New Merc 540 replacement engine
 

Mercruiser's New 540CID Replacement Engine Package
Well it looks as if Mercury is flexing their muscle once again with a new alternative engine replacement. This new 540CID engine package called the 540MAG Bravo 4V . Mercruiser is clear to point out the engine brings 560Ft Lbs of torque but with the rated horsepower numbers we are lead to believe they have cautiously played down the engines actual horsepower.

Mercruiser recognizes there's a world of old tired worn out 454-502 carburetor and fuel injected engines in service that could benefit from a solid powerplant upgrade that comes with a 1 year warrantied direct replacement option for those boaters who want a simple and quick option compared to a full rebuild from an independent builder.

While this new option has not yet been publicly announced, as always *************** has got our ear to the water on whats coming in the industry and we bring it to you as soon as we can.

Specifications:

Power 440 HP (328 kW)
Full Throttle Range 4200-4600 RPM
Displacement 540 CID (8.9L)
Engine Type 8.9L Mercury V8 Iron Block & Remanufactured Heads
Bore & Stroke 4.50” X 4.25” (114 mm X 108 mm)
Compression Ratio 8.6:1 With Forged Pistons
Rocker Arm Ratio 1.7:1 Stamped Steel
Fuel Requirement 87 Octane (R+M)/2
Fuel System Holley 800 CFM Electric Choke Carburetor, Mechanical Fuel Pump
Induction System Single-Plane Aluminum Intake With Bronze Crossover & Pads
Ignition System Thunderbolt V with Knock Control
Charging System 65 Amp / 917 Watt Alternator
Water Drain System Multi-Point Drain – Hand Removeable Blue Drain Plugs
Exhaust System Iron Manifolds with 4” Dia. 316 SS Dry Joint Exhaust Elbows
Cooling System Thermostatically Controlled Raw Water – 143 F
Accessory Drive System Serpentine Belt
Lubrication System High Flow Oil Pump , Copper Oil Cooler, Oil Thermostat
Recommended Engine Oil SAE 25W50 FC-W Synthetic Blend Racing Oil
Audio Warning System Oil Pressure, Coolant Temperature, Drive Lube
Bravo One X & XR Ratios: 1.36, 1.50:1
Bravo One XZ Ratio: 1.50:1
Bravo Two X Ratio: 1.81:1
Bravo Three X Ratio: 1.81:1
Bravo Three XR Ratios: 1.81, 2.00:1
Dimensions (LxWxH) 34” x 33” x 27” (871 mm x 830 mm x 689 mm)
Engine Weight (lbs./kg) 1025 / 465
Fresh Water Cooling: Not Available
Engine Only Part Number 8M0085999

List price is $18,118

Is that for the entire engine/transom assy/drive package?

18k for a 440 HP 540? Holy...

What kind of crank and rods? Might be a good candidate for a blower...

I can believe the high prices on all the mercury motors. I just can't see where they come up with the figures???

Wonder what happens of you spin it to 5500? Other than probably voiding the warranty.

Key word, Retail. Does anyone actually pay retail? -Retail for a new XR Sportmaster is about 13k, no one pays that.

Looks like a pretty sweet package to me.

Probably will not make much power up there so no need to wring its neck that hard. I'm sure it's cammed for under 5k.

Thats engine only, I think street price will be in the $16k range.

I'm really curious; to see what the cranks, rods and pistons are. Stamped steel rocker arms and remand cast iron heads? 800 cfm carb, that would explain; 4500-4800 rpms. What is impressive about less than 1 hp per cid and 560 lbs torque for 15k-18k per engine, using Thunderbolt V with knock protection? Doesn't it seem strange Mercruiser, would now offer a engine with a carb and old ignition system after everything they have produced using EFI ?
For the same money, you could stroke you 502, alum heads, have good rocker arms, and install a 2000 cfm TB, install a Holley HP EFI, easily push 700 HP and 700 lbs torque, all with a hydraulic roller.
Just my engine builder 2 cents worth !!!!

Stump puller. I think they are targeting your 60's - 70's Caddy!

The answer is simple... Its a 540, with a decent cam and intake/fuel injection it would make over 520 hp. They already sell a fancy 520 for more $$

With a bunch of torque and a 4600 redline its the perfect motor... for you searay...

I probably should have posted this in general boating discussions, but I thought being engine related information in might fit in better here.

It is, all good stuff. I asked at a conference earlier this year when it was announced.

Just did exactly that except with dominators for around $15k x 2. Wish I'd went EFI though.

Exactly what I think!! I'm big into the small block side of boating and when the 400 hp scorpion came out I though it was a nice piece till I saw the price tag!!!

Rebuild your tired 502 for half the price

Get a ZZ502 - not much to convert to marine use.

Wannabe

My 540's are .030 over (548CI) with extremely mild cams and aluminum heads made cob=coservative 600 hp 660TQ, how can any 540 be only 440 hp? even with stock iron heads would have to make 550 plus and still be reliable.

You're not seeing their side of it- sales. A 550 HP 540 would undercut their 525 sales and it's much larger price tag. Also, is 550 reliable in front of a bravo? Not really.

Merc puts the XR behind their 600.

Didn't see the specs for the cam. Since they are running the same stock GM heads, I am wondering if they are also running the same wimpy cam that they have in their magnum engines. That would also explain the stamped steel rocker arms. I had actually considered building a 489 stroker like this, and everyone on this forum told my I was crazy. :p ;)