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Mercury 305 CID, Service Manual, Page: 332 / 967

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Mercury 305 CID Service Manual Download Page 332

THUNDERBOLT IV AND V IGNITION SYSTEM - 4B-23

90-823225--1  1096

Spark Plug Wires

1. Inspect spark plugs for damage.

2. Check spark plugs for continuity using Multi-

Meter / DVA (91-99750) or similar.

3. Replace any wires that are cracked, cut, or have

damaged spark plug boots.

4. Replace any wires that do not show continuity

from end to end.

5. Reinstall wires in proper order. Observe the fol-

lowing:

IMPORTANT: Proper positioning in spark plug
wire supports is important to prevent cross-
firing.

IMPORTANT: Before installing coil wire to coil,
apply approximately 1/2 oz. of insulating com-
pound around top of coil lead tower. Force nipple
into coil and wipe off excess. Make sure boot
does not “hydraulically back off” the distributor
cap terminal.

Summary of Contents for 305 CID

Page 1: ...Number 17 Printed in U S A 90 823225 1 1096 1996 Mercury Marine GM V 8 305 CID 5 0L 350 CID 5 7L MARINE ENGINES Book 1 of 2 Sections 1 thru 4...

Page 2: ...ults of each method We have not under taken any such wide evaluation Therefore anyone who uses a service procedure and or tool which is not recommended by the manufacturer first must completely satisf...

Page 3: ...of parts sub jected to salt water and possibly complete failure of the engine Use of parts other than recommended service re placement parts will void the warranty on those parts which are damaged as...

Page 4: ...Above 1996 Thru 1997 350 Magnum OD830982 and Above 350 Magnum EFI Gen OF800500 and Above MCM Bravo MODEL SERIAL NUMBER MODEL YEAR 5 0L OD833077 OF601464 1993 1995 5 7L 4 Barrel OD831826 OF605335 1993...

Page 5: ...hru 1997 350 Magnum EFI Tournament Ski OF225157 OK000000 1994 1996 350 Magnum EFI Gen Tournament Ski OK040006 and Above 1997 350 Magnum EFI MP Tournament Ski OF350583 OF745536 1995 350 Magnum MPI Tour...

Page 6: ...ns Section 3 Engine A 5 0L 305 CID 5 7L 350 CID Section 4 Electrical Systems A Starting System B Ignition System C Charging System D Instrumentation E Electrical Kits F Wiring Diagrams Section 5 Fuel...

Page 7: ...A 1 72000 IMPORTANT INFORMATION GENERAL INFORMATION...

Page 8: ...Directional References 1A 3 Engine Rotation 1A 3 Engine Serial Number Locations 1A 3 Propeller Information 1A 4 Water Testing New Engines 1A 4 Boat and Engine Performance 1A 4 Boat Bottom 1A 4 Marine...

Page 9: ...nt to enable dealers and service me chanics to repair and tune these engines Before attempting repairs or tune up it is suggested that the procedure first be read through to gain knowl edge of the met...

Page 10: ...Description This is the most important column because it gives 1 Description of Part Ref No 1 is a Cylinder Block Assembly No 9 is a Camshaft etc 2 What parts are included with a certain part Notice h...

Page 11: ...observing flywheel rotation from the rear stern end of the engine look ing forward toward water pump end Propeller rota tion is not necessarily the same as engine rotation When ordering replacement en...

Page 12: ...elow rated RPM a decrease in pitch and or diameter is required Normally a change of approximately 300 to 500 RPM will be achieved for each single pitch change of a pro peller CAUTION If a propeller is...

Page 13: ...al veg etable derived occurring on the boat s bottom and drive unit Fouling adds up to drag which reduces boat performance In fresh water fouling results from dirt vegetable matter algae or slime chem...

Page 14: ...in mind each boater should seek out what weight locations best suit his her needs Weight and passenger loading placed well forward increases the wetted area of the boat bottom and in some cases virtu...

Page 15: ...e chart Although some performance can be regained by dropping to a lower pitch propeller the basic problem still exists The propeller is too large in diameter for the reduced power output The experien...

Page 16: ...B 1 IMPORTANT INFORMATION MAINTENANCE...

Page 17: ...illed Engine Crankcase 1B 15 Checking Engine Oil Level Filling 1B 15 Changing Oil and Filter 1B 15 Maintaining Power Steering Pump Fluid Level 1B 16 With Engine Warm 1B 16 With Engine Cold 1B 16 Filli...

Page 18: ...nance requirements Alpha Models SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER OPERATOR NOTE Only perform maintenance which applies to your particular power package Task Interval Engine Crankcas...

Page 19: ...f fi b i d h f Rear Engine Mounts Check torque to 30 40 ft lb 47 54 N m E d f fi b i d h f Gimbal Bearing Lubricate E d f fi b i d h f Cooling System Clean and Inspect E d f fi b i d h f Steering Syst...

Page 20: ...st Fuel Filters Replace O Y Quicksilver Mercathode System Test output O Y Closed Cooling Coolant Test for Alkalinity Once a Year Heat Exchanger Clean seawater section Drive Unit Bellows and Clamps Ins...

Page 21: ...fuel is present Weekly Power Trim Pump Oil Check level Anodes Inspect for erosion Gear Housing Water Pickups Check for marine growth or debris Drive Belt s Inspect condition and check tension Every 10...

Page 22: ...54 N m E d f fi b i d h f Gimbal Bearing Lubricate E d f fi b i d h f Cooling System Clean and Inspect E d f fi b i d h f Engine Alignment Check E d f fi b i d h f Engine Coupling Universal Joint Sha...

Page 23: ...Carburetor If Equipped Inspect and adjust 100 hours of operation or once yearly whichever occurs first Throttle Body EFI Models Inspect occurs first Fuel Filters Replace O Y Quicksilver Mercathode Sys...

Page 24: ...PM 30 60 PSI 207 414 kPa Minimum Oil Pressure at Idle 4 PSI 28 kPa Mechanical Fuel Pump Pressure at 1800 RPM 3 7 PSI 21 48 kPa Electrical System 12 V Negative Ground Minimum Battery Requirements 375 c...

Page 25: ...00 4600 5000 Oil Pressure at 2000 RPM 30 60 PSI 207 414 Minimum Oil Pressure at Idle 4 PSI 28 kPa Mechanical Fuel Pump Pressure 3 7 PSI 21 48 kPa Electrical System 12 V Negative Ground Minimum Battery...

Page 26: ...Pump Pressure 3 7 PSI 21 48 kPa Electrical System 12 V Negative Ground Minimum Battery Requirements 375 cca 450 mca 90 Ah 550 cca 700 mca 120 Ah Firing Order LH Rotation 1 8 4 3 6 5 7 2 RH Rotation 1...

Page 27: ...a Minimum Oil Pressure at Idle 4 PSI 28 kPa Mechanical Fuel Pump Pressure If Equipped 3 7 PSI 21 48 kPa Fuel Pressure Running E F I Only 43 PSI 241 kPa 30 PSI 207 kPa 43 PSI 296 7 kPa 30 PSI 207 kPa E...

Page 28: ...r Winterization Use Only MIE Inboard Model 5 7L Bluewater 5 7L Competition Ski 350 Magnum Tournament Ski Crankcase Oil Capacity With New Filter 1 4 3 8 5 4 7 Seawater Cooling System 2 15 14 1 Closed C...

Page 29: ...full throttle RPM Deterioration of elastomer and plastic parts Fuel permeation through flexible fuel lines Wear and damage of internal engine parts Starting and operating difficulties Some of these a...

Page 30: ...is ETHANOL Alcohol is also more severe in older en gines since newer engines have materials which are more resistant to alcohol EFFECTS OF GASOLINE ALCOHOL BLENDS ON MARINE ENGINES Corrosion of metal...

Page 31: ...s no need for concern If the dividing line between water and fuel becomes cloudy use the middle of the cloudy band Crankcase Oil To help obtain optimum engine performance and to provide maximum protec...

Page 32: ...he crank case if engine has just been run or oil has just been added Checking Engine Oil Level Filling IMPORTANT ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS SPECIFIED IN MAINTENANCE SCHEDULE CHA...

Page 33: ...g 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 With Engine Cold 1 With engine stopped...

Page 34: ...steering wheel back and forth to end of travel in each di rection several times 5 Position drive unit so that it is straight back and stop engine Remove fill cap from pump Allow any foam in pump reser...

Page 35: ...at idle speed in neutral for 10 minutes or until discharge water is clear then stop engine 6 Shut off water tap Remove garden hose and flushing attachment BOAT IN WATER 1 Raise drive unit to full UP p...

Page 36: ...acock or plug hose to prevent seawater from entering boat 2 Using an adaptor connect a garden hose from a water tap to seapump inlet 3 Partially open water tap approximately 1 3 maxi mum Do not use fu...

Page 37: ...rive IMPORTANT To accurately check fluid level en gine MUST BE run at 1500 RPM for 2 minutes im mediately prior to checking level 2 Start engine and run at 1500 RPM for 2 minutes to fill all circuits...

Page 38: ...hrottle Cable MODELS WITH 2 BARREL CARBURETOR 72013 b a a Pivot Points b Guide Contact Surface MODELS WITH 4 BARREL CARBURETOR 72014 b a a Pivot Points b Guide Contact Surface THROTTLE BODY INJECTION...

Page 39: ...STING THROTTLE CABLE 350 MAGNUM MPI GEN TOURNAMENT SKI BLACK SCORPION 1 Place remote throttle lever in idle position and attach cable to throttle lever stud following cable manufacturer s instructions...

Page 40: ...ntact Surface 72016 b a a a b Bravo One and Two MCM Models Typical Shift Cable a Pivot Points b Guide Contact Surface 71208 a a b Hurth a Pivot Points b Guide Contact Surface 72528 a a b Velvet Drive...

Page 41: ...nd installation 71570 MCM Models with Alpha One Drive Without Sealed Steel Hub Coupler MCM Models with Bravo Drives 71569 MCM Models with Alpha One Drive With Sealed Steel Hub Coupler a a 72529 a b b...

Page 42: ...ry 50 Hours of operation or 60 days whichever comes first Salt Water Areas Every 25 hours of operation or 30 days whichever comes first NOTE Operation in salt water is considered severe service 1 Chec...

Page 43: ...ompletely CAUTION A discharged battery can be damaged by freez ing Layup NOTICE Refer to Cold Weather or Extended Storage Precautions in this section BEFORE pro ceeding 1 Fill fuel tank s with fresh g...

Page 44: ...l filter 6 Pour out a small amount of fuel into a suit able container then add approximately 2 fluid ounces 60 ml of Quicksilver 2 Cycle Outboard Oil to fuel in the water separating fuel filter 7 Inst...

Page 45: ...peatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained NOTE It may be necessary to lift bend or lower hoses to allow water to drain completely when hoses are...

Page 46: ...r Pickup Pump to Cooler g Remove seawater pump inlet hose as shown 72532 b a a Seawater Pickup Pump b Hose h Follow instructions 1 or 2 1 On Bravo Drive Equipped Models In sert a small wire repeatedly...

Page 47: ...e seawater inlet hose reconnected prior to starting the engine j After seawater section of cooling system has been drained completely coat threads of drain plugs with Quicksilver Perfect Seal and rein...

Page 48: ...or Extended Storage Precautions in this section BEFORE proceeding a Engine must be as level as possible to ensure complete draining of cooling system b Remove drain plugs port and starboard from cylin...

Page 49: ...moved a 72586 Starboard Shown Port Similar a Bottom Hose Exhaust Manifold To Thermostat Housing 72586 a Starboard Shown Port Similar a Drain Plug e Remove the engine water circulating pump hose as sho...

Page 50: ...m has been drained completely coat threads of drain plugs with Quicksilver Perfect Seal and reinstall Tighten drain plugs securely Re connect hoses and tighten all hose clamps securely If NOT equipped...

Page 51: ...e to ensure complete draining of cooling system b Remove drain plug from heat exchanger 70583 a a Heat Exchanger b Drain Plug c Remove drain plugs if equipped from port and starboard exhaust elbows 71...

Page 52: ...hown 72532 b a a Seawater Pickup Pump b Hose h Follow instructions 1 or 2 1 On Bravo Drive Equipped Models In sert a small wire repeatedly to make sure that speedometer pitot tube trim tab cavity vent...

Page 53: ...not fitted with a seacock seawater inlet hose must remain disconnected and plugged to prevent water from flowing into cooling system and or boat As a precautionary measure attach a tag to the ignitio...

Page 54: ...g Removed e Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained NOTE It may be necessary to lift bend or lower hoses to allow water to drain completely...

Page 55: ...estarted to prevent water from flowing back into cooling system If boat is not fitted with a seacock seawater inlet hose must remain disconnected and plugged to prevent water from flowing into cooling...

Page 56: ...ine layup 5 For drive unit refer to appropriate stern drive manual CAUTION When installing battery in next step be sure to connect positive battery cable to positive ter minal and negative grounded ba...

Page 57: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 1B 40 MAINTENANCE 90 823225 1 1096...

Page 58: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE MAINTENANCE 1B 41 90 823225 1 1096...

Page 59: ...C 1 IMPORTANT INFORMATION TROUBLESHOOTING...

Page 60: ...k Over 1C 11 Charging System Inoperative 1C 11 Noisy Alternator 1C 11 Page Instrumentation Malfunction 1C 12 Radio Noise 1C 12 Poor Fuel Economy 1C 13 Carburetor Malfunctions 1C 14 Engine Runs Poorly...

Page 61: ...ON TAPE Thread brass fitting or plug into fuel pump or fuel filter base until finger tight Tighten fitting or plug an additional 1 3 4 to 2 1 4 turns using a wrench DO NOT OVER TIGHTEN Install fuel li...

Page 62: ...Plug Analysis Normal Condition Few deposits are present and probably will be light tan or gray in color This plug shows that plug heat range is compatible with engine and engine is elec trically and m...

Page 63: ...timing cooling system malfunction lean fuel air mixtures leaking intake manifold or sticking valves Replace spark plugs 72421 High Speed Glazing Insulator has yellowish varnish like color indicating t...

Page 64: ...everse primary coil leads Replace spark plugs 72422 Splashed Deposits Spotted deposits which sometimes occur after long delayed tune up accumulate after a long period of misfiring When normal combusti...

Page 65: ...Propeller pitch too great B hi h C Dirty boat bottom marine growth Bow too high D Poor running engine Bow too high E Improper weight distribution F Rocker in boat bottom G False bottom full of water...

Page 66: ...ocated too close to propeller and or too deep in the water ventilation Drive installed too high on transom wrong gear ratio Operation Unit trimmed out too far Engine coupler slipping Unit trimmed out...

Page 67: ...spark while cranking engine over Repeat procedure with spark plug wires If there is spark at the spark plug wires re move the spark plugs and make sure they are correct type and heat range and not fo...

Page 68: ...k at Coil No Spark at Coil Spark at Coil 1 to 12 Volts 0 Volts 0 Volts Voltage Unplug WHT RED bullet con nector from Dist Term then Check for Voltage on This Lead Replace Ignition Sensor in Distributo...

Page 69: ...New Ignition Coil Check Engine and Instrument Wiring Harness Battery Cables Key Switch With Key in RUN Position Check for 12 Volts at Positive Terminal on Ignition Coil Unplug WHT RED bullet connecto...

Page 70: ...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 S...

Page 71: ...ion 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...

Page 72: ...l 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 ignition components High pitched whine in the r...

Page 73: ...t 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 C...

Page 74: ...idl B Idle mixture screws R h idl C Idle passages dirty Rough idle D Throttle valves not closing E Engine flooding F Vacuum leak G Throttle body heat passages plugged H i i l i fl A Accelerator pump...

Page 75: ...ow top speed or lack of power B Float adjustment Low top speed or lack of power C Main metering jets D Leaking gaskets P ld i i A Idle RPM too low P ld i i B Idle mixture screws Poor cold engine opera...

Page 76: ...upply Plugged fuel tank vent Fuel supply Refer to Carburetor Malfunctions See Table of Contents Ignition timing Low grade of fuel or water in the fuel Spark plugs Fouled burned cracked porcelain incor...

Page 77: ...at 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 readin...

Page 78: ...h components are at fault 5 Sometimes noises can be caused by moving parts coming in contact with other components Examples are flywheel or coupler exhaust flappers rattling against exhaust pipe crank...

Page 79: ...ible Causes C h f f f i i d h lf Crankshaft timing sprocket C h ft f t f i ti d t h lf Timing chain Camshaft area front of engine timed to one half engine speed Fuel Pump engine speed Valve Lifter Cam...

Page 80: ...riking pan or pan baffle Crankshaft area center of engine timed to engine speed Main bearing engine speed Rod bearing C k h f f i i d Loose flywheel cover Crankshaft area rear of engine timed to Loose...

Page 81: ...Vacuum leak Valve adjustment Valve timing Burned or stuck valve Hi i Vacuum leak Hissing Leaking exhaust manifolds or pipes Hissing Loose cylinder heads Blown head gasket Whistle Vacuum leak Whistle D...

Page 82: ...air temperature warms up and engine is running at normal opening temperature it is normal for oil pressure to drop Low engine oil pressure at idle With modern engines and engine oils low oil pressure...

Page 83: ...ling 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 exter...

Page 84: ...valve guides Defective oil cooler if so equipped Crack in cooler tubes Defective piston rings Glazed scuffed worn stuck improperly installed ring grooves worn improper break in wrong end gap Defectiv...

Page 85: ...ead gasket If the water is contained to crankcase only it is usual ly caused by a cracked or porous block a flooded bilge or condensation If the water is located in both the cylinder s and the crankca...

Page 86: ...iming Timing too far advanced or retarded Sticking distributor advance weights Spark plug wires crossed wrong firing order Lean fuel mixture Refer to Carburetor Malfunctions in this section Wrong heat...

Page 87: ...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 E...

Page 88: ...perly installed sea strainer Loose hose connections between seawater pickup and seawater pump inlet Pump will suck air pump may fail to prime or will force air bubbles into cooling system Seawater inl...

Page 89: ...helm Cable or helm partially frozen from rust or corrosion cable over lubricated improper cable installation Binding in stern drive unit Refer to appropriate Stern Drive Service Manual Restriction in...

Page 90: ...ssages Stop nut adjusted improperly Refer to appropriate Stern Drive Service Manual Steering cables installed that do not meet BIA standards Refer to appropriate Stern Drive Service Manual Fluid Leaks...

Page 91: ...ck that black wire in terminal block is grounded to engine b Brown wire in terminal block must have bat tery voltage when mode switch is held in THRU TRANSOM position If not wiring is faulty If voltag...

Page 92: ...A 2 72975 REMOVAL AND INSTALLATION MCM MODELS ALPHA ONE DRIVES...

Page 93: ...E DRIVES 90 823225 1 1096 Table of Contents Page Torque Specification 2A 1 Tools Lubricants Adhesives Sealants 2A 1 Removal 2A 2 Engine Removal 2A 2 Installation 2A 3 Engine Installation Alignment 2A...

Page 94: ...urn Tools Lubricants Adhesives Sealants Part Number Description 91 805475 A1 Quicksilver Engine Alignment Tool 91 816391 A4 Quicksilver Engine Coupler Spline Grease 92 25711 2 Quicksilver Liquid Neopr...

Page 95: ...a Straps retaining them to engine or hoses 6 Slide sleeves back on BLACK and WHITE GREEN or gray wires and disconnect engine harness wires from shift cut out switch harness 7 Disconnect MerCathode wir...

Page 96: ...ents or damage will occur 2 Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when sus pended Refer to Removal section for loca tion of lifting eyes 3 Lift engine in...

Page 97: ...d into engine coupler splines If it will not insert easily proceed to following b While observing the above precautions CAREFULLY raise and lower front of engine with hoist as required until tool will...

Page 98: ...Tighten all exhaust system hose clamps securely as follows use two hose clamps on each connection 72537 b a a Typical a Hose Clamps Tighten Securely b Exhaust Tube Long Tube Port Side Short Tube Starb...

Page 99: ...ine from fuel tank s to engine Make certain connections are secure Check for leaks 5 Connect throttle cable using hardware retained and adjust as follows a Place remote control handle s in neutral idl...

Page 100: ...ion Check to ensure that throttle shutters valves are completely open and throttle shaft lever con tacts carburetor body casting THROTTLE BODY FUEL INJECTION 71711 a b c a Flat Washer and Locknut Tigh...

Page 101: ...hode wires to MerCathode con troller assembly as shown if so equipped Apply a thin coat of Quicksilver Liquid Neoprene to all connections 22232 b c d a a ORANGE Wire From Electrode on Transom Assembly...

Page 102: ...ead or over tighten fittings Earlier Style Control Valve Torque large fitting to 20 25 lb ft 27 34 N m and small fitting to 96 108 lb in 11 12 N m 72026 b a a Large Fitting b Small Fitting Later Style...

Page 103: ...B 2 70246 REMOVAL AND INSTALLATION MCM MODELS ALPHA ONE DRIVES WITH DRIVESHAFT EXTENSION...

Page 104: ...AFT EXTENSIONS 90 823225 1 1096 Table of Contents Page Torque Specification 2B 1 Tools Lubricants Adhesives Sealants 2B 1 Removal 2B 2 Engine Removal 2B 2 Installation 2B 4 Engine Installation Alignme...

Page 105: ...mote Control Shif C bl Cable Barrel Securely Shift Cables Cable End Guide See Note Remote Control Th l C bl Cable Barrel Securely Throttle Cable Cable End Guide See Note NOTE Tighten then back nut off...

Page 106: ...e fitting disconnect and suitably plug fuel line to prevent fuel in tank from leaking into bilge 4 Disconnect throttle cable from carburetor and re tain locknuts and hardware 5 Disconnect bullet conne...

Page 107: ...at housing is used for engine alignment only DO NOT use to lift entire engine CAUTION DO NOT allow lifting sling to hook or compress engine components or damage will occur IMPORTANT To avoid the need...

Page 108: ...drive shaft flanges are engaged in in put shaft and output shaft flanges Flanges MUST BE flush to each other prior to tightening screws or screws may come loose during opera tion CAUTION Failure to al...

Page 109: ...spe cified 70246 b a These Dimensions Must Be Equal 8 After engine has been aligned correctly fasten front and rear engine mounts to stringers Tighten mounting bolts securely 9 Apply Loctite 8831 to t...

Page 110: ...g chart Reading from Step 1 __________ degrees to the _________ side of reference mark IMPORTANT Be sure that boat does not move once reading has been taken from input shaft flange as this reading est...

Page 111: ...ight so that the stringers just contact the engine mount bases CAUTION Failure to properly position output shaft flange as described following may result in bearing damage 8 Relieve hoist tension from...

Page 112: ...corded in Step 1 72593 a Flywheel Housing b Starter Housing Cover Plate c Protractor Thru Prop Exhaust Shown b c a 12 Position protractor on drive shaft and recheck angle Angle should be the same as t...

Page 113: ...Nut 3 8 16 4 Used e Screws 3 Used Hidden in This View Use Loctite 271 c d a e b 15 Proceed to Engine Connections section in structions following Engine Connections IMPORTANT When routing all wire harn...

Page 114: ...on to threads of brass fitting or plug DO NOT USE TEFLON TAPE Thread brass fitting or plug into fuel pump or fuel filter base until finger tight Tighten fitting or plug an additional 1 3 4 to 2 1 4 tu...

Page 115: ...b Attaching Hardware DO NOT Over Tighten c Cable Barrel d Anchor Studs b d a c d b b d Place remote control throttle lever in the wide open throttle W O T position Check to ensure that throttle shutt...

Page 116: ...Position b a 70392 a Throttle Lever Contacts b in Idle Position b Idle Speed Adjustment Screw Idle Position b a b c d e f g h a 74109 Throttle Body Fuel Injection a Cable End Guide b Throttle Lever S...

Page 117: ...tud d Cable Barrel 7 Secure throttle cable with hardware as shown and tighten securely NOTE If Boat is equipped with Quicksilver Zero Ef fort Controls the throttle cable mounting stud must be most for...

Page 118: ...e installation in the following bleed power steering system as out lined in appropriate Stern Drive Service Manual CAUTION Route hoses exactly as shown below This will help avoid stress on the hose fi...

Page 119: ...nsom Exhaust NOTICE THRU TRANSOM EXHAUST Exhaust hoses must be connected to ex haust elbows so that they do not restrict the flow of discharge water from exhaust elbow If hoses are connected incorrect...

Page 120: ...2 72580 C REMOVAL AND INSTALLATION MCM MODELS BRAVO DRIVES...

Page 121: ...e of Contents Page Torque Specifications 2C 1 Tools Lubricants Adhesives Sealants 2C 1 Removal 2C 2 Engine Removal 2C 2 Installation 2C 3 Engine Installation Alignment 2C 3 Engine Connections 2C 6 Fue...

Page 122: ...ne half turn Tools Lubricants Adhesives Sealants DESCRIPTION PART NUMBER Engine Alignment Tool 91 805475A1 Engine Coupler Spline Grease 91 816391A4 Liquid Neoprene 92 27511 2 Loctite Pipe Sealant With...

Page 123: ...wires are disconnected be sure to loos en them from clamps or sta straps retaining them to engine or hoses 6 Disconnect MerCathode wires from MerCathode controller if mounted on engine some models 7...

Page 124: ...use to lift entire engine CAUTION DO NOT allow lifting sling to hook or compress engine components or damage will occur 2 Attach a suitable sling to lifting eyes on engine and adjust so that engine i...

