Page 8 - REPOWER REFERENCE GUIDE (2020)

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About this Manual
Repower Reference Manual Overview

Purpose
The purpose of this Repower Reference Manual is to provide guidance to qualified marine service technicians repowering a
boat with a MerCruiser engine or longblock. Adhering to the requirements and following the recommendations outlined in this
manual will help ensure that the repowered boat meets Mercury MerCruiser's standards, in turn ensuring that the boat owner
will have an enjoyable boating experience. Following the guidelines contained herein will also help ensure that the power
package is eligible for Limited Warranty coverage.
Scope
This manual covers only the repowering of boats with gasoline marine engines and longblocks available from Quicksilver or
Mercury MerCruiser. It is intended as a reference guide only. It is not intended to be comprehensive, step‑by‑step instructions
on how to repower your boat.
How to Use this Manual
IMPORTANT: Familiarize yourself with the entire contents of this manual before beginning the repower process.
Note that the content is presented in roughly the order of the repower process:
1. Introduction: Provides an overview of the manual and important information such as proper boat ventilation, the use of
fuels containing alcohol, and combating vapor lock.
2. Eligibility for Limited Warranty: Explains the eligibility requirements for the Limited Warranty.
3. Engine Failure Diagnosis: Outlines the importance of determining the root cause of an engine failure and provides pointers
on where and how to look for trouble.
4. Repower Considerations: Provides details on items that should be reviewed when repowering a boat. The categories
covered here are:
a. Engine and Drive Installation Requirements: Provides an overview of exhaust system types (refer to Section 7 ‑
Exhaust System—Design and Requirements for details), charts of sterndrive gear ratios, and sterndrive transom
specifications.
b. Propeller Selection: Includes basic information on selecting the proper propeller.
c. Inboard Transmission and Driveline: Provides gear ratio selection and other specifications concerning the propeller
and propeller shaft used for inboard applications.
d. Engine Harness: Addresses common issues involving different engine harnesses.
e. Cooling System: Presents information on various cooling system considerations, including Water Heaters and Cabin
Heaters and Propeller Shaft Log Seal Connections (for inboard applications).
5. Longblock Considerations: Outlines the special considerations for longblock replacements. It includes a list of
recommended replacement items, instructions for pressure testing (required when replacing a longblock), and ignition
system considerations.
6. Inspection of Existing Components: Presents overviews of components that must be inspected when repowering a boat, to
ensure successful operation of the replacement engine.
7. Exhaust System—Design and Requirements: Contains critical detailed information on the requirements and
implementation of the various exhaust system designs. Testing of the exhaust system is covered in a later section.
8. Engine and Drive Installation: Provides a handful of procedures, the details of which are critical to the proper operation of
the engine and drive installation, whether repowering with a full‑dressed engine or a longblock. Includes Ignition Timing
and Engine/Drive Alignment. Oil System Priming for Remanufactured Engines and Longblocks must be performed
for all remanufactured engines and longblocks.
9. Remote Control and Trim Pump Installation: Includes details on shift, throttle, steering, and power trim pump installation.
10. Testing the Installation: Contains details on testing the repower installation, with particular emphasis on Measuring
Exhaust Elbow Height and Testing the Exhaust System.
11. Predelivery Inspection Checklist: Presents a copy of the Predelivery Inspection (PDI) checklist. A copy of the completed
PDI is required for warranty authorization.
Additional Reference Material
The following items are highly recommended as additional reference materials for the repower process:
• Mercury MerCruiser Application Manual applicable to the type of installation (sterndrive or inboard)
• Mercury MerCruiser Service Manuals for the power package being installed
• Mercury MerCruiser Installation Manual for the power package being installed
• Mercury MerCruiser Instruction Sheets for any additional kits or parts being installed
Contact your Mercury Marine representative for help in obtaining these or any other necessary documentation.

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