MerCruiser 305 CID (5.0L) Service Manual Download Page 602

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FUEL INJECTION SYSTEM TROUBLESHOOTING

SERVICE MANUAL NUMBER 24

90-861327--1 OCTOBER 1999

Page 5F-1

FUEL SYSTEMS

Section 5F - Fuel Injection System Troubleshooting

Table of Contents

Scan Tool Normal Specifications (Idle / Warm
Engine / Closed Throttle / Neutral)

5F-2

. . . .

Important Preliminary Checks

. . . . . . . . . . . . . . . . . . .

Visual / Physical Check

5F-3

. . . . . . . . . . . .

Intermittents

5F-4

. . . . . . . . . . . . . . . . . . . . . . . .

Hard Start Symptom

5F-5

. . . . . . . . . . . . . . . . .

Surges and/or Chuggles Symptom

5F-7

. . . .

Lack of Power, Sluggish or
Spongy Symptom

5F-9

. . . . . . . . . . . . . . . . . . .

Detonation / Spark Knock Symptom

5F-11

. . .

Hesitation, Sag, Stumble Symptom

5F-13

. . . .

Cuts Out, Misses Symptom

5F-15

. . . . . . . . . . .

Rough, Unstable, or Incorrect Idle,
Stalling Symptom

5F-17

. . . . . . . . . . . . . . . . . . .

Poor Fuel Economy Symptom

5F-20

. . . . . . . .

Dieseling, Run-On Symptom

. . . . . . . . . . . . . . . . . . .

Index

Summary of Contents for 305 CID (5.0L)

Page 1: ...Number 24 Printed in U S A 90 861327 1 1099 1999 Mercury Marine GM V 8 305 CID 5 0L 350 CID 5 7L MARINE ENGINES SERVICE MANUAL MAIN MENU ...

Page 2: ...90 i MerCruiser 24 GM V 8 305 CID 5 0L 350 CID 5 7L 90 861327 1 MerCruiser 24 GM V 8 305 CID 5 0L 350 CID 5 7L 90 861327 1 ...

Page 3: ...ing 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 There...

Page 4: ...machined honed polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch mm When any product component is serviced care and cleanliness are important Throughout this manu al it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure This is considered standard shop practice even if not s...

Page 5: ... Instrumentation E Wiring Diagrams Section 5 Fuel Systems A Fuel Delivery System For Carbureted Engines B Mercarb 2 Barrel Carburetor C Fuel Delivery System For Electronic Fuel Injection D Fuel Injection Descriptions And System Operation E Fuel Injection Disassembly And Reassembly F Fuel Injection System Troubleshooting G Diagnostics Section 6 Cooling System A Seawater Cooled Models B Closed Coole...

Page 6: ... 18 Changing Oil and Filter 1B 18 Changing Water Separating Fuel Filter 1B 19 MCM Sterndrive Models 1B 19 MIE Inboard and Ski Models 1B 20 Power Steering System 1B 21 Checking Fluid Level 1B 21 Engine Warm 1B 21 Engine Cold 1B 21 Filling and Bleeding 1B 22 Closed Cooling System 1B 23 Checking Coolant Level 1B 23 Flushing System MCM Sterndrive 1B 24 Boat Out of Water 1B 24 Boat In Water 1B 25 Flush...

Page 7: ...n Engine 1C 25 Important Information 1C 25 Water on Top of Pistons 1C 26 Water in Crankcase Oil 1C 26 Engine Overheats Mechanical 1C 27 Engine Overheats Cooling System 1C 28 Insufficient Water Flow from Belt Driven Seawater Pickup Pump 1C 29 Power Steering 1C 30 Poor Erratic or No Assist 1C 30 Noisy Pump 1C 31 Fluid Leaks 1C 31 Troubleshooting Silent Choice Exhaust Silencer System 1C 32 Compressor...

Page 8: ...3A 32 Cleaning and Inspection 3A 32 Installation 3A 33 Cylinder Head and Valve Conditioning 3A 34 Disassembly 3A 34 Valve Guide Bore Repair 3A 37 Valve Springs Checking Tension 3A 37 Rocker Arm Stud Replacement 3A 38 Valve Seat Repair 3A 39 Valve Grinding 3A 40 Reassembly 3A 40 Crankcase Oil Dipstick Specifications 3A 43 All Engines 3A 43 Oil Pan 3A 45 Removal 3A 45 Cleaning and Inspection 3A 45 I...

Page 9: ... Starting System 4A 11 Delco 14MT Direct Drive Starter 4A 12 Specifications 4A 12 Starter Specifications 4A 12 Torque Specifications 4A 12 Lubricants Sealants Adhesives 4A 12 Exploded View 4A 13 Solenoid Switch 4A 14 Removal 4A 14 Installation 4A 14 Motor 4A 14 Removal 4A 14 Cleaning and Inspection 4A 14 Checking Pinion Clearance 4A 15 Checking Commutator End Frame Gap 4A 16 Installation 4A 17 Del...

Page 10: ...4B 18 Rotor Sensor Wheel 4B 19 Removal 4B 19 Cleaning and Inspection 4B 19 Installation 4B 20 Sensor 4B 21 Testing 4B 21 Removal 4B 21 Cleaning and Inspection 4B 21 Installation 4B 22 Distributor Repair 4B 22 Removal 4B 22 Disassembly 4B 22 Reassembly 4B 22 Distributor Installation 4B 23 Replacing Distributor Gear 4B 25 Removal 4B 25 Installation 4B 25 GM EST Distributor 4B 26 Removal 4B 26 Disass...

Page 11: ... 4E 4 MEFI 1 and MEFI 2 MCM 5 0L EFI 5 7L EFI and 350 Mag MPI Engines 4E 6 MEFI 3 MCM 5 0L EFI 5 7L EFI and 350 Mag MPI Engines 4E 8 MIE 5 7L Inboard 4E 10 MIE 350 Mag MPI and Black Scorpion Engines Starting and Charging System Harness 4E 12 Fuel and Ignition System Harness 4E 14 MEFI 1 MCM 5 0L EFI 5 7L EFI Alpha Engines 4E 14 MEFI 3 5 0L EFI and 5 7L EFI Engines 4E 15 MEFI 1 and MEFI 2 MCM 350 M...

Page 12: ...rburetor 5B 16 Repair 5B 17 Removal 5B 17 Exploded View 5B 18 Exploded View Parts List 5B 19 Disassembly 5B 20 Cleaning and Inspection 5B 28 Reassembly 5B 30 Installation 5B 40 Section 5C Fuel Delivery System For Electronic Fuel Injection Specifications 5C 2 Torque Specifications 5C 2 Tools 5C 2 Lubricants Sealants Adhesives 5C 2 Replacement Parts Warning 5C 2 Precautions 5C 3 Fuel Supply Connecti...

Page 13: ...5E 5 Intake Manifold And Fuel Rail 5E 6 Intake Manifold And Fuel Rail 5E 7 Fuel Pressure Relief Procedure 5E 8 350 Mag MPI Components 5E 8 Flame Arrestor 5E 8 Throttle Body 5E 11 Throttle Position Sensor 5E 14 Idle Air Control IAC Valve 5E 16 Knock Sensor 5E 18 Knock Sensor Module 5E 19 Fuel Pump Relay 5E 20 System Relay 5E 20 Electronic Control Module ECM 5E 21 Engine Coolant Temperature ECT Sens...

Page 14: ...ostic Tests 5G 24 On Board Diagnostic OBD System Check 5G 24 Chart A 1 No MIL or No DLC Data 5G 26 Chart A 2 MIL ON Steady Will Not Flash DTC 12 5G 28 Chart A 3 Engine Cranks But Will Not Run 5G 30 Chart A 4 Fuel System Diagnosis 5G 32 Chart A 5 Fuel System Electrical Test 5G 34 Chart A 6 EFI System Ignition Relay Check 5G 36 Chart A 7 Ignition System Check 5G 38 Chart A 8 Idle Air Control IAC Fun...

Page 15: ...ropshaft Coolers 6A 24 Water Flow Diagrams 6A 25 305 cid and 350 cid Bravo Inboard and Ski Engines 6A 25 305 cid and 350 cid Alpha Engines 6A 26 Section 6B Closed Cooled Models Torque Specifications 6B 2 Lubricants Sealants Adhesives 6B 2 Specifications 6B 2 Closed Cooling System Capacity 6B 2 Coolant Specification 6B 2 Thermostat 6B 2 Pressure Cap Rating 6B 2 Description 6B 3 Coolant Recommendati...

Page 16: ...Replacement 7C 5 Component Replacement 7C 6 Below Swim Platform Exhaust Pipe 7C 7 Silent Choice Exhaust System 7C 8 Exhaust Tube Installation 7C 8 Air Tube Routing 7C 10 Maintenance 7C 11 Exhaust Muffler Kit 7C 12 Cleaning and Inspection 7C 13 Installation 7C 14 Maintenance Instructions 7C 15 DRIVES Section 8A Velvet Drive In Line And V Drive Transmission Specifications 8A 2 Identification 8A 2 Ra...

Page 17: ...re Test 8B 23 Transmission Repair 8B 23 Section 8C Hurth Transmissions Identification 8C 2 Specifications 8C 2 Torque Specifications 8C 2 Operating Specifications 8C 2 Fluid Specifications 8C 3 Tools 8C 3 Lubricants Sealants Adhesives 8C 3 Rotation 8C 4 Shift Cable Installation and Adjustment 8C 5 Checking Transmission Fluid Level 8C 10 Draining Transmission 8C 11 Filling Transmission 8C 12 Transm...

Page 18: ...9A 3 Power Steering Pump and Components 9A 3 Serpentine Belt Routing 9A 4 Serpentine Belt Adjustment 9A 6 Removal 9A 6 Installation 9A 6 Important Service Information 9A 7 Pump Pulley Replacement 9A 7 Testing and Repair 9A 8 Checking Pump Fluid Level 9A 8 Filling and Air Bleeding System 9A 8 Pump Assembly 9A 8 Removal 9A 8 Installation 9A 10 Hydraulic Hoses and Fluid Cooler 9A 11 ...

Page 19: ... 2 How to Use This Manual 1A 2 Page Numbering 1A 2 How to Read a Parts Manual 1A 3 Directional References 1A 4 Engine Rotation 1A 4 Engine Serial Number Locations 1A 5 Propeller Information 1A 5 Water Testing New Engines 1A 6 Boat and Engine Performance 1A 6 Boat Bottom 1A 6 Marine Fouling 1A 8 Weight Distribution 1A 9 Water in Boat 1A 9 Elevation and Climate 1A 9 Index ...

Page 20: ...d 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 8 Models Covered ...

Page 21: ...sure 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 ...

Page 22: ...oward bow 72000 STARBOARD RIGHT PORT LEFT FORE or BOW FRONT AFT or STERN REAR 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 D...

Page 23: ...ropellers Changing diameter pitch or coupling of a propeller will affect engine rpm and boat perfor mance The blade configuration also will affect performance Two like propellers same pitch and diameter from two different manufacturers will perform differently 1 It is the responsibility of the boat manufacturer and or selling dealer to equip the boat with the correct propeller to allow the engine ...

Page 24: ...se excessive fuel consumption engine overheating and possible piston damage due to detonation Conversely installing a propeller allowing engine to run above the specified rpm limit will cause excessive wear on internal engine parts which will lead to premature engine failure Water Testing New Engines Use care during the first 20 hours of operation on new Mercury MerCruiser engines or possible engi...

Page 25: ... 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 direc tion It can cause the boa...

Page 26: ...eference 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 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...

Page 27: ...perform ance handling ability and riding comfort In extreme rough water conditions the safety of the boat and passengers may be in jeopardy 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 ...

Page 28: ...GENERAL INFORMATION SERVICE MANUAL NUMBER 24 Page 1A 10 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index Index ...

Page 29: ... Engine Cold 1B 21 Filling and Bleeding 1B 22 Closed Cooling System 1B 23 Checking Coolant Level 1B 23 Flushing System MCM Sterndrive 1B 24 Boat Out of Water 1B 24 Boat In Water 1B 25 Flushing System MIE Inboard and Ski 1B 26 Transmission Fluid 1B 27 Lubrication 1B 28 Throttle Cable 1B 28 Shift Cable and Transmission Linkage 1B 28 MCM Sterndrive Models 1B 28 MIE Inboard and Ski Models 1B 29 Engine...

Page 30: ...ight 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 Index ...

Page 31: ...ements 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 Day Start Each Day End Weekly Every Two Months Check crankcase oil interval can be extended based on experi ence If operating in salt brachish or polluted ...

Page 32: ... 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 ...

Page 33: ...se 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 transmission fluid Check water pickups for debris or marine growth Check water strainer and clean Check coolant level Only perform maintenance which applies to your particular power package Standard Models Horizon Models Index ...

Page 34: ...tributor 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 com...

Page 35: ... at idle rpm 4 10 BTDC Preliminary Idle Mixture 1 1 4 Turns 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 i...

Page 36: ...12YC NGK BPR6EFS Spark Plug Gap 045 in 1 1 mm Timing at idle rpm 5 8 BTDC 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...

Page 37: ...Timing at idle rpm 3 10 BTDC4 8 BTDC4 Preliminary Idle Mixture 1 1 4 Turns Does Not Apply 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 s...

Page 38: ...idle rpm 10 BTDC4 8 BTDC4 Preliminary Idle Mixture 1 1 4 Turns Does Not Apply 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 ...

Page 39: ...ORTANT It may be necessary to adjust oil levels depending on installation angle and cooling systems heat exchanger and fluid lines Model 350 cid 5 7L Crankcase Oil With Filter 1 5 5 5 25 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...

Page 40: ... 1 2 1 33 1 Mobil 424 or Dexron III Automatic Transmission Fluid Do Not Mix Velvet Drive 72 Series V Drive 3 2 75 1 Mobil 424 or Dexron III Automatic Transmission Fluid Do Not Mix 5000A 2 1 2 2 4 5000V 3 2 75 1 Dexron III Automatic Transmission Fluid Walter V Drive Model RV 36 3 4 0 5 1 SAE 30 Heavy Duty Motor Exxon Spartan EP 68 Gear Oil APG 80 Gear Oil ZF Hurth 630V 630A 800A 4 1 4 4 0 3 1 4 3 0...

Page 41: ...l throttle acceleration from IDLE speed Do not operate at full throttle until engine reaches normal operating tempera ture 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...

Page 42: ...e is required in certain areas of the USA The two types of oxygenates used in these fuels is 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 aggrava...

Page 43: ...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 s...

Page 44: ... Drive Dexron IIl Walter V Drive SAE 30 Heavy Duty Motor Exxon Spartan EP 68 Gear Oil or APG 80 Gear Oil Hurth Dexron IIl Power Steering Fluid Use Quicksilver Power Trim and Steering Fluid or automatic transmission Fluid ATF Dexron IIl 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...

Page 45: ...nkcase oil selection The oil filter should always be changed with oil 70534 Quicksilver 4 Cycle Marine Engine Oil SAE 20W SAE 30W SAE 40W 32 F 0 C 50 F 10 C 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 cranksha...

Page 46: ...D 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 ...

Page 47: ...e 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 MCM Sterndr...

Page 48: ...ngine 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 MIE Inboard and Ski Models 1 Remove water separating fuel filter and sealing ring from mounting bracket and discard 2 Coat sealing ring on new filter with motor oil 3 Thread filter onto bracket and tighten securel...

Page 49: ...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 72519...

Page 50: ...eel 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...

Page 51: ... 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 nor...

Page 52: ...ar housing as shown 2 Attach a water hose between the flushing attachment and a water tap 72693 a b 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 ...

Page 53: ...ot 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 a...

Page 54: ...r inlet hose to prevent seawater from entering boat 2 Remove inlet hose from seawater pickup pump 3 Using an adaptor connect a water hose from a water tap to seawater pump inlet 4 Partially open water tap approximately 1 3 maximum Do not use full water pressure 5 Place the remote control lever in neutral position and start engine WARNING When flushing be certain the area around propeller is clear ...

Page 55: ...erating temperature place selector lever in neutral 2 Shut off engine 3 Carefully remove dipstick and wipe clean 4 Immediately insert clean dipstick and read oil level NOTE Oil level must be checked immediately after engine shut down to prevent an incor rect reading Oil drains back into the transmission from the cooler and cooler lines 5 Add or remove oil as necessary until the oil is at the requi...

Page 56: ...urfaces with SAE 30W motor oil 74941 b a a a a b 71359 2 Barrel Carbureted Models EFI Models a Pivot Points b Guide Contact Surface Shift Cable and Transmission Linkage MCM STERNDRIVE MODELS 1 Lubricate pivot points and guide contact surfaces with SAE 30W motor oil 72016 b b a a a Typical Shift Cable a Pivot Points b Guide Contact Surface Index ...

Page 57: ... SKI MODELS 1 Lubricate pivot points and guide contact surfaces with SAE 30W motor oil 72528 b a a Typical Shift Cable a Pivot Points b Guide Contact Surface 2 Lubricate detent ball and holes in lever with SAE 30W motor oil 71457 a Typical In Line Transmission a Poppet Ball Locations Index ...

Page 58: ...ser 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 71569 a 72529 a b b Alpha Drive Coupler Bravo Drive Coupler a Grease Fitting b Quic...

Page 59: ...re to ground coil high tension wire to block Failure to ground coil wire may cause damage to ignition coil in addition to being a safety hazard Stay clear of all moving parts 1 Remove ignition coil high tension wire from distributor cap tower and ground it to engine block with jumper wire While cranking engine with starter motor lubricate starter motor front bushing through oil cover with motor oi...

Page 60: ...le and highly explo sive under certain conditions NEVER use gasoline as a cleaning solvent Top Mounted Flame Arrestor 1 Remove crankcase ventilation hose from fitting on side of flame arrestor housing 2 Remove flame arrestor 75831 76501 a a Early Bracket Models Later Throttle Body Stud Models 75828 76365 a a Early Clamp Models Horizon Models a Flame Arrestor 3 Clean flame arrestor in solvent Blow ...

Page 61: ...rrestor a Flame Arrestor b Clamp c Vent Hose 75779 a b c Later Style Flame Arrestor a Flame Arrestor b Nut c Vent Hose 4 Clean flame arrestor in solvent Blow dry with compressed air 5 Clean crankcase ventilation hoses in solvent Blow dry with compressed air 6 Inspect crankcase ventilation hoses for cracks or deterioration and replace if necessary 7 Install flame arrestor and related components 8 T...

Page 62: ...ulleys are referenced as though you were standing in front of the engine looking at the belt Upper Right Idler Pulley Bracket Stud Stud is threaded into the cylinder head From the cylinder head is a nut a flat washer the lifting eye bracket the oil cooler bracket the idler pulley bracket and then a nut Upper Left Idler Pulley Bracket Bolt From the cylinder head is an idler pulley bracket a flat wa...

Page 63: ... not shown Checking replacing and adjustment procedures are the same 76389 a e b c d a Typical Inboard Model a Idler Pulley b Seawater Pump Pulley c Crankshaft Pulley d Circulating Pump Pulley e Alternator Pulley 76463 a e b c d a Typical Sterndrive Model a Idler Pulley b Seawater Pump Pulley c Crankshaft Pulley d Circulating Pump Pulley e Alternator Pulley Index ...

Page 64: ...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...

Page 65: ...ine 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 caeburetor 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 correc...

Page 66: ... to stablilize NOTE MEFI 1 models only manually adjust remote control throttle lever to get 1200 engine rpm NOTE MEFI 2 and 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 igniton timing If incorrect rotate the distributor until timing is correct Torque clamping screw to 18 lb ft...

Page 67: ... 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 swit...

Page 68: ...rCruiser 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 no...

Page 69: ...es 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 d Turn ignition key to OFF position e Refer to Flushing Cooling System and appropriately remove water supply to the seawater pickup pump 10 Clean flame arrestor and crankcase ventilation hoses and reinstall 11 Lubricate all items listed ...

Page 70: ...starboard manifold fittings 3 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 74073 a b c d e St...

Page 71: ... water circulating pump hose or drain plug if equipped as shown 72587 a 76038 a Hose Water Circulating Pump To Thermostat Housing 6 Remove the drain plug from the water tube or Cool Fuel System cooler if equipped 75081 a 75018 a Some Carbureted Models Fuel Injected Models a Drain Plug 7 Remove seawater pump inlet hose as shown 75533 a b a Seawater Inlet Hose b Hose To Cooler 8 Crank engine over sl...

Page 72: ... 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 10 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 t...

Page 73: ...nifold fittings 3 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 74073 a b c d e Starboard Side...

Page 74: ...plug if equipped as shown 72587 a 76038 b a Hose Water Circulating Pump To Thermostat Housing b Water Circulating Pump Hose Drain Plug 6 Remove the drain plug from the water tube some carbureted models or Cool Fuel Sys tem cooler fuel injected models 75044 a 75018 a Some Carbureted Models Fuel Injected Models a Drain Plug 7 Remove both hoses from the seawater pump 75533 b a a Seawater Inlet Hose b...

Page 75: ...he 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 10 For additional assurance against freezing and corrosion in 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 ...

Page 76: ...olant is used 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 2 Remove drain plug from bottom of port and starboard exhaust manifolds 74073 a a Drain Plug 3 Remove the drain ...

Page 77: ...hanger 6 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained 7 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...

Page 78: ...at the boat is as level as possible to ensure complete draining of cooling sys tem 2 Remove drain plugs port and starboard from bottom of exhaust manifolds 74073 a a Drain Plug 3 Remove the drain plug from the water tube or Cool Fuel System cooler if equipped 74988 a 75018 a Some Carbureted Models Fuel Injected Models a Drain Plug 4 Loosen hose clamps and remove both hoses from seawater pickup pum...

Page 79: ... to purge any water trapped in seawater pickup pump DO NOT ALLOW ENGINE TO START 8 After seawater section of cooling system has been drained completely a Except blue colored drain plugs with seals coat threads of drain plugs with Quicksil ver Perfect Seal Install all drain plugs and tighten securely b Apply Quicksilver Perfect Seal to both sides of new end plate gaskets Assemble new gaskets new se...

Page 80: ...meter 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 71216 a d ...

Page 81: ...ropriate 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 ...

Page 82: ...MAINTENANCE SERVICE MANUAL NUMBER 24 Page 1B 54 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 83: ...C 12 Instrumentation Malfunction 1C 12 Radio Noise 1C 12 Poor Fuel Economy 1C 13 Carburetor Malfunctions 1C 14 Engine Runs Poorly at Idle 1C 15 Engine Runs Poorly At High RPM 1C 16 Engine Acceleration Is Poor 1C 17 Troubleshooting with Vacuum Gauge 1C 17 Engine Noise 1C 18 Important Information 1C 18 Valve Cover Area 1C 18 Cylinder Area 1C 19 Camshaft Area 1C 19 Crankshaft Area 1C 20 Miscellaneous...

Page 84: ...tion 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 com pressed 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 p...

Page 85: ...serviced clean file and regap 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 regap plugs and rei...

Page 86: ...sits are built up on shell insulator and electrodes This is nor mal appearance with certain branded fuels Accumulation on ground electrodes and shell areas may be unusually heavy but may be easily chipped off Plugs can be serviced clean file and regap and reinstalled 72422 Pre Ignition Damage Pre ignition damage is caused by excessive high temperatures Center electrode melts first followed by grou...

Page 87: ...ratures are restored upon installa tion of new plugs deposits loosen from top of piston and head and are thrown against hot insulator Plugs can be serviced clean file and regap 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 c...

Page 88: ...roper 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 Propeller ventilating D...

Page 89: ...o propeller ventila tion keel located too close to propeller and or too deep in the water ventilation Drive installed too high on transom wrong gear ratio Operation Engine coupler slipping Unit trimmed out too far RPM Too Low Cause Special Information Propeller Damaged pitch too great diameter too great Boat Dirty or damaged bottom permanent or power hook in bottom false bottom full of water Drive...

Page 90: ...one of the three are missing weak or arriving at the wrong time the engine will not operate 2 Determine if there is fuel present by looking down the carburetor venturi while actuating throttle There should be a stream of fuel coming out of the accelerator pump nozzles if the carburetor has fuel 3 Check ignition system operation Remove coil wire from tower on distributor cap Hold coil wire near gro...

Page 91: ...lts 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 form coil tower to ground Discon nect WHT GRN lead from distributor Place ignition key in RUN position Rapidly strike the terminal of Spark at Replace igni key in RUN position Rapidly strike the terminal of the WHT GRN lead that comes from module S...

Page 92: ...opening Float adjustment Float leaks or is saturated with fuel Needle and seat leaking Carburetor gaskets leaking Excessive fuel pump pressure Cracked or porous carburetor body Unseats needle and seat Fuel System Lean Cause Special Information Empty fuel tank Fuel shut off valve closed Vapor lock Engine will not start after warm engine shut down Automatic choke Stuck open wrong adjustment Miscella...

Page 93: ...neutral start safety switch Open circuit Starter solenoid Starter motor Mechanical engine malfunction Charging System Inoperative Cause Special Information Loose or broken drive 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 ba...

Page 94: ...adio Noise Cause Special Information A popping noise that will increase with engine rpm Noise will stop as soon as engine is turned off Ignition System wrong spark plugs cracked distributor cap cracked coil tower leaking spark plug wires moisture on igni tion components A High pitched whine in the radio Alternator poor brush contact on the slip rings A hissing or crackling noise when instru ments ...

Page 95: ...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 Carburetor Idle mixture settings accelerator pump adjustments linkage binding choke adjust ment carburetor flooding over main fuel jets clogged or improperly sized Improper fuel Crankcase ventilatio...

Page 96: ...crews improperly adjusted Idle passages dirty Rough idle Throttle valves worn or damaged Engine flooding Vacuum leak Throttle body heat passages plugged Accelerator pump damaged malfunction ing or improperly adjusted Leaking gaskets Automatic choke malfunctioning Power valve broken or improperly adjusted Hesitation or acceleration flatness Throttle valves worn or damaged Throttle body heat passage...

Page 97: ...at adjustment Low top speed or lack of power Main metering jets clogged or improperly sized Leaking gaskets Idle rpm too low Idle mixture screws improperly adjusted Poor cold engine operation Throttle valves worn or damaged Automatic choke malfunctioning Engine flooding Idle rpm too low Idle mixture screws improperly adjusted Engine flooding Engine stalls Automatic choke malfunctioning Engine stal...

Page 98: ...pply Plugged fuel tank vent Improper fuel supply Refer to Carburetor Malfunctions Incorrect ignition timing Low grade of fuel or water in the fuel Spark plugs Fouled burned cracked porcelain incor rect heat range Spark plug wires Poor insulation broken wires Distributor cap or rotor Dirty or cracked Coil Damaged or malfunctioning Distributor Excessive play in shaft Engine overheating Refer to Engi...

Page 99: ...lugs Fouled burned wrong heat range cracked porcelain Float adjustment Dirty carburetor Low compression Troubleshooting with Vacuum Gauge Reading Cause Steady reading between 15 21 inches at idle rpm Normal Extremely low reading but steady at idle rpm Vacuum leak incorrect timing underpow ered boat faulty boat bottom Fluctuates between high and low at idle rpm Blown head gasket between two adjacen...

Page 100: ...bottom This can help determine which components are at fault 5 Sometimes noises can be caused by moving parts coming in contact with other compo nents 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 ...

Page 101: ...ation Possible Causes Crankshaft timing sprocket damaged Timing chain damaged Camshaft area front of engine timed to 1 2 engine speed Fuel pump damaged 1 2 engine speed Valve lifter damaged Cam bearings damaged Fuel pump damaged Camshaft area center of engine timed to 1 2 engine speed Valve lifter damaged 1 2 engine speed Cam bearing damaged Distributor gear damaged Camshaft area rear of engine ti...

Page 102: ...to engine speed Main bearing damaged Rod bearing damaged Crankshaft striking pan or pan baffle Crankshaft area center of engine timed Main bearing damaged to engine speed Rod bearing damaged Loose flywheel cover Loose coupler Crankshaft area rear of engine timed to Loose flywheel engine speed Main bearing damaged Rod bearing damaged Loss of oil pressure Crankshaft area throughout engine timed Main...

Page 103: ...p Popping through carburetor Vacuum leak Valve adjustment Valve timing Burned or stuck valve 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 Drive belt slipping Squeaks or squeals Dry or tight bearing in an access...

Page 104: ...temperature As the air tempera ture warms up and engine is operating at normal temperature it is normal for oil pressure to drop Low engine oil pressure at idle With modern engines and engine oils low oil pressure readings at idle do not neces sarily mean there is a problem If valve lift ers do not clatter at idle there is a suffi cient volume of oil to lubricate all internal moving parts properly...

Page 105: ... idling in cold water condensation Oil pump Relief valve stuck open pickup tube restricted worn parts in oil pump air leak on suction side of oil pump or pickup oil tube Oil leak can be internal or external Oil passage plugs leaking cracked or porous cylinder block Excessive bearing clearance Cam bearings main bearings rod bear ings High Oil Pressure Cause Special Information Oil too thick Wrong v...

Page 106: ...rn valve stems or valve guides Defective oil cooler Crack in cooler tubes Defective piston rings Glazed scuffed worn stuck improperly installed ring grooves worn improper break in wrong end gap Defective cylinders Out of round scored tapered glazed excessive piston to cylinder clearance cracked piston Excessive bearing clearance NOTE ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS SPECIFIED IN M...

Page 107: ...ine and see if problem can be duplicated If problem can be duplicated a mechani cal problem exists If the problem cannot be duplicated the problem is either an operator error or a problem that exists only under certain environmental conditions If 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 crankca...

Page 108: ...per engine or exhaust hose installa tion Cracked exhaust manifold Improper manifold to elbow gasket instal lation Loose cylinder head bolts Blown cylinder head gasket Check for warped cylinder head or cylin der block Cracked valve seat Porous or cracked casting Check cylinder heads cylinder block and intake manifold Water in Crankcase Oil Cause Special Information Water in boat bilge Boat has been...

Page 109: ...haust restriction Valve timing off Jumped timing chain or improperly installed Blown head gasket s 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 Using a clear plastic hose look for air bubbles between seawater pump and engine If ther...

Page 110: ...nked or collapsed Seawater pickup clogged Obstruction on boat bottom causing water turbulence Obstruction will be in front of seawater pickup causing air bubbles to be forced into cooling system Defective thermostat Exhaust elbow water outlet holes plugged Insufficient seawater pump operation Worn pump impeller Obstruction in cooling system such as casting flash sand rust salt etc Refer to water f...

Page 111: ...Clogged or improperly installed sea strainer Loose hose connections between seawa ter pickup and seawater pump inlet Pump will suck air pump may fail to prime or will force air bubbles into cooling sys tem Seawater inlet hose kinked or plugged Seawater pickup plugged Obstruction on boat bottom causing water turbulence Obstruction will be in front of seawater pickup causing air bubbles to be forced...

Page 112: ...s and or steering helm Cable or helm partially frozen from rust or corrosion cable over lubricated improper cable installation Binding in stern drive unit Refer to appropriate Sterndrive Service 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 t...

Page 113: ...es or debris in pas sages Stop nut adjusted improperly Refer to appropriate Sterndrive Service Manual Steering cables installed that do not meet BIA standards Refer to appropriate Sterndrive Service Manual Fluid Leaks Cause Special Information Loose hose connections Refer to SECTION 9A for bleeding instruc tions Damaged hose Oil leaking from top of pump System overfilled fluid contains water fluid...

Page 114: ...BER 24 Page 1C 32 90 861327 1 OCTOBER 1999 Troubleshooting Silent Choice Exhaust Silencer System 72534 b c d e f 72533 a g a Air Cylinder Assembly b Air Pump c Solenoid d Check Valve e Relief Valve f Air Intake Valve g Mode Switch Index ...

