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Mercury MerCruiser MCM 454 Mag MPI, Service Manual

The Mercury MerCruiser MCM 454 Mag MPI Service Manual is a comprehensive guide for maintaining and repairing your engine. Get the manual for free download at manualshive.com and ensure your engine runs smoothly for years to come. Take control of your repairs with this essential user manual.

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454 CID (7.4L) / 502 CID (8.2L)

SERVICE MANUAL NUMBER 23

Page 3A-5

90-861326--1   MARCH 1999

Tools

MERCURY MARINE SPECIAL TOOLS

DESCRIPTION

PART NUMBER

Piston Ring Expander

91-24697

Engine Coupler Wrench

91-35547

Special Tools

KENT-MOORE SPECIAL TOOLS

Kent-Moore Special Tools

29784 Little Mack

Roseville, MI 48066

(313) 574-2332

DESCRIPTION

PART NUMBER

Valve Spring Compressor (Head on)

J5892

Valve Spring Compressor (Head off)

J8062

Valve Spring Tester

J8056

Valve Guide Cleaner

J8101

Carbon Remover Brush

J8089

Piston Pin Tool

J24086-B

Piston Ring Groove Cleaner

J3936-03

Piston Ring Compressor

J8037

Connecting Rod Guide Tool (3/8 -24 Rod
Bolts)

J5239

Connecting Rod Guide Tool (7/16-20 Rod
Bolts)

J35228

Oil Pump Suction Pipe Installer

J21882

Lift Indicator Tool

J8520

Torsional Damper Remover and Installer

J23523-E

Crankcase Front Cover Seal Installer

J22102

Crankshaft Gear and Sprocket Puller

J24420-B

Crankshaft Gear and Sprocket Installer

J20158-20

Air Adapter (Cylinder Inflator)

J23590

Main Bearing Remover and Installer

J8080

Rear Main Seal Installer

J38841

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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Index

Summary of Contents for MerCruiser MCM 454 Mag MPI

Page 1: ...Number 23 Printed in U S A 90 861326 1 MARCH 1999 1999 Mercury Marine MARINE ENGINES GM V8 454 cid 7 4L 502 cid 8 2L Book 1 of 2 Sections 1 thru 4 Downloaded from https needmanual com MAIN MENU...

Page 2: ...ese products which in cludes the use of mechanics common hand tools and the special Mercury Marine or recom mended tools from other suppliers We could not possibly know of and advise the service trade...

Page 3: ...nd manufacturing specifications which are required to provide long life and dependable performance Marine engine parts also must be able to resist the corrosive action of salt or brackish water that w...

Page 4: ...M 454 Mag MPI 0L010029 Up MCM 502 Mag MPI 0L017000 Up Inboard MIE Model Serial Number MIE 454 Mag MPI Horizon 0L002200 Up MIE 8 2L MPI 0L002450 Up L 29 Engines Sterndrive MCM Model Serial Number MCM 7...

Page 5: ...Page iv 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com...

Page 6: ...agrams Section 5 Fuel System A Fuel Delivery System for Electronic Fuel Injection B Multi Port Fuel Injection Descriptions and System Operation C Multi Port Fuel Injection Disassembly and Reassembly D...

Page 7: ...Page vi 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com...

Page 8: ...nual 1A 2 Page Numbering 1A 2 How to Read a Parts Manual 1A 3 Directional References 1A 4 Engine Rotation 1A 4 Engine Serial Number Locations 1A 5 Propeller Information 1A 6 Water Testing New Engines...

Page 9: ...knowledge of the methods and tools used and the cautions and warnings required for safety How to Use This Manual This manual is divided into sections which represent major components and systems Some...

Page 10: ...TH ENDS 7 25 89879 1 O RING 8 25 806232 1 O RING 9 13 35048 1 LOCKWASHER 3 8 in 10 61990 1 CABLE TIE REF NO Number shown next to part on exploded view PART NO Mercury Part Number for ordering If NSS n...

Page 11: ...HT PORT LEFT FORE or BOW FRONT AFT or STERN REAR Engine Rotation Engine rotation is determined by observing flywheel rotation from the rear stern or flywheel end of the engine looking forward toward w...

Page 12: ...23 90 861326 1 MARCH 1999 Page 1A 5 Engine Serial Number Locations 72923 b a Stern Drive MCM a Serial Number Plate b Starter Motor 72924 b a Inboard MIE a Serial Number Plate b Starter Motor Download...

Page 13: ...load engine speed will not fall below specifications If engine exceeds the specified rpm an increase in pitch and or diameter is required If engine is below rated rpm a decrease in pitch and or diame...

Page 14: ...Bottom b Sharp Corner c Transom Stern The bottom is referred to as having a hook if it is concave in the fore and aft direction A hook causes more lift on the bottom near the transom and forces the bo...

Page 15: ...performance Antifouling paint if required may be applied to boat hull observing the following precautions IMPORTANT DO NOT paint anodes or MerCathode System reference electrode and anode as this will...

Page 16: ...ability and riding comfort In extreme rough water conditions the safety of the boat and passengers may be in jeopardy Water in Boat When a boat loses performance check bilge for water Water can add c...

Page 17: ...GENERAL INFORMATION SERVICE MANUAL NUMBER 23 Page 1A 10 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index Index...

Page 18: ...nt for Closed Cooling System 1B 16 Crankcase Oil 1B 16 Overfilled Crankcase 1B 17 Checking Engine Oil Level Filling 1B 17 Changing Oil and Filter 1B 18 Changing Water Separating Fuel Filter 1B 19 MCM...

Page 19: ...s Adhesives DESCRIPTION PART NUMBER Quicksilver Liquid Neoprene 92 25711 3 Quicksilver 2 4 C Marine Lubricant With Teflon 92 825407A3 Loctite Pipe Sealant With Teflon Obtain Locally Quicksilver U Join...

Page 20: ...om battery BEFORE working around electrical systems components to prevent injury to yourself and damage to electrical system should a wire be accidentally shorted Scheduled Maintenance That Can Be Per...

Page 21: ...g Lubricate Cooling System Clean And Inspect Engine Alignment Check Engine Coupling Universal Joint Shaft Splines Lubricate End Of First Boating Season and Steering System Lubricate And Inspect For Lo...

Page 22: ...inity Once a Year Heat Exchanger Clean Seawater Section Drive Unit Bellows and Clamps Inspect Universal Joint Cross Bearings Inspect End Of First Boating Season And Thereafter Every 200 Hours Of Opera...

Page 23: ...Linkage Lubricate Yearly Fuel Filter Change Heat Exchanger Clean Seawater Section Positive Crankcase Ventilation Valve Replace Every Three Years Serpentine Belt Check Tension y Closed Cooling Coolant...

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Page 25: ...8 4 3 6 5 7 2 Spark Plug Type AC MR43LTS Champion RV12YC NGK BPR6EFS AC MR43T Champion RV15YC4 NGK BR6FS Spark Plug Gap 045 in 1 1 mm 040 in 1 mm Timing at Idle rpm 8 BTDC4 Thermostat 160 F 71 C 1 Po...

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Page 27: ...n RV12YC NGK BPR6EFS AC MR43T NGK BR6FZX Platinum AC MR43T Champion RV15YC4 NGK BR6FS Spark Plug Gap 045 in 1 1 mm NGK 035 in 9 mm Others 040 in 1 mm 040 in 1 mm Timing at Idle rpm 8 Degrees BTDC4 The...

Page 28: ...s MODEL MCM AND MIE 454 cid 7 4L MCM AND MIE 502 cid 8 2L Crankcase Oil 1 With Filter 7 6 6 Seawater Cooling System 2 20 19 Closed Cooling System 18 17 1 Use dipstick to determine exact level 2 Seawat...

Page 29: ...With Gear Lube Monitor 88 2603 104 3076 96 2839 80 2365 20 Hour Break In Period IMPORTANT The first 20 hours of operation is the engine break in period Correct break in is essential to obtain minimum...

Page 30: ...load Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at maximum full throttle rpm End of First Season Checkup At the end of the first season of operation an...

Page 31: ...is used in the gasoline in your area refer to Gasolines Containing Alcohol These Reformulated Gasolines are acceptable for use in your MerCruiser engine CA618 GASOLINES CONTAINING ALCOHOL If the gasol...

Page 32: ...can absorb enough moisture to cause trouble but boats often sit idle long enough for phase separation to take place In addition internal corrosion may take place during storage if alcohol has washed...

Page 33: ...cation 1825M CA693 Crankcase Oil To help obtain optimum engine performance and to provide maximum protection we strongly recommend the use of Quicksilver 4 Cycle 25W 40 Marine Engine Oil This oil is a...

Page 34: ...into the crankcase 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 SCHEDU...

Page 35: ...m oil drain hose NOTE If drain plug is not accessible because of boat construction oil may be removed through dipstick tube using a Quicksilver Crankcase Oil Pump See Quicksilver Accessory Guide 4 Aft...

Page 36: ...d factory installed water separating fuel filter have been carefully designed to function properly together Do not install additional fuel filters and or water separating fuel filters between fuel tan...

Page 37: ...r connection for gasoline leaks If leaks exist recheck filter installation 5 Install cover pieces around fuel filter Be certain top part of cover latches to lower part MIE Inboard Models 1 Remove wate...

Page 38: ...d be between the FULL HOT mark and ADD mark on dipstick 72518 a a Proper Fluid Level With Engine Warm 4 If level is below ADD mark but fluid is still visible in pump reservoir add required amount of Q...

Page 39: ...ation and be discharged from pump reservoir Foamy fluid may also cause power steering system to become spongy which may result in poor boat control 1 With engine stopped position drive unit so that it...

Page 40: ...not foam and level remains constant Closed Cooling System Checking Coolant Level WARNING Allow engine to cool down before removing pressure cap Sudden loss of pressure could cause hot coolant to boil...

Page 41: ...a hose between the flushing attachment and a water tap 72693 a b a Flushing Attachment b Hose WARNING When flushing be certain the area around propeller is clear and no one is standing nearby To avoi...

Page 42: ...0 rpm when flushing Suction created by seawater pick up pump may collapse flushing hose causing engine to overheat CAUTION Watch temperature gauge on dash to ensure that engine does not overheat 5 Par...

Page 43: ...to prevent restricting water flow during normal operation A 1 1 4 in 32 mm or larger brass ball valve or gate valve is recommended CAUTION Boats with water lift type exhaust collectors or mufflers En...

Page 44: ...e gauge on dash to ensure that engine does not overheat 6 Operate engine at idle speed in neutral for 10 minutes or until discharge water is clear Stop engine 7 Shut off water tap Remove garden hose a...

Page 45: ...n this procedure If boat is in the water starting engine during this procedure will pull in seawater If boat is out of the water starting engine may damage the seawater pump NOTE Do not use this metho...

Page 46: ...is system has a blue hose connecting the hose fitting to the flush valve NOTE This procedure is not in production at time of printing Illustrations can be found in applicable owner s literature 1 Atta...

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Page 49: ...SION WARM The transmission should be at operating temperature 190 maximum to get an accurate oil level reading Oil will expand when heated Oil will drain back from the cooler Expansion and drain back...

Page 50: ...overnight Insert clean dipstick and read level 2 Put a mark on the dipstick at the cold oil level NOTE You can use the new mark to check the oil level when cold If oil level adjustment is needed add...

Page 51: ...e MCM MODELS 72016 a a b a b Typical Shift Cable a Pivot Points b Guide Contact Surface Shift Cable and Transmission Linkage MIE MODELS 72528 a b a Typical Shift Cable And Transmission Linkage a Pivot...

Page 52: ...Quicksilver 2 4 C Marine Lubricant NOTE Refer to MerCruiser Sterndrive Service Manual for sterndrive unit removal and installation if necessary IMPORTANT Sterndrive Unit does not have to be removed t...

Page 53: ...MBER 23 Page 1B 36 90 861326 1 MARCH 1999 Drive Shaft Extension Models 72018 a a Bearings at Transom End a Lubrication Points 72028 a a Bearings at Engine End a Lubrication Points Downloaded from http...

Page 54: ...damage to ignition coil in addition to being a safety hazard Stay clear of all moving parts 1 Remove ignition coil high tension wire from distributor cap tower and ground it to engine block with jumpe...

Page 55: ...s NEVER use gasoline as a cleaning solvent Plastic Side Mounted Flame Arrestor 1 Remove crankcase ventilation hose from fitting on side of flame arrestor housing 75115 a b a Vent Hose b Flame Arrestor...

Page 56: ...restor 75447 c b a a Cover b Clamp c Flame Arrestor 4 Clean flame arrestor in solvent Blow dry with compressed air 5 Reinstall flame arrestor Tighten clamp securely 6 Reinstall engine cover Metal Side...

Page 57: ...ONLY The brackets and washers on the 3 idler pulleys must be in a certain order or the belt will come off of the serpentine belt All pulleys are referenced as though you were standing in front of the...

Page 58: ...ing and adjustment procedures are the same 75424 e b a d c Inboard Model a Idler Pulley b Seawater Pump Pulley c Crankshaft Pulley d Circulating Pump Pulley e Alternator Pulley 75487 a b c d e f Stern...

Page 59: ...t 2 Install drive belt on pulleys and adjust tension as follows a Loosen 5 8 in locking nut on adjustment stud Leave wrench on adjustment stud NOTE Belt deflection is to be measured on the belt at the...

Page 60: ...crease to a higher rpm You do not have to increase it manually as stated in the following steps 3 Connect the Scan Tool to the DLC connector in the electrical box or on the electrical bracket of the w...

Page 61: ...ickup pump or water pump impeller will be damaged and subsequent overheating damage to engine may result CAUTION Seawater Raw water section of cooling system MUST BE COMPLETELY drained for winter stor...

Page 62: ...ANT MerCruiser strongly recommends that this service be performed by an Authorized MerCruiser Dealer Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty 1 Fill fuel tank s with...

Page 63: ...or and vent hoses 9 Lubricate all items listed in Lubrication section 10 Drain seawater section of cooling system as outlined in Draining Instructions section 11 On Models with Closed Cooling System T...

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Page 65: ...Plug 3 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained NOTE It may be necessary to lift bend or lower hoses to allow water to drain completely when...

Page 66: ...r circulating pump hose as shown 72587 a a Hose Water Circulating Pump To Thermostat Housing 7 Remove the drain plug from the fuel cooler 75081 a a Drain Plug 8 Remove both hoses from seawater pump 75...

Page 67: ...e nontoxic and biodegradable which makes it friendly to lakes and rivers be used in sea water section of the cooling system for cold weather or extended storage Make sure that the propylene glycol ant...

Page 68: ...starboard from cylinder block 75481 74130 a Starboard Side Shown Port Similar a Drain Plug NOTE It may be necessary to lift bend or lower hoses to allow water to drain completely when hoses are disco...

Page 69: ...s drained 5 Remove the engine water circulating pump hose as shown 72587 a a Hose Water Circulating Pump To Thermostat Housing 6 Remove the drain plug from the fuel cooler 75081 a a Drain Plug 7 On Al...

Page 70: ...e used in seawater section of the cooling system for cold weather or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engi...

Page 71: ...flow from the drain holes or removed hoses IMPORTANT Boat must be as level as possible to ensure complete draining of cooling system CAUTION Seawater section of cooling system MUST BE COMPLETELY drain...

Page 72: ...d a Heat Exchanger b Sealing Washer c End Cap d Gasket IMPORTANT Use compressed air to blow any remaining water from the tubes in the heat exchanger 3 Remove drain plug from bottom of port and starboa...

Page 73: ...n plug from the fuel cooler 75081 a a Drain Plug 5 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained 6 Remove both hoses from seawater pump 75533 b a...

Page 74: ...meter Pitot Tube b Anode Cavity Vent Hole c Anode Cavity Drain Passage 8 Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump DO NOT ALLOW ENGINE TO START 9...

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Page 77: ...ing washers and gaskets from the heat exchanger 71515 a b c d a Heat Exchanger b Sealing Washer c End Cap d Gasket IMPORTANT Use compressed air to blow any remaining water from the tubes in the heat e...

Page 78: ...eawater pump hose 75536 a a Drain Plugs One Is Hidden From View 7 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained 8 Crank engine over slightly with...

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Page 81: ...AUTION When installing battery in next step be sure to connect positive battery cable to positive terminal and negative grounded battery cable to negative battery terminal If battery cables are revers...

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Page 84: ...ill Not Crank Over 1C 11 Charging System Inoperative 1C 11 Noisy Alternator 1C 12 Instrumentation Malfunction 1C 12 Radio Noise 1C 12 Poor Fuel Economy 1C 13 Engine Runs Poorly at Idle 1C 13 Engine Ru...

Page 85: ...threads of brass fitting or plug DO NOT USE TEFLON TAPE Thread brass fitting or plug into fuel pump or fuel filter base until finger tight Tighten fitting or plug an additional 1 3 4 to 2 1 4 turns u...

Page 86: ...determining serviceability of spark plug Spark plug condition also can suggest a variety of possible engine malfunctions and therefore can indicate needed engine repairs When old plugs are replaced r...

Page 87: ...gapping Under certain conditions severe detonation also can split insulator firing ends Replace spark plugs 72420 Wet Fouling Oil Deposits Plug becomes shorted by excessive oil entering combustion cha...

Page 88: ...are eroded and there is an absence of deposits Check that correct plug heat range is being used Also check for over advanced ignition timing cooling system malfunction lean fuel air mixtures leaking...

Page 89: ...excessive high temperatures Center electrode melts first followed by ground electrode Normally insulators are white but may be dirty if plug has been misfiring Check for correct plug heat range advanc...

Page 90: ...gs can be serviced clean file and re gap and reinstalled 72423 Mechanical Damage Mechanical damage to spark plug firing end is caused by foreign object in combustion chamber Because of valve overlap s...

Page 91: ...le B Propeller pitch too great C Dirty boat bottom marine growth D Poor running engine Bow too high E Improper weight distribution F Rocker in boat bottom G False bottom full of water H Improperly adj...

Page 92: ...d 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 too f...

Page 93: ...il wire near ground and check for spark while cranking engine over Repeat procedure with spark plug wires If there is spark at the spark plug wires remove the spark plugs and make sure they are correc...

Page 94: ...ch Open circuit Starter solenoid Starter motor Mechanical engine malfunction Charging System Inoperative Cause Special Information Loose or broken serpentine belt Engine rpm too low on initial start R...

Page 95: ...l Information A popping noise that will increase with engine rpm Noise will stop as soon as en gine is turned off Ignition System wrong spark plugs cracked distributor cap cracked coil tower leaking s...

Page 96: ...open throttle Clogged flame arrestor Engine compartment sealed too tight Not enough air for engine to run properly Boat bottom Dirty marine growth hook rocker Improper fuel Crankcase ventilation syste...

Page 97: ...porcelain incorrect heat range Spark plug wires Poor insulation broken wires Distributor cap or rotor Dirty or cracked Coil Distributor Excessive play in shaft Engine overheating Refer to Engine Overh...

Page 98: ...valve train related 2 The use of a stethoscope can aid in locating a noise source however because noise will travel to other metal parts not involved in the problem caution must be exercised 3 If you...

Page 99: ...one cylinder or may be found in any multitude Worn rocker arm y y y of cylinders Bent push rod Collapsed lifter Cylinder Area Location Possible Causes Sticking valve Carbon build up Connecting rod in...

Page 100: ...oughout engine timed to one half engine speed Valve lifters g Cam bearings Crankshaft Area Location Possible Causes Crankshaft timing sprocket Crankshaft area front of engine timed to Timing chain g e...

Page 101: ...ifolds or pipes Hissing Loose cylinder heads Blown head gasket Whistle Vacuum leak Whistle Dry or tight bearing in an accessory Leaking high tension lead Sparks jumping Cracked coil tower Cracked dist...

Page 102: ...rature 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 readings...

Page 103: ...ondensation Oil pump Relief valve stuck open pickup tube restricted worn parts in oil pump air leak on suction side of oil pump or pickup oil tube Oil leak can be internal or external Oil passage plug...

Page 104: ...ng clearance NOTE 454 Mag MPI and 502 Mag MPI ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS SPECIFIED IN MAINTENANCE SCHEDULE It is normal for an engine to use a certain amount of oil in the proce...

Page 105: ...roblem can be duplicated If problem can be duplicated there is a mechanical problem If the problem cannot be duplicated the problem is either an operator error or a problem that exists only under cert...

Page 106: ...sket instal lation Loose cylinder head bolts Blown cylinder head gasket Check for warped cylinder head or cylinder block Cracked valve seat Porous or cracked casting Check cylinder heads cylinder bloc...

Page 107: ...d timing chain or improperly installed Blown head gasket s A blown head gasket s normally cannot be detected by a compression check Nor mally the engine will run at normal temper ature at low rpm but...

Page 108: ...ter pickup clogged Obstruction on boat bottom causing water turbulence Obstruction will be in front of seawater pickup causing air bubbles to be forced into cooling system Defective thermostat Exhaust...

Page 109: ...nstalled sea strainer Loose hose connections between seawa ter pickup and seawater pump inlet Pump will suck air pump may fail to prime or will force air bubbles into cooling system Seawater inlet hos...

Page 110: ...able or helm partially frozen from rust or corrosion cable over lubricated improper cable installation Binding in stern drive unit Refer to appropriate Sterndrive Service Manual Restriction in hydraul...

Page 111: ...Stop nut adjusted improperly Refer to appropriate Sterndrive Service Manual Steering cables installed that do not meet BIA standards Refer to appropriate Sterndrive Service Manual Fluid Leaks Cause S...

Page 112: ...TROUBLESHOOTING SERVICE MANUAL NUMBER 23 Page 1C 29 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index Index...

Page 113: ...of Contents Torque Specifications 2A 2 Tools 2A 2 Lubricants Sealants Adhesives 2A 2 Preparation 2A 3 Removal 2A 3 Installation 2A 4 Engine Installation Alignment 2A 4 Water Hose Connections 2A 10 Ele...

Page 114: ...7 54 Remote Control Cable Barrel Securely Remote Control Shift Cables Cable End Guide See Note Remote Control Cable Barrel Securely Remote Control Throttle Cable Cable End Guide See Note NOTE Tighten...

Page 115: ...d hardware 5 Disconnect bullet connectors of trim sender wires coming from transom assembly from engine harness NOTE After wires are disconnected be sure to loosen them from clamps or sta straps retai...

Page 116: ...shers cemented in place on inner transom plate are present Inspect fiber washers Replace if worn or damaged 2 Install double wound lockwashers onto inner transom plate inside fiber washer 3 Be certain...

Page 117: ...to position in boat using an overhead hoist 8 Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust tubes with exhaust pipe hoses bellows IMPORTANT Engine atta...

Page 118: ...l bearing and or engine coupler CAUTION To avoid damage to gimbal bearing engine coupler or alignment tool DO NOT attempt to force alignment tool DO NOT raise or lower engine with alignment tool inser...

Page 119: ...lignment Tool b Gimbal Bearing c Engine Coupler IMPORTANT Turn both front engine mount adjustment nuts an equal amount in direction required to align engine d Adjust front engine mounts until they res...

Page 120: ...n Counterclockwise To Raise Front Of Engine d Slotted Hole To Front Of Engine e Tab Washer i Remove alignment tool if not already removed 12 Tighten all exhaust system hose clamps securely as follows...

Page 121: ...w If hoses are connected incorrectly discharge water from exhaust elbow will not flow around entire inside diameter of hose This will cause a hot spot in the hose which may eventually burn through 725...

Page 122: ...onnect seawater hose to water tube at gimbal housing with hose clamp Tighten clamp securely NOTE In the following view the engine is not in position for visual clarity in this step 72590 b c a a Water...

Page 123: ...ness c BLACK From Transom d BLACK From Transom Assembly IMPORTANT Do not attach any accessory ground wires to transom plate ground point Accessory ground wires should only be attached to ground stud o...

Page 124: ...e Connect Other End To Positive Battery Terminal c BLACK Wire From Engine Harness d BROWN Wire From Electrode on Transom Assembly 6 Connect battery cables to battery by FIRST connecting positive batte...

Page 125: ...ck casting and or cause a fuel leak Apply 592 Loctite Pipe Sealant with Teflon to threads of brass fitting or plug DO NOT USE TEFLON TAPE Thread brass fitting or plug into fuel pump or fuel filter bas...

Page 126: ...ends and or contact with moving parts DO NOT fasten any items to throttle cable Outer cable must be free to move when cable is actuated 2 Remove flame arrestor 75113 a 75142 b c 454 and 502 Mag MPI Sh...

Page 127: ...sure hole in barrel positions cable as shown 71711 b a a Cable Barrel b Anchor Plate 4 Secure throttle cable with hardware as shown and tighten securely 5 Place remote control throttle lever in the wi...

Page 128: ...nkcase Vent Hose 7 4L MPI MODELS 1 Place remote control handle s in neutral idle position 2 Remove port side engine cover IMPORTANT Be sure that cable is routed to avoid sharp bends and or contact wit...

Page 129: ...moving remote control lever Adjust barrel on throttle cable to align with hole in anchor plate Ensure hole in barrel positions cable as shown 75455 a b a Cable Barrel b Anchor Plate 5 Secure throttle...

Page 130: ...tions IMPORTANT After fluid hose installation in the following bleed power steering system as outlined in SECTION 1B Maintenance of this manual or refer to the appropriate Stern Drive Service Manual C...

Page 131: ...MCM MODELS BRAVO AND BLACKHAWK DRIVES SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 2A 19 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index Index...

Page 132: ...MCM MODELS BRAVO AND BLACKHAWK DRIVES SERVICE MANUAL NUMBER 23 Page 2A 20 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index Index...

Page 133: ...ension Table of Contents Torque Specifications 2B 2 Tools 2B 2 Lubricants Sealants Adhesives 2B 2 Preparation 2B 3 Removal 2B 4 Installation 2B 5 Engine Installation Alignment 2B 5 Engine Connections...

Page 134: ...31 Remote Control Throttle Cable Cable Barrel Securely Cable End Guide See Note Front and Rear Engine Mounts Hose Clamps Securely Battery Cables NOTE Tighten then loosen nut one half turn Tools DESCRI...

Page 135: ...etain locknuts and hardware 4 Using wrench to stabilize brass coupling at water separating fuel filter inlet loosen fuel line fitting disconnect and suitably plug fuel line to prevent fuel in tank fro...

