Mercruiser Service Manual - 17

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Number 17
MARINE ENGINES
GM V-8
305 CID (5.0L) / 350 CID (5.7L)
Book 1 of 2
Sections 1 thru 4
Printed in U.S.A. 1996, Mercury Marine 90-823225--1 1096
Notice We could not possibly know of and advise the service
trade of all conceivable procedures by which a ser-
Throughout this publication, “Dangers,” “Warnings” vice might be performed and of the possible hazards
and “Cautions” are used to alert the mechanic to spe- and/or results of each method. We have not under-
cial instructions concerning a particular service or taken any such wide evaluation. Therefore, anyone
operation that may be hazardous if performed incor- who uses a service procedure and/or tool, which is
rectly or carelessly. Observe them carefully! not recommended by the manufacturer, first
These “Safety Alerts” alone cannot eliminate the haz- must completely satisfy himself that neither his nor
ards that they signal. Strict compliance to these spe- the product’s safety will be endangered by the ser-
cial instructions when performing the service, plus vice procedure selected.
“common sense” operation, are major accident pre- All information, illustrations and specifications con-
vention measures. tained in this manual are based on the latest product
! DANGER information available at time of publication.
It should be kept in mind, while working on the prod-
DANGER - Immediate hazards which will result in uct, that the electrical system and ignition system are
severe personal injury or death. capable of violent and damaging short circuits or se-
! WARNING vere electrical shocks. When performing any work
where electrical terminals could possibly be
WARNING - Hazards or unsafe practices which grounded or touched by the mechanic, the battery
could result in severe personal injury or death. cables should be disconnected at the battery.
! CAUTION Any time the intake or exhaust openings are exposed
during service they should be covered to protect
CAUTION - Hazards or unsafe practices which against accidental entrance of foreign material which
could result in minor personal injury or product could enter the cylinders and cause extensive inter-
or property damage. nal damage when the engine is started.
It is important to note that, during any mainte-
nance procedure, replacement fasteners must have
Notice to Users of This the same measurements and strength as those re-
moved, whether metric or customary. Numbers on
Manual the heads of the metric bolts and on surfaces of met-
This service manual has been written and published ric nuts indicate their strength. Customary bolts use
by the service department of Mercury Marine to aid radial lines for this purpose, while most custom-
our dealers, mechanics and company service per- ary nuts do not have strength markings. Mismatched
sonnel when servicing the products described here- or incorrect fasteners can result in damage or mal-
in. function, or possible personal injury. Therefore, fas-
It is assumed that these personnel are familiar with teners removed should be saved for re-use in the
the servicing procedures of these products, of like or same locations whenever possible. Where the fas-
similar products manufactured and marketed by teners are not satisfactory for re-use, care should be
Mercury Marine, and that they have been trained in taken to select a replacement that meets the
the recommended servicing procedures for these same specifications as the original.
products which include the use of mechanic’s
common hand tools and the special Mercury
Marine or recommended tools from other suppliers.
90-823225--1 1096 i
Engine Mechanical Replacement Parts
Components ! WARNING
Many of the engine mechanical components are de-
signed for marine applications. Unlike automotive Electrical, ignition and fuel system components
engines, marine engines are subjected to extended on MerCruiser Engines and Stern Drives are de-
periods of heavy load and wide-open-throttle opera- signed and manufactured to comply with U.S.
tion and, therefore, require heavy-duty components. Coast Guard Rules and Regulations to minimize
Special marine engine parts have design and man- risks of fire or explosion.
ufacturing specifications which are required to pro- Use of replacement electrical, ignition or fuel
vide long life and dependable performance. Marine system components, which do not comply to
engine parts also must be able to resist the corrosive these rules and regulations, could result in a fire
action of salt or brackish water that will rust or cor- or explosion hazard and should be avoided.
rode standard automotive parts within a short period
When servicing the electrical, ignition and fuel
of time.
systems, it is extremely important that all com-
Failure to use recommended Quicksilver service re- ponents are properly installed and tightened. If
placement parts can result in poor engine perform- not, any electrical or ignition component open-
ance and/or durability, rapid corrosion of parts sub- ing would permit sparks to ignite fuel va-
jected to salt water and possibly complete failure of pors from fuel system leaks, if they existed.
the engine.
Use of parts other than recommended service re-
placement parts, will void the warranty on those parts
which are damaged as a result of the use of other
than recommended replacement parts.
ii 90-823225--1 1096
Models Covered in This Manual
MCM Alpha
MODEL SERIAL NUMBER MODEL YEAR
5.0L OD832472 - OF601000
5.0LX OD831003 - OF601000 1993 - 1995
199
5.7L (4 Barrel) OD830700 - OF601000
5.7L (2 Barrel) OF601000 and Above
5.7LX OF601957 and Above
5.7L EFI OF286830 and Above
1996 Thru
Th 1997
199
5.7LX EFI OF752400 and Above
350 Magnum OD830982 and Above
350 Magnum EFI Gen+ OF800500 and Above
MCM Bravo
5.0L OD833077 - OF601464
1993 - 1995
5.7L (4 Barrel) OD831826 - OF605335
5.7L (2 Barrel) OF605336 and Above
5.7LX OF601645 and Above
5.7L EFI OF225560 and Above
1996 Thru
Th 1997
199
5.7LX EFI OF752408 and Above
350 Magnum OD800300 and Above
350 Magnum EFI Gen+ OF800500 and Above
350 Magnum EFI/MP OF289431 - OF601999 1995
350 Magnum MPI Gen+ OF602000 and Above 1996 Thru 1997
90-823225--1 1096 iii

MIE Ski
5.7L Competition (4 Barrel) OD840220 - OF775199 1993 - 1995
5.7L Competition (2 Barrel) OF775200 and Above 1996 Thru 1997
350 Magnum Tournanment Ski OD840100 and Above 1993 Thru 1997
350 Magnum EFI Tournament Ski OF225157 - OK000000 1994 - 1996
350 Magnum EFI Gen+
OK040006 and Above 1997
Tournament Ski
350 Magnum EFI/MP
OF350583 - OF745536 1995
Tournament Ski
350 Magnum MPI Tournament Ski OF745537 - OK000000 1996
350 Magnum MPI Gen+
OF800000 and Above 1996
Tournament Ski (Black Scorpion)
MIE Inboard
5.7L OD84000 and Above 1993 Thru 1997
5.7L EFI Gen+ OK040300 and Above 1997
iv 90-823225--1 1096
Service Manual Outline
Section 1 - Important Information
A - Specifications
B - Maintenance
Important
Information
1
C - General Information
Section 2 - Removal and Installation
A - MCM Models - Alpha One Drives
B - MCM Models - Alpha One Drives with Driveshaft Extension
Removal and
Installation
2
C - MCM Models - Bravo Drives
D - MCM Models - Bravo Drives with Driveshaft Extension
E - MIE Models - Velvet Drive Transmissions
F - MIE Models - Hurth Transmissions
Engine
3
Section 3 - Engine
A - 5.0L / 305 CID / 5.7L /350 CID
Section 4 - Electrical Systems
A - Starting System
B - Ignition System
Electrical Systems
4
C - Charging System
D - Instrumentation
E - Electrical Kits
F - Wiring Diagrams
Fuel System
5
6
Section 5 - Fuel System
A - Fuel Delivery Systems and Fuel Pumps Cooling System
B - MerCarb 2 Barrel Carburetor
C - Rochester 4 Barrel Carburetor
D - Weber 4 Barrel Carburetor
E - Electronic Fuel Injection (Throttle Body and Multi-Port)
F - BOS / SAV Emission
Section 6 - Cooling System
Exhaust System
7
A - Seawater Cooled Models
B - Closed Cooled Models
Section 7 - Exhaust System
A - General
Drives
8
B - Manifold and Elbows
C - Risers
D - Collectors
Section 8 - Drives
A - Borg-Warner In-Line Transmission
Power Steering
9
B - Borg-Warner V-Drive Transmission
C - Hurth Down Angle Transmission
D - Drive Shaft Models/Propeller Shaft
Section 9 - Power Steering
A - Pump
90-823225--1 1096 v
IMPORTANT INFORMATION 1
A
72000
GENERAL INFORMATION
Index
Table of Contents
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
How to Use This Manual . . . . . . . . . . . . . . . . . . 1A-1
Page Numbering . . . . . . . . . . . . . . . . . . . . . . 1A-1
How to Read Parts Manual . . . . . . . . . . . . . . . . 1A-2
Directional References . . . . . . . . . . . . . . . . . . . . 1A-3
Engine Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Engine Serial Number Locations . . . . . . . . . . . 1A-3
Propeller Information . . . . . . . . . . . . . . . . . . . . . 1A-4
Water Testing New Engines . . . . . . . . . . . . . . . 1A-4
Boat and Engine Performance . . . . . . . . . . . . . 1A-4
Boat Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-4
Marine Fouling . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Weight Distribution . . . . . . . . . . . . . . . . . . . . . 1A-6
Water in Boat . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
Elevation and Climate . . . . . . . . . . . . . . . . . . 1A-7
NOTICE
For information and procedures on
troubleshooting, refer to Section 1C.
Index
1A-0 –GENERAL INFORMATION 90-823225--1 1096
NOTICE How to Use This Manual
Refer to appropriate Stern Drive Service This manual is divided into sections which represent
Manual for transom assembly and stern major components and systems.
drive unit repair. Some sections are further divided into parts which
more fully describe the component.
Page Numbering
Introduction Two number groups appear at the bottom of each
This comprehensive overhaul and repair manual is page. Following is an example and description.
designed as a service guide for the models previous-
ly listed. It provides specific information, including
procedures for disassembly, inspection, assembly
and adjustment to enable dealers and service me-
chanics to repair and tune these engines.
Before attempting repairs or tune-up, it is suggested
that the procedure first be read through to gain knowl-
edge of the methods and tools used and the cautions
and warnings required for safety.
72426
Index
90-823225--1 1096 GENERAL INFORMATION - 1A-1
How to Read Parts Manual
a b
CYLINDER BLOCK AND CAMSHAFT
M0033-D8
REF. c
d
PART NO. NO. DESCRIPTION QUAN.
841-81631 1 CYLINDER BLOCK ASSEMBLY 1
N.S.S. 2 PLUG, expansion (1-1/4”) (GM #3738306) 2
22-87238 3 DRAIN COCK, cylinder block 2
19-34270 4 PLUG, expansion - cylinder block (1-5/8” Diameter) 8
17-35465 5 PIN, dowel - block to head (5/16” Diameter) 4
22-72640 6 PLUG, expansion - camshaft bearing hole 1
23-85674 7 BEARING UNIT, camshaft (set) 1
72638 8 LIFTER, hydraulic valve 16
431-5943 9 CAMSHAFT 1
35378 10 CHAIN, camshaft timing 1
43-35338 11 SPROCKET, camshaft timing 1
43-48338 12 SPROCKET, crankshaft timing 1
10-34505 13 BOLT, camshaft timing sprockets (3/4”) 3
12-39167 14 WASHER, camshaft timing sprocket bolt 3
841-8163 Cylinder Block Assembly includes only standard pistons,

e piston rings, crankshaft bearings and camshaft bearings.
A. Part Number: For part ordering - Note N.S.S. for Reference Number 2, Plug, expansion - that means Not Sold Separately by Mercury Marine
however, in this case, the G.M. Part Number (for the plug) is given in the Description Column.
B. Reference Number: For part Shown on exploded parts view.
C. Description: This is the most important column because it gives:
1) Description of Part: Ref. No. 1 is a Cylinder Block Assembly, No. 9 is a Camshaft, etc.
2) What parts are included with a certain part: Notice how the Description of Part, for Ref. Nos. 1 and 8 thru 14, are at the left side of the column.
Description of Part for Ref. Nos. 2 thru 7 are indented under “Cylinder Block Assembly”. If Ref. No. 1 (Cylinder Block Assembly) was ordered,
all indented parts (Ref. Nos 2thru 7) would come with the part. Ref. Nos. 8 thru 14 would not come with Ref. No. 1 and would have to be ordered
separately. If 2 Cylinder Blocks were listed, both cylinder blocks would come with the indented parts. In some cases, an indented part will have
another part indented under it. The second indented part will come with the first indented part.
3) Serial number break: If serial number information is listed, check product serial number to ensure that correct part is ordered.
4) Special information: Many times special information will be shown after description such as; L.H. Rotation, R. H. Rotation, Filter up, Filter Down,
etc. This will help in selecting the correct part.
D. Quantity: Quantity that has to be ordered.
E. Special Information Block: Additional information, part numbers for gasket sets, etc.
Index
Directional References Engine Serial Number
Front of boat is bow; rear is stern. Starboard side is Locations
right side; port side is left side. In this maintenance
manual, all directional references are given as they
appear when viewing boat from stern looking toward
bow.
AFT or STERN
a
STARBOARD
(RIGHT) (REAR)
FORE or BOW PORT

(FRONT) (LEFT) 72468
72000
Engine Rotation
Engine rotation is determined by observing flywheel
rotation from the rear (stern end) of the engine look- b
ing forward (toward water pump end). Propeller rota-
tion is not necessarily the same as engine rotation.
When ordering replacement engine, short blocks or
parts for engine, be certain to check engine rotation.
Do not rely on propeller rotation in determining en-
gine rotation.
72469
a
a - Serial Number
b - Starter Motor
72001
a - Standard Left Rotation - All MCM Stern Drive Engines,

MIE Inboard, Left Hand Rotation Engines.
b - Opposite Right Hand Rotation - MIE Inboard Right Hand
Rotation Engines.
Index
Propeller Information Water Testing New Engines
Refer to the “Propeller” section in appropriate Mer- Use care during the first 20 hours of operation on new
Cruiser Stern Drive Service Manual, or order publica- MerCruiser engines or possible engine failure may
tion P/N 90-86144, “What You Should Know About occur. If a new engine has to be water-tested at full
Quicksilver Propellers.” throttle before the break-in period is complete, follow
this procedure.
Changing diameter, pitch or coupling of a propeller
will affect engine RPM and boat performance. The 1. Start engine and run at idle RPM until normal op-
blade configuration also will affect performance. Two erating temperature is reached.
like propellers, same pitch and diameter, from two dif-
2. Run boat up on plane.
ferent manufacturers also will perform differently.
3. Advance engine RPM (in 200 RPM increments)
It is the responsibility of the boat manufacturer and/or
until engine reaches its maximum rated RPM.
selling dealer to equip the boat with the correct pro-
peller to allow the engine to operate within its speci- IMPORTANT: Do not run at maximum RPM for
fied RPM range at wide-open-throttle (W.O.T.). more than 2 minutes.
Because of the many variables of boat design and
operation, only testing will determine the best propel-
ler for the particular application. Boat and Engine
To test for correct propeller, operate boat (with an av- Performance
erage load onboard) at W.O.T. and check RPM with
an accurate tachometer. Engine RPM should be near
top of the specified range so that, under heavy load, Boat Bottom
engine speed will not fall below specifications.
For maximum speed, a boat bottom should be as flat
If engine exceeds the specified RPM, an increase in
as possible in a fore-aft direction (longitudinally) for
pitch and/or diameter is required.
approximately the last 5 ft. (1.5 m).
If engine is below rated RPM, a decrease in pitch
and/or diameter is required.
Normally, a change of approximately 300 to 500 RPM
will be achieved for each single pitch change of a pro-
peller.
! CAUTION
If a propeller is installed that does not allow en-
gine RPM to reach the specified full-throttle RPM
range, the engine will “labor” and will not pro-
duce full power. Operation under this condition
will cause excessive fuel consumption, engine 72002
overheating and possible piston damage (due to

detonation). On the other hand, installation of a
propeller, that allows engine to run above the a - Critical Boat Area
specified RPM limit, will cause excessive wear on
internal engine parts which will lead to premature
engine failure.
Index
For best speed and minimum spray, the corner be- Any hook, rocker or surface roughness on the bot-
tween the bottom and the transom should be sharp. tom, particularly in the all-important center-aft portion
will have a negative effect on speed, often several
miles per hour on a fast boat.
Marine Fouling
Fouling is an unwanted build-up (usually animal-veg-
etable-derived) occurring on the boat’s bottom and
drive unit. Fouling adds up to drag, which reduces
boat performance. In fresh water, fouling results from
dirt, vegetable matter, algae or slime, chemicals,
72003
minerals and other pollutants. In salt water, bar-
nacles, moss and other marine growth often produce
a - Flat dramatic build-up of material quickly. Therefore, it is
b - Sharp Corner important to keep the hull as clean as possible in all
The bottom is referred to as having a “hook” if it is water conditions to maximize boat performance.
concave in the fore-and-aft direction. A hook causes Antifouling paint, if required, may be applied to boat
more lift on the bottom near the transom and forces hull observing the following precautions.
the bow to drop. This increases wetted surface and
reduces boat speed. A hook, however, aids in planing IMPORTANT: DO NOT paint anodes or MerCa-
and reduces any porpoising (rhythmical bouncing) thode System reference electrode and anode, as
tendency. A slight hook is often built in by the man- this will render them ineffective as galvanic cor-
ufacturer. A hook also can be caused by incorrect rosion inhibitors.
trailering or storing the boat with support directly un- ! CAUTION
der the transom.
Avoid corrosion damage. Do not apply antifoul-
ing paint to MerCruiser drive unit or transom as-
sembly.
IMPORTANT: If antifouling protection is required,
Tri-Butyl-Tin-Adipate (TBTA) base antifouling
paints are recommended on MerCruiser boating
applications. In areas where Tri-Butyl-Tin-Adi-
pate base paints are prohibited by law, copper
72004
base paints can be used on boat hull and boat
transom. Corrosion damage that results from the
improper application of antifouling paint will not
a - Hook be covered by the limited warranty. Observe the
A “rocker” is the reverse of a hook. The bottom is convex following:
or bulged in the fore-and-aft direction. It can cause the boat
to porpoise.
72005
a - Rocker
Index
Avoid an electrical interconnection between the Weight Distribution
MerCruiser Product, Anodic Blocks, or MerCa-
thode System and the paint by allowing a mini- Weight distribution is extremely important; it affects
mum of 1 in. (26mm) UNPAINTED area on tran- a boat’s running angle or attitude. For best top speed,
som of the boat around these items. all movable weight - cargo and passengers - should
be as far aft as possible to allow the bow to come up
to a more efficient angle (3 to 5 degrees). On the neg-
ative side of this approach is the problem that, as
weight is moved aft, some boats will begin an unac-
ceptable porpoise.
Secondly, as weight is moved aft, getting on plane
becomes more difficult.
Finally, the ride in choppy water becomes more un-
comfortable as the weight goes aft. With these fac-
tors in mind, each boater should seek out what
weight locations best suit his/her needs.
Weight and passenger loading placed well forward
increases the “wetted area” of the boat bottom and,
in some cases, virtually destroys the good perform-
ance and handling characteristics of the boat. Opera-
tion in this configuration can produce an extremely
wet ride, from wind-blown spray, and could even be
unsafe in certain weather conditions or where bow
steering may occur.
Weight distribution is not confined strictly to fore and
aft locations, but also applies to lateral weight distri-
a b bution. Uneven weight concentration to port or star-
71176 board of the longitudinal centerline can produce a se-
vere listing attitude that can adversely affect the
boat’s performance, handling ability and riding com-
fort. In extreme rough water conditions, the safety of
the boat and passengers may be in jeopardy.
a - Antifouling Paint
b - MINIMUM 1 Inch (25.4 mm) UNPAINTED Area
Water in Boat
When a boat loses performance, check bilge for wa-
ter. Water can add considerable weight to the boat,
thereby decreasing the performance and handling.
Make certain that all drain passages are open for
complete draining.
Index
Elevation and Climate
Elevation has a very noticeable effect on the
wide-open- throttle power of an engine. Since air
(containing oxygen) gets thinner as elevation in-
creases, the engine begins to starve for air. Humidity,
barometric pressure and temperature do have a no-
ticeable effect on the density of air. Heat and humidity
thin the air. This phenomenon can become particu-
larly annoying when an engine is propped out on a
cool dry day in spring and later, on a hot, sultry day
in August, doesn’t have its old zip. (See chart.)
Although some performance can be regained by
dropping to a lower pitch propeller, the basic problem
still exists. The propeller is too large in diameter for
the reduced power output. The experienced marine
dealer or a Quicksilver Propeller Repair Station can
determine how much diameter to remove from a low-
er-pitch propeller for specific high-elevation loca-
tions. In some cases, a gear-ratio change to the drive
unit to more reduction is possible and very beneficial.
It is a known fact that weather conditions exert a pro-
found effect on power output of internal combustion
engines. Therefore, established horsepower ratings
refer to the power that the engine will produce at its
rated RPM under a specific combination of weather
conditions.
72006
Index
B
MAINTENANCE
Index
Table of Contents
Page
Maintenance Schedules . . . . . . . . . . . . . . . . . . . 1B-1
Maintenance Intervals . . . . . . . . . . . . . . . . . . 1B-1
Alpha Models . . . . . . . . . . . . . . . . . . . . . . . . . 1B-1
Bravo Models . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4
Tune-Up Specifications . . . . . . . . . . . . . . . . . . . 1B-7
Tune-Up Specifications
(Gen + Engines Only) . . . . . . . . . . . . . . . . . . . 1B-10
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11
All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
20-Hour Break-In Period . . . . . . . . . . . . . . . 1B-12
After Break-In Period . . . . . . . . . . . . . . . . . . 1B-12
Fuel, Oil, Fluid, and Coolant Specifications . 1B-12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Power Steering Fluid . . . . . . . . . . . . . . . . . . 1B-14
Transmission Fluid . . . . . . . . . . . . . . . . . . . . 1B-14
Coolant for Closed Cooling System . . . . . 1B-15
Maintaining Crankcase Oil Level . . . . . . . . . . 1B-15
Overfilled Engine Crankcase . . . . . . . . . . . 1B-15
Checking Engine Oil Level/Filling . . . . . . . 1B-15
Changing Oil and Filter . . . . . . . . . . . . . . . . . . . 1B-15
Maintaining Power Steering Pump
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16
With Engine Warm . . . . . . . . . . . . . . . . . . . . 1B-16
With Engine Cold . . . . . . . . . . . . . . . . . . . . . 1B-16
Filling and Bleeding Power Steering System 1B-17
Maintaining Closed Cooling Coolant Level . . 1B-17
Flushing Cooling System . . . . . . . . . . . . . . . . . 1B-17
MCM Stern Drive . . . . . . . . . . . . . . . . . . . . . 1B-18
MIE Inboard . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Maintaining Transmission Fluid Level . . . . . . 1B-20
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-21
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . 1B-21
Shift Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Engine Coupler/U-Joint Shaft Splines . . . 1B-24
Drive Shaft Extension Models . . . . . . . . . . 1B-24
Starter Motor (MIE Models) . . . . . . . . . . . . 1B-25
Audio Warning System . . . . . . . . . . . . . . . . . . . 1B-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25
Cold Weather or Extended Storage . . . . . . . . 1B-25
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25
Layup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-26
Draining Instructions . . . . . . . . . . . . . . . . . . 1B-28
Recommissioning . . . . . . . . . . . . . . . . . . . . . 1B-39
Index
1B-0 - MAINTENANCE 90-823225--1 1096
Maintenance Schedules
Maintenance Intervals
Maintenance intervals and the tasks to be performed, as shown in this current schedule, or as found in a
previously printed schedules, are generally based on an average boating application and environment.
However, individual operating habits and personal maintenance preferences can have an impact on the
suggested intervals. In consideration of these factors, MerCruiser has adjusted some maintenance intervals and
corresponding tasks to be performed. In some cases, this may allow for more individual tasks to be performed
in a single visit to the serving dealer, rather than multiple visits. Therefore, it is very important that the boat owner
and servicing dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals
to coincide with the individual operating habits, environment, and maintenance requirements.
Alpha Models
SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR
NOTE: Only perform maintenance which applies to your particular power package.
Task Interval
Engine Crankcase Oil - Check level
Closed Cooling Coolant - Check level
Power Steering Fluid - Check level
Stern Drive Unit Oil - Check level
Battery - Check level and inspect for damage
W kl
Weekly
Fuel Pump Sight Tube (If so Equipped) - Check that
no fuel is present
Power Trim Pump Oil - Check level
Anodes - Inspect for erosion
Gear Housing Water Pickups - Check for marine
growth or debris
Every 100 hours of operation or 120 days.
Drive Belt(s) - Inspect condition and check tension
Whichever occurs first.
Propeller Shaft - Lubricate Saltwater Use: Every 50 hours of operation or 60
days Whichever occurs first.
days, first
Power Package - Exterior Surfaces - Spray with rust Freshwater Use: Every 100 hours of operation or
preventative 120 days, Whichever occurs first.
Power Package Exterior Surfaces - Clean and paint Once a year
Cooling System - Flush seawater section Saltwater Use: After every use.
Index
90-823225--1 1096 MAINTENANCE - 1B-1
SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY DEALER
Task Interval
Whenever insufficient seawater flow is suspected.
Seawater Pickup Pump - Disassemble and inspect
(If operating temperature exceeds normal range.)
Crankcase Oil and Filter Change
Ignition system - Clean and Inspect condition.
Flame Arrestor and Crankcase Ventilation Hose -
Clean and Inspect.
Positive Crankcase Ventilation (PCV) Valve
(If Equipped) - Change
Stern Drive unit Oil - Change
Gimbal Ring Clamping Screws
Retorque to 50-55 ft. lb. (67-74 N·m)
Rear Engine Mounts
Check torque to 30-40 ft. lb. (47-54 N·m)
Gimbal Bearing - Lubricate
Cooling System - Clean and Inspect
Steering System - Lubricate and inspect for loose, End
E d off fifirst b
boating
i season and
d thereafter,
h f every 100
damage or missing parts. hours of operation or once yearly, whichever occurs
Electrical System - Check for loose or damaged first.
first
wiring.
Closed Cooling System Pressure Cap - Clean,
inspect and test.
Cooling System Hoses and Clamps - Inspect for
damage and deterioration. Check clamps for
tightness.
Continuity Circuit - Check components for loose
connections, broken or frayed wires.
Shift and Throttle Cable and Linkage - Lubricate and
inspect for loose, damaged or missing parts.
Engine Exhaust System - Inspect externally for
damage, deterioration and restrictions. Check for
tightness.
Ignition System - Check Timing and adjust as needed.
Index
1B-2 - MAINTENANCE 90-823225--1 1096
SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY DEALER (CONTINUED)
Task Interval
Steering Head and Remote Control - Inspect and
lubricate. End of first boating season and thereafter, every 100
Carburetor (If Equipped) - Inspect and adjust. hours of operation or once yearly,
yearly whichever occurs
first.
Throttle Body (EFI Models) - Inspect.
Fuel Filters - Replace.
Quicksilver Mercathode System - Test output.
Closed Cooling Coolant - Test for Alkalinity. Once
O a Year
Y
Heat Exchanger - Clean seawater section.
Drive Unit Bellows and Clamps - Inspect.
Engine Alignment - Check. End of first boating season and thereafter,
Saltwater Use: Every 300 hours of operation or once
Engine Coupling Universal Joint Shaft Splines -
yearly, whichever occurs first.
Lubricate.
Freshwater Use: Every 300 hours of operation or
Universal Joint Cross Bearings- Inspect. once every two years, whichever occurs first.
Closed Cooling Coolant - Replace. Every Two Years
Index
90-823225--1 1096 MAINTENANCE - 1B-3
Bravo Models
SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR
Task Interval
Engine Crankcase Oil - Check level
Closed Cooling Coolant - Check level
Power Steering Fluid - Check level
Stern Drive Unit Oil - Check level
Battery - Check level and inspect for damage
W kl
Weekly
Fuel Pump Sight Tube (If so Equipped) - Check that
no fuel is present
Power Trim Pump Oil - Check level
Anodes - Inspect for erosion
Gear Housing Water Pickups - Check for marine
growth or debris
Every 100 hours of operation or 120 days.
Drive Belt(s) - Inspect condition and check tension
Whichever occurs first.
Propeller Shaft - Lubricate Saltwater Use: Every 50 hours of operation or 60
days, Whichever occurs first.
Power Package - Exterior Surfaces - Spray with rust Freshwater Use: Every 100 hours of operation or
preventative 120 days, Whichever occurs first.
Power Package Exterior Surfaces - Clean and paint Once a year
Cooling System - Flush seawater section Saltwater Use: After every use.
Index
1B-4 - MAINTENANCE 90-823225--1 1096
SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED BY A DEALER (CONTINUED)
Task Interval
Whenever insufficient seawater flow is suspected.
Seawater Pickup Pump - Disassemble and inspect
(If operating temperature exceeds normal range.)
Crankcase Oil and Filter Change
Ignition system - Clean and Inspect condition.
Flame Arrestor and Crankcase Ventilation Hose -
Clean and Inspect.
Positive Crankcase Ventilation (PCV) Valve (If So
Equipped) - Change
Stern Drive unit Oil - Change
Gimbal Ring Clamping Screws - Retorque to 40
ft. lb. (54 N·m)
Rear Engine Mounts - Check torque to 30-40 ft. lb.
(47-54 N·m)
Gimbal Bearing - Lubricate
Cooling System - Clean and Inspect
Engine Alignment - Check
Engine Coupling Universal Joint Shaft Splines -
Lubricate End
E d off first
fi boating
b i season and d thereafter,
h f every
Steering System - Lubricate and inspect for loose, 100 hours of operation or once yearly,
yearly whichever
damage or missing parts. occurs first.
Electrical System - Check for loose or damaged
wiring.
Cooling System Hoses and Clamps - Inspect for
damage and deterioration. Check Clamps for
tightness.
Closed Cooling System Pressure Cap - Clean,
inspect and test.
Continuity Circuit - Check components for loose
connections, broken or frayed wires.
Shift and Throttle Cable and Linkage - Lubricate
and inspect for loose, damaged or missing parts
Engine Exhaust System - Inspect externally for
damage, deterioration and restrictions. Check for
tightness.
Ignition System - Check Timing and adjust as
needed.
Index
90-823225--1 1096 MAINTENANCE - 1B-5
SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED BY A DEALER (CONTINUED)
Task Interval
Steering Head and Remote Control - Inspect and
Lubricate. End of first boating season and thereafter, every
Carburetor (If Equipped) - Inspect and adjust. 100 hours of operation or once yearly,
yearly whichever
occurs first.
Throttle Body (EFI Models) - Inspect
Fuel Filters - Replace
Quicksilver Mercathode System - Test output.
Closed Cooling Coolant - Test for Alkalinity O
Once a Year
Y
Heat Exchanger - Clean seawater section.
Drive Unit Bellows and Clamps - Inspect
End of first boating season and thereafter, every
Universal Joint Cross Bearings - Inspect 200 hours of operation or once yearly, whichever
occurs first.
Closed Cooling Coolant - Replace Every Two Years
Index
1B-6 - MAINTENANCE 90-823225--1 1096
Tune-Up Specifications
Tune up specifications for the Gen + engines start on page 10.
MCM 350
MCM MCM MCM MCM
Model Magnum
5.0L Alpha 5.0LX Alpha 5.7L Alpha 5.7L Bravo
Alpha
Propshaft Rating
190 (141) 205 (152) 235 (175) 250 (186) 250 (250)
HP (KW) 1
Number of Cylinders V-8
Displacement 305 CID (5.0L) 350 CID (5.7L)
Bore/Stroke
3.7 x 3.48 (95 x 88.4) 4.0 x 3.48 (101.6 x 88.4)
In. (mm)
Compression Ratio 9.1:1 9.3:1 9.1:1
Compression Pressure 150 PSI (1034 kPa)
Idle RPM In Neutral 2 650-700
Maximum RPM
4200-4600 4400-4800
(at W.O.T.)
Oil Pressure
30-60 PSI (207-414 kPa)
(at 2000 RPM)
Minimum Oil Pressure
4 PSI (28 kPa)
(at Idle)
Mechanical Fuel
Pump Pressure 3-7 PSI (21-48 kPa)
(at 1800 RPM)
Electrical
12 V Negative (–) Ground
System
Minimum Battery
375 cca/475 mca/90 Ah
Requirements
Firing Order 1-8-4-3-6-5-7-2
Spark Plug Type AC - MR43T/Champion - RV15YC4/NGK - BR6FS
Spark Plug Gap .035 In. (0.9 mm)
Timing (at Idle RPM) 3 8° BTDC
Preliminary Idle
1-1/4 Turns
Mixture
Thermostat 143° F (62° C)
1 Power Rated in Accordance with NMMA (National Marine Manufacturers’ Association) rating procedures.
2 Measured using an accurate service tachometer and Fuel Injection engine at operating temperature.
3 Timingmust be set using a special procedure as outlined in the appropriate Service Manual. Timing cannot be properly set using
the conventional method.
Index
90-823225--1 1096 MAINTENANCE - 1B-7
Tune-Up Specifications, Does Not Include Gen + Engines (Continued)
MCM 5.7L EFI MCM 350 EFI/MP MIE 350 EFI/MP
MCM 5.7L EFI
Model Bravo One, Two Bravo One and Magnum
Alpha
And Three Three Tournament Ski
Propshaft HP
250 (186) 250 (186) 265 (197) 280 (208)
(KW) 1
Number of
V-8
Cylinders
Displacement 350 CID (5.7L)
Bore/Stroke
4.00 x 3.48 (101.6 x 88.4)
In. (mm)
Compression Ratio 9.3:1
Compression
150 PSI (207 kPa)
Pressure
Idle RPM
600
(in Forward Gear) 2
Maximum RPM
4400-4800 4600-5000
(at W.O.T.)
Oil Pressure
30-60 PSI (207-414)
(at 2000 RPM)
Minimum Oil
4 PSI (28 kPa)
Pressure (at Idle)
Mechanical Fuel
3-7 PSI (21-48 kPa)
Pump Pressure
Electrical System 12 V Negative (–) Ground
Minimum Battery
550 cca/700 mca/120 Ah
Requirements
Firing Order LH Rotation 1-8-4-3-6-5-7-2
Timing
8° BTDC
(at Idle RPM) 3
Thermostat 160°F (71°C)
3 Timing cannot be properly set using the conventional method on fuel injected engines.
Index
1B-8 - MAINTENANCE 90-823225--1 1096
Tune-Up Specifications, Does Not Include Gen + Engines (Continued)
MIE 350 EFI
MIE 5.7L MIE 350 Magnum
Model MIE 5.7L Magnum
Competition Ski Tournament Ski
Tournament Ski
Propshaft HP
250 (186) 250 (186) 265 (198) 265 (198)
(KW)1
Number of
V-8
Cylinders
Bore/Stroke
4.00 x 3.48 (101.6 x 88.4)
In. (mm)
Compression Ratio 9.1:1 9.3:1
Compression
150 PSI (207 kPa)
Pressure
Idle RPM In
650-700
Neutral 2
Maximum RPM
4200-4600 4400-4800
(at W.O.T.)
Oil Pressure
30-60 PSI (207-414)
(at 2000 RPM)
Minimum Oil
4 PSI (28 kPa)
Pressure (at Idle)
Mechanical Fuel
3-7 PSI (21-48 kPa)
Pump Pressure
Minimum Battery 550 cca/700 mca
375 cca/450 mca/90 Ah
Requirements 120 Ah
Firing Order LH Rotation 1-8-4-3-6-5-7-2 RH Rotation 1-2-7-5-6-3-4-8
Timing
8° BTDC
(at Idle RPM) 3
Preliminary Idle
1-1/4 Turns
Mixture
Thermostat 143°F (62°C) 160°F (71°C)
2 Measured using an accurate service tachometer and EFI / MPI engine at operating temperature.
3 Timing cannot be properly set using the conventional method on fuel injected engines.
A B
Firing Order Firing Order
LH ROTATION 1-8-4-3-6-5-7-2 RH ROTATION 1-2-7-5-6-3-4-8
FRONT FRONT
72008 72009
Index
90-823225--1 1096 MAINTENANCE - 1B-9
Tune-Up Specifications (Gen + Engines Only)
MCM 350 MAGNUM
MCM 350 MPI 350 MAGNUM 350 MAGNUM MPI GEN +
GEN+ EFI GEN + MIE IN-
GEN + ALPHA TOURNA-
MODEL BOARD5.7L
BRAVO AND 5.7LX EFI GEN + TOURNA- MENT SKI
BLACKHAWK MENT SKI EFI GEN +
BRAVO (BLACK
(4 BBL TBI) SCORPION)
Propshaft
300 (224) 280 (209) 290 (217) 315 (235) 290 (235)
HP (KW) 1
Bore/Stroke
4.00 x 3.48 (101.6 x 88.4)
In. (mm)
Compression
9.4:1
Ratio
Compression
150 PSI (1034 kPa)
Pressure
Idle RPM In
600
Neutral 2
Maximum RPM
4600-5000 4400-4800 4600-5000 4200-4600
(at W.O.T.)
Oil Pressure
30-60 PSI (207-414 kPa)
(at 2000 RPM)
Minimum Oil
4 PSI (28 kPa)
Pressure (at Idle)
Mechanical Fuel
Pump Pressure 3-7 PSI (21-48 kPa)
(If Equipped)
Fuel Pressure
43 PSI 30 PSI 43 PSI 30 PSI
(Running)
(241 kPa) (207 kPa) (296.7 kPa) (207 kPa)
(E.F.I. Only)
Minimum Battery
550 cca/700 mca/120 Ah
Requirements
Firing Order 1-8-4-3-6-5-7-2
Spark Plug Type AC - MR43LTS / Champion - RS12YC / NGK - BPR6EFS
Timing (at Idle
8° BTDC
RPM) 3
Thermostat 160° F (71° C)
3 Timingmust be set using a special procedure as outlined in the appropriate Service Manual. Timing cannot be properly set using
the conventional method.
Index
1B-10 - MAINTENANCE 90-823225--1 1096
Fluid Capacities
NOTICE
All capacities are approximate fluid measures.
Capacities are shown in U.S. Quarts / (Litres)
MCM (Stern Drive) Model All Models

