Mercury Alpha User manual

Gasoline Engines - Alpha / Bravo Models
2001, Mercury Marine90-860168003 201

0
CA940 Identification Record
PLEASE RECORD THE FOLLOWING INFORMATION:
1. Engine Model and
Horsepower Engine Serial
Number
2. Transom Assembly Serial
Number (Sterndrive) Gear
Ratio Sterndrive Unit Serial Number
3. Transmission Model
(Inboard) Gear
Ratio Transmission Serial Number
4. Propeller Number Pitch Diameter
5. Hull Identification Number
(HIN) Purchase
Date
6. Boat Manufacturer Boat
Model Length
7. Exhaust Gas Emissions Certificate Number (Europe Only)
SERIAL NUMBERS
The serial numbers are the manufacturer’s keys to numerous engineering details
which apply to your Mercury MerCruiserpower package. When contacting your
Authorized Mercury 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 incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.
2001, Mercury Marine
The following are registered trademarks of Brunswick Corporation: AutoBlend, Jet-Prop,
Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, RideGuide,
Thruster and MMPP.

1
CA910
71352
ABC12345Z123
-19 48-12345
71345
4
512
2,7
7
2
1
44
5
74677
1,2
COLOR CODE
MERCRUISER
Division of Mercury Marine
Stillwater, OK, U.S.A.
SPECIFICATIONS
MODEL MCM 4.3LX/4.3LXH GEN +.
DISPLACEMENT 262 CID. . . . . . . . .
IGNITION TIMING 10 BTDC. . . . . . .
CYL. FIRING ORDER 1-6-5-4-3-2. . .
SPARK PLUGS AC-MR43LTS. . . . .
ENGINE ROTATION LH. . . . . . . . . . .
MAX W.O.T. rpm 4400-4800. . . . . . .
IDLE rpm IN NEUTRAL 650. . . . . . . .
PLUG GAP .045’. . . . . . . . . . . . . . . . .
For Fuel and Oilrequirements refer to
Operations & Maintenance Manual
SERIAL NUMBERS
74849
2
276454

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CA859 Welcome!
You have selected one of the finest marine power packages
available. It incorporates numerous design features to assure
operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using
this product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read this
manual.
The Operation, Maintenance and Warranty Manual contains specific
instructions for using and maintaining your product. We suggest that
this manual remain with the product for ready reference whenever
you are on the water.
Thank you for purchasing one of our Mercury MerCruiser products.
We sincerely hope your boating will be pleasant!
Consumer Affairs Department
CA741
Warranty Message
The product you have purchased comes with a limited warranty
from Mercury Marine; the terms of the warranty are set forth in the
Warranty Sections of this manual. The warranty statement contains
a description of what is covered, what is not covered, the duration of
coverage, how to best obtain warranty coverage, important
disclaimers and limitations of damages, and other related
information. Please review this important information.

4
TABLE OF CONTENTS
Page
Warranty Information 6
Owner Warranty Registration 6. . . . . . . . . . . . . . . . . . . . . . . . .
International Owner Registration 7. . . . . . . . . . . . . . . . . . . . . .
Mercury MerCruiser Limited Warranty 8. . . . . . . . . . . . . . . . .
3 Year Limited Warranty Against Corrosion Failure 12. . . . . .
Transferable Warranty 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury Product Protection Plan 16. . . . . . . . . . . . . . . . . . . . . .
Read This Manual Thoroughly 18
General Information 21
Lanyard Stop Switch 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Emissions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wave And Wake Jumping 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Impact With Underwater Hazards 26. . . . . . . . . . . . . . . . . . . . .
Operating With Low Water Inlets In Shallow Water 28. . . . . .
Drive Unit Impact Protection 29. . . . . . . . . . . . . . . . . . . . . . . . .
Safe Boating Suggestions 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting People In The Water 34. . . . . . . . . . . . . . . . . . . . . . .
High-Speed And High-Performance Boat Operation 35. . . . .
Conditions Affecting Operation 36
Important Information 42
Operation And Maintenance 42. . . . . . . . . . . . . . . . . . . . . . . . .
Freezing Temperature Operation 44. . . . . . . . . . . . . . . . . . . . .
Drain Plug and Bilge Pump 44. . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions Information (Europe Only) 45. . . . . . . . . . . . . . . . . .
Attention Required After Submersion 45. . . . . . . . . . . . . . . . . .
Trailering Boat 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Launching And Boat Operation Care 46. . . . . . . . . . . . . . . . . .
Stolen Power Package 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Service Parts 47. . . . . . . . . . . . . . . . . . . . . . . . . .
Do-It-Yourself Maintenance Suggestions 48. . . . . . . . . . . . . . .
Multiple EFI Engine Battery Precautions 50. . . . . . . . . . . . . . .
Diagnosing EFI Problems (If Equipped) 51. . . . . . . . . . . . . . . .
20-Hour Break-In Period 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After Break-In Period 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End of First Season Checkup 53. . . . . . . . . . . . . . . . . . . . . . . .

