Page 1 6.2L Mercury MerCruiser S ERV I C E MA NU A L Serial Number 2A456613 and Above...
Page 3 NOTE: Indicates information that helps in the understanding of a particular step or action. This manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. We reserve the right to make changes to this manual without prior notification.
Page 4 Cleanliness and Care of Product A Mercury Marine power product is a combination of many machined, honed, polished, and lapped surfaces with tolerances measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. It should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure.
Page 5 A - Power-Assisted Steering Pump and Related Components B - Compact Hydraulic Steering 9 - Transmissions A - ZF/45C, 45IV, 63A, 65IV Transmissions 10 - Color Diagrams A - Color Diagrams Page iii © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 7: Table Of Contents
Fuel Requirements.............1A-4 Directional References............1A-3 Fuel Ratings..............1A-4 SeaCore................1A-3 Using Reformulated (Oxygenated) Gasoline (USA SeaCore Components and Castings......1A-3 Only)................1A-4 Stainless Steel Fasteners........... 1A-3 Gasoline Containing Alcohol........1A-4 Proper Break‑In..............1A-3 Engine Oil................1A-5 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1A-1...
Page 8: Introduction
Serial Number Decal Placement There are three sets of engine, transom assembly, and sterndrive serial number decal strips provided with each power package. One should be used for each of the following: Page 1A-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 9: Directional References
SeaCore SeaCore Components and Castings Mercury MerCruiser SeaCore power packages are equipped with additional stainless steel components and particular aluminum castings with special coatings. Do not replace SeaCore components with non‑SeaCore. Use only the specified Mercury MerCruiser SeaCore components and castings on these power packages.
Page 10: After The Break-In Period
Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).
Page 11: Engine Oil
IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause trouble;...
Page 13 Preventing Contamination of the Emissions Control Emission Control Information Label Request Form System..............1B-2 ................1B-3 Emissions Regulations............1B-3 Emission Certification Star Label........1B-3 International Regulations Compliance......1B-3 California Regulations for 2007—Low‑Permeation Fuel Hose..............1B-3 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1B-1...
Page 14 Catalyst‑friendly oil, such as Mercury MerCruiser Synthetic Blend Engine Oil, prevents this damage. Approved oils must be used in MerCruiser engines with Emissions Control Technology (ECT), except in special circumstances. Refer to Section 1A ‑Engine Oil for additional information.
Page 15 Emissions Control Emissions Regulations International Regulations Compliance MerCruiser products are designed and manufactured to meet the host of regulatory requirements set forth by the following standards and regulatory organizations: • ABYC (American Boat and Yacht Council) • USCG (United States Coast Guard) •...
Page 16 Emissions Control All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's sterndrive and inboard marine engine 2007 and later exhaust emission standards.
Page 17 Changing..............1C-21 Cold Weather or Extended Storage.........1C-51 Compact Hydraulic Steering..........1C-21 Preparing Power Package for Storage—MPI Models System Check............1C-22 ................1C-51 Bravo Sterndrive Gear Lube..........1C-22 Power Package Recommissioning........1C-52 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-1...
Page 18 Fuel system 92-8M0047932 Oil filter sealing ring Mercury 25W-40 Synthetic 92-8M0078629 Blend 4-Stroke Engine Oil All MerCruiser engines Special Tools Fuel Filter Removal/Installation Tool 91‑896661 Aids in the removal and installation of the fuel filter cap assembly. 24896 Reference Electrode 91‑76675T 1...
Page 19: Engine And Tune-Up Specifications
NOTE: Measure the oil level with the boat in the water. NOTE: All capacities listed are approximate fluid measures. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-3...
Page 20: Power-Assisted Steering And Power Trim Fluids
Seawater‑cooling system 26.5 L (28 US qt) Propylene glycol and purified water 50/50 winterization use only Mercury Extended Life Coolant/Antifreeze or extended‑life ethylene glycol Closed‑cooling system 17 L (17.9 US qt) coolant/antifreeze mixed 50/50 with purified water Power‑Assisted Steering and Power Trim Fluids...
Page 21: Maintenance Schedule-Towsport Models
NOTE: Only perform maintenance that applies to your particular power package. Task Interval Maintenance to Be Performed • Change the transmission fluid. Models equipped with a transmission filter must also have the 25 hours filter changed at this time. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-5...
Page 22: Maintenance Schedule-Sterndrive Models
Check and clean the seawater strainer, if equipped. Weekly • Check the coolant level. • Inspect the sterndrive anodes and replace if eroded 50% or more. • Verify the operation of the MerCathode module, if equipped. Page 1C-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 23: Scheduled Maintenance
Inspect the U‑joints, the splines, and the bellows, and check the clamps. • Lubricate the U‑joint splines and cross bearing. • Inspect the gimbal bearing for roughness. Replace if necessary. See your certified Mercury MerCruiser dealer. • Lubricate the engine coupler.
Page 24: Engine Oil
NOTE: Ensure that the dipstick is installed with oil level indication marks facing the rear of the engine—flywheel end. Install the dipstick fully into the dipstick tube. Wait one minute to allow trapped air to vent. 58400 58402 In-line drive model shown Page 1C-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 25: Changing The Engine Oil And Filter
Engine Oil Capacity Fluid type 4.73 L (5.0 US qt) Mercury 25W‑40 Synthetic Blend 4‑Stroke Engine Oil Confirm that the engine oil level is now up to, but not over, the maximum fill line on the dipstick. Install the oil fill cap.
Page 26 Part No. Mercury 25W-40 Synthetic Blend 4-Stroke Oil filter sealing ring 92-8M0078629 Engine Oil Install the oil filter. Tighten the filter securely following the filter manufacturer's instructions. Do not overtighten. Page 1C-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 27: Transmission Fluid
Where Used Part No. Mercury 25W-40 Synthetic Blend 4-Stroke All MerCruiser engines 92-8M0078629 Engine Oil With the boat at rest in the water, remove the dipstick and check the oil level. Add the specified engine oil to bring the level up to, but not over, the maximum oil fill mark on the dipstick.
Page 28 Install the dipstick and tighten the T‑handle securely. Do not overtighten. Checking the Fluid Level When Hot The process for checking the fluid level when hot is the same as checking the fluid level before operation. Page 1C-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 29: Power Trim Fluid
Maintenance Changing Contact your authorized Mercury MerCruiser dealer. Power Trim Fluid Checking IMPORTANT: Check the fluid level with the sterndrive unit in the full down (in) position only. Place the sterndrive unit in full down (in) position. Observe the fluid level. The fluid level must be between the "MIN" and "MAX" lines on the reservoir.
Page 30: Flame Arrestor
There are two engine covers you must remove to access the flame arrestor: Pull the outside engine cover up to remove it from the four rubber mount grommets. Carefully guide the cover past the O sensors. 58808 Page 1C-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 31: Serpentine Drive Belt
IMPORTANT: The brackets and washers on the pulleys must be in a certain order or the serpentine belt will come off. All pulleys are referenced as though you were standing in front of the engine looking at the belt. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-15...
Page 32: Inspection And Routing
If the tensioner contacts either of the cast stops during operation, check the mounting brackets and the belt length. Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the cast stops. See your authorized MerCruiser dealer for service if these conditions exist. CAUTION Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage.
Page 33: Fuel System
Use the fuel filter removal/installation tool or the shaft of a screwdriver between the lugs on the filter cover and turn the fuel filter cover counterclockwise to loosen it. Do not remove the cover. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-17...
Page 34 Turn the ignition key to the ON or RUN position. Do not start the engine. Inspect the filter housing and hoses for leaking fuel. IMPORTANT: Inspect for leaking fuel before starting the engine. Page 1C-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 35: Closed-Cooling System
For the coolant changing procedures, refer to Section 6C. Power‑Assisted Steering Fluid Power‑Assisted Steering Fluid—Sterndrive only Checking Engine at Normal Operating Temperature Stop the engine. Center the sterndrive. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-19...
Page 36 Turn the steering wheel back and forth to the end of travel in each direction several times. Recheck the fluid level and add fluid, if necessary. Install the fill cap/dipstick. Tighten securely. Page 1C-20 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 37: Changing
To maintain proper fluid level, observe the following: • Do not allow the fluid level to drop more than 6 mm (1/4 in.) below the bottom of the filler hole. • Check the fluid level periodically. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-21...
Page 38: System Check
Fill the monitor with the specified fluid until the gear lube level is in the operating range. Do not overfill. Tube Ref No. Description Where Used Part No. High Performance Gear Gear lube monitor 92-858064K01 Lubricant Page 1C-22 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 39: Changing
Lower the sterndrive unit so the propeller shaft is level. IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit. Fill the sterndrive unit through the oil fill and drain hole with specified gear lubricant until an air‑free stream of lubricant flows from the oil vent hole.
Page 40: Visual Inspections
NOTE: Refer to Section 7 . Ensure that all hose clamps are tight and connections are secure. Inspect the entire system for damage or leaks. Repair or replace as necessary. Page 1C-24 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 41: Seawater Pump
Turn the steering wheel until the steering cable is fully extended. Lightly lubricate the exposed part of the cable with 2‑4‑C. Extended steering cable 6222 Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Exposed part of the steering cable 92-802859A 1 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-25...
Page 42: Corrosion Prevention
Corrosion Prevention Refer to the Mercury Precision Parts / Marine Corrosion Protection Guide available on MercNet. PN is NLA. Maintaining Ground Circuit Continuity The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the engine, transom assembly, and sterndrive components.
Page 43 37462 Steering lever Torx® screw Continuity wire 50215 Bravo model shown Trim‑cylinder‑to‑gimbal‑ring ground wire (2) Gimbal‑housing‑to‑gimbal‑ring ground wire Gimbal‑ring‑to‑bell‑housing ground wire Screw 50216 MerCathode Continuity washers Hydraulic manifold 50217 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-27...
Page 44: Mercathode
Reference Electrode 91‑76675T 1 Refer to the appropriate Mercury MerCruiser sterndrive service manual for testing procedures. Power Package Exterior Surfaces Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for proper application.
Page 45: Seawater System
Open the seacock, if equipped, or remove the plug and reconnect the seawater inlet hose. Upon first starting the engine, check for leaks or air in the system that would indicate an external leak. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-29...
Page 46: Checking The Seawater Pickups
IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the raw water section of the cooling system during freezing temperatures or for extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
Page 47 IMPORTANT: If water does not drain from the distribution housing when both green indicators are extended, remove the blue plug on the distribution housing. Distribution housing water drain Blue plug 55101 Check to ensure water drains out of the seawater pump housing. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-31...
Page 48 OFF position. 13. After the water has drained from the engine, install the blue plugs on the distribution housing and seawater pump if they were removed and tighten securely. Page 1C-32 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 49: Air Actuated Single-Point Drain System (Standard Cooling)
Close the seacock (if equipped) or remove and plug the water inlet hose. Remove the engine front cover by pulling it up. 55105 Remove the blue plug from the engine block crossover. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-33...
Page 50 IMPORTANT: If water does not drain from the distribution housing when both green indicators are extended, remove the blue plug on the distribution housing. Distribution housing water drain Blue plug 55101 10. Check to ensure water drains out of the seawater pump housing. Page 1C-34 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 51 TowSport standard cooling in-line transmission starboard side view 12. Allow the system to drain for a minimum of ten minutes. Pump air as necessary to keep the green indicators extended. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-35...
Page 52: Air Actuated Single-Point Drain System-Bravo Seawater Cooling
Close the seacock (if equipped) or remove and plug the water inlet hose. Remove the engine front cover by pulling it up. 55105 Remove the blue plug from the engine block crossover. Page 1C-36 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 53 Distribution housing water drain Blue plugs 55101 10. Check to ensure water drains out of the seawater pump housing. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-37...
Page 54: Draining The Sterndrive
15. Install the blue plug on the heat exchanger and tighten securely. 16. Mercury MerCruiser recommends the drain system remain open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained. 17. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.
Page 55: Draining The Seawater System
IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the raw water section of the cooling system during freezing temperatures or for extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
Page 56 IMPORTANT: If water does not drain from the distribution housing when both green indicators are extended, remove the blue plug on the distribution housing. Distribution housing water drain Blue plug 55101 Check to ensure water drains out of the seawater pump housing. Page 1C-40 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 57 OFF position. 13. After the water has drained from the engine, install the blue plugs on the distribution housing and seawater pump if they were removed and tighten securely. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-41...
Page 58: Air Actuated Single-Point Drain System (Closed Cooling, Inboard Models)
Remove the cap from the air actuated valve assembly. Blue plug 55099 Ensure that the lever on top of the air pump is flush with the handle (horizontal). Install the air pump on the actuator fitting. Page 1C-42 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 59 IMPORTANT: If water does not drain from the seawater pump housing when both green indicators are extended, remove the blue plugs on the seawater pump housing. Seawater pump housing water drain Blue plugs 56033 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-43...
Page 60 15. Install the blue plug on the heat exchanger and tighten securely. 16. The drain system should remain open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained. Page 1C-44 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 61: Flushing The Power Package (Bravo)
Sterndrive Water Pickups There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water and side water pickups. Dual water pickups require the flushing device and the flush gearcase seal kit. Side water pickups require the flushing device.
Page 62 Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. Press the throttle‑only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM). Page 1C-46 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 63 NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-47...
Page 64: Seacore Power Package Flushing Procedure
Bravo sterndrive. Ensure that the inlet water hose from the sterndrive to the engine is connected. Remove the quick‑connect fitting from the parts bag supplied with the engine. Page 1C-48 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 65 13. Flush the engine for 5 to 10 minutes or until discharge water is clear. 14. Shut off the engine. 15. Allow the water to flush the sterndrive for 10 seconds. 16. Turn off the water source. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-49...
Page 66 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. Quick-connect fitting stored in the boat Quick‑connect fitting (water hose end)
Page 67: Cold Weather Or Extended Storage
21. Open the seacock, if equipped, or reconnect the alternative water inlet source prior to operating the engine. Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures is not covered by the Mercury MerCruiser Limited Warranty.
Page 68: Power Package Recommissioning
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation. Check the antifreeze concentration where applicable. Refer to the Specifications section. Before adding Mercury Quickstor Fuel Stabilizer to the fuel in the tank, determine the type of fuel that is in the fuel tanks and proceed with the following: Vessels using fuel without alcohol—fill the vessel fuel tanks with fresh gasoline that does not contain alcohol and add...
Page 69 Start the engine and closely observe the instrumentation to ensure that all systems are functioning correctly. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks. Inspect the steering system, shift, and throttle control for proper operation. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1C-53...
Page 71 Chart S4: Hesitation, Sag, or Stumble......1D-14 CDS G3 Service Tool Home Screen Overview..1D-24 Chart S5: Engine Misses.......... 1D-15 CDS G3 Fault List.............1D-25 Chart S6: Rough, Unstable, or Incorrect Idle and Stalling..............1D-16 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-1...
Page 72: Introduction
The CDS G3 service tool is required to access all of the available information in the PCM 112 controller. Refer to CDS G3 Service Tool. The CDS G3 service tool is purchased through Mercury Parts and Accessories. PCM 112 engines have a generic onboard diagnostics ‑ marine (OBD‑M) data connector that allows connection of generic J1939 scan tools.
Page 73: Visual/Physical Check
6.7 kPa (2 in. Hg). Refer to MerCruiser Service Bulletin 99‑7 for additional information.
Page 74: Emission Control Fault Indicators
Diagnosis by at this time. symptom, yet there are no or off. The PCM does not detect any Symptom. Diagnosis is diagnostic faults? problems, yet the engine has a problem. complete. Page 1D-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 75: Chart R1: Engine System Fails To Power
Check for battery voltage at purple circuit between the the warning horn purple lead. – Go to step 9. key switch and the Is the voltage within 1.0 V of warning horn. battery? 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-5...
Page 76: Chart R2: Obd-M Lamp Does Not Self-Test
Does each circuit measure within 1.0 V of battery? If the engine system does not power up after successfully completing all of Call MerCruiser Service Go to step 14. Does the engine system power up? the previous steps, there may be a for assistance.
Page 77: Chart R3: Crankshaft Fails To Rotate
The engine will continue to crank until the key switch is released. All MerCruiser engines are designed to use a neutral safety switch. The switch is inside the remote control on sterndrive engines and mounted to the transmission on inboard engines. The switch must be closed when in neutral, and open when in gear.