Crankcase Oil With Filter 1 5-1/2 (5.2)
Seawater Cooling System 2 15 (14.1)
Closed Cooling System
20 U.S. Qts. (19 L)
(With Coolant Flow Thru Exhaust Manifolds)
14.5 Qts. (19 L)
(With Raw Water Flow Thru Exhaust Manifolds)
1 Always Use Dipstick to Determine Exact Quantity of Oil Required
2 Seawater Cooling System Capacity Information is for Winterization Use Only
350 Magnum
MIE (Inboard) Model 5.7L Bluewater 5.7L Competition Ski
Tournament Ski
Crankcase Oil Capacity
4 (3.8) 5 (4.7)
With New Filter 1
Seawater Cooling
15 (14.1)
System 2
(With Coolant Flow Thru 20 (19) Does Not Apply 20 (19)
Exhaust Manifolds)
(With Raw Water Flow 18 (17) Does Not Apply 18 (17)
Thru Exhaust Manifolds)
Transmission 1
2 (1.9)
Velvet Drive 1:1
Transmission 1
3 (2.9)
Velvet Drive 1.5:1 - 3.0:1
Transmission 1
4.5 (4.8) Does Not Apply
Velvet Drive All V-Drives
Transmission 1 Hurth
4.5 (4.8) Does Not Apply
8 Degree Down Angle
1 Always use dipstick to determine exact quantity of oil required.
2 Seawater cooling system capacity information is for winterization use only.
Index
90-823225--1 1096 MAINTENANCE - 1B-11
All Models Fuel, Oil, Fluid, and Coolant
20-Hour Break-In Period Specifications
IMPORTANT: The first 20 hours of operation is
the engine break-in period. Correct break-in is Fuel
essential to obtain minimum oil consumption
and maximum engine performance. During this ! CAUTION
break-in period, the following rules must be ob- Use of improper gasoline can damage the engine
served: seriously. Engine damage that results from use
• Do not operate below 1500 RPM for extended pe- of improper gasoline is considered misuse of the
riods of time for first 10 hours. Shift into gear as engine and is not covered under MerCruiser War-
soon as possible after starting and advance ranty.
throttle above 1500 RPM if conditions permit safe
operation. USA and Canada
Fuel having a posted pump Octane Rating of 87(R +
• Do not operate at one speed consistently for ex- M)/2 minimum. Premium gasoline [92 (R + M)/2] is
tended periods. also acceptable. DO NOT use leaded gasoline.
• Do not exceed 3/4 throttle during first 10 hours. Outside USA and Canada
During next 10 hours, occasional operation at full Fuel having a posted pump Octane Rating of 92 RON
throttle is permissible (5 minutes at a time maxi- minimum. Premium gasoline (98 RON) is also
mum). acceptance. If unleaded is not available, use a major
• Avoid full throttle acceleration from idle speed. brand of leaded gasoline.
• Do not operate at full throttle until engine reaches Gasolines containing alcohol, either methyl alcohol
normal operating temperature. (methanol) or ethyl alcohol (ethanol) may cause
increased:
• Frequently check crankcase oil level. Add oil if
needed. It is normal for oil consumption to be high • Corrosion of metal parts.
during break-in period. • Deterioration of elastomer and plastic parts.
• After 20-hour break-in period, drain crankcase oil
• Fuel permeation through flexible fuel lines.
and replace oil filter (see “Maintenance”). Fill
crankcase with correct oil (see “Specifications”). • Wear and damage of internal engine parts.
• Starting and operating difficulties.
After Break-In Period
Some of these adverse effects are due to the
• Use a propeller that allows the engine to operate tendency of gasolines containing alcohol to absorb
at or near the top of the maximum RPM range (see moisture from the air, resulting in a phase of water
Specifications section) when at full throttle with a and alcohol separating from the gasoline in the fuel
normal boat load. tank.
• Operation at 3/4 throttle setting or lower is recom- The adverse effects of alcohol are more severe with
mended. Refrain from prolonged operation at methyl alcohol (methanol) and are worse with in-
maximum (full throttle) RPM. creasing alcohol content.
• Deterioration of elastomer and plastic parts.
• Fuel permeation through flexible fuel lines.
• Wear and damage of internal engine parts.
• Starting and operating difficulties.
Some of these adverse effects are due to the tenden-
cy of gasolines containing alcohol to absorb moisture
from the air, resulting in a phase of water and alcohol
separating from the gasoline in the fuel tank.
Index
1B-12 - MAINTENANCE 90-823225--1 1096
! WARNING EFFECTS OF GASOLINE/ALCOHOL BLENDS
ON MARINE ENGINES
Fire and Explosion Hazard: Fuel leakage from
any part of the fuel system can be a fire and ex- Corrosion of metals may result from use of alco-
plosion hazard which can cause serious bodily hol-gasoline blends. Portable or permanently in-
injury or death. Careful periodic inspection of the stalled fuel tanks of metal or fiberglass, fuel filters,
entire fuel system is mandatory, particularly after fuel lines and float bowls may be affected by alcohol
storage. All fuel system components including blended fuels. Many fiberglass fuel tanks are slowly
fuel tanks (whether plastic, metal or fiberglass), dissolved by alcohol, leading immediately to filter and
fuel lines, primer bulbs, fittings, fuel filters and carburetor plugging and eventually to tank failure.
carburetors should be inspected for leakage, Fuels containing alcohol will absorb moisture from
softening, hardening, swelling or corrosion. Any the air. At first, this moisture will remain in solution,
sign of leakage or deterioration requires replace- but once the water content of the fuel has built up to
ment before further engine operation. about one-half of one percent, it will separate out
Because of possible adverse effects of alcohol in (phase separation), bringing the alcohol with it. This
gasoline, it is recommended that only alco- alcohol-water mixture settles to the bottom of the fuel
hol-free gasoline be used where possible. If only tank and if this mixture gets into the engine, the en-
fuel containing alcohol is available, or if the pres- gine can be seriously damaged internally, as it may
ence of alcohol is unknown, increased inspec- wash the protective film of oil off the bore of any cylin-
tion frequency for leaks and abnormalities is re- der that it enters. Before the engine can be restarted,
quired. it is necessary to remove the separated alcohol and
water layer, flush out the fuel system with clean fuel
! WARNING and remove and dry the spark plugs.
Avoid gasoline fire or explosion. Improper instal- BOAT/MOTOR STORAGE
lation of brass fittings or plugs into fuel pump or
fuel filter base can crack casting and/or cause a When operating a MerCruiser engine on gasoline
fuel leak. containing alcohol, storage of gasoline in the fuel
tank for long periods of time should be avoided.
IMPORTANT: When operating a MerCruiser en-
gine on gasoline containing alcohol, storage of Long periods of storage, common to boats, create
gasoline in the fuel tank for long periods should unique problems. In cars, gasoline/alcohol blend
be avoided. Long periods of storage, common to fuels normally are consumed before they can absorb
boats, create unique problems. In cars, alco- enough moisture to cause trouble, but boats often sit
hol-blend fuels normally are consumed before idle long enough for phase separation to take place.
they can absorb enough moisture to cause In addition, internal corrosion may take place during
trouble, but boats often sit idle long enough for storage if alcohol has washed protective oil films from
phase separation to take place. In addition, inter- internal components.
nal corrosion may take place during storage if al-
cohol has washed protective oil films from inter- WINTER STORAGE
nal components. If boat is to be placed in winter storage, carburetors
must be run dry at idle RPM. Permanent fuel tanks
GASOLINE/ALCOHOL BLENDS should be drained completely and Quicksilver Gaso-
Many new motor vehicle owner manuals are warning line Stabilizer and Conditioner added to any fuel re-
about the potential damage from using gasoline con- maining in the tank. Portable fuel tanks should be
taining alcohol, especially METHANOL. They cite emptied completely.
possible fuel system damage and performance prob-
lems. These are just two of the hazards that may be WARRANTY
caused by alcohol. These same problems as well as Performance problems and fuel system or other
the additional safety risk of fire and explosion from damage resulting from the use of gasoline-alcohol
fuel system leaks apply to marine inboard engines. blended fuels are not the responsibility of MerCruiser
METHANOL is more severe in its bad effect than is and will not be covered under our warranty.
ETHANOL. Alcohol is also more severe in older en-
gines since newer engines have materials which are
more resistant to alcohol.
Index
90-823225--1 1096 MAINTENANCE - 1B-13
CONTINUING EVALUATIONS IMPORTANT: The use of non-detergent oils, mul-
ti-viscosity oils (other than 20W-40 or 20W-50),
The effects of gasoline with ETHANOL and METHA-
low quality oils or oils which contain solid addi-
NOL are still being evaluated by the United States
tives specifically are not recommended.
Coast Guard, the National Marine Manufacturers As-
sociation (NMMA), Mercury Marine and other engine
and boat manufacturers.
We have recommended pump posting of alcohol
SAE 40W
content of gasoline. Further we recommend using SH or CF/CF-2
gasoline known not to contain any METHANOL or
SAE 30W
ETHANOL when possible. SH or CF/CF-2
TEST FOR ALCOHOL CONTENT IN GASOLINE

SAE 20W
The following is an acceptable and widely used field SH or CF/CF-2
procedure for the detection of alcohol in gasoline.
Use any small transparent bottle or tube that can be
capped and is, or can be, provided with graduations
or a mark at about 1/3 full. A pencil mark on a piece of
72010
adhesive tape may be used.
Procedure
1. Fill the container with water to the mark.
Power Steering Fluid
2. Add fuel almost to fill the container, leaving some
air space, then cap the container. The propor- Use Quicksilver Power Trim and Steering Fluid, or
tions of fuel to water are not critical, but there automatic transmission Fluid (ATF), Dexron, Dexron
should be 2 to 3 times as much fuel as water. II and Dexron IIl.
3. Shake container vigorously and allow it to sit up-
right for 3 to 5 minutes. If the volume of water
appears to have increased, alcohol is present. If
Transmission Fluid
you are not sure, there is no need for concern. If Velvet Drive - 10 wt. tractor hydraulic fluid meeting
the dividing line between water and fuel becomes the C-3/TO-2 specification (preferably Mobil 423,
cloudy, use the middle of the cloudy band. Chevron, or Citgo).
Hurth - Automatic transmission fluid (ATF) Dexron II
and Dexron IIl.
Crankcase Oil
Walter V-Drive - SAE 30W Heavy Duty Motor Oil,
To help obtain optimum engine performance and to Exxon Spatan EP-68 Gear Oil, APG-80 Gear Oil.
provide maximum protection, we strongly recom-
mend the use of Quicksilver 4-Cycle Marine Engine
Oil. If not available, a good grade, straight weight, de-
tergent automotive oil of correct viscosity, with an API
classification of SH, CF/CF-2 may be used.
The following chart is a guide to crankcase oil selec-
tion. Oil filter should always be changed with oil.
In those areas where recommended straight weight
oil is not available, a multi-viscosity 20W-40 (SH, CF/
CF-2) or, as a second but less preferable choice,
20W-50 (SH, CF/CF-2 ) may be used.
Index
1B-14 - MAINTENANCE 90-823225--1 1096
Coolant for Closed Cooling System Checking Engine Oil Level/Filling
! CAUTION IMPORTANT: ENGINE CRANKCASE OIL MUST
BE CHECKED AT INTERVALS SPECIFIED IN
Alcohol or Methanol base antifreeze or plain wa- “MAINTENANCE SCHEDULE” CHART. It is nor-
ter, are not recommended for use in fresh water mal for an engine to use a certain amount of oil
section of cooling system at any time. in the process of lubrication and cooling of the
We recommend that the coolant section of closed engine. The amount of oil consumption is greatly
cooling system be filled with Quicksilver Pre-Mixed dependent upon engine speed, with consump-
Engine Coolant. In areas where the possibility of tion being highest at wide-open-throttle and de-
freezing does not exist, it is permissible to use a solu- creasing substantially as engine speed is re-
tion of rust inhibitor and water (mixed to manufactur- duced.
er’s recommendations). 1. Stop engine and allow boat to come to a rest.
MerCruiser V-8 engines can use any type of perma- 2. Allow oil to drain back into oil pan - approximately
nent antifreeze or any brand antifreeze solution that 5 minutes.
meets GM specification 1825M.
3. Remove dipstick. Wipe clean and reinstall. Push
dipstick all the way into dipstick tube.
4. Remove dipstick and note the oil level.
Maintaining Crankcase Oil
5. Oil level must be between the FULL and ADD
Level marks.
6. If oil level is below ADD mark, proceed to Steps
Overfilled Engine Crankcase 7 and 8.
7. Remove oil filler cap from valve rocker arm cover.
Overfilled crankcases (oil level being too high) can
cause a fluctuation or drop in oil pressure and rocker 8. Add required amount of oil to bring level up to, but
arm “clatter” on MerCruiser engines. The over-full not over, the FULL mark on dipstick.
condition results in the engine crankshaft splashing
and agitating the oil, causing it to foam (become aer-
ated). The aerated oil causes the hydraulic valve lift- Changing Oil and Filter
ers to “bleed down.” This, in turn, results in rocker 1. Start engine and run until it reaches normal oper-
arm “clatter” and loss of engine performance, due to ating temperatures.
the valves not opening properly.
IMPORTANT: Change oil when engine is warm
Care must be taken when checking engine oil level. from operation, as it flows more freely, carrying
Oil level must be maintained between the ADD mark away more impurities.
and the FULL mark on the dipstick. To ensure that
you are not getting a “false reading,” make sure the 2. Stop engine.
following steps are done before checking the oil level. 3. Remove drain plug from oil pan or from oil drain
• Boat “at rest” in the water, or hose.
• If boat is on a trailer, raise or lower bow until the NOTE: If drain plug is not accessible because of boat
boat is setting at the approximate angle that it construction, oil may be removed through dipstick
would be if setting “at rest” in the water. tube, using a Quicksilver Crankcase Oil Pump. (See
Quicksilver Accessory Guide.)
• Allow sufficient time for oil to drain into the crank-
case if engine has just been run or oil has just 4. After oil has drained completely, reinstall drain
been added. plug (if removed) and tighten securely.
5. Remove and discard oil filter and its sealing ring.
6. Coat sealing ring on new filter with engine oil, and
install. Tighten filter securely (following filter man-
ufacturer’s instructions). Do not over-tighten.
7. Fill crankcase with oil.
8. Start engine and check for leaks.
Index
90-823225--1 1096 MAINTENANCE - 1B-15
Maintaining Power Steering 5. If fluid is not visible in reservoir, a leak exists in the
power steering system. Find cause and correct.
Pump Fluid Level
With Engine Cold
With Engine Warm
1. With engine stopped, position drive unit so that it
1. Stop engine and position drive unit so that it is is straight back.
straight back. 2. Remove fill cap/dipstick from power steering
2. Remove fill cap/dipstick from power steering pump and note fluid level.
pump and note fluid level. 3. Level should be between FULL COLD mark and
b a bottom of dipstick.
72519
72517
a - Fill Cap / Dipstick a - Proper Fluid Level With Engine Cold

b - Power Steering Pump
4. If level is below bottom of dipstick, but fluid is still

3. Level should be between the FULL HOT mark visible in pump reservoir, add required amount of
and ADD mark on dipstick. Quicksilver Power Trim and Steering Fluid or au-
tomatic transmission fluid (ATF), Dexron, or Dex-
ron II, through fill cap opening, to bring level up to
FULL COLD mark on dipstick. DO NOT OVER-
FILL.
If fluid is not visible in reservoir, a leak exists in the
power steering system. Find cause and correct.
72518
a - Proper Fluid Level With Engine Warm
4. If level is below ADD mark, but fluid is still visible

in pump reservoir, add required amount of Quick-
silver Power Trim and Steering Fluid or automatic
transmission fluid (ATF), Dexron, or Dexron II,
through fill cap opening, to bring level up to FULL
HOT mark on dipstick. DO NOT OVERFILL.
Index
1B-16 - MAINTENANCE 90-823225--1 1096
Filling and Bleeding Power Maintaining Closed Cooling
Steering System Coolant Level
IMPORTANT: Power steering system must be
! WARNING
filled exactly as explained in the following to be
sure that all air is bled from the system. All air Allow engine to cool down before removing pres-
must be removed, or fluid in pump may foam dur- sure cap. Sudden loss of pressure could cause
ing operation and be discharged from pump res- hot coolant to boil and discharge violently. After
ervoir. Foamy fluid also may cause power steer- engine has cooled, turn cap 1/4 turn to allow any
ing system to become spongy, which may result pressure to escape slowly, then push down and
in poor boat control. turn cap all the way off.
1. With engine stopped, position drive unit so that it
is straight back. Remove fill cap/dipstick from 1. Coolant level in heat exchanger should be full (to
power steering pump. Add Quicksilver Power bottom of filler neck).
Trim and Steering Fluid or automatic transmis-
IMPORTANT: When reinstalling pressure cap, be
sion fluid (ATF), Dexron, or Dexron II, as re-
sure to tighten it until it contacts stop on filler
quired, to bring level up to FULL COLD mark on
neck.
dipstick.
2. Coolant level should be between the ADD and
IMPORTANT: Use only Quicksilver Power Trim
FULL marks on coolant recovery reservoir with
and Steering Fluid or automatic transmission
the engine at normal operating temperature.
fluid (ATF), Dexron, or Dexron II in power steering
system.
2. Turn steering wheel back and forth to end of trav-
el in each direction several times, then recheck a
fluid level and add fluid, if necessary.
3. Install vented fill cap.
! CAUTION
DO NOT operate engine without water being
supplied to seawater pickup pump, or pump im-
peller may be damaged and subsequent over-
heating damage to engine may result.
4. Start engine and run at fast idle (1000-1500
RPM) until engine reaches normal operating
temperature. During this time, turn steering
wheel back and forth to end of travel in each di- 72520
rection several times.
5. Position drive unit so that it is straight back and
stop engine. Remove fill cap from pump. Allow
any foam in pump reservoir to disperse, then a - Coolant Recovery Reservoir
check fluid level and add fluid, as required, to
bring level up to FULL HOT mark on dipstick. DO
NOT OVERFILL. Reinstall fill cap securely. Flushing Cooling System
IMPORTANT: Drive unit must be positioned If engine is operated in salty, polluted, or mineral-lad-
straight back and power steering fluid must be en water, flush cooling system (preferably after each
hot to accurately check fluid level. use) to reduce corrosion and prevent the accumula-
6. If fluid is still foamy (in Step 5), repeat Steps 4 and tion of deposits in the system. Thoroughly flush cool-
5 until fluid does not foam and level remains con- ing system prior to storage.
stant.
Index
90-823225--1 1096 MAINTENANCE - 1B-17
MCM Stern Drive BOAT IN WATER
1. Raise drive unit to full UP position.
BOAT OUT OF WATER
2. Install flushing attachment over water pickup
1. Install flushing attachment over water pickup holes in gear housing as shown.
holes in gear housing as shown.
72012
72012
2. Attach a garden hose between the flushing at- 3. Attach a garden hose between the flushing at-
tachment and a water tap. tachment and a water tap.
! WARNING 4. Lower drive unit to full IN position.
When flushing, be certain the area around pro- ! CAUTION
peller is clear, and no one is standing nearby. To
avoid possible injury, remove propeller. Do not run engine above 1500 RPM when flush-
ing. Suction created by seawater pickup pump
! CAUTION may collapse flushing hose, causing engine to
overheat.
Do not run engine above 1500 RPM when flush-
ing. Suction created by seawater pickup pump ! CAUTION
may collapse flushing hose, causing engine to
overheat. Watch temperature gauge on dash to ensure that
engine does not overheat.
! CAUTION 5. Partially open water tap (approximately 1/2 maxi-
Watch temperature gauge on dash to ensure that mum capacity). DO NOT use full water pressure.
engine does not overheat. 6. Place remote control in neutral, idle speed posi-
3. Partially open water tap (approximately 1/2 maxi- tion, and start engine.
mum capacity). DO NOT use full water pressure. 7. Operate engine at idle speed in neutral for 10
4. Place remote control in neutral, idle speed posi- minutes, then stop engine.
tion, and start engine. 8. Shut off water tap.
5. Operate engine at idle speed in neutral for 10 9. Raise drive unit to full UP position.
minutes, or until discharge water is clear, then
stop engine. 10. Remove garden hose and flushing attachment.
6. Shut off water tap. Remove garden hose and

flushing attachment.
Index
1B-18 - MAINTENANCE 90-823225--1 1096
MIE Inboard 2. Using an adaptor, connect a garden hose from a
water tap to seapump inlet.
! CAUTION 3. Partially open water tap (approximately 1/3 maxi-
If boat is in the water, seacock (water inlet valve), mum). Do not use full water pressure.
if so equipped, must be left closed until engine is 4. Place the remote control lever in neutral position
to be re-started, to prevent water from flowing and start engine.
back into cooling system and/or boat. If boat is
not fitted with a seacock, water inlet hose must ! WARNING
be left disconnected and plugged (to prevent wa-
ter from flowing back into cooling system and/or When flushing, be certain the area around pro-
boat). As a precautionary measure, attach a tag peller is clear, and no one is standing nearby. To
to the ignition switch or steering wheel of the avoid possible injury, remove propeller.
boat with the warning: Open seacock or recon- ! CAUTION
nect water inlet hose before starting engine.
Do not run engine above 1500 RPM when flush-
IMPORTANT: If a seacock is to be installed for ing. Suction created by seawater pickup pump
this purpose, valve used must have an internal may collapse flushing hose, causing engine to
cross-sectional area equal to or greater than wa- overheat.
ter inlet hose to prevent restricting water flow
during normal operation. A 1-1/4 in. (32 mm), or ! CAUTION
larger, brass ball valve or gate valve is recom-
mended. Watch temperature gauge on dash to ensure that
1. Remove inlet hose from seapump.
5. Operate engine at idle speed in neutral for 10
NOTE: If boat is left in water, shut off seacock or plug minutes, or until discharge water is clear. Stop
hose to prevent seawater from entering boat. engine.
6. Shut off water tap. Remove garden hose and
adaptor from pump inlet and reconnect water in-
let hose. Be sure to tighten hose clamp securely.
IMPORTANT: If boat is in the water, do not open
water inlet valve until engine is to be restarted to
prevent contaminated water from flowing back
into engine. If boat is not fitted with a valve, leave
water inlet hose disconnected and plugged.
Index
90-823225--1 1096 MAINTENANCE - 1B-19
Maintaining Transmission a
Fluid Level
IMPORTANT: Be sure to push dipstick all the way
down into dipstick tube when checking fluid
level.
1. Remove dipstick to check transmission fluid lev-
el. Fluid level may be over the full mark because
fluid from the cooler and lines has drained back
into the transmission. If fluid level is low, add the
specified fluid through the dipstick hole until full
mark on dipstick is reached. DO NOT OVER-
FILL.
75192
Walter V-Drive
IMPORTANT: To accurately check fluid level, en-

gine MUST BE run at 1500 RPM for 2 minutes im-
mediately prior to checking level.
2. Start engine and run at 1500 RPM for 2 minutes
to fill all circuits, lines, and cooler.
3. Stop engine and quickly check level before fluid
drains back into transmission. Add fluid if neces-
sary.
4. If fluid level is extremely low, check transmission
72526 case, cooler, and hoses for leaks.
Velvet Drive IMPORTANT: Velvet Drive transmission - use 10

wt. tractor hydraulic fluid meeting the C-3/TO-2
specification (preferably Mobil 423, Chevron, or
Citgo).
Hurth transmission - use Dexron II or Dexron II
automatic transmission fluid (ATF).
Walter V-Drive - SAE 30 Heavy Duty Motor Oil,
Exxon Spartan EP-68 Gear Oil, APG-80 Gear Oil
72527
Hurth
Index
1B-20 - MAINTENANCE 90-823225--1 1096
Lubrication THROTTLE BODY INJECTION
Throttle Cable
MODELS WITH 2 BARREL CARBURETOR
b
b
a
72013
74109
a - Pivot Points
a - Pivot Points b - Guide Contact Surface
b - Guide Contact Surface
MODELS WITH 4 BARREL CARBURETOR

b
72014
a - Pivot Points
Index
90-823225--1 1096 MAINTENANCE - 1B-21
MULTI-PORT INJECTION ATTACHING/ADJUSTING THROTTLE CABLE -
350 MAGNUM MPI GEN+ TOURNAMENT SKI
(BLACK SCORPION)
1. Place remote throttle lever in idle position and
attach cable to throttle lever stud, following cable
manufacturer’s instructions.
2. After throttle cable is adjusted, tighten locknut
against cable end.
b
c
a
a 74174
74838
a - Cable End
b - Throttle Lever Stud
c - Locknut
74183
a - Pivot Points
Index
1B-22 - MAINTENANCE 90-823225--1 1096
Shift Cable
b
a a
b
b
a
72015
a
Alpha
a - Pivot Points 71208
a
b
Hurth
a - Pivot Points
a
b
a
72016
Bravo One and Two MCM Models - Typical Shift Cable

a - Pivot Points
a
b
72528
Velvet Drive MIE Models (Typical) Shift Cable and

Transmission Linkage
a - Pivot Points
Index
90-823225--1 1096 MAINTENANCE - 1B-23
Engine Coupler/U-Joint Shaft Splines Drive Shaft Extension Models
NOTE: Refer to MerCruiser Stern Drive Service
Manual for stern drive unit removal and installation.
a
71570
MCM Models with Alpha One Drive
Without Sealed Steel-Hub Coupler 72018
Transom End
a
b
71569
MCM Models with Alpha One Drive
With Sealed Steel-Hub Coupler
b
a
72028
Engine End
a - Lubrication Points
a
72529
MCM Models with Bravo Drives

a - Quicksilver Engine Coupler Spline Grease
b - Grease Fitting(s)
Index
1B-24 - MAINTENANCE 90-823225--1 1096
Starter Motor (MIE Models) Audio Warning System
! WARNING
Maintenance
When performing the following procedure, be
sure to observe the following: Maintenance inspection is the owner’s responsibility
and must be performed at intervals specified, follow-
• Be sure that engine compartment is well venti-
ing:
lated and that no gasoline vapors are present
to avoid the possibility of a fire. Fresh Water Areas - Every 50 Hours of operation
or 60 days (whichever comes first)
• Be sure to ground coil high-tension wire to
Salt Water Areas - Every 25 hours of operation
block. Failure to ground coil wire may cause
or 30 days (whichever comes first)
damage to ignition coil in addition to being a
safety hazard. NOTE: Operation in salt water is considered severe
service.
• Stay clear of all moving parts.
1. Check buzzer mounting screws, heat switch and
IMPORTANT: Some 5.7 Ski Models do not require
oil pressure switch for adequate tightness. Tight-
lubrication.
en, if loose, but DO NOT over-tighten.
1. Remove ignition coil high-tension wire from dis-
2. Check all wiring connections to be sure that they
tributor cap tower and ground it to engine block
are tight and sealed where necessary.
with jumper wire. While cranking engine with
starter motor, lubricate starter motor front bush-
ing through oil cover with motor oil. Reinstall coil Cold Weather or Extended
high-tension wire.
2. Remove plastic plug from flywheel housing. Lu-
Storage
bricate starter motor shaft with Lubriplate Ex- Precautions
tra-Heavy Gear Shield through hole in flywheel
housing. Reinstall plastic plug. ! WARNING
BE CAREFUL while working on fuel system; gas-
a oline is extremely flammable and highly explo-
sive under certain conditions. Be sure that igni-
tion key is OFF and do not smoke or allow
sources of spark and/or open flames in the area.
! WARNING
To prevent a potential fire hazard, be sure that en-
gine compartment is well ventilated and that
a there are no gasoline vapors present during
starting or fogging of engine.
! CAUTION
DO NOT operate engine without cooling water
72019
being supplied to seawater pickup pump or water
pump impeller will be damaged and subsequent
a - Lubrication Points
overheating damage to engine may result.
! CAUTION
Seawater section of cooling system MUST BE
COMPLETELY drained for winter storage, or im-
mediately after cold weather use, if the possibil-
ity of freezing temperatures exists. Failure to
comply may result in trapped water causing
freeze and/or corrosion damage to engine.
Index
90-823225--1 1096 MAINTENANCE - 1B-25
! CAUTION Layup
If boat is in the water, seacock (water inlet valve), NOTICE
if so equipped, must be left closed until engine is
to be re-started, to prevent water from flowing Refer to “Cold Weather or Extended Storage,”
“Precautions,” in this section, BEFORE pro-
ceeding.
not fitted with a seacock, water inlet hose must
be left disconnected and plugged (to prevent wa- 1. Fill fuel tank(s) with fresh gasoline that does not
ter from flowing back into cooling system and/or contain alcohol and a sufficient amount of Quick-
boat). As a precautionary measure, attach a tag silver Gasoline Stabilizer and Conditioner to treat
to the ignition switch or steering wheel of the the gasoline.
boat with the warning: Open seacock or recon-
nect water inlet hose before starting engine. IMPORTANT: If boat is to be placed in storage
(with fuel containing alcohol in fuel tanks), car-
buretors must be run dry at idle RPM. Fuel tanks
IMPORTANT: Observe the following information should be drained completely and Quicksilver
to ensure complete draining of cooling system. Gasoline Stabilizer and Conditioner added to any
• Engine must be as level as possible. fuel remaining in the tank. Also, refer to “Fuel
Specifications,” see Table of Contents.
• A wire should be repeatedly inserted into all
drain holes to ensure there are no obstruc- 2. Replace all fuel filters
tions in passages. Remove petcock, if neces- 3. Start engine and check for fuel leaks.
sary, to insert wire completely into drain hole.
4. Run engine sufficiently to heat it to normal operat-
ing temperature; shut off engine and change oil
IMPORTANT: To prevent threads in manifolds, el-
and filter.
bows and cylinder blocks from rusting out dur-
ing storage, reinstall plugs using Quicksilver 5. If boat has been operated in salty, polluted or min-
Perfect Seal on threads. Never leave drain plugs eral-laden waters, flush cooling system.
out during storage. a. For engines with carburetors:
(1) Remove flame arrestor assembly and re-
NOTE: If possible, place a container under drains
start engine. While operating engine at
and hoses to prevent water from draining into boat.
fast idle (1000-1500 RPM), fog internal
surfaces of induction system and com-
! CAUTION bustion chambers by squirting approxi-
mately 8 ounces (227 grams) of Quicksil-
If engine is equipped with Closed Cooling Sys- ver Storage Seal or SAE 20W engine oil
tem, Closed Cooling section must be kept filled into carburetor bores. Stall engine by
with a solution of ethylene glycol antifreeze and squirting last 2 ounces (57 grams) of Stor-
water (mix antifreeze to manufacturer’s recom- age Seal or oil rapidly into carburetor.
mended proportions to protect engine to lowest Turn ignition to OFF.
temperature to which it will be exposed). DO NOT
USE PROPYLENE GLYCOL antifreeze in closed b. For fuel injected engines with VST:
cooling section. Seawater section, however,
must be drained completely. ! WARNING
Fuel injection system is pressurized. A special
! CAUTION procedure must be used to remove this pressure
A discharged battery can be damaged by freez- before removing the plug from vapor separator
ing. tank. DO NOT attempt to remove plug without
having pressure removed. Fuel could spray on
hot engine causing fire or explosion.
(1) Relieve fuel pressure from system. Refer
to “Fuel Pressure Relief Procedure” in
Section 5C.
Index
1B-26 - MAINTENANCE 90-823225--1 1096
6. Close fuel shutoff valve, if so equipped. (6) Pour out a small amount of fuel into a suit-
able container, then add approximately 2
a. Remove plug from top of vapor separator
fluid ounces (60 ml) of Quicksilver
tank.
2-Cycle Outboard Oil to fuel in the water
(1) Add approximately 1 fluid ounce (30 ml) separating fuel filter.
of Quicksilver 2-Cycle Outboard Oil to
(7) Install water separating fuel filter.
fuel in the vapor separator tank.
(8) Shut off the fuel supply to the engine.
(2) Shut off the fuel supply to the engine’s
fuel pump. (9) Start and run engine at idle speed for two
minutes.
(3) Start engine and run at idle speed until the
vapor separator tank and fuel injection (10) Stop engine, remove and discard new
system is empty. water separating fuel filter and in line fuel
filter.
(4) Reinstall the plug in top of vapor separa-
tor tank. (11) Install new filters.
b. For fuel injected engines with Cool Fuel (12) Close fuel shut-off valve, if so equipped.
system:
7. Clean flame arrestor and crankcase ventilation
(1) Fill fuel tank(s) with fresh gasoline (that hoses and reinstall.
does not contain alcohol) and a sufficient
8. Lubricate all items outlined in “Lubrication.”
amount of Quicksilver Gasoline Stabilizer
for Marine Engines to treat gasoline. Fol- 9. Drain seawater section of cooling system, as out-
low instructions on container. lined in “Draining Instructions” following.
(2) If boat is to be placed in storage with 10. Closed Cooling System Models: Test coolant
fuel containing alcohol in fuel tanks (if to ensure that it will withstand lowest temperature
fuel without alcohol is not available): expected during storage.
Fuel tanks should be drained completely 11. Service batteries.
and Quicksilver Gasoline Stabilizer for
Marine Engines added to any fuel re- 12. Clean outside of engine and repaint any areas re-
maining in the tank. Refer to “FUEL RE- quired with Quicksilver Primer and Spray Paint.
QUIREMENTS” for additional informa- After paint has dried, spray Quicksilver Corrosion
tion. and Rust Preventive Type II or wipe down with
Quicksilver Storage Seal or SAE 20W engine oil.
(3) Prepare fuel system for extended storage
as follows: 13. For drive unit, refer to appropriate stern drive
manual.
(4) Allow engine to cool down.
(5) Remove the water separating fuel filter. ! CAUTION
Stern drive unit should be stored in full “down”
position. Universal Joint bellows may develop a
“set” if unit is stored in raised position and may
fail when unit is returned to service.
Index
90-823225--1 1096 MAINTENANCE - 1B-27
Draining Instructions NOTE: With the engine level, sufficient draining of
manifolds will occur when exhaust manifold-to-ther-
DRAINING SEAWATER (RAW-WATER) COOLED mostat housing hoses are removed.
MODELS
NOTICE
Refer to “Cold Weather or Extended Storage,”
“Precautions,” in this section, BEFORE pro-
ceeding.
1. MCM (Stern Drive) Models:

a. Engine must be as level as possible to ensure
complete draining of cooling system.
b. Remove drain plugs (port and starboard)
from cylinder block.
a 72586
Starboard Shown (Port Similar)

a - Bottom Hose Exhaust Manifold To Thermostat Housing
a 72609
Starboard Side Shown (Port Similar)

a - Drain Plug
a
c. Repeatedly clean out drain holes using a stiff
piece of wire. Do this until entire system is
drained.
NOTE: It may be necessary to lift, bend, or lower
hoses to allow water to drain completely when hoses
are disconnected.
d. Remove hose or drain plug from bottom of
port and starboard exhaust manifolds.
a - Drain Plug Located In Exhaust Manifold Elbow

b - Later Models Are Equipped With Thumbscrew Drain Plug.
Index
1B-28 - MAINTENANCE 90-823225--1 1096
e. Remove the engine water circulating pump g. Remove seawater pump inlet hose as shown.
hose as shown.
b
a 72532
a - Seawater Pickup Pump
b - Hose
72587 h. Follow instructions “(1)” or “(2)”:

a - Hose, Water Circulating Pump-to-Thermostat Housing (1) On Bravo Drive Equipped Models: In-
sert a small wire (repeatedly) to make
f. Remove the power steering fluid cooler-to- sure that speedometer pitot tube, trim tab
seawater hose, as shown. cavity vent hole, and trim tab cavity drain
passage are unobstructed and open.
a c
a
72588 71217
a - Hose, Seawater Pickup Pump-to-Cooler

Bravo Drive Unit
a - Speedometer Pitot Tube
b - Trim Tab Cavity Vent Hole
c - Trim Tab Cavity Drain Passage
Index
90-823225--1 1096 MAINTENANCE - 1B-29
(2) On Alpha Drive Equipped Models: In- j. After seawater section of cooling system has
sert a small wire (repeatedly) to make been drained completely, coat threads of
sure that vent holes and water drain holes drain plugs with Quicksilver Perfect Seal and
and passages (as shown) are unob- reinstall. Tighten drain plugs securely. Re-
structed and open. connect hoses and tighten all hose clamps
e securely. If NOT equipped with seacock:
b seawater inlet hose must remain discon-
nected and plugged until engine is to be re-
started.
d IMPORTANT: MerCruiser recommends that pro-
f
pylene glycol antifreeze (nontoxic and biode-
c gradable, which makes it friendly to lakes and riv-
a ers) be used in sea-water section of the cooling
system for cold weather or extended storage.
Make sure that the propylene glycol antifreeze
contains a rust inhibitor and is recommended for
71216 use in marine engines. Be certain to follow the
propylene glycol manufacturer’s recommenda-
tions.
k. For additional assurance against freezing
and rust, remove the thermostat cover and
thermostat. Fill the engine seawater cooling
f
c system with a mixture of antifreeze and tap
water mixed to manufacturer’s recommenda-
70134
tion to protect engine to the lowest tempera-
a -
Speedometer Pitot Tube ture to which it will be exposed during cold
b -
Trim Tab Cavity Vent Hole weather or extended storage. Using a new
c -
Trim Tab Cavity Drain Passage
gasket, reinstall thermostat and cover. Tight-
d -
Gear Housing Water Drain Hole (One Each - Port and
Starboard) en cover bolts to 30 lb. ft. (41 N·m).
e - Gear Housing Cavity Vent Hole
f - Gear Housing Cavity Drain Hole
i. Crank engine over slightly with starter motor

to purge any water trapped in seawater pick-
up pump. DO NOT ALLOW ENGINE TO
START.
! CAUTION
If boat is in the water or is to remain in the water,
seacock (if so equipped) must remain closed un-
til engine is to be restarted, to prevent water from
flowing back into cooling system. If boat is not
fitted with a seacock, seawater inlet hose must
remain disconnected and plugged, to prevent
water from flowing into cooling system and/or
boat. As a precautionary measure, attach a tag to
the ignition switch or steering wheel with the
warning that the seacock must be opened or the
seawater inlet hose reconnected prior to starting
the engine.
Index
1B-30 - MAINTENANCE 90-823225--1 1096
NOTE: Hoses shown removed only to indicate flow. 2. MIE (Inboard) Seawater (Raw-Water) Models:
Do not remove hoses.
NOTICE
a
Refer to “Cold Weather or Extended
b Storage,” “Precautions,” in this
section, BEFORE proceeding.
c
d complete draining of cooling system.
f
e b. Remove drain plugs (port and starboard)
g
72589
a - Cover
b - Gasket
c - Spacer
d - Thermostat 72609
a
e - O-Ring
f - Housing
g - Fill Here
a - Drain Plug
c. Repeatedly clean out drain holes using a stiff

a piece of wire. Do this until entire system is
drained.
b hoses to allow water to drain completely when hoses
are disconnected.
c
d. Remove hose or drain plug from bottom of
d port and starboard exhaust manifolds.
71758
Stainless Steel Thermostat Housing

a - Housing
b - O-Ring
c - Thermostat
d - Spacer
e - Gasket
Index
90-823225--1 1096 MAINTENANCE - 1B-31
NOTE: With the engine level, sufficient draining of e. Remove the engine water circulating pump
manifolds will occur when exhaust manifold-to-ther- hose as shown.
mostat housing hoses are removed.
a 72586
Starboard Shown (Port Similar) 72587
a - Bottom Hose Exhaust Manifold To Thermostat Housing a - Hose, Water Circulating Pump-to-Thermostat Housing
f. Remove hose from the seawater pump, as

shown.
72586
a
Starboard Shown (Port Similar) b a

72532
a - Drain Plug
b - Seawater Inlet Hose
Index
1B-32 - MAINTENANCE 90-823225--1 1096
g. Remove the transmission fluid cooler hose as h. Crank engine over slightly with starter motor
shown. to purge any water trapped in seawater pick-
up pump. DO NOT ALLOW ENGINE TO
START.
! CAUTION
If boat is in the water or is to remain in the water,
a remain disconnected and plugged, to prevent
72721
the engine.
i. After seawater section of cooling system has
been drained completely, coat threads of
drain plugs with Quicksilver Perfect Seal and
reinstall. Tighten drain plugs securely. Re-
connect hoses and tighten all hose clamps
a securely. If NOT equipped with seacock:
71782 seawater inlet hose must remain discon-
Typical Transmission Fluid Cooler Locations nected and plugged until engine is to be re-
started.
a - Hose
IMPORTANT: MerCruiser recommends that pro-
a pylene glycol antifreeze (nontoxic and biode-
gradable, which makes it friendly to lakes and
rivers) be used in seawater section of the cool-
ing system for cold weather or extended stor-
age. Make sure that the propylene glycol anti-
freeze contains a rust inhibitor and is
a recommended for use in marine engines. Be cer-
tain to follow the propylene glycol manufactur-
er’s recommendations.
j. For additional assurance against freezing
and rust, remove the thermostat cover and
thermostat. Fill the engine seawater cooling
system with a mixture of antifreeze and tap
water mixed to manufacturer’s recommenda-
75192 tion to protect engine to the lowest tempera-
ture to which it will be exposed during cold
weather or extended storage. Using a new
gasket, reinstall thermostat and cover. Tight-
Walter V-Drive Transmission en cover bolts to 30 lb. ft. (41 N·m).
a - Drain Plug (2) One Hidden In This View
Index
90-823225--1 1096 MAINTENANCE - 1B-33
NOTE: Hoses shown removed only to indicate flow. c. Remove drain plugs (if equipped) from port
Do not remove hoses. and starboard exhaust elbows.
a
b
c
f d
e
a
71330
72589
a - Cover a - Drain Plug
b - Gasket
c - Spacer d. If equipped with 3 in. (76 mm) or 6 in. (152
d - Thermostat mm) risers, remove drain plug as shown from
e - O-Ring port and starboard risers.
f - Housing
g - Fill Here
DRAINING SEAWATER SECTION OF CLOSED

