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Mercruiser Service Manual - 31 2001 - Newer GM Small Block V8

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90% found this document useful (10 votes)

32K views636 pages

Mercruiser Service Manual - 31 2001 - Newer GM Small Block V8

Uploaded by

Des Stirling

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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INDEX

SERVICE MANUAL
Number 31

5.0L/5.7L/6.2L MPI GASOLINE ENGINE

Printed in U.S.A.

2000, Mercury Marine

90-863161 SEPTEMBER 2000

Notice
Throughout this publication, Dangers, Warnings and Cautions (accompanied by the ) are used to alert the mechanic to special instructions International HAZARD Symbol concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus Common Sense operation, are major accident prevention measures.

DANGER
Immediate hazards which will result in severe personal injury or death.

WARNING
Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION
Hazards or unsafe practices which could result in minor personal injury or product or property damage.

Notice to Users of This Manual

This service 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. It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of Mercury MerCruiser product, including the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins, operation maintenance and warranty manuals and installation manuals for other pertinent information concerning the products described in this manual.

90-864260 OCTOBER 2001

Page i

Precautions
It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original.

Engine Mechanical Components

Many of the engine mechanical components are designed for marine applications. Unlike automotive engines, marine engines are subjected to extended periods of heavy load and wide open throttle operation and, therefore, require heavy-duty components. Special marine engine parts have design and manufacturing specifications that are required to provide long life and dependable performance. Marine engine parts also must be able to resist the corrosive action of salt or brackish water that will rust or corrode standard automotive parts within a short period of time. Failure to use recommended Quicksilver service replacement parts can result in poor engine performance and/or durability, rapid corrosion of parts subjected to salt water and possibly complete failure of the engine.

Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting Section 2 - Removal and Installation A - MCM Models B - MIE Models Section 3 - Engine A - Engine Mechanical Section 4 - Electrical System A - Starting System B - Ignition System C - Charging System D - Wiring Diagrams Section 5 - Fuel System A - Fuel Delivery System Section 6 - Cooling System A - All Models B - Seawater Cooled Models C - Closed Cooled Models Section 7 - Exhaust System A - Manifolds and Elbows B - Collectors Section 8 - Drives A - Velvet Drive In-Line And V-Drive Transmission B - Velvet Drive 5000 Series Transmission C - ZF/Hurth 630 And 800 Series Transmission Section 9 - Power Steering A - Power Steering Pump
Important Information

1 2 3 4 5 6 7 8 9

Removal And Installation

Engine

Electrical System

Fuel System

Cooling System

Exhaust System

Drives

Power Steering

90-864260 OCTOBER 2001

Page v

IMPORTANT INFORMATION
Section 1A - General Information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual . . . . . . . . . . . . . . . . . Page Numbering . . . . . . . . . . . . . . . . . . . . Engine Serial Number Locations . . . . . . . . . . Mercury/Quicksilver Lubricants, Sealants And Adhesives . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 1A-2 1A-2 1A-3 1A-4

IMPORTANT INFORMATION
Section 1B - Maintenance
Torque Specifications . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Engine And Tune-Up Specifications . . . . MCM (Sterndrive) Models . . . . . . . . . . MIE (Tow Sports and Inboard) Models Fluid Specifications . . . . . . . . . . . . . . . . . . Engines . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrives . . . . . . . . . . . . . . . . . . . . . . Transmissions . . . . . . . . . . . . . . . . . . . . Maintenance Schedules . . . . . . . . . . . . . . Maintenance Intervals . . . . . . . . . . . . . Gas Sterndrive . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance . . . . . . . . . . . . . Scheduled Maintenance . . . . . . . . . . . Gas Inboard And Tow Sports . . . . . . . . . Routine Maintenance . . . . . . . . . . . . . Scheduled Maintenance . . . . . . . . . . Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . Overfilled Crankcase Oil . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Oil and Filter . . . . . . . . . . . . Flushing The Power Package - MCM . . Sterndrive Water Pickups . . . . . . . . . . Alternative Water Pickups . . . . . . . . . . Flushing The Power Package - MIE . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . Inboard Models . . . . . . . . . . . . . . . . . . . Tow Sports Models . . . . . . . . . . . . . . . . Transmission Fluid . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Changing and Filling . . . . . . . . . . . . . . Sterndrive Unit Oil . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Pump Fluid . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump Fluid . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Filling and Bleeding . . . . . . . . . . . . . . . Water Inlets . . . . . . . . . . . . . . . . . . . . . . . . Seawater Strainer . . . . . . . . . . . . . . . .
Page vi

1B-2 1B-2 1B-3 1B-4 1B-4 1B-5 1B-6 1B-6 1B-6 1B-7 1B-7 1B-7 1B-8 1B-8 1B-9 1B-11 1B-11 1B-12 1B-14 1B-15 1B-15 1B-16 1B-17 1B-19 1B-19 1B-21 1B-23 1B-23 1B-23 1B-25 1B-27 1B-27 1B-28 1B-28 1B-28 1B-28 1B-29 1B-31 1B-31 1B-31 1B-31 1B-32 1B-32 1B-33 1B-35 1B-35

Closed Cooling System . . . . . . . . . . . . . . Checking Coolant Level . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Changing Coolant . . . . . . . . . . . . . . . . Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . Power Package Surfaces . . . . . . . . . . . . . Painting Your Power Package . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruments . . . . . . . . . . . . . . . . . . . . . . . . . Gimbal Ring / Steering Connection . . . . Changing Water Separating Fuel Filter . Steering System . . . . . . . . . . . . . . . . . . . . Remote Control . . . . . . . . . . . . . . . . . . . . . Sterndrive Components . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable . . . . . . . . . . . . . . . . . . . . Shift Cable and Transmission Linkage Sterndrive Components . . . . . . . . . . . Continuity Circuit . . . . . . . . . . . . . . . . . . . . MerCathode . . . . . . . . . . . . . . . . . . . . . . . . Engine Mounts . . . . . . . . . . . . . . . . . . . . . . Electrical System . . . . . . . . . . . . . . . . . . . . Cleaning Flame Arrestor . . . . . . . . . . . . . Serpentine Drive Belt . . . . . . . . . . . . . . . . Inboard and Tow Sports Models . . . . Sterndrive Models . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Replacing Belt and/or Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . Seawater Pump . . . . . . . . . . . . . . . . . . . . . Starter Motor . . . . . . . . . . . . . . . . . . . . . . . 14MT . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Weather And Extended Storage . . Preparing Your Power Package For Storage . . . . . . . . . . . . . . . . . . . . . Draining Instructions . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . Boat In The Water . . . . . . . . . . . . . . . . Boat Out Of The Water . . . . . . . . . . . . All Models . . . . . . . . . . . . . . . . . . . . . . .

1B-36 1B-36 1B-36 1B-36 1B-37 1B-40 1B-41 1B-41 1B-42 1B-42 1B-42 1B-43 1B-44 1B-44 1B-44 1B-44 1B-44 1B-45 1B-46 1B-50 1B-52 1B-52 1B-52 1B-53 1B-54 1B-54 1B-55 1B-55 1B-56 1B-57 1B-57 1B-58 1B-58 1B-59 1B-59 1B-61 1B-62 1B-63 1B-67 1B-70

90-864260 OCTOBER 2001

IMPORTANT INFORMATION
Section 1C - Troubleshooting
Used Spark Plug Analysis . . . . . . . . . . . . . . . Normal Condition . . . . . . . . . . . . . . . . . . . . Chipped Insulator . . . . . . . . . . . . . . . . . . . . Wet Fouling (Oil Deposits) . . . . . . . . . . . . Cold Fouling . . . . . . . . . . . . . . . . . . . . . . . . Overheating . . . . . . . . . . . . . . . . . . . . . . . . High Speed Glazing . . . . . . . . . . . . . . . . . . Scavenger Deposits . . . . . . . . . . . . . . . . . Pre-Ignition Damage . . . . . . . . . . . . . . . . . Reversed Coil Polarity . . . . . . . . . . . . . . . . Splashed Deposits . . . . . . . . . . . . . . . . . . . Mechanical Damage . . . . . . . . . . . . . . . . . Poor Boat Performance And/Or Poor Maneuverability . . . . . . . . . . . . . . . . . . . Improper Full Throttle Engine RPM . . . . . . . . Engine Cranks Over But Will Not Start Or Starts Hard . . . . . . . . . . . . . . . . . . . . . . . . . Important Information . . . . . . . . . . . . . . . . 1C-2 1C-2 1C-3 1C-3 1C-4 1C-4 1C-5 1C-5 1C-6 1C-6 1C-7 1C-7 1C-8 1C-10 1C-11 1C-11 Engine Will Not Crank Over . . . . . . . . . . . . . . Charging System Inoperative . . . . . . . . . . . . . Noisy Alternator . . . . . . . . . . . . . . . . . . . . . . . . Instrumentation Malfunction . . . . . . . . . . . . . . Radio Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . . Engine Runs Poorly at Idle . . . . . . . . . . . . . . . Engine Runs Poorly At High RPM . . . . . . . . . Engine Acceleration Is Poor . . . . . . . . . . . . . . Troubleshooting with Vacuum Gauge . . . . . . Engine Noise . . . . . . . . . . . . . . . . . . . . . . . . . . Important Information . . . . . . . . . . . . . . . . Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . Excessive Oil Consumption . . . . . . . . . . . . . . Water In The Engine . . . . . . . . . . . . . . . . . . . . Important Information . . . . . . . . . . . . . . . . Engine Overheats (Mechanical) . . . . . . . . . . Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . Drain System Will Not Drain Or Drains Slowly 1C-12 1C-12 1C-13 1C-13 1C-13 1C-14 1C-15 1C-16 1C-17 1C-17 1C-18 1C-18 1C-24 1C-27 1C-28 1C-28 1C-30 1C-33 1C-35

90-864260 OCTOBER 2001

Page vii

ELECTRICAL SYSTEM
Section 4C - Charging System
Delco Alternator . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . EFI Electrical System Precautions . . Charging System Components . . . . . . . . Periodic Maintenance . . . . . . . . . . . . . . . . 4C-2 4C-2 4C-2 4C-3 4C-3 4C-3 4C-4 4C-4 4C-5 4C-5 Troubleshooting Tests (Alternator on Engine) . . . . . . . . . . . . . . . Charging System . . . . . . . . . . . . . . . . . Resistance . . . . . . . . . . . . . . . . . . . . . . . Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . Alternator Bracket . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Bracket . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . Battery Isolator Diagram . . . . . . . . . . . 4C-5 4C-6 4C-7 4C-9 4C-11 4C-11 4C-11 4C-12 4C-12 4C-12 4C-14

90-864260 OCTOBER 2001

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ELECTRICAL SYSTEM
Section 4D - Wiring Diagrams
Instrumentation . . . . . . . . . . . . . . . . . . . . . Single Station Installations - Typical . Power Trim System . . . . . . . . . . . . . . . . . . 4D-2 4D-2 4D-4 MerCathode System Wiring Diagram . . Wiring Diagrams . . . . . . . . . . . . . . . . . . . . 4D-5 4D-6

FUEL SYSTEM
Section 5A - Fuel Delivery System
Specifications . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Replacement Parts Warning . . . . . . . . . . Abbreviations . . . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . Fuel Supply Connections . . . . . . . . . . . . . Fuel Delivery System . . . . . . . . . . . . . . . . Recommendations . . . . . . . . . . . . . . . . Exploded Views . . . . . . . . . . . . . . . . . . . . . Fuel Rail and Injectors . . . . . . . . . . . . . Throttle Body . . . . . . . . . . . . . . . . . . . . . Cool Fuel System . . . . . . . . . . . . . . . . . Fuel System Flow Diagrams . . . . . . . . . . Sensor Locations . . . . . . . . . . . . . . . . . . . . Fuel Pressure Relief Procedure . . . . . . . Flame Arrestor . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Throttle Body . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 5A-2 5A-2 5A-3 5A-3 5A-3 5A-4 5A-5 5A-5 5A-6 5A-6 5A-7 5A-7 5A-8 5A-9 5A-10 5A-11 5A-13 5A-13 5A-13 5A-13 5A-13 5A-14 5A-14 5A-16 5A-17 Electronic Control Module (ECM) . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Water Separating Fuel Filter . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Cool Fuel System . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Intake Manifold . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Air Pressure / Temperature (MAPT) Sensor . . . . . . . . . . . . . . . . . . Throttle Position Sensor (TPS) . . . . . Idle Air Control (IAC) Valve . . . . . . . . . Knock Sensor . . . . . . . . . . . . . . . . . . . . Fuel Pump Relay . . . . . . . . . . . . . . . . . Main Power Relay . . . . . . . . . . . . . . . . 5A-18 5A-18 5A-18 5A-18 5A-19 5A-20 5A-20 5A-20 5A-20 5A-22 5A-24 5A-28 5A-29 5A-29 5A-31 5A-35 5A-35 5A-37 5A-41 5A-41 5A-42 5A-44 5A-45 5A-46 5A-47

Page xii

90-864260 OCTOBER 2001

COOLING SYSTEM
Section 6A - All Models
Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Seawater Inlet Recommendations . . . . . Seacock (Seawater Inlet Valve) . . . . . Seawater Strainer . . . . . . . . . . . . . . . . Seawater Pickups . . . . . . . . . . . . . . . . . . . Through the Hull Mounted . . . . . . . . . Transom Mounted . . . . . . . . . . . . . . . . Quicksilver Sea Strainer . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Hot Water Heater Installation . Supply Hose Connection . . . . . . . . . . Return Hose Connection . . . . . . . . . . . 6A-2 6A-2 6A-3 6A-3 6A-3 6A-4 6A-4 6A-6 6A-8 6A-8 6A-9 6A-10 6A-11 6A-11 6A-12 Seawater Pump . . . . . . . . . . . . . . . . . . . . . Output Test . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Water Circulating Pump . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Water Distribution Housing . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning And Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-12 6A-12 6A-14 6A-15 6A-16 6A-16 6A-19 6A-20 6A-20 6A-21 6A-22 6A-23 6A-23 6A-23 6A-23

COOLING SYSTEM
Section 6B - Seawater Cooled Models
Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Seawater Cooling System Capacity . Thermostat . . . . . . . . . . . . . . . . . . . . . . Flushing Seawater Cooling System . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 6B-2 6B-2 6B-2 6B-2 6B-2 6B-3 6B-3 6B-3 6B-4 6B-5 Water Tap Location For Shaft Log Seal . Water Flow Diagrams . . . . . . . . . . . . . . . . Seawater Cooled Models With An Engine Mounted Seawater Pump Seawater Cooled Models Without An Engine Mounted Seawater Pump 6B-6 6B-7 6B-7 6B-8

COOLING SYSTEM
Section 6C - Closed Cooled Models
Torque Specifications . . . . . . . . . . . . . . . . 6C-2 Lubricants / Sealants / Adhesives . . . . . 6C-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Closed Cooling System Capacity . . . 6C-2 Coolant Specification . . . . . . . . . . . . . . 6C-2 Thermostat . . . . . . . . . . . . . . . . . . . . . . 6C-2 Pressure Cap Rating . . . . . . . . . . . . . . 6C-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . 6C-3 Coolant Recommendations . . . . . . . . . . . 6C-3 Maintaining Coolant Level . . . . . . . . . . . . 6C-4 Pressure Cap Maintenance . . . . . . . . . . . 6C-5 Testing Closed Cooling System . . . . . . . 6C-6 Testing Coolant for Alkalinity . . . . . . . 6C-6 Pressure Testing System . . . . . . . . . . 6C-7 Testing for Cylinder Head Gasket Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-9 Testing Pressure Cap . . . . . . . . . . . . . 6C-10 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Heat Exchanger . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning And Inspection . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Heat Exchanger Bracket Hardware . . . . Heat Exchanger Hose Connections . . . . Water Tap Location For Shaft Log Seal . Closed Cooling System Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-12 6C-12 6C-12 6C-14 6C-15 6C-15 6C-15 6C-16 6C-16 6C-16 6C-17 6C-18 6C-19 6C-20 6C-21 6C-22

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EXHAUST SYSTEM
Section 7A - Manifolds, Elbows And Risers
Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2 7A-2 7A-3 7A-4 Cleaning and Inspection . . . . . . . . . . . . . . . . 7A-5 Manifold Leak Test . . . . . . . . . . . . . . . . . . . . 7A-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-6

EXHAUST SYSTEM
Section 7B - Collectors
Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Important Information . . . . . . . . . . . . . . . . . . Exhaust Y -Pipe . . . . . . . . . . . . . . . . . . . . . . . Water Shutter . . . . . . . . . . . . . . . . . . . . . . Through Transom Exhaust . . . . . . . . . . . . . Water Shutter . . . . . . . . . . . . . . . . . . . . . . Below Swim Platform Exhaust Pipe . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning And Inspection . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Silent Choice Exhaust System . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 7B-2 7B-3 7B-4 7B-4 7B-6 7B-6 7B-8 7B-8 7B-8 7B-8 7B-9 7B-9 Cleaning and Inspection . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . Air Tube Routing . . . . . . . . . . . . . . . . . . Air Pump Maintenance . . . . . . . . . . . . . Troubleshooting Silent Choice Exhaust Silencer System . . . . . . . . . . . Exhaust Muffler Kit . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . 7B-10 7B-11 7B-12 7B-13 7B-14 7B-15 7B-15 7B-15 7B-16 7B-17

DRIVES
Section 8A - Velvet Drive In-Line And V-Drive Transmission
Identification . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Operating Specifications . . . . . . . . . . . Ratios And Part Numbers . . . . . . . . . . Fluid Specifications . . . . . . . . . . . . . . . Pressure Specifications . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . Transmission / Propeller Rotation . . . . . . Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 8A-3 8A-3 8A-3 8A-4 8A-4 8A-4 8A-5 8A-5 8A-6 8A-7 8A-7 8A-7 8A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lever Installation . . . . . . . . . . . . . Shift Control And Cables . . . . . . . . . . . . . Transmission Shift Lever and Shift Cable Bracket . . . . . . . . . . . . . . . . . . . Installation and Adjustment . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . Transmission Repair . . . . . . . . . . . . . . . . . 8A-10 8A-11 8A-13 8A-14 8A-15 8A-16 8A-20 8A-20

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90-864260 OCTOBER 2001

DRIVES
Section 8B - Velvet Drive 5000 Series Transmission
Identification . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Ratios and Part Numbers . . . . . . . . . . Fluid Specifications . . . . . . . . . . . . . . . Pressure Specifications . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . Transmission / Propeller Rotation . . . . . . Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2 8B-3 8B-3 8B-3 8B-4 8B-4 8B-4 8B-5 8B-6 8B-7 8B-7 8B-7 8B-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lever Installation . . . . . . . . . . . . . Shift Control And Cables . . . . . . . . . . . . . Transmission Shift Lever and Shift Cable Bracket . . . . . . . . . . . . . . . . . . . Installation and Adjustment . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . Transmission Repair . . . . . . . . . . . . . . . . . 8B-9 8B-10 8B-12 8B-13 8B-14 8B-16 8B-20 8B-20

DRIVES
Section 8C - ZF/Hurth 630 And 800 Series Transmission
Identification . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Operating Specifications . . . . . . . . . . . Ratios and Part Numbers . . . . . . . . . . Fluid Specifications . . . . . . . . . . . . . . . Pressure Specifications . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . Transmission / Propeller Rotation . . . . . . Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2 8C-3 8C-3 8C-3 8C-4 8C-4 8C-4 8C-4 8C-5 8C-5 8C-6 8C-7 8C-7 8C-7 8C-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Shift Control And Cables . . . . . . . . . . . . . Transmission Shift Lever and Shift Cable Bracket . . . . . . . . . . . . . . . . . . . Installation and Adjustment . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . Transmission Repair . . . . . . . . . . . . . . . . . 8C-9 8C-10 8C-13 8C-13 8C-15 8C-19 8C-19

POWER STEERING
Section 9A - Power Steering Pump
Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump And Components Exploded View . . . . . . . . . . . Power Steering Pump Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow Control Valve Servicing . . . . . . . . . Pump Shaft Oil Seal Replacement . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2 9A-2 9A-2 9A-3 9A-3 9A-4 9A-4 9A-4 9A-5 9A-5 9A-6 9A-7 9A-9 Replacing Belt And/Or Adjusting Tension Filling And Bleeding . . . . . . . . . . . . . . . . . . Checking Fluid Level . . . . . . . . . . . . . . . . . . Hydraulic Hoses And Fluid Cooler . . . . . . High Pressure Hose (Pump-To-Control Valve) . . . . . . . . . . . Low Pressure Hose (Pump-To-Fluid Cooler) . . . . . . . . . . . . Low Pressure Hose (Control Valve-To-Fluid Cooler) . . . . . 9A-10 9A-10 9A-10 9A-11 9A-11 9A-13 9A-15

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SERVICE MANUAL NUMBER 31

GENERAL INFORMATION

IMPORTANT INFORMATION
Section 1A - General Information

1
A

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use This Manual . . . . . . . . . . . . . . . . . Page Numbering . . . . . . . . . . . . . . . . . . . . Engine Serial Number Locations . . . . . . . . . . Mercury/Quicksilver Lubricants, Sealants And Adhesives . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 1A-2 1A-2 1A-3 1A-4

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GENERAL INFORMATION

SERVICE MANUAL NUMBER 31

Introduction
This comprehensive overhaul and repair manual is designed as a service guide for the models previously listed. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment to enable dealers and service mechanics to repair and tune these engines. Before attempting repairs or tune-up, it is suggested that the procedure first be read through to gain knowledge of the methods and tools used and the cautions and warnings required for safety.

How To Use This Manual

This manual is divided into sections which represent major components and systems. Some sections are further divided into parts that more fully describe the component. Refer to the Service Manual Outline following Models Covered In This Manual for section titles.

Page Identification
The service manual number and section title appear at the top of the page. Two number groups appear at the bottom of each page. Following is an example and a description.

b c

a b c d e f g

- Section Number - Section Part - Page Number - Manual Number - Revision Number - Month Printed - Year Printed

Page 1A-2

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SERVICE MANUAL NUMBER 31

GENERAL INFORMATION

Engine Serial Number Locations

78018

a - Serial Number Plate b - Starter Motor

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GENERAL INFORMATION

SERVICE MANUAL NUMBER 31

Mercury/Quicksilver Lubricants, Sealants And Adhesives

Tube Ref. #
4 6 7 9

Description
Needle Bearing Assy. Lubricant Dielectric Grease Loctite 271 - Thread Locker Loctite 567 PST Pipe Sealant Loctite Master Gasket Kit 2 Cycle Premium Outboard Oil Perfect Seal Liquid Neoprene Bellows Adhesive Loctite 680 Retaining Compound Special Lubricant 101 U-Joint and Gimbal Bearing Grease Loctite 222 Thread Locker Loctite 242 Thread Locker 4 Cycle 25W40 Engine Oil Premium Gear Lubricant High Performance Gear Lube Engine Coupler Spline Grease Anti-Corrosion Grease 2-4-C with Teflon 4 Stroke 10W30 Outboard Oil Power Trim & Steering Fluid

Container Size
8 oz (226.8 g) tube 8 oz (226.8 g) can 10 ml tube 50 ml tube

Mercury Part Number

N/A N/A N/A N/A N/A

Quicksilver Part Number

92-802868A1 92-823506-1 92-809819 92-809822 92-12564-2 92-802813Q1 92-34227-1 92-25711-3 92-86166Q1 92-809833 92-802865Q1 92-802870Q1 92-809818 92-809821 92-802837Q1 92-802846Q1 92-802854Q1 92-802869Q1 92-802867Q1 92-802859Q1 92-802833Q1 92-802880Q1

14 19 25 27 33 34 42

1 US qt (0.94 L) 16 oz (0.45 kg) can 8 oz (226.8 g) can 1.5 oz (42.5 g) tube 10 ml tube 8 oz (226.8 g) tube

92-802813A1 N/A N/A N/A N/A 92-802865A1 92-802870A1

10 ml tube 10 ml tube

N/A N/A 92-802837A1

1 US qt (0.94 L) 1 US qt (0.94 L) 14 oz (0.39 kg) cartridge 8 oz (226.8 g) tube 8 oz (226.8 g) tube 1 US qt (0.94 L) 8 oz (226.8 g)

92-802846A1 92-802854A1 92-802869A1 92-802867A1 92-802859A1 92-802833A1 92-802880A1

94 95 110

114

Page 1A-4

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SERVICE MANUAL NUMBER 31

GENERAL INFORMATION

Tube Ref. #
115

Description
Premium Plus 2 Cycle TC-W3 Outboard Oil RTV 587 Silcone Sealer Loctite 7649 Primer N Storage Seal Rust Inhibitor Corrosion Guard 15W40 4-cycle Diesel Engine Oil Extended Life Antifreeze/Coolant Marine Engine Coolant Fuel System Treatment and Stabilizer Concentrate Heat Transfer Compound Liquid Gasket T442 Sealant Loctite 5900 Ultra Black RTV Silicone Sealant Loctite Gasket Remover Sealer Kit, Two Part Epoxy Dexron III Automatic Transmission Fluid Loctite 592 Loctite Quick Tite Isopropyl Alcohol Hot Glue Loctite 609 Loctite 405 Cyanacrylate Adhesive 3M Permabond #3M08155 Loctite 262

Container Size
1 US qt (0.94 L) 3 oz (85.05 g) 4.5 oz (127.57 g) 12 oz (325 ml) spray can 12 oz (325 ml) spray can 1.06 US gal.(4 L) 1 US gal. (3.78 L) 1.33 US gal. (5 L) 16 oz (437 ml) 1.5 oz (42.5 g) tube

Mercury Part Number

92-802824A1 N/A N/A 92-802878-56 92-802878 55 92-877695K1 92-877770K1 N/A 92-802876A1 N/A N/A N/A

Quicksilver Part Number

92-802824Q1 92-809825 92-809824 92-802878Q56 92-802878Q55 92-877695Q1 92-877770K1 92-813054A2 92-802876Q1 92-805701 1 92-808137 92-862258 92-809826 92-809828 1 92-65150 1 Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally

116 117 118

119

120

121

122

123

124 125 126

127

13 oz (371 g) tube 18 oz (532 ml) spray can

N/A N/A N/A Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally

128

129

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GENERAL INFORMATION

SERVICE MANUAL NUMBER 31

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Page 1A-6

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MAINTENANCE

IMPORTANT INFORMATION
Section 1B - Maintenance

1
B

Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Engine And Tune-Up Specifications . . . . MCM (Sterndrive) Models . . . . . . . . . . MIE (Tow Sports and Inboard) Models Fluid Specifications . . . . . . . . . . . . . . . . . . Engines . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrives . . . . . . . . . . . . . . . . . . . . . . Transmissions . . . . . . . . . . . . . . . . . . . . Maintenance Schedules . . . . . . . . . . . . . . Maintenance Intervals . . . . . . . . . . . . . Gas Sterndrive . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance . . . . . . . . . . . . . Scheduled Maintenance . . . . . . . . . . . Gas Inboard And Tow Sports . . . . . . . . . Routine Maintenance . . . . . . . . . . . . . Scheduled Maintenance . . . . . . . . . . Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . Overfilled Crankcase Oil . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Oil and Filter . . . . . . . . . . . . Flushing The Power Package - MCM . . Sterndrive Water Pickups . . . . . . . . . . Alternative Water Pickups . . . . . . . . . . Flushing The Power Package - MIE . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . Inboard Models . . . . . . . . . . . . . . . . . . . Tow Sports Models . . . . . . . . . . . . . . . . Transmission Fluid . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Changing and Filling . . . . . . . . . . . . . . Sterndrive Unit Oil . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Pump Fluid . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump Fluid . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Filling and Bleeding . . . . . . . . . . . . . . . Water Inlets . . . . . . . . . . . . . . . . . . . . . . . . Seawater Strainer . . . . . . . . . . . . . . . . 1B-2 1B-2 1B-3 1B-4 1B-4 1B-5 1B-6 1B-6 1B-6 1B-7 1B-7 1B-7 1B-8 1B-8 1B-9 1B-11 1B-11 1B-12 1B-14 1B-15 1B-15 1B-16 1B-17 1B-19 1B-19 1B-21 1B-23 1B-23 1B-23 1B-25 1B-27 1B-27 1B-28 1B-28 1B-28 1B-28 1B-29 1B-31 1B-31 1B-31 1B-31 1B-32 1B-32 1B-33 1B-35 1B-35 Closed Cooling System . . . . . . . . . . . . . . Checking Coolant Level . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Changing Coolant . . . . . . . . . . . . . . . . Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . Power Package Surfaces . . . . . . . . . . . . . Painting Your Power Package . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruments . . . . . . . . . . . . . . . . . . . . . . . . . Gimbal Ring / Steering Connection . . . . Changing Water Separating Fuel Filter . Steering System . . . . . . . . . . . . . . . . . . . . Remote Control . . . . . . . . . . . . . . . . . . . . . Sterndrive Components . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable . . . . . . . . . . . . . . . . . . . . Shift Cable and Transmission Linkage Sterndrive Components . . . . . . . . . . . Continuity Circuit . . . . . . . . . . . . . . . . . . . . MerCathode . . . . . . . . . . . . . . . . . . . . . . . . Engine Mounts . . . . . . . . . . . . . . . . . . . . . . Electrical System . . . . . . . . . . . . . . . . . . . . Cleaning Flame Arrestor . . . . . . . . . . . . . Serpentine Drive Belt . . . . . . . . . . . . . . . . Inboard and Tow Sports Models . . . . Sterndrive Models . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Replacing Belt and/or Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . Seawater Pump . . . . . . . . . . . . . . . . . . . . . Starter Motor . . . . . . . . . . . . . . . . . . . . . . . 14MT . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Weather And Extended Storage . . Preparing Your Power Package For Storage . . . . . . . . . . . . . . . . . . . . . Draining Instructions . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . Boat In The Water . . . . . . . . . . . . . . . . Boat Out Of The Water . . . . . . . . . . . . All Models . . . . . . . . . . . . . . . . . . . . . . . 1B-36 1B-36 1B-36 1B-36 1B-37 1B-40 1B-41 1B-41 1B-42 1B-42 1B-42 1B-43 1B-44 1B-44 1B-44 1B-44 1B-44 1B-45 1B-46 1B-50 1B-52 1B-52 1B-52 1B-53 1B-54 1B-54 1B-55 1B-55 1B-56 1B-57 1B-57 1B-58 1B-58 1B-59 1B-59 1B-61 1B-62 1B-63 1B-67 1B-70

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MAINTENANCE

SERVICE MANUAL NUMBER 31

Torque Specifications
NOTE: Securely tighten all fasteners not listed below. Description Steering Lever Clamping Bolt And Nut Propeller Nut Alpha One, Bravo One and Bravo Two1 Front Propeller Nut Bravo Three Rear Propeller Nut Bravo Three Rear Engine Mounts Flame Arrestor Bracket Nuts
1

Nm 67.8 75 136 81 51.5 12

lb-in.

lb-ft 50 55 100 60 38 9

Amount specified is MINIMUM.

Special Tools
Description Flushing Device Dual Water Pickup Flush Gear Case Seal Kit Low Water Pickups Flushing Attachment Quicksilver Reference Electrode And Test Meter Kent Moore Belt Tension Gauge Part Number 91-44357Q2 91-881150Q1 849996T1 91-76675T1 BT-3373-F

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Lubricants / Sealants / Adhesives

Description 2-4-C Marine Lubricant With Teflon U-joint And Gimbal Bearing Grease High Performance Gear Lube Engine Coupler Spline Grease Dexron III Automatic Transmission Fluid Where Used Hinge pins Sterndrive unit U-joint crosses and bearings, drive shaft Gimbal bearings Propeller shaft Engine coupler splines, U-joint shaft splines Power Steering System 92-802856Q1 92-816391A4 Obtain Locally Part Number 92-802859Q1

92-828052A2

Engine Oil

Pivot points, guide contact surface, starter motor, detent ball and holes, water separating Obtain Locally fuel filter sealing ring, oil filter sealing ring Water separating fuel filter layup Power trim pump Power package Closed Cooling System Fuel System Fuel System Fuel System 92-802813A1 92-802880Q1 92-802878 55 92-877770K1 92-802875A1 92-802876A1 92-802824A1

2-Cycle Premium Outboard Oil Quicksilver Power Trim And Steering Fluid Corrosion Guard Spray Mercury Extended Life Coolant/Antifreeze Mercury Fuel System Treatment and Stabilizer Mercury Fuel System Treatment and Stabilizer Concentrate Premium Plus 2-Cycle TC-W3 Outboard Oil

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Engine And Tune-Up Specifications

MCM (Sterndrive) Models
Models Propshaft Horsepower Propshaft Kilowatts Number of Cylinders Displacement Bore/Stroke in. (mm) Compression Ratio Compression Pressure Specified WOT rpm Range2 Idle rpm in NEUTRAL2 Oil Pressure @ 2000 rpm 5 Oil Pressure @ Idle Thermostat Firing Order Electrical System Alternator Rating - Hot Operating Amps Alternator Rating - Cold Operating Amps Minimum Recommended Battery Rating Spark Plug Type Spark Plug Gap
1 2 Measured 3 Idle

5.0 L MPI 260 1 194 5.0 l (305 cid) 3.74 x 3.48 (95 x 88.4) 9.4:1

350 MAG MPI Horizon 300 1 224 1

350 MAG MPI

MX 6.2 MPI

MX 6.2 MPI Horizon

320 1 238 1 6.2 l (377 cid) 4.0 x 3.75 (101.6 x 95.25) 9.0:1
4

V8 5.7 l (350 cid) 4.0 x 3.48 (101.6 x 88.4) 9.3:1 Minimum 100 psi (670 kPa) 4600-5000 600 rpm 3 Minimum 124 kPa (18 psi) Minimum 55 kPa (4 psi) 296 kPa (43 psi) 71 degrees C (160 degrees F) 1-8-4-3-6-5-7-2 12-Volt Negative () Ground 65 Amps 72 Amps 550 cca / 825 mca / 150 Ah AC Platinum (AC 41-932) 0.060 in.

4800-5200

Fuel Pressure (1800 rpm)

Power rated in accordance with NMMA (National Marine Manufacturers Association) rating procedures. using an accurate service tachometer, with the engine at normal operating temperature. speed on EFI models is not adjustable.

4 Minimum 5 Oil

recorded compression in any one cylinder should not be less than 70 percent of the highest recorded cylinder. pressure must be checked with the engine at normal operating temperature.

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Engine And Tune-Up Specifications (continued)

MIE (Tow Sports and Inboard) Models
Models Propshaft Horsepower Propshaft Kilowatts Number of Cylinders Displacement Bore/Stroke in. (mm) Compression Ratio Compression Pressure Specified WOT rpm Range2 Idle rpm in NEUTRAL 2 Oil Pressure @ 2000 rpm 5 Oil Pressure @ Idle Thermostat Firing Order Electrical System Alternator Rating - Hot Operating Amps Alternator Rating - Cold Operating Amps Minimum Recommended Battery Rating Spark Plug Type Spark Plug Gap
1 2 Measured 3 Idle

350 MAG MPI Tow Sport 315 1 235 1

350 MAG MPI Horizon 300 1 224 1

350 MAG MPI

MX 6.2 MPI 320 1 238 1

MX 6.2 MPI Horizon 320 1 238 1

V8 5.7 l (350 cid) 4.0 x 3.48 (101.6 x 88.4) 9.3:1 Minimum 670 kPa (100 psi) 4600-5000 4400-4800 600 rpm 3 Minimum 124 kPa (18 psi) Minimum 55 kPa (4 psi) 296 kPa (43 psi) 71 degrees C (160 degrees F) 1-8-4-3-6-5-7-2 12-Volt Negative () Ground 65 Amps 72 Amps 550 cca / 825 mca / 150 Ah AC Platinum (AC 41-932) .060 in. 6.2 l (377 cid) 4.0 x 3.75 (101.6 x 95.25) 9.0:1
4

4600-5000

Fuel Pressure (1800 rpm)

4 Minimum 5 Oil

recorded compression in any one cylinder should not be less than 70 percent of the highest recorded cylinder. pressure must be checked with the engine at normal operating temperature.

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Fluid Specifications
IMPORTANT: It may be necessary to adjust oil levels depending on the installation angle and the cooling systems (the heat exchanger and the fluid lines).

Engines
NOTE: All capacities are approximate fluid measures All Models Crankcase Oil (With Filter) 1 Seawater Cooling System 2 Closed Cooling System Capacity Liters (U.S. qts) 5.20 (5-1/2) 20 (21) Fluid Type Quicksilver 4-Cycle 25W-40 Marine Engine Oil Propylene Glycol and Purified Water Mercury Extended Life Coolant/Antifreeze or Extended Life Ethylene Glycol 5/100 Antifreeze/Coolant mixed 50/50 with Purified Water

19 (20)

1 2

Always use the dipstick to determine the exact quantity of oil or fluid required. Seawater Cooling System capacity information is for winterization use only.

Sterndrives
NOTE: All capacities are approximate fluid measures NOTE: Drive unit oil capacity is with the gear lube monitor. Model Alpha One Bravo One Bravo Two Bravo Three Capacity Liters (U.S. qts) 1.89 (2) 2.60 (2.75) 3.08 (3.26) 2.84 (3) High Performance Gear Lube Fluid Type

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Transmissions
NOTE: All capacities are approximate fluid measures NOTE: Always use the dipstick to determine the exact fluid level. Model 5000A 5000V 71C In-Line 71C Gear Reduction 71C Remote V-Drive 72C In-Line 72C Gear Reduction 72C Remote V-Drive 72C V-Drive 630A 630V Capacity Liters (U.S. qts) 2.84 (3) 3.30 (3-1/2) 1.66 (1-3/4) 2.84 (3) 1.66 (1-3/4) 1.66 (1-3/4) 1.66 (1-3/4) 1.66 (1-3/4) 3.79 (4) 4.00 (4-1/2) 4.00 (4-1/2) Mobil 424 or Universal Tractor Hydraulic Oil Do Not Mix! Dexron III Automatic Transmission Fluid Fluid Type Dexron III Automatic Transmission Fluid or Equivalent Mobil 424 or Dexron III Automatic Transmission Fluid Do Not Mix!

Maintenance Schedules
NOTE: Only perform maintenance which applies to your particular power package.

Maintenance Intervals
Maintenance intervals and the corresponding tasks to be performed, as shown in this current schedule or as found in a previously printed schedule, are generally based on an average boating application and environment. However, individual operating habits and personal maintenance preferences can have an impact on the suggested intervals. In consideration of these factors, Mercury MerCruiser has adjusted some maintenance intervals and the corresponding tasks to be performed. In some cases, this may allow for more individual tasks in a single visit to the servicing dealer. Therefore, it is very important that the boat owner and the servicing dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide with the individual operating habits, the environment and the maintenance requirements.

CAUTION
Always disconnect the battery cables from the battery before working around electrical systems components to prevent injury to yourself and damage to the electrical system should a wire be accidentally shorted.

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Gas Sterndrive
Routine Maintenance *
Each Day Start Check the crankcase oil (interval can be extended based on experience). If operating in salt, brackish or polluted waters, flush the cooling system after each use. Check the drive unit oil level, the trim pump oil level and the power steering pump fluid level. Check the water inlets for debris or marine growth. Check the seawater strainer and clean. Check the coolant level. Inspect the drive unit anodes and replace if 50 percent eroded. Lubricate the propeller shaft and retorque the nut (if operating in only freshwater, this maintenance may be extended to every four months). Operating in Saltwater Only: treat the engine surface with corrosion guard. Check the battery connections and the fluid level. Ensure that the gauges and the wiring connections are secure. Clean the gauges.1
* Only perform maintenance which applies to your particular power package
1 If

Each Day End

Weekly

Every Two Months

L L

L L L or 50 hours

operating in saltwater, interval is reduced to every 25 hours or 30 days whichever occurs first

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Gas Sterndrive (continued)

Scheduled Maintenance *
Every Every Every 200 300 100 Every Every hours hours Annual hours or 2 5 or 3 or 3 ly Annually years years years years z z z Touch-up paint the power package and spray with corrosion guard. Change the crankcase oil and filter. Change the drive unit oil and retorque the connection of the gimbal ring to the steering shaft. Replace the fuel filters. Check the steering system and the remote control for loose, missing or damaged parts. Lubricate the cables and the linkages. Inspect the U-joints, the splines and the bellows. Check the clamps. Check the engine alignment. Lubricate the U-joint splines. Lubricate the gimbal bearing and the engine coupler. Check the continuity circuit for loose or damaged connections. Test the MerCathodeR unit output on Bravo Models. Retorque the engine mounts. Check the spark plugs, the wires and the distributor cap. Clean the flame arrestor and the crankcase ventilation hoses. Replace the PCV valve.
* Only perform maintenance which applies to your particular power package z Whichever occurs first * Lubricate the engine coupler every 50 hours if operated at idle for prolonged periods of time

L L L L

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Gas Sterndrive (continued)

Scheduled Maintenance *
Every Every Every 200 300 100 Every Every hours hours Annual hours or 2 5 or 3 or 3 ly Annually years years years years z z z Check the electrical system for loose, damaged or corroded fasteners. Inspect the condition and the tension of the belts. Check the cooling system and exhaust system hose clamps for tightness. Inspect both systems for damage or leaks. Disassemble and inspect the seawater pump and replace worn components. Clean the seawater section of the closed cooling system. Clean, inspect and test the pressure cap. Replace the coolant.
* Only perform maintenance which applies to your particular power package z Whichever occurs first x Interval will be reduced if not using extended life coolant

L L

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Gas Inboard And Tow Sports

Routine Maintenance *
Each Day Start Check the crankcase oil (interval can be extended based on experience). If operating in salt, brackish or polluted waters, flush the cooling system after each use. Check the transmission fluid. Check the water pickups for debris or marine growth. Check the water strainer and clean. Check the coolant level. Check the battery connections and the fluid level. Ensure that the gauges and the wiring connections are secure. Clean the gauges.1
* Only perform maintenance which applies to your particular power package
1 If

Each Day End

Weekly

Every Two Months

L L L L L or 50 hours

operating in saltwater, interval is reduced to every 25 hours or 30 days whichever occurs first

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Gas Inboard And Tow Sports (continued)

Scheduled Maintenance *
Every Every Every 200 300 100 Every Every hours hours Annual Per hours or 2 5 or 3 or 3 ly OEM Annually years years years years z z z Touch-up paint power package and spray with corrosion guard. Change the crankcase oil and filter. Change the transmission fluid. Replace the fuel filters. Check the steering system and remote control for loose, missing or damaged parts. Lubricate the cables and linkages. Retorque the engine mounts. Check the spark plugs, wires, and distributor cap. Clean the flame arrestor and the crankcase ventilation hoses. Replace the PCV valve. Check the electrical system for loose, damaged or corroded fasteners. Inspect the condition and tension of the belts.
z Whichever occurs first

L L L L

L L

* Only perform maintenance which applies to your particular power package

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Gas Inboard And Tow Sports (continued)

Scheduled Maintenance *
Every Every Every 200 300 100 Every Every hours hours Annual Per hours or 2 5 or 3 or 3 ly OEM Annually years years years years z z z Check the cooling system and exhaust system hose clamps for tightness. Inspect both systems for damage or leaks. Disassemble and inspect the seawater pump and replace worn components. Clean the seawater section of the closed cooling system. Clean, inspect and test the pressure cap. Replace the coolant. Check the engine-to-propeller shaft alignment.
* Only perform maintenance which applies to your particular power package z Whichever occurs first x Interval will be reduced if not using extended life coolant

L L

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Crankcase Oil
To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of Quicksilver 4-Cycle 25W-40 Marine Engine Oil. This oil is a special blend of 25-weight and 40-weight oils for marine engines. If not available, a good grade, straight weight, detergent automotive oil of the correct viscosity, with an API classification of SH, CF/CF-2, may be used. In those areas where Quicksilver 4-Cycle 25W-40 Marine Engine Oil or a recommended straight weight oil are not available, a multi-viscosity 20W-40 or, as a second but less preferable choice, 20W-50, with API service ratings of SH, CF/CF-2 may be used. IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other than Quicksilver 25W-40 or a good quality 20W-40 or 20W-50), synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended. The chart below is a guide to crankcase oil selection. The oil filter should always be changed when changing the engine oil.

CAUTION
Mercury MerCruiser or Quicksilver 4-Cycle oil is recommended for use for your engine. Severe engine damage may result from the use of an inferior oil.
Quicksilver 4-Cycle 25W-40 Marine Engine Oil

SAE 40W

SAE 30W

SAE 20W

32 F 0 C

50 F 10 C 75796

AIR TEMPERATURE

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Overfilled Crankcase Oil

An overfilled crankcase (oil level being too high) can cause a fluctuation or drop in oil pressure and rocker arm clatter on Mercury MerCruiser engines. This condition results in the engine crankshaft splashing and agitating the oil, causing it to foam (become aerated). The aerated oil causes the hydraulic valve lifters to bleed down. This, in turn, results in rocker arm clatter and loss of engine performance, due to the valves not opening properly. Care must be taken when checking the engine oil level. The oil level must be maintained between the ADD mark and the FULL or OK RANGE mark on the dipstick. To ensure that you are not getting a false reading, ensure the following: Boat at rest in the water, or If the boat is on a trailer, raise or lower the bow until the boat is setting at the approximate angle that it would be if setting at rest in the water. Allow sufficient time for the oil to drain into the crankcase if the engine has just been operated or oil has just been added.

Checking
1. 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.

77808

2. Remove the dipstick. Wipe it clean and reinstall it fully into the dipstick tube. 3. Remove the dipstick and observe the oil level. The oil level must be between the FULL or OK RANGE and ADD marks. Fill as necessary with the specified fluid. All Models Crankcase Oil (With Filter) 1
1

Capacity Liters (U.S. qts) 5.25 (5-1/2)

Fluid Type 4-Cycle 25W-40 Marine Engine Oil

Always use dipstick to determine exact quantity of oil or fluid required.

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Filling

77842

MIE Shown, MCM Similar 2. Add the specified oil to bring the level up to, but not over the FULL or OK RANGE mark on the dipstick. All Models Crankcase Oil (With Filter) 1
1

Capacity Liters (U.S. qts) 5.25 (5-1/2)

Fluid Type 4-Cycle 25W-40 Marine Engine Oil

Always use the dipstick to determine the exact quantity of oil or fluid required.

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Changing Oil and Filter

Refer to the Maintenance schedule for the change interval. The crankcase oil should be changed before placing the boat in storage. IMPORTANT: Change the crankcase oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only the recommended engine oil (refer to Specifications).

QUICK DRAIN OIL

1. Pull the tether through the bilge drain. 2. Place the oil drain hose in a suitable container. 3. Remove the drain plug from the oil drain hose. 4. After the oil has drained completely, install the drain plug in the oil drain hose. 5. Push the hose through the bilge drain and install the plug. 6. Proceed to ALL MODELS.

CRANKCASE OIL PUMP

1. Remove the dipstick. 2. Insert the hose end of the crankcase oil pump onto an appropriate container and using the handle, pump until the crankcase is empty.

b
a - Crankcase Oil Pump b - Dipstick 3. Remove the pump. 4. Install the dipstick. 5. Proceed to ALL MODELS.

70571

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ALL MODELS
1. Remove and discard the oil filter.

77808

a - Oil Filter 2. Coat the sealing ring on the new filter with engine oil and install. 3. Tighten the filter securely (following filter manufacturers instructions). Do NOT overtighten. 4. Remove the oil fill cap.

77843

MCM Shown, MIE Similar

oil_fill_mcm.dwg

IMPORTANT: Always use the dipstick to determine exactly how much oil is required. 5. Add the recommended engine oil to bring the level up to, but not over, the FULL or OK RANGE mark on the dipstick. All Models Crankcase Oil (With Filter) 1
1

Capacity Liters (U.S. qts) 5.25 (5-1/2)

Fluid Type 4-Cycle 25W-40 Marine Engine Oil

Always use dipstick to determine exact quantity of oil or fluid required.

6. Start the engine and check for leaks.

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Flushing The Power Package - MCM

Your boat could come equipped with one of three different types of water pickups: through the hull, through the transom and through the sterndrive. The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups.

Sterndrive Water Pickups

There are three types of water pickups available on Mercury MerCruiser sterndrives: low water, dual water and side pickups. Dual water pickups require the flushing attachment (44357Q2) and the flush seal kit, low water pickups require the flushing attachment and side pickups require the flushing attachment.

77899

Dual Water Pickup Description Flushing Device

Low Water Pickup

Side Pickup Part Number 91-44357Q2 91-881150Q1 849996T1

Dual Water Pickup Flush Gear Case Seal Kit Low Water Pickups Flushing Attachment

NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results.

CAUTION
If flushing with the boat in the water, seawater can flow into the engine causing engine damage. Water inlet must be closed when flushing the engine. 1. Drain the seawater section of the cooling system. 2. If flushing cooling system with the boat in the water: a. Raise the sterndrive unit to the TRAILER position. b. Install the appropriate flushing attachment over the water intake openings in the gear housing. c. Lower the sterndrive unit to the full DOWN/IN position.

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3. If flushing the cooling system with the boat out of the water: a. Lower the sterndrive unit to the full DOWN/IN position.

WARNING
Contact with moving drive components and the propeller can cause personal injury or death. To avoid possible injury, remove the propeller and ensure that no people or animals are in the area of the drive unit while flushing. b. Remove the propeller. c. Install the appropriate flushing attachment over the water intake openings in the gear housing. 4. Connect a hose between the flushing attachment and a water source. 5. With the sterndrive unit in normal operating position, partially open the water source (about 1/2 maximum). 6. Place the sterndrive in the NEUTRAL IDLE speed position and start the engine.

CAUTION
Suction created by the seawater pickup pump may collapse the flushing water hose causing the engine to overheat. Avoid engine damage from overheating; do NOT operate the engine above 1500 rpm. 7. Slowly advance the throttle until the engine reaches 1300 rpm (+/100 rpm).

CAUTION
Engine overheating can cause engine damage. To avoid, observe the water temperature gauge and ensure that the engine is operating in the normal range. 8. Observe the water temperature gauge to ensure that the engine is operating in the normal range. 9. Operate the engine with the sterndrive in NEUTRAL for about 10 minutes or until the discharge water is clear. 10. Slowly return the throttle to the idle speed position. 11. Stop the engine. 12. Shut off the water and remove the flushing attachment.

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Alternative Water Pickups

NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results. 1. Drain the seawater section of the cooling system. 2. If flushing the cooling system with the boat in the water: a. Raise the sterndrive unit to the TRAILER position. b. Install the appropriate flushing attachment over the water intake openings in the gear housing. c. Lower the sterndrive unit to the full DOWN/IN position. 3. If flushing the cooling system with the boat out of the water: a. Lower the sterndrive unit to the full DOWN/IN position.

WARNING
Contact with moving drive components and the propeller can cause personal injury or death. To avoid possible injury , remove the propeller and ensure that no people or animals are in the area of the drive unit while flushing. b. Remove the propeller. c. Install the appropriate flushing attachment over the water intake openings in the gear housing. 4. Connect a hose between the flushing attachment and a water source. 5. Disconnect the water inlet hose (upper hose) from the aft side of the seawater pump.

77945

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75191

b. All other models: Using an appropriate connector, connect the flushing hose from the water to the water inlet hose (upper hose) of the seawater pickup pump. Proceed to Step 3.

77908

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WARNING
Contact with moving drive components and the propeller can cause personal injury or death. To avoid possible injury, remove the propeller and ensure that no people or animals are in the propeller area while flushing. 2. If flushing the engine with the boat out of the water, remove the propeller. Refer to boat manufacturers instructions. a. Models with Walter V-Drive Transmissions: Disconnect water inlet hose from transmission fitting. Using an appropriate connector, connect the flushing hose. Proceed to Step 3.

75191

b. All other models: Using appropriate connector, connect the flushing hose from the water to the water inlet hose (upper hose) of the seawater pickup pump. Proceed to Step 3.

77908

3. Open the water source. 4. Place remote control in NEUTRAL, idle speed position, and start engine. Operate engine at idle speed, in NEUTRAL, for about 10 minutes or until discharge water is clear. 5. Stop the engine. 6. Remove the flushing connector from the water inlet. 7. Reconnect the water inlet hose. 8. Tighten hose clamp securely. 9. Attach to the next engine, if equipped, and repeat procedure. 10. Turn off the water source. 11. Open the water inlet or remove the plug from the water inlet fitting and reinstall the water inlet hose. 12. Replace the propeller, if removed. Refer to the boat manufacturers instructions.

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Transmission Fluid
WARNING
Do not remove the dipstick with the engine operating. Hot oil can cause burns.

CAUTION
Clean around the area of the dipstick before removing. Small particles of dirt can cause damage to internal components and cause the valves to stick.

Checking
WARM
IMPORTANT: Operate the engine at 1500 rpm for 2 minutes immediately prior to checking level. 1. Velvet Drive Transmissions - Stop engine and quickly check fluid level by turning T-handle counterclockwise, to remove dipstick. Fluid level should be up to full mark. If low, add specified fluid through dipstick tube on transmissions. 2. Hurth Transmissions - Stop engine and remove dipstick to check level. If fluid is below top (full) line, add specified fluid through dipstick hole. Do not overfill. Reinstall dipstick with cap fully seated. 3. Walter V-Drive Transmissions - Stop engine and remove dipstick to check level. If fluid is below top (full) line, add specified fluid through breather elbow. Do not overfill. Reinstall dipstick with cap fully seated.

a b

c
72526

Typical a - Dipstick b - Full Mark c - Dipstick Tube

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COLD
NOTE: Cold Fluid Level Check: To ease checking the fluid level, the dipstick can be marked or scribed with a cold level mark. 1. Follow the procedure for the warm fluid level check, then allow the boat to sit overnight. IMPORTANT: Be sure to push the dipstick all the way down into the dipstick tube when checking the fluid level. 2. Remove the dipstick, wipe clean and reinsert. 3. Remove the dipstick, observe the fluid level and mark the cold fluid level. 4. Reinstall the dipstick, tighten the T-handle securely. Do NOT overtighten.

Changing and Filling

Refer to SECTION 8 for the procedures on changing and filling the transmission.

Sterndrive Unit Oil

Checking
NOTE: Oil level will fluctuate during operation. The oil level should be checked with a cold engine before starting. 1. Check the gear lube monitor oil level. Keep the oil level at or near the FULL line. 2. If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if the oil appears discolored, immediately determine the cause and correct. Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual. Both conditions may indicate a water leak somewhere in the sterndrive unit.

Filling
IMPORTANT: If more than 59ml (2 fl. oz.) of fluid is required to fill the monitor, a seal may be leaking. Damage to the drive unit may occur due to lack of lubrication.

CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. 1. Remove the gear lube monitor cap. 2. Fill to the OPERATING RANGE line. Model Alpha One Bravo One Bravo Two Bravo Three 3. Replace the cap. Capacity Liters (U.S. qts) 1.89 (2) 2.60 (2.75) 3.08 (3.26) 2.84 (3) High Performance Gear Lube Fluid Type

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MAINTENANCE

Changing
1. Remove the gear lube monitor from the bracket.

77813

2. Empty into a suitable container. 3. Install the monitor in the bracket. 4. Bravo One Models: a. Remove the propeller. b. Place the sterndrive unit in the full trim limit IN position. c. Remove the oil fill/drain screw and the sealing washer; drain the oil.

70568

5. All Other Models: a. Place the sterndrive unit in the full trim limit OUT position. b. Remove the oil fill/drain screw and the sealing washer, drain the oil.

72522

IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately.

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6. Remove the oil vent screw and the sealing washer. Allow the oil to drain completely.

77106

7. Lower the sterndrive unit until the propeller shaft is level. IMPORTANT: Use only specified fluid in the drive unit. 8. Fill the drive unit, through the oil fill/drain hole, with the specified gear lube until an air-free stream of lubricant flows from the oil vent hole. 9. Install the oil vent screw and the sealing washer. 10. Continue to pump the gear lube into the gear lube monitor circuit until the gear lube appears in the gear lube monitor. Fill the monitor to the OPERATING RANGE line. 11. Ensure that the rubber gasket is inside the cap and install the cap. Do NOT overtighten. 12. Remove the pump from the oil fill/drain hole. Quickly install the sealing washer and the oil fill/drain screw. Tighten securely. 13. Bravo One and Alpha Models: Grease the propeller shaft heavily, with the specified lubricant. Reinstall the propeller and torque the nut. 14. Bravo Two Models: Grease the propeller shaft heavily, with the specified lubricant. Reinstall the propeller and torque the nut. 15. Bravo Three Models: Grease the propeller shaft heavily, with the specified lubricant. Reinstall the propeller and torque the nut. Description Propeller Nut Alpha One, Bravo One and Bravo Front Propeller Nut Bravo Three Rear Propeller Nut Bravo Three
1

Nm Two1 75 136 81

lb-in.

lb-ft 55 100 60

Amount specified is MINIMUM.

