Service Manual #37

SERVICE
MANUAL
Number 37
MARINE ENGINES
DRY JOINT
Printed in U.S.A. 2002, Mercury Marine 90-864260020 OCTOBER 2002

Notice
Throughout this publication, Dangers, Warnings and Cautions (accompanied by the
International HAZARD Symbol ) are used to alert the mechanic to special instructions
concerning a particular service or operation that may be hazardous if performed incorrectly
or carelessly. OBSERVE THEM CAREFULLY!
These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus common sense operation,
are major accident prevention measures.
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.
90-864260020 OCTOBER 2002 Page i

Notice to Users of This Manual
This service manual supplement has been written and published by the Service Department
of Mercury Marine to aid our dealers’ mechanics and company service personnel when
servicing the products described herein.
It is assumed that these personnel are familiar with marine product servicing procedures.
Furthermore, it is assumed that they have been trained in the recommended service
procedures of Mercury MerCruiser product, including the use of mechanics’ common hand
tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the marine trade of all conceivable procedures
and of the possible hazards and/or results of each method. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
Working On The Product

It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe electrical shocks. When
performing any work where electrical terminals could possibly be grounded or touched by
the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
Replacement fasteners must have the same measurements and strength as those
removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts
indicate their strength. American bolts use radial lines for this purpose, while most American
nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage
or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved
for reuse in the same locations whenever possible. Where the fasteners are not satisfactory
for re-use, care should be taken to select a replacement that matches the original.
Page ii 90-864260020 OCTOBER 2002

Engine Mechanical Components
Many of the engine mechanical components are designed for marine applications. Unlike
automotive engines, marine engines are subjected to extended periods of heavy load
and wide open throttle operation and, therefore, require heavy-duty components. Special
marine engine parts have design and manufacturing specifications that are required to
provide long life and dependable performance. Marine engine parts also must be able to
resist the corrosive action of salt or brackish water that will rust or corrode standard
automotive parts within a short period of time.
Failure to use recommended Mercury Marine service replacement parts can result in poor
engine performance and/or durability, rapid corrosion of parts subjected to salt water and
possibly complete failure of the engine.
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.
Cleanliness And Care Of The Product

A marine power product is a combination of many machined, honed, polished, and lapped
surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any
product component is serviced, care and cleanliness are important. Throughout this
manual, it should be understood that proper cleaning and protection of machined surfaces
and friction areas is a part of the repair procedure. This is considered standard shop practice
even if not specifically stated.
Personnel should not work on or under an engine that is suspended. Engines should be
attached to work stands or lowered to ground as soon as possible.
Whenever components are removed for service, they should be retained in order. At the
time of installation, they should be installed in the same locations and with the same mating
surfaces as when removed.
90-864260020 OCTOBER 2002 Page iii

NOTES:
Page iv 90-864260020 OCTOBER 2002

Models Covered in This Manual
Sterndrive (MCM) Model Serial Number

5.0L 0M600000 Through 0M614999
5.0L 0M615000 And Above
5.0 MPI 0M600000 Through 0M614999
5.0 MPI 0M615000 And Above
5.7L 0M600000 Through 0M614999
350 MAG MPI 0M600000 Through 0M614999
350 MAG MPI 0M615000 And Above
350 MAG MPI Horizon 0M600000 Through 0M614999
350 MAG MPI Horizon 0M615000 And Above
MX 6.2 MPI 0M600000 Through 0M614999
MX 6.2 MPI 0M615000 And Above
MX 6.2 MPI Horizon 0M600000 Through 0M614999
MX 6.2 MPI Horizon 0M615000 And Above
Inboard And Tow Sports (MIE) Model Serial Number

5.7L 0M317000 Through 0M389999
350 MAG MPI 0M317000 Through 0M389999
350 MAG MPI 0M390000 And Above
Black Scorpion 0M317000 Through 0M389999
Black Scorpion 0M390000 And Above
350 MAG MPI Horizon 0M317000 Through 0M389999
350 MAG MPI Horizon 0M390000 And Above
MX 6.2 MPI 0M317000 Through 0M389999
MX 6.2 MPI 0M390000 And Above
MX 6.2 Black Scorpion 0M317000 Through 0M389999
MX 6.2 Black Scorpion 0M390000 And Above
MX 6.2 MPI Horizon 0M317000 Through 0M389999
MX 6.2 MPI Horizon 0M390000 And Above
90-864260020 OCTOBER 2002 Page v

NOTES:
Page vi 90-864260020 OCTOBER 2002

Service Manual Outline
Section 1 - Important Information
A - General Information
Important Information
1
Section 6 -Cooling System
A - All Models
B - Seawater System
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
90-864260020 OCTOBER 2002 Page vii

Table of Contents
Section 1A - General Information
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
Section 6A - Cooling System All Models

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
Section 6B - Seawater Cooled Models

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
Page viii 90-864260020 OCTOBER 2002

Section 6C - Closed Cooled Models
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 . . . . . . . . . . . . . . . . 6C-10 Heat Exchanger Bracket Hardware . . . 6C-23
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 6C-12 Heat Exchanger Hose Connections . . . 6C-24
Exploded View . . . . . . . . . . . . . . . . . . . . . . 6C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6C-14
Section 7A - Dry Joint Identification

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
90-864260020 OCTOBER 2002 Page ix

Section 7B - Manifolds And Elbows
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 Flow Gasket . . . . . . . . . . . . . . . 7B-7
Warm Manifolds . . . . . . . . . . . . . . . . . . . . . 7B-3 Block Off Gasket . . . . . . . . . . . . . . . . . . . . . 7B-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-8
Section 7C - Cold Riser Models

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
Section 7D - Warm Riser Models

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

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
Page x 90-864260020 OCTOBER 2002

SERVICE MANUAL NUMBER 37 GENERAL INFORMATION
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
90-864260020 OCTOBER 2002 Page 1A-1

GENERAL INFORMATION SERVICE MANUAL NUMBER 37
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.
Page 1A-2 90-864260020 OCTOBER 2002

How to Use This Manual

This manual is divided into sections that represent major components and systems.
Some sections are further divided into parts that more fully describe the component.
Page Numbering
Two number groups appear at the bottom of each page. The following is an example and
description.
Page 1A-3 90-860074020 JULY 2002
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
Engine Serial Number Locations
78018
a - Serial number plate

b - Starter motor
90-864260020 OCTOBER 2002 Page 1A-3

Mercury/Quicksilver Lubricants, Sealants, and Adhesives
Tube Mercury Part Quicksilver Part

Description
Ref. No. Number Number
Needle Bearing
4 92-802868A1 N/A
Assembly Lubricant
6 Dielectric Grease 92-823506-1 92-823506-1
7 Loctite 271 92-809819 92-809819

Loctite 567 PST Pipe
9 92-809822 92-809822
Sealant
Loctite Master Gasket
12 92-12564-2 92-12564-2
Kit
2 Cycle Premium
14 92-802813A1 92-802813Q1
Outboard Oil
19 Perfect Seal 92-34227-1 92-34227-1
25 Liquid Neoprene 92-25711-3 92-25711-3
27 Bellows Adhesive N/A 92-86166Q1

Loctite 680 Retaining
33 92-809833 92-809833
Compound
34 Special Lubricant 101 92-802865A1 92-802865Q1
U-joint and Gimbal
42 92-802870A1 92-802870Q1
Bearing Grease
Loctite 222 Thread
51 92-809818 92-809818
Locker
Loctite 242 Thread
66 92-809821 92-809821
Locker
4 Cycle 25W40 Engine
79 92-802837A1 92-802837Q1
Oil
Premium Gear
82 92-802846A1 92-802846Q1
Lubricant
High Performance
87 92-802854A1 92-802854Q1
Gear Lube
Engine Coupler Spline
91 92-802869A1 92-802869Q1
Grease
94 Anti-Corrosion Grease 92-802867A1 92-802867Q1
Page 1A-4 90-864260020 OCTOBER 2002


