Mercruiser Service Bulletins

Bulletins are listed by the date and sequence of when they
were written.

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1988 Mercruiser Service Bulletins
Torquing Bravo One U-Joint
Piston Knock in MCM 224
Replacement starter motor P/N 50-12872 for Mer-Cruiser
Loose Hinge Pins – Bravo
Overrich Acceleration “Bog”
on MerCarb Equipped Models MCM 120/140/2.5L/3.0L
Possible Water Leak in Transom Assembly
Diesel Bravo Two/lnboard Engine Packages
Power Trim Control P/N 55642A13 Assembled Wrong
Alpha One and Bravo One
Upper Swivel Shaft Bushing Removal Tools a
Tilt Steering Wheel Mount
MerCruiser 215E Shift
Required Spark Plug Wire
Laser II Propeller Vent Plug
Possible Water Leak Caused by TR/TRS Transom Cutout
MerCarb Flooding / Hurth Transmission Fluid
New Distributor Gear / 454 Magnum (365 HP) Rocker arms
Alpha One Shift Assist
Assembly and Remote Control Shift
Cable Adjustment


1989 Mercruiser Service Bulletins
1988/89 MerCruiser/Sea Ray Engine Identification GM Engine Models
B.M.W. D190/D150 Models Overheating
MerCruiser Diesel Injector & Pump Diagnosis
MR and Alpha One Shift Cable Adjustment
Use of Proper Anti-Freeze in Diesels
Engine Timing Changes MIE 5.7 / 420 & 575
Water Separating Fuel Filter
HEI Distributor Shaft Roll Pin Oversized hole
Carter Fuel Pump Use on 7.4 / New Prestolite Alternator
Hinge Pin Torque Change
120R-MR - 260R-MR and All Alpha Ones
Shift Spool Assembly All
Digital Distributorless Ignition
Wiring Harness Changes All
Hurth Transmission Tool List
MerCruiser Diesel Service
Bosch Diesel Nozzle Tester
1988 vs. 1989 Bravo Drive
Unit and Transom Assembly Interchangeability
Rattling Sound on MIE 7.4L
Paint Blistering on Oyster
Installation of Dual Engine Console Mount Commander Remote Controls
B.M.W. Stern Drive/Inboards
New Heavy Duty Gears in
1.50:1 Alpha One Upper
Drive Shaft Housing Assembly
Near Net Forged Forward and Pinion Gears in 350
Magnum Alpha One Lower Unit
MCM and MIE 7.4L (454 CID) Cylinder Head Bolts
Selecting A Propeller For Diesel
Bravo Transom Plate Oil Hose
Starting Procedure if Gasoline Engine is Shut-Off
or Stops with the Bravo Drive Unit in Gear
MerCarb Flooding
Alpha One Transom Shift
Attachment of Gear Lube Monitor
Installation of Stop-Start Panel STOP-START PANEL
MerCruiser Diesel Service Manuals
4.3LX and 5.7L Choke Rod
Solid State DC Voltage Regulators
Fuel Recommendations
224 C.I.D. Engine Push Rod
Elimination of Water Drain Petcocks
Alpha One - Bravo One and Bravo Two Trim Sender
Indexing Marks Misaligned
Water Ingestion on MerCruiser V6/V8 Stern Drive
and Inboard Engines


1990 Mercruiser Service Bulletins
USA and Canada Gasoline
Merc Carbs Having Incorrect Choke
Alpha One Bell Housing Shift
Borg Warner Velvet Drive
Removal of Upper Swivel Pin
Shift Plate Inspection
Spark Plug Wire Terminal and Boot Change
Rough Idle or Can’t Adjust Idle Mixture Screws
Diesel Engine Idle RPM
Incorrect Engine Maximum RPM on Serial Number Plate
Wrong Diameter Water Hose Being Connected
Use of Propylene Glycol Antifreeze
OIL LEAK AT FRONT OF ENGINE
Possible Cause for Engine Overheating
Delco EST Ignition System
Timing and Maximum RPM Changes
REPLACEMENT OF GIMBAL HOUSING STUDS
JUST BELOW THE INNER TRANSOM PLATE ENGINE SUPPORTS ON
ALPHA ONE GENERATION II TRANSOM ASSEMBLY
31-35988A12 Bearing Set
POSSIBLE DIFFICULTY SHIFTING OUT OF GEAR
ON BRAVO DRIVE 1.36:1 AND 1.81:1