16. Recheck the oil level after first use. IMPORTANT: The oil level in the gear lube monitor will rise and fall during drive operation; always check the oil level when the drive is cool and the engine is off.

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Power Trim Pump Fluid

Checking
1. Place the sterndrive unit in the full DOWN/IN position.

70979

a - Cap Plug 2. Remove the fill cap from the reservoir and observe the oil level. The level must be up to, but not over the bottom of the filler neck. a. Ensure that the cap plug has been removed from the filler neck and discarded. NOTE: The fill cap is vented. 3. Fill as necessary with specified fluid.

Filling
1. Remove the fill cap from the reservoir. 2. Add fluid to bring the level to the bottom of the filler neck. Description Quicksilver Power Trim and Steering Fluid or SAE 10W-30 Engine Oil 3. Replace the cap. Where Used Power Trim Pump Part Number 92-802880Q1

Changing
Power Trim fluid does not require changing.

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Power Steering Pump Fluid

Checking
ENGINE WARM
1. Stop the engine. Center the sterndrive unit. 2. Remove the fill cap / dipstick from the power steering pump and note the fluid level.

77108

a - Fill Cap / Dipstick b - Power Steering Pump 3. The level should be between the FULL HOT mark and the ADD mark on the dipstick.

a
a - Proper Fluid Level With Engine Warm

72518

4. If the level is below the ADD mark, but fluid is still visible in the pump reservoir, add the required amount of fluid through the fill cap opening to bring the level up to the FULL HOT mark on the dipstick. Do NOT overfill. Description Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid Where Used Power Steering System Part Number 92-802880Q1

5. If fluid is not visible in the reservoir, a leak exists in the power steering system. Find the cause and correct.

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ENGINE COLD
1. With the engine stopped, center the sterndrive unit. 2. Remove the fill cap / dipstick from the power steering pump and note the fluid level. 3. The level should be between the FULL COLD mark and the bottom of the dipstick.

a
a - Proper Fluid Level With Engine Cold

72519

4. If the level is below the bottom of the dipstick, but fluid is still visible in the pump reservoir, add the required amount of specified fluid through the fill cap opening to bring the level up to the FULL COLD mark on the dipstick. Do NOT overfill. If fluid is not visible in the reservoir, a leak exists in the power steering system. Find the cause and correct.

Filling and Bleeding

IMPORTANT: The power steering system must be filled exactly as explained to ensure that all air is bled from the system. All air must be removed or fluid in the pump may foam during operation and be discharged from the pump reservoir. Foamy fluid also may cause the power steering system to become spongy, which may result in poor boat control. 1. With the engine stopped, center the sterndrive unit. 2. Remove the fill cap / dipstick from the power steering pump. IMPORTANT: Use only specified fluid in the power steering system. 3. Add specified fluid, as required, to bring the level up to the FULL COLD mark on the dipstick. 4. Turn the steering wheel back and forth to the end of travel in each direction several times. 5. Recheck the fluid level and add fluid, if necessary.

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6. Install the vented fill cap. Tighten securely.

CAUTION
DO NOT operate engine without water being supplied to seawater pickup pump or pump impeller may be damaged and subsequent overheating damage to engine may result. 7. Start the engine and operate at fast idle (1300 rpm) until the engine reaches normal operating temperature. During this time, turn the steering wheel back and forth to the end of travel in each direction several times. 8. Center the sterndrive unit and stop the engine. 9. Remove the fill cap from the pump. 10. Allow any foam in the pump reservoir to disperse. 11. Check the fluid level and add fluid, as required, to bring the level up to the FULL HOT mark on the dipstick. Do NOT overfill. 12. Reinstall the fill cap. Tighten securely. IMPORTANT: The drive unit must be positioned straight back and the power steering fluid must be hot to accurately check the fluid level. 13. If the fluid is still foamy (in Step 10.), repeat Steps 7. through 12. until the fluid does not foam and the level remains constant.

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MAINTENANCE

Water Inlets
All water inlets should be inspected for obstruction. Refer to the maintenance charts for the interval. 1. Remove debris or marine growth from all water inlets. 2. Flush with clean water.

Seawater Strainer
1. Remove the seawater strainer. 2. Disassemble the components. 3. Clean the filter element.

72673

a - Filter Element 4. Flush with clean water. 5. Reassemble the components. 6. Install the seawater strainer.

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SERVICE MANUAL NUMBER 31

Closed Cooling System

Checking Coolant Level
CAUTION
Allow the engine to cool down before removing the pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. After the engine has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off. 1. Remove the cap from the heat exchanger and observe the fluid level. 2. The coolant level in the heat exchanger should be at the bottom of the filler neck. IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the filler neck. 3. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle. 4. The coolant level should be between the ADD and FULL marks.

72520

5. Add the specified fluid as necessary.

Cleaning and Inspection

NOTE: Refer to SECTION 6C. 1. Ensure that all hose clamps are tight and connections are secure. 2. Inspect the entire system for damage or leaks. 3. Clean the seawater section. 4. Clean, inspect and test the pressure cap.

Changing Coolant
The coolant should be changed periodically based on the use of the specified coolant; refer to the maintenance charts for the interval. For the changing coolant procedures, refer to SECTION 6C.

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MAINTENANCE

Anodes
NOTE: Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for propeller removal and installation. IMPORTANT: Replace the sacrificial anodes if eroded 50 percent or more. Each sterndrive unit is equipped with a sacrificial anodic plate to help protect underwater metal parts from galvanic corrosion. Because of its self-sacrificing nature, the anodic plate MUST BE replaced if eroded 50 percent or more. The sterndrive unit anodes should be inspected for erosion. Refer to the Maintenance Schedules for the interval.

71176

c b

a b c d

- Universal Anodic Plate - Anodic Plate - MerCathode (If Equipped) - Anode Kit (If Equipped)

1. Universal Anodic Plate - Serves as a sacrificial anode.

73919

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SERVICE MANUAL NUMBER 31

2. Anodic Plate - Serves as a sacrificial anode.

a a
a - Anodic Plate 3. Block (if equipped) - Mounted to the underside of the gimbal housing and serves as a sacrificial anode.
70575

70576

4. MerCathode System (if equipped) - Electrode assembly replaces the Anodic block.

70578

The system should be tested to ensure adequate output. The test should be made where the boat is moored, using Quicksilver Reference Electrode and Test Meter. Description Quicksilver Reference Electrode and Test Meter Part Number 91-76675T1

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5. Anode Kit (if equipped) - Mounted to the boat transom. Acts as a sacrificial anode.

70577

6. Trim Cylinder Anodes - Mounted on each trim cylinder. To replace the trim cylinder anodes:

71966

a. Remove two screws from the anode. b. Clean the mounting surfaces down to the bare metal for proper contact. c. Install the new anode. Tighten the screws securely. 7. Bearing Carrier Anode (Alpha and Bravo One) - Located in front of the propeller, between the front side of the propeller and the gear housing. To replace the propeller anode:

72032

a. Remove the propeller. b. Remove two screws from the anode. c. Clean the mounting surfaces down to the bare metal for proper contact. d. Install the new anode. Tighten the screws securely. e. Reinstall the propeller.

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8. Bearing Carrier Anode - Located in front of the propeller, between the front side of the propeller and the gear housing.

72029

9. Gear Housing Anode (Bravo Two and Three) - Located in the splash plate, just above the propellers.

Propeller Shaft
1. Lubricate the propeller shaft splines.

a
76910

72239

77047

77046

Bravo One / Bravo Two Sterndrives a - Propeller Shaft Splines

Bravo Three Sterndrives

2. Retorque the propeller nut. Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual or Operation, Maintenance and Warranty Manual for propeller removal and installation. Description Propeller Nut Alpha One, Bravo One and Bravo Front Propeller Nut Bravo Three Rear Propeller Nut Bravo Three Two1 Nm 75 136 81 lb-in. lb-ft 55 100 60

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MAINTENANCE

Power Package Surfaces

The entire power package should be sprayed at recommended intervals with Corrosion Guard. Follow the instructions on the can for proper application. NOTE: If operating in saltwater, the interval for treating the engine surface with Corrosion Guard will be reduced. Refer to Maintenance Schedules. Description Corrosion Guard Spray Where Used Power package Part Number 92-802878 55

The entire power package should be cleaned and the external surfaces that have become bare should be repainted with Primer and Spray Paint at recommended intervals. Refer to Maintenance Schedules.

Painting Your Power Package

IMPORTANT: Corrosion damage that results from the improper application of anti-fouling paint will not be covered by the limited warranty. 1. Painting the boat hull or the boat transom: Anti-fouling paint may be applied to the boat hull and the boat transom but you must observe the following precautions: IMPORTANT: Do NOT paint the anodes or the MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors. IMPORTANT: If anti-fouling protection is required for the boat hull or the boat transom, copper or tin base paints, if not prohibited by law, can be used. If using copper or tin based anti-fouling paints, observe the following: Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks or MerCathode System and the paint by allowing a minimum of 40 mm (1-1/2 in.) UNPAINTED area on the transom of the boat around these items.

a
71176

a - Minimum Unpainted Area 2. Painting Drive Unit or Transom Assembly: The drive unit and the transom assembly should be painted with a good quality marine paint or an anti-fouling paint that DOES NOT contain copper, tin or any other material that could conduct an electrical current. Do not paint the drain holes, the anodes, the MerCathode system, and items specified by the boat manufacturer.

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SERVICE MANUAL NUMBER 31

Battery
NOTE: Refer to the manufacturers instructions. 1. Ensure that the battery connections are secure. 2. Check the fluid level.

Instruments
1. Ensure that the gauges are tight. Tighten the mounting bracket nuts, if loose. Do NOT overtighten. 2. Ensure that all gauge and wiring connections are tight and insulated where necessary. IMPORTANT: The gauge may be scored or damaged if wiped with abrasive material such as sand, saline or detergent compounds or washed with solvents such as trichlorethylene and turpentine. 3. Clean the gauges with fresh water to remove sand and salt deposits. Wipe with a soft cloth moistened with water.

Gimbal Ring / Steering Connection

NOTE: Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for sterndrive removal and installation. 1. Check the connection between the gimbal ring and the steering shaft. 2. Tighten the steering lever clamping bolt and nut.

a b

a a

Engine and Transom Assembly Installed a - Wrench b - Socket Wrench Description Steering Lever Clamping Bolt And Nut Removed

Page 1B-42

70157

22460

Nm 68

lb-in.

lb-ft 50

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MAINTENANCE

Changing Water Separating Fuel Filter

WARNING
Avoid Fire or Explosion: The fuel injection system is pressurized during operation. Use care when removing the water separating fuel filter. Fuel could spray on the hot engine causing fire or explosion. Allow the engine to cool down before attempting to remove the water separating fuel filter in the following procedure. Also, hold a clean shop towel over the water separating fuel filter when removing it, to help avoid fuel spraying on the engine.

WARNING
Be careful when changing the water separating fuel filter. Gasoline is extremely flammable and highly explosive under certain conditions. Ensure that the ignition key is OFF. Do not smoke or allow spark or open flame in the area when changing the fuel filter. Wipe up any spilled fuel immediately.

WARNING
Ensure that no fuel leaks exist before closing the engine hatch. 1. Activate the Schrader valve located on the fuel rail to relieve pressure. 2. Remove the water separating fuel filter and the sealing ring from the mounting bracket and discard.

a
70573

a - Fuel Filter b - Sealing Ring 3. Coat the sealing ring on the new filter with engine oil. Description Engine Oil Where Used Oil filter sealing ring Part Number Obtain Locally

4. Thread the filter onto the bracket and tighten securely by hand. Do not use a filter wrench. 5. Start and operate the engine. 6. Inspect the filter connection for gasoline leaks. If leaks exist, recheck the filter installation.

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Steering System
1. Inspect the steering system. 2. Ensure that there are no loose, missing or damaged components. 3. Repair or replace, as necessary.

Remote Control
1. Inspect the remote controls. 2. Ensure that there are no loose, missing or damaged components. 3. Repair or replace, as necessary.

Sterndrive Components
1. Inspect the U-joints. 2. Inspect the engine coupler splines. 3. Inspect the shaft splines. 4. Inspect the bellows. 5. Ensure that there are no loose, missing or damaged components. 6. Repair or replace, as necessary.

Lubrication
Throttle Cable
1. Lubricate the pivot points and the guide contact surfaces.

78033

a
a - Pivot Points b - Guide Contact Surfaces Description Engine Oil Where Used Pivot points, guide contact surfaces Part Number Obtain Locally

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MAINTENANCE

Shift Cable and Transmission Linkage

ALL MODELS
1. Lubricate the pivot points and the guide contact surfaces.

71357

Typical a - Pivot Points b - Guide Contact Surfaces Description Engine Oil Where Used Pivot points, guide contact surfaces Part Number Obtain Locally

INBOARD AND TOW SPORTS MODELS

1. Lubricate the detent ball and the holes in the shift lever.

a
Typical In-Line Transmission a - Detent Ball Locations Description Engine Oil Where Used Detent ball and holes

71457

Part Number Obtain Locally

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SERVICE MANUAL NUMBER 31

Sterndrive Components
GIMBAL BEARING
1. Lubricate the gimbal bearing by applying approximately 8-10 pumps of grease from a typical hand-operated grease gun.

77068

a - Grease Fitting Description U-joint And Gimbal Bearing Grease Where Used Gimbal bearings Part Number 92-828052A2

a. Alpha Models - Lubricate the hinge pins by applying a couple of pumps of grease from a typical hand-operated grease gun.

77044

a - Grease Fitting Description 2-4-C Marine Lubricant With Teflon Where Used Hinge pins Part Number 92-802859Q1

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MAINTENANCE

ENGINE COUPLER AND SHAFT SPLINES

NOTE: Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for sterndrive unit removal and installation, if necessary. IMPORTANT: These engines are equipped with a sealed engine coupler. The sealed coupler and the shaft splines can be lubricated without removing the sterndrive unit. 1. Lubricate the engine coupler splines through the grease fittings on the coupler by applying approximately 8-10 pumps of grease from a typical hand-operated grease gun. If the boat is operated at idle for prolonged periods of time, the coupler should be lubricated Bravo Models - every 50 hours; Alpha Models - every 150 hours.

a a
71569 72529

Alpha Drive Coupler a - Grease Fitting Description Engine Coupler Spline Grease

Bravo Drive Coupler

Where Used Engine coupler splines, U-joint shaft splines

Part Number 92-816391A4

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SERVICE MANUAL NUMBER 31

U-JOINTS
NOTE: Alpha Models - Your engine is equipped with Perm-a-Lube U-joints. The Perm-a-Lube U-joints do not require lubrication. NOTE: Bravo Models - The crosses and the bearings on the sterndrive U-joint will need to be lubricated through the grease fittings. The sterndrive unit must be removed to grease these fittings. 1. Remove the sterndrive unit; refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for sterndrive unit removal and installation. 2. Apply grease from a typical hand-operated grease gun until a small amount of grease begins to push out. 3. Lubricate the U-joint shaft splines.

a
72531

Typical Bravo Drive a - Coupler Splines b - Grease Fitting Description A Engine Coupler Spline Grease B U-joint And Gimbal Bearing Grease Where Used Engine coupler splines, U-joint shaft splines Sterndrive unit U-joint crosses and bearings, drive shaft Part Number 92-816391A4 92-828052A2

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MAINTENANCE

DRIVE SHAFT EXTENSION MODELS

1. Lubricate the drive shaft grease fittings at the transom end by applying approximately 10-12 pumps of grease from a typical hand-operated grease gun. 2. Lubricate the drive shaft grease fittings at the engine end by applying approximately 3-4 pumps of grease from a typical hand-operated grease gun.

a a a

72018

a
Transom End a - Grease Fitting Description U-joint And Gimbal Bearing Grease Engine End

72028

Where Used Sterndrive unit U-joint crosses and bearings, drive shaft

Part Number 92-828052A2

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SERVICE MANUAL NUMBER 31

Continuity Circuit
The transom assembly and the sterndrive unit are equipped with ground circuit wires to ensure good electrical continuity between the engine, the transom assembly and the sterndrive components. Good continuity is essential for the Anode and the MerCathode System to function most effectively. 1. Inspect the following ground circuit components for loose connections, broken or fraying wires.

a
a - Steering Lever Ground Wire

22028

22650

77079

a - Inner Transom Plate To Gimbal Housing Ground Wire b - Driveshaft Housing To Gear Housing Ground Plate (Inside Anode Cavity)

77100

a - Gimbal Housing To Gimbal Ring Ground Wire b - Gimbal Ring To Trim Cylinder Ground Wires

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MAINTENANCE

Continuity Circuit (continued)

a b

22028

c
a - Flywheel Housing Grounding Stud b - Ground Wire c - Inner Transom Plate Grounding Screw

22755

22031

a - Gimbal Ring To Bell Housing Ground Wire b - Sterndrive Unit To Bell Housing Ground Plate

70575

22230

a - Driveshaft Housing To Gear Housing Anodic Plate b - Hydraulic Connector Block To Gimbal Housing Ground Washer

b a

50383

22079

a - U-joint Bellows Ground Clip b - Exhaust Bellows Ground Clips

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SERVICE MANUAL NUMBER 31

MerCathode
If the boat is equipped with a Quicksilver MerCathode System, the system should be tested to ensure that it is providing adequate output to protect the underwater metal parts on the boat. The test should be made where the boat is moored, using Quicksilver Reference Electrode and Test Meter. Description Quicksilver Reference Electrode and Test Meter Part Number 91-76675T1

Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for testing procedures.

Engine Mounts
1. Torque the rear engine mounts. Refer to SECTION 2. Description Rear Engine Mounts Nm 51 lb-in. lb-ft 38

Electrical System
NOTE: Refer to SECTION 4 for specific procedures. 1. Inspect the spark plugs. 2. Inspect the spark plug wires. 3. Inspect the distributor cap. 4. Inspect the entire electrical system for loose, damaged or corroded fasteners.

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MAINTENANCE

Cleaning Flame Arrestor

1. Remove the engine cover. 2. Remove the crankcase ventilation hose from the fitting on the side of the flame arrestor housing. 3. Remove the flame arrestor.

78020

a - Flame Arrestor 4. Clean the flame arrestor with water or steam. Dry with compressed air. 5. Clean the crankcase ventilation hoses. Dry with compressed air. 6. Inspect the crankcase ventilation hoses for cracks or deterioration and replace if necessary. 7. Install the flame arrestor and the crankcase ventilation hoses. 8. Install the flame arrestor bracket and tighten the nuts.
Description Flame Arrestor Bracket Nuts Nm 12 lb-in. lb-ft 9

9. Install the engine cover.

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SERVICE MANUAL NUMBER 31

Serpentine Drive Belt

WARNING
Avoid possible serious injury. Ensure that the engine is shut off and the ignition key is removed before inspecting the belt. IMPORTANT: The brackets and washers on the 3 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.

Inboard and Tow Sports Models

e d b
Typical Inboard Model a - Idler Pulley b - Seawater Pump Pulley c - Crankshaft Pulley d - Circulating Pump Pulley e - Alternator Pulley

76503

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MAINTENANCE

Sterndrive Models
d a d a

e e a f c
Without A Seawater Pump a - Idler Pulley b - Seawater Pump Pulley c - Crankshaft Pulley d - Circulating Pump Pulley e - Alternator Pulley f - Power Steering Pulley

f c b
With A Seawater Pump

Inspection

WARNING
Avoid possible serious injury. Ensure that the engine is shut off and the ignition key is removed before inspecting the belt. 1. Inspect the drive belt for the following: Excessive wear Cracks

NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are NOT acceptable. Fraying Glazed surfaces Proper tension - 6 mm (1/4 in.) deflection, with moderate thumb pressure, on the belt at the location that has the longest distance between two pulleys.

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SERVICE MANUAL NUMBER 31

Replacing Belt and/or Adjusting Tension

REMOVAL
1. Loosen the 5/8 in. locking nut on the adjustment stud. 2. Turn the adjustment stud and loosen the belt. 3. Remove the serpentine drive belt.

INSTALLATION AND ADJUSTMENT

1. Install the serpentine drive belt onto the pulleys. 2. Put a wrench on the adjustment stud 5/8 in. locking nut. 3. Use a 5/16 in. socket and tighten adjusting the stud to adjust the belt deflection. 4. Ensure that the correct deflection has been obtained. a. Push down with moderate thumb pressure on the longest stretch of belt. b. Attach the Kent Moore Belt Tension Gauge to the belt. The gauge has different ranges for new and used belts.

b a

77574 77573

a - Kent Moore Tension Gauge b - Serpentine Belt

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MAINTENANCE

5. While holding the adjustment stud at the correct belt tension, tighten the 5/8 in. locking nut.

b a
77827

a - 5/8 in. Locking Nut b - 5/16 in Adjusting Stud 6. Operate the engine for a short period of time and recheck the belt adjustment.

Exhaust System
NOTE: Refer to SECTION 7. 1. Ensure that all hose clamps are tight and connections are secure. 2. Inspect the entire system for damage or leaks.

Seawater Pump
NOTE: Refer to SECTION 6A. 1. Inspect the seawater pump components; replace as necessary.

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SERVICE MANUAL NUMBER 31

Starter Motor
14MT
WARNING
When performing the following procedure, be sure to observe the following: Ensure that the engine compartment is well ventilated and that no gasoline vapors are present to avoid the possibility of a fire. Be sure to ground the coil high-tension wire to the block. Failure to ground the coil wire may cause damage to the ignition coil in addition to being a safety hazard. Stay clear of all moving parts.

1. Remove the ignition coil high-tension wire from the distributor cap tower and ground it to the engine block with the jumper wire. While cranking the engine with the starter motor, lubricate the starter motor front bushing through the oil cover. Reinstall the coil high-tension wire. Description Engine Oil Where Used Starter motor Part Number Obtain Locally

2. Remove the plastic plug from the flywheel housing. Lubricate the starter motor shaft through the hole in the flywheel housing. Reinstall the plastic plug.

72019

a - Lubrication Point Description Engine Oil Where Used Starter motor shaft Part Number Obtain Locally

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MAINTENANCE

Cold Weather And Extended Storage

IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty.

CAUTION
Sterndrive unit should be stored in the full DOWN position. Universal joint bellows may develop a set if unit is stored in raised position and may fail when unit is returned to service. IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze (a nontoxic and environmentally safe antifreeze) be used in the seawater section of the cooling system for cold weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturers recommendations.

CAUTION
The seawater section of the cooling system MUST BE COMPLETELY drained for winter storage, or immediately after cold weather use, if the possibility of freezing temperatures exist. Failure to comply may result in trapped water causing freeze and/or corrosion damage to the engine. Damage caused by freezing is NOT covered by the Mercury MerCruiser Limited Warranty.

Preparing Your Power Package For Storage

1. Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount of Mercury Fuel System Treatment and Stabilizer to treat the gasoline. Follow instructions on the container. 2. If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): Fuel tanks should be drained as low as possible and Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank. NOTE: If desired, a portable fuel tank can be used to perform the remainder of the power package lay up procedures. Be sure to add an appropriate amount of Gasoline Stabilizer to the portable tank. 3. Flush the cooling system. 4. Change the oil and oil filter.

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SERVICE MANUAL NUMBER 31

FUEL SYSTEM

WARNING
The fuel injection system is pressurized. Avoid serious injury from an explosion. Use care when removing water separating fuel filter. Allow engine to cool down before removing the water separating fuel filter. Also, hold a clean shop towel over the water separating fuel filter when removing it, to help avoid fuel spraying on the engine.

WARNING
Fuel vapors can be present in the engine compartment. Avoid injury or power package damage caused by fuel vapors or explosion. Always ventilate the engine compartment prior to servicing the power package. 1. In a 23 l (6 U.S. gal.) remote fuel tank mix: a. 19 l (5 U.S. gal) regular unleaded 87 octane (90 RON) gasoline b. 1.89 l (2 U.S. qts.) Premium Plus 2-Cycle TC-W3 Outboard Oil c. 150ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel System Treatment and Stabilizer Concentrate. Description Mercury Fuel System Treatment and Stabilizer Mercury Fuel System Treatment and Stabilizer Concentrate Premium Plus 2-Cycle TC-W3 Outboard Oil 2. Allow the engine to cool down. 3. Activate the Schrader valve to relieve fuel pressure. 4. Close the fuel shut-off valve, if equipped. Disconnect and plug the fuel inlet fitting if not equipped with a fuel shut-off valve. 5. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting. IMPORTANT: Supply cooling water to the engine. 6. Start and operate the engine at 1300 rpm for 5 minutes. 7. After specified operating time is complete, slowly return throttle to idle rpm and shut engine off. IMPORTANT: Ensure that some fogging mixture remains in the engine. Do NOT allow the engines fuel system to become completely dry. 8. Remove and discard the water separating fuel filter. 9. Install a new filter. BATTERY Follow the battery manufacturers instructions for storage. Where Used Fuel System Fuel System Fuel System Part Number 92-802875A1 92-802876A1 92-802824A1

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MAINTENANCE

Draining Instructions
CAUTION
Ensure that boat is out of the water or seacock is closed and bilge pump is operating before beginning procedure. Excess water in bilge can damage engine or cause boat to sink.

CAUTION
Do not operate engine with drain system open. Excess water in bilge can damage engine or cause boat to sink. IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system. Your power package is equipped with one of three drain systems. Refer to Identification on the following page to determine which instructions apply to your power package. The power package should be drained before flushing or prior to extended or cold weather storage. IMPORTANT: The boat must not be operating at any point during this procedure.

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Identification
MANUAL SINGLE POINT DRAIN SYSTEM

a b b

77917

77947

77949

a - Blue Handle b - Blue Drain Plug Location

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

b a

c d a

d
77955 77955

Closed Cooled Models a - Blue Drain Plug Location b - Blue Air Pump c - Air Manifold d - Green Indicators

Seawater Cooled Models

3 POINT MANUAL DRAIN SYSTEM

a
77917

77908

a - Blue Drain Plug

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Boat In The Water

MANUAL SINGLE POINT DRAIN SYSTEM
1. Close the seacock. 2. Rotate the blue handle COUNTERCLOCKWISE until it stops (approximately 2 turns). The red on the handle shaft indicates that the drain system is open. Do not force the handle as this will create new threads. 3. Immediately remove the blue drain plug from the side of the thermostat housing. This must be removed within 30 seconds to properly vent the cooling system.

a
77947

77949

a - Blue Handle b - Blue Drain Plug Location 4. Visually verify that water is draining. If water does not drain, remove blue drain plug from distribution housing and drain manually.

77917

b a

a - Drain Location - Orange Or Red b - Blue Drain Plug 5. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. 6. Reinstall the blue drain plug in the thermostat housing. 7. Close the drain system by rotating the blue handle CLOCKWISE until it stops and install the blue drain plug, if removed. The handle is fully seated when no red is visible. Do not overtighten the handle as this will create new threads. 8. Open the seacock prior to operating the engine.

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AIR ACTUATED SINGLE POINT DRAIN SYSTEM

NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1. Close the seacock. 2. Remove the blue air pump from the engine. 3. Ensure that lever on top of pump is flush with the handle (horizontal). 4. Install the air pump on the fitting in the air manifold.

77638

a - Green Indicators 5. Pull lever on the air pump up (vertical) to lock pump on the fitting. 6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side. 7. Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger. This must be removed within 30 seconds to properly vent the cooling system.

b a

c d a

d
77955 77955

Closed Cooled Models a - Blue Drain Plug Location b - Blue Air Pump c - Air Manifold d - Green Indicators

Seawater Cooled Models

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MAINTENANCE

8. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain System instructions.

77839

77844

a - Port Side Drain Location b - Starboard Side Drain Location 9. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the green indicators extended. 10. Crank engine over slightly with starter motor to purge any water trapped in seawater pump. Do NOT allow engine to start. 11. Reinstall the blue drain plug in the thermostat housing. 12. Remove the air pump from the air manifold and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained. 14. Before launching boat, pull up on manual release valve. Verify that green indicators are no longer extended.

a
a - Green Indicators 15. Open the seacock prior to operating the engine.

77638

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3 POINT MANUAL DRAIN SYSTEM

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails. 1. Close the seacock. 2. Remove three blue drain plugs: One from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side).

a
77917

77908

a - Blue Drain Plugs 3. Immediately remove the blue drain plug from the side of the thermostat housing. This must be removed within 30 seconds to properly vent the cooling system.

77949

a - Blue Drain Plug Location 4. Verify that water is draining from each opening. 5. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. 6. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. Do NOT allow the engine to start. 7. Prior to launching boat or starting the engine, close the drain system by installing the four blue drain plugs. 8. Open the seacock prior to operating the engine.

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MAINTENANCE

Boat Out Of The Water

MANUAL SINGLE POINT DRAIN SYSTEM
1. Rotate the blue handle COUNTERCLOCKWISE until rotation stops (approximately 2 turns). The red on the handle shaft indicates that the drain system is open. Do not force the handle as this will create new threads.

77947

a - Blue Handle 2. Visually verify that water is draining. If water does not drain, remove blue drain plug from distribution housing and allow to drain manually.

b a
77917

a - Drain Location - Orange Or Red b - Blue Drain Plug 3. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained. 4. Close the drain system by rotating the blue handle CLOCKWISE until it stops or installing the blue drain plug. The handle is fully seated when no red is visible. Do not overtighten the handle as this will create new threads.

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SERVICE MANUAL NUMBER 31

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1. Remove the blue air pump from the engine. 2. Ensure that lever on top of pump is flush with the handle (horizontal). 3. Install the air pump on the fitting in the air manifold.

77638

a - Green Indicators 4. Pull the lever on the air pump up (vertical) to lock the pump on the fitting. 5. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.

b a

c d a

d
77955 77955

Closed Cooled Models a - Blue Drain Plug Location b - Blue Air Pump c - Air Manifold d - Green Indicators

Seawater Cooled Models

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MAINTENANCE

6. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain System.

77839

77844

a - Port Side Drain Location b - Starboard Side Drain Location 7. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the green indicators extended. 8. Crank engine over slightly with starter motor to purge any water trapped in seawater pump. Do NOT allow engine to start. 9. Remove the air pump from the air manifold and return it to the mounting bracket. 10. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained. 11. Before launching boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

a
a - Green Indicators

77638

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SERVICE MANUAL NUMBER 31

3 POINT MANUAL DRAIN SYSTEM

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails. 1. Remove three blue drain plugs: One from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side).

a
77917

77908

a - Blue Drain Plug 2. Verify that water is draining from each opening. 3. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained. 4. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. Do NOT allow engine to start. 5. Prior to launching boat or starting the engine, close the drain system by re-installing the three blue drain plugs.

All Models
1. For additional assurance against freezing and corrosion, fill the cooling system with a mixture of propylene glycol antifreeze and tap water mixed to manufacturers recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage. a. Remove thermostat housing or hose and fill with propylene glycol coolant until engine block is full. If thermostat housing was removed, reinstall and tighten cover bolts securely. Store boat with drive unit in full DOWN/IN position.

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TROUBLESHOOTING

IMPORTANT INFORMATION
Section 1C - Troubleshooting

1
C

Table of Contents
Used Spark Plug Analysis . . . . . . . . . . . . . . . Normal Condition . . . . . . . . . . . . . . . . . . . . Chipped Insulator . . . . . . . . . . . . . . . . . . . . Wet Fouling (Oil Deposits) . . . . . . . . . . . . Cold Fouling . . . . . . . . . . . . . . . . . . . . . . . . Overheating . . . . . . . . . . . . . . . . . . . . . . . . High Speed Glazing . . . . . . . . . . . . . . . . . . Scavenger Deposits . . . . . . . . . . . . . . . . . Pre-Ignition Damage . . . . . . . . . . . . . . . . . Reversed Coil Polarity . . . . . . . . . . . . . . . . Splashed Deposits . . . . . . . . . . . . . . . . . . . Mechanical Damage . . . . . . . . . . . . . . . . . Poor Boat Performance And/Or Poor Maneuverability . . . . . . . . . . . . . . . . . . . Improper Full Throttle Engine RPM . . . . . . . . Engine Cranks Over But Will Not Start Or Starts Hard . . . . . . . . . . . . . . . . . . . . . . . . . Important Information . . . . . . . . . . . . . . . . 1C-2 1C-2 1C-3 1C-3 1C-4 1C-4 1C-5 1C-5 1C-6 1C-6 1C-7 1C-7 1C-8 1C-10 1C-11 1C-11 Engine Will Not Crank Over . . . . . . . . . . . . . . Charging System Inoperative . . . . . . . . . . . . . Noisy Alternator . . . . . . . . . . . . . . . . . . . . . . . . Instrumentation Malfunction . . . . . . . . . . . . . . Radio Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . . Engine Runs Poorly at Idle . . . . . . . . . . . . . . . Engine Runs Poorly At High RPM . . . . . . . . . Engine Acceleration Is Poor . . . . . . . . . . . . . . Troubleshooting with Vacuum Gauge . . . . . . Engine Noise . . . . . . . . . . . . . . . . . . . . . . . . . . Important Information . . . . . . . . . . . . . . . . Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . Excessive Oil Consumption . . . . . . . . . . . . . . Water In The Engine . . . . . . . . . . . . . . . . . . . . Important Information . . . . . . . . . . . . . . . . Engine Overheats (Mechanical) . . . . . . . . . . Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . Drain System Will Not Drain Or Drains Slowly 1C-12 1C-12 1C-13 1C-13 1C-13 1C-14 1C-15 1C-16 1C-17 1C-17 1C-18 1C-18 1C-24 1C-27 1C-28 1C-28 1C-30 1C-33 1C-35

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TROUBLESHOOTING

SERVICE MANUAL NUMBER 31

Used Spark Plug Analysis

Spark plug condition can suggest a variety of possible engine malfunctions and indicate needed engine repairs. When the old plugs are replaced, replace the entire set. Perform plug service only on those plugs suitable for additional service, using the following procedures: 1. Remove any oil deposits with solvent and dry plugs thoroughly. 2. Open the electrode gap wide enough to permit cleaning and filing. 3. Remove the combustion deposits from the firing end of the spark plug with a plug cleaner. Use compressed air to remove abrasives. 4. File the electrode surfaces to restore clean, sharp edges. Remove filings with compressed air. 5. Reset the gap to specifications by bending only the side electrode with the proper tool.

Normal Condition
Few deposits are present and probably will be light tan or gray in color. This plug shows that the plug heat range is compatible with the engine, and the engine is electrically and mechanically in good running condition. With proper plug servicing (clean, file and regap), this plug can be reinstalled with good results.

TROUBLESHOOTING

SERVICE MANUAL NUMBER 31

Cold Fouling
Dry, black deposits indicate a rich fuel mixture or a weak ignition. A clogged flame arrestor, a flooding engine, a sticky choke or weak ignition components all are probable causes. 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.

72421

Overheating
The insulator is dull white or gray and appears blistered. The electrodes are eroded and there is an absence of deposits. Check that the correct plug heat range is being used. Also check for incorrect rotor location, cooling system malfunction, lean fuel/air mixtures, leaking intake manifold or sticking valves. Replace the spark plugs.

72421

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TROUBLESHOOTING

High Speed Glazing

The insulator has yellowish, varnish-like color, indicating that the temperatures suddenly have risen, usually during hard, fast acceleration under heavy load. Normal deposits do not get a chance to blow off. Instead, they melt and form a conductive coating. Replace the spark plugs. If the condition recurs, use colder heat range plug and service plugs more frequently.

72421

Scavenger Deposits
Powdery white or yellow deposits are built up on the shell, the insulator and the electrodes. This is the normal appearance with certain branded fuels. Accumulation on the ground electrodes and the shell areas may be unusually heavy, but may be easily chipped off. The plugs can be serviced (clean, file and regap) and reinstalled.

72422

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Pre-Ignition Damage
Pre-ignition damage is caused by excessive high temperatures. The center electrode melts first, followed by the ground electrode. Normally, the insulators are white but may be dirty if the plug has been misfiring. Check for the correct plug heat range, incorrect rotor location, lean fuel mixture, incorrect fuel used, malfunctioning cooling system, leaking intake manifold or lack of lubrication. Replace the spark plugs.

72422

Reversed Coil Polarity

Concave erosion of the ground electrode is an indication of reversed polarity. The center electrode will show only normal wear. The engine will misfire and idle rough. To correct, reverse the primary coil leads. Replace the spark plugs.

72422

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TROUBLESHOOTING

Splashed Deposits
Spotted deposits, which sometimes occur after long delayed tune-up, accumulate after a long period of misfiring. When normal combustion temperatures are restored, upon the installation of the new plugs, the deposits loosen from the top of the piston and the head and are thrown against the hot insulator. The plugs can be serviced (clean, file and regap) and reinstalled.

72423

Mechanical Damage
Mechanical damage to the spark plug firing end is caused by a foreign object in the combustion chamber. Because of valve overlap, small objects can travel from one cylinder to another. Check all cylinders, the intake manifold and the exhaust material to prevent further damage. Replace the spark plugs.

72423

IMPORTANT: When working on the engine, the spark plug holes, the intake and the throttle body should be kept covered to prevent foreign objects from entering the combustion chamber.

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SERVICE MANUAL NUMBER 31

Poor Boat Performance And/Or Poor Maneuverability

Symptom 1. Bow too low Cause 1.0 Improper drive unit trim angle 1.1 Improper weight distribution 1.2 The boat is underpowered Action 1.0 Trim the drive to the appropriate angle. 1.1 Distribute the weight evenly. 1.2 Replace propeller. If the problem persists, contact the manufacturer regarding the correct power package. 1.3 Correct the boat bottom. 1.4 Siphon the water from the false bottom. Determine the cause of the excess water. 1.5 Adjust the trim tabs or after planes 1.6 Clean the boat bottom. 2.0 Trim the drive to the appropriate angle. 2.1 Replace with a lower pitch propeller. 2.3 Tune the engine. 2.4 Distribute the weight evenly. 2.5 Correct the boat bottom. 2.6 Siphon the water from the false bottom. Determine the cause of the excess water. 2.7 Adjust the trim tabs or after planes.

1.3 Permanent or power hook in the boat bottom 1.4 False bottom full of water

1.5 Improperly adjusted trim tabs or after planes 1.6 Dirty boat bottom (marine growth) 2. Bow too high 2.0 Improper drive unit trim angle 2.1 Propeller pitch too high

2.2 Marine growth on boat bottom 2.2 Clean the boat bottom. 2.3 Poorly operating engine 2.4 Improper weight distribution 2.5 Rocker in the boat bottom 2.6 False bottom full of water

2.7 Improperly adjusted trim tabs or after planes

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TROUBLESHOOTING

Poor Boat Performance And/Or Poor Maneuverability (continued)

Symptom 3. Propeller ventilation Cause 3.0 Dirty or rough boat bottom 3.1 Damaged propeller; pitch too small; diameter too small 3.2 Water pickup or through the hull fittings located too close to the propeller Action 3.0 Clean the boat bottom. 3.1 Replace the propeller. 3.2 Remove the water pickup or the through the hull fittings. Repair the hull. Reinstall the water pickup or the through the hull fittings in the proper locations. 3.3 Repair the boat bottom. 3.4 Clean the propeller. 3.5 Repair the hull.

3.3 Hook in boat bottom 3.4 Propeller plugged up with weeds 3.5 Keel located too close to the propeller or too deep in the water

3.6 Drive unit installed too high on 3.6 Remove the drive unit. Repair the transom the transom. Reinstall the drive unit in the proper position.

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SERVICE MANUAL NUMBER 31

Improper Full Throttle Engine RPM

Symptom 1. Full throttle engine rpm too high Cause 1.0 Propeller damaged, pitch too low, diameter too small, propeller hub slipping 1.1 Water pickup or through the hull fittings mounted too close to the propeller (ventilation) Action 1.0 Replace the propeller.

1.2 Drive unit trimmed out too far 1.3 Keel located too close to the propeller and/or too deep in the water

1.1 Remove the water pickup or through the hull fittings. Repair the hull. Reinstall the water pickup or the through the hull fittings in the proper locations. 1.2 Trim the drive unit to the appropriate angle. 1.3 Repair the hull.

1.4 Drive installed too high on the 1.4 Remove the drive unit. Repair transom the transom. Reinstall the drive unit in the proper position. 1.5 Wrong gear ratio drive unit 2. Full throttle engine rpm too low 2.0 Propeller damaged, pitch too great, diameter too great 2.1 Drive unit trimmed in too far 2.2 Dirty boat bottom 2.3 Damaged boat bottom 2.4 Permanent or power hook in bottom 2.5 False bottom full of water 1.5 Replace the drive unit with the appropriate gear ratio. 2.0 Replace the propeller. 2.1 Trim the drive unit to the appropriate angle. 2.2 Clean the boat bottom. 2.3 Repair the boat bottom. 2.4 Repair the boat bottom. 2.5 Siphon the water from the false bottom. Determine the cause of the excess water. 2.6 Remove the drive unit. Repair the transom. Reinstall the drive unit in the proper position. 2.7 Replace the drive unit with the appropriate gear ratio.

2.6 Drive unit installed too low on the transom 2.7 Wrong gear ratio drive unit

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TROUBLESHOOTING

Engine Cranks Over But Will Not Start Or Starts Hard

Important Information
1. First, determine which engine system is causing the problem. To make an engine operate, basic components - fuel, spark (ignition), and compression - are required. If all three components are present, the engine should operate. If any one of the three are missing, weak or arriving at the wrong time, the engine will not operate. 2. Determine if any faults are present by using a diagnostic tool. If faults are present, correct the fault before proceeding. 3. Determine if there is fuel present at the Schrader valve just behind the throttle body. 4. Remove the spark plugs and make sure they are the correct type and heat range, and not fouled or burned. 5. Run a compression check on the engine to make sure the engine is mechanically acceptable. Symptom 1. Engine cranks over but will not start or starts hard Cause 1.0 Clogged flame arrestor Action 1.0 Clean the flame arrestor.

1.1 Excessive fuel pump pressure 1.1 Determine the cause of the excess pressure and repair. 1.2 Empty fuel tank 1.3 Fuel shut off valve closed 1.4 Vapor lock 1.5 Fuel system lean 1.6 Low grade or stale fuel 1.7 Water in fuel 1.2 Fill the fuel tank. 1.3 Open the fuel shut off valve. 1.4 Refer to Vapor Lock Condition. 1.5 Clean fuel system. 1.6 Drain the fuel tank and refill. 1.7 Treat the contaminated fuel with appropriate fuel treatment. If the problem persists, drain the fuel tank and refill.

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SERVICE MANUAL NUMBER 31

Engine Will Not Crank Over

Symptom 1. Engine will not crank over. Cause 1.0 Remote control lever not in neutral position Action 1.0 Place the remote control lever in NEUTRAL and try the ignition again. If the problem persists, check the remote control level NEUTRAL detent setting. 1.1 Check the electrical connections at the starter. Check the battery cable connections. Check the battery charge and recharge if necessary. 1.2 Reset the circuit breaker. 1.3 Replace the fuse. 1.4 Replace the ignition switch. 1.5 Replace the slave solenoid. 1.6 Replace the neutral start safety switch. 1.7 Replace the starter solenoid. 1.8 Replace the starter motor. 1.9 Determine the cause of the malfunction and repair. 1.10 Deactivate-activate the lanyard stop switch

1.1 Battery charge low, damaged wiring, loose electrical connections

1.2 Circuit breaker tripped 1.3 Blown fuse 1.4 Ignition switch faulty 1.5 Slave solenoid faulty 1.6 Faulty neutral start safety switch 1.7 Starter solenoid faulty 1.8 Starter motor faulty 1.9 Mechanical engine malfunction 1.10 Lanyard stop switch activated

Charging System Inoperative

Symptom Cause Action 1.0 Replace the serpentine drive belt. 1.1 Accelerate the engine to 1500 rpm. 1.2 Check the electrical connections. 1.3 Replace the gauge. 1.4 Check the electrolyte level and fill if necessary. Replace the battery. 1.5 Test the alternator and the regulator and replace if necessary. 1. Charging system inoperative 1.0 Loose or broken drive belt 1.1 Engine rpm too low on initial start 1.2 Loose or corroded electrical connections 1.3 Faulty battery gauge 1.4 Battery will not accept charge

1.5 Faulty alternator or regulator

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TROUBLESHOOTING

Noisy Alternator
Symptom 1. Noisy alternator Cause 1.0 Loose mounting bolts 1.1 Drive belt 1.2 Loose drive pulley 1.3 Worn or dirty bearings 1.4 Faulty diode trio or stator Action 1.0 Tighten the mounting bolts. 1.1 Replace the serpentine drive belt. 1.2 Tighten the pulley. 1.3 Replace the bearings. 1.4 Replace the alternator.

Instrumentation Malfunction
Symptom 1. Instrumentation Malfunction Cause 1.0 Faulty wiring, loose or corroded terminals 1.1 Faulty key switch 1.2 Faulty gauge 1.3 Faulty sender Action 1.0 Check the electrical connections. 1.1 Replace the key switch. 1.2 Replace the gauge. 1.3 Replace the sender.

Radio Noise
Symptom 1. A popping noise that will increase with engine rpm. Noise will stop as soon as engine is turned off Cause 1.0 Wrong spark plugs 1.1 Cracked distributor cap Action 1.0 Change the spark plugs. 1.1 Check the distributor cap for cracks or marks. Replace the cap if necessary. 1.2 Check the ignition coil for cracks or corrosion. 1.3 Change the spark plug wires. 1.4 Check all ignition components for corrosion. 2.0 Test the alternator. Replace if necessary. 3.0 Check the instrument harness connections. Check the antennae routing. 4.0 Disconnect the accessories one at a time until the noise disappears. Replace the faulty accessory.

1.2 Cracked coil tower 1.3 Leaking spark plug wires 1.4 Moisture on ignition components 2. A high pitched whine in the radio 3. A hissing or crackling noise when instruments are jarred with ignition on 4. Varying unexplained noises 2.0 Alternator - poor brush contact on the slip rings 3.0 Instrumentation - loose connections or antennae wire routed too close to instruments 4.0 Accessories - bilge pump, bilge blower; fish finder, depth locator; cabin heater motor, etc.

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SERVICE MANUAL NUMBER 31

Poor Fuel Economy

Symptom 1.0 Poor fuel economy Cause 1.0 Fuel leak Action 1.0 Locate the leak and repair.

1.1 Operator habits - Prolonged 1.1 Educate the operator. idling, slow acceleration, failure to cut back on throttle once boat is on plane, boat overloaded, uneven weight distribution 1.2 Engine laboring - Bent, 1.2 Water test the boat for proper damaged or wrong propeller operating rpm at WOT. 1.3 Clogged flame arrestor 1.4 Engine compartment sealed too tight 1.5 Boat bottom dirty (marine growth), hook, rocker 1.6 Improper fuel 1.7 Crankcase ventilation system clogged or dirty 1.8 Engine needs tune-up 1.3 Clean the flame arrestor. 1.4 Vent the engine hatch appropriately. 1.5 Clean the boat bottom. 1.6 Drain the fuel tank and refill with the correct fuel. 1.7 Clean the crankcase ventilation hoses. 1.8 Change the spark plugs. Check the distributor cap for cracks or marks. Replace the cap if necessary. Check the ignition coil for cracks or corrosion. Change the spark plug wires. Check all ignition components for corrosion.

1.9 Engine running too cold or too 1.9 Check the thermostat. hot Check for kinked or restricted hoses. Clean the cooling system. 1.10 Plugged or restricted exhaust 1.11 Low compression 1.10 Clean the exhaust system. 1.11 Perform the cylinder compression check to determine which cylinder has low compression. Replace the rings, the valves or the pistons.

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TROUBLESHOOTING

Engine Runs Poorly at Idle

Symptom 1. Engine surges Cause 1.0 Leaking idle air control (IAC), intake manifold or throttle body gaskets 1.1 Throttle valves worn or damaged 1.2 Worn or leaking IAC hose or vacuum hose to the pressure regulator 2. Low top speed or lack of power 3. Poor cold engine operation 2.0 Leaking idle air control (IAC), intake manifold or throttle body gaskets Action 1.0 Find and replace the leaking gaskets. 1.1 Inspect the throttle valves. Replace the throttle body if necessary. 1.2 Find and replace the leaking hose. 2.0 Find and replace the leaking gaskets.

3.0 Engine is not reaching normal 3.0 Replace thermostat or operating temperature thermostat housing gasket. 3.1 Faulty engine temperature sensor (ECT) 3.2. Fuel PSI too high or too low 3.3 Throttle valves worn or damaged 3.4 Engine flooding 3.1 Replace the ECT. 3.2 Determine the cause and repair. 3.3 Inspect the throttle valves. Replace the throttle body if necessary. 3.4 Check the fuel pressure. If too high, find cause and correct. Clean the flame arrestor. Perform the cylinder balance test. 4.0 Clean the flame arrestor. Test the IAC to see if it opens and closes properly. 4.1 Check the fuel pressure. If too high, find cause and correct. Inspect the fuel pressure regulator. Inspect the injectors. 4.2 Find and replace the leaking gaskets. 5.0 Check the spark plugs. Check the spark plug wires. Check the distributor cap for cracks or marks. Check the ignition coil operation. Replace the faulty component.

4. Engine stalls

4.0 Idle rpm too low

4.1 Engine flooding

4.2 Leaking idle air control (IAC), intake manifold or throttle body gaskets 5.0 Engine misses 5.0 Fault in the ignition system

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SERVICE MANUAL NUMBER 31

Engine Runs Poorly At High RPM

Symptom 1. Engine runs poorly at high rpm Cause 1.0 Crankcase overfilled with oil Action 1.0 Check the oil level with the boat at rest in the water. Drain the oil if necessary to obtain the correct level. 1.1 Check fuel flow rates and repair, replace or remove anti-siphon valve as necessary. 1.2 Clean the fuel tank vent. 1.3 Inspect fuel supply system. Repair or replace as necessary. 1.4 Reset rotor location. 1.5 Drain the fuel tank and refill with the correct fuel. 1.6 Inspect the spark plugs and service or replace. 1.7 Replace the spark plug wires.

1.1 Anti-siphon valve restricting fuel supply 1.2 Plugged fuel tank vent 1.3 Improper fuel supply 1.4 Incorrect rotor location 1.5 Low grade of fuel or water in the fuel 1.6 Spark plugs fouled, burned, cracked porcelain or incorrect heat range 1.7 Spark plug wires broken or poorly insulated

1.8 Distributor cap or rotor dirty or 1.8 Inspect the distributor cap for cracked cracks or marks. Replace the distributor cap and the rotor if necessary. 1.9 Coil damaged or malfunctioning 1.10 Excessive play in distributor shaft 1.11 Engine overheating 1.12 Low compression worn valves, rings or seals 1.9 Replace the coil. 1.10 Replace distributor. 1.11 Check cooling water supply or coolant level. 1.12 Perform the cylinder compression check to determine which cylinder has low compression. Replace the rings, the valves or the pistons. 1.13 Clean the exhaust system.

1.13 Restricted exhaust

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TROUBLESHOOTING

Engine Acceleration Is Poor

Symptom 1. Engine acceleration is poor Cause 1.0 Incorrect rotor location 1.1 Incorrect distributor or amplifier advance curve 1.2 Damaged distributor cap or rotor Action 1.0 Reset rotor location. 1.1 Replace ECM. 1.2 Inspect the distributor cap for cracks or marks. Replace the distributor cap and the rotor if necessary. 1.3 Determine the source of the vacuum leak and repair. 1.4 Inspect the spark plugs and service or replace. 1.5 Perform the cylinder compression check to determine which cylinder has low compression. Replace the rings, the valves or the pistons.

1.3 Vacuum leak 1.4 Damaged spark plugs 1.5 Low compression

Troubleshooting with Vacuum Gauge

Symptom 1. Steady reading between 381-533 mm (15-21 in.) at idle rpm 2. Extremely low reading, but steady at idle rpm Cause 1.0 Normal Action 1.0 No action necessary

2.0 Vacuum leak, incorrect rotor location, underpowered boat, faulty boat bottom

2.0 Determine the source of the vacuum leak and repair. Remove and reinstall the distributor Replace the propeller. If the problem persists, contact the manufacturer about the correct power package. Repair the boat bottom. 3.0 Determine the cause and replace the head gasket. 4.0 Inspect the spark plugs and service or replace if necessary. 5.0 Ream the valve guides and install a valve with an oversized stem or replace the cylinder head. 6.0 Replace the valve.

3. Fluctuates between high and 3.0 Blown head gasket between low at idle rpm two adjacent cylinders 4. Fluctuates 101-127 mm (4-5 in.) very slowly at idle rpm 5. Fluctuates rapidly at idle, steadies as rpm is increased 6. Continuously fluctuates between low and normal reading at regular intervals at idle rpm 4.0 Spark plug gap too narrow 5.0 Valve guides are worn

6.0 Burned or leaking valve

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Engine Noise
Important Information
No definite rule or test will positively determine the source of engine noise. Use the following information only as a general guide to engine noise diagnosis. 1. Use a timing light to determine if the noise is timed with engine speed or 1/2 engine speed. Noises timed with engine speed are related to the crankshaft, rods, pistons, piston pins and flywheel. Noises timed to 1/2 engine speed are valve train related. 2. The use of a stethoscope can aid in locating a noise source; however, because noise will travel to other metal parts not involved in the problem, caution must be exercised. 3. If you believe the noise is confined to one particular cylinder, ground spark plug leads one at a time. If the noise lessens noticeably or disappears, it is isolated to that particular cylinder. 4. Try to isolate the noise to a location in the engine: front to back, top to bottom. This can help determine which components are at fault. 5. Sometimes noises can be caused by moving parts coming in contact with other components. Examples are: the flywheel or coupler; the exhaust flappers rattling against exhaust pipe; the crankshaft striking the oil pan, oil pan baffle or dipstick tube; the rocker arm striking the valve cover or a loose flywheel cover. In many cases, if this is found to be the problem a complete engine teardown is not necessary. 6. When the noise is isolated to a certain area and component, removal and inspection will be required. Refer to the appropriate sections of the service manual for the information required for service. 7. If the noise cannot be distinguished between the engine and the drive unit, remove the drive from the boat. Supplying water directly to the engine, operate the engine without the drive to determine whether the noise still occurs.

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TROUBLESHOOTING

Engine Noise (continued)

Symptom 1. Engine noise in the valve cover area, timed to 1/2 engine speed, noise could be confined to one cylinder or may be found in any multitude of cylinders 2. Engine noise in cylinder area, may be confined to one cylinder or found in more than one cylinder, timed to engine speed Cause 1.0 Rocker arm striking cover Action 1.0 Inspect the valve cover for damage. Replace if necessary. 1.2 Replace the rocker arm. 1.3 Replace the push rods. 1.4 Replace the filter. 2.0 Inspect the valves and repair or replace. 2.1 Inspect the internal engine components for carbon buildup. Clean or replace. 2.2 Remove the connecting rods and install properly. 2.3 Replace the connecting rod. 2.4 Inspect the piston. Replace if necessary. 2.5 Inspect the piston rings. Replace if necessary.

1.1 Rocker arm out of adjustment 1.1 Adjust the rocker arm. 1.2 Worn rocker arm 1.3 Bent push rod 1.4 Collapsed filter 2.0 Sticking valve 2.1 Carbon build-up

2.2 Connecting rod installed wrong 2.3 Bent connecting rod 2.4 Piston damaged or broken 2.5 Piston rings damaged or broken

2.6 Piston pin damaged or broken 2.6 Inspect the piston pin. Replace if necessary. 2.7 Worn cylinder 2.7 Inspect the cylinder. Bore as necessary. Replace the cylinders if necessary.