Page 125: ...engine with alignment tool inserted or partially inserted in gimbal bearing or engine coupler 7 Align engine as follows a Attempt to insert solid end of Quicksilver Alignment Tool through gimbal bear...

Page 126: ...just front mounts g When alignment is correct tighten locknut or nut with lockwasher on each mount securely h Bend tab washer down against flat on adjust ing nut 72922 b c d a e a Locknut b Adjustment...

Page 127: ...from engine harness 72582 b c d a a BROWN WHITE From Engine Harness b BLACK From Engine Harness c BLACK From Transom d BLACK From Transom Assembly WARNING Be careful when working on fuel system Gaso...

Page 128: ...prevent over tightening hold brass fitting with suitable wrench and tighten fuel line connectors securely Check for fuel leaks 6 Connect fuel line from fuel tank s to engine Make certain connections a...

Page 129: ...the wide open throttle W O T position Check to ensure that throttle shutters valves are completely open and throttle shaft lever con tacts carburetor body casting e Return remote control throttle lev...

Page 130: ...Remove flame arrestor 3 Install cable end guide on throttle lever then push cable barrel end lightly toward throttle lever end This will place a slight preload on shift cable to avoid slack in cable...

Page 131: ...ward position on throttle lever 73855 a a Position for Zero Effort Controls 5 Place remote control throttle level in the wide open throttle W O T position Check to ensure that throttle plates are comp...

Page 132: ...TANT Make hydraulic connections as quickly as possible to prevent fluid leakage IMPORTANT Be careful not to cross thread or over tighten fittings 10 Connect both hydraulic hose fittings a Earlier Styl...

Page 133: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 2C 12 INSTALLATION BRAVO DRIVES 90 823225 1 1096...

Page 134: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE INSTALLATION BRAVO DRIVES 2C 13 90 823225 1 1096...

Page 135: ...D 2 70246 REMOVAL AND INSTALLATION MCM MODELS BRAVO DRIVES WITH DRIVESHAFT EXTENSION...

Page 136: ...NSIONS 90 823225 1 1096 Table of Contents Page Torque Specification 2D 1 Tools Lubricants Adhesives Sealants 2D 1 Removal 2D 2 Engine Removal 2D 2 Installation 2D 4 Engine Installation Alignment 2D 4...

Page 137: ...54 Remote Control Shif C bl Cable Barrel Securely Shift Cables Cable End Guide See Note Remote Control Th l C bl Cable Barrel Securely Throttle Cable Cable End Guide See Note NOTE Tighten then back n...

Page 138: ...wrench to stabilize brass coupling at fuel filter 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...

Page 139: ...ermostat housing is used for engine alignment only DO NOT use to lift entire engine CAUTION DO NOT allow lifting sling to hook or compress engine components or damage will occur IMPORTANT To avoid the...

Page 140: ...E SURE that the pilot on drive shaft flanges are engaged in in put shaft and output shaft flanges Flanges MUST BE flush to each other prior to tightening screws or screws may come loose during opera t...

Page 141: ...e as spe cified 70246 These Dimensions Must Be Equal b a 8 After engine has been aligned correctly fasten front and rear engine mounts to stringers Tighten mounting bolts securely 9 Apply Loctite 8831...

Page 142: ...Be sure that boat does not move once reading has been taken from input shaft flange as this reading establishes a reference point for aligning drive shaft and engine follow ing If boat is moved refer...

Page 143: ...just contact the engine mount bases CAUTION Failure to properly position output shaft flange as described following may result in bearing damage 8 Relieve hoist tension from engine then slide en gine...

Page 144: ...o that protrac tor needle reads exactly the same number of de grees as that recorded in Step 1 72593 a Flywheel Housing b Starter Housing Cover Plate c Protractor Thru Prop Exhaust Shown b c a 12 Posi...

Page 145: ...t 3 8 16 4 Used e Screws 3 Used Hidden in This View Use Loctite 271 c d a e b 15 Proceed to Engine Connections section in structions following Engine Connections IMPORTANT When routing all wire harnes...

Page 146: ...ER TIGHTEN Install fuel line To prevent over tightening hold brass fitting with suitable wrench and tighten fuel line connectors securely Check for fuel leaks 4 Connect fuel line from fuel tank s to e...

Page 147: ...ottle lever in the wide open throttle W O T position Check to ensure that throttle shutters valves are completely open and throttle shaft lever con tacts carburetor body casting e Return remote contro...

Page 148: ...le posi tion 2 Remove flame arrestor 3 Install cable end guide on throttle lever then push cable barrel end lightly toward throttle lever end This will place a slight preload on shift cable to avoid s...

Page 149: ...be most forward position on throttle lever 73855 a a Position for Zero Effort Controls 5 Connect any grounding wires or accessories that may have been disconnected 6 Models with MerCathode Connect wi...

Page 150: ...he large fitting to 23 lb ft 31 N m Torque the small fitting to 100 lb in 11 N m 22023 a b a Small Fitting b Large Fitting b Later Style Control Valve Torque both fit tings to 23 lb ft 31 N m Route ho...

Page 151: ...ter 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 Clamps Not Shown 11 Connect...

Page 152: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 2D 16 MCM MODELS BRAVO MODELS WITH DRIVE SHAFT EXTENSIONS 90 823225 1 1096...

Page 153: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE MCM MODELS BRAVO MODELS WITH DRIVE SHAFT EXTENSIONS 2D 17 90 823225 1 1096...

Page 154: ...E 2 70648 REMOVAL AND INSTALLATION MIE MODELS VELVET DRIVE TRANSMISSIONS...

Page 155: ...Specifications 2E 1 Lubricants Sealants 2E 1 Removal 2E 2 Engine Removal 2E 2 Installation 2E 3 Engine Installation and Initial Alignment 2E 3 Engine Final Alignment 2E 4 Engine Connections 2E 6 Fuel...

Page 156: ...rely Hose Clamps Mount Locking Nut Propeller Shaft Coupler to Transmission Output Flange 50 68 Remote Control Shift Cable Cable Barrel Cable End Guide Note 1 Securely Note 1 Trunnion Clamping Screw Nu...

Page 157: ...event fuel in tank from leak ing into bilge 4 Disconnect throttle cable from carburetor and re tain locknuts and hardware 5 Disconnect shift cable from transmission 6 Disconnect seawater inlet hose fr...

Page 158: ...ustment and establish a uniform height on all mounts Ensure that all mounts are 1 In the center of their up and down adjust ment 2 Mounting hole which is a slot is forward if so designed 350 Magnum To...

Page 159: ...ts to en gine bed with appropriate bolts or lag screws and hardware Tighten lag bolts screws securely 5 Disconnect and remove sling Proceed to En gine Final Alignment section following Engine Final Al...

Page 160: ...0 07 mm out of parallel adjust engine mounts as follows a TO ADJUST ENGINE UP OR DOWN Loos en locking nut on mounts requiring adjust ment and turn both front mount or rear mount adjusting nuts equall...

Page 161: ...ch couplers together with bolts lockwashers and nuts Torque to 50 lb ft 68 N m NOTE If propeller shaft coupler has setscrews the shaft should be dimpled at setscrew locations Set screws should be safe...

Page 162: ...uel Supply Connections WARNING Avoid gasoline fire or explosion Improper instal lation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and or cause a fuel leak Apply 59...

Page 163: ...such a way as to avoid sharp bends and or contact with moving parts DO NOT fasten any items to shift cables NOTE On models with other than Quicksilver shift cables refer to shift cable manufacturer s...

Page 164: ...sharp bends and or contact with moving parts DO NOT fasten any items to shift cables a Place remote control shift lever and transmis sion shift lever in neutral position b Remove nuts and washers from...

Page 165: ...ission shift lever will position proper ly in one gear but not in the other recheck shift cable adjustment If transmission shift le ver will not position properly in both gears move transmission shift...

Page 166: ...le cables referring to cable man ufacturer s instructions b On Models Equipped with Quicksilver Throttle Cables Connect and adjust throttle cable s as outlined following 1 Place remote control throttl...

Page 167: ...Cable Barrel f Anchor Stud g Washer h Washer and Locknut 22553 d c b a e h f g Dual Station 4 Place remote control throttle lever s in the wide open throttle W O T position Check to ensure that thrott...

Page 168: ...y cables to battery by FIRST con necting positive battery cable end to positive battery terminal Tighten clamp securely Then connect negative battery cable end to negative battery terminal Tighten cla...

Page 169: ...throttle lever stud following cable manufacturer s instructions 2 After throttle cable is adjusted tighten locknut against cable end a 74838 c b a Cable End b Throttle Lever Stud c Locknut ROUTING OF...

Page 170: ...to slip and eventually fail 3 Attach cable clip to bracket using screws lock washers and nuts Use center holes in cable clip 4 Remove top transmission mounting bolt and lockwasher from left valve side...

Page 171: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 2E 16 MIE MODELS VELVET DRIVE TRANSMISSIONS 90 823225 1 1096...

Page 172: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE MIE MODELS VELVET DRIVE TRANSMISSIONS 2E 17 90 823325 1 1096...

Page 173: ...F 2 25280 REMOVAL AND INSTALLATION MIE MODELS HURTH TRANSMISSIONS...

Page 174: ...able of Contents Page Torque Specifications 2F 1 Lubricants Sealants 2F 1 Removal 2F 2 Engine Removal 2F 2 Installation 2F 3 Engine Installation and Initial Alignment 2F 3 Engine Final Alignment 2F 4...

Page 175: ...Hose Clamps Mount Locking Nut Propeller Shaft Coupler to Transmission Output Flange 50 68 Remote Control Shift Cable Cable Barrel Cable End Guide Note 1 Securely Note 1 Trunnion Clamping Screw Nut 50...

Page 176: ...in tank from leaking into bilge 4 Disconnect throttle cable from carburetor and re tain locknuts and hardware 5 Disconnect shift cable from transmission 6 Disconnect seawater inlet hose from engine 7...

Page 177: ...the following to center mount ad justment and establish a uniform height on all mounts Ensure that all mounts are 1 In the center of their up and down adjust ment 2 Mounting hole which is a slot is fo...

Page 178: ...l positioned properly then fasten mounts to en gine bed with appropriate bolts or lag screws and hardware Tighten lag bolts screws securely 5 Disconnect and remove sling Proceed to En gine Final Align...

Page 179: ...Feeler Gauge Check at 90 Degree Intervals b Transmission Output Flange c Propeller Shaft Coupler b 5 If coupling centerlines are not aligned or if cou pling faces are more than 003 in 0 07 mm out of...

Page 180: ...eter of mount trunnion MUST NOT extend over 3 4 in 20 mm from mount brackets on any of the mounts 70057 a Torque Clamping Screws and Nuts on All Four Mount Brackets to 50 Lb Ft 68 N m b Tighten Lockin...

Page 181: ...l fuel line To prevent over tightening hold brass fitting with suitable wrench and tighten fuel line connectors securely Check for fuel leaks WARNING Be careful when working on fuel system Gaso line i...

Page 182: ...n direction A when remote con trol handle is placed in forward position 23242 a Be certain anchor stud is installed in the hole appropriate for your transmission refer to Transmission Identification P...

Page 183: ...follows 1 Hold shift lever in position 2 Carefully slide shift cable off of anchor points 3 Attempt to move shift lever further h Place remote control shift lever in reverse gear position and again c...

Page 184: ...proach 50073 a Cable End Guide b Locknut and Washer c Spacer d Bushings e Cable Barrel b d a c Typical Hurth Transmission Shown DUAL STATION INSTALLATIONS 72960 e d b c b a Rear Approach 72956 a e d b...

Page 185: ...e remote control throttle lever s in idle position 2 Install cable end guide on carburetor throttle lever stud as shown Push cable barrel lightly toward throttle lever This will place a slight preload...

Page 186: ...ottle Lever Contacts b In Idle Position b Idle Speed Adjustment Screw Idle Position Shown b c d e f g h a 74109 Throttle Body Injection a Cable End Guide b Throttle Lever Stud c Locknut and Flat Washe...

Page 187: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE MIE MODELS HURTH TRANSMISSION 2F 13 90 823225 1 1096...

Page 188: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 2F 14 MIE MODELS HURTH TRANSMISSION 90 823225 1 1096...

Page 189: ...A 3 72615 ENGINE 5 0L 305 CID 5 7L 350 CID...

Page 190: ...Removal 3A 30 Cleaning and Inspection 3A 30 Installation 3A 30 Valve Stem Oil Seal Valve Spring 3A 30 Removal Head Installed 3A 30 Valve Assembly Exploded View 3A 32 Page Installation Head Installed 3...

Page 191: ...Gears 3A 64 Removal 3A 64 Cleaning and Inspection 3A 64 Installation Timing Gears Opposite Rotation Engine 3A 65 Page Installation Timing Chain Standard Rotation Engine 3A 65 Crankshaft Sprocket Gear...

Page 192: ...3A 0 ENGINES 90 823225 1 1096...

Page 193: ...s An Additional 55 Degrees 20 27 Coupler Flywheel MCM 35 48 Crankshaft Pulley 35 48 Cylinder Head Bolt 65 88 Cylinder Head Bolt Gen First Sequence A l T S d S Sh t B lt 22 30 Angle Torque Second Seque...

Page 194: ...mp Brace to Block 30 41 Power Steering Pump Bracket 30 41 Rear Crankshaft Oil Seal Retainer Screws and Nuts 133 15 Rear Mount MCM 40 54 Rear Mount MIE 50 68 Remote Oil Connector 1 2 in x 13 25 34 Remo...

Page 195: ...802 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 J393...

Page 196: ...s DESCRIPTION PART NUMBER Quicksilver Loctite 8831 92 823089 1 Quicksilver Perfect Seal 92 34227 1 Quicksilver Needle Bearing Assembly Lubricant 92 825265A1 Quicksilver RTV Sealer 92 91601 1 General M...

Page 197: ...Forged Steel Crankshaft Cast Iron Pistons Cast Aluminum Camshaft Cast Iron Fuel Pump Push Rod Steel Engine Model MCM MIE 5 7L 350 CID Alpha and Bravo Displacement 350 CID 5 7 Litre Bore 4 00 101 6 St...

Page 198: ...1 Heads Cast Iron Intake Manifold Cast Aluminum Block Cast Iron 2 Bolt Main Bearing Caps Rods Forged Steel Crankshaft Cast Iron Pistons Cast Aluminum Camshaft Steel Roller Cam Cast Iron Flat Tappet F...

Page 199: ...43 Max Service 0027 0 07 Max PISTON RING COMPRESSION G Cl Production Top 0012 0032 0 030 0 081 Groove Clearance Production 2nd 0012 0032 0 030 0 081 Service High Limit Production 001 0 025 G Productio...

Page 200: ...M i B i P d i No 1 0008 0020 0 020 0 050 M i B i Production No 2 3 0011 0023 0 027 0 058 Main Bearing C No 4 0017 0032 0 043 0 081 g Clearance S i No 1 0010 0015 0 025 0 038 Service No 2 3 0010 0025 0...

Page 201: ...Turn Down from Zero Lash Face Angle Intake 45 Face Angle Exhaust 45 Seat Angle Intake Exhaust 46 Seat Runout Intake Exhaust 002 0 05 Max Seat Width Intake 03215 0625 0 79 1 58 Seat Width Exhaust 0625...

Page 202: ...d Height Intake 1 7 1 45 64 43 Damper Free Length 1 86 1 55 64 47 Damper Approximate Number of Coils 4 NOTE 1 Engines are equipped either roller hydraulic 5 7L 350 CID engines only or flat hydraulic d...

Page 203: ...68 Max PISTON RING COMPRESSION G Cl Production Top 0012 0032 0 030 0 081 Groove Clearance Production 2nd 0012 0032 0 030 0 081 Service High Limit Production 001 0 025 G Production Top 010 020 0 25 0 5...

Page 204: ...0 053 M i B i Production No 2 3 4 0022 00610 0 0009 0 0024 Main Bearing C No 5 00250 00690 0 0010 0 0027 g Clearance S i No 1 0010 0 0020 0 250 0 510 Service No 2 3 4 0010 0025 0 0250 0 0640 No 5 0025...

Page 205: ...6 Seat Runout Intake Exhaust 002 0 05 Max Seat Width Intake 040 0625 1 02 1 65 Seat Width Exhaust 065 098 1 65 2 49 S Production Intake 0010 0027 0 025 0 069 Stem Cl Production Exhaust 0010 0027 0 025...

Page 206: ...02 0 051 Intake 287 7 289 Duration at 050 In 1 27mm C f Exhaust 294 7 467 Cam Lift Intake 307 7 797 Journal Diameter 1 8682 1 8692 47 440 47 490 End Play 011 0 030 0 004 0 0012 Timing Chain Deflection...

Page 207: ...al 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 deter mining the engine models Following is a l...

Page 208: ...tation When ordering replacement engines short blocks or parts for engines be certain to check engine rotation Do not rely on propeller rotation in determining en gine rotation 72001 a Left Hand Rotat...

Page 209: ...tend valve life Hydraulic valve lifters ride directly on the camshaft lobes and transmit the thrust of the lobes to the push rods which in turn actuate the valves through the rocker arm In addition to...

Page 210: ...to the connecting rod bearings through grooves in the upper half of the crankshaft main bearings and oil passages in the crankshaft Oil which is forced out the ends of the connecting rod bearings and...

Page 211: ...verlay Gone from Entire Surface 70436 Scratched by Dirt Lack of Oil Improper Seating Tapered Journal Radius Ride Fatigue Failure Scratches Overlay Wiped Out Dirt Imbedded into Bearing Material Bright...

Page 212: ...rature 72424 Pre Ignition Damage PRE IGNITION CAUSES 1 Hot spots in the combustion chamber from glow ing deposits due in turn to the use of improper oils and or fuels 2 Overheated spark plug electrode...

Page 213: ...neglected OTHER CAUSES OF DETONATION IMPORTANT Use of improper fuels will cause en gine damage and poor performance 1 Over advanced ignition timing 2 Lean fuel mixture at or near full throttle could b...

Page 214: ...Housing MCM a Gasket Used on MCM Engines Only 72319 Some Models b c a Rear Mount Front Mount Front and Rear Mounts and Transmission Base Assembly MIE 5 7L 5 7L Competition Ski 350 Magnum Tournament S...

Page 215: ...ansmission a Transmission Base Assembly 350 Magnum Tournament Ski Only b Rubber Insert Cannot Be Removed 72321 Front and Rear Mounts and Transmission Base Assembly MIE 5 7L with V Drive Transmission 7...

Page 216: ...es from rocker arm covers 5 Disconnect throttle cable from carburetor Re move fuel line and sight tube running between fuel pump and carburetor 6 Remove distributor cap and mark position of rotor on d...

Page 217: ...has an opening for the ex haust crossover port in the intake manifold Without this opening the automatic carbu retor choke will not operate properly The choke will remain ON longer causing rough engin...

Page 218: ...unit with Quicksilver Perfect Seal and install 12 Connect any other items which were discon nected from manifold during removal 13 Start engine Adjust ignition timing and carbure tor Check hose connec...

Page 219: ...rocker arm covers as outlined 2 Remove rocker arm assemblies and push rods IMPORTANT Place rocker arm assemblies and push rods in a rack for reassembly in their origi nal locations Cleaning and Inspec...

Page 220: ...tion the following valves may be adjusted as previously outlined 7 MCM and MIE Left hand Standard Rotation Engines Exhaust 2 5 6 7 Intake 3 4 6 8 MIE Right Hand Opposite Rotation En gines Exhaust 3 4...

Page 221: ...ing 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 li...

Page 222: ...nspect camshaft lobe If push rod seat is scuffed or worn inspect push rod Installation IMPORTANT It is recommended that the engine oil be changed and a new oil filter be installed whenever servicing v...

Page 223: ...ile valve springs retainers and locks are removed or valves will fall into cylinder 3 Using valve spring compressor as shown com press valve spring and remove valve locks 72306 a Valve Spring Compress...

Page 224: ...s not twisted A light coating of oil will help prevent twisting 5 Install valve locks Quicksilver Needle Bearing Assembly Lubricant may be used to hold them in place and slowly release tool making sur...

Page 225: ...l finger tight a All Engines Except Gen Torque head bolts in three steps following torque se quence for each step Start first step at 20 lb ft 27 N m second step at 40 lb ft 54 N m and finish with a f...

Page 226: ...ng 1 Clean push rods and rocker arm assemblies 2 Clean carbon from valves using a wire wheel 3 Clean gasket material from cylinder head mating surfaces 4 Clean all carbon from combustion chambers and...

Page 227: ...clearance will result in noisy and sticky valves 4 Measure valve stem clearance as follows a Attach a dial indicator to cylinder head posi tioning it against the valve stem and close to the valve gui...

Page 228: ...er at top of valve guide Valve Springs Checking Tension Using valve spring tester as shown check valve spring tension with dampers removed Refer to Specifications IMPORTANT Springs should be replaced...

Page 229: ...l Nut Bottoms Out on Stud Threads Then Remove Nut Using Rocker Arm Stud Remover J 5802 01 b a 72310 a Nut b Small Sleeve c Large Sleeve b c a 5 Ream stud hole whenever installing an oversize stud usin...

Page 230: ...which is warped exces sively is refaced a knife edge will be ground on part or all of the valve head due to the amount of metal that must be removed to completely reface Knife edges lead to breakage b...

Page 231: ...light coating of oil will help prevent twisting 72333 a Valve Spring Compressor J 8062 a 7 Install valve locks grease may be used to hold them in place and slowly release tool making sure locks seat...

Page 232: ...n scale Measure from spring seat to top of valve spring as shown If measurement exceeds specified height install a valve spring shim and recheck DO NOT shim valve springs to give an installed height l...

Page 233: ...Pans 1 2 13 1 2 13 1 2 13 1 2 13 31 787 13 29 32 353 32 814 33 1 2 849 14 25 32 375 16 1 4 413 33 1 4 845 15 19 32 396 3 4 19 15 16 24 3 4 19 FULL FULL FULL FULL ADD ADD ADD ADD 23 32 18 15297 MCM All...

Page 234: ...ilver RTV Sealer to joints of rear seal retainer and joints of front cover IMPORTANT Quicksilver RTV Sealer sets up in about 15 minutes Be sure to complete assembly promptly 72343 a Joints of Rear Sea...

Page 235: ...tighten tube at banjo fitting until after tube has been secured at manifold c Install plug in banjo fitting d Tighten all connections on banjo fitting at this time Torque banjo fitting bolt to 180 lb...

Page 236: ...ce gas ket for the oil pan may be reused if still pliable and not cracked torn etc 3 Remove baffle 72344 b a c a Nuts 5 b Baffle c Oil Pump 4 Remove oil pump Disassembly 1 Remove pump cover IMPORTANT...

Page 237: ...screen and pipe assembly was removed mount pump in a soft jawed vise apply Quicksilver Perfect Seal to end of new pipe and using oil pump suction pipe installer J 21882 tap the pipe in place with a h...

Page 238: ...tia weight on the hub will destroy the tuning of the torsional damper 1 Replace key in crankshaft if it is damaged 2 Coat seal surface of torsional damper with en gine oil 3 Install torsional damper o...

Page 239: ...ent oil leak 73123 a Can Be Used on Any Rotation Engine b Seal Lip Toward Inside of Engine Front Seal WITHOUT Helical Grooves b a 73124 a MCM and MIE LH Rotation Engines c d a 73125 b MIE RH Rotation...

Page 240: ...th ap propriate tool as shown 72348 a Crankcase Front Cover Seal Installer J 35468 b Support to Prevent Distorting Cover b a 2 Coat both sides of front cover gasket with Quick silver Perfect Seal and...

Page 241: ...ha One Coupler NOTE Some earlier models did not have sealed steel hub coupler 72350 Bravo Coupler 72351 MIE Drive Plate 72352 Jack Shaft Coupler Inspection 1 Inspect splines in drive plate or coupler...

Page 242: ...75 lb ft 100 N m 3 Check flywheel runout as follows a Attach a dial indicator to engine block b Take readings around outer edge of flywheel Push in on flywheel to remove crankshaft end play c Maximum...

Page 243: ...c a Cleaning and Inspection Clean crankshaft seal running surface and seal re tainer IMPORTANT Correct rotation oil seal must be used to prevent oil leak 73126 a Can Be Used on Any Rotation Engine b S...

Page 244: ...eners with Loctite Pipe Sealant with Teflon 4 Install fasteners and torque to 133 lb in 15 N m 5 Install oil pan fasteners Torque 1 4 20 thd fas teners to 80 lb in 9 N m and 5 16 18 thd fas teners to...

Page 245: ...out of the boat and upside down so crankshaft will rest on the upper bearings and total clearance can be measured be tween lower bearing and journal To assure the proper seating of the crankshaft all...

Page 246: ...regularity of the bear ing or journal Be sure to measure the journal with a micrometer if the flattened gauging plastic indicates more than 001 in difference 6 If the bearing clearance is within speci...

Page 247: ...hole in crankshaft journal If such a tool is not available a cotter pin may be bent as shown to do the job 72622 a Main Bearing Remover Installer J 8080 b Cotter Pin a b 3 Rotate the crankshaft clockw...

Page 248: ...ls and crankpin clean of oil 4 Measure the crankpin for out of round or taper with a micrometer If not within specifications re place or recondition the crankshaft If within specifications and a new b...

Page 249: ...rque nuts to 45 Lb Ft 61 N m b Gen Torque nuts to 20 Lb Ft 27 N m 8 When all connecting rod bearings have been in stalled tap each rod lightly parallel to the crank pin to make sure they have clearanc...

