AEG BP300302 User Manual Download Page 50

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Alpha V8

CA265

ENGINE SPECIFICATIONS

MODEL

5.0 L

5.0 LX

190

Propshaft Horsepower

205

141

Propshaft Kilowatts

152

305 C.I.D. (5 L)

Displacement

Engine Type

3.74 in. (94.99mm)

Bore

3.48 in. (88.39 mm)

Stroke

9.3:1

Compression Ratio

180 psi (1241 kPa)

Compression Pressure

4200-4600 RPM

Maximum RPM @
W.O.T.

650-700 RPM

Idle RPM in
Forward Gear

3-7 psi (21-48 kPa)

Fuel Pump Pressure

30-55 psi (207-379 kPa)

Oil Pressure @ 2000
RPM

4 psi (28 kPa)

Min. Oil Pressure
@ Idle

160

F (71

Thermostat

Power Rated in Accordance with NMMA procedure using Marine Engine Rating Code SAE

J1228 (Technically Identical to ISO 3046 and ICOMIA 28-83).

Summary of Contents for BP300302

Page 1: ...OPERATION MAINTENANCE MANUAL 1994 Brunswick Corporation 90 821051951 1294 Alpha One V8 Models ...

Page 2: ...ontacting your Authorized MerCruiser Dealer about service always specify model and serial numbers The description and specifications contained herein were in effect at the time this guide was approved for printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurr...

Page 3: ...1 Alpha V8 CA2 71348 71352 71350 71360 ABC12345Z123 19 48 12345 71345 5 6 7 1 2 2 3 4 4 1 2 3 4 5 6 7 ...

Page 4: ... 14 Drive Unit Impact Protection 14 Attention Required After Submersion 15 Trailering Boat 15 Launching And Boat Operation Care 16 Stolen Power Package 16 Replacement Service Parts 17 Do it yourself Maintenance Suggestions 18 20 hour Break in Period 20 After Break in Period 20 20 hour Checkup 21 Operation 23 Instrumentation 23 Audio Warning System 25 Electrical System Overload Protection 27 Models...

Page 5: ...93 Inspection And Maintenance 93 Cold Weather Or Extended Storage 94 Power Package Lay Up 94 Draining Instructions 97 Battery Winter Storage 104 Power Package Recommissioning 104 Troubleshooting 105 Warranty Information 112 Owner Warranty Registration 112 International Owner Registration 113 Warranty Policies 114 3 Year Limited Warranty Against Corrosion Failure 118 Warranty Coverage 120 Transfera...

Page 6: ...our boating will be pleasant Consumer Affairs Department CA166 READ THIS MANUAL THOROUGHLY IF YOU DON T UNDERSTAND ANY PORTION CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES NOTICE Throughout this publication and on your power package WARN INGS and CAUTIONS accompanied by the International Hazard Symbol may be used to alert the installer user to special instruc...

Page 7: ...uch a switch ADVANTAGES The purpose of a Lanyard Stop Switch is to stop the engine when the operator leaves the control station either accidentally by falling into the boat or by falling or being ejected overboard This is most likely in certain types of boats such as Iow sided bass boats and high performance boats It is also likely as a result of poor operating practices such as sitting on the bac...

Page 8: ...hey see a powerboat heading toward them even at slow speed Shift the unit to neutral and shut off engine when your boat is near people in the water Serious Injury is likely if a person in the water is struck by a moving boat gear housing propeller or accessory rigidly attached to your boat or motor WARNING The use of accessories not manufactured or sold by Mercury Marine are not recommended for us...

Page 9: ... locate the course nearest you contact Boat U S Founda tion s toll free national boating safety education hot line at 1 800 336 BOAT You should also review the NMMA Sources of Waterway Information booklet It lists regional sources of safety cruising and local naviga tion and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Association 410 N Mich...

Page 10: ... safely enjoy the waterways there are a few precautions that should be observed Check with authorities in regard to local and other governmental boating regulations and restrictions In addition here are suggestions of safety equipment to carry when boating Approved life jackets for each person on board Approved throwable personal flotation device Approved fire extinguisher s paddle or oar Signal d...

Page 11: ...n coming off plane Shifting weight to front bow will Improve ease of planing Improve rough water ride At extremes can cause boat to veer back and forth bow steer CA8 BOTTOM OF BOAT To maintain maximum speed the following conditions of the boat bot tom should be observed A Clean free of barnacles and marine growth B Free of distortion nearly flat where it contacts the water C Straight and smooth fo...

Page 12: ...ng and usually caused by A Drive unit trimmed out too far B A missing propeller diffuser ring C A damaged propeller or gear housing which allows exhaust gases to escape between propeller and gear housing D Drive unit installed too high on transom CA250 PROPELLER SELECTION Select a propeller that will allow the power package to operate at or near the top of the recommender full throttle RPM range w...

Page 13: ...gers pulling skiers etc For better acceleration such as is needed for water skiing use next lower pitch propeller however do not operate at full throttle when us ing ski propeller but not pulling skiers Propellers are available for specific boating requirements Consult your Authorized MerCruiser Dealer for recommendations CA12 HOW ELEVATION AND CLIMATE AFFECT PER FORMANCE Elevation has a very noti...

