Complete workshop repair service manual with electrical wiring diagrams for Mercruiser/Mercury Racing Outboard Engines. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Mercruiser/Mercury Racing Outboard Engines service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

MAKE: Mercury
YEAR: 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2003 2004 2005 2006 2007 2008
MODEL: Mercruiser & Mercury Racing (Sterndrive) Marine Engine

MERCRUISER AND MERCURY RACING (STERNDRIVE) OUTBOARDS SERVICE MANUAL INDEX
 00 Index.pdf
 01. 1963-1973 Engines & Drives (#9068648).pdf
 02. 1974-1977 Engines, Drives & Jet Drive 400 (#9071707).pdf
 03. 1978-1984 Engines.. 4-Cylinder, L6 &V8 (#9095693R1).pdf
 04. 1978-1982 Sterndrives.. MC 120 to 260 (#9086137).pdf
 05. 1978-1993 Sterndrives.. TR & TRS (#9012935).pdf
 06. 1983-1990 Sterndrives.. R, MR, Alpha One & Alpha One SS (#90129342).pdf
 07. 1983-1993 Engines.. GM V6 (#9012410).pdf
 08. 1985-1999 Engines.. MM 4-Cylinder (#9044553R2).pdf
 09. 1985-1988 Engines.. GM V8 (#9014499R1).pdf
 10. 1985-1989 Engines.. GM 4-Cylinder (#90146931R1).pdf
 11. 1988-1998 Sterndrives.. Bravo (#90174314).pdf
 13. 1990-1997 Engines.. GM 4-Cylinder (#90816462R2).pdf
 14. 1991-2008 Sterndrives.. Alpha One Gen II (#908181773).pdf
 15. 1989-1992 Engines.. GM V8 (#90816463).pdf
 16. 1993-1997 Engines.. GM V8 454cid & 502cid (#908232242).pdf
 17. 1993-1997 Engines.. GM V8 5.0L, 454cid & 502cid (#908232251).pdf
 18. 1993-1997 Engines.. GM V6 Gen II Balance Shaft (#908232261).pdf
 22. 1997-2008 Engines.. D-Tronic 2.8L & 4.2L (DI) Diesel (#908600741).pdf
 23. 1998-2001 Engines.. GM V8 Gen VI & L29 (454cid & 502cid) (#908613261).pdf
 24. 1998-2001 Engines.. GM V8 305cid & 350cid (#908613271).pdf
 24-S. 2000-2001 Engines.. GM V8 377cid (6.2L) (Supplement to #24) (#90861327000).pdf
 25. 1998-2001 Engines.. GM V6 262cid (4.3L) (#908613281).pdf
 26. 1998-2001 Engines.. GM 4-Cylinder 181cid (3.0L) (#908613291).pdf
 27. 1998-2002 Engines.. V8 D7.3L D-Tronic (DI) Diesel (#90861784).pdf
 27-S. 1998-2002 Engines.. V8 D7.3L D-Tronic, D-Tronic LD (DI) Diesel (#90861784990).pdf
 28. 2000-2005 Sterndrives.. Bravo 1-2-3 & XZ-XR and Sport Master (#908631601).pdf
 29. 2000-2008 Engines.. Sterndrive D1.7L DTI In-Line Diesel (#90863016).pdf
 30. 2000-2008 Engines.. 496cid (8.1L) Gasoline Engine (#90863161).pdf
 31. 2001-2008 Engines.. 305cid (5.1L), 350cid (5.7L) & 377cid (6.2L) (#90864260001).pdf
 32. 2001-2008 Engines.. Sterndrive 4.3L MPI (#90864261).pdf
 33. 2001-2008 PCM 555 Diagnostics (#90863757002).pdf
 36. 2006-2008 ECM 555 Diagnostics (#90864573001).pdf
 37. 2002-2008 Engines.. Dry Joint Exhaust System (Supplement to #31) (#90864260020).pdf
 40. 2004-2008 Engines.. Gen III Cool Fuel (Supplement to #30, #31) (#90865376).pdf
41. 2004-2008 Engines.. Turn Key Start (TKS) Carburetors (Supplement to #25, #26, & #31) (#90866202).pdf
90-8M0082470 - 200/225/250/275/300 250 & 300 Pro 300 CCT Verado FourStroke Service Manual (2005&up).pdf

90-8M0082470 - 200_225_250_275_300 250 & 300 Pro 300 CCT Verado FourStroke Service Manual (2005&up)...3
  cover...3
    notice.pdf...0
      Notice to Users of This Manual...4
      Precautions...4
      Replacement Parts...5
      Cleanliness and Care of Product...5
      Manual Outline...6
  1A...8
    Section 1A - Master Specifications...8
      Table of Contents...8
      200/225/250/275/300 Verado Master Specifications...9
        General Specifications...9
        Fuel System Specifications...10
        Ignition Specifications...10
        Charging and Starting Specifications...11
        Cylinder Head Specifications...12
        Cylinder Block/Crankcase Specifications...13
        Power Trim Specifications...13
        Oil System Specifications...14
        Gear Housing Specifications (Standard Rotation)...14
        Gear Housing Specifications (Counter Rotation)...15
        Gear Housing Specifications–5.44 in. Diameter Gearcase Torpedo...15
        Power Steering Specifications...16
      Propeller Chart...16
        Mercury/Mariner 200 (6 Cyl., FourStroke) with 4.8 in.  Gearcase Torpedo...16
        Mercury/Mariner 225 (6 Cyl., FourStroke) with 4.8 in.  Gearcase Torpedo...18
        Mercury/Mariner 225 (6 Cyl., FourStroke) with 5.44 in.  Gearcase Torpedo...20
        Mercury/Mariner 250 (6 Cyl., FourStroke) with 4.8 in.  Gearcase Torpedo...21
        Mercury/Mariner 250 Pro (6 Cyl., FourStroke) with 4.8 in.  Gearcase Torpedo...23
        Mercury/Mariner 250 (6 Cyl., FourStroke) with 5.44 in.  Gearcase Torpedo...25
        Mercury/Mariner 275 (6 Cyl., FourStroke) with 4.8 in.  Gearcase Torpedo...27
        Mercury/Mariner 300 (6 Cyl., FourStroke) with 4.8 in.  Gearcase Torpedo...29
        Mercury/Mariner Pro 300 (6 Cyl., FourStroke) with 4.8 in.  Gearcase Torpedo...30
        Mercury/Mariner 300 (6 Cyl., FourStroke) with 5.44 in.  Gearcase Torpedo...32
        Mercury/Mariner 300 HD (6 Cyl., FourStroke) with 5.44 in.  Gearcase Torpedo...34
  1B...38
    Section 1B - Maintenance...38
      Table of Contents...38
      Outboard Care...40
        Selecting Replacement Parts For Your Outboard...40
      EPA Regulations...40
      EPA Emissions...40
        Emission Certification Label...40
        Owner Responsibility...40
      Inspection and Maintenance Schedule...40
        Before Each Use...40
        After Each Use...40
        Every 100 Hours of Use or Once Yearly, Whichever Occurs First...41
        Every 300 Hours of Use or Three Years...41
        Before Periods of Storage...41
      Flushing the Cooling System...41
      Cowl Removal and Installation...42
        Cowl Removal...42
        Cowl Installation...42
      Exterior Care...43
        Cleaning Care for Top and Bottom Cowls...43
        Cleaning Care for the Powerhead in Saltwater Use...43
      Battery Inspection ...43
      Verado Engine Battery Specifications...44
      Air Filter...45
        Air Filter Removal and Cleaning...45
        Air Filter Installation...46
      Closed Compartment Technology...46
        Cowl Removal and Installation...46
          Air Duct Removal...46
          Cowl Removal...47
          Cowl Installation...47
          Air Duct Installation...48
        Idle Relief Hose Connection...49
          Removal...49
          Installation...50
        Intake Air Filter...50
          Air Filter Removal...50
          Air Filter Installation...50
        K & N Air Filter Maintenance...51
        Flushing the Cooling System...51
      Fuel System...51
        Fuel Line Inspection...51
        Water Separating Fuel Filter...51
          Filter Removal...51
          Filter Draining...53
          Filter Installation...53
      Corrosion Control Anode...53
      Propeller Replacement...54
      Spark Plug Inspection and Replacement...55
      Fuses...56
      DTS Wiring System...57
      Accessory Drive Belt Inspection...57
      Checking Power Trim Fluid...57
      Checking Power Steering Fluid...58
      Checking and Adding Engine Oil...58
      Changing Engine Oil ...59
        Engine Oil Capacity...59
        Pump Method...59
        Drain Method...59
        Changing Oil Filter ...60
        Oil Filling...60
      Gearcase Lubrication...61
...
  4A...366
    Section 4A - Cylinder Block/Crankcase...366
      Table of Contents...366
      Cylinder Block/Crankcase Specifications...367
      Port Cylinder Block Components...371
      Starboard Cylinder Block/Oil Cooler (S/N 1B830815 and Below)...373
      Starboard Cylinder Block/Oil Cooler (S/N 1B830816 and Above)...377
      Cylinder Block Components...381
      Crankshaft, Piston, and Connecting Rod Components (Design I)...383
      Crankshaft, Piston, and Connecting Rod Components (Design II)...385
      Powerhead Removal...387
      Removing Powerhead Components...398
        Engine Harness Bracket...398
        Integrated Oil Module (IOM)...399
        Starter...400
        Purge Line...401
        Induction System...401
        Alternator Support Bracket and Knock Sensor...406
        Injector/Coil Harness...406
        Oil Pressure/Temperature Sensor...407
        Electrical Box...407
        Thermostat Housing...408
          Thermostat Removal...408
        Ignition Coil...409
      Powerhead Disassembly...409
        Cylinder Head Removal ...409
        Flywheel...412
        Crankcase and Crankshaft Disassembly/Removal...413
      Cleaning, Inspection, and Repair...415
        Measuring Cylinder Bore...415
        Measuring Piston...416
          Piston Diameter...416
          Piston Ring Groove...417
          Piston Ring Side Clearance...417
          Piston Ring End Gap...417
          Piston Wrist Pin Diameter...418
          Piston Wrist Pin...418
        Measuring Connecting Rod ...419
        Measuring Crankshaft...419
          Crankshaft Runout...419
          Crankshaft Main Bearing and Crankpin Measurement...420
      Powerhead Assembly...420
        Powerhead Preassembly Cleaning Recommendations...420
        Installing Water and Oil Jacket Plugs...420
        Selecting New Crankshaft Bearings...421
        Crankshaft Main Bearing Grade Selection...422
      Piston/Connecting Rod Assembly...423
        Connecting Rod Bearing Grade Selection...423
        Piston Ring Installation...425
        Piston Assembly Installation...427
      Cylinder Head Installation...429
        Timing Chain...432
      Installing the Upper Crankshaft Seal...436
        Preparation...436
        New Crankshaft Installation...437
        Original Crankshaft Installation...438
      Installing Powerhead Components...439
        Ignition Coil...439
        Crankshaft Position Sensor Installation...439
        Flywheel Installation...440
        Thermostat...441
          Thermostat Installation...441
        Thermostat Housing Installation...442
        Electrical Box...442
        Oil Pressure/Temperature Sensors...443
        Injector/Coil Harness...444
        Alternator Support and Knock Sensors...445
        Induction System...446
        Purge Line...451
        Starter...452
         Integrated Oil Module (IOM)...453
        Engine Harness Bracket...454
        Alternator...455
        Alternator/Supercharger Belt...456
        After Servicing Engine...456
        Dressed Powerhead Installation...459
  4B...474
    Section 4B - Cylinder Head...474
      Table of Contents...474
      Cylinder Head Specifications...475
      Cylinder Head Components (S/N 1B517433 and Below)...477
      Cylinder Head Components (S/N 1B517434–1B733951)...481
      Cylinder Head Components (S/N 1B733952 and Above)...485
      Cylinder Head Service Recommendations...489
      Cylinder Head Disassembly...489
        Camshaft Removal...489
        Valve Removal...489
        Cylinder Head Galley Plug Removal...490
      Cleaning/Inspection/Repair  ...491
        Camshaft...491
        Valves...492
        Valve Springs...493
        Cylinder Head...493
        Valve Guides...493
          Valve Guide Replacement...494
        Valve Seat Reconditioning...494
      Cylinder Head Reassembly...495
        Cylinder Head Galley Plug Installation...495
        Valves...495
        Cams...497
      Valve Clearance and Adjustments...498
        Valve Clearance Measurement Steps...498
        Changing Valve Clearance...498
  4C...500
    Section 4C - Lubrication...500
      Table of Contents...500
      Oil System Specifications...501
      Starboard Cylinder Block/Oil Cooler (S/N 1B830815 and Below)...503
      Starboard Cylinder Block/Oil Cooler (S/N 1B830816 and Above)...507
      Oil Pump and Adapter Plate Components (S/N 1B517433 and Below)...511
      Oil Pump and Adapter Plate Components (S/N 1B517434 and Above)...513
      Engine Guardian System...515
        Low Oil Pressure, Engine Guardian...515
      Oil Pump Removal  ...515
      Oil Pump Installation...516
      Integrated Oil Module (IOM)...518
        IOM Removal...518
        IOM Disassembly...518
        IOM Assembly...519
        IOM Installation...521
  5A...522
    Section 5A - Pedestal/Mount Cradle and Driveshaft Housing...522
      Table of Contents...522
      Mount Cradle Components...525
      Pedestal/Power Trim/Steering Cylinder Components...527
      Driveshaft Housing Components (S/N 1B229697 and Below)...531
      Driveshaft Housing Components (S/N 1B229698 and Above)...533
      Top Cowl Components...535
      CCT Top Cowl Components...537
      Rear Cowl Components...539
      CCT Rear Cowl Components...541
      Cowl Latching Components...543
      CCT Rigging Components...545
      Water Poppet Removal/Installation...547
        Removal and Disassembly...547
        Reassembly and Installation...547
      Midsection Disassembly...549
        Preparing Outboard for Midsection Disassembly...549
        Fuel Supply Module (FSM)...549
        Hoses and Harnesses...550
        Driveshaft Housing...551
        Pedestal...552
          Mount Cradle Removal...552
          Power Trim System Removal...553
          Pedestal Bearings and Seals...554
          Steering Tube...556
        Mount Cradle...556
          Cowl Latches...556
          Seal...557
          Rear Motor Mounts...557
          Tilt Lock...557
      Midsection Assembly...560
        Mount Cradle...560
          Rear Motor Mounts...560
          Tilt Lock...560
          Seal...563
          Adapter Plate...563
        Pedestal...563
          Steering Tube...563
          Bearings and Seals...564
          Power Trim System...566
          Mount Cradle  Tilt Pin...568
          Cowl Side Latches...569
          Power Trim Harness...569
          Trim Cylinder Rod Ends...570
        Hoses and Harnesses...570
        Driveshaft Housing...571
        Fuel Supply Module (FSM)...572
        Completing Mid-Section Reassembly...574
  5B...576
    Section 5B -  Adapter Plate...576
      Table of Contents...576
      Upper Shift Components...579
      Oil Pump/Adapter Plate - Upper Components (S/N 1B517433 and Below)...581
      Oil Pump/Adapter Plate - Upper Components (S/N 1B517434 and Above)...585
      Adapter Plate - Lower Components...589
      Adapter Plate Hose Routings Components...591
      CCT Adapter Plate Hose Routings Components...593
      CCT Idle Exhaust Relief Hose Routing...595
      Adapter Plate Disassembly...595
        Preparing Outboard for Adapter Plate Disassembly...595
        Exhaust Tube and Oil Sump...595
          Adapter Plate...596
        Lower Components...596
        Removing from Mount Cradle...596
        Front Bracket Disassembly...598
        Upper Components...600
        Oil Pump...602
        Driveshaft Seals...602
      Adapter Plate Reassembly...602
        Dowel Pins and Plugs...602
        Driveshaft Seals...603
        Oil Pump...604
        Upper Components...604
        Front Bracket Reassembly...606
          Motor Mounts...606
          Grommets and Bushings...607
          Mounting...607
          Shift Components...608
        Adapter Plate to Mount Cradle Seal...609
        Installing in Mount Cradle...611
        Lower Components...613
        Exhaust Tube/Oil Sump...614
        Completing Outboard Adapter Plate Reassembly ...616
  5C...618
    Section 5C - Power Trim...618
      Table of Contents...618
      Power Trim Specifications...619
      Power Trim System Components...621
      Power Trim Cylinder Components...623
      Pressure Operated Check Manifold Components...624
      Power Trim and Tilt...624
        Power Trim Operation...625
        Tilting To Full Up Position...625
          Tilt At Helm...625
          Tilt At Engine...625
        Trailering Boat/Outboard ...626
        Manual Tilting...627
        Auxiliary Tilt Switch...627
        Shallow Water Operation...627
      Check Fluid and Purge the Power Trim System...628
        Checking Power Trim Fluid...628
        Purging Power Trim System...628
      Theory of Operation...629
        Power Trim Hydraulic Diagram...629
        Operation...630
          Trim Circuit - Up...630
          Trim Circuit - Down...630
          Trail Over System...630
      Troubleshooting the Power Trim System...630
        Preliminary...630
        Hydraulic System Troubleshooting...631
          Condition/Problem...631
          Problem/Solution...631
        Testing Power Trim System...631
          Install Test Gauge Adapter Fitting for Up Pressure Test...631
          Up Pressure Circuit Test...633
          Install Test Gauge Adapter Fitting for Down Pressure Test...634
          Down Pressure Circuit Test...635
        Electrical System Troubleshooting...636
          General Checks...636
          Condition/Problem...636
          Problem/Solution...636
          Power Trim Relay Test Procedure...636
          Power Trim Electrical  Circuit...639
          Troubleshooting the Down Circuit...640
          Troubleshooting the Up Circuit...640
          Troubleshooting the Down and Up Circuits (All Circuits Inoperative)...641
          Trim Position Sensor...642
          Troubleshooting the Trim Position Circuit...642
          Trim Position Senor Resistance Table...644
          Breakout Box Connections...644
          Trim Position Sensor Location...644
      General Service Recommendations...644
        Seals...645
      Power Trim System...645
        Power Trim System Removal...645
          Power Trim Harness...645
          Trim Cylinder Rod Ends...646
          Power Trim Assembly...647
        Power Trim System Installation...648
          Power Trim Harness...650
          Trim Cylinder Rod Ends...651
          Purging the Power Trim System...653
      Power Unit...653
        Power Unit Disassembly...653
          Draining the System...654
          Reservoir...654
          Pump and Filter...656
        Power Unit Reassembly...656
          Pump and Filter ...657
          Trim Motor...657
          Reservoir...658
          Filling and Purging System...659
      Trim Cylinder and Pivot Pin...660
        Trim Cylinder and Pivot Pin Removal...660
          Disassembly...660
        Trim Cylinder Disassembly...662
          Cylinder Rod...662
          Shock Piston...662
          End Cap...664
          Memory Piston...665
        Trim Cylinder Reassembly...665
          Memory Piston...665
          End Cap...666
          Shock Piston and Cylinder Rod...667
        Trim Cylinder and Pivot Pin Installation...669
          System Installation...671
      Pressure Operated Check Manifold ...672
        Manifold Disassembly...672
          Removing and Draining the Power Trim System...672
          Manual Release Valve...672
          Pressure Operated Check Valve...672
        Manifold Reassembly...673
          System Installation...674
  6A...676
    Section 6A - Right-Hand Rotation (4.8 in. Diameter)...676
      Table of Contents...676
      Gear Housing Specifications (Standard Rotation)...677
      Gear Housing (Driveshaft)...683
      Gear Housing (Propeller Shaft) (Standard Rotation)...687
      General Service Recommendations...690
        Bearings...690
        Shims...690
        Seals...690
      Gearcase Removal...690
      Gearcase Serviceability Inspection...692
        Draining and Inspecting Gear Housing Lubricant...692
        Propeller Shaft Inspection...693
      Water Pump...693
        Removal and Disassembly...693
        Cleaning and Inspection...694
      Oil Seal Carrier Assembly...695
        Removal...695
        Disassembly...695
        Reassembly...696
      Bearing Carrier and Propeller Shaft...697
        Cleaning/Inspection...699
        Disassembly...700
        Assembly...701
      Driveshaft Assembly...704
        Removal...704
        Disassembly...707
        Inspection...707
        Assembly...708
      Propeller Shaft Assembly and Forward Gear Bearing Cup...709
        Removal...709
        Component Disassembly...710
        Inspection...711
      Forward Gear Assembly...712
        Component Inspection...712
        Disassembly...712
        Assembly...714
      Shift Spool Assembly...714
        Inspection...714