Page 78: Chart R4: Engine Cranks Over But Will Not Start
Refer to Section 5A ‑ Fuel Was the fuel pressure within Go to step 7. Go to Chart T3. Pressure Gauge Setup specification when the pump was and Use. operating? Page 1D-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 79: Chart R5: Hard Start
ECT – Go to step 9. sensor. sensor temperature with an accurate Retest system. reading of ambient air temperature. Are the temperatures within 5.5° C (10° F) of each other? 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-9...
Page 80: Chart R6: Engine Stalls
Low compression Check for mechanical engine problems. Correct the problems and Contact Mercury • Worn camshaft retest the engine. Product Support. Were problems found? • Restricted intake or exhaust system Page 1D-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 81: Diagnosis By Symptom
Was the Visual/Physical Check completed? Go to step 2. Physical Check. Connect the CDS G3 Did the onboard diagnostic (OBD) system check complete? Go to step 3. service tool and scan for faults. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-11...
Page 82: Chart S3: Detonation Or Spark Knock
All of the electrical connections within a suspect circuit or system Chart S3: Detonation or Spark Knock Definition: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with throttle opening. Page 1D-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 83 Section 3 ‑ Engine Go to step 15. • Worn camshaft Mechanical. • Improper valve timing or valve train problem • Restricted exhaust system Was a problem found? 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-13...
Page 84: Chart S4: Hesitation, Sag, Or Stumble
Review all of the procedures in this table. If all procedures have been completed and no problem found, inspect the following: • CDS G3 scan tool data NOTE: If there is an active fault Engine_Misfire , refer to the PCM 112 Service Manual or to MerCruiser Service Bulletin ‑ 11R2 . 2011 •...
Page 85: Chart S5: Engine Misses
Restricted exhaust system Was a problem found? Check the intake and exhaust manifolds for casting flash. Repair or replace. Go to step 11. Retest the system. Was a problem found? 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-15...
Page 86: Chart S6: Rough, Unstable, Or Incorrect Idle And Stalling
All of the electrical connections within a suspect circuit or system Chart S7: Poor Fuel Economy Definition: Fuel economy is noticeably lower than expected. Also, economy is now lower than it was on this engine at one time. Page 1D-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 87: Chart S8: Dieseling Or Run
Chart S8: Dieseling or Run‑On Definition: Engine continues to operate roughly after the key is moved to the off position. If the engine operates smoothly, first check the ignition switch and adjustment. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-17...
Page 88: Chart S9: Backfire
Go to step 9. Was a problem found? Retest the system. Check for adequate spark at all of the spark plugs. Go to step 10. Go to Chart T4. Was adequate spark present? Page 1D-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 89: Troubleshooting Tests
Check for continuity between the MPR harness connector terminal 85 and Locate and repair the good MPR onto the PCM harness connector pin A‑3D. open in the harness. the engine. Retest system. Was continuity present? Retest system. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-19...
Page 90: Chart T2: Fuel System Electrical Test
Block the fuel return line using the fuel shut off valve tool. pressure regulator. good fuel pump. • Turn the ignition key switch on. Retest system. Retest system. Does the fuel pressure remain steady? Page 1D-20 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 91: Chart T4: Ignition System Test
Check continuity between CPS harness connector C and PCM Locate and repair the open in No problem found. harness connector B‑4H. the harness. Retest the system. Retest the system. Was continuity present? 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-21...
Page 92: Troubleshooting Shift Problems
In addition, some faults are programmed to ignore certain engine speeds. For example, the low block pressure sensor fault (sea pump pressure on a MerCruiser) is typically not enabled until enough RPM has been achieved to develop a reasonable amount of water pressure. Therefore, this fault will not be set at idle.
Page 93 CAN H buses must be properly terminated for the tool to communicate. Improper termination will result in communication errors or complete loss of communication. Computer G3 SmartCraft diagnostic interface CAN P/CAN H adapter harness Connect to junction box or diagnostic port 47946 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-23...
Page 94: Cds G3 Service Tool Home Screen Overview
If the G3 CAN P traffic indicator is red or yellow, then there is a communication issue. Refer to the user manual loaded onto the computer diagnostic system laptop (in the Windows® Start menu > All Programs > Mercury Marine > User Manual) or on the G3 software installation disc.
Page 95: Cds G3 Fault List
CDS G3 Fault List IMPORTANT: For additional information on troubleshooting faults, refer to the PCM 112 Service Manual. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 1D-25...
Page 97 Disconnecting the Shift Cable and Throttle Cable..... 2A-4 Fuel Hose..............2A-2 Disconnecting the Electrical Components......2A-5 Steering Hoses (Sterndrive)........2A-2 Continuity Wire Removal (Sterndrive)........2A-6 Seawater Hoses............2A-3 Removing the Engine............2A-6 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2A-1...
Page 98: Preparation
Disconnect the hydraulic hoses from the steering actuator. 16225 Typical power-assisted steering connections Hydraulic hoses Power‑assisted steering actuator Plug or cap all open fittings to prevent contamination and loss of fluid. Page 2A-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 99: Seawater Hoses
It may be more convenient to disconnect the hose at this alternate location. Typical Bravo drive connection Hose Quick‑disconnect 90° fitting Seawater inlet fitting J‑clip 21623 Place the hose out of the way. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2A-3...
Page 100: Disconnecting The Shift Cable And Throttle Cable
Washer and cotter pin Cotter pin 55293 Disconnect the intermediate shift cable from the shift plate, and retain the hardware. Throttle cable Throttle demand sensor pin clip Throttle stop Washer and cotter 55304 Page 2A-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 101: Disconnecting The Electrical Components
Disconnect any ground wires and accessories that are connected to the engine. 16‑pin transom harness Onboard diagnostics ‑ marine (OBD‑M) light connector Tank level connector 14‑pin engine harness connector OBD‑M MIL light 7A clean power 55204 Hot stud 90‑amp fuse 56282 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2A-5...
Page 102: Continuity Wire Removal (Sterndrive)
For reference during assembly, scribe a mark across the yokes for the driveshaft U‑joint and the bearing support U‑joint (output flange). Remove the bolts securing the driveshaft to the bearing support U‑joint yoke. Separate the driveshaft from the bearing support yoke. Page 2A-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 103 26 inches on each length or use a spreader bar so that no components are damaged. 55255 Remove the two rear engine mount bolts on sterndrive models. Rubber washer Spacer Washer Bolt 55237 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2A-7...
Page 104 Lag bolt (with washers) 57182 Removal of water‑cooled shaft log seal connection for TowSport and inboard models. 10. Carefully remove the engine. Do not damage the power‑assisted steering control valve. Page 2A-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 105 General Repower Information........2B-24 Adaptive Speed Control (ASC) Propping with G3..2B-48 Transom Harness—DTS/Mechanical Shift ....2B-25 Wide‑Open Throttle Propping Without G3 Test..2B-50 Transom Ground Connection........2B-25 Checking Shift Operation..........2B-51 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-1...
Page 106 Blocks off the front water inlet holes on the dual water inlet gearcases. 9194 Flushing Attachment 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 Page 2B-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 107: Torque Specifications
92- 25711 3 Slide the rubber boot over the positive (+) terminal after making the connection. Temporarily lay the battery cables over the top of the engine to prevent interference during installation. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-3...
Page 108: Shift Cable Routing
Clean the threads on the front mount studs. Apply Loctite Silver Graphite Anti‑Seize Spray to the entire length of the stud threads. IMPORTANT: Do not use any other type of anti‑seize compound on the stud threads. Page 2B-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 109 IMPORTANT: Maintain a minimum 66 cm (26 in.) on each length or use a spreader bar so that no components are damaged. Lift the engine into position in the boat using an overhead hoist. IMPORTANT: When lowering the engine into position do not set the engine on the shift cable. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-5...
Page 110 13. Disconnect the sling from the engine lifting eyes. IMPORTANT: Alignment tools from other manufacturers may cause improper alignment and damage to the gimbal bearing or engine coupler. Use only the Mercury alignment tool. NOTICE Improper use of the alignment tool may result in personal injury or damage to the gimbal bearing or engine coupler. Do not operate the engine with the alignment tool installed.
Page 111 18. On models where the front engine mounts cannot be lowered enough to allow for proper engine alignment: Attach a suitable sling and lifting arm to the engine lifting eyes and adjust so that the engine is level when suspended. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-7...
Page 112 Front mount locking (jam) nuts – 23. Recheck the alignment with the alignment tool. The tool must enter the coupler splines freely. If not, remove the alignment tool and readjust the front mounts. Page 2B-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 113: Connecting The Fluid Systems
Gear lube monitor hose assembly from gear lube monitor Quick‑connect fitting 7800 Bravo Seawater Inlet Fitting Connection NOTE: The retainer clip must be in the closed position prior to installation. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-9...
Page 114 Shown with engine removed for visual clarity Centerline of water inlet fitting Retainer clip in closed position Hose decal 8514 Perform a pull test on the water hose quick connection. Page 2B-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 115 Quick connect fitting (to seawater inlet fitting) Seawater inlet fitting (to transom) Perform a pull test at the seawater inlet connection to ensure that the seawater inlet hose is connected properly. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-11...
Page 116: Power-Assisted Steering Hoses
NOTE: Ensure that the steering fluid level is correct before first operation. Speedometer and Pitot Connections Refer to the appropriate sterndrive service manual for details on connecting the speedometer and pitot sensor. Page 2B-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 117: Bravo Shift Cable Installation And Adjustment
88.5 – Install a washer onto the shift arm pin. Install the intermediate shift cable. NOTE: The transom assembly intermediate shift cable is factory set and does not require adjustments. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-13...
Page 118 10. Install the shift cable adjustment tool over the intermediate shift cable. Secure the tool in place with a piece of tape over the barrel end if necessary. 11. Install the remote control shift cable barrel onto the stud. Page 2B-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 119: Throttle Cable Installation
After the throttle cable is properly aligned with the throttle demand sensor pin and shift plate stud, rotate the barrel two turns away from the end guide to apply a slight preload on the cable and install the throttle cable. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-15...
Page 120: Connecting The Electrical Components
Connect the transom harness. Connect the depth transducer connector to the data link connector on the engine harness. Connect the paddle wheel/tank level connector. Connect the power harness (with 5‑amp fuse) connector. Page 2B-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 121: Continuity Wire Connection
Mount the MerCathode controller in an accessible area within reach of the harness when installed. Connect the MerCathode harness wires to the MerCathode controller assembly—the orange wire to the A terminal, and the brown wire to the R terminal. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-17...
Page 122 Apply a sealant to all wire connections to prevent corrosion. Tube Ref No. Description Where Used Part No. Liquid Neoprene Exposed terminals and connections 92- 25711 3 Page 2B-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 123: Trim Position Sender Connections
ORG/WHT 49918 Installing the Sterndrive Unit Refer to the appropriate Mercury MerCruiser sterndrive service manual for procedures related to the installation of the sterndrive unit. Battery Connection IMPORTANT: The sterndrive must be installed before connecting the battery. Refer to the appropriate Mercury MerCruiser sterndrive service manual.
Page 124: Power Trim System
Installation Power Trim System NOTE: Outboard or MerCruiser control may be used depending on the application. If MerCruiser control is used then a power trim extension harness also will be used. 55530 Outboard control MerCruiser control To key switch harness...
Page 125: Boat Harness Installation Guidelines-Mpi Sterndrive
IMPORTANT: For dual helm installation, both key switches used must be modified to operate independently. IMPORTANT: Cutting the black/yellow stripe wire disconnects the E‑stop circuit incorporated in the key switch. Do not alter key switches on DTS applications. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-21...
Page 126: Trim Switch
The trim switch connection on the helm harness is only used on Mercury outboard remote controls. MerCruiser models require a separate trim harness from the trim control to the power trim pump connection. A Y‑harness is available with adapters to connect the dual helm power trim harnesses together to connect to the transom harness. DTS models do not need the separate trim harness.
Page 127: Neutral Safety Switch
Optional E‑Stop The E‑stop lanyard switch connection is used on Mercury outboards and can be used on MerCruiser MPI engines. The black and black/yellow wires are connected together through a lanyard switch that is normally open. When the lanyard is pulled and the switch is tripped, the circuit will close and ground the ECM to shut the engine off.
Page 128: Can P (Can 1) Connections
2-pin link harness—CAN General Repower Information • A 6‑pin fuel paddle boat harness is required. Can X terminator DTS only 10‑pin diagnostics Fuses Circuit breaker J1939 diagnostic connection PCM 112 55203 Page 2B-24 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 129: Transom Harness-Dts/Mechanical Shift
Connect the ground wire in the transom harness under the bonding strap screw on the transom. Do not connect any other ground wires here. Use the ground studs on the flywheel housing for other grounding needs. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-25...
Page 130: Bravo Sterndrive Shift Check (Engine Running)
NOTE: The operator at the remote control handle should feel a slight detent before and after each gear: forward, detent, neutral, detent, reverse. Page 2B-26 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 131: Engine Installation And Initial Engine Alignment-Towsport, Inboard
Lift up on the front of the second cover to disengage the cover from the front grommets. Pull the cover toward the front of the vessel to remove it from the two rear grommets. Front grommets Rear grommets 58714 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-27...
Page 132 Loosen the clamping bolts and the nuts on all four of the engine mount brackets to ensure the following: • The large diameter of the mount trunnion is extended. • The mount base slotted mounting hole is positioned forward, if so designed. Page 2B-28 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 133 Adjusting nut Trunnion clamp bolt and nut with lockwasher 10 mm + 2 mm (3/8 in. + 1/16 in.) 67 mm + 2 mm (2‑5/8 in. + 1/16 in.) 58429 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-29...
Page 134: Models With 8 Degree Down-Angle Transmissions
Adjust the engine bed height if necessary to obtain the proper alignment. Do not use the mount adjustments to adjust the engine position at this time. Page 2B-30 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 135: Final Engine Alignment-Towsport, Inboard
With the shaft in the center of the shaft log as determined by the above procedures, align the engine with the shaft. Typical down angle (V-drive similar) Port Down Starboard 7619 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-31...
Page 136 Loosen the lag bolts that fasten the mounts to the engine bed, and move the engine, as required. Tighten the lag bolts securely. Page 2B-32 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 137: Exhaust System Guidelines-Towsport
Exhaust hoses should be no smaller than the minimum sizes. Use larger hoses on applications with long hose runs. Minimum Exhaust Hose Size Model Dual Muffler outlet All Models 88.9 mm to 102 mm (3.5 in.) to (4.0 in.) 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-33...
Page 138: Exhaust System Guidelines-Inboard Models
The exhaust system must be adequately supported for proper orientation and to prevent overstressing the exhaust manifolds and elbows. The support requirements will vary with exhaust system design and the G‑forces to be encountered. • The exhaust system must meet the exhaust back pressure specification. Refer to Mercury MerCruiser Product Applications Manual •...
Page 139: Exhaust Hose Connections-Inboard
Installation • In‑line mufflers, collectors, and hoses must self drain after engine shut‑down. Refer to Mercury MerCruiser Product Applications Manual Exhaust Hose Connections—Inboard NOTICE Hot spots in exhaust hoses can damage hoses and cause leaks. Ensure that discharge water from the exhaust elbow flows without restriction through all hoses and fittings.
Page 140: Measuring Exhaust Elbow Height-Towsport
If the exhaust elbow height or exhaust angle is insufficient, modify the exhaust system or install the appropriate exhaust riser. Refer to the appropriate Mercury Precision Parts and Accessory Guide for part numbers. The maximum exhaust riser height is specified in the table below.
Page 141: Boat Requirements
All boats that only display the US Coast Guard (USCG) capacity plate must use the maximum capacity as stated on the USCG capacity plate to perform the exhaust elbow waterline measurement. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-37...
Page 142: Loading Requirements
• Measurements used for official Mercury MerCruiser audit at the OEM boatbuilder must be performed on current production boats. No prototype hulls or light layup hulls will be considered for official audit purposes.
Page 143 Maximum load (persons and gear) from capacity plate – swim platform load = remaining weight to be placed in the boat. • 1100 lb – 400 lb = 700 lb Remaining weight to be placed in the boat ÷ MerCruiser person weight = number of persons to load onto the boat. • 700 lb ÷ 165 lb = 4.24 persons Total number of persons –...
Page 144: Loading The Boat (Boats Without A Capacity Plate)
55 in. (bench seat length) ÷ 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons. Total number of persons that can sit on designated seating excluding cabin space × MerCruiser person weight = maximum passenger load for measurement.
