Chapter Five
Lay-up, Cooling System Service
and Fitting Out
LAY-UP
Boats that are to be stored for more than 4 or 5
weeks should be carefully prepared. This is
necessary to prevent damage to the engine and the
stern drive unit from freezing, corrosion and/or
fuel system contamination. Preparation for lay-up
should begin, if possible, while the boat is still in
the water.
If the boat has been removed from the water, a
supply of coolant water must be made available to
the engine. This can be accomplished in one of two
ways. The stern drive unit can be submerged in a
test tank, or a garden hose may be attached to the
cooling system using an adapter available at most
marine supply stores.
The suggestions for lay-up preparation which
follow are based on recommendations made by
Mercury Marine. See Table 1 (end of chapter) for
lubricants recommended by Mercury Marine.
In-the-water
Preparation
1. Start the engine. Run at idle until it reaches
normal operating temperature, then shut the engine
off. Drain the engine oil and install a new oil filter
(Figure 1). See Chapter Four.
2. Refill the crankcase with the proper amount of
fresh SAE 20 SE or SF engine oil. Add one pint of
Quicksilver 4-cycle Engine Oil Supplement to
crankcase. See Chapter Four.
3. Shut the fuel supply off at the fuel tank.
4. Restart the engine and run for several minutes
at 800- 1,200 t-pm to allow the oil to circulate to all
internal parts. Check for oil leaks around the new
filter while the engine is running.
5. Shut the engine off and wait approximately 5
minutes, then check the oil level on the dipstick
(Figure 2, typical location). Add oil, if necessary, to
bring the level up to the FULL mark on the
dipstick.
6. Remove flame arrestor cover (if so equipped)
and flame arrestor (Figure 3) from carburetor
intake and restart engine. Increase engine speed to
a fast idle (800- 1,200 t-pm) and slowly pour a can of
Quicksilver Storage Seal into the carburetor intake
to fog the internal surfaces of the induction system.
When the can of Storage Seal has approximately 2
ounces left in it, decrease engine speed to a normal
idle and kill the engine by quickly pouring the
remaining Storage Seal into the carburetor. If the
engine does not stall, shut the ignition off
immediately.
LAY-UP, COOLING SYSTEM SERVICE AND FI’lTING OUT
85
CHAPTER FIVE
86
NOTE
If Quicksilver Storage Seal is not available, pour
about one cup of SAE 20 SE or SF engine oil
into the carburetor. Kill the engine by quickly
pouring in about 2 ounces of SAE 20 SE or SF
engine oil.
7. Clean the flame arrestor with solvent, blow dry
with compressed air (if available) and reinstall on
carburetor.
8. Install a new fuel filter canister (Figure 4,
typical). If equipped with a sediment bowl (Figure
5, typical), remove and clean bowl, then install a
new filter before reinstalling it to the fuel pump.
WARNING
Be sure to have a Coast Guard-approved fire
extinguisher at hand before performing Step 9.
9. Completely drain the fuel tank of all gasoline.
WARNING
Since gasoline is an extreme fire hazard, always
store it in a sealed metal container away from
heat, sparks and flame.
10. Remove boat from water, keeping bow higher
than stem if possible to assist in draining the
exhaust system.
Out-of-water
Preparation
1. Adjust trailer or cradle so that engine is in a
level position. Lower stem drive unit to its “down”
position.
2. Loosen drive belt tension and inspect condition
of all belts. Replace as required. Tighten accessory
unit adjusting bolts without putting tension on
drive belts.
3. Drain cooling system as described in this
chapter.
LAY-UP, COOLING SYSTEM SERVICE AND FITI’ING OUT
05
FUEL PUMP (TYPICAL) A \
and fuel filter
Yoke screw
87
4. Check all hoses for deterioration, cracks or
other defects and replace as required.
5. Remove the spark plugs and pour one ounce of
Quicksilver Storage Seal or SAE 20 SE or SF engine
oil into each cylinder.
6. Disconnect coil high tension lead at distributor
cap (Figure 6). Ground lead and crank engine over
15-20 seconds with the starter to coat cylinder
walls with oil.
7. Wipe up any excess oil from plug holes. Wipe a
thin film of Storage Seal or SAE 20 engine oil on
spark plug threads. Reinstall spark plugs and
connect coil lead.
8. Remove the rocker arm cover(s) and check for
signs of condensation in the rocker arm area.
Carefully wipe away any oil-water mixture found.
Coat valve mechanism and inside of rocker arm
cover(s) generously with Storage Seal or SAE 20
engine oil. Reinstall rocker arm cover(s) using new
gasket(s).
9. Refill cooling system as described in this
chapter.
10. Cover flame arrestor and carburetor with a
plastic bag and tape tightly in place. This prevents
moisture from entering the carburetor and intake
manifold.
11. Remove battery from boat. Tape vent holes
closed and clean battery case with baking soda
solution to remove corrosion and acid traces, then
rinse with cold water. Check electrolyte level in
each cell and top up with distilled water, if
necessary. Cover terminals with a light coat of
petroleum jelly. Store battery in a cool, dry place.
NOTE
Remove battery from storage every 30-45 days.
Check electrolyte level and slow-charge for 5-6
hours at 6 amperes.
12. Tape exhaust outlets closed to prevent
moisture from entering the exhaust manifolds and
valve chambers.
