SERVICE

MANUAL
Number 25

MARINE ENGINES
GM V-6
262 CID (4.3L)

Printed in U.S.A. 1999, Mercury Marine 90-861328--1 1199

MerCruiser #25 GM V-6 90-861328--1
262 CID (4.3L)

i
MerCruiser #25 GM V-6 90-861328--1
262 CID (4.3L)

90-
Notice
Throughout this publication, “Dangers,” “Warnings” and “Cautions” (accompanied by the In-
ternational HAZARD Symbol ) are used to alert the mechanic to special instructions con-
cerning 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
DANGER - Immediate hazards which WILL result in severe personal injury or death.

WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal in-
jury 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 the servicing procedures of these prod-
ucts, or like or similar products manufactured and marketed by Mercury Marine, that they
have been trained in the recommended servicing procedures of these products which in-
cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom-
mended tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. 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 by the
service procedure selected.
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.
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.

90-861328--1 NOVEMBER 1999 Page i

 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 met-
ric 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. Mis-
matched 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 when-
ever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products
described in this manual.

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 which 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 automo-
tive parts within a short period of time.
Failure to use recommended Quicksilver service replacement parts can result in poor en-
gine performance and/or durability, rapid corrosion of parts subjected to salt water and
possibly complete failure of the engine.
Use of parts other than recommended service replacement parts, will void the warranty on
those parts which are damaged as a result of the use of other than recommended replace-
ment parts.

Replacement Parts
WARNING
Electrical, ignition and fuel system components on MerCruiser Engines and Stern-
drives are designed and manufactured to comply with U.S. Coast Guard Rules
and Regulations to minimize risks of fire or explosion.
Use of replacement electrical, ignition or fuel system components, which do not
comply to these rules and regulations, could result in a fire or explosion hazard and
should be avoided.
When servicing the electrical, ignition and fuel systems, it is extremely important
that all components are properly installed and tightened. If not, any electrical or ig-
nition component opening would permit sparks to ignite fuel vapors from fuel sys-
tem leaks, if they existed.

Page ii 90-861328--1 NOVEMBER 1999

Service Manual Outline
Section 1 - Important Information
Important Information
1
A - General Information
B - Maintenance
C - Troubleshooting
Section 2 - Removal and Installation
Removal and Installation
2
A - MCM Models
Section 3 - Engine
A - 262 CID / 4.3L Engines
Section 4 - Electrical Systems
Engine
3
A - Starting System
B - Ignition System
C - Charging System
D - Instrumentation
Electrical Systems
4
E - Wiring Diagrams
Section 5 - Fuel Systems
A - Fuel Delivery System For Carbureted Engines
Fuel Systems
5
B - Mercarb 2 Barrel Carburetor
C - Weber 4 Barrel Carburetor
D - SAV1 Emission Fuel System With Weber Carburetor
E - Fuel Delivery System For Electronic Fuel Injection
Cooling System
6
F - Fuel Injection Descriptions And System Operation
G - Fuel Injection Disassembly And Reassembly
H - Fuel Injection System Troubleshooting
I - Diagnostics
Exhaust System
7
Section 6 - Cooling System
A - Seawater Cooled Models
B - Closed Cooled Models
Section 7 - Exhaust System
Drives
8
A - General
B - Manifolds, Elbows and Risers
C - Collectors
Section 8 - Drives
Power Steering System
9
A - Drive Shaft Models
Section 9 - Power Steering System
A - Pump and Related Components

90-861328--1 NOVEMBER 1999 Page iii

Table of Contents

IMPORTANT INFORMATION
Section 1A - General Information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 Propeller Information . . . . . . . . . . . . . . . . 1A-5
How to Use This Manual . . . . . . . . . . . . . 1A-2 Water Testing New Engines . . . . . . . . . . 1A-6
Page Numbering . . . . . . . . . . . . . . . . . 1A-2 Boat and Engine Performance . . . . . . . . 1A-6
How to Read a Parts Manual . . . . . . . . . 1A-3 Boat Bottom . . . . . . . . . . . . . . . . . . . . . 1A-6
Directional References . . . . . . . . . . . . . . . 1A-4 Marine Fouling . . . . . . . . . . . . . . . . . . . 1A-7
Engine Rotation . . . . . . . . . . . . . . . . . . . . . 1A-4 Weight Distribution . . . . . . . . . . . . . . . . 1A-8
Engine Serial Number Location . . . . . . . 1A-5 Water in Boat . . . . . . . . . . . . . . . . . . . . 1A-9
Elevation and Climate . . . . . . . . . . . . . 1A-9

Section 1B - Maintenance
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Closed Cooling System . . . . . . . . . . . . . . 1B-17
Lubricants / Sealants / Adhesives . . . . . 1B-2 Checking Coolant Level . . . . . . . . . . . 1B-17
Maintenance Schedules . . . . . . . . . . . . . . 1B-3 Flushing System . . . . . . . . . . . . . . . . . 1B-18
Maintenance Intervals . . . . . . . . . . . . . 1B-3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20
Gas Sterndrive . . . . . . . . . . . . . . . . . . . . . . 1B-3 Throttle Cable . . . . . . . . . . . . . . . . . . . . 1B-20
Routine Maintenance * . . . . . . . . . . . . 1B-3 Shift Cable . . . . . . . . . . . . . . . . . . . . . . . 1B-20
Scheduled Maintenance * . . . . . . . . . . 1B-4 Engine Coupler /
Engine and Tune-Up Specifications . . . . 1B-5 U-Joint Shaft Splines . . . . . . . . . . . . . 1B-21
MCM (Sterndrive) . . . . . . . . . . . . . . . . . 1B-5 Sterndrive Drive
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . 1B-6 Shaft Extension Models . . . . . . . . . . . 1B-22
Sterndrive Engines . . . . . . . . . . . . . . . 1B-6 Cleaning Flame Arrestor . . . . . . . . . . . . . 1B-22
Sterndrives . . . . . . . . . . . . . . . . . . . . . . 1B-6 Top Mounted Flame Arrestor . . . . . . . 1B-23
20-Hour Break-In Period . . . . . . . . . . . . . 1B-7 Serpentine Drive Belt . . . . . . . . . . . . . . . . 1B-23
After Break-in Period . . . . . . . . . . . . . . . . 1B-7 Component Location . . . . . . . . . . . . . . 1B-23
End of First Season Checkup . . . . . . . . . 1B-7 Serpentine Belt Routing . . . . . . . . . . . . . . 1B-24
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B-8 S/N 0L619083 and Below . . . . . . . . . . 1B-24
Fuel Recommendations . . . . . . . . . . . 1B-8 S/N 0L619084 and Above . . . . . . . . . 1B-25
Test For Alcohol Content In Gasoline 1B-10 Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-26
Power Steering Fluid . . . . . . . . . . . . . . . . 1B-10 Replacing and/or Adjusting Tension . 1B-26
Coolant for Closed Cooling System . . . . 1B-10 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . 1B-27
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . 1B-11 Thunderbolt V Models . . . . . . . . . . . . . 1B-27
Overfilled Crankcase Oil . . . . . . . . . . . 1B-11 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-28
Checking Engine Oil Level / Filling . . 1B-12 Cold Weather or Extended Storage . . . . 1B-29
Changing Oil and Filter . . . . . . . . . . . . . . . 1B-12 Precautions . . . . . . . . . . . . . . . . . . . . . . 1B-29
Changing Water Separating Fuel Filter . 1B-13 Power Package Layup . . . . . . . . . . . . 1B-31
Power Steering System . . . . . . . . . . . . . . 1B-15 Draining Instructions . . . . . . . . . . . . . . 1B-33
Checking Fluid Level . . . . . . . . . . . . . . 1B-15 Draining Sterndrive . . . . . . . . . . . . . . . 1B-38
Engine Cold . . . . . . . . . . . . . . . . . . . . . 1B-15 Recommissioning . . . . . . . . . . . . . . . . . 1B-39
Filling and Bleeding . . . . . . . . . . . . . . . 1B-16

Page iv 90-861328--1 NOVEMBER 1999

 Section 1C - Troubleshooting
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Poor Fuel Economy . . . . . . . . . . . . . . . . . 1C-14
Used Spark Plug Analysis . . . . . . . . . . . . 1C-3 Engine Runs Poorly at Idle . . . . . . . . . . . 1C-14
Normal Condition . . . . . . . . . . . . . . . . . 1C-3 Engine Runs Poorly At High RPM . . . . . 1C-15
Chipped Insulator . . . . . . . . . . . . . . . . . 1C-3 Engine Acceleration Is Poor . . . . . . . . . . 1C-16
Wet Fouling (Oil Deposits) . . . . . . . . . 1C-4 Troubleshooting with Vacuum Gauge . . 1C-16
Cold Fouling . . . . . . . . . . . . . . . . . . . . . 1C-4 Engine Noise . . . . . . . . . . . . . . . . . . . . . . . 1C-17
Overheating . . . . . . . . . . . . . . . . . . . . . 1C-4 Important Information . . . . . . . . . . . . . 1C-17
High Speed Glazing . . . . . . . . . . . . . . . 1C-5 Valve Cover Area . . . . . . . . . . . . . . . . . 1C-17
Scavenger Deposits . . . . . . . . . . . . . . 1C-5 Cylinder Area . . . . . . . . . . . . . . . . . . . . 1C-18
Pre-Ignition Damage . . . . . . . . . . . . . . 1C-5 Camshaft Area . . . . . . . . . . . . . . . . . . . 1C-18
Reversed Coil Polarity . . . . . . . . . . . . . 1C-6 Crankshaft Area . . . . . . . . . . . . . . . . . . 1C-19
Splashed Deposits . . . . . . . . . . . . . . . . 1C-6 Miscellaneous . . . . . . . . . . . . . . . . . . . . 1C-20
Mechanical Damage . . . . . . . . . . . . . . 1C-6 Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Poor Boat Performance and/or Miscellaneous . . . . . . . . . . . . . . . . . . . . 1C-21
Poor Maneuverability . . . . . . . . . . . . . . . . 1C-7 Low Oil Pressure . . . . . . . . . . . . . . . . . 1C-22
Improper Full Throttle Engine RPM . . . . 1C-8 High Oil Pressure . . . . . . . . . . . . . . . . . 1C-22
RPM Too High . . . . . . . . . . . . . . . . . . . 1C-8 Excessive Oil Consumption . . . . . . . . . . . 1C-23
RPM Too Low . . . . . . . . . . . . . . . . . . . . 1C-8 Water In Engine . . . . . . . . . . . . . . . . . . . . . 1C-24
Engine Cranks Over But Will Not Start Important Information . . . . . . . . . . . . . 1C-24
Or Starts Hard . . . . . . . . . . . . . . . . . . . . . . 1C-9I Water on Top of Pistons . . . . . . . . . . . 1C-25
mportant Information . . . . . . . . . . . . . . . . . 1C-9 Water in Crankcase Oil . . . . . . . . . . . . 1C-25
Thunderbolt V Ignition (No Spark) . . . 1C-10 Engine Overheats . . . . . . . . . . . . . . . . . . . 1C-26
Testing Thunderbolt V Ignition System 1C-10 Mechanical . . . . . . . . . . . . . . . . . . . . . . 1C-26
Fuel System Rich . . . . . . . . . . . . . . . . . 1C-11 Engine Overheats . . . . . . . . . . . . . . . . . . . 1C-27
Fuel System Lean . . . . . . . . . . . . . . . . 1C-11 Cooling System . . . . . . . . . . . . . . . . . . 1C-27
Miscellaneous . . . . . . . . . . . . . . . . . . . . 1C-11 Insufficient Water Flow from
Engine Will Not Crank Over . . . . . . . . . . . 1C-12 Belt Driven Seawater Pickup Pump . 1C-28
Charging System Inoperative . . . . . . . . . 1C-12 Power Steering . . . . . . . . . . . . . . . . . . . . . 1C-29
Noisy Alternator . . . . . . . . . . . . . . . . . . . . . 1C-13 Poor, Erratic or No Assist . . . . . . . . . . 1C-29
Instrumentation Malfunction . . . . . . . . . . 1C-13 Noisy Pump . . . . . . . . . . . . . . . . . . . . . . 1C-30
Radio Noise . . . . . . . . . . . . . . . . . . . . . . . . 1C-13 Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . 1C-30

REMOVAL AND INSTALLATION

Section 2A - MCM Models
Torque Specifications . . . . . . . . . . . . . . . . 2A-2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Lubricants / Sealants / Adhesives . . . . . 2A-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
Installation and Alignment . . . . . . . . . . . . 2A-5
Engine Connections . . . . . . . . . . . . . . 2A-10
Electrical Connections . . . . . . . . . . . . . 2A-11
Mercathode Connections . . . . . . . . . . 2A-12
Shift Cable Installation . . . . . . . . . . . . 2A-12
Power Steering Connections . . . . . . . 2A-12
Fuel Supply Connections . . . . . . . . . . 2A-13
Throttle Cable Installation and
Adjustment . . . . . . . . . . . . . . . . . . . . . . 2A-14

90-861328--1 NOVEMBER 1999 Page v

 ENGINE
Section 3A - 262 cid (4.3L) Engines
Torque Specifications . . . . . . . . . . . . . . . 3A-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-62
Lubricants / Sealants / Adhesives . . . . . 3A-4 Cleaning and Inspection . . . . . . . . . . . 3A-63
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-63
Specifications . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-64
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-64
Bearing Failures . . . . . . . . . . . . . . . . . . . . 3A-14 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-64
Piston Failures . . . . . . . . . . . . . . . . . . . . . . 3A-16 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-65
Pre-Ignition . . . . . . . . . . . . . . . . . . . . . . 3A-16 Rear Main Oil Seal . . . . . . . . . . . . . . . . . . 3A-66
Detonation . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-66
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . 3A-19 Cleaning and Inspection . . . . . . . . . . . 3A-67
Rocker Arm Cover . . . . . . . . . . . . . . . . . . . 3A-20 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-67
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-20 Rear Main Oil Seal Retainer . . . . . . . . . . 3A-68
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-68
Intake Manifold . . . . . . . . . . . . . . . . . . . . . 3A-21 Cleaning and Inspection . . . . . . . . . . . 3A-68
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-68
Cleaning and Inspection . . . . . . . . . . . 3A-23 Main Bearings . . . . . . . . . . . . . . . . . . . . . . 3A-69
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-23 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-69
Rocker Arm / Push Rod . . . . . . . . . . . . . . 3A-27 Replacement . . . . . . . . . . . . . . . . . . . . . 3A-71
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-27 Connecting Rod Bearings . . . . . . . . . . . . 3A-74
Cleaning and Inspection . . . . . . . . . . . 3A-28 Inspection and Replacement . . . . . . . 3A-74
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-28 Connecting Rod / Piston Assembly . . . . 3A-76
Hydraulic Roller Valve Lifters . . . . . . . . . 3A-29 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-76
Locating Noisy Lifters . . . . . . . . . . . . . 3A-30 Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-77
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-31 Cleaning and Inspection . . . . . . . . . . . 3A-78
Cleaning and Inspection . . . . . . . . . . . 3A-34 Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-80
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-34 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-82
Valve Stem Oil Seal / Valve Spring . . . . 3A-36 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 3A-84
Removal - Head Installed . . . . . . . . . . 3A-36 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-84
Valve Assembly (Exploded View) . . . 3A-38 Cleaning and Inspection . . . . . . . . . . . 3A-86
Installation - Head Installed . . . . . . . . 3A-39 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-87
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . 3A-40 Timing Chain and Sprocket . . . . . . . . . . . 3A-88
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-40 Exploded View . . . . . . . . . . . . . . . . . . . 3A-88
Cleaning and Inspection . . . . . . . . . . . 3A-42 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-88
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-43 Cleaning and Inspection . . . . . . . . . . . 3A-89
Cylinder Head and Valve Conditioning . 3A-47 Installation - Timing Chain . . . . . . . . . 3A-89
Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-47 Crankshaft Sprocket . . . . . . . . . . . . . . . . . 3A-89
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 3A-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-89
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-48 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-89
Valve Guide Bore Repair . . . . . . . . . . 3A-49 Checking Timing Chain Deflection . . 3A-90
Valve Springs - Checking Tension . . . 3A-50 Balance Shaft / Gears . . . . . . . . . . . . . . . 3A-91
Valve Seat Repair . . . . . . . . . . . . . . . . 3A-50 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-91
Valve Grinding . . . . . . . . . . . . . . . . . . . 3A-51 Cleaning and Inspection . . . . . . . . . . . 3A-94
Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-52 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-94
Dipstick Specifications . . . . . . . . . . . . . . . 3A-55 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-96
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-56 Measuring Lobe Lift . . . . . . . . . . . . . . . 3A-96
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-56 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-97
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-56 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-98
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-57 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-98
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-57 Camshaft Bearings . . . . . . . . . . . . . . . . . . 3A-99
Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-58 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-99
Cleaning and Inspection . . . . . . . . . . . 3A-58 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-100
Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-58 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-100
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-59 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . 3A-101
Torsional Damper . . . . . . . . . . . . . . . . . . . 3A-59 Cleaning and Inspection . . . . . . . . . . . 3A-101
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-59 Oil Filter By-Pass Valve . . . . . . . . . . . . . . 3A-105
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-60 Inspection and/or Replacement . . . . . 3A-105
Crankcase Front Cover Oil Seal . . . . . . . 3A-61 Remote Oil Filter . . . . . . . . . . . . . . . . . . . . 3A-106
Crankcase Front Cover . . . . . . . . . . . . . . 3A-62 Inspection and/or Replacement . . . . . 3A-106

Page vi 90-861328--1 NOVEMBER 1999

 Section 4A - Starting Systems
Identification . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Periodic Inspection . . . . . . . . . . . . . . . . . . 4A-13
Replacement Parts Warning . . . . . . . . . . 4A-2 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13
General Precautions . . . . . . . . . . . . . . . . . 4A-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4A-13
Starting System Components . . . . . . . . . 4A-3 Disassembly . . . . . . . . . . . . . . . . . . . . . 4A-13
Positive Current Flow . . . . . . . . . . . . . . . . 4A-4 Cleaning and Inspection . . . . . . . . . . . 4A-16
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4 Reassembly . . . . . . . . . . . . . . . . . . . . . 4A-17
Battery Cable Recommendations . . . 4A-4 Checking Pinion Clearance . . . . . . . . 4A-21
Maintenance . . . . . . . . . . . . . . . . . . . . . 4A-6 Installation . . . . . . . . . . . . . . . . . . . . . . . 4A-22
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-7 Delco PG260 Starter . . . . . . . . . . . . . . . . . 4A-23
Storage . . . . . . . . . . . . . . . . . . . . . . . . . 4A-7 PG260 Specifications . . . . . . . . . . . . . 4A-23
Charging Guide . . . . . . . . . . . . . . . . . . 4A-8 Torque Specification . . . . . . . . . . . . . . 4A-23
How Temperature Affects Lubricants / Sealants . . . . . . . . . . . . . . 4A-23
Battery Power . . . . . . . . . . . . . . . . . . . 4A-8 Description . . . . . . . . . . . . . . . . . . . . . . 4A-23
Standard Starter Slave Solenoid . . . . . . 4A-9 PG260 Exploded View . . . . . . . . . . . . . . . 4A-24
Identification . . . . . . . . . . . . . . . . . . . . . 4A-9 Solenoid Switch . . . . . . . . . . . . . . . . . . . . . 4A-25
Standard Type Slave Solenoid . . . . . 4A-9 Periodic Inspection . . . . . . . . . . . . . . . . . . 4A-25
Testing / Replacement . . . . . . . . . . . . . 4A-9 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-26
Installation . . . . . . . . . . . . . . . . . . . . . . . 4A-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4A-26
Permanent Magnet - Gear Reduction Disassembly . . . . . . . . . . . . . . . . . . . . . 4A-26
(PG260F1) Starter Motor . . . . . . . . . . . . . 4A-10 Cleaning and Inspection . . . . . . . . . . . 4A-30
Starter Specifications . . . . . . . . . . . . . 4A-10 Armature Tests . . . . . . . . . . . . . . . . . . . 4A-31
Torque Specifications . . . . . . . . . . . . . 4A-10 Armature Bearing (Commutator End) 4A-32
Lubricants / Sealants . . . . . . . . . . . . . . 4A-10 Gear Bearing . . . . . . . . . . . . . . . . . . . . 4A-32
Description . . . . . . . . . . . . . . . . . . . . . . 4A-11 Shaft Assembly Bearing . . . . . . . . . . . 4A-33
PG260F1 Exploded View . . . . . . . . . . . . . 4A-12 Drive End Housing Bearing . . . . . . . . 4A-33
Solenoid Switch . . . . . . . . . . . . . . . . . . . . . 4A-13 Brushes and Brush Holder . . . . . . . . . 4A-34

Section 4B - Thunderbolt V Ignition System

Replacement Parts Warning . . . . . . . . . . 4B-2 Circuit Description . . . . . . . . . . . . . . . . . . . 4B-10
General Precautions . . . . . . . . . . . . . . . . . 4B-2 Ignition Control Module . . . . . . . . . . . . 4B-10
EFI System Maintenance Precautions . 4B-3 Knock Control Module . . . . . . . . . . . . . 4B-10
Thunderbolt V Ignition System . . . . . . . . 4B-4 Ignition Control System Timing Lead 4B-10
Identification . . . . . . . . . . . . . . . . . . . . . 4B-4 Thunderbolt V Spark Control Graph . . . 4B-11
Timing and Idle Adjustment Procedures 4B-5 Distributor Advance Curves . . . . . . . . . . . 4B-12
Setting Base Ignition Timing . . . . . . . . 4B-5 Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-12
Adjusting Idle Mixture . . . . . . . . . . . . . 4B-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4B-12
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Disassembly . . . . . . . . . . . . . . . . . . . . . 4B-13
Specifications . . . . . . . . . . . . . . . . . . . . 4B-6 Reassembly . . . . . . . . . . . . . . . . . . . . . 4B-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Installation - Engine Not Disturbed . . 4B-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Installation - Engine Disturbed . . . . . . 4B-14
Replacing . . . . . . . . . . . . . . . . . . . . . . . 4B-7 Distributor Cap . . . . . . . . . . . . . . . . . . . . . . 4B-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4B-15
Idle Speed Spark Control . . . . . . . . . . 4B-7 Inspection . . . . . . . . . . . . . . . . . . . . . . . 4B-15
Acceleration Spark Advance . . . . . . . 4B-8 Rotor/Sensor Wheel . . . . . . . . . . . . . . . . . 4B-16
Mean-Best-Timing (MBT) Removal . . . . . . . . . . . . . . . . . . . . . . . . 4B-16
Spark Advance . . . . . . . . . . . . . . . . . . 4B-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . 4B-16
Over-Speed Control . . . . . . . . . . . . . . . 4B-8 Installation . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Knock Retard Spark Control . . . . . . . 4B-8 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Spark Plug Wires . . . . . . . . . . . . . . . . . . . . 4B-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Adjusting Engine Idle Speed . . . . . . . 4B-9 Inspection . . . . . . . . . . . . . . . . . . . . . . . 4B-18
Installation . . . . . . . . . . . . . . . . . . . . . . . 4B-18

90-861328--1 NOVEMBER 1999 Page vii

 Section 4C - Charging System
General Precautions . . . . . . . . . . . . . . . . . 4C-2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-7
EFI Electrical System Precautions . . . . . 4C-2 Charging System . . . . . . . . . . . . . . . . . 4C-7
Replacement Parts Warning . . . . . . . . . . 4C-2 Charging System Resistance . . . . . . . 4C-8
Multiple EFI Engine Battery Precautions 4C-3 Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . 4C-10
Situation . . . . . . . . . . . . . . . . . . . . . . . . . 4C-3 Component . . . . . . . . . . . . . . . . . . . . . . 4C-11
Recommendations . . . . . . . . . . . . . . . . 4C-3 Exploded View . . . . . . . . . . . . . . . . . . . . . . 4C-16
Identification . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 Alternator Repair . . . . . . . . . . . . . . . . . . . . 4C-17
Specifications . . . . . . . . . . . . . . . . . . . . . . . 4C-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4C-17
Mando . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 Disassembly . . . . . . . . . . . . . . . . . . . . . 4C-17
DelcoRemy . . . . . . . . . . . . . . . . . . . . . . 4C-5 Cleaning and Inspection . . . . . . . . . . . 4C-22
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-5 Reassembly . . . . . . . . . . . . . . . . . . . . . 4C-22
Lubricants / Sealants / Adhesives . . . . . 4C-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4C-26
Torque Specifications . . . . . . . . . . . . . . . . 4C-5 Pulley Removal . . . . . . . . . . . . . . . . . . 4C-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . 4C-6 Battery Isolator Diagram . . . . . . . . . . . 4C-28

Section 4D - Instrumentation
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-9
Lubricants / Sealants / Adhesives . . . . . 4D-2 Oil Pressure . . . . . . . . . . . . . . . . . . . . . 4D-9
Identification . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 Water Temperature . . . . . . . . . . . . . . . 4D-10
Special Information . . . . . . . . . . . . . . . . . . 4D-3 Fuel Tank Sender . . . . . . . . . . . . . . . . . 4D-13
Lighting Options . . . . . . . . . . . . . . . . . . 4D-3 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-16
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5 Ignition Key Switch . . . . . . . . . . . . . . . 4D-16
Oil, Fuel and Temperature . . . . . . . . . 4D-5 Lanyard Stop Switches . . . . . . . . . . . . 4D-17
Battery Gauge . . . . . . . . . . . . . . . . . . . 4D-6 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-17
Cruiselog Meter . . . . . . . . . . . . . . . . . . 4D-7 Start/Stop Switch . . . . . . . . . . . . . . . . . 4D-19
Vacuum Gauge . . . . . . . . . . . . . . . . . . . 4D-7 Audio Warning System . . . . . . . . . . . . . . . 4D-20
Speedometer . . . . . . . . . . . . . . . . . . . . 4D-7 Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-20
Tachometer . . . . . . . . . . . . . . . . . . . . . . 4D-8 Oil Pressure Switch . . . . . . . . . . . . . . . 4D-21
Gauge Replacement . . . . . . . . . . . . . . 4D-8 Water Temperature Switch . . . . . . . . . 4D-21

Section 4E - Wiring Diagrams

Wiring Colors for Mercury MerCruiser . . 4E-2
MCM Gasoline Engine Wiring Diagrams 4E-4
Starting and Charging Harness . . . . . 4E-4
Fuel and Ignition System Harnesses 4E-16
Quicksilver Instrumentation . . . . . . . . 4E-22
Dual Station Wiring . . . . . . . . . . . . . . . 4E-24

FUEL SYSTEM
Section 5A - Fuel Delivery System For Carbureted Engines
Identification . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Fuel Delivery System . . . . . . . . . . . . . . . . 5A-4
Replacement Parts Warning . . . . . . . . . . 5A-2 Recommendations . . . . . . . . . . . . . . . . 5A-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Fuel System Components . . . . . . . . . . . . 5A-6
Torque Specifications . . . . . . . . . . . . . . . . 5A-2 Water Separating Fuel Filter . . . . . . . . . . 5A-7
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 Replacement . . . . . . . . . . . . . . . . . . . . . 5A-8
Lubricants / Sealants / Adhesives . . . . . 5A-3 Vent Hose Routing . . . . . . . . . . . . . . . . . . 5A-8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 Carbureted Models . . . . . . . . . . . . . . . 5A-8
Fuel Supply Connections . . . . . . . . . . 5A-3

Page viii 90-861328--1 NOVEMBER 1999

 Section 5B - Mercarb 2 Barrel Carburetor
Identification . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 5B-11
Replacement Parts Warning . . . . . . . . . . 5B-3 Flame Arrestor . . . . . . . . . . . . . . . . . . . 5B-11
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5B-3 Fuel Inlet Filter . . . . . . . . . . . . . . . . . . . 5B-13
Torque Specifications . . . . . . . . . . . . . . . . 5B-3 Choke Inspection . . . . . . . . . . . . . . . . . 5B-14
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Accelerator Rod . . . . . . . . . . . . . . . . . . 5B-14
Exploded View . . . . . . . . . . . . . . . . . . . . . . 5B-6 Choke Setting . . . . . . . . . . . . . . . . . . . . 5B-16
Important Service Information . . . . . . . . . 5B-8 Choke Unloader . . . . . . . . . . . . . . . . . . 5B-17
High Altitude Re-Jetting . . . . . . . . . . . 5B-8 Initial Idle Speed and Mixture . . . . . . . 5B-17
8 Point Carburetor Check List . . . . . . 5B-9 Final Idle Speed and Mixture . . . . . . . 5B-18
Flooding At Idle RPM . . . . . . . . . . . . . 5B-9 Replacing Carburetor . . . . . . . . . . . . . . . . 5B-18
Needle / Seat Change . . . . . . . . . . . . . 5B-9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-19
Adjustable Accelerator Pump Lever . 5B-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . 5B-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Disassembly . . . . . . . . . . . . . . . . . . . . . 5B-20
Cleaning and Inspection . . . . . . . . . . . 5B-28
Reassembly . . . . . . . . . . . . . . . . . . . . . 5B-30
Installation . . . . . . . . . . . . . . . . . . . . . . . 5B-40

Section 5C - Weber 4 Barrel Carburetor

Identification . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 5C-12
Carburetor Metering Rod Flame Arrestor . . . . . . . . . . . . . . . . . . . 5C-12
And Jet Identification . . . . . . . . . . . . . 5C-2 Fuel Inlet Filter . . . . . . . . . . . . . . . . . . . 5C-13
Torque Specifications . . . . . . . . . . . . . . . . 5C-4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 5C-14
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Accelerator Pump . . . . . . . . . . . . . . . . 5C-14
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5 Float Drop . . . . . . . . . . . . . . . . . . . . . . . 5C-16
Replacement Parts Warning . . . . . . . . . . 5C-5 Float Level . . . . . . . . . . . . . . . . . . . . . . . 5C-17
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Electric Choke . . . . . . . . . . . . . . . . . . . 5C-18
Fuel Delivery System . . . . . . . . . . . . . . . . 5C-6 Idle Speed and Mixture . . . . . . . . . . . . 5C-18
Fuel Supply Connections . . . . . . . . . . 5C-6 Replacing Carburetor . . . . . . . . . . . . . . . . 5C-19
8 Point Carburetor Check List . . . . . . . . . 5C-7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-19
Exploded View . . . . . . . . . . . . . . . . . . . . . . 5C-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . 5C-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 5C-21
Important Service Information . . . . . . . . . 5C-11 Cleaning and Inspection . . . . . . . . . . . . . . 5C-32
Adjustable Accelerator Pump Lever . 5C-11 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 5C-33
Hard Starting . . . . . . . . . . . . . . . . . . . . . 5C-11 Installation . . . . . . . . . . . . . . . . . . . . . . . 5C-44

Section 5D - Sav1 Emission Fuel System With Weber 4 Barrel

Carburetor
Identification . . . . . . . . . . . . . . . . . . . . . . . . 5D-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 5D-8
Replacement Parts Warning . . . . . . . . . . 5D-2 Checking Ported Vacuum Switch and
Torque Specifications . . . . . . . . . . . . . . . . 5D-2 Carburetor Vacuum Circuit
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 5D-2 for Correct Operation . . . . . . . . . . . . . 5D-9
Engine Specifications . . . . . . . . . . . . . . . . 5D-3 Service Procedures . . . . . . . . . . . . . . . . . . 5D-11
Carburetor Specifications . . . . . . . . . . . . . 5D-3 Checking Positive Crankcase
Carburetor Adjustment Specifications . . 5D-4 Ventilation (PCV) Valve . . . . . . . . . . . 5D-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . 5D-4 Removing Seals From
Special Notes . . . . . . . . . . . . . . . . . . . . . . . 5D-5 Idle Mixture Screws . . . . . . . . . . . . . . 5D-11
Carburetor Top Cover . . . . . . . . . . . . . 5D-5 Installing New Seals . . . . . . . . . . . . . . 5D-12
Sealed Idle Mixture Screws . . . . . . . . 5D-5 Carburetor Installation . . . . . . . . . . . . . 5D-12
Piston Bore of Emissions Model . . . . 5D-6 Ported Vacuum Switch Installation . . 5D-13
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5D-6 Emissions System Connections . . . . 5D-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 5D-7 Propane Assisted Idle Set Procedure 5D-15
Flame Arrestor . . . . . . . . . . . . . . . . . . . 5D-7 Test Equipment . . . . . . . . . . . . . . . . . . . . . 5D-18
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . 5D-7 Emissions Testing . . . . . . . . . . . . . . . . . . . 5D-19
Positive Crankcase Ventilation (PCV) 5D-8

90-861328--1 NOVEMBER 1999 Page ix

 Section 5E - Fuel Delivery System
For Electronic Fuel Injection
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5E-2 Water Separating Fuel Filter . . . . . . . . . . 5E-7
Torque Specifications . . . . . . . . . . . . . . . . 5E-2 Water Separating Fuel Filter
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-2 Replacement . . . . . . . . . . . . . . . . . . . . 5E-8
Lubricants / Sealants / Adhesives . . . . . 5E-2 Cool Fuel System Repair . . . . . . . . . . . . . 5E-8
Replacement Parts Warning . . . . . . . . . . 5E-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . 5E-8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5E-3 Disassembly . . . . . . . . . . . . . . . . . . . . . 5E-10
Fuel Supply Connections . . . . . . . . . . . . . 5E-3 Reassembly . . . . . . . . . . . . . . . . . . . . . 5E-11
Fuel Delivery System . . . . . . . . . . . . . . . . 5E-4 Installation . . . . . . . . . . . . . . . . . . . . . . . 5E-13
Recommendations . . . . . . . . . . . . . . . . 5E-4 Vacuum and Vent Hose Routing . . . . . . . 5E-15
Cool Fuel System Exploded View . . . . . 5E-5 Throttle Body EFI . . . . . . . . . . . . . . . . . 5E-15
Fuel System Flow Diagrams . . . . . . . . . . 5E-6
Throttle Body Injection . . . . . . . . . . . . 5E-6

Section 5F - Fuel Injection Descriptions And

System Operation
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 5F-2 Electronic Control Module (ECM)
Service Precautions . . . . . . . . . . . . . . . . . 5F-3 and Sensors . . . . . . . . . . . . . . . . . . . . . . . 5F-13
General Information . . . . . . . . . . . . . . . . . 5F-5 General Description . . . . . . . . . . . . . . . 5F-13
Introduction . . . . . . . . . . . . . . . . . . . . . . 5F-5 Computers and Voltage Signals . . . . 5F-13
Visual/Physical Inspection . . . . . . . . . 5F-5 Analog Signals . . . . . . . . . . . . . . . . . . . 5F-13
Basic Knowledge and Tools Required 5F-5 Digital Signals . . . . . . . . . . . . . . . . . . . . 5F-14
Electrostatic Discharge Damage . . . . 5F-5 Engine Control Module (ECM) . . . . . . 5F-15
Diagnostic Information . . . . . . . . . . . . 5F-5 Speed Density System . . . . . . . . . . . . 5F-16
Wiring Harness Service . . . . . . . . . . . 5F-6 ECM Input and Sensor Descriptions . 5F-17
Wiring Connector Service . . . . . . . . . . 5F-7 Spark Management . . . . . . . . . . . . . . . . . . 5F-22
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . 5F-8 High Energy Ignition with
ECM Self-Diagnostics . . . . . . . . . . . . . . . . 5F-9 Ignition Control (IC) . . . . . . . . . . . . . . 5F-22
Diagnostic Code Tool Modes Of Operation . . . . . . . . . . . . . . 5F-23
With Malfunction Indicator Lamp . . . 5F-9 Base Ignition Timing . . . . . . . . . . . . . . 5F-24
Intermittent Malfunction Results of Incorrect Operation . . . . . . 5F-25
Indicator Lamp . . . . . . . . . . . . . . . . . . . 5F-9 Fuel Metering System . . . . . . . . . . . . . . . . 5F-26
Reading Codes . . . . . . . . . . . . . . . . . . . 5F-10 General Description . . . . . . . . . . . . . . . 5F-26
Scan Tools . . . . . . . . . . . . . . . . . . . . . . . 5F-11 Cool Fuel Systems . . . . . . . . . . . . . . . . 5F-26
EFI Diagnostic Circuit Check . . . . . . . 5F-11 Modes of Operation . . . . . . . . . . . . . . . 5F-26
Scan Tool Use With Intermittents . . . 5F-11 Throttle Body Injection Components . 5F-28
Non-Scan Diagnosis of Driveability
Concerns (With No Codes Set) . . . . 5F-12

Section 5G - Fuel Injection Disassembly And Reassembly

Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5G-2 Throttle Body Adapter Plate . . . . . . . . 5G-17
Torque Specifications . . . . . . . . . . . . . . . . 5G-3 Engine Control Module (ECM) . . . . . . 5G-18
Flame Arrestor And Throttle Body . . . . . 5G-4 Knock Sensor (KS) Module
Exploded Views - Throttle Body EFI . . . 5G-7 (MEFI 1 Only) . . . . . . . . . . . . . . . . . . . 5G-19
Throttle Body Body And Adapter . . . . 5G-7 Engine Coolant Temperature
Throttle Body Assembly . . . . . . . . . . . 5G-8 (ECT) Sensor . . . . . . . . . . . . . . . . . . . . 5G-20
Fuel Pressure Relief Procedure . . . . . . . 5G-9 Manifold Absolute Pressure
Throttle Body EFI Components . . . . . . . 5G-9 (MAP) Sensor . . . . . . . . . . . . . . . . . . . 5G-21
Fuel Meter Cover Assembly . . . . . . . . 5G-9 Throttle Position (TP) Sensor . . . . . . . 5G-22
Fuel Injectors . . . . . . . . . . . . . . . . . . . . 5G-11 Idle Air Control (IAC) Valve . . . . . . . . 5G-23
Throttle Body . . . . . . . . . . . . . . . . . . . . 5G-13 Knock Sensor . . . . . . . . . . . . . . . . . . . . 5G-25

Page x 90-861328--1 NOVEMBER 1999

 Section 5H - Fuel Injection System Troubleshooting
Scan Tool Normal Specifications . . . . . . 5H-2 Detonation / Spark Knock Symptom . . . 5H-11
Important Preliminary Checks . . . . . . . . . 5H-3 Hesitation, Sag, Stumble Symptom . . . . 5H-13
Before Starting . . . . . . . . . . . . . . . . . . . 5H-3 Cuts Out, Misses Symptom . . . . . . . . . . . 5H-15
Visual / Physical Check . . . . . . . . . . . . 5H-3 Rough, Unstable or Incorrect Idle,
Intermittents . . . . . . . . . . . . . . . . . . . . . . . . 5H-4 Stalling Symptom . . . . . . . . . . . . . . . . . . . 5H-17
Hard Start Symptom . . . . . . . . . . . . . . . . . 5H-5 Poor Fuel Economy Symptom . . . . . . . . 5H-20
Surges and/or Chuggles Symptom . . . . 5H-7 Dieseling, Run-On Symptom . . . . . . . . . . 5H-22
Lack of Power, Sluggish Backfire Symptom . . . . . . . . . . . . . . . . . . . 5H-23
or Spongy Symptom . . . . . . . . . . . . . . . . 5H-9

Section 5I - Diagnostics
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 5I-2 Clearing Trouble Codes . . . . . . . . . . . . . . 5I-48
Diagnostic Circuit Check . . . . . . . . . . . . . 5I-4 Clearing Codes Using
Scan Tool Normal Specifications . . . . 5I-4 CodeMate Tester . . . . . . . . . . . . . . . . . 5I-48
Diagnostic Trouble Codes . . . . . . . . . . . . 5I-5 Clearing Codes Using Scan Tool . . . . 5I-48
ECM Connector and Diagnostic Testing . . . . . . . . . . . . . . . . . . . 5I-49
EFI Symptoms Chart . . . . . . . . . . . . . . . . 5I-6 Code 14 Engine Coolant Temperature
J-1 Circuits with MEFI 1 . . . . . . . . . . . 5I-6 (ECT) Sensor Circuit . . . . . . . . . . . . . 5I-49
J-2 Circuits with MEFI 1 . . . . . . . . . . . 5I-8 Code 15 Engine Coolant Temperature
J-1 Circuits with MEFI 3 . . . . . . . . . . . 5I-10 (ECT) Sensor Circuit . . . . . . . . . . . . . 5I-52
J-2 Circuits with MEFI 3 . . . . . . . . . . . 5I-12 Code 21 Throttle Position
Wiring System Diagrams . . . . . . . . . . . . . 5I-14 (TP) Sensor Circuit . . . . . . . . . . . . . . . 5I-54
MEFI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 5I-14 Code 22 Throttle Position
MEFI 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 5I-18 (TP) Sensor Circuit . . . . . . . . . . . . . . . 5I-57
General Diagnostic Tests . . . . . . . . . . . . . 5I-21 Code 23 Intake Air Temperature
On-Board Diagnostic (IAT) Sensor Circuit . . . . . . . . . . . . . . 5I-60
(OBD) System Check . . . . . . . . . . . . . 5I-21 Code 25 Intake Air Temperature
Chart A-1 No MIL or No DLC Data . 5I-23 (IAT) Sensor Circuit . . . . . . . . . . . . . . 5I-62
Chart A-2 MIL ON Steady - Code 33 Manifold Absolute Pressure
Will Not Flash DTC 12 . . . . . . . . . . . . 5I-25 (MAP) Sensor Circuit . . . . . . . . . . . . . 5I-64
Chart A-3 Engine Cranks But Code 34 Manifold Absolute Pressure
Will Not Run . . . . . . . . . . . . . . . . . . . . . 5I-27 (MAP) Sensor Circuit . . . . . . . . . . . . . 5I-67
Chart A-4 Fuel System Diagnosis . . 5I-29 Code 41 Ignition Control (IC) Circuit 5I-70
Chart A-5 Fuel System Electrical Test 5I-31 Code 42 Ignition Control (IC) Circuit 5I-72
Chart A-6 EFI System / Code 43 Knock Sensor (KS) Circuit 5I-74
Ignition Relay Check . . . . . . . . . . . . . 5I-33 Code 44 Knock Sensor (KS) Circuit 5I-77
Chart A-7 Ignition System Check . . . 5I-35 Code 45 Ignition Coil Driver Fault . . 5I-80
Chart A-8 Idle Air Control Code 51 Calibration Memory Failure 5I-82
(IAC) Functional Test . . . . . . . . . . . . . 5I-41 Code 52 EEPROM Failure . . . . . . . . 5I-83
Discrete Input Circuit Check - Code 61 Fuel Pressure (FP) Circuit . 5I-84
Non-Scan Only . . . . . . . . . . . . . . . . . . 5I-43 Code 62 Fuel Pressure
(FP) Sensor Circuit . . . . . . . . . . . . . . . 5I-87

90-861328--1 NOVEMBER 1999 Page xi

 COOLING SYSTEM
Section 6A - Seawater Cooled Models
Torque Specifications . . . . . . . . . . . . . . . . 6A-2 Seawater Pump Bearing Housing . . . . . 6A-15
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Disassembly . . . . . . . . . . . . . . . . . . . . . 6A-15
Special Tools . . . . . . . . . . . . . . . . . . . . . 6A-2 Cleaning and Inspection . . . . . . . . . . . 6A-16
Lubricants / Sealants / Adhesives . . . . . 6A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . 6A-17
Specifications . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Water Circulating Pump . . . . . . . . . . . . . . 6A-20
Seawater Inlet Recommendations . . . . . 6A-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . 6A-20
Transom Mounted or Through The Hull Cleaning and Inspection . . . . . . . . . . . 6A-20
Seawater Pickups and Hose . . . . . . . 6A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-20
Seacock (Seawater Inlet Valve) . . . . . 6A-4 Drive Belt Tension Adjustment . . . . . . . . 6A-21
Sea Strainer . . . . . . . . . . . . . . . . . . . . . 6A-4 Flushing Seawater Cooling System . . . . 6A-21
Seawater Pickups . . . . . . . . . . . . . . . . . . . 6A-5 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Through The Hull Mounted . . . . . . . . . 6A-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Transom Mounted . . . . . . . . . . . . . . . . 6A-6 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-22
Quicksilver Sea Strainer . . . . . . . . . . . . . . 6A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Auxiliary Hot Water Heater
Cleaning and Inspection . . . . . . . . . . . 6A-9 Installation Information . . . . . . . . . . . . . . 6A-24
Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Seawater Flow Diagrams . . . . . . . . . . . . . 6A-28
Seawater Pickup Pump . . . . . . . . . . . . . . 6A-11 MCM 262 cid / 4.3L Alpha . . . . . . . . . 6A-28
Output Test . . . . . . . . . . . . . . . . . . . . . . 6A-11 MCM 262 cid / 4.3L Bravo . . . . . . . . . 6A-29
Disassembly . . . . . . . . . . . . . . . . . . . . . 6A-13 Draining Diagrams . . . . . . . . . . . . . . . . . . 6A-30
Reassembly . . . . . . . . . . . . . . . . . . . . . 6A-14 MCM 262 cid / 4.3L Alpha . . . . . . . . . 6A-30
MCM 262 cid / 4.3L Bravo . . . . . . . . . 6A-31

Section 6B - Closed Cooled Models

Torque Specifications . . . . . . . . . . . . . . . . 6B-2 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Lubricants / Sealants / Adhesives . . . . . 6B-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-11
Closed Cooling System Capacity . . . 6B-2 Installation . . . . . . . . . . . . . . . . . . . . . . . 6B-12
Coolant Specification . . . . . . . . . . . . . . 6B-2 Changing Coolant . . . . . . . . . . . . . . . . . . . 6B-13
Thermostat . . . . . . . . . . . . . . . . . . . . . . 6B-2 Closed Cooling Section . . . . . . . . . . . . 6B-13
Pressure Cap Rating . . . . . . . . . . . . . . 6B-2 Change Intervals . . . . . . . . . . . . . . . . . 6B-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3 Draining Instructions . . . . . . . . . . . . . . 6B-13
Coolant Recommendations . . . . . . . . . . . 6B-3 Cleaning System . . . . . . . . . . . . . . . . . . . . 6B-14
Maintaining Coolant Level . . . . . . . . . . . . 6B-3 Closed Cooling Section . . . . . . . . . . . . 6B-14
Pressure Cap Maintenance . . . . . . . . . . . 6B-4 Seawater Section . . . . . . . . . . . . . . . . . 6B-15
Heat Exchanger Repair . . . . . . . . . . . . . . 6B-5 Filling Closed Cooling Section . . . . . . . . 6B-16
Testing Closed Cooling System . . . . . . . 6B-6 Auxiliary Hot Water Heater Installation . 6B-18
Testing Coolant for Alkalinity . . . . . . . 6B-6 Heat Exchanger Bracket Hardware . . . . 6B-19
Pressure Testing System . . . . . . . . . . 6B-6 Heat Exchanger Hose Connections . . . . 6B-20
Testing for Cylinder Head Water Flow Diagram . . . . . . . . . . . . . . . . . 6B-21
Gasket Leak . . . . . . . . . . . . . . . . . . . . . 6B-7 MCM 262 cid / 4.3L Alpha . . . . . . . . . 6B-21
Testing Heat Exchanger . . . . . . . . . . . 6B-8 MCM 262 cid / 4.3L Bravo . . . . . . . . . 6B-22
Testing Pressure Cap . . . . . . . . . . . . . 6B-8

Page xii 90-861328--1 NOVEMBER 1999

 EXHAUST SYSTEM
Section 7A - General
Exhaust System Requirements . . . . . . . . 7A-2
Exhaust Elbow Risers . . . . . . . . . . . . . 7A-2
MCM (Sterndrive) Engines
With Through The Transom Exhaust 7A-2

Section 7B - Manifolds, Elbows and Risers

Torque Specifications . . . . . . . . . . . . . . . . 7B-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7B-6
Lubricants / Sealants / Adhesives . . . . . 7B-2 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . 7B-6
Exhaust Riser (Kit) . . . . . . . . . . . . . . . . . . 7B-2 Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 7B-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 Sterndrive Exhaust Extension . . . . . . 7B-9
Cleaning and Inspection . . . . . . . . . . . . . . 7B-4

Section 7C - Collectors
Torque Specifications . . . . . . . . . . . . . . . . 7C-2
Lubricants / Sealants / Adhesives . . . . . 7C-2
Bullhorn Exhaust . . . . . . . . . . . . . . . . . . . . 7C-3
Shutter Replacement . . . . . . . . . . . . . . 7C-3
Component Replacement . . . . . . . . . . 7C-4

DRIVES
Section 8A - Drive Shaft
Torque Specifications . . . . . . . . . . . . . . . . 8A-2 Replacement Drive Shafts . . . . . . . . . 8A-7
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 Drive Shafts Modified to
Lubricants / Sealants / Adhesives . . . . . 8A-2 Shorter Lengths . . . . . . . . . . . . . . . . . . 8A-8
Flywheel Housing / Output Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8A-8
Housing Repair . . . . . . . . . . . . . . . . . . . . . 8A-3 Bearing Support Repair . . . . . . . . . . . . . . 8A-10
Exploded View . . . . . . . . . . . . . . . . . . . 8A-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . 8A-10
Removal and Installation . . . . . . . . . . 8A-4 Disassembly . . . . . . . . . . . . . . . . . . . . . 8A-10
Disassembly . . . . . . . . . . . . . . . . . . . . . 8A-4 Reassembly . . . . . . . . . . . . . . . . . . . . . 8A-11
Reassembly . . . . . . . . . . . . . . . . . . . . . 8A-5 Installation . . . . . . . . . . . . . . . . . . . . . . . 8A-12
Drive Shaft Repair . . . . . . . . . . . . . . . . . . . 8A-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . 8A-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-7

90-861328--1 NOVEMBER 1999 Page xiii

 POWER STEERING SYSTEM
Section 9A - Pump And Related Components
Torque Specifications . . . . . . . . . . . . . . . . 9A-2 Testing and Repair . . . . . . . . . . . . . . . . . . 9A-8
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2 Checking Pump Fluid Level . . . . . . . . . . . 9A-8
Special Tools . . . . . . . . . . . . . . . . . . . . 9A-2 Filling and Air Bleeding System . . . . . . . 9A-8
Lubricants / Sealants / Adhesives . . . . . 9A-2 Pump Assembly . . . . . . . . . . . . . . . . . . . . . 9A-8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 9A-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . 9A-8
Power Steering Pump and Components Installation . . . . . . . . . . . . . . . . . . . . . . . 9A-10
(Exploded View) . . . . . . . . . . . . . . . . . . . . 9A-3 Hydraulic Hoses and Fluid Cooler . . . . . 9A-11
Serpentine Belt Routing . . . . . . . . . . . . . . 9A-4 High Pressure Hose
S/N 0L619083 and Below . . . . . . . . . . 9A-4 (Pump-to-Control Valve) . . . . . . . . . . 9A-11
S/N 0L619084 and Above . . . . . . . . . 9A-5 Low Pressure Hose
Serpentine Belt Adjustment . . . . . . . . . . . 9A-6 (Cooler-to-Pump) . . . . . . . . . . . . . . . . 9A-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . 9A-6 Low Pressure Hose
Installation . . . . . . . . . . . . . . . . . . . . . . . 9A-6 (Control Valve-to-Cooler) . . . . . . . . . . 9A-15
Important Service Information . . . . . . . . . 9A-7
Pump Pulley Replacement . . . . . . . . . 9A-7

Page xiv 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 GENERAL INFORMATION

IMPORTANT INFORMATION
1
Section 1A - General Information A
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 Propeller Information . . . . . . . . . . . . . . . . 1A-5
How to Use This Manual . . . . . . . . . . . . . 1A-2 Water Testing New Engines . . . . . . . . . . 1A-6
Page Numbering . . . . . . . . . . . . . . . . . 1A-2 Boat and Engine Performance . . . . . . . . 1A-6
How to Read a Parts Manual . . . . . . . . . 1A-3 Boat Bottom . . . . . . . . . . . . . . . . . . . . . 1A-6
Directional References . . . . . . . . . . . . . . . 1A-4 Marine Fouling . . . . . . . . . . . . . . . . . . . 1A-7
Engine Rotation . . . . . . . . . . . . . . . . . . . . . 1A-4 Weight Distribution . . . . . . . . . . . . . . . . 1A-8
Engine Serial Number Location . . . . . . . 1A-5 Water in Boat . . . . . . . . . . . . . . . . . . . . 1A-9
Elevation and Climate . . . . . . . . . . . . . 1A-9

90-861328--1 NOVEMBER 1999 Page 1A-1

GENERAL INFORMATION SERVICE MANUAL NUMBER 25

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 which more fully describe the component.
Sections and section parts are listed on the “Service Manual Outline” page following “V-6
Models Covered in This Manual” page.
Page Numbering
Two number groups appear at the bottom of each page. Following is an example and
description.

a b c d f g
e

a - Section Number
b - Section Part
c - Page Number
d - Manual Part Number
e - Revision Number
f - Month Printed
g - Year Printed

Page 1A-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 GENERAL INFORMATION

How to Read a Parts Manual

Power Steering Pump Assembly

2 8

10

1 6

3 4

REF.
NO. PART NO. SYM. QTY. DESCRIPTION
1 90507A12 1 PUMP ASSEMBLY–Power Steering
2 36- 95805 1 CAP
3 73873A1 1 PULLEY
4 16- 41877 1 STUD
5 57- 65607T 1 V-BELT
6 32- 806684 1 HOSE–Pressure (FITTINGS ON BOTH ENDS)
7 25- 89879 1 O-RING
8 25- 806232 1 O-RING
9 13- 35048 1 LOCKWASHER (3/8 in.)
10 61990 1 CABLE TIE

REF. NO. : Number shown next to part on exploded view

PART NO. : Mercury Part Number for ordering. If NSS (not sold separately) sometimes GM
part number will be given in description column.
QTY. : The quantity that must be ordered.
DESCRIPTION : Description of part, what parts are included with a part (all indented items
come with the main item above the indented parts), serial number information, and special
information.

90-861328--1 NOVEMBER 1999 Page 1A-3

GENERAL INFORMATION SERVICE MANUAL NUMBER 25

Directional References
Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this
manual, all directional references are given as they appear when viewing boat from stern
looking toward bow.

STARBOARD
(RIGHT)

FORE or BOW AFT or STERN

(FRONT) (REAR)

PORT
(LEFT)
72000

Engine Rotation
Engine rotation is determined by observing flywheel rotation from the rear (stern end) of the
engine looking forward (toward water pump end). Propeller rotation is not necessarily the
same as engine rotation. When ordering replacement engine, short blocks or parts for
engine, be certain to check engine rotation. Do not rely on propeller rotation in determining
engine rotation.

72001

Left Hand Rotation

Page 1A-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 GENERAL INFORMATION

Engine Serial Number Location

72975

a - Serial Number Plate

b - Starter Motor

Propeller Information
Refer to the “Propeller” section in appropriate Mercury MerCruiser Sterndrive Service
Manual, or order publication 90-8614492, “What You Should Know About Quicksilver
Propellers.”
Changing diameter, pitch or coupling of a propeller will affect engine rpm and boat
performance. The blade configuration also will affect performance. Two like propellers,
same pitch and diameter, from two different manufacturers also will perform differently.
It is the responsibility of the boat manufacturer and/or selling dealer to equip the boat with
the correct propeller to allow the engine to operate within its specified rpm range at wide
open throttle (WOT).
Because of the many variables of boat design and operation, only testing will determine the
best propeller for the particular application.
To test for correct propeller, operate boat (with an average load onboard) at WOT and check
rpm with an accurate tachometer. Engine rpm should be near top of the specified range so
that, under heavy load, engine speed will not fall below specifications.
If engine exceeds the specified rpm, an increase in pitch and/or diameter is required.
If engine is below rated rpm, a decrease in pitch and/or diameter is required.
Normally, a change of approximately 200 rpm will be achieved for each one inch pitch
change of a propeller.

CAUTION
If a propeller is installed that does not allow engine rpm to reach the specified
full-throttle rpm range, the engine will “labor” and will not produce full power.
Operation under this condition will cause excessive fuel consumption, engine
overheating and possible piston damage (due to detonation). On the other hand,
installation of a propeller, that allows engine to run above the specified rpm limit,
will cause excessive wear on internal engine parts which will lead to premature
engine failure.

90-861328--1 NOVEMBER 1999 Page 1A-5

GENERAL INFORMATION SERVICE MANUAL NUMBER 25

Water Testing New Engines

Use care during the first 20 hours of operation on new Mercury MerCruiser engines or
possible engine failure may occur. If a new engine has to be water-tested at full throttle
before the break-in period is complete, follow this procedure.
1. Start engine and run at idle rpm until normal operating temperature is reached.
2. Run boat up on plane.
3. Advance engine rpm (in 200 rpm increments) until engine reaches its maximum rated
rpm.
IMPORTANT: Do not run at maximum rpm for more than 2 minutes.

Boat and Engine Performance

Boat Bottom
For maximum speed, a boat bottom should be as flat as possible in a fore-aft direction
(longitudinally) for approximately the last 5 ft (1.5 m).

72002

a - Critical Bottom Area

For best speed and minimum spray, the corner between the bottom and the transom should
be sharp.

c b

72003
a
a - Bottom
b - Corner
c - Transom

Page 1A-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 GENERAL INFORMATION

The bottom is referred to as having a “hook” if it is concave in the fore-and-aft direction. A

hook causes more lift on the bottom near the transom and forces the bow to drop. This
increases wetted surface and reduces boat speed. A hook, however, aids in planing and
reduces any porpoising (rhythmical bouncing) tendency. A slight hook is often built in by the
manufacturer. A hook also can be caused by incorrect trailering or storing the boat with
support directly under the transom.

72004
a
a - Hook

A “rocker” is the reverse of a hook. The bottom is convex or bulged in the fore-and-aft
direction. It can cause the boat to porpoise.

a 72005

a - Rocker

Any hook, rocker or surface roughness on the bottom, particularly in the all-important
center-aft portion will have a negative effect on speed, often several miles per hour on a fast
boat.

Marine Fouling
Fouling is an unwanted build-up (usually animal-vegetable-derived) occurring on the boat’s
bottom and drive unit. Fouling adds up to drag, which reduces boat performance. In fresh
water, fouling results from dirt, vegetable matter, algae or slime, chemicals, minerals and
other pollutants. In salt water, barnacles, moss and other marine growth often produce
dramatic build-up of material quickly. Therefore, it is important to keep the hull as clean as
possible in all water conditions to maximize boat performance.
Antifouling paint, if required, may be applied to boat hull observing the following precautions.
IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and
anode, as this will render them ineffective as galvanic corrosion inhibitors.

CAUTION
Avoid corrosion damage. Do not apply antifouling paint to Mercury MerCruiser
drive unit or transom assembly.

90-861328--1 NOVEMBER 1999 Page 1A-7

GENERAL INFORMATION SERVICE MANUAL NUMBER 25

IMPORTANT: If antifouling protection is required, Tri-Butyl-Tin-Adipate (TBTA) base

antifouling paints are recommended on Mercury MerCruiser boating applications. In
areas where Tri-Butyl-Tin-Adipate base paints are prohibited by law, copper base
paints can be used on boat hull and boat transom. Corrosion damage that results
from the improper application of antifouling paint will not be covered by the limited
warranty. Observe the following:
Avoid an electrical interconnection between the Mercury MerCruiser Product,
Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 1-1/2
in. (40mm) UNPAINTED area on transom of the boat around these items.

71176
a
b
a - Anti-Fouling Paint
b - Minimum 1-1/2 in. (40 mm) UNPAINTED Area

Weight Distribution
Weight distribution is extremely important; it affects a boat’s running angle or attitude. For
best top speed, all movable weight - cargo and passengers - should be as far aft as possible
to allow the bow to come up to a more efficient angle (3 to 5 degrees). On the negative side
of this approach is the problem that, as weight is moved aft, some boats will begin an
unacceptable porpoise.
Secondly, as weight is moved aft, getting on plane becomes more difficult.
Finally, the ride in choppy water becomes more uncomfortable as the weight goes aft. With
these factors in mind, each boater should seek out what weight locations best suit his/her
needs.
Weight and passenger loading placed well forward increases the “wetted area” of the boat
bottom and, in some cases, virtually destroys the good performance and handling
characteristics of the boat. Operation in this configuration can produce an extremely wet
ride, from wind-blown spray, and could even be unsafe in certain weather conditions or
where bow steering may occur.
Weight distribution is not confined strictly to fore and aft locations, but also applies to lateral
weight distribution. Uneven weight concentration to port or starboard of the longitudinal
centerline can produce a severe listing attitude that can adversely affect the boat’s
performance, handling ability and riding comfort. In extreme rough water conditions, the
safety of the boat and passengers may be in jeopardy.

Page 1A-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 GENERAL INFORMATION

Water in Boat
When a boat loses performance, check bilge for water. Water can add considerable weight
to the boat, thereby decreasing the performance and handling.
Make certain that all drain passages are open for complete draining.

Elevation and Climate

Elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since
air (containing oxygen) gets thinner as elevation increases, the engine begins to starve for
air. Humidity, barometric pressure and temperature do have a noticeable effect on the
density of air. Heat and humidity thin the air. This phenomenon can become particularly
apparent when an engine is propped out on a cool dry day in spring and later, on a hot, humid
day in August, does not have the same performance. See chart below.
Although some performance can be regained by dropping to a lower pitch propeller, the
basic problem still exists. The propeller is too large in diameter for the reduced power output.
The experienced marine dealer or a Quicksilver Propeller Repair Station can determine how
much diameter to remove from a lower-pitch propeller for specific high-elevation locations.
In some cases, a gear-ratio change to the drive unit to more reduction is possible and very
beneficial. It is a known fact that weather conditions exert a profound effect on power output
of internal combustion engines. Therefore, established horsepower ratings refer to the
power that the engine will produce at its rated rpm under a specific combination of weather
conditions.

72006

90-861328--1 NOVEMBER 1999 Page 1A-9

GENERAL INFORMATION SERVICE MANUAL NUMBER 25

THIS PAGE IS INTENTIONALLY BLANK

Page 1A-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

IMPORTANT INFORMATION 1
Section 1B - Maintenance B
Table of Contents
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Closed Cooling System . . . . . . . . . . . . . . 1B-17
Lubricants / Sealants / Adhesives . . . . . 1B-2 Checking Coolant Level . . . . . . . . . . . 1B-17
Maintenance Schedules . . . . . . . . . . . . . . 1B-3 Flushing System . . . . . . . . . . . . . . . . . . 1B-18
Maintenance Intervals . . . . . . . . . . . . . 1B-3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20
Gas Sterndrive . . . . . . . . . . . . . . . . . . . . . . 1B-3 Throttle Cable . . . . . . . . . . . . . . . . . . . . 1B-20
Routine Maintenance * . . . . . . . . . . . . 1B-3 Shift Cable . . . . . . . . . . . . . . . . . . . . . . . 1B-20
Scheduled Maintenance * . . . . . . . . . . 1B-4 Engine Coupler /
Engine and Tune-Up Specifications . . . . 1B-5 U-Joint Shaft Splines . . . . . . . . . . . . . 1B-21
MCM (Sterndrive) . . . . . . . . . . . . . . . . . 1B-5 Sterndrive Drive
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . 1B-6 Shaft Extension Models . . . . . . . . . . . 1B-22
Sterndrive Engines . . . . . . . . . . . . . . . 1B-6 Cleaning Flame Arrestor . . . . . . . . . . . . . 1B-22
Sterndrives . . . . . . . . . . . . . . . . . . . . . . 1B-6 Top Mounted Flame Arrestor . . . . . . . 1B-23
20-Hour Break-In Period . . . . . . . . . . . . . 1B-7 Serpentine Drive Belt . . . . . . . . . . . . . . . . 1B-23
After Break-in Period . . . . . . . . . . . . . . . . 1B-7 Component Location . . . . . . . . . . . . . . 1B-23
End of First Season Checkup . . . . . . . . . 1B-7 Serpentine Belt Routing . . . . . . . . . . . . . . 1B-24
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1B-8 S/N 0L619083 and Below . . . . . . . . . . 1B-24
Fuel Recommendations . . . . . . . . . . . 1B-8 S/N 0L619084 and Above . . . . . . . . . 1B-25
Test For Alcohol Content In Gasoline 1B-10 Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-26
Power Steering Fluid . . . . . . . . . . . . . . . . 1B-10 Replacing and/or Adjusting Tension . 1B-26
Coolant for Closed Cooling System . . . . 1B-10 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . 1B-27
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . 1B-11 Thunderbolt V Models . . . . . . . . . . . . . 1B-27
Overfilled Crankcase Oil . . . . . . . . . . . 1B-11 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-28
Checking Engine Oil Level / Filling . . 1B-12 Cold Weather or Extended Storage . . . . 1B-29
Changing Oil and Filter . . . . . . . . . . . . . . . 1B-12 Precautions . . . . . . . . . . . . . . . . . . . . . . 1B-29
Changing Water Separating Fuel Filter . 1B-13 Power Package Layup . . . . . . . . . . . . 1B-31
Power Steering System . . . . . . . . . . . . . . 1B-15 Draining Instructions . . . . . . . . . . . . . . 1B-33
Checking Fluid Level . . . . . . . . . . . . . . 1B-15 Draining Sterndrive . . . . . . . . . . . . . . . 1B-38
Engine Cold . . . . . . . . . . . . . . . . . . . . . 1B-15 Recommissioning . . . . . . . . . . . . . . . . . 1B-39
Filling and Bleeding . . . . . . . . . . . . . . . 1B-16

90-861328--1 NOVEMBER 1999 Page 1B-1

MAINTENANCE SERVICE MANUAL NUMBER 25

Tools
Description Part Number
Timing Light 91-99379
Quicksilver Scan Tool 91-823686A2

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver Liquid Neoprene 92-25711--3
Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Loctite Pipe Sealant With Teflon Obtain Locally
Quicksilver U-Joint and Gimbal Bearing Grease 92-828052A2

Page 1B-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

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

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

Gas Sterndrive
Routine Maintenance *
Each Each Every
Day Day Weekly Two
Start End Months
Check crankcase oil (interval can be extended based on experi-

ence).
If operating in salt, brackish or polluted waters, flush cooling sys-

tem after each use.
Check drive unit oil level, trim pump oil level and power steering

pump fluid level.
Check water pickups for debris or marine growth. Check water

strainer and clean. Check coolant level.
Inspect drive unit anodes and replace if 50 percent eroded.

Inspect fuel pump sight tube and have pump replaced if fuel is


present.
Check battery connections and fluid level.

Lubricate propeller shaft and the retorque nut (if operating in only

freshwater, this maintenance may be extended to every four
months).
Operating in Saltwater Only: treat engine surface with corrosion

guard.
Clean air filter every 50 hours of operation.


* Only perform maintenance which applies to your particular power package

Standard Models
 Horizon Models

90-861328--1 NOVEMBER 1999 Page 1B-3

MAINTENANCE SERVICE MANUAL NUMBER 25

Gas Sterndrive(Continued)
Scheduled Maintenance *
Every Every
Every
200 300 Every Every
Annu- 100
hours hours 2 5
ally hours or
or 3 or 3 years years
Annually
years years
Touch-up paint power package and spray with corrosion


guard.
Change crankcase oil and filter.

Change drive unit oil and retorque connection of gimbal


ring to steering shaft.
Replace fuel filter(s).

Check steering system and remote control for loose,
missing or damaged parts. Lubricate cables and link-

ages.
Inspect U-joints, splines and bellows. Check clamps.


Check engine alignment. Lubricate U-joints splines.
Lubricate gimbal bearing and engine coupler.
 
Check continuity circuit for loose or damaged connec-


tions. Test MerCathode unit output on Bravo Models.
Retorque engine mounts.

Check spark plugs, wires, distributor cap and ignition


timing. Check and adjust idle speed.
Clean flame arrestor and crankcase ventilation hoses.


Replace PCV valve.
Check electrical system for loose, damaged or corroded


fasteners.
Inspect condition and tension of belts.

Check cooling system and exhaust system hose clamps


for tightness. Inspect both systems for damage or leaks.
Disassemble and inspect seawater pump and replace


worn components.
Clean seawater section of closed cooling system.


Clean, inspect and test pressure cap.
Replace coolant. 


* Only perform maintenance which applies to your particular power package

Standard Models
 Horizon Models
 Whichever Occurs First
 Interval will be reduced if not using extended life coolant.
 Lubricate engine coupler every 50 hours if operated at idle for prolonged periods of time.

Page 1B-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Engine and Tune-Up Specifications

MCM (Sterndrive)
MCM 4.3L
MCM 4.3L MCM 4.3LH
EFI
Model ALPHA / ALPHA /
ALPHA /
BRAVO BRAVO
BRAVO
Propshaft Horsepower
190 205 (190)2 2101 (188)2
(SAV1 Rating)
Propshaft Kilowatts (SAV1 Rating) 142 153 (142)2 1571 (146)2
Number of Cylinders V-6
Displacement 262 cid (4.3 l)
Bore / Stroke - in. (mm) 4.0 x 3.48 (101.6 x 88.4)
Compression Ratio 9.4:1 9.4:1
Compression Pressure Minimum 100 psi (690 kPa)7
Idle rpm In Neutral3 650 rpm5 600 rpm5
Maximum rpm (at WOT)3 4400-4800 rpm
Oil Pressure (at 2000 rpm) Minimum 30 psi (207 kPa)
Minimum Oil Pressure (at Idle) Minimum 4 psi (28 kPa)
Fuel Pressure (1800 rpm) 3-7 psi (21-48 kPa) 30 psi ( kPa)
Electrical System 12 V Negative (–) Ground
Alternator Rating 55 or 65 amp 8
Minimum Battery Requirements 375 cca / 475 mca / 90 Ah
Firing Order 1-6-5-4-3-2
AC - MR43LTS
Spark Plug Type Champion - RS12YC
NGK - BPR6EFS
Spark Plug Gap .045 in. (1.1 mm)
Timing (at idle rpm)4 10° BTDC 8° BTDC
Preliminary Idle Mixture 1 1/4 Turns DNA
Thermostat 160° F (71° C)
1 Power Rated in Accordance with NMMA (National Marine Manufacturers’ Association) rating procedures.
2 Power Rated in Accordance with SAV1 rating procedures. This rating procedure is used to certify that the
engine complies with “Stage 1” Bodensee and Swiss Regulations. Horsepower differences shown result from
differences in test rpm, allowable test tolerances, and/or installation of special kit components.
3 Measured using an accurate service tachometer with engine at normal operating temperature.
4 Timing must be set using a special procedure as outlined in the appropriate section of this manual. Timing can-
not be properly set using the conventional method.
5A special procedure must be followed to adjust idle rpm. Consult your Authorized Mercury MerCruiser Dealer
before attempting this procedure.
6 Idle speed on EFI models is not adjustable.
7 Minimum recorded compression in any one cylinder should not be less than 70 percent of the highest recorded
cylinder.
8 Serial Number Break for 65 Amp alternator: OL619083 and above.

90-861328--1 NOVEMBER 1999 Page 1B-5

MAINTENANCE SERVICE MANUAL NUMBER 25

Fluid Capacities
NOTICE
Unit Of Measurement: U.S. Quarts (Liters)
All capacities are approximate fluid measures.

Sterndrive Engines
Model All Models
Crankcase Oil (With Filter) 1 4-1/2 (4.3)
Seawater Cooling System 2 15 (14.1)
Closed Cooling System 20 (19)
1 Always use dipstick to determine exact quantity of oil or fluid required.
2 Seawater Cooling System capacity information is for winterization use only.

Sterndrives
NOTICE
Unit Of Measurement: U.S. Fluid Ounces (Milliliters)
All capacities are approximate fluid measures.

Model ALPHA ONE

Drive Unit Oil Capacity (With Gear Lube Monitor) 64 (1892)

Model BRAVO ONE BRAVO TWO BRAVO THREE

Drive Unit Oil Capacity
88 (2603) 104 (3076) 96 (2839)
(With Gear Lube Monitor)

Page 1B-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

20-Hour Break-In Period

IMPORTANT: The first 20 hours of operation is the engine break-in period. Correct
break-in is essential to obtain minimum oil consumption and maximum engine per-
formance. During this break-in period, the following rules must be observed:
• Do not operate below 1500 rpm for extended periods of time for first 10 hours. Shift into
gear as soon as possible after starting and advance throttle above 1500 rpm if condi-
tions permit safe operation.
• Do not operate at one speed consistently for extended periods.
• Do not exceed 3/4 throttle during first 10 hours. During next 10 hours, occasional opera-
tion at full throttle is permissible (5 minutes at a time maximum).
• Avoid full throttle acceleration from IDLE speed.
• Do not operate at full throttle until engine reaches normal operating temperature.

After Break-in Period

To help extend the life of your Mercury MerCruiser power package, the following recommen-
dations should be considered:
• Use a propeller that allows the engine to operate at or near the top of the maximum rpm
range (refer to “Specifications” section) when at full throttle with a normal boat load.
• Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged op-
eration at maximum (full throttle) rpm.

End of First Season Checkup

At the end of the first season of operation, an Authorized Mercury MerCruiser Dealer should
be contacted to discuss and/or perform various scheduled maintenance items. If you are
in an area where the product is operated continuously (year-round operation), you should
contact your dealer at the end of the first 100 hours of operation, or once yearly, whichever
occurs first.

90-861328--1 NOVEMBER 1999 Page 1B-7

MAINTENANCE SERVICE MANUAL NUMBER 25
CA261

Specifications
Fuel Recommendations
IMPORTANT: Use of improper gasoline can damage your engine seriously. Engine
damage resulting from use of improper gasoline is considered misuse of engine, and
damage caused thereby will not be covered under the limited warranty.

FUEL RATINGS

Mercury MerCruiser engines will operate satisfactorily when using a major brand of
unleaded gasoline as follows:
USA and Canada - having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium
gasoline [92 (R+M)/2 Octane] is also acceptable. DO NOT use leaded gasoline.
Outside USA and Canada - having a posted pump Octane Rating of 90 RON minimum.
Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use
a major brand of leaded gasoline.
CA291

USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY)

This type of gasoline is required in certain areas of the USA. The two types of “oxygenates”
used in these fuels are Alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the “oxygen-
ate” that is used in the gasoline in your area, refer to “Gasolines Containing Alcohol.”
These “Reformulated Gasolines” are acceptable for use in your Mercury MerCruiser
engine.

VAPOR LOCKING

Fuels containing alcohol and winter grade fuels will aggravate vapor lock problems. A vapor
lock condition can be identified by the following problems:
• Engine starts and, upon advancing throttle, shuts off and will not restart.
• If engine does restart, it shuts off when advancing throttle.
• Engine is difficult to restart after operating the boat and then leaving the engine off for 1 to
3 hours.

Other factors may combine to increase vapor locking. These factors include but are not lim-
ited to:
• air temperature
• fuel tank location
• fuel supply system
• engine coolant temperature
• temperature and vacuum of fuel to engine
• engine compartment air temperature and ventilation

Other conditions should be ruled out before treating the problem as vapor locking.

Page 1B-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE
CA618

GASOLINES CONTAINING ALCOHOL

If the gasoline in your area contains either “methanol” (methyl alcohol) or “ethanol” (ethyl
alcohol), you should be aware of certain adverse effects that can occur. These adverse
effects are more severe with “methanol.” Increasing the percentage of alcohol in the fuel can
also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb
moisture from the air, resulting in a separation of the water/alcohol from the gasoline in the
fuel tank.
The fuel system components on your Mercury MerCruiser engine will withstand up to 10%
alcohol content in the gasoline. We do not know what percentage your boat’s fuel system
will withstand. Contact your boat manufacturer for specific recommendations on the boats
fuel system components (fuel tanks, fuel lines and fittings). Be aware that gasolines
containing alcohol may cause increased:
• Corrosion of metal parts.
• Deterioration of rubber or plastic parts.
• Fuel permeation through rubber fuel lines.
• Starting and operating difficulties.

WARNING
FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of fuel system can be
a fire and explosion hazard which can cause serious bodily injury or death. Careful
periodic inspection of entire fuel system is mandatory, particularly after storage. All
fuel components including fuel tanks, whether plastic metal or fiberglass, fuel
lines, fittings, fuel filters and carburetors/fuel injection components should be in-
spected for leakage, softening, hardening, swelling or corrosion. Any sign of leak-
age or deterioration requires replacement before further engine operation.
Because of possible adverse effects of alcohol in gasoline, it is recommended that only alco-
hol-free gasoline be used where possible. If only fuel containing alcohol is available, or if
the presence of alcohol is unknown, increased inspection frequency for leaks and abnorma-
lities is required.
IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing
alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long
periods of storage, common to boats, create unique problems. In cars alcohol-blend
fuels normally are consumed before they can absorb enough moisture to cause
trouble, but boats often sit idle long enough for phase separation to take place. In
addition, internal corrosion may take place during storage if alcohol has washed pro-
tective oil films from internal components.

90-861328--1 NOVEMBER 1999 Page 1B-9

MAINTENANCE SERVICE MANUAL NUMBER 25

Test For Alcohol Content In Gasoline

The following is an acceptable and widely used field procedure for the detection of alcohol
in gasoline. Use any small transparent bottle or tube that can be capped and is, or can be,
provided with graduations or a mark at about 1/3 full. A pencil mark on a piece of adhesive
tape may be used.

PROCEDURE

1. Fill the container with water to the mark.

2. Add fuel almost to fill the container, leaving some air space, then cap the container. The
proportions of fuel to water are not critical, but there should be 2 to 3 times as much fuel
as water.
3. Shake container vigorously and allow it to sit upright for 3 to 5 minutes. If the volume
of water appears to have increased, alcohol is present. If you are not sure, there is no
need for concern. If the dividing line between water and fuel becomes cloudy, use the
middle of the cloudy band.

Power Steering Fluid

Use Quicksilver Power Trim and Steering Fluid or automatic transmission Fluid (ATF)
Dexron III.

Coolant for Closed Cooling System

CAUTION
Alcohol or Methanol base antifreeze or plain water, are not recommended for use
in fresh water section of cooling system at any time.
We recommend that the coolant section of closed cooling system be filled with Extended
Life Ethylene Glycol 5/100 Antifreeze/Coolant mixed 50/50 with purified water. In areas
where the possibility of freezing does not exist, it is permissible to use a solution of rust inhi-
bitor and water (mixed to manufacturer’s recommendations).
If any non-compatible coolant is added to this coolant, coolant must be changed every 2
years or 400 hours, whichever occurs first. All coolants other than Extended Life 5/100
Ethylene Glycol Antifreeze/Coolant must be changed every 2 years or 400 hours, whichever
occurs first.
Mercury MerCruiser V-8 engines can use any type of permanent antifreeze or any brand
antifreeze solution that meets GM specification 1825M.

Page 1B-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE
CA693

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 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 multiviscosity 20W-40 (SH, CF/CF-2) 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 Quicksil-
ver 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
with oil.

Quicksilver 4-Cycle Marine Engine Oil

SAE 40W

SAE 30W

SAE 20W

32° F 50° F
0° C 10° C 70534

AIR TEMPERATURE

Overfilled Crankcase Oil

Overfilled crankcases (oil level being too high ) can cause a fluctuation or drop in oil pressure
and rocker arm “clatter” on Mercury MerCruiser engines. The over-full 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 engine oil level. Oil level must be maintained between
the ADD mark and the FULL mark on the dipstick. To ensure that you are not getting a “false
reading,” make sure the following steps are done before checking the oil level.
• Boat “at rest” in the water, or
• If boat is on a trailer, raise or lower 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 oil to drain into the crankcase if engine has just been run or oil
has just been added.

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MAINTENANCE SERVICE MANUAL NUMBER 25

Checking Engine Oil Level / Filling

IMPORTANT: ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS
SPECIFIED IN “MAINTENANCE SCHEDULE” CHART. It is normal for an engine to use
a certain amount of oil in the process of lubrication and cooling of 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
engine speed is reduced.
1. Stop engine and allow boat to come to a rest.
2. Allow oil to drain back into oil pan - approximately 5 minutes.
3. Remove dipstick.
4. Wipe clean and reinstall. Push dipstick all the way into dipstick tube.
5. Remove dipstick and note the oil level.
6. Oil level must be between the FULL or OP RANGE and ADD marks.
7. If oil level is below ADD mark, proceed to Steps 8. and 9.
8. Remove oil filler cap from valve rocker arm cover.
9. Add required amount of oil to bring level up to, but not over, the FULL mark on dipstick.

Changing Oil and Filter

1. Start engine and run until it reaches normal operating temperatures.
IMPORTANT: Change oil when engine is warm from operation, as it flows more freely,
carrying away more impurities.
2. Stop engine.
3. Remove drain plug from oil pan or from oil drain hose.
IMPORTANT: If engine is factory equipped with Quick Drain Oil Hose, pull tether
through bilge drain before removing drain plug from oil drain hose.
NOTE: If drain plug is not accessible because of boat construction, oil may be removed
through dipstick tube, using a Quicksilver Crankcase Oil Pump. (See Quicksilver Accessory
Guide.)
4. After oil has drained completely, reinstall drain plug (if removed) and tighten securely.
5. Remove and discard oil filter and its sealing ring.
6. Coat sealing ring on new filter with engine oil and install. Tighten filter securely (following
filter manufacturer’s instructions). Do not overtighten.
7. Fill crankcase with oil. See “Specifications” for type of oil and quantity.
8. Check dipstick to ensure oil level is up to, but not over, FULL or OP RANGE mark on
dipstick.
9. Start engine and check for leaks.

Page 1B-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Changing Water Separating Fuel Filter

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

WARNING
Make sure no fuel leaks exist before closing engine hatch.

CAUTION
The electric fuel pump and factory installed water separating fuel filter have been
carefully designed to function properly together. Do not install additional fuel filters
and/or water separating fuel filters between fuel tank and engine.
The installation of additional filters may cause:
• Fuel Vapor Locking
• Difficult Warm-Starting
• Piston Detonation Due to Lean Fuel Mixture
• Poor Driveability

1. Unsnap latch and slide top and bottom cover pieces, if equipped, from around the water
separating fuel filter and bracket.

75034

a - Fuel Filter Cover

NOTE: Top and bottom cover pieces are formed with a groove on each side that slides
around the brackets outer edges.

90-861328--1 NOVEMBER 1999 Page 1B-13

MAINTENANCE SERVICE MANUAL NUMBER 25

2. Remove water separating fuel filter and sealing ring from mounting bracket and discard.

a
70573

a - Fuel Filter
b - Sealing Ring

3. Coat sealing ring on new filter with motor oil.

4. Thread filter onto bracket and tighten securely by hand. Do not use a filter wrench.
5. Start and run engine.
6. Check filter connection for gasoline leaks. If leaks exist, recheck filter installation.
7. Install cover pieces around fuel filter. Be certain top part of cover latches to lower part.

Page 1B-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Power Steering System

Checking Fluid Level
ENGINE WARM
1. Stop engine. Position drive unit so that it is straight back.
2. Remove fill cap / dipstick from power steering pump and note fluid level.

a b

74908
a - Fill Cap / Dipstick
b - Power Steering Pump
3. Level should be between the FULL HOT mark and ADD mark on dipstick.

a
72518

a - Proper Fluid Level with Engine Warm

4. If level is below ADD mark, but fluid is still visible in pump reservoir, add required amount
of Quicksilver Power Trim and Steering Fluid or automatic transmission fluid (ATF) Dex-
ron III through fill cap opening, to bring level up to FULL HOT mark on dipstick. DO NOT
OVERFILL.
5. If fluid is not visible in reservoir, a leak exists in the power steering system. Find cause
and correct.
Engine Cold
1. With engine stopped, position drive unit so that it is straight back.
2. Remove fill cap / dipstick from power steering pump and note fluid level.
3. Level should be between FULL COLD mark and bottom of dipstick.

a 72519

a - Proper Fluid Level with Engine Cold

4. If level is below bottom of dipstick, but fluid is still visible in pump reservoir, add required
amount of Quicksilver Power Trim and Steering Fluid or automatic Dexron III transmis-
sion fluid (ATF), through fill cap opening, to bring level up to FULL COLD mark on dip-
stick. DO NOT OVERFILL.
If fluid is not visible in reservoir, a leak exists in the power steering system. Find cause and
correct.

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MAINTENANCE SERVICE MANUAL NUMBER 25

Filling and Bleeding

IMPORTANT: Power steering system must be filled exactly as explained in the follow-
ing to be sure that all air is bled from the system. All air must be removed, or fluid in
pump may foam during operation and be discharged from pump reservoir. Foamy
fluid also may cause power steering system to become spongy, which may result in
poor boat control.
1. With engine stopped, position drive unit so that it is straight back.
2. Remove fill cap / dipstick from power steering pump.
3. Add Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission
fluid (ATF), as required, to bring level up to FULL COLD mark on dipstick.
IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid or Dexron III auto-
matic transmission fluid (ATF), in power steering system.
4. Turn steering wheel back and forth to end of travel in each direction several times.
5. Recheck fluid level and add fluid, if necessary.
6. Install 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 engine and run at fast idle (1000-1500 rpm) until engine reaches normal operating
temperature. During this time, turn steering wheel back and forth to end of travel in each
direction several times.
8. Position drive unit so that it is straight back and stop engine.
9. Remove fill cap from pump.
10. Allow any foam in pump reservoir to disperse.
11. Check fluid level and add fluid, as required, to bring level up to FULL HOT mark on dip-
stick. DO NOT OVERFILL.
12. Reinstall fill cap. Tighten securely.
IMPORTANT: Drive unit must be positioned straight back and power steering fluid
must be hot to accurately check fluid level.
13. If fluid is still foamy (in Step 5.), repeat Steps 7. through 12. until fluid does not foam and
level remains constant.

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SERVICE MANUAL NUMBER 25 MAINTENANCE

Closed Cooling System

Checking Coolant Level
CAUTION
Allow engine to cool down before removing pressure cap. Sudden loss of pressure
could cause hot coolant to boil and discharge violently. After engine has cooled,
turn cap 1/4 turn to allow any pressure to escape slowly, then push down and turn
cap all the way off.
1. Coolant level in heat exchanger should be full (to bottom of filler neck).
IMPORTANT: When reinstalling pressure cap, be sure to tighten it until it contacts on
filler neck.
2. Coolant level should be between the ADD and FULL marks on coolant recovery reser-
voir with the engine at normal operating temperature.

72520

a - Coolant Recovery Reservoir

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MAINTENANCE SERVICE MANUAL NUMBER 25

Flushing System
If engine is operated in salty, polluted or mineral-laden water, flush seawater cooling system
(preferably after each use) to reduce corrosion and prevent the accumulation of deposits
in the system. Thoroughly flush the seawater cooling system prior to storage.
NOTE: For additional protection against freezing and rust to the exhaust manifolds and
other components, a 50-50 mixture of antifreeze and water can be run through the engine
during Power Package Layup.
1. Install flushing attachment and water hose over the water pickup holes in gear housing.

b
72693
a - Flushing Attachment
b - Hose

WARNING
When flushing, be certain the area around propeller is clear, and no one is standing
nearby. To avoid possible injury, remove propeller.

CAUTION
Do not run engine above 1500 rpm when flushing. Suction created by seawater pick-
up pump may collapse flushing hose, causing engine to overheat.

CAUTION
Watch temperature gauge on dash to ensure that engine does not overheat.
2. Open water tap enough to cool the engine, about ½ of its maximum capacity. Adjust as
required so that the engine does not overheat.
3. With drive in neutral gear, start engine and advance the throttle until the engine reaches
1300 rpm.
IMPORTANT: DO NOT run the engine at idle rpm. Watch engine temperature gauge
on dash. Do not run the engine above 1500 rpm or engine overheating may occur.
4. Run engine for 10 minutes or until the discharge water is clear.
5. Slowly return the throttle to the idle position and turn engine off.
IMPORTANT: DO NOT rapidly advance or return throttle as this can cause water in-
gestion.

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SERVICE MANUAL NUMBER 25 MAINTENANCE

BOAT IN WATER

1. Raise drive unit to full UP / OUT position.

2. Install flushing attachment over water pickup holes in gear housing as shown.
3. Attach a water hose between the flushing attachment and a water tap.

b 72693

a - Flushing Attachment
b - Hose

4. Lower drive unit to full DOWN / IN position.

CAUTION
Do not run engine above 1500 rpm when flushing. Suction created by seawater pick-
up pump may collapse flushing hose, causing engine to overheat.

CAUTION
Watch temperature gauge on dash to ensure that engine does not overheat.
5. Partially open water tap (approximately 1/2 maximum capacity). DO NOT use full water
pressure.
6. Place remote control in neutral, idle speed position, and start engine.
7. Operate engine at idle speed in neutral for 10 minutes, then stop engine.
8. Shut off water tap.
9. Raise drive unit to full UP / OUT position.
10. Remove water hose and flushing attachment.

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MAINTENANCE SERVICE MANUAL NUMBER 25

Lubrication
Throttle Cable
1. Lubricate pivot points and guide contact surfaces with SAE 30W motor oil.

b b
a

71359 a 74941

2 Barrel Carbureted Models EFI Models

a - Pivot Points
b - Guide Contact Surface

Shift Cable

MCM (STERNDRIVE) MODELS

1. Lubricate pivot points and guide contact surfaces with SAE 30W motor oil.
a b

a
b
a 72016

Typical Shift Cable

a - Pivot Points
b - Guide Contact Surface

Page 1B-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Engine Coupler / U-Joint Shaft Splines

NOTE: Engine coupler and shaft splines are greased with Quicksilver Engine Coupler
Spline Grease, 92-816391A4; universal joints are greased with Quicksilver 2-4-C Marine
Lubricant.
NOTE: Refer to Mercury MerCruiser Sterndrive Service Manual for sterndrive unit removal
and installation, if necessary.
IMPORTANT: Sterndrive Unit does not have to be removed to grease coupler.
1. Lubricate engine coupler splines through grease fitting on coupler by applying approxi-
mately 8-10 pumps of grease from a typical hand-operated grease gun.

b b
a

a 71569 72529

Typical Alpha Drive Coupler Typical Bravo Drive Coupler

IMPORTANT: Later Bravo Models may be equipped with a coupler that is similar to
the Alpha Coupler.
a - Grease Fitting
b - Quicksilver Engine Coupler Spline Grease

a
72531

Typical Bravo Drive

a - Quicksilver Engine Coupler Spline Grease

90-861328--1 NOVEMBER 1999 Page 1B-21

MAINTENANCE SERVICE MANUAL NUMBER 25

Sterndrive Drive Shaft Extension Models

a
a

72018
a 72028

Transom End Engine End

a - Grease Fitting

Cleaning Flame Arrestor

WARNING
Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly
explosive under certain conditions. Be careful when cleaning flame arrestor and
crankcase ventilation hoses. Be sure that ignition is OFF. DO NOT smoke or allow
sources of spark or open flame in area when cleaning flame arrestor and crankcase
ventilation hoses.

WARNING
Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explo-
sive under certain conditions. NEVER use gasoline as a cleaning solvent.

Page 1B-22 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Top Mounted Flame Arrestor

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

76501

a - Flame Arrestor

4. Clean flame arrestor in solvent. Blow dry with compressed air.

5. Clean crankcase ventilation hose in solvent. Blow dry with compressed air.
6. Inspect crankcase ventilation hose for cracks or deterioration and replace if necessary.
7. Reinstall flame arrestor and crankcase ventilation hose.
8. Reinstall flame arrestor cover.

Serpentine Drive Belt

Component Location
WARNING
Avoid possible serious injury. Make sure engine is shut off and ignition key is
removed before inspecting belt.
NOTE: Some models will have components arranged in a different order. All configurations
are not shown. Checking, replacing and adjustment procedures are the same.

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MAINTENANCE SERVICE MANUAL NUMBER 25

Serpentine Belt Routing

S/N 0L619083 and Below

Alpha With Power Steering Bravo With Power Steering

Alpha With Closed Cooling Bravo Without Power Steering

Without Power Steering

Alpha With Closed Cooling Bravo With Closed Cooling

and Power Steering and Power Steering

Page 1B-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Serpentine Belt Routing (Continued)

S/N 0L619084 and Above

76503 76502

Alpha With Power Steering Bravo With Power Steering

76463
76445

Alpha Without Power Steering Bravo Without Power Steering

90-861328--1 NOVEMBER 1999 Page 1B-25

MAINTENANCE SERVICE MANUAL NUMBER 25

Inspection
1. Inspect drive belt for the following:
• Excessive wear
• Cracks

NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal
cracks (in direction of belt length) that join transverse cracks are NOT acceptable.
• Fraying
• Glazed surfaces

b
a

75130

a - Fraying
b - Cracks

Replacing and/or Adjusting Tension

REMOVAL

1. Loosen 5/8 in. locking nut on adjustment stud.

2. Turn adjustment stud and loosen belt.
3. Remove drive belt.

INSTALLATION AND ADJUSTMENT

4. Install drive belt on pulleys.

5. Adjust tension by loosening 5/8 in. locking nut on adjustment stud. Leave wrench on
adjustment stud.
NOTE: Belt deflection is to be measured on the belt at the location that has the longest dis-
tance between two (2) pulleys. Proper tension is 1/4 in. (6 mm) deflection with moderate
thumb pressure.
6. Use 5/16 in. socket and tighten adjusting stud until the correct deflection of the belt is
obtained at location specified above.