Description
Ref. No. Number Number
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30
110 92-802833A1 92-802833Q1
Outboard Oil
Power Trim and
114 92-802880A1 92-802880Q1
Steering Fluid
Premium Plus 2 Cycle
115
TC-W3 Outboard Oil 92-802824A1 92-802824Q1
RTV 587 Silicone
116 92-809825 92-809825
Sealer
117 Loctite 7649 Primer N 92-809824 92-809824
Storage Seal Rust
119 92-802878-56 92-802878Q56
Inhibitor
120 Corrosion Guard 92-802878 55 92-802878Q55
15W40 4-cycle Diesel
121 92-877695K1 92-877695Q1
Engine Oil
Extended Life
122 92-877770K1 92-877770K1
Antifreeze/Coolant
123 Marine Engine Coolant NA 92-813054A2
Fuel System
124 Treatment and
92-802876A1 92-802876Q1
Stabilizer Concentrate
Heat Transfer
125 92-805701 1 NA
Compound
126 Liquid Gasket 92-808137 NA
127 T442 Sealant 92-862258 NA
Loctite 5900 Ultra
128 Black RTV Silicone 92-809826 NA
Sealant
Loctite Gasket
129 92-809828 1 NA
Remover
Sealer Kit, Two Part
130 NA 92-65150 1
Epoxy
90-864260020 OCTOBER 2002 Page 1A-5


Description
Ref. # Number Number
131 Anti-seize Compound 92-881091K1 NA
132 Torco MTF Gear Oil 92-849864-1 NA
Optimol Longtime PD
133 92-848767 NA
2
Dexron III Automatic
134 Obtain Locally Obtain locally
Transmission Fluid
135 Loctite 592 Obtain Locally Obtain locally
136 Loctite Quick Tite Obtain Locally Obtain locally
137 Isopropyl Alcohol Obtain Locally Obtain locally
138 Hot Glue Obtain Locally Obtain locally
1
Cyanacrylate
1
Adhesive
3M Permabond
3M08155
Page 1A-6 90-864260020 OCTOBER 2002

SERVICE MANUAL NUMBER 37 COOLING SYSTEM ALL MODELS
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
90-864260020 OCTOBER 2002 Page 6A-1

COOLING SYSTEM ALL MODELS SERVICE MANUAL NUMBER 37
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
Description Nm lb-in. lb-ft

Seawater pickup nut 48 35
Seawater pump cover to housing bolt 9.9 88
Seawater pump bracket-to-engine bolt 41 30
Water pump fastener 48 35
Water distribution housing bracket fasteners 38 28
Water distribution housing to bracket screws 13.5 120
Lubricants / Sealants / Adhesives

Description Where Used Part Number
Loctite 271 Seawater pickup fasteners 92-809819
Boat hull and seawater pickup
Marine caulk Obtain locally
joints
Transom mounted seawater
Loctite 567 PST Pipe Sealant 92-809822
pickup fitting and plastic plug
Transom mounted seawater
Silicone sealant or equivalent Obtain locally
pickup screws
Engine oil Seawater pump bearing shaft Obtain locally
Loctite 609 Seawater pump retainer/seal Obtain locally
Water circulating pump gaskets
Perfect Seal 92-34227-1
and fasteners
Seawater pump cover to
Loctite 242 Thread Locker 92-809821
housing bolt
Hose fitting threads, Plastic plug
Loctite 565 PST Obtain locally
threads
Page 6A-2 90-864260020 OCTOBER 2002

Seawater Inlet Recommendations

Specifications
Description Specification
114 liters per minute (30 gallons per
Minimum flow (closed cooled models)
minute) at 4000 rpm
Minimum pressure (closed cooled models) 20 psi (138 kPa) at 4000 rpm
Water pickup 32 mm (1-1/4 in.) ID wire reinforced
Water inlet hose
Seacock 32 mm (1-1/4 in.) connections
Sea strainer
Seacock (Seawater Inlet Valve)

The seacock used must have an internal cross-sectional area equal to or greater than
seawater inlet hose to prevent restricting water flow. Install valve in an area where it will be
easily accessible and supported adequately to prevent hose fatigue. A brass ball or gate
valve is required. Select a proper seacock based on the following chart:
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
90-864260020 OCTOBER 2002 Page 6A-3

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:
Seawater Strainer Minimum Flow Rate

Gasoline engines 114 liters per minute (30 gallons per
minute)
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
a - Engine seawater pump

b - Hose from seawater pump inlet port to y-fitting
c - Y- fitting port to Bravo drive
d - Y-fitting port to additional water inlet
4. Install the water inlet hoses to the water inlet and the sterndrive.
Page 6A-4 90-864260020 OCTOBER 2002

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.

Marine caulk Mounting surfaces Obtain locally
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

A Marine caulk Mounting surfaces Obtain locally
B Loctite 271 Seawater inlet nut 92-809820

Nut 48 35
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.
90-864260020 OCTOBER 2002 Page 6A-5

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)

Hose fitting threads
A Loctite 565 PST
Plastic plug threads Obtain locally
B Silicone sealant or equivalent Screw shaft
Page 6A-6 90-864260020 OCTOBER 2002

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
Water Pickup Installed on Transom

a - Diagonal mount - leading edge of pickup 3.2 mm (1/8 in.) from boat bottom.
b - Vertical mount - corner of leading edge of pickup 3.2 mm (1/8 in.) from boat
bottom
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.
Seawater Pressure Test

IMPORTANT: The boat should be in the water for this test.
1. Connect an appropriate scan tool to the ALDL connector.
2. Ensure the remote control is in the IDLE position.
3. Start the engine and advance the the throttle to 4,000 rpm.
4. Measure the seawater pressure. If seawater pressure does not meet specification,
plumbing changes will have to be made.
Description Specification
Minimum pressure (closed cooled models) 20 psi (138 kPa) at 4000 rpm
90-864260020 OCTOBER 2002 Page 6A-7

Quicksilver Sea Strainer

NOTICE
Refer to the manufacturer’s instructions for information on other than Quicksilver
Sea Strainer.
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 - Seawater inlet hose

b - Seawater strainer
c - Seawater strainer inlet
d - Plug
3. Remove the outlet hose. Drain into a suitable container.
a
b
72643

b - Seawater strainer
4. Remove the mounting bolts. Remove the strainer.
Page 6A-8 90-864260020 OCTOBER 2002

Cleaning and Inspection

1. Remove and clean the filter element.
2. Remove the drain plug.
b a
c
d
f
g
72673
Typical Quicksilver seawater strainer shown

a - Screws and washers
b - Cover
c - Glass
d - O-Ring
e - Strainer
f - Housing
g - Drain plug and sealing washer
h - Gasket
3. Flush the components with clean water.
90-864260020 OCTOBER 2002 Page 6A-9

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
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)
4. Open the seacock, if equipped.
Page 6A-10 90-864260020 OCTOBER 2002

Shaft Log Seal
b
78776
a
Water tap location

a - Port exhaust elbow
b - Shaft log seal fitting at 8 o’clock position
Auxiliary Hot Water Heater Installation

IMPORTANT: When connecting a cabin heater or a hot water heater, certain
requirements must be met:
• The supply hose (from the engine to the heater) and the return hose (from the
heater to the engine) MUST NOT EXCEED 16 mm (5/8 in.) I.D. (inside diameter).
• Make the heater connections ONLY at the locations described in the following
instructions.
• Check the complete system for leaks after the heater is connected into the
cooling system.
• Check for overheating condition (of the engine) after the heater is connected.
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.
90-864260020 OCTOBER 2002 Page 6A-11

Supply Hose Connection

NOTE: Some models may be equipped with additional fittings.
a 78692
Seawater cooled models with air or manual drain

a - Supply hose connection locations
a 78752
Seawater cooled models with multi-point drain

a
78691
Closed cooled models

Page 6A-12 90-864260020 OCTOBER 2002

Return Hose Connection

The hot water return is located on the water circulating pump housing.
78648
a - Return hose connection for hot water heater

b - Water circulating pump housing
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.
90-864260020 OCTOBER 2002 Page 6A-13

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

b - Seawater outlet hose to cooler
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
Page 6A-14 90-864260020 OCTOBER 2002

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.
Engine Mounted Seawater Pump Output For A 15 Second Period

Drive Unit Minimum Quantity
Liter (U.S. Qt.)
Bravo with seawater cooled engine 7.6 (8.0)
Bravo with closed cooled engine 9.5 (10)
All inboard and tow sport models 9.5 (10)
Alpha Sterndrive Seawater Pump Output For A 15 Second Period

Drive Unit Gear Ratio Minimum Quantity
Liter (U.S. Qt.)
2.40:1 1.3 (1.4)
2.00:1 1.6 (1.7)
1.81:1 1.4 (1.5)
1.62:1 1.6 (1.7)
1.47:1 1.8 (1.9)
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.
90-864260020 OCTOBER 2002 Page 6A-15

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
a - Seawater pump back plate (single point drain system)

b - O-ring
c - Impeller
d - Seawater pump bearing housing
e - Rear oil seal
f - Bearing shaft assembly
g - Tolerance ring
h - Retainer/Seal
i - Pulley
j - Seawater pump assembly with bracket (multi point drain systems)
Page 6A-16 90-864260020 OCTOBER 2002


1. Clean the metal parts in solvent and dry with compressed air.
IMPORTANT: Do not spin the bearings at high speed when drying with compressed
air, as the bearings may be scored.
2. After cleaning, lightly coat the shaft and the bearings with lubricant to prevent rust.