COOLING (COOLANT) MODELS
1. MCM (Stern Drive) Models:
NOTICE
Refer to “Cold Weather or Extended a
Storage,” “Precautions,” in this

complete draining of cooling system. 72574
b. Remove drain plug from heat exchanger.
Typical Riser Shown (if equipped)
a - Drain Plug (Removed)
e. Repeatedly clean out drain holes using a stiff

drained.
are disconnected.
a
70583
a - Heat Exchanger
b - Drain Plug
Index
1B-34 - MAINTENANCE 90-823225--1 1096
f. Remove hose from engine power steering
fluid cooler as shown.
a c
a
71217
72588
Bravo Drive
a - Hose, Seawater Pump-to-Cooler b - Trim Tab Cavity Vent Hole
g. Remove seawater pump inlet hose as shown.
b
a 72532
b - Hose
h. Follow instructions “(1)” or “(2)”:

(1) On Bravo Drive Equipped Models: In-
sert a small wire (repeatedly) to make
sure that speedometer pitot tube, trim tab
cavity vent hole, and trim tab cavity drain
passage are unobstructed and open.
Index
90-823225--1 1096 MAINTENANCE - 1B-35
(2) On Alpha Drive Equipped Models: In- j. After seawater section of cooling system has
sert a small wire (repeatedly) to make been drained completely, coat threads of
sure that vent holes and water drain holes drain plugs with Quicksilver Perfect Seal and
and passages (as shown) are unob- reinstall. Tighten drain plugs securely. Re-
structed and open. connect hoses and tighten all hose clamps
e securely. If NOT equipped with seacock:
b seawater inlet hose must remain discon-
started.
2. MIE (Inboard) Models
d
f
NOTICE
c Refer to “Cold Weather or Extended
Storage,” “Precautions,” in this
a

complete draining of cooling system.
71216
b. Remove drain plug from heat exchanger.
f
c
70134
a -
Speedometer Pitot Tube
b -
Trim Tab Cavity Vent Tube
c -
d -
Gear Housing Water Drain Hole (One Each - Port and a
Starboard)
i. Crank engine over slightly with starter motor
to purge any water trapped in seawater pick-
up pump. DO NOT ALLOW ENGINE TO 70583
START.
! CAUTION
a - Heat Exchanger
If boat is in the water or is to remain in the water, b - Drain Plug
the engine.
Index
1B-36 - MAINTENANCE 90-823225--1 1096
c. Remove drain plugs (if equipped) from port f. Remove the transmission fluid cooler hose,
and starboard exhaust elbows. as appropriate on your engine, to drain hose
and cooler.
a 71330
a - Drain Plug a
d. If equipped with 3 in. (76 mm) or 6 in. (152 71782
mm) risers, remove drain plug as shown from
Typical Borg Warner In-Line and
port and starboard risers.
V-Drive Transmissions
a - Hose, Transmission Fluid Cooler
72574
Typical Riser Shown (if equipped)

a
e. Repeatedly clean out drain holes using a stiff
72721
drained.
Typical Hurth Transmission
a - Hose, Transmission Fluid Cooler
are disconnected.
Index
90-823225--1 1096 MAINTENANCE - 1B-37
g. On All Models With a Walter V-Drive Trans- ! CAUTION
mission, disconnect water inlet hose from
the fitting on transmission. If boat is in the water or is to remain in the water,
a fitted with a seacock, seawater inlet hose must
a warning that the seacock must be opened or the
the engine.
j. After seawater section of cooling system has

been drained completely, coat threads of
drain plugs with Quicksilver Perfect Seal and
reinstall. Tighten drain plugs securely. Re-
connect hoses and tighten all hose clamps
75192 securely. If NOT equipped with seacock:
seawater inlet hose must remain discon-
Walter V-Drive Transmission started.
h. Remove seawater pump inlet hose as shown.
b
a 72532
b - Hose
i. Crank engine over SLIGHTLY, with starter

motor, to purge any water trapped in seawa-
ter pickup pump. DO NOT ALLOW ENGINE
TO START.
Index
1B-38 - MAINTENANCE 90-823225--1 1096
Recommissioning
NOTICE
Refer to “Cold Weather or Extended Stor-
age,” “Precautions,” in this section, BE-
FORE proceeding.
1. Check that all cooling system hoses are con-

nected and tight and all petcocks and drain plugs
are installed and tight.
2. If equipped with seacock: Open seacock.
3. Inspect all drive belts.
4. Perform all lubrication and maintenance speci-
fied for completion “At Least Once Yearly” in
maintenance chart, except items which were per-
formed at time of engine layup.
5. For drive unit, refer to appropriate stern drive
manual.
! CAUTION
When installing battery (in next step), be sure to
connect positive battery cable to positive (+) ter-
minal and negative (grounded) battery cable to
negative (–) battery terminal. If battery cables are
reversed, damage to electrical system WILL re-
sult.
6. Install fully charged battery. Clean battery cable

clamps and terminals to help retard corrosion.
7. Start engine and closely observe instrumentation
to ensure that all systems are functioning proper-
ly.
8. Carefully inspect entire engine for fuel, oil, water
and exhaust leaks.
9. Check fuel pump sight tube.
10. Check steering system and shift and throttle con-
trols for proper operation.
Index
90-823225--1 1096 MAINTENANCE - 1B-39
THIS PAGE IS INTENTIONALLY BLANK TO
ALLOW FOR CORRECTIONS OR ADDITIONS
AT A LATER DATE
Index
1B-40 - MAINTENANCE 90-823225--1 1096
AT A LATER DATE
Index
90-823225--1 1096 MAINTENANCE - 1B-41
C
TROUBLESHOOTING
Index
Table of Contents
Page Page
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1 Instrumentation Malfunction . . . . . . . . . . . . . . 1C-12
Used Spark Plug Analysis . . . . . . . . . . . . . . . . . 1C-2 Radio Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Spark Plug Analysis . . . . . . . . . . . . . . . . . . . . . . 1C-2 Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . . 1C-13
Normal Condition . . . . . . . . . . . . . . . . . . . . . . 1C-2 Carburetor Malfunctions . . . . . . . . . . . . . . . . . . 1C-14
Chipped Insulator . . . . . . . . . . . . . . . . . . . . . . 1C-2 Engine Runs Poorly at Idle . . . . . . . . . . . . . . . 1C-15
Wet Fouling (Oil Deposits) . . . . . . . . . . . . . . 1C-2 Engine Runs Poorly At High RPM . . . . . . . . . 1C-16
Cold Fouling . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Engine Acceleration Is Poor . . . . . . . . . . . . . . 1C-17
Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Troubleshooting with Vacuum Gauge . . . . . . 1C-17
High Speed Glazing . . . . . . . . . . . . . . . . . . . . 1C-3 Engine Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Scavenger Deposits . . . . . . . . . . . . . . . . . . . 1C-3 Important Information . . . . . . . . . . . . . . . . . 1C-18
Pre-Ignition Damage . . . . . . . . . . . . . . . . . . . 1C-4 Valve Cover Area . . . . . . . . . . . . . . . . . . . . . 1C-18
Reversed Coil Polarity . . . . . . . . . . . . . . . . . . 1C-4 Cylinder Area . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Splashed Deposits . . . . . . . . . . . . . . . . . . . . . 1C-4 Camshaft Area . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Mechanical Damage . . . . . . . . . . . . . . . . . . . 1C-4 Crankshaft Area . . . . . . . . . . . . . . . . . . . . . . 1C-20
Poor Boat Performance and/or Poor Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Maneuverability . . . . . . . . . . . . . . . . . . . . . . . . . 1C-5 Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Improper Full Throttle Engine RPM . . . . . . . . . 1C-6 Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . 1C-23
RPM Too High . . . . . . . . . . . . . . . . . . . . . . . . 1C-6 High Oil Pressure . . . . . . . . . . . . . . . . . . . . . 1C-23
RPM Too Low . . . . . . . . . . . . . . . . . . . . . . . . . 1C-6 Excessive Oil Consumption . . . . . . . . . . . . . . . 1C-24
Engine Cranks Over but Will Not Start Water In Engine . . . . . . . . . . . . . . . . . . . . . . . . . 1C-25
or Starts Hard . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-7 Important Information . . . . . . . . . . . . . . . . . 1C-25
Important Information . . . . . . . . . . . . . . . . . . 1C-7 Water on Top of Pistons . . . . . . . . . . . . . . . 1C-25
Testing Thunderbolt IV HEI System . . . . . . 1C-8 Water in Crankcase Oil . . . . . . . . . . . . . . . . 1C-26
Testing Thunderbolt V Ignition System . . . . 1C-9 Engine Overheats (Mechanical) . . . . . . . . . . . 1C-26
Fuel System Rich . . . . . . . . . . . . . . . . . . . . . 1C-10 Engine Overheats (Cooling System) . . . . . . . 1C-27
Fuel System Lean . . . . . . . . . . . . . . . . . . . . 1C-10 Insufficient Water Flow from Belt
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 1C-10 Driven Seawater Pickup Pump . . . . . . . . . 1C-28
Engine Will Not Crank Over . . . . . . . . . . . . . . . 1C-11 Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . 1C-29
Charging System Inoperative . . . . . . . . . . . . . 1C-11 Poor, Erratic, or No Assist . . . . . . . . . . . . . 1C-29
Noisy Alternator . . . . . . . . . . . . . . . . . . . . . . 1C-11 Noisy Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-30
Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-30
Troubleshooting Silent Choice Exhaust
Silencer System . . . . . . . . . . . . . . . . . . . . . . . . 1C-31
Index
1C-0 - TROUBLESHOOTING 90-823225--1 1096
Precautions ! WARNING
! WARNING Make sure no fuel leaks exist before closing en-
gine hatch.
Always disconnect battery cables from battery
BEFORE working on fuel system to prevent fire ! CAUTION
or explosion. DO NOT operate engine without cooling water
! WARNING being supplied to water pickup holes in gear
housing, or water pump impeller will be damaged
Be careful when cleaning flame arrestor and and subsequent overheating damage may result.
crankcase ventilation hose; gasoline is extreme-
ly flammable and highly explosive under certain ! CAUTION
conditions. Be sure that ignition key is OFF. DO DO NOT operate engine without water being
NOT smoke or allow sources of spark or open supplied to seawater pickup pump on engine, or
flame in area when cleaning flame arrestor and pump impeller may be damaged and subsequent
crankcase ventilation hose. overheating damage to engine may result. En-
! WARNING gine may be operated with boat out of water, if in-
structions under “Running Engine with Boat Out
Be careful when changing fuel system compo- of Water,” following, are completed.
nents; gasoline is extremely flammable and
highly explosive under certain conditions. Be ! WARNING
sure that ignition key is OFF. DO NOT smoke or When running engine with boat out of water, be
allow sources of spark or flame in the area while certain that area in vicinity of propeller is clear
changing fuel filter. Wipe up any spilled fuel im- and that no person is standing nearby. As a pre-
mediately. cautionary measure, it is recommended that the
! WARNING propeller be removed.
Avoid gasoline fire or explosion. Improper in- ! CAUTION

stallation of brass fittings or plugs into fuel DO NOT run engine above 1500 RPM, as suction
pump or fuel filter base can crack casting and/or created by seawater pickup pump may collapse
cause a fuel leak. Follow specific procedure, giv- water supply hose and cause engine to overheat.
en in Section 4 of this manual, for all fuel line
connections. ! WARNING
! WARNING Be sure that engine compartment is well venti-
lated and that no gasoline vapors are present to
Avoid gasoline fire or explosion. Improper instal- prevent the possibility of a FIRE or EXPLOSION.
fuel filter base can crack casting and/or cause a ! WARNING
fuel leak.
DO NOT leave helm unattended while performing
• Apply #592 Loctite Pipe Sealant with Teflon to idle speed adjustment.
threads of brass fitting or plug. DO NOT USE
TEFLON TAPE.
• Thread brass fitting or plug into fuel pump or
fuel filter base until finger tight.
• Tighten fitting or plug an additional 1-3/4 to
2-1/4 turns using a wrench. DO NOT
OVER-TIGHTEN.
• Install fuel line. To prevent over-tightening,
hold brass fitting with suitable wrench and
tighten fuel line connectors securely.
• Check for fuel leaks.
Index
90-823225--1 1096 TROUBLESHOOTING - 1C-1
Used Spark Plug Analysis Chipped Insulator
Use the following illustrations for determining ser- Chipped insulator usually results from careless plug
viceability of spark plug. Spark plug condition also regapping. Under certain conditions, severe detona-
can suggest a variety of possible engine malfunction also can split insulator firing ends. Plug must be
tions and, therefore, can indicate needed engine re- replaced.
pairs. When old plugs are replaced, replace entire
set. Perform plug service only on those plugs suitable
for additional service, using the following proce-
dures:
1. Remove any oil deposits with solvent and dry
plugs thoroughly.
2. Open electrode gap wide enough to permit clean-
ing and filing.
3. Remove combustion deposits from firing end of
spark plug with a plug cleaner. Blow off with com- 72420
pressed air to remove abrasives.
4. File electrode surfaces to restore clean, sharp
edges. Again remove filings with compressed air.
5. Reset gap to specifications by bending only side
electrode with proper tool. Wet Fouling (Oil Deposits)
Plug becomes shorted by excessive oil entering
combustion chamber, usually in engine with many
Spark Plug Analysis hours of operation. Worn piston rings, cylinder walls,
valve guides or valve stem seals are causes of oil en-
tering combustion chamber. Only engine repairs will
Normal Condition permanently relieve oil wet fouling.
Few deposits are present and probably will be light IMPORTANT: New engines or recently over-
tan or gray in color. This plug shows that plug heat hauled engines may wet foul plugs before normal
range is compatible with engine, and engine is elec- oil control is achieved with proper break-in pro-
trically and mechanically in good running condition. cedures. Such fouled plugs may be serviced
With proper plug servicing (clean, file and regap), this (clean, file and regap) and reinstalled.
plug can be reinstalled with good results.
72420
72420
Index
Cold Fouling High Speed Glazing
Dry, black deposits indicate rich fuel mixture or weak Insulator has yellowish, varnish-like color, indicating
ignition. Clogged flame arrestor, flooding carburetor, that temperatures suddenly have risen, usually dur-
sticky choke or weak ignition components all are ing hard, fast acceleration under heavy load. Normal
probable causes. If, however, only one or two plugs deposits do not get a chance to blow off. Instead, they
in set are fouled, check for sticking valves or bad igni- melt and form a conductive coating. Replace plugs.
tion leads. After correcting cause, service (clean, file If condition recurs, use colder heat range plug and
and regap) plugs and reinstall. service plugs more frequently.
72421 72421
Overheating Scavenger Deposits

Insulator is dull white or gray and appears blistered. Powdery white or yellow deposits are built up on
Electrodes are eroded and there is an absence of de- shell, insulator and electrodes. This is normal ap-
posits. Check that correct plug heat range is being pearance with certain branded fuels. Accumulation
used. Also check for over-advanced ignition timing, on ground electrodes and shell areas may be unusu-
cooling system malfunction, lean fuel/air mixtures, ally heavy, but may be easily chipped off. Plugs can
leaking intake manifold or sticking valves. Replace be serviced (clean, file and regap) and reinstalled.
spark plugs.
72422
72421
Index
Pre-Ignition Damage Splashed Deposits
Pre-ignition damage is caused by excessive high Spotted deposits, which sometimes occur after long
temperatures. Center electrode melts first, followed delayed tune-up, accumulate after a long period of
by ground electrode. Normally, insulators are white misfiring. When normal combustion temperatures
but may be dirty if plug has been misfiring. Check for are restored, upon installation of new plugs, deposits
correct plug heat range, advanced ignition timing, loosen from top of piston and head and are thrown
lean fuel mixture, incorrect fuel used, malfunctioning against hot insulator. Clean and service plugs and re-
cooling system, leaking intake manifold or lack of lu- install.
brication.
72423
72422
Mechanical Damage
Reversed Coil Polarity
Mechanical damage to spark plug firing end is
Concave erosion of ground electrode is an indication caused by foreign object in combustion chamber. Be-
of reversed polarity. Center electrode will show only cause of valve overlap, small objects can travel from
normal wear. Engine will misfire and idle rough. To one cylinder to another. Check all cylinders, intake
correct, reverse primary coil leads. Replace spark manifold and exhaust material to prevent further
plugs. damage.
72423
72422
IMPORTANT: When working on engine, spark

plug holes and carburetor throat should be kept
covered to prevent foreign objects from entering
combustion chamber.
Index
Poor Boat Performance and/or Poor Maneuverability
Symptom Cause
A. Improper drive unit trim angle
B. Improper weight distribution
C. Boat is underpowered
B
Bow too low
l D. Permanent or power hook in boat bottom
E. False bottom full of water
F. Improperly adjusted trim tabs (after planes)
G. Dirty boat bottom (marine growth)
A. Improper drive unit trim angle
B. Propeller pitch too great
C. Dirty boat bottom (marine growth)
D. Poor running engine
B
Bow too high
hi h
E. Improper weight distribution
F. Rocker in boat bottom
G. False bottom full of water
H. Improperly adjusted trim tabs (after planes)
A. Drive unit installed too high on transom
B. Dirty or rough boat bottom
C. Damaged propeller; pitch too small; diameter
too small
D. Keel located too close to propeller or too deep
P
Propeller
ll ventilating
il i
in the water
E. Water pickup or thru hull fittings located too
close to propeller
F. Hook in boat bottom
G. Propeller plugged up with weeds
Index
Improper Full Throttle Engine RPM
RPM Too High
Cause Special Information
Damaged; pitch too low; diameter too small;
Propeller
propeller hub slipping.
Water pickup or thru hull fittings mounted too
close to propeller (ventilation); keel located too
Boat close to propeller and/or too deep in the water
(ventilation). Drive installed too high on
transom; wrong gear ratio.
Operation
Unit trimmed out too far.
far
Engine coupler slipping
RPM Too Low

Propeller Damaged; pitch too great; diameter too great.
Dirty or damaged bottom; permanent or power

Boat hook in bottom; false bottom full of water. Drive
installed too low on transom; wrong gear ratio.
Operation Unit trimmed in too far.
Index
Engine Cranks Over but Will 2. Determine if there is fuel present by looking down
the carburetor venturi while actuating throttle.
Not Start or Starts Hard There should be a stream of fuel coming out of
the accelerator pump nozzles if the carburetor
has fuel.
Important Information 3. Check ignition system operation. Remove coil
1. First, determine which engine system is causing wire from tower on distributor cap. Hold coil wire
the problem. To make an engine run, basic com- near ground and check for spark while cranking
ponents - fuel, spark (ignition), and compression engine over. Repeat procedure with spark plug
- are required. If all three components are pres- wires. If there is spark at the spark plug wires, re-
ent, the engine should run. If any one of the three move the spark plugs and make sure they are
are missing, weak, or arriving at the wrong time correct type and heat range, and not fouled or
the engine will not run. burned.
4. Run a compression check on engine to make
sure the engine is mechanically OK.
Thunderbolt IV (HEI) Ignition (No Spark)
Moisture on ignition components Distributor cap or spark plug wires arcing
Battery, electrical connections, damaged wiring
Ignition switch
Shift interrupter switch (Alpha One Models Only)
Shorted tachometer Disconnect tachometer and try again
Ignition timing
Spark plugs Fouled, burned, cracked porcelain
Spark plug wires Faulty insulation, broken wires
Cracked or dirty distributor cap
Faulty ignition components Check components
Engine synchronizer (if equipped) hooked up Synchronizers must be hooked up directly coil
series on purple ignition wire (dual engines only) terminal (parallel chute)
Index
Testing Thunderbolt IV HEI System
! WARNING IMPORTANT: Use a voltmeter when mak-
Be sure that engine compartment is well venti- ing these tests. DO NOT use a test light.
lated and that there are no gasoline vapors pres-
ent during the following test to prevent a poten-
tial fire hazard.
Check all Terminal Connections

at Distributor, Ignition Module
and Ignition Coil
Replace
Ignition Battery OK?
Module Distributor Clamping Screw
Tight?
0 Volts No Spark
Replace Ignition Check Engine
With Key in RUN Position, and Instrument
Module Harness Check for 12 Volts at Positive 0 Wiring Harness,
(+) Terminal on Ignition Coil Volts Battery Cables,
0 Volts Key Switch
12 Volts
Unplug WHT/
RED bullet con-
Check for 1-12 Volts at WHT/
nector from Dist. 0 RED Terminal on Distributor
Term., then Volts
Check for Voltage
on This Lead 1 to 12 Volts
Voltage Remove High-Tension Lead

from Distributor to Coil. Insert
Replace Ignition a Spark Gap Tester from Coil
Sensor in Tower to Ground. Remove Spark Replace Ignition
Distributor WHT/GRN Lead from Distribu- at Coil Sensor in
tor Terminal - Ignition Key in Distributor
RUN Position. Strike the Termi-
nal on the WHT/GRN Lead
against Ground
No Spark at Coil
Substitute a New Ignition Coil. Spark Install New

Repeat Above Test at Coil Ignition Coil
No Spark at Coil
Replace Ignition Module
Note 1 : Early , large ignition modules did not have a replaceable wiring harness.
Index
Testing Thunderbolt V Ignition System
Check to ensure that tachometer

GRY lead is not shorted to
ground (–) at the tachometer or
within the harness.
No Spark

and Ignition Coil.
Battery OK?
Distributor Clamping Screw
Tight?
No Spark
Check Engine
Check for 12 Volts at Positive 0 Wiring Harness,
12 Volts Key Switch
Unplug WHT/
RED bullet connector
from Distributor.
0 Check for 12 volts
Volts on lead coming
from module.
12 Volts
Reconnect WHT/RED
bullet connectors.
Remove High-Tension Lead
a Spark Gap Tester from Coil
Tower to Ground. Disconnect Replace Ignition
WHT/GRN Lead from Distribu- Spark Sensor in
tor. Place Ignition Key in RUN at Coil Distributor
Position. Rapidly strike the Ter-
minal of the WHT/GRN Lead
that comes from module,
against Ground (–).
(See “IMPORTANT” below)
No Spark at Coil
Substitute a New Ignition Spark Install New

Coil. Repeat Above Test at Coil Ignition Coil
No Spark at Coil
IMPORTANT: The WHT/GRN lead must be touched against ground (–) 2-3 times per second
to simulate a running engine. Repeat this test several times to ensure that spark is present.
Index
Fuel System Rich
Warm engine carburetor percolation Fuel boils out of float bowl when shut off and
warm. Floods intake manifold.
Clogged flame arrestor
Automatic choke not opening
Float adjustment
Float leaks or is saturated with fuel
Needle and seat leaking
Carburetor gaskets leaking
Excessive fuel pump pressure
Cracked or porous carburetor body Unseats needle and seat
Fuel System Lean

Empty fuel tank
Fuel shut-off valve closed (if equipped)
Engine will not start after warm engine shut

Vapor lock
down
Automatic choke Stuck open, wrong adjustment
Miscellaneous
1. Low grade or stale fuel
2. Water in fuel
Index
Engine Will Not Crank Over
Remote control lever not in neutral position
Battery charge low; damaged wiring; loose elec-

trical connections
Circuit breaker tripped
Blown fuse
Ignition switch
Slave solenoid
Faulty neutral start safety switch Open circuit
Starter solenoid
Starter motor
Mechanical engine malfunction
Charging System Inoperative

Loose or broken drive belt
Engine RPM too low on initial start Rev engine to 1500 RPM
Loose or corroded electrical connections
Faulty battery gauge Best way to test is to replace gauge
Battery will not accept charge Low electrolyte or failed battery
Faulty alternator or regulator
Refer to Section 4C for complete

“Charging System” diagnosis procedures
Noisy Alternator
Loose mounting bolts
Drive belt Worn, frayed, loose
Loose drive pulley
Worn or dirty bearings
Faulty diode trio or stator
Index
Instrumentation Malfunction
Faulty wiring, loose or corroded terminals
Faulty key switch Test, as outlined in Section 4D
Faulty gauge Test, as outlined in Section 4D
Faulty sender Test , as outlined in Section 4D
Radio Noise
A “popping” noise that will increase with engine Ignition System - wrong spark plugs; cracked
RPM. Noise will stop as soon as engine is distributor cap; cracked coil tower; leaking spark-
turned off. plug wires; moisture on ignition components
“High pitched whine” in the radio Alternator - poor brush contact on the slip rings
A “hissing or crackling” noise when instruments Instrumentation - loose connections, or

are jarred with ignition on antennae wire routed too close to instruments
Accessories - bilge pump, bilge blower; fish find-
Varying unexplained noises er, depth locator; cabin heater motor, etc. Dis-
connect one at a time until noise disappears.
Index
Poor Fuel Economy
Fuel leaks
Operator habits Prolonged idling; slow acceleration; failure to cut

back on throttle once boat is on plane; boat
overloaded; uneven weight distribution
Engine laboring Bent, damaged, or wrong propeller. Water test
boat for proper operating RPM at wide-open-
throttle
Clogged flame arrestor
Engine compartment sealed too tight Not enough air for engine to run properly
Boat bottom Dirty (marine growth), hook, rocker
Carburetor Idle mixture settings, accelerator pump adjust-

ments,linkage binding, choke adjustment, carbu-
retor flooding over, main fuel jets
Improper fuel
Crankcase ventilation system not working
Engine needs tune-up
Engine running too cold or too hot
Plugged or restricted exhaust
Engine Low compression
Index
Carburetor Malfunctions
Symptoms Cause
A. Needle and seat
B. Float adjustment
C. Saturated float
Flooding
Fl di D. Gaskets leaking
E. Cracked fuel bowl
F. Fuel percolation
G. Automatic choke
2. A. Idle RPM too low
B. Idle mixture screws
C. Idle passages dirty
R
Rough
h idl
idle D. Throttle valves not closing
E. Engine flooding
F. Vacuum leak
G. Throttle body heat passages plugged
A. Accelerator pump
B. Leaking gaskets
C. Automatic choke
D. Power piston or power valve
Hesitation
H i i or acceleration
l i flflatness E. Throttle valves
F. Throttle body heat passages plugged
G. Main metering jets
H. Float adjustment
I. Secondary air valve wind-up
Index
Engine Runs Poorly at Idle
Symptoms Cause
A. Main metering jets
B. Leaking gaskets
C. Float adjustment
E i surges
Engine
D. Saturated float
E. Power piston or valve
F. Throttle valves
A. Power piston or valve
B. Float adjustment
Low top speed
L d or lack
l k off power
C. Main metering jets
D. Leaking gaskets
A. Idle RPM too low
Poor
P cold
ld engine
i operation
i C. Throttle valves
D. Automatic choke
E. Engine flooding
A. Idle RPM too low
C. Engine flooding
Engine
E i stalls
ll D. Automatic choke
E. Dirt in carburetor
F. Accelerator pump
G. Leaking gaskets
Hard starting Refer to “Engine Starts Hard”
Index
Engine Runs Poorly At High RPM
Also refer to “Poor Boat Performance”
Crankcase overfilled with oil Check oil level with boat at rest in the water.
Anti-siphon valve (if equipped) Restricting fuel supply
Plugged fuel tank vent
Fuel supply Refer to “Carburetor Malfunctions”

(See “Table of Contents”)
Ignition timing
Low grade of fuel or water in the fuel
Spark plugs Fouled, burned, cracked porcelain, incorrect

heat range
Spark plug wires Poor insulation, broken wires
Distributor cap or rotor Dirty or cracked
Coil
Distributor Excessive play in shaft
Engine overheating Refer to “Engine Overheats”
Low compression Worn valves, rings, cylinders, etc.
Restricted exhaust
Index
Engine Acceleration Is Poor
Cause Special Instructions
Also refer to “Poor Boat Performance”
Idle mixture screws
Incorrect ignition timing
Incorrect distributor or amplifier advance curve Refer to Section 4B
Check for stream of raw fuel from accelerator

Accelerator pump pump discharge nozzle, when opening throttle
with engine shut off
Cracked or dirty distributor cap or rotor
Vacuum leak Intake manifold or carburetor base
Fouled, burned; wrong heat range; cracked

Spark plugs
porcelain
Float adjustment
Dirty carburetor
Low compression
Troubleshooting with Vacuum Gauge

Reading Cause
Steady reading between 15-21 inches at idle

Normal
RPM
Vacuum leak; incorrect timing; underpowered
Extremely low reading, but steady at idle RPM
boat; faulty boat bottom
Blown head gasket between two adjacent
Fluctuates between high and low at idle RPM
cylinders
Carburetor needs adjustment; spark plug gap
Fluctuates 4 or 5 inches very slowly at idle RPM
too narrow; valves are sticking
Fluctuates rapidly at idle, steadies as RPM is
Valve guides are worn
increased
Continuously fluctuates between low and normal
Burned or leaking valve
reading at regular intervals at idle RPM
Index
Engine Noise 4. Try to isolate the noise to location in engine: front
to back, top to bottom. This can help determine
which components are at fault.
Important Information 5. Sometimes noises can be caused by moving
parts coming in contact with other components.
No definite rule or test will positively determine Examples are: flywheel or coupler; exhaust
source of engine noise; therefore, use the following flappers rattling against exhaust pipe; crankshaft
information only as a general guide to engine noise striking (pan, pan baffle, or dipstick tube); rocker
diagnosis. arm striking valve cover; and loose flywheel
1. Use a timing light to determine if noise is timed cover. In many cases if this is found to be the
with engine speed or one-half engine speed. problem, a complete engine teardown is not
Noises timed with engine speed are related to necessary.
crankshaft, rods, pistons, piston pins, and fly- 6. When noise is isolated to a certain area and com-
wheel. Noises timed to one-half engine speed ponent, removal and inspection will be required.
are valve train related. Refer to proper sections of service manual for in-
2. The use of a stethoscope can aid in locating a formation required for service.
noise source; however, because noise will travel 7. If noise cannot be distinguished between engine
to other metal parts not involved in the problem, and drive unit, remove drive from boat. Run a
caution must be exercised. water supply directly to engine. Run engine
3. If you believe noise is confined to one particular without the drive to determine if noise is still there.
cylinder, ground spark plug leads, one at a time.
If noise lessens noticeably or disappears, it is iso-
lated to that particular cylinder.
Valve Cover Area
Location Possible Cause
Rocker arm striking valve cover
Rocker arm out of adjustment

V l cover area,
Valve area timed
i d to one-half
h lf engine
i
speed, noise could be confined to one cylinder Worn rocker arm
or may be found in any multitude of cylinders
Bent push rod
Collapsed filter
Index
Cylinder Area
Location Possible Causes
Sticking valve
Carbon build-up
Connecting rod installed wrong

Cylinder
C li d area, may b be confined
fi d to one cylinder
li d Bent connecting rod
or found in more than one cylinder
cylinder, timed to
engine speed Piston
Piston rings
Piston pin
Cylinder worn
Camshaft Area

Crankshaft timing sprocket
Timing chain
C h ft
f area, ffrontt off engine,
Camshaft i titimed
i d tto one h lf
half Fuel Pump
engine speed
Valve Lifter
Cam Bearings
Fuel Pump
C h ft area, center
Camshaft t off engine,
i titimed
d tto one h lf
half Valve Lifter
engine speed
Cam bearing
Distributor gear
C h ft area, rear off engine,
Camshaft i titimed
d tto one h lf
half Valve lifter
engine speed
Cam bearings
Loss of oil pressure
C
Camshaft
h ft area, th
throughout
h t engine,
i titimed
d tto one Valve lifters
half engine speed
Cam bearings
Index
Crankshaft Area
Crankshaft timing sprocket
C k h f area,, ffront off engine,

Crankshaft gi , timed
i d to Timing chain
engine speed Main bearing
Rod bearing
Crankshaft striking pan or pan baffle
Crankshaft area,
area center of engine,
engine timed to
Main bearing
engine speed
Rod bearing
Loose flywheel cover
Loose coupler
C k h f area,
Crankshaft area rear off engine,
i
engine timed
i d to
Loose flywheel
engine speed
Main bearing
Rod bearing
Loss of oil pressure
Crankshaft area,
area throughout engine,
engine timed to
Main bearings
engine speed
Rod bearings
Index
Miscellaneous
Noise Possible Cause
Advanced timing
Low octane fuel

E i spark
Engine k kknock
k
Engine running hot
Carbon deposits in engine
Wrong ignition timing
Carburetor set too lean
Faulty accelerator pump
Popping
P i through
h h carburetor
b Vacuum leak
Valve adjustment
Valve timing
Burned or stuck valve
Vacuum leak
Leaking exhaust (manifolds or pipes)

Hi i
Hissing
Loose cylinder heads
Blown head gasket
Vacuum leak
Whistle
Dry or tight bearing in an accessory
Leaking high tension lead
S k jjumping
Sparks i Cracked coil tower
Cracked distributor cap
Drive belt slipping
S
Squeaks
k or squeals
l Dry or tight bearing in an accessory
Parts rubbing together
Rattling in exhaust pipe area Exhaust shutters
Index
Oil Pressure
Use a good automotive oil pressure test gauge.