13. Cover through-hull fuel tank ventilators with
tape to help keep moisture from fuel tank.
14. Clean engine exterior thoroughly and retouch
any blemishes with engine touch-up paint. Apply a
film of Quicksilver Rust and Corrosion Preventive
on exterior surfaces or wipe down with a rag coated
with Storage Seal or SAE 20 engine oil to leave a
light coating on exterior surfaces.
CHAPTER FIVE
88
Stern Drive Unit
Refer to Chapter Four for location of lubrication
points listed below.
1. Insert a length of wire in drive shaft and gear
housing water drain holes to make sure they are
open.
2. Lubricate the following components with
Quicksilver Multipurpose Lubricant:
a. Ride-Guide steering cable end.
b. Steering arm pivot socket.
c. U-joint shaft and engine coupling shaft
splines.
d. Drive unit upper and lower pivot pins.
e. Gimbal or transmission output housing
bearing.
f. Power steering control valve.
3. Lubricate U-joint bearings with Universal Joint
Lubricant.
4. Lubricate drive unit hinge pins with
Anti-corrosion Grease.
5. Remove propeller. Lubricate prop shaft with
Perfect Seal (part No. C-92-34227) and reinstall
propeller.
6. Inspect bellows condition. Replace if required.
7. On I-Drives, check water pump impeller.
Replace if worn, hardened or set.
37
140 AND 161 ENGINE DRAIN
LOCATIONS (PD$TTlDE)
4 -
I”*,
drain plug
III~IIIIVIY
d; rin plug
block petcock
CAUTION
Do not paint sacrificial zinc rings, plugs or bars,
if present. These must be left unpainted in order
to prevent galvanic corrosion damage.
8. Remove all marine growths and deposits from
stem drive unit. Clean metal surfaces that have
become exposed and cover with touch-up paint.
9. Wipe or spray exterior surfaces of stem drive
with Rust and Corrosion Preventive.
10. Store boat with stem drive unit in its normal
operating position. If the unit is stored in a
tilted-up position, the universal joint bellows may
develop a “set” that will lead to premature bellows
failure once the stem drive is returned to service.
Inline engines tend to crack horizontally just
below the core plugs or along the upper edge below
the cylinder head. A V-block will usually crack
near the hydraulic lifters or in the valley of the
block below the intake manifold.
The following procedures are designed to help
you prevent unnecessary engine damage during
winter storage.
To assure that the cooling system is completely
drained, adjust the trailer or cradle so that the front
of the engine is higher than the rear.
COOLING SYSTEM DRAINING
The cooling system must be properly drained for
storage during the winter months in areas where
temperatures fall below 32’ F (0’ C). If it is not, the
engine block may be cracked by expansion of
frozen water.
Standard Cooling System
(Inline Engines)
1. Place containers under manifold and engine
block drain points, if space permits. This will
prevent water from draining into the boat.
LAY-UP, COOLING SYSTEM SERVICE AND FITTING OUT
2. Open the drain valve on the port side of the
engine block and remove the exhaust manifold
drain plug. Remove exhaust elbow drain plug, if so
equipped. See Figure 7 for typical locations.
3 . If equipped with an exhaust elbow riser, remove
the drain plug from the front of the riser.
4. If equipped with power steering, remove the
drain plug from the lower-aft end of the power
steering oil cooler. See Figure 8.
5. Allow cooling system to completely drain, then
coat drain plug threads with Perfect Seal and
reinstall. Close engine block drain valve.
Closed Cooling System
(Inline Engines)
The fresh water section of a closed cooling
system need not be drained during winter months,
provided it is kept filled with a 50/50 solution of
pure soft water and ethylene glycol antifreeze.
However, the seawater section must be drained
completely.
08
89
Seawater section
(Except Models
60, 470, 485 and 488)
1. Place containers under drain points, if space
permits. This will prevent water from draining into
the boat.
2. Remove the exhaust manifold drain plug.
Remove the exhaust elbow drain plug, if so
equipped.
3. If equipped with an exhaust elbow riser, remove
the drain plug at the front of the riser.
4. If equipped with power steering, remove the
drain plug from the bottom of the power steering
oil cooler. See Figure 9.
5. Refer to Figure 10 and disconnect the sea water
inlet hose (A), remove the drain plug from the aft
end of the heat exchanger (B) and remove the zinc
electrode (C), if so equipped.
6. Examine zinc electrode (if so equipped) for
erosion. If it is less than 25 percent eroded, coat
electrode threads with Perfect Seal and reinstall. If
more than 25 percent of the electrode is gone,
install a new one.
7. Allow seawater section to completely drain, then
coat drain plug threads with Perfect Seal and
reinstall. Reconnect sea water inlet hose to heat
exchanger (A, Figure 10).
. POWER STEERING OIL COOLER DRAIN
(STANDARD COOLING SYSTEM)
90
09
010
CHAPTER FIVE
POWER STEERING OIL COOLER DRAIN
(CLOSED COOLING SYSTEM)
HEAT EXCHANGER
DRAIN LOCATIONS
A. Seawater inlet hose
B. Drain plug
C. Zinc electrode
D. Pressure cap
E. Circulating pump hose
LAY-UP, COOLING SYSTEM SERVICE AND FI’ITING OUT
Seawater section
(Model 60)
Refer to Figure 11 or Figure 12 for this
procedure.