Page 145 225 lb × 25% = 56.25 lb • 56.25 lb rounded down = 56 lb To determine the maximum number of passengers to load onto the boat, multiply 9 passengers by 165 lb (MerCruiser person weight) to get a 1485 lb (total passenger load). •...
Page 146: Clear Hose Measurement Method
Installation Divide the remaining weight to be placed onto the boat by the MerCruiser person weight to get the maximum number of passengers to load onto the boat. • 985 lb ÷ 165 lb = 5.9 passengers • 5.90 passengers rounded up = 6 passengers Using the totals in this example load 56 lb cargo in the aft storage, 113 lb cargo in the center storage, and 56 lb cargo in the bow storage onto the boat before adding passenger weight.
Page 147: Electrical Connections-Towsport, Inboard
Description Where Used Part No. Loctite 567 PST Pipe After the first thread of the audio warning temperature switch 92-809822 Sealant Install the switch by hand until resistance is felt. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-43...
Page 148: Boat Harness And Instrumentation Connections-Inboard
Fasten the harnesses to the boat at least every 46 cm (18 in.) using appropriate fasteners. Connect the 14‑pin harness to the engine. Turn the locking ring until a firm snap is felt. 23136 Typical 14-pin connection Page 2B-44 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 149: Smartcraft Product
55244 SmartCraft Product A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are: RPM, coolant temperature, water pressure, battery voltage, fuel consumption, engine operating hours, engine alarm data, and potential problems. The SmartCraft instrument package will also aid in engine diagnostics.
Page 150: Service Engine Light And Obd-M Mil Kit
Turn the ignition switch to the on position without cranking the engine. The service engine icon and MIL will remain illuminated for four seconds if the visual indication system is functioning correctly. Page 2B-46 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 151: Battery Cables Connection
It is the responsibility of the boat manufacturer or the selling dealer to equip the power package with the correct propeller. Specified engine WOT and operating RPM range are listed in the Mercury MerCruiser Operation, Maintenance and Warranty Manual attached to the engine.
Page 152: 6.2L Maximum Rpm Specification
Adaptive Speed Control (ASC) Propping with G3 IMPORTANT: Propping of the boat can be done as normally done with all other MerCruiser products, but to achieve the best optimum propeller selection you can use the propping procedure with the G3 tool to verify your propeller selection.
Page 153 Demand request by control software at 92.63% • Demand request by Guardian at 100% • Trim position percent at 15.97% optimum trim for this boat • Demand request by operator 100% 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-49...
Page 154: Wide-Open Throttle Propping Without G3 Test
Advance the engine RPM (in 200 RPM increments) until the engine reaches its maximum rated RPM. Maximum Rated RPM Engine Model 223 kW (300 hp) 5000–5400 6.2L (sterndrive/inboard) 260 kW (350 hp) 5000–5400 Page 2B-50 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 155: Checking Shift Operation
Shifting from forward and reverse to neutral: ensure drive unit is in neutral before remote control shift lever comes to the neutral detent position. Perform this check using various shifting rates to ensure that the drive unit shifts the same whether shifting fast or slow. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 2B-51...
Page 157 Method 1..............3A-23 Disassembly............. 3A-39 Method 2..............3A-23 Crankshaft, Main Bearings, and Engine Block....3A-40 Intake Manifold Assembly..........3A-24 Exploded View............3A-40 Removal..............3A-24 Removal..............3A-40 Hydraulic Valve Lifters............. 3A-25 Engine Block.............3A-42 Exploded View............3A-25 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-1...
Page 158: Engine Block Codes
The engine can be determined by using the block code. This code contains a component code, family code, and year and time code. 57249 Block code stamped on starter mounting boss Page 3A-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 159: Tools
H ‑ Verado 4 cylinder SC, 4 cylinder NA and 6 cylinder SC Family code J ‑ 4 cylinder 135/150 hp K ‑ 4 cylinder SC 175 hp L ‑ Bedrock M ‑ MerCruiser common N ‑ MerCruiser V6 P ‑ MerCruiser V8 T‑ Tigershark Z ‑ Verado 350 hp racing X ‑...
Page 160: Precautions
NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. Page 3A-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 161: Torque Specifications
Thermostat cap to crossover screws—standard and closed cooling – Crossover to head screws—standard and closed cooling – Throttle body screws 97.3 – Water circulating pump fasteners—3 screws, 1 stud – 21.4 Water pump pulley screws – 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-5...
Page 162: General Information
Stop the engine. Allow approximately five minutes for the oil to drain into the oil pan. The boat must be at rest in the water. Oil dipstick handle Operating range 56496 Remove the dipstick. Wipe clean and insert fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent. Page 3A-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 163: Sterndrive Engine Mounts
NOTE: White or yellow paint is used to identify the top of the mount assembly. The bottom has a knurled edge. Typical flywheel housing, all similar Painted end (not visible) Mount bottom Knurled edge 57656 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-7...
Page 164: Engine Components
Engine Disassembly Engine Components Cylinder Head and Rocker Cover Components 58403 Page 3A-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 165 Head bolt (M10 x 1.5 x 86) Second – 22.1 Final torque +45° Dowel pin Head gasket Screw – Starboard rear—lifting eye bracket Starboard front—lifting eye bracket Elbow, 90° Clamp Hose PCV valve Hose Pushrod 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-9...
Page 166: Timing Chain And Front Cover Components
Engine Disassembly Timing Chain and Front Cover Components 17 18 14 15 59647 Page 3A-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 167 Timing front cover Seal Reluctor wheel Timing chain Crankshaft timing gear Cam timing gear Timing gear screws – 22.1 Timing front cover gasket Belt Water pump pulley Screw 88.5 – Cam sensor 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-11...
Page 168: Crankshaft And Camshaft
Engine Disassembly Crankshaft and Camshaft 59646 Page 3A-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 169 Camshaft bearing set Crankshaft oil seal Crankshaft Dowel pin Main bearing set Thrust bearing First torque 132.7 – Main bearing bolt Second torque – 29.5 Final torque +90° Dowel pin 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-13...
Page 170: Piston And Connecting Rod
Engine Disassembly Piston and Connecting Rod 55056 Page 3A-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 171 Lower oil control ring Piston Piston pin Snap ring (2) Connecting rod Upper bearing half Lower bearing half Bearing cap First torque – 18.4 Bolts Final (angle torque) + 90° 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-15...
Page 172: Intake Manifold And Fuel Rail (Mpi)
Engine Disassembly Intake Manifold and Fuel Rail (MPI) 58417 Page 3A-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 173 – Fuel filter to fuel module line Screw Clamp Hose to fuel tank Bracket Screw – 19.9 Filter assembly Fuel filter Screw Stainless steel screw 106.2 – Worm gear clamp 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-17...
Page 174: Oil Pan And Oil Pump
Engine Disassembly Oil Pan and Oil Pump 57114 Page 3A-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 175 Oil pump First – torque Oil pump screw Final + 65º torque Retainer Oil pump shaft Oil pump drive Dipstick Dipstick tube Dipstick tube screw 11.5 101.8 – Screw – 22.1 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-19...
Page 176: Remote Oil Filter
Engine Disassembly Remote Oil Filter 58537 Page 3A-20 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 177 Screw, M6 x 12 31.1 – 22.9 Oil cooler to filter oil line Bracket Screw, M6 x 12 31.1 – 22.9 Block to cooler oil line Screw, M8 x 16 Bracket 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-21...
Page 178: Rocker Arm Cover
When servicing all rocker arms, bring cylinder number 1 piston up to TDC before removing the rocker arms. Remove the rocker arms. Rocker arm retaining screw 59507 Page 3A-22 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 179: Finding Top Dead Center (Tdc)
1 cylinder intake valve is fully closed. Continue turning the engine over by hand until the block‑mounted timing pointer aligns with the 0° timing mark on the harmonic damper. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-23...
Page 180: Intake Manifold Assembly
Intake manifold bolts IMPORTANT: It may be necessary to pry the intake manifold away from the cylinder heads and block. Use extreme care to prevent damage to the sealing surfaces. Page 3A-24 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 181: Hydraulic Valve Lifters
Removal IMPORTANT: Organize and store the rocker arm assemblies, pushrods, and valve lifters in matched sets for assembly and installation in their original locations. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-25...
Page 182: Oil Pump Drive
Remove the valve lifters. Store the lifters in the upright position in the order of removal. 55006 Valve lifter Oil Pump Drive Removal The oil pump drive connects the oil pump to the camshaft via the intermediate shaft. Page 3A-26 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 183: Flywheel And Housing
IMPORTANT: The flywheel housing bolts must be installed in the same location as removed. Remove the screws and studs from the flywheel housing. Remove the flywheel housing. 30644 Flywheel Removal Remove the flywheel housing. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-27...
Page 184: Oil Pan
Always check for leaks before attempting to start the engine, and wipe up any spilled fuel immediately. Drain the engine oil from the oil pan. Page 3A-28 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 185: Front Engine Cover
Remove the crankshaft harmonic damper with a crankshaft harmonic damper remover and installer tool. Description Part Number Kent‑Moore crankshaft harmonic damper remover and installer J23523‑F Crankshaft harmonic damper puller Crankshaft harmonic damper 55361 Remove the water circulating pump. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-29...
Page 186 Crankcase front cover 30312 Crankcase front cover Cover screws (6) 55359 10. Remove and inspect the crankcase front cover. IMPORTANT: The crankcase front cover is reusable. Gasket must be replaced if removed. Page 3A-30 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 187: Timing Chain And Sprockets
Remove the camshaft sprocket. NOTE: If the sprocket does not come off easily, a light tap on the lower edge of the sprocket with a plastic mallet should dislodge it. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-31...
Page 188: Camshaft
Remove the crankshaft sprocket using the crankshaft sprocket remover tool. Description Part Number Kent‑Moore crankshaft sprocket puller J5825‑A Camshaft Removal Remove the camshaft thrust plate. 59482 Install three 5/16‑18 x 5 in. long bolts in the camshaft bolt holes. Page 3A-32 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 189: Cylinder Head
Remove the cylinder head. Place the cylinder head on wooden blocks, a rubber mat, or other material that will prevent damage to the gasket surfaces. Repeat this process for the second cylinder head. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-33...
Page 190: Valve Spring Assembly Exploded View
Engine Disassembly Valve Spring Assembly Exploded View Valve Valve stem oil seal Valve spring Valve spring retainer Valve spring keeper 55013 Page 3A-34 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 191: Valve Spring Assembly Removal
IMPORTANT: Keep components together as a matched set. Mark and organize parts so that they can be installed in the same location later. Remove and discard the valve stem oil seal. 55050 Typical valve stem oil seal Repeat for each valve. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-35...
Page 192: Connecting Rod, Bearings, And Piston Assembly
Cylinder bore ridge reamer Obtain Locally Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston to collect cuttings. Page 3A-36 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 193: Disassembly
Remove the connecting rod bearings. Keep the bearings with the original connecting rod and connecting rod cap together as a matched set. Disassembly Remove the piston rings from the pistons. Piston Ring Expander 91‑24697 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-37...
Page 194: Rear Oil Seal
Rear main seal 55069 IMPORTANT: Do not nick or gouge the engine block or the rear main bearing cap sealing surface. Protect the crankshaft to seal running surface from damage. Page 3A-38 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 195: Oil Pump
Use caution when removing the diaphragm retaining pin. Remove the retaining pin, spring, and pressure regulator valve from the pump cover. IMPORTANT: The suction pipe and pickup screen assembly are not serviceable and should not be removed. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-39...
Page 196: Crankshaft, Main Bearings, And Engine Block
NOTE: Engine port and starboard cylinder heads are removed for illustration clarity. Ensure that all bearing caps are marked so that they can be installed in their original locations. Main bearing cap Bearing cap marks 55071 Page 3A-40 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 197 Remove the main bearing caps and carefully lift the crankshaft out of the engine block. Crankshaft Main bearing cap Rear main bearing cap Main bearing cap screw 59495 Crankshaft 59493 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-41...
Page 198: Engine Block
Remove the camshaft rear bearing hole expansion cup plug. Rear of engine block camshaft opening Rear camshaft expansion plug 59503 Unscrew the oil gallery plugs. Rear oil gallery plugs 59504 Page 3A-42 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 199 Camshaft Bearings Removal The camshaft bearing service kit is required to remove and install the camshaft bearings. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-43...
Page 200 Camshaft bearing tool assembled (J33049) 53618 Remove the camshaft inner bearing #2, #3, and #4. Insert the J33049 through the front of the engine block and into the camshaft inner bearing #2. Page 3A-44 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 201 Drive the camshaft outer bearing #4 from the camshaft outer bearing bore #5. Loosen the J33049 expander assembly nut. Remove the camshaft outer bearing #5 from the J33049 expander assembly. Remove the J33049 from the engine block. Discard the camshaft bearings. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-45...
Page 203 Main Bearings, Without Crankshaft Removed....3B-68 Inspection..............3B-33 Installation..............3B-68 Installation..............3B-34 Valves and Seals (Without Removing Head)....3B-69 Timing Chain..............3B-35 Valve Spring Assembly Exploded View....3B-69 Inspection..............3B-35 Valve Spring Assembly Removal......3B-69 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-1...
Page 204: General Specifications
Expands piston rings for removal and installation. 6255 General Specifications Description Specification Bore 101.609 mm (4.00 in.) Stroke 95.25 mm (3.75 in.) Firing order 1–8–4–3–6–5–7–2 Compression ratio 9.4:1 Heads Cast iron Page 3B-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 205: Engine Specifications
Groove clearance Production 0.030–0.075 mm (0.0012–0.0029 in.) Production 0.38–0.52 mm (0.015–0.020 in.) Second Compression Description 6.2 Liter (377 cid) Groove clearance Production 0.020–0.060 mm (0.0008–0.0023 in.) Production 0.63–0.82 mm (0.025–0.032 in.) 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-3...
Page 206: Piston Pin
6.2 Liter (377 cid) Clearance Production 0.047–0.110 mm (0.0019–0.0043 in.) Rod side clearance 0.312–0.588 mm (0.013–0.023 in.) Valve Clearance (Lash) Description 6.2 Liter (377 cid) Net lash Intake and exhaust No adjustment Page 3B-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 207 350 N (78.68 lb) at 46.19 mm (1.818 in.) Load Valve open 1084 N (243.69 lb) at 32.3 mm (1.2717 in.) Intake Installed height 46.19 mm (1.818 in.) Exhaust Approximate number of coils 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-5...
Page 208: Camshaft
NOTE: Clean all debris, dirt, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners, or damage to the components. Clean the engine block cylinder head bolt holes. Page 3B-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 209: Cylinder Reconditioning
Engine block core hole plug bores for damage. Engine block for cracks or damage. Engine mount bosses for damage. Cylinder Reconditioning NOTE: The effectiveness of cylinder reconditioning depends upon engine condition at time of repair. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-7...
Page 210: Cylinder Boring
Check used piston to cylinder bore clearance: Measure the cylinder bore diameter with a telescope gauge 64 mm (2.5 in.) from the top of the cylinder bore. 30450 Measuring cylinder bore diameter Page 3B-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 211: Camshaft Bearings
3 o’clock position 59531 Select the handle (10), the expanding driver (4–8), the washer (2 or 3), and the expander assembly (15) from the J33049. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-9...
Page 212 Always install the camshaft outer bearings #1 and #5 first. The camshaft outer bearings serve as a guide for the J33049 and help center the camshaft inner bearings during the installation process. Camshaft bearing service kit driver (J33049) 53619 Page 3B-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 213 Drive the camshaft inner bearing #2 into the camshaft inner bearing bore #2 of the engine block. Loosen the J33049 expander assembly nut. Carefully remove the J33049 from the engine block. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-11...
Page 214: Engine Block Plugs
Wear eye protection when performing the following procedure. Failure to do so may cause personal injury. Apply Loctite 242 Threadlocker sealant to the outside diameter of each new engine block core hole expansion plugs. Page 3B-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 215 Apply sealant to the threads of the oil gallery plugs. Install the oil gallery plugs indicated. Tighten the oil gallery plugs to the specified torque. Rear oil gallery plugs 59504 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-13...
Page 216: Crankshaft And Pistons
Install the engine block coolant drain hole plugs. Tighten the plugs to the specified torque. Description lb‑in. lb‑ft Engine block coolant drain hole plugs – Crankshaft and Pistons Cleaning Connecting rods Clean the connecting rods in cleaning solvent. Page 3B-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 217: Main Bearing Inspection
Main Bearing Inspection This MerCruiser engine uses precision insert type main bearings. If the installed bearing clearance exceeds specification then the bearing assembly must be replaced. Service bearings are available in standard size and 0.0508 mm (0.002 in.), 0.254 mm (0.010 in.), and 0.508 mm (0.020 in.) undersized.