        Disassembly...715
        Reassembly...715
      Propeller Shaft Reassembly...716
      Shift Shaft Assembly...717
        Removal...717
        Disassembly and Inspection...717
        Assembly...718
      Pinion Bearing Removal...720
      Gear Housing Inspection...720
      Pinion Bearing Installation...721
      Forward Bearing Cup...722
        Installation...722
      Shift Shaft Installation...722
      Propeller Shaft Installation...723
      Driveshaft and Pinion Gear Installation...724
      Pinion Gear Height...726
        Checking and Adjusting Using Pinion Gear Locating Tool 91-56048001...726
        Checking and Adjusting using Pinion Gear Locating Tool 91-12349A05...727
      Forward Gear Backlash...728
      Reverse Gear Backlash...730
      Propeller Shaft Bearing Preload...731
      Bearing Carrier Final Installation...733
      Oil Seal Carrier Installation...734
      Water Pump Installation...735
      Checking Gearcase Operation...737
      Gear Lubricant Filling Instructions...737
      Installing Gear Housing to Driveshaft Housing...737
  6B...740
    Section 6B - Left-Hand Rotation (4.8 in. Diameter)...740
      Table of Contents...740
      Gear Housing Specifications (Counter Rotation)...741
      Gear Housing (Driveshaft)...747
      Gear Housing (Propeller Shaft) (Counter Rotation)...751
      General Service Recommendations...754
        Bearings...754
        Shims...754
        Seals...754
      Gearcase Removal...754
      Gearcase Serviceability Inspection...756
        Draining and Inspecting Gear Housing Lubricant...756
        Propeller Shaft Inspection...757
      Water Pump...757
        Removal and Disassembly...757
        Cleaning and Inspection...758
      Oil Seal Carrier Assembly...759
        Removal...759
        Disassembly...759
        Reassembly...760
      Bearing Carrier and Propeller Shaft...761
        Removal...761
        Cleaning/Inspection...763
        Disassembly...764
        Assembly...767
      Driveshaft Assembly...770
        Removal...770
        Disassembly...773
        Inspection...773
        Reassembly...774
      Propeller Shaft Assembly and Reverse Gear Bearing Cup...775
        Removal...775
        Disassembly...776
        Inspection...776
      Reverse Gear Assembly...777
        Inspection...777
        Disassembly...778
        Assembly...779
      Shift Spool Assembly...779
        Inspection...779
        Disassembly...780
        Reassembly...780
      Propeller Shaft Reassembly...781
      Shift Shaft Assembly...782
        Removal...782
        Disassembly and Inspection...782
        Assembly...783
      Pinion Bearing Removal...784
      Gear Housing Inspection...785
      Pinion Bearing Installation...786
      Reverse Gear Bearing Cup...787
        Installation...787
      Shift Shaft Installation...787
      Propeller Shaft Installation...789
      Driveshaft and Pinion Gear Installation...789
      Pinion Gear Height...792
        Checking and Adjusting using Pinion Height Tool 91-56048001...792
        Checking and Adjusting using Pinion Gear Locating Tool 91-12349A05...793
      Bearing Carrier Installation...794
      Reverse Gear Backlash...794
      Forward Gear Backlash...796
      Propeller Shaft Bearing Preload...797
      Bearing Carrier Final Installation...798
      Oil Seal Carrier Installation...799
      Water Pump Installation...800
      Checking Gearcase Operation...802
      Gear Lubricant Filling Instructions...802
      Installing Gear Housing to Driveshaft Housing...803
  6C...806
    Section 6C - Right-Hand and Left-Hand Rotation (5.44 in. Diameter)...806
      Table of Contents...806
      Gear Housing Specifications...807
      Gear Housing Components...815
        Gear Housing (Driveshaft)...815
        Gear Housing (Propeller Shaft)...819
      General Service Recommendations...821
        Bearings...821
        Shims...821
        Seals...821
      Gearcase Serviceability Inspection...821
        Draining and Inspecting Gear Housing Lubricant...821
        Propeller Shaft Inspection...822
      Gearcase Removal...823
      Water Pump Removal...825
        Removal and Disassembly...825
        Cleaning and Inspection...825
      Oil Seal Carrier Assembly...826
        Removal...826
        Disassembly...826
      Bearing Carrier and Propeller Shaft...827
        Cleaning/Inspection...829
        Disassembly...831
        Assembly...833
      Driveshaft Removal, Inspection, Disassembly, and Assembly...836
        Driveshaft Removal...836
        Driveshaft Inspection...838
        Driveshaft Disassembly...839
        Driveshaft Assembly...839
      Propeller Shaft Assembly and Front Gear Bearing Cup...841
        Removal...841
        Component Disassembly...842
        Inspection...843
      Front Gear Assembly...844
        Component Inspection...844
        Disassembly...844
        Assembly...845
      Shift Spool Assembly...846
        Inspection...846
        Disassembly...846
        Reassembly...847
      Propeller Shaft Assembly...847
      Shift Shaft Cover Assembly...848
        Removal...848
        Disassembly and Inspection...849
        Assembly...850
      Pinion Bearing Removal...851
      Gear Housing Inspection...852
      Pinion Bearing Installation...853
      Front Gear Bearing Cup Installation...854
      Shift Shaft Installation...854
      Propeller Shaft Installation...855
      Driveshaft and Pinion Gear Installation...856
      Pinion Gear Height...858
        Checking and Adjusting using Pinion Gear Locating Tool 91-8M0046443...858
      Front Gear Backlash...859
      Rear Gear Backlash...862
      Propeller Shaft Bearing Preload (Design I and Design II)...863
        Propeller Shaft Assembly - Design I...863
        Propeller Shaft Assembly - Design II...863
        Preload Procedure...863
      Bearing Carrier Final Installation...865
      Oil Seal Carrier Installation...868
      Water Pump Installation...868
      Checking Gear Housing Operation...871
        Standard Rotation...871
        Counterrotation...871
      Gear Housing Installation...872
      Gear Lubricant Filling Instructions...874
  7A...876
    Section 7A - Attachments...876
      Table of Contents...876
      Dual Tie Bar...877
        Installation...877
        Maintenance Instructions...881
      Plus One Tie Bar...881
        Installation...881
        Maintenance Instructions...885
        Rudder Sensor Installation Instructions...886
          Rudder Sensor Installation...886
          Magnet Installation...887
           Wire Connections...888
      Liquid Tie Bar...888
        Liquid Tie Bar Installation...888
        Bleeding Instructions...889
        Realignment Instructions...890
          Propellers too Far Apart...890
          Propellers too Close Together...891
      Power Steering...891
        Power Steering Primer Module...891
        Filling Power Steering System with Engine Not Running...892
      Adapter Steering Arm - Kicker Engine...893
        Installation Instructions...893
      Analog Gauge Interface (AGI)...894
        Wire Color Code Abbreviations...894
        Analog Gauge Interface (AGI) Installation...894
          Typical AGI Application with System View...895
        Configuring Analog/Digital Tachometer Signal through PCM...896
          PCM Configuration with CDS...896
  8A...898
    Section 8A - Power Steering...898
      Table of Contents...898
      Power Steering Specifications...899
      Power Steering Cylinder Components...901
      Power Steering Systems...903
        Single Helm - Single Cylinder...903
        Dual Helm - Single Cylinder...904
        Dual Station Steering Helm Identification...904
        Single Helm - Dual Cylinder...905
        Dual Helm - Dual Cylinder...906
        Dual Station Steering Helm Identification...906
      Troubleshooting the Power Steering System...907
        Testing the Power Steering Driver Module...907
      Power Steering Cylinder...908
        Steering Cylinder...908
          Removal...908
          Installation...909
        Steering Cylinder Service...910
      Power Steering Installation...911
        Power Steering System...911
        Installation Procedure...911
          Selecting Location for the Power Steering Pump...911
          Required Mounting Clearances for the Power Steering Pump...912
          Installing Power Steering Pump...912
        Connection of the Hydraulic Hoses to the Steering Helm...912
        Connection of the Hydraulic Hoses to the Power Steering Pump...914
        Connection of the Hydraulic Hoses to the Steering Cylinder...916
        Electrical Connections to the Steering Pump...917
        Filling Power Steering System with Engine Not Running...918
        Filling Power Steering System with Engine Running...920
        Routing Connections Through the Cowl...921
  9A...922
    Section 9A - Color Diagrams...922
      Table of Contents...922
      200/225/250/275 Verado Engine Harness S/N 0T980000–1B229688...925
      200/225/250/275/300 Verado Engine Harness S/N 1B229689 and above...928
      200/225/250/275 Verado Oil Flow Diagram          S/N 0T980000–1B517433...931
      200/225/250/275/300 Verado Oil Flow Diagram    S/N 1B517434 and Above...934
      200/225/250/275/300 Verado Water Flow Diagram S/N 0T980000 and Above...935
      200/225/250/275/300 Verado Fuel Flow Diagram S/N 0T980000 and Above...938
Index...940
  MerCruiser and Mercury Racing (Sterndrive) Service Manual Index...940
    ...940
      Mercury MerCruiser...940
      Mercury Racing Sterndrives...944
Service Manual #01...946
  Models Covered...950
  Section 1-General Information...0
    A-General Information...953
    B-Tuneup...979
    C-Lubrication...993
  Section 2-Removal-Installation-Alignment...0
    A-Mercruiser 60-80-90...1013
    B-MerCruiser I Early...1025
    C-MerCruiser II Early...1043
    D-MerCruiser II Transom...1059
    E-MerCruiser III...1071
    F-MerCruiser 215H...1079
    G-MerCruiser 215E...1089
    H-888 Sterndrive...1101
    J-MerCruiser II-TR Drive Unit...1113
  Secton 3-Electrical Systems...0
    A-Starting System...1125
    B-Ignition System...1157
    C-Alternator System...1193
    D-Instrumentations...1219
    E-Wiring Diagrams...1221
  Section 4-Fuel Systems...0
    A-Fuel Pumps...1261
    B-Carburetors...1277
  Section 5-Engine...0
    A-Inline GM Engine Mechanical...1353
    B. In-Line 60-80-90-Engine Mechanical...1387
    C-V-8 GM Engine Mechanical...1415
    D-V-8 Ford Engine Mechanical...1455
  Section 6-Drive Systems...0
    A-MerCruiser 60-80-90 & MerCruiser I...1495
    B-MerCruiser II...1553
    C-MerCruiser 215...1595
    D-MerCruiser III...1595
    E-Direct Drive Transmission...1615
    F-MerCruiser II-TR Drive Unit...1659
    G-MerCruiser II-TR Drive Unit...1685
  Section 7-Accessories...0
    A-Power Tilt & Trim...1707
    B-Steering System...1743
    C-Remote Controls...1769
    D-Cooling...1799
    E-General Accessories...1827
  Section 8-Specifications...1841
  Section 9-Tools...1881
Service Manual #02...1921
  Models Covered...1924
  Section 1-General Information...0
    A-General Information...1929
    B-Tuneup...1945
    C-Lubrication...1955
  Section 2-Removal/Installation/Alignment...0
    A-MerCruiser 120-140-165-470...1967
    B-MerCruiser V-8 I-Drive Models...1979
    C-MerCruiser II-TR & II-TRS Sterndrive...1993
    D-General Installation...2005
  Section 3-Electrical System...0
    A-Starting System...2019
    B-Ignition System...2041
    C-Alternator System...2063
    D-Instrumentation...2095
    E-Wiring Diagrams...2109
  Section 4-Fuel System...0
    A-Fuel Pumps...2135
    B-Carburetors...2141
  Section 5-Engine...0
    A-Engine Mechanical In-Line...2179
    B-Engine Mechanical V8 Ford...2213
    C-Engine Mechanical V8 GM...2251
    D-Engine Mechanical 470 Model...2283
  Section 6-Drive Systems...0
    A-MerCruiser I Drive Unit...2317
    B-MerCruiser II-TR Drive Unit...2365
    C-MerCruiser II-TRS Drive Unit...2395
    D-Direct Drive Transmission...2409
    E-MerCruiser II_TR & II-TRS Transmission...2431
  Section 7-Accessories...0
    A-Power Trim System...2451
    B-Steering Systems...2471
    C-Remote Controls...2485
    D-Cooling ...2515
    E-General Accessories...2575
  Section 8-Specifications...0
    A-Tune-Up & General...2585
    B-Internal Engine...2619
    C-Torque Specs...2629
    D-Propeller Chart...2643
  Section 9-400 Jet Drive...2644
  Section 10-Troubleshooting...2680
Service Manual #03...2756
  Models Covered...2758
  Section 1-Important Information/Troubleshooting...0
    A-General Information...2762
    B-Maintenance...2780
    C-Troubleshooting...2820
  Section 2-Removal/Installation/Alignment...0
    A-MCM 120/140/165...2848
    B-MCM 120R/140R Driveshaft Extension Models...2858
    C-MCM 470/485/488...2870
    D-MCM 898/228/260...2880
    E-MCM 898/228/260 Driveshaft Ext. Models...2890
    F-MCM 330TR/TRS w/Mercury Transmission...2904
    G-MCM 330 (B-W) TR/TRS...2914
    H-MCM 370/400TRS & Hi-Perf Engines...2924
    I-Mie 470/228/230/255/260/330/340...2938
  Section 3-Electrical System...0
    A-Starting System...2952
    B-Ignition System...2974
    C-Charging System...3014
    D-Instrumentation...3074
    E-Electrical Kits...3084
    F-Wiring Diagrams...3118
  Section 4-Fuel System...0
    A-Fuel Delivery System & Fuel Pumps...3206
    B-Rochester 2 Barrel...3222
    C-MerCarb 2 Barrel...3252
    D-Rochester 4 Barrel...3280
    E-Holley 4 Barrel...3318
  Section 5-Exhaust System...0
    A-Exhaust Manifolds/Elbows...3342
    B-Exhaust Risers...3360
    C-Exhaust Collectors...3376
  Section 6-Engine...0
    A-GM In-Line...3402
    B-Mercury Marine 4 Cylinder...3442
    C-GM V8...3496
  Section 7-Cooling System...0
    A-Seawater Cooled Models...3600
    B-470/485/488...3648
    C-Closed Cooled Models...3682
  Section 8-Drive Systems...0
    A-Velvet Drive (Borg-Warner)...3722
    B-Mercury Marine Transmission...3746
    C-Driveshaft Models/Propeller Shaft...3800
  Section 9-Power Steering System...3810
Service Manual #04...3848
  Models Covered...3850
  Section 1-General Information...3854
  Section 2-Troubleshooting...3866
  Section 3- Drive Unit...0
    A-Driveshaft Housing Assembly...3883
    B-Gear Housing Assembly...3908
  Section 4-Transom Plate Assembly...3934
  Section 5-Power Trim...3975
  Section 6-Power Steering...4017
  Section 7-Service Bulletins...4046
Service Manual #05...4078
  Models Covered...4084
  Section 1 - Important Information...0
    A - Important Information...4082
    B - Maintenance...4088
    C - Basic Cleaning and Inspection...4098
    D - Power Package Layup & Recommissioning...4102
    E - Propellers...4106
    F - Troubleshooting...4132
  Section 2 - Removal, Installation and Adjustments...0
    A - All Models...4140
  Section 3 - Sterndrive Unit...0
    A - General Information...4180
    B - Driveshaft Housing...4186
    C - Gear Housing...4210
  Section 4 - Transom Assembly...0
    A - All Models...4240
  Section 5 - Power Trim...0
    A - Oilydne Power...4272
    B - Prestolite Low Pressure Power Trimp Pump...4306
    C - Prestolite High Pressure Power Trim Pump...4328
    D - Trim Cylinders...4352
    E - Dual Power Trim Control...4364
  Section 6 - Steering Systems...0
    A-Power Steering...4370
Service Manual #06...4404
  Models Covered in This Manual ...4406
  Section 1 - Important Information...0
    A - Important Information...4411
    B - Maintenance...4417
    C - Troubleshooting...4435
  Section 2 - Removal, Installation and Adjustments...0
    A - All Models...4483
  Section 3 - Sterndrive Unit...0
    A - Drive Shaft Housing...4509
    B - Gear Housing - MR/Alpha One/Alpha One SS...4545
    C - Gear Housing - I-R...4601
    D - Gear Housing - Alpha One Counter Rotation...4648
  Section 4 - Transom Assembly...0
    A - Service Procedures Requiring Minor...4713
    B - Service Procedures Requiring Major Disassembly...4739
  Section 5 - Power Trim...0
    A - Oildyne Power Trim Pump (Plastic Reservoir)...4779
    B - Oildyne Power Trim Pump (Aluminum Reservoir)...4815
    C - Prestolite Power Trim Pump...4851
    D - Trim Cylinders...4877
    E - Dual Power Trim Control...4887
    F - Auto Trim II...4895
  Section 6 - Steering Systems...0
    A - Power Steering...4904
    B - Manual Steering...4944
  Section 7 - Corrosion Protection...0
    All Models...4952
Service Manual #07...4970
  7cov...4970
    Models Covered...4972
    Section 1-Important Information...4977
      A-General Information...4977
      B-Maintenance...4988
      C-Troubleshooting...5004
  sec2...5030
    Section 2-Removal & Installation...0
      A-MCM 185 (229 cid)...5030
      B-MCM 175,185,205  43L, 4.3LX...5043
  sec3...5059
    Section 3-Engine Mechancial...0
      B-185-205 (262 cid) 4.3L...5108
  sec4...5157
    Section 4-Electrical...0
      A-Starting System...5157
      B-Ignition System...5179
      C-Charging System...5199
      D-Instrumentation...5234
      E-Wiring Diagrams...5243
    Section 6-Closed Cooling...0
      C-Exhaust System...5157
  sec5...5257
    Section 2-Removal & Installation...5257
    Section 3-Engine Mechancial...5257
    Section 5-Fuel System...5257
      A-Fuel Delivery...5257
      B-Fuel Pump...5263
      C-2 BBL Mercarb...5272
      D-4 BBL Rochester Carburetor...5300
      E-4 BBL Weber Carburetor...5331
  sec6...5362
    Section 6-Closed Cooling...0
      A-Standard Cooling...5362
      B-Closed Cooling...5372
      C-Exhaust System...5384
  sec7...5392
    Section 7-Power Steering...0
      A-Power Steering...5392
Service Manual #08...5407
  Models Covered...5409
  Section 1-Important Information...0
    A-Important Information...5413
    B-Maintenance...5421
    C-Troubleshooting...5437
  Section 2-Removal & Installation...0
    A-4 Cyl.3.7L (224cid)...5463
  Section 3-Engine Mechanical...0
    A-4 Cyl.3.7L (224cid)...5473
  Section 4-Electrical Systems...0
    A-Starting System...5515
    B-Ignition System...5531
    C-Charging Systems...5553
    D-Instrumentation...5567
    E-Wiring Diagrams...5577
  Section 5-Fuel Systems...0
    A-Fuel Delivery System...5587
    B-Fuel Pump...5591
    C-Carburetor...5597
  Section 6-Cooling & Exhaust...0
    A-Cooling System...5647
    B-Exhaust System...5663
  Section 7-Power Steering...0
    A-Power Steering...5669
Service Manual #09...5681
  Models Covered...5682
  Sec1 Important Information...0
    A-Important Information...5684
    B-Maintenance...5696
    C-Troubleshooting...5723
  Sec 2 Removal & Installation...0
    A-MCM Models with I Drive...5766
    B-MCM Models w/I Drive w/Driveshaft Ext...5774
    C-330 (B-W) TR-TRS...5786
    D-MCM Models TR/TRS Drives...5794
    E-MIE Models /5.7 Ski...5805
    F-MCM Models w/Bravo Drive...5818
  Sec 3 Engine...0
    A-V8 GM (305/350cid)...5825
    B-V8 (454/482/540 cid)...5892
  Sec 4 Electrical System...0
    A-Starting System...5966
    B-Ignition System...5979
    C-Charging System...5999
    D-Instrumentation...6050
    E-Electrical Kits...6060
    F-Wiring Diagrams...6072
  Sec 5 Fuel System...0
    A-Fuel Delivery System & Fuel Pumps...6112
    B-MerCarb 2 Barrel...6122
    C-Rochester 4 Barrel...6149
    D-Holley 4 Barrel (Model 4150)...6181
    E-Holley 4 Barrel (Model 4500)...6201
    F-Fuel Injectors/Fuel Rails...6220
  Sec 6 Cooling System...0
    A-Seawater Cooled Models...6224
    B-Closed Cooled Models...6264
  Sec 7 Exhaust System...0
    A-General Information...6286
    B-Exhaust Manifolds/Elbows...6291
    C-Exhaust Risers...6299
    D-Exhaust Collectors...6308
  Sec 8 Drive Systems...0
    A-Velvet Drive (Borg Warner) Transmission...6317
    B-Driveshaft Models/Propeller Shaft...6338
    C-Hurth Transmission...6347
  Sec 9 Power Steering...0
    A-Power Steering...6392
Service Manual #10...6404
Service Manual #11...6712
Service Manual #13...7308
  Models Covered In This Manual...7312
  Section 1 - Importnt Information...0
    A - General Information...7314
    B - Maintenance...7322
