Engine Tle of Contents Setion 3A - Engine Generl Informtion...3A-2 Engine Rottion...3A-2 Engine Lifting Provisions...3A-3 Engine Oil Dipstik Relotion...3A-3 Engine Comprtment Constrution...3A-4 Engine Comprtment Ventiltion...3A-4 Engine Comprtment Sems...3A-4 Clerne...3A-4 Engine Bed Requirements...3A-4 Servieility...3A-5 Engine Alignment...3A-19 Drining the Sewter System...3A-22 Drin System Identifition...3A-22 Air Atuted Single Point Drin System...3A-24 Mnul Single Point Drin System (Alph)...3A-28 Three Point Mnul Drin System...3A-30 Drining the Sterndrive...3A-32 Drining the Sewter System (Sorpion Models)...3A-33 Drining the Sewter System...3A-33 Drin System Identifition...3A-33 Air Atuted Single Point Drin System...3A-35 Multi Point Drin (MPD) System...3A-38 3 A 90-863758070 APRIL 2008 Pge 3A-1
Lurint, Selnt, Adhesives Tue Ref No. Desription Where Used Prt No. 9 Lotite 567 PST Pipe Selnt Fuel inlet fitting 92-809822 Speil Tools Alignment hook 91 863375A 1 Assists during engine lignment. 9190 Generl Informtion Engine Rottion Engine rottion is desried when oserved from the rer of the engine (trnsmission end) looking forwrd (wter pump end). All Merury MerCruiser engines re left hnd (LH) rottion. Propeller rottion is not neessrily the sme s engine rottion; See Setion 2 Trnsmission nd Drive Line. 12710 Pge 3A-2 90-863758070 APRIL 2008
Lifting Provisions Engine Engines re equipped with lifting eye t the front nd the rer. Use suitle sling with the proper weight rting when lifting the engine. Typil engine - Center lifting eye (engine lignment only) - Lifting eye 33415 NOTE: 8.1 H.O. nd Horizon 8.1 engines require lignment hook (91 863375 1). Alignment hook 91 863375A 1 Engine Oil Dipstik Relotion Some models re equipped with n oil dipstik in the port nd strord dipstik tues. If only one dipstik is present nd the engine is equipped with two dipstik tues, you my relote the oil dipstik. 9366 Model shown is equipped with two oil dipstiks - Dipstik option 1 - Dipstik option 2 1. To relote the oil dipstik:. Remove the ruer p from the dipstik tue.. Remove the oil dipstik nd insert it into the opposite dipstik tue.. Ple the ruer p over the dipstik tue tht is not eing used. 90-863758070 APRIL 2008 Pge 3A-3
Engine Comprtment Constrution! WARNING Improper ot design nd onstrution my result in serious injury or deth. Adhere to ll pplile mrine regultions (United Sttes Cost Gurd [USCG], Europen Union Reretionl Crft Diretive [EU RCD], et.) nd the stndrds they referene (Amerin Bot nd Yht Counil [ABYC], Soiety of Automotive Engineers [SAE], Interntionl Stndrds Orgniztion [ISO], et.) when designing nd onstruting the ot nd other omponents, suh s the engine omprtment, fuel delivery system, or exhust system. Engine Comprtment Ventiltion See Setion 4 Air Intke System. Engine Comprtment Sems Clerne NOTICE Wter tht runs onto the ir intke my enter the engine nd use serious internl engine dmge. Design engine omprtments so wter nnot run onto the ir intke or flme rrestor. Exerise re in the design nd onstrution of the engine omprtment. Sems must e loted so tht rin wter is direted wy from the ir intke system nd eletril system. IMPORTANT: The engine omprtment must provide minimum of 13 mm (½ in.) lerne etween the ot nd ny omponent on the engine (i.e. exhust mnifold, elow, oil pn, trnsmission se, et.). This llows for engine mount defletion during opertion. Engine Bed Requirements The engine ed (i.e. stringers) must e designed to support the G fores imposed y the engine during the most severe duty. The ed must lso hndle the torque produed y the engine nd the thrust generted y the propeller. Defletion of the engine ed ould stress the engine omponents, using possile engine mislignment nd trnsmission filure. The proper design of the engine ed vries onsiderly from one ot design to the next. Therefore, Merury MerCruiser mkes no ttempt to provide detiled engine ed design requirements to over ll possile pplitions. The proper design of the engine ed is left to the ot mnufturer. The