Page 136: ...nnect exhaust elbow hoses bellows 5 Remove both shift cables from shift plate Retain locknuts and hardware CAUTION Center lifting eye located on top of thermostat housing is used for engine align ment...

Page 137: ...an overhead hoist 3 Set engine on stringers 4 Grease drive shaft universal joints with Quicksilver U Joint and Gimbal Bearing Grease CAUTION When attaching shaft in next step BE SURE that the pilot o...

Page 138: ...on engine for correct engine and drive shaft lateral alignment as follows a Measure the length of a and b to the centers of bolt holes They MUST BE EQUAL If they are not equal slide the aft and forwar...

Page 139: ...as shown Torque screws to 30 lb ft 41 Nm Then install top shield as shown Torque bolts and nuts to 30 lb ft 41 Nm 72028 a b c Engine End Shown a Shaft Housing b Bottom Shield c Screws 3 Used 2 Hidden...

Page 140: ...LLATION 72429 a a a Reference Marks 1 Refer to SECTION 8F Drive Shaft Models Propeller Shaft and remove drive shaft 2 Position base of protractor against input shaft flange as shown NOTE and RECORD th...

Page 141: ...ut shaft DO NOT install shields at this time CAUTION Engine MUST BE aligned correctly to achieve proper engine operation and to prevent damage to drive shaft If drive shaft is run at an incorrect angl...

Page 142: ...4 In 6 mm 9 Position engine for correct engine and drive shaft lateral alignment as follows a Measure the length of a and b to the centers of bolt holes They MUST BE EQUAL If they are not equal slide...

Page 143: ...using cover plate as shown Now raise or lower front engine mount adjusting nuts as required so that protractor needle reads exactly the same number of degrees as that recorded in Step 1 72593 a b c a...

Page 144: ...d Slotted Hole Toward Front Of Engine e Tab Washer 14 Apply Loctite 271 to threads of bottom drive shaft shield retaining screws and install bot tom shields on engine and transom end as shown Torque s...

Page 145: ...h moving parts 1 Connect seawater hose to water tube at gimbal housing with hose clamp Tighten clamp securely NOTE In the following view the engine is not in position for visual clarity in this step 7...

Page 146: ...From Engine Harness c BLACK From Transom d BLACK From Transom Assembly IMPORTANT Do not attach any accessory ground wires to transom plate ground point Accessory ground wires should only be attached...

Page 147: ...b RED PURPLE Wire Connect Other End to Positive Battery Terminal c BLACK Wire From Engine Harness d BROWN Wire From Electrode on Transom Assembly 6 Connect battery cables to battery by FIRST connectin...

Page 148: ...base can crack casting and or cause a fuel leak Apply 592 Loctite Pipe Sealant with Teflon to threads of brass fitting or plug DO NOT USE TEFLON TAPE Thread brass fitting or plug into fuel pump or fu...

Page 149: ...to avoid sharp bends and or contact with moving parts DO NOT fasten any items to throttle cable Outer cable must be free to move when cable is actuated 2 Remove flame arrestor 75113 a 75142 b c 454 an...

Page 150: ...anchor plate Ensure hole in barrel positions cable as shown 71711 b a a Cable Barrel b Anchor Plate 4 Secure throttle cable with hardware as shown and tighten securely 5 Place remote control throttle...

Page 151: ...wn 75115 a a Crankcase Vent Hose 7 4L MPI MODELS 1 Place remote control handle s in neutral idle position 2 Remove port side engine cover IMPORTANT Be sure that cable is routed to avoid sharp bends an...

Page 152: ...k in cable when moving remote control lever Adjust barrel on throttle cable to align with hole in anchor plate Ensure hole in barrel positions cable as shown 75455 a b a Cable Barrel b Anchor Plate 5...

Page 153: ...Steering Connections IMPORTANT After fluid hose installation in the following bleed power steering system as outlined in SECTION 1B Maintenance of this manual or refer to the appropriate Stern Drive S...

Page 154: ...MCM MODELS BRAVO AND BLACKHAWK DRIVES WITH DRIVESHAFT EXTENSION SERVICE MANUAL NUMBER 23 Page 2B 22 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 155: ...es 2C 2 Preparation 2C 3 Removal 2C 3 Installation 2C 4 Engine Installation and Initial Alignment 2C 4 Engine Final Alignment 2C 6 Engine Connections 2C 9 Seawater Hose Connection 2C 9 Electrical Conn...

Page 156: ...Flange 50 68 Trunnion Clamping Bolt Nut 50 68 Cable Barrel Securely Remote Control Shift Cable Cable End Guide NOTE 1 Cable Barrel Securely Remote Control Throttle Cable Cable End Guide NOTE 1 NOTE 1...

Page 157: ...ust system hoses 8 Disconnect any grounding wires and accessories that are connected to engine 9 Disconnect propeller shaft coupler from transmission output flange WARNING Be careful when working on f...

Page 158: ...uctions a or b a Engine mount s or adjustment WAS NOT DISTURBED during engine service Proceed to following Step 2 b Engine mount s or adjustment WAS DISTURBED during engine service IMPORTANT Engine mo...

Page 159: ...ical a Locking Nut b Adjusting Nut c Trunnion Clamp Bolt And Nut With Lockwasher d Slot Forward e 3 8 In 1 16 In 10 mm 2 mm f 2 5 8 In 1 16 In 67 mm 2 mm g Mount Trunnion CAUTION Center lifting eye lo...

Page 160: ...n following Engine Final Alignment CAUTION To avoid vibration noise and damage to transmission output shaft oil seal and bearings engine must be properly aligned IMPORTANT Engine alignment MUST BE REC...

Page 161: ...shoulder on mating face On these installations use a straight edge to check centerline alignment 72597 Wrong Right IMPORTANT Remote V Drive Models refer to remote V drive manufacturer s instructions...

Page 162: ...engine level from side to side 72594 a c b d Typical Mount a Locking Nut b Adjusting Nut c Clamping Bolts and Nuts With Lockwashers Two Each On Some Models d Slot Forward If So Designed NOT Slotted O...

Page 163: ...4 In 20 mm IMPORTANT All coupler bolts must be SAE Grade 8 Metric Grade 10 9 or better with a shoulder grip length long enough to pass through the face mating plane of couplers 6 Connect propeller sh...

Page 164: ...Teflon to threads of brass fitting or plug DO NOT USE TEFLON TAPE Thread brass fitting or plug into fuel pump or fuel filter base until finger tight Tighten fitting or plug an additional 1 3 4 to 2 1...

Page 165: ...ose This will cause a hot spot in the hose which may eventually burn through 72538 Correct Incorrect NOTE Clamps are not shown Throttle Cable Installation and Adjustment MODELS EXCEPT 7 4L MPI 1 Place...

Page 166: ...knuts b Move crankcase ventilation hose away from against flame arrestor and rocker arm cover fittings 71764 a a Crankcase Vent Hose c Remove flame arrestor NOTE If boat is equipped with Quicksilver Z...

Page 167: ...nsure hole in barrel positions cable as shown 71711 b a a Cable Barrel b Anchor Plate 5 Secure throttle cable with hardware as shown and tighten securely 6 Place remote control throttle lever in the w...

Page 168: ...lame arrestor screws and tighten securely 75113 a 75142 b c 8 2L MPI Shown a Flame Arrestor b Screws c Vent Hose 9 On 454 Mag MPI Horizon Model a Install flame arrestor b Install locknuts 71481 a a a...

Page 169: ...cable must be free to move when cable is actuated 3 Remove flame arrestor 75447 a b c a Flame Arrestor b Clamp c Engine Cover 4 Install cable end guide on throttle lever then push cable barrel end li...

Page 170: ...knut 6 Place remote control throttle lever in the wide open throttle W O T position Ensure that throttle plate is completely open 75453 a a Throttle Plate 7 Return remote control throttle lever to idl...

Page 171: ...IN LINE AND REMOTE V DRIVE IMPORTANT Velvet Drive Transmission Warranty is jeopardized if the shift lever poppet ball or spring is permanently removed if the shift lever is repositioned or changed in...

Page 172: ...th attaching points on transmission 6 Temporarily install shift cable Do not secure at this time 7 Place remote control shift lever in forward gear position Check position of transmission shift lever...

Page 173: ...Remote V Drive In Line And V Drive a Cable End Guide b Cable Barrel c Cable Barrel Stud d Elastic Stop Nut and Washer e Spacer f Cable End Guide Stud g Elastic Stop Nut and Washer 50946 a b c d e g f...

Page 174: ...d guide moving in direction A when remote control handle is placed in forward position For Right Hand Propeller Shaft Rotation Shift cable hookup at remote control must result in shift cable end guide...

Page 175: ...nnect and adjust Quicksilver shift cable s as outlined following WARNING Avoid serious injury or property damage caused by improper shifting Anchor stud for shift cable must be installed in the correc...

Page 176: ...play then adjust cable barrel to align holes in barrel and in cable end guide with attaching points on transmission f Temporarily install shift cable Do not secure at this time g Place remote control...

Page 177: ...esired d Poppet Ball Must Be Centered In This Detent Hole for Neutral Position e Install Shift Lever Stud In This Hole When Using Quicksilver Shift Cables h Place remote control shift lever in opposit...

Page 178: ...Spacer As Required c Elastic Stop Nut And Washer d Bushing s e Cable Barrel s Located Over Bushings Position Indicated In Lower Drawing f Cable Barrel Stud g Cable End Guide Stud 71897 50073 a b c d...

Page 179: ...MIE MODELS VELVET DRIVE TRANSMISSION SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 2C 25 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index Index...

Page 180: ...MIE MODELS VELVET DRIVE TRANSMISSION SERVICE MANUAL NUMBER 23 Page 2C 26 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index Index...

Page 181: ...Adhesives 2D 2 Preparation 2D 3 Removal 2D 3 Installation 2D 4 Engine Installation and Initial Alignment 2D 4 Engine Final Alignment 2D 7 Engine Connections 2D 11 Seawater Hose Connection 2D 11 Elect...

Page 182: ...ange 50 68 Trunnion Clamping Screw Nut 50 68 Cable Barrel Securely Remote Control Shift Cable Cable End Guide NOTE 1 Cable Barrel Securely Remote Control Throttle Cable Cable End Guide NOTE 1 NOTE 1 T...

Page 183: ...st system hoses 8 Disconnect any grounding wires and accessories that are connected to engine 9 Disconnect propeller shaft coupler from transmission output flange WARNING Be careful when working on fu...

Page 184: ...remove engine Installation Engine Installation and Initial Alignment 1 Follow instructions a or b a Engine mount s or adjustment WAS NOT DISTURBED during engine service Proceed to following Step 2 b...

Page 185: ...justing Nut c Trunnion Clamp Screw And Nut With Lockwasher d Slot Forward e 3 8 in 1 16 in 10 mm 2 mm f 2 5 8 in 1 16 in 67 mm 2 mm g Mount Trunnion CAUTION Center lifting eye located on top of thermo...

Page 186: ...ion on engine bed so that enough propeller shaft protrudes through transmission and output flange for propeller shaft coupler to be attached Then install coupler and position engine so no gap can be s...

Page 187: ...ions with solid couplings as well as flexible couplings 1 Check mating surfaces on transmission output flange and propeller shaft coupler faces to make sure they are clean and flat 2 Follow instructio...

Page 188: ...E Some propeller shaft couplers may not have a shoulder on mating face On these installations use a straight edge to check centerline alignment 72597 Wrong Right 4 Check for angular misalignment by ha...

Page 189: ...nt a Locking Nut b Adjusting Nut c Clamping Bolts and Nuts With Lockwashers Two Each on Some Models d Lag Screws Or Bolts e Slot Forward If So Designed NOT Slotted On This Style Rear Mount NOTE Engine...

Page 190: ...Torque Clamping Screw and Nut On All Four Mount Brackets To 50 lb ft 68 Nm b Tighten Locking Nut On All Four Mounts Securely c Bend One Of The Tab Washer Down Onto Flat Of Adjusting Nut d Maximum Ext...

Page 191: ...id coming in contact with hot spots on engine and avoid contact with moving parts 1 Connect seawater inlet hose to seawater pump as shown Tighten hose clamp securely 75533 b a a Seawater Inlet Hose b...

Page 192: ...can crack casting and or cause a fuel leak Apply 592 Loctite Pipe Sealant with Teflon to threads of brass fitting or plug DO NOT USE TEFLON TAPE Thread brass fitting or plug into fuel pump or fuel fi...

Page 193: ...e a hot spot in the hose which may eventually burn through 72538 Correct Incorrect NOTE Clamps are not shown Throttle Cable Installation and Adjustment MODELS EXCEPT 7 4L MPI 1 Place remote control ha...

Page 194: ...nuts b Move crankcase ventilation hose away from flame arrestor and rocker arm cover fit tings 71764 a a Crankcase Ventilation Hose c Remove flame arrestor NOTE If boat is equipped with Quicksilver Ze...

Page 195: ...sure hole in barrel positions cable as shown 71711 b a a Cable Barrel b Anchor Plate 5 Secure throttle cable with hardware as shown and tighten securely 6 Place remote control throttle lever in the wi...

Page 196: ...arrestor b Connect crankcase ventilation hose c Install flame arrestor screws and tighten securely 75113 a 75142 b c 8 2L MPI Shown a Flame Arrestor b Screws c Crankcase Ventilation Hose 9 On 454 Mag...

Page 197: ...with moving parts DO NOT fasten any items to throttle cable Outer cable must be free to move when cable is actuated 3 Remove flame arrestor 75447 a b c a Flame Arrestor b Clamp c Engine Cover 4 Instal...

Page 198: ...cknut 6 Place remote control throttle lever in the wide open throttle W O T position Ensure that throttle plate is completely open 75453 a a Throttle Plate 7 Return remote control throttle lever to id...

Page 199: ...dle is placed in for ward position For Left Hand Propeller Rotation Shift cable hookup at remote control must result in shift cable end guide moving in direction B when remote control handle is placed...

Page 200: ...In Neutral Detent Must Be Approximately 10 Aft Of Vertical c Dimension Between Studs 7 1 8 in 318 mm d Clamping Bolt 3 Place remote control shift lever and transmission shift lever in neutral position...

Page 201: ...remote control shift lever in the reverse gear position Check that transmission is fully in gear following same procedure 10 If transmission shift lever will position properly in one gear but not in...

Page 202: ...te stud the studs are identical 73589 71210 b c d e e b f a g h Typical Single Cable Forward Entry a Cable End Guide b Locknut And Washer c Spacer Fits Over Bushings d Bushings e Cable Barrel Location...

Page 203: ...b Locknut And Washer c Spacer Fits Over Stud d Bushings e Cable Barrel Locations f Cable Barrel Stud g Cable End Guide Stud 73591 50073 g f c b b e e d a Typical Dual Cable Rear Entry a Cable End Gui...

Page 204: ...MIE MODELS HURTH TRANSMISSION SERVICE MANUAL NUMBER 23 Page 2D 24 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 205: ...36 Removal Head Installed 3A 36 Valve Assembly Exploded View 3A 37 Valve Installation Head Installed 3A 38 Cylinder Head 3A 39 Removal 3A 39 Cleaning 3A 39 Inspection 3A 39 Installation 3A 40 Cylinde...

Page 206: ...ecking Timing Chain Deflection 3A 77 Camshaft 3A 78 Measuring Lobe Lift 3A 78 Removal 3A 78 Inspection 3A 79 Installation 3A 79 Camshaft Bearings 3A 79 Removal 3A 79 Inspection 3A 80 Installation 3A 8...

Page 207: ...nder Head 1 Short Bolts 85 115 Cylinder Head 1 Long Bolts 92 125 Distributor Clamp 24 33 Exhaust Manifold 25 34 Exhaust Manifold Elbow 25 34 Filter Adapter 5 16 18 20 27 Flywheel 65 88 Flywheel Drive...

Page 208: ...t MCM 40 54 Rear Mount MIE 50 68 Remote Oil Connector 1 2 in x 13 25 34 Rocker Arm Cover 71 8 Rocker Arm Bolts 40 54 Remote Oil Filter Adapter Nut Fitting 20 27 Seawater Pump Brace To Engine Mount 30...

Page 209: ...alve Guide Cleaner J8101 Carbon Remover Brush J8089 Piston Pin Tool J24086 B Piston Ring Groove Cleaner J3936 03 Piston Ring Compressor J8037 Connecting Rod Guide Tool 3 8 24 Rod Bolts J5239 Connectin...

Page 210: ...ions NOTICE Unit Of Measurement U S Quarts Liters All capacities are approximate fluid measures MODEL 454 MAG 502 MAG 8 2L Displacement 454 cid 7 4L 502 cid 8 2L Bore 4 25 108 4 46 113 28 Stroke 4 00...

Page 211: ...rvice 002 0 05 Max Taper Production Thrust Side 0005 0 0127 Max Taper Relief Side 001 0 0254 Max Service 001 0 02 Over Production PISTON MODEL 454 MAG 502 MAG 8 2L Clearance Production 0025 0037 0 063...

Page 212: ...4 0 081 Compression Service High Production Limit 010 0 02 Max Com ression Production Top 010 018 0 25 0 46 011 021 0 28 0 53 Gap Production 2nd 016 024 0 41 0 61 016 026 0 41 0 66 Service High Limit...

Page 213: ...0 063 0 096 Main Bearing Cl No 1 001 003 0 03 0 07 0010 0015 0 0254 0 0381 Clearance Service No 2 3 4 001 003 0 03 0 07 0010 0025 0 0254 0 0635 No 5 0025 0040 0635 1016 Crankshaft End Play 006 0010 0...

Page 214: ...ake 003 0 07 0037 0 09 Service Exhaust 004 0 10 0049 0 12 Stem Diameter Intake 372 9 45 Stem Diameter Exhaust 372 9 45 Valve Margin Intake and Exhaust 0312 0 79 Valve Lash Intake and Exhaust Fixed Las...

Page 215: ...ke 301 7 645 Duration at 050 In 1 27mm Exhaust 227 Cam Lift Intake 211 Journal Diameter 1 9482 1 9492 49 485 49 509 Journal Out Of Round 001 0 025 Max Camshaft Runout 002 0 051 Max Timing Chain Deflec...

Page 216: ...alf Cast Iron Upper Half Aluminum Block Cast Iron 4 Bolt Main Bearing Caps Rods Forged Steel Pistons Cast Aluminum Crankshaft Nodular Cast Iron Camshaft Steel CYLINDER BORE MODEL 7 4L Diameter 4 2500...

Page 217: ...l Groove Side Clearance Service High Limit Production 001 0 0254 Oil Production 010 030 0 254 0 762 Gap Service High Limit Production 001 0 0254 PISTON PIN MODEL 7 4L Diameter 9895 9897 25 133 25 1383...

Page 218: ...oduction No 1 2 3 4 0011 0024 0279 0609 Main Bearing Clearance Production No 5 0025 0038 0 0635 0 0965 Service No 1 2 3 4 0010 0030 0 0254 0 0762 Service No 5 0025 0040 0635 1016 Crankshaft End Play 0...

Page 219: ...n Exhaust 0012 0031 0 0300 0 0787 Clearance Service Intake 0037 0 0939 Service Exhaust 0049 0 1244 Valve Lash Intake and Exhaust Net Lash CYLINDER HEAD MODEL 7 4L Gasket Surface Flatness 004 0 1016 Ov...

Page 220: ...r head bolts and on threads of all cylinder block external bolts screws and studs Engine Identification The MerCruiser Model can be determined by looking at the last two letters of the engine code sta...

Page 221: ...mes has caused confusion To clarify engine rotation is determined by observing flywheel rotation from the rear transmission or stern drive end of the engine looking forward water pump end PROPELLER RO...

Page 222: ...re used to retard corrosion Valve Train The valves and valve springs are of a heavy duty design to withstand the high engine speeds encountered Valve tips have been hardened to extend valve life Exhau...

Page 223: ...ches the crankshaft main bearings is forced through a hole in the upper half of each bearing and flows in between the bearings and the crankshaft journals Some of the oil is then routed to the connect...

Page 224: ...ARCH 1999 Bearing Failures 70436 a b Scratched By Dirt a Scratches b Dirt Imbedded In Bearing Material 70436 a Tapered Journal a Overlay Gone From Entire Surface 70436 a Lack Of Oil a Overlay Worn Off...

Page 225: ...02 CID 8 2L SERVICE MANUAL NUMBER 23 Page 3A 21 90 861326 1 MARCH 1999 70436 a Improper Seating a Bright Or Polished Sections 70436 a Fatigue Failure a Craters or Pockets Downloaded from https needman...

Page 226: ...ed by the pressure rise This can result in extensive damage to the internal parts from the high increase in combustion cham ber temperature 72424 Pre Ignition Damage 72314 a b c d Combustion Differenc...

Page 227: ...h causes the fuel to explode violently The explosion in turn causes overheating or damage to the spark plugs pistons valves and in severe cases results in pre ignition Use of low octane gasoline is on...

Page 228: ...the foregoing conditions are beyond the control of MerCruiser therefore no warranty will apply to failures which occur under these condi tions 72425 Detonation Damage 72315 a b c d Combustion Descript...

Page 229: ...2L SERVICE MANUAL NUMBER 23 Page 3A 25 90 861326 1 MARCH 1999 Engine Mounts 72317 Front Mount All MCM Sterndrive Models 72318 Rear Mount Flywheel Housing All MCM Sterndrive Models Downloaded from http...

Page 230: ...ANUAL NUMBER 23 Page 3A 26 90 861326 1 MARCH 1999 Engine Mounts Continued 73055 Rear Mount Assembly Most MIE Models 73056 Rear Mount Assembly MIE Models with Velvet Drive In Line Transmission Download...

Page 231: ...UAL NUMBER 23 Page 3A 27 90 861326 1 MARCH 1999 Engine Mounts Continued 72319 Front Mount Assembly All MIE Models 72319 Rear Mount Assembly MIE 7 4L with Velvet Drive Remote V Drive Transmission Downl...

Page 232: ...removal of rocker arm covers 3 Remove rocker arm cover Installation 1 Clean sealing surfaces on cylinder head and rocker arm cover with degreaser 2 Place new rocker arm cover gasket in position in ro...

Page 233: ...as been removed 8 Remove other ignition components 9 Disconnect any other miscellaneous items that will prevent removal of manifold IMPORTANT It may be necessary to pry intake manifold away from cylin...

Page 234: ...und coolant passages both sides 72514 a c c b b a Exhaust Crossover Port Opening in Gasket b Intake Valve Port c Coolant Passages WARNING Be sure to read and follow package label directions when using...

Page 235: ...ld Torque Sequence For 7 4L MPI Engines 6 Connect all electrical leads 7 Connect hoses to thermostat housing 8 Install fuel line into fuel rail 9 Connect crankcase ventilation hoses to rocker arm cove...

Page 236: ...ker arm assemblies and push rods in a rack for reassembly in their original locations Cleaning and Inspection 1 Clean parts with solvent and dry with compressed air 2 Inspect all contact surfaces for...

Page 237: ...ngine from a non adjustable to an adjustable valve lash engine There are 8 studs and 8 nuts in each kit The valve lash is 1 turn down from 0 lash Valve Adjustment No adjustment is required Valve lash...

Page 238: ...normal stickiness b Galling or pickup between plunger and bore of lifter body usually caused by an abrasive piece of dirt or metal wedged between plunger and lifter body 2 Moderate rapping noise proba...

Page 239: ...hat the engine oil be changed and a new oil filter be installed whenever servicing valve lifters or camshaft IMPORTANT Before installing lifters coat the bottom of the lifter with engine oil If new li...

Page 240: ...mpressed air to hold valves in place 3 Using valve spring compressor as shown compress valve spring and remove valve locks 72516 a b a Valve Spring Compressor J 5892 b Rocker Arm Nut 4 Slowly release...

Page 241: ...1 2 3 4 5 6 7 8 7 4L 1 Valve Lock 2 Retainer 3 Oil Shield Seal 4 Oil Shield 5 Outer Spring 6 Rotator 7 Intake Valve 8 Exhaust Valve 72278 1 2 3 4 5 6 7 8 454 Mag 502 Mag 8 2L 1 Valve Lock 2 Retainer 3...

Page 242: ...mpressor and install valve locks grease may be used to hold valve locks in place Slowly release tool making sure valve locks seat properly in valve stem grooves 72516 a b a Valve Spring Compressor J 5...

Page 243: ...e to 15 lb ft 20 Nm Cylinder Head Removal 1 Drain engine cooling system 2 Remove as outlined a Exhaust manifolds b Intake manifold c Rocker arm covers d Rocker arm assemblies and push rods keep in ord...

Page 244: ...ong Bolts 72944 Cylinder Head Torque Sequence 5 Install push rods and rocker arm assemblies in their original positions Coat threads on rocker arm bolt with Perfect Seal Torque to 40 lb ft 54 Nm 6 Ins...

Page 245: ...8062 2 Remove all valve components 3 Remove valves from cylinder head and place in a rack in order for reassembly in their original locations Cleaning 1 Clean push rods and rocker arm assemblies 2 Cle...

Page 246: ...head gasket surface using a machinist s straight edge and feeler gauges as shown Refer to Specifications 72566 a b c a Straight Edge b Feeler Gauge c Take Both Measurements Diagonally Across Head Both...

Page 247: ...alve Stem c Valve Guide c If clearance exceeds specifications it will be necessary to ream valve guides for oversized valves as outlined under Valve Guide Bore Repair Valve Guide Bore Repair IMPORTANT...

Page 248: ...imum power and performance Another important factor is valve head cooling Good contact between each valve and its seat in head is important to ensure that heat in valve head will be properly dispersed...

Page 249: ...a valve head that is warped excessively is refaced a knife edge will be ground on part or all of the valve head due to the amount of metal that must be removed to completely reface Knife edges lead t...

Page 250: ...rt from which it was removed or to which it was fitted 3 Install valve rotators shims springs seals and caps as shown under Valve Assembly Exploded View for each particular engine 4 Using valve spring...

Page 251: ...ooves of valve stem 1 1 2 3 4 5 6 7 8 75721 7 4L 1 Valve Lock 2 Retainer 3 Oil Shield Seal 4 Oil Shield 5 Outer Spring 6 Rotator 7 Intake Valve 8 Exhaust Valve 72278 1 2 3 4 5 6 7 8 454 Mag 502 Mag 8...