    C - Troubleshooting...7343
  Section 2 - Removal and Installation...0
    A - 4 Cylinder 3.0L / 3.0 LX (181 C.I.D...7381
  Section 3 - Engine...0
    A - G.M. In-Line...7395
  Section 4 - Electrical Systems...0
    A - Starting System...7444
    B - Ignition System...7477
    C - Charging System...7504
    D - Instrumentation...7544
    E - Wiring Diagrams...7557
  Section 5 - Fuel System...0
    A - Fuel Pump...7571
    B - MerCarb 2-Barrel...7578
  Section 6 - Cooling and Exhaust...0
    A - Seawater Cooled Models...7607
    B - Closed Cooled Models...7616
    C - Exhaust Manifolds / Elbows...7632
  Section 7 - Power Steering...0
    A - Power Steering...7638
Service Manual #14...7656
  combined SM14.pdf...7656
    14cover.pdf...7656
      Section 1 - Important Information...0
        A - General Information...7658
        B - Maintenace...7668
        C - Troubleshooting...7688
      Section 2 - Removal, Installation and Adjustment...0
        A - All Models...7738
      Section 3 - Sterndrive Unit...0
        A - Drive Shaft Housing...7778
        B - Standard Rotation Gear Housing...7828
        C - Counter Rotation Gear Housing...7910
      Section 4 - Transom Assembly...0
        A - Minor Disassembly...8028
        B - Major Disassembly...8080
      Section 5 - Power Trim...0
        A - Trim Pump...8153
        B - Trim Cylinders...8215
        C - Dual Power Trim System...8233
        D - Auto Trim II...8245
      Section 6 - Steering System...0
        A - Power Steering...8257
        B - Manual Steering...8329
      Section 7 - Corrosion Protection...0
        A - All Models...8341
    14d5.pdf...8245
  14a7.pdf...8341
Service Manual #15...8371
Service Manual #16...9157
  Models Covered...9160
  Section 1 - Importatant Information...0
    A - General Information...9163
    B - Maintenance...9173
    C - Troubleshooting...9211
  Section 2 - Removal and Installation...0
    A - MCM Models - Bravo and Blackhawk Drives...9244
    B - MCM Models - Bravo and Blackhawk with Driveshaft Extension...9258
    C - MIE Models - Velvet Drive Transmissiions...9276
    D - MIE Models - Hurth Transmissions...9294
  Section 3 - Engine...0
    A - 454 CID / 7.4L / 502 CID / 8.2L...9311
  Section 4 - Electrical Systems...0
    A - Starting System...9382
    B - Ignition System...9424
    C - Charging System...9450
    D - Instrumentation...9492
    E - Electrical Kits...9512
    F - Wiring Diagrams...9525
  Section 5 - Fuel System...0
    A - Fuel Delivery Systems and Fuel Pumps...9557
    B - Weber 4 Barrel Carburetor...9567
    C - Electronic Fuel Injection (Throttle Body and Multi-Port Injection)...9614
  Section 6 - Cooling System...0
    A - Seawater Cooled Models...9808
    B - Closed Cooled Models...9869
  Section 7 - Exhaust System...0
    A - General...9895
    B - Manifold and Elbows...9901
    C - Risers...9907
    D - Collectors...9917
  Section 8 - Drives...0
    A - Velvet Drive In-Line Transmission...9929
    B - Velvet Drive V-Drive Transmission...9942
    C - Hurth Down Angel Transmission...9954
    D - Hurth V-Drive Transmission...10004
    E - Drive Shaft Models/Propeller Shaft...10052
  Section 9 - Power Steering...0
    A - Pump...10067
Service Manual #17...10087
  Notice...10088
  Notice to Users of This Manual...10088
  Engine Mechanical Replacement Parts Components...10089
  Models Covered in This Manual...10090
    MCM Alpha...10090
    MCM Bravo...10090
    MIE Ski...10091
    MIE Inboard...10091
  Service Manual Outline...10092
  17A1R2.PDF...0
    Table of Contents...10094
    How to Use This Manual...10095
      Page Numbering...10095
    Introduction...10095
    How to Read Parts Manual...10096
    Directional References Engine Serial Number Locations...10097
    Engine Rotation...10097
    Propeller Information Water Testing New Engines...10098
    Boat and Engine Performance...10098
      Boat Bottom...10098
      Marine Fouling...10099
      Weight Distribution...10100
      Water in Boat...10100
      Elevation and Climate...10101
  17b1r2.pdf...0
    Table of Contents...10103
    Maintenance Schedules...10104
      Maintenance Intervals...10104
      Alpha Models...10104
      Bravo Models...10107
    Tune-Up Specifications...10110
      Tune-Up Specifications, Does Not Include Gen + Engines (Continued)...10111
      Tune-Up Specifications, Does Not Include Gen + Engines (Continued)...10112
    Tune-Up Specifications (Gen + Engines Only)...10113
    Fluid Capacities...10114
    All Models Fuel, Oil, Fluid, and Coolant Specifications...10115
      Hour Break-In Period...10115
      Fuel...10115
      After Break-In Period...10115
      Power Steering Fluid...10117
      Transmission Fluid...10117
      Crankcase Oil...10117
      Coolant for Closed Cooling System Checking Engine Oil Level/Filling...10118
    Maintaining Crankcase Oil Level...10118
      Overfilled Engine Crankcase...10118
    Changing Oil and Filter...10118
    Maintaining Power Steering Pump Fluid Level...10119
      With Engine Cold With Engine Warm...10119
    Filling and Bleeding Power Maintaining Closed Cooling Steering System Coolant Level...10120
      WARNING...10120
      CAUTION...10120
    Flushing Cooling System...10120
      MCM Stern Drive...10121
      MIE Inboard...10122
    Maintaining Transmission Fluid Level...10123
    Lubrication...10124
      Throttle Cable...10124
      Shift Cable...10126
      Engine Coupler/U-Joint Shaft Splines Drive Shaft Extension Models...10127
      Starter Motor (MIE Models)...10128
    Audio Warning System...10128
    Cold Weather or Extended Storage...10128
      Precautions...10128
      Layup CAUTION...10129
      Draining Instructions...10131
      Recommissioning...10142
  17c1r2.pdf...0
    Table of Contents...10146
    Precautions...10147
      Chipped Insulator...10148
    Used Spark Plug Analysis...10148
      Wet Fouling (Oil Deposits)...10148
    Spark Plug Analysis...10148
      Normal Condition...10148
      Cold Fouling High Speed Glazing...10149
      Overheating Scavenger Deposits...10149
      Pre-Ignition Damage Splashed Deposits...10150
      Mechanical Damage Reversed Coil Polarity...10150
    Poor Boat Performance and/or Poor Maneuverability...10151
    Improper Full Throttle Engine RPM...10152
      RPM Too High...10152
      RPM Too Low...10152
    Engine Cranks Over but Will Not Start or Starts Hard...10153
      Important Information...10153
      Thunderbolt IV (HEI) Ignition (No Spark)...10153
      Testing Thunderbolt IV HEI System...10154
      Testing Thunderbolt V Ignition System...10155
      Fuel System Rich...10156
      Fuel System Lean...10156
      Miscellaneous...10156
    Engine Will Not Crank Over...10157
    Charging System Inoperative...10157
      Noisy Alternator...10157
    Instrumentation Malfunction...10158
    Radio Noise...10158
    Poor Fuel Economy...10159
    Carburetor Malfunctions...10160
    Engine Runs Poorly at Idle...10161
    Engine Runs Poorly At High RPM...10162
    Engine Acceleration Is Poor...10163
    Troubleshooting with Vacuum Gauge...10163
    Engine Noise...10164
      Important Information...10164
      Valve Cover Area...10164
      Cylinder Area...10165
      Camshaft Area...10165
      Crankshaft Area...10166
      Miscellaneous...10167
    Oil Pressure...10168
      Low Oil Pressure...10169
      High Oil Pressure...10169
    Excessive Oil Consumption...10170
    Water In Engine...10171
      Important Information...10171
      Water on Top of Pistons...10171
      Water in Crankcase Oil...10172
    Engine Overheats (Mechanical)...10172
    Engine Overheats (Cooling System)...10173
      Insufficient Water Flow from Belt Driven Seawater Pickup Pump...10174
    Power Steering...10175
      Poor, Erratic, or No Assist...10175
      Noisy Pump...10176
      Fluid Leaks...10176
    Troubleshooting Silent Choice Exhaust Silencer System...10177
  17a2r2.pdf...0
    Table of Contents...10179
    Torque Specification...10180
    Tools/Lubricants/Adhesives/Sealants...10180
    Removal...10181
      Engine Removal...10181
    Installation...10182
      Engine Installation/Alignment...10182
      Engine Connections...10184
  17B2R2.PDF...0
    Table of Contents...10190
    Torque Specification...10191
    Tools/Lubricants/Adhesives/Sealants...10191
    Removal...10192
      Engine Removal...10192
    Installation...10194
      Engine Installation/Alignment...10194
      Engine Connections...10199
  17c2r2.pdf...0
    Table of Contents...10207
    Torque Specifications...10208
    Tools/Lubricants/Adhesives/Sealants...10208
    Removal...10209
    Installation...10210
      Engine Installation/Alignment...10210
      Engine Connections...10213
      Throttle Connections...10214
  17d2r2.pdf...0
    Table of Contents...10222
    Torque Specification...10223
    Tools/Lubricants/Adhesives/Sealants...10223
    Removal...10224
      Engine Removal...10224
    Installation...10226
      Engine Installation/Alignment...10226
      Engine Connections...10231
      Throttle Connections...10232
  17e2r2.pdf...0
    Table of Contents...10241
    Torque Specifications Lubricants/Sealants...10242
    Removal...10243
      Engine Removal...10243
    Installation...10244
      Engine Installation and Initial Alignment...10244
      Engine Final Alignment CAUTION CAUTION...10245
      Engine Connections...10247
      Fuel Supply Connections...10248
    Attaching/Adjusting Reversed Attachment Morse Shift Cables...10256
  17f2r2.pdf...0
    Table of Contents...10260
    Torque Specifications Lubricants/Sealants...10261
    Removal...10262
      Engine Removal...10262
    Installation...10263
      Engine Installation and Initial Alignment...10263
      Engine Final Alignment CAUTION...10264
      Engine Connections...10266
      Fuel Supply Connections...10267
  17a3r2.pdf...0
    Table of Contents...10276
    Torque Specifications 5.0L / 305 CID / 5.7L / 350 CID Engines...10279
      CID / 5.7L Torque Specifications (Continued)...10280
      Special Tools...10281
      Lubricants/Sealers/Adhesives...10282
    Engine Specifications...10283
      L / 305 CID / 5.7L / 350 CID Engine Specifications (Does Not Include Gen +)...10285
      L / 305 CID / 5.7L / 350 CID Engine Specifications (Does Not Include Gen +)...10286
      L / 305 CID / 5.7L / 350 CID Engine Specifications (Does Not Include Gen +)...10287
      L / 305 CID / 5.7L / 350 CID Engine Specifications (Does Not Include Gen +)...10288
      CID Gen + Engine Specifications...10289
      CID Gen + Engine Specifications...10290
      CID Gen + Engine Specifications...10291
      Gen + Engine Specifications...10292
    General...10293
      Engine Identification...10293
      Cylinder Head Identification Engine Rotation...10294
      Crankshaft...10294
      Piston and Connecting Rods...10294
      Camshaft and Drive...10295
      Intake Manifold...10295
      CAUTION...10295
      Lubrication System...10295
      Cylinder Head...10295
      Valve Train...10295
    Bearing Failures...10297
    Piston Failures...10298
      Pre-Ignition...10298
      Detonation...10299
    Engine Mounts...10300
    Rocker Arm Cover Intake Manifold...10302
      Removal Removal...10302
      Installation...10302
      Cleaning and Inspection...10302
      Installation...10303
      Cleaning and Inspection...10305
      Installation...10305
    Valve Adjustment...10305
      Engine Stopped...10305
    Rocker Arm/Push Rod...10305
      Removal...10305
      Engine Running...10306
      Locating Noisy Lifters...10307
    Hydraulic Valve Lifters (Flat and Roller Lifter)...10307
      Removal Cleaning and Inspection...10308
      Installation...10308
    Valve Stem Oil Seal/Valve Spring...10308
      Removal - Head Installed...10308
      Valve Assembly (Exploded View)...10310
    Cylinder Head...10310
      Removal...10310
      Installation - Head Installed...10310
      Cleaning and Inspection...10311
      Installation...10311
    Cylinder Head and Valve Conditioning...10312
      Disassembly...10312
      Cleaning...10312
      Inspection...10312
      Valve Guide Bore Repair...10313
      Valve Springs - Checking Tension...10314
      Rocker Arm Stud Replacement...10315
      Valve Seat Repair...10315
      Valve Grinding...10316
      Reassembly...10316
    Dipstick Specifications...10319
      All Engines...10319
    Oil Pan...10320
      Removal...10320
      Installation...10320
      Removal...10322
    Oil Pump...10322
      Disassembly...10322
      Cleaning and Inspection Installation...10323
      Reassembly...10323
    Torsional Damper...10324
      Removal...10324
      Installation...10324
    Crankcase Front Cover/ Oil Seal...10325
      Oil Seal Replacement (Without Removing Front Cover)...10325
    Crankcase Front Cover...10326
      Removal...10326
      Cleaning and Inspection...10326
    Flywheel...10326
      Installation...10326
      Removal...10326
      Inspection...10327
      Installation...10328
    Rear Main Oil Seal...10329
      Removal...10329
      Cleaning and Inspection...10329
      Installation Cleaning and Inspection...10330
      Installation...10330
    Rear Main Oil Seal Retainer...10330
      Removal...10330
    Main Bearings...10330
      Inspection...10331
      Checking Clearances...10331
      Replacement...10333
    Connecting Rod Bearings...10334
      Inspection and Replacement...10334
    Connecting Rod/Piston Assembly...10335
      Removal...10335
      Disassembly...10336
      Cleaning and Inspection...10336
      Reassembly...10338
      Installation...10340
      Cleaning and Inspection...10341
    Crankshaft...10341
      Removal...10341
      Installation...10341
      Removal...10342
      Cleaning and Inspection...10342
    Timing Chain and Sprocket or Timing Gears...10342
      Installation - Timing Gears...10343
    Crankshaft Sprocket/Gear...10343
      (Opposite Rotation Engine)...10343
      Removal...10343
      Installation...10343
      Installation - Timing Chain  (Standard Rotation Engine)...10343
      Checking Timing Chain Deflection...10343
      Checking Timing Gear Backlash and Runout...10344
    Camshaft...10345
      Measuring Lobe Lift...10345
      Removal...10345
      Installation...10346
    Camshaft Bearings...10346
      Removal...10346
      Inspection...10346
      Installation...10347
      Inspection...10347
    Cylinder Block...10348
      Cleaning and Inspection...10348
      Inspection and/or Replacement...10351
    Oil Filter By-Pass Valve and Adaptor Assembly...10351
  17A4R2.PDF...0
    Table of Contents...10353
    Identification Replacement Parts Warning...10354
    Battery...10354
      Battery Cable Recommendations...10354
    Torque Specifications...10354
    Lubricants/Sealants...10354
    Direct Drive Starter Motor...10355
      Specifications...10355
    Torque Specifications...10355
    Lubricants/Sealants...10355
    Positive Current Flow...10355
    Starting System Components...10356
    Starter Motor (Exploded View)...10357
    Periodic Inspection...10358
    Starter Motor Repair...10358
      Removal...10358
      Solenoid Switch...10358
      Starter Motor Disassembly...10360
      Cleaning and Inspection...10360
      Armature Tests...10361
      Field Coil Tests...10361
      Reassembly...10362
      Loose Electrical Connections...10362
      Turning the Commutator...10362
      Clearances...10363
      Installation...10364
    Permanent Magnet Gear Reduction (PG200, PG250 and PG260) Starter Motor...10365
      Specifications...10365
      Maintenance Testing...10366
      Storage...10366
    Standard Starter Slave Solenoid...10367
      Testing/Replacement...10367
    Starting System Components...10368
    Positive Current Flow Description...10369
    PG 200 and PG 250 Starter Motor (Exploded View)...10371
    Solenoid Switch...10372
    Periodic Inspection...10372
    PG 200 and PG 250 Starter Motor Repair...10372
      Removal...10372
      Disassembly...10373
      Cleaning and Inspection...10375
      Armature Tests Armature Bearing (Commutator End)...10375
      Shaft Assembly Bearing...10376
      Gear Bearing...10376
      Drive End Housing Bearing...10376
      Brushes and Brush Holder...10377
      Reassembly...10378
      Installation...10380
    PG 260 Starter Motor ...10381
    Exploded View...10381
    Solenoid Switch...10382
    Periodic Inspection...10382
    PG 260 Starter Motor Repair...10382
      Removal...10382
      Disassembly...10383
      Cleaning and Inspection...10385
      Armature Tests...10386
      Brushes and Brush Holder...10386
      Reassembly...10388
      Clearances...10391
      Installation...10391
  17B4R2.PDF...0
    Table of Contents...10395
    Thunderbolt IV Ignition Replacement Parts Warning System...10396
      Identification...10396
    Thunderbolt IV (HEI) Electronic Ignition System...10396
      Torque Specifications...10396
      Tools/Lubricants/Sealants...10396
      Firing Order ...10397
    Specifications...10397
      Coil...10397
      Spark Plugs...10397
      Distributor Advance Curves...10398
    Repair...10401
      Precautions...10401
      Distributor Cap...10401
      Rotor/Sensor Wheel...10402
      Sensor...10403
      Thunderbolt IV Ignition Module...10404
    Distributor Repair...10404
      Removal...10404
      Thunderbolt IV Exploded View...10405
      Reassembly...10406
      Disassembly...10406
    Distributor Installation...10407
      Engine Not Disturbed...10407
      Engine Disturbed...10407
    Thunderbolt IV Ignition Timing...10408
    Thunderbolt V Ignition System...10409
      Identification...10409
    General Description...10410
      Over-Speed Control...10410
      Idle Speed Spark Control...10410
      Knock Retard Spark Control...10410
      Acceleration Spark Advance...10410
      Mean-Best-Timing (MBT) Spark Advance...10410
    Thunderbolt V Spark Control Graph...10411
      Knock Control Module...10412
    Circuit Description...10412
      Ignition Control Module...10412
      Ignition Control System Timing Lead...10412
    Ignition System Wiring Diagram...10413
    Timing and Idle Adjustment Procedures For Thunderbolt V Ignition...10414
      Setting Base Ignition Timing...10414
      Adjusting Engine Idle Speed...10414
      Adjusting Idle Mixture...10414
    Troubleshooting Thunderbolt V Ignition...10415
      Ignition Control Module / Coil / Distributor...10415
      Knock Control Module...10416
      Spark Plugs...10417
      Spark Plug Wires...10418
  17c4r2.pdf...0
    Table of Contents...10421
    Mando 55 and 65 Amp Specifications Alternator Identification...10422
    Tools/Sealants...10422
    Replacement Parts Warning...10422
    Torque Specifications...10422
    Description...10423
    Precautions...10423
    System Components Periodic Maintenance...10424
      Serpentine Belt...10425
    Drive Belt Tension Adjustment...10425
      V-Belt...10425
    Troubleshooting Tests (Alternator on Engine)...10426
      Circuitry Test...10426
      Current Output Test...10427
      Voltage Output Test...10428
      Exploded View...10431
      Disassembly...10432
    Alternator Repair...10432
      Removal...10432
      Cleaning and Inspection...10435
      Component Testing...10436
      Reassembly...10439
    Installation...10441
    Battery Isolators...10442
      Dual Battery Charging Systems Using a Battery Isolator...10442
    Battery Isolator...10443
  17d4r2.pdf...0
    Table of Contents...10447
    Identification Special Information...10448
      Lighting Options...10448
    Gauges...10449
      Oil, Fuel and Temperature...10449
      Battery Gauge...10450
      Cruiselog Meter Vacuum Gauge...10451
      Speedometer...10451
      Tachometer...10451
      Gauge Replacement...10452
    Senders...10452
      Oil Pressure...10452
      Water Temperature WARNING...10453
      Fuel Tank Sender...10454
    Switches...10456
      Ignition Key Switch...10456
      Lanyard Stop Switches...10457
    Audio Warning System...10458