Page 115: ...block does not have battery voltage when mode switch is held in THRU TRANSOM position Wiring is faulty If voltage is present air pump is faulty Air pump Runs System Inoperative With air pump running check hoses fittings solenoid and relief valve for air leakage Replace parts as needed System operates but goes THRU PROP after air pump stops running 1 Ensure that air pressure is not leaking past sol...

Page 116: ...TROUBLESHOOTING SERVICE MANUAL NUMBER 24 Page 1C 34 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 117: ...ration 2A 3 Removal 2A 3 Installation 2A 5 Drive Shaft Extension Models 2A 7 Engine Mount Adjustment Was Not Disturbed During Service 2A 7 Engine Mount Adjustment Was Disturbed During Service 2A 10 Alignment 2A 15 Water Hose Connections 2A 17 Electrical Connections 2A 18 Fuel Supply Connections 2A 20 Throttle Cable Installation and Adjustment 2A 21 Power Steering Connections 2A 23 Exhaust Hose Con...

Page 118: ...de See Note Drive Shaft 50 68 Extension Housing To Flywheel Housing 30 41 Flywheel Housing 30 41 Front and Rear Engine Mounts Battery Cables Securely Rear Engine Mount Bracket 50 68 NOTE Tighten then loosen 1 2 turn Tools Description Part Number Engine Alignment Tool 91 805475A1 Universal Protractor Obtain Locally Lubricants Sealants Adhesives Description Part Number Engine Coupler Spline Grease 9...

Page 119: ...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 on fuel injection models and retain locknuts and hardware 5 Disconnect bullet connectors of trim sender wires coming from transom assembly from...

Page 120: ...exact same positioning during reassembly Disconnect drive shaft from output flange 70237 c b a Engine End Shown a Matching Parts On Flange And Drive Shaft Connection b Extension Drive Shaft U Joint Yoke c Output Flange CAUTION Center lifting eye located on top of thermostat housing is used for engine align ment only DO NOT use to lift entire engine CAUTION DO NOT allow lifting sling to hook or com...

Page 121: ... stringers 14 Support engine with suitable sling through lifting eyes on engine and remove front and rear engine mounting bolts Retain hardware 76396 a b 72977 72579 b a a Suitable Sling b Engine Lifting Eyes 15 Carefully remove engine DO NOT hit power steering control valve Installation 1 Be certain fiber washers cemented in place on inner transom plate are present Inspect fiber washers Replace i...

Page 122: ...l occur 6 Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended Refer to Removal section for location of lifting eyes 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 IMPORTANT Engine attaching hardware must ...

Page 123: ...ill occur DO NOT allow lifting sling to hook or compress engine components or damage will occur 1 Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended Refer to Removal section for location of lifting eyes 2 Lift engine into approximate position in boat using an overhead hoist 3 Set engine on stringers 4 Grease drive shaft universal joints with Quicksi...

Page 124: ...ut Shaft Flange b Drive Shaft c 4 Bolt 7 16 20 x 1 1 2 In 38 mm Long d 4 Nut 7 16 In 20 e Matching Marks Made Upon Disassembly IMPORTANT Failure to properly position output shaft flange may result in bearing damage 6 Relieve hoist tension from engine then slide engine fore or aft as needed to obtain 1 4 in 6 mm clearance between flange shoulder and extension shaft housing bearing 72591 c c b a a F...

Page 125: ...ecified 70246 a b Top View Shown These Dimensions Must Be Equal a Must equal b b Must equal a 8 After engine has been aligned correctly fasten front and rear engine mounts to stringers Tighten mounting bolts securely 9 Apply Loctite 27131 to threads of bottom drive shaft shield retaining screws and install bottom shield on engine end as shown Torque screws to 30 lb ft 41 Nm 72028 a c b Engine End ...

Page 126: ... OF POWER PACKAGE THROUGHOUT INSTALLATION 72429 a a a Reference Marks 1 Refer to SECTION 8D Drive Shaft Models Propeller Shaft and remove drive shaft 2 Position base of protractor against input shaft flange as shown NOTE and RECORD the number of degrees and to which side of the reference mark the indicator needle has moved in the following chart Reading from Step 1 degrees to the side of reference...

Page 127: ...t U joint centerlines at bearing support input shaft DO NOT install shields at this time CAUTION Engine MUST BE aligned correctly to achieve proper engine operation and to pre vent damage to drive shaft If drive shaft is run at an incorrect angle damage to uni versal joint bearings may result 6 Position base of protractor on drive shaft then raise or lower engine as boat construc tion permits unti...

Page 128: ...ength of a and b to the centers of bolt holes They MUST BE EQUAL If they are not equal slide the aft and forward ends of the engine equal amounts in opposite directions to obtain equal lengths for a and b 70246 a b Top View Shown These Dimensions Must Be Equal a Must equal b b Must equal a b Recheck Step 8 If Step 8 is not as specified adjust and recheck Step 9a Continue this process until both St...

Page 129: ...ousing b Starter Housing Cover Plate c Protractor 12 Position protractor on drive shaft and recheck angle Angle should be the same as that recorded in Step 6 If not raise or lower all four engine mount adjustment nuts an equal amount until correct angle is reached 13 Tighten ALL engine mount nuts securely Bend washer tab down on each adjustment nut 72536 a e b c d a Nut and Lockwasher b Adjustment...

Page 130: ...d install bottom shields on engine and transom end as shown Torque screws to 30 lb ft 41 Nm Then install both top shields as shown Torque bolts and nuts to 30 lb ft 41 Nm 70245 e d a c b Top Shield and Bottom Shield at Transom End Engine End Similar a Top Shield b Bottom Shield c 4 Bolt 3 8 x 16 x 7 8 In 22 mm Long d 4 Nut 3 8 16 e 3 Screws Hidden Index ...

Page 131: ...ttempt 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 If the tool does not fit remove it and carefully raise or lower the from end of the engine as necessary and attempt to insert the alignment tool c Repeat step b until the alignment tool installs easily SLIDES FREELY all the way into and...

Page 132: ...en alignment is correct tighten locknut or nut with lockwasher on each mount securely h Bend tab washer down against flat on adjusting nut 72922 a e b d c 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 i Remove alignment tool if not already removed 2 Tighten all exhaust system hose clamps s...

Page 133: ...meter of hose This will cause a hot spot in the hose which may eventually burn through 72538 Correct Incorrect WATER HOSE 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 secu...

Page 134: ...ing Harness Receptacle Bracket 2 Connect trim position sender leads from gimbal housing to leads from engine harness 72582 a b c d a BROWN WHITE From Engine Harness b BLACK From Engine Harness c BLACK From Transom d BLACK 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 Ind...

Page 135: ...ne Harness b Switch Harness c BLACK d WHITE GREEN or GRAY 5 Connect any grounding wires or accessories that may have been disconnected 6 Connect wires to MerCathode controller assembly as shown Apply a thin coat of Quick silver Liquid Neoprene to all connections 22232 a b c d a ORANGE Wire From Electrode On Transom Assembly b RED PURPLE Wire Connect Other End To Positive Battery Terminal c BLACK W...

Page 136: ... open flame in area Wipe up any spilled fuel immediately WARNING Avoid gasoline fire or explosion Improper installation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and or cause a fuel leak 1 Connect fuel line to appropriate location as shown Refer to the following caution for proper tightening CAUTION Remove plastic plug from fuel inlet hole Apply 592 Loctite Pi...

Page 137: ...parts DO NOT fasten any items to throttle cable Outer cable must be free to move when cable is actuated b 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 mov ing remote control lever Adjust barrel on throttle cable to align with anchor stud c Secure throttle cable with hardware...

Page 138: ... lever contacts carburetor body cast ing 71711 a c b Fuel Injection Models a Flat Washer and Locknut b Cable Barrel c Flat Washer And Locknut e Return remote control throttle lever to idle position Ensure that throttle lever con tacts idle speed adjustment screw 72283 c a b d e 2 Barrel Carburetor Models a Throttle Lever Tang b Carburetor Body c Idle rpm Adjustment Screw d Wide Open Throttle e Idl...

Page 139: ...e Sterndrive Service Manual 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 Be careful not to cross thread or overtighten fittings 1 Connect front hose from the cooler and rear hose from pump Route hoses as shown 2 Torque f...

Page 140: ...xhaust tubes as shown in a or b following Tighten all hose clamps securely a On Engines with Thru Prop Exhaust 72027 a b c c d Starboard Side Engine End Shown Port Similar a Exhaust Pipe b Exhaust Hose c Hose Clamps d Exhaust Tube 72584 a c c b d Starboard Side Transom End Shown Port Similar a Exhaust Separator Assembly b Exhaust Hose c Hose Clamps d Exhaust Tube Index ...

Page 141: ...rge water from exhaust elbow will not flow around entire inside diameter of hose This will cause a hot spot in the hose which may eventually burn through 72538 Correct Incorrect 2 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 black to negative battery terminal ...

Page 142: ...MCM MODELS SERVICE MANUAL NUMBER 24 Page 2A 26 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 143: ...lvet Drive In Line and V Drive Transmissions 2B 2 Velvet Drive Down Angle Transmission 2B 2 Hurth Transmissions 2B 3 Torque Specifications 2B 3 Lubricants Sealants Adhesives 2B 4 Preparation 2B 4 Removal 2B 4 Installation and Alignment 2B 6 Engine Final Alignment 2B 7 Engine Connections 2B 10 Attaching Adjusting Reversed Attachment Morse Shift Cables 2B 22 Index ...

Page 144: ... gear is indicated on a decal on transmission case Transmission rotation is described when viewed from the rear of transmission 22556 a b c In Line Transmission Shown Others Similarly Located a Transmission Identification Plate b Gear Ratio In Forward Gear c Output Flange Rotation Decal In Forward Gear Velvet Drive Down Angle Transmission On the Velvet Drive 5000A and 5000V Transmissions the trans...

Page 145: ...ation plate Transmission output shaft rotation and propeller rota tion required in forward gear is indicated on a decal on transmission case Transmission rotation is described when viewed from the rear of transmission Torque Specifications Fastener Location lb in lb ft Nm Battery Cables Engine Mount Pads Securely Hose Clamps Mount Locking Nut Securely NOTE 2 Propeller Shaft Coupler To Transmission...

Page 146: ...spilled fuel immediately 3 Using wrench to stabilize brass coupling 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 Retain locknuts and hardware 5 Disconnect shift cable from transmission 6 Disconnect seawater inlet hose from engine 7 Disconnect exhaust system hoses 8 Disconnect any grounding ...

Page 147: ... suitable sling through lifting eyes on engine 74510 b 75532 a Typical a Rear Lifting Eye b Front Lifting Eye 2 Remove front and rear engine mounting bolts Retain hardware 72638 b a a Typical Mount a Bolts or Lag Screws with Washers b Slot Forward If So Designed 3 Carefully remove engine Index ...

Page 148: ...so designed 350 Magnum Tourna ment Ski rear mount does not have a slotted hole 3 Large diameter of mount trunnion extended as shown 4 Each mount base is downward Tighten clamping screws and nuts slightly to pre vent moving in or out Mounts must be free to pivot when installing engine 70140 70645 f d a e g c b e a g b f c Front Mount Rear Mount a Locking Nut b Adjusting Nut c Trunnion Clamp Screw s...

Page 149: ...d remove sling Proceed to Engine Final Alignment section following Engine Final Alignment CAUTION To avoid vibration noise and damage to transmission output shaft oil seal and bear ings engine must be properly aligned IMPORTANT Engine alignment MUST BE RECHECKED with boat in the water fuel tanks filled and with a normal load on board Engine must be aligned so that transmission output flange and pr...

Page 150: ...t have a shoulder on mating face On these installations use a straight edge to check centerline alignment 72597 Incorrect Correct IMPORTANT Remote V Drive Models refer to remote V drive manufacturer s instruc tions for drive shaft between transmission and remote V drive alignment 4 Check for angular misalignment by hand holding coupling faces tightly together check for a gap between faces with a 0...

Page 151: ... screw and nut on all four mount brackets move engine to the left or right as necessary to obtain proper alignment On mounts which do have a slotted hole a small amount of adjustment can be obtained with slot on front end of mounts Loosen lag screws which fasten mounts to engine bed and move engine as required Tighten lag screws securely IMPORTANT Large diameter of mount trunnion MUST NOT extend o...

Page 152: ...re 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 inlet hose to seawater pump as shown Tighten hose clamp securely 75533 a b Typical a Seawater Inlet Hose b Seawater Pump 2 Connect the instrumentation wiring harness to engine harness plug at location shown 74938 a Typical a Engine Ha...

Page 153: ...ng with suitable wrench and tighten fuel line connectors securely Check for fuel leaks 3 Connect fuel line from fuel tank s to engine Make certain connection is secure Check for leaks 4 Connect exhaust system tubes and hoses using at least two hose clamps at each con nection CAUTION Avoid exhaust hose failure Discharge water from exhaust elbow must flow around entire inside diameter of hose to avo...

Page 154: ...n models with other than Quicksilver shift cables refer to shift cable manufacturer s instructions IMPORTANT Velvet Drive Transmission Warranty is jeopardized if the shift lever pop pet ball or spring is permanently removed if the shift lever is repositioned or changed in any manner or if remote control and cable do not position shift lever correctly a Verify shift cable stud is in appropriate stu...

Page 155: ...Shift lever must be positioned as previously indicated h Place remote control lever in reverse gear position and again check shift lever posi tion Lever must be positioned as previously indicated i If transmission shift lever will position properly in one gear but not in the other recheck shift cable adjustment If transmission shift lever will not position properly in either gear move transmission...

Page 156: ... to cable barrel stud Tighten until contacts Tighten securely but DO NOT OVERTIGHTEN 50947 a b c d e f g Rear Entry Single Station Installation In Line And Remote V Drive 50947 a b c d e f g Rear Entry Dual Station Installation In Line And V Drive a Cable End Guide b Cable Barrel c Cable Barrel Stud d Elastic Stop Nut and Washer e Spacer f Cable End Guide Stud g Elastic Stop Nut and Washer Index ...

Page 157: ... Drive a Cable End Guide b Cable Barrel c Cable Barrel Stud d Elastic Stop Nut and Washer e Spacer f Cable End Guide Stud g Elastic Stop Nut and Washer NOTE For models equipped with a dual station shift bracket such as the one shown refer to shift cable manufacturer s instructions for adjusting the cable Shift lever must be posi tioned as stated in the preceding steps 22457 Dual Station Shift Brac...

Page 158: ...nd guide moving in direction B when remote control handle is placed in forward position 23242 A B Remote control must provide a total shift cable travel at transmission end of at least 2 3 4 in 70 mm This is necessary to position transmission shift lever fully in the forward and reverse gear positions Insufficient shift cable travel will cause transmission to slip and even tually fail 72602 a a 2 ...

Page 159: ...ts and washers from shift cable attaching studs d Locate center of remote control and control shift cable play backlash as follows 1 Check that remote control is in neutral position 2 Push in on control cable end with enough pressure to remove play mark position a on tube 3 Pull out on control cable end with enough effort to remove play mark position b on tube 4 Measure distance between marks a an...

Page 160: ...ift Lever b Poppet Ball MUST BE Centered in This Detent Hole when LEFT HAND Propel ler Shaft Rotation Is Desired c Poppet Ball MUST BE Centered in This Detent Hole when RIGHT HAND Pro peller Shaft Rotation Is Desired d Poppet Ball MUST BE Centered in This Detent Hole for NEUTRAL Position e Install Shift Lever Stud in This Hole when Using Quicksilver Shift Cables h Place remote control shift lever ...

Page 161: ...de b Spacer As Required c Elastic Stop Nut and Washer d Bushing s e Cable Barrel Stud f Cable End Guide Stud 71897 b g c f a e 50073 a g b c d e f d Typical Dual Cable Installation Rear Approach a Cable End Guide b Spacer As Required c Elastic Stop Nut and Washer d Bushing s e Cable Barrel s Position s Only Indicated In Lower Drawing f Cable Barrel Stud g Cable End Guide Stud Index ...

Page 162: ... in cable when moving remote control levers Then adjust cable bar rel to align with anchor stud and slide barrel onto stud 3 Secure throttle cable with hardware as shown Tighten cable end guide locknut until it contacts and then loosen one full turn Tighten barrel locknut until secure but DO NOT Overtighten as cable s must be able to pivot NOTE Refer to the first drawing of the following for insta...

Page 163: ...ift cable to avoid slack in cable when moving remote control lever 5 Adjust barrel on throttle cable to align with hole in anchor plate 6 Position cable as shown 7 Secure throttle cable with hardware as shown Tighten cable end guide locknut until it contacts and then loosen one half turn Tighten barrel locknut until secure but DO NOT Overtighten as cable s must be able to pivot 74109 e a b c f g h...

Page 164: ...2 A50803 077 9 Nut Hex 1 4 28 2 A50901 016 10 Screw Mach Flat Hd 1 4 28 x 5 8 In Long 1 A50120 561 11 Cable Terminal 2 A3000646 12 E Ring 5 16 In 1 Obtain Locally If your engine transmission package is equipped with the above or is being equipped with the above Morse Marine cables observe the following 2 Place remote control and transmission shift lever in neutral IMPORTANT Remote control must pro...

Page 165: ...al securely to prevent from turning and tighten cable nut against terminal NOTE Be sure control head hand lever and transmission shift lever are in neutral position during the above installation 8 Place terminals on pivot pin and secure with E ring NOTE When using this kit with Models S or SR controls adjust the stop screws in the control head to prevent cable from jamming the clutch arm against i...

Page 166: ...MIE MODELS SERVICE MANUAL NUMBER 24 Page 2B 24 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 167: ...led 3A 31 Cylinder Head 3A 32 Removal 3A 32 Cleaning and Inspection 3A 32 Installation 3A 33 Cylinder Head and Valve Conditioning 3A 34 Disassembly 3A 34 Valve Guide Bore Repair 3A 37 Valve Springs Checking Tension 3A 37 Rocker Arm Stud Replacement 3A 38 Valve Seat Repair 3A 39 Valve Grinding 3A 40 Reassembly 3A 40 Crankcase Oil Dipstick Specifications 3A 43 All Engines 3A 43 Oil Pan 3A 45 Removal...

Page 168: ...ar 3A 79 Removal 3A 79 Installation 3A 79 Checking Timing Chain Deflection 3A 79 Camshaft 3A 80 Measuring Lobe Lift 3A 80 Removal 3A 81 Camshaft Bearings 3A 82 Removal 3A 82 Cleaning and Inspection 3A 83 Installation 3A 83 Cylinder Block 3A 84 Cleaning and Inspection 3A 84 Oil Filter By Pass Valve and Adaptor Assembly 3A 88 Removal 3A 89 Cleaning and Inspection 3A 89 Installation 3A 89 Index ...

Page 169: ...kshaft Pulley 43 58 Crankcase Front Cover Timing Chain Gear Cover 106 12 First Pass Short Bolt Medium Bolt Long Bolt 22 30 Cylinder Head Bolt 111 Final Pass Short Bolt 55 Degrees Final Pass Angle Short Bolt Medium Bolt 55 Degrees 65 Degrees Angle Torque Medium Bolt Long Bolt 65 Degrees 75 Degrees Distributor Hold Down 18 25 Exhaust Manifold Filter Adapter 5 16 18 20 27 Flywheel 75 100 Flywheel Dri...

Page 170: ...er Steering Pump Bracket 30 41 Rear Crankshaft Oil Seal Retainer Bolts and Nuts 106 12 Rear Mount MCM 40 54 Rear Mount MIE 50 68 Remote Oil Connector 1 2 in x 13 25 34 Remote Oil Filter Adapter Nut Fitting 20 27 Rocker Arm Cover 106 12 Roller Lifter Restrictor Retainer Plate 18 25 Seawater Pump Brace Seawater Pump Bracket 30 41 Spark Plugs New Cylinder Head 22 30 Spark Plugs All Others 15 20 Start...

Page 171: ...J5802 01 Rocker Arm Stud Installer J6880 Stud Bore Reamer 003 in oversize J5715 Stud Bore Reamer 013 in oversize J6036 Carbon Remover Brush J8089 Piston Pin Tool J24086 B Piston Ring Groove Cleaner J3936 03 Piston Ring Compressor J8037 Connecting Rod Guide Tool 3 8 24 J5239 Oil Pump Suction Pipe Installer J21882 Camshaft Bearing Installer Remover Tool J6098 01 Ball Socket Adapter J8520 1 Torsional...

Page 172: ...ake Manifold Cast Iron Block Cast Iron 2 Bolt Main Bearing Caps Rods Forged Steel Crankshaft Cast Iron Pistons Cast Aluminum Camshaft Cast Iron Engine Model 350 cid 5 7L Displacement 350 cid 5 7 l Bore 4 00 101 6 Stroke 3 479 in 88 39 mm Firing Order 1 8 4 3 6 5 7 2 Compression Ratio 9 3 1 Heads Cast Iron Intake Manifold Cast Iron Carbureted and EFI Models Aluminum MPI Models Block Cast Iron 2 Bol...

Page 173: ...ver Production PISTON CLEARANCE Production 0 0007 0 002 0 018 0 053 Max Service 0 0007 0 0026 0 018 0 068 Max PISTON RING COMPRESSION Top 0 0012 0 0027 0 030 0 070 Production 2nd 0 0015 0 003 0 040 0 080 Groove Clearance Top 0 0012 0 0035 0 030 0 090 Service 2nd 0 0015 0 004 0 040 0 100 Top 0 009 0 020 0 25 0 51 Production 2nd 0 010 0 020 0 46 0 66 Gap Top 0 010 0 025 0 25 0 65 Service 2nd 0 018 0...

Page 174: ... Production 0 00019 0 005 Max Out of Round Service 0 00098 0 025 Max No 1 0 0007 0 0022 0 018 0 053 Production No 2 3 4 0 00086 0 0024 0 022 0 061 Main Bear No 5 0 00098 0 0027 0 025 0 069 ing Clear ance No 1 0 00098 0 002 0 025 0 051 ance Service No 2 3 4 0 00098 0 0025 0 025 0 064 No 5 0 00149 0 0029 0 038 0 076 Crankshaft End Play 0 0019 0 0078 0 05 0 20 Diameter 2 0977 2 0997 53 284 53 334 Pro...

Page 175: ...059 0 100 1 50 2 56 Intake 0 00098 0 0027 0 025 0 069 Production Exhaust 0 00098 0 0027 0 025 0 069 Stem Clearance Intake 0 00098 0 0037 0 025 0 094 Clearance Service Exhaust 0 00098 0 0037 0 025 0 094 0 0010 0 0076 0 025 0 194 Intake 341 8 66 Stem Diameter Exhaust 341 8 66 Intake 1 84 46 74 1 94 49 28 Valve Diameter Exhaust 1 50 38 1 Valve Margin After Surfacing Intake and Exhaust 0 031 0 79 Mini...

Page 176: ...ournal Out Of Round 0 001 0 025 Maximum Camshaft Runout 0 0026 0 06 Maximum Timing Chain Deflection 0 43 11 Maximum FLYWHEEL Engine 305 cid 5 0L 350 cid 5 7L Runout 0 008 0 203 Maximum CYLINDER HEAD Engine 305 cid 5 0L 350 cid 5 7L Surface Flatness At Exhaust Manifold Deck 0 0019 0 05 Surface Flatness At Engine Block Deck 0 0039 0 10 Surface Flatness At Intake Manifold Deck 0 0039 0 10 Index ...

Page 177: ...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 72312 a a Location Of G M Engine Code Fol...

Page 178: ...p 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 t...

Page 179: ...t The valve lifters also are used to lubricate the valve train bearing surfaces Intake Manifold The carbureted and throttle body fuel injection manifolds are a double level design for effi cient fuel distribution The upper level of passages feeds cylinders 2 3 5 and 8 while the lower level passages feed cylinders 1 4 6 and 7 The multi port injection manifold is a tunnel ram design with the injecto...

Page 180: ...s 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 that is forced out the ends of the connecting rod bearings and crankshaft main bearings and splashes onto the cam shaft cylinder walls pistons and piston pins keeping them lubricated Oil is forced out the front end of the No 1 cran...

Page 181: ... 70436 a b Scratched By Dirt a Scratches b Dirt Imbedded In Bearing Material 70436 a Tapered Journal a Overlay Gone From Entire Surface 70436 a Lack Of Oil a Overlay Worn Off 70436 a Radius Ride a Worn Area 70436 a Improper Seating a Bright Or Polished Sections 70436 a Fatigue Failure a Craters or Pockets Index ...

Page 182: ...mage 72314 a b c d a Ignited By Hot Deposits b Regular Ignition Spark c Ignites Remaining Fuel d Flame Front Collide PRE IGNITION CAUSES 1 Hot spots in the combustion chamber from glowing deposits due 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 ga...

Page 183: ...l cause engine damage and poor performance 2 Over advanced ignition timing 3 Lean fuel mixture at or near full throttle could be caused by carburetor or leaking intake manifold 4 Cross firing spark plugs 5 Excess accumulation of deposits on piston and or combustion chamber that result in higher compression ratio 6 Inadequate cooling of engine due to deterioration of cooling system NOTE Engine fail...

Page 184: ...INES SERVICE MANUAL NUMBER 24 Page 3A 18 90 861327 1 OCTOBER 1999 Engine Mounts 72317 Front Mount All MCM Sterndrive Models 72318 Rear Mount Flywheel Housing All MCM Sterndrive Models 72319 Front Mount Assembly All MIE Models Index ...

Page 185: ...0 cid ENGINES SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 3A 19 Engine Mounts Continued 73055 Rear Mount Assembly Most MIE Models 73056 Rear Mount Assembly MIE Models with Velvet Drive In Line Transmission Index ...

Page 186: ...ation hoses 2 Remove any items that interfere with the removal of rocker arm covers 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 72324 a b a Rocker Arm Cover Gasket b Sealing Surface 3 Install rocker arm cover Torque screws to 90 lb in 10 Nm 4 Reinstall any items that were remove...

Page 187: ... oil pressure sending unit 11 Disconnect any items that interfere with 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 13 Remove intake manifold and carburetor or throttle body assembly NOTE If intake manifold requires replacement transfer ...

Page 188: ...wn Extend sealer 1 2 in 13 mm up on intake gaskets 2 Apply Loctite Pipe Thread Sealant to the threads of the four inner manifold bolts 72325 a a b b a 3 16 Bead Of RTV Sealer b Inner Manifold Bolts With Loctite Pipe Thread Sealant 72326 a a Oil Sending Unit Hole 3 Carefully install manifold assembly and torque bolts to 18 lb ft 24 Nm in sequence as shown 72878 1 2 3 4 5 6 7 8 FRONT 4 Connect all e...

Page 189: ...icing 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 2 Remove rocker arm assemblies and push rods IMPORTANT Place rocker arm assemblies and push rods in a rack for reassembly in their original locations Cleaning and Inspection 1 Clean...

Page 190: ...re time to reach No 1 position 72328 2 Adjust the following valves MCM and MIE Left Hand Standard Rotation Engines Exhaust 1 3 4 8 Intake 1 2 5 7 3 Loosen adjusting nut until lash is felt at push rod and then tighten adjusting nut until all lash is removed Lash can be checked by moving push rod up and down while tightening adjusting nut until all play is removed 72300 4 Hydraulic lifters can be ad...

Page 191: ...ust stops This is zero lash position IMPORTANT The following one turn preload adjustment must be done slowly to allow the lifter to adjust itself This will prevent the valves from hitting the pistons and causing internal damage and or bent push rods 5 Turn nut down 1 4 additional turn 90 degrees and pause 10 seconds until engine runs smoothly Repeat until nut has been turned down one turn 360 degr...

Page 192: ...e 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 ...

Page 193: ...c is shown to exist in one unit it probably exists in all the units Thus it would only be a matter of time before all lifters caused trouble Removal IMPORTANT Keep push rod and hydraulic valve lifter from each valve together as a matched set and mark them so they can be reinstalled in the same location later 1 Remove rocker arm covers 2 Remove intake manifold 3 Remove lifter restrictor retainer on...

Page 194: ...r be installed whenever servicing valve lifters or camshaft IMPORTANT Before installing lifters rollers coat the bottom of the lifter 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 e...

Page 195: ...o 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 72306 b a c a Valve Spring Compressor J5892 b Rocker Arm Nut c Valve Locks 6 Slowly release valve spring compressor 7 Remove cap shi...

Page 196: ...ter Spring 10 Intake Valve 11 Exhaust Valve 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 shield in place 3 Place cap on intake valve and or rotator on exhaust valve 4 While compressing valve spring with valve spring compressor install oil seal in lower groove of valve st...

Page 197: ...st manifolds 3 Remove intake manifold 4 Remove rocker arm covers 5 Remove rocker arm assemblies and push rods keep in order for reassembly in their original locations 6 Remove any components attached to front or rear of cylinder head 7 Remove spark plugs 8 Remove head bolts CAUTION The head gasket may be holding cylinder head to block Use care when prying off cylinder heads DO NOT damage gasket su...

Page 198: ...icksilver Perfect Seal and install finger tight 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 First Pass Short Bolt Medium Bolt Long Bolt 22 lb ft 30 Nm Short Bolt 55 Degrees Second Pass Medium Bolt 65 Degrees Angle Torque Long Bolt 75 Degrees 72332 5 Install push rods and rocker arm assemblies in their origina...

Page 199: ...vide ade quate water supply to seawater pickup CAUTION Ensure that cooling water supply is available before starting the engine 10 Start engine 11 Set timing 12 Set idle speed 13 Check for leaks Cylinder Head and Valve Conditioning Disassembly 1 Using valve spring compressor compress valve spring and remove valve locks Slowly release tool 72333 a a Valve Spring Compressor J 8062 2 Remove all valve...

Page 200: ... clean valve guides with valve guide cleaner 72335 a a Valve Guide Cleaner J 8101 6 Inspect cylinder heads for cracks in exhaust ports water jackets and combustion cham bers especially around spark plug holes and valve seats Replace heads if any cracks are found 7 Inspect cylinder head gasket surface for burrs nicks erosion or other damage 8 Check flatness of cylinder head gasket surface using a m...

Page 201: ...le valve breakage Insufficient clearance will result in noisy and sticky valves 10 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 sp...

Page 202: ...d 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 8 66 J 5830 02 2 Ream valve guide bores 72337 a a Valve Guide Reamer 3 Remove the sharp corner created by reamer at top of valve guide Valve Springs Checking Tension Use valve spring tester to check valve spring tension with dampers removed...

Page 203: ... Place large sleeve flat washer and nut over stud b Turn nut until it contacts stud threads 3 Remove nut and install small sleeve on stud 4 Install nut on stud and turn nut to remove stud 72309 a b a Large Sleeve b 3 8 24 Thd Nut 72310 b c a a Nut b Small Sleeve c Large Sleeve 5 When installing an oversize stud ream stud hole using appropriate reaming tool 6 Install new stud with rocker arm stud i...

Page 204: ...properly dispersed Several different types of equipment are available for reconditioning valve seats Equipment manufacturer s recommendations should be followed carefully to attain proper results 50668 d c b a Typical 3 Angle Valve Seat a Top Angle 30 b Seat Angle 46 c Bottom Angle 60 d Seat Width Intake 1 32 1 16 031 063 In 0 8 1 5 mm Exhaust 1 16 3 32 063 094 In 1 6 2 3 mm Regardless of type of ...

Page 205: ... valve head valve margin is less than 0 031 in 0 79 mm after grinding replace the valve Several different types of equipment are available for refacing valves The manufacturer s recommendation should be carefully followed to attain proper results 50695 a a b b Exhaust Intake a 341 In 8 16 mm b 0 031 0 79 Minimum Reassembly 1 Lubricate valve guides and valve stems with engine oil 2 Install each val...