Page 252: ...b Cutaway Scale a Cut Away This Portion 1 2 Inch 13 mm b Valve Spring Installed Height Crankcase Oil Dipstick Specifications All Engines NOTICE Unit Of Measurement U S Inches millimeter 72341 1 2 13...

Page 253: ...or incorrect oil level readings may be obtained 71308 c b a a Factory Positioned Fitting For Tubes Do Not Move b Port Tube c Starboard Tube 3 Remove oil pan Installation 1 Clean sealing surfaces of en...

Page 254: ...ction torque to 18 lb ft 25 Nm 5 Install dipstick tube s and dipstick s Be certain if equipped with two tubes that they are fitted where they were removed and positioned as shown following IMPORTANT D...

Page 255: ...gulator Spring 10 Retaining Pin 11 Screws The oil pump consists of two gears and a pressure regulator valve enclosed in a two piece housing Oil pump is driven by distributor shaft which is driven by a...

Page 256: ...that would permit oil to leak past ends of gears 6 Inspect pickup screen and pipe assembly for damage to screen and pipe 7 Check pressure regulator valve for fit IMPORTANT Oil pump is not serviceable...

Page 257: ...ece gasket for the oil pan may be reused if still pli able and not cracked torn etc Torsional Damper Removal 1 Remove drive belt 2 Remove drive pulley and water pump pulley 3 Remove torsional damper r...

Page 258: ...ng Torsional Damper Remover and Installer as follows a Install appropriate end of threaded rod into crankshaft IMPORTANT Be sure to install threaded rod in crankshaft at least 1 2 in 13 mm to prevent...

Page 259: ...ront cover or damage crankshaft INSTALLATION 1 Apply Quicksilver Perfect Seal to seal retainer mating surface and apply grease to seal lips 73124 a a Seal Lip 2 Install new seal with open end of seal...

Page 260: ...It must be replaced if damaged 1 Check gasket surface on front cover for distortion and true if necessary Surfaces must be clean and flat or oil leakage may result Installation 1 Install oil seal in...

Page 261: ...water Cooled Models Provide adequate water supply to seawater pickup see SECTION 6A Closed Cooled Models Refill closed cooling section see SECTION 6B and provide adequate water supply to seawater pick...

Page 262: ...boat 2 Remove transmission if equipped 3 Refer to Flywheel Housing description in this section and remove flywheel housing and related parts 4 Remove MCM coupler or MIE drive plate 5 Remove flywheel 7...

Page 263: ...urfaces must be clean bare metal 2 Aligning dowel hole in flywheel with dowel in crankshaft install flywheel Torque bolts to 65 lb ft 88 Nm 3 Check flywheel runout as follows a Attach a dial indicator...

Page 264: ...ck or gouge the engine block or rear main bearing cap sealing surface Protect end of crankshaft and crankshaft seal running surface from damage also Cleaning and Inspection Clean crankshaft seal runni...

Page 265: ...can be assumed that the upper half is also satisfactory If the lower half shows evidence of wear or damage both upper and lower halves should be replaced Never replace one half without replacing the...

Page 266: ...lastic gauge 4 Remove bearing cap The flattened gauging plastic will be found adhering to either the bearing cap or journal 5 On the edge of the gauging plastic envelope there is a graduated scale whi...

Page 267: ...ay produce the proper clearance If not it will be necessary to regrind the crankshaft journal for use with the next undersize bearing After selecting new bearing recheck clearance 8 Proceed to the nex...

Page 268: ...tter pin may be bent as shown to do the job 72556 a b a Main Bearing Remover Installer J 8080 b Cotter Pin 3 Rotate the crankshaft clockwise as viewed from the front of engine This will roll upper bea...

Page 269: ...or taper with a micrometer If not within specifica tions replace or recondition the crankshaft If within specifications and a new bearing is to be installed measure the maximum diameter of the crankp...

Page 270: ...ce cannot be brought to within specifications the crankpin will have to be ground undersize If the crankpin is already at maximum undersize replace crankshaft 7 Coat the bearing surface with oil Insta...

Page 271: ...n to collect cuttings After ridge and or deposits are removed turn crankshaft until piston is at top of stroke then remove cloth and cuttings 3 Mark connecting rods and bearing caps left bank 1 3 5 an...

Page 272: ...damaged connecting rods PISTONS NOTE Cylinder bore and taper must be within specifications before pistons can be consid ered for re use 1 Clean varnish from piston skirts with a cleaning solvent DO NO...

Page 273: ...proper ring action and reduce wear Therefore when fitting new rings clearances between ring and groove surfaces should be measured See Specifications 72367 PISTON PINS 1 Piston pin clearance is desig...

Page 274: ...pistons and or connecting rods are being used be sure to assemble pistons and connecting rods so they can be reinstalled in same cylinder from which they were removed Connecting rod bearing tangs are...

Page 275: ...tangs with cylinder number in which it will be installed PISTON RINGS All compression rings are marked on upper side of ring When installing compression rings make sure that marked side is toward top...

Page 276: ...arked side up using ring expander f Install top compression ring with marked side up using ring expander Installation IMPORTANT Cylinder bores must be clean before piston installation Clean with a lig...

Page 277: ...nd bearing cap should be marked beginning at front of engine 1 3 5 and 7 in left bank and 2 4 6 and 8 in right bank Numbers on connecting rod and bearing cap must be on same side when installed in cyl...

Page 278: ...can be rein stalled in their original locations 8 Remove connecting rod bearing caps then push piston and rod assemblies toward heads 9 Remove main bearing caps and carefully lift crankshaft out of c...

Page 279: ...ft into place Be careful not to damage bearing surface 4 Check clearance of each main bearing following procedure outlined under Main Bear ings If bearing clearances are satisfactory apply engine oil...

Page 280: ...acement remove as outlined Cleaning and Inspection 1 Clean all parts in solvent and dry with compressed air 2 Inspect timing chain for wear and damage 3 Inspect sprockets for wear and damage Installat...

Page 281: ...s outlined Checking Timing Chain Deflection With timing chain and sprockets installed check timing chain deflection as follows 1 Rotate camshaft in either direction to place tension on one side of the...

Page 282: ...int push rod will be in its lowest position 4 Set dial indicator on zero then rotate torsional damper slowly or attach an auxiliary starter switch and bump engine over until push rod is in fully raise...

Page 283: ...earings Removal Camshaft bearings can be replaced while engine is disassembled for overhaul or without complete disassembly To replace bearings without complete disassembly remove cam shaft and cranks...

Page 284: ...nt and rear bearings must be installed last as pilot will not fit into bearing bores if bearings are installed Lubricate outer surface of new camshaft bearings with engine oil to ease installation IMP...

Page 285: ...gs a Install appropriate size remover and installer tool on drive handle b Index front bearing as explained in Important above and drive it into position with tool Check position of oil hole s in bear...

Page 286: ...points around cylinder wall to determine out of round condition If cylinders exceed specifications boring and or honing will be necessary 72385 a b a b Cylinder Measurement a At Right Angle To Centerl...

Page 287: ...r an oversize piston If more than 005 in taper or wear bore and hone to smallest oversize that will permit complete resurfacing of all cylinders 4 When pistons are being fitted and honing is not neces...

Page 288: ...sh and completely rinse with hot water It is extremely essential that a good cleaning operation be performed If any abrasive material remains in cylinder bores it will rapidly wear new rings and cylin...

Page 289: ...some cylinders have low compression use a pump type oil can to inject 3 squirts of oil into each combustion chamber through the spark plug hole Do a second compres sion check on each cylinder 6 No cyl...

Page 290: ...move hose fitting and seal from adaptor 3 Remove connector 4 Clean parts in solvent and blow dry with compressed air 5 Inspect fiber valves for cracks or other damage Check that valves fit tightly aga...

Page 291: ...454 CID 7 4L 502 CID 8 2L SERVICE MANUAL NUMBER 23 Page 3A 87 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 292: ...r Specifications 4A 17 Battery Cable Recommendations 4A 17 Torque Specifications 4A 18 Lubricants Sealants Adhesives 4A 18 PG 260 Starter Motor Exploded View 4A 19 Preparation 4A 20 Removal 4A 20 Sole...

Page 293: ...ng System Components Typical for All Starters 72930 B S I a b c d e f g h i a Ignition Switch b 20 Amp Fuse c Starter Slave Solenoid d Circuit Breaker e Starter Motor f Wire Junction g Neutral Safety...

Page 294: ...ch terminal B to terminal S Ignition switch terminal S to neutral start switch YEL RED NEUTRAL START SWITCH MUST BE AT NEUTRAL POSITION Neutral start switch to wiring harness plug terminal 7 YEL RED W...

Page 295: ...good electrical contact Use electrical grade resin flux solder only Do not use acid flux solder as it may cause corrosion and failure Cable Length Cable Gauge Up to 3 1 2 ft 1 1m 4 25 mm2 3 1 2 6 ft 1...

Page 296: ...STARTING SYSTEM SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 4A 5 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 297: ...AL NUMBER 23 Page 4A 6 90 861326 1 MARCH 1999 Direct Drive Starter Motor Exploded View 72806 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 26 27 28 29 30 31 32 33 34 Downloaded fro...

Page 298: ...ld Frame Brush 20 Field Frame Brush Ground Brush 21 Field Frame Brush 22 Brush Lead Screw 23 Ground And Insulated Holders Support Package 24 Field Frame Brush Spring 25 Dowel Pin Field Frame 26 Shift...

Page 299: ...rame screw studs end frame washer and field frame 72633 a c d b a Screw Studs b End Frame c Washer d Field Frame 3 Remove screws center bearing plate and armature 72634 a b c a Screws b Bearing Plate...

Page 300: ...ly Avoid excessive lubri cation 5 Check fit of bushing in commutator end frame If bushing is damaged or worn excessively replace end frame assembly Apply SAE 20 oil to bushing before reassembly Avoid...

Page 301: ...ace while engaging shift lever with clutch 4 Position field frame over armature and apply Quicksilver Liquid Neoprene between frame against drive housing observing caution to prevent damage to brushes...

Page 302: ...Field Coil Connector 2 Connect 12 volt battery positive lead to solenoid switch and negative lead to sole noid frame 3 Momentarily touch a jumper lead from solenoid motor terminal M to starter motor...

Page 303: ...ommutator end frame and field coil housing must be checked See specifications If the gap exceeds mea surement when checked with a feeler gauge the end frame should be checked for proper seating on the...

Page 304: ...ates armature is shorted After cleaning between commutator bars recheck If saw blade still vibrates replace armature 01440 a b c a Hacksaw Blade b Armature Core c Growler Test for Ground 1 With contin...

Page 305: ...H 1999 Field Coil Tests TEST FOR OPEN CIRCUIT 1 With continuity meter place one lead on each end of field coils insulated brush and field connector bar 72635 2 If meter does not move field coils are o...

Page 306: ...d brush 72636 2 If meter hand moves field coils are grounded and must be replaced Loose Electrical Connections If open soldered connection of armature to commutator leads is found during inspection re...

Page 307: ...itch terminal S to neutral start switch YEL RED NEUTRAL START SWITCH MUST BE AT NEUTRAL POSITION Neutral start switch to wiring harness plug terminal 7 YEL RED Wiring harness plug to starter solenoid...

Page 308: ...Min rpm Max rpm 9000789 10 6 60 95 3000 3000 Brush Spring Tension 83 104 oz 2353 2948 g Pinion Clearance 010 160 in 0 25 4 00 mm Bearing Depth Gear 011 014 in 0 28 0 38 mm Bearing Depth Drive Housing...

Page 309: ...ations Fastener Location lb ft Nm Starter Motor To Block 50 68 All Other Fasteners Tighten Securely Lubricants Sealants Adhesives Description Part Number Quicksilver Liquid Neoprene 92 25711 3 SAE 10W...

Page 310: ...15 16 17 18 19 21 1 Screw 2 2 End Cap 3 Brush With Holder 4 Armature 5 Field Frame With Permanent Magnets 6 Washer 7 Shield 8 Planetary Gears 9 Shaft 10 Gear 11 Drive 12 Collar 13 Retaining Ring 14 Tr...

Page 311: ...Cranking motor and solenoid are completely enclosed in the drive housing to prevent entrance of moisture and dirt However periodic inspection is required as follows 1 Inspect terminals for corrosion a...

Page 312: ...m solenoid and screws from end frame 74041 a b a Brush Lead b Screws 2 Remove screws and separate end frame from field frame and end cap 74040 a b c a End Cap b Screws c Drive Housing 3 Remove brush h...

Page 313: ...eld frame NOTE Permanent magnets inside field frame will be holding armature in place 74086 b a a Armature b Field Frame 6 Remove shield and washer 74038 a b a Shield b Washer 7 Remove the three screw...

Page 314: ...23 8 Remove drive and associated parts from drive housing 74035 a b a Drive Housing b Drive 9 Remove solenoid arm and rubber grommet from the drive housing 74018 74048 74105 a c b a Rubber Grommet b...

Page 315: ...d air to clean components 1 Test over running clutch action of drive Pinion should turn freely in over running direc tion and must not slip in cranking direction Check pinion teeth Check spring for te...

Page 316: ...s armature is shorted After cleaning between commutator bars recheck If saw blade still vibrates replace armature 01440 a b c a Hacksaw Blade b Armature Core c Growler TEST FOR GROUND 1 With continuit...

Page 317: ...ake sure brushes move freely in guides 72069 b a a Brush Leads b Guide INSTALLATION 1 Push each brush up into its guide use a 3 inch 75 mm piece of coat hanger wire or similar stiff wire to retain the...

Page 318: ...a b a Brush Holder b Brush Reassembly 1 Install end frame on brush holder Align holes of end frame with holes of brush holder Tighten screws securely a d b c a Screw 2 b End Cap c Brush Holder d Arma...

Page 319: ...Position snap ring on upper end of shaft and hold in place with block of wood Strike wood block with hammer thus forcing snap ring over end of shaft Slide snap ring down into groove a b c 72073 a Sna...

Page 320: ...4A 29 4 Install solenoid arm and rubber grommet in the drive housing 74018 74048 74105 a c b a Rubber Grommet b Solenoid c Drive Housing 5 Install drive and associated parts in drive housing 74035 a...

Page 321: ...sing and tighten screws 74036 b a c a Drive Housing b Solenoid c Screw 3 7 Install shield and washer in drive housing 74038 a b a Shield b Washer 8 Install field frame over armature Align slot in end...

Page 322: ...ecurely Pinion Clearance Pinion clearance must be checked after reassembly of starter motor 1 Disconnect brush lead from solenoid motor and insulate it carefully 74041 a a Brush Lead 2 Connect 12 volt...

Page 323: ...pinion retainer 6 If clearance is not within limits of 010 160 in 0 25 4 00 mm it may indicate excessive wear of solenoid linkage shift lever yoke or improper assembly of shift lever mecha nism Replac...

Page 324: ...nd red wire to fuse terminal Connect battery cable to large terminal of solenoid Tighten fasteners securely Coat terminals with Quicksilver Liquid Neoprene Install battery cable boot if so equipped 72...

Page 325: ...permanent magnets mounted inside the field frame NOTE The actual configuration of these magnets differs between the PG200 PG250 and PG260 the field frames with permanent magnets are not interchangeabl...

Page 326: ...STARTING SYSTEM SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 4A 35 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 327: ...STARTING SYSTEM SERVICE MANUAL NUMBER 23 Page 4A 36 90 861326 1 MARCH 1999 Exploded View 74270 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 17 Downloaded from https needmanual com Index...

Page 328: ...rter Motor Repair Removal WARNING Disconnect battery cables at battery before removing starter 1 Disconnect battery cables from battery 2 Disconnect wires from solenoid terminals IMPORTANT Some starte...

Page 329: ...d field frame from drive housing 5 Pull armature out of field frame NOTE Permanent magnets inside field frame will be holding armature in place 74270 b a c d e a End Frame and Bearing b Screws 2 c Bru...

Page 330: ...ve housing 74036 c b a a Drive Housing b Solenoid c Screws 3 8 Remove drive and associated parts from drive housing 74035 75821 a b a Drive Housing b Drive 9 Remove solenoid arm metal disc and rubber...

Page 331: ...e drive and gears Use clean rags and compressed air to clean components 1 Test over running clutch action of drive Pinion should turn freely in over running direc tion and must not slip in cranking di...

Page 332: ...armature is shorted After cleaning between commutator bars recheck If saw blade still vibrates replace armature 01440 a b c a Hacksaw Blade b Armature Core c Growler TEST FOR GROUND 1 With continuity...

Page 333: ...ld frame cut out Align holes of end frame with holes of brush holder and drive housing Install end frame on brush holder Tighten screws securely 75821 d c b a a Screw 2 b End Frame c Brush Holder d Ar...

Page 334: ...Position snap ring on upper end of shaft and hold in place with block of wood Strike wood block with hammer thus forcing snap ring over end of shaft Slide snap ring down into groove 72073 c b a a Sna...

Page 335: ...NOTE Solenoid arm is designed to fit only one way Do not use force 75821 a b c d a Rubber Grommet b Metal Disc c Solenoid Arm d Drive Housing 7 Install drive and associated parts in drive housing 7403...

Page 336: ...ll field frame over armature Align slot in field frame with rubber grommet 75821 b c a a Armature b Field Frame Slot c Rubber Grommet 11 Install field frame and end frame in drive housing 12 Install l...

Page 337: ...ully 74041 a a Brush Lead 2 Connect 12 volt battery positive lead to battery terminal and negative lead to frame 3 Momentarily touch a jumper lead from battery terminal to switch terminal This shifts...

Page 338: ...shim if equipped between starter motor and engine block 1 Place starter motor in position and install mounting bolts Torque bolts to 30 lb ft 41 Nm 2 Connect YELLOW RED wire to terminal S of solenoid...

Page 339: ...terminal B to terminal S Ignition switch terminal S to neutral start switch YEL RED NEUTRAL START SWITCH MUST BE AT NEUTRAL POSITION Neutral start switch to wiring harness plug terminal 7 YEL RED Wiri...

Page 340: ...l grade resin flux solder only Do not use acid flux solder as it may cause corrosion and failure Cable Length Cable Gauge Up to 3 1 2 ft 1 1m 4 25 mm2 3 1 2 6 ft 1 1 1 8m 2 35mm2 6 ft 7 1 2 ft 1 8 2 3...

Page 341: ...is not serviceable There are not any service replacements parts includ ing the solenoid for this starter Replace this starter with a complete Delco PG260 Starter Exploded View 08 03 04 05 06 07 17 02...

Page 342: ...4B 2 Lubricants Sealants Adhesives 4B 2 Torque Specifications 4B 2 Ignition Control System Components 4B 3 General Precautions 4B 3 EFI System Maintenance Precautions 4B 3 Spark Plugs 4B 4 Spark Plug...

Page 343: ...l Jumper Plug 91 805747A2 Multi Meter DVA Tester 91 99750A1 Mercruiser Special Timing Tool 91 805747A2 Lubricants Sealants Adhesives Description Part Number Silicone Dielectric Compound 92 802882A1 He...

Page 344: ...y cable connections System is negative ground Do not disconnect battery cables while engine is running When working on engine spark plug holes and carburetor throat should be kept covered to prevent f...

Page 345: ...gs Twist the boot 1 2 turn before removing Firmly grasp and pull on the boot to remove the wire end 2 Remove spark plugs NOTE A thin walled spark plug socket may be required 3 Inspect each spark plug...

Page 346: ...gap with a round feeler gauge Bend side electrode to adjust gap Refer to Specifications in SECTION 1B for correct spark plug gap 75084 a b a Seating Area b Gap IMPORTANT It is recommended that spark p...

Page 347: ...plug wires recommended for Marine application NOTE When replacing spark plug wires it is good practice to replace one wire at a time to reduce the risk of error 1 Disconnect individual spark plug wir...

Page 348: ...istributor Cap CHECKING 1 To remove distributor cap a Loosen the distributor cap retaining screws b Lift cap away from distributor 2 Check cap contacts for excessive burning or corrosion 3 Check cente...

Page 349: ...s in this section if all spark plug wires high tension leads were removed from cap Distributor Assembly NOTICE Refer to General Precautions in the front of this section BEFORE proceeding REMOVAL 1 Dis...

Page 350: ...f e d c b a a Cap b Rotor c Shaft Assembly d Retainer e Shield f Pickup Coil g Pole Piece h Screw i Module j Housing k Gasket l Tang Washer m Washer n Gear o Pin NOTE Whenever disassembling distributo...

Page 351: ...king tab with a screwdriver and carefully prying connector from module 8 Remove pickup coil 9 Remove module retaining screws and remove module CLEANING AND INSPECTION 1 Visually inspect the cap for cr...

Page 352: ...entered on retainer Using a small hammer tap the retainer evenly down onto the distributor housing upper bushing Make sure that both teeth are seated in bushing groove The retainer should hold shield...

Page 353: ...in alignment 3 Install hold down clamp over distributor and bolt it securely to engine surface Torque bolt to 30 lb ft 40 Nm 4 Install distributor cap and secure in place with two screws 5 Connect el...

Page 354: ...I will automatically adjust engine to approximately 1200 1500 rpm when put in the service or timing mode 3 Manually adjust the engine throttle to 1800 rpm 200 4 If Not Using MerCruiser Timing Tool Wit...

Page 355: ...IGNITION SYSTEM SERVICE MANUAL NUMBER 23 Page 4B 14 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 356: ...5 Batteries 4C 5 Battery Cables 4C 5 Multiple EFI Engine Battery Precautions 4C 6 EFI Electrical System Precautions 4C 6 System Components 4C 7 Periodic Maintenance 4C 7 Drive Belt Tension Adjustment...

Page 357: ...MerCruiser are designed and manufactured to comply with U S Coast Guard Rules and Regulations to mini mize risks of fire and explosion Use of replacement electrical ignition or fuel system components...

Page 358: ...ft Nm End Frame Screws 55 5 5 Brush Setscrews 18 1 5 Regulator Mounting Screws 42 4 2 Regulator Leads 25 2 5 Ground Terminal Nut 25 2 5 Pulley Nut 42 57 Alternator to Mounting Bracket 35 48 Alternator...

Page 359: ...he output terminal A diode trio also is connected to the stator windings to supply current to the regulator and the rotor field during operation Voltage output of the alternator is controlled by regul...

Page 360: ...rnator system 6 When installing battery BE SURE to connect the positive battery cable to the positive battery terminal and the negative grounded battery cable to negative battery terminal 7 If a charg...

Page 361: ...ve an ignition miss RECOMMENDATIONS Batteries Boats with multi engine EFI power packages require each engine be connected to its own battery This ensures that the engine s Electronic Control Module EC...

Page 362: ...sed air or a cloth Screen MUST BE clean or alternator may overheat Drive Belt Tension Adjustment 1 Install drive belt on pulleys and adjust tension as follows IMPORTANT If a belt is to be reused it sh...

Page 363: ...undercharged battery check to ensure that undercharged condition has not been caused by excessive accessory current draw or by accessories which have been left on accidentally Also check that undercha...

Page 364: ...PLE d Voltmeter 0 20 Volts e Ground EXCITATION CIRCUIT 1 Connect positive voltmeter lead to tie strap terminal on alternator and negative lead to a ground terminal on alternator Test 1 2 Turn ignition...

Page 365: ...2785 f g a b c d e a Excitation Wire PURPLE b Sensing Wire RED PURPLE c Tie Bar d Voltmeter 0 20 Volts e Ground SENSING CIRCUIT 1 Unplug RED PURPLE lead from voltage regulator 2 Connect positive voltm...

Page 366: ...and ground it to block Turn on all accesso ries and crank engine over with starter motor for 15 20 seconds 5 Turn off accessories and reinstall coil wire Start engine and adjust engine speed to 1500 2...

Page 367: ...onnec tion is good and sensing circuit checked out good in Circuitry Test voltage regulator is faulty and must be replaced Be sure to disconnect battery cables before attempting to remove regulator 72...

Page 368: ...tmeter reading is below 14 5 volts inspect brushes and slip rings for wear dirt or damage If brushes and slip rings are good alternator is faulty internally Disassemble alternator and test components...

Page 369: ...Sensing Wire RED PURPLE 5 Excitation Wire PURPLE 6 Cover 7 Tie Strap 8 Rubber Gasket 9 Condenser 10 Insulator 11 Bolt 4 12 End Frame Rear 13 Cap 2 14 Brush Regulator Assembly 15 Rectifier Assembly 16...

Page 370: ...haul of the alternator In many cases however complete disassembly of alternator is not required and in those cases it is necessary only to perform the operations required to repair or replace the faul...

Page 371: ...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 degrees apart fro...

Page 372: ...slots 11 Unsolder the three stator leads from the rectifier heat sink Place a needle nose pliers on diode terminal between solder joint and diode body to help prevent heat damage to diodes Unsolder j...

Page 373: ...difficult to remove it may be necessary to use a universal puller 72828 b a a Wrench b Old Belt To Protect Pulley 13 Remove the three phillips head screws and lockwashers which secure the front bearin...

Page 374: ...s lack of lubrica tion discoloration from overheating and excessive side or end play Bearing should turn freely without binding or evidence of rough spots e Stator inspect for damaged insulation or wi...

Page 375: ...en or high resistance cannot be found connect ohm meter directly to slip ring terminals If correct reading is now obtained or if reading is still high or infinite replace complete rotor assembly d If...

Page 376: ...ad of ohmmeter to one of the stator leads and the other lead to stator frame Be sure that lead makes good contact with frame b Meter should indicate no continuity meter should not move If continuity d...

Page 377: ...or infinite resistance no meter movement when connected one way and a low reading when connected the other If both readings are high or infinite rectifier is open If both readings are low rectifier i...

Page 378: ...of the rectifiers is shorted or open 6 Connect one lead of an ohmmeter set on R x1 to the common side of the diode and the other lead to the other side of one of the three diodes 72148 a b a Common S...

Page 379: ...eassembly 1 Install new front bearing into front end frame bearing bore using an arbor press If neces sary use a bearing driver that contacts outer race only 72835 b a a Press b Mandrel 2 Install fron...

Page 380: ...g the three leads to the three rectifier terminals 72826 a a Stator Lead Connections NOTE Be sure to connect leads to their original positions 6 Install assembled stator and rectifier assembly into re...

Page 381: ...e d Scribe Marks e Insert Screws 4 Two Hidden 9 Depress brushes flush with top of brush holder and insert a 54 050 in drill bit or smaller into hole in brush holder to hold brushes compressed during r...