      Buzzer...10458
      Oil Pressure Switch...10459
      Water Temperature Switch...10459
      Transmission Fluid Temperature Switch...10462
  17e4r2.pdf...0
    Table of Contents...10467
    Wiring Color Code for MerCruiser Products...10468
    Lanyard Stop Switches...10468
    Audio Warning System...10475
  17f4r2.pdf...0
    Table of Contents...10480
    Thunderbolt IV...10481
      Alpha Drive - All Engines With Ignition Module Mounted On Exhaust Elbow...10481
      MCM V-8 Alpha Thunderbolt V With Knock Sensor...10487
      MCM V-8 Alpha Thunderbolt V Without Knock Sensor...10488
      MCM V-8 Bravo Thunderbolt V With Knock Sensor...10489
      MCM V-8 Bravo Thunderbolt V Without Knock Sensor...10490
      MIE V-8 (Bluewater) Thunderbolt V Without Knock Sensor...10491
      MIE (Bluewater) V-8 Thunderbolt V With Knock Sensor...10492
      MIE (Ski) V-8 Thunderbolt V Without Knock Sensor...10493
      EFI System Harness...10494
    EFI Engine Harness...10496
      MCM 5.7L EFI Alpha With Vapor Separator Tank (VST)...10496
      MCM 5.7L EFI Alpha With Cool Fuel System...10497
      MCM 5.7L EFI Bravo WIth Vapor Separator Tank (VST)...10498
      MCM 5.7L EFI Bravo WIth Cool Fuel System...10499
      MCM 350 MPI Bravo and Blackhawk (Including Gen + Engines) With Vapor Separator Tank (VST)...10500
      MCM 350 Gen+ MPI Bravo and Blackhawk With Cool Fuel System...10501
      MIE 350 Magnum MPI Gen + Tournament Ski (Black Scorpion)...10502
      MIE 350 Magnum EFI Gen + Tournament Ski /  5.7L Gen+ Inboard With Cool Fuel System...10503
      MCM Quicksilver Instrumentation...10504
    Battery Meter Gauge Fuel Gauge and Sender...10511
    Cruiselog Audio Warning System...10511
    Water Temperature Gauge Clock...10512
    Oil Pressure Gauge...10512
  17a5r2.pdf...0
    Table of Contents...10514
    Identification...10515
    Replacement Parts Warning Tools / Lubricants / Sealants...10515
    Specifications Torque Specifications...10515
    Precautions Fuel Delivery System...10516
    Fuel System Components...10517
      Carburetor System...10517
      Throttle Body Injection With Vapor Throttle Body Injection With Cool Separator Tank Fuel System...10518
      Multi-Port Injection With Vapor Multi-Port Injection With Cool Fuel Separator Tank (VST) System...10519
      Earlier Style Starboard Mounted Fuel System for 350 Magnum MPI Gen + Tournament Ski (Black Scorpion)...10520
    Water Separating Fuel Filter...10521
      Replacement...10522
    Sight Tube...10522
      Inspection...10522
    Testing Mechanical Fuel Pump...10523
    Mechanical Fuel Pump...10523
      Replacement...10523
  17b5r2.pdf...0
    Table of Contents...10525
    MerCarb 2 BBL Carburetor...10526
      Torque Specifications...10526
      Tools...10526
      Specifications...10526
    Exploded View...10527
    Identification...10529
    Important Service Information...10529
      Flooding at Idle RPM...10529
      Needle/Seat Change...10529
      Adjustable Accelerator Pump Lever High Altitude Re-Jetting...10530
    Description...10530
    Precautions Maintenance...10531
      Flame Arrestor with Carburetor WARNING Cover...10531
      Fuel Inlet Filter...10532
      Choke Inspection...10533
    Adjustments...10533
      Pump Rod...10533
      Choke Setting...10534
      Preliminary Idle Speed and Mixture...10534
      Choke Unloader...10534
      Final Idle Speed and Mixture...10535
      Installation...10536
    Repair...10536
      Removal...10536
      Disassembly...10537
      Cleaning and Inspection...10542
      Reassembly...10543
  17c5r2.pdf...0
    Table of Contents...10554
    Identification Tools...10555
    Replacement Parts Warning...10555
    Torque Specifications...10555
    Carburetor Specifications...10556
    Carburetor Adjustment Specifications (Note 1)...10556
    Description...10557
    Maintenance...10557
      Flame Arrestor...10557
    Precautions...10557
      Fuel Filter...10558
    Adjustments...10559
      Accelerator Pump...10559
      Air Valve Dashpot...10560
      Float Level...10560
      Air Valve Spring Windup...10560
      Choke Coil Rod...10561
      Vacuum Break...10562
      Preliminary Idle Speed and Mixture Final Idle Speed and Mixture...10563
    Repair...10564
      Removal...10564
      Installation...10566
      Disassembly...10569
      Cleaning and Inspection...10573
      Reassembly...10575
  17d5r2.pdf...0
    Table of Contents...10584
    Identification Torque Specifications...10585
    Tools...10585
    Replacement Parts Warning...10585
    Specifications...10586
      MCM Models...10586
      MIE Models...10586
      Carburetor Adjustment Specifications...10587
    Description...10588
    Precautions...10588
      Hard Starting...10589
    Important Service Information...10589
      Weber Carburetor Adjustable Accelerator Pump...10589
      Carburetor Metering Rod And Jet Identification...10590
    Maintenance...10591
      Flame Arrestor...10591
      Fuel Filter...10592
    Adjustments...10593
      Accelerator Pump...10593
      Choke Pull-Off...10594
      Float Drop...10594
      Float Level...10595
    Idle Speed and Mixture Adjustments...10596
      Thunderbolt IV Equipped Engines...10596
      Thunderbolt V Equipped Engines...10598
    Repair...10599
      Removal...10599
      Installation...10600
      Exploded View...10602
      Disassembly...10603
      Cleaning and Inspection...10612
      Reassembly...10613
  17e5r2.pdf...0
    Table of Contents...10625
    General Information...10628
      Basic Knowledge and Tools Required...10628
      Electrostatic Discharge Damage...10628
      Introduction...10628
      Diagnostic Information...10629
      Wiring Harness Service...10629
      Wiring Connector Service...10629
    Abbreviations...10630
      Changes In Terminology...10631
      Diagnostic Trouble Codes...10631
    ECM Self-Diagnostics...10632
      Reading Codes...10632
      Diagnostic Code Tool With Malfunction Indicator Lamp...10632
      Intermittent Malfunction Indicator Lamp...10632
      EFI Diagnostic Circuit Check...10633
      Scan Tool Use with Intermittents...10633
      Scan Tools...10633
      Non-Scan Diagnosis of Driveability Concerns (With No Codes Set)...10634
      Special Tools...10635
      Service Precautions...10636
    Electronic Control Module (ECM) and Sensors...10637
      General Description...10637
      Computers and Voltage Signals...10637
      Analog Signals...10637
      Digital Signals...10638
      Engine Control Module (ECM)...10638
      Speed Density System...10639
      ECM Input and Sensor Descriptions...10640
      INPUTS...10640
      OUTPUTS...10640
      Distributor Module Mode...10645
    Spark Management...10645
      High Energy Ignition with Ignition Control (IC)...10645
      ECM Control Mode...10645
      Modes Of Operation...10645
      Base Ignition Timing...10645
      Results of Incorrect Operation...10647
    Fuel Metering System...10647
      General Description...10647
      Modes of Operation...10647
      Throttle Body Injection Components...10649
      Multi-Port Injection Components...10651
      Throttle Body Assembly...10652
    ECM Connector and Symptom Charts...10654
    ECM Connector and EFI Symptoms Chart (J-1 Circuits)...10655
    ECM Connector and EFI Symptoms Chart (J-1 Circuits)...10656
    ECM Connector and EFI Symptoms Chart (J-2 Circuits)...10657
    ECM Connector and EFI Symptoms Chart (J-2 Circuits)...10658
      Multi Port Injector Balance Test...10659
      Fuel Injector Balance Test Set-up (Multi-Port Injection)...10660
    Wiring Harness Diagrams...10661
      MCM 5.7L EFI Alpha With Vapor Separator Tank...10661
      MCM 5.7L EFI Alpha With Cool Fuel System...10662
      MCM 5.7L EFI Bravo With Vapor Separator...10663
      MCM 5.7L EFI Bravo WIth Cool Fuel System...10664
      MCM 350 MPI Bravo (Including Gen + Engines) With Vapor Separator Tank...10665
      MCM 350 MPI Gen+ Bravo With Cool Fuel System...10666
      MIE 350 Magnum MPI Gen + Tournament Ski (Black Scorpion)...10667
      MIE 350 Magnum EFI Gen + Tournament Ski / 5.7L Gen+ Inboard With Cool Fuel System...10668
      Multi-Port Injection Wiring Diagram (Chart 1 Of 4)...10669
      Multi-Port Injection Wiring Diagram (Chart 2 Of 4)...10670
      Multi-Port Injection Wiring Diagram (Chart 3 Of 4)...10671
      Multi-Port Injection Wiring Diagram (Chart 4 Of 4)...10672
      Throttle Body Injection Wiring Diagram (Chart 1 of 4)...10673
      Throttle Body Injection Wiring Diagram (Chart 2 Of 4)...10674
      Throttle Body Injection Wiring Diagram (Chart 3 Of 4)...10675
      Throttle Body Injection Wiring Diagram (Chart 4 Of 4)...10676
    Diagnostic Circuit Check...10678
      Scan Tool Normal Specifications (Idle / Warm Engine / Closed Throttle / Neutral)...10678
      No ïMalfunction Indicator Lampì (Marine Diagnostic Code Tool Installed) Chart A-1 (1 of 2)...10681
      No  Malfunction Indicator Lamp  Chart A-1: (2 of 2)...10682
      No DLC Data or Will Not Flash Code 12  Malfunction Indicator Lamp  On Steady (Marine Diagnostic Code Tool Installed) Chart A-2 (1 of 2)...10683
      No DLC Data or Will Not Flash Code 12 Chart A-2: (2 of 2)...10684
      Engine Cranks but Will Not Run Chart A-3 (1 of 4)...10685
      Engine Cranks but Will Not Run (Continued) Chart A-3: (2 of 4)...10686
      Engine Cranks but Will Not Run (Continued) Chart A-3 (3 of 4)...10687
      Engine Cranks but Will Not Run (Continued) Chart A-3: (4 of 4)...10688
      Multi-Port Injection Fuel System Diagnosis Chart A-7 (1 of 6)...10689
      Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7: (2 of 6)...10690
      Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7 (3 of 6)...10691
      Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7: (4 of 6)...10692
      Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7 (5 of 6)...10693
      Multi-Port Injection Fuel System Diagnosis (Continued) Chart A-7: (6 of 6)...10694
      Throttle Body Injection Fuel System Diagnosis Chart A-7 (1 of 6)...10695
      Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7: (2 of 6)...10696
      Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7 (3 of 6)...10697
      Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7: (4 of 6)...10698
      Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7 (5 of 6)...10699
      Throttle Body Injection Fuel System Diagnosis (Continued) Chart A-7: (6 of 6)...10700
      EFI System/Ignition Relay Check (1 of 2)...10701
      EFI System / Ignition Relay Check (Continued) (2 of 2)...10702
      Ignition System Check (1 of 2)...10703
      Ignition System Check(1 of 2)...10704
      Ignition System Check (2 of 2)...10705
      Ignition System Check (2 of 2)...10706
      Idle Air Control (IAC) Functional Test (1 of 2)...10707
      Idle Air Control Functional Test  (2 of 2)...10708
      Lanyard Stop Circuit Check (Emergency Stop) Circuit Check (1 of 2)...10709
      Lanyard Stop (Emergency Stop) Circuit Check (2 of 2)...10710
      Audio Warning Buzzer Circuit Check (1 of 2)...10711
      Audio Warning Buzzer Circuit Check (2 of 2)...10712
      Discrete Input Circuit Check (Power Reduction Mode) (Non-Scan) (1 of 2)...10713
      Discrete Input Circuit Check (2 of 2)...10714
    Diagnostics-Without Scan Tool...10715
      Code 14: Engine Coolant Temperature (ECT) Sensor Circuit (Non-Scan) (1 of 2)...10715
      Code 14: ECT Circuit (Non-Scan)  (2 of 2)...10716
      Code 21: Throttle Position (TP) Sensor Circuit (Non-Scan) (1 Of 2)...10717
      Code 21: Throttle Position (TP) Sensor Circuit (Non Scan)...10718
      Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Non-Scan) (1 Of 2)...10719
      Code 33: MAP Circuit (Non-Scan)  (2 of 2)...10720
      Code 42: Ignition Control (IC) Circuit (Non-Scan) (1 of 2)...10721
      Code 42: IC Circuit (Non-Scan) (2 of 2)...10722
      Code 43: Knock Sensor (KS) (Non-Scan) (1 of 2)...10723
      Code 43: Knock Sensor (KS) Circuit (Non-Scan) (2 of 2)...10724
      Code 51: Calibration Memory Failure Non-Scan Diagnostics (1 of 2)...10725
      Code 51: Calibration Memory Failure (Non-Scan) (2 of 2)...10726
    Diagnostics - Using Scan Tool (Scan)...10727
      Code 14 Engine Coolant Temperature (ECT) Sensor Circuit (Scan) (1 of 2)...10727
      Code 14: ECT Circuit (Scan) (2 of 2)...10728
      Code 21: Throttle Position (TP) Sensor Circuit (Scan) (1 of 2)...10729
      Code 21: TP Sensor Circuit (Scan) (2 of 2)...10730
      Code 23: Intake Air Temperature (IAT) Sensor Circuit (Scan) (1 of 2)...10731
      Code 23: IAT Circuit (Scan) (2 of 2)...10732
      Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Scan) (1 of 2)...10733
      Code 33: MAP Circuit (Scan) (2 of 2)...10734
      Code 42: Ignition Control (IC) Circuit (Scan) (1 Of 2)...10735
      Code 42: IC Circuit (Scan) (2 of 2)...10736
      Code 43: Knock Sensor (KS) (Scan) (1 Of 2)...10737
      Code 43: KS Circuit (Scan) (2 of 2)...10738
      Code 51: Calibration Memory Failure (Scan) (1 Of 2)...10739
      Code 51: Calibration Memory Failure (Scan) (2 of 2...10740
    Troubleshooting...10741
      Changes In Terminology...10741
      Diagnostic Trouble Codes...10741
      Important Preliminary Checks...10741
    Troubleshooting Charts...10742
    Fuel Delivery Systems...10763
      Cool Fuel System Exploded View...10763
      Vapor Separator Tank (VST) Exploded View...10765
      Torque Sequence For VST...10766
      VST Fuel Pump (Exploded View)...10767
      Vapor Separator Tank (VST)...10769
      Float and Needle Assembly...10770
      Diaphragm Assembly...10771
    Throttle Body Injection Torque Specifications Repair Procedures...10773
    Special Tools...10773
    Lubricants/Sealants/ Adhesives...10773
    Throttle Body Injection System Description...10774
    Service Precautions...10774
    Throttle Body Exploded Views...10775
      CID / 5.7L EFI (2 Barrel Throttle Body) Induction System...10775
      CID / 5.7L EFI (4 Barrel Throttle Body) Induction System...10777
      Throttle Body...10779
      Fuel Pressure Relief Procedure...10780
      Fuel Meter Cover Assembly...10780
      Fuel Injectors...10781
      Throttle Body...10782
      Throttle Body Adapter Plate...10783
    Multi-Port Injection System Description...10784
    Service Precautions...10784
    Multi-Port Exploded Views...10785
      Flame Arrestor and Throttle Body (All Multi-Port Injection Engines Equipped Vapor Separator Tank)...10785
      MPI Magnum Gen + Tournament Ski (Black Scorpion) Induction System...10787
      Fuel Pressure Relief Procedure...10788
    Multi-Port Components...10788
      Flame Arrestor...10788
      Throttle Body...10789
      Plenum...10791
      Pressure Regulator...10792
      Fuel Injectors...10793
    Throttle Body Injection and Multi-Port Injection Sensor and Module Servicing...10794
      Precautions...10794
      Electronic Control Module (ECM)...10794
      Knock Sensor (KS) Module...10795
      Engine Coolant Temperature (ECT) Sensor...10796
      Throttle Body Injection Components- Throttle Position (TP) Sensor Manifold Absolute Pressure (MAP) Sensor...10797
      Idle Air Control (IAC) Valve...10798
      Knock Sensor...10799
      Multi-Port Injection Components- Manifold Absolute Pressure (MAP) Sensor...10801
      Throttle Position (TP) Sensor ...10802
      Idle Air Control (IAC) Valve...10803
      Knock Sensor Knock Sensor (KS) Module...10804
      Fuel Pump Relay...10806
    Ignition Control (IC) System Components...10806
      Precautions...10806
      Ignition Coil...10807
      Spark Plug Replacement...10808
  17f5r2.pdf...0
    Table of Contents...10814
    Identification Torque Specifications...10815
    Special Tools...10815
    Replacement Parts Warning...10815
    Carburetor Specifications...10816
    Carburetor Adjustment Specifications...10816
    Engine Specifications...10816
    Description Special Notes...10817
      Carburetor Top Cover...10817
      Sealed Idle Mixture Screws...10817
      Metering Assembly...10818
    Precautions...10819
      Fuel Filter...10820
    Maintenance...10820
      Flame Arrestor...10820
      Positive Crankcase Ventilation (PCV)...10820
    Troubleshooting...10821
      Checking Ported Vacuum Switch and Carburetor Vacuum Circuit for Correct Operation...10821
    Service Procedures...10822
      Checking Positive Crankcase Ventilation (PCV) Valve...10822
      Removing Seals From Idle Mixture Screws...10823
      Carburetor Installation...10823
      Installing New Seals...10823
      Ported Vacuum Switch Installation...10824
      Emissions System Connections...10825
      Propane Assisted Idle Set Procedure...10826
    Emissions Testing...10828
    Test Equipment...10828
  17a6r2.pdf...0
    Table of Contents...10831
    Seawater Inlet Recommendations...10833
      Transom Mounted or Thru-Hull Seawater Pickups and Hose...10833
      Sea Strainer...10833
      Transom Mounted...10834
    Seawater Pickups...10834
      Thru-Hull Mounted...10834
      Removal...10835
    Sea Strainer (Quicksilver)...10835
      Installation...10836
    Stern Drive Unit Seawater Pickup Pump Output Test...10837
      Cleaning and Inspection...10838
    Stern Drive Unit Seawater Pickup Pump Repairs...10838
      Installation...10838
    Water Circulating Pump Replacement...10838
      Removal...10838
    Flushing Seawater Cooling System...10839
      Engines with Stern Drive Seawater Pickup Pump Check/Clean Seawater Strainer...10839
    Thermostat...10840
      Removal...10840
      Testing...10841
      Installation...10842
    Draining Seawater Cooling System...10843
      Draining Precautions...10843
      (MCM) Stern Drive Drain Location...10846
      MIE (Inboard) Models...10847
    Auxiliary Hot Water Heater Installation...10849
    Water Flow Diagrams...10851
      MCM Alpha...10851
      MCM Alpha Gen+ With Cool Fuel System...10852
      MCM Bravo...10853
      MCM Bravo With Cool Fuel System...10854
      MIE Inboard Models...10855
      MIE Inboard With Cool Fuel System...10856
  17b6r2.pdf...0
    Table of Contents...10860
    Water Flow Diagrams...10862
      Engines With Coolant Flow Thru Exhaust Manifolds (Excluding Gen +)...10862
      Engines With Raw Water Flow Thru Exhaust Manifolds...10863
    Description Seawater Pickup Pump (If Equipped)...10864
      Maintenance...10864
      Stern Drive Unit Seawater Pickup Pump...10864
      Belt Driven Seawater Pickup Pump...10864
    Closed Cooling Systems With Coolant Flow Thru Exhaust Manifolds (Excluding Engines With Serpentine Belt)...10877
      Maintaining Coolant Level...10877
    Pressure Cap Maintenance...10877
    Heat Exchanger Repair...10878
    Testing Closed Cooling System...10878
      Testing Coolant for Alkalinity...10878
      Pressure Testing System...10879
      Testing for Cylinder Head Gasket Testing Heat Exchanger Leak...10880
      Testing Pressure Cap...10880
    Thermostat...10881
      Removal...10881
      Testing...10883
      Installation...10884
      Closed Cooling Section...10886
      Coolant Recommendations...10886
    Changing Coolant...10886
      Draining Instructions...10887
    Cleaning System...10887
      Seawater Section...10887
    Flushing Seawater Section of Closed Cooling System...10888
    Draining Seawater Section of Closed Cooling System...10890
      Draining Precautions...10890
    Filling Closed Cooling Section...10892
    Closed Cooling System With Raw Water Flow Thru Exhaust Manifold (Engines With Serpentine Belt Only)...10893
      Maintaining Closed Cooling System WARNING Coolant...10893
      Checking Coolant for Alkalinity...10894
      Changing Coolant...10894
      Pressure Cap Maintenance...10897
      Flushing Seawater Section CAUTION...10898
      Cleaning Seawater Section of Heat Exchanger and Fluid Coolers...10899
      Cleaning Closed Cooling Section...10900
    Cold Weather or Extended Storage...10901
      Seawater Section Draining Instructions...10901
