MerCruiser 13 Manuals

Manuals and User Guides for MerCruiser 13. We have 1 MerCruiser 13 manual available for free PDF download: Service Manual

MerCruiser 13 Service Manual

MerCruiser 13 Service Manual (348 pages)

GM 4 Cylinder

Brand: MerCruiser | Category: Engine | Size: 22.15 MB

Table of Contents

Important Information 1 a

8
- Marine Engines
  1
- Table of Contents
  8
- Introduction
  9
- How to Use this Manual
  9
  - Page Numbering
    9
- How to Read Parts Manual
  10
- Directional References
  11
- Engine Rotation
  11
- Engine Serial Number Locations
  11
- Engine Identification
  11
- Propeller Information
  11
- Water Testing New Engines
  12
- Boat and Engine Performance
  12
  - Boat Bottom
    12
  - Marine Fouling
    13
  - Weight Distribution
    14
  - Water in Boat
    14
  - Elevation and Climate
    14
Important Information 1 B

16
- Maintenance Schedule
  17
  - To be Done by Owner
    17
- Maintenance Schedule (Continued)
  18
  - To be Done by Dealer
    18
- Tune-Up Specifications
  19
- Fluid Capacities
  20
- Cylinder
  21
  - 20-Hour Break-In Period
    21
  - After 20 Hour Break-In Period
    21
  - 20-Hour Checkup
    21
- Fuel, Oil, Fluid, and Coolant Specifications
  22
  - Fuel
    22
    
    Boat/Motor Storage
    23
    
    Continuing Evaluations
    23
    
    Effects of Gasoline/Alcohol Blends on Marine Engines
    23
    
    Gasoline/Alcohol Blends
    23
    
    Test for Alcohol Content in Gasoline
    23
    
    Warranty
    23
    
    Winter Storage
    23
  - Crankcase Oil
    24
  - Priming Engines with Oil
    24
  - Power Steering Fluid
    24
  - Coolant for Closed Cooling System
    25
- Changing Oil and Filter
  25
- Maintaining Crankcase Oil Level
  25
  - Overfilled Engine Crankcase
    25
  - Checking Engine Oil Level/Filling
    25
- Maintaining Power Steering Pump Fluid Level
  26
  - With Engine Warm
    26
  - With Engine Cold
    26
- Filling and Bleeding Power Steering System
  27
- Flushing Cooling System
  27
- Maintaining Closed Cooling Coolant Level
  27
- Lubrication
  29
  - Throttle Cable
    29
  - Shift Cable
    29
  - Engine Coupler/U-Joint Shaft Splines
    30
- Audio Warning System
  30
  - Maintenance
    30
- Cold Weather or Extended Storage
  30
  - Precautions
    30
  - Layup
    31
- Draining Instructions
  32
Important Information 1 C

37
- Precautions
  38
- Spark Plug Analysis
  39
  - Normal Condition
    39
  - Chipped Insulator
    39
  - Wet Fouling (Oil Deposits)
    39
  - Cold Fouling
    40
  - Overheating
    40
  - High Speed Glazing
    40
  - Scavenger Deposits
    40
  - Pre-Ignition Damage
    41
  - Reversed Coil Polarity
    41
  - Splashed Deposits
    41
  - Mechanical Damage
    41
- Used Spark Plug Analysis
  39
- Poor Boat Performance And/Or Poor Maneuverability
  42
- Improper Full Throttle Engine RPM
  43
  - RPM too High
    43
  - RPM too Low
    43
- Engine Cranks over but will Not Start or Is Hard to Start
  44
  - Important Information
    44
  - Breaker Points Ignition (no Spark)
    44
- Digital Distributorless Ignition System (DDIS)
  45
- EST Ignition System Check
  47
  - Test Description
    47
- Charging System Inoperative
  50
- Engine will Not Crank Over/Starter Inoperative
  50
- Fuel System Rich
  51
- Noisy Alternator
  51
- Carburetor Malfunction
  52
- Fuel System Lean
  52
- Engine Runs Poorly at Idle
  53
- Engine Acceleration Is Poor
  55
- Engine Runs Poorly at High RPM
  56
- Poor Fuel Economy
  57
- Radio Noise
  58
- Troubleshooting with Vacuum Gauge
  58
- Instrumentation Malfunction
  59
- Miscellaneous
  59
- Cylinder Area
  60
- Engine Noise
  60
  - Important Information
    60
- Valve Cover Area
  60
- Camshaft Area
  61
- Crankshaft Area
  62
- Miscellaneous
  63
- Oil Pressure
  64
- High Oil Pressure
  65
- Low Oil Pressure
  65
- Excessive Oil Consumption
  66
- Water in Crankcase
  67
- Water in Engine
  67
  - Important Information
    67
- Water on Top Pistons
  68
- Engine Overheats (Mechanical)
  69
- Engine Overheats (Cooling System)
  70
  - Poor, Erratic, or no Assist
    71
  - Noisy Pump
    72
- Fluid Leaks
  72
Engine

