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Service Manual #37
Service Manual #37
MANUAL
Number 37
MARINE ENGINES
DRY JOINT
DANGER
Immediate hazards which will result in severe personal injury or death.
WARNING
Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Replacement Parts
Use of parts other than the recommended service replacement parts, will void the warranty
on those parts that are damaged as a result.
WARNING
Electrical, ignition and fuel system components on Mercury MerCruiser Engines
and Sterndrives are designed and manufactured to comply with U.S. Coast Guard
Rules and Regulations to minimize risks of fire or explosion.
Use of replacement electrical, ignition or fuel system components, which do not
comply to these rules and regulations, could result in a fire or explosion hazard and
should be avoided.
When servicing the electrical, ignition and fuel systems, it is extremely important
that all components are properly installed and tightened. If not, any electrical or
ignition component opening would permit sparks to ignite fuel vapors from fuel
system leaks, if they existed.
3
C - Closed Cooling System
Section 7 - Exhaust System
54
A -General Information
B - Manifolds And Elbows
C - Cold Riser Models
D - Warm Riser Models
Section 10 - Color Diagrams
A - Color Diagrams 6
Cooling System
6
Exhaust System
7
8
Color Diagrams
10
IMPORTANT INFORMATION 1
Section 1A - General Information A
Table of Contents
How to Use This Manual . . . . . . . . . . . . 1A-3 Mercury/Quicksilver Lubricants,
Page Numbering . . . . . . . . . . . . . . . . . 1A-3 Sealants, and Adhesives . . . . . . . . . . . 1A-4
Engine Serial Number Locations . . . . 1A-3
Introduction
NOTICE
For information and procedures not listed, refer to the appropriate Mercury MerCruiser
Service Manual.
NOTICE
Refer to appropriate Mercury MerCruiser Service Manual for transom assembly and
sterndrive unit repair.
The following sections of supplemental information has been prepared to assist in the
identification and servicing of Mercury MerCruiser MPI V-8 gasoline engines equipped with
the Warm Manifolds and Dry Joint Exhaust System.
This supplement is intended to be used in conjunction with the appropriate Mercury
MerCruiser service manual for the engine being serviced, and not in place of the manual.
The scope of this supplement is to highlight new or different specifications, components and
procedural information as they pertain to the small block V-8 engines versus previous small
block V-8 engines.
An understanding of the material contained herein and in subsequent publications issued
when necessary will assist service personnel in properly maintaining the Mercury
MerCruiser engine and control systems at the level of quality to which they are built.
This comprehensive overhaul and repair manual is designed as a service guide for the
models previously listed. It provides specific information, including procedures for
disassembly, inspection, assembly, and adjustment to enable dealers and service
mechanics to repair and tune these engines.
Before attempting repairs or tune-up, it is suggested that the procedure first be read through
to gain knowledge of the methods and tools used and the cautions and warnings required
for safety.
d e f
a b c
a - Section number
b - Section part
c - Page number
d - Supplement manual number
e - Month printed
f - Year printed
78018
COOLING SYSTEM
Section 6A - Cooling System All Models
Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . 6A-2 Seawater Pump . . . . . . . . . . . . . . . . . . . . . 6A-13
Lubricants / Sealants / Adhesives . . . . . 6A-2 Output Test . . . . . . . . . . . . . . . . . . . . . . . 6A-13
Seawater Inlet Recommendations . . . . . 6A-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15
Specifications . . . . . . . . . . . . . . . . . . . . . . 6A-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . 6A-16
Seacock (Seawater Inlet Valve) . . . . . . . 6A-3 Cleaning and Inspection . . . . . . . . . . . . 6A-17
Sea Strainer . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . 6A-17
Y-Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . 6A-20
Seawater Pickup . . . . . . . . . . . . . . . . . . . . . 6A-5 Water Circulating Pump . . . . . . . . . . . . . 6A-21
Through the Hull Mounted . . . . . . . . . . . 6A-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Transom Mounted . . . . . . . . . . . . . . . . . . 6A-6 Cleaning and Inspection . . . . . . . . . . . . 6A-22
Quicksilver Sea Strainer . . . . . . . . . . . . . . 6A-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . 6A-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-8 Water Distribution Housing . . . . . . . . . . 6A-24
Cleaning and Inspection . . . . . . . . . . . . . 6A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Cleaning And Inspection . . . . . . . . . . . . 6A-25
Shaft Log Seal . . . . . . . . . . . . . . . . . . . . . . 6A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . 6A-25
Auxiliary Hot Water Heater Installation 6A-11
Supply Hose Connection . . . . . . . . . . . 6A-12
Return Hose Connection . . . . . . . . . . . . 6A-13 6
A
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
Seacock Size
(Internal Cross-Sectional Area Equal to or Greater Than Size Shown)
Gasoline engines 32 mm (1-1/4 in.)
d 70355
c
Seacock
a - Hose connector 32 mm (1-1/4 in.) I.D. to seawater pump inlet
b - Seacock 32 mm (1-1/4 in.) brass ball or gate valve
c - Through the hull seawater pickup
d - Direction of seawater flow
Sea Strainer
Strainer used must be of sufficient size to ensure that an adequate supply of water will be
maintained for cooling the engine. Select a proper seawater strainer based on the following
chart:
Install seawater strainer in an area where it will be easily accessible for inspection and
cleaning. Strainer should be installed in water inlet hose after the seacock (water inlet valve)
to allow operator to shut off water when cleaning strainer.
Y-Fitting
IMPORTANT: Bravo closed cooled models may 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 y-fitting is installed to the engine seawater pump.
1. Install the hose on the engine seawater pump inlet port.
2. Install the y-fitting on the hose.
3. Secure the hose and the y-fitting with hose clamps.
c
b
d 78905
4. Install the water inlet hoses to the water inlet and the sterndrive.
Seawater Pickup
IMPORTANT: A seacock must be installed when using a through the hull or through
the transom water inlet.
Through the Hull Mounted
1. Seal inside edges of 44 mm (1-3/4 in.) hole in hull using a suitable sealant.
2. Apply sealant to mounting surface on seawater pickup where hull contact will occur
when installed.
3. Ensure slots in seawater pickup are facing forward (toward bow of boat) and install
seawater pickup through hull.
4. Fasten pickup with 4 appropriate mounting screws (if so designed).
5. Apply marine caulking as needed inside boat. Apply sealant to threads of nut and install
on pickup on inside of boat and torque nut.
b
d B
A c
a 72639
a - Seawater pickup
b - Seawater inlet slots
c - Mounting screw holes (if equipped)
d - Nut
NOTE: If pickup being installed does not have mounting screws on underside where
mounted to hull, ensure that after nut is torqued slots are still facing forward.
6. Install a sea strainer and a seacock into the water inlet hose.
7. After engine installation,connect the seawater inlet hose from the seawater pickup to the
Y-fitting or to the seawater pump inlet fitting, depending upon the model and equipment.
Transom Mounted
1. Seal the inside edges of the 38 mm (1-1/2 in.) hole hose fitting.
2. Ensure that the hose fitting and plastic plug are in place and threads have been sealed
prior to tightening each securely.
NOTE: Use a sharp knife or wood chisel to remove excess plastic plug material so that plug
is flush with pickup casting.
3. Position 1 flat washer and 1 rubber O-ring on each 5/16 in. x 102 mm (4 in.) long, round
head screw. Coat each screw shaft with sealant.
4. Place new gasket on pickup housing and hold pickup in place on transom. Install 4 round
head screws (with washers and O-rings in place) into pickup mounting holes and
through drilled 8 mm (21/64 in.) holes in transom.
b d
a e
A f B
c
g h
A
i
j 72640
a - Hose fitting
b - Nut (4)
c - Gasket
d - O-ring (4)
e - Washer (4)
f - Screw (4)
g - Plastic Pug
h - Pickup
i - Screen
j - Screw (2)
NOTE: Some installations may have 5 mm (7/32 in.) holes drilled in transom using four 5/16
in. diameter stainless steel lag bolts in place of round head screws. In any case, flat washers
and O-rings are required as outlined.
a
b
72641
5. Secure water pickup from inside with locknuts and washers (unless using lag bolts).
6. Tighten fasteners securely.
7. Install a sea strainer and a seacock into the water inlet hose.
8. After engine installation, connect the seawater inlet hose from the seawater pickup to
the Y-fitting or to the seawater pump inlet fitting, depending upon the model and
equipment.
Description Specification
Minimum pressure (closed cooled models) 20 psi (138 kPa) at 4000 rpm
Removal
CAUTION
If the boat is in the water while working on the seawater strainer, close the seacock,
if equipped. If the boat is not equipped with a seacock, remove and plug the
seawater inlet hose to prevent a siphoning action that may occur, allowing the
seawater to flow from the drain holes or removed hoses and enter the boat.
1. Models equipped with seacock:
a. Close the seacock (water inlet valve).
b. Disconnect the seawater inlet hose from the seawater strainer.