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Engine Noise (continued)

Symptom 3. Engine noise in camshaft area, front of the engine, timed to 1/2 engine speed Cause 3.0 Crankshaft timing sprocket damaged 3.1 Timing chain damaged 3.2 Fuel pump damaged 3.3 Valve lifter damaged 3.4 Cam bearings damaged 4. Engine noise in camshaft area, center of the engine, timed to 1/2 engine speed 4.0 Fuel pump damaged 4.1 Valve lifter damaged 4.2 Cam bearing damaged 5. Engine noise in camshaft area, rear of the engine, timed to 1/2 engine speed 5.0 Distributor gear damaged 5.1 Valve lifter damaged 5.2 Cam bearings damaged Action 3.0 Inspect the crankshaft timing sprocket. Replace if necessary. 3.1 Inspect the timing chain. Replace if necessary. 3.2 Inspect the fuel pump. Replace if necessary. 3.3 Inspect the valve lifter. Replace if necessary. 3.4 Inspect the cam bearings. Replace if necessary. 4.0 Inspect the fuel pump. Replace if necessary. 4.1 Inspect the valve lifter. Replace if necessary. 4.2 Inspect the cam bearings. Replace if necessary. 5.0 Inspect the distributor gear. Replace if necessary. 5.1 Inspect the valve lifter. Replace if necessary. 5.2 Inspect the cam bearings. Replace if necessary.

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TROUBLESHOOTING

Engine Noise (continued)

Symptom 6. Engine noise in camshaft area, throughout the engine, timed to 1/2 engine speed Cause 6.0 Loss of oil pressure Action 6.0 Check the crankcase oil level. If low, fill the crankcase and determine the cause of the oil loss. Check for leaks. Check the oil pressure gauge operation. Check the oil pump operation. 6.1 Inspect the valve lifters. Replace if necessary. 6.2 Inspect the cam bearings. Replace if necessary. 7.0 Inspect the crankshaft timing sprocket. Replace if necessary. 7.1 Inspect the timing chain. Replace if necessary. 7.2 Inspect the main bearing. Replace if necessary. 7.3 Inspect the rod bearing. Replace if necessary.

6.1 Valve lifters damaged 6.2 Cam bearings damaged 7. Engine noise in crankshaft area, front of the engine, timed to engine speed 7.0 Crankshaft timing sprocket damaged 7.1 Timing chain damaged 7.2 Main bearing damaged 7.3 Rod bearing damaged 8. Engine noise in crankshaft area, center of the engine, timed to engine speed

8.0 Crankshaft striking the oil pan 8.0 Inspect the oil pan and the oil or the oil pan baffle pan baffle. Repair or replace if necessary. 8.1 Main bearing damaged 8.2 Rod bearing damaged 8.1 Inspect the main bearing. Replace if necessary. 8.2 Inspect the rod bearing. Replace if necessary. 9.0 Tighten the flywheel cover fasteners. 9.1 Tighten the coupler fasteners. 9.2 Tighten the flywheel fasteners. 9.3 Inspect the main bearing. Replace if necessary. 9.4 Inspect the rod bearing. Replace if necessary.

9. Engine noise in crankshaft area, rear of the engine, timed to engine speed

9.0 Loose flywheel cover 9.1 Loose coupler 9.2 Loose flywheel 9.3 Main bearing damaged 9.4 Rod bearing damaged

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Engine Noise (continued)

Symptom Cause Action 10.0 Check the crankcase oil level. If low, fill the crankcase and determine the cause of the oil loss. Check for leaks. Check the oil pressure gauge operation. Check the oil pump operation. 10.1 Inspect the main bearing. Replace if necessary. 10.2 Inspect the rod bearing. Replace if necessary. 11.0 Replace the ECM. 11.1 Drain the fuel tank and refill with the appropriate fuel. 11.2 Check cooling water supply or coolant level. 11.3 Inspect the internal engine components for carbon buildup. Clean or replace. 12.0 Locate leak and repair. 12.1 Inspect the exhaust manifolds and elbows for cracks or porosity. Replace the gaskets. 12.2 Ensure that the cylinder head bolts are properly torqued. Replace the bolts if necessary. 12.3 Determine the cause of blown gasket and replace the gasket. 10. Engine noise in the 10.0 Loss of oil pressure crankshaft area, throughout the engine, timed to engine speed

10.1 Main bearings damaged 10.2 Rod bearings damaged 11. Engine spark knock 11.0 Advanced timing 11.1 Low octane fuel 11.2 Engine running hot 11.3 Carbon deposits in the engine 12. Hissing 12.0 Vacuum leak 12.1 Leaking exhaust (manifolds or pipes) 12.2 Loose cylinder heads

12.3 Blown head gasket

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TROUBLESHOOTING

Engine Noise (continued)

Symptom 13. Throttle Body Whistle Cause 13.0 Vacuum leak 13.1 Dry or tight bearing in an accessory 13.2 IAC muffler misaligned or missing. 14. Sparks jumping 14.0 Leaking high tension lead 14.1 Cracked coil tower 14.2 Cracked distributor cap 15. Squeaks or squeals 15.0 Drive belt slipping 15.1 Dry or tight bearing in an accessory 15.2 Parts rubbing together 16. Rattling in the exhaust pipe area 16.0 Exhaust shutters Action 13.0 Test and repair leaks. 13.1 Locate the bearing and lubricate or replace. 13.2 Install new muffler or realign. 14.0 Replace the high tension lead. 14.1 Replace the ignition coil. 14.2 Replace the distributor cap. 15.0 Replace the drive belt. 15.1 Locate the bearing and lubricate or replace. 15.2 Locate the parts and correct the cause. 16.0 Inspect the exhaust shutters for damage. Replace if necessary.

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SERVICE MANUAL NUMBER 31

Oil Pressure
Symptom 1. Loss of engine rpm, oil pressure gauge fluctuation, drop in oil pressure, and hydraulic valve lifter noise at high rpm 2. Low oil pressure; oil pressure gauge fluctuation; internal engine noise and/or damage 3. Change in oil pressure Cause 1.0 Oil level in the crankcase above the FULL mark Action 1.0 Drain excess oil.

2.0 Oil level in the crankcase below the ADD mark

2.0 Add oil to the correct level. Determine if engine noise is still present and if so, diagnose internal engine damage. 3.0 Check oil level. If oil level is accurate and oil pump appears to be working, no further action is necessary.

3.0 This may be a normal condition. Oil pressure may be high in the cooler times of the day and when the engine is not up to operating temperature. As the air temperature warms up and the engine is operating at normal temperature, it is normal for oil pressure to drop. 4.0 With modern engines and engine oils, low oil pressure readings at idle do not necessarily mean there is a problem. If valve lifters do not clatter (at idle), there is a sufficient volume of oil to lubricate all internal moving parts properly. The reason for the drop in oil pressure is that engine heat causes an expansion of the internal tolerances in the engine and the oil will thin out somewhat from heat.

4. Low engine oil pressure at idle

4.0 Check oil level. Add if necessary. Listen for engine noise. If no noise is present, no further action is necessary.

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TROUBLESHOOTING

Oil Pressure (continued)

Symptom 5. Low engine oil pressure at idle after operating at a high rpm Cause 5.0 With modern engines and engine oils, low oil pressure readings at idle do not necessarily mean there is a problem. If valve lifters do not clatter (at idle), there is a sufficient volume of oil to lubricate all internal moving parts properly. The reason for the drop in oil pressure is that engine heat causes an expansion of the internal tolerances in the engine and the oil will thin out somewhat from heat. Action 5.0 Check oil level. Add if necessary. Listen for engine noise. If no noise is present, no further action is necessary.

6. Differences in oil pressure 6.0 It is not uncommon to see between engines on boats with different oil pressure readings dual engines between the two engines, as long as both engines fall within specifications. Differences in oil pressure can be attributed to differences in engine tolerances, gauges, wiring, senders or other differences. 7. Differences in oil pressure 7.0 It is not uncommon to see between stations on boats with different oil pressure readings dual stations between the two stations, as long as both engines fall within specifications. Differences in oil pressure can be attributed to differences in engine tolerances, gauges, wiring, senders or other differences.

6.0 Check oil level. Add if necessary. Listen for engine noise. If no noise is present, no further action is necessary.

7.0 Check oil level. Add if necessary. Listen for engine noise. If no noise is present, no further action is necessary.

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Oil Pressure (continued)

Symptom 8. Low oil pressure Cause 8.0 Low oil level in crankcase 8.1 Defective oil pressure gauge and/or sender 8.2 Thin or diluted oil 8.3 Faulty oil pump Action 8.0 Check the oil level with the dipstick. Add oil as necessary. 8.1 Verify with an automotive test gauge. 8.2 Change the oil. 8.3 Ensure that the relief valve opens and closes properly. Check the pickup tube for restrictions. Rebuild or replace the oil pump. 8.4 Check for oil passage plugs leaking. Check the cylinder block for cracks. 8.5 Inspect bearings and replace if necessary. 9.0 Change the oil. 9.1 Verify with an automotive test gauge. 9.2 Clean all oil passages. 9.3 Repair or replace oil pump.

8.4 Internal or external oil leak

8.5 Excessive bearing clearance 9. High oil pressure 9.0 Oil too thick 9.1 Defective oil pressure gauge and/or sender 9.2 Clogged or restricted oil passage 9.3 Oil pump relief valve stuck closed

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TROUBLESHOOTING

Excessive Oil Consumption

Symptom 1. Excessive oil consumption Cause 1.0 Oil leaks Action 1.0 Clean the bilge, place white paper on the floor of the bilge and run the engine to locate oil leaks. 1.1 Change the oil. 1.2 Drain the oil and verify the cause of the excessive oil. Change the oil and recheck periodically. 1.3 Clean the drain holes.

1.1 Oil too thin 1.2 Oil level too high

1.3 Drain holes in cylinder head plugged causing oil to flood the valves 1.4 Defective valve seals 1.5 Intake manifold gasket leaking 1.6 Worn valve stems or valve guides 1.7 Defective oil cooler 1.8 Defective piston rings 1.9 Excessive bearing clearance

1.4 Replace the valve seals. 1.5 Replace the intake manifold gasket. 1.6 Replace the valves or valve guides. 1.7 Replace the oil cooler 1.8 Replace the piston rings 1.9 Replace the bearings

NOTE: ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS SPECIFIED IN the MAINTENANCE SCHEDULES in SECTION 1B. It is normal for an engine to use a certain amount of oil in the process of lubricating and cooling the engine. The amount of oil consumption is greatly dependent upon engine speed, with consumption being highest at wide open throttle and decreasing substantially as the engine speed is reduced.

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SERVICE MANUAL NUMBER 31

Water In The Engine

Important Information
IMPORTANT: First determine the location of the water in the engine. This information can be of great help when trying to determine where the water came from and how it got into the engine. The three most common problems are: water on top of the pistons, water in the crankcase oil and when both of those conditions occur simultaneously. 1. After locating the water, remove all the water from the engine by removing all the spark plugs and cranking the engine over to pump out the cylinders. 2. Change the oil and the filter. 3. Start the engine and see if the problem can be duplicated. If the problem can be duplicated, a mechanical problem exists. If the problem cannot be duplicated, the problem is either an operator error or a problem that exists only under certain environmental conditions. If the water is contained to the cylinders only, it is usually entering through the intake system, the exhaust system or the head gasket. If the water is contained to the crankcase only, it is usually caused by a cracked or porous block, a flooded bilge or condensation. If the water is located in both the cylinders and the crankcase, it is usually caused by water in the cylinders getting past the rings and valves or complete submersion. Checking for rust in the intake manifold or the exhaust manifolds is a good idea. Rust is a clue that the water entered these areas.

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TROUBLESHOOTING

Water In Engine (continued)

Symptom 1. Water on top of the pistons Cause 1.0 The operator shut the engine off at a high rpm 1.1 Engine diesels or tries to run backwards 1.2 Rain water dripping into the flame arrestor 1.3 Spark plug misfiring Action 1.0 Read and follow the procedures in the Operation Guide. 1.1 Adjust the throttle cable. Ensure engine idles properly. 1.2 Replace the engine cover. 1.3 Inspect and service the spark plugs. Replace if necessary. 1.4 Repair the exhaust system. 1.5 Check the engine installation specifications. 1.6 Replace the exhaust manifold. 1.7 Replace the manifold to elbow gasket. 1.8 Tighten the cylinder head bolts. 1.9 Determine the cause of blown gasket and replace the gasket. 1.10 Replace the valves. 1.11 Inspect and repair or replace as necessary. 2.0 Drain the water from the bilge.

1.4 Backwash through the exhaust system 1.5 Improper engine or exhaust hose installation 1.6 Cracked exhaust manifold 1.7 Improper manifold to elbow gasket installation 1.8 Loose cylinder head bolts 1.9 Blown cylinder head gasket 1.10 Cracked valve seat 1.11 Porous or cracked casting 2. Water in crankcase oil 2.0 Water in boat bilge

2.1 Water seeping past the piston 2.1 Replace the piston rings or rings or valves the valves. 2.2 Engine operating cold 2.2 Replace the thermostat. 2.3 Intake manifold leaking near a 2.3 Inspect the intake manifold for water passage cracks. Check the gaskets. 2.4 Cracked or porous casting 2.4 Check the cylinder head, the cylinder block and the intake manifold for cracks or porosity.

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SERVICE MANUAL NUMBER 31

Engine Overheats (Mechanical)

IMPORTANT: The first step is to verify if the engine is actually overheating or if the temperature gauge or sender is faulty. Symptom 1. Engine overheats (mechanical) Cause 1.0 Engine rpm below specifications at WOT (engine laboring) Action 1.0 Replace the propeller. Clean the boat bottom. Check the false bottom for water. 1.1 Reset rotor location. 1.2 Install the spark plug wires correctly. 1.3 Drain the fuel tank and refill with the appropriate fuel. 1.5 Inspect the exhaust system and repair. 1.6 Refer to the Engine Mechanical section for valve adjustment. 1.7 If the engine overheats above 3000 rpm, replace the head gasket. On seawater cooled engines, install a clear plastic hose between the thermostat housing and the exhaust manifolds. If air bubbles are present at a higher rpm, replace the head gasket. 1.8 Check the oil level. Fill if necessary. Check the oil flow through the oil passages. Clean as necessary.

1.1 Incorrect rotor location 1.2 Spark plug wires crossed (wrong firing order) 1.3 Lean fuel mixture

1.4 Wrong heat range spark plugs 1.4 Replace the spark plugs. 1.5 Exhaust restriction 1.6 Valve timing off

1.7 Blown head gaskets

1.8 Insufficient lubrication to the moving parts of the engine

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TROUBLESHOOTING

Engine Overheats (Mechanical) (continued)

Symptom 2. Engine overheats (cooling system) Cause 2.0 Loose or faulty drive belt 2.1 Seawater shutoff valve partially or fully closed (if equipped) 2.2 Clogged or improperly installed sea strainer Action 2.0 Replace the serpentine drive belt. 2.1 Open the seawater shutoff valve. 2.2 Clean the sea strainer. Reinstall the sea strainer.

2.3 Loose hose connections 2.3 Tighten the all hose clamps. between the seawater pickup and seawater pump inlet 2.4 Seawater inlet hose kinked or 2.4 Visually inspect the seawater collapsed inlet hose and shorten or replace if necessary. 2.5 Seawater pickup clogged 2.6 Obstruction on the boat bottom causing water turbulence 2.7 Defective thermostat 2.8 Exhaust elbow water outlet holes plugged 2.9 Insufficient seawater pump operation 2.10 Obstruction in cooling system such as casting flash, sand, rust and salt. 2.11 Engine circulating pump defective 2.12 Low coolant level 2.13 Antifreeze not mixed properly 2.14 Heat exchanger cores plugged 2.5 Clean the seawater pickup. 2.6 Clean the boat bottom. 2.7 Replace the thermostat. 2.8 Clean the water outlet holes. 2.9 Refer to SECTION 6. 2.10 Flush the cooling system.

2.11 Replace the water circulating pump. 2.12 Fill the coolant reservoir. 2.13 Drain and replace the coolant. 2.14 Clean the heat exchanger.

2.15 Water hoses reversed at the 2.15 Install the hoses properly. water distribution block 2.16 Worn or damaged seawater pump impeller 2.16 Replace the seawater pump impeller.

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Power Steering (continued)

Symptom 2. Noisy pump Cause 2.0 Drive belt loose 2.1 Low fluid level 2.2 Air in fluid Action 2.0 Replace the serpentine belt. 2.1 Fill the power steering pump reservoir and bleed the lines. 2.2 Drain the power steering system, fill the power steering pump reservoir and bleed the lines. 2.3 Replace the pump. 2.4 Inspect and clean the fluid passages. 2.5 Adjust the stop nut. 2.6 Install the appropriate cables. 3.0 Tighten all hose clamps. Bleed the system. 3.1 Inspect and replace the damaged hose. 3.2 Drain excess oil. Bleed the system. 3.3 Replace internal engine components as necessary. 3.4 Replace the seals in the valve. 3.5 Replace the seals or the O-rings in the pump. 3.6 Inspect all power steering components. Place white cloth under the engine to determine the location of the leak.

2.3 Faulty pump 2.4 Restricted fluid passages 2.5 Stop nut adjusted improperly 2.6 Steering cables installed that do not meet BIA standards 3. Fluid leaks 3.0 Loose hose connections 3.1 Damaged hose 3.2 Oil leaking from the top of the pump 3.3 Cylinder piston rod seal 3.4 Faulty seals in valve 3.5 Faulty seals or O-rings in the pump 3.6 Cracked or porous metal parts

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TROUBLESHOOTING

Drain System Will Not Drain Or Drains Slowly

Symptom 1. Drain system will not drain or drains slowly Cause 1.0 Drain system not open Action 1.0 Verify draining procedure.

1.1 Cooling system or drain holes 1.1 Inspect drain hole in the water plugged with debris distribution housing for debris. Remove the blue drain plugs and inspect for blockage. Flush the cooling system and drain the engine. 1.2 Air actuator malfunction 1.2 Inspect the air lines from the air manifold and the drain actuator for kinks, damage and leaks. Inspect the air manifold and the fittings for cracks, leaks,damage or corrosion. 1.3 Boat must be at rest and level when draining the engine. 1.4 Read Boat in the Water Procedure in the Operation, Maintenance and Warranty Manual. 1.5 Thaw engine and inspect for freeze damage. 2.0 Realign the drain rod. 2.1 Replace the drain rod. 2.2 Close drain system. 2.3 Activate pressure relief valve. Inspect and clean the water distribution housing and the sea pump drain actuator. Replace if damaged. 3.0 Realign the drain rod. 3.1 Replace the drain rod. 3.1 Replace the drain rod. 3.2 Replace the housing. 4.0 Replace the drain portion of the seawater pump. 4.1 Empty water from bilge.

1.3 Boat sitting on an incline 1.4 Draining the engine while boat is in the water

1.5 Water in the engine is frozen 2. Drain system leaking at the orange drain seal 2.0 Drain rod misaligned 2.1 Drain rod bent 2.2 Drain rod not closed completely (red visible) 2.3 Actuator piston not closed

3. Manual drain system leaking while underway

3.0 Drain rod misaligned 3.1 Drain rod bent 3.1 Drain rod scratched, cut or damaged 3.2 Water distribution housing seal damaged

4. Water leaking out of the pressure relief valve on the air manifold

4.0 Seawater pump seal leaking

4.1 Vents on the drain actuator are under the waterline

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MCM MODELS

REMOVAL AND INSTALLATION

Section 2A - MCM Models

Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Installation . . . . . . . . . . . . . . . . . . . Electrical Connections . . . . . . . . . . . . . . . EFI Electrical System Precautions . . Installing Continuity Wire . . . . . . . . . . Instrumentation Connections . . . . . . . Trim Position Sender Connections . . MerCathode Connections . . . . . . . . . . Audio Warning Alarm Connections . . Power Trim Pump Connections . . . . . 2A-2 2A-3 2A-4 2A-5 2A-8 2A-13 2A-13 2A-14 2A-14 2A-15 2A-16 2A-17 2A-17 Fluid Connections . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Lube Monitor Hose . . . . . . . . . . Power Steering Hoses . . . . . . . . . . . . . Bravo Models and Alpha Seawater Cooled Models Using Sterndrive Water Pickups . . . . Alpha or Bravo Models Using Alternative Water Pickups . . . Coolant Recovery Bottle . . . . . . . . . . . Shift Cable Installation . . . . . . . . . . . . . . . Alpha Models Drive Unit Not Installed . . . . . . . . . . . Bravo Models . . . . . . . . . . . . . . . . . . . . Throttle Cable Installation and Adjustment . . . . . . . . . . . . . . . . . . Battery Connection . . . . . . . . . . . . . . . Engine Cover Installation . . . . . . . . . . 2A-18 2A-18 2A-19 2A-20 2A-21 2A-21 2A-24 2A-25 2A-25 2A-30 2A-35 2A-37 2A-37

2
A

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MCM MODELS

SERVICE MANUAL NUMBER 31

Torque Specifications
NOTE: Securely tighten all fasteners not listed below. Description Gear Lube Monitor Fitting Speedometer Pickup Barb Fitting Exhaust Pipe or Block-off Plate Power Steering Hydraulic Hose Fittings Power Trim Pump Hose Fittings Propeller Nut Alpha One, Bravo One and Bravo Front Propeller Nut Bravo Three Rear Propeller Nut Bravo Three Rear Engine Mounts Steering Cable Coupler Nut Steering System (Pivot Bolts) Sterndrive Unit Fasteners Transom Assembly Fasteners Seawater Pickup Fitting Flame Arrestor Bolts Fuel Inlet Fitting
1

Nm 9 1.5 31 31 14 Two1 75 136 81 51 48 34 68 31 5 12

lb-in. 80 13

lb-ft

23 23 125 55 100 60 38 35 25 50 23 45 9

Finger tight + 1-3/4 to 2-1/4 turns with a wrench. Do NOT overtighten.

Amount specified is MINIMUM.

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MCM MODELS

Lubricants / Sealants / Adhesives

Description Where Used Coupler Splines Engine Coupler Spline Grease Drive Unit Pilot U-Joint O-rings Drive Shaft Splines Anchor Pins Trim Cylinder Hardware 2-4-C Marine Lubricant With Teflon O-ring Seals Shift Cable End Propeller Splines Pivot Bolts Power Steering Bushings Special Lubricant 101 Clevis Pin Steering Cable End Propeller Splines Dexron III - Automatic Transmission Fluid Power Trim and Steering Fluid Liquid Neoprene Power Steering Pump Power Steering Pump Power Trim Pump Battery Terminals MerCathode Connections Speedometer Barb Fitting Fuel Inlet Fitting Loctite 592 PST Seawater Inlet Hose Fitting Threads Seawater Inlet Plastic Plug Threads Obtain Locally Obtain Locally 92-802880A1 92-25711-3 92-802865A1 92-802859A1 92-802869A1 Part Number

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SERVICE MANUAL NUMBER 31

Lubricants / Sealants / Adhesives (continued)

Description Loctite 271 Engine Oil SAE 10W40 Engine Oil Marine Caulking Power Tune High Performance Gear Lube Silicone Sealant Or Equivalent Where Used Seawater Inlet Nut Power Trim Pump Shift Cable Pivot Points Power Trim Pump Seawater Inlet Mounting Surfaces Exhaust Tubes Sterndrive Unit Screw Shaft Part Number 92-809819 Obtain Locally Obtain Locally Obtain Locally 92-802878-57 92-802854A1 Obtain Locally

Special Tools
Description Transom Drilling Fixture Engine Alignment Tool Shift Cable Adjustment Tool Engine Mount Drilling Fixture Tapered Insert Tool Shift Shaft Slide Stabilizer Tool Part Number 91-43693A2 91-805475A1 91-12427 91-806794A1 91-43579 91-809815A1

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Removal
WARNING
Avoid injury or death and power package damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package. 1. Disconnect the battery cables from the battery. 2. Remove the engine cover. 3. Loosen the clamp and remove the instrument wiring harness plug from the engine wiring harness receptacle.

78031

a - Engine Wiring Harness Receptacle

WARNING
Be careful when working on the fuel system. Gasoline is extremely flammable and highly explosive under certain conditions. Do not smoke or allow spark or open flame in area. Wipe up any spilled fuel immediately. 4. Loosen the hose clamp retaining fuel line to the fuel inlet. 5. Close the fuel shut off valve, if equipped. 6. Disconnect and plug the fuel line to prevent fuel in the line from leaking into the bilge.

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7. Disconnect the throttle cable and retain the fasteners.

a b

78033

a - Flat Washer And Locknut b - Cable Barrel c - End Guide 8. Disconnect the shift cable from the shift plate and retain the fasteners. 9. DIsconnect the power steering hoses. 10. Disconnect the seawater inlet hose from the transom.

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11. Loosen the hose clamps at the bullhorn. 12. Remove the gear lube monitor and the hose and place out of the way. 13. Disconnect any grounding wires and accessories that are connected to the engine.

CAUTION
Engine MUST be lifted with a lifting arm or damage to the engine components will occur. DO NOT allow the lifting sling to hook or compress the engine components or damage will occur.

CAUTION
Engine compartment size may require the removal of additional components. 14. Support the engine with a suitable sling through the lifting eyes on the engine.

CAUTION
Center lifting eye on top of thermostat housing is used for engine alignment only. Do not use to lift entire engine.

c
77912

a - Front Lifting Eye b - Rear Lifting Eye c - Center Lifting Eye

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15. Remove the rear engine mounting bolts. 16. Remove the front lag bolts. Retain the fasteners.

a
72638

a - Lag Bolt (With Washers) 17. Carefully remove the engine.

Engine Installation
NOTE: An engine mount drilling fixture (91-806794A1) can be used to align and adjust the engine mounts. Refer to instructions the with the fixture for proper use. 1. Attach a suitable sling to the lifting eyes on the engine and adjust so that the engine is level when suspended.

CAUTION
Center lifting eye on top of the thermostat housing is used for engine alignment only. Do not use to lift the entire engine. 2. Lift the engine into position in the boat using an overhead hoist.

c
77912

a - Front Lifting Eye b - Rear Lifting Eye c - Center Lifting Eye 3. Ensure that the grounding stud and starter solenoid terminal are free of paint or any other material that could cause a poor electrical connection.

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4. Connect the battery cables to the engine. Apply a thin coat of sealant to the terminals. Description Liquid Neoprene Where Used Battery Terminals Part Number 92-25711-3

5. Slide the rubber boot over the positive (+) terminal. 6. Drape battery cables over top of engine to prevent interference during installation. IMPORTANT: There is a fuse located at the starter solenoid. Do NOT remove this fuse. The positive battery cable must be connected to the same stud as the fuse.

a b c d
a b c d - Positive (+) Battery Cable - Starter Solenoid - 90 Amp Fuse - Do NOT Remove - Rubber Boot Location
74907

7. Push the end of the oil drain hose out of the boat hull through the flange. 8. Pull the oil drain hose out until it is 152 mm (6 in.) from the propeller. 9. Move the alignment clip on the oil drain hose and squeeze to position it on the hose just inside the boat hull against the flange.

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10. Connect the bilge drain plug to the oil drain hose plug using the clip.

b d c

78002

a b c d

- Oil Drain Hose - Alignment Clip - Clip - Bilge Drain Plug

IMPORTANT: If the Quick Drain Oil Fitting is within 13 mm (1/2 in.) of the boat bottom, remove the fitting and install the drain plug from the parts bag directly into the oil pan. 11. Push the oil drain hose through the flange into the boat hull. 12. Install the bilge drain plug in the hull. 13. Align the rear engine mounts with the inner transom plate mounts while simultaneously aligning the exhaust tube with the exhaust pipe bellows.

c d e a f b
22032

a b c d e f g

- Rear Engine Mount - Inner Transom Plate Mount - Bolt - Washer - Spacer - Fiber Washer - Double-Wound Lockwasher

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14. Install both the rear engine mounting bolts and the hardware. Torque the bolts and the hardware. Do not relieve the tension on the hoist.

a
50682

a - Exhaust Pipe Bellows b - Exhaust Tube

Description Nm lb-in. lb-ft

Engine Mounting Bolts and Hardware

IMPORTANT: If the Quick Drain Oil Fitting is within 13 mm (1/2 in.) of the boat bottom, remove the fitting and install the drain plug from the parts bag directly into the oil pan. 15. Ensure that the quick drain oil fitting is more than 13 mm (1/2 in.) above the boat bottom.

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CAUTION
Do NOT use an alignment tool from a manufacturer other than Quicksilver as it may cause improper alignment and damage to the gimbal bearing or the engine coupler.

CAUTION
To avoid damage to the gimbal bearing, the engine coupler or the alignment tool: Do NOT attempt to force the alignment tool! Do NOT raise or lower the engine with the alignment tool inserted (or partially inserted) in the gimbal bearing or the engine coupler.

16. Attempt to insert the solid end of the alignment tool through the gimbal bearing and into the engine coupler splines. 17. If the tool does not fit, remove it and carefully raise or lower the front end of the engine using the center alignment eye and attempt to insert the alignment tool. 18. Repeat Step 17. until the alignment tool installs easily (SLIDES FREELY WITH TWO FINGERS) all the way into and out of the engine coupler splines. Do not check by turning.

b a

22029

a - Alignment Tool (Use Only Recommended Alignment Tool) b - Insert This End Of Alignment Tool Through Gimbal Housing Assembly

c b

a
27647

a - Alignment Tool b - Gimbal Bearing c - Engine Coupler

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IMPORTANT: Finished boat stringer must position the engine so that a minimum mount adjustment exists after the front mount is adjusted down to the stringer. This allows for future adjustments. IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in the direction required to align the engine. 19. Adjust the front engine mounts until they rest on the boat stringers. 20. Relieve the hoist tension entirely and fasten both front mounts to the boat stringer using appropriate hardware. 21. Recheck the alignment with the alignment tool. The tool must enter the engine coupler splines freely. If not, readjust the front mounts. 22. When the alignment is correct, tighten the locknut securely. Recheck the alignment. 23. Bend the tab down on the adjusting nut. 24. Remove the alignment tool. 25. Install the sterndrive unit.

Electrical Connections
EFI Electrical System Precautions

CAUTION
Avoid damage to the EFI electrical system components. Refer to the following precautions when working on or around the EFI electrical harness or when adding other electrical accessories: Do NOT tap the accessories into the engine harness. Do NOT puncture wires for testing (Probing). Do NOT reverse the battery leads. Do NOT splice wires into the harness. Do NOT attempt diagnostics without proper, approved Service Tools. IMPORTANT: When routing all wire harnesses and hoses, ensure that they are routed and secured to avoid coming in contact with hot spots on the engine and to avoid contact with moving parts.

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Installing Continuity Wire

1. Connect the continuity circuit wire from the engine to the transom assembly. IMPORTANT: Do not attach any accessory ground () wires to the transom plate ground point. Accessory ground wires can only be attached to the ground stud on the engine.

a
a - Negative () Battery Cable

71651

Instrumentation Connections
We recommend the use of Quicksilver Instrumentation and Wiring Harnesses which have been specifically designed for compatibility with our engines. Instrumentation wiring extension harnesses are available in several lengths. Refer to Mercury Precision Parts / Quicksilver Accessories Guide for selection. Refer to Instrumentation Wiring Diagrams for specific wiring diagrams.

CAUTION
If a Quicksilver wiring harness is used and a fused accessory panel is to be installed (40-amp current draw maximum), connect it as shown in the wiring diagrams. Do not connect the accessory panel at any other location as the wires in the wiring harness may not be of sufficient size to handle the current load. 1. Connect the instrumentation wiring harness to the engine harness plug at the location shown.

78030

a - Instrumentation Wiring Harness

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2. Place the hose clamp on the location shown.

78031

a - Hose Clamp Location

Trim Position Sender Connections

1. Connect the trim position sender wires from the transom assembly to the engine harness. Use the ORG/GRY wire for analog gauges and the ORG/WHT for digital gauges.

ORG/WHT BLK

BLK BLK

b
74029

a - Engine Harness Bullet Connector b - Transom Assembly Bullet Connectors

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SERVICE MANUAL NUMBER 31

MerCathode Connections
The MerCathode controller assembly is located on the back of the front lifting eye. The upper hose must be disconnected from the thermostat housing for access. 1. Move or remove the thermostat housing hose to gain access to the MerCathode controller assembly.

78129

a - MerCathode Controller Location b - Thermostat Housing Hose 2. Connect the wires to the MerCathode controller assembly as shown. Apply a thin coat of sealant to all wire connections. IMPORTANT: The opposite end of the red/purple wire must be connected directly to the battery positive (+) terminal. Do NOT connect it to a switched positive (+) circuit. The MerCathode system must function continuously for proper corrosion protection.

a
a b c d

22232

- ORANGE Wire - From Electrode on Transom Assembly - RED/PURPLE Wire - Connect (Other End) To Positive (+) Battery Terminal - BLACK Wire - From Engine Harness - BROWN Wire - From Electrode on Transom Assembly Where Used MerCathode Connections Part Number 92-25711-3

Description Liquid Neoprene

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Audio Warning Alarm Connections

1. Connect the PURPLE wire from the alarm to any PURPLE wire terminal on the instrument gauge or the ignition switch. Tighten the connection securely. 2. Connect the TAN/BLUE wire from the alarm to the TAN/ BLUE wire from the instrument harness.

Power Trim Pump Connections

IMPORTANT: Make the hydraulic connections as quickly as possible to prevent oil from leaking out of the system. Be careful not to cross-thread or overtighten the hose fittings. 1. Connect the hydraulic hoses to the trim pump. Torque the fittings.
Description Nm lb-in. lb-ft

Hydraulic Hose Fittings

125

2. Connect the power trim pump control harness to the trim pump. 3. Connect the trim limit switch wires and secure with the wire retainer and tie strap.

c
75126

75127

b f g a

e
50630

50632

a b c d e f g
90-864260 OCTOBER 2001

- Black Hose Fitting (UP Circuit) - Gray Hose Fitting (DOWN Circuit) - Control Harness - Tie Strap - Trim Limit Switch Wire (With Blue Sleeve) To BLUE/WHITE Harness Wire - Trim Limit Switch Wire (With Purple Sleeve) To PURPLE/WHITE Harness Wire - Wire Retainer And Tie Strap
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SERVICE MANUAL NUMBER 31

4. Connect the power trim pump wires to the battery.

b
76631

a - Positive Battery Lead b - Negative Battery Lead

Fluid Connections
Fuel
IMPORTANT: The following information is provided to ensure proper installation of brass fittings or plugs installed into fuel pump or fuel filter base: Use #592 Loctite Pipe Sealant with Teflon on threads of fuel inlet fittings or plugs. DO NOT USE TEFLON TAPE. Fuel inlet fittings or plugs should first be threaded into fuel pump or fuel filter base until finger tight. Fuel inlet fittings or plugs should then be tightened an additional 1-3/4 to 2-1/4 turns using a wrench. DO NOT OVERTIGHTEN. To prevent over-tightening when installing a fuel line, the brass fittings should be held with a suitable wrench as fuel inlet fittings are tightened securely.

WARNING
Boating standards (NMMA, ABYC and others) and Coast Guard regulations must be adhered to when installing fuel delivery system.

WARNING
Avoid gasoline fire or explosion. Improper installation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and/or cause a fuel leak. 1. Connect the fuel inlet line to the water separating fuel filter. 2. Open the fuel shut off valve, if equipped.

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Gear Lube Monitor Hose

IMPORTANT: Avoid using excessive hose when routing it to the gear lube monitor. The hose should be routed directly to the oil reservoir in as straight a line as possible to avoid low spots (traps) in the system.

CAUTION
Ensure that the hose is not kinked when connecting in the following step. If the hose is kinked, the gear lube monitor will not function properly and damage to the drive unit could occur. 1. Route the hose to the gear lube monitor and cut off the excess hose. Connect the hose and secure with a hose clamp. IMPORTANT: The hose must not come in contact with the steering system components, the engine coupler, the U-joint shaft or the drive shaft.

77813

a - Gear Lube Monitor

90-864260 OCTOBER 2001

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SERVICE MANUAL NUMBER 31

Power Steering Hoses

CAUTION
Route the hoses exactly as shown below. This will help avoid stress on the hose fittings and will help avoid kinks in the hose. IMPORTANT: Make the hydraulic connections as quickly as possible to prevent fluid leakage. IMPORTANT: Be careful not to cross-thread or overtighten the fittings. 1. Route the hoses. Secure the hoses to avoid contact with moving components. 2. Connect the power steering hoses to the control valve. Torque both fittings.
Description Nm lb-in. lb-ft

Power Steering Hoses

b c a

77845

a - Rear Fitting (Pressure Hose) b - Front Fitting (Return Hose) c - Control Valve 3. Use extra hose clips to secure the hose to the transom. NOTE: Power steering fluid can be added at this point, if desired.

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Bravo Models and Alpha Seawater Cooled Models Using Sterndrive Water Pickups
1. Connect water hose to water inlet fitting. 2. Secure with hose clamp.

c a b
72040

a - Water Inlet Fitting b - Hose c - Hose Clamp

Alpha or Bravo Models Using Alternative Water Pickups

A water inlet block-off kit must be used if the sterndrive unit water pickup will not be used to supply water to the engine. When installing the block-off plate, it is necessary to cut the water hose that is located between the bell housing and the gimbal housing. This allows water to continue to circulate through the sterndrive unit for cooling.

CAUTION
Avoid overheating the sterndrive unit. The seawater inlet holes must be allowed to flow water without being obstructed or overheating damage to sterndrive may result. Do not dead-end seawater hose from bell housing. Cut hose as recommended in procedures. 1. Remove the existing water fitting and gasket. Discard the screws and lockwashers.

50663

a - Water Fitting b - Screws And Lockwashers

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SERVICE MANUAL NUMBER 31

2. Remove the tapered insert in the gimbal housing using the tapered insert tool. Discard the insert.

c a

a b
22080 22101

a - Tapered Insert b - Tapered Insert Tool c - Gimbal Housing Cross-Sectional View Description Tapered Insert Tool Part Number 91-43579

3. Install the block-off plate with new gasket. Secure with screws and lockwashers. Torque the screws.

a d c

b
75314

75313

a b c d

- Block-Off Plate - Gasket - Screw - Lockwasher Nm 5 lb-in. 45 lb-ft

Description Screw, Block-Off Plate

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4. Move the trim limit switch wires and speedometer hose aside. Reach between the gimbal housing and the bell housing and detach the water hose from the gimbal housing where the tapered insert was removed in Step 2.

b
a b c d e

71184

22101

- Trim Limit Switch Wires - Speedometer Hose - Gimbal Housing - Water Hose - Tapered Insert

WARNING
Avoid water leakage into boat. Damage to U-joint bellows could result in water entering the boat. Do not damage the U-joint bellows when removing a section of the water hose attached between the gimbal housing and bell housing. NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them when cutting the water hose. The existing tie strap and clip can be reused if they are moved and repositioned after the hose is cut. 5. Cut completely through the water hose 127 mm (5 in.) in front of the aft end of the hose where it is fitted into the bell housing. in the area shown. Do NOT damage the U-joint bellows. Discard loose hose piece. 6. Secure the trim limit switch wires and speedometer hose to the remaining section of water hose using existing tie strap and clip.

f b d
a b c d e f - Tie Strap - Clip - Water Inlet Hose - Speedometer Hose - Trim Limit Wire Harness - Cutting Area

71184

90-864260 OCTOBER 2001

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SERVICE MANUAL NUMBER 31

Coolant Recovery Bottle

CAUTION
Avoid engine overheating and subsequent damage to the engine. The coolant recovery system will not operate properly without proper sealing. The plastic tubing MUST seal completely at the connections. 1. Connect the plastic tubing to the bayonet fitting on the heat exchanger. Secure with the tubing clamp provided.

a
a - Plastic Tubing b - Tubing Clamp

70548

2. Remove the cap from the coolant recovery reservoir and fill to the FULL mark with coolant solution. Reinstall the cap. 3. Recheck the coolant level after the first open-throttle boat test and add coolant, if necessary. 4. Maintain the coolant level in the coolant recovery reservoir between the ADD and FULL marks with the engine at normal operating temperature.

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Shift Cable Installation

Alpha Models - Drive Unit Not Installed
We recommend the use of a Quicksilver remote control and cable. Refer to Mercury Precision Parts / Quicksilver Accessories Guide for selection. However, if a control other than Quicksilver is to be used, the control must provide a shift cable travel (at the shift plate end) of 73 mm (2-7/8 in.) to 80 mm (3-1/8 in.) with a 8 kg (18 lb.) load applied to the cable end guide. NOTE: On engines with Alpha drives, the measurement indicated above can be taken by installing the remote control shift cable and using the shift assist assembly (provided) to place the proper load on the shift cable.

d e
a

b a

a
a b c d e - Shift Assist Assembly - Remote Control Shift Cable - In Forward Gear Position - Edge Of Cable End Guide - Remote Control Shift Cable - In Reverse Gear Position - Measurement Taken from Mark To Edge Of Cable End Guide: 73 mm (2-7/8 in.) to 80 mm (3-1/8 in.)

50368

77988

a - Bravo Shift Plate b - Alpha Shift Plate

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IMPORTANT: If the boat is being equipped with a REMOTE CONTROL THAT HAS SEPARATE SHIFT AND THROTTLE LEVERS, the shift assist assembly that is shipped with the engine should NOT be used. The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unexpectedly. The following kit will have to be ordered to connect the remote control shift cable when the shift assist assembly is not used. Spacer Kit 23-11284A1

b c
a b c d - Clevis Pin - Washer - Spacer - Cotter Pin
50310

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NOTE: Do not discard the shift assist assembly until after it is used in step 3., following. IMPORTANT: The shift cable must be connected at the remote control for the appropriate rotation (LH or RH) drive unit, as explained following: RIGHT HAND ROTATION - The control cable will have to be installed in the remote control so that the cable end will move in direction A when the shift handle is placed in the FORWARD position. LEFT HAND ROTATION - The control cable will have to be installed in the remote control so that the cable end will move in direction B when the shift handle is placed in the FORWARD position.

A B
71656

IMPORTANT: Use the following procedure to temporarily install the shift cables if the boat will be shipped without the drive unit installed. (This is NOT an adjustment procedure.) 1. Remove the shift cable attaching hardware.

c
b

50308

a - Cotter Pin b - Clevis Pin And Cotter Pin c - Washer And Locknut 2. Place the remote control shift lever in the NEUTRAL position.

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RH Rotation Bravo One, Two And Three

71663

LH Rotation Bravo One And Two a - Adjustment Tool b - Barrel Retainer c - Shift Lever Stud d - Shift Lever Adjustment Slot 17. Remove the adjustment tool. 18. Lubricate the shift cable pivot points. Description Engine Oil Where Used Shift Cable Pivot Points Part Number Obtain Locally

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Throttle Cable Installation and Adjustment

1. Place the remote control handles in the NEUTRAL IDLE position. IMPORTANT: Ensure that the cable is routed to avoid sharp bends and/or contact with moving parts. Do NOT fasten any items to the throttle cable. The outer cable must be free to move when the cable is actuated. 2. Install the cable end guide on the throttle lever, then push the cable barrel end lightly toward the throttle lever end. (This will place a slight preload on the shift cable to avoid slack in the cable when moving the remote control lever.) Adjust the barrel on the throttle cable to align with the hole in the anchor plate. Ensure that the hole in the barrel positions the cable as shown.

a b

78033

Typical a - Flat Washer And Locknut b - Cable Barrel c - End Guide 3. Secure the throttle cable with the hardware as shown and tighten securely. Loosen locknut 1/2 turn.

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4. Place remote control throttle lever in the wide open throttle (WOT) position. Ensure that throttle plates are completely open.

77939

a - Throttle Plate 5. Return remote control throttle lever to IDLE position and ensure that throttle lever is completely closed.

77939

a - Throttle Plate

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2
B

90-864260 OCTOBER 2001

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Torque Specifications
NOTE: Securely tighten all fasteners not listed below. Description Engine Mount Bracket Screws Trunnion Clamping Bolt and Nut Propeller Shaft Nut Exhaust Manifold Screw Coupler Bolts Fuel Inlet Fitting Nm 64 68 68 27 68 lb-in. lb-ft 47 50 50 20 50

Finger tight + 1-3/4 to 2-1/4 turns with a wrench. DO NOT overtighten.

Lubricants / Sealants / Adhesives

Description Marine Caulking Loctite 271 Loctite 592 PST Liquid Neoprene Engine Coupler Spline Grease Where Used Mounting Surfaces Seawater Pickup Nut Hose Fitting Threads Plastic Plug Threads Fuel Inlet Fitting Battery Terminals Coupler Splines 92-25711-3 92-802869A1 Obtain Locally Part Number Obtain Locally 92-809819

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a b

78031

a - Engine Wiring Harness Receptacle b - Instrument Wiring Harness Plug

WARNING
Avoid extremely flammable and highly explosive conditions. Be careful when working on fuel systems. Do not smoke or allow spark or open flame in area. Wipe up any spilled fuel immediately. 4. Loosen the hose clamp retaining the fuel line to the fuel inlet. 5. Close the fuel shut off, if equipped. 6. Disconnect and plug the fuel line to prevent fuel in the line from leaking into the bilge.

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7. Disconnect the throttle cable and retain the fasteners.

c
a - Washer And Locknut b - Cable Barrel c - Anchor Plate 8. Disconnect the shift cable from the transmission. 9. Disconnect the seawater inlet hose from the seawater pump.

78033

77844

a - Seawater Inlet Hose 10. Disconnect the exhaust system hoses. 11. Disconnect any grounding wires and accessories that are connected to the engine. 12. Disconnect the propeller shaft coupler from the transmission output flange. 13. Disconnect the shaft log seal.

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IMPORTANT: Engine compartment size may require the removal of additional components.

CAUTION
The engine MUST be lifted with a lifting arm or damage to engine components will occur. Do NOT allow the lifting sling to hook or compress the engine components or damage will occur. 14. Support the engine with a suitable sling through the lifting eyes on the engine.

a a

78030

77813

a - Engine Lifting Eyes 15. Remove the front and the rear engine mounting lag bolts. Retain the fasteners.

a a
72638

a - Engine Mounting Lag Bolt (With Washers) 16. Carefully remove the engine.

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Engine Mount Pre-Adjustment

IMPORTANT: The engine mounts must be adjusted, as explained in Steps 1. and 2., to center mount adjustment and establish a uniform height on all mounts. 1. Check all 4 engine mounts to ensure that the distance from the bottom of the mount to the bottom of the trunnion is as shown. a. If not, loosen the mount locking nut and turn the adjusting nut in the direction required to obtain the proper dimension, then retighten the locking nut. NOTE: Leave the mount positioned so that the slot in the base is forward. 2. Loosen the clamping bolts and the nuts on all 4 engine mount brackets to ensure that: The large diameter of the mount trunnion is extended. Mount base slotted mounting hole forward, if so designed. Each mount base is downward. Tighten the clamping bolts and the nuts slightly to prevent moving in or out. The mounts must be free to pivot when installing the engine.

e e a g d f b f
70140

b
70645

Front Mount Rear Mount a - Locking Nut b - Adjusting Nut c - Trunnion Clamp Bolts And Nuts, With Lockwashers d - Slot Forward e - 10 mm + 2 mm (3/8 in. + 1/16 in.) f - 67 mm + 2 mm (2-5/8 in. + 1/16 in.) g - Mount Trunnion

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Engine Preparation
1. Ensure that the grounding stud and starter solenoid terminal are free of paint or any other material that could cause a poor electrical connection. 2. Connect the battery cables to the engine. Apply a thin coat of sealant to the terminals. Description Liquid Neoprene Where Used Battery Terminals Part Number 92-25711-3

3. Slide the rubber boot over the positive (+) terminal. 4. Drape battery cables over top of engine to prevent interference during installation. IMPORTANT: There is a fuse located at the starter solenoid. Do NOT remove this fuse. The positive battery cable must be connected to the same stud as the fuse.

c a b
74904 71651

a b c d

- Negative () Battery Cable - Positive (+) Battery Cable - Starter Solenoid - 90 Amp Fuse - DO NOT Remove

5. Lubricate the splines. Description Engine Coupler Spline Grease Where Used Coupler Splines Part Number 92-802869A1

Engine Oil Dipstick Relocation (If Equipped)

On inboard engines, the crankcase oil dipstick can be located on either the starboard or the port side of the engine to suit installation requirements. To move the dipstick, remove the dipstick from the current location and install in the opposite side. Place the rubber cap over the open dipstick tube.

90-864260 OCTOBER 2001

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Engine Installation And Initial Engine Alignment

Models With 8 Degree Down Angle Transmissions - Velvet Drive Or ZF/Hurth
1. Lift the engine into the boat. 2. Install the quick drain oil hose plug in the oil drain hose. 3. Position the engine on the engine bed so that the transmission output flange and the propeller shaft coupler are visibly aligned (no gap can be seen between the coupling faces when butted together). Adjust the engine bed height if necessary to obtain proper alignment. DO NOT use the mount adjustments to adjust the engine position at this time.

78030

a - Rear Lifting Eye

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MIE MODELS

IMPORTANT: The engine bed must position the engine so that a minimum of 6 mm (1/4 in.) up and down adjustment still exists on all 4 mounts after performing initial alignment. This is necessary to allow for final engine alignment.

74546

a - Propeller Shaft b - Propeller Shaft Coupler c - Transmission Output Flange 4. Ensure that all 4 mounts are still positioned properly, then fasten the mounts to the engine bed with 10 mm (3/8 in.) diameter lag bolts (of sufficient length) and flat washers. Tighten the lag bolts securely. 5. Disconnect the overhead hoist and remove the sling.

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Models with V-Drive Transmissions

1. Lift the engine into the boat. 2. Install the quick drain oil hose plug in the oil drain hose. 3. Position the engine so that enough propeller shaft protrudes through the transmission and the output flange for the propeller shaft coupler to be attached. Then install the coupler and position the engine (no gap can be seen between the coupling faces when butted together). Adjust the engine bed height if necessary to obtain proper alignment. DO NOT use the mount adjustments to adjust the engine position at this time. IMPORTANT: Engine bed must position the engine so that a minimum of 6 mm (1/4 in.) up and down adjustment still exists on all 4 mounts after performing initial alignment. This is necessary to allow for final engine alignment.

d c

a
ZF/Hurth 630V (Others Similar) a - Propeller Shaft b - Propeller Shaft Coupler c - Transmission Output Flange d - No Gap Allowed

50608

4. Ensure that all 4 mounts are still positioned properly. Fasten the mounts to the engine bed with 10 mm (3/8 in.) diameter lag bolts (of sufficient length) and flat washers. Tighten the lag bolts securely. 5. Disconnect the overhead hoist and remove the sling.

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MIE MODELS

All Models
1. Push the end of the oil drain hose out of the boat hull through the flange. 2. Pull the oil drain hose out until it is 152 mm (6 in.) from the propeller. 3. Move the alignment clip on the oil drain hose and squeeze to position it on the hose just inside of the boat hull against the flange. 4. Connect the bilge drain plug to the oil drain hose plug using the clip.

78002

IMPORTANT: If the quick drain oil fitting is within 13 mm (1/2 in.) of the boat bottom, remove the fitting and install the drain plug from the parts bag directly into the oil pan. 5. Push the oil drain hose through the flange into the boat hull. 6. Install the bilge drain plug in the hull.

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Exhaust System Hose / Tube Connections

CAUTION
Avoid exhaust hose failure. Discharge water from the exhaust elbow must flow around the entire inside diameter of the hose to avoid causing hot spots which could eventually result in burned-through exhaust hoses. The exhaust hoses and/ or tubes must be correctly connected to the exhaust elbows so that they do not restrict the flow of discharge water from the exhaust elbow. 1. Install the exhaust hoses and tubes. 2. The exhaust hoses/tubes should be secured at each connection with at least 2 hose clamps.

71653

Correct Connection 3. Tighten all hose clamps securely.

Incorrect Connection

a
73961

a - Hose Clamps IMPORTANT: S-pipes must be routed under the transmission mounts.

a b

74832

Tow Sports Models a - S-pipe b - Transmission Mount

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MIE MODELS

Electrical Connections
EFI Electrical System Precautions

CAUTION
Avoid damage to the EFI electrical system components. Refer to the following precautions when working on or around the EFI electrical harness or when adding other electrical accessories. DO NOT tap the accessories into the engine harness. DO NOT puncture wires for testing (Probing). DO NOT reverse the battery leads. DO NOT splice wires into the harness. DO NOT attempt diagnostics without proper, approved Service Tools. IMPORTANT: When routing all wire harnesses and hoses, ensure that they are routed and secured to avoid contact with hot spots and moving parts on the engine.

Instrumentation Connections
We recommend the use of Quicksilver Instrumentation and Wiring Harnesses which have been specifically designed for compatibility with our engines. Instrumentation wiring extension harnesses are available in several lengths. Refer to the Mercury Precision Parts / Quicksilver Accessories Guide for selection.

CAUTION
If a Quicksilver wiring harness is used and a fused accessory panel is to be installed (40-amp current draw maximum), connect it as shown in the wiring diagrams. Do not connect accessory panel at any other location as wires in the wiring harness may not be of sufficient size to handle the current load. 1. Connect the instrumentation wiring harness to the engine harness plug at the location shown.

78030

a - Engine Wiring Harness Receptacle

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SERVICE MANUAL NUMBER 31

2. Secure the harness with the hose clamp.

78031

a - Hose Clamp

Fluid Connections
CAUTION
Avoid engine overheating and subsequent damage to the engine. The coolant recovery system will not operate properly without proper sealing. Ensure that the plastic tubing seals completely at the connections. 1. Connect the plastic tubing to the bayonet fitting on the heat exchanger. Secure with a tubing clamp.

a
a - Plastic Tubing b - Tubing Clamp

70548

2. Remove the cap from the coolant recovery reservoir and fill to the FULL mark with coolant solution. Install the cap.

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MIE MODELS

Final Engine Alignment

IMPORTANT: Engine alignment MUST BE RECHECKED with the boat in the water, fuel tanks filled and a normal load on board. The engine must be aligned so that the transmission and the propeller shaft coupling centerlines are aligned and the coupling faces are parallel within 0.08 mm (.003 in.). This applies to installations with solid couplings as well as flexible couplings. 1. Check mating faces on the transmission output flange and the propeller shaft coupler to ensure that they are clean and flat. 2. Center the propeller shaft in the shaft log as follows: a. Push down and then lift the shaft as far as it will move. Then place the shaft in the middle of the movement. b. Move the shaft to port and then to starboard as far as the shaft will move. Then place the shaft in the middle of the movement. c. With the shaft in the center of the shaft log as determined by above procedures a. and b. align the engine to the shaft.

a d

c b
Typical Down Angle (V-Drive Similar) a - Up b - Down c - Port d - Starboard
72595

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3. Ensure that the coupling centerlines align. Place the propeller shaft coupler against the transmission output flange. The shoulder on the propeller shaft coupler face should engage the recess on the transmission output flange face with no resistance.

72597

Incorrect

Correct

NOTE: Some propeller shaft couplers may not have a shoulder on the mating face. On these installations, use a straight edge to check centerline alignment.

a
a b c d - Transmission Output Flange - Propeller Shaft Coupler - Propeller Shaft - Straight Edge

b d
74483

4. Check for angular misalignment by holding the coupling faces tightly together and checking for a gap between mating faces with a .08 mm (0.003 in.) feeler gauge.

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MIE MODELS

5. Check the gap at 90 degree intervals.

a b c
75534

Velvet Drive

b c a
50609

b a
50608

ZF/Hurth a - Propeller Shaft Coupler b - Feeler Gauge c - Transmission Output Flange 6. If the coupling centerlines are not aligned or if the coupling faces are more than .08 mm (0.003 in.) out of parallel, adjust the engine mounts. a. TO ADJUST THE ENGINE UP OR DOWN: Loosen the locking nut on the mounts requiring adjustment and turn the adjusting nuts in the desired direction to raise or lower. IMPORTANT: The adjusting nuts on either the front mounts or the rear mounts must be turned equally to keep the engine level from side to side.