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.
90-864260020 OCTOBER 2002 Page 6A-17

4. Install the tolerance ring.
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

Loctite 609 Seawater pump retainer/seal Obtain locally
7. Wipe away excess adhesive.
Page 6A-18 90-864260020 OCTOBER 2002

8. Lubricate the impeller with soapy water.

9. Install the impeller into the pump body.
71118
71150
a - Impeller
10. Install the O-ring into the groove on the pump body.
78140
a - O-ring groove
11. Align pump body with the back plate.
90-864260020 OCTOBER 2002 Page 6A-19

12. Apply sealant to seawater pump bolt threads.

Seawater pump cover to
Loctite 242 Thread Locker 92-809821
housing bolt
13. Install bolts and torque.
78141
a - Seawater pump bolts

Seawater pump bolt 9.9 88
Installation
1. Fasten the seawater pump and bracket to the engine. Torque the bolts.

Seawater pump bracket to engine bolt 41 30
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.
Page 6A-20 90-864260020 OCTOBER 2002

Water Circulating Pump

Removal
NOTE: The water circulating pump pulley on the closed cooled models is a new design and
cannot be replaced with previous Mercury MerCruiser water circulating pump pulley.
1. Allow engine to cool.
2. Drain the seawater and closed cooling (if equipped) sections of the engine.
3. Remove the hoses attached to the water circulating pump.
4. While holding the water circulating pump pulley in place, loosen the pulley bolts.
5. Remove serpentine belt.
6. Remove water circulating pump bolts and pulley.
77954
a - Water circulating pump pulley
7. Remove the fasteners and the water circulating pump.
b
77954
a - Water circulating pump

b - Fasteners
8. Remove and discard the old gaskets.
90-864260020 OCTOBER 2002 Page 6A-21


1. Clean sealing surfaces and remove sealant residue.
2. Check bearing for excessive radial play.
3. Check bearing for abnormal noise when turning the shaft.
77294
4. Check pump body for cracks.

5. Check seal for signs of leaking.
6. Check pump impeller for cracks, corrosion, or damage.
Page 6A-22 90-864260020 OCTOBER 2002

Installation
1. Coat both sides of the new water circulating pump gaskets and the threads of the
attaching fasteners with sealant.

Perfect Seal Water pump fastener 92-34227-1
2. Install new water circulating pump gaskets to the cylinder block.

3. Install the water circulating pump. Torque the bolts.
b
a
c
77954

b - Gaskets
c - Fasteners

Water pump fasteners 48 35
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.
90-864260020 OCTOBER 2002 Page 6A-23

Water Distribution Housing

Removal
1. Drain the seawater section of the cooling system.
2. On air actuated single point drain only: Remove each air line from the water
distribution housing by pressing on the fitting release location and pulling the line out.
a
c
b 78920
a - Air line fitting

b - Release location
c - Air line
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 - Drain rod with blue handle

b - C-clip
c - Drain rod threads
d - Drain rod alignment bracket
e - Bracket for the water distribution housing
f - Water distribution housing assembly
Page 6A-24 90-864260020 OCTOBER 2002

4. Disconnect the hoses from the water distribution housing.

5. Remove the bolt and nut attaching the water distribution housing and bracket to the
engine.
6. Remove the bracket from the the water distribution housing.
Cleaning And Inspection
1. Clean the water distribution housing with water and dry with a clean cloth or compressed
air.
2. Inspect the housing for leaks, cracks, or corrosion damage. Replace, if necessary.
Installation
1. Align the water distribution housing with the bracket.
2. Install and tighten the screws in the order listed.
a. Top right hand side screw.
b. Top left hand side screw.
c. Bottom side screw.
3. Torque the screws in the same order.
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

Water distribution housing-to-bracket screws 13.5 120
4. Install the bracket and water distribution housing to the engine. Finger-tighten the bolt
and nut.
90-864260020 OCTOBER 2002 Page 6A-25

5. On Manual Single Point Drain only:

a. To obtain correct alignment, leave the hoses disconnected from the water
distribution housing during installation.
b. Position the water distribution housing assembly to align with drain rod.
c. Engage the drain rod into the water distribution housing to complete alignment.
d. Ensure the that the rod is correctly aligned. The rod must screw in and out of the
water distribution housing easily and with little pressure.
e. Install c-clip to drain rod.
b
77932
a
a - Water distribution housing

b - Drain rod
c - Drain rod handle
6. Torque the bolt and nut attaching the water distribution housing bracket to the engine.

Water distribution housing bracket fasteners 38 28
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.
Page 6A-26 90-864260020 OCTOBER 2002

SERVICE MANUAL NUMBER 37 SEAWATER COOLED MODELS
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
90-864260020 OCTOBER 2002 Page 6B-1

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 37
Models With Multi-Point Drain Systems
Thermostat housing to intake screws 41 30
Models With Single Point And Manual Three Point Drain Systems
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)
Page 6B-2 90-864260020 OCTOBER 2002

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
90-864260020 OCTOBER 2002 Page 6B-3

MULTI-POINT DRAIN SYSTEM
l
r
n
p
m o
e
q
d
c
a
f
g
b
h
j 78908
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
Page 6B-4 90-864260020 OCTOBER 2002

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
Typical thermostat housing assembly, all models similar

a - Thermostat assembly (lifting eye bracket not shown)
b - Engine water circulating pump
90-864260020 OCTOBER 2002 Page 6B-5

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
7. Replace if specifications are not met or damage is discovered during inspection.
Page 6B-6 90-864260020 OCTOBER 2002

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.

Thermostat housing screws 41 30
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.
9. Start the engine and inspect for leaks.
90-864260020 OCTOBER 2002 Page 6B-7

NOTES:
Page 6B-8 90-864260020 OCTOBER 2002

SERVICE MANUAL NUMBER 37 CLOSED COOLED MODELS
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
90-864260020 OCTOBER 2002 Page 6C-1

CLOSED COOLED MODELS SERVICE MANUAL NUMBER 37
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

Heat exchanger end cap
gaskets
Specifications
Closed Cooling System Capacity
NOTE: All capacities are approximate fluid measures.
Closed Cooled Models Liters (U.S. Qts)

Coolant volume in engine, heat exchanger, and exhaust 19.47 (20.5)
Seawater volume in conduits and tube side of heat
4.3 (4.5)
exchanger
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)
Pressure Cap Rating

Engine Specifications
All engines 110 kPa (16 psi)
Page 6C-2 90-864260020 OCTOBER 2002

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).
90-864260020 OCTOBER 2002 Page 6C-3

Maintaining Coolant Level
72520
Coolant Recovery Bottle

a - Fill cap
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.
Page 6C-4 90-864260020 OCTOBER 2002

Pressure Cap Maintenance

The pressure cap should maintain pressure the closed cooling system at normal engine
operating temperature. This raises the boiling point of the coolant, thereby increasing the
efficiency of the cooling system. To help ensure proper operation, the cap should be
cleaned, inspected and pressure tested periodically.
WARNING
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)
90-864260020 OCTOBER 2002 Page 6C-5

7. Test the pressure cap.

8. Clean the sealing surfaces on the heat exchanger filler neck with a cloth. Inspect the
surfaces for any damage or deposits that may prevent the cap from sealing properly.
9. Clean the coolant recovery passage in the heat exchanger filler neck with a wire and
blow out with compressed air.
72715
a - Sealing surfaces
b - Coolant recovery passages
10. Reinstall the pressure cap. Tighten the cap until it contacts the filler neck.
Testing Closed Cooling System