      Serpentine Drive Belt Adjustment...10904
    Auxiliary Hot Water Heater Installation...10905
  17a7r2.pdf...0
    Table of Contents...10910
    Exhaust System...10911
      Transom Exhaust...10911
    Requirements...10911
      Determining If Exhaust Elbow Risers Are Required...10911
      MIE (Inboard) Engines Exhaust Hose Connection...10912
    Exhaust Tube Requirements...10913
  17b7r2.pdf...0
    Table of Contents...10916
    Torque Specifications...10917
    Sealants...10917
    Removal...10917
    Cleaning and Inspection...10918
    Installation...10918
  17c7r2.pdf...0
    Table of Contents...10922
    Exhaust Riser (Kit) Replacement Information Identification...10923
      Engine Preparation and Parts Removal...10923
    Torque Specifications...10923
    Sealants...10923
    Engine Preparation and Component Removal...10924
      Exhaust Extension Kit Installation...10925
    Installation Diagrams...10925
      Cast Iron Elbows Cast Iron Elbows With Mufflers...10926
      Stainless Steel Elbows Stainless Steel Elbows With Mufflers...10927
    Maintenance Instructions...10928
  17d7r2.pdf...0
    Table of Contents...10931
    Torque Specifications...10932
    Lubricants/Sealants/ Adhesives...10932
      Component Replacement...10933
      Component Replacement...10934
    Thru-Transom Exhaust...10934
      Shutter Replacement...10934
    Below Swim Platform Exhaust Pipe Kit...10934
      Modifying Swim Platform Exhaust...10935
    Silent Choice Exhaust...10935
      Pipe, If Required...10935
    System...10935
      Exhaust Bellows Removal and Exhaust Tube Installation...10935
      Air Tube Routing Maintenance...10937
    Exhaust Muffler Kit...10938
      Cleaning and Inspection...10939
      Installation Maintenance Instructions...10939
  17a8r2.pdf...0
    Table of Contents...10943
    Velvet Drive In-Line (71C and 72C) Specifications...10944
      Transmission Ratios...10944
      Torque Specifications...10944
      Transmission Fluid Capacities...10945
      Transmission Pressure Specifications...10945
      Transmission Output Shaft Rolling Torque...10945
      Transmission Fluid Specification...10945
    Important Information...10946
      Shift Control and Cables...10946
      Engine...10946
      Propeller...10946
      Transmission...10946
      Transmission Shift Lever...10947
    Shift Cable Adjustment...10947
    Checking Transmission Fluid Level...10947
    Changing Transmission Fluid...10948
      Draining Transmission...10948
      Filling Transmission...10949
    Removal and Installation...10950
    Pump Indexing...10951
    Shift Lever Installation Pressure Test...10952
    Transmission Repair...10952
  17b8r2.pdf...0
    Table of Contents...10956
    Identification...10957
      Transmission Ratios...10957
      Torque Specifications...10957
      Transmission Fluid Capacities...10958
      Transmission Pressure Specifications...10958
      Transmission Output Shaft Rolling Torque...10958
      Transmission Fluid Specification...10958
    Important Information...10959
      Shift Control and Cables...10959
      CAUTION...10959
      Engine...10959
      Propeller...10959
      Transmission...10959
      Transmission Shift Lever...10960
    Shift Cable Adjustment...10960
    Checking Transmission Fluid Level...10960
    Changing Transmission Fluid...10961
      Draining Transmission...10961
      Filling Transmission...10962
    Removal and Installation...10963
    Pump Indexing...10964
    Shift Lever Installation Pressure Test...10965
    Transmission Repair...10965
      V-Drive...10965
  17c8r2.pdf...0
    Table of Contents...10969
    Identification Tools/Lubricants/Sealants...10970
    Torque Specifications...10970
      Operating Specifications...10971
    Specifications...10971
      Transmission Fluid Specification...10971
      Transmission Ratios Capacity...10971
    General Shift Cable Installation and Adjustment...10972
    Checking Transmission Fluid Level...10977
    Draining Transmission Filling Transmission...10978
    Transmission Removal...10979
    Transmission Installation...10980
    Transmission Repair...10981
      Disassembly...10981
      Reassembly...10995
      Final Assembly...11010
    Functional Test...11015
  17d8r2.pdf...0
    Table of Contents...11019
    Torque Specifications Tools/Lubricants/Sealants...11020
      Reassembly...11021
    Flywheel Housing/Output Shaft Housing Repair  (MCM Stern Drive Models)...11021
      Removal and Installation...11021
      Disassembly...11021
    Drive Shaft Repair (MCM Stern Drive Models)...11022
      Removal...11022
      Repair...11023
      Replacement Drive Shafts...11023
    Installation...11024
    Bearing Support Repair (MCM Stern Drive Models)...11025
      Disassembly Removal...11025
      Reassembly...11026
      Installation...11027
    Propeller Shaft  (MIE Inboard Models)...11028
      Checks Made with Boat In Water...11028
      Checks Made with Boat Out of Water and Shaft Installed...11029
      Checks Made with Propeller Shaft Removed from Boat...11030
      Strut...11031
  17a9r2.pdf...0
    Table of Contents...11034
    Torque Specifications Precautions...11035
    Tools/Sealants...11035
    Power Steering Pump and Components (Exploded View)...11036
    Serpentine Belt Routing...11037
    Important Service Information...11038
      Pump Pulley Replacement...11038
      Serpentine Belt Adjustment...11039
    Testing and Repair...11039
    Checking Pump Fluid Level...11039
    Filling and Air Bleeding System...11039
    Belt Adjustment...11039
      V-Belt...11039
    Pump Assembly...11040
    Mounting Bracket...11041
    Hydraulic Hoses and Fluid Cooler...11041
      High Pressure Hose (Pump-to-Control Valve)...11041
      Low Pressure Hose (Cooler-to-Pump)...11042
      Low Pressure Hose  (Control Valve-to-Cooler)...11044
    Priority Valve Kit (79691A1) Information...11046
      Installing Reservoir...11046
      Installing Priority Valve...11048
      Filling System with Fluid Maintenance...11051
      System Flow Diagram...11052
Service Manual #18...11054
  Notice...11055
  Notice to Users of This Manual...11055
  Engine Mechanical Replacement Parts Components...11056
  V-6 Models Covered in This Manual...11057
  Service Manual Outline...11058
  18A1R2.PDF...0
    Table of Contents...11060
    Introduction How to Use This Manual...11061
      Page Numbering...11061
    How To Read Parts Manual...11062
    Directional References Engine Serial Number Locations...11063
    Propeller Information Engine Rotation...11063
    Water Testing New Engines...11064
    Boat and Engine Performance...11064
      Boat Bottom...11064
      Marine Fouling...11065
      Weight Distribution Elevation and Climate...11066
      Water in Boat...11066
  18B1R2.PDF...0
    Table of Contents...11068
    Maintenance Schedules...11069
      Maintenance Intervals...11069
      Alpha Models...11069
      Bravo Models...11072
    Tune-Up Specifications...11075
    Tune-Up Specifications...11076
    Fluid Capacities...11077
      Hour Break-In Period...11078
    Fuel, Oil, Fluid, and Coolant Specifications...11078
      Fuel...11078
      Crankcase Oil...11080
    Maintaining Crankcase Oil Level...11081
      Overfilled Engine Crankcase...11081
      Power Steering Fluid...11081
      Coolant for Closed Cooling System...11081
    Maintaining Power Steering Pump Fluid Level...11082
      With Engine Warm...11082
    Changing Oil and Filter...11082
      With Engine Cold...11083
    Filling and Bleeding Power Steering System...11083
    Maintaining Closed Cooling Flushing Cooling System Coolant Level...11084
    Lubrication...11086
      Throttle Cable...11086
      Shift Cable...11087
      Engine Coupler/U-Joint Shaft Splines...11087
    Audio Warning System Cold Weather or Extended Storage...11088
      Maintenance Precautions...11088
      Layup...11089
    Draining Instructions...11090
      Draining Seawater (Raw-Water) Cooled Models...11090
      Draining Seawater Section of Closed Cooled (Coolant) Models...11093
      Recommissioning...11095
  18C1R2.PDF...0
    Table of Contents...11099
    Precautions...11100
    Used Spark Plug Analysis...11100
      Wet Fouling (Oil Deposits)...11101
    Spark Plug Analysis...11101
      Normal Condition...11101
      Cold Fouling...11101
      Chipped Insulator...11101
      Overheating Scavenger Deposits...11102
      Pre-Ignition Damage High Speed Glazing...11102
      Reversed Coil Polarity Mechanical Damage...11103
      Splashed Deposits...11103
    Poor Boat Performance and/or Poor Maneuverability...11104
    Improper Full Throttle Engine RPM...11105
      RPM Too High...11105
      RPM Too Low...11105
    Engine Cranks Over But Will Not Start Or Is Hard To Start...11106
      Important Information...11106
      Thunderbolt IV and V Ignition ( No Spark)...11106
      Testing Thunderbolt IV System...11107
      WARNING...11107
      Testing Thunderbolt V Ignition System...11108
    Fuel System Rich...11109
    Fuel System Lean...11109
    Miscellaneous...11109
    Engine Will Not Crank Over/Starter Inoperative...11110
    Charging System Inoperative...11110
    Noisy Alternator...11111
    Instrumentation Malfunction...11111
    Radio Noise...11111
    Poor Fuel Efficiency...11112
    Carburetor Malfunction...11113
    Carburetor Malfunction (continued)...11114
    Engine Runs Poorly At Idle...11115
    Engine Acceleration Is Poor...11116
    Engine Runs Poorly At High RPM...11117
    Troubleshooting With Vacuum Gauge...11118
    Engine Noise...11119
      Important Information...11119
    Valve Cover Area...11119
    Cylinder Area...11119
    Camshaft Area...11120
    Crankshaft Area...11120
    Miscellaneous...11121
    Oil Pressure...11122
    Low Oil Pressure...11123
    High Oil Pressure...11123
    Excessive Oil Consumption...11124
    Water in Engine...11125
      Important Information...11125
    Water In Crankcase...11125
    Water On Top Pistons...11126
    Engine Overheats (Mechanical)...11127
    Engine Overheats (Cooling System)...11128
    Insufficient Water Flow From Belt Driven Seawater Pump...11129
    Power Steering...11130
      Poor, Erratic, or No Assist...11130
    Noisy Pump...11131
    Fluid Leaks...11131
  18A2R2.PDF...0
    Table of Contents...11133
    Torque Specification...11134
    Tools/Lubricants/Adhesives/Sealants...11134
    Removal...11135
      Engine Removal...11135
    Installation...11136
      Engine Installation/Alignment...11136
      Engine Connections...11138
  18B2R2.PDF...0
    Table of Contents...11144
    Torque Specifications...11145
    Tools/Lubricants/Adhesives/Sealants...11145
    Removal...11146
    Installation...11147
      Engine Installation/Alignment...11147
      Engine Connections...11150
      Throttle Connections...11151
  18A3R2.PDF...0
    Table of Contents...11157
    Torque Specifications 4.3L/4.3LX Engines...11158
    Torque Specifications 4.3L/4.3LX Engines (continued)...11159
    Tools/Lubricants/Sealants...11160
    Engine Specifications...11161
      CID / 4.3L Engine Specifications (Does Not Include Gen +)...11162
      CID / 4.3L Engine Specifications (Does Not Include Gen +)...11163
      CID / 4.3L Engine Specifications (Does Not Include Gen +)...11164
      CID / 4.3L Engine Specifications (Does Not Include Gen +)...11165
      CID / 4.3L Gen + Engine Specifications...11166
      CID / 4.3L Engine Gen + Specifications...11167
      CID / 4.3L Gen + Engine Specifications...11168
      CID / 4.3L Gen + Engine Specifications...11169
      CID / 4.3L Gen + Engine Specifications...11170
      Cylinder Head Identification...11171
    General...11171
      Engine Identification...11171
      Engine Rotation...11171
      Crankshaft Cylinder Head...11172
      Valve Train Piston and Connecting Rods...11172
      Camshaft and Drive...11172
      Intake Manifold...11172
      Balance Shaft...11172
      Lubrication System...11173
    Bearing Failures...11174
    Piston Failures...11174
      Pre-Ignition...11174
      Detonation...11175
    Engine Mounts Rocker Arm Cover...11176
      Removal...11176
      Installation...11176
      Installation...11177
    Intake Manifold...11177
      Removal...11177
      Cleaning and Inspection...11177
    Rocker Arm/Push Rod Hydraulic Roller Valve Lifters...11179
      Removal...11179
      Cleaning and Inspection...11179
      Installation...11179
      Locating Noisy Lifters Removal...11180
      Cleaning and Inspection...11181
      Installation...11181
    Valve Stem Oil Seal/Valve Spring...11182
      Removal - Head Installed...11182
      Valve Assembly (Exploded View)...11182
      Installation - Head Installed...11183
    Cylinder Head...11183
      Removal...11183
      Cleaning and Inspection...11183
      Installation...11184
    Cylinder Head and Valve Conditioning...11184
      Disassembly...11184
      Cleaning Inspection...11185
      Valve Springs - Checking Tension...11186
      Valve Guide Bore Repair...11186
      Valve Seat Repair Valve Grinding...11187
      Reassembly...11188
    Dipstick Specifications...11189
      All Engines...11189
    Oil Pan...11190
      Removal...11190
      Installation...11190
    Oil Pump...11190
      Removal Cleaning and Inspection...11191
      Reassembly...11191
      Disassembly...11191
      Installation Installation...11192
    Torsional Damper...11192
      Removal...11192
    Crankcase Front Cover/Oil Seal...11193
      Oil Seal Replacement (Without Removing Front Cover)...11193
    Crankcase Front Cover...11194
      Removal...11194
      Cleaning and Inspection...11194
    Flywheel...11195
      Removal...11195
      Inspection...11195
      Installation...11195
      Cleaning and Inspection...11196
    Rear Main Oil Seal...11196
      Removal...11196
      Installation Cleaning and Inspection...11197
      Installation...11197
    Rear Main Oil Seal Retainer...11197
      Removal...11197
    Main Bearings...11197
      Inspection...11198
      Checking Clearances...11198
      Replacement...11199
    Connecting Rod Bearings...11200
      Inspection and Replacement...11200
    Connecting Rod/Piston Assembly...11201
      Removal...11201
      Disassembly...11202
      Cleaning and Inspection...11202
      Reassembly...11203
      Installation...11204
    Crankshaft...11205
      Removal...11205
      Cleaning and Inspection...11206
      Installation...11206
      Cleaning and Inspection...11207
    Timing Chain and Sprocket...11207
      Removal...11207
      Installation - Timing Chain...11207
      Checking Timing Chain Deflection...11208
    Crankshaft Sprocket...11208
      Removal...11208
      Installation...11208
    Balance Shaft/Gears...11209
      Removal...11209
      Cleaning and Inspection...11210
      Installation...11210
    Camshaft...11211
      Measuring Lobe Lift...11211
      Removal Installation...11212
    Camshaft Bearings...11212
      Removal...11212
      Inspection...11212
      Installation...11213
      Inspection...11213
    Cylinder Block...11214
      Cleaning and Inspection...11214
    Oil Filter By-Pass Valve...11217
      Inspection and/or Replacement...11217
  18A4R2.PDF...0
    Table of Contents...11222
    Starters (PG260 And Delco-Remy)...11223
      Specifications...11223
      Torque Specifications...11224
      Lubricants, Sealers and Adhesives...11224
      Identification Battery Cable Recommendations...11224
    Starting System Components For PG260 (Typical Diagram)...11225
    Starting System Components for Delco-Remy Direct Drive Starter (Typical Diagram)...11226
      PG 260 Starter Motor (Exploded View)...11227
      Delco-Remy Starter Motor (Exploded View)...11228
    Replacement Parts Warning...11229
      Maintenance...11229
      Testing WARNING CAUTION...11229
      Storage...11230
    Description...11230
    Positive Current Flow...11230
    Solenoid Switch...11230
    Periodic Inspection...11230
    Starter Motor Repair...11231
      Removal...11231
      Disassembly...11231
      Cleaning and Inspection...11233
      Armature Tests...11233
      Armature Bearing (Commutator End)...11233
      Shaft Assembly Bearing...11234
      Gear Bearing...11234
      Drive End Housing Bearing...11234
      Brushes and Brush Holder...11235
      Reassembly...11236
      Clearances...11238
    Standard Starter Slave Solenoid...11239
      Testing/Replacement...11239
      Installation...11239
    Delco PG 260...11240
      Identification...11240
    Replacement Parts Warning Solenoid Switch...11240
    Periodic Inspection...11240
      Maintenance...11240
    Starter Motor Repair...11240
      Removal...11240
      Disassembly...11241
      Armature Tests...11243
      Cleaning and Inspection...11243
      Brushes and Brush Holder...11244
      Reassembly...11244
      Clearances...11247
      Installation...11248
  18B4R2.PDF...0
    Table of Contents...11250
    Thunderbolt IV (HEI) Ignition System...11251
      Special Tools...11251
      Torque Specifications...11251
      Lubricants, Sealers and Adhesives...11251
      Coil Specifications...11251
      Exploded View for Thunderbolt IV Distributor For V-6 Engines...11252
      MCM V-6 262 CID (4.3L) with Thunderbolt IV...11253
      Distributor Advance Curves...11254
    Replacement Parts Warning...11254
    Repair...11254
      Precautions...11254
      Spark Plugs...11254
      Firing Order...11254
      Distributor Cap Rotor/Sensor Wheel...11255
      Sensor...11256
      Spark Plugs...11257
      Ignition Module...11258
    Distributor Repair...11258
      Removal...11258
      Spark Plug Wires...11258
      Disassembly...11258
      Reassembly...11259
    Distributor Installation...11259
      Engine Not Disturbed...11259
      Engine Disturbed...11260
    Ignition Timing...11260
    Thunderbolt V Ignition System...11261
      Identification...11261
    General Description...11262
      Over-Speed Control...11262
      Idle Speed Spark Control...11262
      Knock Retard Spark Control...11262
      Acceleration Spark Advance...11262
      Mean-Best-Timing (MBT) Spark Advance...11262
    Thunderbolt V Spark Control Graph...11263
      Knock Control Module...11264
    Circuit Description...11264
      Ignition Control Module...11264
      Ignition Control System Timing Lead...11264
    Ignition System Wiring Diagram...11265
    Timing and Idle Adjustment Procedures For Thunderbolt V Ignition...11266
      Setting Base Ignition Timing...11266
      Adjusting Engine Idle Speed...11266
      Adjusting Idle Mixture...11266
    Troubleshooting Thunderbolt V Ignition...11267
      Ignition Control Module /Coil /Distributor...11267
      Knock Control Module...11268
      Spark Plugs...11269
      Spark Plug Wires...11270
  18C4R2.PDF...0
    Table of Contents...11272
    Identification Mando 55 and 65 Amp Alternator...11273
    Specifications...11273
    Tools/Sealants...11273
    Replacement Parts Warning...11273
    Torque Specifications...11274
    Description...11274
    Precautions...11274
    Periodic Maintenance...11275
    System Components...11275
    Drive Belt Tension Adjustment...11276
      V-Belt...11276
      Serpentine Belt...11276
    Troubleshooting Tests (Alternator on Engine)...11277
      Circuitry Test...11277
      Current Output Test...11278
      Voltage Output Test...11279
    Alternator Repair...11280
      Removal...11280
      Exploded View...11281
      Disassembly...11282
      Cleaning and Inspection...11284
      Component Testing...11285
      Reassembly...11288
    Battery Isolators...11291
      Dual Battery Charging Systems Using a Battery Isolator...11291
    Installation...11291
    Battery Isolator...11292
  18D4R2.PDF...0
    Table of Contents...11296
    Identification Special Information...11297
      Lighting Options...11297
    Gauges...11298
      Oil, Fuel and Temperature...11298
      Battery Gauge...11299
      Cruiselog Meter Vacuum Gauge...11300
      Speedometer...11300
      Tachometer...11300
      Gauge Replacement...11301