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SERVICE MANUAL NUMBER 25 MAINTENANCE

7. While holding adjustment stud at the correct belt tension, tighten 5/8 in. locking nut.
8. Run engine for a short period of time and recheck belt adjustment.

b
74908

a - 5/8 in. Locking Nut

b - 5/16 in. Adjusting Stud

Ignition Timing
Thunderbolt V Models
1. Connect timing light to number 1 spark plug wire.
2. Connect a shop tachometer to the engine.
IMPORTANT: Before starting the engine, connect a jumper wire from the ignition tim-
ing lead to a good ground. This has to be done before the ignition key is turned ON
to lock the ignition module into Base Timing Mode.
3. Before starting the engine, connect jumper wire from timing lead to a good ground.
NOTE: The PUR/WHT timing lead is located towards the front of the engine near the fuel
line or near the distributor, as equipped for your model.
4. Start engine and run at 1300 rpm until it reaches normal operating temperature.
5. Disconnect throttle cable from the carburetor.
6. With engine at idle rpm, adjust the carburetor idle rpm screw to the specified engine idle
rpm.
7. With the engine still at idle rpm, check the ignition timing. If incorrect, rotate the
distributor until timing is correct. Torque clamping screw to 18 lb-ft (25 Nm).
8. Adjust the idle mixture screw. Inward is LEAN, outward is RICH.
9. Recheck ignition timing.
10. Stop engine. Remove timing light, jumper wire and shop tachometer.
IMPORTANT: Timing jumper wire has to be removed or the ignition module will stay
locked in the Base Timing Mode and it will not be able to advance the ignition timing
correctly when the engine rpm is increased.
11. Adjust and reinstall throttle cable. Open and close remote control throttle lever. Ensure
that the carburetor throttle lever is contacting the idle rpm adjusting screw every time.
12. Restart the engine, increase rpm to 1300 then return to idle position slowly and shut the
engine off. Ensure that the carburetor throttle lever is contacting the idle rpm screw.
13. Shut engine off.
90-861328--1 NOVEMBER 1999 Page 1B-27
MAINTENANCE SERVICE MANUAL NUMBER 25

EFI
1. Connect timing light to number 1 spark plug wire.
2. Start engine and run at 1300 rpm until it reaches normal operating temperature.
3. Stop engine and connect the scan tool or timing tool to the DLC connector on the EFI
wiring harness.
4. Start engine, allow rpm to stabilize.
NOTE: MEFI-1 models only, manually adjust remote control throttle lever to get 1200 engine
rpm.
NOTE: MEFI-3 models only, ECM will automatically adjust engine rpm to approximately
1200 rpm when put in the service mode on a scan tool or when using the timing tool.
5. Check ignition timing. If incorrect, rotate the distributor until timing is correct. Torque
clamping screw to 18 lb-ft (25 Nm).
6. Recheck ignition timing.
7. Disconnect scan tool or timing tool from DLC connector.
8. If required, return remote control throttle lever to idle position and shut off engine.
9. Restart engine, increase rpm to 1300 then return to idle position slowly. Ensure that
engine returns to idle rpm. Readjust throttle cable, if required.
10. Shut engine off.

Page 1B-28 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Cold Weather or Extended Storage

Precautions
WARNING
Always disconnect battery cables from battery BEFORE working on fuel system to
prevent fire or explosion.
WARNING
BE CAREFUL while working on fuel system; 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 and/or open flames in the area. Wipe up any spilled
fuel immediately.

WARNING
Avoid Fire or Explosion: To prevent a potential fire hazard, be sure that engine com-
partment is well ventilated and that there are no gasoline vapors present during
starting or fogging of engine.

WARNING
Avoid Fire or Explosion: Fuel injection system is pressurized during operation. Use
care when removing water separating fuel filter. Fuel could spray on hot engine
causing fire or explosion. Allow 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 spray-
ing on the engine.

CAUTION
If boat is in the water, seacock (water inlet valve), if equipped, must be closed until
engine is to be restarted, 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 discon-
nected 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 that the seacock must be opened or the water
inlet hose reconnected prior to starting engine.

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.

CAUTION
If engine is equipped with Closed Cooling System, Closed Cooling section must be
kept filled with a solution of ethylene glycol antifreeze and water (mix antifreeze to
manufacturer’s recommended proportions to protect engine to lowest temperature
to which it will be exposed). DO NOT USE PROPYLENE GLYCOL antifreeze in closed
cooling section. Seawater section, however, must be drained completely.

CAUTION
A discharged battery can be damaged by freezing.

90-861328--1 NOVEMBER 1999 Page 1B-29

MAINTENANCE SERVICE MANUAL NUMBER 25

CAUTION
Seawater section of cooling system MUST BE COMPLETELY drained for winter
storage, or immediately after cold weather use, if the possibility of freezing temper-
atures exists. Failure to comply may result in trapped water causing freeze and/or
corrosion damage to engine.

WARNING
When running engine with boat out of water, be certain that area in vicinity of
propeller is clear and that no person is standing nearby. As a precautionary
measure, it is recommended that the propeller be removed.

CAUTION
DO NOT run engine above 1500 rpm, as suction created by seawater pickup pump
may collapse water supply hose and cause engine to overheat.

WARNING
Be sure that engine compartment is well ventilated and that no gasoline vapors are
present to prevent the possibility of a FIRE or EXPLOSION.
IMPORTANT: Observe the following information to ensure complete draining of cool-
ing system.
• Engine must be as level as possible.
• A wire should be repeatedly inserted into all drain holes to ensure there are no
obstructions in passages.

IMPORTANT: To prevent threads in manifolds, elbows and cylinder blocks from rust-
ing during storage, reinstall drain plugs. Never leave drain plugs out during storage.
NOTE: If possible, place a container under drains and hoses to prevent water from draining
into boat.

Page 1B-30 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Power Package Layup

NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

IMPORTANT: Mercury MerCruiser strongly recommends that this service be per-

formed by an Authorized Mercury MerCruiser Dealer. Damage caused by freezing IS
NOT covered by the MerCruiser Limited Warranty.
1. Fill fuel tank(s) with fresh gasoline that does not contain alcohol and a sufficient amount
of Quicksilver Gasoline Stabilizer for Marine Engines to treat gasoline. Follow instruc-
tions on container.
2. If 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. Refer to “Fuel Requirements” for additional information.
NOTE: If desired, a portable fuel tank can be used to perform the remainder of the power
package layup procedures. Be sure to add an appropriate amount of Gasoline Stabilizer to
the portable tank.
3. Run engine sufficiently to bring it up to normal operating temperature and allow fuel with
Quicksilver Gasoline Stabilizer to circulate through fuel system.
4. Shut off engine.
5. Change oil and oil filter.
6. Flush cooling system. Refer to “Flushing Cooling System” procedure.
7. Close the fuel shutoff valve, if equipped. If no fuel shutoff valve is present, a suitable
method must be employed to STOP the flow of fuel from the fuel tank to the engine
before proceeding.

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MAINTENANCE SERVICE MANUAL NUMBER 25

8. Prepare EFI fuel system for extended storage as follows:

a. Allow engine to cool down.
b. Remove the water separating fuel filter.
c. Pour out a small amount of fuel into a suitable container, then add approximately 2
fluid ounces (60 ml) of Quicksilver 2-Cycle Outboard Oil to fuel in the water separat-
ing fuel filter.
d. Reinstall water separating fuel filter.
e. Start and operate engine at idle speed until the water separating fuel filter and fuel
injection system are empty and engine stops.
f. Remove and discard water separating fuel filter.
g. Install new filter.

a 75533

a - Water Separating Fuel Filter

9. Prepare carbureted fuel system for extended storage as follows:

a. Remove flame arrestor assembly and start engine.
b. While operating engine at fast idle (1000-1500 rpm), fog internal surfaces of induc-
tion system and combustion chambers by squirting approximately 8 ounces (227
grams) of Quicksilver Storage Seal or SAE 20W engine oil into carburetor bores.
c. Squirt the remaining 2 ounces (57 g) of Storage Seal (or oil) rapidly into carburetor,
just as the engine begins to stall due to lack of fuel. Allow engine to stop.
10. Turn ignition key to OFF position.
11. Refer to “Flushing Cooling System” and appropriately remove water supply to the sea-
water pickup pump.
12. Clean flame arrestor and crankcase ventilation hoses and reinstall.
13. Lubricate all items listed in “Lubrication” section.
14. Drain seawater section of cooling system as outlined in “Draining Instructions” section.
15. On Models with Closed Cooling System: Test coolant to ensure that it will withstand
the lowest temperature expected during storage.
16. Service batteries per manufacturer’s instructions.
17. Clean outside of engine and repaint any areas required with Quicksilver Primer and
Spray Paint. After paint has dried, spray Quicksilver Corrosion and Rust Preventive
Type II or wipe down with Quicksilver Storage Seal or SAE 20W engine oil.
18. For sterndrive unit layup, refer to appropriate sterndrive service manual.
NOTE: For additional protection against freezing and rust to the exhaust manifolds and
other components, a 50-50 mixture of antifreeze and water can be run through the engine
during Power Package Layup.

Page 1B-32 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Draining Instructions

DRAINING SEAWATER (RAW-WATER) COOLED MODELS

NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

IMPORTANT: Engine must be as level as possible to ensure complete draining of

cooling system.
1. Remove drain plugs from bottom of port and starboard manifold fittings.
2. Remove drain plugs (port and starboard) from cylinder block or cylinder block Y-fitting.

CAUTION
Avoid product damage. Do not disturb the Y-fitting when removing the drain plug.
There is an ignition control “Knock Sensor” in the upper hole of the fitting. This sen-
sor must not be loosened or removed. It is tightened to a critical specification at the
factory.

c
a d

b
e
74073

Starboard Side Shown (Port Similar)

a - Exhaust Elbow Drain Plug
b - Cylinder Block Drain Plug
c - Y-Fitting (Fuel Injected Only)
d - Cylinder Block Drain Plug (Fuel Injected Only)
e - Knock Sensor

90-861328--1 NOVEMBER 1999 Page 1B-33

MAINTENANCE SERVICE MANUAL NUMBER 25

3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system
is drained.
NOTE: It may be necessary to lift, bend or lower hoses to allow water to drain completely
when hoses are disconnected.
4. Remove the engine water circulating pump hose or drain plug, as equipped.

b
76038
72587

a - Hose, Water Circulating Pump To Thermostat Housing

b - Water Circulating Pump Hose Drain Plug
5. Remove the drain plug from the water tube or Cool Fuel System cooler, as equipped.

a 75018
a 75081

Some Carbureted Models Fuel Injected Models

a - Drain Plug
6. Remove seawater pump inlet hose as shown.

75533
a
a - Seawater Inlet Hose
b - Hose To Cooler
7. Crank engine over slightly with starter motor to purge any water trapped in seawater
pickup pump. DO NOT ALLOW ENGINE TO START.

Page 1B-34 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

8. After seawater section of cooling system has been drained completely:

a. Install all drain plugs and tighten securely.
b. Reconnect hoses and tighten all hose clamps securely.
c. If NOT equipped with seacock: Seawater inlet hose must remain disconnected
and plugged until engine is to be restarted.
IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze
(nontoxic and biodegradable) be used in seawater section of the cooling system for
cold weather or extended storage. Make sure that the propylene glycol antifreeze
contains a rust inhibitor and is recommended for use in marine engines. Be certain
to follow the propylene glycol manufacturer’s recommendations.
9. For additional assurance against freezing and corrosion in the internal water passages:
a. Remove the thermostat cover and thermostat.
b. Fill the engine seawater cooling system with a mixture of antifreeze and tap water
mixed to manufacturer’s recommendation to protect engine to the lowest tempera-
ture to which it will be exposed during cold weather or extended storage.
c. Using a new gasket, reinstall thermostat and cover. Tighten cover bolts to 30 lb-ft
(41 Nm).
NOTE: Hoses shown removed for visual clarity. Do not remove hoses.

b
c

d
e

74493

a - Housing
b - Gasket
c - Thermostat
d - Spacer
e - Fill Here

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MAINTENANCE SERVICE MANUAL NUMBER 25

DRAINING SEAWATER SECTION OF CLOSED COOLED (COOLANT) MODELS

NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

IMPORTANT: Drain seawater section of closed cooling system only.

IMPORTANT: Engine must be as level as possible to ensure complete draining of
cooling system.
1. Remove drain plug from bottom of port and starboard exhaust manifolds.

74073

a - Drain Plug

2. Remove the drain plug from the water tube or Cool Fuel System cooler, as equipped.

a 75018 a 75081

Some Carbureted Models Fuel Injected Models

a - Drain Plug

NOTE: It may be necessary to lift, bend or lower hoses to allow water to drain completely
when hoses are disconnected.

Page 1B-36 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

3. Remove seawater pump inlet hose.

75533

a - Seawater Inlet Hose

b - Hose To Cooler

4. Remove end caps, sealing washers and gaskets from the heat exchanger. Allow tubes
to drain.

c
71515
d
a - Heat Exchanger
b - Sealing Washer
c - End Cap
d - Gasket

IMPORTANT: Use compressed air to blow any remaining water from the tubes in the
heat exchanger.
5. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system
is drained.
6. After seawater section of cooling system has been drained completely:
a. Install all drain plugs and tighten securely.
b. Reconnect hoses and tighten all hose clamps securely.
c. Apply Quicksilver Perfect Seal to both sides of new end plate gaskets.
d. Assemble new gaskets, new sealing washers and end plates onto heat exchanger.
Torque end plate screws to 36-72 lb-in. (4-8 Nm).
e. If NOT equipped with seacock: Seawater inlet hose must remain disconnected
and plugged until engine is to be restarted.

90-861328--1 NOVEMBER 1999 Page 1B-37

MAINTENANCE SERVICE MANUAL NUMBER 25

Draining Sterndrive
NOTICE
Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To
The Product Owner.

1. On Bravo Drive Equipped Models: Insert a small wire (repeatedly) to make sure that
speedometer pitot tube, anode cavity vent hole and anode cavity drain passage are
unobstructed and drained.

e b

a c
f 71217

Typical
a - Speedometer Pitot Tube
b - Anode Cavity Vent Hole
c - Anode Cavity Drain Passage
d - Gear Housing Water Drain Hole (One Each - Port and Starboard)
e - Gear Housing Cavity Vent Hole
f - Gear Housing Cavity Drain Hole
2. On Alpha Drive Equipped Models: Insert a small wire (repeatedly) to make sure that
speedometer pitot tube, trim tab cavity vent hole and trim tab cavity drain passage are
unobstructed and drained.
e
b

d
a c

71216

a - Speedometer Pitot Tube

b - Trim Tab Cavity Vent Hole
c - Trim Tab Cavity Drain Passage
d - Gear Housing Water Drain Hole (One Each - Port and Starboard)
e - Gear Housing Cavity Vent Hole
f - Gear Housing Cavity Drain Hole

Page 1B-38 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MAINTENANCE

Recommissioning
NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

1. Ensure that all cooling system hoses are connected and tight.
2. Ensure all petcocks and drain plugs are installed and tight.
3. Inspect serpentine drive belt for condition and proper tension.
4. Perform all lubrication and maintenance specified for completion “Annually” and “Every
100 hours or Annually” in maintenance schedule, except items which were performed
at time of engine layup.
5. For sterndrive unit recommissioning, refer to appropriate Sterndrive Service Manual.

CAUTION
When installing battery (in next step), be sure to connect positive battery cable to
positive (+) terminal and negative (grounded) battery cable to negative (–) battery
terminal. If battery cables are reversed, damage to electrical system WILL result.
6. Install fully charged battery. Clean battery cable clamps and terminals to help retard
corrosion.

CAUTION
DO NOT operate engine without cooling water being supplied to seawater pickup
pump or water pump impeller will be damaged and subsequent overheating
damage to engine may result.
7. Start engine and closely observe instrumentation to ensure that all systems are func-
tioning properly.
8. Carefully inspect entire engine for fuel, oil, water and exhaust leaks.
9. Check steering system, shift and throttle controls for proper operation.

90-861328--1 NOVEMBER 1999 Page 1B-39

MAINTENANCE SERVICE MANUAL NUMBER 25

THIS PAGE IS INTENTIONALLY BLANK

Page 1B-40 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

IMPORTANT INFORMATION 1
Section 1C - Troubleshooting C
Table of Contents
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Poor Fuel Economy . . . . . . . . . . . . . . . . . 1C-14
Used Spark Plug Analysis . . . . . . . . . . . . 1C-3 Engine Runs Poorly at Idle . . . . . . . . . . . 1C-14
Normal Condition . . . . . . . . . . . . . . . . . 1C-3 Engine Runs Poorly At High RPM . . . . . 1C-15
Chipped Insulator . . . . . . . . . . . . . . . . . 1C-3 Engine Acceleration Is Poor . . . . . . . . . . 1C-16
Wet Fouling (Oil Deposits) . . . . . . . . . 1C-4 Troubleshooting with Vacuum Gauge . . 1C-16
Cold Fouling . . . . . . . . . . . . . . . . . . . . . 1C-4 Engine Noise . . . . . . . . . . . . . . . . . . . . . . . 1C-17
Overheating . . . . . . . . . . . . . . . . . . . . . 1C-4 Important Information . . . . . . . . . . . . . 1C-17
High Speed Glazing . . . . . . . . . . . . . . . 1C-5 Valve Cover Area . . . . . . . . . . . . . . . . . 1C-17
Scavenger Deposits . . . . . . . . . . . . . . 1C-5 Cylinder Area . . . . . . . . . . . . . . . . . . . . 1C-18
Pre-Ignition Damage . . . . . . . . . . . . . . 1C-5 Camshaft Area . . . . . . . . . . . . . . . . . . . 1C-18
Reversed Coil Polarity . . . . . . . . . . . . . 1C-6 Crankshaft Area . . . . . . . . . . . . . . . . . . 1C-19
Splashed Deposits . . . . . . . . . . . . . . . . 1C-6 Miscellaneous . . . . . . . . . . . . . . . . . . . . 1C-20
Mechanical Damage . . . . . . . . . . . . . . 1C-6 Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Poor Boat Performance and/or Miscellaneous . . . . . . . . . . . . . . . . . . . . 1C-21
Poor Maneuverability . . . . . . . . . . . . . . . . 1C-7 Low Oil Pressure . . . . . . . . . . . . . . . . . 1C-22
Improper Full Throttle Engine RPM . . . . 1C-8 High Oil Pressure . . . . . . . . . . . . . . . . . 1C-22
RPM Too High . . . . . . . . . . . . . . . . . . . 1C-8 Excessive Oil Consumption . . . . . . . . . . . 1C-23
RPM Too Low . . . . . . . . . . . . . . . . . . . . 1C-8 Water In Engine . . . . . . . . . . . . . . . . . . . . . 1C-24
Engine Cranks Over But Will Not Start Important Information . . . . . . . . . . . . . 1C-24
Or Starts Hard . . . . . . . . . . . . . . . . . . . . . . 1C-9I Water on Top of Pistons . . . . . . . . . . . 1C-25
mportant Information . . . . . . . . . . . . . . . . . 1C-9 Water in Crankcase Oil . . . . . . . . . . . . 1C-25
Thunderbolt V Ignition (No Spark) . . . 1C-10 Engine Overheats . . . . . . . . . . . . . . . . . . . 1C-26
Testing Thunderbolt V Ignition System 1C-10 Mechanical . . . . . . . . . . . . . . . . . . . . . . 1C-26
Fuel System Rich . . . . . . . . . . . . . . . . . 1C-11 Engine Overheats . . . . . . . . . . . . . . . . . . . 1C-27
Fuel System Lean . . . . . . . . . . . . . . . . 1C-11 Cooling System . . . . . . . . . . . . . . . . . . 1C-27
Miscellaneous . . . . . . . . . . . . . . . . . . . . 1C-11 Insufficient Water Flow from
Engine Will Not Crank Over . . . . . . . . . . . 1C-12 Belt Driven Seawater Pickup Pump . 1C-28
Charging System Inoperative . . . . . . . . . 1C-12 Power Steering . . . . . . . . . . . . . . . . . . . . . 1C-29
Noisy Alternator . . . . . . . . . . . . . . . . . . . . . 1C-13 Poor, Erratic or No Assist . . . . . . . . . . 1C-29
Instrumentation Malfunction . . . . . . . . . . 1C-13 Noisy Pump . . . . . . . . . . . . . . . . . . . . . . 1C-30
Radio Noise . . . . . . . . . . . . . . . . . . . . . . . . 1C-13 Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . 1C-30

90-861328--1 NOVEMBER 1999 Page 1C-1

TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Precautions
WARNING
Always disconnect battery cables from battery BEFORE working on fuel system to
prevent fire or explosion.

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. Follow
specific procedures given in this manual for all fuel line connections.

WARNING
Make sure no fuel leaks exist before closing engine hatch.

WARNING
When running engine with boat out of water, be certain that area in vicinity of
propeller is clear and that no person is standing nearby. As a precautionary
measure, it is recommended that the propeller be removed.

WARNING
BE CAREFUL while working on fuel system; 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 and/or open flames in the area. Wipe up any spilled
fuel immediately.

WARNING
Avoid Fire or Explosion: Fuel injection system is pressurized during operation. Use
care when removing water separating fuel filter. Fuel could spray on hot engine
causing fire or explosion. Allow 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 spray-
ing on the engine.

WARNING
Be sure that engine compartment is well ventilated and that no gasoline vapors are
present to prevent the possibility of a FIRE or EXPLOSION.

WARNING
DO NOT leave helm unattended while performing idle speed adjustment.

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.

CAUTION
DO NOT run engine above 1500 rpm, as suction created by seawater pickup pump
may collapse water supply hose and cause engine to overheat.

Page 1C-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Used Spark Plug Analysis

Use the following illustrations for determining serviceability of spark plug. Spark plug
condition also can suggest a variety of possible engine malfunctions and, therefore, can
indicate needed engine repairs. When old plugs are replaced, replace 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 electrode gap wide enough to permit cleaning and filing.
3. Remove combustion deposits from firing end of spark plug with a plug cleaner. Blow off
with compressed air to remove abrasives.
4. File electrode surfaces to restore clean, sharp edges. Again remove filings with
compressed air.
5. Reset gap to specifications by bending only side electrode with proper tool.
Normal Condition
Few deposits are present and probably will be light tan or gray in color. This plug shows that
plug heat range is compatible with engine, and engine is electrically and mechanically in
good running condition. With proper plug servicing (clean, file and re-gap), this plug can be
reinstalled with good results.

72420

Chipped Insulator
Chipped insulator usually results from careless plug re-gapping. Under certain conditions,
severe detonation also can split insulator firing ends. Replace spark plug.

72420

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Wet Fouling (Oil Deposits)

Plug becomes shorted by excessive oil entering combustion chamber, usually in engine with
many hours of operation. Worn piston rings, cylinder walls, valve guides or valve stem seals
are causes of oil entering combustion chamber. Only engine repairs will permanently relieve
oil wet fouling.
IMPORTANT: New engines or recently overhauled engines may wet foul plugs before
normal oil control is achieved with proper break-in procedures. Such fouled plugs
may be serviced (clean, file and re-gap) and reinstalled.

72420

Cold Fouling
Dry, black deposits indicate rich fuel mixture or weak ignition. Clogged flame arrestor,
flooding carburetor, sticky choke or weak ignition components all are probable causes. If,
however, only one or two plugs in set are fouled, check for sticking valves or bad ignition
leads. After correcting cause, service (clean, file and re-gap) plugs and reinstall.

72421

Overheating
Insulator is dull white or gray and appears blistered. Electrodes are eroded and there is an
absence of deposits. Check that correct plug heat range is being used. Also check for
over-advanced ignition timing, cooling system malfunction, lean fuel/air mixtures, leaking
intake manifold or sticking valves. Replace spark plugs.

72421

Page 1C-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

High Speed Glazing

Insulator has yellowish, varnish-like color, indicating that 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 plugs. If
condition recurs, use colder heat range plug and service plugs more frequently.

72421

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

72422

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

72422

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Reversed Coil Polarity

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

72422

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
installation of new plugs, deposits loosen from top of piston and head and are thrown against
hot insulator. Plugs may be serviced (clean, file and re-gap) and reinstalled.

72423

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

72423

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

Page 1C-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Poor Boat Performance and/or Poor Maneuverability

Symptom Cause
A. Improper drive unit trim angle
B. Improper weight distribution
C. Boat is underpowered
D. Permanent or power hook in boat bot-
Bow too low tom
E. False bottom full of water
F. Improperly adjusted anode (after
planes)
G. Dirty boat bottom (marine growth)
A. Improper drive unit trim angle
B. Propeller pitch too great
C. Dirty boat bottom (marine growth)
D. Poor running engine
Bow too high E. Improper weight distribution
F. Rocker in boat bottom
G. False bottom full of water
H. Improperly adjusted anode (after
planes)
A. Drive unit installed too high on transom
B. Dirty or rough boat bottom
C. Damaged propeller; pitch too small;
diameter too small
D. Keel located too close to propeller or
Propeller ventilating too deep in the water
E. Water pickup or through hull fittings
located too close to propeller
F. Hook in boat bottom
G. Propeller plugged up with weeds

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Improper Full Throttle Engine RPM

RPM Too High

Cause Special Information
Damaged; pitch too low; diameter too
Propeller
small; propeller hub slipping.
Water pickup or through hull fittings
mounted too close to propeller
(ventilation); keel located too close to
Boat
propeller and/or too deep in the water
(ventilation). Drive installed too high on
transom; wrong gear ratio.
Operation
Unit trimmed out too far.
Engine coupler slipping

RPM Too Low

Cause Special Information

Propeller Damaged; pitch too great; diameter too

great.
Dirty or damaged bottom; permanent or
power hook in bottom; false bottom full of
Boat
water. Drive installed too low on transom;
wrong gear ratio.
Operation Unit trimmed in too far.

Page 1C-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 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 run,
basic components - fuel, spark (ignition), and compression - are required. If all three
components are present, the engine should run. If any one of the three are missing,
weak, or arriving at the wrong time the engine will not run.
2. Check ignition system operation. Remove coil wire from tower on distributor cap. Hold
coil wire near ground and check for spark while cranking engine over. Repeat procedure
with spark plug wires. If there is spark at the spark plug wires, remove the spark plugs
and make sure they are correct type and heat range, and not fouled or burned.
3. Run a compression check on engine to make sure the engine is mechanically OK.
Thunderbolt V Ignition (No Spark)
Cause Special Information

Moisture on ignition components Distributor cap or spark plug wires arcing

Battery, electrical connections, damaged

wiring
Ignition switch

Shift interrupter switch (Alpha One Models

Only)
Shorted tachometer Disconnect tachometer and try again

Ignition timing

Spark plugs Fouled, burned, cracked porcelain

Spark plug wires Faulty insulation, broken wires

Cracked or dirty distributor cap

Faulty ignition components Check components

Engine synchronizer (if equipped) hooked Synchronizers must be hooked up directly

up series on purple ignition wire (dual coil terminal (parallel chute)
engines only)

90-861328--1 NOVEMBER 1999 Page 1C-9

TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Testing Thunderbolt V Ignition System

Ensure that tachometer GRY lead is not shorted to

ground (-) at the tachometer or within the harness.

No Spark

Check all terminal connections at distributor, ignition module and ignition coil.
Battery OK?
Distributor clamping screw tight?

No Spark
Check
engine and
With key in RUN position, check for 12 volts at instrument
0 Volts wiring har-
positive (+) terminal on ignition coil.
ness, battery
cables, key
switch.

Unplug WHT/RED bullet connector from distributor.

0 Volts Check for 12 volts on lead coming from module.

12 Volts

Reconnect WHT/RED bullet connectors. Remove

high-tension lead from distributor to coil. Insert a
spark gap tester from coil tower to ground. Discon-
nect WHT/GRN lead from distributor. Place ignition Replace igni-
key in RUN position. Rapidly strike the terminal of Spark at tion sensor
the WHT/GRN lead that comes from module, coil. in distributor.
against ground (-).

No spark at coil.

Substitute a new ignition coil. Repeat above Spark at Install new

test. coil. ignition coil.

No spark at coil.

Replace ignition module.

IMPORTANT: The WHT/GRN lead must be touched against ground (–) 2-3 times per
second to simulate a running engine. Repeat this test several times to ensure that
spark is present.

Page 1C-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Fuel System Rich

Cause Special Information

Clogged flame arrestor

Excessive fuel pump pressure

Fuel pressure regulator defective

Fuel System Lean

Cause Special Information

Empty fuel tank

Fuel shut-off valve closed (if equipped)

Engine will not start after warm engine

Vapor lock
shut down

Miscellaneous

Cause Special Information

Low grade or stale fuel

Water in fuel

90-861328--1 NOVEMBER 1999 Page 1C-11

TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Engine Will Not Crank Over

Cause Special Information

Remote control lever not in neutral posi-

tion
Battery charge low; damaged wiring; loose
electrical connections
Circuit breaker tripped

Blown fuse

Ignition switch

Slave solenoid

Faulty neutral start safety switch Open circuit

Starter solenoid

Starter motor

Mechanical engine malfunction

Charging System Inoperative

Cause Special Information

Loose or broken serpentine belt

Engine rpm too low on initial start Rev engine to 1500 rpm

Loose or corroded electrical connections

Faulty battery gauge Best way to test is to replace gauge

Battery will not accept charge Low electrolyte or failed battery

Faulty alternator or regulator

Refer to SECTION 4C for complete

“Charging System” diagnosis procedures

Page 1C-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Noisy Alternator

Cause Special Information

Loose mounting bolts

Drive belt Worn, frayed, loose

Loose drive pulley

Worn or dirty bearings

Faulty diode trio or stator

Instrumentation Malfunction

Cause Special Information

Faulty wiring, loose or corroded terminals

Faulty key switch Test, as outlined in SECTION 4D

Faulty gauge Test, as outlined in SECTION 4D

Faulty sender Test, as outlined in SECTION 4D

Radio Noise

Cause Special Information

A “popping” noise that will increase with Ignition System - wrong spark plugs;
engine rpm. Noise will stop as soon as en- cracked distributor cap; cracked coil tower;
gine is turned off. leaking spark plug wires; moisture on
ignition components
“High pitched whine” in the radio Alternator - poor brush contact on the slip
rings
A “hissing or crackling” noise when instru- Instrumentation - loose connections, or
ments are jarred with ignition on antennae wire routed too close to instru-
ments
Accessories - bilge pump, bilge blower;
fish finder, depth locator; cabin heater
Varying unexplained noises
motor, etc. Disconnect one at a time until
noise disappears.

90-861328--1 NOVEMBER 1999 Page 1C-13

TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Poor Fuel Economy

Cause Special Information

Fuel leaks

Prolonged idling; slow acceleration; failure

to cut back on throttle once boat is on
Operator habits
plane; boat overloaded; uneven weight
distribution
Bent, damaged, or wrong propeller. Water
Engine laboring test boat for proper operating rpm at wide-
open-throttle
Clogged flame arrestor

Engine compartment sealed too tight Not enough air for engine to run properly

Boat bottom Dirty (marine growth), hook, rocker

Improper fuel

Crankcase ventilation system not working

Engine running too cold or too hot

Plugged or restricted exhaust

Engine Low compression

Engine Runs Poorly at Idle

Symptoms Cause

Engine surges

Low top speed or lack of power

Refer to “Fuel Injection System Trouble-
Poor cold engine operation shooting,” SECTION 5H

Engine stalls

Hard starting Refer to “Engine Starts Hard”

Page 1C-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Engine Runs Poorly At High RPM

Cause Special Information

Also refer to “Poor Boat Performance”

Crankcase overfilled with oil Check oil level with boat at rest in the
water.
Anti-siphon valve (if equipped) Restricting fuel supply

Plugged fuel tank vent

Fuel supply Refer to “Fuel Injection System

Troubleshooting,” SECTION 5H
Ignition timing

Low grade of fuel or water in the fuel

Spark plugs Fouled, burned, cracked porcelain,

incorrect heat range
Spark plug wires Poor insulation, broken wires

Distributor cap or rotor Dirty or cracked

Coil

Distributor Excessive play in shaft

Engine overheating Refer to “Engine Overheats”

Low compression Worn valves, rings, cylinders, etc.

Restricted exhaust

90-861328--1 NOVEMBER 1999 Page 1C-15

TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Engine Acceleration Is Poor

Cause Special Instructions

Also refer to “Poor Boat Performance”

Idle mixture screws

Incorrect ignition timing

Incorrect distributor or amplifier advance Refer to SECTION 4B

curve
Cracked or dirty distributor cap or rotor

Vacuum leak Intake manifold

Fouled, burned; wrong heat range;

Spark plugs
cracked porcelain
Low compression

Troubleshooting with Vacuum Gauge

Reading Cause

Steady reading between 15-21 inches at

Normal
idle rpm
Extremely low reading, but steady at idle Vacuum leak; incorrect timing;
rpm underpowered boat; faulty boat bottom
Fluctuates between high and low at idle Blown head gasket between two adjacent
rpm cylinders
Fluctuates 4 or 5 inches very slowly at idle Spark plug gap too narrow, valves are
rpm sticking
Fluctuates rapidly at idle, steadies as rpm
Valve guides are worn
is increased
Continuously fluctuates between low and
normal reading at regular intervals at idle Burned or leaking valve
rpm

Page 1C-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

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

Valve Cover Area

Location Possible Causes

Rocker arm striking valve cover

Valve cover area, timed to one-half engine Rocker arm out of adjustment
speed, noise could be confined to one
Worn rocker arm
cylinder or may be found in any multitude
of cylinders Bent push rod

Collapsed lifter

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Cylinder Area

Location Possible Causes

Sticking valve

Carbon build-up

Connecting rod installed wrong

Cylinder area, may be confined to one Bent connecting rod
cylinder or found in more than one
cylinder, timed to engine speed Piston

Piston rings

Piston pin

Cylinder worn

Camshaft Area

Location Possible Causes

Crankshaft timing sprocket
Timing chain
Camshaft area, front of engine, timed to
one half engine speed Valve Lifter
Cam Bearings
Fuel Pump
Camshaft area, center of engine, timed to Valve Lifter
one half engine speed
Cam bearing
Distributor gear
Camshaft area, rear of engine, timed to Valve lifter
one half engine speed
Cam bearings
Loss of oil pressure
Camshaft area, throughout engine, timed Valve lifters
to one half engine speed
Cam bearings

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SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Crankshaft Area
Location Possible Causes
Crankshaft timing sprocket

Crankshaft area, front of engine, timed to Timing chain

engine speed Main bearing
Rod bearing
Crankshaft striking pan or pan baffle
Crankshaft area, center of engine, timed Main bearing
to engine speed
Rod bearing
Loose flywheel cover
Loose coupler
Crankshaft area, rear of engine, timed to Loose flywheel
engine speed
Main bearing
Rod bearing
Loss of oil pressure
Crankshaft area, throughout engine, timed Main bearings
to engine speed
Rod bearings

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Miscellaneous

Noise Possible Cause

Advanced timing

Low octane fuel

Engine spark knock
Engine running hot

Carbon deposits in engine

Vacuum leak

Leaking exhaust (manifolds or pipes)

Hissing
Loose cylinder heads

Blown head gasket

Vacuum leak
Whistle
Dry or tight bearing in an accessory

Leaking high tension lead

Sparks jumping Cracked coil tower

Cracked distributor cap

Serpentine drive belt slipping

Squeaks or squeals Dry or tight bearing in an accessory

Parts rubbing together

Rattling in exhaust pipe area Exhaust shutters

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SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Oil Pressure
Miscellaneous

Cause Special Information

Use a good automotive oil pressure test

Measuring oil pressure gauge. Do not rely on the oil pressure
gauge in the boat.
Check engine oil level with boat at rest in Oil level should be between the ADD and
the water FULL / OP RANGE / OK marks
May cause loss of engine rpm, oil pres-
sure gauge fluctuation, drop in oil pres-
Oil level in crankcase above FULL mark
sure, and hydraulic valve lifter noise at
high rpm
Low oil pressure; oil pressure gauge
Oil level in crankcase below ADD mark fluctuation; internal engine noise and/or
damage
This may be a normal condition. Oil
pressure may read high in the cooler times
of the day, and when engine is not up to
Change in oil pressure operating temperature. As the air
temperature warms up and engine is
running at normal opening temperature, it
is normal for oil pressure to drop.
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
Low engine oil pressure at idle
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, also, the oil
will get thin somewhat from heat.
Low engine oil pressure at idle after run-
Refer to the two preceding steps
ning at a high rpm
It is not uncommon to see different oil
Boats with dual engines pressure readings between the two
engines, as long as both engines fall
within specifications. Differences in oil
pressure can be attributed to differences
Boats with dual stations in engine tolerances, gauges, wiring,
senders, etc.

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Low Oil Pressure

Cause Special Information

Low oil level in crankcase

Verify with an automotive test gauge.

Defective oil pressure gauge and/or
Refer to SECTION 4D for instrument
sender
testing.
Oil broken down; contains water or gas;
wrong viscosity; engine running too hot or
Thin or diluted oil
too cold; excessive idling in cold water
(condensation)
Relief valve stuck open; pickup tube
restricted; worn parts in oil pump; air leak
Oil pump
on suction side of oil pump or pickup oil
tube
Oil passage plugs leaking, cracked or
Oil leak can be internal or external
porous cylinder block
Cam bearings, main bearings, rod
Excessive bearing clearance
bearings

High Oil Pressure

Cause Special Information

Oil too thick Wrong viscosity, oil full of sludge or tar

Defective oil pressure gauge and/or Verify with an automotive test gauge
sender
Clogged or restricted oil passage

Oil pump relief valve stuck closed

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SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Excessive Oil Consumption

Cause Special Information

One quart of oil consumed in 5-15 hours

Normal consumption. of operation at wide-open-throttle (espe-
cially in a new or rebuilt engine) is normal
Clean bilge, run engine with clean white
Oil leaks
paper on bilge floor, locate oil leak(s)
Oil too thin Oil diluted or wrong viscosity

Oil level too high

Drain holes in cylinder head plugged Oil will flood valve guides

Defective valve seals

Intake manifold gasket leaking

Worn valve stems or valve guides

Defective oil cooler (if equipped) Crack in cooler tubes

Glazed, scuffed, worn, stuck, improperly

Defective piston rings installed; ring grooves worn; improper
break-in; wrong end gap
Out of round, scored, tapered, glazed;
Defective cylinders excessive piston to cylinder clearance;
cracked piston
Excessive bearing clearance

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Water In Engine
Important Information
IMPORTANT: First determine location of water in engine. This information can help
determine where the water came from and how it got into the engine. The three most
common problems are water on top of pistons, water in crankcase oil or water in
crankcase oil and on top of pistons.
After locating water remove all the water from the engine by removing all spark plugs and
pumping cylinders out by cranking engine over. Change oil and filter. Replace spark plugs.
Start engine and see if problem can be duplicated. If problem can be duplicated, there is
a mechanical problem. If the problem cannot be duplicated, the problem is either an
operator error or a problem that exists only under certain environmental conditions.
If water is contained to cylinder(s) only, it is usually entering through the intake system,
exhaust system, or head gasket.
If the water is contained to 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 cylinder(s) 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 exhaust manifolds is a good idea. Rust in these
areas will give clues if the water entered these areas.

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SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Water on Top of Pistons

Cause Special Information

Operator shut engine off at high rpm

Poor fuel, high idle rpm, timing set too

Engine “diesels” or tries to run backwards
high
Rain water running into flame arrestor Hatch cover

Improper combustion causes moisture in

Spark plug misfiring
the air to accumulate in the cylinder
Backwash through the exhaust system

Improper engine or exhaust hose

installation
Cracked exhaust manifold

Improper manifold to elbow gasket instal-

lation
Loose cylinder head bolts

Check for warped cylinder head or

Blown cylinder head gasket
cylinder block
Cracked valve seat

Check cylinder heads, cylinder block, and

Porous or cracked casting
intake manifold

Water in Crankcase Oil

Cause Special Information

Boat has been submerged or bilge water

Water in boat bilge was high enough to run in through dipstick
tube
Refer to “Water in Engine” (“On Top of Pis-
Water seeping past piston rings or valves
tons”)
Defective thermostat, missing thermostat;
Engine running cold
prolonged idling in cold water
Intake manifold leaking near a water pas-
sage
Check cylinder head, cylinder block, and
Cracked or porous casting
intake manifold

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Engine Overheats
Mechanical

Cause Special Information

Engine rpm below specifications at wide- Damaged or wrong propeller; growth on

open-throttle (engine laboring) boat bottom; false bottom full of water
Wrong ignition timing Timing too far advanced or retarded

Sticking distributor advance weights

Spark plug wires crossed (wrong firing

order)
Lean fuel mixture

Wrong heat range spark plugs

Exhaust restriction

Jumped timing chain, or improperly

Valve timing off
installed
A blown head gasket(s) normally cannot
be detected by a compression check. Nor-
mally the engine will run at normal temper-
ature at low rpm, but will overheat at
speeds above 3000 rpm.
Engines that are seawater cooled:
Blown head gasket(s) Using a clear plastic hose, look for air
bubbles between seawater pump and
engine. If there are no bubbles present,
install clear plastic hose between
thermostat housing and manifold(s). If air
bubbles are present at a higher rpm, it is a
good indication there is a blown head
gasket.
Insufficient lubrication to moving parts of Defective oil pump, plugged oil passage,
engine low oil level

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SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Engine Overheats
Cooling System

Cause Special Information

IMPORTANT: The first step is to verify if the engine is actually overheating or the
temperature gauge or sender is faulty.
IMPORTANT: Best way to test gauge or sender is to replace them.
Loose or broken drive belt

Seawater shutoff valve partially or fully

closed (if equipped)
Clogged or improperly installed sea
strainer
Loose hose connections between seawa-
Pump will suck air. Pump may fail to prime
ter pickup and seawater pump inlet
or will force air bubbles into cooling sys-
(models with belt driven seawater pump
tem.
only)
Seawater inlet hose kinked or collapsed

Seawater pickup clogged

Obstruction will be in front of seawater

Obstruction on boat bottom causing water
pickup, causing air bubbles to be forced
turbulence
into cooling system
Defective thermostat

Exhaust elbow water outlet holes plugged

Insufficient seawater pump operation Worn pump impeller

Obstruction in cooling system such as Refer to water flow diagram for engine
casting flash, sand, rust, salt, etc. type being serviced
Engine circulating pump defective

Also refer to “Engine Overheats -

Mechanical”
IMPORTANT: In addition to previous checks, make the following checks if engine
is equipped with closed cooling.
Low coolant level

Antifreeze should be mixed 50/50 or

Antifreeze not mixed properly maximum 60/40 (60% antifreeze, 40%
water)
Heat exchanger cores plugged

Water hoses reversed at the water

Refer to water flow diagram in SECTION 6
distribution block

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Insufficient Water Flow from Belt Driven Seawater Pickup Pump

Cause Special Information

Drive belt Loose, worn or broken

Seawater shutoff valve partially or fully

closed
Clogged or improperly installed sea
strainer
Pump will suck air, pump may fail to prime
Loose hose connections between seawa-
or will force air bubbles into cooling
ter pickup and seawater pump inlet
system
Seawater inlet hose kinked or plugged

Seawater pickup plugged

Obstruction will be in front of seawater

Obstruction on boat bottom causing water
pickup, causing air bubbles to be forced
turbulence.
into cooling system
Faulty seawater pump

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SERVICE MANUAL NUMBER 25 TROUBLESHOOTING

Power Steering
Poor, Erratic or No Assist

Cause Special Information

Drive belt Worn, broken or out of adjustment

Low fluid level

Air leak in lines, pump or air from

Air in system installation. Refer to SECTION 9A for
bleeding procedure.
Refer to SECTION 9A for bleeding proce-
Leaking hoses
dure.
Cable or helm partially frozen from rust or
Steering cables and/or steering helm corrosion; cable over-lubricated; improper
cable installation.
Refer to appropriate Sterndrive Service
Binding in sterndrive unit
Manual
Restriction in hydraulic hoses Causes a loss of pressure

Control valve not positioned properly, not

balanced properly, or the mounting nut is
loose
Mounting bracket adjusting screw loose or
mounting tube is loose
Faulty pump Flow control valve may be sticking

Worn piston ring or scored housing bore in Causes loss of pressure

cylinder.
Leaking valve body or loose fitting spool

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Noisy Pump

Cause Special Information

Drive belt Check belt tension

Low fluid level

Air leak in lines, pump or air from

Air in fluid
installation
Use stethoscope to listen for noise in
Faulty pump
pump
Kinks or debris in hoses or debris in
Restricted fluid passages
passages
Refer to appropriate Sterndrive Service
Stop nut adjusted improperly
Manual
Steering cables installed that do not meet Refer to appropriate Sterndrive Service
BIA standards Manual

Fluid Leaks

Cause Special Information

Loose hose connections Refer to SECTION 9A for bleeding instruc-

tions
Damaged hose

System overfilled; fluid contains water;

Oil leaking from top of pump
fluid contains air
Cylinder piston rod seal

Faulty seals in valve

Faulty seals in o-rings in pump

Cracked or porous metal parts

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TROUBLESHOOTING SERVICE MANUAL NUMBER 25

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Page 1C-32 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MCM MODELS

REMOVAL AND INSTALLATION

Section 2A - MCM Models
Table of Contents
2
Torque Specifications . . . . . . . . . . . . . . . . 2A-2 A
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Lubricants / Sealants / Adhesives . . . . . 2A-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
Installation and Alignment . . . . . . . . . . . . 2A-5
Engine Connections . . . . . . . . . . . . . . 2A-10
Electrical Connections . . . . . . . . . . . . . 2A-11
Mercathode Connections . . . . . . . . . . 2A-12
Shift Cable Installation . . . . . . . . . . . . 2A-12
Power Steering Connections . . . . . . . 2A-12
Fuel Supply Connections . . . . . . . . . . 2A-13
Throttle Cable Installation and
Adjustment . . . . . . . . . . . . . . . . . . . . . . 2A-14

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MCM MODELS SERVICE MANUAL NUMBER 25

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Cable Barrel Spread Cotter Key
Drive Unit Shift Cable
Cable End Guide See Note
Hose Clamps Securely
Rear Engine Mounts 35-40 47-54
Power Steering Fluid Hose Fitting 23 31
Remote Control Shift Cable Barrel Securely
Cables Cable End Guide See Note

NOTE: Tighten, then loosen nut 1/2 turn.

Tools
Description Part Number
Engine Alignment Tool 91-805475A1

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver Engine Coupler Spline Grease 91-816391A4
Quicksilver Liquid Neoprene 92-27511-2
Loctite 592 Pipe Sealant With Teflon Obtain Locally

Page 2A-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MCM MODELS

Removal
IMPORTANT: Sterndrive unit must be removed prior to engine removal. Refer to
Sterndrive Service Manual.
1. Disconnect battery cables from battery.
2. Remove instrument harness connector plug from engine harness receptacle after
loosening clamp.

WARNING
Be careful when working on 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.
3. Using wrench to stabilize brass filter nut at fuel inlet, loosen fuel line fitting. Disconnect
and suitably plug fuel line to prevent fuel in tank from leaking into bilge.
4. Disconnect throttle cable from carburetor or throttle body and retain locknuts and hard-
ware.
5. Disconnect trim sender bullet connectors from transom assembly from engine harness.
NOTE: After wires are disconnected be sure to loosen them from clamps or sta-straps
retaining them to engine or hoses.
6. Alpha Models: Slide sleeves back on BLK and WHT/GRN or GRY wires and disconnect
engine harness wires from shift cut-out switch harness.
7. Disconnect MerCathode wires from MerCathode controller if mounted on engine, if
equipped.
8. Disconnect seawater inlet hose from gimbal housing.
9. Disconnect exhaust elbow hoses (bellows).
10. Remove both shift cables from shift plate. Retain locknuts and hardware.
11. Disconnect any grounding wires and accessories connected to engine.
12. Disconnect and plug fluid hoses from power steering control valve on transom.

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MCM MODELS SERVICE MANUAL NUMBER 25

CAUTION
Center lifting eye (located on top of thermostat housing) is used for engine
alignment only. DO NOT use to lift entire engine.

CAUTION
DO NOT allow lifting sling to hook or compress engine components or damage will
occur.
13. Support engine with suitable sling through lifting eyes on engine and remove front and
rear engine mounting bolts. Retain hardware.

a
a

75847

a - Engine Lifting Eyes

14. Carefully remove engine. DO NOT hit power steering control valve.

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SERVICE MANUAL NUMBER 25 MCM MODELS

Installation and Alignment

1. Inspect fiber washers (cemented in place) on inner transom plate. Replace if worn or
damaged.
2. Install double wound lockwashers onto inner transom plate inside fiber washer.
3. Ensure that rear engine mount locknuts are in position.
4. Lubricate exhaust bellows with soap and water to ease installation.
5. Lubricate engine coupler splines with Quicksilver Engine Coupler Spline Grease.

b
c

d 72023

a - Double Wound Lockwasher

b - Fiber Wound Lockwasher (Cemented In Place)
c - Inner Transom Plate Mount (Engine Support)
d - Locknuts (Engine Mounting Bolts)

CAUTION
Center lifting eye (located on top of thermostat housing) is used for engine
alignment only. DO NOT use to lift entire engine.

CAUTION
DO NOT allow lifting sling to hook or compress engine components or damage will
occur.
6. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when
suspended.
7. Lift engine into position (in boat), using an overhead hoist.
8. Align rear engine mounts with inner transom plate mounts while simultaneously aligning
exhaust tubes with exhaust pipe hoses (bellows).

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MCM MODELS SERVICE MANUAL NUMBER 25

IMPORTANT: Engine attaching hardware must be installed in sequence shown.

9. Install both rear engine mounting bolts and hardware as shown. Torque to 37 lb-ft (50
Nm).

a
b
c
d

e
g

h f
72535

a - Rear Engine Mounting Bolt

b - Large Steel Washer
c - Metal Spacer
d - Rear Engine Mount
e - Double Wound Lockwasher
f - Fiber Washer (Cemented in Place)
g - Inner Transom Plate Mounts
h - Locknut (Hidden In This View)

CAUTION
When lowering engine into position DO NOT set engine on shift cable. Shift cable
outer casing can be crushed causing difficult or improper shifting.
10. Set engine down on stringers and relieve hoist tension. Disconnect sling from engine
lifting eyes and switch sling to center lifting eye.

b
a

75847

a - Center Lifting Eye

b - Engine Lifting Eyes

Page 2A-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MCM MODELS

CAUTION
DO NOT use an alignment tool from another manufacturer. Alignment tools other
than Quicksilver Alignment Tool 91-805475A1, may cause improper alignment and
damage to gimbal bearing and/or engine coupler.

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

CAUTION
Avoid damage to exhaust system. On engines with single piece manifolds, stress
can be placed on the lower exhaust pipe if front of engine is raised too high while
performing engine alignment procedure. Ensure that engine is not raised higher
than the top of engine mount adjusting stud.

b e
c
72536
d
Engine Mount
a - Nut and Lockwasher
b - Adjustment Nut
c - Turn Adjustment Nut in This Direction (Counterclockwise)
d - Slotted Hole Toward Front of Engine
e - Tab Washer

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MCM MODELS SERVICE MANUAL NUMBER 25

11. Align engine as follows:

a. Attempt to insert solid end of Quicksilver Alignment Tool through gimbal bearing and
into engine coupler splines. If it will not insert easily proceed to following.
b. While observing the above precautions, CAREFULLY raise and lower front of
engine with hoist, as required, until tool will SLIDE FREELY all the way in and out
of engine coupler splines.

b
a

70013

a - Quicksilver Alignment Tool (91-805475A1)

b - Insert This End of Alignment Tool through Gimbal Housing Assembly

b c

72585

a - Alignment Tool (91-80547A1)

b - Gimbal Bearing
c - Engine Coupler

IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in
direction required to align engine.
c. Adjust front engine mounts until they rest on boat stringers.
d. Relieve hoist tension entirely and fasten both front mounts to boat stringer using
appropriate hardware (lag bolts or through-bolts, etc.).
e. Recheck alignment with alignment tool. Tool must enter coupler splines freely. If not,
readjust front mounts.
f. When alignment is correct, tighten locknut or nut with lockwasher on each mount
securely.

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SERVICE MANUAL NUMBER 25 MCM MODELS

g. Bend tab washer down against flat on adjusting nut.

b e
c

72536
d
a - Locknut
b - Adjustment Nut
c - Turn Adjustment Nut In This Direction (Counterclockwise) To Raise Front Of
Engine
d - Slotted Hole To Front Of Engine
e - Tab Washer

h. Remove alignment tool if not already removed.

12. Tighten all exhaust system hose clamps securely (use two hose clamps on each con-
nection):
a. On Engines with Thru-Prop Exhaust:

72537

Thru Prop Exhaust Shown

a - Hose Clamps
b - Exhaust Tube - Long Tube, Port Side - Short Tube, Starboard Side

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MCM MODELS SERVICE MANUAL NUMBER 25

Engine Connections
IMPORTANT: When routing all wire harnesses and hoses, be sure they are routed and
secured to avoid coming in contact with hot spots on engine and avoid contact with
moving parts.
1. Connect seawater hose to water tube at gimbal housing with hose clamp. Tighten clamp
securely.
NOTE: For visual clarity the engine is not shown in position.

b
72590

Bravo Models
a - Water Inlet Tube
b - Hose Clamp
c - Seawater Inlet

bb
a 72614

Alpha Models
a - Water Inlet Tube
b - Hose Clamp
c - Seawater Inlet

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SERVICE MANUAL NUMBER 25 MCM MODELS

Electrical Connections
1. Connect instrument harness to engine harness with hose clamp. Tighten clamp
securely.
2. Connect trim position sender leads from gimbal housing to leads from engine harness.

c 72582

a - BRN/WHT (From Engine Harness)

b - BLK (From Engine Harness)
c - BLK (From Transom)
d - BLK (From Transom Assembly)

IMPORTANT: Do not attach any accessory ground (–) wires to transom plate ground
point. Accessory ground wires should only be attached to ground stud on engine.
3. Connect any grounding wires or accessories that may have been disconnected.

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MCM MODELS SERVICE MANUAL NUMBER 25

Mercathode Connections (if equipped)

1. Connect MerCathode wires to MerCathode controller assembly. Apply a thin coat of
Quicksilver Liquid Neoprene to all connections.

a b c d 22232
a - ORG Wire - From Electrode on Transom Assembly
b - RED/PUR Wire - To Positive (+) Battery Terminal
c - BLK Wire - From Engine Harness
d - BRN Wire - From Electrode on Transom Assembly

IMPORTANT: Adjust shift cables as outlined in appropriate Sterndrive Service

Manual.
Shift Cable Installation
1. Refer to appropriate Sterndrive Service Manual and install and adjust drive unit and
remote control shift cables, using hardware retained.
Power Steering Connections
IMPORTANT: After fluid hose installation in the following, bleed power steering
system as outlined in SECTION 1B - “Maintenance” or refer to appropriate Sterndrive
Service Manual.
1. Connect power steering fluid hoses to control valve (large fitting first).

CAUTION
Route hoses exactly as shown below. This will help avoid stress on the hose fittings
and will help avoid kinks in the hose.
IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid
leakage.
IMPORTANT: DO NOT cross-thread or overtighten fittings.
2. Torque both fittings to 23 lb-ft (31 Nm).

73786

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SERVICE MANUAL NUMBER 25 MCM MODELS

3. Connect battery cables to battery by FIRST connecting POSITIVE (+) battery cable
(usually RED) to POSITIVE (+) battery terminal. Tighten clamp securely. Then, connect
NEGATIVE (–) battery cable (usually BLK) to NEGATIVE (–) battery terminal. Tighten
clamp securely.
NOTE: Spray terminals with a battery connection sealant to help retard corrosion.

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.
w Apply #592 Loctite Pipe Sealant with Teflon to threads of brass fitting or plug.
DO NOT USE TEFLON TAPE.
w Thread brass fitting or plug into fuel pump or fuel filter base until finger tight.
w Tighten fitting or plug an additional 1-3/4 to 2-1/4 turns using a wrench. DO NOT
OVER TIGHTEN.
w Install fuel line. To prevent over tightening, hold brass fitting with suitable
wrench and tighten fuel line connectors securely.
w Check for fuel leaks.

WARNING
Be careful when working on 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.
1. Connect fuel line from fuel tank(s) to engine. Tighten connections securely.
2. Check for leaks.

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MCM MODELS SERVICE MANUAL NUMBER 25

Throttle Cable Installation and Adjustment

1. Connect throttle cable using hardware retained and adjust as follows:

CARBURETED ENGINES

b b
a c
d d 72013

MerCarb 2 Barrel Carburetor

a - Cable End Guide
b - Attaching Hardware
c - Cable Barrel
d - Anchor Studs
b
c

a b
d

b 72014

Weber 4 Barrel Carburetor

a - Cable End Guide
b - Attaching Hardware (DO NOT Overtighten)
c - Cable Barrel
d - Anchor Studs
1. Place remote control handle(s) in neutral, idle position.
IMPORTANT: Be sure that cable is routed in such a way as to avoid sharp bends and/
or contact with moving parts. DO NOT fasten any items to throttle cable. Outer cable
must be free to move when cable is actuated.
2. Install cable end guide on throttle lever, then push cable barrel lightly toward throttle
lever end. (This will place a slight preload on cable to avoid slack in cable when moving
remote control lever.) Adjust barrel on throttle cable to align with anchor stud.
3. Secure throttle cable with hardware (retained). Tighten cable end guide nut until it con-
tracts and then loosen 1/2 turn. Tighten cable barrel securely. DO NOT OVERTIGHTEN,
as cable must pivot freely.

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SERVICE MANUAL NUMBER 25 MCM MODELS

4. Place remote control throttle lever in the wide-open-throttle (WOT) position. Ensure that
throttle shutters (valves) are completely open and throttle shaft lever contacts
carburetor body casting.
5. Return remote control throttle lever to idle position and check to ensure that throttle lever
contacts idle speed adjustment screw.

74104
b a
Weber 4 Barrel Carburetor Wide-Open-Throttle
a - Throttle Shaft Lever
b - Carburetor Body Casting

b
70392

Weber 4 Barrel Carburetor Idle Position

a - Throttle Lever
b - Idle Speed Adjustment Screw

90-861328--1 NOVEMBER 1999 Page 2A-15

MCM MODELS SERVICE MANUAL NUMBER 25

EFI ENGINES

1. Install cable end guide on throttle lever, then push cable barrel end lightly toward throttle
lever end. (This will place a slight preload on shift cable to avoid slack in cable when
moving remote control lever). Adjust barrel on throttle cable to align with hole in anchor
plate.
2. Secure throttle cable with hardware as shown and tighten securely. Tighten locknut until
it contacts, then loosen one-half turn.
3. Place remote control throttle level in the wide open throttle (WOT) position. Ensure that
throttle plates are completely open.
4. Return remote control throttle lever to idle position.

75867

a - Cable End Guide

b - Flat Washer and Locknut
c - Cable Barrel
d - Flat Washer and Locknut

Page 2A-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MCM MODELS

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MCM MODELS SERVICE MANUAL NUMBER 25

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Page 2A-18 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

ENGINE
Section 3A - 262 cid (4.3L) Engines
Table of Contents
Torque Specifications . . . . . . . . . . . . . . . 3A-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-62
Lubricants / Sealants / Adhesives . . . . . 3A-4 Cleaning and Inspection . . . . . . . . . . . 3A-63
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-63
Specifications . . . . . . . . . . . . . . . . . . . . . . . 3A-6 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-64
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-64
Bearing Failures . . . . . . . . . . . . . . . . . . . .
Piston Failures . . . . . . . . . . . . . . . . . . . . . .
3A-14
3A-16
Inspection . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
3A-64
3A-65
3
Pre-Ignition . . . . . . . . . . . . . . . . . . . . . .
Detonation . . . . . . . . . . . . . . . . . . . . . . .
3A-16
3A-17
Rear Main Oil Seal . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . .
3A-66
3A-66
A
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . 3A-19 Cleaning and Inspection . . . . . . . . . . . 3A-67
Rocker Arm Cover . . . . . . . . . . . . . . . . . . . 3A-20 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-67
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-20 Rear Main Oil Seal Retainer . . . . . . . . . . 3A-68
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-68
Intake Manifold . . . . . . . . . . . . . . . . . . . . . 3A-21 Cleaning and Inspection . . . . . . . . . . . 3A-68
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-68
Cleaning and Inspection . . . . . . . . . . . 3A-23 Main Bearings . . . . . . . . . . . . . . . . . . . . . . 3A-69
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-24 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-69
Rocker Arm / Push Rod . . . . . . . . . . . . . . 3A-27 Replacement . . . . . . . . . . . . . . . . . . . . . 3A-71
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-27 Connecting Rod Bearings . . . . . . . . . . . . 3A-74
Cleaning and Inspection . . . . . . . . . . . 3A-28 Inspection and Replacement . . . . . . . 3A-74
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-28 Connecting Rod / Piston Assembly . . . . 3A-76
Hydraulic Roller Valve Lifters . . . . . . . . . 3A-29 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-76
Locating Noisy Lifters . . . . . . . . . . . . . 3A-30 Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-77
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-31 Cleaning and Inspection . . . . . . . . . . . 3A-78
Cleaning and Inspection . . . . . . . . . . . 3A-34 Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-80
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-34 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-82
Valve Stem Oil Seal / Valve Spring . . . . 3A-36 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 3A-84
Removal - Head Installed . . . . . . . . . . 3A-36 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-84
Valve Assembly (Exploded View) . . . 3A-38 Cleaning and Inspection . . . . . . . . . . . 3A-86
Installation - Head Installed . . . . . . . . 3A-39 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-87
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . 3A-40 Timing Chain and Sprocket . . . . . . . . . . . 3A-88
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-40 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-88
Cleaning and Inspection . . . . . . . . . . . 3A-42 Cleaning and Inspection . . . . . . . . . . . 3A-88
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-43 Installation - Timing Chain . . . . . . . . . 3A-89
Cylinder Head and Valve Conditioning . 3A-47 Crankshaft Sprocket . . . . . . . . . . . . . . . . . 3A-89
Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-89
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 3A-47 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-89
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-48 Checking Timing Chain Deflection . . 3A-90
Valve Guide Bore Repair . . . . . . . . . . 3A-49 Balance Shaft / Gears . . . . . . . . . . . . . . . 3A-91
Valve Springs - Checking Tension . . . 3A-50 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-91
Valve Seat Repair . . . . . . . . . . . . . . . . 3A-50 Cleaning and Inspection . . . . . . . . . . . 3A-93
Valve Grinding . . . . . . . . . . . . . . . . . . . 3A-51 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-94
Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-52 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-96
Dipstick Specifications . . . . . . . . . . . . . . . 3A-55 Measuring Lobe Lift . . . . . . . . . . . . . . . 3A-96
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-56 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-97
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-56 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-98
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-56 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-98
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-57 Camshaft Bearings . . . . . . . . . . . . . . . . . . 3A-99
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-57 Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-99
Disassembly . . . . . . . . . . . . . . . . . . . . . 3A-58 Inspection . . . . . . . . . . . . . . . . . . . . . . . 3A-100
Cleaning and Inspection . . . . . . . . . . . 3A-58 Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-100
Reassembly . . . . . . . . . . . . . . . . . . . . . 3A-58 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . 3A-101
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-59 Cleaning and Inspection . . . . . . . . . . . 3A-101
Torsional Damper . . . . . . . . . . . . . . . . . . . 3A-59 Oil Filter By-Pass Valve . . . . . . . . . . . . . . 3A-105
Removal . . . . . . . . . . . . . . . . . . . . . . . . 3A-59 Inspection and/or Replacement . . . . . 3A-105
Installation . . . . . . . . . . . . . . . . . . . . . . . 3A-60 Remote Oil Filter . . . . . . . . . . . . . . . . . . . . 3A-106
Crankcase Front Cover Oil Seal . . . . . . . 3A-61 Inspection and/or Replacement . . . . . 3A-106
Crankcase Front Cover . . . . . . . . . . . . . . 3A-62

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Torque Specifications 262 cid (4.3L) Engines

Description lb-in. lb-ft Nm
Alternator Brace to Alternator 192 28
Alternator Brace to Engine 30 41
Alternator to Mounting Bracket 35 48
Alternator Mounting Bracket 30 41
Balance Shaft Drive Gear Retaining Stud 120 14
Balance Shaft Driven Gear Bolt
15 20
(Torque Plus 35°)
Balance Shaft Thrust Plate 120 14
Camshaft Sprocket 20 27
Camshaft Thrust Plate 106 12
Carburetor 132 15
Connecting Rod Cap Nuts
20 27
(Torque Plus 70°)
Coupler/Flywheel 35 48
Crankcase Front Cover 124 14
Crankshaft Pulley Bolt (Cast Aluminum) 40 54
Cylinder Head Bolts - First Sequence 22 30
Angle Torque Second Sequence
Short Bolt 55 Degrees
Medium Bolt 65 Degrees
Long Bolt 75 Degrees
Distributor Hold Down 25 34
Exhaust Manifold 20 27
Flywheel 75 100
Flywheel Housing to Block 30 41
Flywheel Housing Cover 80 9
Front Mount Bracket 30 41
Fuel Filter Bracket Bolt 25 25
Fuel Pump Bracket Bolt 25 25
Fuel Pump Inlet Fitting (Large Diameter
96 10.8
See Note)
Fuel Pump Inlet Fitting (Small Diameter
84 9.6
See Note)
Intake Manifold Bolts 11 15
Knock Sensor 15 20

NOTE: Hold fuel pump using flat surface at outlet before tightening brass fitting.

Page 3A-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Torque Specifications 262 cid (4.3L) Engines (continued)

Description lb-in lb-ft Nm
Main Bearing Cap 75 100
Oil Filter Adapter Bolts 15 20
Oil Pan Drain Plug 15 20
Oil Pan Screw (1/4-20) 80 9
Oil Pan Nuts (5/16-20) 165 19
Oil Pump 65 68
Oil Pump Cover 80 9
Power Steering Pump Brace to Block 30 41
Power Steering Pump Bracket 30 41
Rear Crankshaft Oil Seal Retainer
Screws and Nuts 133 15
Rear Mount (MCM) 40 54
Rocker Arm Cover 106 12
Rocker Arm Nuts 22 30
Roller Lifter Restrictor Plate 12 16
Seawater Pump Brace (if equipped) 30 41
Seawater Pump Bracket (if equipped) 30 41
Spark Plugs 15 20
Starter Motor 50 68
Thermostat Housing 30 41
Torsional Damper 40 54
Water Circulating Pump 30 41
Water Temperature Sender 20 27

90-861328--1 NOVEMBER 1999 Page 3A-3

262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver Loctite 27131 92-809820
Quicksilver RTV Sealer 92-91601-1
Quicksilver Perfect Seal 92-34227--1
Quicksilver Needle Bearing Assembly Lubricant 92-825265A1
General Motors Cam and Lifter Prelube or Equivalent Obtain Locally

Tools

Mercury Marine Special Tools

Description Part Number
Piston Ring Expander 91-24697
Engine Coupler Wrench 91-35547

Special Tools

Snap-On Special Tools (see note)

Description Part Number
Torque Angle Gauge (Degree Wheel Torquing) TA 360

NOTE: Snap-On Tools can be ordered from your nearest Snap-On branch sales office or
distributor.

Page 3A-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Kent-Moore Special Tools

Kent-Moore Special Tools
29784 Little Mack
Roseville, MI 48066
(800) 345-2233
Description Part Number
Valve Spring Compressor J5892
Valve Spring Compressor J8062
Valve Spring Tester J8056
Valve Guide Cleaner J8101
Valve Guide Reamer J5830-2
Carbon Remover Brush J8089
Piston Pin Remover Kit J24086-B
Piston Ring Groove Cleaner J3936-03
Piston Ring Compressor J8037
Connecting Rod Bolt Guide Set (3/8-24) J5239
Oil Pump Suction Pipe Installer J21882
Camshaft Bearing Remover and Installer Set J6098-01
Ball Socket Adaptor Tool Kit (Lift Indicator) J8520-1
Torsional Damper Remover and Installer J23523-E
Crankcase Front Cover Seal Installer J35468
Crankshaft Gear and Sprocket Puller J5825-A
Crankshaft Gear and Sprocket Installer J5590
Air Adaptor J23590
Main Bearing Remover/Installer J8080
Rear Main Seal Installer J26817-A
Balance Shaft Rear Bearing Remover J26941
Balance Shaft Bearing Remover/Installer J33834

90-861328--1 NOVEMBER 1999 Page 3A-5

262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Specifications
262 CID / 4.3L Engine Specifications
NOTICE
Unit Of Measurement: Inches (Millimeters)

Displacement 262 cid (4.3 L)

Bore 4.00 (101.6)
Stroke 3.48 (88.39)
Compression Ratio 9.2:1
Heads Cast Iron
Intake manifold Cast Iron
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Pistons Cast Aluminum
Crankshaft Cast Iron
Camshaft Steel

CYLINDER BORE

Diameter 4.0007-4.0017 (101.6178-1016431)

Production .0005 (0.0127) Maximum
Out-of-Round
Service .002 (0.05) Maximum
Thrust Side .0005 (0.0127) Maximum
Production
Taper Relief Side .001 (0.02) Maximum
Service .001 (0.02) Over Production

PISTON

Production .0007-.002 (0.017 - 0.05)

Clearance
Service .002 (0.60) Maximum

Page 3A-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

262 CID / 4.3L Engine Specifications

NOTICE
Unit Of Measurement: Inches (Millimeters)

PISTON RING

Top .02-.06 (0.508-1.524)

Groove Side Production
2nd .04-.08 (1.016-2.032)
Clearance
Service .004 (0.10) Maximum
Compression
Top .010-.016 (0.25-0.40)
Production
Gap 2nd .018-.026 (0.46-0.66) Maximum
Service .06-.035 (1.52-0.88) Maximum
Groove Side Production .02-.07 (0.508-0.177)
Clearance Service .02-.08 (0.50-2.03) Maximum
Oil
Production .015-.050 (0.381-1.27)
Gap
Service .009-.065 (0.23-1.65) Maximum

PISTON PIN

Diameter .9267-.9271 (23.545-23.548)

Production .0002-.0007 (0.0051-0.0177)
Clearance in Piston
Service .001 (0.02) Maximum
Fit in Rod .0008-.0016 (0.021-0.040) Interference

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

262 CID / 4.3L Engine Specifications

CRANKSHAFT

NOTICE
Unit Of Measurement: Inches (Millimeters)

No. 1 2.4488-2.4495 (62.199-62.217)

Diameter No. 2, 3 2.4485-2.4494 (62.191-62.215)
No. 4 2.4479-2.4489 (62.179-62.203)
Main Journal Production .0003 (0.007) Maximum
Taper
Service .001 (0.02) Maximum
Out-of- Production .0002 (0.005) Maximum
Round Service .001 (0.02) Maximum
No. 1 .0008-.0020 (0.0203-0.0508)
Production
Main Bearing No. 2, 3, 4 .0011-.0023 (0.0279-0.0584)
Clearance No. 1 .001-.002 (0.03-0.05)
Service
No. 2, 3, 4 .001-.002 (0.25-0.06)
Crankshaft End Play .002-.008 (0.05-0.20)
Crankshaft Runout .001 (0.025) Maximum
Diameter 2.2487-2.2497 (57.1170-57.1423)
Production .0003 (0.00508) Maximum
Connecting Taper
Service .001 (0.02) Maximum
Rod Journal
Out-of- Production .0002 (0.007) Maximum
Round Service .001 (0.02) Maximum
Production .0013-.0035 (0.0330-0.0889)
Rod Bearing Clearance
Service .001-.003 (0.02-0.07) Maximum
Rod Side Clearance .006-.017 (0.152-0.44)

Page 3A-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

262 CID / 4.3L Engine Specifications

NOTICE
Unit Of Measurement: Inches (Millimeters)

VALVE SYSTEM

Lifter Hydraulic Roller

Rocker Arm Ratio 1.50:1
Intake .414 (10.52)
Valve Lift
Exhaust .428 (10.87)
Valve Lash (Intake and Exhaust) Net Lash No Adjustment
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002 (0.05) Maximum
Intake .035-.060 (0.89-1.52)
Seat Width
Exhaust .062-.093 (1.58-2.38)
Intake
Production .0011-.0027 (0.0279-0.069)
Stem Exhaust
Clearance Intake .001 (0.025) Maximum
Service
Exhaust .002 (0.51) Maximum
Intake
Stem Diameter .341 (8.64)
Exhaust
Valve Margin Intake and Exhaust .031 (0.79)

VALVE SPRING

Free Length 2.03 (51.6)

Valve
Valve Closed 76-84 Lb. (338-374 N) at 1.7 in (43.16 mm)
Spring Pressure
Valve
Open 187-203 Lb. (832-903 N) at 1.27 in (32.25 mm)
Installed Height Intake 1.78 in (45.2 mm)
Installed Height Exhaust 1.69-1.71 in. (42.9-43.43)

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

262 CID / 4.3L Engine Specifications

NOTICE
Unit Of Measurement: Inches (Millimeters)

CAMSHAFT AND DRIVE

Intake .286-.290 (7.26-7.36)

Lobe Lift ±.
± 002(0.051)
Exhaust .292-.296 (7.42-7.52)
Journal Diameter 1.8682-1.8692 (47.452-47.478)
Journal Out of Round .001 (0.025) Maximum
Camshaft Runout .002 (0.051) Maximum
Camshaft End Play .001-.009 (0..0254-0.2286)
Timing Chain Deflection .375 (9.5) from taut position [total .75 (19)]

FLYWHEEL

Runout .008 (0.203) Maximum

CYLINDER HEAD

Gasket Surface Flatness .010 (0.254) Overall Maximum

BALANCE SHAFT

Front Bearing Journal 2.1648-2.1654 (55.985-55.001)

Rear Bearing Journal 1.4994-1.500 (38.084-38.100)
Rear Bearing Inside
Diameter Assembled Production 1.5014-1.503 (37.525-37.575)
Rear Bearing Outside Diameter Production 1.875-1.876 (46.875-46.900)
Rear Cylinder Block
Housing Bore Production 1.873-1.874 (46.825-46.850)
Rear Bearing Journal Clearance .001-.0036 (.025-.091)

Page 3A-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

General
Some of the repairs in this section must be completed with engine removed from boat.
Engine removal depends upon type of repair and boat design. Place engine on repair stand
for major repairs.
When engine removal is not required, make certain that battery cables are disconnected
at the battery prior to performing any on-board engine repair procedure.
Lubricate all moving parts (during reassembly) with engine oil. Apply Quicksilver Perfect
Seal on threads of and under heads of cylinder head bolts and on threads of all cylinder block
external bolts, screws and studs.
Engine Identification
The Mercury MerCruiser Model can be determined by looking at the last two letters of the
engine code stamped into the cylinder block. This code number is stamped on all Mercury
MerCruiser power packages and replacement partial engines, but not replacement cylinder
block assemblies.
If the engine serial number and/or model decals are missing, the engine code letters may
help in determining the engine models.

72873

a - Location of GM Engine Code (Front Starboard Side, Near Cylinder Head

Mating Surface)

MCM (Sterndrive) Code Rotation

4.3L LJ
4.3LH LK LH
4.3L EFI LK

90-861328--1 NOVEMBER 1999 Page 3A-11

262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Cylinder Head Identification

4.3

72875

a - Left Hand Rotation (CCW) - All Sterndrive Engines

Crankshaft
The crankshaft is supported in the block by four insert type bearings. Crankshaft end thrust
is controlled by flanges on the No. 4 bearing. A torsional damper on the forward end of the
crankshaft serves to help dampen any engine torsional vibration.
Piston and Connecting Rods
Piston pins are offset slightly toward the thrust side of the pistons to provide a gradual
change in thrust pressure against the cylinder wall as the piston travels its path. Pins have
a floating fit in the piston and a press fit in the connecting rod (to hold them in place).
Connecting rods are made of forged steel and are connected to the crankshaft through
insert type bearings.
Camshaft and Drive
Camshafts are generally cast iron. However, engines with roller lifters have steel camshafts.
All camshafts are driven at 1/2 crankshaft speed by a timing chain and sprockets, and are
supported by four main bearings, which are pressed into the block.
A helical gear on the aft end of the camshaft drives the distributor and oil pump.
Balance Shaft
The balance shaft is located in the engine block valley directly above and parallel to the
camshaft. The balance shaft extends the entire length of the engine and is supported on
each end by a bearing. It is also driven by the camshaft through a helical gear set. The
function of the balance shaft is to equalize the dynamic forces inherent in particular engine
designs, thus minimizing engine vibration.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Cylinder Head
The cylinder heads are made of cast iron and have individual intake and exhaust ports for
each cylinder.
Stainless steel or graphite composition head gaskets are used to retard corrosion.
Valve Train
The valves and valve springs are of a heavy-duty design to withstand the high engine
speeds encountered. Valve tips have been hardened to extend valve life. Exhaust valve
rotators are used to help extend valve life.
Hydraulic valve roller lifters ride directly on the camshaft lobes and transmit the thrust of the
lobes to the push rods which in turn actuate the valves through the rocker arm.
In addition to transmitting thrust of the cam lobes, the hydraulic lifters also serve to remove
any clearance (lash) from the valve train to keep all parts in constant contact.
The roller lifters are restrained from rotating by two retainers (restrictors) located in the
valley. The valve lifters also are used to lubricate the valve train bearing surfaces.
Intake Manifold
The manifold is of the single level design for efficient fuel distribution. All passages are of
approximately equal length to assure more even fuel-air mixture to the cylinders.
Lubrication System
The engine lubrication system is of the force-feed type in which oil is supplied under full
pressure to the crankshaft, connecting rods, camshaft bearings and valve lifters, and is
supplied under controlled volume to the push rods and rocker arms. All other moving parts
are lubricated by gravity flow or splash.
A positive displacement gear-type oil pump is mounted on the rear main bearing cap and
is driven by an extension shaft from the distributor (which is driven by the camshaft). Oil from
the bottom of the pump in the rear of the oil pan is drawn into the oil pump through an oil
pickup screen and pipe assembly.
If the screen should become clogged, a relief valve in the screen will open and continue to
allow oil to be drawn into the system. Once the oil reaches the pump, the pump forces the
oil through the lubrication system. A spring-loaded relief valve in the pump limits the
maximum pump output pressure.
After leaving the pump, the pressurized oil flows through a full-flow oil filter. On engines with
an engine oil cooler, the oil also flows through the cooler before returning to the block. A
bypass valve allows oil to bypass the filter and oil cooler should they become restricted.
Some of the oil, after leaving the oil cooler and/or filter, is routed to the No. 4 crankshaft main
bearing. The remainder of the oil is routed to the main oil gallery, which is located directly
above the camshaft and runs the entire length of the block. From the main oil gallery, the
oil is routed through individual oil passages to an annular groove in each camshaft bearing
bore. Some of the oil is then used to lubricate camshaft bearings. The remainder of the oil
is routed to the valve lifter oil galleries and No. 1, 2 and 3 crankshaft main bearings by means
of individual oil passages which intersect with the annular grooves.
The camshaft bearings have holes which align with the oil passages or annular grooves in
the block and allow oil to flow in-between the bearings and the camshaft journals. The oil
that is forced out the front end of the No. 1 camshaft bearing drains down onto the camshaft
drive and keeps it lubricated.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

The oil which reaches the crankshaft main bearings is forced through a hole in the upper
half of each bearing and flows in-between the bearings and the crankshaft journals. Some
of the oil is then routed to the connecting rod bearings through grooves in the upper half of
the crankshaft main bearings and oil passages in the crankshaft. Oil which is forced out the
ends of the connecting rod bearings and crankshaft main bearings is splashed onto the
camshaft, cylinder walls, pistons and piston pins, keeping them lubricated. Oil which is
forced out the front end of the No. 1 crankshaft main bearing also assists in lubricating the
camshaft drive.
Oil which reaches the valve lifter oil galleries is forced into each hydraulic valve lifter through
holes in the side of the lifter. From here, the oil is forced through the metering valve in each
of the lifters (which controls the volume of oil flow) and then up through the push rods to the
rocker arms. A hole in each rocker arm push rod seat allows the oil to pass through the
rocker arm and lubricate the valve train bearing surfaces. After lubricating the valve train,
oil drains back to the oil pan through oil return holes in the cylinder head and block.
The distributor shaft and gear also is lubricated by the oil flowing through the right valve lifter
oil gallery.

Bearing Failures

a b 70436

Scratched By Dirt
a - Scratches
b - Dirt Imbedded In Bearing Material

a
70436

Tapered Journal
a - Overlay Gone From Entire Surface

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Bearing Failures (Continued)

a 70436

Lack Of Oil
a - Overlay Worn Off

a 70436

Radius Ride
a - Worn Area

70436

a
Improper Seating
a - Bright Or Polished Sections

a 70436

Fatigue Failure
a - Craters or Pockets

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Piston Failures
NOTE: Engine failure due to pre ignition or detonation are beyond the control of Mercury
MerCruiser. No warranty will apply to failures that occur under these conditions.
Pre-Ignition
Pre-ignition is abnormal fuel ignition, caused by combustion chamber hot spots. Control of
the start of ignition is lost, as combustion pressure rises too early, causing power loss and
rough running. The upward motion on the piston is opposed by the pressure rise. This can
result in extensive damage to the internal parts from the high increase in combustion
chamber temperature.

72424

Pre-Ignition Damage
a b

c d

72314

Combustion Differences
a - Ignited By Hot Deposits
b - Regular Ignition Spark
c - Ignites Remaining Fuel
d - Flame Front Collide

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

PRE-IGNITION CAUSES

1. Hot spots in the combustion chamber from glowing deposits (due in turn to the use of
improper oils and/or fuels).
2. Overheated spark plug electrodes (improper heat range or defective plug).
3. Any other protuberance in the combustion chamber, such as an overhanging piece of
gasket, an improperly seated valve or any other inadequately cooled section of material
which can serve as a source.
Detonation
Detonation, commonly called “fuel knock,” “spark knock” or “carbon knock,” is abnormal
combustion of the fuel which causes the fuel to explode violently. The explosion, in turn,
causes overheating or damage to the spark plugs, pistons, valves and, in severe cases,
results in pre-ignition.
Use of low octane gasoline is one of the most common causes of detonation. Even with high
octane gasoline, detonation could occur if engine maintenance is neglected.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

OTHER CAUSES OF DETONATION

IMPORTANT: Use of improper fuels will cause engine damage and poor performance.
1. Over-advanced ignition timing.
2. Lean fuel mixture at or near full throttle (could be caused by carburetor or leaking intake
manifold).
3. Cross-firing spark plugs.
4. Excess accumulation of deposits on piston and/or combustion chamber (results in
higher compression ratio).
5. Inadequate cooling of engine by deterioration of cooling system.

72425

Detonation Damage

a b

c d

72315

Combustion Description
a - Spark Occurs
b - Combustion Begins
c - Combustion Continues
d - Detonation Occurs

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Engine Mounts

72316

Front Mount

72318

Rear Mount/Flywheel Housing

IMPORTANT: Press rear mount out with press.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Rocker Arm Cover

Removal
It may be necessary to remove exhaust manifold before removing rocker arm cover. (Refer
to Section 7B)
1. Disconnect crankcase ventilation hoses.
2. Remove any items that interfere with the removal of rocker arm covers.
IMPORTANT: DO NOT pry rocker arm cover loose. Gaskets, which may adhere to
cylinder head and rocker arm cover, may be loosened by bumping end of rocker
cover from the rear with palm of hand or a rubber mallet.
3. Remove rocker arm cover.
Installation
1. Clean sealing surfaces on cylinder head and rocker arm cover with degreaser.
2. Place new rocker arm cover gasket in position in rocker arm cover.

75853
a

a - Rocker Arm Cover Gasket

3. Install rocker arm cover. Torque screws to 106 lb-in. (12 Nm).
4. Install exhaust manifolds, if removed.
5. Install any items which were removed to allow removal of rocker arm covers.
6. Connect crankcase ventilation hoses to rocker arm covers.
7. Start engine and check for oil leaks.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Intake Manifold
Removal
1. Drain engine cooling system.
2. Disconnect hoses from thermostat housing.

75847

3. Disconnect electrical leads interfering with removal.

4. Disconnect crankcase ventilation hoses from rocker arm covers.
5. Disconnect throttle cable from carburetor or throttle body.

75867

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

6. Remove fuel line running between fuel pump and carburetor or throttle body.

76404

a - Fuel Line

7. Remove distributor cap and mark position of rotor on distributor housing. Also, mark
position of distributor housing on intake manifold.
8. Remove distributor.
IMPORTANT: Do not crank engine over after distributor has been removed.
9. Remove other ignition components.
10. Remove oil sending unit.
11. Disconnect any other miscellaneous items that will prevent removal of manifold.
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.
12. Remove intake manifold bolts, then remove intake manifold and carburetor assembly.
NOTE: If intake manifold requires replacement, transfer all remaining parts to new manifold.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Cleaning and Inspection

1. Clean gasket material from all mating surfaces.

75853

IMPORTANT: When cleaning cylinder head mating surface, do not allow gasket
material to enter engine crankcase or cylinder head ports.
2. Inspect manifold for cracks or scratches. Machined surfaces must be clean and free of
all marks and deep scratches or leaks may result.
3. Check intake passages for varnish buildup and other foreign material. Clean as
necessary.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Installation
IMPORTANT: When installing intake manifold gaskets, in next step, observe the
following:
• Be sure to install gasket with marked side up. Both gaskets are identical.
• On engines with 2 barrel carburetor, remove metal insert from manifold gasket to
be used on starboard (right) cylinder head to provide clearance for heat pipe on
intake manifold.
• All Mercury MerCruiser V-6 GM engines that have “automatic” carburetor chokes
must use an intake gasket that has an opening for the exhaust crossover port in
the intake manifold. Without this opening the “automatic” carburetor choke will
not operate properly. The choke will remain ON longer causing rough engine op-
eration and wasted fuel.

71850

a - Exhaust Crossover Port Opening

1. Apply Quicksilver Perfect Seal to intake manifold gaskets especially around coolant
passages (both sides).
2. Place gaskets on cylinder heads.

a b a

71850

a - Coolant Passages
b - Gaskets

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

3. Apply a 3/16 in. (5 mm) wide bead of Quicksilver RTV Sealer to engine block as shown.
Extend sealer 1/2 in. (13 mm) up on intake gaskets.
IMPORTANT: DO NOT get Quicksilver RTV Sealer into oil sending unit hole at rear of
engine.

a
a

71850

a - RTV Sealer (Typical Both Ends)

71851

b - Oil Sending Unit Hole

4. Carefully install manifold assembly and torque bolts to 35 lb-ft (48 Nm) in sequence as
shown.

5 1 4 8

7 3 2 6
72878

Intake Manifold Torque Sequence

a - Front

5. Connect all electrical leads.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

6. Connect hoses to thermostat housing.

75847

7. Install fuel line to carburetor and fuel pump.

76404

a - Fuel Line

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

8. Connect crankcase ventilation hoses to rocker arm covers.

9. Install distributor. Position rotor and housing to align with marks made during removal,
then install distributor cap.
10. Install other ignition components and reconnect wires.
11. Coat threads of oil pressure sending unit with Quicksilver Perfect Seal and install.
12. Connect any other items which were disconnected from manifold during removal.
13. Start engine.
14. Adjust ignition timing and carburetor.
15. Check hose connections, gaskets and seals for leaks.
16. Inspect fuel line connections for fuel leaks.

Rocker Arm/Push Rod

Removal
NOTE: When servicing only one cylinder’s rocker arms, bring that cylinder’s piston up to
TDC before removing rocker arms. When servicing all rocker arms, bring No. 1 piston up
to TDC before removing rocker arms.
1. Remove rocker arm covers.

75853

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

2. Remove rocker arm assemblies and push rods.

75674

IMPORTANT: Place rocker arm assemblies and push rods in a rack for reassembly
in their original locations.
Cleaning and Inspection
1. Clean parts with solvent and dry with compressed air.
2. Inspect all contact surfaces for wear. Replace all damaged parts.
Installation
IMPORTANT: When installing rocker arms and rocker arm balls, coat bearing
surfaces of rocker arms and rocker arm balls with engine oil.
1. Install push rods in their original locations. Be sure push rods seat in lifter socket.
2. Install rocker arms, rocker arm balls and rocker arm nuts in their original locations.
3. Torque rocker arm nuts to 22 lb-ft (30 Nm). No valve adjustment is required. Valve lash
is automatically set when rocker arm nuts are torqued to specification.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Hydraulic Roller Valve Lifters

Hydraulic valve lifters require little attention. 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.

1 2
3
4
5
6
7 8
9

72031

1 - Push Rod Seat Retainer

2 - Push Rod Seat
3 - Metering Valve
4 - Plunger
5 - Check Ball
6 - Check Ball Spring
7 - Check Ball Retainer
8 - Plunger Spring
9 - Lifter Body

Valve lifters are retained in position and prevented from rotating by two valve retainers, one
on each side of the engine beneath the intake manifold. Care should be exercised when
installing the retainers to see that the flat portions of the lifters are properly positioned into
the retainers.

71853

a - Retainer
b - Roller Lifter Flat Portion

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Locating Noisy Lifters

Locate a noisy valve lifter by using a piece of garden hose approximately 4 ft (1.2 m) in
length. Place one end of hose near end of each intake and exhaust valve, with other end
of hose to the ear. In this manner, sound is localized, making it easy to determine which lifter
is at fault.
Another method is to place a finger on face of valve spring retainer. If lifter is not functioning
properly, a distinct shock will be felt when valve returns to its seat.
General types of valve lifter noise are as follows:
1. Hard rapping noise - usually caused by plunger becoming tight in bore of lifter body so
that return spring cannot push plunger back up to working position. Probable causes
are:
a. Excessive varnish or carbon deposit, causing abnormal stickiness.
b. Galling or “pickup” between plunger and bore of lifter body, usually caused by an
abrasive piece of dirt or metal wedged between plunger and lifter body.
2. Moderate rapping noise - probable causes are:
a. Excessively high leakdown rate.
b. Leaky check valve seat.
c. Improper adjustment.
3. General noise throughout valve train - this will, in most cases, be a definite indication
of insufficient oil supply or improper adjustment.
4. Intermittent clicking - probable causes are:
a. A microscopic piece of dirt momentarily caught between ball seat and check valve
ball.
b. In rare cases, ball itself may be out of round or have a flat spot.
c. Improper adjustment.
In most cases, where noise exists in one or more lifters, all lifter units should be removed,
disassembled, cleaned in solvent, reassembled and reinstalled in engine. If dirt, corrosion,
carbon, etc., is shown to exist in one unit, it more likely exists in all the units; thus it would
only be a matter of time before all lifters caused trouble.

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Removal
1. Remove rocker arm covers.

75853

2. Remove intake manifold.

IMPORTANT: Keep valve push rod and hydraulic lifter from each valve together as a
matched set and mark or store them so they can be reinstalled in the same location
later.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

3. Remove rocker arm assemblies and push rods.

75670

a - Rocker Arm Assembly

b - Push Rods

NOTE: Engines with roller lifters have additional valve train components shown below.

72329

a - Lifter Restrictor Retainer

b - Fasteners

72340

a - Roller Lifter Restrictor

b - Roller Lifter

4. Remove lifter restrictors and lifters.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

5. Remove fasteners from lifter retainers (restrictors) and remove retainers. Do not disturb
lifters at this time.

71852

a - Lifter Retainer (Restrictor)

b - Fasteners

6. Make matching marks on all retainers and lifters as to location and orientation in bores,
to allow reassembly in exact position on camshaft lobes (so that the roller’s bearing and
roller will roll in the same direction on the same lobe, if reused).
7. Remove valve lifters.

76586

b
b 71853

a - Roller Lifter Retainer

b - Roller Lifter(s)
c - Matching Marks

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Cleaning and Inspection

1. Thoroughly clean all parts in cleaning solvent and inspect them carefully.
2. If any parts are damaged or worn, entire lifter assembly should be replaced.
3. If outer lifter body wall is scuffed or worn, inspect cylinder block lifter bore.
4. If roller is worn or damaged, inspect camshaft lobe.
5. If push rod seat is scuffed or worn, inspect push rod.
Installation
IMPORTANT: It is recommended that the engine oil be changed and a new oil filter be
installed whenever servicing valve lifters or camshaft.
IMPORTANT: Before installing roller lifters, coat the roller with engine oil. If new lifters
or a new camshaft have been installed, an additive containing EP lube (such as
General Motors Cam and Lifter Prelube or equivalent) should be poured over
camshaft lobes before installing lifters.
IMPORTANT: Before installation, coat entire valve lifter with engine oil.
IMPORTANT: DO NOT install used valve lifters if a new camshaft has been installed.
1. Align matching marks made prior to disassembly, and install hydraulic valve lifters and
components. Torque roller lifter retainer (restrictor) plate fasteners to 12 lb-ft (16 Nm).