following generl guidelines re provided: The engine ed must e firmly ffixed to the ot nd should e mde s lrge s possile to distriute the lod evenly. Reinforements should e used where neessry. Mount pd lotions should e s lrge s possile. The engine mounts re designed for the industry stndrd 572 mm (22½ in.) stringer widths (enter to enter), ut n ommodte widths up to 610 mm (24 in.). The engine ed must position the engine so tht minimum 6 mm (¼ in.) of up nd down djustment exists on ll four mounts fter performing the finl engine lignment. This is neessry to llow for relignment in the future. Engine mount isoltors will ompress slightly over time. The front nd rer mount lotions on the engine ed should e in prllel plnes. This n e heked y tying string from the left front mount lotion to the right rer mount lotion nd nother string from the right front to the left rer. The strings should just touh were they ross. Pge 3A-4 90-863758070 APRIL 2008
The engine mounts must rest squrely on the engine ed so tht the ruer isoltor is not preloded in one diretion or the other. Preloding the engine mount will use inresed virtion. 14921 14922 Typil front mount Typil rer mount The metl ring must not ontt the mount se on the front mount. 15889 - Metl ring Typil front mount - Mount se Servieility Engine mounts hve provisions for 10 mm (3/8 in.) fsteners for seuring mounts to the engine ed. Fsteners should e seleted s pproprite for the type of engine ed mteril eing used. The slot in front engine mounts should fe forwrd. Do not instll fsteners t n ngle. All engines require mintenne, nd some require servie repir within the life of the produt. Consider servieility when designing the engine omprtment. In ddition to ustomer nd deler stisftion, onsider the implitions of servieility with respet to our wrrnty poliy. The Merury MerCruiser wrrnty poliy sttes, in prt, tht resonle ess must e provided to the produt for wrrnty servie. Refer to the wrrnty poliy in the pproprite Opertion, Mintenne, nd Wrrnty Mnuls. It sttes tht removl or replement of the ot prtitions or mteril euse of ot design for neessry ess to the produt is not overed. Consider servieility when designing the ot nd engine omprtment to void these types of issues. Consider ll engines options used in ot when designing the engine omprtment. The engine size differenes etween some of the models s well s differenes in servie point lotions my hve mjor effet on servieility. 90-863758070 APRIL 2008 Pge 3A-5
MAJOR SERVICE POINTS LIST The following is list of the mjor servie points to onsider when designing the engine omprtment. Typil illustrtions re shown to ssist you in identifying these lotions. These re typil views nd my not urtely represent the model tht you re working with. The speifi engines, long with their instlltion drwings nd the pproprite Opertion, Mintenne, nd Wrrnty Mnul, should e used when doing the tul design work. Oil filter Engine oil dipstik Crnkse oil fill p Wter seprting fuel filter Trnsmission fluid dipstik Trnsmission/propeller shft oupler Engine mounts Ignition omponents Eletril omponents rket Flme rrestor Strter Cirulting pump Alterntor Exhust mnifolds/elows Oxygen sensors (if equipped) Exhust tlysts (if equipped) Ait intke system Thermostt housing Shift nd throttle linkges Sewter pump Drive elt Wter drins Flush onnetor (if equipped) Het exhnger pressure p nd end ps (if equipped) Closed ooling reovery ottle (if equipped) Se striner (if equipped) Bttery Trnsmission Fuel system Fuel oolers (if equipped) Oil oolers Cylinder heds Complete engine removl Pge 3A-6 90-863758070 APRIL 2008
ENGINE VIEW FOR PRODUCTS WITHOUT EMISSIONS CONTROL f g h d e i j k Typil 8.1 H.O. or Horizon 8.1 inord side view - Trnsmission output flnge - Engine mounts (4) - Trnsmission dipstik d - Strter (inord style) e - Trnsmission fluid ooler f - Ignition omponents 24889 g - Dipstik h - Engine over i - Exhust mnifold nd elow (2) j - Gen III Cool Fuel Module (Inord models) k - Sewter pump 90-863758070 APRIL 2008 Pge 3A-7