Page 14: ...ay With the drop in available horsepower this propel ler will in effect become too large Consequently the engine oper ates at less than its recommended RPM This will result in further loss of horsepower at the propeller with another decrease in boat speed This secondary loss however can be somewhat regained by switch ing to a lower pitch propeller that allows the engine to again run at recommended...

Page 15: ...e op timum performance and dependability and will keep your overall op erating expenses at a minimum See your Authorized MerCruiser Dealer for service aids CA14 Dealer Responsibilities In general a dealer s responsibilities to the customer include prede livery inspection and preparation such as Make sure that the boat is properly equipped Prior to delivery make certain that the MerCruiser power pa...

Page 16: ...17 DRIVE UNIT IMPACT PROTECTION The Power Trim hydraulic system is designed to provide impact pro tection for drive unit If a submerged object is struck while boat is moving forward the hydraulic system will cushion the kickup of drive unit as it clears the object reducing damage to unit After drive unit has cleared object the hydraulic system allows drive unit to return to original operating posi...

Page 17: ...t control of boat If continued running is nec essary do so at greatly reduced speeds IMPORTANT Impact protection system cannot be designed to ensure total protection from impact damage under all condi tions CA18 ATTENTION REQUIRED AFTER SUBMERSION Before recovery contact a MerCruiser Dealer After recovery immediate service by an Authorized MerCruiser Dealer is required to prevent serious damage to...

Page 18: ...his instance water may enter the cylinders through the exhaust system When backing up rapidly the same situation may occur as stated in the pre ceding paragraph In any of these situations water entering the engine could cause se vere damage to internal parts Refer to Attention Required After Submersion CA21 STOLEN POWER PACKAGE If your power package is stolen immediately advise the local authori t...

Page 19: ... for most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard auto motive engine For example one of the most important and probably the least sus pected special replacement part is the cylin...

Page 20: ...e aware of the precautions Cautions and Warn ings and procedures required Your safety is of our concern If you attempt to service the product yourself we suggest you or der the service manual for that model The service manual out lines the correct procedures to follow It is written for the trained mechanic so there may be procedures you don t understand Do not attempt repairs if you do not underst...

Page 21: ... request the repair proce dure It is difficult for them to diagnose a problem over the tele phone A doctor can t and won t diagnose your illness by telephone he must examine you personally just as a mechanic must examine your power package Your Authorized Dealer is there to service your power package He has qualified factory trained mechanics It is recommended you have the dealer do periodic maint...

Page 22: ...issible 5 min utes at a time maximum Avoid full throttle acceleration from IDLE speed Do not operate at full throttle until engine reaches normal operat ing temperature Frequently check crankcase oil level Add oil if needed It is nor mal for oil consumption to be high during break in period After 20 hour break in period drain crankcase oil and replace oil filter see MAINTENANCE Fill crankcase with...

Page 23: ...eck shift and throttle cable adjustments Lubricate and inspect for loose damaged or missing parts Steering System Lubricate and inspect for loose damaged or missing parts Inspect all drive belts Check engine alignment Include proper lubrication of U joint and splined shaft Complete Engine Exhaust System Inspect externally for damage and deterioration check all hose clamps for adequate tightness Re...

Page 24: ...22 Alpha V8 CA26 70514 70515 70516 70523 70517 70522 70518 70521 70520 70519 1 2 3 4 5 6 7 8 9 10 ...

Page 25: ...hat will ap pear on your style gauges 1 Speedometer Indicates boat speed 2 Tachometer Indicates engine RPM 3 Oil Pressure Gauge Indicates engine oil pressure 4 Battery Meter Indicates battery voltage 5 Water Temperature Gauge Indicates engine operating tempera ture 6 Fuel Gauge Indicates fuel tank volume 7 Power Trim Gauge Indicates drive unit angle trim up out and down in 8 Hour Meter Records eng...

Page 26: ...24 Alpha V8 CA244 70516 1A 1B 1C 70518 71985 ...

Page 27: ... ignition switch is first turned to the run position prior to cranking the engine Once the engine starts the buzzer should stop CAUTION Avoid engine damage Do not operate engine once the buzzer has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION The Audio Warning System will not protect the engine from damage It is designed to warn the operator that a problem has occured When the buzzer sounds with ...

Page 28: ...26 Alpha V8 CA29 71466 70525 70528 70527 70526 1 2 5 4 3 71341 ...

Page 29: ...reaker If breaker will not reset electrical overload has not been eliminated Further checks must be made on electrical sys tem 2 A 20 amp fuse may be located in ignition switch I terminal lead to protect electrical system Check for blown fuse if key Is turned to START and nothing happens and circuit breaker is not tripped 3 The Power Trim System is protected from overload by 110 amp fuse and a 20 ...

Page 30: ...28 Alpha V8 CB181 1 4 5 2 3 6 7 ...

Page 31: ...perating procedures 4 Trailer Switch Used to raise drive unit for trailering launching breaching or shallow water operation See Power Trim for detailed trailer switch operation 5 Lanyard Stop Switch Turns ignition Off whenever the opera tor when attached to the lanyard moves far enough away from the operator s position to activate the switch See Lanyard Stop Switch at the front of this manual for ...