Page 382: ...stud on brush rectifier assembly Tighten nuts securely 72823 b a a Studs b Tie Straps 12 Install cover with one phillips head screw and two nuts Install two leads with nuts 72963 a b c a Phillips Head...

Page 383: ...in mounting bracket and install mounting bolts Torque to 35 lb ft 48 Nm 75713 b a b a Bracket b Bolts 2 Position alternator drive belt on pulleys and adjust tension as explained under Drive Belt Tens...

Page 384: ...2 2 2 A B B 2 1 a Circuit Breaker b Harness Connector c Alternator d Starter e Cranking Battery f Ground Stud g Auxiliary Battery h Isolator 1 Disconnect Orange Wire From Alternator Battery Terminal...

Page 385: ...CHARGING SYSTEM SERVICE MANUAL NUMBER 23 Page 4C 30 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

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Page 387: ...CHARGING SYSTEM SERVICE MANUAL NUMBER 23 Page 4C 32 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 388: ...CHARGING SYSTEM SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 4C 33 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 389: ...CHARGING SYSTEM SERVICE MANUAL NUMBER 23 Page 4C 34 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 390: ...4D 5 Battery Gauge 4D 6 Cruiselog Meter 4D 7 Vacuum Gauge 4D 7 Speedometer 4D 7 Tachometer 4D 8 Gauge Replacement 4D 8 Senders 4D 9 Oil Pressure 4D 9 Water Temperature 4D 10 Fuel Tank Sender 4D 12 Sw...

Page 391: ...silver gauges may be installed if equipped with Quicksilver gauges Aside from different gauge face appearances and styling the back of the gauges and wiring connections are different as shown 72746 Ba...

Page 392: ...cuit a Positive 12 Volt Power Supply From Ignition Switch b Contact Strip I c Screw Connection 72967 b a c Separate Instrumentation Lighting Circuit Wiring a Positive 12 Volt Power Supply From Ignitio...

Page 393: ...ories 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 Separate Instrumentation Lighting Circuit Positi...

Page 394: ...there is no repair available TESTING 1 Turn ignition switch to OFF 2 Remove wire from terminal S SEND 72965 a Typical a Terminal S SEND 3 Turn ignition switch to RUN Gauge being tested must be at posi...

Page 395: ...eplace gauge 72749 Position B Typical Battery Gauge TESTING 1 Remove cables from battery and fully charge battery 2 Connect negative jumper lead from battery to gauge terminal G GND 3 Connect positive...

Page 396: ...uge readings at specified rpm with service gauge read ings Readings should be within 3 inches of vacuum of each other IMPORTANT Make sure that vacuum hose between gauge and engine is not leaking and t...

Page 397: ...uge 3 Remove hoses vacuum speedometer gauge 4 Disconnect light socket 5 Remove holding strap and remove gauge 6 Position gauge assembly in appropriate mounting hole 7 Install holding strap and nuts Ti...

Page 398: ...ON 1C Troubleshooting 1 Remove wire from sender terminal 2 Connect ohmmeter between sender terminal and sender case Check ohms reading without engine running zero pressure then check reading with engi...

Page 399: ...tem into a suitable container as outlined in SECTION 6B 2 Remove TAN wire from temperature sender NOTE Hoses are shown removed for clarity 3 Remove temperature sender b a a Water Temperature Sender b...

Page 400: ...t 300 F 150 C Under no circumstances should the operator allow temperatures to exceed test specifications Perform test only in a well ventilated area Use a suitable container such as metal to hold the...

Page 401: ...2 Install sender in thermostat housing and tighten securely a b a Water Temperature Sender b Thermostat Housing 3 Connect tan wire and coat with Liquid Neoprene 4 Refill closed cooling system with ap...

Page 402: ...cal Float Arm 5 With float arm in EMPTY position arm vertical meter should read 240 ohms 5 ohms Sender is defective if not within specifications 72756 a b a Ohmmeter Leads b Vertical Float Arm CAPSULE...

Page 403: ...psule Assembly c Magnet 5 Turn magnet counterclockwise until fuel capsule indicator reads EMPTY Ohmmeter should read 240 ohms 5 ohms 72758 a a Capsule Reading Empty 6 Turn magnet clockwise until fuel...

Page 404: ...RUN position continuity will exist between switch terminals B to I There should no continuity between terminal S and any other terminals 5 With key switch in START continuity will exist between termi...

Page 405: ...TESTING 1 Disconnect switch leads 2 Test switch as follows a Connect an ohmmeter to leads b There should be continuity with switch lanyard connected and no continuity with switch lanyard disconnected...

Page 406: ...p switch in the same manner 6 If continuity exists when in the OPEN not depressed state replace panel button Audio Warning System NOTICE For repair procedures on fuel injected engines refer to Section...

Page 407: ...ngine running and engine oil pressure above 6 psi 41 kPa meter should indicate no continuity Transmission Fluid Temperature Switch Switch is located on transmission Switch is normally open This switch...

Page 408: ...the manufacturer of the heat source The heat source should be checked each time it is used to be sure it is functioning properly The thermometer used in the test should be a high temperature thermome...

Page 409: ...16 C 6 Turn heat source off Allow sand to cool Note thermometer reading to ensure switch opens up at specified temperature 7 Replace switch if switch fails to either open or close within the specified...

Page 410: ...INSTRUMENTATION SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 4D 21 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 411: ...INSTRUMENTATION SERVICE MANUAL NUMBER 23 Page 4D 22 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 412: ...Injection Wiring Harness Diagrams 4E 12 MEFI 1 MCM 454 502 Mag MPI and MIE 454 Mag MPI Horizon and 8 2L MPI Models 4E 12 MEFI 2 MCM 7 4L MPI L 29 Model 4E 14 MEFI 2 MIE 7 4L MPI Model 4E 15 MEFI 3 MC...

Page 413: ...HITE GRN WHT Trim Down Switch TAN TAN Water Temperature Sender to Gauge LIGHT BLUE LT BLU Oil Pressure Sender to Gauge PINK PNK Fuel Gauge Sender to Gauge BROWN WHITE BRN WHT Trim Sender to Trim Gauge...

Page 414: ...WIRING DIAGRAMS SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 4E 3 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 415: ...ICE MANUAL NUMBER 23 Page 4E 4 90 861326 1 MARCH 1999 Starting and Charging System Wiring Harness Diagrams MCM Sterndrive 454 502 MPI 71693 A A B C a b c d 1 2 3 4 5 6 1 2 3 1 2 Downloaded from https...

Page 416: ...lenoid B Audio Warning System 1 Oil Pressure Switch 2 Drive Unit Oil Level Bottle Switch C Instrumentation System 1 Oil Pressure Sender 2 Water Temperature Sender 3 Trim Sender a Positive 12V Power Wi...

Page 417: ...WIRING DIAGRAMS SERVICE MANUAL NUMBER 23 Page 4E 6 90 861326 1 MARCH 1999 MCM Sterndrive 7 4L MPI 75467 A A B C a b c d 1 2 3 4 5 1 1 2 Downloaded from https needmanual com Index...

Page 418: ...Slave Solenoid B Audio Warning System 1 Transmission Temperature Switch If Equipped C Instrumentation System 1 Oil Pressure To Sender 2 Trim Sender To Gauge a Positive 12V Power Wire To Fuel Injectio...

Page 419: ...WIRING DIAGRAMS SERVICE MANUAL NUMBER 23 Page 4E 8 90 861326 1 MARCH 1999 MIE Inboard 454 MPI Horizon 8 2L MPI B 75156 C A A a b c d 1 2 1 2 3 4 5 6 1 2 3 Downloaded from https needmanual com Index...

Page 420: ...Audio Warning System 1 Oil Pressure Switch 2 Transmission Fluid Temperature Switch 3 Accessory Load Must Not Exceed 5 Amps C Instrumentation System 1 Oil Pressure Sender 2 Water Temperature Sender a...

Page 421: ...WIRING DIAGRAMS SERVICE MANUAL NUMBER 23 Page 4E 10 90 861326 1 MARCH 1999 MIE Inboard 7 4L MPI 75687 B A A C 2 1 1 1 2 3 4 5 6 c d a b Downloaded from https needmanual com Index...

Page 422: ...eutral Safety Switch B Instrumentation System 1 Oil Pressure Sender 2 Accessory Load Must Not Exceed 5 Amps C Audio Warning System 1 Transmission Fluid Temperature Switch a Positive 12V Power Wire To...

Page 423: ...rness Diagrams MEFI 1 MCM Sterndrive 454 502 Mag MPI and MIE Inboard 454 Mag MPI Horizon and 8 2L MPI Models NOTE All BLACK wires with a ground symbol are interconnected within the EFI system harness...

Page 424: ...r Control IAC 10 Throttle Position TP Sensor 11 Engine Coolant Temperature ECT Sensor 12 Electronic Control Module ECM 13 Fuel Pump Relay 14 Ignition System Relay 15 Fuse 15 Amp Fuel Pump 16 Fuse 15 A...

Page 425: ...7 Knock Sensor Port and Starboard 8 Idle Air Control IAC 9 Throttle Position TP Sensor 10 Engine Coolant Temperature ECT Sensor 11 Electronic Control Module ECM 12 Fuel Pump Relay 13 Ignition System...

Page 426: ...Pressure MAP Sensor 7 Knock Sensor 8 Idle Air Control IAC 9 Throttle Position TP Sensor 10 Engine Coolant Temperature ECT Sensor 11 Electronic Control Module ECM 12 Fuel Pump Relay 13 Ignition System...

Page 427: ...utor 3 Coil 4 Knock Sensor KS Module 5 Data Link Connector DLC 6 Manifold Absolute Pressure MAP Sensor 7 Idle Air Control IAC 8 Throttle Position TP Sensor 9 Engine Coolant Temperature ECT Sensor 10 E...

Page 428: ...Monitor Bottle Not Used On MIE 5 Data Link Connector DLC 6 Manifold Absolute Pressure MAP Sensor 7 Knock Sensor 8 Idle Air Control IAC 9 Throttle Position TP Sensor 10 Engine Coolant Temperature ECT S...

Page 429: ...ne to connec tion and slide rubber sleeve over connection NOTE 2Power for a fused accessory panel may be taken from this connection Load MUST NOT exceed 40 amps If this is done the panel ground wire M...

Page 430: ...connection and slide rubber sleeve over connection NOTE 2 Power for a second fused accessory panel may be taken from this connection Load MUST NOT exceed 40 amps If this is done the panel ground wire...

Page 431: ...BLK BLK LT BLU BLK PUR TAN PUR BLK RED PUR PUR PUR GRY BLK BLK PUR LT BLU BLK PUR TAN RED PUR PUR BLK YEL RED YEL RED BRN WHT YEL RED YEL RED YEL RED B S I SEND SEND SEND L T L T L T L T SW 12V 12V 12...

Page 432: ...peres NOTE 2 An accessory fuse panel may be connected at this location The combined current draw of the primary station and secondary station MUST NOT exceed 35 amperes NOTE 3Connect wires together wi...

Page 433: ...K PUR TAN PUR BLK RED PUR ORN PUR PUR GRY BLK BLK PUR LT BLU BLK PUR TAN RED PUR PUR BLK YEL RED YEL RED BRN WHT YEL RED YEL RED YEL RED YEL RED SEND SEND SEND L T L T L T L T SW 12V 12V 12V 12V GND U...

Page 434: ...peres NOTE 2 An accessory fuse panel may be connected at this location The combined current draw of the primary station and secondary station MUST NOT exceed 35 amperes NOTE 3Connect wires together wi...

Page 435: ...RY BLK BLK LT BLU BLK PUR TAN PUR BLK RED PUR PUR PUR GRY BLK BLK PUR LT BLU BLK PUR TAN RED PUR PUR BLK YEL RED YEL RED BRN WHT YEL RED YEL RED SEND SEND SEND L T L T L T L T SW 12V 12V 12V 12V GND U...

Page 436: ...peres NOTE 2 An accessory fuse panel may be connected at this location The combined current draw of the primary station and secondary station MUST NOT exceed 35 amperes NOTE 3Connect wires together wi...

Page 437: ...WIRING DIAGRAMS SERVICE MANUAL NUMBER 23 Page 4E 26 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 438: ...Precautions 5A 3 Fuel Delivery System 5A 4 Recommendations 5A 4 Special Tools 5A 6 Rinda Technologies Special Tools 5A 7 Cool Fuel System Exploded View 5A 8 Fuel System Flow Diagram 5A 10 Water Separa...

Page 439: ...Engine Compartment Temperature Maximum 176 80 C 1At idle 3000 rpm full throttle and back at idle Tools Description Part Number Fuel Pressure Gauge Obtain Locally Lubricants Sealants Adhesives Descrip...

Page 440: ...erCruiser are designed and manufactured to comply with U S Coast Guard Rules and Regulations to mini mize risks of fire and explosion Use of replacement electrical ignition or fuel system components w...

Page 441: ...delivery system The main concern of a boat s fuel system is safety this must be achieved through a techni cally sound installation and constant inspection The fuel system from the filler pipe to the f...

Page 442: ...ess otherwise stated must be considered Refer to boating standards NMMA ABYC etc and Coast Guard regulations for complete guidelines NOTE If an Anti Syphon valve is required for a particular applicati...

Page 443: ...1 Visually indicates injector electrical impulses from the ECM Injector Harness Test Light J 34730 2A Displays problem codes stored in the Quicksilver Scan Tool 91 823686A2 Dis lays roblem codes store...

Page 444: ...the fuel injection system Allows for test firing injectors EFI Scan Tool Injec tor Tester Rinda Technologies 94040M Flashes light to display problem codes Diagnostic Code Tool Rinda Technologies 94008...

Page 445: ...TRONIC FUEL INJECTION SERVICE MANUAL NUMBER 23 Page 5A 8 90 861326 1 MARCH 1999 Cool Fuel System Exploded View 75708 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 23 12 Downloaded fro...

Page 446: ...re Regulator 5 Return Fuel Line 6 Retaining Ring 7 O Rings 2 8 Fuel Line To Fuel Rail 9 Gasket 10 Drain Plug 11 Stepped Screw 12 O Rings 4 13 Elbow 14 Fuel Cooler 15 Fuel Pump Wiring Harness 16 Retain...

Page 447: ...h i j k l a Vacuum Line To Plenum b Fuel Pressure Regulator c Fuel Cooler d Electric Fuel Pump e Water Separating Fuel Filter f Fuel Line from Tank g Direction Of Water Flow h Fuel Line to Fuel Pump i...

Page 448: ...Brass Fitting g Fuel Filter Mounting Bracket h Nut i Fuel Inlet Fitting j Plug k Water Separating Fuel Filter l Bottom Cover MCM Models Only Water Separating Fuel Filter Replacement 1 Disconnect batt...

Page 449: ...stem and or boat As a precautionary measure attach a tag to the ignition switch or steering wheel with the warning that the seacock must be opened or the water inlet hose reconnected prior to starting...

Page 450: ...nnect the fuel lines from the assembly 3 Disconnect the elbow fitting and fuel pump from the cooler assembly 4 Remove the elbow fitting from the fuel pump to allow replacement of O rings during assemb...

Page 451: ...x O rings onto the cooler to fuel rail fuel line where it attaches to the cooler if not already present on the line b Completely loosen but do not remove the stepped screw that retains the fuel line c...

Page 452: ...o fuel rail fuel line a retainer ring is provided Do not remove the retainer or stepped screw 75708 a b c d e a Fuel Line O Rings b Fuel Line Cooler to Fuel Rail c Fuel Cooler d Stepped Screw Loosened...

Page 453: ...Install the two engine mounting nuts Torque to 30 lb ft 41 N m MEFI 1 FUEL COOLER TO FUEL RAIL LINE INSTALLATION 4 On All Models Except 7 4L MPI Connect the cooler to fuel rail line as follows a Lubr...

Page 454: ...uel system Tighten hose clamps securely 10 Unplug and connect seawater inlet hose Open seacock if so equipped 11 Unplug and connect fuel tank supply inlet hose Tighten hose clamp securely Open fuel sh...

Page 455: ...hown Ensure that the fuel line is fully seated in fuel rail d Install screw and torque to 108 lb in 12 N m 2 Connect the fuel line to the fuel cooler 76078 a b c d a Upper Fuel Rail Orifice b Fuel Lin...

Page 456: ...ler assembly in the cover base 5 Apply a thin even coating of Thermal Grease on all of the retainer bracket inside surfaces where it contacts the cooler and the fuel pump when installed b a a Retainer...

Page 457: ...r e Vent Hose Front of Plenum to PCV Valve f Vacuum Hose Fuel Pressure Damper to T Fitting g Vacuum Hose T Fitting to Plenum h T Fitting i Front of Engine 7 4L MPI Models With MEFI 2 75740 a b c d e f...

Page 458: ...num to PCV Valve f PCV Valve g Front of Engine 7 4L MPI Models With MEFI 3 75728 a b c e f g h i j k d a Plenum b Cool Fuel Assembly c Vacuum Hose Fuel Pressure Regulator on Cool Fuel Assembly to Plen...

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Page 460: ...n Tool Use With Intermittents 5B 10 Non Scan Diagnosis of Driveability Concerns With No Codes Set 5B 11 Special Tools 5B 12 Precautions 5B 13 Electronic Control Module ECM and Sensors 5B 15 General De...

Page 461: ...0L085014 and Above MEFI 3 MIE 7 4L L29 0L002006 0L086199 MEFI 2 MIE 7 4L MPI 0L086200 and Above MEFI 3 MCM 454 Mag MPI 0L010029 0L085399 MEFI 1 MCM 454 Mag MPI 0L085400 and Above MEFI 3 MIE 454 Mag MP...

Page 462: ...w these instructions Introduction The following manual has been prepared for effective diagnosis of the MerCruiser Electronic Fuel Injection system All information illustrations and specifications con...

Page 463: ...rical contacts and proper splicing methods must be used when necessary The proper operation of low amperage input output circuits depends upon good continuity between circuit connectors It is importan...

Page 464: ...secures the male and female terminals together A secondary lock holds the seal and terminal into the connector When diagnosing open circuits are often difficult to locate by sight because oxidation o...

Page 465: ...gital Volt Ohm Meter ECM Engine Control Module ECT Engine Coolant Temperature EEPROM Electronic Erasable Programmable Read Only Memory HEI High Energy Ignition EMI Electromagnetic Interference ENG Eng...

Page 466: ...de Tool With Malfunction Indicator Lamp There are various manufacturers of Diagnostic Code Tools Most tools are equipped with a Malfunction Indicator Lamp MIL It informs the service technician that a...

Page 467: ...ore it leaves the plant The code s stored in the ECM s memory can be read either through a scan tool a diagnostic scanner that plugs into the DLC connector or by counting the number of flashes of the...

Page 468: ...pretation With an understanding of the data which the tool displays and knowledge of the circuits involved the tool can be very useful in obtaining information which would be more difficult or impossi...

Page 469: ...adings may uncover the problem The scan tool has the ability to save time in diagnosis and prevent the replacement of good parts The key to using the scan tool successfully for diagnosis lies in the t...

Page 470: ...out of range sensor If the sensor is within its working or acceptable parameters as shown the ECM does not detect a problem If the sensor should happen to fall out of this window a code will be store...

Page 471: ...tem MERCRUISER Cartridge 91 861538 Displays problem codes stored in the ECM It also allows monitoring of various circuits and components in the fuel injec tion system Allows for test firing injectors...

Page 472: ...tem Ensure that all cable harnesses are connected solidly and that battery connections are thoroughly clean Never connect or disconnect the wiring harness at the ECM when the ignition is switched ON B...

Page 473: ...eter in series with the test light being tested and power the test light ammeter circuit with the vehicle battery b a c a Test Light b Battery c Ammeter IMPORTANT If the ammeter indicates LESS than 3...

Page 474: ...rent sections inside computers also use voltage signals to communicate with each other There are two kinds of voltage signals analog and digital Both of these are used in computer systems It s importa...

Page 475: ...Wire Sensor a Typical Sensor b ECM c Signal Sensor d 5 Volt e Sensor Ground Digital Signals Digital signals are also variable but not continuously They can only be represented by distinct voltages wi...

Page 476: ...g to another computer each bit can have a meaning SWITCH TYPES Switched inputs also known as discretes to the computer can cause one bit to change resulting in information being communicated to the co...

Page 477: ...In some cases even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low Therefore the use of a 10 megohm input impedance digital voltmeter is required to ass...

Page 478: ...old The IAT sensor is a thermistor that changes its resistance depending on the air temperature When the temperature is low the resistance is high and when the temperature is high the resistance is lo...

Page 479: ...ems Although we will not cover them all in great detail there will be a brief description of each a b c d e f g h i j k l m n o p q r s a System Relay b Distributor For REF rpm c Discrete Switches Aud...

Page 480: ...nt temperature affects most systems the ECM controls A failure in the ECT circuit should set Code 14 Code 15 on 7 4L MPI Models only Remem ber this code indicates a failure in the coolant temperature...

Page 481: ...metric pressure under certain conditions which allows the ECM to automatically adjust for different altitudes The ECM sends a 5 volt reference signal to the MAP sensor As the manifold pressure changes...

Page 482: ...trol the spark knock If the circuit going to the module s E terminal opens or shorts to ground the KS module cannot remove the 8 10 volt signal to the ECM and no spark retard will occur The ground cir...

Page 483: ...P circuits will set a Code 21 Code 22 on 7 4L L 29 MPI Models only Once a trouble code is set the ECM will use a default value for TP DISTRIBUTOR REFERENCE DIST REF GM refers to this as Ignition Contr...

Page 484: ...ngine rpm is A circuit within the IC module converts the pickup coil voltage to a square wave engine rpm reference signal This signal is called Reference High REF HI The ECM needs something to compare...

Page 485: ...or an IC operation failure detected while the engine is running The engine will continue to run but at reduced performance J1 10 J2 10 J1 24 76082 ECM A B J1 20 J1 4 J1 5 450 BLK B A B A J1 3 902 RED...

Page 486: ...n be used by the ECM This square wave engine speed reference signal is known as REF HI The ECM must also have something to compare the REF HI value against Therefore an additional line is provided bet...

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Page 488: ...tops and a spark is developed at the spark plug A small amount of advance is built into the IC module via a timing circuit in case the engine remains in the ignition module tim ing mode With the relay...

Page 489: ...ode tool The IC module will go to base timing The ECM will stabilize timing to allow timing adjustment The ECM incorporates a spark con trol override which allows timing to be lowered if spark knock d...

Page 490: ...1999 Page 5B 31 a Ignition Coil Trigger Signal b Battery c Relay d Module Advance e Signal Converter f Pick Up Coil g Ground h Manifold i Coolant Temperature j ECM k IC l REF HI m Bypass n REF LO o Gr...

Page 491: ...he power transistor to enter the IC mode If the IC line becomes grounded while the engine is being operated the engine will stop and will be difficult to restart An open or ground in the IC or bypass...

Page 492: ...ECM looks at voltages from several sensors to determine how much fuel to give the engine The fuel is delivered under one of several conditions called modes All the modes are controlled by the ECM and...

Page 493: ...e neutral safety switch is closed signal grounded When shifting into gear the switch opens signal open When the transmission is shifted into gear the open signal causes the ECM to add a cali brated am...

Page 494: ...to the crank position the ECM turns the fuel pump relay ON causing the fuel pump to start If the ECM does not receive ignition reference pulses engine cranking or running it shuts OFF the fuel pump r...

Page 495: ...njector tip Fuel is directed at the intake valve causing it to become further atomized and vaporized before entering the combustion chamber An injector that is stuck partly open will cause loss of pre...

Page 496: ...ressure as engine vacuum drops 71716 THROTTLE BODY ASSEMBLY The throttle body assembly is attached to the plenum and is used to control air flow into the engine thereby controlling engine output The t...

Page 497: ...le the proper position of the IAC valve is engine load and engine rpm If the rpm drops below specification and the throttle valve is closed the ECM senses a near stall condi tion and calculates a new...

Page 498: ...el evenly to the injectors 75615 a b c d a Fuel Rail b Fuel Injector c Intake Manifold d Plenum FUEL INJECTORS The EFI injector assembly is a solenoid operated device controlled by the ECM that meters...

Page 499: ...asing fuel pressure as engine vac uum drops 71716 THROTTLE BODY ASSEMBLY The throttle body assembly is attached to the plenum It controls engine output by regulating the flow of air to the engine The...

Page 500: ...idle the proper position of the IAC valve is engine load and engine rpm If the rpm drops below specification and the throttle valve is closed the ECM senses a near stall condi tion and calculates a n...

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Page 502: ...ock Sensor KS Module 5C 24 Engine Coolant Temperature ECT Sensor 5C 26 Manifold Absolute Pressure MAP Sensor 5C 27 Throttle Position TP Sensor 5C 28 Intake Air Temperature IAT Sensor 5C 29 Idle Air Co...

Page 503: ...el filter s Wipe up any spilled fuel immediately WARNING Be sure that the engine compartment is well ventilated and that no gasoline vapors are present to avoid the possibility of fire WARNING Make su...

Page 504: ...2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 Cap Nut 2 Flame Arrestor All Models Except Horizon 3 Stud 4 Throttle Body 5 Gasket 6 Throttle Position TP Sensor 7 Washer 8 Screw 9 O Ring 10 Idle Air Control IAC...

Page 505: ...502 Mag MPI and 8 2L MPI Plenum 72802 1 2 3 4 5 7 8 6 9 10 11 12 13 14 1 Screw 2 Screw 3 Plenum 4 Sleeve 5 Drain Line To Intake Manifold 6 Nut 7 Bracket 8 Stud 9 Screw 10 Intake Air Temperature IAT Se...

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Page 507: ...VICE MANUAL NUMBER 23 Page 5C 6 90 861326 1 MARCH 1999 454 502 Mag MPI and 8 2L MPI Intake Manifold and Fuel Rail 75741 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3...

Page 508: ...Filter 9 O Ring 10 Fuel Damper 11 Plug 12 Bolt 13 Nut 14 Schrader Valve 15 Engine Coolant Temperature ECT Sensor 16 Plug 17 Bolt 18 Thermostat Housing 19 Plug 20 Water Temperature Sender 21 Gasket 22...

Page 509: ...the system 454 502 Mag MPI Multi Port Components Flame Arrestor NOTICE Refer to Precautions in this section BEFORE proceeding REMOVAL Remove four flame arrestor mounting cap nuts and flame arrestor f...