d e f g h i 14926 Typil 8.1 H.O. or Horizon 8.1 inord front view - Drive elt - Het exhnger - Coolnt reservoir d - Pressure p e - Flme rrestor f - Eletril rket g - Thermostt housing h - Alterntor i - Cirulting pump Pge 3A-8 90-863758070 APRIL 2008
Engine ENGINE VIEW FOR PRODUCTS WITH EMISSIONS CONTROL h g i f e d j k l 34669 Typil 8.1 H.O. or Horizon 8.1 inord side view with emissions ontrol - Trnsmission output flnge g - Dipstik - Engine mounts (4) h - Exhust mnifold nd elow - Trnsmission dipstik i - Engine over d - Strter (inord style) j - Gen III Cool Fuel Module (inord models) e - Trnsmission fluid ooler k Sewter pump f - Ignition omponents l - Oxygen sensor over plte 90-863758070 APRIL 2008 Pge 3A-9
Engine d e f g h i 34666 Typil 8.1 H.O. or Horizon 8.1 inord front view with emissions ontrol - Drive elt f - Eletril rket - Het exhnger g - Thermostt housing - Coolnt reservoir h - Alterntor d - Pressure p i - Cirulting pump e - Flme rrestor OIL FILTERS 14333 Typil tow sports engine oil filter - Engine mounted oil filter Pge 3A-10 90-863758070 APRIL 2008
14928 - Engine oil fill p - Remote oil filter Typil inord engine oil filter FUEL CONNECTIONS IMPORTANT: Be sure to remove the rss plug in the fuel inlet fitting. 14851 Models with oost pump - Fuel inlet fitting Models without oost pump 8269 Gen III Cool Fuel Module (Inord models) - Fuel inlet fitting Tue Ref No. Desription Where Used Prt No. 9 Lotite 567 PST Pipe Selnt Fuel inlet fitting 92-809822 90-863758070 APRIL 2008 Pge 3A-11
ELECTRICAL 14957 Typil eletril omponents rket THROTTLE 7926 Typil throttle le nd linkges - Flt wsher nd loknut - Cle rrel - Flt wsher nd loknut Pge 3A-12 90-863758070 APRIL 2008
Typil quik onnet throttle le - Jm nut - Cle rrel - Throttle ody rket 11527 SHIFT - Jm nut - Cle rrel - Brket Typil quik onnet shift le 11531 90-863758070 APRIL 2008 Pge 3A-13
7670 - Shift le Typil trnsmission e g f d Typil dul sttion trnsmission - Cle end guide - Cle rrel - Cle rrel stud d - Elsti stop nut nd wsher 7657 e - Sper f - Cle end guide stud g - Elsti stop nut nd wsher Pge 3A-14 90-863758070 APRIL 2008
NOTE: Shift les re not used on DTS trnsmissions 20418 ZF Mrine (Hurth) trnsmission with eletri shift DTS models FLUSH - Flush onnetor Typil flush onnetor 6090 90-863758070 APRIL 2008 Pge 3A-15
COOLANT d 8295 Typil het exhnger for models with losed ooling - Het exhnger - Gsket - Fstener d - End p d Coolnt reovery ottle modles with losed ooling engines exept 8.1 H.O. nd Horizon 8.1) - Coolnt reovery ottle - Mounting holes 7804 - Hose d - Hose lmp Pge 3A-16 90-863758070 APRIL 2008
SEA STRAINER 7533 STARTER 7766 - Ruer oot - Strter solenoid - 90 mp fuse THERMOSTAT - Housing 8219 90-863758070 APRIL 2008 Pge 3A-17
FUEL AND AIR INDUCTION 14339 FUEL SYSTEMS 14931 - Wter seprting fuel filter over (MPI tow sports models only) - Wter seprting fuel filter 14340 - Fuel ooler Gen II fuel module Pge 3A-18 90-863758070 APRIL 2008
6338 Engine d e h f g Gen III Cool Fuel module - Cool Fuel Module - Cool Fuel Module hrness - Filter p d - Filter ssemly retining srew 8837 e - Fuel filter element f - Filter up g - Cool Fuel Module filter reservoir h - Filter up sel CYLINDER HEADS 12728 Engine Alignment Proper lignment etween the trnsmission, nd the propeller shft is essentil to minimize noise, virtion, nd power loss nd to void overstressing the trnsmission nd drive line omponents. Perform preliminry lignment t engine instlltion. The finl lignment must e done fter the ot is in the wter to ompenste for ny defletion in the hull. On pplitions with rigid propeller shft oupler, dsonnet the oupler from the trnsmission for shipment. Chek the lignment with the ot in the wter. The requirement for heking the lignment should e lerly ommunited to your delers, long with n understnding s to who is finnilly responsile. 90-863758070 APRIL 2008 Pge 3A-19