1991 Mercruiser Service Bulletins
NEW BATTERY AND BATTERY CABLE REQUIREMENTS FOR MERCRUISER PRODUCTS
ENGINE SPECIFICATION CORRECTIONS IN #9 MANUAL
MCM 502 Magnum Specs
815471A3 BRAVO SHIFT CABLE REPLACEMENT KIT
SEAWATER/FUEL PUMP MAINTENANCE
MCM 7.4L Bravo, MIE 7.4L Specs
NEW ENGINE BREAK-IN PROCEDURE FOR DIESEL ENGINES
MCM 350 Magnum Alpha, and Bravo Specs
OIL LEAKING FROM WATER PICKUP HOLES IN GEAR HOUSING ON ALPHA ONE GENERATION II DRIVE
STARTER RELAY “CHATTER” ON DIESEL ENGINES
WARRANTY FRAUD/ Super Chargers
PRIMING 4-CYCLE ENGINES WITH OIL
REPLACEMENT TRIM PUMP FOR THE PRESTOLITE STYLE PUMP
Alpha One Generation II Tool List
MCM 454 Magnum Bravo
MCM 4.3L, 4.3LX Alpha
MERCRUISER INSTRUCTIONAL VIDEO TAPES
ANODE MATERIAL CHANGE
BRAVO DRIVE UNIT/HOUSING COMPARISON AND IDENTIFICATION
DRIVE UNIT GEAR RATIO IDENTIFICATION
ALPHA ONE VERSUS ALPHA ONE GENERATION II UPPER DRIVE SHAFT
USE OF PRIORITY VALVE KIT FOR DUAL POWER STEERING ON 3.0 L AND 3.0 LX
ALPHA ONE/MCI 1990 AND PRIOR, LOWER DRIVE SHAFT
NEW OIL SEAL BUSHING FOR BELL HOUSING
BRAVO CONE CLUTCH
Required Water Separating Fuel Filter Replacement
REQUIRED WATER SEPARATING FUEL FILTER REPLACEMENT


1992 Mercruiser Service Bulletins
224 CID (3.7L) PISTON IDENTIFICATION, TYPE AND CLEARANCE
TRIM PUMP 110 AMP FUSE
BRAVO LOWER GEAR HOUSING PINION NUT
NEW TRIM CYLINDER SPANNER WRENCH TOOL 91-821709
REQUIRED WARNING DECAL INSTALLATION
SEAWATER/FUEL PUMP HOSE CONNECTIONS
ENGINE RPM “HUNTS” AT IDLE SPEED
ENGINE ALIGNMENT TOOL MODIFICATION
REQUIRED DISTRIBUTOR CAP GASKET INSTALLATION
TESTING THUNDERBOLT IV HEI IGNITION SYSTEM
NEW TRIM LIMIT SWITCH AND TRIM SENDER KIT
LEAKAGE BETWEEN EXHAUST PIPE AND GIMBAL HOUSING ASSEMBLY
MCM 502 Magnum/MIE 8.2L
REQUIRED ELECTRIC FUEL PUMP RFI FILTER REPLACEMENT
MCM 5.7L Alpha, MIE 5.7L Inboard and 5.7L Competition Ski Engines
ADDITIONAL IGNITION SYSTEM ADVANCE CURVE SPECIFICATIONS
WEBER CARBURETOR ADJUSTABLE ACCELERATOR PUMP
TORSIONAL (CRANKSHAFT) DAMPER BOLT TORQUE CHANGE
V6/V8 THERMOSTAT HOUSING CHANGE