Page 218 Never replace one half of a bearing set without replacing the other half. 6354 Main bearing failure example Contamination scratches Contamination particles Tapered journal Oil starvation Radius ride Improper seating Fatigue failure Page 3B-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 219: Crankshaft Installation
IMPORTANT: Ensure that all bearings and crankshaft journals are clean. Install the upper main bearing inserts in the engine block. Upper insert Oil groove 59542 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-17...
Page 220 Install the lower main bearing insert into the main bearing caps. 59544 Lower insert Main bearing cap Carefully lower the crankshaft into place. Be careful not to damage the bearing surfaces. Crankshaft 59493 Page 3B-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 221 11. Tighten all main bearing caps, except the rear main cap, to the specified torque. Description lb‑in. lb‑ft 132.7 – First Crankshaft main bearing cap bolt—preferred method – 29.5 Second +90° Final 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-19...
Page 222: Main Bearing Clearance, Plastigauge Method
Crankshaft main bearing cap bolt—preferred method – 29.5 Second +90° Final Remove the bearing cap. The flattened gauging plastic will be found adhering to either the bearing cap or the journal. Page 3B-20 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 223: Crankshaft End Play
Proceed to the next bearing. After all bearings have been checked, oil and install the selected bearings and rotate the crankshaft to check for excessive drag. Crankshaft End Play Firmly force the crankshaft rearward. Firmly force the crankshaft forward. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-21...
Page 224: Preliminary Inspection
Subtract the piston diameter from the cylinder bore diameter to determine piston to bore clearance. Replace the piston if the piston to bore clearance is less than specified. Refer to Piston Selection for cylinder reconditioning and piston replacement. Page 3B-22 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 225 Using a feeler gauge, measure the clearance between the piston ring and the piston ring groove at several points around the piston. 19618 Measuring piston ring to piston clearance Top Compression Description 6.2 Liter (377 cid) Groove clearance Production 0.030–0.075 mm (0.0012–0.0029 in.) 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-23...
Page 226: Piston Ring Gap Inspection
NOTE: Oil control rings are a three‑piece type, consisting of two rings and a spacer. Select rings appropriate for the cylinder bore and piston size. Install the oil control ring spacer in its groove. Page 3B-24 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 227: Piston/Connecting Rod Assembly
47994 Tube Ref No. Description Where Used Part No. Lubriplate SPO 255 Piston pin Obtain Locally Piston and Rod Installation IMPORTANT: Cylinder bores must be thoroughly clean before piston installation. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-25...
Page 228 Carefully wipe any foreign material from the connecting rod bearings and the connecting rod bearing fitting surfaces. IMPORTANT: Do not apply oil to the back of the bearings or the connecting rod bearing mating surfaces. Page 3B-26 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 229 Ring gap locations Oil ring spacer gap Oil ring gaps Lower compression ring gap Upper compression ring gap Front of engine 30387 Use the piston ring compressor and compress rings. 54475 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-27...
Page 230 Install all connecting rods with their matched end caps. 12. Install the connecting rod cap. Installing connecting rod caps Connecting rod screws (2) Connecting rod cap Lower bearing half 54474 Page 3B-28 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 231: Connecting Rod Bearing Clearance, Micrometer Method
Use an inside dial indicator to measure the connecting rod bearing inside diameter and out of round and taper. Measure in several places approximately 90° apart and average the measurements. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-29...
Page 232: Connecting Rod Bearing Clearance, Plastigauge Method
Rotate the crankshaft or move the connecting rod until the upper bearing is fully seated against the connecting rod journal being measured. Page 3B-30 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 233 54229 Description 6.2 Liter (377 cid) Journal clearance Production 0.047–0.110 mm (0.0019–0.0043 in.) If the clearance is not within specifications, select a new, correct size bearing and recheck the clearance. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-31...
Page 234: Oil Pump
Inspect the oil pump locator dowel pins for damage and proper height. Dowel pins Oil pump dowel pin height 55289 Description Height Oil pump dowel pin 8.067–9.683 mm (0.3175–0.3812 in.) Installation Align the oil pump driveshaft with the intermediate shaft. Page 3B-32 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 235: Camshaft
0.05 mm (0.0020 in.) maximum Measure for a bent camshaft or excessive camshaft runout with a dial indicator. If the runout exceeds the specified amount, the camshaft should be replaced. 6347 Checking camshaft alignment 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-33...
Page 236: Installation
Camshaft thrust plate retainer bolt threads 92-809821 Install the camshaft thrust plate retainer and bolts. Tighten the bolts to the specified torque. NOTE: Oil relief grooves face outward on camshaft thrust plate. 59482 Page 3B-34 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 237: Timing Chain
Install the sprocket on the crankshaft by using the rear pinion bearing race installer tool. Rear pinion bearing race installer Crankshaft sprocket 30640 Description Part Number Rear pinion bearing race installer J5590 Align the marks on the crankshaft and the camshaft sprockets. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-35...
Page 238: Checking Timing Chain Deflection
The deflection is the difference between these two measurements. If the deflection exceeds specification, the timing chain should be replaced. Description 6.2 Liter Chain deflection 11 mm (0.4331 in.) maximum Page 3B-36 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 239: Installation
Tighten the screws in sequence shown Description lb‑in. lb‑ft Front cover screw 106.2 – Install a new crankshaft position sensor O‑ring seal and lubricate the seal with clean engine oil. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-37...
Page 240: Rear Seal Installation
Install the crankshaft pulley. Tighten the screw to the specified torque. Description lb‑in. lb‑ft Crankshaft pulley screws – Rear Seal Installation Remove the installation guide from the new crankshaft rear oil seal. Page 3B-38 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 241: Oil Pan
Turn the installer wing‑nut counterclockwise to release the installer from the oil seal. Remove the installer. Wipe off any excess oil. Oil Pan Inspection Inspect the oil pan for cracks, holes, warped sealing surfaces, or other damage. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-39...
Page 242: Installation
Install the oil pan baffle and the bolts. Tighten the oil pan baffle bolts to the specified torque. Description lb‑in. lb‑ft Oil pan baffle bolt 132.7 – Installation IMPORTANT: The adhesive sets up in about 15 minutes. Complete the assembly while the adhesive is still wet. Page 3B-40 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 243 NOTE: The oil pan gasket and oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch. Install a new oil pan gasket. Install the new oil pan gasket into the groove in the oil pan. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-41...
Page 244 The oil pan must always be forward of the rear face of the engine block. NOTE: If the clearance is more than 0.3 mm (0.011 in.), powertrain durability may be reduced. Page 3B-42 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 245: Cylinder Head
The cylinder head assembly is unidirectional and needs a core plug installed in the aft end of the cylinder head. This is determined on what side of the engine it is installed on. Apply Loctite 242 Threadlocker sealant to the outside diameter of the new engine head core expansion plug. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-43...
Page 246: Inspection
Take measurements diagonally across the cylinder head from all four corners and lengthwise straight down the center of the cylinder head. Head deck shown, exhaust and intake decks are similar Cylinder head deck Machinist's straightedge Feeler gauge 30171 Page 3B-44 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 247 7.96 mm (0.3133 in.) Production stem diameter Exhaust 7.97 mm (0.3137 in.) Measure the valve head margin. If the measured value is less than specified, the valve must be replaced. 32997 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-45...
Page 248 Use a vernier caliper to measure the valve spring free length. This is for reference only, springs should be measured for load at specified heights to determine if they are good. 20973 Description 6.2 Liter (377 cid) Free length 53.39 mm (2.10 in.) Page 3B-46 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 249: Repair
Recondition the valve face to the proper angle if the valve face is pitted or worn. Measure the valve margin. If the valve margin is less than the specified amount after reconditioning, replace the valve. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-47...
Page 250 Recondition the valve seats if pitted or worn. 30201 Typical 3 angle valve seat Top correction cut angle Seat angle Bottom correction cut angle Seat width Page 3B-48 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 251: Cylinder Head Reassembly
Outside surface of valve stem bore and all surfaces of the Lubriplate SPO 255 Obtain Locally valve stem oil seal Assemble the valve stem oil seal onto the valve stem and slide down until it contacts the valve spring seat. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-49...
Page 252 Use care when compressing the valve springs or releasing the valve spring compressor tool. Compress the valve spring using a valve spring compressor. Description Part Number Valve spring compressor J8062 10. Coat the valve stem keepers with lubricant to hold in place. Page 3B-50 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 253: Installation
Valve spring installed height 46.19 mm (1.818 in.) minimum Exhaust Typical Cut away scale Valve spring installed height 19503 Installation Ensure that the engine block and cylinder head sealing surfaces are clean. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-51...
Page 254 Engine Inspection and Assembly Place a new head gasket in position over the dowel pins. 59563 Carefully set the cylinder head in place over the dowel pins. 59565 Page 3B-52 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 255 Where Used Part No. Loctite 565 PST Cylinder head bolt threads Obtain Locally Tighten the cylinder head bolts to the specified torque in (passes) using the numbered sequence shown. 59571 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-53...
Page 256: Lifters
Inspect all parts carefully. Replace the valve lifter assemblies that are damaged or excessively worn. Lifter inspection points Seat retainer clip Pushrod seat Valve lifter body Check ball Check ball spring Check ball retainer Plunger spring Oil hole Roller 55004 55115 Page 3B-54 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 257: Lifter Installation
Inspect the drive gear on the oil pump drive for wear. Installation Install the oil pump drive in the block. Rotate the shaft to engage the drive with the camshaft and intermediate shaft. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-55...
Page 258: Rocker Arms And Pushrods
Rocker Arms and Pushrods Inspection Inspect all contact surfaces for excessive wear or scoring. Inspect threads for damage. Inspect pivot points for binding or damage. Contact surfaces Threads Pivot points 55138 Page 3B-56 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 259: Installation
Lubricate the rocker arm and rocker arm ball contact surfaces. Tube Ref No. Description Where Used Part No. Lubriplate SPO 255 Rocker arm and rocker arm ball contact surfaces Obtain Locally 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-57...
Page 260 Align the crankshaft and camshaft alignment marks. Tighten the rocker arm bolts to the specified torque. Rotate the crankshaft one full revolution and check all rocker bolts to the specified torque. Description lb‑in. lb‑ft Rocker arm bolts – 22.1 Page 3B-58 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 261: Intake Manifold Assembly
Apply a 4 mm (0.157 in.) bead of adhesive at each end of the lower intake manifold gasket on the cylinder head side. Do not get sealer into the oil sending unit hole. NOTE: For proper adhesion, the intake manifold gasket must be installed while the adhesive is still wet. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-59...
Page 262 NOTICE The crankshaft bearings are matched sets. Mismatching the bearings can result in engine damage. Replace and install the bearings in matched pairs. Page 3B-60 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 263 10. Install the fuel line. 11. Connect all ignition and electrical leads. 12. Install other ignition components and connect the wires. 13. Connect the crankcase ventilation hoses. 14. Connect any items that were disconnected. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-61...
Page 264: Rocker Arm Cover
This will create hydraulic pressure in the pilot bushing cavity forcing the bushing out. Clean the mating surfaces of the flywheel and the crankshaft until the metal is bare. Page 3B-62 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 265 Description lb‑in. lb‑ft Flywheel mounting screws – Check the flywheel runout: Attach a dial indicator to the engine block. Push in on the flywheel to remove any crankshaft end play. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-63...
Page 266 Run the heads of the screws down flush with the coupler, but do not tighten any of them at this point. This will allow the alignment holes to locate the coupler. Page 3B-64 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 267: Flywheel Housing
Install the studs and screws into their original locations. Tighten the flywheel housing fasteners to the specified torque. Description lb‑in. lb‑ft Flywheel housing fasteners – Install the flywheel housing cover. Tighten to the specified torque. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-65...
Page 268: Oil Lines
Install the power steering cooler (if equipped). Install the water hoses. Install the power package in the boat. Oil Lines Install the O‑rings onto the oil lines. Lubricate the O‑rings with Mercury 25W‑40 Synthetic Blend 4‑Stroke Engine Oil. Tube Ref No. Description Where Used Part No.
Page 269: Crankcase Front Cover Oil Seal (Without Removing Front Cover)
IMPORTANT: Use Loctite 598 RTV Sealant on the crankshaft harmonic damper keyway to prevent oil migration past the key. Tube Ref No. Description Where Used Part No. Loctite 598 RTV Sealant Keyway Obtain Locally Install the crankshaft pulley and belt. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-67...
Page 270: Main Bearings, Without Crankshaft Removed
Description lb‑in. lb‑ft – 18.4 First torque Crankshaft main bearing cap bolt—preferred method +90° Final torque 11. Tighten the rear main bearing cap. Using the method described below. Preferred Method: Page 3B-68 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 271: Valves And Seals (Without Removing Head)
Spark plug port adapter J23590 NOTE: If compressed air is not available, the piston may be brought up to TDC to keep the valves from falling out of the cylinder head. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3B-69...
Page 272 IMPORTANT: If compressed air is not available, do not turn the crankshaft while valve springs, retainers, and locks are removed or the valves will fall into the cylinder. Remove and discard the valve stem oil seal. 29807 Typical valve stem oil seal Page 3B-70 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 273 Low Engine Oil Pressure..........3C-11 High Speed Glazing............3C-6 Water in the Engine............3C-11 Scavenger Deposits........... 3C-6 Important Information..........3C-11 Preignition Damage............ 3C-7 Compression Gauge Testing........... 3C-12 Reversed Coil Polarity..........3C-7 Leak‑Down Testing............3C-12 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3C-1...
Page 274: Troubleshooting With A Vacuum Gauge
Valves are sticking or spark Indicator fluctuates 13.5–17 kPa service or replace if necessary. plug gap is too narrow. (4–5 in. Hg) very slowly at idle RPM Correct sticking valve. 17759 Page 3C-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 275: Measuring Vacuum
17763 Measuring Vacuum IMPORTANT: Use an accurate digital vacuum gauge that reads in either inches of mercury (in. Hg) or kilopascals (kPa) to check engine vacuum. Dial vacuum gauges are not accurate enough. Digital Pressure Meter 91‑892651A01 Carefully follow the gauge manufacturer's instructions to ensure accurate vacuum measurement.
Page 276: Used Spark Plug Analysis
With proper plug servicing (clean, file, and regap), this plug can be reinstalled with good results. 27643 Page 3C-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 277: Chipped Insulator
If, however, only one or two plugs in the set are fouled, check for sticking valves or bad ignition leads. After correcting the cause, service (clean, file, and regap) plugs and reinstall. 27647 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3C-5...
Page 278: Overheating
Accumulation on the ground electrodes and the shell areas may be unusually heavy, but may be easily chipped off. Service (clean, file, and regap) plugs and reinstall. 27650 Page 3C-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 279: Preignition Damage
Service (clean, file, and regap) plugs and reinstall. 27653 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3C-7...
Page 280: Mechanical Damage
Remaining fuel ignition Flame front collision NOTE: Engine failures that result from these conditions are beyond the control of Mercury MerCruiser. No warranty will apply to failures that occur under these conditions. If indicated, inspect the engine for causes of preignition damage to pistons: •...
Page 281: Starter Motor Will Not Crank Engine, Or Cranks Slowly
The accumulation of deposits on the piston and/or combustion chamber that result in a higher compression ratio • Inadequate engine cooling NOTE: Engine failures that result from these conditions are beyond the control of Mercury MerCruiser. No warranty will apply to failures that occur under these conditions. Starter Motor Will Not Crank Engine, or Cranks Slowly...
Page 282: Engine Will Not Start Or Is Hard To Start
Fuel line or tank vent line kinked or clogged. Replace kinked lines or blow out lines with compressed air to remove obstruction. Faulty wire connections. Check wire connections. Check the fuel system. Refer to MerCruiser ECM Fault Information and MPI system fault. Troubleshooting.
Page 283: Low Engine Temperature
2.2 Inspect the intake manifold for cracks. Check the gaskets. water passage. 2.3 Cracked or porous casting. 2.3 Check the cylinder head, the cylinder block, and the intake manifold for cracks or porosity. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3C-11...
Page 284: Compression Gauge Testing
Hold the crankshaft balancer bolt with a large wrench to prevent the crankshaft from rotating when applying air pressure to the cylinder. IMPORTANT: The engine will try to rotate when air pressure is applied. Maintain a firm grip on the wrench to prevent unexpected motion. Page 3C-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 285 A high volume of air leaks into the test cylinder's rocker arm cover and can be felt flowing Leaking piston or piston rings out of the oil fill or breather cap. (Low volume air bleed past the rings is normal.) 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3C-13...
