service manual 31 combined - JustAnswer

MAINTENANCESERVICE MANUAL NUMBER 31

90-864260001 JUNE 2003 Page 1B-87

8. Lubricate all items listed in Lubrication section.

9. Drain seawater section of cooling system as outlined in Draining Instructions section.

10. On Models with Closed Cooling System: Test coolant to ensure that it will withstandthe lowest temperature expected during storage.

11. Clean outside of engine and repaint any areas required with Primer and Spray Paint.After paint has dried, wipe down with Storage Seal rust inhibitor.

Description Where Used Part Number

Storage Seal Rust Inhibitor Carburetor 92-802878-56

Light gray primer Outside of engine 92-802878-52

Phantom black paint Outside of engine 92-802878-1

12. For sterndrive unit layup, refer to appropriate Mercury MerCruiser sterndrive servicemanual.

IMPORTANT: Ensure that some fogging mixture remains in the engine. Do not allowthe engine�s fuel system to become completely dry.

13. Remove and discard the water separating fuel filter.

14. Install a new filter.

Draining Instructions

CAUTIONEnsure that boat is out of the water or seacock is closed and bilge pump is operatingbefore beginning procedure. Excess water in bilge can damage engine or causeboat to sink.

CAUTIONDo not operate engine with drain system open. Excess water in bilge can damageengine or cause boat to sink.

IMPORTANT: Boat must be as level as possible to ensure complete draining ofcooling system.

Your power package is equipped with 1 of 3 drain systems. Refer to Identification on thefollowing page to determine which instructions apply to your power package.

The power package should be drained before flushing or prior to extended or cold weatherstorage.

IMPORTANT: The boat must not be operating at any point during this procedure.

MAINTENANCE SERVICE MANUAL NUMBER 31

Page 1B-88 90-864260001 JUNE 2003

IdentificationCARBURETED MODELS

Description Water Drain System

5.0L Alpha 7 point manual drain system

5.0L Bravo 7 point manual drain system

5.7L Alpha 7 point manual drain system

5.7L Bravo 7 point manual drain system

5.7L Inboard 7 point manual drain system

5.7L Tow Sports 7 point manual drain system

MPI MODELS


5.0L MPI AlphaManual single point drain (standard)

Multi-point drain (MPD) system (optional)

5.0L MPI Bravo

3 point manual drain system (standard)Air actuated single point drain system

(optional)Multi-point drain (MPD) system (optional)

350 MAG MPI AlphaManual single point drain (standard)

Multi-point drain (MPD) system (optional)

350 MAG MPI Bravo



350 MAG MPI Horizon Bravo Air actuated single point drain system(standard)

MX 6.2 MPI Bravo



MX 6.2 MPI Horizon Bravo Air actuated single point drain system(standard)


90-864260001 JUNE 2003 Page 1B-89

MPI MODELS (CONTINUED)


350 MAG MPI Inboard3 point manual drain system (standard)Air actuated single point drain system

(optional)

350 MAG MPI Horizon Inboard Air actuated single point drain system(standard)

MX 6.2 MPI Inboard3 point manual drain system (standard)Air actuated single point drain system

(optional)

MX 6.2 MPI Horizon Inboard Air actuated single point drain system


350 MAG MPI Tow Sports3 point manual drain system (standard)Air actuated single point drain system

(optional)

Scorpion Tow Sports 8 point manual drain system (standard)

MX 6.2 MPI Tow Sports3 point manual drain system (standard)Air actuated single point drain system

(optional)

MX 6.2 Scorpion Tow Sports 8 point manual drain system (standard)

MANUAL SINGLE POINT DRAIN SYSTEM

77947 77949

b

a

77917

b

a - Blue handleb - Blue drain plug location


Page 1B-90 90-864260001 JUNE 2003

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

ba d

c

77955

77955

a

b

c

d

Closed cooled models Seawater cooled models

a - Blue drain plug locationb - Blue air pumpc - Air manifoldd - Green indicators

3 POINT MANUAL DRAIN SYSTEM

7790877917

a

a

a - Blue drain plug


90-864260001 JUNE 2003 Page 1B-91


74073

a

b75018

a b

c

Starboard side Port side

a - Exhaust elbow drain plugb - Cylinder block drain plugc - Water tube drain plug

75533a

b

c76038d

a - Seawater inlet hoseb - Hose to coolerc - Water circulating pump hosed - Drain plug


Page 1B-92 90-864260001 JUNE 2003

0181.1

MULTI-POINT DRAIN (MPD) SYSTEM

78181 78178

a

b

a

b

a - Side of cylinder blockb - Bottom of exhaust manifolds

78182

a

78179

b

a - Water circulating pump hoseb - Fuel cooler to thermostat housing

78180

a

a - Check valve


90-864260001 JUNE 2003 Page 1B-93

Boat In The WaterMANUAL SINGLE POINT DRAIN SYSTEM

1. Close the seacock.

2. Rotate the blue handle COUNTERCLOCKWISE until it stops (approximately 2 turns).The red on the handle shaft indicates that the drain system is open. Do not force thehandle as this will create new threads.