Page 32: ...30 Alpha V8 CB183 1 4 2 6 3 2 4 3 1 6 5 5 ...

Page 33: ...n be depressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 3 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the tension on the control han dle cover must be removed to adjust This will help prevent Creep of the remote control handle Turn screw Clockwise to increase ten sion and C...

Page 34: ...32 Alpha V8 CB185 3 4 70537 71339 1 2 ...

Page 35: ...PM to be increased or decreased 3 FRICTION Screw adjusts control handle friction so motor speed can be set and driver does not have to hold handle Turn screw clockwise to increase friction Do not thread screw all the way out 4 DETENT Screw controls the effort needed to move control han dle out of NEUTRAL To increase tension turn screw clockwise to decrease turn screw counterclockwise Do not thread...

Page 36: ...34 Alpha V8 CA34 71338 1 ...

Page 37: ...of boat Generally increase top speed Increase clearance over submerged objects Cause boat to accelerate and plane off slower In excess cause porpoising and or propeller ventilation Cause overheating if trimmed up out beyond gimbal ring support flanges CAUTION Never trim drive unit up out using TRAILER switch while boat is underway Use extreme caution when operating with drive unit raised Severe da...

Page 38: ...36 Alpha V8 CB187 1 3 2 6 4 5 73976 73977 ...

Page 39: ...Trailer Position Press button until drive unit reaches desired height 2 Trim Up Out Press UP on Trim switch until drive unit reaches de sired trim position 3 Lower Drive Unit Press DOWN on Trim switch until drive unit reaches desired position CB189 Power Trim Operation Console Mount Remote Control Single Engine Version 4 Trailer Position Press button until drive unit reaches desired height 5 Trim ...

Page 40: ...38 Alpha V8 CB190 4 2A 1 1 2B 3 73978 73979 ...

Page 41: ...s button until drive unit reach es desired height for trailering drive units 2 Two Button Trim Control Dual Buttons in Handle used to contol both drive units from the handle Press UP on button s to trim drive unit UP OUT Press down on button s to trim drive unit DOWN IN A Forward Trim Button Used to trim the port drive unit B Rear Trim Button Used to trim the starboard drive unit 3 Three Button Tr...

Page 42: ...40 Alpha V8 CB192 70540 70540 70540 1 2 3 ...

Page 43: ...pen release button s and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed 1 Trailer Position Simultaneously press the UP button top along with the UP OUT button center until drive unit reaches desired trail er position 2 Trim Drive Unit UP OUT Press center UP OUT button until drive unit reaches desired trim position 3 Trim Drive Unit IN DO...

Page 44: ...seconds When engine starts quickly reduce throttle setting to avoid exceeding 1500 RPM Never shift drive unit unless engine is at Idle RPM 1 Perform the following as appropriate A Check all items listed in OPERATION CHART B Perform any other necessary checks as indicated by your dealer or specified in your boat owner s manual C Place drive unit in full down in position D Place control handle in NE...

Page 45: ...le 1000 1500 RPM I After engine has warmed up check water temperature gauge to ensure that engine temperature is not abnormally high If it is stop engine immediately and determine cause J Be sure charging system is functioning correctly K Observe power package for fuel oil water and exhaust leaks L To shift drive unit return control throttle lever to NEUTRAL Move control shift lever with a firm qu...

Page 46: ...ch ON if so equipped Check for fuel oil wa ter fluid and exhaust leaks etc Turn bat tery switch OFF if so equipped Operate bilge blowers if so equipped Check shift and throttle control op eration Close fuel valve Open fuel shutoff valve Check steering operation Close sea cock if so equipped Open seacock if so equipped Flush cool ing system if in saltwa ter area Place drive unit in full down in pos...

Page 47: ...gasoline Outside USA and Canada having a posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also accept able If unleaded gasoline is not available use a major brand of leaded gasoline CA214 Gasolines Containing Alcohol Gasolines containing alcohol either methyl alcohol methanol or ethyl alcohol ethanol may cause increased Corrosion of metal parts Deterioration of elastomer and ...

Page 48: ... is rec ommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alco hol is unknown increased inspection frequency for leaks and abnor malities is required IMPORTANT When operating a MerCruiser engine on gasoline containing alcohol storage of gasoline in the fuel tank for long periods should be avoided Long periods of stora...

Page 49: ...to crankcase oil selection Oil filter should always be changed with oil In those areas where recommended straight weight oil is not avail able a multiviscosity 20W 40 SG or CD or as a second but less preferable choice 20W 50 SG or CD may be used IMPORTANT The use of non detergent oils multi viscosity oils other than 20W 40 or 20W 50 low quality oils or oils which contain solid additives are specif...

Page 50: ...9 3 1 Compression Ratio 180 psi 1241 kPa Compression Pressure 4200 4600 RPM Maximum RPM W O T 650 700 RPM Idle RPM in Forward Gear 3 7 psi 21 48 kPa Fuel Pump Pressure 30 55 psi 207 379 kPa Oil Pressure 2000 RPM 4 psi 28 kPa Min Oil Pressure Idle 160 F 71 C Thermostat 1 Power Rated in Accordance with NMMA procedure using Marine Engine Rating Code SAE J1228 Technically Identical to ISO 3046 and ICO...

