Mercury MERCRUISER Service Manual Download Page 71

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Important Information, Maintenance, and

Troubleshooting

Section 1D - Troubleshooting

Table of Contents

Introduction........................................................................ 1D-2

Before You Begin Troubleshooting.............................1D-2

Situational Awareness................................................ 1D-2

General Troubleshooting Guidelines.......................... 1D-2

Visual/Physical Check....................................................... 1D-3

Emission Control Fault Indicators...................................... 1D-4

Diagnostic Roadmap......................................................... 1D-4

Chart R1: Engine System Fails to Power Up..............1D-5

Chart R2: OBD‑M Lamp Does Not Self‑Test..............1D-6

Chart R3: Crankshaft Fails to Rotate..........................1D-7

Chart R4: Engine Cranks Over but Will Not Start.......1D-8

Chart R5: Hard Start...................................................1D-9

Chart R6: Engine Stalls............................................ 1D-10

Diagnosis by Symptom.................................................... 1D-11

Chart S1: Engine Surges..........................................1D-11

Chart S2: Lack of Power, Sluggish, or Spongy........ 1D-11

Chart S3: Detonation or Spark Knock...................... 1D-12

Chart S4: Hesitation, Sag, or Stumble......................1D-14

Chart S5: Engine Misses.......................................... 1D-15

Chart S6: Rough, Unstable, or Incorrect Idle and

Stalling.................................................................. 1D-16

Chart S7: Poor Fuel Economy..................................1D-16

Chart S8: Dieseling or Run‑On.................................1D-17

Chart S9: Backfire.................................................... 1D-18

Troubleshooting Tests..................................................... 1D-19

Chart T1: Main Power Relay Test............................ 1D-19

Chart T2: Fuel System Electrical Test...................... 1D-20

Chart T3: Fuel System Diagnosis.............................1D-20

Chart T4: Ignition System Test................................. 1D-21

Troubleshooting Shift Problems.......................................1D-22

PCM 112 Calibration Information.....................................1D-22

Default Sensor Values..............................................1D-22

Fault Conditions........................................................1D-22

Sticky and Nonsticky Faults......................................1D-22

OBD‑M Faults...........................................................1D-22

CDS G3 Service Tool...................................................... 1D-22

Introduction...............................................................1D-22

Connecting and Starting G3..................................... 1D-22

CDS G3 Service Tool Home Screen Overview........ 1D-24

CDS G3 Fault List.....................................................1D-25

Troubleshooting

90-8M0099748 eng DECEMBER 2015

Page 1D-1

Summary of Contents for MERCRUISER

Page 1: ...Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mercury Marine All rights reserved Printed in U S A 90 8M0099748 DECEMBER 2015 6 2L Mercury Mer...

Page 2: ......

Page 3: ...hazards and or results of each method Therefore when using a service procedure and or tool that is not recommended by the manufacturer be completely satisfied that neither your personal or product saf...

Page 4: ...if not specifically stated Whenever components are removed they should be retained and marked for installation into their original locations During the assembly process the marked parts are quickly id...

Page 5: ...ctrical Components 5 Fuel System A MPI ECT Fuel System 6 Cooling System A All Models B Models with Standard Cooling C Models with Closed Cooling D Water Flow Diagrams 7 Exhaust System A Important Info...

Page 6: ...90 8M0099748 eng DECEMBER 2015 2016 Mercury Marine Page iv...

Page 7: ...nces 1A 3 SeaCore 1A 3 SeaCore Components and Castings 1A 3 Stainless Steel Fasteners 1A 3 Proper Break In 1A 3 20 Hour Break In Period 1A 3 After the Break In Period 1A 4 Fuel Requirements 1A 4 Fuel...

Page 8: ...r The serial number is located in two places on the engine One is on the engine specification decal located on the engine cover and the other is secured to the starboard side of the engine block near...

Page 9: ...ngs on these power packages Stainless Steel Fasteners SeaCore models are equipped with additional stainless steel fasteners to maximize corrosion resistance in saltwater environments Stainless steel f...

Page 10: ...asoline 91 R M 2 octane is also acceptable for all models Do not use leaded gasoline Outside USA and Canada A posted pump octane rating of 91 RON minimum for all models Premium gasoline 95 RON is also...

Page 11: ...evels of phosphorus may not be covered by the MerCruiser Limited Warranty If Mercury Quicksilver 25W 40 Synthetic Blend Engine Oil is unavailable use the following lubricants listed in order of recomm...

Page 12: ...General Information Notes Page 1A 6 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 13: ...ns Control System 1B 2 Emissions Regulations 1B 3 International Regulations Compliance 1B 3 California Regulations for 2007 Low Permeation Fuel Hose 1B 3 Exhaust Emissions Sampling 1B 3 Emissions Info...

Page 14: ...pproved by Mercury Marine for use on catalyzed engines such as Loctite 587 High Performance Blue Fiberglass is a silica based material that can contaminate the catalyst and the oxygen sensors To reduc...

Page 15: ...ed and undiluted engine exhaust Mercury MerCruiser models covered by these regulations are equipped with or have available exhaust system components that allow access to the exhaust gas stream suitabl...

Page 16: ...Very Low emission 42537 The two star label identifies personal watercraft outboard sterndrive and inboard engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 200...

Page 17: ...Compact Hydraulic Steering 1C 21 System Check 1C 22 Bravo Sterndrive Gear Lube 1C 22 Checking 1C 22 Filling 1C 22 Changing 1C 23 Visual Inspections 1C 24 Battery 1C 24 Instruments 1C 24 Remote Control...

Page 18: ...ended Life Antifreeze Coolant Closed cooling system 92 877770K1 124 Quickstor Fuel Stabilizer Fuel system 92 8M0047932 139 Mercury 25W 40 Synthetic Blend 4 Stroke Engine Oil Oil filter sealing ring Al...

Page 19: ...hp Sterndrive Inboard only 275 kW 370 hp TowSport only Displacement 6 2 L 377 cid Alternator amperage Hot 72 A Cold 65 A RPM WOT operating range 5000 5400 Rev limiter 5550 Idle in neutral 625 not adj...

Page 20: ...ting habits the environment and maintenance requirements Maintenance Schedule Inboard Models Routine Maintenance NOTE Only perform maintenance that applies to your particular power package Task Interv...

Page 21: ...s for tightness Inspect both systems for damage or leaks Disassemble and inspect the seawater pump and replace worn components Clean the seawater section of the closed cooling system Clean inspect and...

Page 22: ...ct the seawater pump and replace worn components Inspect the exhaust system components If the package was equipped with water shutters flapper valves verify that they are not missing or worn Replace t...

Page 23: ...visible Check the steering system and the remote control for loose missing or damaged parts Lubricate the cables and the linkages Check the continuity circuit for loose or damaged connections Test the...

Page 24: ...ng the oil causing it to foam become aerated The aerated oil causes the hydraulic valve lifters to bleed down This in turn results in rocker arm clatter and loss of engine performance due to the valve...

Page 25: ...fill line on the dipstick Engine Oil Capacity Fluid type 4 73 L 5 0 US qt Mercury 25W 40 Synthetic Blend 4 Stroke Engine Oil 3 Confirm that the engine oil level is now up to but not over the maximum f...

Page 26: ...scard the oil filter 58410 Engine oil filter 2 Using a clean lint free cloth wipe the old oil and debris from the filter mounting flange 3 Apply clean engine oil to the sealing ring on the new filter...

Page 27: ...ed engine oil to bring the level up to but not over the maximum oil fill mark on the dipstick 8 Start the engine run the engine for three minutes and check for leaks Stop the engine immediately if lea...

Page 28: ...fluid level on the dipstick The fluid level must be between the minimum and maximum marks Add fluid if necessary but do not overfill 4 Install the dipstick and tighten the T handle securely Do not ove...

Page 29: ...IN and MAX lines 3 Fill as necessary with the specified fluid Refer to Filling Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim pump 92 858074K01 Filling 1 If th...

Page 30: ...and to purge contaminants from the system 4 Repeat the above process until the power trim fluid is no longer contaminated Flame Arrestor WARNING Fuel is flammable and explosive Ensure that the key sw...

Page 31: ...r to air dry completely before use 6 Install the flame arrestor and tighten the flame arrestor clamp to the specified torque Description Nm lb in lb ft Flame arrestor clamp nut 4 35 4 7 Install the en...

Page 32: ...a decal on the front of the engine The decal shows the serpentine belt routing Refer to the decal when installing the serpentine belt The belt tensioner operates within the limits of movement provided...

Page 33: ...ilter when the engine is cold or after the engine has not run for several hours Although the engine may not have run for hours high ambient air temperatures can cause the fuel system to become pressur...

Page 34: ...roved container Dispose of the fuel according to local regulations 58367 Fuel Filter Inspection The fuel filter is an important component in the fuel delivery system and should be inspected for debris...

Page 35: ...arks 6102 5 Add the specified fluid as necessary Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed cooling system 92 877770K1 Cleaning and Inspection NOTE Refer to...

Page 36: ...e removed or fluid in the pump may foam during operation and be discharged from the pump reservoir Foamy fluid may also cause the power assisted steering system to become spongy which may result in po...

Page 37: ...A Power Assisted Steering Pump and Related Components Compact Hydraulic Steering Complete instructions are listed in Section 8B Compact Hydraulic Steering WARNING Failure to fill the system properly c...

Page 38: ...he disposal or recycling of waste and contain and dispose of fluids as required IMPORTANT The gear lube level fluctuates during operation Check before starting when the engine is cold NOTE The gear lu...

Page 39: ...Sealing washer 4 Remove the oil vent screw and sealing washer Allow the fluid to drain completely a Oil vent screw b Sealing washer IMPORTANT If any water drains from the unit or if the fluid appears...

Page 40: ...attery NOTE Refer to the manufacturer s instructions 1 Ensure that the battery connections are secure 2 Check the fluid level Instruments 1 Ensure that all gauges are properly secured Tighten the moun...

Page 41: ...ply approximately three pumps of grease from a typical hand operated grease gun to the steering cable grease fitting a Steering cable grease fitting Tube Ref No Description Where Used Part No 95 2 4 C...

Page 42: ...Ground Circuit Continuity The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the engine transom assembly and sterndrive component...

Page 43: ...rounding wire gimbal housing to transom plate a Steering lever b Torx screw c Continuity wire Bravo model shown a Trim cylinder to gimbal ring ground wire 2 b Gimbal housing to gimbal ring ground wire...

Page 44: ...trode 91 76675T 1 Refer to the appropriate Mercury MerCruiser sterndrive service manual for testing procedures Power Package Exterior Surfaces 1 Spray the entire power package at recommended intervals...

Page 45: ...ter 5 Check the cover gasket and replace when damaged or if it leaks 6 Reinstall the strainer drain plug and sealing washer CAUTION Seawater leaking from the seawater strainer could cause excess water...

Page 46: ...m IMPORTANT The engine must not be operating at any point during the draining procedure IMPORTANT Mercury MerCruiser requires that propylene glycol antifreeze mixed to the manufacturer s instructions...

Page 47: ...ump e Lever locking 7 Pump air into the system until both green indicators extend out of the actuator assembly 8 Check to ensure water drains out of the distribution housing IMPORTANT If water does no...

Page 48: ...5 Starboard side view 11 Allow the system to drain for a minimum of ten minutes Pump air as necessary to keep the green indicators extended 12 Crank the engine over slightly with the starter motor to...

Page 49: ...n indicators 18 Open the seacock if equipped or unplug and connect the water inlet hose prior to operating the engine Air Actuated Single Point Drain System Standard Cooling The following instructions...

Page 50: ...ump e Lever locking 8 Pump air into the system until both green indicators extend out of the actuator assembly 9 Water should begin to drain out of the distribution housing IMPORTANT If water does not...

Page 51: ...angle is greater than the air actuated drain system allows for proper draining of the system Remove the blue plugs shown in the following illustrations 58769 TowSport standard cooling in line transmis...

Page 52: ...open while transporting the boat or while performing other maintenance This helps ensure that all water is drained 19 Before launching the boat pull up on the manual release valve Verify that the gre...

Page 53: ...g 8 Pump air into the system until both green indicators extend out of the actuator assembly 9 Water should begin to drain out of the distribution housing IMPORTANT If water does not drain from the di...

Page 54: ...n on the air pump and remove the pump from the air actuator assembly Install the cap on the fitting 15 Install the blue plug on the heat exchanger and tighten securely 16 Mercury MerCruiser recommends...

Page 55: ...ining the Raw Water CAUTION Water can enter the bilge when the drain system is open damaging the engine or causing the boat to sink Remove the boat from the water or close the seacock disconnect and p...

Page 56: ...ump e Lever locking 7 Pump air into the system until both green indicators extend out of the actuator assembly 8 Check to ensure water drains out of the distribution housing IMPORTANT If water does no...

Page 57: ...5 TowSport closed cooling in line transmission starboard side view 11 Allow the system to drain for a minimum of ten minutes Pump air as necessary to keep the green indicators extended 12 Crank the en...

Page 58: ...t hose prior to operating the engine Air Actuated Single Point Drain System Closed Cooling Inboard Models The following instructions apply to draining procedures performed on engines in vessels that a...

Page 59: ...ain from the distribution housing when both green indicators are extended remove the blue plug on the distribution housing a Distribution housing water drain b Blue plug 9 Check to ensure water drains...

Page 60: ...start IMPORTANT This engine has an automatic start function controlled by the PCM The start function can be terminated by turning the key to the OFF position 13 After the water has drained from the e...

Page 61: ...to the sterndrive water inlets IMPORTANT Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull or through the transom pickup need a supply of cooling w...

Page 62: ...system with the boat in the water a Raise the sterndrive to trailer position b Install the appropriate flushing attachment over the water inlet holes in the gear housing c Lower sterndrive to full do...

Page 63: ...r housing c Lower the sterndrive unit to the full down in position 2 If flushing the cooling system with the boat out of the water a Lower the sterndrive to the full down in position WARNING Rotating...

Page 64: ...ive when performed with the boat and sterndrive out of the water such as on a boat lift or trailer Models Using the Sterndrive Water Pickup IMPORTANT The system is designed to flush the Bravo sterndri...

Page 65: ...and start the engine NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets du...

Page 66: ...e compartment on the boat for easy access IMPORTANT Do not store the quick connect fitting in the flush socket on the engine Doing so would allow the seawater pump to suck air during engine operation...