Testing Coolant for Alkalinity
WARNING
The coolant should be changed per the Maintenance Schedule recommendations and
should be checked for alkalinity at least once between change intervals. To check the
coolant for alkalinity, proceed as follows:
1. Obtain pink litmus paper from a local source.
2. Allow the engine to cool and remove the pressure cap from the heat exchanger and
insert one end of the litmus paper into the coolant.
3. If pink litmus paper turns blue, the coolant is alkaline and need not be replaced.
4. If pink litmus paper remains pink, the coolant is not alkaline and MUST BE
REPLACED, as explained under Changing Coolant.
Page 6C-6 90-864260020 OCTOBER 2002

Pressure Testing System

WARNING
If the coolant section of the closed cooling system is suspected of leaking or not holding
sufficient pressure, and no visible signs of leakage can be found, perform the following test:
1. Remove the pressure cap from the heat exchanger or the reservoir.
2. Clean, inspect and pressure test the pressure cap.
3. Clean the inside of the filler neck to remove any deposits or debris. Examine the lower
inside sealing surface for damage. The surface must be perfectly smooth to achieve a
good seal between it and the rubber seal on the cap. Ensure that the locking cams on
the sides of the filler neck are not bent or damaged.
4. Adjust the coolant level to 25 mm (1 in.) below the filler neck.
5. Attach an automotive-type cooling system pressure tester to the filler neck and
pressurize closed cooling section to amount specified in following chart.
Pressure Cap Rating Amount of Pressure Applied to Closed Cooling System

110 kPa (16 psi) 138 kPa (20 psi)
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.
90-864260020 OCTOBER 2002 Page 6C-7

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.
Page 6C-8 90-864260020 OCTOBER 2002

Testing for Cylinder Head Gasket Leak

A leaking head gasket will cause combustion gas to be forced into the cooling system. The
mixture of coolant and tiny air bubbles is a poor heat conductor and will overheat an engine
quickly. Compression tests or cooling system pressure check normally will not detect the
leak because the test pressure is far below the combustion pressures that cause the leak.
An effective test is as follows:
IMPORTANT: Operate the boat in the water for this test. It is best to operate the engine
at or above cruising speed during this test. Usually a failed head gasket will not cause
the engine to overheat below cruising speed.
1. Install a clear plastic hose between the reservoir and the coolant recovery bottle. Use
a 610-910 mm (2-3 ft) long hose for this test.
2. Route this hose so a U is formed.
3. Put enough coolant into the hose to fill the center 100-130 mm (4-5 in.) of the U-shape.
4. Observe the U-shape while the engine is operating.
a. During Idle and Warm-Up: Some coolant and/or air will leave the reservoir.
b. During Cruising Speed (2500-3500 rpm): Coolant and/or air leaving the reservoir
should stop after approximately five minutes operating at a given rpm. A leaking
head gasket will produce air bubbling through the U-shape, going to the coolant
recovery bottle. The frequency and size of the bubbles will depend on the size of the
leak.
c. At Higher Speeds (4000+ rpm): Normal operation is the same as described above.
A failed head gasket will cause the bubbles to come faster and may be accompanied
by violent, intermittent bursts of coolant.
Do not confuse normal warm-up expansion with a failed head gasket. Normal warm-up
produces an intermittent flow of coolant that will stop within approximately five minutes at
a given rpm. A head gasket leak will not stop because the one thing that marks a failed head
gasket is the continued passage of air. This may be accompanied by violent, intermittent
bursts of coolant leaving the reservoir. If coolant flows evenly from the reservoir at cruising
speed, something other than the head gasket is causing the engine to overheat.
90-864260020 OCTOBER 2002 Page 6C-9

Testing Pressure Cap

The pressure cap is designed to maintain a pressure of approximately its rated capacity
once the engine has attained operating temperature. The cap should be cleaned, inspected
and pressure-tested at regular intervals or whenever the cap is suspected of maintaining
improper pressure.
WARNING
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)
Page 6C-10 90-864260020 OCTOBER 2002

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
7. Reinstall the cap on the reservoir or the heat exchanger.
90-864260020 OCTOBER 2002 Page 6C-11

Thermostat
Exploded View
l m
k
j
i b
c
d
e
a
h g
78909
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.
Page 6C-12 90-864260020 OCTOBER 2002

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
6. Replace if specifications are not met or damage is discovered during inspection.
90-864260020 OCTOBER 2002 Page 6C-13

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.

Thermostat housing to intake screw 33 24
5. Install the rubber seal on the thermostat flange.

6. Install the thermostat into the thermostat housing.
7. Install the thermostat cover. Torque the screws.
a
b
c
d
f e
78909
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)

Thermostat cover screw 30 22
8. Connect the hoses. Tighten the hose clamps securely.

9. Supply cooling water, start the engine, and inspect for leaks.
Page 6C-14 90-864260020 OCTOBER 2002

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.
90-864260020 OCTOBER 2002 Page 6C-15

1. Remove pressure cap from coolant tank.

2. On port and starboard side of engine block, remove the block pipe plugs. Drain coolant
into proper container.
3. On port and starboard side of engine block, remove the coolant hose from the bottom
side of the exhaust manifold. Drain coolant into proper container.
d
a
e
c
b
78905
Port and starboard side similar

a - Engine block
b - Oil pan
c - Engine block drain plug
d - Exhaust manifold
e - Exhaust manifold coolant hose
4. Remove the heat exchanger to water circulating pump hose at the pump connection.
Drain coolant into proper container.
b a
78648

b - Hose from heat exchanger to water circulating pump
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.
Page 6C-16 90-864260020 OCTOBER 2002

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.
90-864260020 OCTOBER 2002 Page 6C-17

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
a - Air line fitting

b - Release location
c - Air line
Page 6C-18 90-864260020 OCTOBER 2002

5. Remove the hoses from the heat exchanger.
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.
90-864260020 OCTOBER 2002 Page 6C-19

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

1. Clean old gasket material and sealant from surfaces. Do not nick or gouge the surfaces.
2. Use a long rod and wire brush to clean out heat exchanger tubes.
3. Inspect each part for cracks or other damage. Replace as necessary.
4. Clean and paint exterior surfaces as required to prevent corrosion.
Repair
IMPORTANT: Braze with BCUP 2 rod or silver solder. Care must be taken not to melt
the other joints during repair.
1. Internal leaks can be repaired by brazing shut the ends of the leaking tube. This is only
a temporary fix because usually another tube will start leaking after a short period of time
and this also causes a reduction in the cooling capacity. Do not close more than three
tubes.
2. Fittings and drains that have been broken off the heat exchanger can be reattached by
brazing.
Page 6C-20 90-864260020 OCTOBER 2002

Assembly
1. Apply sealant to both sides of new end cap gaskets.

Heat exchanger 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

Heat exchanger end cap 6 54
3. If applicable, fasten the air manifold to the heat exchanger.

4. Torque screws.

Air manifold to heat exchanger screw 3 27
90-864260020 OCTOBER 2002 Page 6C-21

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
5. Torque hose clamps.

Hose clamps around heat exchanger and bracket 3 26
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
b. Pull lever on air pump up (vertical) to lock pump on the fitting.

c. Pump air into the system until both green indicators extend. If the green indicators
do not extend, the air lines are not attached properly.
8. Fill closed cooled system.
Page 6C-22 90-864260020 OCTOBER 2002

Heat Exchanger Bracket Hardware
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)
90-864260020 OCTOBER 2002 Page 6C-23

Heat Exchanger Hose Connections
g
a
b
d
f
e
c
77954
Typical Engine Shown

a - Heat exchanger
b - Starboard heat exchanger-to-exhaust manifold hose
c - Water circulating pump hose
d - Port heat exchanger-to-exhaust manifold hose (MCM)
e - Cool fuel system-to-heat exchanger hose
f - Heat exchanger bypass hose
g - Coolant identification decal
Page 6C-24 90-864260020 OCTOBER 2002

SERVICE MANUAL NUMBER 37 DRY JOINT IDENTIFICATION
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
90-864260020 OCTOBER 2002 Page 7A-1

DRY JOINT IDENTIFICATION SERVICE MANUAL NUMBER 37
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.
Serial Number Breaks
Warm Manifold and Cold Riser Models Serial Number

Sterndrive (MCM) Models 0M600000 through 0M614999
Inboard and Tow Sports (MIE) Models 0M317000 through 0M389999
Warm Manifold And Warm Riser Models Serial Number

Sterndrive (MCM) Models 0M615000 And Above
Inboard and Tow Sports (MIE) Models 0M390000 And Above
Page 7A-2 90-864260020 OCTOBER 2002