3. Immediately remove the blue drain plug from the side of the thermostat housing. Thismust be removed within 30 seconds to properly vent the cooling system.

77947

77949

b

a

a - Blue handleb - Blue drain plug location

4. Visually verify that water is draining. If water does not drain, remove blue drain plug fromdistribution housing and drain manually.

77917

a

b

a - Drain location - orange or redb - Blue drain plug

5. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommendsleaving the drain system open while transporting the boat or while performing othermaintenance.

6. Reinstall the blue drain plug in the thermostat housing.

7. Close the drain system by rotating the blue handle CLOCKWISE until it stops and installthe blue drain plug, if removed. The handle is fully seated when no red is visible. Do notovertighten the handle as this will create new threads.

8. Open the seacock prior to operating the engine.


Page 1B-94 90-864260001 JUNE 2003


NOTE: This procedure is written for the air pump that is attached to the engine. However,any air source can be used.


2. Remove the blue air pump from the engine.

3. Ensure that lever on top of pump is flush with the handle (horizontal).

4. Install the air pump on the fitting in the air manifold.

77638

a

a - Green indicators

5. Pull lever on the air pump up (vertical) to lock pump on the fitting.

6. Pump air into the system until both green indicators extend and water drains from bothsides of the engine. The port side will begin draining before the starboard side.

7. Immediately remove the blue drain plug from the side of the thermostat housing or theheat exchanger. This must be removed within 30 seconds to properly vent the coolingsystem.

ba d

c

77955

77955

a

b

c

d




90-864260001 JUNE 2003 Page 1B-95

8. Verify that water is draining from each opening. If not, use the 3 Point Manual DrainSystem instructions.

7784477839 ba

a - Port side drain locationb - Starboard side drain location

9. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep thegreen indicators extended.

10. Crank engine over slightly with starter motor to purge any water trapped in seawaterpump. Do not allow engine to start.

11. Reinstall the blue drain plug in the thermostat housing.

12. Remove the air pump from the air manifold and return it to the mounting bracket.

13. Mercury MerCruiser recommends leaving the drain system open while transporting theboat or while performing other maintenance. This helps ensure that all water is drained.

14. Before launching boat, pull up on manual release valve. Verify that green indicators areno longer extended.

77638a




Page 1B-96 90-864260001 JUNE 2003


NOTE: Use this procedure if your engine is not equipped with an air actuated single pointdrain system or if the single point drain system fails.


2. Remove 3 blue drain plugs: 1 from the distribution housing (lower front, port side) and2 from the seawater pickup pump (front, starboard side).

7790877917a

a

a - Blue drain plug

3. Immediately remove the blue drain plug from the side of the thermostat housing. Thismust be removed within 30 seconds to properly vent the cooling system.

77949

a

a - Blue drain plug location

4. Verify that water is draining from each opening.

5. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommendsleaving the drain system open while transporting the boat or while performing othermaintenance. This helps ensure that all water is drained.

6. Crank engine over slightly with starter motor to purge any water trapped in seawaterpickup pump. Do not allow the engine to start.

7. Prior to launching boat or starting the engine, close the drain system by installing thefour blue drain plugs.



90-864260001 JUNE 2003 Page 1B-97

Boat Out Of The WaterMANUAL SINGLE POINT DRAIN SYSTEM

1. Rotate the blue handle COUNTERCLOCKWISE until rotation stops (approximately 2turns). The red on the handle shaft indicates that the drain system is open. Do not forcethe handle as this will create new threads.

77947

a

a - Blue handle

2. Visually verify that water is draining. If water does not drain, remove blue drain plug fromdistribution housing and allow to drain manually.

77917

a

b

a - Drain location - orange or redb - Blue drain plug

3. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommendsleaving the plugs out while transporting the boat or while performing other maintenance.This helps ensure that all water is drained.

4. Close the drain system by rotating the blue handle CLOCKWISE until it stops or byinstalling the blue drain plug. The handle is fully seated when no red is visible. Do notovertighten the handle as this will create new threads.


Page 1B-98 90-864260001 JUNE 2003


NOTE: This procedure is written for the air pump that is attached to the engine. However,any air source can be used.

1. Remove the blue air pump from the engine.

2. Ensure that lever on top of pump is flush with the handle (horizontal).

3. Install the air pump on the fitting in the air manifold.

77638

a


4. Pull the lever on the air pump up (vertical) to lock the pump on the fitting.

5. Pump air into the system until both green indicators extend and water drains from bothsides of the engine. The port side will begin draining before the starboard side.

ba d

c

77955

77955

a

b

c

d




90-864260001 JUNE 2003 Page 1B-99

6. Verify that water is draining from each opening. If not, use the 3 Point Manual DrainSystem.

7784477839 ba

a - Port side drain locationb - Starboard side drain location

7. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep thegreen indicators extended.