Page 51: ... 650 700 RPM Idle RPM in Forward Gear 3 7 psi 21 48 kPa Fuel Pump Pressure 30 55 psi 207 379 kPa Oil Pressure 2000 RPM 4 psi 28 kPa Min Oil Pressure Idle 160 F 71 C Thermostat 4200 4600 RPM Idle RPM in Neutral 2 650 RPM 1 Power Rated in Accordance with NMMA procedure using Marine Engine Rating Code SAE J1228 Technically Identical to ISO 3046 and ICOMIA 28 83 2 A special procedure must be followed ...

Page 52: ...m 55 Amps Alternator Rating MODEL 5 7L 350 MAGNUM Spark Plug Type 035 in 9mm Spark Plug Gap Timing Idle RPM Firing Order Recommended Battery Rating AC MR43T or Champion RV15YC4 or NGK BR6FS 8 BTDC 1 8 4 3 6 5 7 2 12 Volt Negative Ground Electrical System 55 Amps Alternator Rating 10 BTDC 1 1 8 4 3 6 5 7 2 Minimum 375 cca 475 mca or 90 Ah 1 A special procedure must be followed to check or adjust Ti...

Page 53: ...stick to determine exact quantity of oil required 2 Seawater Cooling System capacity information is for winterization use only MODEL 5 7L 350 MAGNUM Crankcase Oil Capacity w New Filter 1 Approximately 39 2 fl oz 1160ml Drive Unit Oil Capacity w Reservoir Seawater Cooling System 2 15 U S Quarts 14 1L Closed Cooling System 20 U S Quarts 19 3L Approximately 64 fl oz 1892ml Drive Unit Oil Capacity 1 A...

Page 54: ...OTE Maintenance points are color coded for ease of identifica tion See the decal on engine for identification MAINTENANCE AIDS 1 Power Steering System QuickSilver Power Trim and Steering Fluid or Dexron II automatic transmission fluid ATF 2 All Pivot Points SAE 30W motor oil 3 Fogging Winterizing Engine Quicksilver Storage Seal or SAE 20W motor oil 4 Exposed portion of Steering Cable and Propeller...

Page 55: ...oling System Coolant 50 50 mixture of ethylene glycol antifreeze must meet GM specification 1825 M and tap water Areas where temperatures generally do not go below 32 F 0 C rust inhibitor and tap water is acceptable 11Gasoline Stabilizer Quicksilver Marine Fuel System Treatment and Stabilizer 12Grease Fittings on Drive Shaft Extension Models Quicksilver 2 4 C Marine Lubricant ...

Page 56: ...ekly TASK Engine Crankcase Oil Check level Closed Cooling Coolant Check level Power Steering Fluid Check level Stern Drive Unit Oil Check level Battery Check level and inspect for damage Fuel Pump Sight Tube Check that no fuel is present Power Trim Pump Oil Check level Anodes Inspect for erosion Gear Housing Water Pickups Check for ma rine growth or debris INTERVAL ...

Page 57: ...elts All Inspect condition and check tension Propeller Shaft Lubricate Power Package Exte rior Surfaces Spray with rust preventative Power Package Exterior Surfaces Clean and paint Cooling System Flush seawater section INTERVAL Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Operation or 120 Days Whichever Occurs First Once a Year Saltw...

Page 58: ...entilation Hose Clean and inspect Stern Drive unit Oil Change Gimbal Ring Clamping Screws Retorque to 50 55 lb ft 67 74 N m Rear Engine Mounts Check torque to 35 40 lb ft 47 54 N m Gimbal Bearing Lubricate Cooling System Clean inspect Every 100 Hours of Operation or Once Yearly Whichever Occurs First TASK INTERVAL At First 20 Hours of Operation Whenever Insufficient Seawater Flow is Suspected If O...

Page 59: ...Electrical System Check for loose or damaged wiring Cooling System Hoses and Clamps Inspect for damage and deteriora tion Check clamps for tightness Continuity Circuit Check components for loose connections bro ken or frayed wires TASK INTERVAL Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Operation or 120 Days Whichev er Occurs First...

Page 60: ...d Fuel filters Replace Steering Head and Remote Control Inspect and lubricate Quicksilver MerCathode System Test output Closed Cooling Coolant Test for alkalinity Heat Exchanger Clean seawater section Carburetor Inspect and adjust Drive Unit Bellows and Clamps Inspect Closed Cooling Coolant Replace TASK INTERVAL Once a Year Every Two Years Saltwater use Every 50 Hours of Operation or 60 Days Which...

Page 61: ...59 Alpha V8 CA175 THIS PAGE IS BLANK ...

Page 62: ...60 Alpha V8 CA53 71341 1 2 3 4 4 5 6 71448 70543 70544 71340 70547 70546 70545 ...