Page 510: ...eeding REMOVAL 1 Remove four flame arrestor mounting cap nuts and remove flame arrestor from throttle body 72790 a b a Flame Arrestor b Cap Nuts 4 2 Disconnect throttle linkage 72791 a a a Throttle Li...

Page 511: ...Control IAC Valve d Drain Tube IMPORTANT To prevent damage to throttle valve it is essential that throttle body be placed on a holding fixture before performing service IMPORTANT Insert a clean shop...

Page 512: ...hly 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...

Page 513: ...TE If Boat is equipped with Quicksilver Zero Effort Controls the throttle cable mounting stud must be in the most forward position on throttle lever 73855 a a Position For Zero Effort Controls 3 Conne...

Page 514: ...n 6 Nm 72790 a b a Flame Arrestor b Cap Nuts 4 Plenum NOTICE Refer to Precautions in this section BEFORE proceeding REMOVAL 1 Remove flame arrestor and throttle body as outlined previously 2 Disconnec...

Page 515: ...clean shop towel over each of the eight intake manifold open ings to prevent foreign material from entering the engine CLEANING AND INSPECTION IMPORTANT Use care when removing gasket material from int...

Page 516: ...nd install twelve plenum mounting fasteners Torque fasteners to 150 lb in 17 Nm 72797 b a c a Plenum b Intake Manifold c Drain Line 3 Connect vacuum lines 75724 b a c a Vacuum Lines b Fuel Pressure Da...

Page 517: ...fer to SEC TION 5A for complete instructions 76078 a b b c d a a Fuel Rail b Fuel Line Cooler to Fuel Rail c Screw d O Ring REMOVAL 1 Remove flame arrestor throttle body and plenum as outlined in this...

Page 518: ...tors from their respective bores working back and forth toward rear of engine until fuel rail is free 72798 a b c d a Fuel Rail b Intake Manifold c Front Right Bank Fuel Injector d Front Left Bank Fue...

Page 519: ...d a Fuel Rail b Intake Manifold c Rear Right Bank Fuel Injector d Rear Left Bank Fuel Injector 2 Install fuel rail mounting bolts and torque to 105 lb in 12 Nm 3 Install new O ring on fuel inlet line...

Page 520: ...fuel rail for pitting nicks burrs or irregula rities Use a magnifying glass if necessary If any of the above is present replace the fuel rail 2 Clean filter of any debris using solvent Dry using comp...

Page 521: ...ector and nozzle IMPORTANT The fuel injector is an electrical component DO NOT soak in any liquid cleaner or solvent as damage may result IMPORTANT Modules and sensors are electrical devices easily da...

Page 522: ...appearance yet have a different part number and be calibrated for a different flow rate If installed the wrong injector would cause performance difficulty or damage to the ECM 1 Install new O rings o...

Page 523: ...odules and sensors are electrical devices easily damaged by contact with liquid cleaners or solvents Clean with a dry cloth unless specifically directed to do otherwise Electronic Control Module ECM N...

Page 524: ...ect J1 and J2 connectors on the wiring harness for corrosion and terminals that may have backed out of the harness NOTE The ECM is a sealed electrical component If a Code 51 or 52 check has shown it t...

Page 525: ...EFORE proceeding REMOVAL 1 Remove Knock Sensor from electrical bracket 72801 a b Typical a Electrical Bracket b Knock Sensor KS Module 2 Disconnect electrical connector at Knock Sensor KS module CLEAN...

Page 526: ...L NUMBER 23 90 861326 1 MARCH 1999 Page 5C 25 INSTALLATION 1 Connect electrical connector to the Knock Sensor KS module 2 Mount KS module to electrical bracket 72801 a b Typical a Electrical Bracket b...

Page 527: ...ture ECT sensor 72799 a b a Thermostat Housing b Engine Coolant Temperature ECT Sensor 2 Remove ECT from thermostat housing CLEANING AND INSPECTION 1 Clean with a dry cloth removing any excess sealant...

Page 528: ...ifold Absolute Pressure MAP Sensor c Screws d Seal 2 Remove screws from MAP sensor 3 Remove MAP sensor from plenum CLEANING AND INSPECTION 1 Clean off any foreign matter with a dry cloth 2 Inspect for...

Page 529: ...REMOVAL 1 Remove flame arrestor throttle cable and throttle body as outlined in Throttle Body 72800 a b c d a Throttle Body b Throttle Position TP Sensor c Screws With Lockwashers d O Ring 2 Remove T...

Page 530: ...e arrestor as outlined in Throttle Body 3 When negative battery cable has been reconnected start engine and check the TP sensor output voltage It should be approximately 7 Volts at idle and 4 5 Volts...

Page 531: ...flame arrestor as outlined in Plenum 3 Connect electrical connector to IAT sensor Idle Air Control IAC Valve NOTICE Refer to Precautions in this section BEFORE proceeding REMOVAL 1 Remove flame arrest...

Page 532: ...isalignment or a bent pintle shaft 2 Inspect the entire assembly for any obvious physical damage INSTALLATION IMPORTANT If installing a new IAC valve be sure to replace it with an identical part IAC v...

Page 533: ...base 2 Inspect surfaces of knock sensor for signs of wear or physical damage INSTALLATION IMPORTANT If installing a new knock sensor be sure to replace it with an identical part Knock sensors are ver...

Page 534: ...p relay from electrical bracket 72801 a b a Electrical Bracket b Fuel Pump Relay 2 Disconnect electrical connector and remove fuel pump relay IMPORTANT The fuel pump relay is an electrical component D...

Page 535: ...2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 Electrical Bracket 2 Relay 3 Relay 4 Screw 5 Knock Sensor KS Module 6 Screw 7 Slave Solenoid 8 Nut 9 Circuit Breaker 10 Screw 11 Screw 12 MerCathode Co...

Page 536: ...b c e f g h i d a Plenum b Cool Fuel Assembly c Vacuum Hose T Fitting to Fuel Pressure Regulator on Cool Fuel Assembly d Vent Hose Valve Cover to Throttle Body Flame Arrestor e Vent Hose Front of Ple...

Page 537: ...SSEMBLY SERVICE MANUAL NUMBER 23 Page 5C 36 90 861326 1 MARCH 1999 Exploded View 7 4L MPI Intake Manifold Plenum and Fuel Rail 75730 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 2...

Page 538: ...pter Studs 3 8 Adapter Gasket 9 Fuel Injector Harness 10 Fuel Rail Screws 11 Fuel Rail Stud 12 Fuel Rail 13 Fuel Injectors 8 14 O Ring 15 Fuel Rail Plug 16 Intake Manifold Screws 12 17 Manifold Absolu...

Page 539: ...3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 Throttle Body 2 Throttle Body Gasket 3 Throttle Body Adapter 4 Hose Fittings 2 5 Crankcase Vent Hose 6 Throttle Cable Bracket 7 Screw 8 Nut 9 Anchor St...

Page 540: ...until it stops to relieve any fuel pressure in the system 7 4L MPI Components Flame Arrestor NOTICE Refer to Precautions in this section BEFORE proceeding REMOVAL 1 Remove the starboard engine cover...

Page 541: ...ANING AND INSPECTION IMPORTANT DO NOT use cleaners containing methyl ethyl ketone It is not neces sary for cleaning throttle bore and valve deposits IMPORTANT DO NOT allow the TP and IAC valve to come...

Page 542: ...r and IAC valve 4 Connect the throttle cable to the throttle lever 5 Place the flame arrestor over the throttle body and tighten the clamp Plenum NOTICE Refer to Precautions in this section BEFORE pro...

Page 543: ...reather Hose 6 Remove the plenum from the manifold 75615 b a c a Plenum b Intake Manifold c Screws IMPORTANT Place a clean shop towel over the openings to prevent foreign materials from entering the e...

Page 544: ...t d Intake Manifold 3 Install the intake air temperature IAT sensor in the plenum 4 Place the adapter gasket over the studs on the plenum 5 Install the adapter and throttle body on the plenum Install...

Page 545: ...move the fuel line from the fuel rail 3 Remove the plenum as previously described 4 Disconnect the electrical connector at the injector harness 5 Disconnect the injector harness connector from the fue...

Page 546: ...eplace if necessary INSTALLATION IMPORTANT When replacing injectors be certain to replace with the identical part and part number Other injectors may have the same appearance yet have a different part...

Page 547: ...t the injector harness to the fuel injector 4 Lubricate all of the o rings on the fuel rail and carefully place them in the intake manifold 5 Install the screws stud MAP sensor retainer clip and nut t...

Page 548: ...ical connector at the injector harness 5 Remove the screws nut MAP sensor retainer clip and stud from the fuel rail 6 Remove the map sensor from the intake manifold 75615 a b a MAP Sensor b Intake Man...

Page 549: ...arrestor from the throttle body 3 Disconnect the harness connector from the TP sensor 4 Remove the throttle body from the adapter 5 Disconnect the harness connector from the TP sensor 6 Remove the scr...

Page 550: ...nnect the harness connector to the TP sensor 5 Place the flame arrestor over the throttle body and tighten hose clamp securely 6 Position the starboard engine cover and install the screws 7 When negat...

Page 551: ...stall the IAT sensor in the plenum TIGHTEN 2 1 2 TURNS MAXIMUM 75658 a a Intake Air Temperature IAT Sensor 2 Connect harness connector to the IAT sensor Idle Air Control IAC Valve NOTICE Refer to Prec...

Page 552: ...a bent pintle shaft 2 Inspect the entire assembly for physical damage INSTALLATION IMPORTANT If installing a new IAC valve be sure to replace it with an identical part IAC valve pintle shape and diam...

Page 553: ...knock sensors from engine block CLEANING AND INSPECTION 1 Clean knock sensors with a dry cloth paying special attention to threads on base 2 Inspect surfaces of knock sensors for signs of wear or phys...

Page 554: ...teering Cooler Hose Removed a Knock Sensor Module 2 Disconnect electrical connector at Knock Sensor KS module CLEANING AND INSPECTION 1 Clean the external surfaces of the KS module with a dry cloth 2...

Page 555: ...electrical connector to fuel pump relay 2 Mount fuel pump relay on electrical bracket Electronic Control Module ECM NOTICE Refer to Precautions in this section BEFORE proceeding IMPORTANT The ECM is...

Page 556: ...be defective replace the unit with another ECM having the same part number as the origi nal INSTALLATION 1 Mount ECM on electrical bracket 2 Connect J1 and J2 electrical connectors to ECM Engine Cool...

Page 557: ...ss Connector 2 Connect electrical connector to ECT sensor Vacuum Line Routing 7 4L MPI Models 75740 a b c d e f g h i 75728 a Plenum b Cool Fuel Assembly c Vacuum Hose T Fitting to Fuel Pressure Regul...

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Page 560: ...FI 3 454 cid 7 4L 502 cid 8 2L Engines 5D 3 Scan Tool Normal Specifications Idle Warm Engine Closed Throttle Neutral 5D 5 Important Preliminary Checks 5D 6 Visual Physical Check 5D 6 Hard Start Sympto...

Page 561: ...mperature Low Temperature Indicated Code 15 ECT Engine Coolant Temperature High Temperature Indicated Code 21 TP Throttle Position Sensor Signal Voltage High Code 22 TP Throttle Position Sensor Signal...

Page 562: ...53 counts Open circuit Faulty sensor 25 MAT low Minimum run time 10 sec sensor Sensor output low hot 7 counts Short circuit Faulty sensor 33 MAP high kpa 80 and tps 5 and rpm 500 for at least 5 second...

Page 563: ...lt Ignore first 20 spark events requires 8 faults to set code Open secondary wire Open primary cable 51 Checksum error Reserved Invalid ECM checksum Bad ECM 61 Fuel pressure high Minimum run time 10 s...

Page 564: ...itude and Barometric Pressure Bat Volts 12 0 14 5 Volts Spark Advance Degrees 10 to 30 Knock Retard Degrees 0 Idle Air Control IAC Counts Steps 0 40 Counts Minimum IAC Position Counts Steps 0 40 Count...

Page 565: ...s pinches and cuts If wiring harness or connector repair is necessary refer to Description and System Operation section for correct procedure Moisture in primary or secondary ignition circuit connecti...

Page 566: ...22 from memory An intermittent MIL with no stored DTC may be caused by the following Ignition coil shorted to ground and arcing at ignition wires or plugs MIL wire to ECM shorted to ground Poor ECM g...

Page 567: ...proper operation of fuel pump relay circuit Refer to Table A 5 in General Sys tem Diagnostics section 2 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Go to Step...

Page 568: ...reading of ambient air temperature Are the temperatures within the specified value of each other 10 F 12 C Go to Step 11 Go to Step 13 11 1 Using a scan tool display ECT sen sor temperature and note...

Page 569: ...System Check Go to Step 17 17 1 Check or the following Engine Mechanical problems Low compression Leaking cylinder head gaskets Worn or incorrect camshaft Proper valve timing valve train prob lem Rest...

Page 570: ...problem found Go to OBD System Check Go to Step 5 5 1 Check for proper fuel pressure while the condition exists Refer to Table A 4 in General Sys tem Diagnostics section 2 If a problem is found repair...

Page 571: ...cing the spark plugs 2 If a problem is found repair as necessary Was a problem found Go to OBD System Check Go to Step 11 11 1 Check fuel delivery system items that can cause the engine to run rich 2...

Page 572: ...em 3 If a problem is found repair as necessary Was a problem found Go to OBD System Check Contact MerCruiser Customer Service Lack of Power Sluggish or Spongy Symptom Step Action Value s Yes No Defini...

Page 573: ...as a problem found Go to OBD System Check Go to Step 9 9 1 Check for proper ignition voltage output Refer to Table A 7 in General Sys tem Diagnostics section 2 If a problem is found repair as necessar...

Page 574: ...on mode 2 If a problem is found repair as necessary Was a problem found Not Applicable to MerCruiser EFI or MPI Go to Step 15 15 1 Check diagnostic test CKT 451 for being shorted to ground This will c...

Page 575: ...ec essary Was a problem found Go to OBD System Check Contact MerCruiser Customer Service Detonation Spark Knock Symptom Step Action Value s Yes No Definition A mild to severe ping usually worse under...

Page 576: ...necessary Was a problem found Go to OBD System Check Go to Step 8 8 Is a scan tool being used Go to Step 9 Go to Step 10 9 If scan tool readings are normal Refer to Scan Tool Normal Specifications in...

Page 577: ...e timing valve train prob lem Combustion chambers for exces sive carbon build up 2 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Go to Step 14 14 1 Remove exces...

Page 578: ...l pressure while the condition exists Refer to Table A 4 in General Sys tem Diagnostics section 2 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Go to Step 5 5 1...

Page 579: ...or worn 3 An intermittent failure may not store a DTC 4 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Go to Step 10 10 1 Check for engine going into rpm reduct...

Page 580: ...ut 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 Was visual physical check performed Go to Step 3 Go to Visual Physical Check 3 1 Check for contaminate...

Page 581: ...d electrodes Heavy deposits NOTE If spark plugs are gas or oil fouled the cause of the fouling must be determined before replacing the spark plugs 2 If a problem is found repair as nec essary Was a pr...

Page 582: ...system 3 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Contact MerCruiser Customer Service Rough Unstable or Incorrect Idle Stalling Symptom Step Action Value s...

Page 583: ...must be deter mined before replacing the spark plugs 2 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Go to Step 8 8 Check the injector connections If any of th...

Page 584: ...Was a problem found Go to OBD System Check Go to Step 13 13 1 Check ECM grounds for being clean tight and in their proper loca tions 2 Also check that battery cables and ground straps are clean nd se...

Page 585: ...remove as necessary Were deposits found on the intake valves Go to OBD System Check Go to Step 19 19 1 Check for faulty motor mounts 2 If a problem is found repair as nec essary Was a problem found G...

Page 586: ...2 Check for fuel leaks 3 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Go to Step 5 5 1 Check for proper fuel pressure Refer to Table A 4 in General Sys tem Dia...

Page 587: ...s 3 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Go to Step 11 11 1 Check for excessive resistance on the bottom of the boat such as dirt barnacles etc 2 Check...

Page 588: ...r as nec essary Was a problem found Go to OBD System Check Go to Step 4 4 1 Check for proper operation of Igni tion Control IC circuit and the Knock Sensor KS circuit 2 If a problem is found repair as...

Page 589: ...c OBD System Check performed Go to Step 2 Go to OBD System Check 2 Was visual physical check performed Go to Step 3 Go to Visual Physical Check 3 1 Check flame arrestor for proper installation 2 If a...

Page 590: ...or car bon tracking 2 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Go to Step 10 10 1 Check for proper ignition voltage input to the ECM 2 Check for intermitte...

Page 591: ...ft lobe s Incorrect valve timing 2 If a problem is found repair as nec essary Was a problem found Go to OBD System Check Go to Step 14 14 1 Check Intake and exhaust man ifold s for casting flash 2 If...

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Page 593: ...FUEL INJECTION SYSTEM TROUBLESHOOTING SERVICE MANUAL NUMBER 23 Page 5D 34 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 594: ...es for the MEFI 3 454 cid 7 4L 502 cid 8 2L Engines 5E 6 Special Tools 5E 7 MEFI 1 454 502 Mag MPI and 8 2L MPI Symptom Chart J 1 Circuits 5E 10 MEFI 1 454 502 Mag MPI and 8 2L MPI Symptom Chart J 2 C...

Page 595: ...tem would typically display Only the parameters listed below are used in this manual for diagnosing If a scan reads other parameters the values are not recommended for use in diagnosing If all values...

Page 596: ...l read Trans MEFI 1 ECM Connector Chart For 454 502 Mag MPI and 8 2L MPI The following chart will aid in diagnosis of symptoms These voltages were derived from a known good engine The voltages shown w...

Page 597: ...e at operating temperature 2 Ignition on or engine running 3 Scan tool not connected THESE NOTES APPLY TO FOLLOWING ECM CONNECTOR AND SYMPTOM CHARTS The B Symbol indicates a system voltage battery NOT...

Page 598: ...ature Indicated Code 15 ECT Engine Coolant Temperature High Temperature Indicated Code 21 TP Throttle Position Sensor Signal Voltage High Code 22 TP Throttle Position Sensor Signal Voltage Low Code 23...

Page 599: ...circuit Faulty sensor 25 MAT low Minimum run time 10 sec sensor Sensor output low hot 7 counts Short circuit Faulty sensor 33 MAP high kpa 80 and tps 5 and rpm 500 for at least 5 seconds Open circuit...

Page 600: ...0 ohms 2 20 200 k 2 20 m J 23738 Vacuum Pump with Gauge 20 In Hg Minimum Gauge monitors manifold engine vacuum Hand pump used to check fuel pressure regulator J 34142 B Note 2 Unpowered Test Light Use...

Page 601: ...the 7 4L MPI mod el These fittings are included in Fuel Shut Off Tool 91 805918A2 91 805747A1 Timing Tool Jumper Plug Used to set Ignition timing Plug connects to DLC 91 806901 Fuel Line Connector Al...

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Page 603: ...rformance Detonation J1 2 ECT Sig nal 410 YEL 1 95V NOTE 2 1 95V NOTE 2 14 Poor Performance Exhaust Odor Rough Idle RPM Reduction J1 3 Not Used J1 4 Not Used J1 5 Master Slave 916 YEL B B None Lack Of...

Page 604: ...IAT Ground 813 BLK 0 NOTE 5 0 NOTE 5 21 23 High Idle Rough Idle Poor Performance Exhaust Odor J1 14 ECM Ground 450 BLK WHT 0 NOTE 5 0 NOTE 5 None No Start J1 15 TP 5V Refer ence 416 GRY 5V 5V 21 Lack...

Page 605: ...r Stall J1 30 ECM Ground 450 BLK WHT 0 NOTE 5 0 NOTE 5 None No Start J1 31 MAP 5V Refer ence 416 GRY 5V 5V 33 Lack Of Power Surge Rough Idle Exhaust Odor J1 32 Battery 440 ORN B B None No Start MEFI 1...

Page 606: ...p Relay Driver 465 DK GRN WHT 0 NOTE 5 B None No Start J2 10 Not Used J2 11 Coolant Over temp 112 DK GRN 0 0 None Improper Audio Warn ing J2 12 Not Used J2 13 IAC A Low 442 BLU BLK Not Us able Not Usa...

Page 607: ...gnal 423 WHT 0 NOTE 5 1 2V 42 Stall Will Restart In Bypass Mode Lack Of Power J2 24 Ignition Control Bypass 424 TAN BLK 0 NOTE 5 4 5V 42 Lack Of Power Fixed Timing J2 25 Not Used J2 26 Not Used J2 27...

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Page 609: ...J2 29 J1 18 J1 5 J1 7 J2 31 D C B A K J H G F A B C D E A B 441 BLU WHT 442 BLU BLK 443 GRN WHT 444 GRN BLK 461 ORN BLK BLK 450 BLK WHT 916 YEL 451 WHT BLK 419 BRN WHT 465 GRN WHT 901 WHT 901 WHT 450...

Page 610: ...Fuel Pump Relay g Fuel Pump h To ECM BAT Fuse i Idle Air Control Motor j Data Link Connector k Injector Driver l Injector Ground m Fuel Injector Ground n Injector Driver o Port Fuel Jumper p Port Fuel...

Page 611: ...MPI and 8 2L MPI Wiring System Diagram 2 of 4 J1 24 J1 10 J1 15 J1 13 J1 31 J1 9 J1 29 J1 2 410 YEL 472 TAN 417 DK BLU 416 GRY 813 BLK 416 GRY 432 LT GRN 814 BLK 814 BLK 814 BLK B C A B A C B A A B 8...

Page 612: ...take Air Temperature Sensor b Throttle Position Sensor c Manifold Absolute Pressure Sensor d Engine Coolant Temperature Sensor e IAT Sensor f TP Signal g TP 5V Reference h TP and IAT Ground i MAP 5V R...

Page 613: ...m Diagram 3 of 4 75605 J1 14 J2 23 J2 8 J2 11 J2 27 J1 6 J1 30 J2 24 J2 6 E D C B A 450 BLK WHT 450 BLK WHT 121 WHT 112 DK GRN 31 TAN 931 BRN 423 WHT 430 PUR WHT 424 TAN BLK 453 BLK RED B 3 PNK 931 BR...

Page 614: ...Drawing 4 Of 4 c Harness Connector d Ignition Coil e ECM Ground f ECM Ground g Ignition Control Signal h Ignition Control Reference High i Ignition Control Bypass j Ignition Control Reference Low k C...

Page 615: ...439 PNK BLK 485 BLK 486 BRN 496 DK BLU 440 ORN 150 BLK 2 RED 902 RED 439 PNK BLK 3 PNK a b c d e f g h i j k l m n o a To Key Switch b To Battery Positive c System Ignition Relay d ECM BAT fuse 15A e...

Page 616: ...Do not attempt to obtain these voltages by probing wires and connectors Serious damage could result in loss of engine operation or wiring damage Voltages can vary with battery conditions J 1 a b J 1 F...

Page 617: ...ECM CONNECTOR AND SYMPTOM CHARTS The B Symbol indicates a system voltage battery NOTE 1 Battery voltage for first two seconds then 0 volts NOTE 2 Varies with temperature NOTE 3 Varies with manifold v...

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Page 619: ...95V NOTE 2 1 95V NOTE 2 14 Poor Perfor mance Ex haust Odor Rough Idle RPM Reduc tion J1 3 Not Used J1 4 Discrete Switches 911 BRN None Audio Warn ing Activated Low Oil Pressure Low I O Fluid Trans mis...

Page 620: ...erfor mance And Accelera tion Incor rect Idle J1 11 Ignition Fused 439 PNK B B None No Start J1 12 Not Used J1 13 TP and IAT Ground 813 BLK 0 NOTE 5 0 NOTE 5 21 23 High Idle Rough Idle Poor Perfor man...

Page 621: ...0 NOTE 5 None No Start J1 31 MAP 5V Refer ence 416E GRY 5V 5V 33 Lack Of Power Surge Rough Idle Exhaust Odor J1 32 Battery 440 ORN B B None No Start J2 1 Not Used J2 2 Not Used J2 3 Not Used J2 4 Not...

Page 622: ...h Un stable or In correct Idle J2 15 Injector Ground 450 BLK 0 NOTE 5 0 NOTE 5 None Rough Run ning Lack Of Power Poor Perfor mance J2 16 Not Used J2 17 Not Used J2 18 Not Used J2 19 Not Used J2 20 Fue...

Page 623: ...ble Codes DTC s Possible Symptoms J2 26 Discrete Switch Signal 31 DK GRN Audio Warn ing System Activated Audio Warn ing to Buzz er J2 27 Not Used J2 28 IAC A High 441 LT BLU WHT Not Usable Not Usable...

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Page 625: ...5 J1 7 J2 31 D C B A K J H G F A B C D E A B 441 LT BLU WHT 442 LT BLU BLK 443 LT GRN WHT 444 LT GRN BLK 461 ORN BLK 450 BLK 916 YEL 451 BLK WHT 419 BRN WHT 465 DK GRN WHT 901 WHT 901 WHT 450 BLK WHT...

Page 626: ...Fuse f Fuel Pump Relay g Fuel Pump h To ECM BAT Fuse i Idle Air Control Motor j Data Link Connector k Injector Driver l Injector Ground m Fuel Injector Ground n Injector Driver o Port Fuel Jumper p Po...

Page 627: ...4L MPI Wiring System Diagram 2 of 4 75604 J1 24 J1 10 J1 15 J1 13 J1 31 J1 9 J1 29 J1 2 410 YEL 472 TAN 417 DK BLU 416 GRY 813 BLK 416E GRY 432 LT GRN 814 BLK 814 BLK 814 BLK B C A B A C B A A B 813...

Page 628: ...take Air Temperature Sensor b Throttle Position Sensor c Manifold Absolute Pressure Sensor d Engine Coolant Temperature Sensor e IAT Sensor f TP Signal g TP 5V Reference h TP and IAT Ground i MAP 5V R...

Page 629: ...2 23 J2 8 J2 11 J2 26 J1 4 J1 30 J2 24 J2 6 E D C B A 450 BLK WHT 121 WHT 112 GRY 31 TAN 931 BRN 423 WHT 430 PUR WHT 424 TAN BLK 453 RED BLK 902 RED 3 PNK 585 TAN WHT 3 PNK 31A DK GRN DK BLU B A A B 1...