1993 Mercruiser Service Bulletin
MCM 7.4L Bravo Three GM Generation V Engine
A. VAPOR SEPARATOR TANK (VST) RECALL
B. ELECTRIC CONTROL MODULE (ECM) RECALL
UNIVERSAL JOINT CROSS & BEARING CUP SEAL
REQUIRED FLAME ARRESTOR REPLACEMENT
REQUIRED FUEL PUMP PUSH ROD REPLACEMENT
ADD WATER INLET HOSE CLAMP
ALTERNATE GEAR RATIO STERN DRIVE UNITS FOR HIGH ALTITUDE
224 CID (3.7L) MINIMUM OIL PRESSURE
NEW REVERSE GEAR 43-824109 AND THRUST SPACER 23-824108
BRAVO SHIMMING PROCEDURE CHANGE FOR THE GEAR CASE BEARING CARRIER
REQUIRED STARBOARD ENGINE MOUNT BOLT REPLACEMENT
REQUIRED FUEL INLET FITTING REPLACEMENT ON WEBER CARBURETOR
ROCHESTER 4 BBL QUADRAJET CARBURETOR
EXHAUST BELLOWS FALLING OFF
224 CID (3.7L) EXHAUST ELBOW/RESERVOIR TORQUE AND RETORQUE
V6 AND V8 THERMOSTAT HOUSINGS
Blackhawk Drive Applications
Service/Repair Of Electrical Test Equipment
POSSIBLE WATER LEAKAGE PAST TRANSOM MOUNTING STUDS ON ALPHA AND BRAVO TRANSOM ASSEMBLIES.
Stern Drive Setback System
MERCRUISER EFI TESTER
BRAVO THREE BEARING CARRIER OIL SEALS
MCM 454 Magnum EFI, MIE 454 EFI Ski GM Gen V 454 Magnum 454 EFI
REQUIRED EFI VST FUEL FILTER REPLACEMENT
ENGINE CONTROL MODULE (ECM) RECALL
DHB Power Steering Valve (806034A1)
MCM 350 EFI Magnum
INCORRECT ANEROID ADJUSTMENT


1994 Mercruiser Service Bulletins
BRAVO TRIM IN LIMIT SPACER KITS
THUNDERBOLT V IGNITION SYSTEM
A. CYLINDER HEAD BOLT CHANGE
B. CYLINDER HEAD TORQUE SEQUENCE CHANGE
C. THRU-HULL WATER PICK UP ELIMINATED ON MCM D4.2L
GASOLINE RECOMMENDATION FOR ALL MERCRUISER MODELS
Drive Unit Trim Tab / New Anodic Plate
DHB POWER STEERING CONTROL VALVE
STERN DRIVE – REAR ENGINE MOUNT BOLT TORQUE
REQUIRED FUEL INJECTOR “POD” AND ECM REPLACEMENT
BATTERY REQUIREMENTS FOR MERCRUISER PRODUCTS
REQUIRED ENGINE GROUNDING STUD REPLACEMENT
SEAWATER HOSE / POWER STEERING LINE INTERFERENCE
EFI GASOLINE RECOMMENDATION CHANGES NUMBER 1 and 2
Universal-Joint & Gimbal Bearing Grease
WIRING MODIFICATION Diesel Engines
REQUIRED ENGINE FUEL FILTER REPLACEMENT
BRAVO THREE TRIM “IN” LIMIT BLOCKS
OPERATION AND MAINTENANCE MANUALS FOR BODENSEE EMISSIONS MODELS


1995 Mercruiser Service Bulletins
ALPHA ONE GENERATION II UPPER GEARS
OILDYNE TRIM PUMP ADAPTOR CONNECTORS
MCM 3.0L, LX Starter Motor Bolt Breakage
Hino Diesel - Excessive Black Smoke Emission
MerCruiser GM Engine Identification
OilDyne Trim Pump Trouble Shooting Chart
Reformulated Gasoline (USA)
Mercruiser Steering Recommendations
Diesel Fuel Filters and Fuel Additives
MerCruiser MCM D7.3L/270 Diesel Stern Drive Replacement
Ignition Advance Curves and Point Setting
Engine Compartment Temperature
Alpha One Generation II Over Heat
Cooling Systems Maintenance
MerCruiser MCM D7.3L Diesel Overheat
Low Sulfur Diesel Fuels
Engine Noise or Noisy Lifters
Hino Diesel-Excessive Black Smoke
Turbo Charger Waste-Gate
Bearing Cup Installation In The Bravo One Bearing Carrier
Shrink Wrapping Boats
Velvet Drive Distributors
Hurth Marine Gear Distributors