Page 287 Engine Wiring Harness Engine Mechanical Section 3D - Engine Wiring Harness Table of Contents Engine Wiring Harness............3D-2 Harness Installation............ 3D-5 Harness Removal............3D-2 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3D-1...
Page 288 Starboard precatalyst oxygen sensor Port precatalyst oxygen sensor 59362 Starter connection Starboard exhaust temperature sensor 59363 Disconnect the wires at the starter. Disconnect the starboard and port exhaust temperature sensors. Page 3D-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 289 Disconnect the drive lube connector, ground harness, crank sensor connector, and J‑clip. Drive lube connector Ground harness Crank sensor connector 59365 Fused connector Coils Throttle body Temperature sensor Oil pressure sensor Ground stud 59367 Remove the fused connector. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3D-3...
Page 290 12. Remove the PCM relay bracket with harness from the engine. PCM relay bracket with harness 57212 13. Remove the relays and fuses from the PCM relay bracket. 14. Remove the circuit breaker from the PCM relay bracket. Page 3D-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 291 Attach the harness to the PCM relay bracket using cable ties. Attach the circuit breaker to the PCM relay bracket. PCM relay bracket upside down to show the cable ties Cable ties Circuit breaker 57226 Attach the relays and fuses to the PCM relay bracket. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3D-5...
Page 292 Connect the throttle body, temperature sensor, and oil pressure sensor. Connect the ground wires to the ground stud. Connect the drive lube connector, ground harness, crank sensor connector, and J‑clip. Drive lube connector Ground harness Crank sensor connector 59365 Page 3D-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 293 Connect the coolant sensor connector and the fuel pump connector. Coolant sensor connector Fuel pump connector 59364 Connect the wires at the starter. Starter connection Starboard exhaust temperature sensor 59363 10. Connect the starboard and port exhaust temperature sensors. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3D-7...
Page 294 Engine Wiring Harness 11. Connect the port and starboard precatalyst oxygen sensors. Starboard precatalyst oxygen sensor Port precatalyst oxygen sensor 59362 12. Install the PCM relay bracket screws. Mounting screws 56506 Page 3D-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 295 Starter Solenoid............4A-9 Starter Motor Circuit............4A-6 Starter Installation.............4A-10 Starter Relay..............4A-7 Starting System Tests............4A-11 Starting Circuit Overload Protection........4A-7 Low Voltage Tests............ 4A-11 Battery Cables for MerCruiser Models.......4A-7 Voltage Drop Test.............4A-12 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4A-1...
Page 296: Precautions
Precautions WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.
Page 297: Wire Color Code Abbreviations
No Load Test Delco Engine Model Voltage ID Number Rotation Minimum Current Draw Maximum Current Draw Minimum RPM Maximum RPM PG260G 8000669 12.0 V 35 A 85 A 2550 4150 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4A-3...
Page 298: Starter Motor Exploded View
Starting System Starter Motor Exploded View 56738 Page 4A-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 299 Starting System Starter Motor Exploded View Torque Ref. No. Qty. Description lb‑in. lb‑ft Starter motor assembly Bolt (M10 x 1.5) 47.5 – Nut (M8 x 1.5) – Lockwasher 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4A-5...
Page 300: Starting System Electrical Diagrams
Refer to the diagram above. Once the starter‑mounted solenoid is engaged, the high current needed to run the starter motor flows: From the battery positive (+) post to the engine‑mounted hot stud (red battery cable) From the hot stud to the starter‑mounted solenoid (red battery cable) Page 4A-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 301: Starter Relay
55252 For additional details, refer to Section 4E ‑ Electrical System Overload Protection. Battery Cables for MerCruiser Models IMPORTANT: The OEM or designer of the vessel is responsible for selecting the proper battery cable size to replace the minimum size listed in the Circuit Length and Cable Size table, if the cables are used for electrical loads in addition to cranking the engine.
Page 302: Hot Stud
Two numbers are provided for minimum cable size. The second number (in parentheses) is the American Wire Gauge (AWG) cable recommended by MerCruiser for the indicated cranking circuit length. The first number is an approximate cross‑sectional area equivalent to the AWG number, expressed in square millimeters (mm ).
Page 303: Starter Removal
If they are clean and gold in color, the starter motor has not had water inside of it. • If they are dirty and discolored the starter motor may have water contamination and should be replaced. IMPORTANT: Starter damage caused by water contamination is not covered by the Mercury MerCruiser warranty. Starter Solenoid Removal Disconnect the jumper between the starter motor and solenoid by removing the nut on the lower solenoid stud.
Page 304: Starter Installation
NOTE: The positive battery cable should be connected from the battery to the hot stud, and then to the starter. Description lb‑in. lb‑ft Battery terminal nut – Coat all terminals with Liquid Neoprene. Page 4A-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 305: Starting System Tests
87 of the relay (refer to Starting System Electrical Diagrams for circuit details). 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4A-11...
Page 306: Voltage Drop Test
Move the voltmeter positive (+) lead to the battery cable itself, which is inside the crimped battery cable ring terminal. Test each battery cable connection in this manner back to the battery post. Page 4A-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 307 Ignition Components............4B-3 Installation..............4B-4 Wire Color Code Abbreviations..........4B-4 Ignition Coil................ 4B-5 Spark Plug Removal, Inspection, and Installation....4B-4 Ignition Coil Voltage Test..........4B-5 Removal..............4B-4 Removal..............4B-6 Inspection..............4B-4 Ignition Coil Resistance Test........4B-6 Installation..............4B-4 Installation..............4B-7 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4B-1...
Page 308: Precautions
Precautions WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.
Page 309: Waste Spark System Specifications
Firing Order and Ignition Timing Description Specification Firing order 1‑8‑4‑3‑6‑5‑7‑2 Ignition timing Ignition Components Battery Ignition coils Spark plugs Crankshaft position sensor 59408 For diagnostics also refer to the PCM 112 Diagnostic Manual. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4B-3...
Page 310: Wire Color Code Abbreviations
Check for correct routing. Keep the spark plug wires as far away as possible from the engine wiring harness. Installation IMPORTANT: Use only Mercury marine‑grade spark plug wires. Use of aftermarket spark plug wires may result in performance issues not covered by the Mercury limited warranty.
Page 311: Ignition Coil
If battery voltage is not present on the red/yellow wire to the engine ground, there is an open circuit between the splice point and the red/yellow wire connector. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4B-5...
Page 312: Removal
Use a DMT 2004 digital multimeter and perform the following test. Pin A Pin B Coil towers 42625 Ignition Coil Resistance Test (Ω) Between coil towers 7200–8800 Between pin A and B 0.3–0.5 DMT 2004 Digital Multimeter 91‑892647A01 Page 4B-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 313: Installation
Waste Spark System Installation Install the ignition coil onto the engine using two screws. 59409 Ignition coil Screws Wiring harness connector Connect the high‑tension coil lead. Connect the wire harness connector. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4B-7...
Page 315 Alternator Removal............4C-6 Voltage Drop Test (Alternator Circuit)...... 4C-11 Alternator Installation............4C-7 Sensing and Excitation Circuits........ 4C-12 Serpentine Drive Belt............4C-7 Battery Will Not Recharge........4C-13 Sterndrive Models............4C-8 Battery Isolator Diagrams..........4C-14 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4C-1...
Page 316: Precautions
Precautions WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.
Page 317 Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC voltages; records maximums and minimums simultaneously, and accurately H z TEMP reads in high RFI environments. TEMP C O M 4516 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4C-3...
Page 318: Alternator And Brackets Exploded View
Charging System Alternator and Brackets Exploded View 56827 Page 4C-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 319 Torque Ref. No. Qty. Description lb‑in. lb‑ft Coolant crossover and alternator bracket Hex head bolt (M8 x 110) – 25.1 Alternator assembly Hex head screw (M6 x 1.0) – 25.1 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4C-5...
Page 320: Periodic Maintenance
Disconnect the alternator lead and ground wires. Disconnect the alternator excitation wire. Remove the drive belt. Remove the alternator mounting screws, washers, and nuts. Hex flange bolt, washer, and nut Screw 56572 Remove the alternator. Page 4C-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 321: Alternator Installation
IMPORTANT: The brackets and washers on the idler pulleys must be in a certain order or the serpentine belt will come off. All pulleys are referenced as though you were standing in front of the engine looking at the belt. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4C-7...
Page 322: Sterndrive Models
Without a seawater pump Hole not used 57443 Sterndrive Models With a seawater pump Alternator pulley Water circulating pump pulley Crankshaft pulley Seawater pump pulley Belt tensioner Power steering pump pulley 55041 Page 4C-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 323: Replacing
If the tensioner contacts either of the cast stops during operation, check the mounting brackets and the belt length. Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the cast stops. See your authorized MerCruiser dealer for service if these conditions exist. CAUTION Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage.
Page 324: Troubleshooting
Check the alternator drive belt for proper tension, excessive wear, cracks, fraying or glazed surfaces. Replace if necessary. Charging Output Tests Check the drive belt condition and tension. Check battery charge and condition. Connect the digital multi‑tester (DMT) leads directly to the battery posts. Page 4C-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 325: Voltage Drop Test (Alternator Circuit)
Reconnect the coil wire, insert the fuel injector fuse, and verify that all accessories are off. Connect the DMT positive (+) lead to the alternator output terminal. Connect the DMT negative (–) lead to the battery positive (+) post. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4C-11...
Page 326: Sensing And Excitation Circuits
Unplug the purple and red/pink connector from the alternator. Connect the positive (+) digital multi‑tester (DMT) lead to the red/pink lead and the negative (–) DMT lead to the ground terminal. DMT 2004 Digital Multimeter 91‑892647A01 Page 4C-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 327: Battery Will Not Recharge
Check all associated electrical connections and wires (especially battery cables). damaged wiring. Clean and tighten faulty connections. Repair or replace damaged wiring. Faulty alternator Test alternator output, replace if necessary. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4C-13...
Page 328: Battery Isolator Diagrams
Alternator sense wire Battery isolator Auxiliary battery Cranking battery Engine ground 50587 Typical battery isolator with disconnect switch Alternator sense wire Battery isolator Auxiliary battery Battery disconnect switch Cranking battery Engine ground Page 4C-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 329 Charging System 50588 Typical dual-engine application Starboard engine Alternator sense wire Port engine Battery isolator Battery disconnect switch Port engine cranking battery Starboard engine cranking battery Engine ground 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4C-15...
Page 331 Helm Mechanical............4D-20 Installation..............4D-3 Analog Gauge Harness..........4D-22 Analog Gauge Testing............4D-4 MerCruiser Remote Control Only to the Harness Oil Pressure, Fuel Level, and Coolant Temperature Assembly (Control Harness Assembly)....4D-23 Gauges..............4D-4 Power Trim System with a MerCruiser Remote Battery or Voltage Gauge...........
Page 332: Precautions
Precautions WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.
Page 333: Configuring The Pcm Tachometer Signal (Non-Dts)
Remove the holding strap or unscrew the mounting ring around the gauge, and remove the gauge. Installation Position the gauge assembly in the appropriate mounting hole. IMPORTANT: Do not distort the case or bracket by overtightening. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4D-3...
Page 334: Analog Gauge Testing
Turn the ignition switch to the "RUN" or "1" position, whichever applies to the key switch style. The needle of the gauge must be in the indicated position. 48572 Typical gauge Turn the ignition switch to the "OFF" or "0" position, whichever applies to the key switch. Page 4D-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 335: Battery Or Voltage Gauge
Check the position of the gauge needle. If it does not indicate the voltage of the source, replace the gauge. Cruiselog (Engine Hour Meter) Remove the battery cables and fully charge the battery. Remove the wires from the rear of the gauge. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4D-5...
Page 336: Tachometer
72 km/h ± 1.6 km/h (45 mph ± 1 mph) SmartCraft Instrumentation SmartCraft Compatibility IMPORTANT: Digital gauges are available for use on Mercury MerCruiser engines equipped with the ECM 555 or later model controllers. All System Series instruments are compatible with MerCruiser products.
Page 337: Can Bus Overview
If the fuse opens, the engine will stop and will not restart until the fuse is corrected. Boat Wiring NOTE: Twin engines are treated as two single engines in the same boat. No twin engine disconnect is required. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4D-7...
Page 338: Boat Harness Installation Guidelines-Mpi Sterndrive
Use the proper length harness from the Y to the upper station. 25132 Y-adapter for dual helm installations Boat Harness Installation Guidelines—MPI Sterndrive Boat Harness Connector to Engine Select the boat harness by length. Page 4D-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 339 To modify the non‑DTS key switches, cut the black/yellow stripe wire at each key switch and cover both open wire ends with heat shrink tubing. Typical key switch Black/yellow stripe wire 25136 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4D-9...
Page 340 The trim switch connection on the helm harness is only used on Mercury outboard remote controls. MerCruiser models require a separate trim harness from the trim control to the power trim pump connection. A Y‑harness is available with adapters to connect the dual helm power trim harnesses together to connect to the transom harness. DTS models do not need the separate trim harness.
Page 341 Optional E-Stop The E‑stop lanyard switch connection is used on Mercury outboards and can be used on MerCruiser MPI engines. The black and black/yellow wires are connected together through a lanyard switch that is normally open. When the lanyard is pulled and the switch is tripped, the circuit will close and ground the ECM to shut the engine off.
Page 342 This transom harness is designed so that connections can be made after the transom is installed in the boat but before the engine is installed. Connections made before the engine is installed are: • MerCathode connection • Trim connections Page 4D-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 343 Wire Color Abbreviations Black Blue Brown GRY or GRA Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4D-13...
Page 344: System Link Gauges
Malfunction indicator lamp (MIL) kits containing a dash‑mounted service engine light and a special harness that connects to the engine harness may be purchased separately. Page 4D-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 345: Audio Warning System
If the helm has not been properly configured using the G3 service tool, the audio warning system will sound for five one‑second intervals. Horn (on or off) Time (in seconds) 53402 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4D-15...
Page 346: Guardian Strategy
Listen for the audio alarm. The alarm will sound if the system is functioning correctly. Guardian Strategy The MerCruiser Engine Guardian system reduces the potential for engine damage by restricting engine power when the PCM detects a potential problem. Below are some examples of what Engine Guardian monitors: •...
Page 348 Instrumentation and Controls BLK/GRN GRY/RED PPL/BLK BLK/GRN PPL/BLK WHT/ORN ORN/PNK PPL/BLK BLK/GRN BRN/PNK WHT/ORN GRY/RED YEL/WHT ORN/PNK BRN/PNK BLU/BLK GRN/BLK GRN/WHT LT BLU/WHT 55583 Page 4D-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 349 TAN/YEL 58503 Transmission shift sensor Steering/pitot sensor 16‑pin transom harness connector Transmission over‑temperature sensor Trim/transmission over‑temperature sensor ground Shift solenoid B Shift solenoid A Reverse pressure sensor Forward pressure sensor 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4D-19...
Page 350: Helm Mechanical
Instrumentation and Controls Helm Mechanical Drawing 14-pin Non-DTS 14‑pin Deutsch connector Key switch connector Trim switch (outboard control) Neutral switch Lanyard switch (MerCruiser control) or key switch + connection Lanyard (outboard control) E‑stop connection Warning horn 12340 Accessory relay connection (15...
Page 351 Up to 15 amps total accessory power can be provided; on purple wire (switched) and the red wire (continuous power). An accessory relay kit can be used for loads up to 40 amps. Refer to the MerCruiser Parts and Accessory Guide or MerCruiser Rigging Guide.
Page 352: Analog Gauge Harness
DK_BLU BRN_WHT LTBLU LTBLU DK_BLU 12318 Connector to boat harness Trim Tach Key on (+) Temp Ground (–) CAN (+) or spare CAN (–) or spare 10 - 12V (+) Page 4D-22 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 353: Mercruiser Remote Control Only To The Harness Assembly (Control Harness Assembly)
Instrumentation and Controls MerCruiser Remote Control Only to the Harness Assembly (Control Harness Assembly) Connection to control box helm control Connection to transom harness Connections to trim limit switch 12323 Connection to control box Connection to transom harness Connections to trim limit...