Measuring oil pressure
Do not rely on the oil pressure gauge in the boat.
Oil level should be between the ADD and FULL
Check engine oil level with boat at rest in the water
marks
May cause loss of engine RPM, oil pressure
Oil level in crankcase above FULL mark gauge fluctuation, drop in oil pressure, and
hydraulic valve lifter noise at high RPM
Low oil pressure; oil pressure gauge fluctuation;
Oil level in crankcase below ADD mark
internal engine noise and/or damage
This may be a normal condition. Oil pressure
may read high in the cooler times of the day, and
when engine is not up to operating temperature.
Change in oil pressure
As the air temperature warms up and engine is
running at normal opening temperature, it is
normal for oil pressure to drop.
With modern engines and engine oils, low oil
pressure readings at idle do not necessarily
mean there is a problem. If valve lifters do not
“clatter” (at idle), there is a sufficient volume of
Low engine oil pressure at idle oil to lubricate all internal moving parts properly.
The reason for the drop in oil pressure is that
engine heat causes an expansion of the internal
tolerances in the engine and, also, the oil will
thinout somewhat from heat.
Low engine oil pressure at idle after running at a
Refer to No. 5 and 6, preceding
high RPM
It is not uncommon to see different oil pressure
readings between the two engines, as long as
both engines fall within specifications.
Boats with dual engines
Differences in oil pressure can be attributed to
differences in engine tolerances, gauges, wiring,
senders, etc.
Boats with dual stations Refer to No. 8. preceding
Index
Low Oil Pressure
Low oil level in crankcase
Verify with an automotive test gauge. Refer to

Defective oil pressure gauge and/or sender
Section 4D for instrument testing.
Oil broken down; contains water or gas; wrong
Thin or diluted oil viscosity; engine running too hot or too cold;
excessive idling in cold water (condensation)
Relief valve stuck open; pickup tube restricted;
Oil pump worn parts in oil pump; air leak on suction side of
oil pump or pickup oil tube
Oil passage plugs leaking, cracked or porous
Oil leak can be internal or external
cylinder block
Excessive bearing clearance Cam bearings, main bearings, rod bearings
High Oil Pressure

Oil too thick Wrong viscosity, oil full of sludge or tar
Defective oil pressure gauge and/or sender Verify with an automotive test gauge
Clogged or restricted oil passage
Oil pump relief valve stuck closed
Index
Excessive Oil Consumption
One quart of oil consumed in 5-15 hours of

Normal consumption. operation at wide-open-throttle (especially in a
new or rebuilt engine) is normal
Clean bilge, run engine with clean white paper
Oil leaks
on bilge floor, locate oil leak(s)
Oil too thin Oil diluted or wrong viscosity
Oil level too high
Drain holes in cylinder head plugged Oil will flood valve guides
Defective valve seals
Intake manifold gasket leaking
Worn valve stems or valve guides
Defective oil cooler (if so equipped) Crack in cooler tubes
Glazed, scuffed, worn, stuck, improperly

Defective piston rings installed; ring grooves worn; improper break-in;
wrong end gap
Out of round, scored, tapered, glazed; excessive
Defective cylinders
piston to cylinder clearance; cracked piston
Excessive bearing clearance
NOTE: ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS SPECIFIED IN “MAINTENANCE

SCHEDULE” in Section 1B. It is normal for an engine to use a certain amount of oil in the process of lubricating
and cooling the engine. The amount of oil consumption is greatly dependent upon engine speed, with consump-
tion being highest at wide-open-throttle and decreasing substantially as engine speed is reduced.
Index
Water In Engine If water is contained to cylinder(s) only, it is usually
entering through the intake system, exhaust system,
or head gasket.
Important Information If the water is contained to crankcase only, it is usual-
ly caused by a cracked or porous block, a flooded
IMPORTANT: First determine location of water in bilge, or condensation.
engine. This information can be of great help
when trying to determine where the water came If the water is located in both the cylinder(s) and the
from and how it got into the engine. The three crankcase, it is usually caused by water in the cylin-
most common problems are “water on top of pis- ders getting past the rings and valves, or complete
tons, water in crankcase oil, water in crankcase submersion.
oil and on top of pistons.” Checking for rust in the intake manifold or exhaust
The first step, after locating water, is to remove all the manifolds is a good idea. Rust in these areas will give
water from the engine by removing all spark plugs clues if the water entered these areas.
and pumping cylinders out by cranking engine over.
Next change oil and filter. Now, start engine and see
if problem can be duplicated. If problem can be dupli-
cated, there more than likely is a mechanical prob-
lem. If the problem cannot be duplicated, the problem
is either an operator error or a problem that exists
only under certain environmental conditions.
Water on Top of Pistons
Operator shut engine off at high RPM
Engine out of tune, poor fuel, high idle RPM,

Engine “diesels” or tries to run backwards
timing set too high
Rain water running into flame arrestor Hatch cover
Improper combustion causes moisture in the air

Spark plug misfiring
to accumulate in the cylinder
Backwash through the exhaust system
Improper engine or exhaust hose installation
Cracked exhaust manifold
Improper manifold to elbow gasket installation
Loose cylinder head bolts
Blown cylinder head gasket Check for warped cylinder head or cylinder block
Cracked valve seat
Check cylinder heads, cylinder block, and intake

Porous or cracked casting
manifold
Index
Water in Crankcase Oil
Boat has been submerged or bilge water was

Water in boat bilge
high enough to run in through dipstick tube
Water seeping past piston rings or valves Refer to “Water in Engine” (“On Top of Pistons”)
Defective thermostat, missing thermostat;

Engine running cold
prolonged idling in cold water
Intake manifold leaking near a water passage
Check cylinder head, cylinder block, and intake

Cracked or porous casting
manifold
Engine Overheats (Mechanical)

Engine RPM below specifications at wide- Damaged or wrong propeller; growth on boat
open-throttle (engine laboring) bottom;false bottom full of water
Wrong ignition timing Timing too far advanced or retarded
Sticking distributor advance weights
Spark plug wires crossed (wrong firing order)
Lean fuel mixture Refer to “Carburetor Malfunctions” in this section
Wrong heat range spark plugs
Exhaust restriction
Valve timing off Jumped timing chain, or improperly installed
A blown head gasket(s) normally cannot be

detected by a compression check. Normally the
engine will run at normal temperature at low
RPM, but will overheat at speeds above 3000
RPM.
Blown head gasket(s) Engines that are seawater cooled: Using a

clear plastic hose, look for air bubbles between
seawater pump and engine. If there are no
bubbles present, install clear plastic hose
between thermostat housing and manifold(s).If
air bubbles are present at a higher RPM, it is a
good indication there is a blown head gasket.
Defective oil pump, plugged oil passage, low oil
Insufficient lubrication to moving parts of engine
level
Index
Engine Overheats (Cooling System)
IMPORTANT: The first step is to verify if the en-

gine is actually overheating or the temperature IMPORTANT: Best way to test gauge or sender is
gauge or sender is faulty. to replace them.
Loose or broken drive belt
Seawater shutoff valve partially or fully closed

(if equipped)
Clogged or improperly installed sea strainer
Loose hose connections between seawater

Pump will suck air. Pump may fail to prime or will
pickup and seawater pump inlet (models with
force air bubbles into cooling system.
belt driven seawater pump only)
Seawater inlet hose kinked or collapsed
Seawater pickup clogged
Obstruction will be in front of seawater pickup,

Obstruction on boat bottom causing water
causing air bubbles to be forced into cooling
turbulence
system
Defective thermostat
Exhaust elbow water outlet holes plugged
Insufficient seawater pump operation Worn pump impeller
Obstruction in cooling system such as casting Refer to water flow diagram for engine type
flash, sand, rust, salt, etc. being serviced
Engine circulating pump defective
Also refer to “Engine Overheats (Mechanical)”
IMPORTANT: In addition to previous checks,

make the following checks if engine is equipped
with closed cooling.
Low coolant level
Antifreeze should be mixed 50/50 or maximum

Antifreeze not mixed properly
60/40 (60% antifreeze, 40% water)
Heat exchanger cores plugged
Water hoses reversed at the water distribution

Refer to water flow diagram in Section 6
block
Index
Insufficient Water Flow from Belt Driven Seawater Pickup Pump
Drive belt Loose, worn or broken
Seawater shutoff valve partially or fully closed
Clogged or improperly installed sea strainer
Loose hose connections between seawater pickup Pump will suck air, pump may fail to prime or will
and seawater pump inlet force air bubbles into cooling system
Seawater inlet hose kinked or plugged
Seawater pickup plugged
Obstruction will be in front of seawater pickup,

Obstruction on boat bottom causing water turbu-
causing air bubbles to be forced into cooling
lence.
system
Faulty seawater pump
Index
Power Steering
Poor, Erratic, or No Assist
Drive belt Worn, broken or out of adjustment
Low fluid level
Air leak in lines, pump, or air from installation.

Air in system
Refer to Section 9A for bleeding procedure.
Leaking hoses Refer to Section 10A for bleeding procedure.
Cable or helm partially frozen from rust or

Steering cables and/or steering helm corrosion; cable over-lubricated; improper cable
installation.
Binding in stern drive unit Refer to appropriate Stern Drive Service Manual
Restriction in hydraulic hoses Causes a loss of pressure
Control valve not positioned properly, not

balanced properly, or the mounting nut is loose
Mounting bracket adjusting screw loose or
mounting tube is loose
Faulty pump Flow control valve may be sticking
Worn piston ring or scored housing bore in cylinder. Causes loss of pressure
Leaking valve body or loose fitting spool
Index
Noisy Pump
Drive belt Check belt tension
Low fluid level
Air in fluid Air leak in lines, pump, or air form installation
Faulty pump Use stethoscope to listen for noise in pump
Restricted fluid passages Kinks or debris in hoses or debris in passages
Stop nut adjusted improperly Refer to appropriate Stern Drive Service Manual
Steering cables installed that do not meet BIA

Refer to appropriate Stern Drive Service Manual
standards
Fluid Leaks
Loose hose connections Refer to Section 10A for bleeding instructions
Damaged hose
Oil leaking from top of pump System overfilled; fluid contains water; fluid
contains air
Cylinder piston rod seal
Faulty seals in valve
Faulty seals in o-rings in pump
Cracked or porous metal parts
Index
Troubleshooting Silent NOTE: Perform the following tests with engine(s) not
running.
Choice Exhaust Silencer Compressor will not run
System 1. Testing mode switch (ignition switch in RUN posi-
tion).
a. Purple wire must have battery voltage. If not,
fuse is blown or wiring is faulty.
b. Brown wire must have battery voltage when
mode switch is held in THRU-TRANSOM po-
a sition. If not, switch is faulty.
c. Gray wire must have battery voltage when
the mode switch is held in THRU-PROP posi-
tion. If not, switch is faulty.
2. Testing air pump (ignition switch in RUN posi-
72533
tion).
a. Check that black wire, in terminal block, is
grounded to engine.
b. Brown wire in terminal block, must have bat-
tery voltage when mode switch is held in
THRU-TRANSOM position. If not, wiring is
faulty. If voltage is present, air pump is faulty.
Air pump runs - system inoperative
With air pump running, check hoses, fittings, sole-
noid, and relief valve for air leakage. Replace parts
b c g as needed.
System operates but goes THRU-PROP after air
pump stops running
1. Check that air pressure is not leaking past sole-
noid. If so, replace.
2. Check that air pressure is not leaking back
through air pump. If so, replace check valve.
3. Check that air pressure is not leaking at air cylin-
d der assemblies. If so, replace faulty ones.
System stays in THRU-TRANSOM mode, will not
go back to THRU-PROP mode
Gray wire, in terminal block, must have battery volt-
age when mode switch is held in THRU-PROP posi-
tion. If not, wiring is faulty. If voltage is present, sole-
f noid is faulty.
e 72534
a - Air Cylinder Assembly

b - Air Pump
c - Solenoid
d - Check Valve
e - Relief Valve
f - Air Intake Valve
g - Mode Switch
Index
REMOVAL AND
INSTALLATION
2
A
72975
MCM MODELS - ALPHA ONE DRIVES
Index
Table of Contents
Page
Torque Specification . . . . . . . . . . . . . . . . . . . . . . 2A-1
Tools/Lubricants/Adhesives/Sealants . . . . . . . 2A-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
Engine Installation/Alignment . . . . . . . . . . . . 2A-3
Engine Connections . . . . . . . . . . . . . . . . . . . 2A-5
Index
2A-0 - INSTALLATION - ALPHA ONE DRIVES 90-823225--1 1096
Torque Specification
Fastener Location Lb. In. Lb. Ft. Nm
Drive Unit Cable Barrel Spread Cotter Key
Shif C
Shift Cable
bl Cable End Guide See Note
Hose Clamps Securely
Rear Engine Mounts 35-40 47-54
Power Steering Fluid Hose Fitting
Earlier Style Large 23 31
Small 100 11
Later Style 23 31
Remote Control Cable Barrel Securely
Shif C
Shift Cables
Th l C
Throttle Cable
NOTE: Tighten, then back nut off one half turn
Tools/Lubricants/Adhesives/Sealants
Part Number Description
91-805475 A1 Quicksilver Engine Alignment Tool
91-816391 A4 Quicksilver Engine Coupler Spline Grease
92-25711--2 Quicksilver Liquid Neoprene
Obtain Locally Loctite Pipe Sealant with Teflon
! CAUTION
DO NOT use an alignment tool from another manufacturer. Alignment tools other than Quicksilver Align-
ment Tools (91-805475A1 or a properly modified 91-57797A3) may cause improper alignment and dam-
age to gimbal bearing and/or engine coupler.
e
f a
d c
a - Material To Be Removed (Shaded Area) To Alpha or Bravo Coupling
b - Measurement - 1.150 in. (29.21 mm)
c - Measurement - 2.750 in. (69.85 mm)
d - Measurement - 2.200 in. (55.88 mm)
e - Radius - .060 (1.5 mm)
f - Chamfer - .060 in. (1.5 mm) x 45 degree
Quicksilver Engine Alignment Tool (91-57797A3) Modification
Index
90-823225--1 1096 INSTALLATION - ALPHA ONE DRIVES - 2A-1
Removal ! CAUTION
IMPORTANT: Stern drive unit must be removed DO NOT allow lifting sling to hook or compress
prior to engine removal. Refer to Stern Drive Ser- engine components or damage will occur.
vice Manual.
13. Support engine with suitable sling through lifting
Engine Removal eyes on engine and remove front and rear engine
1. Disconnect battery cables from battery. mounting bolts. Retain hardware.
2. Remove instrument harness connector plug from
engine harness receptacle after loosening
a
clamp.
! WARNING
Be careful when working on fuel system. Gaso-
line is extremely flammable and highly explosive
under certain conditions. Do not smoke or allow
spark or open flame in area. Wipe up any spilled b 72977
fuel immediately.
3. Disconnect and suitably plug fuel line to prevent a

fuel in tank from leaking into bilge.
4. Disconnect throttle cable from carburetor and re-
tain locknuts and hardware.
5. Disconnect bullet connectors of trim sender wires
(coming from transom assembly) from engine
harness.
NOTE: After wires are disconnected be sure to loos-
en them from clamps or Sta-Straps retaining them to
engine or hoses.
6. Slide sleeves back on BLACK and WHITE/
GREEN (or gray) wires and disconnect engine
harness wires from shift cut-out switch harness.
7. Disconnect MerCathode wires from MerCathode 72581
controller if so equipped.
8. Disconnect seawater inlet hose from gimbal
housing.
9. Disconnect exhaust elbow hoses (bellows).
10. Remove both shift cables from shift plate. Retain b a
locknuts and hardware.
11. Disconnect any grounding wires and accessories
that are connected to engine. 72579
12. Disconnect (and suitably plug) fluid hoses from a - Suitable Sling
power steering control valve on transom. b - Engine Lifting Eyes
14. Carefully remove engine. DO NOT hit power

! CAUTION
steering control valve.
Center lifting eye (located on top of thermostat
housing) is used for engine alignment only. DO
NOT use to lift entire engine.
Index
Installation IMPORTANT: Engine attaching hardware must be
installed in sequence shown.
Engine Installation/Alignment 5. Install both rear engine mounting bolts and hard-
ware as shown. Torque to 35-40 lb. ft. (47-54
1. Follow instructions “a”-“e”:
N·m).
a. Be certain fiber washers (cemented in place)
on inner transom plate are present. Inspect fi-
ber washers. Replace if worn or damaged.
a
b. Install double wound lockwashers onto inner
transom plate inside fiber washer. c b
c. Be certain rear engine mount locknuts are in
position as shown. d
d. Lubricate exhaust bellows with soap and wa- e
ter to ease installation.
g
e. Lubricate engine coupling splines with Quick-
silver Engine Coupler Spline Grease. h f
72535
a
a - Bolt, Rear Engine Mounting
b - Washer, Large Steel
b c - Spacer, Metal
d - Rear Engine Mount
c e - Double Wound Lockwasher
f - Fiber Washer (Cemented in Place)
g - Inner Transom Plate Mounts
h - Locknuts (Hidden In This View)
d 72023
a - Double Wound Lockwasher ! CAUTION

b - Fiber Washer (Cemented in Place)
c - Inner Transom Plate Mount (Engine Support)
When lowering engine into position DO NOT set
d - Locknuts (Engine Mounting Bolts) engine on shift cable. Shift cable outer casing
can be crushed causing difficult or improper
! CAUTION shifting.
Center lifting eye (located on top of thermostat 6. Set engine down on stringers and relieve hoist
housing) is used for engine alignment only. DO tension. Disconnect sling from engine lifting eyes
NOT use to lift entire engine. and switch sling to center lifting eye.
! CAUTION
DO NOT allow lifting sling to hook or compress
engine components or damage will occur.
2. Attach a suitable sling to lifting eyes on engine

and adjust so that engine is level when sus-
pended. (Refer to “Removal” section for loca-
tion of lifting eyes.)
3. Lift engine into position (in boat), using an over-
head hoist. a
4. Align rear engine mounts with inner transom
plate mounts while simultaneously aligning ex- 72024
haust tubes with exhaust pipe hoses (bellows). a - Center Lifting Eye
Index
! CAUTION
DO NOT use an alignment tool from another man- c
ufacturer. Alignment tools other than Quicksilver b
Alignment Tool 91-805475A1, may cause improp-
er alignment and damage to gimbal bearing and/
or engine coupler.
! CAUTION
To avoid damage to gimbal bearing, engine cou- a
pler, or alignment tool:
• DO NOT attempt to force alignment tool!

72585
• DO NOT raise or lower engine with alignment
tool inserted (or partially inserted) in gimbal
a - Alignment
bearing or engine coupler. b - Gimbal Bearing
c - Engine Coupler
7. Align engine as follows:
a. Attempt to insert solid end of Quicksilver IMPORTANT: Turn both front engine mount ad-
Alignment Tool through gimbal bearing and justment nuts an equal amount in direction re-
into engine coupler splines. If it will not insert quired to align engine.
easily proceed to following.
c. Adjust front engine mounts until they rest on
b. While observing the above precautions, boat stringers.
CAREFULLY raise and lower front of engine
with hoist, as required, until tool will SLIDE d. Relieve hoist tension entirely and fasten both
FREELY all the way in and out of engine cou- front mounts to boat stringer using appropri-
pler splines. ate hardware (lag bolts or thru-bolts, etc).
b
a
70013
a - Alignment Tool (Use Only Quicksilver Alignment Tool

91-805475A1, or Properly Modified 91-57797A3)
b - Insert This End of Alignment Tool through Gimbal Housing
Assembly
Index
e. Recheck alignment with alignment tool. Tool 9. Proceed to “Engine Connections” section in-
must enter coupler splines freely. If not, structions following.
readjust front mounts.
f. When alignment is correct, tighten locknut or
Engine Connections
nut with lockwasher on each mount securely. IMPORTANT: When routing all wire harnesses
g. Bend tab washer down against flat on adjust- and hoses, be sure they are routed and secured
ing nut. to avoid coming in contact with hot spots on en-
gine and avoid contact with moving parts.
1. Connect seawater hose to water tube at gimbal
housing with hose clamp. Tighten clamp secure-
ly.
NOTE: In the following view the engine is not in posi-
a tion, for visual clarity in this step.
b e c
c
72536
d
a - Nut and Lockwasher

b - Adjustment Nut
c - Turn Adjustment Nut in This Direction (Counterclockwise)
d - Slotted Hole Toward Front of Engine
e - Tab Washer
b
h. Remove alignment tool if not already re-
a
moved. 72614
8. Tighten all exhaust system hose clamps securely a - Water Inlet Tube
as follows (use two hose clamps on each b - Hose Clamp
connection): c - Seawater Inlet
72537
Typical
a - Hose Clamps - Tighten Securely
b - Exhaust Tube - Long Tube - Port Side; Short Tube -
Starboard Side
Index
2. Connect instrument harness to engine harness ! WARNING
with hose clamp. Tighten clamp securely.
spark or open flame in area. Wipe up any spilled
fuel immediately.
4. Connect fuel line from fuel tank(s) to engine.

Make certain connections are secure. Check for
leaks.
5. Connect throttle cable using hardware retained
and adjust as follows:
a. Place remote control handle(s) in neutral, idle
a position.
c b IMPORTANT: Be sure that cable is routed in such
a way as to avoid sharp bends and/or contact
72025 with moving parts. DO NOT fasten any items to
throttle cable. Outer cable must be free to move
a - Engine Wiring Harness Receptacle Bracket when cable is actuated.
b - Instrumentation Wiring Harness Plug
c - Hose Clamp b. Install cable end guide on throttle lever, then
push cable barrel lightly toward throttle lever
3. Connect trim position sender leads from gimbal end. (This will place a slight preload on cable
housing to leads from engine harness. to avoid slack in cable when moving remote
control lever.) Adjust barrel on throttle cable
to align with anchor stud.
c. Secure throttle cable with hardware (re-
tained) as shown. Tighten cable end guide
locknut until it bottoms out and then back off
b one full turn. Tighten cable barrel securely.
DO NOT OVER-TIGHTEN, as cable must
a pivot freely.
c 72992
a - BROWN/WHITE (From Engine Harness)

b - BLACK (From Engine Harness)
c - BLACK (From Transom Assembly)
d - BLACK (From Transom Assembly)
Index
2 BARREL CARBURETOR THROTTLE BODY FUEL INJECTION
b b
c
d a
d
72013 71711
c
b
a - Cable End Guide
b - Attaching Hardware
c - Cable Barrel a - Flat Washer and Locknut - Tighten Until Nut Bottoms Out,
d - Anchor Studs Then Back Off 1/2 Turn.
b - Cable Barrel
4 BARREL CARBURETOR c - Flat Washer And Locknut
e. Return remote control throttle lever to idle po-

b
sition and check to ensure that throttle lever
c contacts idle speed adjustment screw.
MERCARB 2 BARREL CARBURETOR

d
a b
d
b c
72014 W.O.
T.
IDLE
a - Cable End Guide b
c - Cable Barrel a 72283
d - Anchor Studs
a - Throttle Lever Tang
d. Place remote control throttle lever in the b - Carburetor Body
wide-open-throttle (W.O.T.) position. Check c - Idle RPM Adjustment Screw
to ensure that throttle shutters (valves) are
completely open and throttle shaft lever con-
tacts carburetor body casting.
Index
WEBER 4 BARREL CARBURETOR 7. Connect MerCathode wires to MerCathode con-
troller assembly as shown, if so equipped. Apply
a thin coat of Quicksilver Liquid Neoprene to all
connections.
71159
a
Wide Open Throttle Position

a - Throttle Shaft Lever [Contacts (b) at W.O.T. Position]
b - Carburetor Body Casting
a c 22232
b d
a - ORANGE Wire - From Electrode on Transom Assembly

a b - RED/PURPLE Wire - Connect (Other End) to Positive
(+) Battery Terminal
c - BLACK WIRE - From Engine Harness
d - BROWN WIRE - From Electrode on Transom Assembly
b
70392 IMPORTANT: Adjust shift cables as outlined in
appropriate Stern Drive Service Manual.
Idle Position 8. Refer to appropriate Stern Drive Service Manual
a - Throttle Shaft Lever [Contacts (b) at W.O.T. Position] and install and adjust drive unit and remote con-
b - Idle Speed Adjustment Screw trol shift cables, using hardware retained.
IMPORTANT: After fluid hose installation in the
IMPORTANT: Do not attach any accessory following, bleed power steering system as out-
ground (–) wires to transom plate ground point. lined in SECTION 1B - “Maintenance” or refer to
Accessory ground wires should only be attached appropriate Stern Drive Service Manual.
to ground stud on engine.
6. Connect any grounding wires or accessories that
may have been disconnected.
Index
9. Connect power steering fluid hoses to control Later Style Control Valve: Torque both fittings to 23
valve (large fitting first) as shown. lb. ft. (31 N·m).
! CAUTION
Route hoses exactly as shown below. This will
help avoid stress on the hose fittings and will
help avoid kinks in the hose.
IMPORTANT: Make hydraulic connections as

quickly as possible to prevent fluid leakage.
IMPORTANT: Be careful not to cross-thread or

73786
over tighten fittings.
Earlier Style Control Valve: Torque large fitting to 10. Connect battery cables to battery by FIRST con-
necting POSITIVE (+) battery cable (usually red)
20-25 lb. ft. (27-34 N·m) and small fitting to 96-108 lb.
to POSITIVE (+) battery terminal. Tighten clamp
in. (11-12 N·m). securely. Then, connect NEGATIVE (–) battery
a cable (usually black) to NEGATIVE (–) battery
terminal. Tighten clamp securely.
NOTE: Spray terminals with a battery connection

sealant to help retard corrosion.
72026
a - Large Fitting
b - Small Fitting
Index
REMOVAL AND
INSTALLATION
2
B
70246
MCM MODELS – ALPHA ONE DRIVES

WITH DRIVESHAFT EXTENSION
INDEX
Table of Contents
Page
Torque Specification . . . . . . . . . . . . . . . . . . . . . . 2B-1
Tools/Lubricants/Adhesives/Sealants . . . . . . . 2B-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4
Engine Installation/Alignment . . . . . . . . . . . . 2B-4
Engine Connections . . . . . . . . . . . . . . . . . . . 2B-9
INDEX
2B-0 - ALPHA DRIVES - WITH DRIVE SHAFT EXTENSIONS 90-823225--1 1096
Shif C
Shift Cable
Small 100 11
Later Style 23 31
Shif C
Shift Cables
Th l C
Throttle Cable
Description Part Number
Quicksilver Engine Alignment Tool 91-805475 A1
Quicksilver Engine Coupler Spline Grease 91-816391 A4
Quicksilver Liquid Neoprene 92-25711--2
Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Loctite 8831 92-823089-1
Universal Protractor
Obtain Locally
Loctite Pipe Sealant with Teflon
INDEX
90-823225--1 1096 ALPHA DRIVES - WITH DRIVE SHAFT EXTENSIONS - 2B-1
Removal 6. Slide sleeves back on black and white/green (or
gray) wires and disconnect engine harness wires
from shift cut-out switch harness.
IMPORTANT: It is not necessary to remove the
engine to service the drive shaft and/or bearing 7. Disconnect MerCathode wires from MerCathode
support (tailstock). Refer to instructions as out- controller if mounted on engine (some models).
lined in Section 8D - “Drive Shaft Repair” or 8. Disconnect seawater inlet hose from engine.
“Bearing Support Repair” for servicing these
items only. 9. Disconnect exhaust elbow hoses (bellows).
10. Remove both shift cables from shift plate. Retain
IMPORTANT: Stern drive unit does not have to be locknuts and hardware.
removed prior to engine removal. If stern drive is 11. Disconnect any grounding wires and accessories
going to be removed, refer to appropriate Stern that are connected to engine.
Drive Service Manual.
12. Disconnect (and suitably plug) fluid hoses from
power steering control valve on transom.
Engine Removal 13. Remove top and then bottom drive shaft shields
at engine end of extension drive shaft.
1. Disconnect battery cables from battery.
clamp.
! WARNING
fuel immediately. a
d
3. Using wrench to stabilize brass coupling at fuel
filter inlet, loosen fuel line fitting, disconnect and
suitably plug fuel line to prevent fuel in tank from
c
leaking into bilge.
4. Disconnect throttle cable from carburetor and re- b
72033
a - Top Shield
5. Disconnect bullet connectors of trim sender wires b - Bottom Shield
(coming from transom assembly) from engine c - 4 Screws/Nuts (2 Hidden)
harness. d - 3 Screws (Hidden)
NOTE: After wires are disconnected, be sure to loos-
engine or hoses.
INDEX
14. Mark extension drive shaft U-joint yoke/output 15. Support engine with suitable sling through lifting
flange connections at engine end (to assist in ex- eyes on engine and remove front and rear en-
act same positioning during reassembly). Dis- gine mounting bolts from boat stringers. Retain
connect drive shaft from output flange. hardware.
c a
b 72578
b a
70237
Engine End Shown

a - Matching Marks on Flange and Drive Shaft Connection
b - Extension Drive Shaft U-Joint Yoke
c - Flange, Output
! CAUTION
! CAUTION
72581
IMPORTANT: To avoid the need for a complete re-

alignment (after engine repair), DO NOT MOVE
b a
FRONT AND REAR MOUNT ADJUSTMENT. Re-
move mounting bolts from boat stringers.
72579
a - Suitable Sling
b - Engine Lifting Eyes a
a
Typical Mounting Shown 72536

a - Mounting Bolts
16. Carefully remove engine.
INDEX
Installation 5. As shown, attach engine output flange to drive-
shaft flange exactly as marked during disassem-
bly. Torque fasteners to 50 lb. ft. (68 N·m).
Engine Installation/Alignment
a
ENGINE MOUNT ADJUSTMENT WAS NOT
DISTURBED DURING SERVICE
! CAUTION b e
! CAUTION d
engine components or damage to them will oc-
c
cur.
70237
Engine End Shown
pended. (Refer to “Removal” section for loca- a - Output Shaft Flange
tion of lifting eyes.) b - Drive Shaft
c - Screw 7/16-20 x 1-1/2 In. (38 mm) Long (4 Used)
2. Lift engine into approximate position (in boat), us- d - Nut 7/16-20 (4 Used)
ing an overhead hoist. e - Matching Marks Made upon Disassembly - Aligned
3. Set engine on stringers.
4. Grease drive shaft universal joints with Quicksil- IMPORTANT: Failure to properly position output
ver 2-4-C Marine Lubricant with Teflon. shaft flange may result in bearing damage.
! CAUTION 6. Relieve hoist tension from engine, then slide en-
gine fore or aft as needed to obtain 1/4 in. (6 mm)
When attaching shaft in next step, BE SURE that clearance between flange shoulder and exten-
the pilot on drive shaft flanges are engaged in in- sion shaft housing bearing.
put shaft and output shaft flanges. Flanges
MUST BE flush to each other prior to tightening
c
screws or screws may come loose during opera-
tion.
! CAUTION
Failure to align shaft flanges with matching
marks made on disassembly may cause improp-
erly aligned drive unit and extension drive shaft
U-joint centerlines resulting in a severe vibration b
problem.
a
72591
a - Flange Shoulder
b - Bearing
c - 1/4 In. (6 mm)
INDEX
7. Position engine for correct engine and drive shaft 9. Apply Loctite 8831 to threads of bottom drive
lateral alignment as follows: shaft shield retaining screws and install bottom
shield on engine end as shown. Torque screws
a. Measure the length of (a) and (b) to the cen-
to 30 lb. ft. (41 N·m). Then install top shield
ters of bolt holes. They MUST BE EQUAL. If
as shown. Torque screws and nuts to 30 lb.
they are not equal, slide the aft and forward
ft. (41 Nm).
ends of the engine equal amounts in oppo-
site directions to obtain equal lengths for (a)
and (b).
b. Recheck Step 6. If Step 6 is not as specified,
adjust and recheck Step 7a. Continue this
process until both Steps 6 and 7a are as spe-
cified.
a
a
70246
b
These Dimensions Must Be Equal c 72028
Engine End Shown
8. After engine has been aligned correctly, fasten a - Shaft Housing
front and rear engine mounts to stringers. Tighten b - Bottom Shield
mounting bolts securely. c - Screws (3 Used - Two Hidden in This View)
(Use Loctite 271)
a
d
c
b 72033
Engine End Shown

a - Top Shield
b - Bottom Shield
c - 4 Screws/Nuts (2 Hidden)
d - 3 Screws (2 Hidden)
10. Proceed to “Engine Connections” section in-

structions following.
INDEX
ENGINE MOUNT ADJUSTMENT WAS IMPORTANT: Be sure that boat does not move
DISTURBED DURING SERVICE once reading has been taken from input shaft
flange, as this reading establishes a reference
NOTE: A Universal Protractor is recommended for
point for aligning drive shaft and engine follow-
measuring the angles in the following steps.
ing. If boat is moved, reference point may be al-
tered and subsequently, improper drive shaft and
IMPORTANT: In the following steps, the protrac- engine alignment may occur. Alignment tool
tor readings will be taken off of vertical and hori- MUST BE in place during entire alignment proce-
zontal surfaces; therefore, both the 0 degree and dure if drive unit is not installed.
the 90 degree marks will be used. It should be
kept in mind that these are reference marks only a b
and the assigned numbers should be ignored. It
is only necessary to determine the number of de-
grees and to which side (left or right) of the refer-
ence marks the indicator needle rests. PRO-
TRACTOR MUST BE VIEWED FROM THE SAME
SIDE OF POWER PACKAGE THROUGHOUT IN-
STALLATION.
c
REFER-
ENCE
MARK
72592
a - Indicator Shaft Flange

b - Protractor
c - Indicator Needle
REFER-
ENCE
MARK NOTE: For ease of installation we recommend the
use of a chain leveler in the following steps.
3. Adjust engine mounts so that an equal amount of
72429 up and down adjustment exists.
4. Attach a suitable lifting chain to lifting eyes on en-
1. Refer to Section 8D - “Drive Shaft Models/Propel- gine and adjust so that engine will be level when
ler Shaft,” and remove drive shaft. suspended, then place engine into its approxi-
mate position (in boat) using an overhead hoist.
2. Position base of protractor against input shaft
flange, as shown. NOTE and RECORD the num- 5. Refer to Section 8D - “Drive Shaft Models/Propel-
ber of degrees and to which side of the reference ler Shaft,” and install drive shaft while observing
mark the indicator needle has moved in the fol- precautions in Section 8D, especially about
lowing chart. aligning gimbal bearing U-joint centerlines with
extension drive shaft U-joint centerlines at bear-
Reading from Step 1. __________ degrees to the ing support input shaft. DO NOT install shields at
_________ side of reference mark. this time.
INDEX
! CAUTION 8. Relieve hoist tension from engine, then slide en-
Engine MUST BE aligned correctly to achieve between flange shoulder and extension shaft
proper engine operation and to prevent damage housing bearing, as shown.
to drive shaft. If drive shaft is run at an incorrect
angle, damage to universal joint bearings may re- c
sult.
6. Position base of protractor on drive shaft, then
raise or lower engine (as boat construction per-
mits) until indicator needle is 1 degree to 3 de-
grees on either side of reading taken in Step 1.
Record this reading in the following chart for later
use. b
b
c a
a
72591
a - Flange Shoulder
b - Bearing
c - 1/4 In. (6 mm)
70238
9. Position engine for correct engine and drive shaft
lateral alignment as follows:
a - Drive Shaft
b - Protractor a. Measure the length of (a) and (b) to the cen-
c - Output Shaft Flange ters of bolt holes. They MUST BE EQUAL. If
ends of the engine equal amounts in opposite
directions to obtain equal lengths for (a) and
Reading from Step 6. __________ degrees to the (b).
_________ side of reference mark.
7. Adjust stringer height so that the stringers just

contact the engine mount bases.
b
! CAUTION
Failure to properly position output shaft flange 70246
(as described following) may result in bearing These Dimensions Must Be Equal
damage.
cified.
INDEX
10. After engine has been aligned correctly, fasten 12. Position protractor on drive shaft and recheck
front and rear engine mounts to stringers. Tighten angle. Angle should be the same as that re-
securely. corded in Step 6. If not, raise or lower all four en-
gine mount adjustment nuts an equal amount un-
til correct angle is reached.
13. Tighten ALL engine mount nuts securely. Bend
washer tab down on each adjustment nut.
a
a
a
e
b
72536
c
Typical Mounting Shown
a - Mounting Bolts
11. Position protractor on starter housing cover d 72536

plate, as shown. Now, raise or lower front engine a - Nut and Lockwasher (350 Magnum - Locknut Only)
mount adjusting nuts as required so that protrac- b - Adjustment Nut
c - Turn Adjustment Nut in This Direction
tor needle reads exactly the same number of de- (Counterclockwise) to Raise Front of Engine
grees as that recorded in Step 1. d - Slotted Hole toward Front of Engine
a e - Tab Washer
72593
Thru-Prop Exhaust Shown
a - Flywheel Housing
b - Starter Housing Cover Plate
c - Protractor
INDEX
14. Apply Loctite 8831 to threads of bottom drive Engine Connections
shaft shield retaining screws and install bottom
shields on engine and transom end as shown.
Torque screws to 30 lb. ft. (41 N·m). Then install IMPORTANT: When routing all wire harnesses
both top shields as shown. Torque screws and and hoses, be sure they are routed and secured
nuts to 30 lb. ft. (41 N·m). to avoid coming in contact with hot spots on en-
1. Connect seawater inlet hose to engine. Tighten
hose clamp securely.
a
c
b
70245
a
Top Shield and Bottom Shield at Transom End 72532
(Engine End Similar) a - Seawater Inlet Hose Connection
a - Top Shield
b - Bottom Shield
c - Bolt 3/8-16 x 7/8 In. (22 mm Long) (4 Used) 2. Connect instrument harness to engine harness
d - Nut 3/8-16 (4 Used) with hose clamp. Tighten clamp securely.
e - Screws (3 Used - Hidden in This View) (Use Loctite 271)

c b
72025
a - Engine Wiring Harness Receptacle Bracket

c - Hose Clamp - Tighten Securely
INDEX
3. Connect two trim position sender leads from gim- ! WARNING
bal housing to leads from engine harness.
b fuel immediately.
a FUEL SUPPLY CONNECTIONS
! WARNING
d Avoid gasoline fire or explosion. Improper instal-
fuel filter base can crack casting and/or cause a
fuel leak.
c • Apply #592 Loctite Pipe Sealant with Teflon to
72582
a - Brown/White (From Engine Harness) TEFLON TAPE.
b - Black (From Engine Harness)
c - Black (From Transom Assembly)
d - Black (From Transom Assembly) fuel filter base until finger tight.
4. Reconnect shift cut-out switch harness to engine 2-1/4 turns using a wrench. DO NOT
harness. OVER-TIGHTEN.
c tighten fuel line connectors securely.
a
Make sure connection is secure. Check for leaks.
d 6. Connect throttle cable(s) using hardware re-

tained and adjust as follows:
c a. Place remote control handle(s) in neutral, idle
d
position.
IMPORTANT: Be sure that cable is routed in such

with moving parts. DO NOT fasten any items to
b when cable is actuated.
72034
b. Install cable end guide on throttle lever, then
a - Engine Harness
b - Switch Harness push cable barrel lightly toward throttle lever
c - BLACK end. (This will place a slight preload on cable
d - WHITE-GREEN (or GRAY) to avoid slack in cable when moving remote
INDEX
c. Secure throttle cable with hardware (re- e. Return remote control throttle lever to idle
tained) as shown. Tighten cable end guide position and check to ensure that throttle
nut until it bottoms out and then back off one lever contacts idle speed adjustment screw.
full turn. Tighten cable barrel securely. DO
NOT OVER-TIGHTEN, as cable must pivot
freely.
c
W.O.
T.
b b
c
d a IDL
d b E
2 Barrel Carburetor 72013
a 72283
a - Cable End Guide
b - Attaching Hardware (DO NOT Over-Tighten)
c - Cable Barrel
d - Anchor Studs Mercarb 2 Barrel Carburetor
b - Carburetor Body
b c - Idle RPM Adjustment Screw
c
c
d
IDLE
a
a b
d
b
b W.O.T.
4 Barrel Carburetor 72014
a - Cable End Guide

72583
b - Attaching Hardware (DO NOT Over-Tighten) Rochester 4 Barrel Carburetor
c - Cable Barrel a - Tang
d - Anchor Studs b - Carburetor Body
c - Idle RPM Adjustment Screw
d. Place remote control throttle lever in the
wide-open-throttle (W.O.T.) position. Check
INDEX
WEBER 4 BARREL CARBURETOR h
f
g
e
a
71159
Wide-Open-Throttle Position
d
b
c
74109
Throttle Body Fuel Injection

a - Cable End Guide
c - Locknut and Flat Washer - Tighten Until Nut Bottom
Out,Then Back Off One Half Turn
d - Throttle Lever
e - Throttle Bracket
a f - Cable Barrel
g - Flat Washer and Locknut
h - Throttle Cable Anchor Stud
70392
Idle Position
a - Throttle Lever [Contacts (b) in Idle Position]
b - Idle Speed Adjustment Screw
INDEX
7. Secure throttle cable with hardware as shown
and tighten securely.
NOTE: If Boat is equipped with Quicksilver Zero Ef-
fort Controls, the throttle cable mounting stud must
be most forward position on throttle lever.
b a
a - Position for Zero Effort Controls 73855
74174
IMPORTANT: Do not attach any accessory
ground (–) wires to transom plate ground point.
Accessory ground wires should only be attached
74183
Multi-Port Injection
a - Lock Nut and Flat Washer Tighten Until Bottoms Out, Then
Back Off One Half Turn.
b - Cable End Guide
c - Throttle Cable Anchor Stud
d - Cable Barrel
INDEX
IMPORTANT: Do not attach any accessory ! CAUTION
Accessory ground wires should only be attached Route hoses exactly as shown below. This will
to ground stud on engine. help avoid stress on the hose fittings and will
9. Models with MerCathode: Connect MerCa- quickly as possible to prevent fluid leakage.
thode wires to MerCathode controller assembly
as shown. Apply a thin coat of Quicksilver Liquid
Neoprene to all connections. IMPORTANT: Be careful not to cross-thread or
overtighten fittings.
IMPORTANT: Adjust shift cables as outlined in

10. Connect both hydraulic hose fittings.
a. Earlier Style Control Valves: Torque the
large fitting to 23 lb. ft. (31 N·m). Torque the
small fitting to 100 lb. in. (11 N·m).
a b
a b c d
22232
a - ORANGE Wire - From Electrode on Transom Assembly

b - RED/PURPLE Wire - Connect (Other End) to Positive
c - BLACK Wire - From Engine Harness
d - BROWN Wire - From Electrode on Transom Assembly
22023
IMPORTANT: After fluid hose installation in the a - Small Fitting

following, bleed power steering system as out- b - Large Fitting
lined in appropriate Stern Drive Service Manual. b. Later Style Control Valve: Torque both fit-
tings to 23 lb. ft. (31 N·m). Route hoses as
shown for each model
73786
a - Hose Fittings
INDEX
11. Using double hose clamps on all connections, in- b. On Engines with Thru-Transom Exhaust:
stall exhaust hoses and exhaust tubes as shown
in “a” or “b” following. Tighten all hose clamps se-
curely. NOTICE (THRU-TRANSOM EXHAUST)
a. On Engines with Thru-Prop Exhaust: Exhaust hoses must be connected to ex-

haust elbows so that they do not restrict
the flow of discharge water from exhaust
elbow. If hoses are connected incorrectly,
discharge water from exhaust elbow will
not flow around entire inside diameter of
hose. This will cause a hot spot in the
hose which may eventually burn through.
a
c b c CORRECT
d 72027
Starboard Side Engine End Shown

(Port Similar)
a - Exhaust Pipe
b - Exhaust Hose
c - Hose Clamps
d - Exhaust Tube INCORRECT
72538
Clamps Not Shown
12. Connect battery cables to battery by FIRST con-

necting positive (+) battery cable (usually red) to
positive (+) battery terminal. Tighten clamp se-
curely. Then, connect negative (–) battery cable
(usually black) to negative (–) battery terminal.
a Tighten clamp securely.
c
b c NOTE: Spray terminals with a battery connection
d 72584
Starboard Side Transom End Shown
(Port Similar)
a - Exhaust Separator Assembly
b - Exhaust Hose
c - Hose Clamps
d - Exhaust Tube
INDEX
REMOVAL AND
INSTALLATION
2
C
72580
MCM MODELS - BRAVO DRIVES
INDEX
Table of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . 2C-1
Tools/Lubricants/Adhesives/Sealants . . . . . . 2C-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2
Engine Removal . . . . . . . . . . . . . . . . . . . . . . 2C-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3
Engine Installation/Alignment . . . . . . . . . . . 2C-3
Engine Connections . . . . . . . . . . . . . . . . . . 2C-6
Fuel Supply Connections . . . . . . . . . . 2C-6
Throttle Connections . . . . . . . . . . . . . . . . . . 2C-7
2C-0 - INSTALLATION - BRAVO DRIVES 90-823225--1 1096

INDEX
Torque Specifications
S f C
Shift Cable Cable End Guide See Note
Small 100 11
Later Style 23 31
S f C
Shift Cables Cable End Guide See Note
Throttle C
Cable Cable End Guide See Note
NOTE: Tighten, then back nut off one half turn.
DESCRIPTION PART NUMBER

Engine Alignment Tool 91-805475A1
Engine Coupler Spline Grease 91-816391A4
Liquid Neoprene 92-27511-2
Loctite Pipe Sealant With Teflon Obtain Locally
! CAUTION
DO NOT use an alignment tool from another manufacturer. Alignment tools other than Quicksilver Align-
ment Tools (91-805475A1 or a properly modified 91-57797A3) may cause improper alignment and dam-
age to gimbal bearing and/or engine coupler.
e
f a
d c
a - Material To Be Removed (Shaded Area) To Alpha or Bravo Coupling
b - Measurement - 1.150 in. (29.21 mm)
c - Measurement - 2.750 in. (69.85 mm)
d - Measurement - 2.200 in. (55.88 mm)
e - Radius - .060 (1.5 mm)
f - Chamfer - .060 in. (1.5 mm) x 45 degree
Quicksilver Engine Alignment Tool (91-57797A3) Modification
90-823225--1 1096 INSTALLATION - BRAVO DRIVES - 2C-1

INDEX
Removal ! CAUTION
IMPORTANT: Stern drive unit must be removed engine components or damage will occur.
prior to engine removal. Refer to Stern Drive Ser-
vice Manual.
! CAUTION
Engine Removal Multi-Port engines MUST be lifted with a lifting
1. Disconnect battery cables from battery. arm or damage to engine components will occur.
2. Remove instrument harness connector plug from 12. Support engine with suitable sling through lifting
engine harness receptacle after loosening eyes on engine and remove front and rear engine
clamp. mounting bolts. Retain hardware.
a
! WARNING
fuel immediately.
b 72578
3. Using wrench to stabilize brass filter nut at fuel in-
let, loosen fuel line fitting, disconnect and suitably
plug fuel line to prevent fuel in tank from leaking a
into bilge.
4. Disconnect throttle cable from carburetor, or
throttle body on Fuel Injection models, and retain
5. Disconnect bullet connectors of trim sender wires
(coming from transom assembly) from engine
harness.
NOTE: After wires are disconnected be sure to loos-
en them from clamps or sta-straps retaining them to
engine or hoses.
6. Disconnect MerCathode wires from MerCathode
controller if mounted on engine (some models).
7. Disconnect seawater inlet hose from gimbal
housing. 72580
8. Disconnect exhaust elbow hoses (bellows).