1. Place containers under drain points, if possible.
This will prevent water from draining into the
boat.
2. Remove heat exchanger drain plug.
0 11
MERCRUISER 6 0
(STARBOARD SIDE)
0 12
MERCRUISER 60 (PORT SIDE)
91
3. Remove both drain plugs from the exhaust
manifold.
4. Disconnect hose at elbow fitting on bottom of
exhaust manifold.
5. Allow seawater section to completely drain, then
coat drain plug threads with Perfect Seal and
reinstall.
6. Reconnect hose to exhaust manifold elbow
fitting.
-
CHAPTER
92
Seawater section
(Models 470, 485 and 488)
Refer to Figure 13 (serial No. 4886619 and
below) or Figure 14 (serial No. 4886620 and above)
for this procedure.
1. Place containers under drain points, if space
permits. This will prevent water from draining into
the boat.
2. Remove the exhaust elbow drain plug and heat
exchanger seawater drain plug.
3. If equipped with an exhaust elbow riser, remove
the drain plug from the front of the riser.
4. On engines equipped with a water-cooled
voltage regulator (serial No. 4886620 and above),
disconnect the sea water inlet hose at the regulator.
5. If equipped with power steering, remove the
drain plug from the lower-aft end of the power
steering oil cooler. See Figure 8.
013
MODEL 470 DRAIN
(SERIAL NO. 4888818
6. Allow seawater section to completely drain, then
coat drain plug threads with Perfect Seal and
reinstall. Reconnect seawater inlet hose to
regulator.
Fresh water section
(except Models 60, 470, 485 and 488)
1. Place containers under drain points, if space
permits. This will prevent coolant from draining
into the boat.
2. Remove pressure fill cap from reservoir. See D,
Figure 10.
3. Open engine block drain valve on port side of
block. See Figure 7 for typical location.
LOCATIONS
AND BELOW)
A.
B.
C.
D.
E.
F.
0.
FIVE
Pressure fill cap Exhaust elbow drain plug
Exhaust manifold drain plug
Cylinder block drain plug
Fresh water drain plug
Seawater drain plug
Heat exchanger
LAYUP, COOLING SYSTEM SERVICE AND FITTING OUT
4. Disconnect the circulating pump-to-heat
exchanger hose (E, Figure 10) from the front of the
heat exchanger. Lower hose to let coolant drain.
5. Remove the coolant recovery hose (if so
equipped) from the mounting bracket. Drain the
coolant.
6. Allow fresh water section to completely drain,
then close the engine block drain valve. Reconnect
the circulating pump hose to the heat exchanger.
014
MODEL 470 DRAIN LOCATIONS
(SERIAL NO. 4888820 AND ABOVE)
93
Fresh water section
(Model 60)
Refer to Figure 11 and Figure 12 for this
procedure.
1. Place containers under drain points, if space
permits. This will prevent coolant from draining
into the boat.
2. Remove heat exchanger pressure cap.
3. Remove drain plugs from the engine block, heat
exchanger and 180 degree elbow fitting.
4. Allow fresh water section to completely drain,
then coat the drain plug threads with Perfect Seal
and reinstall.
5. Install the heat exchanger pressure cap.
Fresh water section
(Models 470, 485 and 488)
Refer to Figure 13 (serial No. 4886619 and
below) or Figure 14 (serial No. 4886620 and above)
for this procedure.
1. Place containers under drain points, if space
permits. This will prevent coolant from draining
into the boat.
2. Remove pressure fill cap from reservoir.
3. Remove heat exchanger, exhaust manifold and
engine block drain plugs.
4. Remove the circulating pump drain plug at the
bottom of the front cover. See Figure 15.
5. Remove the coolant recovery reservoir (if so
equipped) from the mounting bracket. Drain the
coolant.
\..r --3
6.
C.
D.
E.
F.
0.
H.
I.
Exhaust elbow drain plug
G
Exhaust manifold drain plug
Water-cooled voltage regulator
Cylinder block drain plug (hidden)
Seawater inlet hose
Fresh water drain plug
Seawater drain plug
Heat exchanger
H
iuv’
CHAPTER FIVE
94
6. Allow fresh water section to completely drain,
then coat drain plug threads with Perfect Seal and
reinstall.
Standard Cooling System
(V6 and V8 Engines)
016
DRAIN LOCATIONS (PORT SIDE)
.
Models 888, 255-S, 233,
898, 228,250 and260
Refer to Figure 16 and Figure 17 (Models 888,
25% and 233) or Figure 18 and Figure 19 (Models
898, 228, 250 and 260) for this procedure.
1. Place containers under drain points, if space
permits. This will prevent water from draining into
the boat.
2. Remove the exhaust manifold and elbow drain
plugs from both sides of the engine. Open the
engine block drain valve on each side of the engine.
3. If equipped with exhaust elbow risers under the
exhaust elbows, remove the drain plug from each
riser.
NOTE
C. Cylinder block petcock
[f power steering oil cooler has no drain plug,
remove hose A in Figure 18.
4A. Power steering-remove drain plug from
lower-aft end of power steering oil cooler. See B,
Figure 18.
4B. Non-power steering-disconnect water inlet
hose at thermostat housing. Lower hose to let water
drain from the lowest part.
5. Disconnect circulating pump hose at the pump
and lower the hose to drain the water.