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NOTE: Some rear mounts have 1 clamping bolt and nut on each side. b. TO MOVE THE ENGINE TO THE LEFT OR THE RIGHT: Loosen the clamping bolts and the nuts on all 4 mount brackets and move the engine to the left or the right as necessary to obtain proper alignment. A small amount of adjustment can be obtained with the slot on the front end of some mounts. Loosen the lag bolts (which fasten the mounts to the engine bed) and move the engine, as required. Retighten the lag bolts securely. IMPORTANT: The large diameter of the mount trunnion MUST NOT extend over 45 mm (1-3/4 in.) from the mount brackets on any of the mounts. 7. After the engine has been properly aligned, secure the engine mounts. 8. Torque the clamping bolts and the nuts on all 4 mounts.
Description Nm lb-in. lb-ft

Clamping Bolts And Nuts 9. Tighten the locknut on all four mounts.

10. Bend one of the tabs on the tab washer down onto the flat of the adjusting nut. NOTE: Some rear mounts have 1 clamping screw and nut on each side. IMPORTANT: All coupler bolts must be Metric Grade 10.9 (SAE Grade 8) or better, with a shoulder (grip length) sufficient to pass through the mating face plane of the couplers. 11. Secure the coupling together with the bolts, the lockwashers and the nuts. Torque the bolts.

b
75535

a - Bolts b - Transmission Coupler

Description Nm lb-in. lb-ft

Coupler, Propeller Shaft

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MIE MODELS

12. If the propeller shaft coupler has set screws: a. Remove the set screws and mark the dimple locations using a transfer punch. b. Remove the propeller shaft coupler and drill shallow dimples at the locations marked with the punch. c. Install the propeller shaft coupler and torque the bolts. Install the set screws and tighten securely. Safety wire the set screws to ensure that they do not loosen.

b c d e

a
50608

a b c d e

- Propeller Shaft Coupler - Bolts - Set Screws - Safety Wire - Transmission Output Flange Nm 68 lb-in. lb-ft 50

Description Bolts 13. Connect the shaft log seal.

Engine Cover Installation

1. Install the flame arrestor and secure with the bracket. 2. Torque the bolts. Description Flame Arrestor Bolts 3. Install the engine cover and tighten the knob securely. Nm 12 lb-in. lb-ft 9

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Fuel Supply Connections

Refer to SECTION 2A, Fluid Connections.

Throttle Cable Installation And Adjustment

Refer to SECTION 2A.

Shift Cable Installation And Adjustment

Refer to SECTION 8

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MIE MODELS

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SERVICE MANUAL NUMBER 31

THIS PAGE IS INTENTIONALLY BLANK

Page 2B-22

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ENGINE MECHANICAL

ENGINE MECHANICAL
Section 3A - 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid)

Table of Contents
Identification . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . 5.0 l (305 cid) . . . . . . . . . . . . . . . . . . . . 5.7 l (350 cid) . . . . . . . . . . . . . . . . . . . . 6.2 l (377 cid) . . . . . . . . . . . . . . . . . . . . Engine Specifications 5.0 l (305 cid) and 5.7 l (350 cid) . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . Cylinder Bore . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . Piston Bore Clearance . . . . . . . . . . . . Piston Rings . . . . . . . . . . . . . . . . . . . . . Piston Pin . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod . . . . . . . . . . . . . . . . . . Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . Timing Chain . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications - 6.2 l (377 cid) . . Cylinder Head . . . . . . . . . . . . . . . . . . . . Cylinder Bore . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . Piston Clearance . . . . . . . . . . . . . . . . . Piston Rings . . . . . . . . . . . . . . . . . . . . . Piston Pin . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod . . . . . . . . . . . . . . . . . . Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . Timing Chain . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . Repair Procedures . . . . . . . . . . . . . . . . Special Notice . . . . . . . . . . . . . . . . . . . . Engine Rotation . . . . . . . . . . . . . . . . . . Crankcase Oil Dipstick Measurements Engine Mounts . . . . . . . . . . . . . . . . . . . . . . Exploded Views . . . . . . . . . . . . . . . . . . Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-3 3A-4 3A-4 3A-4 3A-5 3A-6 3A-6 3A-6 3A-6 3A-6 3A-7 3A-7 3A-8 3A-9 3A-9 3A-11 3A-11 3A-11 3A-12 3A-12 3A-12 3A-12 3A-12 3A-13 3A-13 3A-14 3A-15 3A-15 3A-17 3A-17 3A-17 3A-18 3A-22 3A-23 3A-25 3A-26 3A-26 3A-26 3A-26 3A-27 3A-28 3A-28 3A-30 3A-30 3A-30 3A-30 Rocker Arm / Valve Pushrod . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Seal / Valve Spring Cylinder Head Installed . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Valve Adjustment . . . . . . . . . . . . . . . . . . . . Engine Stopped . . . . . . . . . . . . . . . . . . Intake Manifold Assembly . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Upper And Lower Intake Manifolds . . Installation . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Valve Lifters . . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . Special Information . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Camshaft and Camshaft Bearings . . . . . Measuring Camshaft Lobe Lift . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-31 3A-31 3A-31 3A-31 3A-32 3A-33 3A-33 3A-34 3A-35 3A-38 3A-38 3A-40 3A-40 3A-41 3A-43 3A-43 3A-43 3A-43 3A-46 3A-46 3A-46 3A-47 3A-48 3A-48 3A-49 3A-50 3A-50 3A-52 3A-54 3A-54 3A-55 3A-59 3A-59 3A-60 3A-61 3A-62 3A-67 3A-72 3A-75 3A-77 3A-77 3A-77 3A-78 3A-78

3
A

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Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-81 Exploded View . . . . . . . . . . . . . . . . . . . 3A-81 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-82 Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-82 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 3A-83 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-83 Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-84 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-86 Crankshaft Balancer . . . . . . . . . . . . . . . . . 3A-87 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-87 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 3A-87 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-87 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-88 Front Cover Oil Seal . . . . . . . . . . . . . . . . . 3A-90 Oil Seal Replacement Without Removing Front Cover . . . . . . . . . . . . . . . . . . . . . 3A-90 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . 3A-91 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-91 Cleaning and Inspection . . . . . . . . . . . 3A-92 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-92 Connecting Rod, Bearings and Piston Assembly . . . . . . . . . . . . . . . . . . . . 3A-94 Exploded View . . . . . . . . . . . . . . . . . . . 3A-94 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-95 Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-96 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 3A-97 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-97 Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-112 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-115 Crankshaft, Main Bearings And Engine Block . . . . . . . . . . . . . . . . . . . 3A-119 Exploded View . . . . . . . . . . . . . . . . . . . 3A-119 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-120 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 3A-123 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-126 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-138

Timing Chain And Sprockets . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Flywheel Housing . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal Retainer . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Oil Filter By-Pass Valve and Block Adapter . . . . . . . . . . . . . . . . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . .

3A-150 3A-150 3A-151 3A-151 3A-151 3A-152 3A-153 3A-153 3A-154 3A-154 3A-154 3A-155 3A-155 3A-156 3A-156 3A-158 3A-158 3A-159 3A-159 3A-159 3A-161 3A-161 3A-161 3A-161 3A-162 3A-163 3A-163 3A-164 3A-165 3A-165 3A-166

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ENGINE MECHANICAL

Identification
The Mercury MerCruiser Model can be determined by looking at the last two or three letters of the engine code stamped into the engine block. This code number is stamped on all Mercury MerCruiser power packages and replacement partial engines, but not replacement engine block assemblies. If the engine serial number and/or model decals are missing, the engine code letters may help in determining the engine models.

a
72312

a - Location Of Engine Code The following is a list of Mercury MerCruiser engines and their respective GM code letters. Sterndrive (MCM) 5.0L MPI Alpha and Bravo 350 MAG MPI Alpha and Bravo 350 MAG MPI Alpha and Bravo Horizon MX 6.2 MPI MX 6.2 MPI Horizon Code 2ZB 2MN 2MN 2MNB 2MNB

Inboard (MIE) 350 MAG MPI Inboard 350 MAG MPI Horizon Inboard MX 6.2 MPI Inboard MX 6.2 MPI Horizon Inboard Tow Sports 350 MAG MPI Tow Sports

Code 2ML 2ML 2MLB 2MLB Code 2MN

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General Specifications
5.0 l (305 cid)
Displacement Bore Stroke Firing Order Compression Ratio Heads Intake Manifold - Two Piece Block Rods Crankshaft Pistons Camshaft Upper Lower 5.0 l (305 cid) 94.89 mm (3.736 in.) 88.39 mm (3.480 in.) 1-8-4-3-6-5-7-2 9.4:1 Cast Iron Aluminum Cast Iron Cast Iron (2 Bolt Main Bearing Caps) Forged Steel Cast Iron Cast Aluminum Cast Iron

5.7 l (350 cid)

Displacement Bore Stroke Firing Order Compression Ratio Heads Intake Manifold - Two Piece Block Rods Crankshaft Pistons Camshaft Upper Lower 5.7 l (350 cid) 101.6 mm (4.00 in.) 88.39 mm (3.480 in.) 1-8-4-3-6-5-7-2 9.4:1 Cast Iron Aluminum Cast Iron Cast Iron (2 Bolt or 4 Bolt Main Bearing Caps) Forged Steel Cast Iron Cast Aluminum Steel

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ENGINE MECHANICAL

General Specifications (continued)

6.2 l (377 cid)
Displacement Bore Stroke Firing Order Compression Ratio Heads Intake Manifold - Two Piece Block Rods Crankshaft Pistons Camshaft Upper Lower 6.2 l (377 cid) 101.6 mm (4.00 in.) 95.25 mm (3.750 in.) 1-8-4-3-6-5-7-2 9.0:1 Cast Iron Aluminum Cast Iron Cast Iron (2 Bolt Main Bearing Caps) Forged Steel Forged Steel Cast Aluminum Steel

90-864260 OCTOBER 2001

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Engine Specifications - 5.0 l (305 cid) and 5.7 l (350 cid)

Cylinder Head
Description At Exhaust Manifold Deck Surface Flatness At Engine Block Deck - Within An 152 mm (6.0 in.) Area At Intake Manifold Deck 5.0 l (305 cid) 5.7 l (350 cid)

0.05 mm (0.0020 in.)

0.10 mm (0.0039 in.)

Cylinder Bore
Description Diameter Out Of Round Production Service Production Thrust Side Taper Production Relief Side Service Limit 5.0 l (305 cid) 94.894-94.947 mm (3.7360-3.7381 in.) 5.7 l (350 cid) 101.618-101.643 mm (4.0007-4.0017 in.)

0.025 mm (0.0010 in.) Maximum 0.05 mm (0.0020 in.) Maximum 0.012 mm (0.0005 in.) Maximum 0.025 mm (0.0010 in.) Maximum 0.025 mm (0.0010 in.) Over Production

Oil Pump
Description Oil Pump Dowel Pin Height 6.4 mm (0.2520 in.)

Piston Bore Clearance

Description Production Service 5.0 l (305 cid) 0.018-0.061 mm (0.0007-0.0024 in.) 0.018-0.068 mm (0.0007-0.0026 in.) 5.7 l (350 cid) 0.018-0.053 mm (0.0007-0.0020 in.) 0.018-0.061 mm (0.0007-0.0024 in.)

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Engine Specifications - 5.0 l (305 cid) and 5.7 l (350 cid) (continued)
Piston Rings
TOP COMPRESSION
Description Groove Clearance Production Service Production Gap Service 5.0 l (305 cid) 5.7 l (350 cid)

0.030-0.070 mm (0.0012-0.0028 in.) 0.030-0.090 mm (0.0012-0.0035 in.) 0.25-0.51 mm (0.0098-0.0201 in.) 0.25-0.65 mm (0.0098-0.0259 in.) 0.25-0.40 mm (0.0098-0.0157 in.) 0.25-0.50 mm (0.0098-0.0197 in.)

SECOND COMPRESSION
Description Groove Clearance Production Service Production Gap Service 5.0 l (305 cid) 0.030-0.074 mm (0.0012-0.0029 in.) 0.030-0.090 mm (0.0012-0.0035 in.) 0.46-0.66 mm (0.0181-0.0298 in.) 0.46-0.90 mm (0.0181-0.0354 in.) 5.7 l (350 cid) 0.038-0.080 mm (0.0015-0.0031 in.) 0.040-0.100 mm (0.0016-0.0039 in.) 0.038-0.058 mm (0.0015-0.0023 in.) 0.46-0.80 mm (0.0181-0.0315 in.)

OIL CONTROL
Description Groove Clearance Production Service Production Gap Service 5.0 l (305 cid) 0.051-0.203 mm (0.0020-0.0080 in.) 0.051-0.22 mm (0.0020-0.0009 in.) 0.25-0.89 mm (0.0098-0.0350 in.) 5.7 l (350 cid) 0.046-0.096 mm (0.0018-0.0038 in.) 0.046-0.100 mm (0.0018-0.0039 in.) 0.25-0.90 mm (0.0098-0.0354 in.)

0.25-0.76 mm (0.0098-0.0299 in.)

Piston Pin
Description Diameter Clearance Production Service Limit Fit In Connecting Rod 5.0 l (305 cid) 0.010-0.020 mm (0.0004-0.0008 in.) 5.7 l (350 cid) 0.013-0.023 mm (0.0005-0.0009 in.) 23.545-23.548 mm (0.9270-0.9271 in.)

0.013-0.025 mm (0.0005-0.0010 in.) 0.012-0.050 mm (0.0005-0.0020 in.) Interference

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Engine Specifications - 5.0 l (305 cid) and 5.7 l (350 cid) (continued)
Crankshaft
MAIN BEARING JOURNAL
Description Number 1 Diameter Number 2, 3, 4 Number 5 Taper Out Of Round Production Service Production Service 5.0 l (305 cid) 5.7 l (350 cid)

62.189-62.212 mm (2.4484-2.4493 in.) 62.181-62.207 mm (2.4481-2.4491 in.) 62.185-62.207 mm (2.4482-2.4491 in.) 0.005 mm (0.0002 in.) Maximum 0.025 mm (0.0010 in.) Maximum 0.005 mm (0.0002 in.) Maximum 0.025 mm (0.0010 in.) Maximum

MAIN BEARING CLEARANCE

Description Number 1 Production Number 2, 3, 4 Number 5 Number 1 Service Number 2, 3, 4 Number 5 5.0 l (305 cid) 5.7 l (350 cid)

0.018-0.053 mm (0.0007-0.0021 in.) 0.030-0.068 mm (0.0012-0.0027 in.) 0.020-0.060 mm (0.0008-0.0024 in.) 0.025-0.051 mm (0.0010-0.0020 in.) 0.025-0.064 mm (0.0010-0.0025 in.) 0.038-0.063 mm (0.0015-0.0025 in.)

CONNECTING ROD JOURNAL

Description Diameter Taper Out Of Round Production Service Production Service 5.0 l (305 cid) 5.7 l (350 cid)

56.505 - 56.533 mm (2.2246-2.2257 in.) 0.007 mm (0.0003 in.) Maximum 0.025 mm (0.0010 in.) Maximum 0.007 mm (0.0003 in.) Maximum 0.025 mm (0.0010 in.) Maximum

MISCELLANEOUS
Description Runout End Play (Thrust Clearance) 5.0 l (305 cid) 5.7 l (350 cid)

0.038 mm (0.0015 in.) 0.05-0.20 mm (0.0020-0.0079 in.)

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Engine Specifications - 5.0 l (305 cid) and 5.7 l (350 cid) (continued)
Connecting Rod
CONNECTING ROD BEARING
Description Clearance Production Service Limit 5.0 l (305 cid) 5.7 l (350 cid)

0.033-0.078 mm (0.0013-0.0031 in.) 0.025-0.063 mm (0.0010-0.0025 in.) 0.15-0.61 mm (0.0059-0.0240 in.)

Rod Side Clearance

Valve
CLEARANCE (LASH)
Description Intake and Exhaust 5.0 l (305 cid) 5.7 l (350 cid)

Rotate the valve rocker arm nut clockwise 360 degrees (1 turn) from zero clearance

LIFTER
Description Type Rocker Arm Ratio Valve Lift Intake Exhaust 5.0 l (305 cid) 1.50 : 1 6.97-7.07 mm (0.2744-0.2783 in.) 7.20-7.30 mm (0.2834-2874 in.) 5.7 l (350 cid)

Hydraulic Roller

HEAD AND STEM

Description Valve Diameter Face Angle Margin After Surfacing Stem Diameter Service Stem Oversize Diameter Valve Stem Oil Seal
1

5.0 l (305 cid) Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Exhaust Only Installed Height 1 46.74 mm (1.84 in.)

5.7 l (350 cid) 49.28 mm (1.94 in.)

38.1 mm (1.5000 in.) 45 degrees 45 degrees 0.79 mm (0.0311 in.) Minimum 1.524 - 2.032 mm (0.0600 - 0.0800 in.) 8.661 - 8.679 mm (0.3410 - 0.3417 in.) + 0.774 mm (+0.0305 in.) 1 - 2 mm (0.0394 - 0.0787 in.)

Measured from the top of the valve guide bevel to the bottom of the oil stem seal.

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Engine Specifications - 5.0 l (305 cid) and 5.7 l (350 cid) (continued)
Valve (continued)
STEM CLEARANCE
Description Production Service Intake Exhaust Intake Exhaust 5.0 l (305 cid) 5.7 l (350 cid)

0.025-0.069 mm (0.0010-0.0027 in.) 0.025-0.069 mm (0.0010-0.0027 in.) 0.025-0.094 mm (0.0010-0.0037 in.) 0.025-0.094 mm (0.0010-0.0037 in.)

SEAT
Description Seat Angle Top Correction Cut Angle Bottom Correction Cut Angle Intake And Exhaust 5.0 l (305 cid) 5.7 L (350 cid)

46 degrees 30 degrees 60 degrees Intake 1.14-1.78 mm (0.0449-0.0701 in.) 1.65-2.49 mm (0.0650-0.0980 in.) 1.02-1.65 mm (0.0402-0.0650 in.) 1.50-2.56 mm (0.0591-0.1008 in.)

Width Exhaust Runout Intake And Exhaust

0.05 mm (0.0020 in.) Maximum

SPRING
Description Free Length Valve Closed Pressure Installed Height Valve Open Intake Exhaust 5.0 l (305 cid) 5.7 l (350 cid)

51.3 mm (2.02 in.) 338-374 N (76-84 lb.) at 43.2 mm (1.7008 in.) 832-903 N (187-203 lb.) at 32.3 mm (1.2717 in.) 42.92-43.43 mm (1.6898-1.7098 in.) 4

Approximate Number Of Coils

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Engine Specifications - 5.0 l (305 cid) and 5.7 l (350 cid) (continued)
Camshaft
Description Journal Diameter Journal Out Of Round Camshaft Runout 5.0 l (305 cid) 5.7 l (350 cid) 47.440-47.490 mm (1.8677-1.8697 in.) 0.025 mm (0.0010 in.) Maximum 0.065 mm (0.0026 in.) Maximum

Timing Chain
Description Chain Deflection 5.0 l (305 cid) 5.7 l (350 cid) 11 mm (0.4331 in.) Maximum

Flywheel
Description Runout 5.0 l (305 cid) 5.7 l (350 cid) 0.203 mm (0.0080 in.) Maximum

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Engine Specifications - 6.2 l (377 cid)

Cylinder Head
Description At Exhaust Manifold Deck Surface Flatness At Engine Block Deck - Within An 152 mm (6.0 in.) Area At Intake Manifold Deck 6.2 l (377 cid) 0.05 mm (0.0020 in.)

0.10 mm (0.0039 in.)

Cylinder Bore
Description Diameter Out of Round Production Service Production Thrust Side Taper Production Relief Side Service Limit 6.2 l (377 cid) 101.618-101.643 mm (4.0007-4.0017 in.) 0.025 mm (0.0010 in.) Maximum 0.05 mm (0.0020 in.) Maximum 0.012 mm (0.0005 in.) Maximum 0.025 mm (0.0010 in.) Maximum 0.025 mm (0.0010 in.) Over Production

Oil Pump
Description Oil Pump Dowel Pin Height 6.4 mm (0.2520 in.)

Piston Clearance
Description Production Service 6.2 l (377 cid) 0.018-0.053 mm (0.0007-0.0021 in.) 0.018-0.068 mm (0.0007-0.0027 in.)

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Engine Specifications - 6.2 l (377 cid) (continued)

Piston Rings
TOP COMPRESSION
Description Groove Clearance Gap Production Service Production Service 6.2 l (377 cid) 0.030-0.070 mm (0.0012-0.0027 in.) 0.030-0.090 mm (0.0012-0.0035 in.) 0.25-0.51 mm (0.0098-0.0201 in.) 0.30-0.68 mm (0.01118-0.0268 in.)

SECOND COMPRESSION
Description Groove Clearance Gap Production Service Production Service 6.2 l (377 cid) 0.040-0.080 mm (0.0015-0.0030 in.) 0.040-0.100 mm (0.0015-0.0040 in.) 0.46-0.66 mm (0.0181-0.0260 in.) 0.51-0.94 mm (0.0201-0.0370 in.)

OIL CONTROL
Description Groove Clearance Gap Production Service Production Service Limit 6.2 l (377 cid) 0.051-0.17 mm (0.0020-0.0067 in.) 0.051-0.195 mm (0.0020-0.0076 in.) 0.25-0.76 mm (0.0098-0.0299 in.) 0.28-0.81 mm (0.0110-0.0319 in.)

Piston Pin
Description Diameter Production Clearance Service Limit 6.2 l (377 cid) 23.545-23.548 mm (0.9269-0.9270 in.) 0.013-0.023 mm (0.0005-0.0009 in.) 0.013-0.025 mm ( 0.0005-0.0010 in.) Maximum 0.021-0.040 mm (0.0008-0.0016 in.) Interference

Fit In Rod

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Engine Specifications - 6.2 l (377 cid) (continued)

Crankshaft
MAIN BEARING JOURNAL
Description Number 1 Diameter Number 2, 3, 4 Number 5 Taper Out Of Round Production Service Production Service 6.2 l (377 cid) 62.189-62.212 mm (2.4484-2.4493 in.) 62.181-62.207 mm (2.4481-2.4491 in.) 62.177-62.207 mm (2.4479-2.4491 in.) 0.005 mm (0.0002 in.) Maximum 0.025 mm (0.0010 in.) Maximum 0.005 mm (0.0002 in.) Maximum 0.025 mm (0.0010 in.) Maximum

MAIN BEARING CLEARANCE

Description Number 1 Production Number 2, 3, 4 Number 5 Number 1 Service Number 2, 3, 4 Number 5 6.2 l (377 cid) 0.018-0.053 mm (0.0007-0.0021 in.) 0.022-0.061 mm (0.0009-0.0024 in.) 0.025-0.069 mm (0.0010-0.0027 in.) 0.025-0.051 mm (0.0010-0.0020 in.) 0.025-0.064 mm (0.0010-0.0025 in.) 0.038-0.076 mm (0.0015-0.0030 in.)

CONNECTING ROD JOURNAL

Description Diameter Taper Out Of Round Production Service Production Service 6.2 l (377 cid) 53.284-53.334 mm (2.0978-2.0998 in.) 0.007 mm (0.0003 in.) Maximum 0.025 mm (0.0010 in.) Maximum 0.007 mm (0.0003 in.) Maximum 0.025 mm (0.0010 in.) Maximum

MISCELLANEOUS
Description Runout End Play (Thrust Clearance) 6.2 l (377 cid) 0.05-0.20 mm (0.0020-0.0079 in.) 0.05-0.20 mm (0.0020-0.0079 in.)

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Engine Specifications - 6.2 l (377 cid) (continued)

Connecting Rod
CONNECTING ROD BORE (CRANKSHAFT END)
Description Diameter Taper Out of Round Production Service Limit Production Service Limit 6.2 l (377 cid) 53.284-53.334 mm (2.0977-2.0997 in.) 0.025 mm (0.0010 in.) 0.025 mm (0.0010 in.)

CONNECTING ROD BEARING

Description Clearance Rod Side Clearance Production Service 6.2 l (377 cid) 0.033-0.088 mm (0.0013-0.0035 in.) 0.025-0.076 mm (0.0010-0.0030 in.) 0.15-0.61 mm (0.0059-0.0240 in.)

Valve
CLEARANCE (LASH)
Description Intake and Exhaust 6.2 l (377 cid) Rotate the valve rocker arm nut clockwise 360 degrees (1 turn) from zero clearance

LIFTER
Description Type Rocker Arm Ratio Valve Lift Intake Exhaust 6.2 l (377 cid) Hydraulic Roller 1.50 : 1 7.90-8.00 mm (0.3114-0.3153 in.) 8.00-8.10 mm (0.3160-3200 in.)

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Engine Specifications - 6.2 l (377 cid) (continued)

HEAD AND STEM
Description Valve Diameter Face Angle Margin After Surfacing Stem Diameter Service Stem Oversize Diameter Valve Stem Oil Seal
1

6.2 l (377 cid) Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Exhaust Only Installed Height 1 49.28 mm (1.94 in.) 38.1 mm (1.50 in.) 45 degrees 45 degrees 0.79 mm (0.031 in.) Minimum 1.524-2.032 mm (0.0600-0.0800 in.) 8.66 mm (0.341 in.) 8.66 mm (0.341 in.) + 0.0774 mm (+ 0.0305 in.) 1 - 2 mm (0.0394 - 0.0787 in.)

Measured from the top of the valve guide bevel to the bottom of the oil stem seal.

STEM CLEARANCE
Description Production Service Intake Exhaust Intake Exhaust 6.2 l (377 cid) 0.025-0.069 mm (0.0010-0.0027 in.) 0.025-0.069 mm (0.0010-0.0027 in.) 0.025-0.094 mm (0.0010-0.0037 in.) 0.025-0.194 mm (0.0010-0.0076 in.)

SEAT
Description Seat Angle Top Correction Cut Angle Bottom Correction Cut Angle Width Runout Intake and Exhaust 6.2 l (377 cid) 46 degrees 30 degrees 60 degrees Intake Exhaust Intake Exhaust 1.02-1.65 mm (0.0434-0.0650 in.) 1.50-2.56 mm (0.0591-0.1008 in.) 0.05 mm (0.0020 in.) Maximum

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Engine Specifications - 6.2 l (377 cid) (continued)

Valve (continued)
SPRING
Description Free Length Valve Closed Pressure Valve Open Installed Height Intake Exhaust 6.2 l (377 cid) 51.3 mm (2.0197 in.) 338-374 N at 43.2 mm (76-84 lb at 1.7008 in.) 832-903 N at 32.3 mm (187-203 lb at 1.2717 in.) 42.92-43.43 mm (1.6898-1.7098 in.) 42.92-43.43 mm (1.6898-1.7098 in.) 4

Approximate Number of Coils

Camshaft
Description Journal Diameter Journal Out Of Round Camshaft Runout 6.2 l (377 cid) 47.440-47.490 mm (1.8677-1.8697 in.) 0.025 mm (0.0010 in.) Maximum 0.065 mm (0.0026 in.) Maximum

Timing Chain
Description Chain Deflection 6.2 l (377 cid) 11 mm (0.4331 in.) Maximum

Flywheel
Description Runout 6.2 l (377 cid) 0.203 mm (0.0080 in.) Maximum

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Torque Specifications (continued)

Description Fuel Rail Bracket Bolt Fuel Rail Retainer Nut Ignition Coil Bolt Lower Intake Manifold Bolt (Each Pass In Sequence) First Pass Second Pass Final Pass Knock Sensor MAPT Sensor Bolt Oil Deflector Nut Oil Filter Adapter (5/16 in. -18) Oil Filter Adapter Bolt Oil Gallery Plug Oil Lines Oil Pan Bolt or Nut Oil Pan Stud (Front) Oil Pan Stud Nut Oil Pan Fitting Hollow Bolt Oil Pan Drain Plug Oil Pressure Switch Fitting Oil Pump Bolt (To Rear Crankshaft Bearing Cap) First Pass Final Pass Oil Pump Cover Bolt Rear Main (Crankshaft) Oil Seal Retainer Bolts and Nuts 12 12 20 + 65 degrees 106 106 15 3 12 15 20 12 40 27 25 20 27 12 6 25 20 25 15 180 18 11 106 53 18 106 30 20 18 15 20 27 106 132 15 Nm 6 3 12 lb-in. 53 27 106 lb-ft

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Torque Specifications (continued)

Description Rear Mount - Sterndrive (MCM) Rear Mount - Inboard (MIE) and Tow Sports Rear Oil Seal Retainer Nuts And Bolts Rear Oil Seal Retainer Stud Remote Oil Connector Remote Oil Filter Adapter Nut / Fitting Valve Cover Bolt Seawater Pump Bracket Spark Plug Initial Installation (New Cylinder Head) All Subsequent Installations Starter Motor Bolt Thermostat Housing Bolt Throttle Body Stud Nut Stud Transmission to Flywheel Housing Upper Intake Manifold Stud First Pass Final Pass Valve Lifter Guide Retainer Bolt Water Circulating Pump Bolt Water Pump Pulley Bolt Water Temperature Sender 5 10 25 45 25 27 44 89 19 33 19 20 10 9 68 88 80 50 30 15 50 41 22 11 37 30 Nm 51 12 6 34 27 12 41 106 30 106 53 25 20 lb-in. lb-ft 38

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Description Where Used Cylinder head bolts Engine block coolant drain hole plug Engine block oil gallery plug Engine Coolant Temperature (ECT) sensor Expansion cup plug (camshaft rear bearing hole) Loctite 565 PST (Pipe Sealant With Teflon) Expansion cup plug (engine block core hole) Knock sensor Oil dipstick tube Oil pressure sender Oil gallery plugs Oil pressure switch Oil pressure switch fitting Oil pickup screen pipe to oil pump body Water circulating pump bolt Engine Oil 80W Gear Lube On all moving parts during assembly as indicated Rocker arm ball stud Lifters, camshafts and camshafts lobes Valve pushrods, rocker arm and rocker arm ball contact surfaces Valve stem locks Obtain Locally Obtain Locally Part Number

Obtain Locally

Johnson EP Lube Needle Bearing Assembly Lubricant

92-801779

92-082868A1

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Precautions
WARNING
Avoid injury or death and power package damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package.

WARNING
BE CAREFUL while working on fuel system; gasoline is extremely flammable and highly explosive under certain conditions. Ensure that ignition key is OFF and do not smoke or allow sources of spark and/or open flames in the area.

CAUTION
If boat is in the water, seacock must remain closed until engine is to be re-started to prevent water from flowing back into cooling system and/or boat. If boat is not fitted with a seacock, water inlet hose must be left disconnected and plugged to prevent water from flowing back into cooling system and/or boat. As a precautionary measure, attach a tag to the ignition switch or steering wheel of the boat with the warning: Open seacock or reconnect water inlet hose before starting engine.

CAUTION
Compressed air could cause injury. Always wear safety glasses while using compressed air.

CAUTION
DO NOT operate engine without water flowing through seawater pickup pump, as pump impeller may be damaged and subsequent overheating damage to engine or sterndrive unit may result. IMPORTANT: To provide the initial lubrication during first starting, lubricate all engine moving parts during assembly with clean engine oil, unless otherwise specified.

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

General Information
Repair Procedures
Some of the repairs in this section must be completed with the engine removed from the boat. Engine removal depends upon the type of repair and boat design. Place the engine on a repair stand for major repairs. When engine removal is not required, ensure that the battery cables are disconnected at the battery prior to performing any on-board repair procedures. Lubricate all moving parts during reassembly with clean engine oil or as specified. Apply appropriate lubricant, sealant or adhesive to all fasteners as specified.

Special Notice
Servicing the cylinder heads and engine block is the primary concern of this section. Some external components that are not mentioned in the procedural steps must be removed. Refer to appropriate sections of this manual for complete service information concerning any component hindering service or repairs to the cylinder heads and engine block.

Engine Rotation
Engine rotation is described when observed from the rear of the engine (transmission or sterndrive end) looking forward (water pump end). Propeller rotation is not necessarily the same as engine rotation. IMPORTANT: All sterndrive (MCM), inboard (MIE) and tow sports (Ski) engines covered by this service manual are left hand (LH) rotation.

72001

a - Left Hand Rotation (Counterclockwise)

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Crankcase Oil Dipstick Measurements

NOTICE Unit Of Measurement: millimeters (inches) Part Number 861942-2 861942-3 Length A 330 (13) 349 (14) Length B 19 (3/4) 13 (1/2) Length C 396 (15-1/2) 396 (15-1/2) Model All MIE Engines All MIE Engines With Remote Drive Transmissions All MCM Service And Tow Sports All Sterndrive (MCM) Engines

861942-7 861942-9

787 (31) 851 (33-1/2)

19 (3/4) 13 (1/2)

845 (33-1/4) 895 (33-1/4)

c a

77646

a - Length A b - Length B c - Length C

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Engine Mounts
Exploded Views

72317

Front Mount - All Sterndrive (MCM) Models

72318

Rear Mount / Flywheel Housing - All Sterndrive (MCM) Models

72319

Front Mount Assembly - All Inboard (MIE) Models

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ENGINE MECHANICAL

Exploded Views (Continued)

73055

Rear Mount Assembly - Most Inboard (MIE) And Tow Sports Models

73056

Typical Rear Mount Assembly - Inboard (MIE) And Tow Sports Models with Velvet Drive In-Line Transmission

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Valve Cover
Removal
NOTE: It may be necessary to remove the exhaust manifold before removing a valve cover. Refer to SECTION 7 for exhaust manifold removal. 1. Disconnect crankcase ventilation hoses. 2. Remove any items that interfere with the removal of valve covers. 3. Remove valve covers.

Cleaning and Inspection

1. Clean gasket material from all sealing surfaces. 2. Put on safety glasses. 3. Clean sealing surfaces on cylinder head and valve cover with degreaser.

Installation
1. Place new valve cover gasket in position.

72324

a - Gasket b - Sealing Surface 2. Install valve cover. Torque bolts.

Description Nm lb-in. lb-ft

Valve Cover Bolt 3. Install any items that were removed. 4. Connect crankcase ventilation hoses. 5. Supply cooling water to the power package. 6. Start engine and check for oil leaks.

106

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ENGINE MECHANICAL

Rocker Arm / Valve Pushrod

Removal
NOTE: When servicing only one cylinders rocker arms, bring that cylinders piston up to TDC (Top Dead Center) before removing rocker arms. When servicing all rocker arms, bring cylinder number 1 piston up to TDC before removing rocker arms. 1. Remove valve covers. 2. Remove rocker arm assemblies and valve pushrods. IMPORTANT: Organize rocker arm assemblies and valve pushrods in a rack for reassembly in their original locations.

Cleaning
1. Clean rocker arm assemblies and pushrods. 2. Clean valve pushrod oil passages. 3. Put on safety glasses. 4. Dry parts with compressed air.

Inspection
1. Inspect all contact surfaces for excessive wear or scoring. 2. Ensure valve pushrod oil passage is not restricted. 3. Roll valve pushrod on a flat surface and inspect shafts for bends. 4. Replace all damaged parts.

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Installation
1. Lubricate the outer surfaces and ends of valve pushrods. 2. Install the valve pushrods in their original locations. Ensure that the pushrods seat in the lifter socket. 3. Lubricate the rocker arm and rocker arm ball contact surfaces. 4. Lubricate the threads of the valve rocker arm studs. 5. Install the rocker arms, rocker arm balls and rocker arm nuts in their original locations.
A

b d

e
A

c a
A

76695

72301

a b c d e

- Pushrod - Rocker Arm - Rocker Arm Ball - Rocker Arm Nut - Rocker Arm Stud Where Used Valve pushrods, rocker arm and rocker arm ball contact surfaces Rocker arm ball stud Part Number 92-801779 Obtain Locally

Description A Johnson EP Lube B 80W Gear Lube 6. Adjust valve clearance.

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ENGINE MECHANICAL

Valve Stem Oil Seal / Valve Spring - Cylinder Head Installed

Exploded View
1 2 2 3 4 5 6 1

78152

1 2 3 4 5 6 7

- Valve Locks - Cap - Intake Valve Stem Oil Seal - Exhaust Valve Stem Oil Seal - Spring - Intake Valve - Exhaust Valve

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Removal
1. Remove valve cover. 2. Remove spark plug of affected cylinder. 3. Remove rocker arm assembly. IMPORTANT: Keep air pressure in cylinder while springs, caps and valve locks are removed or valves will fall into cylinder. 4. Install air line adapter tool (J23590) in spark plug hole and apply compressed air to hold valves in place. NOTE: If compressed air is not available, piston may be brought up to TDC and used to keep valves from falling out of valve guides. 5. Using valve spring compressor under rocker arm nut as shown, compress valve spring and remove valve locks.

77869 72306

a - Valve Spring Compressor (J5892) b - Rocker Arm Nut c - Valve Locks 6. Slowly release valve spring compressor. 7. Remove valve spring cap and valve spring. IMPORTANT: If compressed air was not available, do not turn crankshaft while valve springs, retainers and locks are removed or valves will fall into cylinder. 8. Remove and discard valve stem seal.

77867

Typical a - Valve Stem Seal

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ENGINE MECHANICAL

Installation
IMPORTANT: The intake valve oil stem seal is black. The exhaust valve stem seal material is either brown with a white paint stripe on the outer diameter or it is red with no paint stripe. Also, the letters EX are molded into the top of the exhaust valve stem seal. 1. Select the appropriate intake or exhaust valve stem oil seal. 2. Coat the outside surface of the valve stem bore and all surfaces of the valve stem oil seal with clean engine oil. Description Engine Oil Where Used Part Number

Valve stem bore and valve stem Obtain Locally oil seal

3. Install the valve stem seal onto the valve stem and push down until it is seated against the head. 4. Install special valve stem seal installer tool and press the valve stem seal until the tool contacts the spring seat.

77867

Typical a - Valve Stem Seal Installer Tool (J42073)

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5. For all intake and exhaust valves, ensure that the installed height (the gap between the bottom edge of the valve stem oil seal and the cylinder head valve guide boss) is as specified.

77868

a - Bottom Of Valve Stem Oil Seal b - Valve Guide Boss c - Installed Height (Gap) 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) Installed Height 1 1 - 2 mm (0.0394 - 0.0787 in.)

Description Valve Stem Oil Seal

Measured from top of valve guide bevel to bottom of oil stem seal.

6. Install the valve spring. 7. Place the valve spring cap on valve spring. 8. Temporarily install the rocker arm nut onto the corresponding stud.

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ENGINE MECHANICAL

9. Coat the valve stem locks with the lubricant to hold them in place. 10. While compressing valve spring with valve spring compressor, install the valve stem locks. 11. Ensure that the valve stem locks are seated properly in the groove of the valve stem. 12. Slowly release valve spring compressor and remove the rocker arm nut.

c b a

77869 72306

a b c d e

- Valve Spring - Cap - Valve Stem Locks - Valve Spring Compressor (J5892) - Nut Where Used Valve stem locks Part Number 92-082868A1

Description A Needle Bearing Assembly Lubricant

13. Install pushrods and rocker arm assemblies. 14. Remove the airline adapter tool (J23590). 15. Adjust valves as outlined under Valve Adjustment. 16. Install valve cover. 17. Install and torque spark plugs.
Description Nm lb-in. lb-ft

Spark Plug Initial Installation (New Cylinder Head) All Subsequent Installations
30 15 22 11

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Valve Adjustment
Engine Stopped
With valve cover removed, adjust valves when lifter is on low part of camshaft lobe. 1. Turn engine in direction of engine rotation until mark on crankshaft balancer lines up with center 0 mark on timing tab. NOTE: Ensure engine is in cylinder number 1 firing position by placing fingers on cylinder number 1 valves as mark on crankshaft balancer comes near 0 mark on timing tab. If valves move as marks align the engine is in cylinder number 6 firing position and should be rotated 360 degrees to cylinder number 1 firing position.

72328

2. With engine positioned as in Step 1., adjust the following valves. Description Exhaust Valves Intake Valves Cylinder Number 1-3-4-8 1-2-5-7

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ENGINE MECHANICAL

3. Adjust the valves indicated as follows: a. Loosen rocker arm nut until valve lash is felt at valve pushrod. b. Tighten rocker arm nut until all valve lash is removed. Zero valve lash can be felt by moving the valve pushrod up and down between the thumb and forefinger until there is no more vertical movement of the pushrod. c. Tighten the rocker arm nut an additional turn (360 degrees). No other adjustment is required.

72300

Engine Intake and Exhaust

5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) Rotate the valve rocker arm nut clockwise 360 degrees (1 turn) from zero clearance

4. Turn engine in direction of engine rotation 360 degrees until timing tab 0 mark and crankshaft balancer mark are aligned. This is cylinder number 6 firing position. With engine in this position, the following valves may be adjusted as previously outlined. 5. With engine positioned as in Step 4., adjust the following valves. Description Exhaust Valves Intake Valves 6. Adjust the valves indicated as follows: a. Loosen rocker arm nut until valve lash is felt at valve pushrod. b. Tighten rocker arm nut until all valve lash is removed. Zero valve lash can be felt by moving the valve pushrod up and down between the thumb and forefinger until there is no more vertical movement of the pushrod. c. Tighten the rocker arm nut an additional turn (360 degrees). No other adjustment is required. Cylinder Number 2-5-6-7 3-4-6-8

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Intake Manifold Assembly

NOTE: The upper and lower intake manifold parts may be removed as an assembly. Unless service is required, it is not necessary to remove individual intake manifold components other than as outlined. Refer to SECTION 5 for disassembly, cleaning, inspection and reassembly of individual intake manifold components.

Exploded View
5
77849

8 1

10 9

78150

1 - Upper Intake Manifold 2 - Lower Intake Manifold 3 - Lower Intake Manifold Bolts 4 - Thermostat Housing 5 - Ignition Coil Wire 6 - Distributor and Clamp 7 - Distributor Clamp Bolt 8 - Distributor Gasket 9 - Fuel Rail 10 - Fuel Line 11 - Intake Manifold Gasket

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ENGINE MECHANICAL

Removal
1. Drain engine seawater and closed cooling systems. 2. Disconnect hoses from thermostat housing. 3. Disconnect electrical leads interfering with removal. 4. Disconnect crankcase ventilation hoses from valve covers. 5. Disconnect throttle cable.

CAUTION
Avoid fuel system damage. Do not allow dirt or debris to enter the fuel system. Seal open ends of fuel lines and fuel system. 6. Using fuel line removal tool, disconnect fuel line. 7. Remove the ignition coil wire from the ignition coil and distributor cap.

77849

IMPORTANT: Do NOT engage starter after distributor has been removed.

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8. Remove the distributor clamp bolt. 9. Remove the distributor and the distributor clamp. 10. Remove the distributor gasket and discard.

a b

c
a - Clamp Bolt b - Clamp c - Gasket

77951

11. Disconnect and remove items that interfere with removal of intake manifold assembly. 12. Remove lower intake manifold bolts.

77833

IMPORTANT: It may be necessary to pry intake manifold away from cylinder heads and block, in next step. Use extreme care to prevent damage to sealing surfaces. 13. Remove intake manifold assembly. 14. Remove and discard the lower intake manifold gaskets. NOTE: If part of the intake manifold assembly requires replacement, disassemble and transfer all remaining parts to new intake manifold component. Refer to SECTION 5.

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ENGINE MECHANICAL

Cleaning
IMPORTANT: When cleaning cylinder head mating surface, do not allow gasket material to enter engine crankcase or intake ports. 1. Clean gasket material from all mating surfaces. 2. Clean varnish buildup and other contaminants from intake passages. 3. Put on safety glasses. Clean bolt holes in cylinder head and dry with compressed air.

Inspection
1. Inspect intake manifold assembly for cracks or scratches. 2. Ensure all machined mating surfaces are clean and free of all marks and deep scratches.

Upper And Lower Intake Manifolds

Refer to SECTION 5, for disassembly, cleaning, inspection and reassembly of the individual components.

Installation

CAUTION
Excessive amounts of adhesive or sealer on gaskets or component surfaces may cause improper sealing resulting in intake manifold air or fluid leaks. Do not apply excessive amounts of adhesive or sealer. 1. Apply a 4 mm (5/32 in.) bead of adhesive at each end of the lower intake manifold gasket on the cylinder head side. Do NOT get sealer into oil sending unit hole. NOTE: For proper adhesion, the lower intake manifold gasket must be installed while the adhesive is still wet. 2. Align lower intake manifold gaskets with locator pins. Install lower intake manifold gaskets onto the cylinder heads.

c d
A

a b c
77884 77833

a b c d

- Area Of Adhesive - Locator Pin - Gasket - Locator Pin Hole Where Used Lower intake manifold gaskets Part Number 92-809826

Description A Ultra-Black Loctite 5900

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3. Apply a 5 mm (13/64 in.) wide bead of adhesive to front and rear of engine block as shown. Extend adhesive bead 13 mm (1/2 in.) up on intake gaskets.
A

b b

a
77847

a
A

77846 72325

a - Bead Of Adhesive b - Front Top Of Engine Block c - Rear Top Of Engine Block Description A Ultra-Black Loctite 5900 Where Used Engine block at the lower intake manifold sealing surfaces Part Number 92-809826

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ENGINE MECHANICAL

4. Coat threads of the lower intake manifold bolts with sealant. 5. Carefully install lower intake manifold assembly onto engine block.

CAUTION
Avoid engine damage. Crankshaft bearing bore alignment may become distorted resulting in damage to the crankshaft bearings if intake manifold fastener tightening sequence and torque are done improperly. Always torque the bolts in sequence to the specified amount in each of the three passes required. 6. Torque lower intake manifold bolts in sequence and passes indicated.
A 7 1 3 5

b
8 4 2 6
72878 77833

a - Intake Manifold Bolts b - Front Description A Loctite 242 Description Lower Intake Manifold Bolt (Each Pass In Sequence) First Pass Second Pass Final Pass 3 12 15 27 106 132 Where Used Lower intake manifold bolt Nm Part Number
92-809821

lb-in.

lb-ft

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SERVICE MANUAL NUMBER 31

7. Connect all ignition and electrical leads. 8. Connect hoses to thermostat housing. 9. Install fuel line. 10. Connect crankcase ventilation hoses. 11. Install the distributor. 12. Install the ignition coil wire. 13. Install other ignition components and reconnect wires. 14. Connect any items that were disconnected. 15. Refill closed cooling system, if equipped.

Hydraulic Valve Lifters

Exploded View
1 2 3 4 5 6 7 8 9 10

72031

Valve Lifter 1 - Pushrod Seat Retainer Clip 2 - Pushrod Seat 3 - Metering Valve 4 - Plunger 5 - Check Ball 6 - Check Ball Spring 7 - Check Ball Retainer 8 - Plunger Spring 9 - Lifter Body 10 - Roller

Special Information
Hydraulic valve lifters require little attention. These lifters are extremely simple in design. Normally, readjustments are not necessary and servicing requires only that care and cleanliness be exercised in the handling of parts. Refer to SECTION 1C for troubleshooting information such as locating a noisy lifter.

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ENGINE MECHANICAL

Removal
1. Drain seawater and closed cooling systems. 2. Remove valve covers. IMPORTANT: Keep rocker arm assembly, valve pushrod and hydraulic valve lifter from each valve together as a matched set. Mark and organize parts so that they can be installed in the same location later. 3. Remove rocker arm assemblies and pushrods. Keep parts in matched sets. 4. Remove intake manifold. 5. Remove lifter guide retainer.

77872

a - Lifter Guide Retainer b - Bolts IMPORTANT: Store the valve lifters in the upright position to prevent oil loss. 6. Remove lifter guides and lifters. Store lifters in the upright position in order of removal.

72340

a - Lifter Guide b - Lifter

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Cleaning
1. Put on safety glasses. 2. Except for the valve lifters, clean the parts with cleaning solvent. 3. Dry parts with compressed air. 4. While holding upright, wipe the valve lifters with a clean, oil saturated, lint free cloth. Store lifters in the upright position.

Inspection
1. Ensure that the lifter seat retainer clip is not broken or damaged. 2. Inspect pushrod seat. If seat is scuffed or worn, inspect pushrod. 3. Inspect outer lifter body wall. If wall is scuffed or worn, inspect engine block lifter bore. 4. Inspect the roller of lifter. If roller is scuffed or worn, inspect camshaft lobe. 5. Ensure oil hole is unobstructed. 6. Inspect all parts carefully. If any are damaged or worn, the entire lifter assembly should be replaced.

a b

c d

e
Inspection Of Lifter a - Seat Retainer Clip b - Pushrod Seat c - Lifter Body d - Roller e - Oil Hole

72031

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ENGINE MECHANICAL

Installation
IMPORTANT: Do NOT install used valve lifters if a new camshaft has been installed. IMPORTANT: Before installing valve lifters, coat the camshaft lobes and lifters with EP lube. 1. Lubricate and install valve lifters. Install lifters in original locations if being reused. Description Johnson EP Lube 2. Install lifter guides. 3. Install lifter guide retainer. Torque bolts. Where Used Lifters, camshafts and camshafts lobes Part Number 92-801779

77872

a - Lifter Guide Retainer b - Bolts

Description Nm 25 lb-in. lb-ft 19

Valve Lifter Guide Retainer Bolt

4. Lubricate and install valve pushrods and rocker arm assemblies. Description Engine Oil 5. Adjust valve clearance. 6. Install intake manifold. 7. Install valve covers. 8. Change engine oil and filter. 9. Check for leaks when engine is started. Where Used Part Number

Valve pushrods and rocker arm Obtain Locally assemblies

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Camshaft and Camshaft Bearings

IMPORTANT: Camshaft bearings can be replaced while engine is disassembled for overhaul or without complete disassembly. To replace bearings without complete disassembly, remove camshaft and crankshaft, leaving cylinder heads attached and pistons in place. Disconnect and fasten connecting rods against sides of engine so that they will not interfere while replacing camshaft bearings.

Measuring Camshaft Lobe Lift

NOTE: Procedure is similar to checking valve timing. If improper valve operation is indicated, measure lift of each pushrod in consecutive order and record readings. 1. Remove valve covers. IMPORTANT: Keep rocker arm assembly from each valve together as a matched set. Mark and organize parts so that they can be installed in the same location later. 2. Remove rocker arm assemblies. Keep in matched sets. 3. Position indicator with ball socket adapter tool on valve pushrod. Ensure that pushrod is in lifter socket.

72380

a - Ball Socket Adapter Tool (J8520-1) 4. Rotate crankshaft balancer slowly in direction of engine rotation until lifter is on the heel of the cam lobe. At this point, the pushrod will be in its lowest position. 5. Set dial indicator on zero, then rotate crankshaft balancer slowly until pushrod is in fully raised position.

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6. Compare total lift, recorded from dial indicator, to specification. Description Valve Lift Description Valve Lift Intake Exhaust Intake Exhaust 5.0 l (305 cid) / 5.7 l (350 cid) 6.97-7.07 mm (0.2744-0.2783 in.) 7.20-7.30 mm (0.2834-0.2874 in.) 6.2 l (377 cid) 7.90-8.00 mm (0.3114-0.3153 in.) 8.00-8.10 mm (0.3160-0.3200 in.)

7. Continue to rotate engine until indicator reads zero. This will ensure accuracy of original indicator reading. 8. Replace the camshaft if valve lift is not within specifications. 9. If camshaft readings for all lobes are within specifications, remove dial indicator assembly. 10. Install rocker arm assemblies. 11. Adjust valve clearance. 12. Install valve covers. 13. Check for leaks when engine is started.

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ENGINE MECHANICAL

e. Coat outer diameter of a new camshaft rear bearing hole expansion cup plug with sealant. f. Install new camshaft rear bearing hole expansion plug. IMPORTANT: Camshaft rear bearing hole plug must be installed 8.8 mm (0.3465 in.) deep and must be parallel with rear surface of engine block.

a
A

77893

a - Camshaft Rear Bearing Hole Expansion Cup Plug b - Measurement - 8.8 mm (0.3465 in.) Description A Loctite 565 PST Where Used Part Number

Expansion cup plug (camshaft Obtain Locally rear bearing hole)

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SERVICE MANUAL NUMBER 31

CAMSHAFT
1. Install three 5/16-18 x 5 in. bolts in camshaft bolt holes. 2. Lubricate camshaft journals with engine oil and install camshaft. Be careful not to damage bearings. Description Engine Oil Where Used Camshaft journals Part Number Obtain Locally

3. Lubricate camshaft lobes with EP lube or equivalent. Description Johnson EP Lube Where Used Camshafts and camshafts lobes Part Number 92-801779

4. Remove the three bolts in camshaft bolt holes. 5. Coat threads of camshaft thrust plate retainer bolts with adhesive. Description Loctite 242 Threadlocker Where Used Camshaft thrust plate retainer bolt Part Number 92-809821

6. Install camshaft thrust plate retainer and bolts. Torque bolts. Description Camshaft Thrust Plate (Retainer) Bolts 7. Install timing chain. 8. Install new crankcase front cover and gasket. 9. Install valve lifters. 10. Install rocker arm assemblies. 11. Adjust valve clearance. 12. Install valve covers. Nm 12 lb-in. 106 lb-ft

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ENGINE MECHANICAL

Cylinder Head
Removal
1. Drain seawater and closed cooling systems. 2. Remove exhaust elbows and manifolds. 3. Remove valve covers. 4. Remove intake manifold assembly. IMPORTANT: Keep rocker arm assembly, valve pushrod and hydraulic valve lifter from each valve together as a matched set. Mark and organize parts so that they can be reinstalled in the same location later. 5. Remove rocker arm assemblies and pushrods. Keep in matched sets. 6. Remove any components attached to the cylinder head. 7. Remove spark plugs. 8. Remove cylinder head bolts.

a b c

77878

a - Long Bolts b - Medium Bolts c - Short Bolts

CAUTION
The head gasket may be holding cylinder head to block. Use care when prying off cylinder heads. Do NOT damage gasket surfaces. Do NOT drop cylinder heads. 9. Remove cylinder head. 10. Place cylinder head on wooden blocks to prevent damage to gasket surfaces.

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Disassembly
1. Using valve spring compressor, compress valve spring and remove valve locks. Slowly release tool.

77883

a - Valve Spring Compressor (J8062) IMPORTANT: Keep components together as a matched set. Mark and organize parts so that they can be reinstalled in the same location later. 2. Remove valve cap and spring. 3. Remove valves from cylinder head. 4. Mark and organize components for installation in the same location later.

77175

5. Remove and discard valve stem oil seals. 6. Place cylinder head on wooden blocks to prevent damage to gasket surfaces.

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ENGINE MECHANICAL

Cleaning
VALVE COMPONENTS
1. Put on safety glasses. 2. Clean the valve stem locks, valve spring caps and valve springs in cleaning solvent. 3. Clean carbon from valves using a wire wheel. 4. Clean the valves in cleaning solvent. 5. Dry parts with compressed air.

CYLINDER HEAD
1. Put on safety glasses. 2. Clean gasket material and sealer from engine block and cylinder head sealing surfaces. 3. Clean all carbon from combustion chambers and valve ports using carbon remover brush.

72334

a - Carbon Remover Brush (J8089) 4. Thoroughly clean valve guides with valve guide cleaner.

72335

a - Valve Guide Cleaner (J8101) 5. Clean and dry the cylinder head. 6. Clean cylinder head bolt threads and engine block bolt hole threads to ensure that no dirt, old oil or coolant remain. 7. Dry parts with compressed air, including cylinder head bolt threads and engine block bolt hole threads.

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Inspection
CYLINDER HEAD
1. Inspect sealing surfaces for burrs, scratches, deep nicks, erosion or other damage. 2. Inspect for cracks in exhaust ports, water jackets and combustion chambers (especially around spark plug holes and valve seats). 3. Replace heads if necessary. 4. Inspect for rusted, damaged or leaking core plugs. Replace plugs if necessary. 5. Inspect for corrosion around cooling passages. 6. Check flatness of cylinder head gasket surfaces, using a machinists straight edge and feeler gauges as shown. Take measurements diagonally (C, D), across head both ways (A, B, E, F) and straight down center of head (G).

a
E C B A G D F

b
72307

Measuring Engine Block Deck Surface Flatness All Decks Similarly Measured a - Straight Edge b - Feeler Gauge 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) At Exhaust Manifold Deck Surface Flatness At Engine Block Deck - Within a 152 mm (6.0 in.) area At Intake Manifold Deck 0.05 mm (0.002 in.)

Description

0.10 mm (0.004 in.)

7. If measured value is greater than specified, the cylinder head must be repaired or replaced to provide proper alignment.

