Page 1: Marine Engines
MAIN MENU Number 17 MARINE ENGINES GM V-8 305 CID (5.0L) / 350 CID (5.7L) Book 1 of 2 Sections 1 thru 4 1996, Mercury Marine Printed in U.S.A. 90-823225--1 1096...
Page 2 This service manual has been written and published radial lines for this purpose, while most custom- by the service department of Mercury Marine to aid ary nuts do not have strength markings. Mismatched our dealers, mechanics and company service per-...
Page 3: Replacement Parts
Engine Mechanical Replacement Parts Components WARNING Many of the engine mechanical components are de- Electrical, ignition and fuel system components signed for marine applications. Unlike automotive engines, marine engines are subjected to extended on MerCruiser Engines and Stern Drives are de- periods of heavy load and wide-open-throttle opera- signed and manufactured to comply with U.S.
Page 4 Models Covered in This Manual MCM Alpha MODEL SERIAL NUMBER MODEL YEAR 5.0L OD832472 - OF601000 5.0LX OD831003 - OF601000 1993 199 1993 - 1995 5.7L (4 Barrel) OD830700 - OF601000 5.7L (2 Barrel) OF601000 and Above 5.7LX OF601957 and Above 5.7L EFI OF286830 and Above 1996 Th...
Page 5 MIE Ski MODEL SERIAL NUMBER MODEL YEAR 5.7L Competition (4 Barrel) OD840220 - OF775199 1993 - 1995 5.7L Competition (2 Barrel) OF775200 and Above 1996 Thru 1997 350 Magnum Tournanment Ski OD840100 and Above 1993 Thru 1997 350 Magnum EFI Tournament Ski OF225157 - OK000000 1994 - 1996 350 Magnum EFI Gen+...
Page 6 E - MIE Models - Velvet Drive Transmissions F - MIE Models - Hurth Transmissions Section 3 - Engine A - 5.0L / 305 CID / 5.7L /350 CID Electrical Systems Section 4 - Electrical Systems A - Starting System...
Page 7 IMPORTANT INFORMATION 72000 GENERAL INFORMATION Index...
Page 8: Table Of Contents
Table of Contents Page Introduction ......1A-1 How to Use This Manual .
Page 9: Introduction
How to Use This Manual NOTICE This manual is divided into sections which represent Refer to appropriate Stern Drive Service major components and systems. Manual for transom assembly and stern drive unit repair. Some sections are further divided into parts which more fully describe the component.
Page 10: How To Read Parts Manual
Part Number: For part ordering - Note N.S.S. for Reference Number 2, Plug, expansion - that means Not Sold Separately by Mercury Marine however, in this case, the G.M. Part Number (for the plug) is given in the Description Column.
Page 11: Directional References
Directional References Engine Serial Number Locations Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this maintenance manual, all directional references are given as they appear when viewing boat from stern looking toward bow.
Page 12: Propeller Information
Propeller Information Water Testing New Engines Refer to the “Propeller” section in appropriate Mer- Use care during the first 20 hours of operation on new Cruiser Stern Drive Service Manual, or order publica- MerCruiser engines or possible engine failure may tion P/N 90-86144, “What You Should Know About occur.
Page 13: Marine Fouling
For best speed and minimum spray, the corner be- Any hook, rocker or surface roughness on the bot- tween the bottom and the transom should be sharp. tom, particularly in the all-important center-aft portion will have a negative effect on speed, often several miles per hour on a fast boat.
Page 14: Weight Distribution
Avoid an electrical interconnection between the Weight Distribution MerCruiser Product, Anodic Blocks, or MerCa- Weight distribution is extremely important; it affects thode System and the paint by allowing a mini- a boat’s running angle or attitude. For best top speed, mum of 1 in.
Page 15: Elevation And Climate
Elevation and Climate Elevation has a very noticeable effect on the wide-open- throttle power of an engine. Since air (containing oxygen) gets thinner as elevation in- creases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a no- ticeable effect on the density of air.
Page 16 IMPORTANT INFORMATION MAINTENANCE Index...
Page 17 Table of Contents Page Maintenance Schedules ....1B-1 Maintenance Intervals ....1B-1 Alpha Models .
Page 18: Maintenance Schedules
Maintenance Schedules Maintenance Intervals Maintenance intervals and the tasks to be performed, as shown in this current schedule, or as found in a previously printed schedules, are generally based on an average boating application and environment. However, individual operating habits and personal maintenance preferences can have an impact on the suggested intervals.
Page 19 SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY DEALER NOTE: Only perform maintenance which applies to your particular power package. Task Interval Whenever insufficient seawater flow is suspected. Seawater Pickup Pump - Disassemble and inspect (If operating temperature exceeds normal range.) Crankcase Oil and Filter Change Ignition system - Clean and Inspect condition.
Page 20 SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY DEALER (CONTINUED) NOTE: Only perform maintenance which applies to your particular power package. Task Interval Steering Head and Remote Control - Inspect and End of first boating season and thereafter, every 100 lubricate. hours of operation or once yearly whichever occurs hours of operation or once yearly, whichever occurs Carburetor (If Equipped) - Inspect and adjust.
Page 21: Bravo Models
Bravo Models SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR NOTE: Only perform maintenance which applies to your particular power package. Task Interval Engine Crankcase Oil - Check level Closed Cooling Coolant - Check level Power Steering Fluid - Check level Stern Drive Unit Oil - Check level Battery - Check level and inspect for damage Weekly...
Page 22 SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED BY A DEALER (CONTINUED) NOTE: Only perform maintenance which applies to your particular power package. Task Interval Whenever insufficient seawater flow is suspected. Seawater Pickup Pump - Disassemble and inspect (If operating temperature exceeds normal range.) Crankcase Oil and Filter Change Ignition system - Clean and Inspect condition.
Page 23 SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED BY A DEALER (CONTINUED) NOTE: Only perform maintenance which applies to your particular power package. Task Interval Steering Head and Remote Control - Inspect and End of first boating season and thereafter, every Lubricate. 100 hours of operation or once yearly whichever 100 hours of operation or once yearly, whichever Carburetor (If Equipped) - Inspect and adjust.
Page 24: Tune-Up Specifications
190 (141) 205 (152) 235 (175) 250 (186) 250 (250) HP (KW) Number of Cylinders Displacement 305 CID (5.0L) 350 CID (5.7L) Bore/Stroke 3.7 x 3.48 (95 x 88.4) 4.0 x 3.48 (101.6 x 88.4) In. (mm) Compression Ratio 9.1:1 9.3:1...
Page 25 Tune-Up Specifications, Does Not Include Gen + Engines (Continued) MCM 5.7L EFI MCM 350 EFI/MP MIE 350 EFI/MP MCM 5.7L EFI Model Bravo One, Two Bravo One and Magnum Alpha And Three Three Tournament Ski Propshaft HP 250 (186) 250 (186) 265 (197) 280 (208) (KW)
Page 26 Tune-Up Specifications, Does Not Include Gen + Engines (Continued) MIE 350 EFI MIE 5.7L MIE 350 Magnum Model MIE 5.7L Magnum Competition Ski Tournament Ski Tournament Ski Propshaft HP 250 (186) 250 (186) 265 (198) 265 (198) (KW) Number of Cylinders Displacement 350 CID (5.7L)
Page 27: Tune-Up Specifications (Gen + Engines Only)
Tune-Up Specifications (Gen + Engines Only) 350 MAGNUM MCM 350 MPI 350 MAGNUM 350 MAGNUM MPI GEN + MIE IN- GEN+ EFI GEN + GEN + ALPHA TOURNA- MODEL BOARD5.7L BRAVO AND TOURNA- 5.7LX EFI GEN + MENT SKI EFI GEN + BLACKHAWK BRAVO MENT SKI...
Page 28: Fluid Capacities
Fluid Capacities NOTICE All capacities are approximate fluid measures. Capacities are shown in U.S. Quarts / (Litres) MCM (Stern Drive) Model All Models Crankcase Oil With Filter 5-1/2 (5.2) Seawater Cooling System 15 (14.1) Closed Cooling System 20 U.S. Qts. (19 L) (With Coolant Flow Thru Exhaust Manifolds) Closed Cooling System 14.5 Qts.
Page 29: All Models
All Models Fuel, Oil, Fluid, and Coolant Specifications 20-Hour Break-In Period IMPORTANT: The first 20 hours of operation is Fuel the engine break-in period. Correct break-in is essential to obtain minimum oil consumption CAUTION and maximum engine performance. During this break-in period, the following rules must be ob- Use of improper gasoline can damage the engine served:...
Page 30 EFFECTS OF GASOLINE/ALCOHOL BLENDS WARNING ON MARINE ENGINES Fire and Explosion Hazard: Fuel leakage from Corrosion of metals may result from use of alco- any part of the fuel system can be a fire and ex- hol-gasoline blends. Portable or permanently in- plosion hazard which can cause serious bodily stalled fuel tanks of metal or fiberglass, fuel filters, injury or death.
Page 31: Crankcase Oil
NOL are still being evaluated by the United States tives specifically are not recommended. Coast Guard, the National Marine Manufacturers As- sociation (NMMA), Mercury Marine and other engine and boat manufacturers. We have recommended pump posting of alcohol SAE 40W content of gasoline.
Page 32: Coolant For Closed Cooling System
Coolant for Closed Cooling System Checking Engine Oil Level/Filling IMPORTANT: ENGINE CRANKCASE OIL MUST CAUTION BE CHECKED AT INTERVALS SPECIFIED IN Alcohol or Methanol base antifreeze or plain wa- “MAINTENANCE SCHEDULE” CHART. It is nor- ter, are not recommended for use in fresh water mal for an engine to use a certain amount of oil section of cooling system at any time.
Page 33: Maintaining Power Steering Pump Fluid Level
Maintaining Power Steering 5. If fluid is not visible in reservoir, a leak exists in the power steering system. Find cause and correct. Pump Fluid Level With Engine Cold With Engine Warm 1. With engine stopped, position drive unit so that it 1.
Page 34: Filling And Bleeding Power Steering System 1B-17
Filling and Bleeding Power Maintaining Closed Cooling Steering System Coolant Level IMPORTANT: Power steering system must be WARNING filled exactly as explained in the following to be sure that all air is bled from the system. All air Allow engine to cool down before removing pres- must be removed, or fluid in pump may foam dur- sure cap.
Page 35: Mcm Stern Drive
MCM Stern Drive BOAT IN WATER 1. Raise drive unit to full UP position. BOAT OUT OF WATER 2. Install flushing attachment over water pickup 1. Install flushing attachment over water pickup holes in gear housing as shown. holes in gear housing as shown. 72012 72012 2.
Page 36: Mie Inboard
MIE Inboard 2. Using an adaptor, connect a garden hose from a water tap to seapump inlet. CAUTION 3. Partially open water tap (approximately 1/3 maxi- mum). Do not use full water pressure. If boat is in the water, seacock (water inlet valve), if so equipped, must be left closed until engine is 4.
Page 37: Maintaining Transmission Fluid Level
Maintaining Transmission Fluid Level IMPORTANT: Be sure to push dipstick all the way down into dipstick tube when checking fluid level. 1. Remove dipstick to check transmission fluid lev- el. Fluid level may be over the full mark because fluid from the cooler and lines has drained back into the transmission.
Page 38: Lubrication
Lubrication THROTTLE BODY INJECTION Throttle Cable MODELS WITH 2 BARREL CARBURETOR 72013 74109 a - Pivot Points a - Pivot Points b - Guide Contact Surface b - Guide Contact Surface MODELS WITH 4 BARREL CARBURETOR 72014 a - Pivot Points b - Guide Contact Surface Index 90-823225--1 1096...
Page 39 MULTI-PORT INJECTION ATTACHING/ADJUSTING THROTTLE CABLE - 350 MAGNUM MPI GEN+ TOURNAMENT SKI (BLACK SCORPION) 1. Place remote throttle lever in idle position and attach cable to throttle lever stud, following cable manufacturer’s instructions. 2. After throttle cable is adjusted, tighten locknut against cable end.
Page 40: Shift Cable
Shift Cable 72015 Alpha a - Pivot Points 71208 b - Guide Contact Surface Hurth a - Pivot Points b - Guide Contact Surface 72016 Bravo One and Two MCM Models - Typical Shift Cable a - Pivot Points b - Guide Contact Surface 72528 Velvet Drive MIE Models (Typical) Shift Cable and Transmission Linkage...
Page 41: Engine Coupler/U-Joint Shaft Splines
Engine Coupler/U-Joint Shaft Splines Drive Shaft Extension Models NOTE: Refer to MerCruiser Stern Drive Service Manual for stern drive unit removal and installation. 71570 MCM Models with Alpha One Drive Without Sealed Steel-Hub Coupler 72018 Transom End 71569 MCM Models with Alpha One Drive With Sealed Steel-Hub Coupler 72028 Engine End...
Page 42: Starter Motor (Mie Models)
Starter Motor (MIE Models) Audio Warning System WARNING Maintenance When performing the following procedure, be Maintenance inspection is the owner’s responsibility sure to observe the following: and must be performed at intervals specified, follow- Be sure that engine compartment is well venti- ing: lated and that no gasoline vapors are present Fresh Water Areas - Every 50 Hours of operation...
Page 43: Layup
Layup CAUTION If boat is in the water, seacock (water inlet valve), NOTICE if so equipped, must be left closed until engine is Refer to “Cold Weather or Extended Storage,” to be re-started, to prevent water from flowing “Precautions,” in this section, BEFORE pro- back into cooling system and/or boat.
Page 44 6. Close fuel shutoff valve, if so equipped. (6) Pour out a small amount of fuel into a suit- able container, then add approximately 2 a. Remove plug from top of vapor separator fluid ounces (60 ml) of Quicksilver tank. 2-Cycle Outboard Oil to fuel in the water (1) Add approximately 1 fluid ounce (30 ml) separating fuel filter.
Page 45: Draining Instructions
Draining Instructions NOTE: With the engine level, sufficient draining of manifolds will occur when exhaust manifold-to-ther- mostat housing hoses are removed. DRAINING SEAWATER (RAW-WATER) COOLED MODELS NOTICE Refer to “Cold Weather or Extended Storage,” “Precautions,” in this section, BEFORE pro- ceeding.
Page 46 e. Remove the engine water circulating pump g. Remove seawater pump inlet hose as shown. hose as shown. 72532 a - Seawater Pickup Pump b - Hose 72587 h. Follow instructions “(1)” or “(2)”: a - Hose, Water Circulating Pump-to-Thermostat Housing (1) On Bravo Drive Equipped Models: In- sert a small wire (repeatedly) to make Remove the power steering fluid cooler-to-...
Page 47 (2) On Alpha Drive Equipped Models: In- After seawater section of cooling system has sert a small wire (repeatedly) to make been drained completely, coat threads of sure that vent holes and water drain holes drain plugs with Quicksilver Perfect Seal and and passages (as shown) are unob- reinstall.
Page 48 NOTE: Hoses shown removed only to indicate flow. 2. MIE (Inboard) Seawater (Raw-Water) Models: Do not remove hoses. NOTICE Refer to “Cold Weather or Extended Storage,” “Precautions,” in this section, BEFORE proceeding. a. Engine must be as level as possible to ensure complete draining of cooling system.
Page 49 NOTE: With the engine level, sufficient draining of e. Remove the engine water circulating pump manifolds will occur when exhaust manifold-to-ther- hose as shown. mostat housing hoses are removed. 72586 72587 Starboard Shown (Port Similar) a - Bottom Hose Exhaust Manifold To Thermostat Housing a - Hose, Water Circulating Pump-to-Thermostat Housing Remove hose from the seawater pump, as shown.
Page 50 g. Remove the transmission fluid cooler hose as h. Crank engine over slightly with starter motor shown. to purge any water trapped in seawater pick- up pump. DO NOT ALLOW ENGINE TO START. CAUTION If boat is in the water or is to remain in the water, seacock (if so equipped) must remain closed un- til engine is to be restarted, to prevent water from flowing back into cooling system.
Page 51 NOTE: Hoses shown removed only to indicate flow. c. Remove drain plugs (if equipped) from port Do not remove hoses. and starboard exhaust elbows. 71330 72589 a - Cover a - Drain Plug b - Gasket d. If equipped with 3 in. (76 mm) or 6 in. (152 c - Spacer mm) risers, remove drain plug as shown from d - Thermostat...
Page 52 Remove hose from engine power steering fluid cooler as shown. 71217 72588 Bravo Drive a - Speedometer Pitot Tube a - Hose, Seawater Pump-to-Cooler b - Trim Tab Cavity Vent Hole c - Trim Tab Cavity Drain Passage g. Remove seawater pump inlet hose as shown. 72532 a - Seawater Pickup Pump b - Hose...
Page 53 (2) On Alpha Drive Equipped Models: In- After seawater section of cooling system has sert a small wire (repeatedly) to make been drained completely, coat threads of sure that vent holes and water drain holes drain plugs with Quicksilver Perfect Seal and and passages (as shown) are unob- reinstall.
Page 54 c. Remove drain plugs (if equipped) from port Remove the transmission fluid cooler hose, and starboard exhaust elbows. as appropriate on your engine, to drain hose and cooler. 71330 a - Drain Plug d. If equipped with 3 in. (76 mm) or 6 in. (152 71782 mm) risers, remove drain plug as shown from Typical Borg Warner In-Line and...
Page 55 g. On All Models With a Walter V-Drive Trans- CAUTION mission, disconnect water inlet hose from If boat is in the water or is to remain in the water, the fitting on transmission. seacock (if so equipped) must remain closed un- til engine is to be restarted, to prevent water from flowing back into cooling system.
Page 56: Recommissioning
Recommissioning NOTICE Refer to “Cold Weather or Extended Stor- age,” “Precautions,” in this section, BE- FORE proceeding. 1. Check that all cooling system hoses are con- nected and tight and all petcocks and drain plugs are installed and tight. 2. If equipped with seacock: Open seacock. 3.
Page 57 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 1B-40 - MAINTENANCE 90-823225--1 1096...
Page 58 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 MAINTENANCE - 1B-41...
Page 59 IMPORTANT INFORMATION TROUBLESHOOTING Index...
Page 60 Table of Contents Page Page Precautions ......1C-1 Instrumentation Malfunction ....1C-12 Used Spark Plug Analysis .
Page 61: Precautions
Precautions WARNING Make sure no fuel leaks exist before closing en- WARNING gine hatch. Always disconnect battery cables from battery CAUTION BEFORE working on fuel system to prevent fire or explosion. DO NOT operate engine without cooling water being supplied to water pickup holes in gear WARNING housing, or water pump impeller will be damaged Be careful when cleaning flame arrestor and...
Page 62: Used Spark Plug Analysis
Used Spark Plug Analysis Chipped Insulator Chipped insulator usually results from careless plug Use the following illustrations for determining ser- regapping. Under certain conditions, severe detona- viceability of spark plug. Spark plug condition also tion also can split insulator firing ends. Plug must be can suggest a variety of possible engine malfunc- replaced.
Page 63: Cold Fouling
Cold Fouling High Speed Glazing Dry, black deposits indicate rich fuel mixture or weak Insulator has yellowish, varnish-like color, indicating ignition. Clogged flame arrestor, flooding carburetor, that temperatures suddenly have risen, usually dur- sticky choke or weak ignition components all are ing hard, fast acceleration under heavy load.
Page 64: Pre-Ignition Damage
Pre-Ignition Damage Splashed Deposits Pre-ignition damage is caused by excessive high Spotted deposits, which sometimes occur after long temperatures. Center electrode melts first, followed delayed tune-up, accumulate after a long period of by ground electrode. Normally, insulators are white misfiring. When normal combustion temperatures but may be dirty if plug has been misfiring.
Page 65: Poor Boat Performance And/Or Poor Maneuverability
Poor Boat Performance and/or Poor Maneuverability Symptom Cause A. Improper drive unit trim angle B. Improper weight distribution C. Boat is underpowered Bow too low D. Permanent or power hook in boat bottom E. False bottom full of water F. Improperly adjusted trim tabs (after planes) G.
Page 66: Improper Full Throttle Engine Rpm
Improper Full Throttle Engine RPM RPM Too High Cause Special Information Damaged; pitch too low; diameter too small; Propeller propeller hub slipping. Water pickup or thru hull fittings mounted too close to propeller (ventilation); keel located too Boat close to propeller and/or too deep in the water (ventilation).
Page 67: Engine Cranks Over But Will Not Start Or Starts Hard
Engine Cranks Over but Will 2. Determine if there is fuel present by looking down the carburetor venturi while actuating throttle. Not Start or Starts Hard There should be a stream of fuel coming out of the accelerator pump nozzles if the carburetor has fuel.
Page 68: Testing Thunderbolt Iv Hei System
Testing Thunderbolt IV HEI System WARNING IMPORTANT: Use a voltmeter when mak- ing these tests. DO NOT use a test light. Be sure that engine compartment is well venti- lated and that there are no gasoline vapors pres- ent during the following test to prevent a poten- tial fire hazard.
Page 69: Testing Thunderbolt V Ignition System
Testing Thunderbolt V Ignition System Check to ensure that tachometer GRY lead is not shorted to ground (–) at the tachometer or within the harness. No Spark Check all Terminal Connections at Distributor, Ignition Module and Ignition Coil. Battery OK? Distributor Clamping Screw Tight? No Spark...
Page 70: Fuel System Rich
Fuel System Rich Cause Special Information Warm engine carburetor percolation Fuel boils out of float bowl when shut off and warm. Floods intake manifold. Clogged flame arrestor Automatic choke not opening Float adjustment Float leaks or is saturated with fuel Needle and seat leaking Carburetor gaskets leaking Excessive fuel pump pressure...
Page 71: Engine Will Not Crank Over
Engine Will Not Crank Over Cause Special Information Remote control lever not in neutral position Battery charge low; damaged wiring; loose elec- trical connections Circuit breaker tripped Blown fuse Ignition switch Slave solenoid Faulty neutral start safety switch Open circuit Starter solenoid Starter motor Mechanical engine malfunction...
Page 72: Instrumentation Malfunction
Instrumentation Malfunction Cause Special Information Faulty wiring, loose or corroded terminals Faulty key switch Test, as outlined in Section 4D Faulty gauge Test, as outlined in Section 4D Faulty sender Test , as outlined in Section 4D Radio Noise Cause Special Information A “popping”...
Page 73: Poor Fuel Economy
Poor Fuel Economy Cause Special Information Fuel leaks Operator habits Prolonged idling; slow acceleration; failure to cut back on throttle once boat is on plane; boat overloaded; uneven weight distribution Engine laboring Bent, damaged, or wrong propeller. Water test boat for proper operating RPM at wide-open- throttle Clogged flame arrestor Engine compartment sealed too tight...
Page 74: Carburetor Malfunctions
Carburetor Malfunctions Symptoms Cause A. Needle and seat B. Float adjustment C. Saturated float Flooding D. Gaskets leaking E. Cracked fuel bowl F. Fuel percolation G. Automatic choke 2. A. Idle RPM too low B. Idle mixture screws C. Idle passages dirty Rough idle h idl h idl...
Page 75: Engine Runs Poorly At Idle
Engine Runs Poorly at Idle Symptoms Cause A. Main metering jets B. Leaking gaskets C. Float adjustment Engine surges Engine surges D. Saturated float E. Power piston or valve F. Throttle valves A. Power piston or valve B. Float adjustment Low top speed or lack of power Low top speed or lack of power C.
Page 76: Engine Runs Poorly At High Rpm
Engine Runs Poorly At High RPM Cause Special Information Also refer to “Poor Boat Performance” Crankcase overfilled with oil Check oil level with boat at rest in the water. Anti-siphon valve (if equipped) Restricting fuel supply Plugged fuel tank vent Fuel supply Refer to “Carburetor Malfunctions”...
Page 77: Engine Acceleration Is Poor
Engine Acceleration Is Poor Cause Special Instructions Also refer to “Poor Boat Performance” Idle mixture screws Incorrect ignition timing Incorrect distributor or amplifier advance curve Refer to Section 4B Check for stream of raw fuel from accelerator Accelerator pump pump discharge nozzle, when opening throttle with engine shut off Cracked or dirty distributor cap or rotor Vacuum leak...
Page 78: Engine Noise
Engine Noise 4. Try to isolate the noise to location in engine: front to back, top to bottom. This can help determine which components are at fault. Important Information 5. Sometimes noises can be caused by moving parts coming in contact with other components. No definite rule or test will positively determine Examples are: flywheel or coupler;...
Page 79: Cylinder Area
Cylinder Area Location Possible Causes Sticking valve Carbon build-up Connecting rod installed wrong C li d C li d C li d Cylinder area, may be confined to one cylinder li d li d li d Bent connecting rod or found in more than one cylinder timed to or found in more than one cylinder, timed to Piston engine speed...
Page 80: Crankshaft Area
Crankshaft Area Location Possible Causes Crankshaft timing sprocket Timing chain Crankshaft area, front of engine, timed to k h f engine speed Main bearing Rod bearing Crankshaft striking pan or pan baffle Crankshaft area center of engine timed to Crankshaft area, center of engine, timed to Main bearing engine speed engine speed...
Page 81: Miscellaneous
Miscellaneous Noise Possible Cause Advanced timing Low octane fuel Engine spark knock Engine spark knock Engine running hot Carbon deposits in engine Wrong ignition timing Carburetor set too lean Faulty accelerator pump Vacuum leak Popping through carburetor Valve adjustment Valve timing Burned or stuck valve Vacuum leak Leaking exhaust (manifolds or pipes)
Page 82: Oil Pressure
Oil Pressure Cause Special Information Use a good automotive oil pressure test gauge. Measuring oil pressure Do not rely on the oil pressure gauge in the boat. Oil level should be between the ADD and FULL Check engine oil level with boat at rest in the water marks May cause loss of engine RPM, oil pressure Oil level in crankcase above FULL mark...
Page 83: Low Oil Pressure
Low Oil Pressure Cause Special Information Low oil level in crankcase Verify with an automotive test gauge. Refer to Defective oil pressure gauge and/or sender Section 4D for instrument testing. Oil broken down; contains water or gas; wrong Thin or diluted oil viscosity;...
Page 84: Excessive Oil Consumption
Excessive Oil Consumption Cause Special Information One quart of oil consumed in 5-15 hours of Normal consumption. operation at wide-open-throttle (especially in a new or rebuilt engine) is normal Clean bilge, run engine with clean white paper Oil leaks on bilge floor, locate oil leak(s) Oil too thin Oil diluted or wrong viscosity Oil level too high...
Page 85: Water In Engine
Water In Engine If water is contained to cylinder(s) only, it is usually entering through the intake system, exhaust system, or head gasket. Important Information If the water is contained to crankcase only, it is usual- ly caused by a cracked or porous block, a flooded IMPORTANT: First determine location of water in bilge, or condensation.
Page 86: Water In Crankcase Oil
Water in Crankcase Oil Cause Special Information Boat has been submerged or bilge water was Water in boat bilge high enough to run in through dipstick tube Water seeping past piston rings or valves Refer to “Water in Engine” (“On Top of Pistons”) Defective thermostat, missing thermostat;...
Page 87: Engine Overheats (Cooling System)
Engine Overheats (Cooling System) Cause Special Information IMPORTANT: The first step is to verify if the en- gine is actually overheating or the temperature IMPORTANT: Best way to test gauge or sender is gauge or sender is faulty. to replace them. Loose or broken drive belt Seawater shutoff valve partially or fully closed (if equipped)
Page 88: Insufficient Water Flow From Belt Driven Seawater Pickup Pump
Insufficient Water Flow from Belt Driven Seawater Pickup Pump Cause Special Information Drive belt Loose, worn or broken Seawater shutoff valve partially or fully closed Clogged or improperly installed sea strainer Loose hose connections between seawater pickup Pump will suck air, pump may fail to prime or will and seawater pump inlet force air bubbles into cooling system Seawater inlet hose kinked or plugged...
Page 89: Power Steering
Power Steering Poor, Erratic, or No Assist Cause Special Information Drive belt Worn, broken or out of adjustment Low fluid level Air leak in lines, pump, or air from installation. Air in system Refer to Section 9A for bleeding procedure. Leaking hoses Refer to Section 10A for bleeding procedure.
Page 90: Noisy Pump
Noisy Pump Cause Special Information Drive belt Check belt tension Low fluid level Air in fluid Air leak in lines, pump, or air form installation Faulty pump Use stethoscope to listen for noise in pump Restricted fluid passages Kinks or debris in hoses or debris in passages Stop nut adjusted improperly Refer to appropriate Stern Drive Service Manual Steering cables installed that do not meet BIA...
Page 91: Troubleshooting Silent Choice Exhaust Silencer System
Troubleshooting Silent NOTE: Perform the following tests with engine(s) not running. Choice Exhaust Silencer Compressor will not run System 1. Testing mode switch (ignition switch in RUN posi- tion). a. Purple wire must have battery voltage. If not, fuse is blown or wiring is faulty. b.
Page 92 REMOVAL AND INSTALLATION 72975 MCM MODELS - ALPHA ONE DRIVES Index...
Page 93 Table of Contents Page Torque Specification ..... . 2A-1 Tools/Lubricants/Adhesives/Sealants ..2A-1 Removal ....... . 2A-2 Engine Removal .
Page 94: Torque Specification
Torque Specification Fastener Location Lb. In. Lb. Ft. Cable Barrel Spread Cotter Key Drive Unit Shif C bl Shift Cable Cable End Guide See Note Hose Clamps Securely Rear Engine Mounts 35-40 47-54 Power Steering Fluid Hose Fitting Earlier Style Large Small Later Style Rear Engine Mounts...
Page 95: Removal
Removal CAUTION DO NOT allow lifting sling to hook or compress IMPORTANT: Stern drive unit must be removed prior to engine removal. Refer to Stern Drive Ser- engine components or damage will occur. vice Manual. 13. Support engine with suitable sling through lifting Engine Removal eyes on engine and remove front and rear engine mounting bolts.
Page 96: Installation
Installation IMPORTANT: Engine attaching hardware must be installed in sequence shown. Engine Installation/Alignment 5. Install both rear engine mounting bolts and hard- ware as shown. Torque to 35-40 lb. ft. (47-54 1. Follow instructions “a”-“e”: N·m). a. Be certain fiber washers (cemented in place) on inner transom plate are present.
Page 97 CAUTION DO NOT use an alignment tool from another man- ufacturer. Alignment tools other than Quicksilver Alignment Tool 91-805475A1, may cause improp- er alignment and damage to gimbal bearing and/ or engine coupler. CAUTION To avoid damage to gimbal bearing, engine cou- pler, or alignment tool: DO NOT attempt to force alignment tool! 72585...
Page 98: Engine Connections
e. Recheck alignment with alignment tool. Tool 9. Proceed to “Engine Connections” section in- must enter coupler splines freely. If not, structions following. readjust front mounts. Engine Connections When alignment is correct, tighten locknut or nut with lockwasher on each mount securely. IMPORTANT: When routing all wire harnesses and hoses, be sure they are routed and secured g.
Page 99 2. Connect instrument harness to engine harness WARNING with hose clamp. Tighten clamp securely. Be careful when working on fuel system. Gaso- line is extremely flammable and highly explosive under certain conditions. Do not smoke or allow spark or open flame in area. Wipe up any spilled fuel immediately.
Page 100 2 BARREL CARBURETOR THROTTLE BODY FUEL INJECTION 72013 71711 a - Cable End Guide b - Attaching Hardware c - Cable Barrel a - Flat Washer and Locknut - Tighten Until Nut Bottoms Out, Then Back Off 1/2 Turn. d - Anchor Studs b - Cable Barrel 4 BARREL CARBURETOR c - Flat Washer And Locknut...
Page 101 WEBER 4 BARREL CARBURETOR 7. Connect MerCathode wires to MerCathode con- troller assembly as shown, if so equipped. Apply a thin coat of Quicksilver Liquid Neoprene to all connections. 71159 Wide Open Throttle Position a - Throttle Shaft Lever [Contacts (b) at W.O.T. Position] b - Carburetor Body Casting 22232 a - ORANGE Wire - From Electrode on Transom Assembly...
Page 102 9. Connect power steering fluid hoses to control Later Style Control Valve: Torque both fittings to 23 valve (large fitting first) as shown. lb. ft. (31 N·m). CAUTION Route hoses exactly as shown below. This will help avoid stress on the hose fittings and will help avoid kinks in the hose.
Page 103 REMOVAL AND INSTALLATION 70246 MCM MODELS – ALPHA ONE DRIVES WITH DRIVESHAFT EXTENSION INDEX...
Page 104 Table of Contents Page Torque Specification ..... . 2B-1 Tools/Lubricants/Adhesives/Sealants ..2B-1 Removal ....... . 2B-2 Engine Removal .
Page 105 Torque Specification Fastener Location Lb. In. Lb. Ft. Cable Barrel Spread Cotter Key Drive Unit Shif C bl Shift Cable Cable End Guide See Note Hose Clamps Securely Rear Engine Mounts 35-40 47-54 Power Steering Fluid Hose Fitting Earlier Style Large Small Later Style Rear Engine Mounts...
Page 106: Removal
Removal 6. Slide sleeves back on black and white/green (or gray) wires and disconnect engine harness wires from shift cut-out switch harness. IMPORTANT: It is not necessary to remove the 7. Disconnect MerCathode wires from MerCathode engine to service the drive shaft and/or bearing controller if mounted on engine (some models).
Page 107 14. Mark extension drive shaft U-joint yoke/output 15. Support engine with suitable sling through lifting flange connections at engine end (to assist in ex- eyes on engine and remove front and rear en- act same positioning during reassembly). Dis- gine mounting bolts from boat stringers. Retain connect drive shaft from output flange.
Page 108: Installation
Installation 5. As shown, attach engine output flange to drive- shaft flange exactly as marked during disassem- bly. Torque fasteners to 50 lb. ft. (68 N·m). Engine Installation/Alignment ENGINE MOUNT ADJUSTMENT WAS NOT DISTURBED DURING SERVICE CAUTION Center lifting eye (located on top of thermostat housing) is used for engine alignment only.
Page 109 7. Position engine for correct engine and drive shaft 9. Apply Loctite 8831 to threads of bottom drive lateral alignment as follows: shaft shield retaining screws and install bottom shield on engine end as shown. Torque screws a. Measure the length of (a) and (b) to the cen- to 30 lb.
Page 110 ENGINE MOUNT ADJUSTMENT WAS IMPORTANT: Be sure that boat does not move DISTURBED DURING SERVICE once reading has been taken from input shaft flange, as this reading establishes a reference NOTE: A Universal Protractor is recommended for point for aligning drive shaft and engine follow- measuring the angles in the following steps.
Page 111 8. Relieve hoist tension from engine, then slide en- CAUTION gine fore or aft as needed to obtain 1/4 in. (6 mm) Engine MUST BE aligned correctly to achieve between flange shoulder and extension shaft proper engine operation and to prevent damage housing bearing, as shown.
Page 112 10. After engine has been aligned correctly, fasten 12. Position protractor on drive shaft and recheck front and rear engine mounts to stringers. Tighten angle. Angle should be the same as that re- securely. corded in Step 6. If not, raise or lower all four en- gine mount adjustment nuts an equal amount un- til correct angle is reached.
Page 113: Engine Connections
14. Apply Loctite 8831 to threads of bottom drive Engine Connections shaft shield retaining screws and install bottom shields on engine and transom end as shown. IMPORTANT: When routing all wire harnesses Torque screws to 30 lb. ft. (41 N·m). Then install and hoses, be sure they are routed and secured both top shields as shown.
Page 114 3. Connect two trim position sender leads from gim- WARNING bal housing to leads from engine harness. Be careful when working on fuel system. Gaso- line is extremely flammable and highly explosive under certain conditions. Do not smoke or allow spark or open flame in area.