Page 250: ...t slightly to disconnect and remove some connecting rod and piston assemblies 72364 a Connecting Rod Bolt Guide 3 8 24 J 5239 a Disassembly Disassemble piston from connecting rod using piston pin remo...

Page 251: ...oove to make sure that ring is free as shown If binding occurs at any point determine cause If caused by ring groove remove by dressing with a fine cut file If binding is caused by a distorted ring re...

Page 252: ...were re moved Connecting rod bearing tangs are always to ward outside of cylinder block 72368 a Rod Bearing Tangs a To determine if engine is left hand standard rotation or right hand opposite rotati...

Page 253: ...press ring down into cylinder bore about 1 4 in 6 mm below ring travel Be sure that ring is square with cylinder wall 3 Measure gap between ends of ring with a feeler gauge as shown 72372 4 If gap be...

Page 254: ...th connecting rod bolt guide Use a hammer handle with light blows to install piston into bore Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore IMPOR...

Page 255: ...ning and Inspection 1 Wash crankshaft in solvent and dry with com pressed air 2 Measure main bearing journals and crankpin di mensions with a micrometer for out of round ta per or undersize see Specif...

Page 256: ...pstick tube and oil pan e Spark plugs f Torsional damper and crankshaft pulley g Water pump h Belts i Flywheel and drive coupler plate j Flywheel housing k Starter 12 Install new oil filter Fill crank...

Page 257: ...procket Hold sprocket vertical with chain hanging down Align marks on camshaft and crankshaft sprockets IMPORTANT Do not attempt to drive sprocket on camshaft as welsh plug at rear of engine can be di...

Page 258: ...h on cam shaft gear Indicator stem should be as per pendicular to gear tooth surface as possible b Check the backlash between the camshaft gear and crankshaft gear while applying in ward pressure on c...

Page 259: ...ol on push rod Be sure that push rod is in lifter socket 72380 a Ball Socket Adaptor Tool J 8520 1 a 3 Rotate crankshaft torsional damper slowly in di rection of rotation until lifter is on heel of ca...

Page 260: ...ll fuel pump push rod and fuel pump 3 Install crankcase front cover and valve lifters as outlined Camshaft Bearings Removal Camshaft bearings can be replaced while engine is disassembled for overhaul...

Page 261: ...nter bearings must be positioned so that oil holes are at the 5 o clock position toward left side of block and at a position even with bottom of cylinder bore Rear bearing must be posi tioned so that...

Page 262: ...d inspect water passages in cylinder block 6 Inspect cylinder block for cracks in cylinder walls water jacket valve lifter bores and main bearing webs 7 Measure cylinder walls for taper out of round o...

Page 263: ...block is suitable for continued use except for out of round or tapered cylinders they can be conditioned by honing or boring 3 If cylinders have less than 005 in 0 127 mm ta per or wear they can be co...

Page 264: ...al 4 Permanently mark piston for cylinder to which it has been fitted and proceed to hone cylinders and fit remaining pistons IMPORTANT Handle pistons with care and do not attempt to force them throug...

Page 265: ...ssembly or remote oil filter parts 1 Remove oil filter on engines with block mounted filter or cylinder block adaptor on engines with remote oil filter and remove by pass valve and adaptor assembly 2...

Page 266: ...ELECTRICAL SYSTEMS STARTING SYSTEM A 72079 4...

Page 267: ...2 Maintenance 4A 13 Testing 4A 13 Storage 4A 13 Standard Starter Slave Solenoid 4A 14 Testing Replacement 4A 14 Page Starting System Components 4A 15 Positive Current Flow 4A 16 Description 4A 16 PG 2...

Page 268: ...ons could result in a fire or explosion hazard and should be avoided Battery IMPORTANT Terminals must be soldered to cable ends to ensure good electrical contact Use electrical grade resin flux solder...

Page 269: ...ction RED PUR Wire junction to wiring harness plug RED PUR terminal 6 Wiring harness plug to 20 amp fuse RED PUR 20 amp fuse to ignition switch terminal I RED PUR At this point ignition switch is turn...

Page 270: ...TEM 4A 3 90 823225 1 1096 Starting System Components 72930 B S I a b c e f g h d a Ignition Switch b 20 Amp Fuse c Starter Slave Solenoid d Circuit Breaker e Starter Motor f Wire Junction g Neutral Sa...

Page 271: ...4A 4 STARTING SYSTEM 90 823225 1 1096 Starter Motor Exploded View 1 2 3 4 5 6 7 8 9 10 11 25 29 30 31 32 33 34 26 12 15 16 19 28 27 13 14 17 18 22 23 20 21 24 72806...

Page 272: ...ft Lever Stud Washer 29 Shift Lever Stud Nut 30 Shift Lever Plunger 31 Plunger To Shift Lever Pin 32 Plunger Return Spring 33 Solenoid Switch Screw 34 Solenoid Switch Assembly Periodic Inspection Cran...

Page 273: ...tor connec tor strap terminal wire to remove terminal or wire will be too short 72632 b c d e f g h i a J a Solenoid Body b To Hold In Coil c Switch Terminal d Motor Connector Strap Terminal e To Pull...

Page 274: ...ould be cleaned and inspected Field coils should be removed only where defects are indicated by tests Defective parts should be replaced or repaired IMPORTANT DO NOT use grease dissolving sol vents fo...

Page 275: ...n growler and holding hack saw blade over armature core while ro tating armature If saw blade vibrates armature is shorted After cleaning between commutator bars recheck If saw blade still vibrates re...

Page 276: ...as outlined Reassembly After all parts are thoroughly tested and inspected and worn or damaged parts replaced reassemble starter as follows 1 Assemble brushes and related parts to field frame as follo...

Page 277: ...6 Install solenoid return spring on plunger 7 Position solenoid assembly to starter motor end frame and turn solenoid to engage flange in slot 8 Install and tighten securely screws which hold solenoid...

Page 278: ...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 measurement when c...

Page 279: ...25 0 45 mm PG 250 STARTER MOTOR Delco I D No Load Test I D Number Volts Min Amps Max Amps Min RPMS Max RPMS 9000789 10 6 60 95 2750 3250 Brush Spring Tension 83 104 oz 2353 2948 g Pinion Clearance 010...

Page 280: ...sure to adhere to the following When installing battery be sure to connect the positive battery cable to positive battery terminal first and then the negative battery cable to negative battery termin...

Page 281: ...225 1 1096 Standard Starter Slave Solenoid Testing Replacement 1 Using continuity meter connect test leads as shown and connect 12 volt battery with jumper leads as shown 72630 2 If no meter movement...

Page 282: ...15 90 823225 1 1096 Starting System Components 72929 B S I b c d e f g h a a ignition Switch b 20 Amp Fuse c Neutral Safety Switch d Ground Stud e Starter Motor f Circuit Breaker g Starter Slave Solen...

Page 283: ...D causing starter motor to crank Description The Permanent Magnet Gear Reduction PG200 and PG250 starter motors feature small permanent magnets mounted inside the field frame NOTE The actual configura...

Page 284: ...STARTING SYSTEM 4A 17 90 823225 1 1096 THIS PAGE IS INTENTIONALLY BLANK...

Page 285: ...4A 18 STARTING SYSTEM 90 823225 1 1096 PG 200 and PG 250 Starter Motor Exploded View 72079 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 17...

Page 286: ...aced Periodic Inspection Cranking motor and solenoid are completely en closed in the drive housing to prevent entrance of moisture and dirt However periodic inspection is re quired as follows 1 Inspec...

Page 287: ...emove thru bolts and separate field frame with armature from drive housing 72061 b c a a Field Frame Armature b Drive Housing c Thru Bolts 3 Pull armature out of field frame NOTE Permanent magnets ins...

Page 288: ...e a screwdriver as shown to disengage shift lever from drive 72064 a a Shift Lever 7 Remove thrust collar retaining ring and collar Remove drive 72067 b c d a a Thrust Collar b Retaining Ring c Collar...

Page 289: ...d undercut commu tator 4 Inspect all roller bearing surfaces for wear Check that bearings roll freely If any roughness is felt replace bearings 5 Inspect planetary gear assembly Gears must mesh easily...

Page 290: ...icate bearing and gear teeth with a small amount of Quicksilver 2 4 C Marine Lubricant with Teflon Shaft Assembly Bearing IMPORTANT Roller bearing is not replaceable If bearing is defective replace en...

Page 291: ...uides REMOVAL 1 Remove armature bearing as previously de scribed 2 Remove brush holder INSTALLATION 1 Push each brush up into its guide to allow spring to hold it in place as shown 72072 c a b a Brush...

Page 292: ...l pull armature in place 72062 a b a Brush Holder Lead b Notch 3 Coat roller bearings and gear with a small amount of Quicksilver 2 4 C Marine Lubricant with Teflon 72627 b c a a Roller Bearing b Roll...

Page 293: ...ollar and squeeze until snap ring is forced into retainer 72074 b c a a Retainer b Thrust Collar c Snap Ring 6 Apply a thin coating of Quicksilver 2 4 C Marine Lubricant with Teflon to roller bearing...

Page 294: ...er motor in position and install mount ing bolts Torque bolts to 30 lb ft 41 N m 2 Connect YELLOW RED wire to terminal S of so lenoid Connect ORANGE wire RED wire and battery cable to large terminal o...

Page 295: ...4A 28 STARTING SYSTEM 90 823225 1 1096 PG 260 Starter Motor Exploded View 1 2 3 4 5 6 7 8 9 10 11 12 13 15 17 18 19 20 21 74270 14 16...

Page 296: ...to prevent entrance of moisture and dirt However periodic inspection is re quired as follows 1 Inspect terminals for corrosion and loose con nections 2 Inspect wiring for frayed and worn insulation 3...

Page 297: ...e and end cap 74040 b a c a End Cap b Thru Bolts c Drive Housing 3 Remove brush holder from end cap 74037 b a c a Brush Holder b End Cap c Screws 2 4 Remove armature and field frame from drive housing...

Page 298: ...Screws 3 8 Remove drive and associated parts from drive housing a b 74035 a Drive Housing b Drive 9 Remove solenoid arm and rubber grommet from the drive housing 74048 74018 a b 74105 c a Rubber Gromm...

Page 299: ...Pinion should turn freely in over running direction and must not slip in cranking direction Check pinion teeth Check spring for tension and drive collar for wear Replace if necessary 2 Check that bru...

Page 300: ...till vibrates replace armature 01440 b c a a Hacksaw Blade b Armature Core c Growler TEST FOR GROUND 1 With continuity meter place one lead on arma ture core or shaft and other lead on commutator 2 If...

Page 301: ...h piece of coat hanger wire or similar stiff wire to retain the spring while installing armature as shown c a b d a Brush b Guide c Brush Spring d 3 Inch Piece Of Coat Hanger Or Stiff Wire 2 Place bru...

Page 302: ...c Brush Holder d Armature 2 Install gear and drive over planetary shaft 74087 b a c a Planetary Shaft b Gear c Drive 3 Assemble drive on shaft assembly as follows a Lubricate drive end of shaft assemb...

Page 303: ...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...

Page 304: ...ve housing a b 74038 a Shield b Washer 9 Install field frame over armature Align slot in end cap and field frame for proper positioning of rub ber grommet 10 Install field frame and end cap in drive h...

Page 305: ...cessive wear of solenoid linkage shift lever yoke or improper assembly of shift lever mechanism Replace worn or defective parts since no provision is made for adjusting pinion clearance 72077 b c a a...

Page 306: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE STARTING SYSTEM 4A 39 90 823225 1 1096...

Page 307: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 4A 40 STARTING SYSTEM 90 823225 1 1096...

Page 308: ...B 4 72722 90 823224 692 4B IGNITION SYSTEM ELECTRICAL SYSTEMS THUNDERBOLT IV AND V IGNITION SYSTEM...

Page 309: ...t IV Ignition Timing 4B 13 Thunderbolt V Ignition System 4B 14 Identification 4B 14 General Description 4B 15 Idle Speed Spark Control 4B 15 Acceleration Spark Advance 4B 15 Mean Best Timing MBT Spark...

Page 310: ...Guard Rules and Regulations to minimize risks of fire and explo sion Use of replacement electrical ignition or fuel system components which do not comply with these rules and regulations could result...

Page 311: ...tance 60 80 Ohms Secondary Resistance 9 400 11 700 Ohms Spark Plugs Model All MIE and MCM Except Gen Engines Spark Plug 040 In 1 mm Spark Plug Type AC MR43T NGK BR6FS Champion RV15YC4 Model All MIE an...

Page 312: ...ance curve charts do not include the initial engine timing Basic initial tim ing must be added to chart for total advance curve The spark advance is controlled by the ignition mod ule Identification M...

Page 313: ...ude the initial engine timing Basic initial tim ing must be added to chart for total advance curve IMPORTANT The spark advance is controlled by the ignition module Identification Mark V8 22A Module Ad...

Page 314: ...advance curve charts do not include the initial engine timing Basic initial tim ing must be added to chart for total advance curve IMPORTANT The spark advance is controlled by the ignition module Ide...

Page 315: ...not reverse battery cable connections System is negative ground Do not disconnect battery cables while en gine is running Distributor Cap 1 Loosen four distributor cap retaining screws 2 Remove distr...

Page 316: ...o ward you Line up three screw holes and locat ing pin hole on sensor wheel with the figure If wheel is indexed properly all the fingers on wheel will line up with those in the figure 4 If there are p...

Page 317: ...e sensor from housing 72732 b a a Mounting Screws b Senor Assembly 4 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 i...

Page 318: ...distributor body Remove module IMPORTANT Thermalconductive Grease must be applied to the back of the ignition module to conduct heat away from the module and to pre vent corrosion 3 Apply a thin coat...

Page 319: ...4B 10 THUNDERBOLT IV AND V IGNITION SYSTEM 90 823225 1 1096 Thunderbolt IV Exploded View 72058 1 3 4 5 7 8 6 11 14 13 12 22 21 20 19 17 16 15 2 10 9 18...

Page 320: ...th a dial indicator and V blocks Maximum runout is 002 in 0 5 mm Reassembly 1 Lubricate shaft with engine oil Install E clip if removed on shaft in housing 2 Install washer on shaft Install original g...

Page 321: ...ocker cover and crank engine until No 1 intake valve closes continuing to crank slowly until pointer lines up with timing mark on crankshaft pulley 2 Position distributor to opening in block in normal...

Page 322: ...tab located on timing gear cover and crankshaft torsional damper IMPORTANT GM engine timing marks on tab are in 2 degree increments MCM and MIE LH en gines will have A Advance mark to the left of 0 T...

Page 323: ...gnition System Identification The Thunderbolt V ignition system uses the same distributor as the Thunderbolt IV system The Ignition Control Module and Knock Control Module are mounted with the ignitio...

Page 324: ...d vance At a given RPM the module will try to add a small amount of advance and wait to see if there is an RPM change If RPM increases it will try to in crease timing more The module will continue to...

Page 325: ...ge Acceleration Advance Range MBT Advance Range 4B 16 THUNDERBOLT IV AND V IGNITION SYSTEM 90 823225 1 1096 Thunderbolt V Spark Control Graph IMPORTANT The graph below shows the typical advance ranges...

Page 326: ...wires 5 that have bullet connectors This circuit is reserved for future options On current models the two BLACK wires must be connected for the system to function properly The TAN BLU wire 6 carries a...

Page 327: ...BLK 12 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 Knock Sensor Wire 2 Ground Wire For Knock Module 3 Knoc...

Page 328: ...essary because of the Idle Speed Control feature that exists in the ignition module See information on the previous pages about this feature 1 Using a jumper wire connect the ignition system timing le...

Page 329: ...let connectors Remove High Tension Lead from Distributor to Coil Insert a Spark Gap Tester from Coil Tower to Ground Disconnect WHT GRN Lead from Distribu tor Place Ignition Key in RUN Position Rapidl...

Page 330: ...s too high or too low a false signal can also be sent TESTING KNOCK MODULE AND SENSOR NOTE A digital volt ohmmeter DVOM and an un powered test light low power test light 300mA or less are needed to co...

Page 331: ...sary 2 Inspect each spark plug for make and heat range All plugs must be the same make and number and heat range Refer to Specifications for spark plug numbers 3 Adjust spark plug gaps with a round fe...

Page 332: ...4 Replace any wires that do not show continuity from end to end 5 Reinstall wires in proper order Observe the fol lowing IMPORTANT Proper positioning in spark plug wire supports is important to preven...

Page 333: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 4B 24 THUNDERBOLT IV AND V IGNITION SYSTEM 90 823225 1 1096...

Page 334: ...C 4 72078 ELECTRICAL SYSTEM CHARGING SYSTEM...

Page 335: ...e 4C 3 Drive Belt Tension Adjustment 4C 4 V Belt 4C 4 Serpentine Belt 4C 4 Troubleshooting Tests Alternator on Engine 4C 5 Circuitry Test 4C 5 Current Output Test 4C 6 Voltage Output Test 4C 7 Explode...

Page 336: ...ription Specification Excitation Circuit 1 3 to 2 5 Volts Current Output 55 A 50 A Mi p 55 Amp 50 Amp Min 65 Amp 60 Amp Min Voltage Output 13 9 to 14 7 Volts Min Brush Length 1 4 in 6 mm Tools Sealant...

Page 337: ...not require regula tion as maximum current output is self limited by the design of the alternator As long as the voltage is reg ulated within the prescribed limits the alternator can not produce exce...

Page 338: ...days in salt water areas CAUTION Remove all battery cables from battery before conducting the following check to prevent acci dentally shorting out electrical system 1 Inspect entire alternator system...

Page 339: ...k belt tension after running for five minutes Serpentine Belt 1 Loosen 5 8 Inch locking nut on adjustment stud Leave wrench on adjustment stud 2 Use a 5 16 Inch socket and tighten adjusting stud until...

Page 340: ...a 0 20 volt DC volt meter to check that all of the circuits between the al ternator and the other components within the alterna tor system are in good condition OUTPUT CIRCUIT 1 Connect positive volt...

Page 341: ...ing circuit red purple lead for loose or dirty connection or damaged wiring 72786 b c d a e a Output Wire ORANGE b Excitation Wire PURPLE c Sensing Wire RED PURPLE d Voltmeter 0 20 Volts e Ground Curr...

Page 342: ...s test If necessary charge battery with a battery charger or allow engine to run a sufficient length of time to fully charge bat tery before taking reading 1 Connect positive voltmeter lead to positiv...

Page 343: ...500 RPM while observing volt meter DO NOT allow voltage to exceed 16 volts 5 If a voltmeter reading of 14 5 volts or above is now obtained voltage regulator is faulty and must be replaced If voltmeter...

Page 344: ...CHARGING SYSTEM 4C 9 90 823225 1 1096 THIS PAGE IS INTENTIONALLY BLANK...

Page 345: ...4C 10 CHARGING SYSTEM 90 823225 1 1096 Exploded View 72276 3 7 10 12 16 26 29 27 28 2 13 9 2 2 5 4 1 3 6 8 10 2 13 2 1 14 17 18 15 11 10 23 19 20 21 22 24 25 3...

Page 346: ...ine attaching bolt and alternator mounting bolt then pivot alterna tor inward and remove alternator drive belt 5 Remove alternator mounting bolt washers if used spacer and nut and remove alternator Di...

Page 347: ...ngs in next step as stator windings may be damaged 7 Separate rear end frame and stator assembly from front end frame and rotor assembly using two thin blade screwdrivers positioned 180 de grees apart...

Page 348: ...ow diode terminal to cool before removing pliers 72827 a b b a Heat Sink b Stator Leads 3 IMPORTANT With alternator disassembled to this point stator rectifier diodes and rotor may be tested as explai...

Page 349: ...spinning rotor in a lathe Blow off dust with com pressed air Inspect slip rings for grooves pits flat spots or out of round 002 in 0 051 mm maximum and replace rotor if present d Rotor shaft and fron...

Page 350: ...to be sure that they are not bent and touching outer slip ring Also be sure that excess solder is not shorting termi nals to aft slip ring If cause for short cannot be found unsolder field winding lea...

Page 351: ...ut good and alternator fails to produce rated output stator probably is shorted and should be replaced Also examine stator for heat discolor ation as this usually is a sure sign of a short RECTIFIER A...

Page 352: ...rminals And Stud 5 Replace assembly if any one of the rectifiers is shorted or open 6 Connect one lead of an ohmmeter set on R x1 to the common side of the diode and the other lead to the other side o...

Page 353: ...ted 4 Slide fan spacer onto rotor shaft Install fan pulley lockwasher and nut on shaft Clamp pulley in a vise using protective jaws or an old oversize V belt to protect pulley and torque nut to specif...

Page 354: ...ghten screws securely 72561 b c a e d a Rear End Frame b Stator c Front End Frame d Scribe Marks e Insert Screws 4 Two Hidden 9 Depress brushes flush with top of brush holder and insert a 54 050 in dr...

Page 355: ...alternator in mounting bracket and in stall mounting bolt washers if used spacer and nut Place washers if used on each side of spacer DO NOT tighten securely at this time 2 Fasten alternator brace to...

Page 356: ...accessories connected to the auxiliary battery from drawing power from the crank ing battery Mercury Marine does not manufacture any battery isolator systems Battery isolators must be bought from an...

Page 357: ...HT DRK DARK Alternator with Voltmeter Circuit Typical Wiring Shown NOTE Disconnect ORANGE wire from alternator Batt terminal Splice sufficient length of proper gauge wire and connect as shown A Wiring...

Page 358: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE CHARGING SYSTEM 4C 23 90 823225 1 1096...

Page 359: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 4C 24 CHARGING SYSTEM 90 823225 1 1096...

Page 360: ...D 4 72747 ELECTRICAL SYSTEM INSTRUMENTATION...

Page 361: ...erature 4D 6 Page Dual Station Sender identification 4D 6 Removal 4D 6 Testing 4D 6 Installation 4D 7 Fuel Tank Sender 4D 7 Flange Type 4D 7 Capsule Type 4D 8 Switches 4D 9 Ignition Key Switch 4D 9 Te...

Page 362: ...NAL SERIES These gauges may be wired so that the illumination lighting is provided from the ignition switch or a sepa rate instrumentation lighting switch By removing contact strip I from between term...

Page 363: ...ves are available through the Quicksilver Accessories and can be assembled to the bulb 72968 a Ignition Switch Lighting Circuit Position a Positive 12 Volt Power Supply From Ignition Switch 72969 b a...

Page 364: ...g tested must read at position B If not replace gauge 72749 Position B Typical Battery Gauge TESTING 1 Remove cables from battery and fully charge bat tery 2 Connect negative jumper lead from battery...

Page 365: ...uum of each other IMPORTANT Make sure that vacuum hose be tween gauge and engine is not leaking and that all connections are tight Speedometer TESTING IMPORTANT When testing speedometer gauge for accu...

Page 366: ...all terminals with Quicksilver Liquid Neo prene 13 Reconnect battery cables to battery Senders Oil Pressure DUAL STATION SENDER IDENTIFICATION Sender will have 353 AM stamped on hex of sender TESTING...

Page 367: ...recautions Wear personal protective clothing such as rubber gloves a non flammable apron and eye protection preferably full face shield or safety glasses The appropriate heat source should only be ele...

Page 368: ...er Temperature Ohms Reading 140 F 60 C 121 147 194 F 90 C 47 55 212 F 100 C 36 41 3 Replace sender if ohmmeter readings are other than as shown for each temperature INSTALLATION 1 Apply Loctite Pipe S...

Page 369: ...tions 72756 b a a Ohmmeter Leads b Vertical Float Arm CAPSULE TYPE Testing 1 Disconnect wire from terminal on fuel tank capsule 2 Remove two screws and remove capsule assembly 3 Place a magnet under f...

Page 370: ...itch in OFF position there should be no continuity between switch terminals 4 With key switch in RUN position continuity will exist between switch terminals B to I There should no continuity between t...

Page 371: ...h as follows a Connect an ohmmeter to leads b There should be no continuity with switch lan yard connected and continuity with switch lanyard disconnected b a 74062 Remote Control Mounted Style Switch...

Page 372: ...ity should exist 4 Depress switch button and continuity should exist 5 Check stop switch in the same manner 6 If continuity exists when in the OPEN not de pressed state replace panel button Audio Warn...

Page 373: ...ureted and EFI Engines No Timer Circuit Oil Pressure Switch TESTING 1 Remove wire from sender terminal 2 Connect continuity meter between sender termi nal and sender hex Sender shown removed for clari...

Page 374: ...fety glasses The appropriate heat source should only be electric Heat source should be operated by a qualified person Be sure to follow all instruc tions of the manufacturer of the heat source The hea...

Page 375: ...a Suitable Container b Thermometer c Heat Source d Water Temperature Switch e Ohmmeter Leads c As temperature rises switch will close and ohmmeter will indicate continuity Refer to chart below for sp...

Page 376: ...earlier models and may be mounted in a fitting on transmission fluid cooler on later models Switch is normally open This switch is used on all MIE engines if so equipped 87 88031 Switch Opens 180 200...

Page 377: ...old the sand Avoid use of glass containers unless the operator first confirms for himself herself that the glass container is an appro priate high temperature vessel Because the components will reach...

Page 378: ...stall switch with sealing washer in transmission and tighten securely NOTE Switch is mounted in a fitting on transmission cooler on some later models 3 Reconnect harness wires and coat with Liquid Neo...

Page 379: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 4D 18 INSTRUMENTATION 90 823225 1 1096...