6. Allow cooling system to completely drain, then
coat drain plug threads with Perfect Seal and
reinstall.
7. Close engine block drain valves and reconnect
hoses.
DRAIN LOCATIONS (STARBOARD SIDE)
Models 225II- TR, 255II- TR
(S/N 4175499 and below), 255II-TRS
Refer to Figure 19 and Figure 20 for this
procedure.
1. Place containers .under drain points, if space
permits. This will prevent water from draining into
the boat.
2. Remove the drain plug from each exhaust
manifold. Remove the port exhaust elbow drain
Ph3.
3. Open the engine block drain valves on each side
of the engine.
A.
8.
C.
D.
E.
Exhaust elbow drain plug (hidden)
Exhaust manifold drain plug
Thermostat housing water inlet hose
Cylinder block petcock (hidden)
Thermostat housing to circulating pump hose
017
LAYUP,
COOLING SYSTEM SERVICE AND FITTING OUT
4. Disconnect the circulating pump-to-heat
exchanger hose (E, Figure 10) from the front of the
heat exchanger. Lower hose to let coolant drain.
5. Remove the coolant recovery hose (if so
equipped) from the mounting bracket. Drain the
coolant.
6. Allow fresh water section to completely drain,
then close the engine block drain valve. Reconnect
the circulating pump hose to the heat exchanger.
01 4
MODEL 470 DRAIN LOCATIONS
(SERIAL NO. 4888820 AND ABOVE)
93
Fresh water section
(Model 60)
Refer to Figure 11 and Figure 12 for this
procedure.
1. Place containers under drain points, if space
permits. This will prevent coolant from draining
into the boat.
2. Remove heat exchanger pressure cap.
3. Remove drain plugs from the engine block, heat
exchanger and 180 degree elbow fitting.
4. Allow fresh water section to completely drain,
then coat the drain plug threads with Perfect Seal
and reinstall.
5. Install the heat exchanger pressure cap.
Fresh water section
(Models 470, 485 and 488)
Refer to Figure 13 (serial No. 4886619 and
below) or Figure 14 (serial No. 4886620 and above)
for this procedure.
1. Place containers under drain points, if space
permits. This will prevent coolant from draining
into the boat.
2. Remove pressure fill cap from reservoir.
3. Remove heat exchanger, exhaust manifold and
engine block drain plugs.
4. Remove the circulating pump drain plug at the
bottom of the front cover. See Figure 15.
5. Remove the coolant recovery reservoir (if so
equipped) from the mounting bracket. Drain the
coolant.
C.
D.
E.
F.
0.
H.
I.
Exhaust manifold drain plug
Water-cooled voltage regulator
Cylinder block drain plug (hidden)
Seawater inlet hose
Fresh water drain plug
Seawater drain plug
Heat exchanger
CHAPTER FIVE
94
6. Allow fresh water section to completely drain,
then coat drain plug threads with Perfect Seal and
reinstall.
Standard Cooling System
(V6 and V8 Engines)
016
DRAIN LOCATIONS (PORT SIDE)
.
Models 888, 255-S, 233,
898, 228, 250 and 260
Refer to Figure 16 and Figure 17 (Models 888,
25% and 233) or Figure 18 and Figure 19 (Models
898, 228, 250 and 260) for this procedure.
1. Place containers under drain points, if space
permits. This will prevent water from draining into
the boat.
2. Remove the exhaust manifold and elbow drain
plugs from both sides of the engine. Open the
engine block drain valve on each side of the engine.
3. If equipped with exhaust elbow risers under the
exhaust elbows, remove the drain plug from each
riser.
B. Exhaust manifold drain $ug
C. Cylinder block petcock
NOTE
Jf power steering oil cooler has no drain plug,
remove hose A in Figure 18.
4A. Power steering-remove drain plug from
lower-aft end of power steering oil cooler. See B,
Figure 18.
4B. Non-power steering-disconnect water inlet
hose at thermostat housing. Lower hose to let water
drain from the lowest part.
5. Disconnect circulating pump hose at the pump
and lower the hose to drain the water.
6. Allow cooling system to completely drain, then
coat drain plug threads with Perfect Seal and
reinstall.
7. Close engine block drain valves and reconnect
hoses.
DRAIN LOCATIONS (STARBOARD SIDE)
Models 225II- TR, 255II- TR
(S/N 4175499 and below), 255II-TRS
Refer to Figure 19 and Figure 20 for this
procedure.
1. Place containers .under drain points, if space
permits. This will prevent water from draining into
the boat.
2. Remove the drain plug from each exhaust
manifold. Remove the port exhaust elbow drain
plug.
3. Open the engine block drain valves on each side
of the engine.
A.
B.
C.
D.
E.
Exhaust elbow drain plug (hidden)
Exhaust manifold drain plug
Thermostat housing water inlet hose
Cylinder block petcock (hidden)
Thermostat housing to circulating pump hose
017
LAY-UP, COOLING SYSTEM SERVICE AND FI’lTING OUT
POWER STEERING OIL COOLER
95
020
MODELS 225ll=TR, 255lbTR
(SERIAL NO. 4175499 AND BELOW)
AND 255IbTRS DRAIN LOCATION
(STARBOARD SIDE)
A. Hose
8. Drain plug
019
MODELS 225ll=TR, ?SSII=TR
(SERIAL NO. 4175499 AND BELOW)
AND 255ll-TRS DRAIN
LOCATIONS (PORT SIDE)
; .- . .