    Senders...11301
      Oil Pressure...11301
      Water Temperature WARNING...11302
      Fuel Tank Sender...11303
    Switches...11305
      Ignition Key Switch...11305
      Lanyard Stop Switches...11306
      Start/Stop Switch Buzzer...11307
    Audio Warning System...11307
      Oil Pressure Switch...11308
      Water Temperature Switch...11308
  18E4R2.PDF...0
    Table of Contents...11313
    Wiring Colors for MerCruiser...11314
      MCM V-6 Alpha Thunderbolt IV...11315
      MCM V-6 Gen + Alpha Thunderbolt V Without Knock Sensor...11316
      MCM V-6 Gen + Bravo Thunderbolt V Without Knock Sensor...11317
      MCM 262 Magnum EFI Gen + Alpha and Bravo Starting and Charging Harness...11318
      MCM 262 Magnum EFI Gen + Alpha (Vapor Separator Tank [VST]) EFI System Harness...11319
      MCM 262 Magnum EFI Gen + Bravo (Vapor Separator Tank [VST]) EFI System Harness...11320
      MCM 262 Magnum EFI Gen + Alpha (Cool Fuel System) EFI System Harness...11321
      MCM 262 Magnum EFI Gen + Bravo (Cool Fuel System) EFI System Harness...11322
      Quicksilver Instrumentation...11323
      Dual Station Wiring (Using a Neutral Safety Switch in Only One Remote Control)...11324
      Dual Station Wiring (Using A Neutral Safety Switch In Both Remote Controls)...11325
      Dual Station Wiring (Using a Neutral Safety Switch in Engine Wiring Harness)...11326
      EFI Wiring Diagram (Chart 1 Of 4)...11327
      EFI Wiring Diagram (Chart 2 Of 4)...11328
      EFI Wiring Diagram (Chart 3 Of 4)...11329
      EFI Wiring Diagram (Chart 4 Of 4)...11330
  18A5R2.PDF...0
    Table of Contents...11333
    CID / 4.3L...11334
      Torque Specifications...11334
      Special Tools...11334
      Lubricants, Sealers and Adhesives...11334
      Specifications...11334
    Identification...11334
    Replacement Parts Warning Precautions...11335
      Fuel Supply Connections...11335
      Description...11336
    Fuel System Components (Carburetor) Fuel Delivery System...11336
      Recommendations...11336
    Water Separating Fuel Filter...11336
    Testing Fuel Pump...11338
      Replacement...11338
    Electric Fuel Pump For Carbureted and VST Equipped Engine...11338
      Replacement...11338
      Fuel System For Carbureted Engines...11341
      VST System for Throttle Body Cool Fuel System For Throttle Body Injection Injection...11342
  18B5R2.PDF...0
    Table of Contents...11345
    MerCarb 2 BBL Carburetor...11346
      Torque Specifications...11346
      Tools...11346
      Specifications...11346
    Exploded View...11347
    Identification...11349
    Important Service Information...11349
      Flooding at Idle RPM...11349
      Needle/Seat Change...11349
      Adjustable Accelerator Pump Lever High Altitude Re-Jetting...11350
    Description...11350
    Precautions Maintenance...11351
      Flame Arrestor with Carburetor WARNING Cover...11351
      Fuel Inlet Filter...11352
      Choke Inspection...11353
    Adjustments...11353
      Pump Rod...11353
      Choke Setting...11354
      Preliminary Idle Speed and Mixture...11354
      Choke Unloader...11354
      Final Idle Speed and Mixture...11355
      Installation...11356
    Repair...11356
      Removal...11356
      Disassembly...11357
      Cleaning and Inspection...11362
      Reassembly...11363
  18C5R2.PDF...0
    Table of Contents...11374
    Identification Torque Specifications...11375
    Tools...11375
    Replacement Parts Warning...11375
    Specifications...11376
      Jet Changes for Altitude...11376
      Carburetor Adjustment Specifications...11377
    Description...11378
    Precautions...11378
      Hard Starting...11379
    Important Service Information...11379
      Weber Carburetor Adjustable Accelerator Pump...11379
      Carburetor Metering Rod And Jet Identification...11380
    Maintenance...11381
      Flame Arrestor...11381
      Fuel Filter...11382
    Adjustments...11383
      Accelerator Pump...11383
      Choke Pull-Off...11384
      Float Drop...11384
      Float Level...11385
    Idle Speed and Mixture Adjustments...11386
      Thunderbolt IV Equipped  Engines...11386
      Thunderbolt V Equipped Engines...11388
    Repair...11389
      Removal...11389
      Installation...11390
      Exploded View...11392
      Disassembly...11393
      Cleaning and Inspection...11402
      Reassembly...11403
  18D5R2.PDF...0
    Table of Contents...11415
    General Information...11418
      Basic Knowledge and Tools Required...11418
      Electrostatic Discharge Damage...11418
      Introduction...11418
      Diagnostic Information...11419
      Wiring Harness Service...11419
      Wiring Connector Service...11419
    Abbreviations...11420
      Changes In Terminology...11421
      Diagnostic Trouble Codes...11421
    ECM Self-Diagnostics...11422
      Reading Codes...11422
      Diagnostic Code Tool With Malfunction Indicator Lamp...11422
      Intermittent Malfunction Indicator Lamp...11422
      EFI Diagnostic Circuit Check...11423
      Scan Tool Use with Intermittents...11423
      Scan Tools...11423
      Non-Scan Diagnosis of Driveability Concerns (With No Codes Set)...11424
      Special Tools...11425
      Service Precautions...11426
    Electronic Control Module (ECM) and Sensors...11427
      General Description...11427
      Computers and Voltage Signals...11427
      Analog Signals...11427
      Digital Signals...11428
      Engine Control Module (ECM)...11428
      Speed Density System...11429
      ECM Input and Sensor Descriptions...11430
      INPUTS...11430
      OUTPUTS...11430
      Distributor Module Mode...11433
    Spark Management...11433
      High Energy Ignition with Ignition Control (IC)...11433
      ECM Control Mode...11433
      Modes Of Operation...11433
      Base Ignition Timing...11433
      Results of Incorrect Operation...11435
    Fuel Metering System...11435
      General Description...11435
      Modes of Operation...11435
      Cool Fuel System...11436
      Throttle Body Injection Components...11438
    ECM Connector and Symptom Charts...11442
    ECM Connector and EFI Symptoms Chart (J-1 Circuits)...11443
    ECM Connector and EFI Symptoms Chart (J-1 Circuits)...11444
    ECM Connector and EFI Symptoms Chart (J-2 Circuits)...11445
    ECM Connector and EFI Symptoms Chart (J-2 Circuits)...11446
      Throttle Body Injection Wiring Diagram (Chart 1 of 4)...11447
      Throttle Body Injection Wiring Diagram (Chart 2 Of 4)...11448
      Throttle Body Injection Wiring Diagram (Chart 3 Of 4)...11449
      Throttle Body Injection Wiring Diagram (Chart 4 Of 4)...11450
    Diagnostic Circuit Check...11452
      Scan Tool Normal Specifications (Idle /Warm Engine/Closed Throttle/Neutral)...11452
      No ïMalfunction Indicator Lampì (Marine Diagnostic Code Tool Installed) Chart A-1 (1 of 2)...11455
      No  Malfunction Indicator Lamp  Chart A-1: (2 of 2)...11456
      No DLC Data or Will Not Flash Code 12  Malfunction Indicator Lamp  On Steady (Marine Diagnostic Code Tool Installed) Chart A-2 (1 of 2)...11457
      No DLC Data or Will Not Flash Code 12 Chart A-2: (2 of 2)...11458
      Engine Cranks but Will Not Run Chart A-3 (1 of 4)...11459
      Engine Cranks but Will Not Run (Continued) Chart A-3: (2 of 4)...11460
      Engine Cranks but Will Not Run (Continued) Chart A-3 (3 of 4)...11461
      Engine Cranks but Will Not Run (Continued) Chart A-3: (4 of 4)...11462
      Fuel System Diagnosis Chart A-7 (1 of 6)...11463
      Fuel System Diagnosis (Continued) Chart A-7: (2 of 6)...11464
      Fuel System Diagnosis (Continued) Chart A-7 (3 of 6)...11465
      Fuel System Diagnosis (Continued) Chart A-7: (4 of 6)...11466
      Fuel System Diagnosis (Continued) Chart A-7 (5 of 6)...11467
      Fuel System Diagnosis (Continued) Chart A-7: (6 of 6)...11468
      EFI System/Ignition Relay Check (1 of 2)...11469
      EFI System / Ignition Relay Check (Continued) (2 of 2)...11470
      Ignition System Check (1 of 2)...11471
      Ignition System Check(1 of 2)...11472
      Ignition System Check (2 of 2)...11473
      Ignition System Check (2 of 2)...11474
      Idle Air Control (IAC) Functional Test (1 of 2)...11475
      Idle Air Control Functional Test  (2 of 2)...11476
      Lanyard Stop Circuit Check (Emergency Stop) Circuit Check (1 of 2)...11477
      Lanyard Stop (Emergency Stop) Circuit Check (2 of 2)...11478
      Audio Warning Buzzer Circuit Check (1 of 2)...11479
      Audio Warning Buzzer Circuit Check (2 of 2)...11480
    Diagnostics-Without Scan Tool...11481
      Code 14: Engine Coolant Temperature (ECT) Sensor Circuit (Non-Scan) (1 of 2)...11481
      Code 14: ECT Circuit (Non-Scan)  (2 of 2)...11482
      Code 21: Throttle Position (TP) Sensor Circuit (Non-Scan) (1 Of 2)...11483
      Code 21: Throttle Position (TP) Sensor Circuit (Non Scan)...11484
      Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Non-Scan) (1 Of 2)...11485
      Code 33: MAP Circuit (Non-Scan)  (2 of 2)...11486
      Code 42: Ignition Control (IC) Circuit (Non-Scan) (1 of 2)...11487
      Code 42: IC Circuit (Non-Scan) (2 of 2)...11488
      Code 43: Knock Sensor (KS) (Non-Scan) (1 of 2)...11489
      Code 43: Knock Sensor (KS) Circuit (Non-Scan) (2 of 2)...11490
      Code 51: Calibration Memory Failure Non-Scan Diagnostics (1 of 2)...11491
      Code 51: Calibration Memory Failure (Non-Scan) (2 of 2)...11492
    Diagnostics - Using Scan Tool (Scan)...11493
      Code 14 Engine Coolant Temperature (ECT) Sensor Circuit (Scan) (1 of 2)...11493
      Code 14: ECT Circuit (Scan) (2 of 2)...11494
      Code 21: Throttle Position (TP) Sensor Circuit (Scan) (1 of 2)...11495
      Code 21: TP Sensor Circuit (Scan) (2 of 2)...11496
      Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Scan) (1 of 2)...11497
      Code 33: MAP Circuit (Scan) (2 of 2)...11498
      Code 42: Ignition Control (IC) Circuit (Scan) (1 Of 2)...11499
      Code 43: Knock Sensor (KS) (Scan) (1 Of 2)...11501
      Code 43: KS Circuit (Scan) (2 of 2)...11502
      Code 51: Calibration Memory Failure (Scan) (1 Of 2)...11503
      Code 51: Calibration Memory Failure (Scan) (2 of 2...11504
    Troubleshooting...11505
      Changes In Terminology...11505
      Diagnostic Trouble Codes...11505
      Important Preliminary Checks...11505
    Troubleshooting Charts...11506
    Fuel Delivery Systems...11527
      Cool Fuel System Exploded View...11527
      Vapor Separator Tank (VST) Exploded View...11529
      Torque Sequence For VST...11530
      VST Fuel Pump (Exploded View)...11531
      Vapor Separator Tank (VST)...11533
      Float and Needle Assembly...11534
      Diaphragm Assembly...11535
    Repair Procedures Torque Specifications...11537
    Special Tools...11537
    Lubricants/Sealants/ Adhesives...11537
    Throttle Body Injection System Description...11538
    Service Precautions...11538
    Throttle Body Exploded Views...11539
      Induction System...11539
      Throttle Body...11540
      Fuel Pressure Relief Procedure...11541
      Fuel Meter Cover Assembly...11541
      Fuel Injectors...11542
      Throttle Body...11543
      Throttle Body Adapter Plate...11544
    Throttle Body Injection Sensor and Module Servicing...11545
      Precautions...11545
      Electronic Control Module (ECM)...11545
      Knock Sensor (KS) Module Engine Coolant Temperature (ECT) Sensor...11546
      Manifold Absolute Pressure (MAP) Sensor...11547
      Idle Air Control (IAC) Valve...11548
      Knock Sensor...11549
      Fuel Pump Relay...11552
    Ignition Control (IC) System Components...11552
      Precautions...11552
      Ignition Coil...11553
      Spark Plug Replacement...11554
  18E5R2.PDF...0
    Table of Contents...11560
    Identification Torque Specifications...11561
    Special Tools...11561
    Replacement Parts Warning...11561
    Carburetor Specifications...11562
    Carburetor Adjustment Specifications...11562
    Engine Specifications...11562
    Description Special Notes...11563
      Carburetor Top Cover...11563
      Sealed Idle Mixture Screws...11563
      Metering Assembly...11564
    Precautions...11565
      Fuel Filter...11566
    Maintenance...11566
      Flame Arrestor...11566
      Positive Crankcase Ventilation (PCV)...11566
    Troubleshooting...11567
      Checking Ported Vacuum Switch and Carburetor Vacuum Circuit for Correct Operation...11567
    Service Procedures...11568
      Checking Positive Crankcase Ventilation (PCV) Valve...11568
      Removing Seals From Idle Mixture Screws...11569
      Installing New Seals...11569
      Carburetor Installation Ported Vacuum Switch Installation...11570
      Emissions System Connections...11571
      Propane Assisted Idle Set Procedure...11572
    Emissions Testing...11574
    Test Equipment...11574
  18A6R2.PDF...0
    Table of Contents...11578
    Seawater Inlet Recommendations...11582
      Transom Mounted or Thru-Hull Seawater Pickups and Hose...11582
      Sea Strainer...11582
      Transom Mounted...11583
    Seawater Pickups...11583
      Thru-Hull Mounted...11583
      Removal...11584
    Sea Strainer (Quicksilver)...11584
      Installation...11585
    Stern Drive Unit Seawater Pickup Pump Output Test...11586
      Cleaning and Inspection...11587
    Stern Drive Unit Seawater Pickup Pump Repairs...11587
      Installation...11587
    Water Circulating Pump Replacement...11587
      Removal...11587
    Flushing Seawater Cooling System...11588
      Engines with Stern Drive Seawater Pickup Pump Check/Clean Seawater Strainer...11588
    Thermostat...11589
      Removal...11589
      Testing...11590
      Installation...11591
    Draining Seawater Cooling System...11592
      Draining Precautions...11592
    Auxiliary Hot Water Heater Installation Information...11595
  18B6R2.PDF...0
    Table of Contents...11600
    Water Flow Diagrams...11602
      Engines With Coolant Flow Thru Exhaust Manifolds (Excluding Gen +)...11602
      Engines With Raw Water Flow Thru Exhaust Manifolds...11603
    Description Seawater Pickup Pump (If Equipped)...11604
      Maintenance...11604
      Stern Drive Unit Seawater Pickup Pump...11604
      Belt Driven Seawater Pickup Pump...11604
    Closed Cooling Systems With Coolant Flow Thru Exhaust Manifolds (Excluding Engines With Serpentine Belt)...11617
      Maintaining Coolant Level...11617
    Pressure Cap Maintenance...11617
    Heat Exchanger Repair...11618
    Testing Closed Cooling System...11618
      Testing Coolant for Alkalinity...11618
      Pressure Testing System...11619
      Testing for Cylinder Head Gasket Testing Heat Exchanger Leak...11620
      Testing Pressure Cap...11620
    Thermostat...11621
      Removal...11621
      Testing...11623
      Installation...11624
      Coolant Recommendations...11626
      Change Intervals...11626
      Draining Instructions CAUTION WARNING...11626
    Changing Coolant...11626
      Closed Cooling Section...11626
      Seawater Section...11627
    Cleaning System...11627
      Closed Cooling Section...11627
    of Closed Cooling System...11628
    Flushing Seawater Section...11628
    Draining Seawater Section of Closed Cooling System...11630
      Draining Precautions...11630
    Filling Closed Cooling Section...11632
    Closed Cooling System With Raw Water Flow Thru Exhaust Manifold (Engines With Serpentine Belt Only)...11633
      Maintaining Closed Cooling System WARNING Coolant...11633
      Checking Coolant for Alkalinity...11634
      Changing Coolant...11634
      Flushing Seawater Section CAUTION...11638
      Cleaning Seawater Section of Heat Exchanger and Fluid Coolers...11639
      Cleaning Closed Cooling Section...11640
    Cold Weather or Extended Storage...11641
      Seawater Section Draining Instructions...11641
      Serpentine Drive Belt Adjustment...11644
    Auxiliary Hot Water Heater Installation...11645
  18A7R2.PDF...0
    Table of Contents...11650
    Exhaust System Requirements...11651
      All Engines...11651
  18B7R2.PDF...0
    Table of Contents...11655
    Torque Specifications...11656
    Sealants...11656
    Removal...11656
    Installation...11657
    Cleaning and Inspection...11657
  18C7R2.PDF...0
    Table of Contents...11661
    Exhaust Riser (Kit) Replacement Information Identification...11662
      Engine Preparation and Parts Removal...11662
    Additional Kit...11662
      Riser Installation...11662
    Torque Specifications...11662
    Sealants...11662
    Installation Diagrams ...11664
  18D7R2.PDF...0
    Table of Contents...11668
    Torque Specifications...11669
      Shutter Replacement...11669
      Component Replacement...11669
  18A8R2.PDF...0
    Table of Contents...11672
    Torque Specifications Precautions...11673
    Tools/Sealants...11673
    Power Steering Pump and Components (Exploded View)...11674
    Serpentine Belt Routing...11675
    Important Service Information...11676
      Pump Pulley Replacement...11676
      Serpentine Belt Adjustment...11677
    Testing and Repair...11677
    Checking Pump Fluid Level...11677
    Filling and Air Bleeding System...11677
    Belt Adjustment...11677
      V-Belt...11677
    Pump Assembly...11678
    Mounting Bracket...11679
    Hydraulic Hoses and Fluid Cooler...11679
      High Pressure Hose (Pump-to-Control Valve)...11679
      Low Pressure Hose (Cooler-to-Pump)...11680
      Low Pressure Hose  (Control Valve-to-Cooler)...11682
    Priority Valve Kit (79691A1) Information...11684
      Installing Reservoir...11684
      Installing Priority Valve...11686
      Filling System with Fluid Maintenance...11689
      System Flow Diagram...11690
Service Manual #22  4.2 D-Tronic  Diesel...11692
Service Manual #23...12570
Service Manual #24 Suppliment...13597
  Models Covered...13600
  Section 1 - Important Information...0
    A - General Information...13607
    B - Maintenance...13610
  Section 3 - Engine...0
    A - 377 CID / 6.2L Engines...13655
  Section 4 - Electrical Systems...0
    E - Wiring Diagrams...13744
  Section 5 - Fuel Systems...0
    E - Fuel Injection System Assembly and Disassembly...13752
    G - Diagnostics...13794
Service Manual #24...13808
  Section 1 - Important Information...0
    A - General Information...13826
    B - Maintenance...13836
    C - Troubleshooting...13890
  Section 2 - Removal and Installation...0
    A - MCM Models...13924
    B - MIE Models...13950
  Section 3 - Engine...0
    A - 350 cid / 5.0L / 305 cid / 5.7L Engines...13974
  Section 4 - Electrical Systems...0
    A - Starting System...14063
    B - Ignition System...14093
    C - Charging System...14123
    D - Instrumentation...14153
    E - Wiring Diagrams...14173
  Section 5 - Fuel Systems...0
    A - Fuel Delivery System for Carbureted Engines...14191
    B - MerCarb 2 Barrel Carburetor...14199
    C - Fuel Delivery System for Electronic Fuel Injection...14241
    D - Fuel Injection Descriptions and System Operation...14261
    E - Fuel Injection Disassembly and Reassembly...14367
    F - Fuel Injection System Troubleshooting...14409
    G - Diagnostics...14435
  Section 6 - Cooling System...0
    A - Seawater Cooled Models...14529
    B - Closed Cooled Models...14557
  Section 7 - Exhaust System...0
    A - General...14581
    B - Manifolds, Elbows and Risers...14587
    C - Collectors...14595
  Secton 8 - Drives...0
    A - Velvet Drive In-Line and V-Drive Transmission...14611
    B - Velvet Drive 5000 Series Transmission...14625
    C - Hurth Models...14649
    D - Drive Shaft / Propeller Shaft Models...14667
  Section 9 - Power Steering System...0
    A - Pump and Related Components...14685
Service Manual #25...14703
  A Section Cover.pdf...14704
  Section 1A General Information.pdf...14718
  Section 1B Maintenance.pdf...14728
  Section 1C Troubleshooting.pdf...14768
  Section 2A Removal and Installation.pdf...14800
  Section 3A Engine.pdf...14818
  Section 4A Starting Systems.pdf...14927
  Section 4B Thunderbolt V Ign. Sys..pdf...14963
  Section 4C Charging System.pdf...14983
  Section 4D Instrumentation.pdf...15013
  Section 4E Wiring Diagrams.pdf...15039