Page 380: ...E 4 72761 ELECTRICAL SYSTEM ELECTRICAL KITS...

Page 381: ...Color Code for MerCruiser Products 4E 1 Lanyard Stop Switches 4E 1 65503A2 Kit 4E 1 87 19674A2 or 87 814324A2 Kit 4E 1 Audio Warning System 4E 8 86047A14 Kit 4E 8 NOTICE For information and procedure...

Page 382: ...er installation is completed 3 Coat all electrical connections with Quicksilver Liquid Neoprene after checking switch operation 4 Attach stop switch cap to operator s person with a suitable cord lanya...

Page 383: ...Engines a Self Tapping Screw Drill Pilot Holes Appropriate Drill Bit Aluminum 5 32 in 4 mm Wood Fiberglass 11 64 in 4 5 mm 72810 a Flush Mount Dual Engines a 2 1 8 in 54 mm Hole Use Hole Saw IMPORTANT...

Page 384: ...ainer and Sta Straps 72811 b a a Join Connectors b Secure With Sta Strap 5 When installation is complete reconnect battery leads at battery and perform operational test IMPORTANT On installations wher...

Page 385: ...f a d e g h NOTE Connect wires together with screw and hex nut Apply Liquid Neoprene to connection and slide rubber sleeve over connection a Tachometer b Oil Pressure c Water Temperature d Battery Me...

Page 386: ...connection a Lanyard Stop Switch Use With Console Mount Remote Control b Lead Not Used On 454 502 Multi Port Injection c Lanyard Stop Switch Multi Port Throttle Body Injection Adapter Harness d Tacho...

Page 387: ...SWITCH THESE LEADS NOT USED ON MERCRUISER PUR BLK WHT BLK WHT PUR PUR YEL RED YEL RED NOTE IMPORTANT On installations where gauge options will not be used tape back and isolate any unused leads NOTE...

Page 388: ...ELECTRICAL KITS 4E 7 90 823225 1 1096 LANYARD STOP SWITCH WIRING DIAGRAM DUAL ENGINES 75330 A B C D NOTE 1 NOTE 1 YEL RED YEL RED PUR BLK WHT...

Page 389: ...t with Te flon DO NOT use Teflon tape to seal threads Tighten securely b Attach TAN BLUE wire to heat switch with nut and lockwasher Tighten nut securely c Coat connections with Quicksilver Liquid Neo...

Page 390: ...itch securely b Coat connections with Quicksilver Liquid Neoprene c Connect TAN BLUE wire from audio warning heat switch to audio warning oil pressure switch with lockwasher and nut Torque nut to 15 l...

Page 391: ...HEN OIL PRESSURE IS TOO LOW OR TEMP IS TOO HOT TO TEST HORN Figure 2 1 TURN KEY TO ON POSITION ENGINE OFF 2 WAIT 7 TO 14 SEC FOR HORN TO SOUND 8 Reconnect battery leads 9 Fill closed cooling system on...

Page 392: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE ELECTRICAL KITS 4E 11 90 823225 1 1096...

Page 393: ...F 4 72938 ELECTRICAL SYSTEMS WIRING DIAGRAMS...

Page 394: ...em Harness 4F 14 EFI Engine Harness 4F 16 MCM 5 7L EFI Alpha With Vapor Separator Tank VST 4F 16 MCM 5 7L EFI Alpha With Cool Fuel System 4F 17 MCM 5 7L EFI Bravo WIth Vapor Separator Tank VST 4F 18 M...

Page 395: ...MS 4F 1 90 823225 1 1096 Thunderbolt IV Alpha Drive All Engines With Ignition Module Mounted On Exhaust Elbow 50843 A Ignition System C Audio Warning System B Starting and Charging System D Instrument...

Page 396: ...823225 1 1096 ALPHA DRIVE ALL ENGINES WITH IGNITION MODULE MOUNTED ON DISTRIBUTOR 72935 DISTRIBUTOR BLK WHT RED WHT GRN GRY PUR A Ignition System C Audio Warning System B Starting and Charging System...

Page 397: ...3 90 823225 1 1096 BRAVO DRIVE ALL ENGINES WITH IGNITION MODULE MOUNTED ON EXHAUST ELBOW 50844 A Ignition and Choke System C Audio Warning System B Starting and Charging System D Instrumentation Syst...

Page 398: ...823225 1 1096 BRAVO DRIVE ALL ENGINES WITH IGNITION MODULE MOUNTED ON DISTRIBUTOR 72936 DISTRIBUTOR BLK WHT RED WHT GRN GRY PUR A Ignition System C Audio Warning System B Starting and Charging System...

Page 399: ...90 823225 1 1096 MIE INBOARD AND SKI ENGINES WITH IGNITION MODULE MOUNTED ON EXHAUST ELBOW 50773 A Ignition and Choke System C Audio Warning System B Starting and Charging System D Instrumentation Sy...

Page 400: ...25 1 1096 MIE ALL INBOARD AND SKI ENGINES WITH IGNITION MODULE MOUNTED ON DISTRIBUTOR 72937 DISTRIBUTOR BLK WHT RED WHT GRN GRY PUR A Ignition System C Audio Warning System B Starting and Charging Sys...

Page 401: ...nition System 1 Distributor 2 Ignition Coil 3 Shift Cut Out Switch 4 Knock Sensor B Starting System 1 Alternator 2 Electric Choke 3 Ground Bolt 4 Starter 5 Circuit Breaker 6 Starter Slave Solenoid C A...

Page 402: ...or A Ignition System 1 Distributor 2 Ignition Coil 3 Shift Cut Out Switch B Starting System 1 Alternator 2 Electric Choke 3 Ground Bolt 4 Starter 5 Circuit Breaker 6 Starter Slave Solenoid C Audio War...

Page 403: ...ibutor A Ignition System 1 Distributor 2 Ignition Coil 3 Knock Sensor B Starting System 1 Alternator 2 Electric Choke 3 Ground Bolt 4 Starter 5 Circuit Breaker 6 Starter Slave Solenoid C Audio Warning...

Page 404: ...at distributor A Ignition System 1 Distributor 2 Ignition Coil B Starting System 1 Alternator 2 Electric Choke 3 Ground Bolt 4 Starter 5 Circuit Breaker 6 Starter Slave Solenoid C Audio Warning Syste...

Page 405: ...AMPS NOTE 2 Taped back TAN BLUE wire not used A Ignition System 1 Distributor 2 Ignition Coil B Starting System 1 Alternator 2 Electric Choke 3 Ground Bolt 4 Starter 5 Circuit Breaker 6 Starter Slave...

Page 406: ...TE 2 Taped back TAN BLUE wire not used A Ignition System 1 Distributor 2 Ignition Coil 3 Knock Sensor B Starting System 1 Alternator 2 Electric Choke 3 Ground Bolt 4 Starter 5 Circuit Breaker 6 Starte...

Page 407: ...PS NOTE 2 Taped back TAN BLUE wire not used A Ignition System 1 Distributor 2 Ignition Coil B Starting System 1 Alternator 2 Electric Choke 3 Ground Bolt 4 Starter 5 Circuit Breaker 6 Starter Slave So...

Page 408: ...Fluid Temperature Switch B Instrumentation System 1 Oil Pressure Sender 2 Water Temperature Sender C Charging and Starting System 1 Alternator 2 Ground Stud 3 Starter 4 Circuit Breaker 5 Starter Slave...

Page 409: ...g System 1 Oil Pressure Switch 2 Drive Unit Oil Level B Instrumentation System 1 Oil Pressure Sender 2 Water Temperature Sender 3 Trim Sender C Charging and Starting System 1 Alternator 2 Ground Stud...

Page 410: ...ta Link Connector DLC 1 Vapor Separator Tank VST 2 Throttle Body 3 Distributor 4 Coil 5 Knock Sensor KS Module 6 Data Link Connector DLC 7 Manifold Absolute Pressure MAP Sensor 8 Knock Sensor 9 Idle A...

Page 411: ...7 Manifold Absolute Pressure MAP Sensor 8 Knock Sensor 9 Idle Air Control IAC 10 Throttle Position TP Sensor 11 Engine Coolant Temperature Sensor ECT 12 Electronic Control Module ECM 13 Fuel Pump Rela...

Page 412: ...ata Link Connector DLC 1 Vapor Separator Tank VST 2 Throttle Body 3 Distributor 4 Coil 5 Knock Sensor KS Module 6 Data Link Connector DLC 7 Manifold Absolute Pressure MAP Sensor 8 Knock Sensor 9 Idle...

Page 413: ...onnector DLC 7 Manifold Absolute Pressure MAP Sensor 8 Knock Sensor 9 Idle Air Control IAC 10 Throttle Position TP Sensor 11 Engine Coolant Temperature Sensor ECT 12 Electronic Control Module ECM 13 F...

Page 414: ...ng the YEL wire to the Data Link Connector DLC 1 Vapor Separator Tank VST 2 Throttle Body 3 Distributor 4 Coil 5 Electronic Spark Control KS Module 6 Data Link Connector DLC 7 Manifold Absolute Pressu...

Page 415: ...nk 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...

Page 416: ...d by routing the YEL wire to the Data Link Connector DLC 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 Idle...

Page 417: ...e capability is relocated by routing the YEL wire to the Data Link Connector DLC 1 Fuel Pump 2 Throttle Body 3 Distributor 4 Coil 5 Electronic Spark Control KS Module 6 Data Link Connector DLC 7 Manif...

Page 418: ...r for a fused accessory panel may be taken from this connection Load MUST NOT exceed 35 40 amps Panel ground wire MUST BE connected to instrument terminal that has an 8 gauge black Ground harness wire...

Page 419: ...ER Refer to gauge manufacturer s instructions for specific connections NOTE 1 Connect Wires Together with Screw and Hex Nut Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection...

Page 420: ...ther with screw and hex nut Apply Liquid Neoprene to connection and slide rubber sleeve over connection NOTE 2 Power for a fused accessory panel may be taken from this connection Load MUST NOT exceed...

Page 421: ...and hex nut Apply Liquid Neoprene to connection and slide rubber sleeve over connection NOTE 2 Power for a fused accessory panel may be taken from this connection Load MUST NOT exceed 35 40 amps Pane...

Page 422: ...y station MUST NOT exceed 35 amps NOTE 3 Connect wires together with screw and hex nut Apply Liquid Neoprene to connection and slide rubber sleeve over connection STOP START PANEL TACHOMETER OIL PRESS...

Page 423: ...n MUST NOT exceed 35 amps NOTE 3 Connect wires together with screw and hex nut Apply Liquid Neoprene to connection and slide rubber sleeve over connection STOP START PANEL TACHOMETER OIL PRESSURE WATE...

Page 424: ...L RED SEND SEND SEND LT LT LT LT SW 12V 12V 12V 12V GND UNSW SIG GND GND GND B S I SEND SEND SEND LT LT LT LT SW 12V 12V 12V 12V GND UNSW SIG GND GND GND NOTE 1 Brown white wire is taped back at instr...

Page 425: ...ure or Oil Pressure Gauge b c a Cruiselog 72815 a Connect to Ignition Switch Activated 12 Volt Positive Source Purple Wire b Connect to Negative Ground Black Wire b a Fuel Gauge and Sender 72816 Audio...

Page 426: ...ure Gauge 72819 BIA Color Code Leads to a Black a Ground b Purple b Switched 12 Volt Terminal c Light Blue c Sender Lead b c a Clock 72818 Connect to Instrument Harness RED PURPLE Lead and Slide a Rub...

Page 427: ...A 5 50830 90 823224 692 5A FUEL DELIVERY SYSTEMS AND FUEL PUMPS FUEL SYSTEM FUEL DELIVERY SYSTEMS AND FUEL PUMPS...

Page 428: ...ection With Vapor Separator Tank 5A 4 Throttle Body Injection With Cool Fuel System 5A 4 Multi Port Injection With Vapor Separator Tank VST 5A 5 Multi Port Injection With Cool Fuel System 5A 5 Earlier...

Page 429: ...ass fittings or plugs into fuel pump or fuel filter base can crack casting and or cause a fuel leak Apply 592 Loctite Pipe Sealant with Teflon to threads of brass fitting or plug DO NOT USE TEFLON TAP...

Page 430: ...ABYC etc federal standards and Coast Guard regulations MUST BE adhered to when installing fuel deliv ery system When designing and installing fuel delivery system the following information MUST BE ob...

Page 431: ...90 823225 1 1096 Fuel System Components Carburetor System 50830 b c d a e f g h i 1 a Fuel Tank b Anti Siphon Valve c Water Separating Fuel Filter d Fuel Pump e Carburetor f Fuel Filter g Vent Hose h...

Page 432: ...rator Tank VST e Inlet Line From VST f Water Separating Fuel Filter g Fuel From Tank Throttle Body Injection With Cool Fuel System 74871 h d a i b e f c g a Vacuum Line To Flame Arrestor b Fuel Pressu...

Page 433: ...r Separating Fuel Filter g Water Separating Fuel Filter h Fuel Line From Tank Multi Port Injection With Cool Fuel System b e a c f d g i 74871 k l a Vacuum Line To Intake Manifold b Fuel Pressure Regu...

Page 434: ...tarboard Mounted Fuel System for 350 Magnum MPI Gen Tournament Ski Black Scorpion 74868 b e a d f g h c a Fuel Pressure Regulator b Fuel Cooler c Electric Fuel Pump d In Line Fuel Filter e Water Separ...

Page 435: ...l filter base and fil ter element 72678 b c a Carburetor and VST Equipped Engines a Fuel Filter Mounting Bracket b Filter Element c Sealing Ring b c d e f g h i a J k l Cool Fuel System Water Separati...

Page 436: ...er with SAE engine oil 4 Install new filter tightening securely by hand 5 Reconnect battery cables make sure water is supplied to cooling system start engine and check for fuel leaks Sight Tube Inspec...

Page 437: ...prevent fuel in tank from leaking into bilge 3 Remove fuel filter 4 Using wrench to stabilize brass couplings on fuel pump loosen fuel line fittings and disconnect from fuel pump 5 Clean gasket from...

Page 438: ...B 5 72681 FUEL SYSTEM MERCARB 2 BARREL CARBURETOR...

Page 439: ...hange 5B 4 Adjustable Accelerator Pump Lever 5B 5 High Altitude Re Jetting 5B 5 Description 5B 5 Precautions 5B 6 Maintenance 5B 6 Flame Arrestor with Carburetor Cover 5B 6 Fuel Inlet Filter 5B 7 Chok...

Page 440: ...Scale BT 8128 B Specifications Units of Measurements In mm ENGINE MODEL 5 0L 5 7L Carburetor Type MerCarb 35mm MerCarb 43mm Carburetor Number 1389 9670 3310 806082 3310 807312 Float Level 9 16 14 Note...

Page 441: ...ARBURETOR 90 823225 1 1096 Exploded View 72686 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 21 22 23 24 25 26 29 30 31 32 27 28 35 36 37 38 39 40 41 42 43 44 45 46 47 48 51 52 53 54 55 49 50 56 57 58...

Page 442: ...and Seat Spring Loaded Optional 22 Baffle Plate 23 Float 24 Float Bowl 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 Thr...

Page 443: ...les and Regulations to minimize risks of fire and explo sion Use of replacement electrical ignition or fuel system components which do not comply with these rules and regulations could result in a fir...

Page 444: ...t had sev eral coils cut off Make sure the venturi cluster is the correct one as outlined previously under Specifica tions High Altitude Re Jetting Engine flooding problems at idle RPM are generally r...

Page 445: ...rces of spark or flame in the area while changing fuel filter Wipe up any spilled fuel im mediately WARNING Make sure no fuel leaks exist before closing en gine hatch Fuel Supply Connections CAUTION D...

Page 446: ...ove in the following order a Fuel line from fuel inlet filter nut b Fuel inlet filter nut and small gasket c Large gasket d Filter e Spring f Small gasket from inside filter nut 72406 b c d a e f a Fu...

Page 447: ...r choke cleaner Fol low directions on can IMPORTANT Choke valve and shaft and lever as sembly is not serviceable If valve and or shaft and lever assembly is worn or damaged air horn assembly must be r...

Page 448: ...hoke plate and air horn assembly Rod should just slide through 72684 b c a a 080 In 0 2mm Drill Rod b Choke Plate c Air Horn 4 Bend tang on throttle lever if necessary to obtain specified dimension 72...

Page 449: ...buretor has been installed turn idle mixture needle in clockwise until it lightly contacts seat then back out needle 1 1 4 turns This will provide a sufficient setting to allow starting engine 3 Start...

Page 450: ...washers and remove carburetor IMPORTANT Place a clean cloth over intake man ifold opening to prevent dirt or foreign material from entering manifold 8 Remove and discard gaskets Installation 1 Thoroug...

Page 451: ...ny unnecessary steps CHOKE HOUSING ASSEMBLY 1 Remove choke cover 72403 a a Choke Cover 2 Remove choke lever Remove choke housing 72401 b a a Choke Lever b Choke Housing AIR HORN ASSEMBLY 1 Remove fuel...

Page 452: ...ching screws as shown Carefully lift air horn from float bowl assembly 72280 a a a a a Air Horn Attaching Screws 72400 b a a Air Horn Assembly b Float Bowl Assembly 5 Invert air horn and carefully lay...

Page 453: ...at weight as shown 72122 b a a Grams Scale b Float 8 Remove air horn gasket and baffle 72399 b a a Baffle b Air Horn Gasket 9 Remove needle assembly 72287 b a a Needle Assembly b Needle Seat 10 Remove...

Page 454: ...n remove accelerator pump assembly 72398 b c a a Set Screw b Lever Assembly c Pump Assembly 12 Remove retainer clip and washer from pump shaft and lever assembly then remove accelera tor pump assembly...

Page 455: ...enturi gasket straight up 72292 b a a Venturi Cluster Brass Tubes b Gasket 5 Using a needle nose pliers remove accelerator pump check ball spring retainer Turn float bowl over to remove spring and che...

Page 456: ...to clean jet passages or tubes in carburetor as this may enlarge orifices and seriously affect carburetor calibration CAUTION To avoid damage to carburetor DO NOT leave car buretor in immersion type c...

Page 457: ...kness or distortion f Idle Mixture Needle Inspect idle mixture needle If damaged needle must be re placed g Levers and Linkages Check levers links and rods for wear h Throttle Valve and Shaft Check th...

Page 458: ...asket line up with screw holes in throttle body Tighten screws evenly and securely 72294 b c d a b a Screws b Lockwashers Not Shown c Throttle Body Assembly d Gasket FLOAT BOWL ASSEMBLY IMPORTANT Plac...

Page 459: ...center screw Lockwashers and flat washers are used on outer screws Tighten screws evenly and se curely 72405 b c a b a Center Screw b Outside Screws c Fiber Washer 5 Install main metering jets with ga...

Page 460: ...with washer and retainer clip as shown 72409 b c a a Pump Assembly b Retainer Clip c Pump Lever 2 Insert pump shaft and lever assembly and wash er into air horn then align indexed hole in pump lever w...

Page 461: ...down on hinge pin to ensure it moves freely 72297 b a a Float Assembly b Float Hinge Pin FLOAT LEVEL 1 Turn air horn upside down Pivot float assembly up and down on hinge pin to ensure it moves freel...

Page 462: ...ob tain specified dimension 72688 a a Bend Float Arm at This Point 4 Visually check float alignment after adjustment FLOAT DROP 1 Hold air horn right side up to allow float to hang free 2 Measure flo...

Page 463: ...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 attach ing screws Tighten screws evenly and securely 72280 a a a a a...

Page 464: ...e in pump shaft and lever assembly 72393 b a a Accelerator Pump Rod b Pump Shaft and Lever Assembly 11 Insert remaining end of accelerator pump rod into hole in throttle lever and secure with retainer...

Page 465: ...OR 90 823225 1 1096 2 Install choke cover Make sure hook on end of choke coil engages with choke lever Rotate choke cover until index marks align as shown Tighten screws securely 72403 b c a a Scribed...

Page 466: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE MERCARB 2 BARREL CARBURETOR 5B 27 90 823225 1 1096...

Page 467: ...C 5 72085 FUEL SYSTEMS ROCHESTER 4 BARREL CARBURETOR...

Page 468: ...ons 5C 2 Description 5C 3 Precautions 5C 3 Maintenance 5C 3 Flame Arrestor 5C 3 Fuel Filter 5C 4 Adjustments 5C 5 Accelerator Pump 5C 5 Air Valve Dashpot 5C 6 Air Valve Spring Windup 5C 6 Float Level...

Page 469: ...59339 Universal Carburetor Gauge Tachometer Part Number Description Part Number Description J9789 118 J22769 Carburetor Stand Needle Valve Seat Remover Kent Moore Special Tools Can be ordered from Ke...

Page 470: ...r Valve Dashpot Air Valve Rod Vacuum Break Air Valve Spring Windup Choke Coil Rod Note 3 Idle Mixture Screw Preliminary Setting Float Weight Max Rochester 4MV 17080565 15 64 5 9 Inner 23 64 9 1 025 0...

Page 471: ...vicing the unit Precautions WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire or explosion WARNING Be careful when cleaning flame arrestor and crankca...

Page 472: ...b Sealing Washer c Carburetor Cover d Sta Strap e Crankcase Ventilation Hose f Flame Arrestor b c d a e f d e Fuel Filter NOTICE Refer to Precautions in this section BEFORE proceeding 1 Remove Fuel l...

Page 473: ...w b Throttle Lever b a 2 Pump rod must be in inner hole of lever 72088 a Pump Rod b Inner Hole b a 3 Close throttle valves completely and measure from flame arrestor mounting surface to top of pump pl...

Page 474: ...cale until air valve begins to open check scale reading for correct specifications 72092 a Carburetor Casting b Gram Scale c Contact Area of Arm on Air Valve d Rotate b c d a 2 To adjust spring windup...

Page 475: ...carburetor casting 72084 a Read Here a 4 If float requires adjustment refer to Reassemb ly later in this section for adjustment procedure Choke Coil Rod 1 Push choke coil rod down 72096 a Vacuum Break...

Page 476: ...rection shown by arrow 72097 a Vacuum Break Control Diaphragm a 2 Rotate vacuum break choke lever counterclock wise until tang contacts vacuum break rod Choke rod must be at bottom of choke shaft leve...

Page 477: ...that engine idles smoothly with boat in the water engine at normal op erating temperature and drive unit in forward gear To adjust idle speed and mixture proceed as follows IMPORTANT DO NOT attempt t...

Page 478: ...idle mixture screw out counterclock wise until the speed begins to drop due to a rich mixture c Turn screw in to a point between these two extremes to obtain maximum engine smooth ness and RPM d Repea...

Page 479: ...a IMPORTANT Place a clean cloth in bores of car buretor to prevent dirt and foreign material from falling into bores 4 Turn off fuel supply at the fuel tank 5 Disconnect fuel line 72101 a Fuel Line a...

Page 480: ...Nuts c Throttle Bracket b c a 9 Remove old gasket from carburetor and man ifold Installation 1 Install new gasket onto manifold 2 Install carburetor and throttle bracket and torque to 132 lb in 15 N m...

Page 481: ...Link b Clip b a 6 To install throttle cable refer to Section 2 Re moval and Installation 7 Install flame arrestor and tighten securely 8 Reconnect battery cables to battery 9 Start engine and check f...

Page 482: ...ip 23 Rod 24 Clip 25 Screw 26 Control 27 Hose 28 Power Piston 29 Retainer Power Piston 30 Retainer Pump Discharge Ball 31 Ball Pump Discharge 32 Spring Power Piston 33 Insert Float Bowl 34 Float Bowl...

Page 483: ...Disassembly IMPORTANT Place carburetor on a holding fix ture to prevent throttle valve damage AIR HORN 1 Remove vacuum pump rod clip and rod 72105 a Rod Clip a 72106 a Rod a 2 Remove choke shutter cli...

Page 484: ...and remove accelerator pump lever and rod 72109 a Roll Pin Not Shown b Pump Lever c Rod b c a 4 Remove screw secondary metering rods and hanger 72110 a Screw b Metering Rods c Hanger b c a 5 Remove a...

Page 485: ...Pump Plunger b Return Spring c Gasket b c a 2 Remove insert block power piston and spring 72114 a Insert Block b Power Piston c Spring b c a 3 Remove float assembly needle and retaining pin 72115 a F...

Page 486: ...d check ball 72117 a Primary Metering Jets b Pump Discharge Retainer c Check Ball Not Shown b c a 6 Remove baffle 72118 a Baffle a 7 Remove vacuum control assembly and hose 72119 a Vacuum Control Asse...

Page 487: ...be disas sembled any further than shown Throttle body is serviced as an assembly Cleaning and Inspection CAUTION DO NOT keep carburetor in immersion type car buretor cleaner for more than two hours CA...

Page 488: ...ast idle cam Power piston Accelerator pump seal 5 Check all valves for binding 6 Check vacuum break unit for leaks as follows a Depress plunger and seal hose connection 72124 a Plunger b Hose Connecti...

Page 489: ...Install new gasket and assemble throttle body to float bowl Tighten securely 72121 a Attaching Screws b Throttle Body c Gasket d Float Bowl b c d a FLOAT BOWL IMPORTANT Place carburetor on a holding...

Page 490: ...ntrol Assembly b c a 3 Install pump discharge check ball retainer and primary main metering jets Tighten securely 72128 a Check Ball Not Shown b Retainer c Primary Main Metering Jets b c a IMPORTANT F...