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
a - Full flow gasket

b - Block off gasket
c - Restrictor gasket
NOTE: Gasket is not reusable. Inspect for proper gasket replacement before disassembly
and assembly.
90-864260020 OCTOBER 2002 Page 7A-3

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
Exhaust manifold outlet water port with pipe plug
78900
Exhaust manifold outlet water port with hose fitting

NOTE: Using Perfect Seal on water ports is a preventive measure for corrosion
deterioration.
Manifold Leak Test
NOTE: One block-off plate must have an attachment for a compressed air hose.
1. Using suitable block-off plates, plugs and new gaskets, seal the manifold openings.
2. Attach an air hose to the block-off plate.
3. Apply 138 kPa (20 psi) of air pressure and submerge the manifold in water.
4. Air bubbles will indicate a leak. Repair or replace, if necessary.
Page 7A-4 90-864260020 OCTOBER 2002

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
76 mm (3 in.) riser 152 mm (6 in.) riser

a - Cold riser water port is positioned to the bottom side of casting, closest to
exhaust manifold
b - Drain holes on bottom of 76 mm (3 in.) casting
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.
deterioration.
90-864260020 OCTOBER 2002 Page 7A-5

Warm Riser Casting

NOTE: The position of the threaded water port is different between the cold riser model and
the warm riser model.
The 76 mm (3 in.) and 152 mm (6 in.) warm riser identified in this service manual supplement
is a new casting design and cannot be replaced with the previous Mercury MerCruiser riser
castings. Riser castings used for the cold riser model cannot be used for warm riser models.
Warm riser castings can be used on cold riser models, but require the use of additional hose
kits. The engine will have to be changed to warm risers.
b
78893
76 mm (3 in.) riser 152 mm (6 in.) riser

a - Warm riser water port is positioned to the top side of casting, closest to exhaust
elbow
b - Drain holes on top and bottom of 76 mm (3 in.) casting
deterioration.
Page 7A-6 90-864260020 OCTOBER 2002

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
a - 169 mm (6.65 in.)

b - 7 degree
c - 120 mm (4.74 in.)
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
a - 207 mm (8.15 in.)

b - 14 degree
c - 120 mm (4.74 in.)
90-864260020 OCTOBER 2002 Page 7A-7

Exhaust Elbow Fasteners
Assembly scenario Engine Model Fastener Description

Elbow to manifold or elbow to All MCM Models, 3/8-16 X 5-3/4 in. (146.05 mm)
152 mm (6 in.) riser and Ski V-drive (7 long hex flange head with pre-
degree elbow) applied locking compound
Elbow and 76 mm (3 in.) riser MCM models with 3/8-16 X 9 in. (228.6 mm) long
to manifold 76 mm (3 in.) riser hex head with pre-applied lock-
ing compound and flat washer
152 mm (6 in.) riser to manifold Any model with 152 3/8-16 X 1 in. (25.4 mm) long
mm (6 in.) riser hex flange head with pre-ap-
plied locking compound
Elbow to manifold or elbow to All inboards with 14 3/8-16 X 7-1/2 in. (190.5 mm)
152 mm (6 in.) riser degree elbow (taller long hex head with pre-applied
elbow) locking compound and flat
washer
Elbow and 76 mm (3 in.) riser All inboards with 14 3/8-16 X 10-1/2 in. (266.7 mm)
to manifold degree elbow (taller long hex head with pre-applied
elbow) and 76 mm locking compound and flat
(3 in.) riser washer
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.
Page 7A-8 90-864260020 OCTOBER 2002

SERVICE MANUAL NUMBER 37 MANIFOLDS AND ELBOWS
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
90-864260020 OCTOBER 2002 Page 7B-1

MANIFOLDS AND ELBOWS SERVICE MANUAL NUMBER 37
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.

Exhaust elbow to exhaust manifold screw
Tighten screws evenly First pass 9 84
using X pattern from
corner to corner Final pass 61 45
Exhaust manifold to cylinder head bolt 34 25
Exhaust manifold and exhaust elbow pipe plug 50 37
Exhaust manifold and exhaust elbow hose fitting 50 37

Water ports on the exhaust
Quicksilver Perfect Seal manifold and exhaust elbow 92-34227-1
92 34227 1
Screw threads
Loctite 567 Pipe Sealant Hose fitting and pipe plug 92-804874
Page 7B-2 90-864260020 OCTOBER 2002

Exploded View
Warm Manifolds
78887
d e
f
g
c
Seawater cooled assembly Closed cooled assembly
NOTE: 7 degree elbows shown, 14 degree similar

a - Exhaust manifold
b - Manifold to cylinder head bolt
c - Restrictor gasket with turbulator (seawater cooled models)
d - Exhaust elbow
e - Pipe plug
f - Hose fitting
g - Block off gasket with turbulator (closed cooled models)
h - Exhaust elbow to exhaust manifold screw
i - Flat washer used with 14 degree elbow (Refer to Section 7A - Dry Joint
Identification)
90-864260020 OCTOBER 2002 Page 7B-3

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.

1. Clean the gasket material from all surfaces and wash the parts in solvent.
2. Inspect the water passages for foreign material. The passages must be clean for
efficient cooling.
NOTE: If more thorough inspection is desired, the pipe plugs may be removed from the
exhaust manifold and the exhaust elbow.
IMPORTANT: If the pipe plugs are removed, coat the threads with sealant before
reinstalling.

Loctite 567 Pipe Sealant Pipe plug 92-804874
Page 7B-4 90-864260020 OCTOBER 2002

3. Inspect the manifold, elbow, and riser for cracks.

4. Inspect all parts carefully. Machined surfaces must be clean and free of all marks and
deep scratches or water and exhaust leaks may result.
5. Inspect for damaged metal caused by saltwater or exhaust gas corrosion in the
manifold, elbow, and riser.
IMPORTANT: If bare metal is present on the gasket sealing surface, Perfect Seal
should be applied to that area before assembly.
6. Measure the surface flatness of all gasket surfaces on the manifold, elbow, and riser.
78748
a - Gasket sealing surface
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.
and assembly.
7. Replace all damaged components.
90-864260020 OCTOBER 2002 Page 7B-5

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
a - Exhaust manifold (cross section)

b - Exhaust manifold water port
c - Edge of water port (area to apply sealant)

A Perfect Seal Edge of water ports 92-34227-1
Page 7B-6 90-864260020 OCTOBER 2002

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 - Full flow passage

b - Restricted flow passage
c - Turbulator oriented up
Block Off Gasket

IMPORTANT: Block off gasket must be used on all CLOSED COOLED engines.
IMPORTANT: On engines without risers, the block off gasket must be placed between
the exhaust manifold and the exhaust elbow.
a
b
78806
a - No opening for coolant flow

b - Turbulator oriented up
90-864260020 OCTOBER 2002 Page 7B-7

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
b - Pipe plug
c - Sealant applied to threads

A Loctite 567 Pipe Sealant Pipe plug 92-804874
2. Torque pipe plug.

Page 7B-8 90-864260020 OCTOBER 2002

3. Closed cooled models: Apply sealant to threads of hose fitting and install to exhaust
manifold.
a
c A
78887
b - Hose fitting

A Loctite 567 Pipe Sealant Hose fitting 92-804874
4. Torque hose fitting.

5. Using new exhaust manifold gasket, install exhaust manifold to cylinder head. Torque
fasteners.

Exhaust manifold to cylinder head bolt 43 32
90-864260020 OCTOBER 2002 Page 7B-9

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

A Loctite 567 Pipe Sealant Hose fitting and pipe plug 92-804874
7. Torque hose fitting and pipe plug.