89
- Tools/Lubricants/Sealants
  92
- Engine Specifications
  93
  - Cylinder Bore
    93
  - Piston Clearance
    93
  - Piston Ring: Compression
    93
  - Piston Ring: Oil
    93
  - Piston Pin
    93
  - Crankshaft
    94
  - Camshaft
    94
  - Cylinder Head
    94
  - Valve System
    95
- General
  96
  - Engine Identification
    96
  - Engine Rotation
    96
  - Firing Order
    96
- Priming Engine with Oil
  97
  - Tool Required
    97
- Bearing Failures
  98
- Piston Failures
  98
  - Pre-Ignition
    98
    
    Pre-Ignition Causes
    98
  - Detonation
    99
    
    Other Causes of Detonation
    99
- Engine Mounts
  100
- Rocker Arm Cover
  100
  - Removal
    100
  - Installation
    100
- Rocker Arm/Push Rod
  101
  - Removal
    101
  - Cleaning and Inspection
    101
  - Installation
    101
- Valve Adjustment
  102
  - Engine Not Running
    102
  - Engine Running
    102
- Hydraulic Valve Lifters
  103
  - Locating Noisy Lifters
    103
  - Removal
    103
  - Cleaning and Inspection
    104
  - Installation
    104
- Valve Stem Oil Seal/Valve Spring
  105
  - Replacement Oil Seal Head Installed
    105
- Cylinder Head
  106
  - Cleaning and Inspection
    106
  - Installation
    106
- Cylinder Head and Valve Conditioning
  107
  - Disassembly
    107
  - Cleaning
    107
  - Inspection
    108
- Specifications
  108
  - Rocker Arm Studs
    109
  - Valve Guide Bore Repair
    109
  - Valve Springs - Checking Tension
    109
  - Valve Seats
    110
  - Reassembly
    110
- Dipstick Specifications
  112
  - All Engines
    112
- Oil Pan
  112
  - Removal
    112
  - Installation
    112
- Oil Pump
  113
  - Removal
    113
  - Disassembly
    113
  - Cleaning and Inspection
    113
  - Reassembly
    113
  - Installation
    114
- Torsional Damper
  114
  - Removal
    114
- Crankcase Front Cover
  115
  - Removal
    116
  - Cleaning and Inspection
    116
  - Installation
    116
- Crankcase Front Cover/Oil Seal
  115
  - Oil Seal Replacement (Without Removing Front Cover)
    115
    
    Installation
    115
    
    Removal
    115
- Flywheel and Engine Coupler
  116
  - Inspection
    117
  - Installation
    117
- Rear Main Oil Seal
  118
  - Removal
    118
  - Cleaning and Inspection
    118
  - Installation
    118
- Main Bearings
  119
  - Inspection
    119
  - Checking Clearances
    119
  - Main Bearing Replacement
    120
  - Connecting Rod Bearings
    120
  - Inspection and Replacement
    121
- Connecting Rod/Piston Assembly
  122
  - Cylinder Block
    134
  - Electrical Systems
    137
Electrical Systems