Page 354: Power Trim System With A Mercruiser Remote Control
Instrumentation and Controls Power Trim System with a MerCruiser Remote Control 58236 MerCruiser remote control 4‑pin Molex connector To ignition switch harness 3‑pin connector Power trim extension harness Transom harness 16‑pin connector to engine harness Steering Digital trim Pitot MerCathode...
Page 355: Power Trim System With An Outboard Remote Control
Transom harness 16‑pin connector to engine harness Steering Digital trim Pitot MerCathode Trim pump connection Not used with the outboard remote control Trim pump Ground Up solenoid Down solenoid 20‑amp fuse 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4D-25...
Page 356: 14-Pin Engine Harness Connector
To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system. Page 4D-26 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 357: Weather Caps
NOTE: Connect only one data harness of the required length between the engine and helm. If a data harness is too short, do not connect multiple harnesses together to make up the required length. For installations requiring a data harness length longer than 12.2 m (40 ft), contact Mercury Marine for more information. Weather Caps Weather caps are to be used whenever there are any unused connectors on a harness.
Page 358: Junction Box (If Equipped)
Fasten all junction box connections within 25.4 cm (10 in.) of the junction box. • Seal all unused connections with weather caps. Clamp Weather cap (859318T 2) Junction box 25.4 cm (10 in.) DTS command module harness 29220 Page 4D-28 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 359 Port Side View............4E-4 Transom Harness............4E-10 Propulsion Control Module (PCM)........4E-5 Transom Harness Wiring Diagram (Sterndrive)..4E-10 PCM 112 Controller............ 4E-5 Wire Color Code Abbreviations........4E-12 PCM Removal and Installation........4E-5 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4E-1...
Page 360: Engine Control And Sensor Locations
Starboard precatalyst oxygen sensor connection Fuses 10‑pin diagnostics 50‑amp circuit breaker J1939 diagnostic connection Port precatalyst oxygen sensor connection Port postcatalyst oxygen sensor connection PCM 112 Starboard postcatalyst oxygen sensor Page 4E-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 361: Rear View
Electrical Components Rear View 59413 Ignition coils (4) Seawater pump pressure sensor Hot stud 90‑amp fuse Oil pressure sensor 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4E-3...
Page 362: Port Side View
Electrical Components Port Side View 59414 Fuel pump relays, starter relay, and main power relay Trim relays MerCathode Page 4E-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 363: Propulsion Control Module (Pcm)
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4E-5...
Page 364 Remove connector A in the same manner. NOTE: When installing the PCM, attach the connectors in the reverse order: connector A first, followed by connector B, and finally, connector C. Page 4E-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 365: Electrical System Overload Protection
The main circuit breaker is located at the front of the engine next to the engine oil fill port, beneath the engine cover. It provides overload protection for the engine wiring harness and the instrumentation power lead. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4E-7...
Page 366: Fuses
Engine and trim relays Spare fuse Alternator and fuel pump relay Fuel injectors DTS helm power Malfunction indicator lamp (MIL) Ignition coils Oxygen sensor fuses (4) Fuse holder location 58288 Page 4E-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 367 For circuit protection, the MerCathode system has a 5‑amp blade fuse connected into the controller's positive (+) lead. If the fuse is open, the system will not operate and will not protect against corrosion. Replace an open fuse with the same style and rating as that which is removed. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4E-9...
Page 368: Transom Harness
Electrical Components Transom Harness Transom Harness Wiring Diagram (Sterndrive) BLK/GRN GRY/RED PPL/BLK BLK/GRN PPL/BLK WHT/ORN ORN/PNK PPL/BLK BLK/GRN BRN/PNK WHT/ORN GRY/RED YEL/WHT ORN/PNK BRN/PNK BLU/BLK GRN/BLK GRN/WHT LT BLU/WHT 55583 Page 4E-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 369 TAN/YEL 58503 Transmission shift sensor Steering/pitot sensor 16‑pin transom harness connector Transmission over‑temperature sensor Trim/transmission over‑temperature sensor ground Shift solenoid B Shift solenoid A Reverse pressure sensor Forward pressure sensor 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 4E-11...
Page 370: Wire Color Code Abbreviations
Wire Color Abbreviations Black Blue Brown GRY or GRA Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark Page 4E-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 371 Fuel System Module........... 5A-9 Fuel Delivery Systems.......... 5A-31 Fuel System..............5A-10 Equipment Used to Test Fuel RVP, Fuel Fuel Delivery System..........5A-10 Temperature, or Fuel System Vacuum....5A-32 Anti‑Siphon Valve............. 5A-10 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-1...
Page 372: Precautions
Precautions WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.
Page 373: Fuel Pressure Specifications
Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).
Page 374: Gasoline Containing Alcohol
Bu16 Butanol Fuel Blends Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines, and fittings).
Page 375 • Appropriate sized barbed hose fitting. • Fuel pressure adapter (90‑803135) from Mercury or other equivalent adapter. Pressure relief collection tool One‑gallon fuel can (collection tank) Separate fuel can vent Clear hose Fuel pressure adapter (90‑803135)
Page 376: Priming The Fuel System
A portable fuel tank is connected to the engine and no fuel is in the boat fuel tank. After test running the engine connect the fuel line from the boat fuel tank to the fuel system. Follow the precautions in the appropriate Mercury MerCruiser Installation Manual for disconnecting the portable fuel tank and reconnecting the fuel line from the boat fuel tank to the boat fuel system.
Page 377: Important Information
Wipe up any fuel that may have spilled. 10. Ventilate the engine compartment. 11. After priming the fuel system, continue the engine preparation. Refer to the appropriate Mercury MerCruiser Installation Manual. All other procedures in the installation manual remain the same.
Page 378: Fuel Supply Connections
Exploded Views Fuel Rail Exploded View 59419 Torque Ref. No. Qty. Description lb‑in. lb‑ft Schrader valve Fuel connection Fuel rail mounting screws 12.2 – Fuel injector retainer Fuel injector O‑ring Page 5A-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 379: Throttle Body
Clamp Flame arrestor Clamp cover 59421 Fuel System Module Water‑separating fuel filter Fuel supply module Manifold hose Hose to fuel rail Supply hose Cooling hose Hose to strainer assembly 56553 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-9...
Page 380: Fuel System
IMPORTANT: The electric fuel pump and factory installed water‑separating fuel filter have been carefully designed to function properly together. Do not install additional water‑separating fuel filters between the fuel tank and the engine. Use the Mercury in‑line fuel filter with the boost pump.
Page 381: Fsm Disassembly
NOTE: The FSM cannot be completely drained of fuel prior to disassembly. Use appropriate containers to capture fuel during the disassembly process. Wipe up fuel spills immediately and dispose of in an appropriate container. Place the FSM in an appropriate container to capture any fuel that will spill. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-11...
Page 382 Insert two pry tools between the upper and lower housing and carefully separate the housing. NOTE: Use caution when separating the housing. The lower housing may be completely filled with fuel. 49141 Carefully lift the upper housing to access the power wire connections. Page 5A-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 383 49318 Remove the manifold from the tubes and fuel pumps. Manifold Fuel lift pump Tubes (4) High‑pressure fuel pump 49147 Remove the tubes and fuel pumps from the lower housing. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-13...
Page 384 12. Carefully spread the retainers and remove the fuel pressure regulator. IMPORTANT: Use extreme care not to spread the retainers excessively. Spreading the retainers excessively will cause the retainer to break off the manifold. Page 5A-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 385: Fsm Assembly
Lubricate the O‑rings on the tubes with 2‑4‑C with PTFE. O‑rings Water tube Fuel tube 49167 Tube Ref No. Description Where Used Part No. 2-4-C with PTFE O-rings 92-802859A 1 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-15...
Page 386 Install the fuel tubes into the lower housing. 49168 Install the water tubes. Water tube Fuel tube 49199 Install the seal grommet halfway onto the high‑pressure fuel pump outlet. 49206 Page 5A-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 387 Install the fuel lift pump into the lower housing so the outlet port of the pump faces towards the center of the FSM. Install the seal grommet halfway onto the outlet port of the fuel lift pump. 10. Install the seal grommet onto the high‑pressure fuel pump. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-17...
Page 388 Ensure the fuel pump wires are not binding between the water tube and the fuel pump. Manifold seated on fuel pump Wires are not binding 49223 15. Verify the spacer is installed onto the fuel pressure regulator. Page 5A-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 389 23. Install new O‑rings onto the fuel pump wire harness seal grommet. Verify the blue O‑ring is installed on the upper groove of the seal grommet. Lubricate the O‑rings with 2‑4‑C with PTFE. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-19...
Page 390 28. Lubricate all the visible O‑rings and seal grommets with 2‑4‑C with PTFE. Black wires Red wires 49234 Tube Ref No. Description Where Used Part No. 2-4-C with PTFE O-rings and seal grommets 92-802859A 1 Page 5A-20 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 391 32. Install a 16.2 mm metal hose clamp onto the high‑pressure hose and install the hose onto the FSM upper housing. Use the hose clamp tool to secure the hose to the FSM. 57375 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-21...
Page 392: Throttle Body
Inspect the gasket mating surfaces for damage that could affect sealing. Inspect the throttle body casting for cracks. Inspect the throttle plates, linkage, return springs, and other components for damage, wear, and foreign material. Page 5A-22 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 393: Throttle Body Installation
Use compressed air to remove dirt and debris from the fuel rail and injector area before removing the rail and injectors. Remove the PCM relay bracket as follows. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-23...
Page 394 Disconnect the three PCM connectors. To release the connector, push the locking tab and rotate the lock as shown. Locking tab Shift anticipate connector (not used 6.2L) Neutral switch connector Demand sensor harness 56514 Disconnect the neutral switch connector, and the demand sensor harness. Page 5A-24 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 395 OBD‑M MIL light Clean power connector Cable ties h h h 56516 Remove the remaining relays and the transom harness connector. Remove the clean power connector and the OBD‑M MIL light connector. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-25...
Page 396 Disconnect the manifold absolute pressure (MAP) sensor and lift it off the PCM relay bracket. Loosen the clamp and remove the flame arrestor. Flame arrestor Clamp securing the flame arrestor 58395 Page 5A-26 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 397: Installation
Installation NOTE: Refer to the illustrations in the Removal procedure as necessary. Inspect the fuel injector seals for damage. Replace if necessary. Attach the injectors to the fuel rails. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-27...
Page 398 Install the four mounting screws, holding the PCM relay bracket to manifold. Connect the neutral switch connector, and the demand sensor harness. 10. Install the engine cover. 11. Connect the battery, installing the positive (+) battery lead first. Page 5A-28 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 399: Fuel Rail Pressure Damper
PCM connector A Injector 6 Injector 8 Injector 4 Injector 3 Injector 2 Injector 1 Injector 7 Injector 5 10 - Engine fuses 11 - From main power relay terminal 87 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-29...
Page 400: Troubleshooting
12. Reattach the reference line. The pressure should drop back to the initial pressure with the engine running. 13. Stop the engine. 14. Turn off the cooling water. 15. Correct the problem, if the system is out of specification. Page 5A-30 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 401: Checking For Restrictions/Vapor Lock Problems In Fuel Delivery Systems
EFI fuel system There is a MerCruiser specification for allowable vacuum, when measured at the inlet side of the engine‑mounted MerCruiser water‑separating fuel filter or if there is none mounted on the engine, at the inlet side of a fuel pump. Use a digital vacuum gauge (an analog gauge may not give accurate enough readings at these low levels) that reads in either kPa (kilopascals) or in.
Page 402: Equipment Used To Test Fuel Rvp, Fuel Temperature, Or Fuel System Vacuum
2.7 kPa (0.8 in. Hg) Good See MerCruiser Service Bulletin 99‑7 (Rev. 1/01) for information on gasoline engine vapor locking. Equipment Used to Test Fuel RVP, Fuel Temperature, or Fuel System Vacuum The following information is contained in Mercury MerCruiser Service Bulletin 99‑7 (Revised October 2000).
Page 403 From fuel supply T‑fitting 6.35 mm (1/4 in.) Water‑separating fuel filter Pipe fitting 6.35 mm x 38 mm (1/4 in. x 11/2 in.) Schrader valve Temperature probe Compression fitting Reducer bushing 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 5A-33...
Page 405 Seawater Pump Assembly..........6A-7 Poppet Valve Replacement........6A-15 Water Circulating Pump............. 6A-9 Water Distribution Housing..........6A-16 Removal..............6A-9 Removal..............6A-16 Cleaning and Inspection........... 6A-10 Cleaning and Inspection........... 6A-16 Installation..............6A-10 Water Distribution Housing Installation.....6A-16 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6A-1...
Page 406: Seawater Inlet Specifications
General Cooling System Information Mercury MerCruiser engines come equipped with either standard cooling or closed cooling. On engines with standard cooling, the engine is cooled entirely by seawater (the water in which the boat is being operated). Closed‑cooling systems use two cooling circuits, one of which uses seawater similarly to standard cooing.
Page 407: Seawater Pump Output Test
The supply hose—from the engine to the heater, and return hose—from the heater to the engine, must not exceed 16 mm (5/8 in.) inside diameter (ID). • Using the water heater fitting kit, make the heater connections only at the locations shown. Refer to the Mercury Precision Parts Accessories Guide, for kit details. •...
Page 408: Supply Hose Connection
Location for the water supply—to the heater 55241 Return Hose Connection All models—water circulating pump housing Cam sensor, remove connector Location for the hot water return—from the heater, use 3/8 hex socket to remove 60065 Page 6A-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 409: Seawater Pump (If Equipped)
M10 x 35 hex flange screw 40.7 – M10 hex flange nut 67.8 – Seawater Pump Replacement NOTE: The seawater pump does not need to be removed for servicing the impeller or wear plate. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6A-5...
Page 410: Seawater Pump Disassembly
Using an appropriate puller, remove the hub from the bearing shaft assembly. Remove the lip seal from the front of the seawater pump housing. Remove the snap ring. Press the bearing shaft assembly out of the housing from the impeller side. Page 6A-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 411: Cleaning And Inspection
Use 2‑4‑C with PTFE to lubricate the bearing shaft next to the rear shaft bearing, so that the lubricant is between the rear oil seal and the rear shaft bearing when the shaft is installed. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6A-7...
Page 412 Outer diameter of the lip seal Obtain Locally Install the lip seal onto the bearing shaft assembly and slide it down until it contacts the end of the impeller housing. 56789 Lip seal Page 6A-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 413: Water Circulating Pump
Mark the direction of belt rotation and remove the serpentine drive belt. Remove the water circulating pump pulley screws and pulley. Remove the water circulating pump fasteners (three screws and one stud) and the water circulating pump. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6A-9...
Page 414: Cleaning And Inspection
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. Supply cooling water to the engine. 10. Start the engine and check for leaks. Page 6A-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 415: Air-Actuated Drain System
Removing the snap ring from the top of the air‑actuated drain valve can allow the components to come apart forcefully, resulting in injury or product damage. Do not try to repair the valve or remove the snap ring. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6A-11...
Page 416: Air Manifold
When there is no water pressure from the seawater pump, such as when the engine is off, the check ball falls down into the grooved drain fitting. This allows water to drain from the exhaust manifold, elbow, and seawater hoses (depending on cooling system type). Page 6A-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 417: Exploded View
Use a screwdriver to pry the drain fitting from the assembly. Discard the drain fitting. Inspect the remaining parts for debris or damage. Clean or replace parts as necessary. Use a new drain fitting for reassembly. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6A-13...
Page 418: Poppet Valve
There are two major functions of the poppet valve. The poppet valve controls the amount of seawater supplied to the exhaust system from idle to wide‑open throttle. Page 6A-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 419: Poppet Valve Replacement
Slide the poppet subassembly into the poppet valve housing. Use two screws to secure the housing cover to the poppet housing. Tighten all screws to the specified torque. Description lb‑in. lb‑ft Poppet assembly screws 75.2 – 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6A-15...
Page 420: Water Distribution Housing
Inspect the housing for leaks, cracks, or corrosion damage. Replace, if necessary. Water Distribution Housing Installation Align the water distribution housing with the bracket. Install and tighten the screws to the specified torque in the following order. Top right screw Page 6A-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 421 Drain rod Water distribution housing 56692 Ensure that the rod is correctly aligned. The rod must screw in and out of the water distribution housing easily and with minimal pressure. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6A-17...
Page 422 6 mm (1/4 in.) onto the connectors. Connect the 3/16 in. O.D. air lines into the lower connectors on the air manifold, the water distribution housing, and the seawater pump. Page 6A-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 423 Pull on the lines to ensure that each air line is securely connected. Secure the air lines with cable ties. Connect the hoses to the water distribution housing. Securely tighten the hose clamps. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6A-19...