Page 206: ...8062 7 Install valve locks grease may be used to hold them in place and slowly release tool Ensure locks seat properly in upper grooves of valve stem 72331 1 1 2 5 3 4 6 7 8 9 10 11 Intake Exhaust 1 Valve Locks 2 Retainer 3 Rotator 4 Cap 5 Valve Guide Oil Seal 6 Oil Shield 7 Valve Stem Oil Seal 8 Inner Spring 9 Outer Spring 10 Intake Valve 11 Exhaust Valve 8 Check installed height of valve springs...

Page 207: ...9 Page 3A 41 IMPORTANT If measurement exceeds specified height install a valve spring shim and re check DO NOT shim valve springs to give an installed height less than the minimum speci fied 05037 72339 b a a Valve Spring Installed Height b Cut Away Scale Grind Out This Portion Index ...

Page 208: ...7 FULL ADD 1 2 13 13 29 32 353 15 19 32 396 15 16 24 72341 c d 1 2 13 1 2 13 FULL ADD FULL ADD 3 4 19 23 32 18 16 1 4 413 32 814 33 1 2 849 14 25 32 375 Earlier Models a All MCM Engines 15297 b MIE Inboard Engines With In Line or Down Angle Transmissions 805395 1 c All MIE Ski Engines 16482 d MIE Inboard Engines With V Drive Transmissions 805394 1 1 Engines with Plastisol Coated Oil Pans Index ...

Page 209: ...tinued 76497 ADD a b c d OP RANGE 13 330 15 1 2 396 3 4 22 ADD OP RANGE 14 349 15 1 2 396 1 2 15 ADD OP RANGE 33 1 4 845 31 787 3 4 19 ADD OP RANGE 33 1 2 851 35 1 4 895 1 2 13 Later Models a All MIE Engines 861942 2 b All MIE Engines Remote Drive Transmissions 861942 3 c All MCM Service And Ski 861942 7 d All MCM Engines 861942 9 Index ...

Page 210: ...tion of banjo fitting on bottom of pan 71859 a b a Banjo Fitting b Dipstick Tube 4 Remove oil pan Cleaning and Inspection 1 Clean sealing surfaces of engine block and oil pan Installation 1 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 com plete assembly promptly 72343...

Page 211: ... to 18 lb ft 25 Nm and oil pan reinforcement bolt or stud to 106 lb in 12 Nm 4 Install dipstick tube and dipstick On MIE models install dipstick tube as follows a Install banjo fitting as shown Do not tighten banjo fitting bolt at this time NOTE Dipstick tube can be positioned on either side of engine b Install dipstick tube and secure with hardware as shown Do not tighten tube at banjo fitting c ...

Page 212: ...ting at this time Torque banjo fitting bolt to 180 lb in 20 Nm Tighten dipstick tube and plug securely 71860 a b c 76386 a c Typical Dipstick Styles a Gage b Clamp Secured by Manifold Screw c Dipstick Tube g Install appropriate gage 5 Fill crankcase with required quantity of oil of specified viscosity See SECTION 1B Maintenance Index ...

Page 213: ... It is only available as an assembly The oil pump is driven by the distributor shaft which is driven by a helical gear on camshaft Exploded View 72146 1 2 3 4 5 9 8 7 11 12 10 6 Oil Pump Assembly 1 Extension Shaft 2 Shaft Coupling 3 Pump Body 4 Drive Gear and Shaft 5 Idler Gear 6 Pick Up Screen and Pipe 7 Pump Cover 8 Pressure Regulator Valve 9 Pressure Regulator Spring 10 Plug 11 Pin 12 Screws In...

Page 214: ...ssary Loss of press fit condition could result in an air leak and loss of oil pres sure 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 cov...

Page 215: ...ure 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 4 Align marks made in disassembly 5 Fill gear cavity with engine oil 6 Install pump cover and torque attaching screws to 80 lb in 9 Nm 7 Turn extension shaft by hand to check for smooth operation Installation 1 Install pump and extension shaft...

Page 216: ...ional damper remover and installer J 23523 E 72345 a a Torsional Damper Remover and Installer J 23523 E Installation IMPORTANT The inertia weight section of the 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...

Page 217: ...bearing washer and nut on rod c Install torsional damper on crankshaft by turning nut until it contacts 72346 a a Torsional Damper Remover and Installer J 23523 E d Remove tool from crankshaft e To prevent oil leakage apply Quicksilver RTV sealant to torsional damper keyway f Install torsional damper bolt Torque to 60 lb ft 81 Nm 4 Install drive pulley s Torque bolts to 35 lb ft 48 Nm 5 Install an...

Page 218: ... damage crankshaft INSTALLATION 1 Apply Quicksilver Perfect Seal to seal retainer mating surface and apply grease to seal lips 73124 b a a Seal Lip Toward Inside of Engine b Rotation of Crankshaft as Viewed from Front End Looking Toward Flywheel End 2 Install new seal with open end of seal inward using crankcase front cover seal installer Drive seal in until it just contacts IMPORTANT Do not use e...

Page 219: ...pection 1 Clean old gasket material and sealer from mating surfaces on cylinder block IMPORTANT Surfaces must be clean and flat or oil leakage may result Installation 1 Install oil seal in new cover with lip of seal toward inside of engine using crankcase front cover seal installer Support cover around seal area with appropriate tool as shown 72348 b a a Crankcase Front Cover Seal Installer J 3546...

Page 220: ...ase with engine oil 8 Follow procedures in 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 9 Start engine and check for wate...

Page 221: ...e engine from boat 2 Remove transmission if equipped 3 Remove flywheel housing and related parts 4 Remove MCM coupler or MIE drive plate 5 Remove flywheel 72349 a Alpha Coupler a Some earlier models did not have sealed steel hub coupler 72350 Bravo Coupler 72351 MIE Drive Plate 72352 Drive Shaft Extension Coupler Index ...

Page 222: ...old transmission input shaft in bore of bushing and hitting it with a hammer This will create hydraulic pressure in pilot bushing cavity that should force bushing out 1 Install flywheel while aligning dowel hole in flywheel with dowel in crankshaft Apply Loctite 27131 to threads of flywheel bolts Torque bolts in sequence to 75 lb ft 100 Nm 2 Check flywheel runout as follows a Attach a dial indicat...

Page 223: ...ive plate 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 Install transmission MIE Torque bolts to 50 lb ft 68 Nm 8 Install engine Rear Main Oil Seal The rear crankshaft oil seal can be replaced without removing the oil pan or rear main bear ing cap from engine Removal 1 Remo...

Page 224: ...PORTANT Do not allow oil or other lubricants to contact the seal surface of the rear oil main seal 73127 c a b a Rear Main Oil Seal b Seal Lip Toward Inside of Engine c Rotation of Crankshaft as Viewed from Flywheel End Looking Forward 3 Install seal using rear main seal installer as shown 72356 a a Rear Main Seal Installer J 26817 A NOTE Tool J35621 A not shown may also be used to install the sea...

Page 225: ...ary refer to Rear Main Oil Seal as outlined 4 Inspect alignment pin for damage Replace if necessary Installation IMPORTANT Always use a new crankshaft rear main oil seal and new oil seal retainer gasket when installing the crankshaft rear main oil seal retainer 1 Install new oil seal retainer gasket IMPORTANT Do not allow oil or other lubricants to contact the seal surface of the rear main oil sea...

Page 226: ...he same manner as previously described 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...

Page 227: ...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 Measure the journal with a micrometer if th...

Page 228: ...xtreme Forward Position Replacement NOTE Main bearings may be replaced with or without removing crankshaft 72359 a b c Main Bearing Inserts a Lower Bearing Insert b Upper Bearing Insert c Oil Groove WITH CRANKSHAFT REMOVED 1 Remove and inspect the crankshaft 2 Remove the main bearings from the cylinder block and main bearing caps 3 Coat bearing surfaces of new main bearings with oil 4 Install the ...

Page 229: ...m the front of engine This will roll upper bearing out of block 6 Oil new upper bearing 7 Insert plain unnotched end between crankshaft and indented or notched side of block 8 Rotate the bearing into place and remove tool from oil hole in crankshaft journal 9 Oil new lower bearing and install in bearing cap 10 Install main bearing cap with arrows pointing toward front of engine 11 Torque all main ...

Page 230: ... evidence of wear and damage Do not reinstall a worn or damaged bearing 4 Wipe both upper and lower bearing shells and crankpin clean of oil 5 Measure the crankpin for out of round or taper with a micrometer a Not within specifications replace or recondition the crankshaft b Within specifications and a new bearing is to be installed measure the maximum diameter of the crankpin to determine require...

Page 231: ...astic width at the widest point 72362 7 If the clearance exceeds specifications select a new correct size bearing and remea sure 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 to within specifications the crankpin will have to be ground undersize If the crankpin is already at maximum unders...

Page 232: ...and or deposits are removed turn crankshaft until piston is at top of stroke then remove cloth and cuttings 5 Use a ridge reamer to remove any ridge and or deposits from upper end of cylinder bore 6 Mark connecting rods and bearing caps left bank 1 3 5 and 7 right bank 2 4 6 and 8 from front to rear on same side as piston thrust 7 Remove connecting rod cap and install connecting rod bolt guide 3 8...

Page 233: ... 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 consid ered 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 s...

Page 234: ...ion and reduce wear Therefore when fitting new rings clearances between ring and groove surfaces should be measured See Specifications 7 Replace pistons that are damaged or show signs of excessive wear 72367 PISTON PINS 1 Piston pin clearance is designed to maintain adequate clearance under all engine oper ating conditions Because of this piston and piston pin are a matched set and not serv iced s...

Page 235: ...ds 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 a Rod Bearing Tangs To determine if engine is left hand standard rotation or right hand opposite rotation inspect camshaft drive If engine has a timing chain engine is left hand rotation If engine has timing gears engine is right hand rotation...

Page 236: ...er 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 ...

Page 237: ...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 2 Install connecting rod bearings in rods and rod caps 3 Lightly coat pistons rings and cylinder walls with light engine oil 4 With bearing caps removed install connecting rod bolt guide 3...

Page 238: ...en 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 num ber 72374 a a Piston Ring Compressor J 8037 9 Remove connecting rod bolt guide 10 Install bearing caps and torque nuts to 45 lb ft 61 Nm 11 Check connecting rod side clearance as previously...

Page 239: ...n crankcase oil 3 Remove starter 76489 a b a Starter b Mounting Bolts 4 Remove flywheel housing 5 Remove drive coupler plate and flywheel 76490 a b a Flywheel b Bolts 6 Remove belts 7 Remove circulating pump 8 Remove crankshaft pulley and torsional damper 9 Remove spark plugs 10 Remove oil pan and dipstick tube 11 Remove baffle and oil pump Index ...

Page 240: ...emove timing chain 14 Turn crankshaft to align timing mark with camshaft mark 15 Remove camshaft sprocket or gear 76488 16 Remove rear main seal and retainer 17 Ensure all bearing caps main and connecting rods are marked so they can be rein stalled in their original locations 18 Remove connecting rod bearing caps then push piston and rod assemblies toward heads Index ...

Page 241: ...d or connecting rod bearing inserts from connecting rod and caps Install new bearings following procedures outlined 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 see Specifications 3 Check crankshaft for runout by supporting at front and rear main bearing...

Page 242: ...l Groove 4 Carefully lower crankshaft into place Be careful not to damage bearing surface 5 Check clearance of each main bearing following procedure outlined under Main Bear ings If bearing clearances are satisfactory apply engine oil to journals and bearings 6 Install main bearing caps 7 Torque bolts to specifications When tightening rear main bearing cap follow procedure outlined under Main Bear...

Page 243: ...6 Install new oil filter 27 Fill crankcase with oil 28 Install engine in boat 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 align ment NOTE Flat lifter timing gear is shown Roller lifter gears have similar timing marks 72376 b a Standard LH Rotation Shown a Timing Marks ...

Page 244: ...nd sprocket puller J 5825 A b On right hand rotation engines remove crankshaft gear using a universal puller Installation 1 Using crankshaft gear and sprocket installer as shown install sprocket or gear on crankshaft 72377 a a Crankshaft Gear and Sprocket Installer J 5590 2 Install timing chain or gear 3 Install crankcase cover and torsional damper Checking Timing Chain Deflection 1 Install timing...

Page 245: ... push rod Be sure that push rod is in lifter socket 72380 a a Ball Socket Adapter Tool J 8520 1 3 Rotate crankshaft torsional damper slowly in direction of 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 ra...

Page 246: ... alignment with V blocks and dial indicator which indicates exact amount camshaft is out of true If out of true more than 002 in 0 051 mm dial indicator reading camshaft should be replaced On engines with timing gears inspect camshaft gear and thrust plate for wear and damage 72382 Checking Camshaft Alignment Installation 1 Install camshaft as follows a Install two 5 16 18 x 5 in bolts in camshaft...

Page 247: ...uiring a minimum amount of turns to remove all bearings 2 Using Install nut and thrust washer to end of threads on camshaft bearing remover and installer set P N J 6098 01 3 Position pilot in front camshaft bearing 4 Install puller screw through pilot 5 Install tool with shoulder toward bearing Be sure a sufficient amount of threads are engaged 6 Using two wrenches hold puller screw while turning ...

Page 248: ...aring must be positioned so that oil hole is at the 12 o clock position INTERMEDIATE AND CENTER BEARINGS 1 Install nut and thrust washer onto puller screw 2 Position pilot in front camshaft bearing bore and insert screw through pilot 3 Index center camshaft bearing 4 Position appropriate size removal and installation tool in bearing and thread puller screw into tool Be sure at least 1 2 in 13 mm o...

Page 249: ... jacket valve lifter bores and main bearing webs 9 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 ...

Page 250: ...taper may not clean up entirely when fitted to a high limit piston To entirely clean up the bore it will be necessary to rebore 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 2 When pistons are being fitted and honing is not necessary cylinder bores may be cleaned with a hot water and detergent wash...

Page 251: ...MPORTANT Handle pistons with care and do not attempt to force them through cyl inder 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 abr...

Page 252: ...o bore clearance d Determine if piston to bore clearance is in acceptable range shown in Specifica tions 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 acceptable range 4 Mark p...

Page 253: ... Oil Filter 72390 a With Remote Oil Filter a Fiber Valve IMPORTANT Oil by pass valve and adaptor assembly should be inspected whenever engine is disassembled for major repair or whenever inadequate oil filtration is sus pected IMPORTANT Refer to Engine Parts List when ordering parts for oil filter by pass valve adaptor assembly or remote oil filter parts Index ...

Page 254: ...mage 3 Ensure that valve fits tightly against its seat 4 Push valve down and release it Valve should return freely to its seat If valve operation is questionable by pass valve and adaptor assembly should be replaced Bypass valve may be replaced separately on remote filter assembly 72391 a Typical By Pass Valve and Adaptor Assembly a Fiber Valve 5 Wipe out valve chamber in cylinder block to remove ...

Page 255: ...5 0l 305 cid 5 7l 350 cid ENGINES SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 3A 89 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 256: ...Voltage 4A 10 Voltage Drop In Starting System 4A 11 Delco 14MT Direct Drive Starter 4A 12 Specifications 4A 12 Starter Specifications 4A 12 Torque Specifications 4A 12 Lubricants Sealants Adhesives 4A 12 Exploded View 4A 13 Solenoid Switch 4A 14 Removal 4A 14 Installation 4A 14 Motor 4A 14 Removal 4A 14 Cleaning and Inspection 4A 14 Checking Pinion Clearance 4A 15 Checking Commutator End Frame Gap...

Page 257: ...gnition 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 General Precautions CAUTION The starter motor is designed to operate under great overload and produce a high horsepower for its size It can do this only for a short time since considerable heat accumulates and can cause serious damage For this reas...

Page 258: ...OCTOBER 1999 Page 4A 3 Typical Starting System Components 72930 B S I a b c d e f g h i a Ignition Switch b 20 Amp Fuse c Starter Slave Solenoid d Circuit Breaker e Starter Motor f Wire Junction g Neutral Safety Switch h 90 Amp Fuse i Engine Ground Index ...

Page 259: ... neutral start switch YEL RED NEUTRAL START SWITCH MUST BE AT NEUTRAL POSITION Neutral start switch to wiring harness plug terminal 7 YEL RED Wiring harness plug to starter solenoid small terminal YEL RED Also ensure that black small terminal wire is grounded Starter solenoid is now closed completing circuit between large terminal RED PUR and other large terminal YEL RED causing starter motor to c...

Page 260: ...ngine s Electronic Control Module ECM has a stable voltage source Battery Switches Battery switches should always be positioned so each engine is running off its own battery DO NOT operate engines with switches in BOTH or ALL position In an emergency another engine s battery can be used to start an engine with a dead battery Battery Isolators Isolators can be used to charge an auxiliary battery us...

Page 261: ...tery compartment or area where batteries are located is well vented Battery electrolyte is a corrosive acid and should be handled with care If electrolyte is spilled or splashed on any part of the body immediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible CAUTION To prevent damage to the electrical system be sure to adhere to the following When...

Page 262: ...h DC voltmeter 76498 b 9 5 a a Voltmeter b Battery Place battery under heavy load as during engine cranking or with a variable resistor tester and test cell voltage while under load Certain conditions must be met before testing Battery must be 60 to 100 F 16 to 38 C Electrolyte level must be correct in all cells Battery must be at least half charged No obvious defects 1 Check voltage per manufactu...

Page 263: ...ours 2 1 2 Hours 2 Hours 1 1 2 Hours Above 75 to 100 Ampere Hours 20 Hours 10 Hours 5 Hours 3 Hours 2 1 2 Hours 2 Hours Above 100 to 150 Ampere Hours 30 Hours 15 Hours 7 1 2 Hours 5 Hours 3 1 2 Hours 3 Hours Above 150 Ampere Hours 20 Hours 10 Hours 6 1 2 Hours 5 Hours 4 Hours 1 Initial rate for constant voltage taper rate charger To avoid damage charging rate must be reduced or temporarily halted ...

Page 264: ... 861327 1 OCTOBER 1999 Page 4A 9 How Temperature Affects Battery Power 74310 POWER WATTS AVAILABLE POWER WATTS REQUIRED 80 F 27 C 100 83 61 45 32 F 0 C 0 F 18 C 20 F 29 C 100 165 250 350 Standard Starter Slave Solenoid Identification 76517 Index ...

Page 265: ...ault 2 With a fully charged battery connect the voltmeter positive lead to the terminal on the starter solenoid 3 Connect the voltmeter negative lead to the starter motor case Ensure that there is good metal contact to prevent a false voltage reading 4 Crank the engine over for about 10 seconds and record voltmeter reading 5 A reading of 9 5 volts or more shows the starter motor is getting suffici...

Page 266: ...to prevent the possibility of voltmeter damage 3 Crank the engine over and record voltmeter reading The reading should not exceed 5 volts A reading over 5 volts suggests excessive resistance 4 Test the negative battery cable by connecting the voltmeter negative lead to the battery negative post 5 Connect the voltmeter positive lead to the starter motor case Ensure that there is good contact with m...

Page 267: ...r Volts Min Amps Max Amps Min rpm Max rpm Tension Oz Grams 10455602 LH 10 6 70 120 5400 10800 56 105 1588 2976 Pinion Clearance 010 140 0 25 3 5 mm Commutator End Frame Gap 025 Max 0 6 mm Max Torque Specifications Fastener Location lb ft Nm Starter Motor To Block 50 68 All Other Fasteners Tighten Securely Lubricants Sealants Adhesives Description Part Number Quicksilver Liquid Neoprene 92 25711 3 ...

Page 268: ... Pole Shoe Field Coil 13 Pole Shoe Field Coil Screw 14 Field Coil Grommet Field Frame 15 Field Coil Assembly 16 Leather Washer Commutator End Frame 17 Lower Commutator End Frame 18 Screw Stud 19 Insulator Holder Field Frame Brush 20 Field Frame Brush Ground Brush 21 Field Frame Brush 22 Brush Lead Screw 23 Ground Insulated Holders Support Package 24 Field Frame Brush Spring 25 Dowel Pin Field Fram...

Page 269: ...s from solenoid terminals Removal 1 Remove starter mounting bolts 2 Remove from engine Cleaning and Inspection IMPORTANT DO NOT use grease dissolving solvents for cleaning Such a solvent would dissolve grease packed in clutch mechanism and damage armature and field coil insulation Field coils should be removed only where defects are indicated by tests Defective parts should be replaced or repaired...

Page 270: ...are fully 72631 a a Motor Field Coil Connector 2 Connect 12 volt battery positive lead to solenoid switch and negative lead to sole noid frame 3 Momentarily touch a jumper lead from solenoid motor terminal M to starter motor frame This shifts pinion into cranking position where it will remain until battery is disconnected 01447 b a a Jumper Lead b Starter Motor Frame 4 Push pinion back toward comm...

Page 271: ...fective parts since no provision is made for adjusting pinion clearance 72077 a b c a Pinion b Retainer c Feeler Gauge Checking Commutator End Frame Gap To keep the ignition proof and safety requirement the gap between the commutator end frame and field coil housing must be checked See specifications If the gap exceeds mea surement when checked with a feeler gauge the end frame should be checked f...

Page 272: ... Place starter motor in position and install mounting bolts Torque bolts to 50 lb ft 68 Nm 2 Fasten wires 3 Coat solenoid terminal connections with Quicksilver Liquid Neoprene 4 Place rubber boot over positive battery cable connection 72637 0 0 a b a Positive Battery Cable b Rubber Boot Index ...

Page 273: ...Sealants Adhesives Description Part Number Quicksilver Liquid Neoprene 92 25711 3 Quicksilver 2 4 C Marine Lubricant With Teflon 92 825407A3 Description The Permanent Magnet Gear Reduction PG200 and PG250 starter motors feature small permanent magnets mounted inside the field frame NOTE The actual configuration of these magnets differs between the PG200 PG250 and PG260 the field frames with perman...

Page 274: ... 20 21 22 17 1 Screw 2 2 End Frame and Bearing 3 Brush With Holder 4 Armature 5 Field Frame With Permanent Magnets 6 Washer 7 Shield 8 Planetary Gears 9 Shaft 10 Gear 11 Drive 12 Collar 13 Retaining Ring 14 Trust Collar 15 Drive Housing 16 Nut 17 Solenoid 18 Solenoid Drive Arm 19 Screw 3 20 Long Screw 2 21 Rubber Grommet 22 Metal Disc Index ...

Page 275: ...ls IMPORTANT Some starter motors may use a special mounting shim for gaining fly wheel clearance Do not lose this shim it will be needed when remounting starter on engine block 1 Remove starter mounting bolts 2 Pull starter assembly away from flywheel and remove from engine Disassembly 1 Remove brush lead from solenoid and long screws from end frame 75820 a b c d e a Brush Lead b Screws c Solenoid...

Page 276: ...nd field frame from drive housing NOTE Permanent magnets inside field frame will be holding armature in place 74270 b a c d e a End Frame and Bearing b Screws 2 c Brush Holder d Armature e Field Frame 3 Remove shield and washer from drive housing 74038 c b a a Shield b Washer c Drive Housing Index ...

Page 277: ...ve solenoid from drive housing 74036 c b a a Drive Housing b Solenoid c Screws 3 5 Remove drive and associated parts from drive housing 74035 75821 a b a Drive Housing b Drive 6 Remove solenoid arm metal disc and rubber grommet from the drive housing 75821 a b c d a Rubber Grommet b Metal Disc c Solenoid Arm d Drive Housing Index ...

Page 278: ... Remove thrust collar retaining ring and collar from planetary shaft with drive 75821 b a c d a Thrust Collar b Retaining Ring Inside Collar c Collar d Planetary Shaft and Drive 8 Remove drive and gear from planetary shaft 74087 a b c Typical a Gear b Shaft Assembly c Drive Index ...

Page 279: ...nking direction 2 Check pinion teeth 3 Check spring for tension and drive collar for wear 4 Check that bearings roll freely If any roughness is felt replace bearing 5 Inspect planetary gear assembly Gears must mesh easily and roll freely with no binding Reassembly 1 Install gear and drive over planetary gear shaft 74087 a b c Typical a Planetary Gear Shaft Assembly b Gear c Drive 2 Assemble drive ...

Page 280: ...rcing snap ring over end of shaft Slide snap ring down into groove 72073 c b a a Snap Ring b Groove c Retainer f Assemble thrust collar on shaft with shoulder next to snap ring g Position retainer and thrust collar next to snap ring Then using two pliers grip retainer and thrust collar and squeeze until snap ring is forced into retainer 72074 b a c a Retainer b Thrust Collar c Snap Ring Index ...

Page 281: ...aft assembly 4 Install solenoid arm metal disc and rubber grommet in the drive housing NOTE Solenoid arm is designed to fit only one way Do not use force 75821 a b c d a Rubber Grommet b Metal Disc c Solenoid Arm d Drive Housing 5 Install drive and associated parts in drive housing 74035 75821 a b a Drive Housing b Drive Index ...

Page 282: ... 74036 b a c d a Drive Housing b Solenoid c Screw 3 d Solenoid Arm 7 Install washer and shield in drive housing 74038 75821 a c b a Washer b Shield c Drive Housing 8 Install field frame over armature Align slot in field frame with rubber grommet 75821 b c a a Armature b Field Frame Slot c Rubber Grommet 9 Install field frame and end frame in drive housing Index ...

Page 283: ...sembly of starter motor 1 Disconnect brush lead from solenoid switch and insulate it carefully 74041 a a Brush Lead 2 Connect 12 volt battery positive lead to battery terminal and negative lead to frame 3 Momentarily touch a jumper lead from battery terminal to switch terminal This shifts pin ion into cranking position where it will remain until battery is disconnected 72629 4 Push pinion back tow...

Page 284: ...special mounting shim if equipped between starter motor and engine block 1 Place starter motor in position and install mounting bolts Torque bolts to 30 lb ft 41 Nm 2 Connect YELLOW RED wire to terminal S of solenoid Connect ORANGE wire RED wire and battery cable to large terminal of solenoid Tighten fasteners securely Coat terminals with Quicksilver Liquid Neoprene Install battery cable boot if s...

Page 285: ...STARTING SYSTEM SERVICE MANUAL NUMBER 24 Page 4A 30 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 286: ...t V Ignition 4B 11 Spark Control Features 4B 11 Circuit Description 4B 12 Thunderbolt V Spark Control Graph 4B 13 Ignition System Wiring Diagram 4B 14 Thunderbolt V Ignition Module 4B 15 Knock Control Module 4B 15 Mercury Marine Distributor 4B 17 Description 4B 17 Exploded View 4B 17 Distributor Cap 4B 18 Removal 4B 18 Cleaning and Inspection 4B 18 Installation 4B 18 Rotor Sensor Wheel 4B 19 Remov...

Page 287: ...al 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 Whe...

Page 288: ...essories 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 Torque Specifications Fastener Location lb in lb ft Nm Spark Plugs New Cylinder Head 22 30 Spark Plugs All Others 15 20 Knock Sensor 14 19 Tools Description Part Number DMT 2000 T...

Page 289: ... Distributor Description GM EST Mercury Distributor Part Number 805222A1 805185A36 Coil Description GM EST Mercury Coil Part Number 392 7803A4 392 7803A4 Primary Resistance 60 80 Ohms 60 80 Ohms Secondary Resistance 9 400 11 700 Ohms 9 400 11 700 Ohms Spark Plugs Model All MIE and MCM Engines Spark Plug 045 in 1 1 mm Spark Plug Type AC MR43LTS NGK BPR6EFS Champion RS12YC Firing Order 72008 Firing ...

Page 290: ...m 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 ...

Page 291: ...que 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 Spark Plugs Removal 1 Di...

Page 292: ...with a round feeler gauge Bend side electrode to adjust gap Refer to SECTION 1B Specifications for correct spark plug gap 75084 a b 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 tigh...

Page 293: ...ecommended for Marine application NOTE When replacing spark plug wires replace one wire at a time to reduce the risk of error 1 Disconnect individual spark plug wires 2 Install spark plug wires in proper order Observe the following IMPORTANT When replacing plug wires route the wires correctly through the proper supports Correct positioning of spark plug wires and supports is important to prevent c...

Page 294: ...ire Terminal NOTE Make sure boot does not come off of tower due to hydraulic air pressure inside boot Ignition Coil NOTICE Refer to Service Precautions in the front of this section BEFORE proceeding REMOVAL 1 Disconnect wire harness connectors at coil a b 72921 a Wire Harness Connection b High Tension Coil Lead Connection 2 Remove high tension coil lead 3 Remove coil bracket fasteners and remove c...

Page 295: ...e very low or zero If not replace the ignition coil 76521 b a c a Ground b Test 1 c Test 2 INSTALLATION 1 Install coil bracket with coil to engine bracket using fasteners IMPORTANT Mercury Marine Coil Only before installing coil wire high tension lead to coil apply approximately 1 2 oz of Silicone Dielectric Compound Quicksilver 92 802882A1 around top of coil high tension lead tower Do not apply t...

Page 296: ... of advance and wait to see if there is an rpm change If rpm increases it will 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 Between 1200 4000 rpm the Ignition Module can add approximately 10 15 degrees of spark advance to the base spark timing curve NOT...

Page 297: ...meter signal is carried to the instrument panel through the GRY wire 11 The PUR WHT wire 3 carries the signal from the Knock Control Module to the Igni tion Control Module There are two BLK wires 5 that have bullet connectors This circuit is reserved for future options On current models the two BLK wires must be connected for the sys tem to function properly The TAN BLU wire 6 carries a signal fro...

Page 298: ...ÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ TOTAL SPARK ADVANCE MINUS INITIAL TIMING ENGINE RPM ÅÅÅ ÅÅÅ ÇÇÇ ÇÇÇ ÇÇÇ ÂÂÂ ÂÂÂ ÂÂÂ Base Timing Advance Curve Idle Speed Advance Range Knock Retard Range Acceleration Advance Range MBT Advance Range Not A Function On Ski Model IGNITION SYSTEM SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 4B 13 Thunderbolt V Spark Control Graph IMPORTANT The graph below shows the ...

Page 299: ... 3 9 WHT GRN 1 NOTE 1 Alpha Models Are Equipped With A Shift Cut Out Switch 305 and 350 cid Bravo Models Will Have Two BLACK Leads Connected Together 1 Knock Sensor Wire 2 Ground Wire For Knock Module 3 Knock Module Signal Wire 4 Battery Positive Wire To Knock Module 5 Battery Positive Wire To Ignition Module Pin C 6 Audio Warning System Wire Pin D 7 Shift System Interrupt Switch If Equipped Pin E...

Page 300: ...or must be used Using an incor rect Knock Module or Sensor will result in unrecognized spark knock and engine damage The Knock Module terminal B is powered by 12 volts from the ignition switch If the 12 volt power source is not present the Knock Module cannot send an 8 10 volt signal to the Igni tion Control Module and a false constant spark retard will result Terminal E of the Knock Module is the...

Page 301: ...connect the harness connector BLU wire from the Knock Sensor 7 Connect the unpowered test light to a positive 12 volt source 8 To simulate an AC voltage rapidly tap the Knock Sensor harness terminal with test light 9 If Knock Module and wiring is functioning properly you should see a voltage drop on the DVOM If a voltage drop is not seen check the BLU wire from the sensor to the Knock Module for a...

Page 302: ...I 3 ECM models except Black Scorpion The Black Scorpion models use the Delco EST ignition system Exploded View 00000 1 3 4 5 7 8 6 11 12 2 10 9 14 15 17 16 18 20 13 19 1 Distributor Cap 2 Vent 3 Gasket 4 Rotor 5 Senor Wheel 6 Screws 5 7 E Clip 8 Shaft 9 Screws 2 10 Lockwashers 2 11 Sensor 12 Upper Bushing 13 Distributor Housing 14 Lockwasher 15 Nut 16 Lower Bushing 17 Gasket 18 Washer 19 Gear 20 R...