138
- Identification
  139
- Important Information
  139
- Battery
  140
  - Battery Cable Recommendations
    140
  - Precautions
    140
- Replacement Parts Warning
  140
- Testing
  141
  - Load Test
    141
  - Hydrometer Test
    141
  - Storage
    142
- Charging Guide
  143
  - Volt Battery Recommended Rate* and Time for Fully Discharged Condition 4A
    143
- Slave Solenoid Identification
  144
  - Types
    144
  - Standard Type Slave Solenoid
    144
  - Switch Type Slave Solenoid
    144
  - Testing/Replacement
    145
- Lubricants/Sealants
  146
- Specifications
  146
- Torque Specifications
  146
- Starter Motor (Exploded View)
  147
- Starting System Components
  148
- Periodic Inspection
  149
- Positive Current Flow
  149
- Starter Motor Repair
  149
  - Removal
    149
  - Solenoid Switch
    150
  - Starter Motor Disassembly
    151
  - Cleaning and Inspection
    152
  - Armature Tests
    152
  - Field Coil Tests
    153
  - Loose Electrical Connections
    153
  - Turning the Commutator
    153
  - Reassembly
    154
  - Clearances
    155
  - Installation
    156
  - Description
    156
  - PG200 Specifications
    157
  - Torque Specification
    157
- Starting System Components
  158
- PG200 Exploded View
  159
- Periodic Inspection
  161
- Solenoid Switch
  161
- Starter Motor Repair
  161
  - Removal
    161
  - PG200 Disassembly
    161
  - Cleaning and Inspection
    163
  - Armature Tests
    163
  - Armature Bearing (Commutator End)
    164
  - Gear Bearing
    164
  - Shaft Assembly Bearing
    165
  - Drive End Housing Bearing
    165
  - Brushes and Brush Holder
    165
  - PG200 Reassembly
    166
- Standard Starter Slave Solenoid
  168
  - Testing/Replacement
    168
  - Installation
    169
Electrical Systems

171
- Identification
  172
- Replacement Parts Warning
  172
  - Spark Plugs
    173
- L Breaker Point Ignition Prestolite Distributor System
  173
- Specifications
  173
  - Coil
    173
  - Distributor
    173
  - Firing Order
    173
  - Distributor Advance Curves
    174
  - Precautions
    175
  - Distributor Cap and Rotor
    175
  - Spark Plug Wires
    175
  - Contact Points
    176
  - Replacement
    177
  - Condenser
    179
  - Coil
    179
  - Ignition Resistance Wire
    179
- Tools/Lubricants/Sealants
  173
- Torque Specifications
  173
- Distributor Repair
  179
  - Removal
    179
  - Disassembly
    180
  - Reassembly
    180
- Distributor Installation
  181
  - Engine Not Disturbed
    181
  - Engine Disturbed
    181
- Ignition Timing
  181
- (DDIS) Digital Distributorless Ignition System
  183
  - Specifications
    183
  - Torque Specifications
    183
- Tools/Lubricants/Sealants
  183
  - Spark Plugs
    183
  - Overspeed Prevention Control
    183
- DDIS System Components
  184
- Description
  184
- Advance Curve Chart (Reference Only)
  185
- MCM 3.0 L DDIS Models
  185
- Spark Advance Control
  185
- Advance Curve Chart (Reference Only)
  186
- MCM 3.0 LX (DDIS) Models
  186
- Spark Advance Control
  186
- Components Tests
  187
  - Ignition Amplifier
    187
  - Ignition Coil
    188
  - Motion Sensor
    189
  - Shift Interrupter Switch
    189
- Motion Sensor
  190
  - Removal
    190
  - Installation
    190
- DDIS Ignition Timing
  191
- Delco EST Ignition
  192
- Specifications
  192
  - Spark Plugs
    192
- Tools/Lubricants/Sealants
  192
- Torque Specifications
  192
- Component Tests
  194
- MCM 3.0L, 3.0LX with EST
  195
Electrical Systems