  Section 5A Fuel system for carbed engines.pdf...15069
  Section 5B Mercarb 2bbl Carb.pdf...15079
  Section 5C Weber 4bbl Carb.pdf...15121
  Section 5D Sav1 Emission.pdf...15169
  Section 5E Fuel Deliv Sys for EFI.pdf...15191
  Section 5F Fuel Infection Description and Sys Operation.pdf...15207
  Section 5G Fuel Injection Disassembly and Reassembly.pdf...15241
  Section 5H Fuel Injection system Troubleshooting.pdf...15269
  Section 5I Diagnostics.pdf...15295
  Section 6A Seawater Cooled Models.pdf...15385
  Section 6B Closed Cooled Models.pdf...15417
  Section 7A Exhaust System General.pdf...15441
  Section 7B manifolds, Elbows and Risers.pdf...15445
  Section 7C Collectors.pdf...15455
  Section 8A Drive Shaft.pdf...15461
  Section 9A Power Steering System.pdf...15475
Service Manual #26...15493
  Models Covered...15496
  Section 1 - Important Information...0
    A - General Information...15499
    B - Maintenance...15509
    C - Troubleshooting...15539
  Section 2 - Removal and Installation...0
    A - MCM 3.0L (1.81 CID) - Alpha Drive...15575
  Section 3 - Engine...0
    A - 3.0L (181 CID)...15595
  Section 4 - Electrical System...0
    A - Starting System...15667
    B - Ignition System...15711
    C - Charging System...15729
    D - Instrumentation...15765
    E - Wiring Diagrams...15787
  Section 5 - Fuel System...0
    A - Fuel Pump...15803
    B - Closed Cooled Models...15815
  Section 6 - Cooling System...0
    A - Seawater Cooled Models...15851
    B - Closed Cooled Models...15869
  Section 7 - Exhaust System...0
    A - Exhaust Manifolds / Elbows...15891
  Section 8 - Power Steering...0
    A - Power Steering...15899
Service Manual #27 suppliment...15915
Service Manual #27...16186
Service Manual #28...16817
  Models Covered...16817
  Section 1 - Important Information...0
    A - General Information...16831
    B - Maintenance...16835
    C - Troubleshooting...16863
  Section 2 - Removal, Installation and Adjustment...0
    A - All Models...16891
  Section 3 - Sterndrive Unit...0
    A - Drive Shaft Housing...16935
    B - Gear Housing - Bravo One...17013
    C - Gear Housing - Bravo Two...17075
    D - Gear Housing - Bravo Three...17133
  Section 4 - Transcom Assembly...0
    A - Service Procedures Requiring Minor Disassembly...17199
    B - Service Procedures Requiring Major Disassembly...17247
  Section 5 - Power Trim...0
    A - Oildyne Power Trim Pump...17313
    B - Trim Cylinders...17381
    C - Dual Power Trim Control...17403
  Section 6 - Steering Systems...0
    A - Power Steering...17415
    B - Compact Hydraulic Steering...17459
  Section 7 - Corrosion Protection...0
    A - All Models...17477
Service Manual #29...17505
Service Manual #30...18042
Service Manual #31...18397
  Models Covered...18399
  Section 1 - Important Information...0
    A - General Information...18423
    B - Maintenance...18429
    C - Troubleshooting...18535
    D - California Emissions Information...18577
  Section 2 - Removal and Installation...0
    A - MCM Models...18581
    B - MIE Models...18623
  Section 3 - Engine...0
    A - Engine Mechanical...18669
  Section 4 - Electrical System...0
    A - Starting System...18871
    B - Carbureted Ignition System...18889
    C - MPI Ignition System...18921
    D - Charging System...18943
    E - Instrumentation...18963
  Section 5 - Fuel System...0
    A - Carbureted Fuel System...18997
    B - MPI Fuel System Excluding Scorpion Models...19049
    C - Scorpion Fuel System...19093
  Section 6 - Cooling System...0
    A - All Models...19145
    B - Seawater Cooled Models...19189
    C - Closed Cooled Models...19209
  Section 7 - Exhaust System...0
    A - Manifolds, Elbows, and Risers for Wet Joint...19241
    B - Dry Joint Identification...19251
    C - Manifolds and Elbows with Dry Joint...19261
    D - Cold Riser with Dry Joint...19279
    E - Warm Riser with Dry Joint...19303
    F - Collectors...19325
  Section 8 - Drives...0
    A - Velvet Drive In-Line and V-Drive Transmission...19339
    B - Velvet Drive 5000 Series Transmission...19369
    C - ZF/Hurth 630 and 800 Series Transmission...19393
    D - ZF Marine/Hurth 45C In-Line Transmission...19415
  Section 9 - Power Steering...0
    A - Power Steering Pump...19425
  Section 10 - Water Flow Diagrams...0
    A - General Information...19449
    B - Seawater Cooled Carbureted Models...19453
    C - Seawater Cooled MPI Models...19461
    D - Closed Cooled Carbureted Models...19473
    E - Closed Cooled MPI Models...19479
Service Manual #32...19493
Service Manual #33...20003
  90-863757002_FM...20004
    Notice to Users of This Manual...20004
    Precautions...20005
    Replacement Parts...20005
    Cleanliness and Care of Product...20005
    Manual Outline...20006
  90-863757002_1A...20008
    Section 1A - General Information...20008
      Table of Contents...20008
      How To Use This Guide...20009
      ECM and PCM Abbreviations...20009
      Precautions...20017
        Service Precautions ...20018
      General Information...20019
        Electrostatic Discharge Damage...20019
        Wiring Harness Service...20019
        Wire Repair...20020
        Wiring Connector Service...20020
        Intermittent Problems...20021
      PCM 555 Ignition System...20022
        PCM 555 Controller...20022
        Main Power Relay (MPR)...20022
        Fuse...20022
        Crankshaft Position (CPS) Sensor...20022
        Crankshaft Reluctor Wheel...20023
        Camshaft Position (CMP) Sensor...20023
        Camshaft Reluctor Wheel...20023
        Ignition Coil Harness...20023
        Ignition Coils ...20024
        PCM 555 Ignition System Operation...20024
      PCM 555 Diagnostics...20024
        Abbreviated Procedure:...20025
        Visual and Physical Check:...20026
        Clearing Codes:...20028
        DTS Faults...20028
      Propulsion Control Module (PCM) and Sensors...20029
        General Description...20029
        Computers and Voltage Signals...20029
        Analog Signals...20029
        Digital Signals...20031
        Propulsion Control Module (PCM)...20032
      Engine Guardian System...20032
        General Description...20032
      Audio Warning System...20032
        All Serial Numbers 0M000000 and Above...20033
        All Serial Numbers 0M000000 and Above...20033
        All Digital Throttle and Shift (DTS) Sterndrive and Inboard Engines...20034
      Setting the Trim Limit on 496 Mechanical Engines (with 3-wire SmartCraft sender)...20034
      Setting Trailer and Trim Position on MerCruiser DTS Engines...20036
      General Reference Charts...20050
        Manifold Vacuum and Pressure...20050
        Vacuum Gauge versus MAP Sensor...20051
        Centigrade to Fahrenheit Conversion...20052
  90-863757002_2A...20054
    Section 2A -  Troubleshooting...20054
      Table of Contents...20054
      Troubleshooting Without a Diagnostic Tool...20057
      Troubleshooting with a Diagnostic Tool—CDS...20058
      Troubleshooting with the CDS Tool...20058
        DTS System Troubleshooting...20058
        CDS Connection to the Engine...20059
        CDS Power Up...20059
        Testing DTS Engine Components...20059
      Troubleshooting Worksheet for PCM...20060
        PCM Calibration Label...20060
        Data Collection...20061
        PCM 555/ECM 555 Scan Tool Worksheet...20061
        PCM 555/ECM 555 CDS Worksheet...20063
      Preliminary Checks...20065
      Symptom Charts...20066
        Chart A-1 Engine Cranks Over but Will Not Start...20067
        Chart A-2 Main Power Relay Test...20068
         Chart A-3 Fuel System Electrical Test...20069
        Chart A-4 Fuel System Diagnosis...20069
        Chart A-5 Ignition System Test...20071
        Chart A-6 Hard Start Symptom...20072
        Chart A-7 Engine Surges Symptom...20074
        Chart A-8 Lack of Power, Sluggish, or Spongy Symptom...20075
        Chart A-9 Detonation or Spark Knock Symptom...20077
        Chart A-10 Hesitation, Sag, or Stumble Symptom...20078
        Chart A-11 Engine Misses Symptom...20080
        Chart A-12 Rough, Unstable, or Incorrect Idle and Stalling Symptom...20081
        Chart A-13 Poor Fuel Economy Symptom...20082
        Chart A-14 Dieseling or Run-On Symptom...20083
        Chart A-15 Backfire Symptom...20084
      Fuel Pressure Gauge Setup for PCM Engines...20086
        Installation...20086
        Test...20087
        Removal...20087
      Injector Balance  Test ...20087
        Test Procedure...20087
      Troubleshooting With a Vacuum Gauge...20089
        Vacuum Gauge Troubleshooting Guide...20089
      Engine Fault Quick Reference Chart...20091
      MerCruiser PCM Fault List...20091
        MerCruiser ECM/PCM Fault List...20091
        ECM/PCM Fault List Information...20091
          Fault Conditions...20091
          Sticky and Non-Sticky Faults...20092
          Default Sensor Values...20092
        MerCruiser ECM/PCM Fault List Table Columns...20092
          Fault #...20092
          CDS Fault Message...20092
          DDT Fault Status Message...20092
          Icon/Horn/Guardian Column...20092
            ♠- System View Icon...20092
            ♥- Warning Horn Signals...20092
            ♦- Engine Guardian...20093
          Fault Explanation...20093
          Possible Root Cause...20093
        MerCruiser ECM/PCM Fault List Table...20093
      PCM Frequently Asked Questions...20106
        What is a circuit (CKT) high or low fault?...20106
         What is a STR (Strategy)?...20106
        What is a TPI/TPS High or Low Range fault?...20107
        Why do we use the loaded volts lead on some pinpoint tests? ...20107
         How can I switch between the data screens and the service manual?...20107
        Why do some faults take longer to set than others?...20107
        What is an (MPR) Main Power Relay Output Fault?...20107
        What’s wrong when I see a PWR1 or 5VDC Power Low fault?...20107
        Why does an EST or ECM Trigger Open not register as a fault when the engine is running? ...20108
         What are MAP Diff or TPI Diff errors?...20108
         What is a MAP Idle Check or MAP Idle Err?...20108
        What do Overspeed Fault and Engine Guardian Fault indicate?...20108
        What is a MPRLY REQ (Main Power Relay Request) in the Freeze Frame buffer?...20108
         Why is the engine slowing down and how do I know if Engine Guardian is active?...20109
         I see the following faults: OIL LVL IN(ckt) HI, FUEL LVL IN(ckt) HI or SEA TEMP IN(ckt) HI. Is there a problem and how can I eliminate these faults?...20109
         What is a good tool to use to diagnose boat wiring problems?...20109
         Why can I not get the active data screen to list any values?...20109
        What should I do if the CDS system locks up?...20109
        Why do I have to connect the ohm meter leads together at the start of the pinpoint tests?...20109
        Why do the pinpoint tests ask me if I have started the engine?...20109
        Why am I not able to get past the Ohmmeter verification screen during the pinpoint tests?...20110
         Why am I not able to get the VOM meter to communicate with the CDS system? ...20110
         I have multiple engines on the boat, but do not have the ability to view data from all the engines from a single connection with the CDS system. Why? ...20110
         How does the cylinder-misfire test work?...20110
        Why do I need to run the cylinder misfire test at a higher RPM or under load?...20110
        Why do I need to disconnect power to both fuel pumps? ...20110
         How do I perform a fuel injector test on a MerCruiser PCM 555 system? ...20111
         How do I test a MerCruiser ECM 555 system with one ignition coil?...20111
         How do I configure a digital throttle and shift helm station? ...20111
        How do I calibrate the cursor/screen on my Panasonic touch-screen PC's?...20111
         What does IAT and MAT stand for?...20111
         What does DTS stand for?...20111
        Why is my laptop battery charge low after long-term storage?...20111
         Why am I having trouble zeroing the ohms reading on my multimeter? ...20112
         Why does the DMT 2004 voltmeter report high readings for the 5-volt reference signal?...20112
        What is the difference between a sticky and non-sticky fault?...20112
        What is Engine Guardian?...20113
        What does Fault Seconds information tell me?...20113
        How do I tell the difference between 2004, 2005, and 2006 and newer DTS systems?...20113
        What does the Unit of Measurement Counts stand for? ...20114
         How do I detect a COM port setting for my multimeter?...20114
         What is a trim delta test?...20114
         What is shadow mode?...20114
        Why don’t my Freeze Frame buffers and FPC (Fuel per Cylinder) data items display correctly? ...20115
         Why do MerCruiser engines with Hurth Electronically controlled transmissions have fewer active tests? ...20115
         What is AutoSync? ...20115
      DTS Command Module Faults...20115
  90-863757002_3A...20120
    Section 3A - Diagrams—Mechanical...20120
      Table of Contents...20120
      Sensor Locations on the 8.1 Liter (496 CID) Engine...20121
      Engine Harness...20122
        Wiring Color Legend...20122
        Wire Splice Description—Mechanical...20122
        PCM 555 Pin-out—Mechanical...20123
      Wiring Diagrams...20126
        Wire Harness Connector Socket Identification...20126
        5-Volt Sensor Circuit—Mechanical...20127
        Coil Harness Circuit...20128
        Fuel Injector Circuit (Engine Harness)...20129
        Fuel Injector Circuit (Injector Harness)...20130
        Ground Circuit...20131
        Ignition Circuit...20132
        Positive Current Flow...20133
        Start Circuit with Start Solenoid Relay...20136
        Typical Starting System Components—10-Pin Engine Harness...20137
      Single Circuit Diagrams...20137
        Control Area Network (CAN) Circuit...20138
        Crank Position Sensor (CPS) and Camshaft Position Sensor (CMP) Circuits...20139
        Diagnostics Circuit...20140
        Engine Coolant Temperature Sensor (ECT) Circuit...20141
        Exhaust Manifold Coolant Temperature Sensor (EMCT) Circuit...20142
        Fuel Level Sensor Circuit—Harness 84-865457A02...20143
        Fuel Pump Relay Circuit...20144
        Fuse Circuit...20145
        Gear Lube Monitor or Transmission Overtemp Circuit...20146
        Idle Air Control Valve (IAC) Circuit—Mechanical...20147
        Main Power Relay (MPR) Circuit—Serial Number OW000000  and Below...20148
        Manifold Absolute Pressure Sensor (MAP) Circuit...20149
        Manifold Air Temperature Sensor (MAT) Circuit...20150
        Odd and Even Knock Sensor Circuits ...20151
        Oil Pressure Sensor Circuit...20152
        Paddle Wheel and Seawater Temperature Circuit...20153
        Throttle Position Sensor (TPS) Circuit—Harness 84-863084A1 and 84-862536A1...20154
        Transom Circuit (Transom Harness)—Sterndrive Mechanical...20155
        Trim Up Relay Circuit...20156
        Seawater Pump Circuit...20157
        Smart Transom Circuit (Engine Harness)...20158
  90-863757002_3B...20160
    Section 3B - Diagrams—Integrated ...20160
      Table of Contents...20160
      Engine Harness...20161
        Wiring Color Legend...20161
        Wire Splice Description—Integrated...20161
        PCM 555 Pin-out—Integrated, Non-DTS...20162
      Wiring Diagrams...20165
        Typical Starting System Components...20165
        Positive Current Flow...20165
        5 Volt Sensor Circuit—Integrated...20167
        Coil Harness Circuit—496/8.1...20168
        Fuel Injector Circuit (Engine Harness)—Harness 84-865457A02 and 84-865457A05...20169
        Fuel Injector Circuit (Injector Harness)...20170
        Ignition Circuit...20172
        Start Circuit with Start Solenoid Relay...20173
        Start Relay Circuit—Mechanical...20174
      Single Circuit Diagrams...20174
        10 Pin Harness Circuit—84-865457A01 and 84-865457A02...20175
        10 Pin Harness Circuit—84-865457A05...20176
        14 Pin Harness Circuit—84-865457A05...20177
        Control Area Network (CAN) Circuit—Harness 84-865457A02...20178
        Control Area Network (CAN) Circuit—Harness 84-865457A05...20179
        Crank Position and Camshaft Position Circuits...20180
        Diagnostics Circuit...20181
        Engine Coolant Temperature Sensor (ECT) Circuit...20182
        Exhaust Manifold Coolant Temperature Sensor (EMCT) Circuits...20183
        Fuel Level Sensor Circuit—Harness 84-865457A02...20184
        Fuel Level Sensor Circuit—Harness 84-865457A05 and 84-865457A06...20185
        Fuel Pump Relay Circuit...20186
        Fuse Circuit—Harness 84-865457A02...20187
        Gear Lube Monitor and Transmission Over-Temperature Circuit ...20188
        Gear Position Switch...20189
        Idle Air Control Valve (IAC) Circuit—Integrated...20190
        Main Power Relay Circuit—Serial Numbers OW000000 and Above...20191
        Manifold Absolute Pressure Sensor (MAP) Circuit...20192
        Manifold Air Temperature Sensor (MAT) Circuit...20193
        Odd And Even Knock Sensor Circuits ...20194
        Oil Pressure Sensor Circuit...20195
        Seawater  Pump Circuit...20196
        Smart Transom Circuit (Engine Harness)—Harness 84-865457A02...20197
        Smart Transom Circuit (Engine Harness)—Harness 84-865457A05...20198
        Throttle Position Sensor (TPS) Circuit...20199
        Transom Circuit (Transom Harness)...20200
        Trim Up Relay Circuit—84-865457A02...20201
        Trim Up Relay Circuit—84-865457A05...20202
  90-863757002_3C...20204
    Section 3C - Diagrams—14 Pin...20204
      Table of Contents...20204
      Sensor Locations—14 Pin...20205
      Engine Harness...20205
        Wiring Color Legend...20205
        Wire Splice Description—14 Pin...20206
        PCM 555 Pin-out—14 Pin, 496/8.1...20207
      Wiring Diagrams...20210
        5 Volt Sensor Circuit—PCM Power 1...20210
        Coil Harness Circuit—496/8.1...20211
        Fuel Injector Harness—496/8.1...20212
        Fuel Injector Circuit (Engine Harness)...20213
        Power 2 Circuit...20214
        Start Relay Circuit—Mechanical...20215
      Single Circuit Diagrams...20215
        14 Pin Harness Circuit—84-865457A06...20216
        Main Power Relay Circuit—Serial Numbers OW000000 and Above...20217
        Control Area Network (CAN)  Circuit—Mechanical...20218
        Crank Position Sensor (CPS) and Camshaft Position Sensor (CMP)  Circuits—Mechanical 496/8.1...20219
        Diagnostics Circuit...20220
        Electronic Shift Control (ESC) Circuit—Sterndrive DTS...20221
        Electronic Throttle Control (ETC)—Sterndrive and Inboard DTS...20222
        Engine Coolant Temperature Sensor (ECT) Circuit...20223
        Exhaust Manifold Coolant Temperature (EMCT) Sensor Circuits–496/8.1...20224
        Fuel Level Sensor Circuit—Harness 84-865457A05 and 84-865457A06...20225
        Fuel Level Sensor Circuit—Harness 84-865458A01...20226
        Fuel Level Sensor Circuit—Harnesses 84-865653A03 and 84-865653A04...20227
        Fuel Pump Relay Circuit...20228
        Fuse Circuit—DTS...20229
        Fuse Circuit—Mechanical...20229
        Gear Lube Monitor or Transmission Overtemp Circuit...20230
        Gear Position Switch...20231
        Idle Air Control Valve (IAC) Circuit—14 Pin...20232
        Manifold Absolute Pressure Sensor (MAP) Circuit—496/8.1...20233
        Manifold Air Temperature Sensor (MAT) Circuit—496/8.1...20234
        Odd and Even Knock Sensor Circuits—Harness 84-865458A01 and 84-865653A03...20235
        Odd and Even Knock Sensor Circuits—Harness 84-865457A06 and 84-865653A04...20236
        Oil Pressure Sensor Circuit...20237
        Seawater  Pump Circuit...20238
        Smart Transom Circuit—DTS Sterndrive...20239
        Smart Transom Circuit—DTS Inboard...20240
        Smart Transom Circuit (Engine Harness)—Mechanical...20241
        Start Relay Circuit—DTS...20242