8. Apply sealant to the edge of each of the 2 water ports located on the exhaust manifold.
78807

A Quicksilver Perfect Seal Edge of water ports 92-34227-1
Page 7B-10 90-864260020 OCTOBER 2002

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
MCM and MIE Inline exhaust seawater cooled model

a - Restrictor gasket positioned between exhaust manifold and exhaust elbow
b - Restricted water port of gasket is in line with hose fitting of exhaust elbow
c - Exhaust elbow inlet water port with hose fitting
d - Exhaust manifold outlet water port with pipe plug
90-864260020 OCTOBER 2002 Page 7B-11

78889
MIE V-drive seawater cooled model

a - Restrictor gasket positioned between exhaust manifold and exhaust elbow
b - Restricted water port of gasket is in line with hose fitting of exhaust elbow
d - Exhaust manifold outlet water port with pipe plug
Page 7B-12 90-864260020 OCTOBER 2002

10. Closed cooled models: Place the block-off gasket on the exhaust manifold with the
side marked “UP” visible.
c
78890
MCM and MIE Inline exhaust closed cooled model

a - Block-off gasket positioned between exhaust manifold and exhaust elbow
b - Exhaust elbow inlet water port with hose fitting
c - Exhaust manifold outlet coolant port with hose fitting
90-864260020 OCTOBER 2002 Page 7B-13

11. Apply sealant to the edge of each of the 2 water ports located on the exhaust elbow.
78807

12. Place the exhaust elbow on the exhaust manifold as shown.
78910 78890
Seawater cooled inline exhaust Closed cooled inline exhaust model

model
Page 7B-14 90-864260020 OCTOBER 2002

78889 78888
Seawater cooled V-drive model Closed cooled V-drive model
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.

Quicksilver Perfect Seal Edge of water ports 92-34227-1
15. Align the exhaust elbow to the engine exhaust system.

NOTE: Gasket is not reusable. Inspect for proper gasket and component position before
torquing.
16. Torque the exhaust elbow fasteners.

Exhaust elbow to exhaust manifold screws
90-864260020 OCTOBER 2002 Page 7B-15

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
a - Engine coolant hose

c - Hose fitting of the exhaust manifold
19. Closed cooling models: Connect the engine water hose from the heat exchanger to
the exhaust elbow and tighten hose clamps securely.
a
78759
a - Engine water hose

b - Exhaust elbow
c - Hose fitting of the exhaust elbow
Page 7B-16 90-864260020 OCTOBER 2002

20. MCM models:Install shift plate assembly on exhaust elbow.
78788
a - Exhaust elbow
b - Shift bracket
c - Shift bracket to exhaust elbow screw
21. MCM models: Connect both shift cables.

22. Install ECM and ECM bracket on exhaust elbow.
a c
d 78685
a - Exhaust elbow
b - ECM bracket
c - Screw, short
d - ECM
90-864260020 OCTOBER 2002 Page 7B-17

23. Secure the engine exhaust system.

24. Install any additional components removed during disassembly.
25. Closed cooled models: Fill closed cooling system to operating level. Refer to Section
6C - Closed Cooled Models.
26. Reconnect the battery cables to the battery. Tighten securely.
CAUTION
during operation.
28. Start the engine and check for exhaust and water leaks.
Page 7B-18 90-864260020 OCTOBER 2002

SERVICE MANUAL NUMBER 37 COLD RISER MODELS
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
90-864260020 OCTOBER 2002 Page 7C-1

COLD RISER MODELS SERVICE MANUAL NUMBER 37
General Information

Exhaust elbow to riser and riser to exhaust manifold screw

Quicksilver Perfect Seal manifold, riser, and exhaust
elbow 92-34227-1
Screw threads
Loctite 567 Pipe Sealant Hose fitting and pipe plug 92-804874
V-8 Models With Cold Risers Serial Number

Sterndrive (MCM) Models 0M600000 through 0M614999
Inboard and Tow Sports (MIE) Models 0M317000 through 0M389999
Page 7C-2 90-864260020 OCTOBER 2002

Exploded View
h
k
k
d g
j
f e
c
j
k
b a
78792
a - Exhaust manifold g - Full flow gasket, with turbulator

b - Manifold-to-cylinder head bolt (4) h - Exhaust elbow
c - Restrictor gasket, with turbulator i - Exhaust elbow to riser or exhaust
(seawater cooled models) manifold screw and washer (4
d - 76 mm (3 in.) cold riser each)
e - 152 mm (6 in.) cold riser j - Hose fitting
f - Riser to exhaust manifold screw (4) k - Pipe plug
90-864260020 OCTOBER 2002 Page 7C-3

d k
g
j
e
f
c
j
j
b a
78903
a - Exhaust manifold g - Full flow gasket, with turbulator

b - Manifold-to-cylinder head bolt 4) h - Exhaust elbow
c - Block off gasket, with turbulator i - Exhaust elbow to riser or exhaust
(closed cooled models) manifold screw and washer (4
d - 76 mm (3 in.) cold riser each)
e - 152 mm (6 in.) cold riser j - Hose fitting
f - Riser to exhaust manifold screw (4) k - Pipe plug
Page 7C-4 90-864260020 OCTOBER 2002

Removal
WARNING
the power package.
CAUTION
are removed.
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.

efficient cooling.
reinstalling.

90-864260020 OCTOBER 2002 Page 7C-5


6. Measure the surface flatness of all gasket surfaces on the manifold, elbow, and riser.
a
d
c
78748
a - Exhaust manifold gasket sealing surface

b - Riser gasket sealing surface on top side
c - Riser gasket sealing surface on bottom side
d - Exhaust elbow gasket sealing surface
Maximum overall
Surface Flatness 0.07 (0.003)
difference
the manifold.
and assembly.
7. Replace all damaged components.
Page 7C-6 90-864260020 OCTOBER 2002

Reassembly
A
c
A
a
A
b
78748
a - Exhaust manifold water port sealing surface

b - Exhaust elbow water port sealing surface
c - Riser water port sealing surface on top side
d - Riser water port sealing surface on bottom side
A
c
b
a
78807


90-864260020 OCTOBER 2002 Page 7C-7

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
a - Passages fully open

Restrictor Gasket
IMPORTANT: On cold riser models, the restrictor gasket must be placed between the
exhaust manifold and the riser.
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
a - No opening for water flow

Page 7C-8 90-864260020 OCTOBER 2002

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

A Loctite 567 Pipe Sealant Hose Fitting 92-804874

90-864260020 OCTOBER 2002 Page 7C-9

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


Page 7C-10 90-864260020 OCTOBER 2002

5. Seawater cooled models: Apply sealant to the threads of the pipe plug and install into
the exhaust manifold.
c A
b
78893
b - Pipe plug


90-864260020 OCTOBER 2002 Page 7C-11

7. Closed cooled models: Apply sealant to the threads of the hose fitting and install into
the exhaust manifold.
c A
b
78893
b - Hose fitting

A Loctite 567 Pipe Sealant hose fitting 92-804874

78807

Page 7C-12 90-864260020 OCTOBER 2002

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
MCM and MIE inline exhaust seawater cooled model

a - Restrictor gasket positioned between exhaust manifold and riser
b - Full flow gasket positioned between riser and exhaust elbow
c - Restricted water port of gasket is in line with hose fitting of riser
d - Exhaust elbow inlet water port with pipe plug
e - Riser inlet water port with hose fitting
f - Exhaust manifold outlet water port with pipe plug
90-864260020 OCTOBER 2002 Page 7C-13

d
b
f
c
SCALE 0.250
78886
MIE V-drive seawater cooled model

a - Restrictor gasket positioned between exhaust manifold and riser
c - Restricted water port of gasket is in line with hose fitting of riser
d - Exhaust elbow inlet water port with pipe plug
e - Riser inlet water port with hose fitting
Page 7C-14 90-864260020 OCTOBER 2002

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
MCM and MIE inline exhaust closed cooled model

a - Block off gasket positioned between exhaust manifold and riser
c - Exhaust elbow inlet water port with pipe plug
d - Riser inlet water port with hose fitting
e - Exhaust manifold outlet water port with hose fitting
90-864260020 OCTOBER 2002 Page 7C-15

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
b - Full flow gasket
d - Passages fully open
Page 7C-16 90-864260020 OCTOBER 2002

A
78807

17. Place the exhaust elbow on the riser as shown.
78891
78892
Seawater cooled 152 mm (6 in.) Closed cooled 152 mm (6 in.) riser

riser
SCALE 0.250
78886 78885
Seawater cooled V-drive 152 mm (6 Closed cooled V-drive 152 mm (6

in.) riser in.) riser
90-864260020 OCTOBER 2002 Page 7C-17

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”.
assembly.

Quicksilver Perfect Seal Screw threads 92-34227-1
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.
torquing.

Exhaust elbow and riser to exhaust manifold screws
22. If applicable, ensure that washers are in place between bolt and exhaust elbow.