Page 115 c. Secure throttle cable with hardware (re- e. Return remote control throttle lever to idle tained) as shown. Tighten cable end guide position and check to ensure that throttle nut until it bottoms out and then back off one lever contacts idle speed adjustment screw. full turn.
Page 116 WEBER 4 BARREL CARBURETOR 71159 Wide-Open-Throttle Position a - Throttle Shaft Lever [Contacts (b) at W.O.T. Position] b - Carburetor Body Casting 74109 Throttle Body Fuel Injection a - Cable End Guide b - Throttle Lever Stud c - Locknut and Flat Washer - Tighten Until Nut Bottom Out,Then Back Off One Half Turn d - Throttle Lever e - Throttle Bracket...
Page 117 7. Secure throttle cable with hardware as shown and tighten securely. NOTE: If Boat is equipped with Quicksilver Zero Ef- fort Controls, the throttle cable mounting stud must be most forward position on throttle lever. 73855 a - Position for Zero Effort Controls 74174 IMPORTANT: Do not attach any accessory ground (–) wires to transom plate ground point.
Page 118 IMPORTANT: Do not attach any accessory CAUTION ground (–) wires to transom plate ground point. Route hoses exactly as shown below. This will Accessory ground wires should only be attached help avoid stress on the hose fittings and will to ground stud on engine. help avoid kinks in the hose.
Page 119 11. Using double hose clamps on all connections, in- b. On Engines with Thru-Transom Exhaust: stall exhaust hoses and exhaust tubes as shown in “a” or “b” following. Tighten all hose clamps se- NOTICE (THRU-TRANSOM EXHAUST) curely. Exhaust hoses must be connected to ex- a.
Page 120 REMOVAL AND INSTALLATION 72580 MCM MODELS - BRAVO DRIVES INDEX...
Page 121 Table of Contents Page Torque Specifications ....2C-1 Tools/Lubricants/Adhesives/Sealants ..2C-1 Removal ....... 2C-2 Engine Removal .
Page 122: Torque Specifications
Torque Specifications Fastener Location Lb. In. Lb. Ft. Cable Barrel Spread Cotter Key Drive Unit S f C Shift Cable Cable End Guide See Note Hose Clamps Securely Rear Engine Mounts 35-40 47-54 Power Steering Fluid Hose Fitting Earlier Style Large Small Later Style Rear Engine Mounts...
Page 123: Removal
Removal CAUTION DO NOT allow lifting sling to hook or compress IMPORTANT: Stern drive unit must be removed engine components or damage will occur. prior to engine removal. Refer to Stern Drive Ser- vice Manual. CAUTION Engine Removal Multi-Port engines MUST be lifted with a lifting arm or damage to engine components will occur.
Page 124: Installation
Installation 2. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when sus- pended. (Refer to “Removal” section for loca- tion of lifting eyes.) Engine Installation/Alignment 3. Lift engine into position (in boat), using an over- 1.
Page 125 6. Set engine down on stringers and relieve hoist 7. Align engine as follows: tension. Disconnect sling from engine lifting eyes a. Attempt to insert solid end of Quicksilver and switch sling to center lifting eye. Alignment Tool through gimbal bearing and into engine coupler splines.
Page 126 IMPORTANT: Turn both front engine mount ad- 8. Tighten all exhaust system hose clamps securely justment nuts an equal amount in direction re- as follows (use two hose clamps on each connec- quired to align engine. tion): d. Adjust front engine mounts until they rest on a.
Page 127: Engine Connections
Engine Connections 3. Connect trim position sender leads from gimbal housing to leads from engine harness. IMPORTANT: When routing all wire harnesses and hoses, be sure they are routed and secured to avoid coming in contact with hot spots on en- gine and avoid contact with moving parts.
Page 128 4. Connect fuel line from fuel tank(s) to engine. b. Install cable end guide on throttle lever, then Make certain connections are secure. Check for push cable barrel lightly toward throttle lever leaks. end. (This will place a slight preload on cable to avoid slack in cable when moving remote 5.
Page 129 e. Return remote control throttle lever to idle po- sition and check to ensure that throttle lever contacts idle speed adjustment screw. W.O.T. 72014 4 Barrel Carburetor IDLE a - Cable End Guide b - Attaching Hardware (DO NOT Over-Tighten) c - Cable Barrel 72283 d - Anchor Studs...
Page 130 WEBER 4 BARREL CARBURETOR ELECTRONIC FUEL INJECTION (EFI) 1. Place remote control handle in neutral idle posi- tion. 2. Remove flame arrestor. 3. Install cable end guide on throttle lever, then push cable barrel end lightly toward throttle lever end. (This will place a slight preload on shift cable to avoid slack in cable when moving remote control lever).
Page 131 4. Secure throttle cable with hardware as shown and tighten securely. NOTE: If Boat is equipped with Quicksilver Zero Ef- fort Controls, the throttle cable mounting stud must be most forward position on throttle lever. 73855 a - Position for Zero Effort Controls 74174 5.
Page 132 IMPORTANT: Adjust shift cables as outlined in b. Later Style Control Valve: Torque both fit- appropriate Stern Drive Service Manual. tings to 23 lb. ft. (31 N·m). Route hoses as shown for each model. 9. Refer to appropriate Stern Drive Service Manual and install and adjust drive unit and remote con- trol shift cables, using hardware retained.
Page 133 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 2C-12 - INSTALLATION - BRAVO DRIVES 90-823225--1 1096 INDEX...
Page 134 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 90-823225--1 1096 INSTALLATION - BRAVO DRIVES - 2C-13 INDEX...
Page 135 REMOVAL AND INSTALLATION 70246 MCM MODELS – BRAVO DRIVES WITH DRIVESHAFT EXTENSION INDEX...
Page 136 Table of Contents Page Torque Specification ..... . 2D-1 Tools/Lubricants/Adhesives/Sealants ..2D-1 Removal ....... . 2D-2 Engine Removal .
Page 137 Torque Specification Fastener Location Lb. In. Lb. Ft. Cable Barrel Spread Cotter Key Drive Unit Shif C bl Shift Cable Cable End Guide See Note Hose Clamps Securely Rear Engine Mounts 35-40 47-54 Power Steering Fluid Hose Fitting Earlier Style Large Small Later Style Rear Engine Mounts...
Page 138: Removal
Removal 6. Disconnect MerCathode wires from MerCathode controller if mounted on engine (some models). IMPORTANT: It is not necessary to remove the 7. Disconnect seawater inlet hose from engine. engine to service the drive shaft and/or bearing support (tailstock). Refer to instructions as out- 8.
Page 139 13. Mark extension drive shaft U-joint yoke/output flange connections at engine end (to assist in ex- act same positioning during reassembly). Dis- connect drive shaft from output flange. 72578 70237 Engine End Shown 72581 a - Matching Marks On Flange and Drive Shaft Connection b - Extension Drive Shaft U-Joint Yoke c - Flange- Output CAUTION...
Page 140: Installation
Installation 5. As shown, attach engine output flange to drive shaft flange exactly as marked during disassem- bly. Torque fasteners to 50 lb. ft. (68 N·m). Engine Installation/Alignment ENGINE MOUNT ADJUSTMENT WAS NOT DISTURBED DURING SERVICE CAUTION Center lifting eye (located on top of thermostat housing) is used for engine alignment only.
Page 141 7. Position engine for correct engine and drive shaft 8. After engine has been aligned correctly, fasten lateral alignment as follows: front and rear engine mounts to stringers. Tighten mounting bolts securely. a. Measure the length of (a) and (b) to the cen- ters of bolt holes.
Page 142 ENGINE MOUNT ADJUSTMENT WAS IMPORTANT: Be sure that boat does not move DISTURBED DURING SERVICE once reading has been taken from input shaft flange, as this reading establishes a reference NOTE: A Universal Protractor is recommended for point for aligning drive shaft and engine follow- measuring the angles in the following steps.
Page 143 6. Position base of protractor on drive shaft; then CAUTION raise or lower engine (as boat construction per- Failure to properly position output shaft flange mits) until indicator needle is 1 degree to 3 de- (as described following) may result in bearing grees on either side of reading taken in Step 1.
Page 144 b. Recheck Step 8. If Step 8 is not as specified, 12. Position protractor on drive shaft and recheck adjust and recheck Step 9a. Continue this angle. Angle should be the same as that re- process until both Steps 8 and 9a are as spe- corded in Step 6.
Page 145: Engine Connections
14. Apply Loctite 8831 to threads of bottom drive Engine Connections shaft shield retaining screws and install bottom IMPORTANT: When routing all wire harnesses shields on engine and transom end as shown. and hoses, be sure they are routed and secured Torque screws to 30 lb.
Page 146: Throttle Connections
3. Connect two trim position sender leads from gim- Install fuel line. To prevent over-tightening, bal housing to leads from engine harness. hold brass fitting with suitable wrench and tighten fuel line connectors securely. Check for fuel leaks. 4. Connect fuel line from fuel tank(s) to engine. Make certain connections are secure.
Page 147 e. Return remote control throttle lever to idle po- sition and check to ensure that throttle lever contacts idle speed adjustment screw. W.O.T. 72014 IDLE 4 Barrel Carburetor a - Cable End Guide 72283 b - Attaching Hardware (DO NOT Over-Tighten) c - Cable Barrel Mercarb 2 Barrel Carburetor d - Anchor Studs...
Page 148 WEBER 4 BARREL CARBURETOR ELECTRONIC FUEL INJECTION (EFI) 1. Place remote control handle in neutral idle posi- tion. 2. Remove flame arrestor. 3. Install cable end guide on throttle lever, then push cable barrel end lightly toward throttle lever end. (This will place a slight preload on shift cable to avoid slack in cable when moving remote control lever).
Page 149 4. Secure throttle cable with hardware as shown and tighten securely. NOTE: If Boat is equipped with Quicksilver Zero Ef- fort Controls, the throttle cable mounting stud must be most forward position on throttle lever. 73855 a - Position for Zero Effort Controls 5.
Page 150 IMPORTANT: After fluid hose installation in the 10. Using double hose clamps on all connections, in- following, bleed power steering system as out- stall exhaust hoses and exhaust tubes as shown lined in appropriate Stern Drive Service Manual. in “a” or “b” following. Tighten all hose clamps se- curely.
Page 151 b. On Engines with Thru-Transom Exhaust: NOTICE (THRU-TRANSOM EXHAUST) Exhaust hoses must be connected to ex- haust elbows so that they do not restrict the flow of discharge water from exhaust elbow. If hoses are connected incorrectly, dis- charge water from exhaust elbow will not flow around entire inside diameter of hose.
Page 152 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE INDEX 2D-16 – MCM MODELS - BRAVO MODELS WITH DRIVE SHAFT EXTENSIONS 90-823225--1 1096...
Page 153 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE INDEX 90-823225--1 1096 MCM MODELS- BRAVO MODELS WITH DRIVE SHAFT EXTENSIONS - 2D-17...
Page 154 REMOVAL AND INSTALLATION 70648 MIE MODELS - VELVET DRIVE TRANSMISSIONS INDEX...
Page 155 Table of Contents Page Torque Specifications ..... 2E-1 Lubricants/Sealants ..... . 2E-1 Removal .
Page 156: Torque Specifications
Torque Specifications Lubricants/Sealants Part Number Description Fastener Location Lb. Ft. (N m) Quicksilver 2-4-C Marine Lubricant 92-825407A3 Battery Cables Securely With Teflon Engine Mount Pads Securely 92-25711-2 Quicksilver Liquid Neoprene Securely Hose Clamps Securely Mount Locking Nut Note 2 Propeller Shaft Coupler-to- 50 (68) Transmission Output Flange Securely...
Page 157: Removal
Removal CAUTION Center lifting eye (located on top of thermostat housing) is used for engine alignment only. DO Engine Removal NOT use to lift entire engine. 1. Disconnect battery cables from battery. CAUTION 2. Remove instrument panel harness connector DO NOT allow lifting sling to hook or compress plug from engine harness receptacle after loos- engine components or damage to them will oc- ening clamp.
Page 158: Installation
11. Remove front and rear engine mounting bolts. Retain hardware. 72638 70140 Typical Mount Front Mount - Typical a - Bolts or Lag Screws (with Washers) b - Slot Forward (If So Designed) 12. Carefully remove engine. Installation Engine Installation and Initial Alignment 1.
Page 159: Engine Final Alignment
Engine Final Alignment CAUTION Center lifting eye (located on top of thermostat CAUTION housing) is used for engine alignment only. DO To avoid vibration, noise and damage to trans- NOT use to lift entire engine. mission output shaft oil seal and bearings, en- CAUTION gine must be properly aligned.
Page 160 3. Check that coupling centerlines align, by butting 5. If coupling centerlines are not aligned or if cou- propeller shaft coupler against transmission out- pling faces are more than .003 in. (0.07 mm) out put flange. Shoulder on propeller shaft coupler of parallel, adjust engine mounts as follows: should engage recess on transmission output a.
Page 161: Engine Connections
IMPORTANT: Large diameter of mount trunnion Engine Connections MUST NOT extend over 3/4 in. (20 mm) from IMPORTANT: When routing all wire harnesses mount brackets on any of the mounts. and hoses, be sure they are routed and secured to avoid coming in contact with hot spots on en- gine and avoid contact with moving parts.
Page 162: Fuel Supply Connections
3. Connect instrument harness to engine harness WARNING and secure with clamp. Be careful when working on fuel system. Gaso- line is extremely flammable and highly explosive under certain conditions. Do not smoke or allow spark or open flame in area. Wipe up any spilled fuel immediately.
Page 163 6. Connect and adjust Quicksilver shift cable(s) as NOTICE outlined following: Exhaust hoses must be connected to IMPORTANT: When installing shift cables, be exhaust elbows so that they do not restrict sure that cables are routed in such a way as to the flow of discharge water from exhaust avoid sharp bends and/or contact with moving elbow.
Page 164 Remote control must provide a total shift cable travel IMPORTANT: When installing shift cables, be (at transmission end) of at least 2-3/4 in. (70 mm). sure that cables are routed in such a way as to This is necessary to position transmission shift lever avoid sharp bends and/or contact with moving fully in the forward and reverse gear positions.
Page 165 Place remote control shift lever in forward SINGLE STATION INSTALLATIONS gear position and check position of transmis- sion shift lever. Shift lever must be positioned as shown. CAUTION Remote control and shift cable must position transmission shift lever exactly as shown, or transmission failure may occur.
Page 166 DUAL STATION INSTALLATIONS 7. Follow instructions “a” or “b”: a. On Models Equipped with Other Than Quicksilver Throttle Cables: Attach and adjust throttle cables referring to cable man- ufacturer’s instructions. b. On Models Equipped with Quicksilver Throttle Cables: Connect and adjust throttle cable(s) as outlined following: (1) Place remote control throttle lever(s) in idle position.
Page 167 NOTE: Refer to the following for installations where (4) Place remote control throttle lever(s) in dual station length anchor studs are present but only the wide-open-throttle (W.O.T.) position. a single station cable has been installed. Check to ensure that throttle shutters (valves) are completely open.
Page 168 70392 Weber 4 Barrel Carburetor Shown in Idle Position a - Throttle Lever [Contacts (b) In Idle Position] b - Idle Speed Adjustment Screw 8. Connect any ground wires or accessories that were disconnected from engine. 9. Connect battery cables to battery by FIRST con- 74109 necting positive (+) battery cable end to positive (+) battery terminal.
Page 169 ATTACHING/ADJUSTING THROTTLE CABLE - 350 MAGNUM MPI GEN+ TOURNAMENT SKI 1. Place remote throttle lever in idle position and attach cable to throttle lever stud, following cable manufacturer’s instructions. 2. After throttle cable is adjusted, tighten locknut against cable end. 74174 74838 a - Cable End...
Page 170: Attaching/Adjusting Reversed Attachment Morse Shift Cables
Attaching/Adjusting 3. Attach cable clip to bracket using screws, lock- washers and nuts. Use center holes in cable clip. Reversed Attachment Morse 4. Remove top transmission mounting bolt and Shift Cables lockwasher from left (valve) side of transmission; position bracket, replace bolt and lockwasher. 1.
Page 171 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 2E-16 - MIE MODELS - VELVET DRIVE TRANSMISSIONS 90-823225--1 1096 INDEX...
Page 172 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 90-823325--1 1096 MIE MODELS - VELVET DRIVE TRANSMISSIONS - 2E-17 INDEX...
Page 173 REMOVAL AND INSTALLATION 25280 MIE MODELS – HURTH TRANSMISSIONS INDEX...
Page 174 Table of Contents Page Torque Specifications ..... 2F-1 Lubricants/Sealants ..... . 2F-1 Removal .
Page 175: Torque Specifications
Torque Specifications Lubricants/Sealants Part Number Description Lb. Ft. (N m) Fastener Location 92-825407A3 Quicksilver 2-4-C Marine Lubricant Battery Cables Securely With Teflon Engine Mount Pads Securely Quicksilver Liquid Neoprene 92-25711-2 Hose Clamps Securely Securely Mount Locking Nut Note 2 Propeller Shaft Coupler-to- 50 (68) Transmission Output Flange Cable Barrel...
Page 176: Removal
Removal CAUTION Center lifting eye (located on top of thermostat housing) is used for engine alignment only. DO Engine Removal NOT use to lift entire engine. 1. Disconnect battery cables from battery. CAUTION 2. Remove instrument panel harness connector plug from engine harness receptacle after loos- DO NOT allow lifting sling to hook or compress ening clamp.
Page 177: Installation
11. Remove front and rear engine mounting bolts. (4) Each mount base is downward. Tighten Retain hardware. clamping screws and nuts slightly to pre- vent moving in or out. Mounts must be free to pivot when installing engine. 72638 a - Bolts or Lag Screws (with Washers) 70140 b - Slot Forward Front Mount - Typical...
Page 178: Engine Final Alignment
Engine Final Alignment CAUTION Center lifting eye (located on top of thermostat housing) is used for engine alignment only. DO CAUTION NOT use to lift entire engine. To avoid vibration, noise and damage to trans- mission output shaft oil seal and bearings, en- CAUTION gine must be properly aligned.
Page 179 3. Check that coupling centerlines align, by butting 5. If coupling centerlines are not aligned or if cou- propeller shaft coupler against transmission out- pling faces are more than .003 in. (0.07 mm) out put flange. Shoulder on propeller shaft coupler of parallel, adjust and retighten engine mounts as should engage recess on transmission output follows:...
Page 180: Engine Connections
b. TO MOVE ENGINE TO THE LEFT OR 6. Connect propeller shaft coupler to transmission RIGHT: Loosen clamping screw and nut on output flange. Attach couplers together with all four mount brackets; move engine to the bolts, lockwashers and nuts. Torque to 50 lb. ft. left or right as necessary to obtain proper (68 N·m).
Page 181: Fuel Supply Connections
2. Connect instrument harness to engine harness WARNING with hose clamp. Tighten hose clamp securely. Be careful when working on fuel system. Gaso- line is extremely flammable and highly explosive under certain conditions. Do not smoke or allow spark or open flame in area. Wipe up any spilled fuel immediately.
Page 182 5. Connect and adjust shift cable(s) as outlined fol- IMPORTANT: Check that shift lever is positioned lowing: approximately 10 degrees aft of vertical when in the neutral detent position and that the distance IMPORTANT: When installing shift cables, be (c) between studs in the following is set at 7-1/8 sure that cables are routed in such a way as to in.
Page 183 b. Place remote control shift lever and transmis- h. Place remote control shift lever in reverse sion shift lever in neutral position. gear position and again check to ensure transmission is fully in gear as follows: c. Remove nuts and washers from shift cable attaching studs.
Page 184 SINGLE STATION INSTALLATIONS DUAL STATION INSTALLATIONS 72957 Rear Approach Rear Approach 72960 72956 72956 Front Approach Front Approach 50073 50073 Typical Hurth Transmission Shown Typical Hurth Transmission Shown a - Cable End Guide a - Cable End Guide b - Locknut and Washer b - Locknut and Washer c - Spacer c - Spacer...
Page 185 NOTE: To change cable approach direction on single or dual station installations, only the spacers/bush- ings have to be switched to the opposite stud (the studs are identical). 6. Follow instructions “a” or “b”: IMPORTANT: When installing throttle cables, be sure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts.
Page 186 (4) Place remote control throttle lever(s) in the wide-open-throttle (W.O.T.) position. Check to ensure that throttle shutters (valves) are completely open. (5) Return remote control throttle lever to idle position and check to ensure that throttle lever contacts idle speed adjustment screw.
Page 187 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 90-823225--1 1096 MIE MODELS - HURTH TRANSMISSION - 2F-13 INDEX...
Page 188 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 2F-14 –MIE MODELS - HURTH TRANSMISSION 90-823225--1 1096 INDEX...
Page 189 ENGINE 72615 5.0L / 305 CID / 5.7L / 350 CID Index...
Page 190 Table of Contents Page Page Torque Specifications 5.0L / 305 CID / 5.7L / 350 Installation - Head Installed ... . 3A-32 CID Engines ......
Page 191 Page Page Main Bearings ......3A-52 Installation - Timing Chain Inspection ......3A-53 (Standard Rotation Engine) .
Page 192 Index 3A-0 - ENGINES 90-823225--1 1096...
Page 193 Torque Specifications 5.0L / 305 CID / 5.7L / 350 CID Engines NOTE: Any Differences in Gen + Engines Will Be Noted With “Gen +”. DESCRIPTION Lb. In. Lb. Ft. Alternator Brace to Alternator Alternator Brace to Engine Alternator to Mounting Bracket...
Page 194 350 CID / 5.7L Torque Specifications (Continued) NOTE: Any Differences in Gen + Engines Will Be Noted With Gen +. DESCRIPTION Lb. In. Lb. Ft. Main Bearing Cap Gen + Oil Baffle Nuts Oil Filter Adapter Bolt Oil Pan Drain Plug Oil Pan Corner Nut Oil Pan Nuts (5/16-18) Oil Pump...
Page 195 Special Tools MERCURY MARINE SPECIAL TOOLS DESCRIPTION PART NUMBER Piston Ring Expander 91-24697 Engine Coupler Wrench 91-35547 Rocker Stopper 91-66273 KENT-MOORE SPECIAL TOOLS DESCRIPTION PART NUMBER Valve Spring Compressor (Head on) J5892 Valve Spring Compressor (Head off) J8062 Valve Spring Tester...
Page 196: Lubricants/Sealers/Adhesives
Lubricants/Sealers/Adhesives DESCRIPTION PART NUMBER Quicksilver Loctite 8831 92-823089-1 Quicksilver Perfect Seal 92-34227-1 Quicksilver Needle Bearing Assembly Lubricant 92-825265A1 Quicksilver RTV Sealer 92-91601-1 General Motors Cam and Lifter Prelube or Obtain Locally Equivalent Index 3A-4 - ENGINES 90-823225--1 1096...
Page 197: Engine Specifications
Engine Specifications UNIT OF MEASUREMENT In. (mm) Engine MCM 5.0L / 305 CID Alpha and Bravo Model Displacement 305 CID (5.0 L) Bore 3.74 (95) Stroke 3.48 (88.4) Compression 9.1:1 Ratio Heads Cast Iron Intake Cast Iron Manifold Block Cast Iron (2 Bolt Main Bearing Caps)
Page 198 Engine MCM / MIE 5.7L / 350 CID Alpha and Bravo Gen + Model Displacement 350 CID (5.7 Litre) Bore 4.00 (101.6) Stroke 3.48 (88.4) Compression 9.4:1 Ratio Heads Cast Iron Intake Cast Aluminum Manifold Block Cast Iron (2 Bolt Main Bearing Caps) Rods Forged Steel Crankshaft...
Page 199: L / 305 Cid / 5.7L / 350 Cid Engine
5.0L / 305 CID / 5.7L / 350 CID Engine Specifications (Does Not Include Gen +) Unit Of Measurement In. (mm) CYLINDER BORE ENGINE 5.0L / 305 CID 5.7L / 350 CID 3.7350-3.7385 3.9995-4.0025 Diameter (94.8690-94.9579) (101.5873-101.6635) Out of Round Production .001 (0.025) Max...
Page 200 5.0L / 305 CID / 5.7L / 350 CID Engine Specifications (Does Not Include Gen +) Unit Of Measurement In. (mm) CRANKSHAFT ENGINE 5.0L / 305 CID / 5.7L / 350 CID Main Diameter No.1 2.4484-2.4493 (62.198-62.212) Journal No. 2, 3 2.4481-2.4490 (62.181-62.204)
Page 201 5.0L / 305 CID / 5.7L / 350 CID Engine Specifications (Does Not Include Gen +) Unit Of Measurement In. (mm) VALVE SYSTEM ENGINE 5.0L / 305 CID 5.7L / 350 CID Lifter Type (NOTE 1) Flat Hydraulic Lifter Type (NOTE 1)
Page 202 5.0L / 305 CID / 5.7L / 350 CID Engine Specifications (Does Not Include Gen +) Unit Of Measurement In. (mm) VALVE SPRING ENGINE 5.0L / 305 CID / 5.7L / 350 CID Valve Spring Free Length 2.03 (51.6) (See Note 1)
Page 203 350 CID Gen + Engine Specifications Unit Of Measurement In. (mm) NOTE: These specifications cover only Gen + engines. CYLINDER BORE 4.0007-4.0017 Diameter (101.618-101.643) Production .0005 (0.12) Max Out of Round Out of Round Service .002 (0.05) Max Thrust Side .0005 (0.012) Max Production Production...
Page 204 350 CID Gen + Engine Specifications Unit Of Measurement In. (mm) CRANKSHAFT Main Diameter No.1 2.4484-2.4493 (62.189-62.212) Journal No. 2, 3, 4 2.4481-2.4490 (62.182-62.205) Diameter Diameter No.5 2.4479-2.4488 (62.177-62.199) Production .0002 (0.005) Max Main Taper Taper Journal Service .001 (0.025) Max Production .0002 (0.005) Max Out of Round...
Page 205 350 CID Gen + Engine Specifications Unit Of Measurement In. (mm) VALVE SYSTEM Lifter Type Roller Hydraulic Rocker Arm Ratio 1.50 to 1 Intake .431 (10.947) Valve Lift Valve Lift Exhaust .450 (11.43) Valve Lash (Intake & Exhaust) 1 Turn Down from Zero Lash Face Angle (Intake &...
Page 206: Gen + Engine Specifications
350 Gen + Engine Specifications Unit Of Measurement In. (mm) CAMSHAFT Exhaust .300 (7.62) Lobe Lift Lobe Lift .002 (0.051) 002 (0 051) Intake .287 (7.289) Exhaust .294 (7.467) Duration at .050 In. (1.27mm) Cam Lift Intake .307 (7.797) Journal Diameter 1.8682-1.8692 (47.440-47.490) End Play .011-0.030 (0.004-0.0012)
Page 207: General
General Some of the repairs in this section must be completed MCM (Stern Drive) Code Rotation with engine removed from boat. Engine removal de- 5.0L Alpha and Bravo pends upon type of repair and boat design. Place en- 5.0LX Alpha gine on repair stand for major repairs.
Page 208: Cylinder Head Identification
Cylinder Head Identification Engine Rotation Engine rotation terminology at times has caused confusion. To clarify, engine rotation is determined by observing flywheel rotation from the rear (trans- mission or stern drive end) of the engine looking forward (water pump end). PROPELLER ROTATION IS NOT NECESSARILY THE SAME as engine rotation.
Page 209: Camshaft And Drive
Connecting rods are made of forged steel and are Hydraulic valve lifters ride directly on the camshaft connected to the crankshaft through insert type bear- lobes and transmit the thrust of the lobes to the push ings. rods which in turn actuate the valves through the rocker arm.
Page 210 Some of the oil, after leaving the oil cooler and/or fil- Oil which reaches the valve lifter oil galleries is forced ter, is routed to the No. 5 crankshaft main bearing. into each hydraulic valve lifter through holes in the The remainder of the oil is routed to the main oil gal- side of the lifter.
Page 211: Bearing Failures
Bearing Failures Overlay Wiped Bright (Polished) Scratches Dirt Imbedded Sections into Bearing Scratched Lack of Oil Improper Seating Material by Dirt Radius Ride Craters or Pockets Overlay Gone from Entire Surface 70436 Tapered Journal Radius Ride Fatigue Failure Index 90-823225--1 1096 ENGINES - 3A-19...
Page 212: Piston Failures
72424 Pre-Ignition Damage Engine failures, which result from the foregoing con- ditions, are beyond the control of Mercury Marine; PRE-IGNITION CAUSES therefore, no warranty will apply to failures which oc- 1. Hot spots in the combustion chamber from glow- cur under these conditions.
Page 213: Detonation
Detonation Detonation, commonly called “fuel knock,” “spark knock” or “carbon knock,” is abnormal combustion of the fuel which causes the fuel to explode violently. The explosion, in turn, causes overheating or dam- age to the spark plugs, pistons, valves and, in severe cases, results in pre-ignition.
Page 214: Engine Mounts
Engine Mounts 72318 Rear Mount /Flywheel Housing - MCM a - Gasket Used on MCM Engines Only 72316 Some Models Front Mount - MCM 5.0L/5.0LX/5.7L Rear Mount Front Mount 72319 Front and Rear Mounts and Transmission Base Assembly - MIE 5.7L/5.7L Competition Ski/ 350 Magnum Tournament Ski with In-Line 72317 Transmission...
Page 215 REAR FRONT 72322 Flywheel Housing - MIE Inboard Engines 72320 a - Gasket Used On Some Engines Front and Rear Mounts and Transmission Base Assembly - MIE 5.7L with Hurth 630A Down Angle Transmission a - Transmission Base Assembly (350 Magnum Tournament Ski Only) b - Rubber Insert Cannot Be Removed 72323 Flywheel Housing and Drive Shaft Extension...
Page 216: Rocker Arm Cover
Rocker Arm Cover Intake Manifold Removal Removal It may be necessary to remove exhaust manifold be- 1. Drain engine cooling system. fore removing rocker arm cover. Refer to Section 7B 2. Disconnect hoses from thermostat housing. for removal. Also remove any component that will in- 3.
Page 217: Installation
Installation 2. Place gaskets on cylinder heads. 3. Apply a 3/16 in. (5 mm) wide bead of Quicksilver ALL ENGINES EXCEPT GEN+ RTV Sealer to engine block as shown. Extend sealer 1/2 in. (13 mm) up on intake gaskets. IMPORTANT: When installing intake manifold IMPORTANT: DO NOT get Quicksilver RTV Sealer gaskets, in next step, be sure to do the following: into oil sending unit hole at rear of engine.
Page 218 4. Carefully install manifold assembly and torque GEN+ ENGINES bolts to 35 lb. ft. (48 N·m) in sequence as shown. IMPORTANT: When installing intake manifold gaskets, in next step, be sure to do the following: 1. Apply a 3/16 in. (5 mm) wide bead of Quicksilver RTV Sealer to engine block as shown.
Page 219: Rocker Arm/Push Rod
3. Carefully install manifold assembly and torque 2. Remove rocker arm assemblies and push rods. bolts to 18 lb. ft. (24 N·m) in sequence as shown. IMPORTANT: Place rocker arm assemblies and push rods in a rack for reassembly in their origi- nal locations.
Page 220: Engine Running
2. With engine in No. 1 firing position as determined 6. Crank engine one revolution until pointer “0” above, the following valves may be adjusted. mark and torsional damper mark are again in alignment. This is No.6 firing position. With en- gine in this position, the following valves may be adjusted as previously outlined.
Page 221: Hydraulic Valve Lifters (Flat And Roller Lifter)
5. Repeat Steps 2, 3, 4 to adjust other valves. Locating Noisy Lifters 6. Remove rocker stoppers after all valves are ad- Locate a noisy valve lifter by using a piece of garden justed. hose approximately 4 ft. (1.2 m) in length. Place one end of hose near end of each intake and exhaust 7.
Page 222: Removal
Removal Cleaning and Inspection Thoroughly clean all parts in cleaning solvent and in- IMPORTANT: Keep push rod and hydraulic valve spect them carefully. If any parts are damaged or lifter from each valve together as a matched set worn, entire lifter assembly should be replaced. If and mark them so they can be reinstalled in the outer lifter body wall is scuffed or worn, inspect cylin- same location later.
Page 223 2. Install air line adaptor tool (J-23590) in spark plug 5. Remove seals from valve stems and valve guide. hole and apply compressed air to hold valves in place. NOTE: If compressed air is not available, piston may be brought up to TDC and used to keep valves from falling out of valve guides.
Page 224: Valve Assembly (Exploded View)
Valve Assembly (Exploded View) 5. Install valve locks (Quicksilver Needle Bearing Assembly Lubricant may be used to hold them in place) and slowly release tool, making sure locks seat properly in upper grooves of valve stem. 72306 a - Valve Spring Compressor (J-%892) b - Rocker Arm Nut 6.
Page 225: Cleaning And Inspection
a. All Engines Except Gen+: Torque head CAUTION bolts in three steps, following torque se- The head gasket may be holding cylinder head to quence for each step. Start first step at 20 lb. block. Use care when prying off cylinder heads. ft.
Page 226: Cylinder Head And Valve Conditioning
Cylinder Head and Valve 4. Clean all carbon from combustion chambers and valve ports using carbon remover brush. Conditioning Disassembly 1. Using valve spring compressor, compress valve spring and remove valve locks. Slowly release tool. 72334 a - Carbon Remover Brush (J-8089) 5.
Page 227: Valve Guide Bore Repair
2. Inspect cylinder head gasket surface for burrs, b. Holding valve head off seat about 1/16 in. (2 nicks, or erosion or other damage. Also, check mm), move valve stem back and forth in di- flatness of cylinder head gasket surface, using a rection shown.
Page 228: Valve Springs - Checking Tension
2. Ream valve guide bores, as shown. Valve Springs - Checking Tension Using valve spring tester, as shown, check valve spring tension with dampers removed. Refer to “Specifications.” IMPORTANT: Springs should be replaced if not within 10 lb. ft. (13.5 N m) of specified tension. 72337 3.
Page 229: Rocker Arm Stud Replacement
Rocker Arm Stud Replacement 5. Ream stud hole, whenever installing an oversize stud, using appropriate reaming tool. 1. Rocker arm studs which are worn or loose should 6. Install new stud with rocker arm stud installer. be replaced with oversize studs. 2.
Page 230: Valve Grinding
Several different types of equipment are available for Valve Grinding reseating valve seats. Equipment manufacturer’s Valves that are pitted must be refaced to the proper recommendations should be followed carefully to at- angle. Valve stems which show excessive wear, or tain proper results.
Page 231 5. Place cap on intake valve and/or rotator on ex- 7. Install valve locks (grease may be used to hold haust valve. them in place) and slowly release tool, making sure locks seat properly in upper grooves of valve 6. While compressing valve spring with valve spring stem.
Page 232 8. Check installed height of valve springs using a narrow, thin scale. Measure from spring seat to top of valve spring, as shown. If measurement exceeds specified height, install a valve spring shim and recheck. DO NOT shim valve springs to give an installed height less than the minimum specified.
Page 233: Dipstick Specifications
Dipstick Specifications All Engines UNIT OF MEASUREMENT In. (mm) (13) (13) (13) (13) 14-25/32 31 (787) 13-29/32 (814) (375) (353) 16-1/4 (413) 33-1/2 (849) 33-1/4 (845) 15-19/32 (396) FULL FULL FULL 23/32 FULL 15/16 (18) (19) (24) (19) 72341 15297 805395 16482 805394...
Page 234: Oil Pan
Oil Pan IMPORTANT: Quicksilver RTV Sealer sets up in about 15 minutes. Be sure to complete assembly promptly. Removal 1. Drain crankcase oil. 2. If necessary, disconnect outlet hose from seawa- ter pump. 3. Remove dipstick and tube. On MIE models, be carefull not to disturb orientation of banjo fit- ting on bottom of pan.
Page 235 5. Install dipstick tube and dipstick. On MIE mod- c. Install plug in banjo fitting. els, install dipstick tube as follows: d. Tighten all connections on banjo fitting at this a. Install banjo fitting as shown. Do not tighten time. Torque banjo fitting bolt to 180 lb. in. (20 banjo fitting bolt at this time.
Page 236: Oil Pump
Oil Pump Removal 1. Remove oil pan as outlined. 2. Remove gasket carefully as the one-piece gas- ket for the oil pan may be reused if still pliable and not cracked, torn, etc. 3. Remove baffle. 72146 Oil Pump Assembly 1 - Extension Shaft 2 - Shaft Coupling 3 - Pump Body...
Page 237: Cleaning And Inspection
Cleaning and Inspection Installation 1. Wash all parts in cleaning solvent and dry with 1. Install pump, with extension shaft, to rear main compressed air. bearing, aligning extension shaft with distributor drive shaft. 2. Inspect pump body and cover for cracks or ex- cessive wear.
Page 238: Torsional Damper
Torsional Damper 3. Install torsional damper on crankshaft, using tor- sional damper remover and installer as follows: a. Install appropriate end of threaded rod into Removal crankshaft. 1. Remove drive belts. IMPORTANT: Be sure to install threaded rod in 2. Remove drive pulley, then remove torsional crankshaft at least 1/2 in.
Page 239: Crankcase Front Cover/Oil Seal
Crankcase Front Cover/ Oil Seal Oil Seal Replacement (Without Removing Front Cover) IMPORTANT: The following information refers to all engines except Gen+ Engines. Crankcase front cover is not reusable per G.M. Specifica- tion. It must be replaced if removed. 73125 REMOVAL b - MIE (RH) Rotation Engines c - Seal Lip Toward Inside of Engine...