IN A. Exhaust elbow drain plu<
8. Exhaust manifold drain plug
C. Cylinder block petcock
A. Exhaust elbow
8. Exhaust manifold drain plug
C. Thermostat housing to circulating pump hose
D. Seawater pickup pump
E. Cylinder biock drain petcock (hidden)
F. Power steering oil cooler drain plug
0. Transmission oil cooler
H. Transmission oil cooler outlet hose
4. If equipped with exhaust elbow risers under the
exhaust elbows, remove the drain plug from each.
5. Disconnect the circulating pump hose at the
pump and lower to let the water drain.
6. If equipped with power steering, remove drain
plug from lower-aft end of power steering oil
cooler.
7. Disconnect inlet hose at aft end of sea water
pickup pump. If engine is not equipped with power
steering, also disconnect the pump outlet hose.
8. Disconnect the coil secondary lead from the
center distributor tower and ground it to the engine
block.
9. Crank engine over to purge any water remaining
in the seawater pickup pump.
10. Remove outlet hose from transmission oil
cooler fitting on starboard exhaust elbow. Lower
96
C H A P T E R FIVE
hose below transmission to drain water from the
oil cooler.
021
CA UTION
If freezing weather is anticipated during lay-up,
Jill transmission oil cooler with antifreeze
through the outlet hose until it appears at the
power steering oil cooler drain (power steering
models) or seawater pickup pump outlet
(non-power steering models). Reconnect hose.
MODELS 228ll=TR, 255ll=TR
(SERIAL NO. 4175100 AND ABOVE),
280ll=TRS, 330ll-TR AND
330ll-TRS DRAIN LOCATIONS
11. After cooling system has completely drained,
coat drain plug threads with Perfect Seal and
reinstall plugs.
12. Close engine block drain valves, reconnect all
hoses and reinstall coil secondary lead.
Models 228II- TR, 255II- TR
(serial No. 4175500 and above),
28OII- TRS, 33OII- TR and 33OII- TRS
Refer to Figure 21 and Figure 22 for this
procedure.
1. Place containers under drain points, if space
permits. This will prevent water from draining into
the boat.
2. Remove the drain plug from each exhaust
manifold. Remove the port exhaust elbow drain
plug, if so equipped.
3. Open the engine block drain valves on each side
of the engine.
4. Model 25511-TR and 28011-TRS engines with
water distribution blocks-remove drain plug from
each distribution block (located under exhaust
elbows). See Figure 23.
5. If equipped with exhaust elbow risers, remove
the drain plug from each riser.
6. Disconnect the circulating pump hose at the
pump and drain the hose of water.
7. If equipped with power steering, remove drain
plug from lower-aft end of power steering oil
cooler. Late model oil coolers have no drain plug;
the cooler is drained in Step 8.
8. Disconnect the inlet/outlet hoses from the aft
end of the sea water pickup pump.
9. Disconnect the coil secondary lead from the
center distributor tower and ground it to the engine
block.
10. Crank engine over to purge any water
remaining in the sea water pickup pump.
11. Remove outlet hose from transmission oil
cooler fitting on starboard exhaust elbow. Lower
4. Exhaust elbow drainpitig ’
3. Exhaust manifold drain plug,
Z. Cylinder block drain petcock (hidden)
022
MODELS 228ll=TR, 25Sll=TR
(SERIAL NO. 4175500 AND ABOVE),
280ll=TRS, 330lbTR AND 330ll-TRS
DRAIN LOCATIONS (STARBOARD SIDE)
4.
3.
:.
I.
5.
:.
3.
Exhaust elbow drain plug (hidden)
Exhaust manifold drain plug
Power steering oil cooler drain plug
Transmission oil cooler outlet hose
Cylinder block drain petcock
Seawater pickup pump
Thermostat housing to circulating pump hose
LAY-UP. COOLING SYSTEM SERVICE AND FITTING OUT
97
hose below transmission to drain water from the
oil cooler.
CA UTIOA’
If freezing weather is anticipated during lay-up,
fill transmission oil cooler with antifreeze
through the outlet hose until it appears at the
power steering oil cooler drain (power steering
models) or seawater pickup pump outlet
(non-power steering models). Reconnect hose.
12. After cooling system has completely drained,
coat drain plug threads with Perfect Seal and
reinstall plugs.
13. Close engine block drain valves, reconnect all
hoses and reinstall coil secondary lead.
WATER DISTRIBUTION ’ BLOCK DRAIN PLUG
Closed Cooling System (V6 and VS Engines)
02 4
HEAT EXCHANGER DRAIN LOCATIONS
-._
?
A. Pressure%11 cap
0. Heat exchanger to circulating pump hose
C. Seawater drain plug
D. Zinc electrode (if so equipped)
The fresh water section of a closed cooling
system need not be drained during winter months,
provided it is kept filled with a 50/50 solution of
pure soft water and ethylene glycol antifreeze.
However, the seawater section must be drained
completely.
Seawater section
(Models 888, 255S and 233)
1. Place containers under drain points, if space
permits. This will prevent water from draining into
the boat.
2. Remove both exhaust elbow drain plugs.
3. If equipped with exhaust elbow risers, remove
the drain plug at the front of each riser.