198
- Mando 55 Amp Alternator
  
  199
  - Description
    199
  - Replacement Parts Warning
    199
  - Specifications
    199
  - Tools/Sealants
    199
  - Precautions
    201
  - System Components
    201
  - Drive Belt Tension Adjustment
    202
    
    Alternator
    202
  - Periodic Maintenance
    202
  - (Alternator on Engine)
    203
    
    Circuitry Test
    203
    
    Excitation Circuit
    203
    
    Output Circuit
    203
    
    Current Output Test
    204
    
    Sensing Circuit
    204
    
    Voltage Output Test
    205
  - Troubleshooting Tests
    203
  - Alternator Repair
    206
    
    Removal
    206
    
    Exploded View
    207
    
    Disassembly
    208
    
    Cleaning and Inspection
    210
    
    Component Testing
    211
    
    Rotor
    211
    
    Stator
    212
    
    Rectifier and Diode Assembly
    213
    
    Condenser
    214
    
    Reassembly
    214
  - Installation
    217
- Prestolite 55 Amp Alternator
  
  217
  - Replacement Parts Warning
    217
  - Specifications
    217
  - Tools/Sealants
    217
  - Description
    218
  - Precautions
    218
  - Torque Specifications
    218
  - Exploded View
    219
  - Periodic Maintenance
    220
  - System Components
    220
  - (Alternator on Engine)
    221
    
    Alternator Output Test
    221
    
    Circuitry Test
    221
    
    Harness Voltage Test
    222
    
    Open Diode-Trio Test
    222
    
    Current Output Test
    223
    
    Open Regulator Test
    224
  - Drive Belt Tension Adjustment
    221
    
    Alternator
    221
  - Troubleshooting Tests
    221
  - Alternator Repair
    225
    
    Disassembly
    225
    
    Removal
    225
    
    Cleaning and Inspection
    227
  - Front Bearing
    227
    
    Installation
    227
    
    Removal
    227
  - Slip Rings/Rear Bearing
    228
    
    Installation
    228
    
    Removal
    228
  - Component Testing
    229
    
    Rotor
    229
    
    Stator
    230
    
    Identification
    231
    
    Negative (-) Rectifier
    231
    
    Positive (+) Rectifier and Diode-Trio
    231
    
    Positive/Negative Rectifier and Diode-Trio Assembly
    231
    
    Condenser
    232
  - Reassembly
    232
  - Installation
    234
  - Battery Isolators
    235
    
    Dual Battery Charging Systems Using a Battery Isolator
    235
    
    Battery Isolator Diagram
    236
Electrical Systems

238
- Identification
  239
- Special Information
  239
  - Lighting Options
    239
    
    Commodore and International Series
    239
    
    QSI Series
    240
- Gauges
  240
  - Oil, Fuel and Temperature
    240
  - Battery Gauge
    241
  - Cruiselog Meter
    242
  - Vacuum Gauge
    242
  - Speedometer
    242
    
    Calibration Chart
    242
  - Tachometer
    242
    
    Testing
    242
  - Gauge Replacement
    242
- Senders
  243
  - Oil Pressure
    243
    
    Dual Station Sender Identification
    243
    
    Testing
    243
  - Water Temperature Sender
    243
    
    Installation
    244
    
    Dual Station Sender Identification
    245
- Fuel Tank Sender
  245
  - Flange Type
    245
  - Capsule Type
    246
- Switches
  246
  - Ignition Key Switch
    246
    
    Testing
    246
- Audio Warning System
  247
  - Buzzer
    247
  - Oil Pressure Switch
    248
    
    Switch Identification
    248
  - Water Temperature Switch
    248
    
    Testing
    248
Electrical Systems

251
- Wiring Colors for Mercruiser
  252
- Wiring Diagrams
  253
- Battery Meter Gauge
  262
- Cruiselog
  262
- Fuel Gauge and Sender
  262
- Audio Warning System
  263
- Clock
  263
- Oil Pressure Gauge
  263
- Water Temperature Gauge
  263
Fuel System