Page 240: Removal
Crankcase Front Cover 2. Coat both sides of front cover gasket with Quick- silver Perfect Seal and place in position on en- gine. IMPORTANT: The following information refers to 3. Install front cover, making sure holes in cover all engines except Gen+ Engines. Crankcase align with dowel pins in block.
Page 241: Inspection
5. Remove flywheel. NOTE 72349 Alpha One Coupler 72352 NOTE: Some earlier models did not have sealed, Jack Shaft Coupler steel hub coupler. Inspection 1. Inspect splines in drive plate or coupler for wear. 2. Check flywheel ring gear for worn and missing teeth.
Page 242: Installation
Installation IMPORTANT: Insert three rubber bumpers in Al- pha coupler before installation on flywheel. NOTE: If crankshaft is to be replaced, but old pilot bushing is to be reused, bushing can be removed without damage by filling pilot bushing cavity with grease, then inserting an old transmission input shaft in bore of bushing and hitting it with a hammer.
Page 243: Rear Main Oil Seal
Rear Main Oil Seal IMPORTANT: Correct rotation oil seal must be used to prevent oil leak. The rear crankshaft oil seal can be replaced without removing the oil pan or rear main bearing cap from engine. Removal Remove seal by using a screwdriver to pry it out of retainer as shown.
Page 244: Installation
Installation Cleaning and Inspection 1. Apply Quicksilver Perfect Seal to seal retainer 1. Clean gasket material from mating surfaces. mating surface. Apply grease to seal lips. 2. Inspect oil seal retainer for cracks or scored sur- 2. Install seal using rear main seal installer. face.
Page 245: Checking Clearances
When a production crankshaft cannot be precision 2. Place a piece of gauging plastic the full width of fitted by this method, it is then ground .009 in. under- the bearing (parallel to the crankshaft) on the size ON ONLY THOSE MAIN JOURNALS THAT journal as shown.
Page 246 5. On the edge of the gauging plastic envelope 8. Proceed to the next bearing. After all bearings there is a graduated scale which is correlated in have been checked, rotate the crankshaft to see thousandths of an inch. Without removing the that there is no excessive drag.
Page 247 Replacement 2. Install main bearing remover/installer in oil hole in crankshaft journal. If such a tool is not NOTE: Main bearings may be replaced with or with- available, a cotter pin may be bent, as shown, to out removing crankshaft. do the job.
Page 248: Connecting Rod Bearings
Connecting Rod Bearings a. Place a piece of gauging plastic, the length of the bearing (parallel to the crankshaft), on the Connecting rod bearings are of the precision insert crankpin or bearing surface as shown. Posi- type and do not use shims for adjustment. DO NOT tion the gauging plastic in the middle of the FILE RODS OR ROD CAPS.
Page 249 d. Remove the bearing cap and using the scale 9. Measure all connecting rod side clearances (see on the gauging plastic envelope, measure the “Specifications”) between connecting rod caps gauging plastic width at the widest point as as shown. shown. 72362 72363 6.
Page 250 3. Mark connecting rods and bearing caps (left bank Disassembly 1, 3, 5 and 7; right bank 2, 4, 6 and 8 from front Disassemble piston from connecting rod using piston to rear on same side as piston thrust). pin remover as shown. Follow instructions supplied 4.
Page 251 PISTONS 6. Proper clearance of piston ring in its piston ring groove is very important to provide proper ring NOTE: Cylinder bore and taper must be within speci- action and reduce wear. Therefore, when fitting fications before pistons can be considered for re-use. new rings, clearances between ring and groove 1.
Page 252 Connecting rod bearing tangs are always to- ward outside of cylinder block. a - Notch 72369 305 CID / 5.0L Engines 72368 a - Rod Bearing Tangs To determine if engine is left-hand (standard) rotation or right-hand (opposite) rotation, in- spect camshaft drive.
Page 253 1. Assemble piston to connecting rod using piston 3. Measure gap between ends of ring with a feeler pin remover as shown. Follow instructions gauge as shown. supplied with kit. 72372 4. If gap between ends of ring is below specifica- 72371 tions, remove ring and try another for fit.
Page 254 Installation IMPORTANT: Be sure to install new pistons in same cylinders for which they were fitted, and used pistons in same cylinder from which they IMPORTANT: Cylinder bores must be clean be- were removed. Each connecting rod and bearing fore piston installation. Clean with a light honing, cap should be marked, beginning at front of en- as necessary.
Page 255 Crankshaft Cleaning and Inspection 1. Wash crankshaft in solvent and dry with com- pressed air. Removal 2. Measure main bearing journals and crankpin di- 1. Remove engine from boat. mensions with a micrometer for out-of-round, ta- per or undersize (see “Specifications”). 2.
Page 256 3. Carefully lower crankshaft into place. Be careful Removal not to damage bearing surface. 1. Remove torsional damper, oil pan and crankcase 4. Check clearance of each main bearing, following front cover as outlined. procedure outlined under “Main Bearings.” If 2.
Page 257 Installation - Timing Gears Crankshaft Sprocket/Gear (Opposite Rotation Engine) 1. If removed, install crankshaft timing gear as out- Removal lined in “Crankshaft Sprocket/Gear.” 1. Remove torsional damper and crankcase front 2. Position camshaft timing gear so that timing mark cover as outlined. aligns with timing mark on crankshaft timing gear, then align camshaft dowel with hole in camshaft 2.
Page 258 2. Establish a reference point on the block (on taut b. Check the backlash between the camshaft side of chain) and measure from this point to the gear and crankshaft gear while applying in- chain. ward pressure on camshaft gear. 3.
Page 259 d. Check crankshaft timing gear runout in same 2. Position indicator with ball socket adaptor tool on manner. Runout should not exceed .003 in. push rod. Be sure that push rod is in lifter socket. (0.076 mm). Replace both gears, if runout is excessive.
Page 260 b. Install two 5/16-18 x 5 in. bolts in camshaft Installation bolt holes and carefully remove camshaft as 1. Install camshaft as follows: shown. a. Install two 5/16-18 x 5 in. bolts in camshaft bolt holes, then lubricate camshaft journals with engine oil and install camshaft, being careful not to damage bearings.
Page 261 5. Remove remaining bearings (except front and Installation rear) in same manner. It will be necessary to posi- Front and rear bearings must be installed last as pilot tion pilot in rear camshaft bearing to remove rear will not fit into bearing bores if bearings are installed. intermediate bearing.
Page 262: Cylinder Block
3. Install a new camshaft rear plug. 7. Measure cylinder walls for taper, out-of-round or excessive ridge at top of ring travel. This should be done with a dial indicator or inside micrometer. IMPORTANT: Plug must be installed flush to 1/32 Carefully work gauge up and down cylinder to de- in.
Page 263 8. Check cylinder head gasket surfaces for war- page with a machinist’s straight-edge and a feel- er gauge, as shown. Take measurements diago- nally across surfaces (both ways) and straight down center. If surfaces are warped more than .003 in. (0.07 mm) in a 6 in. area or .007 in. (0.2 mm) overall, block must be resurfaced by an au- tomotive machine shop.
Page 264 CYLINDER BORING PISTON SELECTION 1. Before using any type boring bar, file off top of cyl- 1. Check used piston to cylinder bore clearance as inder block to remove dirt or burrs. This is very im- follows: portant to prevent boring bar tilt, with result that a.
Page 265 2. If used piston is not satisfactory, determine if a Inspection and/or Replacement new piston can be selected to fit cylinder bore Oil by-pass valve and adaptor assembly should be within acceptable range. inspected whenever engine is disassembled for ma- 3.
Page 266 ELECTRICAL SYSTEMS 72079 STARTING SYSTEM Index...
Page 267 Table of Contents Page Page Identification ......4A-1 Starting System Components ... . . 4A-15 Replacement Parts Warning .
Page 268: Identification
Identification Replacement Parts Warning The starter identification number is located as shown. WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufac- tured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explo- sion.
Page 269: Direct Drive Starter Motor
Direct Drive Starter Motor Specifications Brush No Load Test Delco Engine Engine Spring Ten- Spring Ten- Identification Min. Max. Min. Max. Rotation sion Volts Number Amps Amps Oz. (Grams) 56-105 10455602 10.6 5400 10800 (1588-2976) Pinion Clearance .010-.140 (0.25-3.5 mm) Commutator End Frame Gap .025 Max.
Page 270: Starting System Components
Starting System Components 72930 a - Ignition Switch b - 20 Amp Fuse c - Starter Slave Solenoid d - Circuit Breaker e - Starter Motor f - Wire Junction g - Neutral Safety Switch Index 90-823225--1 1096 STARTING SYSTEM - 4A-3...
Page 271: Starter Motor (Exploded View)
Starter Motor (Exploded View) 72806 Index 4A-4 - STARTING SYSTEM 90-823225--1 1096...
Page 272: Periodic Inspection
1 - End Housing Periodic Inspection 2 - End Housing Bushing 3 - Thrust Collar Cranking motor and solenoid are completely en- 4 - Retaining Ring - Pinion Stop Collar closed in the drive housing to prevent entrance of 5 - Pinion Stop Collar moisture and dirt.
Page 273 3. Twist solenoid to disengage tab, and remove. IMPORTANT: DO NOT cut starter motor connec- tor strap terminal wire (to remove terminal) or wire will be too short. 72631 a - Field Coil Screws b - Attaching Screws REPLACEMENT OF CONTACTS 72632 1.
Page 274: Starter Motor Disassembly
INSTALLATION 3. Remove screws, center bearing plate and arma- ture. 1. Install solenoid onto plunger. 2. Twist solenoid to engage tab. 3. Install screws and tighten securely. 4. Install field coil connector screw. Starter Motor Disassembly 1. Remove screw from field coil connector. 72634 a - Screws b - Bearing Plate...
Page 275: Armature Tests
5. Check fit of bushing in commutator end frame. If TEST FOR GROUND bushing is damaged or worn excessively, replace 1. With continuity meter, place one lead on arma- end frame assembly. Apply SAE 20 oil to bushing ture core or shaft and other lead on commutator. before reassembly.
Page 276: Loose Electrical Connections
TEST FOR GROUND Reassembly IMPORTANT: Be sure that positive brushes and After all parts are thoroughly tested and inspected leads do not contact field frame assembly during and worn or damaged parts replaced, reassemble test, or false reading will result. starter as follows: 1.
Page 277: Clearances
e. Assemble thrust collar on shaft with shoulder 2. Connect 12 volt battery positive (+) lead to sole- next to snap ring. noid switch and negative (–) lead to solenoid frame. Place thrust collar and retainer next to snap ring and using two pliers squeeze both until 3.
Page 278: Installation
4. Push pinion back toward commutator end to COMMUTATOR END FRAME GAP eliminate slack. To keep the ignition-proof and safety requirement, 5. Measure distance between pinion and pinion re- the gap between the commutator end frame and field tainer. coil housing must be checked. See specifications. If the gap exceeds measurement when checked with 6.
Page 279: Permanent Magnet Gear Reduction
Permanent Magnet Gear Reduction (PG200, PG250 and PG260) Starter Motor Specifications PG 200 STARTER MOTOR No Load Test Delco I.D. Min. Max. Min. Max. Volts Number Amps Amps RPMS RPMS 9000762 10.6 3000 3000 9000768 Brush Spring Tension 83-104 oz. (2353-2948 g.) Pinion Clearance .010-.160 in.
Page 280: Maintenance
Maintenance Testing WARNING CAUTION DO NOT use jumper cables and a booster battery Test battery in well ventilated area as gases given to start engine. DO NOT recharge a weak battery off by battery are hazardous. in the boat. Remove battery and recharge in a Place battery under heavy load (as during engine well ventilated area away from fuel vapors, cranking or with a variable resistor tester) and test...
Page 281: Standard Starter Slave Solenoid
Standard Starter Slave Solenoid Testing/Replacement 1. Using continuity meter, connect test leads as shown, and connect 12 volt battery with jumper leads as shown. 72630 2. If no meter movement is present, replace sole- noid. Index 4A-14 - STARTING SYSTEM 90-823225--1 1096...
Page 282: Starting System Components
Starting System Components 72929 a - ignition Switch b - 20 Amp. Fuse c - Neutral Safety Switch d - Ground Stud e - Starter Motor f - Circuit Breaker g - Starter Slave Solenoid h - Wire Junction Index 90-823225--1 1096 STARTING SYSTEM - 4A-15...
Page 283: Positive Current Flow
Positive Current Flow Description This is a general description of the positive current The Permanent Magnet Gear Reduction (PG200 flow, from the battery and through the system until the and PG250) starter motors feature small permanent starter motor cranks. magnets mounted inside the field frame (NOTE: The actual configuration of these magnets differs be- Battery to the solenoid switch (on starter) tween the PG200, PG250 and PG260;...
Page 284 THIS PAGE IS INTENTIONALLY BLANK Index 90-823225--1 1096 STARTING SYSTEM - 4A-17...
Page 285: And Pg 250 Starter Motor (Exploded View)
PG 200 and PG 250 Starter Motor (Exploded View) 72079 Index 4A-18 - STARTING SYSTEM 90-823225--1 1096...
Page 286: Solenoid Switch
1 - Field Frame (with Permanent Magnets) Solenoid Switch 2 - End Frame 3 - Ball Bearing The solenoid switch, along with plunger, return 4 - Brushes With Frame spring, and shift lever, are completely sealed and 5 - Brush Spring permanently mounted in the drive housing.
Page 287: Disassembly
Disassembly 3. Pull armature out of field frame. NOTE: Permanent magnets inside field frame will be 1. Remove brush lead from solenoid and screws holding armature in place. from end frame. 72062 72060 a - Armature a - Brush Lead b - Field Frame b - Screws 4.
Page 288 5. Remove shield. 7. Remove thrust collar, retaining ring and collar. Remove drive. 72067 72065 a - Thrust Collar a - Shield b - Retaining Ring c - Collar d - Drive 6. Use a screwdriver, as shown, to disengage shift lever from drive.
Page 289: Cleaning And Inspection
Cleaning and Inspection TEST FOR GROUND 1. With continuity meter, place one lead on arma- IMPORTANT: Do not use grease dissolving sol- ture core or shaft and other lead on commutator. vents to clean electrical components, planetary gears, or drive. Solvent will damage insulation 2.
Page 290: Gear Bearing
INSTALLATION Shaft Assembly Bearing IMPORTANT: Brush holder must be installed on IMPORTANT: Roller bearing is not replaceable. If armature before installing armature bearing. bearing is defective, replace entire shaft assem- bly. Apply Quicksilver 2-4-C Marine Lubricant Using the correct size driver, press on inner bearing with Teflon to bearing before starter reassembly.
Page 291: Brushes And Brush Holder
Brushes and Brush Holder INSTALLATION 1. Push each brush up into its guide to allow spring INSPECTION to hold it in place, as shown. Replace brushes and holder when brush leads are touching guide. Make sure brushes move freely in guides. 72072 a - Brush b - Guide...
Page 292: Reassembly
Reassembly 3. Coat roller bearings and gear with a small amount of Quicksilver 2-4-C Marine Lubricant 1. Install end frame on brush holder. Align holes of with Teflon. end frame with holes of brush holder. Tighten screws securely. 72627 a - Roller Bearing b - Roller Bearing c - Gear 72063...
Page 293 d. Position snap ring on upper end of shaft and 6. Apply a thin coating of Quicksilver 2-4-C Marine hold in place with block of wood. Strike wood Lubricant with Teflon to roller bearing in drive block with hammer, thus forcing snap ring housing.
Page 294: Installation
9. Install thru bolts and brush lead. Tighten fasten- ers securely. IMPORTANT: Do not overtighten thru bolts. Over- tightening will bend end frame. 72060 a - Thru Bolts b - Brush Lead Installation IMPORTANT: Install special mounting shim (if equipped) between starter motor and engine block.
Page 295: Pg 260 Starter Motor
PG 260 Starter Motor Exploded View 74270 Index 4A-28 - STARTING SYSTEM 90-823225--1 1096...
Page 296: Solenoid Switch
1 - Screw (2) Solenoid Switch 2 - End Cap 3 - Brush With Holder The solenoid switch can be removed and replaced if 4 - Armature defective. 5 - Field Frame (With Permanent Magnets) 6 - Washer 7 - Shield 8 - Planetary Gears Periodic Inspection 9 - Shaft...
Page 297: Disassembly
Disassembly 4. Remove armature and field frame from drive housing. 1. Remove brush lead from solenoid and screws 5. Pull armature out of field frame. from end frame. NOTE: Permanent magnets inside field frame will be holding armature in place. 74041 a - Brush Lead 74086...
Page 298 7. Remove the three screws retaining the solenoid. 9. Remove solenoid arm and rubber grommet from Remove solenoid from drive housing. the drive housing. 74105 74048 74036 a - Drive Housing b - Solenoid c - Screws (3) 8. Remove drive and associated parts from drive housing.
Page 299: Cleaning And Inspection
11. Remove drive and gear from planetary shaft. Cleaning and Inspection IMPORTANT: Do not use grease dissolving sol- vents to clean electrical components, planetary gears, or drive. Solvent will damage insulation and wash the lubricant out of the drive and gears. Use clean rags and compressed air to clean com- ponents.
Page 300: Armature Tests
Armature Tests 2. If meter hand moves, armature is grounded and must be replaced. TEST FOR SHORTS Check armature for shorts by placing on growler and holding hack saw blade over armature core while ro- tating armature. If saw blade vibrates, armature is shorted.
Page 301 INSTALLATION 2. Place brush holder on armature and remove pieces of wires from brush holder. 1. Push each brush up into its guide, use a 3 inch piece of coat hanger wire or similar stiff wire to retain the spring while installing armature, as shown.
Page 302: Reassembly
Reassembly 2. Install gear and drive over planetary shaft. 1. Install end frame on brush holder. Align holes of end frame with holes of brush holder. Tighten screws securely. 74087 a - Planetary Shaft b - Gear c - Drive 3.
Page 303 e. Position snap ring on upper end of shaft and 5. Install solenoid arm and rubber grommet in the hold in place with block of wood. Strike wood drive housing. block with hammer, thus forcing snap ring over end of shaft. Slide snap ring down into groove.
Page 304 7. Place solenoid in drive housing and tighten 9. Install field frame over armature. Align slot in end screws. cap and field frame for proper positioning of rub- ber grommet. 10. Install field frame and end cap in drive housing align slots in field frame with recess in drive hous- 74036 ing.
Page 305: Clearances
Clearances 5. Measure distance between pinion and pinion retainer. PINION CLEARANCE 6. If clearance is not within limits of .010-.160 in. (0.25-4.00 mm), it may indicate excessive wear Pinion clearance must be checked after reassembly of solenoid linkage, shift lever yoke, or improper of starter motor.
Page 306 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 STARTING SYSTEM - 4A-39...
Page 307 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 4A-40 - STARTING SYSTEM 90-823225--1 1096...
Page 308 ELECTRICAL SYSTEMS 72722 THUNDERBOLT IV AND V IGNITION SYSTEM Index 4B - IGNITION SYSTEM 90-823224 692...
Page 309: Notice
Table of Contents Page Page Thunderbolt IV Ignition System ... . . 4B-1 Thunderbolt IV Ignition Timing ... . 4B-13 Identification .
Page 310 Thunderbolt IV Ignition Replacement Parts Warning System WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufac- Identification tured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explo- sion. Use of replacement electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a fire...
Page 311: Specifications
Specifications Firing Order Coil Firing Order 1-8-4-3-6-5-7-2 Description Specification Coil Part Number 392-7803A4 Primary Resistance .60-.80 Ohms Secondary Resistance 9,400-11,700 Ohms Spark Plugs All MIE and MCM Model Except Gen+ Engines Spark Plug .040 In. (1 mm) AC-MR43T Spark Plug Type NGK BR6FS 72008 Champion RV15YC4...
Page 312: Distributor Advance Curves
Distributor Advance Curves MCM 5.0L ALPHA/MCM 5.0LX ALPHA/MCM 5.0L BRAVO IMPORTANT: Distributor advance curve charts do not include the initial engine timing. Basic initial tim- ing must be added to chart for total advance curve. The spark advance is controlled by the ignition mod- ule.
Page 313 MCM 5.7L ALPHA/MIE 5.7L IMPORTANT: Distributor advance curve charts do not include the initial engine timing. Basic initial tim- ing must be added to chart for total advance curve. IMPORTANT: The spark advance is controlled by the ignition module. Identification Mark: V8-22A Module Advance: 22 Degrees Initial Timing: 8 Degrees BTDC Total Advance: 30 Degrees...
Page 314 MCM 5.7L BRAVO/MCM 350 MAGNUM ALPHA/MIE 5.7L COMPETITION SKI/MIE 350 MAGNUM TOURNAMENT SKI IMPORTANT: Distributor advance curve charts do not include the initial engine timing. Basic initial tim- ing must be added to chart for total advance curve. IMPORTANT: The spark advance is controlled by the ignition module. Identification Mark: V8-24S Module Advance: 24 Degrees Initial Timing: 8 Degrees BTDC...
Page 315: Repair
Repair IMPORTANT: If high tension leads are removed from cap refer to “Spark Plug Wires” in this sec- tion and the following illustrations for installa- tion. Precautions WARNING When performing the following procedure, be sure to observe the following: Be sure that engine compartment is well ven- tilated and that no gasoline vapors are pres- ent, to avoid the possibility of fire.
Page 316: Rotor/Sensor Wheel
Rotor/Sensor Wheel IMPORTANT: If there is any doubt if sensor wheel is located properly, lay sensor wheel on top of the 1. Remove distributor rotor/sensor wheel assembly figure above with sensor fingers facing up (to- from distributor shaft. Rotor and sensor wheel ward you).
Page 317: Sensor
IMPORTANT: The rotor should fit very tight. It 4. Use a magnifying glass and light to inspect the may be necessary to heat rotor with torch lamp two metal “jumper leads” for cracks. If a crack is to properly install. It is important not to let any found in either metal “jumper lead,”...
Page 318: Thunderbolt Iv Ignition Module
Thunderbolt IV Ignition Module Distributor Repair IGNITION MODULE MOUNTED ON EXHAUST Removal ELBOW 1. Unplug wiring harness from ignition module on 1. Unplug wiring harness connector from ignition module. distributor housing, or disconnect wires from igni- tion module mounted on exhaust elbow. Discon- 2.
Page 319: Thunderbolt Iv Exploded View
Thunderbolt IV Exploded View 72058 Index 4B-10 - THUNDERBOLT IV AND V IGNITION SYSTEM 90-823225--1 1096...
Page 320: Disassembly
1 - Distributor Cap Reassembly 2 - Vent 3 - Gasket 1. Lubricate shaft with engine oil. Install E-clip (if 4 - Rotor removed) on shaft in housing. 5 - Senor Wheel 6 - Screws (5) 2. Install washer on shaft. Install original gear; slide 7 - E-Clip onto shaft and install roll pin.
Page 321: Distributor Installation
Distributor Installation b. Remove rocker cover and crank engine until No. 1 intake valve closes, continuing to crank slowly until pointer lines up with timing mark on crankshaft pulley. Engine Not Disturbed 2. Position distributor to opening in block in normal 1.
Page 322: Thunderbolt Iv Ignition Timing
Thunderbolt IV Ignition 5. Adjust timing by loosening distributor clamp and rotating distributor body as required until timing Timing mark on damper or pulley lines up with the mark on tab specified in “Specifications.” Tighten 1. Connect timing light (91-99379 or similar) to No. clamp and recheck location of timing mark.
Page 323: Thunderbolt V Ignition System
Thunderbolt V Ignition System Identification The Thunderbolt V ignition system uses the same distributor as the Thunderbolt IV system. The Ignition Control Module and Knock Control Module are mounted with the ignition control module. 73999 a - Ignition Control Module b - Knock Control Module Index 4B-14 - THUNDERBOLT IV AND V IGNITION SYSTEM...
Page 324: General Description
General Description NOTE: The Audio Warning System is also connected into the ignition module circuit. If the audio warning The Thunderbolt V ignition system has several spark system becomes activated by the closing of one of control features that will be described following: the audio warning system switches, the MBT feature is deactivated.
Page 325: Thunderbolt V Spark Control Graph
Thunderbolt V Spark Control Graph IMPORTANT: The graph below shows the typical advance ranges for a Thunderbolt V ignition control module. The numbers plotted on the graph are not representative of any particular model. It is only pres- ented to provide an understanding of how the system functions. Â...
Page 326: Circuit Description
Circuit Description Knock Control Module The knock control module receives it’s power (+) Refer to the circuit wiring diagram on the following from the PURPLE wire “4”. page for reference to this circuit description. Knock module ground (–) is accomplished thru Ignition Control Module the BLACK wire “2”.
Page 327: Ignition System Wiring Diagram
Ignition System Wiring Diagram = BLACK TO ENGINE HARNESS TO DISTRIBUTOR = BLUE = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE = PINK = PURPLE = RED = TAN WHT = WHITE = YELLOW = LIGHT = DARK IGNITION KNOCK CONTROL...
Page 328: Timing And Idle Adjustment Procedures
Timing and Idle Adjustment 1. Using a jumper wire, connect the ignition system timing lead “13” (PUR/WHT wire) to a good en- Procedures For Thunderbolt gine ground (–). This locks the ignition module into the “Base Timing Mode”. V Ignition 2.
Page 329: Troubleshooting Thunderbolt V Ignition
Troubleshooting Thunderbolt V Ignition Ignition Control Module / Coil / Distributor Check to ensure that tachometer GRY lead is not shorted to ground (–) at the tachometer or 00000 within the harness. No Spark Check all Terminal Connections at Distributor, Ignition Module and Ignition Coil.
Page 330: Knock Control Module
Knock Control Module IMPORTANT: If there is abnormal mechanical en- gine noise (rattles or knocks), they may give a The Knock Control Module contains solid state cir- false knock retard signal. If fuel octane is too high cuitry which monitors the knock sensor’s AC voltage or too low, a false signal can also be sent.
Page 331: Spark Plugs
INSTALLATION OF KNOCK SENSOR Spark Plugs 1. Inspect each plug individually for badly worn IMPORTANT: If installing a new knock sensor, be electrodes, glazed, broken or blistered porcelain sure to replace it with an identical part. Knock and replace where necessary. sensors are very sensitive and designed for each 2.
Page 332: Spark Plug Wires
Spark Plug Wires 1. Inspect spark plugs for damage. 2. Check spark plugs for continuity using Multi- Meter / DVA (91-99750) or similar. 3. Replace any wires that are cracked, cut, or have damaged spark plug boots. 4. Replace any wires that do not show continuity from end to end.
Page 333 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 4B-24 - THUNDERBOLT IV AND V IGNITION SYSTEM 90-823225--1 1096...
Page 334 ELECTRICAL SYSTEM 72078 CHARGING SYSTEM Index...
Page 335 Table of Contents Page Mando 55 and 65 Amp Alternator Identification ......4C-1 Replacement Parts Warning .
Page 336: Mando 55 And 65 Amp Alternator Identification
Mando 55 and 65 Amp Specifications Alternator Identification Description Specification Excitation Circuit 1.3 to 2.5 Volts Current Output 55 A 55 Amp. 50 A 50 Amp. Min. 65 Amp. 60 Amp. Min. Voltage Output 13.9 to 14.7 Volts Min. Brush Length 1/4 in.
Page 337: Description
Description Due to the lack of residual magnetism in the rotor pole pieces, a small amount of current must be The alternator has a rotor, which is supported in two supplied to the rotor field to initially start the alternator end frames by ball bearings, and is driven by a charging.
Page 338: System Components
System Components Periodic Maintenance The alternator system consists of the alternator, bat- The following maintenance check should be per- tery, the ignition switch and the wiring which connects formed every 50 hours or 60 days (whichever comes these components. first) in fresh water areas or every 25 hours or 30 days in salt water areas.
Page 339: Drive Belt Tension Adjustment
Drive Belt Tension Serpentine Belt Adjustment 1. Loosen 5/8 Inch locking nut on adjustment stud. Leave wrench on adjustment stud. 2. Use a 5/16 Inch socket and tighten adjusting stud V-Belt until the correct deflection (1/4 Inch) is obtained. NOTE: Belt deflection should be measured at the 1.
Page 340: Troubleshooting Tests (Alternator On Engine)
Troubleshooting Tests 2. Wiggle engine wiring harness while observing voltmeter. Meter should indicate approximate (Alternator on Engine) battery voltage and should not vary. If no reading is obtained, or if reading varies, check alternator Use the following tests in conjunction with the “Trou- output circuit for loose or dirty connections or bleshooting”...
Page 341: Current Output Test
5. If reading is between 6.0 and 7.0 volts, rotor field 3. Voltmeter should indicate battery voltage. If bat- circuit probably is open. Remove regulator and tery voltage is not present, check sensing circuit inspect for worn brushes or dirty slip rings. Re- (red/purple lead) for loose or dirty connection or place brushes if less than 1/4 in.
Page 342: Voltage Output Test
5. Turn off accessories and reinstall coil wire. Start 2. Start engine and run at fast idle until engine engine and adjust engine speed to 1500-2000 reaches normal operating temperature. Adjust RPM. Quickly observe ammeter. Reading should engine speed to 1500-2000 RPM and observe be at least 30 amps.
Page 343 4. Remove four nuts holding excitation and sensing wires and Phillips screw. Remove regulator cover and install wires and nuts for testing. Connect a jumper wire from the ground stud to the brush ter- minal on the lower right-hand side of the brush assembly.
Page 344 THIS PAGE IS INTENTIONALLY BLANK Index 90-823225--1 1096 CHARGING SYSTEM - 4C-9...
Page 345: Exploded View
Exploded View 72276 Index 4C-10 - CHARGING SYSTEM 90-823225--1 1096...
Page 346: Alternator Repair
1 - Screws (3) Disassembly 2 - Nut (9) 3 - Flat Washer (4) 4 - Sensing Wire (RED / PURPLE) IMPORTANT: The following instructions are for 5 - Excitation Wire (PURPLE) complete disassembly and overhaul of the alter- 6 - Cover nator.
Page 347 4. Remove two brush/regulator attaching screws 7. Separate rear end frame and stator assembly and remove brush/regulator assembly. from front end frame and rotor assembly using two thin blade screwdrivers (positioned 180 de- grees apart from one another) at the locations shown.
Page 348 9. Turn end frame over (stator upward) and remove IMPORTANT: With alternator disassembled to one Phillips head screw which secures rectifiers this point, stator, rectifier, diodes, and rotor may to end frame. be tested, as explained under “Component Test- ing,” following. IMPORTANT: DO NOT clamp vise on rotor pole pieces when removing pulley nut (in next step), as pole pieces may be distorted.
Page 349: Cleaning And Inspection
13. Remove the three phillips head screws and lock- Cleaning and Inspection washers which secure the front bearing retaining 1. Clean all parts with a clean, soft cloth. DO NOT plate. use solvent, or electrical components may be damaged. 2. Inspect the following parts for wear and damage: a.
Page 350: Component Testing
Component Testing d. If reading is low, a short exists in the field cir- cuit. Inspect slip rings to be sure that they are not bent and touching outer slip ring. Also, be ROTOR sure that excess solder is not shorting termi- 1.
Page 351 STATOR RECTIFIER AND DIODE ASSEMBLY NOTE: Failure of any component in tests following IMPORTANT: Stator leads MUST BE discon- will require replacement of entire rectifier assembly. nected from rectifier for this test. NEGATIVE (–) RECTIFIER 1. Test stator for grounds (Test 1), using an ohmme- ter (set on R x1 scale) as follows: IMPORTANT: Rectifier MUST BE disconnected a.
Page 352 POSITIVE (+) RECTIFIER AND DIODES 6. Connect one lead of an ohmmeter (set on R x1) to the common side of the diode and the other lead to the other side, of one of the three diodes. CAUTION DO NOT use a test instrument with more than a 12 volt source (in the following test), as rectifier may be damaged.
Page 353: Reassembly
Reassembly 3. Slide front end frame over rotor. 1. Install new front bearing into front end frame IMPORTANT: DO NOT clamp vise on rotor pole bearing bore using an arbor press. If necessary, pieces when tightening pulley nut (in next step), use a bearing driver that contacts outer race only.
Page 354 7. Position stator down with rear end frame up and 9. Depress brushes flush with top of brush holder reinstall insulators, nuts and condenser. and insert a #54, .050 in. drill bit or smaller into hole in brush holder to hold brushes compressed during reassembly.
Page 355: Installation
11. Install tie strap to rectifier stud and stud on brush/ 13. Install insulator caps. rectifier assembly. Tighten nuts securely. 72078 72823 a - Studs a - Insulator Caps b - Tie Straps Installation 12. Install cover with one phillips head screw and two nuts.
Page 356: Battery Isolators
Mercury Marine does not manufacture any battery isolator systems. Battery isolators must be bought from an outside manufacturer. Mercury Marine sug- gests following the manufacturer’s instructions care- fully.
Page 357: Battery Isolator
Battery Isolator = BLACK = BLUE = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE = PINK = PURPLE = RED = TAN WHT = WHITE = YELLOW = LIGHT = DARK 73080 Alternator with Voltmeter Circuit (Typical Wiring Shown) NOTE: Disconnect ORANGE wire from alternator ”Batt”...
Page 358 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 CHARGING SYSTEM - 4C-23...
Page 359 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 4C-24 - CHARGING SYSTEM 90-823225--1 1096...
Page 360 ELECTRICAL SYSTEM 72747 INSTRUMENTATION Index...
Page 361 Table of Contents Page Page Identification ......4D-1 Dual Station Sender identification .
Page 362: Identification
Identification Special Information NOTE: One of three distinct lines (Series) of Quicksil- Lighting Options ver gauges may be installed (if equipped with Quick- silver gauges). Aside from different gauge face ap- pearances and styling, the back of the gauges and COMMODORE AND INTERNATIONAL SERIES wiring connections are different as shown.
Page 363: Qsi Series
QSI SERIES Gauges These gauges are equipped with optional illumina- Oil, Fuel and Temperature tion lighting. Light bulb socket can be removed and contacts can be aligned to be used with ignition IMPORTANT: If testing proves gauge to be defec- switch lighting circuit +12 V or separate instrumenta- tive, it must be replaced as there is no repair tion lighting circuit LT.
Page 364: Battery Gauge
Connect jumper wire from terminal G (GND) to Battery Gauge terminal S (SEND). TESTING Remove cables from battery and fully charge bat- tery. Connect negative (–) jumper lead from battery to gauge terminal G (GND). Connect positive (+) jumper lead from battery to gauge terminal I or +12 V.
Page 365: Cruiselog Meter
Cruiselog Meter Vacuum Gauge TESTING TESTING Disconnect vacuum hose from engine. Connect Connect jumper wire from negative (–) battery service vacuum gauge to engine and record en- terminal to negative (–) gauge terminal. gine vacuum readings at idle, 1000, 2000 and 3000 RPM.
Page 366: Gauge Replacement
Gauge Replacement Senders Disconnect battery cables from battery. Oil Pressure Remove wires from back of gauge. DUAL STATION SENDER IDENTIFICATION Remove hoses (vacuum, speedometer gauge). Sender will have 353-AM stamped on hex of sender. Disconnect light socket. Remove holding strap and remove gauge. TESTING Position gauge assembly in appropriate mount- IMPORTANT: Use following test procedure for...
Page 367: Water Temperature