Page 303: ...re removed from cap refer to Spark Plug Wires in this section and the following illustrations for installation 72726 a a Alignment Notch 72728 a a Vent Installation IMPORTANT Use only a distributor cap recommended for Marine application 1 Install distributor cap by aligning tab in distributor cap with notch on distributor body Tighten the retaining screws NOTE Use care when removing spark plug wir...

Page 304: ...ated rotor sensor wheel assembly to avoid severe burns Cleaning and Inspection 1 Inspect the locating key inside the rotor The locating key will appear as a clean edged 1 8 in 3 mm wide sloped ramp at the bottom of the splined hole 72730 a b c d a Locating Key b Screws c Senor Wheel d Locating Pin NOTE If there is any doubt if sensor wheel is located properly lay sensor wheel on top of the figure ...

Page 305: ...ibutor shaft a Ensure rotor locating key is aligned with keyway in distributor shaft Press rotor down on the shaft with your hand until it stops 5 Let Loctite cure overnight with distributor in inverted position IMPORTANT The rotor should fit very tight It may be necessary to heat rotor with heat lamp to properly install Do not let any Loctite run down distributor shaft Loctite could get into top ...

Page 306: ...o screws that hold sensor into distributor housing Remove sensor from housing 00000 a b a Mounting Screws b Senor Assembly Cleaning and 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 a Jumper Leads CAUTION Do not use any type of silicone sealer on the inside of the distribut...

Page 307: ...nd hold down clamp and remove distributor IMPORTANT To simplify distributor installation do not turn crankshaft when distrib utor is removed from engine Disassembly NOTICE Refer to exploded view preceding for parts identification during disassembly and reassembly 1 Remove rotor sensor wheel sensor and Ignition Module if mounted on distributor 2 Remove roll pin washer and driven gear from distribut...

Page 308: ...r and Ignition Module if mounted on distributor 8 Install distributor Distributor Installation ENGINE NOT ROTATED 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 IMPORTANT You ...

Page 309: ...oil pump shaft end to engage bottom of distributor drive gear prior to inserting dis tributor if necessary 3 Position rotor to point toward No 1 cylinder on cap with distributor housing held in in stalled attitude then turn rotor counterclockwise approximately 1 8 turn more and work distributor down to engage camshaft and oil pump shaft It may be necessary to rotate rotor slightly until engagement...

Page 310: ...Install E clip on shaft in housing 3 Install washer on shaft 4 If installing original gear slide onto shaft and install roll pin IMPORTANT Gear will only fit in one direction 5 If installing a new gear slide gear onto shaft and align hole in gear with hole in shaft 6 Using these holes as a guide drill through other side of gear with a 3 16 in carbide tipped drill bit IMPORTANT If gear only has a d...

Page 311: ...sition of rotor Also mark position of distributor housing on intake manifold 4 Remove distributor and gasket from intake manifold IMPORTANT DO NOT crank engine over after distributor has been removed 5 Align rotor with scribe mark on distributor housing Scribe a line on the gear in line with housing to intake manifold scribe mark Disassembly 72411 i o n m l k j i h g f e d c b a a Cap b Rotor c Sh...

Page 312: ...housing 7 Disconnect pickup coil connector from module by lifting up locking tab with a screwdriver and carefully prying connector from module 8 Remove pickup coil 9 Remove module retaining screws and remove module Cleaning and Inspection 1 Visually inspect the cap for cracks or carbon tracks Replace the cap if it shows any sign of damage 2 Check metal terminals in the cap for evidence of corrosio...

Page 313: ...l fitting tab at bottom of coil into anchor hole of housing 4 Connect pickup coil electrical connector to module making sure locking tab is in place 5 Install shield onto coil 6 Install retainer with teeth facing up using a 5 8 in 15 mm socket centered on retainer Using a small hammer tap the retainer evenly down onto the distributor housing upper bushing Make sure that both teeth are seated in bu...

Page 314: ...e shaft Repeat this adjustment as many times as needed until the dis tributor can be firmly seated and all components are in alignment 3 Install hold down clamp over distributor and bolt it securely to engine surface Torque bolt to 30 lb ft 40 Nm 4 Install distributor cap and secure in place with two screws 5 Connect electrical connectors to module IMPORTANT Before proceeding to the following step...

Page 315: ...IGNITION SYSTEM SERVICE MANUAL NUMBER 24 Page 4B 30 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 316: ...tuation 4C 3 Recommendations 4C 3 Identification 4C 4 Specifications 4C 4 Mando 4C 4 DelcoRemy 4C 5 Tools 4C 5 Lubricants Sealants Adhesives 4C 5 Torque Specifications 4C 5 Description 4C 6 Testing 4C 7 Charging System 4C 7 Charging System Resistance 4C 8 Circuitry 4C 10 Component 4C 11 Exploded View 4C 16 Alternator Repair 4C 17 Removal 4C 17 Disassembly 4C 17 Cleaning and Inspection 4C 22 Reasse...

Page 317: ...used BE SURE to connect it in parallel with exist ing battery positive to positive negative to negative EFI Electrical System Precautions NOTE All references to EFI models apply to all EFI and MPI engines 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 accessorie...

Page 318: ...l Module ECM has a stable voltage source Battery Switches While engines are running battery switches should be positioned so each engine is running off its own individual battery DO NOT run engines with battery switches in BOTH or ALL position In an emergency another engine s battery can be used to start an engine with a dead battery Battery Isolators Isolators can be used to charge an auxiliary b...

Page 319: ...ing Wire RED PURPLE c Part Number and Amperage Rating Hidden In This View 72078 a Delco 65 Amp Alternator a Part Number Specifications Mando Description Specification 55 Amp 65 Amp 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 Index ...

Page 320: ...ifications 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 ...

Page 321: ...ounted 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 ...

Page 322: ... 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 76498 c 76533 a b X X Typical a Output Term...

Page 323: ...ion 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 76498 c 76533 a b d X X Typical a Output Terminal b Ground Terminal c Voltmeter d Battery 5 Start engine and run at 1300 1500 rpm Read voltmeter A rea...

Page 324: ... 1999 Page 4C 9 6 Connect the voltmeter negative lead to the alternator ground terminal Connect volt meter positive lead to the battery negative post 76498 c 76533 a b d X X Typical a Output Terminal b Ground Terminal c Voltmeter d Battery 7 Repeat Step 5 Index ...

Page 325: ...battery voltage and should not vary If no reading is obtained or if reading varies go to Resistance in this section 72784 e a b c d 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 ...

Page 326: ...g circuit red purple lead for loose or dirty connection or damaged wiring 72786 e a b c d 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 72831 a b Testing Rotor Field Circuit a Test 1 b Test 2 a Connect...

Page 327: ...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 alter...

Page 328: ... 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 he...

Page 329: ...ale to 1 4 in stud on positive rectifier heat sink and the other lead to one of the rectifier terminals Note the meter reading 7 Reverse leads and again note reading 8 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 sh...

Page 330: ... 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 14 Repeat Steps 6 through 8 for the other two diodes 15 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 de...

Page 331: ...Nut 9 3 Flat Washer 4 4 Sensing Wire RED PUR 5 Excitation Wire PUR 6 Cover 7 Tie Strap 8 Rubber Gasket 9 Condenser 10 Insulator 11 Bolt 4 12 End Frame Rear 13 Cap 2 14 Brush Regulator Assembly 15 Rectifier Assembly 16 Flat Washer 17 Screw 18 Stator 19 Rotor And Slip Ring 20 Retaining Plate 21 Front Bearing 22 End Frame Front 23 Screw 3 24 Fan Spacer 25 Fan 26 Pulley Spacer 27 Pulley 28 Lockwasher ...

Page 332: ... c d d 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 i...

Page 333: ...rom 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 72823 a b c d 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 fou...

Page 334: ...er 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 rectif...

Page 335: ...NT 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 countercl...

Page 336: ...ing plate 72829 b a 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 72830 a b c 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 Index ...

Page 337: ...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 bo...

Page 338: ...ree rectifier terminals 72826 a 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 Po...

Page 339: ...r 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 72836 a 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 sho...

Page 340: ...o rectifier stud and stud on brush rectifier assembly Tighten nuts securely 72823 b a a Studs b Tie Bar 11 Install cover with one phillips head screw and two nuts Install two leads with nuts 72963 a b c a Phillips Head Screw b Nuts 4 c Leads 12 Install insulator caps 72078 a a Insulator Caps Index ...

Page 341: ...5713 b a b 76471 b a Typical Models V Drive 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 72838 d a b c a Excitation Lead PURPLE b Sensing Lead RED PURPLE c Ground Lead BLACK d Output Lead ORANGE 4 Connect negative battery cable to battery Index ...

Page 342: ...ve serpentine belt 2 Clamp pulley in a vise using an old belt or protective jaws to protect pulley to remove nut 72828 a 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 Index ...

Page 343: ... c d e f c d g f h 1 2 2 2 A B B 2 1 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 Index ...

Page 344: ...CHARGING SYSTEM SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 4C 29 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 345: ...CHARGING SYSTEM SERVICE MANUAL NUMBER 24 Page 4C 30 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 346: ...ircuits 4D 4 Oil Fuel and Temperature 4D 4 Battery Gauge 4D 6 Cruiselog Meter 4D 7 Vacuum Gauge 4D 7 Speedometer 4D 8 Tachometer 4D 8 Gauge Replacement 4D 8 Senders 4D 9 Oil Pressure 4D 9 Water Temperature 4D 10 Switches 4D 12 Ignition Key Switch 4D 12 Lanyard Stop Switches 4D 13 Start Stop Switch 4D 14 Audio Warning System 4D 14 Buzzer 4D 14 Oil Pressure Switch 4D 15 Transmission Fluid Temperatur...

Page 347: ...ometer Obtain Locally Continuity Meter Lubricants Sealants Adhesives Description Part Number Quicksilver Liquid Neoprene 92 25711 3 Loctite Pipe Sealant with Teflon Obtain Locally Identification 72965 b a c d e c a d b d c a b 76372 76373 a Battery 12v Terminal b Ground Terminal c Sender Terminal d Light Terminal e Engine Type Dial Index ...

Page 348: ...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...

Page 349: ...h a POS 12v B IGN or I 2 The ground terminal is the ground for the gauge The terminal may be marked with a G GND GRD or no mark 3 The light terminal supplies 12v battery voltage to the gauge s light This terminal may be marked with a LT light I or no mark This terminal is usually next to the light bulb 4 The sender terminal receives the signal from the sender on the engine This terminal may be mar...

Page 350: ...to RUN Indicator needle on gauge should be positioned as shown 72747 Typical 4 Turn ignition switch to OFF 5 Connect jumper wire from ground terminal to sender terminal 72748 Typical 6 Turn ignition switch to RUN 7 Indicator needle must be positioned as shown If not replace gauge 72749 Typical Index ...

Page 351: ...attery Check voltage with voltmeter 2 Connect a jumper wire from the positive battery post to the positive gauge terminal 3 Connect a jumper wire from the negative battery post to the gauge terminal 72750 Typical 4 Gauge should read approximately the same voltage that the when checking the battery in step1 72751 Typical Index ...

Page 352: ...gauge 72753 a a Indicator Vacuum Gauge TESTING 1 Disconnect vacuum hose from engine 2 Connect service vacuum gauge to engine and record engine vacuum readings at idle 1000 2000 and 3000 rpm 3 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 gau...

Page 353: ...ompare readings between the service tachometer and the original tachometer 2 Replace if not within specifications Tachometer Allowance 6000 rpm 150 rpm Gauge Replacement 1 Disconnect battery cables from battery 2 Remove wires from back of gauge 3 Remove hoses if applicable vacuum speedometer gauge 4 Disconnect light socket if applicable 5 Remove holding strap 6 Remove gauge 7 Position new gauge as...

Page 354: ...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 Ohms Reading Oil Pressure psi Single Dual 0 227 257 114 128 20 138 kPa 142 162 71 81 40 276 kPa 92 ...

Page 355: ...ture Sender b Thermostat Housing TESTING 1 Connect an ohmmeter between temperature sender terminal and hex for ground as shown 72768 a b a Ohmmeter Leads b Water Temperature Sender 2 With ohmmeter connected as outlined and using suitable container thermometer and heat source suspend sender with tip in water 3 Heat water and observe thermometer 4 As temperature rises ohmmeter readings must be withi...

Page 356: ...ter Temperature Ohms Reading 140 F 60 C 121 147 194 F 90 C 47 55 212 F 100 C 36 41 6 Replace sender if ohmmeter readings are other than as shown for each temperature INSTALLATION 1 Apply Loctite Pipe Sealant with Teflon to threads of temperature sender 2 Install sender in thermostat housing and tighten securely 3 Connect tan wire and coat with Liquid Neoprene 4 Refill closed cooling system with ap...

Page 357: ...een 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 ...

Page 358: ...l injected engines refer to SECTION 5 TESTING 1 Disconnect switch leads 2 Connect an ohmmeter to leads 3 There should be continuity with switch lanyard connected and no continuity with switch lanyard disconnected 74061 b a Remote Control Mounted Switch a Switch Lanyard b Leads 72762 a b Panel Mounted Switch a Switch Cap b Switch Index ...

Page 359: ... 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 Audio Warning System NOTICE For repair procedures on fuel injected engines refer to SECTION 5 Buzzer TESTING 1 Turn key to RUN position engine off 2 Buzzer should sound briefly 3 If horn does not sound a Disconnect TAN BLU wire at buzzer...

Page 360: ...nuity 4 With engine running and engine oil pressure above 6 psi 41 kPa meter should indicate no continuity Transmission Fluid Temperature Switch Switch is located on transmission Switch is normally open This switch is used on MIE engines if equipped 87 88031 Switch Opens 180 200 F 82 93 C Closes 220 240 F 104 116 C REMOVAL 1 Disconnect harness wires at switch 2 Remove switch and sealing washer 728...

Page 361: ...tructions 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 U...

Page 362: ...tch 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 Engine Coolant Temperature 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 87 88031 Switch Opens 180 200 F 82 93 C Closes 220 240 F 104 116 C 6 Turn heat source off A...

Page 363: ...a b Transmission Fluid Temperature Switch Typical Location a Switch With Sealing Washer b Harness Wires 4 Check transmission fluid level Sterndrive Gear Lube Monitor Switch The gear lube monitor is normally open no continuity between wires when the gear lube is at the correct level When the gear lube is low switch will close causing continuity between wires and buzzer will sound If buzzer is sound...

Page 364: ...INSTRUMENTATION SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 4D 19 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 365: ...INSTRUMENTATION SERVICE MANUAL NUMBER 24 Page 4D 20 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 366: ... 5 7L EFI and 350 Mag MPI Engines 4E 6 MEFI 3 MCM 5 0L EFI 5 7L EFI and 350 Mag MPI Engines 4E 8 MIE 5 7L Inboard 4E 10 MIE 350 Mag MPI and Black Scorpion Engines Starting and Charging System Harness 4E 12 Fuel and Ignition System Harness 4E 14 MEFI 1 MCM 5 0L EFI 5 7L EFI Alpha Engines 4E 14 MEFI 3 5 0L EFI and 5 7L EFI Engines 4E 15 MEFI 1 and MEFI 2 MCM 350 Mag MPI Bravo Engines 4E 16 MEFI 3 35...

Page 367: ...27 1 OCTOBER 1999 Starting and Charging Harness MCM 5 0L Engines 75568 BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 2 5 6 7 1 1 1 1 2 2 2 3 3 3 3 4 4 A B C D Index ...

Page 368: ...ot used on Bravo 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 Starter Slave Solenoid C Audio Warning Components 1 Oil Pressure Switch 2 Gear Lube Monitor 3 Water Temperature Switch D Instrumentation Components 1 Oil Pressure Sender 2 Water Temperature Sender 3 Trim Sender Index ...

Page 369: ... 4E 4 90 861327 1 OCTOBER 1999 MCM 5 7L Engines 75548 BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 1 1 1 1 2 2 2 2 3 3 3 4 4 5 5 6 7 8 3 A B C D Index ...

Page 370: ... used on Bravo 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 Gear Lube Monitor 3 Water Temperature Switch D Instrumentation Components 1 Oil Pressure Sender 2 Water Temperature Sender 3 Trim Sender Index ...

Page 371: ...REEN ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK A B C a b c 1 2 1 2 3 4 5 3 2 1 MAINTENANCE SERVICE MANUAL NUMBER Page 4E 6 90 861327 1 OCTOBER 1999 MEFI 1 and MEFI 2 MCM 5 0L EFI 5 7L EFI and 350 Mag MPI Engines Index ...

Page 372: ...t 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 Index ...

Page 373: ...MAINTENANCE SERVICE MANUAL NUMBER Page 4E 8 90 861327 1 OCTOBER 1999 MEFI 3 MCM 5 0L EFI 5 7L EFI and 350 Mag MPI Engines 76061 90 Amp Fuse a b c 1 1 2 1 2 3 4 5 6 7 A B C Index ...

Page 374: ...strumentation 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 Index ...

Page 375: ... Inboard BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 75754 1 2 3 4 1 2 3 1 2 3 1 2 3 4 5 6 7 8 9 A C B D NOTE BROWN WHITE wire may be used for an Accessory LOAD MUST NOT EXCEED 5 AMPS Index ...

Page 376: ...oke Components 1 Alternator 2 Electric Choke 3 Ground Plug 4 Starter Motor 5 Oil Pressure Switch 6 Fuel Pump 7 Circuit Breaker 8 Neutral Safety Switch 9 Starter Slave Solenoid C Audio Warning Components 1 Oil Pressure Switch 2 Water Temperature Switch 3 Transmission Temperature Switch D Instrumentation Components 1 Oil Pressure Sender 2 Water Temperature Sender 3 See NOTE below Index ...

Page 377: ... YELLOW LIT LIGHT DRK DARK A B C 76062 3 1 1 2 c a b 2 1 5 6 7 4 MAINTENANCE SERVICE MANUAL NUMBER Page 4E 12 90 861327 1 OCTOBER 1999 MIE 350 Mag MPI and Black Scorpion Engines Starting and Charging System Harness NOTE Taped back BROWN WHITE wire may be used for an Accessory LOAD MUST NOT EXCEED 5 AMPS Index ...

Page 378: ...umentation Components 1 Oil Pressure Sender 2 Wire Not Used C Charging and Starting Components 1 Alternator 2 Ground Stud 3 Starter 4 90 Amp Fuse DO NOT REMOVE 5 Circuit Breaker 6 Starter Slave Solenoid 7 Neutral Safety Switch a Positive Power Wire To EFI System Harness b Harness Connector To EFI System Harness c Auxiliary Tachometer Lead Index ...

Page 379: ...l 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 16 Fuse 15 Amp ECM DLC Battery 17 Fuse 10...

Page 380: ...tion 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 Injector 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 21 Gear Lub...

Page 381: ...and orientation shown is arranged for visual clarity and ease of circuit identification 1 Fuel Pump 2 Distributor 3 Coil 4 Electronic Spark Control KS Module 5 Data Link Connector DLC 6 Manifold Absolute Pressure MAP Sensor 7 Knock Sensor 8 Idle Air Control IAC 9 Throttle Position TP Sensor 10 Engine Coolant Temperature ECT Sensor 11 Electronic Control Module ECM 12 Fuel Pump Relay 13 Ignition Sys...

Page 382: ...ease of circuit identification 1 Fuel Pump 2 Distributor 3 Coil 4 Knock Sensor KS Module 5 Data Link Connector DLC 6 Manifold Absolute Pressure MAP Sensor 7 Idle Air Control IAC 8 Throttle Position TP Sensor 9 Engine Coolant Temperature ECT Sensor 10 Electronic Control Module ECM 11 Fuel Pump Relay 12 Ignition System Relay 13 Fuse 15 Amp Fuel Pump Fuse 15 Amp ECM DLC Battery Fuse 10 Amp ECM Inject...

Page 383: ...MAINTENANCE SERVICE MANUAL NUMBER Page 4E 18 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 384: ...s Identification 5A 2 Replacement Parts Warning 5A 2 Specifications 5A 3 Torque Specifications 5A 2 Tools 5A 3 Lubricants Sealants Adhesives 5A 3 Precautions 5A 4 Fuel Supply Connections 5A 3 Fuel Delivery System 5A 4 Recommendations 5A 4 Fuel System Components 5A 5 Carburetor System 5A 5 Water Separating Fuel Filter 5A 5 Replacement 5A 6 Vent Hose Routing 5A 6 Carbureted Models 5A 6 Index ...

Page 385: ... 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 Fit...

Page 386: ...ng ing fuel filters Wipe up any spilled fuel immediately WARNING Make sure that no fuel leaks exist before closing engine hatch CAUTION DO NOT operate engine without cooling water being supplied to seawater pickup pump or pump impeller will be damaged and subsequent overheating damage may result Fuel Supply Connections WARNING Avoid gasoline fire or explosion Improper installation of brass fitting...

Page 387: ...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 rubb...

Page 388: ...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 Fuel System Components Carburetor System 71882 a b c d a Fuel Tank b Water Separating Fuel Filter c Fuel Pump d Carburetor Water Separating Fuel Filter The water separating fuel filter is standard on all engines Th...

Page 389: ...ed 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 75826 b d e g f c a a Carburetor b Flame Arrestor c PCV Valve d Vent Hose PCV Valve to Back Of Carburetor e Vent Hose Valv...

Page 390: ...FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 5A 7 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 391: ...FUEL DELIVERY SYSTEM FOR CARBURETED ENGINES SERVICE MANUAL NUMBER 24 Page 5A 8 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 392: ...ation 5B 7 8 Point Carburetor Check List 5B 7 Flooding At Idle RPM 5B 7 Needle Seat Change 5B 7 Adjustable Accelerator Pump Lever 5B 8 Description 5B 8 Maintenance 5B 9 Flame Arrestor with Carburetor Cover 5B 9 Fuel Inlet Filter 5B 11 Choke Inspection 5B 12 Adjustments 5B 12 Pump Rod 5B 12 Choke Setting 5B 14 Choke Unloader 5B 14 Initial Idle Speed and Mixture 5B 15 Final Idle Speed and Mixture 5B...

Page 393: ... 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 72779 a b Venturi Cluster Identification a Identification Number See Specifications b Accelerator Pump Discharge Holes Index ...

Page 394: ... 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 explosi...

Page 395: ...on 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 ap...

Page 396: ... 5 7L Carburetor Type MerCarb 43mm MerCarb 43mm Carburetor Number 3310 861448 3310 861245 Float Level 11 32 in 9 mm See Notes Float Drop 15 16 in 24 mm See Notes Pump Rod Location Middle Hole Of Pump Arm Choke Setting 2 Marks Right Of Index Mark Lean Choke Unloader 5 64 in 080 mm See Notes Idle Mixture Screw 1 1 2 Turns Out Float Weight 9 Grams Maximum Main Jet Size 1 65 mm Power Valve Size 0 90 m...

Page 397: ... ft 1525 2745 m 9000 ft 2745 m and Above 5 0L 1389 9563A_ 3310 806081A_ 3310 861080A_ 1389 9670A_ 3310 806082A 3310 861448A 1 70 mm 1 85 mm 1 65 mm 1 60 mm 1 75 mm 1 50 mm 1 55 mm 1 65 mm 1 45 mm 5 7L 3310 807312A 3310 861245A_ 1 65 mm 0 90 mm 1 50 mm 0 90 mm 1 45 mm 0 74 mm 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 81185...

Page 398: ...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 while the engine is off Y N 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 ...

Page 399: ...s 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 ea...

Page 400: ... Remove carburetor 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 ...

Page 401: ...ver 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 6 Install nut Tighten securely 75844 d a b f e g c h 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...

Page 402: ...nside filter nut 72406 b c d e f a 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 inle...

Page 403: ...mes 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 Pump ...

Page 404: ... OCTOBER 1999 Page 5B 13 2 With throttle valves completely closed measure from flame arrestor mounting surface to top of pump rod 72682 a a See Specifications 3 Carefully bend pump rod where shown to obtain specified dimension 72683 a b a Pump Rod b Bend Here Index ...

Page 405: ...ke cover retaining screws 2 Adjust as shown 3 Tighten screws securely 72403 a c b d d 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 72684 a b c a 080 in 0...

Page 406: ...r 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 72284 a b 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 ...

Page 407: ...mpering 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...

Page 408: ...or 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...

Page 409: ...UAL NUMBER 24 Page 5B 18 90 861327 1 OCTOBER 1999 Exploded View 75842 1 2 3 4 5 7 14 15 16 17 18 19 21 22 23 30 31 32 35 36 13 34 20 33 6 8 9 10 11 12 25 24 26 28 27 29 39 38 37 40 41 42 43 44 45 46 47 48 51 52 53 49 50 54 57 58 55 56 Index ...

Page 410: ...Pump Assembly 19 Spring 20 Screw 21 Inlet Needle and Seat Spring Loaded 22 Baffle Plate 23 Float 24 Carburetor Body 25 Cam Idle 26 Screw 27 Idle Mixture Adjusting Needle 28 Spring 29 Washer 30 Nut 31 Clip Pump Rod 32 Washer Locking 33 Nut 34 Throttle Lever 35 Spring 36 Screw Idle Speed Adjustment 37 PCV Tube Connection Fitting 38 Check Ball 39 Spring 40 Retainer 41 Screw 42 Lever Assembly 43 Screw...

Page 411: ... 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 72403 a a Choke Cover 2 Remove choke lever Remove choke hou...

Page 412: ...outlined previously 2 Remove accelerator pump rod retaining clip 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 72283 b a c a Accelerator Pump Rod b Retainer Clip c Pump Shaft and Lever Assembly 4 Remove idle cam screw 72282 c a b a Idle Cam Screw b Idle Cam c Choke Rod Index ...

Page 413: ...ing ear on rod and slot in choke lever align allowing rod to be pulled out 72286 a c b a Choke Rod b Choke Lever c Slot 6 Remove air horn attaching screws 7 Carefully lift air horn from float bowl assembly 72280 a a a a a Air Horn Attaching Screws 72400 a b a Air Horn Assembly b Float Bowl Assembly 8 Invert air horn and carefully lay on bench Index ...

Page 414: ...BER 1999 Page 5B 23 9 Remove float hinge pin and lift float assembly from air horn 72288 b a a Float Hinge Pin b Float Assembly 10 Check float weight as shown 72122 b a a Grams Scale b Float 11 Remove air horn gasket and baffle 72399 b a a Baffle b Air Horn Gasket Index ...

Page 415: ...7 1 OCTOBER 1999 12 Remove needle assembly 72287 a b a Needle Assembly b Needle Seat 13 Remove needle seat 72289 c b a a Needle Seat b Gasket c Screwdriver 72290 a b Needle and Seat Assemblies a Spring Loaded Type Needle Kit 3302 9029 b Solid Type Needle Kit 3302 9407 Index ...

Page 416: ...f air horn 16 Remove accelerator pump assembly 72398 a c b 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 72409 a b c a Pump Assembly b Retainer Clip c Lever Assembly FLOAT BOWL 1 Remove accelerator pump return spring from pump well 72402 a a Accelerator Pump Spring Index ...

Page 417: ... b b a 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 72397 a b a Venturi Cluster Brass Tube...

Page 418: ... extreme care when handling carburetor body so as not to damage throttle valves 1 Remove idle mixture adjusting needle and spring 72293 a b a Idle Mixture Adjusting Needle b Spring 2 Remove idle speed adjustment screw and spring if replacement is necessary a b 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 comp...

Page 419: ...ty 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 cl...

Page 420: ... 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 ran...

Page 421: ...st 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 72293 a b a Idle Mixing Adjusting Needle b Spring 2 Thread idle speed adjustment screw and spring into throttle lever a b 72395 a Idle Speed Screw b Spring Index ...

Page 422: ... check ball spring and retainer in passage Push retainer firmly into slots 72408 a b c a Check Ball b Spring c Retainer 2 Install new gasket on venturi cluster 72296 a b a Venturi Cluster b Gasket 3 Install venturi cluster in carburetor 72397 b a a Venturi Cluster b Gasket 4 Install flat washer and new fiber washer on center screw Lockwashers and flat washers are used on outer screws Tighten screw...

Page 423: ... washer will cause improper fueling 72405 a b c b d a Center Screw b Outer Screws c Fiber Washer d Lock Washer and Flat Washer 5 Install main metering jets with gaskets Tighten securely 72291 a b a Main Metering Jets b Gaskets Not Shown 6 Install power valve with new gasket Tighten securely 72404 a b a Power Valve b Gaskets Not Shown Index ...

Page 424: ... 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 72409 a b c 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...

Page 425: ...ket Tighten securely 72289 a b c 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 b a Needle Assembly b Needle Seat 7 Install baffle and gasket 72399 a b a Baffle b Gasket Index ...

Page 426: ... 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 a Measurement With 2 Piece Solid Inlet Needle 3 8 ...

Page 427: ...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 a Measurement 15 16 in 24 mm 3 Bend float assembly tang as shown to obtain specified dimension 72690 a a Float Assembly Tang 4 Recheck BOTH float level and float drop ...

Page 428: ...oned in fuel well Lower air horn straight down to install 72400 a b a Air Horn Assembly b Float Bowl Assembly 6 Install seven short and one long air horn attaching screws Tighten screws evenly and securely 72280 a a a a a Air Horn Attaching Screws 7 Place end of choke rod in choke lever and collar assembly 72299 a b a Choke Rod b Choke Lever and Collar Assembly Index ...

Page 429: ...e 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 72282 c a b a Screw b Idle Cam c Choke Rod 10 Place accelerator pump rod in hole in pump shaft and lever assembly 72393 a b a Accelerator Pump Rod b Pump Shaft and Lever Assembly Index ...

Page 430: ...er Clip CHOKE HOUSING 1 Install choke housing on air horn Tighten screws securely 2 Install choke lever Tighten screw securely 72401 a b c 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 72403 a c b d a Scribed Mark b More C...

Page 431: ...th 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 c...

Page 432: ...MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 5B 41 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 433: ...MERCARB 2 BARREL CARBURETOR SERVICE MANUAL NUMBER 24 Page 5B 42 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 434: ...Fuel Supply Connections 5C 3 Fuel Delivery System 5C 4 Recommendations 5C 4 Cool Fuel System Exploded View 5C 5 Fuel System Flow Diagrams 5C 6 Throttle Body Injection 5C 6 Multi Port Injection with MEFI 1 and MEFI 2 5C 7 Multi Port Injection with MEFI 3 5C 8 Water Separating Fuel Filter 5C 9 Water Separating Fuel Filter Replacement 5C 10 Cool Fuel System Repair 5C 10 Removal 5C 10 Disassembly 5C 1...

Page 435: ...Part Number Quicksilver Perfect Seal 92 34227 1 592 Loctite Pipe Sealant with Teflon Obtain Locally NOTE Refer To Fuel Supply Connections Warning following this chart 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 re...

Page 436: ...atch 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 wit...

Page 437: ...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 Coa...

Page 438: ...w Component List 1 Bracket 2 Cover Base 3 Screw and Washer 2 4 Fuel Pressure Regulator 5 Return Fuel Line 6 Retaining Ring 7 O Rings 2 8 Fuel Line To Fuel Rail 9 Gasket 10 Drain Plug 11 Stepped Screw 12 O Rings 4 13 Elbow 14 Fuel Cooler 15 Fuel Pump Wiring Harness 16 Retainer Bracket 17 Nut 2 18 Electric Fuel Pump 19 Inlet Fitting 20 Fuel Line Inlet 21 Cover 22 Filter 23 Seawater Hoses Hose Clamps...