Page 3A-34 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

NOTE: Components shown removed in left drawing for visual clarity

c

a b

b
b 71853

76586

a - Roller Lifter Retainer

b - Roller Lifter(s)
c - Matching Marks

71852

a - Lifter Retainer (Restrictor)

b - Fasteners

2. Install intake manifold.

3. Install push rods. Ensure push rods seat in lifter socket.
4. Install rocker arms and rocker arm nuts. Torque nuts to 22 lb-ft (30 Nm).
5. Install rocker arm cover. Torque fasteners to 106 lb-in. (12 Nm).
6. Start engine and check for leaks.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Valve Stem Oil Seal / Valve Spring Replacement

Removal - Head Installed
1. Remove rocker arm cover.

75853

2. Remove spark plug of affected cylinder.

3. Remove rocker arm assembly.

75670

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

4. Install air line adaptor tool (J-23590) in spark plug hole and apply compressed air to hold
valves in place.

76572

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.
IMPORTANT: Do not turn crankshaft while valve springs, retainers and locks are
removed or valves will fall into cylinder.
5. Using valve spring compressor as shown, compress valve spring and remove valve
locks.

b 72881

a - Valve Spring Compressor (J-5892)

b - Rocker Arm Nut

6. Slowly release valve spring compressor. Remove cap, retainer or rotator, and valve
spring.
IMPORTANT: Keep air pressure in cylinder while springs, caps and valve locks are
removed or valves will fall into cylinder.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

7. Remove seals from valve stems and valve guide.

72330

a - Intake Valve Guide Seal

Valve Assembly (Exploded View)

a
c b

h
g

75843

a - Valve Locks
b - Retainer
c - Rotator
d - Cap
e - Outer Spring
f - Valve Stem Oil Seal
g - Intake Valve
h - Exhaust Valve

1. Lubricate valve guides and valve stems with engine oil.

2. Install each valve in the port from which it was removed or to which it was fitted.

Page 3A-38 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Installation - Head Installed

1. Install valve guide seal (intake valve only) over valve stem and push down until seated
against head.
2. Set valve spring (with damper installed) and cap in place.
3. Place retainer on intake valve and/or rotator on exhaust valve.

76573

4. While compressing valve spring with valve spring compressor, install oil seal in lower
groove of valve stem, making sure seal is not twisted. A light coating of oil will help pre-
vent twisting.
5. Install valve locks (Quicksilver Needle Bearing Assembly Lubricant may be used to hold
them in place) and slowly release tool, making sure locks seat properly in upper grooves
of valve stem.

b 72881

a - Valve Spring Compressor (J-5892)

b - Rocker Arm Nut

6. Install push rods and rocker arm assemblies.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

7. Torque rocker arm nuts to 22 lb-ft (30 Nm).

76569

8. Install rocker arm cover. Torque to 106 lb-in. (12 Nm).

9. Install spark plug torque to 15 lb-ft (20 Nm).

Cylinder Head
Removal
1. Drain engine cooling system.
2. Remove exhaust manifolds.

75052

One Piece Exhaust Manifold Shown

a - Exhaust Manifold

3. Remove intake manifold.

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4. Remove rocker arm covers.

75853

5. Remove rocker arm assemblies and push rods (keep in order for reassembly in their
original locations).

75670

6. Remove any components attached to front or rear of cylinder head.

7. Remove spark plugs.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

8. Remove head bolts.

76589

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. Place cylinder head on wooden blocks to prevent damage to gasket surfaces.

76576

Cleaning and Inspection

1. Clean gasket material and sealer from engine block and cylinder heads.
2. Inspect sealing surfaces for deep nicks and scratches.
3. Inspect for corrosion around cooling passages.
4. Clean head bolt threads and engine block bolt hole threads, making sure no dirt, old oil
or coolant remain.

Page 3A-42 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Installation
CAUTION
When using ribbed stainless steel head gaskets, apply a thin coating of Quicksilver
Perfect Seal to both sides of gasket. Too much sealer may hold gasket away from
head or block causing leakage. DO NOT use sealer on graphite composition head
gaskets.
1. Place head gasket in position over dowel pins.

76588

2. Carefully set cylinder head in place over dowel pins.

76576

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

3. Coat threads of head bolts with Quicksilver Perfect Seal and install finger-tight.

76589

4. Torque cylinder heads in two steps. First pass, torque all bolts to 22 lb-ft (30 Nm).
Second pass is an angle torque sequence as follows:

Short Bolt
First Pass Medium Bolt 22 lb-ft (30 Nm)
Long Bolt
Short Bolt + 55 Degrees
Second Pass
Medium Bolt + 65 Degrees
(Angle Torque)
Long Bolt + 75 Degrees

72883

Cylinder Head Torque Sequence

a - Front

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

5. Install push rods, rocker arm assemblies and lifter restrictors in their original positions.

76567 76568

6. Torque rocker arm nuts to 22 lb-ft (30 Nm).

7. Install intake manifold.
8. Install rocker arm covers.

75853

9. Install exhaust manifolds.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

10. Install spark plugs.

76587

11. Install any components removed from front or rear of cylinder heads.
12. Follow procedures below for your model. Refer to SECTION 6A or 6B of this manual.
Seawater Cooled Models: Provide for adequate water supply to seawater pickup (see
Section 6A).
Closed Cooled Models: Refill closed cooling section (see Section 6B), and provide ade-
quate water supply to seawater pickup.

CAUTION
Ensure that cooling water supply is available before starting the engine.
13. Start engine.
14. Set timing.
15. Set idle speed.
16. Check for leaks.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Cylinder Head and Valve Conditioning

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

72884

a - Valve Spring Compressor (J-8062)

2. Remove all valve components.

3. Remove valves from cylinder head and place in a rack, in order, for reassembly in their
original locations.
Cleaning
1. Clean push rods and rocker arm assemblies.
2. Clean carbon from valves using a wire wheel.
3. Clean gasket material from cylinder head mating surfaces.
4. Clean all carbon from combustion chambers and valve ports using carbon remover
brush.

72334

a - Carbon Remover Brush (J-8089)

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

5. Thoroughly clean valve guides with valve guide cleaner.

72335

a - Valve Guide Cleaner (J-8101)

Inspection
1. Inspect cylinder heads for cracks in exhaust ports, water jackets, and combustion
chambers (especially around spark plug holes and valve seats). Replace heads if any
cracks are found.
2. Inspect cylinder head gasket surface for burrs, nicks, erosion or other damage. Also,
check flatness of cylinder head gasket surface, using a machinist’s straight edge and
feeler gauges as shown. Take measurements diagonally across head (both ways) and
straight down center head. Refer to “Specifications.”
a

b
72885

a - Straight Edge
b - Feeler Gauge

IMPORTANT: Cylinder head-to-block gasket surface should be resurfaced if warped

more than specified. When head resurfacing is required, cylinder head-to-intake
manifold gasket surface on head must be milled to provide proper alignment
between intake manifold and head.
3. Inspect valves for burned heads, cracked faces or damaged stems.

Page 3A-48 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

IMPORTANT: Excessive valve stem to bore clearance will cause excessive oil
consumption and possible valve breakage. Insufficient clearance will result in noisy
and sticky valves.
4. Measure valve stem clearance as follows:
a. Attach a dial indicator to cylinder head, positioning it against the valve stem and
close to the valve guide.
b. Holding valve head off seat about 1/16 in. (2 mm), move valve stem back and forth
in direction shown. Compare stem clearance with specifications.
c. If clearance exceeds specifications, it will be necessary to ream valve guides for
oversized valves, as outlined under “Valve Guide Bore Repair.”

b
c

a 72336

a - Valve Stem
b - Dial Indicator
c - Valve Guide
Valve Guide Bore Repair
IMPORTANT: Be sure to measure valve stem diameter of both the intake and exhaust
valve, as valve stem diameter may or may not be the same for both valves.
If .015 in. oversize valves are required, ream valve guide bores for oversize valves, as
follows:
1. Measure valve stem diameter of old valve being replaced and select proper size valve
guide reamer from chart below.

Standard Valve Stem Diameter Reamer Required for .015 in. Oversize Valve
.341 in. J-5830-2

2. Ream valve guide bores, as shown.

72886

3. Remove the sharp corner created by reamer at top of valve guide.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Valve Springs - Checking Tension

Using valve spring tester, as shown, check valve spring tension with dampers removed.
Refer to “Specifications.”
IMPORTANT: Springs should be replaced if not within 10 lbs. (44 N) of specified
tension.

72308

a - Valve Spring Tester (J-8056)

b - Torque Wrench

Valve Seat Repair

Valve seat reconditioning is very important, since seating of valves must be perfect for
engine to deliver maximum power and performance.
Another important factor is valve head cooling. Good contact between each valve and its
seat in head is important to ensure that heat in valve head will be properly dispersed.
Several different types of equipment are available for reseating valve seats. Equipment
manufacturer’s recommendations should be followed carefully to attain proper results.

a d
b c

50668

Typical “3-Angle” Valve Seat

a - Top Angle (30°)
b - Seat Angle (46°)
c - Bottom Angle (60°)
d - Seat Width

Page 3A-50 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Regardless of type of equipment, however, it is essential that valve guide bores be free from
carbon or dirt to achieve proper centering of pilot in valve guide, ensuring concentricity.

72338

Measuring Valve Seat Concentricity

Valve Grinding
Valves that are pitted must be refaced to the proper angle. Valve stems which show
excessive wear, or valves that are warped excessively, must be replaced. When a valve
head which is warped excessively is refaced, a knife edge will be ground on part or all of
the valve head, due to the amount of metal that must be removed to completely reface. Knife
edges lead to breakage, burning, or pre-ignition due to heat localizing on this knife edge.
If the edge of the valve head is less than 1/32 in. (0.8 mm) after grinding, replace the valve.
Several different types of equipment are available for refacing valves. The recommendation
of the manufacturer of the equipment being used should be carefully followed to attain
proper results.

50695

a - 1/3 [.341 in] (8.16 mm)

b - 1/32 [.031 in] (0.79 mm) Min

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Reassembly
1. Lubricate valve guides and valve stems with engine oil.
2. Install each valve in the port from which it was removed or to which it was fitted.
3. Install valve guide seal (intake valve only) over valve stem and push down until seated
against head.
4. Install quad ring over exhaust valve stem until it touches cylinder head with valve closed.
IMPORTANT: The exhaust valve guide seals have been removed. They are replaced
with a quad ring as shown below. If repairing heads with seals, replace them with the
quad ring upon reassembly.

a
b 75307

a - Quad Ring
b - Valve Seal

5. Set valve spring (with damper installed) and cap in place.

6. Place retainer on intake valve and/or rotator on exhaust valve.
7. While compressing valve spring with valve spring compressor, install oil seal in lower
groove of valve stem, making sure seal is not twisted. A light coating of oil will help
prevent twisting.

72884

a - Valve Spring Compressor (J-8062)

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8. Install valve locks (Quicksilver Needle Bearing Assembly lube may be used to hold them
in place) and slowly release tool, making sure locks seat properly in upper grooves of
valve stem.

a
b

76573

a
c b

h
g

75843

a - Valve Locks
b - Retainer
c - Rotator
d - Cap
e - Valve Stem Oil Seal
f - Outer Spring
g - Intake Valve
h - Exhaust Valve

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

9. Check installed height of valve springs using a narrow, thin scale. Measure from spring
seat to top of valve spring, as shown. If measurement exceeds specified height, install
a valve spring shim and recheck. DO NOT shim valve springs to give an installed height
less than the minimum specified.
b

05037

72339

a - Valve Spring Installed Height

b - Cut Away Scale (Grind Out This Portion)

Page 3A-54 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Dipstick Specifications
All Engines

34-13/16 (884)
13/16

23-11/16
27-1/2 (699)

27-7/16

FULL OP. RANGE

1-1/8 (29)
1-1/16
ADD
ADD

75851 76497

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Oil Pan
Removal
1. Drain crankcase oil.
2. Remove dipstick and tube.
3. Remove oil pan.
Installation
1. Clean sealing surfaces of engine block and oil pan.
2. Apply a small amount of Quicksilver RTV Sealer to joints of rear seal retainer and joints
of front cover.
IMPORTANT: Quicksilver RTV Sealer sets up in about 15 minutes. Be sure to
complete assembly promptly.

b
a

72888

a - Joints of Rear Seal Retainer

b - Joints of Front Cover
3. Install oil pan gasket in position.
NOTE: A one-piece oil pan gasket may be reused if it is still pliable and is not cracked, torn
or otherwise damaged.

72889

a - Oil Pan Gasket

4. Install oil pan. Starting from the center and working outward in each direction, torque
nuts and bolts to 18 lb-ft (25 Nm).
5. Install dipstick tube and dipstick.
6. Fill crankcase with required quantity of oil of specified viscosity. Refer to SECTION 1B
- “Maintenance.”

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Oil Pump
3 5
9
7

8 12
11
4

1
10
2 6 72145

Oil Pump Assembly

1 - Extension Shaft
2 - Shaft Coupling
3 - Pump Body
4 - Drive Gear and Shaft
5 - Idler Gear
6 - Pickup Screen and Pipe
7 - Pump Cover
8 - Pressure Regulator Valve
9 - Pressure Regulator Spring
10 - Plug
11 - Retaining Pin
12 - Screws
The oil pump consists of two gears and a pressure regulator valve enclosed in a two-piece
housing. Oil pump is driven by distributor shaft which is driven by a helical gear on camshaft.
Removal
1. Remove oil pan.
2. Remove gasket carefully, the one-piece gasket for the oil pan may be reused if still pli-
able and not cracked, torn or damaged.

a
72889

a - Oil Pump
b - Pickup Screen and Pipe
3. Remove oil pump.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Disassembly
1. Remove pump cover.
IMPORTANT: Mark gear teeth for reassembly with same teeth indexing.
2. Remove idler gear and drive gear from pump body.
3. Remove retaining pin, spring, and pressure regulator valve from pump cover.
IMPORTANT: Do not remove pickup screen and pipe assembly, unless replacement
is necessary. Loss of press fit condition could result in an air leak and loss of oil
pressure.
IMPORTANT: Do not disturb pickup screen on pipe. This is serviced as an assembly.
4. If pickup screen and pipe assembly requires replacement, mount pump in a soft-jawed
vise and extract pipe from pump.
Cleaning and Inspection
1. Wash all parts in cleaning solvent and dry with compressed air.
2. Inspect pump body and cover for cracks or excessive wear.
3. Inspect pump gears for damage and excessive wear.
4. Check for loose drive gear shaft in pump body.
5. Inspect inside of pump cover for wear that would permit oil to leak past ends of gears.
6. Inspect pickup screen and pipe assembly for damage to screen and pipe.
7. Check pressure regulator valve for fit.
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.
Reassembly
CAUTION
Be careful of twisting, shearing or collapsing pipe while installing in pump. Pickup
screen must be parallel to oil pan bottom when oil pump is installed.
If pickup screen and pipe assembly was removed, mount pump in a soft-jawed vise, apply
Quicksilver Perfect Seal to end of new pipe and, using oil pump suction pipe installer
(J-21882), tap the pipe in place with a hammer.
IMPORTANT: Oil internal parts liberally before installation.
1. Install pressure regulator valve and related parts.
2. Install drive gear in pump body.
3. Install idler gear in pump body with smooth side of gear toward pump cover opening.
Align marks made in disassembly.
4. Fill gear cavity with engine oil.
5. Install pump cover and torque attaching bolts to 106 lb-in. (12 Nm).
6. Turn extension shaft by hand to check for smooth operation.

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Installation
1. Install pump, with extension shaft, to rear main bearing, aligning extension shaft with
distributor drive shaft.
2. Tighten oil pump bolt to 65 lb-ft (88 Nm).

a 72889

a - Oil Pump
b - Pickup Screen and Pipe

3. Install oil pan. The one-piece oil pan gasket may be reused if still pliable and not dam-
aged.

Torsional Damper
Removal
1. Remove drive belt.
2. Remove drive pulley, then remove torsional damper retaining bolt.
IMPORTANT: Do not use a universal claw type puller to remove torsional damper (in
next step) as outside ring of torsional damper is bonded in rubber to the hub and use
of claw type puller may break the bond.
3. Remove torsional damper with torsional damper remover and installer.

72890

a
a - Torsional Damper Remover and Installer (J-23523-E)

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Installation
IMPORTANT: The inertia weight section of torsional damper is assembled 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
torsional damper.
1. Replace key in crankshaft if it is damaged.
2. Coat seal surface of torsional damper with engine oil.
3. Install torsional damper on crankshaft, using torsional damper remover and installer as
follows:
b. Install appropriate end of threaded rod into crankshaft.
IMPORTANT: Be sure to install threaded rod in crankshaft at least 1/2 in. (13 mm) to
prevent damage to threads.
c. Install plate, thrust bearing, washer and nut on rod.
d. Install torsional damper on crankshaft by turning nut until it contracts.

72346

a - Torsional Damper Remover and Installer (J-23523-E)

b. Remove tool from crankshaft.

c. To prevent oil leakage, apply Quicksilver RTV sealant to torsional damper keyway.
d. Install torsional damper bolt. Torque to 74 lb-ft (100 Nm).
4. Install drive pulley(s). Torque bolts to 35 lb-ft (48 Nm).
5. Install and adjust drive belt.

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Crankcase Front Cover Oil Seal

Oil Seal Replacement (Without Removing Front Cover)
REMOVAL

1. Remove torsional damper.

2. Pry seal out of cover from the front with a large screwdriver, being careful not to distort
front cover or damage crankshaft.

INSTALLATION

IMPORTANT: Correct rotation oil seal must be used to prevent oil leak.

73123
a
Front Seal WITHOUT Helical Grooves
a - Can Be Used on Any Rotation Engine
b - Seal Lip Toward Inside of Engine

b c a

73124

Front Seals WITH Helical Grooves

a - MCM (LH) Rotation Engines
b - Seal Lip Toward Inside of Engine
c - Rotation of Crankshaft as Viewed from Front End Looking Toward Flywheel
End

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

1. Apply Quicksilver Perfect Seal to seal retainer mating surface and apply grease to seal
lips.
2. Install new seal with open end of seal inward, using crankcase front cover seal installer.
Drive seal in until it just contracts. Do not use excessive force.

a 72347

a - Crankcase Front Cover Seal Installer (J-35468)

3. Reinstall torsional damper.

Crankcase Front Cover

Removal
1. Remove engine from boat if necessary to gain access to cover.
2. Remove torsional damper and oil pan.
3. Remove water circulating pump.
IMPORTANT: Crankcase front cover is not reusable per G.M. Specification. It must be
replaced if removed.
4. Remove crankcase front cover.

76577

5. Drive oil seal out of front cover (from the rear) using a punch.

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Cleaning and Inspection

1. Clean old gasket material and sealer from mating surface on cylinder block.
2. Surfaces must be clean and flat or oil leakage may result.

Installation
IMPORTANT: Crankcase front cover is not reusable per G.M. Specification. It must be
replaced if removed.
1. Install oil seal in cover with lip of seal toward inside of engine, using crankcase front
cover seal installer. To prevent distortion support cover around seal area with an
appropriate tool as shown.

72348

a - Crankcase Front Cover Seal Installer (J-35468)

b - Support

2. Coat both sides of front cover gasket with Quicksilver Perfect Seal and place in position
on engine.
3. Install front cover, making sure holes in cover align with dowel pins in block. Torque front
cover attaching screws to 100 lb-in. (11 Nm).

76577

4. Install oil pan and torsional damper.

5. Install water circulating pump.
6. Install engine in boat.
7. Fill crankcase with engine oil.
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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

8. Follow procedures in SECTION 6A or 6B of this manual:

Seawater Cooled Models: Provide for adequate water supply to seawater pickup (Refer
to SECTION 6A).
Closed Cooled Models: Refill closed cooling section (Refer to SECTION 6B), and provide
adequate water supply to seawater pickup.

CAUTION
Ensure that cooling water supply is available before starting the engine.
9. Start engine and check for water and oil leaks.

Flywheel
Removal
1. Remove engine from boat. Refer to SECTION 2 - “Removal and Installation”.
2. Refer to “Flywheel Housing” description in this section and remove flywheel housing and
related parts.
3. Remove coupler.
4. Remove flywheel.

72349

Alpha One Coupler

72350

Bravo Coupler

Inspection
1. Inspect splines in coupler for wear.
2. Check flywheel ring gear for worn and missing teeth.

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Installation
1. Clean mating surfaces of flywheel and crankshaft. Remove any burrs. Mating surfaces
must be clean bare metal.
2. Aligning dowel hole in flywheel with dowel in crankshaft, install flywheel. Torque bolts
to 75 lb-ft (100 Nm).
3. Check flywheel runout as follows:
a. Attach a dial indicator to engine block.
b. Take readings around outer edge of flywheel. Push in on flywheel as far as it will go
to remove crankshaft end play.
c. Maximum runout - .008 in. (0.203 mm).

72353

a - .008 In. (0.203 mm) Max Runout

IMPORTANT: Insert three rubber bumpers in Alpha coupler before installation on

flywheel.

72354

a - Rubber Bumper

4. Install drive coupler. Torque bolts to 35 lb-ft (48 Nm).

5. Install flywheel housing and related parts. Torque bolts to 30 lb-ft (41 Nm).
6. Install flywheel housing cover. Torque bolts to 80 lb-in. (9 Nm).
7. Refer to SECTION 2 “Removal and Installation” and install engine.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Rear Main Oil Seal

The rear crankshaft oil seal can be replaced without removing the oil pan or rear main
bearing cap from engine.
Removal
Remove seal by using a screwdriver to pry it out of retainer as shown.

b
72355
a
a - Rear Seal
b - Seal Retainer
c - Slots (Three)

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Cleaning and Inspection

Clean crankshaft/seal running surface and seal retainer.
IMPORTANT: Correct rotation oil seal must be used to prevent oil leak.

a 73126

Rear Seal WITHOUT Helical Grooves

a - Can Be Used On Any Rotation Engine
b - Seal Lip Toward Inside Of Engine

b
c a

73127

Rear Seal WITH Helical Grooves

a - MCM (LH) Rotation Engines
b - Seal Lip Toward Inside Of Engine
c - Rotation Of Crankshaft As Viewed From Flywheel End Looking Forward

Installation
1. Apply Quicksilver Perfect Seal to seal retainer mating surface. Apply grease to seal lips.
2. Install seal using rear main seal installer. (J-26817-A)

a 72356

a - Rear Main Seal Installer

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Rear Main Oil Seal Retainer

Removal
1. Remove oil pan.
2. Remove oil seal retainer fasteners.
3. Remove oil seal retainer.

a
72464
a - Fasteners
b - Oil Seal Retainer

Cleaning and Inspection

1. Clean gasket material from mating surfaces.
2. Inspect oil seal retainer for cracks or scored surface.
3. Inspect oil seal for worn, dry or torn rubber. Replace if necessary, refer to “Rear Main
Oil Seal.”
4. Inspect alignment pin for damage; replace if necessary.
Installation
1. Coat seal lips with clean 30W motor oil.
2. Install gasket and oil seal retainer with rear main seal.
3. Coat threads of oil seal retainer fasteners with Loctite Pipe Sealant with Teflon.
4. Install fasteners and torque to 133 lb-in.(15 Nm).
5. Install oil pan fasteners. Torque engine oil pan nuts and bolts 18 lb-ft (25 Nm).
NOTE: A one-piece oil pan gasket may be reused if it is still pliable and is not damaged.

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Main Bearings
IMPORTANT: Before removing main bearing caps or connecting rod caps, mark them
for reassembly in their original locations.
Main bearings are of the precision insert type and do not use shims for adjustment. If
clearances are found to be excessive, a new bearing, both upper and lower halves, will be
required. Service bearings are available in standard size and .001 in., .010 in. and .020 in.
undersize.
Selective fitting of both rod and main bearing inserts is necessary in production in order to
obtain close tolerances. For this reason you may find one half of a standard insert with one
half of a .001 in. undersize insert which will decrease the clearance .0005 in. from using a
full standard bearing.
IMPORTANT: If crankshaft has an undersize journal and a new bearing is required,
journal must be reconditioned to accept a .010 or .020 in. undersize bearing as .009
in. undersize bearings are not available for service.
Inspection
In general, the lower half of the bearing (except No. 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, both upper and lower halves should be replaced. Never replace one half without
replacing the other half.
Checking Clearances
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 clear-
ance can be measured between lower bearing and journal.
To ensure the proper seating of the crankshaft, all bearing cap bolts should be at their
specified torque. In addition, before to checking fit of bearings, the surface of the crankshaft
journal and bearing should be wiped clean of oil.
1. With the oil pan and oil pump removed, 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)
on the journal as shown.

b 72357

a - Gauging Plastic
b - Journal
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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

3. Install the bearing cap and evenly torque the retaining bolts to specifications. Bearing
cap MUST be torqued to specification in order to assure proper reading. Variations in
torque affect the compression of the plastic gauge.
IMPORTANT: Do not rotate the crankshaft while the gauging plastic is between the
bearing and journal.
4. Remove bearing cap. The flattened gauging plastic will be found adhering to either the
bearing cap or journal.
5. On the edge of the gauging plastic envelope there is a graduated scale correlated in
thousandths of an inch. Without removing the gauging plastic, measure its compressed
width (at the widest point) with the graduations on the gauging plastic envelope.

a b

72358

a - Compressed Gauging Plastic

b - Graduated Scale

NOTE: Normally main bearing journals wear evenly and are not out of round. However, if
a bearing is being fitted to an out-of-round journal (.001 in. max.), be sure to fit to the
maximum diameter of the journal: If the bearing is fitted to the minimum diameter, and the
journal is out of round .001 in., interference between the bearing and journal will result in
rapid bearing failure. If the flattened gauging plastic tapers toward the middle or ends, there
is a difference in clearance indicating taper, low spot or other irregularity of the bearing or
journal. Be sure to measure the journal with a micrometer if the flattened gauging plastic
indicates more than .001 in. difference.
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 .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.
c. After selecting new bearing, recheck clearance.
8. Proceed to the next bearing. After all bearings have been checked, rotate the crankshaft
to see that there is no excessive drag. When checking No. 1 main bearing, loosen
accessory drive belts to prevent tapered reading with plastic gauge.

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9. Measure crankshaft end play by forcing the crankshaft to the extreme front position.
Measure at the front end of the rear main bearing with a feeler gauge as shown
[Specifications - .002-.006 (0.06-0.15)].

72360

a - Force Crankshaft to Extreme Forward Position

Replacement
NOTE: Main bearings may be replaced with or without removing crankshaft.
a
b

c
72359

Main Bearing Inserts

a - Lower Bearing Insert (Install in Cap)
b - Upper Bearing Insert (Install in Block)
c - Oil Groove

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

WITH CRANKSHAFT REMOVED

1. Remove and inspect the crankshaft.

76580

2. Remove the main bearings from the cylinder block and main bearing caps.

76582

3. Coat bearing surfaces of new, correct size, main bearings with oil and install in the
cylinder block and main bearing caps.

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4. Install the crankshaft.

76579

WITHOUT CRANKSHAFT REMOVED

1. With oil pan, oil pump and spark plugs removed, remove cap on main bearing requiring
replacement and remove bearing from cap.
2. Install main bearing remover/installer in oil hole in crankshaft journal. If such a tool is not
available, a cotter pin may be bent, as shown, to do the job.

72622

a
a - Main Bearing Remover/Installer (J-8080)
b - Cotter Pin

3. Rotate the crankshaft clockwise as viewed from the front of engine. This will roll upper
bearing out of block.
4. Oil new selected size upper bearing and insert plain (un-notched) end between
crankshaft and indented or notched side of block. Rotate the bearing into place and
remove tool from oil hole in crankshaft journal.
5. Oil new lower bearing and install in bearing cap.
6. Install main bearing cap with arrows pointing toward front of engine.
7. Torque all main bearing caps, EXCEPT THE REAR MAIN CAP, to 75 lb-ft (102 Nm).
Torque rear main bearing cap to 10-12 lb-ft (14-16 Nm); then tap end of crankshaft, first
rearward then forward with a lead hammer. This will line up rear main bearing and
crankshaft thrust surfaces. Torque rear main bearing cap to 75 lb-ft (102 Nm).

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Connecting Rod Bearings

Connecting rod bearings are of the precision insert type and do not use shims for
adjustment. DO NOT FILE RODS OR ROD CAPS. 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, and in .010 in.
and .020 in. undersize for use with reconditioned crankshafts.
On removing a connecting rod cap, it is possible to find a .010 in. undersize bearing. These
are used in manufacturing for selective fitting.
Inspection and Replacement
IMPORTANT: Before you remove the connecting rod cap, mark the side of the rod and
cap with the cylinder number to assure matched reassembly of rod and cap.
1. With oil pan and oil pump removed, remove the connecting rod cap and bearing.
2. Inspect the bearing for evidence of wear and damage. Do not reinstall a worn or
damaged bearing.
3. Wipe both upper and lower bearing shells and crankpin clean of oil.
4. Measure the crankpin for out-of-round or taper with a micrometer. If not within
specifications, replace or recondition the crankshaft. If within specifications and a new
bearing is to be installed, measure the maximum diameter of the crankpin to determine
new bearing size required.
5. If within specifications, measure new or used bearing clearances with gauging plastic
or its equivalent. If a bearing is being fitted to an out-of-round crankpin, be sure to fit to
the maximum diameter of the crankpin. If the bearing is fitted to the minimum diameter,
and the crankpin is out of round .001 in., interference between the bearing and crankpin
will result in rapid bearing failure.
a. Place a piece of gauging plastic, the length of the bearing (parallel to the crankshaft),
on the crankpin or bearing surface as shown. Position the gauging plastic in the
middle of the bearing shell. (Bearings are eccentric and false readings could occur
if placed elsewhere.)

72361

a - Gauging Plastic

b. Install the bearing in the connecting rod and cap.

c. Install the bearing cap and evenly torque nuts to 45 lb-ft (61 Nm).
IMPORTANT: Do not turn the crankshaft with the gauging plastic installed.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

d. Remove the bearing cap and using the scale on the gauging plastic envelope,
measure the gauging plastic width at the widest point as shown.

a b

72358

6. If the clearance exceeds specifications, select a new, correct size bearing and measure
the clearance.
NOTE: Be sure to check what size bearing is being removed in order to determine proper
replacement size bearing. If clearance cannot be brought within specifications, the crankpin
will have to be ground undersize. If the crankpin is already at maximum undersize, replace
crankshaft.
7. Coat the bearing surface with oil, install the rod cap and torque nuts to 45 lb-ft (61 Nm).
8. When all connecting rod bearings have been installed, tap each rod lightly (parallel to
the crankpin) to make sure they have clearance.
9. Measure all connecting rod side clearances between connecting rod caps as shown
[Specifications - .006-.014 (0.152-0.356)].

72891

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Connecting Rod/Piston Assembly

Removal
1. Remove oil pan and dipstick tube.
2. Remove oil pump.

76571

3. Remove distributor and intake manifold.

4. Remove cylinder heads.

76576

5. Use a ridge reamer to remove any ridge and/or deposits from upper end of cylinder bore.
IMPORTANT: Before ridge and/or deposits are removed, turn crankshaft until piston
is at bottom of stroke and place a cloth on top of piston to collect cuttings. After ridge
and / or deposits are removed, turn crankshaft until piston is at top of stroke, then
remove cloth and cuttings.
6. Mark connecting rods and bearing caps (left bank 1, 3 and 5; right bank 2, 4 and 6 from
front to rear on same side as piston thrust).
7. Remove connecting rod cap and install connecting rod bolt guide (3/8-24) on bolts. Push
connecting rod and piston assembly out of top of cylinder block.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

NOTE: It will be necessary to turn crankshaft slightly to disconnect and remove some
connecting rod and piston assemblies.

72892

a - Connecting Rod Bolt Guide (3/8-24) [J-5239]

Disassembly
Disassemble piston from connecting rod using piston pin remover.
b

d
72893
e
a - Piston Pin Remover (J-24086-B)
b - Arched Base
c - Piston
d - Connecting Rod
e - Rod Support

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Cleaning and Inspection

CONNECTING RODS

1. Wash connecting rods in cleaning solvent and dry with compressed air.
2. Check for twisted and bent rods and inspect for nicks and cracks. Replace damaged
connecting rods.

PISTONS

NOTE: Cylinder bore and taper must be within specifications before pistons can be
considered for re-use.
1. Clean varnish from piston skirts with a cleaning solvent. DO NOT WIRE BRUSH ANY
PART OF PISTON. Clean ring grooves with a groove cleaner and make sure oil ring
holes are clean.
2. Inspect piston for damaged ring lands, skirts and pin bosses, wavy or worn ring lands,
scuffed or damaged skirts and eroded areas at top of piston.
3. Inspect grooves for nicks and burrs that might cause rings to hang up.
4. Measure piston skirt and check clearance as outlined under “Piston Selection.”
5. Slip outer surface of a new top and second compression ring into respective piston ring
groove and roll ring entirely around the groove to make sure that ring does not bind. If
ring groove causes binding, remove by dressing with a fine cut file. If a distorted ring
causes binding, recheck with another ring.

72894

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

6. Proper clearance of piston ring in its groove is necessary for proper ring action.
Therefore, when fitting new rings, clearances between ring and groove surfaces should
be measured. See “Specifications.”

72895

PISTON PINS

1. 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.
2. Inspect piston pin bores and piston pins for wear. Piston pin bores and piston pins must
be free of varnish and scuffing when measured. Measure piston pin with a micrometer
and piston pin bore with a dial bore gauge or inside micrometer. If clearance is in excess
of the .001 in. (0.02 mm) wear limit, replace piston and piston pin assembly.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Reassembly
PISTONS AND PISTON PINS

IMPORTANT: When reassembling pistons and connecting rods, be aware that:

• 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 cylinder block.

72368

a - Rod Bearing Tangs

IMPORTANT: Notch in piston must be positioned facing toward the front of the
engine.

72896

a - Notch

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

1. Assemble piston to connecting rod using piston pin remover as shown. Follow instruc-
tions supplied with kit.

72897

a - Piston Pin Remover (J-24086-B)

2. Once assembled, check piston for freedom of movement in all directions on connecting
rod; piston should move freely. If it does not, piston pin bore is tight and piston/pin as-
sembly 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.

PISTON RINGS

All compression rings are marked on upper side of ring. When installing compression rings,
make sure 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. Slip compression ring in cylinder bore, then press ring down into cylinder bore about 1/4
in. (6 mm) (below ring travel). Be sure that ring is square with cylinder wall.
3. Measure gap between ends of ring with a feeler gauge as shown.

72372

4. If gap between ends of ring is below specifications, remove ring and try another for fit.
5. Fit each compression ring to cylinder in which it is going to be used.
6. Clean and inspect pistons.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

7. Install piston rings as follows:

a. Install oil ring spacer in groove and insert anti-rotation tang in oil hole.
b. Hold spacer ends together and install lower steel oil ring rail with gap properly lo-
cated.
c. Install upper steel oil ring rail with gap properly located.
d. Flex the oil ring assembly to make sure ring is not binding. If ring groove is causing
binding, remove with a fine cut file. If a distorted ring is causing binding, use a new
ring.
IMPORTANT: Use piston ring expander (91-24697) for compression ring installation.
e. Install lower compression ring with marked side up, using ring expander.
f. Install top compression ring with marked side up, using ring expander.
Installation
IMPORTANT: Cylinder bores must be clean before piston installation. Clean with a
light honing, as necessary. Then clean with hot water and detergent wash. After
cleaning, swab bores several times with light engine oil and clean cloth, then wipe
with a clean dry cloth.
1. Lubricate connecting rod bearings and install in rods and rod caps.
2. Lightly coat pistons, rings and cylinder walls with light engine oil.
3. With bearing caps removed, install connecting rod bolt guide (3/8-24) (J-5239) on con-
necting rod bolts.
IMPORTANT: Be sure ring gaps are properly positioned as shown.

e f g

c a d

b
72373

Ring Gap Location

a - Oil Ring Spacer Gap (Tang In Hole Or Slot Within Arc)
b - Oil Ring Gaps
c - 2nd Compression Ring Gap
d - Top Compression Ring Gap
e - Port Side
f - Engine Front
g - Starboard Side

4. Install each connecting rod and piston assembly in its respective bore. Install with
connecting rod bearing tangs toward outside of cylinder block. Use piston ring
compressor to compress rings. Guide connecting rod into place on crankshaft journal
with connecting rod bolt guide. Use a hammer handle with light blows to install piston
into bore. Hold ring compressor firmly against cylinder block until all piston rings have
entered cylinder bore.

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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 and 5 in left bank and 2, 4 and 6 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.

72552

a - Piston Ring Compressor (J-8037)

5. Remove connecting rod bolt guide.

6. Install bearing caps and torque nuts to 20 lb-ft (27 Nm), then tighten nuts an additional
70 degrees angular torque using a Torque Angle Gauge.
7. Check connecting rod side clearance.
NOTE: If bearing replacement is required, refer to “Connecting Rod Bearings.”
8. Install oil pump.
a. Install dipstick and oil pan.
b. Install cylinder heads.
c. Install intake manifold.
d. Install distributor.
9. Fill crankcase with oil. Refer to SECTION 1 - “Maintenance.”
10. Torque rocker arm nuts to 22 lb-ft (30 Nm).

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Crankshaft
Removal
1. Remove engine from boat.
2. Drain crankcase oil.
3. Remove starter.

76489
b

a - Starter
b - Mounting Bolts

4. Remove flywheel housing.

5. Remove drive coupler and flywheel.

b
76490

a - Flywheel
b - Bolts

6. Remove belts.
7. Remove water pump.
8. Remove crankshaft pulley and torsional damper.
9. Remove spark plugs.
10. Remove oil pan and dipstick tube.
11. Remove oil pump.

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12. Timing chain cover.

76491

a - Timing Chain Gear Cover

13. Turn crankshaft to align timing mark with camshaft mark.

14. Remove camshaft sprocket.

76488

15. Remove rear main seal and retainer.

16. Make sure all bearing caps (main and connecting rods) are marked so they can be rein-
stalled in their original locations.
17. Remove connecting rod bearing caps, then push piston and rod assemblies toward
heads.
18. Remove main bearing caps and carefully lift crankshaft out of cylinder block.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

19. If new main and/or connecting rod bearings are to be installed, remove main bearing
inserts from cylinder block and bearing caps, and/or connecting rod bearing inserts from
connecting rod and caps. Install new bearings following procedures outlined.

76581

76582

76579

Cleaning and Inspection

1. Wash crankshaft in solvent and dry with compressed air.
2. Measure main bearing journals and crankpin dimensions with a micrometer for
out-of-round, taper or undersize. Refer to “Specifications.”
3. Check crankshaft for runout (by supporting at front and rear main bearings journals in
V-blocks) and check at front and rear intermediate journals with a dial indicator. Refer
to “Specifications.”
4. Replace or recondition crankshaft if not within specifications.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Installation
1. If a new crankshaft is being installed, remove timing sprocket from old crankshaft and
reinstall on new crankshaft as outlined.
IMPORTANT: Be sure that all bearings and crankshaft journals are clean.
2. Install main bearings in engine block as follows.
a
b c

72359

Main Bearing Inserts

a - Lower Bearing Insert (Install in Cap)
b - Upper Bearing Insert (Install in Block)
c - Oil Groove

3. Carefully lower crankshaft into place. Be careful not to damage bearing surface.
4. Check clearance of each main bearing. If bearing clearances are satisfactory, apply en-
gine oil to journals and bearings.
5. Install main bearing caps. Torque bolts to 75 lb-ft (102 Nm). Refer to “Main Bearings”
when tightening rear main bearing cap.
6. Check crankshaft end play.
7. Install rear main seal retainer and seal. Torque fasteners to 133 lb-in. (15 Nm).
8. Check clearance for each connecting rod bearing. If bearing clearances are satisfactory,
apply engine oil to journals and bearings.
9. Install rod caps and torque nuts to 45 lb-ft (61 Nm).
10. Reverse Steps 3 - 13 in Removal.
11. Install new oil filter.
12. Fill crankcase with oil.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Timing Chain and Sprocket

Removal
1. Remove torsional damper, oil pan and crankcase front cover.
2. Turn crankshaft until timing marks on crankshaft and camshaft sprockets are in
alignment.

72899

a - Timing Marks Aligned

b - Locating Pin

3. Remove camshaft sprocket and timing chain. (If sprocket does not come off easily, a
light tap on the lower edge of the sprocket using a plastic mallet, should dislodge it.)
4. Remove crankshaft sprocket if it requires replacement.
Cleaning and Inspection
1. Clean all parts in solvent and dry with compressed air.
2. Inspect timing chain for wear and damage.
3. Inspect sprockets for wear and damage.
Installation - Timing Chain
1. Install crankshaft sprocket if removed.

CAUTION
When timing marks are aligned in this procedure, the No. 4 cylinder is on
compression (TDC); therefore, if the distributor is to be installed, the rotor MUST
BE positioned at the No. 4 post on the distributor cap.
2. Install timing chain on camshaft sprocket. Hold sprocket vertical with chain hanging
down. Align marks on camshaft and crankshaft sprockets.
IMPORTANT: Do not attempt to drive sprocket on camshaft, as welsh plug at rear of
engine can be dislodged.
3. Install sprocket on camshaft. Torque bolts to 18 lb-ft (24 Nm).
4. Lubricate timing chain with engine oil.
5. Install crankcase front cover and torsional damper.

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Crankshaft Sprocket
Removal
1. Remove torsional damper and crankcase front cover.
2. Remove camshaft timing chain.
3. Using crankshaft gear and sprocket puller (P/N J-5825-A), remove crankshaft sprocket.
Installation
1. Using crankshaft gear and sprocket installer, as shown, install sprocket on crankshaft.

72377

a - Crankshaft Gear and Sprocket Installer (J-5590)

2. Install timing chain.

3. Install crankcase cover and torsional damper.
Checking Timing Chain Deflection
With timing chain and sprockets installed, check timing chain deflection, as follows:
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 3/4 in. (19 mm), timing chain should be replaced.

72899

a - Reference Point

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Balance Shaft / Gears

Removal
1. Remove manifold.
IMPORTANT: Crankcase front cover is not reusable per G.M. Specification. It must be
replaced if removed.
2. Remove crankcase front cover.

76577

3. Remove timing chain.

4. Insert hard wood wedge between gear teeth and remove TORX bolt retaining balance
shaft driven gear. Remove gear.

a b

72900

a - Wedge
b - Driven Gear
c - Drive Gear

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5. Unscrew stud and remove balance shaft drive gear on camshaft as shown.

72901

a - Stud
b - Drive Gear

6. Remove two TORX bolts retaining balance shaft thrust plate.

IMPORTANT: Care should be taken in next step as damage to cylinder block and/or
balance shaft could result.
7. Insert pry bar in aft section between balance shaft and cylinder block. Gently apply for-
ward pressure and remove balance shaft.

72902
c

a - Pry Bar
b - Balance Shaft
c - Bearing Housing

NOTE: When replacing balance shaft rear bearing, place a cloth in valley to prevent any
debris from entering the crankcase.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

8. Balance shaft rear bearing can be replaced using balance shaft removal and installer
tool in conjunction with bearing puller.

b
72903

a - Balance Shaft Removal and Installation Tool

b - Bearing Puller

Cleaning and Inspection

1. Wash balance shaft in solvent and blow dry with compressed air.
2. Inspect rear bearing for wear or damage. See “Specifications.”
NOTE: Front bearing is not serviceable and may be replaced only with the balance shaft
assembly.
3. Inspect front bearing for secure fit on shaft or excessive side to side play. Also check
for scored bearings or roughness while rotating.
4. Inspect front cylinder block bore for scoring or evidence of bearing spinning in bore.
5. Inspect gears for chips or excessive wear on teeth.
6. Inspect balance shaft gear key way and shaft dowel pin for excessive wear.

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Installation
NOTE: GM shim (10229872) is placed on installer tool prior to the bearing. This will assure
proper depth setting of rear bearing when installed.
1. Use balance shaft remover and installer tool along with GM shim to insert bearing.

76590

2. Lubricate bearings with engine oil and install balance shaft.

3. Using a soft face mallet, tap shaft until front bearing retaining ring seats against cylinder
block.

b 72904

a - Retaining Ring
b - Cylinder Block

4. Install thrust plate and two TORX bolts. Torque to 120 lb-in. (14 Nm).
5. Install driven gear on balance shaft.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

6. Align marks on drive and driven gear and install drive gear on camshaft.

72905
a - Alignment Marks

7. Install bolts to retain camshaft sprocket and torque to 20 lb-ft (27 Nm).
8. Apply thread adhesive to threads of balance shaft bolt and install.
9. Insert hard wood wedge between gear teeth and torque driven gear retaining bolt to 15
lb-ft (20 Nm), then tighten bolt an additional 35 degrees angular torque using a Torque
Angle Gauge.

a
72906

a - Wedge
b - Driven Gear

10. Install timing chain.

11. Install crankcase front cover.
12. Install manifold.

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Camshaft
Measuring Lobe Lift
NOTE: Procedure is similar to checking valve timing. If improper valve operation is
indicated, measure lift of each push rod in consecutive order and record readings.
1. Remove valve mechanism.
2. Position indicator with ball socket adaptor tool on push rod. Ensuer that push rod is in
lifter socket.

72907

a - Ball Socket Adaptor Tool (J-8520-1)

3. Rotate crankshaft torsional damper slowly in direction of engine rotation until lifter is on
heel of cam lobe. At this point, push rod will be in its lowest position.
4. Set dial indicator on zero, then rotate balancer slowly (or attach an auxiliary starter
switch and “bump” engine over) until push rod is in fully raised position.
5. Compare total lift, recorded from dial indicator, with “Specifications.”
6. Continue to rotate engine until indicator reads zero. This will be a check on accuracy of
original indicator reading.
7. If camshaft readings for all lobes are within specifications, remove dial indicator
assembly.
8. Install rocker arm and push rod. Torque nuts to 20 lb-ft (27 Nm).

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Removal
1. Remove valve lifters.

76585

IMPORTANT: Crankcase front cover is not reusable per G.M. Specification. It must be
replaced if removed.
2. Remove crankcase front cover.

76577

3. Remove camshaft as follows:

a. Remove timing chain, sprocket and camshaft thrust plate.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

b. Install two 5/16-18 x 5 in. bolts in camshaft bolt holes and carefully remove camshaft
as shown.

72908

Inspection
Measure camshaft bearing journals with a micrometer for out-of-round condition. If journals
exceed .001 in. (0.025 mm) out-of-round, camshaft should be replaced.
Also check camshaft for alignment with V-blocks and dial indicator which indicates exact
amount camshaft is out of true. If out more than .002 in. (0.05 mm) (dial indicator reading)
camshaft should be replaced.

72909

Checking Camshaft Alignment

Installation
1. Install camshaft as follows:
a. Install two 5/16-18 x 5 in. bolts in camshaft bolt holes, then lubricate camshaft jour-
nals with engine oil and install camshaft. DO NOT damage bearings.
b. Lubricate camshaft lobes with General Motors Cam and Lifter Prelube or equivalent.
c. Install timing chain.
2. Install crankcase front cover and valve lifters.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Camshaft Bearings
Removal
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. Before
removing crankshaft, fasten connecting rods against sides of engine so that they will not
interfere while replacing camshaft bearings.
1. With camshaft and crankshaft removed, drive camshaft rear plug from cylinder block.
NOTE: This procedure is based on removal of bearings from center of engine first, thus
requiring a minimum amount of turns to remove all bearings.
2. Using camshaft bearing remover and installer set (J-6098-01) (with nut and thrust
washer installed to end of threads), position pilot in front camshaft bearing and install
puller screw through pilot.
3. Install tool with shoulder toward bearing. Ensure a sufficient amount of threads are
engaged.
4. Using two wrenches, hold puller screw while turning nut. When bearing has been pulled
from bore, remove tool and bearing from puller screw.
5. Remove remaining bearings (except front and rear) in same manner. You must position
pilot in rear camshaft bearing to remove rear intermediate bearing.

c b

72383
d
a - Index Point
b - Puller Screw
c - Driver
d - Bearing

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6. Assemble driver on driver handle and remove front and rear camshaft bearings by
driving toward center of cylinder block.

b 72870

a - Driver
b - Driver Handle
c - Bearing (Hidden In This View)

Inspection
Clean camshaft bearing bores in cylinder block with solvent and blow out with compressed
air. Be sure grooves and drilled oil passages are clean.
Installation
Front and rear bearings must be installed last as pilot will not fit into bearing bores if bearings
are installed.
Lubricate outer surface of new camshaft bearings with engine oil to ease installation.
IMPORTANT: All camshaft bearings are not the same. Be sure to install bearings in
proper locations (Indicated by bearing manufacturer) and to position bearings as
follows (directional references are in reference to engine in its normal operating
position):
• Front bearing must be positioned so that oil holes are equal distance from 6
o’clock position in the block. Intermediate and center bearings must be posi-
tioned so that oil holes are at the 5 o’clock position (toward left side of block and
at a position even with bottom of cylinder bore). Rear bearing must be positioned
so that oil hole is at the 12 o’clock position.
1. Installing intermediate and center bearings:
a. Install nut and thrust washer all the way onto puller screw, then position pilot in front
camshaft bearing bore and insert screw through pilot.
b. Index center camshaft bearing, then position appropriate size remover and installer
tool in bearing and thread puller screw into tool. Be sure at least 1/2 in. (13 mm) of
threads are engaged.
c. Using two wrenches, hold puller screw and turn nut until bearing has been pulled into
position. Remove the remover and installer tool and check to ensure that oil hole(s)
in bearing are positioned correctly.
d. Install intermediate bearings in same manner being sure to index bearings correctly.
It will be necessary to position pilot in rear camshaft bearing bore to install rear
intermediate bearing.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

2. Installing front and rear bearings:

a. Install appropriate size remover and installer tool on drive handle.
b. Index front bearing (as explained in “Important” above), and drive it into position with
tool. Check position of oil hole(s) in bearing to ensure bearing is positioned correctly.
c. Install rear bearing in same manner, being sure to index bearing correctly.
3. Install a new camshaft rear plug.
IMPORTANT: Plug must be installed flush to 1/32 in. (0.8 mm) deep and must be
parallel with rear surface of cylinder block.
4. Install crankshaft and camshaft.

Cylinder Block
Cleaning and Inspection
1. Remove all engine components.
2. Wash cylinder block thoroughly in cleaning solvent and clean all gasket surfaces.
3. Remove oil gallery plugs and clean all oil passages.
4. Remove expansion plugs.
NOTE: These plugs may be removed with a sharp punch or they may be drilled and pried
out.
5. Clean and inspect water passages in cylinder block.
6. Inspect cylinder block for cracks in cylinder walls, water jacket valve lifter bores and main
bearing webs.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

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 work gauge up
and down cylinder to determine taper and turn it to different points around cylinder wall
to determine out-of-round condition. If cylinders exceed specifications, boring and/or
honing will be necessary.
a

b b

a 72385

Cylinder Measurement
a - At Right Angle To Centerline Of Engine
b - Parallel to Centerline Of Engine
“Out Of Round” Equals The Difference Between “red a” and “red b”
Measurement At Top Of Cylinder Bore and
Measurement At Bottom Of Cylinder Bore

72386
72387

Measuring Cylinder Bore Measuring Cylinder Bore

with Telescope Gauge with Dial Indicator

8. Check cylinder head gasket surfaces for warp with a machinist’s straight-edge and a
feeler gauge. Take measurements diagonally across surfaces (both ways) and straight
down center. If surfaces are warped more than .003 in. (0.07 mm) in a 6 in. area or .007
in. (0.2 mm) overall, block must be resurfaced by an automotive machine shop.

a 72910
b

a - Machinist’s Straight Edge

b - Feeler Gauge

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

CYLINDER CONDITIONING

1. Performance of the following operation depends upon engine condition at time of repair.
2. If cylinder block inspection indicates that block is suitable for continued use (except for
out-of-round or tapered cylinders), they can be conditioned by honing or boring.
3. If cylinders have less than .005 in. (0.127 mm) taper or wear, they can be conditioned
with a hone and fitted with high limit standard size piston. A cylinder bore of more than
.005 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
.005 in. taper or wear, bore and hone to smallest oversize that will permit complete
resurfacing of all cylinders.
4. When pistons are being fitted and honing is not necessary, cylinder bores may be
cleaned with a hot water and detergent wash. After cleaning, swab cylinder bores
several times with light engine oil and a clean cloth, then wipe with a clean dry cloth.

CYLINDER BORING

1. Before using a boring bar, file off top of cylinder block to remove dirt or burrs. This is very
important to prevent boring bar tilt. Boring bar tilt causes the bored cylinder wall to not
be at right angles to crankshaft.
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 instructions furnished by manufacturer of equipment being used.

CYLINDER HONING

1. Follow hone manufacturer’s recommendations for use of hone and cleaning and
lubrication during honing.
2. Occasionally, during the honing operation, thoroughly 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) 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 this type piston can be distorted
by careless handling.
5. Thoroughly clean cylinder bores with hot water and detergent. Scrub well 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 and cylinder bores in addition to bearings lubricated by the
contaminated oil. Swab 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 cylinder block to remove excess material spread during honing
operation.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

PISTON SELECTION

1. Check used piston to cylinder bore clearance as follows:

a. Measure cylinder bore diameter with a telescope gauge 2-1/2 in. (64 mm) from top
of cylinder bore as shown.

72386

b. Measure piston diameter at skirt across center line of piston pin as shown.

72911

c. Subtract piston diameter from cylinder bore diameter to determine piston-to-bore

clearance.
Determine if piston-to-bore clearance is in acceptable “Specifications” range.
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 (across centerline
of piston pin), then hone cylinder bore to correct clearance (preferable range).
4. Mark piston to identify cylinder for which it was fitted.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

Oil Filter By-Pass Valve

Inspection and/or Replacement
Oil by-pass valve should be inspected whenever engine is disassembled for major repair
or whenever inadequate oil filtration is suspected.
1. Remove oil filter from cylinder block and remove by-pass valve.
2. Clean by-pass valve in solvent and blow dry with compressed air.
3. Inspect fiber valve for cracks or other damage. Ensure that valve fits tightly against its
seat on the seal. Push valve down and release it. Valve should return freely to its seat.
If valve operation is questionable, by-pass valve should be replaced.

72912

Typical By-Pass Valve

a - Fiber Valve

4. Wipe out valve chamber in cylinder block to remove any foreign material.
5. Install by-pass valve and cylinder block adaptor to engine block.
6. Lubricate oil filter rubber seal and install hand-tight only.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

Remote Oil Filter

Inspection and/or Replacement
1. Remove nut from back side of power steering pump bracket.

75010

Typical
a - Nut

2. The outer oil line on the oil filter housing must be removed in order to install the bracket.

75010

a - Remove This Line

NOTE: Oil lines must be routed under the return line to the power steering pump. Ensure
that the oil lines do not rub or chafe on the exhaust manifold or engine mount.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

3. Place bracket over the stud and install nut. Torque nut to 12 lb-ft (16 Nm).

c 75010

a - Bracket
b - Nut
c - Power Steering Return Line

4. Install bracket screw from the front side of power steering bracket.

75011

a - Bracket Screw

5. Install previously removed oil line into oil filter housing. Torque fitting 20 to lb-ft (27 Nm).
6. Lightly lubricate seal on oil filter with engine oil. Install oil filter on oil filter adapter. Hand
tighten only.
7. Route oil lines past engine mount. Use hose clip to retain hoses. Remove upper screw
from port side engine mount. Place hose clip over screw and reinstall screw.

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SERVICE MANUAL NUMBER 25 262 CID (4.3L) ENGINES

8. Place the seal in adapter and lightly lubricate with engine oil. Position adaptor over en-
gine block and install the bushing in the block. Torque bushing to 40 ft-lb (50 Nm).

75175

a - Engine Block To Adapter Seal

b - Adapter
c - Quad Ring
d - Bushing

9. Install oil lines in adapter and orientate as shown. Torque fittings to 20 lb-ft (27 Nm).

a
75163

a - Oil Lines

10. Check oil level and fill if necessary.

11. Start engine and check for oil leaks.

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262 CID (4.3L) ENGINES SERVICE MANUAL NUMBER 25

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90-861328--1 NOVEMBER 1999 Page 3A-109

SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

ELECTRICAL SYSTEMS
Section 4B - Thunderbolt V Ignition System
Table of Contents
Replacement Parts Warning . . . . . . . . . . 4B-2 Circuit Description . . . . . . . . . . . . . . . . . . . 4B-10
General Precautions . . . . . . . . . . . . . . . . . 4B-2 Ignition Control Module . . . . . . . . . . . . 4B-10
EFI System Maintenance Precautions . 4B-3 Knock Control Module . . . . . . . . . . . . . 4B-10
Thunderbolt V Ignition System . . . . . . . . 4B-4 Ignition Control System Timing Lead 4B-10
Identification . . . . . . . . . . . . . . . . . . . . . 4B-4 Thunderbolt V Spark Control Graph . . . 4B-11
Timing and Idle Adjustment Procedures 4B-5 Distributor Advance Curves . . . . . . . . . . . 4B-12
Setting Base Ignition Timing . . . . . . . . 4B-5 Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-12
Adjusting Idle Mixture . . . . . . . . . . . . .
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . .
4B-5
4B-6
Removal . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . .
4B-12
4B-13 4
Specifications . . . . . . . . . . . . . . . . . . . . 4B-6 Reassembly . . . . . . . . . . . . . . . . . . . . . 4B-13 B
Removal . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Installation - Engine Not Disturbed . . 4B-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Installation - Engine Disturbed . . . . . . 4B-14
Replacing . . . . . . . . . . . . . . . . . . . . . . . 4B-7 Distributor Cap . . . . . . . . . . . . . . . . . . . . . . 4B-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4B-15
Idle Speed Spark Control . . . . . . . . . . 4B-7 Inspection . . . . . . . . . . . . . . . . . . . . . . . 4B-15
Acceleration Spark Advance . . . . . . . 4B-8 Rotor/Sensor Wheel . . . . . . . . . . . . . . . . . 4B-16
Mean-Best-Timing (MBT) Removal . . . . . . . . . . . . . . . . . . . . . . . . 4B-16
Spark Advance . . . . . . . . . . . . . . . . . . 4B-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . 4B-16
Over-Speed Control . . . . . . . . . . . . . . . 4B-8 Installation . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Knock Retard Spark Control . . . . . . . 4B-8 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Spark Plug Wires . . . . . . . . . . . . . . . . . . . . 4B-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Adjusting Engine Idle Speed . . . . . . . 4B-9 Inspection . . . . . . . . . . . . . . . . . . . . . . . 4B-18
Installation . . . . . . . . . . . . . . . . . . . . . . . 4B-18

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THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

Replacement Parts Warning

WARNING
Electrical, ignition and fuel system components on your MerCruiser power package
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 that do not

comply with these rules and regulations could result in a fire or explosion hazard
and should be avoided.

General Precautions
CAUTION
Avoid personal injury and/or property damage. Listed below are some of the pre-
cautions, along with others listed throughout this manual, that you should observe
to help ensure an accident-free maintenance experience:
• Always disconnect battery cables from battery BEFORE working on electrical
system to prevent injury to yourself or damage to electrical system.
• Be sure that engine compartment is well ventilated and that no gasoline vapors
are present, to avoid the possibility of fire.
• Be sure to keep hands, feet and clothing clear of moving parts.
• DO NOT touch or disconnect any ignition system parts while engine is running.
• DO NOT reverse battery cable connections. System is negative (–) ground.
• DO NOT disconnect battery cables while engine is running.
• When working on engine, spark plug holes and carburetor throat should be kept
covered to prevent foreign objects from entering combustion chamber.
• Replace a component if there is any doubt as to the condition of the component.

WARNING
When performing the following procedure, be sure to observe the following:
• Be sure that engine compartment is well ventilated and that no gasoline vapors
are present, to avoid the possibility of fire.
• Be sure to keep hands, feet and clothing clear of moving parts.
• DO NOT touch or disconnect any ignition system parts while engine is running.
• DO NOT reverse battery cable connections. System is negative (–) ground.
• DO NOT disconnect battery cables while engine is running.

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SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

EFI System Maintenance Precautions

WARNING
Avoid Injury or Electrical System Damage: Always disconnect battery cables from
battery before working around electrical system components. See CAUTION
following:

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 accessories into engine harness.
• DO NOT puncture wires for testing (Probing).
• DO NOT reverse battery leads.
• DO NOT splice wires into harness.
• DO NOT attempt diagnostics without proper, approved Service Tools.

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THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

Thunderbolt V Ignition System

Identification
1

1
3
4

10

75856

1 - Cable Kit - Ignition (Spark Plug and Coil)

2 - Boot
3 - Screw
4 - Spark Plug
5 - Cap
6 - Gasket
7 - Rotor
8 - Sensor Wheel
9 - Sensor Assembly
10 - Housing

Page 4B-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

Timing and Idle Adjustment Procedures

Setting Base Ignition Timing
1. Connect timing light (91-99379 or similar) to No. 1 spark plug wire. Connect power
supply leads, if applicable, on light to 12 volt battery.
2. Connect a shop tachometer to engine.
3. Using a jumper wire, connect the ignition system timing lead (PUR/WHT wire) to a good
engine ground (–). This locks the ignition module into the Base Timing Mode.
NOTE: Before starting engine make sure the timing tab and marks on damper are clean.
Chalk or white paint on timing marks may help visibility.
4. Start engine and run at normal idle speed. Allow engine to reach normal operating
temperature.
5. Aim timing light at timing tab, located on the timing gear cover and crankshaft torsional
damper.
6. If adjustment is required, adjust timing by loosening distributor clamp and rotating
distributor body as required until timing mark on damper or pulley lines up with the mark
on tab specified in “Specifications.” Tighten clamp and recheck location of timing mark.
7. Make sure that the distributor has been tightened. Remove the jumper wire from the
timing terminal.
8. Remove jumper wire between the timing lead (PUR/WHT wire) and ground (–).
IMPORTANT: Be sure to disconnect the jumper wire from between the ignition system
timing lead and ground (–) before attempting to resume normal operations. If the
jumper wire is left in place, the ignition module will operate in the Base Timing Mode.
This means that the additional timing advance features would not function.
9. Stop engine and remove timing light.
Adjusting Idle Mixture
The procedure for adjusting carburetor idle mixture can be found in the appropriate engine
service manual. This procedure also requires that the ignition module be locked in the “Base
Timing Mode.”
IMPORTANT: In order to properly set idle mixture, the ignition module MUST BE
locked in the Base Timing Mode. This is necessary because of the Idle Speed Control
feature that exists in the ignition module. See information on the previous pages
about this feature.
To adjust the idle mixture screw correctly, the throttle plates must be nearly closed. Please
do the following:
1. Disconnect throttle cable.
2. Set idle speed (rpm) screw so engine idles at 550-600 rpm in neutral gear.
3. Adjust idle mixture screw.
4. Reset the idle speed screw until engine idles at its recommended rpm.
5. Adjust and connect throttle cable.

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THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

Spark Plugs
Specifications
Model 4.3L / 4.3LH 4.3L EFI
Spark Plug Gap .045 in. (1.1 mm)
AC-MR43LTS
Spark Plug Type NGK-BPR6EFS
Champion RS12YC

Removal
1. Disconnect spark plug wires (high tension leads) from spark plugs.
NOTE: Use care when removing spark plug wires and boots from spark plugs. Twist the boot
1/2 turn before removing. Firmly grasp and pull on the boot to remove the wire end.
2. Remove spark plugs.
NOTE: A “thin-walled” spark plug socket may be required.
Inspection
1. Inspect each spark plug for manufacturer and spark plug number. All plugs must be from
the same manufacturer and have the same spark plug number. Refer to SECTION 1B.
- “Specifications” for spark plug numbers.
2. Inspect each plug individually for badly worn electrodes, glazed, broken or blistered
porcelain and replace where necessary.

b
c

f
d
72734
e
a - Porcelain Insulator
b - Insulator - Cracks Often Occur at This Point
c - Shell
d - Proper Gap
e - Side Electrode
f - Center Electrode (When Adjusting Gap - DO NOT Bend)

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SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

Replacing
1. Clean the plug seating area on the cylinder heads.
2. Adjust spark plug gap with a round feeler gauge. Bend side electrode to adjust gap.
Refer to SECTION 1B – “Specifications” for correct spark plug gap.

a
b 75084
a - Seating Area
b - Gap

IMPORTANT: It is recommended that spark plugs 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. Then, securely
tighten with appropriate wrench and socket.
3. Install spark plugs and torque to specifications. Refer to “Torque Specifications” in this
section.
4. Install spark plug wires in proper order. Refer to “Engine Rotation and Firing Order”
and/or “Spark Plug Wires,” following.

Description
The Thunderbolt V ignition system has several spark control features that will be described
following:
• Idle Speed Spark Control
• Acceleration Spark Advance
• Mean-Best-Timing Spark Advance
• Over-Speed Control (Rev-Limiter)
• Knock Retard Spark Control

Idle Speed Spark Control

The ignition module will control ignition timing to maintain a calibrated idle speed. This is
accomplished by making small spark advance adjustments. This feature is only active within
a certain rpm range. This range may be slightly different from one engine model to another.
The approximate range is 400-700 rpm.

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THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

Acceleration Spark Advance

This feature is active during acceleration only. When accelerating, the ignition module may
add more spark advance to the “Base Spark Timing Curve”. The amount of spark advance
added, is totally dependant on how fast rpm increases (how fast the throttle is moved). This
feature is also active within a certain rpm range. This range may be slightly different from
one engine model to another. The approximate rpm range for this feature is 1200-4000 rpm.
Within this range, the module can add approximately 10 degrees of spark advance to the
base spark timing curve.
Mean-Best-Timing (MBT) Spark Advance
During light load cruising, the ignition module searches for the optimal ignition timing. This
is also accomplished by small changes to the spark advance. At a given rpm, the module
will try to add a small amount of advance and wait to see if there is an rpm change. If rpm
increases, it will try to increase timing more. The module will continue to advance timing until
it no longer gets an increase in rpm. Conversely, if it senses an rpm drop, it will start to retard
some of the spark timing. The approximate rpm range for this feature is 1200-4000 rpm.
Within this range, the ignition module can add approximately 10-15 degrees of spark
advance to the base spark timing curve.
NOTE: The Audio Warning System is also connected into the ignition module circuit. If the
audio warning system becomes activated by the closing of one of the audio warning system
switches, the MBT feature is deactivated.
Over-Speed Control
The ignition module will prevent the engine speed from exceeding a preset limit by stopping
the spark. This feature has an rpm range that varies from model to model. The over-speed
limit for a particular engine is set slightly higher than the top end of the rpm range for that
model. For example, if the recommended range is 4600-5000 rpm, the over-speed limit
would be set at 5100 rpm. When rpm reaches this limit, spark is turned-off until engine rpm
drops down to a “Reset rpm”, which would be approximately 4750 rpm for this example. At
this point, spark comes back on.
Knock Retard Spark Control
The knock control feature helps provide protection from harmful detonation. Knock control
is handled by the Knock Control Module. This module receives a signal from a sensor that
is mounted on the engine block. The knock control module works in conjunction with the
ignition module to retard the timing if spark knock is present.

Page 4B-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

Spark Plug Wires

1. Inspect spark plugs for damage.
2. Check spark plugs for continuity using Multi-Meter / DVA (91-99750) or similar.
3. Replace any wires that are cracked, cut, or have damaged spark plug boots.
4. Replace any wires that do not show continuity from end to end.
5. Reinstall wires in proper order. Observe the following:
IMPORTANT: Proper positioning in spark plug wire supports is important to prevent
cross-firing.
IMPORTANT: Before installing coil wire to coil, apply approximately 1/2 oz of
insulating compound around top of coil lead tower. Force nipple into coil and wipe
off excess. Make sure boot does not hydraulically remove from the distributor cap
terminal.
Adjusting Engine Idle Speed
This procedure should be done with boat in the water, drive unit in neutral and engine at
normal operating temperature. Refer to the SECTION 1B - “Specifications” for the correct
idle speed.
1. Disconnect the throttle cable from carburetor.
IMPORTANT: In order to properly set idle speed, the ignition module MUST BE locked
in the Base Timing Mode. This is necessary because of the Idle Speed Control feature
that exists in the ignition module. See information on the previous pages about this
feature.
2. Connect a shop tachometer to engine.
3. Using a jumper wire, connect the ignition system timing lead 13 (PUR/WHT wire) to a
good engine ground (–). This locks the ignition module into the Base Timing Mode.
4. Start engine and allow it to reach normal operating temperature.
5. Adjust idle speed to recommended rpm.
6. Stop engine. Readjust cable barrel and reinstall the throttle.
IMPORTANT: Be sure to disconnect the jumper wire from the ignition system test
terminal before attempting to resume normal operations. If the jumper wire is left in
place, the ignition module will operate in the Base Timing Mode. This means that the
additional timing advance features would not be functioning.
7. Remove the jumper wire from the timing terminal.

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THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

Circuit Description
Refer to the circuit wiring diagram on the following page for reference to this circuit
description.
Ignition Control Module
• The ignition module receives its power (+) thru the PUR wire “9”.
• Ignition module ground (–) is accomplished thru the BLK wire “10”.
• There is also a Case Ground (–) wire “12” that is connected to one of the ignition module
attaching screws.
• The 12 volt signal from the ignition module to the distributor is carried through the WHT/
RED wire “8”, to the distributor sensor and back to the ignition module through the WHT/
GRN wire “7”.
• The tachometer signal is carried to the instrument panel thru the GRY wire “11”.
• The PUR/WHT wire “3” carries the signal from the knock control module to the ignition
control module.
• There are two BLK wires “5” that have bullet connectors. This circuit is reserved for fu-
ture options. On current models, the two BLK wires must be connected for the system to
function properly.
• The TAN/BLU wire “6” carries a signal from the audio warning circuit to the ignition mod-
ule.

Knock Control Module

• The knock control module receives it’s power (+) from the PUR wire “4”.
• Knock module ground (–) is accomplished thru the BLK wire “2”.
• The PUR/WHT wire “3” carries the signal from the knock control module to the ignition
control module.
• The BLU wire “1” carries the signal from the knock sensor to the knock module.

Ignition Control System Timing Lead

The ignition control system has a lead with bullet connector “11” that is connected into the
PUR/WHT wire “3”. This lead is used for performing the following tests and procedures:
• Setting Base Ignition Timing
• Setting Engine Idle Speed
• Setting Idle Mixture
• Testing Knock Control Circuit
This lead, when connected to an engine ground (–), locks the ignition control module into
the Base Timing mode.

Page 4B-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

Thunderbolt V Spark Control Graph

IMPORTANT: The graph below shows the typical advance ranges for a Thunderbolt
V ignition control module. The numbers plotted on the graph are not representative
of any particular model. It is only presented to provide an understanding of how the
system functions.

ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ
35° ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
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ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ
30°
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
25°
ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
20°
TOTAL SPARK ADVANCE
MINUS INITIAL TIMING

15° ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
10°
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÅÅ
ÅÅ
ÅÅ
5°

0°
ÅÅ
ÅÅ
–5°
ÅÅ
ÅÅ
ÅÅ
–10° ÅÅ
–15°

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

ENGINE R.P.M.

ÅÅ
ÅÅ
= Base Timing Advance Curve

ÅÅ
= Idle Speed Advance Range

ÇÇ
= Knock Retard Range

ÇÇ
ÇÇ
ÂÂ
= Acceleration Advance Range

ÂÂ = MBT Advance Range

90-861328--1 NOVEMBER 1999 Page 4B-11

THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

Distributor Advance Curves

1. Distributor advance curve charts do not include the initial engine timing. Basic initial
timing must be added to chart for total advance curve.
2. The spark advance is controlled by the ignition module.

35°

30°
TOTAL SPARK ADVANCE

25°

20°

15°

10°

5°

500 1000 1500 2000 2500 3000 3500 4000 4500 5000

ENGINE RPM
70808-15

Distributor
Removal
1. Unplug wiring harness from ignition amplifier on distributor housing.
2. Remove distributor cap. Do not remove high tension leads unless necessary.
3. Crank engine over until timing marks line up and rotor is pointing toward No. 1 cylinder
on distributor cap.
4. Mark distributor housing in reference to engine block.
5. Remove bolt and hold-down clamp and remove distributor.
6. To simplify distributor installation, do not turn crankshaft when distributor is removed
from engine.

Page 4B-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

Disassembly
1. Remove rotor, sensor wheel and sensor.
2. Remove roll pin, washer and driven gear from distributor shaft.
3. Check for side play between shaft and distributor housing bushings. Maximum side play
is .002 in. (0.05 mm).
4. Remove shaft from housing and check shaft for being bent with a dial indicator and
V-blocks. Maximum runout is .002 in. (0.5 mm).
Reassembly
1. Lubricate shaft with engine oil. Install E-clip (if removed) on shaft in housing.
2. Install washer on shaft. Install original gear; slide onto shaft and install roll pin.
3. Hole may be offset and gear will only fit in one direction.
4. If installing a new gear, the gear will come drilled on one side. Slide gear onto shaft; align
hole in gear with hole in shaft. Using these holes as guides, drill through other side of
gear with a 3/16 in. carbide tripped drill.
5. If a new gear has only a dimple, you will have to drill through one side of the gear before
you slide gear onto shaft. In most cases it is recommended to have a machine shop
complete the drilling operation for new gear installation.

b d

c 72735

a - Drill Press
b - 3/16 In. Carbide Tip Drill
c - V - Block
d - New Gear

6. Install sensor, sensor wheel and rotor.

7. Install distributor.

90-861328--1 NOVEMBER 1999 Page 4B-13

THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

Installation - Engine Not Disturbed

1. Install new gasket on distributor housing.
2. Turn rotor approximately 1/8-turn in a counterclockwise direction past mark previously
scratched on distributor housing.
3. Work distributor down into position in engine block with distributor positioned as noted
during removal.
4. It may be necessary to move rotor slightly to start gear into mesh with camshaft gear,
but rotor should line up with the mark when distributor is down in place. Distributor shaft
must enter oil pump shaft for complete installation.
5. Replace and tighten distributor hold-down bolt and clamp. Connect leads. Also install
spark plug and coil secondary wires, if removed.
6. Install cap. Refer to “Spark Plug Wires ” and install wires.
7. Plug wiring harness into ignition amplifier on distributor housing.
8. Time ignition as outlined under “Ignition Timing.”

Installation - Engine Disturbed

CAUTION
If timing chain has been aligned as outlined in Section 3A - “Timing Chain and
Sprocket,” the No. 4 cylinder is on compression (TDC) and the distributor MUST BE
installed with the rotor positioned at the No. 4 post on the distributor cap.
Electrical timing on No. 1 spark plug remains the same as outlined following.
1. Locate No. 1 piston in firing position by either of two methods described below.
a. Remove No. 1 spark plug and, with finger on plug hole, crank engine until
compression is felt in No. 1 cylinder. Continue cranking until pointer lines up with
timing mark on crankshaft pulley, or
b. Remove rocker cover and crank engine until No. 1 intake valve closes, continuing
to crank slowly until pointer lines up with timing mark on crankshaft pulley.
2. Position distributor to opening in block in normal installed attitude.
3. Position rotor to point toward No. 1 cylinder on cap (with distributor housing held in
installed attitude), then turn rotor counterclockwise approximately 1/8-turn more and
push distributor down to engage camshaft. It may be necessary to rotate rotor slightly
until camshaft engagement is felt.
4. While pressing down firmly on distributor housing, engage starter a few times to make
sure oil pump shaft is engaged. Install hold-down clamp and bolt and snug up bolt.
5. Place distributor cap in position and check that rotor lines up with terminal for No. 1 spark
plug. Install cap.
6. Refer to “High Tension Leads” and install wires. Refer to “Specifications” for firing order.
7. Time ignition as outlined under “Ignition Timing.”

Page 4B-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

Distributor Cap
Removal
1. Loosen four distributor cap retaining screws.
2. Remove distributor cap.
Inspection
1. Clean cap with warm soap and water and blow off with compressed air.
2. Check cap contact for excessive burning or corrosion. Check center contact for
deterioration.
3. Check cap for cracks or carbon tracks using magneto analyzer.
4. Check condition of distributor cap gasket. Replace gasket if damaged or missing.
5. If high tension leads are removed from cap refer to ”Spark Plug Wires” in this section
and the following illustrations for installation.

72981

Wiring
a - Alignment Notch

72978

a - Vent

90-861328--1 NOVEMBER 1999 Page 4B-15

THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

Rotor/Sensor Wheel
Removal
1. Remove distributor rotor/sensor wheel assembly from distributor shaft. Rotor and
sensor wheel are secured to the shaft with Loctite. Use two flat blade screwdrivers. The
screwdrivers are positioned opposite each other with the blade tips on the underside of
the rotor and sensor wheel assembly. Make sure blade tips are toward distributor shaft
until they come in contact with shaft. A downward push on both screwdriver handles at
the same time will pry off rotor/sensor wheel assembly. The use of torch lamp will also
aid in the removal of the rotor/sensor wheel assembly.

WARNING
Wear protective gloves when handling heated rotor/sensor wheel assembly to
avoid severe burns.

Inspection
1. With the rotor/sensor wheel assembly removed, inspect the locating key inside the rotor.
2. The locating key will appear as a clean edged, 1/8 in. (3 mm) wide, sloped ramp at the
bottom of the splined hole.

72980
c
a - Locating Key
b - Screws (Hex Head)
c - Sensor Wheel
d - Locating Pin

3. If there is any doubt if sensor wheel is located properly, lay sensor wheel on top of the
figure above with sensor fingers facing up (toward you). Line up three screw holes and
locating pin hole on sensor wheel with the figure. If wheel is indexed properly all the
fingers on wheel will line up with those in the figure.
4. If there are pieces of material shaved off the key or if it appears to have been damaged
by being forced down while misaligned with slot in distributor shaft, the rotor must be
replaced.
5. Check rotor for burned or corroded center contact.
6. Check rotor for cracks and carbon tracks using magneto analyzer and instructions
supplied with analyzer.

Page 4B-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

7. If rotor is damaged, replace rotor by removing three hex bolts and separating sensor
wheel from rotor. Reinstall sensor wheel to new rotor making sure locating pin on rotor
is installed in locating hole in sensor wheel. Tighten three hex bolts securely.
8. Bend carbon brush tang upward slightly until a distance of 1/4 in. (6.4 mm) is obtained
between rotor and tang.

72979

a - 1/4 in. (6.5 mm)

Installation
1. Put 2 drops of Loctite 27131 into the rotor so it lands on the locating key.
2. Put 2 drops of Loctite 27131 in keyway on upper portion of distributor shaft.
3. Immediately install rotor assembly onto distributor shaft. Make sure rotor locating key
is aligned with keyway in distributor shaft before pressing rotor all the way down on the
shaft, until it stops, with the palm of your hand. Let Loctite cure overnight with distributor
in inverted position.
4. The rotor should fit very tight. It may be necessary to heat rotor with torch lamp to
properly install. It is important not to let any Loctite run down distributor shaft. Loctite
could get into top distributor housing bushing.
5. Reinstall distributor cap on distributor.
6. Install spark plug wires (if removed). Refer to “Spark Plug Wires” in this section.

Sensor
Removal
1. Remove rotor and sensor wheel.
2. Remove two screws that hold sensor into distributor housing.
3. Remove sensor from housing.

b
a
72732

a - Mounting Screws
b - Sensor Assembly

90-861328--1 NOVEMBER 1999 Page 4B-17

THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

Inspection
1. Use a magnifying glass and light to inspect the two metal “jumper leads” for cracks. If
a crack is found in either metal “jumper lead,” install a new sensor.

72733

a - Jumper Leads

CAUTION
Do not use any type of silicone sealer on the inside of the distributor. Most silicone
sealers give off an acidic vapor during the curing stage of the sealer. This acid can
cause corrosion on the ignition components.

Installation
1. Install sensor into housing and install two retaining screws.
2. Install sensor wheel, rotor and distributor cap.

Page 4B-18 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 THUNDERBOLT V IGNITION SYSTEM

THIS PAGE IS INTENTIONALLY BLANK

90-861328--1 NOVEMBER 1999 Page 4B-19

THUNDERBOLT V IGNITION SYSTEM SERVICE MANUAL NUMBER 25

THIS PAGE IS INTENTIONALLY BLANK

Page 4B-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

ELECTRICAL SYSTEM
Section 4C - Charging System
Table of Contents
General Precautions . . . . . . . . . . . . . . . . . 4C-2 Charging System Resistance . . . . . . . 4C-7
EFI Electrical System Precautions . . . . . 4C-2 Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . 4C-9
Replacement Parts Warning . . . . . . . . . . 4C-2 Component . . . . . . . . . . . . . . . . . . . . . . 4C-10
Identification . . . . . . . . . . . . . . . . . . . . . . . . 4C-3 Exploded View . . . . . . . . . . . . . . . . . . . . . . 4C-15
Specifications . . . . . . . . . . . . . . . . . . . . . . . 4C-3 Alternator Repair . . . . . . . . . . . . . . . . . . . . 4C-16
Mando . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4C-16
DelcoRemy . . . . . . . . . . . . . . . . . . . . . . 4C-4 Disassembly . . . . . . . . . . . . . . . . . . . . . 4C-16
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives . . . . .
4C-4
4C-4
Cleaning and Inspection . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . .
4C-21
4C-21 4
Torque Specifications . . . . . . . . . . . . . . . . 4C-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4C-25 C
Description . . . . . . . . . . . . . . . . . . . . . . . . . 4C-5 Pulley Removal . . . . . . . . . . . . . . . . . . 4C-26
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-6 Battery Isolator Diagram . . . . . . . . . . . 4C-27
Charging System . . . . . . . . . . . . . . . . . 4C-6

90-861328--1 NOVEMBER 1999 Page 4C-1

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

General Precautions
The following precautions MUST BE observed when working on the alternator system.
Failure to observe these precautions may result in serious damage to the alternator or
alternator 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 specifi-
cally instructed in the “Troubleshooting Tests,” following.
3. NEVER disconnect the alternator output lead or battery cables when the alternator is
being driven by the engine.
4. NEVER disconnect regulator lead from alternator regulator terminal when the alternator
is being driven by the engine.
5. ALWAYS remove negative (–) battery cable from battery before working on alternator
system.
6. When installing battery, BE SURE to connect the positive (+) battery cable to the positive
(+) battery terminal and the negative (–) (grounded) battery cable to negative (–) battery
terminal.
7. If a charger or booster battery is to be used, BE SURE to connect it in parallel with exist-
ing 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 engine harness.
• DO NOT puncture wires for testing (Probing).
• DO NOT reverse battery leads.
• DO NOT splice wires into harness.
• DO NOT attempt diagnostics without proper, approved Service Tools.

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 mini-
mize 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.
IMPORTANT: Alternators are equipped with an excitation circuit. This circuit will have
approximately a 7 milliamp draw on the battery with the key in the off position. This
draw is normal.

Page 4C-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

Identification

72078
a

Mando 55 Amp and 65 Amp Alternator (S/N 0L619083 and Below)

a - Excitation Wire - PURPLE
b - Sensing Wire - RED/PURPLE
c - Part Number and Amperage Rating (Hidden In This View)

72078

Delco 65 Amp Alternator (S/N 0L619084 and Above)

a - Part Number

Specifications
Mando
Description Specification
55 Amp 65 Amp
Part Number 807652T 807653T
Excitation Circuit 1.3 to 2.5 Volts 1.3 to 2.5 Volts
Current Output 50 Amp. Min. 60 Amp. Min.
Voltage Output 13.9 to 14.7 Volts 13.9 to 14.7 Volts
Min. Brush Length 1/4 in. (6 mm) 1/4 in. (6 mm)

90-861328--1 NOVEMBER 1999 Page 4C-3

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

DelcoRemy
Description Specification
Part Number 862031T
Rating 12 (V) x 65 (A)
Output (1300 / 2500 / 6500 Grpm) 8 / 47 / 65 (A) @ 20’
Regulator Setting Voltage 14.4 - 15 Volts @ 25’

Tools
Description Part Number
Bearing Removal and Installation Kit 91-31229A7
Universal Puller Plate 91-37241
Ammeter (0-100 Amp) Obtain Locally
Multimeter 91-854009A1

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver Liquid Neoprene 92-25711--3

Torque Specifications
Fastener Location lb-in. lb-ft Nm
End Frame Screws 55 5.5
Brush Setscrews 18 1.5
Regulator Mounting Screws 42 4.2
Regulator Leads 25 2.5
Ground Terminal Nut 25 2.5
Pulley Nut 42 57
Alternator to Mounting Bracket 35 48
Alternator Mounting Bracket 30 41
Belt Tension See Note
Ground Terminal Nut (Delco 65 Amp Alternator) 55 5.5
Pulley Nut (Delco 65 Amp Alternator) 70 95

NOTE: Belt deflection is to be measured on the belt at the location that has the longest
distance between two (2) pulleys. Normally this location is between the power steering
pump and the belt adjustment pulley. This location will be different on engines with closed
cooling or models without power steering.

Page 4C-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

Description
This package uses an integral regulator charging system. The integrated circuit regulator
is a solid state unit that is mounted inside the alternator to the slip ring end frames. All regula-
tor components are enclosed in a solid mold to protect them from the heat and corrosive
elements. The regulator voltage cannot be adjusted.
The alternator rotor gears contain enough grease to eliminate the need for periodic lubrica-
tions. Two brushes carry current through two slip rings to the field coil mounted on the rotor.
Under normal conditions, this arrangement is capable of providing long periods of attention
free service.
Stator windings are assembled inside a laminated core that is mounted between the alterna-
tor drive end frame and the slip ring end frame. A rectified bridge that contains six diodes
is connected to the stator winding. These diodes electrically change stator AC voltage into
DC voltage. This DC voltage is then transmitted to the alternator output terminal.
A capacitor or condenser, mounted in the regulator, protects the rectifier bridge. This capaci-
tor also suppresses radio noise.
NOTE: There are no repair or replacement internal parts for this alternator. The alternator
has to be replaced as a complete assembly. The only part that is available is the pulley.

90-861328--1 NOVEMBER 1999 Page 4C-5

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

Testing
Charging System
1. Check belt condition and tension.
2. Check battery condition.

X.X

+ –

– +
76498

3. With a fully charged battery, connect voltmeter leads directly to the battery posts.
4. Start engine and run at 1300-1500 rpm. Read voltmeter. Most systems will read
13.8-14.8 volts.
NOTE: If the voltage reading is within specifications, switch voltmeter to AC volt position.
There should not be more than a 0.250 AC voltage reading with the engine running. A read-
ing more than 0.250 AC volts indicate defective diodes in the alternator.
5. If the voltmeter reading at the battery posts is below 13.5 volts, connect the voltmeter
positive (+) lead to the alternator output terminal. Connect the voltmeter negative (–)
lead to the ground terminal on the alternator. Repeat step 4.

X.X
a

– +
76498

76533

Typical
a - Output Terminal
b - Ground Terminal
c - Voltmeter

6. If voltmeter reading is now within specifications, there is too much resistance between
the alternator and the battery.
7. If the reading is below 12.5 volts, the alternator may not be charging. Check all wiring
leading to the alternator.

Page 4C-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

Charging System Resistance

1. Ground the ignition coil high tension wire so engine does not start.
2. Crank engine over for 15 seconds to discharge the battery slightly.
3. Reconnect coil high tension 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 voltmeter leads to the battery post, NOT the battery cable end.

c
d
X.X
+ –
a

– +
76498

76533

Typical
a - Output Terminal
b - Ground Terminal
c - Voltmeter
d - Battery

5. Start engine and run at 1300–1500 rpm. Read voltmeter. A reading of more than 0.5
volts show excessive resistance in wiring.

90-861328--1 NOVEMBER 1999 Page 4C-7

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

6. Connect the voltmeter negative (–) lead to the alternator ground terminal. Connect volt-
meter positive (+) lead to the battery negative (–) post.

c
d
X.X
+ –
a

– +
76498

76533

Typical
a - Output Terminal
b - Ground Terminal
c - Voltmeter
d - Battery

7. Repeat Step 5.

Page 4C-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

Circuitry
Perform the following tests, using a 0-20 volt DC voltmeter, to check that all of the circuits
between the alternator and the other components within the alternator system are in good
condition.

OUTPUT CIRCUIT

1. Ensure battery is fully charged by using the hydrometer test outlined in 4A.
2. Start engine and increase RPM to approximately 1500 rpm.
3. Check voltage reading. The voltage should read between 13.8 and 14.2 volts. If the
reading is below 13.8 volts:
a. Connect positive (+) voltmeter lead to alternator output post.
b. Connect negative (–) lead to ground post on alternator.
c. Wiggle engine wiring harness while observing voltmeter. Meter should indicate ap-
proximate battery voltage and should not vary. If no reading is obtained, or if reading
varies, go to “Resistance” in this section.

c
72784
b
Typical
a - Output Wire - ORANGE
b - Excitation Wire - PURPLE
c - Sensing Wire - RED/PURPLE
d - Voltmeter (0-20 Volts)
e - Ground

EXCITATION CIRCUIT

1. Connect positive (+) voltmeter lead to tie strap terminal on alternator and negative (–)
lead to a ground terminal on alternator (Test 1).
2. Turn ignition switch to ON position and note voltmeter reading. Reading should be 1.3
to 2.5 volts.
3. If no reading is obtained, an opening exists in alternator excitation lead or in excitation
circuit of regulator. Unplug PURPLE lead from regulator. Connect positive voltmeter
lead to PURPLE lead and negative voltmeter leads to ground (Test 2). If voltmeter now
indicates approximate battery voltage, voltage regulator is defective and must be
replaced. If no voltage is indicated, check excitation circuit for loose or dirty connections
or damaged wiring.

90-861328--1 NOVEMBER 1999 Page 4C-9

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

SENSING CIRCUIT

1. Unplug RED/PURPLE lead from voltage regulator.

2. Connect positive (+) voltmeter lead to red/purple lead and negative (–) voltmeter lead
to ground terminal.
3. Voltmeter should indicate battery voltage. If battery voltage is not present, check sens-
ing circuit (red/purple lead) for loose or dirty connection or damaged wiring.

b c 72786

Typical
a - Output Wire - ORANGE
b - Excitation Wire - PURPLE
c - Sensing Wire - RED/PURPLE
d - Voltmeter (0-20 Volts)
e - Ground
Component
ROTOR
1. Test rotor field circuit for opens, shorts or high resistance (Test 1), using an ohmmeter
(set on R x1 scale), as follows:
a b

72831

Testing Rotor Field Circuit

a - Test 1
b - Test 2

a. Connect one ohmmeter lead to each slip ring.

b. Ohmmeter reading should be 4.2 to 5.5 ohms with rotor at room temperature
70-80°F (21-26°C).

Page 4C-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

c. If reading is high or infinite (no meter movement), high resistance or an open exists
in the field circuit. Check for poor connections between field winding leads and slip
ring terminals. If cause for open or high resistance cannot be found, connect ohm-
meter directly to slip ring terminals. If correct reading is now obtained, or if reading
is still high or infinite, replace complete rotor assembly.
d. If reading is low, a short exists in the field circuit. Inspect slip rings to be sure that
they are not bent and touching outer slip ring. Also, be sure that excess solder is not
shorting terminals to aft slip ring. If cause for short cannot be found, unsolder field
winding leads from slip ring terminals and connect ohmmeter directly to leads. If
correct reading is now obtained, or if reading is still low, slip rings and rotor field
windings are shorted, and complete rotor assembly must be replaced.

b
c

a
73112

a - Field Winding Leads

b - Slip Rings
c - Rotor Shaft
d - Pole Pieces

2. Test rotor field circuit for grounds (Test 2), using an ohmmeter (set on R x1 scale) as
follows:
a. Connect one lead of ohmmeter to either slip ring and the other lead to rotor shaft or
pole pieces.
b. Meter should indicate no continuity (meter should not move).
c. If continuity does exist, complete rotor assembly must be replaced.
IMPORTANT: If alternator has output at low speeds, but no output at high speeds,
rotor field winding may be shorting or grounding out, due to centrifugal force.
Replace rotor if all other electrical components test good.

STATOR

IMPORTANT: Stator leads MUST BE disconnected from rectifier for this test.
1. Test stator for grounds (Test 1), using an ohmmeter (set on R x1 scale) as follows:
a. Connect one lead of ohmmeter to one of the stator leads and the other lead to stator
frame. Be sure that lead makes good contact with frame.
b. Meter should indicate no continuity (meter should not move). If continuity does exist,
stator is grounded and must be replaced.
2. Test for opens in stator (Test 2), using an ohmmeter (set on R x1 scale) as follows:
a. Connect ohmmeter between each pair of stator windings (three different ways).

90-861328--1 NOVEMBER 1999 Page 4C-11

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

b. Continuity should be present in all three cases (meter should move). If it does not,
one or more of the windings are open and stator must be replaced.
a b b b

72833

Testing Stator
a - Test 1
b - Test 2

3. A short in the stator is difficult to detect without special equipment, because of the low
windings resistance. If all other electrical components test out good, and alternator fails
to produce rated output, stator probably is shorted and should be replaced. Also,
examine stator for heat discoloration, as this usually is a sure sign of a short.

RECTIFIER AND DIODE ASSEMBLY

NOTE: Failure of any component in tests following will require replacement of entire rectifier
assembly.

NEGATIVE (–) RECTIFIER

IMPORTANT: Rectifier MUST BE disconnected from stator for this test.