Page 425 Section 6B - Models with Standard Cooling Table of Contents Specifications..............6B-2 Thermostat Removal from the Crossover....6B-2 Crossover with Thermostat—Exploded View.....6B-2 Thermostat Testing.............6B-2 Thermostat Assembly............6B-2 Thermostat Installation into the Crossover....6B-3 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6B-1...
Page 426 Remove the thermostat cap gasket, thermostat, and thermostat housing gasket from the crossover assembly. Thermostat Testing Remove the thermostat. Place the thermostat on blocks in a container. Add water to the container until it covers the thermostat. Page 6B-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 427 Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. Supply cooling water to the engine. Start the engine and inspect for leaks. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6B-3...
Page 429 Heat Exchanger Disassembly........6C-18 Maintaining Coolant Level........6C-11 Cleaning and Inspection........... 6C-18 Pressure Cap Maintenance and Testing......6C-11 Heat Exchanger Repair..........6C-18 Testing the Closed‑Cooling System........ 6C-12 Heat Exchanger Installation........6C-19 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6C-1...
Page 430: Specifications
14.3 L (15.1 US qt) Thermostat operating temperature 77° C (170° F) Pressure cap rating 110 kPa (16 psi) Coolant Specification Description Part Number Extended Life Coolant (orange color) 92‑877770K1 Page 6C-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 431: Heat Exchanger Assembly-Exploded View
Blue vacuum release plug Hand‑tight Purge valve Pressure cap Hex head cap screw 14.9 131.8 – Screw with captive lockwasher 60.1 – Thermostat cover Thermostat seal Thermostat (77° C [170° F]) 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6C-3...
Page 432: Crossover For Closed Cooling-Exploded View
Northern Hemisphere or below the 50th parallel of the Southern Hemisphere. When additional water inlets are used, a Y‑fitting is installed onto the seawater pump. Refer to Installing the Y‑Fitting. Page 6C-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 433: Installing The Y-Fitting
Y‑fitting port to water inlet at transom Y‑fitting port to through‑the‑hull or through‑the‑transom seawater pickup 10 cm (4 in.) hose, from seawater pump inlet to Y‑fitting port Seawater pump 56840 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6C-5...
Page 434: Installing The Seawater Supply Hose
Models with Closed Cooling NOTE: For models not factory equipped with a Y‑fitting, refer to Mercury Parts Catalog, Closed ‑ Cooling Systems (Bravo) to order the specified Y‑fitting, seawater supply bulk hose, and hose clamps that meet MerCruiser specifications. Cut a 10 cm (4 in.) piece of the supply hose and connect it to the seawater pump inlet and the Y‑fitting port.
Page 435: Seawater Strainer
Some industry standards and regulations require that the pickup be connected into the boat's bonding system to minimize stray current corrosion. Refer to applicable standards and regulations for more details. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6C-7...
Page 436: Seacock
Refer to applicable standards and regulations for specific requirements. The seacock also allows the seawater to be shut off when servicing the engine. Page 6C-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 437: Seawater Strainer
Seawater Strainer Installation Refer to the manufacturer's instructions for detailed installation, operation, and maintenance. IMPORTANT: Use the following guidelines when installing a Mercury seawater strainer. Position the seawater strainer in an appropriate location, below the level of the seawater pump.
Page 438: Cleaning The Seawater Strainer, If Equipped
400 hours of operation, whichever comes first. In areas where the possibility of freezing does not exist, it is permissible to use a solution of rust inhibitor and water (mixed to manufacturer's recommendations). Page 6C-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 439: Maintaining Coolant Level
Inspect the gasket (if used) and the rubber seal on the cap for tears, cuts, cracks, or other signs of deterioration. Replace the gasket, if damaged. Replace the cap if the rubber seal is damaged. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6C-11...
Page 440: Testing The Closed-Cooling System
A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap. Page 6C-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 441: Seawater Pressure Test
If no leakage can be found in the above steps, the entire engine must be disassembled and inspected for leaks. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6C-13...
Page 442: Testing For A Cylinder Head Gasket Leak
Wooden blocks Stirring rod Thermometer Thermostat 50079 Observe the thermostat and check the temperature when the thermostat fully opens. If the temperature is not within specifications, then replace the thermostat. Page 6C-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 443: Thermostat Installation
Remove the pressure cap from the coolant tank. On the port and starboard sides of the engine block, remove the block pipe plugs. Drain the coolant into a proper container. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6C-15...
Page 444: Cleaning The Cooling System
Remove the pressure cap from the heat exchanger. Open the vent on the top of the thermostat housing to purge the air from the system. Page 6C-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 445: Heat Exchanger Assembly
Remove each air line from the air manifold by pressing on the fitting and pulling the line out. Release location Air line fitting Air line 50080 Remove the hoses from the heat exchanger. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6C-17...
Page 446: Heat Exchanger Disassembly
Assemble the heat exchanger. Tighten the heat exchanger end cap fasteners to the specified torque. Description lb‑in. lb‑ft Heat exchanger end cap fasteners 14.9 131.8 – Fasten the air manifold and bracket to the heat exchanger. Tighten the nut to the specified torque. Page 6C-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 447: Heat Exchanger Installation
Pump air into the system until both green indicators extend. If the green indicators do not extend, the air lines are not attached properly. Fill the closed‑cooling system with the specified coolant. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6C-19...
Page 449 Glycol Circuit Inboard V‑Drive ........6D-8 Models with Closed Cooling..........6D-4 Glycol Circuit Inboard In‑line ........6D-10 Seawater Circuit (All Models with Closed Cooling) Glycol Circuit TowSport Reverse V‑Drive ....6D-12 ................6D-4 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6D-1...
Page 450: Models With Standard Cooling
Water Flow Diagrams Models with Standard Cooling Bravo with Air‑Actuated Drain 60019 Page 6D-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 451 Water circulating pump Port engine block drain hose To engine block (from water circulating pump) Oil cooler NOTE: When the poppet valve opens water will flow into (r and s) 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6D-3...
Page 452: Models With Closed Cooling
Water Flow Diagrams Models with Closed Cooling Seawater Circuit (All Models with Closed Cooling) 59995 Page 6D-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 453 Oil cooler Exhaust and seawater outlet Fuel supply module water inlet strainer Exhaust elbow seawater inlet—poppet valve closed Fuel supply module Exhaust elbow seawater inlet—poppet valve open Distribution housing Seawater pump 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6D-5...
Page 454: Glycol Circuit Towsport V-Drive
Water Flow Diagrams Glycol Circuit TowSport V‑Drive 60455 Page 6D-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 455 Water circulating pump Detail of rear of heat exchanger, showing thermostat (shaded) To engine block—from water circulating pump NOTE: Seawater hoses are not shown, for clarity. To crossover (from engine block) 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6D-7...
Page 456: Glycol Circuit Inboard V-Drive
Water Flow Diagrams Glycol Circuit Inboard V‑Drive 60455 Page 6D-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 457 No inlet hose to the sea pump To crossover (from engine block) on Inboard V‑Drive and transmission cooler oil lines are Exhaust manifold coolant inlet different. Exhaust manifold coolant outlet 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6D-9...
Page 458: Glycol Circuit Inboard In-Line
Water Flow Diagrams Glycol Circuit Inboard In‑line 59982 Page 6D-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 459 Water circulating pump Detail of rear of heat exchanger, showing thermostat (shaded) To engine block—from water circulating pump NOTE: Seawater hoses are not shown, for clarity. To crossover (from engine block) 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6D-11...
Page 460: Glycol Circuit Towsport Reverse V-Drive
Water Flow Diagrams Glycol Circuit TowSport Reverse V‑Drive 59982 Page 6D-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 461 To crossover (from engine block) the seawater circuit. There is an inlet hose to the sea Exhaust manifold coolant inlet pump, and the transmission cooler oil lines are different. Exhaust manifold coolant outlet 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 6D-13...
Page 463 Loading the Boat (Boats without a Capacity Plate) System................7A-2 ................7A-6 Determining Catalyst Health..........7A-2 Clear Hose Measurement Method......7A-8 Measuring Engine Exhaust Elbow Height......7A-3 Clear Hose Measurement Method from Seacock or General Information............ 7A-3 Muffler Drain............7A-9 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7A-1...
Page 464: Exhaust System Notice
ABYC Standards. Exhaust system connections to components other than those supplied by Mercury MerCruiser must use two stainless steel clamps with a minimum width of 13 mm (1/2 in.) at each joint.
Page 465: Measuring Engine Exhaust Elbow Height
Measurements for all loading conditions must meet the following specifications: Minimum Exhaust Elbow Height Model Specification Sterndrive 27.9 cm (11 in.) TowSport and inboard 33 cm (13 in.) 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7A-3...
Page 466: Loading Requirements
• 1 U.S. gallon of gasoline = 6 lb • 1 liter of gasoline = 0.72 kg For the purpose of MerCruiser waterline height measurements: • One person is equivalent to 74.84 kg (165 lb) • Cargo per person is equivalent to 11.34 kg (25 lb) Add weight for any additional boat options: extra battery, battery charger, tower, arch, generator, ballast tanks, ballast sacks, television, carpet, anchor, stereo/entertainment equipment, washer/dryer, safe, etc.
Page 467 Maximum load (persons and gear) from capacity plate – swim platform load = remaining weight to be placed in the boat. • 1100 lb – 400 lb = 700 lb Remaining weight to be placed in the boat ÷ MerCruiser person weight = number of persons to load onto the boat. • 700 lb ÷ 165 lb = 4.24 persons Total number of persons –...
Page 468: Loading The Boat (Boats Without A Capacity Plate)
55 in. (bench seat length) ÷ 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons. Total number of persons that can sit on designated seating excluding cabin space × MerCruiser person weight = maximum passenger load for measurement.
Page 469 225 lb × 25% = 56.25 lb • 56.25 lb rounded down = 56 lb To determine the maximum number of passengers to load onto the boat, multiply 9 passengers by 165 lb (MerCruiser person weight) to get a 1485 lb (total passenger load). •...
Page 470: Clear Hose Measurement Method
Important Information Divide the remaining weight to be placed onto the boat by the MerCruiser person weight to get the maximum number of passengers to load onto the boat. • 985 lb ÷ 165 lb = 5.9 passengers • 5.90 passengers rounded up = 6 passengers Using the totals in this example load 56 lb cargo in the aft storage, 113 lb cargo in the center storage, and 56 lb cargo in the bow storage onto the boat before adding passenger weight.
Page 471: Clear Hose Measurement Method From Seacock Or Muffler Drain
Slowly take your finger off of the end of the hose to let the water level stabilize. The water will seek the level of the water in the muffler. Keep the hose close to the exhaust elbow and as vertical as possible. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7A-9...
Page 472 V-Drive to sea pump pulley Clear hose for measuring waterline Minimum exhaust elbow height with maximum load Exhaust distance sea pump to muffler 15.24 cm–60.96 cm ( 6 in.–24 in.) Sea pump pulley Page 7A-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 473 Important Information IMPORTANT: Horizontal waterlift mufflers are NOT permitted for use. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7A-11...
Page 475 Intermediate Exhaust Elbow Kit........7B-7 Removal..............7B-16 Riser Kits..............7B-7 Installation..............7B-16 Exhaust Elbow Removal..........7B-7 Exhaust Manifold Coolant Temperature (EMCT) Sensor Exhaust Elbow Installation..........7B-8 ..................7B-16 Exhaust Manifolds............7B-10 Removal..............7B-16 Exhaust Manifold Removal........7B-10 Installation..............7B-16 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7B-1...
Page 476: Elbow-To-Manifold Gaskets
51103 51104 Models with closed cooling Seawater-cooled models Blocked water ports Open water ports Indicator tabs No indicator tabs Page 7B-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 478: Exhaust Manifold And Elbow Exploded View
Manifolds and Elbows Exhaust Manifold and Elbow Exploded View 60035 Page 7B-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 479 Brass plug – 36.8 Straight fitting (0.750‑14) (closed cooling) – 36.8 Wideband oxygen sensor – 36.8 Straight fitting with threaded hole (0.750‑14 with 0.25‑18 hole) Hand‑tight—plus two turns Check valve – 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7B-5...
Page 480 Manifolds and Elbows Exhaust Manifold and Elbow Exploded View 60035 Page 7B-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 481: Exhaust Elbows
Cover bracket O2 sensor 8M2004597 Screw, 1/4‑20 hex flange 8M2007128 Plug O2 sensor (non‑ECT) 8M0082363 Copper washer (non‑ECT) 8M0097283 Exhaust Elbow Removal Turn the engine off and allow it to cool. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7B-7...
Page 482: Exhaust Elbow Installation
Select the appropriate elbow‑to‑manifold gasket for your cooling type. Refer to the table below. Cooling Type Gasket Ports Part Number Models with seawater cooling Open water ports 8M2004414 Models with closed cooling Blocked water ports 8M2004606 Page 7B-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 483 Connect the hose from the top fitting on the poppet valve to the fitting nearest the exhaust outlet. • Connect the hose from the bottom fitting on the poppet valve to the fitting nearest the EMCT sensor. • Tighten both hose clamps to the specified torque. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7B-9...
Page 484: Exhaust Manifolds
On models with closed cooling, drain the coolant until the level is below the exhaust elbow joint area. Refer to Section 6C ‑ Draining. Note the locations and connections of the hoses for reassembly. Page 7B-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 485 It may be necessary to remove the elbow and the catalyst to reduce the weight of the assembly to an amount that is safe to lift without the use of a hoist. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7B-11...
Page 486: Manifold Cleaning And Inspection
Replace all damaged parts. Exhaust Manifold Installation Ensure that the mating surfaces on the manifold and the cylinder head are clean and free from defects. Page 7B-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 487 Attach all cooling hoses, securing them with hose clamps to the specified torque. Connect the exhaust hoses, securing them with two hose clamps to the specified torque at each connection point. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7B-13...
Page 488 Exhaust manifold mounting screws (6) 59455 Freshwater cooled Exhaust hose (shown attached to intermediate elbow, other models similar) Seawater bypass hose Exhaust manifold coolant temperature sensor Seawater hose from poppet valve 56945 Page 7B-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 489: Oxygen Sensor
13. Connect both battery cables. Be certain to connect the negative (–) cable last. 14. Upon starting the engine, inspect all exhaust and cooling hose connections for leaks. Oxygen Sensor 51233 NOTE: Refer to the appropriate exploded view for oxygen sensor location. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7B-15...
Page 490: Removal
Hand‑start the EMCT sensor into the exhaust elbow. Tighten the EMCT sensor to the specified torque. Description lb‑in. lb‑ft Sensor – Connect the EMCT sensor connector to the engine harness. Page 7B-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 491 Hose Clamp Identification..........7C-4 General Information............7C-7 Tridon® Hose Clamp..........7C-4 Exhaust Angle Measurement........7C-8 6.2L Exhaust..............7C-4 Component Replacement..........7C-8 Switchable Exhaust............7C-5 Through‑the‑Propeller Exhaust........7C-8 6.2L MIE Exhaust Installation ........7C-5 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7C-1...
Page 492: Exhaust System Components
Exhaust Pipe and Through-the-Propeller Exhaust Exhaust System Components 56958 Page 7C-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 493 4–4.7 35.4–41.6 – Exhaust tube Exhaust pipe Water shutter assembly Grommet Screw – 25.1 Lockwasher NOTE: Torque values shown are for Tridon® hose clamps. Refer to Hose Clamp Identification . 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7C-3...
Page 494: Hose Clamp Identification
Exhaust Pipe and Through-the-Propeller Exhaust Hose Clamp Identification IMPORTANT: Tridon types of hose clamps are used in various locations on Mercury MerCruiser power packages. ® Tridon hose clamp Hex head screw (5/16 in.) Slot cut through the band 57208 Tridon® Hose Clamp ®...
Page 495: Switchable Exhaust
Elbow Outlet Hose Minimum amount shutter assembly inserted into hose 50.8 mm (2 in.) 59018 IMPORTANT: The shutter should be inserted in the hose a minimum 50.8 mm (2 in.). 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 7C-5...
Page 496 ABYC standards also specify the use of stainless steel clamps with a minimum 13 mm (½ in.) bandwidth. Do not use spring tension clamps. Every exhaust hose connection must be secured with at least two stainless steel hose clamps. Page 7C-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 497: Towsport Exhaust
If the exhaust elbow height or exhaust angle is insufficient, modify the exhaust system or install the appropriate exhaust riser. Refer to the appropriate Mercury Precision Parts and Accessory Guide for part numbers. The maximum exhaust riser height is specified in the table below.