Page 439: ...ion 74871 a b c d e f g h i 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 Index ...

Page 440: ... g 74871 a b c d e f g h k j i 350 Mag MPI Shown Scorpion Is Similar a Vacuum Line To Intake Manifold Base 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 Fuel Line To Fuel Rail i Excess Fuel Return To Water Separating Fuel Filter j Fuel Injectors 8 k Fuel Rail Index ...

Page 441: ...71 a b c d e f g h k j i 350 Mag MPI Shown Scorpion Is Similar a Vacuum Line To Intake Manifold Base 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 Fuel Line To Fuel Rail i Excess Fuel Return To Water Separating Fuel Filter j Fuel Injectors 8 k Fuel Rail Index ...

Page 442: ...r to Precautions in this section BEFORE proceeding a b c d e f g h i j k l MCM Model Shown a Top Cover Some Models 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 Some Models Index ...

Page 443: ...ve 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 coo...

Page 444: ... cooler bracket to the engine 12 Carefully remove the cool fuel system assembly 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 2 Disconnect the fuel lines from the assembly 3 Disconnect the elbow fitting and fuel pump from the coole...

Page 445: ...ator Tighten securely 75708 c d e c a b a a Filter b Fuel Cooler Orifice c Pressure Regulator d Screw and Washer e Fuel Line 4 Install the fuel rail fuel line as follows a Install two of six O rings onto the cooler to fuel rail 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...

Page 446: ... 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 wi...

Page 447: ... 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 Connect the fuel lines to the fuel filter adapter Tighten securely 75533 a b c a Filter Assembly b Fuel Lines c Lock Nuts 3 Route the fuel lines as needed and place the Cool Fu...

Page 448: ...nnect the fuel line to the fuel rail fitting at location shown Tighten securely 75696 b a a Fuel Line Fuel Cooler to Fuel Rail b Fuel Rail Fitting 6 On Throttle Body EFI Install the cooler to throttle body fuel line as follows a Route the fuel line to the back side of engine b Connect the fuel line to the throttle body fitting at location shown Tighten securely 75806 a b a Fuel Line Fuel Cooler to...

Page 449: ...f 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 13 Clean battery cable clamps and terminals and reconnect cables see CAUTION listed above Secure each cable clamp when...

Page 450: ...Mag MPI Models a b c d e f g h i a Throttle Body Adapter b Cool Fuel Assembly c Vacuum Hose Throttle Body Adapter to Fuel Pressure Regulator on Cool Fuel Assembly d Vent Hose PCV Valve to Throttle Body Adapter e Vent Hose Valve Cover Fitting To Flame Arrestor f PCV Valve g Vacuum Hose T Fitting to Plenum h Flame Arrestor i Front of Engine Index ...

Page 451: ...dy Adapter b Cool Fuel Assembly c Vacuum Hose Forward Fitting On Intake Manifold To Fuel Pressure Regulator on Cool Fuel Assembly d Vent Hose PCV Valve to Throttle Body Adapter e Vent Hose Valve Cover to Flame Arrestor f PCV Valve g Vent Hose Fitting h Flame Arrestor i Front of Engine j MAP Sensor k Vacuum Hose Rear Fitting On Intake Manifold To MAP Sensor Index ...

Page 452: ...ody EFI a b c d e f g h i a Plenum 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 Throttle Body Adapter e PCV Valve f Vent Hose Valve Cover Fitting To Flame Arrestor g Valve Cover Fitting h Flame Arrestor i Front of Engine Index ...

Page 453: ...FUEL DELIVERY SYSTEM FOR ELECTRONIC FUEL INJECTION SERVICE MANUAL NUMBER 24 Page 5C 20 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 454: ...0 EFI Diagnostic Circuit Check 5D 10 Scan Tool Use With Intermittents 5D 10 Non Scan Diagnosis of Driveability Concerns With No Codes Set 5D 11 Electronic Control Module ECM and Sensors 5D 12 General Description 5D 12 Computers and Voltage Signals 5D 12 Analog Signals 5D 12 Digital Signals 5D 13 Engine Control Module ECM 5D 14 Speed Density System 5D 15 ECM Input and Sensor Descriptions 5D 16 Spar...

Page 455: ...ring of various circuits and components in the fuel injec tion system Allows for test firing injectors Tool can read MEFI 1 MEFI 2 and MEFI 3 ECM 94008 Code Mate Tester Flashes light to display problem codes 91 99379 Timing Light Used to check ignition timing Must have inductive signal pickup 91 16850A5 Fuel Pressure Gauge Kit Used to check fuel system pressure Kit includes 91 803135 Test Port Ada...

Page 456: ...ngine without the battery being solidly connected Never separate the battery from the on board electrical system while the engine is running Never separate the battery feed wire from the charging system while the engine is running 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 thorough...

Page 457: ...digital multime ter in series with the test light being tested and power the test light ammeter circuit with the vehicle battery b a c 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 tes...

Page 458: ...ively 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 con...

Page 459: ...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 er...

Page 460: ...ostic N C Normally Closed DIST Distributor N O Normally Open DLC Data Link Connector PROM Programmable Read Only 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 ECT Engine Coolant Temperature ROM Read Only Memory EEPROM Electronic Erasable Program mable Read Only Memory SLV Slave HEI High E...

Page 461: ...he 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 perform...

Page 462: ...lash 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 o...

Page 463: ...to step 2 2 If a code is stored go directly to the numbered code chart in SECTION 5F or 5G as ap propriate This will determine 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 ...

Page 464: ...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...

Page 465: ...ther 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 ...

Page 466: ...b c d e 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...

Page 467: ...ts 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...

Page 468: ...ectronic 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 Ener...

Page 469: ...s various systems Although we will not cover them all in great detail there will be a brief description of each a b c d e f g h i j k l m n o p q r s a System Relay b Distributor For REF rpm c Discrete Switches Audio Warning d Knock Module e Knock Sensor f TP g MAP h ECT i IAT j Serial Data k Audio Warning Buzzer l Fuel Injectors m IAC Motor n Ignition Control Module o Fuel Pump Relay p Fuel Pump ...

Page 470: ...P 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 73046 a a 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 throttl...

Page 471: ...nition spark timing retard and a Code will be set e a b c 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 w...

Page 472: ...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 bro...

Page 473: ... 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...

Page 474: ...sitive 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 igniti...

Page 475: ...ce 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 p o n m l k j i h g f e d c b a t s Distributor Module Mode j k n m l r q i h g f e d c b...

Page 476: ... 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 ...

Page 477: ...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 ...

Page 478: ... 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 he...

Page 479: ...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 tu...

Page 480: ...CE MANUAL NUMBER 24 90 861327 OCTOBER 1999 Page 5D 27 THROTTLE BODY UNIT EXPLODED VIEW 73766 a b c d e f g 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 Index ...

Page 481: ...w 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 73773 a b c d 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 spri...

Page 482: ...e spikes caused by the fuel injectors 76499 a 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 72800 a b c a IAC Valve Air Flow Diagram a IAC Valve b EFI Throttle Body c Air Flow Index ...

Page 483: ...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 conditions 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 ...

Page 484: ...INTAKE MANIFOLD ASSEMBLY The fuel rail performs several functions It positions the injectors in the intake manifold dis tributes fuel evenly to the injectors 75829 a b c 350 Mag MPI Models a Fuel Rail b Fuel Injector c Intake Manifold 75839 a b c Black Scorpion Models a Fuel Rail b Fuel Injector c Intake Manifold Index ...

Page 485: ... finely atomized fuel at the injector tip Fuel is directed at the intake valve causing it to become further atomized and vaporized before entering the combustion chamber An injector that is stuck partly open will cause loss of pressure after engine shutdown This can result in long cranking times Dieseling can also occur because some fuel might be de livered to the engine after the ignition is turn...

Page 486: ...rops The fuel pressure regulator is located on the cool fuel assembly 71716 THROTTLE BODY ASSEMBLY The throttle body assembly is used to control air flow into the engine thereby controlling engine output The throttle valve within the throttle body is opened by the operator through the accelerator controls During engine idle the throttle valve is almost closed and air flow control is handled by the...

Page 487: ... the DLC connector During idle the proper position of the IAC valve is engine load and engine rpm If the rpm drops below specification and the throttle valve is closed the ECM senses a near stall condi tion 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 Controlled idle speed is programmed ...

Page 488: ...FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 24 90 861327 OCTOBER 1999 Page 5D 35 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 489: ...FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION SERVICE MANUAL NUMBER 24 Page 5D 36 90 861327 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 490: ...ake Manifold And Fuel Rails 5E 26 Fuel Pressure Relief Procedure 5E 27 Black Scorpion Components 5E 27 Flame Arrestor 5E 27 Throttle Body 5E 29 Plenum 5E 35 Fuel Rails 5E 37 Fuel Injectors 5E 39 MAP Sensor 5E 40 Throttle Position Sensor 5E 41 Idle Air Control IAC Valve 5E 43 Knock Sensor 5E 45 Knock Sensor Module 5E 46 Fuel Pump Relay 5E 46 System Relay 5E 47 Engine Control Module 5E 47 Engine Coo...

Page 491: ...a 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 w...

Page 492: ... 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 Rail 105 12 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 Flame Arrestor Clamp Tighten Securely Index ...

Page 493: ...arlier Models 1 Cover 2 Washer 3 Nut 1 4 28 4 Flame Arrestor Bracket 5 Nut 1 4 20 6 Washer 7 Washer 8 Flame Arrestor 9 Clamp 10 Throttle Body Assembly 11 Gasket 12 Throttle Body Adaptor Plate 13 Gasket 14 3 16 In Barb Fitting From Fuel Pressure Regulator 15 3 8 In Barb Elbow Fitting From PCV Valve 16 Screw 5 16 18 x 1 1 4 in 32 mm 17 Throttle Lever and Linkage 18 Throttle Cable Bracket 19 Shoulder...

Page 494: ...1 Cover 2 Washer 3 Nut 1 4 28 4 Washer 5 Flame Arrestor 6 Throttle Body Assembly 7 Stud 8 Screw 1 4 20 9 Gasket 10 3 16 in Barb Fitting From Fuel Pres sure Regulator 11 Pipe Plug 1 4 18 Socket Head 12 Screw 5 16 18 x 1 1 4 in 32 mm 13 Washer 14 Throttle Body Adaptor Plate 15 Gasket 16 Stud Kit 17 Throttle Cable Bracket 18 Screw 5 16 18 x 1 in 19 Washer 20 Washer 21 Stud 1 4 x 1 3 4 in 22 Nut 1 4 2...

Page 495: ...8 9 14 10 13 11 12 MEFI 1 and MEFI 2 Models 1 Intake Manifold 2 Gasket 3 Pipe Plug 4 Screw 5 16 18 x 1 3 8 in 35 mm 5 Fuel Injector 6 Upper O Ring 7 MAP Sensor 8 Clip 9 Screw 8 32 x 1 4 in 6 mm 10 T Fitting 11 Fuel Rail 12 Elbow Fitting 13 Stud 2 14 Screw 1 4 20 15 Schrader Valve 16 Cap 17 24 In 609 mm Fuel Line 18 21 In 533 mm Fuel Line 19 Location of Fuel Line From Fuel Pump Index ...

Page 496: ...13 13 17 17 17 17 16 12 10 15 19 MEFI 3 Models 1 Intake Manifold 2 Gasket 3 Pipe Plug 4 Screw 5 16 18 x1 3 8 in 35 mm 5 Fuel Injector 6 O Ring 7 MAP Sensor 8 Clip 9 Screw 8 32 x 1 4 in 6 mm 10 Pipe Plug 1 8 in hex head 11 Fuel Rail 12 Schrader Valve 13 Screws 1 4 20 x 1 1 2 in 14 MAT Sensor 15 Cap 16 Fuel Lines 17 O Rings 18 Location of Fuel Line From Fuel Pump 19 Pressure Sensor Index ...

Page 497: ...ng 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 350 Mag MPI Components Flame Arrestor NOTICE Refer to Service Precautions at front of this section BEFORE proceeding REMOVAL 1 Remove the flame arrestor cover 75831 a b c 76365 a Typical Connections a Flame Arrestor Cover b Nut c W...

Page 498: ...e flame arrestor cover bracket DO NOT remove the fuel rail stud 75830 a b b a Bracket b Nuts and Fuel Rail Stud 3 If equipped loosen the clamp and remove the flame arrestor 75828 a b c a Throttle Body b Clamp c Flame Arrestor 4 If equipped loosen the nut and remove the flame arrestor 76501 a b a Flame Arrestor b Nut Index ...

Page 499: ... 2 Wear eye protection Dry flame arrestor with compressed air INSTALLATION 1 Replace components as appropriate for your model Tighten all fasteners securely 75828 a b c 75830 d e e Earlier Models a Throttle Body b Clamp c Flame Arrestor d Bracket e Nut and Washers 76518 a b b c d e Later Models a Nut b Washer c Flame Arrestor Cover d Flame Arrestor e Stud Index ...

Page 500: ... 76365 a d d Typical Connections a Flame Arrestor Cover b Nut c Washer d Flame Arrestor Throttle Body NOTICE Refer to Service Precautions at front of this section BEFORE proceeding REMOVAL 1 Remove the flame arrestor 2 Disconnect the throttle linkage from the throttle body 75830 a b c b Typical a Bracket If Equipped b Nuts Both Sides or Top As Equipped c Throttle Cable Index ...

Page 501: ...5788 a b a IAC Valve Connector b Throttle Position Sensor Connector 4 Remove the screws 3 retaining the throttle body and remove the throttle body from the adapter Refer to Exploded View 75828 a b c d a b c d a Adapter b Gasket c Throttle Body d Screws IMPORTANT Insert a clean shop towel into the opening of the plenum to prevent for eign material from entering the engine Index ...

Page 502: ...e body 1 Carefully remove all gasket material from adapter and throttle body 2 Thoroughly clean all parts of throttle body Make certain that all passages are free of dirt and burrs 3 Inspect mating surfaces for damage that could affect gasket sealing 4 Inspect throttle body for cracks in casting 5 Inspect throttle plates linkage return springs etc for damage wear and foreign mate rial 6 Check adap...

Page 503: ...6 Install the flame arrestor cover bracket 7 Install the flame arrestor cover Throttle Position Sensor NOTICE Refer to Service Precautions in front of this section BEFORE proceeding 1 Remove the flame arrestor cover 2 Remove the flame arrestor from the throttle body 3 Disconnect the harness connector from the TP sensor 4 Remove the throttle body from the adapter 5 Disconnect the harness connector ...

Page 504: ... 20 lb in 2 Nm 75832 a b c d a Screw 2 b Throttle Position TP Sensor c Throttle Body d Dust Seal 2 Place a new gasket on the adapter 3 Install throttle body on the adapter Torque screws to 89 lb in 10 Nm 4 Connect the harness connector to the TP sensor 5 Place the flame arrestor over the throttle body and tighten clamp securely 6 Install the flame arrestor cover Tighten nut securely 7 When negativ...

Page 505: ... AND INSPECTION IMPORTANT Do not 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 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 care ful not to push or ...

Page 506: ...ring on IAC valve 75657 75784 a d c b a Screw 2 b Idle Air Control IAC Valve c Throttle Body d O Ring 2 Install IAC valve in throttle body using screws Torque to 20 lb in 2 Nm 3 Place a new gasket between throttle body and adapter 4 Install the throttle body on the adapter and torque the screws to 89 lb in 10 Nm 5 Reset IAC valve pintle position as follows a Turn ignition key ON for ten seconds b ...

Page 507: ...aying 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 specifi...

Page 508: ...e electrical box 75833 a b a Knock Sensor Module b Electrical Box 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 Mount KS module on bracket 2 Connect electrical connector to the KS module Index ...

Page 509: ...r solvent damage may result 1 Clean the external surfaces with a dry cloth 2 Inspect surfaces for evidence of damage INSTALLATION 1 Connect electrical connector to fuel pump relay 2 Attach fuel pump relay to bracket System Relay REMOVAL 1 Remove system relay from electrical box 75835 3 PNK 902 RED 30 86 85 87 150 BLK 2 RED a a System Relay 2 Disconnect electrical connector and remove relay CLEANIN...

Page 510: ... BEFORE proceeding IMPORTANT The ECM is a sensitive electrical device subject to electrostatic damage DO NOT touch connector pins when removing or installing the module REMOVAL 1 Disconnect J1 and J2 electrical connectors at engine control module ECM DO NOT touch connector pins when removing 75836 a b c d Typical a Electrical Bracket b MEFI 1 and MEFI 2 ECM c J1 Electrical Connector Front Connecto...

Page 511: ...ing harness for corrosion and terminals that may have backed out of the harness NOTE The ECM is a sealed electrical component If a Code 51or 52 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 using screws and washers 2 Connect J1 and J2 electrical connectors to the ECM DO NOT touch c...

Page 512: ...ect electrical connector at engine coolant temperature ECT sensor 72799 a a Engine Coolant Temperature ECT Sensor 2 Remove ECT sensor 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 sensor INSTALLATION 1 Install ECT sensor Tighten hand tight...

Page 513: ... Models 75837 a b c d e f g h i a Throttle Body Adapter b Cool Fuel Assembly c Vacuum Hose Throttle Body Adapter to Fuel Pressure Regulator on Cool Fuel Assembly d Vent Hose PCV Valve to Throttle Body Adapter e Vent Hose Valve Cover Fitting To Flame Arrestor f PCV Valve g Vacuum Hose T Fitting to Plenum h Flame Arrestor i Front of Engine Index ...

Page 514: ...iews Black Scorpion Plenum Throttle Body And Flame Arrestor 75838 10 11 12 13 1 2 3 4 5 6 7 8 9 14 1 Intake Plenum 2 Gasket 3 Stud 4 Nut 2 5 Plenum Screw 6 MAP Sensor 7 Screw and Bracket 8 Hose 9 Throttle Body 10 Screw 11 Flame Arrestor 12 Clamp 13 Throttle Lever and Linkage 14 Gasket See Changes Previously Index ...

Page 515: ...Intake Manifold And Fuel Rails 75839 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 5 3 5 5 1 Intake Manifold 2 Intake Gasket 2 3 Fuel Rail 2 4 Screw 5 Connector Fittings 6 Schrader Valve 7 Cap 8 Fuel Injector 9 Upper Seal 10 O Ring 11 Screen 12 Lower Seal 13 Stud 14 Spacer 15 Washer 16 Nut 17 Fuel Lines Index ...

Page 516: ...fuel pressure in the system Black Scorpion Components Flame Arrestor NOTICE Refer to Service Precautions in front of this section BEFORE proceeding REMOVAL 1 Remove flame arrestor and related components in the following order 2 EARLIER STYLE Remove clamp 3 LATER STYLE Remove nut 4 Remove crankcase ventilation hose from against flame arrestor and rocker arm cover fittings 5 Remove flame arrestor 75...

Page 517: ...essed air or allow to air dry completely 3 Inspect crankcase ventilation hoses for cracks or deterioration and replace if necessary INSTALLATION 1 EARLIER STYLE Position clamp on flame arrestor 2 Install flame arrestor 3 EARLIER STYLE Tighten clamp securely 4 LATER STYLE Tighten nut 5 Position crankcase ventilation hose against flame arrestor and attach to rocker arm cover fittings 75046 75779 a b...

Page 518: ...0 861327 1 OCTOBER 1999 Page 5E 29 Throttle Body NOTICE Refer to Service Precautions in front of this section BEFORE proceeding REMOVAL 1 Remove the flame arrestor 2 Disconnect the throttle cable from the throttle lever 74838 a b a Throttle Cable b Flame Arrestor Index ...

Page 519: ...1 OCTOBER 1999 3 Disconnect the wiring connectors from the IAC valve and the TP sensor 75788 a b Earlier Style Throttle Body a IAC Valve Connector b Throttle Position Sensor Connector 75777 75778 a b Later Style Throttle Body a Throttle Position Sensor Connector b IAC Valve Connector Index ...

Page 520: ...fer to Exploded View 75838 a b c a Throttle Body b Screws c Gasket Single On Earlier Models NOTE The later style throttle body uses two gaskets and a plate between the throttle body and the plenum 75783 a b c Later Style With Gaskets and Plate a Throttle Body b Gaskets c Plate IMPORTANT Insert a clean shop towel into the opening of the plenum to prevent foreign material from entering the engine In...

Page 521: ...asket material from plenum and throttle body 2 Thoroughly clean all parts of throttle body Make certain that all passages are free of dirt and burrs 3 Inspect mating surfaces for damage that could affect gasket sealing 4 Inspect throttle body for cracks in casting 5 Inspect throttle plates linkage return springs etc for damage wear and foreign material 6 Check for loose parts and foreign material ...

Page 522: ...nuts or 3 screws on Earlier Style and torque to 75 lb in 8 5 Nm 75781 a b c c Later Style With Screw And Nuts a Throttle Body b Screw c Nuts 3 Connect the harness connectors to the TP sensor and IAC valve 75788 a b Earlier Style Throttle Body a IAC Valve Connector b Throttle Position Sensor Connector 75777 b a Later Style Throttle Body a TP Sensor b Connector Index ...

Page 523: ...CE MANUAL NUMBER 24 Page 5E 34 90 861327 1 OCTOBER 1999 75778 a b Later Style Throttle Body a IAC Valve b Connector 4 Connect the throttle cable to the throttle lever Refer to SECTION 2 for throttle cable adjustment 5 Install the flame arrestor Index ...

Page 524: ...ORTANT Use care when removing gasket material from intake manifold and plenum Failure to do so could result in damage to the intake manifold and plenum 1 Carefully remove all gasket material from intake manifold and plenum 2 Clean plenum in solvent and dry with compressed air 3 Inspect mating surfaces for damage that could affect gasket sealing 4 Inspect plenum for cracks in casting INSTALLATION 1...

Page 525: ...Screws 6 b Plenum c Gasket d Nuts e MAP Sensor Location 6 Place remote control throttle lever in idle position Attach cable to throttle lever stud Refer to SECTION 2 for throttle cable adjustment 7 After throttle cable is adjusted tighten locknut against cable end 74838 a b c a Cable End b Throttle Lever Stud c Locknut 8 Connect the harness connector and the vacuum hose to the MAP sensor Index ...

Page 526: ...ons Aft View a Fuel Rail Connector Fittings b Rail to Rail Fuel Lines c Cool Fuel to Fuel Rail Line d Distributor Cap 3 Disconnect fuel lines from front end of fuel rail connector fittings 75697 a b a Fuel Lines and Connections Front View a Fuel Rail Connector Fittings b Rail to Rail Fuel Lines 4 Remove plenum 5 Disconnect harness connector from each injector 6 Remove fuel rail screws 7 Gently mov...

Page 527: ...the injectors in the rail 3 Inspect rails for cracks INSTALLATION 1 Position injectors in the fuel rails 2 Install fuel rail by pushing down gently while moving it back and forth 3 Install fuel rail fasteners Torque to 105 lb in 12 Nm 4 Route the rail to rail fuel lines as shown Temporarily hand tighten the lines to the fuel rail connector fittings 5 Torque the four fuel line connections to 18 lb ...

Page 528: ...NG AND INSPECTION 1 Inspect fuel injectors for damage replace if necessary 2 Inspect screen on inlet side of injector for debris Clean or replace as necessary INSTALLATION 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 in...

Page 529: ...b Manifold Absolute Pressure MAP Sensor c Vacuum Hose To Intake Manifold d Screws 2 2 Remove MAP sensor CLEANING AND INSPECTION 1 Clean off any foreign matter with a dry cloth 2 Inspect for any obvious signs of physical damage to the sensor INSTALLATION 1 Install MAP sensor using screws Torque screws to 44 62 lb in 5 7 Nm 2 Connect electrical connector to MAP sensor 3 Connect vacuum hose to intake...

Page 530: ... position TP sensor 2 Remove TP sensor from throttle body Remove the dust seal 75788 a b Earlier Style Throttle Body a Throttle Position TP Sensor Harness b Screws 75777 a b Later Style Throttle Body a Throttle Position TP Sensor Harness b 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 Index ...

Page 531: ...ensor and gasket on throttle body using screws with washers and Loctite 242 applied to threads Torque screws to 20 lb in 2 Nm a b c d 75785 c a b c d Earlier Style Throttle Body Later Style Throttle Body a Screws b Throttle Position TP Sensor c Throttle Body d Seal 2 Connect electrical connector to TP sensor 3 Install throttle body throttle linkage and flame arrestor 4 Start engine and check for T...

Page 532: ...s 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 Inspec...

Page 533: ...ater Style Throttle Body a Idle Air Control IAC Valve b Screws 3 Connect electrical connector to IAC valve 75788 a 75788 a Earlier Style Throttle Body Later Style Throttle Body a Idle Air Control IAC Valve Connector 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 fo...

Page 534: ... 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 o...

Page 535: ...or evidence of damage INSTALLATION 1 Connect electrical connector to the Knock Sensor Module 2 Place KS module in electrical box 00000 a a Knock Sensor KS Module Fuel Pump Relay REMOVAL 1 Remove fuel pump relay from electrical box 00000 450 BLK 120 GRY 30 86 85 87 465 DK GRN WHT 2C PNK a a Fuel Pump Relay 2 Disconnect electrical connector and remove fuel pump relay IMPORTANT The fuel pump relay is...

Page 536: ...ach electrical connector to relay 2 Place system relay in electrical box Engine Control Module 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 REMOVAL 1 Disconnect J1 and J2 electrical connectors at engine control module ECM 72801 a b c a MEFI 1 and MEFI 2 ECM Shown MEFI 3 Simi...

Page 537: ...s the original INSTALLATION 1 Mount new ECM to electrical bracket using screws and washers 2 Connect J1 and J2 electrical connectors to the ECM DO NOT touch connector pins when installing Engine Coolant Temperature Sensor REMOVAL NOTE Handle the ECT sensor carefully Damage to it will affect operation of the system 1 Disconnect electrical connector at Engine Coolant Temperature ECT sensor 72799 a b...

Page 538: ...a Throttle Body Adapter b Cool Fuel Assembly c Vacuum Hose Forward Fitting On Intake Manifold To Fuel Pressure Regulator on Cool Fuel Assembly d Vent Hose PCV Valve to Throttle Body Adapter e Vent Hose Valve Cover to Flame Arrestor f PCV Valve g Vent Hose Fitting h Flame Arrestor i Front of Engine j MAP Sensor k Vacuum Hose Rear Fitting On Intake Manifold To MAP Sensor Index ...

Page 539: ... MANUAL NUMBER 24 Page 5E 50 90 861327 1 OCTOBER 1999 Exploded Views Throttle Body EFI Throttle Body Body And Adapter 75841 1 2 3 4 5 6 7 5 5 76500 1 Throttle Body 2 Screws 3 3 Gasket 4 Throttle Body Adapter 5 Screws 4 6 Gasket 7 Intake Manifold Index ...

Page 540: ...8 9 1 13 1 Cap Screw 2 Cover Assembly 3 Fuel Pressure Regulator 4 Cover Assembly Gasket 5 Upper O Ring 6 Fuel Meter Outlet Gasket 7 Fuel Injector 2 8 Fuel Filter 2 9 Lower O Ring 10 Screw 11 Body 12 Throttle Body To Fuel Meter Body Gasket 13 Throttle Body 14 Throttle Position TP Sensor 15 Screws 2 16 Seal 17 O Ring 18 Idle Air Control IAC Valve 19 Screws 2 20 Fuel Inlet Index ...

Page 541: ...o Service 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 inj...

Page 542: ...maged 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...

Page 543: ...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 th...

Page 544: ... 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 0 Nm and flame arrestor as outlined in this section 5 Connect electric...

Page 545: ...rs Squeeze plastic tabs on injectors and pull straight up 73750 a 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 immer...

Page 546: ... plate and torque the screws 30 lb ft 40 Nm 4 Connect throttle linkage to throttle body 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 ...

Page 547: ...OVAL 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 refer to Throttle Body Section 3 Remove screws and the throttle body adapter from the intake manifold 75841 1 2 3 4 5 6 7 5 5 76500 Typical 1 Throttle Body 2 Screws 3 3 Gasket 4 Throttle Body Adapter 5 Screws 4 6 Gasket 7 Intak...

Page 548: ...tor Front Connector d J2 Electrical Connector Rear Connector 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 t...

Page 549: ...E 60 90 861327 1 OCTOBER 1999 INSTALLATION 1 Mount new ECM to electrical bracket 2 Connect J1 and J2 electrical connectors to the ECM 72801 a b c d MEFI 1 Shown a Electrical Bracket b ECM c J1 Electrical Connector Front Connector d J2 Electrical Connector Rear Connector Index ...

Page 550: ...tions at front of this section BEFORE proceeding REMOVAL 1 Remove Knock Sensor from electrical bracket 72801 a b MEFI 1 Shown a Electrical Bracket b Knock Sensor KS Sensor 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 Index ...

Page 551: ... Electrical Bracket b Knock Sensor KS Sensor 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 72799 a b a Thermostat Housing b Engine Coolant Temperature ECT Senso...

Page 552: ...ecautions at front of this section BEFORE proceeding REMOVAL 1 Disconnect electrical connector from manifold absolute pressure MAP sensor 75840 a c e b d 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 senso...

Page 553: ...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 which 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 73758 b a c b a Throttle Body b Screws With Loc...

Page 554: ...lve 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 me...

Page 555: ...ew O ring on IAC valve 73766 a b d c 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 73754 a b 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 ignit...

Page 556: ...ces 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 pe...

Page 557: ...le Body EFI Models 00000 a b c d e f g h i a Plenum 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 Throttle Body Adapter e PCV Valve f Vent Hose Valve Cover Fitting To Flame Arrestor g Valve Cover Fitting h Flame Arrestor i Front of Engine Index ...

Page 558: ...FUEL INJECTION DISASSEMBLY AND REASSEMBLY SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 5E 69 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 559: ...FUEL INJECTION DISASSEMBLY AND REASSSEMBLY SERVICE MANUAL NUMBER 24 Page 5E 70 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 560: ...r 5E 15 Knock Sensor Module 5E 16 Fuel Pump Relay 5E 16 System Relay 5E 17 Electronic Control Module ECM 5E 17 Engine Coolant Temperature ECT Sensor 5E 18 Vacuum And Vent Hose Routing 5E 19 MX 6 2 MPI Models 5E 19 Exploded Views MX 6 2 Black Scorpion 5E 20 Plenum Throttle Body And Flame Arrestor 5E 20 Intake Manifold And Fuel Rails 5E 21 Fuel Pressure Relief Procedure 5E 22 MX 6 2 Black Scorpion C...

Page 561: ... 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 components in the fuel system CAUTION DO NOT operate eng...

Page 562: ... 16 16 22 Black Scorpion Plenum 150 17 Fuel Rail Fasteners 105 12 Rail to Rail Fuel Line 18 24 Fuel Meter Cover Assembly Screws 28 3 Fuel Inlet and Return Lines 23 31 Engine Coolant Temperature Sensor Tighten Hand Tight 2 1 2 turns maximum Flame Arrestor Cover Bracket Flame Arrestor Clamp Tighten Securely Lubricants Sealants Adhesives Description Part Number Loctite 242 Sensor Voltage Description ...

Page 563: ...w the early model cover 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 19 22 1 77439 1 Cover 2 Washer 3 Nut 1 4 28 4 Washer 5 Flame Arrestor 6 Throttle Body Assembly 7 Stud 8 Screw 1 4 20 9 Gasket 10 3 16 in Barb Fitting From Fuel Pres sure Regulator 11 Pipe Plug 1 4 18 Socket Head 12 Screw 5 16 18 x 1 1 4 in 32 mm 13 Washer 14 Throttle Body Adaptor Plate 15 Gasket 16 Stud Kit 17 Throttle Cabl...