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Page
Operation 54
Instrumentation 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Audio Warning System 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Overload Protection 58. . . . . . . . . . . . . . . . .
Remote Controls 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting, Shifting And Stopping 67. . . . . . . . . . . . . . . . . . . . . . .
Operation Chart 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 72
Fuel Recommendations 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seacock Size Recommendation 75. . . . . . . . . . . . . . . . . . . . . .
Crankcase Oil 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 83
Maintenance Aids 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Capacities 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Chart 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluids 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Sight Tube Inspection 3.0L Models 93. . . . . . . . .
Changing Fluids 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Water Separating Fuel Filter 99. . . . . . . . . . . . . . . .
Cleaning Flame Arrestor and Related Components 102. . . . .
Lubrication 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belts 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrosion And Corrosion Protection 128. . . . . . . . . . . . . . . . . . .
Emissions (Europe Only) 134. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Maintenance 139. . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage 140
Power Package Lay Up 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Instructions 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System 158. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Winter Storage 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Package Recommissioning 162. . . . . . . . . . . . . . . . . . . .
Troubleshooting 164
Owner Service Assistance 173

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CA455 Warranty Information
Owner Warranty Registration
UNITED STATES AND CANADA ONLY
•It is important that your selling dealer fills out the Warranty
Registration Card completely and mails it to the factory
immediately upon sale of the new product.
•It identifies name and address of the original purchaser, product
model and serial number(s), date of sale, type of use and selling
dealer’s code, name and address. The dealer also certifies that
you are the original purchaser and user of the product.
•Upon receipt of the Warranty Registration Card at the factory, you
will be issued a plastic Owner Warranty Registration Card which
is your only valid registration identification. It must be presented
to the servicing dealer should warranty service be required.
Warranty 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
during this period, present the temporary registration card to the
dealer. He will attach it to your warranty claim form.
•Because of your selling dealer’s continuing personal interest in
your satisfaction, the product should be returned to him for
warranty service.
•If your plastic card is not received within 30 days from date of new
product sale, please contact your selling dealer.
•The product warranty is not effective until the product is registered
at the factory.
•NOTICE: Registration lists must be maintained by factory and
dealer on marine products sold in the United States, should
notification under the Federal Boat Safety Act be required.

7
International Owner Registration
OUTSIDE THE UNITED STATES AND CANADA
•It is important that your selling dealer fills out the Warranty
Registration Card completely and mails it to the distributor or
Marine Power Service Center responsible for administering the
warranty registration/claim program for your area.
•The Warranty Registration Card identifies your name and
address, product model and serial number(s), date of sale, type
of use and the selling distributor’s/dealer’s code number, name
and address. The distributor/dealer also certifies that you are the
original purchaser and user of the product.
•A copy of the Warranty Registration Card, designated as the
“Purchaser’s Copy,”MUST be given to you immediately after the
card has been completely filled out by the selling
distributor/dealer. This card represents your factory registration
identification, and should be retained by you for future use when
required. Should you ever require warranty service on this
product, your 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
Registration Card from your distributor/dealer. If you receive a
plastic Warranty Registration Card, you may discard the
“Purchaser’s Copy”that you received from the distributor/dealer
when you purchased the product. Ask your distributor/dealer if
this plastic card program applies to you.
•For further information concerning the Warranty Registration
Card and its relationship to Warranty Claim processing, refer to
the “International Warranty.”Refer to “Table of Contents.”
IMPORTANT: Registration lists must be maintained by the
factory and dealer in some countries by law. It is our desire to
have ALL products registered at the factory should it ever be
necessary to contact you. Make sure your dealer/distributor
fills out the warranty registration card immediately and sends
the factory copy to the Marine Power International Service
Center for your area.

8
CC1048 Warranty Policies
Mercury MerCruiser One Year Limited Warranty
(Gasoline Fueled Products Only)
WHAT IS COVERED
Mercury Marine warrants its new products to be free of defects in ma-
terial and workmanship during the period described below.
DURATION OF COVERAGE
This Limited Warranty provides coverage for either one (1) year from
the date the product is first sold to a recreational use retail purchaser,
or the date on which the product is first put into service, whichever
occurs first. Commercial users of these products receive warranty
coverage of either one (1) year from the date of first retail sale, or the
accumulation of 500 hours of operation, whichever occurs first. Com-
mercial use is defined as any work or employment related use of the
product, or any use of the product which generates income, for any
part of the warranty period, even if the product is only occasionally
used for such purposes. The repair or replacement of parts, or the
performance of service under this warranty, does not extend the life
of this warranty beyond its original expiration date. Unexpired war-
ranty coverage can be transferred from one recreational use cus-
tomer to a subsequent recreational use customer upon proper re-
registration of the product. Unexpired warranty coverage cannot be
transferred either to or from a commercial use customer.