Page 67: ...etely fill the fuel delivery system This fuel mix stabilizes the fuel and lubricates the fuel pumps fuel pressure regulator fuel injectors and reduces internal oxidation of the fuel system metal compo...

Page 68: ...pen the fuel shut off valve if equipped 9 Change the oil and oil filter 10 Replace the water separating fuel filter element where applicable 11 Drain the engine seawater cooling system Refer to Draini...

Page 69: ...ine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 5 Start the engine and closely observe the instrumenta...

Page 70: ...Maintenance Notes Page 1C 54 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 71: ...Chart S3 Detonation or Spark Knock 1D 12 Chart S4 Hesitation Sag or Stumble 1D 14 Chart S5 Engine Misses 1D 15 Chart S6 Rough Unstable or Incorrect Idle and Stalling 1D 16 Chart S7 Poor Fuel Economy 1...

Page 72: ...ng mysterious about it A methodological approach combined with experience knowledge and the right tools can eliminate guesswork from the process 1 Talk to the customer to get as much information as po...

Page 73: ...e propeller to avoid injury 7 Unplug and inspect the main harness connector between the engine and boat harnesses If there is any doubt about the boat harness substitute a shop harness and key switch...

Page 74: ...engine Start with step 1 answer the question and proceed accordingly Do not skip any step as each step depends on the results of previous steps to ensure success You may be directed to other sections...

Page 75: ...o a battery switch The PCM power harness connects the battery to a 2 pin engine harness connector Go to step 5 Replace the fuse Reroute or reconnect the harness as necessary Install the harness if it...

Page 76: ...cessfully completing all of the previous steps there may be a problem with the PCM 112 Go to step 14 Call MerCruiser Service for assistance 14 Does the OBD M lamp self test The OBD M lamp should compl...

Page 77: ...itch is released All MerCruiser engines are designed to use a neutral safety switch The switch is inside the remote control on sterndrive engines and mounted to the transmission on inboard engines The...

Page 78: ...o the appropriate sterndrive service manual Go to step 13 13 Is the motor locked up Check for water in cylinders internal mechanical issues and corrosion Refer to Section 3 Engine Mechanical Contact M...

Page 79: ...water separating fuel filter Try starting the engine with a portable tank of known good fuel Check for poor fuel quality and improper octane rating Use known good fuel Replace fuel filters Go to step...

Page 80: ...If all procedures have been completed and no problem found inspect the following CDS G3 scan tool data All of the electrical connections within a suspect circuit or system NOTE The crankshaft positio...

Page 81: ...wire routing Check the condition of the spark plug wires Was a problem found Repair or replace bad spark plug wires Retest the system Go to step 8 8 Check the vacuum hoses for splits kinks and imprope...

Page 82: ...sor MAP sensor and TPS circuits Was a problem found Locate and repair the open or short in the harness Go to step 11 11 Inspect the PCM harness connections and ground connections for being tight clean...

Page 83: ...obvious overheating issues Loose serpentine belt Faulty or incorrect seawater pump Restriction in the cooling system Faulty or incorrect thermostat Was a problem found Repair or replace Retest the sy...

Page 84: ...s a problem found Locate and repair the problem in the harness Retest system Go to step 5 5 Using the scan tool check for proper operation of the TPS Check throttle linkage for sticking binding or wea...

Page 85: ...the condition exists Was a problem found Go to Chart T3 Go to step 5 5 Check the fuel injectors Was a problem found Repair or replace the faulty injector Go to step 6 6 Check for adequate spark at al...

Page 86: ...uel injectors Was a problem found Repair or replace the faulty injector Go to step 6 6 Check for adequate spark at all of the spark plugs Was adequate spark present Go to step 7 Go to Chart T4 7 Remov...

Page 87: ...lem found Repair or replace the faulty injector Go to step 10 10 Check for adequate spark at all of the spark plugs Was adequate spark present Go to step 11 Go to Chart T4 11 Remove the spark plugs an...

Page 88: ...n Yes No 1 Was the Visual Physical Check completed Go to step 2 Go to the Visual Physical Check 2 Did the onboard diagnostic OBD system check complete Go to step 3 Connect the CDS G3 service tool and...

Page 89: ...lem found For repair refer to Section 3 Engine Mechanical Go to step 14 14 Review all of the procedures in this table If all procedures have been completed and no problem found inspect the following C...

Page 90: ...les to the battery Turn the ignition key switch on The fuel pump will operate for 3 5 seconds Note the fuel pressure while the pump is operating The pressure may drop after the pump stops but should n...

Page 91: ...ion key switch on Using the DMT check for B at the coil driver harness connector A Turn the ignition key switch off With the ignition key on was B present Go to step 8 Locate and repair the open in th...

Page 92: ...ult once set will continue to show up as active even if the circuit or problem has corrected itself A key switch cycle is required to reset a sticky fault A nonsticky fault is a fault that will change...

Page 93: ...e 9 pin connector to the CAN P CAN H adapter harness 9 pin connector 3 Connect the CAN P CAN H adapter harness to the junction box or diagnostic port IMPORTANT Ensure that the correct termination resi...

Page 94: ...e User Manual or on the G3 software installation disc CDS G3 Service Tool Home Screen Overview The CDS G3 service tool home screen is your main menu for selecting the major tasks you wish to perform o...

Page 95: ...le to perform certain operations such as actuating a fuel injector on the connected engine Reflash Reflash is the reprogramming of a module with a newer or improved calibration Not all modules can be...

Page 96: ...Troubleshooting Notes Page 1D 26 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 97: ...2A 2 Steering Hoses Sterndrive 2A 2 Seawater Hoses 2A 3 Gear Lube Monitor Sterndrive 2A 3 Disconnecting the Shift Cable and Throttle Cable 2A 4 Disconnecting the Electrical Components 2A 5 Continuity...

Page 98: ...and explosive Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the...

Page 99: ...n below is located at the transom Some models have a quick disconnect fitting in the gear lube monitor hose closer to the engine It may be more convenient to disconnect the hose at this alternate loca...

Page 100: ...t cable and shift assist assembly c Washer and cotter pin Without shift assist assembly a Washer and cotter pin b Cotter pin 2 Disconnect the intermediate shift cable from the shift plate and retain t...

Page 101: ...ector from the engine harness 4 If equipped disconnect the depth transducer from the data link connector DLC on the engine harness 5 Disconnect any ground wires and accessories that are connected to t...

Page 102: ...ved lifting device Do not allow the lifting device to hook or compress any engine components IMPORTANT Engine compartment size may necessitate the removal of additional components 2 On models with a d...

Page 103: ...osite side front lifting eye maintain a minimum 26 inches on each length or use a spreader bar so that no components are damaged 55255 4 Remove the two rear engine mount bolts on sterndrive models a R...

Page 104: ...ssion assembly 8 Remove the fasteners for example lag bolts that hold the front mounts to the engine bed Retain the fasteners and hardware a Lag bolt with washers 9 Removal of water cooled shaft log s...

Page 105: ...2B 24 Transom Harness DTS Mechanical Shift 2B 25 Transom Ground Connection 2B 25 Bravo Sterndrive Shift Check Engine Running 2B 26 Engine Installation and Initial Engine Alignment TowSport Inboard 2B...

Page 106: ...minals and connections 92 25711 3 80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally Special Tools Alignment Tool Assembly 91 805475A 1 9183 Aligns the engine and the sterndrive unit during...

Page 107: ...4 Preparation 1 Connect the battery cables to the engine Observe the following a Ensure that the grounding stud and hot stud terminal are free of paint or any other material that could cause a poor el...

Page 108: ...side of the boat between the exhaust pipe and the engine flywheel housing 2 The cable should then be routed under the starboard rear engine mount and turn toward the transom 3 The cable should then go...

Page 109: ...or other approved lifting device Do not allow the lifting device to hook or compress any engine components 4 Attach a suitable sling lifting corner to corner across the engine and lifting arm to the e...

Page 110: ...gnment is set turn the front mount adjusting nuts two full turns up NOTE This compensates for the softer front mount when weight is applied 12 Relieve the hoist tension entirely and fasten both mounts...

Page 111: ...nylock top nut c If alignment has to be adjusted the nylock top nut must be almost completely removed so that the lock collar can be lifted above the adjustment nut 17 Attempt to insert the solid end...

Page 112: ...ne on the boat stringers f Relieve the hoist tension g Disconnect the sling from the engine lifting eyes 19 Attempt to insert the solid end of the alignment tool through the gimbal bearing and into th...

Page 113: ...ube clamps Description Nm lb in lb ft Tridon hose clamp exhaust tube 4 4 7 35 4 41 6 Connecting the Fluid Systems Gear Lube Monitor Connection IMPORTANT Route hoses to determine the minimum length of...

Page 114: ...arge slot d Seawater inlet fitting e Small tab f Large tab g Center of retainer clip toward engine h Centerline of water inlet fitting toward engine d Ensure that the center line of the water inlet fi...

Page 115: ...ter inlet hose b To engine c Quick connect fitting d Seawater inlet fitting e Hose clamps 5 Models using the seawater extension hose assembly NOTE The seawater inlet hose connects to the engine and th...

Page 116: ...sisted steering hoses to the actuator Ensure that the quick connect fittings snap into place a Power assisted steering actuator b High pressure hydraulic supply hose c Low pressure hydraulic return ho...

Page 117: ...eller is always right hand rotation The shift cable end guide must move in direction A when the remote control lever is placed into forward gear position A 21621 Bravo Models Remote Control Shift Cabl...

Page 118: ...b c Measure the distance between a and b and place another mark c in the center a b c 55295 9 Adjust the shift cable barrel so the center to center measurement is 181 0 mm 7 125 in Verify the measure...

Page 119: ...t the adjustment tool so that the slot is above the stud 20 Shift the remote control into reverse gear position and repeat the adjustment process a Right hand rotation forward Bravo One Two and Three...

Page 120: ...d secured to avoid coming in contact with hot spots on engine and to avoid contact with moving parts Tube Ref No Description Where Used Part No 25 Liquid Neoprene All electrical connections 92 25711 3...

Page 121: ...Bonding strap screw b Continuity wire Quick Connect MerCathode System Connection NOTE MerCathode systems are standard on Bravo applications they are optional on Alpha applications 1 Mount the MerCatho...

Page 122: ...oller and connect the other end directly to the positive terminal of the battery 5 Connect one end of the ground cable to the negative terminal of the MerCathode controller Secure the ground ring term...

Page 123: ...al Tighten the clamp securely 3 Connect the negative battery cable usually black to the negative battery terminal Tighten the clamp securely 4 Ensure that all of the battery terminal connections are t...

Page 124: ...n Ground o Up solenoid p Down solenoid q Power trim extension harness r 20 amp fuse YEL RED YEL RED TAN A B C D E F G H J K L M N P R S PPL BLK BLK GRN WHT ORN GRY RED YEL WHT ORN PNK BRN PNK BLK BLK...

Page 125: ...art The four position key switch is available with mounting hardware 25045 25044 Typical four position key switch off accessory run start NOTE When installing the key switch verify that the drain hole...

Page 126: ...nstall an eye terminal on the black wire from the connector side Cover cut wire ends with heat shrink tubing c Install an eye terminal on the black yellow stripe wire from the connector side Cover cut...

Page 127: ...anyard is pulled and the switch is tripped the circuit will close and ground the ECM to shut the engine off When this connection is not used the wires should be kept separate and capped Warning Horn T...

Page 128: ...ust be removed from the helm harness or junction box and a jumper harness must be installed at the helm to connect the port and starboard CAN P CAN 1 lines together If the boat is dual engine and dual...

Page 129: ...s installed After the engine is in place make the single connection between the transom and the engine DTS engines are shipped with an adapter to connect the transom harness to the power trim pump Tra...

Page 130: ...to contact the ground Typical single handle remote control shown a Drive trim switch b Drive trailer button 2 Connect a water hose between the flushing attachment and a water source Dual Water Pick u...

Page 131: ...d shift cable b Check the shift cable installation and adjustment Refer to the Bravo sterndrive service manual for detailed instructions IMPORTANT Be sure that the shift cables are routed in such a wa...

Page 132: ...n on each chain or use a spreader bar so that no components are damaged 55255 5 Check all four engine mounts two front two rear to ensure that the distance from the bottom of the mount to the bottom o...

Page 133: ...m the front engine mounts 2 Insert the long trunnions into the front engine mounts 3 Install and align the engine 4 Ensure that the trunnion clamping bolts and locknuts are tightened to the specified...

Page 134: ...nsure that all four mounts are still positioned properly then fasten the mounts to the engine bed with 10 mm 3 8 in diameter lag bolts of sufficient length and flat washers Tighten the lag bolts secur...

Page 135: ...the sling Final Engine Alignment TowSport Inboard IMPORTANT Engine alignment must be checked with the boat in the water fuel tanks filled and with a normal load onboard 1 Check the mating faces on the...

Page 136: ...mission output flange 5 If the flange coupling centerlines are not aligned or if the flange coupling faces are more than 0 07 mm 0 003 in out of parallel adjust the engine mounts a To adjust the engin...

Page 137: ...t locations marked with a punch c Install the propeller shaft flange and tighten the bolts to the specified torque Install the set screws and tighten securely Safety wire the set screws to ensure that...

Page 138: ...Portion Single Hose Portion All Models 127 mm 5 0 in 102 mm 4 in 102 cm 4 in 102 mm 4 in Sharp bends in exhaust hoses should be avoided Exhaust hoses can be installed at up to a 5 angle relative to t...

Page 139: ...e exhaust elbow must flow around the entire inside diameter of the hose to avoid causing hot spots that could burn through the hose Exhaust hoses must be installed at the angle shown following 33233 3...

Page 140: ...l affect the exhaust system must be clearly communicated to the operator in the owner s manual For example the number of people that can be located on the swim platform simultaneously should be includ...

Page 141: ...clamps c Muffler d 3 5 in outlet Boat Requirements IMPORTANT Consider the following requirements before performing the exhaust elbow waterline height measurement No prototype hulls or light layup hull...

Page 142: ...ximum rated swim platform weight capacity to the swim platform b Boats less than 8 84 m 29 ft long not including boats that are 8 84 m 29 ft long that do not have a maximum rated swim platform weight...

Page 143: ...NOTE The total weight loaded onto the boat must not exceed the maximum capacity displayed on the capacity plate NOTE The following example is provided as a reference Example NOTE This example uses a...