10. Disconnect any grounding wires and accessories b a
that are connected to engine.
11. Disconnect (and suitably plug) fluid hoses from
power steering control valve on transom. 72579
a - Suitable Sling
! CAUTION b - Engine Lifting Eyes
Center lifting eye (located on top of thermostat 13. Carefully remove engine. DO NOT hit power
housing) is used for engine alignment only. DO steering control valve.

INDEX
Installation 2. Attach a suitable sling to lifting eyes on engine
pended. (Refer to “Removal” section for loca-
tion of lifting eyes.)
3. Lift engine into position (in boat), using an over-
1. Follow instructions “a”-“e”: head hoist.
a. Be certain fiber washers (cemented in place) 4. Align rear engine mounts with inner transom
on inner transom plate are present. Inspect plate mounts while simultaneously aligning ex-
fiber washers. Replace if worn or damaged. haust tubes with exhaust pipe hoses (bellows).
b. Install double wound lockwashers onto inner
transom plate inside fiber washer. IMPORTANT: Engine attaching hardware must be
c. Be certain rear engine mount locknuts are in installed in sequence shown.
position as shown. 5. Install both rear engine mounting bolts and
d. Lubricate exhaust bellows with soap and hardware as shown. Torque to 35-40 lb. ft.
water to ease installation. (47-54 N·m).
e. Lubricate engine coupler splines with Quick-
silver Engine Coupler Spline Grease.
a
a c b
b d
c
e
g
d
72023
h f
a - Double Wound Lockwasher
b - Fiber Wound Lockwasher (Cemented In Place)
c - Inner Transom Plate Mount (Engine Support)
72535
d - Locknuts (Engine Mounting Bolts)
a - Bolt, Rear Engine Mounting
b - Washer, Large Steel
! CAUTION c - Metal Spacer
d - Rear Engine Mount
Center lifting eye (located on top of thermostat e - Double Wound Lockwasher
housing) is used for engine alignment only. DO f - Fiber Washer
NOT use to lift entire engine. g - Inner Transom Plate Mounts
h - Locknut (Hidden In This View)
! CAUTION
! CAUTION
engine components or damage will occur. When lowering engine into position DO NOT set
engine on shift cable. Shift cable outer casing
can be crushed causing difficult or improper
shifting.

INDEX
6. Set engine down on stringers and relieve hoist 7. Align engine as follows:
tension. Disconnect sling from engine lifting eyes
a. Attempt to insert solid end of Quicksilver
and switch sling to center lifting eye.
Alignment Tool through gimbal bearing and
into engine coupler splines. If it will not insert
easily proceed to following.
b. If the tool does not fit, remove it and carefully
raise or lower the from end of the engine, as
necessary, and attempt to insert the align-
ment tool.
c. Repeat step “b” until the alignment tool in-
stalls easily (SLIDES FREELY) all the way
into and out of engine coupler splines.
b
a
72024
a - Center Lifting Eye
! CAUTION
DO NOT use an alignment tool from another man-
ufacturer. Alignment tools other than Quicksilver
Alignment Tool 91-805475A1, may cause improp-
er alignment and damage to gimbal bearing and/
or engine coupler. 70013
a - Alignment Tool (Use Only Quicksilver Alignment Tool
(91-805475A1)
! CAUTION b - Insert This End of Alignment Tool through Gimbal Housing
Assembly
To avoid damage to gimbal bearing, engine cou-
pler, or alignment tool:
c
• DO NOT attempt to force alignment tool! b
• DO NOT raise or lower engine with alignment tool
inserted (or partially inserted) in gimbal bearing or
engine coupler.
72585
a - Alignment Tool
b - Gimbal Bearing
c - Engine Coupler

INDEX
IMPORTANT: Turn both front engine mount ad- 8. Tighten all exhaust system hose clamps securely
justment nuts an equal amount in direction reas follows (use two hose clamps on each connec-
quired to align engine. tion):
d. Adjust front engine mounts until they rest on a. On Engines with Thru-Prop Exhaust:
boat stringers.
e. Relieve hoist tension entirely and fasten both
front mounts to boat stringer using appropri-
ate hardware (lag bolts or thru-bolts, etc.). b
f. Recheck alignment with alignment tool. Tool
must enter coupler splines freely. If not,
readjust front mounts.
g. When alignment is correct, tighten locknut or
nut with lockwasher on each mount securely. a
h. Bend tab washer down against flat on adjust-
ing nut. a
72537
a - Hose Clamps - Tighten Securely

a b - Exhaust Tube - Long Tube, Port Side - Short Tube, Star-
board Side
b e
c
CORRECT
d
72922
a - Locknut
b - Adjustment Nut INCORRECT
c - Turn Adjustment Nut In This Direction (Counterclockwise)
To Raise Front Of Engine
d - Slotted Hole To Front Of Engine 72538
e - Tab Washer
i. Remove alignment tool if not already re-

moved.

INDEX
Engine Connections 3. Connect trim position sender leads from gimbal
housing to leads from engine harness.
IMPORTANT: When routing all wire harnesses
and hoses, be sure they are routed and secured
to avoid coming in contact with hot spots on en-
b
1. Connect seawater hose to water tube at gimbal
housing with hose clamp. Tighten clamp se- a
curely.
NOTE: In the following view the engine is not in
position, for visual clarity in this step.
d
a
72582
c
a - BROWN/WHITE (From Engine Harness)

b - BLACK (From Engine Harness)
c c - BLACK (From Transom)
d - BLACK (From Transom Assembly)
! WARNING
b
72590 Be careful when working on fuel system. Gaso-
a - Water Inlet Tube under certain conditions. Do not smoke or allow
b - Hose Clamp (Tighten Securely) spark or open flame in area. Wipe up any spilled
c - Seawater Inlet fuel immediately.
2. Connect instrument harness to engine harness FUEL SUPPLY CONNECTIONS

! WARNING
Avoid gasoline fire or explosion. Improper instal-
fuel leak.
• Apply #592 Loctite Pipe Sealant with Teflon to
TEFLON TAPE.
• Thread brass fitting or plug into fuel pump or fuel
filter base until finger tight.
• Tighten fitting or plug an additional 1-3/4 to 2-1/4
a
turns using a wrench. DO NOT OVER-TIGHTEN.
c b • Install fuel line. To prevent over-tightening, hold
brass fitting with suitable wrench and tighten fuel
72025
line connectors securely.
a - Engine Wiring Harness Receptacle Bracket • Check for fuel leaks.

INDEX
4. Connect fuel line from fuel tank(s) to engine. b. Install cable end guide on throttle lever, then
Make certain connections are secure. Check for push cable barrel lightly toward throttle lever
leaks. end. (This will place a slight preload on cable
to avoid slack in cable when moving remote
5. Connect throttle cable using hardware retained
and adjust following instructions “a” or “b”:
Throttle Connections c. Secure throttle cable with hardware (re-
tained) as shown. Tighten cable end guide
! WARNING nut until it bottoms out and then back off one
Be careful when working on fuel system. Gaso- full turn. Tighten cable barrel securely. DO
line is extremely flammable and highly explosive NOT OVER-TIGHTEN, as cable must pivot
under certain conditions. Do not smoke or allow freely.
fuel immediately.
Fuel Supply Connections

! WARNING
fuel leak.
b b
• Apply #592 Loctite Pipe Sealant with Teflon to c
threads of brass fitting or plug. DO NOT USE d a
d
TEFLON TAPE.
• Thread brass fitting or plug into fuel pump or 2 Barrel Carburetor 72013
fuel filter base until finger tight. a - Cable End Guide

• Tighten fitting or plug an additional 1-3/4 to b - Attaching Hardware (DO NOT Over-Tighten)
c - Cable Barrel
2-1/4 turns using a wrench. DO NOT d - Anchor Studs
OVER-TIGHTEN.
Make certain connections are secure. Check for
leaks.
7. Connect throttle cable(s) using hardware re-
position.
when cable is actuated.

INDEX
b sition and check to ensure that throttle lever
c contacts idle speed adjustment screw.
a b
d
c
b W.O.T.
72014
4 Barrel Carburetor IDLE

a - Cable End Guide b
c - Cable Barrel a 72283
d - Anchor Studs
Mercarb 2 Barrel Carburetor
d. Place remote control throttle lever in the a - Throttle Lever Tang
b - Carburetor Body
wide-open-throttle (W.O.T.) position. Check c - Idle RPM Adjustment Screw

INDEX
WEBER 4 BARREL CARBURETOR ELECTRONIC FUEL INJECTION (EFI)
1. Place remote control handle in neutral idle posi-
tion.
2. Remove flame arrestor.
3. Install cable end guide on throttle lever, then push
cable barrel end lightly toward throttle lever end.
(This will place a slight preload on shift cable to
b avoid slack in cable when moving remote control
lever). Adjust barrel on throttle cable to align with
hole in anchor plate.
h
f
a g
71159 e
d
b
c
b 74109
70392
Throttle Body Injection
a - Cable End Guide
Idle Position b - Throttle Lever Stud
a - Throttle Lever [Contacts (b) in Idle Position] c - Locknut and Flat Washer - Tighten Until Nut Bottoms
b - Idle Speed Adjustment Screw Out, Then Back Off One Half Turn
d - Throttle Lever
f - Cable Barrel

INDEX
b a
73855
a - Position for Zero Effort Controls

74174
5. Place remote control throttle level in the wide
open throttle (W.O.T.) position. Check to ensure
that throttle plates are completely open.
6. Return remote control throttle lever to idle posi-
c tion and check to ensure that throttle plates are
completely closed.
8. Models with MerCathode: Connect wires to
d MerCathode controller assembly as shown.
Apply a thin coat of Quicksilver Liquid Neoprene
to all connections.
74183
Multi-Port Injection
Back Off One Half Turn.
b - Cable End Guide
d - Cable Barrel
IMPORTANT: Do not attach any accessory
Accessory ground wires should only be attached
a b c d
to ground stud on engine. 22232
a - ORANGE Wire - From Electrode On Transom Assembly
b - RED/PURPLE Wire - Connect (Other End) to Positive
c - BLACK Wire - From Engine Harness
d - BROWN Wire - From Electrode on Transom Assembly

INDEX
IMPORTANT: Adjust shift cables as outlined in b. Later Style Control Valve: Torque both fit-
appropriate Stern Drive Service Manual. tings to 23 lb. ft. (31 N·m). Route hoses as
shown for each model.
9. Refer to appropriate Stern Drive Service Manual
and install and adjust drive unit and remote con-
trol shift cables, using hardware retained.
a
IMPORTANT: After fluid hose installation in the
following, bleed power steering system as out-
lined in SECTION 1B - “Maintenance” of this man-
ual, or refer to the appropriate Stern Drive Ser-
vice Manual.
73786
! CAUTION a - Hose Fittings
help avoid stress on the hose fittings and will 11. Connect battery cables to battery by FIRST con-
help avoid kinks in the hose. necting positive (+) battery cable (usually RED)
to positive (+) battery terminal. Tighten clamp se-
(usually BLACK) to negative (–) battery terminal.
Tighten clamp securely.
IMPORTANT: Be careful not to cross-thread or NOTE: Spray terminals with a battery connection
over- tighten fittings. sealant to help retard corrosion.

large fitting to 23 lb. ft. (31 N·m). Torque the
a b
22023
a - Small Fitting
b - Large Fitting

INDEX
AT A LATER DATE

INDEX
AT A LATER DATE

INDEX
REMOVAL AND
INSTALLATION
2
D
70246
MCM MODELS – BRAVO DRIVES

WITH DRIVESHAFT EXTENSION
INDEX
Table of Contents
Page
Torque Specification . . . . . . . . . . . . . . . . . . . . . . 2D-1
Tools/Lubricants/Adhesives/Sealants . . . . . . . 2D-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . 2D-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4
Engine Installation/Alignment . . . . . . . . . . . . 2D-4
Engine Connections . . . . . . . . . . . . . . . . . . . 2D-9
Throttle Connections . . . . . . . . . . . . . . . . . . 2D-10
INDEX
2D-0 – MCM MODELS - BRAVO MODELS WITH DRIVE SHAFT EXTENSIONS 90-823225--1 1096
Shif C
Shift Cable
Small 100 11
Later Style 23 31
Shif C
Shift Cables
Th l C
Throttle Cable
Quicksilver Engine Alignment Tool 91-805475 A1
Quicksilver Engine Coupler Spline Grease 91-816391 A4
Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Loctite 8831 92-823089-1
Universal Protractor
Obtain Locally
INDEX
90-823225--1 1096 MCM MODELS- BRAVO MODELS WITH DRIVE SHAFT EXTENSIONS - 2D-1
Removal 6. Disconnect MerCathode wires from MerCathode
controller if mounted on engine (some models).
engine to service the drive shaft and/or bearing 7. Disconnect seawater inlet hose from engine.
support (tailstock). Refer to instructions as out- 8. Disconnect exhaust elbow hoses (bellows).
lined in Section 8D - “Drive Shaft Repair” or
“Bearing Support Repair” for servicing these
items only.
IMPORTANT: Stern drive unit does not have to be
removed prior to engine removal. If stern drive is
going to be removed, refer to appropriate Stern 11. Disconnect (and suitably plug) fluid hoses from
Drive Service Manual. power steering control valve on transom.
12. Remove top and then bottom drive shaft shields
at engine end of extension drive shaft.
Engine Removal
clamp.
! WARNING
spark or open flame in area. Wipe up any spilled a
fuel immediately. d
filter inlet, loosen fuel line fitting, disconnect and
suitably plug fuel line to prevent fuel in tank from c
leaking into bilge.
b
72033
tain locknuts and hardware. a - Top Shield
b - Bottom Shield
5. Disconnect bullet connectors of trim sender wires c - 4 Screws/Nuts (2 Hidden)
(coming from transom assembly) from engine d - 3 Screws (Hidden)
harness.
NOTE: After wires are disconnected, be sure to loos-
engine or hoses.
INDEX
13. Mark extension drive shaft U-joint yoke/output
flange connections at engine end (to assist in ex-
act same positioning during reassembly). Dis- a
connect drive shaft from output flange.
c b 72578
b a
70237
Engine End Shown 72581
a - Matching Marks On Flange and Drive Shaft Connection

b - Extension Drive Shaft U-Joint Yoke
c - Flange- Output
! CAUTION
Center lifting eye (located on top of thermostat b a
72579
! CAUTION
a - Suitable Sling
DO NOT allow lifting sling to hook or compress b - Engine Lifting Eyes
a
IMPORTANT: To avoid the need for a complete re- a
alignment (after engine repair), DO NOT MOVE
FRONT AND REAR MOUNT ADJUSTMENT. Re-
move mounting bolts from boat stringers.
14. Support engine with suitable sling through lifting
eyes on engine and remove front and rear engine
72536
mounting bolts from boat stringers. Retain hard-
ware. Typical Mounting Shown
a - Mounting Bolts
INDEX
Installation 5. As shown, attach engine output flange to drive
shaft flange exactly as marked during disassem-
bly. Torque fasteners to 50 lb. ft. (68 N·m).
ENGINE MOUNT ADJUSTMENT WAS NOT

DISTURBED DURING SERVICE a
! CAUTION
Center lifting eye (located on top of thermostat b e
! CAUTION d
cur. c
70237
pended. (Refer to “Removal” section for loca- Engine End Shown
tion of lifting eyes.) a - Output Shaft Flange
b - Drive Shaft
2. Lift engine into approximate position (in boat), c - Screw
using an overhead hoist. d - Nut
e - Matching Marks Made Upon Disassembly - Aligned
3. Set engine on stringers.
4. Grease drive shaft universal joints with Quicksil- IMPORTANT: Failure to properly position output
ver 2-4-C Marine Lubricant. shaft flange may result in bearing damage.
6. Relieve hoist tension from engine, then slide en-
! CAUTION gine fore or aft as needed to obtain 1/4 in. (6 mm)
clearance between flange shoulder and exten-
When attaching shaft in next step, BE SURE that sion shaft housing bearing.
the pilot on drive shaft flanges are engaged in in-
put shaft and output shaft flanges. Flanges c
MUST BE flush to each other prior to tightening
screws or screws may come loose during opera-
tion.
! CAUTION
Failure to align shaft flanges with matching b
marks made on disassembly may cause improp-
erly aligned drive unit and extension drive shaft
a
U-joint centerlines resulting in a severe vibration
problem.
72591
a - Flange Shoulder
b - Bearing
c - 1/4 In. (6 mm)
INDEX
7. Position engine for correct engine and drive shaft 8. After engine has been aligned correctly, fasten
lateral alignment as follows: front and rear engine mounts to stringers. Tighten
mounting bolts securely.
ters of bolt holes. They MUST BE EQUAL. If 9. Apply Loctite 8831 to threads of bottom drive
they are not equal, slide the aft and forward shaft shield retaining screws and install bottom
ends of the engine equal amounts in opposite shield on engine end as shown. Torque screws
directions to obtain equal lengths for (a) and to 30 lb. ft. (41 N·m). Then install top shield
(b). as shown. Torque screws and nuts to 30 lb.
ft. (41 N·m).
cified.
a
a
70246
These Dimensions Must Be Equal

b
c
72028
Engine End Shown
a - Shaft Housing
b - Bottom Shield
c - Screws (3 Used - Two Hidden in This View)
(Use Loctite 271)
a
d
c
b
72033
Engine End Shown
a - Top Shield
b - Bottom Shield
c - 4 Screws/Nuts (2 Hidden)
d - 3 Screws (2 Hidden)

INDEX
ENGINE MOUNT ADJUSTMENT WAS IMPORTANT: Be sure that boat does not move
DISTURBED DURING SERVICE once reading has been taken from input shaft
flange, as this reading establishes a reference
NOTE: A Universal Protractor is recommended for
point for aligning drive shaft and engine follow-
measuring the angles in the following steps.
ing. If boat is moved, reference point may be al-
IMPORTANT: In the following steps, the protrac- tered and subsequently, improper drive shaft and
tor readings will be taken off of vertical and hori- engine alignment may occur. Alignment tool
zontal surfaces; therefore, both the 0 degree and MUST BE in place during entire alignment proce-
the 90 degree marks will be used. It should be dure if drive unit is not installed.
kept in mind that these are reference marks only
and the assigned numbers should be ignored. It a b
is only necessary to determine the number of de-
grees and to which side (left or right) of the refer-
ence marks the indicator needle rests. PRO-
TRACTOR MUST BE VIEWED FROM THE SAME
SIDE OF POWER PACKAGE THROUGHOUT IN-
STALLATION.
c
REFER-
ENCE
MARK
72592
a - Indicator Shaft Flange

REFER- b - Protractor
ENCE c - Indicator Needle
MARK
NOTE: For ease of installation we recommend the

use of a chain leveler in the following steps.
72429
3. Adjust engine mounts so that an equal amount of
up and down adjustment exists.
4. Attach a suitable lifting chain to lifting eyes on en-
gine and adjust so that engine will be level when
1. Refer to Section 8D - “Drive Shaft Models/Propel- suspended, then place engine into its approxi-
ler Shaft,” and remove drive shaft. mate position (in boat) using an overhead hoist.
2. Position base of protractor against input shaft 5. Refer to Section 8D - “Drive Shaft Models/Propel-
flange, as shown. NOTE and RECORD the num- ler Shaft,” and install drive shaft while observing
ber of degrees and to which side of the reference precautions in Section 8D, especially about
mark the indicator needle has moved in the fol- aligning gimbal bearing U-joint centerlines with
lowing chart. extension drive shaft U-joint centerlines at bear-
ing support input shaft. DO NOT install shields at
Reading from Step 1. __________ degrees to the
_________ side of reference mark.
this time.
! CAUTION
Engine MUST BE aligned correctly to achieve
proper engine operation and to prevent damage
to drive shaft. If drive shaft is run at an incorrect
angle, damage to universal joint bearings may re-
sult.
INDEX
6. Position base of protractor on drive shaft; then ! CAUTION
raise or lower engine (as boat construction per-
mits) until indicator needle is 1 degree to 3 de- Failure to properly position output shaft flange
grees on either side of reading taken in Step 1. (as described following) may result in bearing
Record this reading in the following chart for later damage.
use. 8. Relieve hoist tension from engine, then slide en-
b between flange shoulder and extension shaft
c
a housing bearing, as shown.
70238 b
a - Drive Shaft
b - Protractor a
c - Output Shaft Flange
72591
a - Flange Shoulder
Reading from Step 6. __________ degrees to the b - Bearing
_________ side of reference mark. c - 1/4 In. (6 mm)
9. Position engine for correct engine and drive shaft

7. Adjust stringer height so that the stringers just
lateral alignment as follows:
contact the engine mount bases.
ters of bolt holes. They MUST BE EQUAL. If
ends of the engine equal amounts in opposite
directions to obtain equal lengths for (a) and
(b).
70246
These Dimensions Must Be Equal
INDEX
b. Recheck Step 8. If Step 8 is not as specified, 12. Position protractor on drive shaft and recheck
adjust and recheck Step 9a. Continue this angle. Angle should be the same as that re-
process until both Steps 8 and 9a are as spe- corded in Step 6. If not, raise or lower all four en-
cified. gine mount adjustment nuts an equal amount un-
til correct angle is reached.
10. After engine has been aligned correctly, fasten
front and rear engine mounts to stringers. Tighten 13. Tighten ALL engine mount nuts securely. Bend
securely. washer tab down on each adjustment nut.
a
a
a
e
b
c
d
72536 72536
a - Nut and Lockwasher (5.7L - Locknut Only)

Typical Mounting Shown b - Adjustment Nut
a - Mounting Bolts c - Turn Adjustment Nut in This Direction (Counterclockwise)
to Raise Front of Engine
d - Slotted Hole toward Front of Engine
e - Tab Washer
11. Position protractor on starter housing cover
plate, as shown. Now, raise or lower front engine
mount adjusting nuts as required so that protrac-
tor needle reads exactly the same number of de-
grees as that recorded in Step 1.
a
c
72593
Thru-Prop Exhaust Shown

a - Flywheel Housing
b - Starter Housing Cover Plate
c - Protractor
INDEX
14. Apply Loctite 8831 to threads of bottom drive Engine Connections
shaft shield retaining screws and install bottom
shields on engine and transom end as shown. IMPORTANT: When routing all wire harnesses
Torque screws to 30 lb. ft. (41 N·m). Then install and hoses, be sure they are routed and secured
both top shields as shown. Torque screws and to avoid coming in contact with hot spots on en-
nuts to 30 lb. ft. (41 N·m). gine and avoid contact with moving parts.
1. Connect seawater inlet hose to seawater pump
as shown. Tighten hose clamp securely.
a
c
d
b
70245
a
72532
Top Shield and Bottom Shield at Transom End
(Engine End Similar) a - Seawater Inlet Hose Connection
a - Top Shield
b - Bottom Shield
c - Bolt 3/8-16 x 7/8 In. (22 mm Long) (4 Used)
d - Nut 3/8-16 (4 Used)
e - Screws (3 Used - Hidden in This View) (Use Loctite 271) 2. Connect instrument harness to engine harness
c b
72025
a - Engine Wiring Harness Receptacle Bracket

INDEX
3. Connect two trim position sender leads from gim- • Install fuel line. To prevent over-tightening,
bal housing to leads from engine harness. hold brass fitting with suitable wrench and
b Make certain connections are secure. Check for
leaks.
a 5. Connect throttle cable(s) using hardware re-
position.
d
c when cable is actuated.
72582 b. Install cable end guide on throttle lever, then
push cable barrel lightly toward throttle lever
a - Brown/White (From Engine Harness)
b - Black (From Engine Harness) end. (This will place a slight preload on cable
c - Black (From Transom Assembly) to avoid slack in cable when moving remote
d - Black (From Transom Assembly) control lever.) Adjust barrel on throttle cable
c. Secure throttle cable with hardware (re-
Throttle Connections tained) as shown. Tighten cable end guide
nut until it bottoms out and then back off one
! WARNING full turn. Tighten cable barrel securely. DO
Be careful when working on fuel system. Gaso- NOT OVER-TIGHTEN, as cable must pivot
line is extremely flammable and highly explosive freely.
fuel immediately.

! WARNING
fuel leak. b b
• Apply #592 Loctite Pipe Sealant with Teflon to c
d a
threads of brass fitting or plug. DO NOT USE d
TEFLON TAPE. 72013
2 Barrel Carburetor
a - Cable End Guide
fuel filter base until finger tight. b - Attaching Hardware (DO NOT Over-Tighten)
• Tighten fitting or plug an additional 1-3/4 to c - Cable Barrel
d - Anchor Studs
OVER-TIGHTEN.
INDEX
b sition and check to ensure that throttle lever
contacts idle speed adjustment screw.
c
a b
d
c
W.O.T.
b
72014
IDLE
b
4 Barrel Carburetor
a - Cable End Guide a 72283
c - Cable Barrel Mercarb 2 Barrel Carburetor
d - Anchor Studs
b - Carburetor Body
d. Place remote control throttle lever in the c - Idle RPM Adjustment Screw
wide-open-throttle (W.O.T.) position. Check
INDEX
WEBER 4 BARREL CARBURETOR ELECTRONIC FUEL INJECTION (EFI)
1. Place remote control handle in neutral idle posi-
tion.
3. Install cable end guide on throttle lever, then push
cable barrel end lightly toward throttle lever end.
(This will place a slight preload on shift cable to
b avoid slack in cable when moving remote control
lever). Adjust barrel on throttle cable to align with
hole in anchor plate.
h
f
a g
71159 e
a
d
b
c
74109
b
70392 a - Cable End Guide
Idle Position Out,Then Back Off One Half Turn
a - Throttle Lever [Contacts (b) in Idle Position] d - Throttle Lever
b - Idle Speed Adjustment Screw e - Throttle Bracket
f - Cable Barrel
INDEX
b a
a - Position for Zero Effort Controls 73855
74174 5. Connect any grounding wires or accessories that

6. Models with MerCathode: Connect wires to
MerCathode controller assembly as shown. Ap-
ply a thin coat of Quicksilver Liquid Neoprene to
all connections.
c
74183
a b c d
Multi-Port Injection 22232
a - Lock Nut and Flat Washer Tighten Until Bottoms Out, Then a - Orange Wire - From Electrode on Transom Assembly
Back Off One Half Turn. b - Red/Purple Wire - Connect (Other End) to Positive
b - Cable End Guide (+) Battery Terminal
c - Throttle Cable Anchor Stud c - Black Wire - From Engine Harness
d - Cable Barrel d - Brown Wire - From Electrode on Transom Assembly
IMPORTANT: Do not attach any accessory 7. Place remote control throttle level in the wide
open throttle (W.O.T.) position. Check to ensure
Accessory ground wires should only be attached that throttle plates are completely open.
8. Return remote control throttle lever to idle posi-
tion and check to ensure that throttle plates are
completely closed.
INDEX
IMPORTANT: After fluid hose installation in the 10. Using double hose clamps on all connections, in-
following, bleed power steering system as out- stall exhaust hoses and exhaust tubes as shown
lined in appropriate Stern Drive Service Manual. in “a” or “b” following. Tighten all hose clamps se-
curely.
a. On Engines with Thru-Prop Exhaust:
! CAUTION
IMPORTANT: Make hydraulic connections as a

IMPORTANT: Be careful not to cross-thread or

overtighten fittings.
large fitting to 23 lb. ft. (31 N·m). Torque the c b c
d 72027
a b Starboard Side Engine End Shown (Port

Similar)
a - Exhaust Pipe
b - Exhaust Hose
c - Hose Clamps
d - Exhaust Tube
22023
a - Small Fitting
b - Large Fitting
b. Later Style Control Valve: Torque both fit-
tings to 23 lb. ft. (31 N·m). Route hoses as
shown for each model.
a c
a b c
d 72584
Starboard Side Transom End Shown

(Port Similar)
73786
a - Exhaust Separator Assembly
a - Hose Fittings b - Exhaust Hose
c - Hose Clamps
NOTE: Spray terminals with a battery connection d - Exhaust Tube
INDEX
b. On Engines with Thru-Transom Exhaust:
NOTICE (THRU-TRANSOM EXHAUST)

Exhaust hoses must be connected to ex-
haust elbows so that they do not restrict the
flow of discharge water from exhaust elbow.
If hoses are connected incorrectly, dis-
charge water from exhaust elbow will not
flow around entire inside diameter of hose.
This will cause a hot spot in the hose which
may eventually burn through.
CORRECT
INCORRECT
72538
Clamps Not Shown

necting positive (+) battery cable (usually red) to
positive (+) battery terminal. Tighten clamp se-
(usually black) to negative (–) battery terminal.
INDEX
AT A LATER DATE
INDEX
AT A LATER DATE
INDEX
REMOVAL AND
INSTALLATION
2
E
70648
MIE MODELS - VELVET DRIVE

TRANSMISSIONS
INDEX
Table of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 2E-1
Lubricants/Sealants . . . . . . . . . . . . . . . . . . . . . . 2E-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . 2E-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-3
Engine Installation and Initial Alignment . . 2E-3
Engine Final Alignment . . . . . . . . . . . . . . . . . 2E-4
Engine Connections . . . . . . . . . . . . . . . . . . . 2E-6
Fuel Supply Connections . . . . . . . . . . . . . . . 2E-7
Attaching/Adjusting Reversed Attachment
Morse Shift Cables . . . . . . . . . . . . . . . . . . . . . . 2E-15
2E-0 - MIE MODELS - VELVET DRIVE TRANSMISSIONS 90-823225--1 1096

INDEX
Torque Specifications Lubricants/Sealants
Fastener Location Lb. Ft. (N•m)
Battery Cables Securely 92-825407A3 Quicksilver 2-4-C Marine Lubricant
With Teflon
Engine Mount Pads Securely
92-25711-2 Quicksilver Liquid Neoprene
Securely
Mount Locking Nut
Note 2
Propeller Shaft Coupler-to- 50 (68)
Transmission Output Flange
Shift Cable Cable End Guide Note 1
Throttle Cable Cable End Guide Note 1
Trunnion Clamping Screw/Nut 50 (68)
NOTE 1: Tighten, then back nut off one half turn.

NOTE 2: Bend tab against adjusting nut.
90-823325--1 1096 MIE MODELS - VELVET DRIVE TRANSMISSIONS - 2E-1

INDEX
Removal ! CAUTION
Engine Removal NOT use to lift entire engine.
1. Disconnect battery cables from battery. ! CAUTION
2. Remove instrument panel harness connector
plug from engine harness receptacle after loos-
ening clamp.
cur.
! WARNING 10. Support engine with suitable sling through lifting
Be careful when working on fuel system. Gaso- eyes on engine.
under certain conditions. Do not smoke or allow a
fuel immediately.
inlet, loosen fuel line fitting, disconnect and suit-
ably plug fuel line to prevent fuel in tank from leak-
ing into bilge. b 72578
a
5. Disconnect shift cable from transmission.
6. Disconnect seawater inlet hose from engine.
7. Disconnect exhaust system hoses.
9. Disconnect propeller shaft coupler from trans-
mission output flange.
72581
b a
72579
a - Suitable Sling 72024

b - Engine Lifting Eyes

INDEX
11. Remove front and rear engine mounting bolts.
Retain hardware.
e
g
a
d
a
a b
c
b f
72638
70140
Typical Mount Front Mount - Typical
a - Bolts or Lag Screws (with Washers)
b - Slot Forward (If So Designed) e
a
d
c
Installation g
Engine Installation and Initial b
Alignment f
1. Follow instructions “a” or “b”:

a. Engine mount(s) or adjustment WAS NOT
DISTURBED during engine service: Pro- 72594
ceed to following Step 2.
Rear Mount - 5.7L and 5.7L Competition Ski
b. Engine mount(s) or adjustment WAS DIS-
TURBED during engine service:
e
IMPORTANT: Engine mounts must be adjusted,
as explained in the following, to center mount ad-
justment and establish a uniform height on all a
mounts.
g c
Ensure that all mounts are:
(1) In the center of their up-and-down adjust-
ment. b
(2) Mounting hole, which is a slot, is forward f

(if so designed; 350 Magnum Tourna-
ment Ski rear mount does not have a
slotted hole). 71182
(3) Large diameter of mount trunnion ex- Rear Mount - 350 Magnum Tournament Ski
tended as shown.
a - Locking Nut
(4) Each mount base is downward. Tighten b - Adjusting Nut
clamping screws and nuts slightly to pre- c - Trunnion Clamp Screw and Nut, with Lockwasher
vent moving in or out. Mounts must be d - Slot Forward
free to pivot when installing engine. e - 3/8 In. ± 1/16 In. (10 mm ± 2 mm)
f - 2-5/8 In. ± 1/16 In. (67 mm ± 2 mm)
g - Mount Trunnion

INDEX
! CAUTION Engine Final Alignment
Center lifting eye (located on top of thermostat ! CAUTION
NOT use to lift entire engine. To avoid vibration, noise and damage to trans-
mission output shaft oil seal and bearings, en-
! CAUTION gine must be properly aligned.
DO NOT allow lifting sling to hook or compress IMPORTANT: Engine alignment MUST BE RE-
engine components or damage to them will oc- CHECKED with boat in the water, fuel tanks filled
cur. and with a normal load on board.
2. Attach a suitable sling to lifting eyes on engine. Engine must be aligned so that transmission output
Refer to “Removal” section for location of lift- flange and propeller shaft coupler centerlines are
ing eyes. aligned and coupling faces are parallel within .003 in.
(0.07 mm). This applies to installations with solid cou-
IMPORTANT: Engine bed must position engine
plings, as well as flexible couplings.
so that a minimum of 1/4 in. (6 mm) up-and-down
adjustment still exists on all four mounts after 1. Check mating surfaces on transmission output
performing final alignment. This is necessary to flange and propeller shaft coupler faces to make
allow for final engine alignment. sure they are clean and flat.
3. Lift engine into boat and position on engine bed 2. Center propeller shaft in shaft log as follows:
so that transmission output flange and propeller a. Push down and then lift shaft as far as it will
shaft coupler are visibly aligned (no gap can be move. Then place shaft in the middle of the
seen between coupling faces when butted to- movement.
gether). Adjust engine bed height, if necessary,
to obtain proper alignment. DO NOT use mount b. Move shaft to port and then to starboard as
adjustments to adjust engine position at this time. far as shaft will move. Then place shaft in the
middle of the movement.
4. Check all four mounts to ensure that they are still
positioned properly, then fasten mounts to en- c. With shaft in center of shaft log, as deter-
gine bed with appropriate bolts or lag screws and mined by above procedures “a” and “b,” align
hardware. Tighten lag bolts/screws securely. engine to shaft.
5. Disconnect and remove sling. Proceed to “En-
gine Final Alignment” section following.
a
b
72595
a - Up
b - Down
c - Port
d - Starboard

INDEX
3. Check that coupling centerlines align, by butting 5. If coupling centerlines are not aligned or if cou-
propeller shaft coupler against transmission out- pling faces are more than .003 in. (0.07 mm) out
put flange. Shoulder on propeller shaft coupler of parallel, adjust engine mounts as follows:
should engage recess on transmission output
a. TO ADJUST ENGINE UP OR DOWN: Loos-
flange face with no resistance.
en locking nut on mounts requiring adjust-
NOTE: Some propeller shaft couplers may not have ment and turn both front mount or rear mount
a shoulder on mating face. On these installations, adjusting nuts equally.
use a straight edge to check centerline alignment.
IMPORTANT: Both front mount (or rear mount)
adjusting nuts must be turned equally to keep en-
gine level from side to side.
a
INCORRECT
CORRECT
c
d b
INCORRECT
72597
IMPORTANT: Remote V-Drive Models: refer to re-

mote V-drive manufacturer’s instructions for
drive shaft (between transmission and remote
V-drive) alignment.
4. Check for angular misalignment, by hand holding 72594
coupling faces tightly together; check for a gap
between faces with a .003 in. (0.07 mm) feeler Typical Mount
gauge at 90° intervals. a - Locking Nut
b - Adjusting Nut
a c - Clamping Screws and Nuts, with Lockwashers
(Two Each on Some Mounts)
d - Slot Forward (if So Designed - NOT Slotted on
b This Style Rear Mount)
b. TO MOVE ENGINE TO THE LEFT OR

RIGHT: Loosen clamping screw and nut on all
four mount brackets; move engine to the left
or right as necessary to obtain proper align-
c ment. On mounts which do have a slotted
hole, a small amount of adjustment can be
72598
obtained with slot on front end of mounts.
a - Feeler Gauge
b - Transmission Coupling
Loosen lag screws (which fasten mounts to
c - Propeller Shaft engine bed) and move engine, as required.
Tighten lag screws securely.
c. After engine has been properly aligned:
Tighten engine mount nuts securely, and be
certain to bend one of the tabs on the tab
washer down onto flat of mount adjusting nut.
Torque clamping screws and nuts to 50 lb. ft.
(68 N·m).