Page 630: ...on Coil f Gear Lube Switch g Oil Pressure Switch h ECM Ground i ECM Ground j Ignition Control Signal k Ignition Control Reference High l Ignition Control Bypass m Ignition Control Reference Low n Cool...

Page 631: ...4L MPI Wiring System Diagram 4 of 4 75606 J1 11 J1 32 J1 16 J1 1 30 86 85 87 A B C D E 2B RED 2 RED 440 ORN 440 ORN 439 PNK 485 GRN 486 PUR 496 DK BLU 440 ORN 150 BLK 2B RED 902 RED 439 PNK BLK 3 PNK...

Page 632: ...tch b 2 Pin Harness Connector c Inj ECM fuse 10A d System Ignition Relay e ECM BAT Fuse 15A f To Fuel Pump Relay g To DLC Connector h Knock Module i Knock Sensor j To Ignition Coil B k To Injectors l...

Page 633: ...h the electrical system intact and operational These are voltage requirements to operate the different circuits CAUTION Do not attempt to obtain these voltages by probing wires and connectors Serious...

Page 634: ...Injector Driver 467 DK BLU B B None Rough Idle Lack Of Power Stalling J1 3 Ignition Control Ref Low 453 RED BLK 0 NOTE 5 0 NOTE 5 None Poor Performance J1 4 ECM Ground 450 BLK 0 NOTE 5 0 NOTE 5 None...

Page 635: ...Fuel Pump Relay Driver 465 DK GRN WHT 0 NOTE 1 5 B None No Start J1 24 Ignition Control Bypass 424 TAN BLK 0 NOTE 5 4 5V 42 Lack Of Power Fixed Timing J1 26 Audio Warning Horn 29 DK GRN None J1 27 IA...

Page 636: ...ete Switch 114 BLU None J2 8 Discrete Switch 585 TAN WHT None J2 10 Ignition Control Ref High 430 PUR WHT 5V 1 6V None No Restart J2 11 ECT Signal 410 YEL 1 95V NOTE 2 1 95V NOTE 2 14 Poor Performance...

Page 637: ...Poor Perfor mance J2 24 Discrete Switch 906 TAN WHT NONE J2 26 TP Signal 417 DK BLU 62V NOTE 4 62V NOTE 4 21 Poor Performance And Accel eration Incorrect Idle J2 27 Map Signal 432 LT GRN 4 9V 1 46V N...

Page 638: ...15A MALFUNCTION INDICATOR LAMP DLC J1 1 J1 17 J1 23 From INJ ECM FUSE 10 AMP J1 28 J1 12 J1 11 J1 27 From B J2 22 J1 9 87 86 85 30 J1 32 SERIAL DATA 76079 467 DK BLU 468 DK GRN 481 BLK 465 DK GRN WHT...

Page 639: ...IAT A B C J2 26 J2 4 J2 3 76080 SENSOR GROUND 813 BLK 813 BLK 417 DK BLU 416 GRY ENGINE COOLANT TEMPERATURE ECT ENGINE COOLANT TEMPERATURE ECT SENSOR SIGNAL J2 19 J2 27 J2 18 J2 11 416 GRY 432 LT GRN...

Page 640: ...150 BLK 923 WHT KNOCK SENSOR 1 J1 30 496 DK BLU KNOCK SENSOR 1 114 BLU 150 BLK TRANSMISSION NEUTRAL SAFETY SWITCH MIE ONLY 86 85 87 ECM BAT FUSE DLC 15A SYSTEM IGNITION RELAY TO DLC CONNECTOR IGN INJ...

Page 641: ...VERTEMP SWITCH FROM IGNITION RELAY J1 20 J1 4 J1 5 450 BLK ECM GROUND ECM GROUND ECM GROUND D C B A E F B A B A AUDIO WARNING CIRCUIT J1 26 208 BRN 585 TAN WHT TO TACH TO IGN TO TEMP GAUGE J2 10 J1 10...

Page 642: ...auge to fuel pressure tap Disconnect harness connectors at all injectors and connect injector tester to one injector Use adaptor harness furnished with injector tester to energize injectors Follow man...

Page 643: ...ter Drop EXAMPLE Cylin der 1 2 3 4 5 6 7 8 1st Reading 38 PSI 262 kPa 38 PSI 262 kPa 38 PSI 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 kP...

Page 644: ...gines are MEFI 2 IMPORTANT Non scan tool refers to the CodeMate Tester On Board Diagnostic OBD System Check Non Scan 461 ORN BLK 451 WHT BLK a b c d e f g h i j k l m n a ECM DLC 15 Amp Fuse b DLC Con...

Page 645: ...er mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness TEST DESCRIPTION Number s below refer to the Step number s on the Diagnostic Table 1...

Page 646: ...ce mode 2 Ignition ON engine OFF 3 Observe the Malfunction Indica tor Lamp on the MDTC tool Does the MIL Flash DTC 12 Go to Step 4 Go to Chart A 2 4 1 Switch MDTC tool to Normal Mode 2 Attempt to star...

Page 647: ...eck must be the starting point for any driveability com plaint diagnosis Before using this procedure you should perform a careful visual physical check of the ECM and engine grounds for being clean an...

Page 648: ...tion ON engine OFF If not chart A 1 should be used to isolate the malfunction 2 Checks the serial data circuit and ensures that the ECM is able to transmit serial data 3 If the engine will not start c...

Page 649: ...to Step 4 Go to Chart A 3 4 Select Display DTCs with the scan tool Are Any Trouble Codes Stored Go to applicable DTC Chart Go to Step 5 5 Compare ECM data values displayed on the scan tool to the typi...

Page 650: ...s g Serial Data h ECM Ground i ECM Ground j Diagnostic Test Terminal k Malfunction Indicator Lamp l Ignition Feed m Battery Feed n Battery Feed CIRCUIT DESCRIPTION When the Marine Diagnostic Trouble C...

Page 651: ...r a faulty light bulb or an open in the MIL driver circuit CKT 419 If the engine cranks but will not run check for an open ECM ignition or battery feed or a poor ECM to engine ground TEST DESCRIPTION...

Page 652: ...Light Illuminate Brightly Go to Step 11 Go to Step 5 5 1 Ignition OFF 2 Disconnect ECM J2 connector 3 Using a DVOM measure the resis tance between ECM harness con nector terminal J2 31 and DLC termina...

Page 653: ...rounds 2 If a problem is found repair as necessary Is Action Complete _ Go to OBD System Check Go to Step 17 13 Locate and repair open in CKT 419 Is Action Complete _ Go to OBD System Check __ 14 Loca...

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Page 655: ...eed n Battery Feed CIRCUIT DESCRIPTION When the Marine Diagnostic Trouble Code MDTC tool is installed it plugs into the DLC terminals F and E It receives voltage through CKT 440 terminal F Terminal E...

Page 656: ...rminal to wire connection and damaged harness TEST DESCRIPTION Number s below refer to the Step number s on the Diagnostic Table 3 If the light goes OFF when the ECM connectors are disconnected CKT 41...

Page 657: ...e DLC 3 Connect test light between ECM connector terminal J1 7 and battery positive B Does Test Light Illuminate Brightly Go to Step 5 Go to Step 8 5 1 Verify correct operation of MDTC tool on a known...

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Page 659: ...onnector terminal B After supply voltage passes through the injector ECM fuse it branches out into two separate CKT s 439 One is the supply voltage for injector harness CKT 481 and the other goes to E...

Page 660: ...nside the insulation Check for the following items Poor connection or damaged harness Inspect the ECM harness and connectors for improper mating broken locks improperly formed or damaged terminals poo...

Page 661: ...pressure with pump running The pressure may drop after the pump stops run ning Is Fuel Pressure Within Specified Value 34 38 psi 234 262 kPa Refer to Diag nostic Aids on Facing Page Go to Chart A 4 8...

Page 662: ...lluminate Brightly Go to Step 19 Go to Step 18 14 Replace faulty TP sensor Is Action Complete Go to OBD System Check 15 1 Locate and repair open or short to ground in CKT 430 2 If OK replace faulty ig...

Page 663: ...m Check 21 1 All checks made to this point would indicate that the ECM is at fault However there is a possibility of CKT 467 and CKT 468 being shorted to a voltage source in the engine harness or the...

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Page 665: ...urned to the water separating fuel filter DIAGNOSTIC AIDS An intermittent may be caused by a poor connection rubbed through wire insulation or a wire broken inside the insulation Check for the followi...

Page 666: ...ressure that leaks down is caused by the fuel pressure regulator valve leaking injec tor s sticking open a defective fuel pump or external fuel leak 11 Restricting the fuel return line allows the fuel...

Page 667: ...hold pressure for at least 15 to 20 seconds Is fuel pressure within specified value 34 38 psi 234 262 kPa Go to Step 3 Go to Step 5 3 Start engine and idle at normal operating temper ature Is fuel pre...

Page 668: ...gnition ON 3 Block fuel return line using fuel shut off valve tool Does fuel pressure hold Go to Step 16 Go to Step 15 9 Is fuel pressure below specified value 34 psi 234 kPa Go to Step 10 Go to Step...

Page 669: ...urn line from fuel pressure regulator to water separating fuel filter adapter Was a problem found Go to OBD System Check Go to Step 16 14 Locate and repair vacuum source to fuel pressure regulator Is...

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Page 671: ...energizes the fuel pump relay within 2 seconds after the ignition is turned ON or the engine is stopped DIAGNOSTIC AIDS An intermittent may be caused by a poor connection rubbed through wire insulatio...

Page 672: ...ep 4 Go to Step 12 4 1 Ignition OFF 2 Disconnect fused jumper wire 3 Using a test light connected to battery positive B probe terminal 86 of the fuel pump relay connector Does The Test Light Illuminat...

Page 673: ...T 339 or CKT 902 Is Action Complete Go to OBD System Check 11 Locate and repair short to ground in CKT 339 or CKT 120 Also check for contamination in fuel lines or fuel tank If OK replace fuel pump an...

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Page 675: ...the system relay Voltage and current are then supplied to the ignition control mod ule injectors ECM and fuel pump relay through terminal 87 CKT 902 of the system relay DIAGNOSTIC AIDS An intermitten...

Page 676: ...est Light Illuminate Brightly On Both Terminals Go to Step 3 Go to Step 5 3 Using test light connected to battery positive B probe relay harness connector terminal 85 Does Test Light Illuminate Bright...

Page 677: ...B is connected to the black connector terminal B Supply voltage is delivered from the ignition coil black connector terminal B to the distributor Ignition Control IC mod ule terminal through CKT 3 Ins...

Page 678: ...ltage would indicate an open or a high resistance circuit from the distributor to the coil or ignition switch If C terminal voltage was low but terminal voltage is 10 volts or more circuit from C term...

Page 679: ...ding with this table 2 Disconnect 5 wire harness connector WHITE and PINK wires 3 Install a temporary jumper wire between the 2 PINK wires at the connector of the boat harness This is CkT 3 for the ig...

Page 680: ...ng Greater Than The Specified Value At Both Terminals 10 volts Go to Step 8 Go to Step 7 7 Is Voltage Reading Less Than The Specified Value At Both Terminals 10 volts Go to Step 20 Go to Step 21 8 1 R...

Page 681: ...to a known good ground Does The Voltage Drop _ Go to Step 12 Go to Step 23 12 Check for spark from the coil wire as the test battery lead is removed Is Adequate Spark Present Go to Step 17 Go to Step...

Page 682: ...red wire from the EFI system relay to the ignition coil Is Action Complete Go to OBD System Check 21 Check for open or short to ground in CKT 121 the brown wire from the ignition module C terminal to...

Page 683: ...through wire insulation or a wire broken inside the insulation Check for the following items Poor connection or damaged harness Inspect the ECM harness and connectors for improper mating broken locks...

Page 684: ...in 75 RPM of the original recorded RPM within 30 seconds Does RPM Return To Original Recorded RPM Go to Step 5 Go to Step 4 4 1 Ignition OFF for 10 seconds 2 Disconnect IAC harness con nector 3 Restar...

Page 685: ...used in conjunction with the ECM to detect critical conditions to engine operation If a discrete switch changes states from its normal at rest position that is normally open to closed or closed to op...

Page 686: ...operly Proceed to Testing Switches or Testing Circuits 5 Check to ensure that there is battery power to the PUR wire going to buzzer If there is replace buzzer and verify repair Starting at Step 1 6 D...

Page 687: ...ace gear lube monitor Verify repair 4 Gear lube monitor switch is working properly TESTING TRANSMISSION TEMPERATURE SWITCH STEP ACTION VALUE YES NO PROCEED TO 1 1 Disconnect both wires from transmissi...

Page 688: ...mis sion temperature switch if equipped 4 Key ON engine OFF Does audio warning buzzer sound Step 2 Step 3 2 1 Key OFF 2 Disconnect ECM J1 connector 3 Check for continuity between all wires disconnecte...

Page 689: ...Step 3 Step 2 Does audio warning buzzer sound when grounding BLU TAN wire from gear lube switch Step 3 Step 2 Does audio warning buzzer sound when grounding BLU TAN wire from transmission switch Step...

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Page 691: ...used in conjunction with the ECM to detect critical conditions to engine operation If a discrete switch changes states from its normal at rest position that is normally open to closed or closed to op...

Page 692: ...to Testing Switches or Testing Circuits 5 Check to ensure that there is battery power to the PUR wire going to buzzer If there is replace buzzer and verify repair Starting at Step 1 6 Discrete switche...

Page 693: ...ube monitor Verify repair 4 Gear lube monitor switch is working properly TESTING TRANSMISSION TEMPERATURE SWITCH STEP ACTION VALUE YES NO PROCEED TO 1 1 Disconnect both wires from transmission tempera...

Page 694: ...wire from transmis sion temperature switch if equipped 4 Key ON engine OFF Does audio warning buzzer sound Step 2 Step 3 2 1 Key OFF 2 Disconnect ECM J1 connector 3 Check for continuity between all w...

Page 695: ...rounding PUR wire Step 3 Step 2 Does audio warning buzzer sound when grounding TAN WHT wire Step 3 Step 2 Does audio warning buzzer sound when grounding BLU TAN wire Step 3 Step 2 2 1 Key OFF 2 Discon...

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Page 698: ...ode 23 1 of 2 Intake Air Temperature IAT Sensor Circuit 5F 9 Code 33 1 of 3 Manifold Absolute Pressure MAP Sensor Circuit 5F 11 Code 42 1 of 3 Ignition Control IC Circuit 5F 14 Code 43 1 of 3 Knock Se...

Page 699: ...GNOSTICS 454 502 MAG MPI 8 2L MPI Page 5F 2 90 861326 1 MARCH 1999 IMPORTANT These procedures apply to the MEFI 1 Product only MEFI 3 Procedures will appear at the end of the section when available Do...

Page 700: ...8 Select Service Mode on code tool 9 Turn key ON and read codes If codes are still present check preceding Note and re peat from Step 1 10 Refer to appropriate Troubleshooting and or Diagnostic Charts...

Page 701: ...lant warms the sensor resistance becomes less and the voltage drops DIAGNOSTIC AIDS An intermittent problem may be caused by a poor or corroded connection rubbed through wire connection a wire that is...

Page 702: ...reading would stabilize when the thermostat opens Step 7 This step identifies if CKT 410 is open or shorted to ground IMPORTANT If replacing the ECT tighten hand tight plus 2 1 2 turns maximum STEP AC...

Page 703: ...tions faulty ECT sensor refer to chart below for sensor values 7 Disconnect J 1 connector Step 8 Step 9 7 Is test light on Ste 8 Ste 9 8 CKT 410 shorted to ground 9 CKT 410 shorted to sensor ground or...

Page 704: ...t complaint should be thoroughly checked for backed out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wiring connections corroded terminals and or wiri...

Page 705: ...ery positive B 3 Touch test light to harness terminal C throttle position sensor signal Step 7 Step 10 throttle osition sensor signal Is test light on Ste 7 Ste 10 5 Connect DVOM between harness termi...

Page 706: ...through wire connection a wire that is broken inside the insulation or a corroded wire Any circuitry that is suspected as causing the intermittent complaint should be thoroughly checked for backed out...

Page 707: ...terminals It should be less than 25 000 Ohms refer to table for approximate temperature to resis tance values Is it Less Than 25 000 Ohms Step 4 Step 8 4 Check for signal circuit shorted to voltage I...

Page 708: ...d through wire connection a wire that is broken inside the insulation or a corroded wire Any circuitry that is suspected as causing the intermittent complaint should be thoroughly checked for backed o...

Page 709: ...in the supply 5 Volt reference or ground circuit Step 16 Low manifold vacuum may result from vacuum leaks in the engine induction sys tem NOTE Using a test light with 100 mA or less rating may show a...

Page 710: ...ess terminal B See Note Step 11 Step12 7 Connect DVOM from MAP sensor harness ter minal C to a good ground on engine Step 14 Step 13 7 minal C to a good ground on engine Is voltage reading over 4 volt...

Page 711: ...n Coil CIRCUIT DESCRIPTION When the system is running on the ignition module that is no voltage on the bypass line the ignition module grounds the IC signal The ECM expects to detect no voltage on the...

Page 712: ...nd that the fault causing the code is present Step 3 Check for a normal IC ground path through the ignition module An IC CKT 423 shorted to ground will also read more than 3000 ohms however this will...

Page 713: ...aulty igni tion module 6 With Ohmmeter connected to ECM harness CKT 423 and ground probe harness CKT 424 with test light connected to battery positive B Step 8 Step 7 6 B As test light contacts CKT 42...

Page 714: ...ubbed through wire connection a wire that is broken inside the insulation or a corroded wire Any circuitry that is suspected as causing the intermittent complaint should be thoroughly checked for back...

Page 715: ...D System Check 1 Disconnect 5 way KS module connector 2 2 Using DVOM measure resistance be tween terminal E and ground 3 3K to 4 5K 2 3 Resistance should be between 3 3K and 4 5K Ohms 4 5K Ohms Is it...

Page 716: ...Step 13 1 Connect a test light to ground 7 2 Disconnect KS module harness connec tor 7 3 Touch the test light to KS module har ness connector terminal B CKT439 Is the test light on Step 11 Step 12 8 I...

Page 717: ...an once but is intermittent replace ECM An intermittent problem may be caused by a poor or corroded connection rubbed through wire connection a wire that is broken inside the insulation or a corroded...

Page 718: ...5 to 2 0 volts DIAGNOSTIC AIDS Check harness routing for a potential short to ground in CKT 410 Scan tool displays engine temperature in degrees Fahrenheit and Celsius After engine is started the tem...

Page 719: ...2 F 30 C Ste 3 Ste 5 3 Does scan tool display a coolant tempera ture value greater than 266 F 130 C Step 6 4 Does scan tool display a coolant tempera ture value less than 22 F 30 C Step 7 5 Code 14 is...

Page 720: ...nd percentage of throttle blade opening With ignition ON or at idle TP signal voltage should read between 3 and 8 volt with the throttle closed and increase at a steady rate as throttle is moved towar...

Page 721: ...indicate throttle position sensor voltage greater than 4 volts Step 5 Step 3 Does scan tool indicate throttle position sensor voltage less than 36 volts Step 4 Step 3 3 Code 21 is intermittent refer...

Page 722: ...e should be greater than 4 volts is it Step 11 Step 12 8 Check CKT 417 shorted to voltage faulty ECM connection or faulty ECM 9 Throttle position sensor signal CKT 417 open shorted to ground faulty co...

Page 723: ...ne is cold and rises as engine compartment temperature increases The IAT sensor in this engine is located on the starboard underside of the plenum Carefully check harness and connections for possible...

Page 724: ...stem Check Ignition ON 2 Does scan tool indicate display an intake air temperature of less than 22 F 30 C Step 3 Step 11 2 Does scan tool indicate display an intake air temperature greater than 266 F...

Page 725: ...fer to Troubleshooting for items which can cause an unsta ble idle With the ignition ON and the engine OFF the manifold pressure is equal to atmospheric pressure and the signal voltage will be high Th...

Page 726: ...Board Diagnostic OBD System Check Performed Step 2 Go to OBD System Check 2 Engine idling Does scan tool display a MAP sensor volt age of less than 1 volt Step 4 Step 3 Does scan tool display a MAP se...

Page 727: ...C 3 Ignition ON Voltage should be greater than 4 volts Is it Step 12 Step 13 8 MAP sensor signal CKT 432 shorted to volt age faulty ECM connections or faulty ECM 9 Check for MAP sensor signal CKT 432...

Page 728: ...Coil CIRCUIT DESCRIPTION When the system is running on the ignition module that is no voltage on the bypass line the ignition module grounds the IC signal The ECM expects to detect a low voltage on th...

Page 729: ...c table Step 2 Code 42 means the ECM has seen an open or short to ground in the IC or bypass circuits This test confirms Code 42 and that the fault causing the code is present Step 4 Check for a norma...

Page 730: ...s CKT 423 and ground probe harness CKT 424 with test light connected to battery positive B 7 As test light contacts CKT 424 resistance should change from over 3000 Ohms to under 1000 Ohms Does it Step...

Page 731: ...be caused by a poor or corroded connection rubbed through wire connection a wire that is broken inside the insulation or a corroded wire Any circuitry that is suspected as causing the intermittent co...

Page 732: ...rt engine 3 4 Hold engine speed steady at 2500 rpm 5 Repeatedly touch test light to knock sensor harness connector terminal CKT 496 Does a noticeable rpm drop occur or using timing light did timing dr...

Page 733: ...est light to KS module harness connector terminal B CKT439 Is the test light on Step 11 Step 12 8 Inspect knock sensor terminal contacts If OK replace knock sensor 9 Check for open or short in CKT 496...

Page 734: ...51 failed more than once but is intermittent replace ECM An intermittent problem may be caused by a poor or corroded connection rubbed through wire connection a wire that is broken inside the insulat...

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Page 743: ...SERVICE MANUAL NUMBER 23 TROUBLE CODE DIAGNOSTICS 454 502 MAG MPI 8 2L MPI Page 5F 46 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 744: ...SERVICE MANUAL NUMBER 23 TROUBLE CODE DIAGNOSTICS 454 502 MAG MPI 8 2L MPI 90 861326 1 MARCH 1999 Page 5F 47 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 745: ...SERVICE MANUAL NUMBER 23 TROUBLE CODE DIAGNOSTICS 454 502 MAG MPI 8 2L MPI Page 5F 48 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 746: ...it or Grounded Bypass Circuit 5G 28 Code 43 1 of 2 Knock Sensor KS Circuit Continuous Knock Detected 5G 31 Code 44 1 of 3 Knock Sensor KS Circuit No Knock Detected 5G 33 Code 51 1 of 2 Calibration Mem...

Page 747: ...SERVICE MANUAL NUMBER 23 Page 5G 2 90 861326 1 MARCH 1999 IMPORTANT These procedures apply to the MEFI 1 Product only MEFI 3 Procedures will appear at the end of the section when available Downloaded...

Page 748: ...Service Mode on code tool 9 Turn key ON and read codes If codes are still present check preceding Note and repeat from Step 1 10 Refer to appropriate Troubleshooting and or Diagnostic Charts A poorly...

Page 749: ...normal operating temperature 160 F 180 F 71 C 82 C the voltage will measure about 1 5 2 0 volts DIAGNOSTIC AIDS Check for the following conditions Poor connection at ECM Inspect harness connectors for...

Page 750: ...S NO PROCEED TO 1 Was the On Board Diagnostic OBD System Check Performed Step 2 Go to OBD System Check 2 1 Ignition OFF 2 Disconnect ECT sensor harness terminals 3 Ignition ON engine OFF 4 Connect DVO...

Page 751: ...n High Temperature Indicated a b c d a Engine Coolant Temperature ECT Sensor b To Map Sensor c Engine Coolant Temperature ECT d Sensor Ground CIRCUIT DESCRIPTION The Engine Coolant Temperature ECT sen...

Page 752: ...e Codes procedure at the front of this section Failure to do so may result in DTC s not properly being cleared TEST DESCRIPTION Number s below refer to circled number s on the diagnostic chart Step 2...

Page 753: ...f OK replace faulty ECT sensor 4 Locate and repair short to ground in CKT 410 If a problem is found repair as necessary Was a problem found Verify Repair Step 5 5 Repair faulty ECM connections or repl...

Page 754: ...l send a voltage signal back to the ECM through CKT 417 according to where the throttle blades are positioned DIAGNOSTIC AIDS Check for the following conditions Poor connection at ECM Inspect harness...

Page 755: ...l to Ser vice Mode and note the trouble code Is the trouble code 22 present Step 4 Step 3 3 1 TP sensor harness connector disconnected 2 Ignition ON engine OFF 3 Connect DVOM from harness terminal B C...

Page 756: ...gh CKT 417 according to where the throttle blades are positioned DIAGNOSTIC AIDS Check for the following conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper...

Page 757: ...de Tool to Ser vice Mode and note trouble code Is trouble code 21 present Step 4 Step 3 3 1 Remove jumper wire from CKT 416 and CKT 417 2 Connect DVOM from harness terminal A CKT 416 to harness termin...

Page 758: ...TROUBLE CODE DIAGNOSTICS 7 4L MPI SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 5G 13 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 759: ...1 C 82 C the voltage will measure about 1 5 2 0 volts DIAGNOSTIC AIDS Check for the following conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating brok...

Page 760: ...ACTION VALUE YES NO PROCEED TO 1 Was the On Board Diagnostic OBD System Check Performed Step 2 Go to OBD System Check 2 1 Ignition OFF 2 Disconnect IAT sensor harness terminals 3 Ignition ON engine OF...

Page 761: ...uit Non Scan High Temperature Indicated A B a b c d a Intake Air Temperature Sensor b To TP Sensor c IAT Sensor Signal d Sensor Ground CIRCUIT DESCRIPTION The Intake Air Temperature IAT sensor uses a...

Page 762: ...indicate the location of the fault Check harness routing for a potential short to ground in CKT 472 After repairs clear DTC s following Clearing Trouble Codes procedure at the front of this section Fa...

Page 763: ...he sensor harness terminals Is voltage above the specified value 4 Volts Step 3 Step 4 3 Locate and repair intermittent faulty connec tions If OK replace faulty IAT sensor 4 Locate and repair short to...

Page 764: ...ld pressure DIAGNOSTIC AIDS Check for the following conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged term...

Page 765: ...OBD System Check Performed Step 2 Go to OBD System Check 2 1 Ignition OFF 2 Disconnect vacuum at MAP sensor and install a vacuum gauge 3 Start engine and increase RPM to 1000 in neutral 4 The vacuum...