The omplete lignment proedure is outlined in the instlltion mnuls. Importnt elements of this proess inlude: Align the engine to position the pilot on the propeller shft oupler into the reess in the trnsmission output flnge so tht the mting surfes of the flnge nd the oupler re prllel within 0.07 mm (0.003 in.). Chek lignment y holding the flnge nd the oupler together nd heking t 90 intervls with feeler guge. The oupler should e rotted 180 nd lignment reheked to ensure tht the oupler nd flnge re in lignment. 7534 7535 - Propeller shft oupler - Feeler guge - Trnsmission output flnge Speifition mm in. Trnsmission output flnge to propeller shft oupler lignment tolerne 0.0 0.07 0.0 0.003 The slot on the front mounts should fe forwrd. The djusting nuts on the port nd strord mounts should e djusted evenly. Pge 3A-20 90-863758070 APRIL 2008
A minimum of 6 mm (.25 in.) of up nd down djustment must exist on ll four engine mounts fter finl lignment to llow for relignment in the future. d 7536-6 mm (.25 in.) minimum djustment required for future lignment - Adjusting nut - Loknut d - Slot Trunnions must not extend more thn 45 mm (1.75 in.) nd no less thn 10 mm (.375 in.). d - Trunnion extension 45 mm (1.75 in.). 10 mm (.375 in.) is nominl - Trunnion lmping srews nd nuts 7537 - Loknut d - T wsher Tighten mount loknuts seurely. Bend the t wsher t (tht is losest to the djent flt on the loknut) ginst the flt to prevent it from loosening. 90-863758070 APRIL 2008 Pge 3A-21
Tighten the trunnion lmping srews nd nuts to speifition. 7538 - Coupler olts nd nuts (4) - Set srews - Sfety wire Tighten oupling olts to speifition. Seure set srews, if equipped, with sfety wire Desription Nm l. in. l. ft. Loknuts 68 50 Coupler olts 68 50 Drining the Sewter System! CAUTION Wter n enter the ilge when the drin system is open, dmging the engine or using the ot to sink. Remove the ot from the wter or lose the seok, disonnet nd plug the sewter inlet hose, nd ensure the ilge pump is opertionl efore drining. Do not operte the engine with the drin system open. IMPORTANT: Only drin the sewter setion of the losed ooling system. IMPORTANT: The ot must e s level s possile to ensure omplete drining of the ooling system. Your power pkge is equipped with drin system. Refer to Drin System Identifition to determine whih instrutions pply to your power pkge. IMPORTANT: The engine must not e operting t ny point during the drining proedure. IMPORTANT: Merury MerCruiser requires tht propylene glyol ntifreeze, mixed to the mnufturer's instrutions, e used in the sewter setion of the ooling system for freezing tempertures or extended storge. Mke sure tht the propylene glyol ntifreeze ontins rust inhiitor nd is reommended for use in mrine engines. Be ertin to follow the propylene glyol mnufturer's reommendtions. Drin System Identifition NOTE: All drin plugs re fitted with lue wing nuts. Pge 3A-22 90-863758070 APRIL 2008
AIR ACTUATED SINGLE POINT DRAIN SYSTEM d d Closed ooled models 33144 - Blue drin plug lotion - Blue ir pump Sewter-ooled models - Air mnifold d - Green inditors 33150 MANUAL SINGLE POINT DRAIN SYSTEM (ALPHA) 6128 - Blue hndle - Blue drin plug lotion THREE POINT MANUAL DRAIN SYSTEM 6126 - Blue drin plug 90-863758070 APRIL 2008 Pge 3A-23
MULTI-POINT DRAIN (MPD) SYSTEM 10226 M110050 93235672 6129 - Side of ylinder lok - Bottom of exhust mnifolds 33155 Fuel ooler to thermostt housing - Chek vlve (if equipped) 6131 Air Atuted Single Point Drin System BOAT IN THE WATER NOTE: This proedure is written for the ir pump tht is tthed to the engine. However, ny ir soure n e used. 1. Close the seok (if equipped) or remove nd plug the wter inlet hose. 2. Remove the ir pump from the engine. 3. Ensure tht the lever on top of the pump is flush with the hndle (horizontl). 4. Instll the ir pump on the tutor fitting. Pge 3A-24 90-863758070 APRIL 2008
5. Pull lever on ir pump (vertil) to lok pump on the fitting. e d - Atutor fitting - Green inditors - Mnul relese vlve 8293 d - Blue ir pump e - Lever (loking) 6. Pump ir into the system until oth green inditors extend nd wter drins from oth sides of the engine. The port side will egin drining efore the strord side. 7. Immeditely remove the lue drin plug from the side of the thermostt housing or the het exhnger. This must e removed within 30 seonds to properly vent the ooling system. d d Closed Cooled Models 33144 - Blue drin plug lotion - Blue ir pump Sewter Cooled Models - Air mnifold d - Green inditors 33150 90-863758070 APRIL 2008 Pge 3A-25