Page 63: ...raight back 4 Remove FILLCAP DIPSTICK and observe level Add specified fluid if required Reinstall FILLCAP DIPSTICK IMPORTANT If fluid is not visible in pump contact your Autho rized MerCruiser Dealer CA56 Checking Engine Coolant Closed Cooled Models Only WARNING DonotremovecoolantcapwhenengineishotCoolantmaydischargeviolent ly 5 Check coolant level in coolant recovery bottle Add specified cool ant...

Page 64: ...62 Alpha V8 CA57 1 71345 2 A 70979 2 B 70551 71985 ...

Page 65: ...to fill monitor a seal may be leaking Damage to drive unit may occur due to lack of lubrica tion Contact your Authorized MerCruiser Dealer for service CB41 Checking Power Trim Pump Fluid Place drive unit in full down in position 2 Remove fill cap from reservoir and observe oil level Level must be up to but not over bottom of filler neck Add Quicksilver Power Trim and Steering Fluid or SAE 10W 30 m...

Page 66: ...64 Alpha V8 CA62 71345 1 2 3 2 70571 70572 71344 70544 ...

Page 67: ...1 With engine at normal operating temperature remove dipstick In stall Quicksilver Crankcase Oil Pump onto dipstick tube Insert hose end of crankcase oil pump into an appropriate container and using pump handle pump until crankcase is empty Remove crankcase oil pump 2 Turn oil filter counterclockwise to left remove and discard old oil filter and old sealing ring Coat sealing ring on new filter wit...

Page 68: ...66 Alpha V8 CA66 71345 70021 70569 1 2 3 71985 ...

Page 69: ...mmediately by your Authorized MerCruiser Dealer Lower drive unit so anti ventilation plate is level Fill drive unit through OIL FILL DRAIN hole with Specified Gear Lube until an air free stream of lubricant flows from OIL VENT hole Remove tube from OIL FILL DRAIN hole Quickly install sealing washer and OIL FILL DRAIN screw Tighten securely 3 Fill gear lube monitor with Specified Gear Lube When oil...

Page 70: ...68 Alpha V8 CA144 71345 50681 70573 4 5 ...

Page 71: ...oat sealing rings on new filter with motor oil Thread filter clockwise onto bracket and tighten securely by hand Do not use a filter wrench Start and run engine Check filter connection for gasoline leaks If leaks exist recheck filter installation If leaks continue stop engine im mediately and contact your Authorized MerCruiser Dealer WARNING Make sure no leaks exist before closing engine hatch CA1...

Page 72: ...70 Alpha V8 CA70 4 5 71357 71359 1 3 71903 71904 71901 2 ...

Page 73: ...trol NOTE If steering cable does not have grease fitting inner wire of cable cannot be greased 2 With steering cable fully extended lubricate exposed part of cable with Special Lubricant 101 3 Lubricate steering system pivot points with SAE 30W motor oil On dual engine boats lubricate all pivot points including tie bar pivot points with SAE 30W motor oil CA72 Shift Cable 4 Lubricate pivot points w...

Page 74: ...72 Alpha V8 CA74 6 70558 71569 8 ...

Page 75: ...ler and Perm a Lube U joints The sealed coupler and shaft splines can be lubricated without removing the drive unit The Perm a Lube U joints do not require lubrication The engine coupler is lubricated with Quicksilver Engine Coupler Spline Grease Contact your Authorized MerCruiser Dealer for this ser vice CAUTION Speedometer water hose must be disconnected from drive unit BEFORE re moving drive un...

Page 76: ...74 Alpha V8 CA76 1 2 70560 ...

Page 77: ...re moving propeller nut CAUTION Periodically check propeller nut for tightness during boating season A mini mum of 55 lbs ft 75 N m torque is required CA78 Removal 1 Place wood block between propeller blade and anti ventilation plate to prevent rotation Straighten bent tabs on tab washer 2 Turn propeller shaft nut counterclockwise to remove nut 3 Slide tab washer spline washer continuity washer pr...

Page 78: ...76 Alpha V8 CA80 4 5 6 7 8 70134 ...

Page 79: ... stepped side toward pro peller hub 6 Align splines and place propeller and thrust hub on propeller shaft 7 Place continuity washer spline washer and tab washer onto shaft 8 Install propeller nut Tighten nut securely A minimum of 55 lbs ft 75 N m torque is required Bend three tabs on tab washer down into grooves in spline washer After first use bend the three tabs straight retighten propeller nut ...

Page 80: ...78 Alpha V8 CA195 1 2 3 70565 71353 70564 ...

Page 81: ...water at specified intervals CA84 Seawater Raw Water Cooled Models If flushing cooling system with boat in water raise drive unit to TRAIL ER position install flushing attachment and lower drive unit to full down in position 1 Install Quicksilver flushing attachment or equivalent over water intake openings in gear housing 2 Connect hose between flushing attachment and water tap 3 With drive unit i...

Page 82: ...80 Alpha V8 CA177 1 2 3 4 70565 71353 70564 71333 ...

Page 83: ...ll down in position IMPORTANT Water must be supplied to both the drive unit and engine during flushing procedure This ensures that drive unit does not overheat while flushing engine 1 Install Quicksilver flushing attachment or equivalent over water intake openings in gear housing 2 Connect hose between flushing attachment and water tap 3 Disconnect water inlet hose from aft end of seawater pickup ...