2. Models without seacock:
a. Disconnect the seawater inlet hose from the seawater strainer inlet and plug the
seawater inlet hose.
a
b c d
70062
a
b
72643
b a
c
d
f
g
72673
Installation
IMPORTANT: Mount the seawater strainer in a vibration-free location. Never mount
it on the engine or the transmission. Hoses must not be kinked or allowed to come
in contact with hot or moving engine or transmission parts.
1. Mount the seawater strainer. The arrow indicates the required water flow direction and
must point toward the seawater pump. Tighten the mounting bolts securely.
b
a
c
c
72644
a - Seawater strainer
b - Arrow
c - Mounting bolt hole location (bolts not shown)
2. Remove the plug from the seawater inlet hose (if installed previously) and install the
hose on the strainer. Install the seawater outlet hose. Use two hose clamps on each
hose connection. Tighten the clamps securely.
c c
b
a
72645
a - Seawater inlet hose
b - Seawater outlet hose
c - Double hose clamps
3. Check the drain plug and the lens cover bolts. Tighten securely. Do not overtighten the
cover bolts or the cover may warp and leak water into the boat.
72644
a - Drain plug
b - Lens cover bolts (2, one not shown in this view)
b
78776
a
CAUTION
Avoid a performance loss and/or possible engine damage. Engine coolant must
flow continuously from the engine intake manifold to the engine water circulating
pump. NEVER close off or block the coolant flow to or from a heater.
CAUTION
Avoid engine overheating which could result in engine damage. On models
equipped with Closed Cooling, an air pocket may form in the closed cooling system
if some coolant is lost from the system and the cabin heater or hot water heater is
mounted higher than the fill cap on the heat exchanger. Heater must be mounted
lower than the fill cap of the heat exchanger on models so equipped.
a 78692
a 78752
a
78691
78648
Seawater Pump
Output Test
If an overheating problem exists, use this test to determine if a sufficient amount of water
is being supplied to cool the engine.
IMPORTANT: The following information should be observed before proceeding with
the test:
• THE BOAT MUST BE IN THE WATER FOR THIS TEST. This test CANNOT BE
performed with a flush-test device and water hose.
• The ability of this test to detect a problem is greatly dependent upon the
accuracy with which it is performed. An error in setting the engine rpm, timing
the test or measuring the water output will affect the overall accuracy of the
test and may produce misleading results. To help ensure accurate results, a
shop tachometer with an error of less than 5 percent should be used. The boat
tachometer definitely should not be used as it may not have the necessary
precision. A stop watch should be used to time the duration of the test to help
ensure that the accuracy is maintained within one second. A 9.5 Liter (10 U.S.
qt.) or larger capacity container should be used to measure the water output.
• Due to the manner in which this test is performed, it may not be possible to
detect a marginal condition or a high-speed water pump output problem.
1. Models With Engine Mounted Seawater Pump - Remove the water hose that is
between the pump outlet and the engine, and replace with another hose of the same
diameter, but approximately 1 m (3 ft.) longer. The hose should be of adequate wall
thickness to prevent it from kinking when performing the test. Clamp the hose at the
pump outlet only. Do not clamp the hose at the engine cooler end.
77908
2. Models With Sterndrive (Alpha) Mounted Seawater Pump - Remove the water inlet
hose, which is between the gimbal housing water tube and the engine, and replace with
another hose of the same diameter, but approximately 1 m (3 ft.) longer. The hose should
be of adequate wall thickness to prevent it from kinking when performing the test. Clamp
the hose at the gimbal housing water tube only. Do not clamp the hose at the engine end.
b
a 72614
a - Water tube
b - Hose clamp
c - Water hose
3. Place a 9.5 Liter (10 U.S. qt.) or larger container near the unclamped end of the hose.
4. With the assistance of another person, start the engine and adjust the speed to exactly
1000 rpm while holding the unclamped end of the hose on the connection on the engine.
Remove the hose from the connection on the engine and direct the water flow into the
container for exactly 15 seconds. At the end of 15 seconds, direct the water flow
overboard, return the engine to idle and stop the engine. Reconnect the hose to the
engine.
5. Measure the quantity of water discharged into the container and compare with the
specifications given in the following chart.
6. Repeat the test four times to check the repeatability of the results.
Removal
1. Drain the seawater section of the cooling system.
2. Remove both of the hoses from the aft side of the seawater pump.
3. Remove the serpentine belt.
4. Remove the two bolts attaching the seawater pump and bracket to the engine.
Disassembly
1. Press off the pulley.
2. Remove the six bolts from the rear of the seawater pump.
3. Remove and discard the O-ring.
4. Remove the impeller.
5. Remove the retainer/seal from the front of the seawater pump.
6. Remove the tolerance ring.
7. From the impeller side, press the bearing shaft out of the housing.
8. Remove the rear oil seal from the housing.
j
b
a
c f
h
e
i
78136
3. Clean all gasket material and sealant from the sealing surfaces.
4. Inspect the bearing housing. Examine the surfaces (where the bearings contact the
housing) for evidence of the bearing outer races turning in the housing.
5. Inspect the seals in the bearing housing.
6. Inspect the pump body.
7. Inspect the pump impeller for wear on the sides and the tips of the blades. Also inspect
the blades for cracks in the area where the blades flex. Replace the impeller if the blades
have taken a set (remain in curved position).
8. Inspect the pump pulley.
9. Inspect the serpentine drive belt for excessive wear.
Reassembly
1. Place the rear oil seal into the bearing shaft housing with the side with the spring towards
the impeller cavity.
2. Lubricate the bearing shaft assembly.
78137
a - Seawater pump bearing housing
b - Rear oil seal
c - Bearing shaft assembly
NOTE: The bearing shaft assembly into the seawater pump bearing housing is a slip fit and
only requires light force to install.
3. Install the bearing shaft assembly into the housing.
78138
a - Tolerance ring
5. Apply adhesive to the retainer/seal outer edges. Do not apply adhesive to the seal
portion of the retainer.
6. Place retainer/seal on the shaft and press it into place.
78139
a - Retainer/Seal
71118
71150
a - Impeller
10. Install the O-ring into the groove on the pump body.
78140
a - O-ring groove
78141
Installation
1. Fasten the seawater pump and bracket to the engine. Torque the bolts.
2. Attach the hoses to the aft side of the seawater pump. Tighten the hose clamps securely.
NOTE: Do not use a press to install the seawater pump pulley because it will damage the
bearings.
3. Press the pulley onto the seawater pump shaft using a screw with a flat washer as a
pressing tool assembly. The washer should be larger than the pulley’s ID.
a. Align seawater pump pulley to the seawater pump shaft.
b. Engage the screw assembly into the threaded ID of shaft.
c. Further engage the screw to force pulley onto shaft.
4. Install the serpentine belt.
77954
b
77954
77294
Installation
1. Coat both sides of the new water circulating pump gaskets and the threads of the
attaching fasteners with sealant.
b
a
c
77954
4. Install the water circulating pump pulley to the water circulating pump. Tighten the bolts
securely.
5. Reconnect the hoses to the water circulating pump.
6. Install the serpentine drive belt and adjust the belt tension.
7. Fill the closed cooling system, if equipped.
8. Supply cooling water to the engine.
9. Start the engine and check for leaks.
a
c
b 78920
3. On manual single point drain only: Remove the drain rod from the water distribution
housing.
a. Remove the c-clip from the drain rod. Retain the c-clip.
b. Turn the drain rod handle counter clockwise until the drain rod threads clear the
alignment bracket. Pull the drain rod straight up to completely remove.
d a
b
77947
e
f
78916
a
b
78916
c
a - Top right hand side screw
b - Top left hand side screw
c - Bottom side screw
d - Bracket for the water distribution housing
e - Water distribution housing assembly
4. Install the bracket and water distribution housing to the engine. Finger-tighten the bolt
and nut.
b
77932
a
6. Torque the bolt and nut attaching the water distribution housing bracket to the engine.
7. On air actuated single point drain only: Install the air lines to the air manifold by
inserting the line into the fitting until a positive stop is encountered.
8. Reconnect the hoses to the water distribution housing. Tighten the hose clamps
securely.