8. Verify tht wter is drining from eh opening. If not, use the Three Point Mnul Drin System instrutions. - Port side drin lotion 6133 - Strord side drin lotion 9. Allow the system to drin for minimum of five minutes. Pump ir s neessry to keep the green inditors extended. 10. Crnk the engine over slightly with the strter motor to purge ny wter trpped in the sewter pump. Do not llow engine to strt. 11. Reinstll the lue drin plug in the thermostt housing or het exhnger. 12. Remove the ir pump from the ir mnifold nd return it to the mounting rket. 13. Merury MerCruiser reommends leving the drin system open while trnsporting the ot or while performing other mintenne. This helps ensure tht ll wter is drined. 14. Before lunhing the ot, pull up on the mnul relese vlve. Verify tht the green inditors re no longer extended. BOAT OUT OF THE WATER - Green inditors 6135 15. Open the seok, if equipped, or unplug nd reonnet the wter inlet hose prior to operting the engine. NOTE: This proedure is written for the ir pump tht is tthed to the engine. However, ny ir soure n e used. 1. Ple the ot on lever surfe to ensure omplete drining of system. 2. Remove the ir pump from the engine. 3. Ensure tht the lever on top of the pump is flush with the hndle (horizontl). 4. Instll the ir pump on the tutor fitting. Pge 3A-26 90-863758070 APRIL 2008
5. Pull lever on ir pump (vertil) to lok pump on the fitting. e d - Atutor fitting - Green inditors - Mnul relese vlve 8293 d - Blue ir pump e - Lever (loking) 6. Pump ir into the system until oth green inditors extend nd wter drins from oth sides of the engine. The port side will egin drining efore the strord side. d d Closed Cooled Models 33144 - Blue drin plug lotion - Blue ir pump Sewter Cooled Models - Air mnifold d - Green inditors 33150 90-863758070 APRIL 2008 Pge 3A-27
7. Verify tht wter is drining from eh opening. If not, use the Three Point Mnul Drin System instrutions. - Port side drin lotion 6133 - Strord side drin lotion 8. Allow the system to drin for minimum of five minutes. Pump ir s neessry to keep the green inditors extended. 9. Crnk the engine over slightly with strter motor to purge ny wter trpped in the sewter pump. Do not llow engine to strt. 10. Remove the ir pump from the ir mnifold nd return it to the mounting rket. 11. Merury MerCruiser reommends leving the drin system open while trnsporting the ot or while performing other mintenne. This helps ensure tht ll wter is drined. 12. Before lunhing the ot, pull up on the mnul relese vlve. Verify tht the green inditors re no longer extended. - Green inditors Mnul Single Point Drin System (Alph) BOAT IN THE WATER 1. Close the seok (if equipped) or remove nd plug the wter inlet hose. 6135 2. Rotte the lue hndle ounterlokwise until it stops (pproximtely two turns). The red on the hndle shft indites tht the drin system is open. Do not fore the hndle s this will rete new threds. Pge 3A-28 90-863758070 APRIL 2008
3. Immeditely remove the lue drin plug from the side of the thermostt housing. This must e removed within 30 seonds to properly vent the ooling system. - Blue hndle - Blue drin plug lotion 4. Visully verify tht wter is drining. If wter does not drin, remove the lue drin plug from the distriution housing nd drin mnully. 6136 - Blue drin plug - Drin lotion ornge or red 33152 BOAT OUT OF THE WATER 5. Allow the system to drin for minimum of five minutes. We reommend leving the drin system open while trnsporting the ot or performing other mintenne. 6. Reinstll the lue drin plug in the thermostt housing. 7. Close the drin system y rotting the lue hndle lokwise until it stops nd instll the lue drin plug, if removed. The hndle is fully seted when no red is visile. Do not overtighten the hndle, s this tion will rete new threds. 8. Open the seok (if equipped) or unplug nd reonnet the wter inlet hose efore operting the engine. 1. Ple the ot on level surfe to ensure omplete drining of system. 90-863758070 APRIL 2008 Pge 3A-29