INDEX
IMPORTANT: Large diameter of mount trunnion Engine Connections
MUST NOT extend over 3/4 in. (20 mm) from
mount brackets on any of the mounts. IMPORTANT: When routing all wire harnesses
and hoses, be sure they are routed and secured
to avoid coming in contact with hot spots on en-
d
1. Connect seawater inlet hose to seawater pump
as shown. Tighten hose clamp securely.
b a
72532
Bottom Hose
72599
a - Torque Clamping Screw and Nut on All Four Mount a - Seawater Inlet Hose Connection
Brackets to 50 Lb. Ft. (68 N·m)
b - Tighten Locking Nut on All Four Mounts Securely 2. On All Models With a Walter V-Drive Trans-
c - Bend One of the Tabs on Tab Washer Down onto Flat of mission, connect water inlet hose to the fitting on
Adjusting Nut
d - Maximum Extension of Large Diameter of Trunnion -
transmission.
3/4 In. (20 mm)
a
6. Connect propeller shaft coupler to transmission
output flange. Attach couplers together with
bolts, lockwashers and nuts. Torque to 50 lb. ft.
(68 N·m).
NOTE: If propeller shaft coupler has setscrews, the
shaft should be dimpled at setscrew locations. Set-
screws should be safety wired after being tightened
securely.
b
75191
a - Water Inlet Fitting

b - Hose

INDEX
and secure with clamp.
a line is extremely flammable and highly explosive
c fuel immediately.
b
! WARNING
50921 fuel leak.
Harness Connection - 5.7L threads of brass fitting or plug. DO NOT USE
a - Engine Wiring Harness Receptacle Bracket TEFLON TAPE.
b - Instrument Wiring Harness Plug
c - Hose Clamp
OVER-TIGHTEN.
a
c Make certain connection is secure. Check for
leaks.
b 5. Connect exhaust system tubes and hoses using
at least two hose clamps at each connection.
Tighten hose clamps securely.
72600
Harness Connection - 5.7L Competition

Ski and 350 Magnum Tournament Ski
a - Engine Wiring Harness Connector
c - Hose Clamp

INDEX
6. Connect and adjust Quicksilver shift cable(s) as
NOTICE outlined following:
Exhaust hoses must be connected to
exhaust elbows so that they do not restrict IMPORTANT: When installing shift cables, be
the flow of discharge water from exhaust sure that cables are routed in such a way as to
elbow. If hoses are connected incorrectly, avoid sharp bends and/or contact with moving
discharge water from exhaust elbow will not parts. DO NOT fasten any items to shift cables.
flow around entire inside diameter of hose. NOTE: On models with other than Quicksilver shift
This will cause a hot spot in the hose which cables refer to shift cable manufacturer’s instructions
may eventually burn through. or, if so equipped, to following separate section - “At-
taching/Adjusting Reversed Attachment Morse Shift
Cables.”
IMPORTANT: Velvet Drive Transmission Warran-
CORRECT ty is jeopardized if the shift lever poppet ball or
spring is permanently removed, if the shift lever
is repositioned or changed in any manner or if re-
mote control and shift cable do not position shift
lever exactly as shown.
F N R
INCORRECT a
72538 d
Clamps Not Shown
b
IMPORTANT: BLACK SCORPION S-pipes must
be routed under the transmission mounts.
c
72601
a - Transmission Shift Lever

b - Shift Lever Must Be Over This Letter when Propelling
a Boat FORWARD
c - Shift Lever Must Be Over This Letter when Propelling
Boat in REVERSE
d - Poppet Ball Must Be Centered in Detent Hole for Each
F-N-R Position (Forward Gear Shown)
74832
a - S-Pipe

INDEX
Remote control must provide a total shift cable travel IMPORTANT: When installing shift cables, be
(at transmission end) of at least 2-3/4 in. (70 mm). sure that cables are routed in such a way as to
This is necessary to position transmission shift lever avoid sharp bends and/or contact with moving
fully in the forward and reverse gear positions. Insuf- parts. DO NOT fasten any items to shift cables.
ficient shift cable travel will cause transmission to slip
a. Place remote control shift lever and transmis-
and eventually fail.
sion shift lever in neutral position.
b c
b. Remove nuts and washers from shift cable
a attaching studs.
c. Locate center of remote control and control
72602 shift cable play (backlash) as follows:
a - 2-3/4 In. (70 mm) Minimum (1) Check that remote control is in neutral po-
b - Forward Gear sition.
c - Reverse Gear
(2) Push in on control cable end with enough
pressure to remove play; mark position
d (a) on tube.
(3) Pull out on control cable end with enough
b effort to remove play; mark position (b) on
tube.
(4) Measure distance between marks (a) and
(b); mark position (c), half-way between
marks (a) and (b).
c b c
c a
a
14920
a - Cable Barrel (Does Not Move)

b - Cable End Guide (Does Move, Inner Core Wire Extends) 72603
c - Cable End Guide MUST Move in This Direction when
Remote Control Is Shifted to Forward Gear Position
d - Transmission Shift Lever d. Center cable-end play, then adjust cable bar-
rel to align holes in barrel and in cable end
guide, with attaching points on transmission.
e. Temporarily install shift cable. Do not secure
at this time.
IMPORTANT: Transmission is “fully” in gear
when shift lever comes to a stop, in either direc-
tion.

INDEX
f. Place remote control shift lever in forward SINGLE STATION INSTALLATIONS
gear position and check position of transmis-
sion shift lever. Shift lever must be positioned e
as shown. g
! CAUTION
Remote control and shift cable must position
transmission shift lever exactly as shown, or
transmission failure may occur. Do not remove
poppet ball or spring. f
a b
F N R
a
c d
d
e 72528
b Single Station Installation In-line and

V-Drive - Rear Approach
a - Cable End Guide
b - Cable Barrel
c c - Cable Barrel Stud
72601
d - Elastic Stop Nut and Washer
a - Transmission Shift Lever e - Spacer
b - Shift Lever Must Be Over This Letter when Propelling f - Cable End Guide Stud
Boat FORWARD g - Elastic Stop Nut and Washer
c - Shift Lever Must Be Over This Letter when Propelling
Boat in REVERSE
d - Poppet Ball Must Be Centered in Detent Hole for
Each F-N-R Position (Forward Gear Shown) b
e - Install Shift Lever Stud in This Hole, if Necessary, to
Center Poppet Ball in Forward or Reverse Detent Holes d
g. Place remote control shift lever in reverse

gear position and again check transmission
shift lever position. Lever must be positioned
as shown by (c).
h. If transmission shift lever will position proper- c
ly in one gear, but not in the other, recheck a
shift cable adjustment. If transmission shift le- e
ver will not position properly in both gears,
move transmission shift lever stud (a), from
top hole in shift lever, to bottom hole (e), and g
f
recheck for proper positioning. If proper posi- 72605
tioning is still not obtained, remote control
Single Station Installation In-Line and
does not provide sufficient shift cable travel
V-Drive - Front Approach
and must be replaced.
a - Cable End Guide
i. Install nut and washer to cable end guide
b - Cable Barrel
stud. Tighten until snug, then back off one full c - Cable Barrel Stud
turn. d - Elastic Stop Nut and Washer
j. Install nut and washer to cable barrel stud. e - Spacer
f - Cable End Guide Stud
Tighten until they bottom out. Tighten secure- g - Elastic Stop Nut and Washer
ly, but DO NOT OVER-TIGHTEN.

INDEX
DUAL STATION INSTALLATIONS 7. Follow instructions “a” or “b”:
e a. On Models Equipped with Other Than
Quicksilver Throttle Cables: Attach and
g adjust throttle cables referring to cable man-
ufacturer’s instructions.
b. On Models Equipped with Quicksilver
Throttle Cables: Connect and adjust throttle
cable(s) as outlined following:
f (1) Place remote control throttle lever(s) in
idle position.
a
b (2) Install cable end guide on carburetor
throttle lever stud as shown. Push cable
barrel lightly toward throttle lever. (This
c d will place a slight preload on cable to
avoid slack in cable when moving remote
72604
control levers.) Then adjust cable barrel
to align with anchor stud and slide barrel
Dual Station Installation In-Line and onto stud.
V-Drive - Rear Approach (3) Secure throttle cable with hardware as
a - Cable End Guide shown. Tighten cable end guide locknut
b - Cable Barrel until it bottoms out and then back off one
c - Cable Barrel Stud
full turn. Tighten barrel locknut until se-
e - Spacer cure, but DO NOT OVER-TIGHTEN as
f - Cable End Guide Stud cable(s) must be able to pivot.
g - Elastic Stop Nut and Washer
b b
c
d
c a b
e d
a
f g b
72606 72014
Dual Station Installation In-Line and a – Cable End Guide
V-Drive - Front Approach b - Attaching Hardware (DO NOT Over-Tighten)
c - Cable Barrel
a - Cable End Guide
d - Anchor Studs
b - Cable Barrel
c - Cable Barrel Stud
e - Spacer
f - Cable End Guide Stud
g - Elastic Stop Nut and Washer

INDEX
NOTE: Refer to the following for installations where (4) Place remote control throttle lever(s) in
dual station length anchor studs are present but only the wide-open-throttle (W.O.T.) position.
a single station cable has been installed. Check to ensure that throttle shutters
(valves) are completely open.
(5) Return remote control throttle lever to idle
d
position and check to ensure that throttle
c lever contacts idle speed adjustment
e screw.
b a c
g
d IDLE
a
f h
b
Dual Station 22552
W.O.T.
a - Cable End Guide
c - Washer and Locknut
d - Spacer
72583
e - Cable Barrel
f - Anchor Stud Weber 4 Barrel Carburetor Shown in
g - Washer Idle Position
h - Washer and Locknut
a - Tang
b - Carburetor Body
c - Idle RPM Adjustment Screw
d
b g
a
e
b
f h
22553 a
Dual Station
71159
a - Cable End Guide
d - Spacer Weber 4 Barrel Carburetor Shown in
e - Cable Barrel Wide-Open-Throttle Position
f - Anchor Stud
g - Washer

INDEX
h
f
g
e
b
a
70392
a
Weber 4 Barrel Carburetor Shown in
Idle Position
a - Throttle Lever [Contacts (b) In Idle Position]
8. Connect any ground wires or accessories that

were disconnected from engine. d
b
9. Connect battery cables to battery by FIRST con- c
necting positive (+) battery cable end to positive 74109
(+) battery terminal. Tighten clamp securely.
Then, connect negative (–) battery cable end to Throttle Body Injection
negative (–) battery terminal. Tighten clamp se- a - Cable End Guide
curely. b - Throttle Lever Stud
d - Throttle Lever
f - Cable Barrel

INDEX
ATTACHING/ADJUSTING THROTTLE CABLE -
1. Place remote throttle lever in idle position and
attach cable to throttle lever stud, following cable
2. After throttle cable is adjusted, tighten locknut
against cable end.
b
c
a
b a
74174
74838
c a - Cable End
c - Locknut
ROUTING OF THROTTLE AND SHIFT CABLES -

d 1. Throttle cable - Route cable along starboard
stringer under engine mount and up to the port
side of electrical box.
2. Shift cable - Route shift cable from the starboard
74183 to port side of engine, then between intake man-
ifold and elbow. Position cable so it will not inter-
fere with flame arrestor.
Mutli-Port Fuel Injection
Back Off One Half Turn. a
b - Cable End Guide
d - Cable Barrel
74833
a - Sta-Straps
b - Shift Cable

INDEX
Attaching/Adjusting 3. Attach cable clip to bracket using screws, lock-
washers and nuts. Use center holes in cable clip.
Reversed Attachment Morse 4. Remove top transmission mounting bolt and
Shift Cables lockwasher from left (valve) side of transmission;
position bracket, replace bolt and lockwasher.
MORSE MARINE PRODUCTS PART NUMBER

A35627
7
8 9 b
1 6
4
a
5
3
2
8
9 a - Bolt
b - Lockwasher
12 11 10
72608
5. Fasten pivot pin securely through hole (not coun-
tersunk) in adaptor plate using lockwasher and
Item
Description No. Part nut.
No. Req’d No.
1 Cable Clip 1 A35531

6. Attach adaptor plate to transmission shift lever
using screw, lockwasher and nut.
2 Bracket 1 B35762
7. Fasten cable hubs in cable clip and screw termi-
3 Screw, Mach., Fill. Hd. #10-32 x 2 A50112-545
1/2 In. Long nals onto cable rods until holes in terminals line
4 Lockwasher, Internal Tooth, #10 2 A50803-059
up with pivot pin. Hold each terminal securely to
prevent from turning and tighten cable nut
5 Nut, Hex, #10-32 2 A50900-076
against terminal.
6 Pivot Pin 1 A300965
NOTE: Be sure control head hand lever and trans-
7 Adaptor Plate 1 A47151
mission shift lever are in neutral position during the
8 Lockwasher, Internal Tooth, 1/4 In. 2 A50803-077 above installation.
9 Nut, Hex, 1/4-28 2 A50901-016 8. Place terminals on pivot pin and secure with E-
10 Screw, Mach., Flat Hd. 1/4-28 x 1 A50120-561 ring.
5/8 In. Long
11 Cable Terminal 2 A300646
NOTE: When using this kit with Models “S” or “SR”
controls, adjust the stop screws in the control head
12 E-Ring 5/16 In. 1 Comm’l.
to prevent cable from jamming the clutch arm against
If your engine/transmission package is equipped with its stops at forward and reverse.
the above or is being equipped with the above Morse 9. Refer to control head installation instructions for
Marine cables observe the following: final check and adjustment procedures.
2. Place remote control and transmission shift lever 10. Connect battery cables to battery by FIRST con-
in neutral. necting positive (+) battery cable end to positive
IMPORTANT: Remote control must provide a to- (+) battery terminal. Tighten clamp securely.
tal shift cable travel (at transmission end) of at Then, connect negative (–) battery cable end to
least 2-3/4 in. (70 mm). This is necessary to posi- negative (–) battery terminal. Tighten clamp se-
tion transmission shift lever fully in the forward curely.
and reverse gear positions. Insufficient shift
cable travel will cause transmission to slip and
eventually fail.
INDEX
AT A LATER DATE

INDEX
AT A LATER DATE

INDEX
REMOVAL AND
INSTALLATION
2
F
25280
MIE MODELS – HURTH

TRANSMISSIONS
INDEX
Table of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 2F-1
Lubricants/Sealants . . . . . . . . . . . . . . . . . . . . . . 2F-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-2
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . 2F-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-3
Engine Installation and Initial Alignment . . 2F-3
Engine Final Alignment . . . . . . . . . . . . . . . . . 2F-4
Engine Connections . . . . . . . . . . . . . . . . . . . 2F-6
Fuel Supply Connections . . . . . . . . . . . . . . . 2F-7
2F-0 –MIE MODELS - HURTH TRANSMISSION 90-823225--1 1096

INDEX
Torque Specifications Lubricants/Sealants
Fastener Location Lb. Ft. (N•m) Part Number Description
Battery Cables Securely 92-825407A3 Quicksilver 2-4-C Marine Lubricant
With Teflon
Engine Mount Pads Securely
Hose Clamps Securely 92-25711-2 Quicksilver Liquid Neoprene
Securely
Mount Locking Nut
Note 2
Propeller Shaft Coupler-to- 50 (68)

Transmission Output Flange

Shift Cable Cable End Guide Note 1

Throttle Cable Cable End Guide Note 1
Trunnion Clamping Screw/Nut 50 (68)
NOTE 1: Tighten, then back nut off one half turn.

NOTE 2: Bend tab against adjusting nut.
90-823225--1 1096 MIE MODELS - HURTH TRANSMISSION - 2F-1

INDEX
Removal ! CAUTION
Engine Removal NOT use to lift entire engine.
2. Remove instrument panel harness connector ! CAUTION
plug from engine harness receptacle after loos-
ening clamp.
cur.
! WARNING 10. Support engine with suitable sling through lifting
Be careful when working on fuel system. Gaso- eyes on engine.
under certain conditions. Do not smoke or allow a
fuel immediately.

filter inlet, disconnect and suitably plug fuel line
to prevent fuel in tank from leaking into bilge.
b 72578
a
5. Disconnect shift cable from transmission.
6. Disconnect seawater inlet hose from engine.
7. Disconnect exhaust system hoses.
9. Disconnect propeller shaft coupler from trans-
mission output flange.
72581
b a
72579
a - Suitable Sling
b - Engine Lifting Eyes

INDEX
11. Remove front and rear engine mounting bolts. (4) Each mount base is downward. Tighten
Retain hardware. clamping screws and nuts slightly to pre-
vent moving in or out. Mounts must be
free to pivot when installing engine.
g
a
a
d
b
a b
c
f
72638
a - Bolts or Lag Screws (with Washers)

70140
b - Slot Forward
Front Mount - Typical
e
Installation
a
g
Engine Installation and Initial c
d
Alignment
1. Follow instructions “a” or “b”: b
a. Engine mount(s) or adjustment WAS NOT

f
DISTURBED during engine service: Pro-
ceed to following Step 2.
b. Engine mount(s) or adjustment WAS DIS-
TURBED during engine service: 70158
IMPORTANT: Engine mounts must be adjusted, Rear Mount - Typical

as explained in the following, to center mount ad- a - Locking Nut
b - Adjusting Nut
justment and establish a uniform height on all c - Trunnion Clamp Screw and Nut, with Lockwasher
mounts. d - Slot Forward (If So Designed)
e - 3/8 In. ± 1/16 In. (10 mm ± 2 mm)
Ensure that all mounts are:
f - 2-5/8 In. ± 1/16 In. (67 mm ± 2 mm)
(1) In the center of their up-and-down adjust- g - Mount Trunnion
ment.
(2) Mounting hole, which is a slot, is forward
(if so designed; new style is not slotted).
(3) Large diameter of mount trunnion ex-
tended as shown.

INDEX
! CAUTION Engine Final Alignment
housing) is used for engine alignment only. DO ! CAUTION
To avoid vibration, noise and damage to trans-
mission output shaft oil seal and bearings, en-
! CAUTION gine must be properly aligned.
engine components or damage to them will oc- IMPORTANT: Engine alignment MUST BE RE-
cur. CHECKED with boat in the water, fuel tanks filled
and with a normal load on board.
2. Attach a suitable sling to lifting eyes on engine.
(Refer to “Removal” section for location of Engine must be aligned so that transmission output
lifting eyes.) flange and propeller shaft coupler centerlines are
aligned and coupling faces are parallel within .003 in.
IMPORTANT: Engine bed must position engine (0.07mm). This applies to installations with solid cou-
so that a minimum of 1/4 in. (6 mm) up-and-down plings, as well as flexible couplings.
adjustment still exists on all four mounts after
performing final alignment. This is necessary to 1. Check mating surfaces on transmission output
allow for final engine alignment. flange and propeller shaft coupler faces to make
sure they are clean and flat.
3. Lift engine into boat and position on engine bed
so that transmission output flange and propeller 2. Center propeller shaft in shaft log as follows:
shaft coupler are visibly aligned (no gap can be a. Push down and then lift shaft as far as it will
seen between coupling faces when butted to- move. Then place shaft in the middle of the
gether). Adjust engine bed height, if necessary, movement.
to obtain proper alignment. DO NOT use mount
adjustments to adjust engine position at this time. b. Move shaft to port and then to starboard as
far as shaft will move. Then place shaft in the
middle of the movement.
c. With shaft in center of shaft log, as deter-
mined by above procedures “a” and “b,” align
engine to shaft.
c
d
c
b a 72596
a - Propeller Shaft b 72595

b - Propeller Shaft Coupler
c - Transmission Output Flange a - Up
b - Down
4. Check all four mounts to ensure that they are still c - Port
positioned properly, then fasten mounts to en- d - Starboard
gine bed with appropriate bolts or lag screws and
hardware. Tighten lag bolts/screws securely.
5. Disconnect and remove sling. Proceed to “En-
gine Final Alignment” section following.

INDEX
3. Check that coupling centerlines align, by butting 5. If coupling centerlines are not aligned or if cou-
propeller shaft coupler against transmission out- pling faces are more than .003 in. (0.07 mm) out
put flange. Shoulder on propeller shaft coupler of parallel, adjust and retighten engine mounts as
should engage recess on transmission output follows:
flange face with no resistance.
a. TO ADJUST ENGINE UP OR DOWN: Loos-
NOTE: Some propeller shaft couplers may not have en locking nut on mounts requiring adjust-
a shoulder on mating face. On these installations, ment and turn both front mount or rear mount
use a straight edge to check centerline alignment. adjusting nuts equally.
IMPORTANT: Both front mount (or rear mount)
adjusting nuts must be turned equally to keep en-
gine level from side to side.
INCORRECT
CORRECT
e c
INCORRECT
72597
b
4. Check for angular misalignment, by hand holding

coupling faces tightly together; check for a gap
between faces with a .003 in. (0.07 mm) feeler
gauge at 90° intervals.
70056
Typical Mount
a
a - Locking Nut
b - Adjusting Nut
c - Clamping Screws and Nuts, with Lockwashers
(Only One Each on Some Mounts)
d - Lag Screws (or Bolts)
b e - Slot Forward (if So Designed - NOT Slotted on
This Style Rear Mount)
NOTE: Engine mount shown is typical. All models

are similar and adjust in the same manner.
c
50609
a - Feeler Gauge (Check at 90 Degree Intervals)
b - Transmission Output Flange
c - Propeller Shaft Coupler

INDEX
b. TO MOVE ENGINE TO THE LEFT OR 6. Connect propeller shaft coupler to transmission
RIGHT: Loosen clamping screw and nut on output flange. Attach couplers together with
all four mount brackets; move engine to the bolts, lockwashers and nuts. Torque to 50 lb. ft.
left or right as necessary to obtain proper (68 N·m).
alignment. On mounts which do have a
NOTE: If propeller shaft coupler has setscrews, the
slotted hole, a small amount of adjustment
shaft should be dimpled at setscrew locations. Set-
can be obtained with slot on front end of
screws should be safety wired after being tightened
mounts. Loosen lag screws or bolts (which
securely.
fasten mounts to engine bed) and move en-
gine, as required. Tighten lag screws or bolts
securely.
Engine Connections
c. After engine has been properly aligned:
Tighten engine mount nuts securely, and be IMPORTANT: When routing all wire harnesses
certain to bend one of the tabs on the tab and hoses, be sure they are routed and secured
washer down onto flat of mount adjusting nut. to avoid coming in contact with hot spots on en-
Torque clamping screws and nuts to 50 lb. ft. gine and avoid contact with moving parts.
(68 N·m). 1. Connect seawater inlet hose to seawater pump
NOTE: Some rear mounts have only one clamping assembly as shown. Tighten hose clamp
screw and nut on each side, instead of the style with securely.
two shown following.
IMPORTANT: Large diameter of mount trunnion
MUST NOT extend over 3/4 in. (20 mm) from
mount brackets on any of the mounts.
d a
72532
Bottom Hose
a - Seawater Inlet Hose Connection
70057
a - Torque Clamping Screws and Nuts on All Four Mount
Brackets to 50 Lb. Ft. (68 N·m)
b - Tighten Locking Nut on All Four Mounts Securely
c - Bend One of the Tabs on Tab Washer Down onto Flat of
Adjusting Nut
d - Maximum Extension of Large Diameter of Trunnion 3/4 In.
(20 mm)

INDEX
with hose clamp. Tighten hose clamp securely.
a under certain conditions. Do not smoke or allow
fuel immediately.
c
Make certain connection is secure. Check for
leaks.
b
4. Connect exhaust system tubes and hoses using
at least two hose clamps at each connection.
Tighten hose clamps securely.
NOTICE
Exhaust hoses must be connected to
exhaust elbows so that they do not restrict
22557 the flow of discharge water from exhaust
elbow. If hoses are connected incorrectly,
discharge water from exhaust elbow will not
Harness Connection flow around entire inside diameter of hose.
a - Engine Wiring Harness Receptacle Bracket This will cause a hot spot in the hose which
b - Instrument Wiring Harness Plug may eventually burn through.
c - Hose Clamp

! WARNING CORRECT

fuel leak.
• Apply #592 Loctite Pipe Sealant with Teflon to INCORRECT
TEFLON TAPE.
• Thread brass fitting or plug into fuel pump or 72538
fuel filter base until finger tight. Clamps Not Shown
OVER-TIGHTEN.

INDEX
5. Connect and adjust shift cable(s) as outlined fol- IMPORTANT: Check that shift lever is positioned
lowing: approximately 10 degrees aft of vertical when in
the neutral detent position and that the distance
IMPORTANT: When installing shift cables, be
(c) between studs in the following is set at 7-1/8
sure that cables are routed in such a way as to
in. (318 mm). If necessary, loosen clamping bolt
avoid sharp bends and/or contact with moving
position lever to obtain dimension described
parts. DO NOT fasten any items to shift cables.
above, and retighten bolt.
IMPORTANT: The Hurth transmission is a full re-
versing transmission. Direction of output/pro-
peller rotation is determined by hookup of shift
cable at remote control.
NOTE: Shift cable must be hooked up to remote con-
trol before starting installation and adjustment proce-
dures.
For Standard Left-Hand Propeller Rotation - shift
cable hookup at remote control must result in shift
cable end guide moving in direction (B), when remote c
control handle is placed in forward position.
For Right-Hand Propeller Rotation - shift cable a
hookup at remote control must result in shift cable
end guide moving in direction (A), when remote con-
trol handle is placed in forward position. d
72958
23242
b
a. Be certain anchor stud is installed in the hole
appropriate for your transmission (refer to
Transmission Identification Plate for specific
transmission model designation).
! WARNING a
Avoid serious personal injury or property dam-
age caused by improper shifting. Anchor stud for
shift cable must be installed in the correct hole.
b
b
a a
d
50228
c c
Typical Hurth Transmission Shown

71041
a - Shift Lever
71020 b - Lever, in Neutral Detent, Must Be Approximately
10 Degrees Aft of Vertical
Anchor Stud Position Shown for Hurth c - Dimension Between Studs - 7-1/8 In. (318 mm)
630A Transmission d - Clamping Bolt
a - Bracket, Shift Cable

b - Shift Cable Anchor Stud
c - Bracket-to-Transmission Fasteners

INDEX
b. Place remote control shift lever and transmis- h. Place remote control shift lever in reverse
sion shift lever in neutral position. gear position and again check to ensure
transmission is fully in gear as follows:
c. Remove nuts and washers from shift cable
attaching studs. (1) Hold shift lever in position.
d. Locate center of remote control and control (2) Carefully slide shift cable off of anchor
shift cable play (backlash) as follows: points.
(1) Check that remote control is in neutral po- (3) Attempt to move shift lever further.
sition.
i. If transmission shift lever will position proper-
(2) Push in on control cable end with enough ly in one gear, but not in the other, recheck
pressure to remove play; mark position shift cable adjustment. If transmission shift le-
(a) on tube. ver will not position properly in both gears,
move transmission shift lever stud (a), from
(3) Pull out on control cable end with enough
top hole (c) in shift lever, to bottom hole, and
effort to remove play; mark position (b) on
recheck for proper positioning. If proper posi-
tube.
tioning is still not obtained, remote control
(4) Measure distance between marks (a) and does not provide sufficient shift cable travel
(b); mark position (c), half-way between and must be replaced.
marks (a) and (b).
b c
b
c a
72603 a
e. Center cable-end play, then adjust cable bar-

rel to align holes in barrel and in cable end
guide with attaching points on transmission.
50228
f. Temporarily install shift cable. Do not secure
at this time. Typical Hurth Transmission Shown
IMPORTANT: Transmission is “fully” in gear a - Shift Lever Stud (in Bottom Hole, if Required)
when shift lever comes to a stop, in either direc- b - Lever, in Neutral Detent, Must Be Approximately
10 Degrees Aft of Vertical
tion. c - Shift Lever Top Hole
g. Place remote control shift lever in forward
gear position. Check to ensure transmission j. Install nut and washer to cable end guide
is fully in gear, as follows: stud. Tighten until snug, then back off one full
turn.
(1) Hold shift lever in position.
k. Install nut and washer to cable barrel stud.
(2) Carefully slide shift cable off of anchor
Tighten until they bottom out. Tighten secure-
points.
ly, but DO NOT OVER-TIGHTEN.
(3) Attempt to move shift lever further.

INDEX
SINGLE STATION INSTALLATIONS DUAL STATION INSTALLATIONS
c
a
c
b e
e
b
d
a d
b b
72957
Rear Approach Rear Approach 72960
e
a e
a
c
b c
b
d
d
b
b
72956
72956
Front Approach
Front Approach
a a
c c
d b d
b
50073
50073
Typical Hurth Transmission Shown Typical Hurth Transmission Shown
a - Cable End Guide
a - Cable End Guide b - Locknut and Washer
b - Locknut and Washer c - Spacer
c - Spacer d - Bushings
d - Bushings e - Cable Barrel
e - Cable Barrel

INDEX
NOTE: To change cable approach direction on single
or dual station installations, only the spacers/bush-
d
ings have to be switched to the opposite stud (the
studs are identical). c
6. Follow instructions “a” or “b”: e
b a
IMPORTANT: When installing throttle cables, be g
sure that cables are routed in such a way as to
avoid sharp bends and/or contact with moving
parts. DO NOT fasten any items to throttle cables. d
a. On Models Equipped with Other than

Quicksilver Throttle Cables: Attach and
f h
adjust throttle cables following cable man-
ufacturer’s instructions.
b. On Models Equipped with Quicksilver 22552
Throttle Cables: Connect and adjust throttle Single Station
cable(s) as outlined following: a - Cable End Guide
(1) Place remote control throttle lever(s) in b - Throttle Lever Stud
idle position. d - Spacer
(2) Install cable end guide on carburetor e - Cable Barrel
f - Anchor Stud
throttle lever stud as shown. Push cable g - Washer
barrel lightly toward throttle lever. (This h - Washer and Locknut
will place a slight preload on cable to
avoid slack in cable when moving remote
control levers.) Then adjust cable barrel
to align with anchor stud and slide barrel
onto stud. d
(3) Secure throttle cable with hardware as
shown. Tighten cable end guide locknut c
until it bottoms out and then back off one
full turn. Tighten barrel locknut until se- b g
a
cure, but DO NOT OVER-TIGHTEN as
cable(s) must be able to pivot.
e
f h
22553
Dual Station
a - Cable End Guide
d - Spacer
e - Cable Barrel
f - Anchor Stud
g - Washer

INDEX
(4) Place remote control throttle lever(s) in h
f
the wide-open-throttle (W.O.T.) position.
g
Check to ensure that throttle shutters e
(valves) are completely open.
(5) Return remote control throttle lever to idle
position and check to ensure that throttle
lever contacts idle speed adjustment
screw.
d
b b
c
74109

a - Cable End Guide
a
71159 c - Locknut and Flat Washer - Tighten Until Nut Bottom
Wide-Open-Throttle Position Shown d - Throttle Lever
a - Throttle Shaft Lever [Contacts (b) at W.O.T. Position] e - Throttle Bracket
b - Carburetor Body Casting f - Cable Barrel
7. Connect any ground wires or accessories that

were disconnected from engine.
necting positive (+) battery cable end to positive
(+) battery terminal. Tighten clamp securely.
Then, connect negative (–) battery cable end to
negative (–) battery terminal. Tighten clamp se-
b a curely.
70392
Idle Position Shown

a - Throttle Lever [Contacts (b) In Idle Position]

INDEX
AT A LATER DATE

INDEX
AT A LATER DATE

INDEX
ENGINE
3
A
72615
5.0L / 305 CID / 5.7L / 350 CID
Index
Table of Contents
Page Page
Torque Specifications 5.0L / 305 CID / 5.7L / 350 Installation - Head Installed . . . . . . . . . . . . 3A-32
CID Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-32
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-32
Lubricants/Sealers/Adhesives . . . . . . . . . . . 3A-4 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-33
Engine Specifications . . . . . . . . . . . . . . . . . . . . . 3A-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33
5.0L / 305 CID / 5.7L / 350 CID Engine Cylinder Head and Valve Conditioning . . . . . 3A-34
Specifications (Does Not Include Gen +) . 3A-10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34
350 Gen + Engine Specifications . . . . . . . 3A-14 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34
Engine Identification . . . . . . . . . . . . . . . . . . 3A-15 Valve Guide Bore Repair . . . . . . . . . . . . . . 3A-35
Cylinder Head Identification . . . . . . . . . . . . 3A-16 Valve Springs - Checking Tension . . . . . . . 3A-36
Engine Rotation . . . . . . . . . . . . . . . . . . . . . . 3A-16 Rocker Arm Stud Replacement . . . . . . . . . 3A-37
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16 Valve Seat Repair . . . . . . . . . . . . . . . . . . . . 3A-37
Piston and Connecting Rods . . . . . . . . . . . 3A-16 Valve Grinding . . . . . . . . . . . . . . . . . . . . . . . 3A-38
Camshaft and Drive . . . . . . . . . . . . . . . . . . . 3A-17 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-38
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Dipstick Specifications . . . . . . . . . . . . . . . . . . . 3A-41
Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-41
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-42
Lubrication System . . . . . . . . . . . . . . . . . . . 3A-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-42
Bearing Failures . . . . . . . . . . . . . . . . . . . . . . . . 3A-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-42
Piston Failures . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-20 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-44
Pre-Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-44
Detonation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-21 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-44
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-22 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-45
Rocker Arm Cover . . . . . . . . . . . . . . . . . . . . . . . 3A-24 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-24 Torsional Damper . . . . . . . . . . . . . . . . . . . . . . . 3A-46
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 3A-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-46
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-24 Crankcase Front Cover/Oil Seal . . . . . . . . . . . 3A-47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-25 Oil Seal Replacement
Rocker Arm/Push Rod . . . . . . . . . . . . . . . . . . . 3A-27 (Without Removing Front Cover) . . . . . . . . 3A-47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-27 Crankcase Front Cover . . . . . . . . . . . . . . . . . . 3A-48
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-27 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-48
Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 3A-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-48
Engine Stopped . . . . . . . . . . . . . . . . . . . . . . 3A-27 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-48
Engine Running . . . . . . . . . . . . . . . . . . . . . . 3A-28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-48
Hydraulic Valve Lifters Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-49
(Flat and Roller Lifter) . . . . . . . . . . . . . . . . . . . . 3A-29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-50
Locating Noisy Lifters . . . . . . . . . . . . . . . . . 3A-29 Rear Main Oil Seal . . . . . . . . . . . . . . . . . . . . . . 3A-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-51
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-30 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-52
Valve Stem Oil Seal/Valve Spring . . . . . . . . . . 3A-30 Rear Main Oil Seal Retainer . . . . . . . . . . . . . . 3A-52
Removal - Head Installed . . . . . . . . . . . . . . 3A-30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-52
Valve Assembly (Exploded View) . . . . . . . 3A-32 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-52
Index
3A-–2 - ENGINES 90-823225--1 1096
Page Page
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-52 Installation - Timing Chain
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-53 (Standard Rotation Engine) . . . . . . . . . . . . 3A-65
Checking Clearances . . . . . . . . . . . . . . . . . 3A-53 Crankshaft Sprocket/Gear . . . . . . . . . . . . . . . . 3A-65
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 3A-55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-65
Connecting Rod Bearings . . . . . . . . . . . . . . . . 3A-56 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-65
Inspection and Replacement . . . . . . . . . . . 3A-56 Checking Timing Chain Deflection . . . . . . 3A-65
Connecting Rod/Piston Assembly . . . . . . . . . 3A-57 Checking Timing Gear Backlash
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-57 and Runout . . . . . . . . . . . . . . . . . . . . . . . . . 3A-66
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-58 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-67
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-58 Measuring Lobe Lift . . . . . . . . . . . . . . . . . . . 3A-67
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-67
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-62 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-68
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-63 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-68
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-63 Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . 3A-68
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-63 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-68
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-63 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-69
Timing Chain and Sprocket or Timing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-69
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-64 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-64 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-70
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-64 Oil Filter By-Pass Valve and Adaptor
Installation - Timing Gears Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-73
(Opposite Rotation Engine) . . . . . . . . . . . . 3A-65 Inspection and/or Replacement . . . . . . . . . 3A-73
Index
90-823225--1 1096 ENGINES - 3A-–1
Index
3A-0 - ENGINES 90-823225--1 1096
Torque Specifications 5.0L / 305 CID / 5.7L / 350 CID Engines
NOTE: Any Differences in Gen + Engines Will Be Noted With “Gen +”.
DESCRIPTION Lb. In. Lb. Ft. N⋅m

Alternator Brace to Alternator 192 28
Alternator Brace to Engine 30 41
Alternator to Mounting Bracket 35 48
Alternator Mounting Bracket 30 41
Camshaft Sprocket Gear 216 24
Carburetor 132 15
Connecting Rod Cap Nuts 45 61
Connecting Rod Cap Nuts
20 27
Gen + (Plus An Additional 55 Degrees)
Coupler/Flywheel(MCM)
35 48
Crankshaft Pulley
Cylinder Head Bolt 65 88
Cylinder Head Bolt Gen + First Sequence 22 30
A l Torque
Angle T Second
S d Sequence
S Short
Sh t BBolt
lt 55 Degrees
g
Medium Bolt 65 Degrees
g
Long Bolt D
75 Degrees
Distributor Hold Down 25 34
Exhaust Manifold
20 27
Filter Adapter (5/16-18)
Flywheel 75 100
Flywheel Drive Plate (MIE) 35 48
Flywheel Housing to Block 30 41
Flywheel Housing Cover 80 9
Front Mount Bracket 30 41
Fuel Pump 25 34
Intake Manifold (All Engines Except Gen +) 35 48
Intake Manifold Gen + 18 24
Main Bearing Cap 80 109
Index
90-823225--1 1096 ENGINES - 3A-1
350 CID / 5.7L Torque Specifications (Continued)
NOTE: Any Differences in Gen + Engines Will Be Noted With Gen +.