Water Temperature WARNING The following test involves the use of intense DUAL STATION SENDER IDENTIFICATION heat. Failure to follow appropriate procedures or Sender will have 362-BC stamped on hex. warnings can cause burns which can result in se- vere personal injury. While performing the fol- REMOVAL lowing test, observe these general precautions: Drain coolant from closed cooling system into a...
Page 368: Installation
Follow these instructions: INSTALLATION a. With ohmmeter connected as outlined and Apply Loctite Pipe Sealant with Teflon to threads using suitable container, thermometer and of temperature sender. heat source, suspend sender with tip in water. Install sender in thermostat housing and tighten b.
Page 369: Capsule Type
With float arm in FULL position (arm horizontal), CAPSULE TYPE ohmmeter should read 30 ohms (+ 5 ohms). Testing Disconnect wire from terminal on fuel tank capsule. Remove two screws and remove capsule assembly. Place a magnet under fuel capsule. Connect ohmmeter between fuel capsule termi- nal and metal portion of capsule housing.
Page 370: Switches
Turn magnet clockwise until fuel capsule indica- With key switch in OFF position, there should be tor reads FULL. Ohmmeter should read 30 ohms no continuity between switch terminals. (+ 5 ohms). Fuel capsule is defective if not within With key switch in RUN position, continuity will specifications.
Page 371: Lanyard Stop Switches
Lanyard Stop Switches NOTICE For repair procedures on MPI / EFI Engines, refer to Section 5C. TESTING 74062 Remote Control Mounted Style Switch - Carbu- reted Engines a - Switch Leads b - Leads (PUR) Disconnect switch leads. Test switch as follows. 74061 a.
Page 372: Start/Stop Switch
IMPORTANT: The BLK/YEL lead is not used. It Audio Warning System should be well insulated and taped to harness. NOTICE Disconnect switch leads. For repair procedures on Fuel Injection Connect an ohmmeter to switch leads. Engines, refer to Section 5C. Switch should have continuity with toggle in the RUN position and no continuity with toggle in the OFF position.
Page 373: Oil Pressure Switch
c. If horn sounds, problem is in tan/blue wire Oil Pressure Switch back to engine or switches on engine. TESTING Remove wire from sender terminal. Connect continuity meter between sender termi- nal and sender hex. (Sender shown removed for clarity.) –...
Page 374: Testing
NOTE: Coolant hoses shown removed for clarity. WARNING Remove switch. The following test involves the use of intense heat. Failure to follow appropriate procedures or TESTING warnings can cause burns which can result in se- vere personal injury. While performing the fol- Connect an ohmmeter between water tempera- lowing test, observe these general precautions: ture switch terminal (+) and hex (case) for ground...
Page 375 c. As temperature rises, switch will close and WARNING ohmmeter will indicate continuity. Refer to Use only clean, dry sand such as used for general chart below for specifications. sandblasting purposes. Use of sand containing contaminants could result in hazards such as 48952 Switch fire, short circuiting, hot-spots, or other hazards.
Page 376: Installation
INSTALLATION REMOVAL Apply Loctite Pipe Sealant with Teflon to threads Disconnect harness wires at switch. of water temperature switch. Remove switch and sealing washer. Install switch in thermostat housing and tighten securely. Connect tan/blue wire and coat connection with Liquid Neoprene. 72770 a - Transmission (Typical) b - Transmission Fluid Temperature Switch With Sealing...
Page 377 Follow these instructions: WARNING a. With an ohmmeter connected as outlined and The following test involves the use of intense using suitable container, thermometer and heat. Failure to follow appropriate procedures or heat source, suspend sender with tip in sand. warnings can cause burns which can result in se- vere personal injury.
Page 378: Installation
INSTALLATION Apply Loctite Pipe Sealant with Teflon to threads of transmission fluid temperature switch. Install switch with sealing washer in transmission and tighten securely. NOTE: Switch is mounted in a fitting on transmission cooler on some later models. Reconnect harness wires and coat with Liquid Neoprene.
Page 379 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 4D-18 - INSTRUMENTATION 90-823225--1 1096...
Page 380 ELECTRICAL SYSTEM 72761 ELECTRICAL KITS Index...
Page 381: Notice
Table of Contents Page Wiring Color Code for MerCruiser Products 4E-1 Lanyard Stop Switches ....4E-1 65503A2 Kit ......4E-1 87-19674A2 or 87-814324A2 Kit .
Page 382 Wiring Color Code for 65503A2 Kit MerCruiser Products INSTALLATION INFORMATION BLK = BLACK 1. Route stop switch wire harness to engine so that BLU = BLUE it will not chafe or flex unnecessarily. Secure har- BRN = BROWN ness with cable ties provided. GRY = GRAY 2.
Page 383 If dashboard is vinyl covered, use a razor blade to re- move vinyl from area to be drilled to keep vinyl from tearing. 72809 Surface Mount - Dual Engines a - Self-Tapping Screw - Drill Pilot Holes Appropriate Drill Bit Aluminum - 5/32 in.
Page 384 4. Secure bullet connectors with retainer and 5. When installation is complete, reconnect battery Sta-Straps. leads at battery and perform operational test. IMPORTANT: On installations where gauge op- tions will not be used, tape back and isolate any unused leads. 72811 a - Join Connectors b - Secure With Sta-Strap...
Page 385 LANYARD STOP SWITCH WIRING DIAGRAM - SINGLE ENGINE 75328 NOTE: Connect wires together with screw and hex nut. Apply Liquid Neoprene to connection and slide rubber sleeve over connection. a - Tachometer b - Oil Pressure c - Water Temperature d - Battery Meter e - Ignition Switch f - Lanyard Stop Switch...
Page 386 LANYARD STOP SWITCH WIRING DIAGRAM - SINGLE FUEL INJECTION ENGINE NOTE Console Mount Remote Control YEL/BLK NOTE NOTE: Lanyard stop switch and neutral start leads must be soldered and covered with shrink tube for a water proof connection. If alternate method of connection is made (use of electrical butt connector) verify connection is secure and sealed for waterproof connection.
Page 387 LANYARD STOP SWITCH WIRING DIAGRAM - DUAL ENGINES NOTE NOTE NOTE THESE LEADS NOT USED ON MERCRUISER YEL/RED BLK/WHT BLK/WHT LANYARD STOP SWITCH 75329 IMPORTANT: On installations where gauge options will not be used, tape back and isolate any unused leads.
Page 388 LANYARD STOP SWITCH WIRING DIAGRAM - DUAL ENGINES NOTE 1 NOTE 1 YEL/RED 75330 Index 90-823225--1 1096 ELECTRICAL KITS - 4E-7...
Page 389 Audio Warning System c. Coat connections with Quicksilver Liquid Neoprene. 5. Reconnect water hoses. WARNING Audio Warning Heat Switch on V-8 Engines Always disconnect battery cables from battery with Closed Cooling before working around electrical system compo- 1. Drain cooling system. nents to prevent injury to yourself and damage to electrical system.
Page 390 Audio Warning Oil Pressure Switch Warning Buzzer 1. Audio warning oil pressure switch (with reducer) is installed in place of engine block plug at the fol- lowing location: 72813 72820 a - Engine Block Plug (Typical) 2. Disconnect TAN/BLUE wire (from audio warning heat switch) at audio warning oil pressure switch.
Page 391 3. Attach PURPLE lead to +12 volt switched termi- 8. Reconnect battery leads. nal of any adjacent gauge [PURPLE to PURPLE 9. Fill closed cooling system (on engines so (BIA)]. The attaching terminal should be OFF equipped) with water/antifreeze solution. when ignition switch is in the OFF position.
Page 392 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 ELECTRICAL KITS - 4E-11...
Page 393 ELECTRICAL SYSTEMS 72938 WIRING DIAGRAMS Index...
Page 394 Table of Contents Page Thunderbolt IV ......4F-1 Alpha Drive - All Engines With Ignition Module Mounted On Exhaust Elbow .
Page 395: Thunderbolt Iv
Thunderbolt IV Alpha Drive - All Engines With Ignition Module Mounted On Exhaust Elbow A. Ignition System C. Audio Warning System B. Starting and Charging System D. Instrumentation System 50843 Index 90-823225--1 1096 WIRING DIAGRAMS - 4F-1...
Page 396 ALPHA DRIVE - ALL ENGINES WITH IGNITION MODULE MOUNTED ON DISTRIBUTOR DISTRIBUTOR WHT/RED WHT/GRN 72935 A. Ignition System C. Audio Warning System B. Starting and Charging System D. Instrumentation System Index 4F-2 - WIRING DIAGRAMS 90-823225--1 1096...
Page 397 BRAVO DRIVE - ALL ENGINES WITH IGNITION MODULE MOUNTED ON EXHAUST ELBOW IGNITION MODULE A: Ignition and Choke System C: Audio Warning System 50844 B: Starting and Charging System D: Instrumentation System Index 90-823225--1 1096 WIRING DIAGRAMS - 4F-3...
Page 398 BRAVO DRIVE - ALL ENGINES WITH IGNITION MODULE MOUNTED ON DISTRIBUTOR DISTRIBUTOR WHT/RED WHT/GRN A. Ignition System C. Audio Warning System 72936 B. Starting and Charging System D. Instrumentation System Index 4F-4 - WIRING DIAGRAMS 90-823225--1 1096...
Page 399 MIE - INBOARD AND SKI ENGINES WITH IGNITION MODULE MOUNTED ON EXHAUST ELBOW IGNITION MODULE A: Ignition and Choke System C: Audio Warning System B: Starting and Charging System D: Instrumentation System 50773 Index 90-823225--1 1096 WIRING DIAGRAMS - 4F-5...
Page 400 MIE - ALL INBOARD AND SKI ENGINES WITH IGNITION MODULE MOUNTED ON DISTRIBUTOR DISTRIBUTOR WHT/RED WHT/GRN 72937 A. Ignition System C. Audio Warning System B. Starting and Charging System D. Instrumentation System Index 4F-6 - WIRING DIAGRAMS 90-823225--1 1096...
Page 401: Mcm V-8 Alpha Thunderbolt V With Knock Sensor
MCM V-8 Alpha Thunderbolt V With Knock Sensor NOTE 74593 NOTE: TAN/BLU wire is not used at distributor. A -Ignition System C-Audio Warning System 1 -Distributor 1 -Water Temperature 2 -Ignition Coil 2 -Drive Unit Oil Level (If Equipped) 3 -Shift Cut-Out Switch 3 -Oil Pressure Switch 4 -Knock Sensor D -Instrumentation System...
Page 402: Mcm V-8 Alpha Thunderbolt V Without Knock Sensor
MCM V-8 Alpha Thunderbolt V Without Knock Sensor NOTE 74593 NOTE: TAN/BLU wire is not used at distributor. A -Ignition System C-Audio Warning System 1 -Distributor 1 -Water Temperature 2 -Ignition Coil 2 -Drive Unit Oil Level (If Equipped) 3 -Shift Cut-Out Switch 3 -Oil Pressure Switch B -Starting System D -Instrumentation System...
Page 403: Mcm V-8 Bravo Thunderbolt V With Knock Sensor
MCM V-8 Bravo Thunderbolt V With Knock Sensor NOTE 1 73996 NOTE: TAN/BLU wire is not used at distributor. A -Ignition System C-Audio Warning System 1 -Distributor 1 -Water Temperature 2 -Ignition Coil 2 -Drive Unit Oil Level (If Equipped) 3 -Knock Sensor 3 -Oil Pressure Switch B -Starting System...
Page 404: Mcm V-8 Bravo Thunderbolt V Without Knock Sensor
MCM V-8 Bravo Thunderbolt V Without Knock Sensor NOTE 1 74592 NOTE: TAN/BLU wire is not used at distributor. A -Ignition System C-Audio Warning System 1 -Distributor 1 -Water Temperature 2 -Ignition Coil 2 -Drive Unit Oil Level (If Equipped) B -Starting System 3 -Oil Pressure Switch 1 -Alternator...
Page 405: Mie V-8 (Bluewater) Thunderbolt V Without Knock Sensor
MIE V-8 (Bluewater) Thunderbolt V Without Knock Sensor NOTE 2 NOTE 1 74592 NOTE 1: Taped back BROWN/WHITE wire may be used for an accessory. LOAD MUST NOT EXCEED 5 AMPS. NOTE 2: Taped back TAN/BLUE wire not used. A -Ignition System C-Audio Warning System 1 -Distributor 1 -Water Temperature Switch...
Page 406: Mie (Bluewater) V-8 Thunderbolt V With Knock Sensor
MIE (Bluewater) V-8 Thunderbolt V With Knock Sensor NOTE 2 NOTE 1 74160 NOTE 1: Taped back BROWN/WHITE wire may be used for an accessory. LOAD MUST NOT EXCEED 5 AMPS. NOTE 2: Taped back TAN/BLUE wire not used. A -Ignition System C-Audio Warning System 1 -Distributor 1 -Water Temperature Switch...
Page 407: Mie (Ski) V-8 Thunderbolt V Without Knock Sensor
MIE (Ski) V-8 Thunderbolt V Without Knock Sensor NOTE 2 NOTE 1 74160 NOTE 1: Taped back BROWN/WHITE wire may be used for an accessory. LOAD MUST NOT EXCEED 5 AMPS. NOTE 2: Taped back TAN/BLUE wire not used. A -Ignition System C-Audio Warning System 1 -Distributor 1 -Water Temperature Switch...
Page 408: Efi System Harness
EFI System Harness 90 AMP FUSE A - Audio Warning System C - Charging and Starting System 1 - Oil Pressure Switch 1 - Alternator 2 - Transmission Fluid Temperature 2 - Ground Stud Switch 3 - Starter 4 - Circuit Breaker B - Instrumentation System 5 - Starter Slave Solenoid 1 - Oil Pressure Sender...
Page 409 MCM ALPHA, BRAVO AND BLACKHAWK OLD STYLE BOTTLE NEW STYLE BOTTLE 90 AMP FUSE 71693 A - Audio Warning System C - Charging and Starting System 1 - Oil Pressure Switch 1 - Alternator 2 - Drive Unit Oil Level 2 - Ground Stud 3 - Starter B - Instrumentation System...
Page 410: Efi Engine Harness
EFI Engine Harness MCM 5.7L EFI Alpha With Vapor Separator Tank (VST) NOTE 1 NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness. NOTE 1: As a mid year (96-1/2) model change, the EFI (Throttle Body Injection) models have the lanyard stop connector removed from the wiring harness.
Page 411: Mcm 5.7L Efi Alpha With Cool Fuel System
MCM 5.7L EFI Alpha With Cool Fuel System 7371 NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness. 1 - Electric Fuel Pump 12- Electronic Control Module (ECM) 2 - Throttle Body 13- Fuel Pump Relay 3 - Distributor 14- Ignition/System Relay 4 - Coil...
Page 412: Mcm 5.7L Efi Bravo With Vapor Separator Tank (Vst)
MCM 5.7L EFI Bravo WIth Vapor Separator Tank (VST) NOTE 1 73717 NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness. NOTE 1: As a mid year (96-1/2) change, the EFI (Throttle Body Injection) models have the lanyard stop connec- tor removed from the wiring harness.
Page 413: Mcm 5.7L Efi Bravo With Cool Fuel System
MCM 5.7L EFI Bravo WIth Cool Fuel System 73717 NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness. 1 - Vapor Separator Tank (VST) 12- Electronic Control Module (ECM) 2 - Throttle Body 13- Fuel Pump Relay 3 - Distributor 14- Ignition/System Relay 4 - Coil...
Page 414: Mcm 350 Mpi Bravo And Blackhawk (Including Gen + Engines) With Vapor Separator Tank (Vst)
MCM 350 MPI Bravo and Blackhawk (Including Gen + Engines) With Vapor Separator Tank (VST) NOTE 1 74182 Note: All BLACK Wires With A Ground Symbol Are Interconnected Within The EFI System Harness. NOTE 1: As a mid year (96-1/2) model change, the MPI (Multi Port Injection) models have the lanyard stop con- nector and dual engine data link connector removed from the wiring harness.
Page 415: Mcm 350 Gen+ Mpi Bravo And Blackhawk With Cool Fuel System
MCM 350 Gen+ MPI Bravo and Blackhawk With Cool Fuel System 74182 Note: All BLACK Wires With A Ground Symbol Are Interconnected Within The EFI System Harness. 1 - Electrical Fuel Pump 12- Electronic Control Module (ECM) 2 - Throttle Body 13- Fuel Pump Relay 3 - Distributor 14- Ignition/System Relay...
Page 416: Mie 350 Magnum Mpi Gen + Tournament Ski (Black Scorpion)
MIE 350 Magnum MPI Gen + Tournament Ski (Black Scorpion) NOTE 1 74893 Note: All BLACK Wires With A Ground Symbol Are Interconnected Within The EFI System Harness. NOTE 1: As a mid year (96-1/2) model change, the MPI (Multi Port Injection) models have the lanyard stop con- nector removed from the wiring harness.
Page 417: Mie 350 Magnum Efi Gen + Tournament Ski / 5.7L Gen+ Inboard With Cool Fuel System
MIE 350 Magnum EFI Gen + Tournament Ski / 5.7L Gen+ Inboard With Cool Fuel System NOTE 1 75001 Note: All BLACK Wires With A Ground Symbol Are Interconnected Within The EFI System Harness. NOTE 1: As a mid year (96-1/2) model change, the MPI (Multi Port Injection) models have the lanyard stop con- nector removed from the wiring harness.
Page 418: Mcm Quicksilver Instrumentation
MCM Quicksilver Instrumentation MCM EARLIER STYLE CONTROLS AND AUDIO WARNING BUZZER 72938 NOTE 1: Connect wires together with screw and hex nut. Apply Liquid Neoprene to connection and slide rubber sleeve over connection. NOTE 2: Power for a fused accessory panel may be taken from this connection. Load MUST NOT exceed 35-40 amps.
Page 419 MCM LATER STYLE CONTROLS AND AUDIO WARNING BUZZER Refer to gauge manufacturer’s instructions for specific connections. NOTE 1. Connect Wires Together with Screw and Hex Nut; Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection. NOTE 2. Power for a Fused Accessory Panel May Be Taken from This Connection.
Page 420 MIE QUICKSILVER INSTRUMENTATION EARLIER STYLE AUDIO WARNING BUZZER 72939 NOTE 1: Connect wires together with screw and hex nut. Apply Liquid Neoprene to connection and slide rubber sleeve over connection. NOTE 2: Power for a fused accessory panel may be taken from this connection. Load MUST NOT exceed 35-40 amps.
Page 421 MIE LATER STYLE AUDIO WARNING BUZZER 74274 NOTE 1: Connect wires together with screw and hex nut. Apply Liquid Neoprene to connection and slide rubber sleeve over connection. NOTE 2: Power for a fused accessory panel may be taken from this connection. Load MUST NOT exceed 35-40 amps.
Page 422 DUAL STATION WIRINGUSING A NEUTRAL SAFETY SWITCH IN ONLY ONE REMOTE CONTROL SECONDARY STATION STOP-START TACHOMETER WATER BATTERY PRESSURE PANEL TEMPERATURE METER UNSW SEND SEND SEND NOTE 3 YEL/RED NOTE 1 PRIMARY STATION WATER BATTERY IGNITION TACHOMETER TEMPERATURE METER PRESSURE SWITCH RED/PUR BRN/WHT...
Page 423 DUAL STATION WIRING USING A NEUTRAL SAFETY SWITCH IN BOTH REMOTE CONTROLS SECONDARY STATION STOP-START TACHOMETER WATER BATTERY PRESSURE PANEL TEMPERATURE METER UNSW SEND SEND SEND NOTE 3 NOTE 3 YEL/RED NOTE 1 PRIMARY STATION WATER BATTERY IGNITION TACHOMETER TEMPERATURE METER PRESSURE SWITCH...
Page 424 DUAL STATION WIRING USING A NEUTRAL SAFETY SWITCH IN ENGINE WIRING HARNESS SECONDARY STATION STOP-START TACHOMETER WATER BATTERY PRESSURE PANEL TEMPERATURE METER UNSW SEND SEND SEND NOTE 3 YEL/RED NOTE 1 PRIMARY STATION WATER BATTERY IGNITION TACHOMETER TEMPERATURE METER PRESSURE SWITCH RED/PUR BRN/WHT...
Page 425: Battery Meter Gauge
Battery Meter Gauge Fuel Gauge and Sender 72814 a - Lamp Mounting Hole b - Purple (or White) Jumper Wire from This Terminal to I (or +) Terminal on Water Temperature or Oil PressureGauge c - Black Jumper Wire from This Terminal to Ground Terminal on Water Temperature or Oil Pressure Gauge 72816 Cruiselog...
Page 426: Water Temperature Gauge
Water Temperature Gauge Clock Connect to a Terminal on an Adjacent Gauge or to Another Suitable Ground Connect to Instrument Harness RED/PURPLE Lead and Slide a Rubber Sleeve over Connection Connect to an “I” Terminal of an Adjacent Gauge or to Any Switched 12 Volt Terminal 72818 72819 BIA Color Code...
Page 427 FUEL SYSTEM 50830 FUEL DELIVERY SYSTEMS AND FUEL PUMPS Index 5A - FUEL DELIVERY SYSTEMS AND FUEL PUMPS 90-823224 692...
Page 428 Table of Contents Page Identification ......5A-1 Replacement Parts Warning ....5A-1 Torque Specifications .
Page 429: Identification
Identification Fuel Supply Connections WARNING Avoid gasoline fire or explosion. Improper instal- lation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and/or cause a fuel leak. Apply #592 Loctite Pipe Sealant with Teflon to threads of brass fitting or plug.
Page 430: Precautions
Precautions Fuel Delivery System WARNING Recommendations Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire WARNING or explosion. Boating industry standards (BIA, ABYC, etc.) federal standards and Coast Guard regulations WARNING MUST BE adhered to when installing fuel deliv- Be careful when changing fuel system compo- ery system.
Page 431: Fuel System Components
Fuel System Components Carburetor System 50830 a - Fuel Tank b - Anti-Siphon Valve c - Water Separating Fuel Filter d - Fuel Pump e - Carburetor f - Fuel Filter g - Vent Hose h - Fuel Line i - Sight Tube 1 - Boat Fuel System Index 90-823225--1...
Page 432: Throttle Body Injection With Vapor Separator Tank
Throttle Body Injection With Vapor Throttle Body Injection With Cool Separator Tank Fuel System 74871 73895 a - Vacuum Line To Flame Arrestor b - Fuel Pressure Regulator a - Throttle Body Unit c - Fuel Cooler b - Fuel Line To Throttle Body d - Electric Fuel Pump c - Return Line From Throttle Body e - Water Separating Fuel Filter...
Page 433: Multi-Port Injection With Vapor Separator Tank (Vst)
Multi-Port Injection With Vapor Multi-Port Injection With Cool Fuel Separator Tank (VST) System 74871 a - Vacuum Line To Intake Manifold b - Fuel Pressure Regulator c - Fuel Cooler d - Electric Fuel Pump 73895 e - Water Separating Fuel Filter a - Fuel Injector (8) f - Fuel From Tank b - Fuel Rail...
Page 434: Earlier Style Starboard Mounted Fuel System For 350 Magnum Mpi Gen + Tournament Ski (Black Scorpion)
Earlier Style Starboard Mounted Fuel System for 350 Magnum MPI Gen + Tournament Ski (Black Scorpion) 74868 a - Fuel Pressure Regulator b - Fuel Cooler c - Electric Fuel Pump d - In-Line Fuel Filter e - Water Separating Fuel Filter f - Starboard Fuel Rail g - Port Fuel Rail h - From Fuel Tank...
Page 435: Water Separating Fuel Filter
Water Separating Fuel Filter NOTICE Refer to “Precautions,” in this section, BEFORE proceeding. The water separating fuel filter is standard on all en- gines. The fuel filter consists of the fuel filter base and fil- ter element. 72678 Carburetor and VST Equipped Engines a - Fuel Filter Mounting Bracket b - Filter Element c - Sealing Ring...
Page 436: Replacement
Replacement NOTICE Refer to “Precautions,” in this section, BEFORE proceeding. 1. Disconnect battery cables from battery. 2. Remove fuel filter from base. A filter wrench may be needed to loosen element. 3. Lubricate sealing ring(s) of new filter with SAE engine oil.
Page 437: Testing Mechanical Fuel Pump
Testing Mechanical Fuel 1. Disconnect battery cables from battery. Pump CAUTION NOTICE Plug fuel supply hose after removal to prevent Refer to “Precautions,” in this section, fuel from leaking into boat. BEFORE proceeding. 2. Use a wrench to stabilize brass coupling at fuel filter inlet fitting, loosen fuel line fitting, disconnect and suitably plug fuel line to prevent fuel in tank 1.
Page 438 FUEL SYSTEM 72681 MERCARB 2 BARREL CARBURETOR Index...
Page 439 Table of Contents Page MerCarb 2 BBL Carburetor ....5B-1 Torque Specifications ....5B-1 Tools .
Page 440: Mercarb 2 Bbl Carburetor
MerCarb 2 BBL Carburetor Units of Measurements In. (mm) 00000 Torque Specifications DESCRIPTION LB. FT. N·m Carburetor To Manifold Fuel Line to Carburetor Fuel Inlet Filter Nut Tools DESCRIPTION PART NUMBER Universal Carburetor Gauge 91-36392 Boroughs Special Tool and Equipment Inc. 2429 N.
Page 441: Exploded View
Exploded View 72686 Index 5B-2 - MERCARB 2 BARREL CARBURETOR 90-823225--1 1096...
Page 442 1 - Rod - Accelerator Pump 32- Washer-Locking 2 - Accelerator Pump Shaft and Lever Assembly 33- Nut 3 - Washer (Outer) 34- Throttle 4 - Washer (Inner) 35- Spring 5 - Screw 36- Screw - Idle Speed Adjustment 6 - Washer 37- Throttle Body 7 - Screw 38- Screw...
Page 443: Identification
Identification WARNING Electrical, ignition and fuel system components on your MerCruiser are designed and manufac- tured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explo- sion. Use of replacement electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a fire 33049565...
Page 444: Adjustable Accelerator Pump Lever
Adjustable Accelerator Pump Lever High Altitude Re-Jetting This new lever with will allow you to change the Engine flooding problems, at idle RPM, are generally amount of fuel delivered to the engine by the acceler- related to the altitude (above sea level) at which they ator pump.
Page 445: Precautions
Precautions Maintenance Flame Arrestor with Carburetor WARNING Cover Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire NOTICE or explosion. Refer to “Precautions,” in this section, BEFORE proceeding. WARNING 1. Remove in the following order: a.
Page 446: Fuel Inlet Filter
3. Install in the following order: Fuel Inlet Filter a. Flame arrestor. NOTICE b. Crankcase ventilation hoses to flame arres- Refer to “Precautions,” in this section, BEFORE tor and rocker arm covers. proceeding. c. Carburetor cover. 1. Remove in the following order: d.
Page 447: Choke Inspection
Choke Inspection 2. With throttle valves completely closed, measure from flame arrestor mounting surface to top of The choke does not require any periodic mainte- pump rod. nance; however, if a choke malfunction is suspected, the following should be done: 1.
Page 448: Choke Setting
Choke Setting 4. Bend tang on throttle lever, if necessary, to obtain specified dimension. Normal choke setting is such that scribed mark on cover is in line with long case mark on choke hous- ing. 72685 a - Tang b - Throttle Lever 72403 Preliminary Idle Speed and Mixture a - Scribed Mark...
Page 449: Final Idle Speed And Mixture
2. Turn idle mixture needle in until lightly seated, 2. If new or rebuilt carburetor has been installed, then back needle out 1-1/4 turns. turn idle mixture needle in (clockwise) until it lightly contacts seat, then back out needle 1-1/4 turns.
Page 450: Repair
Repair Installation 1. Thoroughly clean gasket surfaces. NOTICE 2. Place new carburetor base gasket on intake Refer to “Precautions,” in this section, manifold. Install carburetor and secure with nuts BEFORE proceeding. and washers. Torque to 132 lb. in. (15 N·m). 3.
Page 451: Disassembly
Disassembly AIR HORN ASSEMBLY IMPORTANT: Before performing any service on 1. Remove fuel inlet filter nut, washers, spring, and carburetor, it is essential that carburetor be filter, as outlined previously. placed in a holding fixture to prevent possible 2. Remove accelerator pump rod retaining clip. damage to throttle valves.
Page 452 72400 a - Air Horn Assembly 72286 b - Float Bowl Assembly a - Choke Rod 5. Invert air horn and carefully lay on bench. b - Choke Lever c - Slot 6. Remove float hinge pin and lift float assembly from air horn.
Page 453 7. Check float weight as shown. 9. Remove needle assembly. 72122 72287 a - Grams Scale a - Needle Assembly b - Float b - Needle Seat 8. Remove air horn gasket and baffle. 10. Remove needle seat. 72399 a - Baffle b - Air Horn Gasket 72289 a - Needle Seat...
Page 454 FLOAT BOWL ASSEMBLY 1. Remove accelerator pump return spring from pump well. 72290 Needle and Seat Assemblies a - Spring Loaded Type Needle (Kit 3302-9029) b - Solid Type Needle (Kit 3302-9407) 11. Loosen accelerator pump screw. Slide pump shaft and lever assembly (and washer) out of air horn, then remove accelerator pump assembly.
Page 455 3. Remove main metering jets. 5. Using a needle-nose pliers, remove accelerator pump check ball spring retainer. Turn float bowl over to remove spring and check ball. 72407 72291 a - Spring Retainer b - Spring and Check Ball (Not Shown) a - Main Metering Jets THROTTLE BODY ASSEMBLY b - Gaskets (Not Shown)
Page 456: Cleaning And Inspection
2. Remove idle mixture adjusting needle and Cleaning and Inspection spring. IMPORTANT: DO NOT use a wire or drill to clean jet passages or tubes in carburetor, as this may enlarge orifices and seriously affect carburetor calibration. CAUTION To avoid damage to carburetor DO NOT leave car- buretor in immersion type carburetor cleaner for more than two hours.
Page 457: Reassembly
1. Thoroughly clean all metal parts in a commercial placed if choke valve and shaft and lever as- carburetor cleaner, until all deposits have been sembly are worn or damaged. removed. Follow cleaner manufacturer’s instruc- Inspect Casting for visible damage. Inspect tions for proper cleaning and rinsing procedure.
Page 458 3. Turn float bowl assembly upside down and place FLOAT BOWL ASSEMBLY new throttle body gasket on bowl, making sure gasket is properly positioned on location dowels. IMPORTANT: Place float bowl and throttle assem- blies in holding fixture to prevent throttle valves from being damaged.
Page 459 3. Install venturi cluster in carburetor as shown. 5. Install main metering jets with gaskets as shown. Tighten securely. 72397 72291 a - Venturi Cluster a - Main Metering Jets b - Gasket b - Gaskets (Not Shown) 4. Install flat washer and new fiber washer on center 6.
Page 460 7. Place accelerator pump spring in pump well. 2. Insert pump shaft and lever assembly (and wash- er) into air horn; then, align indexed hole in pump lever with shaft and lever assembly and slide shaft all the way into lever so that shoulder on shaft is hitting lever.
Page 461 4. Place needle assembly in needle seat. 6. Install float assembly and hinge pin. Pivot float assembly up and down on hinge pin to ensure it moves freely. 72287 a - Needle Assembly 72297 b - Needle Seat a - Float Assembly 5.
Page 462 FLOAT DROP 1. Hold air horn right side up to allow float to hang free. 2. Measure float drop using Universal Carburetor Gauge (91-36392). Measure from gasket to toe of float. 72687 a - Measurement with 2 Piece Solid Inlet Needle - 3/8 in. (10mm) Measurement with Spring Loaded Inlet Needle - 9/16 in (14mm)
Page 463 4. Recheck BOTH float level and float drop. 7. Place end of choke rod in choke lever and collar assembly. 5. Carefully place air horn on float bowl, making sure accelerator pump is correctly positioned in fuel well. Lower air horn straight down to install. 72299 72400 a - Choke Rod...
Page 464 9. Secure idle cam (with choke rod installed on 11. Insert remaining end of accelerator pump rod into cam) on float bowl assembly, using screw. Check hole in throttle lever and secure with retainer clip. that cam is free to move without binding. 72283 72282 a - Accelerator Pump Rod...
Page 465 2. Install choke cover. Make sure hook on end of choke coil engages with choke lever. Rotate choke cover until index marks align as shown. Tighten screws securely. 72403 a - Scribed Mark b - More Choke c - Less Choke Index 5B-26 - MERCARB 2 BARREL CARBURETOR 90-823225--1 1096...
Page 466 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 MERCARB 2 BARREL CARBURETOR - 5B-27...
Page 467 FUEL SYSTEMS 72085 ROCHESTER 4 BARREL CARBURETOR Index...
Page 468 Table of Contents Page Identification ......5C-1 Replacement Parts Warning ....5C-1 Torque Specifications .
Page 469 Identification Tools Part Number Description 91-36392 Universal Carburetor Gauge 91-59339 Tachometer Kent-Moore Special Tools Can be ordered from: Kent-Moore Tools, Inc. 29784 Little Mack Roseville, MI 48066 Phone: (313) 574-2332 Part Number Description J9789-118 Carburetor Stand J22769 Needle Valve Seat Remover Wagner Special Tools 72085 Can be ordered from:...
Page 470: Carburetor Specifications
Carburetor Specifications Carb Primary Secondary Type Mercury No. Primary Metering Metering (Note) (Manufacturer No.) Rods Rods Model Jet Size MCM 5.0LX Rochester 1347-9661 .069 In. .042 In. (17080565) Rochester MIE 5.7L 1347-9415 .069 In. .042 In. Competition Ski (17085013) NOTE: Rochester Quadrajets are 4MV type. The “V” or “C” designates choke type, NOT bore size.
Page 471: Description
Description WARNING The Quadrajet carburetor has two stages in opera- Be careful when changing fuel system compo- tion. The primary (fuel inlet) side has small bores with nents; gasoline is extremely flammable and highly explosive under certain conditions. Be a triple venturi set-up equipped with plain tube sure that ignition key is OFF.
Page 472: Fuel Filter
2. Clean and Inspect: Fuel Filter a. Clean flame arrestor in solvent and blow dry NOTICE with compressed air. Refer to “Precautions,” in this section, BEFORE b. Clean crankcase ventilation hoses. proceeding. c. Inspect crankcase ventilation hose for cracks or deterioration; replace if necessary. 1.
Page 473: Adjustments
Adjustments 3. Close throttle valves completely and measure from flame arrestor mounting surface to top of pump plunger stem. NOTICE Refer to “Precautions,” in this section, BEFORE proceeding. Accelerator Pump 1. Back out idle stop screw until it no longer contacts throttle lever.
Page 474: Air Valve Dashpot
Air Valve Dashpot 2. To adjust spring windup, hold tension spring screw and loosen Allen head screw. 1. Seat vacuum break diaphragm and close air 3. Adjust tension and retighten allen screw secure- valve completely. Bend rod to adjust gap to speci- fications.
Page 475: Choke Coil Rod
2. Tap float gauge down lightly to assure free move- Choke Coil Rod ment. 1. Push choke coil rod down. 72082 a - Gauge 72096 a - Vacuum Break Choke Lever 3. Take gauge reading at top of carburetor casting. b - Choke Coil Rod 2.
Page 476: Vacuum Break
3. Bend rod to adjust. 2. Rotate vacuum break choke lever counterclock- wise until tang contacts vacuum break rod. Choke rod must be at bottom of choke shaft lever slot. 72097 72095 a - Tang b - Choke Rod a - Bend Here c - Vacuum Break Rod 3.
Page 477: Preliminary Idle Speed And Mixture
Preliminary Idle Speed and Mixture Final Idle Speed and Mixture Initial start setting; make final adjustments with en- gine running. IMPORTANT: Boat MUST BE in the water and en- gine at normal operating temperature to accu- rately check and adjust idle speed and mixture. 1.
Page 478: Repair
Repair WARNING DO NOT leave the helm unattended while per- forming idle speed and mixture adjustments, fol- NOTICE lowing. BE CAREFUL NOT TO ACCIDENTALLY Refer to “Precautions,” in this section, BEFORE ACCELERATE ENGINE WHILE PERFORMING proceeding. ADJUSTMENTS. 4. With boat in open water, place remote control in IMPORTANT: Carburetor malfunctions are, in forward gear, idle position.
Page 479 3. Disconnect sight tube (if equipped). 6. Disconnect throttle cable. 72103 72100 a - Throttle Cable a - Sight Tube 7. Disconnect cable end guide. IMPORTANT: Place a clean cloth in bores of car- buretor to prevent dirt and foreign material from falling into bores.
Page 480: Installation
8. Remove retaining nuts and bolts; remove carbu- Installation retor and cable bracket. 1. Install new gasket onto manifold. 2. Install carburetor and throttle bracket and torque IMPORTANT: Place a clean cloth over intake man- to 132 lb. in. (15 N·m). ifold opening to prevent dirt or foreign material from entering manifold.
Page 481 4. Connect fuel sight tube. 6. To install throttle cable refer to Section 2 - “Re- moval and Installation.” 7. Install flame arrestor and tighten securely. 8. Reconnect battery cables to battery. 9. Start engine and check for gasoline leaks. If leaks exist, STOP ENGINE IMMEDIATELY and re- check connections.
Page 482 1 - Air Horn Assembly 2 - Screw 3 - Hanger 4 - Metering Rod, Secondary 5 - Screw 6 - Screw 7 - Screw 8 - Lever 9 - Roll Pin 10 - Pump 11 - Spring 12 - Needle and Seat 13 - Gasket 14 - Pull Clip 15 - Gasket...
Page 483: Disassembly
Disassembly 2. Remove choke shutter clip and rod. IMPORTANT: Place carburetor on a holding fix- ture to prevent throttle valve damage. AIR HORN 1. Remove vacuum pump rod clip and rod. 72107 a - Clip 72105 a - Rod Clip 72108 a - Choke Shutter Rod 72106...
Page 484 3. Drive roll pin back and remove accelerator pump 5. Remove air horn screws and air horn. lever and rod. 72109 72111 a - Roll Pin (Not Shown) a - Air Horn Screws b - Pump Lever c - Rod 4.
Page 485 FLOAT BOWL 3. Remove float assembly, needle and retaining pin. 1. Remove pump plunger, return spring and gasket. 72113 72115 a - Pump Plunger a - Float Assembly b - Return Spring b - Needle c - Gasket c - Retaining Pin 4.
Page 486 5. Remove primary metering jets, pump discharge 7. Remove vacuum control assembly and hose. check ball retainer and check ball. 72117 a - Primary Metering Jets b - Pump Discharge Retainer 72119 c - Check Ball (Not Shown) a - Vacuum Control Assembly b - Hose 6.
Page 487: Cleaning And Inspection
9. Separate throttle body from float bowl and re- THROTTLE BODY move gasket. 1. Remove idle mixture screws and springs. 72121 a - Attaching Screws 72123 b - Throttle Body a - Screw c - Gasket b - Spring d - Float Bowl IMPORTANT: Throttle body should not be disas- FLOAT WEIGHT sembled any further than shown.
Page 488 2. Using compressed air, blow out all passages in b. Maintain seal on hose connection; plunger carburetor to remove any foreign material. must remain seated. If plunger extends, re- place unit. 3. Wipe off all parts that cannot be cleaned in carburetor cleaner with a clean, dry cloth.
Page 489: Reassembly
Reassembly FLOAT BOWL IMPORTANT: Place carburetor on a holding fix- THROTTLE BODY ture to prevent damage to throttle valve. 1. Install baffle plate. NOTICE Refer to “Adjustments” for all adjustment pro- cedures. IMPORTANT: Seat idle mixture screws lightly or damage to needles and seats will result. 1.
Page 490 b. Insert choke shaft on vacuum break control IMPORTANT: Float needle and seat should be re- assembly to engage flat sided hole of choke placed as a set only. lever, and secure with screw. Tighten se- 4. Install float needle seat and gasket. curely.