Exhaust elbow and riser to exhaust manifold screw
Page 7C-18 90-864260020 OCTOBER 2002

24. Seawater cooled models: Connect the engine water hoses to the hose fitting of riser
and tighten hose clamps securely.
CAUTION
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
a - Engine coolant hose

c - Hose fitting of the exhaust manifold
26. Closed cooling models: Connect the engine water hose from the heat exchanger to
the exhaust riser and tighten hose clamps securely.
a
78759
a - Engine water hose

b - Exhaust elbow
c - Hose fitting of the riser
90-864260020 OCTOBER 2002 Page 7C-19

27. Starboard exhaust elbow: MCM only.

a. For 152mm (6 in.) riser, install the drop down shift plate bracket.
b. Install the shift plate assembly to the elbow.
c. Tighten securely.
c
a
78788
Drop down bracket for the 152 mm (6 in.) riser assembly

a - Exhaust manifold, riser, elbow and assembly
b - Bracket mounting holes
c - Drop down bracket
d - Shift bracket
Page 7C-20 90-864260020 OCTOBER 2002

28. Port exhaust elbow with 76 mm (3 in.) riser: All models.

a. Install the ECM drop-down bracket.
b. Install the ECM bracket and the ECM to the exhaust elbow.
a d
78787
f
a - Exhaust manifold, riser, and elbow assembly
d - ECM Bracket
e - Short screw
f - ECM
90-864260020 OCTOBER 2002 Page 7C-21

a
d
f 78789

d - ECM bracket
e - Short screw
f - ECM
30. Secure the engine exhaust system.

32. Closed cooled models: Refill closed cooling system to operating level.
CAUTION
during operation.
Page 7C-22 90-864260020 OCTOBER 2002

SERVICE MANUAL NUMBER 37 WARM RISER MODELS
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
90-864260020 OCTOBER 2002 Page 7D-1

WARM RISER MODELS SERVICE MANUAL NUMBER 37
General Information

Screws, exhaust elbow to riser and riser to exhaust manifold

Quicksilver Perfect Seal manifold, riser, and exhaust
elbow 92-34227-1
Screw threads
Loctite 567 Pipe Sealant Hose fitting 92-804874
Models With Warm Risers Serial Number

Sterndrive (MCM) Models 0M615000 And Above
Inboard and Tow Sports (MIE) Models 0M390000 And Above
Page 7D-2 90-864260020 OCTOBER 2002

Exploded View
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
a - Exhaust manifold g - Restrictor gasket, with turbulator

b - Manifold-to-cylinder head bolt (4) (seawater cooled models)
c - Full flow gasket, with turbulator h - Exhaust elbow
d - 76 mm (3 in.) warm riser i - Exhaust elbow to riser or exhaust
e - 152 mm (6 in.) warm riser manifold bolt and washer (4 each)
f - Riser to exhaust manifold bolt (4) j - Hose fitting
k - Pipe plug
90-864260020 OCTOBER 2002 Page 7D-3

h
k
j
g
d e
j f j
a
b
78803
a - Exhaust manifold g - Block off gasket, with turbulator

b - Manifold-to-cylinder head bolt(4) (closed cooled models)
c - Full flow gasket, with turbulator h - Exhaust elbow
d - 76 mm (3 in.) warm riser i - Exhaust elbow to riser or exhaust
e - 152 mm (6 in.) warm riser manifold bolt and washer (4 each)
f - Riser to exhaust manifold bolt (4) j - Hose fitting
k - Pipe plug
Page 7D-4 90-864260020 OCTOBER 2002

Removal
WARNING
the power package.
CAUTION
are removed.
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.

efficient cooling.
reinstalling.

90-864260020 OCTOBER 2002 Page 7D-5


6. Use a straightedge and feeler gauge to measure the profile flatness of all gasket
surfaces on the manifold, elbow, and riser.
7. Ensure that the straightedge is contacting all 3 surfaces simultaneously.
a
d
c 78748
78807
a - Exhaust manifold gasket sealing surface

b - Riser gasket sealing surface on top side
c - Riser gasket sealing surface on bottom side
d - Exhaust elbow gasket sealing surface
e - Tolerance zone
Surface profile Tolerance zone 0.07 (0.003)
the manifold.
8. If any components do not meet specifications replace the damaged components.
Page 7D-6 90-864260020 OCTOBER 2002

Reassembly
A
c
A
a
A
b
78748
a - Exhaust manifold water port sealing surface

b - Exhaust elbow water port sealing surface
c - Riser water port sealing surface on top side
d - Riser water port sealing surface on bottom side
A c
b
a
78807


90-864260020 OCTOBER 2002 Page 7D-7

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
a - Passages fully open

Restrictor Flow Gasket

IMPORTANT: On warm riser models, the restrictor gasket must be placed between the
riser and the exhaust elbow.
a
c
b
78805

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
a - No opening for water flow

Page 7D-8 90-864260020 OCTOBER 2002

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
c - Pipe plug

A Loctite 567 Pipe Sealant Pipe plug 92-804874

Pipe plug to riser 50 37
90-864260020 OCTOBER 2002 Page 7D-9

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
c - Hose fitting


Hose fitting to riser 50 37
78807

Page 7D-10 90-864260020 OCTOBER 2002

6. Place the full flow gasket on the exhaust manifold with the side marked “UP” visible.
c
b
78485
d
b - Full flow gasket
d - Passages fully open
7. Apply sealant to the edge of each of the 4 water ports located on the riser.
A
78807

90-864260020 OCTOBER 2002 Page 7D-11

8. Place the riser on the exhaust manifold as shown.

NOTE: Position of the riser outlet water port is closest to exhaust elbow.
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.
Page 7D-12 90-864260020 OCTOBER 2002

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
MCM and MIE inline exhaust seawater cooled models

a - Full flow gasket positioned between exhaust manifold and riser
b - Restrictor gasket positioned between riser and exhaust elbow
c - Restricted water port of gasket is in line with hose fitting of exhaust elbow
d - Exhaust elbow inlet water port with hose fitting
e - Riser outlet water port with pipe plug
90-864260020 OCTOBER 2002 Page 7D-13

a
d
78912
MIE V-drive seawater cooled models

b - Restrictor gasket positioned between riser and exhaust elbow
c - Restricted water port of gasket is in line with hose fitting of exhaust elbow
d - Exhaust elbow inlet water port with hose fitting
e - Riser outlet water port with pipe plug
Page 7D-14 90-864260020 OCTOBER 2002

11. On closed cooled models: Place the block-off gasket on the riser with the side marked
“UP” visible.
a
c
d
e
78882
MCM and MIE inline exhaust closed cooled models

b - Block off gasket positioned between riser and exhaust elbow
d - Riser outlet water port with hose fitting
e - Exhaust manifold outlet water port with pipe plug
90-864260020 OCTOBER 2002 Page 7D-15

A
78807

13. Place the exhaust elbow on the riser as shown.
78913 78807
Seawater cooled 76 mm (3in.) riser Closed cooled 76 mm (3 in.) riser
788911 78882
Seawater cooled 152 mm (6 in.) Closed cooled 152 mm (6 in.) riser

riser
Page 7D-16 90-864260020 OCTOBER 2002

78912
78913
Seawater cooled V-drive 152 mm (6 Closed cooled V-drive 152 mm (6

in.) riser in.) riser
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.”
assembly.

Perfect Seal Edge of water ports 92-34227-1
16. Align the exhaust elbow to the engine exhaust system.

17. On 152 mm (6 in.) riser model: Tighten and torque the screws holding the riser to the
exhaust manifold.
torquing.

18. If applicable, ensure that washers are in place between bolt and exhaust elbow.

90-864260020 OCTOBER 2002 Page 7D-17

20. On seawater cooled models: Connect the engine water hoses to the exhaust elbows
and tighten hose clamps securely.
CAUTION
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
a - Exhaust elbow fitting

b - Engine water hose
Page 7D-18 90-864260020 OCTOBER 2002

23. Starboard exhaust elbow: MCM only.

a. On 152 mm (6 in.) riser, install the drop-down shift plate bracket.
b. Install the shift plate assembly to the elbow.
c a
78788
Drop-down bracket for the 152 mm (6 in.) riser assembly

a - Exhaust manifold, riser, elbow and assembly
c - Drop-down bracket
d - Shift bracket
90-864260020 OCTOBER 2002 Page 7D-19


c
a
d 78787

d - ECM bracket
e - Short screw
f - ECM
Page 7D-20 90-864260020 OCTOBER 2002

a d
f 78789

d - ECM bracket
e - Short screw
f - ECM
26. Install the exhaust hoses and the cooling hoses.