Page 84: ...82 Alpha V8 CA246 3 2 71354 70564 71333 1 71355 ...

Page 85: ...sages in heat exchanger by inserting a suitable size wire brush into each passage Use compressed air to blow loose par ticles out Apply Quicksilver Perfect Seal to both sides of new end plate gaskets Assemble new gaskets new sealing washers and end plates onto heat exchanger Install bolts and tighten securely Start engine and inspect cooling system for leaks CA88 SEAWATER PUMP IMPELLER This mainte...

Page 86: ...84 Alpha V8 CA89 5 1 3 2 6 4 71351 70562 71349 70563 ...

Page 87: ...needs adjustment see your Authorized MerCruiser Dealer 1 Alternator Drive Belt Inspect drive belt for excessive wear or damage 2 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 2 in 13mm 3 Power Steering Pump Drive Belt Inspect drive belt for excessive wear or damage 4 Check belt tension by depressing upper strand of belt at point shown Belt should depres...

Page 88: ...86 Alpha V8 CA204 71335 70578 70577 70576 70033 4 2 3 5 1 73919 ...

Page 89: ...ode Remove plug from drive shaft housing to access attaching screw and insert 1 2 inch socket Unthread attaching screw and remove univer sal anodic plate Do not remove screw Install new anodic plate and tighten screw securely Install plug 2 Anodic Plate serves as a sacrificial anode Unscrew both at taching screws and remove Install a new anodic plate and tighten securely 3 Block Is mounted to unde...

Page 90: ...88 Alpha V8 CA162 71958 71957 1 2 B ...

Page 91: ... and tighten securely CA164 2 Propeller Anode is located in front of the propeller between the front side of the propeller and the gear housing Refer to Propeller section in this manual for propeller removal and installation To re place the propeller anode A Remove propeller B Remove two screws from anode C Install new anode and tighten securely D Reinstall propeller ...

Page 92: ...90 Alpha V8 CA93 1 2 71176 3 ...

Page 93: ...nts observe the following 2 Avoid any electrical interconnection between the MerCruiser Product Anodic Blocks or MerCathode System and the paint by allowing a minimum of 1 1 2 in 40mm UNPAINTED area on transom of the boat around these items 3 Painting Drive Unit or Transom Assembly Drive unit and tran som assembly should be painted with a good quality marine paint or an anti fouling paint that DOE...

Page 94: ...eries also produce hydrogen and oxygen gases when beingcharged This explosive gas escapes fill vent cell caps and may form an explosive atmosphere around the battery for several hours after it has been charged Sparks or flames can ignite the gas and cause an explosion which may shatter the battery and could cause blindness or other serious injury Safety glasses and rubber gloves are recommended wh...

Page 95: ...ation CA105 INSPECTION AND MAINTENANCE Inspect power package often and at regular intervals to help main tain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all accessible engine parts Check for loose damaged or missing parts hoses and clamps tight en or replace as required Check plug leads and electrica...

Page 96: ...ve unit may result IMPORTANT Before starting engine a water source must be attached to the seawater intake openings in gear housing Fol low all warnings and flushing attachments procedures stated in FLUSHING COOLING SYSTEM 1 Run engine sufficiently to bring it up to normal operating tempera ture Shut off engine and change oil and oil filter 2 Flush cooling system WARNING Be sure engine compartment...

Page 97: ...in alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer and Condi tioner to treat gasoline Follow instructions on container 5 If boat is to be placed in storage with fuel containing alcohol in fuel tanks carburetors must be run dry at idle RPM Fuel tanks should be drained completely and Quicksilver Gasoline Stabilizer and Con ditioner added to any fuel remaining in the tank Also refe...

Page 98: ...96 Alpha V8 CB232 2 2 74158 71332 3 ...

Page 99: ...or corrosion damage to engine 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from cylinder block as follows A 5 0L 5 7L Models Port Starboard from cylinder block B 350 Magnum Model Port Side from cylinder block C 350 Magnum Model Starboard Side from Y fitting Do not dis turb the Y fitting when removing the drain plug There is an ignition ...

Page 100: ...98 Alpha V8 CA264 5 6 7 8 71448 71334 71216 74493 ...

Page 101: ...tally safe antifreeze be used in the seawater section of the cooling system for cold weather or ex tended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufactur er s recommendations 8 For additional assurance against freezing and rust remove the thermostat cover and thermosta...

Page 102: ...100 Alpha V8 CA111 2 3 2 3 71330 70583 71332 ...

Page 103: ...t Failure to comply may result in trapped water causing freeze and or corrosion damage to engine IMPORTANT Closed cooling section must be kept filled year round with recommended coolant If engine will be ex posed to freezing temperatures make sure closed cooling sec tion is filled with an ethylene glycol antifreeze and water Solu tion properly mixed to protect engine to lowest temperature to which...

Page 104: ...102 Alpha V8 CA113 5 71333 71334 71216 6 8 ...

Page 105: ...Make sure gear housing water drain holes and speedometer pitot hole are open and unobstructed After seawater section of cooling system has been drained com pletely coat threads of drain plugs with Quicksilver Perfect Seal and reinstall Reconnect hoses and tighten all hose clamps securely After draining perform all checks inspections lubrication and fluid changes outlined in MAINTENANCE CHART under...