COOLING SYSTEM
Section 6B - Seawater Cooled Models
Table of Contents
Torque Specifications . . . . . . . . . . . . . . 6B-2 Exploded View . . . . . . . . . . . . . . . . . . . . . 6B-3
Models With Multi-Point Drain Thermostat Assembly . . . . . . . . . . . . . 6B-3
Systems . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Single Point And Manual Three
Models With Single Point And Manual Point Drain Systems . . . . . . . . . . . 6B-3
Three Point Drain Systems . . . . . . . . 6B-2 Multi-Point Drain System . . . . . . . . 6B-4
Specifications . . . . . . . . . . . . . . . . . . . . . 6B-2 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
Seawater Cooling System Capacity . 6B-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
Thermostat . . . . . . . . . . . . . . . . . . . . . . 6B-2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-6
Installation . . . . . . . . . . . . . . . . . . . . . . . 6B-7
6
B
Torque Specifications
Models With Multi-Point Drain Systems
Description Nm lb-in. lb-ft
Thermostat housing to intake screws 41 30
Models With Single Point And Manual Three Point Drain Systems
Description Nm lb-in. lb-ft
Thermostat housing to intake screws 33 24
Specifications
Seawater Cooling System Capacity
Engine Liter (U.S. Quart)
Seawater cooled models 20 (21)
Thermostat
Engine Specification
Seawater cooled models 71 Degrees C (160 Degrees F)
Exploded View
Thermostat Assembly
SINGLE POINT AND MANUAL THREE POINT DRAIN SYSTEMS
k
l
e b
d
c
f
a b
n
g
h m
j 78907
a - Thermostat housing
b - Pipe plug (2)
c - Water temperature sender
d - Lockwasher
e - Nut
f - Temperature sensor
g - Thermostat gasket
h - Thermostat
i - Thermostat sleeve
j - Thermostat housing gasket to intake
k - Screw (2)
l - Lifting eye
m - Air vent plug (for use when draining seawater)
n - O-ring
l
r
n
p
m o
e
q
d
c
a
f
g
b
h
j 78908
a - Thermostat housing
b - Plug, pipe
c - Water temperature sender
d - Lockwasher
e - Nut
f - Temperature sensor
g - Thermostat gasket
h - Thermostat
i - Thermostat sleeve
j - Thermostat housing gasket to intake
k - Screw (2)
l - Lifting eye
m - Tee-fitting
n - Check ball (2)
o - Spring (2)
p - Washer (2)
q - Screw
r - Locknut
Thermostat
Removal
1. Drain the seawater from the engine.
2. Remove the hoses from the thermostat housing.
3. Remove the thermostat housing assembly.
4. Remove the sleeve, thermostat, and gasket from the thermostat housing.
78692
Testing
1. Remove the thermostat.
2. Place the thermostat on blocks in a container.
3. Completely submerge the thermostat in water.
4. Heat the water.
5. Stir the water constantly to avoid direct heat being applied to the thermostat.
6. Refer to Specifications:
a. Check the thermostat initial opening temperature.
b. Check the thermostat full opening temperature.
c. Check valve lift at fully open position.
d d
c
77724
Typical thermostat
a - Thermometer
b - Agitating Rod
c - Wooden Blocks
d - Thermostat
Installation
NOTE: Refer to exploded view preceding for parts identification during assembly.
1. Clean the gasket surfaces inside the thermostat housing, on the thermostat housing,
and on the intake manifold.
2. Place a new thermostat gasket in the thermostat housing. Ensure that it is positioned
properly in the housing.
3. Place the thermostat in the thermostat housing with the thermostatic element end
toward the housing bottom.
4. Align the sleeve with the groove in the thermostat housing bore and install the sleeve
into the housing.
5. Position a new thermostat housing gasket on the intake manifold.
6. Install the thermostat housing and torque the screws.
7. Reconnect the hoses to the thermostat housing. Tighten the hose clamps securely.
CAUTION
Overheating from insufficient cooling water will cause engine and drive system
damage. Ensure that there is sufficient water always available at water inlet holes
during operation.
8. Supply cooling water to the engine.
9. Start the engine and inspect for leaks.
NOTES:
COOLING SYSTEM
Section 6C - Closed Cooled Models
Table of Contents
Torque Specifications . . . . . . . . . . . . . . 6C-2 Changing Coolant . . . . . . . . . . . . . . . . . . 6C-15
Lubricants / Sealants / Adhesives . . . 6C-2 Closed Cooling Section . . . . . . . . . . . . 6C-15
Specifications . . . . . . . . . . . . . . . . . . . . . 6C-2 Change Intervals . . . . . . . . . . . . . . . . . 6C-15
Closed Cooling System Capacity . . . 6C-2 Draining . . . . . . . . . . . . . . . . . . . . . . . . . 6C-15
Coolant Specification . . . . . . . . . . . . . . 6C-2 Cleaning System . . . . . . . . . . . . . . . . . . . 6C-17
Thermostat . . . . . . . . . . . . . . . . . . . . . . 6C-2 Closed Cooling Section . . . . . . . . . . . . 6C-17
Pressure Cap Rating . . . . . . . . . . . . . . 6C-2 Seawater Section . . . . . . . . . . . . . . . . . 6C-17
Description . . . . . . . . . . . . . . . . . . . . . . . . 6C-3 Heat Exchanger . . . . . . . . . . . . . . . . . . . . 6C-18
Coolant Recommendations . . . . . . . . . 6C-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
Maintaining Coolant Level . . . . . . . . . . 6C-4 Internal Leaks . . . . . . . . . . . . . . . . . 6C-18
Pressure Cap Maintenance . . . . . . . . . 6C-5 Blockage . . . . . . . . . . . . . . . . . . . . . . 6C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
Testing Closed Cooling System . . . . . 6C-6 Disassembly . . . . . . . . . . . . . . . . . . . . . 6C-20
Testing Coolant for Alkalinity . . . . . . . 6C-6 Cleaning And Inspection . . . . . . . . . . . 6C-20
Pressure Testing System . . . . . . . . . . 6C-7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-20
Testing for Cylinder Head Gasket Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6C-21
Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-9 Installation . . . . . . . . . . . . . . . . . . . . . . . 6C-22
Testing Pressure Cap . . . . . . . . . . . . .
Thermostat . . . . . . . . . . . . . . . . . . . . . . . .
6C-10
6C-12
Heat Exchanger Bracket Hardware . .
Heat Exchanger Hose Connections . .
6C-23
6C-24
6
Exploded View . . . . . . . . . . . . . . . . . . . 6C-12 C
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 6C-12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13
Installation . . . . . . . . . . . . . . . . . . . . . . . 6C-14
Torque Specifications
Description Nm lb-in. lb-ft
Heat exchanger end cap 12 108
Thermostat cover screw 30 22
Thermostat housing to intake screw 33 24
Air manifold to heat exchanger screw 3 27
Hose clamps around heat exchanger and bracket 3 26
Hose clamps
Securely
Drain plugs
Specifications
Closed Cooling System Capacity
NOTE: All capacities are approximate fluid measures.
Coolant Specification
Description Part Number
Extended Life Coolant 5/100 (Orange Color) 92-877770K1
Thermostat
Engine Specifications
Closed cooled model 77 Degrees C (170 Degrees F)
Description
The cooling system is composed of two separate subsystems: the seawater system and the
closed cooling system. The seawater system is similar in function to the fan used in an
automobile because it absorbs heat from the closed cooling system as it passes through
the heat exchanger. The closed cooling system is similar in function to the rest of the cooling
system in an automobile.
The coolant recovery system keeps the reservoir full. Normal coolant overflow into the
recovery bottle is approximately 230 ml. (1/2 pint) during warm-up. The coolant recovery
system draws coolant back into the reservoir from the recovery bottle as the engine cools.
As long as there is coolant in the recovery bottle, the reservoir should remain completely
full. If not, there is a vacuum leak, usually at the hose leaving the reservoir or the gasket
under the recovery filler cap.
IMPORTANT: The coolant (antifreeze) flows around the outside of the cooling tubes
while seawater flows through the inside of the cooling tubes in the heat exchanger.
Coolant Recommendations
CAUTION
Alcohol or Methanol base antifreeze or plain water are not recommended for use in
the fresh water section of cooling system at any time.
NOTE: All factory installed closed cooling systems come filled with Extended Life Coolant.
This antifreeze requires draining and replacing every five years or 1000 hours of operation,
whichever comes first. For best results any top-off fluid used should be Extended Life
Coolant. If Extended Life Coolant is unavailable, any type of ethylene glycol based
antifreeze may be used, but it will require the draining and replacing of the coolant every
two years or 400 hours of operation, whichever comes first.
In areas where the possibility of freezing DOES NOT exist, it is permissible to use a solution
of rust inhibitor and water (mixed to manufacturer’s recommendations).
72520
Before starting the engine each day, ensure that the coolant is visible in the coolant recovery
bottle.
If the coolant is not visible, check the closed cooling system (including the coolant recovery
system) for leaks and repair. Refill with the recommended coolant solution as outlined under
Changing Coolant.
If the coolant is visible, start the engine and operate until it reaches normal operating
temperature, then recheck the coolant level in the coolant recovery bottle. The coolant level
MUST be between the ADD and FULL marks on the front of the bottle.
WARNING
Allow the engine to cool before removing the pressure cap. A sudden loss of pres-
sure could cause the hot coolant to boil and discharge violently. After the engine
has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push
down and remove the cap.
If the level is low, remove the fill cap from the coolant recovery bottle and add the required
amount of coolant solution. Refer to Coolant Recommendations in this section.
Occasionally, ensure that the coolant recovery system is functioning properly by removing
the pressure cap from the heat exchanger and checking the level. The coolant level should
be up to the bottom of the heat exchanger filler neck. If low, examine the entire closed cooling
section (especially the coolant recovery system) for leaks and repair.