Page 491: ...needle into bowl 72115 a Float b Needle c Retaining Pin b c a IMPORTANT Top of retaining pin must extend above casting by 010 in 0 254 mm for good pin retention 6 If float requires adjustment hold hi...

Page 492: ...wer Piston Hanger b Tension Spring c Metering Rods b a c 10 Install power piston assembly guiding metering rod tips into main metering jets 72133 a Power Piston Assembly b Metering Rod Tip in Main Met...

Page 493: ...all accelerator pump plunger spring 72136 a Spring a AIR HORN 1 Install new gasket and slide tab under power pis ton hanger 72137 a Power Piston Hanger b Gasket Tab b a 2 Install accelerator pump plun...

Page 494: ...rences in carburetor castings Al ways install the same size hanger as was re moved from the carburetor Difference in hang ers is the hole location which affects secondary fuel metering 72139 a Hole Lo...

Page 495: ...stall rod into lever inner hole and place lever into casting mount 72109 a Rod b Lever c Inner Hole d Casting Mount b c d a 9 Press roll pin into place using a screwdriver 72141 a Roll Pin a 10 Instal...

Page 496: ...ter Rod b Clip c Choke Blade Lever b c a 12 Install rod into air valve lever 72106 a Rod b Air Valve Lever b a 13 Install rod into vacuum break arm and install clip 72105 a Rod b Vacuum Break Arm c Cl...

Page 497: ...D 5 70389 90 823224 692 5B WEBER 4 BARREL CARBURETOR FUEL SYSTEMS WEBER 4 BARREL CARBURETOR...

Page 498: ...Hard Starting 5D 5 Carburetor Metering Rod And Jet Identification 5D 6 Maintenance 5D 7 Flame Arrestor 5D 7 Fuel Filter 5D 8 Adjustments 5D 9 Accelerator Pump 5D 9 Choke Pull Off 5D 10 Float Drop 5D 1...

Page 499: ...ents which do not comply with these rules and regulations could result in a fire or explosion hazard and should be avoided Torque Specifications Fastener Location in lb lb ft N m Carburetor To Manifol...

Page 500: ...Ignition 3310 807262 9781 098 092 16 686462 Green MIE Models Engine Model Carb Type Mercury Number Manufacturer Number Primary Jet Size Second ary Jet Size Metering Rod Number Metering Rod Spring Colo...

Page 501: ...ump Rod Hole Location Third Hole From End Accelerator Pump 7 16 in 11 mm 1 Choke Pull Off 15 64 in 6 mm Choke Coil Rod Top Of Rod Even With Bottom Of Lever Hole 2 Preliminary Mixture Idle Screw Settin...

Page 502: ...FORE working on fuel system to prevent fire or explosion WARNING Be careful when cleaning flame arrestor and crankcase ventilation hose gasoline is extreme ly flammable and highly explosive under cert...

Page 503: ...y the accelerator pump could be changed 70472 b c a a Rich b Lean c Leaner Hard Starting If a hard starting condition exists after engine has not been operated for a period of time proceed with the fo...

Page 504: ...ep a a b b d d e e c c a Piston b Metering Rod c Spring d Jet e Piston Cover METERING JETS The metering jets in this carburetor are taller than the jets in a standard carburetor 73728 a b Two Step Thr...

Page 505: ...ame Arrestor NOTICE Refer to Precautions in this section BEFORE proceeding 1 Remove in the following order a Nut b Sealing washer c Carburetor cover d Crankcase ventilation hoses from flame ar restor...

Page 506: ...d d Flame Arrestor with Carburetor Cover Typical a Nut b Sealing Washer c Carburetor Cover d Sta Strap e Crankcase Cover f Crankcase Ventilation Hose g Flame Arrestor Fuel Filter NOTICE Refer to Preca...

Page 507: ...Back out idle speed screw until it no longer con tacts throttle lever 70474 a b a Idle Speed Screw b Throttle Lever Contact Point 70473 b a a Idle Speed Screw b Throttle Lever 2 Close throttle valves...

Page 508: ...in 6 mm 70471 70471 d b c a a Vacuum Diaphragm b Choke Plate c Housing d Gap Measurement 2 Bend choke pull off linkage to achieve setting giv en in Step 1 70471 a a linkage Bend Float Drop 1 Measure...

Page 509: ...float level from bottom side of carbure tor top with gasket in place to toe of float as shown It must be set at 1 9 32 in 33 mm 70468 a b a Float Level Measurement b Gasket 2 If float level requires...

Page 510: ...t with engine running refer to Final Idle Speed and Mixture 1 Turn idle speed screw until it contacts throttle lever 70474 a b a Idle Speed Screw b Throttle Lever Contact Point 2 Turn idle mixture scr...

Page 511: ...ure adjustments following BE CAREFUL NOT TO ACCIDENTALLY ACCELERATE ENGINE WHILE PERFORMING ADJUSTMENTS 4 With boat in open water place remote control in forward gear idle position 5 Disconnect thrott...

Page 512: ...rating temperature Refer to the Operation and Mainte nance Manual for the correct idle speed 1 Disconnect the throttle cable from carburetor IMPORTANT In order to properly set idle speed the ignition...

Page 513: ...over Remove crankcase ventilation hoses from flame arrestor then re move flame arrestor IMPORTANT Place a clean cloth in bores of car buretor to prevent dirt and foreign material from falling into bor...

Page 514: ...ake man ifold 2 If so equipped install adaptor or wedge plate de pending on model Place appropriate new gasket on top 3 Install carburetor and throttle bracket with at taching hardware Torque fastener...

Page 515: ...and tighten nut securely 8 Reconnect battery cables to battery by first in stalling positive battery cable to positive bat tery terminal Tighten clamp securely Then in stall negative battery cable to...

Page 516: ...4 BARREL CARBURETOR 90 823225 1 1096 Exploded View Weber Carburetor 1 2 4 5 6 7 8 9 10 3 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 29 30 31 32 33 27 28 34 35 36 37 38 39 40 41 43 44 45 46 47 48...

Page 517: ...Rod Choke Plate 36 S Link 37 Accelerator Pump Lever 38 Screw 39 Linkage Rod Accelerator Pump 40 Wire Clip 41 Wire Clip 42 Gasket 43 Screw 4 44 Gasket 2 45 Jet Secondary Fuel 2 46 Secondary Air Valve a...

Page 518: ...ect vacuum hose from choke pull off dia phragm 70393 b a a Vacuum Hose b Choke Pull Off Diaphragm 4 Remove screws from choke pull off diaphragm bracket to disengage choke pull off linkage NOTE Dependi...

Page 519: ...Rod Cover s c Air Deflectors If Equipped IMPORTANT Be careful not to mix metering rods when removing them 6 Carefully lift metering rod assemblies straight out 70396 a a Metering Rod Assembly s 7 Remo...

Page 520: ...choke linkage 70399 10 Slide pin out to remove the float IMPORTANT Be careful not to mix up floats after removal 70400 a a b b a Pin s b Float s 11 Remove inlet needle from seat IMPORTANT Be careful...

Page 521: ...r removal 70447 b c a a Seat b Gasket c Inlet Filter 13 Remove gasket from top of carburetor 70448 a a Gasket 14 Remove accelerator pump lever 70449 b c a a Accelerator Pump b Accelerator Pump Lever c...

Page 522: ...usters it is important to note which clusters are equipped with a distribution tab This distribution tab arrangement varies from one carburetor to another 70452 a a Distribution Tab s Location And Tot...

Page 523: ...mary Venturi Cluster 20 Remove two screws that secure secondary ven turi clusters 70456 a b a Screw s Two Each Side b Secondary Venturi Cluster s 21 Remove secondary venturi cluster by lifting it stra...

Page 524: ...lve And Weight Assembly 24 Remove two screws that secure pump jet hous ing 70460 b a a Screw s b Pump Jet Housing 25 Remove pump jet housing 70461 a a Pump Jet Housing 26 Remove gasket from beneath pu...

Page 525: ...t mix up the primary and sec ondary jets Make note of the jet sizes and their location before removal to be certain that during reassembly they are installed in the carburetor side from which they wer...

Page 526: ...ular attention to the following a Idle mixture screws Replace if damaged or worn b Fuel inlet needle valve and seat Replace with new needle and seat if worn or damaged c Casting surfaces Inspect accel...

Page 527: ...ll snug IMPORTANT Be sure that primary and secondary jets are installed in the appropriate location Be sure that the size matches the same size re corded during disassembly 70466 b a a Primary Fuel Je...

Page 528: ...a Gasket Pump Jet Housing 6 Install pump jet housing 70461 a a Pump Jet Housing 7 Install two screws that secure pump jet housing Tighten securely 70460 b a a Screws b Pump Jet Housing 8 Install the...

Page 529: ...ement varies from one carburetor to another 70452 a a Distribution Tab s Location And Total Number May Vary 9 Position the secondary venturi cluster gaskets 70458 a a Gasket Secondary Venturi Cluster...

Page 530: ...enturi clusters 70454 a b a a Gasket Primary Venturi Cluster One Not Visible In This View b Primary Venturi Cluster 14 Secure each cluster with two screws Tighten se curely 70453 a a b a Screws Two Ea...

Page 531: ...ct accelerator pump lever to pump rod us ing the S link Secure pump lever with pivot screw Tighten securely Check to ensure lever actuates the accelerator pump 70449 b a c d a Accelerator Pump Lever b...

Page 532: ...oted during disassembly 20 Install appropriate inlet needles into inlet seats 70446 b a 70401 a b a Inlet Needle s b Seat s IMPORTANT If using existing floats be sure to reinstall them on the same sid...

Page 533: ...same side from which removed during disassembly 25 Carefully install metering rod assemblies in the appropriate holes Push down lightly on metering rods to ensure that plunger will spring up and down...

Page 534: ...Reinstall choke pull off diaphragm Secure with two screws and tighten securely 70394 b a a Screw s b linkage Rod 28 Reconnect vacuum hose to choke pull off dia phragm 70393 a a Vacuum Hose 29 Reconnec...

Page 535: ...d or refer to Important Service Information in this section for information regarding adjust ment Accelerator pump linkage adjustment should be checked at this time refer to Adjust ments Accelerator P...

Page 536: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 5D 38 WEBER 4 BARREL CARBURETOR 90 823225 1 1096...

Page 537: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 90 823225 1 1096 WEBER 4 BARREL CARBURETOR 5D 39...

Page 538: ...5 71692 E FUEL SYSTEMS MULTI PORT AND THROTTLE BODY FUEL INJECTION...

Page 539: ...p Multi Port Injection 5E 33 Wiring Harness Diagrams 5E 34 MCM 5 7L EFI Alpha With Vapor Separator Tank 5E 34 MCM 5 7L EFI Alpha With Cool Fuel System 5E 35 Page MCM 5 7L EFI Bravo With Vapor Separato...

Page 540: ...5E 146 Lubricants Sealants Adhesives 5E 146 Torque Specifications 5E 146 Throttle Body Injection System Description 5E 147 Service Precautions 5E 147 Throttle Body Exploded Views 5E 148 350 CID 5 7L...

Page 541: ...90 823225 1 1096 5E 0 ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY THIS PAGE IS INTENTIONALLY BLANK...

Page 542: ...properly main taining the quality to which MerCruiser engine control systems are built Visual Physical Inspection A careful visual and physical inspection must be performed as part of any diagnostic...

Page 543: ...ls found in the system it is important that the best possible bond be made at all wire splices by soldering the splices as shown in the following illustrations Use care when probing a connector or rep...

Page 544: ...mable Read Only Memory HEI High Energy Ignition EMI Electromagnetic Interference ENG Engine GND Ground GPH Gallons Per Hour IAC Idle Air Control IAT Intake Air Temperature IC Ignition Control IGN Igni...

Page 545: ...Position MAT Manifold Air Temperature IAT Intake Air Temperature EST Electronic Spark Timing IC Ignition Control ESC Electronic Spark Control KS Knock Sensor ALDL Assembly Line Data Link DLC Data Link...

Page 546: ...ss one can assume that these codes were set by an intermit tent malfunction and could be helpful in diagnosing the system An intermittent code may or may not reset IF IT IS AN INTERMITTENT FAILURE A D...

Page 547: ...k The correct procedure to diagnose a problem is to fol low two basic steps 1 Are the on board diagnostics working This is determined by performing the EFI Diagnostic Cir cuit Check Since this is the...

Page 548: ...shooting an out of range sensor may be sus pected Because of the unique design of the EFI sys tem fail safes have been incorporated into the ECM to replace a sensed value with a default value in the c...

Page 549: ...ECM It also allows monitoring of various circuits and compo nents in the fuel injection system 91 822608 1 MERCRUISER Cartridge nents in the fuel injection system 94040M EFI Scan Tool Injector Tester...

Page 550: ...take place 10 Use only the test equipment specified in the diag nostic charts since other test equipment may ei ther give incorrect results or damage good com ponents 11 All voltage measurements usin...

Page 551: ...to understand the difference between them and the different ways they are used Analog Signals An analog signal is continuously variable This means that the signal can be any voltage within a cer tain...

Page 552: ...t a lower level Although the computer uses 8 bit digital codes internally and when talking to another computer each bit can have a meaning SWITCH TYPES Switched inputs also known as discretes to the c...

Page 553: ...eration That is three specific signals to the ECM establish the engine speed and air density fac tors SPEED The engine speed signal comes from the distributor s High Energy Ignition HEI module to the...

Page 554: ...sed by the ECM to control its various systems Al though we will not cover them all in great detail there will be a brief description of each INPUTS OUTPUTS ECM SYSTEM RELAY FUEL PUMP RELAY FUEL PUMP D...

Page 555: ...a 5 volt signal to the sensor through a resistor in the ECM and measures the volt age The voltage will be high when the intake air is cold and low when the intake manifold air is hot A failure in the...

Page 556: ...e is the signal line from the knock sensor If this circuit opens or shorts to ground the KS module will never remove the 8 10 volt signal from terminal C to the ECM and no spark retard will occur The...

Page 557: ...h changes state from its normal at rest posi tion that is normally open to closed the ECM senses a change in voltage and responds by entering power reduction mode This engine protection feature allows...

Page 558: ...ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY 5E 17 90 823225 1 1096 THIS PAGE IS INTENTIONALLY BLANK...

Page 559: ...following describes IC operation during cranking and when the engine starts running To help under stand how IC circuits operate a relay with a double set of contact points is shown in the IC module r...

Page 560: ...ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY 5E 19 90 823225 1 1096 Distributor Module Mode IC MODULE ADVANCE TRANSISTOR BASE ECM Control Mode IC Module Advance...

Page 561: ...of the ground or open it will not be able to energize the relay Therefore the relay will stay de energized and the IC line will remain grounded When the ECM sees the IC line not toggling it will not e...

Page 562: ...n the ignition is OFF to prevent dieseling Also fuel pulses are not delivered if the ECM receives no distributor reference pulses which means the engine is not running The fuel cutoff mode is also ena...

Page 563: ...n reference pulses engine cranking or running it shuts Off the fuel pump relay causing the fuel pump to stop THROTTLE BODY UNIT The throttle body unit consists of three assemblies Fuel meter cover and...

Page 564: ...Body FUEL PRESSURE REGULATOR VST EQUIPPED ONLY The pressure regulator is a diaphragm operated relief valve with fuel pump pressure on one side and regulator spring pressure and intake manifold vacuum...

Page 565: ...le 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 valv...

Page 566: ...h Spring i Housing j Solenoid Coil k Tape l Bobbin m O Ring n Inner Collar o Sleeve p Terminal q Connector r Filter s O Ring PRESSURE REGULATOR ASSEMBLY The pressure regulator is a diaphragm operated...

Page 567: ...connector During idle the proper position of the IAC valve is en gine load and engine RPM If the RPM drops below specification and the throttle valve is closed the ECM senses a near stall condition a...

Page 568: ...ctor J 2 a J 2 Rear 32 Pin Output Connector a Shaded Area Denotes Pin Connector Location Used On Terminal NOTE The Intake Air Temperature IAT Sensor J1 24 Port Fuel Jumper J2 7 and J2 22 is not used o...

Page 569: ...ck Of Data From Other Engine Dual Engine Only J1 6 Discrete Switch 931 BRN None Power Reduction Mode J1 7 Diag nostic Test 451 WHT BLK B B None Incorrect Idle Poor Performance J1 8 Not Used J1 9 Map S...

Page 570: ...h 942 PNK 0 0 NONE No Start J1 22 Not Used J1 23 Not Used J1 24 IAT Sensor 472 TAN 5V NOTE 2 23 Poor Fuel Economy Exhaust Odor J1 25 Not Used J1 26 Not Used J1 27 Not Used J1 28 Not Used J1 29 MAP Gro...

Page 571: ...NOTE 5 None 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...

Page 572: ...ack Of Power Stalling J2 22 Port Fuel Jumper 901 WHT J2 23 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...

Page 573: ...s at all injectors and connect injector tester to one injector Use adaptor harness furnished with injector tester to energize in jectors Follow manufacturer s instructions for use of adaptor harness I...

Page 574: ...I 262 kPa 38 PSI 262 kPa 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 kP...

Page 575: ...e YEL wire to the Data Link Connector DLC 1 Vapor Separator Tank VST 2 Throttle Body 3 Distributor 4 Coil 5 Knock Sensor KS Module 6 Data Link Connector DLC 7 Manifold Absolute Pressure MAP Sensor 8 K...

Page 576: ...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 Sensor ECT 12 Electronic Control Module EC...

Page 577: ...L wire to the Data Link Connector DLC 1 Vapor Separator Tank VST 2 Throttle Body 3 Distributor 4 Coil 5 Knock Sensor KS Module 6 Data Link Connector DLC 7 Manifold Absolute Pressure MAP Sensor 8 Knock...

Page 578: ...ule 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 Sensor ECT 12 Electronic Contro...

Page 579: ...ed by routing the YEL wire to the Data Link Connector DLC 1 Vapor Separator Tank VST 2 Throttle Body 3 Distributor 4 Coil 5 Electronic Spark Control KS Module 6 Data Link Connector DLC 7 Manifold Abso...

Page 580: ...e 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...

Page 581: ...Spark Control 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 Co...

Page 582: ...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 1...

Page 583: ...ASTER SLAVE 461 ORN BLK TO ECM BAT FUSE 15A 440 ORN 441 BLU WHT 442 BLU BLK 443 GRN WHT 444 GRN BLK 10A MALFUNCTION INDICATOR LAMP DK GRN DLC R BLK SOME MODELS WILL HAVE THE DUAL ENGINE DATA LINK MOVE...

Page 584: ...E COOLANT TEMPERATURE ECT SENSOR SIGNAL INTAKE AIR TEMPERATURE IAT SENSOR INTAKE AIR TEMPERATURE IAT SENSOR SIGNAL A B C ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY 5E 43 90 823225 1 1096 M...

Page 585: ...121 WHT 931 BRN TO BUZZER COOLANT OVERTEMP TO BUZZER AUDIO WARNING SWITCHES J1 6 D C B A IGNITION CONTROL IC MODULE 86 430 PUR WHT BRN E FROM KNOCK SENSOR MODULE BLACK SCORPION ONLY BLU TO KNOCK SEN S...

Page 586: ...C CONNECTOR KNOCK SENSOR KS MODULE KNOCK SENSOR KS 439 PNK BLK CONNECTOR NOT PRESENT ON SOME MULTI PORT MODELS TO IGN COIL TERM B TO FUEL PUMP RELAY FUSE 15A TO INJECTORS BLK ELECTRONIC FUEL INJECTION...

Page 587: ...BLK TO ECM BAT FUSE 15A 440 ORN 441 BLU WHT 442 BLU BLK 443 GRN WHT 444 GRN BLK 10A MALFUNCTION INDICATOR LAMP DK GRN DLC R BLK SOME MODELS WILL HAVE THE DUAL ENGINE DATA LINK MOVED TO THE DLC INJECTO...

Page 588: ...COOLANT TEMPERATURE ECT SENSOR ENGINE COOLANT TEMPERATURE ECT SENSOR SIGNAL A B C ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY 5E 47 90 823225 1 1096 Throttle Body Injection Wiring Diagram C...

Page 589: ...A IGNITION CONTROL IC MODULE 86 430 PUR WHT BRN TO BUZZER TO IGN TO AUDIO WARNING SWITCHES TO TACH TO BUZZER COOLANT OVERTEMP TO BUZZER AUDIO WARNING SWITCHES TO KNOCK SEN SOR BLACK SCORPION ONLY FROM...

Page 590: ...IGNITION RELAY TO DLC CONNECTOR KNOCK SENSOR KS MODULE KNOCK SENSOR KS 439 PNK BLK CONNECTOR NOT PRESENT ON SOME MULTI PORT MODELS TO INJECTORS TO FUEL PUMP RELAY FUSE 15A BLK ELECTRONIC FUEL INJECTIO...

Page 591: ...90 823225 1 1096 5E 50 ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY THIS PAGE IS INTENTIONALLY BLANK...

Page 592: ...her parame ters the values are not recommended for use in diag nosing If all values are within the range illustrated refer to Troubleshooting Scan Tool Normal Specifications Idle Warm Engine Closed Th...

Page 593: ...and able to start the engine with ad equate cranking RPM 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...

Page 594: ...s a real fault in system check note preceding and repeat Step 1 YES USE CHART A 2 NO YES REFER TO APPLICABLE SCAN CODE CHART START WITH LOWEST CODE FIRST LINK SCAN TOOL AND CHECK FOR CODES DOES SCAN T...

Page 595: ...providing a ground path through CKT 419 to the ECM TEST DESCRIPTION Number s below refer to circled number s on the diagnostic chart 1 This step insures that battery voltage is available to terminal...

Page 596: ...E LIGHT ON ON ALL CIRCUITS CONNECT TEST LIGHT BETWEEN DLC TERMINALS F AND E LIGHT SHOULD BE ON IS IT FAULTY DIAG NOSTIC CODE TOOL REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO YES FAULTY ECM GROUNDS OR E...

Page 597: ...CM With the diagnostic test terminal grounded CKT 419 the lamp should flash a Code 12 followed by any trouble code s stored in memory A steady light suggests a short to ground in the lamp control CKT...

Page 598: ...GNOSTIC CODE TOOL INSTALLED IGNITION ON ENGINE OFF IS THE MALFUNCTION INDICATOR LIGHT ON IF PROBLEM WAS NO DLC DATA USING SCAN TOOL CHECK SERIAL DATA CKT 461 FOR OPENS OR SHORTS TO GROUND IF OK IT IS...

Page 599: ...related to the causes of a no spark condi tion 3 The test light should blink indicating the ECM is controlling the injectors OK 4 All injectors should be within 1 0 ohm of each oth er and should not...

Page 600: ...OK NOT OK 5 NO USING AN INDUCTIVE PICKUP TIMING LIGHT CONNECTED TO ANY SPARK PLUG WIRE CHECK FOR SPARK WHILE CRANKING CHECK TWO WIRES IS SPARK PRESENT REVIEW THE DIAGNOSTIC AIDS ON FACING PAGE FOR ADD...

Page 601: ...7 and CKT 468 3 All checks made to this point would indicate that the ECM is at fault However there is a possibility of CKT 467 or CKT 468 being shorted to a voltage source either in the engine harnes...

Page 602: ...IN THE HARNESS TO THE TESTED INJECTOR IGNITION ON PROBE INJECTOR HARNESS TERMINALS WITH A TEST LIGHT TO GROUND LIGHT SHOULD BE ON AT BOTH TERMINALS CHECK INJECTOR DRIVER CIRCUIT WITH TEST LIGHT FOR S...

Page 603: ...ic chart 1 If pump does not run check fuel pump relay and fuse 2 Wrap a shop towel around the fuel pressure con nector to absorb any small amount of fuel leak age that may occur when installing the ga...

Page 604: ...LD SEE CHART A 7 4 OF 6 IGNITION OFF APPLY 12 VOLTS TO FUEL PUMP CONNECTOR GRAY WIRE LISTEN FOR FUEL PUMP RUNNING NOT HOLDING HOLDS NOT OK REPAIR VACUUM SOURCE TO REGULATOR OK REPLACE REGULATOR ASSEMB...

Page 605: ...as Regulated pressure less than 34 PSI 234 kPa The system will be running lean Also hard start ing when cold and overall poor performance will be noticed Restricted flow causing pressure drop Normally...

Page 606: ...E 38 PSI 262 kPa 34 38 PSI 234 262 kPa CHECK FOR RESTRICTED FUEL RETURN LINE FROM FUEL PRESSURE REGULATOR TO POINT WHERE FUEL LINE WAS DISCONNECTED REPAIR FUEL LINE AND RECHECK ABOVE 38 PSI 262 kPa FA...

Page 607: ...ED 339 PNK BLK 465 DK GRN WHT 450 BLK WHT 450 BLK WHT 120 GRY 150 BLK TEST DESCRIPTION Number s below refer to circled number s on the diagnostic chart 1 This step checks if there is power to the fuel...

Page 608: ...CKT 339 AND REPLACE FUSE IGNITION OFF DISCONNECT FUSED JUMPER CONNECT TEST LIGHT TO BATTERY POSITIVE B AND PROBE CAVITY 86 OF THE FUEL PUMP RELAY CONNECTOR LIGHT SHOULD BE ON IS IT CHECK FOR OPEN WIRE...

Page 609: ...30 PSI 207 kPa nominal Excess fuel is then returned to the water separating fuel filter TEST DESCRIPTION Number s below refer to circled number s on the diagnostic chart NOTE If pump does not run che...