CAUTION
DO NOT use a test instrument with more than a 12 volt source (in the following test),
as rectifier may be damaged.
1. Connect one lead of an ohmmeter (set on R x1 scale) to negative (–) rectifier heat sink
and the other lead to one of the rectifier terminals. Note the reading.
2. Reverse leads and again note reading.
3. Meter should indicate a high or infinite resistance (no meter movement) when
connected one way and a low reading when connected the other. If both readings are
high or infinite, rectifier is open. If both readings are low, rectifier is shorted.
4. Repeat Steps 1. through 3. for two other rectifiers in heat sink.

Page 4C-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

5. Replace assembly if any of the rectifiers is shorted or open.

72147
a

a - Heat Sink
b - Rectifier Terminal
c - Test These Two Rectifiers In The Same Manner

POSITIVE (+) RECTIFIER AND DIODES

CAUTION
DO NOT use a test instrument with more than a 12 volt source (in the following test),
as rectifier may be damaged.
1. Connect one lead of an ohmmeter (set on R x1 scale) to 1/4 in. stud on positive (+)
rectifier heat sink and the other lead to one of the rectifier terminals. Note the meter
reading.
2. Reverse leads and again note reading.
3. Meter should indicate a high or infinite resistance (no meter movement) when
connected one way and a low reading when connected the other. If both readings are
high or infinite, rectifier is open. If both readings are low, rectifier is shorted.
4. Repeat Steps 1. through 3. for two other rectifiers in heat sink.

72834
a
a - Stud
b - Rectifier Terminal
c - Repeat Test Between These Terminals And Stud

90-861328--1 NOVEMBER 1999 Page 4C-13

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

5. Replace assembly if any one of the rectifiers is shorted or open.

6. Connect one lead of an ohmmeter (set on R x1) to the common side of the diode and
the other lead to the other side, of one of the three diodes.

b
a

72148

a - Common Side Of Diode Circuit Board

b - Repeat Test For Two Diodes

7. Reverse leads and again note reading.

8. Meter should indicate a high or infinite resistance (no meter movement) when con-
nected one way and a low reading when connected the other. If both readings are high
or infinite, diode is open. If both readings are low, diode is shorted.
9. Repeat Steps 1. through 3. for the other two diodes.
10. Replace rectifier assembly if any one of the diodes is shorted or open.

CONDENSER

1. Using magneto analyzer and accompanying instructions, perform the following con-
denser tests:
a. Condenser Capacity Test (must be .5 mfd).
b. Condenser Short or Leakage Test.
c. Condenser Series Resistance Test.
2. Replace condenser if test results are not within specifications.

Page 4C-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

Exploded View

19
20
22 21

25
24

27 26
1
3
6 2 4
28 23
29 2
3
10 8 5
9
2 2
12 13
10
1
3 13
16 15
17 14 2
7
18 10

11

72276

1 - Screws (3) 16 - Flat Washer

2 - Nut (9) 17 - Screw
3 - Flat Washer (4) 18 - Stator
4 - Sensing Wire (RED / PUR) 19 - Rotor And Slip Ring
5 - Excitation Wire (PUR) 20 - Retaining Plate
6 - Cover 21 - Front Bearing
7 - Tie Strap 22 - End Frame (Front)
8 - Rubber Gasket 23 - Screw (3)
9 - Condenser 24 - Fan Spacer
10 - Insulator 25 - Fan
11 - Bolt (4) 26 - Pulley Spacer
12 - End Frame (Rear) 27 - Pulley
13 - Cap (2) 28 - Lockwasher
14 - Brush / Regulator Assembly 29 - Nut
15 - Rectifier Assembly

90-861328--1 NOVEMBER 1999 Page 4C-15

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

Alternator Repair
Removal
1. Disconnect negative (–) battery cable from battery.
2. Disconnect wiring harness from alternator.
3. Loosen serpentine belt with the adjustment pulley.
4. Turn the adjustment stud and loosen belt. Remove belt.
5. Remove alternator mounting bolt, washers and remove alternator.

a
d b

76465

Delco Alternator Shown, Mando Similar

a - Serpentine Belt
b - Adjustment Pulley
c - Adjustment Stud
d - Mounting Bolt

Disassembly
NOTE: Mando Alternator shown throughout, Delco Alternator should be replaced if it tests
defective
IMPORTANT: The following instructions are for complete disassembly and overhaul
of the alternator. In many cases, however, complete disassembly of alternator is not
required and, in those cases, it is necessary only to perform the operations required
to repair or replace the faulty part.
1. Mount alternator in a vise so that rear end frame is facing you.

Page 4C-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

2. Disconnect regulator leads from terminals on rear end frame. Remove four nuts, Phillips
head screw and two regulator leads. Then pull regulator cover away from rear end
frame.

b
c
d
a 72963

a - Regulator Leads
b - Nuts (4)
c - Phillips Head Screw
d - Regulator Cover

3. Remove stud cover insulator, two nuts and tie strap from brush/regulator assembly.
IMPORTANT: Scribe pieces during disassembly to assist in exact same positioning
during reassembly.
4. Remove two brush/regulator attaching screws and remove brush/regulator assembly.

d
72823
a
a - Screws
b - Brush / Regulator Assembly
c - Stud Cover Insulator
d - Tie Strap

5. Scribe a mark on rear end frame, stator and front end frame to ensure proper
reassembly later.
6. Remove four screws which secure end frames and stator together.
IMPORTANT: DO NOT insert screwdriver blades more than 1/16 in. (1.5 mm) into
openings (in next step), as stator windings may be damaged.

90-861328--1 NOVEMBER 1999 Page 4C-17

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

7. Separate rear end frame and stator assembly from front end frame and rotor assembly
using two thin blade screwdrivers (positioned 180 degrees apart from one another) at
the locations shown. Use the two slots shown to initially separate units.

c
e
a a

d
72824

a - DO NOT Insert Screwdriver Blades More Than 1/16 In. (1.5 mm) Into Slots.
b - Rear End Frame
c - Stator
d - Front End Frame
e - Scribe Marks

8. Place rear end frame and stator assembly on the bench with stator downward. Be sure
that bench is clean and free of metal chips. Remove nuts, washers, insulators and con-
denser from output and ground studs.
9. Turn end frame over (stator upward) and remove one Phillips head screw which secures
rectifiers to end frame.

b
72826

a - Rectifier Assembly
b - Phillips Head Screw

10. Separate stator and rectifier assembly from rear end frame using screwdriver slots.

Page 4C-18 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

11. Unsolder the three stator leads from the rectifier heat sink. Place a needle nose pliers
on diode terminal between solder joint and diode body to help prevent heat damage to
diodes. Unsolder joints as quickly as possible and allow diode terminal to cool before
removing pliers.

72827
b

a - Heat Sink
b - Stator Leads (3)

IMPORTANT: With alternator disassembled to this point, stator, rectifier, diodes, and
rotor may be tested, as explained under “Component Testing,” following.
IMPORTANT: DO NOT clamp vise on rotor pole pieces when removing pulley nut (in
next step), as pole pieces may be distorted.
12. Remove pulley retaining nut by clamping pulley in a vise (using an old belt or protective
jaws to protect pulley) and turning nut counterclockwise with a wrench. Remove
lockwasher, slide pulley and fan from shaft. If pulley is difficult to remove, it may be
necessary to use a universal puller.

b
a

72828
a - Wrench
b - Old Belt To Protect Pulley

90-861328--1 NOVEMBER 1999 Page 4C-19

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

13. Remove the three phillips head screws and lockwashers which secure the front bearing
retaining plate.

b 72829

a - Phillips Head Screws and Lockwashers

b - Front Bearing Retaining Plate

14. Remove front bearing from front end frame using an arbor press and a suitable size
mandrel. Discard bearing.

a
b

72830

a - Press
b - Mandrel
c - Bearing

15. If rotor slip rings or rear bearing requires replacement, entire rotor must be replaced.
Parts cannot be purchased separately.

Page 4C-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

Cleaning and Inspection

1. Clean all parts with a clean, soft cloth. DO NOT use solvent, or electrical components
may be damaged.
2. Inspect the following parts for wear and damage:
a. Brush/regulator assembly - inspect for cracked casing, damaged brush leads,
poor brush lead solder connections, weak or broken brush springs or worn brushes.
Replace brush set if brushes are less than 1/4 in. (6 mm) long.
b. Rotor - inspect for stripped threads, scuffed pole piece fingers or damaged bearing
surfaces (because of bearing turning on shaft).
c. Rotor-slip rings - clean slip rings with 400 grain (or finer) polishing cloth while spin-
ning rotor in a lathe. Blow off dust with compressed air. Inspect slip rings for grooves,
pits, flat spots or out-of-round [.002 in. (0.051 mm) maximum] and replace rotor, if
present.
d. Rotor shaft and front end bearings - inspect for damaged seals, lack of lubrica-
tion, discoloration (from overheating) and excessive side or end play. Bearing
should turn freely without binding or evidence of rough spots.
e. Stator - inspect for damaged insulation or wires; also inspect insulating enamel for
heat discoloration, as this is usually a sign of a shorted or grounded winding or a
shorted diode.
f. Front and rear end frames - inspect for cracks, distortion, stripped threads or wear
in bearing bore (from bearing outer race spinning in bore). End frame(s) MUST BE
replaced, if bearing has spun. Also, inspect bearing retainer recess in front end
frame for damage.
g. Fan - inspect for cracked or bent fins, broken welds (bi-rotational fan only) or worn
mounting hole (from fan spinning on shaft).
h. Pulley - inspect pulley mounting bore end for wear. Inspect drive surface of pulley
sheaves for trueness, excessive wear, grooves, pits, nicks and corrosion. Repair
damaged surfaces, if possible, with a fine file and a wire brush or replace pulley, if
beyond repair. Drive surfaces MUST BE perfectly true and smooth or drive belt wear
will be greatly accelerated.

Reassembly
1. Install new front bearing into front end frame bearing bore using an arbor press. If neces-
sary, use a bearing driver that contacts outer race only.

72835

a - Press
b - Mandrel

90-861328--1 NOVEMBER 1999 Page 4C-21

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

2. Install front bearing retaining plate using three Phillips head screws and lockwashers.

b
72829

a - Phillips Head Screws And Lockwashers

b - Front Bearing Retaining Plate

3. Slide front end frame over rotor.

4. Assemble stator to rectifier by soldering the three leads to the three rectifier terminals.

72826

a - Stator Lead Connections

NOTE: Be sure to connect leads to their original positions.

5. Install assembled stator and rectifier assembly into rear end frame, aligning scribe
marks on each (scribed during disassembly), and install Phillips head screw and washer
to retain.
IMPORTANT: The insulating washers MUST BE installed as shown or damage to the
alternator will result.
6. Position stator down with rear end frame up and reinstall insulators, nuts and condenser.
b c
b

72561

a - Insulators (3)
b - Nuts (5) One Removed
c - Condenser

Page 4C-22 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

7. Position rear end frame and stator assembly over front end frame and rotor assembly
and align scribe marks on each (scribed during disassembly). Hand-press end frames
together, then install four screws. Tighten screws securely.

a e
d

c 72561
b
a - Rear End Frame
b - Stator
c - Front End Frame
d - Scribe Marks
e - Insert Screws (4) (Two Hidden)

8. Depress brushes flush with top of brush holder and insert a #54,.050 in. (1 mm) drill bit
or smaller into hole in brush holder to hold brushes compressed during reassembly.

a 72836

a - Drill Bit

NOTE: Rubber gasket shown removed for clarity.

9. Install brush/regulator assembly in rear end frame cavity and secure with two mounting
screws, as shown. Tighten screws securely. Remove drill bit to release brushes against
slip rings.

72837
a - Brush / Regulator Assembly
b - Mounting Screws

90-861328--1 NOVEMBER 1999 Page 4C-23

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

10. Install tie bar to rectifier stud and stud on brush/rectifier assembly. Tighten nuts securely.

a 72823

a - Studs
b - Tie Bar

11. Install cover with one phillips head screw and two nuts. Install two leads with nuts.

b a

72963
c

a - Phillips Head Screw

b - Nuts (4)
c - Leads

12. Install insulator caps.

72078

a - Insulator Caps

Page 4C-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

Installation
1. Position alternator in mounting bracket and install mounting bolts. Torque to 35 lb-ft
(48 Nm).

a
b 75713

Typical Models
a - Bracket
b - Bolts

2. Position alternator drive belt on pulleys and adjust tension as explained under “Drive
Belt Tension Adjustment,” preceding.
3. Reconnect wiring harness to alternator.

a 72838

a - Excitation Lead -(PURPLE)

b - Sensing Lead - (RED / PURPLE)
c - Ground Lead - (BLACK)
d - Output Lead - (ORANGE)

4. Attach wires to engine with clip.

76093

5. Connect negative battery cable to battery.

90-861328--1 NOVEMBER 1999 Page 4C-25

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

Pulley Removal
1. Remove serpentine belt.
2. Clamp pulley in a vise (using an old belt or protective jaws to protect pulley) to remove
nut.

72828

a - Old Belt to Protect Pulley

3. Slide components off of alternator shaft.

4. Install components and pulley on alternator shaft.
5. Torque pulley adjustment nut to specifications.

Page 4C-26 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

Battery Isolator Diagram

a b

h
B2 A B1

c 2 2 2
d

c 1

d
f

72934

a - Circuit Breaker
b - Harness Connector
c - Alternator
d - Starter
e - Cranking Battery
f - Ground Stud
g - Auxiliary Battery
h - 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

90-861328--1 NOVEMBER 1999 Page 4C-27

CHARGING SYSTEM SERVICE MANUAL NUMBER 25

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Page 4C-28 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CHARGING SYSTEM

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CHARGING SYSTEM SERVICE MANUAL NUMBER 25

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Page 4C-30 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

ELECTRICAL SYSTEM
Section 4D - Instrumentation
Table of Contents
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-9
Lubricants / Sealants / Adhesives . . . . . 4D-2 Oil Pressure . . . . . . . . . . . . . . . . . . . . . 4D-9
Identification . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 Water Temperature . . . . . . . . . . . . . . . 4D-10
Special Information . . . . . . . . . . . . . . . . . . 4D-3 Fuel Tank Sender . . . . . . . . . . . . . . . . . 4D-13
Lighting Options . . . . . . . . . . . . . . . . . . 4D-3 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-16
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5 Ignition Key Switch . . . . . . . . . . . . . . . 4D-16
Oil, Fuel and Temperature . . . . . . . . . 4D-5 Lanyard Stop Switches . . . . . . . . . . . . 4D-17
Battery Gauge . . . . . . . . . . . . . . . . . . .
Cruiselog Meter . . . . . . . . . . . . . . . . . .
4D-6
4D-7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . .
Start/Stop Switch . . . . . . . . . . . . . . . . .
4D-17
4D-19 4
Vacuum Gauge . . . . . . . . . . . . . . . . . . .
Speedometer . . . . . . . . . . . . . . . . . . . .
4D-7
4D-8
Audio Warning System . . . . . . . . . . . . . . .
Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . .
4D-20
4D-20
D
Tachometer . . . . . . . . . . . . . . . . . . . . . . 4D-8 Oil Pressure Switch . . . . . . . . . . . . . . . 4D-21
Gauge Replacement . . . . . . . . . . . . . . 4D-8 Water Temperature Switch . . . . . . . . . 4D-21

90-861328--1 NOVEMBER 1999 Page 4D-1

INSTRUMENTATION SERVICE MANUAL NUMBER 25

Tools
Description Part Number
Voltmeter
Ohmmeter
Obtain Locally
Service Tachometer
Continuity Meter

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver Liquid Neoprene 92-25711--3
Loctite Pipe Sealant with Teflon Obtain Locally

Identification
NOTE: One of three distinct lines (Series) of Quicksilver gauges may be installed (if
equipped with Quicksilver gauges). Aside from different gauge face appearances and
styling, the back of the gauges and wiring connections are different as shown.

72746

Back of Commodore and International Series Gauge - Typical

72965

Back of QSI Series Gauge - Typical

Page 4D-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

Special Information
Lighting Options

COMMODORE AND INTERNATIONAL SERIES

These gauges may be wired so that the illumination lighting is provided from the ignition
switch or a separate instrumentation lighting switch.
By removing contact strip “I” from between + terminal and the screw as shown following, and
supplying a separate +12 V power supply to the screw connection, illumination lights can
be operated independent of ignition switch.

a 72966

Ignition Switch Lighting Circuit

a - Positive (+) 12 Volt Power Supply From Ignition Switch
b - Contact Strip “I”
c - Screw Connection

b 72967

Separate Instrumentation Lighting Circuit Wiring

a - Positive (+) 12 Volt Power Supply From Ignition Switch
b - Contact Strip “I”
c - Screw Connection

90-861328--1 NOVEMBER 1999 Page 4D-3

INSTRUMENTATION SERVICE MANUAL NUMBER 25

QSI SERIES
These gauges are equipped with optional illumination lighting. Light bulb socket can be
removed and contacts can be aligned to be used with ignition switch lighting circuit +12 V
or separate instrumentation lighting circuit LT.
IMPORTANT: Light socket must be removed from gauge and turned counterclock-
wise (facing back of gauge) when adjusting to desired setting. Turning socket while
still installed in gauge could result in damage to gauge or socket.
NOTE: For different lighting effects, colored sleeves are available through the Quicksilver
Accessories and can be assembled to the bulb.

a
72968

Ignition Switch Lighting Circuit Position

a - Positive (+) 12 Volt Power Supply From Ignition Switch

72969

Separate Instrumentation Lighting Circuit Position

a - Positive (+) 12 Volt Power Supply From Ignition
b - Positive (+) 12 Volt Power Supply From Separate Instrumentation Lighting
Circuit

Page 4D-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

Gauges
Oil, Fuel and Temperature
IMPORTANT: If testing proves gauge to be defective, it must be replaced as there is
no repair available.

TESTING
1. Turn ignition switch to OFF.
2. Remove wire from terminal S (SEND).

a 72965

Typical
a - Terminal S (SEND)

3. Turn ignition switch to RUN. Gauge being tested must be at position A.

72747

Position A (Typical)

4. Turn ignition switch to OFF.

5. Connect jumper wire from terminal G (GND) to terminal S (SEND).

72748

Typical

90-861328--1 NOVEMBER 1999 Page 4D-5

INSTRUMENTATION SERVICE MANUAL NUMBER 25

6. Turn ignition switch to RUN.

7. Indicator needle of gauge being tested must read at position B. If not, replace gauge.

72749

Position B (Typical)

Battery Gauge

TESTING
1. Remove cables from battery and fully charge battery.
2. Connect negative (–) jumper lead from battery to gauge terminal G (GND).
3. Connect positive (+) jumper lead from battery to gauge terminal I or +12 V.

72750

Typical

4. Check gauge reading; if not as shown replace gauge.

72751

Typical

Page 4D-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

Cruiselog Meter

TESTING
1. Connect jumper wire from positive (+) battery terminal to positive (+) gauge terminal.
2. Connect jumper wire from negative (–) battery terminal to negative (–) gauge terminal.

72752

3. Observe gauge run indicator. If indicator is turning, gauge is operable. If not, replace
gauge.

a
72753

a - Indicator

Vacuum Gauge

TESTING
1. Disconnect vacuum hose from engine. Connect service vacuum gauge to engine and
record engine vacuum readings at idle, 1000, 2000 and 3000 rpm. Reconnect vacuum
hose and compare vacuum gauge readings (at specified rpm) with service gauge
readings. Readings should be within 3 inches of vacuum of each other.
IMPORTANT: Make sure that vacuum hose between gauge and engine is not leaking
and that all connections are tight.
2. If gauge readings are not within specifications, gauge is defective.

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INSTRUMENTATION SERVICE MANUAL NUMBER 25

Speedometer

TESTING
IMPORTANT: When testing speedometer gauge for accuracy, the air supply used for
the test must be regulated to the specified air pressure. Do not apply excessive air
pressure to speedometer gauge.
1. Apply air pressure directly to speedometer gauge (specified in chart) and note gauge
reading. Light tapping of pressure gauge is required during accuracy check.
2. If gauge readings are not within specifications, gauge is defective.

CALIBRATION CHART

Air Pressure Gauge psi Speedometer Gauge MPH (km/Hr)

5.3 20±2 (32±1.6)
27.8 45±1 (72±1.6)

Tachometer

TESTING
1. Connect a service tachometer to engine and compare readings.
2. Replace if not within specifications.

Tachometer Allowance
6000 rpm ± 150 rpm
8000 rpm ± 200 rpm

Gauge Replacement
1. Disconnect battery cables from battery.
2. Remove wires from back of gauge.
3. Remove hoses (vacuum, speedometer gauge).
4. Disconnect light socket.
5. Remove holding strap and remove gauge.
6. Position gauge assembly in appropriate mounting hole.
7. Install holding strap and nuts. Tighten nuts evenly and securely.
IMPORTANT: Do not distort case or bracket by overtightening.
8. Connect ground (BLK) wire to ground terminal, if gauge is not mounted in metal panel.
9. Connect other wires to gauge as shown in SECTION 4E.
10. Connect hoses (vacuum, speedometer gauges).
11. Install gauge light socket.
12. Coat all terminals with Quicksilver Liquid Neoprene.
13. Reconnect battery cables to battery.

Page 4D-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

Senders
Oil Pressure

TESTING
IMPORTANT: Use following test procedure for checking accuracy of oil pressure
sender only. If oil pressure gauge indicates zero oil pressure, refer to SECTION 1C
“Troubleshooting.”
1. Remove wire from sender terminal.
2. Connect ohmmeter between sender terminal and sender case. Check ohms reading
without engine running (zero pressure), then check reading with engine running.
Compare oil pressure and ohms readings as shown in following chart:

d
b
c

72754

a - Positive Lead
b - Negative Lead
c - Wire Removed
d - Oil Pressure Sender

Oil Ohms Reading

Pressure
(psi) Single Dual
0 227-257 113.5-128.5
20 142-162.5 71-81.25
40 91.7-113.6 45.8-56.8
80 9-49 4.5-24.5

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INSTRUMENTATION SERVICE MANUAL NUMBER 25

Water Temperature

REMOVAL
1. Drain coolant from closed cooling system into a suitable container as outlined in
SECTION 6B.
2. Remove TAN wire from temperature sender.

a b
75846

a - TAN Wire
b - Water Temperature Sender

TESTING
1. Connect an ohmmeter between temperature sender terminal (+) and hex (case) for
ground (–) as shown.

b
72768

a - Ohmmeter Leads
b - Water Temperature Sender

Page 4D-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

WARNING
The following test involves the use of intense heat. Failure to follow appropriate
procedures or warnings can cause burns which can result in severe personal injury.
While performing the following test, observe these general precautions:
• Wear personal protective clothing such as rubber gloves, a non-flammable
apron, and eye protection - preferably full face shield or safety glasses.
• The appropriate heat source should only be electric. Heat source should be
operated by a qualified person. Be sure to follow all instructions of the
manufacturer of the heat source. The heat source should be checked each time
it is used to be sure it is functioning properly.
• The thermometer used in the test should be a high-temperature thermometer
with a maximum reading of at least 300°F (150°C). Under no circumstances
should the operator allow temperatures to exceed test specifications.
• Perform test only in a well ventilated area.
• Use a suitable container, such as metal, to hold the water. Avoid use of glass
containers unless the operator first confirms for himself/herself that the glass
container is an appropriate high-temperature vessel.
• Because the components will reach high temperatures DO NOT handle
materials or components until COMPLETELY cooled.
2. Follow these instructions:
a. With ohmmeter connected as outlined and using suitable container, thermometer
and heat source, suspend sender with tip in water.
b. Heat water and observe thermometer.
c. As temperature rises ohmmeter readings must be within the ranges specified for
each temperature (see chart below).

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INSTRUMENTATION SERVICE MANUAL NUMBER 25

d. Turn heat source off. Allow water and components to cool.

NOTE: While water cools you may recheck ohmmeter readings.

e
d b

c
72769

a - Suitable Container
b - Thermometer
c - Heat Source
d - Water Temperature
e - Ohmmeter Leads

Water Temperature Ohms Reading

140° F (60° C) 121-147
194° F (90° C) 47-55
212° F (100° C) 36-41

3. Replace sender if ohmmeter readings are other than as shown for each temperature.

Page 4D-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

INSTALLATION
1. Apply Loctite Pipe Sealant with Teflon to threads of temperature sender.
2. Install sender in thermostat housing and tighten securely.

a b
75846

a - TAN Wire
b - Water Temperature Sender

3. Connect tan wire and coat with Liquid Neoprene.

4. Refill closed cooling system with approved coolant as outlined in SECTION 6B.

Fuel Tank Sender

FLANGE TYPE
Testing
1. Disconnect wire from terminal on sending unit and ground wire from sending unit
mounting screw.
2. Remove sending unit from fuel tank.
3. Connect ohmmeter between sending unit terminal and sending unit housing.
4. With float arm in FULL position (arm horizontal), ohmmeter should read 30 ohms (+ 5
ohms).

72755
b
a - Ohmmeter Leads
b - Vertical Float Arm

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INSTRUMENTATION SERVICE MANUAL NUMBER 25

5. With float arm in EMPTY position (arm vertical) meter should read 240 ohms (+ 5 ohms).
Sender is defective if not within specifications.

72756

a - Ohmmeter Leads
b - Vertical Float Arm

CAPSULE TYPE
Testing
1. Disconnect wire from terminal on fuel tank capsule.
2. Remove two screws and remove capsule assembly.
3. Place a magnet under fuel capsule.
4. Connect ohmmeter between fuel capsule terminal and metal portion of capsule housing.

c 72757

a - Ohmmeter Leads
b - Capsule Assembly
c - Magnet

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SERVICE MANUAL NUMBER 25 INSTRUMENTATION

5. Turn magnet counterclockwise until fuel capsule indicator reads EMPTY. Ohmmeter
should read 240 ohms (+ 5 ohms).

72758

a - Capsule Reading Empty

6. Turn magnet clockwise until fuel capsule indicator reads FULL. Ohmmeter should read
30 ohms (+ 5 ohms). Fuel capsule is defective if not within specifications.

72759

a - Capsule Reading Full

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INSTRUMENTATION SERVICE MANUAL NUMBER 25

Switches
Ignition Key Switch

TESTING

CAUTION
Disconnect battery cables from battery before testing ignition key switch with wires
still connected to switch.
1. Disconnect battery cables, if testing ignition key switch with wires connected to switch.
2. With key switch in OFF position, there should be no continuity between switch terminals.
3. With key switch in RUN position, continuity will exist between switch terminals B to I.
There should no continuity between terminal S and any other terminals.
4. With key switch in START, continuity will exist between terminals B to I and B to S.
5. Terminals are to make contact at angles shown and to stay in contact condition as switch
is rotated toward START.
6. If ignition key switch tests bad, disconnect wire connections and remove switch. Test
switch again, as in Steps 2-5, preceding. If switch tests good, wiring in harness is bad,
There should be no continuity between any harness wires with key switch removed.

f
e
d
c

a b

B
S
I
72760

Key View Back View

a - Key
b - Off
c - Continuity, B to I Terminals
d - Run
e - Continuity B to S Terminals
f - Start

Page 4D-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

Lanyard Stop Switches

Testing

74061

Remote Control Mounted Style Switch

Electronic Fuel Injection (EFI) Engines
a - Switch Lanyard
b - Leads (BLK/YEL)

1. Disconnect switch leads.

2. Test switch as follows.
a. Connect an ohmmeter to leads.
b. There should be no continuity with switch lanyard connected and continuity with
switch lanyard disconnected.

b
a

74062

Remote Control Mounted Style Switch

Carbureted Engines
a - Switch Leads
b - Leads (PUR)

90-861328--1 NOVEMBER 1999 Page 4D-17

INSTRUMENTATION SERVICE MANUAL NUMBER 25

3. Disconnect switch leads.

4. Test switch as follows:
a. Connect an ohmmeter to leads.
b. There should be continuity with switch lanyard connected and no continuity with
switch lanyard disconnected.

72762

Toggle Style Switch

a - Switch Cap
b - Switch

IMPORTANT: The BLK/YEL lead is not used. It should be well insulated and taped to
harness.
5. Disconnect switch leads.
6. Connect an ohmmeter to switch leads.
7. Switch should have continuity with toggle in the RUN position and no continuity with
toggle in the OFF position.

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SERVICE MANUAL NUMBER 25 INSTRUMENTATION

Start/Stop Switch

TESTING

WARNING
Disconnect battery leads at battery before testing.
1. Disconnect battery leads.
2. Check for continuity between the terminals on the start switch with a continuity meter.

72763

3. No continuity should exist.

4. Depress switch button and continuity should exist.
5. Check stop switch in the same manner.
6. If continuity exists when in the OPEN (not depressed) state, replace panel button.

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INSTRUMENTATION SERVICE MANUAL NUMBER 25

Audio Warning System

NOTICE
For repair procedures on fuel injected engines, refer to SECTION 5.

Buzzer
WARNING
The following test involves the use of electricity. Failure to follow appropriate
procedures can cause burns or shock which can result in severe personal injury or
death.

TESTING
1. Turn the ignition switch to the ON position without cranking the engine. The horn will
sound if the system is working correctly.
2. If horn does not sound:
a. Connect jumper wires as shown.
b. If horn does not sound, replace it.
3. If horn worked in Step 3:
a. Connect jumper wires as shown.
b. Repeat Step 2.
c. If horn sounds, problem is in TAN/BLUE wire back to engine or switches on engine.

74046

Page 4D-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

Oil Pressure Switch

TESTING
1. Remove wire from sender terminal.
2. Connect continuity meter between sender terminal and sender hex. (Sender shown re-
moved for clarity.)

72764

3. With engine not running, meter should indicate full continuity.

4. Start engine. With engine running and engine oil pressure above 6 psi (41 kPa), meter
should indicate no continuity.

Water Temperature Switch

REMOVAL
1. If equipped with closed cooling, drain coolant from closed cooling system into a suitable
container. Refer to SECTION 6B.
2. Remove TAN wire from temperature switch.

a b
72611

Seawater Cooled Model Shown, Closed Cooled Similar Location

a - TAN Wire
b - Water Temperature Switch

3. Remove switch.

90-861328--1 NOVEMBER 1999 Page 4D-21

INSTRUMENTATION SERVICE MANUAL NUMBER 25

TESTING
1. Connect an ohmmeter between water temperature switch terminal (+) and hex (case)
for ground (–) as shown.

a
72765

a - Ohmmeter Leads
b - Water Temperature Switch

2. Switch should read no continuity.

WARNING
The following test involves the use of intense heat. Failure to follow appropriate
procedures or warnings can cause burns which can result in severe personal injury.
While performing the following test, observe these general precautions:
• Wear personal protective clothing such as rubber gloves, a non-flammable
apron, and eye protection - preferably full face shield or safety glasses.
• The appropriate heat source should only be electric. Heat source should be
operated by a qualified person. Be sure to follow all instructions of the
manufacturer of the heat source. The heat source should be checked each time
it is used to be sure it is functioning properly.
• The thermometer used in the test should be a high- temperature thermometer
with a maximum reading of at least 300°F (150°C). Under no circumstances
should the operator allow temperatures to exceed test specifications.
• Perform test only in a well ventilated area.
• Use a suitable container, such as metal, to hold the sand. Avoid use of glass
containers unless the operator first confirms for himself/herself that the glass
container is an appropriate high-temperature vessel.
• Because the components will reach high temperatures DO NOT handle
materials or components until COMPLETELY cooled.

WARNING
Use only clean, dry sand such as used for general sandblasting purposes. Use of
sand containing contaminants could result in hazards such as fire, short circuiting,
hot-spots, or other hazards.
3. With an ohmmeter connected as outlined and using suitable container, thermometer
and heat source, suspend sender with tip in sand.

Page 4D-22 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

4. Heat sand and observe temperature on thermometer.

e b
d

a
c
72766

a - Suitable Container
b - Thermometer
c - Heat Source
d - Water Temperature Switch
e - Ohmmeter Leads

5. As temperature rises, switch will close and ohmmeter will indicate continuity. Refer to
chart below for specifications.

Coolant Temperature Switch

Opens Closes
48952 Switch 150-170°F (66-77°C) 190-200°F (88-93°C)
87-86080 Switch 175-195°F (79-91°C) 215-225°F (102-107°C)

a
b

72767

Switch Identification
a - 48952 Switch With Red Mylar Sleeve
b - 87-86080 Switch With Black Mylar Sleeve

6. Turn heat source off. Allow sand to cool. Note thermometer reading to ensure switch
“opens” up at specified temperature.
7. Replace switch if switch fails to either open or close within the specified temperatures.

90-861328--1 NOVEMBER 1999 Page 4D-23

INSTRUMENTATION SERVICE MANUAL NUMBER 25

INSTALLATION
1. Apply Loctite Pipe Sealant with Teflon to threads of water temperature switch.
2. Install switch in thermostat housing and tighten securely.
3. Connect TAN wire and coat connection with Liquid Neoprene.

a b
72611

Seawater Cooled Model Shown, Closed Cooled Similar Location

a - TAN Wire
b - Water Temperature Switch

4. If equipped with closed cooling, refill closed cooling system with approved coolant.
Refer to SECTION 6.

Page 4D-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 INSTRUMENTATION

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90-861328--1 NOVEMBER 1999 Page 4D-25

INSTRUMENTATION SERVICE MANUAL NUMBER 25

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Page 4D-26 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

ELECTRICAL SYSTEMS
Section 4E - Wiring Diagrams
Table of Contents
Wiring Colors for Mercury MerCruiser . . 4E-2
MCM Gasoline Engine Wiring Diagrams 4E-4
Starting and Charging Harness . . . . . 4E-4
Fuel and Ignition System Harnesses 4E-16
Quicksilver Instrumentation . . . . . . . . 4E-22
Dual Station Wiring . . . . . . . . . . . . . . . 4E-24

4
E

90-861328-–1 NOVEMBER 1999 Page 4E-1

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

Wiring Colors for Mercury MerCruiser

Note: Color codes listed below DO NOT apply to fuel injection system harnesses.

Color Code And Abbreviations Where Used

BLACK (BLK) All Grounds
BROWN (BLU) Reference Electrode - MerCathode
ORANGE (ORN) Anode Electrode - MerCathode
LT. BLUE/WHITE (LT BLU/WHT) Trim - “Up” Switch
GRAY (GRY) Tachometer Signal
GREEN/WHITE (GRN/WHT) Trim - “Down” Switch
TAN (TAN) Water Temperature Sender to Gauge
LIGHT BLUE (LIT BLU) Oil Pressure Sender to Gauge
PINK (PNK) Fuel Gauge Sender to Gauge
BROWN/WHITE (BRN/WHT) Trim Sender to Trim Gauge
PURPLE/WHITE (PUR/WHT) Trim - “Trailer” Switch
RED (RED) Unprotected Wires from Battery
RED/PURPLE (RED/PUR) Protected (Fused) Wires from Battery
RED/PURPLE (RED/PUR) Protected (+12V) to Trim Panel
ORANGE (ORN) Alternator Output
PURPLE/YELLOW (PUR/YEL) Ballast Bypass
PURPLE (PUR) Ignition Switch (+12V)
Starter Switch to Starter Solenoid to Neu-
YELLOW/RED (YEL/RED)
tral Start Switch

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90-861328-–1 NOVEMBER 1999 Page 4E-3

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

MCM Gasoline Engine Wiring Diagrams

Starting and Charging Harness
MCM 4.3L ALPHA ENGINES

A 1

1 3
4
C
2

3
3
1 2

1 B

7
4

5
75566

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SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

A - Ignition Components
1 - Distributor
2 - Timing Lead
3 - Shift Cutout Switch
4 - Ignition Coil
B - Starting, Charging and Choke Components
1 - Alternator
2 - Electric Choke
3 - Ground Stud
4 - Starter Motor
5 - Oil Pressure Switch
6 - Fuel Pump
7 - Fuse
8 - Starter Slave Solenoid
C - Audio Warning Components
1 - Oil Pressure Switch
2 - Drive Unit Gear Lube Monitor
3 - Water Temperature Sender
D - Instrumentation Components
1 - Oil Pressure Sender
2 - Water Temperature Sender
3 - Trim Sender

90-861328-–1 NOVEMBER 1999 Page 4E-5

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

MCM 4.3LH ALPHA ENGINES

1
A
2

C
2 4

3
3
2
1

1 B

4
7

2
3

5
75547

Page 4E-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

A - Ignition Components
1 - Distributor
2 - Timing Lead
3 - Shift Cutout Switch
4 - Ignition Coil
B - Starting, Charging and Choke Components
1 - Alternator
2 - Electric Choke
3 - Ground Stud
4 - Starter Motor
5 - Oil Pressure Switch
6 - Fuel Pump
7 - Circuit Breaker
8 - Starter Slave Solenoid
C - Audio Warning Components
1 - Oil Pressure Switch
2 - Drive Unit Gear Lube Monitor
3 - Water Temperature Sender
D - Instrumentation Components
1 - Oil Pressure Sender
2 - Water Temperature Sender
3 - Trim Sender

90-861328-–1 NOVEMBER 1999 Page 4E-7

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

MCM 4.3L AND 4.3LH BRAVO MODELS

1 2

1
3
3
C

3
1

2
D

1
8

4
7
B
3

2
5
75549

Page 4E-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

A - Ignition Components
1 - Distributor
2 - Timing Lead
3 - Ignition Coil
B - Starting, Charging and Choke Components
1 - Alternator
2 - Electric Choke
3 - Ground Stud
4 - Starter Motor
5 - Oil Pressure Switch
6 - Fuel Pump
7 - Circuit Breaker
8 - Starter Slave Solenoid
C - Audio Warning Components
1 - Oil Pressure Switch
2 - Drive Unit Gear Lube Monitor
3 - Water Temperature Sender
D - Instrumentation Components
1 - Oil Pressure Sender
2 - Water Temperature Sender
3 - Trim Sender

90-861328-–1 NOVEMBER 1999 Page 4E-9

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

MEFI 1 MCM 4.3L EFI ALPHA MODELS

A
2

B 3

1 2
c
5

3
90 Amp
Fuse
2
C a
75462

Page 4E-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

A - Audio Warning Components

1 - Oil Pressure Switch
2 - Drive Unit Oil Level
B - Instrumentation Components
1 - Oil Pressure Sender
2 - Water Temperature Sender
3 - Trim Sender
C - Charging and Starting Components
1 - Alternator
2 - Ground Stud
3 - Starter
4 - Circuit Breaker
5 - Starter Slave Solenoid

a - Positive Power Wire To EFI System Harness

b - Harness Connector To EFI System Harness
c - Auxiliary Tachometer Lead

90-861328-–1 NOVEMBER 1999 Page 4E-11

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

MEFI 1 MCM 4.3L EFI BRAVO MODELS

A
2

B 3

1 2
c
5

3
90 Amp
Fuse
2
C a
75462

Page 4E-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

A - Audio Warning Components

1 - Oil Pressure Switch
2 - Drive Unit Oil Level
B - Instrumentation Components
1 - Oil Pressure Sender
2 - Water Temperature Sender
3 - Trim Sender
C - Charging and Starting Components
1 - Alternator
2 - Ground Stud
3 - Starter
4 - Circuit Breaker
5 - Starter Slave Solenoid

a - Positive Power Wire To EFI System Harness

b - Harness Connector To EFI System Harness
c - Auxiliary Tachometer Lead

90-861328-–1 NOVEMBER 1999 Page 4E-13

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

MEFI 3 MCM 4.3L EFI ENGINES

A
1

2
1

4
1 5

C b

2 3 6

90 Amp
Fuse a
7

76061

Page 4E-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

A - Audio Warning Components

1 - Oil Pressure Switch
B - Instrumentation Components
1 - Oil Pressure Sender
2 - Trim Sender
C - Charging and Starting Components
1- Alternator
2- Ground Stud
3- Starter
4- Circuit Breaker
5- Starter Slave Solenoid
6- Jumper Wire Connection
7- Battery

a - Positive Power Wire To EFI System Harness

b - Harness Connector To EFI System Harness
c - Auxiliary Tachometer Lead

90-861328-–1 NOVEMBER 1999 Page 4E-15

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

Fuel and Ignition System Harnesses

MEFI 1 MCM 4.3L EFI ALPHA

Note: All BLACK wires with a ground symbol are interconnected within the EFI system
harness.
Note: Component position and orientation shown is arranged for visual clarity and ease of
circuit identification.

3 18

8
4 12

9
10

2
6

11 5
15
14
16
13
17

1 75463

Page 4E-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

1 - Fuel Pump
2 - Throttle Body
3 - Distributor
4 - Coil
5 - Electronic Spark Control (KS) Module
6 - Data Link Connector (DLC)
7 - Manifold Absolute Pressure (MAP) Sensor
8 - Knock Sensor
9 - Idle Air Control (IAC)
10 - Throttle Position (TP) Sensor
11 - Engine Coolant Temperature (ECT) Sensor
12 - Electronic Control Module (ECM)
13 - Fuel Pump Relay
14 - Ignition/System Relay
15 - Fuse (15 Amp) Fuel Pump
Fuse (15 Amp) ECM/DLC/Battery
Fuse (10 Amp) ECM/Injector/Ignition/Knock Module
16 - Harness Connector To Starting/Charging Harness
17 - Positive (+) Power Wire To Engine Circuit Breaker
18 - Shift Cutout Switch

90-861328-–1 NOVEMBER 1999 Page 4E-17

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

MEFI 1 MCM 4.3L EFI BRAVO MODELS

Note: All BLACK wires with a ground symbol are interconnected within the EFI system
harness.
Note: Component position and orientation shown is arranged for visual clarity and ease of
circuit identification.

8
4 12

9
10

2
6

11 5 15
14
16
13
17

1
75464

Page 4E-18 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

1 - Fuel Pump
2 - Throttle Body
3 - Distributor
4 - Coil
5 - Electronic Spark Control (KS) Module
6 - Data Link Connector (DLC)
7 - Manifold Absolute Pressure (MAP) Sensor
8 - Knock Sensor
9 - Idle Air Control (IAC)
10 - Throttle Position (TP) Sensor
11 - Engine Coolant Temperature (ECT) Sensor
12 - Electronic Control Module (ECM)
13 - Fuel Pump Relay
14 - Ignition/System Relay
15 - Fuse (15 Amp) Fuel Pump
Fuse (15 Amp) ECM/DLC/Battery
Fuse (10 Amp) ECM/Injector/Ignition/Knock Module
16 - Harness Connector To Starting/Charging Harness
17 - Positive (+) Power Wire To Engine Circuit Breaker

90-861328-–1 NOVEMBER 1999 Page 4E-19

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

MEFI 3 4.3L EFI ENGINES

Note: All BLACK wires with a ground symbol are interconnected within the EFI system har-
ness.
Note: Component position and orientation shown is arranged for visual clarity and ease of
circuit identification.

22 21

17

7 5

9 12

10

20

6
2
13

11 8
16
15
18
14
19

1
(+) (–)

4 3

76063

Page 4E-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

1 - Fuel Pump
2 - Throttle Body
3 - Distributor
4 - Coil
5 - Manifold Air Temperature (MAT) Sensor
6 - Data Link Connector (DLC)
7 - Manifold Absolute Pressure (MAP) Sensor
8 - Knock Sensor
9 - Idle Air Control (IAC)
10 - Throttle Position (TP) Sensor
11 - Engine Coolant Temperature (ECT) Sensor
12 - Electronic Control Module (ECM)
13 - Water Temperature Sender
14 - Fuel Pump Relay
15 - Ignition/System Relay
16 - Fuses (15 Amp) Fuel Pump, (15 Amp) ECM/DLC/Battery, (10 Amp) ECM/Injec-
tor/Ignition/Knock Module
17 - Oil Pressure Sensor
18 - Harness Connector To Starting/Charging Harness
19 - Positive (+) Power Wire To Engine Circuit Breaker
20 - Shift Plate (Alpha Models)
21 - Gear Lube Monitor
22 - Fuel Pressure Switch

90-861328-–1 NOVEMBER 1999 Page 4E-21

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

Quicksilver Instrumentation
Note: Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene
to connection and slide rubber sleeve over connection.
Note: Power for a second fused accessory panel may be taken from this connection. Load
MUST NOT exceed 35-40 amps. Panel ground wire MUST BE connected to instrument
terminal that has an 8 gauge BLACK (ground) harness wire connected to it.

To Engine Harness
1
3 4 5

6 NOTE 2

9 NOTE 1

7
NOTE 1

NOTE 1

74046

1 - Tachometer
2 - Audio Warning Buzzer (if Equipped)
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
6 - Ignition Switch
7 - Trim Indicator
8 - To 12 Volt Source (PURPLE wire connection)
9 - 20 Ampere Fuse

Page 4E-22 90-861328--1 NOVEMBER 1999

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90-861328-–1 NOVEMBER 1999 Page 4E-23

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

Dual Station Wiring (Using a Neutral Safety Switch in Only One Remote
Control)

A 2
1 3 4 5

L GND
T SW
UNSW GND
L GND L GND L
12V
T 12V T 12V T 12V

SEND SEND SEND

SIG

PUR

GRY

LT. BLU

PUR
PUR

PUR

BLK
BLK
BLK
BLK

BLK

TAN
YEL/RED

GRY
PUR

NOTE 3
YEL/RED
NOTE 1

1 2 3 5
RED/PUR 4 BRN/WHT
GND
L
B T SW UNSW
SI GND L GND GND
L L
12V T T
12V 12V T 12V

SEND SEND SEND

SIG

ORN
PUR
PUR

TAN
BLK
BLK

LT. BLU

RED/PUR
BLK
YEL/RED

ORN

BLK
GRY
PUR

NOTE 2
PUR

PUR

YEL/RED

NOTE 3
NOTE 3

NOTE 3
NOTE 1
BRN/WHT
YEL/RED
B YEL/RED 6
72940

Note: BROWN/WHITE wire is taped back at instrument end. If installing on boat that is
equipped with MerCruiser stern drive, BROWN/WHITE wire is connected to trim sender
terminal block. If installing on MerCruiser Inboard, BROWN/WHITE wire is taped back at
engine end, or it may be used for an accessory (limit 5 amperes).
Note: An accessory fuse panel may be connected at this location. The combined current
draw of the primary station and secondary station MUST NOT exceed 35 amperes.
Note: Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene
to connection and slide rubber sleeve over connection.

Page 4E-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

A - Secondary Station
1 - Stop -Start Panel
2 - Tachometer
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
B - Primary Station
1 - Ignition Switch
2 - Tachometer
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
6 - To Engine
7 - 20 Ampere Fuse

90-861328-–1 NOVEMBER 1999 Page 4E-25

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

Dual Station Wiring (Using A Neutral Safety Switch In Both Remote Controls)

A
1 2 3 4 5

L GND
T SW
UNSW L
L L GND GND
12V GND T
T T
12V 12V 12V

SEND SEND SEND

SIG

PUR

YEL/RED
GRY

LT. BLU

PUR
PUR

PUR

BLK
BLK
BLK
BLK

BLK

TAN
YEL/RED

GRY
PUR

NOTE 3
NOTE 3
YEL/RED NOTE 1

1 2 3 5
RED/PUR 4 BRN/WHT
GND
L
B T SW UNSW
S L GND L GND L GND
I T
12V T 12V T 12V
12V

7 SIG
SEND SEND SEND

ORN
BLK

RED/PUR
PUR
PUR

TAN
LT. BLU
BLK

BLK
GRY
YEL/RED

PUR

NOTE 2
ORN

BLK
PUR
PUR
6

NOTE 3

YEL/RED
NOTE 1 YEL/RED
NOTE 3 BRN/WHT NOTE 3
B YEL/RED
YEL/RED
72941

Note: BROWN/WHITE wire is taped back at instrument end. If installing on boat that is
equipped with MerCruiser stern drive, BROWN/WHITE wire is connected to trim sender ter-
minal block. If installing on MerCruiser Inboard, BROWN/WHITE wire is taped back at en-
gine end, or it may be used for an accessory (limit 5 amperes).
Note: An accessory fuse panel may be connected at this location. The combined current
draw of the primary station and secondary station MUST NOT exceed 35 amperes.
Note: Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene
to connection and slide rubber sleeve over connection.

Page 4E-26 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

A - Secondary Station
1 - Stop -Start Panel
2 - Tachometer
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
B - Primary Station
1 - Ignition Switch
2 - Tachometer
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
6 - To Engine
7 - 20 Ampere Fuse

90-861328-–1 NOVEMBER 1999 Page 4E-27

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

Dual Station Wiring (Using a Neutral Safety Switch in Engine Wiring Harness)

A
1 2 3 4 5

L GND
T SW
UNSW
L L GND L GND
12V GND T
T T
12V 12V 12V

SEND SEND SEND

SIG

PUR

GRY
1

LT. BLU

PUR
PUR

PUR

BLK
BLK
BLK
BLK

BLK

TAN
YEL/RED

GRY
PUR

NOTE 3
YEL/RED NOTE 1

1 2 3 5
RED/PUR
4 BRN/WHT
GND
L
B T SW UNSW
S L GND L GND L GND
I T T
12V 12V T 12V
12V

7 SIG
SEND SEND SEND

ORN
BLK
BLK

PUR
PUR

TAN
LT. BLU

RED/PUR
BLK
PUR
GRY
YEL/RED

ORN

BLK
PUR NOTE 2
PUR

6
YEL/RED

NOTE 3
NOTE 3

NOTE 1 YEL/RED
BRN/WHT NOTE 3
B

72942

Note: BROWN/WHITE wire is taped back at instrument end. If installing on boat that is
equipped with MerCruiser stern drive, BROWN/WHITE wire is connected to trim sender ter-
minal block. If installing on MerCruiser Inboard, BROWN/WHITE wire is taped back at en-
gine end, or it may be used for an accessory (limit 5 amperes).
Note: An accessory fuse panel may be connected at this location. The combined current
draw of the primary station and secondary station MUST NOT exceed 35 amperes.
Note: Connect wires together with screw and hex nut. Apply Quicksilver Liquid Neoprene
to connection and slide rubber sleeve over connection.

Page 4E-28 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WIRING DIAGRAMS

A - Secondary Station
1 - Stop -Start Panel
2 - Tachometer
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
B - Primary Station
1 - Ignition Switch
2 - Tachometer
3 - Oil Pressure
4 - Water Temperature
5 - Battery Meter
6 - To Engine
7 - 20 Ampere Fuse

90-861328-–1 NOVEMBER 1999 Page 4E-29

WIRING DIAGRAMS SERVICE MANUAL NUMBER 25

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Page 4E-30 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES

FUEL SYSTEM
Section 5A - Fuel Delivery System For Carbureted Engines
Table of Contents
Identification . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Fuel Delivery System . . . . . . . . . . . . . . . . 5A-4
Replacement Parts Warning . . . . . . . . . . 5A-2 Recommendations . . . . . . . . . . . . . . . . 5A-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Fuel System Components . . . . . . . . . . . . 5A-6
Torque Specifications . . . . . . . . . . . . . . . . 5A-2 Water Separating Fuel Filter . . . . . . . . . . 5A-7
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 Replacement . . . . . . . . . . . . . . . . . . . . . 5A-8
Lubricants / Sealants / Adhesives . . . . . 5A-3 Vent Hose Routing . . . . . . . . . . . . . . . . . . 5A-8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 Carbureted Models . . . . . . . . . . . . . . . 5A-8
Fuel Supply Connections . . . . . . . . . . 5A-3

5
A

90-861328--1 NOVEMBER 1999 Page 5A-1

FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES SERVICE MANUAL NUMBER 25

Identification

75523

a - Fuel Pump

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 mini-
mize 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.

Specifications
Description Specification
Pump Pressure 3-7 PSI (21-48 kPa)

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Fuel Lines 18 24
Fuel Fittings Into Adapter See Note

NOTE: Refer To “Fuel Supply Connections” Warning following this chart.

Page 5A-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES

Tools
Description Part Number
Fuel Pressure Connector (Carburetor) 91-18078
Fuel Pressure Gauge Obtain Locally

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver Perfect Seal 92-34227--1
#592 Loctite Pipe Sealant with Teflon Obtain Locally

Precautions
WARNING
Always disconnect battery cables from battery BEFORE working on fuel system to
prevent fire or explosion.

WARNING
Be careful when changing fuel system components; gasoline is extremely flam-
mable 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. 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.

90-861328--1 NOVEMBER 1999 Page 5A-3

FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES SERVICE MANUAL NUMBER 25

Fuel Delivery System

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

GENERAL

The fuel tank is an integrated component of the boat. Refer to the special information on
service and maintenance that you have received from the tank manufacturer.
Only a few points related to function and safety are listed here. Refer to boating standards
(NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines:
• All connections should be on the upper side of the tank.
• The drain plug at the lowest point on the tank serves to permit the removal of water and
sediment.
• The filler pipe outer diameter should be at least 2 in. (51 mm).
• The tank breather pipe must have an inner diameter of at least 1/2 in. (13mm) and must
be fitted with a swan neck to prevent water from entering the tank.
It is recommended that the exact route and length of the fuel lines be established at the first
installation of the engine to prevent problems later in connecting them to the engine.
All fuel lines must be well secured. The holes where the lines run 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 tank should be mounted below carburetor level (if possible) or gravity feed may
cause carburetor fuel inlet needle to unseat and flooding may result.
2. Fuel pickup should be at least 1 in. (25mm) from the bottom of fuel tank to prevent pick-
ing up impurities.
3. Fuel lines used must be Coast Guard approved (USCG Type A1).
Diameter of fittings and lines must not be smaller than 5/16 in. (8 mm) inside diameter (I.D.)
4. On Multi-Engine Installations: It is best to use a fuel pickup and supply line for each
engine. If a single pickup and line is used, line must not be smaller than 1/2 in. (13mm)
I.D.

Page 5A-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES

5. Larger diameter (than previously specified) lines and fittings must be used on installa-
tions requiring long lines or numerous fittings.
6. Fuel line(s) 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.

90-861328--1 NOVEMBER 1999 Page 5A-5

FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES SERVICE MANUAL NUMBER 25

Fuel System Components

d 75869

a - Fuel Line to Carburetor

b - Fuel Pump
c - Fuel Line to Fuel Pump
d - Water Separating Fuel Filter
e - Fuel Filter Base
f - Carburetor

Page 5A-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES

Water Separating Fuel Filter

The water separating fuel filter is standard on all engines.
The fuel filter consists of the fuel filter base and filter element.

72678

a - Fuel Filter Mounting Bracket

b - Filter Element
c - Sealing Ring

90-861328--1 NOVEMBER 1999 Page 5A-7

FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES SERVICE MANUAL NUMBER 25

Replacement
NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

1. Disconnect battery cables from battery.

2. Remove fuel filter from base. A filter wrench may be needed to loosen element.
3. Lubricate sealing ring of new filter with SAE engine oil.
4. Install new filter, tightening securely by hand.
5. Reconnect battery cables.
6. Make sure water is supplied to cooling system.
7. Start engine.
8. Check for fuel leaks.

Vent Hose Routing

Carbureted Models

d c

e f
75826

a - Carburetor
b - Flame Arrestor
c - PCV Valve
d - Vent Hose - PCV Valve to Back Of Carburetor
e - Vent Hose - Valve Cover Fitting To Flame Arrestor
f - Valve Cover Fitting
g - Front of Engine

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FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES SERVICE MANUAL NUMBER 25

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Page 5A-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

FUEL SYSTEM
Section 5B - Mercarb 2 Barrel Carburetor
Table of Contents
Identification . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 5B-11
Replacement Parts Warning . . . . . . . . . . 5B-3 Flame Arrestor . . . . . . . . . . . . . . . . . . . 5B-11
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5B-3 Fuel Inlet Filter . . . . . . . . . . . . . . . . . . . 5B-13
Torque Specifications . . . . . . . . . . . . . . . . 5B-3 Choke Inspection . . . . . . . . . . . . . . . . . 5B-14
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Accelerator Rod . . . . . . . . . . . . . . . . . . 5B-14
Exploded View . . . . . . . . . . . . . . . . . . . . . . 5B-6 Choke Setting . . . . . . . . . . . . . . . . . . . . 5B-16
Important Service Information . . . . . . . . . 5B-8 Choke Unloader . . . . . . . . . . . . . . . . . . 5B-17
High Altitude Re-Jetting . . . . . . . . . . . 5B-8 Initial Idle Speed and Mixture . . . . . . . 5B-17
8 Point Carburetor Check List . . . . . . 5B-9 Final Idle Speed and Mixture . . . . . . . 5B-18
Flooding At Idle RPM . . . . . . . . . . . . . 5B-9 Replacing Carburetor . . . . . . . . . . . . . . . . 5B-18
Needle / Seat Change . . . . . . . . . . . . . 5B-9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-19
Adjustable Accelerator Pump Lever .
Description . . . . . . . . . . . . . . . . . . . . . . . . .
5B-10
5B-10
Removal . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . .
5B-19
5B-20
5
Cleaning and Inspection . . . . . . . . . . . 5B-28 B
Reassembly . . . . . . . . . . . . . . . . . . . . . 5B-30
Installation . . . . . . . . . . . . . . . . . . . . . . . 5B-40

90-861328--1 NOVEMBER 1999 Page 5B-1

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Identification

33049565
2301
a
b

72680

2 Barrel MerCarb Carburetor Part Number Location

a - Part Number
b - Date Code
Date Code Explanation: Example 2301
First Figure is Year:
2 = 1992, 3 = 1993, etc.
Second Figure is Month:
2 = February, 3 = March, etc.
X = October, Y = November, Z = December
Third and Fourth Figures are Day of Month:
01 = First day, 02 = Second day, etc.

b
72779

Venturi Cluster Identification

a - Identification Number (See Specifications)
b - Accelerator Pump Discharge Holes

Page 5B-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

Replacement Parts Warning

WARNING
Electrical, ignition and fuel system components on your Mercury MerCruiser are
designed and manufactured to comply with U.S. Coast Guard Rules and Regula-
tions to minimize risks of fire and explosion.
Use of replacement electrical, ignition or fuel system components, that do not com-
ply with these rules and regulations could result in a fire or explosion hazard and
should be avoided.

Precautions
WARNING
Always disconnect battery cables from battery BEFORE working on fuel system to
prevent fire or explosion.

WARNING
Be careful when cleaning flame arrestor and crankcase ventilation hose; 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 open flame in area
when cleaning flame arrestor and crankcase ventilation hose.

WARNING
Be careful when changing fuel system components; gasoline is extremely flam-
mable 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 filter. Wipe up any spilled fuel immediately.

WARNING
Make sure no fuel leaks exist, before closing engine hatch.

CAUTION
DO NOT operate engine without cooling water being supplied to water pickup holes
in gear housing, or water pump impeller will be damaged and subsequent overheat-
ing damage to engine may result.

Torque Specifications
Description lb-in. lb-ft Nm
Carburetor To Manifold 20 27
Fuel Line to Carburetor 18 24
Fuel Inlet Filter Nut 18 24

90-861328--1 NOVEMBER 1999 Page 5B-3

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Specifications
Engine Model 4.3L
Carburetor Type MerCarb 43mm
Carburetor Number 3310-807764
Float Level 9/16 (14) See Notes
Float Drop 1-3/32 (27) See Notes
Pump Rod (Location) Middle Hole Of Pump Arm
Choke Setting 2 Marks Right Of Index Mark (Lean)
Choke Unloader 5/64 [.080] (2)
Idle Mixture Screw 1-1/4 Turns Out
Float Weight 9 grams Maximum
Main Jet Size 1.55 mm
Power Valve Size 0.74 mm
Venturi Cluster ID Number 472
Accelerator Pump Discharge Hole Size 0.035 (0.9)
Fuel Pump Pressure 3-7 psi (21-48 kPa)

NOTE: Measurement taken from gasket.

NOTE: All measurements are +/– 1/64 in. (0.4 mm)

Tools
Description Part Number
Tachometer 91-59339
Universal Carburetor Gauge 91-36392
Float Gram Scale Obtain Locally

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SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

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90-861328--1 NOVEMBER 1999 Page 5B-5

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Exploded View
12 11
10 41
9 42
8 43
5 7 44
4 6
3 45
2 46
1

47 48 49 50
51
13 52
14 53
15 54
16 55
17 56
18 57
19 58
20
21
27 24
22
28
23 26 25

29 40
39
30 38
31 37
32
36
33 35
34 75842

Page 5B-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

Exploded View Parts List

1 - Rod - Accelerator Pump 29 - Washer
2 - Accelerator Pump Shaft and Lever 30 - Nut
Assembly 31 - Clip-Pump Rod
3 - Washer (Outer) 32 - Washer-Locking
4 - Washer (Inner) 33 - Nut
5 - Screw 34 - Throttle Lever
6 - Washer 35 - Spring
7 - Screw 36 - Screw - Idle Speed Adjustment
8 - Spring 37 - PCV Tube Connection Fitting
9 - Filter 38 - Check Ball
10 - Gasket 39 - Spring
11 - Gasket 40 - Retainer
12 - Nut-Fuel Inlet 41 - Screw
13 - Choke Rod 42 - Lever Assembly
14 - Gasket 43 - Screw
15 - Clip - Retainer 44 - Choke/Housing
16 - Washer 45 - Gasket
17 - Pump Shaft and Lever Assembly 46 - Air Horn
18 - Accelerator Pump Assembly 47 - Pin
19 - Spring 48 - Screw
20 - Screw 49 - Gasket
21 - Inlet Needle and Seat (Spring 50 - Screw
Loaded) 51 - Screw
22 - Baffle Plate 52 - Lock Washer
23 - Float 53 - Flat Washer
24 - Carburetor Body 54 - Gasket
25 - Cam-Idle 55 - Venturi Cluster
26 - Screw 56 - Power Valve Assembly
27 - Idle Mixture Adjusting Needle 57 - Gasket
28 - Spring 58 - Gasket

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Important Service Information

High Altitude Re-Jetting
Engine flooding problems, at idle rpm, are generally related to the altitude (above sea level)
at which they are operated. If engine is running too rich at higher elevation, order a smaller
jet from the chart. A jet stamped “165” is a 1.65 mm jet.

5000 ft.
Carburetor Part (1525 m) 5000-9000 ft. 9000 ft. (2745 m)
Models Number and Below (1525-2745 m) and Above
4.3 1389-9565A4 1.65 mm # 1.55 mm 1.50 mm
1389-9565A_ 1.60 mm # 1.50 mm 1.45 mm
3310-806972A__

JET SIZES

Jet Size Quicksilver Part Number

1.30 3302-811849
1.35 3302-811850
1.40 3302-811851
1.45 3302-9050
1.50 3302-811852
1.55 3302-811853
1.60 3302-810923
1.65 3302-9058
1.70 3302-9055
1.75 3302-881854
1.80 3302-811855
1.85 3302-811856
1.90 3302-811857

POWER VALVES

Jet Size Quicksilver Part Number

0.74 3302–9435
0.90 3302–9059

Page 5B-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

8 Point Carburetor Check List

To ensure that the carburetor is the cause of the problem, make the following checks
BEFORE ordering and installing a new carburetor. If questions 1, 2, 3, 5, 6 and 7 are YES
and 8 is NO, the carburetor may not be the problem.

1. Does the choke close completely before starting? Y N

2. Does the choke open completely during engine warm-up? Y N
3. Is idle mixture screw set correctly? Y N
(Engines with Thunderbolt V ignition must have module locked in
Base Timing Mode).
4. What is the idle mixture screw setting? ____Turn
5. Is the engine idle speed rpm correct? Y N
6. Is venturi cluster discharging fuel by 2000 rpm? Y N
7. Is a good stream of fuel being discharged by both discharge
holes in venturi cluster when throttle lever is moved repeatedly Y N
while the engine is off.
8. Does the engine flood at idle? Y N

Flooding At Idle RPM

If your engine floods at idle rpm, check the following:
1. Problem in ignition system causing engine to run rough.
2. Idle mixture screw adjusted incorrectly.
3. Bad needle and seat.
4. Incorrect float level or drop.
Needle / Seat Change
MerCarbs are factory equipped with a spring loaded needle. If the preceding steps did not
correct your problem, change to the solid type needle.

b 72290

Needle and Seat Assemblies

a - Spring Loaded Type Needle (Kit 3302-9029)
b - Solid Type Needle (Kit 3302-9407)

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Adjustable Accelerator Pump Lever

This new 3 hole lever allows you to change the amount of fuel delivered to the engine by
the accelerator pump. The hole closest to the lever’s shaft will give the same amount of fuel
as the single hole lever did. The center hole gives approximately 0.5 cc less fuel and the
hole furthest away will give about 1.0 cc less fuel.

a
b
c

73131

a - Full Accelerator Pump Stroke

b - 0.5 cc Less Fuel per Stroke
c - 1.0 cc Less Fuel per Stroke

When installing the 3-hole lever, remove any metal ball that may have been placed in the
accelerator pump well to limit pump travel. Also, ensure that the duration spring on the accel-
erator pump is stock and hasn’t had coils removed. Ensure that the correct venturi cluster
is being used.

Description
This MerCarb carburetor is a two bore carburetor that has a separate fuel feed for each
venturi. This model is equipped with an electric choke. A removable venturi cluster (secured
to float bowl assembly) has the calibrated main well tubes and pump jets built into it. The
venturi cluster is serviced as a unit. The serviceable main metering jets are bleeds to
properly meter the correct fuel / air mixture to the engine.

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SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

Maintenance
Flame Arrestor
NOTICE
Refer to “Precautions” in this section, BEFORE proceeding.

REMOVAL
1. Remove nut.
2. Remove sealing washer.
3. Remove flame arrestor cover.
4. Remove crankcase ventilation hose from flame arrestor and starboard rocker arm
cover.
5. Remove Positive Crankcase Vent (PCV) hose to carburetor tube and port rocker arm
PCV Valve connection.
6. Remove flame arrestor.
CLEANING AND INSPECTION
1. Clean flame arrestor in solvent and blow dry with compressed air.
2. Clean crankcase ventilation and PCV hoses.
3. Inspect hoses for cracks or deterioration and replace if necessary.

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

INSTALLATION
1. Install flame arrestor.
2. Install crankcase ventilation hose to flame arrestor and starboard rocker arm cover.
3. Install positive crankcase vent (PCV) hose from port rocker arm PCV valve connection
to carburetor tube.
4. Install carburetor cover.
5. Install sealing washer and nut. Tighten securely.

d a
b

e f
h
g

c 75844

a - Nut
b - Sealing Washer
c - Carburetor
d - Cover (Depending On Model)
e - Crankcase Ventilation Hose
f - Flame Arrestor
g - Positive Crankcase Vent (PCV) Hose (On Carburetor)
h - Positive Crankcase Vent (PCV) Hose

Page 5B-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

Fuel Inlet Filter

NOTICE
Refer to “Precautions” in this section, BEFORE proceeding.

REMOVAL
1. Remove fuel line from fuel inlet filter nut.
2. Remove fuel inlet filter nut and small gasket.
3. Remove large gasket.
4. Remove filter.
5. Remove spring.
6. Remove small gasket from inside filter nut.

b c d e

72406
a - Fuel Line
b - Fuel Inlet Filter Nut
c - Gasket (Larger)
d - Gasket (Small)
e - FIlter
f - Spring

CLEANING
1. Clean filter nut and spring in solvent and dry with compressed air.
INSTALLATION
1. Install spring in carburetor body.
2. Install filter, open end to inlet filter nut.
3. Install small gasket inside filter nut.
4. Install large gasket over filter nut threads.
5. Install fuel inlet filter nut. Torque nut to 18 lb-ft (24 Nm).
IMPORTANT: Hold filter nut with wrench while tightening fuel line.
6. Install fuel line. Torque to 18 lb-ft (24 Nm).

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Choke Inspection
The choke does not require any periodic maintenance. However, if a choke malfunction is
suspected, do the following:
1. With engine turned OFF, remove flame arrestor.
2. Open and close choke several times to check for binding, loose or disconnected link-
ages or other signs of damage.
3. If choke or linkage binds or sticks, clean with carburetor choke cleaner.
IMPORTANT: Choke valve and shaft and lever assembly is not serviceable. If valve
and/or shaft and lever assembly is worn or damaged, air horn assembly must be
replaced.

Adjustments
NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

Accelerator Rod
1. Loosen idle speed screw until it no longer contacts idle cam.

72284
a - Idle Speed Screw
b - Idle Cam

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SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

2. With throttle valves completely closed, measure from flame arrestor mounting surface
to top of pump rod.

72682

a - See Specifications

3. Carefully bend pump rod (where shown) to obtain specified dimension.

b
72683

a - Pump Rod
b - Bend Here

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Choke Setting
Normal choke setting: mark on cover is set 2 index marks clockwise from larger, center index
mark.
If choke adjustment is necessary:
1. Loosen choke cover retaining screws.
2. Adjust as shown.
3. Tighten screws securely.

c
b d
d

72403
d
a - Scribed Mark
b - More Choke
c - Less Choke
d - 3 Retaining Screws

Choke Unloader
1. Hold throttle valves completely open.
2. Gently press down on choke plate.
3. Using an .080 in. [5/64 in.] (0.2 mm) drill rod, slide rod between upper edge of choke
plate and air horn assembly. Rod should just slide through.

a
b
c

72684
a - .080 in. (0.2mm) Drill Rod
b - Choke Plate
c - Air Horn

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SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

4. Bend tang on throttle lever, if necessary, to obtain specified dimension.

b
a
72685
a - Tang
b - Throttle Lever

Initial Idle Speed and Mixture

IMPORTANT: The following adjustments will provide a sufficient idle speed and mix-
ture for starting engine. Final adjustments must be made with engine running.
1. Loosen idle speed screw until it no longer contacts idle cam. Turn idle speed screw in
until it just contacts idle cam, then turn screw in an additional two turns.

a
72284
a - Idle Speed Screw
b - Idle Cam

IMPORTANT: DO NOT turn idle mixture needle tightly against seat (in the following
step), as damage to seat and/or needle may result.
2. Turn idle mixture needle in until lightly seated, then loosen needle 1-1/4 turns.

72281

a - Idle Mixture Needle

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Final Idle Speed and Mixture

The ignition module must be locked into the timing mode to adjust idle speed and mixture.
Refer to SECTION 4B - “Timing - Thunderbolt V Models.”
EMISSIONS CARBURETOR
Sealed Carburetor Mixture Screw
The carburetor on this engine has a seal on the carburetor mixture screw. This seal prevents
adjustment of the fuel mixture setting.

CAUTION
Do not remove mixture screw seal and/or attempt to adjust fuel mixture setting.
Tampering with the mixture setting on this engine could affect the exhaust
emissions level, thus voiding the emissions certification. This seal should only be
removed by an authorized dealer or emissions testing agency.

Replacing Carburetor
NOTICE
Refer to “Precautions” in this section, BEFORE proceeding.

IMPORTANT: First follow the steps in “8 Point Carburetor Check List” to decide if the
problem is with the carburetor.
1. Remove the battery cables.
2. Remove the carburetor.
3. Clean gasket surfaces.
4. Use a new gasket and install new carburetor.
5. Hold the carburetor filter nut with a wrench and tighten fuel line fitting securely.
6. Reconnect or install choke wires, vent hoses and flame arrestor.
7. Adjust carburetor and throttle cable.

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SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

Repair
NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

Removal
IMPORTANT: Carburetor problems are, in many cases, caused by the presence of
dirt, water or other foreign matter in carburetor. To aid in diagnosis, carefully remove
carburetor from engine without draining fuel from bowl. Contents of fuel bowl may
then be inspected for contamination as carburetor is disassembled.
1. Remove battery cables.
2. Remove crankcase ventilation and PCV hose from flame arrestor.
3. Remove flame arrestor.
IMPORTANT: Place a clean cloth in bores of carburetor to prevent dirt and foreign
material from falling into bores.
4. Turn fuel supply off at fuel tank.
5. Disconnect throttle cable from carburetor.
6. Remove fuel line from fuel inlet nut, using wrench to stabilize fuel inlet nut.
7. Disconnect electric choke.
8. Remove carburetor attaching nuts and washers and remove carburetor.
IMPORTANT: Place a clean cloth over intake manifold opening to prevent dirt or for-
eign material from entering manifold.
9. Remove and discard gaskets.

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Disassembly
IMPORTANT: Before performing any service on carburetor, it is essential that carbu-
retor be placed in a holding fixture to prevent possible damage to throttle valves.
The following is a step-by-step procedure for completely overhauling the carburetor
removed from engine. Complete overhaul is not always necessary. You should perform only
those steps required to repair the carburetor malfunction. Read the instructions carefully to
prevent unnecessary steps.
CHOKE HOUSING
1. Remove choke cover.

a
72403
a - Choke Cover

2. Remove choke lever. Remove choke housing.

72401
a - Choke Lever
b - Choke Housing

AIR HORN
1. Remove fuel inlet filter nut, washers, spring, and filter.
2. Remove accelerator pump rod retaining clip.

Page 5B-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

3. Pivot rod (as required) until retaining ear on rod and slot in pump shaft and lever assem-
bly align, allowing rod to be pulled out.

b 72283

a - Accelerator Pump Rod

b - Retainer Clip
c - Pump Shaft and Lever Assembly

4. Remove idle cam screw.

b a
72282
a - Idle Cam Screw
b - Idle Cam
c - Choke Rod

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

5. Remove choke rod by pivoting rod (as required) until retaining ear on rod and slot in
choke lever align, allowing rod to be pulled out.

c
a

72286

a - Choke Rod
b - Choke Lever
c - Slot

6. Remove air horn attaching screws.

7. Carefully lift air horn from float bowl assembly.
a

a
a

a 72280

a - Air Horn Attaching Screws

b 72400

a - Air Horn Assembly

b - Float Bowl Assembly

8. Invert air horn and carefully lay on bench.

Page 5B-22 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

9. Remove float hinge pin and lift float assembly from air horn.

a
72288

a - Float Hinge Pin

b - Float Assembly

10. Check float weight as shown.

b
72122

a - Grams Scale
b - Float

11. Remove air horn gasket and baffle.

72399
b a
a - Baffle
b - Air Horn Gasket

90-861328--1 NOVEMBER 1999 Page 5B-23

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

12. Remove needle assembly.

72287

a - Needle Assembly
b - Needle Seat

13. Remove needle seat.

a b
72289

a - Needle Seat
b - Gasket
c - Screwdriver

b 72290

Needle and Seat Assemblies

a - Spring Loaded Type Needle (Kit 3302-9029)
b - Solid Type Needle (Kit 3302-9407)

Page 5B-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

14. Loosen accelerator pump screw.

15. Slide pump shaft and lever assembly (and washer) out of air horn.
16. Remove accelerator pump assembly.

b
a

c
72398
a - Set Screw
b - Lever Assembly
c - Pump Assembly

17. Remove retainer clip and washer from pump shaft and lever assembly, then remove
accelerator pump assembly.
b

c
a

72409

a - Pump Assembly
b - Retainer Clip
c - Lever Assembly

FLOAT BOWL
1. Remove accelerator pump return spring from pump well.

72402

a - Accelerator Pump Spring

90-861328--1 NOVEMBER 1999 Page 5B-25

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

2. Remove power valve assembly and gasket.

a b

72404

a - Power Valve Assembly

b - Gasket (Not Shown)

3. Remove main metering jets.

b b
72291

a - Main Metering Jets

b - Gaskets (Not Shown)

IMPORTANT: Use care when removing venturi cluster to prevent damaging brass
tubes which protrude from bottom of cluster. DO NOT REMOVE TUBES. These tubes
are permanently pressed into the venturi cluster and are not replaceable.
4. Remove venturi cluster screws and carefully lift cluster and venturi gasket straight up.

a
b

72397

a - Venturi Cluster Brass Tubes

b - Gasket

Page 5B-26 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

5. Using needle-nose pliers, remove accelerator pump check ball spring retainer. Turn
float bowl over to remove spring and check ball.

72407
b
a - Spring Retainer
b - Spring and Check Ball (Not Shown)
IMPORTANT: Use extreme care when handling carburetor body to prevent damaging
throttle valves.
1. Remove idle mixture adjusting needle and spring.

a
b

72293
a - Idle Mixture Adjusting Needle
b - Spring
2. Remove idle speed adjustment screw and spring, if replacement is necessary.

b
a
72395

a - Idle Speed Screw

b - Spring
IMPORTANT: DO NOT remove throttle valves. If any of the throttle parts are found to
be worn or damaged, complete carburetor body assembly MUST BE replaced.
Assembly can be cleaned in carburetor cleaner.

90-861328--1 NOVEMBER 1999 Page 5B-27

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Cleaning and Inspection

IMPORTANT: DO NOT use a wire or drill to clean jet passages or tubes in carburetor,
as this may enlarge orifices and seriously affect carburetor calibration.

CAUTION
To avoid damage to carburetor DO NOT leave carburetor in immersion type carbure-
tor cleaner for more than two hours.
IMPORTANT: DO NOT clean float bowl gasket surfaces with a gasket scraper or knife,
as sealing bead will be damaged and float bowl replacement will be necessary.

CAUTION
The float assembly, float needle, accelerator pump plunger and fuel filter MUST NOT
BE immersed in carburetor cleaner, as they will swell, harden and/or distort.

c a
d 72410
a - Accelerator Pump Plunger
b - Float Needle
c - Fuel Filter
d - Float Assembly

WARNING
Avoid personal injury by always wearing safety goggles when using compressed
air.
1. Clean all metal parts in a commercial carburetor cleaner until all deposits have been re-
moved. Follow cleaner manufacturer’s instructions for proper cleaning and rinsing pro-
cedure. Dry parts with compressed air.
2. Using compressed air, blow out all passages in carburetor to remove any foreign
material.
3. Wipe off all parts that cannot be cleaned in carburetor cleaner with a clean, dry cloth.
4. Carefully inspect all carburetor parts for wear and damage. Pay particular attention to
the following:
a. Float Needle and Seat: If float needle or seat is worn or damaged, replace with new
needle and seat assembly.
IMPORTANT: Float needle and seat are factory matched and tested and should be
replaced as a set only.
b. Float Assembly and Hinge Pin: Check float density (to see if it is saturated with
fuel) by comparing weight of float with specifications. If weight is high, float assembly
must be replaced. Check hinge pin and holes for wear.

Page 5B-28 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

c. Fuel and Air Passages: Passages must be perfectly clean for proper carburetor
operation.
d. Accelerator Pump Plunger and Return Spring: Inspect pump plunger cup, pump
plunger spring (on pump assembly) and return spring.
e. Power Piston Spring: Check power piston spring for weakness or distortion.
f. Idle Mixture Needle: Inspect idle mixture needle. If damaged, needle must be
replaced.
g. Levers and Linkages: Check levers, links and rods for wear.
h. Throttle Valve and Shaft: Check throttle shaft for excessive looseness in throttle
body. Ensure throttle valve and shaft open and close completely. Throttle body
assembly must be replaced if throttle valve and shaft are worn or damaged.
i. Choke Valve and Shaft and Lever Assembly: Check shaft and lever assembly for
excessive looseness in air horn assembly. Check choke valve and shaft and lever
assembly for binding through entire operating range, making sure valve opens and
closes completely. Air horn assembly must be replaced if choke valve and shaft and
lever assembly are worn or damaged.
j. Inspect Casting for visible damage. Inspect gasket surfaces. Inspect accelerator
pump plunger well for scoring or deposits.

90-861328--1 NOVEMBER 1999 Page 5B-29

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Reassembly
CARBURETOR BODY
IMPORTANT: DO NOT force idle mixture needle against seat as damage to needle
and/or seat will result.
1. Screw idle mixture needle and spring into throttle body until they lightly seat, then back
out needle 1-1/2 turns as a preliminary idle mixture setting.

a
b

72293
a - Idle Mixing Adjusting Needle
b - Spring

2. Thread idle speed adjustment screw and spring into throttle lever.

b
a
72395

a - Idle Speed Screw

b - Spring

Page 5B-30 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

FLOAT BOWL
IMPORTANT: Place float bowl and throttle assemblies in holding fixture to prevent
throttle valves from being damaged.
1. Install check ball, spring, and retainer in passage. Push retainer firmly into slots.
c
b
a

72408

a - Check Ball
b - Spring
c - Retainer

2. Install new gasket on venturi cluster.

72296
a - Venturi Cluster
b - Gasket

3. Install venturi cluster in carburetor.

b
a

72397

a - Venturi Cluster
b - Gasket

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

4. Install flat washer and new fiber washer on center screw. Lockwashers and flat washers
are used on outer screws. Tighten screws evenly and securely.
IMPORTANT: Do not damage the fiber washer. A damaged washer will cause
improper fueling.

a
b b
c

72405

a - Center Screw
b - Outer Screws
c - Fiber Washer
d - Lock Washer and Flat Washer

5. Install main metering jets with gaskets. Tighten securely.

b
72291

a - Main Metering Jets

b - Gaskets (Not Shown)

6. Install power valve with new gasket. Tighten securely.

b a

72404

a - Power Valve
b - Gaskets (Not Shown)

Page 5B-32 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

7. Place accelerator pump spring in pump well.

72402

a - Accelerator Pump Spring

AIR HORN
IMPORTANT: Accelerator pump assembly MUST BE installed correctly. If pump
assembly is installed incorrectly, top of pump assembly will contact air horn casting.
1. If accelerator pump assembly was removed from pump lever, secure pump assembly
to pump lever with washer and retainer clip.

b
c a

72409
a - Pump Assembly
b - Retainer Clip
c - Pump Lever

2. Insert pump shaft and lever assembly (and washer) into air horn.
3. Align indexed hole in pump lever with shaft and lever assembly and slide shaft all the
way into lever so that shoulder on shaft is hitting lever.
4. Tighten set screw securely.

b
c 72398

a - Set Screw
b - Lever Assembly
c - Pump Assembly

90-861328--1 NOVEMBER 1999 Page 5B-33

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

5. Install needle seat and gasket. Tighten securely.

a
b
72289

a - Needle Seat
b - Gasket
c - Screwdriver

IMPORTANT: Float needle and needle seat are factory matched and tested and
should be replaced as a set only.
6. Place needle assembly in needle seat.

72287
a - Needle Assembly
b - Needle Seat

7. Install baffle and gasket.

72399
b a
a - Baffle
b - Gasket

Page 5B-34 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

8. Install float assembly and hinge pin. Pivot float assembly up and down on hinge pin to
ensure it moves freely.

a 72297

a - Float Assembly
b - Float Hinge Pin

FLOAT LEVEL
1. Turn air horn upside down. Pivot float assembly up and down on hinge pin to ensure it
moves freely.
IMPORTANT: Before checking float level, raise float and allow it to fall; however, DO
NOT force downward by hand.
2. Measure float level using Universal Carburetor Gauge (91-36392). Measure from
gasket to toe of float.

72298
a
a - Measure From This Point (Dot) To Gasket

72687
a - Measurement With 2 Piece Solid Inlet Needle - 3/8 in. (10 mm)
b - Measurement with Spring Loaded Inlet Needle - 11/32 in. (9 mm)

90-861328--1 NOVEMBER 1999 Page 5B-35

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

3. Bend float arm up or down at point shown to obtain specified dimension.

a
72688

a - Bend Float Arm at This Point

4. Visually check float alignment after adjustment.

FLOAT DROP
1. Hold air horn right side up to allow float to hang free.
2. Measure float drop using Universal Carburetor Gauge (91-36392). Measure from
gasket (air horn) to “dot” on float.

72689
a - Measurement - 15/16 in. (24 mm)

3. Bend float assembly tang, as shown, to obtain specified dimension.

72690

a - Float Assembly Tang

4. Recheck BOTH float level and float drop.

Page 5B-36 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

5. Place air horn on float bowl, making sure accelerator pump is correctly positioned in fuel
well. Lower air horn straight down to install.

b
72400
a - Air Horn Assembly
b - Float Bowl Assembly

6. Install seven short and one long air horn attaching screws. Tighten screws evenly and
securely.
a

a
a

72280
a
a - Air Horn Attaching Screws

7. Place end of choke rod in choke lever and collar assembly.

72299
a - Choke Rod
b - Choke Lever and Collar Assembly

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

8. Place idle cam on choke rod.

a
b

72392
a - Idle Cam
b - Choke Rod

9. Secure idle cam (with choke rod installed on cam) on float bowl assembly, using screw.
Ensure that cam is free to move without binding.

b
a
72282
a - Screw
b - Idle Cam
c - Choke Rod

10. Place accelerator pump rod in hole in pump shaft and lever assembly.

72393
a - Accelerator Pump Rod
b - Pump Shaft and Lever Assembly

Page 5B-38 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MERCARB 2 BARREL CARBURETOR

11. Insert other end of accelerator pump rod into hole in throttle lever and secure with
retainer clip.

a c b 72283

a - Accelerator Pump Rod

b - Throttle Lever
c - Retainer Clip

CHOKE HOUSING
1. Install choke housing on air horn. Tighten screws securely.
2. Install choke lever. Tighten screw securely.

a
72401

a - Choke Housing
b - Choke Housing Attaching Screws
c - Choke Lever

3. Install choke cover. Make sure hook on end of choke coil engages with choke lever.
4. Adjust choke cover until index marks align as shown. Tighten screws securely.
a
c b d

72403

a - Scribed Mark
b - More Choke (Richer)
c - Less Choke (Leaner)
d - Cover Screws

90-861328--1 NOVEMBER 1999 Page 5B-39

MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Installation
1. Thoroughly clean gasket surfaces and install new gaskets.
2. Place new carburetor base gasket on intake manifold.
3. Install carburetor and secure with nuts and washers. Torque to 132 lb-in. (15 Nm).
4. If fuel inlet filter nut was disturbed, remove, clean all threads with brush and carburetor
cleaner or Quicksilver Leveler, and replace.
5. Connect fuel line to fuel inlet filter nut. Hold filter nut with wrench, tighten fuel line fitting
securely.
6. Connect electric choke wires to choke cover.
7. Install throttle cable. Refer to SECTION 2.
8. Install flame arrestor, crankcase ventilation and PCV hose.
9. Reconnect battery cables to battery.
10. Ensure that water is supplied to cooling system.
11. Start engine.
12. Check for gasoline leaks. If leaks exist, STOP ENGINE IMMEDIATELY and recheck
connections.
13. Adjust idle speed and idle mixture.

Page 5B-40 90-861328--1 NOVEMBER 1999

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MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

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Page 5B-42 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

FUEL SYSTEMS 5
Section 5C - Weber 4 Barrel Carburetor C
Table of Contents
Identification . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 5C-12
Carburetor Metering Rod Flame Arrestor . . . . . . . . . . . . . . . . . . . 5C-12
And Jet Identification . . . . . . . . . . . . . 5C-2 Fuel Inlet Filter . . . . . . . . . . . . . . . . . . . 5C-13
Torque Specifications . . . . . . . . . . . . . . . . 5C-4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 5C-14
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Accelerator Pump . . . . . . . . . . . . . . . . 5C-14
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5 Float Drop . . . . . . . . . . . . . . . . . . . . . . . 5C-16
Replacement Parts Warning . . . . . . . . . . 5C-5 Float Level . . . . . . . . . . . . . . . . . . . . . . . 5C-17
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Electric Choke . . . . . . . . . . . . . . . . . . . 5C-18
Fuel Delivery System . . . . . . . . . . . . . . . . 5C-6 Idle Speed and Mixture . . . . . . . . . . . . 5C-18
Fuel Supply Connections . . . . . . . . . . 5C-6 Replacing Carburetor . . . . . . . . . . . . . . . . 5C-19
Eight Point Carburetor Checklist . . . . . . . . . 5C-7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-19
Exploded View . . . . . . . . . . . . . . . . . . . . . . 5C-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . 5C-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 5C-21
Important Service Information . . . . . . . . . 5C-11 Cleaning and Inspection . . . . . . . . . . . . . . 5C-32
Adjustable Accelerator Pump Lever . 5C-11 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 5C-33
Hard Starting . . . . . . . . . . . . . . . . . . . . . 5C-11 Installation . . . . . . . . . . . . . . . . . . . . . . . 5C-44

90-861328--1 NOVEMBER 1999 Page 5C-1

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Identification

75682
a
a - Weber Identification Number Location

NOTICE
For information and procedures on troubleshooting, refer to SECTION 1C.

Carburetor Metering Rod And Jet Identification

METERING ASSEMBLY
The metering rod assemblies are shown in the following:
b
a

d c

e 73732

Three Step Metering Rod

a - Piston
b - Metering Rod
c - Spring
d - Jet
e - Piston Cover

Page 5C-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

METERING JETS
The metering jets in this carburetor are as shown.

a
73728
a - Three Step Metering Rod Jet

METERING ROD HAS THREE STEPS

a b
b
b
73726
a - Metering Rod
b - Steps (3)

PISTON SHAPE WITH SECOND SPRING

a
b
73730

a - Piston
b - Second Spring

THREE STEP PISTON ASSEMBLY COVER

73735

a 73725

a - Cover

90-861328--1 NOVEMBER 1999 Page 5C-3

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

PISTON BORE STEP

a
b

73737

a - Piston Bore
b - Step

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Carburetor To Manifold 132 15
Fuel Line To Carburetor 18 24
Fuel Inlet Filter Nut 18 24

Specifications
Engine Model 4.3LH Alpha and Bravo
Carburetor Type WFB
Mercury Number (Manufacturer Number) 3310-807826 (9666S)
Primary Jet Size .092 in.
Secondary Jet Size .089 in.
Metering Rod Number 16-686457
Metering Rod Spring Color Green
Float Level 1-9/32 in. (33 mm)
Float Drop 2 in. (51 mm)
Pump Rod Hole Location Third Hole From End
Accelerator Pump 7/16 in. (11 mm) 1
Choke Pull Off 1.28 (32.5)
Electric Choke Setting Lean - Counter- Rich - Clock-
clockwise wise
Idle Mixture Screw Setting 1-1/4 Turns
1 Measurement taken from top of carburetor to bottom of S-link
NOTE: All measurements are +/– 1/64 in. (0.4 mm)

Page 5C-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

Tools
Description Part Number
Universal Carburetor Gauge 91-36392
Tachometer 91-59339
Universal Carburetor Stand
Obtain Locally
Torx Screwdriver (15, 20, 25)1
1 : Weber carburetors will have a “star” shaped socket in the head of some screws. A TORX screwdriver must
be used on this type of screw. The sizes used are numbers 15, 20 and 25.

Replacement Parts Warning

WARNING
Electrical, ignition and fuel system components on your Mercury 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.

90-861328--1 NOVEMBER 1999 Page 5C-5

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Precautions
WARNING
Always disconnect battery cables from battery BEFORE working on fuel system to
prevent fire or explosion.

WARNING
Be careful when cleaning flame arrestor and crankcase ventilation hose: 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 open flame in area
when cleaning flame arrestor and crankcase ventilation hose.

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 open flame in area while
changing fuel filter. Wipe up any spilled fuel immediately.

WARNING
Make sure no fuel leaks exist, before closing engine hatch.

CAUTION
DO NOT operate engine without cooling water being supplied to water pickup holes
in gear housing or water pickup inlet, or water pump impeller will be damaged and
subsequent overheating damage to engine may result.

Fuel Delivery System

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 over-tightening, hold brass fitting with suitable
wrench and tighten fuel line connectors securely.
• Check for fuel leaks.

Page 5C-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

8 Point Carburetor Check List

To ensure that the carburetor is the cause of the engine s problem, make the following
checks BEFORE ordering and installing a new carburetor. If questions 1, 2, 3, 5, 6 and 7
are YES and 8 is NO, the carburetor may not be the problem.