Page 144: ...l number of persons that can sit on designated seating excluding cabin space MerCruiser person weight maximum passenger load for measurement Number of persons 165 lb MerCruiser person weight XXXX lb m...

Page 145: ...s the number of passengers that can sit on designated seating excluding cabin space 24863 1 2 3 4 5 7 8 6 9 Designated seating diagram This example uses nine persons as the maximum passenger load NOTE...

Page 146: ...o d MerCruiser person weight three e MerCruiser person weight four f MerCruiser person weight five g MerCruiser person weight six h Aft storage i Center storage j Bow storage Clear Hose Measurement Me...

Page 147: ...ies to avoid damage to the electrical system Do not tap accessories into the engine harness Do not puncture wires for testing probing Do not reverse the battery leads Do not splice wires into the harn...

Page 148: ...il leaks at the threaded connection Boat Harness and Instrumentation Connections Inboard IMPORTANT The maximum accessory load on the engine harness is 15 amps If additional accessory load is needed an...

Page 149: ...fuel vapor is present such as engine or fuel tank compartments 1 Select a location for the audio warning alarm that meets all of the following Alarm can be easily heard yet is out of sight Alarm can b...

Page 150: ...trol technology ECT catalyzed engines must be equipped with a SmartCraft enabled gauge capable of displaying the service engine icon or a dash mounted service engine light Malfunction indicator lamp M...

Page 151: ...his plug must remain installed 1 Remove the plug from the poppet valve hose assembly 2 Install the reducer fitting shipped with the parts bag 3 Attach the shaft log seal cooling water hose to the redu...

Page 152: ...ally done with all other MerCruiser products but to achieve the best optimum propeller selection you can use the propping procedure with the G3 tool to verify your propeller selection NOTE The followi...

Page 153: ...an at 100 Trim position percent at 15 97 optimum trim for this boat Demand request by operator 100 RPM at 4692 indicating that the engine is overpropped 57316 Nonoptimal propping set up overpropped Al...

Page 154: ...propping using the parameters shown Wide Open Throttle Propping Without G3 Test IMPORTANT To operate the engine at full throttle before the break in period is complete follow this procedure 1 Place t...

Page 155: ...lant if necessary Checking Shift Operation With sterndrive unit installed and engine operating ensure that the drive unit shifts properly as explained following 1 Shift into forward and reverse gear e...

Page 156: ...Installation Notes Page 2B 52 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 157: ...22 Finding Top Dead Center TDC 3A 23 Method 1 3A 23 Method 2 3A 23 Intake Manifold Assembly 3A 24 Removal 3A 24 Hydraulic Valve Lifters 3A 25 Exploded View 3A 25 Special Information 3A 25 Removal 3A...

Page 158: ...ton Ring Expander 91 24697 6255 Expands piston rings for removal and installation Engine Block Codes Identification The engine can be determined by using the block code This code contains a component...

Page 159: ...er V6 P MerCruiser V8 T Tigershark Z Verado 350 hp racing X Multi Family part usage 3 Year The last digit of the build year 4 6 Julian day The julian day of the build year 7 8 Military hour Two digit...

Page 160: ...ning servicing installing or removing engine or drive components WARNING Fuel is flammable and explosive Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start...

Page 161: ...4 6 59457 5 First pass 27 20 Second pass 54 39 8 Final pass 54 39 8 Exhaust elbow screws tighten screws using an X pattern use torque sequence listed for each pass 1 2 3 4 57899 First pass 46 33 9 Fi...

Page 162: ...t interferes with engine service or repair Engine Rotation Engine rotation is observed from the rear of the engine transmission or sterndrive end looking forward water pump end Engine rotation is not...

Page 163: ...White or yellow paint is used to identify the top of the mount assembly The bottom has a knurled edge Typical flywheel housing all similar a Painted end not visible b Mount bottom c Knurled edge b a b...

Page 164: ...Cylinder Head and Rocker Cover Components 58403 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 26 27 27 28 29 30 23 23 24 25 31 18 Engine Disassembly Page 3A 8 2016 Mercury Marine 90 8M0099748...

Page 165: ...ve seat not serviced 13 8 Valve seat not serviced 14 16 Valve seal 15 16 Spring 16 16 Retainer 17 32 Keeper 18 2 Expansion plug 19 18 Head bolt M10 x 1 5 x 49 First 15 132 7 Second 30 22 1 Final torqu...

Page 166: ...Chain and Front Cover Components 1 2 3 4 4 5 6 29 7 8 9 10 9 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28 21 30 31 59647 Engine Disassembly Page 3A 10 2016 Mercury Marine 90 8M0099748 eng DECEMB...

Page 167: ...9 13 1 Crankshaft pulley 14 1 Lockwasher 15 1 Washer 16 1 Harmonic damper 17 1 Crank sensor screw 10 88 5 18 1 Crank sensor 19 6 Screw 12 106 2 20 1 Timing front cover 21 1 Seal 22 1 Reluctor wheel 2...

Page 168: ...Crankshaft and Camshaft 1 3 3 2 2 2 2 3 3 3 4 2 5 6 14 15 3 7 8 9 10 11 12 13 16 17 18 19 21 20 22 22 59646 Engine Disassembly Page 3A 12 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 169: ...mshaft 11 1 Dowel pin part of camshaft not serviced separate 12 1 Retainer 13 2 Screw 12 106 2 14 1 Camshaft bearing set 15 1 Crankshaft oil seal 16 1 Crankshaft 17 1 Dowel pin 18 1 Key 19 1 Main bear...

Page 170: ...Piston and Connecting Rod 1 2 3 4 5 6 7 8 9 10 11 12 13 55056 8 Engine Disassembly Page 3A 14 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 171: ...oil control ring 4 6 Oil control ring spacer 5 6 Lower oil control ring 6 6 Piston 7 6 Piston pin 8 12 Snap ring 2 9 6 Connecting rod 10 6 Upper bearing half 11 6 Lower bearing half 12 6 Bearing cap 1...

Page 172: ...old and Fuel Rail MPI 58417 1 2 2 3 7 8 9 10 11 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26 27 28 29 31 33 4 5 6 30 20 32 20 34 Engine Disassembly Page 3A 16 2016 Mercury Marine 90 8M0099748 eng D...

Page 173: ...et 14 1 Clip 15 1 Bracket 16 1 Bracket 17 1 Stainless steel washer 18 2 Worm gear clamp 19 1 Fuel module to water strainer hose 20 3 Screw 21 3 Fuel supply module dual pump 22 1 Screw 10 88 5 23 1 Fue...

Page 174: ...Oil Pan and Oil Pump 57114 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Engine Disassembly Page 3A 18 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 175: ...4 17 7 5 1 U clamp 6 12 Oil pan screw 35 25 8 7 1 Oil pump 8 1 Oil pump screw First torque 20 177 Final torque 65 9 1 Retainer 10 1 Oil pump shaft 11 1 Oil pump drive 12 1 Dipstick 13 1 Dipstick tube...

Page 176: ...Remote Oil Filter 58537 1 2 3 4 5 6 7 8 10 4 4 12 9 11 13 13 13 14 Engine Disassembly Page 3A 20 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 177: ...4 O ring 5 2 Screw M10 x 16 6 1 Oil filter to block oil line 7 1 Bracket 8 2 Screw M6 x 12 31 1 22 9 9 1 Oil cooler to filter oil line 10 1 Bracket 11 2 Screw M6 x 12 31 1 22 9 12 1 Block to cooler o...

Page 178: ...of the rocker arm covers 4 Remove the rocker arm covers a Rocker arm cover gasket b Rocker arm cover c Grommets d Screws Rocker Arms and Valve Pushrods Removal NOTE When servicing only one cylinder s...

Page 179: ...1 Remove the cylinder number 1 spark plug 2 Attach a suitable socket wrench to the crankshaft pulley nut 3 Place a finger over the plug hole and turn the engine over in its normal rotation until compr...

Page 180: ...the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately...

Page 181: ...spring h Lifter body i Roller Special Information Hydraulic valve lifters require little attention These lifters are extremely simple in design Normally adjustments are not necessary and servicing req...

Page 182: ...oil loss 2 Remove the valve lifters Store the lifters in the upright position in the order of removal 55006 Valve lifter Oil Pump Drive Removal The oil pump drive connects the oil pump to the camshaf...

Page 183: ...sing 2 Remove the ground wires from the flywheel housing IMPORTANT The flywheel housing bolts must be installed in the same location as removed 3 Remove the screws and studs from the flywheel housing...

Page 184: ...rd is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vap...

Page 185: ...bracket 4 Remove the idler pulley with bracket 5 Remove the crankshaft pulley a Water circulating pump bolts b Crankshaft harmonic damper 6 Remove the hoses from the water circulating pump NOTE Do no...

Page 186: ...ont cover a Crankcase front cover b Cover screws 6 10 Remove and inspect the crankcase front cover IMPORTANT The crankcase front cover is reusable Gasket must be replaced if removed 30312 a b c b 5535...

Page 187: ...kshaft to cylinder number 1 TDC a Crankshaft sprocket b Camshaft sprocket c Timing marks 3 Check the timing chain deflection Refer to Section 3B Checking Timing Chain Deflection 4 Remove the camshaft...

Page 188: ...sprocket remover tool Description Part Number Kent Moore crankshaft sprocket puller J5825 A Camshaft Removal 1 Remove the camshaft thrust plate 59482 2 Install three 5 16 18 x 5 in long bolts in the...

Page 189: ...lts a Short bolts M10 x 1 5 x 49 b Long bolts M10 x 1 5 x 86 3 Remove the cylinder head 4 Place the cylinder head on wooden blocks a rubber mat or other material that will prevent damage to the gasket...

Page 190: ...Assembly Exploded View a Valve b Valve stem oil seal c Valve spring d Valve spring retainer e Valve spring keeper a b c d e 55013 Engine Disassembly Page 3A 34 2016 Mercury Marine 90 8M0099748 eng DE...

Page 191: ...ing compressor cylinder head off the engine J8062 2 Carefully release the valve spring compressor 3 Remove the valve spring cap and valve spring IMPORTANT Keep components together as a matched set Mar...

Page 192: ...ring half 11 Lower bearing half 12 Bearing cap 13 Screw 2 Removal 1 Using a ridge reamer remove any ridge or combustion deposits from the top of the cylinder bore Description Part Number Cylinder bore...

Page 193: ...location later 4 Remove the connecting rod bearing cap 52472 Connecting rod bearing cap IMPORTANT Wrap a clean lint free towel around the connecting rod ends when removing the piston from the cylinde...

Page 194: ...e replaced without removing the oil pan or the rear main bearing cap from the engine 1 Remove the flywheel 2 Remove the seal by carefully using a screwdriver to pry it out of the engine block as shown...

Page 195: ...he idler gear and drive gear from the pump body CAUTION The plunger and diaphragm are spring loaded and can be forcefully expelled from the diaphragm body Always wear eye protection when servicing the...

Page 196: ...in bearing bolts Removal If only the main bearings are being serviced refer to Section 3B Main Bearings without Crankshaft Removed NOTE Engine port and starboard cylinder heads are removed for illustr...

Page 197: ...y lift the crankshaft out of the engine block a Crankshaft b Main bearing cap c Rear main bearing cap d Main bearing cap screw a Crankshaft a c b d 59495 59493 a Engine Disassembly 90 8M0099748 eng DE...

Page 198: ...ecting rods and caps Install new bearings Engine Block Disassembly 1 Remove all engine components 2 Remove the camshaft rear bearing hole expansion cup plug a Rear of engine block camshaft opening b R...

Page 199: ...linder bores and other machined surfaces with clean engine oil Tube Ref No Description Where Used Part No 80 SAE Engine Oil 30W Cylinder bores and other machined surfaces Obtain Locally Camshaft Beari...

Page 200: ...the J33049 a Position 1 cam bearing b Position 2 cam bearing c Position 3 cam bearing d Position 4 cam bearing e Position 5 cam bearing NOTE The cam bearings are the same size IMPORTANT Always remove...

Page 201: ...J33049 p Drive the camshaft inner bearing 4 from the camshaft inner bearing bore 4 q Loosen the J33049 expander assembly nut r Remove the camshaft inner bearing 4 from the J33049 expander assembly 4...

Page 202: ...Engine Disassembly Notes Page 3A 46 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 203: ...aft 3B 33 Inspection 3B 33 Installation 3B 34 Timing Chain 3B 35 Inspection 3B 35 Assembly 3B 35 Checking Timing Chain Deflection 3B 36 Installation 3B 37 Crankcase Front Cover 3B 37 Installation 3B 3...

Page 204: ...ournals camshaft and camshaft lobes Valve stem Outside surface of valve stem bore and all surfaces of the valve stem oil seal Valve stem keepers Camshaft lobes and valve lifters Valve lifters Outer su...

Page 205: ...0005 in maximum Service 0 05 mm 0 0020 in Taper Production thrust side 0 012 mm 0 0005 in maximum Production relief side 0 025 mm 0 0010 in maximum Service 0 025 mm 0 0010 in over production Oil Pump...

Page 206: ...ng Clearance Description 6 2 Liter 377 cid Production Number 1 2 3 4 0 043 0 107 mm 0 0017 0 0042 in Number 5 0 043 0 107 mm 0 0017 0 0042 in Connecting Rod Journal Description 6 2 Liter 377 cid Diame...

Page 207: ...mm 0 in Stem Clearance Description 6 2 Liter 377 cid Production Intake 0 023 0 065 mm 0 0009 0 0025 in Exhaust 0 033 0 075 mm 0 0012 0 00295 in Seat Description 6 2 Liter 377 cid Seat angle Intake and...

Page 208: ...Clean and Inspect 1 Clean the engine block with cleaning solvent 2 Flush the engine block with clean water or steam 3 Clean the cylinder bores 4 Clean the oil galleries and the oil passages 5 Clean th...

Page 209: ...nder bores for scratches or gouging c Valve lifter bores for excessive scoring or wear d Threaded holes for damage e Crankshaft bearing webs for cracks f Crankshaft bearing caps and the crankshaft bea...

Page 210: ...equipment manufacturer s instructions Cylinder Honing 1 Follow the instructions provided with the cylinder hone kit Description Part Number Kent Moore cylinder hone tool kit J5902 01 2 Frequently clea...