1996 Mercruiser Service Bulletins
Bravo Transom Assemblies for the 1996-1/2 Model Year
Water In Fuel Module (WIF) Warning Light
Serpentine Belt Adjustment
Quicksilver Digital Diagnostic Terminal (DDT)
Troubleshooting Shift Problems
Modifying MerCruiser Engines To Increase Performance Or Horsepower
Modifying MerCruiser’s Exhaust System
Brass Power Steering Hose Coupling
MerCruiser Scan Tool
Piston Ring End Gap
Hurth Transmissions
Changes To The 1997 Operation And Maintenance Manuals
Commander 3000 Remote Control Recall
Aftercooler Torque Specifications
Required ECM Replacement
Hurth V-Drive Output Flange Torque


1997 Mercruiser Service Bulletins
Torquing Intake Manifold on Gen+ Engines
MerCruiser MCM/MIE Inline Diesel Heat Exchanger End Cover Torque
Required Flame Arrestor Replacement
MCI /Alpha One / Alpha One Generation II Gear Case and Bearing Bore Differences
Multiple EFI Engine Battery Precautions
MerCruiser GM Engine Identification
Bravo Drives and Transoms
MerCarb 2 bbl Carburetor
Weber 4 bbl Carburetor
Alternate Gear Ratio Sterndrive Units for High Altitude
AC Spark Plug Replacement
Battery and Battery Cable Requirements for MerCruiser D-tronic Diesels
Service/Repair Of Electrical Test Equipment
Engine Specification Model: 1998 MCM 5.0L Alpha and Bravo.
Timing 1998 350 Mag MPI and 7.4L MPI Models
Engine Specifications Model: 1998 MCM/MIE D-Tronic D4.2L
Engine ‘Dieseling’ or ‘Running-On’
1997 1/2 Shift Changes for Bravo One / Two / Three and BlackHawk
Extended Life Coolant (Antifreeze) In Gasoline Engines
EFI and MPI Fuel Line Replacement
Required ECM Replacement
Engine Oil Level - D2.8L D-Tronic
MerCruiser Gasoline Engine Oil Recommendation
Heat Transfer Compound
Fuel Pressure Gauge Kit
Gasoline Engine Compression Test


1998 Mercruiser Service Bulletins
MCM 3.0L Flame Arrestor Decal
Operating a Bravo One Performance Drive with Low Water Inlets in shal-low water
Regulator Piston for Velvet Drive Transmissions
Electric Fuel Pump Check Valve Sticking
USA Gasoline Additive Causing Fuel System Component Problems
7.4L (L29) Exhaust Valve Inspection
MerCruiser Lower Unit Shift Shaft Tool
New One Piece Oil Seal Carrier for Alpha One Generation II
Installation Issues With MCM D7.3L D-Tronics
Injection Pump Timing Specifications
Required MIE 7.4L MPI (L29) ECM Replacement
Gimbal Housing Oil Reservoir Bulkhead Fitting -Material Change
Required #1 Injector Replacement
3.0L Engines with Blown Head Gasket
Shift Cable Measurements For Transmissions
Modification of Tool Kit 91-806563A1 for D-Tronic Diesels
Second Station Start/Stop Kit Instruction Sheets


1999 Mercruiser Service Bulletins
Delco Starter Motors
V6 and V8 305/350 cid Engines with MEFI-3
MEFI-3 Diagnostic Trouble Codes and Audio Warning System
Sensor Failures in MEFI-3 Mercury Distributors Used on V6 and V8 305/350 cid Engines
Proper Oil Fill Level On Velvet Drive Transmissions
Proper Shift Set-up For The Commander 3000 Classic
Control When Used With Alpha One Product
Gasoline Engine Vapor Locking
EFI / MPI Fuel Pumps With Low Pressure
New Flushing Procedure for Alpha and Bravo Engines When
Using a Flush Attachment on the Sterndrive
Exhaust Manifolds, Risers and Exhaust Elbows
MCM 3.0L Flame Arrestor Decal
Water Drain Plugs Installed
Delco Starter Motors
2000 Mercruiser Service Bulletins
-Alpha One Delayed Shift
Bravo Three / BlackHawk Lower Unit Oil Seal Installation Tool Modification
Serpentine Belt Power Steering Pulleys
-Stainless Steel Electric Fuel Pumps
Commander 3000 Classic Remote Control Decal