1. Does the choke close completely (before starting)? Y N

2. Does the choke open completely (during engine warm
up)? Y N
3. Are idle mixture screws set correctly? Y N
(Engines with Thunderbolt V ignition must have module locked in base timing
mode).
4. What is the idle mixture screw setting? Choke side: _____ Turn.
Cable side: Turn.
5. Is the engine idle speed (rpm) correct? Y N
6. Is primary venturi cluster discharging fuel (by 2000
rpm)? Y N
7. Is a good stream of fuel being discharged by both pump injector
nozzles? (When throttle lever is pumped with engine off). Y N
8. Does the engine flood at idle? Y N

90-861328--1 NOVEMBER 1999 Page 5C-7

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Exploded View

1
2
3
4
5
6
7
34
8
35
9
10 36
11 37
12 38
39
13
40
14
41
15
16 42
17 43
18 44
19 45
20 46
21 47
22 48
23 49
24 50
25
26
27

28
29
30
31
32
33

Page 5C-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

1-Air Deflector (2)

2-Screw (2)
3-Cover, Metering Rod (2)
4-Metering Rod Assembly (2)
5-Spring, Metering Rod (2)
6-Fuel Inlet Fitting
7-Sealing Washer
8-Screw
9-Linkage Rod, Choke Pull-Off
10-Screw
11-Air Horn (Carburetor Top)
12-Filter, Fuel Inlet (2)
13-Gasket (2)
14-Seat, Fuel Inlet (2)
15-Needle Valve, Fuel Inlet (2)
16-Pin (2)
17-Float (2)
18-Secondary Venturi Cluster (2)
19-Baffle Plate, Float Bowl (2)
20-Screw (4)
21-Primary Venturi Cluster (2)
22-Gasket (2)
23-Jet, Primary Fuel (2)
24-Screw (2)
25-Fuel Pump Injector Housing
26-Gasket
27-Check-Spring
28-Screw and Clip
29-Electric Choke Assembly
30-Retainer, Choke
31-Idle Mixture Screw (2)
32-Spring, Idle Mixture Screw (2)
33-Gasket, Carburetor Base
34-Linkage Rod, Choke Plate
35-S-Link
36-Accelerator Pump Lever
37-Screw
38-Linkage Rod, Accelerator Pump
39-Wire Clip
40-Wire Clip
41-Gasket
42-Screw (4)
43-Gasket (2)
44-Jet, Secondary Fuel (2)
45-Secondary Air Valve and Weight Assembly
46-Plunger Washer
47-Plunger Guide
48-Accelerator Pump
49-Spring, Accelerator Pump
50-Float Bowl/Body (Carburetor Bottom)

90-861328--1 NOVEMBER 1999 Page 5C-9

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Description
Weber WFB carburetor is unique in design, as the main body and flange are cast as a one
piece unit. This, along with the bowl cover, make up the two piece construction that is made
of light, durable aluminum to dissipate heat.
There are two separate float circuits. Each float circuit supplies fuel to a primary low speed
circuit and a primary and secondary high speed circuit. The bowls are vented to the inside
of the air horn. A connecting vent passage affects the balance of the air pressure between
the two bowls.
The float needle valves are installed at an angle to provide the best possible seating action
on the needles. This also provides better needle response to float movement.
The high speed circuits use staged step-up rods in the main metering jets to control the
amount of fuel admitted to the nozzles. The position of the step-up rod is controlled by
manifold vacuum applied to the vacuum piston.
A primary air bleed located in the venturi cluster prevents a rich condition or bog as the high
speed circuit is reactivated after deceleration.
Small “L” shaped metal tabs, called “distribution tab(s),” are attached to some venturi
clusters and protrude into the air stream at the proper location to aid distribution of fuel on
selected applications.

Page 5C-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

Important Service Information

Adjustable Accelerator Pump Lever
The accelerator pump lever on Weber Carburetors has three holes in it. The closest hole
to the lever’s pivot point is the richest, the second hole is leaner and the hole furthest away
is the leanest. All production carbs have the pump rod installed in the closest (richest) hole.
If you are having a “rich” bog on acceleration, move the rod to the second or third hole.
Weber put the three holes in the lever so the amount of fuel delivered by the accelerator
pump could be changed.

a
b
c

70472
a - Rich
b - Lean
c - Leaner

Hard Starting
If a hard starting condition exists, after engine has not been operated for a period of time,
proceed with the following:
1. Before starting engine, remove flame arrestor then operate throttle to see if choke
closes.
2. If choke is stuck open, check choke and choke linkage on both sides of carburetor for
cause of sticking. Possible paint or interference to rod or linkage.
3. Check for any paint or binding on choke rod linkages.
4. Make sure choke is getting 12 volts.
5. Make sure choke opens all the way after 3 minute running.

90-861328--1 NOVEMBER 1999 Page 5C-11

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Maintenance
Flame Arrestor
NOTICE
Refer to “Precautions,” in this section, BEFORE proceeding.

a
c
b
f
d
d

e
e 71372

Flame Arrestor with Carburetor Cover (Typical)

a - Nut
b - Sealing Washer
c - Cover
d - Clamps
e - Crankcase Ventilation Hose
f - Flame Arrestor

REMOVAL
1. Remove nut.
2. Remove sealing washer.
3. Remove carburetor cover.
4. Remove crankcase ventilation hoses from flame arrestor and rocker arm covers.
5. Remove flame arrestor.
CLEANING AND INSPECTION
1. Clean flame arrestor in solvent and blow dry with compressed air.
2. Clean crankcase ventilation hoses.
3. Inspect crankcase ventilation hoses for cracks or deterioration, and replace if neces-
sary.
INSTALLATION
1. Install flame arrestor.
2. Install crankcase ventilation hoses to flame arrestor and rocker arm covers.
3. Install carburetor cover.
4. Install sealing washer.
5. Install nut. Tighten securely.

Page 5C-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

Fuel Inlet Filter

NOTICE
Refer to “Precautions,” in this section, BEFORE proceeding.

Carburetor inlet fuel filter is installed in bottom side of fuel inlet seat (in the carburetor top).
Refer to “Disassembly” and “Reassembly” to service.

70447

a - Fuel Inlet Seat (with Gasket)

b - Fuel Inlet Filter

90-861328--1 NOVEMBER 1999 Page 5C-13

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Adjustments
NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

Accelerator Pump
IMPORTANT: Refer to “Important Service Information” in this section, regarding the
three accelerator pump linkage holes and placement of linkage rod.
1. Loosen idle speed screw until it no longer contacts throttle lever.

70474

a - Idle Speed Screw

b - Throttle Lever Contact Point

a
70473

b
a - Idle Speed Screw
b - Throttle Lever

Page 5C-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

2. Accelerator pump is set at 7/16 in. (11 mm), which is measured from the carburetor top
to the bottom of the S-link as shown.

70472

3. Adjustment of accelerator pump is done by bending the linkage as necessary to achieve

the proper dimension as stated above.

a
70473
a - Bend Here

90-861328--1 NOVEMBER 1999 Page 5C-15

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Float Drop
1. Measure float drop from bottom side of carburetor top to toe of float (lowest part). It must
be set at 2 in. (51 mm).

a 70469

a - Drop Measurement

2. If float drop is not correct, hold hinge pin firmly and bend tab, as needed.
IMPORTANT: Do not put pressure on fuel needle valve and seat while bending tab or
damage may result.

a 70470

a - Float
b - Tab (Bend)

Page 5C-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

Float Level
1. Measure float level from bottom side of carburetor top (with gasket in place) to toe of float
as shown. It must be set at 1-9/32 in. (33 mm).

70468
a - Float Level Measurement
b - Gasket

2. If float level requires adjustment, hold hinge pin firmly and bend float arm shown, as
needed.
IMPORTANT: Do not put pressure on fuel needle valve and seat while bending tab,
or damage may result.
a

70468

a - Float Level Tab (Bend)

90-861328--1 NOVEMBER 1999 Page 5C-17

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Electric Choke
The electric choke should be set with marks aligned.

b a

75862
a - Carburetor Body Mark
b - Choke Marks

1. Loosen choke housing screws

2. Adjust choke by turning.
Idle Speed and Mixture
IMPORTANT: In order to properly set idle mixture, the ignition module MUST BE
locked in the Base Timing Mode. This is necessary because of the Idle Speed Control
feature that exists in the ignition module. See information on the previous pages
about this feature.
1. Using a jumper wire, connect the ignition system timing lead “13” (PUR/WHT wire) to
a good engine ground (–). This locks the ignition module into the Base Timing Mode.
2. Disconnect throttle cable.
3. Set idle speed (rpm) screw so engine idles at 550-600 rpm in neutral.
4. Adjust idle mixture screws.
5. Reset the idle speed screw so engine idles at its recommended rpm.
6. Adjust and connect throttle cable.
7. Remove the jumper wire from the timing terminal.
ENGINE IDLE SPEED
This procedure should be done with boat in the water, drive unit in neutral and engine at
normal operating temperature. Refer to the Operation and Maintenance Manual for the
correct idle speed.
1. Disconnect the throttle cable from carburetor.
IMPORTANT: In order to properly set idle speed, the ignition module MUST BE locked
in the “Base Timing Mode”. This is necessary because of the “Idle Speed Control”
feature that exists in the ignition module.
2. Connect a shop tachometer to engine.

Page 5C-18 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

3. Using a jumper wire, connect the ignition system timing lead 13 (PUR/WHT wire) to a
good engine ground (–). This locks the ignition module into the Base Timing Mode.
4. Start engine and allow it to reach normal operating temperature. Place the remote
control lever in forward gear, idle position.
5. Adjust idle speed to recommended rpm.
6. Stop engine. Readjust cable barrel and reinstall the throttle.
IMPORTANT: Be sure to disconnect the jumper wire from the ignition system test
terminal before attempting to resume normal operations. If the jumper wire is left in
place, the ignition module will operate in the Base Timing Mode. This means that the
additional timing advance features would not be functioning.
7. Remove the jumper wire from the timing terminal.

Replacing Carburetor
NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

IMPORTANT: First follow the steps in “8 Point Carburetor Check List” to decide if the
problem is with the carburetor.
1. Remove the battery cables.
2. Remove the carburetor.
3. Clean gasket surfaces.
4. Use a new gasket and install new carburetor.
5. Hold the carburetor filter nut with a wrench and tighten fuel line fitting securely.
6. Reconnect or install choke wires, vent hoses and flame arrestor.
7. Adjust carburetor and throttle cable.

Repair
NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

Removal
IMPORTANT: Carburetor malfunctions are often caused by the presence of dirt, water
or other foreign matter. To aid in diagnosis, carefully remove carburetor from engine
without draining fuel from bowl. Contents of fuel bowl may then be inspected for
contamination as carburetor is disassembled.
1. Turn off fuel supply at fuel tank.
2. Remove carburetor cover. Remove crankcase ventilation hoses from flame arrestor,
then remove flame arrestor.
IMPORTANT: Place a clean cloth in bores of carburetor to prevent dirt and foreign
material from falling into bores.

90-861328--1 NOVEMBER 1999 Page 5C-19

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

3. Disconnect throttle cable attaching hardware from throttle bracket and throttle lever
anchor studs. Remove throttle cable.
b
d

d
a
c 71097

a - Throttle Cable
b - Bracket
c - Attaching Hardware
d - Anchor Studs

4. Remove fuel line and carburetor attaching hardware. Remove carburetor and throttle
bracket. Discard gasket.

c
b

75862 75863

a - Fuel Line
b - Attaching Hardware
c - Throttle Bracket

IMPORTANT: Cover intake manifold to prevent entry of dirt or foreign material

through openings.
5. Place a clean cloth over intake manifold openings.

Page 5C-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

Disassembly
The following is a step-by-step procedure for completely overhauling carburetor after
removal from engine. In many cases, however, complete overhaul is not necessary and, in
these cases, only the steps required to repair the carburetor malfunction should be
performed. Read the instructions carefully to prevent doing unnecessary steps.
IMPORTANT: Before performing any service on carburetor, it is essential that
carburetor be placed in a holding fixture to prevent possible damage to throttle
valves.
1. Remove wire clip to disconnect accelerator pump linkage.

b
a

70390

a - Wire Clip
b - Accelerator Pump Linkage Rod

2. Remove wire clip and disconnect electric choke link rod from choke plate lever.
IMPORTANT: Metering rods should always be removed before separating top and
bottom halves of carburetor.
3. Loosen (not necessary to remove, depending on amount of service required) metering
rod cover screws. Turn or remove cover to expose metering rod.
c
a
b

71094

71095

a - Screws
b - Metering Rod Cover(s)
c - Air Deflectors If Equipped)

90-861328--1 NOVEMBER 1999 Page 5C-21

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

IMPORTANT: Be careful not to mix metering rods when removing them.

4. Carefully lift metering rod assemblies straight out.
a

70396

a - Metering Rod Assembly(s)

5. Remove metering rod springs.

IMPORTANT: Metering rod springs are color coded and should not be interchanged
with other carburetors.
a

70397

a - Spring(s)

6. Remove nine screws to separate top and bottom halves of carburetor.

a 70398

a - Screw(s)

Page 5C-22 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

7. Carefully lift off carburetor top and disconnect choke linkage.

70399

8. Slide pin out to remove the float.

IMPORTANT: Be careful not to mix up floats after removal.

a
a 70400

a - Pin(s)
b - Float(s)

9. Remove inlet needle from seat.

IMPORTANT: Be careful not to mix up inlet needles and seats after removal.

a
a

b
b 70401
70446
a - Inlets Needle(s)
b - Seat(s)

90-861328--1 NOVEMBER 1999 Page 5C-23

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

10. Remove seat, gasket and inlet filter.

IMPORTANT: Be careful not to mix up seats after removal.

a
b
c

70447

a - Seat
b - Gasket
c - Inlet Filter

11. Remove gasket from top of carburetor.

70448

a - Gasket

12. Remove accelerator pump lever.

b
a 70449

a - Accelerator Pump
b - Accelerator Pump Lever
c - Retaining Screw

Page 5C-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

13. Remove accelerator pump.

b
c

70450

a - Accelerator Pump
b - Plunger Guide
c - Plunger Washer (Not Visible In This View)

14. Remove accelerator pump spring from bottom half of carburetor.

b 70451

a - Accelerator Pump Spring

b - Carburetor Bottom

90-861328--1 NOVEMBER 1999 Page 5C-25

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

IMPORTANT: Before removing venturi clusters, it is important to note which clusters

are equipped with a “distribution tab.” This distribution tab arrangement varies from
one carburetor to another.

70452

a - Distribution Tab(s) - Location And Total Number May Vary

15. Remove two screws that secure primary venturi cluster.

a a
b

70453

a - Screw(s) - Two On Each Side

b - Primary Venturi Cluster(s)

16. Remove primary venturi cluster by lifting straight up.

70454

Page 5C-26 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

17. Remove gasket from beneath venturi cluster.

70455

a - Gasket, Primary Venturi Cluster

18. Remove two screws that secure secondary venturi clusters.

b
70456
a - Screw(s) - Two Each Side
b - Secondary Venturi Cluster(s)

90-861328--1 NOVEMBER 1999 Page 5C-27

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

19. Remove secondary venturi cluster by lifting it straight up.

70457

20. Remove gaskets from beneath secondary venturi clusters.

70458
a - Gasket, Secondary Venturi Cluster

21. Remove secondary air valve and weight assembly by lifting it straight out.

70459

a - Secondary Air Valve And Weight Assembly

Page 5C-28 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

22. Remove two screws that secure pump jet housing.

70460
a - Screw(s)
b - Pump Jet Housing

23. Remove pump jet housing.

70461

a - Pump Jet Housing

24. Remove gasket from beneath pump jet housing.

70462
a - Gasket, Pump Jet Housing

25. Remove check-ball and check-spring from hole beneath pump jet housing.

90-861328--1 NOVEMBER 1999 Page 5C-29

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

IMPORTANT: Check ball spring is tapered. Ensure tapered end is down during reas-
sembly.

70463

a - Ball Location

a b

70464

a - Check Ball
b - Check Spring

26. Remove float bowl baffle plates, if necessary.

70465

a - Baffle Plate

IMPORTANT: Do not mix up the primary and secondary jets. Make note of the jet sizes
and their location before removal to be certain that during reassembly they are
installed in the carburetor side from which they were removed.
NOTE: If jets are difficult to remove, place a screwdriver of the correct width in the jet slot
and lightly tap the end of the screwdriver with a hammer.

Page 5C-30 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

27. Remove primary and secondary jets.

b a

70466

a - Primary Fuel Jet

b - Secondary Fuel Jet

IMPORTANT: Before removing mixture screws, check and note the number of turns
from the fully seated position. Do NOT mix up the two screws.
28. Remove mixture screws.

b 70467

a - Idle Mixture Screw

b - Spring, Idle Mixture Screw

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WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Cleaning and Inspection

CAUTION
Rubber, plastic parts, pump plungers or diaphragms cannot be immersed in
carburetor cleaner.

CAUTION
Avoid damage to carburetor. Do not leave carburetor in immersion-type cleaner for
more than two hours.
IMPORTANT: Do not immerse metering rod springs in carburetor cleaner; the color,
if not “natural” metal, may be removed. Clean separately as needed.
1. Clean metal carburetor parts in a commercial, immersion-type cleaner, until all deposits
have been removed. Follow manufacturer’s instructions of cleaner being used for
proper cleaning and rinsing procedures.

CAUTION
Avoid personal injury. Always wear safety glasses when using compressed air.
2. Blow out passages with compressed air. Do not drill through passages.
IMPORTANT: DO NOT use a wire or drill to clean jets, passages, or tubes in
carburetor, as this may enlarge orifices and seriously affect carburetor calibration.
3. Wipe all parts that cannot be cleaned in immersion cleaner with a clean, dry cloth.
4. Carefully inspect all carburetor parts for damage or wear; pay particular attention to the
following:
a. Idle mixture screws - Replace if damaged or worn.
b. Fuel inlet needle valve and seat - Replace with new needle and seat if worn or
damaged.
c. Casting surfaces - Inspect accelerator pump plunger well for scoring or deposits.
Replace worn or corroded components.
d. All linkage rods and levers - Replace if worn or damaged.
e. Accelerator pump and plunger parts - Replace pump and parts if worn or
damaged.
f. Float assembly and hinge pin - Float weight of each should be the same. Replace
either if fuel can be heard inside when shaken. Check hinge pin and holes for wear.
Replace components if worn or defective.
g. Throttle valves and shafts - Check for binding (through entire operating range,
making sure valves open and close completely) or for looseness in carburetor body.
IMPORTANT: DO NOT remove throttle valves. If any of the throttle parts or float
bowl/carburetor body shaft bores are found to be worn or damaged, carburetor
replacement is required.
h. Choke valve and shaft/lever assembly - Check shaft and lever for excessive
looseness in air horn. Check choke valve and shaft/lever assembly for binding
through entire operating range. Air horn assembly must be replaced if choke valve
and shaft/lever are worn.
5. Check that choke pull-off diaphragm plunger retracts when vacuum is applied to unit,
and that it holds vacuum (plunger remains seated if vacuum is maintained).

Page 5C-32 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

Reassembly
1. Install mixture screws (needles) with springs in place. Turn idle mixture screws in
(clockwise) until LIGHTLY seated, then loosen 1-1/4 turns if previous settings were not
noted on disassembly.
IMPORTANT: Do not turn idle mixture screws tightly against seat, as damage to seat
and/or needle may result.

b 70467

a - Idle Mixture Screw

b - Spring, Idle Mixture Screw

2. Install the primary and secondary jets. Tighten securely.

IMPORTANT: Be sure that primary and secondary jets are installed in the appropriate
location. Be sure that the size matches the same size recorded during disassembly.

b a

70466

a - Primary Fuel Jet

b - Secondary Fuel Jet

3. Install the float bowl baffle plates, if previously removed.

70465

a - Baffle Plate

90-861328--1 NOVEMBER 1999 Page 5C-33

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

4. Into bore beneath pump jet housing location, install check-ball and then check-weight
or, if so equipped, check-ball and check-spring.
IMPORTANT: If your carburetor had a ball and weight combination, replace with ball
and weight. If your carburetor used a ball and spring combination, replace with ball
and spring.
a a

b c d
b
70463

70464
a - Bore
b - Check Ball
c - Check Weight
d - Check Spring

5. Position pump jet housing gasket.

70462

a - Gasket, Pump Jet Housing

Page 5C-34 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

6. Install pump jet housing.

70461
a - Pump Jet Housing

7. Install two screws that secure pump jet housing. Tighten securely.

b
70460

a - Screws
b - Pump Jet Housing

8. Install the secondary air valve and weight assembly.

70459

a - Secondary Air Valve And Weight Assembly

90-861328--1 NOVEMBER 1999 Page 5C-35

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

IMPORTANT: Before installing venturi clusters, it is important to note which clusters

were equipped with a “distribution tab.” This distribution tab arrangement varies
from one carburetor to another.

70452

a - Distribution Tab(s) Location And Total Number May Vary

9. Position the secondary venturi cluster gaskets.

70458

a - Gasket, Secondary Venturi Cluster

10. Install the secondary venturi clusters.

70457
a - Secondary Venturi Cluster

Page 5C-36 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

11. Secure each cluster with two screws. Tighten securely.

b 70456
a - Screws (Two On Each Side)
b - Secondary Venturi Cluster(s)

12. Position the primary venturi cluster gaskets.

70455

a - Gasket, Primary Venturi Cluster

13. Install the primary venturi clusters.

b

a
a

70454

a - Gasket, Primary Venturi Cluster (One Not Visible In This View)

b - Primary Venturi Cluster

90-861328--1 NOVEMBER 1999 Page 5C-37

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

14. Secure each cluster with two screws. Tighten securely.

a a
b

70453

a - Screws (Two Each Side)

b - Primary Venturi Cluster(s)

15. Install the accelerator pump spring into bottom half of carburetor.

70451
b
a - Accelerator Pump Spring
b - Carburetor Bottom

Page 5C-38 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

16. Install accelerator pump in top of carburetor housing, after placing washer and guide in
position.

b
c

70450
a - Accelerator Pump
b - Plunger Guide
c - Plunger Washer (Not Visible In This View)

17. Connect accelerator pump lever to pump rod using the S-link.
18. Secure pump lever with pivot screw. Tighten securely. Check to ensure lever actuates
the accelerator pump.
c

a
b 70449

a - Accelerator Pump Lever

b - Accelerator Pump
c - S-Link
d - Retainer Screw

19. Install gasket on top of carburetor.

70448

a - Gasket

90-861328--1 NOVEMBER 1999 Page 5C-39

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

20. Install inlet filter in bottom of inlet seat.

21. Install inlet seat with gasket in place. Tighten securely.

a
b
c

70447

a - Seat
b - Gasket
c - Inlet Filter

IMPORTANT: If using existing needles and seats, be sure to reinstall them as matched
sets, as noted during disassembly.
22. Install appropriate inlet needles into inlet seats.

b 70401

70446

a - Inlet Needle(s)
b - Seat(s)

Page 5C-40 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

IMPORTANT: If using existing floats, be sure to reinstall them on the same side as
removed.
23. Install floats using hinge pins.

a a 70400

a - Pin(s)
b - Floats(s)

24. Carefully lower top of carburetor onto bottom part.

70399

90-861328--1 NOVEMBER 1999 Page 5C-41

WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

25. Ensure gasket is properly positioned between the two parts and secure the top to bottom
with screws (nine total). Tighten securely.

a 70398

a - Screw(s)

70397

a - Spring(s)

IMPORTANT: If using existing metering rods, be sure that they are reinstalled in the
same side from which removed during disassembly.
26. Carefully install metering rod assemblies in the appropriate holes. Push down lightly on
metering rods to ensure that plunger will spring up and down.
a

70396
a - Metering Rod Assembly(s)

IMPORTANT: Some carburetors are equipped with air deflectors that are attached to
the screw that holds down the metering rod covers. Be sure to reinstall the deflectors
if your model carburetor requires them.

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SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

27. Position metering rod covers (and air deflectors, if equipped) over metering rods and
install screws. Tighten securely.
c
a
b

71094

71095

a - Screws
b - Metering Cover(s)
c - Air Deflectors (If Equipped)

28. Reconnect accelerator pump linkage rod to hole in accelerator pump lever where
originally connected. Secure using wire clip.

a
b

70390

a - Accelerator Pump Linkage Rod

b - Wire Clip

29. Connect electric choke link rod to choke plate lever. Secure using wire clip.
30. Refer to “Installation” and install carburetor.

Installation
1. Place appropriate new gasket on intake manifold.
2. If equipped, install adaptor or wedge plate, depending on model. Place appropriate new
gasket on top.

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WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

3. Install carburetor and throttle bracket with attaching hardware. Torque fasteners to
132 lb-in. (15 Nm).

a c

75862
75863
a - Fuel Line
b - Attaching Hardware
c - Throttle Bracket

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SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

4. Install fuel line. To prevent over-tightening, hold fuel inlet filter nut with suitable wrench
and tighten fuel line connector securely.
c
b
a

b
75862
a - Fuel Line
b - Fuel Line Connector
c - Fuel Inlet Filter Nut

5. Refer to SECTION 2. Install and adjust throttle cable following instructions appropriate
to your power package.
6. Install flame arrestor and tighten nut securely.
7. Installing positive battery cable to positive (+) battery terminal. Tighten clamp securely.
8. Install negative battery cable to negative (–) battery terminal. Tighten clamp securely.
9. Turn on fuel supply at fuel tank.
10. Start engine and check for gasoline leaks. If leaks exist, STOP ENGINE IMMEDIATELY
and recheck connections.
11. Adjust idle speed and idle mixture, as previously outlined under “Adjustments.”

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WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

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SERVICE MANUAL NUMBER 25 WEBER 4 BARREL CARBURETOR

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WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

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SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

FUEL SYSTEM
Section 5D - Sav1 Emission Fuel System With Weber 4 Barrel
Carburetor
Table of Contents
Identification . . . . . . . . . . . . . . . . . . . . . . . . 5D-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 5D-8
Replacement Parts Warning . . . . . . . . . . 5D-2 Checking Ported Vacuum Switch and
Torque Specifications . . . . . . . . . . . . . . . . 5D-2 Carburetor Vacuum Circuit
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 5D-2 for Correct Operation . . . . . . . . . . . . . 5D-9
Engine Specifications . . . . . . . . . . . . . . . . 5D-3 Service Procedures . . . . . . . . . . . . . . . . . . 5D-11
Carburetor Specifications . . . . . . . . . . . . . 5D-3 Checking Positive Crankcase
Carburetor Adjustment Specifications . . 5D-4 Ventilation (PCV) Valve . . . . . . . . . . . 5D-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . 5D-4 Removing Seals From
Special Notes . . . . . . . . . . . . . . . . . . . . . . . 5D-5 Idle Mixture Screws . . . . . . . . . . . . . . 5D-11
Carburetor Top Cover . . . . . . . . . . . . . 5D-5 Installing New Seals . . . . . . . . . . . . . . 5D-12
Sealed Idle Mixture Screws . . . . . . . .
Piston Bore of Emissions Model . . . .
5D-5
5D-6
Carburetor Installation . . . . . . . . . . . . .
Ported Vacuum Switch Installation . .
5D-12
5D-13 5
Precautions . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . .
5D-6
5D-7
Emissions System Connections . . . .
Propane Assisted Idle Set Procedure
5D-13
5D-15
D
Flame Arrestor . . . . . . . . . . . . . . . . . . . 5D-7 Test Equipment . . . . . . . . . . . . . . . . . . . . . 5D-18
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . 5D-7 Emissions Testing . . . . . . . . . . . . . . . . . . . 5D-19
Positive Crankcase Ventilation (PCV) 5D-8

90-861328--1 NOVEMBER 1999 Page 5D-1

SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Identification
The SAV1 Emissions version of the Weber WFB carburetor has vacuum fittings on the front
side.

a 73701

a - Vacuum Fittings

Replacement Parts Warning

WARNING
Electrical, ignition and fuel system components on your Mercury 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.

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Carburetor to Manifold 132 15
Fuel Line to Carburetor 18 24
Fuel Inlet Filter Nut 18 24

Special Tools
Mercury Marine Special Tools
Description Part Number
Universal Carburetor Gauge 91-36392
Tachometer 91-59339

Page 5D-2 90-861328-–1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

Other Special Tools

Description Part Number
Universal Carburetor Stand
TORX Screwdrivers (15, 20 & 25) Obtain Locally
Propane Bottle [14 oz. (400 grams)]
Propane Enrichment Kit (1) J26911
(2) YA7148
(Various Suppliers) (3) 7148
Ported Vacuum Switch (PVS) (1) No P/N
Socket Wrench (2) S9842A
(Various Suppliers) (3) 7267

Special Tool Suppliers:

(1) Kent-Moore Part Number
(2) Snap-On Part Number
(3) OTC Part Number
NOTE: Weber carburetors will have a “star” shaped socket in the head of some screws. A
TORX screwdriver must be used on this type of screw. The sizes used are numbers 15,
20 and 25.

Engine Specifications

Model MCM 4.3LH

Thermostat 160°F (71°C)
Ignition Timing 10° BTDC
Idle Speed in Neutral 775 rpm
Propane Idle Speed (See Procedure) 850 rpm

Carburetor Specifications
NOTICE
Unit Of Measurement: U.S. Inches (Millimeters)
All measurements are +/– 1/64 in. (0.4 mm)

Metering
Mercury Number Metering
Engine Carb Primary Secondary Rod
(Manufacturer Rod
Model Type Jet Size Jet Size Spring
Number) Number
Color
MCM Weber 3310-860076 .087
.086 (2.18) 16-656457 Natural
4.3LH WFB (9667S) (2.21)

90-861328--1 NOVEMBER 1999 Page 5D-3

SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Carburetor Adjustment Specifications

Make And Model Weber WFB
Float Level 1-9/32 (33)
Float Drop 2 In. (51)
Number 3 from end (Hole
Pump Rod Hole Location
closest to lever pivot point)
Accelerator Pump 7/16 (11) (Note 1)

NOTE: Measured from top of Carburetor to bottom of S-Link

Description
The Emissions system is designed to lower exhaust emissions to meet regulations. It
consists of the following items: a Positive Crankcase Ventilation (PCV) circuit, a Ported
Vacuum Switch (PVS) circuit and a specially designed Weber WFB carburetor.
Weber WFB carburetor is unique in design, as the main body and flange are cast as a one
piece unit. This, along with the bowl cover, make up the two piece construction which is
made of light, durable aluminum to dissipate heat.
There are two separate float circuits. Each float circuit supplies fuel to a primary low speed
circuit and a primary and secondary high speed circuit. The bowls are vented to the inside
of the air horn. A connecting vent passage effects a balance of the air pressure between the
two bowls.
The float needle valves are installed at an angle to provide the best possible seating action
on the needles. This provides better needle response to float movement, also.
The PVS circuit is used in conjunction with the idle circuit. When the engine is cold, the PVS
circuit is closed. This shuts off a metered air-bleed to the idle circuit, to maintain a rich idle
circuit for warm-up. Once the engine warms up [approximately 128°F (54°C)], the PVS
opens, allowing a metered amount of air to be mixed into the idle circuit. This leans the idle
circuit to the proper operating air-fuel ratio.
The high speed circuits use staged step-up rods in the main metering jets to control the
amount of fuel admitted to the nozzles. The position of the step-up rod is controlled by
manifold vacuum applied to the vacuum piston.
A primary air bleed located in the venturi cluster prevents a rich condition or bog as the high
speed circuit is reactivated after deceleration.
Small “L” shaped metal tabs, called “distribution tab(s),” are attached to some venturi
clusters and protrude into the air stream at the proper location to aid distribution of fuel on
selected applications.
The PCV circuit ventilates crankcase vapors (unburned gases) back into the intake manifold
to be burned again.

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SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

Special Notes
IMPORTANT: Disassembly and repair of the SAV1 Emissions carburetor is basically
the same as the other Weber WFB carburetors. There are some internal and external
differences that are noted following:

Carburetor Top Cover

The carburetor top cover (air-horn) has vacuum fittings for connection to the “Ported
Vacuum Switch” (PVS).

a 73701

a - Vacuum Fittings

Sealed Idle Mixture Screws

The idle mixture screws have seals that prevent tampering with the idle mixture after the
mixture has been properly adjusted.

a 71798

Typical
a - Screw Seals

90-861328--1 NOVEMBER 1999 Page 5D-5

SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Piston Bore of Emissions Model

The piston bore of the Emissions Model of the Weber carburetor has a machined step as
shown.

73737

Precautions
WARNING
Always disconnect battery cables from battery BEFORE working on fuel system to
prevent fire or explosion.

WARNING
Be careful when cleaning flame arrestor and crankcase ventilation hose: 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 open flame in area
when cleaning flame arrestor and crankcase ventilation hose.

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 open flame in area while
changing fuel filter. Wipe up any spilled fuel immediately.

WARNING
Make sure no fuel leaks exist, before closing engine hatch.

CAUTION
DO NOT operate engine without cooling water being supplied to water pickup holes
in gear housing or water pickup inlet, or water pump impeller will be damaged and
subsequent overheating damage to engine may result.

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SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

Maintenance

Flame Arrestor
Maintenance for the flame arrestor is the same as standard engine (Refer to SECTION 5C).
The only difference in the flame arrestor on an engine with the Bodensee Emissions system
is in the vent hose bracket. This bracket has a fitting on one side only.
a
b

71798

71797

a - Stud
b - Vent Hose Bracket
c - Vent Hose To Starboard Valve Cover
d - NO VENT HOSE ON THIS SIDE

Fuel Filter
Maintenance for fuel inlet filters is the same as standard engine (See SECTION 5C.).

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SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Positive Crankcase Ventilation (PCV)

The Positive Crankcase Ventilation (PCV) valve should be replaced once a year.

a
71925

Typical
a - PCV Valve
b - Hose

Troubleshooting
NOTE: Review the “Description” section of this manual for an understanding of system
operation, before troubleshooting the carburetor. Do not assume that a problem exists
inside the carburetor without first eliminating other engine system components as potential
problem areas. Be sure to check the following items:
• Engine operating temperature (Proper Thermostat - See “Engine Specification Chart”).
• Correct ignition timing (See “Engine Specification Chart”).
• Cylinder compression.
• Ported Vacuum Switch (PVS) functioning properly.
Use the following procedure to check for a faulty Ported Vacuum Switch (PVS):

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SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

Checking Ported Vacuum Switch and

Carburetor Vacuum Circuit for Correct Operation
NOTE: The engine must be cold before performing the first 4 steps.
1. Start engine. Disconnect the hose from the carburetor at the location shown.

73733

2. Plug the hose with your finger. You should not feel vacuum on the hose at this time.

73734

3. Allow engine to run and warm up to normal operating temperature.

4. Disconnect the hose again and check for vacuum. If PVS is functioning properly, there
should be vacuum present at this time. If vacuum is not present, ensure that hoses are
properly connected and are not cracked or plugged.
5. Proceed to check the carburetor vacuum circuit.
6. Reconnect rear hose to carburetor.
NOTE: The engine must be warm before performing the next step.
7. Start engine and allow it to reach normal operating temperature.

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SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

8. Disconnect the two hoses on the front of carburetor.

73738

IMPORTANT: Ensure that engine is running at 775 rpm or below. This ensures that
the carburetor is not running on the “Off-Idle” circuit.
9. Connect a tachometer to the engine.
10. Plug the vacuum ports on the front of the carburetor. Be sure to only plug one port at a
time. When vacuum port is covered, the engine rpm should increase.
11. Repeat test on the other port. If vacuum is not present, a vacuum port may be plugged.
Clean vacuum ports and repeat the entire test.

73740 73739

12. When test is complete and PVS is determined to be functioning properly, reconnect all
hoses in vacuum circuit.

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SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

Service Procedures
Checking Positive Crankcase Ventilation (PCV) Valve
1. Start engine and allow it to reach normal operating temperature.
2. Remove PCV valve from valve cover. Plug the opening with your finger. A vacuum
should be felt.
3. Stop the engine.
4. Shake the valve to ensure that the internal components are free to move.

73743

Removing Seals From Idle Mixture Screws

WARNING
Avoid fire or explosion. Using a cutting wheel to cut the seals will cause sparks,
which will ignite any fuel that is present. Ensure that there is no fuel present and
that carburetor is removed from engine prior to cutting the seals from the
carburetor idle mixture screws.
1. Remove carburetor from the engine.
2. Drain all fuel from the carburetor.
3. Using a cutting wheel, make a cut on both sides of the seal casing.
4. Using a suitable device, pry the plug from the inside of the seal. Once the plug is
removed, the idle mixture screw can be removed and the seal casing can be removed.

a
73744

a - Cutting Wheel

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SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

Installing New Seals

1. Install new seal cup, spring and idle mixture screw.
IMPORTANT: Do not install the seal plug until the “Propane Assisted Idle Mixture
Adjustment” procedure has been completed.
2. Align the opening in the plug with the tab on the cup and push down until it snaps in place.

a
b 73789

a - Opening In Plug
b - Tab On Cup

Carburetor Installation
1. Place new gasket on adapter plate.
2. Install carburetor and throttle bracket and secure with new attaching hardware. Torque
fasteners to 132 lb-in. (15 Nm).
3. Connect fuel line. To prevent over-tightening, hold fuel inlet nut with a suitable wrench
and tighten fuel line connector securely.

b c

75862 75863

Weber 4 Barrel Weber 4 Barrel

Starboard Front Starboard Rear
a - Fuel Line
b - Attaching Hardware
c - Throttle Bracket

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SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

Ported Vacuum Switch Installation

CAUTION
Be careful not to break off fittings when installing the ported vacuum switch (PVS)
in the following step.
NOTE: A special tool is available to install the PVS. Refer to the “Tool Chart” at the beginning
of this manual.
1. If removed, install ported vacuum switch (PVS) into reducer bushing. Apply Loctite Pipe
Sealant with Teflon to threads before installing. Tighten PVS securely and position the
fittings toward back of engine as shown.

a 71913

a - Reducer Bushing
b - Ported Vacuum Switch (PVS)

Emissions System Connections

1. Install the positive crankcase ventilation (PCV) valve in the port valve cover.
2. Connect hose to PCV valve. Connect opposite end of hose to fitting on front of
carburetor.

a
71925
c 73701

a - PCV Valve
b - Hose
c - Carburetor Fitting (Connect Hose Here)

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SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

3. Connect hoses to ported vacuum switch (PVS) as shown.

c
c
d a 71924
d

b
73702

a
a - Ported Vacuum Switch
b - Hoses (Switch To Y-Fitting)
c - Hoses (To Front Side Of Carburetor)
d - Hose (Y-Fitting To Back Side Of Carburetor)

IMPORTANT: The hose that runs from the T-Fitting to the back side of the carburetor
must be routed beneath the throttle linkage as shown in the following illustration. En-
sure that the hose does not rub against linkage.

b 71916
71917
a

a - T-Fitting
b - Hose, T-Fitting To Back Of Carburetor

Page 5D-14 90-861328-–1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

Propane Assisted Idle Set Procedure

WARNING
Avoid fire or explosion. Observe the following precautions when performing this
procedure.
• Do not operate the engine without the flame arrestor installed, above the
speeds listed in this procedure.
• Propane is extremely flammable and explosive. Ensure that the following test
is performed in a well ventilated area with the engine hatch open.
• Ensure that there is no spark or open flame in the test area.
• Do not start the flow of propane until the hose has been placed into the carbure-
tor and the engine has been started.
• Keep a fire extinguisher available when performing this test.
NOTE: This test must be performed any time the carburetor has been disassembled and
internal components have been disturbed or the idle mixture screws have been tampered
with. The test should also be performed if other component parts of the emissions system
have been altered, repaired or replaced.
IMPORTANT: Ensure that the PVS is functioning properly before performing this
procedure.
1. As a starting point, set both idle mixture screws at 1 turn out from the fully seated
position.
2. Start engine and allow it to warm up to normal operating temperature. If engine has been
run above idle speed, allow engine to idle for 3 to 5 minutes to stabilize the engine.
3. Remove flame arrestor.
4. Insert special “Y”-Adapter hoses into carburetor as shown. Place the hoses behind the
choke plate to help hold them in place.

73731

5. Connect the hose from the propane bottle valve to the “Y”-Fitting.

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SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

6. With engine idling at normal operating temperature, press the propane flow button on
the valve. Slowly begin opening the propane metering valve until maximum engine rpm
is reached. When too much propane is added, engine rpm will decrease. “Fine tune” the
metering valve to obtain the highest rpm.

b 73673

a - Propane Flow Valve

b - Propane Metering Valve

7. With propane still flowing, adjust the idle speed screw (not the mixture screws) to obtain
850 rpm. Again, fine tune the propane metering valve to obtain the highest engine rpm.
If there has been a change in the maximum rpm, readjust the idle speed screw to 850
rpm.
8. Release the propane flow valve and allow engine speed to stabilize. Slowly adjust the
mixture screws by equal amounts, pausing between adjustments to allow engine speed
to stabilize, to achieve 775 rpm.

73722

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SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

9. Press the propane flow valve. Engine rpm should increase to 850 rpm. If it does not,
repeat steps 5 through 7.

73662

10. If after performing the above procedure several times, the correct results can still not be
obtained, check the following:
• PVS not working properly.
• Incorrect float level.
• Vacuum leaks.

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SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

11. Once the idle speed and mixture adjustment is correct, install the seal plugs over mixture
screws. Ensure the opening in plug snaps into the tab in the cup.

c
b 73789

71798

a - Screw Seal
b - Tab In Cup
c - Opening In Cup

12. Reinstall the flame arrestor.

Test Equipment
The following equipment, provided by the Dealer or Inspector, is needed to perform an
emissions test on this engine:
• Test Probes.
• Test Probe Collector.
• Exhaust System Analyzer.

b
a

73723

a - Exhaust Probe Collector

b - To Exhaust Analyzer

Page 5D-18 90-861328-–1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

Emissions Testing
b a

71926

a - Exhaust Test Probes (2)

b - Exhaust Elbow Adapter Fittings (2)

1. Remove plugs from both exhaust elbows.

75319

Typical
a - Plugs (Port And Starboard Elbows)

2. Install exhaust elbow adapter fittings into elbows. Apply Loctite Pipe Sealant with Teflon
to threads that go into elbow. Tighten securely.

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SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR SERVICE MANUAL NUMBER 25

3. Insert exhaust test probes into fittings and tighten securely.

75319

b
71923

75324

a - Adapter Fittings
b - Exhaust Test Probes

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SERVICE MANUAL NUMBER 25 SAV1 EMISSION FUEL SYSTEM WITH WEBER 4 BARREL CARBURETOR

4. When exhaust emissions test is complete, remove test probes and adapter fittings and
reinstall the plugs. Apply Perfect Seal to threads before installing. Torque to 150 lb-in.
(17 Nm).

NOTICE to INSTALLER
Your engine is equipped with special design features and special tuning to minimize emis-
sion output from the engine. You should follow:
• Recommended maintenance schedules particularly the ignition system
• Proper engine tuning procedures to ensure these features remain in good operating
order.
• Proper steps to maintain the engine within specification.
The instructions in the Emissions Kit provide the necessary information to properly con-
vert the engine to meet the applicable SAV1 Regulations. There is another item within the
regulation that is beyond the control of Mercury Marine. This item is related to the fuel
filling system on the boat. The requirements for the fuel filler neck are as follows:
• Must be designed so that it is impossible to use a fuel nozzle with an outside diameter
of more than 23.6 mm.
• The filler neck shall be durable and designed so that modifications are not possible.
• A durable, legible plate shall be mounted on the boat near the fuel filler neck. This
plate shall read “UNLEADED GASOLINE ONLY.”
Any questions about the fuel filler neck requirement and availability would be directed to
the boat manufacturer.

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SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION

FUEL SYSTEM
Section 5E - Fuel Delivery System
For Electronic Fuel Injection
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5E-2 Water Separating Fuel Filter . . . . . . . . . . 5E-7
Torque Specifications . . . . . . . . . . . . . . . . 5E-2 Water Separating Fuel Filter
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-2 Replacement . . . . . . . . . . . . . . . . . . . . 5E-8
Lubricants / Sealants / Adhesives . . . . . 5E-2 Cool Fuel System Repair . . . . . . . . . . . . . 5E-8
Replacement Parts Warning . . . . . . . . . . 5E-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . 5E-8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5E-3 Disassembly . . . . . . . . . . . . . . . . . . . . . 5E-10
Fuel Supply Connections . . . . . . . . . . . . . 5E-3 Reassembly . . . . . . . . . . . . . . . . . . . . . 5E-11
Fuel Delivery System . . . . . . . . . . . . . . . . 5E-4 Installation . . . . . . . . . . . . . . . . . . . . . . . 5E-13
Recommendations . . . . . . . . . . . . . . . . 5E-4 Vacuum and Vent Hose Routing . . . . . . . 5E-15
Cool Fuel System Exploded View . . . . . 5E-5 Throttle Body EFI . . . . . . . . . . . . . . . . . 5E-15
Fuel System Flow Diagrams . . . . . . . . . . 5E-6
Throttle Body Injection . . . . . . . . . . . . 5E-6 5
E

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FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION SERVICE MANUAL NUMBER 25

Specifications
Description Specification
Pump Pressure 30 PSI (207 kPa)

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Fuel Lines 18 24
Fuel Fittings See Note

Tools
Description Part Number
Fuel Pressure Gauge Obtain Locally

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver Perfect Seal 92-34227--1
#592 Loctite Pipe Sealant with Teflon Obtain Locally

NOTE: Refer To “Fuel Supply Connections” Warning following.

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 mini-
mize 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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SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION

Precautions
WARNING
Always disconnect battery cables from battery BEFORE working on fuel system to
prevent fire or explosion.

WARNING
BE CAREFUL while working on fuel system; 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 and/or open flames in the area. Wipe up any spilled
fuel immediately.

WARNING
Make sure that no fuel leaks exist before closing engine hatch.

WARNING
Avoid Fire or Explosion: Fuel injection system is pressurized during operation. Use
care when removing water separating fuel filter. Fuel could spray on hot engine
causing fire or explosion. Allow 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 spray-
ing on the engine.

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.

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
OVER-TIGHTEN.
• Install fuel line. To prevent over-tightening, hold brass fitting with suitable
wrench and tighten fuel line connectors securely.
• Check for fuel leaks.

90-861328--1 NOVEMBER 1999 Page 5E-3

FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION SERVICE MANUAL NUMBER 25

Fuel Delivery System

Recommendations
WARNING
Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be ad-
hered 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.
All fuel lines must be well secured. The holes where the lines run 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, ap-
plying to all engines unless otherwise stated, must be considered. Refer to boating stan-
dards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines.
1. Fuel pickup should be at least 1 in. (25mm) from the bottom of fuel tank to prevent pick-
ing up impurities.
2. Fuel lines used must be Coast Guard approved (USCG Type A1).
3. 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, line must not be smaller than 1/2 in.
(13mm) I.D.
4. Larger diameter (than previously specified) lines and fittings must be used on installa-
tions requiring long lines or numerous fittings.
5. Fuel line(s) should be installed free of stress and firmly secured to prevent vibration and/
or chafing.
6. Sharp bends in fuel lines should be avoided.
7. 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.

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SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION

Cool Fuel System Exploded View

24
2

7 8
3
6

23
4 9
10

22
5 12
13
11
23 14 12

16

15

18 17
19
20 21
75708

Exploded View Component List

1 - Bracket 14 - Fuel Cooler

2 - Cover Base 15 - Fuel Pump Wiring Harness
3 - Screw and Washer (2) 16 - Retainer Bracket
4 - Fuel Pressure Regulator 17 - Nut (2)
5 - Return Fuel Line 18 - Electric Fuel Pump
6 - Retaining Ring 19 - Inlet Fitting
7 - O-Rings (2) 20 - Fuel Line Inlet
8 - Fuel Line To Throttle Body 21 - Cover
9 - Gasket 22 - Filter
10 - Drain Plug 23 - Seawater Hoses (Hose Clamps Not
11 - Stepped Screw Shown)
12 - O-Rings (4) 24 - Vacuum Hose
13 - Elbow

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FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION SERVICE MANUAL NUMBER 25

Fuel System Flow Diagrams

Throttle Body Injection

b a
c

j d

74871

All Throttle Body Fuel Injection Is Similar

a - Diaphragm Rupture Line To Flame Arrestor
b - Fuel Pressure Regulator
c - Fuel Cooler
d - Electric Fuel Pump
e - Water Separating Fuel Filter
f - Fuel From Tank
g - Direction Of Water Flow
h - Throttle Body Unit
i - Fuel Line To Throttle Body
j - Excess Fuel Return To Water Separating Fuel Filter

Page 5E-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION

Water Separating Fuel Filter

NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

c
b
d
g

e f

h
i
j

a - Top Cover (If Equipped)

b - Insulator Plate
c - Fuel Return Line from Regulator
d - Brass Fitting
e - Fuel Line to Fuel Pump
f - Brass Fitting
g - Fuel Filter Mounting Bracket
h - Nut
i - Fuel Inlet Fitting
j - Plug
k - Water Separating Fuel Filter
l - Bottom Cover (If Equipped)

90-861328--1 NOVEMBER 1999 Page 5E-7

FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION SERVICE MANUAL NUMBER 25

Water Separating Fuel Filter Replacement

NOTICE
Refer to “Precautions” in this section BEFORE proceeding.

1. Disconnect battery cables from battery.

2. Remove fuel filter from base. A filter wrench may be needed.
3. Lubricate sealing ring(s) of new filter with engine oil.
4. Install new filter. Tighten securely by hand.
5. Reconnect battery cables.
6. Supply water to cooling system.
7. Start engine.
8. Check for fuel leaks.

Cool Fuel System Repair

Removal
1. Disconnect battery cables from battery.
IMPORTANT: Suitably plug open ends of fuel line connections to prevent fuel leaks
and entry of water or contaminates into lines while working.
2. Close fuel shutoff 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.

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. As a
precautionary measure, attach a tag to the ignition switch or steering wheel with the
warning that the seacock must be opened or the water inlet hose reconnected prior
to starting the engine
3. Close seacock, if equipped. If boat is not equipped with a seacock, remove and plug the
seawater inlet hose.
4. Drain seawater system. Refer to SECTION 1B.
5. Disconnect seawater hoses from fuel cooler.

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SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION

6. Disconnect fuel lines from water separating fuel filter adapter.

b a

75533

a - Filter Adapter
b - Fuel Lines

7. Disconnect the fuel line from the throttle body.

8. Remove the cover from the cool fuel system.
9. Disconnect the fuel pump electrical connector.
10. Disconnect the vacuum hose connected to the pressure regulator.
11. Remove the two upper engine mount bracket nuts retaining fuel cooler bracket to the
engine.
12. Carefully remove the cool fuel system assembly.

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FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION SERVICE MANUAL NUMBER 25

Disassembly
NOTE: Retain all fasteners and hardware unless instructed otherwise.
1. Remove the two nuts from the Cool Fuel retaining bracket studs. Lift the retainer bracket
and cooler/pump assembly from the cover base.
IMPORTANT: To prevent loss of the stepped screw used to secure the cooler-to-
throttle body fuel line, a retainer ring is provided. Do not remove the retainer or
stepped screw.

b
e
a

b c

f
c
75708
d 75708

a - Fuel Line O-Rings

b - Fuel Line, Cooler-to-Throttle Body
c - Fuel Cooler
d - Stepped Screw - Loosened To Accept Fuel Line
e - Retainer Ring
f - Stepped Screw - Torqued

2. Disconnect the fuel lines from the assembly.

3. Disconnect the elbow fitting and fuel pump from the cooler assembly.
4. Remove the elbow fitting from the fuel pump (to allow replacement of O-rings during
assembly).
5. Remove the two screws retaining the fuel pressure regulator to the fuel cooler.
6. Remove the regulator.
7. Remove and retain the seawater drain plug and seal from the cooler.

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SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION

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 to 53 lb-in. ( 5.8 Nm).
3. Using wrench to stabilize the fitting, connect the fuel line to the regulator. Tighten
securely.
d

e
c

b a

75708

a - Filter
b - Fuel Cooler Orifice
c - Pressure Regulator
d - Screw and Washer
e - Fuel Line

4. Install the throttle body fuel line as follows:

a. Install two (of six) O-rings onto the cooler-to-throttle body fuel line where it attaches
to the cooler, if not already present.
b. Completely loosen, but do NOT remove, the stepped screw that retains the fuel line.
c. Lubricate the two fuel line O-rings with a small amount of liquid dish soap (obtain
locally).
d. Insert the fuel line into the cooler orifice. Hand tighten the special screw.
e. Torque the stepped screw to 81 lb-in. (9 Nm).

90-861328--1 NOVEMBER 1999 Page 5E-11

FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION SERVICE MANUAL NUMBER 25

IMPORTANT: To prevent loss of the stepped screw used to secure the cooler-to-
throttle body fuel line, a retainer ring is provided. Do not remove the retainer or
stepped screw.

b
e
a

b c

f
c
75708
d 75708

a - Fuel Line O-Rings

b - Fuel Line, Cooler-to-Throttle Body
c - Fuel Cooler
d - Stepped Screw - Loosened To Accept Fuel Line
e - Retainer Ring
f - Stepped Screw - Torqued
g - Retainer Ring

5. Install the fuel pump to the cooler as follows:

a. Install the remaining four (of six) O-rings on the fuel pump / cooler elbow fitting as
shown.
b. Lubricate O-rings for the elbow fitting with a small amount of liquid dish soap (obtain
locally).
c. Install the elbow in the fuel pump.
d. Install the fuel pump with elbow fitting in the cooler assembly.

a
b

c b

75708

a - O-Rings (4)
b - Elbow Fitting
c - Fuel Pump
d - Fuel Cooler

Page 5E-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION

6. Position the completed fuel cooler assembly in the cover base.

7. Apply a thin, even coating of Thermal Grease on all of the retainer bracket inside sur-
faces where it contacts the cooler and the fuel pump when installed.

b
a

a - Retainer Bracket
b - Thermal Grease

8. Install the retainer bracket over the cooler and fuel pump. Apply Loctite 242 to the
threads of the mounting studs. Torque the two nuts to 50 lb-in. (5.6 Nm).
9. Install and securely tighten the seawater drain plug.

Installation
1. If removed, reinstall the fuel filter assembly and secure using the two self locking nuts.
Tighten securely.
2. Using wrench to stabilize brass filter nut, connect the fuel lines to the fuel filter adapter.
Tighten securely.

a c
b

75533

a - Filter Assembly
b - Fuel Lines
c - Lock Nuts

3. Route the fuel lines as needed and place the Cool Fuel assembly on the engine mount
studs. Install the two engine mounting nuts. Torque to 30 lb-ft (41 Nm).
4. Install the cooler-to-throttle body fuel line as follows:
a. Route the fuel line to the back side of engine.

90-861328--1 NOVEMBER 1999 Page 5E-13

FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION SERVICE MANUAL NUMBER 25

b. Using wrench to stabilize brass filter nut, connect the fuel line to the throttle body
fitting at location shown. Tighten securely.

75806

a - Fuel Line, Fuel Cooler-to-Throttle Body

b - Fuel Fitting

5. Install distributor cap (if removed).

6. Connect vacuum line to fuel pressure regulator.
7. Attach engine harness electrical connector to fuel pump harness connector.

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.
8. Connect seawater hoses to Cool Fuel system. Tighten hose clamps securely.
9. Unplug and connect seawater inlet hose. Open seacock, if equipped.
10. Unplug and connect fuel tank supply inlet hose. Tighten hose clamp securely. Open fuel
shutoff valve, if equipped.

CAUTION
When installing battery, be sure to connect POSITIVE (+) battery cable to POSITIVE
(+) battery terminal FIRST, and NEGATIVE (–) battery cable to NEGATIVE (–) battery
terminal LAST. If battery cables are reversed, or connection order is reversed, elec-
trical system damage will result.
11. Clean battery cable clamps and terminals and reconnect cables (see CAUTION listed
above). Secure each cable clamp when connecting. Coat terminals with a battery termi-
nal anti-corrosion spray to help retard corrosion.
12. Start the engine and check for fuel and water leaks. Stop the engine immediately if any
leaks exist. Make necessary corrections.
13. Install cool fuel system cover.

WARNING
Make sure no leaks exist before closing engine hatch.

Page 5E-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION

Vacuum and Vent Hose Routing

Throttle Body EFI

b
e

c d

f
g
a - Throttle Body
b - Cool Fuel Assembly
c - Diaphragm Rupture Hose - Fuel Pressure Regulator on Cool Fuel Assembly To
Side of Flame Arrestor
d - Vent Hose - PCV Valve to Flame Arrestor
e - PCV Valve
f - Vent Hose - Valve Cover Fitting To Throttle Body
g - Valve Cover Fitting
h - Flame Arrestor
i - Front of Engine

90-861328--1 NOVEMBER 1999 Page 5E-15

FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION SERVICE MANUAL NUMBER 25

THIS PAGE IS INTENTIONALLY BLANK

Page 5E-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

FUEL SYSTEMS
Section 5F - Fuel Injection Descriptions And
System Operation
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 5F-2 Electronic Control Module (ECM)
Service Precautions . . . . . . . . . . . . . . . . . 5F-3 and Sensors . . . . . . . . . . . . . . . . . . . . . . . 5F-13
General Information . . . . . . . . . . . . . . . . . 5F-5 General Description . . . . . . . . . . . . . . . 5F-13
Introduction . . . . . . . . . . . . . . . . . . . . . . 5F-5 Computers and Voltage Signals . . . . 5F-13
Visual/Physical Inspection . . . . . . . . . 5F-5 Analog Signals . . . . . . . . . . . . . . . . . . . 5F-13
Basic Knowledge and Tools Required 5F-5 Digital Signals . . . . . . . . . . . . . . . . . . . . 5F-14
Electrostatic Discharge Damage . . . . 5F-5 Engine Control Module (ECM) . . . . . . 5F-15
Diagnostic Information . . . . . . . . . . . . 5F-5 Speed Density System . . . . . . . . . . . . 5F-16
Wiring Harness Service . . . . . . . . . . . 5F-6 ECM Input and Sensor Descriptions . 5F-17
Wiring Connector Service . . . . . . . . . . 5F-7 Spark Management . . . . . . . . . . . . . . . . . . 5F-22
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . 5F-8 High Energy Ignition with
ECM Self-Diagnostics . . . . . . . . . . . . . . . .
Diagnostic Code Tool
5F-9 Ignition Control (IC) . . . . . . . . . . . . . .
Modes Of Operation . . . . . . . . . . . . . .
5F-22
5F-23
5
With Malfunction Indicator Lamp . . .
Intermittent Malfunction
5F-9 Base Ignition Timing . . . . . . . . . . . . . .
Base Ignition Timing (Continued) . . .
5F-24
5F-25
F
Indicator Lamp . . . . . . . . . . . . . . . . . . . 5F-9 Results of Incorrect Operation . . . . . . 5F-25
Reading Codes . . . . . . . . . . . . . . . . . . . 5F-10 Fuel Metering System . . . . . . . . . . . . . . . . 5F-26
Scan Tools . . . . . . . . . . . . . . . . . . . . . . . 5F-11 General Description . . . . . . . . . . . . . . . 5F-26
EFI Diagnostic Circuit Check . . . . . . . 5F-11 Cool Fuel Systems . . . . . . . . . . . . . . . . 5F-26
Scan Tool Use With Intermittents . . . 5F-11 Modes of Operation . . . . . . . . . . . . . . . 5F-26
Non-Scan Diagnosis of Driveability Throttle Body Injection Components . 5F-28
Concerns (With No Codes Set) . . . . 5F-12

90-861328--1 NOVEMBER 1999 Page 5F-1

FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

Special Tools

Part Number Tool Name Description

Minimum 10 megohm input impedance
J-34029-A required on all voltage ranges. As amme-
High Impedance
ter, accurately measures low value current
(Note 1 and 2) Multimeter (DVM)
flow. As ohmmeter, reads 0-200 ohms,
2/20/200 kΩ, 2/20 mΩ.
Vacuum Pump with Gauge monitors manifold engine vacuum.
J-23738 Gauge - 20 In. Hg Hand pump used to check fuel pressure
Minimum regulator.
Unpowered Test Used to check circuit wiring, short to
J-34142-B (Note 3)
Light ground or voltage.
Injector Harness Visually indicates injector electrical im-
J-34730-2A
Test Light pulses from the ECM.
Harness Test Allows multi-meter connections with wiring
J-35616
Adapter harness.
Displays problem codes stored in the
MerCruiser Scan ECM. It also allows monitoring of various
94050m Tool Version 3.4 circuits and components in the fuel injec-
(English) tion system. Allows for test firing injectors.
Tool can read MEFI 1 and MEFI 3 ECM.
94008 Code Mate Tester Flashes light to display problem codes.
Used to check ignition timing. Must have
91-99379 Timing Light
inductive signal pickup.
Used to check fuel system pressure. Kit
Fuel Pressure
91-16850A5 includes 91-803135 Test Port Adaptor Kit
Gauge Kit
and 91-806901 TBI Pressure Valve.
Displays problem codes stored in the
Quicksilver Digital
ECM. It also allows monitoring of various
91-823686A2 Diagnostic Terminal
circuits and components in the fuel injec-
(DDT)
tion system.
Displays problem codes stored in the
ECM. It also allows monitoring of various
MerCruiser DDT
91-803999 circuits and components in the fuel injec-
Cartridge Version 2
tion system. Tool can read MEFI 1 and
MEFI 3 ECM.
Displays problem codes stored in the
DDT Adaptor Har- ECM. It also allows monitoring of various
84-822560A2
ness circuits and components in the fuel injec-
tion system.
Used to set Ignition timing. Plug connects
91-805747A2 EFI Timing Tool
to DLC.
Used to perform fuel system pressure
91-805918A2 Fuel Shutoff Tool
test.
Fuel Line Connec- Allows connection of Fuel Pressure
91-806901
tor Gauge.

Page 5F-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

Special Tools (continued)

NOTE: 1 The High Impedance Multimeter that comes with the existing Outboard 2 Cycle EFI
Tester, P/N 91-11001A2 meets the requirements listed above.
NOTE: 2 Quicksilver Digital Tachometer / Multi-Meter (DMT 2000) P/N 91-854009A1, meets
the requirements listed above.
NOTE: 3 Using a test light with 100 mA or less rating may show a faint glow when test actual-
ly states no light.

Kent-Moore Tools, Inc. Rinda Technologies

29784 Little Mack 4563 N. Elston Ave.
Roseville, MI 48066 Chicago, IL 60630
Phone: 800-345-2233 Phone: 773-736-6633
Fax: 773-736-2950
E-mail: [email protected]

Service Precautions
The following requirements must be observed:
• Before removing any ECM system component, disconnect the negative battery cable.
• Never start the engine without the battery being solidly connected.
• Never separate the battery from the on-board electrical system while the engine is run-
ning.
• Never separate the battery feed wire from the charging system while the engine is run-
ning.
• When charging the battery, disconnect it from the boat’s electrical system.
• Ensure that all cable harnesses are connected solidly and that battery connections are
thoroughly clean.
• Never connect or disconnect the wiring harness at the ECM when the ignition is switched
ON.
• Before attempting any electric arc welding, disconnect the battery leads and the ECM
connector(s).
• When steam cleaning engines, do not direct the steam cleaning nozzle at ECM system
components. If this happens, corrosion of the terminals or damage of components can
take place.
• Use only the test equipment specified in the diagnostic charts, since other test equip-
ment may either give incorrect results or damage good components.
• All voltage measurements using a voltmeter require a digital voltmeter with a rating of 10
megohms input impedance.

90-861328--1 NOVEMBER 1999 Page 5F-3

FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

• When a test light is specified, a “low-power” test light must be used. DO NOT use a high-
wattage test light. While a particular brand of test light is not suggested, a simple test, as
shown below, on any test light will ensure it to be safe for system circuit testing. Connect
an accurate ammeter (such as the high impedance digital multimeter) in series with the
test light being tested, and power the test light ammeter circuit with the vehicle battery.

a
b

a - Test Light
b - Battery
c - Ammeter

IMPORTANT: If the ammeter indicates LESS than 3/10 amp. current flow (.3 A or 300
mA), the test light is SAFE to use.
If the ammeter indicates MORE than 3/10 amp. current flow (.3 A or 300 mA), the test
light is NOT SAFE to use.
NOTE: Using a test light with 100 mA or less rating may show a faint glow when test actually
states no light.
w When using a DVOM to perform voltage measurements, turn the ignition OFF when
connecting the DVOM to the circuitry to be tested.

CAUTION
To reduce the chance of personal injury and/or property damage, the following
instructions must be carefully observed: proper service and repair are important to
the safety of the service technician and the safe, reliable operation of all MerCruiser
Electronic Fuel Injection equipped engines. If part replacement is necessary, the
part must be replaced with one of the same part number or with an equivalent part.
Do not use a replacement part of lesser quality. The service procedures recom-
mended and described in this service manual are effective methods of performing
service and repair. Some of these procedures require the use of tools specially de-
signed for the purpose. Accordingly, anyone who intends to use a replacement part,
service procedure or tool, which is not recommended by the system manufacturer,
must first determine that neither his safety nor the safe operation of the engine will
be jeopardized by the replacement part, service procedure or tool selected. It is im-
portant to note that this manual contains various “Cautions” and “Notes” that must
be carefully observed in order to reduce the risk of personal injury during service
or repair, or the possibility that improper service or repair may damage the engine
or render it unsafe. It is also important to understand that these “Cautions” and
“Notes” are not exhaustive, because it is impossible to warn of all the possible haz-
ardous consequences that might result from failure to follow these instructions.

Page 5F-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

General Information
Introduction
The following manual has been prepared for effective diagnosis of the MerCruiser
Electronic Fuel Injection system.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication approval. The right is reserved
to make changes at any time without notice.
An understanding of the material contained herein and in subsequent publications issued
when necessary, will assist service personnel in properly maintaining the quality to which
MerCruiser engine control systems are built.
Visual/Physical Inspection
A careful visual and physical inspection must be performed as part of any diagnostic
procedure. This can often lead to fixing a problem without further steps. Inspect all
vacuum hoses for correct routing, pinches, cuts, or disconnects. Be sure to inspect hoses
that are difficult to see. Inspect all the wires in the engine compartment for proper connec-
tions, burned or chafed spots, pinched wires, or contact with sharp edges or hot exhaust
manifolds. This visual/physical inspection is very important. It must be done carefully and
thoroughly.
Basic Knowledge and Tools Required
To use this manual most effectively, a general understanding of basic electrical circuits and
circuit testing tools is required. You should be familiar with wiring diagrams; the meaning of
volts, ohms and amperes; the basic theories of electricity; and understand what happens
in an open or shorted wire. To perform system diagnosis, several special tools and equip-
ment are required. Please become acquainted with the tools and their use before attempting
to diagnose the system. Special tools which are required for system service are listed later
in this section (see “Table of Contents”).
Electrostatic Discharge Damage
Electronic components are often designed to carry very low voltage and are susceptible to
damage caused by electrostatic discharge. It is possible for less than 100 volts of static elec-
tricity to cause damage to some electronic components. By comparison, it takes 4,000 volts
for a person to even feel the effect of a static discharge.
There are several ways for a person to become statically charged. The most common meth-
ods of charging are by friction and by induction. An example of charging by friction is a per-
son sliding across a seat, in which a charge of as much as 25,000 volts can build up. Charg-
ing by induction occurs when a person with well-insulated shoes stands near a highly
charged object and momentarily touches ground. Charges of the same polarity are drained
off, leaving the person highly charged with the opposite polarity. Static charges of either type
can cause damage. Use care when handling and testing electronic components.
Diagnostic Information
The diagnostic charts and functional checks in this manual are designed to locate a faulty
circuit or component through logic based on the process of elimination. The charts are pre-
pared with the requirement that the system functioned correctly at the time of assem-
bly and that there are no multiple failures.

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

Wiring Harness Service

Marine engine control circuits contain many special design features not found in standard
land vehicle wiring. Environmental protection is used extensively to protect electrical con-
tacts and proper splicing methods must be used.
The proper operation of low amperage input/output circuits depends upon good continuity
between circuit connectors. Before component replacement and/or during normal trouble-
shooting procedures, visually inspect any questionable mating connector. Mating surfaces
should be properly formed, clean and likely to make proper contact. Some typical causes
of connector problems are listed below.
1. Improperly formed contacts and/or connector housing.
2. Damaged contacts or housing due to improper engagement.
3. Corrosion, sealer or other contaminants on the contact mating surfaces.
4. Incomplete mating of the connector halves during initial assembly or during subsequent
troubleshooting procedures.
5. Tendency for connectors to come apart due to vibration and/or temperature cycling.
6. Terminals not fully seated in the connector body.
7. Inadequate terminal crimps to the wire.
Wire harnesses should be replaced with proper part number harnesses. When signal wires
are spliced into a harness, use the same gauge wire with high temperature insulation only.
With the low current and voltage levels found in the system, it is important that the best pos-
sible bond be made at all wire splices by soldering the splices, as shown in the following
illustrations. Use care when probing a connector or replacing connector terminals. It is pos-
sible to short between opposite terminals. If this happens, certain components can be dam-
aged. Always use jumper wires with the corresponding mating terminals between connec-
tors for circuit checking. NEVER probe through connector seals, wire insulation, secondary
ignition wires, boots, nipples or covers. Microscopic damage or holes will result in eventual
water intrusion, corrosion and/or component or circuit failure.

WIRE REPAIR

1. Locate damaged wire.

2. Remove insulation as required.

73048
3. Splice two wires together using splice clips and rosin core solder.

73048
4. Cover splice with heat shrink sleeve to insulate from other wires.

73048

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

Wiring Connector Service

Most connectors in the engine compartment are protected against moisture and dirt that
could create oxidation and deposits on the terminals. This protection is important because
of the very low voltage and current levels found in the electronic system. The connectors
have a lock which secures the male and female terminals together. A secondary lock holds
the seal and terminal into the connector.
When diagnosing, open circuits are often difficult to locate by sight because oxidation or ter-
minal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor
or in the wiring harness may locate the open circuit condition. This should always be consid-
ered when an open circuit or failed sensor is indicated. Intermittent problems may also be
caused by oxidized or loose connections.
Before making a connector repair, be certain of the type of connector. Some connectors look
similar but are serviced differently. Replacement connectors and terminals are listed in the
Parts Catalog.
Ensure that the connector seals are not deformed or crushed when mating the connectors
together.

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

Abbreviations

in. hg Inches Of Mercury IGN Ignition

BARO Barometric Pressure INJ Injection
Battery Positive Terminal, Bat-
BAT kPa Kilopascal
tery or System Voltage
B+ Battery Positive KS Knock Sensor System
CKT Circuit KV Kilovolts
Manifold Absolute
CONN Connector MAP
Pressure
CYL Cylinder MIL Malfunction Indicator Lamp
DEG Degrees mSec Millisecond
DIAG Diagnostic N/C Normally Closed
DIST Distributor N/O Normally Open
Programmable Read Only
DLC Data Link Connector PROM
Memory
DTC Diagnostic Trouble Code RAM Random Access Memory
DVOM Digital Volt Ohm Meter REF HI Reference High
ECM Engine Control Module REF LO Reference Low
Engine Coolant
ECT ROM Read Only Memory
Temperature
Electronic Erasable Program-
EEPROM SLV Slave
mable Read Only Memory
HEI High Energy Ignition SW Switch
Electromagnetic
EMI TACH Tachometer
Interference
ENG Engine TERM Terminal
GND Ground TP Throttle Position
GPH Gallons Per Hour V Volts
IAC Idle Air Control VAC Vacuum
IAT Intake Air Temperature WOT Wide Open Throttle
IC Ignition Control

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

ECM Self-Diagnostics
The ECM performs a continual self-diagnosis on certain control functions. This diagnostic
capability is complemented by the diagnostic procedures contained in this manual. The
ECM’s language for communicating the source of a malfunction is a system of diagnostic
codes. The codes are two digit numbers that can range from 12 to 51. When a malfunction
is detected by the ECM, a code is set and the Malfunction Indicator Lamp is illuminated.
Diagnostic Code Tool With Malfunction Indicator Lamp
There are various manufacturers of Diagnostic Code Tools. Most Tools are equipped with
a Malfunction Indicator Lamp (MIL).
• It informs the service technician that a problem has occurred and that the vessel is in
need of service as soon as reasonably possible.
• It displays Codes stored by the ECM which help the technician diagnose system prob-
lems.
As a bulb and system check, the lamp will come ON with the key on and the engine not run-
ning. When the engine is started, the light will turn OFF. If the lamp remains ON, the self-
diagnostic system has detected a problem. If the problem goes away, the light will go out
in most cases after ten seconds, but a code will remain stored in the ECM.
When the lamp remains ON while the engine is running, or when a malfunction is suspected
due to a driveability problem, “EFI Diagnostic Circuit Check” must be performed. These
checks will expose malfunctions which may not be detected if other diagnostics are per-
formed prematurely.
Intermittent Malfunction Indicator Lamp
In the case of an intermittent problem, the Malfunction Indicator Lamp will light for ten
seconds and then will go out. However, the corresponding code will be stored in the memory
of the ECM. When unexpected codes appear during the code reading process, one can
assume that these codes were set by an intermittent malfunction and could be helpful in
diagnosing the system.
An intermittent code may or may not reset. IF IT IS AN INTERMITTENT FAILURE, A DIAG-
NOSTIC CODE CHART IS NOT USED. Consult the “Diagnostic Aids” on the same page
as the diagnostic code chart. “Troubleshooting” also covers the topic of “Intermittents.” A
physical inspection of the applicable sub-system most often will resolve the problem.

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

Reading Codes
The provision for communicating with the ECM is the Data Link Connector (DLC) connector.
It is part of the EFI engine wiring harness, and is a 10-pin connector, which is electrically
connected to the ECM. It is used in the assembly plant to receive information in checking
that the engine is operating properly before it leaves the plant. The code(s) stored in the
ECM’s memory can be read either through a scan tool, (a diagnostic scanner that plugs into
the DLC connector), or by counting the number of flashes of the Malfunction Indicator Lamp
when the diagnostic code tool is installed and SERVICE mode is selected.

73053

DLC Connector

Once the diagnostic code tool has been connected, the ignition switch must be moved to
the ON position, with the engine not running. At this point, the Malfunction Indicator Lamp
should flash Code 12 three times consecutively. This would be the following flash sequence:
flash, pause, flash-flash, long pause, flash, pause, flash-flash, long pause, flash, pause,
flash-flash. Code 12 indicates that the ECM’s diagnostic system is operating. If Code 12 is
not indicated, a problem is present within the diagnostic system itself, and should be ad-
dressed by consulting the appropriate diagnostic chart in “Diagnostics.”
Following the output of Code 12, the Malfunction Indicator Lamp will indicate a diagnostic
code three times if a code is present, or it will simply continue to output Code 12. If more
than one diagnostic code has been stored in the ECM’s memory, the codes will be output
from the lowest to the highest, with each code being displayed three times.
If a scan tool is used to read the codes, follow the manufacturer’s instructions.

SERVICE MODE

When the diagnostic code tool is installed at the Data Link Connector (DLC) and the selector
switch is set at SERVICE, the system will enter what is called the SERVICE mode. In this
mode the ECM will:
1. Display a Code 12 by flashing the Malfunction Indicator Lamp (indicating the system is
operating correctly).
2. Display any stored codes by flashing the Malfunction Indicator Lamp. Each code will be
flashed three times, then Code 12 will be flashed again.
3. Holds ignition advance steady.

NORMAL MODE

Engines can be monitored in the normal mode. Certain parameters can be observed without
changing the engine operating characteristics.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

Scan Tools
The ECM can communicate a variety of information through the DLC connector. This data
is transmitted at a high frequency which requires a scan tool for interpretation.
With an understanding of the data which the tool displays, and knowledge of the circuits in-
volved, the tool can be very useful in obtaining information which would be more difficult or
impossible to obtain with other equipment.
Scan tools do not make the use of diagnostic charts unnecessary, nor can they indicate ex-
actly where a problem is in a particular circuit. Diagnostic tables incorporate diagnosis pro-
cedures using a scan tool where possible or a Diagnostic Code Tool (non-scan) if a scan
tool is unavailable.
EFI Diagnostic Circuit Check
After the visual/physical inspection, the On Board Diagnostic (OBD) Circuit Check is the
starting point for all diagnostic procedures. Refer to SECTION 5I.
The correct procedure to diagnose a problem is to follow two basic steps.
1. Are the on-board diagnostics working? This is determined by performing the On Board
Diagnostic Circuit Check. Since this is the starting point for the diagnostic procedures,
always begin here. If the on-board diagnostics are not working, the EFI Diagnostic Cir-
cuit Check will lead to a diagnostic chart in “Diagnostics” to correct the problem. If the
on-board diagnostics are working correctly, go to step 2.
2. If a code is stored, go directly to the numbered code chart in SECTION 5I. This will deter-
mine if the fault is still present.
Scan Tool Use With Intermittents
The scan tool allows manipulation of wiring harnesses or components with the engine not
running, while observing the scan tool readout.
The scan tool can be plugged in and observed while running the vessel under the condition
when the Malfunction Indicator Lamp turns ON momentarily or when the engine driveability
is momentarily poor. If the problem seems to be related to certain parameters that can be
checked on the scan tool, they should be checked while running the vessel. If there does
not seem to be any correlation between the problem and any specific circuit, the scan tool
can be checked on each position, watching for a period of time to see if there is any change
in the readings that indicates intermittent operation.
The scan tool is also an easy way to compare the operating parameters of a poorly operating
engine with those of a known good one. For example, a sensor may shift in value but not
set a trouble code. Comparing the senor’s readings with those of the typical scan tool data
readings may uncover the problem.
The scan tool has the ability to save time in diagnosis and prevent the replacement of good
parts. The key to using the scan tool successfully for diagnosis lies in the technician’s ability
to understand the system he is trying to diagnose as well as an understanding of the scan
tool operation and limitations. The technician should read the tool manufacturer’s operating
manual to become familiar with the tool’s operation.

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

Non-Scan Diagnosis of Driveability Concerns (With No Codes Set)

If a driveability concern still exists after following the diagnostic circuit check and reviewing
“Troubleshooting,” an out-of-range sensor may be suspected. Because of the unique de-
sign of the EFI system, fail-safes have been incorporated into the ECM to replace a sensed
value with a default value in the case of a sensor malfunction or sensor wiring concern. By
allowing this to occur, limited engine performance is restored until the vessel is repaired. A
basic understanding of sensor operation is necessary in order to diagnose an out-of-range
sensor.
If the sensor is within its working or acceptable parameters, as shown, the ECM does not
detect a problem. If the sensor should happen to fall out of this “window,” a code will be
stored. A known default value will replace the sensed value to restore engine performance.
If the sensor is out of range, but still within the operating window of the ECM, the problem
will go undetected by the ECM and may result in trouble later.
A good example of this would be if the coolant sensor was reading incorrectly and indicating
to the ECM that coolant temperature was at 20° F, but actual coolant temperature was 175°
F. This would cause the ECM to deliver more fuel than was actually needed and result in
an overly rich, rough running condition. This condition would not have caused a code to set
as the ECM interprets this as within its range.
To identify a sensor which is out of range, unplug it while running the engine. After approxi-
mately two minutes, the diagnostic code for that sensor will set, a code, and replace the
sensed value with a default value. If at that point a noticeable performance increase is ob-
served, the non-scan code chart for that particular sensor should be followed to correct the
problem.
NOTE: Be sure to clear each code after disconnecting and reconnecting each sensor. Fail-
ure to do so may result in a misdiagnosis of the problem.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

Electronic Control Module (ECM) and Sensors

General Description
The MerCruiser Electronic Fuel Injection system is equipped with a computer that provides
the operator with state-of-the-art control of fuel and spark delivery. Computers use voltage
to send and receive information.
Computers and Voltage Signals
Voltage is electrical pressure. Voltage does not flow in circuits. Instead, voltage causes cur-
rent. Current does the real work in electrical circuits. It is current, the flow of electrically
charged particles, that energizes solenoids, closes relays and lights lamps.
Besides causing currents in circuits, voltage can be used as a signal. Voltage signals can
send information by changing levels, changing waveform (shape), or changing the speed
at which the signal switches from one level to another. Computers use voltage signals to
communicate with one another. The different sections inside computers also use voltage
signals to communicate with each other.
There are two kinds of voltage signals, analog and digital. Both of these are used in comput-
er systems. It’s important to understand the difference between them and the different ways
they are used.
Analog Signals
An analog signal is continuously variable. This means that the signal can be any voltage
within a certain range. An analog signal usually gives information about a condition that
changes continuously over a certain range. For example, in a marine engine, temperature
is usually provided by an analog signal. There are two general types of sensors that produce
analog signals: the 3-wire and the 2-wire sensor.

THREE-WIRE SENSORS (MAP AND TP)

The following figure shows a schematic representation of a 3-wire sensor. All 3-wire sensors
have a reference voltage, a ground and a variable “wiper.” The lead coming off of the wiper
will be the signal to the Engine Control Module (ECM). As this wiper position changes, the
signal voltage returned to the computer also changes.
b
a
c
d

3-Wire Sensor
a - Typical Sensor
b - ECM
c - Voltage Out
d - Signal Input
e - Sensor Ground

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

TWO-WIRE SENSOR (ECT)

The following figure is the schematic of a 2-wire type sensor. This sensor is basically a vari-
able resistor in series with a fixed-known resistor within the computer. By knowing the values
of the input voltage and the voltage drop across the known resistor, the value of the variable
resistor can be determined. The variable resistors that are commonly used are called therm-
istors. A thermistor’s resistance varies inversely with temperature.
b
a c
d

2-Wire Sensor
a - Typical Sensor
b - ECM
c - Signal Sensor
d - 5 Volt
e - Sensor Ground

Digital Signals
Digital signals are also variable, but not continuously. They can only be represented by dis-
tinct voltages within a range. For example, 1 V, 2 V or 3 V would be allowed, but 1.27 V or
2.65 V would not. Digital signals are especially useful when the information can only refer
to two conditions - YES and NO, ON and OFF, or HIGH and LOW. This would be called a
digital binary signal. A digital binary signal is limited to two voltage levels. One level is a posi-
tive voltage, the other is no voltage (zero volts). As you can see in the following figure, a
digital binary signal is a square wave.

d e g
a
c f h

b
Digital Binary Signal
a - Voltage
b - Time
c - Lo
d - Hi
e - On
f - Off
g - Yes
h - No

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

The computer uses digital signals in a code that contains only ones and zeros. The high volt-
age of the digital signal represents a one (1), and no voltage represents a zero (0). Each
zero and each one is called a bit of information, or just a “bit.” Eight bits together are called
a “word.” A word, therefore, contains some combination of eight binary code bits: eight ones,
eight zeros, five ones and three zeros, and so on.
Binary code is used inside a computer and between a computer and any electronic device
that understands the code. By stringing together thousands of bits, computers can commu-
nicate and store an infinite variety of information. To a computer that understands binary,
11001011 might mean that it should reset engine rpm at a lower level. Although the comput-
er uses 8-bit digital codes internally and when talking to another computer, each bit can have
a meaning.

SWITCH TYPES

Switched inputs (also known as discretes) to the computer can cause one bit to change,
resulting in information being communicated to the computer. Switched inputs can come in
two types: they are “pull-up” and “pull-down” types. Both types will be discussed.
With a pull-up type switch, the ECM will sense a voltage when the switch is CLOSED. With
the pull-down switch, the ECM recognizes the voltage when the switch is OPEN.
Discretes can also be used to inform a computer of FREQUENCY information.

PULSE COUNTERS

For the computer to determine frequency information from a switched input, the computer
must measure the time between voltage pulses. As a number of pulses are recorded in a
set amount of time, the computer can calculate the frequency. The meaning of the frequency
number can have any number of meanings to the computer.
An example of a pulse counter type of input is the distributor reference pulse input. The com-
puter can count a train of pulses, a given number of pulses per engine revolution, and deter-
mine the rpm of the engine.
Engine Control Module (ECM)
The Engine Control Module (ECM) is the control center of the fuel injection system. It
constantly monitors information from various sensors, and controls the systems that affect
engine performance.
The ECM also performs a diagnostic function check of the system. It can recognize opera-
tional problems and store a code or codes which identify the problem areas to aid the techni-
cian in making repairs.

72801

76358

MEFI-1 ECM MEFI-3 ECM

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

ECM FUNCTION

The ECM supplies 5 or 12 volts to power various sensors or switches. This is done through
resistances in the ECM which are so high in value that a test light will not light when con-
nected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accu-
rate reading because its resistance is too low. Therefore, the use of a 10 megohm input
impedance digital voltmeter is required to assure accurate voltage readings.

MEMORY

There are three types of memory storage within the ECM: ROM, RAM and EEPROM.
Read Only Memory (ROM) is a permanent memory that is physically soldered to the circuit
boards within the ECM. The ROM contains the overall control programs. Once the ROM is
programmed, it cannot be changed. The ROM memory is non-erasable, and does not need
power to be retained.
Random Access Memory (RAM) is the microprocessor “scratch pad.” The processor can
write into, or read from, this memory as needed. This memory is erasable and needs a
constant supply of voltage to be retained.
Electronic Erasable Programmable Read Only Memory (EEPROM) is the portion of the
ECM that contains the different engine calibration information that is specific to each marine
application.
Speed Density System
The Electronic Fuel Injection system is a speed and air density system. The system is based
on speed / density fuel management.
Three specific data sensors provide the ECM with the basic information for the fuel manage-
ment portion of its operation. That is, three specific signals to the ECM establish the engine
speed and air density factors.

SPEED

The engine speed signal comes from the distributor’s High Energy Ignition (HEI) module to
the ECM on the distributor reference high circuit. The ECM uses this information to deter-
mine the speed or rpm factor for fuel and ignition management.

DENSITY

The Manifold Absolute Pressure (MAP) sensor is a 3-wire sensor that monitors the changes
in intake manifold pressure which results from changes in engine loads. These pressure
changes are supplied to the ECM in the form of electrical signals.
As intake manifold pressure increases (vacuum decreases), the air density in the intake
manifold also increases, and additional fuel is required.
The MAP sensor sends this pressure information to the ECM, and the ECM increases the
amount of fuel injected by increasing the injector pulse width. As manifold pressure
decreases (vacuum increases), the amount of fuel is decreased.
These two inputs from MAP and rpm are the major determinants of the air/fuel mixture, deliv-
ered by the fuel injection system.
The remaining sensors and switches provide electrical inputs to the ECM which are used
for modification of the air/fuel mixture, as well as for other ECM control functions, such as
Idle Air Control (IAC).

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

ECM Input and Sensor Descriptions

The following lists the sensors, switches and other inputs used by the ECM to control its
various systems. Although we will not cover them all in great detail, there will be a brief
description of each.

d e
a b f g h i

o n m l

p
k

a - System Relay j - Serial Data

b - Distributor For REF rpm k - Audio Warning Buzzer
c - Discrete Switches (Audio Warning) l - Fuel Injectors
d - Knock Module m - IAC Motor
e - Knock Sensor n - Ignition Control Module
f - TP o - Fuel Pump Relay
g - MAP p - Fuel Pump
h - ECT q - Inputs
i - IAT r - Outputs
s - ECM

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

The Engine Coolant Temperature (ECT) Sensor is a thermistor (a resistor which changes
value based on temperature) immersed in the engine coolant stream. Low coolant tempera-
ture produces a high resistance, while high temperature causes low resistance.

a 73052
c
a - Engine Coolant Temperature (ECT) Sensor
b - Harness Connector
c - Locking Tab

The ECM supplies a 5 volt signal to the ECT through a resistor in the ECM and measures
the voltage. The voltage will be high when the engine is cold, and low when the engine is
hot. By measuring the voltage, the ECM knows the engine coolant temperature. Engine
coolant temperature affects most systems the ECM controls.
A failure in the ECT circuit should set Code 14. Remember, this code indicates a failure in
the coolant temperature sensor circuit, so proper use of the chart will lead to either repairing
a wiring problem or replacing the sensor.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

The Manifold Absolute Pressure (MAP) sensor is a pressure transducer that measures the
changes in the intake manifold pressure. The pressure changes as a result of engine load
and speed change, and the MAP sensor converts this to a voltage output.

a a
73046
Earlier Style Later Style
a - Manifold Absolute Pressure (MAP) Sensor

A closed throttle on engine coast-down would produce a relatively low MAP output voltage,
while a wide open throttle would produce a high MAP output voltage. This high output volt-
age is produced because the pressure inside the manifold is the same as outside the man-
ifold, so 100% of outside air pressure is measured. When manifold pressure is high, vacuum
is low. The MAP sensor is also used to measure barometric pressure under certain condi-
tions, which allows the ECM to automatically adjust for different altitudes.
The ECM sends a 5 volt reference signal to the MAP sensor. As the manifold pressure
changes, the electrical resistance of the MAP sensor also changes. By monitoring the sen-
sor output voltage, the ECM knows the manifold pressure. A higher pressure, low vacuum
(high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) re-
quires less fuel. The ECM uses the MAP sensor to control fuel delivery and ignition timing.
A failure in the MAP sensor circuit should set a Code 33.

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KNOCK SENSOR

On MEFI 1, the knock sensor is mounted on the lower right side of the engine block. MEFI
3 models do not have a knock sensor module mounted on the engine; it is located internal
to the ECM.

73051

When abnormal engine vibrations (spark knock) are present, the sensor produces a voltage
signal which is sent to the KS Module and then to the ECM. The ECM uses this signal to
aid in calculating ignition timing.

KNOCK SENSOR (KS) MODULE (MEFI 1 MODELS ONLY)

When the key switch is turned on, 12 volts are supplied to the KS module B terminal through
the system relay. If this 12 volts are not present, the KS module cannot send the 8-10 volt
signal to the ECM. This will cause a false constant ignition spark timing retard and a Code
will be set.
b
c
a
e

d
Knock Sensor System
a - Electronic Control Module (ECM)
b - 12 Volts Battery Positive
c - 8-12 Volts
d - Knock Sensor
e - Knock Sensor Module

The KS module monitors the knock sensor’s AC voltage signal on terminal E. If no spark
knock is present, an 8-10 volt signal is sent to the ECM by the KS module’s terminal C. If
spark knock is present, the module will remove this 8-10 volt signal to the ECM. The ECM
will then retard the ignition spark timing to control the spark knock. If the circuit going to the
module’s E terminal opens or shorts to ground, the KS module cannot remove the 8-10 volt
signal to the ECM and no spark retard will occur. The ground circuit for the KS module is
connected to terminal D. If this circuit is open, the module cannot remove the 8-10 volt signal
to the ECM either and spark knock cannot be controlled.

CAUTION
The correct Knock Sensor and KS module for an engine must be used or a spark
knock may not be detected causing sever engine damage.

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

KNOCK SENSOR CIRCUITRY (MEFI-3 MODELS ONLY)

The MEFI-3 ECM is used with the knock sensor to control spark knock. The KS module cir-
cuitry is within the MEFI-3 ECM. When spark knock is present, a small AC voltage signal
is sent from the knock sensor to the ECM through pin connector J1-30. (If the engine has
a second KS, its voltage signal goes through pin connector J1-14). An AC voltage monitor
inside the ECM will detect the spark knock and start retarding spark timing. A Code will be
set only if the ECM does not see any activity on the KS signal circuit(s).

THROTTLE POSITION (TP) SENSOR

The Throttle Position (TP) Sensor is a potentiometer connected to the throttle shaft on the
throttle body. The TP has one end connected to 5 volts from the ECM and the other to ECM
ground. A third wire is connected to the ECM to measure the voltage from the TP. As the
throttle valve angle is changed, the voltage output of the TP also changes. At a closed
throttle position, the voltage output of the TP is low (approximately .5 volt). As the throttle
valve opens, the output increases so that at wide-open-throttle (W.O.T.), the output voltage
should be near 4.5 volts. By monitoring the output voltage from the TP, the ECM can deter-
mine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP can
cause intermittent bursts of fuel from the injector and an unstable idle, because the ECM
thinks the throttle is moving.

73049

If the TP circuit is open, the ECM will set a Code 21. If the TP circuit is shorted, and a trouble
Code 21 will be set. A problem in any of the TP circuits will set a Code 21. Once a trouble
code is set, the ECM will use a default value for TP.

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DISTRIBUTOR REFERENCE (DIST REF)

The distributor reference (engine speed signal) is supplied to the ECM by way of the “Dist
Ref Hi” line from the High Energy Ignition (HEI). This pulse counter type input creates the
timing signal for the pulsing of the fuel injectors, as well as the Ignition Control (IC) functions.
This signal is used for a number of control and testing functions within the ECM.

DISCRETE SWITCH INPUTS

Several discrete switch inputs are utilized by the system to identify abnormal conditions that
may affect engine operation. These switches are used in conjunction with the ECM to detect
critical conditions to engine operation.
The switches which are used with the fuel injection system to detect critical engine operation
parameters are:

Switch Normal State

Oil Pressure N/O
(With Pressure)
Gear Lube Monitor N/O
Level on Sterndrive (When Full)

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

Spark Management
High Energy Ignition with Ignition Control (IC)
The Electronic Fuel Injection is controlled by an Engine Control Module (ECM). This module
is the nerve/decision center of the system. It uses all the information it gathers to manage
ignition spark, delivering increased fuel economy and maximum engine performance.
The system uses inputs from sensors to make decisions on the amount of spark advance
or retard allowed.
The system has been designed to control ignition advance and retard electronically by the
ECM.
In order for the ECM to properly calculate spark advance, it must always know at what speed
the engine is running. The engine speed signal is accomplished by a circuit within the distrib-
utor module which converts the pickup coil voltage to a square wave reference signal that
can be used by the ECM. This square wave engine speed reference signal is known as REF
HI. With MEFI 1, the ECM must also have something to compare the REF HI value against.
Therefore, an additional line is provided between the ECM and the distributor module that
is known as REF LO. These two lines, between the ECM and the distributor, provide a pre-
cise indication of engine speed.
With MEFI 1, the two other lines between the ECM and distributor that control the Ignition
Control (IC) operation are known as the bypass and IC circuits.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

Modes Of Operation
DISTRIBUTOR MODULE MODE (MEFI 1 ONLY)

The ignition system operates independent of the ECM. The distributor module module in
the distributor maintains a base ignition timing and is able to advance timing to a total of 27
degrees. This mode is in control when a Code 42 is detected while engine is running and
will have a noticeable effect on engine operation.
The following describes IC operation during cranking and when the engine starts running.
To help understand how IC circuits operate, a relay with a double set of contact points is
shown in the IC module (refer to the figures “Ignition Control Mode” and “ECM Control
Mode”). Solid state circuitry is used in the module, but showing the relay makes it easier to
visualize how the IC module functions.
During cranking, the relay is in the de-energized position (see figure “Distributor Module
Mode”). This connects the pickup coil to the base of the transistor via the signal converter.
When the pickup coil applies a positive voltage to the transistor, the transistor turns ON.
When voltage is removed, the transistor turns OFF. When the transistor turns ON, current
flows through the primary winding of the ignition coil. When it turns OFF, the primary current
stops and a spark is developed at the spark plug. A small amount of advance is built into
the IC module via a timing circuit, in case the engine remains in the ignition module timing
mode.
With the relay de-energized, a set of contacts (shown closed) would ground the IC line sig-
nal.