4. If equipped with power steering, remove the
drain plug from the bottom of the power steering
oil cooler. See Figure 18. On late models without a
drain plug, the oil cooler is drained during Step 7.
5. Refer to Figure 24 and remove the drain plug
(C) from the bottom of the heat exchanger.
Remove the zinc electrode (D), if so equipped.
6. Examine zinc electrode (if so equipped) for
erosion. If it is less than 25 percent eroded, coat
electrode threads with Perfect Seal and reinstall. If
more than 25 percent of the electrode is gone,
install a new one.
7. Disconnect inlet hose from aft end of seawater
pickup pump. If equipped with power steering but
-
CHAPTER FIVE
98
no oil cooler drain plug, also disconnect the pump
outlet hose. See Figure 25.
8. Disconnect the coil secondary lead from the
center distributor tower and ground it to the engine
block.
9. Crank engine over to purge any water remaining
in the seawater pickup pump.
10. Allow seawater section to completely drain,
then coat drain plug threads with Perfect Seal and
reinstall plugs.
11. Close engine block drain valves, reconnect all
hoses and reinstall coil secondary lead.
025
seawater section
(Models 898, 228, 250 and 260)
Refer to Figure 26 and Figure 27 for this
procedure.
1. Place containers under drain points, if space
permits. This will prevent water from draining into
the boat.
2. Remove both exhaust elbow drain plugs.
3. If equipped with water distribution blocks
under exhaust elbows, remove drain plug from
each block. See Figure 28.
4. If equipped with exhaust elbow risers, remove
the drain plug at the front of each riser.
5. Remove the heat exchanger drain plug.
6. If equipped with power steering, remove the
drain plug from the bottom of the power steering
oil cooler. See Figure 18. On late models without a
drain plug, the oil cooler is drained during Step 7.
7. Disconnect inlet/outlet hoses from the aft end of
the seawater pump. Be sure to reconnect hoses to
their proper fitting.
8. Disconnect the coil secondary lead from the
center distributor tower and ground it to the engine
block.
9. Crank engine over to purge any water remaining
in the seawater pickup pump.
10. Allow seawater section to completely drain,
then coat drain plug threads with Perfect Seal and
reinstall plugs.
11. Close engine block drain valves, reconnect all
hoses and reinstall coil secondary lead.
Models 225II- TR, 255II- TR
(serial No. 4175499 and below and 255II-TRS)
1. Place containers under drain points, if space
permits. This will prevent water from draining into
the boat.
A. Outlet hose
B. Inlet (hose shown disconnected)
C. Seawater pickup pump
A. Exhaust elbow drain plug
B. Exhaust manifold drain plug
C. Cylinder block drain petcock
MODELS 898,228,2SO
AND 280 ENGINE DRAIN LOCATIONS
(STANDARD COOLING SYSTEM,
PORT SIDE)
LAY-UP, COOLING SYSTEM SERVICE AND FI’ITING OUT
0 280
27 MODELS 888,228,250 AND
ENGINE DRAIN LOCATIONS
(STANDARD COOLINQ SYSTEM,
STARBOARD SIDE)
A.
B.
C.
D.
E.
Exhaust elbow drain plug (hidden)
Exhaust manifold drain plug
Thermostat housing inlet hose
Thermostat housing to circulating pump hose
Cylinder block drain petcock
0
28
?=PASSAGE DISTRIBUTION
BLOCK DRAIN LOCATIONS
A. Water distribution block
B. Drain plug
029
HEAT EXCHANGER DRAIN LOCATIONS
A.
B.
C.
D.
Pressure fill cap
Heat exchanger to circulating pump hose
Seawater drain plug
Zinc electrode (if so equipped)
2. Remove exhaust elbow drain plug.
3. If equipped with exhaust elbow risers, remove
the drain plug at the front of each riser.
4. If equipped with power steering, remove the
drain plug from the bottom of the power steering
oil cooler. See Figure 18. On late models without a
drain plug, the oil cooler is drained during Step 7.
5. Remove the drain plug from the bottom of the
heat exchanger.
6. Refer to Figure 29 and remove the zinc
electrode (D), if so equipped. Examine zinc
electrode for erosion. If it is less than 25 percent
eroded, coat electrode threads with Perfect Seal and
reinstall. If more than 25 percent of the electrode is
gone, install a new one.
7. Disconnect inlet hose from aft end of seawater
pickup pump. If equipped with power steering but
no oil cooler drain plug, also disconnect the pump
outlet hose. See Figure 25.
8. Disconnect the coil secondary lead from the
center distributor tower and ground it to the engine
block.
9. Crank engine over to purge any water remaining
in the seawater pickup pump.
10. Remove outlet hose from transmission oil
cooler fitting on starboard exhaust elbow. Lower
CHAPTER FIVE
100
hose below transmission to drain seawater from the
oil cooler.
CAUTION
If freezing weather is anticipated during lay-up,
fill transmission oil cooler with antifreeze
through the outlet hose until it appears at the
power steering oil cooler drain (power steering
models) or seawater pickup pump outlet
(non-power steering models). Reconnect hose.
11. Allow seawater section to completely drain,
then coat drain plug threads with Perfect Seal and
reinstall plugs.
12. Reconnect all hoses and reinstall coil
secondary lead.