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ENGINE MECHANICAL

VALVE
1. Inspect valves for burned heads, cracked or pitted faces or damaged stems.

a
76777

b
76776

a - Cracked, Pitted Face b - Damaged Stems IMPORTANT: Excessive valve stem to bore clearance will cause excessive oil consumption and possibly broken valves. Insufficient clearance will result in noisy, binding valves. 2. Measure valve stem diameter in three places. 3. If the measured value is less than specified limit, the valve must be replaced.

77196

Description Production Stem Diameter Service Stem Oversize Diameter Intake Exhaust Exhaust Only

5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) 8.661 - 8.679 mm (0.3410 - 0.3417 in.) + 0.774 mm (+ 0.0305 in.)

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4. Measure valve head margin. 5. If measured value is less than specified, the valve must be replaced.

77197

Description Margin After Surfacing Intake Exhaust

5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) 0.79 mm (0.031 in.) Minimum 1.524 - 2.032 mm (0.060 - 0.080 in.)

VALVE STEM TO BORE CLEARANCE

1. Using a valve with specified stem diameter or a new valve, measure valve stem clearance. a. Attach a dial indicator to cylinder head. Position it against the valve stem and close to the valve guide. b. Holding valve head off the seat about 2 mm (1/16 in.), move valve stem side to side in the guide as shown. Compare stem clearance with specifications.

72336

Measuring Stem Clearance Description Production Service Intake Exhaust Intake Exhaust 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) 0.025-0.069 mm (0.0010-0.0027 in.) 0.025-0.069 mm (0.0010-0.0027 in.) 0.025-0.094 mm (0.0010-0.0037 in.) 0.025-0.094 mm (0.0010-0.0037 in.)

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ENGINE MECHANICAL

c. If clearance exceeds specifications on exhaust valve and exhaust guide: it will be necessary to ream valve guide and install a valve with an oversized stem. Refer to Repair - Valve Guide Bore. d. If clearance exceeds specifications on intake valve and intake guide: it will be necessary to replace the cylinder head. Intake valves are NOT available with oversize stems.

VALVE SPRINGS
1. Use a vernier caliper to measure the valve spring free length. Replace spring if it is more or less than specified limit.

77198

Description Free Length 2. Measure the valve for squareness.

5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) 51.3 mm (2.02 in.)

77199

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3. Use a spring tester to measure the valve spring tension. Replace spring if measured value is less than specified limit.

72308

a - Valve Spring Tester (J9666) b - Torque Wrench 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) Valve Closed Pressure Valve Open 338-374 N (76-84 lb.) at 43.2 mm (1.7 in.) 832-903 N (187-203 lb.) at 32.3 mm (1.27 in.)

Description

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90-864260 OCTOBER 2001

50668

Typical 3 Angle Valve Seat a - Top Correction Cut Angle b - Seat Angle c - Bottom Correction Cut Angle d - Seat Width 5.7 l (350 cid) / 6.2 l (377 cid)

Description Seat Angle Top Correction Cut Angle Bottom Correction Cut Angle Intake and Exhaust

5.0 l (305 cid)

46 degrees 30 degrees 60 degrees Intake 1.14-1.78 mm (0.045-0.070 in.) 1.65-2.49 mm (0.065-0.098 in.) 1.02-1.65 mm (0.040-0.065 in.) 1.50-2.56 mm (0.059-0.101 in.)

Width Exhaust

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6. Measure valve seat concentricity. 7. Recondition the seat if measured value exceeds specified limit.

72338

Measuring Valve Seat Concentricity Description Runout Intake Exhaust 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) 0.05 mm (0.0020 in.) Maximum

ROCKER ARM STUD REPLACEMENT

IMPORTANT: Replace worn or loose valve rocker arm studs with oversize studs. The studs are pressed into the cylinder head. Two replacement valve rocker arm ball studs sizes are available: Description First Oversize Second Oversize 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) + .003 in. + .013 in.

1. Place rocker arm stud remover and flat washer over stud. 2. Install a 3/8 in.-24 threaded nut. 3. Turn nut clockwise to remove stud.

b a

72309

a - Rocker Arm Stud Remover (J5802-01) b - Flat Washer c - Nut

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ENGINE MECHANICAL

IMPORTANT: Valve rocker arm ball stud hole must be reamed with appropriate tool to accept an oversize replacement stud. 4. Ream rocker arm ball stud hole using appropriate reaming tool.

77864

Reaming Rocker Arm Stud Hole Description Stud Bore Reamer Tool (.003 in. First Oversize) Stud Bore Reamer Tool (.013 in. Oversize) 5. Coat the end of the oversize rocker arm stud with lubricant. 6. Install oversize stud with rocker arm stud installer. NOTE: When using the rocker arm stud installer J6880 the installation depth is correct when tool contacts the cylinder head. Part Number J5715 J6036

72311

a - Oversize Rocker Arm Stud b - Rocker Arm Stud Installer (J6880) Description A 80W Gear Lube Where Used Rocker arm ball stud Part Number Obtain Locally

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SERVICE MANUAL NUMBER 31

Reassembly
1. Lubricate valve, valve guide bores and valve stems with clean engine oil. Description Engine Oil Where Used Valve, valve guide bore and valve stem Part Number Obtain Locally

2. Install each valve in the port from which it was removed or for which it has been fitted. IMPORTANT: The intake valve oil stem seal material is black. The exhaust valve oil stem seal material is either brown with a white paint stripe on the outer diameter or it is red with no paint stripe. Also, the letters EX are molded into the top of the exhaust valve oil stem seal. 3. Select the appropriate intake or exhaust valve stem oil seal. 4. Coat outside surfaces of valve guides and all surfaces of all the valve stem oil seals with clean engine oil. Description Engine Oil Where Used Valve guide and valve stem oil seal Part Number Obtain Locally

5. Install the valve guide seal onto the valve stem and push down until seated against the guide. 6. Install the valve stems. 7. Ensure that the valve stem seal is not pressed too far onto valve guide in the head. A specified gap should exist between the bottom edge of the valve stem oil seal and the cylinder head valve guide boss.

a b

77868

a - Bottom Of Valve Stem Oil Seal b - Valve Guide Boss c - Installed Height (Gap) 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) Installed Height 1 1 - 2 mm (0.0394 - 0.0787 in.)

Description Valve Stem Oil Seal

Measured from top of valve guide bevel to bottom of oil stem seal.

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8. Install valve spring. 9. Place valve spring cap on valve spring.

CAUTION
Improperly compressed springs or improperly locked valve caps could allow the spring to be ejected with tremendous force, which could cause personal injury. Use care when compressing the valve springs or releasing the valve spring compressor tool. 10. Compress the valve spring using valve spring compressor. 11. Coat the valve stem locks with lubricant to hold in place. 12. Install the valve stem locks. 13. Ensure valve stem locks are seated properly in the groove of the valve stem.

a
A

c b d

77869 77883

a b c d

- Valve Spring Compressor (J8062) - Cap - Valve Locks - Spring Where Used Valve stem locks Part Number 92-082868A1

Description A Needle Bearing Assembly Lubricant

180

a c b

76386

a - Dipstick b - Clamp c - Dipstick Tube 8. Fill crankcase with specified engine oil. Refer to SECTION 1B.

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ENGINE MECHANICAL

Oil Pump
Exploded View
5 3 9 7

12 11

1 2 Oil Pump Assembly 1 - Driveshaft 2 - Driveshaft Retainer 3 - Pump Body 4 - Drive Gear And Shaft 5 - Idler Gear 6 - Pick Up Screen And Suction Pipe 7 - Pump Cover 8 - Pressure Regulator Valve 9 - Pressure Regulator Spring 10 - Plug 11 - Retaining Pin 12 - Screw (4)

10
72146

90-864260 OCTOBER 2001

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Removal
1. Remove oil pan. 2. Remove and discard the oil pan gasket. 3. Remove crankshaft oil deflector.

a b
a - Nuts (5) b - Crankshaft Oil Deflector c - Oil Pump 4. Remove oil pump, driveshaft retainer and driveshaft.

72344

Disassembly
1. Remove pump cover. IMPORTANT: Gear teeth must be marked for exact repositioning when reassembled. 2. Make alignment marks on the idler gear and drive gear teeth. 3. Remove idler gear and drive gear from pump body.

CAUTION
Pressure regulator valve spring is compressed. Use care when removing or installing retaining pin to prevent personal injury. 4. Put on safety glasses. 5. Remove retaining pin, spring and pressure regulator valve from pump cover.

CAUTION
Do not remove suction pipe and pickup screen assembly unless replacement is necessary. Loss of press fit condition could result in an air leak and loss of oil pressure causing engine damage. The pipe and screen are serviced as an assembly. 6. If pickup screen and suction pipe assembly require replacement, mount pump in a soft-jawed vise and extract the suction pipe from the pump.

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Cleaning
1. Put on safety glasses. 2. Clean all parts in cleaning solvent. 3. Dry parts with compressed air.

Inspection
IMPORTANT: Pump gears and body are not serviced separately. If pump gears or body are damaged or worn, replacement of entire oil pump assembly is necessary. 1. Inspect pump body and cover for cracks or excessive wear. 2. Inspect pump gears for damage and excessive wear, such as chipped teeth and galling. 3. Check gear shafts in pump body for galling, scoring or excessive shaft-to-bore clearance. 4. Inspect inside of pump cover for wear that would permit oil to leak past ends of gears. 5. Inspect pickup screen and suction pipe assembly for damage. 6. Check pressure regulator valve for smooth, non-binding fit in bore of oil pump cover. 7. Inspect the oil pump locator dowel pins for damage and proper height.

a b

77874

a - Dowel Pins b - Measurement Description Oil Pump Dowel Pin Height 6.4 mm (0.25 in.)

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Reassembly
IMPORTANT: Liberally coat oil pump internal parts before installation. 1. Liberally coat surfaces of pressure regulator valve, pressure relief spring and pressure regulator bore in oil pump with lubricant. Description Engine Oil Where Used Pressure regulator valve, pressure relief spring and pressure regulator bore Part Number Obtain Locally

CAUTION
Pressure regulator valve spring is compressed. Use care when removing or installing retaining pin to avoid personal injury. 2. Put on safety glasses. 3. Install pressure regulator valve, a new pressure relief spring if reusing existing pump and retaining pin. 4. Liberally coat surfaces of oil pump gears and shafts with lubricant. Description Engine Oil 5. Install drive gear in pump body. 6. Install idler gear in pump body with smooth side of gear toward pump cover. 7. Align gear teeth marks made in disassembly. 8. Fill gear cavity with engine oil. 9. Install oil pump cover and cover bolts. Torque bolts in a diagonal pattern. Where Used Oil pump gears Part Number Obtain Locally

77862

a - Cover b - Bolts Description Oil Pump Cover Bolt Nm 12 lb-in. 106 lb-ft

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ENGINE MECHANICAL

10. Turn oil pump driveshaft by hand to ensure smooth pump operation.

CAUTION
Be careful of twisting, shearing or collapsing the suction pipe while installing in pump. Pickup screen must be parallel to oil pan bottom when oil pump is installed. 11. If pickup screen and pipe assembly was removed: a. Mount pump in a soft-jawed vise. b. Apply sealant to end of new pipe. Description A Loctite 565 PST Where Used Oil pickup screen pipe to oil pump body Part Number Obtain Locally

c. Using the suction pipe installer tool, tap the suction pipe in place with a hammer.

78149

d. Ensure that the pickup screen is parallel to the oil pan bottom when installed.

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Installation
IMPORTANT: Do NOT reuse the oil pump driveshaft retainer. Oil pump driveshaft retainer must be replaced. 1. Align oil pump driveshaft with distributor driveshaft. 2. Instal oil pump driveshaft, a new driveshaft retainer and oil pump to rear main bearing cap. 3. Install crankshaft oil deflector, nuts and oil pump bolt. 4. Torque oil pump bolt and oil deflector nuts.

c b a d
2
72344

77870

a b c d e

- Driveshaft - Driveshaft Retainer - Oil Pump Assembly - Oil Deflector Nut - Oil Pump Bolt Nm First Pass Final Pass 20 + 65 degrees 40 30 lb-in. lb-ft 15

Description 1 Oil Pump Bolt (To Rear Crankshaft Bearing Cap)

2 Oil Deflector Nut IMPORTANT: Always install a new oil pan gasket. 5. Install a new oil pan gasket. 6. Install oil pan.

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ENGINE MECHANICAL

Crankshaft Balancer
Removal
1. Remove drive belt. 2. Remove crankshaft drive pulley. 3. Remove crankshaft balancer retaining bolt. IMPORTANT: Do not use a universal claw type puller to remove crankshaft balancer as outside ring of balancer is bonded in rubber to the hub. Use of claw type puller may break the bond. 4. Remove crankshaft balancer with remover and installer tool.

72345

a - Crankshaft Balancer Remover And Installer Tool (J23523 F).

Cleaning
1. Put on safety glasses. 2. Clean the crankshaft balancer in cleaning solvent. 3. Dry the parts with compressed air.

Inspection
1. Inspect crankshaft balancer for worn or damaged bolt hole threads. 2. Inspect crankshaft balancer for damaged or deteriorated rubber between inner and outer pieces. 3. Inspect crankshaft balancer for improperly installed or loose balance weights. 4. Inspect crankshaft balancer keyway for damage.

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SERVICE MANUAL NUMBER 31

Installation
IMPORTANT: The inertia weight section of the crankshaft balancer is bonded to the hub with a rubber type material. The installation procedure (with proper tool) must be followed or movement of the inertia weight on the hub will destroy the tuning of the crankshaft balancer. 1. Coat seal surface of crankshaft balancer with engine oil. Description Engine Oil Where Used Crankshaft Balancer Seal Surface Part Number Obtain Locally

2. Replace crankshaft key if it is damaged. 3. To prevent oil leaks, apply sealant to crankshaft balancer keyway. Description Ultra-Black Loctite 5900 Where Used Crankshaft Balancer Keyway Part Number 92-809826

4. Align the keyway of the crankshaft balancer with the crankshaft balancer woodruff key. 5. Use the Balancer Remover and Installer Tool J23523-F to press the crankshaft balancer onto the crankshaft. a. Install the plate and bolts onto the front of the crankshaft balancer and torque the bolts.
Description J23523-F Plate Bolts Nm 25 lb-in. lb-ft 18

b. Install the screw into the end of the crankshaft. c. Install the bearing, the washer and the nut onto the screw. d. Rotate the nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring. 6. Remove the Balancer Remover and Installer Tool.

72346

a - Crankshaft Balancer Remover And Installer Tool (J23523-F)

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ENGINE MECHANICAL

7. Install crankshaft pulley. Torque bolts.

77875

Description Crankshaft Pulley Bolt

Nm 58

lb-in.

lb-ft 43

a. Install crankshaft balancer washer with washer crown facing front of engine. b. Install crankshaft balancer bolt. Torque bolt.

b a c

77887

a - Washer b - Washer Crown c - Bolt

Description Nm lb-in. lb-ft 70

Crankshaft Balancer (Torsional Damper) Bolt 8. Install and adjust drive belts.

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SERVICE MANUAL NUMBER 31

Front Cover Oil Seal

Oil Seal Replacement Without Removing Front Cover
REMOVAL
1. Remove belts and pulleys. 2. Remove crankshaft balancer. 3. Pry seal out of cover from the front with a large screwdriver. Be careful not to distort front cover or damage crankshaft.

INSTALLATION
1. Apply sealant to the seal mating surface and lubricate seal edge. 2. Install new seal with open end of seal inward, using crankcase front cover seal installer. Drive seal in until it just contacts. IMPORTANT: Do not use excessive force installing seal.

a
B

a
A

73124

72347

a - Seal Edge b - Rotation Of Crankshaft As Viewed From Front End Looking Toward Flywheel End c - Crankcase Front Cover Seal Installer (J35468) Description A Ultra-Black Loctite 5900 B Engine Oil 3. Reinstall crankshaft balancer. Where Used Front cover seal retainer-to-seal mating surface Front seal lips Part Number 92-809826 Obtain Locally

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ENGINE MECHANICAL

Front Cover
Removal
1. Drain engine seawater and closed cooling systems. 2. Remove the serpentine belt. 3. Remove the crankshaft pulley. 4. Remove the hoses from the water circulating pump. 5. Remove crankshaft balancer. 6. Remove water circulating pump. 7. Remove oil pan. 8. Remove the crankshaft position sensor.

b a
77871

a - Sensor Bolt b - Sensor IMPORTANT: Crankcase front cover is not reusable per manufacturers specification. It must be replaced if removed. 9. Remove and discard crankcase front cover.

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Cleaning and Inspection

IMPORTANT: Surfaces must be clean or oil may leak. 1. Clean old gasket material and sealer from sealing surfaces on engine block. 2. Remove and discard the crankshaft position sensor O-ring seal.

78151

a - Sensor O-ring

Installation
NOTE: New front covers are complete with gasket material and a seal. 1. Lubricate seal edge. Description Engine Oil Where Used Front seal lips Part Number Obtain Locally

2. Install new front cover, ensuring holes in cover align with dowel pins in block. Torque front cover bolts.

a
77865

a - Front Cover Description Front Cover Bolt Nm 12 lb-in. 106 lb-ft

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ENGINE MECHANICAL

3. Install a new crankshaft position sensor O-ring seal. IMPORTANT: Ensure that the crankshaft position sensor is fully seated in the front cover. Erratic engine operation can occur if sensor is not completely and properly mounted. 4. Install crankshaft position sensor. Ensure that the sensor is fully seated in cover. 5. Install crankshaft position sensor bolt. Torque bolt.

a b
77871

a - Sensor b - Sensor Bolt c - O-ring

Description Nm lb-in. lb-ft

72364

a - Protective Cap 14. Push piston and connecting rod out of cylinder. IMPORTANT: The mating surfaces of the connecting rods and the connecting rod bearing caps form an individual fit and as a result must not be interchanged or damaged under any circumstances. To avoid damage, do not lay connecting rods or connecting rod bearing caps on their mating surfaces. 15. Remove the connecting rod bearings. Keep the bearings with the original connecting rod and connecting rod cap together as a matched set.

Disassembly
1. Remove the piston rings from the pistons. 2. Press piston pin from connecting rod using a piston pin remover. Follow tool manufacturers instructions.

d
72365

e
a b c d e - Piston Pin Remover (J24086-C) - Arched Base - Piston - Connecting Rod - Rod Support

3. Mark, separate and organize parts so that they can be reinstalled in the same location.

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Cleaning
CONNECTING RODS
1. Put on safety glasses. 2. Clean connecting rods in cleaning solvent. 3. Dry parts with compressed air.

CONNECTING ROD BEARINGS

1. Put on safety glasses. 2. Clean connecting rod bearings in cleaning solvent. 3. Wipe bearings clean with a soft cloth. Do NOT scratch the bearing contact surfaces. 4. Dry parts with compressed air.

PISTONS
IMPORTANT: Do not wire brush any part of a piston. 1. Put on safety glasses. 2. Clean pistons in cleaning solvent. 3. Clean varnish from piston skirts and pins with a suitable cleaning solvent. 4. Clean piston ring grooves. 5. Clean piston oil lubrication holes and slots. 6. Dry parts with compressed air.

PISTON PIN
1. Put on safety glasses. 2. Clean parts in cleaning solvent and dry with compressed air. 3. Dry parts with compressed air.

Inspection
IMPORTANT: Measurements should be taken when components are at room temperature.

CONNECTING ROD
1. Check for twisted and bent connecting rods. 2. Inspect for nicks and cracks. 3. Inspect for damage to the bearing cap and bolt threads.

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CONNECTING ROD BEARINGS

NOTE: Refer to Crankshaft, Main Bearings and Engine Block - Main Bearings, for examples of bearing failures similar to the following. 1. Inspect the connecting rod bearings for craters, pockets or flattened sections. 2. Inspect the connecting rod bearings for excessive scoring, discoloration or damage. 3. Inspect the connecting rod bearings for dirt or debris imbedded in the bearing material. 4. Replace damaged or faulty bearings.

CONNECTING ROD BEARING CLEARANCE - MICROMETER METHOD

Connecting rod bearings are of the precision insert type and do not use shims for adjustment. If clearances are found to be excessive, a new bearing will be required. Service bearings are available in standard size and .001 in. and .002 in. undersize for use with new and used standard size crankshafts. They are also available in .010 in. and .020 in. undersize for use with reconditioned crankshafts. When removing a connecting rod cap, you may find a .010 in. undersize bearing. These are used in manufacturing for selective fitting. The micrometer method is the preferred method of determining connecting rod bearing clearance. 1. Wipe both upper and lower connecting rod bearings clean. 2. Install the upper and lower connecting rod bearings. 3. Install the bearing cap. Bearing cap MUST be torqued to specification in order to ensure proper reading. 4. In a two pass sequence, torque nuts.
Description Nm lb-in. lb-ft

Connecting Rod Nut - 5.0 l (305 cid) and 5.7 l (350 cid) First Pass Final Pass (Angle Torque) Connecting Rod Nut - 6.2 l (377 cid) First Pass Final Pass (Angle Torque) 27 + 45 degrees 20 27 + 70 degrees 20

5. Use an inside dial indicator to measure the connecting rod bearing inside diameter, out of round and taper. Measure in several places approximately 90 degrees apart and average the measurements.

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IMPORTANT: Do not measure diameter close to split line for rod and bearings. Bearings are eccentric and false readings could occur.

77217

Measuring Connecting Rod Bearing Inside Diameter 6. Record the measurements. 7. Wipe crankshaft connecting rod journal clean of oil. 8. Using a micrometer measure crankshaft connecting rod journal diameters at points a and b on one side of journal then repeat measurements on opposite side of journal.

a b a b

22215

Connecting Rod Journal Measurement - Typical Crankshaft Shown Description Diameter Taper Out of Round Production Service Limit Production Service 5.0 l (305 cid) / 5.7 l (350 cid) 56.50556.533 mm (2.2246-2.2257 in.) 0.025 mm (0.0010 in.) 0.025 mm (0.0010 in.)

Description Diameter Taper Out of Round Production Service Limit Production Service

6.2 l (377 cid) 53.28453.334 mm (2.0977-2.0997 in.) 0.025 mm (0.0010 in.) 0.025 mm (0.0010 in.)

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9. If journal diameters are not within specifications, replace or recondition the crankshaft.

CAUTION
Avoid bearing failure. If a bearing is being fitted to an out-of-round journal, be sure to fit bearing to the maximum diameter of the journal. If the bearing is fitted to the minimum diameter and the journal is out of round 0.0254 mm (0.001 in.), interference between the bearing and journal will result in rapid bearing failure. 10. If journal diameters are within specifications, determine bearing clearance by subtracting the crankshaft connecting rod journal outer diameter from the inner diameter of the bearing. Description Clearance Description Clearance Production Service Limit Production Service Limit 5.0 l (305 cid) /5.7 l (350 cid) 0.033-0.078 mm (0.0013-0.0031 in.) 0.025-0.063 mm (0.0010-0.0025 in.) 6.2 l (377 cid) 0.033-0.088 mm (0.0013-0.0035 in.) 0.025-0.076 mm (0.0010-0.0029 in.)

11. If the clearance exceeds specifications, select a new, correct size bearing and determine the clearance.

CONNECTING ROD BEARING CLEARANCE PLASTIC GAUGE METHOD

The plastic gauge method is an optional method of determining connecting rod bearing clearance. The preferred method use a micrometer. 1. Wipe both upper and lower bearings and crankshaft connecting rod journal clean of oil. 2. Install the bearings in the connecting rod and cap.

CAUTION
Avoid possible engine bearing failure. The connecting rod and upper bearing must be seated against the connecting rod journal before installing the lower bearing and rod cap. Unreliable measurement may result if the journal and upper bearing are not fully seated. 3. Rotate the crankshaft or move the connecting rod until the upper bearing is fully seated against the connecting rod journal being measured. IMPORTANT: Position the gauging plastic on the crankshaft journal in an area that will be the middle of the bearing shell.

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4. Place a piece of gauging plastic parallel to the crankshaft on the middle of the open crankshaft connecting rod journal surface as shown.

72361

a - Gauging Plastic 5. Install the bearing cap. IMPORTANT: Bearing cap MUST be torqued as specified to ensure proper measurement. Variations in torque affect the compression of the plastic gauge. 6. In a two pass sequence, torque nuts.
Description Nm lb-in. lb-ft

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Detonation Damage

72315

a b c d

- Spark Occurs - Combustion Begins - Combustion Continues - Detonation Occurs

5. Inspect engine for causes of detonation damage to pistons: IMPORTANT: Use of improper fuels will cause engine damage and poor performance. a. Use of low octane gasoline or neglecting engine maintenance. b. Lean fuel mixture at or near full throttle (could be caused by leaking intake manifold). c. Cross-firing spark plugs. d. Excess accumulation of deposits on piston and/or combustion chamber that result in higher compression ratio. e. Inadequate cooling of engine due to deterioration of cooling system. NOTE: Engine failures that result from the foregoing conditions are beyond the control of Mercury MerCruiser. No warranty will apply to failures that occur under these conditions. 6. Inspect piston for cracked ring lands, skirts and pin bosses, wavy or worn ring lands, scuffed or damaged skirts and eroded areas at top of piston. 7. Inspect ring grooves for nicks and burrs that might cause rings to bind.

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8. Inspect piston wear by checking clearance as follows: a. Measure piston diameter 11 mm (0.433 in.) from the bottom of the skirt at a right angle to the piston pin bore as shown.

72624

Measuring Piston Diameter b. Measure cylinder bore diameter with a telescope gauge 64 mm (2-1/2 in.) from top of cylinder bore at 90 degrees from crankshaft centerline as follows.

72386

Measuring Cylinder Bore Description Diameter 5.0 l (305 cid) 94.894-94.947 mm (3.7360-3.7381 in.) 5.7 l (350 cid) / 6.2 l (377 cid) 101.618-101.643 mm (4.0007-4.0017 in.)

Description Out of Round Production Service Production -Thrust Side Taper Production - Relief Side Service Limit

5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) 0.025 mm (0.001 in.) Maximum 0.05 mm (0.002 in.) Maximum 0.012 mm (0.0005 in.) Maximum 0.025 mm (0.001 in.) Maximum 0.025 mm (0.001 in.) Over Production

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c. Subtract piston diameter from cylinder bore diameter to determine piston-to-bore clearance. d. Replace the piston if the piston bore clearance is less than specified. Refer to Crankshaft, Main Bearings and Engine Block for cylinder reconditioning and piston replacement. Piston-Bore Clearance Description Production Service Description Production Service 9. 5.0 l (305 cid) 0.018-0.061 mm (0.0007-0.0024 in.) 0.018-0.068 mm (0.0007-0.0026 in.) 5.7 l (350 cid) 0.018-0.053 mm (0.0007-0.0020 in.) 0.018-0.061 mm (0.0007-0.0024 in.)

6.2 l (377 cid) 0.018-0.053 mm (0.0007-0.0021 in.) 0.018-0.068 mm (0.0007-0.0027 in.)

Insert edge of rings into respective piston ring groove and roll ring entirely around the groove to ensure that ring moves freely.

IMPORTANT: Do not remove excess material in the following step. Verify with feeler gauge and compare to specifications. a. If binding occurs at any point, determine cause. If caused by ring groove, remove by dressing with a fine cut file. If binding is caused by a distorted ring, recheck with another ring.

72366

90-864260 OCTOBER 2001

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

10. Using a feeler gauge, measure the clearance between the piston ring and the piston ring groove at several points around the piston.

72367

Measuring Ring Groove Clearance Top Compression Description Groove Clearance Production Service 5.0 l (305 cid) / 5.7 l (350 cid) / 377 cid (6.2 l) 0.030-0.070 mm (0.0012-0.0027 in.) 0.030-0.090 mm (0.0012-0.0035 in.)

Second Compression Description Groove Clearance Production Service 5.0 l (305 cid) 0.030-0.074 mm (0.0012-0.0029 in.) 0.030-0.090 mm (0.0012-0.0035 in.) 5.7 l (350 cid) 0.038-0.080 mm (0.0015-0.0031 in.) 0.040-0.100 mm (0.0016-0.0039 in.)

Description Groove Clearance Oil Control Description Groove Clearance Production Service Production Service

377 cid (6.2 l) 0.040-0.080 mm (0.0015-0.0030 in.) 0.040-0.100 mm (0.0015-0.0040 in.)

5.0 l (305 cid) 0.051-0.203 mm (0.0020-0.0080 in.) 0.051-0.22 mm (0.0020-0.0009 in.)

5.7 l (350 cid) 0.046-0.096 mm (0.0018-0.0038 in.) 0.046-0.100 mm (0.0018-0.0039 in.)

Description Groove Clearance Production Service

377 cid (6.2 l) 0.051-0.17 mm (0.0020-0.006 in.) 0.051-0.195 mm (0.0020-0.0076 in.)

11. Replace piston if groove clearance exceeds the specified limit.

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ENGINE MECHANICAL

PISTON PINS
IMPORTANT: Piston pin clearance is designed to maintain adequate clearance under all engine operating conditions. Because of this, piston and piston pin are a matched set and not serviced separately. NOTE: Piston pin bores and piston pins must be free of varnish and scuffing when measured. 1. Inspect piston pin bores and piston pins for wear. a. Measure piston pin with a micrometer. b. Measure piston pin bore with a dial bore gauge or inside micrometer.

77231

77230

Measuring Piston Pin

Measuring Piston Pin Bore

c. Subtract piston pin diameter from piston pin bore diameter to determine clearance. Description Diameter Production Clearance Service Limit Fit In Rod Description Diameter Production Clearance Service Limit 5.0 l (305 cid) 0.010-0.020 mm (0.0004-0.0008 in.) 5.7 l (350 cid) 0.013-0.023 mm (0.0005-0.0009 in.)

23.545-23.548 mm (0.9270-0.9271 in.)

0.013-0.025 mm (0.0005-0.0010 in.) Maximum 0.012-0.050 mm (0.0005-0.0020 in.) Interference 6.2 l (377 cid) 23.545-23.548 mm (0.9269-0.9270 in.) 0.013-0.023 mm (0.0005-0.0009 in.) 0.013-0.025 mm ( 0.0005-0.00098 in.) Maximum 0.021-0.040 mm (0.00082-0.00157 in.) Interference

Fit in Rod

d. If clearance exceeds service limit, replace piston and piston pin assembly.

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PISTON RING GAP

IMPORTANT: Fit each compression ring to the cylinder in which it is going to be used. 1. Insert the piston ring into the cylinder bore. 2. Using a piston inserted upside down, push the piston ring into the cylinder bore until it reaches measuring point a. NOTE: Ensure that piston ring is not slanted to one side or the other. It must be perfectly square with cylinder wall. 3. Using a feeler gauge, measure the piston ring gap.

d c

a b
72372 77190

Piston Ring Gap a - Measurement Point - 6 mm (1/4 in.) b - Cylinder Bore c - Feeler Gauge d - Ring Gap Top Compression Description Production Gap Service Description Gap Production Service 5.0 l (305 cid) 0.25-0.51 mm (0.0098-0.020 in.) 0.25-0.65 mm (0.0098-0.026 in.) 5.7 l (350 cid) 0.25-0.40 mm (0.0098-0.016 in.) 0.25-0.50 mm (0.0098-0.0197 in.)

6.2 l (377 cid) 0.25-0.51 mm (0.009-0.020 in.) 0.30-0.68 mm (0.012-0.027 in.)

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Second Compression Description Production Gap Service Description Gap Oil Control Description Production Gap Service 5.0 l (305 cid) 0.25-0.89 mm (0.0098-0.035 in.) 5.7 l (350 cid) 0.25-0.90 mm (0.0098-0.035 in.) Production Service 5.0 l (305 cid) 0.46-0.66 mm (0.018-0.026 in.) 0.46-0.90 mm (0.018-0.035 in.) 5.7 l (350 cid) 0.038-0.058 mm (0.0015-0.023 in.) 0.46-0.80 mm (0.018-0.031 in.)

6.2 l (377 cid) 0.46-0.66 mm (0.010-0.020 in.) 0.51-0.94 mm (0.020-0.037 in.)

0.25-0.76 mm (0.0098-0.030 in.)

Description Gap Production Service Limit

6.2 l (377 cid) 0.25-0.76 mm (0.009-0.029 in.) 0.28-0.81 mm (0.011-0.0320 in.)

4. Replace ring if gap exceeds service limits. If gap between ends of ring is below specifications, remove ring and try another.

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SERVICE MANUAL NUMBER 31

Reassembly
IMPORTANT: When reassembling pistons and connecting rods, the following must be kept in mind. Piston and pin are machine fitted to each other and must remain together as a matched set. Do not intermix pistons and pins. If original pistons and/or connecting rods are being used, be sure to assemble pistons and connecting rods so they can be reinstalled in same cylinder from which they were removed. Connecting rod bearing tangs are always toward outside of engine block.

72368

a - Connecting Rod Bearing Tangs Notch on the piston must be positioned toward the front of the engine (water pump end).

72369

72370

5.0 l (305 cid) a - Notch b - Notch

5.7 l (350 cid) and 6.2 l (377 cid)

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

PISTON
1. Assemble piston to connecting rod using piston pin remover. Follow tool manufacturers instructions.

72371

a - Piston Pin Remover (J24086-B) 2. Once assembled, check piston for freedom of movement (back and forth, up and down) on connecting rod. Piston should move freely in all directions. If it does not, piston pin bore is tight and piston / pin assembly must be replaced. 3. If a new connecting rod has been installed, mark connecting rod and cap (on side of rod and cap with slots for connecting rod bearing tangs) with cylinder number in which it will be installed.

90-864260 OCTOBER 2001

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

PISTON RINGS
All compression rings are marked on upper side of ring. When installing compression rings, ensure that marked side is toward top of piston. Oil control rings are a three-piece type, consisting of two rings and a spacer. 1. Select rings comparable in size to cylinder bore and piston size. 2. Install piston rings as follows: a. Install oil control ring spacer in groove. b. Hold spacer ends together and install lower oil control piston ring with gap properly located. c. Install upper oil control piston ring with gap properly located. d. Flex the oil ring assembly to ensure that the ring is free. If binding occurs at any point, determine the cause. If binding is caused by ring groove, remove by dressing groove with a fine cut file. If binding is caused by a distorted ring, use a new ring.

e b c b
Ring Gap Location a - Oil Ring Spacer Gap b - Oil Ring Rail Gaps c - Lower Compression Ring Gap d - Upper Compression Ring Gap e - Engine Front IMPORTANT: Use piston ring expander (91-24697) for compression ring installation. e. Using ring expander, install lower compression ring with marked side up. f. Using ring expander, install upper compression ring with marked side up.

d
72373

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ENGINE MECHANICAL

Installation
IMPORTANT: Cylinder bores must be clean before piston installation. 1. Clean cylinder bores with a light honing, as necessary. Then clean with hot water and detergent wash. After cleaning, lightly lubricate bores several times with light engine oil and clean cloth, then wipe with a clean dry cloth. 2. Rotate the crankshaft until the crankpin is at before dead center (BDC) for cylinder that is ready for first piston to be installed. 3. Carefully wipe any foreign material from the connecting rod bearings and the connecting rod bearing fitting surfaces. NOTE: Do not apply engine oil to the bearing back faces and the connecting rod bearing fitting surfaces. 4. Insert bearing shells into connecting rod and matching rod cap.

77251

5. Lubricate connecting rod bearings, pistons, rings and cylinder walls. Description Engine Oil Where Used Connecting rod bearings, pistons, rings and cylinder walls Part Number Obtain Locally

6. With bearing caps removed, install connecting rod bolt guides on connecting rod bolts. It is acceptable to use clean rubber tubing for the connecting rod bolt guides.

76719

a - Connecting Rod Bolt Guide (J5239)

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

IMPORTANT: Ensure ring gaps are properly positioned. 7. Position ring gaps as shown.

e b c b
Ring Gap Location a - Oil Ring Spacer Gap b - Oil Ring Rail Gaps c - Lower Compression Ring Gap d - Upper Compression Ring Gap e - Engine Front 8. Use piston ring compressor and compress rings.

d
72373

a
00000

a - Piston Ring Compressor (J8037) IMPORTANT: Be sure to install new pistons in same cylinders for which they were fitted and used pistons in same cylinder from which they were removed. Each connecting rod and bearing cap should be marked, beginning at front of engine (1, 3, 5 and 7 in left bank and 2, 4, 6 and 8 in right bank). Numbers on connecting rod and bearing cap must be on same side when installed in cylinder bore. If a connecting rod is ever transposed from one block or cylinder to another, new bearings should be fitted and connecting rod should be numbered to correspond with new cylinder number. 9. Install each connecting rod and piston assembly in its respective bore with connecting rod bearing tangs toward outside of engine block and piston notch toward front of engine. 10. Guide connecting rod into place on crankshaft journal with connecting rod bolt guide. 11. Hold ring compressor firmly against engine block until all piston rings have entered cylinder bore.

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ENGINE MECHANICAL

12. Using a wooden or plastic hammer handle, lightly tap the piston into bore.

72374

a - Piston Ring Compressor (J8037) 13. Remove connecting rod bolt guides. 14. Apply a coat of engine oil to the threads and mating faces of each connecting rod cap, bolt and nut. Description Engine Oil Where Used Connecting rod and rod cap Part Number Obtain Locally

CAUTION
The connecting rod caps MUST be installed in the correct direction. Reversing the cap direction will result in serious engine damage. 15. Install the connecting rod cap.

a c

76716

a - Connecting Rod Nuts b - Connecting Rod Caps c - Lower Bearing

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

16. In a two pass sequence, torque connecting rod cap nuts.

Description Nm lb-in. lb-ft

17. Lightly tap each connecting rod assembly parallel to the crankpin to ensure clearance. 18. Measure all connecting rod side clearances between connecting rod caps.

72363

Measuring Connecting Rod Side Clearance Description Rod Side Clearance 19. Install oil pump and crankshaft oil deflector. 20. Install dipstick and oil pan. 21. Install cylinder heads. 22. Install intake manifold assembly. 23. Install distributor. 24. Adjust valves. 25. Install valve covers. 26. Install exhaust elbow and manifold assemblies. 27. Fill crankcase with proper viscosity and quantity of oil. Refer to SECTION 1B. 28. Install all components removed from the front of the engine. 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) 0.15-0.61 mm (0.0059-0.0240 in.)

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

Crankshaft, Main Bearings And Engine Block

Exploded View

2 6

76682

1 2 3 4 5 6

- Piston And Rod Assemblies - Four Bolt Main Bearing Cap (Some Models) - Two Bolt Main Bearing Cap (Most Models) - Main Bearings - Crankshaft - Rear Main Seal

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Removal
NOTICE If only the main bearings are being serviced refer to Installation - Bearings Without Crankshaft Removed. 1. MCM Models: Remove sterndrive unit. 2. Remove engine from boat. 3. MIE Models: Remove transmission. 4. Drain crankcase oil. 5. Remove starter. 6. Remove flywheel housing. 7. Remove coupler / drive plate. 8. Remove flywheel. 9. Remove belt. 10. Remove water circulating pump. 11. Remove crankshaft pulley and crankshaft balancer. 12. Remove spark plugs. 13. Remove dipstick tube and oil pan. 14. Remove crankshaft oil deflector and oil pump. 15. Remove crankshaft position sensor. Discard O-ring seal.

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ENGINE MECHANICAL

16. Remove engine front cover. 17. Remove the crankshaft position sensor reluctor ring.

a b

b
76491

77866

a - Front Cover b - Reluctor Ring 18. Turn crankshaft to align timing mark with camshaft mark or turn crankshaft to cylinder number 1 TDC and mark both gears for alignment in reassembly.

c b
77478

a - Camshaft Gear b - Crankshaft Gear c - Alignment Marks

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

19. Remove camshaft sprocket. 20. Remove timing chain. 21. Remove crankshaft sprocket.

76488

22. Remove rear main seal and retainer. 23. Remove connecting rod and piston assemblies. IMPORTANT: Inspect bearing caps for orientation marks prior to removal. If no markings exist, make suitable marks before disassembly so that they can be reinstalled in their original locations. 24. Ensure that all bearing caps are marked so that they can be reinstalled in their original locations.

77467

Typical a - Bearing Cap Mark

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ENGINE MECHANICAL

25. Remove main bearing caps and carefully lift crankshaft out of engine block.

76492

Two Bolt Main Bearing Caps Shown (Four Bolt Similar) a - Main Bearing Cap b - Rear Main Bearing Cap c - Crankshaft 26. If new main or connecting rod bearings are to be installed, remove main bearing inserts from engine block and bearing caps or connecting rod bearing inserts from connecting rod and caps. Install new bearings.

Cleaning
CRANKSHAFT
1. Put on safety glasses. 2. Clean the crankshaft in cleaning solvent. Ensure oil passages are clear of all sludge and restrictions. 3. Dry part with compressed air.

MAIN BEARINGS
4. Put on safety glasses. 1. Clean the crankshaft bearings in cleaning solvent. Wipe the crankshaft bearings clean with a soft cloth, do not scratch the crankshaft bearing surfaces. 2. Dry parts with compressed air.

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

ENGINE BLOCK
1. Remove all engine components. 2. Remove the camshaft rear bearing hole expansion cup plug.

77893

3. Remove oil pressure sender and oil gallery plugs indicated.

b a

c
77895 77895

a - Rear Oil Gallery Plugs b - Left Rear Top Oil Gallery Plug c - Oil Pressure Sender Location 4. Put on safety glasses. 5. Insert a 3/8 in. x 26 in. rod into rear oil gallery holes and drive out (remove) oil gallery plugs at front of engine block. Discard plugs.

77892

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

6. Remove engine block core hole expansion plugs. NOTE: These plugs may be removed with a sharp punch or they may be drilled and pried out.

77894

7. Clean all sealing surfaces. 8. Remove sealant residue. 9. Clean the engine block with cleaning solvent. 10. Flush the engine block with clean water or steam clean. 11. Clean the cylinder bores. 12. Clean the oil galleries and oil passages. 13. Clean scale and deposits from coolant passages.

CAUTION
Avoid engine damage. 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 engine. 14. Clean the engine block cylinder head bolt holes and dry with compressed air. 15. After cleaning the engine block, spray or wipe the cylinder bores and the machined surfaces with clean engine oil. Description Engine Oil Where Used Cylinder bores and the machined surfaces Part Number Obtain Locally

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Inspection
CRANKSHAFT
1. Inspect crankshaft for deep grooves, scratches, pitted surfaces or uneven wear. 2. Inspect crankshaft rear oil seal surface for scoring or damage. 3. Inspect crankshaft oil passages for restrictions. 4. Inspect the thrust journal surface wear or damage. 5. Inspect the crankshaft threaded bolt hole for damage. 6. Inspect the crankshaft balancer keyway for damage. 7. Measure the main bearing journals with a micrometer for out-of-round, taper or undersize. NOTE: Measure the crankshaft journal diameter in several places, approximately 90 degrees apart, and average the measurements. Description Number 1 Diameter Number 2, 3, 4 Number 5 Description Number 1 Diameter Number 2, 3, 4 Number 5 5.0 l (305 cid) / 5.7 l (350 cid) 62.189-62.212 mm (2.4484-2.4493 in.) 62.181-62.207 mm (2.4481-2.4491 in.) 62.185-62.207 mm (2.4482-2.4491 in.) 6.2 l (377 cid) 62.189-62.212 mm (2.4483-2.4492 in.) 62.181-62.207 mm (2.4480-2.4490 in.) 62.177-62.207 mm (2.4479-2.4490 in.) 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) Production Service Production Service 0.005 mm (0.0002 in.) Maximum 0.025 mm (0.0010 in.) Maximum 0.005 mm (0.0002 in.) Maximum 0.025 mm (0.0010 in.) Maximum

Description Taper Out of Round

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ENGINE MECHANICAL

8. Measure connecting rod bearing journals with a micrometer for out of round, taper or undersize. Description Diameter Description Diameter 5.0 l (305 cid) / 5.7 l (350 cid) 56.50556.533 mm (2.2246-2.2257 in.) 6.2 l (377 cid) 53.28453.334 mm (2.0977-2.0997 in.) 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) Production Service Limit Production Service 0.007 mm (0.0003 in.) Maximum 0.025 mm (0.0010 in.) Maximum 0.007 mm (0.0003 in.) Maximum 0.025 mm (0.0010 in.) Maximum

Description Taper Out of Round

9. To check crankshaft for runout, support at the front and rear main bearings journals in V-blocks. 10. Check at front and rear intermediate journals with a dial indicator. Description Runout 5.0 l (305 cid) / 5.7 l (350 cid) 0.038 mm (0.0015 in.)

Description Runout

6.2 l (377 cid) 0.05-0.20 mm (0.0020-0.0079 in.)

11. Replace or recondition crankshaft if not within specifications.

MAIN BEARINGS
Main bearings are of the precision insert type and do not use shims for adjustment. If clearances are excessive, a new bearing, both upper and lower halves, will be required. Service bearings are available in standard size and .0254 mm(.001 in.), .254 mm (.010 in.) and .508 mm (.020 in.) undersize. Selective fitting of both rod and main bearing inserts is necessary in production to obtain close tolerances. For this reason you may find 1/2 of a standard insert with 1/2 of a .0254 mm (.001 in.) undersize insert, which will decrease the clearance .0127 mm (.0005 in.) from using a full standard bearing. When a production crankshaft cannot be precision fitted by this method, it is then ground .229 mm (.009 in.) undersize, ON ONLY THOSE MAIN JOURNALS THAT CANNOT BE PROPERLY FITTED. ALL JOURNALS WILL NOT NECESSARILY BE GROUND UNDERSIZE. A .229 mm (.009 in.) undersize bearing and .254 mm (.010 in.) undersize bearing may be used for precision fitting in the same manner as previously described. In general, the lower half of the bearing (except number 1 bearing) shows a greater wear and the most distress from fatigue. If upon inspection the lower half is suitable for use, it can be assumed that the upper half is also satisfactory. If the lower half shows evidence of wear or damage, replace both upper and lower halves. Never replace one half without replacing the other half.

90-864260 OCTOBER 2001

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Examples of Bearing Failures

c
Lack Of Oil

d
70436

Scratched By Dirt a b c d

Improper Seating

- Scratches - Dirt Imbedded Into Bearing Material - Overlay Wiped Out - Bright (Polished) Sections

a
Tapered Journal

b
Radius Ride

c
70436

Fatigue Failure

a - Overlay Gone From Entire Surface b - Radius Ride c - Craters Or Pockets

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ENGINE MECHANICAL

MAIN BEARING TENSION

1. Ensure that the main bearing installs under tension. It should require firm pressure to fit the bearing into position.

77214

Main Bearing Tension

MAIN BEARING CLEARANCE - GAUGING PLASTIC METHOD

To obtain accurate measurements while using Plastigage or its equivalent, engine must be out of the boat and upside down so crankshaft will rest on the upper bearings and total clearance can be measured between lower bearing and journal. To assure the proper seating of the crankshaft, all bearing cap bolts should be at their specified torque. In addition, preparatory to checking fit of bearings, the surface of the crankshaft journal and bearing should be wiped clean of oil. 1. Remove bearing cap and wipe oil from journal and bearing cap to be inspected. 2. Place a piece of gauging plastic the full width of the bearing, parallel to the crankshaft journal as shown.

b
a - Gauging Plastic b - Journal

ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

6. If the bearing clearance is within specifications, the bearing insert is satisfactory. If the clearance is not within specifications, replace the insert. Always replace both upper and lower inserts as a unit. 7. A standard or 0.025 mm (0.001 in.) undersize bearing may produce the proper clearance. If not, it will be necessary to regrind the crankshaft journal for use with the next undersize bearing. IMPORTANT: After selecting new bearing, recheck clearance. 8. Check clearance with newly selected bearing. If the bearing clearance is within specifications, the bearing insert is satisfactory. If not, repeat previous steps. 9. Proceed to the next bearing. After all bearings have been checked, rotate the crankshaft to check for excessive drag. When checking number 1 main bearing, loosen accessory drive belts to prevent tapered reading with plastic gauge.

CRANKSHAFT END PLAY

1. Firmly force the crankshaft rearward. 2. Firmly force the crankshaft forward. 3. Measure clearance at the front end of the rear main bearing with a feeler gauge as shown.

72360

a - Feeler Gauge 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) 0.05-0.20 mm (0.0020-0.0079 in.)

Description End Play (Thrust Clearance)

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ENGINE MECHANICAL

ENGINE BLOCK
1. Inspect the engine block for cracks in coolant jackets. 2. Inspect the cylinder bores for scratches or gouging. 3. Inspect the valve lifter bores for excessive scoring or wear. 4. Inspect the threaded holes, crankshaft bearing caps, bearing bores and engine block core hole expansion plug bores for damage. 5. Inspect the engine block, engine mount bosses and crankshaft bearing webs for cracks or damage. 6. Check engine block head gasket surfaces for warp with a machinists straight-edge and a feeler gauge. Take measurements diagonally across surfaces (both ways) and straight down center. If surfaces are warped more than specified, engine block must be resurfaced by a machine shop.

72388

b
a - Machinists Straight-Edge b - Feeler Gauge 5.0 l (305 cid), 5.7 l (350 cid) / 6.2 l (377 cid) Within An 152 mm (6 in.) Area 0.10 mm (0.0040 in.)

Description Cylinder head gasket surface flatness

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

7. Measure cylinder walls for taper, out of round or excessive ridge at top of ring travel. This should be done with a dial indicator or inside micrometer. Carefully move gauge up and down cylinder to determine taper. Turn gauge to different points around cylinder wall to determine out of round condition. Taper = Difference between measurement a at top of cylinder bore and a measurement at bottom of cylinder bore Out of Round = Difference between a and b

a b a
72385

Cylinder Measurement Points a - At Right Angle To Centerline Of Engine b - Parallel To Centerline Of Engine 5.7 l (350 cid) / 6.2 l (377 cid) 101.618-101.643 mm (4.0007-4.0017 in.)

Description Diameter

5.0 l (305 cid) 94.894-94.947 mm (3.7360-3.7381 in.)

8. If cylinder bore exceeds specifications, boring and/or honing will be necessary.

72386

72387

Methods Of Measuring Cylinder Bore Description Out Of Round Production Service Production Thrust Side Taper Production - Relief Side Service Limit 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid) 0.025 mm (0.0010 in.) Maximum 0.05 mm (0.0020 in.) Maximum 0.012 mm (0.0005 in.) Maximum 0.025 mm (0.0010 in.) Maximum 0.025 mm (0.0010 in.) Over Production

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ENGINE MECHANICAL

CYLINDER RECONDITIONING
NOTE: Performance of the following operation depends upon engine condition at time of repair. NOTE: If engine block inspection indicates that the block is suitable for continued use, out of round or tapered cylinders can be reconditioned by honing or boring. 1. If cylinders have less than 0.127 mm (0.0050 in.) taper or wear, they can be conditioned with a hone and fitted with high limit standard size piston. A cylinder bore of more than 0.127 mm (0.0050 in.) wear or taper may not clean up entirely when fitted to a high limit piston. To entirely clean up the bore, it will be necessary to bore for an oversize piston. If more than 0.127 mm (0.0050 in.) taper or wear, bore and hone to smallest oversize that will permit complete resurfacing of all cylinders. 2. When pistons are being fitted and honing is not necessary, cylinder bores may be cleaned with a hot water and detergent wash. After cleaning, lightly lubricate cylinder bores with engine oil and a clean cloth and then wipe with a clean dry cloth.

CYLINDER BORING
IMPORTANT: Before using any type of boring bar, file top of engine block to remove dirt or burrs. This prevents boring bar tilt (the bored cylinder wall is not at right angles to crankshaft.) 1. File top of engine block to remove dirt and burrs. 2. Measure piston to be fitted with a micrometer, measuring at center of piston skirt and at right angles to piston pin. Bore cylinder to same diameter as piston and hone to give specified clearance. NOTE: Hone cylinders as outlined under Cylinder Honing and Piston Selection, following. 3. Carefully observe equipment manufacturers instructions.

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

CYLINDER HONING
1. Follow manufacturers instructions. 2. Occasionally, during the honing operation, clean cylinder bore and check piston for correct fit in cylinder. 3. When finish-honing a cylinder bore to fit a piston, move hone up and down at a sufficient speed to obtain very fine uniform surface finish marks in a crosshatch pattern of approximately 30 degrees to cylinder bore. Finish marks should be clean but not sharp, free from imbedded particles and torn or folded metal. 4. Permanently mark piston for cylinder to which it has been fitted (refer to Piston Selection) and proceed to hone cylinders and fit remaining pistons. IMPORTANT: Handle pistons with care and do not attempt to force them through cylinder until cylinder is honed to correct size, as these pistons can be distorted by careless handling. 5. Thoroughly clean cylinder bores with hot water and detergent. Scrub with a stiff bristle brush and rinse thoroughly with hot water. It is extremely essential that a good cleaning operation be performed. If any abrasive material remains in cylinder bores, it will rapidly wear new rings, cylinder bores and bearings lubricated by the contaminated oil. lightly lubricate bores several times with light engine oil on a clean cloth, then wipe with a clean dry cloth. Cylinder should not be cleaned with kerosene or gasoline. Clean remainder of engine block to remove excess material spread during honing operation.

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

PISTON SELECTION
1. Check used piston to cylinder bore clearance as follows: a. Measure cylinder bore diameter with a telescope gauge 64 mm (2-1/2 in.) from top of cylinder bore.

72386

b. Measure piston diameter at skirt 11 mm (0.4331 in.) from the bottom of the skirt at a right angle to the piston pin bore.

a b
72624

a - Measurement - 11 mm (0.4331 in.) b - Bottom Of Skirt c. Subtract piston diameter from cylinder bore diameter to determine piston-to-bore clearance. d. Determine if piston bore clearance is in acceptable range. Piston Bore Clearance Description Production Service Description Production Service 5.0 l (305 cid) 0.018-0.061 mm (0.0007-0.0024 in.) 0.018-0.068 mm (0.0007-0.0026 in.) 5.7 l (350 cid) 0.018-0.053 mm (0.0007-0.0020 in.) 0.018-0.061 mm (0.0007-0.0024 in.)

377 cid (6.2 l) 0.018-0.053 mm (0.0007-0.0021 in.) 0.018-0.068 mm (0.0007-0.0027 in.)

90-864260 OCTOBER 2001

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

2. If used piston is not satisfactory, determine if a new piston can be selected to fit cylinder bore within acceptable range. 3. If cylinder bore must be reconditioned, measure new piston diameter, then hone cylinder bore to correct clearance. 4. Mark piston to identify cylinder for which it was fitted.