Page 491 b. If a new float or needle and seat are used, 6. If float requires adjustment hold hinge pin firmly, bend float arm slightly upward at notch for turn carburetor upside down and measure from easier adjustment. casting surface to toe of float with universal car- buretor gauge.
Page 492 9. Install primary main metering rods in power pis- 11. Push power piston retainer down until flush with ton hanger, and connect spring as shown. casting. 72134 72132 a - Power Piston Retainer a - Power Piston Hanger b - Tension Spring c - Metering Rods 12.
Page 493 13. Install accelerator pump plunger spring. 2. Install accelerator pump plunger. 72138 72136 a - Plunger a - Spring 3. Install air horn. AIR HORN 1. Install new gasket and slide tab under power pis- ton hanger. 72112 72137 a - Air Horn a - Power Piston Hanger b - Gasket Tab Index...
Page 494 4. Install nine attaching screws. Tighten securely in 5. Install secondary metering rods into hanger with sequence as numbered. upper ends toward each other as shown. 72111 72140 a - Long a - Hanger b - Short b - Metering Rods c - Countersunk 6.
Page 495 7. Install pump lever rod. 9. Press roll pin into place using a screwdriver. 72080 a - Pump Lever Rod 72141 a - Roll Pin 8. Install rod into lever inner hole and place lever into casting mount. 10. Install bottom end of choke shutter rod into inter- mediate choke lever in float bowl.
Page 496 11. Install upper end of choke shutter rod into the 13. Install rod into vacuum break arm and install clip. choke blade lever; install clip onto choke shutter rod. 72105 a - Rod b - Vacuum Break Arm c - Clip 72107 14.
Page 497 FUEL SYSTEMS 70389 WEBER 4 BARREL CARBURETOR Index 5B - WEBER 4 BARREL CARBURETOR 90-823224 692...
Page 498 Table of Contents Page Identification ......5D-1 Replacement Parts Warning ....5D-1 Torque Specifications .
Page 499: Identification
Identification Torque Specifications Fastener Location in. lb. lb. ft. N·m Carburetor To Manifold Fuel Line To Carburetor Tools Description Part Number Universal Carburetor 91-36392 Gauge 70389 Tachometer 91-59339 Universal Carburetor Stand a - Weber Identification Number Location Obtain Locally Obtain Locally Torx Screwdriver (15,20,25) Replacement Parts Warning...
Page 500 Specifications MCM Models Metering Mercury Number Second- Metering Carb Primary Engine Model (Manufacturer ary Jet Spring Type Jet Size Number) Size Number Color 3310-805484 (9661) .104 .101 16-7147 Natural 5.7L Alpha L Al h 3310-806761 (9665) .101 .095 16-7052 Pink 3310-806761 (9665S) .101...
Page 501: Carburetor Adjustment Specifications
UNIT OF MEASUREMENT In. (mm) ALL MEASUREMENTS ARE 1/64 In. (0.4 mm). Carburetor Adjustment Specifications Float Level 1-9/32 in. (33 mm) Float Drop 2 in. (51 mm) Pump Rod Hole Location Third Hole From End Accelerator Pump 7/16 in. (11 mm) Choke Pull-Off 15/64 in.
Page 502: Description
Description WARNING Be careful when changing fuel system compo- Weber WFB carburetor is unique in design, as the nents: gasoline is extremely flammable and high- main body and flange are cast as a one piece unit. ly explosive under certain conditions. Be sure This, along with the bowl cover, make up the two that ignition key is OFF.
Page 503: Important Service Information
Important Service Hard Starting Information If a hard starting condition exists, after engine has not been operated for a period of time, proceed with the following: Weber Carburetor Adjustable 1. Before starting engine, remove flame arrestor Accelerator Pump then operate throttle to see if choke closes. 2.
Page 504: Carburetor Metering Rod And Jet Identification
Carburetor Metering Rod And Jet METERING JETS Identification The metering jets in this carburetor are taller than the jets in a standard carburetor. METERING ASSEMBLY Three Step Two Step The metering rod assemblies are different in the fol- lowing ways: Three Step 73728 a - Three Step Metering Rod...
Page 505: Maintenance
PISTON ASSEMBLY COVER IS HIGHER ELECTRIC CHOKE The electric choke should be set with marks aligned. 73735 Two Step Three Step 73725 74104 Maintenance Flame Arrestor 73736 NOTICE PISTON BORE HAS A STEP ON THREE STEP Refer to “Precautions,” in this section, MODEL BEFORE proceeding.
Page 506: Fuel Filter
3. Install (in the following order): Fuel Filter a. Flame arrestor NOTICE b. Crankcase ventilation hoses to flame arres- Refer to “Precautions,” in this section, tor and rocker arm covers BEFORE proceeding. c. Carburetor cover Carburetor inlet fuel filter is installed in bottom side of d.
Page 507: Adjustments
Adjustments 2. Close throttle valves completely. 3. Accelerator pump is set at 7/16 in. (11 mm), which NOTICE is measured from the carburetor top to the bottom Refer to “Precautions,” in this section, of the S-link as shown. BEFORE proceeding. Accelerator Pump IMPORTANT: Refer to “Important Service Infor- mation”...
Page 508: Choke Pull-Off
Choke Pull-Off 2. Bend choke pull-off linkage to achieve setting giv- en in Step 1. 1. Choke pull-off is checked by holding in on vacu- um diaphragm and attempting to close choke plate. The gap between the plate and housing is to be set at 15/64 in.
Page 509: Float Level
IMPORTANT: Do not put pressure on fuel needle 2. If float level requires adjustment, hold hinge pin valve and seat while bending tab, or damage may firmly and bend float arm shown, as needed. result. IMPORTANT: Do not put pressure on fuel needle valve and seat while bending tab, or damage may result.
Page 510: Idle Speed And Mixture Adjustments
Idle Speed and Mixture IMPORTANT: Do not turn idle mixture screws tightly against seat, as damage to seat and/or Adjustments needle may result. Thunderbolt IV Equipped Engines PRELIMINARY IDLE SPEED AND MIXTURE Initial start settings are given following. Make final ad- justment with engine running (refer to “Final Idle Speed and Mixture”).
Page 511 FINAL IDLE SPEED AND MIXTURE 4. With boat in open water, place remote control in forward gear, idle position. IMPORTANT: Boat MUST BE in the water and en- 5. Disconnect throttle cable barrel from anchor gine at normal operating temperature to accu- stud.
Page 512: Thunderbolt V Equipped Engines
Thunderbolt V Equipped Engines IMPORTANT: In order to properly set idle speed, the ignition module MUST BE locked in the “Base Timing Mode”. This is necessary because of the ADJUSTING IDLE MIXTURE “Idle Speed Control” feature that exists in the The procedure for adjusting carburetor idle mixture ignition module.
Page 513: Repair
Repair 4. Disconnect retaining clip and choke linkage rod. NOTICE Refer to “Precautions,” in this section, BEFORE proceeding. Removal IMPORTANT: Carburetor malfunctions are, in many cases, caused by the presence of dirt, wa- ter or other foreign matter in carburetor. To aid in diagnosis, carefully remove carburetor from en- 71096 gine without draining fuel from bowl.
Page 514: Installation
6. Remove adaptor/wedge plate (if so equipped) from manifold and discard old gasket. 7. Place a clean cloth over intake manifold open- ings. IMPORTANT: Covering intake manifold prevents entry of dirt or foreign material through open- ings. Installation 1. Place appropriate new gasket on intake man- ifold.
Page 515 5. Connect choke linkage rod and install retaining clip. 71096 a - Clip b - Linkage Rod 6. Refer to Section 2. Install and adjust throttle cable following instructions appropriate to your power package. 7. Install flame arrestor and tighten nut securely. 8.
Page 516: Exploded View
Exploded View Weber Carburetor Index 5D-18 - WEBER 4 BARREL CARBURETOR 90-823225--1 1096...
Page 517 1-Air Deflector (2) Disassembly 2-Screw (2) The following is a step-by-step procedure for com- 3-Cover, Metering Rod (2) 4-Metering Rod Assembly (2) pletely overhauling carburetor after removal from en- 5-Spring, Metering Rod (2) gine. In many cases, however, complete overhaul is 6-Fuel Inlet Fitting not necessary and, in these cases, only the steps re- 7-Sealing Washer...
Page 518 2. Remove wire clip to disconnect choke plate link- 4. Remove screws from choke pull-off diaphragm age. bracket to disengage choke pull-off linkage. NOTE: Depending on amount of service required, it may not be necessary to remove diaphragm and bracket. 70391 70394 a - Screws...
Page 519 5. Loosen (not necessary to remove, depending on 7. Remove metering rod springs. amount of service required) metering rod cover screws. Turn cover, or remove, to expose meter- IMPORTANT: Metering rod springs are color ing rod. coded and should not be interchanged with other carburetors.
Page 520 9. Carefully lift off carburetor top and disconnect 11. Remove inlet needle from seat. choke linkage. IMPORTANT: Be careful not to mix up inlet needles and seats after removal. 70399 70401 10. Slide pin out to remove the float. IMPORTANT: Be careful not to mix up floats after removal.
Page 521 12. Remove seat, gasket, and inlet filter. 14. Remove accelerator pump lever. IMPORTANT: Be careful not to mix up seats after removal. 70449 a - Accelerator Pump b - Accelerator Pump Lever c - Retaining Screw 15. Remove accelerator pump. 70447 a - Seat b - Gasket...
Page 522 16. Remove accelerator pump spring from bottom 17. Remove two screws that secure primary venturi half of carburetor. cluster. 70453 70451 a - Accelerator Pump Spring a - Screw(s) Two On Each Side b - Carburetor Bottom b - Primary Venturi Cluster(s) IMPORTANT: Before removing venturi clusters, it 18.
Page 523 19. Remove gasket from beneath venturi cluster. 21. Remove secondary venturi cluster by lifting it straight up. 70455 70457 a - Gasket Primary Venturi Cluster 22. Remove gaskets from beneath secondary ven- 20. Remove two screws that secure secondary ven- turi clusters.
Page 524 23. Remove secondary air valve and weight assem- 25. Remove pump jet housing. bly by lifting it straight out. 70461 70459 a - Pump Jet Housing a - Secondary Air Valve And Weight Assembly 26. Remove gasket from beneath pump jet housing. 24.
Page 525 IMPORTANT: If your carburetor had a ball and IMPORTANT: Do not mix up the primary and sec- weight combination, replace with ball and ondary jets. Make note of the jet sizes and their weight. If your carburetor used a ball and spring location before removal to be certain that during combination, replace with ball and spring.
Page 526: Cleaning And Inspection
30. Remove mixture screws. IMPORTANT: DO NOT use a wire or drill to clean jets, passages, or tubes in carburetor, as this may enlarge orifices and seriously affect carbu- retor calibration. 3. Wipe all parts that cannot be cleaned in immer- sion cleaner with a clean, dry cloth.
Page 527: Reassembly
Reassembly 3. Install the float bowl baffle plates, if previously removed. 1. Install mixture screws (needles) with springs in place. Turn idle mixture screws in (clockwise) un- til LIGHTLY seated, then back out one and quar- ter (1-1/4) turns if previous settings were not noted on disassembly.
Page 528 5. Position pump jet housing gasket. 7. Install two screws that secure pump jet housing. Tighten securely. 70462 70460 a - Gasket, Pump Jet Housing a - Screws b - Pump Jet Housing 6. Install pump jet housing. 8. Install the secondary air valve and weight assem- bly.
Page 529 IMPORTANT: Before installing venturi clusters, it 10. Install the secondary venturi clusters. is important to note which clusters were equipped with a “distribution tab.” This distribu- tion tab arrangement varies from one carburetor to another. 70457 a - Secondary Venturi Cluster 11.
Page 530 12. Position the primary venturi cluster gaskets. 14. Secure each cluster with two screws. Tighten se- curely. 70455 70453 a - Gasket, Primary Venturi Cluster a - Screws (Two Each Side) 13. Install the primary venturi clusters. b - Primary Venturi Cluster(s) 15.
Page 531 16. Install accelerator pump in top of carburetor 18. Install gasket on top of carburetor. housing, after placing washer and guide in posi- tion. 70448 a - Gasket 19. Install inlet filter in bottom of inlet seat. Install inlet seat with gasket in place. Tighten securely. 70450 a - Accelerator Pump b - Plunger Guide...
Page 532 IMPORTANT: If using existing needles and seats, 21. Install floats using hinge pins. be sure to reinstall them as matched sets, as noted during disassembly. 20. Install appropriate inlet needles into inlet seats. 70400 a - Pin(s) b - Floats(s) 22.
Page 533 23. Ensure gasket is properly positioned between 25. Carefully install metering rod assemblies in the the two parts and secure the top to bottom with appropriate holes. Push down lightly on metering screws (nine total). Tighten securely. rods to ensure that plunger will spring up and down.
Page 534 27. Reconnect choke pull-off linkage to carburetor. 29. Reconnect choke plate linkage. Secure with wire Reinstall choke pull-off diaphragm. Secure with clip. two screws and tighten securely. 70392 70394 a - Screw(s) b - linkage Rod 28. Reconnect vacuum hose to choke pull-off dia- phragm.
Page 535 30. Reconnect accelerator pump linkage rod to hole in accelerator pump lever where originally con- nected or refer to “Important Service Information” in this section for information regarding adjust- ment. Accelerator pump linkage adjustment should be checked at this time; refer to Adjust- ments - “Accelerator Pump”...
Page 536 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 5D-38 - WEBER 4 BARREL CARBURETOR 90-823225--1 1096...
Page 537 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 WEBER 4 BARREL CARBURETOR - 5D-39...
Page 538 FUEL SYSTEMS 71692 MULTI-PORT AND THROTTLE BODY FUEL INJECTION Index...
Page 539 Table of Contents Page Page General Information ..... 5E-1 MCM 5.7L EFI Bravo With Introduction ......5E-1 Vapor Separator Tank .
Page 540 Page Page Diagnostics-Without Scan Tool ..5E-88 350 CID / 5.7L EFI (4 Barrel Throttle Body) Code 14: Engine Coolant Temperature (ECT) Induction System ....5E-150 Sensor Circuit (Non-Scan) (1 of 2) .
Page 541 THIS PAGE IS INTENTIONALLY BLANK Index 5E-0 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 542: General Information
General Information Visual/Physical Inspection A careful visual and physical inspection must be performed as part of any diagnostic procedure. CAUTION This can often lead to fixing a problem without To reduce the chance of personal injury and/or further steps. Inspect all vacuum hoses for correct property damage, the following instructions routing, pinches, cuts, or disconnects.
Page 543: Diagnostic Information
Diagnostic Information damaged. Always use jumper wires with the corre- sponding mating terminals between connectors for The diagnostic charts and functional checks in this circuit checking. NEVER probe through connector manual are designed to locate a faulty circuit or com- seals, wire insulation, secondary ignition wires, ponent through logic based on the process of elimi- boots, nipples or covers.
Page 544: Abbreviations
Electromagnetic Interference TERM Terminal Engine Throttle Position Ground Volts Gallons Per Hour Vacuum Idle Air Control Wide Open Throttle Intake Air Temperature in-hg Inches Of Mercury Ignition Control Index 90-823225--1 1096 ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) - 5E-3...
Page 545 Changes In Terminology Due to industry standardization of terminology for certain electronic engine controls some names and abbrevi- ations have changed. From (CTS) Coolant Temperature Sensor (ECT) Engine Coolant Temperature (TPS) Throttle Position Sensor (TP) Throttle Position (MAT) Manifold Air Temperature (IAT) Intake Air Temperature (EST) Electronic Spark Timing (IC) Ignition Control...
Page 546: Ecm Self-Diagnostics
ECM Self-Diagnostics An intermittent code may or may not reset. IF IT IS AN INTERMITTENT FAILURE, A DIAGNOSTIC The ECM performs a continual self-diagnosis on cer- CODE CHART IS NOT USED. Consult the “Diagnos- tain control functions. This diagnostic capability is tic Aids”...
Page 547: Scan Tools
If a scan tool is used to read the codes, follow the EFI Diagnostic Circuit Check manufacturer’s instructions. After the visual/physical inspection, the EFI Diagnos- tic Circuit Check is the starting point for all diagnostic SERVICE MODE procedures. Refer to EFI Diagnostic Circuit Check. When the diagnostic code tool is installed at the Data The correct procedure to diagnose a problem is to fol- Link Connector (DLC) and the selector switch is set...
Page 548: Non-Scan Diagnosis Of Driveability Concerns (With No Codes Set)
CLEARING CODES USING DIAGNOSTIC CODE Non-Scan Diagnosis of Driveability TOOL (NON-SCAN) Concerns (With No Codes Set) 1. Install diagnostic code tool. If a driveability concern still exists after following the 2. Turn key ON. diagnostic circuit check and reviewing “Trouble- shooting,”...
Page 549: Special Tools
Special Tools Part Number Tool Name Description Minimum 10 megohm input impedance required on all voltage ranges. As ammeter, accurately mea- High Impedance Multi- J-34029-A(Note 1) sures low value current flow. As ohmmeter, reads meter (DVM) 0-200 ohms, 2/20/200 kΩ, 2/20 mΩ Vacuum Pump with Gauge monitors manifold engine vacuum.
Page 550: Service Precautions
Service Precautions (such as the high impedance digital multimeter) in series with the test light being tested, and pow- The following requirements must be observed: er the test light ammeter circuit with the vehicle battery. 1. Before removing any ECM system component, disconnect the negative battery cable.
Page 551: Electronic Control Module (Ecm) And Sensors
Electronic Control Module THREE-WIRE SENSORS (MAP AND TP) The following figure shows a schematic representa- (ECM) and Sensors tion of a 3-wire sensor. All 3-wire sensors have a ref- erence voltage, a ground and a variable “wiper.” The lead coming off of the wiper will be the signal to the General Description Engine Control Module (ECM).
Page 552: Digital Signals
Digital Signals SWITCH TYPES Switched inputs (also known as discretes) to the Digital signals are also variable, but not continuously. computer can cause one bit to change, resulting in in- They can only be represented by distinct voltages formation being communicated to the computer. within a range.
Page 553: Speed Density System
ECM FUNCTION SPEED The ECM supplies 5 or 12 volts to power various sen- The engine speed signal comes from the distributor’s sors or switches. This is done through resistances in High Energy Ignition (HEI) module to the ECM on the the ECM which are so high in value that a test light distributor reference high circuit.
Page 554: Ecm Input And Sensor Descriptions
ECM Input and Sensor Descriptions The following lists the sensors, switches, and other inputs used by the ECM to control its various systems. Al- though we will not cover them all in great detail, there will be a brief description of each. DISCRETE SWITCHES (AUDIO WARNING) KNOCK...
Page 555 ENGINE COOLANT TEMPERATURE (ECT) The ECM supplies a 5 volt signal to the sensor SENSOR through a resistor in the ECM and measures the volt- age. The voltage will be high when the intake air is The Engine Coolant Temperature (ECT) Sensor is a cold, and low when the intake manifold air is hot.
Page 556 KNOCK SENSOR It is extremely important that the correct KS sensor and module be used for the engine application. Using The knock sensor is mounted on the lower right side an incorrect KS module will result in unrecognized of the engine block. spark knock and engine damage.
Page 557 If the TP circuit is open, the ECM will set a Code 21. Switches which are used with the Fuel Injection sys- If the TP circuit is shorted, and a trouble Code 21 will tem to detect critical engine operation parameters be set.
Page 558 THIS PAGE IS INTENTIONALLY BLANK Index 90-823225--1 1096 ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) - 5E-17...
Page 559: Spark Management
Spark Management Distributor Module Mode The following describes IC operation during cranking High Energy Ignition with Ignition and when the engine starts running. To help under- stand how IC circuits operate, a relay with a double Control (IC) set of contact points is shown in the IC module (refer to the figures “Ignition Control Mode”...
Page 560 TRANSISTOR BASE MODULE ADVANCE Distributor Module Mode Module Advance ECM Control Mode Index 90-823225--1 1096 ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) - 5E-19...
Page 561: Results Of Incorrect Operation
Results of Incorrect Operation Open or Grounded REF HI Line - This line provides the ECM with engine speed information. If this line is Open IC Line from the ECM to the Distributor open or grounded, the ECM will not know that the en- Module - While the engine is cranking, the ECM ex- gine is cranking or running and will not run.
Page 562 CLEAR FLOOD MODE POWER REDUCTION MODE (1996 AND OLDER MODELS) If the engine floods, it can be cleared by opening the throttle half way (50%). (Open throttle handle until re- The ECM will go into power reduction mode when the sistance from secondary throttle [Multi-Port only] is following conditions are met: felt.) The ECM discontinues fuel injector pulsation as...
Page 563: Throttle Body Injection Components
Throttle Body Injection Components THROTTLE BODY UNIT EXPLODED VIEW FUEL PUMP ELECTRICAL COMPONENTS When the ignition switch is turned to the RUN posi- tion, the ECM will turn ON the fuel pump relay for two seconds. When the ignition switch is turned to the crank posi- tion, the ECM turns the fuel pump relay ON causing the fuel pump to start.
Page 564 FUEL INJECTORS FUEL DAMPER (COOL FUEL SYSTEM ONLY) The injector assembly is a solenoid operated device, The fuel damper acts as an equalization device to re- controlled by the ECM, that meters pressurized fuel duce the pressure spikes caused by the fuel injec- to the intake manifold.
Page 565: Multi-Port Injection Components
By moving a conical valve known as a pintle, IN, to- Multi-Port Injection Components ward the seat (to decrease air flow), or OUT, away from the seat (to increase air flow), a controlled FUEL PUMP ELECTRICAL CIRCUIT amount of air moves around the throttle valve. If RPM When the ignition switch is turned to the RUN posi- is too low, more air is bypassed around the throttle tion, the ECM will turn ON the fuel pump relay for two...
Page 566: Throttle Body Assembly
FUEL INJECTORS PRESSURE REGULATOR ASSEMBLY The EFI injector assembly is a solenoid-operated de- The pressure regulator is a diaphragm-operated re- vice, controlled by the ECM, that meters pressurized lief valve with fuel pump pressure on one side, and fuel to a single engine cylinder. The ECM grounds the regulator spring pressure and intake manifold vacu- injector solenoid, which opens a pintle valve, allow- um on the other.
Page 567 IDLE AIR CONTROL (IAC) VALVE If the IAC valve is disconnected and reconnected with the engine running, the idle speed may be The purpose of the IAC valve assembly is to control wrong. In this case, the IAC valve can be reset by engine idle speed, while preventing stalls due to doing the following: Turn off engine, wait ten se- changes in engine load.
Page 568: Ecm Connector And Symptom Charts
ECM Connector and Symptom Charts The following chart will aid in diagnosis of symptoms. These voltages were derived from a known good engine. The voltages shown were done with the electrical system intact and operational. These are voltage requirements to operate the different circuits. CAUTION Do not attempt to obtain these voltages by probing wires and connectors.
Page 569 ECM Connector and EFI Symptoms Chart (J-1 Circuits) Circuit Diag Normal Voltage (CKT) nostic Wire Wire Possible Possible Func- Num- Trouble Color Symptoms Ignition Engine tion Codes Running DTC(s) Knock Poor Fuel Economy, J1-1 9.5V 9.5V Sensor Poor Performance Signal Detonation Poor Performance, 1.95V...
Page 570 ECM Connector and EFI Symptoms Chart (J-1 Circuits) Circuit Diag- Normal Voltage (CKT) nostic Wire Wire Possible Possible Func- Num- Trouble Color Symptoms Ignition Engine tion Codes Running DTC(s) J1-17 – – – – – – Used Serial ORN/ No Serial Data J1-18 None Data...
Page 571 ECM Connector and EFI Symptoms Chart (J-2 Circuits) Circuit Diag- Normal Voltage (CKT) nostic Wire Wire Possible Possible Func- Num- Trouble Color Symptoms Ignition Engine tion Codes Running DTC(s) J2-1 – – – – – – Used J2-2 – – –...
Page 572 ECM Connector and EFI Symptoms Chart (J-2 Circuits) Circuit Diag- Normal Voltage (CKT) nostic Wire Wire Possible Possible Func- Num- Trouble Color Symptoms Ignition Engine tion Codes Running DTC(s) J2-17 – – – – – – Used J2-18 – – –...
Page 573: Multi Port Injector Balance Test
Multi Port Injector Balance Test At this point, insert clear tubing attached to vent valve into a suitable container and bleed air from gauge (Refer to the following figure for test set-up.) and hose to ensure accurate gauge operation. Re- peat this step until all air is bled from gauge.
Page 574: Fuel Injector Balance Test Set-Up (Multi-Port Injection)
Fuel Injector Balance Test Set-up (Multi-Port Injection) 300ms EXAMPLE Cylinder 1st. 38 PSI 38 PSI 38 PSI 38 PSI 38 PSI 38 PSI 38 PSI 38 PSI Reading (262 kPa) (262 kPa) (262 kPa) (262 kPa) (262 kPa) (262 kPa) (262 kPa) (262 kPa) 19 PSI...
Page 575: Wiring Harness Diagrams
Wiring Harness Diagrams MCM 5.7L EFI Alpha With Vapor Separator Tank NOTE 1 NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness. NOTE 1: As a mid year (96-1/2) model change, the EFI (Throttle Body Injection) models have the lanyard stop connector removed from the wiring harness.
Page 576: Mcm 5.7L Efi Alpha With Cool Fuel System
MCM 5.7L EFI Alpha With Cool Fuel System 7371 NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness. 1 - Electric Fuel Pump 12- Electronic Control Module (ECM) 2 - Throttle Body 13- Fuel Pump Relay 3 - Distributor 14- Ignition/System Relay 4 - Coil...
Page 577: Vapor Separator Tank
MCM 5.7L EFI Bravo With Vapor Separator NOTE 1 73717 NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness. NOTE 1: As a mid year (96-1/2) change, the EFI (Throttle Body Injection) models have the lanyard stop connec- tor removed from the wiring harness.
Page 578: Mcm 5.7L Efi Bravo With Cool Fuel System
MCM 5.7L EFI Bravo WIth Cool Fuel System 73717 NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness. 1 - Electric Fuel Pump 12- Electronic Control Module (ECM) 2 - Throttle Body 13- Fuel Pump Relay 3 - Distributor 14- Ignition/System Relay 4 - Coil...
Page 579: Mcm 350 Mpi Bravo (Including Gen + Engines) With Vapor Separator Tank
MCM 350 MPI Bravo (Including Gen + Engines) With Vapor Separator Tank NOTE 1 74182 Note: All BLACK Wires With A Ground Symbol Are Interconnected Within The EFI System Harness. NOTE 1: As a mid year (96-1/2) model change, the MPI (Multi Port Injection) models have the lanyard stop con- nector and dual engine data link connector removed from the wiring harness.
Page 580: Mcm 350 Mpi Gen+ Bravo With Cool Fuel System
MCM 350 MPI Gen+ Bravo With Cool Fuel System 74182 Note: All BLACK Wires With A Ground Symbol Are Interconnected Within The EFI System Harness. 1 - Electric Fuel Pump 12- Electronic Control Module (ECM) 2 - Throttle Body 13- Fuel Pump Relay 3 - Distributor 14- Ignition/System Relay 4 - Coil...
Page 581: Mie 350 Magnum Mpi Gen + Tournament Ski (Black Scorpion)
MIE 350 Magnum MPI Gen + Tournament Ski (Black Scorpion) 74893 Note: All BLACK Wires With A Ground Symbol Are Interconnected Within The EFI System Harness. 1 - Fuel Pump 10- Electronic Control Module (ECM) 2 - Distributor 11- Fuel Pump Relay 3 - Coil 12- Ignition/System Relay 4 - Electronic Spark Control (KS) Module...
Page 582: Mie 350 Magnum Efi Gen + Tournament Ski / 5.7L Gen+ Inboard With Cool Fuel System
MIE 350 Magnum EFI Gen + Tournament Ski / 5.7L Gen+ Inboard With Cool Fuel System 75001 Note: All BLACK Wires With A Ground Symbol Are Interconnected Within The EFI System Harness. 1 - Fuel Pump 11- Engine Coolant Temperature (ECT) Sensor 2 - Throttle Body 12- Electronic Control Module (ECM) 3 - Distributor...
Page 583: Multi-Port Injection Wiring Diagram (Chart 1 Of 4)
Multi-Port Injection Wiring Diagram (Chart 1 Of 4) INJECTORS 2, 3, 5, 8 467 DK BLU INJECTORS 1, 4, 6, 7 DK GRN 87a 30 85 86 87 441 BLU/WHT IDLE AIR 442 BLU/BLK CONTROL 443 GRN/WHT (IAC) VALVE 444 GRN/BLK DUAL ENGINE DATA LINK (MULTIPLE ENGINE 916 YEL...
Page 584: Multi-Port Injection Wiring Diagram (Chart 2 Of 4)
Multi-Port Injection Wiring Diagram (Chart 2 Of 4) INTAKE AIR TEMPERATURE INTAKE AIR (IAT) SENSOR SIGNAL TEMPERATURE (IAT) SENSOR (TP) ENGINE COOLANT TEMPERATURE (ECT) ENGINE COOLANT SENSOR TEMPERATURE (ECT) SENSOR SIGNAL Index 90-823225--1 1096 ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) - 5E-43...
Page 585: Multi-Port Injection Wiring Diagram (Chart 3 Of 4)
Multi-Port Injection Wiring Diagram (Chart 3 Of 4) IC MODULE EST MODULE ELECTRONIC SPARK TIMING (EST) IGNITION CONTROL 430 PUR/WHT DIST. REFERENCE “HIGH” BYPASS DIST. REFERENCE “LOW” FROM KNOCK SENSOR MODULE (BLACK SCORPION ONLY) TO KNOCK SEN- SOR (BLACK SCORPION ONLY) 121 TAN TO BUZZER TAN/BLU...
Page 586: Multi-Port Injection Wiring Diagram (Chart 4 Of 4)
Multi-Port Injection Wiring Diagram (Chart 4 Of 4) TO IGN COIL TERM B TO FUEL PUMP RELAY FUSE 15A TO INJECTORS SYSTEM/IGNITION RELAY ECM BAT FUSE/ DLC 15A TO DLC CONNECTOR 439 PNK/BLK KNOCK KNOCK SENSOR (KS) SENSOR (KS) MODULE LANYARD STOP SWITCH CIRCUIT CONNECTOR NOT PRESENT...
Page 587: Throttle Body Injection Wiring Diagram (Chart 1 Of 4)
Throttle Body Injection Wiring Diagram (Chart 1 of 4) INJECTOR 467 DK BLU INJECTOR DK GRN 87a 30 85 86 87 441 BLU/WHT IDLE AIR 442 BLU/BLK CONTROL 443 GRN/WHT (IAC) VALVE 444 GRN/BLK DUAL ENGINE DATA LINK (MULTIPLE ENGINE 916 YEL J1-5 MASTER/SLAVE...
Page 588: Throttle Body Injection Wiring Diagram (Chart 2 Of 4)
Throttle Body Injection Wiring Diagram (Chart 2 Of 4) (TP) ENGINE COOLANT TEMPERATURE ENGINE COOLANT (ECT) SENSOR TEMPERATURE (ECT) SENSOR SIGNAL Index 90-823225--1 1096 ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) - 5E-47...
Page 589: Throttle Body Injection Wiring Diagram (Chart 3 Of 4)
Throttle Body Injection Wiring Diagram (Chart 3 Of 4) IC MODULE EST MODULE ELECTRONIC SPARK TIMING (EST) IGNITION CONTROL 430 PUR/WHT DIST. REFERENCE “HIGH” BYPASS DIST. REFERENCE “LOW” TO KNOCK SEN- SOR (BLACK SCORPION ONLY) TAN/BLU 121 TAN TO BUZZER TO IGN 3 PNK TO AUDIO...
Page 590: Throttle Body Injection Wiring Diagram (Chart 4 Of 4)
Throttle Body Injection Wiring Diagram (Chart 4 Of 4) TO IGN COIL TERM B TO FUEL PUMP RELAY FUSE 15A TO INJECTORS SYSTEM/IGNITION RELAY ECM BAT FUSE/ DLC 15A TO DLC CONNECTOR 439 PNK/BLK KNOCK KNOCK SENSOR (KS) SENSOR (KS) MODULE LANYARD STOP SWITCH CIRCUIT...
Page 591 THIS PAGE IS INTENTIONALLY BLANK Index 5E-50 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 592: Diagnostic Circuit Check
Diagnostic Circuit Check The scan tool data listed in the table may be used for comparison. After completing the diagnostic circuit The Diagnostic Circuit Check is an organized ap- check and finding the on-board diagnostics function- proach to identifying a problem created by an elec- ing properly and no trouble codes displayed.
Page 593 CLEARING CODES USING DIAGNOSTIC CODE 10. Refer to appropriate Troubleshooting and/or TOOL (NON-SCAN) Diagnostic Charts. 1. Install diagnostic code tool. NOTE: When clearing codes without the use of a scan tool, the battery must be fully charged and 2. Turn key ON. cranking speed must be at least 300 RPM.
Page 594 CLEARING CODES USING SCAN TOOL (SCAN) 4. Clear codes. 1. Connect scan tool. 5. Turn key OFF. 2. Start engine. 6. Turn key ON and read codes. If codes are still present, (there is a real fault in system) check 3.
Page 595: No "Malfunction Indicator Lamp" (Marine Diagnostic Code Tool Installed)
No “Malfunction Indicator Lamp” (Marine Diagnostic Code Tool Installed) Chart A-1 (1 of 2) DUAL ENGINE DATA LINK (DUAL ENGINE APPLICATION 916 YEL MASTER/SLAVE J1-5 ONLY) 461 ORN/BLK ECM/DLC TO ECM 15A 15AMP FUSE BATTERY DIAGNOSTIC TEST FUSE 451 WHT/BLK TERMINAL MALFUNCTION IN- DICATOR LAMP...
Page 596 No “Malfunction Indicator Lamp” Chart A-1: (2 of 2) DOES THE ENGINE START? IS THE 10 AND 15 AMP IGNITION “ON.” ECM FUSE OK? REMOVE MARINE DIAGNOSTIC CODE TOOL. USING A TEST LIGHT CONNECTED TO GROUND, PROBE TERMINAL “F” OF THE DLC CONNECTOR.
Page 597 No DLC Data or Will Not Flash Code 12 “Malfunction Indicator Lamp” On Steady (Marine Diagnostic Code Tool Installed) Chart A-2 (1 of 2) DUAL ENGINE DATA LINK (DUAL ENGINE APPLICATION 916 YEL J1-5 MASTER/SLAVE ONLY) 461ORN/BLK TO ECM 15A BATTERY FUSE 451 WHT/BLK...
Page 598 No DLC Data or Will Not Flash Code 12 Chart A-2: (2 of 2) MARINE DIAGNOSTIC CODE TOOL INSTALLED. IGNITION “ON,” ENGINE “OFF.” IS THE “MALFUNCTION INDICATOR LIGHT “ON”? ENTER SERVICE MODE ON DIAGNOSTIC CHART A-1 CODE TOOL. DOES “MALFUNCTION INDICATOR LAMP” FLASH CODE 12? IF PROBLEM WAS NO DLC DATA (USING SCAN TOOL) IGNITION “OFF.”...
Page 599: Engine Cranks But Will Not Run Chart
Engine Cranks but Will Not Run Chart A-3 (1 of 4) INJ/ECM/KS MODULE FUSE IGNITION CONTROL DIST. REFERENCE “HIGH” BYPASS DIST. REFERENCE “LOW” CIRCUIT DESCRIPTION: 4. All injectors should be within 1.0 ohm of each oth- er and should not be less than 12 ohms at 70 F This chart assumes that battery condition and engine (21 C).
Page 600 Engine Cranks but Will Not Run (Continued) Chart A-3: (2 of 4) ENSURE THE ENGINE IS NOT IN SERVICE OR BASE TIMING NOTE 1: IF A SCAN TOOL IS NOT AVAILABLE WHILE MODE CHECKING TP AND ECT READINGS, USE THE CHECK THAT LANYARD STOP SWITCH IS NOT ACTIVATED CHECK THE FOLLOWING.
Page 601 Engine Cranks but Will Not Run (Continued) Chart A-3 (3 of 4) INJ/ECM FUSE 10A INJECTORS IGNITION CONTROL DIST. REFERENCE “HIGH” BYPASS DIST. REFERENCE “LOW” INJECTORS THROTTLE BODY MULTI-PORT TEST DESCRIPTION: To test for this condition: Number(s) below refer to circled number(s) on the Disconnect all injectors.
Page 602 Engine Cranks but Will Not Run (Continued) Chart A-3: (4 of 4) FROM (2 OF 4) NO BLINKING LIGHT AT INJECTOR NO LIGHT STEADY LIGHT IGNITION “ON.” CHECK INJECTOR DRIVER CIRCUIT WITH TEST PROBE INJECTOR HARNESS LIGHT FOR SHORT TO GROUND. TERMINALS WITH A TEST LIGHT TO IF CIRCUIT IS NOT SHORTED, CHECK RESISTANCE GROUND.
Page 603: Multi-Port Injection Fuel System Diagnosis Chart
Multi-Port Injection Fuel System Diagnosis Chart A-7 (1 of 6) FUEL INLET PORT FUEL RAIL PORT FUEL RAIL SCHRADER VALVE CONNECT SCHRADER FUEL VALVE PRESSURE FUEL INLET CONNECT GUAGE FUEL HERE PRESSURE GUAGE HERE FUEL RETURN STARBOARD FUEL RAIL STARBOARD FUEL RAIL EARLIER STYLE (MCM &...
Page 604 Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7: (2 of 6) FROM NOTE: THE IGNITION MAY HAVE TO BE CYCLED CHART A-3 (2 OF 4) “ON” MORE THAN ONCE TO OBTAIN MAXIMUM PRESSURE. ALSO, IT IS NORMAL FOR THE PRESSURE TO DROP SLIGHTLY WHEN THE PUMP STOPS.
Page 605 Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7 (3 of 6) FUEL INLET PORT FUEL RAIL PORT FUEL RAIL SCHRADER VALVE CONNECT SCHRADER FUEL VALVE PRESSURE CONNECT FUEL INLET GUAGE FUEL HERE PRESSURE GUAGE HERE FUEL RETURN STARBOARD FUEL RAIL STARBOARD FUEL RAIL EARLIER STYLE (MCM &...
Page 606 Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7: (4 of 6) * NOTE: THE IGNITION MAY HAVE TO BE CYCLED CONTINUED FROM “ON” MORE THAN ONCE TO OBTAIN MAXI- CHART A-7 MUM PRESSURE. (2 OF 6) ABOVE 38 PSI (262 kPa) HAS PRESSURE, BUT LESS THAN 34 PSI (234 kPa) DISCONNECT FUEL RETURN LINE.
Page 607 Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7 (5 of 6) SYSTEM 902 RED 339 PNK/BLK RELAY FUEL PUMP RELAY FUSE FUEL FUEL PUMP PUMP J2-9 465 DK GRN/WHT RELAY DRIVER RELAY 450 BLK/WHT 450 BLK/WHT 120 GRY 150 BLK FUEL PUMP TEST DESCRIPTION: Number(s) below refer to circled number(s) on the...
Page 608 Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7: (6 of 6) FROM CHART (4 OF 6) IGNITION “OFF.” REMOVE FUEL PUMP RELAY. IGNITION “ON.” WITH TEST LIGHT CONNECTED TO GROUND, PROBE FUEL PUMP RELAY CONNECTOR CAVITY “30” TEST LIGHT SHOULD BE “ON.” IS IT? IGNITION “OFF.”...
Page 609: Throttle Body Injection Fuel System Diagnosis Chart
Throttle Body Injection Fuel System Diagnosis Chart A-7 (1 of 6) FUEL LINE TO ELECTRIC FUEL PUMP WATER SEPARATING FUEL FILTER SHUT-OFF TOOL NOTE: If pump does not run, check fuel pump relay IMPORTANT: Check for contaminated fuel tank, stuck anti-siphon valve or fuel system vacuum and fuse.