Page 564: ...8 9 13 10 11 12 13 13 17 17 17 17 16 12 10 15 19 1 Intake Manifold 2 Gasket 3 Pipe Plug 4 Screw 5 16 18 x1 3 8 in 35 mm 5 Fuel Injector 6 O Ring 7 MAP Sensor 8 Clip 9 Screw 8 32 x 1 4 in 6 mm 10 Pipe Plug 1 8 in hex head 11 Fuel Rail 12 Schrader Valve 13 Screws 1 4 20 x 1 1 2 in 14 MAT Sensor 15 Cap 16 Fuel Lines 17 O Rings 18 Location of Fuel Line From Fuel Pump 19 Pressure Sensor ...

Page 565: ...pump 2 Crank engine for ten seconds if engine starts allow it run until it stops to relieve any fuel pressure in the system MX 6 2 MPI Components Flame Arrestor NOTICE Refer to Service Precautions at front of this section BEFORE proceeding NOTE The 6 2L engine may be equipped with one of two covers Both covers are shown below but most pictures will show the early model cover REMOVAL 1 Remove the f...

Page 566: ...he flame arrestor 76501 a b a Flame Arrestor b Nut CLEANING AND INSPECTION 1 Clean flame arrestor in solvent 2 Wear eye protection Dry flame arrestor with compressed air INSTALLATION 1 Replace components as appropriate for your model Tighten all fasteners securely 76518 a b b c d e a Nut b Washer c Flame Arrestor Cover d Flame Arrestor e Stud ...

Page 567: ... 76365 d a a Flame Arrestor Cover b Nut c Washer d Flame Arrestor Throttle Body NOTICE Refer to Service Precautions at front of this section BEFORE proceeding REMOVAL 1 Remove the flame arrestor 2 Disconnect the throttle linkage from the throttle body 3 Disconnect the wiring connectors from the IAC valve and the TP sensor 75788 a b a IAC Valve Connector b Throttle Position Sensor Connector ...

Page 568: ...5E 9 4 Remove the screws 3 retaining the throttle body and remove the throttle body from the adapter Refer to Exploded View 75828 a b c d a b c d a Adapter b Gasket c Throttle Body d Screws IMPORTANT Insert a clean shop towel into the opening of the plenum to prevent for eign material from entering the engine ...

Page 569: ...nd throttle body 1 Carefully remove all gasket material from adapter and throttle body 2 Thoroughly clean all parts of throttle body Make certain that all passages are free of dirt and burrs 3 Inspect mating surfaces for damage that could affect gasket sealing 4 Inspect throttle body for cracks in casting 5 Inspect throttle plates linkage return springs etc for damage wear and foreign mate rial 6 ...

Page 570: ...the flame arrestor 6 Install the flame arrestor cover Throttle Position Sensor NOTICE Refer to Service Precautions in front of this section BEFORE proceeding 1 Remove the flame arrestor cover 2 Remove the flame arrestor from the throttle body 3 Disconnect the harness connector from the TP sensor 4 Remove the throttle body from the adapter 5 Disconnect the harness connector from the TP sensor 6 Rem...

Page 571: ...screws to 20 lb in 2 Nm 75832 a b c d a Screw 2 b Throttle Position TP Sensor c Throttle Body d Dust Seal 2 Place a new gasket on the adapter 3 Install throttle body on the adapter Torque screws to 89 lb in 10 Nm 4 Connect the harness connector to the TP sensor 5 Place the flame arrestor over the throttle body and tighten clamp securely 6 Install the flame arrestor cover Tighten nut securely 7 Whe...

Page 572: ...CLEANING AND INSPECTION IMPORTANT Do not 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 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 care ful not to ...

Page 573: ...all new O ring on IAC valve 75657 75784 a d c b a Screw 2 b Idle Air Control IAC Valve c Throttle Body d O Ring 2 Install IAC valve in throttle body using screws Torque to 20 lb in 2 Nm 3 Place a new gasket between throttle body and adapter 4 Install the throttle body on the adapter and torque the screws to 89 lb in 10 Nm 5 Reset IAC valve pintle position as follows a Turn ignition key ON for ten ...

Page 574: ...y 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 precis...

Page 575: ...Mount KS module on bracket 2 Connect electrical connector to the KS module Fuel Pump Relay REMOVAL 1 Remove fuel pump relay from electrical bracket 75834 450 BLK 120 GRY 30 86 85 87 465 DK GRN WHT 2C PNK a a Fuel Pump Relay 2 Disconnect electrical connector and remove fuel pump relay CLEANING AND INSPECTION IMPORTANT The fuel pump relay is an electrical component DO NOT soak in any liq uid cleaner...

Page 576: ...tion BEFORE proceeding IMPORTANT The ECM is a sensitive electrical device subject to electrostatic damage DO NOT touch connector pins when removing or installing the module REMOVAL 1 Disconnect J1 and J2 electrical connectors at engine control module ECM DO NOT touch connector pins when removing 2 Remove ECM from electrical bracket CLEANING AND INSPECTION 1 Clean the exterior of the ECM with a dry...

Page 577: ... 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 72799 a a Engine Coolant Temperature ECT Sensor 2 Remove ECT sensor 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 b...

Page 578: ... 6 2 MPI Models 75837 a b c d e f g h i a Throttle Body Adapter b Cool Fuel Assembly c Vacuum Hose Throttle Body Adapter to Fuel Pressure Regulator on Cool Fuel Assembly d Vent Hose PCV Valve to Throttle Body Adapter e Vent Hose Valve Cover Fitting To Flame Arrestor f PCV Valve g Vacuum Hose T Fitting to Plenum h Flame Arrestor i Front of Engine ...

Page 579: ...oded Views MX 6 2 Black Scorpion Plenum Throttle Body And Flame Arrestor 75838 10 11 12 13 1 2 3 4 5 6 7 8 9 14 1 Intake Plenum 2 Gasket 3 Stud 4 Nut 2 5 Plenum Screw 6 MAP Sensor 7 Screw and Bracket 8 Hose 9 Throttle Body 10 Screw 11 Flame Arrestor 12 Clamp 13 Throttle Lever and Linkage 14 Gasket See Changes Previously ...

Page 580: ...e 5E 21 Intake Manifold And Fuel Rails 75839 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 5 3 5 5 1 Intake Manifold 2 Intake Gasket 2 3 Fuel Rail 2 4 Screw 5 Connector Fittings 6 Schrader Valve 7 Cap 8 Fuel Injector 9 Upper Seal 10 O Ring 11 Screen 12 Lower Seal 13 Stud 14 Spacer 15 Washer 16 Nut 17 Fuel Lines ...

Page 581: ...engine for ten seconds if engine starts allow it run until it stops to relieve any fuel pressure in the system MX 6 2 Black Scorpion Components Flame Arrestor NOTICE Refer to Service Precautions in front of this section BEFORE proceeding REMOVAL 1 Remove flame arrestor and related components 2 Remove nut 3 Remove crankcase ventilation hose from against flame arrestor and rocker arm cover fittings ...

Page 582: ...pletely 2 Clean crankcase ventilation hoses in solvent Blow dry with compressed air or allow to air dry completely 3 Inspect crankcase ventilation hoses for cracks or deterioration and replace if necessary INSTALLATION 1 Install flame arrestor 2 Tighten nut 3 Position crankcase ventilation hose against flame arrestor and attach to rocker arm cover fittings 75779 a b c d 75776 b a Flame Arrestor b ...

Page 583: ... Service Precautions in front of this section BEFORE proceeding REMOVAL 1 Remove the flame arrestor 2 Disconnect the throttle cable from the throttle lever 74838 a b a Throttle Cable b Flame Arrestor 3 Disconnect the wiring connectors from the IAC valve and the TP sensor 75777 75778 a b a Throttle Position Sensor Connector b IAC Valve Connector ...

Page 584: ...2000 Page 5E 25 4 Remove the hardware retaining the throttle body and remove the throttle body from the adapter Refer to Exploded View 75783 a b c a Throttle Body b Gaskets c Plate IMPORTANT Insert a clean shop towel into the opening of the plenum to prevent foreign material from entering the engine ...

Page 585: ...le body 1 Carefully remove all gasket material from plenum and throttle body 2 Thoroughly clean all parts of throttle body Make certain that all passages are free of dirt and burrs 3 Inspect mating surfaces for damage that could affect gasket sealing 4 Inspect throttle body for cracks in casting 5 Inspect throttle plates linkage return springs etc for damage wear and foreign material 6 Check for l...

Page 586: ...327000 JULY 2000 Page 5E 27 3 Connect the harness connectors to the TP sensor and IAC valve 75777 b a a TP Sensor b Connector 75778 a b a IAC Valve b Connector 4 Connect the throttle cable to the throttle lever Refer to SECTION 2 for throttle cable adjustment 5 Install the flame arrestor ...

Page 587: ...CTION IMPORTANT Use care when removing gasket material from intake manifold and plenum Failure to do so could result in damage to the intake manifold and plenum 1 Carefully remove all gasket material from intake manifold and plenum 2 Clean plenum in solvent and dry with compressed air 3 Inspect mating surfaces for damage that could affect gasket sealing 4 Inspect plenum for cracks in casting INSTA...

Page 588: ... d d e a Screws 6 b Plenum c Gasket d Nuts e MAP Sensor Location 6 Place remote control throttle lever in idle position Attach cable to throttle lever stud Refer to SECTION 2 for throttle cable adjustment 7 After throttle cable is adjusted tighten locknut against cable end 74838 a b c a Cable End b Throttle Lever Stud c Locknut 8 Connect the harness connector and the vacuum hose to the MAP sensor ...

Page 589: ...d Connections Aft View a Fuel Rail Connector Fittings b Rail to Rail Fuel Lines c Cool Fuel to Fuel Rail Line d Distributor Cap 3 Disconnect fuel lines from front end of fuel rail connector fittings 75697 a b a Fuel Lines and Connections Front View a Fuel Rail Connector Fittings b Rail to Rail Fuel Lines 4 Remove plenum 5 Disconnect harness connector from each injector 6 Remove fuel rail screws 7 ...

Page 590: ...aling of the injectors in the rail 3 Inspect rails for cracks INSTALLATION 1 Position injectors in the fuel rails 2 Install fuel rail by pushing down gently while moving it back and forth 3 Install fuel rail fasteners Torque to 105 lb in 12 Nm 4 Route the rail to rail fuel lines as shown Temporarily hand tighten the lines to the fuel rail connector fittings 5 Torque the four fuel line connections ...

Page 591: ...INSPECTION 1 Inspect fuel injectors for damage replace if necessary 2 Inspect screen on inlet side of injector for debris Clean or replace as necessary INSTALLATION 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...

Page 592: ... Plenum b Manifold Absolute Pressure MAP Sensor c Vacuum Hose To Intake Manifold d Screws 2 2 Remove MAP sensor CLEANING AND INSPECTION 1 Clean off any foreign matter with a dry cloth 2 Inspect for any obvious signs of physical damage to the sensor INSTALLATION 1 Install MAP sensor using screws Torque screws to 44 62 lb in 5 7 Nm 2 Connect electrical connector to MAP sensor 3 Connect vacuum hose t...

Page 593: ...nsor 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 which are included in the service package 1 Install TP sensor and gasket on throttle body using screws with washers and Loctite 242 applied to threads Torque screws to 20 lb in 2 Nm 75785 c a b c d a Screws b Throttle Position TP Sensor c Thro...

Page 594: ... 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 f...

Page 595: ...orque to 20 lb in 2 Nm 75784 a b a Idle Air Control IAC Valve b Screws 3 Connect electrical connector to IAC valve 75788 a a Idle Air Control IAC Valve Connector 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 596: ...or 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 ...

Page 597: ...ectrical box 00000 a a Knock Sensor KS Module 2 Disconnect electrical connector at knock sensor 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 module 2 Place KS module in electrical box 00000 a a Knock Sensor KS Module ...

Page 598: ...cal component DO NOT soak in any liquid cleaner or solvent damage may result INSTALLATION 1 Attach electrical connector to fuel pump relay 2 Place fuel pump relay in electrical box System Relay REMOVAL 1 Remove system relay from electrical box 00000 3 PNK 902 RED 30 86 85 87 150 BLK 2 RED a a System Relay 2 Disconnect electrical connector and remove relay IMPORTANT The system relay is an electrica...

Page 599: ...00 Engine Control Module 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 REMOVAL 1 Disconnect J1 and J2 electrical connectors at engine control module ECM 76358 2 Remove ECM from electrical box ...

Page 600: ... number as the original INSTALLATION 1 Mount new ECM to electrical bracket using screws and washers 2 Connect J1 and J2 electrical connectors to the ECM DO NOT touch connector pins when installing Engine Coolant Temperature Sensor REMOVAL NOTE Handle the ECT sensor carefully Damage to it will affect operation of the system 1 Disconnect electrical connector at Engine Coolant Temperature ECT sensor ...

Page 601: ...0 a b c d e f g h i j k a Throttle Body b Cool Fuel Assembly c Vacuum Hose Forward Fitting On Intake Manifold To Fuel Pressure Regulator on Cool Fuel Assembly d Vent Hose PCV Valve to Throttle Body e Vent Hose Valve Cover to Flame Arrestor f PCV Valve g Vent Hose Fitting h Flame Arrestor i Front of Engine j MAP Sensor k Vacuum Hose Rear Fitting On Intake Manifold To MAP Sensor ...

Page 602: ...2 Important Preliminary Checks 5F 3 Before Starting 5F 3 Visual Physical Check 5F 3 Intermittents 5F 4 Hard Start Symptom 5F 5 Surges and or Chuggles Symptom 5F 7 Lack of Power Sluggish or Spongy Symptom 5F 9 Detonation Spark Knock Symptom 5F 11 Hesitation Sag Stumble Symptom 5F 13 Cuts Out Misses Symptom 5F 15 Rough Unstable or Incorrect Idle Stalling Symptom 5F 17 Poor Fuel Economy Symptom 5F 20...

Page 603: ... Depends on Altitude and 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 Injector On Time Cranking msec 2 5 3 5 msec Depends on Water Air Temperature Fuel Consumption GPH L ...

Page 604: ...his 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 loca tion Vacuum hoses for splits kinks and proper connections Check thoroughly for any type of leak or restriction Air leaks at throt...

Page 605: ...ng 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 com...

Page 606: ...4 in General System Diagnostics section Was fuel pressure 30 psi for EFI or 3 7 psi for carbureted engines OBD Step 7 7 1 Check for proper ignition voltage output Refer to Table A 7 in General System Diagnostics section Was a problem found OBD Step 8 8 Is a scan tool being used Step 10 Step 9 9 1 Check for a ECT sensor shifted in value 2 With engine completely cool measure the resistance of the EC...

Page 607: ...he MAP sensor circuits Was a problem found Step 15 15 1 Check for proper operation of the TP sen sor 2 Check or throttle linkage sticking binding or worn causing TP sensor voltage to be higher than normal Is TP sensor operating improperly or is voltage higher than normal Step 16 16 1 Check for proper operation of the IAC valve Table A 8 Was a problem found Step 17 17 1 Check or the following engin...

Page 608: ... 4 in General System Diagnostics section Was fuel pressure 30 psi for EFI or 3 7 psi for carbureted engines Step 5 5 1 Check for intermittent opens or short to grounds in the ECT sensor MAP sensor and TP sensor circuits Also check or throttle linkage sticking binding or worn 2 An intermittent failure may not store a DTC Was a problem found OBD Step 6 6 1 Check for proper ignition voltage output Re...

Page 609: ...oblem found Step 12 12 1 Check the injector connections for proper mating 2 If any of the injectors connectors are con nected to an incorrect cylinder correct as necessary Were any injectors improperly connected OBD Step 13 13 1 Check ECM grounds for being clean tight and in the proper locations Were ECM grounds dirty loose or improperly connected Step 14 14 1 Visually physically check vacuum hose...

Page 610: ... Check water separating fuel filter Was a problem found Step 6 6 1 Check for proper fuel pressure while the condition exists Refer to Table A 4 in General System Diagnostics section Was fuel pressure 30 psi for EFI or 3 7 psi for carbureted engines Step 7 7 1 Check for injector driver CKT 467 or CKT 468 for an open Did you find an open Step 8 8 1 Check for proper operation of Ignition Con trol IC ...

Page 611: ...horted to ground This will cause the rpm to be lowered Was a problem found Step 15 15 1 Check for proper alternator voltage output Is voltage between 11 16 volts Step 16 16 1 Check for the following Engine Mechanical problems Low compression Leaking cylinder head gaskets Worn or incorrect camshaft Proper valve timing valve train problem Restricted exhaust system Was a problem found Step 17 17 1 Ch...

Page 612: ...nd Step 5 5 1 Check for good ignition system ground 2 Check spark plugs for proper gap and heat range Was a problem found Step 6 6 1 Check for contaminated fuel 2 Check for poor fuel quality and proper octane rating Was a problem found Step 7 7 1 Check for proper fuel pressure Refer to Table A 4 in General System Diagnostics section Was fuel pressure 30 psi for EFI or 3 7 psi for carbureted engine...

Page 613: ...ompression Low oil level Excessive oil in the combustion chambers 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 14 1 Remove excessive carbon buildup with a top engine cleaner Refer to instructions on top engine cleaner can 2 Re evaluate engine performance Is detonation...

Page 614: ...ts Refer to Table A 4 in General System Diagnostics section Was a problem found Step 5 5 1 Check fuel injectors Refer to Injector Balance Test in Test General System Diagnostics section Was a problem found Step 6 6 1 Check for proper operation of Ignition Con trol IC circuit and the Knock Sensor KS circuit Was a problem found Step 7 7 1 Check integrity of the primary and second ary wiring 2 Check ...

Page 615: ...OBD Step 10 10 1 Check for proper alternator voltage output Is voltage between 11 16 volts Step 11 11 1 Check for faulty or incorrect thermostat Is thermostat faulty Step 12 12 1 Check intake valves for valve deposits and remove if found Were deposits found on the intake valves Step 13 13 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctio...

Page 616: ...neral System Diagnostics section Was fuel pressure 30 psi for EFI or 3 7 psi for carbureted engines Step 5 5 1 Disconnect all injector harness connectors and install an injector test light J 34730 2 between the harness terminal connector of each injector 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 ...

Page 617: ...ence 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 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 12 1 Review all diagnostic procedures within this table 2 If all p...

Page 618: ...d Step 4 4 1 Check for proper operation of Ignition Con trol IC circuit and the Knock Sensor KS circuit Was a problem found Step 5 5 1 Check integrity of the primary and second ary wiring 2 Check routing of the wiring 3 Check condition of IC module pick up coil distributor cap rotor and spark plug wires Was a problem found Step 6 6 1 Check ignition coil for cracks or carbon tracking Were cracks or...

Page 619: ... for fuel in pressure regulator vac uum hose 2 If fuel is present replace the fuel pressure regulator assembly Refer to Fuel Metering System in De scription and System Operation section Was a problem found Step 12 12 1 Check for intermittent opens or short to grounds in the ECT sensor MAP sensor and TP sensor circuits Also check or throttle linkage sticking binding or worn 2 An intermittent failur...

Page 620: ...orn camshaft lobe s Valve timing Broken valve springs Was a problem found Step 18 18 1 Check intake valves for valve deposits 2 If deposits are found remove as neces sary Were deposits found on the intake valves Step 19 19 1 Check for faulty motor mounts Was a problem found Step 20 20 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions h...

Page 621: ...2 Check for fuel leaks Was a problem found Step 5 5 1 Check for proper fuel pressure Refer to Table A 4 in General System Diagnostics section Was fuel pressure 30 psi for EFI or 3 7 psi for carbureted engines Step 6 6 1 Check for proper operation of Ignition Con trol IC circuit and the Knock Sensor KS circuit Was a problem found Step 7 7 1 Remove spark plugs check for wet plugs cracks wear imprope...

Page 622: ...1 1 Check for excessive resistance on the bot tom of the boat such as dirt barnacles etc 2 Check for proper propeller size and pitch for that application Was a problem found OBD Step 12 12 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 Visual physical inspection Scan tool data All connection...

Page 623: ... operation of Ignition Con trol IC circuit and the Knock Sensor KS circuit Was a problem found OBD Step 5 5 1 Check for obvious overheating problems Loose water pump belt Faulty or incorrect water pump Restriction in cooling system Faulty or incorrect thermostat Was a problem found OBD Step 6 6 1 Check for proper operation of the EFI sys tem relay Refer to Table A 6 in General System Diagnostics s...

Page 624: ... Diagnostics section Was fuel pressure 30 psi for EFI or 3 7 psi for carbureted engines Step 5 5 1 Check the injector connections Correct as necessary Was a problem found Step 6 6 1 Check fuel injectors Refer to Injector Balance Test in Gener al System Diagnostics section Was a problem found Step 7 7 1 Check for proper operation of Ignition Con trol IC circuit and the Knock Sensor KS circuit Was a...

Page 625: ...spark plugs damaged Step 12 12 1 Check for intermittent opens or short to grounds in the MAP sensor and TP sensor circuits Also check for throttle linkage sticking binding or worn 2 An intermittent failure may not store a DTC Was a problem found Step 13 13 1 Check engine mechanical for the following conditions Low compression Sticking or leaking valves Worn camshaft lobe s Incorrect valve timing W...

Page 626: ...FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 5F 25 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 627: ...FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 24 Page 5F 26 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 628: ...m Electrical Test 5G 34 Chart A 6 EFI System Ignition Relay Check 5G 36 Chart A 7 Ignition System Check 5G 38 Chart A 8 Idle Air Control IAC Functional Test 5G 44 Discrete Input Circuit Check Non Scan Only 5G 46 Clearing Trouble Codes 5G 52 Using Code Mate Tester 5G 52 Using Scan Tool 5G 52 Diagnostic Testing 5G 53 Code 14 Engine Coolant Temperature ECT Sensor Circuit 5G 53 Code 15 Engine Coolant ...

Page 629: ...ircuits and components in the fuel injec tion system Allows for test firing injectors Tool can read MEFI 1 MEFI 2 and MEFI 3 ECM 94008 Code Mate Tester Flashes light to display problem codes 91 99379 Timing Light Used to check ignition timing Must have inductive signal pickup 91 16850A5 Fuel Pressure Gauge Kit Used to check fuel system pressure Kit includes 91 803135 Test Port Adaptor Kit and 91 8...

Page 630: ...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 29784 Little Mack Roseville MI 48066 Phone 800 345 2233 Rinda Technologies 4563 N Elston Ave Chicago IL 60630 Phone 773 736 6633 Fax 773 736 2950...

Page 631: ...ting 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 MAP Volts or kPa 1 3 Volts or 45 55 kPa Depends on Va...

Page 632: ... MAT Manifold Air Temperature Low Temperature Indicated x Code 25 MAT Manifold Air Temperature High Temperature Indicated x Code 33 MAP Manifold Absolute Pressure Signal Voltage High x x x Code 34 MAP Manifold Absolute Pressure Signal Voltage Low x x Code 41 IC Ignition Control Open IC Circuit x x Code 42 IC Ignition Control Grounded IC Circuit Open or Grounded Bypass x x x Code 43 KS Knock Sensor...

Page 633: ...wing 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 ...

Page 634: ...RN 4 9V 1 46V NOTE 3 33 Poor Performance Surge Poor Fuel Economy Exhaust Odor J1 10 TP Signal 417 DK BLU 62V NOTE 4 62V NOTE 4 21 Poor Performance And Acceleration Incorrect Idle J1 11 Ignition Fused 439 PNK BLK B B None No Start J1 13 Sensor Ground 813 BLK 0 NOTE 5 0 NOTE 5 21 23 High Idle Rough Idle Poor Performance Exhaust Odor J1 14 ECM Ground 450 BLK WHT 0 NOTE 5 0 NOTE 5 None No Start J1 15 ...

Page 635: ...ne Poor Performance J2 7 Port Fuel Jumper 901 WHT None J2 8 Ignition Control Ref High 430 PUR WHT 5V 1 6V None No Restart J2 9 Fuel Pump Relay Driver 465 DK GRN WHT 0 NOTE 1 5 B None No Start J2 11 Coolant Over temp 112 DK GRN 0 0 None Power Reduction Mode or Improper Audio Warning J2 13 IAC A Low 442 RED Not Usable Not Usable None Rough Unstable or Incorrect Idle J2 14 IAC B Low 443 YEL Not Usabl...

Page 636: ...3 Ignition Control Signal 423 WHT 0 NOTE 5 1 2V 42 Stall Will Restart In Bypass Mode Lack Of Power J2 24 Ignition Control Bypass 424 TAN BLK 0 NOTE 5 4 5V 42 Lack Of Power Fixed Timing J2 26 Discrete Switch 31 TAN Audio Warning System Activation J2 27 Discrete Switch 31 TAN Audio Warning System Activation J2 28 IAC A High 441 BRN Not Usable Not Usable None Rough Unstable or Incorrect Idle J2 29 IA...

Page 637: ... 453 RED BLK 0 NOTE 5 0 NOTE 5 None Poor Performance J1 4 ECM Ground 450 BLK 0 NOTE 5 0 NOTE 5 None No Start J1 5 ECM Ground 450 BLK 0 NOTE 5 0 NOTE 5 None No Start J1 9 MIL Lamp 419 BRN WHT 0 NOTE 5 0 NOTE 5 None Lamp Inoperative J1 10 Ignition Control Signal 423 WHT 0 NOTE 5 1 2V 42 Stall Will Restart In Bypass Mode Lack Of Power J1 11 IAC B Low 443 GRN WHT Not Usable Not Usable None Rough Unsta...

Page 638: ...Start J1 24 Ignition Control Bypass 424 TAN BLK 0 NOTE 5 4 5V 42 Lack Of Power Fixed Timing J1 26 Audio Warning Horn 29 DK GRN None J1 27 IAC B Low 444 GRN BLK Not Usable Not Usable None Rough Unstable or Incorrect Idle J1 28 IAC A High 441 BLU WHT Not Usable Not Usable None Rough Unstable or Incorrect Idle J1 30 Knock Sensor Signal 496 BLU 43 44 Poor Fuel Economy Poor Per formance Detonation J1 3...

Page 639: ...ance Exhaust Odor J2 4 TP 5V Power 416 GRY 5V 5V 21 Lack Of Power Idle High J2 7 Discrete Switch 114 BLU None J2 8 Discrete Switch 585 TAN WHT None J2 9 Shift Switch 923 WHT 0 0 None Incorrect Idle J2 10 Ignition Control Ref High 430 PUR WHT 5V 1 6V None No Restart J2 11 ECT Signal 410 YEL 1 95V NOTE 2 1 95V NOTE 2 14 Poor Performance Exhaust Odor Rough Idle rpm Reduction J2 12 Fuel Pres sure 475 ...

Page 640: ...al Engine Only J2 22 Diag nostic Test 451 BLK WHT B B None Incorrect Idle Poor Perfor mance J2 24 Discrete Switch 906 TAN WHT None J2 26 TP Signal 417 DK BLU 62V NOTE 4 62V NOTE 4 21 Poor Performance And Accel eration Incorrect Idle J2 27 Map Signal 432 LT GRN 4 9V 1 46V NOTE 3 33 Poor Performance Surge Poor Fuel Economy Exhaust Odor J2 30 IAT Sensor 472 TAN 5V NOTE 2 23 Poor Fuel Economy Exhaust ...

Page 641: ...K 440 ORN 450 BLK WHT 916 YEL 902 RED 120 GRY 150 BLK 468 DK GRN 450 BLK WHT 461 ORN BLK M IDLE AIR CONTROL MOTOR DATA LINK CONNECTOR FUEL PUMP FUEL PUMP RELAY TO IGNITION RELAY TO INJECTOR FUSE TO ECM BAT FUSE FUEL PUMP FUSE INJECTOR DRIVER INJECTOR DRIVER INJECTOR GROUND INJECTOR GROUND PORT FUEL JUMPER MPI ONLY FUEL PUMP RELAY DRIVER IAC COIL A HIGH IAC COIL A LOW IAC COIL B HIGH IAC COIL B LOW...

Page 642: ...LT GRN 814 BLK 814 BLK 814 BLK B C A C B A A B THROTTLE POSITION SENSOR MANIFOLD ABSOLUTE PRESSURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR J1 19 923 WHT SHIFT CUTOUT SWITCH MEFI 2 ONLY 150 BLK SHIFT INTERRUPT SENSOR GROUND THROTTLE POSITION SENSOR SIGNAL 5 VOLT REFERENCE 5 VOLT REFERENCE SENSOR GROUND MAP SENSOR SIGNAL ENGINE COOLANT TEMPERATURE SENSOR SIGNAL BRAVO REQUIRES JUMPER PLUG Index ...

Page 643: ...24 TAN BLK 453 BLK RED B 3 PNK 931 BRN 3 PNK 31 TAN NOT USED B A A B 121 BRN 3 PNK A A B C D 902 RED IC MODULE HARNESS CONNECTOR TOO IGNITION RELAY IGNITION COIL 423 WHT ECM GROUND ECM GROUND IGNITION CONTROL DISTRIBUTOR REFERENCE HIGH BYPASS DISTRIBUTOR REFERENCE LOW OUT TO BUZZER COOLANT OVERHEAT OUT TO BUZZER AUDIO WARNING SYSTEM SWITCHES INPUT FROM AUDIO WARNING SYSTEM SWITCHES SHIFT CUTOUT SW...

Page 644: ...RN 440 ORN 439 PNK BLK 485 GRN 486 PUR 496 DK BLU 440 ORN 150 BLK 2 RED 902 RED 439 PNK BLK 3 PNK ECM BAT FUSE 15A INJ ECM FUSE 10A TO IGN COIL B TO INJECTORS TO KEY SWITCH TO DLC CONNECTOR SYSTEM IGNITION RELAY KNOCK MODULE KNOCK SENSOR TO BATTERY POSITIVE TO FUEL PUMP RELAY 902 RED 902 RED 439 PNK BLK IGNITION FEED BATTERY FEED BATTERY FEED KNOCK SENSOR SIGNAL Index ...

Page 645: ...C J1 1 J1 17 J1 23 From INJ ECM FUSE 10 AMP J1 28 J1 12 J1 11 J1 27 From B J2 22 J1 9 87 86 85 30 J1 32 SERIAL DATA 76097 467 DK BLU 468 DK GRN 481 BLK 465 DK GRN WHT 439 PNK 339 PNK 439 PNK 443 YEL OR GRN WHT 442 RED OR BLU BLK 461 ORN 150 BLK 916 YEL 450 BLK 451 BLK WHT 444 GRN BLK 419 BRN WHT 440 ORN 2 INJECTORS ONE IF EFI FOUR IF MPI INJECTORS ONE IF EFI FOUR IF MPI 481 BLK DIAGNOSTIC TEST TER...

Page 646: ...GRN J2 7 OIL PRESSURE SWITCH ENGINE COOLANT TEMPERATURE ECT ENGINE COOLANT TEMPERATURE ECT SENSOR SIGNAL J2 19 J2 27 J2 18 J2 11 416 GRY 432 LT GRN 814 BLK 814 BLK 814 BLK 410 YEL 496 DK BLU LUBE BOTTLE J2 24 906 TAN WHT J2 9 SHIFT INTERRUPT SIGNAL B A INTAKE AIR TEMPERATURE IAT SENSOR SIGNAL J2 30 813 BLK 472 TAN 150 BLK SHIFT SWITCH 207 PPL FUEL PRES SURE SENSOR FP KNOCK SENSOR 1 J1 30 KNOCK SEN...