2. Rotte the lue hndle ounterlokwise until it stops (pproximtely two turns). The red on the hndle shft indites tht the drin system is open. Do not overtighten the hndle, s this tion will rete new threds. 6141 - Blue hndle 3. Visully verify tht wter is drining. If wter does not drin, remove the lue drin plug from the distriution housing nd drin mnully. - Blue drin plug 33152 - Drin lotion ornge or red 4. Allow the system to drin for minimum of five minutes. We reommend leving the plugs out while trnsporting the ot or performing other mintenne to ensure tht ll wter is drined. 5. Close the drin system y rotting the lue hndle lokwise until it stops or instlling the lue drin plug. The hndle is fully seted when no red is visile. Do not overtighten hndle, s this tion will rete new threds. Three Point Mnul Drin System BOAT IN THE WATER NOTE: Use this proedure if your engine is not equipped with n ir tuted single point drin system or if the ir tuted single point drin system fils. 1. Close the seok (if equipped) or remove nd plug the wter inlet hose. Pge 3A-30 90-863758070 APRIL 2008
2. Remove the lue drin plug from the distriution housing (lower front, port side). Engine - Blue drin plug 6138 3. To properly vent the ooling system, remove the lue drin plug from the side of the thermostt housing within 30 seonds. - Blue drin plug lotion 6139 4. Remove the two lue drin plugs from the sewter pikup pump (front, strord side). - Blue drin plugs 6140 5. Verify tht wter is drining from eh opening. 6. Allow the system to drin for minimum of five minutes. We reommend leving the drin system open while trnsporting the ot or performing other mintenne to ensure tht ll wter is drined. 7. Crnk the engine over slightly with strter motor to purge ny wter trpped in the sewter pikup pump. Do not llow the engine to strt. 8. Before lunhing the ot or strting the engine, lose the drin system y instlling the four lue drin plugs. 9. Open the seok, if equipped, or unplug nd reonnet the wter inlet hose prior to operting the engine. 90-863758070 APRIL 2008 Pge 3A-31
BOAT OUT OF THE WATER NOTE: Use this proedure if your engine is not equipped with n ir tuted single point drin system or if the single point drin system fils. 1. Ple the ot on level surfe to ensure omplete drining of the system. 2. Remove three lue drin plugs: one from the distriution housing (lower front, port side) nd two from the sewter pikup pump (front, strord side). 6142 - Blue drin plug 3. Verify tht wter is drining from eh opening. 4. Allow the system to drin for minimum of five minutes. We reommend leving the drin system open while trnsporting the ot or performing other mintenne to ensure tht ll wter is drined. 5. Crnk the engine over slightly with strter motor to purge ny wter trpped in the sewter pikup pump. Do not llow the engine to strt. 6. Before lunhing the ot or strting the engine, lose the drin system y instlling the three lue drin plugs. Drining the Sterndrive NOTE: This proedure is needed only for slty, rkish, minerl lden, or polluted wter pplitions; nd for freezing tempertures or extended storge. 1. Insert smll wire repetedly to mke sure tht vent holes, wter drin holes, nd pssges re unostruted nd open. e d f 6146 Sterndrive Wter Drin Holes - Speedometer pitot tue - Trim t vity vent hole - Trim t vity drin pssge d - Ger housing wter drin hole (1 eh port nd strord) e - Ger housing vity vent hole f - Ger housing vity drin hole Pge 3A-32 90-863758070 APRIL 2008