Page 498: Exhaust Angle Measurement
IMPORTANT: The exhaust pipe and the gimbal housing mating surface must be clean and free of nicks and scratches, and the O‑ring must be properly seated in the groove or water may leak into the boat. Inspect and clean the mating surfaces on the gimbal housing. Page 7C-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 499 25.1 Water Shutter Replacement IMPORTANT: Exhaust system connections to components other than those supplied by Mercury Marine must use two stainless steel clamps that are at least 13 mm (½ in.) wide at each joint. Remove and retain the intermediate exhaust pipe from the Y‑pipe.
Page 500 Install the exhaust tube and the intermediate exhaust pipe onto the exhaust Y‑pipe and secure with hose clamps. Tighten the hose clamps to the specified torque. Exhaust tube Exhaust Y‑pipe Hose clamps 18530 Description lb‑in. lb‑ft ® 4‑4.7 35.4‑41.6 – Tridon hose clamp (exhaust tube) Page 7C-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 501 Return Hose (Control Valve to Fluid Cooler).... 8A-21 Power‑Assisted Steering Pump Pulley—Removal... 8A-12 Power‑Assisted Steering System Tests......8A-22 Power‑Assisted Steering Pump Pulley—Installation Power‑Assisted Steering System Pressure Test..8A-22 ................8A-13 Pump Pressure Test..........8A-24 Power‑Assisted Steering Pump Assembly.......8A-14 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-1...
Page 502 Removes the pulley on the power steering pump. 18598 Pulley Pusher Installer 91‑ 93656A 1 Installs the pulley onto the power steering pump. 10047 Power Steering Test Gauge Kit 91‑38053A05 Tests the power steering system pressure. 10804 Page 8A-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 503 Power-Assisted Steering Pump and Related Components Notes: 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-3...
Page 504: Power-Assisted Steering Components Exploded View
Power-Assisted Steering Pump and Related Components Power‑Assisted Steering Components Exploded View 57119 Page 8A-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 505 Bracket Strap Clevis pin Clevis pin Cotter pin O‑ring O‑ring Fitting Fitting Cylinder to cooler hose Clamp Power steering cooler Sensor Elbow (45°) Cable tie Fitting to the transom Clamp 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-5...
Page 506: Hydraulic Diagrams
Power-Assisted Steering Pump and Related Components Hydraulic Diagrams Neutral 56916 Page 8A-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 507 The image represents the view from the inside of the boat looking at the transom Piston Control valve Power steering fluid cooler Pump Relief valve (inside of the pump housing) Pump housing High pressure Low pressure 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-7...
Page 508: Left Turn
Power-Assisted Steering Pump and Related Components Left Turn 56915 Page 8A-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 509 The image represents the view from the inside of the boat looking at the transom Piston Control valve Power steering fluid cooler Pump Relief valve (inside of the pump housing) Pump housing High pressure Low pressure 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-9...
Page 510: Right Turn
Power-Assisted Steering Pump and Related Components Right Turn 56914 Page 8A-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 511: Description
Mercury recommends that only the shift cable be routed behind the steering cylinder. Vessel hoses and wiring routed behind the steering cylinder hinders service of the cylinder and may become damaged over time.
Page 512: Power-Assisted Steering Pump
Always disconnect the negative (‑) battery cable first and connect it last. Disconnect both battery cables from the battery. Be certain to disconnect the negative (–) cable first. Remove the serpentine belt. Refer to Section 1C ‑ Replacing Belt. Page 8A-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 513: Power-Assisted Steering Pump Pulley-Installation
Thread the stud from the pulley pusher completely into the power‑assisted steering pump shaft. Place the spacer on the pulley. Place the spacer and the bearing over the pulley pusher stud so that the spacer is against the pulley. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-13...
Page 514: Power-Assisted Steering Pump Assembly
Drain the fluid from the steering pump assembly: Allow the fluid to cool. Remove the power‑assisted steering pump reservoir cap and dipstick. Remove the high‑pressure hose and the return hose from the power‑assisted steering pump. Page 8A-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 515: Steering Pump Assembly Installation
IMPORTANT: Do not cross‑thread or overtighten the hose fittings. Place the power‑assisted steering pump onto the mounting brackets. Tighten the bracket to the specified torque. Description lb‑in. lb‑ft Power steering bracket to the block 35.2 – 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-15...
Page 516: Replacing The Belt And Adjusting Tension
Remove the cap and dipstick from the power‑assisted steering pump. Add approved fluid to bring the level up to the "FULL COLD" mark on the dipstick. IMPORTANT: Use only Power Trim and Steering Fluid in the power‑assisted steering system. Page 8A-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 517: Power Steering Fluid
The proper fluid level with the engine cold should be within the cold range. Warm range Cold range 54972 IMPORTANT: If fluid is not visible in the reservoir, contact your authorized Mercury MerCruiser dealer. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-17...
Page 518: Power-Assisted Steering Hoses
Install the fill cap/dipstick. Changing Power steering fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Power‑Assisted Steering Hoses IMPORTANT: Make the hydraulic connections as quickly as possible to prevent fluid from leaking.
Page 519 Install the high‑pressure hose onto the quick‑connect fitting on the control valve at the transom. Ensure that the quick‑connect fitting snaps into place. Fill and bleed the system. Refer to Filling and Bleeding. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-19...
Page 520: Return Hose (Pump Reservoir To Fluid Cooler)
Return hose 56934 Installation IMPORTANT: Route the hoses to avoid extreme heat, stress on the hose fittings, and hose kinks. Route the return hose in the manner noted prior to removal. Page 8A-20 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 521: Return Hose (Control Valve To Fluid Cooler)
Note the position and routing of the return hose before removal. Loosen the hose clamp and remove the return hose from the fluid cooler. Return hose and hose clamp 56935 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-21...
Page 522: Power-Assisted Steering System Tests
Power‑Assisted Steering System Tests Power‑Assisted Steering System Pressure Test These test procedures are arranged so that a defective component can be detected through the process of elimination. Perform these tests in order. Page 8A-22 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 523 If the boat is out of the water, connect a flushing device to the sterndrive (refer to Section 1C). The cooling system is full when water is discharged through the propeller. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8A-23...
Page 524: Pump Pressure Test
Remove the high‑pressure hose at the control valve, and install the test gauge between the hose and the control valve. Control valve High‑pressure hose Test gauge Gauge‑to‑control‑valve hose 50206 Power Steering Test Gauge Kit 91‑38053A05 Page 8A-24 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 525 If the pressure readings are 7932–8621 kPa (1150–1250 psi) and are within 345 kPa (50 psi) of each other, then the pump is within specifications. If the pump is within specifications, but system pressure was low (as tested under the Power‑Assisted Steering System Pressure Test), refer to the appropriate Mercury MerCruiser sterndrive service manual for additional information.
Page 526 Power-Assisted Steering Pump and Related Components Notes: Page 8A-26 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 527 Checking Fluid Level After the Initial Fill......8B-5 Maintenance..............8B-10 Checking Fluid Level............8B-5 Troubleshooting Guide.............8B-10 Engine Warm.............. 8B-5 Important Information..........8B-10 Engine Cold..............8B-6 Troubleshooting Chart..........8B-10 Steering Circuit Component Diagram........ 8B-7 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8B-1...
Page 528: Approved Hydraulic Steering Fluids
Ensure that the pivot bolt bushings on the new steering cylinder are clean. Lubricate the pivot bolt bushings and pivot bolt threads. Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Pivot bolt bushings and pivot bolt threads 92-802859A 1 Page 8B-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 529 Pivot bolt (2) Tab washer (2) Spacer (2) Pivot bolt bushing (2) Ridge on transom plate Transom plate Port hydraulic elbow fitting Steering cylinder assembly Starboard hydraulic elbow fitting 57218 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8B-3...
Page 530: Initial Filling
NOTE: This initial fill procedure only fills the steering helm and the pressure and tank hoses. Purging the Hydraulic Steering System Disconnect the hydraulic hoses at the steering cylinder. Connect the ends of the hoses to each other using the 892526 union fitting. Page 8B-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 531: Checking Fluid Level After The Initial Fill
If the fluid is still foamy, repeat steps 1–7 until the fluid does not foam and the level remains constant. Checking Fluid Level Engine Warm Stop the engine. Center the sterndrive. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8B-5...
Page 532: Engine Cold
If fluid is not visible in the reservoir, a leak exists in the power‑assisted steering system. Find the cause and correct it. Engine Cold With the engine stopped, center the sterndrive. Remove the cap and dipstick from the power‑assisted steering pump and note the fluid level. Page 8B-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 533: Steering Circuit Component Diagram
Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Clevis pin and clevis 92-802859A 1 Connect the clevis to the steering lever. Spread both ends of the cotter pin. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8B-7...
Page 534: Connecting The Hydraulic Hoses To The Tilt Steering Helm
Do not over‑tighten the hose connections. Helm Fitting ID Mark Hose ID Mark lb‑in. lb‑ft "P" "P" – "T" "T" – 26.5 "R" "R‑STAR" – "L" "L‑PORT" – Page 8B-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 535: Hydraulic Fluid Level
IMPORTANT: In the following procedure, turn the wheel with enough force to exceed the pressure relief valve in the helm. This action should not harm the helm or the system. Turn the steering wheel (any wheel on a multi‑steering station) very hard to port to pressurize the system. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8B-9...
Page 536: Maintenance
When troubleshooting requires component removal from the vessel or the dismantling of steering system components, this work must be carried out by a qualified marine mechanic. The following is offered as a guide only, and neither Mercury MerCruiser nor the helm manufacturer are responsible for any consequences resulting from incorrect repairs.
Page 537 Quad ring No. 210 is supplied in Seastar® Helm Seal Kit HS5151. 9. Vent/fill plug leaks when turning to Cylinder rod extended during Ensure that the cylinder rod is retracted during filling. port. filling. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 8B-11...
Page 539 Transmission Fluid............9A-10 63A DTS..............9A-6 Transmission Removal..........9A-13 Important Information............9A-6 Transmission Installation.......... 9A-14 Engine.................9A-6 Shift Cable Installation and Adjustment......9A-16 Propeller..............9A-6 Shift Cable Installation..........9A-16 Precautions................ 9A-6 Pressure Test..............9A-17 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 9A-1...
Page 540: Identification
Gear ratio with shifting position "B" 59763 Specifications Operating Specifications Specification Description Model 45C/45IV Model 63A/63 2150–2350 kPa (312–341 psi) at 2000 Shifting pressure 1400–2000 kPa (203–290 psi) Operating temperature 54–79° C (130–175° F) Page 9A-2 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 541 Closed 110° C (230° F) Ratios and Part Numbers The ratio is shown on the identification plate. The ratio may be rounded off in some cases. ZF Marine Model Ratio Mercury Marine Part Number 1.0:1 864336A03 45IV 1.46:1 Not available 1.5:1...
Page 542: Transmission And Related Parts
ZF/45C, 45IV, 63A, 65IV Transmissions Transmission and Related Parts 45IV 59766 Page 9A-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 543: 45C Dts And 45C Mechanical
ZF/45C, 45IV, 63A, 65IV Transmissions 45C DTS and 45C Mechanical 59767 45C DTS 59768 45C Mechanical 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 9A-5...
Page 544: 63A Dts
On MIE engines equipped with in‑line transmissions having 1:1 gear ratio, the transmission output shaft rotation is the same as the engine rotation with the transmission in forward gear. Engine rotation is LH (CCW), so a LH propeller is required. NOTE: 45C transmissions are not full power reversing. Page 9A-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 545: Transmission Fluid
CAUTION Using the reverse gear to propel the boat forward will damage the transmission. Install the shift cable so shifting the helm control forward engages the transmission’s forward gear. Mercury Marine does not cover improperly installed components under warranty. Forward...
Page 546 Clean the breather valve, allow it to dry, and coat it with automatic transmission fluid. Tube Ref No. Description Where Used Part No. Dexron® III Automatic Breather valve Obtain Locally Page 9A-8 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 547 12. Fill the transmission with the specified fluid through the dipstick hole. Refer to Specifications. 13. Install the dipstick and O‑ring. Tube Ref No. Description Where Used Part No. Dexron III Automatic ZF/45IV transmissions Obtain Locally Filling IMPORTANT: Use only the specified transmission fluid. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 9A-9...
Page 548: 63A Down-Angle And 63Iv V-Drive Transmissions
If the fluid level is low, add transmission fluid to bring the level up to the maximum mark on the dipstick. Dipstick Threaded hole Maximum fluid level Minimum fluid level 16604 Page 9A-10 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 549 Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required. Clean the exterior of the transmission around the fluid filter assembly. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 9A-11...
Page 550 Remove and discard the filter element and O‑rings. Coat the new O‑rings with new transmission fluid. Tube Ref No. Description Where Used Part No. Dexron III Automatic Filter element O-rings Obtain Locally Page 9A-12 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 551: Transmission Removal
If required, drain the transmission fluid. Dispose of the fluid according to local regulations. Disconnect the water hoses from the transmission fluid cooler. NOTE: The fluid cooler should be removed with the transmission. On non‑DTS transmissions: 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 9A-13...
Page 552: Transmission Installation
11. Install the transmission fluid cooler hoses. Tighten the hose fittings at the transmission housing to the specified torque. Description lb‑in. lb‑ft Transmission fluid cooler hose fitting – 12. For non‑DTS transmissions: Connect the neutral start switch and fluid temperature switch wiring connectors. Page 9A-14 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 553 15. After final engine and coupler alignment has been properly set—with the boat in the water, connect the propeller shaft coupler to the transmission output flange with bolts, lockwashers, and nuts. Tighten the bolts to the specified torque. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 9A-15...
Page 554: Shift Cable Installation And Adjustment
19. Connect the battery cables. Be certain to connect the negative (–) cable last. 20. Check for leaks and check the fluid level after the first engine start‑up. Shift Cable Installation and Adjustment Shift Cable Installation 59776 Page 9A-16 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 555: Pressure Test
Position B Repair or replace the transmission if measurements are not as specified. Remove the pressure gauge and thermocouple. Apply Loctite 567 PST Pipe Sealant to the fluid temperature switch threads. 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 9A-17...
Page 556 12. Connect the two fluid temperature switch wires. Apply Liquid Neoprene to the exposed electrical terminals and connections. Tube Ref No. Description Where Used Part No. Liquid Neoprene Exposed electrical terminals and connections 92- 25711 3 13. Upon first operation, check for leaks. Page 9A-18 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 557 Color Diagrams Color Diagrams Section 10A - Color Diagrams Table of Contents 6.2L Mechanical Wiring Diagram Non‑DTS..... 10A-4 Wire Color Code Abbreviations........10A-6 6.2L DTS Wiring Diagram..........10A-5 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 10A-1...
Page 560 26 - Starter fuse to the 50‑amp circuit breaker 57 - PCM B 27 - CAN resistor 58 - PCM A 28 - Alternator excite circuit 29 - Camshaft position sensor Page 10A-4 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 561 6.2L Mechanical Wiring Diagram Non-DTS D C B A 4 6 2 1 5 3 D C A B 2 4 6 5 3 1 YEL/RED 87 308685 A B C D E F G H K J H G F E D C B A K J H G F E D C B A YEL/RED RED/BLU...
Page 562 6.2L DTS Wiring Diagram D C B A 4 6 2 1 5 3 D C A B 2 4 6 5 3 1 YEL/RED 87 308685 A B C D E F G H K J H G F E D C B A K J H G F E D C B A YEL/RED RED/BLU...
Page 563 26 - Starter fuse 57 - PCM B 27 - Starter fuse to the 50‑amp circuit breaker 58 - PCM A 28 - Alternator excite circuit 29 - Camshaft position sensor 90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 10A-5...
Page 564 Wire Color Abbreviations Black Blue Brown GRY or GRA Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark Page 10A-6 © 2016 Mercury Marine 90-8M0099748 eng DECEMBER 2015...
Page 566 Parc Industriel de Petit-Rechain 41-71 Bessemer Drive P.O. Box 1939 B-4800 Verviers, Belgium Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA © Mercury Marine. All rights reserved. 90-8M0099748 DECEMBER 2015 Printed in U.S.A.

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Mercury MerCruiser Service Manual

Important Information, Maintenance, and 1

Important Information, Maintenance, and 1

Important Information, Maintenance, and 1

Removal and Installation 2

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Engine Mechanical 3

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