IMPORTANT: When reinstalling the pressure cap, tighten it until it contacts the stops
on the filler neck.
WARNING
Allow the engine to cool before removing the pressure cap. A sudden loss of pres-
sure could cause hot coolant to boil and discharge violently. After the engine has
cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down
and turn the cap all the way off.
1. Remove the pressure cap from the heat exchanger.
2. Wash the cap with clean water to remove any deposits or debris from the sealing
surfaces.
3. Inspect the rubber seal on the cap for cuts, cracks or other signs of deterioration. If the
seal is damaged, the cap MUST be replaced.
4. Inspect the gasket for deterioration and replace if necessary.
5. Check the condition of the locking tabs on the cap. Replace the cap if the tabs are bent
or cracked.
6. Check the gasket for cracks or other damage.
IMPORTANT: The cap MUST be replaced if damaged.
c a
72714
a - Rubber seal
b - Gasket
c - Locking tabs (1 not shown)
72715
a - Sealing surfaces
b - Coolant recovery passages
10. Reinstall the pressure cap. Tighten the cap until it contacts the filler neck.
6. Observe the gauge reading for approximately two minutes; the pressure should not drop
during this time. If the pressure drops, proceed with the following steps until leakage is
found.
7. While maintaining the specified pressure on the closed cooling section, visually inspect
the external portion of the cooling system (hoses, gaskets, drain plugs, petcocks, core
plugs, circulating pump seal, etc.) for leakage. Also listen closely for bubbling or hissing.
8. Test the heat exchanger.
9. If no leakage could be found in the above steps, the engine is leaking internally. Leaking
may be caused by one or more of the following: loose cylinder head bolts or damaged
gasket, loose intake manifold bolts or damaged gasket, loose exhaust elbow or
distribution block retaining nuts or damaged gasket, cracked or porous cylinder head
or block or cracked or porous exhaust manifold. Proceed as follows until the location of
the internal leak is found.
a. Start the engine. Re-pressurize the system to the previously specified amount and
observe the pressure gauge on the tester. If the needle in the gauge vibrates, the
compression or the combustion is leaking into the closed cooling section from a leak
in the combustion chamber. Exact cylinders where the leakage is taking place can
sometimes be found by removing the spark plug wires (one at a time) while
observing the pressure gauge. Vibration will decrease or stop when the plug wire
is removed from the leaking cylinder. Stop the engine.
b. Remove the spark plugs (one at a time) from the cylinders and examine for the
presence of coolant. A spark plug that is perfectly clean or milky appearing is a sure
indication of a leak.
c. Drain the oil from the engine and examine for coolant. Oil will usually be milky if
coolant is present. If coolant is present, remove the engine from the boat and drop
the oil pan. With the engine in the upright position, re-pressurize the closed cooling
section to the previously specified amount and examine the internal surfaces of the
engine to locate the leak.
d. If no leakage can be found in the above steps, the entire engine must be
disassembled and inspected for leaks.
WARNING
Allow the engine to cool before removing the pressure cap. A sudden loss of pres-
sure could cause hot coolant to boil and discharge violently. After the engine has
cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down
and turn the cap all the way off.
1. Carefully remove the pressure cap from the reservoir or the heat exchanger.
2. Wash the cap with clean water to remove any deposits or debris from the sealing
surfaces.
3. Inspect the gasket (if used) and the rubber seal on the cap for tears, cuts, cracks or other
signs of deterioration. Replace the gasket, if damaged.
4. Replace the cap if the rubber seal is damaged.
5. Check the condition of the locking tabs on the cap. Replace the cap if the tabs are bent
or cracked.
IMPORTANT: The cap MUST be replaced if damaged.
c a
72714
a - Rubber seal
b - Gasket
c - Locking tabs (1 not shown)
6. Using a cooling system pressure tester (similar to one shown), test the cap to ensure
that it releases at the proper pressure and does not leak. (Refer to the instructions which
accompany the tester for the correct test procedure.) The cap must relieve pressure at
110 kPa (16 psi), and must hold the rated pressure for 30 seconds without going below
75.8 kPa (11 psi). Replace the cap if it fails to fall within these limits.
72716
IMPORTANT: Before reinstalling the cap in the next step, examine the lower inside
sealing surface in the filler neck to ensure that it is perfectly smooth and free of
debris. Also, inspect the cam lock flanges on the sides of the filler neck to ensure that
they are not bent.
72715
a - Sealing surfaces
b - Coolant recovery passages
Thermostat
Exploded View
l m
k
j
i b
c
d
e
a
h g
78909
a - Thermostat housing
b - Thermostat
c - Thermostat seal
d - Thermostat housing cover
e - Thermostat housing cover screw (2)
f - Plug
g - Temperature sensor
h - Gasket
i - Temperature sender
j - Lockwasher
k - Nut
l - Air vent
m - Screw (2)
Removal
NOTE: If the coolant flow is restricted or fails to occur, a wire should be repeatedly inserted
into all drain holes to ensure that there are no obstructions in the passages. Remove the
fitting, if necessary, to insert the wire completely into the drain hole.
1. Drain the coolant from the engine.
2. Disconnect the hoses from the thermostat cover.
3. Remove the thermostat cover bolts, the cover, and the gasket.
4. Remove the thermostat from the thermostat housing.
Testing
1. Place the thermostat on blocks in a container.
2. Completely submerge the thermostat in water.
3. Heat the water.
4. Stir the water constantly to avoid direct heat being applied to the thermostat.
5. Refer to Specifications:
a. Check the thermostat initial opening temperature.
b. Check the thermostat full opening temperature.
c. Check valve lift at fully open position.
d d
c
77724
Typical thermostat
a - Thermometer
b - Agitating rod
c - Wooden blocks
d - Thermostat
Installation
1. Remove the thermostat housing and the gaskets. Discard the gaskets.
2. Clean the gasket surfaces on the thermostat cover, the thermostat housing, and the
intake manifold.
3. Position the gasket on the intake manifold. Place the thermostat housing on the gasket.
4. Torque the screws.
a
b
c
d
f e
78909
a - Thermostat housing
b - Thermostat
c - Thermostat housing seal
d - Thermostat housing cover
e - Thermostat housing cover screw (2)
f - Gasket
g - Thermostat housing to intake screw (2)
Changing Coolant
Closed Cooling Section
The engine and exhaust sections of closed cooling system should remain filled year-round
with the recommended coolant solution. Do not drain closed cooling section for storage, as
this will promote rusting of internal surfaces. If engine will be exposed to freezing
temperatures, make sure that closed cooling section is filled with Extended Life Coolant or
an ethylene glycol antifreeze and water solution, mixed to manufacturer’s recommended
proportions, to protect engine to lowest temperature to which it will be exposed. If necessary,
change coolant using coolant specified in “Coolant Recommendations.”
Change Intervals
If the closed cooling system is factory installed, drain and flush coolant from the closed
cooling system at least every five years or 1000 hours of operation, whichever comes first.
It should also be changed whenever exhaust gases have entered the system.
If the system is not factory installed or has had anti-freeze other than Extended Life Coolant
added, it must be changed every two years or 400 hours of operation, whichever comes first.
Draining
WARNING
Allow engine to cool before removing pressure cap. Sudden loss of pressure could
cause hot coolant to boil and discharge violently. After engine has cooled, turn cap
1/4 turn to allow any pressure to escape slowly, then push down and turn cap all the
way off.
IMPORTANT: A wire should be inserted into drain holes to ensure that foreign
material is not obstructing the drain holes. On some models with two piece petcock,
removal of petcock may be required so that wire can be inserted completely into drain
hole.
IMPORTANT: Engine must be as level as possible to ensure complete draining of
cooling system.
IMPORTANT: Closed cooling section must be kept filled year round with
recommended coolant. If engine will be exposed to freezing temperatures, make sure
closed cooling section is filled with Extended Life Coolant or an ethylene glycol
antifreeze and water solution properly mixed to protect engine to lowest temperature
to which it will be exposed.
The following draining instructions apply to all engines equipped with closed cooling. The
location of petcocks that require opening and hoses that require removal are represented
on the following pages for the individual engines.
d
a
e
c
b
78905
4. Remove the heat exchanger to water circulating pump hose at the pump connection.
Drain coolant into proper container.
b a
78648
5. After coolant has drained completely, reinstall block pipe plug and hoses. Tighten
clamps securely.
6. Remove coolant recovery bottle from mounting bracket and discard the coolant into a
proper container.
Cleaning System
Closed Cooling Section
Closed cooling section of closed cooling system should be cleaned at least once every five
years or whenever decreased cooling efficiency is experienced.
A good grade automotive cooling system cleaning solution may be used to remove rust,
scale or other foreign material. Always follow manufacturer’s instructions for the cleaner.
If closed cooling section is extremely dirty, a pressure flushing device may be used to flush
out remaining deposits. Flushing should be done in direction opposite normal coolant flow
to allow water to get behind deposits and force them out. Refer to instructions that
accompany flushing device for proper hookup and flushing procedure.