Page 106: ...ical system damage will result 2 Install fully charged battery Clean battery cable clamps and ter minals and reconnect cables see CAUTION listed above Tighten each cable clamp securely when connecting 3 Coat terminal connections with a battery terminal anti corrosion agent 4 Perform all checks in OPERATION CHART in the BEFORE STARTING column CAUTION Refer to FLUSHING COOLING SYSTEM before starting...

Page 107: ...nnections or damaged wiring Bad battery Turn switch on Position control lever in neutral Check and reset circuit breaker or replace fuse Check all electrical con nections and wires espe cially battery cables Clean and tighten faulty connection Test and replace if bad 105 Alpha V8 CB215 TROUBLESHOOTING STARTER MOTOR WILL NOT CRANK ENGINE OR CRANKS SLOW ...

Page 108: ...ll tank or open valve Check sight tube for fuel Have Authorized Mer Cruiser Dealer replace pump if fuel is present Check that choke is closed when engine is cold Check that it opens when engine warms up Do not attempt to start en gine for at least 5 minutes Refer to STARTING PRO CEDURES Service ignition system Replace filters If contaminated drain tank Fill with fresh fuel Replace kinked lines or ...

Page 109: ...rs If contaminated drain tank Fill with fresh fuel Replace kinked line or blow out line with compressed air to remove obstruction Clean flame arrestor Possible Cause Remedy Throttle not fully open Damaged or improper pro peller Excessive bilge water Boat overloaded or load improperly distributed Boat bottom fouled or dam aged Flame arrestor dirty Inspect throttle cable and linkages for proper oper...

Page 110: ...pped Closed cooling section dirty If Equipped Faulty seawater pickup pump Seawater discharge re stricted or plugged Open Replace and or adjust belt Remove obstruction Replace Check for cause of low coolant level and repair Fill system with proper coolant solution Clean heat exchanger Check for leaks Clean in spect and test pressure cap Clean Repair Clean exhaust elbows Possible Cause Remedy Faulty...

Page 111: ... cause for dilution excessive id ling faulty fuel pump etc Possible Cause Remedy Excessive current draw from battery Loose or dirty electrical connections or damaged wiring Alternator drive belt loose or in poor condition Unacceptable battery condition Turn off non essential ac cessories Check all associated elec trical connections and wires especially battery cables Clean and tighten faulty conne...

Page 112: ...e cable if damaged beyond repair Possible Cause Remedy Low power steering pump fluid level Drive belt loose or in poor condition Insufficient lubrication on steering system compo nents Loose or missing steering fasteners or parts Contaminated power steering fluid Refill system with fluid Replace and or adjust Lubricate Check all parts and fasten ers If any are loose or missing see Authorized MerCr...

Page 113: ...s and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring Possible Cause Remedy Trim pump oil level low Drive unit binding in gimbal ring Fill pump with oil Check for obstruction 111 Alpha V8 POWER TRIM DOES NOT OPERATE MOTOR DOESN T RUN POWER TRIM DOES NOT OPERATE MOTOR RUNS BUT DRIVE UNIT DOES NOT MOVE ...

Page 114: ...ar ranty claims will not be accepted without presentation of this card A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service dur ing this period present the temporary registration card to the deal er He ...

Page 115: ...ur dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registra tion Card from your distributor dealer If you receive a...

Page 116: ...and workman ship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of mainte nance accident abnormal operation or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Operation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or preparing for racing or other co...

Page 117: ...uired Warranty claims will not be accepted without presentation of the Warranty Registration Card VI Our obligation under this Warranty shall be limited to repairing a defective part or at our option refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workman ship as covered by this Warranty We reserve t...

Page 118: ... removal of parts or 6 Water entering engine cylinder s through exhaust system or carbure tor s III Reasonable access must be provided to the Product for war ranty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other consequential damages or 2 Removal and or replace ment of boat...

Page 119: ... shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty We reserve the right to improve the design of any Product without assuming any obli gation to modify any Product previously manufactured VII ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM...

Page 120: ...arranty registration card and shall re main effective for a period of three years from the date of pur chase III This warranty does not cover 1 electrical system corrosion 2 corrosion resulting from damage abuse or improper ser vice 3 corrosion to accessories instruments steering sys tems 4 damage due to marine growth 5 Product sold with less than a one year limited Product warranty except for Bra...

Page 121: ...r Galvanic Isolator These certain types of corrosion damage are damage due to stray electrical currents on shore power con nections nearby boats submerged metal or improper application of copper base anti fouling paint If anti fouling protection is required Tri Butyl Tin Adipate TBTA base antifouling paints are recommended on MerCruiser boating applications In areas where Tri Butyl Tin Adipate bas...

Page 122: ...tact your authorized dealer They will be pleased to answer any ques tions that you may have WARRANTY DOES NOT APPLY TO THE FOL LOWING Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connec tion with normal services Damage caused by neglect lack of maintenance accident...