Page 766: ...Check for plugged or leaking sensor vacuum fitting If OK replace faulty MAP sensor Is action complete Verify Repair 7 Locate and repair short to voltage in CKT 432 If a problem is found repair as nece...

Page 767: ...alue that will vary with RPM The MAP sensor voltage of 5 volts is delivered to the MAP sensor through CKT 416E CKT 814 is the ground circuit for the MAP sensor The MAP signal CKT 432 will send a volta...

Page 768: ...gnizes the high signal voltage and sets a DTC 33 the ECM and wiring are OK STEP 3 This step checks CKT 416E for the 5 volt reference STEP ACTION VALUE YES NO PROCEED TO 1 Was the On Board Diagnostic O...

Page 769: ...ace faulty MAP sensor Is action complete 5 Locate and repair open or short to ground in CKT 432 If a problem is found repair as nec essary Was a problem found Verify Step 7 6 Locate and repair open or...

Page 770: ...running on the ignition module or crank mode there is no voltage on the bypass line the ignition module grounds the IC signal The ECM expects to detect no volt age on the IC line during this condition...

Page 771: ...Check for a normal IC ground path through the IC module Step 4 Confirms that trouble code 41 is a faulty ECM and not an intermittent open in CKT 423 Code 41 2 of 3 Ignition Control IC Circuit Non Sca...

Page 772: ...arine Diagnostic Code Tool to Service Mode and note trouble code Is trouble code 41 present Step 7 Step 8 5 Locate and repair open in CKT 423 If a problem is found repair as necessary Was a problem fo...

Page 773: ...system is running on the ignition module or crank mode there is no voltage on the bypass line the ignition module grounds the IC signal The ECM expects to detect no volt age on the IC line during thi...

Page 774: ...de is present Step 3 Check for a normal IC ground path through the IC module An IC CKT 423 shorted to ground will also read than 3000 Ohms Step 4 When the test light touches CKT 424 the module should...

Page 775: ...minal J2 24 CKT424 Does light illuminate Step 6 Step 9 6 Disconnect ignition module 4 way connector Does test light illuminate Step 10 Step 11 7 1 Reconnect ECM 2 Start engine and idle for 2 minutes o...

Page 776: ...out terminals improper mating broken locks improperly formed or damaged terminals and poor ter minal to wire connection Damaged harness Inspect the wiring harness for damage If CKT 496 is routed too c...

Page 777: ...module harness terminal D CKT 486 Does the test light illuminate Step 4 Step 6 4 1 Ignition OFF 2 Reconnect KS module harness connec tor 3 Disconnect ECM J1 connector 4 Ignition ON engine OFF 5 Conne...

Page 778: ...out terminals improper mating broken locks improperly formed or damaged terminals and poor ter minal to wire connection Damaged harness Inspect the wiring harness for damage After repairs clear DTC s...

Page 779: ...inal E CKT496 to a known good ground near the knock sensor 3500 to 4700 Ohms Is resistance between the specified value Step 3 Step 7 3 1 Reconnect KS module harness connec tor 2 Disconnect knock senso...

Page 780: ...Inspect knock sensor terminal contacts Also check for abnormal mechanical engine noises If OK replace faulty knock sensor Is action complete Verify Repair 9 Locate and repair open in ground CKT 486 Is...

Page 781: ...ent replace the ECM TEST DESCRIPTION Number s below refer to step number s on the diagnostic table Step 2 This step checks to see if the fault is present during diagnosis If present the ECM is not fun...

Page 782: ...place the ECM TEST DESCRIPTION Number s below refer to step number s on the diagnostic table Step 2 This step checks to see if the fault is present during diagnosis If present the ECM is not functioni...

Page 783: ...nspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor ter minal to wire connection Damaged harness Inspect the wiring harness...

Page 784: ...p 2 Go to OBD System Check 2 Ignition ON 22 F Does the scan tool display a coolant tem perature less than the specified value 22 F 30 C Step 3 Step 4 3 1 Ignition OFF 2 Disconnect ECT harness connecto...

Page 785: ...emperature Indicated a b c d a Engine Coolant Temperature ECT Sensor b To Map Sensor c Engine Coolant Temperature ECT d Sensor Ground CIRCUIT DESCRIPTION The Engine Coolant Temperature ECT Sensor uses...

Page 786: ...coolant sensor After engine is started the temperature should rise steadily and then stabilize at operating temperature when the thermostat opens Check harness routing for a potential short to ground...

Page 787: ...to Diagnostic Aids 5 Locate and repair short to ground in CKT 410 If a problem is found repair as necessary Was a problem found Verify Repair Step 7 6 Repair faulty ECT sensor Is action complete 7 Rep...

Page 788: ...o the ECM through CKT 417 according to where the throttle blades are positioned DIAGNOSTIC AIDS Check for the following conditions Poor connection at ECM Inspect harness connectors for backed out term...

Page 789: ...System Check 2 1 Throttle closed 2 Ignition OFF Does scan tool indicate TP sensor voltage greater than the specified value 4 Volts Step 3 Step 5 3 1 Ignition OFF 2 Disconnect TP sensor harness connec...

Page 790: ...to where the throttle blades are positioned DIAGNOSTIC AIDS Check for the following conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks i...

Page 791: ...s the On Board Diagnostic OBD System Check Performed Step 2 Go to OBD System Check 2 1 Throttle closed 2 Ignition OFF Does scan tool indicate TP sensor voltage less than the specified value 36 Volt St...

Page 792: ...ete 9 Repair faulty ECM connections or replace faulty ECM Is action complete Code 23 1 of 3 Intake Air Temperature IAT Sensor Circuit Scan Low Temperature Indicated A B a b c d a Intake Air Temperatur...

Page 793: ...After engine is started the temperature should rise steadily and then stabilize at operating temperature After repairs clear DTC s following Clearing Trouble Codes procedure at the front of this secti...

Page 794: ...tions 5 Locate and repair open in CKT 472 or CKT 813 If a problem is found repair as necessary Was a problem found Verify Repair Step 7 6 Repair faulty IAT sensor Is action complete 7 Repair faulty EC...

Page 795: ...for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor ter minal to wire connection Damaged harness Inspect the wiring harness for damage If the harness...

Page 796: ...ol display a temperature greater than the specified value 266 F 130 C Step 3 Step 4 3 1 Ignition OFF 2 Disconnect IAT harness connector 22 F 3 Ignition ON engine OFF 22 F 30 C Does scan tool display a...

Page 797: ...ss connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor ter minal to wire connection Damaged harness Inspect the wiring harness for damage I...

Page 798: ...Diagnostic OBD System Check Performed Step 2 Go to OBD System Check 2 1 Ignition OFF 2 Install a vacuum gauge to manifold vacu um 14 in HG 3 Start engine and raise RPM to 1000 HG 45 5 4 The vacuum rea...

Page 799: ...intermittent faulty connections Refer to Diag nostic Aids 8 Locate and repair short to voltage in CKT 432 If a problem is found repair as necessary Was a problem found Verify Step 11 9 Locate and rep...

Page 800: ...nection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor ter minal to wire connection Damaged harness Inspect the...

Page 801: ...Was the On Board Diagnostic OBD System Check Performed Step 2 Go to OBD System Check 2 1 Ignition OFF 2 Install a vacuum gauge 14 in 3 Start engine and raise RPM to 1000 HG 45 5 4 The vacuum reading s...

Page 802: ...faulty connections Refer to Diag nostic Aids 8 Locate and repair open or short to ground in CKT 416E If a problem is found repair as necessary Was a problem found Verify Step 11 9 Locate and repair op...

Page 803: ...n the system is running on the ignition module or crank mode no voltage on the bypass line the ignition module grounds the IC signal The ECM expects to detect a low voltage on the IC line during this...

Page 804: ...N Step 2 DTC 41 means the ECM has seen an open in the IC circuit This test confirms DTC 41 and that the fault causing the DTC is present Step 3 Checks for a normal IC ground path through the Ignition...

Page 805: ...f the ECM sees voltage it sets Code 41 and will not go into the IC mode When the RPM for IC is reached about 300 RPM and bypass voltage applied the IC should no longer be grounded in the ignition modu...

Page 806: ...tch check for open in bypass CKT 424 bypass CKT 424 shorted to ground or faulty ignition module Step 7 Confirms that DTC 42 is a faulty ECM and not an intermittent in CKT 423 or CKT 424 STEP ACTION VA...

Page 807: ...s or until trouble code 42 sets Is trouble code trouble code 42 present Step 12 Step 13 8 Locate and repair short to ground in CKT 423 If a problem is found repair as necessary Was a problem found Ste...

Page 808: ...minals improper mating broken locks improperly formed or damaged terminals and poor ter minal to wire connection Damaged harness Inspect the wiring harness for damage If CKT 496 is routed too close to...

Page 809: ...module harness terminal D CKT 486 Does test light illuminate Step 4 Step 6 4 1 Ignition OFF 2 Reconnect KS module harness connec tor 3 Disconnect J1 connector 8 10 4 Ignition ON engine OFF Volts 5 Co...

Page 810: ...his signals the ECM to start retarding timing The ECM will retard timing when knock is detected and RPM or engine coolant temperature is above a certain value DIAGNOSTIC AIDS Check for the following c...

Page 811: ...tep 6 This step determines it CKT 485 is shorted to voltage or if the KS module is faulty STEP ACTION VALUE YES NO PROCEED TO 1 Was the On Board Diagnostic OBD System Check Performed Step 2 Go to OBD...

Page 812: ...round in CKT 496 If a problem is found repair as nec essary Was a problem found Step 11 8 Inspect knock sensor terminal contacts Also check for abnormal mechanical engine noises If OK replace faulty k...

Page 813: ...alter the designed function of EFI DIAGNOSTIC AIDS If DTC 51 failed more than once but is intermittent replace the ECM TEST DESCRIPTION Step 2 This step checks to see if the fault is present during di...

Page 814: ...he designed function of EFI DIAGNOSTIC AIDS If DTC 52 failed more than once but is intermittent replace the ECM TEST DESCRIPTION Step 2 This step checks to see if the fault is present during diagnosis...

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Page 826: ...Test 6A 10 Seawater Pump Disassembly 6A 11 Seawater Pump Reassembly 6A 12 Seawater Pump Bearing Housing 6A 13 Disassembly 6A 13 Cleaning and Inspection 6A 15 Reassembly 6A 16 Water Circulating Pump 6...

Page 827: ...g Bracket 35 48 Water Circulating Pump 35 48 Seawater Pump Clamping Screw On Casting Bracket 20 27 Water Temperature Sender 20 27 Drain Plug Note Hose Clamps Securely Petcocks Securely Pulleys NOTE Co...

Page 828: ...bricant With Teflon 92 825407A3 Quicksilver High Performance Gear Lube 92 816026A2 Quicksilver Liquid Neoprene 92 25711 3 Quicksilver Special Lubricant 101 92 13872A1 Loctite 22423 92 12564 2 Silicone...

Page 829: ...se clamps Seacock Seawater Inlet Valve If a seacock is being used it must be installed between water pickup and seawater pickup pump or sea strainer to allow operator to shut off the seawater in case...

Page 830: ...4 in 44 mm hole in hull using a suitable sealer 2 Apply marine caulking sealer to mounting surface on seawater pickup where hull con tact will occur when installed 3 Ensure slots in seawater pickup ar...

Page 831: ...hole hose nipple 2 Be certain hose nipple and plastic plug are in place and threads have been sealed with Loctite Pipe Sealant with Teflon prior to tightening each securely NOTE Use a sharp knife or w...

Page 832: ...2 in 5 mm holes drilled in transom using four 5 16 in diameter stainless steel lag bolts in place of round head screws In any case flat washers and O rings are required as outlined 72641 a b Water Pic...

Page 833: ...g action that may occur allowing seawater to flow from the drain holes or removed hoses and enter boat IMPORTANT Be certain engine is off and cooling system is cold 1 Follow a or b instructions a Mode...

Page 834: ...ontact with hot or moving engine or transmission parts 1 Mount seawater strainer Arrow indicates required water flow direction and must point toward seawater pump Tighten mounting bolts securely 72644...

Page 835: ...ter hose The ability of this test to detect a problem is greatly dependent upon the accuracy with which it is performed An error in setting the engine RPM timing the test or measuring the water output...

Page 836: ...her person start engine and adjust speed to exactly 1000 RPM while holding unclamped end of hose on connection on engine Remove hose from con nection on engine and direct water flow into container for...

Page 837: ...earing Housing d Quad Ring Not Shown In This View 3 Remove the impeller from seawater pump body Seawater Pump Reassembly 1 Lubricate seawater pump impeller with a water and soap solution Install impel...

Page 838: ...y of the pump requires the mounting bracket to be installed while per forming the following step 5 Install two screws in seawater pump body holes as shown Use these two screws to align pump then insta...

Page 839: ...press 72648 a a Universal Puller Plate 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 pulley end...

Page 840: ...ings to prevent rust 3 Clean all gasket material and sealer from sealing surfaces 4 Inspect bearing housing Examine surfaces where bearings contact housing for evi dence of outer races turning in hous...

Page 841: ...that Shell Alvania No 2 Grease be used when packing seal and bearings in the following steps If Shell Alvania No 2 Grease is not available it is permissible to use Quicksilver 2 4 C With Teflon Howeve...

Page 842: ...tute Slide bearings and shaft into bearing housing bore and install snap ring 72661 a a Shaft With Bearings 72658 a a Snap Ring 5 Apply a thin coat of Loctite 27131 to outside diameter of new bearing...

Page 843: ...p shaft to dimension shown 72664 a a 260 Inch 6 6 mm IMPORTANT Pulley hub must be pressed onto shaft to exact dimension on pumps with stamped steel mounting bracket as this establishes proper drive be...

Page 844: ...and erosion Replace complete pump if any damage exists 3 Check impeller shaft and bearings for excessive side play If play can be felt replace complete pump 4 Inspect pump pulley for bends cracks corr...

Page 845: ...ngest dis tance between two pulleys Normally this location is between the seawater pump and the idler pulley 2 Use 5 16 in socket and tighten adjusting stud until the correct deflection of the belt is...

Page 846: ...ing engine to overheat IMPORTANT If cooling system is to be flushed with boat in the water seacock if equipped must be closed or water inlet hose must be disconnected and plugged to prevent water from...

Page 847: ...ped with seacock Reconnect water inlet hose and tighten hose clamp securely Open seacock accordingly b If NOT equipped with seacock Unplug and reconnect seawater inlet hose accord ingly Tighten hose c...

Page 848: ...occur allowing seawater to flow from the drain holes or removed hoses CAUTION Do not overtighten cover screws or cover will warp and leak Removal and Disassembly 1 Visually inspect seawater strainer t...

Page 849: ...with screws and washers 3 Open seacock or unplug and reconnect seawater inlet hose 4 Tighten hose clamps securely 5 After starting engine check for leaks and or air in system which would indicate an...

Page 850: ...round the valve perimeter is accept able 72717 a a Check For Light Leakage Around Perimeter Of Valve 4 Check opening and closing temperature of thermostat using a tester similar to the one shown as fo...

Page 851: ...preceding tests Installation 1 Clean gasket surfaces on thermostat housing and intake manifold IMPORTANT Gasket has continuity rivets Do not coat with Quicksilver Perfect Seal or Audio Warning Tempera...

Page 852: ...heater to engine MUST NOT EXCEED 5 8 in 15 8 mm I D inside diameter Make heater connections ONLY at locations described in the following instructions Check complete system for leaks after heater is co...

Page 853: ...cause the engine to vapor lock or run too cold MIE Inboard Models Only Splice into the port side exhaust manifold water hose This provides the temperatures and pressures required to cool the packing g...

Page 854: ...our particu lar power package but the water flow paths remain similar on all engines 1 Thermostat Housing 2 Engine Circulating Pump 3 Seawater Pickup Pump 4 Seawater Inlet 5 Engine Oil Cooler 6 Exhaus...

Page 855: ...SEAWATER COOLED MODELS SERVICE MANUAL NUMBER 23 Page 6A 30 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 856: ...re Testing System 6B 6 Testing for Cylinder Head Gasket Leak 6B 7 Testing Heat Exchanger 6B 8 For Internal Leak 6B 8 For Blockage 6B 8 Testing Pressure Cap 6B 8 Thermostat 6B 10 Removal 6B 10 Testing...

Page 857: ...ine Lubricant With Teflon 92 825407A3 Quicksilver Perfect Seal 92 34227 1 Quicksilver Liquid Neoprene 92 25711 3 Loctite Pipe Sealant With Teflon Obtain Locally Specifications Closed Cooling System Ca...

Page 858: ...the outer rim of the filler neck IMPORTANT The coolant antifreeze flows around the outside of the cooling tubes while seawater flows through the inside of the cooling tubes in the heat exchanger Maint...

Page 859: ...ing point of the coolant thereby increasing the efficiency of the cooling system To help ensure proper operation cap should be cleaned inspected and pressure tested periodically as follows WARNING All...

Page 860: ...acity Do not close more than three tubes 2 Nipples and drains that have been broken off the heat exchanger can be reattached by brazing Testing Closed Cooling System Testing Coolant for Alkalinity WAR...

Page 861: ...ed to Closed Cooling System 16 PSI 110 kPa 20 PSI 138 kPa 6 Observe gauge reading for approximately two minutes pressure should not drop during this time If pressure drops proceed with the following s...

Page 862: ...recovery bottle Use a 2 3 ft 610 910 mm long hose for this test 2 Route this hose so a U is formed 3 Put enough coolant into hose to fill the center 4 or 5 inches 100 130 mm of the U 4 Observe the U...

Page 863: ...p is designed to maintain a pressure of approximately its rated capacity refer to Specifications in closed cooling section once engine has attained operating tempera ture Cap should be cleaned inspect...

Page 864: ...16 PSI 110 kPa and must hold rated pressure for 30 seconds without going below 11 PSI Replace cap if it fails to fall within these limits 72716 IMPORTANT Before reinstalling cap in next step examine...

Page 865: ...e completely into drain hole 1 Drain engine block by removing drain plug Be sure to drain both port and starboard sides 74130 a Starboard Side Shown Port Side Similar a Hose b Drain Plug In Exhaust Ma...

Page 866: ...p with tap water Do not use distilled water b Open thermostat valve and insert thread Position thermostat on nylon string so that it will be just below water level when suspended then allow valve to c...

Page 867: ...ousing on gasket IMPORTANT If gasket has continuity rivets do not coat with Quicksilver Perfect Seal or audio warning temperature switch may not work properly 4 Install thermostat as previously shown...

Page 868: ...first The color of this antifreeze is orange For best results any top off fluid used should be Extended Life 5 100 Coolant If Extended Life 5 100 Coolant is unavailable any type of ethylene glycol ba...

Page 869: ...nstall petcocks and hoses Tighten clamps and petcocks securely 4 Remove coolant recovery bottle from mounting bracket and pour out coolant 5 Clean system as outlined in Cleaning System 6 Fill system a...

Page 870: ...en remove end plates seal washers and gaskets Discard seal washers and gaskets Clean gasket material from end plates and heat exchanger 71515 a b c d a Heat Exchanger b Sealing Washer c End Cap d Gask...

Page 871: ...ystem with coolant mixture as follows a Open bleeder valve on thermostat housing 75598 a a Hex Head Bleeder Valve b Fill with coolant mixture through heat exchanger fill neck until coolant appears at...

Page 872: ...ing temperature is normal If gauge indicates excessive temperature stop engine immediately and examine for cause WARNING Allow engine to cool down before removing pressure cap Sudden loss of pressure...

Page 873: ...system for leaks after heater is connected into cooling system Check for overheating condition of engine after heater is connected CAUTION On closed cooling models the heater must be mounted lower tha...

Page 874: ...milar a Starboard Thermostat Housing To Heat Exchanger Hose b Port Thermostat Housing To Heat Exchanger Hose c Engine Water Circulating Pump To Heat Exchanger Hose d Upper Alternator Bracket And Fuel...

Page 875: ...8 a b c e f g h a c e MIE Inboard Engine Shown All Similar a Heat Exchanger b Large Hose Clamps c Starboard Heat Exchanger To Exhaust Manifold Hose d Port Heat Exchanger To Exhaust Manifold Hose e Oil...

Page 876: ...Seawater Intake 2 Power Steering Cooler MCM or Transmission Cooler MIE 3 Fuel Cooler 4 Heat Exchanger 5 Thermostat Housing and Cover Assembly 6 Engine Water Circulating Pump 7 Engine Block and Cylind...

Page 877: ...861326 1 MARCH 1999 Draining Diagram Coolant Section of System 75005 a b b a Remove Hoses Lift Lower or Bend To Completely Drain b Remove Block Plugs Repeatedly Clean Out Holes Using A Stiff Wire Unt...

Page 878: ...CLOSED COOLED FRESH WATER MODELS SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 6B 23 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 879: ...CLOSED COOLED FRESH WATER MODELS SERVICE MANUAL NUMBER 23 Page 6B 24 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 880: ...eneral Table of Contents Exhaust System Requirements 7A 2 Determining If Exhaust Elbow Risers Are Required 7A 2 MCM Sterndrive Engines With Through Transom Exhaust 7A 2 MIE Inboard Engines 7A 3 Exhaus...

Page 881: ...w To Top Of Transom Model a Minus b Must Be at Least All 13 In 330 mm MCM Sterndrive Engines With Thru Transom Exhaust When designing and installing exhaust system the following must be observed Minim...

Page 882: ...exist at any point in the exhaust hose or pipe 4 Exhaust outlet must be slightly above the waterline with boat at rest in the water and full load aboard Exhaust outlet should be equipped with an inter...

Page 883: ...on installation of an exhaust tube will increase exhaust noise With Bravo One and Bravo Two Drives an exhaust tube MAY BE INSTALLED for a slight increase in performance With a Silent Choice Exhaust Sy...

Page 884: ...e if grounding clip is not installed b Install grounding clip on tube NOTE Bellows adhesive is not used when installing an exhaust tube c Position tube so that SIDE markings on tube are facing toward...

Page 885: ...GENERAL SERVICE MANUAL NUMBER 23 Page 7A 6 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 886: ...26 1 MARCH 1999 Page 7B 1 EXHAUST SYSTEM Section 7B Manifolds And Elbows Table of Contents Torque Specifications 7B 2 Lubricants Sealants Adhesives 7B 2 Removal 7B 2 Cleaning 7B 3 Inspection 7B 3 Inst...

Page 887: ...emoved 2 Drain water from manifold and exhaust elbow Refer to SECTION 1B 3 Disconnect exhaust bellows and cooling hoses 4 Starboard Manifold a Disconnect both shift cables MCM only b Disconnect instru...

Page 888: ...ugs may be removed from exhaust man ifold and exhaust elbow IMPORTANT If plugs are removed coat threads with Quicksilver Perfect Seal before reinstalling 2 Check for cracks 3 To test manifold body for...

Page 889: ...aust elbow if necessary 4 Starboard Manifold a Install bolt to secure water separating fuel filter bracket to exhaust manifold b Install shift plate assembly on exhaust elbow MCM only c Connect instru...

Page 890: ...MANIFOLDS AND ELBOWS SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 7B 5 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 891: ...Exhaust Risers 7C 3 Removal 7C 3 Cleaning 7C 3 Inspection 7C 3 Installation 7C 3 Exhaust Extension 7C 4 Maintenance Instructions 7C 5 Installation Diagrams 7C 5 Cast Iron Elbows With 3 Inch Riser 7C 5...

Page 892: ...ants Description Part Number Quicksilver Perfect Seal 92 34227 1 Preparation WARNING Avoid possible injury or damage to equipment should wires be accidentally shorted Disconnect BOTH battery cables fr...

Page 893: ...een risers Refer to Installation Diagrams at the end of this section 2 Position gaskets REFER TO EXPLODED VIEWS ON FOLLOWING PAGES install elbows to risers and attach using nuts and washers from kit T...

Page 894: ...Plate c Back Up Plate 1 d Screws 6 3 4 In 19 mm e Nuts 6 f Screws 4 7 8 In 22 mm 8 Refill closed cooling system if equipped Refer to SECTION 6B Closed Cooled Models 9 Upon first start up of engine ch...

Page 895: ...riser during freezing temper atures Failure to perform draining procedures can cause severe damage Installation Diagrams Cast Iron Elbows With 3 Inch Riser 70621 d e f g h i j a c k a Exhaust Elbow b...

Page 896: ...strictor Gasket g Nut 8 h Stud 8 9 3 8 Inch 238 mm i Stud 8 10 3 8 Inch 264 mm Used With Remote Oil Filter j Washer 8 k Exhaust Manifold l Refer To Note Following NOTE Later models will have an open g...

Page 897: ...y at Remote Oil Filter Bracket if Equipped f Hex Head Screw 4 1 In 25 mm g Exhaust Manifold h Drop Down Bracket 1 i Washers 6 j Screws 6 1 2 In 12 mm k Refer To Note Following NOTE Later models will h...

Page 898: ...mm or Bolt 2 8 In 203 mm Used Only at Remote Oil Filter Bracket if So Equipped g Exhaust Manifold h Drop Down Bracket 1 i Restrictor Gasket j Washers 6 k Screws 6 1 2 In 12 mm l Refer To Note Followin...

Page 899: ...RISERS SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 7C 9 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 900: ...t 7D 3 Component Replacement 7D 4 Through Transom Exhaust 7D 5 Shutter Replacement 7D 5 Component Replacement 7D 6 Below Swim Platform Exhaust Pipe 7D 6 Silent Choice Exhaust System 7D 7 Exhaust Tube...

Page 901: ...Lower Exhaust Pipe Exhaust Elbow Air Pump Mount Muffler End Plate Mode Switch Securely Hose Clamps Water Shutter Bolt Nut Lubricants Sealants Adhesives Description Part Number Quicksilver 2 4 C Marine...

Page 902: ...T Engine does not have to be removed to change shutters 1 Loosen clamps and remove exhaust pipe elbow and exhaust hose 2 Replace water shutter as shown 3 Reinstall pipe elbow and hose Tighten clamps s...

Page 903: ...ting 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 securely 72736 b a a Mating Surface b O...

Page 904: ...057 a b a Block Off Plate b Bolts 4 1 Remove exhaust hose clamps then hose 2 Chisel rivets away from both support members 27761 a b c d c d a Shutter Hinge b Water Shutter Opens Toward Outside Of Boat...