265
- Identification
  266
- Replacement Parts Warning
  266
- Specifications
  266
- Tools/Lubricants/Sealants
  266
- Torque Specifications
  266
- Fuel Delivery System
  267
  - Recommendations
    267
  - Description
    267
- Precautions
  267
- Fuel System Components (Typical)
  268
- Water Separating Fuel Filter
  268
  - Replacement
    268
- Fuel Pump Fuel Filter
  269
  - Replacement
    269
- Testing Fuel Pump
  269
- Fuel Pump Replacement
  270
  - Removal
    270
Fuel System

272
- For Information and Procedures on Troubleshoot
  272
- Ing, Refer to SECTION 1C
  272
- Identification
  273
- Replacement Parts Warning
  273
- Tools
  273
- Torque Specifications
  273
- Specifications
  274
  - High Altitude Re-Jetting
    275
- Description
  276
- Important Service Information
  276
  - Flooding at Idle RPM
    276
  - Needle/Seat Change
    276
  - Adjustable Accelerator Pump Lever
    276
- Maintenance
  277
  - Flame Arrestor with Carburetor Cover
    277
  - Fuel Inlet Filter
    278
  - Choke Inspection
    279
- Precautions
  277
  - Fuel Supply Connections
    277
- Adjustments
  279
  - Pump Rod
    279
  - Choke Setting
    280
  - Choke Unloader
    280
  - Preliminary Idle Speed and Mixture
    281
  - Final Idle Speed and Mixture
    281
- Repair
  282
  - Removal
    282
  - Installation
    282
  - Exploded View Parts List
    285
Cooling System

301
- Stern Drive Seawater Pickup Pump
  303
- Testing
  303
- Thermostat
  303
  - Removal
    303
- Installation
  304
- Cold Weather or Extended Storage
  305
- Auxiliary Hot Water Heater Installation
  306
- Cooling System Flow Diagram
  308
Cooling System

310
- Notice
  310
- Heat Exchanger Repair
  312
- Pressure Cap Maintenance
  312
- Testing Closed Cooling System
  313
  - Testing Coolant for Alkalinity
    313
  - Pressure Testing System
    313
  - Testing for Cylinder Head Gasket Leak
    314
  - Testing Heat Exchanger
    314
  - Testing Pressure Cap
    315
- Thermostat
  316
  - Removal
    316
  - Testing
    316
  - Installation
    317
- Changing Coolant
  317
  - Closed Cooling Section
    318
  - Coolant Recommendations
    318
  - Change Intervals
    318
  - Draining Instructions
    318
  - Draining Diagram
    319
- Cleaning System
  320
  - Closed Cooling Section
    320
  - Seawater Section
    320
- Flushing Seawater Section of Closed Cooling System
  321
- Draining Seawater Section of Closed Cooling System
  322
  - Recommissioning
    323
- Filling Closed Cooling Section
  324
  - Exhaust System
    325
  - Cleaning and Inspection
    328
Power Steering 7 a

332
- Checking Power Steering Pump Fluid Level
  333
  - With Cold Engine
    333
  - With Engine Warm from Operation
    334
- Precautions
  333
- Tools/Sealants/Fluids
  333
- Torque Specifications
  333
- Filling and Air Bleeding Power Steering System
  334
- Pump Drive Belt Tension Adjustment
  334
  - Pump Pulley Replacement
    335
  - Removal
    335
  - Installation
    335
- Power Steering Pump and Cooler
  336
  - Replacment
    336
    
    Installation
    339
  - Low Pressure Hose (Control Valve-To-Cooler)
    340
    
    Installation
    340
    
    Removal
    340
- Priority Valve Kit (79691A1) Information
  342
  - Installing Reservoir
    342
  - Installing Priority Valve
    343
  - Filling System with Fluid
    347
  - Maintenance
    347
  - System Flow Diagram
    348

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