Page 647: ...E F C B A F E D A B C 30 440 0RN 440 0RN 439 PNK 121 WHT 121 WHT 121 WHT 901 TAN 902 RED 439 PNK 2 RED A B 29 DK GRN 585 TAN WHT 208 BRN TRANSMISSION OVERTEMP J2 8 J1 26 TO B TO B IGNITION BATTERY FEED 150 BLK 450 BLK 450 BLK 450 BLK ECM GROUND ECM GROUND ECM GROUND DIST REF IGN COIL 902 RED 902 RED 430 PPL WHT TEMP SENDER IGNITION COIL T0 TRANSMISSION TO TRANSMISSION TEMP SWITCH TO AUDIO WARNING ...

Page 648: ...208 BRN TRANSMISSION OVERTEMP J2 8 J1 26 TO B TO B IGNITION BATTERY FEED 150 BLK 450 BLK 450 BLK 450 BLK ECM GROUND ECM GROUND ECM GROUND DIST REF HIGH TEMP SENDER 2 RED 2 RED TO FUEL PUMP RELAY FUSE 3 PNK 3 PNK ECM CONNECTOR HALVES TAN PUR GRY TAN BLU BLU TAN YEL BLK J2 10 J1 10 J1 3 J1 24 423 WHT 424 TAN BLK 430 PUR WHT 453 RED BLK SYSTEM IGNITION RELAY TO DLC CONNECTOR 902 RED 440 0RN 440 0RN 4...

Page 649: ... injector tester to energize injectors Follow manufactur er s instructions for use of adaptor harness Ignition must be OFF at least ten seconds to complete ECM shutdown cycle Fuel pump should run about two seconds after ignition is turned ON At this point insert clear tubing attached to vent valve into a suitable container and bleed air from gauge and hose to ensure accurate gauge operation Repeat...

Page 650: ...38 psi 262 kPa 38 psi 262 kPa 38 psi 262 kPa 38 psi 262 kPa 2nd Reading 19 psi 131 kPa 17 psi 117 kPa 21 psi 145 kPa 19 psi 131 kPa 19 psi 131 kPa 19 psi 131 kPa 19 psi 131 kPa 19 psi 131 kPa Amount of Drop 19 psi 131 kPa 21 psi 145 kPa 17 psi 117 kPa 19 psi 131 kPa 19 psi 131 kPa 19 psi 131 kPa 19 psi 131 kPa 19 psi 131 kPa OK Rich Too Much Fuel Drop Lean Too Little Fuel Drop OK OK OK OK OK Index...

Page 651: ...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 ru...

Page 652: ... Trouble shooting Diag nostic Testing 6 a Ignition ON engine OFF b Install CodeMate Tester and switch it to Normal Mode c Observe the MIL Is the MIL ON Step 7 Chart A 1 7 a With CodeMate Tester on normal mode b Ignition ON engine OFF c Observe the MIL on the CodeMate Tester Does the MIL Flash DTC 12 Step 12 Step 8 8 a Switch CodeMate Tester to Service Mode b Ignition ON engine OFF c Observe the MI...

Page 653: ... 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 o...

Page 654: ...tep 13 5 Are you using a Scan Tool Step 6 Step 11 6 Check the ECM DLC fuse Is The Fuse Good Step 7 Step 14 7 a Ignition OFF b Disconnect the ECM connectors c Using a test light connected to ground probe ECM CKT 440 Does The Test Light Illuminate Step 8 Step 10 8 a Ignition ON engine 0FF b Using a test light connected to ground probe ECM CKT 439 Does The Test Light Illuminate Step 12 Step 9 9 Check...

Page 655: ... 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 interm...

Page 656: ...L Flash DTC 12 Step 10 Step 4 4 a Ignition OFF disconnect ECM connectors b Ignition ON engine OFF observe the MIL Is The MIL ON Step 7 Step 5 5 a Ignition OFF b With ECM connectors disconnected jump terminals A to B at the DLC c Connect test light between CKT 451 and battery posi tive B Does Test Light Illuminate Step 6 Step 8 6 Verify correct operation of CodeMate Tester on a known good system 7 ...

Page 657: ...or 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 electri...

Page 658: ... Disconnect ECM connectors c Measure resistance between ECM CKT 467 and ECM CKT 468 Is The Resistance Greater Than 1 ohm Step 6 Step 10 6 Check resistance across each injector in the circuit MPI Is Resistance Greater Than 10 ohms TBI Is Resistance Greater Than 1 ohm Step 7 Step 8 7 a Reconnect injectors b Ignition OFF c Disconnect ECM d Ignition ON e Using a test light connected to ground probe EC...

Page 659: ...psi 234 262 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 t...

Page 660: ...s of vacuum Did fuel pressure drop by approximately 5 psi 34 kPa Step 13 Step 11 5 Was fuel pressure present at all Step 6 Chart A 5 6 Does the system establish fuel pressure and then drop quickly to 0 psi Step 7 Step 9 7 a Ignition OFF b Block fuel pressure line between the fuel pump and fuel rail or throttle body inlet fitting on TBI Models using fuel shut off valve tool c Ignition ON Does fuel ...

Page 661: ...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 wir...

Page 662: ...tive B probe terminal 86 of the fuel pump relay connector Does The Test Light Illuminate Step 5 Step 12 5 a Using a test fight connected to ground probe terminal 85 of the fuel pump relay connector b Ignition ON Does Test Light Illuminate For 2 Seconds And Then Go Off Step 8 Step 7 6 Check fuel pump relay fuse Is Fuse Ok Step 9 Step 10 7 Locate and repair faulty ECM connection at J2 9 or repair op...

Page 663: ... 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...

Page 664: ...l connected to ground probe relay har ness connector terminals 86 and 30 Does Test Light Illuminate On Both Terminals Step 3 Step 5 3 Using test light connected to battery positive B probe relay harness connector terminal 85 Does Test Light Illuminate Step 4 Step 6 4 Check relay connector for poor contact or corrosion If OK replace faulty EFI system relay 5 Locate and repair open or short to groun...

Page 665: ...l 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...

Page 666: ...EFI 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 s...

Page 667: ...r damaged terminals poor termi nal 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 har ness connector 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 eng...

Page 668: ...of distributor rotor Is The Distributor Rotor Turning Step 4 Step 22 4 Do you have a MEFI 3 ECM and a distributor with a two wire connection Step 24 Step 5 5 a Disconnect distributor 4 wire connector b Check for secondary spark Is Adequate Spark Present Step 17 Step 6 6 a Reconnect distributor 4 wire connector b Check for secondary spark from the coil tower using a known good coil wire Is Adequate...

Page 669: ...sent Step 16 Step 12 12 Replace ignition coil and recheck for spark using Steps 10 and 11 Is Adequate Spark Present Step 13 13 Reinstall coil and check coil wire from distributor cap If OK replace ignition module 14 Check for faulty connections or open tach lead If OK replace ignition module and recheck for spark using Steps 10 and 11 Is Adequate Spark Present Verify Repair Step 15 15 Replace igni...

Page 670: ...HT RED bullet connectors b Remove high tension lead from distributor at coil c Insert a spark gap tester from coil tower to ground d Disconnect WHT GRN lead from distributor 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 Step 29 Step 27 27 a Substitute a new ignition coil b Repeat above test Is There Spark...

Page 671: ...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 termi nal to wire connection and damaged harness Check for vacuum leaks ...

Page 672: ...m Step 3 Step 4 3 a Reinstall IAC harness connector b Idle speed should gradually return within 75 rpm of the original recorded rpm within 30 seconds Does rpm Return To Original Recorded rpm Step 5 Step 4 4 a Ignition OFF for 10 seconds b Disconnect IAC harness connector c Restart engine d Using a test light connected to ground probe each one of the four IAC harness terminals Does The Test Light B...

Page 673: ...Only 1 of 5 MEFI 1 MEFI 2 AND BLACK SCORPION MEFI 3 902 RED B A 3 PNK 121 BRN OR GRY 121 WHT IC MODULE ECM MEFI 1 MEFI 2 J2 23 J2 8 J2 24 J2 6 MEFI 3 J1 10 J2 10 J1 24 J1 3 COIL B DISTRIBUTOR E D C B A 121 WHT 112 DK GRN 31 TAN 931 BRN 931 BRN 3 PNK 31 TAN NOT USED HARNESS CONNECTOR TO IGN J2 11 J2 27 J1 6 Index ...

Page 674: ... 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...

Page 675: ...orking properly Proceed to Testing Switches or Testing Circuits 5 Ensure that there is battery power to the PUR wire going to buzzer If there is replace buzzer Verify Repair 6 Discrete switches may all be functioning properly Proceed to check all discrete circuits to verify each works properly Verify Repair TESTING OIL PRESSURE SWITCH Step Action Yes No PROCEED TO 1 a Disconnect MEFI 1 or MEFI 2 B...

Page 676: ...s there continuity Step 3 Switch OK 3 Replace gear lube monitor Verify Repair TESTING TRANSMISSION TEMPERATURE SWITCH Step Action Yes No PROCEED TO 1 a Disconnect BLU TAN and BLK wires from transmission temperature switch b Ensure switch is at a cool temperature less than normal operating temperature c Check for continuity between both terminals Is there continuity Step 2 Step 3 2 a Heat the switc...

Page 677: ...f equipped d Key ON engine OFF Does audio warning buzzer sound Step 2 Step 3 2 a Key OFF b Disconnect ECM connectors c Check for continuity between all wires disconnected in Step 1 and engine ground Is there continuity on MEFI 1 or MEFI 2 BLU TAN or MEFI 3 BLU wire from oil pressure switch Is there continuity on MEFI 1 or MEFI 2 BLU TAN or MEFI 3 TAN WHT wire from gear lube switch Is there continu...

Page 678: ...n grounding MEFI 1 or MEFI 2 BLU TAN or MEFI 3 BLU wire from oil pressure switch Does audio warning buzzer sound when grounding MEFI 1 or MEFI 2 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 Step 3 Step 2 2 a Key OFF b Disconnect ECM connectors Is there continuity on MEFI 1 or MEFI 2 BLU TAN or MEFI 3 BLU w...

Page 679: ...nd 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 ...

Page 680: ...ged terminals and poor terminal 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 wir ing harnesses 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 ...

Page 681: ...des were stored refer to Diagnostic Aids a Ignition OFF b Disconnect ECT sensor 6 c Ignition ON Does scan tool display coolant temperature below 22 F 30 C Step 12 Step 14 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 266 F 130 C Step 12 Step 15 NOTE Following steps do not require a Scan Tool a Ignition OF...

Page 682: ...ntermittent connections or replace faulty ECT sensor refer to chart below for sensor val ues For MEFI 1 and 2 disconnect J 1 connector 13 For MEFI 3 disconnect J 2 connector Is test light on Step 14 Step 15 14 CKT 410 shorted to ground Locate and repair short 15 CKT 410 shorted to sensor ground or faulty ground Lo cate and repair 16 Locate and repair open sensor ground in CKT 814 or faulty connect...

Page 683: ... formed or damaged terminals and poor terminal 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 wir ing harnesses 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 ...

Page 684: ... 130 C Step 4 Step 6 a Ignition OFF b Disconnect ECT harness connector 4 c Ignition ON engine OFF Does scan tool display a coolant temperature below 22 F 30 C Step 6 Step 7 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 6 Locate and repair intermittent faulty conn...

Page 685: ...s improper mating broken locks improperly formed or damaged terminals and poor terminal 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 re...

Page 686: ... b Disconnect throttle position sensor electrical connector Jumper throttle position sensor harness terminals A and C together 5 c Ignition ON Does scan tool indicate throttle position sensor volt age greater than 4 volts Step 15 Step 7 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 Disconn...

Page 687: ...reading over 4 volts Step 13 Step 14 11 Connect DVOM from throttle position sensor harness ter minal A to a good ground on engine 11 Is voltage reading over 4 volts Step 18 Step 17 a Disconnect ECM 12 b Touch test light to harness terminal C throttle position sensor signal Is test light on Step 16 Step 14 13 Check for CKT 417 shorted to voltage 14 Locate and repair open in CKT 417 or faulty connec...

Page 688: ...mproper mating broken locks improperly formed or damaged terminals and poor terminal 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...

Page 689: ...terminal A CKT 416 to a known good ground Does scan tool indicate TP sensor voltage greater than the specified value Step 10 Step 11 6 Trouble code 22 is intermittent Locate and repair inter 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...

Page 690: ...Circuit Step Action Yes No PROCEED TO 9 Locate and repair intermittent faulty connections or re place faulty throttle position sensor 10 Locate and repair open or short to ground in CKT 417 or faulty ECM connections Verify Repair 11 Locate and repair open or short to ground in CKT 416 or faulty ECM connections Index ...

Page 691: ...r mating broken locks improperly formed or damaged terminals and poor terminal 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 harnesses related to the IAT sensor A change in the IAT display will indicate the location of the fault The scan tool displays intake air te...

Page 692: ...re above 266 F 130 C Step 9 Step 6 5 Trouble code 23 is intermittent Locate and repair inter mittent faulty connections Verify 6 Locate and repair open in CKT 472 or CKT 813 Repair 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 termi...

Page 693: ...ing broken locks improperly formed or damaged terminals and poor terminal 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 harnesses related to the IAT sensor A change in the IAT display will indicate the location of the fault The scan tool displays intake air tempera...

Page 694: ...l display a temperature below 22 F 30 C Step 8 Step 6 5 Trouble code 25 is intermittent Locate and repair inter mittent faulty connections Refer to Diagnostic Aids 6 Locate and repair short to ground in CKT 472 If a prob lem is found repair as necessary Was a problem found Verify Repair Step 10 a Ignition OFF b Disconnect IAT sensor harness terminals 7 c Ignition ON engine OFF d Connect DVOM acros...

Page 695: ...ls improper mating broken locks improperly formed or damaged terminals and poor terminal 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 wiring harnesses related to the MAP sensor A change in the MAP sensor dis play will indicate the location of the fault If the idle...

Page 696: ...tep 10 Allow the engine to idle 4 Does the scan tool indicate MAP sensor voltage greater than 4 volts Step 5 Step 11 a Ignition OFF b Disconnect MAP sensor harness connector 5 c Ignition ON engine OFF Does the scan tool indicate MAP sensor voltage less than 1 volt Step 6 Step 13 a Ignition OFF b Connect DVOM from harness terminal A CKT 814 to harness terminal C CKT 416 6 c Ignition ON engine OFF D...

Page 697: ...nd 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 11 Trouble code is intermittent Locate and repair intermit tent faulty connections Refer to Diagnos...

Page 698: ...t terminals improper mating broken locks improperly formed or damaged terminals and poor terminal 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 wiring harnesses related to the MAP sensor A change in the MAP sensor dis play will indicate the location of the fault If...

Page 699: ...r harness connector 5 c Connect a jumper wire from harness terminal B CKT 432 to harness terminal C CKT 416 d Ignition ON engine OFF Does the scan tool indicate MAP sensor voltage greater than 4 volts Step 10 Step 6 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 greater than 4 volts Step...

Page 700: ...tage reading above 4 volts Step 12 Step 13 9 Repair low or unsteady vacuum problem 10 Check for plugged or leaking sensor vacuum fitting If OK replace faulty MAP sensor 11 Locate and repair intermittent faulty connections If OK replace faulty MAP sensor Verify 12 Locate and repair open or short to ground in CKT 432 or faulty ECM connections Repair 13 Locate and repair open or short to ground in CK...

Page 701: ...e 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 Po...

Page 702: ...F 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 4 b Start engine and idle for 2 minutes or until trouble code 41 sets whichever occurs first Is trouble code 41 present Step 5 Step 7 5 Locate and repair open in CKT 423 or faulty ECM con nections Was a problem found Step 6 6 Replace faulty dist...

Page 703: ...tion 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 con...

Page 704: ...T 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 5 Using a test light connected to battery positive B probe ECM CKT 424 5 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 7 Locate and rep...

Page 705: ...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 On 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 b...

Page 706: ...nnector 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 7 a Disconnect ECM J1 connector b Using DVOM measure resistance between CKT 496...

Page 707: ...5G 80 90 861327 1 OCTOBER 1999 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 15 Trouble code 43 is intermittent Refer To Diagnostic Aids on facing page Repair Index ...

Page 708: ...e 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 On 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...

Page 709: ...tor c Disconnect ECM J1 connector 5 d Ignition ON engine OFF e Connect DVOM from ECM CKT 485 to a known good ground 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 7 a Disconnect ECM J1 connector b Using DVOM measure resistance between CKT ...

Page 710: ...1327 1 OCTOBER 1999 Page 5G 83 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 15 Trouble code 44 is intermittent Refer To Diagnostic Aids on facing page Repair Index ...

Page 711: ...ve 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 terminal...

Page 712: ...tance from ECM CKT 121 to ground Is Resistance Less Than 1 ohm Step 9 Step 5 5 a Ignition OFF b Disconnect ECM J1 connector c Check resistance between positive and negative terminals of coil Is Resistance Less Than 2 ohms Step 6 Step 10 6 a Ignition OFF b Disconnect ECM J1 connector c Remove secondary ignition wire from coil d Measure resistance between secondary coil tower and negative terminal o...

Page 713: ...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 1 Was the On Board Diagnostic OBD Sys tem Check Performed Step 2 OBD 2 Ignition ON Clear trouble code 51 Does Code 51 reset Step 4 Refer to Diag 3 Fault is not present at thi...

Page 714: ...y 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 1 Was the On Board Diagnostic OBD System Check Performed Step 2 OBD a Clear trouble code 52 Refer to 2 b Ignition ON Diag nostic Does trouble code 52 reset Ste...

Page 715: ...onditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal 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 eng...

Page 716: ...acing page a Ignition OFF 5 b Disconnect fuel pressure sensor electrical connector Jumper fuel pressure sensor harness terminals B and C together 5 c Ignition ON Does scan tool indicate fuel pressure sensor voltage greater than 4 volts Step 15 Step 7 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 7 a Ignition O...

Page 717: ...ading over 4 volts Step 13 Step 14 11 Connect DVOM from fuel pressure sensor harness termi nal B to a good ground on engine 11 Is voltage reading over 4 volts Step 18 Step 17 a Disconnect ECM 12 b Touch test light to harness terminal C fuel pressure sensor signal Is test light on Step 16 Step 14 13 Check for CKT 475 shorted to voltage 14 Locate and repair open in CKT 475 or faulty connection at EC...

Page 718: ...ng conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal 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...

Page 719: ...OM from harness terminal B CKT 416 to a known good ground Does DVOM indicate a voltage greater than 4 volts Step 10 Step 11 6 Trouble code 62 is intermittent Locate and repair inter 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...

Page 720: ...Circuit Step Action Yes No PROCEED TO 9 Locate and repair intermittent faulty connections or re place faulty fuel pressure sensor 10 Locate and repair open or short to ground in CKT 475 or faulty ECM connections Verify Repair 11 Locate and repair open or short to ground in CKT 416 or faulty ECM connections Index ...

Page 721: ...DIAGNOSTICS SERVICE MANUAL NUMBER 24 Page 5G 94 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 722: ...ver Sea Strainer 6A 7 Removal 6A 7 Cleaning and Inspection 6A 8 Installation 6A 8 Seawater Pickup Pump 6A 10 Output Test 6A 10 Disassembly 6A 12 Reassembly 6A 13 Seawater Pump Bearing Housing 6A 14 Disassembly 6A 14 Cleaning and Inspection 6A 15 Reassembly 6A 16 Water Circulating Pump 6A 19 Removal 6A 19 Cleaning and Inspection 6A 19 Installation 6A 19 Drive Belt Tension Adjustment 6A 20 Flushing ...

Page 723: ...Nut Alternator To Mounting Bracket Water Circulating Pump 35 48 Seawater Pump Clamping Screw On Casting Bracket Water Temperature Sender 20 27 Drain Plug Note Hose Clamps Petcocks Securely 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 Numb...

Page 724: ...ups and Hose Water pickup must be large enough to permit sufficient water flow to engine seawater pickup pump for adequate engine cooling 30 gal per min 114 L per 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 pr...

Page 725: ...cting water flow Install seacock in an area where it will be easily accessible and self supporting to prevent hose fatigue 70355 a b c d Seacock with Thru Hull Pickup Shown a Hose Connector 1 1 4 in 32 mm I D To Seawater Pump Inlet b Seacock 1 1 4 in 32 mm 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 suff...

Page 726: ...l 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 so des...

Page 727: ...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 mm holes in transom NOTE Some installations may have 7 32 in 5 mm holes drilled in transom us...

Page 728: ...ction that may occur allowing seawater to flow from the drain holes or removed hoses and enter boat 1 Follow a or b instructions a Models Equipped with Seacock 1 Close seacock seawater inlet valve 2 Disconnect seawater inlet hose from seawater strainer b Models without Seacock 1 Disconnect seawater inlet hose from seawater strainer inlet and plug seawater inlet hose 70062 a b c d a Seawater Inlet ...

Page 729: ...g 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 mounti...

Page 730: ... outlet hose Use two hose clamps on each hose connection Tighten clamps securely 72645 a b c c 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 b a Drain Plug b Lens Cover Bolts 2 One Hidden In This View 4 Open seacock if equipped Index ...

Page 731: ... 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 accura cy is maintained within one second An 8 U S qt 7 6 L or larger capacity con tainer should be used to measure water output Due to the manner...

Page 732: ... 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 specificatio...

Page 733: ...isassembly 1 Remove the five screws from the seawater pump body 75277 a b a Screws 5 b Seawater Pump Body 2 Remove seawater pump body and wear plate from bearing housing 75275 a b c d a Seawater Pump Body b Wear Plate c Bearing Housing 3 Remove the impeller from seawater pump body Index ...

Page 734: ...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 scr...

Page 735: ...sassembly 1 Remove gasket inner wear plate and quad ring seal Discard gasket and quad ring seal 72655 72656 a a a Quad Ring Seal 2 Press hub off shaft with Universal Puller Plate and an arbor press 72648 a a Universal Puller Plate 91 37241 3 Puncture front oil seal with a tool and pry from bearing housing 72649 Index ...

Page 736: ...ith 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 p...

Page 737: ... 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 se...

Page 738: ...ing bore and install snap ring 72661 a a Shaft With Bearings 72658 a 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 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 ...

Page 739: ... 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 72655 a a Quad Ring Seal 9 Place the wear plate over the bearin...

Page 740: ... 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 Q...

Page 741: ...on System 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 71758 a b c d e a Housing b O Ring c Thermostat Stainless Steel d Spacer e Gasket Index ...

Page 742: ...t 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 ...

Page 743: ...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...

Page 744: ...CEED 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 sys tem Check for overheating condition of engine after heater is connected 74973 a Supply Hose Connection If Location is Available a Location for Hot Water Supply 71758 a b Supply Hose Alternate Location a T...

Page 745: ...opshaft Coolers IMPORTANT Tapping into the wrong location can cause the engine to vapor lock or run too cold MIE Inboard Models Only Splice into the port side exhaust manifold water hose This provides the temperatures and pressures required to cool the packing glands without damaging them 76254 T Fitting Index ...

Page 746: ...ckage but the water flow paths remain similar on all engines 75149 1 2 3 4 5 6 7 8 9 10 11 1 Seawater Intake From Sterndrive 2 Seawater Pump 3 Power Steering Fluid Cooler Or Transmission Fluid Cooler 4 Fuel Cooler EFI and MPI Models 5 Thermostat Housing and Cover Assembly 6 Engine Water Circulating Pump 7 Engine Block and Cylinder Head Assembly 8 Exhaust Manifold Typical 9 Restrictor Gasket 10 Exh...

Page 747: ... power package but the water flow paths remain similar on all engines 75125 1 2 3 4 5 6 7 8 9 10 1 Seawater Intake From Sterndrive 2 Power Steering Cooler 3 Fuel Cooler EFI and MPI Models 4 Thermostat Housing and Cover Assembly 5 Engine Water Circulating Pump 6 Engine Block and Cylinder Head Assembly 7 Exhaust Manifold Typical 8 Restrictor Gasket 9 Exhaust Elbow Assembly Typical 10 Water Flow Over...

Page 748: ...SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 6A 27 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 749: ...SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 24 Page 6A 28 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 750: ...ystem 6B 6 Testing Coolant for Alkalinity 6B 6 Pressure Testing System 6B 6 Testing for Cylinder Head Gasket Leak 6B 7 Testing Heat Exchanger 6B 8 Testing Pressure Cap 6B 8 Thermostat 6B 10 Removal 6B 10 Testing 6B 11 Installation 6B 12 Changing Coolant 6B 13 Closed Cooling Section 6B 13 Change Intervals 6B 13 Draining Instructions 6B 13 Cleaning System 6B 14 Closed Cooling Section 6B 14 Seawater ...

Page 751: ... 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 Co...

Page 752: ...the gasket under the re covery 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 close...

Page 753: ... 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 ...

Page 754: ...ean coolant recovery passage in heat exchanger filler neck with a wire and blow out with compressed air 72715 a b 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 brazin...

Page 755: ... 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 Exa...

Page 756: ...ces 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 pr...

Page 757: ...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 re...

Page 758: ...rect 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 n...

Page 759: ...e 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 74130 a 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 75746 a b c d a Thermo...

Page 760: ...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 72675 a b c a Thermometer b Nylon String c Thermostat Typical c Place thermometer in container and position so that bottom of thermometer is even with bo...

Page 761: ...ce 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 75746 a b c d a Thermostat Housing b Thermostat c Gasket d Thermost...

Page 762: ...d 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 do...

Page 763: ...one 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 Seawater Sect...

Page 764: ...ow 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 p...

Page 765: ...oolant section of Closed Cooling System with coolant mixture as follows a Open bleeder valve on thermostat housing 75598 a 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 plasti...

Page 766: ...l 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 fil...

Page 767: ...xchanger 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 a Supply Hose Connection a Location For Hot Water Supply Hose Thermostat Housing As Viewed From Above 75480 a Return Hose Connection a Location For Hot Water Return Hose Index ...

Page 768: ... 75213 75598 a a b c d e f f g g i i h l k 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 Index ...

Page 769: ...hown 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 MIE f Port Heat Exchanger to Exhaust Manifold Hose MCM g Cool Fuel System or Seawater Pipe if so equipped to Heat Exchanger Hose h Coolant Identification Decal i Fuel Lines Aligned to Avoid Starboard Water Hose Index ...

Page 770: ... 2 Seawater Pump 3 Transmission Fluid Cooler or Power Steering Cooler 4 Fuel Cooler 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 Exhaust Elbow Assembly Typical 11 Overboard Water and Exhaust Discharge a Freshwater Coolant Anti Freeze Flow b Seawater Raw Water Flow Index ...

Page 771: ...Page 6B 22 90 861327 1 OCTOBER 1999 Draining Diagram Coolant Section of System 75005 a b b 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 Index ...

Page 772: ...CLOSED COOLED MODELS SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 6B 23 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 773: ...CLOSED COOLED MODELS SERVICE MANUAL NUMBER 24 Page 6B 24 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 774: ...age 7A 1 EXHAUST SYSTEM Section 7A General Table of Contents Exhaust System Requirements 7A 2 Exhaust Elbow Risers 7A 2 MCM Sterndrive Engines With Thru Transom Exhaust 7A 2 MIE Inboard Engines 7A 3 Exhaust Hose Connection 7A 3 Exhaust Tube Requirements 7A 4 Index ...

Page 775: ...om Highest Point On Exhaust Elbow To Top Of Transom Model a Minus b Must Be at Least All 13 In 330 mm MCM Sterndrive Engines With Thru 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 ...

Page 776: ... must be constant so that a low spot does not exist at any point in the exhaust hose or pipe 4 Exhaust outlet must be slightly above the waterline with boat at rest in the water and full load aboard Exhaust outlet should be equipped with an internal shutter to prevent sea water from running back into exhaust system The use of an exhaust flapper on each outlet also is recommended 5 System must not ...

Page 777: ...b a a Exhaust Bellows b Clamps IMPORTANT When installing through propeller exhaust With any application installation of an exhaust tube will increase exhaust noise With a Silent Choice Exhaust System the exhaust bellows must be removed and an exhaust tube MUST BE INSTALLED 2 If required install exhaust tube on gimbal housing as follows a Remove and discard clamps and exhaust bellows CAUTION Exhaus...

Page 778: ...NERAL SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 7A 5 e Tighten clamp Torque to 35 lb in 4 Nm 22184 22184 d e c b a a Exhaust Tube b Clamp c SIDE Marking d Exhaust Tube e Grounding Clip Index ...

Page 779: ...GENERAL SERVICE MANUAL NUMBER 24 Page 7A 6 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 780: ...1999 Page 7B 1 EXHAUST SYSTEM Section 7B Manifolds Elbows And Risers Table of Contents Torque Specifications 7B 2 Lubricants Sealants Adhesives 7B 2 Disassembly 7B 2 Cleaning and Inspection 7B 3 Installation 7B 5 Gaskets 7B 5 Manifold 7B 6 Sterndrive Exhaust Extension 7B 7 Index ...

Page 781: ...y 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 r...

Page 782: ...ore 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 ...

Page 783: ...old 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 76355 a b a Gasket s Fire Ring has Manifo...

Page 784: ...s 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 P N 92 804874 around all holes on both sides of a new fire ring gasket 76360 a a 1 8 in 3 mm Bead of LOCTITE 510 Sealant 2 Assemble parts immediately and torque fasteners to specifications 3 Allow sealant to cur...

Page 785: ...d Torque fasteners to 25 lb ft 34Nm 70621 70593 e g a b b c d f h i 75749 j i b Elbows With Risers Elbows Without Risers a Exhaust Elbow b 4 Slot Gasket c 3 in 76 mm Exhaust Riser d 6 in 152 mm Exhaust Riser e Nut 8 f Stud 8 9 3 8 in 238 mm g Stud 8 10 3 8 in 264 mm Used With Some MIE Remote Oil Filters h Washer 8 i Exhaust Manifold j Bolts 3 Port Manifold a Install remote oil filter and bracket b...

Page 786: ...ed Cooled Models Refill closed cooling system to operating level with proper ly 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 raise...

Page 787: ...MANIFOLDS ELBOWS AND RISERS SERVICE MANUAL NUMBER 24 Page 7B 8 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 788: ...n Exhaust 7C 3 Shutter Replacement 7C 3 Component Replacement 7C 4 Thru Transom Exhaust 7C 5 Shutter Replacement 7C 5 Component Replacement 7C 6 Below Swim Platform Exhaust Pipe 7C 7 Silent Choice Exhaust System 7C 8 Exhaust Tube Installation 7C 8 Air Tube Routing 7C 10 Maintenance 7C 11 Exhaust Muffler Kit 7C 12 Cleaning and Inspection 7C 13 Installation 7C 14 Maintenance Instructions 7C 15 Index...

Page 789: ...aust 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 Qu...

Page 790: ...haust 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 3 Reinstall pipe elbow and hose Tighten clamps securely 75760 a b a Exhaust Flapper b Rubber Grommets Index ...

Page 791: ... be adhered to All mating 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 b a a Mating Surface b O Ring 72737 b a c a d e f a c a Clamps b Exhaust Pipe Elbow c Exhaust Hose d Water Shutters e Bolts and Lockwashers f Exhaust Pipe Index ...

Page 792: ...wim platform kits 22057 a b a Block Off Plate b Bolts 4 1 Remove exhaust hose clamps then hose 2 Chisel rivets away from both support members 27761 a b c d c d a Shutter Hinge b Water Shutter Opens Toward Outside Of Boat c Support Member d Rivets 4 3 Install new shutter as shown in Component Replacement following Tighten screws and nut securely 4 Reinstall exhaust hose Tighten clamps securely Inde...

Page 793: ... 90 861327 1 OCTOBER 1999 Component Replacement 72740 a b c d e f g h Transom Exhaust Kit a Screw And Nut 4 b Support Member c Water Shutter Hinge Must Be Vertical d Gasket e Exhaust Flange f Bolts Washers and Nuts 3 g Clamp h Cover Flapper Index ...