ECM CONTROL MODE

The ECM control mode controls the ignition timing. The ECM calculates the desired ignition
timing based on information it gets from its input sensors.
(MEFI 1) When the engine rpm reaches a predetermined value (for this example, 300 rpm),
the ECM considers the engine running and applies five volts on the bypass line to the IC
module. This energizes the relay and causes the contacts from the pickup coil as well as
the grounding contacts for the IC line to open (see figure “ECM Control Mode”). This con-
nects the IC line to the base of the transistor, and bypasses the ignition module timing con-
trol.
The IC system is now controlled by the IC signal from the ECM and the time at which the
spark occurs can be determined by a variable time circuit in the ECM.

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

Base Ignition Timing

In order to check or change base timing on a EFI system the ECM has to be entered into
the service mode by using a scan tool or code tool. The ECM will stabilize timing to allow
timing adjustment. The ECM incorporates a spark control override, which allows timing to
be lowered if spark knock (detonation) is encountered during normal operation. At this time,
the timing can be adjusted by turning the distributor.

j
f
h
a i

b
s c d
t k o
l
e m p

g n

Distributor Module Mode

j
f h

a i

b
c d k q
l
e m r

g n

ECM Control Module

Page 5F-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

Base Ignition Timing (Continued)

a - Ignition Coil Trigger Signal
b - Battery
c - Relay
d - Module Advance
e - Signal Converter
f - Pick Up Coil
g - Ground
h - Manifold
i - Coolant Temperature
j - ECM
k - IC
l - REF HI
m - Bypass
n - REF LO
o - Grounded
p - No Voltage Applied
q - Not Grounded
r - Voltage Applied

Results of Incorrect Operation

Open IC Line from the ECM to the Distributor Module - While the engine is cranking, the
ECM expects to see the IC signal pulled to virtually zero because it is grounded in the distrib-
utor module. Since the IC line is open, it cannot be grounded by the module and the IC signal
will be able to rise and fall, or do what is called toggling. The ECM recognizes the toggling
as an abnormal condition, and will not apply bypass voltage to the distributor module when
the engine reaches run rpm.
Since bypass voltage is not applied to the relay, it remains open and the engine continues
to run on the pickup coil triggering in the ignition module timing mode.
If this condition occurs while the engine is running, the engine will stop, but it will restart and
run in the ignition module timing mode with reduced power.
Grounded IC Line - During cranking, the IC voltage is at virtually zero so the ECM does
not recognize a problem. When engine rpm reaches the value for the run condition, the ECM
applies bypass voltage to the distributor module. Bypass voltage on the module switches
the distributor power transistor to the IC line. Because the IC line is grounded, it will have
no voltage applied so it cannot operate the power transistor to enter the IC mode.
If the IC line becomes grounded while the engine is being operated, the engine will stop and
will be difficult to restart.
An open or ground in the IC or bypass will cause the engine to run on the distributor module
timing. This will cause reduced performance, poor fuel economy and erratic idle.
Grounded or Open Bypass Line - While the engine is cranking, the IC line will be grounded
and the ECM will not notice anything abnormal. When run rpm is reached, the ECM applies
bypass voltage to the bypass line but because of the ground or open, it will not be able to
energize the relay. Therefore, the relay will stay de-energized and the IC line will remain
grounded.
When the ECM sees the IC line not toggling, it will not enter the IC mode. Since the relay
is de-energized, the engine will continue to run in the ignition module timing mode.
If this condition occurs while the engine is running, the engine will simply operate in the igni-
tion module timing mode.

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

Open or Grounded REF HI Line - This line provides the ECM with engine speed informa-
tion. If this line is open or grounded, the ECM will not know that the engine is cranking or
running and will not run.
Open or Grounded REF LO Line - This wire is grounded in the ignition module and pro-
vides a reference ground from the ignition module to the ECM. The ECM compares refer-
ence ground with reference high voltage. If this circuit is open, or grounded at any other loca-
tion than through the module, it may cause poor performance.

Fuel Metering System

General Description
The function of the fuel metering system is to deliver the correct amount of fuel to the engine
under all operating conditions. The fuel is delivered to the engine by individual fuel injectors
mounted in the intake manifold near each cylinder (MPI) or from two injectors mounted on
top of the intake manifold (EFI).
Cool Fuel Systems
This system was used on later MerCruiser MEFI-1 and MEFI-3 ECM engines. This system
has a fuel cooler and the electric fuel pump inside a box on the lower, port side of the engine.
The fuel regulator for this system is mounted on the fuel cooler.
Early versions of the MEFI-1 systems had a second regulator mounted in the fuel rail. This
regulator does not control system fuel pressure. It is used to dampen fuel system pulsation
only. Later versions of the MEFI-1 and the MEFI-3 have this regulator removed from the fuel
rail.
Modes of Operation
The ECM looks at voltages from several sensors to determine how much fuel to give the
engine. The fuel is delivered under one of several conditions, called modes. All the modes
are controlled by the ECM and are described below.

STARTING MODE

When the ignition switch is turned to the crank position, the ECM turns ON the fuel pump
relay and the fuel pump builds up pressure. The ECM then checks the Engine Coolant Tem-
perature (ECT) sensor and Throttle Position (TP) sensor and determines the proper air/fuel
ratio for starting. The ECM controls the amount of fuel delivered in the starting mode by
changing how long the injectors are turned ON and OFF. This is done by pulsing the injectors
for very short times.

CLEAR FLOOD MODE

If the engine floods, it can be cleared by opening the throttle half way (50%). The ECM dis-
continues fuel injector pulsation as long as the throttle is between 50 to 75 % and the engine
rpm is below 300. If the throttle position becomes more than 75% or less than 50%, the ECM
returns to the starting mode.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

RUN MODE

When the engine is started and rpm is above 300, the system operates in the run mode. The
ECM will calculate the desired air/fuel ratio based on these ECM inputs: rpm, Manifold Abso-
lute Pressure (MAP) sensor, and Engine Coolant Temperature (ECT) sensor . Higher en-
gine load (from MAP) and colder engine temperature (from ECT) requires more fuel, or a
richer air/fuel ratio.

ACCELERATION MODE

The ECM looks at rapid changes in Throttle Position (TP) and provides extra fuel by increas-
ing the injector pulse width.

FUEL CUTOFF MODE

No fuel is delivered by the injectors when the ignition is OFF, to prevent dieseling. Also, fuel
pulses are not delivered if the ECM receives no distributor reference pulses, which means
the engine is not running. The fuel cutoff mode is also enabled at high engine rpm, as an
overspeed protection for the engine. When cutoff is in effect due to high rpm, injection pulses
will resume after engine rpm drops slightly.

DECELERATION MODE

The IAC is similar to a carburetor dashpot. It provides additional air when the throttle is
rapidly moved to the idle position to prevent the engine from dying.

REV-LIMIT MODE

A fuel cutoff function is enabled at higher engine rpm. When the ECM senses that the engine
has exceeded its specified maximum rpm, no fuel is delivered by the injectors. After the rpm
drops below the specified maximum rpm, the ECM will resume fuel delivery.

MEFI-3 LOAD ANTICIPATION MODE

The Load Anticipation mode is available on MIE inboard engines only. The function is used
to help inboard engines during shifting. An electrical signal from the neutral safety switch
(on the transmission) is used to tell the ECM if the switch is closed or open. In neutral gear,
the neutral safety switch is closed (signal grounded). When shifting into gear, the switch
opens (signal open).
When the transmission is shifted into gear, the open signal causes the ECM to add a cali-
brated amount of bypass air with the IAC. This is done to increase the load handling capabili-
ty of the engine when going into gear on larger boats. When shifting back into neutral gear,
the additional IAC bypass air is removed in an attempt to limit engine rpm flares. The amount
of IAC air used is constantly monitored by the ECM. After the transmission is shifted, and
the engine has stabilized, the ECM calculates an ‘error band’ from the Moving Desired rpm
mode and adjusts the Load Anticipation mode IAC count accordingly. This allows the ECM
to ‘learn’ the best IAC bypass air position to use for shift conditions in each particular boat.

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

MOVING DESIRED RPM MODE

IMPORTANT: An improperly adjusted throttle cable can cause the engine idle rpm to
be higher than the normal 600 rpm even when the control lever returns to the idle rpm
position.
A Moving Desired RPM mode has been added to the MEFI 3 ECM. this mode will increase
the desired idle rpm to a calibrated set point according to the throttle position. When the
Throttle Position (TP) sensor is at the closed throttle setting, the ECM will use Idle Air Control
(IAC) and Ignition Control (IC) to maintain the calculated desired rpm. This will smooth the
transition from idle (closed throttle) to higher throttle settings. It will also help maintain
constant low engine speeds from approximately 600 to 1200 rpm. At 5% or greater TP sen-
sor setting, the Moving Desired RPM mode is not active.

Throttle Body Injection Components

FUEL PUMP ELECTRICAL COMPONENTS

When the ignition switch is turned to the RUN position, the ECM will turn ON the fuel pump
relay for two seconds.
When the ignition switch is turned to the crank position, the ECM turns the fuel pump relay
ON causing the fuel pump to start.
If the ECM does not receive ignition reference pulses (engine cranking or running), it shuts
Off the fuel pump relay, causing the fuel pump to stop.

THROTTLE BODY UNIT

The throttle body unit consists of three assemblies.

• Fuel meter cover and fuel damper
• Fuel meter body and fuel injectors
• Throttle Body
-Two Throttle Valves To Control Air Flow Into The Engine
-Idle Air Control (IAC) Valve
-Throttle Position (TP) Sensor

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

THROTTLE BODY UNIT EXPLODED VIEW

b
73766

a - Throttle Body
b - Idle Air Control (IAC) Valve
c - Throttle Position (TP) Sensor
d - Fuel Meter Cover
e - Fuel Damper
f - Fuel Meter Body
g - Fuel Injector (2)

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

FUEL INJECTORS

The injector assembly is a solenoid operated device, controlled by the ECM, that meters
pressurized fuel to the intake manifold. The ECM energizes the injector solenoid, which
opens a ball valve, allowing fuel to flow past the ball valve, and through a recessed flow di-
rector plate.
The director plate has six machined holes that control the fuel flow, generating a conical
spray pattern of finely atomized fuel at the injector tip. Fuel is directed at the throttle, causing
it to become further atomized before entering the intake manifold.

b
c

73773

a - Fuel Injector
b - Fuel Filter
c - Seal Ring
d - Fuel Meter Body

FUEL PRESSURE REGULATOR

The pressure regulator is a diaphragm-operated relief valve with fuel pump pressure on one
side, and regulator spring pressure on the other. The regulator’s function is to maintain a
constant pressure differential across the injectors at all times. The regulator is located on
the cool fuel assembly. Refer to “Fuel Delivery System for Electronic Fuel Injection” Section
of this manual.

a 71716

a - Fuel Pressure Regulator

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION

FUEL DAMPER

The fuel damper acts as an equalization device to reduce the pressure spikes caused by
the fuel injectors.

a 76499

a - Fuel Damper

IDLE AIR CONTROL (IAC) VALVE

The purpose of the IAC valve assembly is to control engine idle speed, while preventing
stalls due to changes in engine load. The IAC valve, mounted in the throttle body, controls
bypass air around the throttle valves.

a 72800

a
IAC Valve Air Flow Diagram
a - IAC Valve
b - EFI Throttle Body
c - Air Flow

By moving a conical valve known as a pintle, IN, toward the seat (to decrease air flow), or
OUT, away from the seat (to increase air flow), a controlled amount of air moves around the
throttle valve. If rpm is too low, more air is bypassed around the throttle valve to increase
it. If rpm is too high, less air is bypassed around the throttle valve to decrease it.

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FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 25

The ECM moves the IAC valve in small steps, called counts. These can be measured by
scan tool test equipment, which plugs into the DLC.
During idle, the proper position of the IAC valve is based on engine rpm. If the rpm drops
below specification and the throttle valve is closed, the ECM senses a near stall condition
and calculates a new valve position to prevent stalling.
• Engine idle speed is a function of total air flow into the engine based on IAC valve pintle
position + throttle valve stop screws and PCV.
• “Controlled” idle speed is programmed into the ECM, which determines the correct IAC
valve pintle position to maintain the desired idle speed for all engine operating condi-
tions and loads.
• The minimum idle air rate is set at the factory with stop screws. This setting allows
enough air flow by the throttle valves to cause the IAC valve pintle to be positioned a
calibrated number of steps (counts) from the seat during “controlled” idle operation.
• If the IAC valve is disconnected and reconnected with the engine running, the idle speed
may be wrong. In this case, the IAC valve can be reset by doing the following: turn off
engine, wait ten seconds, and restart engine.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

FUEL SYSTEM
Section 5G - Fuel Injection Disassembly And Reassembly
Table of Contents
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 5G-2 Throttle Body Adapter Plate . . . . . . . . 5G-17
Torque Specifications . . . . . . . . . . . . . . . . 5G-3 Engine Control Module (ECM) . . . . . . 5G-18
Flame Arrestor And Throttle Body . . . . . 5G-4 Knock Sensor (KS) Module
Exploded Views - Throttle Body EFI . . . 5G-7 (MEFI 1 Only) . . . . . . . . . . . . . . . . . . . 5G-19
Throttle Body Body And Adapter . . . . 5G-7 Engine Coolant Temperature
Throttle Body Assembly . . . . . . . . . . . 5G-8 (ECT) Sensor . . . . . . . . . . . . . . . . . . . . 5G-20
Fuel Pressure Relief Procedure . . . . . . . 5G-9 Manifold Absolute Pressure
Throttle Body EFI Components . . . . . . . 5G-9 (MAP) Sensor . . . . . . . . . . . . . . . . . . . 5G-21
Fuel Meter Cover Assembly . . . . . . . . 5G-9 Throttle Position (TP) Sensor . . . . . . . 5G-22
Fuel Injectors . . . . . . . . . . . . . . . . . . . . 5G-11 Idle Air Control (IAC) Valve . . . . . . . . 5G-23
Throttle Body . . . . . . . . . . . . . . . . . . . . 5G-13 Knock Sensor . . . . . . . . . . . . . . . . . . . . 5G-25

5
G

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

Precautions
WARNING
Always disconnect battery cables from battery BEFORE working on fuel system to
prevent fire or explosion.

WARNING
Be careful when cleaning flame arrestor and crankcase ventilation hose; 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 open flame in area
when cleaning flame arrestor and crankcase ventilation hose.

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 open flame in the area while
changing fuel filter(s). Wipe up any spilled fuel immediately.

WARNING
Be sure that the engine compartment is well ventilated and that no gasoline vapors
are present to avoid the possibility of fire.

WARNING
Make sure no fuel leaks exist, before closing engine hatch.

CAUTION
Fuel pressure MUST BE relieved before servicing high pressure component in the
fuel system.

CAUTION
DO NOT operate engine without cooling water being supplied to water pickup holes
in gear housing, or water pump impeller will be damaged and subsequent overheat-
ing damage to engine may result.
The following information MUST BE adhered to when working on the fuel system:
• Always keep a dry chemical fire extinguisher at the work area.
• Always install new O-rings when assembling fuel pipe fittings.
• DO NOT replace fuel pipe with fuel hose.
• DO NOT attempt any repair to the fuel system until instructions and illustrations
relating to that repair are thoroughly understood.
• Observe all Notes and Cautions.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Throttle Body to Adapter 15 19
TP Sensor 20 2
IAC Valve 20 2
MAP Sensor 44-62 5-7
Knock Sensor to Block 12-16 16.3-21.7
Intake Manifold to Plenum 150 17
Fuel Line Connections 18 24
Fuel Meter Cover Assembly Screws 28 3
Fuel Inlet and Return Lines 23 31
ECT Sensor Hand Tight + 2 1/2 turns maximum
Flame Arrestor Cover Bracket
Tighten Securely
Flame Arrestor Clamp

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

Flame Arrestor And Throttle Body

5
2

7
8
9
6 10
4

3
30

29 1

28
12
27
9
16
14
17
15
19
20 21 22
25 18
11
24 26 23
19
20 22
13 22 23

76543

1 - Cover 16 - Screw (#10-24 x 1/2 in.)

2 - Decal Set 17 - Clip
3 - Washer 18 - Stud Kit
4 - Nut (1/4-20) 19 - Bolt
5 - Flame Arrestor 20 - Washer
6 - Stud 21 - Connector
7 - Breather Hose 22 - Washer
8 - Elbow (90 degree) 23 - Nut (5/16-24)
9 - Grommet 24 - Shaft
10 - Screw (5/16-18 x 2-1/4 in.) 25 - Washer
11 - Adapter Assembly - TBI 26 - Plate
12 - Gasket 27 - Valve - PVC
13 - Gasket 28 - Hose - PVC (3\8 in I.D.)
14 - Screw (5/16-18 x 3/4 in.) 29 - Connector
15 - Map Sensor 30 - Hose (7/32 in. I.D.)

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

REMOVAL

NOTICE
Refer to “Precautions” at front of this section BEFORE proceeding.

1. Remove the flame arrestor cover.

b
c

76543

a - Flame Arrestor Cover

b - Nut
c - Washer

2. Remove the flame arrestor.

76501

a - Flame Arrestor

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

CLEANING AND INSPECTION

1. Clean flame arrestor in solvent.
2. Wear eye protection. Dry flame arrestor with compressed air.
INSTALLATION
1. Replace components. Tighten all fasteners securely.
a
b

e 76543

a - Nut
b - Washer
c - Flame Arrestor Cover
d - Flame Arrestor
e - Stud

Page 5G-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Exploded Views - Throttle Body EFI

Throttle Body Body And Adapter
1

3
5

76500

75841
1 - Throttle Body
2 - Screws (3)
3 - Gasket
4 - Throttle Body Adapter
5 - Screws (4)
6 - Gasket
7 - Intake Manifold

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

Throttle Body Assembly

1

2
4
3
5

7
6
8
9
10 11

12
13

20

13

14
17
15
18
16
19 73766

1 - Cap Screw 11 - Body

2 - Cover Assembly 12 - Throttle Body To Fuel Meter Body
3 - Fuel Pressure Regulator Gasket
4 - Cover Assembly Gasket 13 - Throttle Body
5 - Upper O-Ring 14 - Throttle Position (TP) Sensor
6 - Fuel Meter Outlet Gasket 15 - Screws (2)
7 - Fuel Injector (2) 16 - Seal
8 - Fuel Filter (2) 17 - O-Ring
9 - Lower O-Ring 18 - Idle Air Control (IAC) Valve
10 - Screw 19 - Screws (2)
20 - Fuel Inlet

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Fuel Pressure Relief Procedure

NOTICE
Refer to “Precautions” in front of this section BEFORE proceeding.

1. Disconnect electrical connector at fuel pump.

2. Crank engine for ten seconds (if engine starts allow it run until it stops) to relieve any
fuel pressure in the system.

Throttle Body EFI Components

Fuel Meter Cover Assembly
NOTICE
Refer to “Precautions,” at front of this section BEFORE proceeding.

CAUTION
DO NOT remove the four screws securing the pressure regulator to the fuel meter
cover. The fuel pressure regulator includes a large spring under heavy compres-
sion which, if accidentally released, could cause personal injury.
REMOVAL
1. Remove the flame arrestor from the throttle body.
2. Disconnect electrical connectors to fuel injectors. (Squeeze plastic tabs and pull
straight up.)
3. Remove the fuel meter cover screw assemblies.
4. Remove fuel meter cover assembly.
d

b c
e

73767

a - Fuel Meter Cover

b - Fuel Damper
c - Gaskets (Regulator Passages)
d - Screws
e - Fuel Meter Outlet Gasket

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

CLEANING AND INSPECTION

IMPORTANT: DO NOT immerse the fuel meter cover (with pressure regulator) in
cleaner, as damage to the regulator diaphragm and gasket could occur.
1. Inspect pressure regulator seating area for damage. Use a magnifying glass if
necessary. If damaged, replace the cover assembly.
INSTALLATION
1. Install new pressure regulator seal, fuel meter outlet passage gasket, and cover gasket.
2. Install fuel meter cover assembly.
3. Install attaching screws, precoated with appropriate locking compound to threads.
(Short screws are next to injectors.)
4. Torque screws to 28 lb-in. (3 Nm).
5. Connect electrical connectors to fuel injectors.
6. With engine OFF, and ignition ON, check for leaks around gasket and fuel line couplings.
d

b
c

73767

a - Fuel Meter Cover

b - Pressure Regulator Assembly
c - Gaskets (Regulator Passages)
d - Screws

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Fuel Injectors
NOTICE
Refer to “Precautions” at front of this section BEFORE proceeding.

REMOVAL
NOTE: Use care in removing fuel injectors to prevent damage to the electrical connector
and nozzle.
IMPORTANT: The fuel injector is an electrical component. DO NOT soak in any liquid
cleaner or solvent, as damage may result.
1. Remove flame arrestor and fuel meter cover as outlined in this section.
2. Using a screwdriver carefully pry up on fuel injector to remove it from the fuel meter body
(Use a screwdriver or rod under the the screwdriver when prying up. Leave old gasket
in place to prevent damage to fuel meter body).

73770

CLEANING AND INSPECTION

Inspect fuel injectors for damage; replace if necessary.
IMPORTANT: When replacing injectors, be certain to replace with the identical part
and part number. Other injectors may have the same appearance, yet have a different
part number and be calibrated for a different flow rate, and if installed, would cause
performance difficulty or damage to the ECM.
a

73772
a - Part Indentification Number

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

INSTALLATION
1. Install new lower O-rings on fuel injectors. Lubricate O-rings using a water soap solution.

b
a

73766
a - Fuel Injector
b - Upper O-Ring
c - Lower O-Ring
d - Fuel Filter

2. Install upper O-rings in fuel meter body. Lubricate O-rings with water soap solution.
3. Install fuel injectors into the fuel meter body. Align the raised lug on the injector base with
the notch in fuel meter cavity.

73771

NOTE: The electrical terminals of the injectors should be parallel with throttle shaft.
4. Install gasket and fuel meter cover, torque screws to 28 lb-in. (3 Nm) and flame arrestor
as outlined in this section.
5. Connect electrical connections to fuel injectors.
6. With engine OFF, and ignition ON, check for leaks around gasket and fuel line couplings.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Throttle Body
REMOVAL

CAUTION
Ensure that fuel pressure is relieved before removing the fuel inlet and return lines.
IMPORTANT: DO NOT allow the TP sensor, fuel pressure regulator, fuel injectors and
IAC valve to come into contact with solvent or cleaner. These components should be
removed prior to immersion in solvent.
1. Remove the flame arrestor from the throttle body.

a
c

76543

a - Flame Arrestor Cover

b - Flame Arrestor
c - Throttle Body Unit
d - Gasket
e - Throttle Body Adapter

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

2. Disconnect throttle cable.

75867

3. Disconnect the electrical connections from the TP sensor, IAC and fuel injectors.
(Squeeze plastic tabs on injectors and pull straight up).

73750
a
a - Electrical Connections

4. Remove fuel inlet and outlet lines from throttle body.

5. Remove screws retaining the throttle body to adapter plate.
NOTE: Place a shop rag over the intake manifold opening to prevent debris from entering
intake manifold.

CLEANING AND INSPECTION

1. Thoroughly clean metal parts of throttle body in a cold immersion type cleaner. Dry with
compressed air. Make certain that all passages are free of dirt and burrs.
2. Inspect mating surfaces for damage that could affect gasket sealing.
3. Inspect throttle body for cracks in casting.
4. Inspect throttle plates, linkage, return springs, etc., for damage, wear and foreign
material.
5. Check intake manifold plenum for loose parts and foreign material.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

INSTALLATION
1. Install fuel injectors and fuel meter body.
2. Install a new gasket on adapter plate.
3. Install throttle body on adapter plate and torque the screws 30 lb-ft (40 Nm).

a
c

76543

a - Flame Arrestor Cover

b - Flame Arrestor
c - Throttle Body Unit
d - Gasket
e - Throttle Body Adapter

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

4. Connect throttle linkage to throttle body.

75867

5. Move throttle from idle to WOT and check that the throttle movement is not binding.
6. Connect the fuel inlet and return lines. Torque to 23 lb-ft (31 Nm).
7. Connect TP sensor, IAC, and fuel injectors connections.
8. Turn key to ON position and check for fuel leaks around the inlet and return line connec-
tions.
9. Start engine and check for fuel leaks.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Throttle Body Adapter Plate

NOTICE
Refer to “Service Precautions” at front of this section BEFORE proceeding.

REMOVAL
IMPORTANT: Place a clean shop towel over the intake manifold opening to prevent
foreign material from entering the engine.
1. Remove flame arrestor.
2. Remove throttle body.
3. Remove screws and throttle body adapter from the intake manifold.
1

3
5

5
76500

75841

Typical
1 - Throttle Body
2 - Screws (3)
3 - Gasket
4 - Throttle Body Adapter
5 - Screws (4)
6 - Gasket
7 - Intake Manifold

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

Engine Control Module (ECM)

IMPORTANT: The ECM is a sensitive electrical device, subject to electrostatic
damage. Therefore, take care not to touch connector pins when removing or
installing the module.

a d

d c

b 72801 76253

MEFI 1 MEFI 3
NOTE: Connectors are reversed between MEFI 1 and MEFI 3.
a - Electrical Bracket
b - ECM
c - J1- Electrical Connector
d - J2- Electrical Connector

REMOVAL
1. Disconnect J1 and J2 electrical connectors at engine control module (ECM).
2. Remove ECM from electrical bracket.

CLEANING AND INSPECTION

1. Clean the exterior of the ECM with a dry cloth being 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 J1 and J2 connectors on the wiring harness for corrosion and terminals
that may have backed of the harness.
NOTE: The ECM is a sealed electrical component. If a Code 51 check has shown it to be
defective, replace the unit with another ECM having the same part number as the original.

INSTALLATION
1. Mount new ECM to electrical bracket.
2. Connect J1 and J2 electrical connectors to the ECM.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Knock Sensor (KS) Module (MEFI 1 Only)

NOTICE
Refer to “Service Precautions,” at front of this section BEFORE proceeding.

72801

MEFI 1
a - Electrical Bracket
b - Knock Sensor (KS) Sensor

REMOVAL
1. Remove Knock Sensor from electrical bracket.
2. Disconnect electrical connector at Knock Sensor (KS) Module.

CLEANING AND INSPECTION

1. Clean the external surfaces of the KS Module with a dry cloth.
2. Inspect surfaces of KS Module for evidence of damage.

INSTALLATION
1. Connect electrical connector to the Knock Sensor (KS) Module.
2. Mount KS Module to electrical bracket.

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

Engine Coolant Temperature (ECT) Sensor

NOTICE
Refer to “Service Precautions,” at front of this section BEFORE proceeding.

REMOVAL
NOTE: Handle the ECT carefully as any damage to it will affect operation of the system.
1. Disconnect electrical connector at Engine Coolant Temperature (ECT) Sensor.

a
72799

a - Thermostat Housing
b - Engine Coolant Temperature (ECT) Sensor

2. Remove ECT from thermostat housing.

CLEANING AND INSPECTION

1. Clean with a dry cloth, removing any excess sealant from the base threads.
2. Look for evidence of any physical damage to base or connector surfaces of the ECT.

INSTALLATION
1. Install ECT in thermostat housing. Tighten hand tight plus 2-1/2 turns maximum.
2. Connect electrical connector to ECT.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Manifold Absolute Pressure (MAP) Sensor

NOTICE
Refer to “Service Precautions,” at front of this section BEFORE proceeding.

REMOVAL
1. Disconnect electrical connector from Manifold Absolute Pressure (MAP) Sensor.

c
a d
75840

a - Electrical Connector
b - Manifold Absolute Pressure (MAP) Sensor
c - Clip
d - Screw
e - Intake Manifold

2. Remove MAP sensor from throttle body adapter.

CLEANING AND INSPECTION

1. Clean the surfaces of the MAP sensor with a dry cloth.
2. Inspect the MAP sensor for signs of wear or damage.
3. Inspect seal on MAP sensor. Replace if deteriorated or hardened.

INSTALLATION
1. Install seal on MAP sensor.
2. Install MAP sensor on intake manifold using clip and screw. Torque screw to 44-62 lb-in.
(5-7 Nm).
3. Connect electrical connector to MAP sensor.

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

Throttle Position (TP) Sensor

NOTICE
Refer to “Service Precautions,” at front of this section BEFORE proceeding.

REMOVAL
1. Disconnect electrical connector at Throttle Position (TP) Sensor.
2. Remove TP sensor from throttle body.
a
c

73758
b
a - Throttle Body
b - Throttle Position (TP) Sensor
c - Screws
CLEANING AND INSPECTION
1. Clean the surfaces of the TP sensor with a dry cloth.
2. Inspect the TP sensor for signs of wear or damage.
INSTALLATION
IMPORTANT: If the TP sensor is to be replaced with a new unit, be sure to secure it
in place with the new screws that are included in the service package.
1. Install TP sensor to throttle body using screws with washers and Loctite 242 applied to
threads. Torque screws to 20 lb-in. (2 Nm).

a
b

b
c
73758
a - Throttle Body
b - Screws With Lockwashers
c - Seal
2. Connect electrical connector to TP sensor.
3. Install throttle body, throttle linkage and flame arrestor. Refer to “Throttle Body.”
4. Start engine and check for TP sensor output voltage. It should be approximately .7 V
at idle and 4.5 V at WOT.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Idle Air Control (IAC) Valve

NOTICE
Refer to “Service Precautions,” at front of this section BEFORE proceeding.

REMOVAL
1. Remove flame arrestor, throttle cable and throttle body.
2. Disconnect electrical connector at Idle Air Control (IAC) Valve.
a

73754

a - Throttle Body
b - Idle Air Control (IAC) Valve

3. Remove IAC from throttle body.

CLEANING AND INSPECTION

1. Remove and discard sealing O-ring from IAC valve. Clean sealing surfaces, pintle valve
seat, and air passage with a carburetor cleaner to remove carbon deposits, being
careful not to push or pull on the IAC valve pintle. Force exerted on the pintle might
damage the worm drive. DO NOT use a cleaner that contains the extremely strong
solvent methyl ethyl ketone.
NOTE: Shiny spots on the pintle, or seat, are normal and do not indicate misalignment or
a bent pintle shaft.
2. Inspect the entire assembly for any obvious physical damage.

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

INSTALLATION
IMPORTANT: If installing a new IAC valve, be sure to replace it with the correct IAC
valve pintle shape and diameter are designed for the specific application.
1. Install new O-ring on IAC valve.
a

b
d 73766

a - Throttle Body
b - Idle Air Control (IAC) Valve
c - O-Ring
d - Screws

2. Install IAC valve in throttle body using screws. Torque to 20 lb-in. (2 Nm).
3. Connect electrical connector to IAC valve.
a

b
73754

a - Throttle Body
b - Idle Air Control (IAC) Valve

4. Reset IAC valve pintle position after reconnecting negative (–) battery cable.
a. Turn ignition key ON for ten seconds.
b. Turn ignition key OFF for ten seconds.
c. Restart engine and check for proper idle operation.

Page 5G-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

Knock Sensor
NOTICE
Refer to “Service Precautions” at front of this section BEFORE proceeding.

REMOVAL
1. Disconnect electrical connector at knock sensor located just ahead of starter motor.

a
73757

a - Knock Sensor

2. Remove knock sensor 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.
IMPORTANT: Ensure that the knock sensor is installed in the upper location on the
Y-fitting.
1. Install knock sensor in engine block. Torque to 12-16 lb-ft (16-22 Nm).

a
73756
a - Knock Sensor

2. Connect electrical connector to knock sensor.

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FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 25

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SERVICE MANUAL NUMBER 25 FUEL INJECTION DISASSEMBLY AND REASSEMBLY

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SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

FUEL SYSTEMS
Section 5H - Fuel Injection System Troubleshooting
Table of Contents
Scan Tool Normal Specifications . . . . . . 5H-2 Detonation / Spark Knock Symptom . . . 5H-11
Important Preliminary Checks . . . . . . . . . 5H-3 Hesitation, Sag, Stumble Symptom . . . . 5H-13
Before Starting . . . . . . . . . . . . . . . . . . . 5H-3 Cuts Out, Misses Symptom . . . . . . . . . . . 5H-15
Visual / Physical Check . . . . . . . . . . . . 5H-3 Rough, Unstable or Incorrect Idle,
Intermittents . . . . . . . . . . . . . . . . . . . . . . . . 5H-4 Stalling Symptom . . . . . . . . . . . . . . . . . . . 5H-17
Hard Start Symptom . . . . . . . . . . . . . . . . . 5H-5 Poor Fuel Economy Symptom . . . . . . . . 5H-20
Surges and/or Chuggles Symptom . . . . 5H-7 Dieseling, Run-On Symptom . . . . . . . . . . 5H-22
Lack of Power, Sluggish Backfire Symptom . . . . . . . . . . . . . . . . . . . 5H-23
or Spongy Symptom . . . . . . . . . . . . . . . . 5H-9

5
H

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FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Scan Tool Normal Specifications

(Idle / Warm Engine / Closed Throttle / Neutral)
Scan Position Units Displayed Typical Data Value
rpm rpm 600-700 rpm
Desired rpm rpm 600 or 650 rpm - Depends on Model 2
Coolant Temp. ° F(° C) 150-170° F (66-77° C)
Manifold Air Temp. ° F (° C) Varies with Ambient Temperature
Throttle Position Volts .4 to .8 Volts
Throttle Angle 0-100 % 0-1%
1-3 Volts or (45-55 kPa) (Depends on
MAP Volts or kPa
Vacuum and Baro Pressure)
3-5 Volts (Depends on Altitude and
Baro Volts or kPa
Barometric Pressure)
Bat Volts 12.0-14.5 Volts
Spark Advance Degrees -10 to 30°
Knock Retard Degrees 0°
Idle Air Control IAC Counts (Steps) 0-40 Counts
Minimum IAC Position Counts (Steps) 0-40 Counts
Idle Air Control Follower Counts (Steps) 0 Counts
Injector Pulse Width msec. 2-3 msec.
2.5–3.5 msec. (Depends on Water/Air
Injector On Time Cranking msec.
Temperature)
Fuel Consumption GPH (L/h) 1-2 GPH(3.7-7.5 L/h)
Time From Start 0:00:00-1092:00 Varies
Memory Calibration Calibration and Check
Varies with Software revision in ECM
Check Sum Sum
Oil Press/IO Level 1 OK/LO OK
Engine Overtemp OK/Overheating OK
Lanyard Stop Mode OFF/ON OFF
1: MCM will read I/O Level and MIE will read Trans.
2: Refer to “Engine and Tune-Up Specifications.”

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SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Important Preliminary Checks

Before Starting
Before using this section you should have performed the “On-Board Diagnostic (OBD) Sys-
tem Check” in the “General System Diagnostics” section and determined that:
• The ECM and/or MIL (Malfunction Indicator Lamp) are operating correctly.
• There are no DTC(s) stored.
Verify the customer complaint and locate the correct symptom in the table of contents.
Check the items indicated under that symptom.
Visual / Physical Check
Several of the symptom procedures call for a careful Visual/ Physical Check. The impor-
tance of this step cannot be stressed too strongly. It can lead to correcting a problem without
further checks and can save valuable time. This check should include:
• Engine in good mechanical condition.
• ECM grounds and sensor connections for being clean, tight and in their proper location.
• Vacuum hoses for splits, kinks and proper connections. Check thoroughly for any type of
leak or restriction.
• Air leaks at throttle body mounting area and intake manifold sealing surfaces.
• Ignition wires for cracking, hardness, proper routing and carbon tracking.
• Wiring for proper connections, pinches and cuts. If wiring harness or connector repair is
necessary, refer to “Description and System Operation” section for correct procedure.
• Moisture in primary or secondary ignition circuit connections.
• Salt corrosion on electrical connections and exposed throttle body linkages.

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FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Intermittents
IMPORTANT: Problem may or may not turn ON the Malfunction Indicator Lamp (MIL)
or store a DTC. DO NOT use the Diagnostic Trouble Code (DTC) tables for intermittent
problems. The fault must be present to locate the problem.
Most intermittent problems are caused by faulty electrical connections or wiring. Perform
careful visual/physical check. Check for the following conditions:
• Poor mating of the connector halves, or a terminal not fully seated in the connector body
(backed out or loose).
• Improperly formed or damaged terminals and/or connectors.
All connector terminals in the problem circuit should be carefully checked for proper contact
tension.
• Poor terminal to wire connection (crimping).This requires removing the terminal from the
connector body to check. Refer to “Wiring Harness Service” in the “Description and Sys-
tem Operation” section.
The vessel may be driven with a Digital Multimeter connected to a suspected circuit. An
abnormal voltage when malfunction occurs is a good indication that there is a fault in the
circuit being monitored.
A scan tool (see “Special Tools” for part numbers) can be used to help detect intermittent
conditions. The scan tools have several features that can be used to locate an intermittent
condition. The following features can be used in finding an intermittent fault:
The “Record” feature or choosing not to erase data can be triggered to capture and store
engine parameters within the scan tool when the malfunction occurs. This stored informa-
tion can then be reviewed by the service technician to see what caused the malfunction.
To check loss of DTC memory, disconnect TP sensor and idle engine until the MIL comes
ON. A trouble code should be stored and kept in memory when ignition is turned OFF. If not,
the ECM is faulty. When this test is completed, make sure that you clear the DTC 22 from
memory.
An intermittent MIL with no stored DTC may be caused by the following:
• Ignition coil shorted to ground and arcing at ignition wires or plugs.
• MIL wire to ECM shorted to ground.
• Poor ECM grounds, Go to ECM wiring diagrams.
• Check for an electrical system interference caused by a sharp electrical surge. Normally,
the problem will occur when the faulty component is operated.
• Check for improper installation of electrical options such as lights, ship to shore radios,
sonar, etc.
• Check that knock sensor wires are routed away from spark plug wires, ignition system
components and charging system components.
• Check for secondary ignition components shorted to ground, or an open ignition coil
ground (coil mounting brackets).
• Check for components internally shorted to ground such as starters, alternators or
relays.
All Ignition Control (IC) module wiring should kept away from the alternator. Check all wires
from the ECM to the ignition control module for poor connections.

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SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Hard Start Symptom

Step Action Yes No
PROCEED TO
Definition: Engine cranks OK, but does not start for a long time. Does eventually
run, or may start but immediately dies.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
Does the driver know the correct starting
2
procedure? Step 3 System normal
Visual/Physical
3 Was visual/physical check performed?
Step 4 Check
1. Check for proper operation of fuel pump
relay circuit.
4 • Refer to Table A-5 in “General System
Diagnostics” section.
Was a problem found? OBD Step 5
1. Check for contaminated fuel.
5 2. Check water separating fuel filter.
Was a problem found? OBD Step 6
1. Check for proper fuel pressure.
• Refer to Table A-4 in “General System
6 Diagnostics” section.
Was fuel pressure 30 psi for EFI or 3-7 psi
for carbureted engines? OBD Step 7
1. Check for proper ignition voltage output.
• Refer to Table A-7 in “General System
7
Diagnostics” section.
Was a problem found? OBD Step 8
8 Is a scan tool being used? Step 10 Step 9
1. Check for a ECT sensor shifted in value.
2. With engine completely cool, measure the
resistance of the ECT sensor.
3. Refer to the Engine Coolant Temperature
Sensor Temperature vs Resistance value
9 table on the facing page of DTC 14 in the
“Trouble Code Diagnostics” section.
Compare the approximate temperature of
the ECT sensor to an accurate reading of
ambient air temperature.
Are the readings within the specified
value? Step 14 Step 13
1. Check ECT sensor for being shifted in
value.
2. With the engine completely cool, compare
10 the ECT sensor temperature with an accu-
rate reading of ambient air temperature.
Are the temperatures within 10° F (-12° C) of
each other? Step 11 Step 13

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FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Hard Start Symptom (Continued)

Step Action Yes No
PROCEED TO
1. Using a scan tool, display ECT sensor tem-
perature and note value.
2. Check resistance of ECT sensor.
3. Go to Engine Coolant Temperature Sensor
11 Temperature vs Resistance value table on
the facing page of DTC 14 in the Diagnos-
tics section.
Is resistance value of ECT sensor near the
resistance of the value noted? Step 14 Step 12
1. Locate and repair high resistance or poor
connection in the ECT signal circuit or the
12 ECT sensor ground.
Is action complete? –
13 Replace the ECT sensor. –
1. Check for intermittent opens or shorts to
14 ground in the MAP sensor circuits.
Was a problem found? Step 15
1. Check for proper operation of the TP sen-
sor.
2. Check for throttle linkage sticking, binding
15 or worn causing TP sensor voltage to be
higher than normal.
Is TP sensor operating improperly or is
voltage higher than normal? Step 16
1. Check for proper operation of the IAC
16 valve. (Table A-8)
Was a problem found? Step 17
1. Check for the following engine problems:
• Low compression.
• Leaking cylinder head gaskets.
17 • Worn or incorrect camshaft.
• Proper valve timing/valve train problem.
• Restricted exhaust system.
Was a problem found? OBD Step 18
1. Review all diagnostic procedures within
this table.
2. If all procedures have been completed and
no malfunctions have been found, review/
18 inspect the following:
• Visual/physical inspection. Contact
Mercury
• Scan tool data. MerCruiser
• All electrical connections within a sus- Customer
pected circuit and/or system. OBD Service

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SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Surges and/or Chuggles Symptom

Step Action Yes No
PROCEED TO
Definition: Engine power variation under steady throttle or cruise. Feels like the
engine speeds up and slows down with no change in the throttle lever position.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
Visual/Physical
2 Was visual/physical check performed?
Step 3 Check
1. Check for contaminated fuel.
3 2. Check fuel filters and water separator.
Was a problem found? Step 4
1. Check for proper fuel pressure while the
condition exists.
• Refer to Table A-4 in “General System
4
Diagnostics” section.
Was fuel pressure 30 psi for EFI or 3-7 psi
for carbureted engines? Step 5
1. Check for intermittent opens or short to
grounds in the ECT sensor, MAP sensor
and TP sensor circuits. Also check or
5 throttle linkage sticking, binding or worn.
2. An intermittent failure may not store a DTC.
Was a problem found? Step 6
1. Check for proper ignition voltage output.
• Refer to Table A-7 in “General System
6
Diagnostics” section.
Was a problem found? Step 7
1. Check ignition coil for cracks or carbon
7 tracking.
Were cracks or carbon tracks found? Step 8
1. Check integrity of the primary and second-
ary wiring.
2. Check routing of the wiring.
8 3. Check condition of IC module, pick-up coil,
distributor cap, rotor and spark plug wires.
4. If a problem is found, repair as necessary.
Was a problem found? OBD Step 9

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FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Surges and/or Chuggles Symptom (Continued)

Step Action Yes No
PROCEED TO
1. Remove spark plugs and check for wet
plugs. cracks, wear, improper gap, burned
electrodes or heavy deposits.
• Refer to Distributor Ignition System in “De-
9 scription and System Operation” section.
NOTE: If spark plugs are gas or oil fouled, the
cause of the fouling must be determined before
replacing the spark plugs.
Were spark plugs damaged? Step 10
1. Check fuel delivery system items that can
10 cause the engine to run rich.
Was a problem found? Step 11
1. Check fuel delivery system items that can
11 cause the engine to run lean.
Was a problem found? Step 12
1. Check the injector connections for proper
mating.
2. If any of the injectors connectors are con-
12
nected to an incorrect cylinder, correct as
necessary.
Were any injectors improperly connected? Step 13
1. Check ECM grounds for being clean, tight
and in the proper locations.
13
Were ECM grounds dirty, loose or
improperly connected? Step 14
1. Visually/physically check vacuum hoses
for splits, kinks and proper connections and
14
routing.
Was a problem found? Step 15
1. Check or proper alternator voltage output.
15
Is voltage between 11 - 16 volts? Step 16
1. Review all diagnostic procedures within
this table.
2. If all procedures have been completed and
no malfunctions have been found, review/
inspect the following:
16 • Visual/physical inspection.
Contact
• Scan tool data.
Mercury
• All electrical connections within a sus- MerCruiser
pected circuit and/or system. Customer
Was a problem found? OBD Service

Page 5H-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Lack of Power, Sluggish or Spongy Symptom

Step Action Yes No
PROCEED TO
Definition: Engine delivers less than expected power. Little or no increase in speed when
throttle lever is advanced part way.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
If possible, compare engine performance with
a similar engine.
2
Is engine performance close to similar No problem
engine? found Step 3
Visual/Physical
3 Was visual / physical check performed?
Step 4 Check
1. Remove and check flame arrestor for dirt,
or for being restricted.
4
2. Clean or replace flame arrestor.
Was flame arrestor dirty or restricted? Step 5
1. Check for contaminated fuel.
5 2. Check water separating fuel filter.
Was a problem found? Step 6
1. Check for proper fuel pressure while the
condition exists.
• Refer to Table A-4 in “General System
6
Diagnostics” section.
Was fuel pressure 30 psi for EFI or 3-7 psi
for carbureted engines? Step 7
1. Check for injector driver CKT 467 or CKT
7 468 for an open.
Did you find an open? Step 8
1. Check for proper operation of Ignition Con-
trol (IC) circuit and the Knock Sensor (KS)
8
circuit.
Was a problem found? Step 9
1. Check for proper ignition voltage output.
• Refer to Table A-7 in “General System
9
Diagnostics” section.
Was a problem found? Step 10
1. Remove spark plugs, check for wet plugs,
cracks, wear, improper gap, burned elec-
trodes or heavy deposits.
• Refer to “Distributor Ignition System” in
“Description and System Operation” sec-
10 tion.
NOTE: If spark plugs are gas or oil fouled, the
cause of the fouling must be determined before
replacing the spark plugs.
Were spark plugs damaged? OBD Step 11

90-861328--1 NOVEMBER 1999 Page 5H-9

FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Lack of Power, Sluggish or Spongy Symptom (Continued)

Step Action Yes No
PROCEED TO
1. Check ignition coil for cracks or carbon
11 tracking.
Were cracks or carbon tracks found? Step 12
1. Check for intermittent opens or short to
grounds in the ECT sensor, MAP sensor
and TP sensor circuits. Also check or
12
throttle linkage sticking, binding or worn.
2. An intermittent failure may not store a DTC.
Was a problem found? Step 13
1. Check ECM grounds for cleanliness, tight-
ness and proper location.
13
Were ECM grounds dirty, loose or
improperly connected? OBD Step 14
1. Check diagnostic test CKT 451 for being
shorted to ground. This will cause the rpm
14
to be lowered.
Was a problem found? Step 15
1. Check for proper alternator voltage output.
15
Is voltage between 11 - 16 volts? Step 16
1. Check for the following Engine Mechanical
problems:
• Low compression.
• Leaking cylinder head gaskets.
16
• Worn or incorrect camshaft.
• Proper valve timing/valve train problem.
• Restricted exhaust system.
Was a problem found? Step 17
1. Check for excessive resistance on the bot-
tom of the boat such as dirt, barnacles, etc.
17 2. Check for proper propeller size and pitch
for that application.
Was a problem found? OBD Step 18
1. Review all diagnostic procedures within
this table.
2. When all procedures have been completed
and no malfunctions are found, review/in-
spect the following:
18 • Visual/physical inspection.
Contact
• Scan tool data.
Mercury
• All connections within a suspected circuit MerCruiser
and/or system. Customer
Was a problem found? OBD Service

Page 5H-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Detonation / Spark Knock Symptom

Step Action Yes No
PROCEED TO
Definition: A mild to severe ping, usually worse under acceleration. The engine
makes sharp metallic knocks that change with throttle opening.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
Visual/Physical
2 Was visual/physical check performed?
Step 3 Check
1. Check base timing.
• Refer to Ignition Timing Set Procedure in
3
the Distributor Ignition section.
Was a problem found? Step 4
1. Check for proper operation of Ignition Con-
trol (IC) circuit and the Knock Sensor (KS)
4
circuit.
Was a problem found? Step 5
1. Check for good ignition system ground.
2. Check spark plugs for proper gap and heat
5
range.
Was a problem found? Step 6
1. Check for contaminated fuel.
2. Check for poor fuel quality and proper
6
octane rating.
Was a problem found? Step 7
1. Check for proper fuel pressure.
• Refer to Table A-4 in “General System
7 Diagnostics” section.
Was fuel pressure 30 psi for EFI or 3-7 psi
for carbureted engines? OBD Step 8
8 Is a scan tool being used? Step 9 Step 10
1. If scan tool readings are normal (Refer to
“Scan Tool Normal Specifications” in this
section) and there are no engine mechani-
9 cal faults, fill fuel tank with a known high
quality gasoline.
Is detonation present? Step 10 OBD
1. Check for obvious overheating problems:
• Loose water pump belt.
• Faulty or incorrect water pump.
10
• Restriction in cooling system.
• Faulty or incorrect thermostat.
Was a problem found? OBD Step 11

90-861328--1 NOVEMBER 1999 Page 5H-11

FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Detonation / Spark Knock Symptom (Continued)

Step Action Yes No
PROCEED TO
1. Check fuel delivery system items that can
11 cause an engine to run lean.
Was a problem found? Step 12
1. Check for ECT sensor being shifted in
value.
2. Check for proper output voltage of the TP
12 sensor at closed throttle and wide open
throttle. Also check throttle linkage for stick-
ing, binding or worn.
Was a problem found? Step 13
1. Check for the following Engine Mechanical
problems:
• Low compression.
• Low oil level.
• Excessive oil in the combustion chambers
13 due to valve seals leaking.
• Worn or incorrect camshaft.
• Proper valve timing/valve train problem.
• Combustion chambers for excessive car-
bon build up.
Was a problem found? OBD Step 14
1. Remove excessive carbon buildup with a
top engine cleaner.
• Refer to instructions on top of engine
14
cleaner can.
2. Re-evaluate engine performance.
Is detonation still present? Step 15 OBD
1. Review all diagnostic procedures within
this table.
2. If all procedures have been completed and
no malfunctions have been found, review/
inspect the following:
15 • Visual/physical inspection.
Contact
• Scan tool data.
Mercury
• All electrical connections within a sus- MerCruiser
pected circuit and/or system. Customer
Was a problem found? OBD Service

Page 5H-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Hesitation, Sag, Stumble Symptom

Step Action Yes No
PROCEED TO
Definition: Momentary lack of response as the throttle lever is advanced. Can occur
at all engine speeds. Usually most severe when first starting out. May cause engine
to stall if severe enough.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
Visual/Physical
2 Was visual/physical check performed?
Step 3 Check
1. Check for contaminated fuel.
3 2. Check water separating fuel filter.
Was a problem found? Step 4
1. Check or proper fuel pressure while the
condition exists.
4 • Refer to Table A-4 in “General System
Diagnostics” section.
Was a problem found? Step 5
1. Check fuel injectors.
• Refer to Injector Balance Test in “Test Gen-
5
eral System Diagnostics” section.
Was a problem found? Step 6
1. Check for proper operation of Ignition Con-
trol (IC) circuit and the Knock Sensor (KS)
6
circuit.
Was a problem found? Step 7
1. Check integrity of the primary and second-
ary wiring.
2. Check routing of the wiring.
7
3. Check condition of IC module, pick-up coil,
distributor cap, rotor and spark plug wires.
Was a problem found? Step 8
1. Remove spark plugs and check for wet
plugs, cracks. wear, improper gap, burned
electrodes or heavy deposits.
• Refer to Distributor Ignition System.
8
NOTE: If spark plugs are gas or oil fouled, the
cause of the fouling must be determined before
replacing the spark plugs.
Were spark plugs damaged? OBD Step 9

90-861328--1 NOVEMBER 1999 Page 5H-13

FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Hesitation, Sag, Stumble Symptom (Continued)

Step Action Yes No
PROCEED TO
1. Check for the ECT sensor shifted in value.
2. Check for intermittent opens or short to
grounds in the ECT sensor, MAP sensor
9 and TP sensor circuits. Also check or
throttle linkage sticking, binding or worn.
3. An intermittent failure may not store a DTC.
Was a problem found? OBD Step 10
1. Check for proper alternator voltage output.
10
Is voltage between 11 - 16 volts? Step 11
1. Check for faulty or incorrect thermostat.
11
Is thermostat faulty? Step 12
1. Check intake valves for valve deposits and
12 remove if found.
Were deposits found on the intake valves? Step 13
1. Review all diagnostic procedures within
this table.
2. If all procedures have been completed and
no malfunctions have been found, review/
inspect the following:
13 • Visual/physical inspection.
• Scan tool data. Contact
• All electrical connections within a sus- Mercury
MerCruiser
pected circuit and/or system. Customer
Was a problem found? OBD Service

Page 5H-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Cuts Out, Misses Symptom

Step Action Yes No
PROCEED TO
Definition: Steady pulsation or jerking that follows engine speed, usually more
pronounced as engine load increases. The exhaust has a steady spitting sound at
idle, low speed or on hard acceleration for fuel starvation that can cause engine to
cut out.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
Visual/Physical
2 Was visual/physical check performed?
Step 3 Check
1. Check for contaminated fuel.
3 2. Check water separating fuel filter.
Was a problem found? Step 4
1. Check for proper fuel pressure while the
condition exists.
• Refer to Table A-4 in “General System
4
Diagnostics” section.
Was fuel pressure 30 psi for EFI or 3-7 psi
for carbureted engines? Step 5
1. Disconnect all injector harness connectors
and install an injector test light J 34730-2
between the harness terminal connector of
each injector.
5 2. Crank engine and note light on each con-
nector. If test light fails to blink at any one of
the connectors, it is a faulty injector drive
circuit harness, connector or terminal.
Was a problem found? Step 6
1. Check fuel injectors.
• Refer to Injector Balance Test in “General
6
System Diagnostics” section.
Was a problem found? Step 7
1. Check for proper spark at each cylinder.
7
Was a problem found? OBD Step 8
1. Check the spark plugs for the following:
• Insulator cracks.
• Improper gap.
• Burned electrodes.
8 • Heavy deposits.
NOTE: If spark plugs are gas or oil fouled, the
cause of the fouling must be determined before
replacing the spark plugs.
Were spark plugs damaged? OBD Step 9

90-861328--1 NOVEMBER 1999 Page 5H-15

FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Cuts Out, Misses Symptom (Continued)

Step Action Yes No
PROCEED TO
1. Check engine mechanical for the following
conditions.
• Low compression.
• Sticking or leaking valves.
• Bent push rods
9
• Worn rocker arms.
• Broken valve springs.
• Worn camshaft lobe(s).
• Incorrect valve timing.
Was a problem found? Step 10
1. Check intake and exhaust manifold(s) for
10 casting flash.
Was a problem found? Step 11
1. Check for Electromagnetic Interference
(EMI). A missing condition can be caused
by EMI on the reference circuit. EMI can
usually be detected by monitoring engine
rpm with a scan tool or tachometer. A sud-
11 den increase in rpm with little change in
actual engine rpm change, indicates EMI is
present.
2. If EMI is present, locate and repair the
source.
Was a problem found? Step 12
1. Review all diagnostic procedures within
this table.
2. If all procedures have been completed and
no malfunctions have been found, review/
inspect the following:
12 • Visual/physical inspection.
• Scan tool data.
• All electrical connections within a sus- Contact
pected circuit and/or system. Mercury
MerCruiser
3. If a problem is found, repair as necessary. Customer
Was a problem found? OBD Service

Page 5H-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Rough, Unstable or Incorrect Idle, Stalling Symptom

Step Action Yes No
PROCEED TO
Definition: Engine runs unevenly at idle. If severe, the engine or vessel may shake.
Engine idle speed may vary in rpm. Either condition may be severe enough to stall
the engine.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
Visual/Physical
2 Was visual/physical check performed?
Step 3 Check
1. Check for proper operation of the IAC
valve.
3 • Refer to Table A-8 in “General System
Diagnostics” section.
Was a problem found? Step 4
1. Check for proper operation of Ignition Con-
trol (IC) circuit and the Knock Sensor (KS)
4
circuit.
Was a problem found? Step 5
1. Check integrity of the primary and second-
ary wiring.
2. Check routing of the wiring.
5
3. Check condition of IC module, pick-up coil,
distributor cap, rotor and spark plug wires.
Was a problem found? Step 6
1. Check ignition coil for cracks or carbon
6 tracking.
Were cracks or carbon tracks found? Step 7
1. Remove spark plugs, check for wet plugs,
cracks, wear, improper gap, burned elec-
trodes or heavy deposits.
• Refer to Distributor Ignition System.
7
NOTE: If spark plugs are gas or oil fouled, the
cause of the fouling must be determined before
replacing the spark plugs.
Were spark plugs damaged? Step 8
1. Check the injector connections. Correct as
8 necessary.
Was a problem found? OBD Step 9

90-861328--1 NOVEMBER 1999 Page 5H-17

FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Rough, Unstable or Incorrect Idle, Stalling Symptom

(Continued)
Step Action Yes No
PROCEED TO
1. Disconnect all injector harness connectors
and install an injector test light J 34730-2
between the harness terminal connector of
each injector.
9 2. Crank engine and note light on each con-
nector. If test light fails to blink at any one of
the connectors, it is a faulty injector drive
circuit harness, connector or terminal.
Was a problem found? Step 10
1. Check fuel injectors.
• Refer to Injector Balance Test in “General
10
System Diagnostics” section.
Was a problem found? Step 11
1. Check for fuel in pressure regulator vac-
uum hose.
2. If fuel is present, replace the fuel pressure
11 regulator assembly.
• Refer to Fuel Metering System in “Descrip-
tion and System Operation” section.
Was a problem found? Step 12
1. Check for intermittent opens or short to
grounds in the ECT sensor, MAP sensor
and TP sensor circuits. Also check or
12
throttle linkage sticking, binding or worn.
2. An intermittent failure may not store a DTC.
Was a problem found? Step 13
1. Check ECM grounds for being clean, tight
and in their proper locations.
2. Also check that battery cables and ground
13
straps are clean and secure.
Were ECM grounds dirty, loose or
improperly connected? Step 14
1. Check fuel delivery system items that can
14 cause the engine to run rich.
Was a problem found? Step 15
1. Check fuel delivery system items that can
15 cause the engine to run lean.
Was a problem found? OBD Step 16

Page 5H-18 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Rough, Unstable or Incorrect Idle, Stalling Symptom

(Continued)
Step Action Yes No
PROCEED TO
1. Check or proper alternator voltage output.
2. The voltage should be between specified
16
values.
Is voltage between 11 - 16 volts? Step 17
1. Check the following Engine Mechanical
items:
• Check compression.
• Sticking or leaking valves.
17
• Worn camshaft lobe(s).
• Valve timing.
• Broken valve springs.
Was a problem found? Step 18
1. Check intake valves for valve deposits.
2. If deposits are found, remove as neces-
18
sary.
Were deposits found on the intake valves? Step 19
1. Check for faulty motor mounts.
19
Was a problem found? Step 20
1. Review all diagnostic procedures within
this table.
2. If all procedures have been completed and
no malfunctions have been found, review/
inspect the following:
20 • Visual/physical inspection.
Contact
• Scan tool data.
Mercury
• All electrical connections within a sus- MerCruiser
pected circuit and/or system. Customer
Was a problem found? OBD Service

90-861328--1 NOVEMBER 1999 Page 5H-19

FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Poor Fuel Economy Symptom

Step Action Yes No
PROCEED TO
Definition: Fuel economy is noticeably lower than expected. Also, economy is
noticeably lower than it was on this engine at one time.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
Visual/Physical
2 Was visual/physical check performed?
Step 3 Check
1. Check operators driving habits. Are exces-
sively heavy loads being carried? Is opera-
3
tor accelerating too much, too often?
Was a problem found? System normal Step 4
1. Check flame arrestor for dirt or being
plugged.
4
2. Check for fuel leaks.
Was a problem found? Step 5
1. Check for proper fuel pressure.
• Refer to Table A-4 in “General System
5 Diagnostics” section.
Was fuel pressure 30 psi for EFI or 3-7 psi
for carbureted engines? Step 6
1. Check for proper operation of Ignition Con-
trol (IC) circuit and the Knock Sensor (KS)
6
circuit.
Was a problem found? Step 7
1. Remove spark plugs, check for wet plugs,
cracks, wear, improper gap, burned elec-
trodes or heavy deposits.
• Refer to Distributor Ignition System.
7
NOTE: If spark plugs are gas or oil fouled, the
cause of the fouling must be determined
before replacing the spark plugs.
Were spark plugs damaged? Step 8
1. Visual (physically) check vacuum hoses
for splits, kinks and improper connections
8
and routing.
Was a repair required? Step 9
1. Check engine compression for being low.
9
Was a problem found? OBD Step 10

Page 5H-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Poor Fuel Economy Symptom (Continued)

Step Action Yes No
PROCEED TO
1. Check exhaust system for possible restric-
tion.
10 2. Inspect exhaust system for damaged or
collapsed pipes.
Was a problem found? OBD Step 11
1. Check for excessive resistance on the bot-
tom of the boat such as dirt, barnacles, etc.
11 2. Check for proper propeller size and pitch
for that application.
Was a problem found? OBD Step 12
1. Review all diagnostic procedures within
this table.
2. When all procedures have been completed
and no malfunctions are found, review/
inspect the following:
12 • Visual/physical inspection.
• Scan tool data. Contact
• All connections within a suspected circuit Mercury
MerCruiser
and/or system. Customer
Was a problem found? OBD Service

90-861328--1 NOVEMBER 1999 Page 5H-21

FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Dieseling, Run-On Symptom

Step Action Yes No
PROCEED TO
Definition: Engine continues to run after key is turned “OFF,” but runs very rough.
If engine runs smooth, check ignition switch and adjustment.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
Visual/Physical
2 Was visual/physical check performed?
Step 3 Check
1. Check for leaking fuel injectors.
• Refer to Table A-4 in “General System
3
Diagnostics” section.
Was a problem found? OBD Step 4
1. Check for proper operation of Ignition Con-
trol (IC) circuit and the Knock Sensor (KS)
4
circuit.
Was a problem found? OBD Step 5
1. Check for obvious overheating problems:
• Loose water pump belt.
• Faulty or incorrect water pump.
5
• Restriction in cooling system.
• Faulty or incorrect thermostat.
Was a problem found? OBD Step 6
1. Check for proper operation of the EFI sys-
tem relay.
6 • Refer to Table A-6 in “General System
Diagnostics” section.
Was a problem found? OBD Step 7
1. Review all diagnostic procedures within
this table.
2. If all procedures have been completed and
no malfunctions have been found, review/
inspect the following:
7 • Visual physical inspection.
Contact
• Scan tool data.
Mercury
• All electrical connections within a sus- MerCruiser
pected circuit and/or system. Customer
Was a problem found? OBD Service

Page 5H-22 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

Backfire Symptom
Step Action Yes No
PROCEED TO
Definition: Fuel ignites in the intake manifold, or in the exhaust system, making
loud popping noise.
Was the “On-Board Diagnostic” (OBD)
1
System Check performed? Step 2 OBD
Visual/Physical
2 Was visual/physical check performed?
Step 3 Check
1. Check flame arrestor for proper installa-
3 tion.
Was a problem found? Step 4
1. Check for proper fuel pressure.
• Refer to Table A-4 in “General System
4 Diagnostics” section.
Was fuel pressure 30 psi for EFI or 3-7 psi
for carbureted engines? Step 5
1. Check the injector connections. Correct as
5 necessary.
Was a problem found? Step 6
1. Check fuel injectors.
• Refer to Injector Balance Test in “General
6
System Diagnostics” section.
Was a problem found? Step 7
1. Check for proper operation of Ignition Con-
trol (IC) circuit and the Knock Sensor (KS)
7
circuit.
Was a problem found? Step 8
1. Check integrity of the primary and second-
ary wiring.
2. Check routing of the wiring.
8
3. Check condition of IC module, pick-up coil,
distributor cap, rotor and spark plug wires.
Was a problem found? Step 9
1. Check ignition coil for cracks or carbon
9 tracking.
Were cracks or carbon tracks found? OBD Step 10

90-861328--1 NOVEMBER 1999 Page 5H-23

FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

Backfire Symptom (Continued)

Step Action Yes No
PROCEED TO
1. Check for proper ignition voltage input to
the ECM.
2. Check for intermittent open or short to
10
ground on the ignition voltage input circuit
to the ECM.
Was a problem found? Step 11
1. Remove spark plugs, check for wet plugs,
cracks, wear, improper gap, burned elec-
trodes or heavy deposits.
• Refer to Distributor Ignition System in “De-
11 scription and System Operation” section.
NOTE: If spark plugs are gas or oil fouled, the
cause of the fouling must be determined before
replacing the spark plugs
Were spark plugs damaged? Step 12
1. Check for intermittent opens or short to
grounds in the MAP sensor and TP sensor
circuits. Also check for throttle linkage
12
sticking, binding or worn.
2. An intermittent failure may not store a DTC.
Was a problem found? Step 13
1. Check engine mechanical for the following
conditions:
• Low compression.
13 • Sticking or leaking valves.
• Worn camshaft lobe(s).
• Incorrect valve timing.
Was a problem found? Step 14
1. Check intake and exhaust manifold(s) for
14 casting flash.
Was a problem found? Step 15
1. Review all diagnostic procedures within
this table.
2. If all procedures have been completed and
no malfunctions have been found, review/
inspect the following:
15 • Visual/physical inspection.
Contact
• Scan tool data.
Mercury
• All electrical connections within a sus- MerCruiser
pected circuit and/or system. Customer
Was a problem found? OBD Service

Page 5H-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 FUEL INJECTION SYSTEM TROUBLESHOOTING

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90-861328--1 NOVEMBER 1999 Page 5H-25

FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 25

THIS PAGE IS INTENTIONALLY BLANK

Page 5H-26 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

FUEL SYSTEMS
Section 5I - Diagnostics
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 5I-2 Clearing Trouble Codes . . . . . . . . . . . . . . 5I-48
Diagnostic Circuit Check . . . . . . . . . . . . . 5I-4 Clearing Codes Using
Scan Tool Normal Specifications . . . . 5I-4 CodeMate Tester . . . . . . . . . . . . . . . . . 5I-48
Diagnostic Trouble Codes . . . . . . . . . . . . 5I-5 Clearing Codes Using Scan Tool . . . . 5I-48
ECM Connector and Diagnostic Testing . . . . . . . . . . . . . . . . . . . 5I-49
EFI Symptoms Chart . . . . . . . . . . . . . . . . 5I-6 Code 14 Engine Coolant Temperature
J-1 Circuits with MEFI 1 . . . . . . . . . . . 5I-6 (ECT) Sensor Circuit . . . . . . . . . . . . . 5I-49
J-2 Circuits with MEFI 1 . . . . . . . . . . . 5I-8 Code 15 Engine Coolant Temperature
J-1 Circuits with MEFI 3 . . . . . . . . . . . 5I-10 (ECT) Sensor Circuit . . . . . . . . . . . . . 5I-52
J-2 Circuits with MEFI 3 . . . . . . . . . . . 5I-12 Code 21 Throttle Position
Wiring System Diagrams . . . . . . . . . . . . . 5I-14 (TP) Sensor Circuit . . . . . . . . . . . . . . . 5I-54
MEFI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 5I-14 Code 22 Throttle Position
MEFI 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 5I-18 (TP) Sensor Circuit . . . . . . . . . . . . . . . 5I-57
General Diagnostic Tests . . . . . . . . . . . . . 5I-21 Code 23 Intake Air Temperature
On-Board Diagnostic (IAT) Sensor Circuit . . . . . . . . . . . . . . 5I-60
(OBD) System Check . . . . . . . . . . . . . 5I-21 Code 25 Intake Air Temperature
Chart A-1 No MIL or No DLC Data . 5I-23 (IAT) Sensor Circuit . . . . . . . . . . . . . . 5I-62
Chart A-2 MIL ON Steady - Code 33 Manifold Absolute Pressure
Will Not Flash DTC 12 . . . . . . . . . . . . 5I-25 (MAP) Sensor Circuit . . . . . . . . . . . . . 5I-64
Chart A-3 Engine Cranks But Code 34 Manifold Absolute Pressure
Will Not Run . . . . . . . . . . . . . . . . . . . . . 5I-27 (MAP) Sensor Circuit . . . . . . . . . . . . . 5I-67
Chart A-4 Fuel System Diagnosis . . 5I-29 Code 41 Ignition Control (IC) Circuit 5I-70
Chart A-5 Fuel System Electrical Test
Chart A-6 EFI System /
5I-31 Code 42 Ignition Control (IC) Circuit
Code 43 Knock Sensor (KS) Circuit
5I-72
5I-74 5
Ignition Relay Check . . . . . . . . . . . . .
Chart A-7 Ignition System Check . . .
5I-33
5I-35
Code 44 Knock Sensor (KS) Circuit
Code 45 Ignition Coil Driver Fault . .
5I-77
5I-80
I
Chart A-8 Idle Air Control Code 51 Calibration Memory Failure 5I-82
(IAC) Functional Test . . . . . . . . . . . . . 5I-41 Code 52 EEPROM Failure . . . . . . . . 5I-83
Discrete Input Circuit Check - Code 61 Fuel Pressure (FP) Circuit . 5I-84
Non-Scan Only . . . . . . . . . . . . . . . . . . 5I-43 Code 62 Fuel Pressure
(FP) Sensor Circuit . . . . . . . . . . . . . . . 5I-87

90-861328--1 NOVEMBER 1999 Page 5I-1

DIAGNOSTICS SERVICE MANUAL NUMBER 25

Special Tools

Part Number Tool Name Description

Minimum 10 megohm input impedance
J-34029-A required on all voltage ranges. As amme-
High Impedance
ter, accurately measures low value current
(Note 1 and 2) Multimeter (DVM)
flow. As ohmmeter, reads 0-200 ohms,
2/20/200 kΩ, 2/20 mΩ.
Vacuum Pump with Gauge monitors manifold engine vacuum.
J-23738 Gauge - 20 In. Hg Hand pump used to check fuel pressure
Minimum regulator.
Unpowered Test Used to check circuit wiring, short to
J-34142-B (Note 3)
Light ground or voltage.
Injector Harness Visually indicates injector electrical im-
J-34730-2A
Test Light pulses from the ECM.
Harness Test Allows multi-meter connections with wiring
J-35616
Adapter harness.
Displays problem codes stored in the
MerCruiser Scan ECM. It also allows monitoring of various
94050m Tool Version 3.4 circuits and components in the fuel injec-
(English) tion system. Allows for test firing injectors.
Tool can read MEFI 1 and MEFI 3 ECM.
94008 Code Mate Tester Flashes light to display problem codes.
Used to check ignition timing. Must have
91-99379 Timing Light
inductive signal pickup.
Used to check fuel system pressure. Kit
Fuel Pressure
91-16850A5 includes 91-803135 Test Port Adaptor Kit
Gauge Kit
and 91-806901 TBI Pressure Valve.
Displays problem codes stored in the
Quicksilver Digital
ECM. It also allows monitoring of various
91-823686A2 Diagnostic Terminal
circuits and components in the fuel injec-
(DDT)
tion system.
Displays problem codes stored in the
ECM. It also allows monitoring of various
MerCruiser DDT
91-803999 circuits and components in the fuel injec-
Cartridge Version 2
tion system. Tool can read MEFI 1 and
MEFI 3 ECM.
Displays problem codes stored in the
DDT Adaptor Har- ECM. It also allows monitoring of various
84-822560A2
ness circuits and components in the fuel injec-
tion system.
Used to set Ignition timing. Plug connects
91-805747A2 EFI Timing Tool
to DLC.
Used to perform fuel system pressure
91-805918A2 Fuel Shutoff Tool
test.
Fuel Line Connec- Allows connection of Fuel Pressure
91-806901
tor Gauge.

Page 5I-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Special Tools (continued)

NOTE: 1 The High Impedance Multimeter that comes with the existing Outboard 2 Cycle EFI
Tester, P/N 91-11001A2 meets the requirements listed above.
NOTE: 2 Quicksilver Digital Tachometer / Multi–Meter (DMT 2000) P/N 91-854009A1,
meets the requirements listed above.
NOTE: 3 Using a test light with 100 mA or less rating may show a faint glow when test
actually states no light.

Kent-Moore Tools, Inc. Rinda Technologies

29784 Little Mack 4563 N. Elston Ave.
Roseville, MI 48066 Chicago, IL 60630
Phone: 800-345-2233 Phone: 773-736-6633
Fax: 773–736–2950
E–mail: [email protected]

90-861328--1 NOVEMBER 1999 Page 5I-3

DIAGNOSTICS SERVICE MANUAL NUMBER 25

Diagnostic Circuit Check

IMPORTANT: All references to Scan Tool work with either the Quicksilver Digital Diag-
nostic Tool or the Rinda Scan Tool.
The Diagnostic Circuit Check is an organized approach to identifying a problem created by
an electronic engine control system malfunction.
NOTE: A scan tool that displays faulty data should not be used. This could result in misdiag-
nosis and unnecessary parts replacement.
The scan tool data listed in the following table may be used for comparison after finding the
on-board diagnostics functioning properly and no trouble codes displayed. The “Typical
Data Values” are intended to represent what a normally functioning system would display.
Only the parameters listed in the scan position column below are used in this manual. If a
scan reads other parameters, the values are not recommended for use in diagnosing. If all
values are within the range illustrated, refer to “Troubleshooting.”
Scan Tool Normal Specifications (Idle/Warm Engine/Closed Throttle/Neutral)
Scan Position Units Displayed Typical Data Value
rpm rpm 600-700 rpm
Desired rpm rpm 600 or 650 rpm (Depends on Model2)
Coolant Temp. ° F(° C) 150-170° F (66-77° C)
Manifold Air Temp. ° F (° C) Varies with Ambient Temperature
Throttle Position Volts .4 to .8 Volts
Throttle Angle 0-100 % 0-1%
1-3 Volts or (45-55 kPa) (Depends
MAP Volts or kPa
on Vacuum and Baro Pressure)
3-5 Volts (Depends on Altitude and
Baro Volts or kPa
Barometric Pressure)
Bat Volts 12.0-14.5 Volts
Spark Advance Degrees -10 to 30°
Knock Retard Degrees 0°
Idle Air Control IAC Counts (Steps) 0-40 Counts
Minimum IAC Position Counts (Steps) 0-40 Counts
Idle Air Control Follower Counts (Steps) 0 Counts
Injector Pulse Width msec. 2-3 msec.
2.5–3.5 msec. (Depends on Water/
Injector On Time Cranking msec.
Air Temperature)
Fuel Consumption GPH (L/h) 1-2 GPH(3.7-7.5 L/h)
Time From Start 0:00:00-1092:00 Varies
Memory Calibration Check
Calibration Check Sum Varies with Software revision in ECM
Sum
Oil Press/IO Level1 OK/LO OK
Engine Overtemp OK/Overheating OK
Lanyard Stop Mode OFF/ON OFF
1: MCM will read I/O Level and MIE will read Trans.
2: Refer to “Engine and Tune-Up Specifications.”

Page 5I-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Diagnostic Trouble Codes

Code Number Code Description MEFI

1 3
Code 14 (ECT) Engine Coolant Temperature - Low Tem- x x
perature Indicated
Code 15 (ECT) Engine Coolant Temperature - High Tem- x
perature Indicated
Code 21 (TP) Throttle Position Sensor - Signal Voltage x x
High
Code 22 (TP) Throttle Position Sensor - Signal Voltage x
Low
Code 23 (MAT) Manifold Air Temperature - Low Tempera- x
ture Indicated
Code 25 (MAT) Manifold Air Temperature - High Tempera- x
ture Indicated
Code 33 (MAP) Manifold Absolute Pressure - Signal x x
Voltage High
Code 34 (MAP) Manifold Absolute Pressure - Signal x
Voltage Low
Code 41 (IC) Ignition Control - Open IC Circuit x
Code 42 (IC) Ignition Control - Grounded IC Circuit, Open x x
or Grounded Bypass
Code 43 (KS) Knock Sensor - Continuous Knock Detected x x
Code 44 (KS) Knock Sensor - No Knock Detected x
Code 45 Coil Driver x
Code 51 (ECM) Calibration Memory Failure x x
Code 61 Fuel Pressure High x
Code 62 Fuel Pressure Low x

90-861328--1 NOVEMBER 1999 Page 5I-5

DIAGNOSTICS SERVICE MANUAL NUMBER 25

ECM Connector and EFI Symptoms Chart

The following charts will aid in diagnosis of symptoms. These voltages were derived from
a known good engine. The voltages shown were done with the electrical system intact and
operational. These are voltage requirements to operate the different circuits.

CAUTION
Do not attempt to obtain these voltages by probing wires and connectors. Serious
damage could result in loss of engine operation or wiring damage. Voltages can
vary with battery conditions.
In the following J-1 and J-2 Circuit/Symptom Charts only those pins which are used by the
ECM are shown. Pin numbers not listed are not used.
NOTE: All pins are not used on all models.
IMPORTANT: The following conditions must be met before testing.
1. Engine at operating temperature.
2. Ignition on or engine running.
3. Scan tool not connected.
THESE NOTES APPLY TO FOLLOWING ECM CONNECTOR AND SYMPTOM CHARTS.
The “B+” Symbol indicates a system voltage (battery).
NOTE: 1 Battery voltage for first two seconds, then 0 volts.
NOTE: 2 Varies with temperature.
NOTE: 3 Varies with manifold vacuum.
NOTE: 4 Varies with throttle movement.
NOTE: 5 Less than .5 volt (500 mV).

J-1 Circuits with MEFI 1

J-1 Front Pin 32 Pin Input Connector

a - Shaded Area Denotes Pin Connector Location Used On Terminal

Page 5I-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

J-1 Circuits with MEFI 1 (Continued)

Pin Normal Voltage
Wire
Pin Func- CKT Ignition Engine DTC Possible Symptoms
Color
tion ON Running
Knock Poor Fuel Economy, Poor
J1-1 485 GRN 9.5V 9.5V 43
Sensor Performance Detonation
ECT 1.95V 1.95V Poor Performance, Exhaust Odor,
J1-2 410 YEL 14
Signal (NOTE 2) (NOTE 2) Rough Idle rpm Reduction
Discrete Power Reduction Mode Alarm
J1-4 931 BRN – – None
Switch Activation
Master/ Lack Of Data From Other Engine
J1-5 916 YEL B+ B+ None
Slave (Dual Engine Only)
Discrete Power Reduction Mode Alarm
J1-6 931 BRN – – None
Switch Activation
Diag-
BLK/
J1-7 nostic 451 B+ B+ None Incorrect Idle, Poor Performance
WHT
Test
Map LT 1.46V Poor Performance, Surge, Poor Fuel
J1-9 432 4.9V 33
Signal GRN (NOTE 3) Economy, Exhaust Odor
TP DK .62V .62V Poor Performance And Acceleration,
J1-10 417 21
Signal BLU (NOTE 4) (NOTE 4) Incorrect Idle
Ignition PNK/
J1-11 439 B+ B+ None No Start
Fused BLK
Sensor 0 0 High Idle, Rough Idle, Poor
J1-13 813 BLK 21,23
Ground (NOTE 5) (NOTE 5) Performance Exhaust Odor
ECM BLK/ 0 0
J1-14 450 None No Start
Ground WHT (NOTE 5) (NOTE 5)

TP 5V
J1-15 416 GRY 5V 5V 21 Lack Of Power, Idle High
Power
J1-16 Battery 440 ORN B+ B+ None No Start
Serial ORN/
J1-18 461 5V 5V None No Serial Data
Data BLK
Shift
J1-19 923 WHT 0 0 None Incorrect Idle
Switch
Lanyard
J1-21 942 PNK 0 0 None No Start
Stop
MAP 0 0 Lack Of Performance,Exhaust Odor,
J1-29 814 BLK 33
Ground (NOTE 5) (NOTE 5) Stall
ECM BLK/ 0 0
J1-30 450 None No Start
Ground WHT (NOTE 5) (NOTE 5)

MAP 5V Lack Of Power, Surge, Rough Idle,

J1-31 416 GRY 5V 5V 33
Power Exhaust Odor
J1-32 Battery 440 ORN B+ B+ None No Start

90-861328--1 NOVEMBER 1999 Page 5I-7

DIAGNOSTICS SERVICE MANUAL NUMBER 25

J-2 Circuits with MEFI 1

a

J-2 Rear 32 Pin Output Connector

a - Shaded Area Denotes Pin Connector Location Used On Terminal

Pin Normal Voltage

Wire
Pin Func- CKT Ignition Engine DTC Possible Symptoms
Color
tion ON Running
Injector LT
J2-5 468 B+ B+ None Rough Idle, Lack Of Power, Stall
Driver GRN
Ignition
Control RED/ 0 0
J2-6 463 None Poor Performance
Ref. BLK (NOTE 5) (NOTE 5)
Low
Not
J2-7 – – – – None Not Used
Used
Ignition
Control PUR/
J2-8 430 5V 1.6V None No Restart
Ref. WHT
High
Fuel
DK 0
Pump
J2-9 465 GRN/ (NOTE B+ None No Start
Relay
WHT 1&5)
Driver
Coolant
DK Power Reduction Mode or
J2-11 Over 112 0 0 None
GRN Improper Audio Warning
temp.
IAC “A” Not Not Rough Unstable or Incorrect
J2-13 442 RED None
Low Usable Usable Idle
IAC “B” Not Not Rough Unstable or Incorrect
J2-14 443 YEL None
Low Usable Usable Idle
Injector BLK/ 0 0 Rough Running, Lack Of Power,
J2-15 450 None
Ground WHT (NOTE 5) (NOTE 5) Poor Performance

Page 5I-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

J-2 Circuits with MEFI 1 (Continued)

Pin Normal Voltage

Wire
Pin Func- CKT Ignition Engine DTC Possible Symptoms
Color
tion ON Running
Fuel
BLK/ 0 0 Rough Running, Poor Idle, Lack
J2-20 Injector 450 None
WHT (NOTE 5) (NOTE 5) Of Performance
Ground
Injector DK Rough Idle, Lack Of Power,
J2-21 467 B+ B+ None
Driver BLU Stalling
Not
J2-22 – – – – – Not Used
Used
Ignition
0 Stall, Will Restart In Bypass
J2-23 Control 423 WHT 1.2V 42
(NOTE 5) Mode, Lack Of Power
Signal
Ignition
TAN/ 0
J2-24 Control 424 4.5V 42 Lack Of Power, Fixed Timing
BLK (NOTE 5)
Bypass
Discrete Audio Warning System
J2-26 31 TAN – – –
Switch Activation
Discrete Audio Warning System
J2-27 31 TAN – – –
Switch Activation
IAC
Not Not Rough, Unstable or Incorrect
J2-28 “A” 441 BRN None
Usable Usable Idle
High
IAC
GRN/ Not Not Rough, Unstable or Incorrect
J2-29 “B” 444 None
BLK Usable Usable Idle
Low
MIL BRN/ 0 0
J2-31 419 None Lamp Inoperative
Lamp WHT (NOTE 5) (NOTE 5)

90-861328--1 NOVEMBER 1999 Page 5I-9

DIAGNOSTICS SERVICE MANUAL NUMBER 25

J-1 Circuits with MEFI 3

J-1 Front Pin 32 Pin Input Connector

a - Shaded Area Denotes Pin Connector Location Used On Terminal

Pin Normal Voltage

Wire
Pin Func- CKT Ignition Engine DTC Possible Symptoms
Color
tion ON Running
Injector DK Rough Idle, Lack Of Power, Stal-
J1-1 467 B+ B+ None
Driver BLU ling
Ignition Not Us- Not Us- Rough Running, Poor Idle, Lack
J1-2 121 WHT 45
Coil able able of Performance
Ignition
Control RED/ 0 0
J1-3 453 None Poor Performance
Ref. BLK (NOTE 5) (NOTE 5)
Low
ECM 0 0
J1-4 450 BLK None No Start
Ground (NOTE 5) (NOTE 5)

ECM 0 0
J1-5 450 BLK None No Start
Ground (NOTE 5) (NOTE 5)

MIL BRN/ 0 0
J1-9 419 None Lamp Inoperative
Lamp WHT (NOTE 5) (NOTE 5)

Ignition
0 Stall, Will Restart In Bypass
J1-10 Control 423 WHT 1.2V 42
(NOTE 5) Mode, Lack Of Power
Signal
IAC “B” GRN/ Not Not
J1-11 443 None Rough Unstable or Incorrect Idle
Low WHT Usable Usable
IAC “A” BLU/ Not Not
J1-12 442 None Rough Unstable or Incorrect Idle
Low BLK Usable Usable
Injector DK
J1-17 468 B+ B+ None Rough Idle, Lack Of Power, Stall
Driver GRN
ECM 0 0 Rough Running, Poor Idle, Lack
J1-20 450 BLK None
Ground (NOTE 5) (NOTE 5) Of Performance

Page 5I-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

J-1 Circuits with MEFI 3 (Continued)

Pin Normal Voltage

Wire
Pin Func- CKT Ignition Engine DTC Possible Symptoms
Color
tion ON Running
Fuel
DK 0
Pump
J1-23 465 GRN/ (NOTES B+ None No Start
Relay
WHT 1&5)
Driver
Ignition
TAN/ 0
J1-24 Control 424 4.5V 42 Lack Of Power, Fixed Timing
BLK (NOTE 5)
Bypass
Audio
DK
J1-26 Warning 29 – – None –
GRN
Horn
IAC
GRN/ Not Not Rough Unstable or Incorrect
J1-27 “B” 444 None
BLK Usable Usable Idle
Low
IAC
BLU/ Not Not Rough Unstable or Incorrect
J1-28 “A” 441 None
WHT Usable Usable Idle
High
Knock
Poor Fuel Economy, Poor Per-
J1-30 Sensor 496 BLU – – 43, 44
formance Detonation
Signal
Serial
J1-32 461 ORN 5V 5V None No Serial Data
Data

90-861328--1 NOVEMBER 1999 Page 5I-11

DIAGNOSTICS SERVICE MANUAL NUMBER 25

J-2 Circuits with MEFI 3

a

J-2 Rear 32 Pin Output Connector

a - Shaded Area Denotes Pin Connector Location Used On Terminal

Pin Normal Voltage

Wire
Pin Func- CKT Ignition Engine DTC Possible Symptoms
Color
tion ON Running
J2-1 Battery 440 ORN B+ B+ None No Start
Sensor 0 0 High Idle, Rough Idle, Poor Per-
J2-3 813 BLK 21,23
Ground (NOTE 5) (NOTE 5) formance Exhaust Odor
TP 5V
J2-4 416 GRY 5V 5V 21 Lack Of Power, Idle High
Power
Discrete
J2-7 114 BLU – – None –
Switch
Discrete TAN/
J2-8 585 – – None –
Switch WHT
Shift
J2-9 923 WHT 0 0 None Incorrect Idle
Switch
Ignition
Control PUR/
J2-10 430 5V 1.6V None No Restart
Ref. WHT
High
ECT 1.95V 1.95V Poor Performance, Exhaust
J2-11 410 YEL 14
Signal (NOTE 2) (NOTE 2) Odor, Rough Idle rpm Reduction
Fuel
J2-12 Pres- 475 GRN 3V 3V 61, 62 –
sure
MAP 0 0 Lack Of Performance,Exhaust
J2-18 814 BLK 33
Ground (NOTE 5) (NOTE 5) Odor, Stall
MAP 5V
Lack Of Power, Surge, Rough
J2-19 Refer- 416 GRY 5V 5V 33
Idle, Exhaust Odor
ence
Discrete
J2-20 208 BRN – – – –
Switch

Page 5I-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

J-2 Circuits with MEFI 3 (Continued)

Pin Normal Voltage

Wire Possible
Pin Func- CKT Ignition Engine
Color DTC Symptoms
tion ON Running
Master/ Lack Of Data From Other En-
J2-21 916 YEL B+ B+ None
Slave gine (Dual Engine Only)
Diag-
BLK/ Incorrect Idle, Poor Perfor-
J2-22 nostic 451 B+ B+ None
WHT mance
Test
Discrete TAN/
J2-24 906 – – None
Switch WHT
TP DK .62V .62V Poor Performance And Accel-
J2-26 417 21
Signal BLU (NOTE 4) (NOTE 4) eration, Incorrect Idle
Map LT 1.46V Poor Performance, Surge, Poor
J2-27 432 4.9V 33
Signal GRN (NOTE 3) Fuel Economy, Exhaust Odor
IAT Poor Fuel Economy, Exhaust
J2-30 472 TAN 5V (NOTE 2) 23
Sensor Odor
Ignition
J2-32 439 PNK B+ B+ None No Start
Fused

90-861328--1 NOVEMBER 1999 Page 5I-13

DIAGNOSTICS SERVICE MANUAL NUMBER 25

Wiring System Diagrams

MEFI 1

467 DK BLU J2-21 INJECTOR DRIVER

INJECTOR

450 BLK/WHT J2-15 INJECTOR GROUND

TO INJECTOR FUSE
439 PNK/BLK
450 BLK/WHT J2-20 INJECTOR GROUND

468 DK GRN J2-5 INJECTOR DRIVER

TO IGNITION RELAY INJECTOR
902 RED

FUEL PUMP
465 GRN/WHT J2-9
RELAY DRIVER
450 BLK/WHT
FUEL PUMP FUSE

120 GRY A M B 150 BLK

FUEL PUMP

FUEL PUMP RELAY D J2-28 IAC COIL “A” HIGH

441 BRN or BLU/WHT
C 442 RED or BLU/BLK J2-13 IAC COIL “A” LOW
TO ECM/BAT FUSE B 443 YEL or GRN/WHT J2-14 IAC COIL “B” HIGH
A 444 GRN/BLK J2-29 IAC COIL “B” LOW
IDLE AIR CONTROL MOTOR

461 ORN/BLK J1-18 MASTER/SLAVE

916 YEL J1-5 SERIAL DATA

BLK
461 ORN/BLK

450 BLK/WHT
916 YEL

K A
DIAGNOSTIC “TEST”
J B 451 WHT/BLK J1-7
TERMINAL
H C

G D
MALFUNCTION
440 ORN F E 419 BRN/WHT J2-31 INDICATOR LIGHT

DATA LINK CONNECTOR

75600

Page 5I-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

MEFI 1 (Continued)

SHIFT CUTOUT SWITCH

BRAVO REQUIRES JUMPER PLUG

923 WHT J1-19 SHIFT INTERRUPT

150 BLK

B 813 BLK J1-13 SENSOR GROUND

C 417 DK BLU J1-10 THROTTLE POSITION

SENSOR SIGNAL
A 416 GRY J1-15 +5 VOLT
REFERENCE
THROTTLE POSITION SENSOR

C 416 GRY +5 VOLT

J1-31
REFERENCE
B 432 LT GRN J1-9 MAP SENSOR
SIGNAL
A 814 BLK

MANIFOLD ABSOLUTE PRESSURE SENSOR

814 BLK J1-29 SENSOR GROUND

A 814 BLK
ENGINE COOLANT
B 410 YEL J1-2 TEMPERATURE SENSOR
SIGNAL
ENGINE COOLANT TEMPERATURE SENSOR

75602

90-861328--1 NOVEMBER 1999 Page 5I-15

DIAGNOSTICS SERVICE MANUAL NUMBER 25

MEFI 1 (Continued)

450 BLK/WHT J1-14 ECM GROUND

450 BLK/WHT J1-30 ECM GROUND

IC MODULE SHIFT CUTOUT SWITCH

BRAVO REQUIRES JUMPER PLUG

B A A B C D

423 WHT 423 WHT J2-23 IGNITION CONTROL

J2-8 DISTRIBUTOR
430 PUR/WHT REFERENCE “HIGH”
424 TAN/BLK J2-24 BYPASS

453 BLK/RED J2-6 DISTRIBUTOR

REFERENCE “LOW”
121 BRN
HARNESS CONNECTOR TOO IGNITION RELAY

3 PNK

902 RED B B
3 PNK A A

E NOT USED IGNITION COIL OUT TO BUZZER

112 DK GRN J2-11
(COOLANT OVERHEAT)
D 31 TAN
OUT TO BUZZER
31 TAN J2-27 (AUDIO WARNING
C 3 PNK SYSTEM SWITCHES)

J1-6 INPUT FROM AUDIO

B 931 BRN 931 BRN WARNING SYSTEM
SWITCHES
A
121 WHT

75877

Page 5I-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

MEFI 1 (Continued)

TO FUEL PUMP RELAY

TO IGN COIL B+
TO INJECTORS
150 BLK

902 RED
902 RED

439 PNK/BLK
TO KEY SWITCH
3 PNK

TO BATTERY POSITIVE (+)

2 RED 902 RED 439 PNK/BLK J1-11 IGNITION FEED
INJ/ECM FUSE 10A

30 86 85 87
2 RED

SYSTEM/IGNITION RELAY

ECM BAT FUSE 15A 440 ORN J1-32 BATTERY FEED

2 RED
440 ORN J1-16 BATTERY FEED

440 ORN
TO DLC CONNECTOR

B 439 PNK/BLK

C KNOCK SENSOR
485 GRN J1-1
SIGNAL
D 486 PUR

E 496 DK BLU

KNOCK MODULE

KNOCK SENSOR
75608

90-861328--1 NOVEMBER 1999 Page 5I-17

DIAGNOSTICS SERVICE MANUAL NUMBER 25

MEFI 3

INJECTOR
From
INJ/
ECM 481 J1-1
467 DK BLU
FUSE BLK
10 AMP

439 PNK

15A INJECTOR

481 468 DK GRN J1-17

BLK

From
B+

439 PNK
2
465 DK GRN/WHT J1-23

339 PNK

15A
87a 30 85 86 87

ECM
150
BLK

441 BRN OR BLU/WHT J1-28

IDLE AIR 442 RED OR BLU/BLK J1-12
CONTROL
(IAC) VALVE 443 YEL OR GRN/WHT J1-11
444 GRN/BLK J1-27

461 ORN J1-32 SERIAL DATA

916 YEL J2-21 MASTER/SLAVE

150 BLK
DLC
450 BLK

FROM
ECM/BAT 451 BLK/WHT J2-22 DIAGNOSTIC “TEST”
FUSE TERMINAL
15A

440 ORN 419 BRN/WHT MALFUNCTION INDICATOR

J1-9
LAMP

76097

Page 5I-18 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

MEFI 3 (Continued)

INTAKE AIR 472 TAN J2-30 INTAKE AIR TEMPERATURE

TEMPERATURE (IAT) (IAT) SENSOR SIGNAL
813 BLK

813 BLK 813 BLK J2-3 SENSOR GROUND

B 813 BLK
C 417 DK BLU J2-26
(TP)
A

416 GRY J2-4

B
FUEL PRES- FUEL PRESSURE
C 475 GRN J2-12
SURE SENSOR SIGNAL
SENSOR (FP) A

813 BLK

416 GRY J2-19

432 LT GRN J2-27

ECM
814 BLK

814 BLK J2-18

ENGINE COOLANT 814 BLK

TEMPERATURE (ECT) ENGINE COOLANT
410 YEL J2-11 TEMPERATURE (ECT)
SENSOR SIGNAL

496 DK BLU J1-30 KNOCK SENSOR 1

114 BLU J2-7 OIL PRESSURE

SWITCH
KNOCK
SENSOR 1

150 BLK 906 TAN/WHT J2-24 LUBE BOTTLE

150 BLK
SHIFT SWITCH
B

A 207 PPL J2-9 SHIFT INTERRUPT

SIGNAL
76098

90-861328--1 NOVEMBER 1999 Page 5I-19

DIAGNOSTICS SERVICE MANUAL NUMBER 25

MEFI 3 With Mercury Distributor

TO FUEL PUMP RELAY
FUSE

440 0RN J2-1 BATTERY

2 RED FEED

ECM BAT FUSE/ 440 0RN TO DLC

DLC 15A CONNECTOR

TO SYSTEM/IGNITION RELAY
B 2 RED
B+ IGN / INJ FUSE
TO 902 RED
A 2 RED 30 87 439 PNK J2-32 IGNITION
B+

150
3 PNK 86 85 BLK

T0 INJECTORS
AND
902 RED FUEL PUMP RELAY

DISTRIBUTOR

450

ECM
BLK J1-4 ECM
WHT/GRN WHT/RED GROUND
450
BLK J1-5 ECM
GROUND
450
J1-20 ECM
BLK
GROUND

439 PNK

430 PPL/WHT J2-10 DIST. REF.

902 RED 121 WHT 121 WHT J1-2 IGN. COIL

+ –

IGNITION
COIL

TEMP SENDER

121 WHT

A F 208 BRN J2-20 LOAD ANTICIPATION

901 TAN B E 585 TAN/WHT J2-8 TRANSMISSION

OVERTEMP
3 PNK C D AUDIO WARNING
29 DK GRN J1-26
CIRCUIT
CONNECTOR HALVES
TO IGN PUR C D TAN/BLU TO AUDIO WARNING HORN

TO TEMP GAUGE TAN B E BLU/TAN TO TRANSMISSION TEMP SWITCH

TO TACH GRY A F YEL/BLK T0 TRANSMISSION

76099

Page 5I-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

General Diagnostic Tests

On-Board Diagnostic (OBD) System Check

ECM
MEFI 1 MEFI 3

461 ORN/BLK or ORN

J1-18 J1-32
450 BLK/WHT or BLK J1-14 J1-4
TO ECM 15A
BATTERY DLC 450 BLK/WHT or BLK J1-5
FUSE 450 BLK/WHT or BLK
TO ECM 15A CONNECTOR J1-30 J1-20
BATTERY
FUSE 450 BLK/WHT or BLK

451 WHT/BLK J1-7 J2-22

(BLK/WHT - Some Models)

J2-31 J1-9
IGN, INJECTOR KS 439 PNK/BLK or PNK J1-11 J2-32
MODULE 10 AMP
FUSE

J1-32 J2-1

J1-16

CIRCUIT DESCRIPTION:
The on-board diagnostic system check must be the starting point for any diagnosis. Before
using this procedure, check the ECM and engine grounds for cleanliness and tightness.
The on-board diagnostic system check is an organized approach to identifying a problem
created by an electronic engine control system malfunction.