Seawater section
(Models 228II- TR, 255II-TR
serial No. 4175500 and above,
28OII- TRS, 33OII- TR and 33OII- TRS)
1. Place containers under drain points, if space
permits. This will prevent water from draining into
the boat.
NOTE
Older Model 255II- TR and 28OII- TRS engines
do not have an exhaust elbow drain plug.
2. Remove port exhaust elbow drain plug, if so
equipped.
3. Remove drain plugs from aft end of both
distribution blocks. See Figure 28.
4. If equipped with exhaust elbow risers, remove
the drain plug at the front of each riser.
5. If equipped with power steering, remove the
drain plug from the bottom of the power steering
oil cooler. See Figure 18. On late models without a
drain plug, the oil cooler is drained during Step 8.
6. Remove the drain plug from the bottom of the
heat exchanger.
7. Refer to Figure 29 and remove the zinc
electrode (D), if so equipped. Examine zinc
electrode for erosion. If it is less than 25 percent
eroded, coat electrode threads with Perfect Seal and
reinstall. If more than 25 percent of the electrode is
gone, install a new one.
8. Disconnect inlet hose from aft end of seawater
pickup pump. If equipped with power steering but
no oil cooler drain plug, also disconnect the pump
outlet hose. See Figure 25.
9. Disconnect the coil secondary lead from the
center distributor tower and ground it to the engine
block.
10. Crank engine over to purge any water
remaining in the seawater pickup pump.
11. Remove outlet hose from transmission oil
cooler fitting on starboard exhaust elbow. Lower
hose below transmission to drain seawater from the
oil cooler.
CAUTION
If freezing weather is anticipated during lay-up,
fill transmission oil cooler with antgreeze
through the outlet hose until it appears at the
power steering oil cooler drain (power steering
models) or seawater pickup pump outlet
(non-power steering models). Reconnect hose.
1 2 . Allow seawater section to completely drain,
then coat drain plug threads with Perfect Seal and
reinstall plugs.
13. Reconnect all hoses and reinstall coil
secondary lead.
Fresh water section
(all V-8 engines)
Refer to Figure 16 and Figure 17 for Models 888,
2553, 233, 898, 228, 250 and 260. Refer to Figure
19 and Figure 20 for Models 22511-TR, 25511-TR
(serial No. 4175499 and below) and 25511-TRS.
Refer to Figure 21 and Figure 22 for Models
22811-TR, 25511-TR (serial No. 4175500 and
above), 28011-TRS, 33011-TR and 33011-TRS.
LAY-UP, COOLING SYSTEM SERVICE AND FITTING OUT
101
COOLING SYSTEM FILLING
In Preparation For Storage
Under normal circumstances, the fresh water
section of a closed cooling system would not be
drained until just before the boat is to be returned
to service from winter storage. The procedures that
follow pertain to standard cooling systems and are
designed to provide additional protection against
freeze damage during winter temperatures.
CAUTION
Do not run the engine after performing the
storage cooling service procedures that follow.
Before returning the boat to service, drain the
coolant as described in this chapter and tighten
all fasteners and clamps to specifications.
Mine engines
1. Remove the water distribution block cover
(Figure 30, typical).
2. Remove the thermostat and gasket. Discard the
gasket.
3. Disconnect the hose at the manifold front end
cap (Figure 31, typical).
4. Pour a 50/50 solution of pure soft water and
ethylene glycol antifreeze into the water
distribution block until the cylinder head, block
and manifold are full.
5. Reinstall thermostat with a new gasket. Tighten
water distribution block cover securely (Figure 30).
6. Install the hose to the manifold front end cap
(Figure 31).
1. Place containers under drain points, if possible.
This prevents coolant from draining into the boat.
2. Remove the pressure fill cap from the heat
exchanger reservoir. See Figure 24.
3. Remove exhaust manifold drain plugs and open
drain valves on both sides of the engine.
4. Disconnect the circulating pump hose at the
pump and drain the water in it.
5. Remove the coolant recovery reservoir (if so
equipped) from its mounting bracket. Drain
reservoir.
6. Allow fresh water section to completely drain,
then coat drain plug threads with Perfect Seal and
reinstall plugs.
7. Close engine block drain valves and reconnect
pump hose.
V6 and V8 engines
1. Loosen the hose clamps at the front manifold
end caps. See A, Figure 32 (typical) for GM engines
and Figure 33 (typical) for Ford engines. Remove
hoses from end caps.
2. Remove thermostat housing cover. See B,
Figure 32 (typical) for GM engines and Figure 34
(typical) for Ford engines.
3. Remove thermostat and gasket. Discard the
gasket.
4. Pour a 50/50 solution of pure soft water and
ethylene glycol antifreeze into the thermostat
housing until it is full.
5. Pour the coolant solution into the opening of
each manifold end cap until the level reaches the
top of the cap.
s
CHAPTER FIVE
102
6. Install the thermostat with a new gasket.
Tighten the thermostat housing cover screws
snugly (B, Figure 32 or Figure 34, typical).
7. Connect the hoses to the front manifold end
caps and snug down the clamps (A, Figure 32 or
Figure 33, typical).
Returning Engine to Service
Most ethylene glycol antifreeze solutions used in
closed cooling systems tend to become corrosive to
aluminum after approximately 3 years of use or if a
blown head gasket allows exhaust gases to enter the
cooling system. While such corrosive tendencies
will not cause significant damage to the engine,
they do produce loose particles that can eventually
plug the coolant side of the heat exchanger.