NOTICE
For information and procedures on draining and flushing Seawater Section of
Closed Cooling (Coolant) Models, and for cold weather or extended storage, refer
to the appropriate Mercury MerCruiser Service Manual.
Seawater Section
Cooling efficiency of an engine with closed cooling is greatly dependent upon heat transfer
through the tubes within the heat exchanger. During engine operation, contaminants within
the seawater (such as salt, silt, lime, etc.) collect on the inside of the tubes, thus reducing
heat transfer and greatly decreasing heat exchanger efficiency. It is, therefore,
recommended that the seawater section of the heat exchanger be cleaned as specified in
the appropriate Mercury MerCruiser Service manual or whenever decreased cooling
efficiency is suspected.
Heat Exchanger
Testing
INTERNAL LEAKS
An internal leak will allow coolant to enter into the seawater circuit when the closed cooling
circuit is pressurized.
1. Remove a seawater hose from the exchanger. Do not drain the exchanger.
2. Pressurize the closed cooling circuit to 110-138 kPa (16-20 psi) with a radiator tester.
3. If seawater begins to flow from the seawater hose fitting of the heat exchanger, there
is a leak.
BLOCKAGE
IMPORTANT: Seawater flows THROUGH the tubes in the exchanger. Closed cooling
coolant flows AROUND the tubes.
1. Remove the end caps and inspect for any blockage in the seawater circuit (broken
impeller blades, weeds, etc.).
2. Remove the closed cooling circuit hoses and inspect the tubes just inside the nipples.
Because the complete exchanger cannot be inspected, the heat exchanger should be
replaced if blockage is suspected.
Removal
1. Allow engine to cool.
2. Drain the seawater from the engine.
3. Drain the coolant from the engine.
4. Remove each air line from the air manifold by pressing on the fitting and pulling the line
out.
a
c
b 78920
e
d
c
b
g
h
i
a
78906
a - Heat exchanger
b - Air manifold
c - Air manifold screws and washers
d - Air pump bracket (later style)
e - Air pump
f - Heat exchanger cap
g - Air vent plug
h - O-ring
i - Air pump bracket (early style)
6. Remove the 2 large hose clamps fastening the heat exchanger to the engine.
7. Remove the heat exchanger.
Disassembly
1. Remove the air pump from the air pump bracket.
2. If air pump bracket is secured with adhesive, do not remove.
3. If air pump bracket is secured by screws, remove the air pump bracket.
4. Remove the air manifold.
5. Remove the screws attaching the end cap to the heat exchanger.
6. Remove the end caps and gaskets.
c
71515
b
a - Heat exchanger
b- Sealing washer
c - End cap
d- Gasket
Assembly
1. Apply sealant to both sides of new end cap gaskets.
2. Install new gaskets, new sealing washers, and end caps onto heat exchanger. Torque
the end cap screws.
c
71515
b
a - Heat exchanger
b- Sealing washer
c - End cap
d- Gasket
Installation
1. Lower heat exchanger onto bracket and simultaneously attach water hoses.
2. Ensure that all hose ends are aligned and fully seated on heat exchanger fittings.
Tighten all hose clamps securely.
3. Install large hose clamps around heat exchanger bracket and heat exchanger.
4. Install the hose clamps around the heat exchanger. The rubber hose should be
underneath the bracket to prevent the bracket from directly contacting the hose clamp
and potentially breaking it.
78405
a - Hose clamp
b - Rubber hose
6. Install the air lines to the air manifold by inserting the line into the fitting until a positive
stop is encountered.
7. Ensure the air lines are installed properly.
a. Install air pump on the fitting in the air manifold.
77638
a - Green indicators
e
d
c
b
g
h
i
a
78906
a - Heat exchanger
b - Air manifold
c - Air manifold screws and washers
d - Air pump bracket (later style)
e - Air pump
f - Heat exchanger cap
g - Air vent plug
h - O-ring
i - Air pump bracket (early style)
g
a
b
d
f
e
c
77954
EXHAUST SYSTEMS
Section 7A - Dry Joint Identification
Table of Contents
General Information . . . . . . . . . . . . . . . . . . 7A-2 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . 7A-4
Closed Cooled Models . . . . . . . . . . . . . . 7A-2 Manifold Leak Test . . . . . . . . . . . . . . . . . . 7A-4
Seawater Cooled Models . . . . . . . . . . . . 7A-2 Exhaust Riser . . . . . . . . . . . . . . . . . . . . . . . . 7A-5
Warm Manifolds . . . . . . . . . . . . . . . . . . . . 7A-2 Cold Riser Casting . . . . . . . . . . . . . . . . . . 7A-5
Dry Joint . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2 Warm Riser Casting . . . . . . . . . . . . . . . . . 7A-6
Serial Number Breaks . . . . . . . . . . . . . . . . 7A-2 Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . 7A-7
Turbulator Gasket . . . . . . . . . . . . . . . . . . . . 7A-3 MCM Models And Ski V-Drive Models . 7A-7
Identification . . . . . . . . . . . . . . . . . . . . . . . 7A-3 Inboard Models . . . . . . . . . . . . . . . . . . . . . 7A-7
Exhaust Elbow Fasteners . . . . . . . . . . . . 7A-8
7
A
General Information
IMPORTANT: The Identification section outlines new components and information
needed for Section 7-Exhaust Systems.
Closed Cooled Models
Engine models covered in this service manual supplement are considered a full closed
cooling system. The term full closed cooling system, also known as full fresh water cooled
or full FWC refers to the use of ethylene glycol mixture in the engine and the exhaust water
jackets. Engine models in service manuals number 24, 25, 31,and 32 are one-half (1/2)
closed cooling systems or 1/2 systems. The term 1/2 closed cooling system refers to the
use of ethylene glycol mixture in the engine cooling passages and the use of seawater in
the exhaust water jackets.
Seawater Cooled Models
The term seawater cooled, also known as raw water cooled or RWC, refers to the use of
water for cooling throughout the system, such as seawater in the engine cooling passages
and in the exhaust water jackets. This water source is picked up through the sterndrive and
engine seawater pump.
Warm Manifolds
Warm manifolds contain fluid temperature that enters the exhaust manifold at greater than
or equal to 54 degree Celsius (130 degree Fahrenheit). The temperature is warm enough
to evaporate moisture that collects on interior exhaust passages due to condensation. The
models covered in this Service Manual Supplement are warm manifold engines.
Dry Joint
Dry joint is the new exhaust system where the water porting in the exhaust components has
been designed to prevent water from entering the engine. The models covered in this
Service Manual Supplement are dry joint engines.
Turbulator Gasket
Identification
CAUTION
Avoid severe engine damage. The turbulator gasket used MUST BE the Mercury
MerCruiser turbulator gasket specified for your engine package. Engine damage
that results from improper gasket use is considered misuse of the engine and is not
covered under Mercury MerCruiser Warranty.
IMPORTANT: Gasket identification can be viewed externally on the engine package.
The outer edge of each turbulator gasket identifies the gasket and the gasket
position.
• The full flow gasket is contoured at the edge to show full flow at each water port.
• The block off gasket is straight at the edge to show no flow at each port.
• The restrictor gasket is contoured at one edge of gasket to show full flow. The other
edge of gasket is straight to show restricted flow.
78805
c
NOTE: Gasket is not reusable. Inspect for proper gasket replacement before disassembly
and assembly.
Exhaust Manifold
The warm exhaust manifold used in this service manual supplement is a new casting design
and cannot be replaced with the previous Mercury MerCruiser exhaust manifold casting.
This warm exhaust manifold casting is used in cold riser and warm riser applications.
78900
78900
Exhaust Riser
Cold Riser Casting
NOTE: The position of the riser water port and castings are different between the cold riser
model and the warm riser model.
The 76 mm (3 in.) and the 152 mm (6 in.) cold risers identified in this service manual
supplement can only be replaced with Mercury MerCruiser warm riser castings as cold
risers will not be ofered as a service part. Warm riser castings require the use of additional
hose kits. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.
Cold riser castings can be easily identified by the water ports and drain holes on the casting.
a
b
78893
Warm riser castings can be used on cold riser models, but require the use of the hose kits.
The engine will have to be changed to warm risers.
NOTE: Using Perfect Seal on water ports is a preventive measure for corrosion
deterioration.
b
78893
NOTE: Using Perfect Seal on water ports is a preventive measure for corrosion
deterioration.
Exhaust Elbow
MCM Models And Ski V-Drive Models
The 7 degree exhaust elbows identified are a new casting design and should not be
replaced with previous Mercury MerCruiser elbow castings.
78904
Inboard Models
The 14 degree exhaust elbows identified are a new casting design and should not be
replaced with previous Mercury MerCruiser elbow castings.
78904
IMPORTANT: To ensure correct torque, the 7-1/2 in. (190.5 mm) long, 9 in. (228.6 mm)
long and 10-1/2 in. (266.7 mm) long exhaust elbow screws require that a specific flat
washer be used in conjunction with the screw. Refer to the Mercury Precision
Parts/Quicksilver Accessories Guide.