Page 905: ...Nut 4 b Support Member c Water Shutter Hinge Must Be Vertical d Gasket e Exhaust Flange f Bolts Washers and Nuts 3 g Clamp h Cover Flapper Below Swim Platform Exhaust Pipe This exhaust kit may be use...

Page 906: ...in 102 mm two exhaust bellows and eight bellows hose clamps are required If engine is equipped with thru transom exhaust an exhaust pipe kit P N 44266A6 is required containing the exhaust pipe and nec...

Page 907: ...gimbal housing 22116 a b 2 If required install exhaust tube on gimbal housing as follows 3 Remove and discard clamps and exhaust bellows CAUTION Exhaust tube clamp may corrode if grounding clip is not...

Page 908: ...IDE markings on tube are facing toward the right and left sides 2 Install clamp 3 Tighten clamp securely 22184 22184 a b c d e a Exhaust Tube b Clamp c Side Marking d Exhaust Tube e Grounding Clip 725...

Page 909: ...ir tubing close to hot surfaces Excessive heat will damage air tubes 72775 c d b a d Single Engine a Air Tube b T Fittings c Air Pump Assembly d Air Tube To Air Cylinder On Each Silencer Valve 72776 a...

Page 910: ...enter of casting and install new filter Be careful not to coat filter or clog air intake holes with adhesive 72534 a b c d e f g h i j k c e a Mode Switch b Keyway Install In DOWN Position c BROWN Wir...

Page 911: ...t elbow risers which are included in the kit IMPORTANT If a thru transom exhaust kit other than the one from Mercury Marine is used the exhaust kit must be equipped with internal shutters and external...

Page 912: ...slots instead of a restrictor gasket two slots and two holes If replacing gaskets it is acceptable to replace the old gaskets with the open gaskets Be sure that the same type of gasket is used on both...

Page 913: ...81 d d a b c a Muffler b Molded Exhaust Tube Muffler To Elbow c Exhaust Hose Muffler To Thru Transom Fitting Cut To Length d Double Clamp Each Connection Not Shown On Hose C 2 Double clamp each connec...

Page 914: ...ng a Check condition of O ring seal if dried out or shrunk below mating surface remove and replace Clean groove thoroughly b Glue new O ring seal in groove using Sound Blanket Glue Wipe off excess glu...

Page 915: ...COLLECTORS SERVICE MANUAL NUMBER 23 Page 7D 16 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 916: ...sion Pressure Specifications 8A 3 Transmission Fluid Specification 8A 3 Important Information 8A 3 Shift Control and Cables 8A 3 Engine 8A 4 Transmission 8A 4 Propeller 8A 4 Transmission Shift Lever 8...

Page 917: ...2 Identification Plate Color Code 1 1 1 1 1 5 1 Green 2 5 1 Green 2 8 1 NOTE 1 This ratio is shown on identification plate Ratio may be rounded off in some cases NOTE 2 These transmissions are for LH...

Page 918: ...matic Transmission Fluid Dexron III 72C Reduction Drive or Equivalent Important Information Shift Control and Cables CAUTION Shift control and shift cable must position transmission shift lever exactl...

Page 919: ...ransmission at engine speeds above 1000 RPM 4 Free wheeling of one propeller in a twin engine boat at trolling speeds will not cause damage to the transmission however boat operation above trolling sp...

Page 920: ...ions IMPORTANT To accurately check fluid level engine must be run at 1500 RPM for 2 minutes immediately prior to checking level 72526 a c b a Dipstick b Full Mark c Dipstick Tube 1 Start engine and ru...

Page 921: ...ct hose from elbow fitting b Remove elbow fitting from bushing c Drain oil from transmission cooler and cooler hoses into a suitable container 72840 a b Transmission With 1 1 Ratio a Hose b Elbow Fitt...

Page 922: ...dication of cooler hose wear Hoses should be inspected for cracks or fraying Replace damaged hoses CAUTION Avoid severe transmission damage or possible failure of transmission Strainer must be properl...

Page 923: ...k Tube IMPORTANT To accurately check fluid level run engine at 1500 RPM for 2 minutes immediately prior to checking level 2 Start engine and run at 1500 RPM for 2 minutes to fill all hydraulic circuit...

Page 924: ...se two long studs will help support weight of transmission during removal and installation 10 Remove remaining transmission attaching bolts 11 Pull transmission straight back and off engine 12 Check t...

Page 925: ...r b Shift Lever Must Be Over This Letter when Propelling Boat FORWARD c Shift Lever Must Be Over This Letter when Propelling Boat in REVERSE d Poppet Ball Must Be Centered in Detent Hole for Each F N...

Page 926: ...parts must be assembled as shown 1 Lubricate poppet ball spring and holes in shift lever with Quicksilver 2 4 C Marine Lubricant 2 Install poppet spring and ball Retain ball by placing shift lever on...

Page 927: ...oes not stock or sell replacement parts for the in line transmission Velvet Drive has a network of distributors throughout the world to service their product These dis tributors in turn have a dealer...

Page 928: ...VELVET DRIVE IN LINE TRANSMISSION SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 8A 13 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 929: ...n Pressure Specifications 8B 3 Important Information 8B 4 Engine 8B 4 Transmission 8B 4 Propeller 8B 4 Transmission Propeller Rotation 8B 5 Shift Control and Cables 8B 7 Transmission Shift Lever and S...

Page 930: ...mission Identification Plate a Model Number b Ratio In Forward c Serial Number d Identification Plate Model Color Code Transmission Ratios and Part Numbers Ratio in Forward Gear1 Identification Plate...

Page 931: ...50 68 Neutral Start Safety Switch 120 13 Propeller Shaft Coupler To Out put Flange 50 68 Transmission Fluid Type Obtain Locally ATF Dexron lII Fluid Capacity Model U S Qts Liters 5000A Down Angle All...

Page 932: ...boat operation above trolling speed should be avoided Be sure proper fluid level exists before free wheeling propeller 5 DO NOT paint shift lever poppet ball and spring An accumulation of paint here w...

Page 933: ...etermined by shift cable attachment at the remote control Be sure to use correct rotation propeller and shift cable hook up for direction desired 71888 c a b a Direction Of Shift Lever Engagement Towa...

Page 934: ...ontrol handle is placed in forward position 23242 A B Remote control must provide a total shift cable travel at transmission end of at least 2 3 4 in 70 mm This is necessary to position transmission s...

Page 935: ...ent Hole For Neutral Position e Install Shift Lever Stud In This Hole When Using Quicksilver Shift Cables Shift Control and Cables CAUTION Shift control and shift cable must position transmission shif...

Page 936: ...ever b Shift Cable Anchor Stud Location For Quicksilver Shift Cables WARNING Avoid serious personal injury or property damage caused by improper shifting Anchor stud for shift cable must be installed...

Page 937: ...remote control and shift cable do not position shift lever exactly as shown 73248 a b c d e a Transmission Shift Lever b Poppet Ball Must Be Centered In This Detent Hole When Left hand Propeller Shaft...

Page 938: ...Output Shaft 73285 a b c Position Is Forward Gear For LH Rotation Propeller a Input b Output c Output Shaft For Left Hand Propeller Shaft Rotation Shift cable hookup at remote control must result in s...

Page 939: ...lever fully in the forward and reverse gear positions Insufficient shift cable travel will cause transmission to slip and even tually fail 72602 a a 2 3 4 In 70 mm Minimum IMPORTANT The distance betwe...

Page 940: ...tube c Pull out on control cable end with enough effort to remove play mark position b on tube d Measure distance between marks a and b mark position c half way between marks a and b a b c c 72603 220...

Page 941: ...Ball Must Be Centered in This Detent Hole for Neutral Position e Install Shift Lever Stud in This Hole when Using Quicksilver Shift Cables 7 Place remote control shift lever in opposite gear position...

Page 942: ...proach a Cable End Guide b Spacer As Required c Elastic Stop Nut And Washer d Bushing s e Cable Barrel s Position s Only Indicated In Right Drawing f Cable Barrel Stud g Cable End Guide Stud 71897 500...

Page 943: ...ission fluid to bring level up to full mark on dipstick 73250 b a c a Dipstick b Full Mark c Dipstick Tube IMPORTANT To accurately check fluid level engine must be run at 1500 RPM for 2 minutes immedi...

Page 944: ...3 Check oil for the following foreign matter Metal Particles A few small particles are normal Larger metal chips are an early sign of transmission failure which may mean transmission should be disass...

Page 945: ...ransmission fluid as needed to bring level up to full mark on dipstick 4 Reinstall dipstick Be sure to tighten T handle securely Removal NOTICE The following procedure describes removal of transmissio...

Page 946: ...and lines Installation 1 Apply Quicksilver Engine Coupler Spline Grease to transmission input shaft splines and engine drive plate splines 2 Using a suitable hoist position transmission in boat and a...

Page 947: ...Cables 9 Refer to SECTION 2C and check engine final alignment as outlined 10 After final engine and coupler alignment has been properly set with boat in the water connect propeller shaft coupler to t...

Page 948: ...ver and related parts must be assembled as shown 1 Lubricate poppet ball spring and holes in shift lever with Quicksilver 2 4 C Marine Lubricant 2 Install poppet spring and ball Retain ball by placing...

Page 949: ...re readings Transmission Repair Mercury Marine does not stock or sell replacement parts for the down angle transmission Velvet Drive has a network of distributors throughout the world to service their...

Page 950: ...VELVET DRIVE 5000A DOWN ANGLE TRANSMISSION SERVICE MANUAL NUMBER 23 Page 8B 22 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 951: ...sure Specifications 8C 3 Transmission Fluid Specification 8C 3 Important Information 8C 3 Shift Control and Cables 8C 3 Engine 8C 3 Transmission 8C 4 Propeller 8C 4 Transmission Shift Lever 8C 4 Shift...

Page 952: ...nsmission Ratios and Part Numbers Ratio in For ward Gear 1 Identification Plate Color Code Velvet Drive Model Number Mercury Marine Part Number 1 5 1 20 02 003 807481A5 2 1 Blue 20 02 004 807481A6 2 5...

Page 953: ...smission Fluid Dexron III or Equivalent Important Information Shift Control and Cables CAUTION Shift control and shift cable must position transmission shift lever exactly as stated in this manual or...

Page 954: ...r to installing a new or rebuilt transmission Metallic particles from a failure tend to collect in the cooler and hoses and will gradually flow back into the fluid system and damage transmission 7 Alw...

Page 955: ...t hand Propeller Shaft Rotation Is Desired d Poppet Ball Must Be Centered In This Detent Hole For Neutral Position e Install Shift Lever Stud In This Hole When Using Quicksilver Shift Cables IMPORTANT...

Page 956: ...able travel will cause transmission to slip and even tually fail 72602 a a 2 3 4 In 70 mm Minimum IMPORTANT The distance between studs Dimension C shown in the following illus tration is set at 7 1 8...

Page 957: ...mark position b on tube d Measure distance between marks a and b mark position c half way between marks a and b 72603 a b c c 11 Center cable end play then adjust cable barrel to align holes in barrel...

Page 958: ...l Must Be Centered in This Detent Hole for Neutral Position e Install Shift Lever Stud in This Hole when Using Quicksilver Shift Cables 14 Place remote control shift lever in opposite gear position an...

Page 959: ...Cable End Guide b Thick Spacer c Thin Spacer d Elastic Stop Nut and Washer e Cable Barrel Position Only Indicated In Lower Drawing f Bushing s g Cable Barrel Stud h Cable End Guide Stud 71897 b a e d...

Page 960: ...ssion fluid to bring level up to full mark on dipstick 73250 a b c a Dipstick b Full Mark c Dipstick Tube IMPORTANT To accurately check fluid level engine must be run at 1500 RPM for 2 minutes immedia...

Page 961: ...ly sign of transmission failure which may mean transmission should be disassembled and inspected for internal damage Rubber Particles Indication of cooler hose wear Hoses should be inspected for crack...

Page 962: ...d if necessary to bring level up to full mark on dipstick 4 Reinstall dipstick Be sure to tighten T handle securely Removal NOTICE to INSTALLER The following procedure describes removal of transmissio...

Page 963: ...Torque all bolts to 50 lb ft 68 N m 8 Relieve hoist tension and fasten rear engine mounts to engine bed Tighten bolts securely 9 Connect wires to neutral start safety switch 10 Connect wires to fluid...

Page 964: ...oved or if the shift lever is changed in any manner or repo sitioned or if the linkage between the remote control and the transmission shift lever does not have sufficient travel in both directions Sh...

Page 965: ...cations for pressure readings Transmission Repair V Drive Mercury Marine does not stock or sell replacement parts for the V drive transmission Velvet Drive has a network of distributors throughout the...

Page 966: ...VELVET DRIVE 5000V V DRIVE TRANSMISSION SERVICE MANUAL NUMBER 23 Page 8C 16 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 967: ...Specifications 8D 2 Operating Specifications 8D 2 Tools 8D 3 Lubricants Sealants 8D 3 Capacity 8D 3 Rotation 8D 3 Shift Cable Installation and Adjustment 8D 4 Checking Transmission Fluid Level 8D 10 D...

Page 968: ...A B a Late Style Identification Plate a Serial Number and Gear Ratio Torque Specifications Item Fastener Location Lb Ft N m Transmission Housing Halves Bolts and Nuts 36 49 Control Block To Housing 18...

Page 969: ...Obtain Locally Loctite 515 Capacity Model U S Qt L Hurth 630V 5 4 7 Always use dipstick to determine exact quantity of fluid required Rotation The Hurth transmission is a full power reversing transmi...

Page 970: ...hen shift handle is placed in the forward position 23242 A B Shift Cable Installation and Adjustment IMPORTANT Check that shift lever is positioned approximately 10 aft of vertical as shown when in th...

Page 971: ...Cable Bracket b Shift Cable Anchor Stud c Bracket To Transmission Fasteners 2 Place remote control shift lever and transmission shift lever in neutral position 3 Remove nuts and washers from shift cab...

Page 972: ...nsure trans mission is fully in gear as follows a Hold shift lever in position b Carefully slide shift cable off of anchor points c Attempt to move shift lever further 9 If transmission shift lever wi...

Page 973: ...ft cable s with hardware as shown referring to appropriate configuration following NOTE To change cable approach direction on single or dual station installations only the spacer bushings have to be s...

Page 974: ...urn c Spacer Fits Over Bushings d Bushing e Cable Barrel f Cable Barrel Stud g Cable End Guide Stud 72956 71211 e b b d a c g h Typical Dual Cable Forward Approach a Cable End Guide a Cable End Guide...

Page 975: ...b d a b d g h Typical Dual Cable Rear Approach a Cable End Guide b Locknut And Washer Tighten Until Bottoms Out Then Loosen 1 2 Turn c Spacer Fits Over Bushings d Bushing e Cable Barrel f Spacers Fit...

Page 976: ...d back into transmission If low add transmission fluid to bring level up to full mark on dipstick 27661 Typical Hurth Transmission Shown IMPORTANT To accurately check fluid level engine must be run at...

Page 977: ...rth transmissions will be equipped with an allen head socket screw on the oil filter cover 2 Remove oil filter from housing by turning counterclockwise and pulling at the same time 27666 a a Set Screw...

Page 978: ...ing on filter cover with transmission fluid 27662 a b a Filter Cover b O Ring CAUTION Transmission fluid filter and cover must be properly seated to avoid fluid foaming and or loss of fluid thus resul...

Page 979: ...uid should be between min and max lines on dip stick 27661 Typical Hurth Transmission Shown Transmission Removal 1 Disconnect wires from neutral safety switch and audio warning temperature switch 2 Di...

Page 980: ...3 Remove bolts and locknuts and remove transmission 72720 a b a Bolts 2 One On Each Side b Locknuts 4 Two On Each Side Transmission Installation 1 Coat splines on input shaft with Quicksilver Engine C...

Page 981: ...l housing and secure with hardware shown Torque fas teners to 50 lb ft 68 N m 72720 a b a Bolts 2 One On Each Side b Locknuts 4 Two On Each Side 3 Connect seawater hoses to transmission fluid cooler a...

Page 982: ...emperature Switch Functional Tests 1 Connect a pressure gauge and thermometer to fluid pump at locations shown 50686 a b a Pressure Gauge m10x1 Thread Remove Plug b Thermometer 3 8 In Thread Remove Te...

Page 983: ...600 800 Idling Speed A B Position Repeatedly 1 2 3 1500 2500 B Position 1 1 2 4 600 800 Idling Speed A B Position Repeatedly 1 2 3 Idling Maximum Speed A Position 1 2 5 2 600 800 From A B Posi tion 1...

Page 984: ...HURTH V DRIVE TRANSMSSION SERVICE MANUAL NUMBER 23 Page 8D 18 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 985: ...ve Transmission Table of Contents Specifications 8E 2 Transmission Fluid Capacities 8E 2 Transmission Fluid Specification 8E 2 Checking Transmission Fluid 8E 2 Changing Transmission Fluid 8E 3 Drainin...

Page 986: ...O NOT use SAE 80 motor oil or any type of multi grade oils 10W30 or 10W40 Walter RV 26D V Drive SAE 30 Heavy Duty Motor Oil Exxon Spartan EP 68 Gear Oil APG 80 Gear Oil Checking Transmission Fluid IMP...

Page 987: ...connect oil hose from strainer fitting on bottom cover 3 Remove oil strainer fitting from bottom cover Do not remove elbow fitting from oil strainer fitting 75192 a b c d a Oil Hose b Magnetic Plug c...

Page 988: ...NT To accurately check fluid level run engine for 2 minutes immediately prior to checking level Removal 1 Refer to the Draining Procedures in the maintenance section to drain the cooling sys tem 2 Dis...

Page 989: ...9 Page 8E 5 5 Disconnect the wires to the oil pressure switch 75647 a b b a Oil Pressure Switch b Water Hoses 6 Remove nuts from the adapter housing 75191 a a Nuts 6 7 Remove the Walter V Drive transm...

Page 990: ...to align the splines on the adapter flange on the Walter V Drive transmission and the out drive flange on the in line transmission 2 Install the nuts and torque to 50 lb ft 68 N m 75191 a a Nuts 3 Con...

Page 991: ...stick and check fluid level 75192 a a Dipstick 6 Connect the propshaft coupling to the output shaft flange of the transmission Torque screws and nuts to 50 lb ft 68 N m 7 Check with a feeler gauge in...

Page 992: ...WALTER V DRIVE TRANSMISSION SERVICE MANUAL NUMBER 23 Page 8E 8 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 993: ...Reassembly 8F 3 Drive Shaft Repair MCM Sterndrive Models 8F 5 Removal 8F 5 Repair 8F 6 Replacement Drive Shafts 8F 7 Drive Shafts Modified to Shorter Lengths 8F 7 Installation 8F 8 Bearing Support Rep...

Page 994: ...Housing MCM Models 30 41 Engine Coupling 35 48 Bearing Support Housing Attaching Bolts 35 54 47 73 Coupling Set Screws If Equipped Securely1 Safety wire set screws Tools Description Part Number Quick...

Page 995: ...unts 3 Remove output shaft housing attaching screws then remove housing 4 Remove snap ring then pull output shaft out of housing 5 Remove snap ring from housing 6 Using Quicksilver Slide Hammer Puller...

Page 996: ...rough grease fitting 5 1 2 3 4 5 6 7 8 11 9 8 10 12 8 8 8 13 14 15 16 17 18 19 20 21 22 23 Flywheel Housing Output Shaft Housing 1 Output Shaft 2 O Rings 3 Snap Ring Ball Bearing 4 Ball Bearing 5 Shaf...

Page 997: ...and Bottom Shield at Transom End Engine End Similar a Top Shield b Bottom Shield c Bolt 3 3 16 x 7 8 In 22 2 mm 4 Used d Nut 3 8 16 4 Used e Screws 3 Used Hidden In This View 2 Suitably mark drive sha...

Page 998: ...237 a b c Engine End Shown Transom End Similar a Output 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 R...

Page 999: ...dered from the boat manufacturer that installed the MerCruiser Power Package IMPORTANT Dana Corporation Spicer Regional Drive Shaft Centers will not shorten replacement drive shafts for dealers or con...

Page 1000: ...shaft flanges Flanges MUST BE flush with each other prior to tightening screws or screws may come loose during operation CAUTION Failure to properly align shaft flanges with matching marks made on dis...

Page 1001: ...install bot tom shields on engine and transom end Then install both top shields as shown Torque all fasteners to 30 lb ft 41 N m 70245 a b c d e Top Shield and Bottom Shield at Transom End Engine End...

Page 1002: ...line Lack of alignment will cause a severe vibration problem 1 Remove drive shaft as previously outlined 2 Remove sterndrive unit refer to appropriate Stern Drive Service Manual 3 Remove bearing suppo...

Page 1003: ...er Reassembly 1 If removed install new plug in end of input shaft 2 Apply Quicksilver Loctite 27131 to outer diameter of new oil seal 3 Press oil seal into bearing support Lip of seal faces away from...

Page 1004: ...Ball Bearing c Ball Bearing d Bearing Support e Grease Fitting f Oil Seal g Grease Fitting h Input Shaft i Plug Input Shaft Installation 1 Install bearing support assembly tailstock on transom plate u...

Page 1005: ...This End Of Alignment Tool Through Gimbal Housing Assembly 3 DO NOT remove alignment tool from gimbal housing CAUTION Both attaching bolts MUST BE struck firmly in the following step to properly seat...

Page 1006: ...to shafts struts shaft logs and rudders refer to boat manufactur er s service manual If boat is equipped with V drive or a remote mounted V drive refer to SECTION 8B or boat manufacturer s service man...

Page 1007: ...install the key and coupling Make sure coupling still lines up with the mark This ensures that key is not oversize and holding the tapers apart 3 Check output coupling flange of transmission Checking...

Page 1008: ...t behind the propeller then remove propeller e Install the key and propeller Make sure propeller still lines up with mark This ensures that key is not oversize and holding the tapers apart Retighten p...

Page 1009: ...a Metal Straight Edge Held To Rudder With C Clamp b Rudder c Rotate Propeller One Complete Turn Check At Three Different Points On Blades Checks Made With Propeller Shaft Removed From Boat 1 Check pro...

Page 1010: ...Dial Indicator c Coupling Flange Rotate One Complete Turn d Shaft Against Block To Prevent Fore And Aft Movement Strut Refer to boat manufacturer s service manual for alignment and replacement Normall...

Page 1011: ...DRIVE SHAFT PROPELLER SHAFT MODELS SERVICE MANUAL NUMBER 23 90 861326 1 MARCH 1999 Page 8F 19 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

Page 1012: ...elt Routing 9A 4 Serpentine Belt Adjustment 9A 4 Important Service Information 9A 5 Pump Pulley Replacement 9A 5 Testing and Repair 9A 6 Checking Pump Fluid Level 9A 6 Filling and Air Bleeding System...

Page 1013: ...48066 313 574 2332 Pulley Removal Tool J 25034 Lubricants Sealants Description Part Number Quicksilver Perfect Seal 92 34227 1 Transmission Fluid Dexron III or Equivalent Obtain Locally Precautions C...

Page 1014: ...2 3 4 5 6 7 8 9 1 9 1 Power Steering Pump Assembly 2 Stud 3 Cap 4 Pulley 5 Serpentine Belt 6 O Ring High Pressure Hose Fitting 7 Hose High Pressure Fittings on Both Ends 8 Hose Low Pressure 9 Clamp 1...

Page 1015: ...d b Turn adjustment stud and loosen belt Remove belt a b 75483 a Adjustment Stud b Locking Nut 2 Install drive belt on pulleys and adjust tension as follows 3 Loosen 5 8 in locking nut on adjustment s...

Page 1016: ...ol See your local automotive repair dealer for appropriate tool or use Snap On P N CJ124A 1 Install appropriate puller on end of pulley and shaft as shown 2 While holding tool with suitable wrench tur...

Page 1017: ...tion Tool Shown a Power Steering Pump Pulley b Stud c Bearing d Nut e Tool Shaft Testing and Repair Refer to appropriate MerCruiser Sterndrive Service Manual Checking Pump Fluid Level Refer to SECTION...

Page 1018: ...entine belt from the power steering pulley 75483 a a Adjusting Nut NOTE Use a suitable container catch ant power steering fluid when removing the power steering hoses 2 Remove the high pressure hose a...

Page 1019: ...g fasteners from pump 72949 a a Nuts 4 Remove the power steering pump from the bracket 75490 a b a Power Steering Pump b Power Steering Bracket 5 Refer to appropriate Sterndrive Service Manual for pow...

Page 1020: ...readed fitting in back of pump assembly Tighten fitting securely Connect low pressure hose on back of pump Tighten hose clamp securely 72848 a b a Return Hose b High Pressure Hose 3 Install mounting h...

Page 1021: ...ons as quickly as possible to prevent fluid leakage IMPORTANT Be careful to not cross thread or overtighten hose fittings High Pressure Hose Pump to Control Valve REMOVAL NOTE Catch fluid that drains...

Page 1022: ...23 ft in 31 N m Do not cross thread or overtighten 73860 a a Power Steering Hose Fitting 2 Route hose along valve cover and secure with J clamp s provided 3 Be certain a new high pressure hose O ring...

Page 1023: ...o Pump REMOVAL NOTE Catch fluid that drains from hose cooler and pump in a suitable container 1 Loosen hose clamp and remove hose from fluid cooler 75595 a a Hose 2 Loosen hose clamp and remove hose f...

Page 1024: ...nstall new hose on back of pump Tighten clamp securely 72848 a b a Hose Clamp b Hose 2 Using hose clamp install hose on fluid cooler Tighten clamp securely 75595 a a Hose 3 Fill and air bleed system R...

Page 1025: ...l valve at transom Remove hose 73860 a a Power Steering Hose Fitting INSTALLATION CAUTION Route hoses exactly as shown below This will help avoid stress on the hose fittings and will help avoid kinks...

Page 1026: ...overtighten hose fittings 2 Route hose along flywheel housing and secure with J clamp s provided 3 Using hose clamp install hose on fluid cooler Tighten clamp securely 75595 a a Hose 4 Fill and air bl...

Page 1027: ...PUMP SERVICE MANUAL NUMBER 23 Page 9A 16 90 861326 1 MARCH 1999 THIS PAGE IS INTENTIONALLY BLANK Downloaded from https needmanual com Index...

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