NOTICE Engine The universl joint ellows my develop set when stored in rised or up position, using the ellows to fil when returned to servie nd llowing wter to enter the ot. Store the sterndrive in the full down position. 2. Lower the sterndrive unit to the full down/in position. 3. For dditionl ssurne ginst freezing nd rust, fter drining, fill the ooling system with propylene glyol mixed to the mnufturer's reommendtion to protet engine to the lowest temperture to whih it will e exposed during freezing tempertures or extended storge IMPORTANT: Merury MerCruiser requires tht propylene glyol ntifreeze, mixed to the mnufturers instrutions, e used in the sewter setion of the ooling system for freezing tempertures or extended storge. Mke sure tht the propylene glyol ntifreeze ontins rust inhiitor nd is reommended for use in mrine engines. Be ertin to follow the propylene glyol mnufturer's reommendtions. Drining the Sewter System (Sorpion Models) Drining the Sewter System! CAUTION Wter n enter the ilge when the drin system is open, dmging the engine or using the ot to sink. Remove the ot from the wter or lose the seok, disonnet nd plug the sewter inlet hose, nd ensure the ilge pump is opertionl efore drining. Do not operte the engine with the drin system open. IMPORTANT: Only drin the sewter setion of the losed ooling system. IMPORTANT: The ot must e s level s possile to ensure omplete drining of the ooling system. Your power pkge is equipped with drin system. Refer to Drin System Identifition to determine whih instrutions pply to your power pkge. IMPORTANT: The engine must not e operting t ny point during the drining proedure. IMPORTANT: Merury MerCruiser requires tht propylene glyol ntifreeze, mixed to the mnufturer's instrutions, e used in the sewter setion of the ooling system for freezing tempertures or extended storge. Mke sure tht the propylene glyol ntifreeze ontins rust inhiitor nd is reommended for use in mrine engines. Be ertin to follow the propylene glyol mnufturer's reommendtions. Drin System Identifition NOTE: All drin plugs re fitted with lue wing nuts. 90-863758070 APRIL 2008 Pge 3A-33
AIR ACTUATED SINGLE POINT DRAIN SYSTEM Sorpion models - Air mnifold - Green inditors - Blue drin plug lotions 33151 MULTI-POINT DRAIN (MPD) SYSTEM 10226 M110050 93235672 - Side of ylinder lok 6129 - Bottom of exhust mnifolds - Chek vlve (if equipped) 6131 Pge 3A-34 90-863758070 APRIL 2008
Air Atuted Single Point Drin System BOAT IN THE WATER Engine NOTE: This proedure is written for the ir pump tht is tthed to the engine. However, ny ir soure n e used. 1. Close the seok (if equipped) or remove nd plug the wter inlet hose. 2. Remove the ir pump from the engine. 3. Ensure tht the lever on top of the pump is flush with the hndle (horizontl). 4. Instll the ir pump on the tutor fitting. 5. Pull lever on ir pump (vertil) to lok pump on the fitting. e d - Atutor fitting - Green inditors - Mnul relese vlve 8293 d - Air pump e - Lever (loking) 6. Pump ir into the system until oth green inditors extend nd wter drins from oth sides of the engine. The port side will egin drining efore the strord side. 7. Immeditely remove the lue drin plug from the side of the thermostt housing or the het exhnger. This must e removed within 30 seonds to properly vent the ooling system. - Air mnifold - Green inditors - Blue drin plug lotions 33151 90-863758070 APRIL 2008 Pge 3A-35
8. Verify tht wter is drining from eh opening. If not, use the Three Point Mnul Drin System instrutions. - Port side drin lotion - Strord side drin lotion 6133 9. Allow the system to drin for minimum of five minutes. Pump ir s neessry to keep the green inditors extended. 10. Crnk the engine over slightly with the strter motor to purge ny wter trpped in the sewter pump. Do not llow engine to strt. 11. Reinstll the lue drin plug in the thermostt housing or het exhnger. 12. Remove the ir pump from the ir mnifold nd return it to the mounting rket. 13. Merury MerCruiser reommends leving the drin system open while trnsporting the ot or while performing other mintenne. This helps ensure tht ll wter is drined. 14. Before lunhing the ot, pull up on the mnul relese vlve. Verify tht the green inditors re no longer extended. BOAT OUT OF THE WATER - Green inditors 6135 15. Open the seok, if equipped, or unplug nd reonnet the wter inlet hose prior to operting the engine. NOTE: This proedure is written for the ir pump tht is tthed to the engine. However, ny ir soure n e used. 1. Ple the ot on lever surfe to ensure omplete drining of system. 2. Remove the ir pump from the engine. 3. Ensure tht the lever on top of the pump is flush with the hndle (horizontl). Pge 3A-36 90-863758070 APRIL 2008