EXHAUST SYSTEMS
Section 7B - Manifolds And Elbows
Table of Contents
General Information . . . . . . . . . . . . . . . . . . 7B-2 Cleaning And Inspection . . . . . . . . . . . . . . 7B-4
Torque Specifications . . . . . . . . . . . . . . . . 7B-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 7B-6
Lubricants / Sealants / Adhesives . . . . . 7B-2 Gasket Application . . . . . . . . . . . . . . . . . . . 7B-7
Exploded View . . . . . . . . . . . . . . . . . . . . . . . 7B-3 Restrictor Gasket . . . . . . . . . . . . . . . . . . . 7B-7
Warm Manifolds . . . . . . . . . . . . . . . . . . . . 7B-3 Block Off Gasket . . . . . . . . . . . . . . . . . . . 7B-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-8
7
A B
General Information
This section contains new components and procedures. Before attempting repairs or
tune-up, it is suggested that the procedure first be read through to gain knowledge of the
methods and tools used and the cautions and warnings required for safety.
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
Exploded View
Warm Manifolds
78887
d e
f
g
c
Removal
WARNING
Avoid injury or death and power package damage from an electrical shock, fire or
explosion. Always disconnect both battery cables from the battery before servicing
the power package.
1. Disconnect both battery cables from the battery.
CAUTION
Avoid severe engine damage. Exhaust elbows and manifolds MUST BE drained to
prevent coolant / water from entering combustion chambers when exhaust elbows
are removed.
1. Seawater cooled models: Drain the seawater section of the engine.
1. Closed cooled models: Drain the coolant section of the engine. Refer to Section 6C.
2. Disconnect the engine exhaust hoses. Retain fasteners.
3. Disconnect all hoses from the exhaust manifold and exhaust elbow. Retain fasteners.
4. Remove and retain any items or components that are mounted to the manifold and the
exhaust elbow of the engine.
5. Remove the exhaust elbow. Retain fasteners.
6. Remove the exhaust manifold. Retain fasteners.
7. Discard used gaskets.
78748
NOTE: Only use this specification if the gasket surfaces on used exhaust components have
to be machined to remove minor corrosion.
Description mm (in.)
Maximum overall
Surface Flatness 0.07 (0.003)
difference
NOTE: The maximum material that can be removed is 0.25 mm (0.010 in.). When torquing
the attaching bolts, ensure that they are not contacting the bottom of the threaded hole in
the manifold.
NOTE: Gasket is not reusable. Inspect for proper gasket replacement before disassembly
and assembly.
7. Replace all damaged components.
Reassembly
IMPORTANT: The edge of the water ports on all cast iron parts must be coated with
Perfect Seal during assembly.
1. If exhaust elbow assembly is disassembled or risers are added, apply sealant to edge
of all water ports (exhaust manifold, both sides of the riser, and exhaust elbow).
A
a
78748
a - Water ports
b - Exhaust manifold
c - Exhaust elbow
A c
b
a
78807
Gasket Application
Restrictor Gasket
IMPORTANT: Restrictor gasket must be used on all SEAWATER COOLED engines.
IMPORTANT: On engines without risers, the restrictor gasket must be placed
between the exhaust manifold and the exhaust elbow.
IMPORTANT: The restrictor end of the gasket must be positioned to the seawater inlet
side of the exhaust elbow.
78805
a
b
78806
Installation
CAUTION
Avoid severe engine damage. The correct turbulator gasket MUST BE properly
installed to avoid overheating due to insufficient water flow or coolant loss through
exhaust.
IMPORTANT: Refer to Section 7B - Cold Risers and Section 7C - Warm Risers if ex-
haust risers are used.
1. Seawater cooled models: Apply sealant to threads of pipe plug and install to exhaust
manifold.
A c
b
a
78887
a - Exhaust manifold
b - Pipe plug
c - Sealant applied to threads
3. Closed cooled models: Apply sealant to threads of hose fitting and install to exhaust
manifold.
a
c A
78887
a - Exhaust manifold
b - Hose fitting
c - Sealant applied to threads
5. Using new exhaust manifold gasket, install exhaust manifold to cylinder head. Torque
fasteners.
6. Apply sealant to threads of hose fitting and pipe plug and install in exhaust elbow.
A
d
c
a
b
A d 78893
a - Exhaust elbow
b - Hose fitting
c - Pipe plug
d - Sealant applied to threads
8. Apply sealant to the edge of each of the 2 water ports located on the exhaust manifold.
78807
9. Seawater cooled models : Place the restrictor gasket on the exhaust manifold with the
side marked “UP” visible. Ensure that the restricted water port of restrictor gasket is on
the same side as the hose fitting of the exhaust elbow.
d
78910
78889
10. Closed cooled models: Place the block-off gasket on the exhaust manifold with the
side marked “UP” visible.
c
78890
11. Apply sealant to the edge of each of the 2 water ports located on the exhaust elbow.
78807
78910 78890
78889 78888
IMPORTANT: The 7-1/2 in. (190.5 mm) long, 9 in. (228.6 mm) long, and 10-1/2 in. (266.7
mm) long exhaust elbow screws require that a specific flat washer be used in
conjunction with the screw. Refer to “Mercury Precision Parts/Quicksilver
Accessories Guide.”
13. If applicable, assemble washers to the exhaust elbow screws.
14. Apply sealant to exhaust elbow screw threads and hand-start to temporarily secure the
assembly.
17. Seawater cooled models: Connect the engine water hoses to the exhaust elbows and
tighten hose clamps securely.
CAUTION
Avoid severe engine damage due to improper hose connection, causing coolant to
discard out exhaust. DO NOT connect the engine coolant hose to the exhaust
elbow.
18. Closed cooling models: Connect the engine coolant hose from the thermostat housing
to the hose fitting of the top of the exhaust manifold. Tighten hose clamps securely.
c
a
78758
19. Closed cooling models: Connect the engine water hose from the heat exchanger to
the exhaust elbow and tighten hose clamps securely.
a
78759
78788
a - Exhaust elbow
b - Shift bracket
c - Shift bracket to exhaust elbow screw
a c
d 78685
a - Exhaust elbow
b - ECM bracket
c - Screw, short
d - ECM
CAUTION
Overheating from insufficient cooling water will cause engine and drive system
damage. Ensure that there is sufficient water always available at water inlet holes
during operation.
27. Supply cooling water to the engine.
28. Start the engine and check for exhaust and water leaks.
EXHAUST SYSTEM
Section 7C - Cold Riser Models
7
Table of Contents
General Information . . . . . . . . . . . . . . . . . . 7C-2 Cleaning And Inspection . . . . . . . . . . . . . . 7C-5
Torque Specifications . . . . . . . . . . . . . . . . 7C-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 7C-7
Lubricants / Sealants / Adhesives . . . . . 7C-2 Gasket Application . . . . . . . . . . . . . . . . . . . 7C-8
Serial Number Breaks . . . . . . . . . . . . . . . . 7C-2 Full Flow Gasket . . . . . . . . . . . . . . . . . . . . 7C-8
Exploded View . . . . . . . . . . . . . . . . . . . . . . . 7C-3 Restrictor Gasket . . . . . . . . . . . . . . . . . . . 7C-8
Seawater Cooled Models . . . . . . . . . . . . 7C-3 Block-Off Gasket . . . . . . . . . . . . . . . . . . . 7C-8
Closed Cooled Models . . . . . . . . . . . . . . 7C-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-5
7
C
General Information
This section contains new components and procedures. Before attempting repairs or
tune-up, it is suggested that the procedure first be read through to gain knowledge of the
methods and tools used and the cautions and warnings required for safety.
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
Exploded View
Seawater Cooled Models
h
k
k
d g
j
f e
c
j
k
b a
78792
d k
g
j
e
f
c
j
j
b a
78903
Removal
WARNING
Avoid injury or death and power package damage from an electrical shock, fire or
explosion. Always disconnect both battery cables from the battery before servicing
the power package.
1. Disconnect both battery cables from the battery.
CAUTION
Avoid severe engine damage. Exhaust elbows and manifolds MUST BE drained to
prevent coolant / water from entering combustion chambers when exhaust elbows
are removed.
1. Seawater cooled models: Drain the seawater section of the engine.
1. Closed cooled models: Drain the coolant section of the engine. Refer to Section 6C.
2. Disconnect the engine exhaust hoses. Retain fasteners.
3. Disconnect all hoses from the exhaust manifold, riser, and exhaust elbow. Retain
fasteners.
4. Remove and retain any items or components that are mounted to the exhaust manifold,
riser, and the exhaust elbow of the engine.
5. Remove the exhaust elbow and riser. Retain fasteners.
6. Remove the exhaust manifold. Retain fasteners.
7. Discard used gaskets.
a
d
c
78748
NOTE: Only use this specification if the gasket surfaces on used exhaust components have
to be machined to remove minor corrosion.