Page 123: ... as a matter of normal mainte nance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for war ranty consideration Participating in or preparing for racing or other competitive activ ity Engine noise does not necessarily indicate a serious engine prob lem If diagnosis indicates a serious internal engine condition which could result...

Page 124: ...nted too high Use of fuels and lubricants which are not suitable for use with or on the product Our limited warranty does not apply to any damage to our prod ucts caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered un der warranty if they otherwise meet the terms of t...

Page 125: ...and a copy of the bill of sale to show proof of ownership In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 A new Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file There is no cha...

Page 126: ...CE LOCAL REPAIR SERVICE Always return your MerCruiser powered boat to your local Autho rized Dealer should the need for service arise Only he has the facto ry trained mechanics knowledge special tools and equipment and the genuine Quicksilver parts and accessories to properly service your engine should the need occur He knows your engine best Quicksilver parts and accessories are engineered and bu...

Page 127: ...ems with service sales warranty or operation of your MerCruiser power package will be resolved by your dealer He also is your primary source of information on your boat power package and trailer Should there be a misunderstand ing or if your problem has not been resolved to your satisfaction please follow these steps STEP ONE DISCUSS YOUR PROBLEM WITH ONE OF THE DEALERSHIP MANAGEMENT PERSONNEL Mis...

Page 128: ...ND TWO AND YOUR COMPLAINT HAS NOT BEEN RE SOLVED STEP THREE CONTACT CONSUMER AFFAIRS DEPARTMENT United States MERCRUISER 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6515 Canada Contact Nearest Regional Service Center Other Countries Contact the Nearest Marine Power International Service Center The customer service representatives will review all the facts in volved If they feel ...

Page 129: ...issauga Ontario L4Y 2C2 Canada Telephone 905 270 4481 Fax 905 270 4510 MEXICO CENTRAL AMERICA SOUTH AMERICA CARIBBEAN Marine Power International 9350 SW 72nd St Sunset Dr Suite 100 Miami FL 33173 U S A Telephone 305 596 9606 Fax 305 596 3869 EUROPE MIDDLE EAST AFRICA Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Telephone 0 87 32 32 11 Fax 32 87 31 19 65 ...

Page 130: ...822 Fax 61 3 791 5880 ASIA Marine Power International Ltd Block 1002 Jalan Bukit Merah 07 08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone 65 270 7680 Fax 65 270 7898 JAPAN Marine Power International Japan No 27 2 Muramatsu Chisaki Shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone 81 543 34 2500 Fax 81 543 34 2022 ...

Page 131: ...r Road P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest Ma rine Power International Service Center for further information When ordering be sure to 1 List your product model year and serial number s 2 Check the literature and quantities you want 3 Enclose full remittance in check or money order NO C O D s ...

Page 132: ...s 27 33179 2 27 53045 1 27 33179 2 27 53045 1 8 Alternator Belt 57 49213A1 57 49213A1 9 Power Steering Belt 57 816295T 57 816295T 10 Sea Water Pump Belt 57 49213A1 57 49213A1 11 Water Separating Filter 55 805269 1 55 805269 1 12 Quicksilver Motor Oil 92 816096A12 92 816096A12 13 Storage Seal 92 86145A12 92 86145A12 14 Valvtane Plus 92 17955A12 92 17955A12 15 Fuel Treatment and Stabilizer 92 817529...

Page 133: ... 816761A17 6 807252 2 807252 2 7 27 33179 2 27 53045 1 27 33179 2 27 53045 1 8 57 48120A1 57 48120A1 9 57 816295T 57 816295T 10 57 74271T 57 13457T 11 55 805269 1 55 805269 1 12 92 816096A12 92 816096A12 13 92 86145A12 92 86145A12 14 92 17955A12 92 17955A12 15 92 817529A12 92 817529A12 16 92 17885A12 92 17885A12 17 92 815869A12 92 815869A12 ...

Page 134: ...aring Carrier Anode 806105A1 Drain Screw 10 14834 Drain Screw O Ring 19183 Vent Screw 10 79953 Vent Screw O ring 12 19183 Drive Mounting Gasket 27 64818A3 Drive Mounting O ring 27 35982 Trim Pump 20 Amp Fuse 88 79091 Trim Pump 10 Amp Fuse 88 79023A10 Water Pump Impeller 47 43026 2 Wafter Pump Cover Gasket 27 817227 Water Pump Base Gasket 27 43033 1 2 4 C Marine Lubricant 92 825407A2 Engine Coupler...

Page 135: ...isassembly of the engine or stern drive Parts Manual shows the exploded view of the engine or stern drive with corresponding part number Operation and maintenance manual Owner s Guide explains basic operation and maintenance Manual Part Number Official Use Only Qty Price Each Total Price Service Manual Engine 90 30 00 Service Manual Drive 90 30 00 Service Manual Remote Control 90 30 00 Parts Manua...

Page 136: ...n with Payment to Mercury Marine Attn Publications Dept P O Box 1939 Fond du Lac WI 54936 1939 Ship To Please Print or Type This is your Shipping Label Name Address City State Zip 134 Alpha V8 Method of Payment No Cash or C O D Personal Check Cashiers Check Money Order Visa MasterCard ...

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