Page 211: ...3 If the cylinder bore must be reconditioned measure the new piston diameter then hone the cylinder bore to the correct clearance 4 Mark each piston to identify the cylinder for which it was fitted C...

Page 212: ...tion 4 cam bearing e Position 5 cam bearing IMPORTANT The camshaft bearings vary in size When ordering the new camshaft bearings be sure to order the correct camshaft bearings for the application to b...

Page 213: ...clock position of the camshaft inner bearing bore 4 of the engine block d Push the J33049 guide cone into the camshaft front bearing bore 1 in order to align the J33049 e Drive the camshaft inner bear...

Page 214: ...0 039 in past the chamfer Tube Ref No Description Where Used Part No 66 Loctite 242 Threadlocker Expansion cup plug camshaft rear bearing hole 92 809821 Engine Block Plugs Installation CAUTION Wear ey...

Page 215: ...escription Where Used Part No 66 Loctite 242 Threadlocker Outside diameter of engine block core hole expansion plug 92 809821 3 Apply sealant to the threads of the oil gallery plugs 4 Install the oil...

Page 216: ...scription Nm lb in lb ft Oil gallery plug 10 mm 9 79 6 Oil gallery plug 18 mm 22 16 2 Oil gallery plug 24 mm 55 40 5 Tube Ref No Description Where Used Part No Loctite 565 PST Threads of the oil galle...

Page 217: ...ng grooves d Clean the piston oil lubrication holes and slots e Dry parts with compressed air 4 Piston pin a Clean the parts in cleaning solvent b Dry the parts with compressed air Main Bearing Inspec...

Page 218: ...the lower bearing half shows evidence of wear or damage replace the entire bearing set Never replace one half of a bearing set without replacing the other half Main bearing failure example a Contamin...

Page 219: ...bushing is to be reused the bushing can be removed without damage as follows a Fill the pilot bushing cavity with grease b Insert an old transmission input shaft in the bore of the bushing and hit it...

Page 220: ...ring caps a Lower insert b Main bearing cap 5 Carefully lower the crankshaft into place Be careful not to damage the bearing surfaces a Crankshaft a b 59544 59493 a Engine Inspection and Assembly Page...

Page 221: ...Part No 136 Lubriplate SPO 255 Main bearings and crankshaft bearing journals Obtain Locally 9 Install the main bearing caps a Crankshaft b Main bearing cap c Rear main bearing cap d Main bearing cap b...

Page 222: ...earings and the total clearance can be measured between the lower bearing and journal To ensure the proper seating of the crankshaft all bearing cap bolts should be at the specified torque In addition...

Page 223: ...plastigauge a Compressed gauging plastic b Scale Main Bearing Clearance Description 6 2 Liter 377 cid Production Number 1 2 3 4 0 043 0 107 mm 0 0017 0 0042 in Number 5 0 043 0 107 mm 0 0017 0 0042 i...

Page 224: ...or faulty bearings Piston Inspection NOTE Cylinder bore and taper must be within specifications before pistons can be considered for reuse 1 Inspect the piston for cracked ring lands skirts and pin bo...

Page 225: ...or burrs Minor internal damage can be dressed with a fine file If the piston ring groove is clean and free of defects check the groove with a different ring The ring used for inspection may be bent 1...

Page 226: ...2 Measuring piston ring gap Description 6 2 Liter 377 cid Top compression ring gap Production 0 38 0 52 mm 0 015 0 020 in Second compression ring gap Production 0 63 0 82 mm 0 025 0 032 in Oil control...

Page 227: ...ed side up Piston Connecting Rod Assembly 1 Install the connecting rod into the piston with the odd number cylinder Connecting rod dot down piston dome dot up Even number cylinder connecting rod dot u...

Page 228: ...htly oil the cylinder bores with a clean lint free white cloth with engine oil Repeat until the cloth remains clean e Wipe down the cylinder bores a final time with a clean lint free white cloth Tube...

Page 229: ...nd 4 Stroke Marine Engine Oil Connecting rod bearings pistons rings and cylinder walls 92 8M0078629 6 Position ring gaps as shown Ring gap locations a Oil ring spacer gap b Oil ring gaps c Lower compr...

Page 230: ...n assembly in its respective bore with the piston notch toward the front of the engine 9 Hold the piston ring compressor firmly against the engine block until all piston rings have entered the cylinde...

Page 231: ...oom temperature Connecting rod bearings are of the precision insert type and do not use shims for adjustment Replace the bearing if clearance is found to be excessive Service bearings are available in...

Page 232: ...aring journal diameters are within specifications determine bearing clearance by subtracting the crankshaft connecting rod journal outer diameter from the inner diameter of the bearing from step 5 Des...

Page 233: ...lb in lb ft Bearing cap screws First torque 25 18 4 Final torque 90 IMPORTANT Do not rotate the crankshaft while the gauging plastic is between the bearing and journal 7 Without rotating the cranksha...

Page 234: ...d cover for cracks or excessive wear 2 Inspect the pump gears for damage and excessive wear such as chipped teeth and galling 3 Check the gear shafts in the pump body for galling scoring or excessive...

Page 235: ...scored or damaged bearing journals or lobes 3 Inspect the camshaft for bolt hole threads 4 Inspect the camshaft sprocket locator pin 5 Measure the camshaft bearing journals with a micrometer If journ...

Page 236: ...cally 3 Lubricate the camshaft lobes with Lubriplate SPO 255 or equivalent 4 Remove the three bolts in the camshaft bolt holes 5 Coat the threads of the camshaft thrust plate retainer bolts with Locti...

Page 237: ...way of the crankshaft sprocket with the crankshaft balancer key 3 The crankshaft balancer key should be parallel to the crankshaft or with a slight incline 4 Install the sprocket on the crankshaft by...

Page 238: ...side of chain and measure from this point to the chain 59549 Measuring timing chain deflection 3 Rotate the camshaft in the opposite direction to provide slack in the chain 4 Push the chain in toward...

Page 239: ...M0078629 2 Install the crankcase front cover using a new gasket ensuring that the holes in the cover align with the dowel pins in the block Tighten the screws in sequence to the specified torque 1 2 3...

Page 240: ...yway of the harmonic damper to prevent oil migration past the key 6 Install the crankshaft harmonic damper Tighten the screw to the specified torque Tube Ref No Description Where Used Part No 142 Loct...

Page 241: ...n the graphic NOTE The dowel pin on the crankshaft may have to be removed to allow seal installation using tool or tool may need modification Description Part Number Kent Moore rear main seal installe...

Page 242: ...e bolts Tighten the oil pan baffle bolts to the specified torque Description Nm lb in lb ft Oil pan baffle bolt 15 132 7 Installation IMPORTANT The adhesive sets up in about 15 minutes Complete the as...

Page 243: ...f No Description Where Used Part No 137 Loctite 5512 Adhesive Both right and left side joints of the rear seal retainer and joints of the front cover 92 858006K02 IMPORTANT Always install a new oil pa...

Page 244: ...do not tighten 6 Measure the pan to transmission housing clearance using a feeler gauge and a straightedge Use a feeler gauge to check the clearance between the oil pan to housing measurement points I...

Page 245: ...ate engine oil dipstick a Dipstick b Dipstick tube c Clamp Cylinder Head Core Plug Installation The cylinder head assembly is unidirectional and needs a core plug installed in the aft end of the cylin...

Page 246: ...e 2 Inspect for cracks in exhaust ports water jackets and combustion chambers especially around spark plug holes and valve seats 3 Replace the cylinder heads if necessary 4 Inspect for rusted damaged...

Page 247: ...ted face b Damaged stem IMPORTANT Excessive valve stem to bore clearance will cause excessive oil consumption and possibly broken valves Insufficient clearance will result in noisy binding valves 2 Me...

Page 248: ...0 0010 0 0037 in 4 If the clearance exceeds specifications on the exhaust valve and exhaust guide it is necessary to replace the cylinder head or install thin wall valve guide inserts 5 If the cleara...

Page 249: ...spring compressor J9666 Description 6 2 Liter 377 cid Pressure Valve closed 350 N 78 68 lb at 46 19 mm 1 818 in Valve open 1084 N 243 69 lb at 32 3 mm 1 2717 in Repair Valve Reconditioning 1 Reconditi...

Page 250: ...it is essential that the valve guide bores be free from carbon or dirt to achieve proper centering of the pilot in the valve guide ensuring concentricity when reconditioning the valve seats NOTE Sever...

Page 251: ...ch it has been fitted 1 Assemble a valve into its proper port and valve guide Apply clean engine oil to the valve stem Tube Ref No Description Where Used Part No 136 Lubriplate SPO 255 Valve stem Obta...

Page 252: ...e top of the valve guide bevel to the bottom of the oil stem seal 0 mm 0 in minimum 7 Install the valve spring 8 Place a spring retainer on the valve spring CAUTION Improperly compressed springs or im...

Page 253: ...he spring seat to the top of the valve spring IMPORTANT To ensure correct measurement measure the spring height from the top of the valve spring not the top of the valve IMPORTANT If measurement excee...

Page 254: ...head gasket in position over the dowel pins 59563 3 Carefully set the cylinder head in place over the dowel pins 59565 Engine Inspection and Assembly Page 3B 52 2016 Mercury Marine 90 8M0099748 eng D...

Page 255: ...ription Where Used Part No Loctite 565 PST Cylinder head bolt threads Obtain Locally 5 Tighten the cylinder head bolts to the specified torque in passes using the numbered sequence shown 1 2 3 4 5 6 7...

Page 256: ...3 Inspect the outer lifter body wall If the wall is scuffed or worn inspect the engine block lifter bore 4 Inspect the roller of the valve lifter If the roller is scuffed or worn inspect the camshaft...

Page 257: ...ir original locations if being reused a Lifter b Lifter guide retainer 2 c Retainer bolt 8 Tube Ref No Description Where Used Part No 136 Lubriplate SPO 255 Valve lifters Obtain Locally 2 Install the...

Page 258: ...ll the flange screw Tighten the screw to the specified torque Description Nm lb in lb ft Oil pump drive flange screw 30 22 1 Rocker Arms and Pushrods Inspection 1 Inspect all contact surfaces for exce...

Page 259: ...Lubriplate SPO 255 Outer surfaces and ends of valve pushrods Obtain Locally 2 Install the valve pushrods in their original locations Ensure that the pushrods seat in the lifter socket 3 Install the ro...

Page 260: ...ankshaft and camshaft alignment marks Tighten the rocker arm bolts to the specified torque Rotate the crankshaft one full revolution and check all rocker bolts to the specified torque Description Nm l...

Page 261: ...ling resulting in intake manifold air or fluid leaks Do not apply excessive amounts of adhesive or sealer 1 Apply a 4 mm 0 157 in bead of adhesive at each end of the lower intake manifold gasket on th...

Page 262: ...tite 5900 Ultra Black RTV Silicone Sealant A wide bead of adhesive to the front and rear of the engine block extending the adhesive bead 92 809826 4 Coat the threads of the intake manifold bolts with...

Page 263: ...torque 24 17 7 7 Install the alternator Refer to Section 4C Alternator Installation 8 Install the fuel injector rail with injectors Refer to Section 5A Fuel Rail Installation 9 Connect the injector w...

Page 264: ...drive plate or coupler for damage or excessive wear 4 Replace components as necessary Installation NOTE Two designs of flywheels are used The first design has a three hole pattern in the flywheel The...

Page 265: ...ified torque 59594 1 2 3 4 5 6 59612 Tighten sequence Description Nm lb in lb ft Flywheel mounting screws 80 59 3 Check the flywheel runout a Attach a dial indicator to the engine block b Push in on t...

Page 266: ...lywheel using six screws and washers driving them loosely into place a Slotted hole used for alignment b Small hole tightly held diameter used for alignment c This hole is used for manufacturing not f...

Page 267: ...t or stud holes and excessive wear Replace if necessary 2 Inspect the guide dowels for the correct amount of protrusion from the engine block Repair if necessary a Guide dowels 2 b Measured protrusion...

Page 268: ...Stroke Engine Oil O rings 92 8M0078629 3 Install the oil lines along with the retaining bracket onto the engine block 4 Secure the retaining bracket with two screws Do not tighten the screws 5 Instal...

Page 269: ...No Description Where Used Part No 139 Mercury 25W 40 Synthetic Blend 4 Stroke Engine Oil Rubber sealing surface 92 8M0078629 3 Install the new seal with the open end of the seal facing inward Using th...

Page 270: ...crankshaft and the indented or notched side of the engine block 7 Rotate the bearing into place and remove the tool from the oil hole in the crankshaft journal 8 Lubricate a new lower bearing and inst...

Page 271: ...ring retainer e Valve spring lock Valve Spring Assembly Removal 1 Remove the rocker arm cover 2 Remove the spark plug of the cylinder being serviced 3 Remove the rocker arm assembly IMPORTANT Keep air...

Page 272: ...892 D 6 Carefully release the valve spring compressor 7 Remove the valve spring cap and valve spring IMPORTANT If compressed air is not available do not turn the crankshaft while valve springs retaine...

Page 273: ...its 3C 6 Preignition Damage 3C 7 Reversed Coil Polarity 3C 7 Splashed Deposits 3C 7 Mechanical Damage 3C 8 Piston Inspection 3C 8 Starter Motor Will Not Crank Engine or Cranks Slowly 3C 9 Engine Will...

Page 274: ...Steady reading 51 71 kPa 15 21 in Hg at idle RPM Normal No action necessary 17757 Extremely low reading but indicator steady at idle RPM Vacuum leak at intake manifold or incorrect timing or underpow...

Page 275: ...o ensure accurate vacuum measurement Mechanical Engine Noise WARNING Moving parts can cause serious injury or death Wear eye protection and keep hands hair and clothing away from moving parts when per...

Page 276: ...Spark Plug Analysis Spark plug condition can suggest a variety of possible engine malfunctions and indicate needed engine repairs When the old plugs are replaced replace the entire set Perform plug s...

Page 277: ...ieve oil wet fouling IMPORTANT New engines or recently overhauled engines may wet foul the plugs before normal oil control is achieved with proper break in procedures Such fouled plugs may be serviced...

Page 278: ...y during hard fast acceleration under heavy load Normal deposits do not get a chance to blow off Instead they melt and form a conductive coating Replace the spark plugs If the condition recurs use col...

Page 279: ...ground electrode is an indication of reversed polarity The center electrode will show only normal wear The engine will misfire and idle rough To correct reverse the primary coil leads Replace the spa...