Main Bearing Cap Gen + 74 100
Oil Baffle Nuts 25 34
Oil Filter Adapter Bolt 15 20
Oil Pan Drain Plug 15 20
Oil Pan Corner Nut 15 20
Oil Pan Nuts (5/16-18) 106 12
Oil Pump 65 88
Oil Pump Cover 80 9
Power Steering Pump Brace to Block
30 41
Power Steering Pump Bracket
Rear Crankshaft Oil Seal Retainer Screws and
133 15
Nuts
Rear Mount (MCM) 40 54
Rear Mount (MIE) 50 68
Remote Oil Connector (1/2 in. x 13) 25 34
Remote Oil Filter Adapter Nut/Fitting 20 27
Spark Plugs 15 20
Starter Motor 50 50
Thermostat Housing 30 41
Timing Chain or Gear Cover 106 12
Torsional Damper 40 54
Transmission To Housing 50 68
Water Circulating Pump 30 41
Water Temperature Sender 20 27
Rocker Arm Cover 90 10
Roller Lifter Restrictor Retainer Plate 12 16
Seawater Pump Brace
30 41
Seawater Pump Bracket
Index
3A-2 - ENGINES 90-823225--1 1096
Special Tools
MERCURY MARINE SPECIAL TOOLS
Piston Ring Expander 91-24697
Engine Coupler Wrench 91-35547
Rocker Stopper 91-66273
KENT-MOORE SPECIAL TOOLS
Valve Spring Compressor (Head on) J5892
Valve Spring Compressor (Head off) J8062
Valve Spring Tester J8056
Valve Guide Cleaner J8101
Valve Guide Reamer (Standard) J7049
Valve Guide Reamer (.015 in. oversize) J5830-02
Rocker Arm Stud Remover J5802-01
Rocker Arm Stud Installer J6880
Stud Bore Reamer (.003 in. oversize) J5715
Stud Bore Reamer (.013 in. oversize) J6036
Carbon Remover Brush J8089
Piston Pin Tool J24086-B
Piston Ring Groove Cleaner J3936-03
Piston Ring Compressor J8037
Connecting Rod Guide Tool (3/8 -24) J5239
Oil Pump Suction Pipe Installer J21882
Camshaft Bearing Installer/Remover Tool J6098-01
Ball Socket Adapter J8520-1
Torsional Damper Remover and Installer J23523-E
Crankcase Front Cover Seal Installer J35468
Crankshaft Gear and Sprocket Puller J5825-A
Crankshaft Gear and Sprocket Installer J5590
Air Adapter J23590
Main Bearing Remover and Installer J8080
Rear Main Seal Installer J26817-A
Index
90-823225--1 1096 ENGINES - 3A-3
Lubricants/Sealers/Adhesives
Quicksilver Loctite 8831 92-823089-1
Quicksilver Perfect Seal 92-34227-1
Quicksilver Needle Bearing Assembly Lubricant 92-825265A1
Quicksilver RTV Sealer 92-91601-1
General Motors Cam and Lifter Prelube or
Obtain Locally
Equivalent
Index
3A-4 - ENGINES 90-823225--1 1096
Engine Specifications
UNIT OF MEASUREMENT
In. (mm)
Engine
MCM 5.0L / 305 CID Alpha and Bravo
Model
Displacement 305 CID (5.0 L)
Bore 3.74 (95)
Stroke 3.48 (88.4)
Compression
9.1:1
Ratio
Heads Cast Iron
Intake
Cast Iron
Manifold
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Crankshaft Cast Iron
Pistons Cast Aluminum
Camshaft Cast Iron
Fuel Pump
Steel
Push Rod
Engine
MCM / MIE 5.7L / 350 CID Alpha and Bravo
Model
Displacement 350 CID (5.7 Litre)
Bore 4.00 (101.6)
Stroke 3.48 (88.4)
Compression
9.3:1
Ratio
Heads Cast Iron
Intake
Cast Iron (High Rise on Magnum and 4 Barrel EFI Models)
Manifold
Rods Forged Steel
Camshaft Steel (See Note 1)
Fuel Pump
Cast Iron (See Note 1)
Push Rod
Index
90-823225--1 1096 ENGINES - 3A-5
Engine
MCM / MIE 5.7L / 350 CID Alpha and Bravo Gen +
Model
Displacement 350 CID (5.7 Litre)
Bore 4.00 (101.6)
Stroke 3.48 (88.4)
Compression
9.4:1
Ratio
Heads Cast Iron
Intake
Cast Aluminum
Manifold
Rods Forged Steel
Steel (Roller Cam)
Camshaft
Cast Iron (Flat Tappet)
Fuel Pump Cast Iron (Roller Cam)
Push Rod Steel (Flat Tappet)_
A B
LH ROTATION RH ROTATION
FRONT FRONT
Firing Order Firing Order

1-8-4-3-6-5-7-2 1-2-7-5-6-3-4-8
72008 72009
Index
3A-6 - ENGINES 90-823225--1 1096
5.0L / 305 CID / 5.7L / 350 CID Engine Specifications (Does Not Include Gen +)
Unit Of Measurement
In. (mm)
CYLINDER BORE
ENGINE 5.0L / 305 CID 5.7L / 350 CID

3.7350-3.7385 3.9995-4.0025
Diameter
(94.8690-94.9579) (101.5873-101.6635)
Out of Round Production .001 (0.025) Max
Out of Round Service .002 (0.05) Max
Thrust Side .0005 (0.012) Max
Production
T
Taper Relief Side .001 (0.02) Max
Service .001 (0.02) Over Production
PISTON CLEARANCE
Production .0007-.0017 (0.017-0.043) Max

Service .0027 (0.07) Max
PISTON RING: COMPRESSION
Top
Production .0012-.0032
0012- 0032 (0.030-0.081)
(0 030-0 081)
G
Groove Clearance
Cl 2nd
Service High Limit Production + .001 (0.025)
Top .010-.020 (0.254-0.508)
( )
Production
G
Gap 2nd .010-.025 (.0254-.0635)
( )
PISTON RING: OIL
Production .002-.007 (0.051-0.177)

Groove Clearance
Production .015-.055 (0.381-1.397)
Gap
Service Limit High Limit Production + .010 (0.254)
PISTON PIN
Diameter .9269-.9271 (23.545-23.553)

Production .0002–.0007 (0.005-0.017)
Clearance
Service Limit .001 (0.02) Max
Fit in Rod .0008-.0016 (0.020-0.406) Interference
Index
90-823225--1 1096 ENGINES - 3A-7
Unit Of Measurement
In. (mm)
CRANKSHAFT
ENGINE 5.0L / 305 CID / 5.7L / 350 CID

Main
Diameter No.1 2.4484-2.4493 (62.198-62.212)
Journal
No. 2, 3 2.4481-2.4490 (62.181-62.204)
Diameter
No.4 2.4479-2.4488 (62.176-62.199)
Main
M i Production .0002 (0.005) Max
Taper
Journal Service .001 (0.02) Max
Production .0002 (0.005) Max
Out of Round
No.1 .0008-.0020 (0.020-0.050)
P d i
Production No. 2, 3 .0011-.0023 (0.027-0.058)
Main
M i Bearing
B i g No.4 .0017-.0032 (0.043-0.081)
C
Clearance No.1 .0010-.0015 (0.025-0.038)
S i
Service No. 2, 3 .0010-.0025 (0.03-0.06)
No.4 .0025-.0035 (0.07-0.08)
Crankshaft End Play .002-.006 (0.05-0.15)
Diameter 2.0988-2.0998 (57.117–57.142)
C
Connecting
i R Rod
d Taper
Journal
Out of Round
Production .0013-.0035 (0.033-0.088)
Rod Bearing Clearance
Rod Side Clearance .006-.014 (0.15-0.35)
Crankshaft Runout .0015 (0.0381) Max
Index
3A-8 - ENGINES 90-823225--1 1096
Unit Of Measurement
In. (mm)
VALVE SYSTEM
ENGINE 5.0L / 305 CID 5.7L / 350 CID

Lifter Type (NOTE 1) Flat Hydraulic
Lifter Type (NOTE 1) Roller Hydraulic
Rocker Arm Ratio 1.50 to 1
Intake .394 (10.00)
Valve Lift
Exhaust .404 (10.26)
Valve Lash (Intake and Exhaust) 1 Turn Down from Zero Lash
Intake 45°
Face Angle
Exhaust 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002 (0.05) Max
Intake .03215-.0625 (0.79-1.58)
Seat Width
Exhaust .0625-.09375 (1.58-2.38)
Intake .0010-.0027 (0.025-0.069)
Production
Stem
S Exhaust .0010-.0027 (0.025-0.069)
Cl
Clearance Intake .0037 (0.09) Max
Service
Exhaust .0047 (0.11) Max
Intake .341 (8.66)
Stem Diameter
Exhaust .372 (9.45)
Intake 1.84 (46.74) 1.94 (49.28)
Valve Diameter
Exhaust 1.50 (38.1)
Valve Margin Intake and Exhaust .0312 (0.79)
Index
90-823225--1 1096 ENGINES - 3A-9
Unit Of Measurement
In. (mm)
VALVE SPRING
ENGINE 5.0L / 305 CID / 5.7L / 350 CID
Valve Spring
24-48347 Free Length 2.03 (51.6) (See Note 1)
Lavender
Stripe
Valve
Pressure 76-84 Lb. Ft. (103-113 N⋅m) at 1.785 (43.16)
Valve Spring
p g Closed
24 4834
24-48347 (NOTE 2)
Valve Open 194-204 Lb. Ft. (263-279 N⋅m) at 1.250 (31.75)
Lavender
Stripe Installed Height Intake 1.7 [1-45/64] (43)
Free Length 1.86 [1-55/64] (47)
Damper
Approximate Number of Coils 4
NOTE 1: Engines are equipped either roller hydraulic (5.7L / 350 CID engines only) or flat hydraulic depending
on model designation.
NOTE 2: Test spring pressure with damper removed
CAMSHAFT AND DRIVE
ENGINE 5.0L / 305 CID 5.7L / 350 CID

1.8682-1.8692
Journal Diameter 1.8682-1.8692 (47.452-47.478)
(47.452-47.478)
Journal Out Of Round .001 (0.025) Max
Camshaft Runout .002 (0.051) Max
Timing Chain Deflection
.375 (9.5) from taut position [total .75 (19)]
[LH Rotation]
FLYWHEEL
Runout .008 (0.203) Max
CYLINDER HEAD
Gasket Surface Flatness .004 (0.1016) Overall Maximum
Index
3A-10 - ENGINES 90-823225--1 1096
350 CID Gen + Engine Specifications
Unit Of Measurement
In. (mm)
NOTE: These specifications cover only Gen + engines.
CYLINDER BORE
4.0007-4.0017
Diameter
(101.618-101.643)
Out of Round
Thrust Side .0005 (0.012) Max
Production
T
Taper Relief Side .001 (0.025) Max
Service .001 (0.025) Over Production
PISTON CLEARANCE
Production .0007-.0021 (0.018-0.053) Max

PISTON RING: COMPRESSION
Top
Production .0012-.0032
0012- 0032 (0.030-0.081)
(0 030-0 081)
G
Groove Clearance
Cl 2nd
Top .010-.020 (0.25-0.51)
Production
G
Gap 2nd .018-.026 (0.46-0.66)
Service High Limit Production ± .010 (0.25)
PISTON RING: OIL
Production .002-.007 (0.051-0.17)

Groove Clearance
Service High Limit Production ± .001 (0.025)
Production .010-.030 (0.25-0.76)
Gap
Service Limit High Limit Production ± .001 (0.25)
PISTON PIN
Diameter .9270-.9271 (23.545-23.548)

Production .0004-.0008 (0.0120-0.0210)
Clearance
Service Limit .0010 (0.025) Max
Fit in Rod .0008-.0016 (0.021-0.40) Interference
Index
90-823225--1 1096 ENGINES - 3A-11
Unit Of Measurement
In. (mm)
CRANKSHAFT
Main
Diameter No.1 2.4484-2.4493 (62.189-62.212)
Journal
No. 2, 3, 4 2.4481-2.4490 (62.182-62.205)
Diameter
No.5 2.4479-2.4488 (62.177-62.199)
Main
M i Production .0002 (0.005) Max
Taper
Journal Service .001 (0.025) Max
Out of Round
No.1 .0007-.0021 (0.018-0.053)
P d i
Production No. 2, 3, 4 .0022-.00610 (0.0009-0.0024)
Main
M i Bearing
B i g No.5 .00250-.00690 (0.0010-0.0027)
C
Clearance No.1 .0010-.0.0020 (0.250-0.510)
S i
Service No. 2, 3, 4 .0010-.0025 (0.0250-0.0640)
No.5 .0025-.0035 (0.0760-0.0380)
Crankshaft End Play .002-.008 (0.0500-0.2000)
Diameter 2.0978-2.0998 (53.2840-53.3340)
C
Connecting
i R Rod
d Taper
Journal
Out of Round
Production .0006-.0014 (0.16-0.35)
Rod Bearing Clearance
Service 0.0010-0.0030 (0.025-0.076)
Rod Side Clearance .006-.014 (0.15-0.35)
Index
3A-12 - ENGINES 90-823225--1 1096
Unit Of Measurement
In. (mm)
VALVE SYSTEM
Lifter Type Roller Hydraulic

Rocker Arm Ratio 1.50 to 1
Intake .431 (10.947)
Valve Lift
Exhaust .450 (11.43)
Valve Lash (Intake & Exhaust) 1 Turn Down from Zero Lash
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002 (0.05) Max
Intake .040-.0625 (1.02-1.65)
Seat Width
Exhaust .065-.098 (1.65-2.49)
Intake .0010-.0027 (0.025-0.069)
Production
Stem
S Exhaust .0010-.0027 (0.025-0.069)
Cl
Clearance Intake High Limit Production + .001 (0.025)
Service
Exhaust High Limit Production + .0002 (0.050)
VALVE SPRING
Free Length 2.02 (51.3)

Valve
76-84 Lb. Ft. (338-374 N) at 1.70 (43.18)
Pressure Closed
Valve Spring
Valve Open 187-203 Lb. Ft. (832-903 N) at 1.27 (32.26)
Installed Height Intake 1.69-1.71 (42.92-43.43)
Index
90-823225--1 1096 ENGINES - 3A-13
350 Gen + Engine Specifications
Unit Of Measurement
In. (mm)
CAMSHAFT
Exhaust .300 (7.62)

Lobe Lift ± .002
002 (0
(0.051)
051)
Intake .287 (7.289)
Duration at .050 In. ((1.27mm)) Exhaust .294 (7.467)
C
Cam Lift
f Intake .307 (7.797)
Journal Diameter 1.8682-1.8692 (47.440-47.490)
End Play .011-0.030 (0.004-0.0012)
Timing Chain Deflection .375 (9.5) from taut position
[LH Rotation] [total .75 (19)]
FLYWHEEL
Runout .008 (0.203) Max
CYLINDER HEAD
Gasket Surface Flatness .004 (0.10) Overall Maximum
Index
3A-14 - ENGINES 90-823225--1 1096
General
Some of the repairs in this section must be completed MCM (Stern Drive) Code Rotation
with engine removed from boat. Engine removal de- 5.0L Alpha and Bravo ZC
pends upon type of repair and boat design. Place en-
gine on repair stand for major repairs. 5.0LX Alpha ZD
Lubricate all moving parts (during reassembly) with 5.7L Bravo MJ
engine oil. Apply Quicksilver Perfect Seal on threads MJ
5.7L Alpha
of and under heads of cylinder head bolts, and on MB
threads of all cylinder block external bolts, screws CD
and studs. 5.7L Bravo
MD
5.7L Alpha EFI CD
MD
Engine Identification 5.7L Bravo EFI MJ LH
The MerCruiser Model can be determined by looking 5.7LX, Alpha
at the last two letters of the engine code stamped into 5.7LX Bravo CD
the cylinder block. This code number is stamped on 350 Magnum Alpha MD
all MerCruiser power packages and replacement 5.7L EFI/MP Bravo
partial engines, but not replacement cylinder block 350 Magnum EFI
assemblies. Alpha Gen +
If the engine serial number and/or model decals are 350 Bravo EFI MH
missing, the engine code letters may help in deter-
350 Magnum MPI Gen +
mining the engine models. Following is a list of GM
Bravo and Blackhawk
engines and their respective code letters.
MIE (Inboard) Code Rotation

MM
LH
5.7L NN
NR
RH
MB
5.7L
5 7L Competition
C titi Ski MJ
MB
a
MH
350 Magnum Tournament Ski CD
72312
MD
a - Lcation Of G.M. Engine Code 350 Magnum EFI LH
Tournament Ski CD
350 Magnum EFI/MP MD
Tournament Ski
350 Magnum MPI Tournament
MH
Ski (Black Scorpion)
Index
90-823225--1 1096 ENGINES - 3A-15
Cylinder Head Identification Engine Rotation
Engine rotation terminology at times has caused
confusion. To clarify, engine rotation is determined
by observing flywheel rotation from the rear (trans-
mission or stern drive end) of the engine looking
forward (water pump end).
PROPELLER ROTATION IS NOT NECESSARILY
THE SAME as engine rotation.
72647 When ordering replacement engines, short blocks or
MCM 5.0L parts for engines, be certain to check engine rotation.
Do not rely on propeller rotation in determining en-
gine rotation.
72313 a
MCM 5.7L/MCM 350 Magnum
IDENTIFICATION OF GEN + CYLINDER HEADS
The Gen + cylinder head has four 5/16 inch x 18 in-

take bolts verus six 3/8 x 16 bolts on cylinder head b
prior to Gen +. There is not a provision for water
crossover in the center of the head.
72001
a - Left-Hand Rotation (CCW) - All Stern Drive Engines,

MIE Inboard LH (Standard) Rotation
b - Right-Hand Rotation (CW) - MIE Inboard RH (Opposite)
Rotation
Crankshaft
The crankshaft is supported in the block by five insert
type bearings. Crankshaft end thrust is controlled by
flanges on the No. 5 bearing. A torsional damper on
the forward end of the crankshaft serves to help
dampen any engine torsional vibration.
Piston and Connecting Rods

Piston pins are offset slightly toward the thrust side
a b of the pistons to provide a gradual change in thrust
72325
a - Cylinder Head Prior To Gen+ pressure against the cylinder wall as the piston
b - Gen+ Cylinder Head travels its path. Pins have a floating fit in the piston
and a press fit in the connecting rod (to hold them in
place).
Index
3A-16 - ENGINES 90-823225--1 1096
Connecting rods are made of forged steel and are Hydraulic valve lifters ride directly on the camshaft
connected to the crankshaft through insert type bear- lobes and transmit the thrust of the lobes to the push
ings. rods which in turn actuate the valves through the
rocker arm.
In addition to transmitting thrust of the cam lobes, the
Camshaft and Drive hydraulic lifters also serve to remove any clearance
Camshafts are generally made of cast iron, except on (lash) from the valve train to keep all parts in constant
engines with roller lifters which have camshafts contact.
made of steel. All camshafts are driven at one-half The valve lifters also are used to lubricate the valve
crankshaft speed by a timing chain and sprockets, or train bearing surfaces.
by timing gears, and are supported by five main bear-
ings, which are pressed into the block.
A helical gear on the aft end of the camshaft drives Intake Manifold
the distributor and oil pump, while an eccentric cam
The carbureted and throttle body fuel injection man-
on the front of the camshaft actuates the fuel pump
ifolds are a double level design for efficient fuel distri-
through a push rod. The fuel pump push rod is made
bution. The upper level of passages feeds cylinders
of different material when used on engines with steel
2, 3, 5 and 8 while the lower level passages feed cyl-
camshafts and roller lifters, than for engines with cast
inders 1, 4, 6 and 7.
iron camshafts.
The multi-port injection manifold is a tunnel ram de-
sign wiht the injectors mounted directly above intake
! CAUTION port in cylinder head.
Avoid rapid and severe camshaft and fuel pump
push rod wear which could result in engine dam-
age. Always use the fuel pump push rod speci- Lubrication System
fied for use with the cast iron or steel camshaft in
The engine lubrication system is of the force-feed
your engine.
type in which oil is supplied under full pressure to the
On engines with cast iron camshaft and flat faced lift- crankshaft, connecting rods, camshaft bearings and
ers, a taper on the lobes, coupled with a spherical valve lifters, and is supplied under controlled volume
foot on the hydraulic valve lifters, causes the valve to the push rods and rocker arms. All other moving
lifters to rotate, thus reducing wear. However, on en- parts are lubricated by gravity flow or splash.
gines with steel camshaft and roller lifters, eight re-
A positive displacement gear-type oil pump is
strictors, held in place by a retaining plate, hold the
mounted on the rear main bearing cap and is driven
hydraulic valve lifters from rotating so that they follow
by an extension shaft from the distributor (which is
the cam lobes precisely.
driven by the camshaft). Oil from the bottom of the
pump in the rear of the oil pan is drawn into the oil
pump through an oil pickup screen and pipe
Cylinder Head assembly.
The cylinder heads are made of cast iron and have If the screen should become clogged, a relief valve
individual intake and exhaust ports for each cylinder. in the screen will open and continue to allow oil to be
Stainless steel or graphite composition head gaskets drawn into the system. Once the oil reaches the
are used to retard corrosion. pump, the pump forces the oil through the lubrication
system. A spring-loaded relief valve in the pump lim-
its the maximum pump output pressure.
Valve Train After leaving the pump, the pressurized oil flows
through a full-flow oil filter. On engines with an engine
The valves and valve springs are of a heavy-duty de-
oil cooler, the oil also flows through the cooler before
sign to withstand the high engine speeds encoun-
returning to the block. A bypass valve allows oil to
tered. Valve tips have been hardened to extend valve
bypass the filter and oil cooler should they become
life. Exhaust valve rotators are used on some en-
restricted.
gines to help extend valve life.
Index
90-823225--1 1096 ENGINES - 3A-17
Some of the oil, after leaving the oil cooler and/or fil- Oil which reaches the valve lifter oil galleries is forced
ter, is routed to the No. 5 crankshaft main bearing. into each hydraulic valve lifter through holes in the
The remainder of the oil is routed to the main oil gal- side of the lifter. From here, the oil is forced through
lery, which is located directly above the camshaft and the metering valve in each of the lifters (which con-
runs the entire length of the block. From the main oil trols the volume of oil flow) and then up through the
gallery, the oil is routed through individual oil pas- push rods to the rocker arms. A hole in each rocker
sages to an annular groove in each camshaft bearing arm push rod seat allows the oil to pass through the
bore. Some of the oil is then used to lubricate cam- rocker arm and lubricate the valve train bearing sur-
shaft bearings. The remainder of the oil is routed to faces. After lubricating the valve train, oil drains back
the valve lifter oil galleries and No. 1, 2, 3, and 4 to the oil pan through oil return holes in the cylinder
crankshaft main bearings by means of individual oil head and block.
passages which intersect with the annular grooves.
The distributor shaft and gear also is lubricated by the
The camshaft bearings have holes which align with oil flowing through the right valve lifter oil gallery. The
the oil passages or annular grooves in the block and fuel pump push rod is lubricated by oil thrown off from
allow oil to flow in-between the bearings and the cam- the camshaft eccentric.
shaft journals. The oil that is forced out the front end
of the No. 1 camshaft bearing drains down onto the
camshaft drive and keeps it lubricated.
The oil which reaches the crankshaft main bearings
is forced through a hole in the upper half of each
bearing and flows in-between the bearings and the
crankshaft journals. Some of the oil is then routed to
the connecting rod bearings through grooves in the
upper half of the crankshaft main bearings and oil
passages in the crankshaft. Oil which is forced out
the ends of the connecting rod bearings and crank-
shaft main bearings is splashed onto the camshaft,
cylinder walls, pistons and piston pins, keeping them
lubricated. Oil which is forced out the front end of the
No. 1 crankshaft main bearing also assists in lubricat-
ing the camshaft drive. A baffle plate, mounted on the
bottom of the main bearings or in the oil pan, prevents
oil thrown from the crankshaft and connecting rods
from aerating the oil in the oil pan.
Index
3A-18 - ENGINES 90-823225--1 1096
Bearing Failures
Overlay Wiped Bright (Polished)

Scratches Dirt Imbedded Out Sections
Scratched into Bearing Lack of Oil Improper Seating
Material
by Dirt
Overlay Gone from Radius Ride Craters or Pockets

Entire Surface 70436
Tapered Journal Radius Ride Fatigue Failure
Index
90-823225--1 1096 ENGINES - 3A-19
Piston Failures 3. Any other protuberance in the combustion cham-
ber, such as an overhanging piece of gasket, an
improperly seated valve or any other inade-
quately cooled section of material which can
Pre-Ignition serve as a source.
Pre-ignition is abnormal fuel ignition, caused by com-
bustion chamber hot spots. Control of the start of igni-
tion is lost, as combustion pressure rises too early,
causing power loss and rough running. The upward
motion on the piston is opposed by the pressure rise.
This can result in extensive damage to the internal
parts from the high increase in combustion chamber
temperature. 1 2
72424
3 4
Pre-Ignition Damage
Engine failures, which result from the foregoing con-
PRE-IGNITION CAUSES ditions, are beyond the control of Mercury Marine;
therefore, no warranty will apply to failures which oc-
1. Hot spots in the combustion chamber from glow- cur under these conditions.
ing deposits (due in turn to the use of improper
oils and/or fuels).
2. Overheated spark plug electrodes (improper
heat range or defective plug).
Index
3A-20 - ENGINES 90-823225--1 1096
Detonation
Detonation, commonly called “fuel knock,” “spark
knock” or “carbon knock,” is abnormal combustion of
the fuel which causes the fuel to explode violently.
The explosion, in turn, causes overheating or dam-
age to the spark plugs, pistons, valves and, in severe
cases, results in pre-ignition.
Use of low octane gasoline is one of the most com-
mon causes of detonation. Even with high octane
gasoline, detonation could occur if engine mainte-
nance is neglected.
1 2
OTHER CAUSES OF DETONATION
IMPORTANT: Use of improper fuels will cause en-

gine damage and poor performance.
1. Over-advanced ignition timing.
2. Lean fuel mixture at or near full throttle (could be
caused by carburetor or leaking intake manifold).
3. Cross-firing spark plugs.
4. Excess accumulation of deposits on piston and/
or combustion chamber (results in higher com- 3 4
pression ratio).
72315
5. Inadequate cooling of engine by deterioration of
cooling system.
NOTE: Engine failures, which result from the forego-
ing conditions, are beyond the control of MerCruiser;
therefore, no warranty will apply to failures which oc-
cur under these conditions.
72425
Detonation Damage
Index
90-823225--1 1096 ENGINES - 3A-21
Engine Mounts
a 72318
Rear Mount /Flywheel Housing - MCM

a - Gasket Used on MCM Engines Only
72316
Some Models
Front Mount - MCM 5.0L/5.0LX/5.7L
Rear
Mount
b
Front
Mount
72319
Front and Rear Mounts and Transmission Base

Assembly - MIE 5.7L/5.7L Competition Ski/
350 Magnum Tournament Ski with In-Line
72317
Transmission
Front Mount - MCM 350 Magnum a - Rubber Insert Cannot Be Removed
b - Transmission Base Assembly (Some Models)
c - Horizontal Rear Mount (With Rear Mount)
Index
3A-22 - ENGINES 90-823225--1 1096
REAR
FRONT
a
a
72322
b
72320
Flywheel Housing - MIE Inboard Engines
a - Gasket Used On Some Engines

Assembly - MIE 5.7L with Hurth 630A Down Angle
Transmission
a - Transmission Base Assembly
(350 Magnum Tournament Ski Only)
b - Rubber Insert Cannot Be Removed
72323
Flywheel Housing and Drive Shaft Extension

Housing - MCM Engines
72321

Assembly - MIE 5.7L with V-Drive Transmission
Index
90-823225--1 1096 ENGINES - 3A-23
Rocker Arm Cover Intake Manifold
Removal Removal
It may be necessary to remove exhaust manifold be- 1. Drain engine cooling system.
fore removing rocker arm cover. Refer to Section 7B
2. Disconnect hoses from thermostat housing.
for removal. Also remove any component that will in-
terfere with the removal of the manifold or rocker arm 3. Disconnect electrical leads interfering with re-
cover. moval.
1. Disconnect crankcase ventilation hoses. 4. Disconnect crankcase ventilation hoses from
rocker arm covers.
2. Remove any items that interfere with the removal
of rocker arm covers. 5. Disconnect throttle cable from carburetor. Re-
move fuel line and sight tube running between
3. Remove rocker arm cover.
fuel pump and carburetor.
6. Remove distributor cap and mark position of rotor
Installation on distributor housing. Also, mark position of dis-
tributor housing on intake manifold. Remove dis-
1. Clean sealing surfaces on cylinder head and tributor.
rocker arm cover with degreaser.
2. Place new rocker arm cover gasket in position in IMPORTANT: Do not crank engine over after dis-
rocker arm cover. tributor has been removed.
7. Remove other ignition components.
8. Remove oil sending unit.
a
9. Disconnect any other miscellaneous items that
will prevent removal of manifold.
IMPORTANT: It may be necessary to pry intake

manifold away from cylinder heads and block, in
next step. Use extreme care to prevent damage to
sealing surfaces.
10. Remove intake manifold bolts, then remove in-
take manifold and carburetor assembly.
NOTE: If intake manifold requires replacement,
72324 transfer all remaining parts to new manifold.
a - Rocker Arm Cover Gasket
Cleaning and Inspection

3. Install rocker arm cover. Torque screws to 90 lb. 1. Clean gasket material from all mating surfaces.
in. (10 N·m).
4. Reinstall exhaust manifolds, if removed. IMPORTANT: When cleaning cylinder head mat-
5. Reinstall any items which were removed to allow ing surface, do not allow gasket material to enter
removal of rocker arm covers. engine crankcase or intake ports.
6. Connect crankcase ventilation hoses to rocker 2. Inspect manifold for cracks or scratches. Ma-
arm covers. chined surfaces must be clean and free of all
marks and deep scratches or leaks may result.
7. Start engine and check for oil leaks.
3. Check intake passages for varnish buildup and
other foreign material. Clean as necessary.
Index
3A-24 - ENGINES 90-823225--1 1096
Installation 2. Place gaskets on cylinder heads.
3. Apply a 3/16 in. (5 mm) wide bead of Quicksilver
ALL ENGINES EXCEPT GEN+ RTV Sealer to engine block as shown. Extend
sealer 1/2 in. (13 mm) up on intake gaskets.
IMPORTANT: When installing intake manifold IMPORTANT: DO NOT get Quicksilver RTV Sealer
gaskets, in next step, be sure to do the following: into oil sending unit hole at rear of engine.
• Be sure to install gasket with marked side up.
Both gaskets are identical.
• On the 5.0L engine with 2 barrel carburetor,
remove metal insert from manifold gasket to a
be used on starboard (right) cylinder head to
provide clearance for heat pipe on intake
manifold.
• All MerCruiser V-8 GM engines that have “au-
tomatic” carburetor chokes must use an in-
take gasket that has an opening for the ex-
haust crossover port in the intake manifold.
Without this opening the “automatic” carbu-
retor choke will not operate properly. The
choke will remain ON longer causing rough
engine operation and wasted fuel.
a
1. Apply Quicksilver Perfect Seal to intake manifold
gaskets around coolant passages (both sides).
72325
a - Coolant Passages
b
a
72325
72326
a - Exhaust Crossover Port Opening in Gasket
b - Intake Valve Ports a - Oil Sending Unit Hole
Index
90-823225--1 1096 ENGINES - 3A-25
4. Carefully install manifold assembly and torque GEN+ ENGINES
bolts to 35 lb. ft. (48 N·m) in sequence as shown.
6 8
7 IMPORTANT: When installing intake manifold
gaskets, in next step, be sure to do the following:
2 1. Apply a 3/16 in. (5 mm) wide bead of Quicksilver
RTV Sealer to engine block as shown. Extend
3
5 sealer 1/2 in. (13 mm) up on intake gaskets.
9 2. Apply Loctite Pipe Thread Sealant to the threads
1 of the four inner manifold bolts.
4 a
11 10
b
12
72327
Intake Manifold Torque Sequence
5. Connect all electrical leads.