9
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN
WARRANTY COVERAGE
Warranty coverage is available only to retail customers that pur-
chase from a Dealer authorized by Mercury Marine to distribute the
product in the country in which the sale occurred, and then only after
the Mercury Marine specified pre-delivery inspection process is
completed and documented. Warranty coverage becomes available
upon proper registration of the product by the authorized dealer. In-
accurate warranty registration information regarding recreational
use, or subsequent change of use from recreational to commercial
(unless properly re-registered) may void the warranty at the sole dis-
cretion of Mercury Marine. Routine maintenance outlined in the Op-
eration and Maintenance Manual must be timely performed in order
to obtain warranty coverage. Mercury Marine reserves the right to
make any warranty coverage contingent upon proof of proper main-
tenance.
WHAT MERCURY WILL DO
Mercury’s sole and exclusive obligation under this warranty is limited
to, at our option, repairing a defective part, replacing such part or
parts with new or Mercury Marine certified re-manufactured parts, or
refunding the purchase price of the Mercury product. Mercury re-
serves the right to improve or modify products from time to time with-
out assuming an obligation to modify products previously manufac-
tured.

10
HOW TO OBTAIN WARRANTY COVERAGE
The customer must provide Mercury with a reasonable opportunity
to repair, and reasonable access to the product for warranty service.
Warranty claims shall be made by delivering the product for inspec-
tion to a Mercury dealer authorized to service the product. If purchas-
er cannot deliver the product to such a dealer, written notice must be
given to Mercury.We will then arrange for the inspection and any cov-
ered repair. Purchaser in that case shall pay for all related transporta-
tion charges and/or travel time. If the service provided is not covered
by this warranty, purchaser shall pay for all related labor and materi-
al, and any other expenses associated with that service. Purchaser
shall not, unless requested by Mercury, ship the product or parts of
the product directly to Mercury. The warranty registration card is the
only valid registration identification and must be presented to the
dealer at the time warranty service is requested in order to obtain
coverage.
WHAT IS NOT COVERED
This limited warranty does not cover routine maintenance items, tune
ups, adjustments, normal wear and tear, damage caused by abuse,
abnormal use, use of a propeller or gear ratio that does not allow the
engine to run in its recommended RPM range (see the Operation and
Maintenance Manual), operation of the product in a manner incon-
sistent with the recommended operation/duty cycle section of the
Operation and Maintenance Manual, neglect, accident, submersion,
improper installation (proper installation specifications and tech-
niques are set forth in the installation instructions for the product), im-
proper service, use of an accessory or part which damages the Mer-
cury product and was not manufactured or sold by us, jet pump
impellers and liners, operation with fuels, oils or lubricants which are
not suitable for use with the product (see the Operation and Mainte-
nance Manual), alteration or removal of parts, water entering the en-
gine through the fuel intake, air intake or exhaust system or damage
to the product from insufficient cooling water caused by blockage of
the cooling system by a foreign body, running the engine out of water,
mounting the engine too high on the transom, or running the boat with
the engine trimmed out too far. Use of the product for racing or other
competitive activity, or operating with a racing type lower unit, at any
point, even by a prior owner of the product, voids the warranty.

11
Expenses related to haul-out, launch, towing, storage, telephone,
rental, inconvenience, slip fees, insurance coverage, loan pay-
ments, loss of time, loss of income, or any other type of incidental or
consequential damages are not covered by this warranty. Also, ex-
penses associated with the removal and/or replacement of boat
partitions or material caused by boat design for access to the product
are not covered by this warranty.
No individual or entity, including Mercury Marine authorized dealers,
has been given authority by Mercury Marine to make any affirmation,
representation or warranty regarding the product, other than those
contained in this limited warranty, and if made, shall not be enforce-
able against Mercury Marine.
DISCLAIMERS AND LIMITATIONS
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY
DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DIS-
CLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN
DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCI-
DENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED
FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/
COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIM-
ITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RE-
SULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY
GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO
HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO
STATE AND COUNTRY TO COUNTRY.