Installation
ENGINE BLOCK PLUGS
1. Put on safety glasses. 2. Apply sealant to the outside diameter of each new engine block core hole expansion plugs. 3. Install engine block core hole expansion plugs flush with the inside chamfer of the engine block core hole.

a - Core Hole b - Inside Chamfer Description A Loctite 242 Where Used Engine block core hole expansion plug Part Number 92-809821

Page 3A-138

90-864260 OCTOBER 2001

77894

SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

4. Apply sealant to the outside diameter of the new camshaft rear bearing hole expansion cup plug. 5. Install the camshaft rear bearing hole expansion cup plug as indicated.

a
A

b
77893

a - Camshaft Bearing Hole b - Measurement - 8.8 mm (0.3465 in.) Description A Loctite 242 Where Used Camshaft rear bearing hole expansion plug Part Number 92-809821

6. Apply sealant to the threads of the oil pressure sender and oil gallery plugs. 7. Install oil pressure sender and oil gallery plugs indicated.

b
A

A A

c
1
77895 77895

a - Rear Oil Gallery Plugs b - Left Rear Top Oil Gallery Plug c - Oil Pressure Sender Location Description A Loctite 565 PST
Description 1

Where Used Oil gallery plugs Oil pressure sender

Nm 20

Part Number Obtain Locally

lb-in. lb-ft 15

Oil Gallery Plug

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

8. Coat the threads of the new engine block oil gallery plugs. Description Loctite 565 PST Where Used Oil gallery plug Part Number Obtain Locally

9. Install front oil gallery plugs less than flush with engine block front surface as indicated.

b a

77892

a - Front Oil Gallery Plugs b - Engine Block Front Surface c - Measurement - 0.11 mm (0.004 in.) 10. Coat the threads of the engine block coolant drain plugs. Description Loctite 565 PST Where Used Engine block coolant drain hole plug Part Number Obtain Locally

11. Install engine block coolant drain hole plugs. Torque plugs. Description Engine Block Coolant Drain Hole Plug Nm
20

lb-in.

lb-ft
15

Page 3A-140

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SERVICE MANUAL NUMBER 31

ENGINE MECHANICAL

MAIN BEARINGS - WITHOUT CRANKSHAFT REMOVED

1. Remove the cap on the main bearing requiring replacement. 2. Remove the bearing from the cap. 3. Install the main bearing remover/installer in the oil hole in the crankshaft journal. If this tool is not available, a cotter pin may be bent as shown and used.

a
a - Main Bearing Remover/Installer (J8080) b - Cotter Pin

72622

4. Rotate the crankshaft clockwise as viewed from the front of engine. This will roll the upper bearing out of the engine block. 5. Lubricate a new upper bearing. 6. Insert the plain (unnotched) end between the crankshaft and the indented or notched side of the engine block. 7. Rotate the bearing into place and remove the tool from the oil hole in the crankshaft journal. 8. Lubricate a new lower bearing and install in bearing cap. Description Engine Oil Where Used Upper Bearing, Lower Bearing Part Number Obtain Locally

9. Install the main bearing cap in the original location with the markings pointing toward the front of the engine.

77467

a - Bearing Cap Marking

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

10. Torque all main bearing caps, EXCEPT the rear main bearing cap.
Description Nm lb-in. lb-ft

Crankshaft Main Bearing Cap Bolt and Stud - Preferred Method Two Bolt Type Cap First Pass Final Pass First Pass - Inboard and Outboard Bolts and Studs Four Bolt Type Cap Final Pass - Outboard Bolt Final Pass - Inboard Bolt and Stud Crankshaft Main Bearing Cap Bolt and Stud - Optional Method Two Bolt Type Cap One Pass - All Bolts Evenly Tightened One Pass - All Inboard Bolts Evenly Tightened One Pass - All Outboard Bolts Evenly Tightened 105 105 90 77 77 66 20 + 43 degrees + 73 degrees 20 + 73 degrees 15 15

Four Bolt Type Cap

Page 3A-142

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ENGINE MECHANICAL

11. Torque the rear main bearing cap. a. Preferred Method - Do first pass torque on rear main bearing cap.
Description Nm lb-in. lb-ft

Crankshaft (Main) Bearing Cap Bolt and Stud - Preferred Method Two Bolt Type Cap Four Bolt Type Cap First Pass First Pass - Inboard and Outboard Bolts and Studs 20 20 15 15

b. Preferred Method - Using a lead hammer, tap the end of the crankshaft to the rear. c. Preferred Method - Using a lead hammer, tap the end of the crankshaft to the front. d. Preferred Method - Do final pass torque on bearing cap.
Description Nm lb-in. lb-ft

Crankshaft (Main) Bearing Cap Bolt and Stud - Preferred Method Two Bolt Type Cap Four Bolt Type Cap Final Pass Final Pass - Outboard Bolt Final Pass - Inboard Bolt and Stud + 73 degrees + 43 degrees + 73 degrees

e. Optional Method - Tap the end of the crankshaft to the rear and then to the front with a lead hammer. f. Optional Method - Evenly torque the rear main bearing cap to the specified amount.
Nm lb-in. lb-ft

Description

Crankshaft (Main) Bearing Cap Bolt and Stud - Optional Method Two Bolt Type Cap One Pass - All Bolts Evenly Tightened One Pass - All Inboard Bolts Evenly Tightened One Pass - All Outboard Bolts Evenly Tightened 105 105 90 77 77 66

Four Bolt Type Cap

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SERVICE MANUAL NUMBER 31

MAIN BEARINGS AND CRANKSHAFT

1. Remove timing sprocket from old crankshaft and reinstall on new crankshaft. 2. On driveshaft extension models - if old pilot bushing is to be reused, bushing can be removed without damage as follows. a. Fill pilot bushing cavity with grease, b. Insert an old transmission input shaft in bore of bushing and hit it with a hammer. This will create hydraulic pressure in pilot bushing cavity that should force bushing out. IMPORTANT: Ensure that all bearings and crankshaft journals are clean. 3. Install upper main bearing inserts in engine block.

72359

a - Upper Insert b - Oil Groove 4. Install lower main bearing insert in main bearing caps.

a
a - Lower Insert b - Main Bearing Cap

72359

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ENGINE MECHANICAL

5. Carefully lower crankshaft into place. Be careful not to damage bearing surfaces. 6. Install main bearing cap in original location with markings pointing toward front of engine.

a b

a
77467

76492

a - Main Bearing Cap b - Rear Main Bearing Cap c - Bearing Cap Marking 7. Check clearance of each main bearing, following procedure outlined under Inspection - Main Bearing Clearance. 8. When bearing clearances meet specifications, lubricate the main bearings and crankshaft bearing journals. Description Engine Oil 9. Install main bearing caps. Where Used Main bearings and crankshaft bearing journals Part Number Obtain Locally

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SERVICE MANUAL NUMBER 31

10. Torque all main bearing caps, EXCEPT THE REAR MAIN CAP, to specifications.
Description Nm lb-in. lb-ft

Four Bolt Type Cap

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ENGINE MECHANICAL

11. Torque the rear main bearing cap. a. Preferred Method - Do first pass torque on rear main bearing cap.
Description Nm lb-in. lb-ft

Crankshaft (Main) Bearing Cap Bolt and Stud - Preferred Method Two Bolt Type Cap Four Bolt Type Cap First Pass First Pass - Inboard and Outboard Bolts and Studs 20 20 15 15

Description

Four Bolt Type Cap

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SERVICE MANUAL NUMBER 31

Cleaning
1. Put on safety glasses. 2. Clean all parts in solvent. 3. Dry with compressed air.

Inspection
1. Inspect timing chain for wear and damage. 2. Inspect sprockets for wear and damage.

Reassembly
1. Install sprocket on crankshaft with crankshaft gear and sprocket installer.

72377

a - Crankshaft Gear And Sprocket Installer (J5590) 2. Align the marks on the crankshaft and the camshaft sprockets. 3. Install camshaft sprocket and timing chain. Torque sprocket bolts.
Description Nm 25 lb-in. lb-ft 18

Camshaft Sprocket Bolt

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SERVICE MANUAL NUMBER 31

CHECKING TIMING CHAIN DEFLECTION

1. Rotate camshaft (in either direction) to place tension on one side of the chain. 2. Establish a reference point on the block (on taut side of chain) and measure from this point to the chain. 3. Rotate camshaft in the opposite direction to slacken the chain, then force chain out with fingers and again measure the distance between reference point and timing chain. 4. The deflection is the difference between these two measurements. If the deflection exceeds specification, timing chain should be replaced.

72376

a - Reference Point 5.0 l (305 cid) / 5.7 l (350 cid ) / 6.2 l (377 cid) 11 mm (0.43 in.) Maximum

Description Chain Deflection

Installation
1. Install the crankshaft position sensor reluctor ring. 2. Install front cover. 3. Install oil pan. 4. Install crankshaft balancer. 5. Install the water circulating pump. 6. Install the serpentine belt.

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ENGINE MECHANICAL

Flywheel Housing
Removal
1. Remove engine from boat. 2. MIE Models: Remove transmission. IMPORTANT: Use caution when removing water hoses; Do NOT bend ends of power steering cooler. 3. Remove water hoses from power steering cooler. 4. MIE Models: Remove rear mounted starter, if equipped. 5. Remove power steering cooler. 6. Remove flywheel housing cover.

00000

MCM Shown, MIE Similar a - Flywheel Housing Cover b - Screws 7. Remove ground wires from flywheel housing. IMPORTANT: Flywheel housing bolts must be installed in same location as removed. 8. Remove the bolts and studs from the flywheel housing. 9. Remove the flywheel housing.

77444

MCM Shown, MIE Similar

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Cleaning
1. Put on safety glasses. 2. Clean all parts in cleaning solvent. 3. Dry with compressed air.

Inspection
1. Visually inspect flywheel housing for cracks, damaged bolt or stud holes and excessive wear. Replace if necessary. 2. Inspect guide dowels for proper position. Repair if necessary.

a a
77831

a - Guide Dowel b - Measurement - 13 mm (0.5 in.)

Installation
1. Align flywheel housing onto guide dowels on engine. IMPORTANT: Flywheel housing fasteners must be installed in same location as removed. 2. Install studs and bolts in the original locations. 3. Torque flywheel housing studs and bolts. Description Flywheel Housing Studs and Bolts 4. Install flywheel housing cover.
Description Nm 9 lb-in. 80 lb-ft

Nm 41

lb-in.

lb-ft 30

Flywheel Housing Cover 5. Install the ground wires. 6. Install power steering cooler. 7. Install water hoses.

8. MIE Models: Install the transmission and the rear mounted starter, if equipped. 9. Install the engine in the boat.

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ENGINE MECHANICAL

Flywheel
Removal
1. Remove engine from boat. 2. MIE Models: Remove transmission. 3. Remove flywheel housing. 4. Remove coupler or drive plate.

72349

72350

Alpha Coupler

Bravo Coupler

72351

72352

MIE Drive Plate 5. Remove the flywheel.

Drive Shaft Extension Coupler

b
76490

a - Flywheel b - Bolts

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

Cleaning and Inspection

1. Clean mating surfaces of flywheel and crankshaft. Remove any burrs. Mating surfaces must be clean, bare metal. 2. Check flywheel ring gear for worn and missing teeth. 3. Inspect splines in drive plate or coupler for wear.

Installation
1. Align dowel hole in flywheel with dowel in crankshaft. 2. Install flywheel. 3. Install flywheel bolts. Torque bolts in sequence.

c
1 6 3 5 4 2

b
76490

a - Flywheel b - Bolt c - Numbered Sequence Description Engine Flywheel Bolt Nm 100 lb-in. lb-ft 74

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ENGINE MECHANICAL

4. Check flywheel runout as follows: a. Attach a dial indicator to engine block. Take measurement around outer edge of flywheel. b. Push in on flywheel to remove crankshaft end play. c. Turn flywheel and measure runout.

72353

a - Dial Indicator 5.0 l (305 cid) / 5.7 l (350 cid) / 6.2 l (377 cid ) 0.203 mm (0.0080 in.) Maximum

Description Runout

5. Insert three rubber bumpers in Alpha coupler before installation on flywheel.

b
Typical a - Rubber Bumper (Alpha Coupler Only) b - Coupler

72354

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ENGINE MECHANICAL

SERVICE MANUAL NUMBER 31

6. Install drive coupler or drive plate. Torque bolts. Description Coupler-to-Flywheel Bolts (MCM) Drive Plate-to-Flywheel Bolts (MIE) 7. Install flywheel housing. 8. MIE Models: Install transmission. 9. Install the engine in the boat. Nm 48 lb-in. lb-ft 35

Rear Oil Seal

The rear crankshaft oil seal can be replaced without removing the oil pan or rear main bearing cap from engine.

Removal
1. Remove the flywheel. 2. Remove rear oil seal by using a screwdriver to pry it out of the seal retainer.

c
73127 72355

a
a - Oil Seal b - Seal Retainer c - Slots (3)

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ENGINE MECHANICAL

Cleaning
1. Clean crankshaft sealing surface. 2. Clean the rear oil seal retainer bore.

Removal
1. Remove oil line from oil filter adapter. 2. Remove oil line from fitting/bushing. 3. Remove fitting/bushing and quad ring seal. Discard quad ring seal. 4. Remove oil filter adapter and seal. Discard seal. 5. Remove block adapter with by-pass valve.
76699

h g f e a d c

b
78162

Typical a - Filter Adapter Oil Line b - Fitting/Bushing Oil Line c - Fitting/Bushing d - Quad Ring Seal e - Oil Filter Adapter f - Seal g - Bolt h - Block Adapter

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ENGINE MECHANICAL

Cleaning
1. Put on safety glasses. 2. Clean by-pass valve and block adapter assembly in solvent. 3. Dry with compressed air. 4. Clean fitting/bushing and oil filter adapter in solvent. 5. Dry with compressed air.

Inspection
1. Inspect the block adapter for cracks, thread wear or other damage. 2. Inspect by-pass (fiber) valve for cracks or other damage. 3. Ensure that by-pass valve fits tightly against its seat. 4. Push by-pass valve down and release it. Valve should return freely to its original position. If by-pass valve operation is questionable, replace the block adapter assembly.

72391

Typical Block Adapter Assembly With By-Pass Valve a - Block Adapter Assembly b - By-Pass (Fiber) Valve 5. Inspect the oil filter adapter and fitting/bushing for cracks, threads wear or other damage.

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SERVICE MANUAL NUMBER 31

Installation
1. Install block adapter with by-pass valve on engine block. Torque bolts.

76699

a b
00000

a - Block Adapter b - Bolts Description By-Pass Valve Block Adapter Bolt Nm 27 lb-in. lb-ft 20

2. Place a new seal in the oil filter adapter and lightly lubricate the sealing surfaces. 3. Install a new seal and oil filter adapter on engine block. 4. Lightly lubricate a new quad ring seal and place on the fitting/bushing. 5. Install fitting/bushing with quad ring seal. Torque fitting/bushing.
76699

a b c d
A

00000

a b c d

- Seal - Adapter - Quad Ring Seal - Fitting/Bushing Where Used Part Number

Description A Engine Oil Description Fitting/Bushing 6. Install oil lines on fitting/bushing and adapter. Description Oil Lines

Oil filter adapter, quad ring for Obtain Locally oil filter adaptor fitting/bushing Nm 50 lb-in. lb-ft 37

Nm 27

lb-in.

lb-ft 20

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STARTING SYSTEM

ELECTRICAL SYSTEM
Section 4A - Starting System

Table of Contents
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . . . Typical Starting System Components . . . . Positive Current Flow . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Cable Recommendations . . . . . Delco PG260F1 Starter . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Starter Specifications . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . Delco PG260L Starter . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Starter Specifications . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . 4A-2 4A-3 4A-3 4A-4 4A-5 4A-5 4A-5 4A-6 4A-6 4A-6 4A-6 4A-7 4A-7 4A-7 4A-7 Delco 14MT Starter . . . . . . . . . . . . . . . . . . . . 4A-8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 Starter Specifications . . . . . . . . . . . . . . . . 4A-8 Torque Specifications . . . . . . . . . . . . . . . 4A-8 Lubricants / Sealants / Adhesives . . . . . . . 4A-8 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-11 Solenoid Switch . . . . . . . . . . . . . . . . . . . 4A-12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13

4
A

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STARTING SYSTEM

SERVICE MANUAL NUMBER 31

Identification

75820

Delco PG260F1

78136
SCALE 0.500

Delco PG260L

76505

Delco 14MT Direct Drive Starter

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STARTING SYSTEM

Replacement Parts Warning

WARNING
Electrical, ignition and fuel system components comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explosion. Use of replacement electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a fire or explosion hazard and should be avoided.

Precautions
CAUTION
The starter motor is designed to operate under great overload and produce a high horsepower for its size. It can do this only for a short time, since considerable heat accumulates and can cause serious damage. For this reason, the cranking motor must never be used for more than 30 seconds at any one time. Cranking should not be repeated without a pause of at least 2 minutes to permit the heat to escape.

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STARTING SYSTEM

SERVICE MANUAL NUMBER 31

Typical Starting System Components

b a
B I

d f h e

g
72930

a b c d e f g h

- Ignition Switch - 20 Amp Fuse - Starter Slave Solenoid - Circuit Breaker - Starter Motor - Neutral Safety Switch - 90 Amp. Fuse - Engine Ground (-)

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STARTING SYSTEM

Positive Current Flow

This is a general description of the positive current flow from the battery through the system until the starter motor cranks. NOTE: Ensure that all connections are tight and have the required resistance. Battery to the solenoid switch (on starter) (RED battery cable). Solenoid switch to the circuit breaker (RED). Circuit breaker to the wire junction (RED/PUR). Wire junction to the wiring harness plug (RED/PUR) terminal 6. Wiring harness plug to the 20 amp fuse (RED/PUR). 20 amp fuse to the ignition switch terminal I (RED/PUR). At this point, the ignition switch is turned to START. Ignition switch terminal I to terminal C. Ignition switch terminal C to the neutral start switch (YEL/RED). NEUTRAL START SWITCH MUST BE AT NEUTRAL POSITION. Neutral start switch to the wiring harness plug terminal 7 (YEL/RED). Wiring harness plug to the starter solenoid (small terminal) (YEL/RED). Also, ensure that the black (small terminal) wire is grounded. Starter solenoid is now closed, completing the circuit between the large terminal (RED/PUR) and the other large terminal (YEL/RED), causing the starter motor to crank.

Battery
Battery Cable Recommendations
IMPORTANT: The terminals must be soldered to the cable ends to ensure good electrical contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder as it may cause corrosion and failure. Cable Length 1.1 m (Up to 3-1/2 ft) 1.1 - 1.8 m (3-1/2 - 6 ft) 1.8 - 2.3 m (6 ft - 7-1/2 ft) 2.3 - 2.9 m (7-1/2 - 9-1/2 ft) 2.9 - 3.7 m (9-1/2 - 12 ft) 3.7 - 4.6 m (12 - 15 ft) 4.6 - 5.8 m (15 - 19 ft) 25 mm2 35 mm2 50 mm2 50 mm2 70 mm2 95 mm2 120 mm2 Cable Gauge (4) (2) (1) (0) (00) (000) (0000)

Both positive (+) and negative () cables

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STARTING SYSTEM

SERVICE MANUAL NUMBER 31

Delco PG260F1 Starter Specifications

Starter Specifications
PG260F1 Starter Motor Mercury MerCruiser Part Number Delco Identification Number 9000884 Engine Rotation LH Volts 12.0 50-863007A1 No Load Test Minimum Maximum Minimum Maximum Amp Amp rpm rpm 35 85 2550 4150

Torque Specifications
Description Starter Mounting Bolts Battery Terminal Switch Terminal Resistor Terminal External Thru-bolt All Other Fasteners Nm 41 9.5 2.3 2.3 4.6 84 20 20 41 lb-in. lb-ft 30

Tighten Securely

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STARTING SYSTEM

Delco PG260L Starter Specifications

Starter Specifications
PG260L Starter Motor Mercury MerCruiser Part Number Delco Identification Number 9000888 Engine Rotation LH Volts 12.0 50-808011-1 No Load Test Minimum Maximum Minimum Maximum Amp Amp rpm rpm 35 85 2550 4150

Torque Specifications
Description Starter Mounting Bolts Battery Terminal Switch Terminal Resistor Terminal External Thru-bolt All Other Fasteners Nm 41 9.5 2.3 2.3 4.6
84

lb-in.

lb-ft 30

20 20 41

Tighten Securely

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STARTING SYSTEM

SERVICE MANUAL NUMBER 31

Delco 14MT Starter Specifications

Starter Specifications
PG260F1 Starter Motor Mercury MerCruiser Part Number Delco Identification Number 19010615 Engine Rotation LH Volts 12.0 50-808011 No Load Test Minimum Maximum Minimum Maximum Amp Amp rpm rpm 60 100 6000 9200

Torque Specifications
Description Starter Mounting Bolts Battery Terminal Switch Terminal Resistor Terminal All Other Fasteners Nm 41 10.3 2.3 2.3 91 20 20 lb-in. lb-ft 30

Tighten Securely

Lubricants / Sealants / Adhesives

Description Liquid Neoprene Where Used Terminals on the starter solenoid Part Number 92-25711--3

Description
The Permanent Magnet Gear Reduction starter motors feature small permanent magnets mounted inside the field frame (NOTE: The actual configuration of these magnets differs between the PG200, PG250 and PG260; the field frames with permanent magnets are not interchangeable. Otherwise, the units are similar.) These magnets take the place of current-carrying field coils mounted on iron pole pieces. Internal gear reduction, approximately 4:1 ratio, through planetary gears results in armature speeds in the 7000 rpm range. The armature and drive shaft are mounted on roller or ball bearings in place of bushings. The solenoid switch, plunger, return spring, and shift lever are permanently mounted in the drive housing.

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STARTING SYSTEM

Testing
Other than water damage, low voltage causes most starter motor failures. Low voltage causes excessive heat to build up in the starter motor. It can also cause starter motor solenoid contact problems. IMPORTANT: Perform these tests with a digital voltmeter before removing the starter from the engine. 1. Set the digital voltmeter to zero before testing. 2. Ensure that the battery is fully charged. 3. Remove the coil wire from the distributor cap and ground it to prevent the engine from starting. 4. Connect the voltmeter positive (+) lead directly to the large, threaded terminal. 5. Connect the voltmeter negative () lead directly to an unpainted metal surface on the starter housing. 6. Crank the engine over with the key switch for 10-15 seconds while watching the voltmeter. A voltmeter reading of 9.5 volts or more indicates that the battery is supplying sufficient voltage to the starter to operate properly. If the starter does not function properly, the starter or the engine are malfunctioning. Remove the spark plugs and try turning the engine over by hand to rule out an engine problem. A voltmeter reading below 9.5 volts indicates a voltage loss between the starter motor and the battery. Example: Voltage measured at the battery posts indicates 12.5 volts. Voltage measured at the starter indicates 9 volts. There is a 3.5 volt drop between the battery posts and the starter. Corroded battery cables, loose or dirty connections, loose battery cable terminal crimps, under size battery cable gauge for length used in boat, painted surfaces or battery switches could be the cause of this voltage drop.

IMPORTANT: The maximum voltage drop allowed is 0.5 volts.

LOW VOLTAGE TEST

1. Test the battery positive (+) cable first. Connect voltmeter positive (+) lead directly to the battery positive (+) post, not the battery cable ring terminal. Connect voltmeter negative () lead directly to the large, threaded starter motor terminal that the battery positive (+) cable is connected to. NOTE: Remove one voltmeter lead before starter motor is turned off or voltmeter damage may occur. The starter may produce a voltage spike that can damage a voltmeter. 2. Crank the engine over while watching the voltmeter. The maximum allowed drop is 0.25 volts.

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3. To find the point where the resistance is highest, leave the voltmeter positive (+) lead on the battery post and move the voltmeter negative () lead to the battery positive (+) cable ring terminal, that is on the threaded starter terminal. 4. Move voltmeter negative () lead to the battery cable itself that is inside the crimped battery cable ring terminal. 5. Test each battery cable connection in this manner all the way back to the battery positive (+) post. If a battery switch is used, check between the battery cable ring terminal and the switchs terminal. 6. Check for voltage drop on battery negative () cable. Connect voltmeter negative () lead directly to the battery negative () post, not the battery cable ring terminal. Connect voltmeter positive (+) lead to an unpainted surface of the starter housing. NOTE: Remove one voltmeter lead before starter motor is turned off or voltmeter damage may occur. The starter may produce a voltage spike that can damage a voltmeter. 7. Crank engine over while looking at the voltmeter. IMPORTANT: The maximum allowed drop is 0.25 volts. 8. To find the point where the resistance is highest, leave voltmeter negative () lead on battery negative () post and move voltmeter positive (+) lead to the ground stud where the battery negative () cable is connected. 9. Move the voltmeter negative (+) lead to the battery negative () cable ring terminal that is on the ground stud. 10. Move voltmeter positive (+) lead to the battery cable itself that is inside the crimped battery cable ring terminal. 11. Test each battery cable connection in this manner back to the battery post. 12. After testing to ensure that the starter motor is getting at least 9.5 volts, test the starter motor solenoid to see if it is getting at least 9.5 volts from the slave solenoid during cranking. Low voltage at the starter solenoid can cause intermittent operation of the solenoid contacts and shorten the life of the solenoid. 13. Connect the voltmeter positive (+) lead to the terminal on the starter solenoid that has the YEL/RED wire from the slave solenoid connected to it. 14. Connect the voltmeter negative () lead to unpainted surface of the starter housing. 15. Crank engine over and watch the voltmeter. If the starter solenoid is not getting 9.5 volts, the YEL/RED wire or the slave solenoid could be the cause of the low voltage.

WATER OR CORROSION INSPECTION

1. Remove the 2 short screws from the end cap and look at the threads. If they are clean and gold in color, the starter motor did not have water inside of it. If they are dirty and black or gray in color, the starter motor may have had water on the inside of it and it should be replaced.

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STARTING SYSTEM

Removal
WARNING
Avoid injury or death and power package damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package. 1. Disconnect the battery cables from the battery. 2. Disconnect the wires from the solenoid terminals. 3. Remove the starter mounting bolts. 4. Pull the starter assembly away from the flywheel and remove from the engine.

77945

PG260F1

78133

14MT, Shown PG260L Similar

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STARTING SYSTEM

SERVICE MANUAL NUMBER 31

Solenoid Switch
The solenoid switch can be removed and replaced if defective. 1. Remove the three fasteners retaining the solenoid. Remove the solenoid from the drive housing.

b c

a
14MT (Others Similar) a - Drive Housing b- Solenoid c - Fasteners (3)

78123

Inspection
The cranking motor and the solenoid are completely enclosed in the drive housing to prevent the entrance of moisture and dirt. However, periodic inspection is required as follows: 1. Inspect the terminals for corrosion and loose connections. 2. Inspect the wiring for frayed and worn insulation. 3. Ensure that the starter mounting bolts are tight.

a b

c
77907

PG260F1 a - Wiring b - Terminals c - Mounting Bolts

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STARTING SYSTEM

Installation
IMPORTANT: Install the special mounting shim (if equipped) between the starter motor and the engine block. 1. Place the starter motor in position and install the mounting bolts. Torque the bolts.
Description Starter Motor Mounting Bolts Nm 41 lb-in. lb-ft 30

2. Connect the YELLOW/RED wire to the upper solenoid terminal. Connect the ORANGE wire, the RED wire, and the battery cable to the lower solenoid terminal. Coat the terminals with sealant. Install the battery cable boot, if equipped.

b a

c
78123

14MT Shown, Others Similar a - Battery Terminal b - Switch Terminal (Not Shown) c - Resistor Terminal Description Liquid Neoprene PG 260 Series
Description Nm lb-in. 84 lb-ft

Where Used Terminals on the starter solenoid

Part Number 92-25711--3

Battery Terminal Switch Terminal Resistor Terminal External Thru-bolt All Other Fasteners 14MT Description Battery Terminal Switch Terminal

9.5 2.3 2.3 4.6

20 20 41

Tighten Securely

Nm 10.3 2.3

lb-in. 91 20

lb-ft

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STARTING SYSTEM

SERVICE MANUAL NUMBER 31

Resistor Terminal All Other Fasteners

2.3

Tighten Securely

3. Connect the positive (+) battery cable to the positive (+) battery terminal and tighten the cable clamp. 4. Connect the negative () battery cable to the negative () battery terminal and tighten the clamp.

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STARTING SYSTEM

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IGNITION SYSTEM

ELECTRICAL SYSTEM
Section 4B - Ignition System

Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . Distributor . . . . . . . . . . . . . . . . . . . . . . . . . Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing Order . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . Replacing . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug Wires . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 4B-2 4B-2 4B-2 4B-2 4B-2 4B-3 4B-3 4B-3 4B-3 4B-4 4B-5 4B-5 4B-5 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9 Disassembly . . . . . . . . . . . . . . . . . . . . . . 4B-10 Cleaning and Inspection . . . . . . . . . . . . 4B-12 Reassembly . . . . . . . . . . . . . . . . . . . . . . 4B-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . 4B-13

4
B

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IGNITION SYSTEM

SERVICE MANUAL NUMBER 31

Specifications
Spark Plugs
Description Spark Plug AC Platinum (AC 41-932) Specification 0.060 in. Gap

Distributor
Description Distributor Part Number 864236

Coil
Description Coil Primary Resistance Secondary Resistance Specification Part Number 392-863704 0.60 - 0.80 Ohms 9,400-11,700 Ohms

Firing Order

72008

Description Firing Order

Specification 1-8-4-3-6-5-7-2

Torque Specifications
Description Nm lb-in. lb-ft 22 11 18

Spark Plugs

Initial Installation (NEW Cylinder Head) All Subsequent Installations

30 15 25

Distributor Hold Down Clamp

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IGNITION SYSTEM

Lubricants / Sealants / Adhesives

Description Silicone Dielectric Compound Where Used Coil High Tension Lead Tower Part Number 92-823506-1

Special Tools
Description Multi-Meter / DVA Tester (DMM) Part Number 91-99750A1

Spark Plugs
Removal
1. Disconnect the spark plug wires (high tension leads) from the spark plugs. NOTE: Use care when removing the spark plug wires and boots from the spark plugs. Twist the boot 1/2 turn before removing. Firmly grasp and pull on the boot to remove the wire. 2. Remove the spark plugs. NOTE: A thin-walled spark plug socket may be required.

Inspection
1. Inspect each spark plug for the manufacturer and spark plug number. All plugs must be from the same manufacturer and have the same spark plug number. Description Spark Plug AC Platinum (AC 41-932) Specification 0.060 in. Gap

2. Inspect each plug individually for badly worn electrodes and for glazed, broken or blistered porcelain. Check the joint between the insulator and the shell for cracks. Replace where necessary.

a b c f e
a b c d e f
90-864260 OCTOBER 2001

d
72734

- Porcelain Insulator - Insulator - Shell - Proper Gap - Side Electrode - Center Electrode (When Adjusting Gap - DO NOT Bend)
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IGNITION SYSTEM

SERVICE MANUAL NUMBER 31

Replacing
1. Clean the spark plug seating area on the cylinder heads. 2. Adjust the spark plug gap with a round feeler gauge. Bend the side electrode to adjust the gap. Do NOT bend the center electrode.

a b
a - Seating Area b - Gap IMPORTANT: Spark plugs should be torqued to the amount specified. In the absence of a torque wrench or access problems to the plugs, the spark plugs should be hand tightened until the plug seats on the cylinder head and then securely tightened with the appropriate ratchet and socket. 3. Install the spark plugs and torque.
Description Nm lb-in. lb-ft 22 11
75084

Spark Plugs

Initial Installation (NEW Cylinder Head) All Subsequent Installations

30 15

4. Install the spark plug wires in the proper order.

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IGNITION SYSTEM

Spark Plug Wires

Inspection
1. Visually inspect the spark plug wires and the coil wire for damage. 2. Visually inspect the spark plug boots for damage. NOTE: Use care when removing the spark plug wires and the boots from the spark plugs. Twist the boot 1/2 turn before removing. Firmly grasp and pull on the boot to remove the wire end. 3. Check the spark plug wires and the coil wire for continuity using a DMM. Replace any wires that do not show continuity from end to end. 4. Replace any damaged wires.

Replacing
IMPORTANT: Use only the spark plug wires recommended for marine applications. NOTE: When replacing the spark plug wires, replace one wire at a time to reduce the risk of error. 1. Disconnect the individual spark plug wires. 2. Install the spark plug wires in the proper order. Observe the following: IMPORTANT: When replacing the plug wires, route the wires correctly through the proper supports. Correct positioning of the spark plug wires and supports is important to prevent cross-firing. a. Position the wires in the spark plug wire supports and retainers. b. Attach the plug wires to the appropriate spark plug and terminal on the distributor cap. Each end should fit securely.
3 4 8 1 2 6 8 5 6 7 4 2 7 5

3 1

a - Front

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IMPORTANT: Before installing the coil wire (high tension lead) to the coil, apply approximately 1/2 oz. of silicone dielectric compound around the top of the coil high tension lead tower. Do not apply to the inside of the tower hole. c. Seal the coil high tension lead tower. Attach the coil wire to the center terminal on the distributor cap and to the coil. Description Silicone Dielectric Compound Where Used Coil high tension lead tower Part Number 92-823506-1

d. Push the end of the high tension wire into the coil tower. Position the boot over the coil tower and wipe off excess insulating compound.

a b

78032

a - Coil Wire b - Coil NOTE: Ensure that the boot does not come off of the tower due to hydraulic air pressure inside the boot.

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Disassembly
a d

e i g

h i
78115

j
a b c d e f - Cap - Rotor - Shaft Assembly - Screw - Module (Not Used) - Housing g h i j k - Gasket - Tang Washer - Washer - Gear - Pin

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IGNITION SYSTEM

1. Remove the rotor from the shaft by removing 2 torx fasteners.

77918

2. Remove the roll pin.

b
a - Gear b - Roll Pin

72917

3. Remove the gear, the washer and the tang washer. 4. Remove the shaft assembly from the housing.

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4. Install the hold-down clamp over the distributor and bolt it securely to the engine surface. Torque the bolt.

77858

Description Distributor Hold Down Clamp

Nm 40

lb-in.

lb-ft 30

5. Install the distributor cap and secure in place with two torx fasteners. 6. Connect the spark plug wires.

77923

a - Plug Not Used b - Spark Plug Wires

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CHARGING SYSTEM

ELECTRICAL SYSTEM
Section 4C - Charging System

Table of Contents
Delco Alternator . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . Replacement Parts Warning . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . EFI Electrical System Precautions . . Charging System Components . . . . . . . . Periodic Maintenance . . . . . . . . . . . . . . . . 4C-2 4C-2 4C-2 4C-3 4C-3 4C-3 4C-4 4C-4 4C-5 4C-5 Troubleshooting Tests (Alternator on Engine) . . . . . . . . . . . . . . . Charging System . . . . . . . . . . . . . . . . . Resistance . . . . . . . . . . . . . . . . . . . . . . Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . Alternator Bracket . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Bracket . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . Battery Isolator Diagram . . . . . . . . . . . 4C-5 4C-6 4C-7 4C-9 4C-11 4C-11 4C-11 4C-12 4C-12 4C-12 4C-14

4
C

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CHARGING SYSTEM

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Delco Alternator
Identification

78134

Replacement Parts Warning

WARNING
The electrical, the ignition and the fuel system components on your Mercury MerCruiser are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize the risks of fire and explosion. Use of replacement electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a fire or an explosion hazard and should be avoided.

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CHARGING SYSTEM

Specifications
Description Excitation Circuit Current Output Voltage Output Minimum Brush Length Specification 1.3 to 2.5 volts 60 Amp Minimum 13.9 to 14.7 volts 6 mm (1/4 in.)

Torque Specifications
Description Alternator to Mounting Bracket Alternator Mounting Bracket Belt Tension Battery Nut Terminal Mounting Bolts M8 x 1.25 7 11 Nm 48 41 See Note 62 8 lb-in. lb-ft 35 30

NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between 2 pulleys. Refer to SECTION 1B.

Special Tools
Description Multi-Meter / DVA Tester (DMM) Ammeter (0-100 Amp) Part Number 91-99750A1 Obtain Locally

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Precautions
The following precautions MUST BE observed when working on the charging system. Failure to observe these precautions may result in serious damage to the alternator or charging system. 1. Do NOT attempt to polarize the alternator. 2. Do NOT short across or ground any of the terminals on the alternator, except as specifically instructed in the Troubleshooting Tests. 3. NEVER disconnect the alternator output lead or battery cables when the alternator is operating. 4. NEVER disconnect the regulator lead from the alternator regulator terminal when the alternator is operating. 5. ALWAYS remove the negative () battery cable from the battery before working on the charging system. 6. When installing the battery, BE SURE to connect the positive (+) battery cable to the positive (+) battery terminal and the negative () (grounded) battery cable to the negative () battery terminal. 7. If a charger or booster battery is to be used, BE SURE to connect it in parallel with the existing battery (positive to positive; negative to negative).

EFI Electrical System Precautions

CAUTION
Avoid damage to the EFI electrical system and components. Refer to the following precautions when working on or around the EFI electrical harness or when adding other electrical accessories: DO NOT tap accessories into the engine harness. DO NOT puncture wires for testing (Probing). DO NOT reverse the battery leads. DO NOT splice wires into the harness. DO NOT attempt diagnostics without proper, approved Service Tools.

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CHARGING SYSTEM

Charging System Components

The charging system consists of the alternator, the battery, the ignition switch and the wiring that connects these components.

Periodic Maintenance
WARNING
Avoid injury or death and power package damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package. 1. Inspect the entire alternator system for corroded or loose connectors. 2. Check the wiring for frayed or worn insulation. 3. Check the alternator drive belt for excessive wear, cracks, fraying and glazed surfaces. Also, check the drive belt tension and adjust; refer to SECTION 1B. 4. Check the alternator mounting bolts for adequate tightness. 5. Inspect the flame arrestor screen for debris and clean using compressed air or a cloth. The screen MUST BE clean or the alternator may overheat.

Troubleshooting Tests (Alternator on Engine)

Use the following tests in conjunction with SECTION 1C - Troubleshooting. Before proceeding with the tests, perform the following checks to eliminate possible problem areas. Observe the Precautions to prevent damage to the alternator system. 1. An undercharged battery can be caused by excessive current draw, from accessories or by operating the engine at low speeds for extended periods. 2. Check the physical condition and the battery charge. The battery MUST BE at least 75 percent (1.230 specific gravity) of fully charged to obtain valid results in the following tests. If not, charge the battery before testing the system. 3. Inspect the entire charging system wiring for defects. Ensure that all connections are secure and clean. 4. Check the alternator drive belt for excessive wear, cracks, fraying and glazed surfaces. Replace if necessary. Also, check the drive belt tension and adjust if necessary.

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Charging System
1. Check the belt condition and tension. 2. Check the battery condition. 3. With a fully charged battery, connect the voltmeter leads directly to the battery posts.

14.0

+ +

76498

4. Supply cooling water to the engine. 5. Start the engine and operate at 1300-1500 rpm. Read the voltmeter in VDC position. Most systems will read 13.8-14.8 volts. 6. If the reading is between 13.5 and 14.8 volts, switch the DVOM to the AC volt position. and observe. A reading of 0.25 AC volts or less indicates that the alternator diodes are fully functional. A reading above 0.25 AC volts indicates that the diodes are faulty and the alternator must be replaced. 7. If the reading is below 13.5 volts: a. Connect the positive (+) voltmeter lead to the alternator output post. b. Connect the negative () lead to the ground post on the alternator.

c
X.X

a +
76498

b
76533

Typical a - Output Terminal b - Ground Terminal c - Voltmeter

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CHARGING SYSTEM

c. Wiggle the engine wiring harness while observing the voltmeter. The meter should indicate the approximate battery voltage and should not vary. If no reading is obtained, or if the reading varies, refer to Resistance in this section. d. If the reading is above 15 volts:, the alternator is overcharging and must be replaced. e. If the voltmeter reading is now within specifications, there is too much resistance between the alternator and the battery. f. If the reading is below 12.5 volts, the alternator may not be charging. Check all wiring leading to the alternator.

Resistance
1. Disconnect the coil wire so that the engine does not start. 2. Crank the engine over for 15 seconds to discharge the battery slightly. 3. Reconnect both the coil wire and turn off all accessories. 4. Connect the voltmeter positive (+) lead to the alternator output terminal. Connect the voltmeter negative () lead to the battery positive (+) post. NOTE: Connect the voltmeter leads to the battery post, NOT the battery cable end.

c
X.X

d +

a +

76498

b
76533

Typical a - Output Terminal b - Ground Terminal c - Voltmeter d - Battery 5. Start the engine and operate at 1300-1500 rpm. Read the voltmeter. A reading of more than 0.5 volts shows excessive resistance in the wiring.

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6. Connect the voltmeter negative () lead to the alternator ground terminal. Connect the voltmeter positive (+) lead to the battery negative () post.

c
X.X

d +

a +

76498

b
76533

Typical a - Output Terminal b - Ground Terminal c - Voltmeter d - Battery 7. Repeat Step 5.

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CHARGING SYSTEM

Circuitry
Perform the following tests with a DMM to ensure that all of the circuits between the alternator and the other components within the charging system are in good condition. 1. Connect the DVOM positive (+) lead to the battery positive (+) post. 2. Connect the DVOM negative (-) lead to the battery negative (-) post.

OUTPUT CIRCUIT
1. Start the engine and increase rpm to approximately 1300 rpm. 2. Observe the voltage reading. 3. If the reading is between 13.5 and 14.2 volts, switch the DVOM to the AC volt position. and observe. A reading of 0.25 AC volts or less indicates that the alternator diodes are fully functional. A reading above 0.25 AC volts indicates that the diodes are faulty and the alternator must be replaced. 4. If the reading is below 13.5 volts: a. Connect the positive (+) voltmeter lead to the alternator output post. b. Connect the negative () lead to the ground post on the alternator. c. Wiggle the engine wiring harness while observing the voltmeter. The meter should indicate the approximate battery voltage and should not vary. If no reading is obtained, or if the reading varies, refer to Resistance in this section.

X.X

a +

b
78145

a - Output Wire - ORANGE b - Ground 5. If the reading is above 15 volts, the alternator is overcharging and must be replaced.

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EXCITATION CIRCUIT
1. Connect the positive (+) voltmeter lead to the tie strap terminal on the alternator and the negative () lead to a ground terminal on the alternator. 2. Turn the ignition switch to the ON position and note the voltmeter reading. The reading should be 1.3 to 2.5 volts. 3. If no reading is obtained, an open exists in the alternator excitation lead or in the excitation circuit of the regulator. Unplug the PURPLE lead from the regulator. Connect the positive voltmeter lead to the PURPLE lead and the negative voltmeter leads to the ground. If the voltmeter now indicates the approximate battery voltage, the voltage regulator is defective and must be replaced. If no voltage is indicated, check the excitation circuit for loose or dirty connections or damaged wiring.

SENSING CIRCUIT
1. Unplug the RED and RED/PUR connector from the alternator. 2. Connect the positive (+) voltmeter lead to the RED/PUR pin and the negative () voltmeter lead to the ground terminal. 3. The voltmeter should indicate the battery voltage. If battery voltage is not present, check the RED/PUR wire for loose or dirty connection or damaged wiring.

b a

X.X

78146

a - Connector Location b - RED and RED/PUR Connector c - Ground

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CHARGING SYSTEM

Removal
Alternator

a b

c
77954 78114

a - MIE Mounting Bracket b - MCM Mounting Bracket c - Serpentine Belt 6. Remove the alternator.

Alternator Bracket
1. Drain the cooling system. 2. Remove the water circulating pump hose. 3. Remove the bracket

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CHARGING SYSTEM

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Installation
Alternator Bracket
1. Install the alternator bracket Description Alternator Mounting Bracket Nm 41 lb-in. lb-ft 30

2. Install the water circulating pump hope and securely tighten the hose clamps.

Alternator
1. Install the idler brace. 2. Position the alternator in the mounting bracket. 3. Install the mounting bolts and torque.

a b

77954

78114

a - MIE Mounting Bracket b - MCM Mounting Bracket Description Mounting Bolts M8 x 1.25 Nm 11 lb-in. lb-ft 8

4. Position the alternator drive belt on the pulleys and adjust the tension.

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CHARGING SYSTEM

5. Reconnect the wiring harness to the alternator.

b
78134 77945

c
a - RED and RED/PURPLE Connector b - ORG Wire c - Ground 6. Connect the both battery cables to the battery. 7. Fill the cooling system with the correct fluid.

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Battery Isolator Diagram

a b

h
B2 A B1

d
1

d f

f g e

78147

a b c d e f g h

- Circuit Breaker - Harness Connector - Alternator - Starter - Cranking Battery - Ground Stud - Auxiliary Battery - Isolator

1 - Disconnect ORANGE Wire From Alternator Battery Terminal. Splice Sufficient Gauge Wire To The Orange Wire And Connect As Shown. 2 - 8 Gauge Minimum

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WIRING DIAGRAMS

ELECTRICAL SYSTEM
Section 4D - Wiring Diagrams

Table of Contents
Instrumentation . . . . . . . . . . . . . . . . . . . . . Single Station Installations - Typical . Power Trim System . . . . . . . . . . . . . . . . . . 4D-2 4D-2 4D-4 MerCathode System Wiring Diagram . . Wiring Diagrams . . . . . . . . . . . . . . . . . . . . 4D-5 4D-6

4
D

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WIRING DIAGRAMS

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WIRING DIAGRAMS

MerCathode System Wiring Diagram

d b

BLK BLU BRN GRY GRN ORN PNK PUR RED TAN WHT YEL LT OR LIT DRK

= = = = = = = = = = = = = =

BLACK BLUE BROWN GRAY GREEN ORANGE PINK PURPLE RED TAN WHITE YELLOW LIGHT DARK

73596

a b c d

- Controller - 20 Amp Fuse - Electrode - BLACK Wire - With Engine Harness or Separate

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Wiring Diagrams

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service@manual@number@SQ

wiring@diagrams

YPMXVTRVP@@@october@RPPQ

p@TdMW

wiring@diagrams

service@manual@number@SQ

this@page@is@intentionally@blank

p@TdMX

YPMXVTRVP@@@october@RPPQ

service@manual@number@SQ

wiring@diagrams

YPMXVTRVP@@@october@RPPQ

p@TdMY

Special Tools
Description Fuel Pressure Gauge Part Number Obtain Locally

Lubricants / Sealants / Adhesives

Description Thermal Grease Loctite 242 Loctite 592 Pipe Sealant With Teflon Engine Oil Ultra Black Loctite 5900 Where Used Cool Fuel Retainer Bracket Throttle Body Studs, Fuel Cooler Mounting Studs, Lower Intake Manifold Bolts Fuel Fittings Filter Sealing Ring Lower Intake Manifold Gaskets, Engine Block at Lower Intake Manifold Sealing Surfaces Part Number Obtain Locally 92-809824 Obtain Locally Obtain Locally 92-809826

Replacement Parts Warning

WARNING
Electrical, ignition and fuel system components on your MerCruiser are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire and explosion. Use of replacement electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a fire or explosion hazard and should be avoided.

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

Abbreviations
amp Bat B+ CMP CPS Deg DMM DMT DVM DVOM ECM ECT EFI ENG GND IAC in. hg INJ kPa mA MPR MAPT mohms mSec TACH TERM TPS V WOT Amperes Battery Positive Terminal, Battery or System Voltage Battery Positive Camshaft Position Sensor Crankshaft Position Sensor Degrees

Digital Multimeter

Engine Control Module Engine Coolant Temperature Electronic Fuel Injector Engine Ground Idle Air Control Inches Of Mercury Injection Kilopascal milliamperes Main Power Relay Manifold Air Pressure and Temperature Milliohms Millisecond Tachometer Terminal Throttle Position Sensor Volts Wide Open Throttle

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FUEL DELIVERY SYSTEM

Precautions
WARNING
Avoid personal injury or death and power package damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package.

WARNING
Be careful when changing fuel system components; gasoline is extremely flammable and highly explosive under certain conditions. Be sure that ignition key is OFF. Do NOT smoke or allow sources of spark or flame in the area while changing fuel filters. Wipe up any spilled fuel immediately.

WARNING
Make sure that no fuel leaks exist before closing engine hatch.

CAUTION
Do NOT operate engine without cooling water being supplied to seawater pickup pump or pump impeller will be damaged and subsequent overheating damage may result.

Fuel Supply Connections

WARNING
Avoid gasoline fire or explosion. Improper installation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and/or cause a fuel leak. Apply #592 Loctite Pipe Sealant with Teflon to threads of brass fitting or plug. Do NOT use teflon tape. Thread brass fitting or plug into fuel pump or fuel filter base until finger tight. Tighten fitting or plug an additional 1-3/4 to 2-1/4 turns using a wrench. Do NOT overtighten. Install fuel line. To prevent overtightening, hold brass fitting with suitable wrench and tighten fuel line connectors securely. Check for fuel leaks.

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

Fuel Delivery System

Recommendations

WARNING
Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be adhered to when installing fuel delivery system. The Fuel Tank is an integrated component of the boat. Refer to the special information on service and maintenance, which you have received from the tank or boat manufacturer. NOTE: On Ski Boat Applications: If during testing for a particular application, you experience fuel starvation in sharp high speed turns, baffles or a fuel sump may be needed in the tank to help correct this condition. All fuel lines must be well secured. The holes where the lines go through the bulkheads should be carefully rounded off or protected with rubber grommets. This prevents damage to the lines from abrasion. The following, but not limited to the following, additional fuel connection related points, applying to all engines unless otherwise stated, must be considered. Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines. 1. Fuel pickup should be at least 25 mm (1 in.) from the bottom of fuel tank to prevent picking up impurities. 2. Fuel lines used must be Coast Guard approved (USCG Type A1). 3. Diameter of fittings and lines must be smaller than 10 mm (3/8 in.) ID. 4. On Multi-Engine Gasoline Installations: It is best to use a fuel pickup and supply line for each engine. If a single pickup and line is used, the line must be 13 mm (1/2 in.) ID or larger. 5. Larger diameter (than previously specified) lines and fittings must be used on installations requiring long lines or numerous fittings. 6. Fuel lines should be installed free of stress and firmly secured to prevent vibration and/or chafing. 7. Sharp bends in fuel lines should be avoided. 8. A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine to absorb deflection when engine is running. IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of todays fuels. It can also cause poor engine performance due to fuel starvation. 9. The maximum measured vacuum at engine fuel inlet must not exceed 6.9 kPa (2 in. Hg) at 650, 3000, WOT and idle rpm.
correction: the MINIMUM fuel line size is 10 mm (3/8 in.)

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FUEL DELIVERY SYSTEM

Exploded Views
Fuel Rail and Injectors
7

6 4 5

77833

1 2 3 4

- Intake Manifold - O-rings (8) - Fuel Injectors (8) - Fuel Injector Retainer Clip

5 6 7 8

- Schrader Valve (Fuel Pressure Relief) - Fuel Rail - Fuel Rail Nuts - Fuel Rail Studs

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SERVICE MANUAL NUMBER 31

Throttle Body
18 18 15

14 16 17

9 2

6 5 4

7 3

77840

1 2 3 4 5 6 7 8 9

- Bolt (2) - Washer (2) - Throttle Position Sensor - O-ring - C-clip - Washer - Spacer - Throttle Plate Bar - Rivet (2)

10 - IAC Plug 11 - Throttle Plate 12 - Sealing Ring 13 - Alignment Dowels (2) 14 - Throttle Body 15 - Throttle Body Studs (3) 16 - Spring Cover 17 - Spring 18 - Throttle Cable Bracket

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FUEL DELIVERY SYSTEM

Cool Fuel System

1 22 2 3 6 4 21 7 8

5 21

10 12 10

14 13 16 18 17 15 19
77941

1 - Bracket 2 - Cover Base 3 - Screw And Washer (2) 4 - Fuel Pressure Regulator 5 - Return Fuel Line 6 - Retaining Ring 7 - O-rings (2) 8 - Fuel Line, Fuel Pump-To-Fuel Rail 9 - Stepped Screw 10 - O-rings (4) 11 - Elbow Fitting

12 - Fuel Cooler 13 - Fuel Pump Wiring Harness 14 - Retainer Bracket 15 - Nut (2) 16 - Electric Fuel Pump 17 - Inlet Fitting 18 - Fuel Line Inlet 19 - Cover 20 - Filter 21 - Seawater Hoses (Hose Clamps Not Shown) 22 - Vacuum Hose

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

Fuel System Flow Diagrams

1. Activate the Schrader valve located on the fuel rail to release pressure.

Flame Arrestor
Removal
1. Remove the engine cover. 2. Remove the flame arrestor retainer bracket. 3. Remove the flame arrestor from the throttle body.

78020

a - Engine Cover b - Retainer Bracket c - Flame Arrestor

Cleaning and Inspection

1. Clean flame arrestor in steam or water. 2. Wear eye protection. Dry flame arrestor with compressed air.

Installation
1. Install the flame arrestor on the throttle body. 2. Install the flame arrestor retainer bracket. Description Nut, Flame Arrestor Retainer Bracket 3. Install the engine cover. Nm 12 lb-in. 108 lb-ft

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Throttle Body
Removal
1. Remove the engine cover and the flame arrestor. 2. Disconnect the throttle linkage from the throttle body.

78033

a - Nuts b - Throttle Cable 3. Disconnect the harness connector from the throttle position sensor. 4. Remove the IAC hose from the throttle body.

b a

77906

a - Throttle Position Sensor b - IAC Hose

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FUEL DELIVERY SYSTEM

5. Remove the throttle body attaching studs.

78161

6. Remove the throttle body. 7. Remove and discard the throttle body sealing ring.

78158

a - Sealing Ring IMPORTANT: Insert a clean shop towel into the opening of the intake manifold to prevent foreign material from entering the engine.

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Cleaning and Inspection

IMPORTANT: Do NOT use cleaners containing methyl ethyl ketone. IMPORTANT: Do NOT get solvent or cleaner on the TPS. IMPORTANT: Do NOT damage the adapter and throttle body when removing gasket material from adapter and throttle body. 1. Carefully remove all gasket material from adapter and throttle body. 2. Remove the IAC muffler.

77927

a - IAC Muffler Installed In Throttle Body 3. Thoroughly clean all parts of throttle body. Ensure that all passages are free of dirt and burrs. 4. Inspect mating surfaces for damage that could affect gasket sealing. 5. Inspect throttle body for cracks in casting. 6. Inspect throttle plates, linkage, return springs and other components for damage, wear and foreign material.

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FUEL DELIVERY SYSTEM

Installation
1. Install a new throttle body sealing ring into the groove in the throttle body. 2. Align the dowels and install the throttle body onto the upper intake manifold. 3. If reusing the fasteners, apply adhesive to the threads of the throttle body attaching studs. Description Loctite 242 Where Used Throttle Body Studs Part Number 92-809821

4. Install the throttle body attaching studs. Torque the studs. Description Studs, Throttle Body 5. Install the IAC muffler. Nm 9 lb-in. 80 lb-ft

b a

77926

a - Throttle Body b - IAC Muffler 6. Install the throttle cable bracket. NOTE: Ensure that the stud and nut are threading correctly. Description Nuts, Throttle Cable Bracket 7. Install the IAC hose to the IAC plug. 8. Install the flame arrestor. Description Nut, Flame Arrestor Retainer Bracket 9. Install the engine cover. Nm 12 lb-in. 108 lb-ft Nm 19 lb-in. 168 lb-ft

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

Electronic Control Module (ECM)

IMPORTANT: The ECM is a sensitive electrical device, subject to electrostatic damage. Do NOT touch connector pins when removing or installing the module.

a b c
78019

a - ECM Bracket b - Electrical Connectors c - Fasteners

Removal
1. Disconnect the electrical connectors at the ECM. Do NOT touch the connector pins. 2. Remove the ECM from the electrical bracket.

Cleaning and Inspection

1. Clean the exterior of the ECM with a dry cloth, be careful to avoid contact with connector pins. 2. Inspect outer surfaces for any obvious damage. 3. Visually inspect electrical pins at both ends of ECM for straightness and corrosion. 4. Visually inspect the connectors on the wiring harness for corrosion and terminals that may have loose connections. NOTE: The ECM is a sealed electrical component. If it is defective, replace the ECM.

Installation
1. Mount the ECM to electrical bracket using screws and washers. 2. Connect the electrical connectors to the ECM. Do NOT touch the connector pins.

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FUEL DELIVERY SYSTEM

Water Separating Fuel Filter

b c f d e g i

j
78131

a b c d e f g h i j

- Insulator Plate - Fuel Return Line from Regulator - Brass Fitting - Fuel Line to Fuel Pump - Brass Fitting - Fuel Filter Mounting Bracket - Nut - Fuel Inlet Fitting - Plug - Water Separating Fuel Filter

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SERVICE MANUAL NUMBER 31

Removal

WARNING
Avoid injury or death and power package damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package. 1. Disconnect both battery cables from the battery. 2. Activate the Schrader valve to relieve fuel pressure. 3. Remove the fuel filter from the base. A filter wrench may be needed.

Installation
1. Lubricate sealing ring of new filter with engine oil. Description Engine Oil 2. Install a new filter. Tighten securely by hand. 3. Connect both battery cables to the battery. 4. Supply water to cooling system. 5. Start engine. 6. Check for fuel leaks. Where Used Sealing Ring Part Number Obtain Locally

Cool Fuel System

Removal

CAUTION
If boat is to remain in the water, the seacock, if equipped, must remain closed until engine is to be restarted to prevent water from flowing back into seawater cooling system. If boat is not fitted with a seacock, water inlet hose must be disconnected and plugged to prevent water from flowing into cooling system and/or boat. 2. Close the seacock, if equipped. If boat is not equipped with a seacock, remove and plug the seawater inlet hose. 3. Drain the seawater system. Refer to SECTION 1B. 4. Disconnect the seawater hoses from the fuel cooler. IMPORTANT: Plug open ends of fuel line connections to prevent fuel leaks and entry of water or contaminates into lines while working. 5. Close fuel shut off valve, if equipped, and remove the fuel tank inlet line from the water separating fuel filter. If boat is not equipped with a fuel tank shut off valve, remove the fuel tank inlet line at the water separating fuel filter and plug the line.
Page 5A-20 90-864260 OCTOBER 2001

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FUEL DELIVERY SYSTEM

6. Activate the Schrader valve to relieve fuel pressure. 7. Disconnect fuel lines from water separating fuel filter adapter.