Page 280: ...ection 1 Replace pistons that are damaged or show signs of excessive wear 2 Inspect the piston for damage caused by preignition 14394 Typical preignition damage a Preignition begins b Controlled ignit...

Page 281: ...lt from these conditions are beyond the control of Mercury MerCruiser No warranty will apply to failures that occur under these conditions Starter Motor Will Not Crank Engine or Cranks Slowly Possible...

Page 282: ...t Information and Troubleshooting Poor Performance Possible Cause Remedy Throttle not fully open Inspect the throttle body for proper operation Damaged or improper propeller Replace the propeller Exce...

Page 283: ...ering through the exhaust system If the water is contained to the crankcase only it is usually caused by water entering through the intake manifold a flooded bilge or condensation If the water is loca...

Page 284: ...l Compression builds quickly and evenly in each cylinder None Leaking piston rings Compression is low on the first stroke increases on the following strokes but does not reach normal compression Injec...

Page 285: ...ard leaking up through the intake manifold at the throttle body Leaking exhaust valve Air is heard leaking into the exhaust system Leaking piston or piston rings A high volume of air leaks into the te...

Page 286: ...Engine Troubleshooting Notes Page 3C 14 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 287: ...al Section 3D Engine Wiring Harness Table of Contents Engine Wiring Harness 3D 2 Harness Removal 3D 2 Harness Installation 3D 5 Engine Wiring Harness 90 8M0099748 eng DECEMBER 2015 2016 Mercury Marine...

Page 288: ...ng the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system Always disconnect the negative battery cable first and connect it last 1 Disconn...

Page 289: ...harness crank sensor connector and J clip a Drive lube connector b Ground harness c Crank sensor connector a Fused connector b Coils c Throttle body d Temperature sensor e Oil pressure sensor f Ground...

Page 290: ...hing the PCM relay bracket to the manifold a Mounting screws 12 Remove the PCM relay bracket with harness from the engine a PCM relay bracket with harness 13 Remove the relays and fuses from the PCM r...

Page 291: ...opriate measures to protect all electrical wires Do not overtighten clamps and keep harnesses away from heat sources during installation 1 Attach the harness to the PCM relay bracket using cable ties...

Page 292: ...nsor e Oil pressure sensor f Ground stud 5 Connect the throttle body temperature sensor and oil pressure sensor 6 Connect the ground wires to the ground stud 7 Connect the drive lube connector ground...

Page 293: ...ector b Fuel pump connector 9 Connect the wires at the starter a Starter connection b Starboard exhaust temperature sensor 10 Connect the starboard and port exhaust temperature sensors a b 59364 b a 5...

Page 294: ...ygen sensors a Starboard precatalyst oxygen sensor b Port precatalyst oxygen sensor 12 Install the PCM relay bracket screws a Mounting screws a b 59362 a a a a 56506 Engine Wiring Harness Page 3D 8 20...

Page 295: ...4A 6 Starter Motor Circuit 4A 6 Starter Relay 4A 7 Starting Circuit Overload Protection 4A 7 Battery Cables for MerCruiser Models 4A 7 Hot Stud 4A 8 Starter 4A 8 Inspection 4A 8 Starter Removal 4A 9...

Page 296: ...d in the engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five minutes WARNIN...

Page 297: ...ng field coils mounted on iron pole pieces A 4 1 ratio internal gear reduction results in armature speeds in the 7000 RPM range The armature and driveshaft are mounted on roller or ball bearings in th...

Page 298: ...Starter Motor Exploded View 1 2 3 4 56738 Starting System Page 4A 4 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 299: ...d View Ref No Qty Description Torque Nm lb in lb ft 1 1 Starter motor assembly 2 1 Bolt M10 x 1 5 47 5 35 3 1 Nut M8 x 1 5 9 5 84 4 1 Lockwasher Starting System 90 8M0099748 eng DECEMBER 2015 2016 Mer...

Page 300: ...erminal 87 6 From terminal 87 to the S connector on the starter mounted solenoid yellow red 7 From the solenoid S connector across the starter solenoid coil NOTE When the starter solenoid coil is ener...

Page 301: ...ectrical System Overload Protection Battery Cables for MerCruiser Models IMPORTANT The OEM or designer of the vessel is responsible for selecting the proper battery cable size to replace the minimum s...

Page 302: ...ing only Hot Stud The hot stud is located at the rear of the engine It is normally covered by a protective boot It is also located next to the 90 amp fuse The hot stud provides a ready connection poin...

Page 303: ...Remove the starter mounting bolts 4 Pull the starter assembly away from the flywheel and remove it from the engine 56782 Water and Corrosion Inspection Remove the two short screws from the starter mo...

Page 304: ...between the starter motor and the engine block must be reused 1 Place the starter motor into position and install the mounting bolts Tighten the starter mounting bolts to the specified torque Descrip...

Page 305: ...nections a Solenoid S terminal b Positive battery terminal 5 Connect the negative meter lead directly to an unpainted metal surface on the starter housing 6 Crank the engine over with the key switch f...

Page 306: ...cable connection back to the battery positive post c If a battery switch is used check between the battery cable ring terminal and the switch s terminal 2 Check for voltage drop across the solenoid c...

Page 307: ...iations 4B 4 Spark Plug Removal Inspection and Installation 4B 4 Removal 4B 4 Inspection 4B 4 Installation 4B 4 Spark Plug Wires 4B 4 Inspection 4B 4 Installation 4B 4 Ignition Coil 4B 5 Ignition Coil...

Page 308: ...engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five minutes WARNING Fuel i...

Page 309: ...n components In a typical engine it requires only about 2 3 kV to fire the cylinder on the exhaust strokes The remaining coil energy is available to fire the spark plug under compression typically abo...

Page 310: ...et and socket 3 Install the spark plugs and tighten them to the specified torque Description Nm lb in lb ft Spark plugs new cylinder head 30 22 1 Spark plugs used cylinder head 14 123 9 4 Install the...

Page 311: ...r from all of the coils 2 Perform a visual inspection of the pins at the coil and the wires coming to the connector Look for broken bent and corroded pins at the coil and loose broken or corroded wire...

Page 312: ...nce Test 1 Remove the spark plug lead from the ignition coil Twist the ignition coil boot slightly while removing 2 Use a DMT 2004 digital multimeter and perform the following test a Pin A b Pin B c C...

Page 313: ...he engine using two screws a Ignition coil b Screws c Wiring harness connector 2 Connect the high tension coil lead 3 Connect the wire harness connector a b b c 59409 Waste Spark System 90 8M0099748 e...

Page 314: ...Waste Spark System Notes Page 4B 8 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 315: ...Alternator Installation 4C 7 Serpentine Drive Belt 4C 7 Sterndrive Models 4C 8 Replacing 4C 9 Troubleshooting 4C 10 Before You Begin 4C 10 Charging Output Tests 4C 10 Voltage Drop Test Alternator Circ...

Page 316: ...es contained in the engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five min...

Page 317: ...Measures serpentine belt deflection DMT 2004 Digital Multimeter 91 892647A01 A COM mA V Hz mV V Hz TEMP mA A IG IP OFF Hz TEMP 4516 Measures RPM on spark ignition SI engines ohms amperes AC and DC vol...

Page 318: ...Alternator and Brackets Exploded View 1 2 3 4 5 56827 Charging System Page 4C 4 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 319: ...iption Torque Nm lb in lb ft 1 1 Coolant crossover and alternator bracket 2 1 Hex head bolt M8 x 110 34 25 1 3 1 Nut 4 2 Alternator assembly 5 2 Hex head screw M6 x 1 0 34 25 1 Charging System 90 8M00...

Page 320: ...use product damage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing inst...

Page 321: ...5 Reconnect both battery cables being certain to connect the negative cable last Serpentine Drive Belt WARNING Inspecting the belts with the engine running may cause serious injury or death Turn off...

Page 322: ...e used without seawater pump Without a seawater pump a Hole not used Sterndrive Models With a seawater pump a Alternator pulley b Water circulating pump pulley c Crankshaft pulley d Seawater pump pull...

Page 323: ...he front of the engine The decal shows the serpentine belt routing Refer to the decal when installing the serpentine belt The belt tensioner operates within the limits of movement provided by the cast...

Page 324: ...t and recharge in a ventilated area away from sparks or flames IMPORTANT The charging system may be damaged by Reversed battery cables Running the engine with the battery cables disconnected An open c...

Page 325: ...The meter should indicate the approximate battery voltage and should not vary If no reading is obtained or if the reading varies refer to Voltage Drop Test Alternator Circuit d If the reading is above...

Page 326: ...ctions 9 Start the engine and operate at 1300 1500 RPM A DMT reading of more than 0 5 volts indicates excessive resistance in the wiring Sensing and Excitation Circuits Perform the following tests to...

Page 327: ...ation b Purple and red pink connector c Ground terminal Battery Will Not Recharge Possible Cause Remedy Excessive current draw from battery Turn off non essential accessories Alternator drive belt loo...

Page 328: ...ry d Cranking battery e Engine ground Typical battery isolator with disconnect switch a Alternator sense wire b Battery isolator c Auxiliary battery d Battery disconnect switch e Cranking battery f En...

Page 329: ...ire c Port engine d Battery isolator e Battery disconnect switch f Port engine cranking battery g Starboard engine cranking battery h Engine ground 1 2 B O 1 2 B O b d f h b 50588 d h e e g a c Chargi...

Page 330: ...Charging System Notes Page 4C 16 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 331: ...ystem Link Gauge Connections 4D 14 System Link Gauge Extension Harness Installation 4D 14 Warning System 4D 14 Service Engine Light and OBD M MIL Kit 4D 14 Audio Warning System 4D 15 Guardian Strategy...

Page 332: ...lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure t...

Page 333: ...abrasive material for example sand saline or detergent compounds or washed with solvents such as trichloroethylene or turpentine Analog Gauges Gauge Lighting Options Some gauges Admiral and Flagship...

Page 334: ...ttery Analog Gauge Testing Oil Pressure Fuel Level and Coolant Temperature Gauges IMPORTANT A defective gauge must be replaced Repair is not available 1 Turn the ignition switch key switch to the OFF...

Page 335: ...e should match the voltage measured by the DMM If the values do not match replace the gauge Bench Testing If the gauge is disconnected from the boat s wiring the gauge may be checked with any known go...

Page 336: ...speedometer gauge pitot tube and compare the gauge readings to the specification Lightly tap the pressure gauge during the accuracy check 2 If the gauge readings are not within specifications replace...

Page 337: ...he SmartCraft gauges and displays It is also used by diagnostic tools such as CDS G3 There is one CAN P bus per boat regardless of the number of engines or helms Termination Resistors Termination resi...

Page 338: ...tions Use the proper length harness from the Y to the lower station Use the proper length harness from the Y to the upper station 25132 Y adapter for dual helm installations Boat Harness Installation...

Page 339: ...y switch verify that the drain hole in the barrel of the key switch is positioned downward for proper drainage For non DTS applications For dual helm installation a key switch is used at the upper and...

Page 340: ...rminals connected to momentary switch d Momentary switch Trim Switch The trim switch connection on the helm harness is only used on Mercury outboard remote controls MerCruiser models require a separat...

Page 341: ...ontinue to run An accessory relay kit connected to this location can provide up to 40 amps of accessory power The key switch will power up the relay in the accessory position and run position 25048 Re...

Page 342: ...n transom harness b Depth RS 485 c Boat harness tanks d 14 pin data harness e OBD M MIL light f 7A clean power Description Part Number Fuel tank auxiliary tank and paddle wheel harness 84 859743T03 Tr...

Page 343: ...Do not connect any other ground wires here Use the ground studs on the flywheel housing for other grounding needs NOTE In some cases a ground wire to connect to the flywheel housing may be attached to...

Page 344: ...ess Installation The System Link gauge extension harness comes in five lengths ranging from 15 cm to 9 1 m 6 in to 30 ft Install an extension harness anywhere in the System Link gauge series if you re...

Page 345: ...ds on the severity of the problem There are two warning horn states Caution Critical There is also an alarm that sounds if the helm has not been properly configured using the G3 service tool Caution I...

Page 346: ...d might not respond to throttle operation The PCM stores the fault for diagnostics For example if the water inlet becomes partially blocked Engine Guardian reduces the available power level of the eng...

Page 347: ...Instrumentation and Controls Notes 90 8M0099748 eng DECEMBER 2015 2016 Mercury Marine Page 4D 17...

Page 348: ...BLK BLU BLK GRN BLK GRN WHT RED LT BLU WHT TAN TAN BLK BRN PNK ORN PNK WHT ORN BLK GRN PPL BLK PPL BLK GRY RED BLK GRN BLK GRN PPL BLK YEL WHT GRN BLK BLU BLK RED RED LT BLU WHT GRN WHT 1 2 4 5 6 7 8...

Page 349: ...on over temperature sensor ground f Shift solenoid B g Shift solenoid A h Reverse pressure sensor i Forward pressure sensor S R P N M L K J H G F E D C B A GRA BLK PNK YEL GRN RED GRN PPL BLK GRA RED...

Page 350: ...r control or key switch connection 6 Lanyard outboard control E stop connection 7 Warning horn 8 Accessory relay connection 15 amp 9 Gauge connector CAN connector for SmartCraft 10 CAN P CAN 1 with re...

Page 351: ...used NOTE Outboard control E stop switch black and black yellow wires connects ground to ECM to stop engine The switch is normally open the circuit closes when the switch is activated Wires must be se...

Page 352: ...or to boat harness 2 Trim 3 Tach 4 Key on 5 Temp 6 Oil 7 Ground 8 CAN or spare 9 CAN or spare 10 12V 1 2 3 4 5 6 7 8 9 10 12312 1 2 3 4 5 6 7 8 9 10 RED RED DK_BLU DK_BLU WHT WHT BLK BLK LTBLU LTBLU T...

Page 353: ...som harness c Connections to trim limit switch a Connection to control box b Connection to transom harness c Connections to trim limit switch a b c 12323 b a C1 T2 T1 C2 DK BLU WHT DK BLU WHT PPL WHT...

Page 354: ...fuse s Trim bypass from transom harness YEL RED YEL RED TAN A B C D E F G H J K L M N P R S PPL BLK BLK GRN WHT ORN GRA RED YEL WHT ORN PNK BRN PNK BLK BLK BLU BLK GRN BLK GRN WHT RED LT BLU WHT BLK...