Page 610 Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7: (2 of 6) NOTE: THE IGNITION MAY HAVE TO BE CYCLED “ON” MORE THAN ONCE TO OBTAIN MAXIMUM PRESSURE. ALSO, IT IS NORMAL FOR THE PRESSURE FROM CHART A-3 TO DROP SLIGHTLY WHEN THE PUMP STOPS. (2 OF 4) INSTALL FUEL PRESSURE GAUGE, 91-16850 AND FUEL PRESSURE ADAPTER IGNITION “OFF”...
Page 611 Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7 (3 of 6) RETURN LINE FROM FUEL PRESSURE REGULATOR WATER SEPARATING FUEL FILTER SHUT-OFF TOOL IMPORTANT: Check for contaminated fuel tank, 2. Restricting the fuel return line (Shut-Off Valve) al- stuck anti-siphon valve or fuel system vacuum lows the fuel pressure to build above regulated leak anywhere before the electrical fuel pump pressure.
Page 612 Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7: (4 of 6) * NOTE: THE IGNITION MAY HAVE TO BE CYCLED CONTINUED FROM “ON” MORE THAN ONCE TO OBTAIN MAXI- CHART A-7 MUM PRESSURE. (2 OF 6) ABOVE 32 PSI (231 kPa) HAS PRESSURE, BUT LESS THAN 28 PSI (193 kPa) DISCONNECT FUEL RETURN LINE.
Page 613 Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7 (5 of 6) SYSTEM 902 RED 339 PNK/BLK RELAY FUEL PUMP RELAY FUSE FUEL FUEL PUMP PUMP J2-9 465 DK GRN/WHT RELAY DRIVER RELAY 450 BLK/WHT 450 BLK/WHT 120 GRY 150 BLK FUEL PUMP TEST DESCRIPTION: Number(s) below refer to circled number(s) on the...
Page 614 Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7: (6 of 6) FROM CHART A-7 (4 OF 6) IGNITION “OFF.” REMOVE FUEL PUMP RELAY. IGNITION “ON.” WITH TEST LIGHT CONNECTED TO GROUND, PROBE FUEL PUMP RELAY CONNECTOR CAVITY “30” TEST LIGHT SHOULD BE “ON.”...
Page 615: Efi System/Ignition Relay Check (1 Of 2)
EFI System/Ignition Relay Check (1 of 2) TO IN-LINE BOAT HARNESS CIRCUIT BREAKER 90 AMP FUSE INJ/ECM/KS MODULE FUSE CIRCUIT DESCRIPTION: 2. This step ensures that battery and ignition volt- age are available at the relay. An open or shorted Battery voltage is constantly supplied to terminal 30 condition in either supply would cause the relay of the system relay.
Page 616 EFI System / Ignition Relay Check (Continued) (2 of 2) IGNITION “ON.” USING A TEST LIGHT CONNECTED TO GROUND, PROBE IGNITION COIL CONNECTOR TERMINAL “B.” LIGHT SHOULD BE “ON.” IS IT? IGNITION “OFF.” REFER TO “IGNITION REMOVE SYSTEM RELAY CONNECTOR. SYSTEM CHECK”...
Page 617: Ignition System Check (1 Of 2)
Ignition System Check (1 of 2) IGNITION CONTROL DIST. REFERENCE “HIGH” BYPASS DIST. REFERENCE “LOW” TO TACH TO DISTRIBUTOR TEST DESCRIPTION: 4. Checks for a shorted module or grounded circuit from the ignition coil to the module. The distribu- Number(s) below refer to circled number(s) on the tor module should be turned OFF, so normal volt- diagnostic chart.
Page 618 Ignition System Check(1 of 2) DISCONNECT TACH BEFORE PROCEEDING WITH THE TEST. CHECK SPARK AT PLUG WIRE USING AN INDUCTIVE PICKUP TIMING LIGHT WHILE CRANKING. A FLASHING LIGHT INDICATES SPARK. (IF NO SPARK ON FIRST WIRE, CHECK SECOND WIRE.) A FEW SPARKS AND THEN NOTHING IS CONSIDERED NO SPARK.
Page 619: Ignition System Check (2 Of 2)
Ignition System Check (2 of 2) IGNITION CONTROL DIST. REFERENCE “HIGH” BYPASS DIST. REFERENCE “LOW” TO IN-LINE HARNESS (TACH) TO DISTRIBUTOR TEST DESCRIPTION: 2. This should turn OFF the module and cause a spark. If no spark occurs, the fault is most likely Number(s) below refer to circled number(s) on the in the ignition coil because most module prob- diagnostic chart.
Page 620 Ignition System Check (2 of 2) TEST LIGHT TO DC POWER SUPPLY (1.5 to 8 V) CHART CONTINUED FROM PAGE 75 LIGHT LIGHT ON BLINKS STEADY Fig. 1 DISCONNECT DISTRIBUTOR 4 TERMINAL CONNECTOR. REPLACE IGNITION COIL AND REMOVE DISTRIBUTOR CAP. RECHECK DISCONNECT PICK-UP COIL CONNECTOR FROM MODULE.
Page 621: Idle Air Control (Iac) Functional Test (1 Of2)
Idle Air Control (IAC) Functional Test (1 of 2) 441 BLU/WHT 442 BLU/BLK IDLE AIR CONTROL 443 GRN/WHT (IAC) VALVE 444 GRN/BLK CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: The ECM controls idle speed to a calculated, “de- Check for vacuum leaks, unconnected or brittle vacu- sired”...
Page 622 Idle Air Control Functional Test (2 of 2) START ENGINE, ALLOW IDLE TO STABILIZE, AND RECORD ENGINE RPM. PLACE ENGINE IN BASE TIMING OR SERVICE MODE.. DOES A NOTICEABLE DROP IN RPM OCCUR OR DOES ENGINE DIE? SEE NOTE. NOTE IN STEP 1A: A 502/BLACKHAWK MAY NOT DIE, BUT IDLE WILL DROP EXIT SERVICE MODE AND...
Page 623: Lanyard Stop Circuit Check (Emergency Stop) Circuit Check (1 Of 2)
Lanyard Stop Circuit Check (Emergency Stop) Circuit Check (1 of 2) IN LINE 2 WAY CONNECTOR NORMALLY OPEN LANYARD STOP SWITCH CIRCUIT 942 PNK J1-21 1996 AND EARLIER MODELS LANYARD STOP SWITCH NOTE: Some models are no longer equipped with 4.
Page 624 Lanyard Stop (Emergency Stop) Circuit Check (2 of 2) NOTE: THIS CHART ASSUMES THE ENGINE CRANKS BUT WILL NOT START. TURN IGNITION “OFF.” TURN IGNITION “ON” AND CRANK ENGINE DOES ENGINE START? LANYARD STOP CIRCUIT FUNCTIONING CHECK LANYARD STOP SWITCH TO MAKE PROPERLY.
Page 625: Audio Warning Buzzer Circuit Check (1 Of 2)
Audio Warning Buzzer Circuit Check (1 of 2) TAN/ 121 TAN TO BUZZER TO SYSTEM TO IGN 3 PNK RELAY TERM BLU/ TO AUDIO WARNING “87” SWITCHES TO TACH TO BUZZER (COOLANT OVERTEMP) 121 WHT TO BUZZER (AUDIO WARNING SWITCHES) FROM AUDIO WARNING J1-6 931 BRN...
Page 626 Audio Warning Buzzer Circuit Check (2 of 2) IGNITION “ON.” BUZZER SHOULD SOUND AND THEN SILENCE WITHIN 2 SECONDS. DOES IT? NO PROBLEM FOUND. RE- FER TO DIAGNOSTIC AIDS ON FACING PAGE. BUZZER NEVER SOUNDS. BUZZER REMAINS “ON” CONSTANTLY WITH IGNITION “ON.” CHECK CIRCUIT BREAKER IN DISCONNECT HARNESS CONNECTOR TO STARTING/CHARGING SYS-...
Page 627 Discrete Input Circuit Check (Power Reduction Mode) (Non-Scan) (1 of 2) TO SYSTEM RELAY TERM “87” TAN/ 121 TAN TO BUZZER 3 PNK TO IGN TO AUDIO BLU/ WARNING SWITCHES TO TACH TO BUZZER (COOLANT OVERTEMP) 121 WHT TO BUZZER (AUDIO WARNING SWITCHES) COIL FROM AUDIO WARNING...
Page 628: Discrete Input Circuit Check (Power Reduction Mode) (Non-Scan) (1
Discrete Input Circuit Check (2 of 2) OIL PRESSURE SWITCH DISCONNECT TAN/BLU WIRE FROM OIL PRESSURE SWITCH. START ENGINE, THERE SHOULD BE RESISTANCE (NO CONTINUITY) FROM OIL PRESSURE SWITCH AND GROUND (ENGINE BLOCK). ENGINE OFF, IGNITION ON, CHECK RESISTANCE FROM OIL PRESSURE SWITCH AND GROUND (ENGINE BLOCK).
Page 629 Diagnostics-Without Scan Tool Code 14: Engine Coolant Temperature (ECT) Sensor Circuit (Non-Scan) (1 of 2) ENGINE ENGINE CIRCUIT DESCRIPTION: 3. This step will isolate the problem to CKT 410 (5 volt reference) or to the sensor ground. The Engine Coolant Temperature (ECT) sensor uses a thermistor to control the signal voltage to the ECM.
Page 630 Code 14: ECT Circuit (Non-Scan) (2 of 2) IGNITION “OFF.” DISCONNECT ECT SENSOR CONNECTOR. IGNITION “ON.” CONNECT DVM ACROSS COOLANT SENSOR HARNESS TERMINALS. IS VOLTAGE ABOVE 4 VOLTS? CONNECT POSITIVE DVM LEAD FROM HARNESS INTERMITTENT CONNECTIONS TERMINAL “B” CKT 410 (5 VOLT REFERENCE). CONNECT NEGATIVE DVM LEAD TO A GOOD FAULTY ECT SENSOR.
Page 631 Code 21: Throttle Position (TP) Sensor Circuit (Non-Scan) (1 Of 2) CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: The Throttle Position (TP) sensor provides a voltage An intermittent problem may be caused by a poor or signal that changes, relative to the throttle blade. Sig- corroded connection, rubbed through wire connec- nal voltage should vary from about .7 volts at idle to tion, a wire that is broken inside the insulation, or a...
Page 632 Code 21: Throttle Position (TP) Sensor Circuit (Non Scan) IGNITION “OFF.” DISCONNECT THROTTLE POSITION SENSOR ELECTRICAL CONNECTOR. IGNITION “ON.” CONNECT A DVM FROM HARNESS TERMINAL “A” (5 VOLT REFERENCE TO HARNESS TERMINAL “B” SENSOR GROUND). IS VOLTAGE READING OVER 4 VOLTS? CONNECT DVM FROM HARNESS TERMINAL “A”...
Page 633 Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Non-Scan) (1 Of 2) 814 BLK MAP AND ECT SENSOR GROUND CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: The Manifold Absolute Pressure (MAP) sensor re- An intermittent problem may be caused by a poor or sponds to changes in manifold pressure (vacuum).
Page 634 Code 33: MAP Circuit (Non-Scan) (2 of 2) IGNITION “OFF.” DISCONNECT VACUUM PLUG LOCATED UNDER PLENUM AT FRONT AND INSTALL A VACUUM GAUGE IN THE VACUUM PORT. START ENGINE AND RAISE RPM TO ABOUT 1000 RPM. VACUUM GAUGE READING SHOULD BE 14in. Hg (45.5 kPa) OR MORE AND STEADY.
Page 635 Code 42: Ignition Control (IC) Circuit (Non-Scan) (1 of 2) IGNITION CONTROL (IC) MODULE 902 RED IGNITION CONTROL (IC) DIST. REFERENCE “HIGH” 3 PNK BYPASS DIST. REFERENCE 121 GRY “LOW” 121 WHT TO IN-LINE HARNESS (TACH) TO DISTRIBUTOR CIRCUIT DESCRIPTION: TEST DESCRIPTION: When the system is running on the ignition module, Number(s) below refer to circled number(s) on the...
Page 636 Code 42: IC Circuit (Non-Scan) (2 of 2) DIAGNOSTIC AIDS: backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor An intermittent problem may be caused by a poor or terminal-to-wiring connections, corroded terminals corroded connection, rubbed through wire connec- and/or wiring, or physical damage to the wiring har- tion, a wire that is broken inside the insulation, or a ness.
Page 637 Code 43: Knock Sensor (KS) (Non-Scan) (1 of 2) FUSE 15A TO SYSTEM RELAY KNOCK SENSOR KNOCK SENSOR MODULE SIGNAL CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: The ability to sense engine knock or detonation is ac- If CKT 496 is routed too close to secondary ignition complished with a module that sends a voltage signal wires, the KS module may see the interference as a to the ECM.
Page 638 Code 43: Knock Sensor (KS) Circuit (Non-Scan) (2 of 2) DISCONNECT 5 WAY KS MODULE CONNECTOR. USING DVM, MEASURE RESISTANCE BETWEEN TERMINAL “E” AND GROUND. RESISTANCE SHOULD BE BETWEEN 3.3KΩ AND 4.5KΩ OHMS. IS IT? CHECK FOR OPEN OR SHORT RECONNECT 5 WAY KS MODULE CONNECTOR.
Page 639 Code 51: Calibration Memory Failure Non-Scan Diagnostics (1 of 2) 72801 CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: This test allows the ECM to check for a calibration An intermittent Code 51 may be caused by a bad cell failure by comparing the calibration value to a known in the EEPROM that is sensitive to temperature value stored in the EEPROM.
Page 640 Code 51: Calibration Memory Failure (Non-Scan) (2 of 2) IGNITION “ON.” USING CLEAR CODE PROCEDURE, CLEAR CODES. DOES CODE 51 RESET? REPLACE ECM AND VERIFY CODE DOES NOT RESET. FAULT IS NOT PRESENT AT THIS TIME. REFER TO “DIAGNOSTIC AIDS” ON FACING PAGE.
Page 641 Diagnostics - Using Scan Tool (Scan) Code 14 Engine Coolant Temperature (ECT) Sensor Circuit (Scan) (1 of 2) ENGINE COOLANT TEMPERATURE (ECT) SENSOR ENGINE COOLANT TEMPERATURE (ECT) CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: The Engine Coolant Temperature (ECT) Sensor Check harness routing for a potential short to ground uses a thermistor to control the signal voltage to the in CKT 410.
Page 642 Code 14: ECT Circuit (Scan) (2 of 2) IGNITION “ON.” DOES SCAN TOOL DISPLAY A COOLANT TEMPERATURE VALUE GREATER THAN 266 F (130 C) OR LESS THAN –22 F (–30 C)? CODE 14 IS INTERMITTENT. IF NO ADDITIONAL CODES WERE STORED, REFER TO “DIAGNOSTIC AIDS”...
Page 643 Code 21: Throttle Position (TP) Sensor Circuit (Scan) (1 of 2) CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: The Throttle Position (TP) Sensor provides a voltage The scan tool reads throttle position in voltage and signal that changes as throttle blades open or close. percentage of throttle blade opening.
Page 644 Code 21: TP Sensor Circuit (Scan) (2 of 2) THROTTLE CLOSED. IGNITION “ON.” DOES SCAN TOOL INDICATE THROTTLE POSITION SENSOR VOLTAGE GREATER THAN 4 VOLTS OR LESS THAN .36 VOLT? CODE 21 IS INTERMITTENT, REFER TO “DIAGNOSTIC AIDS” ON FACING PAGE. VOLTAGE LESS THAN .36 VOLT.
Page 645 Code 23: Intake Air Temperature (IAT) Sensor Circuit (Scan) (1 of 2) INTAKE IAT SENSOR SIGNAL REFERENCE CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: The Intake Air Temperature (IAT) sensor uses a The scan tool reads temperature of the air entering thermistor to control the signal voltage to the Elec- the engine and should read close to ambient air tem- tronic Control Module (ECM).
Page 646 Code 23: IAT Circuit (Scan) (2 of 2) IGNITION “ON.” DOES SCAN TOOL DISPLAY IAT TEMPERATURE OF LESS THAN –22 F (–30 C) OR GREATER THAN 266 F (130 C). CODE 23 IS INTERMITTENT, REFER TO “DIAGNOSTIC AIDS” ON FACING PAGE. TEMPERATURE LESS THAN –22 F (–30 C) TEMPERATURE GREATER THAN 266 F (130 C).
Page 647 Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Scan) (1 of 2) 814 BLK MAP AND ECT GROUND CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: The Manifold Absolute Pressure (MAP) sensor re- If the idle is rough or unstable, refer to “Troubleshoot- sponds to changes in manifold pressure (vacuum). ing”...
Page 648 Code 33: MAP Circuit (Scan) (2 of 2) IF ENGINE IDLE IS ROUGH, UNSTABLE, OR INCORRECT, CORRECT CONDITION BEFORE USING CHART, SEE THE TROUBLESHOOTING SECTION. ENGINE IDLING. DOES SCAN TOOL DISPLAY A MAP SENSOR VOLTAGE OF LESS THAN 1 VOLT OR GREATER THAN 4 VOLTS? CODE 33 IS INTERMITTENT, IF NOT ADDITIONAL CODES WERE STORED,...
Page 649 Code 42: Ignition Control (IC) Circuit (Scan) (1 Of 2) IGNITION CONTROL (IC) MODULE 902 RED IGNITION CONTROL (IC) DIST. REFERENCE “HIGH” 3 PNK BYPASS DIST. REFERENCE “LOW” 121 GRY 121 WHT TO IN-LINE HARNESS (TACH) TO DISTRIBUTOR CIRCUIT DESCRIPTION: TEST DESCRIPTION: When the system is running on the ignition module, Number(s) below refer to circled number(s) on the...
Page 650 Code 42: IC Circuit (Scan) (2 of 2) DIAGNOSTIC AIDS: Any circuitry that is suspected as causing the inter- mittent complaint should be thoroughly checked for Refer to “Intermittents” in “Troubleshooting.” backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor An intermittent problem may be caused by a poor or terminal-to-wiring connections, corroded terminals corroded connection, rubbed through wire connec-...
Page 651 Code 43: Knock Sensor (KS) (Scan) (1 Of 2) FUSE 15A TO SYSTEM RELAY KNOCK SENSOR KNOCK SIGNAL (KS) SIGNAL MODULE CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: Sensing engine detonation or spark knock is accom- If CKT 496 is routed too close to secondary ignition plished with a module that sends a voltage signal to wires, the KS module may see the interference as a the ECM.
Page 652 Code 43: KS Circuit (Scan) (2 of 2) INSTALL SCAN TOOL. ENGINE IDLING, COOLANT TEMP. ABOVE 150 F (66 C). DOES SCAN TOOL INDICATE A FIXED VALUE GREATER THAN ZERO DEGREES OF KNOCK RETARD? CHECK FOR OPEN OR SHORT RECONNECT 5 WAY KS MODULE CONNECTOR. IN CKT 496.
Page 653 Code 51: Calibration Memory Failure (Scan) (1 Of 2) 72801 CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS: This test allows the ECM to check for a calibration An intermittent Code 51 may be caused by a bad cell in the EEPROM that is sensitive to temperature failure by comparing the calibration value to a known value stored in the EEPROM.
Page 654 Code 51: Calibration Memory Failure (Scan) (2 of 2 IGNITION “ON.” USING SCAN TOOL, CLEAR CODES. DOES CODE 51 RESET? REPLACE ECM AND VERIFY CODE DOES NOT RESET. FAULT IS NOT PRESENT AT THIS TIME. REFER TO “DIAGNOSTIC AIDS” ON FACING PAGE.
Page 655 Troubleshooting Changes In Terminology Due to industry standardization of terminology for certain electronic engine controls some names and abbrevi- ations have changed. From (CTS) Coolant Temperature Sensor (ECT) Engine Coolant Temperature (TPS) Throttle Position Sensor (TP) Throttle Position (MAT) Manifold Air Temperature (IAT) Intake Air Temperature (EST) Electronic Spark Timing (IC) Ignition Control...
Page 656: Troubleshooting Charts
Troubleshooting Charts IMPORTANT PRELIMINARY CHECKS BEFORE USING THIS SECTION Before using this section you should have performed the “EFI Diagnostic Circuit Check” and de- termined that: 1. The ECM is operating correctly. 2. There are no diagnostic trouble codes (DTC) stored. SYMPTOM Verify the customer complaint, and locate the correct symptom.
Page 657 INTERMITTENTS Definition: Problem occurs randomly. May or may not store a Diagnostic Trouble Code (DTC). DO NOT use the diagnostic trouble code charts for intermittent problems, unless instructed to do so. If a fault is intermittent, incorrect use of diagnostic trouble code charts may result in replacement of good parts.
Page 658 HARD START Definition: Engine cranks OK, but does not start for a long time. Engine does eventually run, or may start but immediately dies. PRELIMINARY CHECKS Make sure proper starting procedure is being used. See Owner’s Manual. Perform the careful visual/physical checks as described at the start of “Troubleshooting Charts” section.
Page 659 HARD START (continued) CHECK SENSORS AND CONTROLS FOR: 1. Possible open in Engine Coolant Temperature (ECT) sensor and Manifold Absolute Pressure (MAP) sensor Ground CKT 814. Also may have set a DTC 14 and/or DTC 33. 2. Throttle Position (TP) sensor,ground CKT 813 could have a possible open and set DTC 21. 3.
Page 660 SURGES Definition: Engine power variation under steady throttle or cruise. Feels like the engine speeds up and slows down with no change in the throttle control. PRELIMINARY CHECKS Perform the visual/physical checks as described at the start of “Troubleshooting Charts” section. CHECK FUEL SYSTEM FOR: 1.
Page 661 SURGES (continued) ADDITIONAL CHECKS FOR: 1. Proper alternator output voltage. 2. Leaks or kinks in vacuum lines. 3. Power reduction mode activated (if equipped). 4. Clean and tight ECM grounds and in their proper locations. Index 5E-120 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 662 HESITATION, SAG OR STUMBLE Definition: Momentary lack of response as the throttle is opened. Can occur at all engine speeds. May cause engine to stall if severe enough. PRELIMINARY CHECKS Perform the visual/physical checks as described at the start of “Troubleshooting Charts” section. CHECK FUEL SYSTEM FOR: 1.
Page 663 HESITATION, SAG OR STUMBLE (continued) CHECK SENSORS AND CONTROLS FOR: 1. Binding or sticking Throttle Position (TP) sensor or salt corrosion. Throttle Position (TP) sensor voltage should increase as throttle is moved toward Wide Open Throttle (WOT). 2. Throttle Position (TP) sensor-5 volt reference CKT 416 for open, DTC 21 may be set. 3.
Page 664 DETONATION/SPARK KNOCK Definition: A mild to severe ping, usually worse under acceleration or heavy load. The engine makes sharp metallic knocks that change with throttle opening. PRELIMINARY CHECKS Perform the visual/physical checks as described at the start of “Troubleshooting Charts” section. CHECK FUEL SYSTEM FOR: 1.
Page 665 DETONATION/SPARK KNOCK (continued) CHECK ENGINE FOR: 1. Low oil level. 2. Excessive oil in the combustion chamber. Valve seals for leaking. 3. Perform a compression test. 4. Combustion chambers for excessive carbon build-up. Remove carbon with top engine cleaner. 5. Proper camshaft timing. 6.
Page 666 LACK OF POWER, SLUGGISH OR SPONGY Definition: Engine delivers less than expected power. Little or no increase in speed when throttle control is moved toward Wide Open Throttle (WOT). PRELIMINARY CHECKS Perform the careful visual/physical checks as described at the start of “Troubleshooting Charts” section.
Page 667 LACK OF POWER, SLUGGISH OR SPONGY (continued) CHECK SENSORS AND CONTROLS FOR: 1. Possible open in Engine Coolant Temperature (ECT) and Manifold Absolute Pressure (MAP) sensors (Ground CKT 814). Also could have and set a DTC 14 and/or 33. 2. Throttle Position (TP) sensor circuit if DTC 21 set for open or grounds. 3.
Page 668 CUTS OUT AND MISSES Definition: Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases. PRELIMINARY CHECKS Perform the important preliminary checks as described at the start of the “Troubleshooting Charts” section. CHECK IGNITION SYSTEM FOR: 1.
Page 669 CUTS OUT AND MISSES (continued) CHECK SENSORS AND CONTROLS FOR: 1. Open or grounds in CKT 417 Throttle Position (TP) sensor signal. 2. Open or grounds in CKT 416 Throttle Position (TP) sensor 5 volt reference. CHECK ENGINE MECHANICAL FOR: 1.
Page 670 ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Definition: Engine runs unevenly or rough at idle, also the idle may vary in RPM (called hunt- ing). Either condition may be severe enough to cause stalling. Engine idles at incorrect speed. PRELIMINARY CHECKS Perform the important preliminary checks as described at the start of the “Troubleshooting Charts”...
Page 671 ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING (continued) CHECK SENSORS AND CONTROLS FOR: 1. Proper Idle Air Control (IAC) operation. 2. Possible open the in following circuits for CKTs 410, 417, 416, 813 and 814. 3. Possible short to ground in CKT 417, Throttle Position (TP) sensor signal, CKT 416 Throttle Position (TP) sensor 5 volt reference and CKT 451 diagnostic test circuit.
Page 672 BACKFIRE (INTAKE) Definition: Fuel ignites in the manifold, making a loud popping noise. PRELIMINARY CHECKS Perform the important preliminary checks as described at the start of the “Troubleshooting Charts” section. CHECK FUEL SYSTEM FOR: 1. An abnormal fuel system condition: If necessary perform fuel system diagnosis. 2.
Page 673 BACKFIRE (EXHAUST) Definition: Fuel ignites in the manifold, making a loud popping noise. PRELIMINARY CHECKS Perform the important preliminary checks as described at the start of the “Troubleshooting” section. CHECK FUEL SYSTEM FOR: 1. An abnormal fuel system condition: If necessary perform fuel system diagnosis. 2.
Page 674 DIESELING, RUN-ON Definition: Engine continues to run after key is turned “OFF,” but runs very roughly. If engine runs smoothly, check ignition switch and adjustment. PRELIMINARY CHECKS Perform the important preliminary checks as described at the start of the “Troubleshooting” section. CHECK FUEL SYSTEM FOR: 1.
Page 675 POOR FUEL ECONOMY Definition: Fuel economy is noticeably lower than expected. PRELIMINARY CHECKS Perform the important preliminary checks as described at the start of “Troubleshooting” section. 1. Operator’s driving habits. 2. Dirty or plugged flame arrestor. 3. Fuel leaks. CHECK FUEL SYSTEM FOR: 1.
Page 676 POOR FUEL ECONOMY (continued) CHECK SENSORS AND CONTROLS FOR: 1. If MAP, TP, or Coolant Sensor are erratic there will be poor economy. CHECK ENGINE FOR: 1. Proper cylinder compression. 2. Exhaust system restriction. 3. Excessive resistance on bottom of boat (dirt, barnacles, etc.). 4.
Page 677 Fuel Delivery Systems Cool Fuel System Exploded View Index 5E-136 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 678 1 -Screws (4) 2 -Nut (2) 3 -Bracket 4 -Cover Base 5 -Reference Line To Plenum Or Flame Arrestor 6 -Fitting 7 -Tubing 8 -Fuel Pressure Regulator 9 -Screw (2) 10 -Washer (2) 11 -Washer 12 -Fuel Return Line Fitting 13 -Rubber Bushing (8) 14 -Filter 15 -Outlet Fuel Line To Fuel Rail Or Throttle Body...
Page 679 Vapor Separator Tank (VST) Exploded View 72803 Index 5E-138 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 680 1 -Cover Torque Sequence For VST 2 -Seal 3 -Spring 4 -Diaphragm 5 -O-ring 6 -Diaphragm Cover 7 -Screw 8 -Valve Seat 9 -Float Valve 10 -Float Valve Pin 11 -Clip 12 -Float 13 -Float Arm Pin 14 -VST Body 15 -Fuel Screen 16 -Plate 17 -Rubber Cushion...
Page 681 VST Fuel Pump (Exploded View) 72803 1 - Collar 13- Insulators (2) 2 - O-Rings (2) 14- Lockwashers (2) 3 - Adapters (2) 15- Nuts (2) 4 - O-Ring 16- Electrical Connector 5 - Plate 17- Screw 6 - Electric Fuel Pump 18- Spring Washer 7 - Rubber Cushion 19- L-Joint...
Page 682 VAPOR SEPARATOR TANK (VST) 73719 1 - Vapor Separator Tank (VST) 2 - Grommet 3 - Hose (Some Models Connected To Top Fitting) 4 - Fuel Line Return 5 - Plug 6 - O-Ring 7 - Fuel Line VST Supply 8 - Grommet 9 - Bushing 10- Screw...
Page 683 Vapor Separator Tank (VST) INSTALLATION 1. Install VST to intake manifold. Apply Loctite 8831 NOTICE to threads of attaching screw. Torque bolt to 105 Refer to “Service Precautions,” in “Repair lb. in. (12 N·m). Procedures,” BEFORE proceeding. 2. Connect all lines to cover of vapor separator tank. Torque fuel line fittings to 23 lb.
Page 684 INSTALLATION Float and Needle Assembly 1. Install rubber cushion and plate, making sure to REMOVAL align cutout in plate with pump inlet. 1. Disconnect fuel pump electrical connector. (Elec- 2. Install screen on fuel pump. tric fuel pump removed for visual clarity.) 3.
Page 685 2. Label and then disconnect all fuel lines from Diaphragm Assembly cover of vapor separator tank. REMOVAL 3. Remove electrical line from retaining clip (some models). 1. Disconnect fuel pump electrical connector. (Elec- tric fuel pump removed for visual clarity.) 4.
Page 686 2. Label and then disconnect all fuel lines from cover of vapor separator tank. 3. Remove electrical line from retainer clip. 4. Remove cover screws and remove cover and electrical line retaining clip. 5. Remove float arm pin retaining fastener and re- move float and needle assembly.
Page 687 Throttle Body Injection Torque Specifications Repair Procedures Fastener Location Lb. In. Lb. Ft. Flame Arrestor To WARNING Throttle Body Throttle Body To Electrical, ignition and fuel system components Adapter on your MerCruiser are designed and manufac- Adapter To Intake tured to comply with U.S Coast Guard Rules and Manifold Regulations to minimize risks of fire and explo- sion.
Page 688 Throttle Body Injection WARNING System Description Be sure that the engine compartment is well ven- tilated and that no gasoline vapors are present to avoid the possibility of fire. Service Precautions WARNING Make sure no fuel leaks exist before closing en- WARNING gine hatch.
Page 689 Throttle Body Exploded Views 350 CID / 5.7L EFI (2 Barrel Throttle Body) Induction System 73766 75067 74109 Index 5E-148 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 690 1 - Throttle Body 2 - Screws (3) 3 - Gasket 4 - Throttle Body Adapter 5 - Screws (4) 6 - Gasket 7 - Intake Manifold 8 - Fuel Meter Cover 9 - Gasket 10 -O-ring 11 -Fuel Pressure Regulator 12 -Gasket 13 -Fuel Injector 14 -Fuel Meter Body...
Page 691 350 CID / 5.7L EFI (4 Barrel Throttle Body) Induction System 73766 73965 74109 Index 5E-150 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 692 1 - Screw (3) 2 - Throttle Body Unit 3 - Gasket 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Screw (4) 6 - Throttle Body Adapter 7 - Gasket 8 - Fuel Meter Cover 9 - Gasket 10- Fuel Line From VST To Fuel Filter 11- Fuel Pressure Regulator 12- Gasket 13- Fuel Injector...
Page 693 Throttle Body 73766 1 - Cap Screw 11- Body 2 - Cover Assembly 12- Throttle Body To Fuel Meter Body Gasket 3 - Fuel Pressure Regulator 13- Throttle Body 4 - Cover Assembly Gasket 14- Throttle Position (TP) Sensor 5 - Upper O-Ring 15- Screws (2) 6 - Fuel Meter Outlet Gasket 16- Seal...
Page 694 Fuel Pressure Relief Procedure 4. Remove fuel meter cover assembly. NOTICE Refer to “Service Precautions,” in “Repair Procedures,” BEFORE proceeding. 1. Disconnect electrical connector from fuel pump. 2. Crank engine for ten seconds (if engine starts al- low it to run until it dies) to relieve any fuel pres- sure in the system.
Page 695 INSTALLATION 1. Remove flame arrestor and fuel meter cover as outlined in this section. 1. Install new pressure regulator seal, fuel meter outlet passage gasket, and cover gasket. 2. Using a screwdriver carefully pry up on fuel in- jector to remove it from the fuel meter body (Use 2.
Page 696 INSTALLATION Throttle Body 1. Install new lower O-rings on fuel injectors. Lubri- REMOVAL cate O-rings using a water soap solution. CAUTION Ensure that fuel pressure is relieved before re- moving the fuel inlet and return lines. IMPORTANT: DO NOT allow the TP sensor, fuel pressure regulator, fuel injectors and IAC valve to come into contact with solvent or cleaner.
Page 697 CLEANING AND INSPECTION Throttle Body Adapter Plate 1. Thoroughly clean metal parts of throttle body in NOTICE a cold immersion type cleaner. Dry with com- Refer to “Service Precautions,” in “Repair pressed air. Make certain that all passages are Procedures,” BEFORE proceeding. free of dirt and burrs.
Page 698 Multi-Port Injection System WARNING Description Make sure no fuel leaks exist, before closing en- gine hatch. Service Precautions CAUTION WARNING Fuel pressure MUST BE relieved before servicing high pressure component in the fuel system. Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire or explosion.
Page 699 Multi-Port Exploded Views Flame Arrestor and Throttle Body (All Multi-Port Injection Engines Equipped Vapor Separator Tank) 75068 Index 5E-158 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 700 1 - Nut (4) 2 - Flame Arrestor 3 - Stud (4) 4 - Throttle Body 5 - Manifold Absolute Pressure (MAP) Sensor 6 - Plenum 7 - Screw (4) 8 - Fuel Line From Fuel Filter To Starboard Fuel Rail 9 - Fuel Filter 10- Fuel Line From VST To Fuel Filter 11- Fuel Line From Starboard To Port Fuel Rail...
Page 701 350 MPI Magnum Gen + Tournament Ski (Black Scorpion) Induction System 75046 Index 5E-160 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 702 1 - Flame Arrestor Fuel Pressure Relief Procedure 2 - Flame Arrestor Clamp 3 - Throttle Body NOTICE 4 - Throttle Body Gasket Refer to “Service Precautions,” in “Repair 5 - Manifold Absolute Pressure (MAP) Sensor 6 - Plenum Procedures,” BEFORE proceeding. 7 - Fuel Rail Fitting (2) 8 - Fuel Line 9 - Screw (2)
Page 703 Throttle Body 3. Remove four throttle body mounting studs using a stud driver. NOTICE Refer to “Service Precautions,” in “Repair Procedures,” BEFORE proceeding. REMOVAL 1. Remove four flame arrestor mounting cap nuts and remove flame arrestor from throttle body. 72792 a - Throttle Body b - Throttle Body Mounting Studs Turn throttle body as shown and disconnect TP, drain...
Page 704 5. Remove TP with O-ring and IAC valve with O-ring INSTALLATION from throttle body. NOTE: To prevent difficult removal of fasteners and damage to fastener heads, do not use a higher strength thread locking compound than recom- mended. 1. Connect TP and IAC electrical connectors, then install throttle body with new gasket using four throttle body mounting studs.
Page 705 NOTE: If Boat is equipped with Quicksilver Zero Ef- 4. Install flame arrestor to throttle body. Apply Loc- fort Controls, the throttle cable mounting stud must tite 242 to threads of studs. Install four flame ar- be most forward position on throttle lever. restor mounting cap nuts.
Page 706 3. Remove eight plenum mounting fasteners and lift CLEANING AND INSPECTION straight up from intake manifold. Turn plenum IMPORTANT: Use care when removing gasket slightly and rest on intake manifold as shown. material from intake manifold and plenum. Fail- ure to do so could result in damage to the intake manifold and plenum.
Page 707 6. Remove screws and fuel pressure regulator. 1. Install new O-rings on fuel injectors. Lubricate O- rings using a water soap solution. 75068 a - Fuel Rail b - Fuel Pressure Regulator c - Adapter Fitting d - Adapter Block 72799 Fuel Injectors a - Fuel Injector...
Page 708 Throttle Body Injection and REMOVAL 1. Disconnect J1 and J2 electrical connectors at en- Multi-Port Injection Sensor gine control module (ECM). and Module Servicing Precautions WARNING BEFORE attempting to disconnect and remove any module or sensor, check to make sure that the engine ignition system is OFF.
Page 709 INSTALLATION Knock Sensor (KS) Module 1. Mount new ECM to electrical bracket. NOTICE 2. Connect J1 and J2 electrical connectors to the Refer to “Service Precautions,” in “Repair ECM. Procedures,” BEFORE proceeding. REMOVAL 1. Remove Knock Sensor from electrical bracket. 72801 All Engines Except Black Scorpion a - Electrical Bracket...
Page 710 INSTALLATION 1. Disconnect electrical connector at Engine Cool- ant Temperature (ECT) sensor. 1. Connect electrical connector to the Knock Sen- sor (KS) module. 2. Mount KS module to electrical bracket. 72799 a - Thermostat Housing b - Engine Coolant Temperature (ECT) Sensor 2.
Page 711 Throttle Body Injection Components- Throttle Position (TP) Sensor Manifold Absolute Pressure (MAP) NOTICE Sensor Refer to “Service Precautions,” in “Repair Procedures,” BEFORE proceeding. NOTICE Refer to “Service Precautions,” in “Repair Procedures,” BEFORE proceeding. REMOVAL 1. Disconnect electrical connector at throttle posi- tion (TP) sensor.
Page 712 INSTALLATION Idle Air Control (IAC) Valve IMPORTANT: If the TP sensor is to be replaced NOTICE with a new unit, be sure to secure it in place with Refer to “Service Precautions,” in “Repair the new screws which are included in the service Procedures,”...
Page 713 INSTALLATION 4. Reset IAC valve pintle position after reconnect- ing negative (–) battery cable. IMPORTANT: If installing a new IAC valve, be sure to replace it with the correct IAC valve pintle a. Turn ignition key ON for ten seconds. shape and diameter are designed for the specific b.
Page 714 CLEANING AND INSPECTION 1. Clean knock sensor with a dry cloth, paying spe- cial attention to threads on base. 2. Inspect surfaces of knock sensor for signs of wear or physical damage. INSTALLATION IMPORTANT: If installing a new knock sensor, be sure to replace it with an identical part.
Page 715 Multi-Port Injection Components- 2. Remove screws from MAP sensor. Manifold Absolute Pressure (MAP) 3. Remove MAP sensor from plenum. Sensor CLEANING AND INSPECTION NOTICE 1. Clean off any foreign matter with a dry cloth. Refer to “Service Precautions,” in “Repair Procedures,”...
Page 716 Throttle Position (TP) Sensor CLEANING AND INSPECTION 1. Clean the surfaces of the TP with a dry cloth. NOTICE 2. Inspect the TP for signs of wear or damage. Refer to “Service Precautions,” in “Repair Procedures,” BEFORE proceeding. INSTALLATION 1. Install TP sensor to throttle body using screws REMOVAL with washers and Loctite 242 applied to threads.
Page 717 Idle Air Control (IAC) Valve CLEANING AND INSPECTION 1. Remove and discard sealing O-ring from IAC NOTICE valve. Clean sealing surfaces, pintle valve seat, Refer to “Service Precautions,” in “Repair and air passage with a carburetor cleaner to re- Procedures,” BEFORE proceeding. move carbon deposits, being careful not to push or pull on the IAC valve pintle.
Page 718 Knock Sensor Knock Sensor (KS) Module NOTICE NOTICE Refer to “Service Precautions,” in “Repair Refer to “Service Precautions,” in “Repair Procedures,” BEFORE proceeding. Procedures,” BEFORE proceeding. REMOVAL REMOVAL 1. Disconnect electrical connector at knock sensor 1. Remove KS module from electrical bracket or located just ahead of starter motor.
Page 719 ELECTRICAL BOX (EXCEPT BLACK SCORPION) 72801 1 - Bracket 2 - Relay 3 - Relay 4 - Screw 5 - Knock Sensor (KS) Sensor 6 - Screw 7 - Slave Solenoid 8 - Nut 9 - Circuit Breaker 10- Screw 11- Screw 12- MerCathode 13- Data Link Connector (DLC)
Page 720 Fuel Pump Relay Ignition Control (IC) System Components NOTICE Refer to “Service Precautions,” in “Repair Procedures,” BEFORE proceeding. Precautions REMOVAL WARNING 1. Detach fuel pump relay from bracket. When performing the following procedures, be sure to observe the following precautions to avoid damage to equipment or personal injury: DO NOT touch or disconnect any ignition system parts while the engine is running.
Page 721: Ignition Coil
Ignition Coil RESISTANCE CHECK Use an ohmmeter or the ohms function of a DVM for NOTICE the following check. Refer to “Service Precautions,” in “Repair 1. Connect meter as shown with meter 1 in the fig- Procedures,” BEFORE proceeding. ure below. REMOVAL 1.
Page 722: Spark Plug Replacement
2. Connect high tension coil lead. Spark Plug Replacement SPARK PLUG WIRING AND BOOT PRECAUTIONS 1. Twist boots one-half turn before removing. 2. When removing boot, DO NOT use pliers or other sharp tools which might tear the boot. 3. DO NOT force any object between the wire and the boot or through the silicone jacket of the wiring.
Page 723 INSTALLATION 1. Install spark plugs. Torque to 11 lb. ft. (15 N·m). 2. Connect spark plug wires to their respective spark plug. IMPORTANT: Wire routing must be kept intact during service and followed exactly when wires have been disconnected or when wire replace- ment is necessary.
Page 724 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) - 5E-183...
Page 725 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 5E-184 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096...