75533

a - Filter Adapter b - Fuel Lines 8. Disconnect the fuel line from the rail. 9. Disconnect the fuel pump electrical connector. 10. Disconnect the vacuum hose between the pressure regulator and the intake manifold. 11. Remove the two fuel cooler bracket nuts from the engine mount bracket studs. 12. Carefully remove the cool fuel system assembly.

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

Disassembly

1 22 2 3 6 4 21 7 8

5 21

10 12 10

14 13 16 18 17 15 19
78160

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FUEL DELIVERY SYSTEM

NOTE: Retain all fasteners and hardware unless instructed otherwise. 1. Remove the cool fuel system cover. 2. Remove the two nuts from the cool fuel retaining bracket studs. 3. Remove the retainer bracket. 4. Unclip the wiring harness from the cover base. 5. Remove the fuel cooler and the electric fuel pump assembly from the cover base. IMPORTANT: To prevent loss of the stepped screw used to secure the fuel cooler-to-fuel rail fuel line, a retainer ring is provided. Do not remove the retainer ring or stepped screw. 6. Loosen the stepped screw and remove the fuel line. 7. Hold the fuel line and fuel pump or fuel cooler fittings securely and remove the fuel lines. 8. Disconnect the elbow fitting and fuel pump from the fuel cooler assembly by pulling firmly. 9. Remove the elbow fitting from the fuel pump by pulling firmly. 10. Hold the fuel line and regulator fittings securely and remove the fuel line. 11. Remove the fuel line fitting from the fuel pressure regulator. 12. Remove the two screws and washers retaining the fuel pressure regulator to the fuel cooler. 13. Remove the regulator. 14. Remove the conical filter from the fuel cooler. 15. Disconnect the vacuum hose from the regulator by pulling firmly.

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

Reassembly
1. Install the small filter (conical side DOWN) in the orifice of the new fuel cooler where the fuel pressure regulator mounts. 2. Install the regulator onto the cooler using the two screws with washers. Torque the screws. Description Fuel Pressure Regulator Screws 3. Install the fitting into the regulator. Tighten securely. 4. Connect the fuel line to the regulator. Tighten securely. Nm 5.8 lb-in. 53 lb-ft

a b

75708

a b c d e f

- Filter - Fuel Cooler Orifice - Fuel Pressure Regulator - Screw And Washer (2) - Fuel Line - Fitting

5. Install the vacuum hose onto the regulator. 6. Install the 4 O-rings on the fuel pump / cooler elbow fitting. 7. Lubricate O-rings for the elbow fitting with a small amount of liquid dish soap (obtain locally).

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FUEL DELIVERY SYSTEM

8. Install the elbow fitting in the fuel pump. 9. Install the fuel pump with elbow fitting in the cooler assembly.

d b
75708

c
a b c d - O-rings (4) - Elbow Fitting - Fuel Pump - Fuel Cooler

10. Install the fitting into the end of the fuel pump. 11. Install the fuel line for the water separating fuel filter to the fuel pump fitting. 12. Install fuel line seal onto the cooler-to-fuel rail fuel line where it attaches to the cooler. 13. Completely loosen, but do NOT remove, the stepped screw that retains the fuel line. 14. Lubricate the fuel line seal with a small amount of liquid dish soap (obtain locally).

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

15. Insert the fuel line into the cooler orifice. Torque the stepped screw. Description Stepped Screw Nm 9 lb-in. 81 lb-ft

IMPORTANT: To prevent loss of the stepped screw used to secure the cooler-to-fuel rail fuel line, a retainer ring is provided. Do not remove the retainer ring or stepped screw.

b a b c d
a b c d e f g
78159

g c f
75708

- Fuel Line Seal - Fuel Line, Fuel Cooler-To-Fuel Rail - Fuel Cooler - Stepped Screw - Loosened To Accept Fuel Line - Retainer Ring - Stepped Screw - Torqued - Retainer Ring

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FUEL DELIVERY SYSTEM

16. Position the completed fuel cooler assembly in the cover base. 17. Apply a thin, even coating of Thermal Grease on all of the retainer bracket inside surfaces where it contacts the cooler and the fuel pump when installed.

b a

a - Retainer Bracket b - Thermal Grease Description Thermal Grease Where Used Cool Fuel Retainer Bracket Part Number Obtain Locally

18. Install the retainer bracket over the cooler and fuel pump. Apply sealant to the threads of the mounting studs. Description Nuts, Retainer Bracket Description Loctite 242 Where Used Fuel Cooler Mounting Studs Nm 5.6 lb-in. 50 Part Number 92-809821 lb-ft

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FUEL DELIVERY SYSTEM

10. Remove the valve covers. 11. Remove the lower intake manifold bolts. IMPORTANT: The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.

CAUTION
Dirt or debris may enter the fuel system causing fuel system or engine failure. Seal the ends of the fuel system properly. 12. Remove the intake manifold assembly.

77995

13. Remove and discard the lower intake manifold gaskets.

Disassembly
1. Remove all crankcase ventilation hoses.

a a

a
a - Hoses

77997

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

2. Remove the throttle cable bracket nuts. The stud at the rear of the intake manifold may loosen instead of the nut.

b a

77998

a - Throttle Cable Stud b - Throttle Cable Bracket 3. Remove the IAC bracket nuts. 4. Remove the IAC and bracket.

a b

77999

a - IAC b - IAC Bracket

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FUEL DELIVERY SYSTEM

5. Remove the ignition coil. 6. Remove the throttle body attaching studs.

78161

7. Remove the throttle body. 8. Remove and discard the throttle body sealing ring.

78158

a - Sealing Ring 9. Remove the thermostat housing. 10. Remove the MAPT and discard the seal.

78083

a - Seal

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

11. Remove the fuel rail studs. 12. Remove the fuel rail.

78082

a - Fuel Rail b - Fuel Rail Studs 13. Remove the upper intake manifold studs. 14. Remove the upper intake manifold.

78153

15. Remove and discard the upper intake manifold to lower intake manifold gasket. 16. Remove the brackets on both sides of the lower intake manifold.

c d
A

a b c
77884 77833

a b c d

- Area Of Adhesive - Locator Pin - Gasket - Locator Pin Hole Where Used Lower intake manifold gaskets Part Number 92-809826

Description A Ultra-Black Loctite 5900

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

3. Apply a 5 mm (13/64 in.) wide bead of adhesive to front and rear of engine block as shown. Extend adhesive bead 13 mm (1/2 in.) up on intake gaskets; avoid blocking the hole.
A

b b

a
77847

a
A

77846 72325

d
a b c d - Bead Of Adhesive - Front Top Of Engine Block - Rear Top Of Engine Block - Hole Where Used Engine Block At The Lower Intake Manifold Sealing Surfaces Part Number 92-809826

Description A Ultra-Black Loctite 5900

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FUEL DELIVERY SYSTEM

4. Coat threads of the lower intake manifold bolts with sealant. 5. Carefully install lower intake manifold, or intake manifold assembly, onto the engine block.

a - Intake Manifold Bolts Description A Loctite 242 Description Lower Intake Manifold Bolt (Each Pass In Sequence) First Pass Second Pass Final Pass 7. Install the valve covers. 8. Connect all ignition and electrical leads. 9. Connect hoses to thermostat housing. 10. Install fuel line to fuel rail. 11. Connect crankcase ventilation hoses. 3 12 15 27 106 132 Where Used Lower Intake Manifold Bolt Nm Part Number
92-809821

lb-in.

lb-ft

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

12. Install the distributor. Description Distributor Hold Down Clamp Bolt 13. Install the ignition coil wire. 14. Install other ignition components and reconnect wires. 15. Connect any items that were disconnected. 16. Refill closed cooling system, if equipped. Nm 25 lb-in. lb-ft 18

CAUTION
Overheating caused by insufficient cooling water will result in engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation. 17. Provide cooling water to the engine. 18. Start engine. 19. Check hose connections, gaskets and seals for leaks. 20. Inspect fuel line connections for fuel leaks. 21. Install the flame arrestor. Description Nut, Flame Arrestor Retainer Bracket 22. Install engine cover. Nm 12 lb-in. 108 lb-ft

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FUEL DELIVERY SYSTEM

Sensors
Manifold Air Pressure / Temperature (MAPT) Sensor
REMOVAL
1. Disconnect the wiring harness connection from the MAPT. 2. Remove the MAPT and discard the seal.

78083

a - Seal

CLEANING AND INSPECTION

1. Clean the surfaces of the MAPT with a dry cloth. 2. Inspect the MAPT for signs of wear or damage.

INSTALLATION
3. Install a new MAPT sensor seal onto the MAPT sensor. 4. Apply 1 drop of clean engine oil to the MAPT sensor seal. 5. Install the MAPT sensor into the upper intake manifold. Description MAPT Fasteners 6. Connect electrical connector to the MAPT. Nm 6 lb-in. 53 lb-ft

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

Throttle Position Sensor (TPS)

1. Remove the engine cover and flame arrestor. 2. Disconnect the harness connector from the TPS. 3. Remove the screws from the TPS. 4. Remove the TPS from the throttle body.

c b a
a - Screw (2) b - Throttle Position Sensor c - O-ring
78124

CLEANING AND INSPECTION

1. Clean the surfaces of the TPS with a dry cloth. 2. Inspect the TPS for signs of wear or damage.

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FUEL DELIVERY SYSTEM

INSTALLATION
1. Apply adhesive to screw threads. Install the TPS on the intake manifold. Torque screws.

c b a
a - Screw (2) b - Throttle Position Sensor c - O-ring Description Loctite 242 Description Throttle Position Sensor (TPS) 2. Place a new sealing ring in the groove. 3. Install throttle body on the intake manifold. Torque nuts. Description Nuts, Throttle Body 4. Connect electrical connector to the TPS. 5. Install the flame arrestor. Description Nut, Flame Arrestor Retainer Bracket 6. Install the engine cover. 7. When negative () battery cable has been reconnected, start engine and check for TPS output voltage. It should be approximately 0.7 volts at idle and 4.5 volts at wide open throttle. Nm 12 lb-in. 108 lb-ft Nm 10 lb-in. 88 lb-ft Where Used TPS Screws Nm 2 Part Number 92-809821 lb-in. 20 lb-ft
78124

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

Idle Air Control (IAC) Valve

REMOVAL
1. Remove the engine cover. 2. Remove the IAC hoses. 3. Disconnect the electrical connector. 4. Remove the IAC bracket nuts. 5. Remove the IAC and bracket.

77999

6. Remove the 2 screws retaining the IAC to the bracket.

78088

INSTALLATION
1. Install IAC valve and bracket onto intake. Torque fasteners. Description Bolts, IAC to Bracket Nuts, IAC Bracket 2. Connect electrical connector to IAC. Nm 19 15 lb-in. 168 132 lb-ft

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FUEL DELIVERY SYSTEM

Knock Sensor
REMOVAL
1. Disconnect electrical connector at knock sensor located below the port valve cover on the rear of the engine. 2. Remove knock sensors from engine block.

CLEANING AND INSPECTION

1. Clean knock sensor with a dry cloth, paying special attention to threads on base. 2. Inspect surfaces of knock sensor for signs of wear or physical damage.

INSTALLATION
IMPORTANT: If installing a new knock sensor, be sure to replace it with an identical part. Knock sensors are very sensitive and designed for each specific application. IMPORTANT: In the following step, it is very important that the knock sensor be torqued to the precise specification. Incorrect torquing will result in unsatisfactory performance. Do NOT use sealer on threads. 1. Install knock sensor in engine block. Torque nut. Description Nut, Knock Sensor 2. Connect electrical connector to knock sensor. Nm 20 lb-in. lb-ft 15

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FUEL DELIVERY SYSTEM

SERVICE MANUAL NUMBER 31

Fuel Pump Relay

REMOVAL
1. Remove fuel pump relay from electrical bracket.

77905

a - Fuel Pump Relay 2. Disconnect electrical connector and remove fuel pump relay.

CLEANING AND INSPECTION

1. Clean the external surfaces with a dry cloth. 2. Inspect surfaces for signs of wear or physical damage.

INSTALLATION
1. Connect the electrical connector to the relay. 2. Attach fuel pump relay to bracket.

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FUEL DELIVERY SYSTEM

Main Power Relay

REMOVAL
1. Remove the main power relay from electrical box.

77905

a - Main Power Relay 2. Disconnect the electrical connector and remove the relay.

CLEANING AND INSPECTION

1. Clean the external surfaces with a dry cloth. 2. Inspect surfaces for evidence of damage.

INSTALLATION
1. Attach the electrical connector to the relay. 2. Attach the main power relay to the electrical bracket.

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THIS PAGE IS INTENTIONALLY BLANK

Page 5A-48

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ALL MODELS

COOLING SYSTEM
Section 6A - All Models

Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Seawater Inlet Recommendations . . . . . Seacock (Seawater Inlet Valve) . . . . . Seawater Strainer . . . . . . . . . . . . . . . . Seawater Pickups . . . . . . . . . . . . . . . . . . . Through the Hull Mounted . . . . . . . . . Transom Mounted . . . . . . . . . . . . . . . . Quicksilver Sea Strainer . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Hot Water Heater Installation . Supply Hose Connection . . . . . . . . . . Return Hose Connection . . . . . . . . . . . 6A-2 6A-2 6A-3 6A-3 6A-3 6A-4 6A-4 6A-6 6A-8 6A-8 6A-9 6A-10 6A-11 6A-11 6A-12 Seawater Pump . . . . . . . . . . . . . . . . . . . . . Output Test . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Water Circulating Pump . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Water Distribution Housing . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning And Inspection . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-12 6A-12 6A-14 6A-15 6A-16 6A-16 6A-19 6A-20 6A-20 6A-21 6A-22 6A-23 6A-23 6A-23 6A-23

6
A

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ALL MODELS

SERVICE MANUAL NUMBER 31

Torque Specifications
NOTE: Securely tighten all fasteners not listed below. Description Nut, Seawater Pickup Bolt, Seawater Pump Fastener, Water Pump Fasteners, Water Distribution Housing Bracket Screws, Water Distribution Housing-To-Bracket Nm 48 9.9 48 38 13.5 120 88 35 28 lb-in. lb-ft 35

Lubricants / Sealants / Adhesives

Description Loctite 271 Marine Caulk Loctite 567 PST Pipe Sealant Silicone Sealant Or Equivalent Engine Oil Loctite 609 Quicksilver Perfect Seal Where Used Seawater pickup fasteners Boat hull and seawater pickup joints Transom mounted seawater pickup fitting and plastic plug Transom mounted seawater pickup screws Seawater pump bearing shaft Seawater pump retainer/seal Water circulating pump gaskets and fasteners Part Number 92-809819 Obtain Locally 92-809822 Obtain Locally Obtain Locally Obtain Locally 92-34227-1

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ALL MODELS

Seawater Inlet Recommendations

Seacock (Seawater Inlet Valve)
The seacock used must have an internal cross-sectional area equal to or greater than seawater inlet hose to prevent restricting water flow. Install valve in an area where it will be easily accessible and supported adequately to prevent hose fatigue. A brass ball or gate valve is required. Select a proper seacock based on the following chart: Seacock Size (Internal Cross-Sectional Area Equal to or Greater Than Size Shown) Gasoline Engines 1-1/4 in. (32 mm)

70355

Seacock a - Hose Connector 32 mm (1-1/4 in.) I.D. To Seawater Pump Inlet b - Seacock 32 mm (1-1/4 in.) Brass Ball Or Gate Valve c - Through-The Hull Seawater Pickup d - Direction Of Seawater Flow

Seawater Strainer
Strainer used must be of sufficient size to ensure that an adequate supply of water will be maintained for cooling the engine. Select a proper seawater strainer based on the following chart: Seawater Strainer Minimum Flow Rate 1 Gasoline Engines
1 Amounts

114 (30)

listed are in liters per minute and (gallons per minute).

Install seawater strainer in an area where it will be easily accessible for inspection and cleaning. Strainer should be installed in water inlet hose after the seacock (water inlet valve) to allow operator to shut off water when cleaning strainer.

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ALL MODELS

SERVICE MANUAL NUMBER 31

Seawater Pickups
NOTICE Refer to the manufacturers instructions for information on removal and installation of other than Quicksilver Seawater Pickups. IMPORTANT: Seal the inside edges of any hole made through the hull with a suitable sealant to prevent water absorption and deterioration.

Through the Hull Mounted

b d c

a
a b c d - Seawater Pickup - Seawater Inlet Slots - Mounting Screw Holes - Nut

72639

1. Seal the inside edges of the 44 mm (1-3/4 in.) hole in the hull using a suitable sealer. 2. Apply marine caulking (sealer) to the mounting surface on the seawater pickup where the hull contact will occur when installed.

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ALL MODELS

IMPORTANT: The seawater inlet slots must face forward - parallel with the flow of water. 3. Ensure that the slots in the seawater pickup are facing forward (toward the bow of the boat) and install the seawater pickup through the hull. 4. Fasten the pickup with mounting screws. 5. Apply sealant as needed inside the boat. Apply adhesive to the threads of the nut. 6. Install on the pickup and torque. 7. Ensure that the seawater inlet holes face forward. Description Loctite 271 Marine Caulk Description Nut, Seawater Pickup Where Used Seawater pickup fasteners Boat hull and seawater pickup joints Nm 48 Part Number 92-809819 Obtain Locally lb-in. lb-ft 35

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ALL MODELS

SERVICE MANUAL NUMBER 31

Transom Mounted
b a c g h i j
a b c d e - Hose Fitting - Nut (4) - Gasket - Pickup-To-Transom - O-Ring (4) - Washer (4) f g h i j - Screw (4) - Plastic Plug - Pickup - Screen - Screw (2)
72640

1. Seal the inside edges of the 38 mm (1-1/2 in.) hole hose fitting and the plastic plug. Description Loctite 567 PST Pipe Sealant Where Used Transom mounted seawater pickup fitting and plastic plug Part Number 92-809822

NOTE: Use a sharp knife or wood chisel to remove excess plastic plug material so that the plug is flush with the pickup casting. 2. Position one flat washer and one rubber O-ring on each 5/16 in. x 4 in. (102 mm) long, round head screw. Coat each screw shaft with sealant. Description Silicone Sealant Or Equivalent Where Used Transom mounted seawater pickup screws Part Number Obtain Locally

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3. Place the new gasket on the pickup housing and hold the pickup in place on the transom. Install four round head screws (with washers and O-rings in place) into the pickup mounting holes and through the drilled 8 mm (21/64 in.) holes in the transom. NOTE: Some installations may have 5 mm (7/32 in.) holes drilled in the transom using four 5/16 in. diameter stainless steel lag bolts in place of round head screws. Flat washers and O-rings are always required.

72641

Water Pickup Installed on Transom a - Diagonal Mount - Leading Edge Of Pickup 3.2 mm (1/8 in.) From Boat Bottom b - Vertical Mount - Corner Of Leading Edge Of Pickup 3.2 mm (1/8 in.) From Boat Bottom 4. Secure the water pickup from the inside with the locknuts and washers (unless using lag bolts). 5. Tighten the fasteners securely.

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SERVICE MANUAL NUMBER 31

Quicksilver Sea Strainer

NOTICE Refer to the manufacturers instructions for information on other than Quicksilver Sea Strainer.

Removal

CAUTION
If the boat is in the water while working on the seawater strainer, close the seacock, if equipped. If the boat is not equipped with a seacock, remove and plug the seawater inlet hose to prevent a siphoning action that may occur, allowing the seawater to flow from the drain holes or removed hoses and enter the boat. 1. Models Equipped with Seacock: a. Close the seacock (water inlet valve). b. Disconnect the seawater inlet hose from the seawater strainer. 2. Models without Seacock: a. Disconnect the seawater inlet hose from the seawater strainer inlet and plug the seawater inlet hose.

b
a b c d - Seawater Inlet Hose - Seawater Strainer - Seawater Strainer Inlet - Plug

a
70062

3. Remove the outlet hose. Drain into a suitable container.

a b
a - Seawater Inlet Hose b - Seawater Strainer 4. Remove the mounting bolts. Remove the strainer.
72643

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ALL MODELS

Cleaning and Inspection

1. Remove and clean the filter element. 2. Remove the drain plug.

b c d

e h f g
72673

Quicksilver Seawater Strainer Shown a - Screws And Washers b - Cover c - Glass d - O-Ring e - Strainer f - Housing g - Drain Plug And Sealing Washer h - Gasket 3. Flush the components with clean water.

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SERVICE MANUAL NUMBER 31

Installation
IMPORTANT: Mount the seawater strainer in a vibration-free location. Never mount it on the engine or the transmission. Hoses must not be kinked or allowed to come in contact with hot or moving engine or transmission parts. 1. Mount the seawater strainer. The arrow indicates the required water flow direction and must point toward the seawater pump. Tighten the mounting bolts securely.

a c c
72644

a - Seawater Strainer b - Arrow c - Mounting Bolt Hole Location (Bolts Not Shown) 2. Remove the plug from the seawater inlet hose (if installed previously) and install the hose on the strainer. Install the seawater outlet hose. Use two hose clamps on each hose connection. Tighten the clamps securely.

a
72645

a - Seawater Inlet Hose b - Seawater Outlet Hose c - Double Hose Clamps 3. Check the drain plug and the lens cover bolts. Tighten securely. Do not overtighten the cover bolts or the cover may warp and leak water into the boat.

a
72644

a - Drain Plug b - Lens Cover Bolts (2, One Not Shown In This View) 4. Open the seacock, if equipped.

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ALL MODELS

Auxiliary Hot Water Heater Installation

IMPORTANT: When connecting a cabin heater or a hot water heater, certain requirements must be met: The supply hose (from the engine to the heater) and the return hose (from the heater to the engine) MUST NOT EXCEED 16 mm (5/8 in.) I.D. (inside diameter). Make the heater connections ONLY at the locations described in the following instructions. Check the complete system for leaks after the heater is connected into the cooling system. Check for overheating condition (of the engine) after the heater is connected.

Supply Hose Connection

NOTE: Some models may be equipped with additional fittings.

a a

77816

77815

Seawater Cooled Models

Closed Cooled Models

77933

a
All Models a - Location For Hot Water Supply

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SERVICE MANUAL NUMBER 31

Return Hose Connection

a
77954

a - Location For Hot Water Return

Seawater Pump
Output Test
If an overheating problem exists, use this test to determine if a sufficient amount of water is being supplied to cool the engine. IMPORTANT: The following information should be observed before proceeding with the test: THE BOAT MUST BE IN THE WATER FOR THIS TEST. This test CANNOT BE performed with a flush-test device and water hose. The ability of this test to detect a problem is greatly dependent upon the accuracy with which it is performed. An error in setting the engine rpm, timing the test or measuring the water output will affect the overall accuracy of the test and may produce misleading results. To help ensure accurate results, a shop tachometer with an error of less than 5 percent should be used. The boat tachometer definitely should not be used as its accuracy is questionable. A stop watch should be used to time the duration of the test to help ensure that the accuracy is maintained within one second. An 7.6 Liter (8 U.S. qt.) or larger capacity container should be used to measure the water output. Due to the manner in which this test is performed, it may not be possible to detect a marginal condition or a high-speed water pump output problem.

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1. Models With Engine Mounted Seawater Pump - remove the water hose that is between the pump outlet and the engine, and replace with another hose of the same diameter, but approximately 1 m (3 ft.) longer. The hose should be of adequate wall thickness to prevent it from kinking when performing the test. Clamp the hose at the pump outlet only. Do not clamp the hose at the cooler end.

77908

a - Seawater Inlet Hose b - Seawater Outlet Hose To Cooler 2. Models With Sterndrive (Alpha) Mounted Seawater Pump - remove the water inlet hose, which is between the gimbal housing water tube and the engine, and replace with another hose of the same diameter, but approximately 1 m (3 ft.) longer. The hose should be of adequate wall thickness to prevent it from kinking when performing the test. Clamp the hose at the gimbal housing water tube only. Do not clamp the hose at the engine end.

b a
a - Water Tube b - Hose Clamp c - Water Hose
72614

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3. Place an 7.6 Liter (8 U.S. qt.) or larger container near the unclamped end of the hose. 4. With the assistance of another person, start the engine and adjust the speed to exactly 1000 rpm while holding the unclamped end of the hose on the connection on the engine. Remove the hose from the connection on the engine and direct the water flow into the container for exactly 15 seconds. At the end of 15 seconds, direct the water flow overboard, return the engine to idle and stop the engine. Reconnect the hose to the engine. 5. Measure the quantity of water discharged into the container and compare with the specifications given in the following chart. 6. Repeat the test four times to check the repeatability of the results. Engine Mounted Seawater Pump Output For A 15 Second Period 7.1 Liter (7.5 U.S. Qt.) Minimum

Alpha Sterndrive Seawater Pump Output For A 15 Second Period Drive Unit Gear Ratio 1.98:1 1.84:1 1.65:1 1.50:1 1.32:1 Minimum Quantity Liter (U.S. Qts.) 2.8 (3.0) 3.1 (3.3) 3.4 (3.6) 3.8 (4.0) 4.3 (4.5)

NOTE: Refer to the Alpha Sterndrive Service Manual for repair of the seawater pump.

Removal
1. Drain the seawater section of the cooling system. 2. Remove both of the hoses from the aft side of the seawater pump. 3. Remove the serpentine belt. 4. Remove the two bolts attaching the seawater pump and bracket to the engine.

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Disassembly
1. Press off the pulley. 2. Remove the six bolts from the rear of the seawater pump. 3. Remove and discard the O-ring. 4. Remove the impeller. 5. Remove the retainer/seal from the front of the seawater pump. 6. Remove the retainer ring. 7. From the impeller side, press the bearing shaft out of the housing. 8. Remove the rear oil seal from the housing.

b d a c e g i
78136

f h

a b c d e f g h i

- Seawater Pump Backplate - O-ring - Impeller - Seawater Pump Bearing Housing - Rear Oil Seal - Bearing Shaft Assembly - Tolerance Ring - Retainer/Seal - Pulley

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Cleaning and Inspection

1. Clean the metal parts in solvent and blow dry with compressed air. IMPORTANT: Do not spin the bearings at high speed when drying with compressed air, as the bearings may be scored. 2. After cleaning, lightly coat the shaft and the bearings to prevent rust. Description Engine Oil Where Used Seawater pump bearing shaft Part Number Obtain Locally

3. Clean all gasket material and sealer from the sealing surfaces. 4. Inspect the bearing housing. Examine the surfaces (where the bearings contact the housing) for evidence of the bearing outer races turning in the housing. 5. Inspect the seals in the bearing housing. 6. Inspect the pump body. 7. Inspect the pump impeller for wear on the sides and the tips of the blades. Also inspect the blades for cracks in the area where the blades flex. Replace the impeller if the blades have taken a set (remain in curved position). 8. Inspect the pump pulley. 9. Inspect the serpentine drive belt for excessive wear.

Reassembly
1. Place the rear oil seal into the bearing shaft housing with the side with the spring towards the main pump body. 2. Lubricate the bearing shaft assembly. Description Engine Oil Where Used Seawater pump bearing shaft Part Number Obtain Locally

a b c

78137

a - Seawater Pump Bearing Housing b - Rear Oil Seal c - Bearing Shaft Assembly 3. Install the bearing shaft assembly into the housing.

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4. Install the tolerance ring.

a
78138

a - Tolerance Ring 5. Apply adhesive to the retainer/seal outer edges. Do NOT apply adhesive to the seal portion of the retainer. 6. Place retainer / seal on the shaft and press it into place.

78139

a - Retainer/Seal Description Loctite 609 7. Wipe away excess adhesive. 8. Lubricate the impeller with soapy water. Where Used Seawater pump retainer/seal Part Number Obtain Locally

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SERVICE MANUAL NUMBER 31

9. Install the impeller into the pump body.

71118

71150

a - Impeller 10. Install the O-ring into the groove on the pump body.

78140

a - O-ring Groove 11. Align pump body with the back plate.

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ALL MODELS

12. Install the bolts and torque.

78141

a - Seawater Pump Bolts Description Bolt, Seawater Pump Nm 9.9 lb-in. 88 lb-ft

Installation
1. Fasten the seawater pump and bracket to the engine. Torque the bolts. Description Bolt, Seawater Pump Bracket-To-Engine Nm 41 lb-in. lb-ft 30

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SERVICE MANUAL NUMBER 31

Installation
1. Coat both sides of the new circulating pump gaskets and the threads of the attaching fasteners with sealant. Description Perfect Seal Where Used Water Circulating Pump Gaskets And Fasteners Part Number 92-34227-1

2. Install new water pump gaskets to cylinder block. 3. Install water pump. Torque bolts.

b a

c
a - Water Circulating Pump b - Gaskets c - Fasteners Description Fastener, Water Pump Nm 48 lb-in. lb-ft 35

4. Install water pump pulley to the water pump. Tighten the bolts securely. 5. Reconnect the hoses to the water pump. 6. Install the serpentine drive belt and adjust belt tension. 7. Fill closed cooling system, if equipped. 8. Supply cooling water to the engine. 9. Start the engine and check for leaks.

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ALL MODELS

Water Distribution Housing

Removal
1. Drain the seawater section of the cooling system. 2. Disconnect the hoses from the water distribution housing. 3. Remove the bolt and nut attaching the water distribution housing and bracket to the engine. 4. Remove the bracket from the the water distribution housing.

78100

a - Water Distribution Housing b - Bracket

Cleaning And Inspection

1. Clean the water distribution housing with water and dry with a clean cloth or compressed air. 2. Inspect the housing for leaks, cracks or corrosion damage. Replace, if necessary.

Installation
1. Align the water distribution housing with the bracket. 2. Attach the housing to the bracket. Torque the screws. Description Screws, Water Distribution Housing-To-Bracket Nm 13.5 lb-in. 120 lb-ft

3. Install the bracket and water distribution housing onto the engine. Finger-tighten the bolt and nut.

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SERVICE MANUAL NUMBER 31

4. On Manual Single Point Drain only: a. Install the drain rod into the water distribution housing. b. Ensure the that the rod is correctly aligned. The rod must screw in and out of the water distribution housing easily and with little pressure.

b a
a - Water Distribution Housing b - Drain Rod c - Drain Rod Handle 5. Torque the bolt and nut attaching the bracket to the engine. Description Fasteners, Water Distribution Housing Bracket Nm 38 lb-in.

77932

lb-ft 28

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SEAWATER COOLED MODELS

COOLING SYSTEM
Section 6B - Seawater Cooled Models

Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Seawater Cooling System Capacity . Thermostat . . . . . . . . . . . . . . . . . . . . . . Flushing Seawater Cooling System . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 6B-2 6B-2 6B-2 6B-2 6B-2 6B-3 6B-3 6B-3 6B-4 6B-5 Water Tap Location For Shaft Log Seal . Water Flow Diagrams . . . . . . . . . . . . . . . . Seawater Cooled Models With An Engine Mounted Seawater Pump Seawater Cooled Models Without An Engine Mounted Seawater Pump 6B-6 6B-7 6B-7 6B-8

6
B

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Page 6B-1

SEAWATER COOLED MODELS

SERVICE MANUAL NUMBER 31

Torque Specifications
Description Screws, Thermostat Housing Nm 41 lb-in. lb-ft 30

Lubricants / Sealants / Adhesives

Description Perfect Seal Where Used Thermostat housing gasket Part Number 92-34227-1

Specifications
Seawater Cooling System Capacity
Engine All Liter (U.S. Quart) 20 (21)

Thermostat
Engine All Specification 71 Degrees C (160 Degrees F)

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SEAWATER COOLED MODELS

Flushing Seawater Cooling System

Refer to Section 1B - Maintenance

Thermostat
Removal
1. Drain the water from the engine. 2. Remove the hoses from the thermostat housing. 3. Remove the thermostat housing assembly. 4. Remove the thermostat from the thermostat housing or the cover.

b c

d e
77816

a b c d e

- Housing - O-ring - Thermostat (Stainless Steel) - Spacer - Gasket

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SEAWATER COOLED MODELS

SERVICE MANUAL NUMBER 31

Testing
1. Remove the thermostat. 2. Place the thermostat on blocks in a container. 3. Completely submerge the thermostat in water. 4. Heat the water. 5. Stir the water constantly to avoid direct heat being applied to the thermostat. 6. Refer to Specifications: a. Check the thermostat initial opening temperature. b. Check the thermostat full opening temperature. c. Check valve lift at fully open position.

b d

c
77724

a b c d

- Thermometer - Agitating Rod - Wooden Blocks - Thermostat

7. Replace if specifications are not met or damage is discovered during inspection.

Page 6B-4

90-864260 OCTOBER 2001

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SEAWATER COOLED MODELS

Installation
1. Clean the gasket surfaces on the thermostat housing and the intake manifold. IMPORTANT: The gasket has continuity rivets. Do not coat with Perfect Seal or the Audio Warning Temperature Switch may not work properly. 2. Place the O-ring in the thermostat housing. Be certain it is positioned properly in the housing. 3. Place the thermostat in the thermostat housing with the thermostatic element end toward the housing bottom. 4. Align the sleeve with the groove in the thermostat housing bore and install the sleeve into the housing. 5. Coat both sides of the new thermostat housing gasket with sealant and position on the intake manifold. Description Perfect Seal Where Used Thermostat housing gasket Part Number 92-34227-1

6. Reinstall the thermostat housing and torque the screws . Description Screws, Thermostat Housing Nm 41 lb-in. lb-ft 30

7. Reconnect the hoses to the thermostat housing. Tighten the hose clamps securely. 8. Start the engine and inspect for leaks.

b c

d e
77816

a b c d e

- Housing - O-Ring - Thermostat, Stainless Steel - Spacer - Gasket

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SEAWATER COOLED MODELS

SERVICE MANUAL NUMBER 31

Water Tap Location For Shaft Log Seal

IMPORTANT: Tapping into the wrong location can cause the engine to vapor lock or operate too cold. MIE (Inboard) Models Only: 1. Using a T-fitting, splice into the port exhaust manifold water hose, as shown in the water flow diagrams. 2. Fasten with hose clamps. Tighten securely. This provides the temperatures and the pressures required to cool the packing glands without damaging them.

a d b

76254

a b c d

- Thermostat Housing - Shaft Log Seal - Exhaust Elbow - T-fitting

Page 6B-6

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SEAWATER COOLED MODELS

Water Flow Diagrams

Seawater Cooled Models With An Engine Mounted Seawater Pump
a

b i

h e

j d g

f
a b c d e f g h i j - Exhaust Elbow - Exhaust Manifold - Seawater Pump - Water Circulating Pump - Thermostat Housing - Water Distribution Housing - Cool Fuel Box - Check Valve - Power Steering Cooler - Shaft Log Seal Connection Point

77929

90-864260 OCTOBER 2001

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SEAWATER COOLED MODELS

SERVICE MANUAL NUMBER 31

Seawater Cooled Models Without An Engine Mounted Seawater Pump

g d

e
a b c d e f g h - Exhaust Elbow - Exhaust Manifold - Water Circulating Pump - Thermostat Housing - Water Distribution Housing - Cool Fuel Box - Check Valve - Power Steering Cooler

77931

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90-864260 OCTOBER 2001

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CLOSED COOLED MODELS

COOLING SYSTEM
Section 6C - Closed Cooled Models

Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Closed Cooling System Capacity . . . . . Coolant Specification . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . Pressure Cap Rating . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Recommendations . . . . . . . . . . . Maintaining Coolant Level . . . . . . . . . . . . Pressure Cap Maintenance . . . . . . . . . . . Testing Closed Cooling System . . . . . . . Testing Coolant for Alkalinity . . . . . . . . . Pressure Testing System . . . . . . . . . . . . Testing for Cylinder Head Gasket Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Pressure Cap . . . . . . . . . . . . . . . 6C-2 6C-2 6C-2 6C-2 6C-2 6C-2 6C-2 6C-3 6C-3 6C-4 6C-5 6C-6 6C-6 6C-7 6C-9 6C-10 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . Heat Exchanger . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . Cleaning And Inspection . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . Heat Exchanger Bracket Hardware . . . . Heat Exchanger Hose Connections . . . . Water Tap Location For Shaft Log Seal . Closed Cooling System Water Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-12 6C-12 6C-12 6C-14 6C-15 6C-15 6C-15 6C-16 6C-16 6C-16 6C-17 6C-18 6C-19 6C-20 6C-21 6C-22

6
C

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SERVICE MANUAL NUMBER 31

Torque Specifications
Description Heat Exchanger End Cap Thermostat Cover Hose Clamps Drain Plugs Nm 6 41 Securely lb-in. 54 30 lb-ft

Lubricants / Sealants / Adhesives

Description Extended Life Coolant/Antifreeze Perfect Seal Where Used Closed Cooling System Heat Exchanger End Cap Gaskets Part Number 92-877770K1 92-34227-1

Specifications
Closed Cooling System Capacity
NOTE: All capacities are approximate fluid measures. Model Seawater Cooling System Closed Cooling System Liters (U.S. Qts) 20 (21) 19 (20)

Coolant Specification
Closed Cooled Models Extended Life Coolant 5/100 (Orange Color)

Thermostat
Engine All Engines Specifications 71 Degrees C (160 Degrees F)

Pressure Cap Rating

WARNING
Allow the engine to cool before removing the pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. After the engine has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off. 1. Remove the pressure cap from the heat exchanger. 2. Wash the cap with clean water to remove any deposits or debris from the sealing surfaces. 3. Inspect the rubber seal on the cap for cuts, cracks or other signs of deterioration. If the seal is damaged, the cap MUST be replaced. 4. Inspect the coolant recovery gasket for deterioration and replace if bad. 5. Check the condition of the locking tabs on the cap. Replace the cap if the tabs are bent or cracked. 6. Check the gasket for cracks or other damage. IMPORTANT: The cap MUST be replaced if damaged.

a b

72714

a - Rubber Seal b - Gasket c - Locking Tabs (1 Not Shown)

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CLOSED COOLED MODELS

SERVICE MANUAL NUMBER 31

7. Test the pressure cap. 8. Clean the sealing surfaces on the heat exchanger filler neck with a cloth. Inspect the surfaces for any damage or deposits that may prevent the cap from sealing properly. 9. Clean the coolant recovery passage in the heat exchanger filler neck with a wire and blow out with compressed air.

b
72715

a - Sealing Surfaces b - Coolant Recovery Passages 10. Reinstall the pressure cap. Tighten the cap until it contacts the filler neck.

Testing Closed Cooling System

Testing Coolant for Alkalinity

A leaking head gasket will cause combustion gas to be forced into the cooling system. The mixture of coolant and tiny air bubbles is a poor heat conductor and will overheat an engine quickly. Compression tests or cooling system pressure check normally will not detect the leak because the test pressure is far below the combustion pressures that cause the leak. An effective test is as follows: IMPORTANT: Operate the boat in the water for this test. It is best to operate the engine at or above cruising speed during this test. Usually a failed head gasket will not cause the engine to overheat below cruising speed. 1. Install a clear plastic hose between the reservoir and the coolant recovery bottle. Use a 610-910 mm (2-3 ft) long hose for this test. 2. Route this hose so a U is formed. 3. Put enough coolant into the hose to fill the center 100-130 mm (4-5 in.) of the U-shape. 4. Observe the U-shape while the engine is operating. a. During Idle and Warm-Up: Some coolant and/or air will leave the reservoir. b. During Cruising Speed (2500-3500 rpm): Coolant and/or air leaving the reservoir should stop after approximately five minutes operating at a given rpm. A leaking head gasket will produce air bubbling through the U-shape, going to the coolant recovery bottle. The frequency and size of the bubbles will depend on the size of the leak. c. At Higher Speeds (4000+ rpm): Normal operation is the same as described above. A failed head gasket will cause the bubbles to come faster and may be accompanied by violent, intermittent bursts of coolant. Do not confuse normal warm-up expansion with a failed head gasket. Normal warm-up produces an intermittent flow of coolant that will stop within approximately five minutes at a given rpm. A head gasket leak will not stop because the one thing that marks a failed head gasket is the continued passage of air. This may be accompanied by violent, intermittent bursts of coolant leaving the reservoir. If coolant flows evenly from the reservoir at cruising speed, something other than the head gasket is causing the engine to overheat.

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SERVICE MANUAL NUMBER 31

Testing Pressure Cap

The pressure cap is designed to maintain a pressure of approximately its rated capacity once the engine has attained operating temperature. The cap should be cleaned, inspected and pressure-tested at regular intervals or whenever the cap is suspected of maintaining improper pressure.

WARNING
Allow the engine to cool before removing the pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. After the engine has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off. 1. Carefully remove the pressure cap from the reservoir or the heat exchanger. 2. Wash the cap with clean water to remove any deposits or debris from the sealing surfaces. 3. 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. 4. Replace the cap if the rubber seal is damaged. 5. Check the condition of the locking tabs on the cap. Replace the cap if the tabs are bent or cracked. IMPORTANT: The cap MUST be replaced if damaged.

a b

72714

a - Rubber Seal b - Gasket c - Locking Tabs (1 not shown)

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CLOSED COOLED MODELS

6. Using a cooling system pressure tester (similar to one shown), test the cap to ensure that it releases at the proper pressure and does not leak. (Refer to the instructions which accompany the tester for the correct test procedure.) The cap must relieve pressure at 110 kPa (16 psi), and must hold the rated pressure for 30 seconds without going below 75.8 kPa (11 psi). Replace the cap if it fails to fall within these limits.

72716

IMPORTANT: Before reinstalling the cap in the next step, examine the lower inside sealing surface in the filler neck to ensure that it is perfectly smooth and free of debris. Also, inspect the cam lock flanges on the sides of the filler neck to ensure that they are not bent.

b
72715

a - Sealing Surfaces b - Coolant Recovery Passages 7. Reinstall the cap on the reservoir or the heat exchanger.

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CLOSED COOLED MODELS

SERVICE MANUAL NUMBER 31

Thermostat
Removal
NOTE: If the coolant flow is restricted or fails to occur, a wire should be repeatedly inserted into all drain holes to ensure that there are no obstructions in the passages. Remove the fitting, if necessary, to insert the wire completely into the drain hole. 1. Drain the engine. 2. Disconnect the hoses from the thermostat cover. 3. Remove the thermostat cover attaching bolts and the lockwashers, then remove the cover and the gasket. 4. Remove the thermostat from the thermostat housing.

b d a c

78148

a b c d

- Thermostat Housing - Thermostat - Gasket - Thermostat Housing Cover

Page 6C-12

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CLOSED COOLED MODELS

b d

c
77724

a b c d

- Thermometer - Agitating Rod - Wooden Blocks - Thermostat

7. Replace if specifications are not met or damage is discovered during inspection.

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CLOSED COOLED MODELS

SERVICE MANUAL NUMBER 31

Installation

CAUTION
Avoid seawater pickup pump impeller damage. DO NOT operate the engine without cooling water being supplied to the seawater pickup pump. 1. Remove the thermostat housing and the gaskets. Discard the gaskets. 2. Clean the gasket surfaces on the thermostat cover, the thermostat housing and the intake manifold. 3. Position the gasket on the intake manifold. Place the thermostat housing on the gasket. IMPORTANT: If the gasket has continuity rivets, do NOT coat with Perfect Seal, or the audio warning temperature switch may not work properly. 4. Install the thermostat into the thermostat housing. 5. Position the gasket on the thermostat and reinstall the thermostat cover. Torque the bolts.

b d a c

78148

a b c d

- Thermostat Housing - Thermostat - Gasket - Thermostat Housing Cover Nm 41 lb-in. lb-ft 30

Description Bolt, Thermostat Cover

6. Connect the hoses to the thermostat cover. Tighten the hose clamps securely. 7. Supply cooling water start the engine and inspect for leaks.

Page 6C-14

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CLOSED COOLED MODELS

Heat Exchanger
Testing
INTERNAL LEAKS
An internal leak will cause coolant to go into the seawater circuit when pressure is put on the closed cooling circuit. 1. Remove a seawater hose from the exchanger. Do not drain the exchanger. 2. Pressurize the closed cooling circuit to 110-138 kPa (16-20 psi) with a radiator tester. 3. If seawater begins to flow from the seawater hose fitting, there is a leak.

FOR BLOCKAGE
IMPORTANT: Seawater flows THROUGH the tubes in the exchanger. Closed cooling coolant flows AROUND the tubes. 1. Remove the end caps and inspect for any blockage in the seawater circuit (broken impeller blades, weeds, etc.). 2. Remove the closed cooling circuit hoses and inspect the tubes just inside the nipples. Because the complete exchanger cannot be inspected, the heat exchanger should be replaced if blockage is suspected.

Removal
1. Allow engine to cool. 2. Drain the seawater and closed cooling systems. 3. Remove the hoses from the heat exchanger. 4. Remove the air manifold hoses from the air actuator by pushing in on the bottom of the manifold and pulling the hoses out.

e d

f c

b a
78148

a - Heat Exchanger b - Air Manifold c - Bolts d - Air pump Bracket e - Air pump f - Screws 5. Remove the 2 large hose clamps fastening the heat exchanger to the engine. 6. Remove the heat exchanger.

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CLOSED COOLED MODELS

SERVICE MANUAL NUMBER 31

Disassembly
1. Remove the air pump from the air pump bracket. 2. Remove the air pump bracket. 3. Remove the air manifold. 4. Remove the screws attaching the end plates to the heat exchanger.

c
71515

d
a - Heat Exchanger b - Sealing Washer c - End Cap d - Gasket 5. Remove the end plates and gaskets.

Cleaning And Inspection

1. Clean old gasket material and sealant from surfaces. Do not nick or gouge the surfaces. 2. Use a long rod to clean out heat exchanger tubes. 3. Inspect each part for cracks or other damage. Replace as necessary. 4. Clean and paint exterior surfaces as required to prevent corrosion.

Repair
IMPORTANT: Braze with BCUP 2 rod or silver solder. Care must be taken not to melt the other joints during repair. 1. Internal leaks can be repaired by brazing shut the ends of the leaking tube. This is only a temporary fix because usually another tube will start leaking after a short period of time and this also causes a reduction in the cooling capacity. Do not close more than three tubes. 2. Fittings and drains that have been broken off the heat exchanger can be reattached by brazing.

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CLOSED COOLED MODELS

Assembly
1. Apply sealant to both sides of new end plate gaskets. Description Perfect Seal Where Used Heat Exchanger End Cap Gaskets Part Number 92-34227-1

2. Install new gaskets, new sealing washers and end plates onto heat exchanger. Torque the end plate screws.

a b c
71515

d
a - Heat Exchanger b - Sealing Washer c - End Cap d - Gasket Description Heat Exchanger End Cap Nm 6 lb-in. 54 lb-ft

3. Fasten the air pump bracket to the heat exchanger. Tighten the screws securely. 4. Fasten the air manifold to the heat exchanger. Tighten the bolts securely.

e d

Heat Exchanger Hose Connections

a b f e c d g

77954

Typical Engine Shown a - Heat Exchanger b - Starboard Heat Exchanger-To-Exhaust Manifold Hose c - Water Circulating Pump Hose d - Port Heat Exchanger-To-Exhaust Manifold Hose (MCM) e - Cool Fuel System-To-Heat Exchanger Hose f - Heat Exchanger Bypass Hose g - Coolant Identification Decal h - Thermostat Housing-To-Heat Exchanger Hose (Not Visible)

Page 6C-20

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SERVICE MANUAL NUMBER 31

CLOSED COOLED MODELS

Water Tap Location For Shaft Log Seal

a d b

76254

a b c d

- Thermostat Housing - Shaft Log Seal - Port Exhaust manifold - T-fitting

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CLOSED COOLED MODELS

SERVICE MANUAL NUMBER 31

Closed Cooling System Water Flow Diagram

Closed Cooled Models
a k l b j

f d

h e

m g
77928

a - Exhaust Elbow b - Exhaust Manifold c - Seawater Pump d - Heat Exchanger e - Water Circulating Pump f - Thermostat Housing g - Water Distribution Housing h - Cool Fuel Box i - Check Valve j - Power Steering Cooler k - Flush Fitting (Inboard Models) l - Flush Connection (Inboard Models) m - Shaft Log Seal Connection Point

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CLOSED COOLED MODELS

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CLOSED COOLED MODELS

SERVICE MANUAL NUMBER 31

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MANIFOLDS, ELBOWS AND RISERS

EXHAUST SYSTEMS
Section 7A - Manifolds, Elbows And Risers

Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Exploded View . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2 7A-2 7A-3 7A-4 Cleaning and Inspection . . . . . . . . . . . . . . . . 7A-5 Manifold Leak Test . . . . . . . . . . . . . . . . . . . . 7A-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-6

7
A

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MANIFOLDS, ELBOWS AND RISERS

SERVICE MANUAL NUMBER 31

Torque Specifications
NOTE: Securely tighten all fasteners not listed below. Description Bolt, Exhaust Elbow To Exhaust Manifold Bolt, Exhaust Manifold To Cylinder Head Bolt, 6 Inch Riser To Exhaust Manifold Nm 45 34 45 lb-in. lb-ft 33 25 33

Lubricants / Sealants / Adhesives

Description Perfect Seal Where Used Exhaust Manifold And Elbow Plugs Part Number 92-34227-1

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MANIFOLDS, ELBOWS AND RISERS

Exploded View
11 9

9 14 4

6 7 12 10 13 2 5

8 No Riser 3 Inch Riser 1 - Exhaust Manifold 2 - Restrictor Gasket 3 - Exhaust Elbow 4 - 3 Inch Riser 5 - 6 Inch Riser 6 - Open Gasket 7 - Plug 8 - Bolt And Washer, Manifold-To-Cylinder Head 9 - Bolt, Exhaust Elbow-To-Exhaust Manifold 10 - Stud 11 - Nut And Washer, Exhaust Elbow-To-3 Inch Riser 12 - Bolt, 6 Inch Riser-To-Exhaust Manifold 13 - Hose Fitting 14 - Pipe Plug 6 Inch Riser

90-864260 OCTOBER 2001

77832

Page 7A-3

MANIFOLDS, ELBOWS AND RISERS

SERVICE MANUAL NUMBER 31

Removal
WARNING
Avoid possible injury or damage to equipment should wires be accidentally shorted. Disconnect BOTH battery cables from the battery before proceeding. 1. Disconnect both battery cables from the battery.

CAUTION
To avoid severe engine damage, exhaust elbows and manifolds MUST BE drained to prevent water from entering the combustion chambers when the exhaust elbows are removed. 2. Drain the seawater section of the engine. Refer to SECTION 1B. 3. Disconnect the exhaust hoses and the cooling hoses from the exhaust manifold and elbow. 4. MCM only - Remove the shift plate. 5. Remove the ECM and the ECM bracket. 6. Remove any other components that are mounted to the manifold, the elbow and the riser. 7. Remove the elbow and the riser. 8. Remove the exhaust manifold and discard the gaskets.

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MANIFOLDS, ELBOWS AND RISERS

Cleaning And Inspection

1. Clean the gasket material from all surfaces and wash the parts in solvent. 2. Inspect the water passages for foreign material. The passages must be clean for efficient cooling. NOTE: If more thorough inspection is desired, the pipe plugs may be removed from the exhaust manifold and the exhaust elbow. IMPORTANT: If the pipe plugs are removed, coat the threads with sealant before reinstalling. Description Perfect Seal 3. Inspect for cracks. 4. Inspect all parts carefully. Machined surfaces must be clean and free of all marks and deep scratches or water and exhaust leaks may result. 5. Inspect for damaged metal caused by saltwater or exhaust gas corrosion in the manifold, elbow and riser. 6. Measure the surface flatness of all gasket surfaces on the manifold, elbow and riser. Where Used Exhaust Manifold And Elbow Plugs Part Number 92-34227-1

77836

a - Gasket Surfaces Description Surface Flatness Maximum overall difference Difference within 25 mm (1 in.) mm (in.) 0.07 (0.003) 0.02 (0.001)

NOTE: The maximum material that can be removed is 0.25 mm (0.010 in.). When torquing the attaching bolts, ensure that they are not contacting the bottom of the threaded hole in the manifold. 7. Replace all damaged components.

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MANIFOLDS, ELBOWS AND RISERS

SERVICE MANUAL NUMBER 31

Manifold Leak Test

NOTE: One block-off plate must have an attachment for a compressed air hose. 1. Using suitable block-off plates, plugs and new gaskets, seal the manifold openings. 2. Attach an air hose to the block-off plate. 3. Apply 276 kPa (40 psi) of air pressure and submerge the manifold in water. 4. Air bubbles will indicate a leak. Repair or replace, if necessary.

Installation
1. Using a new gasket, install the exhaust manifold, elbow and riser to the cylinder head. 2. Torque the bolts. Description Bolt, Exhaust Elbow To Exhaust Manifold Bolt, Exhaust Manifold To Cylinder Head Bolt, 6 Inch Riser To Exhaust Manifold 3. Starboard Exhaust Elbow: MCM only. a. Install the drop-down shift plate bracket, if equipped. b. Install the shift plate assembly to the elbow. c. Tighten securely. Nm 45 34 45 lb-in. lb-ft 33 25 33

c
a - Shift Plate b - Exhaust Elbow c - Bolts

a
77825

Page 7A-6

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SERVICE MANUAL NUMBER 31

MANIFOLDS, ELBOWS AND RISERS

4. Port Exhaust Elbow: All engines. a. Install the ECM drop-down bracket, if equipped. b. Install the ECM bracket and the ECM to the exhaust elbow. c. Tighten securely.

b a
77825

a - ECM b - ECM Bracket c - Exhaust Elbow 5. Install the exhaust hoses and the cooling hoses. 6. Tighten hose clamps securely. 7. Install any additional components removed during disassembly. 8. Reconnect the battery cables to the battery. Tighten securely.

CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation. 9. Supply cooling water to the engine. 10. Start the engine and check for exhaust and water leaks.

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MANIFOLDS, ELBOWS AND RISERS

SERVICE MANUAL NUMBER 31

THIS PAGE IS INTENTIONALLY BLANK

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SERVICE MANUAL NUMBER 31

COLLECTORS

EXHAUST SYSTEM
Section 7B - Collectors

Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Important Information . . . . . . . . . . . . . . . . . . Exhaust Y -Pipe . . . . . . . . . . . . . . . . . . . . . . . Water Shutter . . . . . . . . . . . . . . . . . . . . . . Through Transom Exhaust . . . . . . . . . . . . . Water Shutter . . . . . . . . . . . . . . . . . . . . . . Below Swim Platform Exhaust Pipe . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning And Inspection . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Silent Choice Exhaust System . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 7B-2 7B-3 7B-4 7B-4 7B-6 7B-6 7B-8 7B-8 7B-8 7B-8 7B-9 7B-9 Cleaning and Inspection . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . Air Tube Routing . . . . . . . . . . . . . . . . . . Air Pump Maintenance . . . . . . . . . . . . . Troubleshooting Silent Choice Exhaust Silencer System . . . . . . . . . . . Exhaust Muffler Kit . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . 7B-10 7B-11 7B-12 7B-13 7B-14 7B-15 7B-15 7B-15 7B-16 7B-17

7
B

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Page 7B-1

COLLECTORS

SERVICE MANUAL NUMBER 31

Torque Specifications
Description Nuts, Exhaust Elbow Nm 30.5 lb-in. lb-ft 23

Lubricants / Sealants / Adhesives

Description Where Used Part Number

2-4-C Marine Lubricant With Teflon Sound Blanket Glue

Air Cylinder To Silencer Pipe Flapper At Clevis And Pin Air Pump Intake Filter, Exhaust Muffler O-ring Seal

92-825407A3 92-25234

Page 7B-2

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SERVICE MANUAL NUMBER 31

COLLECTORS

Important Information
To replace any components in the exhaust system, the following must be adhered to: All mating surfaces must be clean. The O-ring must remain in the groove to properly seal the joints to prevent leak. Tighten all clamps securely.

b
72736

a - Mating Surface b - O-ring IMPORTANT: Each exhaust hose connection must be double clamped at each connection. Tighten hose clamps securely.

a b

a a c d e f

72737

a - Clamps b - Exhaust Pipe Elbow c - Exhaust Hose

d - Water Shutters e - Bolts And Lockwashers f - Exhaust Pipe

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Page 7B-3

COLLECTORS

SERVICE MANUAL NUMBER 31

Exhaust Y -Pipe
Water Shutter
REMOVAL
IMPORTANT: The engine does not have to be removed to change the shutters. 1. Loosen the hose clamps. 2. Remove the exhaust elbow and exhaust hose. 3. Remove and discard the old water shutter.

a b

a a c d e f

72737

a - Clamps b - Exhaust Pipe Elbow c - Exhaust Hose

d - Water Shutters e - Bolts And Lockwashers f - Exhaust Pipe

Page 7B-4

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

COLLECTORS

INSTALLATION
IMPORTANT: Each exhaust hose connection must be double clamped at each connection. Tighten the hose clamps securely. 1. Install the new water shutter, ensuring that the shutter is seated in the rubber grommets.