Page 355: ...olenoid q 20 amp fuse RED PPL BLU WHT GRN WHT A B C D E F G H J K L M N P R S PPL BLK BLK GRN WHT ORN GRA RED YEL WHT ORN PNK BRN PNK BLK BLK BLU BLK GRN BLK GRN WHT RED LT BLU WHT BLK BRN PNK ORN PNK...

Page 356: ...icate with the PCM112 controller at this time Refer to the following information when configuring the vessel or the engine using the CDS tool Configuring the PCM The computer diagnostic system CDS wil...

Page 357: ...teries for the main engine starting battery IMPORTANT Boating industry standards BIA ABYC etc federal standards and Coast Guard regulations must be adhered to when installing the battery Ensure that b...

Page 358: ...size requirements DO NOT USE WING NUTS 37 895387 3486 13 5Nm 120 lbs in Place decal on or near battery box for future service reference 5 16 and 3 8 hex nuts supplied for wing nut replacement Metric...

Page 359: ...sion Control Module PCM 4E 5 PCM 112 Controller 4E 5 PCM Removal and Installation 4E 5 Electrical System Overload Protection 4E 7 50 Amp Main Circuit Breaker 4E 7 Fuses 4E 8 Transom Harness 4E 10 Tran...

Page 360: ...diagnostics d 50 amp circuit breaker e J1939 diagnostic connection f Port precatalyst oxygen sensor connection g Port postcatalyst oxygen sensor connection h PCM 112 i Starboard postcatalyst oxygen s...

Page 361: ...View a Ignition coils 4 b Seawater pump pressure sensor c Hot stud d 90 amp fuse e Oil pressure sensor a a b c d 59413 e Electrical Components 90 8M0099748 eng DECEMBER 2015 2016 Mercury Marine Page...

Page 362: ...Port Side View a Fuel pump relays starter relay and main power relay b Trim relays c MerCathode a b c 59414 Electrical Components Page 4E 4 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 363: ...nd timing of the spark The PCM 112 also monitors information from various sensor inputs that include the following The throttle position sensor TPS The engine coolant temperature ECT sensor The manifo...

Page 364: ...on the side of PCM connector C and rotate the locking lever 90 or until it clicks Remove the connector from the PCM a PCM connector locking lever b Locking lever tab NOTE When reinstalling the connec...

Page 365: ...e bushings grommets washers and screws Tighten the screws to the specified torque Description Nm lb in lb ft PCM mounting screws 5 44 3 2 Connect and lock the electrical connectors to the PCM Do not t...

Page 366: ...th a higher current rating will not protect the circuit and components from overload Engine and Oxygen Sensor Fuses All of the engine protection fuses are located at the front of the engine To access...

Page 367: ...ttery connection a 20 amp spade fuse b 110 amp fuse Clean Power Fuse A power harness connected to the engine starting battery minimizes voltage drop to the electrical system This harness is protected...

Page 368: ...GRY RED YEL WHT ORN PNK BRN PNK BLK BLU BLK GRN BLK GRN WHT RED LT BLU WHT TAN TAN BLK BRN PNK ORN PNK WHT ORN BLK GRN PPL BLK PPL BLK GRY RED BLK GRN BLK GRN PPL BLK YEL WHT GRN BLK BLU BLK RED RED L...

Page 369: ...er temperature sensor ground f Shift solenoid B g Shift solenoid A h Reverse pressure sensor i Forward pressure sensor S R P N M L K J H G F E D C B A GRA BLK PNK YEL GRN RED GRN PPL BLK GRA RED WHT O...

Page 370: ...s BLK Black BLU Blue BRN Brown GRY or GRA Gray GRN Green ORN or ORG Orange PNK Pink PPL or PUR Purple RED Red TAN Tan WHT White YEL Yellow LT or LIT Light DK or DRK Dark Electrical Components Page 4E...

Page 371: ...l System Module 5A 9 Fuel System 5A 10 Fuel Delivery System 5A 10 Anti Siphon Valve 5A 10 Fuel Supply Module FSM 5A 10 FSM Removal 5A 10 FSM Disassembly 5A 11 FSM Assembly 5A 15 Throttle Body 5A 22 Th...

Page 372: ...perate the bilge blower or vent the engine compartment for at least five minutes WARNING Fuel is flammable and explosive Ensure that the key switch is off and the lanyard is positioned so that the eng...

Page 373: ...ine Engine damage resulting from the use of improper gasoline is considered misuse of the engine and will not be covered under the limited warranty Fuel Ratings Mercury MerCruiser engines will operate...

Page 374: ...ods Cars normally consume these blended fuels before they can absorb enough moisture to cause trouble boats often sit idle long enough for phase separation to take place Internal corrosion may occur d...

Page 375: ...e visible in the hose Appropriate sized barbed hose fitting Fuel pressure adapter 90 803135 from Mercury or other equivalent adapter Pressure relief collection tool a One gallon fuel can collection ta...

Page 376: ...fuel tank to the fuel system Follow the precautions in the appropriate Mercury MerCruiser Installation Manual for disconnecting the portable fuel tank and reconnecting the fuel line from the boat fuel...

Page 377: ...the cap 9 Wipe up any fuel that may have spilled 10 Ventilate the engine compartment 11 After priming the fuel system continue the engine preparation Refer to the appropriate Mercury MerCruiser Instal...

Page 378: ...base until they are finger tight Fuel inlet fittings or plugs should then be tightened an additional 1 3 4 to 2 1 4 turns using a wrench Do not overtighten To prevent fitting damage or overtightening...

Page 379: ...Clamp cover Fuel System Module a Water separating fuel filter b Fuel supply module c Manifold hose d Hose to fuel rail e Supply hose f Cooling hose g Hose to strainer assembly h g e f d c b a i 59421...

Page 380: ...he first installation of the engine to prevent problems later in connecting them to the engine To prevent chafing holes where the lines run through the bulkheads should be rounded off or protected wit...

Page 381: ...lways disconnect the negative battery cable first and connect it last 3 Loosen the clamp on the water hose to crossover and remove the hose a Water hose to crossover b To intake manifold vacuum line c...

Page 382: ...l the upper housing slightly to partially separate the upper housing from the lower housing 5 Insert two pry tools between the upper and lower housing and carefully separate the housing NOTE Use cauti...

Page 383: ...tion not to twist the fuel pumps when removing them Use a vice grip tool to clamp onto the manifold webbing and pull the manifold out of the upper housing a Manifold webbing 8 Remove the manifold from...

Page 384: ...el lift pump seal grommet 11 Remove three O rings and a spacer from the manifold a O rings b Spacer on fuel pressure regulator 12 Carefully spread the retainers and remove the fuel pressure regulator...

Page 385: ...using by pushing on the seal grommet from the outside of the upper housing with a blunt tool FSM Assembly 1 Install the O rings onto the water tubes and fuel tubes 2 Lubricate the O rings on the tubes...

Page 386: ...housing 49168 4 Install the water tubes a Water tube b Fuel tube 5 Install the seal grommet halfway onto the high pressure fuel pump outlet 49206 49199 a b MPI ECT Fuel System Page 5A 16 2016 Mercury...

Page 387: ...A 1 7 Install the seal grommet onto the fuel lift pump and lubricate with 2 4 C with PTFE 49214 Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Seal grommet 92 802859A 1 8 Install the fu...

Page 388: ...essed air to remove debris which may be blocking the hole Do not use wire or any ridged device that may damage the hole a Hole in manifold b O rings 14 Carefully install the manifold while aligning th...

Page 389: ...nstall the fuel pressure regulator onto the manifold 19 Install the spacer and O ring onto the fuel pressure regulator a O ring b Spacer 20 Install the seal grommet halfway onto the manifold 21 Insert...

Page 390: ...re from the upper housing to the positive terminal on the fuel lift pump 26 Connect the black wire from the upper housing to the negative terminal on the fuel lift pump 27 Connect the high pressure fu...

Page 391: ...osed the wires may be pinched or a seal grommet is not properly aligned 31 Install the screws and tighten the screws to the specified torque a No gap b Screw 4 Description Nm lb in lb ft Screw 10 88 5...

Page 392: ...rial from entering the engine Throttle Body Cleaning and Inspection IMPORTANT Do not use cleaners containing methyl ethyl ketone IMPORTANT Do not damage the adapter or throttle body when removing gask...

Page 393: ...battery can cause product damage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining...

Page 394: ...nector push the locking tab and rotate the lock as shown a Locking tab b ECM c Shift anticipate connector not used 6 2L d Neutral switch connector e Demand sensor harness c Disconnect the neutral swit...

Page 395: ...ector port side post O2 sensor connector and relays a Fuel pump relay b Starter relay c Main power relay d Trim relays e Transom harness f OBD M MIL light g Clean power connector h Cable ties g Remove...

Page 396: ...s tanks connectors m Remove the nut on the 14 pin data harness connector and remove the connector NOTE The 14 pin data harness connector may have to be rotated slightly after removing the retaining nu...

Page 397: ...rom pressurized fuel and vapors NOTE To release the fuel feed line push the blue release and pull off the fuel feed line a Fuel feed line b Release 9 Disconnect the remaining wiring harness from the i...

Page 398: ...connectors d Install the circuit breaker e Install the fuses 10 pin diagnostics connector and the J1939 diagnostic connection f Attach the wire harness to the PCM relay bracket with three cable ties g...

Page 399: ...RG Orange PNK Pink PPL or PUR Purple RED Red TAN Tan WHT White YEL Yellow LT or LIT Light DK or DRK Dark Fuel Injector Wiring Diagram 1 PCM connector A 2 Injector 6 3 Injector 8 4 Injector 4 5 Injecto...

Page 400: ...auge Kit 91 881833A03 Digital Pressure Meter 91 892651A01 5 Turn the key switch on to purge all of the air from the fuel pressure gauge line NOTE Turn the key switch on and off several times to purge...

Page 401: ...ze connector fittings undersize fuel shut off valve passages etc undersize fuel line or a malfunctioning anti siphon valve a Fuel tank b Clear hose can be used to check for air bubbles c T fitting d D...

Page 402: ...psi that has an accuracy of within 2 of the reading Cole Parmer P N P 68950 00 Note 1 1 Gauge guard 101 kPa to 103 kPa 30 in Hg to 15 psi Cole Parmer P N U 07359 02 Note 1 1 Gauge guard liquid 118 cc...

Page 403: ...se an incorrect gauge reading Fittings used to measure fuel temperature or Vacuum a From fuel supply b T fitting 6 35 mm 1 4 in c Water separating fuel filter d Pipe fitting 6 35 mm x 38 mm 1 4 in x 1...

Page 404: ...MPI ECT Fuel System Notes Page 5A 34 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 405: ...6A 7 Water Circulating Pump 6A 9 Removal 6A 9 Cleaning and Inspection 6A 10 Installation 6A 10 Air Actuated Drain System 6A 11 Air Manifold and Air Pump Exploded View 6A 11 General Information 6A 11 T...

Page 406: ...hich the boat is being operated Closed cooling systems use two cooling circuits one of which uses seawater similarly to standard cooing The second circuit uses a mixture of freshwater and coolant anti...

Page 407: ...qt or larger container near the unclamped end of the hose 3 With the assistance of another person start the engine and adjust the speed to exactly 1000 RPM while holding the unclamped end of the hose...

Page 408: ...ap on the heat exchanger Mount the heater lower than the fill cap of the heat exchanger and maintain the recommended coolant level Supply Hose Connection IMPORTANT For models with closed cooling the c...

Page 409: ...8 2 Blue drain plug with O ring Hand tight 9 1 M8 x 20 hex head flange screw 24 17 7 10 3 M8 x 35 hex head flange screw 24 17 7 11 1 Rear oil seal 12 1 Bearing shaft assembly 13 1 Retaining ring 14 1...

Page 410: ...t is to be reused it should be installed in the same direction of rotation as before 4 Install the serpentine drive belt Refer to Section 4C Serpentine Drive Belt NOTICE Without sufficient cooling wat...

Page 411: ...r grooves and replace as necessary 8 Inspect the pump impeller and replace it if any of the following conditions exist Wear on the ends and tips of the blades Cracks in the area where the blades flex...

Page 412: ...ler housing The end of the shaft with flat surfaces should extend into the impeller cavity Clean any assembly lube or oil from the forward end of the impeller housing 56786 Bearing shaft assembly 6 In...

Page 413: ...ng assembly onto the seawater pump cover 5 Apply Loctite 242 Threadlocker to the threads of the seawater pump cover screws Tube Ref No Description Where Used Part No 66 Loctite 242 Threadlocker Seawat...

Page 414: ...b Screws 3 c Water circulating pump d Gaskets 2 4 Install the water circulating pump pulley onto the water circulating pump and hand tighten the screws 5 Reconnect the hose to the water circulating pu...

Page 415: ...is uncovered that allows compressed air to flow back to the air manifold and cause the green indicator to extend The drains are closed by opening the manual release valve that releases the compressed...

Page 416: ...es from the air manifold Push in and hold the plastic ring around the air line and pull the air line out of the fitting a Plastic ring b Air line fitting c Air line Installation 1 Connect each pair of...

Page 417: ...system 2 Remove the seawater hoses from the check valve assembly 3 For models with standard cooling remove the check valve assembly from the manifold 4 Use a screwdriver to pry the drain fitting from...

Page 418: ...valve housing 12 1 Cover 13 2 M6 x 25 hex head flange screw 8 5 75 2 14 1 Poppet valve bracket 15 2 J clip 16 2 M6 x 12 hex head flange screw 8 5 75 2 Poppet Valve Operation A poppet valve is installe...

Page 419: ...lips Cleaning and Inspection NOTE For parts reference refer to the preceding exploded view 1 Remove the two screws from the poppet housing cover to remove the poppet valve subassembly 2 Carefully remo...

Page 420: ...lignment bracket Pull the drain rod straight up to remove a Drain rod with blue handle b C clip c Drain rod threads d Drain rod alignment bracket e Bracket for the water distribution housing f Water d...

Page 421: ...point drain a To obtain correct alignment leave the hoses disconnected from the water distribution housing during installation b Position the water distribution housing assembly to align with the dra...

Page 422: ...emain cylindrical The air line must not be distorted when cut The end of the air line must be within 1 mm 0 04 in of square a Using an air line cutter cut the bulk air line to the appropriate length a...