Page 726 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) - 5E-185...
Page 727 FUEL SYSTEMS 73662 BOS / SAV EMISSIONS Index...
Page 728 Table of Contents Page Identification ......5F-1 Replacement Parts Warning ....5F-1 Torque Specifications .
Page 729: Identification
Carburetor to NOTE: The third fitting on the 5.7L version is for the Manifold fuel pump sight tube connection. Fuel Line to Carburetor Special Tools Mercury Marine Special Tools Description Part Number Universal Carburetor Gauge 91-36392 Tachometer 91-59339 Other Special Tools...
Page 730: Carburetor Specifications
Carburetor Specifications Units of Measurements In. (mm) Meter- Second- Primary Metering Carb Mercury Number Engine Model Type (Manufacturer Number) Size Number Spring Size Color 3310-806545 (9663) .089 .092 16-656357 Natural 1994 Models and Earlier Weber MIE and MCM 3310-808012 (9668) .089...
Page 731: Description
Description Special Notes The Bodensee Emissions system is designed to IMPORTANT: Disassembly and repair of the Bo- lower exhaust emissions to meet regulations on the densee Emissions carburetor is basically the “Bodensee”. It consists of the following items: a same as the other Weber WFB carburetors. There Positive Crankcase Ventilation (PCV) circuit, a are some internal and external differences that Ported Vacuum Switch (PVS) circuit, a higher...
Page 732: Metering Assembly
Metering Assembly METERING JETS The metering jets in this carburetor are taller than the The metering rod assemblies are different in the fol- jets in a standard carburetor. lowing ways: Emissions Standard Emissions 73728 a - Jet for 3-Step Metering Rod b - Jet for 2-Step Metering Rod METERING ROD HAS “THREE STEPS”...
Page 733: Piston Assembly Cover Is Higher
PISTON ASSEMBLY COVER IS HIGHER Precautions WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire or explosion. WARNING Be careful when cleaning flame arrestor and 73735 crankcase ventilation hose: gasoline is extreme- ly flammable and highly explosive under certain conditions.
Page 734: Maintenance
Maintenance Fuel Filter Maintenance for fuel inlet filters is the same as stan- dard engine (see the Weber WFB carburetor section Flame Arrestor of the appropriate MerCruiser Service Manual). Maintenance for the flame arrestor is the same as standard engine (See the Weber WFB carburetor Positive Crankcase Ventilation (PCV) section of the appropriate MerCruiser Service Manu- al).
Page 735: Troubleshooting
Troubleshooting 2. Plug the hose with your finger. You should not feel vacuum on the hose at this time. NOTE: Review the “Description” section of this manual for an understanding of system operation, before troubleshooting the carburetor. Do not as- sume that a problem exists inside the carburetor without first eliminating other engine system compo- nents as potential problem areas.
Page 736: Service Procedures
IMPORTANT: Ensure that engine is running at Service Procedures 775 RPM or below. This ensures that the carbure- tor is not running on the “Off-Idle” circuit. Checking Positive Crankcase 7. Connect a tachometer to the engine. Ventilation (PCV) Valve 8. Plug the vacuum ports on the front of the carbure- 1.
Page 737: Removing Seals From Idle Mixture Screws
Removing Seals From 2. Align the opening in the plug with the tab on the cup and push down until it snaps in place. Idle Mixture Screws WARNING Avoid fire or explosion. Using a cutting wheel to cut the seals will cause sparks, which will ignite any fuel that is present.
Page 738: Ported Vacuum Switch Installation
2. Install new carburetor as follows: Ported Vacuum Switch Installation a. Place new gasket on adapter plate. CAUTION b. Install carburetor and throttle bracket and se- Be careful not to break off fittings when installing cure with new attaching hardware. Torque the ported vacuum switch (PVS) in the following fasteners to 132 lb.
Page 739: Emissions System Connections
Emissions System Connections 3. Connect hoses to ported vacuum switch (PVS) as shown. 1. Install the positive crankcase ventilation (PCV) valve in the port valve cover. 2. Connect hose to PCV valve. Connect opposite end of hose to fitting on front of carburetor. 71924 71925 a - Ported Vacuum Switch...
Page 740: Propane Assisted Idle Set Procedure
IMPORTANT: The hose that runs from the T-Fit- Propane Assisted Idle Set Procedure ting to the back side of the carburetor must be WARNING routed beneath the throttle linkage as shown in the following illustration. Use care to ensure that Avoid fire or explosion.
Page 741 5. Connect the hose from the propane bottle valve 8. Release the propane flow valve and allow engine to the “Y”-Fitting. speed to stabilize. Slowly adjust the mixture screws by equal amounts, pausing between ad- 6. With engine idling at normal operating tempera- justments to allow engine speed to stabilize, to ture, press the propane flow button on the valve.
Page 742: Test Equipment
11. Once the idle speed and mixture adjustment is Emissions Testing correct, install the seal plugs over mixture NOTE: This test will be performed by an authorized screws. Ensure the opening in plug snaps into agency for the area that the boat will be operated. the tab in the cup.
Page 743 2. Install exhaust elbow adapter fittings into elbows. NOTE: Be certain to place test probes and adapter fittings in suitable storage aboard the boat for use in Apply Loctite Pipe Sealant with Teflon to threads that go into elbow. Tighten securely. the future.
Page 744 COOLING SYSTEM 22381 SEAWATER COOLING MODELS Index...
Page 745 Table of Contents Page MCM 350 CID / 5.7L ....6A-1 Torque Specifications ....6A-1 Tools/Lubricants/Sealants .
Page 746: Mcm 350 Cid / 5.7L
MCM 350 CID / 5.7L TORQUE SPECIFICATIONS DESCRIPTION Lb. In. Lb. Ft. Alternator Brace to Alternator Alternator Brace to Block Alternator to Mounting Bracket Alternator/Power Steering Pump Mounting Bracket Power Steering Pump Brace to Block Power Steering Pump Bracket Thermostat Cover Thermostat Housing Water Circulating Pump Water Temperature Sender...
Page 747: Seawater Inlet Recommendations
Seawater Inlet Seacock (Seawater Inlet Valve) Recommendations If a seacock is being used, it must be installed be- tween water pickup and seawater pickup pump (or sea strainer), to allow operator to shut off the seawa- ter in case of a leak or when boat is not in use. This Transom Mounted or Thru-Hull will allow the operator to flush or drain the engine, or Seawater Pickups and Hose...
Page 748: Seawater Pickups
Seawater Pickups Transom Mounted (Quicksilver Part Number: 88845A1) NOTICE Refer to manufacturer’s instructions for in- formation on removal and installation of other than Quicksilver Seawater Pickups. IMPORTANT: Seal the inside edges of any hole made through the hull with a suitable sealant to prevent water absorption and deterioration.
Page 749: Sea Strainer (Quicksilver)
NOTE: Some installations may have 7/32 in. (5.5 Removal mm) holes drilled in transom using four 5/16 in. diam- eter stainless steel lag bolts in place of round head CAUTION screws. In any case, flat washers and O-rings are re- quired as outlined.
Page 750: Installation
2. Remove outlet hose. Drain into a suitable con- 2. Install inlet and outlet hoses. Use two hose tainer. clamps on each hose connection. Tighten clamps securely. 72645 72643 a - Seawater Inlet Hose a - Seawater Outlet Hose b - Seawater Strainer b - Seawater Strainer c - Double Hose Clamps 3.
Page 751: Stern Drive Unit Seawater Pickup Pump Output Test
Stern Drive Unit Seawater 1. Remove water inlet hose, which runs between gimbal housing water tube and engine, and re- Pickup Pump Output Test place with another hose of same diameter, but approximately 3 ft. (1 m) longer. Hose should be If an overheating problem exists, use this test to de- wire reinforced or of adequate wall thickness to termine if a sufficient amount of water is being...
Page 752: Stern Drive Unit Seawater Pickup Pump Repairs
5. Repeat test four times to check repeatability of 5. Remove pump pulley attaching bolts, lockwash- results. ers, clamping ring (if so equipped) and pulley. 6. Disconnect hose(s) from pump. Alpha Stern Drive Pump Output 7. Remove bolts, which secure pump to cylinder for 15 Second Period block, and remove pump and old gaskets (dis- Minimum Quantity...
Page 753: Flushing Seawater Cooling System
Flushing Seawater Cooling 2. Connect hose between flushing attachment and water tap. System If engine is operated in salty, polluted or mineral- laden waters, seawater cooling system should be flushed periodically (preferably after each use) with fresh water to reduce corrosion and prevent the accumulation of deposits in the system.
Page 754: Thermostat
NOTE: If equipped with a lifting eye (not shown in CAUTION following), note placement of lifting eye so that it may Do not over-tighten cover screws or cover will be positioned exactly the same upon installation, or warp and leak. it may interfere with the fit of the flame arrestor cover.
Page 755: Testing
Testing 4. Check opening and closing temperature of ther- mostat (using a tester similar to the one shown) 1. Clean thermostat in soap and water to remove as follows: any deposits or debris. a. Fill tester to within 1 in. (25mm) of top with tap 2.
Page 756: Installation
Installation 8. Reconnect hose(s) to thermostat housing. Tight- en hose clamps securely. 1. Clean gasket surfaces on thermostat cover and 9. Start engine and inspect for leaks. thermostat housing. 2. If thermostat housing was disturbed during re- moval of thermostat, remove thermostat hous- ing.
Page 757: Draining Seawater Cooling System
Draining Seawater Cooling NOTE: If possible, place a container under drains and hoses to prevent water from draining into boat. System NOTICE NOTICE Refer to “Draining Precautions,” in this For cold weather or extended storage infor- section, BEFORE proceeding. mation and procedures, refer to SECTION 1B. 1.
Page 758 NOTE: With the engine level, sufficient draining of 5. Remove the engine water circulating pump hose manifolds will occur when exhaust manifold-to-ther- as shown. mostat housing hoses are removed. 72993 72587 Starboard Side Shown (Port Similar) a - Hose, Water Circulating Pump to Thermostat Housing a - Bottom Hose, Exhaust Manifold to Thermostat Housing 6.
Page 759 7. Bravo models need to remove both hoses from b. Remove the drain plug from the water tube seawater pump. (carburetor models) or Cool Fuel system (fuel injection models). 71170 a - Seawater Inlet And Outlet Hoses 8. For 1996 and newer models, the additional 75081 following steps must be performed: a.
Page 760: (Mcm) Stern Drive Drain Location
(MCM) Stern Drive Drain Location b. Bravo Drive Equipped Models: Insert a small wire (repeatedly) to make sure that 1. Follow instructions “a” or “b”: speedometer pitot tube, trim tab cavity vent hole, and trim tab cavity drain passage are a.
Page 761: Mie (Inboard) Models
3. Crank engine over SLIGHTLY with starter motor 4. Remove hose or drain plug from bottom of port to purge any water trapped in seawater pickup and starboard manifolds. pump. DO NOT ALLOW ENGINE TO START. NOTE: Some exhaust manifolds have draincock(s) 4.
Page 762 5. Remove the engine water circulating pump hose 7. Remove seawater pump inlet hose as shown. as shown. 72587 72532 a - Hose, Water Circulating Pump-to-Thermostat Housing a - Seawater Pickup Pump 6. Remove the transmission fluid cooler hose, as b - Seawater Inlet Hose shown.
Page 763: Auxiliary Hot Water Heater Installation
10. Remove the transmission fluid cooler hose as Auxiliary Hot Water Heater shown. Installation IMPORTANT: When connecting a cabin heater or hot water heater, certain requirements must be met. Supply hose (from engine to heater) and re- turn hose (from heater to engine) MUST NOT EXCEED 5/8 in.
Page 764 SUPPLY HOSE CONNECTION - ENGINES WITH RETURN HOSE CONNECTION - ENGINES WITH RAW WATER OR CLOSED COOLING SYSTEM RAW WATER OR CLOSED COOLING SYSTEM 72708 72705 Primary Location Earlier Style Quicksilver Kit Location a - Plug a - T-Fitting b - Reducer Bushing c - Hose Connector 71758 Raw Water Cooling Models - Alternate Location...
Page 765: Water Flow Diagrams
Water Flow Diagrams MCM Alpha OVERBOARD ENGINE BLOCK INTAKE MANIFOLD WATER INLET AND CYLINDER HEAD (FROM STERN ASSY. DRIVE) EXHAUST ELBOW THERMOSTAT COVER RESTRICTOR POWER STEERING THERMOSTAT FLUID HOUSING COOLER EXHAUST MANIFOLD ENGINE CIRCULATING PUMP 22382 TO EXHAUST MANIFOLDS TO EXHAUST ELBOW (NOTE) FROM WATER INLET...
Page 766: Mcm Alpha Gen+ With Cool Fuel System
MCM Alpha Gen+ With Cool Fuel System OVERBOARD WATER INLET (FROM STERN DRIVE) POWER STEERING FLUID COOLER ENGINE BLOCK EXHAUST ELBOW INTAKE MANIFOLD AND CYLINDER HEAD ASSY. THERMOSTAT HOUSING RESTRICTOR FUEL COOLER EXHAUST MANIFOLD ENGINE CIRCULATING PUMP Index 90-823225--1 1096 SEAWATER COOLING MODELS - 6A-21...
Page 767: Mcm Bravo
MCM Bravo ENGINE OIL AND POWER STEERING FLUID COOLER 72998 TO EXHAUST MANIFOLDS TO EXHAUST ELBOW (NOTE) FROM WATER INLET (VIA FLUID COOLER) FROM ENGINE 72532 SEAWATER PUMP THERMOSTAT LEGEND TO ENGINE COLD 22380 CIRCULATING NOTE: Thermostat housing WARM PUMP check-balls will not be present on later models.
Page 768: Mcm Bravo With Cool Fuel System
MCM Bravo With Cool Fuel System WATER INLET (FROM STERN OVERBOARD DRIVE) POWER STEERING FLUID COOLER ENGINE BLOCK INTAKE MANIFOLD EXHAUST ELBOW AND CYLINDER HEAD ASSY. THERMOSTAT HOUSING RESTRICTOR FUEL COOLER EXHAUST MANIFOLD ENGINE CIRCULATING PUMP Index 90-823225--1 1096 SEAWATER COOLING MODELS - 6A-23...
Page 769: Mie Inboard Models
MIE Inboard Models OVERBOARD SEAWATER INLET ENGINE BLOCK INTAKE MANIFOLD AND CYLINDER HEAD ASSY SEAWATER PICKUP PUMP THERMOSTAT COVER EXHAUST ELBOW RESTRICTOR THERMOSTAT TRANSMISSION HOUSING FLUID COOLER EXHAUST ENGINE MANIFOLD CIRCULATING PUMP TO EXHAUST MANIFOLDS 24728 TO EXHAUST ELBOW (NOTE) FROM WATER INLET (VIA FLUID COOLER) FROM...
Page 770: Mie Inboard With Cool Fuel System
MIE Inboard With Cool Fuel System WATER INLET (FROM STERN OVERBOARD DRIVE) TRANSMISSION FLUID COOLER ENGINE BLOCK INTAKE MANIFOLD EXHAUST ELBOW AND CYLINDER HEAD SEAWATER PUMP ASSY. THERMOSTAT HOUSING RESTRICTOR FUEL COOLER EXHAUST MANIFOLD ENGINE CIRCULATING PUMP 75149 Index 90-823225--1 1096 SEAWATER COOLING MODELS - 6A-25...
Page 771 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 6A-26 - SEAWATER COOLING MODELS 90-823225--1 1096...
Page 772 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 SEAWATER COOLING MODELS - 6A-27...
Page 773 COOLING SYSTEM 72987 CLOSED COOLED MODELS Index...
Page 774 Table of Contents Page Page 305/350 CID / 5.0L/5.7L ....6B-1 Changing Coolant ..... . . 6B-26 Water Flow Diagrams .
Page 775: 305/350 Cid / 5.0L/5.7L
305/350 CID / 5.0L/ 5.7L TORQUE SPECIFICATIONS DESCRIPTION Lb. In. Lb. Ft. Heat Exchanger End Caps 36-72 Seawater Pump Brace 30 (41) 30 (41) Seawater Pump Bracket to Block Seawater Pump Cover Seawater Pump Mounting Nuts to Stamped Steel Brackets Thermostat Cover Thru Hull Pickup Nut Drain Plugs...
Page 776: Water Flow Diagrams
Water Flow Diagrams Engines With Coolant Flow Thru Exhaust Manifolds (Excluding Gen +) COOLANT FLOW RAW WATER FLOW 72989 Typical Thermostat and Thermostat Housing Shown (All Similar) a - Remove Hoses (Lift, Lower or Bend To Completely Drain) b - Remove Block Plugs (Repeatedly Clean Out Holes Using A Stiff Wire Until Entire System Is Drained) c - Remove Drain Plugs From Exhaust Exhaust Manifold Drain Elbows (Repeatedly Clean Out Holes Using A Stiff Wire Until Entire System Is Drained) Index...
Page 777: Engines With Raw Water Flow Thru Exhaust Manifolds
Engines With Raw Water Flow Thru Exhaust Manifolds 75005 COOLANT FLOW RAW WATER FLOW a - Remove Hoses (Lift, Lower or Bend To Completely Drain) b - Remove Block Plugs (Repeatedly Clean Out Holes Using A Stiff Wire Until Entire System Is Drained) c - Remove Drain Plugs From Exhaust Exhaust Manifold Drain Elbows (Repeatedly Clean Out Holes Using A Stiff Wire Until Entire System Is Drained) Index...
Page 778: Description
Description Seawater Pickup Pump (If Equipped) There are several configurations of this cooling sys- tem, but the operation is essentially identical. Basi- cally, the system is composed of two separate sub- systems: the seawater system and the closed Maintenance cooling system. The seawater system is similar in Whenever insufficient water flow is suspected, sea- function to the fan used in an automobile because it water pickup pump should be disassembled and in-...
Page 779 OUTPUT TEST 1. Remove water hose, which runs between pump outlet and engine, and replace with another hose of same diameter, but approximately 3 ft. (1 m) If an overheating problem exists, use this test to de- longer. Hose should be wire reinforced or of ade- termine if a sufficient amount of water is being quate wall thickness to prevent it from kinking supplied to cool engine.
Page 780 REMOVAL 3. If pump is to be disassembled, loosen the four pump pulley attaching screws. Do not remove screws at this time. CAUTION 4. Remove power steering pump drive belt to allow If boat is in the water, be sure to close seacock removal of seawater pickup pump drive belt.
Page 781 72646 Two Piece Pump Assembly 1 - Screw (5) 74577 2 - Washer (5) 3 - Cover One Piece Pump Assembly 4 - Gasket 5 - Wear Plate (Outer) 1 - Screw (5) 6 - Gasket 2 - Washer (5) 7 - Plug 3 - One Piece Body 8 - Impeller...
Page 782 DISASSEMBLY (TWO PIECE BODY) 1. Remove cover and body attaching screws and washers. 72652 a - Gasket (with Large Opening) b - Wear Plate (Outer) c - Gasket (with Two Openings) 72650 3. Slide pump body off shaft. Remove impeller from pump body and rubber plug from impeller.
Page 783 2. Remove seawater pump body and wear plate from bearing housing. 72656 a - Quad Ring Seal 75275 SEAWATER PUMP DISASSEMBLY a - Seawater Pump Body (ONE PIECE BODY) b - Wear Plate c - Bearing Housing 1. Remove the five screws from the seawater pump body.
Page 784 2. Press hub off shaft with Universal Puller Plate 4. Remove snap ring from bearing housing bore and an arbor press. and press shaft and bearings out pulley end of housing. Bearings have a slip fit in housing; do not use excessive force. 72657 72648 a - Universal Puller Plate (91-37241)
Page 785 5. If bearings require replacement, remove bear- 6. Inspect pump shaft bearings. ings from shaft with Universal Puller Plate and an 7. Inspect pump shaft for grooves in surface where arbor press. Bearings must be replaced, if re- seals contact shaft. Also inspect surface where moved.
Page 786 3. Using an arbor press and suitable tool, press ball 5. Apply a thin coat of Quicksilver Loctite 8831 to bearings onto shaft until they seat. Press on inner outside diameter of new bearing housing front oil race of bearing only. seal and press seal into housing (with seal lip fac- ing inward) until it bottoms out.
Page 787 7. Clamp bearing housing in a soft jaw vise with REASSEMBLY (TWO PIECE BODY) flange end up. 1. Place inner wear plate on housing and align 8. Coat quad ring seal with Quicksilver 2-4-C Ma- holes. Coat both sides of a new wear plate gasket rine Lubricant With Teflon and install into groove with a thin film of Quicksilver Perfect Seal and po- in housing.
Page 788 71150 72651 a - Impeller a - Gasket (with Large Opening) b - Wear Plate (Outer) 3. Slide impeller and pump body assembly onto c - Gasket (with Two Openings) shaft. Position pump body so that holes align with holes in wear plate, gasket and bearing housing. 5.
Page 789 2. Place wear plate over bearing housing shaft. IMPORTANT: Pump must be positioned correctly or overheating of engine may occur. 3. Place quad ring in groove in seawater pump body. a - Quad Ring 72666 b - Seawater Pump 4. Align flats on impeller and bearing housing shaft, slide seawater pump body on shaft.
Page 790 2. Install pulley on pump and secure with four screws, lockwashers and clamping ring (some models). Tighten screws finger-tight only at this time. 3. Attach pump, mounting bracket and brace as- sembly to engine. Do not tighten attaching screws at this time. 4.
Page 791: Maintaining Coolant Level
Closed Cooling Systems If level is low, remove fill cap from coolant recovery bottle and add required amount of coolant solution. With Coolant Flow Thru Use a 50/50 mixture of ethylene glycol antifreeze and pure, soft water for coolant additions. If frequent addi- Exhaust Manifolds tions of coolant are required, check fresh water sec- (Excluding Engines With...
Page 792: Heat Exchanger Repair
5. Check condition of locking tabs on cap. Replace Heat Exchanger Repair cap if tabs are bent or cracked. IMPORTANT: Braze with BCUP 2 rod or silver sol- der. Care must be taken not to melt other joints during repair. 1.
Page 793: Pressure Testing System
Pressure Testing System 7. While maintaining specified pressure on closed cooling section, visually inspect external portion of cooling system (hoses, gaskets, drain plugs, WARNING petcocks, core plugs, circulating pump seal, etc.) for leakage. Also listen closely for bubbling or Allow engine to cool before removing pressure hissing, as they usually are a sure indication of a cap.
Page 794: Testing For Cylinder Head Gasket Leak
Testing for Cylinder Head Gasket Testing Heat Exchanger Leak FOR INTERNAL LEAK: An internal leak will cause coolant to go into the seawater circuit when pressure A leaking head gasket will cause combustion gas to is put on the closed cooling circuit. be forced into the cooling system.
Page 795: Thermostat
3. Inspect gasket (if used) and rubber seal on cap IMPORTANT: Before reinstalling cap in next step, for tears, cuts, cracks or other signs of deteriora- examine lower inside sealing surface in filler tion. Replace gasket, if damaged, or entire cap if neck to ensure that it is perfectly smooth and free rubber seal is damaged.
Page 796 b. Drain engine block by removing plug or open- 4. Remove thermostat from thermostat housing. ing petcocks. Be sure to drain both port and starboard sides. 72993 Port Side Shown a - Drain Plug (Cylinder Block) b - Hose 73111 Models Without Sleeve a - Drain Plug (Cylinder Block) a - Bolts...
Page 797: Testing
Testing 1. Clean thermostat in soap and water to remove any deposits or debris. 2. Inspect thermostat for corrosion or other visible damage. 3. If thermostat is suspected of producing insuffi- cient engine temperature, check thermostat for leakage by holding it up to lighted background. Light leakage around the thermostat valve indi- cates that thermostat is not closing completely and should be replaced.
Page 798: Installation
4. Check opening and closing temperature of ther- Installation mostat (using a tester similar to the one shown), as follows: CAUTION a. Fill tester to within 1 in. (25 mm) of top with tap water. Do not use distilled water. Do not operate engine without cooling water be- ing supplied to the seawater pickup pump, or b.
Page 799 5. Position gasket on thermostat housing and reinstall thermostat cover. Install lifting eye (not shown following) if so equipped. Torque bolts to 30 lb. ft. (41 N·m). 73111 Models Without Sleeve a - Bolts b - Lockwashers 73110 c - Cover d - Gasket Models With Sleeve e - Thermostat (Typical)
Page 800: Changing Coolant
Closed Cooling Section Closed cooling section of closed cooling system should be kept filled year-round with recommended coolant solution. Do not drain closed cooling section for storage, as this will promote rusting of internal surfaces. If engine will be exposed to freezing temperatures, make sure that closed cooling section is filled with an ethylene glycol antifreeze and water solution, mixed to manufacturer’s recommended...
Page 801: Draining Instructions
Draining Instructions Cleaning System WARNING Closed Cooling Section Allow engine to cool before removing pressure cap. Sudden loss of pressure could cause hot Closed cooling section of the cooling system should coolant to boil and discharge violently. After en- be cleaned at least once every two years or gine has cooled, turn cap 1/4 turn to allow any whenever decreased cooling efficiency is experi- pressure to escape slowly, then push down and...
Page 802: Flushing Seawater Section Of Closed Cooling System
1. Remove seawater drain plug from bottom of heat Flushing Seawater Section exchanger and allow water to drain. After water of Closed Cooling System has drained completely, coat threads of drain plug with Quicksilver Perfect Seal and reinstall. If engine is operated in salty, polluted or mineral- laden waters, seawater section of closed cooling system should be flushed periodically (preferably after each use) with fresh water to reduce corrosion...
Page 803 a. All Models: (1) Install Quicksilver Flushing Attachment (or equivalent) over water intake open- ings in gear housing. (2) Connect hose between flushing attach- ment and water tap. 72532 a - Seawater Pickup Pump b - Seawater Inlet Hose 2. Partially open water tap (approximately 1/2 maxi- mum capacity) and allow drive unit and cooling system to fill completely.
Page 804: Draining Seawater Section Of Closed Cooling System
a. If equipped with seacock: Observing pre- 1. Close seacock (if so equipped) or disconnect and caution above, open seacock. plug seawater inlet hose. b. If NOT equipped with seacock: Observing 2. Check that engine is as level as possible to en- precaution above, remove plug from seawa- sure complete draining of cooling system.
Page 805 5. If equipped with 3 in. (76 mm) or 6 in. (152 mm) risers, remove drain plug as shown from port and starboard risers (if equipped). 74752 Rear Mounted Fluid Cooler a - Hose, From Seawater Pump (Bravo) Or From Transom 73175 Assembly (Alpha) a - Drain Plug (Removed)
Page 806: Filling Closed Cooling Section
10. After seawater section of cooling system has CAUTION been drained completely, coat threads of drain Models with belt drive seawater pickup pump plugs with Quicksilver Perfect Seal and reinstall. must be in the water when running engine be- Tighten drain plugs securely. Reconnect hoses cause garden hose will not supply enough water and tighten all hose clamps securely.
Page 807: Maintaining Closed Cooling System
Closed Cooling System With IMPORTANT: ALCOHOL OR METHANOL BASE ANTIFREEZE OR PLAIN WATER ARE NOT REC- Raw Water Flow Thru OMMENDED FOR USE IN CLOSED COOLING SYSTEM AT ANY TIME. In areas where ethylene Exhaust Manifold glycol is not available, and the possibility of (Engines With Serpentine freezing does not exist, it is permissible to use a solution of rust inhibitor and pure, soft water...
Page 808: Checking Coolant For Alkalinity
Checking Coolant for Alkalinity WARNING Coolant section of Closed Cooling System is equipped with a 16 psi (110 kPa) pressure cap (fill cap). Before removing pressure cap (in next step), first allow engine to cool down, as sudden loss of pressure could cause hot coolant to boil and discharge violently.
Page 809 4. Disconnect heat exchanger-to-circulating pump FILLING INSTRUCTIONS hose from pump and allow coolant to drain. CAUTION Alcohol or Methanol base antifreeze or plain wa- ter, are not recommended for use in coolant sec- tion of Closed Cooling System at any time. It is recommended that coolant section of Closed Cooling System be filled with a 50/50 mixture of ethy- lene glycol antifreeze and pure, soft water.
Page 810 6. With engine still running, check hose connec- CAUTION tions, fittings and gaskets for leaks. Also observe DO NOT operate engine without water flowing engine temperature gauge to make sure that thru seawater pickup pump, as pump impeller engine operating temperature is normal. If gauge may be damaged and subsequent overheating indicates excessive temperature, stop engine damage to engine or stern drive unit may result.
Page 811: Pressure Cap Maintenance
Pressure Cap Maintenance 4. Inspect coolant recovery gasket for deterioration and replace if bad. 5. Check condition of locking tabs on cap. Replace WARNING cap, if tabs are bent or cracked. Allow engine to cool down before removing pres- 6. Have pressure cap pressure-tested by your local sure cap (in next step), as sudden loss of pres- servicing dealer.
Page 812: Flushing Seawater Section
Flushing Seawater Section CAUTION If boat is operated in salty, polluted or mineral-laden DO NOT run engine above 1500 RPM, as suction waters, seawater section of cooling system should created by seawater pickup pump may collapse be flushed periodically (preferably after each use) to water supply hole, interrupting water flow and remove corrosive water and and prevent the accu- causing engine to overheat.
Page 813: Cleaning Seawater Section Of Heat Exchanger And Fluid Coolers
Cleaning Seawater Section of Heat 3. Follow appropriate instructions “a” or “b”: Exchanger and Fluid Coolers a. On Engines Without Cool Fuel System: Proceed to Step 4. During operation, contaminants in the seawater may collect on tubes within the heat exchanger and fluid b.
Page 814: Cleaning Closed Cooling Section
6. Clean tubes (passages) in heat exchanger and 9. Install all hoses previously disconnected . Tight- coolers by running a suitable wire brush through en hose clamps securely. each tube. 10. Start engine and check for leaks. Cleaning Closed Cooling Section Closed Cooling section of cooling system should be cleaned whenever decreased cooling efficiency (due to internal deposits) is experienced.
Page 815: Cold Weather Or Extended Storage
Cold Weather or Extended 1. Remove drain plug from port and starboard ex- haust manifolds. Storage CAUTION Seawater section of cooling system MUST BE COMPLETELY drained for winter storage, or im- mediately after cold weather use, if the possibil- ity of freezing temperatures exist or if the boat is to be stored for an extended period.
Page 816 3. Follow instructions “a” or “b”: 4. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is a. On Engines With Cool Fuel System: Re- drained. move drain plug from Cool Fuel System sea- water pipe.
Page 817 6. Follow instructions “a” or “b”: (2) Crank engine over slightly, with starter motor, to purge any water trapped in sea- water pickup pump. Do not allow engine a. On Engines WITHOUT Engine Mounted to start. Seawater Pump: Proceed to Step 7. 7.
Page 818: Serpentine Drive Belt Adjustment
Serpentine Drive Belt Adjustment 1. Loosen 5/8 in. locking nut on adjustment stud. Leave wrench on adjustment stud. 74931 Belt Routing WITH Power Steering and WITHOUT 74908 Engine Mounted Seawater Pump Typical 5/8 In. Locking Nut Adjustment Stud 2. Install drive belt on pulleys. Route belt for your type of power package.
Page 819: Auxiliary Hot Water Heater Installation
Auxiliary Hot Water Heater SUPPLY HOSE CONNECTION Installation IMPORTANT: When connecting a cabin heater or hot water heater, certain requirements must be met. Supply hose (from engine to heater) and re- turn hose (from heater to engine) MUST NOT EXCEED 5/8 in. (15.8 mm) I.D. (inside diame- ter).
Page 820 RETURN HOSE CONNECTION 72705 Earlier Style Quicksilver Kit Location a - T-Fitting 72702 Later Style Quicksilver Kit Location a - Pipe Plug b - Hose Connector c - T-Fitting d - Hose Clamps Index 6B-46 - CLOSED COOLING MODELS 90-823225--1 1096...
Page 821 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 CLOSED COOLING MODELS - 6B-47...
Page 822 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 6B-48 - CLOSED COOLING MODELS 90-823225--1 1096...
Page 823 EXHAUST SYSTEM 72699 GENERAL Index...
Page 824 Table of Contents Page Exhaust System Requirements ... . . 7A-1 Determining If Exhaust Elbow Risers Are Required ......7A-1 MCM (Stern Drive) Engines With Thru Transom Exhaust...
Page 825: Exhaust System Requirements
4. Exhaust outlet must be slightly above the water- line with boat at rest in the water and full load aboard. 5. Back pressure must not exceed 4 in. (102 mm) of mercury when measured with a mercury manom- eter to exhaust elbow outlets. 72700 Exhaust Elbow Measurement...
Page 826: Mie (Inboard) Engines
5. System must not cause excessive back pres- tion with two hose clamps. sure. Back pressure MUST NOT exceed 4 in. (102 mm) of mercury when measured with a mer- cury manometer at exhaust elbow outlets. Mini- mum exhaust hose sizes are given in chart.
Page 827: Exhaust Tube Requirements
Exhaust Tube Requirements IMPORTANT: When installing thru-transom ex- haust, it is recommended that the exhaust bellows on the transom assembly be removed. This is necessary to avoid creating a vacuum at the exhaust outlet in the propeller at higher boat speeds.
Page 828 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 7A-4 - GENERAL 90-823225--1 1096...
Page 829 EXHAUST SYSTEM 72695 MANIFOLDS AND ELBOWS Index...
Page 830 Table of Contents Page Torque Specifications ..... 7B-1 Sealants ....... . 7B-1 Removal .
Page 831 Torque Specifications 7. Remove exhaust manifold fasteners; remove manifold assembly and discard gaskets. Fastener Location Lb. Ft. N·m Hose Clamp Securely Exhaust Elbow Exhaust Manifold Sealants Description Part Number Quicksilver Perfect Seal 92-34227-1 Removal WARNING 72695 Avoid possible injury or damage to equipment Stainless Steel Elbow With Restrictor Gasket should wires be accidentally shorted.
Page 832 Cleaning and Inspection 5. Install exhaust elbows and cooling hoses. 6. On Closed Cooled Models: Refill closed cool- 1. Clean gasket material from all surfaces and wash ing system to operating level with properly mixed parts in solvent. coolant. Refer to SECTION 6B. 2.
Page 833 72696 Stainless Steel Elbow With Separator Gasket (Cast Iron Elbow Similar) a - Exhaust Elbow b - Bolts (4) c - Gasket - Seawater Cooled (Aligned As Shown) d - Exhaust Manifold e - Plug f - Bolts (4) Index 90-823225--1 1096 MANIFOLDS AND ELBOWS - 7B-3...
Page 834 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 7B-4 - MANIFOLDS AND ELBOWS 90-823225--1 1096...
Page 835 EXHAUST SYSTEM 70593 RISERS Index...
Page 836 Table of Contents Page Exhaust Riser (Kit) Identification ... . 7C-1 Torque Specifications ..... 7C-1 Sealants .
Page 837 Exhaust Riser (Kit) Replacement Information Identification Engine Preparation and Parts IMPORTANT: All listed MCM and MIE Models can Removal be adapted to 9 inch (228 mm) exhaust risers by stacking 3 inch (76 mm) riser kit (93320A7) and the 6 inch (152 mm) riser kit (9322A4) with stain- WARNING less steel elbows.
Page 838 Engine Preparation and 6. Assemble harness bracket and plastic backup plate, if so equipped, using four small screws. Component Removal 1. Assemble studs to exhaust manifold and position all gaskets as shown between risers. Refer to “In- stallation Diagrams” at the end of this section. IMPORTANT: Restrictor gaskets or manifold sep- arator gaskets must be installed in order shown.
Page 839 Exhaust Extension Kit Installation 1. Install appropriate exhaust extension (see “Addi- tional Kits”) for MCM Models with thru prop ex- haust, using two hose clamps at each end. 50930 Typical Exhaust Extension (See “Additional Kits” at Front of Section for Kit Part Number) a - Cut Along Bottom Edge Of Welt For With 3in.
Page 840 Cast Iron Elbows Cast Iron Elbows With Mufflers 70621 70622 a - Exhaust Elbow a - Exhaust Elbow b - Separator Gasket b - Muffler Spacer 1-1/4 Inch (32 mm) c - 3 Inch (76 mm) Exhaust Riser c - Open Gasket d - Open Gasket d - Exhaust Riser 3 Inch (76 mm) e - Restrictor Gasket...
Page 841 Stainless Steel Elbows Stainless Steel Elbows With Mufflers 70593 70602 a - Exhaust Manifold a - Exhaust Manifold b - Exhaust Elbow b - Exhaust Elbow c - Stud 6-1/2 Inch (165 mm) c - Stud 9-3/8 Inch (238 mm) d - Stud 7-1/2 Inch (191 mm) For Use With Remote Oil Filter d - Stud 10-3/8 Inch (264 mm) For USe With Remote Oil Filter e - Nuts (8)
Page 842 Maintenance Instructions Maintenance inspection is owner’s responsibility and must be performed at intervals specified in owner’s “Operation and Maintenance Manual”. 1. Check to ensure exhaust elbow and manifold fas- teners are adequately tightened. 2. Check to ensure hose clamps are adequately tightened.
Page 843 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 RISERS - 7C-7...
Page 844 EXHAUST SYSTEM 72737 COLLECTORS Index...
Page 845 Table of Contents Page Torque Specifications ..... 7D-1 Lubricants/Sealants/ Adhesives ... . 7D-1 Shutter Replacement .
Page 846: Torque Specifications
