2. Install a seawater supply hose to the Yfitting port and the sterndrive's water inlet at the transom. Cut off any excess hose as needed. 3. Install a seawater supply hose to the Yfitting port and the throughthehull or throughthetransom seawater pickup. Cut off any excess hose as needed. 4. Properly secure all hoses to all fittings to prevent water leaking into the boat.

Installing the Seawater Supply HoseFor engine models not using throughthehull or throughthetransom seawater pickup: 1. If applicable, remove the Yfitting at the seawater pump inlet. 2. Install a seawater supply hose that meets MerCruiser specifications to the engine's seawater pump inlet. 3. Route the seawater supply hose directly to the seawater inlet fitting on the transom. Cut off any excess hose as needed. 4. Properly secure the hose at both ends to prevent water leaking into the boat. NOTE: For models not factoryequipped with a seawater supply hose, refer to the Mercury Parts Catalog, Standard Cooling Systems (Bravo) to order the specified bulk hose, hose clamps, and

quick connect fittings that meet MerCruiser specifications. NOTE: For models with quick connection fittings and pull test information, refer to Section 6, Seawater Inlet Fitting Connection .

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Closed CoolingDescriptionClosed cooling is a standard feature on some models and is available as an accessory or a factory installed option on others. When closed cooling is used, a mixture of antifreeze and water is circulated through the water jackets in the engine block, cylinder heads, andon some applicationsthe exhaust manifolds to dissipate the heat. Refer to Water Flow Diagrams. This coolant is then passed though a heat exchanger. Here the coolant rejects heat to seawater (water in which the boat is being operated), which is simultaneously being passed through the exchanger. The heat is then carried away by the seawater and discharged overboard via the exhaust elbows. The design of the heat exchanger allows for the transfer of heat, while ensuring that the two coolants are separated. In this manner, the expensive engine components are never exposed to seawater, which can be corrosive in salty, polluted, or mineral laden water areas. Mercury MerCruiser's closed cooling systems are developed by the same people who design our engines to ensure compatibility and the same high quality standards. Our systems employ several exclusive features to provide unsurpassed cooling efficiency and durability. An exclusive doubleacting thermostat is used on V6 and V8 models, which provides increased coolant velocity through the engine and heat exchanger to prevent hot spots and improve performance. Mercury MerCruiser's heat exchangers also incorporate several stateoftheart designs to enhance the heat transfer between the coolants for an additional margin of cooling capacity. Features like these allow our systems to continually operate at WOT in water temperatures up to 38 C (100 F), where most aftermarket systems fall short of this mark. This additional cooling capacity translates into longer cooling system life with fewer problems regardless of where the boat is operated. Contact your sales representative to order your closed cooling systems factory installed or refer to the Mercury Precision Parts and Accessories Guide to obtain the part numbers for the accessory kits. The term full closed cooling, also known as full fresh water cooled or full FWC refers to the use of an ethylene glycol mixture in the engine and the exhaust water jackets. The ethylene glycol coolant mixture is circulated through the exhaust cooling passages as well as the engine cooling passages.

Antifreeze Recommendations

NOTICEUsing propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed. Factory installed closed cooling systems come filled with an extended life antifreeze. This coolant allows for a service interval of 5 years or 1000 hours (whichever occurs first), versus 2 years or 400 hours for standard antifreeze. When adding coolant to these systems (i.e. when filling coolant recovery bottle, installing hot water heater), we recommend that only an extendedlife antifreeze be used. Mixing this coolant with even a small amount of regular antifreeze will require that the service interval be reduced 2 years. If you are installing closed cooling kits at your facility, we would also encourage you to use the extended Life coolant to allow your customer to take advantage of the reduced maintenance costs. Premixed extended life coolant is available from Quicksilver or can be purchased at most automotive stores and other locations where antifreeze is sold. Extendedlife coolant is available from Texaco under the name Havoline Extended Life Dex Cool. Prestone also offers a version of this antifreeze called Extended Life 5/100. Only coolants that state that they are compatible with Dex Cool should be used. Extendedlife coolants can be identified by their orange color (vs. green for standard coolant) and their corresponding orange cap on the container. All antifreeze should be mixed 50/50 with pure water (Quicksilver coolant is already premixed). If installing closed cooling kits at your facility, be sure to observe the special filling procedure in the installation instructions.Closed Cooling System Capacity

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COOLING SYSTEM

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