Page 423: ...tor air line connector 5 32 in d Lower water distribution housing air actuator air line connector 3 16 in e Upper air manifold assembly air line connector 5 32 in f Lower air manifold assembly air lin...

Page 424: ...All Models Notes Page 6A 20 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 425: ...s 6B 2 Crossover with Thermostat Exploded View 6B 2 Thermostat Assembly 6B 2 Thermostat Removal from the Crossover 6B 2 Thermostat Testing 6B 2 Thermostat Installation into the Crossover 6B 3 Models w...

Page 426: ...t housing gasket 11 2 Crossover seal 12 1 Temperature sensor 16 3 144 2 13 1 Barbed hose fitting 10 9 96 4 Thermostat Assembly Thermostat Removal from the Crossover 1 Allow the engine to cool and drai...

Page 427: ...in the crossover Ensure that it is positioned properly in the opening 3 Place the thermostat in the opening in the crossover with the thermostatic element end toward the bottom 4 Position a new thermo...

Page 428: ...Models with Standard Cooling Notes Page 6B 4 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 429: ...tions 6C 10 Maintaining Coolant Level 6C 11 Pressure Cap Maintenance and Testing 6C 11 Testing the Closed Cooling System 6C 12 Testing Coolant for Alkalinity 6C 12 Pressure Testing the System 6C 12 Se...

Page 430: ...Computer Diagnostic System Specifications Seawater Inlet Recommendations Description Specification Minimum flow 105 L min 27 3 gal min at 4000 RPM Minimum pressure at full flow If restrictions are pr...

Page 431: ...5 1 Air manifold bracket 6 1 Hex head stud 14 9 131 8 7 2 End cap 8 4 O ring 9 2 Flat seal 10 1 Blue vacuum release plug Hand tight 11 1 Purge valve 12 1 Pressure cap 13 1 Hex head cap screw 14 9 131...

Page 432: ...completely full If not there is a vacuum leak usually at the hose leaving the reservoir or the gasket under the recovery filler cap Within the heat exchanger the coolant antifreeze flows around the o...

Page 433: ...fer to Installing the Y Fitting Greater or less than 64 km h 40 mph Models operated above the 50th parallel of the Northern Hemisphere or below the 50th parallel of the Southern Hemisphere 30181 30180...

Page 434: ...nd quick connect fittings that meet MerCruiser specifications NOTE For models with quick connection fittings refer to Bravo Seawater Inlet Fitting Connection in Section 2B Through the Hull Seawater Pi...

Page 435: ...d be in an area that provides a solid air free flow of seawater under all operating conditions Avoid areas with a disturbed seawater flow such as those behind or in close proximity to the propeller Lo...

Page 436: ...lant Hose fitting threads and plastic plug threads 92 809822 116 RTV 587 Ultra Blue Silicone Sealer Sealing surfaces and screw shaft 92 809825 Seacock The American Boat and Yacht Council ABYC and othe...

Page 437: ...free location Do not mount the seawater strainer on the engine If not equipped with a seacock mount the seawater strainer above the seawater line to prevent seawater entry into the boat when servicing...

Page 438: ...er screws a Screws and washers b Cover with glass c Strainer d Housing e Drain plug and sealing washer f Seal 8 Open the seacock if equipped or remove the plug and reconnect the seawater inlet hose 9...

Page 439: ...evel should be up to the bottom of the heat exchanger filler neck If it is low examine the entire closed cooling section especially the coolant recovery system for leaks and make any necessary repairs...

Page 440: ...udden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns Allow the engine to cool down before removing the coolant pressure cap The coolant s...

Page 441: ...6124 2 Start the engine When the engine is at normal operating temperature shift into forward gear 3 Advance the throttle to 4000 RPM 4 Check the seawater pressure with G3 If seawater pressure does no...

Page 442: ...igher speeds 4000 RPM Normal operation is the same as described above A failed head gasket will cause the bubbles to come faster and may be accompanied by violent intermittent bursts of coolant Do not...

Page 443: ...pecified in Coolant Recommendations Change Intervals If the closed cooling system is factory installed drain and flush the coolant from the closed cooling system at least every five years or 1000 hour...

Page 444: ...upon heat transfer through the tubes within the heat exchanger During engine operation contaminants within the seawater such as salt silt or lime collect on the inside of the tubes reducing heat tran...

Page 445: ...recovery bottle Heat Exchanger Assembly Testing Internal Leaks An internal leak will allow coolant to enter into the seawater circuit when the closed cooling circuit is pressurized 1 Remove a seawater...

Page 446: ...Exchanger Repair IMPORTANT Braze with BCUP 2 rod or silver solder Do not melt the other joints during repair Internal leaks can be repaired by brazing shut the ends of the leaking tube This is only a...

Page 447: ...Connect the air lines to the air manifold by inserting the line into the fitting until a positive stop is encountered 6 Ensure that the air lines are installed properly a Attach the air pump to the f...

Page 448: ...Models with Closed Cooling Notes Page 6C 20 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 449: ...D 2 Models with Closed Cooling 6D 4 Seawater Circuit All Models with Closed Cooling 6D 4 Glycol Circuit TowSport V Drive 6D 6 Glycol Circuit Inboard V Drive 6D 8 Glycol Circuit Inboard In line 6D 10 G...

Page 450: ...els with Standard Cooling Bravo with Air Actuated Drain a b c d m i e g j l n o p q r p r l m f h k 60019 s x s w t v r u Water Flow Diagrams Page 6D 2 2016 Mercury Marine 90 8M0099748 eng DECEMBER 20...

Page 451: ...60 C 140 F thermostat o Exhaust manifold seawater inlet and drain p Exhaust and seawater outlet q Poppet valve assembly green r Exhaust elbow seawater inlet poppet valve closed s Exhaust manifold seaw...

Page 452: ...Models with Closed Cooling Seawater Circuit All Models with Closed Cooling 59995 Water Flow Diagrams Page 6D 4 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 453: ...Fuel supply module h Distribution housing i Heat exchanger j Poppet valve assembly k Check ball T fitting l Drain T fitting m Exhaust and seawater outlet n Exhaust elbow seawater inlet poppet valve c...

Page 454: ...Glycol Circuit TowSport V Drive b a c d e g g 60455 d e h Water Flow Diagrams Page 6D 6 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 455: ...water circulating pump e To crossover from engine block f Exhaust manifold coolant inlet g Exhaust manifold coolant outlet h Detail of rear of heat exchanger showing thermostat shaded NOTE Seawater ho...

Page 456: ...Glycol Circuit Inboard V Drive b a c d e g g 60455 d e h Water Flow Diagrams Page 6D 8 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 457: ...t g Exhaust manifold coolant outlet h Detail of rear of heat exchanger showing thermostat shaded NOTE Seawater hoses are not shown for clarity NOTE Inboard V Drive is the same as TowSport V Drive exce...

Page 458: ...Glycol Circuit Inboard In line h 59982 Water Flow Diagrams Page 6D 10 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 459: ...ater circulating pump e To crossover from engine block f Exhaust manifold coolant inlet g Exhaust manifold coolant outlet h Detail of rear of heat exchanger showing thermostat shaded NOTE Seawater hos...

Page 460: ...Glycol Circuit TowSport Reverse V Drive h 59982 Water Flow Diagrams Page 6D 12 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 461: ...coolant outlet h Detail of rear of heat exchanger showing thermostat shaded NOTE Seawater hoses are not shown for clarity NOTE TowSport reverse V Drive FWC is the same as the Inboard In line fresh wat...

Page 462: ...Water Flow Diagrams Notes Page 6D 14 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 463: ...alyst Health 7A 2 Measuring Engine Exhaust Elbow Height 7A 3 General Information 7A 3 Loading Requirements 7A 4 Loading the Boat Boats with a Capacity Plate 7A 4 Loading the Boat Boats without a Capac...

Page 464: ...xcept in special circumstances Refer to Section 1A Engine Oil for additional information NOTICE Acetoxy silicone sealants and other compounds can damage oxygen sensors and catalysts Use only compounds...

Page 465: ...e robust and accurate resulting in more precise fueling The sensor needs precise temperature control for accuracy Each sensor contains a heater controller and heater diagnostic chip Refer to PCM 112 D...

Page 466: ...uding boats that are 8 84 m 29 ft long that do not have a maximum rated swim platform weight capacity must add 181 45 kg 400 lb to the swim platform c Boats 8 84 m 29 ft long and greater than 8 84 m 2...

Page 467: ...e boat to the next row of seats until a person weight is loaded into each seat NOTE The total weight loaded onto the boat must not exceed the maximum capacity displayed on the capacity plate NOTE The...

Page 468: ...mber of persons that can sit on designated seating excluding cabin space MerCruiser person weight maximum passenger load for measurement Number of persons 165 lb MerCruiser person weight XXXX lb maxim...

Page 469: ...e number of passengers that can sit on designated seating excluding cabin space 24863 1 2 3 4 5 7 8 6 9 Designated seating diagram This example uses nine persons as the maximum passenger load NOTE Use...

Page 470: ...weight two d MerCruiser person weight three e MerCruiser person weight four f MerCruiser person weight five g MerCruiser person weight six h Aft storage i Center storage j Bow storage Clear Hose Measu...

Page 471: ...viously to fill the muffler with water IMPORTANT On engines equipped with more than one exhaust elbow perform the exhaust elbow waterline height measurement on the side that sits lower in the water 1...

Page 472: ...d c Exhaust distance flywheel housing to muffler 27 94 cm 73 66 11in 29in d Block machine surface for flywheel housing V Drive to sea pump pulley a Clear hose for measuring waterline b Minimum exhaust...

Page 473: ...IMPORTANT Horizontal waterlift mufflers are NOT permitted for use Important Information 90 8M0099748 eng DECEMBER 2015 2016 Mercury Marine Page 7A 11...

Page 474: ...Important Information Notes Page 7A 12 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 475: ...xhaust Elbow Removal 7B 7 Exhaust Elbow Installation 7B 8 Exhaust Manifolds 7B 10 Exhaust Manifold Removal 7B 10 Manifold Cleaning and Inspection 7B 12 Exhaust Manifold Installation 7B 12 Oxygen Senso...

Page 476: ...skets Gaskets with open water ports are used in seawater cooled systems Gaskets with blocked water ports are used in closed cooling systems Indicator tabs around the perimeter of the gasket allow easy...

Page 477: ...Manifolds and Elbows Notes 90 8M0099748 eng DECEMBER 2015 2016 Mercury Marine Page 7B 3...

Page 478: ...nifold and Elbow Exploded View 1 3 4 5 27 9 8 6 9 8 2 7 13 14 15 17 18 19 20 21 22 24 12 16 28 17 25 26 23 10 11 28 29 29 60035 Manifolds and Elbows Page 7B 4 2016 Mercury Marine 90 8M0099748 eng DECE...

Page 479: ...to manifold with open water ports seawater cooling 13 1 Gasket elbow to manifold with blocked water ports closed cooling 14 2 Brass pipe plug 0 25 8 15 1 Brass pipe fitting seawater cooling 0 750 4 5...

Page 480: ...nifold and Elbow Exploded View 1 3 4 5 27 9 8 6 9 8 2 7 13 14 15 17 18 19 20 21 22 24 12 16 28 17 25 26 23 10 11 28 29 29 60035 Manifolds and Elbows Page 7B 6 2016 Mercury Marine 90 8M0099748 eng DECE...

Page 481: ...Copper washer non ECT 8M0097283 102 mm 4 0 in Riser Kit for Emissions Control and Non ECT Exhaust Manifolds 8M0104210 Qty Description Part Number 1 Exhaust elbow port 102 mm 4 0 in 8M8027598 1 Exhaus...

Page 482: ...re sensor from the harness 7 Remove and retain the four fasteners securing the exhaust elbow to the manifold IMPORTANT Remove the exhaust elbow carefully to ensure that the catalyst does not fall from...

Page 483: ...non ECT models Install the oxygen sensor plug into the oxygen sensor port Tighten it to the specified torque Description Nm lb in lb ft Screws 0 375 16 x 2 5 hex flange head 1st Stage 46 1 34 2nd Sta...

Page 484: ...battery cables from the battery before maintaining servicing installing or removing engine or drive components 1 Disconnect both battery cables from the battery Be certain to disconnect the negative c...

Page 485: ...alve 5 Remove the oil filter mounting bracket bolts 6 Disconnect both oxygen sensors and the exhaust manifold coolant temperature sensor CAUTION To avoid the possibility of injury or component damage...

Page 486: ...material The passages must be clean for efficient cooling 3 Inspect all parts for damage or wear Repair or replace as necessary 4 To test the exhaust manifold use block off plates plugs or short hose...

Page 487: ...le lifting strap through the exhaust manifold as shown Attach the strap to a suitable hoist and move the manifold into position 59600 4 Attach the exhaust manifold to the cylinder head using the six m...

Page 488: ...ate elbow other models similar e Seawater bypass hose f Exhaust manifold coolant temperature sensor g Exhaust manifold mounting screws 6 Freshwater cooled a Exhaust hose shown attached to intermediate...

Page 489: ...models b Starboard postcatalyst O2 sensor ECT models only c Mounting screws two shown one hidden d Power steering reservoir bracket Description Nm lb in lb ft Oxygen sensor 50 36 8 12 Fill the closed...

Page 490: ...hten the screw to the specified torque Description Nm lb in lb ft Oxygen sensor cover bracket screw 11 6 102 6 3 Connect the sensor to the engine harness Exhaust Manifold Coolant Temperature EMCT Sens...

Page 491: ...Tridon Hose Clamp 7C 4 6 2L Exhaust 7C 4 Switchable Exhaust 7C 5 6 2L MIE Exhaust Installation 7C 5 TowSport Exhaust 7C 7 General Information 7C 7 Exhaust Angle Measurement 7C 8 Component Replacement...

Page 492: ...Exhaust System Components 1 3 5 6 7 8 9 10 4 2 4 2 56958 Exhaust Pipe and Through the Propeller Exhaust Page 7C 2 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 493: ...rmediate elbow kit 4 in riser 1 Intermediate elbow kit 6 in riser 4 8 Worm gear clamp see Note 4 4 7 35 4 41 6 5 2 Exhaust tube 6 1 Exhaust pipe 7 2 Water shutter assembly 8 4 Grommet 9 4 Screw 34 25...