        Throttle Position Sensor (TPS) Circuit...20243
        Transom Circuit (Engine Harness)—84-865457A06...20244
        Transom Circuit (Transom Harness)—8.1, Inboard Mechanical...20245
        Transom Circuit (Transom Harness)—Inboard DTS...20246
        Transom Circuit (Transom Harness)—Sterndrive DTS...20247
        Transom Circuit (Transom Harness)—Sterndrive Mechanical...20248
        Trim Relay Circuit—DTS...20249
        Trim Up Relay Circuit—Mechanical...20250
  90-863757002_3D...20252
    Section 3D - Diagrams—DTS 5.0, 5.7, and 6.2...20252
      Table of Contents...20252
      Sensor Locations—DTS...20253
      Engine Harness...20253
        Wiring Color Legend...20253
        Wire Splice Description—DTS 5.0, 5.7, and 6.2...20254
        PCM 555 Pinout-DTS...20255
      Wiring Diagrams...20258
        Coil Harness Circuit—5.0, 5.7, 6.2...20258
        Fuel Injector Circuit (Engine Harness)—5.0, 5.7 and 6.2...20259
        Fuel Injector Circuit (Injector Harness)—5.0, 5.7, 6.2...20260
      Single Circuit Diagrams...20260
        Control Area Network (CAN) Circuit—DTS...20261
        Crank Position Sensor (CPS) and Camshaft Position Sensor (CMP) Circuits—Mechanical 5.0, 5.7, and 6.2...20262
        Electronic Shift Control (ESC) Circuit—Inboard...20263
        Electronic Throttle Control (ETC)—Sterndrive and Inboard DTS...20264
        Fuse Circuit—DTS...20265
        Smart Transom Circuit—DTS Inboard...20266
        Smart Transom Circuit—DTS Sterndrive...20267
        Start Relay Circuit—DTS...20268
        Temperature and Manifold Absolute Pressure Sensor (TMAP) Circuit—5.0, 5.7, and 6.2...20269
        Transom Circuit (Transom Harness)—Inboard DTS...20270
        Transom Circuit (Transom Harness)—Sterndrive DTS...20271
        Trim Relay Circuit—DTS...20272
Service Manual #36 Rev 1 SBC...20274
  Cover...20274
  Binder1.pdf...20275
    Index...20275
      Notice to Users of This Manual...20275
      Precautions...20276
      Replacement Parts...20276
      Cleanliness and Care of Product...20276
      Manual Outline...20277
    Section 1A General Information...20279
      Section 1A - General Information...20279
        Table of Contents...20279
        How To Use This Guide...20280
        ECM and PCM Abbreviations...20280
        Precautions...20288
          Service Precautions ...20289
        General Information...20290
          Electrostatic Discharge Damage...20290
          Wiring Harness Service...20290
          Wire Repair...20291
          Wiring Connector Service...20291
          Intermittent Problems...20292
        ECM 555 Ignition System...20293
        Electronic Control Module (ECM) and Sensors...20293
          General Description...20293
          Computers and Voltage Signals...20293
          Analog Signals...20293
          Digital Signals...20295
          Engine Control Module (ECM)...20296
        Engine Guardian System...20296
          General Description...20296
        General Reference Charts...20297
          Manifold Vacuum and Pressure...20297
          Vacuum Gauge vs MAP Sensor...20298
          Centigrade to Fahrenheit Conversion...20299
    Section 2A Troubleshooting...20301
      Section 2A -  Troubleshooting...20301
        Table of Contents...20301
        ECM 555 Diagnostics...20304
          Abbreviated Procedure...20305
          Visual/Physical Check...20306
          Clearing Codes...20308
          Important Notes...20308
          DTS Faults...20309
        Troubleshooting Without a Diagnostic Tool...20309
        Troubleshooting With a Diagnostic Tool—CDS...20309
        CDS Connection to the Engine...20310
        CDS Power Up...20310
        ECM Troubleshooting Worksheet...20311
          ECM Calibration Label...20311
          Data Collection...20311
          PCM 555 and ECM 555 CDS Worksheet...20311
        Symptom Charts...20313
          Chart A-1 Engine Cranks Over but Will Not Start...20313
          Chart A-2 Main Power Relay Test...20314
           Chart A-3 Fuel System Electrical Test...20315
          Chart A-4 Fuel System Diagnosis...20315
          Chart A-5 Ignition System Test...20316
          Chart A-6 Hard Start Symptom...20318
          Chart A-7 Engine Surges Symptom...20319
          Chart A-8 Lack of Power, Sluggish, or Spongy Symptom...20320
          Chart A-9 Detonation or Spark Knock Symptom...20322
          Chart A-10 Hesitation, Sag, or Stumble Symptom...20323
          Chart A-11 Engine Misses Symptom...20324
          Chart A-12 Rough, Unstable, or Incorrect Idle and Stalling Symptom...20326
          Chart A-13 Poor Fuel Economy Symptom...20327
          Chart A-14 Dieseling or Run-On Symptom...20328
          Chart A-15 Backfire Symptom...20328
        Fuel Pressure Gauge Setup for ECM Engines...20330
          Installation...20330
          Test...20330
          Removal...20331
        Injector Balance  Test ...20331
          Test Procedure...20331
        Troubleshooting With a Vacuum Gauge...20333
          Vacuum Gauge Troubleshooting Guide...20333
        Engine Fault Quick Reference Chart...20334
        MerCruiser ECM/PCM Fault List...20334
          ECM/PCM Fault List Information...20334
            Fault Conditions...20335
            Sticky and Non-Sticky Faults...20335
            Default Sensor Values...20335
          MerCruiser ECM/PCM Fault List Table Columns...20335
            Fault #...20335
            CDS Fault Message...20335
            DDT Fault Status Message...20335
            Icon/Horn/Guardian Column...20335
              ♠- System View Icon...20336
              ♥- Warning Horn Signals...20336
              ♦- Engine Guardian...20336
            Fault Explanation...20336
            Possible Root Cause...20336
          MerCruiser ECM/PCM Fault List Table...20336
        ECM Frequently Asked Questions...20349
          What is a circuit (CKT) high or low fault?...20349
           What is a STR (Strategy)?...20350
          What is a TPI/TPS High or Low Range fault?...20350
          Why do we use the loaded volts lead on some pinpoint tests? ...20350
           How can I switch between the data screens and the service manual?...20350
          Why do some faults take longer to set than others?...20350
          What is a Main Power Relay (MPR) Output Fault?...20350
          What is wrong when I see a PWR1 or 5VDC Power Low fault?...20350
          Why does an EST or ECM Trigger Open not register as a fault when the engine is running? ...20351
           What are MAP Diff or TPI Diff errors?...20351
           What is a MAP Idle Check or MAP Idle Err?...20351
          What do Overspeed Fault and Engine Guardian Fault indicate?...20351
          What is a Main Power Relay Request (MPRLY REQ) in the Freeze Frame buffer?...20352
           Why is the engine slowing down and how do I know if Engine Guardian is active?...20352
           I see the following faults: OIL LVL IN (CKT) HI, FUEL LVL IN (CKT) HI or SEA TEMP IN (CKT). Is there a problem and how can I eliminate these faults?...20352
           What is a good tool to use to diagnose boat wiring problems?...20352
           Why can I not get the active data screen to list any values?...20352
          What should I do if the CDS system locks up?...20352
          Why do I have to connect the ohm meter leads together at the start of the pinpoint tests?...20353
          Why do the pinpoint tests ask me if I have started the engine?...20353
          Why am I not able to get past the ohmmeter verification screen during the pinpoint tests?...20353
           Why am I not able to get the VOM meter to communicate with the CDS system? ...20353
           I have multiple engines on the boat, but do not have the ability to view data from all the engines from a single connection with the CDS system. Why? ...20353
           How does the cylinder misfire test work?...20353
          Why do I need to run the cylinder misfire test at a higher RPM or under load?...20353
          Why do I need to disconnect power to both fuel pumps? ...20353
           How do I perform a fuel injector test on a MerCruiser ECM555 system? ...20354
           How do I test a MerCruiser ECM555 system with one ignition coil?...20354
           How do I configure a digital throttle and shift helm station? ...20354
          How do I calibrate the cursor or screen on my Panasonic touch-screen PCs?...20354
           What does IAT mean?...20354
           What does DTS mean?...20354
          Why is my laptop battery charge low after long-term storage?...20354
           How do I connect to a MEFI 4 engine system?...20355
           Why am I having trouble zeroing the ohms reading on my multimeter? ...20355
           Why does the DMT 2004 voltmeter report high readings for the 5-volt reference signal?...20355
          What is the difference between a sticky and non-sticky fault?...20356
          What is Engine Guardian?...20356
          What does Fault Seconds information tell me?...20356
          How do I tell the difference between 2004, 2005, and 2006  and Newer DTS systems?...20356
          What does the Unit of Measurement Counts stand for? ...20357
           How do I detect a COM port setting for my multimeter?...20357
           What is a trim delta test?...20358
           What is shadow mode?...20358
          Why do my Freeze Frame buffers and FPC (Fuel per Cylinder) data items display incorrectly? ...20358
    Section 3A Wiring Diagrams...20359
      Section 3A -  Wiring Diagrams–ECM with 10-Pin Harness...20359
        Table of Contents...20359
        Engine Harness Legend...20360
          Wire Splice Description...20360
          Wire Color Code Abbreviations...20360
        10-Pin ECM 555 Pinouts...20361
        EFI System Engine Wiring Harness Diagrams...20363
          10-Pin Engine Harness Starting System...20363
          Wake, Horn, and Tachometer Circuits...20365
          Fuses, IAC, and Relays...20366
          Manifold Air Pressure and Temperature, Crankshaft Position, and Throttle Position Sensors: V6 Engines...20367
          Manifold Air Pressure and Temperature, Crankshaft Position, Camshaft Position, and Throttle Position Sensors—V8 Engines...20368
          Engine Coolant Temperature, Seawater Pump, and Oil Pressure Sensors...20369
          Gear Indicator and Shift Interrupt—Sterndrive...20370
          Fuel Injector Control Circuits and Diagnostic Circuits–Batch-Fired Injector System...20371
          Fuel Injector Control Circuits and Diagnostic Circuits—Batch-Fired Injector System (V6 Sterndrive)...20372
          Fuel Injector Control Circuits and Diagnostic Circuits—Semi–Batch-Fired (V8)...20373
          Ignition System Without Cam Position Sensor...20374
          Ignition System With Cam Position Sensor...20375
          CAN, Fuel Level, Paddle Wheel, and Temperature Circuits—V6 Sterndrive ...20376
          CAN, Fuel Level, Paddle Wheel, and Temperature Circuits—V8 Sterndrive and Inboard...20377
          Transom Harness Connector (to Engine)...20378
          Starter Solenoid Circuit...20379
          Alternator Output Circuit...20380
          Engine 12-Volt Ground Circuit—All engines...20381
        Single Circuit Diagrams...20382
          Seawater Pump Circuit...20382
          Diagnostics Circuit...20383
          Engine Coolant Temperature Circuit...20384
          IAC Circuit...20385
          TMAP Circuit...20385
            MAT circuit...20386
            MAP Circuit...20386
          Throttle Position Circuit...20386
          Oil Pressure Circuit...20387
          ECM Single Knock Sensor Signal—V6...20388
          ECM Dual Knock Sensor Signal—V8...20389
          Paddle Wheel Connector Circuit—All Engines...20390
          Fuel Level Circuit—V6 and V8 Sterndrive...20391
          Fuel Level Circuit—V8 Inboard...20392
          Fuel Pump Relay Circuit—All Engines...20393
          Control Area Network (CAN) Circuit—V6 and V8...20394
Service Manual #37...20395
  Models Covered...20400
  Section 1-Important Information...0
    A-General Information...20406
  Section 6-Cooling System...0
    A-All Models...20412
    B-Seawater System...20438
    C-Closed Cooling System...20446
  Section 7-Exhaust System...0
    A-General Information...20470
    B-Manifolds & Elbows...20478
    C-Cold Riser Models...20496
    D-Warm Riser Models...20518
  Section 10-Color Diagrams...0
    Color Diagrams...20540
Service Manual #40...20558
  Frontmatter...20558
    Notice to Users of This Manual...20559
    Precautions...20560
    Replacement Parts...20560
    Cleanliness and Care of Product...20560
    Manual Outline...20561
  90-865376_1A...20562
    Section 1A - General Information...20562
      Table of Contents...20562
      Introduction...20563
      Gen III Cool Fuel Module Exploded View...20564
  90-865376_1B...20565
    Section 1B - Maintenance...20565
      Table of Contents...20565
      Changing Water Separating Fuel Filter Element...20566
  90-865376_2A...20569
    Section 2A - Gen III Cool Fuel Module Removal and Disassembly...20569
      Table of Contents...20569
      Gen III Cool Fuel Module Removal...20570
      Gen III Cool Fuel Module Disassembly...20573
  90-865376_2B...20577
    Section 2B - Gen III Cool Fuel Module Assembly and Installation...20577
      Table of Contents...20577
      Gen III Cool Fuel Module Assembly...20578
        Fuel Inlet Adapter Fitting...20578
        Top Cover and Fuel Pumps ...20578
        Fuel Pressure Regulator...20583
      Gen III Cool Fuel Module Installation...20584
  90-865376_3A...20589
    Section 3A - Troubleshooting and Repair...20589
      Table of Contents...20589
      Gen III Cool Fuel Module Diagnostics...20590
        Electrical...20590
        Checking Fuel Pressure and Fuel Supply Vacuum...20590
        In-Water Test...20590
  90-865376_3B...20592
    Section 3B - Fuel Flow Diagram...20592
      Table of Contents...20592
      Gen III Cool Fuel Module Fuel Flow Diagram...20593
  90-865376_4A...20594
    Section 4A - Coolant and Water Flow Diagrams...20594
      Table of Contents...20594
      Water Flow Diagrams...20595
        Sterndrive Water Flow Diagrams...20595
          V-8 Closed Cooled Bravo Models with Risers...20595
          V8 Closed Cooled Bravo Models...20596
          V8 Seawater Cooled Bravo MPD Models...20597
          V8 Seawater Cooled Bravo Models Except MPD Models...20598
        Inboard Water Flow Diagrams...20599
          Closed Cooled Inline Exhaust Models...20599
          Closed Cooled V-drive Exhaust Models...20600
          Seawater Cooled Models...20601
Service Manual #41...20602
  866202_ Front matter...20602
    Notice to Users of This Manual...20603
    Precautions...20604
    Replacement Parts...20604
    Cleanliness and Care of Product...20605
    Manual Outline...20607
  866202_1A...20608
    Section 1A - General Information...20608
      Table of Contents...20608
      Important Information...20609
        General Information...20609
        How To Use This Manual...20609
        Page Identification...20609
        Directional References...20610
  866202_1B...20611
    Section 1B - Maintenance...20611
      Table of Contents...20611
      Maintenance...20612
        Torque Specifications...20612
        Special Tools...20612
  866202_1C...20613
    Section 1C - Troubleshooting...20613
      Table of Contents...20613
      Turn Key Start: Theory of Operation...20614
        TKS Starting Characteristics...20614
        TKS Special Information...20615
      Troubleshooting...20615
        TKS Troubleshooting...20615
          Normal Starting Procedure...20615
          Hard Start - Cold...20616
          Hard Start - Hot...20617
          Engine Does Not Start...20617
          Engine Does Not Idle Correctly...20617
          Hissing Noise...20617
  866202_3A...20618
    Section 3A - Oil Pressure Switch...20618
      Table of Contents...20618
      Oil Pressure Switch...20619
        Oil Pressure Switch Test and Inspection...20619
          Inspect the TKS Oil Pressure Switch...20619
          Testing the 3.0L Oil Pressure Switch...20620
          Testing the V-6 and V-8 Oil Pressure Switch...20621
        Oil Pressure Switch Replacement...20621
  866202_4E...20622
    Section 4E - Wiring Diagrams...20622
      Table of Contents...20622
      TKS Wiring Diagrams...20623
        Wire Color Code Abbreviations...20623
      3.0L TKS Wiring Diagram...20625
      3.0L TKS Retrofit Wiring Diagram...20627
      4.3L and 5.0L TKS Alpha Wiring Diagram...20629
      5.0L and 5.7L TKS Bravo Wiring Diagram ...20631
      4.3L, 5.0L, and 5.7L TKS Retrofit Wiring Diagram...20633
  866202_5B...20635
    Section 5B - TKS Carburetor...20635
      Table of Contents...20635
      Maintenance...20636
        Identification...20636
          TKS Carburetor Part Number and Date Code...20636
          Venturi Cluster Identification...20637
        Replacement Parts Warning ...20638
        Identification of TKS Carburetors...20638
          The 3.0L TKS Carburetor...20638
            Generation 2...20638
          The 4.3L TKS Carburetor...20639
            Generation 1...20639
            Generation 2...20639
          The 5.0/5.7L TKS Carburetor...20640
            Generation 1...20640
            Generation 2...20640
        Specifications...20641
        Important Service Information...20643
          8 Point Carburetor Check List...20643
          Flooding At Idle RPM...20644
          Needle / Seat Change...20644
          Adjustable Accelerator Pump Lever...20644
          Description...20645
          Flame Arrestor with Carburetor Cover...20645
            REMOVAL...20645
            CLEANING AND INSPECTION...20645
            INSTALLATION...20645
          Fuel Inlet Filter...20646
            REMOVAL...20646
            CLEANING...20647
            INSTALLATION...20647
      Adjustments...20647
      Replacing Carburetor...20649
      Repair...20650
      Exploded View Generation 1...20652
      Exploded View Generation 2...20654
        Disassembly...20658
          TKS Module...20658
          Air Horn...20659
          Float Bowl...20666
        Cleaning and Inspection...20672
          ...20672
        Reassembly...20673
          Carburetor Body...20673
          Float Bowl...20675
          Air Horn...20681
          Float Level...20685
          Float Drop...20687
          TKS Module...20690
        Carburetor Installation...20691
  866202_5G...20693
    Section 5G - Diagnostics...20693
      Table of Contents...20693
      3.0L TKS General Diagnostics...20694
      V6-V8 TKS  General Diagnostics...20696
      TKS Fuel System Diagnostics...20698
        Troubleshoot the Fuel System...20698
          Test Power to the Fuel Pump...20698
          Test TKS Enrichment Circuit...20698
          Clean Carburetor Enrichment Circuit...20698
        Replacement Parts Warning...20698
      TKS Electrical System Diagnostics...20698
        Electrical System Diagnostics...20698
        TKS Coolant Temperature Switch...20698
        TKS Oil Pressure Switch...20698
        TKS Module...20699
          Electrical Supply ...20699
          Heater Function...20699
          TKS Module Resistance Check...20699
          TKS Module Bench Test...20699
  866202_6A...20701
    Section 6A - Cooling System...20701
      Table of Contents...20701
      Raw Water Cooled...20702
        3.0L TKS Thermostat Housing Removal...20702
        Replace the 3.0L TKS Temperature Switch...20702
        Test the TKS Coolant Temperature Switch ...20702
          On-engine Test...20702
          Bench Test...20703
        Install the TKS Thermostat Housing...20704
        Replace the V-6 and V-8 TKS Temperature Switch ...20705
      Close Cooled...20705
        Replace the Close Cooled 3.0L TKS Temperature Switch Unit...20705
          Test the TKS Coolant Temperature Switch...20706
        Replace the Close Cooled V-6 and V-8 TKS Temperature Switch...20706

Mercruiser/Mercury Racing Outboard Engines Service Repair Manual