75760

a - Water Shutter b - Rubber Grommets 2. Install the exhaust elbow and exhaust hose. Tighten the clamps securely. 3. Start the engine and check for leaks.

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Page 7B-5

COLLECTORS

SERVICE MANUAL NUMBER 31

Through The Transom Exhaust

Water Shutter
REMOVAL
IMPORTANT: The engine does not have to be removed to change the shutters. 1. Remove the exhaust hose clamps and the exhaust hose. 2. Chisel the rivets away from both support members.

c d

d c
a b c d - Shutter Hinge - Water Shutter - Support Member - Rivets (4)

27761

3. Remove and discard the old water shutter.

Page 7B-6

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

COLLECTORS

INSTALLATION
1. Using screws and nuts, install the support members. Ensure that the water shutter hinge will be vertical.

d e g h

f
Transom Exhaust Kit a b c d - Screw And Nut (4) - Support Member - Water Shutter - Gasket e f g h - Exhaust Flange - Bolt, Washer And Nut (3) - Clamp - Cover (Flapper)

72740

2. Tighten the screws and the nuts securely. 3. Install the water shutter. IMPORTANT: Each exhaust hose connection must be double clamped at each connection. Tighten the hose clamps securely. 4. Install the exhaust hoses and hose clamps. Tighten the hose clamps securely.

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Page 7B-7

COLLECTORS

SERVICE MANUAL NUMBER 31

Below Swim Platform Exhaust Pipe

Removal
1. Drain the sea water section of the engine. 2. Loosen the hose clamps from the exhaust pipe. 3. Remove the exhaust pipe.

a
72742

a - Exhaust Pipe b - Hose Clamps

Cleaning And Inspection

1. Check the water passages for foreign material. The passages must be clean for efficient cooling. 2. Inspect the exhaust pipe for deep scratches, cuts and cracks. 3. Inspect for damaged metal caused by salt water or exhaust gas corrosion. 4. Inspect for unpainted surfaces. Repaint as needed. 5. Replace all damaged components.

Installation
1. Install the exhaust pipe to the exhaust tubes and hoses. IMPORTANT: Each exhaust hose connection must be double clamped at each connection. Tighten hose clamps securely. 2. Secure with two hose clamps at each connection. 3. Tighten hose clamps securely. 4. Start the engine and check for exhaust and water leaks.

Page 7B-8

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COLLECTORS

Silent Choice Exhaust System

Removal
1. Drain the seawater section of the cooling system. 2. Disconnect the air tube to the silencer valve assembly. 3. Loosen the hose clamps from the silencer valve assembly.

72539

a - Silencer Valve Assembly b - Hose Clamps 4. Remove the silencer valve assembly.

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Page 7B-9

COLLECTORS

SERVICE MANUAL NUMBER 31

Cleaning and Inspection

1. Inspect the water passages for foreign material. The passages must be clean for efficient cooling. 2. Inspect for cracks. 3. Inspect all parts carefully. Machined surfaces must be clean and free of all marks and deep scratches or water and exhaust leaks may result. 4. Inspect for damaged metal caused by salt water or exhaust gas corrosion in the silencer valve assembly. Replace all damaged components. 5. Lubricate the air cylinder-to-silencer pipe flapper at the clevis and pin, as needed.

72778

a - Clevis And Pin Description 2-4-C Marine Lubricant Where Used Air Cylinder to Silencer Pipe Flapper at Clevis and Pin Part Number 92-802859Q1

Page 7B-10

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

COLLECTORS

Installation
1. Install the silencer valve assembly to the exhaust tubes, the hoses and the Y-pipe. IMPORTANT: Each exhaust hose connection must be double clamped at each connection. Tighten the hose clamps securely. 2. Secure with two hose clamps at each connection. 3. Tighten the hose clamps securely. 4. Install the air tube to the silencer valve assembly. 5. Start the engine and check for exhaust and water leaks.

72539

a - Silencer Valve Assembly b - Hose Clamps

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Page 7B-11

COLLECTORS

SERVICE MANUAL NUMBER 31

Air Tube Routing

1. Route the air tubing from the air pump to the silencer valve cylinders. Do NOT route the air tubing close to hot surfaces. Excessive heat will damage the air tubes.

d a

d c
Single Engine a - Air Tube b - T-fittings c - Air Pump Assembly d - Air Tube To Air Cylinder

b
72775

d a

d c
Dual Engine a - Air Tube b - T-Fittings c - Air Pump Assembly d - Air Tube To Air Cylinder

72776

Page 7B-12

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SERVICE MANUAL NUMBER 31

COLLECTORS

Air Pump Maintenance

1. The air intake filter must be inspected annually. If the filter is clogged or partially clogged, replace. 2. Remove the filter pad with needle-nose pliers. 3. Clean the surface in the casting. 4. Apply a single dot of adhesive to the center of the casting. Description Sound Blanket Glue Where Used Air Pump Intake Filter Part Number 92-25234

5. Install the new filter. Be careful not to coat the filter or clog the air intake holes with the adhesive.

72534

a
a - Air Pump b - Air Intake Filter

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Page 7B-13

COLLECTORS

SERVICE MANUAL NUMBER 31

Troubleshooting Silent Choice Exhaust Silencer System

NOTE: Perform the following tests with engines not operating. COMPRESSOR WILL NOT OPERATE - TESTING MODE SWITCH Cause PUR wire does not have battery voltage BRN wire does not have battery voltage when mode switch is held in through the transom position GRY wire does not have battery voltage when mode switch is held in through the prop position. COMPRESSOR WILL NOT OPERATE - TESTING AIR PUMP Cause Special Information Special Information Fuse is blown or wiring is faulty Switch is faulty

Switch is faulty

NOTE: Ensure that BLK wire in terminal block is grounded to engine. BRN wire, in terminal block, does not have Wiring is faulty. battery voltage when mode switch is held If voltage is present, air pump is faulty. in through the transom position. AIR PUMP OPERATES - SYSTEM INOPERATIVE With air pump operating, check hoses, fittings, solenoid and relief valve for air leakage. Replace parts as needed. System operates but goes through the prop after air pump stops running 1. Ensure that air pressure is not leaking past solenoid. Replace as necessary. 2. Ensure that air pressure is not leaking back through air pump. Replace check valve if necessary. 3. Ensure that air pressure is not leaking at air cylinder assemblies. Replace as necessary. System stays in through the transom mode, will not go back to through the prop mode GRY wire, in terminal block, must have battery voltage when mode switch is held in through the prop position. If not, wiring is faulty. If voltage is present, solenoid is faulty.

Page 7B-14

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SERVICE MANUAL NUMBER 31

COLLECTORS

Exhaust Muffler Kit

Removal
1. Drain the seawater section of the cooling system. 2. Loosen the hose clamps retaining the exhaust mufflers and the hoses to the engine. 3. Remove the exhaust mufflers.

c a

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SERVICE MANUAL NUMBER 31

VELVET DRIVE IN-LINE AND V-DRIVE TRANSMISSION

DRIVES
Section 8A - Velvet Drive In-Line And V-Drive Transmission

Table of Contents
Identification . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Operating Specifications . . . . . . . . . . . Ratios And Part Numbers . . . . . . . . . . Fluid Specifications . . . . . . . . . . . . . . . Pressure Specifications . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . Transmission / Propeller Rotation . . . . . . Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 8A-3 8A-3 8A-3 8A-4 8A-4 8A-4 8A-5 8A-5 8A-6 8A-7 8A-7 8A-7 8A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lever Installation . . . . . . . . . . . . . Shift Control And Cables . . . . . . . . . . . . . Transmission Shift Lever and Shift Cable Bracket . . . . . . . . . . . . . . . . . . . Installation and Adjustment . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . Transmission Repair . . . . . . . . . . . . . . . . . 8A-10 8A-11 8A-13 8A-14 8A-15 8A-16 8A-20 8A-20

8
A

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VELVET DRIVE IN-LINE AND V-DRIVE TRANSMISSION

SERVICE MANUAL NUMBER 31

Identification
The transmission identification plate is located on the top left side of the transmission.

b c
Typical Transmission Identification Plate a - Model Number b - Ratio (In Forward Gear) c - Serial Number d - Identification Plate Model Color Code
72839

Page 8A-2

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SERVICE MANUAL NUMBER 31

VELVET DRIVE IN-LINE AND V-DRIVE TRANSMISSION

Specifications
Operating Specifications
Description Temperature Switch Settings +/ 10 degrees Open 87.8 degrees C (190 degrees F) Specification Close 110 degrees C (230 degrees F)

Ratios And Part Numbers

NOTE: The ratio is shown on the identification plate. The ratio may be rounded off in some cases.

71C DIRECT
Ratio in Forward Gear 1.0:1 Identification Plate Velvet Drive Model Color Code Number Red 10-17-004 Mercury Marine Part Number 47805A7

71C IN-LINE
Ratio in Forward Gear 1.5:1 2.5:1 Identification Plate Velvet Drive Model Color Code Number Red 10-17-006 10-17-012 Mercury Marine Part Number 47806A7 47808A7

72C V-DRIVE
Ratio in Forward Gear 1.5:1 2.0:1 2.5:1 2.5:1 Green Identification Plate Velvet Drive Model Color Code Number 10-05-011 10-05-002 10-05-005 10-05-004 Mercury Marine Part Number 6095A6 60960A6 60961A6 gear 60961A8 chain

72C DIRECT
Ratio in Forward Gear 1.0:1 Identification Plate Velvet Drive Model Color Code Number Green 10-18-002 Mercury Marine Part Number 47810A19

72C IN-LINE
Ratio in Forward Gear 1.5:1 2.0:1 2.5:1 3.0:1 Green Identification Plate Velvet Drive Model Color Code Number 10-18-004 10-18-006 10-18-010 10-18-012 Mercury Marine Part Number 47811A7 47812A7 47813A7 47814A7

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Fluid Specifications
NOTICE
Unit Of Measurement: Liters (U.S. Quarts) All capacities are approximate fluid measures. NOTE: Always use the dipstick to determine the exact fluid level. Model 71C In-Line 71C Gear Reduction 71C Remote V-Drive 72C In-Line 72C Gear Reduction 72C Remote V-Drive 72C V-Drive Capacity 1.66 (1-3/4) 2.84 (3) 1.66 (1-3/4) 1.66 (1-3/4) 2.84 (3) 1.66 (1-3/4) 3.79 (4) Mobil 424 or Universal Tractor Hydraulic Oil Do Not Mix! Fluid Type Dexron III Automatic Transmission Fluid or Mobil 424 Do Not Mix!

Pressure Specifications
Engine RPM 250 600 2000 3000 Neutral Gear kPa (PSI) Minimum 793 (115) Maximum 931 (135) Forward Gear kPa (PSI) Minimum 483 (70) 793 (115) 862 (125) 931 (135) Maximum 965 (140) 1103 (160) 1241 (180) Reverse Gear kPa (PSI) Minimum 483 (70) 827 (120) 862 (125) Maximum 965 (140) 1103 (160)

Torque Specifications
NOTE: Securely tighten all fasteners not listed below. Description Bushing Fluid Hose-To-Bushing Pump Housing-To-Adapter Rear Mounts-To-Transmission Shift Lever-To-Valve Transmission-To-Flywheel Housing Neutral Start Safety Switch Propeller Shaft Coupler-To-Output Flange Shift Lever Nut Nm 34 34 26 61 13 68 12.5 68 13 115 111 50 115 50 lb-in. lb-ft 25 25 19 45

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VELVET DRIVE IN-LINE AND V-DRIVE TRANSMISSION

Lubricants / Sealants / Adhesives

Description Perfect Seal 2-4-C Marine Lubricant With Teflon Engine Coupler Spline Grease Loctite 242 Where Used Bushing threads, elbow fitting threads Transmission shift lever poppet ball, spring and holes Transmission input shaft splines, engine drive plate splines Transmission bracket retention bolts Part Number 92-34227-1 92-802859A1 92-802869A1 92-809821

Precautions
Do NOT start or crank the engine without fluid in the transmission. Except in an emergency, never shift the transmission at engine speeds above 1000 rpm. Free wheeling of one propeller (in a twin engine boat) at trolling speeds will not cause damage to the transmission. However, boat operation above trolling speed should be avoided. Ensure that the proper fluid level exists before free wheeling the propeller. Do NOT paint the shift lever poppet ball and spring. An accumulation of paint will prevent proper action of the detent. Always replace the oil cooler and the hoses after a transmission failure or prior to installing a new or rebuilt transmission. Metallic particles from a failure tend to collect in the cooler and hoses and will gradually flow back into the fluid system and damage the transmission. Always use the specified oil cooler, hoses and fittings. The hoses must be at least 10.5 mm (13/32 in.) I.D. The oil cooler, hoses and fittings must be sufficient size to maintain the transmission fluid (in sump) at 60-88 degrees C (140-190 degrees F).

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Transmission / Propeller Rotation

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: 71C and 72C transmissions are NOT full power reversing.

CAUTION
Avoid transmission failure. Shift cable connections at both the remote control and the transmission must always be in FORWARD position for forward movement and in the REVERSE position for reverse movement.

b
77966

Forward a - Direction Of Shift Lever Engagement (Toward Flywheel) b - Engine/Transmission Input Shaft Shaft Rotation Direction (LH) c - Transmission Output/Propeller Shaft Rotation Direction (LH)

a c

b
77966

Reverse a - Direction Of Shift Lever Engagement (Away From Flywheel) b - Engine/Transmission Input Shaft Rotation Direction (LH) c - Transmission Output/Propeller Shaft Rotation Direction (RH)

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Fluid Level
Checking
Refer to SECTION 1B - Maintenance.

Changing
IMPORTANT: Do NOT start or crank the engine without fluid in the transmission. Transmission fluid should be changed when servicing the transmission.

CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. 1. Clean the area around the cooler hose. 2. Disconnect the hose from the elbow fitting. 3. Remove the elbow fitting from the bushing.

a b
72840

Typical In-Line a - Cooler Hose b - Elbow Fitting

a b
71305

c
Typical V-Drive a - Cooler Hose b - Elbow Fitting c - Bushing
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4. Drain the oil from the transmission, cooler and cooler hoses into a suitable container. 5. Remove the bushing, spring and strainer tube from the transmission case. Allow the transmission to drain completely.

71307

a
a - Bushing b - Spring c - Plastic Strainer Tube

6. Clean the strainer tube in suitable solvent. 7. Check the oil for the following foreign matter: Metal Particles - A few small particles are normal. Larger metal chips are an early sign of transmission failure, which may mean the transmission should be disassembled and inspected for internal damage. Rubber Particles - Indication of cooler hose wear. The hoses should be inspected for cracks or fraying. Replace the damaged hoses.

CAUTION
Avoid severe transmission damage or possible failure of the transmission. The strainer must be properly installed. 8. Install the plastic strainer tube with the notch DOWN and OUT toward the side of the case.

71306

b
a - Plastic Strainer Tube b - Notch

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9. Install the spring. 10. Coat the bushing threads with sealant. Install and torque the bushing. Description Perfect Seal Description Bushing Where Used Bushing threads, elbow fitting threads Nm 34 Part Number 92-34227-1 lb-in. lb-ft 25

11. Coat the elbow fitting threads with sealant and install in the bushing. Tighten securely. Description Perfect Seal Where Used Bushing threads, elbow fitting threads Part Number 92-34227-1

12. Reconnect the hose and tighten securely. 13. Fill the transmission with specified fluid.

Filling
IMPORTANT: Use only specified transmission fluid. 1. Remove the dipstick. 2. Fill the transmission with fluid through the dipstick hole to bring the level up to the full mark.

a b

72526

a - Dipstick b - Full Mark

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IMPORTANT: Do NOT start or crank the engine without fluid in the transmission. IMPORTANT: To accurately check the fluid level, operate the engine at 1500 rpm for 2 minutes immediately prior to checking the fluid level. 3. Start the engine and operate at 1500 rpm for 2 minutes to fill all hydraulic circuits. IMPORTANT: Be sure to push the dipstick all the way down into the dipstick tube when checking the fluid level. 4. Stop the engine and quickly check the fluid level. Add transmission fluid, if necessary, to bring the level up to the full mark on the dipstick. 5. Reinstall the dipstick; tighten the T-handle securely. Do NOT overtighten.

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Shift Control And Cables

IMPORTANT: The Velvet Drive Warranty is jeopardized if the shift lever poppet ball or the spring is permanently removed, if the shift lever is repositioned or changed in any manner, or if the remote control and the shift cable do not position the shift lever exactly as shown. The remote control used must position the transmission shift lever over the letter F embossed on the transmission case when the remote control is placed in the FORWARD gear position. Transmission failure will occur if the transmission shift lever is positioned over the letter R and the wrong rotation propeller is used to propel boat forward. The remote control must provide shift cable travel (at the transmission) of at least 70 mm (2-3/4 in.) to position the transmission shift lever fully in the FORWARD and the REVERSE gear positions. Insufficient shift cable travel will cause the transmission to slip and eventually fail.
R F

a
72602

a - 70 mm (2-3/4 in.) Minimum

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Transmission Shift Lever and Shift Cable Bracket

a d b
F R
71301

c
a b c d

72601

- Transmission Shift Lever - Shift Lever Must Be Over This Letter When Propelling Boat FORWARD - Shift Lever Must Be Over This Letter When Propelling Boat In REVERSE - Poppet Ball Must Be Centered In Detent Hole For Each F-N-R Position (Forward Gear Shown) e - Shift Cable Anchor Stud Location

IMPORTANT: The distance between the anchor studs in the shift lever and the shift cable bracket must be 181 mm (7-1/8 in.).

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Installation and Adjustment

IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. Do NOT fasten any items to the shift cables. NOTE: On models with other than Quicksilver shift cables, refer to the shift cable manufacturers instructions. IMPORTANT: The Velvet Drive Warranty is jeopardized if the shift lever poppet ball or the spring is permanently removed, if the shift lever is repositioned or changed in any manner, or if the remote control and the shift cable do not position the shift lever exactly as shown. 1. Verify that the shift cable stud is in appropriate stud hole as indicated. Tighten the elastic stop nut securely.

50947

a - Shift Cable Anchor Stud Hole 2. Place the remote control shift lever and the transmission shift lever in the NEUTRAL position. 3. Remove the nuts and washers from the shift cable attaching studs. 4. Locate the center of the remote control and the control shift cable play (backlash), as follows: a. Ensure that the remote control is in the NEUTRAL position. b. Push in on the control cable end with enough pressure to remove the play and mark position a on the tube. c. Pull out on the control cable end with enough pressure to remove the play and mark position b on the tube. d. Measure the distance between marks a and b, and mark position c, halfway between marks a and b.

b c

a
22024

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5. Center the cable-end play, then adjust the cable barrel to align the holes in the barrel and in the cable end guide with the attaching points on the transmission. 6. Temporarily install the shift cable. Do NOT secure at this time. IMPORTANT: Transmission is fully in gear when shift lever comes to a stop in either direction.

CAUTION
Remote control and shift cable must position transmission shift lever exactly as shown, or transmission failure may occur. Do not remove poppet ball or spring. 7. Place remote control shift lever in gear and check position of transmission shift lever. Shift lever must be positioned as shown. 8. Place remote control shift lever in opposite gear position and check transmission shift lever position. Shift lever must be positioned as shown. 9. If the transmission shift lever will position properly in one gear, but not in the other gear, recheck the shift cable adjustment. If the transmission shift lever will not position properly in either gear, move the transmission shift lever stud from the top hole in the shift lever to the bottom hole and recheck for proper positioning. If proper positioning is still not obtained, the remote control does not provide sufficient shift cable travel and must be replaced.
F- N - R

a d e b
F R

c
a b c d

72601

NOTE: Move the shift lever stud to lower hole if necessary, to center the poppet ball in the FORWARD and REVERSE detent holes. 10. Install the nut and the washer to the cable end guide stud. Tighten until the nut contacts, then loosen 1/2 turn. 11. Install the nut and the washer to the cable barrel stud. Tighten until the nut contacts. Tighten securely, but DO NOT overtighten.

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e d f b a

c d
Typical Single Cable Installation - Rear Approach
50947

e d

f b a c

50947

Typical Dual Cable Installation - Rear Approach a - Cable End Guide b - Cable Barrel c - Cable Barrel Stud d - Elastic Stop Nut And Washer e - Spacer f - Cable End Guide Stud

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b a

c e d

50946

Typical Single Cable Installation - Front Approach

b d

e c f d
50946

Typical Dual Cable Installation - Front Approach a - Cable End Guide b - Cable Barrel c - Cable Barrel Stud d - Elastic Stop Nut And Washer e - Spacer f - Cable End Guide Stud NOTE: For models equipped with a dual station shift bracket such as the one shown, refer to the shift cable manufacturers instructions for adjusting the cable. The shift lever must be positioned as stated in the preceding steps.

22457

Dual Station Shift Bracket (Not Quicksilver)

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Pressure Test
1. Remove the temperature switch. 2. Install the pressure gauge in the main line pressure tap.

a
72845

a - Main Line Pressure Tap 3. With the boat in the water, start the engine and operate until the normal operating temperature is reached. 4. Refer to Specifications for pressure readings.

Transmission Repair
Mercury Marine does not stock or sell replacement parts for these transmissions. Velvet Drive has a network of distributors throughout the world to service their product. These distributors, in turn, have a dealer network to service the transmissions. Also, service manuals for each transmission can be obtained from Velvet Drive. For the location of your closest distributor or service literature contact: Velvet Drive Transmissions Division of Regal Beloit Theodore Rice Boulevard Industrial Park New Bedford, MA 02745 Phone: (508) 995-2616

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VELVET DRIVE 5000 SERIES TRANSMISSION

DRIVES
Section 8B - Velvet Drive 5000 Series Transmission

Table of Contents
Identification . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Ratios and Part Numbers . . . . . . . . . . Fluid Specifications . . . . . . . . . . . . . . . Pressure Specifications . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . Transmission / Propeller Rotation . . . . . . Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2 8B-3 8B-3 8B-3 8B-4 8B-4 8B-4 8B-5 8B-6 8B-7 8B-7 8B-7 8B-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lever Installation . . . . . . . . . . . . . Shift Control And Cables . . . . . . . . . . . . . Transmission Shift Lever and Shift Cable Bracket . . . . . . . . . . . . . . . . . . . Installation and Adjustment . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . Transmission Repair . . . . . . . . . . . . . . . . . 8B-9 8B-10 8B-12 8B-13 8B-14 8B-16 8B-20 8B-20

8
B

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Identification
The transmission identification plate is located on the top left side of the transmission.

73247

Velvet Drive 5000A Down Angle Transmission Identification Plate a - Model Number b - Ratio (In Forward Gear) c - Serial Number d - Identification Plate Model Color Code

c
Velvet Drive 5000V V-Drive Transmission Identification Plate a - Model Number b - Ratio (In Forward Gear) c - Serial Number d - Identification Plate Model Color Code

72839

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VELVET DRIVE 5000 SERIES TRANSMISSION

Specifications
Description Temperature Switch Settings +/ 10 degrees Open 87.8 degrees C (190 degrees F) Specification Close 110 degrees C (230 degrees F)

Ratios and Part Numbers

NOTE: The ratio is shown on the identification plate. The ratio may be rounded off in some cases.

5000A
Ratio in Forward Gear 1.25:1 1.5:1 2.0:1 2.5:1 2.8:1 Black Identification Plate Velvet Drive Model Color Code Number 20-01-002 20-01-003 20-01-004 20-01-005 20-01-006 Mercury Marine Part Number 805495A8 805495A6 805495A4 805495A5 805495A7

5000V
Ratio in Forward Gear 1.5:1 2.0:1 2.5:1 Blue Identification Plate Velvet Drive Model Color Code Number 20-02-003 20-02-004 20-02-005 Mercury Marine Part Number 807481A5 807481A6 807481A7

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Pressure Specifications
Engine RPM 900 2400 4500 Neutral Gear kPa (psi) Minimum 69 (10) 103 (15) Maximum 345 (50) 483 (70) 1724 (250) 2758 (400) Forward Gear or Reverse Gear kPa (psi) Minimum Maximum

Torque Specifications
NOTE: Securely tighten all fasteners not listed below. Description Drain Plug Fluid Hose-To-Cooler Fluid Hose-To-Housing Transmission-To-Flywheel Housing Rear Mounts-To-Transmission Shift Lever-To-Valve Neutral Start Safety Switch Propeller Shaft Coupler-To-Output Flange 75 61 13 13 68 115 115 50 55 45 34 25 Nm lb-in. lb-ft

Lubricants / Sealants / Adhesives

Description Perfect Seal Engine Coupler Spline Grease 2-4-C Marine Lubricant With Teflon Loctite 242 Where Used Drain plug Transmission input shaft splines, engine drive plate splines Transmission shift lever poppet ball, spring and holes Transmission bracket retention bolts Part Number 92-34227-1 92-802869a1 92-802859a1 92-809821

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Precautions
Do NOT start or crank the engine without fluid in the transmission. Except in an emergency, never shift the transmission at engine speeds above 1000 rpm. Free wheeling of one propeller (in a twin engine boat) at trolling speeds will not cause damage to the transmission. However, boat operation above trolling speed should be avoided. Ensure that the proper fluid level exists before free wheeling the propeller. Do NOT paint the shift lever poppet ball and spring. An accumulation of paint will prevent proper action of the detent. Always replace the oil cooler and the hoses after a transmission failure or prior to installing a new or rebuilt transmission. Metallic particles from a failure tend to collect in the cooler and the hoses and will gradually flow back into the fluid system and damage the transmission. Always use the specified oil cooler, hoses and fittings. The hoses must be 11 mm (13/32 in.) ID minimum. The oil cooler, hoses and fittings must be sufficient size to maintain the transmission fluid (in sump) at 60-79 degrees C (140-175 degrees F).

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Transmission / Propeller Rotation

These transmissions are full power reversing transmissions, allowing a standard (LH rotation) engine to be used for both propeller rotations. Propeller rotation (output shaft rotation) is determined by shift cable attachment at the remote control. Be sure to use correct rotation propeller and shift cable hook up for direction desired. Transmission rotation is described when viewed from the rear of transmission with the transmission in the forward gear selector position.

Removal
CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. NOTICE The following procedure describes removal of the transmission without removing the engine. If the engine must be removed, refer to SECTION 2. 1. Disconnect negative battery cable. 2. Drain the transmission fluid. 3. Disconnect the fluid cooler hoses. NOTE: Fluid cooler should be removed with transmission. 4. Disconnect the shift cable from the transmission. 5. Disconnect the wires from the neutral start safety switch. 6. Disconnect the wires from the transmission fluid temperature switch. 7. Loosen the trunnion clamping fasteners on the engine mounts (port and starboard). 8. Remove the coupling nuts and bolts and separate the propeller shaft flange from the transmission output flange. 9. Remove the four rear engine mount-to-engine bed fasteners and hardware. 10. Support the rear part of the engine with a hoist or put wooden blocks under the flywheel housing. 11. Support the transmission with a hoist or by other suitable means through the lifting eye on the transmission case. 12. Remove the port and starboard rear mount brackets (with base and trunnion) from the transmission.

CAUTION
Avoid damage to transmission input shaft or engine coupler. Ensure that the transmission is completely supported before removing hardware attaching transmission to flywheel housing. 13. Remove all hardware attaching the transmission to the flywheel housing. 14. Pull the transmission straight back and away from the engine to completely disengage the splines on the input shaft. 15. Carefully lift out the transmission.

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Installation
1. Check the transmission output shaft rolling torque. 2. Apply lubricant to the transmission input shaft splines and engine drive plate splines. Description Engine Coupler Spline Grease Where Used Transmission input shaft splines, engine drive plate splines Part Number 92-802869A1

3. Using a suitable hoist, position the transmission in the boat and align the transmission splines with the drive plate splines. 4. Slide the transmission into place and secure with attaching hardware. Torque the transmission to flywheel housing fasteners. Description Transmission To Flywheel Housing 5. Remove the hoist. 6. Install the rear mount brackets to the transmission. Torque the fasteners and hardware. Description Rear Mounts To Transmission Nm 61 lb-in. lb-ft 45 Nm 75 lb-in. lb-ft 55

7. Using hoist, raise engine and transmission to remove blocks (if used). 8. Lower the assembly to the engine bed. 9. Securely tighten the four rear engine mount-to-engine bed fasteners and hardware. 10. Relieve the hoist tension. 11. Connect the wires to the neutral start safety switch. 12. Connect the wires to the transmission fluid temperature switch. 13. Connect the fluid cooler water hoses and tighten the hose clamps securely.

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CAUTION
Improper shift cable connection and adjustment can cause premature clutch failure. 14. Connect and adjust the shift cables. 15. Check the engine final alignment. Refer to SECTION 2. 16. After the engine has been properly aligned, connect the propeller shaft coupler to the transmission output flange with bolts, lockwashers and nuts. Torque the fasteners. Description Propeller Shaft Coupler To Output Flange Nm 68 lb-in. lb-ft 50

17. Torque the trunnion clamping fasteners on the engine mounts (port and starboard) that were loosened during removal. IMPORTANT: All coupler bolts must be Metric Grade 10.9 (SAE Grade 8) or better, with a shoulder (grip length) long enough to pass through the face mating plane of couplers. 18. Install the transmission fluid cooler and hoses. Torque hose fittings at cooler and transmission housing. Description Fluid Hose To Housing Nm 34 lb-in. lb-ft 25

IMPORTANT: Do NOT start or crank the engine without fluid in the transmission. 19. Refill the transmission with specified fluid. 20. Connect the negative battery cable. Tighten the clamp securely. 21. Start the engine and check for leaks. 22. Check the fluid level.

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Shift Lever Installation

IMPORTANT: The Velvet Drive Warranty is jeopardized if the shift lever poppet spring and/or ball is permanently removed, or if the shift lever is changed, repositioned or if the linkage between the remote control and the transmission shift lever does not have sufficient travel in both directions. The shift lever and the related parts must be assembled as shown. 1. Lubricate the poppet ball, spring and holes in the shift lever. Description 2-4-C Marine Lubricant With Teflon Where Used Transmission shift lever poppet ball, spring and holes Part Number 92-825407A3

2. Install the poppet spring and ball. Retain the ball by placing the shift lever on the shaft. 3. Install the flat washer, lockwasher and nut on the shaft. 4. Torque the nut.

d c b a f

e
73251

Typical Shift Lever a - Nut b - Lockwasher c - Flat Washer d - Shift Lever e - Poppet Ball f - Poppet Spring Description Shift Lever To Valve Nm 13 lb-in. 120 lb-ft

5. After installation, move the shift lever through the FORWARD, NEUTRAL and REVERSE positions. No more than finger-tip effort should be required. If the valve binds, the cause for binding must be found and corrected.

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Shift Control And Cables

a c

72602

a - Position A b - Position B c - 70 mm (2-3/4 in.) Minimum

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Transmission Shift Lever and Shift Cable Bracket

a e e

a b d
73248

73249

a - Transmission Shift Lever b - Poppet Ball Must Be Centered In This Detent Hole When Left-Hand Propeller Shaft Rotation Is Desired c - Poppet Ball Must Be Centered In This Detent Hole When Right-Hand Propeller Shaft Rotation Is Desired d - Poppet Ball Must Be Centered In This Detent Hole For NEUTRAL Position e - Shift Lever Stud Location (For Quicksilver Shift Cables) For Left-Hand Propeller Shaft Rotation: Shift cable hookup at remote control must result in shift cable end guide moving in direction A when remote control handle is placed in forward position. For Right-Hand Propeller Shaft Rotation: Shift cable hookup at remote control must result in shift cable end guide moving in direction B when remote control handle is placed in forward position.

A B
23242

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WARNING
Avoid serious personal injury or property damage caused by improper shifting. Anchor stud for shift cable must be installed in the correct hole when using bracket with four anchor location holes. IMPORTANT: Ensure that the anchor stud is installed in the front hole as shown in the illustration following.

a b

73284

74090

a - Shift Cable Bracket b - Anchor Stud In Front Hole (For Quicksilver Shift Cables) IMPORTANT: The distance between the anchor studs in the shift lever and the shift cable bracket must be 181 mm (7-1/8 in.).

b d

c b a

73284

a b c d

- Shift Lever - Anchor Stud - Dimension Between Studs - 181 mm (7-1/8 in.) - Shift Cable Bracket

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Page 8B-15

g f c d f
71897

50073

Typical Dual Cable Installation - Rear Approach a - Cable End Guide b - Spacer (As Required) c - Elastic Stop Nut And Washer d - Bushings e - Cable Barrels [Positions Only Indicated In Right Drawing] f - Cable Barrel Stud g - Cable End Guide Stud

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VELVET DRIVE 5000 SERIES TRANSMISSION

b a

c d f
Typical Single Cable Installation - Front Approach

e
50946

b d

e c f d
50946

Typical Dual Cable Installation - Front Approach a - Cable End Guide b - Cable Barrel c - Cable Barrel Stud d - Elastic Stop Nut And Washer e - Spacer f - Cable End Guide Stud

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SERVICE MANUAL NUMBER 31

Pressure Test
1. Remove the temperature switch. 2. Install the pressure gauge in the main line pressure tap.

73247

a - Main Line Pressure Tap 3. With the boat in the water, start the engine and operate until the normal operating temperature is reached. 4. Refer to Specifications for pressure readings.

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VELVET DRIVE 5000 SERIES TRANSMISSION

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SERVICE MANUAL NUMBER 31

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

DRIVES
Section 8C - ZF/Hurth 630 And 800 Series Transmission

Table of Contents
Identification . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Operating Specifications . . . . . . . . . . . Ratios and Part Numbers . . . . . . . . . . Fluid Specifications . . . . . . . . . . . . . . . Pressure Specifications . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . Transmission / Propeller Rotation . . . . . . Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . Changing . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2 8C-3 8C-3 8C-3 8C-4 8C-4 8C-4 8C-4 8C-5 8C-5 8C-6 8C-7 8C-7 8C-7 8C-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Shift Control And Cables . . . . . . . . . . . . . Transmission Shift Lever and Shift Cable Bracket . . . . . . . . . . . . . . . . . . . Installation and Adjustment . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . Transmission Repair . . . . . . . . . . . . . . . . . 8C-9 8C-10 8C-13 8C-13 8C-15 8C-19 8C-19

8
C

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

SERVICE MANUAL NUMBER 31

Identification
The transmission identification plate is located on the top rear of the transmission.

77626

72959

Typical ZF/Hurth Transmission Identification Plate a - Serial Number And Gear Ratio

Page 8C-2

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

Specifications
Operating Specifications
Description Shifting Pressure Operating Temperature Temperature Switch Settings +/ 10 degrees Specification 21.5-23.5 bar (312-341 psi) 54-79 degrees C (130-175 degrees F) Open 87.8 degrees C (190 degrees F) Close 110 degrees C (230 degrees F)

Ratios and Part Numbers

NOTE: The ratio is shown on the identification plate. The ratio may be rounded off in some cases.

630A
Ratio (Normal) 1.5:1 2.0:1 2.5:1 2.7:1 HSW630A ZF/Hurth Model Number Mercury Marine Part Number 863744T2 863744T3 863744T4 863744T5

630V
Ratio (Normal) 1.55:1 2.0:1 2.5:1 HSW630V ZF/Hurth Model Number Mercury Marine Part Number 863745T2 863745T3 863745T4

800A
Ratio (Normal) 2.85:1 ZF/Hurth Model Number HSW800A Mercury Marine Part Number 806730A1

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

SERVICE MANUAL NUMBER 31

Pressure Specifications
NOTICE
Unit Of Measurement: Bar (PSI) Engine RPM 2000 Shifting Pressure Position A 21.5-23.5 (312-341) Position B 21.5-23.5 (312-341)

Torque Specifications
NOTE: Securely tighten all fasteners not listed below. Description Transmission-To-Flywheel Housing Rear Mount Brackets Coupler-To-Output Flange Hose Fittings at Fluid Cooler Nm 61 61 68 34 lb-in. lb-ft 45 45 50 25

Special Tools
Description Thermometer [(3/8-NPT, Thread 18 to 132 degrees C (0 - 270 degrees F) Pressure Gauge (0-500 psi), (3/8-NPT) Part Number Obtain Locally

Page 8C-4

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

Lubricants / Sealants / Adhesives

Description Engine Coupler Spine Grease Liquid Neoprene Loctite 242 Where Used Transmission input shaft splines Connections on neutral safety switch Transmission bracket retention bolts Part Number 92-802869A1 92-25711--3 92-809821

Precautions
Transmission gear ratio is marked on transmission identification plate, which is located on the top of transmission. Transmission rotation is described when viewed from the rear of transmission. Do NOT start or crank engine without fluid in transmission. Except in an emergency, never shift transmission at engine speeds above 1000 rpm. Free wheeling of one propeller (in a twin engine boat) at trolling speeds will not cause damage to the transmission; however, boat operation above trolling speed should be avoided. Ensure that proper fluid level exists before free wheeling propeller. Always replace oil cooler and hoses after a transmission failure or prior to installing a new or rebuilt transmission. Metallic particles from a failure tend to collect in the cooler and hoses and will gradually flow back into the fluid system and damage transmission. Always use specified oil cooler, hoses and fittings.

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

SERVICE MANUAL NUMBER 31

Transmission / Propeller Rotation

The ZF/Hurth 630 and 800 Series transmissions are full power reversing transmissions, allowing a standard LH rotation engine to be used for both propeller rotations. Propeller rotation is determined by shift cable attachment at the remote control. Be sure to use correct rotation propeller and shift cable hook up for direction desired.

b c e

25506

ZF/Hurth 630A - 8 Degree Down-Angle Transmissions

a b d b

c
72959

e
72959

ZF/Hurth 630V - V-Drive Transmissions a - Direction Of Shift Lever Engagement (Toward Flywheel) b - Engine/Transmission Input Shaft Rotation Direction (LH) c - Transmission Output/Propeller Shaft Rotation Direction (LH) d - Direction Of Shift Lever Engagement (Away From Flywheel) e - Transmission Output/Propeller Shaft Rotation Direction (RH)

Page 8C-6

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SERVICE MANUAL NUMBER 31

ZF/HURTH 630 AND 800 SERIES TRANSMISSION

Fluid Level
Checking
Refer to SECTION 1B.

Changing
IMPORTANT: Do NOT start or crank the engine without fluid in the transmission. Transmission fluid should be changed when servicing the transmission.

CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. 1. Clean the exterior of transmission before disassembly. 2. Using an allen wrench on the set screw, remove the oil filter from the housing by turning counterclockwise and pulling up at the same time.

27666

a - Set Screw 3. 630V Only: Remove drain plug from transmission and allow fluid to drain.

73013

a - Drain Plug a. Reinstall drain plug and tighten securely.

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

SERVICE MANUAL NUMBER 31

4. 630A Only: Suction fluid out through filter tube. 5. Check the oil for the following foreign matter: Metal Particles - A few small particles are normal. Larger metal chips are an early sign of transmission failure which may mean the transmission should be disassembled and inspected for internal damage. Rubber Particles - Indication of cooler hose wear. The hoses should be inspected for cracks or fraying. Replace the damaged hoses.

6. Fill the transmission with specified fluid.

Filling
IMPORTANT: Use only specified transmission fluid. IMPORTANT: The fluid level dipstick is located on the port side of transmission. 1. Remove dipstick. 2. Fill the transmission with fluid through the dipstick tube to bring the level up to the full mark. IMPORTANT: Do not screw dipstick into housing; press it firmly in and remove. 3. Replace the dipstick.

77564

a - Dipstick Tube IMPORTANT: Do NOT start or crank the engine without fluid in the transmission. IMPORTANT: To accurately check the fluid level, operate the engine at 1500 rpm for 2 minutes immediately prior to checking the fluid level. 4. Start the engine and operate at 1500 rpm for 2 minutes to fill all hydraulic circuits. IMPORTANT: Do not screw dipstick in; press it firmly in and remove. 5. Stop the engine and quickly check the fluid level. Add transmission fluid, if necessary, to bring the level up to the full mark on the dipstick.

Page 8C-8

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

ZF/HURTH 630 AND 800 SERIES TRANSMISSION

WARNING
Avoid injury or death and power package damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package. 1. Disconnect the battery cables from the battery. 2. Drain the transmission fluid. 3. Disconnect fluid cooler hoses. NOTE: Fluid cooler should be removed with transmission. 4. Disconnect the shift cable from the transmission. 5. Disconnect the wires from the neutral start safety switch. 6. Disconnect the wires from the transmission fluid temperature switch. 7. Loosen the trunnion clamping fasteners on the engine mounts (port and starboard). 8. Remove the coupling nuts and bolts and separate the propeller shaft flange from the transmission output flange. 9. Remove the four rear engine mount-to-engine bed fasteners and hardware. 10. Support the rear part of the engine with a hoist or put wooden blocks under the flywheel housing. 11. Support the transmission with a hoist or by other suitable means through the lifting eye on the transmission case. 12. Remove the port and starboard rear mount brackets (with base and trunnion) from the transmission.

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

SERVICE MANUAL NUMBER 31

Installation
1. Check the transmission output shaft rolling torque. 2. Apply lubricant to the transmission input shaft splines and engine drive plate splines.

71044

a - Input Shaft Description Engine Coupler Spine Grease Where Used Transmission input shaft splines, engine drive plate splines Part Number 92-802869A1

Page 8C-10

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

ZF/HURTH 630 AND 800 SERIES TRANSMISSION

5. Remove the hoist. 6. Install the rear mount brackets to the transmission. Torque the fasteners and hardware. Description Rear Mount Brackets Nm 61 lb-in. lb-ft 45

72720

a - Bolts (4), 2 On Each Side b - Locknuts (2), 1 On Each Side 10. Relieve the hoist tension. 11. Connect the wires to the neutral start safety switch, coat connections on the neutral start safety switch with sealant. Description Liquid Neoprene Where Used Connections on neutral start safety switch Part Number 92-25711--3

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

SERVICE MANUAL NUMBER 31

12. Connect the wires to the audio warning temperature switch.

50686

a - Neutral Safety Switch b - Audio Warning Temperature Switch 13. Connect the fluid cooler hoses and tighten the hose clamps securely.

CAUTION
Improper shift cable connection and adjustment can cause premature clutch failure. 14. Connect and adjust shift cables. 15. Check engine final alignment. Refer to SECTION 2. IMPORTANT: All coupler bolts must be Metric Grade 10.9 (SAE Grade 8) or better, with a shoulder (grip length) long enough to pass through the face mating plane of couplers. 16. After the engine has been properly aligned, connect the propeller shaft coupler to the transmission output flange with bolts, lockwashers and nuts. Torque the fasteners. Description Propeller Shaft Coupler To Output Flange Nm 68 lb-in. lb-ft 50

17. Torque the trunnion clamping fasteners on the engine mounts (port and starboard) that were loosened during removal. Description Hose Fittings at Fluid Cooler Nm 34 lb-in. lb-ft 25

IMPORTANT: Do NOT start or crank the engine without fluid in the transmission. 18. Refill transmission with specified fluid. 19. Connect negative battery cable. Tighten clamp securely. 20. Check for leaks and check fluid level after first engine start-up.

Page 8C-12

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

ZF/HURTH 630 AND 800 SERIES TRANSMISSION

Shift Control And Cables

Transmission Shift Lever and Shift Cable Bracket
The shift lever has two holes. The shift cable anchor stud is installed in the top hole when using Quicksilver remote control cables.

a
77520

a - Shift Lever b - Shift Cable Anchor Stud Location (For Quicksilver Remote Control Cables)

WARNING
Avoid serious personal injury or property damage caused by improper shifting. Anchor stud for shift cable must be installed in the correct hole when using bracket with two anchor location holes. 1. On bracket with two anchor location holes: Be certain anchor stud is installed in the correct hole for application 630 or 800.

b a

71041 71020

Shift Cable Bracket - Anchor Stud Position Shown for 630 Transmission a - Shift Cable Bracket b - Shift Cable Anchor Stud c - Bracket Fasteners

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

SERVICE MANUAL NUMBER 31

IMPORTANT: Ensure that shift lever is positioned approximately 10 degrees aft of vertical as shown when in the neutral detent position. Also, ensure that the distance between studs in the following is set at 181 mm (7-1/8 in.). If necessary, loosen clamping bolt and position lever so that dimension c is as shown when in the NEUTRAL detent position, and retighten clamping bolt.

a c d
72958 50228

NOTE: To change cable approach direction on single or dual station installations, only the spacer/bushings have to be switched to the opposite stud. The studs are identical.

e b

d c

b f
72955

71210

Typical Single Cable Installation - Forward Approach a - Cable End Guide b - Locknut and Washer c - Spacer (Fits Over Bushings) d - Bushing e - Cable Barrel f - Spacers (Fits Over Stud) g - Cable Barrel Stud h - Cable End Guide Stud

f e b a g

b
72957

c d

50229

Typical Single Cable Installation - Rear Approach a - Cable End Guide b - Locknut And Washer c - Spacer (Fits Over Bushings) d - Bushing e - Cable Barrel f - Spacers (Fits Over Stud) g - Cable Barrel Stud h - Cable End Guide Stud

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

SERVICE MANUAL NUMBER 31

e b

a
72956

71211

b
Typical Dual Cable Installation - Forward Approach a - Cable End Guide a - Cable End Guide b - Locknut And Washer c - Spacer (Fits Over Bushings) d - Bushing e - Cable Barrel f - Spacers (Fits Over Stud) g - Cable Barrel Stud h - Cable End Guide Stud

e d b a h
50073 72960

d b

Typical Dual Cable Installation - Rear Approach a - Cable End Guide b - Locknut And Washer c - Spacer (Fits Over Bushings) d - Bushing e - Cable Barrel f - Spacers (Fits Over Stud) g - Cable Barrel Stud h - Cable End Guide Stud

Page 8C-18

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

ZF/HURTH 630 AND 800 SERIES TRANSMISSION

Pressure Test
1. Remove pressure service port plug from Port A. 2. Connect a pressure gauge to Port A. 3. Remove temperature sender and install thermocouple at Port B.

b a
50686

a - Port A b - Port B 4. Ensure that fluid temperature and shifting pressure meet specification. 5. Check for leaks.

Transmission Repair
Mercury Marine stocks a limited number of replacement parts for these transmissions. ZF Marine has a network of distributors throughout the world to service their product. These distributors, in turn, have a dealer network to service the transmissions. Also, service manuals for each transmission can be obtained from ZF Marine. For the location of your closest distributor or service literature contact: ZF Marine 3101 Southwest 42nd St. Fort Lauderdale, FL 33312 (954) 581-4099

90-864260 OCTOBER 2001

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ZF/HURTH 630 AND 800 SERIES TRANSMISSION

SERVICE MANUAL NUMBER 31

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Page 8C-20

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

POWER STEERING PUMP

POWER STEERING
Section 9A - Power Steering Pump

Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . . . Lubricants / Sealants / Adhesives . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump And Components Exploded View . . . . . . . . . . . Power Steering Pump Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow Control Valve Servicing . . . . . . . . . Pump Shaft Oil Seal Replacement . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2 9A-2 9A-2 9A-3 9A-3 9A-4 9A-4 9A-4 9A-5 9A-5 9A-6 9A-7 9A-9 Replacing Belt And/Or Adjusting Tension Filling And Bleeding . . . . . . . . . . . . . . . . . . Checking Fluid Level . . . . . . . . . . . . . . . . . . Hydraulic Hoses And Fluid Cooler . . . . . . High Pressure Hose (Pump-To-Control Valve) . . . . . . . . . . . Low Pressure Hose (Pump-To-Fluid Cooler) . . . . . . . . . . . . Low Pressure Hose (Control Valve-To-Fluid Cooler) . . . . . 9A-10 9A-10 9A-10 9A-11 9A-11 9A-13 9A-15

9
A

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POWER STEERING PUMP

SERVICE MANUAL NUMBER 31

Torque Specifications
Description Nm 47 41 31 lb-in. lb-ft 35 30 23

Fitting Assembly Pump Mounting Bracket Power Steering Hose Fittings

Lubricants / Sealants / Adhesives

a
77827

a Adjusting Nut

CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. 2. Drain the fluid into a suitable container. 3. Remove the high pressure hose and the return hose from the power steering pump.

a
77827

a Low Pressure Hose b High Pressure Hose

90-864260 OCTOBER 2001

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POWER STEERING PUMP

SERVICE MANUAL NUMBER 31

4. Remove the mounting fasteners from the pump.

b
77829 77830

a Nut b Bolts 5. Remove the front bracket from the pump. 6. Remove the power steering pump from the bracket.

Flow Control Valve Servicing

1. Drain the fluid from the pump. 2. Remove the high pressure fitting assembly.

76869

a b c d

High Pressure Fitting Control Valve Assembly Flow Control Spring O-rings

Page 9A-6

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

POWER STEERING PUMP

3. Inspect the control valve assembly and the fitting assembly for contamination and damage. 4. Install the components and torque the fitting assembly.

76869

a b c d

Fitting Assembly Control Valve Assembly Flow Control Spring New O-rings
Nm 47 lb-in. lb-ft 35

Description

Fitting Assembly

Pump Shaft Oil Seal Replacement

1. Remove the power steering pump pulley.

72821

a Kent Moore Pulley Removal Tool (J25034)

90-864260 OCTOBER 2001

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POWER STEERING PUMP

SERVICE MANUAL NUMBER 31

2. Push a 0.13 mm (.005 in.) shim stock past the oil seal until it seats in the pump body (approximately 64 mm [2-1/2 in.] long).

a b

76830

a Oil Seal b Shim Stock 3. Remove the oil seal. Remove the shim stock.

22152

a Oil Seal b Suitable Tool 4. Install the new oil seal metal side up. Properly support the pump reservoir so that the reservoir back does not distort.

a b

c
a New Oil Seal b Suitable Mandrel c Pump Reservoir

22151

Page 9A-8

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

POWER STEERING PUMP

5. Install the pulley, as follows, using the Pulley Pusher Installer: Description Pulley Pusher Installer Part Number 91-93656A1

a. Grease the pump shaft and place the power steering pulley pump onto the pump shaft. Description Power Trim and Steering Fluid Where Used Pump shaft Part Number 92-802880Q1

b. Thread the stud all the way into the pump shaft. Place the bearing over the stud. Do NOT use the spacer from the kit. c. Thread the nut onto the pump shaft. Thread the pump shaft (and the nut) all the way onto the stud. d. Ensure that the power steering pump pulley is flush with the pump flange.

Installation
IMPORTANT: Be careful to not cross-thread or overtighten the hose fittings. 1. Place the power steering pump on the bracket and install the bolts and nuts. Torque the pump mounting bracket.

b
77829 77830

a Nuts b Bolts c Spacer

Description Nm 41 lb-in. lb-ft 30

Pump Mounting Bracket

2. Using a new high pressure hose O-ring, install the threaded fitting in the back of the pump assembly. Tighten the fitting securely.

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POWER STEERING PUMP

SERVICE MANUAL NUMBER 31

3. Connect the low pressure hose on the back of the pump. Tighten the hose clamp securely. Do NOT cross-thread or overtighten.

a
77827

a Low Pressure Hose b High Pressure Hose 4. Install the mounting hardware and the fasteners to retain the pump to the bracket.

Replacing Belt And/Or Adjusting Tension

Refer to SECTION 1B.

Filling And Bleeding

Refer to SECTION 1B.

Checking Fluid Level

Refer to SECTION 1B.

Page 9A-10

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

POWER STEERING PUMP

Hydraulic Hoses And Fluid Cooler

The following information is provided to assist in the replacement of the power steering fluid hoses and to assure proper routing and connection to the cooler. IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leaking. IMPORTANT: Be careful to not cross-thread or overtighten the hose fittings.

High Pressure Hose (Pump-To-Control Valve)

REMOVAL

CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. NOTE: Catch the fluid that drains from the pump and the hoses in a suitable container. 1. Remove the high pressure hose fitting with the O-ring seal from the pump fitting on the rear of the pump.

a
a High Pressure Hose Fitting (O-ring Not Shown) b Pump Fitting

77827

90-864260 OCTOBER 2001

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POWER STEERING PUMP

SERVICE MANUAL NUMBER 31

2. Remove the hose where routed and secured (port or starboard side), across the top of the engine, near the valve cover. 3. Remove the fitting from the control valve at the transom. Remove the hose.

a
77845

a Power Steering Hose Fitting

INSTALLATION

CAUTION
Route the hoses exactly as shown below. This will help avoid stress on the hose fittings and will help avoid kinks in the hoses. IMPORTANT: Be careful to not cross-thread or overtighten the hose fittings. 1. Route the hose in the same position as prior to removal. Install the power steering hose fitting and torque. Do NOT cross-thread or overtighten.

77845

a Power Steering Hose Fitting

Description Nm 31 lb-in. lb-ft 23

Power Steering Hose Fitting

Page 9A-12

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

POWER STEERING PUMP

2. Using a new high pressure hose O-ring, install the threaded fitting in the back of the pump assembly fitting. Tighten the fitting securely. Do NOT cross-thread or overtighten.

a
77827

a High Pressure Hose Fitting (O-ring Not Shown) b Pump Fitting 3. Fill and air bleed the system. Refer to SECTION 1B.

Low Pressure Hose (Pump-To-Fluid Cooler)

REMOVAL

CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. NOTE: Catch the fluid that drains from the hose, the cooler and the pump in a suitable container. 1. Loosen the hose clamp and remove the hose from the fluid cooler.

a
a Hose

77826

90-864260 OCTOBER 2001

Page 9A-13

POWER STEERING PUMP

SERVICE MANUAL NUMBER 31

2. Loosen the hose clamp and remove the hose from the back of the pump.

a
a Hose

77827

INSTALLATION
1. Using the hose clamp, install the new hose on the back of the pump. Tighten the clamp securely.

77827

a Hose 2. Using the hose clamp, install the hose on the fluid cooler. Tighten the clamp securely.

a
77826

a Hose 3. Fill and air bleed the system. Refer to SECTION 1B.

Page 9A-14

90-864260 OCTOBER 2001

SERVICE MANUAL NUMBER 31

POWER STEERING PUMP

Low Pressure Hose (Control Valve-To-Fluid Cooler)

REMOVAL

CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. NOTE: Catch the fluid that drains from the hose, the cooler and the pump in a suitable container. 1. Loosen the hose clamp and remove the hose from the fluid cooler.

a
77826

a Hose 2. Remove the fitting from the control valve at the transom. Remove the hose.

a
77845

a Power Steering Hose Fitting

90-864260 OCTOBER 2001

Page 9A-15

POWER STEERING PUMP

SERVICE MANUAL NUMBER 31

INSTALLATION

CAUTION
Route the hoses exactly as shown below. This will help avoid stress on the hose fittings and will help avoid kinks in the hoses. IMPORTANT: Be careful to not cross-thread or overtighten the hose fittings. 1. Position the hose properly (as prior to removal). Install the fitting and torque. Do NOT cross-thread or overtighten.

a
77845

a Power Steering Hose Fitting

Description Nm 31 lb-in. lb-ft 23

Power Steering Hose Fitting

2. Route the hose along the flywheel housing and secure with the J-clamps provided. 3. Using the hose clamp, install the hose on the fluid cooler. Tighten the clamp securely.

a
77826

a Hose 4. Fill and air bleed the system. Refer to SECTION 1B.

Page 9A-16

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POWER STEERING PUMP

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90-864260 OCTOBER 2001

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POWER STEERING PUMP

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Page 9A-18

90-864260 OCTOBER 2001

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YPMXVTRVP@@@october@RPPQ

p@TdMW

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