4. Instll the ir pump on the tutor fitting. 5. Pull lever on ir pump (vertil) to lok pump on the fitting. e d - Atutor fitting - Green inditors - Mnul relese vlve 8293 d - Air pump e - Lever (loking) 6. Pump ir into the system until oth green inditors extend nd wter drins from oth sides of the engine. The port side will egin drining efore the strord side. 7. Immeditely remove the lue drin plug from the side of the thermostt housing or the het exhnger. This must e removed within 30 seonds to properly vent the ooling system. Sorpion models - Air mnifold - Green inditors - Blue drin plug lotions 33151 90-863758070 APRIL 2008 Pge 3A-37
8. Verify tht wter is drining from eh opening. If not, use the Three Point Mnul Drin System instrutions. - Port side drin lotion - Strord side drin lotion 6133 9. Allow the system to drin for minimum of five minutes. Pump ir s neessry to keep the green inditors extended. 10. Crnk the engine over slightly with strter motor to purge ny wter trpped in the sewter pump. Do not llow engine to strt. 11. Remove the ir pump from the ir mnifold nd return it to the mounting rket. 12. Merury MerCruiser reommends leving the drin system open while trnsporting the ot or while performing other mintenne. This helps ensure tht ll wter is drined. 13. Before lunhing the ot, pull up on the mnul relese vlve. Verify tht the green inditors re no longer extended. - Green inditors Multi Point Drin (MPD) System BOAT OUT OF THE WATER 1. Ple the ot on level surfe to ensure omplete drining of the system. 6135 2. Remove the lue drin plugs from the following lotions. If neessry, len out the drin holes using stiff piee of wire. Do so until the entire system is drined.. Port nd strord side of ylinder lok Pge 3A-38 90-863758070 APRIL 2008
. Bottom of exhust mnifolds 10226 M110050 93235672 - Cylinder lok drin plug - Exhust mnifold drin plug 6129. Chek vlve - Drin plug (if equipped) 6131 3. On models with sewter pikup pump, remove the two lue drin plugs. If the sewter pikup pump does not hve lue drin plugs, or you re unle to ess them, loosen the lmps nd remove oth hoses. - Hose lmps - Blue drin plugs 6145 4. Crnk the engine over slightly with the strter motor to purge ny wter trpped in the sewter pikup pump. Do not llow the engine to strt. 5. After the ooling system hs een drined ompletely, instll the drin plugs, reonnet the hoses, nd tighten ll hose lmps seurely. 90-863758070 APRIL 2008 Pge 3A-39
BOAT IN THE WATER 1. Close the seok (if equipped) or remove nd plug the wter inlet hose. 2. Remove the lue drin plugs from the following lotions. If neessry, len out the drin holes using stiff piee of wire. Do so until the entire system is drined.. Port nd strord side of ylinder lok. Bottom of exhust mnifolds 10226 M110050 93235672 - Cylinder lok drin plug 6129 - Exhust mnifold drin plug. Wter irulting pump hose - Drin plug 6143 d. Chek vlve - Drin plug (if equipped) 6131 Pge 3A-40 90-863758070 APRIL 2008
3. On models with sewter pikup pump, remove the two lue drin plugs. If the sewter pikup pump does not hve lue drin plugs, or you re unle to ess them, loosen the lmps nd remove oth hoses. - Hose lmps - Blue drin plugs 6145 4. Crnk the engine over slightly with the strter motor to purge ny wter trpped in the sewter pikup pump. Do not llow the engine to strt. 5. Before lunhing the ot or strting the engine, lose the drin system y instlling the lue drin plugs. 6. Open the seok, if equipped, or unplug nd reonnet the wter inlet hose efore operting the engine. 90-863758070 APRIL 2008 Pge 3A-41
Notes: Pge 3A-42 90-863758070 APRIL 2008