Page 610: ...NG PUMP RUNS CHECK FOR RESTRICTED FUEL LINE DISCONNECTED HOSE IF OK CHECK FOR OPEN WIRE IN CKT 120 OPEN PUMP GROUND CKT 150 IF OK REPLACE ELECTRIC FUEL PUMP 2 NOTE THE IGNITION MAY HAVE TO BE CYCLED O...

Page 611: ...poor performance will be noticed Restricted flow causing pressure drop Normally an engine with a fuel pressure of less than 24 PSI 165 kPa at idle will not be driveable However if the pressure drop oc...

Page 612: ...STRICTED FUEL LINES ABOVE 32 PSI 231 kPa 28 32 PSI 193 231 kPa CHECK FOR RESTRICTED FUEL RETURN LINE FROM FUEL PRESSURE REGULATOR TO POINT WHERE FUEL LINE WAS DISCONNECTED REPAIR FUEL LINE AND RECHECK...

Page 613: ...RED 339 PNK BLK 465 DK GRN WHT 450 BLK WHT 450 BLK WHT 120 GRY 150 BLK TEST DESCRIPTION Number s below refer to circled number s on the diagnostic chart 1 This step checks if there is power to the fue...

Page 614: ...N CKT 339 AND REPLACE FUSE IGNITION OFF DISCONNECT FUSED JUMPER CONNECT TEST LIGHT TO BATTERY POSITIVE B AND PROBE CAVITY 86 OF THE FUEL PUMP RELAY CONNECTOR LIGHT SHOULD BE ON IS IT CHECK FOR OPEN WI...

Page 615: ...lay fuse through terminal 87 of the system relay TEST DESCRIPTION Number s below refer to circled number s on the diagnostic chart 1 This step identifies if the relay is functioning prop erly If a fau...

Page 616: ...IVE B AND PROBE RELAY CONNECTOR CAVITY 85 TEST LIGHT SHOULD LIGHT DID IT REPAIR OPEN OR SHORT TO GROUND IN CIRCUIT THAT DID NOT LIGHT NO YES CHECK RELAY CONNECTOR FOR POOR CONTACT OR CORROSION IF OK R...

Page 617: ...there should be battery voltage at the C and terminals Low voltage would indicate an open or a high resistance circuit from the dis tributor to the coil or ignition switch If C terminal voltage was l...

Page 618: ...N AND C PNK TERMI NALS OF DISTRIBUTOR HARNESS CONNECTION 1A 2 3 RECONNECT DISTRIBUTOR 2 TERMINAL CONNECTOR WITH IGNITION ON CHECK VOLT AGE FROM TACH TERMINAL TO GROUND BOTH TERMINALS 10 VOLTS OR MORE...

Page 619: ...al to turn the module ON This test can be performed by using a DC battery with a rating of 1 5 to 8 volts The use of the test light is mainly to allow the P terminal to be probed more easily Some digi...

Page 620: ...M A VOLTAGE SOURCE 1 5 TO 8 V TO MODULE TERMINAL P CHART 1 OF 2 PAGE 78 LIGHT ON STEADY LIGHT BLINKS NO DROP IN VOLTAGE CHECK MODULE GROUND IF OK REPLACE MODULE CHECK FOR SPARK FROM COIL WIRE WITH TIM...

Page 621: ...rk plugs bad sensors These items should be in proper working order to en sure correct diagnosis TEST DESCRIPTION Number s below refer to circled number s on the functional check chart 1 This step dete...

Page 622: ...LL DROP DRASTICALLY IAC CIRCUIT FUNCTIONING PROPERLY NO YES EXIT SERVICE MODE AND RESTART ENGINE ENGINE SPEED SHOULD GRADUALLY RETURN WITHIN 75 RPM OF RECORDED RPM WITHIN 30 SECONDS DOES IT IGNITION O...

Page 623: ...e engine operation until the position of the switch is restored to its normally open position and the ignition key switch has been cycled TEST DESCRIPTION 1 If a Lanyard Stop was recognized by the ECM...

Page 624: ...RESISTANCE SHOULD BE INFINITE ON LANYARD STOP HARNESS SIDE IS IT POSITION SWITCH CORRECTLY AND REPEAT STEP 1 NO YES RESISTANCE LOWER ON ECM SIDE OF CONNECTOR RESISTANCE LOWER ON LANYARD STOP SWITCH S...

Page 625: ...uit energizing the buzzer TEST DESCRIPTION Number s below refer to circled number s on the functional check chart 1 This step performs a functional check of the buzzer circuit 2 This step identifies a...

Page 626: ...IN AFFECTED CIRCUIT BETWEEN BUZZER AND CONNECTOR DISCONNECT HARNESS CONNECTOR USING FUSED JUMPER CONNECTED TO GROUND PROBE CONNECTOR BUZZER SIDE OF AFFECTED CIRCUIT BUZZER SHOULD SOUND DOES IT CHECK F...

Page 627: ...o warning system NOTE Power reduction mode is not used 1997 and later models This engine protection feature allows the driver full engine power up to 2800 RPM but disables four fuel injectors above 28...

Page 628: ...N LINE HARNESS CONNECTOR YES NO CHECK CONTINUITY ON TAN BLU WIRE FROM IN LINE HARNESS CONNECTOR TO J1 6 TERMINAL ON ECM CONNECTOR YES REPAIR SHORT IN CIRCUIT NO YES NO DISCONNECT ECM J1 CONNECTOR FROM...

Page 629: ...tance should steadily decrease as the engine coolant warms up The resistance reading would stabilize when the ther mostat opens 3 This step will isolate the problem to CKT 410 5 volt reference or to t...

Page 630: ...N AT ECM OR FAULTY ECM NO YES DISCONNECT ECMJ 1 CONNECTOR IS TEST LIGHT ON 2 INTERMITTENT CONNECTIONS OR FAULTY ECT SENSOR REFER TO DIAGNOSTIC AID CHART FOR SENSOR VALUES CONNECT POSITIVE DVM LEAD FRO...

Page 631: ...uit to the ECM is open 4 This step completes the test for the ECM and wir ing If the test light is not ON the TP sensor has an internal problem DIAGNOSTIC AIDS An intermittent problem may be caused by...

Page 632: ...4 VOLTS IGNITION OFF CONNECT A TEST LIGHT TO B BATTERY POSITIVE TOUCH TEST LIGHT TO HARNESS TERMINAL C THROTTLE POSITION SENSOR SIGNAL IS TEST LIGHT ON IGNITION OFF DISCONNECT THROTTLE POSITION SENSO...

Page 633: ...mines if the MAP signal circuit to the ECM is open 6 This step completes the test for the ECM and wir ing If the test light is not ON the MAP sensor has an internal problem To confirm an internal MAP...

Page 634: ...ORE AND STEADY IS IT REPAIR LOW OR UNSTEADY VACUUM PROBLEM 2 NO YES NO DISCONNECT ECM TOUCH TEST LIGHT CONNECTED TO BATTERY POSITIVE B TO HARNESS TERMINAL B IS TEST LIGHT ON SEE NOTE MAP SENSOR FAULTY...

Page 635: ...C mode so the IC voltage will be low and Code 42 will be set If the IC line is grounded the ignition module will switch to IC but because the line is grounded there will be no IC signal A Code 42 will...

Page 636: ...C CODE TOOL CLEAR CODES REFER TO CLEARING CODES IDLE ENGINE FOR 1 MINUTE OR UNTIL MALFUNCTION INDICATOR LAMP COMES ON IGNITION ON ENGINE STOPPED ENTER SERVICE MODE ON CODE TOOL AND NOTE CODES CODE 42...

Page 637: ...ty of the KS module to remove the voltage from the signal line when it sees spark knock Since the knock sensor pro duces an AC voltage signal it may be necessary to repeatedly touch the harness connec...

Page 638: ...BATTERY POSITIVE B START ENGINE HOLD ENGINE SPEED STEADY AT 2500 RPM REPEATEDLY TOUCH TEST LIGHT TO KNOCK SENSOR HARNESS CONNECTOR TERMINAL CKT 496 DOES A NOTICEABLE RPM DROP OCCUR OR USING TIMING LI...

Page 639: ...eld repro grammed to correct this failure Replacement of the ECM with a factory reprogrammed ECM is necessary if Code 51 is current and resets when clearing codes is completed DIAGNOSTIC AIDS An inter...

Page 640: ...0 823225 1 1096 Code 51 Calibration Memory Failure Non Scan 2 of 2 IGNITION ON USING CLEAR CODE PROCEDURE CLEAR CODES DOES CODE 51 RESET 1 REPLACE ECM AND VERIFY CODE DOES NOT RESET FAULT IS NOT PRESE...

Page 641: ...gnal voltage indicates a coolant tempera ture below 22 F 30 C 2 This test will determine if CKT 410 is shorted to ground which will cause the condition for Code 14 DIAGNOSTIC AIDS Check harness routin...

Page 642: ...NO YES IGNITION OFF DISCONNECT COOLANT TEMPERATURE SENSOR JUMPER TERMINALS A AND B TOGETHER IGNITION ON SCAN TOOL SHOULD DISPLAY COOLANT TEMPERATURE ABOVE 266 F 130 C DOES IT COOLANT TEMPERATURE SCAN...

Page 643: ...ecks the sensor ground A faulty sensor ground will cause a Code 21 DIAGNOSTIC AIDS The scan tool reads throttle position in voltage and percentage of throttle blade opening With ignition ON or at idle...

Page 644: ...O VOLTAGE OR FAULTY ECM CONNECTION OR FAULTY ECM VOLTAGE LESS THAN 36 VOLT IGNITION OFF DISCONNECT THROTTLE POSITION SENSOR ELECTRICAL CONNECTOR JUMPER THROTTLE POSITION SENSOR HARNESS TERMINALS A AND...

Page 645: ...ound CKT 813 is open 3 This step will determine if the fault is in the IAT sensor or the circuit DIAGNOSTIC AIDS The scan tool reads temperature of the air entering the engine and should read close to...

Page 646: ...AGNOSTIC AIDS ON FACING PAGE NO YES IGNITION OFF DISCONNECT IAT SENSOR IGNITION ON SCAN TOOL SHOULD DISPLAY TEMPERATURE LESS THAN 22 F 30 C DOES IT CKT 472 SHORTED TO GROUND OR FAULTY ECM TEMPERATURE...

Page 647: ...ooting 2 If the ECM recognizes the low MAP signal the ECM and wiring are OK DIAGNOSTIC AIDS If the idle is rough or unstable refer to Troubleshoot ing for items which can cause an unstable idle With t...

Page 648: ...SCAN TOOL SHOULD DISPLAY A VOLTAGE OF LESS THAN 1 VOLT DOES IT VOLTAGE LESS THAN 1 VOLT IGNITION OFF DISCONNECT MAP SENSOR ELECTRICAL CONNECTOR JUMPER MAP SENSOR HARNESS TERMINALS C AND B TOGETHER STA...

Page 649: ...C mode so the IC voltage will be low and Code 42 will be set If the IC line is grounded the ignition module will switch to IC but because the line is grounded there will be no IC signal A Code 42 will...

Page 650: ...VOLTAGE AS TEST LIGHT CONTACTS CKT 424 RESISTANCE SHOULD SWITCH FROM OVER 3000 TO UNDER 1000 OHMS DOES IT CLEAR CODES IDLE ENGINE FOR 1 MINUTE OR UNTIL CODE 42 SETS DOES CODE 42 SET CODE 42 INTERMITTE...

Page 651: ...out 3 2 degrees of timing retard 2 This step checks if there is a voltage source to the knock sensor from the KS module 3 This step will determine if the knock sensor is faulty DIAGNOSTIC AIDS If CKT...

Page 652: ...NECTOR J 2 IGNITION ON CONNECT DVOM FROM ECM HARNESS CONNECTOR TERMINAL C CKT 485 TO GROUND ARE 8 10 VOLTS PRESENT NO YES FAULTY ECM RECONNECT 5 WAY KS MODULE CONNECTOR DISCONNECT KNOCK SENSOR HARNESS...

Page 653: ...med to correct this failure Replacement of the ECM with a factory reprogrammed ECM is necessary if Code 51 is current and resets when clearing codes is completed DIAGNOSTIC AIDS An intermittent Code 5...

Page 654: ...5E 113 90 823225 1 1096 Code 51 Calibration Memory Failure Scan 2 of 2 IGNITION ON USING SCAN TOOL CLEAR CODES DOES CODE 51 RESET 1 YES REPLACE ECM AND VERIFY CODE DOES NOT RESET NO FAULT IS NOT PRESE...

Page 655: ...sor Code 23 IAT Intake Air Temperature Code 33 MAP Manifold Absolute Pressure Code 42 IC Ignition Control Code 43 KS Knock Sensor Code 51 Calibration Memory Failure Important Preliminary Checks Before...

Page 656: ...mportance of this step cannot be stressed too strongly It can lead to correcting a problem without further checks and can save valuable time These checks should include 1 ECM grounds and sensors for b...

Page 657: ...rmed or replaced to insure proper contact ten sion 3 Poor terminal to wire connection crimping An intermittent may be caused by 1 Electrical system interference caused by a sharp electrical surge Norm...

Page 658: ...dirty water separating fuel filter 3 Contaminated fuel or winter grade fuel during warm weather 4 Vapor lock condition or engine flooding Check fuel pressure 5 VST fault stuck float leaking vapor reg...

Page 659: ...a DTC 14 and or DTC 33 2 Throttle Position TP sensor ground CKT 813 could have a possible open and set DTC 21 3 A sticking throttle shaft or binding linkage causes a high Throttle Position TP sensor v...

Page 660: ...Intermittent ground connection on ignition coil 3 Proper operation advancing or retarding of Ignition Control IC 4 Condition of distributor cap rotor and spark plug wires 5 Proper and clean connection...

Page 661: ...TION MULTI PORT AND THROTTLE BODY SURGES continued ADDITIONAL CHECKS FOR 1 Proper alternator output voltage 2 Leaks or kinks in vacuum lines 3 Power reduction mode activated if equipped 4 Clean and ti...

Page 662: ...l checks as described at the start of Troubleshooting Charts section CHECK FUEL SYSTEM FOR 1 Water contaminated fuel and dirty or restricted fuel filter 2 Fuel pressure within specification 3 Proper f...

Page 663: ...uld increase as throttle is moved toward Wide Open Throttle WOT 2 Throttle Position TP sensor 5 volt reference CKT 416 for open DTC 21 may be set 3 Throttle Position TP sensor circuit for open or grou...

Page 664: ...nated fuel 2 Poor fuel quality and proper octane rating 3 Fuel pressure within specification CHECK IGNITION SYSTEM FOR 1 Proper ignition timing 2 Proper operation of Knock Sensor KS system Ensure wire...

Page 665: ...ued CHECK ENGINE FOR 1 Low oil level 2 Excessive oil in the combustion chamber Valve seals for leaking 3 Perform a compression test 4 Combustion chambers for excessive carbon build up Remove carbon wi...

Page 666: ...at the start of Troubleshooting Charts section Remove flame arrestor and check for dirt or for being plugged Replace as necessary CHECK FUEL SYSTEM FOR 1 Dirty or plugged water separating fuel filter...

Page 667: ...record Throttle Position TP sensor voltage It should read less than 7 volt with throttle closed or at idle position A sticky throttle shaft or binding linkage causes a high voltage 4 Power reduction...

Page 668: ...h engine OFF reconnect IAC motor c If there is no RPM drop on one or more cylinders or excessive variation in RPM drop check for spark on the suspected cylinder s d If there is a spark remove spark pl...

Page 669: ...FOR 1 Proper cylinder compression 2 Bent push rods worn rocker arms broken valve springs worn camshaft lobes Repair or replace as necessary ADDITIONAL CHECKS A misfire can be caused by Electromagnetic...

Page 670: ...e stalling Engine idles at incorrect speed PRELIMINARY CHECKS Perform the important preliminary checks as described at the start of the Troubleshooting Charts section CHECK FUEL SYSTEM FOR 1 Open in C...

Page 671: ...inkage or salt corrosion will cause a high Throttle Position TP sensor voltage open throttle indication the ECM will not control idle Using a scan tool or volt meter record Throttle Position TP sensor...

Page 672: ...stem condition If necessary perform fuel system diagnosis 2 Properly functioning fuel injectors CHECK IGNITION SYSTEM FOR 1 Opens and grounds in CKTs 423 424 and 430 2 Proper output voltage of ignitio...

Page 673: ...ooting section CHECK FUEL SYSTEM FOR 1 An abnormal fuel system condition If necessary perform fuel system diagnosis 2 Proper functioning of fuel injectors CHECK IGNITION SYSTEM FOR 1 Opens and grounds...

Page 674: ...HECKS Perform the important preliminary checks as described at the start of the Troubleshooting section CHECK FUEL SYSTEM FOR 1 Leaking injectors 2 Flooded VST CHECK IGNITION SYSTEM FOR 1 Properly fun...

Page 675: ...ction 1 Operator s driving habits 2 Dirty or plugged flame arrestor 3 Fuel leaks CHECK FUEL SYSTEM FOR 1 Quality and type of fuel 2 Flooded VST 3 Fuel pressure within specification CHECK IGNITION SYST...

Page 676: ...continued CHECK SENSORS AND CONTROLS FOR 1 If MAP TP or Coolant Sensor are erratic there will be poor economy CHECK ENGINE FOR 1 Proper cylinder compression 2 Exhaust system restriction 3 Excessive r...

Page 677: ...823225 1 1096 5E 136 ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY Fuel Delivery Systems Cool Fuel System 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 24 25 27 2...

Page 678: ...or 6 Fitting 7 Tubing 8 Fuel Pressure Regulator 9 Screw 2 10 Washer 2 11 Washer 12 Fuel Return Line Fitting 13 Rubber Bushing 8 14 Filter 15 Outlet Fuel Line To Fuel Rail Or Throttle Body 16 O Ring 17...

Page 679: ...IC FUEL INJECTION MULTI PORT AND THROTTLE BODY Vapor Separator Tank VST Exploded View 72803 36 21 22 23 24 25 20 19 18 17 16 15 2 46 47 28 29 30 31 32 38 39 40 41 33 34 35 48 49 1 44 27 45 12 10 8 3 4...

Page 680: ...Plate 20 O ring 21 Adapter 22 O ring 23 Collar 24 O ring 25 Adapter 26 Lockwasher 27 Screw 28 O ring 29 Insulator 30 Lockwasher 31 Nut 32 Electrical Connector 33 Screw 34 Lockwasher 35 L Joint 36 O ri...

Page 681: ...1 22 23 25 2 4 8 14 15 16 17 24 1 Collar 2 O Rings 2 3 Adapters 2 4 O Ring 5 Plate 6 Electric Fuel Pump 7 Rubber Cushion 8 Plate 9 Fuel Filter 10 Seal 11 Chamber Body 12 O Rings 2 13 Insulators 2 14 L...

Page 682: ...90 823225 1 1096 VAPOR SEPARATOR TANK VST 1 4 6 5 8 11 73719 9 7 9 2 3 10 1 Vapor Separator Tank VST 2 Grommet 3 Hose Some Models Connected To Top Fitting 4 Fuel Line Return 5 Plug 6 O Ring 7 Fuel Lin...

Page 683: ...nds and then off four times waiting 10 se conds after each key off to prime the fuel system and check for leaks NOTE If VST is dry remove the vent screw and fill with fuel REMOVAL VST FUEL PUMP 1 Disc...

Page 684: ...t onto cover Tighten screw securely 8 Connect all fuel lines to cover of vapor separator tank Torque fuel line fittings to 23 lb ft 31 N m 9 Connect fuel pump electrical connector 10 With engine OFF c...

Page 685: ...TE Float is not adjustable 2 Install float and needle assembly and secure float arm pin using fastener 3 Apply Loctite 8831 to threads of cover screws Install cover and electrical line retainer clip a...

Page 686: ...t spring for wear Replace if necessary INSTALLATION 1 Install spring diaphragm O ring and diaphragm cover using diaphragm cover screws Tighten screws 2 Install float and needle assembly and secure flo...

Page 687: ...osion hazard and should be avoided Special Tools Description Part Number Fuel Pressure Gauge 91 168850A1 Lubricants Sealants Adhesives Description Part Number Loctite 8831 92 823089 1 Loctite 262 Obta...

Page 688: ...g fuel filter s Wipe up any spilled fuel immediately WARNING Be sure that the engine compartment is well ven tilated and that no gasoline vapors are present to avoid the possibility of fire WARNING Ma...

Page 689: ...E 148 ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY Throttle Body Exploded Views 350 CID 5 7L EFI 2 Barrel Throttle Body Induction System 75067 73766 8 11 12 14 17 18 19 9 10 13 15 16 74109 A...

Page 690: ...crews 4 6 Gasket 7 Intake Manifold 8 Fuel Meter Cover 9 Gasket 10 O ring 11 Fuel Pressure Regulator 12 Gasket 13 Fuel Injector 14 Fuel Meter Body 15 Gasket 16 Fuel Inlet And Outlet Connections 17 Thro...

Page 691: ...823225 1 1096 5E 150 ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY 350 CID 5 7L EFI 4 Barrel Throttle Body Induction System 73965 1 2 3 4 5 6 7 73766 8 11 12 14 17 18 19 9 10 13 15 16 74109 A...

Page 692: ...6 Throttle Body Adapter 7 Gasket 8 Fuel Meter Cover 9 Gasket 10 Fuel Line From VST To Fuel Filter 11 Fuel Pressure Regulator 12 Gasket 13 Fuel Injector 14 Fuel Meter Body 15 Gasket 16 Fuel Inlet And...

Page 693: ...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 T...

Page 694: ...large spring under heavy compression which if accidentally released could cause personal injury REMOVAL 1 Remove the flame arrestor from the throttle body 2 Disconnect electrical connectors to fuel in...

Page 695: ...n removing fuel injectors to prevent damage to the electrical connector and nozzle IMPORTANT The fuel injector is an electrical component DO NOT soak in any liquid cleaner or solvent as damage may res...

Page 696: ...onnections to fuel injectors 6 With engine OFF and ignition ON check for leaks around gasket and fuel line couplings Throttle Body REMOVAL CAUTION Ensure that fuel pressure is relieved before re movin...

Page 697: ...rque the screws 30 ft lb 40 N m 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 lin...

Page 698: ...in the area while changing fuel filter s Wipe up any spilled fuel immediately WARNING Be sure that the engine compartment is well ven tilated and that no gasoline vapors are present to avoid the poss...

Page 699: ...INJECTION MULTI PORT AND THROTTLE BODY Multi Port Exploded Views Flame Arrestor and Throttle Body All Multi Port Injection Engines Equipped Vapor Separator Tank 4 6 8 11 13 14 16 17 12 5 12 15 18 7506...

Page 700: ...l Filter 11 Fuel Line From Starboard To Port Fuel Rail 12 Fuel Rail 2 13 Fuel Pressure Regulator 14 Fuel Block 15 Fuel Line From Fuel Block To VST 16 Fuel Injector 8 17 Intake Manifold 18 Engine Coola...

Page 701: ...1 1096 5E 160 ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY 350 MPI Magnum Gen Tournament Ski Black Scorpion Induction System 75046 2 4 7 9 10 12 14 8 7 17 18 13 1 3 5 6 10 7 13 15 16 11 18 1...

Page 702: ...Hose System b Cool Fuel System Fuel Pressure Relief Procedure NOTICE Refer to Service Precautions in Repair Procedures BEFORE proceeding 1 Disconnect electrical connector at fuel pump 2 Crank engine f...

Page 703: ...ections 3 Remove four throttle body mounting studs using a stud driver 72792 a b a Throttle Body b Throttle Body Mounting Studs 4 Turn throttle body as shown and disconnect TP drain tube and IAC elect...

Page 704: ...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...

Page 705: ...n securely Se cure cable end guide to lever stud Thread lock nut on stud until it contacts end guide a a 74183 74174 a Throttle Linkage Connections 4 Install flame arrestor to throttle body Apply Loc...

Page 706: ...manifold and plenum 1 Carefully remove all gasket material from intake manifold and plenum 2 Clean plenum in solvent and dry with com pressed air 3 Inspect mating surfaces for damage that could affec...

Page 707: ...m and fuel rail as outlined in this section 2 Remove fuel injectors from fuel rail and intake manifold CLEANING AND INSPECTION Inspect fuel injectors for damage replace if neces sary INSTALLATION IMPO...

Page 708: ...ore take care not to touch connector pins when re moving or installing the module NOTICE Refer to Service Precautions in Repair Procedures BEFORE proceeding REMOVAL 1 Disconnect J1 and J2 electrical c...

Page 709: ...nector d J2 Electrical Connector Rear Connector Knock Sensor KS Module NOTICE Refer to Service Precautions in Repair Procedures BEFORE proceeding REMOVAL 1 Remove Knock Sensor from electrical bracket...

Page 710: ...g REMOVAL NOTE Handle the ECT carefully as any damage to it will affect operation of the system 1 Disconnect electrical connector at Engine Cool ant Temperature ECT sensor 72799 b a a Thermostat Housi...

Page 711: ...ff any foreign matter with a dry cloth 2 Inspect for any obvious signs of physical damage to the sensor INSTALLATION 1 Install MAP sensor to throttle body adapter using screws Torque screws to 44 62 l...

Page 712: ...at W O T Idle Air Control IAC Valve NOTICE Refer to Service Precautions in Repair Procedures BEFORE proceeding REMOVAL 1 Remove flame arrestor throttle cable and throttle body as outlined in Throttle...