Page 794: ...pplications by cutting pipe at location shown 72743 a b c a Cut Line See Notes b To Engine c To Transom NOTE If riser kits are installed or if more vertical drop is required cut a must be made and the upper and lower sections of the pipe rejoined with a 4 in 102 mm I D exhaust hose of the required length Secure with hose clamps NOTE Prime and paint any raw cut aluminum surface IMPORTANT Each exhau...

Page 795: ...e propeller performance on some boats CAUTION It is the responsibility of the boat manufacturer or installing dealer to properly locate the engine and install 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 Mercury MerCruiser Warranty unless this da...

Page 796: ...sition tube so that SIDE markings on tube are facing toward the right and left sides 2 Install clamp 3 Tighten clamp securely 22184 22184 d e c a b a Exhaust Tube b Clamp c Side Marking d Exhaust Tube e Grounding Clip 72539 a b b b a Silencer Valve Assembly b Hose Clamps Index ...

Page 797: ...inders Do not route air tubing close to hot surfaces Excessive heat will damage air tubes 72775 c d b a d Single Engine a Air Tube b T Fittings c Air Pump Assembly d Air Tube To Air Cylinder On Each Silencer Valve 72776 a c b d d d d Dual Engine a Air Tube b T Fittings c Air Pump Assembly d Air Tube To Air Cylinder On Each Silencer Valve Index ...

Page 798: ... air intake holes with adhesive 72534 a b c d e f g h i j k c e a Mode Switch b Keyway Install In DOWN Position c BROWN Wire To Terminal 3 Activates Compressor d PURPLE Wire 12 Volt Connect To 12 Volt Source In Control Panel Area e GRAY Wire To Terminal 1 Activates Solenoid f Air Pump g Solenoid h Check Valve i Relief Valve 30 PSI j 2 Ft 610 mm Ground Wire Connect To Terminal Must Be Grounded To E...

Page 799: ...nter the exhaust manifolds and combustion chambers and severely damage the engine Damage caused by water in the engine will not be covered by Mercury MerCruiser Warranty unless this damage is the result of defective part s IMPORTANT Restrictor gaskets if equipped must be installed in order shown 72780 g a b c d e f 1 1 4 Inch Muffler Riser Installation a Exhaust Manifold b Exhaust Elbow c Bolt 4 E...

Page 800: ...ble End Plate b 4 Screws Secure End Plate c O Ring Seal d Element When Reassembling Seat Tab In Slot In Casting 2 Clean using pressurized water and inspect parts including filter element and O ring seal If required replace O ring securing in place with Quicksilver Sound Blanket Glue 3 Reassemble as shown above Tighten end plate screws securely Index ...

Page 801: ...ks on muffler body casting at the upper rear corner on the port side 72783 IMPORTANT A MOLDED exhaust tube MUST be used at exhaust elbow connection to maintain positive separation of exhaust outlet and muffler inlet 72781 d d a b c a Muffler b Molded Exhaust Tube Muffler To Elbow c Exhaust Hose Muffler To Thru Transom Fitting Cut To Length d Double Clamp Each Connection Not Shown On Hose C 2 Doubl...

Page 802: ...and interior of muffler Clean thoroughly at least once each year using pressurized water 72782 a b c d a Removable End Plate b 4 Screws Secure End Plate c O Ring Seal d Element When Reassembling Seat Tab In Slot In Casting a Check condition of O ring seal if dried out or shrunk below mating surface remove and replace Clean groove thoroughly b Glue new O ring seal in groove using Sound Blanket Glue...

Page 803: ...COLLECTORS SERVICE MANUAL NUMBER 23 Page 7C 16 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 804: ...ns 8A 2 Fluid Specifications 8A 3 Pressure Specifications 8A 3 Important Information 8A 4 Shift Control and Cables 8A 4 Engine 8A 4 Transmission 8A 4 Propeller 8A 5 Transmission Shift Lever 8A 5 Shift Cable Adjustment 8A 5 Checking Transmission Fluid Level 8A 6 Changing Transmission Fluid 8A 7 Draining Transmission 8A 7 Filling Transmission 8A 9 Removal 8A 10 Installation 8A 10 Shift Lever Install...

Page 805: ...ification Plate Model Color Code Ratio Ratio in Forward Gear Note 1 2 1 1 NOTE 1 This ratio is shown on identification plate NOTE 2 These transmissions are for LH standard rotation engines and the propeller shaft rotation is LH standard when in forward gear Torque Specifications Description lb in lb ft Nm Drain Plug Bushing 25 34 Fluid Hose to Bushing 25 34 Pump Housing to Adapter 17 22 23 29 Rear...

Page 806: ...k The transmission should be at operating temperature 190 F 90 C maximum to receive an accurate oil level reading Cold Fluid Level Check To ease checking fluid level the dipstick can be marked or scribed First the procedure for warm fluid level must be performed then allow boat to sit overnight Remove and wipe clean the dipstick Insert clean dipstick and mark the cold fluid level Pressure Specific...

Page 807: ...stalled angle of MIE inboard transmission and engine should not exceed a maximum of 18 of the water line Transmission Transmission gear ratio in forward gear is marked on transmission identification plate which is located on the port left side of transmission Transmission output shaft rotation and propeller rotation required is indicated on a decal on transmission case Transmission rotation is des...

Page 808: ...H refers to rotation in the counterclockwise CCW direction The term right hand RH refers to rotation in the clockwise CW direction A LH propeller will move the boat forward when rotated counterclockwise A RH propeller will move the boat forward when rotated clockwise Propeller rotation is not necessarily the same as engine rotation Transmission Shift Lever The lever has three holes as illustrated ...

Page 809: ... 72526 a c b a Dipstick b Full Mark c Dipstick Tube 1 Start engine and run at 1500 rpm for 2 minutes to fill all hydraulic circuits IMPORTANT Be sure to push dipstick all the way down into dipstick tube when checking fluid level 2 Stop engine and check fluid level Add transmission fluid if necessary to bring level up to full mark on dipstick 3 Reinstall dipstick Be sure to tighten T handle securel...

Page 810: ...mission 1 Clean area around cooler hose shown and proceed as follows a Disconnect hose from elbow fitting b Remove elbow fitting from bushing c Drain oil from transmission cooler and cooler hoses into a suitable container 72840 a b Transmission With 1 1 Ratio a Hose b Elbow Fitting 72841 a b Transmission with Reduction Ratios a Hose b Bushing Index ...

Page 811: ...a Bushing b Spring c Plastic Strainer Tube 4 Check oil for the following foreign matter Metal Particles A few small particles are normal Larger metal chips are an early sign of transmission failure which may mean transmission should be disassembled and in spected for internal damage Rubber Particles Indication of cooler hose wear Hoses should be inspected for cracks or fraying Replace damaged hose...

Page 812: ...nsmission IMPORTANT Use only specified transmission fluid Refer to Specifications 1 Remove dipstick Fill transmission with fluid through dipstick hole to bring up to full mark 72526 a b c a Dipstick b Full Mark c Dipstick Tube IMPORTANT To accurately check fluid level run engine at 1500 rpm for 2 minutes immediately prior to checking level 2 Start engine and run at 1500 rpm for 2 minutes to fill a...

Page 813: ... IMPORTANT These two long studs will help support weight of transmission during removal and installation 10 Remove remaining transmission attaching bolts 11 Pull transmission straight back and off engine Installation 1 Check transmission output shaft rolling torque Refer to Specifications 2 Apply Quicksilver Engine Coupler Spline Grease to transmission input shaft splines and engine drive plate sp...

Page 814: ...d a Transmission Shift Lever b Shift Lever Must Be Over This Letter when Propelling Boat FORWARD c Shift Lever Must Be Over This Letter when Propelling Boat in REVERSE d Poppet Ball Must Be Centered in Detent Hole for Each F N R Position Forward Gear Shown 12 Refer to SECTION 2C MIE Models Velvet Drive Transmissions and check engine final alignment as outlined 13 After engine has been properly ali...

Page 815: ... lever and related parts must be assembled as shown 1 Lubricate poppet ball spring and holes in shift lever with Quicksilver 2 4 C Marine Lubricant 2 Install poppet spring and ball Retain ball by placing shift lever on shaft 3 Install flat washer lockwasher and nut on shaft 4 Torque nut to 96 132 lb in 11 15 Nm 72844 a b c d e f Typical Shift Lever a Nut b Lockwasher c Flat Washer d Shift Lever e ...

Page 816: ...on Repair Mercury Marine does not stock or sell replacement parts for the in line transmission Velvet Drive has a network of distributors throughout the world to service their product These dis tributors in turn have a dealer network to service the transmissions Also service manuals for each transmission can be obtained from Velvet Drive For the location of your closest distributor or service lite...

Page 817: ...VELVET DRIVE IN LINE AND V DRIVE TRANSMISSION SERVICE MANUAL NUMBER 24 Page 8A 14 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 818: ...n 8B 4 Transmission Ratios and Part Numbers 8B 4 Transmission Fluid Capacities 8B 4 Transmission Fluid Specification 8B 4 Transmission Pressure Specifications 8B 5 Torque Specifications 8B 5 Shift Control and Cables 8B 5 Important Information 8B 6 Engine 8B 6 Transmission 8B 6 Propeller 8B 6 Transmission Propeller Rotation 8B 7 Shift Control and Cables 8B 9 Transmission Shift Lever and Shift Cable...

Page 819: ... Model Color Code Transmission Ratios and Part Numbers Ratio in Forward Gear1 Identification Plate Color Code Velvet Drive Model Number Mercury Marine Part Number 1 5 1 20 01 003 805495A6 2 1 20 01 004 805495A4 2 5 1 Black 20 01 005 805495A5 2 8 1 20 01 006 805495A7 1This ratio is shown on identification plate Ratio may be rounded off in some cases Transmission Fluid Capacity Model U S Quarts Lite...

Page 820: ...i kPa Engine rpm Min Max Min Max 900 10 69 50 344 2400 50 344 70 483 200 1379 400 2757 Torque Specifications Fastener Location lb in lb ft Nm Drain Plug Fluid Hose to Cooler 25 34 Fluid Hose to Housing Rear Mounts to Transmission 45 61 Shift Lever to Valve 96 132 11 15 Transmission to Flywheel Hous ing 50 68 Neutral Start Safety Switch 120 13 Propeller Shaft Coupler To Out put Flange 50 68 Index ...

Page 821: ... 1 5 1 20 02 003 807481A5 2 1 Blue 20 02 004 807481A6 2 5 1 20 02 005 807481A7 1This ratio is shown on identification plate Ratio may be rounded off in some cases Transmission Fluid Capacities Model U S Quarts Liters 5000V 3 2 3 4 1 NOTE 1 Use dipstick to determine exact fluid level Warm Fluid Level Check The transmission should be at operating temperature 190 F 90 C maximum to receive an accurate...

Page 822: ...sion to Flywheel Housing 50 68 Neutral Start Switch 8 11 11 14 Shift Control and Cables CAUTION Shift control and shift cable must position transmission shift lever exactly as stated in this manual or transmission as a result of improper shift lever positioning will not be covered by Velvet Drive Warranty IMPORTANT Velvet Drive Warranty is jeopardized if the shift lever poppet ball or spring is pe...

Page 823: ...mission however boat operation above trolling speed should be avoided Be sure proper fluid level exists before free wheeling propeller 5 DO NOT paint shift lever poppet ball and spring An accumulation of paint here will pre vent proper action of the detent 6 Always replace oil cooler and hoses after a transmission failure or prior to installing a new or rebuilt transmission Metallic particles from...

Page 824: ...shift cable attachment at the remote control Be sure to use correct rotation propeller and shift cable hook up for direction desired 71888 c a b Typical a Direction Of Shift Lever Engagement Toward Flywheel b Engine Transmission Input Shaft Shaft Rotation Direction LH c Transmission Output Propeller Shaft Rotation Direction LH 71888 a c b Typical a Direction Of Shift Lever Engagement Away From Fly...

Page 825: ...on B when remote control handle is placed in forward position 23242 A B Remote control must provide a total shift cable travel at transmission end of at least 2 3 4 in 70 mm This is necessary to position transmission shift lever fully in the forward and reverse gear positions Insufficient shift cable travel will cause transmission to slip and even tually fail 72602 a a 2 3 4 Inch 70 mm Minimum IMP...

Page 826: ...tered In This Detent Hole For Neutral Position e Install Shift Lever Stud In This Hole When Using Quicksilver Shift Cables Shift Control and Cables CAUTION Shift control and shift cable must position transmission shift lever exactly as stated in this manual or transmission as a result of improper shift lever positioning will not be covered by Velvet Drive Warranty IMPORTANT Velvet Drive Warranty i...

Page 827: ...3249 a b a Shift Lever b Shift Cable Anchor Stud Location For Quicksilver Shift Cables WARNING Avoid serious personal injury or property damage caused by improper shifting Anchor stud for shift cable must be installed in the correct hole when using bracket with four anchor location holes 2 Be certain anchor stud is installed in the lower front hole as shown in the illustration fol lowing 74090 a b...

Page 828: ... any manner or if remote control and shift cable do not position shift lever exactly as shown 73248 a b c d e a Transmission Shift Lever b Poppet Ball Must Be Centered In This Detent Hole When Left hand Propeller Shaft Rotation Is Desired c Poppet Ball Must Be Centered In This Detent Hole When Right hand Propeller Shaft Rotation Is Desired d Poppet Ball Must Be Centered In This Detent Hole For Neu...

Page 829: ...opeller a Input b Output c Output Shaft 73285 a b c Position Is Forward Gear For LH Rotation Propeller a Input b Output c Output Shaft For Left Hand Propeller Shaft Rotation Shift cable hookup at remote control must result in shift cable end guide moving in direction A when remote control handle is placed in for ward position For Right Hand Propeller Shaft Rotation Shift cable hookup at remote con...

Page 830: ...ansmission shift lever fully in the forward and reverse gear positions Insufficient shift cable travel will cause transmission to slip and even tually fail 72602 a a 2 3 4 In 70 mm Minimum IMPORTANT The distance between studs Dimension C shown in the following illus tration is set at 7 1 8 in 318 mm 73284 a b b c d a Shift Lever b Anchor Stud c Dimension Between Studs 7 1 8 Inch 318 mm d Shift Lev...

Page 831: ...y mark position a on tube c Pull out on control cable end with enough effort to remove play mark position b on tube d Measure distance between marks a and b mark position c half way between marks a and b a b c c 72603 4 Center cable end play then adjust cable barrel to align holes in barrel and in cable end guide with attaching points on transmission 5 Temporarily install shift cable Do not secure...

Page 832: ... Desired d Poppet Ball Must Be Centered in This Detent Hole for Neutral Position e Install Shift Lever Stud in This Hole when Using Quicksilver Shift Cables 7 Place remote control shift lever in opposite gear position and again check transmission shift lever position Lever must be positioned as shown by c 8 If transmission shift lever will not position properly in one gear or both gears recheck sh...

Page 833: ...llation Rear Approach a Cable End Guide b Spacer As Required c Elastic Stop Nut And Washer d Bushing s e Cable Barrel s Position s Only Indicated In Right Drawing f Cable Barrel Stud g Cable End Guide Stud 71897 50073 a b c d f e g a a b c d e f g Typical Dual Cable Installation Rear Approach a Cable End Guide b Spacer As Required c Elastic Stop Nut and Washer d Bushing s e Cable Barrel s Position...

Page 834: ...add specified transmission fluid to bring level up to full mark on dipstick 73250 b a c a Dipstick b Full Mark c Dipstick Tube IMPORTANT To accurately check fluid level engine must be run at 1500 rpm for 2 minutes immediately prior to checking level 2 Start engine and run at 1500 rpm for 2 minutes to fill all hydraulic circuits IMPORTANT Be sure to push dipstick all the way down into dipstick tube...

Page 835: ...n matter Metal Particles A few small particles are normal Larger metal chips are an early sign of transmission failure which may mean transmission should be disassembled and in spected for internal damage Rubber Particles Indication of cooler hose wear Hoses should be inspected for cracks or fraying Replace damaged hoses 4 Coat drain plug threads with Quicksilver Perfect Seal Install and torque dr...

Page 836: ...engine and quickly check fluid level Add transmission fluid as needed to bring level up to full mark on dipstick 4 Reinstall dipstick Be sure to tighten T handle securely Removal NOTICE The following procedure describes removal of transmission without removing engine If engine must be removed refer to SECTION 2 1 Disconnect negative battery cable 2 If required drain transmission fluid and disconne...

Page 837: ... input shaft 14 Carefully lift out transmission Installation 1 Apply Quicksilver Engine Coupler Spline Grease to transmission input shaft splines and engine drive plate splines 2 Using a suitable hoist position transmission in boat and align transmission splines with drive plate splines 3 Slide transmission into place and secure with attaching hardware Torque transmission to flywheel housing faste...

Page 838: ... Quicksilver Shift Cables 9 Refer to SECTION 2C and check engine final alignment as outlined 10 After final engine and coupler alignment has been properly set with boat in the water connect propeller shaft coupler to transmission output flange Attach couplers together with bolts lockwashers and nuts Torque to 50 lb ft 68 Nm IMPORTANT Be certain to torque trunnion clamping fasteners on engine mount...

Page 839: ...irections Shift lever and related parts must be assembled as shown 1 Lubricate poppet ball spring and holes in shift lever with Quicksilver 2 4 C Marine Lubricant 2 Install poppet spring and ball Retain ball by placing shift lever on shaft 3 Install flat washer lockwasher and nut on shaft 4 Torque nut to 96 132 lb in 11 15 Nm 73251 a b c d e f a Nut b Lockwasher c Flat Washer d Shift Lever e Poppe...

Page 840: ...respective pressure readings Transmission Repair Mercury Marine does not stock or sell replacement parts for the down angle transmission Velvet Drive has a network of distributors throughout the world to service their product These distributors in turn have a dealer network to service the transmissions Also service manuals for each transmission can be obtained from Velvet Drive For the location of...

Page 841: ...VELVET DRIVE 5000 SERIES TRANMISSION SERVICE MANUAL NUMBER 24 Page 8B 24 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 842: ... 8C 2 Torque Specifications 8C 2 Operating Specifications 8C 2 Fluid Specifications 8C 3 Tools 8C 3 Lubricants Sealants Adhesives 8C 3 Rotation 8C 4 Shift Cable Installation and Adjustment 8C 5 Checking Transmission Fluid Level 8C 10 Draining Transmission 8C 11 Filling Transmission 8C 12 Transmission Removal 8C 14 Transmission Installation 8C 15 Functional Tests 8C 17 Index ...

Page 843: ...ST GERMANY A B a Late Style Identification Plate a Serial Number and Gear Ratio Specifications Torque Specifications Item Fastener Location lb in lb ft Nm Transmission Housing Halves Bolts and Nuts 36 49 Control Block To Housing 18 25 Output Flange 14 18 Mounts Transmission To Flywheel Housing 50 68 Operating Specifications Description Specification Shifting Pressure 312 377 PSI 2151 2599 kPa Oper...

Page 844: ...reading Cold Fluid Level Check To ease checking fluid level the dipstick can be marked or scribed First the procedure for warm fluid level must be performed then allow boat to sit overnight Remove and wipe clean the dipstick Insert clean dipstick and mark the cold fluid level Tools Description Part Number Thermometer 3 8 In Thread 0 270 F 18 to 132 C Obtain Locally Pressure Gauge M10x1 Thread Obta...

Page 845: ...Left Hand rotation engines NEVER connect a Hurth Transmission to a Right Hand rotation engine IMPORTANT Transmission propeller rotation is determined by the shift cable instal lation in the remote control RIGHT HAND PROPELLER ROTATION Control cable will have to be installed in re mote control so that cable end will move in direction A when shift handle is placed in the forward position LEFT HAND P...

Page 846: ...58 a c d 50228 a b d Typical Hurth Transmission Shown a Shift Lever b Lever In Neutral Detent Must Be Approximately 10 Degrees Aft Of Vertical c Dimension Between Studs 7 1 8 In 181 mm d Clamping Bolt 1 On bracket with two anchor location holes Be certain anchor stud is installed in the hole marked 630 WARNING Avoid serious personal injury or property damage caused by improper shifting Anchor stud...

Page 847: ...n c halfway between marks a and b 22024 a b c c 5 Center cable end play then adjust cable barrel to align holes in barrel and in cable end guide with attaching points on transmission 6 Temporarily install shift cable Do not secure at this time IMPORTANT Transmission is fully in gear when shift lever comes to a stop in either direction 7 Place remote control shift lever in forward gear position Ens...

Page 848: ...ioning If proper positioning is still not obtained remote control does not provide sufficient shift cable travel and must be replaced 50228 a b c a Shift Lever Stud In Bottom Hole If Required b Lever In Neutral Detent Must Be Approximately 10 Degrees Of Vertical c Shift Lever Top Hole 10 Install nut and washer to cable end guide stud Tighten until contacts then loosen one full turn 11 Install nut ...

Page 849: ...the opposite stud The studs are identical IMPORTANT Tighten locknut until it contacts and then loosen 1 2 turn 72955 71210 e b c d b a f g h Typical Single Cable Forward Approach a Cable End Guide b Locknut and Washer c Spacer Fits Over Bushings d Bushing e Cable Barrel f Spacers Fits Over Stud g Cable Barrel Stud h Cable End Guide Stud 72957 50229 a b f b c d e g h Typical Single Cable Rear Appro...

Page 850: ... Guide b Locknut And Washer c Spacer Fits Over Bushings d Bushing e Cable Barrel f Spacers Fits Over Stud g Cable Barrel Stud h Cable End Guide Stud 72960 50073 e b d a b d g h Typical Dual Cable Rear Approach a Cable End Guide b Locknut And Washer c Spacer Fits Over Bushings d Bushing e Cable Barrel f Spacers Fits Over Stud g Cable Barrel Stud h Cable End Guide Stud Index ...

Page 851: ...n fluid cooler and hoses may have drained back into transmission If low add transmission fluid to bring level up to full mark on dipstick 27661 Typical Hurth Transmission IMPORTANT To accurately check fluid level engine must be operated at 1500 RPM for two minutes immediately prior to checking level 2 Start engine and operate at 1500 RPM for two minutes to fill all hydraulic circuits IMPORTANT Be ...

Page 852: ...TE Later model Hurth transmissions will be equipped with an allen head socket screw on the oil filter cover 2 Remove oil filter from housing by turning counterclockwise and pulling at the same time 27666 a a Set Screw Later Models 3 Remove drain plug from transmission and allow fluid to drain Reinstall drain plug and tighten securely 73013 a a Drain Plug Index ...

Page 853: ...cifications 2 Install filter as follows a Coat O ring on filter cover with transmission fluid 27662 a b a Filter Cover b O Ring CAUTION Transmission fluid filter and cover must be properly seated to avoid fluid foaming and or loss of fluid thus resulting in decreased efficiency and or damage to trans mission b Push down until cover is fully seated top of cover flush with housing then Turn T handle...

Page 854: ...R 24 90 861327 1 OCTOBER 1999 Page 8C 13 3 Start engine and run for two minutes to fill system with fluid 4 Stop engine and check fluid level Fluid should be between minimum and maximum lines on dipstick 27661 Typical Hurth Transmission Index ...

Page 855: ...oval 1 Disconnect wires from neutral safety switch and audio warning temperature switch 2 Disconnect seawater hoses from transmission fluid cooler 72711 a a a Seawater Hoses 3 Remove bolts and locknuts and remove transmission 72720 a b a Bolts 2 One On Each Side b Locknuts 4 Two On Each Side Index ...

Page 856: ... Installation 1 Coat splines on input shaft with Quicksilver Engine Coupler Spline Grease 71044 a a Input Shaft 2 Install transmission on flywheel housing and secure with hardware shown Torque fas teners to 50 lb ft 68 Nm 72720 a b a Bolts 2 One On Each Side b Locknuts 4 Two On Each Side Index ...

Page 857: ... fluid cooler and tighten hose clamps securely 72711 a b a b a Seawater Hoses b Hose Clamps 4 Connect wires to neutral safety switch and to audio warning temperature switch Coat connections on neutral safety switch with Quicksilver Liquid Neoprene 50686 a b a Neutral Safety Switch b Audio Warning Temperature Switch Index ...

Page 858: ...ations for correct readings Tests to Be Carried Out 1 Leakages 2 Noise emission 3 Direction of rotation LH RH 4 Fluid temperature 5 Shifting pressure Motor Speed RPM Shift Lever Position Duration Minutes Tests 800 1000 Neutral 5 1 2 600 800 Idling Speed A B Position Repeatedly 1 2 3 1500 2500 B Position 1 1 2 4 600 800 Idling Speed A B Position Repeatedly 1 2 3 Idling Maximum Speed A Position 1 2 ...

Page 859: ...HURTH TRANSMISSIONS SERVICE MANUAL NUMBER 24 Page 8C 18 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 860: ...Installation 8D 4 Disassembly 8D 4 Reassembly 8D 5 Drive Shaft Repair MCM Sterndrive Models 8D 5 Removal 8D 5 Repair 8D 7 Replacement Drive Shafts 8D 7 Drive Shafts Modified to Shorter Lengths 8D 8 Installation 8D 8 Bearing Support Repair MCM Sterndrive Models 8D 10 Removal 8D 10 Disassembly 8D 10 Reassembly 8D 11 Installation 8D 12 Propeller Shaft MIE Inboard Models 8D 14 Checks Made With Boat In...

Page 861: ...Flywheel Housing MCM Models 30 41 Engine Coupling 35 48 Bearing Support Housing Attaching Bolts 35 54 47 73 Coupling Set Screws If Equipped Securely 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...

Page 862: ...ations the engine also must be removed Exploded View 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 8 8 8 8 Flywheel Housing Output Shaft Housing 1 Output Shaft 2 O Rings 3 Ball Bearing Snap Ring 4 Ball Bearing 5 Shaft Bearing 6 Output Shaft Snap Ring 7 Rear Engine Mount 8 Lockwasher 9 Screw 4 10 Screw 6 11 Flywheel Housing 12 Plate 13 Screw 2 14 Nut 1 15 Bolt 4 16 Washer 1 17 Clamp 1...

Page 863: ...nd 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...

Page 864: ...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...

Page 865: ...t to assist in exact same positioning during assembly at engine and transom end 70237 a b c 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 70237 a b c Engine End Shown Transom End Similar a Output Shaft Flange b Drive Shaft c Bolt With Nut 4 Total Index ...

Page 866: ...ge 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 b c c d d e a Tube b Yoke Tube c Flange d Universal Joint e Sound Deadener Cardboard Tube The...

Page 867: ...ase 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 ...

Page 868: ...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 70245 a b c d e Top Shield and Bottom Shield at Transom End Engine End Simil...

Page 869: ...enter 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 e c 75279 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...

Page 870: ...er 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 En...

Page 871: ...support assembly as shown 75279 a b c d e f g h 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 71401 a b Typical S...

Page 872: ...culty 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 Installatio...

Page 873: ...connect propeller shaft coupling from transmission coupling 2 Check fit of coupling to propeller shaft Straight Bore Type a Loosen set screws b Try to move coupling by hand The bore of the coupling should be a semi press fit to shaft c Check shaft for wear If worn replacement of shaft may be necessary d If shaft is not worn try another coupling Tapered Bore Type a Check nut on shaft for tightness ...

Page 874: ...et screws if equipped Checks Made With Boat Out Of Water And Shaft Installed Possible causes for vibration may be propeller shaft propeller to shaft fit or propeller All three can be checked by using the rudder a strong metal straight edge and a C clamp 1 Check installation of propeller to shaft a Remove propeller b Check for chipped or cracked keyway in propeller on shaft without key c Install pr...

Page 875: ...ft Wobbles Replace Shaft b Rudder 3 Check the diameter of all propeller blades If not the same repair propeller a b c a Metal Straight Edge Held To Rudder With C Clamp b Rudder c Rotate Propeller One Complete Turn 4 Check that all propeller blades are the same pitch and that propeller is properly seated on shaft Repair or replace if necessary a b c a Metal Straight Edge Held To Rudder With C Clamp...

Page 876: ... Rotate One Complete Turn 2 Check that bore of coupling is 90 degrees from coupling flange Replace coupling if needle moves d c a b a V Blocks b Dial Indicator c Coupling Flange Rotate One Complete Turn d Shaft Against Block To Prevent Fore And Aft Movement Strut Refer to boat manufacturer s service manual for alignment and replacement Normally the shaft should be centered in the cutlass bearing S...

Page 877: ...DRIVE SHAFT PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 24 Page 8D 18 90 861327 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 878: ...ealants Adhesives 9A 2 Precautions 9A 3 Power Steering Pump and Components 9A 3 Serpentine Belt Routing 9A 4 Serpentine Belt Adjustment 9A 6 Removal 9A 6 Installation 9A 6 Important Service Information 9A 7 Pump Pulley Replacement 9A 7 Testing and Repair 9A 8 Checking Pump Fluid Level 9A 8 Filling and Air Bleeding System 9A 8 Pump Assembly 9A 8 Removal 9A 8 Installation 9A 10 Hydraulic Hoses and F...

Page 879: ...e 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 Transmiss...

Page 880: ...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 72951 1 3 4 5 6 7 8 9 10 11 2 9 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 B...

Page 881: ...BER 1999 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 Index ...

Page 882: ...L NUMBER 24 90 861327 1 OCTOBER 1999 Page 9A 5 Serpentine Belt Routing Continued S N 0L619000 and Above 76502 76503 Alpha With Power Steering Bravo With Power Steering 76445 76463 Alpha Without Power Steering Bravo Without Power Steering Index ...

Page 883: ... 2 Install drive belt on pulleys 3 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 engi...

Page 884: ...ool with suitable wrench turn threaded screw until pulley is removed 72821 a b 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 lar...

Page 885: ...l 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 a Adjusting Nut NOTE Use a suitable container catch ant power steering fluid when removing the power steering hoses Index ...

Page 886: ... steering pump 75228 a b Power Steering Pump Typical Location a Return Hose b High Pressure Hose 3 Remove mounting fasteners from pump 75798 a b 75228 a 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 Index ...

Page 887: ... 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 a b 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 In...

Page 888: ...PORTANT 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 75228 b a Power Steering Pump Typical Location a High Pressure Hose Fitting With O Ring Not Visible In This View b Pump Fit...

Page 889: ...al Install fitting and torque to 23 lb ft 31 Nm Do not cross thread or overtighten 73860 a 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 b a Power Steering Pum...

Page 890: ... 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 75595 a a Hose 2 Loosen hose clamp and remove hose from back of pump 75228 a b Power Steering Pump Typical Location a Hose Clamp b Hose Index ...

Page 891: ...STALLATION 1 Using hose clamp install new hose on back of pump Tighten clamp securely 75228 a b Power Steering Pump Typical Location a Hose Clamp b Hose 2 Using hose clamp install hose on fluid cooler Tighten clamp securely 75595 a a Hose 3 Fill and air bleed system Refer to SECTION 1B Index ...

Page 892: ...ressure 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 a Hose 2 Remove fitting from control valve at transom Remove hose 73860 a a Power Steering Hose Fitting Index ...

Page 893: ...d or overtighten hose fittings 1 Position hose properly as prior to removal Install fitting and torque to 23 ft in 31 Nm Do not cross thread or overtighten 73860 a 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 sec...

Page 894: ...PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 24 90 861327 1 OCTOBER 1999 Page 9A 17 THIS PAGE IS INTENTIONALLY BLANK Index ...

Page 895: ...PUMP AND RELATED COMPONENTS SERVICE MANUAL NUMBER 24 Page 9A 18 90 861327 1 OCTOBER 1999 THIS PAGE IS INTENTIONALLY BLANK Index ...

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MerCruiser 305 CID (5.0L), Service Manual

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