Torque Specifications Shutter Replacement IMPORTANT: Engine does not have to be re- Fastener Location Lb. Ft. N·m moved to change shutters. Block-Off Plate 1. Loosen clamps and remove exhaust pipe elbow and exhaust hose. Exhaust Pipe to Gimbal 2. Replace water shutter as shown. Housing 3.
Page 847: Component Replacement
Later Style Shutter a - Exhaust Flapper 72737 b - Rubber Grommets a - Clamps b - Exhaust Pipe Elbow c - Exhaust Hose Component Replacement d - Water Shutters e - Bolts and Lockwashers To replace any components(s) in exhaust system, f - Exhaust Pipe the following must be adhered to: All mating joint surfaces must be clean.
Page 848: Thru-Transom Exhaust
Thru-Transom Exhaust Component Replacement Shutter Replacement IMPORTANT: A block off plate must be installed when using thru-transom exhaust or below swim platform kits. 72740 Transom Exhaust Kit a - Screw And Nut (4) b - Support Member c - Water Shutter (Hinge Must Be Vertical) 22057 d - Gasket a - Block Off Plate...
Page 849: Modifying Swim Platform Exhaust Pipe, If Required
Modifying Swim Platform Exhaust Silent Choice Exhaust Pipe, If Required System If engine is equipped with thru-prop exhaust, a thru-transom kit [4 in. (102 mm)], two exhaust bel- lows, and eight bellows hose clamps, are required. ENGINE If engine is equipped with thru-transom exhaust, an exhaust pipe kit (P/N 44266A6) is required, contain- ing the exhaust pipe and necessary parts.
Page 850 2. If required, install exhaust tube on gimbal hous- CAUTION ing as follows: It is the responsibility of the boat manufacturer or 3. Remove and discard clamps and exhaust bel- installing dealer to properly locate the engine lows. and install exhaust system. Improper installation may allow water to enter the exhaust manifolds CAUTION and combustion chambers, and severely dam-...
Page 851: Air Tube Routing
Air Tube Routing Maintenance 1. Air Intake Filter (32-17272) must be checked 1. Route air tubing from air pump to silencer valve once each year. If filter is clogged or partially cylinders. Do not route air tubing close to hot sur- clogged, replace.
Page 852: Exhaust Muffler Kit
- Exhaust Elbow IMPORTANT: If a thru-transom exhaust kit other c - Bolt (4 Each Manifold) than the one from Mercury Marine is used, the ex- d - Bolt, Remote OIl Filter Bracket (2) haust kit must be equipped with internal shutters e - Gasket - Lightly Coat Both Sides With Quicksilver Perfect and external flappers.
Page 853: Cleaning And Inspection
Cleaning and Inspection IMPORTANT: A MOLDED exhaust tube MUST be used at exhaust elbow connection to maintain 1. Disassemble muffler as shown. positive separation of exhaust outlet and muffler inlet. 72782 a - Removable End Plate b - 4 Screws Secure End Plate 72781 c - O-Ring Seal a - Muffler...
Page 854 4. As needed, depending on use conditions, re- 5. Reinstall muffler end plate with four screws. move mufflers, then remove four screws secur- Tighten securely. ing forward end plate, and remove end plate and 6. Reinstall muffler into tubes/hoses. Double clamp. element and interior of muffler.
Page 855 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 7D-10 - COLLECTORS 90-823225--1 1096...
Page 856 DRIVES VELVET DRIVE IN-LINE TRANSMISSION Index...
Page 857 Table of Contents Page Velvet Drive In-Line (71C and 72C) Specifications ......8A-1 Transmission Ratios .
Page 858: Velvet Drive In-Line (71C And 72C) Specifications
Velvet Drive In-Line (71C and 72C) Specifications The transmission identification plate is located on the top left side of the transmission. Refer to charts following to determine engine and transmission combinations 72839 Transmission Identification Plate a - Model Number b - Ratio (in Forward Gear) c - Serial Number d - Identification Plate Model Color Code Transmission Ratios...
Page 859: Transmission Fluid Capacities
Transmission Fluid Capacities MODEL U.S. QTS. (LITRES) 1-1/2 (1.3) (See Note) NOTE: Use dipstick to determine fluid exact level. Warm Fluid Level Check: The transmission should be at operating temperature [190 F (90 C)] maximum to receive an accurate oil level reading. Cold Fluid Level Check: To ease checking fluid level, the dipstick can be marked or scribed.
Page 860: Important Information
Important Information On MIE engines equipped with in-line transmissions having 1:1 or 3:1 gear ratios, transmission output Shift Control and Cables shaft rotation is the same as engine rotation with transmission in forward gear. Engine rotation is LH (CCW), so a LH propeller is required. CAUTION 1.
Page 861: Transmission Shift Lever
Transmission Shift Lever IMPORTANT: To accurately check fluid level, en- gine must be run at 1500 RPM for 2 minutes im- The lever has three holes as illustrated following. mediately prior to checking level. 71304 72526 a - Dipstick b - Full Mark Shift Cable Adjustment c - Dipstick Tube Refer to Section 2C - “MIE Models - Borg-Warner...
Page 862: Changing Transmission Fluid
Changing Transmission Fluid Draining Transmission 1. Clean area around cooler hose shown and pro- ceed as follows: a. Disconnect hose from elbow fitting. b. Remove elbow fitting from bushing. c. Drain oil from transmission, cooler, and cool- er hoses into a suitable container. 72841 Transmission with Reduction Ratios a - Hose...
Page 863: Filling Transmission
4. Check oil for the following foreign matter: Filling Transmission Metal Particles - A few small particles are IMPORTANT: Use only specified transmission normal. Larger metal chips are an early sign fluid (see “Specifications”). of transmission failure which may mean 1.
Page 864: Removal And Installation
Removal and Installation 20. Connect wires to neutral start safety switch. 21. Connect tan/blue wire to fluid temperature NOTICE switch. The following procedure describes removal 22. Connect fluid cooler hoses to transmission. of transmission without removing engine. If engine must be removed, refer to Section 2 23.
Page 865: Pump Indexing
Pump Indexing 4. Rotate pump until arrow indicating the proper di- rection of pump rotation is near the top of trans- Pump must be correctly indexed to correspond with mission. engine rotation. If pump is not indexed correctly, 5. Reinstall four pump-to-adaptor attaching bolts pump will not create fluid pressure allowing the trans- and torque to 204-264 lb.
Page 866: Shift Lever Installation
3. Refer to “Specifications” (see “Table of Con- tents”) for pressure readings. Transmission Repair Mercury Marine does not stock or sell replacement parts for the in-line transmission. Velvet Drive has a network of distributors throughout the world to ser- vice their product. These distributors, in turn, have a dealer network to service the transmissions.
Page 867 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 8A-10 - VELVET DRIVE IN-LINE TRANSMISSION 90-823225--1 1096...
Page 868 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 VELVET DRIVE IN-LINE TRANSMISSION - 8A-11...
Page 869 DRIVES VELVET DRIVE V-DRIVE AND WALTER V-DRIVE TRANSMISSION Index...
Page 870 Table of Contents Page Identification ......8B-1 Transmission Ratios ....8B-1 Torque Specifications .
Page 871 Identification The transmission identification plate is located on the top left side of the transmission. Refer to charts following to determine engine and transmission combinations. 72839 Transmission Identification Plate a - Model Number b - Ratio (in Forward Gear) c - Serial Number d - Identification Plate Model Color Code Transmission Ratios Identification Plate...
Page 872: Transmission Fluid Capacities
Transmission Fluid Capacities MODEL U.S. QTS. (LITRES) Velvet Drive 71C V-Drive 3 (2-3/4) (See Note) Walter RV26D V-Drive 1 (.9) NOTE: Use dipstick to determine fluid exact level. Warm Fluid Level Check: The transmission should be at operating temperature [190 F (90 C)] maximum to receive an accurate oil level reading.
Page 873: Important Information
Important Information On MIE engines which are equipped with V-drive transmissions, transmission output shaft rotation is Shift Control and Cables the same as engine rotation with transmission in for- ward gear. Because of reversed engine mounting po- sition, however, a RH propeller is required, if engine CAUTION is LH (CCW) rotation;...
Page 874: Transmission Shift Lever
Transmission Shift Lever Check transmission fluid before starting engine each day, as follows: The lever has three holes as illustrated following. 1. Remove dipstick. Check fluid level as indicated on dipstick. Fluid level may be somewhat over full mark, as some of the fluid from transmission fluid cooler and hoses may have drained back into transmission.
Page 875: Changing Transmission Fluid
Changing Transmission 3. Coat elbow fitting threads with Quicksilver Per- fect Seal and install in bushing. Tighten securely. Fluid 4. Reconnect hose and tighten securely. Draining Transmission 5. Refill transmission with specified fluid. Refer to “Filling Transmission.” VELVET DRIVE WALTER V-DRIVE 1.
Page 876: Filling Transmission
Filling Transmission WALTER V-DRIVE 1. Remove dipstick from top cover. Fill transmission VELVET DRIVE with fluid, through dipstick hole, to bring up to full mark. IMPORTANT: Use only specified automatic trans- mission fluid (see “Specifications”). 1. Remove dipstick. Fill transmission with fluid, through dipstick hole, to bring up to full mark.
Page 877: Removal And Installation
Removal and Installation 19. Relieve hoist tension and fasten rear engine mounts to engine bed. Tighten bolts securely. NOTICE 20. Connect wires to neutral start safety switch. The following procedure describes removal 21. Connect tan/blue wire to fluid temperature of transmission without removing engine. If switch.
Page 878: Pump Indexing
Pump Indexing 5. Reinstall four pump-to-adaptor attaching bolts and torque to 204-264 lb. in. (23-29 N·m). Pump must be correctly indexed to correspond with engine rotation. If pump is not indexed correctly, pump will not create oil pressure and transmission will not shift.
Page 879: Shift Lever Installation
Transmission Repair V-Drive Mercury Marine does not stock or sell replacement parts for the V-drive transmission. Velvet Drive has a network of distributors throughout the world to ser- vice their product. These distributors, in turn, have a dealer network to service the transmissions.
Page 880 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 8B-10 - VELVET DRIVE V-DRIVE AND WALTER V-DRIVE TRANSMISSIONS 90-823225--1 1096...
Page 881 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 VELVET DRIVE V-DRIVE AND WALTER V-DRIVE TRANSMISSIONS - 8B-11...
Page 882 DRIVES 25280 HURTH DOWN ANGLE TRANSMISSION Index...
Page 883 Table of Contents Page Identification ......8C-1 Torque Specifications ..... 8C-1 Tools/Lubricants/Sealants .
Page 884 Identification Tools/Lubricants/Sealants The transmission identification plate is located on the Description Part Number top rear of the transmission. Tapered Roller Bearing 91-813950 Inner Race Puller Tapered Roller Bearing 91-813951 Outer Bearing Puller Pressure Plate 91-813952 Removal Tool Revers- ing Clutch Tapered Roller Bearing 91-813953 Inner Race Puller Plate...
Page 885: Specifications
Specifications Operating Specifications Description Specification Transmission Fluid Specification 312-377 PSI Shifting Pressure (2151-2599 kPa) Description Part Number Operating Temperature 130-176 F (54-80 C) ATF Dexron II-D Or Maximum Temperature 220 F (105 C) Obtain Locally Dexron lll Transmission Ratios Capacity Transmission Model 630A Model...
Page 886: General
General Shift Cable Installation and Adjustment The Hurth transmission is a “full power reversing” transmission, allowing a standard (LH rotation) en- IMPORTANT: When installing shift cables, be gine to be used for both rotations. Propeller rotation sure that cables are routed in such a way as to is determined by shift cable attachment at the remote avoid sharp bends and/or contact with moving control.
Page 887 IMPORTANT: Check that shift lever is positioned WARNING approximately 10 degrees aft of vertical when in Avoid serious personal injury or property dam- the neutral detent position and that the distance age caused by improper shifting. Anchor stud for (c) between studs in the following is set at 7-1/8 shift cable must be installed in the correct hole.
Page 888 2. Place remote control shift lever, and transmission IMPORTANT: Transmission is fully in gear when shift lever, in neutral position. shift lever comes to a stop, in either direction. 3. Remove nuts and washers from shift cable at- 7. Place remote control shift lever in forward gear taching studs.
Page 889 10. Install nut and washer to cable end guide stud. SINGLE CABLE - FORWARD ENTRY Tighten until snug, then back off one full turn. 11. Install nut and washer to cable barrel stud. Tighten until they bottom out. Tighten securely, but do not over-tighten.
Page 890 SINGLE CABLE - REAR ENTRY DUAL CABLE - FORWARD ENTRY 72957 72956 50229 71211 1 - Cable Barrel Stud 1 - Cable Barrel Stud 2 - Cable End Guide Stud 2 - Cable End Guide Stud a - Cable End Guide a - Cable End Guide b - Locknut and Washer (Tighten Until Bottoms Out, Then b - Locknut and Washer (Tighten Until Bottoms Out, Then...
Page 891: Checking Transmission Fluid Level
DUAL CABLE - REAR ENTRY Checking Transmission Fluid Level IMPORTANT: Use only specified transmission fluid (see “Specifications”). Check transmission fluid before starting engine each day, as follows: 1. Remove dipstick. Check fluid level as indicated on dipstick. Fluid level may be somewhat over full mark, as some of the fluid from transmission fluid cooler and hoses may have drained back into transmission.
Page 892: Draining Transmission
Draining Transmission Filling Transmission IMPORTANT: Use only Automatic Transmission 1. Clean the exterior of transmission before disas- Fluid (ATF) as recommended in “Specifications.” sembly. 1. Fill transmission to proper level, through oil filter NOTE: Later model Hurth transmissions have an cavity.
Page 893: Transmission Removal
Transmission Removal CAUTION Transmission fluid filter and cover must be prop- erly seated to avoid fluid foaming and/or loss of 1. Disconnect wires from neutral safety switch and fluid, thus resulting in decreased efficiency and/ audio warning temperature switch. or damage to transmission. b.
Page 894: Transmission Installation
3. Remove bolts and locknuts and remove trans- 2. Install transmission on flywheel housing and se- mission. cure with hardware shown. Torque fasteners to 50 lb. ft. (68 N·m). 72720 a - Bolts (2), One On Each Side 72720 b - Locknuts (4), Two On Each Side a - Bolts (2), One On Each Side b - Locknuts (4), Two On Each Side Transmission Installation...
Page 895: Transmission Repair
4. Connect wires to neutral safety switch and to au- TRANSMISSION FLUID COOLER dio warning temperature switch. Coat connec- tions on neutral safety switch with Quicksilver 1. Disconnect transmission fluid hoses from cooler Liquid Neoprene. and remove clamps that secure cooler to hous- ing.
Page 896 2. Remove cover and filter element from transmis- 5. Remove dipstick by turning (counterclockwise) sion. and pulling at the same time. 27662 3. Remove filter element from cover and inspect O-rings for wear. Replace if necessary. 27661 6. Inspect seal for wear and replace if necessary. 50975 a - O-Rings 4.
Page 897 BREATHER VALVE OUTPUT FLANGE 1. Remove breather valve. Clean with suitable 1. Remove bolt, washer and O-ring. cleaner, allow to dry and coat with oil. 71049 71048 a - Breather Valve MOUNTS 1. Remove mounts from transmission housing. In- spect mounts for damage and replace if neces- sary.
Page 898 2. Reinstall bolt and remove flange using appropri- CONTROL BLOCK ate puller. 1. Remove hex head bolts. 27661 a - Hex Head Bolts (6) 2. Remove control block and gasket from housing. 71051 27666 71052 a - Bolt b - Flange c - Puller Index 90-823225--1 1096...
Page 899 2. Remove input side of housing. Be sure to locate CAUTION and save locator pins. Be careful not to allow dirt to enter control block from front side. 3. Cover openings in control block with a protective cloth. 71053 27665 a - Locator Pins a - Openings 3.
Page 900 4. Remove intermediate shaft assembly. 6. Remove output shaft assembly. 71055 5. Remove baffle plate as follows: 71058 a. Bend tabs up away from screws. b. Remove screws, then remove baffle plate. BEARING, GEAR AND SEAL INSPECTION 1. Inspect all tapered roller bearings, the piston rings on the input shaft and all gears for wear.
Page 901 SEALS b. Remove screws and hold-down plate. c. Remove suction pipe by pulling downward 1. Remove suction pipe seal as follows: out of seal. 71060 a - Screws b - Hold Down Plate d. Remove seal from top side. 27666 a - Seal a.
Page 902 2. Remove input shaft seal using appropriate man- TAPERED ROLLER BEARING CUPS drel. IMPORTANT: Do not remove tapered roller bear- ing cups unless replacing tapered roller bear- ings. Bearing and cup must be replaced as a set. IMPORTANT: Do not mix up shims under cups on the input housing side.
Page 903 b. Pull bearing cup from housing using tool as TAPERED ROLLER BEARINGS shown. CAUTION Gears should never be removed from intermedi- ate shaft or output shaft, as this will affect proper gear alignment. 1. Remove tapered roller bearings from intermedi- ate shaft and output shaft by using a universal puller plate and pressing bearings off.
Page 904 REVERSING CLUTCH, GEARS AND TAPERED b. Tighten jaws onto bearing by turning on ROLLER BEARINGS knurled part of tool. Tighten assembly. 1. Remove tapered roller bearing from splined end of input shaft using special tool as follows: a. Place tool over tapered roller bearing. Ensure jaws of tool will be pulling on bottom edge of rollers and NOT on the cage.
Page 905 2. Remove butting ring from splined end of input 4. Remove needle bearings. shaft by installing special tool as shown and light- ly tapping upward on tool. 27673 a - Special Tool b - Butting Ring 27680 3. Remove butting ring and gear assembly. 5.
Page 906 6. Remove tapered roller bearing, butting ring and 1. Position snap ring compression tool on clutch as- gear from piston end of shaft using special tool as sembly so that compression screws are centered shown. Press all components off at the same over slots in clutch housing.
Page 907 d. If necessary, remove end disc and snap ring from tool. 27675 27676 NOTE: For ease of reassembly, end disc and snap a - End Disc ring should not be removed from tool unless their b - Snap Ring condition is questionable. 27676 a - End Disc (Snap Ring Compressed) Index...
Page 908 IMPORTANT: Thrust discs have a wave pattern. 3. Remove discs. These discs must be reinstalled in a specific pat- tern when reassembled. Make note of notches in thrust disc tabs, and how they are arranged. 50248 27680 4. Inspect thrust discs and inner discs for wear. Re- place if there is any questionable wear.
Page 909: Reassembly
Reassembly 2. Install discs in clutch housing. CLUTCH DISCS IMPORTANT: Thrust discs have a wave pattern. These discs must be reinstalled in a specific manner as explained following. 27680 50248 3. Align snap ring opening with reference marks on 1. Arrange thrust discs and inner discs as shown. end disc and clutch housing.
Page 910 4. If end disc and snap ring were removed from tool, c. Tighten compression screws evenly to com- reinstall as follows: pletely compress snap ring into end disc. a. Loosen all compression screws on tool. 27677 a - Compression Screws b.
Page 911 5. Tap lightly around top of tool until end disc bot- 6. Double check that snap ring has been properly toms. Loosen compression screws and remove seated by prying up lightly on end disc. tool. 27679 7. Reinstall discs on opposite side of clutch in same manner.
Page 912 GEAR ASSEMBLY TAPERED ROLLER BEARING 1. Reinstall gear assembly. Twist gear assembly CAUTION from side to side to allow splines to engage with Do not touch bearing once it has been heated. Se- inner discs. Ensure all inner discs are engaged vere burns could result.
Page 913 3. Reinstall piston rings on input shaft. Ensure ends OUTPUT SHAFT of rings are coupled as shown. Then position WARNING rings so that ends are staggered so no two are aligned. Do not touch bearing once it has been heated. Se- vere burns could result.
Page 914 PREASSEMBLY OF OUTPUT HALF OF WARNING HOUSING Use care in handling housing once it has been IMPORTANT: If tapered roller bearing cups were heated. Severe burns could result. Use special removed, ensure output shaft seal IS NOT in protective gloves to handle housing. place, as it will be necessary to heat housing prior to installing bearing cups.
Page 915 Output Shaft Seal 2. Reinstall suction pipe. Place one drop of Quick- silver Loctite 8831 on screw threads. Then se- cure suction pipe down with retainer plate. Tight- 1. If bearing were not replaced and no shimming en screws securely. is required, push new seal onto special mandrel.
Page 916 3. Install baffle plate. Apply one drop of Quicksilver 5. Install input shaft. Ensure all gears mesh as Loctite 8831 to screws. Tighten screws securely shown. and bend tabs down over screws. 71057 a - Tabs b - Screws c - Baffle Plate 4.
Page 917 PREASSEMBLY OF INPUT HALF OF HOUSING WARNING Use care in handling housing once it has been 1. Install breather valve (do not overtighten). heated. Severe burns could result. Use special protective gloves to handle housing. 3. Heat each tapered roller bearing cup bore with a torch lamp.
Page 918 4. Install input half of housing onto output half. En- b. Mount dial indicator on input shaft. Turn input sure locator pins are in place. Install bolts and shaft several times to seat bearing. lockwashers and torque to 36 lb. ft. (49 N·m). 71064 27685 Input Shaft Preload...
Page 919 d. Slowly turn the special tool knob clockwise to e. Make note of reading. The bearing clearance push the shaft upward. (Perform the above measured PLUS the preload required is sequence several times to ensure an accu- equal to the amount of shim thickness to be rate reading.) ADDED.
Page 920 Intermediate Shaft Preload d. Zero dial indicator. 1. Measure bearing clearance as follows: a. Remove hex plug from housing. 71065 27685 b. Screw special bolt with nut into intermediate IMPORTANT: The following step should be done shaft and tighten snugly. Turn nut up until it very carefully, to obtain the actual bearing clear- touches bolt head.
Page 921 Make note of the reading. The bearing clear- Output Shaft Preload ance measured PLUS the preload required is equal to the amount of shim thickness to be 1. Measure the bearing clearance as follows: ADDED. a. Install flange washer and bolt. Tighten snugly. b.
Page 922 d. Pry up on washer to lift output shaft. 2. When thickness of shims to be ADDED has been determined, the input half of housing must again be removed. Remove bolts and lockwashers, then lift off input half of housing. 71068 e.
Page 923 b. Pull bearing cup from housing as shown. 5. Heat each tapered roller bearing cup bore with a torch lamp. Install bearing cups into appropriate bore and tap into place using a suitable mandrel. When housing has cooled (DO NOT cool with water), tap bearing cups to ensure they are fully seated.
Page 924: Final Assembly
Final Assembly 4. Install bolts and lockwashers and torque to 36 lb. ft. (49 N·m). INPUT SHAFT SEAL 1. Push new seal onto special mandrel. Ensure seal will be positioned with lip of seal facing inward. Drive seal uniformly into bore of housing to the point that it is countersunk .040 in.
Page 925 CONTROL BLOCK FLUID FILTER 1. Ensure piston rings are in place and the key is in 1. Coat new O-rings with ATF. keyway. Align key on shaft with keyway in control block. 2. Install new gasket between control block and housing.
Page 926 DIPSTICK 4. Install O-ring into flange and coat with ATF. 5. Install washer and bolt. Torque to 63 lb. ft. 1. Coat sealing ring on dipstick with ATF. (85 N·m). 2. Install dipstick into transmission and tighten by pressing down and turning clockwise at the same time.
Page 927 TRANSMISSION FLUID COOLER 2. Install filter as follows: a. Bring flat spot on filter into agreement with flat 1. Install transmission fluid cooler on housing. Se- surface inside of housing. cure with clamps and screws as shown. Torque to 18 lb. ft. (25 N·m). 2.
Page 928 NOTE: Later model Hurth transmissions have an al- len head socket screw on oil filter cover. 3. Remove oil filter from housing by turning (coun- terclockwise) and pulling at the same time. 27666 a - Set Screw (Later Models) 4. Check fluid level. Fluid should be between min. and max.
Page 929: Functional Test
Functional Test 2. Perform functional tests as shown in chart follow- ing. Refer to “Operating Specifications” for cor- rect readings. 1. Connect a pressure gauge and thermometer to Tests to Be Carried Out: fluid pump at locations shown. 1. Leakages 2.
Page 930 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 HURTH DOWN ANGLE TRANSMISSION - 8C-47...
Page 931 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 8C-48 - HURTH DOWN ANGLE TRANSMISSION 90-823225--1 1096...
Page 932 DRIVES DRIVE SHAFT / PROPELLER SHAFT MODELS index...
Page 933 Table of Contents Page Torque Specifications ..... 8D-1 Tools/Lubricants/Sealants ....8D-1 Flywheel Housing/Output Shaft Housing Repair (MCM Stern Drive Models)
Page 934: Torque Specifications
Torque Specifications Tools/Lubricants/Sealants Fastener Location Lb. Ft. N·m Description Part Number Drive Shaft To Bearing Support Quicksilver Alignment 91-805475A1 Flange (MCM Models) Tool Drive Shaft To Output Shaft Quicksilver Slide 91-34569A1 (MCM Models) Hammer Puller Propeller Shaft Coupling To 2-4-C Marine Lubricant 92-825407A3 Transmission Coupling With Teflon...
Page 935: Repair (Mcm Stern Drive Models)
Flywheel Housing/Output Reassembly Shaft Housing Repair 1. Install engine coupling. Torque to 35 lb. ft. (48 N·m). (MCM Stern Drive Models) 2. Install flywheel housing. Torque to 30 lb. ft. (41 N·m). NOTICE 3. Using new gasket, install flywheel cover. Tighten The following repair procedure requires re- screws securely.
Page 936 11. Using Quicksilver U-Joint and Gimbal Bearing Drive Shaft Repair Grease, grease ball bearing through grease fit- (MCM Stern Drive Models) ting. Removal IMPORTANT: It is not necessary to remove the engine to service the drive shaft. 1. Remove top and bottom drive shaft shields around transom end and engine end of drive shaft.
Page 937: Repair
70237 e - Sound Deadener (Cardboard Tube) Engine End Shown (Transom End Similar) The complete drive shaft can be ordered from Mercury Marine. a - Output Shaft Flange b - Drive Shaft c - Bolt With Nut (4 Total) index...
Page 938: Installation
Drive Shafts Modified to Shorter Lengths CAUTION The complete modified (shortened) drive shaft has to Failure to properly align shaft flanges with be ordered from the boat manufacturer that installed matching marks made on disassembly may the MerCruiser Power Package. cause improperly aligned drive unit and exten- sion drive shaft U-joint centerlines resulting in a IMPORTANT: Dana Corporation - Spicer Regional...
Page 939: Bearing Support Repair (Mcm Stern Drive Models)
3. Apply Loctite 271 to threads of bottom drive shaft CAUTION shield retaining screws and install bottom shields If bearing support is removed, you must remove on engine and transom end. Then install both top the stern drive unit so you can properly align shields as shown.
Page 940: Reassembly
7. Replace any damaged parts. 2. Apply Quicksilver Loctite 8831 to outer diameter of new oil seal. 3. Press oil seal into bearing support. Lip of seal faces away from ball bearing. 4. Apply Loctite 290 to outer diameter of ball bear- ing and inner diameter of bearing support.
Page 941: Installation
Installation 2. Insert solid end of Quicksilver Alignment Tool through bearing in gimbal housing and into input 1. Install bearing support assembly (tailstock) on shaft splines of bearing support. transom plate using hardware as shown. Tighten bolts until snug. DO NOT TORQUE BOLTS AT THIS TIME.
Page 942: Propeller Shaft (Mie Inboard Models)
4. Strike the head of BOTH bearing support attach- Propeller Shaft ing bolts firmly with a hammer. (MIE Inboard Models) NOTICE The following information can be used as a guide for determining vibration problems on boats powered by inboard engines (MIE models).
Page 943: Checks Made With Boat Out Of Water And Shaft Installed
3. Check output coupling flange of transmission. Checks Made with Boat Out of Water and Shaft Installed Possible causes for vibration may be propeller shaft, propeller to shaft fit or propeller. All three can be checked by using the rudder, a strong metal straight edge and a C-clamp.
Page 944: Checks Made With Propeller Shaft Removed From Boat
3. Check the diameter of all propeller blades. If not Checks Made with Propeller Shaft the same, repair propeller. Removed from Boat 1. Check propeller shaft for straightness. Check at three or four places. If dial indicator deflects over .004 in. (0.1 mm), replace shaft. a - V-Blocks b - Dial Indicator a - Metal Straight Edge (Held T Rudder With C-Clamp)
Page 945: Strut
Strut Refer to boat manufacturer’s service manual for alignment and replacement. Normally, the shaft should be centered in the cutlass bearing. Shims (placed between the strut and hull) are used to align the strut to the shaft. 71091 a - Strut b - Cutlass Bearing index 8D-12 - DRIVE SHAFT / PROPELLER SHAFT MODELS...
Page 946 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE index 90-823225--1 1096 DRIVE SHAFT / PROPELLER SHAFT MODELS - 8D-13...
Page 947 POWER STEERING 72951 PUMP Index...
Page 948 Table of Contents Page Torque Specifications ..... 9A-1 Tools/Sealants ......9A-1 Precautions .
Page 949 Torque Specifications Precautions CAUTION Fastener Location Lb. Ft. Lb. In. N·m Do not operate engine without cooling water be- Crankshaft Pulley To ing supplied to water pickup pump or water pump Torsional Damper impeller will be damaged and subsequent over- Torsional Damper To heating damage to engine may result.
Page 950: Power Steering Pump And Components
Power Steering Pump and Components (Exploded View) 72951 1 - Power Steering Pump Assembly 13- Hose, Pump To Fluid Cooler 2 - Stud 14- Clamp 3 - Cap 15- Hose, Control Valve To Fluid Cooler (Fitting On One End) 4 - Spacer 16- Mounting Bracket, Cast 5 - Brace 17- Bolt...
Page 951: Serpentine Belt Routing
Serpentine Belt Routing BRAVO WITH POWER STEERING ALPHA WITH POWER STEERING BRAVO WITHOUT POWER STEERING ALPHA WITH CLOSED COOLING WITHOUT POWER STEERING BRAVO WITH CLOSED COOLING ALPHA WITH CLOSED COOLING AND AND POWER STEERING POWER STEERING Index 90-823225--1 1096 POWER STEERING - 9A-3...
Page 952: Important Service Information
Important Service INSTALLATION Install pulley, as follows, using pulley installer tool Information (91-93656A1), and a long straight edge: 1. Place pulley on pump shaft. Pump Pulley Replacement 2. Thread stud all the way into pump shaft. Place bearing over stud. Do not use spacer from kit. REMOVAL 3.
Page 953: Testing And Repair
Testing and Repair Serpentine Belt Adjustment 1. Using a 5/8 inch wrench, loosen the nut on the ad- Refer to appropriate MerCruiser Stern Drive justment stud. Service Manual. 2. Place the 5/16 inch deep socket on the hex end of the adjustment stud rotate starboard tensioner Checking Pump Fluid Level until there is 1/4 inch (6 mm) deflection is achieved between the pulleys with the greatest...
Page 954: Pump Assembly
Pump Assembly 2. Install mounting hardware and fasteners to retain pump to bracket. (Refer to “Exploded View” for specific details on your engine.) IMPORTANT: Be careful to not cross-thread or over-tighten hose fittings. 1. Be certain a new high pressure hose O-ring is present, and install threaded fitting in back of pump assembly.
Page 955: Mounting Bracket
Mounting Bracket 2. Remove hose where routed and secured (port or starboard side), across top of engine, near valve Mounting bracket is removable after pump (refer to cover. previous instructions) and alternator (refer to Section 3. Remove small fitting from control valve at tran- 4C - “Charging System”) have been removed.
Page 956 Later Style Control Valve: Torque fittings to 23 lb. ft. Low Pressure Hose (Cooler-to-Pump) (31 N·m). REMOVAL NOTE: Catch fluid that drains from hose, cooler and pump in a suitable container. 1. Loosen hose clamp and remove hose from fluid cooler.
Page 957 2. Loosen hose clamp and remove hose from back 2. Using hose clamp, install hose on fluid cooler. of pump. Tighten clamp securely. 72588 Port Side Mounted Fluid Cooler a - Fluid Cooler b - Hose Clamp 72848 c - Hose a - Hose Clamp b - Hose INSTALLATION...
Page 958: Low Pressure Hose (Control Valve-To-Cooler)
Low Pressure Hose 2. Remove hose where routed and secured across top of engine flywheel housing. (Control Valve-to-Cooler) REMOVAL NOTE: Catch fluid that drains from hose, cooler and pump in a suitable container. 1. Loosen hose clamp and remove hose from fluid cooler.
Page 959 INSTALLATION 3. Using hose clamp, install hose on fluid cooler. Tighten clamp securely. CAUTION Route hoses exactly as shown below. This will help avoid stress on the hose fittings and will help avoid kinks in the hoses. IMPORTANT: Be careful to not cross-thread or over-tighten hose fittings.
Page 960: Priority Valve Kit (79691A1) Information
Priority Valve Kit (79691A1) b. Install reservoir mounting bracket with hard- ware supplied. Information This kit information (in “Installation Instruction” form) is provided to assist personnel when servicing dual installations where both engines are equipped with power steering pumps, coolers, related hardware and hoses, and one transom assembly is equipped with power steering.
Page 961 IMPORTANT: A two-way valve is required on the 6. Secure hoses with Sta-Straps to keep them be- reservoir cap for cold weather operation below low reservoir fluid level line and away from heat 40 F (4 C). and moving parts. 3.
Page 962: Installing Priority Valve
Installing Priority Valve NOTE: The 90 elbow locations on priority valve are marked with a “T” stamped into the valve. NOTE: Priority valve mounting bracket can be 2. Apply liquid pipe joint sealer to threads and install used in various mounting configurations. fittings into priority valve.
Page 963 NOTE: Engines with power steering 7. Install return hose (large fitting on one end only, equipped with a hose that is connected to the from kit) to power steering control valve. Route power steering fluid cooler. A fitting on the other hose to priority valve, cut hose to length, and con- end of the hose would normally be connected to nect to fitting on priority valve.
Page 964 8. Install pressure hose (fittings on both ends, from 9. Connect No. 1 (starboard) engine pressure hose kit) between power steering control valve and (from pump) to inverted flare fitting marked by “1” large inverted flare fitting on priority valve. (This on priority valve.
Page 965: Filling System With Fluid
Filling System with Fluid Maintenance 1. Fill pump reservoirs with automatic transmission Maintenance inspection is the owner’s responsibility fluid (ATF) Dexron ll or Dexron lll. and must be performed at the following intervals: 2. Install and tighten pump cap by turning cap clock- Normal Service - Every 50 hrs.
Page 966: System Flow Diagram
System Flow Diagram Pressure Line Return Line Gravity Feed Line 72995 1 - Reservoir Bottle and Bracket 2 - Priority Valve and Mounting Bracket 3 - Power Steering Control Valve 4 - Power Steering Pump 5 - Power Steering Fluid Cooler a - Pressure Hose (Fitting On Both Ends - Supplied In Kit) b - Return Hose (Fitting On One End - Supplied In Kit) c - Return Hose From Pump (Cut From Bulk Hose Supplied)
Page 967 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE Index 90-823225--1 1096 POWER STEERING - 9A-19...

This manual is also suitable for:

350 cid

Mercury 305 CID Service Manual

Important Information 1 a

Important Information 1 B

Important Information 1 C

Removal and Installation 2

Removal and Installation 2

Removal and Installation 2

Removal and Installation 2

Removal and Installation 2

Removal and Installation 2

Engine

Electrical Systems

Quick Links

MARINE ENGINES

Chapters

Troubleshooting

Related Manuals for Mercury 305 CID

Summary of Contents for Mercury 305 CID