The increasing usage of aluminum components
in engines, water pumps, manifolds and radiators
has led to the development of an antifreeze formula
recommended for use with aluminum engines.
Mercury Marine recommends that this new type
antifreeze formulation be used in all Met-Cruiser
closed cooling systems. Check the antifreeze
container to see if it meets one of the major
specifications,
such as Ford
automakers’
specification ESE-M97B44-A or GM specification
1825M.
1. Remove the pressure fill cap from the reservoir
or heat exchanger.
2. Fill the fresh water section with a 50/50 mixture
of pure soft water and ethylene glycol antifreeze
until the fluid level reaches the top of the filler
neck.
CAUTION
Water must flow through seawater pump in Step
3 or possible damage to the pump and engine
may result.
3. Start the engine and run at fast idle (l,OOO- 1,500
rpm), adding coolant to the reservoir or heat
exchanger as necessary to maintain the coolant
level at the top of the filler neck. When engine
reaches normal operating temperature and coolant
level remains constant, reinstall pressure fill cap.
4. If equipped with a coolant recovery system,
remove the reservoir cap and fill with coolant to
the “FULL” mark on the reservoir.
5. Check for leaks while the engine is running and
note the position of the engine temperature
gauge-it should be normal.
WARNING
Do not remove the pressure Jill cap when the
engine is warm or hot. You may be seriously
scalded or burned by coolant escaping under
pressure.
6. Shut engine off and allow to cool for 30 minutes.
Turn pressure fill cap to first detent and allow any
pressure to escape, then remove the cap.
7. Recheck the coolant level in the reservoir or
heat exchanger and add coolant as required to
bring the level to the top of the filler neck.
8. If equipped with a coolant recovery system, add
coolant as required to bring the reservoir level to a
LAY-UP, COOLING SYSTEM SERVICE AND FI’lTING OUT
point between the “ADD” and “FULL” marks
when the engine is at normal operating
temperature.
FITTING
OUT
Preparing the boat for use after storage is
relatively easy if the engine and stem drive unit
were properly prepared before storage. The
following suggestions for fitting out are based on
recommendations made by Mercury Marine.
1. Clean the engine and stem drive unit with a
solvent such as kerosene to remove accumulated
dirt and preservative oil. Retouch any paint
blemishes.
NOTE
If the boat is to be left in the water for an
extended period, it may be advisable to cover the
underwater surfaces, including the stern drive
unit, with an antifouling paint. Do not use a
paint containing copper or mercury, as these
elements may hasten galvanic corrosion
damage.
2. Remove protective covers installed on flame
arrestor, carburetor, exhaust outlets and fuel tank
ventilators.
3. Drain antifreeze from standard cooling systems,
if installed.
4. Make sure that all drain valves and plugs are
tightly closed and that all cooling system hoses are
securely clamped in place.
5. Inspect all hoses for cracks, weak walls and
leaks. Replace any that appear questionable.
6. Check all through-hull fittings for leaks and
proper valve operation.
7. Remove, clean and install flame arrestor.
8. Check fuel system. Refill tanks if they were
drained. Turn the fuel shut-off valve(s) on and
check all fuel lines for leaks.
Quicksilver
Quicksilver
Quicksilver
Quicksilver
Quicksilver
Quicksilver
Quicksilver
9. Check battery electrolyte level and fill if
necessary. Make certain battery has a full charge.
Clean battery terminals and lightly lubricate with
petroleum jelly. Install battery, making certain
cables are connected with proper polarity. Cover
battery terminals with a light coat of petroleum
jelly.
10. Drain preservative oil from stem drive unit.
^
Refill with oil of the proper viscosity and grade. See :‘i:, :0c$cS
,..,, : ’
Chapter Four.
Il. Check oil level in crankcase. Add oil if V ”
necessary. If oil was not changed at time of lay-up
or if engine has been in storage for an extended
period, change the oil and oil filter.
12. Check power steering and power trim pump oil
levels and top up, if necessary.
13. Readjust drive belt tension.
14. Make a thorough check of the boat, engine and
stem drive unit for loose or missing nuts, bolts and
screws. Pay particular attention to the stem drive
transom connection. Tighten, replace or take such
other corrective actions as may be necessary,
15. Examine sacrificial zinc elements, if present,
and replace if more than 25 percent eroded.
16. Remove distributor cap and examine
distributor breaker points (if so equipped). Replace
points if any wear is evident. If old points are to be
reused, clean thoroughly with alcohol or acetone to
remove all traces of oil. Install and set points using
a dwell meter. Clean and install distributor cap. See
Chapter Four.
17. Provide a source of water for engine cooling.
Make certain a Coast Guard-approved fire
extinguisher is handy, then start engine. Allow
engine to warm up, making certain that water is
circulating properly and the engine does not
overheat.
18. Proceed with engine tune-up. See Chapter Four
for instructions and specifications.
Part No.
Type
4-cycle Engine Oil Supplement
4-cycle Storage Seal
Rust and Corrosion Preventive
Multipurpose Lubricant
Universal Joint Lubricant
Anti-corrosion Grease
Perfect Seal
103
C-92-78372-l 2
C-92-54778
C-92-83280
C-92-83250
C-92-58299
C-92-83290
c-92-34227