Page 494: ...Exhaust system installation specifications Sterndrive models 11 in elbow height Static waterline height Switchable allowed Quick and Quiet baffles required for Corsa installation Inboard and TowSport...

Page 495: ...haust hose with the open end toward the engine Position the shutter assembly so that the rubber shutter is facing down Locate the shutter assembly no less than 66 04 cm 10 in after the elbow a 25 4 66...

Page 496: ...t and Yacht Council ABYC Society of Automotive Engineers SAE International Standards Organization ISO etc when designing and constructing the boat and other components such as the engine compartment f...

Page 497: ...bility of the boat manufacturer Any load distribution conditions that will affect the exhaust system must be clearly communicated to the operator in the owner s manual For example the number of people...

Page 498: ...oaded Refer to Loading Requirements Typical exhaust a Minimum 152 4 mm 6 in maximum 406 4 mm 16 in b Inclinometer c Exhaust hose or tube Typical muffler assembly a Hose b Hose clamps c Muffler d 88 9...

Page 499: ...RTANT Exhaust system connections to components other than those supplied by Mercury Marine must use two stainless steel clamps that are at least 13 mm in wide at each joint 1 Remove and retain the int...

Page 500: ...ose clamps Tighten the hose clamps to the specified torque a Exhaust tube b Exhaust Y pipe c Hose clamps Description Nm lb in lb ft Tridon hose clamp exhaust tube 4 4 7 35 4 41 6 c a c b 18530 Exhaust...

Page 501: ...13 Power Assisted Steering Pump Assembly 8A 14 Steering Pump Assembly Removal 8A 14 Steering Pump Assembly Installation 8A 15 Replacing the Belt and Adjusting Tension 8A 16 Power Assisted Steering Flu...

Page 502: ...system 92 858074K01 Special Tools Power Assisted Steering Pump Pulley Remover Obtain locally 18598 Removes the pulley on the power steering pump Pulley Pusher Installer 91 93656A 1 10047 Installs the...

Page 503: ...Power Assisted Steering Pump and Related Components Notes 90 8M0099748 eng DECEMBER 2015 2016 Mercury Marine Page 8A 3...

Page 504: ...s Exploded View 24 25 26 27 28 29 31 30 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17 18 19 20 21 22 23 30 57119 32 20 Power Assisted Steering Pump and Related Components Page 8A 4 2016 Mercury Marin...

Page 505: ...4 11 1 Clip 12 1 Reservoir to cooler hose 13 1 Power steering cylinder 14 2 Stainless steel screw 15 3 Screw 16 1 Bracket 17 1 Strap 18 1 Clevis pin 19 1 Clevis pin 20 2 Cotter pin 21 1 O ring 22 1 O...

Page 506: ...Hydraulic Diagrams Neutral g a b c d e f h 56916 Power Assisted Steering Pump and Related Components Page 8A 6 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 507: ...transom a Piston b Control valve c Power steering fluid cooler d Pump e Relief valve inside of the pump housing f Pump housing g High pressure h Low pressure Power Assisted Steering Pump and Related...

Page 508: ...Left Turn g h a b c d e f 56915 Power Assisted Steering Pump and Related Components Page 8A 8 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 509: ...transom a Piston b Control valve c Power steering fluid cooler d Pump e Relief valve inside of the pump housing f Pump housing g High pressure h Low pressure Power Assisted Steering Pump and Related...

Page 510: ...Right Turn a b c d e f h 56914 g Power Assisted Steering Pump and Related Components Page 8A 10 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 511: ...st be free of protruding hull structures through the hull fittings harnesses cables wires or any other obstructions between the TVM and transom to allow the steering cylinder a full range of motion Me...

Page 512: ...ower assisted steering pump assembly remains mounted to the engine WARNING Performing service or maintenance without first disconnecting the battery can cause product damage personal injury or death d...

Page 513: ...Trim and Steering Fluid Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power assisted steering pump shaft 92 858074K01 2 Start the pulley on the steering pump shaft a Ins...

Page 514: ...g engine or drive components CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system Always disconnect...

Page 515: ...emove the power assisted steering pump from the mounting brackets Steering Pump Assembly Installation IMPORTANT Do not cross thread or overtighten the hose fittings 1 Place the power assisted steering...

Page 516: ...rive Belt in Section 1C Power Assisted Steering Fluid Filling and Bleeding IMPORTANT Fill the power assisted steering system exactly as explained in the following procedure to ensure that all air is b...

Page 517: ...he straight ahead position and steering fluid must be hot for an accurate reading of the fluid level 11 Check the fluid level and add fluid as required to bring the level up to the FULL HOT mark on th...

Page 518: ...d or overtighten the hose fittings High Pressure Hose Pump to Control Valve Removal NOTICE Discharge of oil coolant or other engine drive fluids into the environment is restricted by law Use caution n...

Page 519: ...the fitting onto the power assisted steering pump assembly Tighten the fitting to the specified torque a High pressure hose O ring not shown Description Nm lb in lb ft High pressure hose fitting 31 2...

Page 520: ...ntainer to catch the fluid that drains from the pump and hoses 1 Note the routing of the return hose before removal 2 Loosen the hose clamp and remove the return hose from the fluid cooler a Return ho...

Page 521: ...se caution not to spill oil coolant or other fluids into the environment when using or servicing your boat Be aware of the local restrictions governing the disposal or recycling of waste and contain a...

Page 522: ...id cooler and secure it with hose clamps a Return hose and hose clamp 3 Install the return hose onto the control valve quick connect fitting located at the transom a Pressure hose b Return hose 4 Fill...

Page 523: ...control valve hose Power Steering Test Gauge Kit 91 38053A05 5 Completely open the valve on the power steering test gauge NOTICE Without sufficient cooling water the engine the water pump and other c...

Page 524: ...increase in pressure when the block is pushed in both directions 10 Push the steering cable in until the booster cylinder piston rod is fully retracted With the piston rod in this position push the st...

Page 525: ...ighest pressure reading attained during each cycle a If the pressure readings are 7932 8621 kPa 1150 1250 psi and are within 345 kPa 50 psi of each other then the pump is within specifications If the...

Page 526: ...Power Assisted Steering Pump and Related Components Notes Page 8A 26 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 527: ...el After the Initial Fill 8B 5 Checking Fluid Level 8B 5 Engine Warm 8B 5 Engine Cold 8B 6 Steering Circuit Component Diagram 8B 7 Connecting the Clevis 8B 7 Connecting the Hydraulic Hoses to the Tilt...

Page 528: ...ered steering wheel cannot be maintained with a hydraulic steering system For best results use an equal distance spoke steering wheel IMPORTANT This section will not guide you through installation of...

Page 529: ...t f Ensure that the steering cylinder assembly pivots freely g Tighten the pivot bolts to the specified torque Description Nm lb in lb ft Pivot bolts 33 24 h Bend the washer tabs against corresponding...

Page 530: ...ted steering pump 2 Add approved fluid to bring the level up to the FULL COLD mark on the dipstick IMPORTANT Use only Synthetic Power Steering Fluid SAE 0W 30 in the power assisted steering system Tub...

Page 531: ...Hoses to the Tilt Steering Helm Checking Fluid Level After the Initial Fill 1 Start the engine and operate it at fast idle 1000 1500 RPM until it reaches normal operating temperature During this time...

Page 532: ...g the level up to the WARM mark on the dipstick Do not overfill Tube Ref No Description Where Used Part No 138 Synthetic Power Steering Fluid SAE 0W 30 Power steering reservoir 92 858077K01 5 If fluid...

Page 533: ...ering cylinder helm connection L d Hose to steering cylinder helm connection R e Cooler to pump reservoir hose f Oil cooler g Union fitting 892527 h High pressure hose 8M2018435 power steering pump to...

Page 534: ...discard the shipping caps from ends of the four fittings on the steering helm Ensure the O ring seals did not lift off with the shipping caps 3 Ensure the O ring seals are in place on the end of the...

Page 535: ...in the filler tube is at the top of the plastic filler fitting Continue turning steering wheel clockwise turn more and then stop Close the bleeder valve 4 Remove the filler tube The fluid level shoul...

Page 536: ...ghten loose parts and replace badly worn parts Check the cylinder shaft for nicks and scratches Troubleshooting Guide Important Information When troubleshooting requires component removal from the ves...

Page 537: ...tion instructions If the problem cannot be rectified by changing the steering wheel proceed with next cause and solution or consult the factory Incorrect setting of trim tabs if equipped Adjust tabs i...

Page 538: ...Compact Hydraulic Steering Notes Page 8B 12 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 539: ...9A 6 Precautions 9A 6 45C and 63 In Line Transmissions 9A 6 Transmission and Propeller Rotation 9A 6 Transmission Fluid 9A 7 63A Down Angle and 63IV V Drive Transmissions 9A 10 Transmission Fluid 9A 1...

Page 540: ...Transmission input shaft splines and engine drive plate splines 8M0071842 Identification The transmission identification plate is located on the top rear of the transmission ZF Marine 45C a Identifica...

Page 541: ...44T2 2 1 1 863744T3 2 5 1 863744T4 63IV 1 55 1 863745T2 2 0 1 863745T3 2 5 1 863745T4 Fluid Specifications Listed capacities are approximate Always use the dipstick to determine the exact fluid level...

Page 542: ...Transmission and Related Parts 45IV 59766 ZF 45C 45IV 63A 65IV Transmissions Page 9A 4 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 543: ...45C DTS and 45C Mechanical 59767 45C DTS 59768 45C Mechanical ZF 45C 45IV 63A 65IV Transmissions 90 8M0099748 eng DECEMBER 2015 2016 Mercury Marine Page 9A 5...

Page 544: ...in an emergency never shift the transmission at engine speeds above 1000 RPM Freewheeling of one propeller in a twin engine boat at trolling speeds will not cause damage to the transmission However f...

Page 545: ...ement away from flywheel b Engine transmission input shaft shaft rotation direction LH c Transmission output propeller shaft rotation direction RH Transmission Fluid Checking IMPORTANT Always check th...

Page 546: ...he engine without fluid in the transmission Change the transmission fluid when servicing the transmission The transmission fluid change and filter service point is located on the bottom side of the tr...

Page 547: ...fraying Replace the damaged hoses 7 Inspect the seal for wear and replace it if necessary 8 Clean the filter element with Loctite 703 Fast Cleaner or equivalent Tube Ref No Description Where Used Part...

Page 548: ...luid level Add transmission fluid if necessary to bring the level up to the full mark on the dipstick 63A Down Angle and 63IV V Drive Transmissions Transmission Fluid Checking 1 Remove the dipstick IM...

Page 549: ...Use only the specified automatic transmission fluid a Dipstick b Threaded hole c Maximum fluid level d Minimum fluid level Tube Ref No Description Where Used Part No 28 Dexron III Automatic 63A and 6...

Page 550: ...in plug b Install and securely tighten the drain plug after the transmission is drained 5 Check the fluid for Metal particles A few small particles are normal Larger metal chips are an early sign of t...

Page 551: ...cal shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engine or drive components NOTICE Discharge of oil coo...

Page 552: ...sengage the splines on the input shaft 15 Carefully lift out the transmission Transmission Installation 1 Check the transmission output shaft rolling torque Refer to the manufacturer s service manual...

Page 553: ...s for B side shift solenoid and pressure transducer b Connect the transmission fluid temperature switch wiring connector a Wire connections b Fluid temperature switch 14 Check engine final alignment R...

Page 554: ...lb in lb ft Trunnion clamping fasteners on the engine mounts 68 50 2 17 Refill the transmission with the specified fluid Refer to Filling 18 Connect and adjust the shift cables Refer to Shift Cable In...

Page 555: ...d remove the fluid temperature switch from port B 4 Install a thermocouple in port B Typical ZF Marine transmission a Pressure service port plug port A b Fluid temperature switch port B 5 Operate the...

Page 556: ...ter 63A and 63IV Parker Hannifin M10 1 8F8OHG 45C Parker Hannifin M14 1 8F8OHG 11 Install the pressure service port plug and tighten securely 12 Connect the two fluid temperature switch wires Apply Li...

Page 557: ...Color Diagrams Table of Contents 6 2L Mechanical Wiring Diagram Non DTS 10A 4 6 2L DTS Wiring Diagram 10A 5 Wire Color Code Abbreviations 10A 6 Color Diagrams 90 8M0099748 eng DECEMBER 2015 2016 Merc...

Page 558: ...Notes Color Diagrams Page 10A 2 2016 Mercury Marine 90 8M0099748 eng DECEMBER 2015...

Page 559: ...Notes Color Diagrams 90 8M0099748 eng DECEMBER 2015 2016 Mercury Marine Page 10A 3...

Page 560: ...24 Main relay 25 Starter fuse 26 Starter fuse to the 50 amp circuit breaker 27 CAN resistor 28 Alternator excite circuit 29 Camshaft position sensor 30 Electronic throttle control ETC 31 Crankshaft p...

Page 561: ...BLK TAN PPL RED YEL GRN PPL RED YEL GRN YEL RED YEL GRN RED RED YEL GRN BRN BLK ORN BRN WHT BLU BRN BLK BLK BLU WHT WHT BLU PPL BRN BLU LT GRN RED ORN BLU ORN BLU BLK ORN ORN GRA RED WHT RED WHT ORN B...

Page 562: ...A RED WHT ORN BLK GRN LT BLU WHT BLK BRN PNK PPL BLK PPL YEL BLK ORN TAN ORN GRA BLU BLK GRN PPL BLK PNK BLK TAN PPL WHT GRN PPL YEL RED YEL GRN PPL RED YEL GRN YEL RED YEL GRN RED RED YEL GRN BRN BLK...

Page 563: ...rter relay 25 Main power relay 26 Starter fuse 27 Starter fuse to the 50 amp circuit breaker 28 Alternator excite circuit 29 Camshaft position sensor 30 Electronic throttle control ETC 31 Crankshaft p...

Page 564: ...ions BLK Black BLU Blue BRN Brown GRY or GRA Gray GRN Green ORN or ORG Orange PNK Pink PPL or PUR Purple RED Red TAN Tan WHT White YEL Yellow LT or LIT Light DK or DRK Dark Color Diagrams Page 10A 6 2...

Page 565: ......

Page 566: ...Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mercury Marine All rights reserved Printed in U S A 90 8M0099748 DECEMBER 2015 6 2L Mercury Mer...

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