DIAGNOSTIC AIDS:
An intermittent may be caused by a poor connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for the following items:
• Poor connection or damaged harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or damaged terminals, poor terminal
to wire connection and damaged harness.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

On-Board Diagnostic (OBD) System Check

Step Action Yes No
PROCEED TO
1. Are you using a Scan Tool? Step 2. Step 6.
a. Ignition OFF.
b. Install a scan tool.
Chart
2. c. Ignition ON. Step 3.
A-1
d. Attempt to display ECM data with the scan tool.
Does The Scan Tool Display ECM Data?
Attempt to start the engine. Chart
3. Step 4.
Did The Engine Start And Continue To Run? A-3
Select “Display DTCs” with the scan tool. DTC
4. Step 5.
Are Any Trouble Codes Stored? Chart
Compare ECM data values displayed on the scan tool to the
Diag-
typical scan tool data values page. Trouble-
5. nostic
Are The Displayed Values Normal Or Close To The shooting
Testing
Typical Values?
a. Ignition ON, engine OFF.
b. Install CodeMate Tester and switch it to “Normal Mode.” Chart
6. Step 7.
c. Observe the MIL. A-1
Is the MIL ON?
a. With CodeMate Tester on “Normal Mode.”
b. Ignition ON, engine OFF.
7. Step 12. Step 8.
c. Observe the MIL on the CodeMate Tester.
Does the MIL Flash DTC 12?
a. Switch CodeMate Tester to “Service Mode.”
b. Ignition ON, engine OFF. Chart
8. Step 9.
c. Observe the MIL on the CodeMate Tester. A-2
Does the MIL Flash DTC 12?
a. Switch CodeMate Tester to “Normal Mode.”
Chart
9. b. Attempt to start the engine. Step 10.
A-3
Did The Engine Start And Continue To Run?
a. Ignition ON, Engine OFF.
DTC
10. b. Switch CodeMate Tester to “Service Mode.” Step 11.
Chart
Are Any Additional DTC Stored?
Diag-
Does A Customer Complaint Or Driveability Problem Symp-
11. nostic
Currently Exist? toms
Aids
Verify
12. Check CKT 451 for a short to ground. –
Repair

Page 5I-22 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-1 (1 of 2): No MIL or No DLC Data

ECM
MEFI 1 MEFI 3

461 ORN/BLK or ORN

J1-18 J1-32
450 BLK/WHT or BLK J1-14 J1-4
TO ECM 15A
BATTERY DLC 450 BLK/WHT or BLK J1-5
FUSE 450 BLK/WHT or BLK
TO ECM 15A CONNECTOR J1-30 J1-20
BATTERY
FUSE 450 BLK/WHT or BLK

451 WHT/BLK J1-7 J2-22

(BLK/WHT - Some Models)

J2-31 J1-9
IGN, INJECTOR KS 439 PNK/BLK or PNK J1-11 J2-32
MODULE 10 AMP
FUSE

J1-32 J2-1

J1-16

CIRCUIT DESCRIPTION:
When the CodeMate Tester is installed, it plugs into the DLC terminals “F” and “E.” It
receives voltage through CKT 440 terminal “F.” Terminal “E” is ground through CKT 419.
There should always be a steady MIL with the ignition ON and the engine stopped. The
Engine Control Module (ECM) turns the MIL on by grounding the MIL driver circuit.

DIAGNOSTIC AIDS:
An intermittent may be caused by a poor connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for the following items:
• Poor connection or damaged harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or damaged terminals, poor terminal
to wire connection and damaged harness.
If the engine runs OK, check for a faulty light bulb or an open in the MIL driver circuit (CKT
419). If the engine cranks but will not run, check for an open ECM ignition or battery feed
or a poor ECM to engine ground.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-1 (2 of 2): No MIL or No DLC Data

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Remove CodeMate Tester or Scan Tool.
b. Ignition ON, engine OFF.
2. c. Using a test light connected to ground (–), probe termi- Step 3. Step 10.
nal “F” of the DLC.
Does The Test Light Illuminate?
Using a test light connected to battery positive (B+), probe
3. terminal “E” of the DLC. Step 11. Step 4.
Does The Test Light Illuminate?
a. Ignition OFF.
b. Disconnect ECM connectors.
4. c. Using a DVOM, measure the resistance between ECM Step 5. Step 13.
CKT 419 and DLC terminal “E.”
Is The Resistance Less Than 1 ohm?
5. Are you using a Scan Tool? Step 6. Step 11.
Check the ECM / DLC fuse.
6. Step 7. Step 14.
Is The Fuse Good?
a. Ignition OFF.
b. Disconnect the ECM connectors.
7. c. Using a test light connected to ground, probe ECM CKT Step 8. Step 10.
440.
Does The Test Light Illuminate?
a. Ignition ON, engine 0FF.

8. b. Using a test light connected to ground (–), probe ECM Step 12. Step 9.
CKT 439.
Does The Test Light Illuminate?
Check the Ignition / Injection fuse. Chart
9. Step 15.
Is The Fuse Good? A-6
10. Locate and repair open or short to ground in CKT 440.
11. Repair or replace faulty CodeMate Tester.
If problem was no DLC data (using scan tool), check serial
12. data CKT 461 for an open or short to ground or locate and Verify
repair faulty ECM grounds. –
Repair
13. Locate and repair open in CKT 419.
14. Locate and repair short to ground in the battery feed circuit.
15. Locate and repair short to ground in CKT 439.

Page 5I-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-2 (1 of 2): MIL ON Steady - Will Not Flash DTC 12

ECM
MEFI 1 MEFI 3

461 ORN/BLK or ORN

J1-18 J1-32
450 BLK/WHT or BLK J1-14 J1-4
TO ECM 15A
BATTERY DLC 450 BLK/WHT or BLK J1-5
FUSE 450 BLK/WHT or BLK
TO ECM 15A CONNECTOR J1-30 J1-20
BATTERY
FUSE 450 BLK/WHT or BLK

451 WHT/BLK J1-7 J2-22

(BLK/WHT - Some Models)

J2-31 J1-9
IGN, INJECTOR KS 439 PNK/BLK or PNK J1-11 J2-32
MODULE 10 AMP
FUSE

J1-32 J2-1

J1-16

CIRCUIT DESCRIPTION:
When the CodeMate Tester is installed, it plugs into the DLC terminals “F” and “E.” It
receives voltage through CKT 440 terminal “F.” Terminal “E” is ground through CKT 419 from
the ECM. There should always be a steady MIL with the ignition ON and the engine stopped.
The Engine Control Module (ECM) turns the MIL ON by grounding the MIL driver circuit.
When the diagnostic tests terminal on the DLC is grounded by jumping terminal “B” to termi-
nal “A,” the ground circuit is completed. The MIL will flash a DTC 12 followed by any DTC
stored in memory. A steady light suggests CKT 419 is shorted to ground or an open in CKT
451 from the ECM to the DLC.

DIAGNOSTIC AIDS:
An intermittent may be caused by a poor connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for the following items:
• Poor connection or damaged harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or damaged terminals, poor terminal
to wire connection and damaged harness.
If the engine runs OK, check for a faulty light bulb or an open in the MIL driver circuit (CKT
419). If the engine cranks but will not run, check for an open ECM ignition or battery feed
or a poor ECM to engine ground.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-2 (2 of 2): MIL ON Steady - Will Not Flash DTC 12

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Ignition ON, engine OFF.
2. b. Switch CodeMate Tester to “Normal Mode.” Step 9. Step 3.
Does The MIL Flash DTC 12?
a. Ignition ON, engine OFF.
3. b. Switch CodeMate Tester to “Service Mode.” Step 10. Step 4.
Does The MIL Flash DTC 12?
a. Ignition OFF, disconnect ECM connectors.
4. b. Ignition ON, engine OFF, observe the MIL. Step 7. Step 5.
Is The MIL ON?
a. Ignition OFF.
b. With ECM connectors disconnected, jump terminals “A”
to “B” at the DLC.
5. Step 6. Step 8.
c. Connect test light between CKT 451 and battery posi-
tive (B+).
Does Test Light Illuminate?
Verify correct operation of CodeMate Tester on a known
6.
good system.
7. Locate and repair short to ground in CKT 419.
Verify
–
8. Locate and repair open in CKT 450 and/or CKT 451. Repair
9. Check CKT 451 for short to ground.
10. Locate and repair intermittent faulty connections.

Page 5I-26 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-3 (1 of 2): Engine Cranks But Will Not Run

ECM
MEFI 1 MEFI 3

467 DK BLU J2-21 J1-1

INJECTOR

TO INJECTOR FUSE
439 PNK/BLK
OR PNK

468 DK GRN J2-5 J1-17

INJECTOR

CIRCUIT DESCRIPTION:
In the Distributor Ignition (Dl) system and the fuel injector circuit, the supply voltage comes
from the EFI system relay. From the EFI system relay, CKT 902 delivers supply voltage to
the injector/ECM fuse, and to the ignition coil.
After supply voltage passes through the injector/ECM fuse, it branches out into two separate
CKTs 439. The ECM will control the opening and closing of the injectors through injector
driver CKT 467 and CKT 468 by connecting them to ground.
DIAGNOSTIC AIDS:
This chart assumes that battery voltage and engine cranking speed are OK, and there is
adequate fuel in the tank.
Water or foreign material in fuel system can cause a no start.
A defective MAP sensor may cause a no start or a start and stall condition. To determine
if the MAP sensor is causing the problem, disconnect the electrical connector. The ECM will
then use a default value for the sensor. If the condition is corrected and the connections are
OK, then replace the sensor.
An intermittent may be caused by a poor connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for the following items:
Poor connection or damaged harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or damaged terminals, poor terminal to
wire connection, and damaged harness.
If above are all OK, refer to “Hard Start” in “Troubleshooting” section.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-3 (2 of 2): Engine Cranks But Will Not Run

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Key OFF for minimum of 10 seconds.
b. Key ON. Chart
2. Step 3.
c. Listen for fuel pump to run. A-5
Does Fuel Pump Run For 2 Seconds?
Check for secondary ignition spark. Chart
3. Step 4.
Is Adequate Spark Present? A-7
a. Install fuel pressure gauge.
b. Ignition OFF for 10 seconds.
c. Ignition ON. Fuel pump will run for about 2 seconds. Chart
4. Step 5.
A-4
d. Note fuel pressure with pump running. The pressure
may drop after the pump stops running.
Is Fuel Pressure Greater Than 25 psi (172 kPa)?
a. Ignition OFF.
b. Disconnect ECM connectors.
5. c. Measure resistance between ECM CKT 467 and ECM Step 6. Step 10.
CKT 468.
Is The Resistance Greater Than 1 ohm?
Check resistance across each injector in the circuit.
6. Step 7. Step 8.
TBI: Is Resistance Greater Than 1 ohm?
a. Reconnect injectors.
b. Ignition OFF.
c. Disconnect ECM.
7. d. Ignition ON. Step 11. Step 9.

e. Using a test light connected to ground, probe ECM CKT

467 and CKT 468.
Does Test Light Illuminate?
Locate and repair short to ground or replace any injector
8.
that measures low.
9. Locate and repair open in CKT 467 or CKT 468.
10. Check for short to ground in CKT 467 or CKT 468.
a. Disconnect all injectors. Verify
–
Repair
b. Ignition ON.
11. c. Using a test light connected to ground, probe CKT 467
and CKT 468 on the ECM side of the injector harness
(Test one injector harness on each side of the engine).
If light is ON, locate and repair short to voltage.

Page 5I-28 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-4 (1 of 2): Fuel System Diagnosis

CIRCUIT DESCRIPTION:
When the ignition is turned ON, the Engine Control Module (ECM) will turn the fuel pump
ON for 2 seconds. During engine cranking, the ECM will turn ON the fuel pump. It will remain
ON as long as the engine is cranking or running, and the ECM is receiving ignition reference
pulses. If there are no reference pulses, the ECM will shut OFF the fuel pump.
The pump will deliver fuel to the throttle body and injectors, then to the pressure regulator,
where the system pressure is controlled to approximately 30 psi (207 kPa).
Excess fuel is then returned to the water separating fuel filter.

DIAGNOSTIC AIDS:
An intermittent may be caused by a poor connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for the following items:
• Poor connection or damaged harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or damaged terminals, poor terminal
to wire connection and damaged harness.
• Contaminated or dirty fuel may cause the fuel pump to seize, which will cause the fuel
pump relay fuse to fail.
• The ability to maintain a constant fuel pressure is very critical in the driveability of fuel
injection. If the fuel pressure drops below the specification of that application, multiple
driveability problems may occur. The vessel may have to be operated under a load, or
certain conditions, as the lack of fuel pressure may be intermittent.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-4 (2 of 2): Fuel System Diagnosis

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Install fuel pressure gauge.
b. Ignition OFF.
c. Ignition ON.
2. d. Fuel pump will run for about 2 seconds. Note fuel Step 3. Step 5.
pressure with pump running. The pressure may
drop after the pump stops running, but should not
drop immediately to 0 psi.
Is fuel pressure below 25 psi (172 kPa)?
Attempt to start engine and idle at normal operating
3. temperature. Step 4. Step 6.
Did engine start?
With engine still idling, connect an external vacuum
source to the fuel pressure regulator and apply 10
4. inches of vacuum. Step 13. Step 11.
Did fuel pressure drop by approximately 5 psi (34
kPa)?
Chart
5. Was fuel pressure present at all? Step 6.
A-5
Does the system establish fuel pressure and
6. Step 7. Step 9.
then drop quickly to 0 psi?
a. Ignition OFF.
b. Block fuel pressure line between the fuel pump and
7. throttle body inlet fitting. Step 10. Step 8.
c. Ignition ON.
Does fuel pressure hold?
a. Ignition OFF.
b. Block fuel return line.
8. Step 11. Step 12.
c. Ignition ON.
Does fuel pressure hold?
9. Check for restricted fuel lines.
Locate and repair leaking injector(s) or fuel line
10.
connections.
11. Replace faulty fuel pressure regulator. Verify
–
Repair
Check for leaking pump fittings or lines, inlet filter, and
12.
low battery voltage. If OK, replace faulty fuel pump.
Problem is intermittent or fuel supply to engine is re-
13.
stricted or low.

Page 5I-30 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-5 (1 of 2): Fuel System Electrical Test

FUEL PUMP
RELAY FUSE
15A
TO
SYSTEM 902 RED 339 PNK/BLK
RELAY OR PNK

ECM
87a MEFI 1 MEFI 3
FUEL 30
PUMP 85 465 DK GRN/WHT J2-9 J1-23
RELAY
86 450 BLK/WHT
OR BLK
87

120 GRY A M B 150 BLK

FUEL PUMP

CIRCUIT DESCRIPTION
The fuel system circuit receives a supply voltage from the system relay CKT 902. The fuel
system is protected by a 15 amp fuse. After the fuse, supply voltage is delivered by CKT 339
to fuel pump relay terminal “30.” The fuel pump relay is turned on by the ECM by supplying
voltage to CKT 465. The fuel pump relay will remain ON as long as the engine is running
or cranking and the ECM is receiving reference pulses. If no reference pulses are present,
the ECM de-energizes the fuel pump relay within 2 seconds after the ignition is turned ON
or the engine is stopped.

DIAGNOSTIC AIDS
An intermittent may be caused by a poor connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for the following items:
• Poor connection or damaged harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or damaged terminals, poor terminal
to wire connections and damaged harness.
• Contaminated or dirty fuel may cause the fuel pump to seize, which will cause the fuel
pump relay fuse to fail.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-5 (2 of 2): Fuel System Electrical Test

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Ignition OFF.
b. Remove fuel pump relay.

2. c. Ignition ON. Step 3. Step 6.

d. Using test light connected to ground, probe fuel pump
relay harness connector terminal “30.”
Does Test Light Illuminate?
a. Ignition OFF.
b. Using a fused jumper wire, connect terminals “30” and
3. “87” of the fuel pump relay connector together. Step 4. Step 11.
c. Ignition ON.
Does Fuel Pump Run?
a. Ignition OFF.
b. Disconnect fused jumper wire.
4. c. Using a test light connected to battery positive (B+), Step 5. Step 12.
probe terminal “86” of the fuel pump relay connector.
Does The Test Light Illuminate?
a. Using a test fight connected to ground, probe terminal
“85” of the fuel pump relay connector.
5. b. Ignition ON. Step 8. Step 7.
Does Test Light Illuminate For 2 Seconds And Then Go
Off?
Check fuel pump relay fuse.
6. Step 9. Step 10.
Is Fuse Ok?
Locate and repair faulty ECM connection at “J2-9” or repair
7.
open in CKT 465.
Check for plugged fuel filter, vapor lock condition, restricted
8.
fuel lines, disconnected hoses, and proper fuel level.
9. Locate and repair open in CKT 339 or CKT 902.
Verify
Locate and repair short to ground in CKT 339 or CKT 120. –
Repair
10. Also check for contamination in fuel lines or fuel tank. If OK,
replace fuel pump and fuse.
Locate and repair open in CKT 120 or CKT 150. If okay,
11.
replace faulty fuel pump.
12. Locate and repair open in CKT 450.

Page 5I-32 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-6 (1 of 2): EFI System/Ignition Relay Check

IGNITION

50A
CIRCUIT 86 85
BREAKER
90 AMP
FUSE 30 87 902 RED

TO ECM TO FUEL
PUMP
RELAY TO IGN
COIL
INJ/ECM/KS
MODULE

CIRCUIT DESCRIPTION:
Battery voltage is constantly supplied to terminal “30” of the system relay. When the ignition
switch is moved to the “RUN” position, battery voltage is supplied to terminal “86” of the sys-
tem relay. The pull-in coil is then energized creating a magnetic field which closes the con-
tacts of the system relay. Voltage and current are then supplied to the ignition control mod-
ule, injectors, ECM and fuel pump relay through terminal “87” CKT 902 of the system relay.

DIAGNOSTIC AIDS
An intermittent may be caused by a poor connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for the following items:
• Poor connection or damaged harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or damaged terminals, poor terminal
to wire connection and damaged harness.
• Contaminated or dirty fuel may cause the fuel pump to seize, which will cause the fuel
pump relay fuse to fail.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-6 (2 of 2): EFI System/Ignition Relay Check

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Ignition OFF.
b. Remove EFI system relay connector.

2. c. Ignition ON. Step 3. Step 5.

d. With test light still connected to ground, probe relay har-
ness connector terminals “86” and “30.”
Does Test Light Illuminate On Both Terminals?
Using test light connected to battery positive (B+), probe
3. relay harness connector terminal “85.” Step 4. Step 6.
Does Test Light Illuminate?
Check relay connector for poor contact or corrosion. If OK,
4.
replace faulty EFI system relay.
Locate and repair open or short to ground in circuit that did Verify
5. –
not light (CKT 2 and/or CKT 3). Repair

6. Locate and repair open ground CKT 150.

Page 5I-34 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-7 (1 of 6): Ignition System Check

MEFI 1:

IC MODULE

DISTRIBUTOR ECM
B+ MEFI 1 MEFI 3
902 RED AB
COIL
J2-23
3 PNK J2-8
J2-24
121 BRN OR GRY J2-6

121 WHT
HARNESS CONNECTOR

E NOT USED
112 DK GRN J2-11
D 31 TAN
31 TAN J2-27
C 3 PNK TO IGN
J1-6
B 931 BRN 931 BRN

A
121 WHT

CIRCUIT DESCRIPTION MEFI 1:

The Distributor Ignition (Dl) system receives supply voltage from the system relay through
CKT 902 to the ignition coil gray connector “B”. Inside the ignition coil, the gray connector
terminal “B” is connected to the black connector terminal “B.” Supply voltage is delivered
from the ignition coil black connector terminal “B” to the distributor Ignition Control (IC) mod-
ule “+” terminal through CKT 3.
Inside the distributor, the pick-up coil and pole piece will produce a voltage signal for cylinder
spark. The voltage signals are processed in the IC module and sent to the ECM. The ECM
will decide if the engine is in the cranking or running mode and adjust timing accordingly.
The voltages or signals are sent between the ECM and the IC module through CKT’s 423,
430 and 424. CKT 453 is the ground circuit.
The IC module will send the voltage signal to the ignition coil black connector terminal “A”
through CKT 121. The signal will trigger the coil creating secondary spark to be produced.
This secondary spark is sent to the distributor by a high tension lead.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-7 (2 of 6): Ignition System Check

MEFI 3

DISTRIBUTOR

WHT/GRN WHT/RED

ECM
MEFI 1 MEFI 3

439 PNK

430 PPL/WHT J2-10

B+ 902 RED 121 WHT 121 WHT

J1-2
+ –

IGNITION
COIL

TEMP SENDER

121 WHT MEFI 1 MEFI 3

A F 208 BRN J2-20

901 TAN B E 585 TAN/WHT J2-8
IGNITION 3 PNK C D 29 DK GRN J1-26

CIRCUIT DESCRIPTION MEFI 3:

The Distributor Ignition (Dl) system receives supply voltage from the system relay through
CKT 902 to the ignition coil positive (+) connector.
Inside the distributor, the pick-up sensor will produce a voltage signal for cylinder spark. The
voltage signals are processed in the ECM. The ECM will decide if the engine is in the crank-
ing or running mode and adjust timing accordingly.
The ECM will send a signal to the ignition coil negative (–) terminal through CKT 121. The
signal will trigger the coil creating secondary spark to be produced. This secondary spark
is sent to the distributor by a high tension lead.

Page 5I-36 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-7 (3 of 6): Ignition System Check

DIAGNOSTIC AIDS:
An intermittent may be caused by a poor connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for the following items:
• Poor connection or damaged harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or damaged terminals, poor terminal
to wire connection, and damaged harness
• The “tach” needs to be disconnected while testing the ignition system. You will also need
a place to check coil trigger voltage. By disconnecting the 5-way or 6-way harness con-
nector, you will get test terminals to check coil trigger voltage as needed in several steps.
After “tach” is disconnected, try starting the engine. If the engine starts, check for a short
to ground in the boat tach circuit.
• Check all terminal connections at distributor, ignition module, and ignition coil. Is the bat-
tery OK? Is the distributor clamping screw tight?

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-7 (4 of 6): Ignition System Check

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Check spark plug wires for open circuits, cracks in
insulation, or improper seating of terminals at spark
plugs, distributor cap, and coil tower before proceeding
with this table.
b. Disconnect 5-way or 6-way harness connectors.

2. c. Install a temporary jumper wire between CKT 3 and the Step 23. Step 3.
purple ignition lead in the harness connectors.
d. Attempt to start engine and check tor secondary spark.
If there is “no spark” at one wire, check a few more
wires. A few sparks and then nothing is considered “no
spark.”
Is Adequate Spark Present?
Remove distributor cap and verify rotation of distributor
3. rotor. Step 4. Step 22.
Is The Distributor Rotor Turning?
Do you have a MEFI 3 ECM and a distributor with a
4. Step 24. Step 5.
two-wire connection?
a. Disconnect distributor 4-wire connector.
5. b. Check for secondary spark. Step 17. Step 6.
Is Adequate Spark Present?
a. Reconnect distributor 4-wire connector.

6. b. Check for secondary spark from the coil tower using a Step 18. Step 7.
known good coil wire.
Is Adequate Spark Present?
a. Disconnect distributor 2-wire connector.
b. Ignition ON, engine OFF.
7. Step 8. Step 19.
c. Using DVOM, check voltage at both terminals.
Is Voltage Reading Greater Than 10 Volts?
a. Reconnect distributor 2-wire connector.
b. Ignition ON engine OFF.
8. c. Using DVOM, check voltage from CKT 121 tach termi- Step 9. Step 14.
nal to ground.
Is Voltage Reading Greater Than 10 Volts?
a. Using a test light connected to ground , probe CKT 121
tach terminal at the 5-way or 6-way harness connector.
9. Step 12. Step 10.
b. Observe the test light while cranking engine.
Is Test Light Blinking?

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-7 (5 of 6): Ignition System Check

Step Action Yes No
PROCEED TO
a. Disconnect distributor 4-wire connector.
b. Remove distributor cap.
c. Disconnect pick-up coil connector from the distributor
ignition control module.
d. Connect D\/OM to CKT 121 tach terminal at the 5-way
or 6-way harness connector and ground.
10. Step 11. Step 20.
e. Ignition ON, engine OFF.
f. Connect positive (+) end of a known good 1.5 volt test
battery to the “P” terminal on the distributor ignition con-
trol module. Observe the voltage at the tach terminal as
the negative (-) end of the test battery is momentarily
grounded to a known good ground.
Does The Voltage Drop?
Check for spark from the coil wire as the test battery lead
11. is removed? Step 16. Step 12.
Is Adequate Spark Present?
Replace ignition coil and recheck for spark using Steps 10.
12. and 11. Step 13. –
Is Adequate Spark Present?
Reinstall coil and check coil wire from distributor cap. If OK,
13. –
replace ignition module.
Check for faulty connections or open tach lead. If OK,
replace ignition module and recheck for spark using Steps Verify
14. 10. and 11. Repair Step 15.
Is Adequate Spark Present?
15. Replace ignition coil. –
16. Is the rotating pole piece still magnetized? Step 17. Step 21.
17. Replace faulty pick-up coil.
Inspect distributor cap for water, cracks, etc. If OK, replace
18.
faulty distributor rotor.
Check for open or short to ground in CKT 3, open CKT 902,
19. open or short to ground in CKT 121. If OK, replace faulty
ignition coil. Verify
–
Check ignition module ground. If OK, replace faulty ignition Repair
20.
module.
21. Replace distributor pole piece and shaft assembly.
A mechanical repair will be necessary before continuing
22.
with this test.
23. Locate and repair intermittent faulty connections.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-7 (6 of 6): Ignition System Check

Step Action Yes No
PROCEED TO
With key in RUN position, measure voltage at positive (+)
terminal on ignition coil. Chart
24. Step 25.
A–6
Is Voltage Greater Than 10 Volts?
Unplug WHT/RED bullet connectors from distributor and
25. measure voltage on CKT 439 from harness. Step 26. Step 28.
Is Voltage Greater Than 10 Volts?
a. Reconnect WHT/RED bullet connectors.
b. Remove high tension lead from distributor at coil.
c. Insert a spark gap tester from coil tower to ground.

26. d. Disconnect WHT/GRN lead from distributor. Step 29. Step 27.
e. Ignition ON.
f. Rapidly (2 – 3 times per second) strike the terminal of
the PPL/WHT lead from the harness against ground (–).
Is There Spark at Coil?
a. Substitute a new ignition coil.
27. b. Repeat above test. Step 30. Step 31.
Is There Spark at Coil?
Check IGN / INJ fuse.
28. Step 32. Step 33.
Is Fuse Good?
29. Replace ignition sensor in distributor.
30. Install new ignition coil.
31. Repair CKT 430. Verify
–
Repair
32. Repair open CKT 439 to distributor.
33. Replace fuse.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Chart A-8 (1 of 2): Idle Air Control (IAC) Functional Test

ECM
MEFI 1 MEFI 3

441 BRN OR BLU/WHT J2-28 J1-28

IDLE AIR 442 RED OR BLU/BLK J2-13 J1-12
CONTROL
(IAC) VALVE
443 YEL OR GRN/WHT J2-14 J1-11
444 LT GRN/BLK
J2-29 J1-27

CIRCUIT DESCRIPTION:
The ECM controls idle speed to a calibrated “desired” rpm based on sensor inputs and
actual engine rpm. The ECM uses four (4) circuits to move the Idle Air Control (IAC) valve.
The movement of the IAC valve varies the amount of air flow bypassing the throttle plates.
The ECM controls idle speed by determining the position of the IAC valve.

DIAGNOSTIC AIDS:
An intermittent may be caused by a poor connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for the following items:
• Poor connection or damaged harness. Inspect the ECM harness and connectors for
improper mating, broken locks, improperly formed or damaged terminals, poor terminal
to wire connection, and damaged harness.
• Check for vacuum leaks, disconnected or brittle vacuum hoses, cuts, etc. Examine man-
ifold and throttle body gaskets for proper seal. Check for cracked intake manifold.
• Check for poor connections, opens, or short to grounds in CKT’s 441, 442, 443, and 444.
This may result in improper idle control.
• An IAC valve which is “frozen” and will not respond to the ECM, a throttle stop screw
which has been tampered with, or a damaged throttle body or linkage may cause
improper idle.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Chart A-8 (2 of 2): Idle Air Control (IAC) Functional Test

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Engine should be at normal operating temperature.
b. Start engine and allow idle to stabilize.
c. Record rpm.

2. d. Ignition OFF for 10 seconds. Step 3. Step 4.

e. Disconnect IAC harness connector.
f. Restart engine and record rpm.
Is rpm Higher Than The First Recorded rpm By More
Than 200 rpm?
a. Reinstall IAC harness connector.

3. b. Idle speed should gradually return within 75 rpm of the Step 5. Step 4.
original recorded rpm within 30 seconds.
Does rpm Return To Original Recorded rpm?
a. Ignition OFF for 10 seconds.
b. Disconnect IAC harness connector.

4. c. Restart engine. Step 7. Step 6.

d. Using a test light connected to ground, probe each one
of the four IAC harness terminals.
Does The Test Light Blink On All Four Terminals?
5. IAC circuit is functioning properly. –
Locate and repair poor connection, open, or short to ground
6. in the IAC circuit that did not blink or repair faulty ECM
Verify –
connections
Repair
Check for poor IAC connections or replace the faulty IAC
7.
valve.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Discrete Input Circuit Check - Non-Scan Only (1 of 5)

MEFI 1

IC MODULE

DISTRIBUTOR ECM
B+ MEFI 1 MEFI 3
902 RED AB
COIL
J2-23 J1-10
3 PNK J2-8 J2-10
J2-24 J1-24
121 BRN OR GRY J2-6 J1-3

121 WHT
HARNESS CONNECTOR

E NOT USED
112 DK GRN J2-11
D 31 TAN
31 TAN J2-27
C 3 PNK TO IGN
J1-6
B 931 BRN 931 BRN

A
121 WHT

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

MEFI 3

DISTRIBUTOR

WHT/GRN WHT/RED

ECM
MEFI 1 MEFI 3

439 PNK

430 PPL/WHT J2-10

B+ 902 RED 121 WHT 121 WHT

J1-2
+ –

IGNITION
COIL

TEMP SENDER

121 WHT MEFI 1 MEFI 3

A F 208 BRN J2-20

901 TAN B E 585 TAN/WHT J2-8
IGNITION 3 PNK C D 29 DK GRN J1-26

CIRCUIT DESCRIPTION:
Several discrete switch inputs are utilized by the fuel injection system to identify abnormal
conditions that may affect engine operation. A pull-up switch is currently used in conjunction
with the ECM to detect critical conditions to engine operation.
If a discrete switch changes states from its normal at-rest position, that is normally open to
closed (or closed to open), the ECM senses a change in voltage and responds by activating
the audio warning system.

DIAGNOSTIC AIDS:
• Check engine oil and gear lube levels.
An intermittent problem may be caused by a poor or corroded connection, rubbed through
wire connection, or a wire that is broken inside the insulation.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Discrete Input Circuit Check(2 of 5)

NOTE: The ECM should only be replaced after all switches and circuits have been tested
and found to be functioning properly.
TESTING BUZZER

Step Action Yes No

PROCEED TO
Key ON, Engine OFF.
1. Step 2. OBD
Does buzzer sound?
Start engine.
2. Step 3. Step 6.
Does buzzer sound?
a. Disconnect TAN/BLU or BLU wire at buzzer.
b. Key ON, Engine OFF.
3. Step 4. Step 5.
c. Touch TAN/BLU or BLU wire to ground (–).
Does buzzer sound?
Buzzer is working properly. Proceed to “Testing Switches”
4. – –
or “Testing Circuits.”
Ensure that there is battery power (+) to the PUR wire Verify
5. –
going to buzzer. If there is, replace buzzer. Repair.
Discrete switches may all be functioning properly.
Verify
6. Proceed to check all discrete circuits to verify each works –
Repair.
properly.

TESTING OIL PRESSURE SWITCH

Step Action Yes No

PROCEED TO
a. Disconnect MEFI 1 BLU/TAN or MEFI 3 BLU wire from
oil pressure switch.
b. Engine OFF.
1. Step 2. Step 3.
c. Check for continuity between terminal on switch and
ground (–).
Is there continuity?
a. Start engine.
b. Check for continuity between terminal on switch and Switch
2. Step 3.
ground (–). OK
Is there continuity?
Verify
3. Replace oil pressure switch. –
Repair.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Discrete Input Circuit Check (3 of 5)

TESTING GEAR LUBE MONITOR SWITCH

Step Action Yes No

PROCEED TO
a. Disconnect BLU/TAN or TAN/WHT wire from gear lube
monitor.
b. Empty gear lube from monitor.
1. Step 2. Step 3.
c. Check for continuity between TAN/BLU wire and
ground (–).
Is there continuity?
a. Refill gear lube monitor.
b. Check for continuity between TAN/BLU wire and Switch
2. Step 3.
ground (–). OK
Is there continuity?
Verify
3. Replace gear lube monitor. –
Repair.

Discrete Input Circuit Check (4 of 5)

TESTING CIRCUITS FOR SHORT-TO-GROUND (–)

Step Action Yes No

PROCEED TO
a. Disconnect BLU/TAN or BLU wire from oil pressure
switch.
b. Disconnect BLU/TAN or TAN/WHT wire from gear lube
monitor.
1. Step 2. Step 3.
c. Disconnect BLU/TAN wire from transmission tempera-
ture switch (if equipped).
d. Key ON, engine OFF.
Does audio warning buzzer sound?
a. Key OFF.
b. Disconnect ECM connectors.
c. Check for continuity between all wires disconnected in
Step 1. and engine ground (–).
2. Is there continuity on MEFI 1 BLU/TAN or MEFI 3 BLU Step 4. Step 3.
wire from oil pressure switch?
Is there continuity on MEFI 1 BLU/TAN or MEFI 3
TAN/WHT wire from gear lube switch?
Is there continuity on BLU/TAN wire from transmis-
sion switch?
3. Circuit(s) is not shorted to ground (–). Check switches. – –
4. Repair short-to-ground (–) in affected circuit. – –

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Discrete Input Circuit Check (5 of 5)

TESTING FOR OPEN CIRCUITS

Step Action Yes No

PROCEED TO
a. Disconnect BLU/TAN or BLU wire from oil pressure
switch.
b. Disconnect BLU/TAN or TAN/WHT wire from gear lube
monitor.
c. Disconnect BLU/TAN wire from transmission tempera-
ture switch (if equipped).
d. Key ON, engine OFF.

1. e. One at a time, touch each wire to ground (–) that was Step 3. Step 2.
disconnected.
Does audio warning buzzer sound when grounding
MEFI 1 BLU/TAN or MEFI 3 BLU wire from oil pres-
sure switch?
Does audio warning buzzer sound when grounding
MEFI 1 BLU/TAN or MEFI 3 TAN/WHT wire from gear
lube switch?
Does audio warning buzzer sound when grounding
BLU/TAN wire from transmission switch?
a. Key OFF.
b. Disconnect ECM connectors.
Is there continuity on MEFI 1 BLU/TAN or MEFI 3 BLU
2. wire from oil pressure switch to ECM CKT? Step 3. Step 4.
Is there continuity on MEFI 1 BLU/TAN or MEFI 3
TAN/WHT wire from gear lube switch to ECM CKT?
Is there continuity on BLU/TAN wire from transmis-
sion switch to ECM CKT?
3. Circuit(s) is not open. – –
4. Repair open circuit. – –

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Clearing Trouble Codes

Clearing Codes Using CodeMate Tester
NOTE: When clearing codes without the use of a scan tool, the battery must be fully
charged. The ability to clear codes is directly dependent on the battery being fully charged
and able to start the engine with adequate cranking rpm.
1. Install diagnostic CodeMate Tester.
2. Turn key ON.
3. Select “Service Mode” on CodeMate Tester.
4. To clear codes, move the throttle, while in NEUTRAL, from 0% to 100% then back to 0%.
5. Exit “Service Mode” on CodeMate Tester.
6. Start engine and let run for fifteen seconds.
7. Turn key OFF for 5 seconds.
8. Select “Service Mode” on CodeMate Tester.
9. Turn key ON and read codes. If codes are still present, check preceding “Note” and
repeat from Step 1.
10. Refer to appropriate Troubleshooting and/or Diagnostic Charts.
A poorly charged battery or engine cranking problem may result in an ECM “reset” and may
not allow stored trouble codes to be cleared from EEPROM memory. If this condition exists,
BE SURE the battery is fully charged.
NOTE: If a low battery condition does exists the audio warning buzzer will come on for 2
seconds (as a result of an ECM reset) after engine start-up.

Clearing Codes Using Scan Tool

IMPORTANT: All references to Scan Tool work with either the Quicksilver Digital Diag-
nostic Tool or the Rinda Scan Tool.
1. Connect scan tool.
2. Start engine.
3. Select clear codes function.
4. Clear codes.
5. Turn key OFF.
6. Turn key ON and read codes. If codes are still present, there is a real fault in system.
Refer to appropriate Troubleshooting and/or Diagnostic Charts.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Diagnostic Testing
Code 14 (1 of 3): Engine Coolant Temperature (ECT) Sensor Circuit

ECM
MEFI 1 MEFI 3

J1-2 J2-11
J1-29 J2-18

CIRCUIT DESCRIPTION:
The Engine Coolant Temperature (ECT) Sensor uses a thermistor to control the signal volt-
age to the ECM. The ECM applies a voltage on CKT 410 to the sensor. When the engine
coolant is cold, the sensor (thermistor) resistance is high. Therefore, the ECM will see high
signal voltage. As the engine coolant warms, the sensor resistance becomes less and the
voltage drops.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage. If the harness appears to be
OK, observe the ECT display on the scan tool while moving connectors and wiring har-
nesses related to the ECT sensor. A change in the ECT display will indicate the location
of the fault.
• A scan tool displays engine coolant temperature in degrees celsius and fahrenheit. If the
engine is cold (not running within 8 hours), the scan tool should display a ECT sensor
value within a few degrees of outside air temperature. This may help aid in diagnosing a
“shifted” coolant sensor. After engine is started, the temperature should rise steadily and
then stabilize at operating temperature when the thermostat opens.
• Check harness routing for a potential short to ground in CKT 410.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 14 (2 of 3): Engine Coolant Temperature (ECT) Sensor Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 8.
a. Ignition ON.
3. Does scan tool display a coolant temperature value Step 4. Step 5.
greater than 266° F (130° C) or less than -22° F (-30°
C)?
Does scan tool display a coolant temperature value
4. Step 6. Step 7.
greater than 266° F (130° C)?
Code 14 is intermittent. If no additional codes were
5. – –
stored, refer to “Diagnostic Aids.”
a. Ignition OFF.
b. Disconnect ECT sensor.
6. c. Ignition ON.
Does scan tool display coolant temperature below
Step 12. Step 14.
-22° F (-30° C).
a. Ignition OFF.
b. Disconnect ECT sensor.
c. Jumper terminals “A” and “B” together.
7.
d. Ignition ON.
Does scan tool display coolant temperature above
Step 12. Step 15.
266° F(130° C).
NOTE: Following steps do not require a Scan Tool.
a. Ignition OFF.
b. Disconnect ECT sensor connector.
8. c. Ignition ON, engine OFF.
d. Connect DVOM across coolant sensor harness termi-
nals.
Is voltage above 4 volts? Step 12. Step 9.
a. Connect positive DVOM lead from harness terminal “B”
CKT 410 (5 volt reference).
9. b. Connect negative DVOM lead to a good ground (–) on
engine.
Is voltage above 4 volts? Step 16. Step 10.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 14 (3 of 3): Engine Coolant Temperature (ECT) Sensor Circuit

Step Action Yes No
PROCEED TO
a. Remove DVOM.
b. Ignition ON.
10. c. Connect a test light to battery positive (B+).
d. Touch test light to sensor harness terminal “B” CKT 410.
Is test light on? Step 13. Step 11.
Locate and repair open in CKT 410 or faulty connection
11. – –
at ECM.
Locate and repair Intermittent connections or replace
12. faulty ECT sensor (refer to chart below for sensor val- – –
ues).
For MEFI 1, disconnect J-1 connector.
13. For MEFI 3, disconnect J-2 connector. Step 14. Step 15.
Is test light on?
14. CKT 410 shorted to ground. Locate and repair short. – –
CKT 410 shorted to sensor ground or faulty ground. Lo-
15. – –
cate and repair.
Locate and repair open sensor ground in CKT 814 or
16. – –
faulty connection at ECM.

ENGINE COOLANT TEMPERATURE SENSOR CHART

ECT Sensor
Temperature - to - Resistance Values
(Approximate)
°F °C OHMS
210 100 185
160 70 450
100 38 1,800
70 20 3,400
40 4 7,500
20 -7 13,500
0 -18 25,000
-40 -40 100,700

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 15 (1 of 2): Engine Coolant Temperature (ECT) Sensor Circuit

ECM
MEFI 3

J2-11
J2-18

CIRCUIT DESCRIPTION:
The Engine Coolant Temperature (ECT) Sensor uses a thermistor to control the signal volt-
age to the ECM. The ECM applies a voltage on CKT 410 to the sensor. When the engine
coolant is cold, the sensor (thermistor) resistance is high, therefore, the ECM will see high
signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the
voltage drops.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage. If the harness appears to be
OK, observe the ECT display on the scan tool while moving connectors and wiring har-
nesses related to the ECT sensor. A change in the ECT display will indicate the location
of the fault.
• A scan tool displays engine coolant temperature in degrees celsius and fahrenheit. If the
engine is cold (not running within 8 hours), the scan tool should display a ECT sensor
value within a few degrees of outside air temperature. After engine is started, the tem-
perature should rise steadily and then stabilize at operating temperature when the ther-
mostat opens.
• Check harness routing for a potential short to ground in CKT 410.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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Code 15 (2 of 2): Engine Coolant Temperature (ECT) Sensor Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 5.
Ignition ON.
3. Does the scan tool display a coolant temperature
Step 4. Step 6.
greater than 266°F (130°C)?
a. Ignition OFF.
b. Disconnect ECT harness connector.
4. c. Ignition ON, engine OFF.
Does scan tool display a coolant temperature below
Step 6. Step 7.
-22°F (-30°C)?
a. Ignition OFF.
b. Disconnect ECT sensor harness terminals.
c. Ignition ON, engine OFF.
5.
d. Connect DVOM across the coolant sensor harness ter-
minals.
Is voltage above 4 Volts? Step 6. Step 7.
Locate and repair intermittent faulty connections or
6.
replace faulty ECT sensor.
Verify
Locate and repair short to ground in CKT 410 or repair –
Repair
7. faulty ECM connections.
Was a problem found?

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 21 (1 of 3): Throttle Position (TP) Sensor Circuit

ECM
B MEFI 1 MEFI 3
B
J1-13 J2-3
C C
J1-10 J2-26
A
A
J1-15 J2-4

CIRCUIT DESCRIPTION:
The Throttle Position (TP) Sensor provides a voltage signal that changes as throttle blades
open or close. Signal voltage should vary from about .5 volts at idle to about 4.5 volts at Wide
Open Throttle (WOT).
The TP signal is one of the most important inputs used by the Electronic Control Module
(ECM) for fuel control and for most of the ECM controlled outputs.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage. If the harness appears to be
OK, observe the TP sensor display on the scan tool while moving connectors and wiring
harnesses related to the TP sensor. A change in the TP sensor display will indicate the
location of the fault.
• The scan tool reads throttle position in voltage and percentage relative to the throttle
blade opening With ignition ON, engine OFF, throttle blades closed (idle), the voltage
should be 0.3-0.8 volts The voltage should steadily increase as the throttle is moved
toward Wide Open Throttle (WOT).
• If DTC 34 is also set, check for a short to ground in CKT 416.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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Code 21 (2 of 3): Throttle Position (TP) Sensor Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 7.
a. Throttle closed.
b. Ignition ON.
3. Does scan tool indicate throttle position sensor volt-
Step 6. Step 4.
age greater than 4 volts?
Does scan tool indicate throttle position sensor volt-
Step 5. Step 4.
age less than .3 volts?
Code 21 is intermittent, refer to “Diagnostic Aids” on
4. – –
facing page.
a. Ignition OFF.
b. Disconnect throttle position sensor electrical connector.
Jumper throttle position sensor harness terminals “A”
5. and “C” together.
c. Ignition ON
Does scan tool indicate throttle position sensor volt-
Step 15. Step 7.
age greater than 4 volts?
a. Ignition OFF.
b. Disconnect throttle position sensor connector.
6.
c. Ignition ON.
Does scan tool indicate voltage over 4 volts? Step 13. Step 7.
a. Ignition OFF.
b. Disconnect throttle position sensor harness connector.
c. Ignition ON.
7.
d. Connect DVOM from harness terminal “A” (5 volt refer-
ence to harness terminal “B” (sensor ground).
Is voltage reading over 4 volts? Step 8. Step 11.
Connect DVOM from harness terminal “A” (CKT 416) to
harness terminal “C” (throttle position sensor signal, CKT
8. 417).
Is voltage reading over 4 volts? Step 9. Step 10.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 21 (3 of 3): Throttle Position (TP) Sensor Circuit

Step Action Yes No
PROCEED TO
a. Ignition OFF.
b. Connect a test light to battery positive (B+).
9. c. Touch test light to harness terminal “C” (throttle position
sensor signal).
Is test light on? Step 12. Step 15.
Connect DVOM between harness terminal “C” and
10. engine ground (–).
Is voltage reading over 4 volts? Step 13. Step 14.
Connect DVOM from throttle position sensor harness ter-
11. minal “A” to a good ground on engine.
Is voltage reading over 4 volts? Step 18. Step 17.
a. Disconnect ECM.
b. Touch test light to harness terminal “C” (throttle position
12.
sensor signal).
Is test light on? Step 16. Step 14.
13. Check for CKT 417 shorted to voltage. – –
Locate and repair open in CKT 417 or faulty connection
14. – –
at ECM.
15. Replace throttle position sensor. – –
16. Check for CKT 417 shorted to ground. – –
CKT 416 open or shorted to ground or faulty connection
17. – –
at ECM.
18. CKT 813 open faulty connection at ECM. – –

Page 5I-56 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 22 (1 of 3): Throttle Position (TP) Sensor Circuit

ECM
MEFI 3

J2-3
C C J2-26
B
A J2-4
A
B

CIRCUIT DESCRIPTION:
The Throttle Position (TP) Sensor provides a voltage signal that changes as throttle blades
open or close. Signal voltage should vary from about .5 volts at idle to about 4.5 volts at Wide
Open Throttle (WOT).
The TP signal is one of the most important inputs used by the Electronic Control Module
(ECM) for fuel control and for most of the ECM controlled outputs.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage. If the harness appears to be
OK, observe the TP sensor display on the scan tool while moving connectors and wiring
harnesses related to the TP sensor. A change in the TP sensor display will indicate the
location of the fault.
• The scan tool reads throttle position in voltage and percentage relative to the throttle
blade opening With ignition ON, engine OFF, throttle blades closed (idle), the voltage
should be 0.3-0.8 volts The voltage should steadily increase as the throttle is moved
toward Wide Open Throttle (WOT).
• If DTC 34 is also set, check for a short to ground in CKT 416.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 22 (2 of 3): Throttle Position (TP) Sensor Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 7.
a. Throttle closed.
b. Ignition OFF.
3.
Does scan tool indicate TP sensor voltage less than
Step 4. Step 6.
.30 volt?
a. Ignition OFF
b. Disconnect TP sensor harness connector.
c. Connect a jumper wire from harness terminal “A” CKT
4. 416 to harness terminal “B” CKT 417.
d. Ignition ON, engine OFF.
Does scan tool indicate TP sensor voltage greater
Step 9. Step 5.
than 4 volts?
a. Ignition OFF.
b. Connect DVOM from harness terminal “A” (CKT 416) to
5. a known good ground.
Does scan tool indicate TP sensor voltage greater
Step 10. Step 11.
than the specified value?
Trouble code 22 is intermittent. Locate and repair inter-
6. – –
mittent faulty connections. Refer to “Diagnostic Aids.”
a. Switch CodeMate Tester to the normal mode.
b. Ignition OFF.
c. Disconnect throttle sensor harness connector.
d. Connect a jumper wire form harness terminal “A” CKT
416 to harness terminal “C” CKT 417.
7. e. Start engine and idle for 2 minutes or until CodeMate
Tester indicates a stored trouble code, whichever oc-
curs first.
f. Ignition ON, engine OFF.
g. Switch CodeMate Tester to “Service Mode” and note
trouble code.
Is trouble code 21 present? Step 9. Step 10.
a. Remove jumper wire from CKT 416 and CKT 417.
b. Connect DVOM from harness terminal “A” CKT 416 to
8.
harness terminal “B” CKT 813.
Is voltage reading above 4 volts? Step 10. Step 11.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 22 (3 of 3): Throttle Position (TP) Sensor Circuit

Step Action Yes No
PROCEED TO
Locate and repair intermittent faulty connections or re-
9. –
place faulty throttle position sensor.
Locate and repair open or short to ground in CKT 417 or Verify
10. –
faulty ECM connections. Repair
Locate and repair open or short to ground in CKT 416 or
11. –
faulty ECM connections.

90-861328--1 NOVEMBER 1999 Page 5I-59

DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 23 (1 of 3): Intake Air Temperature (IAT) Sensor Circuit

ECM
B A
MEFI 3

J2-30
J2-3

CIRCUIT DESCRIPTION:
The Intake Air Temperature (IAT) Sensor uses a thermistor to control the signal voltage to
the ECM. The ECM applies a voltage on CKT 472 to the sensor. When the intake air is cold,
the sensor (thermistor) resistance is high, therefore, the ECM will see high signal voltage.
As the intake air warms, the sensor resistance becomes less, and the voltage drops. At nor-
mal engine operating temperature, 160-180°F (71-82°C), the voltage will measure about
1.5 to 2.0 volts.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage. If the harness appears to be
OK, observe the IAT display on the scan tool while moving connectors and wiring har-
nesses related to the IAT sensor. A change in the IAT display will indicate the location of
the fault.
• The scan tool displays intake air temperature in degrees Celsius and Fahrenheit. If the
intake air is cold (not running within 8 hours), the scan tool should display a IAT sensor
value within a few degrees of outside air temperature. This may help aid in diagnosing a
“shifted” sensor. After engine is started, the temperature should rise steadily and then
stabilize at operating temperature.
• If DTC 21 is also set, check for open ground CKT 813.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 23 (2 of 3): Intake Air Temperature (IAT) Sensor Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 7.
Ignition ON
3. Does the scan tool display a temperature less than
Step 4. Step 5.
-22°F (-30°C)?
a. Ignition OFF
b. Disconnect IAT harness connector.
c. Connect a jumper wire from harness terminal “A” CKT
4. 472 to harness terminal “B” CKT 813.
d. Ignition ON, engine OFF.
Does scan tool display a temperature above 266°F
Step 9. Step 6.
(130°C)?
Trouble code 23 is intermittent. Locate and repair inter-
5. Verify –
mittent faulty connections.
Repair
6. Locate and repair open in CKT 472 or CKT 813.
a. Ignition OFF.
b. Disconnect IAT sensor harness terminals.
7. c. Ignition ON, engine OFF.
4. Connect DVOM across the sensor harness terminals.
Is voltage above 4 volts? Step 9. Step 8.
a. Connect positive (+) DVOM lead to harness terminal “B”
CKT 472 (5 volt reference).
8. b. Connect negative (–) DVOM lead to a known good
ground.
Is voltage above 4 volts? Step 11. Step 10.
Locate and repair intermittent faulty connections. If OK,
9. –
replace faulty IAT sensor.
Locate and repair open CKT 472 or faulty ECM connec- Verify
10. –
tions. Repair
Locate and repair open ground CKT 813 or faulty ECM
11. –
connections.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 25 (1 of 3): Intake Air Temperature (IAT) Sensor Circuit

ECM
B A
MEFI 3

J2-30
J2-3

CIRCUIT DESCRIPTION:
The Intake Air Temperature (IAT) Sensor uses a thermistor to control the signal voltage to
the ECM. The ECM applies a voltage on CKT 472 to the sensor. When the intake air is cold,
the sensor (thermistor) resistance is high, therefore, the ECM will see high signal voltage.
As the intake air warms, the sensor resistance becomes less, and the voltage drops. At nor-
mal engine operating temperature, 160-180°F (71-82°C), the voltage will measure about
1.5 to 2.0 volts.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage. If the harness appears to be
OK, observe the IAT display on the scan tool while moving connectors and wiring har-
nesses related to the IAT sensor. A change in the IAT display will indicate the location of
the fault.
• The scan tool displays intake air temperature in degrees celsius and fahrenheit. If the
engine is cold (not running within 8 hours), the scan tool should display a IAT sensor
value within a few degrees of outside air temperature. This may help aid in diagnosing a
“shifted” sensor. After engine is started, the temperature should rise steadily and then
stabilize at operating temperature.
• Check harness routing for a potential short to ground in CKT 472.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 25 (2 of 2): Engine Coolant Temperature (IAT) Sensor Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 7.
Ignition ON.
3. Does the scan tool display a temperature greater
Step 4. Step 5.
than 266°F (130°C)?
a. Ignition OFF.
b. Disconnect IAT harness connector.
4. c. Ignition ON, engine OFF.
Does scan tool display a temperature below -22°F
Step 8. Step 6.
(-30°C)?
Trouble code 25 is intermittent. Locate and repair inter-
5. –
mittent faulty connections. Refer to “Diagnostic Aids.”
Verify
Locate and repair short to ground in CKT 472. If a prob-
Repair
6. lem is found, repair as necessary. Step 10.
Was a problem found?
a. Ignition OFF.
b. Disconnect IAT sensor harness terminals.
7. c. Ignition ON, engine OFF.
d. Connect DVOM across the sensor harness terminals.
Is voltage above 4 volts? Step 8. Step 9.
Locate and repair intermittent faulty connections or
8. –
replace faulty IAT sensor.
Verify
9. Locate and repair short to ground in CKT 472. Repair Step 10.
10. Repair faulty ECM connections. –

90-861328--1 NOVEMBER 1999 Page 5I-63

DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 33 (1 of 3): Manifold Absolute Pressure (MAP) Sensor Circuit

ECM
MEFI 1 MEFI 3

J1-31 J2-19
J1-9 J2-27
814 BLK J1-29 J2-18

CIRCUIT DESCRIPTION:
The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure
(vacuum). The ECM receives this information as a signal voltage that will vary from about
1.0-2.0 volts at idle to about 4.0-5.0 volts at Wide Open Throttle (WOT).
If the MAP sensor fails, the ECM will substitute a default MAP value that will vary with rpm.
A reference voltage of 5 volts is provided to the MAP sensor through CKT 416. CKT 814 is
the ground circuit for the MAP sensor. MAP sensor CKT 432 will send a voltage signal to
the ECM proportional to the manifold pressure.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage. If the harness appears to be
OK, observe the MAP sensor display on the scan tool while moving connectors and wir-
ing harnesses related to the MAP sensor. A change in the MAP sensor display will indi-
cate the location of the fault.
• If the idle is rough or unstable, refer to “Troubleshooting” section for items which may
cause an unstable idle.
• With the ignition ON, engine OFF, the manifold pressure is equal to atmospheric pres-
sure and the signal voltage will be high. This information is used by the ECM as an
indication of altitude and is referred to as BARO. Comparison of this BARO reading, with
a known good MAP sensor, is a good way to check the accuracy of a “suspect” sensor.
Reading should be the same, plus or minus 0.4 volt.
• If DTC 14 is also set, check for open in ground CKT 814.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 33 (2 of 3): Manifold Absolute Pressure (MAP) Sensor Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 7.
a. Ignition OFF.
b. Install a vacuum gauge to manifold vacuum.
3. c. Start engine and raise rpm to 1000 in NEUTRAL.
Is the vacuum reading steady and above 14 in. HG
Step 4. Step 10.
(45.5 kPa)?
Allow the engine to idle.
4. Does the scan tool indicate MAP sensor voltage
Step 5. Step 11.
greater than 4 volts?
a. Ignition OFF.
b. Disconnect MAP sensor harness connector.
5. c. Ignition ON, engine OFF.
Does the scan tool indicate MAP sensor voltage less
Step 6. Step 13.
than 1 volt?
a. Ignition OFF.
b. Connect DVOM from harness terminal “A” CKT 814 to
harness terminal “C” CKT 416.
6.
c. Ignition ON, engine OFF.
Does the scan tool indicate MAP sensor voltage
Step 12. Step 14.
greater than 4 volts?
a. Ignition OFF.
b. Install a vacuum gauge.
7. c. Start engine and raise rpm to 1000 in NEUTRAL.
Is the vacuum reading steady and above 14 In. Hg
Step 8. Step 10.
(45.5 kPa)?

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 33 (3 of 3): Manifold Absolute Pressure (MAP) Sensor Circuit

Step Action Yes No
PROCEED TO
a. Switch CodeMate Tester to the “Normal Mode.”
b. Ignition OFF.
c. Disconnect MAP sensor harness connector.
d. Start engine and idle for 2 minutes or until CodeMate
Tester indicates a stored trouble code, whichever oc-
8.
curs first.
e. Ignition ON, engine OFF.
f. Switch CodeMate Tester to the “Service Mode and note
trouble code.
Is trouble code 34 present? Step 12. Step 9.
a. MAP sensor harness connector disconnected.
b. Ignition ON engine OFF.
9. c. Connect DVOM from harness terminal “A” CKT 814 to
harness terminal “C” CKT 416.
Is voltage reading above 4 volts? Step 13. Step 14.
10. Repair low or unsteady vacuum problem. –
Trouble code is intermittent. Locate and repair intermit-
11. –
tent faulty connections. Refer to “Diagnostic Aids.”
Check for plugged or leaking sensor vacuum fitting. If
12. Verify –
OK, replace faulty MAP sensor.
Repair
Locate and repair short to voltage in CKT 432 or faulty
13. –
ECM connections.
Locate and repair open in CKT 814 or repair faulty ECM
14. –
connections.

Page 5I-66 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 34 (1 of 3): Manifold Absolute Pressure (MAP) Sensor Circuit

ECM
MEFI 3

MANIFOLD J2-19
PRESSURE J2-27
(VACUUM)
814 BLK J2-18

CIRCUIT DESCRIPTION:
The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure
(vacuum). The ECM receives this information as a signal voltage that will vary from about
1.0-2.0 volts at idle to about 4.0-5.0 volts at Wide Open Throttle (WOT).
If the MAP sensor fails, the ECM will substitute a default MAP value that will vary with rpm.
A reference voltage of 5 volts is provided to the MAP sensor through CKT 416. CKT 814 is
the ground circuit for the MAP sensor. MAP sensor CKT 432 will send a voltage signal to
the ECM proportional to the manifold pressure.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage. If the harness appears to be
OK, observe the MAP sensor display on the scan tool while moving connectors and wir-
ing harnesses related to the MAP sensor. A change in the MAP sensor display will indi-
cate the location of the fault.
• If the idle is rough or unstable, refer to “Troubleshooting” section for items which may
cause an unstable idle.
• With the ignition ON, engine OFF, the manifold pressure is equal to atmospheric pres-
sure and the signal voltage will be high. This information is used by the ECM as an
indication of altitude and is referred to as BARO. Comparison of this BARO reading, with
a known good MAP sensor, is a good way to check the accuracy of a “suspect” sensor.
Reading should be the same, plus or minus 0.4 volt.
• If DTC 14 is also set, check for open in ground CKT 814.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

90-861328--1 NOVEMBER 1999 Page 5I-67

DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 34 (2 of 3): Manifold Absolute Pressure (MAP) Sensor Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 7.
a. Ignition OFF
b. Install a vacuum gauge.
3. c. Start engine and raise rpm to 1000 in NEUTRAL.
Is the vacuum reading steady and above 14 in. HG
Step 4. Step 9.
(45.5 kPa)?
Allow the engine to idle.
4. Does the scan tool indicate MAP sensor voltage less
Step 5. Step 11.
than 1 volt?
a. Ignition OFF.
b. Disconnect MAP sensor harness connector.
c. Connect a jumper wire from harness terminal “B” CKT
5. 432 to harness terminal “C” CKT 416.
d. Ignition ON, engine OFF.
Does the scan tool indicate MAP sensor voltage
Step 10. Step 6.
greater than 4 volts?
a. Ignition OFF.
b. Connect DVOM from harness terminal “C” CKT 416 to
a known good ground.
6.
c. Ignition ON, engine OFF.
Does the scan tool indicate MAP sensor voltage
Step 12. Step 13.
greater than 4 volts?
a. Switch CodeMate Tester to “Normal Mode.”
b. Ignition OFF.
c. Disconnect MAP sensor harness connector.
d. Connect a jumper wire from terminal “B” CKT 432 to
harness terminal “C” CKT 416.
7.
e. Start engine and raise rpm to 1000 in NEUTRAL.
f. Ignition ON, engine OFF.
g. Switch CodeMate Tester to “Service Mode” and watch
for a trouble code.
Is trouble code 33 present? Step 11. Step 8.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 34 (3 of 3): Manifold Absolute Pressure (MAP) Sensor Circuit

Step Action Yes No
PROCEED TO
a. Remove the jumper wire from CKT 416 and 432.
b. Connect DVOM from harness terminal “A” CKT 814 to
8.
harness terminal “C” CKT 416.
Is voltage reading above 4 volts? Step 12. Step 13.
9. Repair low or unsteady vacuum problem. –
Check for plugged or leaking sensor vacuum fitting. If
10. –
OK, replace faulty MAP sensor.
Locate and repair intermittent faulty connections. If OK,
11. –
replace faulty MAP sensor. Verify
Locate and repair open or short to ground in CKT 432 or Repair
12. –
faulty ECM connections.
Locate and repair open or short to ground in CKT 416 or
13. faulty ECM connections. Also check CKT 416 to the TP –
sensor for a short to ground.

90-861328--1 NOVEMBER 1999 Page 5I-69

DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 41 (1 of 2): Ignition Control (IC) Circuit

IC MODULE

DISTRIBUTOR
ECM
IGNITION MEFI 3
902 RED AB
COIL
J1-10
3 PNK J2-10
J1-24
121 BRN OR GRY
J1-3

121 WHT TACH

CIRCUIT DESCRIPTION:
When the system is running on the ignition module or in crank mode, there is no voltage on
CKT 424, and the ignition module grounds CKT 423. The ECM expects to detect a low volt-
age on CKT 423 during this condition. If the ECM sees voltage, it sets Code 41 and will not
go into the Ignition Control (IC) mode.
When the rpm for IC is reached (about 300 rpm), and CKT 424 voltage applied, CKT 423
should no longer be grounded in the ignition module, and the voltage should be varying.
If CKT 424 is open or grounded, the ignition module will not switch to IC mode. The CKT
423 voltage will be low and Code 42 will be set.
If CKT 423 stays grounded, the IC module will switch to IC mode but, because the line is
grounded, there will not be an IC signal and a trouble code 42 will be set.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage.
• If the engine starts and stalls, it may set a false DTC 41 or 42. Clear DTC and repair stal-
ling condition.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 41 (2 of 2): Ignition Control (IC) Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Clear trouble code 41.
b. Start engine and idle for 2 minutes or until trouble code
2.
41 sets, whichever occurs first.
Is trouble code 41 present? Step 3. Step 7.
a. Ignition OFF.
b. Disconnect ECM harness connectors.
3. c. Using a DVOM set on Ohms, probe ECM CKT 423 to
ground.
Is resistance above 3000 ohms? Step 4. Step 5.
a. Reconnect ECM.
b. Start engine and idle for 2 minutes or until trouble code
4.
41 sets, whichever occurs first.
Is trouble code 41 present? Step 5. Step 7.
Locate and repair open in CKT 423 or faulty ECM con-
5. nections. Step 6.
Was a problem found?
Verify
6. Replace faulty distributor ignition module. Repair –
Trouble code is intermittent. Refer to “Diagnostic Aids” on
7. facing page. Check harness and connectors for an inter- –
mittent open in CKT 423.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 42 (1 of 3): Ignition Control (IC) Circuit

IC MODULE

DISTRIBUTOR
ECM
IGNITION MEFI 1 MEFI 3
902 RED AB
COIL
J2-23 J1-10
3 PNK J2-8 J2-10
J2-24 J1-24
121 BRN OR GRY J2-6 J1-3

121 WHT TACH

When the system is running on the ignition module or in crank mode, there is no voltage on
CKT 424 and the ignition module grounds CKT 423. The ECM expects to detect a low volt-
age on CKT 423 during this condition. If the ECM sees voltage, it sets Code 41 and will not
go into the Ignition Control (IC) mode.
When the rpm for IC is reached (about 300 rpm), and CKT 424 voltage applied, CKT 423
should no longer be grounded in the ignition module, and the voltage should be varying.
If CKT 424 is open or grounded, the ignition module will not switch to IC mode. The CKT
423 voltage will be low and Code 42 will be set.
If CKT 423 stays grounded, the IC module will switch to IC mode but, because the line is
grounded, there will not be an IC signal and a trouble code 42 will be set.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage.
• If the engine starts and stalls, it may set a false DTC 41 or 42. Clear DTC and repair stal-
ling condition.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 42 (2 of 2): Ignition Control (IC) Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Clear trouble code 42.
b. Start engine and idle for 2 minutes or until trouble code
2.
42 sets, whichever occurs first.
Is trouble code 42 present? Step 3. Step 11.
a. Ignition OFF.
b. Disconnect ECM harness connectors.
3. c. Using a DVOM selected for Ohms, probe ECM harness
terminal CKT 423 to ground.
Is resistance over 3000 ohms? Step 4. Step 7.
a. Leave DVOM connected from ECM harness terminal
CKT 423 to ground.
b. Using a test light connected to battery positive (B+),
probe ECM CKT 424.
4.
c. As the test light contacts CKT 424, the resistance
should switch from over 3000 Ohms to under 1000
Ohms.
Does the resistance switch to under 1000 ohms? Step 11. Step 5.
Using a test light connected to battery positive (B+),
5. probe ECM CKT 424.
Does test light illuminate? Step 6. Step 8.
Disconnect the ignition module 4-wire connector.
6.
Does the test light illuminate? Step 9. Step 10.
Locate and repair short to ground in CKT 423 or faulty
7. ECM connections. Step 10.
Was a problem found?
Locate and repair open in CKT 424. Verify
8. Step 10.
Was a problem found? Repair
Locate and repair short to ground in CKT 424 or faulty
9. –
ECM connections.
10. Replace faulty ignition module. –
Trouble code 42 is intermittent. Refer To “Diagnostic
Aids” on facing page. Check harness and connectors for
11. – –
an intermittent open or short to ground in CKT 424 or an
intermittent short to ground in CKT 423.

90-861328--1 NOVEMBER 1999 Page 5I-73

DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 43 (1 of 3): Knock Sensor (KS) Circuit

TO SYSTEM FUSE 15A

RELAY
ECM
MEFI 1 MEFI 3
KNOCK SENSOR 485 GRN
MODULE J1-1
486 PUR

496 DK BLU J1-30

KNOCK
SENSOR

CIRCUIT DESCRIPTION:
MEFI 1
Engine detonation or spark knock is sensed with a module that sends a voltage signal to
the ECM. As the knock sensor detects engine knock, the voltage from the KS module to the
ECM drops, and this signals the ECM to start retarding timing. The ECM will retard timing
when knock is detected and rpm and engine coolant temperature are above a certain value.
MEFI 3
Engine detonation or spark knock is detected with a sensor that sends a voltage signal to
the ECM. As the knock sensor detects engine knock, the voltage output level increases and
this signals the ECM to start retarding timing. The ECM will retard timing when knock is
detected and rpm and engine coolant temperature are above a certain value.
NOTE: MEFI 3 products do not have a knock module. The sensor connects directly to the
ECM.

DIAGNOSTIC AIDS
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage.
• If CKT 496 is routed too close to secondary ignition wires, the KS module may see the
interference as a knock signal, resulting in false timing retard.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.
NOTE: If there are abnormal mechanical engine noises (rattles or knocks), they may give
a false DTC 43. If fuel octane is too low, a false DTC 43 may be set.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 43 (2 of 3): Knock Sensor (KS) Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Do you have a MEFI 3 ECM? Step 7. Step 3.
a. Disconnect 5-wire KS module connector
b. Ignition ON, engine OFF.
3. c. Using a test light connected to ground, probe KS mod-
ule harness terminal “B” CKT 439.
Does test light illuminate? Step 4. Step 9.
a. Using a test light connected to battery positive (B+),
4. probe KS module harness terminal “D” CKT 486.
Does test light illuminate? Step 5. Step 10.
a. Ignition OFF
b. Reconnect KS module harness connector.
c. Disconnect ECM J1 connector.
5. d. Ignition ON, engine OFF.
e. Connect DVOM from ECM CKT 485 to a known good
ground.
Is the voltage within 8-10 volts? Step 6. Step 11.
a. Allow DVOM voltage to stabilize.
b. Connect a test light to battery positive (B+).
6.
c. Touch test light to CKT 496.
Does voltage value change? Step 15. Step 12.
a. Disconnect ECM J1 connector

7. b. Using DVOM, measure resistance between CKT 496 Step 15. Step 8.
and ground.
Is resistance between 3000 - 5000 ohms?
a. Disconnect KS connector.

8. b. Using DVOM, measure resistance between KS and Step 12. Step 14.
ground.
Is resistance between 3000 - 5000 ohms?
9. Locate and repair open or short to ground in CKT 439. –
10. Locate and repair open in CKT 486. –
a. Locate and repair open or short to ground in CKT 485. Verify
11. Repair Step 13.
Was a problem found?
12. a. CKT 496 open or shorted to ground. –

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 43 (3 of 3): Knock Sensor (KS) Circuit

Step Action Yes No
PROCEED TO
13. Replace faulty KS module. –
14. Replace faulty KS. Verify
Trouble code 43 is intermittent. Refer To “Diagnostic Repair
15. –
Aids” on facing page.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 44 (1 of 3): Knock Sensor (KS) Circuit

TO SYSTEM FUSE 15A

RELAY
ECM
MEFI 3
KNOCK SENSOR 485 GRN
MODULE
486 PUR

496 DK BLU J1-30

KNOCK
SENSOR

CIRCUIT DESCRIPTION:
MEFI 1
Engine detonation or spark knock is sensed with a module that sends a voltage signal to
the ECM. As the knock sensor detects engine knock, the voltage from the KS module to the
ECM drops, and this signals the ECM to start retarding timing. The ECM will retard timing
when knock is detected and rpm and engine coolant temperature are above a certain value.
MEFI 3
Engine detonation or spark knock is detected with a sensor that sends a voltage signal to
the ECM. As the knock sensor detects engine knock, the voltage output level increases and
this signals the ECM to start retarding timing. The ECM will retard timing when knock is
detected and rpm and engine coolant temperature are above a certain value.
NOTE: MEFI 3 products do not have a knock module. The sensor connects directly to the
ECM.

DIAGNOSTIC AIDS
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage.
• If CKT 496 is routed too close to secondary ignition wires, the KS module may see the
interference as a knock signal, resulting in false timing retard.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.
NOTE: if fuel octane is too high, a false DTC 44 may be set.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 44 (2 of 3): Knock Sensor (KS) Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Do you have a MEFI 3 ECM? Step 7. Step 3.
a. Disconnect 5-wire KS module connector
b. Ignition ON, engine OFF.
3. c. Using a test light connected to ground, probe KS mod-
ule harness terminal “B” CKT 439.
Does test light illuminate? Step 4. Step 9.
a. Using a test light connected to battery positive (B+),
4. probe KS module harness terminal “D” CKT 486.
Does test light illuminate? Step 5. Step 10.
a. Ignition OFF
b. Reconnect KS module harness connector.
c. Disconnect ECM J1 connector.
5. d. Ignition ON, engine OFF.
e. Connect DVOM from ECM CKT 485 to a known good
ground.
Is the voltage within 8-10 volts? Step 6. Step 11.
a. Allow DVOM voltage to stabilize.
b. Connect a test light to battery positive (B+).
6.
c. Touch test light to CKT 496.
Does voltage value change? Step 15. Step 12.
a. Disconnect ECM J1 connector

7. b. Using DVOM, measure resistance between CKT 496 Step 15. Step 8.
and ground.
Is resistance between 3000 - 5000 ohms?
a. Disconnect KS connector.

8. b. Using DVOM, measure resistance between KS and Step 12. Step 14.
ground.
Is resistance between 3000 - 5000 ohms?
9. Locate and repair open or short to ground in CKT 439. –
10. Locate and repair open in CKT 486. –
a. Locate and repair open or short to ground in CKT 485. Verify
11. Repair Step 13.
Was a problem found?
12. a. CKT 496 open or shorted to ground. –

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 44 (3 of 3): Knock Sensor (KS) Circuit

Step Action Yes No
PROCEED TO
13. Replace faulty KS module.
14. Replace faulty KS. Verify
–
Trouble code 44 is intermittent. Refer To “Diagnostic Repair
15.
Aids” on facing page.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 45 (1 of 2): Ignition Coil Driver Fault

ECM

MEFI 3
B+ 902 RED 121 WHT 121 WHT J1-2
+ –

IGNITION
COIL

TO IGN
TEMP SENDER

121 WHT

A F 208 BRN J2-20

901 TAN B E 585 TAN/WHT J2-8
3 PNK C D 29 DK GRN J1-26

CIRCUIT DESCRIPTION:
On MEFI 3 product, the coil driver circuitry is integrated into the ECM. When the engine is
running, a diagnostic check of the coil drive circuitry is constantly taking place. If the diag-
nostic system detects excessive current to the coil through CKT 121, a fault code will set
although the engine should continue to operate.

DIAGNOSTIC AIDS
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage.
• Shorted CKT 121 or tach lead in harness.
• Damaged ignition coil or improper coil. The ignition system is calibrated for Mercury ap-
proved coils only.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 45 (2 of 2):
Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Ignition ON, engine OFF.

2. b. Using DVOM, measure voltage at coil positive (+) termi- Step 3. Step 7.
nal.
Is Voltage Greater Than 12 Volts?
a. Ignition OFF.
b. Disconnect ECM J1 connector.
3. c. Check continuity from ECM CKT 121 to negative (–) ter- Step 4. Step 8.
minal of coil.
Is Resistance Less Than 1 ohm?
a. Ignition OFF.
b. Disconnect ECM J1 connector.
4. Step 9. Step 5.
c. Check resistance from ECM CKT 121 to ground.
Is Resistance Less Than 1 ohm?
a. Ignition OFF.
b. Disconnect ECM J1 connector.
5. c. Check resistance between positive (+) and negative (–) Step 6. Step 10.
terminals of coil.
Is Resistance Less Than 2 ohms?
a. Ignition OFF.
b. Disconnect ECM J1 connector.
c. Remove secondary ignition wire from coil.
6. Step 11. Step 10.
d. Measure resistance between secondary coil tower and
negative terminal of coil.
Is Resistance Greater Than 5 Ohms And Less Than
15 ohms?
7. Locate and repair open or short to ground in CKT 902.
8. Locate and repair open in CKT 121. Verify
9. Locate and repair short to ground in CKT 121. Repair
–
10. Replace ignition coil.
Trouble code 44 is intermittent. Check ignition wires and
11. –
plugs.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 51 (1 of 1): Calibration Memory Failure

76358

72801

CIRCUIT DESCRIPTION:
This test allows the ECM to check for a calibration failure by comparing the calibration value
to a known value stored in the EEPROM.
This test is also used as a security measure to prevent improper use of calibrations or
changes to these calibrations that may alter the designed function of EFI.

DIAGNOSTIC AIDS:
If DTC 51 failed more than once, but is intermittent, replace the ECM.

Step Action VALUE YES NO

PROCEED TO
Was the “On-Board Diagnostic” (OBD) Sys-
1. – Step 2. OBD
tem Check Performed?
Ignition ON.
2. Clear trouble code 51.
Refer to
Does Code 51 reset? – Step 4. Diag-
Refer to nostic
Diag- Aids
3. Fault is not present at this time. –
nostic
Aids
Replace faulty ECM and verify trouble code 51 Verify -
4. –
does not reset. Repair –

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 52 (1 of 1): EEPROM Failure

76358

72801

CIRCUIT DESCRIPTION:
This test allows the ECM to check for a calibration failure by comparing the calibration value
to a known value stored in the EEPROM.
This test is also used as a security measure to prevent improper use of calibrations or
changes to these calibrations that may alter the designed function of EFI.

DIAGNOSTIC AIDS:
If DTC 52 failed more than once, but is intermittent, replace the ECM.

Step Action Yes No

PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
a. Clear trouble code 52. Refer to
Diag-
2. b. Ignition ON. Step 3.
nostic
Does trouble code 52 reset? Aids
Replace faulty ECM and verify trouble code 52 does not Verify
3. –
reset. Repair

90-861328--1 NOVEMBER 1999 Page 5I-83

DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 61 (1 of 2) Fuel Pressure (FP) Circuit

ECM
MEFI 3
B
B
416 GRY
J2-3
C C 475 GRN J2-26
A 813 BLK J2-4
A

CIRCUIT DESCRIPTION:
The fuel pressure (FP) Sensor provides a voltage signal that changes with measured fuel
pressure. Signal voltage should be between 2.5 and 3.5 volts.
The FP signal provides inputs to the Electronic Control Module (ECM) for fuel control.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage and test by moving the FP
connector and harness.
• The scan tool reads fuel pressure in voltage relative to the pressure regulator setting.
With ignition ON, engine OFF, the voltage should be 2.5-3.5 volts.
• If DTC 62 is also set, check for a short to ground in CKT 416.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 61 (2 of 3) Fuel Pressure (FP) Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 7.
a. Ignition ON.
Does scan tool indicate fuel pressure sensor voltage
Step 6. Step 4.
3. greater than 4 volts?
Does scan tool indicate fuel pressure sensor voltage
Step 5. Step 4.
less than .3 volts?
Code 61 is intermittent, refer to “Diagnostic Aids” on
4. – –
facing page.
a. Ignition OFF.
b. Disconnect fuel pressure sensor electrical connector.
Jumper fuel pressure sensor harness terminals “B” and
5. “C” together.
c. Ignition ON.
Does scan tool indicate fuel pressure sensor voltage
Step 15. Step 7.
greater than 4 volts?
a. Ignition OFF.
b. Disconnect fuel pressure sensor connector.
6.
c. Ignition ON.
Does scan tool indicate voltage over 4 volts? Step 13. Step 7.
a. Ignition ON.
b. Connect DVOM from harness terminal “B” (5 volt refer-
7.
ence to harness terminal “A” (sensor ground).
Is voltage reading over 4 volts? Step 8. Step 11.
Connect DVOM from harness terminal “B” (CKT 416) to
harness terminal “C” (fuel pressure sensor signal, CKT
8. 475).
Is voltage reading over 4 volts? Step 9. Step 10.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 61 (3 of 3) Fuel Pressure (FP) Circuit

Step Action Yes No
PROCEED TO
a. Ignition OFF.
b. Connect a test light to battery positive (B+).
9. c. Touch test light to harness terminal “C” (fuel pressure
sensor signal).
Is test light on? Step 12. Step 15.
Connect DVOM between harness terminal “C” and en-
10. gine ground (–).
Is voltage reading over 4 volts? Step 13. Step 14.
Connect DVOM from fuel pressure sensor harness termi-
11. nal “B” to a good ground on engine.
Is voltage reading over 4 volts? Step 18. Step 17.
a. Disconnect ECM.
b. Touch test light to harness terminal “C” (fuel pressure
12.
sensor signal).
Is test light on? Step 16. Step 14.
13. Check for CKT 475 shorted to voltage. – –
Locate and repair open in CKT 475 or faulty connection
14. – –
at ECM.
15. Replace fuel pressure sensor. – –
16. Check for CKT 475 shorted to ground. – –
CKT 416 open or shorted to ground or faulty connection
17. – –
at ECM.
18. CKT 813 open or faulty connection at ECM. – –

Page 5I-86 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 62 (1 of 3) Fuel Pressure (FP) Sensor Circuit

ECM
MEFI 3
B
B
416 GRY
J2-3
C C 475 GRN J2-26
A 813 BLK J2-4
A

CIRCUIT DESCRIPTION:
The fuel pressure (FP) Sensor provides a voltage signal that changes with measured fuel
pressure. Signal voltage should be between 2.5 and 3.5 volts.
The FP signal provides inputs to the Electronic Control Module (ECM) for fuel control.

DIAGNOSTIC AIDS:
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or damaged terminals, and poor ter-
minal to wire connection.
• Damaged harness. Inspect the wiring harness for damage and test by moving the FP
connector and harness.
• The scan tool reads fuel pressure in voltage relative to the pressure regulator setting.
With ignition ON, engine OFF, the voltage should be 2.5-3.5 volts.
• If DTC 61 is also set, check for a short to ground in CKT 416.
After repairs, clear DTC following “Clearing Trouble Codes” procedure at the front of this
section. Failure to do so may result in DTC not properly being cleared.

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DIAGNOSTICS SERVICE MANUAL NUMBER 25

Code 62 (2 of 3) Fuel Pressure (FP) Sensor Circuit

Step Action Yes No
PROCEED TO
Was the “On-Board Diagnostic” (OBD) System Check
1. Step 2. OBD
Performed?
2. Are you using a Scan Tool? Step 3. Step 7.
a. Ignition OFF.
3. Does scan tool indicate fuel pressure sensor voltage
Step 4. Step 6.
less than .30 volt?
a. Ignition OFF
b. Disconnect fuel pressure sensor harness connector.
4. c. Connect a jumper wire from harness terminal “B” CKT
416 to harness terminal “C” CKT 475.
d. Ignition ON, engine OFF.
Does scan tool indicate fuel pressure sensor voltage
Step 9. Step 5.
greater than 4 volts?
a. Ignition OFF.
b. Connect DVOM from harness terminal “B” (CKT 416) to
5.
a known good ground.
Does DVOM indicate a voltage greater than 4 volts? Step 10. Step 11.
Trouble code 62 is intermittent. Locate and repair inter-
6. – –
mittent faulty connections. Refer to “Diagnostic Aids.”
a. Switch CodeMate Tester to the normal mode.
b. Ignition OFF.
c. Disconnect fuel pressure sensor harness connector.
d. Connect a jumper wire form harness terminal “B” CKT
416 to harness terminal “C” CKT 475.
7. e. Start engine and idle for 2 minutes or until CodeMate
Tester indicates a stored trouble code, whichever oc-
curs first.
f. Ignition ON, engine OFF.
g. Switch CodeMate Tester to “Service Mode” and note
trouble code.
Is trouble code 61 present? Step 9. Step 10.
a. Remove jumper wire from CKT 416 and CKT 475.
b. Connect DVOM from harness terminal “B” CKT 416 to
8.
harness terminal “A” CKT 813.
Is voltage reading above 4 volts? Step 10. Step 11.

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SERVICE MANUAL NUMBER 25 DIAGNOSTICS

Code 62 (3 of 3) Fuel Pressure (FP) Sensor Circuit

Step Action Yes No
PROCEED TO
Locate and repair intermittent faulty connections or re-
9. –
place faulty fuel pressure sensor.
Locate and repair open or short to ground in CKT 475 or Verify
10. –
faulty ECM connections. Repair
Locate and repair open or short to ground in CKT 416 or
11. –
faulty ECM connections.

90-861328--1 NOVEMBER 1999 Page 5I-89

DIAGNOSTICS SERVICE MANUAL NUMBER 25

THIS PAGE IS INTENTIONALLY BLANK

Page 5I-90 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

COOLING SYSTEM
Section 6A - Seawater Cooled Models
Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . 6A-2 Seawater Pump Bearing Housing . . . . . 6A-15
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Disassembly . . . . . . . . . . . . . . . . . . . . . 6A-15
Special Tools . . . . . . . . . . . . . . . . . . . . . 6A-2 Cleaning and Inspection . . . . . . . . . . . 6A-16
Lubricants / Sealants / Adhesives . . . . . 6A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . 6A-17
Specifications . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Water Circulating Pump . . . . . . . . . . . . . . 6A-20
Seawater Inlet Recommendations . . . . . 6A-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . 6A-20
Transom Mounted or Through The Hull Cleaning and Inspection . . . . . . . . . . . 6A-20
Seawater Pickups and Hose . . . . . . . 6A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-20
Seacock (Seawater Inlet Valve) . . . . . 6A-4 Drive Belt Tension Adjustment . . . . . . . . 6A-21
Sea Strainer . . . . . . . . . . . . . . . . . . . . . 6A-4 Flushing Seawater Cooling System . . . . 6A-21
Seawater Pickups . . . . . . . . . . . . . . . . . . . 6A-5 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Through The Hull Mounted . . . . . . . . . 6A-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Transom Mounted . . . . . . . . . . . . . . . . 6A-6 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-22
Quicksilver Sea Strainer . . . . . . . . . . . . . . 6A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Auxiliary Hot Water Heater
Cleaning and Inspection . . . . . . . . . . . 6A-9 Installation Information . . . . . . . . . . . . . . 6A-24
Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Seawater Flow Diagrams . . . . . . . . . . . . . 6A-28
Seawater Pickup Pump . . . . . . . . . . . . . .
Output Test . . . . . . . . . . . . . . . . . . . . . .
6A-11
6A-11
MCM 262 cid / 4.3L Alpha . . . . . . . . .
MCM 262 cid / 4.3L Bravo . . . . . . . . .
6A-28
6A-29 6
Disassembly . . . . . . . . . . . . . . . . . . . . . 6A-13 Draining Diagrams . . . . . . . . . . . . . . . . . . 6A-30 A
Reassembly . . . . . . . . . . . . . . . . . . . . . 6A-14 MCM 262 cid / 4.3L Alpha . . . . . . . . . 6A-30
MCM 262 cid / 4.3L Bravo . . . . . . . . . 6A-31

90-861328--1 NOVEMBER 1999 Page 6A-1

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Alternator Brace to Alternator 192 28
Alternator Mounting Bracket
Alternator Brace to Block
Alternator/Power Steering Pump Mounting Bracket
Power Steering Pump Bracket
Seawater Pump Brace
30 41
Seawater Pump Bracket To Block
Seawater Pump Cover
Thermostat Cover
Thermostat Housing
Thru-Hull Pickup Nut
Alternator To Mounting Bracket
35 48
Water Circulating Pump
Seawater Pump Clamping Screw On Casting Bracket
20 27
Water Temperature Sender
Drain Plug (Note)
Hose Clamps
Securely
Petcocks
Pulleys

NOTE: Coat threads with Quicksilver Perfect Seal before installing.

Tools
Description Part Number
Universal Puller Plate 91-37241
Quicksilver Flushing Attachment 44357A2

Special Tools
Description Part Number
Kent-Moore Tools, Inc.
29784 Little Mack
Roseville, MI 48066
Phone: (313) 574-2332
Pulley Puller (Kent Moore) J-25034-C

Page 6A-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver Loctite 27131 92-809820
Quicksilver Perfect Seal 92-34227--1
Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Quicksilver High Performance Gear Lube 92-816026A2
Quicksilver Liquid Neoprene 92-25711--3
Quicksilver Special Lubricant 101 92-13872A1
Silicone Sealant Or Equivalent
Shell Alvania No. 2 Grease
Obtain Locally
Loctite Pipe Sealant with Teflon
Marine Caulking

Specifications
Cooling System Capacity 15 qts (14 l)
Thermostat 160° F (71° C)

90-861328--1 NOVEMBER 1999 Page 6A-3

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

Seawater Inlet Recommendations

Transom Mounted or Through The Hull Seawater Pickups and Hose
Water pickup must be large enough to permit sufficient water flow to engine seawater pickup
pump for adequate engine cooling [30 gal/min (114 l/min) minimum]. Pickup also must
supply a positive head while underway.