Description mm (in.)
Maximum overall
Surface Flatness 0.07 (0.003)
difference
NOTE: The maximum material that can be removed is 0.25 mm (0.010 in.). When torquing
the attaching bolts, ensure that they are not contacting the bottom of the threaded hole in
the manifold.
NOTE: Gasket is not reusable. Inspect for proper gasket replacement before disassembly
and assembly.
7. Replace all damaged components.
Reassembly
IMPORTANT: The edge of the water ports on all cast iron parts must be coated with
Perfect Seal during assembly.
1. If exhaust elbow assembly is disassembled or risers are added, apply sealant to edge
of all water ports (exhaust manifold, both sides of the riser, and exhaust elbow).
A
c
A
a
A
b
78748
A
c
b
a
78807
Gasket Application
Full Flow Gasket
IMPORTANT: Full flow gasket is used on engines with risers.
IMPORTANT: On cold riser models, the full flow gasket must be placed between riser
and exhaust elbow.
a
b
78804
Restrictor Gasket
IMPORTANT: Restrictor gasket must be used on all SEAWATER COOLED engines.
IMPORTANT: On cold riser models, the restrictor gasket must be placed between the
exhaust manifold and the riser.
IMPORTANT: The restrictor end of the gasket must be positioned to the seawater inlet
side of the exhaust elbow.
a
c
b
78805
Block-Off Gasket
IMPORTANT: Block off gasket must be used on all CLOSED COOLED engines.
IMPORTANT: On cold riser models, the block off gasket must be placed between the
exhaust manifold and the riser.
b a
78806
Installation
CAUTION
Avoid severe engine damage. The correct turbulator gasket MUST BE properly
installed to avoid overheating due to insufficient water flow or coolant loss through
exhaust.
1. Apply sealant to the threads of the pipe plug and install into the exhaust elbows.
A
a c
b
78893
a - Exhaust elbow
b - Pipe plug
c - Sealant applied to threads
3. Apply sealant to the threads of the hose fitting and install into the risers.
A
d
c A
d
a c
b
78893
a - 76 mm (3 in.) riser
b - 152 mm (6 in.) riser
c - Hose fitting
d - Sealant applied to threads
5. Seawater cooled models: Apply sealant to the threads of the pipe plug and install into
the exhaust manifold.
c A
b
78893
a - Exhaust manifold
b - Pipe plug
c - Sealant applied to threads
7. Closed cooled models: Apply sealant to the threads of the hose fitting and install into
the exhaust manifold.
c A
b
78893
a - Exhaust manifold
b - Hose fitting
c - Sealant applied to threads
9. Apply sealant to the edge of each of the 2 water ports located on the exhaust manifold.
78807
10. For seawater cooled models only: Place the restrictor gasket on the exhaust manifold
with the side marked “UP” visible. Ensure that the restricted water port of restrictor
gasket is on the same side as the hose fitting of the riser.
a
d
c e
f
78892
d
b
f
c
SCALE 0.250
78886
11. For closed cooled models only: Place the block-off gasket on the exhaust manifold
with the side marked “UP” visible.
a c
e
d
SCALE
78891
12. Apply sealant to the edge of each of the 4 water ports located on the riser.
A
78807
13. Place the riser on the exhaust manifold. Refer to exploded view preceding for correct
placement.
NOTE: Position of the riser water port is placed closest to exhaust manifold.
IMPORTANT: Ensure that the hose fitting located in the riser water port is positioned
to accept the engine water hose.
14. For 152 mm (6 inch) riser: Install and hand-tighten 4 screws, 3/8-16 x 1.00 in. (25 mm)
long, to temporarily secure the riser and gasket to the exhaust manifold.
CAUTION
Avoid severe engine damage. The turbulator gasket MUST BE properly installed to
avoid overheating due to insufficient water flow or coolant loss through exhaust.
15. Place the full flow gasket on the riser with the side marked “UP” visible.
c
b
78485
d
a - Exhaust manifold
b - Full flow gasket
c - Turbulator oriented up
d - Passages fully open
16. Apply sealant to the edge of each of the 2 water ports located on the exhaust elbow.
A
78807
78891
78892
SCALE 0.250
78886 78885
IMPORTANT: The 7-1/2 in. (190.5 mm), 9 in. (228.6 mm) long and 10-1/2 in. (266.7mm)
exhaust elbow screws require that a specific flat washer be used in conjunction with
the screw. Refer to “Mercury Precision Parts/Quicksilver Accessories Guide”.
18. If applicable, assemble washers to the exhaust elbow screws.
19. Apply sealant to exhaust elbow screw threads and hand-start to temporarily secure the
assembly.
20. Align the exhaust elbow to the intermediate elbow or engine exhaust system.
21. For 152 mm (6 inch) riser: Tighten and torque screws holding the riser to the exhaust
manifold.
NOTE: Gasket is not reusable. Inspect for proper gasket and component position before
torquing.
22. If applicable, ensure that washers are in place between bolt and exhaust elbow.
23. Torque the exhaust elbow fasteners.
24. Seawater cooled models: Connect the engine water hoses to the hose fitting of riser
and tighten hose clamps securely.
CAUTION
Avoid severe engine damage due to improper hose connection, causing coolant to
discard out exhaust. Do NOT connect the engine coolant hose to the exhaust elbow.
25. Closed cooling models: Connect the coolant hose from the thermostat housing to the
hose fitting of the top of the exhaust manifold. Tighten hose clamps securely.
c
a
78758
26. Closed cooling models: Connect the engine water hose from the heat exchanger to
the exhaust riser and tighten hose clamps securely.
a
78759
c
a
78788
a d
78787
f
Drop down bracket for the 76 mm (3 in.) riser assembly
a - Exhaust manifold, riser, and elbow assembly
b - Bracket mounting holes
c - Drop down bracket
d - ECM Bracket
e - Short screw
f - ECM
29. Port exhaust elbow with 152 mm (6 in.) riser: All models.
a. Install the ECM drop-down bracket.
b. Install the ECM bracket and the ECM to the exhaust elbow.
c. Tighten securely.
a
d
f 78789
CAUTION
Overheating from insufficient cooling water will cause engine and drive system
damage. Ensure that there is sufficient water always available at water inlet holes
during operation.
34. Supply cooling water to the engine.
35. Start the engine and check for exhaust and water leaks.
EXHAUST SYSTEMS
Section 7D - Warm Riser Models
Table of Contents
General Information . . . . . . . . . . . . . . . . . . 7D-2 Cleaning And Inspection . . . . . . . . . . . . . . 7D-5
Torque Specifications . . . . . . . . . . . . . . . . 7D-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 7D-7
Lubricants / Sealants / Adhesives . . . . . 7D-2 Gasket Application . . . . . . . . . . . . . . . . . . . 7D-8
Serial Number Breaks . . . . . . . . . . . . . . . . 7D-2 Full Flow Gasket . . . . . . . . . . . . . . . . . . . . 7D-8
Exploded View . . . . . . . . . . . . . . . . . . . . . . . 7D-3 Restrictor Flow Gasket . . . . . . . . . . . . . . 7D-8
Seawater Cooled Models . . . . . . . . . . . . 7D-3 Block-Off Gasket . . . . . . . . . . . . . . . . . . . 7D-8
Closed Cooled Models . . . . . . . . . . . . . . 7D-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-5
7
D
General Information
This section contains new components and procedures. Before attempting repairs or
tune-up, it is suggested that the procedure first be read through to gain knowledge of the
methods and tools used and the cautions and warnings required for safety.
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
Exploded View
Seawater Cooled Models
IMPORTANT: On seawater cooled models, always position the restrictor gasket with
the restricted port on the same side of the exhaust manifold as the exhaust elbow or
riser hose fitting.
j
g
e
f
d k k
b a
78900
h
k
j
g
d e
j f j
a
b
78803
Removal
WARNING
Avoid injury or death and power package damage from an electrical shock, fire or
explosion. Always disconnect both battery cables from the battery before servicing
the power package.
1. Disconnect both battery cables from the battery.
CAUTION
Avoid severe engine damage. Exhaust elbows and manifolds MUST BE drained to
prevent coolant / water from entering combustion chambers when exhaust elbows
are removed.
1. Seawater cooled models: Drain the seawater section of the engine.
1. Closed cooled models: Drain the coolant section of the engine. Refer to Section 6C.
2. Disconnect the engine exhaust hoses. Retain fasteners.
3. Disconnect all hoses from the exhaust manifold, riser, and exhaust elbow. Retain
fasteners.
4. Remove and retain any items or components that are mounted to the exhaust manifold,
riser, and the exhaust elbow of the engine.
5. Remove the exhaust elbow and riser. Retain fasteners.
6. Remove the exhaust manifold. Retain fasteners.
7. Discard used gaskets.
a
d
c 78748
78807
NOTE: Only use this specification if the gasket surfaces on used exhaust components have
to be machined to remove minor corrosion.
Description mm (in.)