8. Crank engine over slightly with starter motor to purge any water trapped in seawaterpump. Do not allow engine to start.

9. Remove the air pump from the air manifold and return it to the mounting bracket.

10. Mercury MerCruiser recommends leaving the plugs out while transporting the boat orwhile performing other maintenance. This helps ensure that all water is drained.

11. Before launching boat, pull up on the manual release valve. Verify that the greenindicators are no longer extended.

77638a



Page 1B-100 90-864260001 JUNE 2003


1. Remove three blue drain plugs: 1 from the distribution housing (lower front, port side)and 2 from the seawater pickup pump (front, starboard side).

7790877917a

a

a - Blue drain plug

2. Verify that water is draining from each opening.

3. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommendsleaving the plugs out while transporting the boat or while performing other maintenance.This helps ensure that all water is drained.

4. Crank engine over slightly with starter motor to purge any water trapped in seawaterpickup pump. Do not allow engine to start.

5. Prior to launching boat or starting the engine, close the drain system by re-installing the3 blue drain plugs.


90-864260001 JUNE 2003 Page 1B-101


NOTE: This procedure will not work with 3.0L Single Point Drain System. See specificinstructions later in this manual.

CAUTIONIf boat is to remain in water after draining, seawater inlet hose must be removed andplugged to prevent a siphoning action that may occur, allowing seawater to flowfrom the drain holes or removed hoses.

IMPORTANT: Boat must be as level as possible to ensure complete draining ofcooling system.

CAUTIONSeawater section of cooling system MUST BE COMPLETELY drained for winterstorage, or immediately after cold weather use, if the possibility of freezingtemperatures exists. Failure to comply may result in trapped water causing freezeand/or corrosion damage to engine. Damage caused by freezing IS NOT covered bythe Mercury MerCruiser Limited Warranty.

1. Ensure that the engine is as level as possible to ensure complete draining of coolingsystem.

2. Remove drain plugs from the following locations, if equipped:

74073

a

b75018

a b

c

Starboard side Port side

a - Exhaust elbow drain plugb - Cylinder block drain plugc - Water tube drain plug

3. Remove seawater pump inlet hose.

75533a

b

a - Seawater inlet hoseb - Hose to cooler


Page 1B-102 90-864260001 JUNE 2003


5. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire systemis drained.

NOTE: It may be necessary to lift or bend hoses to allow water to drain completely.

6. Remove the engine water circulating pump hose or drain plug, if equipped.

7. For sterndrive models, ensure that the gear housing water vent and drain holes,speedometer pitot hole, and trim tab cavity vent and drain holes are open andunobstructed.

71216

ac

d

76038

e

b

a - Water circulating pump hoseb - Drain plugc - Gear housing water vent holesd - Speedometer pitot holese - Trim tab cavity vents and drain holes


9. After cooling system has been drained completely, install drain plugs, reconnect hoses,and tighten all hose clamps securely.

10. For additional assurance against freezing and rust, fill the cooling system with a mixtureof propylene glycol and tap water mixed to manufacturer�s recommendation to protectengine to the lowest temperature to which it will be exposed during cold weather orextended storage.

a. Remove thermostat housing or hose and fill with coolant until he engine block andthe cylinder head are full. If thermostat housing was removed, reinstall and tightencover bolts securely.

b. Remove water hose from exhaust manifold and fill manifold with coolant. Reinstallhose and tighten clamp securely.

11. For sterndrive models, store boat with sterndrive unit in full DOWN/IN position.


90-864260001 JUNE 2003 Page 1B-103

MULTI-POINT DRAIN (MPD) SYSTEM

1. Place the boat on a level surface to ensure complete draining of system.

2. Remove blue drain plugs from the following locations. It may be necessary to clean outdrain holes using a stiff piece of wire. Do so until the entire system is drained.

a. Port and starboard side of cylinder block.

b. Bottom of exhaust manifolds.

c. Fuel cooler.

79166

a

b

Starboard side

79167

a

b

c

Port sidea - Side of cylinder blockb - Bottom of exhaust manifoldc - Fuel cooler


Page 1B-104 90-864260001 JUNE 2003

d. Water circulating pump hose.

e. Seawater pump.

79165

a

b

a - Water circulating pump hoseb - Seawater pump

3. Crank engine over slightly with starter motor to purge any water trapped in seawater pickuppump. Do not allow engine to start.

4. After cooling system has been drained completely, install drain plugs, reconnect hoses andtighten all hose clamps securely.

IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxicand environmentally safe) antifreeze be used in the seawater section of the coolingsystem for cold weather or extended storage. Ensure that the propylene glycol anti-freeze contains a rust inhibitor and is recommended for use in marine engines. Becertain to follow the propylene glycol manufacturer�s recommendations.

service manual 31 combined - JustAnswer

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