12
CC1049
3 Year Limited Warranty Against Corrosion
(Worldwide)
WHAT IS COVERED
Mercury Marine warrants that each new Mercury, Mariner, Mercury
Racing, Sport Jet, M2Jet Drive, tracker by Mercury Marine Outboard,
MerCruiser Inboard or sterndrive engine (Product) will not be ren-
dered inoperative as a direct result of corrosion for the period of time
described below.
DURATION OF COVERAGE
This limited corrosion warranty provides coverage for three (3) years
from either the date the product is first sold, or the date on which the
product is first put into service, whichever occurs first. The repair and
replacement of parts, or the performance of service under this war-
ranty does not extend the life of this warranty beyond its original expi-
ration date. Unexpired warranty coverage can be transferred to sub-
sequent (noncommercial use) purchaser upon proper re-registration
of the product.

13
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN
WARRANTY COVERAGE
Warranty coverage is available only to retail customers that pur-
chase from a Dealer authorized by Mercury Marine to distribute the
product in the country in which the sale occurred, and then only after
the Mercury Marine specified pre-delivery inspection process is
completed an documented. Warranty coverage becomes available
upon proper registration of the product by the authorized dealer. Cor-
rosion prevention devices specified in the Operation and Mainte-
nance Manual must be in use on the boat, and routine maintenance
outlined in the Operation and Maintenance Manual and must be
timely performed (including without limitation the replacement of
sacrificial anodes, use of specified lubricants, and touch-up nicks
and scratches) in order to maintain warranty coverage. Mercury Ma-
rine reserves the right to make warranty coverage contingent upon
proof of proper maintenance.
WHAT MERCURY WILL DO
Mercury’s sole and exclusive obligation under this warranty is limited
to, at our option, repairing a corroded part, replacing such part or
parts with new or Mercury Marine certified re-manufactured parts, or
refunding the purchase price of the Mercury product. Mercury re-
serves the right to improve or modify products from time to time with-
out assuming an obligation to modify products previously manufac-
tured.

14
HOW TO OBTAIN WARRANTY COVERAGE
The customer must provide Mercury with a reasonable opportunity
to repair, and reasonable access to the product for warranty service.
Warranty claims shall be made by delivering the product for inspec-
tion to a Mercury dealer authorized to service the product. If purchas-
er cannot deliver the product to such a dealer, written notice must be
given to Mercury.We will then arrange for the inspection and any cov-
ered repair. Purchaser in that case shall pay for all related transporta-
tion charges and/or travel time. If the service provided is not covered
by this warranty, purchaser shall pay for all related labor and materi-
al, and any other expenses associated with that service. Purchaser
shall not, unless requested by Mercury, ship the product or parts of
the product directly to Mercury. The warranty registration card is the
only valid registration identification and must be presented to the
dealer at the time warranty service is requested in order to obtain
coverage.
WHAT IS NOT COVERED
This limited warranty does not cover electrical system corrosion; cor-
rosion resulting from damage, corrosion which causes purely cos-
metic damage, abuse or improper service; corrosion to accessories,
instruments, steering systems; corrosion to factory installed jet drive
unit; damage due to marine growth; product sold with less than a one
year limited Product warranty; replacement parts (parts purchased
by the Customer); products used in a commercial application. Com-
mercial use is defined as any work or employment related use of the
product, or any use of the product which generates income, for any
part of warranty period, even if the product is only occasionally used
for such purposes.

15
CA459 Transferable Warranty
The product warranty is transferable to a subsequent purchaser, but
only for the remainder of the unused portion of the limited warranty.
This will not apply to products used for commercial applications.
Direct Sale By Owner
•The second owner can be registered as the new owner and retain
the unused portion of the limited warranty by sending the former
owner’s plastic Owner Warranty Registration Card 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 charge for this service.
Outside the United States and Canada, please contact the
distributor in your country, or the Marine Power International
Service Center closest to you, for the transferable warranty
procedure that would apply to you.

16
CA862
Mercury Product Protection Plan
United States And Canada Only
(Certain performance products, triple engine installations, and
commercial applications are excluded)
The Mercury Product Protection Plan provides coverage against
unexpected mechanical and electrical breakdowns that may occur
beyond the standard limited warranty.
The optional Mercury Product Protection Plan is the only Factory
Plan available for your engine.
Two, three or four - year term plans can be purchased up to 12
months after the original engine registration date.
See your participating Mercury MerCruiser dealer for complete
program details.

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18
CA755 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,
WARNINGS and CAUTIONS, accompanied by the International
Hazard Symbol !, may be used to alert the installer/user to special
instructions concerning a particular service or operation that may be
hazardous if performed incorrectly or carelessly. Observe them
carefully.
These “Safety Alerts”alone cannot eliminate the hazards that they
signal. Strict compliance with these special instructions while
performing the service, plus “common sense”operation, are major
accident prevention measures.
WARNING
WARNING-Hazards or unsafe practices which could result in
severe personal injury or death.