Page 713: ...dy using screws Torque to 20 lb in 2 N m 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 reconnect ing negati...

Page 714: ...h an identical part Knock sensors are very sensitive and designed for each specific application IMPORTANT In the following step it is very im portant that the knock sensor be torqued to the precise sp...

Page 715: ...ept Black Scorpion a Manifold Absolute Pressure MAP Sensor b Seal c Plenum d Screws 75046 b c a d Black Scorpion a Manifold Absolute Pressure MAP Sensor b Seal c Plenum d Screws 2 Remove screws from M...

Page 716: ...ing 75326 a b b Black Scorpion a Throttle Position TP Sensor b Screws 2 Remove TP from throttle body CLEANING AND INSPECTION 1 Clean the surfaces of the TP with a dry cloth 2 Inspect the TP for signs...

Page 717: ...r to re move 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 s...

Page 718: ...t is very im portant that the knock sensor be torqued to the precise specification Incorrect torquing will re sult in unsatisfactory performance DO NOT use sealer on threads 1 Install knock sensor in...

Page 719: ...6 7 9 11 12 10 13 14 17 16 19 18 1 3 8 15 1 Bracket 2 Relay 3 Relay 4 Screw 5 Knock Sensor KS Sensor 6 Screw 7 Slave Solenoid 8 Nut 9 Circuit Breaker 10 Screw 11 Screw 12 MerCathode 13 Data Link Conn...

Page 720: ...cket Ignition Control IC System Components Precautions WARNING When performing the following procedures be sure to observe the following precautions to avoid damage to equipment or personal injury DO...

Page 721: ...meter as shown with meter 1 in the fig ure below 72920 1 2 3 2 Setting the meter to its highest ohms scale check resistance The reading should indicate infinite resistance If it does not replace the c...

Page 722: ...disconnect it from DLC connector 8 Manually close throttle to bring engine down to idle state Spark Plug Replacement SPARK PLUG WIRING AND BOOT PRECAUTIONS 1 Twist boots one half turn before removing...

Page 723: ...ssary Failure to route wires properly can lead to radio frequency interference cross firing of the plugs and or shorting of leads to ground NOTE When replacing spark plug wires it is good practice to...

Page 724: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY 5E 183 90 823225 1 1096...

Page 725: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 90 823225 1 1096 5E 184 ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY...

Page 726: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE ELECTRONIC FUEL INJECTION MULTI PORT AND THROTTLE BODY 5E 185 90 823225 1 1096...

Page 727: ...F 5 73662 FUEL SYSTEMS BOS SAV EMISSIONS...

Page 728: ...Piston assembly cover is higher 5F 5 Precautions 5F 5 Maintenance 5F 6 Flame Arrestor 5F 6 Fuel Filter 5F 6 Positive Crankcase Ventilation PCV 5F 6 Troubleshooting 5F 7 Checking Ported Vacuum Switch a...

Page 729: ...uld result in a fire or explosion hazard and should be avoided Torque Specifications Description lb ft lb in N m Carburetor to Manifold 132 15 Fuel Line to Carburetor 18 24 Special Tools Mercury Marin...

Page 730: ...nt Specifications Make And Model Weber WFB Float Level 1 9 32 33 Float Drop 2 In 51 Pump Rod Hole Location Number 3 from end Hole closest to lever pivot point Accelerator Pump 7 16 11 Note 1 Choke Pul...

Page 731: ...y 128 F 54 C the PVS opens allowing a metered amount of air to be mixed into the idle circuit This leans the idle circuit to the proper operating air fuel ratio The high speed circuits use staged step...

Page 732: ...b Metering Rod c Spring d Jet e Piston Cover METERING JETS The metering jets in this carburetor are taller than the jets in a standard carburetor 73728 Standard Emissions a b a Jet for 3 Step Metering...

Page 733: ...allow sources of spark or open flame in area when cleaning flame arrestor and crankcase ventilation hose WARNING Be careful when changing fuel system compo nents gasoline is extremely flammable and hi...

Page 734: ...ons system is in the vent hose bracket This bracket has a fitting on one side only 71798 71797 b a d c a Stud b Vent Hose Bracket c Vent Hose to Starboard Valve Cover d NO VENT HOSE ON THIS SIDE Fuel...

Page 735: ...tch and Carburetor Vacuum Circuit for Correct Operation NOTE The engine must be cold before performing the first 4 steps 1 Start engine Disconnect the hose from the car buretor at the location shown 7...

Page 736: ...est on the other port If vacuum is not present a vacuum port may be plugged Clean vacuum ports and repeat the entire test 73740 73739 9 When test is complete and PVS is determined to be functioning pr...

Page 737: ...oved and the seal casing can be removed 73744 Installing New Seals 1 Install new seal cup spring and idle mixture screw IMPORTANT Do not install the seal plug until the Propane Assisted Idle Mixture A...

Page 738: ...Throttle Bracket b Attaching Hardware c Fuel Line d Fuel Inlet Nut Ported Vacuum Switch Installation CAUTION Be careful not to break off fittings when installing the ported vacuum switch PVS in the fo...

Page 739: ...ite end of hose to fitting on front of carburetor 71925 73701 b a c a PCV Valve b Hose c Carburetor Fitting Connect Hose Here 3 Connect hoses to ported vacuum switch PVS as shown 71924 73702 a b a b c...

Page 740: ...ot start the flow of propane until the hose has been placed into the carburetor and the engine has been started Keep a fire extinguisher available when per forming this test NOTE This test must be per...

Page 741: ...w not the mixture screws to obtain 850 RPM Again fine tune the propane metering valve to obtain the highest engine RPM If there has been a change in the maximum RPM read just the idle speed screw to 8...

Page 742: ...zer Testing Agency 73723 a b a Exhaust Probe Collector b To Exhaust Analyzer Emissions Testing NOTE This test will be performed by an authorized agency for the area that the boat will be operated This...

Page 743: ...arly as to the ignition sys tem Proper engine tuning procedures to ensure these features remain in good operating order Proper steps to maintain the engine within specification The instructions in the...

Page 744: ...A 6 22381 COOLING SYSTEM SEAWATER COOLING MODELS...

Page 745: ...rive Unit Seawater Pickup Pump Repairs 6A 7 Water Circulating Pump Replacement 6A 7 Removal 6A 7 Cleaning and Inspection 6A 7 Installation 6A 7 Flushing Seawater Cooling System 6A 8 Engines with Stern...

Page 746: ...ter Circulating Pump Water Temperature Sender 20 27 Drain Plugs See Note S l Hose Clamps Securely Petcocks Securely Pulleys NOTE Coat threads with Quicksilver Perfect Seal before installing TOOLS LUBR...

Page 747: ...hose clamps Seacock Seawater Inlet Valve If a seacock is being used it must be installed be tween water pickup and seawater pickup pump or sea strainer to allow operator to shut off the seawa ter in...

Page 748: ...esigned 5 Apply marine caulking as needed inside boat Apply Loctite to threads of nut and install on pick up on inside of boat and torque nut to 35 lb ft 42 N m NOTE If pickup being used does not have...

Page 749: ...mation on removal and installation of other than Quicksilver Sea Strainer Removal CAUTION If boat is in water while working on seawater strainer close seacock if so equipped If boat is not equipped wi...

Page 750: ...n gine or transmission parts 1 Mount seawater strainer arrow must point to ward seawater pump Tighten mounting bolts securely 72644 b c a c a Seawater Strainer b Arrow c Mounting Bolt Hole Location Bo...

Page 751: ...e water output Due to the manner in which this test is per formed it may not be possible to detect a marginal condition or a high speed water pump output problem 1 Remove water inlet hose which runs b...

Page 752: ...ing if so equipped and pulley 6 Disconnect hose s from pump 7 Remove bolts which secure pump to cylinder block and remove pump and old gaskets dis card gaskets Cleaning and Inspection 1 Clean gasket s...

Page 753: ...system with boat in water raise drive unit to trailer position install flushing attach ment and lower drive unit to full IN DOWN position 1 Install Quicksilver Flushing Attachment or equivalent over...

Page 754: ...r in system which would indicate an external leak 72673 b c d e f g h a Quicksilver Seawater Strainer Shown a Screws and Washers b Cover c Glass d O Ring e Strainer f Housing g Drain Plug and Sealing...

Page 755: ...water b Open thermostat valve and insert nylon string Position thermostat on string so that it will be just below water level when sus pended then allow valve to close Suspend thermostat in water c P...

Page 756: ...in thermostat housing as shown Stainless Steel Thermostat 71801 72674 a b Brass Thermostat a Install Thermostat With This End Down Toward Thermostat Housing 5 Align tang on sleeve with groove in therm...

Page 757: ...stem Engine must be as level as possible A wire should be repeatedly inserted into all drain holes to ensure there are no obstruc tions in passages IMPORTANT To prevent threads in manifolds el bows an...

Page 758: ...Side Shown Port Similar a Bottom Hose Exhaust Manifold to Thermostat Housing b c b Drain Plug in Exhaust Manifold Elbow c Later Models Are Equipped With This Style Of Drain Plug 5 Remove the engine w...

Page 759: ...d newer models the additional following steps must be performed a Remove the drain plug from the Y fitting from the port side of the block a a Drain Plug b Remove the drain plug from the water tube ca...

Page 760: ...rd e Gear Housing Cavity Vent Hole f Gear Housing Cavity Drain Hole b Bravo Drive Equipped Models Insert a small wire repeatedly to make sure that speedometer pitot tube trim tab cavity vent hole and...

Page 761: ...t and starboard from cylinder block 72586 Starboard Side Shown Port Similar a Petcock or Plug a 3 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained NO...

Page 762: ...e Seawater Pickup Pump to Cooler a 7 Remove seawater pump inlet hose as shown 72532 a Seawater Pickup Pump b Seawater Inlet Hose b a 8 Crank engine over SLIGHTLY with starter motor to purge any water...

Page 763: ...nt is lost in the system an air pocket may form in the closed cooling system This in turn can cause the engine to overheat Make heater connections ONLY at locations described in the following instruct...

Page 764: ...hing c Hose Connector 71758 a Raw Water Cooling Models Alternate Location a Location for Hot Water Supply Install Bayonet Fitting Here RETURN HOSE CONNECTION ENGINES WITH RAW WATER OR CLOSED COOLING S...

Page 765: ...AKE MANIFOLD AND CYLINDER HEAD ASSY WATER INLET FROM STERN DRIVE EXHAUST ELBOW RESTRICTOR EXHAUST MANIFOLD POWER STEERING FLUID COOLER 22382 TO EXHAUST MANIFOLDS TO EXHAUST ELBOW FROM ENGINE TO ENGINE...

Page 766: ...M Alpha Gen With Cool Fuel System THERMOSTAT HOUSING ENGINE CIRCULATING PUMP ENGINE BLOCK INTAKE MANIFOLD AND CYLINDER HEAD ASSY POWER STEERING FLUID COOLER EXHAUST MANIFOLD RESTRICTOR EXHAUST ELBOW O...

Page 767: ...WER STEERING FLUID COOLER 72998 TO EXHAUST MANIFOLDS TO EXHAUST ELBOW FROM ENGINE TO ENGINE CIRCULATING PUMP FROM WATER INLET VIA FLUID COOLER THERMOSTAT LEGEND COLD WARM 22380 NOTE Thermostat housing...

Page 768: ...MCM Bravo With Cool Fuel System OVERBOARD ENGINE BLOCK INTAKE MANIFOLD AND CYLINDER HEAD ASSY WATER INLET FROM STERN DRIVE EXHAUST ELBOW RESTRICTOR EXHAUST MANIFOLD POWER STEERING FLUID COOLER THERMOS...

Page 769: ...FOLD AND CYLINDER HEAD ASSY EXHAUST ELBOW RESTRICTOR EXHAUST MANIFOLD TRANSMISSION FLUID COOLER TO EXHAUST MANIFOLDS TO EXHAUST ELBOW FROM ENGINE TO ENGINE CIRCULATING PUMP FROM WATER INLET VIA FLUID...

Page 770: ...d With Cool Fuel System OVERBOARD ENGINE BLOCK INTAKE MANIFOLD AND CYLINDER HEAD ASSY WATER INLET FROM STERN DRIVE EXHAUST ELBOW RESTRICTOR EXHAUST MANIFOLD TRANSMISSION FLUID COOLER THERMOSTAT HOUSIN...

Page 771: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 6A 26 SEAWATER COOLING MODELS 90 823225 1 1096...

Page 772: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE SEAWATER COOLING MODELS 6A 27 90 823225 1 1096...

Page 773: ...B 6 72987 COOLING SYSTEM CLOSED COOLED MODELS...

Page 774: ...rmostat 6B 21 Removal 6B 21 Testing 6B 23 Installation 6B 24 Page Changing Coolant 6B 26 Closed Cooling Section 6B 26 Coolant Recommendations 6B 26 Change Intervals 6B 26 Draining Instructions 6B 27 C...

Page 775: ...Clamps LUBRICANTS SEALERS AND ADHESIVES DESCRIPTION PART NUMBER Quicksilver 2 4 C Marine Lubricant with Teflon 92 825407A3 Quicksilver Perfect Seal 92 34227 1 Quicksilver Liquid Neoprene 92 25711 2 Qu...

Page 776: ...Housing Shown All Similar a a a a b b c c a b RAW WATER FLOW COOLANT FLOW a Remove Hoses Lift Lower or Bend To Completely Drain b Remove Block Plugs Repeatedly Clean Out Holes Using A Stiff Wire Until...

Page 777: ...WATER FLOW b a c c b b a a a Remove Hoses Lift Lower or Bend To Completely Drain b Remove Block Plugs Repeatedly Clean Out Holes Using A Stiff Wire Until Entire System Is Drained c Remove Drain Plugs...

Page 778: ...to the reservoir from the recovery bottle as the engine cools As long as there is coolant in the recovery bottle the reservoir should remain completely full If not there s a vacuum leak usually at the...

Page 779: ...ay not be possible to detect a marginal condition or a high speed water pump output problem 1 Remove water hose which runs between pump outlet and engine and replace with another hose of same diameter...

Page 780: ...ed on engine 1 Close seacock if so equipped or disconnect and plug seawater inlet hose 2 Disconnect water inlet and outlet hoses from pump 3 If pump is to be disassembled loosen the four pump pulley a...

Page 781: ...8 Impeller 9 Body 10 Gasket 11 Wear Plate Inner 12 O Ring or Quad Ring 13 Oil Seal 14 Housing 15 Ball Bearing 16 Shaft 17 Ball Bearing 18 Snap Ring 19 Oil Seal 20 Hub 74577 1 2 3 4 5 6 7 8 9 10 11 12...

Page 782: ...sket outer wear plate and gasket discard gaskets 72651 b c a a Gasket with Large Opening b Wear Plate Outer c Gasket with Two Openings 72652 b c a a Gasket with Large Opening b Wear Plate Outer c Gask...

Page 783: ...mp body 75277 b a a Screws 5 b Seawater Pump Body 2 Remove seawater pump body and wear plate from bearing housing 75275 a c b a Seawater Pump Body b Wear Plate c Bearing Housing 3 Remove the impeller...

Page 784: ...ess 72648 a a Universal Puller Plate 91 37241 3 Puncture front oil seal with a tool and pry from bearing housing 72649 4 Remove snap ring from bearing housing bore and press shaft and bearings out pul...

Page 785: ...of inner races turning on shaft 8 Inspect pump body 9 Inspect inner and outer wear plate 10 Inspect pump impeller for wear on sides and tips of blades Also inspect blades for cracks in area where bla...

Page 786: ...ite 8831 to outside diameter of new bearing housing front oil seal and press seal into housing with seal lip fac ing inward until it bottoms out 72662 a a Front Oil Seal IMPORTANT Be sure to support i...

Page 787: ...Seal REASSEMBLY TWO PIECE BODY 1 Place inner wear plate on housing and align holes Coat both sides of a new wear plate gasket with a thin film of Quicksilver Perfect Seal and po sition on wear plate 7...

Page 788: ...ew gaskets on each side aligning holes in plate and gaskets with holes in pump body 72652 b c a a Gasket with Large Opening b Wear Plate Outer c Gasket with Two Openings 72651 b c a a Gasket with Larg...

Page 789: ...as shown Use these two screws to align pump then install the remaining screws 75277 a a a Bolt Holes For Alignment INSTALLATION 1 Position pump in mounting bracket so that outlet connection will be di...

Page 790: ...engine Do not tighten attaching screws at this time 4 Torque pump pulley attaching screws 5 Position drive belt on pulleys and adjust belt ten sion as outlined in Drive Belt Tension Adjust ment 6 Con...

Page 791: ...AT ANY TIME In areas where ethylene glycol is not available and the possibility of freezing does not exist it is permissible to use a solution of rust in hibitor and pure soft water mixed to manufac...

Page 792: ...mporary fix because usually another tube will start leaking after a short period of time and this also causes a reduction in cooling capacity Do not close more than three tubes 2 Nipples and drains th...

Page 793: ...found 7 While maintaining specified pressure on closed cooling section visually inspect external portion of cooling system hoses gaskets drain plugs petcocks core plugs circulating pump seal etc for l...

Page 794: ...iven RPM A head gasket leak will not stop because the one thing that marks a failed head gasket is the continued pas sage of air This may be accompanied by violent in termittent bursts of coolant leav...

Page 795: ...ure 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 surface in filler ne...

Page 796: ...m thermostat cover 3 Remove thermostat cover attaching bolts and lockwashers then remove cover and gasket NOTE Some engines may be equipped with a Lifting Eye bracket not shown following under thermos...

Page 797: ...deposits or debris 2 Inspect thermostat for corrosion or other visible damage 3 If thermostat is suspected of producing insuffi cient engine temperature check thermostat for leakage by holding it up t...

Page 798: ...ead Thermostat must open at 138 145 F 59 63 C Thermostat must be completely open at 170 F 77 C e Unplug tester and allow water to cool to a temperature 10 F 5 C below specified tem perature on thermos...

Page 799: ...ts to 30 lb ft 41 N m 73111 b c f a g e d Models Without Sleeve a Bolts b Lockwashers c Cover d Gasket e Thermostat Typical f Housing g Gasket With Continuity Rivets 73110 b c d e f g h a i Models Wit...

Page 800: ...d coolant solution Do not drain closed cooling section for storage as this will promote rusting of internal surfaces If engine will be exposed to freezing temperatures make sure that closed cooling se...

Page 801: ...Quicksilver Perfect Seal and install drain plugs and hoses Tighten clamps and drain plugs securely 4 Remove coolant recovery bottle from mounting bracket and pour out coolant 5 Clean system as outline...

Page 802: ...ter Section of Closed Cooling System If engine is operated in salty polluted or mineral laden waters seawater section of closed cooling system should be flushed periodically preferably after each use...

Page 803: ...ity and allow drive unit and cooling system to fill completely Do not use full tap water pressure NOTE Drive unit is full when water is discharged out of drive unit and or seawater section of closed c...

Page 804: ...ignition switch or steering wheel of the boat with the warning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine IMPORTANT Observe the following informat...

Page 805: ...On Engines Equipped with a Belt Driven Sea water Pickup Pump Remove seawater inlet hose as shown 72532 b a a Seawater Pickup Pump b Seawater Inlet Host 9 Crank engine over SLIGHTLY with starter motor...

Page 806: ...CAUTION Models with belt drive seawater pickup pump must be in the water when running engine be cause garden hose will not supply enough water to system at higher RPM 3 With pressure cap off start eng...

Page 807: ...check coolant section for leaks 71712 a a Fill Cap IMPORTANT ALCOHOL OR METHANOL BASE ANTIFREEZE OR PLAIN WATER ARE NOT REC OMMENDED FOR USE IN CLOSED COOLING SYSTEM AT ANY TIME In areas where ethyle...

Page 808: ...is not al kaline and MUST BE REPLACED as explained under Changing Fresh Water Coolant follow ing Changing Coolant DRAINING INSTRUCTIONS 1 Remove coolant recovery bottle and pour out coolant WARNING Co...

Page 809: ...or use in coolant sec tion of Closed Cooling System at any time It is recommended that coolant section of Closed Cooling System be filled with a 50 50 mixture of ethy lene glycol antifreeze and pure s...

Page 810: ...ic tubing above heat exchanger filler neck Allow coolant to flow down through tubing to purge air through filler neck fitting 5 Install pressure cap on heat exchanger 6 With engine still running check...

Page 811: ...llows 1 Remove pressure cap from heat exchanger 2 Wash cap with clean water to remove any depos its or debris from sealing surfaces 3 Inspect rubber seal on cap for cuts cracks or other signs of deter...

Page 812: ...n and partially open water tap approximately 1 2 minimum capacity DO NOT use full city water pressure WARNING When flushing cooling system with boat out of the water be certain that area in vicinity o...

Page 813: ...raining Instructions and drain seawater section 2 Remove end cover attaching screw O ring and rubber gasket from port and starboard ends of heat exchanger 71515 b c d a Starboard End Cover Shown Port...

Page 814: ...securely 10 Start engine and check for leaks Cleaning Closed Cooling Section Closed Cooling section of cooling system should be cleaned whenever decreased cooling efficiency due to internal deposits i...

Page 815: ...ow water to drain com pletely CAUTION If seawater section of the Closed Cooling System is to be drained with boat in the water seacock water inlet valve if boat is so equipped must be closed or water...

Page 816: ...g from port side seawater pipe b a 74988 a Seawater Pipe b Seawater Pipe Drain Plug 4 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained 5 Remove end c...

Page 817: ...otor to purge any water trapped in sea water pickup pump Do not allow engine to start 7 After cooling system has drained completely re install drain plugs and connect all seawater hoses Tighten each s...

Page 818: ...stud until the correct deflection of 1 4 in 6 mm with moderate thumb pressure on the belt at location indicated by arrow and dashed lines of the belt is obtained at location shown 74933 Belt Routing W...

Page 819: ...instructions Check complete system for leaks after heater is connected into cooling system Check for overheating condition of engine after heater is connected 1 Refer to Changing Coolant Draining Ins...

Page 820: ...OOLING MODELS 90 823225 1 1096 RETURN HOSE CONNECTION 72705 a Earlier Style Quicksilver Kit Location a T Fitting 72702 a b Later Style Quicksilver Kit Location a Pipe Plug b Hose Connector c T Fitting...

Page 821: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE CLOSED COOLING MODELS 6B 47 90 823225 1 1096...

Page 822: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 6B 48 CLOSED COOLING MODELS 90 823225 1 1096...

Page 823: ...A 7 72699 EXHAUST SYSTEM GENERAL...

Page 824: ...ontents Page Exhaust System Requirements 7A 1 Determining If Exhaust Elbow Risers Are Required 7A 1 MCM Stern Drive Engines With Thru Transom Exhaust 7A 1 MIE Inboard Engines 7A 2 Exhaust Hose Connect...

Page 825: ...st Point On Exhaust Elbow To Top Of Transom Model a Minus b Must Be at Least All 13 In 330 mm MCM Stern Drive Engines With Thru Transom Exhaust When designing and installing exhaust system the followi...

Page 826: ...exist at any point in the exhaust hose or pipe 4 Exhaust outlet must be slightly above the water line with boat at rest in the water and full load aboard Exhaust outlet should be equipped with an int...

Page 827: ...d degrade propeller performance on some boats IMPORTANT When installing thru propeller ex haust With any application installation of an ex haust tube will increase exhaust noise With Bravo One and Bra...

Page 828: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 7A 4 GENERAL 90 823225 1 1096...

Page 829: ...B 7 72695 EXHAUST SYSTEM MANIFOLDS AND ELBOWS...

Page 830: ...7B 0 MANIFOLDS AND ELBOWS 90 823225 1 1096 Table of Contents Page Torque Specifications 7B 1 Sealants 7B 1 Removal 7B 1 Cleaning and Inspection 7B 2 Installation 7B 2 7B MANIFOLDS AND ELBOWS...

Page 831: ...isconnect exhaust bellows and cooling hoses 4 Starboard Manifold a Disconnect both shift cables MCM only b Disconnect instrument harness plug from en gine harness if mounted on exhaust elbow c Remove...

Page 832: ...stallation 1 Using new gasket install exhaust manifold to cyl inder head Torque fasteners to 25 lb ft 34 N m IMPORTANT See Section 7C if exhaust risers are used 2 Using a new gasket install exhaust el...

Page 833: ...BOWS 7B 3 90 823225 1 1096 72696 c d e b f a Stainless Steel Elbow With Separator Gasket Cast Iron Elbow Similar a Exhaust Elbow b Bolts 4 c Gasket Seawater Cooled Aligned As Shown d Exhaust Manifold...

Page 834: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 7B 4 MANIFOLDS AND ELBOWS 90 823225 1 1096...

Page 835: ...C 7 70593 EXHAUST SYSTEM RISERS...

Page 836: ...7C 1 Replacement Information 7C 1 Engine Preparation and Parts Removal 7C 1 Engine Preparation and Component Removal 7C 2 Exhaust Extension Kit Installation 7C 3 Installation Diagrams 7C 3 Cast Iron E...

Page 837: ...or damage to equipment should wires be accidentally shorted Discon nect BOTH battery cables from battery before proceeding 1 Disconnect battery cables from battery CAUTION Avoid severe engine damage E...

Page 838: ...rs between riser plate if so equipped and fasten with existing nuts Tighten securely 5 Reattach and tighten securely all parts previously removed from elbow to appropriate position on riser bracket if...