27. Tighten hose clamps securely.
CAUTION
during operation.
90-864260020 OCTOBER 2002 Page 7D-21

NOTES:
Page 7D-22 90-864260020 OCTOBER 2002

SERVICE MANUAL NUMBER 37 COLOR DIAGRAMS
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
90-864260020 OCTOBER 2002 Page 10A-1

COLOR DIAGRAMS SERVICE MANUAL NUMBER 37
Water Flow Diagrams

Seawater Cooled Alpha Models Except MPD Models
j a
c e
i
h
f
g 78689
a - Seawater inlet (From transom)

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
Page 10A-2 90-864260020 OCTOBER 2002

Seawater Cooled Alpha MPD Models

j
a
i
e
c c
h g
f
78688
a - Seawater inlet (From transom)

c - Drain plug
d - Fuel cooler
g - Check valve (MPI models only)
j - Exhaust elbow
90-864260020 OCTOBER 2002 Page 10A-3

Seawater Cooled Bravo Models Except MPD Models
c e
i
k
d
h
f
g
78746
a - Seawater inlet
c - Check valve
d - Fuel cooler
j - Exhaust elbow
k - Seawater pump
Page 10A-4 90-864260020 OCTOBER 2002

Seawater Cooled Bravo MPD Models

j
b
a
i
e
c c
h g
f
78688
a - Seawater inlet
c - Drain plug
d - Fuel cooler
g - Check valve
j - Exhaust elbow
k - Seawater pump
90-864260020 OCTOBER 2002 Page 10A-5

Closed Cooled Sterndrive Models
a n
j
i
b
m
k
l c e
1
g
2
78687
a - Y-fitting (Bravo models only) h - Water circulating pump

b - Power steering cooler i - Thermostat housing
c - Check valve j - Exhaust elbow
d - Fuel cooler k - Seawater pump
e - Exhaust and seawater outlet l - Heat exchanger
f - Exhaust manifold m - Warm riser (6 in.)
g - Distribution housing n - Hose fitting port
1 - Seawater
2 - Ethylene glycol mix
Page 10A-6 90-864260020 OCTOBER 2002

Seawater Cooled Inline Inboard Models
c j
a e
i
d
k
h
f
78933
a - Seawater inlet g - Distribution housing

b - Transmission cooler h - Water circulating pump
c - Check valve i - Thermostat housing
d - Fuel cooler j - Exhaust elbow
e - Exhaust and seawater outlet k - Seawater pump
90-864260020 OCTOBER 2002 Page 10A-7

Seawater Cooled V-drive Inboard Models
b
e
c
a
i
d
k
h f
g
78932

Page 10A-8 90-864260020 OCTOBER 2002

Closed Cooled Inline Inboard Models
b
i
a
k
j
c e
l
d
f
1
g
2
78927

f - Exhaust manifold l - Heat exchanger
1 - Seawater
90-864260020 OCTOBER 2002 Page 10A-9

Closed Cooled V-drive Inboard Models
i
e b
a
k
c
l
d
f
g 1
2
78928

1 - Seawater
Page 10A-10 90-864260020 OCTOBER 2002

Seawater Cooled Bravo And Inline Inboard Models With Cold Risers
c e
a
i j
k
h d
f
g
78925

d - Fuel cooler j - 14 degree exhaust elbow shown (7
e - Exhaust and seawater outlet degree exhaust elbow similar)
f - Exhaust manifold k - Seawater pump
90-864260020 OCTOBER 2002 Page 10A-11

Seawater Cooled V-drive Models With Cold Risers
e
b
c j
a
i
k d
h f
78923
g

Page 10A-12 90-864260020 OCTOBER 2002

Closed Cooled Sterndrive And Inline Inboard Models With Cold Risers
i
b
a
k
c j
e
d
f
h g
1
2
78924
a - Seawater inlet h - Water circulating pump

b - Transmission cooler i - Thermostat housing
c - Check valve j - 14 degree exhaust elbow shown (7
d - Fuel cooler degree exhaust elbow similar)
1 - Seawater
90-864260020 OCTOBER 2002 Page 10A-13

Closed Cooled V-drive Inboard Models With Cold Risers
e i
b
a
c
k
d
f
1
g 2
78926

1 - Seawater
Page 10A-14 90-864260020 OCTOBER 2002

Seawater Cooled Bravo And Inline Inboard Models With Warm Risers
c e
a
i
k
h
f
g 78934

d - Fuel cooler j - 14 degree exhaust elbow shown (7
e - Exhaust and seawater outlet degree exhaust elbow similar)
f - Exhaust manifold k - Seawater pump
90-864260020 OCTOBER 2002 Page 10A-15

Seawater Cooled V-drive Inboard Models With Warm Risers
e
b
a
i
d
k
h
f
78931
g

Page 10A-16 90-864260020 OCTOBER 2002

Closed Cooled Bravo And Inline Inboard Models With Warm Risers
i
b
a
k j
e
c
h 1
2
78929
g
a - Seawater inlet h - Water circulating pump

b - Transmission cooler i - Thermostat housing
c - Check valve j - 14 degree exhaust elbow shown (7
d - Fuel cooler degree exhaust elbow similar)
1 - Seawater
90-864260020 OCTOBER 2002 Page 10A-17

Closed Cooled V-drive Inboard Models With Warm Risers
e i
b
a
k
c
l
h
1
2
g
78930

1 - Seawater
Page 10A-18 90-864260020 OCTOBER 2002

Service Manual #37

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SERVICE

Printed in U.S.A. 2002, Mercury Marine 90-864260020 OCTOBER 2002

90-864260020 OCTOBER 2002 Page i

Working On The Product

Page ii 90-864260020 OCTOBER 2002

Cleanliness And Care Of The Product

90-864260020 OCTOBER 2002 Page iii

Page iv 90-864260020 OCTOBER 2002

Sterndrive (MCM) Model Serial Number

Inboard And Tow Sports (MIE) Model Serial Number

90-864260020 OCTOBER 2002 Page v

Page vi 90-864260020 OCTOBER 2002

90-864260020 OCTOBER 2002 Page vii

Section 6A - Cooling System All Models

Section 6B - Seawater Cooled Models

Page viii 90-864260020 OCTOBER 2002

Section 7A - Dry Joint Identification

90-864260020 OCTOBER 2002 Page ix

Section 7C - Cold Riser Models

Section 7D - Warm Riser Models

Section 10 - Color Diagrams

Page x 90-864260020 OCTOBER 2002

90-864260020 OCTOBER 2002 Page 1A-1

Page 1A-2 90-864260020 OCTOBER 2002

How to Use This Manual

Page 1A-3 90-860074020 JULY 2002

Engine Serial Number Locations

a - Serial number plate

90-864260020 OCTOBER 2002 Page 1A-3

Mercury/Quicksilver Lubricants, Sealants, and Adhesives

Tube Mercury Part Quicksilver Part

7 Loctite 271 92-809819 92-809819

25 Liquid Neoprene 92-25711-3 92-25711-3

27 Bellows Adhesive N/A 92-86166Q1

Page 1A-4 90-864260020 OCTOBER 2002

Tube Mercury Part Quicksilver Part

90-864260020 OCTOBER 2002 Page 1A-5

Tube Mercury Part Quicksilver Part

Page 1A-6 90-864260020 OCTOBER 2002

90-864260020 OCTOBER 2002 Page 6A-1

Description Nm lb-in. lb-ft

Lubricants / Sealants / Adhesives

Page 6A-2 90-864260020 OCTOBER 2002

Seawater Inlet Recommendations

Seacock (Seawater Inlet Valve)

90-864260020 OCTOBER 2002 Page 6A-3

Seawater Strainer Minimum Flow Rate

a - Engine seawater pump

Page 6A-4 90-864260020 OCTOBER 2002

Description Where Used Part Number

Description Where Used Part Number

Description Nm lb-in. lb-ft

90-864260020 OCTOBER 2002 Page 6A-5

Description Where Used Part Number

Page 6A-6 90-864260020 OCTOBER 2002

Water Pickup Installed on Transom

Seawater Pressure Test

90-864260020 OCTOBER 2002 Page 6A-7

Quicksilver Sea Strainer

a - Seawater inlet hose

3. Remove the outlet hose. Drain into a suitable container.

a - Seawater inlet hose

4. Remove the mounting bolts. Remove the strainer.