Surface profile Tolerance zone 0.07 (0.003)
NOTE: The maximum material that can be removed is 0.25 mm (0.010 in.). When torquing
the attaching bolts, ensure that they are not contacting the bottom of the threaded hole in
the manifold.
8. If any components do not meet specifications replace the damaged components.
Reassembly
IMPORTANT: The edge of the water ports on all cast iron parts must be coated with
Perfect Seal during assembly.
1. If exhaust elbow assembly is disassembled or risers are added, apply sealant to edge
of all water ports (exhaust manifold, both sides of the riser, and exhaust elbow).
A
c
A
a
A
b
78748
A c
b
a
78807
Gasket Application
Full Flow Gasket
IMPORTANT: Full flow gasket is not used on engines without risers.
IMPORTANT: On warm riser models, the full flow gasket must be placed between
exhaust manifolds and riser.
a
b
78804
Block-Off Gasket
IMPORTANT: Block-off gasket must be used on all CLOSED COOLED engines.
IMPORTANT: On warm riser models, the block-off gasket must be placed between the
riser and the exhaust elbow.
b a
78806
Installation
CAUTION
Avoid severe engine damage. The turbulator gasket MUST BE properly installed to
avoid overheating due to insufficient water flow or coolant loss through exhaust.
1. On seawater cooled models: Apply sealant to threads of the pipe plug and install into
the riser.
A
A
d
d
c
a c b
78893
a - 76 mm (3 in.) riser
b - 152 mm (6 in.) riser
c - Pipe plug
d - Sealant applied to threads
3. On closed cooled models: Apply sealant to threads of the hose fittings and install into
the risers.
A
d
A
d c
a c b
78893
a - 76 mm (3 in.) riser
b - 152 mm (6 in.) riser
c - Hose fitting
d - Sealant applied to threads
5. Apply sealant to the edge of each of the 2 water ports located on the exhaust manifold.
78807
6. Place the full flow gasket on the exhaust manifold with the side marked “UP” visible.
c
b
78485
d
a - Exhaust manifold
b - Full flow gasket
c - Turbulator oriented up
d - Passages fully open
7. Apply sealant to the edge of each of the 4 water ports located on the riser.
A
78807
a
b
78893
Seawater cooled models (76 mm [3 in.] riser shown, 152 mm [6 inch] riser similar)
a - Exhaust elbow inlet water port with hose fitting
b - Riser outlet water port with pipe plug (seawater cooled)
c - Exhaust manifold outlet water port with pipe plug
78893
Closed cooled models (152 mm [6 in.] riser shown, 76 mm [3 in.] riser similar)
a - Exhaust elbow inlet water port with hose fitting
b - Riser outlet water port with hose fitting (closed cooled)
c - Exhaust manifold outlet water port with pipe plug
NOTE: Closed cooled models: Ensure that the hose fitting, located in the riser outlet water
port, is positioned to accept the engine coolant hose.
9. On 152 mm (6 inch) riser: Install and hand-tighten screws to temporarily secure the
riser and gasket to the exhaust manifold.
10. On seawater cooled models only: Place the restrictor gasket on the riser with the side
marked “UP” visible. Ensure that the restricted water port of the restrictor gasket is on
the same side as the hose fitting of the exhaust elbow.
d
a
78911
a
d
78912
11. On closed cooled models: Place the block-off gasket on the riser with the side marked
“UP” visible.
a
c
d
e
78882
12. Apply sealant to the edge of each of the 2 water ports located on the exhaust elbow.
A
78807
78913 78807
788911 78882
78912
78913
IMPORTANT: The 7-1/2 in. (190.5 mm), 9 in. (228.6 mm) long and 10-1/2 in. (266.7mm)
exhaust elbow screws require that a specific flat washer be used in conjunction with
the screw. Refer to “Mercury Precision Parts/Quicksilver Accessories Guide.”
14. If applicable, assemble washers to the exhaust elbow screws.
15. Apply sealant to exhaust elbow screw threads and hand-start to temporarily secure the
assembly.
18. If applicable, ensure that washers are in place between bolt and exhaust elbow.
19. Torque the exhaust elbow fasteners.
20. On seawater cooled models: Connect the engine water hoses to the exhaust elbows
and tighten hose clamps securely.
CAUTION
Avoid severe engine damage due to improper hose connection, causing coolant to
discard out exhaust. DO NOT connect the engine coolant hose to the exhaust
elbow.
21. On closed cooling models: Connect the coolant hose from the thermostat housing to
the hose fitting of the riser. Tighten hose clamps securely.
b
78758
a - Riser fitting
b - Engine coolant hose
22. On closed cooled models: Connect the engine water hose from the heat exchanger
to the exhaust elbow and tighten hose clamps securely.
b
78759
c a
78788
c
a
d 78787
25. Port exhaust elbow with 152 mm (6 in.) riser: All models.
a. Install the ECM drop-down bracket.
b. Install the ECM bracket and the ECM to the exhaust elbow.
c. Tighten securely.
a d
f 78789
CAUTION
Overheating from insufficient cooling water will cause engine and drive system
damage. Ensure that there is sufficient water always available at water inlet holes
during operation.
30. Supply cooling water to the engine.
31. Start the engine and check for exhaust and water leaks.
NOTES:
COLOR DIAGRAMS
Section 10 - Color Diagrams
Table of Contents
Water Flow Diagrams . . . . . . . . . . . . . . . 10A-2 Seawater Cooled V-drive Models
Seawater Cooled Alpha Models With Cold Risers . . . . . . . . . . . . . . . . . 10A-12
Except MPD Models . . . . . . . . . . . . . . 10A-2 Closed Cooled Sterndrive And
Seawater Cooled Alpha Inline Inboard Models
MPD Models . . . . . . . . . . . . . . . . . . . . 10A-3 With Cold Risers . . . . . . . . . . . . . . . . . 10A-13
Seawater Cooled Bravo Models Closed Cooled V-drive Inboard
Except MPD Models . . . . . . . . . . . . . . 10A-4 Models With Cold Risers . . . . . . . . . . 10A-14
Seawater Cooled Bravo Seawater Cooled Bravo And
MPD Models . . . . . . . . . . . . . . . . . . . . 10A-5 Inline Inboard Models
Closed Cooled Sterndrive Models . . 10A-6 With Warm Risers . . . . . . . . . . . . . . . . 10A-15
Seawater Cooled Inline Seawater Cooled V-drive Inboard
Inboard Models . . . . . . . . . . . . . . . . . . 10A-7 Models With Warm Risers . . . . . . . . . 10A-16
Seawater Cooled V-drive Closed Cooled Bravo And
Inboard Models . . . . . . . . . . . . . . . . . . 10A-8 Inline Inboard Models
Closed Cooled Inline With Warm Risers . . . . . . . . . . . . . . . . 10A-17
Inboard Models . . . . . . . . . . . . . . . . . . 10A-9 Closed Cooled V-drive Inboard
Closed Cooled V-drive Models With Warm Risers . . . . . . . . . 10A-18
Inboard Models . . . . . . . . . . . . . . . . . . 10A-10
Seawater Cooled Bravo And
Inline Inboard Models
With Cold Risers . . . . . . . . . . . . . . . . . 10A-11
10
A
j a
c e
i
h
f
g 78689
i
e
c c
h g
f
78688
c e
i
k
d
h
f
g
78746
a - Seawater inlet
b - Power steering cooler
c - Check valve
d - Fuel cooler
e - Exhaust and seawater outlet
f - Exhaust manifold
g - Distribution housing
h - Water circulating pump
i - Thermostat housing (lifting eye bracket not shown)
j - Exhaust elbow
k - Seawater pump
b
a
i
e
c c
h g
f
78688
a - Seawater inlet
b - Power steering cooler
c - Drain plug
d - Fuel cooler
e - Exhaust and seawater outlet
f - Exhaust manifold
g - Check valve
h - Water circulating pump
i - Thermostat housing (lifting eye bracket not shown)
j - Exhaust elbow
k - Seawater pump
a n
j
i
b
m
k
l c e
1
g
2
78687
c j
a e
i
d
k
h
f
78933
b
e
c
a
i
d
k
h f
g
78932
b
i
a
k
j
c e
l
d
f
1
g
2
78927
i
e b
a
k
c
l
d
f
g 1
2
78928
Seawater Cooled Bravo And Inline Inboard Models With Cold Risers
c e
a
i j
k
h d
f
g
78925
e
b
c j
a
i
k d
h f
78923
g
Closed Cooled Sterndrive And Inline Inboard Models With Cold Risers
i
b
a
k
c j
e
d
f
h g
1
2
78924
e i
b
a
c
k
d
f
1
g 2
78926
Seawater Cooled Bravo And Inline Inboard Models With Warm Risers
c e
a
i
k
h
f
g 78934
e
b
a
i
d
k
h
f
78931
g
Closed Cooled Bravo And Inline Inboard Models With Warm Risers
i
b
a
k j
e
c
h 1
2
78929
g
e i
b
a
k
c
l
h
1
2
g
78930