Page 839: ...or With 3in 76 mm Riser b Leave Full Length For Use With 6 In 152 mm Riser 2 Tighten hose clamps securely 3 Upon first start up of engine check for leaks Installation Diagrams IMPORTANT Remember what...

Page 840: ...mm h Stud 8 10 3 8 Inch 264 mm Used With Remote Oil Filter i Washer 8 j Exhaust Manifold Cast Iron Elbows With Mufflers A B f i c e J a b d k g h g h c d i J 70622 a Exhaust Elbow b Muffler Spacer 1 1...

Page 841: ...r e Nuts 8 f Washers 8 g Open Gasket h 3 Inch 76 mm Riser i Restrictor Gasket j Separator Gasket Stainless Steel Elbows With Mufflers 70602 a b c c d d e e f f h g i J k i i A B a Exhaust Manifold b E...

Page 842: ...aust elbows manifolds and riser gaskets for leakage Replace gaskets if necessary 4 IF THE POSSIBILITY OF FREEZING EXISTS remove drain plug from the exhaust elbow riser and allow water to drain complet...

Page 843: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE RISERS 7C 7 90 823225 1 1096...

Page 844: ...D 7 72737 EXHAUST SYSTEM COLLECTORS...

Page 845: ...t 7D 3 Shutter Replacement 7D 3 Component Replacement 7D 3 Below Swim Platform Exhaust Pipe Kit 7D 3 Modifying Swim Platform Exhaust Pipe If Required 7D 4 Silent Choice Exhaust System 7D 4 Exhaust Bel...

Page 846: ...rt Number Quicksilver 2 4 C Marine Lubricant With Teflon 92 825407A3 Loctite 35 92 59328 1 Loctite Primer 92 59327 1 Quicksilver Bellows Adhesive 92 86166 Quicksilver Perfect Seal 92 34227 1 Quicksilv...

Page 847: ...owing must be adhered to All mating joint surfaces must be clean O ring must remain in groove to properly seal joints to prevent leakage Torque all bolts to 20 25 lb ft 27 34 N m Tighten all clamps se...

Page 848: ...e Of Boat c Support Member d Rivets 4 3 Install new shutter as shown in Component Re placement following Tighten screws and nut se curely 4 Reinstall exhaust hose Tighten clamps securely Component Rep...

Page 849: ...m exhaust an exhaust pipe kit P N 44266A6 is required contain ing the exhaust pipe and necessary parts IMPORTANT When installing Silent Choice ex haust it is recommended that the exhaust bel lows on t...

Page 850: ...sides 2 Install clamp 3 Tighten clamp Torque to 35 lb in 4 N m a b c e d 22184 22184 a Exhaust Tube b Clamp c Side Marking d Exhaust Tube e Grounding Clip CAUTION It is the responsibility of the boat...

Page 851: ...ar If filter is clogged or partially clogged replace The filter pad is glued in and may be removed with a needle nose pliers Clean surface in casting apply a single dot of Quicksilver Sound Blanket Gl...

Page 852: ...y 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 an...

Page 853: ...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 muff...

Page 854: ...e place Clean groove thoroughly b Glue new O ring seal in groove using Sound Blanket Glue Wipe off excess glue immedi ately 5 Reinstall muffler end plate with four screws Tighten securely 6 Reinstall...

Page 855: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 7D 10 COLLECTORS 90 823225 1 1096...

Page 856: ...A 8 DRIVES VELVET DRIVE IN LINE TRANSMISSION...

Page 857: ...tput Shaft Rolling Torque 8A 2 Transmission Fluid Specification 8A 2 Important Information 8A 3 Shift Control and Cables 8A 3 Engine 8A 3 Transmission 8A 3 Propeller 8A 3 Transmission Shift Lever 8A 4...

Page 858: ...sion Ratios Ratio in Forward Gear NOTE 1 2 Identification Plate Color Code 1 1 Red 1 1 Green 1 1 Green 1 5 1 2 5 1 2 91 1 Green NOTE 1 This ratio is shown on identification plate Ratio may be rounded...

Page 859: ...allow boat to sit overnight Remove and wipe clean the dipstick Insert clean dipstick and mark the cold fluid level Transmission Pressure Specifications Engine RPM Neutral Gear PSI kPa Forward Gear PSI...

Page 860: ...n transmission case Trans mission rotation is described when viewed from the rear of transmission with transmission in forward gear selector position On MIE engines equipped with in line transmissions...

Page 861: ...RPM for 2 minutes im mediately prior to checking level 72526 b c a 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...

Page 862: ...ting from bushing c Drain oil from transmission cooler and cool er hoses into a suitable container 72840 a b Transmission With 1 1 Ratio a Hose b Elbow Fitting 72841 b a Transmission with Reduction Ra...

Page 863: ...h Quicksilver Perfect Seal Install and torque bushing to 25 lb ft 34 N m 8 Coat elbow fitting threads with Quicksilver Per fect Seal and install in bushing Tighten securely 9 Reconnect hose and tighte...

Page 864: ...m 16 Align transmission splines with drive plate splines 17 Slide transmission into place and secure with bolts 18 Remove two long studs installed in Step 9 and install remaining two bolts Torque all...

Page 865: ...as follows 1 Remove four pump attaching bolts 2 Loosen the pump housing A soft tip mallet may be used to tap the fluid passage boss Do not strike the bolt bosses IMPORTANT Do not remove the pump from...

Page 866: ...lever through for ward neutral and reverse positions No more than finger tip effort should be required If valve binds cause for binding must be found and cor rected Pressure Test 1 Install pressure ga...

Page 867: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 8A 10 VELVET DRIVE IN LINE TRANSMISSION 90 823225 1 1096...

Page 868: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE VELVET DRIVE IN LINE TRANSMISSION 8A 11 90 823225 1 1096...

Page 869: ...B 8 DRIVES VELVET DRIVE V DRIVE AND WALTER V DRIVE TRANSMISSION...

Page 870: ...lling Torque 8B 2 Transmission Fluid Specification 8B 2 Important Information 8B 3 Shift Control and Cables 8B 3 Engine 8B 3 Transmission 8B 3 Propeller 8B 3 Transmission Shift Lever 8B 4 Shift Cable...

Page 871: ...ar c Serial Number d Identification Plate Model Color Code Transmission Ratios Ratio in Forward Gear NOTE 1 2 Identification Plate Color Code 1 5 1 R d 1 99 1 Red 1 99 1 Red 2 49 1 NOTE 1 This ratio i...

Page 872: ...Transmission Pressure Specifications Engine RPM Neutral Gear PSI kPa Forward Gear PSI kPa Reverse Gear PSI kPa g MIn Max Min Max Min Max 250 70 483 70 483 600 115 793 135 931 115 793 140 965 120 827...

Page 873: ...n is described when viewed from the rear of transmission with transmission in forward gear selector position On MIE engines which are equipped with V drive transmissions transmission output shaft rota...

Page 874: ...luid cooler and hoses may have drained back into transmission If low add specified transmission fluid to bring level up to full mark on dipstick 72526 b c a a Dipstick b Full Mark c Dipstick Tube IMPO...

Page 875: ...mage Rubber Particles Indication of cooler hose wear Hoses should be inspected for cracks or fraying Replace damaged hoses NOTE Coat threads of bushing with Quicksilver Per fect Seal and install in tr...

Page 876: ...to checking level 2 Start engine and run at 1500 RPM for 2 minutes to fill all hydraulic circuits NOTE Be sure to push dipstick all the way down into dipstick tube when checking fluid level 3 Stop en...

Page 877: ...rque to 45 lb ft 61 N m 16 Align transmission splines with drive plate splines 17 Slide transmission into place and secure with bolts 18 Remove two long studs installed in Step 9 and install remaining...

Page 878: ...fluid passage boss Do not strike the bolt bosses IMPORTANT Do not remove the pump from the shaft unless a seal protector is used to prevent the shaft splines from cutting the pump seal Care must be t...

Page 879: ...rse positions No more than finger tip effort should be required If valve binds cause for binding must be found and cor rected Pressure Test 1 Install pressure gauge 72845 a a Main Line Pressure Tap Mo...

Page 880: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 8B 10 VELVET DRIVE V DRIVE AND WALTER V DRIVE TRANSMISSIONS 90 823225 1 1096...

Page 881: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE VELVET DRIVE V DRIVE AND WALTER V DRIVE TRANSMISSIONS 8B 11 90 823225 1 1096...

Page 882: ...C 8 25280 DRIVES HURTH DOWN ANGLE TRANSMISSION...

Page 883: ...pacity 8C 2 Operating Specifications 8C 2 Transmission Ratios 8C 2 General 8C 3 Shift Cable Installation and Adjustment 8C 3 Checking Transmission Fluid Level 8C 8 Draining Transmission 8C 9 Filling T...

Page 884: ...unts 50 63 Transmission To Flywheel Housing 50 68 Tools Lubricants Sealants Description Part Number Tapered Roller Bearing Inner Race Puller 91 813950 Tapered Roller Bearing Outer Bearing Puller 91 81...

Page 885: ...e dipstick to determine exact quantity of fluid required Operating Specifications Description Specification Shifting Pressure 312 377 PSI 2151 2599 kPa Operating Temperature 130 176 F 54 80 C Maximum...

Page 886: ...242 A B 72709 Shifting Lever in Position Propeller Rotation Propeller A Opposite to Engine Rotation Right Hand RH B Same as Engine Rotation Left Hand LH Shift Cable Installation and Adjustment IMPORTA...

Page 887: ...n c Bracket Mounting Bolts IMPORTANT Check that shift lever is positioned approximately 10 degrees aft of vertical when in the neutral detent position and that the distance c between studs in the foll...

Page 888: ...p in either direction 7 Place remote control shift lever in forward gear position Check to ensure transmission is fully in gear as follows a Hold shift lever in position b Carefully slide shift cable...

Page 889: ...gs e Cable Barrel 12 Once shift cable adjustment is correct secure shift cable s with hardware as shown referring to appropriate configuration following NOTE To change cable approach direction on sing...

Page 890: ...and Washer Tighten Until Bottoms Out Then Back Off 1 2 Turn c Spacer Fits Over Bushings d Bushing e Cable Barrel DUAL CABLE FORWARD ENTRY 72956 71211 b d a b c e 1 2 1 Cable Barrel Stud 2 Cable End G...

Page 891: ...from transmission 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 Shown IMPORT...

Page 892: ...e and pulling at the same time 27666 a Set Screw Later Models 3 Push hose of suction pump through suction pipe and down to the bottom of the housing Pump fluid from housing 71043 Filling Transmission...

Page 893: ...tighten allen head screw clockwise until tight 27666 a Set Screw Later Models 3 Start engine and run for two minutes to fill system with fluid 4 Stop engine and check fluid level Fluid should be betw...

Page 894: ...input shaft with Quicksilver En gine Coupler Spline Grease 71044 a a Input Shaft 2 Install transmission on flywheel housing and se cure with hardware shown Torque fasteners to 50 lb ft 68 N m 72720 b...

Page 895: ...air Disassembly IMPORTANT Ensure work area is clean before disassembly is started Be sure to use lint free cloths when cleaning and or handling parts TRANSMISSION FLUID COOLER 1 Disconnect transmissio...

Page 896: ...om cover and inspect O rings for wear Replace if necessary 50975 a a O Rings 4 Push hose of suction pump through suction pipe and down to the bottom of the housing Pump fluid from housing 71043 5 Remo...

Page 897: ...and coat with oil 71048 a a Breather Valve MOUNTS 1 Remove mounts from transmission housing In spect mounts for damage and replace if neces sary a 72711 b a Transmission Mount b Retaining Screws 4 Tot...

Page 898: ...823225 1 1096 2 Reinstall bolt and remove flange using appropri ate puller 71052 71051 b c a b a Bolt b Flange c Puller CONTROL BLOCK 1 Remove hex head bolts 27661 a a Hex Head Bolts 6 2 Remove contr...

Page 899: ...lock from front side 3 Cover openings in control block with a protective cloth 27665 a a Openings HOUSING 1 Remove hex head bolts from input side of hous ing 71044 a a Bolts 12 2 Remove input side of...

Page 900: ...SEAL INSPECTION 1 Inspect all tapered roller bearings the piston rings on the input shaft and all gears for wear If damage has been found on the gearing of the in termediate or output shaft it is ALW...

Page 901: ...ove suction pipe seal as follows 27666 a a Seal a Bend tabs up away from screws 71059 a a Tabs b Remove screws and hold down plate c Remove suction pipe by pulling downward out of seal 71060 b a a Scr...

Page 902: ...r ing cups unless replacing tapered roller bear ings Bearing and cup must be replaced as a set IMPORTANT Do not mix up shims under cups on the input housing side Shims are required for ad justing the...

Page 903: ...move and retain shims DO NOT MIX UP 27682 TAPERED ROLLER BEARINGS CAUTION Gears should never be removed from intermedi ate shaft or output shaft as this will affect proper gear alignment 1 Remove tape...

Page 904: ...al tool as follows a Place tool over tapered roller bearing Ensure jaws of tool will be pulling on bottom edge of rollers and NOT on the cage 27671 b a a Jaws b Bottom Edge Of Rollers b Tighten jaws o...

Page 905: ...ed end of input shaft by installing special tool as shown and light ly tapping upward on tool 27673 b a a Special Tool b Butting Ring 3 Remove butting ring and gear assembly 27675 b a a Butting Ring b...

Page 906: ...g and end disc to aid in locating the snap ring opening 27675 a a Reference Marks 1 Position snap ring compression tool on clutch as sembly so that compression screws are centered over slots in clutch...

Page 907: ...7675 NOTE For ease of reassembly end disc and snap ring should not be removed from tool unless their condition is questionable 27676 a a End Disc Snap Ring Compressed d If necessary remove end disc an...

Page 908: ...nged 50248 27679 b c a 630A Clutch Arrangement Shown 800AM Simi lar a Thrust Discs 5 Per Side See Note b Inner Discs 4 Per Side See Note c Notches NOTE 800AM transmissions have additional thrust discs...

Page 909: ...notches on thrust disc tabs are aligned as shown 27679 b c a 630A Clutch Arrangement Shown 800AM Simi lar a Thrust Discs 5 Per Side See Note b Inner Discs 4 Per Side See Note c Notches NOTE 800AM tran...

Page 910: ...oove in end disc and compress by hand so that compression dogs will hold in on snap ring 27677 b c a a End Disc b Snap Ring c Compression Dogs c Tighten compression screws evenly to com pletely compre...

Page 911: ...l until end disc bot toms Loosen compression screws and remove tool 27675 27678 6 Double check that snap ring has been properly seated by prying up lightly on end disc 27679 7 Reinstall discs on oppos...

Page 912: ...Se vere burns could result Use special protective gloves to handle bearing 1 Heat inner race of tapered roller bearing using a torch lamp and press bearing onto shaft When bearing has cooled DO NOT co...

Page 913: ...bearing to ensure proper seating against gear using a soft copper punch Tap on inner race only 71045 2 Install tapered roller bearing on opposite end of shaft in the same manner OUTPUT SHAFT WARNING...

Page 914: ...porarily install control block to install this tapered roller bearing cup 1 Temporarily install control block on outer hous ing Tighten bolts securely 27682 27666 b a a a Input Shaft Bearing Cup b Con...

Page 915: ...ountersunk 040 in 1 mm with reference to housing surface 71061 a a Seal Suction Pipe 1 Reinstall suction pipe seal in bottom of oil filter bore Coat seal with ATF automatic transmission fluid 27660 a...

Page 916: ...ffle plate Apply one drop of Quicksilver Loctite 8831 to screws Tighten screws securely and bend tabs down over screws 71057 b c a b a a Tabs b Screws c Baffle Plate 4 Install intermediate shaft 71055...

Page 917: ...n the input half of the housing NOTE Shims which have been removed during dis assembly may be reused 2 Subtract approximately 008 in 0 2 mm of shims from each bearing cup bore Remove and set aside but...

Page 918: ...lows a Install special tool as shown Tighten hold down bolts securely 27863 b a a Special Tool b Hold Down Bolts b Mount dial indicator on input shaft Turn input shaft several times to seat bearing 27...

Page 919: ...ard Perform the above sequence several times to ensure an accu rate reading 27682 e Make note of reading The bearing clearance measured PLUS the preload required is equal to the amount of shim thickne...

Page 920: ...bolt head Turn output shaft several times to ensure bearing is seated 71066 a a Special Bolt with Nut d Zero dial indicator 27685 IMPORTANT The following step should be done very carefully to obtain t...

Page 921: ...dicator special bolt and nut and reinstall hex plug Tighten securely Output Shaft Preload 1 Measure the bearing clearance as follows a Install flange washer and bolt Tighten snugly b Mount dial indica...

Page 922: ...n Bearing Preload Required 004 in Shims to Be Added 014 in f Remove dial indicator Remove bolt and flange washer 2 When thickness of shims to be ADDED has been determined the input half of housing mus...

Page 923: ...care in handling housing once it has been heated Severe burns could result Use special protective gloves to handle housing 5 Heat each tapered roller bearing cup bore with a torch lamp Install bearin...

Page 924: ...with ATF 3 Apply a thin layer of Loctite 515 Sealer to ma chined surfaces on housing halves Reinstall in put half of housing Ensure locator pins are prop erly positioned 71053 b a a Locator Pins b Mac...

Page 925: ...g 27666 b a a Key b Piston Rings 3 Carefully push control block onto input shaft 4 Coat each hex socket head bolt with a drop of Quicksilver Loctite 8831 Secure control block to housing with bolts and...

Page 926: ...7661 OUTPUT FLANGE 1 Coat output shaft splines with a thin coat of Quicksilver Engine Coupler Spline Grease 2 Coat lip of output shaft seal with ATF 3 Install output shaft flange Be careful not to dam...

Page 927: ...hown Tighten securely 72721 b a a Transmission Fluid Hoses b Clamps FILLING WITH TRANSMISSION FLUID IMPORTANT Use only ATF Automatic Transmis sion Fluid such as Dexron II D or lll 1 Fill transmission...

Page 928: ...rth transmissions have an al len head socket screw on oil filter cover 3 Remove oil filter from housing by turning coun terclockwise and pulling at the same time 27666 a Set Screw Later Models 4 Check...

Page 929: ...or cor rect 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 Tes...

Page 930: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE HURTH DOWN ANGLE TRANSMISSION 8C 47 90 823225 1 1096...

Page 931: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 8C 48 HURTH DOWN ANGLE TRANSMISSION 90 823225 1 1096...

Page 932: ...E 8 DRIVES DRIVE SHAFT PROPELLER SHAFT MODELS...

Page 933: ...Reassembly 8D 2 Drive Shaft Repair MCM Stern Drive Models 8D 3 Removal 8D 3 Repair 8D 4 Replacement Drive Shafts 8D 4 Installation 8D 5 Bearing Support Repair MCM Stern Drive Models 8D 6 Removal 8D 6...

Page 934: ...0 41 Output Shaft Housing To Fly wheel Housing MCM Models 30 41 Engine Coupling 35 48 Coupling Setscrews If Equipped Securely NOTE NOTE Safety wire set screws Tools Lubricants Sealants Description Par...

Page 935: ...remove housing 4 Remove snap ring then pull output shaft out of housing 5 Remove snap ring from housing 6 Using Quicksilver Slide Hammer Puller remove bearing from housing 7 Remove flywheel cover 8 Re...

Page 936: ...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 18 Stud 1 19 Gasket 20 Cover Flywheel 21 Screw 7 22 Coupling Engine 23 Bushing Drive Shaft Repair M...

Page 937: ...tput Shaft Flange b Drive Shaft c Bolt With Nut 4 Total Repair CAUTION Be sure U joint locking rings are seated properly after replacing U joints 1 Replace U joints if required 2 Replace flange if req...

Page 938: ...381 mm Installation IMPORTANT The following instructions are to be used if ONLY the drive shaft was removed for ser vice Refer to appropriate sections for installa tion of other components which requi...

Page 939: ...drive shaft and or bearing support CAUTION If bearing support is removed you must remove the stern drive unit so you can properly align drive unit U joint centerline with extension drive shaft U joint...

Page 940: ...ing and inner diameter of bearing support 5 Install bearing with sealed side toward snap ring by using a press After installation wipe up excessive Loctite Install snap ring 6 Apply Loctite 290 to ou...

Page 941: ...upport 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...

Page 942: ...service manual for all servicing and troubleshooting For MIE engine installation and alignment re fer to Sections 2E and 2F Checks Made with Boat In Water 1 Disconnect propeller shaft coupling from t...

Page 943: ...ropeller 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 chi...

Page 944: ...Held T Rudder With C Clamp b Rudder c Rotate Propeller One Complete Turn Check At Three Dif ferent Points On Blades Checks Made with Propeller Shaft Removed from Boat 1 Check propeller shaft for strai...

Page 945: ...Strut Refer to boat manufacturer s service manual for alignment and replacement Normally the shaft should be centered in the cutlass bearing Shims placed between the strut and hull are used to align t...

Page 946: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE DRIVE SHAFT PROPELLER SHAFT MODELS 8D 13 90 823225 1 1096...

Page 947: ...A 9 72951 POWER STEERING PUMP...

Page 948: ...p Fluid Level 9A 5 Filling and Air Bleeding System 9A 5 Belt Adjustment 9A 5 V Belt 9A 5 Serpentine Belt Adjustment 9A 5 Pump Assembly 9A 6 Mounting Bracket 9A 7 Hydraulic Hoses and Fluid Cooler 9A 7...

Page 949: ...ants Description Part Number Pulley Installer 91 93656A1 Quicksilver Perfect Seal 92 34227 1 Pulley Removal Tool Kent Moore J 25034 Kent Moore Special Tools 29784 Little Mack Roseville MI 48066 313 57...

Page 950: ...acer 5 Brace 6 Spacer 7 Lockwasher 8 Bolt Pump To Brace 9 Pulley 10 Belt 11 O Ring High Pressure Hose Fitting 12 Hose High Pressure Fittings on Both Ends 13 Hose Pump To Fluid Cooler 14 Clamp 15 Hose...

Page 951: ...pentine Belt Routing BRAVO WITH POWER STEERING BRAVO WITHOUT POWER STEERING BRAVO WITH CLOSED COOLING AND POWER STEERING ALPHA WITH POWER STEERING ALPHA WITH CLOSED COOLING WITHOUT POWER STEERING ALPH...

Page 952: ...2821 a a Kent Moore Pulley Removal Tool J 25034 INSTALLATION Install pulley as follows using pulley installer tool 91 93656A1 and a long straight edge 1 Place pulley on pump shaft 2 Thread stud all th...

Page 953: ...sion securely tighten pump brace and pump mounting bolts 2 If a new drive belt has been installed recheck belt tension after running for five minutes 72847 b a a Belt Should Depress 1 4 In 6 mm b Scre...

Page 954: ...ck of pump Tighten hose clamp securely 72850 b c d a a Pump b Bracket c Threaded Fitting d Low Pressure Hose 2 Install mounting hardware and fasteners to retain pump to bracket Refer to Exploded View...

Page 955: ...thread or over tighten 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 and O...

Page 956: ...ting securely Do not cross thread or over tighten 72848 a a Fitting With O Ring Not Visible In This View 4 Fill and air bleed system Refer to Section 1B Maintenance see Table of Contents Low Pressure...

Page 957: ...hose on back of pump Tighten clamp securely 72848 b a a Hose Clamp b Hose 2 Using hose clamp install hose on fluid cooler Tighten clamp securely 72588 a b c Port Side Mounted Fluid Cooler a Fluid Coo...

Page 958: ...72588 a Port Side Mounted Fluid Cooler a Fluid Cooler b Hose Clamp c Hose 74752 a b Rear Mounted Fluid Cooler a Fluid Cooler b Hose 2 Remove hose where routed and secured across top of engine flywheel...

Page 959: ...emoval Earlier Style Control Valve Torque large fitting to 20 25 lb ft 27 34 N m 72026 a a Large Fitting Later Style Control Valve Torque fittings to 23 lb ft 31 N m 73786 2 Route hose along flywheel...

Page 960: ...iagram is located on the last page of this section Installing Reservoir 1 Mount reservoir bracket a Find a location between both power steering pumps that affords both accessibility and easy visual in...

Page 961: ...er steering pumps Allow extra hose for routing IMPORTANT When routing and installing hoses in the following steps be sure that the bend ra dius in the hose is sufficient to eliminate a load being plac...

Page 962: ...and routing preferably on a stringer near transom b Mount bracket using lag bolts and washers supplied 72859 b a b a Mounting Bracket b Lag Bolts and Washers NOTE The 90 elbow locations on priority v...

Page 963: ...bulk hose supplied of suffi cient length to extend from power steering cool ers to respective fittings on priority valve 6 Connect one end of each hose to its respective power steering fluid cooler an...

Page 964: ...b a a Power Steering Control Valve b Hose Fitting 72866 b a a Priority Valve b Hose Fitting 9 Connect No 1 starboard engine pressure hose from pump to inverted flare fitting marked by 1 on priority va...

Page 965: ...p cap Fill bottle reservoir and repeat this process for the other pump 4 Double check both caps to ensure they are both tight Maintenance Maintenance inspection is the owner s responsibility and must...

Page 966: ...et 2 Priority Valve and Mounting Bracket 3 Power Steering Control Valve 4 Power Steering Pump 5 Power Steering Fluid Cooler a Pressure Hose Fitting On Both Ends Supplied In Kit b Return Hose Fitting O...

Page 967: ...THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE POWER STEERING 9A 19 90 823225 1 1096...

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