CAUTION
Do not install water pickup directly in line with propeller, as pickup may create
turbulence and allow air to flow into the “propeller slipstream.” This will cause
propeller ventilation and will adversely affect boat performance.
Water pickup should be located as close to seawater pickup pump inlet as possible and in
an area where an uninterrupted, solid stream of water will flow past when boat is underway.
Connect water pickup to seawater pickup pump inlet with 1-1/4 in. (32 mm) I.D. wire
reinforced hose of adequate wall thickness to prevent it from collapsing from pump suction.
Be sure to secure hose connections with hose clamps.
Seacock (Seawater Inlet Valve)
If a seacock is being used, it must be installed between water pickup and seawater pickup
pump (or sea strainer), to allow operator to shut off the seawater in case of a leak or when
boat is not in use. This will allow the operator to flush or drain the engine, or clean the sea
strainer while boat is in the water. Seacock used must have an internal cross-sectional area
equal to or greater than hose to prevent restricting water flow. Install seacock in an area
where it will be easily accessible and self-supporting to prevent hose fatigue.

d 70355
c
Seacock (With Through The Hull Pickup Shown)
a - Hose Connector [1-1/4 in. (32mm) I.D.] to Seawater Pump Inlet
b - Seacock [1-1/4 In. (32mm)] Brass Ball or Gate Valve
c - Seawater Pickup
d - Direction of Seawater Flow

Sea Strainer
If boat is equipped with a sea strainer, it must be of sufficient size to ensure that an adequate
supply of water is maintained for engine cooling. 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 water inlet valve to allow operator to shut off water when cleaning strainer.

Page 6A-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

Seawater Pickups
NOTICE
Refer to manufacturer’s 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

a 72639

a - Seawater Pickup
b - Seawater Inlet Slots
c - Mounting Screw Holes (If Equipped)
d - Nut

1. Seal inside edges of 1-3/4 in. (44 mm) hole in hull using a suitable sealer.
2. Apply marine caulking (sealer) to mounting surface on seawater pickup where hull con-
tact will occur when installed.
IMPORTANT: Seawater inlet slots must face forward - parallel with the flow of water.
3. Ensure slots in seawater pickup are facing forward (toward bow of boat) and install sea-
water pickup through hull.
4. Fasten pickup with four appropriate mounting screws (if equipped).
5. Apply marine caulking as needed inside boat. Apply Loctite 27131 to threads of nut and
install on pickup on inside of boat and torque nut to 35 lb-ft (42 Nm).
NOTE: If pickup being installed does not have mounting screws on underside where
mounted to hull, be certain, after nut is torqued, that slots are still facing forward.

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SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

Transom Mounted
(Quicksilver Part Number: 88845A1)
a b
c
d
e
f

g
h

i
j 72640

Seawater Pickup Installation

a - Hose Fitting
b - Nuts (4)
c - Gasket - Between Pickup and Transom
d - O-Ring (4)
e - Washer (4)
f - Screw (4)
g - Plastic Plug
h - Pickup
i - Screen
j - Screw

1. Seal the inside edges of the 1-1/2 in. (38 mm) hole for hose fitting.
2. Be certain hose fitting and plastic plug are in place and threads have been sealed with
Loctite Pipe Sealant with Teflon prior to tightening each securely.
3. Position one flat washer and one rubber O-ring on each 5/16 in. x 4 in. (102 mm) long,
round head screw as shown. Coat each screw shaft with silicone sealant or equivalent.
4. Place new gasket on pickup housing and hold pickup in place on transom. Install four
round head screws (with washers and O-rings in place) into pickup mounting holes and
through drilled 21/64 in. (8.5 mm) holes in transom.

Page 6A-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

NOTE: Some installations may have 7/32 in. (5.5 mm) holes drilled in transom using four
5/16 in. diameter stainless steel lag bolts in place of round head screws. In any case, flat
washers and O-rings are required as outlined.

a
b

72641

Water Pickup Installed on Transom

a - Diagonal Mount - Leading Edge of Pickup 1/8 in. (3mm) from Boat Bottom
b - Vertical Mount - Corner of Leading Edge of Pickup 1/8 in. (3mm) from Boat
Bottom

5. Secure water pickup from inside with locknuts and washers (unless using lag bolts).
6. Tighten fasteners securely.

Quicksilver Sea Strainer

NOTICE
Refer to manufacturer’s instructions for information on removal and installation of
other than Quicksilver Sea Strainer

Removal
CAUTION
If boat is in water while working on seawater strainer, close seacock, if so equipped.
If boat is not equipped with a seacock, remove and plug seawater inlet hose to
prevent a siphoning action that may occur, allowing seawater to flow from the drain
holes or removed hoses and enter boat.
IMPORTANT: Be certain engine is off and cooling system is cold.
1. Models Equipped with Seacock:
a. Close seacock (seawater inlet valve).
b. Disconnect seawater inlet hose from seawater strainer.
a

b
72691
a - Seawater Inlet Hose
b - Seawater Strainer

90-861328--1 NOVEMBER 1999 Page 6A-7

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

2. Models without Seacock:

a. Disconnect seawater inlet hose from seawater strainer inlet and plug seawater inlet
hose.

a 70062
b c d

a - Seawater Inlet Hose

b - Seawater Strainer
c - Seawater Strainer Inlet
d - Plug

3. Remove outlet hose.

4. Drain into a suitable container.

a
b
72643
a - Seawater Inlet Hose
b - Seawater Strainer

5. Remove mounting bolts.

6. Remove strainer.

Page 6A-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

Cleaning and Inspection

1. Remove and clean filter element.
2. Remove drain plug
b a
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 components with clean water.

Installation
IMPORTANT: Mount seawater strainer in a vibration-free location. Never mount it on
the engine or transmission. Hoses must not be kinked or allowed to come in contact
with hot or moving engine or transmission parts.
1. Mount seawater strainer. Arrow indicates required water flow direction and must point
toward seawater pump. Tighten mounting bolts securely.
b

a
c c
72644
a - Seawater Strainer
b - Arrow
c - Mounting Bolt Hole Location (Bolts Not Shown)

90-861328--1 NOVEMBER 1999 Page 6A-9

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

2. Remove plug from seawater inlet hose (if installed previously) and install hose on
strainer. Install seawater outlet hose. Use two hose clamps on each hose connection.
Tighten clamps securely.

c c
b

a
72645

a - Seawater Inlet Hose

b - Seawater Outlet Hose
c - Double Hose Clamps

3. Check drain plug and lens cover bolts. Tighten securely. Do not overtighten cover bolts
or cover may warp and leak water into boat.

72644

a - Drain Plug
b - Lens Cover Bolts (2, One Hidden In This View)

4. Open seacock, if equipped.

Page 6A-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

Seawater Pickup 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
test:
• 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% 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 with-
in one second. An 8 U.S. qt. (7.6 l) or larger capacity container should be used to
measure 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.
1. Models With Engine Mounted Seawater Pump - remove water hose, which runs be-
tween pump outlet and engine, and replace with another hose of same diameter, but
approximately 3 ft (1 m) longer. Hose should be of adequate wall thickness to prevent
it from kinking when performing test. Clamp hose at pump outlet only. Do not clamp hose
at engine end.

b
75533
a

a - Seawater Inlet Hose

b - Hose To Cooler

90-861328--1 NOVEMBER 1999 Page 6A-11

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

2. Models With Sterndrive (Alpha) Mounted Seawater Pump - remove water inlet hose,
which runs between gimbal housing water tube and engine, and replace with another
hose of same diameter, but approximately 3 ft (1 m) longer. Hose should be of adequate
wall thickness to prevent it from kinking when performing test. Clamp hose at gimbal
housing water tube only. Do not clamp hose at engine end.

b
a 72614

a - Water Tube
b - Hose Clamp
c - Water Hose

3. Place an 8 U.S. qt. (7.6 l) or larger container near unclamped end of hose.
4. With assistance of another person, start engine and adjust speed to exactly 1000 rpm
while holding unclamped end of hose on connection on engine. Remove hose from con-
nection on engine and direct water flow into container for exactly 15 seconds. At the end
of 15 seconds, direct the water flow overboard, return engine to idle and stop engine.
Reconnect hose to engine.
5. Measure quantity of water discharged into container and compare with specifications
given in the following chart.
6. Repeat test four times to check repeatability of results.

Engine Mounted Seawater Pump Output for a 15 Second Period

7.5 U.S. qt. (7.1 l) Minimum

Alpha Sterndrive Seawater Pump Output for a 15 Second Period

Drive Unit Gear Ratio Minimum Quantity
U.S. qts.(l)
1.98:1 3.0 (2.8)
1.84:1 3.3 (3.1)
1.65:1 3.6 (3.4)
1.50:1 4.0 (3.8)
1.32:1 4.5 (4.3)

NOTE: Refer to Alpha Sterndrive Service Manual for repair of seawater pump.

Page 6A-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

Disassembly
1. Remove the five screws from the seawater pump body.

a
b 75277

a - Screws (5)
b - Seawater Pump Body

2. Remove seawater pump body and wear plate from bearing housing.

c
b
75275
a d
a - Seawater Pump Body
b - Wear Plate
c - Bearing Housing

3. Remove the impeller from seawater pump body.

90-861328--1 NOVEMBER 1999 Page 6A-13

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

Reassembly
1. Lubricate seawater pump impeller with a water and soap solution. Install impeller into
housing by rotating and pushing it into place. Push it down until flush with housing.

71118

71150

a - Impeller

2. Place wear plate over bearing housing shaft.

3. Place quad ring in groove in seawater pump body.

a b

a - Quad Ring
b - Seawater Pump

4. Align flats on impeller and bearing housing shaft, slide seawater pump body on shaft.
NOTE: Reassembly of the pump requires the mounting bracket to be installed while per-
forming the following step.
5. Install two screws in seawater pump body holes as shown. Use these two screws to align
pump, then install the remaining screws.

a 75277

a - Bolt Holes For Alignment

Page 6A-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

Seawater Pump Bearing Housing

Disassembly
1. Remove gasket, inner wear plate and quad ring seal. Discard gasket and quad ring seal.

a
a 72655 72656

a - Quad Ring Seal

2. Press hub off shaft with Universal Puller Plate and an arbor press.

72648

a - Universal Puller Plate (91-37241)

3. Puncture front oil seal with a tool and pry from bearing housing.

72649

90-861328--1 NOVEMBER 1999 Page 6A-15

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

4. Remove snap ring from bearing housing bore and press shaft and bearings out pulley
end of housing. Bearings have a slip fit in housing; do not use excessive force.

72657 72658
a - Snap Ring

5. If bearings require replacement, remove bearings from shaft with Universal Puller Plate
and an arbor press. Bearings must be replaced, if removed.

72659

6. If rear seals require replacement, press seals from bearing housing with an appropriate
tool.
Cleaning and Inspection
1. Clean metal parts in solvent and blow dry with compressed air.
IMPORTANT: Do not spin bearings at high speed when drying with compressed air,
as bearings may be scored.
2. After cleaning, apply a coat of light engine oil to shaft and bearings to prevent rust.
3. Clean all gasket material and sealer from sealing surfaces.
4. Inspect bearing housing. Examine surfaces (where bearings contact housing) for evi-
dence of bearing outer races turning in housing.
5. Inspect seals in bearing housing.
6. Inspect pump shaft bearings.
7. Inspect pump shaft for grooves in surface where seals contact shaft. Also inspect sur-
face where bearings contact shaft for evidence of inner races turning on shaft.
8. Inspect pump body.
9. Inspect inner and outer wear plate.
10. Inspect pump impeller for wear on sides and tips of blades. Also inspect blades for
cracks in area where blades flex. Replace impeller if blades have taken a set (remain
in curved position).
11. Inspect pump pulley.
12. Check drive belt for excessive wear.

Page 6A-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

Reassembly
1. Apply a thin coat of Loctite 27131 to outside diameter of two new bearing housing rear
seals; then install seals in housing with seal lips facing impeller end. Press first seal in
until it bottoms out and second seal in until flush with housing.

a
b

72660

a - Outer (Water) Seal

b - Face of Housing

IMPORTANT: It is recommended that Shell Alvania No. 2 Grease be used when pack-
ing seal and bearings in the following steps. If Shell Alvania No. 2 Grease is not avail-
able, it is permissible to use Quicksilver 2-4-C With Teflon. However, Quicksilver
2-4-C Marine Lubricant With Teflon is not recommended for applications where con-
tinuous high speed heavy-duty operation will be encountered.
2. Pack cavity between seals with Shell Alvania No. 2 Grease or substitute.
3. Using an arbor press and suitable tool, press ball bearings onto shaft until they seat.
Press on inner race of bearing only.

a 72663
a - Bearings

90-861328--1 NOVEMBER 1999 Page 6A-17

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

4. Pack bearings and cavity between bearings with Shell Alvania No. 2 Grease or substi-
tute. Slide bearings and shaft into bearing housing bore and install snap ring.
a

72661

a - Shaft With Bearings

72658
a - Snap Ring

5. Apply a thin coat of Loctite 27131 to outside diameter of new bearing housing front oil
seal and press seal into housing (with seal lip facing inward) until it bottoms out.

72662

a - Front Oil Seal

IMPORTANT: Be sure to support impeller end of pump shaft when installing pulley
hub in next step to prevent placing a load on bearings.

Page 6A-18 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

6. Apply Quicksilver Special Lubricant 101 to pump shaft. Using an arbor press and appro-
priate tool, press pulley hub onto pump shaft to dimension shown.

72664
a - .260 Inch (6.6 mm)

IMPORTANT: Pulley hub must be pressed onto shaft to exact dimension on pumps
with stamped steel mounting bracket as this establishes proper drive belt alignment.
7. Clamp bearing housing in a soft jaw vise with flange end up.
8. Coat quad ring seal with Quicksilver 2-4-C Marine Lubricant With Teflon and install into
groove in housing.

a
72655

a - Quad Ring Seal

9. Place the wear plate over the bearing housing.

72660

a - Bearing Housing
b - Wear Plate

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SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

Water Circulating Pump

Removal
1. Drain water from cylinder block.
2. Break loose circulating pump pulley attaching bolts. Do not remove bolts at this time.
3. Loosen alternator tensioner pulley, then pivot alternator inward and remove the serpen-
tine drive belt.
4. Remove pump pulley attaching bolts, lockwashers, clamping ring (if equipped) and
pulley.
5. Disconnect hose(s) from pump.
6. Remove bolts, which secure pump to cylinder block, and remove pump and old gaskets
(discard gaskets).

Cleaning and Inspection

1. Clean gasket surfaces on water pump and cylinder block.
2. Inspect water pump for blockage, cracks, sand holes, corrosion or other damage.
Inspect pump impeller for cracks and erosion. Replace complete pump if any damage
exists.
3. Check impeller shaft and bearings for excessive side play. If play can be felt, replace
complete pump.
4. Inspect pump pulley for bends, cracks, corrosion or other physical damage. Inspect
pulley for rotational trueness. Replace pulley if damaged or untrue.

Installation
1. Coat both sides of new circulating pump gasket with Quicksilver Perfect Seal, then posi-
tion gaskets and circulating pump on cylinder block. Coat threads of circulating pump
attaching bolts with Quicksilver Perfect Seal and install bolts and alternator brace (if
applicable). Torque bolts to specifications.
2. Reconnect hoses to pump.
3. Install pump pulley and clamping ring (if used) on pump hub and secure with bolts and
lockwashers. Tighten bolts securely.
4. Install drive belts and adjust tension as outlined in “Drive Belt Tension Adjustment.”
5. Start engine and check for leaks.

Page 6A-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

Drive Belt Tension Adjustment

NOTICE
Refer to SECTION 1B - “Maintenance”

Flushing Seawater Cooling System

NOTICE
Refer to SECTION 1B - “Maintenance”

Thermostat
Removal
1. Drain water from cylinder block and exhaust manifolds.
2. Remove thermostat housing and related components.
3. Remove thermostat from thermostat housing or cover.

b
c

e
71758
a - Housing
b - O-Ring
c - Thermostat (Stainless Steel)
d - Spacer
e - Gasket

90-861328--1 NOVEMBER 1999 Page 6A-21

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

Testing
1. Clean thermostat in soap and water to remove any deposits or debris.
2. Inspect thermostat for corrosion or other visible damage.
3. If thermostat is suspected of producing insufficient engine temperature, check thermo-
stat for leakage by holding it up to a lighted background. Light leakage around the ther-
mostat valve indicates that thermostat is not closing completely and should be replaced.
(A small amount of leakage at one or two points around the valve perimeter is accept-
able.)

72717

a
a - Check For Light Leakage Around Perimeter Of Valve

4. Check opening and closing temperature of thermostat (using a tester similar to the one
shown) as follows:
a. Fill tester to within 1 in. (25 mm) of top with tap water. Do not use distilled water.
b. Open thermostat valve and insert nylon string. Position thermostat on string so that
it will be just below water level when suspended, then allow valve to close. Suspend
thermostat in water.
c. Place thermometer in container and position so that bottom of thermometer is even
with bottom of thermostat. Do not allow thermometer to touch container.
a

72675
a - Thermometer
b - Nylon String
c - Thermostat

IMPORTANT: When performing procedures d. - f. water must be agitated thoroughly

to obtain accurate results.
d. Plug in tester and observe temperature at which thermostat opens (thermostat
drops off thread). Thermostat must open at specified temperature stamped on ther-
mostat.
e. Continue to heat water until a temperature 25°F (14°C) above temperature specified
on thermostat is obtained. Thermostat valve must be completely open at this
temperature.

Page 6A-22 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

f. Unplug tester and allow water to cool to a temperature 10°F (5°C) below specified
temperature on thermostat. Thermostat must be completely closed at this tempera-
ture.
g. Replace a thermostat that fails to meet all of the preceding tests.

Installation
1. Clean gasket surfaces on thermostat housing and intake manifold.
IMPORTANT: Gasket has continuity rivets. Do not coat with Quicksilver Perfect Seal,
or Audio Warning Temperature Switch may not work properly.
2. Place O-ring in the thermostat housing. Be certain it is positioned properly in housing.
3. Place thermostat in thermostat housing with thermostatic element end toward housing
bottom, as shown.
4. Align sleeve with groove in thermostat housing bore and install sleeve into housing.
5. Coat both sides of new thermostat housing gasket with Quicksilver Perfect Seal and
position on intake manifold.
6. Reinstall thermostat housing and torque screws with lockwashers to 30 lb-ft (41 Nm).
7. Reconnect hose(s) to thermostat housing. Tighten hose clamps securely.

75846
a - Hoses

8. Start engine and inspect for leaks.

b
c

e 71758

a - Housing
b - O-Ring
c - Thermostat (Stainless Steel)
d - Spacer
e - Gasket

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SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

Auxiliary Hot Water Heater Installation Information

IMPORTANT: When connecting a cabin heater or hot water heater, certain
requirements must be met.
• Supply hose (from engine to heater) and return hose (from heater to engine)
MUST NOT EXCEED 5/8 in. (15.8 mm) I.D. (inside diameter).
• Make heater connections ONLY at locations described in the following
instructions.
• Check complete system for leaks after heater is connected into cooling system.
• Check for overheating condition (of engine) after heater is connected.
1. Hot water heater supply hose can be connected at several different locations. On some
models, there may be other accessories and options that are using these hot water
supply locations. One of the following should be available for use when connecting the
hot water heater system.
NOTE: On some models it may be necessary to remove the audio warning heat switch from
port side of thermostat housing and reposition to water circulating pump opening as outlined
following.
a. Starboard side of thermostat housing, unless being used for engine temperature
switch.

75846

IMPORTANT: Do not reposition engine temperature switch, it must remain where

installed by factory.

Page 6A-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

b. Intake manifold near thermostat housing (some models).

72708

Intake Manifold (If Engine Temperature Sender is Not Installed at This Location)

74973

Engines with Raw Water Cooling - If Location is Available

a - Location for Hot Water Supply

71758

Raw Water Cooling Models - Alternate Location

a - Location for Hot Water Supply (Install Bayonet Fitting Here)

90-861328--1 NOVEMBER 1999 Page 6A-25

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

2. Connect hot water heater SUPPLY hose to desired location following instructions:
a. Remove pipe plug.
b. Coat threads of fitting(s) (obtained locally) with Quicksilver Perfect Seal and install
fitting(s) in threaded hole from which pipe plug was removed.
c. Connect hot water heat supply hose to fitting and secure with a hose clamp (not
provided).

75480

a - Location for Hot Water Return

3. Connect hot water heater return hose into system as follows (refer to figures):
a. Cut approximately 3/4 in. (19 mm) out of hose to maintain proper hose configuration.

72587

a - Cut Here

Page 6A-26 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

b. Secure T-fitting in hose with hose clamps (provided in kit) and tighten securely.

75859

Typical
a - T-Fitting

c. Connect hot water heater return hose to T-fitting and secure with hose clamp
(provided).
4. Secure hoses, as required, to ensure they do not rub or chafe against engine
components.
5. With boat in water, start engine and check for leaks and overheating.

90-861328--1 NOVEMBER 1999 Page 6A-27

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

Seawater Flow Diagrams

MCM 262 cid / 4.3L Alpha
NOTE: Certain components in the following diagram may look different than on your
particular power package, but the water and coolant flow paths remain similar on all
engines.

6
10

4
9

3 7

75854

1 - Seawater Intake (From Sterndrive)

2 - Power Steering Cooler
3 - Fuel Cooler - EFI Models
4 - Thermostat Housing Assembly
5 - Engine Water Circulating Pump
6 - Engine Block and Cylinder Head Assembly
7 - Exhaust Manifold, Typical
8 - Gasket
9 - Exhaust Elbow Assembly, Typical
10 - Water Flow Overboard

Page 6A-28 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

MCM 262 cid / 4.3L Bravo

NOTE: Certain components in the following diagram may look different than on your
particular power package, but the water and coolant flow paths remain similar on all
engines.
1

2 7
11

10

4
8

75861

1 - Seawater Intake(From Through The Hull or Through The Transom Pickup)

2 - Seawater Pump
3 - Power Steering Cooler
4 - Fuel Cooler EFI Models
5 - Thermostat Housing Assembly
6 - Engine Water Circulating Pump
7 - Engine Block and Cylinder Head Assembly
8 - Exhaust Manifold, Typical
9 - Gasket
10 - Exhaust Elbow Assembly, Typical
11 - Overboard (Water and Exhaust Discharge)

90-861328--1 NOVEMBER 1999 Page 6A-29

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

Draining Diagrams
MCM 262 cid / 4.3L Alpha
Two Piece Manifold, One Piece Similar

b
c

a
75854

a Remove Hoses (Lift, Lower or Bend To Completely Drain).

-
b Remove Block Plugs (Repeatedly Clean Out Holes Using A Stiff Wire Until
-
Entire System Is Drained).
c - Remove Drain Plugs From Exhaust Exhaust Manifold Drain Elbows and Fuel
Cooler or Water Tube (Repeatedly Clean Out Holes Using A Stiff Wire Until
Entire System Is Drained)

Page 6A-30 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 SEAWATER COOLED MODELS

MCM 262 cid / 4.3L Bravo

Two Piece Manifold, One Piece Similar

b
c
a

a
c

74818

a Remove Hoses (Lift, Lower or Bend To Completely Drain).

-
b - Remove Block Plugs (Repeatedly Clean Out Holes Using A Stiff Wire Until
Entire System Is Drained).
c - Remove Drain Plugs From Exhaust Exhaust Manifold Drain Elbows and Fuel
Cooler or Water Tube (Repeatedly Clean Out Holes Using A Stiff Wire Until
Entire System Is Drained)

90-861328--1 NOVEMBER 1999 Page 6A-31

SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 25

THIS PAGE IS INTENTIONALLY BLANK

Page 6A-32 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

COOLING SYSTEM
Section 6B - Closed Cooled Models
Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . 6B-2 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Lubricants / Sealants / Adhesives . . . . . 6B-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-11
Closed Cooling System Capacity . . . 6B-2 Installation . . . . . . . . . . . . . . . . . . . . . . . 6B-12
Coolant Specification . . . . . . . . . . . . . . 6B-2 Changing Coolant . . . . . . . . . . . . . . . . . . . 6B-13
Thermostat . . . . . . . . . . . . . . . . . . . . . . 6B-2 Closed Cooling Section . . . . . . . . . . . . 6B-13
Pressure Cap Rating . . . . . . . . . . . . . . 6B-2 Change Intervals . . . . . . . . . . . . . . . . . 6B-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3 Draining Instructions . . . . . . . . . . . . . . 6B-13
Coolant Recommendations . . . . . . . . . . . 6B-3 Cleaning System . . . . . . . . . . . . . . . . . . . . 6B-14
Maintaining Coolant Level . . . . . . . . . . . . 6B-3 Closed Cooling Section . . . . . . . . . . . . 6B-14
Pressure Cap Maintenance . . . . . . . . . . . 6B-4 Seawater Section . . . . . . . . . . . . . . . . . 6B-15
Heat Exchanger Repair . . . . . . . . . . . . . . 6B-5 Filling Closed Cooling Section . . . . . . . . 6B-16
Testing Closed Cooling System . . . . . . . 6B-6 Auxiliary Hot Water Heater Installation . 6B-18
Testing Coolant for Alkalinity . . . . . . . 6B-6 Heat Exchanger Bracket Hardware . . . . 6B-19
Pressure Testing System . . . . . . . . . . 6B-6 Heat Exchanger Hose Connections . . . . 6B-20
Testing for Cylinder Head Water Flow Diagram . . . . . . . . . . . . . . . . . 6B-21
Gasket Leak . . . . . . . . . . . . . . . . . . . . . 6B-7 MCM 262 cid / 4.3L Alpha . . . . . . . . . 6B-21
Testing Heat Exchanger . . . . . . . . . . .
Testing Pressure Cap . . . . . . . . . . . . .
6B-8
6B-8
MCM 262 cid / 4.3L Bravo . . . . . . . . . 6B-22
6
B

90-861328--1 NOVEMBER 1999 Page 6B-1

CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Heat Exchanger End Cap 36-72 4-8
Thermostat Cover 30 41
Heat Exchanger Mounting Brackets
Hose Clamps Securely
Drain Plugs

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Quicksilver Perfect Seal 92-34227--1
Quicksilver Liquid Neoprene 92-25711--3
Loctite Pipe Sealant With Teflon Obtain Locally

Specifications
Closed Cooling System Capacity
NOTICE
Unit of Measurement: U.S. Quarts (Liters)
All Capacities are approximate fluid measures.

Model All Engines

Seawater Cooling System 15 (14.1)
Closed Cooling System 20 (19)

Coolant Specification
All Models
Extended Life Coolant 5/100 (Orange Color)

Thermostat
Engine Specification
All Engines 160°F (71°C)

Pressure Cap Rating

Engine Specifications
All Engines 16 psi (110 kPa)

Page 6B-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

Description
The cooling system is composed of two separate subsystems: the seawater system and the
closed cooling system. The seawater system is similar in function to the fan used in an auto-
mobile because it absorbs heat from the closed cooling system as it passes through the heat
exchanger. The closed cooling system is similar in function to the rest of the cooling system
in an automobile.
The coolant recovery system keeps the reservoir full. Normal coolant overflow into recovery
bottle is approximately 1/2 pint (230 mL) during warm-up. The coolant recovery system
draws coolant back into the reservoir from the recovery bottle as the engine cools. As long
as there is coolant in the recovery bottle, the reservoir should remain completely full. If not,
there is a vacuum leak, usually at the hose leaving the reservoir or the gasket under the
recovery filler cap.
IMPORTANT: The coolant (antifreeze) flows around the outside of the cooling tubes
while seawater flows through the inside of the cooling tubes in the heat exchanger.

Coolant Recommendations
CAUTION
Alcohol or Methanol base antifreeze or plain water are not recommended for use in
fresh water section of cooling system at any time.
NOTE: All factory installed closed cooling systems come filled with Extended Life Coolant.
This antifreeze requires draining and replacing every five years or 1000 hours of operation,
whichever comes first. For best results any “top-off” fluid used should be Extended Life
Coolant. If Extended Life Coolant is unavailable, any type of ethylene glycol based anti-
freeze may be used, but it will require the draining and replacing of the coolant every two
years or 400 hours of operation, whichever comes first.
In areas where the possibility of freezing DOES NOT exist, it is permissible to use solution
of rust inhibitor and water (mixed to manufacturer’s recommendations).

Maintaining Coolant Level

72520

Coolant Recovery Bottle

a - Fill Cap

90-861328--1 NOVEMBER 1999 Page 6B-3

CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

Before starting engine each day, ensure that coolant is visible in coolant recovery bottle.
If coolant is not visible, check fresh water section of cooling system (including coolant recov-
ery system) for leaks and repair. Refill fresh water section with recommended coolant solu-
tion as outlined under “Changing Coolant,” following.
If coolant is visible, start engine and run until it reaches normal operating temperature, then
recheck coolant level in coolant recovery bottle. Coolant level MUST be between the ADD
and FULL marks (on front of bottle).

WARNING
Allow engine to cool before removing pressure cap. Sudden loss of pressure could
cause hot coolant to boil and discharge violently. After engine has cooled, turn cap
1/4 turn to allow any pressure to escape slowly, then push down and remove cap.
If level is low, remove fill cap from coolant recovery bottle and add required amount of cool-
ant solution. Refer to “Coolant recommendations” in this section.
IMPORTANT: ALCOHOL OR METHANOL BASE ANTIFREEZE OR PLAIN WATER ARE
NOT RECOMMENDED FOR USE IN COOLING SYSTEM AT ANY TIME. In areas where
ethylene glycol is not available, and the possibility of freezing does not exist, it is
permissible to use a solution of rust inhibitor and pure, soft water (mixed to
manufacturer’s recommendations).
Occasionally, ensure that coolant recovery system is functioning properly by removing
pressure cap from heat exchanger and checking level. Coolant level should be up to bottom
of heat exchanger filler neck. If low, examine entire fresh water section (especially coolant
recovery system) for leaks and repair.
IMPORTANT: When reinstalling pressure cap, tighten it until it contacts on filler neck.

Pressure Cap Maintenance

Pressure cap should maintain pressure in fresh water section of closed cooling system at
normal engine operating temperature. This raises the boiling point of the coolant, thereby
increasing the efficiency of the cooling system. To help ensure proper operation, cap should
be cleaned, inspected and pressure tested periodically as follows:

WARNING
Allow engine to cool before removing pressure cap. Sudden loss of pressure could
cause hot coolant to boil and discharge violently. After engine has cooled, turn cap
1/4 turn to allow any pressure to escape slowly, then push down and turn cap all the
way off.
1. Remove pressure cap from heat exchanger.
2. Wash cap with clean water to remove any deposits or debris from sealing surfaces.
3. Inspect rubber seal on cap for cuts, cracks or other signs of deterioration. If seal is dam-
aged, cap MUST be replaced.
4. Inspect coolant recovery gasket for deterioration and replace if bad.

Page 6B-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

5. Check condition of locking tabs on cap. Replace cap if tabs are bent or cracked.
6. Check gasket for cracks or other damage.
IMPORTANT: Cap MUST be replaced if damaged.

c a

72714

a - Rubber Seal
b - Gasket
c - Locking Tabs (1 Hidden)

7. Test pressure cap. Refer to “Testing Pressure Cap.”

8. Clean sealing surfaces on heat exchanger filler neck with a cloth. Inspect surfaces for
any damage or deposits that may prevent cap from sealing properly.
9. Clean coolant recovery passage in heat exchanger filler neck with a wire and blow out
with compressed air.

72715

a - Sealing Surfaces
b - Coolant Recovery Passages

10. Reinstall pressure cap. Tighten cap until it contacts filler neck.

Heat Exchanger Repair

IMPORTANT: Braze with BCUP 2 rod or silver solder. Care must be taken not to melt
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 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.

90-861328--1 NOVEMBER 1999 Page 6B-5

CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

Testing Closed Cooling System

Testing Coolant for Alkalinity
WARNING
Allow engine to cool before removing pressure cap as sudden loss of pressure
could cause hot coolant to boil and discharge violently. After engine has cooled,
turn cap 1/4 turn to allow any pressure to escape slowly, then push down and turn
cap all the way off.
Coolant in fresh water section should be changed per Maintenance Schedule recommenda-
tions and should be checked for alkalinity at least once between change intervals. To check
coolant for alkalinity, proceed as follows:
1. Obtain pink litmus paper from a local supplier (drug store, pet shop, etc.).
2. Remove pressure cap from heat exchanger and insert one end of litmus paper into cool-
ant.
3. If pink litmus paper turns blue, coolant is alkaline and need not be replaced.
4. If pink litmus paper remains pink, coolant is not alkaline and MUST BE REPLACED,
as explained under “Changing Coolant.”
Pressure Testing System
WARNING
Allow engine to cool before removing pressure cap. Sudden loss of pressure could
cause hot coolant to boil and discharge violently. After engine has cooled, turn cap
1/4 turn to allow any pressure to escape slowly, then push down and turn cap all the
way off.
If coolant section of closed cooling system is suspected of leaking or not holding sufficient
pressure, and no visible signs of leakage can be found, perform the following test:
1. Remove pressure cap from heat exchanger or reservoir.
2. Clean, inspect and pressure test pressure cap, as outlined in “Testing Pressure Cap.”
3. Clean inside of filler neck to remove any deposits or debris. Examine lower inside seal-
ing surface for damage. Surface must be perfectly smooth to achieve a good seal be-
tween it and rubber seal on cap. Also check locking cams on sides of filler neck to be
sure that they are not bent or damaged.
4. Adjust coolant level in fresh water section to 1 in. (25 mm) below filler neck.
5. Attach an automotive-type cooling system pressure tester to filler neck and pressurize
closed cooling section to amount specified in following chart.

Pressure Cap Rating Amount of Pressure Applied to Closed Cooling System

16 psi (110 kPa) 20 psi (138 kPa)

6. Observe gauge reading for approximately two minutes; pressure should not drop during
this time. If pressure drops, proceed with the following steps until leakage is found.
7. While maintaining specified pressure on closed cooling section, visually inspect exter-
nal portion of cooling system (hoses, gaskets, drain plugs, petcocks, core plugs, circu-
lating pump seal, etc.) for leakage. Also listen closely for bubbling or hissing.
8. Refer to “Testing Heat Exchanger” in this section and test as outlined.

Page 6B-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

9. If no leakage could be found in above steps, engine is leaking internally. Leaking may
be caused by one or more of the following:
• loose cylinder head bolts or damaged gasket,
• loose intake manifold bolts or damaged gasket,
• loose exhaust elbow or distribution block retaining nuts or damaged gasket,
• cracked or porous cylinder head or block, or
• cracked or porous exhaust manifold.
Proceed as follows until location of internal leak is found.
a. Start engine. Re-pressurize system to previously specified amount and observe
pressure gauge on tester. If needle in gauge vibrates, compression or combustion
is leaking into closed cooling section from a leak in the combustion chamber. Exact
cylinders where leakage is taking place can sometimes be found by removing spark
plug wires (one at a time) while observing pressure gauge. Vibration will decrease
or stop when plug wire is removed from leaking cylinder. Stop engine.
b. Remove spark plugs (one at a time) from cylinders and examine for presence of
coolant. A spark plug that is perfectly clean or milky appearing is a sure indication
of a leak.
c. Drain oil from engine and examine for coolant. Oil will usually be milky if coolant is
present. If coolant is present, remove engine from boat and drop the oil pan. With
engine in the upright position, re-pressurize closed cooling section to previously
specified amount and examine internal surfaces of engine to locate leak.
d. If no leakage can be found in above steps, entire engine must be disassembled and
inspected for leakage.
Testing for Cylinder Head Gasket Leak
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: Run boat in lake for this test. It is best to run 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 coolant recovery bottle. Use a 2-3
ft. (610-910 mm) long hose for this test.
2. Route this hose so a “U” is formed.
3. Put enough coolant into hose to fill the center 4 or 5 inches (100-130 mm) of the “U.”
4. Observe the “U” while the engine is running.
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 running at a given rpm. A leaking head
gasket will produce air bubbling through the “U,” 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 in b.
above. A failed head gasket will cause the bubbles to come faster and may be
accompanied by violent, intermittent bursts of coolant.

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CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

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.
Testing Heat Exchanger
FOR INTERNAL LEAK: 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 16-20 psi (110-138 kPa) with a radiator tester.
3. If seawater begins to flow from the nipple there is a leak.
FOR BLOCKAGE:
IMPORTANT: Seawater flows THROUGH the tubes in the exchanger. Closed cooling
coolant flows AROUND the tubes.
1. Remove end caps and inspect for any blockage in the seawater circuit (broken impeller
blades, weeds, etc.).
2. Remove 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.
Testing Pressure Cap
Pressure cap is designed to maintain a pressure of approximately its rated capacity (refer
to “Specifications”) in closed cooling section once engine has attained operating tempera-
ture. Cap should be cleaned, inspected and pressure-tested at regular tune-up intervals or
whenever cap is suspected of maintaining improper pressure as follows:

WARNING
Allow engine to cool before removing pressure cap. Sudden loss of pressure could
cause hot coolant to boil and discharge violently. After engine has cooled, turn cap
1/4 turn to allow any pressure to escape slowly, then push down and turn cap all the
way off.
1. Carefully remove pressure cap from reservoir or heat exchanger.
2. Wash cap with clean water to remove any deposits or debris from sealing surfaces.
3. Inspect gasket (if used) and rubber seal on cap for tears, cuts, cracks or other signs of
deterioration. Replace gasket, if damaged, or entire cap if rubber seal is damaged.
4. Check condition of locking tabs on cap. Replace cap if tabs are bent or cracked.

Page 6B-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

IMPORTANT: Cap MUST be replaced if damaged.

c a

72714

a - Rubber Seal
b - Gasket

5. Using a cooling system pressure tester (similar to one shown), test cap to be sure that
it releases at proper pressure and does not leak. (Refer to instructions which
accompany tester for correct test procedure.) Cap must relieve pressure at 16 psi (110
kPa), and must hold rated pressure for 30 seconds without going below 11 psi. Replace
cap if it fails to fall within these limits.

72716

IMPORTANT: Before reinstalling cap in next step, examine lower inside sealing sur-
face in filler neck to ensure that it is perfectly smooth and free of debris. Also, inspect
cam lock flanges on sides of filler neck to be sure that they are not bent.

72715

a - Sealing Surfaces
b - Coolant Recovery Passages

6. Reinstall cap on reservoir or heat exchanger.

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CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

Thermostat
Removal
NOTE: If coolant flow is restricted or fails to occur, a wire should be repeatedly inserted into
all drain holes to ensure there are no obstructions in passages. Remove fitting, if necessary,
to insert wire completely into drain hole.
1. Drain engine block by removing drain plugs. Be sure to drain port and starboard sides.

75052

Starboard Side Shown (Port Side Similar)

a - Hose

2. Disconnect hoses from thermostat cover.

3. Remove thermostat cover attaching bolts and lockwashers, then remove cover and
gasket.
4. Remove thermostat from thermostat housing.

b
c
75746
d
a - Thermostat Housing
b - Thermostat
c - Gasket
d - Thermostat Housing Cover

Page 6B-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

Testing
1. Clean thermostat in soap and water to remove any deposits or debris.
2. Inspect thermostat for corrosion or other visible damage.

75747

3. If thermostat is suspected of producing insufficient engine temperature, check thermo-

stat for leakage by holding it up to lighted background. Light leakage around the thermo-
stat valve indicates that thermostat is not closing completely and should be replaced.
(A small amount of leakage at one or two points around the valve perimeter is accept-
able.)
4. Check opening and closing temperature of thermostat (using a tester similar to the one
shown), as follows:
a. Fill tester to within 1 in. (25 mm) of top with tap water. Do not use distilled water.
b. Open thermostat valve and insert thread. Position thermostat on nylon string so that
it will be just below water level when suspended, then allow valve to close. Suspend
thermostat in water.

b
a

72675

a - Thermometer
b - Nylon String
c - Thermostat (Typical)

c. Place thermometer in container and position so that bottom of thermometer is even

with bottom of thermostat. Do not allow thermometer to touch container.
IMPORTANT: When performing instructions d. and e. water must be agitated thor-
oughly to obtain accurate results.
d. Plug in tester and observe temperature at which thermostat opens (thermostat
drops off thread).
e. Unplug tester and allow water to cool to a temperature 10°F (5°C) below specified
temperature on thermostat. Thermostat must be completely closed at this tempera-
ture.
f. Replace a thermostat that fails to meet all of the preceding tests.

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CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

Installation
CAUTION
Avoid seawater pickup pump impeller damage. DO NOT operate engine without
cooling water being supplied to seawater pickup pump.
1. Remove thermostat housing and gaskets. Discard gaskets.
2. Clean gasket surfaces on thermostat cover, thermostat housing and intake manifold.
3. Position gasket on intake manifold. Place thermostat housing on gasket.
IMPORTANT: If gasket has continuity rivets, do not coat with Quicksilver Perfect Seal,
or audio warning temperature switch may not work properly.
4. Install thermostat, as previously shown, into thermostat housing.
5. Position gasket on thermostat and reinstall thermostat cover. Torque bolts to 30 lb-ft
(41 Nm).

b
c
75746
d
a - Thermostat Housing
b - Thermostat
c - Gasket
d - Thermostat Housing Cover

6. Connect hoses to thermostat cover. Tighten hose clamps securely.

7. With boat in the water and/or cooling water properly supplied to seawater pickup pump,
start engine and inspect for leaks.

Page 6B-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

Changing Coolant
NOTICE
For information and procedures on draining the seawater cooling system of
Seawater Cooled (Rawwater) Models, refer to SECTION 6A. For information and
procedures on draining the Seawater Section of Closed Cooling (Coolant) Models
refer to SECTION 1B. For cold weather or extended storage, refer to SECTION 1B.

Closed Cooling Section

Closed cooling section of closed cooling system should be kept filled year-round with
recommended coolant solution. Do not drain closed cooling section for storage, as this will
promote rusting of internal surfaces. If engine will be exposed to freezing temperatures,
make sure that closed cooling section is filled with Extended Life Coolant or an ethylene
glycol antifreeze and water solution, mixed to manufacturer’s recommended proportions,
to protect engine to lowest temperature to which it will be exposed. If necessary, change
coolant using coolant specified in “Coolant Recommendations.”
Change Intervals
If the closed cooling system is factory installed, drain and flush coolant from the closed cool-
ing system at least every five years or 1000 hours of operation, whichever comes first. It
should also be changed whenever exhaust gases have entered the system.
If the system is not factory installed or has had anti-freeze other than Extended Life Coolant
added, it must be changed every two years or 400 hours of operation, whichever comes first.
Draining Instructions
WARNING
Allow engine to cool before removing pressure cap. Sudden loss of pressure could
cause hot coolant to boil and discharge violently. After engine has cooled, turn cap
1/4 turn to allow any pressure to escape slowly, then push down and turn cap all the
way off.
IMPORTANT: A wire should be inserted into drain holes to ensure that foreign
material is not obstructing the drain holes. On some models with two piece petcock,
removal of petcock may be required so that wire can be inserted completely into drain
hole.
IMPORTANT: Engine must be as level as possible to ensure complete draining of
cooling system.
IMPORTANT: Closed cooling section must be kept filled year round with recom-
mended coolant. If engine will be exposed to freezing temperatures, make sure
closed cooling section is filled with Extended Life Coolant or an ethylene glycol anti-
freeze and water solution properly mixed to protect engine to lowest temperature to
which it will be exposed.

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CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

The following draining instructions apply to all engines equipped with closed cooling. The
location of petcocks that require opening and hoses that require removal are represented
on the following pages for the individual engines.
IMPORTANT: Observe precautions previously outlined before proceeding.
1. Remove pressure cap from coolant tank.
2. Drain coolant from locations as shown in the “Draining Diagram.”
3. After coolant has drained completely, reinstall petcocks and hoses. Tighten clamps and
petcocks securely.
4. Remove coolant recovery bottle from mounting bracket and pour out coolant.
5. Clean system as outlined in “Cleaning System.”
6. Fill system as outlined in “Filling Closed Cooling Section.”

Cleaning System
Closed Cooling Section
Closed cooling section of closed cooling system should be cleaned at least once every two
years or whenever decreased cooling efficiency is experienced.
A good grade automotive cooling system cleaning solution may be used to remove rust,
scale or other foreign material. Always follow manufacturer’s instructions for the cleaner.
If closed cooling section is extremely dirty, a pressure flushing device may be used to flush
out remaining deposits. Flushing should be done in direction opposite normal coolant flow
to allow water to get behind deposits and force them out. Refer to instructions that
accompany flushing device for proper hookup and flushing procedure.

NOTICE
For information and procedures on draining and flushing Seawater Section of
Closed Cooling (Coolant) Models, refer to SECTION 1B. For cold weather or
extended storage, refer to SECTION 1B.

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SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

Seawater Section
Cooling efficiency of an engine with closed cooling is greatly dependent upon heat transfer
through the tubes within the heat exchanger. During engine operation, contaminants within
the seawater (such as salt, silt, lime, etc.) collect on the inside of the tubes, thus reducing
heat transfer and greatly decreasing heat exchanger efficiency. It is, therefore, recom-
mended that the seawater section of the heat exchanger be cleaned as specified in SEC-
TION 1B “Scheduled Maintenance” or whenever decreased cooling efficiency is suspected.
1. Remove bolts securing end plates to heat exchanger.
2. Then remove end plates, seal washers and gaskets.
3. Discard seal washers and gaskets.
4. Clean gasket material from end plates and heat exchanger.

c
d 71515

a - Heat Exchanger
b - Sealing Washer
c - End Cap
d - Gasket

5. Clean water passages in heat exchanger by inserting a suitable size wire brush into
each passage. Use compressed air to blow loose particles out of water passages.
6. Apply Quicksilver Perfect Seal to both sides of new end plate gaskets.
7. Reinstall end plates, using new gaskets and seal washers. (Be sure to install seal wash-
ers between end plates and gaskets.)
8. Torque end plate bolts to specifications.

CAUTION
Avoid seawater pickup pump impeller damage. DO NOT operate engine without
water being supplied to seawater pickup pump.
9. With boat in the water and/or cooling water properly supplied to seawater pickup pump,
start engine and inspect for leaks.

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CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

Filling Closed Cooling Section

CAUTION
Alcohol or Methanol base antifreeze or plain water are not recommended for use in
coolant section of Closed Cooling System at any time.
It is recommended that coolant section of Closed Cooling System be filled with a 50/50 mix-
ture of Extended Life Coolant and pure, soft water. This coolant MUST BE used regardless
of whether freezing temperatures are expected to provide adequate corrosion protection.
In areas where Extended Life Coolant is not available and the possibility of freezing DOES
NOT exist, it is permissible to use a solution of rust inhibitor and pure, soft water (mixed to
manufacturer’s recommendations).
NOTE: See SECTION 1B for coolant section capacity.
1. Fill coolant section of Closed Cooling System with coolant mixture as follows:
a. Open bleeder valve on thermostat housing.

75598

a - Hex Head Bleeder Valve

b. Fill with coolant mixture through heat exchanger fill neck until coolant appears at
bleeder valve opening.
c. Close bleeder valve securely.
d. Continue filling until coolant level is into filler neck and begins to flow into coolant
recovery bottle plastic tubing.

CAUTION
Avoid seawater pickup pump impeller damage. DO NOT operate engine without
water being supplied to seawater pickup pump.

CAUTION
Front of engine should be higher than rear to purge trapped air out of the system
during initial filling. This will minimize the possibility of air being trapped in the
closed cooling section which can cause engine to overheat.
IMPORTANT: Coolant flows rapidly. Higher idle speeds increase dispersion of
trapped air into system making it more difficult to purge trapped air. Operate at idle
during filling and air purging when specified.
2. Start engine and run at IDLE.

Page 6B-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

3. Add coolant solution to heat exchanger, as required, to maintain coolant level at filler
neck.
4. After engine has reached normal operating temperature thermostat is fully open and
coolant level remains constant, fill heat exchanger until coolant level is into filler neck
and begins to flow into coolant recovery bottle plastic tubing.
5. Remove cap from coolant recovery reservoir and fill to FULL mark with coolant solution.
6. Reinstall cap.
7. Lift recovery bottle and plastic tubing above heat exchanger filler neck. Allow coolant
to flow down through tubing to purge air through filler neck fitting.
8. Install pressure cap on heat exchanger.
9. With engine still running, check hose connections, fittings and gaskets for leaks. Also
observe engine temperature gauge to make sure that engine operating temperature is
normal. If gauge indicates excessive temperature, stop engine immediately and
examine for cause.

WARNING
Allow engine to cool down before removing pressure cap. Sudden loss of pressure
could cause hot coolant to boil and discharge violently. After engine has cooled,
turn cap 1/4-turn to allow any pressure to escape slowly, then push down and re-
move cap.
10. Recheck coolant level after first boat test and add coolant, if necessary.
11. Maintain coolant level in coolant recovery reservoir between ADD and FULL marks with
engine at normal operating temperature.
Coolant section of Closed Cooling System should be kept filled year around with recom-
mended coolant solution. DO NOT drain coolant from fresh water section for storage, as this
will promote rusting of internal surfaces. If engine will be exposed to freezing temperatures,
make sure that coolant section is filled with Extended Life Coolant and water solution, mixed
to manufacturer’s recommended proportion, to protect engine to lowest temperature to
which it will be exposed.

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CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

Auxiliary Hot Water Heater Installation

IMPORTANT: When connecting a cabin heater or hot water heater, certain require-
ments must be met:
• Supply hose (from engine to heater) and return hose (from heater to engine)
MUST NOT EXCEED 5/8 in. (16 mm) I.D. (inside diameter).
• Make heater connections ONLY at locations described in the following instruc-
tions.
• Check complete system for leaks after heater is connected into cooling system.
• Check for overheating condition (of engine) after heater is connected.

CAUTION
On closed cooling models, the heater must be mounted lower than the fill cap on
the heat exchanger. If the heater is higher than the fill cap on the heat exchanger
and some coolant is lost from system, an air pocket may form in the closed cooling
system. This can cause the engine to overheat.

75503

Supply Hose Connection

a - Location For Hot Water Supply Hose (Thermostat Housing As Viewed From
Above)

75480

Return Hose Connection

a - Location For Hot Water Return Hose

Page 6B-18 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

Heat Exchanger Bracket Hardware

d g
e f
l

c i
b
a f
g k
75598
h
i 74745

75213
a

74988
Typical Engine Shown
a - Gasket
b - Heat Exchanger Bracket and Pads
c - Thermostat Housing
d - Screws, Stainless Steel
e - Bleeder Valve
f - Thermostat
g - Quad-Ring Seal
h - Outer Diameter of Thermostat
i - Thermostat Cover
j - Screws with Lockwashers
k - Engine Temperature Gauge Sender
l - ECT Sender

90-861328--1 NOVEMBER 1999 Page 6B-19

CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

Heat Exchanger Hose Connections

g a

bb
c
74073
c
d
e

h f

75209

75212

Typical Engine Shown

a - Heat Exchanger
b - Large Hose Clamps
c - Starboard Heat Exchanger-to-Exhaust Manifold Hose
d - Water Circulating Pump Hose
e - Port Heat Exchanger-to-Exhaust Manifold Hose (MCM)
f - Cool Fuel System (or Seawater Pipe, if equipped)-to-Heat Exchanger Hose
g - Coolant Identification Decal
h - Fuel Lines Aligned to Avoid Starboard Water Hose

Page 6B-20 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

Water Flow Diagram

MCM 262 cid / 4.3L Alpha
NOTE: Certain components in the following diagram may look different than on your
particular power package, but the water and coolant flow paths remain similar on all
engines.

COOLANT FLOW 11

SEAWATER FLOW 10

9
8

2
7

75855

1 - Seawater Intake (From Sterndrive) 7 - Engine Block And Cylinder Head

2 - Power Steering Cooler Assembly
3 - Fuel Cooler - EFI Models 8 - Exhaust Manifold, Typical
4 - Heat Exchanger, Typical 9 - Gasket
5 - Thermostat Housing Assembly 10 - Exhaust Elbow Assembly, Typical
6 - Engine Water Circulating Pump 11 - Overboard (Water and Exhaust
Discharge)

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CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

MCM 262 cid / 4.3L Bravo

12
COOLANT FLOW 11
SEAWATER FLOW
10

3
1

5
7

75860

1 - Seawater Intake (From Through The Hull or Through The Transom Pickup)
2 - Seawater Pump
3 - Power Steering Cooler
4 - Fuel Cooler, If Equipped
5 - Heat Exchanger, Typical
6 - Thermostat Housing and Cover Assembly
7 - Engine Water Circulating Pump
8 - Engine Block and Cylinder Head Assembly
9 - Exhaust Manifold, Typical
10 - Gasket
11 - Exhaust Elbow Assembly, Typical
12 - Overboard (Water and Exhaust Discharge)

Page 6B-22 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 CLOSED COOLED MODELS

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CLOSED COOLED MODELS SERVICE MANUAL NUMBER 25

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Page 6B-24 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 GENERAL

EXHAUST SYSTEM
Section 7A - General
Table of Contents
Exhaust System Requirements . . . . . . . . 7A-2
Exhaust Elbow Risers . . . . . . . . . . . . . 7A-2
Through The Transom Exhaust . . . . . 7A-3

7
A

90-861328--1 NOVEMBER 1999 Page 7A-1

GENERAL SERVICE MANUAL NUMBER 25

Exhaust System Requirements

IMPORTANT: It is the responsibility of the boat manufacturer or installing dealer to
properly locate the engine and install the exhaust system. Improper installation may
allow water to enter the exhaust manifolds and combustion chambers and severely
damage the engine. Damage caused by water in the engine will not be covered by
MerCruiser Limited Warranty, unless this damage is the result of defective part(s).
Exhaust Elbow Risers
On all engines to determine if exhaust elbow risers are required, take measurements (a) and
(b), with boat at rest in the water and maximum load aboard. Subtract (b) from (a). If (a)
minus (b) is less than specified in chart, select appropriate size exhaust elbow riser kit and
exhaust extension kit that will correctly position exhaust elbow.

b
a

72700

Exhaust Elbow Measurement

a - From Waterline To Top Of Transom
b - From Highest Point On Exhaust Elbow To Top Of Transom

Model (a) Minus (b) Must Be at Least

All 13 in. (330 mm)

Page 7A-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 GENERAL

Through The Transom Exhaust

When designing and installing exhaust system, the following must be observed:

Minimum Hose Size

Model Single Outlet Dual Outlet
All 4 in. (102 mm) 3 in. (76 mm)

1. Exhaust flanges must be of proper size to accommodate 4 in. (102 mm) I.D. exhaust
hoses. They must also be equipped with internal water shutters, and use an exhaust
flapper over each outlet.
2. The exhaust hoses and pipes must not be higher than exhaust elbows at any point.
3. The exhaust outlet must be located so that a minimum of 1/2 in. (13 mm) drop per foot
(305 mm) downward pitch exists in the exhaust hose from the engine exhaust elbow to
the outlet. (This is an American Boat & Yacht Council recommendation.) The drop must
be constant so that a low spot does not exist at any point in the exhaust hose.
4. Exhaust outlet must be slightly above the waterline with boat at rest in the water and full
load aboard.
5. Back pressure must not exceed 4 in. (102 mm) of mercury when measured with a
mercury manometer to exhaust elbow outlets.
There are no kits to convert these engines from through the drive to through the transom
exhaust. By using block off plates, inboard exhaust elbows, exhaust hoses and transom out-
let fittings, some engines have been converted to through the transom exhaust. In addition
to the preceding information, the following should be adhered to:
• “Exhaust Elbow Measurement” (as previously outlined) must be checked.
• Block-off plates (for thru drive exhaust system) must be able to prevent water from enter-
ing boat (Quicksilver Block-Off Plate Part Number 97350T--1). Refer to appropriate
Sterndrive Manual.
• Exhaust bellows (between gimbal housing and bell housing) should be removed to allow
propeller to draw air. Refer to appropriate Sterndrive Manual.

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GENERAL SERVICE MANUAL NUMBER 25

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Page 7A-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MANIFOLDS, ELBOWS AND RISERS

EXHAUST SYSTEM 7
Section 7B - Manifolds, Elbows and Risers B
Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . 7B-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7B-6
Lubricants / Sealants / Adhesives . . . . . 7B-2 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . 7B-6
Exhaust Riser (Kit) . . . . . . . . . . . . . . . . . . 7B-2 Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 7B-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 Sterndrive Exhaust Extension . . . . . . 7B-9
Cleaning and Inspection . . . . . . . . . . . . . . 7B-4

90-861328--1 NOVEMBER 1999 Page 7B-1

MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 25

Torque Specifications

Fastener Location lb-in. lb-ft Nm

Hose Clamps Securely
Exhaust Elbow or Risers to Manifold 33 45
Exhaust Manifold 25 34

Lubricants / Sealants / Adhesives

Description Part Number

Quicksilver Perfect Seal 92-34227--1
Quicksilver Loctite 510 Sealant 92-804874

Exhaust Riser (Kit)

3 in. (76 mm) and 6 in. (152 mm) riser kits are available for engines with two piece manifolds.
IMPORTANT: All listed MCM Models can be adapted to 9 inch (228 mm) exhaust risers
by stacking 3 inch (76 mm) riser kit and 6 inch (152 mm) riser kit.
No riser kit is available for one piece manifold. An exhaust extension kit may be needed
when risers are installed.

Disassembly
WARNING
Avoid possible injury or damage to equipment should wires be accidentally
shorted. Disconnect BOTH battery cables from battery before proceeding.
1. Disconnect battery cables from battery.

CAUTION
To avoid severe engine damage. Exhaust elbows and manifolds MUST BE drained
to prevent water from entering combustion chambers when exhaust elbows are
removed.
2. Drain water from manifold, elbow and riser, if equipped.
3. Disconnect exhaust and cooling hoses.
4. Remove any other components that are mounted to the manifold, elbow and riser, if
equipped.

Page 7B-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MANIFOLDS, ELBOWS AND RISERS

5. Remove elbow and riser, if equipped.

6. Remove exhaust manifold fasteners. Remove manifold assembly and discard gaskets.
a

e
72991

MCM 4.3L / 4.3LH / 4.3L EFI Two Piece Cast Iron Manifold
a - Exhaust Elbow
b - Restrictor Gasket
c - Open Gasket (Later Models and Service)
d - Exhaust Manifold
e - Bolts (6)

75865

MCM 4.3L / 4.3LH / 4.3L EFI Seawater Cooled With One Piece Cast Iron Manifold

90-861328--1 NOVEMBER 1999 Page 7B-3

MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 25

Cleaning and Inspection

1. Clean gasket material from all surfaces and wash parts in solvent.
2. Check water passages for foreign material. Passages must be clean for efficient cooling.
3. If more thorough inspection is desired, pipe plugs may be removed from exhaust man-
ifold and exhaust elbow.
IMPORTANT: If plugs are removed, coat threads with Quicksilver Perfect Seal before
reinstalling.
4. Check for cracks.
5. To test manifold body for leaks, block-off plates, plugs or short hoses with plugged ends
must be used. One block-off plate must have a threaded hole for attaching compressed
air hose. Use new gaskets when installing block-off plate(s). Apply 40 psi (276 kPa) of
air pressure and submerge manifold in water. Air bubbles will indicate a leak.
6. Inspect all parts carefully. Machined surfaces must be clean and free of all marks and
deep scratches, or water and exhaust leaks may result.
7. Check the flatness of all gasket surfaces. Maximum overall is .003 in. (0.07 mm), with
not more than a .001 in. (0.02 mm) difference within 1in. (25 mm).
NOTE: Maximum material that can be removed is .010 in. (0.25 mm) to true a gasket surface
up. When torquing the attaching bolts, make sure that they are not bottoming out in the man-
ifold’s threaded hole.
8. Look at the condition of the metal around the exhaust outlet in the casting. Inspect for
damaged metal caused by salt water or exhaust gas corrosion in the manifold, elbow
and riser, if equipped. Replace all damaged parts.

76341

a - Inspect Area Around Exhaust Outlet

9. Check the fire ring gasket fit on the manifold gasket surface. Place a new gasket on the
surface. Thread 4 short 3/8-16 bolts into the bolt holes. Move the gasket fore and aft,
then side to side to make sure the gasket’s fire ring has manifold gasket surface under
it in all 4 positions.
NOTE: If the gasket’s fire ring does not have a solid gasket surface in all 4 positions, the
manifold should be replaced.

Page 7B-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MANIFOLDS, ELBOWS AND RISERS

76355

a - Gasket’s Fire Ring has Manifold Gasket Surface Under It in All 4 Positions
b - Manifold Gasket Surface

a
76359

a - Gasket’s Fire Ring Does Not have Manifold Gasket Surface Under It in All 4
Positions
b - Manifold Gasket Surface

90-861328--1 NOVEMBER 1999 Page 7B-5

MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 25

Installation
Gaskets
NOTE: The service replacement gasket may not be the same type of gasket that was used
in production.
The fire ring gasket with 4 slots is used between all manifolds, risers and exhaust elbows.
IMPORTANT: After applying Loctite 510 to the gasket, assemble components im-
mediately.
1. Apply a 1/8 in. (3 mm) bead of LOCTITE 510 Sealant around all holes on both sides of
a new fire ring gasket.

76360

a - 1/8 in. (3 mm) Bead of LOCTITE 510 Sealant

2. Assemble parts immediately and torque fasteners to specifications.

3. Allow sealant to cure 2-3 hours before starting the engine.

Page 7B-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MANIFOLDS, ELBOWS AND RISERS

Manifold
1. Using new gasket, install exhaust manifold to cylinder head. Torque fasteners to 25 lb-ft
(34Nm).
2. Using a new gasket, install exhaust elbow to exhaust manifold. Torque fasteners to 25
lb-ft (34Nm).
3 IN. RISERS

e e
a
h h
a
c

d c
d k

c
b

j c b

c
f j
g
f
g
i
i

76510
76511

Models Without Mufflers Models With Mufflers

a - Exhaust Elbow
b - 3 in. (76 mm) Exhaust Riser
c - Open Gasket
d - Restrictor Gasket
e - Nut (8)
f - Stud (8) 9-3/8 in. (238 mm)
g - Stud (8) 10-3/8 in. (264 mm) Used With Remote Oil Filter
h - Washer (8)
i - Exhaust Manifold
j - Separator Gasket - See Notice
k - Muffler Spacer 1-1/4 in. (32 mm)

90-861328--1 NOVEMBER 1999 Page 7B-7

MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 25

6 IN. RISERS

a b a b
c c

e
d
e
i
m j m f
d
h f

j
i l i h
g
g

l
j
i n
k o

k
n

76506

76507

Models With Mufflers Models Without Mufflers

a - Screws [Supplied With Muffler Kit]
b - Exhaust Elbow
c - Spacer (3) [Supplied With Engine]
d - Riser Bracket
e - Restrictor Gasket (2)
f - Fasteners (3) [Supplied With Engine]
g - Spacers or Phenolic Washers in Step 5.
h - 1-1/4 Inch (32 mm) Muffler Spacer
i - Open Gasket (2)
j - Nut (6)
k - Screw (4)
l - 6 Inch (152 mm) Riser
m - Screw (4)
n - Exhaust Manifold
o - Separator Gasket (Used On Models With Exhaust Manifolds In The Closed
Cooling System)

3. Port Manifold:
a. Install remote oil filter and bracket.
b. Install components on exhaust elbow (if necessary).

Page 7B-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 MANIFOLDS, ELBOWS AND RISERS

4. Starboard Manifold:
a. Install bolt to secure water separating fuel filter bracket to exhaust manifold.
b. Install shift plate assembly on exhaust elbow (MCM only).
c. Connect instrument harness plug to engine harness, if disconnected previously.
d. Connect both shift cables (MCM only).
5. Install exhaust elbows and cooling hoses.
6. On Closed Cooled Models: Refill closed cooling system to operating level with
properly mixed coolant. Refer to SECTION 6B.
7. Reconnect battery cables to battery. Tighten securely.
8. Start engine and check for fuel, exhaust and water leaks.

Sterndrive Exhaust Extension

1. Install appropriate exhaust extension for MCM Models with thru prop exhaust, using two
hose clamps at each end.
2. Cut along bottom edge of raised bead for 3 in. (76 mm) risers or use full length for 6 in.
(152 mm) risers.

50930

Typical Exhaust Extension

a - Bottom Edge Of Raised Bead

3. Tighten hose clamps securely.

4. Upon first start-up of engine, check for leaks.

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MANIFOLDS, ELBOWS AND RISERS SERVICE MANUAL NUMBER 25

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Page 7B-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 COLLECTORS

EXHAUST SYSTEM
Section 7C - Collectors
Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . 7C-2
Lubricants / Sealants / Adhesives . . . . . 7C-2
Bullhorn Exhaust . . . . . . . . . . . . . . . . . . . . 7C-3
Shutter Replacement . . . . . . . . . . . . . . 7C-3
Component Replacement . . . . . . . . . . 7C-4

7
C

90-861328--1 NOVEMBER 1999 Page 7C-1

COLLECTORS SERVICE MANUAL NUMBER 25

Torque Specifications

Fastener Location lb-in. lb-ft Nm

Block-Off Plate
Exhaust Pipe to Gimbal Housing
Exhaust Pipe to T-Pipe
20-25 27-34
T-Pipe to Gimbal Housing
Upper Exhaust Pipe to Lower Exhaust Pipe
Exhaust Elbow
Air Pump Mount
Muffler End Plate
Mode Switch Securely
Hose Clamps
Water Shutter Bolt/Nut

Lubricants / Sealants / Adhesives

Description Part Number

Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Loctite 35 92-809833
Loctite Primer 92-809824
3M Brand Adhesive 92-86166--1
Quicksilver Perfect Seal 92-34227--1
Quicksilver Liquid Neoprene 92-25711--3
Quicksilver Sound Blanket Glue 92-25234

Page 7C-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 COLLECTORS

Bullhorn Exhaust
Shutter Replacement
IMPORTANT: Engine does not have to be removed to change shutters.
1. Loosen clamps and remove exhaust pipe elbow and exhaust hose.
2. Replace water shutter as shown.
3. Reinstall pipe elbow and hose. Tighten clamps securely.

75760

Later Style Shutter

a - Exhaust Flapper
b - Rubber Grommets

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COLLECTORS SERVICE MANUAL NUMBER 25

Component Replacement
To replace any components in exhaust system, the following must be adhered to:
• All mating joint surfaces must be clean.
• O-ring must remain in groove to properly seal joints to prevent leakage.
• Torque all bolts to 20-25 lb-ft (27-34 Nm).
• Tighten all clamps securely.

72736

a - Mating Surface
b - O-Ring

c c
e
d

c
c f

e g

h
72737

a - Mating Surface
b - O-Ring
c - Clamps
d - Exhaust Pipe Elbow
e - Exhaust Hose
f - Water Shutters
g - Bolts and Lockwashers
h - Exhaust Pipe

Page 7C-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 COLLECTORS

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COLLECTORS SERVICE MANUAL NUMBER 25

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Page 7C-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DRIVE SHAFT

DRIVES
Section 8A - Drive Shaft
Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . 8A-2 Replacement Drive Shafts . . . . . . . . . 8A-7
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 Drive Shafts Modified to
Lubricants / Sealants / Adhesives . . . . . 8A-2 Shorter Lengths . . . . . . . . . . . . . . . . . . 8A-8
Flywheel Housing / Output Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8A-8
Housing Repair . . . . . . . . . . . . . . . . . . . . . 8A-3 Bearing Support Repair . . . . . . . . . . . . . . 8A-10
Exploded View . . . . . . . . . . . . . . . . . . . 8A-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . 8A-10
Removal and Installation . . . . . . . . . . 8A-4 Disassembly . . . . . . . . . . . . . . . . . . . . . 8A-10
Disassembly . . . . . . . . . . . . . . . . . . . . . 8A-4 Reassembly . . . . . . . . . . . . . . . . . . . . . 8A-11
Reassembly . . . . . . . . . . . . . . . . . . . . . 8A-5 Installation . . . . . . . . . . . . . . . . . . . . . . . 8A-12
Drive Shaft Repair . . . . . . . . . . . . . . . . . . . 8A-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . 8A-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-7

8
A

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DRIVE SHAFT SERVICE MANUAL NUMBER 25

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Drive Shaft To Bearing Support Flange (MCM Models)
50 68
Drive Shaft To Output Shaft (MCM Models)
Flywheel Housing To Block (MCM Models)
30 41
Output Shaft Housing To Flywheel Housing (MCM Models)
Engine Coupling 35 48
Bearing Support Housing Attaching Bolts 35-54 47-73
Securely
Coupling Set Screws (If Equipped)
(See Note)

NOTE: Safety wire set screws.

Tools
Description Part Number
Quicksilver Alignment Tool 91-805475A1
Quicksilver Slide Hammer Puller 91-34569A1

Lubricants / Sealants / Adhesives

Description Part Number
2-4-C Marine Lubricant With Teflon 92-825407A3
U-Joint and Gimbal Bearing Grease 92-828052A2
Quicksilver Engine Coupler Spline Grease 91-816391A4
Quicksilver Loctite 27131 92-809820
Loctite 290 Obtain Locally

Page 8A-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DRIVE SHAFT

Flywheel Housing / Output Shaft Housing Repair

NOTICE
The following procedure requires removal of the drive shaft. In most cases,
because of engine compartment space limitations, the engine also must be
removed.

Exploded View
1

2 3 10
4
8

9 8

14 13
15 8
6
12 7
11
8
17
16

18
23

19
20
8 21 22

Flywheel Housing/Output Shaft Housing

1 - Output Shaft 13 - Screw (2)

2 - O-Rings 14 - Nut (1)
3 - Ball Bearing Snap Ring 15 - Bolt (4)
4 - Ball Bearing 16 - Washer (1)
5 - Shaft Bearing 17 - Clamp (1)
6 - Output Shaft Snap Ring 18 - Stud (1)
7 - Rear Engine Mount 19 - Gasket
8 - Lockwasher 20 - Flywheel Cover
9 - Screw (4) 21 - Screw (7)
10 - Screw (6) 22 - Engine Coupling
11 - Flywheel Housing 23 - Bushing
12 - Plate

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DRIVE SHAFT SERVICE MANUAL NUMBER 25

Removal and Installation

1. Remove drive shaft as outlined following in this section.
2. If engine must be removed, refer to appropriate instructions in SECTION 2 - “Removal
and Installation.”
Disassembly
IMPORTANT: This disassembly procedure, beginning with Step 1. assumes that
engine does not require removal from boat. If engine removal is required, refer to
SECTION 2 for removal and installation instructions. With engine removed from boat,
proceed with disassembly, beginning with Step 3.
1. If Engine Is Removed From Boat, Go To Step 3. If Engine Is In Boat: Support rear
of engine with overhead hoist or wooden blocks under the rear of the engine.
2. Remove stringer bolts (rear engine mounts).
3. Remove output shaft housing attaching screws, then remove housing.
4. Remove snap ring, then pull output shaft out of housing.
5. Remove snap ring from housing.
6. Using Quicksilver Slide Hammer Puller, remove bearing from housing.
7. Remove flywheel cover.
8. Remove flywheel housing.
9. Remove engine coupling.
10. Clean and inspect all parts. Replace any damaged parts.

Page 8A-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DRIVE SHAFT

Reassembly
1. Install engine coupling. Torque to 35 lb-ft (48 Nm).
2. Install flywheel housing. Torque to 30 lb-ft (41 Nm).
3. Using new gasket, install flywheel cover. Tighten screws securely.
IMPORTANT: Groove in outside diameter of ball bearing must align with grease fitting
hole.
4. Install ball bearing into output shaft housing, then install snap ring.
5. Apply Quicksilver 2-4-C Marine Lubricant With Teflon to O-rings (on output shaft), then
slide shaft through bearing. Secure shaft with snap ring.
6. Apply Quicksilver Engine Coupler Spline Grease to splines on output shaft.
7. Install output shaft housing to flywheel housing. Torque screws to 30 lb-ft (48 Nm).
8. Secure rear engine mounts to stringer with bolts. Tighten securely.
9. Remove hoist (or wooden blocks).
10. Install drive shaft and check alignment. (Refer to SECTION 2B for engine and drive shaft
alignment if engine was removed.)
11. Using Quicksilver U-Joint and Gimbal Bearing Grease, grease ball bearing through
grease fitting.

Drive Shaft Repair

Removal
IMPORTANT: It is not necessary to remove the engine to service the drive shaft.
1. Remove top and bottom drive shaft shields around transom end and engine end of drive
shaft.

d
b 70245

Top Shield and Bottom Shield at Transom End (Engine End Similar)
a - Top Shield
b - Bottom Shield
c - Bolt 3/3-16 x 7/8 In. (22.2 mm); 4 Used
d - Nut 3/8 16: 4 Used
e - Screws (3 Used Hidden In This View)

90-861328--1 NOVEMBER 1999 Page 8A-5

DRIVE SHAFT SERVICE MANUAL NUMBER 25

2. Suitably mark drive shaft U-joint yokes / flange connections (engine output and drive unit
input) to assist in exact same positioning during assembly at engine and transom end.

b a
70237

Engine End Shown (Transom End Similar)

a - Suitable Mark On Flange and Drive Shaft Connection
b - Extension Drive Shaft U-Joint Yoke
c - Flange

3. Remove drive shaft fasteners and drive shaft.

c 70237

Engine End Shown (Transom End Similar)

a - Output Shaft Flange
b - Drive Shaft
c - Bolt With Nut (4 Total)

Page 8A-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DRIVE SHAFT

Repair
CAUTION
Be sure U-joint locking rings are seated properly after replacing U-joints.
1. Replace U-joints, if required.
2. Replace flange, if required.
c

a
b

a - Flange
b - U-Joint
c - Drive Shaft

Replacement Drive Shafts

MerCruiser furnishes a 58 in. (1473 mm) or 34-1/2 in. (876 mm) long drive shaft with
extension shaft models. Some boat manufacturers modify the drive shafts to a shorter
length. Because of this, use the following procedure to obtain replacement drive shafts.
“X”
a

b e b c
c d d

a - Tube
b - Yoke - Tube
c - Flange
d - Universal Joint
e - Sound Deadener (Cardboard Tube)

The complete drive shaft can be ordered from Mercury Marine.

90-861328--1 NOVEMBER 1999 Page 8A-7

DRIVE SHAFT SERVICE MANUAL NUMBER 25

Drive Shafts Modified to Shorter Lengths

The complete modified (shortened) drive shaft has to be ordered from the boat
manufacturer that installed the Mercury MerCruiser Power Package.
IMPORTANT: Dana Corporation - Spicer Regional Drive Shaft Centers will not shorten
replacement drive shafts for dealers or consumers.
If a boat manufacturer is currently having extension drive shafts modified, they must be
modified by one of Dana Corporation - Spicer Regional Drive Shaft Centers to maintain
Mercury MerCruiser warranty. The modified drive shaft must meet the following
specifications.
• U-joints aligned radially within 0° (± 1/2°).
• U-joints greased, after welding, with Quicksilver U-Joint and Gimbal Bearing Grease.
• Assembly balanced to within 1.5 oz-in. (0.01 Nm) to 4500 rpm.
• Tube to have .005 in. (0.127 mm) to .010 in. (0.254 mm) interference fit with tube yoke.
• Tube must be straight and round within .015 in. (0.381 mm).

Installation
IMPORTANT: The following instructions are to be used if ONLY the drive shaft was
removed for service. Refer to appropriate sections for installation of other compo-
nents which require special alignment.
1. Grease both drive shaft universal joints with Quicksilver U-Joint and Gimbal Bearing
Grease.

CAUTION
When attaching shaft in next step, BE SURE that the pilot on drive shaft flanges are
engaged in input shaft and output shaft flanges. Flanges MUST BE flush with each
other prior to tightening screws or screws may come loose during operation.

CAUTION
Failure to properly align shaft flanges with matching marks made on disassembly
may cause improperly aligned drive unit and extension drive shaft U-joint center-
lines resulting in a severe vibration problem.

Page 8A-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DRIVE SHAFT

2. As shown, attach drive shaft output flange and input shaft flange exactly as marked upon
disassembly. Torque fasteners to 50 lb-ft (68 Nm).

e
d

c
70237
b
Engine End Shown (Transom End Similar)
a - Output Shaft Flange
b - Drive Shaft
c - Bolt 7/16-20 x 1-1/2 In. (38 mm) Long (4 Used)
d - Nut 7/16-20 (4 Used)
e - Suitable Matching Marks Made Upon Disassembly - Aligned

3. Apply Loctite 27131 to threads of bottom drive shaft shield retaining screws and install
bottom shields on engine and transom end. Then install both top shields as shown.
Torque all fasteners to 30 lb-ft (41 Nm).
a

e b
70245
d
Top Shield and Bottom Shield at Transom End (Engine End Similar)
a - Top Shield
b - Bottom Shield
c - Bolt 3/8-16 x 7/8 in. (22 mm); 4 Used
d - Nut 3/8-16; 4 Used
e - Screws (3 Used - Hidden In This View)

90-861328--1 NOVEMBER 1999 Page 8A-9

DRIVE SHAFT SERVICE MANUAL NUMBER 25

Bearing Support Repair

Removal
IMPORTANT: It is not necessary to remove the engine to service the drive shaft and/or
bearing support.

CAUTION
If bearing support is removed, you must remove the sterndrive unit so you can
properly align drive unit U-joint centerline with extension drive shaft U-joint center-
line. Lack of alignment will cause a severe vibration problem.
1. Remove drive shaft as previously outlined.
2. Remove sterndrive unit. Refer to appropriate Sterndrive Service Manual.
3. Remove bearing support and retain hardware.
a

b
c

d c 75279

e
a - Bolt, Bearing Support (2)
b - Flat Washer (2)
c - Spherical Washer (4)
d - Bearing Support (Tailstock)
e - Nut (2)

Disassembly
1. Remove snap ring, then remove input shaft.
2. Remove larger snap ring.
3. Using Quicksilver Slide Hammer Puller, remove ball bearing.
4. Remove oil seal.
5. If required, remove plug from end of input shaft.
6. Clean and inspect all parts.
7. Replace any damaged parts.

Page 8A-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DRIVE SHAFT

Reassembly
1. If removed, install new plug in end of input shaft.
2. Apply Quicksilver Loctite 27131 to outer diameter of new oil seal.
3. Press oil seal into bearing support. Lip of seal faces away from ball bearing.
4. Apply Loctite 290 to outer diameter of ball bearing and inner diameter of bearing sup-
port.
5. Install bearing (with sealed side toward snap ring) by using a press. After installation,
wipe up excessive Loctite. Install snap ring.
6. Apply Loctite 290 to outer diameter of input shaft (bearing area) and inside diameter of
bearing race.
7. Install input shaft, then install snap ring. Wipe up excessive Loctite.
IMPORTANT: Do not let Loctite get into ball bearing.
8. Fill bearing area with Quicksilver U-Joint and Gimbal Bearing Grease through grease
fitting.
9. Apply Quicksilver Engine Coupler Spline Grease to splines of input shaft before install-
ing drive unit.

a b e
c
f g
h

d 75281

a - Snap Ring - Input Shaft

b - Snap Ring - Ball Bearing
c - Ball Bearing
d - Bearing Support
e - Grease Fitting
f - Oil Seal
g - Grease Fitting
h - Input Shaft
i - Plug - Input Shaft

90-861328--1 NOVEMBER 1999 Page 8A-11

DRIVE SHAFT SERVICE MANUAL NUMBER 25

Installation
1. Install bearing support assembly (tailstock) on transom plate using hardware as shown.
Tighten bolts until they contact. DO NOT TORQUE BOLTS AT THIS TIME.
IMPORTANT: The spherical washers MUST be positioned so that the rounded side of
the washers are toward the bearing support assembly as shown.

g
h a
b
c
d

e 75279

f
a - Bolts 1/2-20 x 4 In. (102 mm)
b - Steel Washer (Flat)
c - Spherical Washer (Rounded On One Side)
d - Bearing Support
e - Spherical Washer (Rounded On One Side)
f - Nut 1/2-20
g - Transom Plate
h - Bearing Support (Tailstock)

2. Insert solid end of Quicksilver Alignment Tool through bearing in gimbal housing and into
input shaft splines of bearing support.

b a

71401

Typical Sterndrive Unit Shown

a - Quicksilver Alignment Tool
b - Insert This End Of Alignment Tool Through Gimbal Housing Assembly

3. DO NOT remove alignment tool from gimbal housing.

Page 8A-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 DRIVE SHAFT

CAUTION
Both attaching bolts MUST be struck firmly in the following step to properly seat
spherical washers. If procedure is not followed, difficulty in the installation of the
sterndrive unit may be experienced and subsequent damage to the input bearing
may result.
4. Strike the head of BOTH bearing support attaching bolts firmly with a hammer.

71098

5. Torque bolts to 35-54 lb-ft (47-73 Nm).

71099

6. Refer to appropriate Sterndrive Service Manual and install drive unit.

7. Refer to appropriate SECTION 2 - “Removal and Installation – Engine Installation/Align-
ment,” if engine was removed.

90-861328--1 NOVEMBER 1999 Page 8A-13

DRIVE SHAFT SERVICE MANUAL NUMBER 25

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Page 8A-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 PUMP AND RELATED COMPONENTS

POWER STEERING SYSTEM

Section 9A - Pump And Related Components
Table of Contents
Torque Specifications . . . . . . . . . . . . . . . . 9A-2 Testing and Repair . . . . . . . . . . . . . . . . . . 9A-8
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2 Checking Pump Fluid Level . . . . . . . . . . . 9A-8
Special Tools . . . . . . . . . . . . . . . . . . . . 9A-2 Filling and Air Bleeding System . . . . . . . 9A-8
Lubricants / Sealants / Adhesives . . . . . 9A-2 Pump Assembly . . . . . . . . . . . . . . . . . . . . . 9A-8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 9A-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . 9A-8
Power Steering Pump and Components Installation . . . . . . . . . . . . . . . . . . . . . . . 9A-10
(Exploded View) . . . . . . . . . . . . . . . . . . . . 9A-3 Hydraulic Hoses and Fluid Cooler . . . . . 9A-11
Serpentine Belt Routing . . . . . . . . . . . . . . 9A-4 High Pressure Hose
S/N 0L618999 and Below . . . . . . . . . . 9A-4 (Pump-to-Control Valve) . . . . . . . . . . 9A-11
S/N 0L619000 and Above . . . . . . . . . 9A-5 Low Pressure Hose
Serpentine Belt Adjustment . . . . . . . . . . . 9A-6 (Cooler-to-Pump) . . . . . . . . . . . . . . . . 9A-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . 9A-6 Low Pressure Hose
Installation . . . . . . . . . . . . . . . . . . . . . . . 9A-6 (Control Valve-to-Cooler) . . . . . . . . . . 9A-15
Important Service Information . . . . . . . . . 9A-7
Pump Pulley Replacement . . . . . . . . . 9A-7

9
A

90-861328--1 NOVEMBER 1999 Page 9A-1

PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 25

Torque Specifications
Fastener Location lb-in. lb-ft Nm
Crankshaft Pulley To Torsional Damper 35 42
Torsional Damper To Crankshaft 60 81
Pump Mounting Bracket To Engine 30 41
Power Steering Hose Fittings 23 31

Tools
Description Part Number
Pulley Installer 91-93656A1

Special Tools
Description Part Number
Kent-Moore Special Tools
29784 Little Mack
Roseville, MI 48066
(313) 574-2332
Pulley Removal Tool J-25034

Description Part Number

Snap-On Special Puller Tool CJ124A

Lubricants / Sealants / Adhesives

Description Part Number
Quicksilver Perfect Seal 92-34227--1
Transmission Fluid Dexron III or Equivalent Obtain Locally

Page 9A-2 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 PUMP AND RELATED COMPONENTS

Precautions
CAUTION
Do not operate engine without cooling water being supplied to water pickup pump
or water pump impeller will be damaged and subsequent overheating damage to
engine may result.

WARNING
Always disconnect battery cables from battery before working on engine to prevent
fire or explosion.

CAUTION
Do not pry on power steering pump or alternator when adjusting belt tension. Seri-
ous damage may result.

Power Steering Pump and Components (Exploded View)

3
1

4 6

5 2 7

10
8

11 9 72951

1 - Power Steering Pump Assembly

2 - Stud
3 - Cap
4 - Pulley
5 - Serpentine Belt
6 - O-Ring, High Pressure Hose Fitting
7 - Hose, High Pressure (Fittings on Both Ends)
8 - Hose, Low Pressure
9 - Clamp
10 - Hose, Control Valve To Fluid Cooler (Fitting On One End)
11 - Power Steering Cooler

90-861328--1 NOVEMBER 1999 Page 9A-3

PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 25

Serpentine Belt Routing

S/N 0L618999 and Below

Alpha With Power Steering Bravo With Power Steering

Alpha With Closed Cooling Bravo Without Power Steering

Without Power Steering

Alpha With Closed Cooling Bravo With Closed Cooling

and Power Steering and Power Steering

Page 9A-4 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 PUMP AND RELATED COMPONENTS

Serpentine Belt Routing (Continued)

S/N 0L619000 and Above

76503 76502

Alpha With Power Steering Bravo With Power Steering

76463
76445

Alpha Without Power Steering Bravo Without Power Steering

90-861328--1 NOVEMBER 1999 Page 9A-5

PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 25

Serpentine Belt Adjustment

IMPORTANT: If a belt is to be reused, it should be installed in the same direction of
rotation as before.
Removal
1. Remove drive belt as follows:
NOTE: The upper, starboard idler pulley is the belt adjustment pulley.
a. Loosen 5/8 in. locking nut on adjustment stud.
b. Turn adjustment stud and loosen belt. Remove belt.

b
a

75483

a - Adjustment Stud
b - Locking Nut

Installation
1. Install drive belt on pulleys.
2. Adjust tension as follows:
a. Loosen 5/8 in. locking nut on adjustment stud. Leave wrench on adjustment stud
locking nut.
NOTE: Belt deflection is to be measured on the belt at the location that has the longest dis-
tance between two (2) pulleys. Normally this location is between the power steering pump
and the belt adjustment pulley. This location will be different on engines with closed cooling
or models without power steering.
b. Use 5/16 in. socket and tighten adjusting stud until the correct deflection of the belt
is obtained at location specified above.
c. While holding adjustment stud at the correct belt tension, tighten 5/8 in. locking nut.

Page 9A-6 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 PUMP AND RELATED COMPONENTS

Important Service Information

Pump Pulley Replacement

REMOVAL

NOTE: Serpentine belt pulley requires a special puller tool. See your local automotive repair
dealer for appropriate tool or use Snap-On P/N CJ124A.
1. Install appropriate puller on end of pulley and shaft as shown.
2. While holding tool with suitable wrench, turn threaded screw until pulley is removed.

72821

a - Typical Puller
b - Serpentine Pulley

INSTALLATION

Install pulley, using appropriate pulley installation tool as follows:

1. Place pulley on pump shaft.
2. Thread stud all the way into pump shaft. Place bearing over stud.
3. Thread nut onto shaft. Thread tool shaft (and nut) all the way onto stud (threaded into
pump shaft).
4. Turn large pusher nut until face of pulley is even with edge of shaft.
c d
b e

a 75751

Typical Installation Tool Shown

a - Power Steering Pump Pulley
b - Stud
c - Bearing
d - Nut
e - Tool Shaft

90-861328--1 NOVEMBER 1999 Page 9A-7

PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 25

Testing and Repair

Refer to appropriate MerCruiser Sterndrive Service Manual.

Checking Pump Fluid Level

Refer to SECTION 1B “Maintenance.”

Filling and Air Bleeding System

Refer to SECTION 1B “Maintenance.”

Pump Assembly
Removal
1. Loosen the adjusting stud and remove the serpentine belt from the power steering
pulley.

75483

a - Adjusting Nut

NOTE: Use a suitable container catch ant power steering fluid when removing the power
steering hoses.

Page 9A-8 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 PUMP AND RELATED COMPONENTS

2. Remove the high pressure hose and return hose from the power steering pump.

75228

Power Steering Pump Typical Location

a - Return Hose
b - High Pressure Hose

3. Remove mounting fasteners from pump.

a
a

75798
75228

Power Steering Pump Typical Location

a - Nut
b - Bolts

4. Remove the power steering pump from the bracket.

5. Refer to appropriate Sterndrive Service Manual for power steering pump repair proce-
dures.

90-861328--1 NOVEMBER 1999 Page 9A-9

PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 25

Installation
IMPORTANT: Be careful to not cross-thread or overtighten hose fittings.
1. Place the power steering pump on the bracket and install the screws and nut. Torque
to 30 lb-ft (41 Nm).

a
a

75798
75228

Power Steering Pump Typical Location

a - Nut
b - Bolts

2. Be certain a new high pressure hose O-ring is present. Install threaded fitting in back
of pump assembly. Tighten fitting securely. Connect low pressure hose on back of pump.
Tighten hose clamp securely.

75228

Power Steering Pump Typical Location

a - Return Hose
b - High Pressure Hose

3. Install mounting hardware and fasteners to retain pump to bracket. (Refer to “Exploded
View” for specific details on your engine.)
4. Install drive belt and adjust tension. Refer to “Pump Drive Belt Adjustment” as previously
outlined.
5. Fill and air bleed system. Refer to SECTION 1B - “Maintenance.”

Page 9A-10 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 PUMP AND RELATED COMPONENTS

Hydraulic Hoses and Fluid Cooler

The following information is provided to assist in replacement of power steering fluid hoses
and to assure proper routing and connection to the cooler.
Replace high or low pressure hoses following:
IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid
leakage.
IMPORTANT: Be careful to not cross-thread or overtighten hose fittings.
High Pressure Hose (Pump-to-Control Valve)

REMOVAL

NOTE: Catch fluid that drains from pump and hoses in a suitable container.
1. Remove high pressure hose fitting with O-ring seal from pump fitting on rear of pump.

a
75228

Power Steering Pump Typical Location

a - High Pressure Hose Fitting (With O-Ring - Not Visible In This View)
b - Pump Fitting

2. Remove hose where routed and secured (port or starboard side), across top of engine,
near valve cover.
3. Remove fitting from control valve at transom. Remove hose.

73860

a - Power Steering Hose Fitting

90-861328--1 NOVEMBER 1999 Page 9A-11

PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 25

INSTALLATION

CAUTION
Route hoses exactly as shown below. This will help avoid stress on the hose fittings
and will help avoid kinks in the hoses.
IMPORTANT: Be careful to not cross-thread or overtighten hose fittings.
1. Position hose properly (as it was prior to removal). Install fitting and torque to 23 lb-ft
(31 Nm). Do not cross-thread or overtighten.

73860

a - Power Steering Hose Fitting

2. Route hose along valve cover and secure with J-clamp(s) provided.
3. Be certain a new high pressure hose O-ring is present. Install threaded hose fitting in
back of pump assembly fitting. Tighten hose fitting securely. Do not cross-thread or over-
tighten.

75228

Power Steering Pump Typical Location

a - High Pressure Hose Fitting (With O-Ring - Not Visible In This View)
b - Pump Fitting

4. Fill and air bleed system. Refer to SECTION 1B.

Page 9A-12 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 PUMP AND RELATED COMPONENTS

Low Pressure Hose (Cooler-to-Pump)

REMOVAL

NOTE: Catch fluid that drains from hose, cooler and pump in a suitable container.
1. Loosen hose clamp and remove hose from fluid cooler.

76403
a - Hose

2. Loosen hose clamp and remove hose from back of pump.

a b

75228

Power Steering Pump Typical Location

a - Hose Clamp
b - Hose

90-861328--1 NOVEMBER 1999 Page 9A-13

PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 25

INSTALLATION

1. Using hose clamp, install new hose on back of pump. Tighten clamp securely.

a b

75228

Power Steering Pump Typical Location

a - Hose Clamp
b - Hose

2. Using hose clamp, install hose on fluid cooler. Tighten clamp securely.

75595

a - Hose

3. Fill and air bleed system. Refer to SECTION 1B.

Page 9A-14 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 PUMP AND RELATED COMPONENTS

Low Pressure Hose (Control Valve-to-Cooler)

REMOVAL

NOTE: Catch fluid that drains from hose, cooler and pump in a suitable container.
1. Loosen hose clamp and remove hose from fluid cooler.

75595

a - Hose

2. Remove fitting from control valve at transom. Remove hose.

73860

a - Power Steering Hose Fitting

90-861328--1 NOVEMBER 1999 Page 9A-15

PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 25

INSTALLATION

CAUTION
Route hoses exactly as shown below. This will help avoid stress on the hose fittings
and will help avoid kinks in the hoses.
IMPORTANT: Be careful to not cross-thread or overtighten hose fittings.
1. Position hose properly (as prior to removal). Install fitting and torque to 23 lb-ft (31 Nm).
Do not cross-thread or overtighten.

73860

a - Power Steering Hose Fitting

IMPORTANT: Be careful to not cross-thread or overtighten hose fittings.

2. Route hose along flywheel housing and secure with J-clamp(s) provided.
3. Using hose clamp, install hose on fluid cooler. Tighten clamp securely.

75595
a - Hose

4. Fill and air bleed system. Refer to SECTION 1B.

Page 9A-16 90-861328--1 NOVEMBER 1999

SERVICE MANUAL NUMBER 25 PUMP AND RELATED COMPONENTS

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PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 25

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Page 9A-18 90-861328--1 NOVEMBER 1999