6. Connect hoses to thermostat housing.
7. Install fuel line and sight tube to carburetor and
fuel pump.
b
8. Connect crankcase ventilation hoses to rocker
arm covers.
9. Install distributor. Position rotor and housing to
align with marks made during removal, then in- 72325
stall distributor cap. a
10. Install other ignition components and reconnect a - 3/16 Bead Of RTV Sealer
wires. b - Apply Loctite Pipe Thread Sealant
11. Coat threads of oil pressure sending unit with
Quicksilver Perfect Seal and install. IMPORTANT: DO NOT get Quicksilver RTV Sealer
into oil sending unit hole at rear of engine.
12. Connect any other items which were discon-
nected from manifold during removal. a
13. Start engine. Adjust ignition timing and carbure-
tor. Check hose connections, gaskets and seals
for leaks.
14. Inspect fuel line connections for fuel leaks.
72326
a - Oil Sending Unit Hole
Index
3A-26 - ENGINES 90-823225--1 1096
3. Carefully install manifold assembly and torque 2. Remove rocker arm assemblies and push rods.
bolts to 18 lb. ft. (24 N·m) in sequence as shown.
IMPORTANT: Place rocker arm assemblies and
5 1 4 8 push rods in a rack for reassembly in their origi-
nal locations.
FRONT
7 3 2 6
1. Clean parts with solvent and dry with com-
pressed air.
72878
2. Inspect all contact surfaces for wear. Replace all
4. Connect all electrical leads. damaged parts.
5. Connect hoses to thermostat housing.
6. Install fuel line and sight tube to carburetor and Installation
fuel pump.
7. Connect crankcase ventilation hoses to rocker IMPORTANT: When installing rocker arms and
arm covers. rocker arm balls, coat bearing surfaces of rocker
arms and rocker arm balls with engine oil.
8. Install distributor. Position rotor and housing to
align with marks made during removal, then in- 1. Install push rods in their original locations. Be
stall distributor cap. sure push rods seat in lifter socket.
9. Install other ignition components and reconnect 2. Install rocker arms, rocker arm balls and rocker
wires. arm nuts in their original locations.
10. Coat threads of oil pressure sending unit with 3. Adjust valves as outlined under “Valve Adjust-
Quicksilver Perfect Seal and install. ment - Engine Stopped.”
11. Connect any other items which were discon-
nected from manifold during removal.
12. Start engine. Adjust ignition timing and carbure- Valve Adjustment
tor. Check hose connections, gaskets and seals
for leaks.
Engine Stopped
13. Inspect fuel line connections for fuel leaks.
With valve cover removed, adjust valves when lifter
is on low part of camshaft lobe, as follows:
Rocker Arm/Push Rod 1. Crank engine with starter or turn over in normal
direction of rotation until mark on torsional damp-
er lines up with center “0” mark on timing tab, and
Removal engine is in No. 1 firing position. This may be de-
termined by placing fingers on No. 1 valve as
NOTE: When servicing only one cylinder’s rocker mark on torsional damper comes near “0” mark
arms, bring that cylinder’s piston up to TDC before re- on timing mark. If valves move as mark comes up
moving rocker arms. When servicing all rocker arms, to timing tab, engine is in No. 6 firing position and
bring No. 1 piston up to TDC before removing rocker should be turned over one more time to reach No.
arms. 1 position.
1. Remove rocker arm covers as outlined.
Index
90-823225--1 1096 ENGINES - 3A-27
2. With engine in No. 1 firing position as determined 6. Crank engine one revolution until pointer “0”
above, the following valves may be adjusted. mark and torsional damper mark are again in
alignment. This is No.6 firing position. With en-
gine in this position, the following valves may be
adjusted as previously outlined.
7. MCM and MIE Left-hand (Standard Rotation
Engines:
Exhaust - 2-5-6-7 Intake - 3-4-6-8
MIE Right-Hand (Opposite) Rotation En-
gines:
Exhaust - 3-4-6-8 Intake - 2-5-6-7
Engine Running
Following procedure is performed with engine run-
ning:
1. After engine has been rechecked for normal op-
72328 erating temperature, remove rocker arm covers
and install rocker stoppers as shown.
3. MCM and MIE Left-Hand (Standard) Rotation

Engines:
Exhaust - 1-3-4-8 Intake - 1-2-5-7 a
MIE Right-Hand (Opposite) Rotation En-
gines:
Exhaust - 1-2-5-7 Intake - 1-3-4-8
4. Back out adjusting nut until lash is felt at push rod,
then turn in adjusting nut until all lash is removed.
This can be determined by moving push rod up
and down while turning adjusting nut until all play
is removed.
72301
a - Rocker Stoppers (91-66273)
2. With engine running at idle, loosen rocker arm

nuts (one at a time) until rocker arm starts to clat-
ter.
3. Turn rocker arm nut down until clatter just stops.
This is zero lash position.
4. Turn nut down 1/4 additional turn and pause 10
seconds until engine runs smoothly. Repeat until
nut has been turned down one turn from the zero
lash position.
72300
IMPORTANT: This one-turn preload adjustment

must be done slowly to allow the lifter to adjust
5. Hydraulic lifters now can be adjusted by tighten- itself and prevent the valves from hitting the pis-
ing adjustment nut an additional one turn. No oth- tons, causing internal damage and/or bent push
er adjustment is required. rods.
Index
3A-28 - ENGINES 90-823225--1 1096
5. Repeat Steps 2, 3, 4 to adjust other valves. Locating Noisy Lifters
6. Remove rocker stoppers after all valves are ad- Locate a noisy valve lifter by using a piece of garden
justed. hose approximately 4 ft. (1.2 m) in length. Place one
7. Install rocker arm covers; torque screws to 90 lb. end of hose near end of each intake and exhaust
in. (10 N·m). valve, with other end of hose to the ear. In this man-
ner, sound is localized, making it easy to determine
8. Adjust carburetor idle mixture and idle speed. which lifter is at fault.
Check for leaks.
Another method is to place a finger on face of valve
spring retainer. If lifter is not functioning properly, a
distinct shock will be felt when valve returns to its
Hydraulic Valve Lifters seat.
(Flat and Roller Lifter) General types of valve lifter noise are as follows:
1. Hard rapping noise - usually caused by plunger
1
2 becoming tight in bore of lifter body so that return
3 spring cannot push plunger back up to working
4 position. Probable causes are:
5 a. Excessive varnish or carbon deposit, causing

6 abnormal stickiness.
7
FLAT 8 b. Galling or “pickup” between plunger and bore
of lifter body, usually caused by an abrasive
9
piece of dirt or metal wedged between plung-
er and lifter body.
1 2. Moderate rapping noise - probable causes are:
2 a. Excessively high leakdown rate.
3
4 72030
b. Leaky check valve seat.
5 c. Improper adjustment.
6
7 3. General noise throughout valve train - this will, in
8 most cases, be a definite indication of insufficient
9 oil supply or improper adjustment.
ROLLER
4. Intermittent clicking - probable causes are:
a. A microscopic piece of dirt momentarily
caught between ball seat and check valve
ball.
b. In rare cases, ball itself may be out of round
72031 or have a flat spot.
1 - Push Rod Seat Retainer
2 - Push Rod Seat
c. Improper adjustment.
3 - Metering Valve In most cases, where noise exists in one or more lift-
4 - Plunger
5 - Check Ball
ers, all lifter units should be removed, disassembled,
6 - Check Ball Spring cleaned in solvent, reassembled and reinstalled in
7 - Check Ball Retainer engine. If dirt, corrosion, carbon, etc., is shown to ex-
8 - Plunger Spring ist in one unit, it more likely exists in all the units; thus
9 - Lifter Body
it would only be a matter of time before all lifters
caused trouble.
Hydraulic valve lifters require little attention. Lifters
are extremely simple in design. Normally, readjust-
ments are not necessary and servicing requires only
that care and cleanliness be exercised in the handl-
ing of parts.
Index
90-823225--1 1096 ENGINES - 3A-29
Removal Cleaning and Inspection
Thoroughly clean all parts in cleaning solvent and in-
IMPORTANT: Keep push rod and hydraulic valve spect them carefully. If any parts are damaged or
lifter from each valve together as a matched set worn, entire lifter assembly should be replaced. If
and mark them so they can be reinstalled in the outer lifter body wall is scuffed or worn, inspect cylin-
same location later. der block lifter bore. If bottom of lifter is scuffed or
Remove as outlined: worn, inspect camshaft lobe. If push rod seat is
scuffed or worn, inspect push rod.
1. Remove rocker arm covers.
2. Remove intake manifold.
Installation
3. Remove lifter restrictor retainer on roller lifter
models.
IMPORTANT: It is recommended that the engine
4. Remove rocker arm assemblies and push rods.
oil be changed and a new oil filter be installed
NOTE: Engines with roller lifters have additional whenever servicing valve lifters or camshaft.
valve train components shown below.
IMPORTANT: Before installing lifters/rollers, coat
b the bottom of the lifter/roller with engine oil. If
new lifters or a new camshaft have been in-
stalled, an additive containing EP lube (such as
a General Motors Cam and Lifter Prelube or equiv-
alent) should be poured over camshaft lobes be-
fore installing lifters.
IMPORTANT: Before installation, coat entire

valve lifter with engine oil.
72329 IMPORTANT: DO NOT install used valve lifters if

a - Lifter Restrictor Retainer a new camshaft has been installed.
b - Fasteners 1. Install hydraulic valve lifters and components.
Torque roller lifter restrictor retainer plate fasten-
ers to 12 lb. ft. (16 N·m) on roller lifter engines.
a 2. Install intake manifold.
3. Install and adjust valve mechanism as outlined.
4. Install rocker arm cover.
b 5. Start engine and check for leaks.
Valve Stem Oil Seal/Valve

Spring
72340
a - Roller Lifter Restrictor Removal - Head Installed

b - Roller Lifter
1. Remove:
a. Rocker arm cover.
5. Remove lifter restrictors on roller lifters models.
b. Spark plug of affected cylinder.
c. Rocker arm assembly.
Index
3A-30 - ENGINES 90-823225--1 1096
2. Install air line adaptor tool (J-23590) in spark plug 5. Remove seals from valve stems and valve guide.
hole and apply compressed air to hold valves in
place.
NOTE: If compressed air is not available, piston may
be brought up to TDC and used to keep valves from
falling out of valve guides. a
IMPORTANT: Do not turn crankshaft while valve

springs, retainers, and locks are removed or
valves will fall into cylinder.
3. Using valve spring compressor as shown, com-
press valve spring and remove valve locks.
72330
a - Valve Guide Seal
b
a
72306
a - Valve Spring Compressor (J-5892)

b - Rocker Arm Nut
4. Slowly release valve spring compressor. Re-

move cap, shield, and valve spring.
IMPORTANT: Keep air pressure in cylinder while

springs, caps, and valve locks are removed or
valves will fall into cylinder.
Index
90-823225--1 1096 ENGINES - 3A-31
Valve Assembly (Exploded View) 5. Install valve locks (Quicksilver Needle Bearing
Assembly Lubricant may be used to hold them in
1 place) and slowly release tool, making sure locks
seat properly in upper grooves of valve stem.
2 1
4
5 b
6
a
72306
9
a - Valve Spring Compressor (J-%892)
b - Rocker Arm Nut
6. Install push rods and rocker arm assemblies.

10 7. Adjust valves as outlined under “Valve Adjust-
11 ment - Engine Stopped.”
8. Install rocker arm cover [torque to 90 lb. in.
(10 N·m)] and spark plug [torque to 15 lb. ft.
(20 N·m)].
1 - Valve Locks 72331

2 - Retainer
3 - Rotator
Cylinder Head
4 - Cap
5 - Valve Guide Oil Seal
6 - Oil Shield Removal
7 - Valve Stem Oil Seal
8 - Inner Spring 1. Drain engine cooling system.
9 - Outer Spring
10 -Intake Valve 2. Remove as outlined:
11- Exhaust Valve
a. Exhaust manifolds.
b. Intake manifold.
Installation - Head Installed
c. Rocker arm covers.
1. Install valve guide seal (intake valve only) over
d. Rocker arm assemblies and push rods (keep
valve stem and push down until seated against
in order for reassembly in their original loca-
head.
tions).
2. Set valve spring (with damper installed) and
e. Any components attached to front or rear of
shield in place.
cylinder head.
3. Place cap on intake valve and/or rotator on ex-
f. Spark plugs.
haust valve.
g. Head bolts.
4. While compressing valve spring with valve spring
compressor, install oil seal in lower groove of
valve stem, making sure seal is not twisted. A
light coating of oil will help prevent twisting.
Index
3A-32 - ENGINES 90-823225--1 1096
! CAUTION a. All Engines Except Gen+: Torque head
bolts in three steps, following torque se-
The head gasket may be holding cylinder head to quence for each step. Start first step at 20 lb.
block. Use care when prying off cylinder heads. ft. (27 N·m), second step at 40 lb. ft. (54 N·m),
DO NOT damage gasket surfaces. DO NOT drop and finish with a final torque of 65 lb. ft. (88
cylinder heads. N·m).
3. Place cylinder head on wooden blocks to prevent
damage to gasket surfaces.

1. Clean gasket material and sealer from engine
block and cylinder heads.
72332
2. Inspect sealing surfaces for deep nicks and
scratches. b. Gen+ Engines Only: Torque cylinder heads
in two steps. Initial pass, torque all bolts to 22
3. Inspect for corrosion around cooling passages.
lb. ft. (30 N·m). Second pass is an angle
4. Clean head bolt threads and engine block bolt torque sequence:
hole threads, making sure no dirt, old oil or cool- short bolts 55 degrees
ant remain. medium bolts 65 degrees
long bolts 75 degrees
4. Install push rods and rocker arm assemblies in
Installation their original positions. On roller cam engines
only, install baffle plate and retainers.
! CAUTION 5. Adjust valves as outlined under “Valve Adjust-
ment - Engine Stopped.”
When using ribbed stainless steel head gaskets,
apply a thin coating of Quicksilver Perfect Seal to 6. Install as outlined:
both sides of gasket. Too much sealer may hold a. Intake manifold.
gasket away from head or block causing leakage.
DO NOT use sealer on graphite composition b. Rocker arm covers.
head gaskets. c. Exhaust manifolds.
1. Place head gasket in position over dowel pins. d. Spark plugs.
2. Carefully set cylinder head in place over dowel e. Any components removed from front or rear
pins. of cylinder heads.
3. Coat threads of head bolts with Quicksilver Per- 7. Follow procedures in Section 6A or 6B of this
fect Seal and install finger-tight. manual:
Seawater Cooled Models: Provide for adequate
water supply to seawater pickup (see Section
6A).
Closed Cooled Models: Refill closed cooling
section (see Section 6B), and provide adequate
water supply to seawater pickup.
! CAUTION
Ensure that cooling water supply is available be-
fore starting the engine.
8. Start engine, set timing, set idle speed, and
check for leaks.
Index
90-823225--1 1096 ENGINES - 3A-33
Cylinder Head and Valve 4. Clean all carbon from combustion chambers and
valve ports using carbon remover brush.
Conditioning
a
Disassembly
1. Using valve spring compressor, compress valve
spring and remove valve locks. Slowly release
tool.
72334
a - Carbon Remover Brush (J-8089)
5. Thoroughly clean valve guides with valve guide

cleaner.
72333
2. Remove all valve components.

3. Remove valves from cylinder head and place in a
a rack, in order, for reassembly in their original lo-
cations.
Cleaning
1. Clean push rods and rocker arm assemblies.
2. Clean carbon from valves using a wire wheel.
72335
3. Clean gasket material from cylinder head mating
surfaces. a - Valve Guide Cleaner (J-8101)
Inspection
1. Inspect cylinder heads for cracks in exhaust
ports, water jackets, and combustion chambers
(especially around spark plug holes and valve
seats). Replace heads if any cracks are found.
Index
3A-34 - ENGINES 90-823225--1 1096
2. Inspect cylinder head gasket surface for burrs, b. Holding valve head off seat about 1/16 in. (2
nicks, or erosion or other damage. Also, check mm), move valve stem back and forth in di-
flatness of cylinder head gasket surface, using a rection shown. Compare stem clearance with
machinist’s straight edge and feeler gauges as specifications.
shown. Refer to “Specifications.”
c. If clearance exceeds specifications, it will be
necessary to ream valve guides for oversized
valves, as outlined under “Valve Guide Bore
a Repair.”
b
b
c
72307
a - Straight Edge
b - Feeler Gauge
c - Take Measurements Diagonally Across Head Both Ways)
and Straight Down Center Head
a
72336
IMPORTANT: Cylinder head-to-block gasket sur- a - Valve Stem
face should be resurfaced if warped more than b - Dial Indicator
specified. When head resurfacing is required, c - Valve Guide
cylinder head-to-intake manifold gasket surface
on head must be milled to provide proper align-
ment between intake manifold and head.
Valve Guide Bore Repair
3. Inspect valves for burned heads, cracked faces
or damaged stems.
IMPORTANT: Be sure to measure valve stem di-
ameter of both the intake and exhaust valve, as
IMPORTANT: Excessive valve stem to bore clear- valve stem diameter may or may not be the same
ance will cause excessive oil consumption and for both valves.
possible valve breakage. Insufficient clearance
will result in noisy and sticky valves. If .015 in. oversize valves are required, ream valve
guide bores for oversize valves, as follows:
4. Measure valve stem clearance as follows:
1. Measure valve stem diameter of old valve being
a. Attach a dial indicator to cylinder head, posi- replaced and select proper size valve guide
tioning it against the valve stem and close to reamer from chart below.
the valve guide.
Standard Valve Reamer Required for
Stem Diameter .015 In. Oversize Valve
.341 In. J-5830-2
.372 In. J-7049
Index
90-823225--1 1096 ENGINES - 3A-35
2. Ream valve guide bores, as shown. Valve Springs - Checking Tension
Using valve spring tester, as shown, check valve
spring tension with dampers removed. Refer to
“Specifications.”
IMPORTANT: Springs should be replaced if not

within 10 lb. ft. (13.5 N•m) of specified tension.
72337
3. Remove the sharp corner created by reamer at

top of valve guide.
72308
a - Valve Spring Tester (P/N J-8056)

b - Torque Wrench
Index
3A-36 - ENGINES 90-823225--1 1096
Rocker Arm Stud Replacement 5. Ream stud hole, whenever installing an oversize
stud, using appropriate reaming tool.
1. Rocker arm studs which are worn or loose should
be replaced with oversize studs. 6. Install new stud with rocker arm stud installer.
2. Use rocker arm stud remover to partially remove

old stud by placing large sleeve, flat washer and
nut over stud, then turn nut until it bottoms out on
stud threads.
3. Remove nut and install small sleeve on stud.
a
4. Install nut on stud and turn nut to remove stud.
a b
72311
a - Rocker Arm Stud Installer (J-6880)
72309
Valve Seat Repair
a - Large Sleeve Valve seat reconditioning is very important, since
b - 3/8-24 Thd. Nut - Turn until Nut Bottoms Out on seating of valves must be perfect for engine to deliver
Stud Threads, Then Remove Nut Using Rocker maximum power and performance.
Arm Stud Remover (J-5802-01)
Another important factor is valve head cooling. Good
contact between each valve and its seat in head is
important to ensure that heat in valve head will be
properly dispersed.
b a
72310
a - Nut
b - Small Sleeve
c - Large Sleeve
Index
90-823225--1 1096 ENGINES - 3A-37
Several different types of equipment are available for Valve Grinding
reseating valve seats. Equipment manufacturer’s
recommendations should be followed carefully to at- Valves that are pitted must be refaced to the proper
tain proper results. angle. Valve stems which show excessive wear, or
valves that are warped excessively, must be re-
placed. When a valve head which is warped exces-
a sively is refaced, a knife edge will be ground on part
d
b c or all of the valve head, due to the amount of metal
that must be removed to completely reface. Knife
edges lead to breakage, burning, or pre-ignition due
to heat localizing on this knife edge. If the edge of the
valve head is less than 1/32 in. (0.8 mm) after grind-
ing, replace the valve.
Several different types of equipment are available for
refacing valves. The recommendation of the man-
50668 ufacturer of the equipment being used should be
Typical “3 Angle” Valve Seat carefully followed to attain proper results.
a - Top Angle (30°) EXHAUST INTAKE
b - Seat Angle (46°)
c - Bottom Angle (60°)
d - Seat Width
Intake 1/32-1/16 [.031-.063] In. (0.8-1.5 mm)
Exhaust 1/16-3/32 [.063-.094] In. (1.6-2.3 mm) a a
Regardless of type of equipment, however, it is es-

sential that valve guide bores be free from carbon or
dirt to achieve proper centering of pilot in valve guide,
ensuring concentricity.
b b
50695
Exhaust
a - .372 In. (9.45 mm)
b - 1/32 [.031] In. (0.79 mm) Min.
Intake
a - .341 In. (8.16 mm)
b - 1/32 [.031] In. (0.79 mm) Min.
Reassembly
1. Lubricate valve guides and valve stems with en-
72338 gine oil.
Measuring Valve Seat Concentricity 2. Install each valve in the port from which it was re-
moved or to which it was fitted.
3. Install valve guide seal (intake valve only) over
valve stem and push down until seated against
head.
4. Set valve spring (with damper installed) and
shield in place.
Index
3A-38 - ENGINES 90-823225--1 1096
5. Place cap on intake valve and/or rotator on ex- 7. Install valve locks (grease may be used to hold
haust valve. them in place) and slowly release tool, making
sure locks seat properly in upper grooves of valve
6. While compressing valve spring with valve spring
stem.
compressor, install oil seal in lower groove of
valve stem, making sure seal is not twisted. A 1
light coating of oil will help prevent twisting. 2 1
a 3
5 4
6
7
10
11
72333
72331
1 - Valve Locks
2 - Retainer
3 - Rotator
4 - Cap
5 - Valve Guide Oil Seal
6 - Oil Shield
7 - Valve Stem Oil Seal
8 - Inner Spring
9 - Outer Spring
10 -Intake Valve
11- Exhaust Valve
Index
90-823225--1 1096 ENGINES - 3A-39
8. Check installed height of valve springs using a
narrow, thin scale. Measure from spring seat to
top of valve spring, as shown. If measurement
exceeds specified height, install a valve spring
shim and recheck. DO NOT shim valve springs to
give an installed height less than the minimum
specified.
05037
Cutaway Scale
72339
a - Valve Spring Installed Height
Index
3A-40 - ENGINES 90-823225--1 1096
Dipstick Specifications
All Engines
UNIT OF MEASUREMENT
In. (mm)
1/2 1/2 1/2 1/2

(13) (13) (13) (13)
31 (787) 13-29/32 32 14-25/32

(353) (814) (375)
33-1/4 (845) 15-19/32 (396) 33-1/2 (849) 16-1/4 (413)
FULL FULL FULL FULL 23/32

3/4 15/16 3/4
(24) (19) (18)
ADD (19) ADD ADD ADD
72341
15297 805395 16482 805394
MCM (All) MIE Inboards MIE Ski Models MIE Inboards
with In-Line or (All) with V-Drive
Down-Angle Transmissions*
Transmissions*
* Engines with Plastisol Coated Oil Pans
Index
90-823225--1 1096 ENGINES - 3A-41
Oil Pan IMPORTANT: Quicksilver RTV Sealer sets up in
about 15 minutes. Be sure to complete assembly
promptly.
Removal
1. Drain crankcase oil.
a
2. If necessary, disconnect outlet hose from seawa- b
ter pump.
3. Remove dipstick and tube. On MIE models, be
carefull not to disturb orientation of banjo fit-
ting on bottom of pan.
b a
72343
a - Joints of Rear Seal Retainer
b - Joints of Front Cover
3. Install oil pan gasket in position as shown.
71859
NOTE: A one-piece oil pan gasket may be re-used if
it is still pliable and is not cracked, torn or otherwise
a - Banjo Fitting
b - Dipstick Tube damaged.
4. Remove oil pan.

a
Installation
1. Clean sealing surfaces of engine block and oil
pan.
2. Apply a small amount of Quicksilver RTV Sealer
to joints of rear seal retainer and joints of front
cover.
72344
a - Oil Pan Gasket
4. Install oil pan. Starting from the center and work-

ing outward in each direction, tighten 1/4-20 thd.
fasteners to 80 lb. in. (9 N·m) and 5/16-18 thd.
fasteners to 165 lb. in. (19 N·m).
Index
3A-42 - ENGINES 90-823225--1 1096
5. Install dipstick tube and dipstick. On MIE mod- c. Install plug in banjo fitting.
els, install dipstick tube as follows:
d. Tighten all connections on banjo fitting at this
a. Install banjo fitting as shown. Do not tighten time. Torque banjo fitting bolt to 180 lb. in. (20
banjo fitting bolt at this time. N⋅m). Tighten dipstick tube and plug securely.
NOTE: Dipstick tube can be positioned on either side e. Install appropriate gage.
of engine.
6. Fill crankcase with required quantity of oil of spe-
b. Install dipstick tube and secure with hardware cified viscosity. See Section 1B - “Maintenance.”
as shown. Do not tighten tube at banjo fitting
until after tube has been secured at manifold.
c
c
d
b b
71861
71859
a - Banjo Fitting
b - Banjo Fitting Bolt
c - Plug
d - Gaskets
g
e - Dipstick Tube
f - Clamp (Secured by Manifold Screw)
g - Gage
f
e
71860
Index
90-823225--1 1096 ENGINES - 3A-43
Oil Pump Removal
3 5 1. Remove oil pan as outlined.
9
7 2. Remove gasket carefully as the one-piece gas-
ket for the oil pan may be reused if still pliable and
12 not cracked, torn, etc.
8 3. Remove baffle.
11
4
1
10
2
6
72146
Oil Pump Assembly

1 - Extension Shaft a
2 - Shaft Coupling
3 - Pump Body
4 - Drive Gear and Shaft
5 - Idler Gear b c 72344
6 - Pick Up Screen and Pipe
7 - Pump Cover a - Nuts (5)
8 - Pressure Regulator Valve b - Baffle
9 - Pressure Regulator Spring c - Oil Pump
10- Plug
11- Screws
4. Remove oil pump
The oil pump consists of two gears and a pressure
regulator valve enclosed in a two-piece housing. Oil
pump is driven by distributor shaft which is driven by Disassembly
a helical gear on camshaft. 1. Remove pump cover.
IMPORTANT: Mark gear teeth for reassembly with

same teeth indexing.
2. Remove idler gear and drive gear from pump
body.
3. Remove retaining pin, spring, and pressure regu-
lator valve from pump cover.
IMPORTANT: Do not remove pickup screen and

pipe assembly, unless replacement is necessary.
Loss of press fit condition could result in an air
leak and loss of oil pressure.
IMPORTANT: Do not disturb pickup screen on

pipe. This is serviced as an assembly.
4. If pickup screen and pipe assembly requires re-
placement, mount pump in a soft-jawed vise and
extract pipe from pump.
Index
3A-44 - ENGINES 90-823225--1 1096
Cleaning and Inspection Installation
1. Wash all parts in cleaning solvent and dry with 1. Install pump, with extension shaft, to rear main
compressed air. bearing, aligning extension shaft with distributor
drive shaft.
2. Inspect pump body and cover for cracks or ex-
cessive wear. 2. Install baffle. Tighten baffle nuts to 25 lb. ft. (34
N·m). Tighten oil pump bolt to 65 lb. ft. (88 N·m).
3. Inspect pump gears for damage and excessive
wear.
4. Check for loose drive gear shaft in pump body.
5. Inspect inside of pump cover for wear that would
permit oil to leak past ends of gears.
6. Inspect pickup screen and pipe assembly for
damage to screen and pipe.
7. Check pressure regulator valve for fit.
IMPORTANT: Pump gears and body are not serv-

iced separately. If pump gears or body are dam-
aged or worn, replacement of entire oil pump as- a
sembly is necessary.
Reassembly b c 72344
a - Nuts (5)
b - Baffle
! CAUTION c - Oil Pump
Be careful of twisting, shearing or collapsing
pipe while installing in pump. Pickup screen
must be parallel to oil pan bottom when oil pump 3. Install oil pan as outlined. The one-piece gasket
is installed. for the oil pan may be reused if still pliable and not
If pickup screen and pipe assembly was removed, cracked, torn, etc.
mount pump in a soft-jawed vise, apply Quicksilver
Perfect Seal to end of new pipe and, using oil pump
suction pipe installer (J-21882), tap the pipe in place
with a hammer.
IMPORTANT: Oil internal parts liberally before in-

stallation.
1. Install pressure regulator valve and related parts.
2. Install drive gear in pump body.
3. Install idler gear in pump body with smooth side
of gear toward pump cover opening. Align marks
made in disassembly.
4. Fill gear cavity with engine oil.
5. Install pump cover and torque attaching screws
to 80 lb. in. (9 N·m).
6. Turn extension shaft by hand to check for smooth
operation.
Index
90-823225--1 1096 ENGINES - 3A-45
Torsional Damper 3. Install torsional damper on crankshaft, using tor-
sional damper remover and installer as follows:
a. Install appropriate end of threaded rod into
Removal crankshaft.
1. Remove drive belts.
IMPORTANT: Be sure to install threaded rod in
2. Remove drive pulley, then remove torsional crankshaft at least 1/2 in. (13 mm) to prevent dam-
damper retaining bolt. age to threads.
b. Install plate, thrust bearing, washer and nut
IMPORTANT: Do not use a universal claw type on rod.
puller to remove torsional damper (in next step)
as outside ring of torsional damper is bonded in c. Install torsional damper on crankshaft by
rubber to the hub and use of claw type puller may turning nut until it bottoms out.
break the bond.
3. Remove torsional damper with torsional damper
remover and installer.
72346
a - Torsional Damper Remover and Installer

a (J-23523-E)
72345
d. Remove tool from crankshaft.
a - Torsional Damper Remover and
Installer (J-23523-E) e. To prevent oil leakage, apply Quicksilver RTV
sealant to torsional damper keyway.
f. Install torsional damper bolt. Torque to 60 lb.
ft. (81 N·m).
Installation
4. Install drive pulley(s). Torque bolts to 35 lb. ft.
(48 N·m).
IMPORTANT: The inertia weight section of tor-
sional damper is assembled to the hub with a rub- 5. Install and adjust drive belts.
ber type material. The installation procedure
(with proper tool) must be followed or movement
of the inertia weight on the hub will destroy the
tuning of the torsional damper.
1. Replace key in crankshaft if it is damaged.
2. Coat seal surface of torsional damper with en-
gine oil.
Index
3A-46 - ENGINES 90-823225--1 1096
Crankcase Front Cover/
Oil Seal
Oil Seal Replacement
(Without Removing Front Cover)
c
IMPORTANT: The following information refers to
all engines except Gen+ Engines. Crankcase d
front cover is not reusable per G.M. Specifica-
tion. It must be replaced if removed.
73125
b
REMOVAL b - MIE (RH) Rotation Engines
1. Remove torsional damper. c - Seal Lip Toward Inside of Engine
d - Rotation of Crankshaft as Viewed from
2. Pry seal out of cover from the front with a large Front End Looking Toward Flywheel End
screwdriver, being careful not to distort front cov- Front Seals WITH Helical Grooves
er or damage crankshaft.
1. Apply Quicksilver Perfect Seal to seal retainer
INSTALLATION
mating surface and apply grease to seal lips.
IMPORTANT: Correct rotation oil seal must be 2. Install new seal with open end of seal inward, us-
used to prevent oil leak. ing crankcase front cover seal installer. Drive
seal in until it just bottoms out. Do not use exces-
sive force.
a
73123
Front Seal WITHOUT Helical Grooves

a - Can Be Used on Any Rotation Engine a
b - Seal Lip Toward Inside of Engine 72347
a - Crankcase Front Cover Seal Installer (J-35468)
3. Reinstall torsional damper as outlined.
c d
73124
a - MCM and MIE (LH) Rotation Engines
Index
90-823225--1 1096 ENGINES - 3A-47
Crankcase Front Cover 2. Coat both sides of front cover gasket with Quick-
silver Perfect Seal and place in position on en-
gine.
IMPORTANT: The following information refers to
all engines except Gen+ Engines. Crankcase 3. Install front cover, making sure holes in cover
front cover is not reusable per G.M. Specifica- align with dowel pins in block. Torque front cover
tion. It must be replaced if removed. attaching screws to 100 lb. in. (11 N·m).
4. Install oil pan and torsional damper as outlined.
5. Install water circulating pump.
Removal
6. Reinstall engine in boat.
1. Remove engine from boat if necessary to gain
access to cover. 7. Fill crankcase with engine oil.
2. Remove torsional damper and oil pan. 8. Follow procedures in Section 6A or 6B of this
manual:
3. Remove water circulating pump.
Seawater Cooled Models: Provide for adequate
4. Remove crankcase front cover. water supply to seawater pickup (see Section
5. If damaged, drive oil seal out of front cover (from 6A).
the rear) using a punch. Closed Cooled Models: Refill closed cooling
section (see Section 6B), and provide adequate
water supply to seawater pickup.
Clean front cover in solvent and dry with compressed ! CAUTION
air. Clean old gasket material and sealer from mating
surfaces on cover and cylinder block. Check gasket Ensure that cooling water supply is available be-
surface on front cover for distortion, and true if neces- fore starting the engine.
sary. Surfaces must be clean and flat or oil leakage 9. Start engine and check for water and oil leaks.
may result.
Installation Flywheel
1. Install oil seal in cover with lip of seal toward in-
side of engine, using crankcase front cover seal Removal
installer. Support cover around seal area with ap-
propriate tool as shown. 1. Remove engine from boat.
2. Remove transmission, if so equipped.
3. Refer to “Flywheel Housing” description in this
a section and remove flywheel housing and related
parts.
4. Remove MCM coupler or MIE drive plate.
72348
a - Crankcase Front Cover Seal Installer J-35468)

b - Support (to Prevent Distorting Cover)
Index
3A-48 - ENGINES 90-823225--1 1096
5. Remove flywheel.
NOTE
72349
Alpha One Coupler 72352
NOTE: Some earlier models did not have sealed, Jack Shaft Coupler
steel hub coupler.
Inspection
1. Inspect splines in drive plate or coupler for wear.
2. Check flywheel ring gear for worn and missing
teeth.
72350
Bravo Coupler
72351
MIE Drive Plate
Index
90-823225--1 1096 ENGINES - 3A-49
Installation IMPORTANT: Insert three rubber bumpers in Al-
pha coupler before installation on flywheel.
NOTE: If crankshaft is to be replaced, but old pilot
bushing is to be reused, bushing can be removed
without damage by filling pilot bushing cavity with a
grease, then inserting an old transmission input shaft
in bore of bushing and hitting it with a hammer. This
will create hydraulic pressure in pilot bushing cavity
which should force bushing out.
1. Clean mating surfaces of flywheel and crank-
shaft. Remove any burrs. Mating surfaces must
be clean bare metal.
2. Aligning dowel hole in flywheel with dowel in
crankshaft, install flywheel. Torque bolts to 75 lb.
ft. (100 N·m).
3. Check flywheel runout as follows:
a. Attach a dial indicator to engine block.
b. Take readings around outer edge of flywheel.
Push in on flywheel to remove crankshaft end 72354
play.
a - Rubber Bumper
c. Maximum runout - .008 in. (0.203 mm).
4. Install drive coupler or drive plate. Torque bolts to

35 lb. ft. (48 N·m).
5. Install flywheel housing and related parts. Torque
bolts to 30 lb. ft. (41 N·m).
b a
6. Install flywheel housing cover. Torque bolts to 80
lb. in. (9 N·m).
7. Install transmission (MIE). Torque bolts to 50 lb.
ft. (68 N·m).
8. Refer to Section 2 “Removal and Installation” and
install engine.
72353
a - .008 in. (0.203 mm) Max. Runout

b - Push Flywheel and Crankshaft Forward as Far
as It Will Go when Taking Reading
Index
3A-50 - ENGINES 90-823225--1 1096
Rear Main Oil Seal IMPORTANT: Correct rotation oil seal must be
used to prevent oil leak.
The rear crankshaft oil seal can be replaced without
removing the oil pan or rear main bearing cap from
engine.
b
Removal
Remove seal by using a screwdriver to pry it out of
retainer as shown.
a
73126
a - Can Be Used on Any Rotation Engine
b - Seal Lip Toward Inside of Engine
Rear Seal WITHOUT Helical Grooves
a b d
72355
a - Rear Seal a
b - Seal Retainer
c - Slots (Three) 73127
a - MCM and MIE (LH) Rotation Engines

Clean crankshaft/seal running surface and seal re-
tainer.
c
d
b 73128
b - MIE (RH) Rotation Engines

c - Seal Lip Toward Inside of Engine
d - Rotation of Crankshaft as Viewed from
Flywheel End Looking Forward
Rear Seal WITH Helical Grooves
Index
90-823225--1 1096 ENGINES - 3A-51
Installation Cleaning and Inspection
1. Apply Quicksilver Perfect Seal to seal retainer 1. Clean gasket material from mating surfaces.
mating surface. Apply grease to seal lips.
2. Inspect oil seal retainer for cracks or scored sur-
2. Install seal using rear main seal installer. face.
3. Inspect oil seal for worn, dry or torn rubber. Re-
place if necessary (refer to “Rear Main Oil Seal”
as outlined).
4. Inspect alignment pin for damage; replace if nec-
essary.
Installation
1. Coat seal lips with clean 30W motor oil.
2. Install gasket and oil seal retainer with rear main
seal.
3. Coat threads of oil seal retainer fasteners with
Loctite Pipe Sealant with Teflon.
a
72356 4. Install fasteners and torque to 133 lb. in. (15
N·m).
a - Rear Main Seal Installer (J-26817-A)
5. Install oil pan fasteners. Torque 1/4-20 thd. fas-
teners to 80 lb. in. (9 N·m) and 5/16-18 thd. fas-
teners to 165 lb. in. (19 N·m).
Rear Main Oil Seal Retainer NOTE: A one-piece oil pan gasket may be re-used if
it is still pliable and is not cracked, torn or otherwise
damaged.
Removal
1. Remove oil pan.
2. Remove oil seal retainer fasteners. Main Bearings
3. Remove oil seal retainer.
IMPORTANT: Before removing main bearing
caps or connecting rod caps, mark them for reas-
a sembly in their original locations.
Main bearings are of the precision insert type and do
not use shims for adjustment. If clearances are found
to be excessive, a new bearing, both upper and lower
halves, will be required. Service bearings are avail-
able in standard size and .001 in., .010 in. and .020
in. undersize.
b Selective fitting of both rod and main bearing inserts
is necessary in production in order to obtain close tol-
erances. For this reason you may find one half of a
standard insert with one half of a .001 in. undersize
insert which will decrease the clearance .0005 in.
a
from using a full standard bearing.
72464
a - Fasteners
b - Oil Seal Retainer
Index
3A-52 - ENGINES 90-823225--1 1096
When a production crankshaft cannot be precision 2. Place a piece of gauging plastic the full width of
fitted by this method, it is then ground .009 in. under- the bearing (parallel to the crankshaft) on the
size ON ONLY THOSE MAIN JOURNALS THAT journal as shown.
CANNOT BE PROPERLY FITTED. ALL JOURNALS
WILL NOT NECESSARILY BE GROUND UNDER-
SIZE. A .009 in. undersize bearing and .010 in. un-
dersize bearing may be used for precision fitting in a
the same manner as previously described.
Inspection
In general, the lower half of the bearing (except
No. 1 bearing) shows a greater wear and the most
distress from fatigue. If, upon inspection, the lower
half is suitable for use, it can be assumed that
the upper half is also satisfactory. If the lower half
shows evidence of wear or damage, both upper
and lower halves should be replaced. Never re-
place one half without replacing the other half. b 72357
a - Gauging Plastic
b - Journal
Checking Clearances
To obtain accurate measurements while using Plasti-
NOTICE
gage, or its equivalent, engine must be out of the boat
and upside down so crankshaft will rest on the upper Do not rotate the crankshaft while the
bearings and total clearance can be measured be- gauging plastic is between the bearing and
tween lower bearing and journal. journal.
To assure the proper seating of the crankshaft, all
bearing cap bolts should be at their specified torque.
In addition, preparatory to checking fit of bearings, 3. Install the bearing cap and evenly torque the re-
the surface of the crankshaft journal and bearing taining bolts to specifications. Bearing cap MUST
should be wiped clean of oil. be torqued to specification in order to assure
proper reading. Variations in torque affect the
1. With the oil pan and oil pump removed, remove compression of the plastic gauge.
bearing cap and wipe oil from journal and bearing
cap to be inspected. 4. Remove bearing cap. The flattened gauging
plastic will be found adhering to either the bearing
cap or journal.
Index
90-823225--1 1096 ENGINES - 3A-53
5. On the edge of the gauging plastic envelope 8. Proceed to the next bearing. After all bearings
there is a graduated scale which is correlated in have been checked, rotate the crankshaft to see
thousandths of an inch. Without removing the that there is no excessive drag. When checking
gauging plastic, measure its compressed width No. 1 main bearing, loosen accessory drive belts
(at the widest point) with the graduations on the so as to prevent tapered reading with plastic
gauging plastic envelope as shown. gauge.
9. Measure crankshaft end play (see “Specifica-
tions”) by forcing the crankshaft to the extreme
front position. Measure at the front end of the rear
main bearing with a feeler gauge as shown.
a b
72358
a - Compressed Gauging Plastic

b - Graduated Scale
NOTE: Normally main bearing journals wear evenly

and are not out of round. However, if a bearing is be-
ing fitted to an out-of-round journal (.001 in. max.), be 72360
sure to fit to the maximum diameter of the journal: If
a - Force Crankshaft to Extreme Forward Position
the bearing is fitted to the minimum diameter, and the
journal is out of round .001 in., interference between
the bearing and journal will result in rapid bearing fail-
ure. If the flattened gauging plastic tapers toward the
middle or ends, there is a difference in clearance indi-
cating taper, low spot or other irregularity of the bear-
ing or journal. Be sure to measure the journal with a
micrometer if the flattened gauging plastic indicates
more than .001 in. difference.
6. If the bearing clearance is within specifications,
the bearing insert is satisfactory. If the clearance
is not within specifications, replace the insert. Al-
ways replace both upper and lower inserts as a
unit.
7. A standard, or .001 in., undersize bearing may
produce the proper clearance. If not, it will be nec-
essary to regrind the crankshaft journal for use
with the next undersize bearing.
After selecting new bearing, recheck clearance.
Index
3A-54 - ENGINES 90-823225--1 1096
Replacement 2. Install main bearing remover/installer in oil hole
in crankshaft journal. If such a tool is not
NOTE: Main bearings may be replaced with or with- available, a cotter pin may be bent, as shown, to
out removing crankshaft. do the job.
a b
b
c 72359
Main Bearing Inserts

a - Lower Bearing Insert (Install in Cap)
b - Upper Bearing Insert (Install in Black)
c - Oil Groove
WITH CRANKSHAFT REMOVED a

72622
1. Remove and inspect the crankshaft as outlined.
a - Main Bearing Remover/Installer (J-8080)
2. Remove the main bearings from the cylinder b - Cotter Pin
block and main bearing caps.
3. Coat bearing surfaces of new, correct size, main 3. Rotate the crankshaft clockwise as viewed from
bearings with oil and install in the cylinder block the front of engine. This will roll upper bearing out
and main bearing caps. of block.
4. Install the crankshaft. 4. Oil new selected size upper bearing and insert
plain (unnotched) end between crankshaft and
WITHOUT CRANKSHAFT REMOVED indented or notched side of block. Rotate the
1. With oil pan, oil pump and spark plugs removed, bearing into place and remove tool from oil hole
remove cap on main bearing requiring replace- in crankshaft journal.
ment and remove bearing from cap. 5. Oil new lower bearing and install in bearing cap.
6. Install main bearing cap with arrows pointing to-
ward front of engine.
7. Torque all main bearing caps, EXCEPT THE
REAR MAIN CAP, to 80 lb. ft. (109 N·m). Torque
rear main bearing cap to 10-12 lb. ft. (14-16
N·m); then tap end of crankshaft, first rearward
then forward with a lead hammer. This will line up
rear main bearing and crankshaft thrust sur-
faces. Torque rear main bearing cap to 80 lb. ft.
(109 N·m).
Index
90-823225--1 1096 ENGINES - 3A-55
Connecting Rod Bearings a. Place a piece of gauging plastic, the length of
the bearing (parallel to the crankshaft), on the
Connecting rod bearings are of the precision insert crankpin or bearing surface as shown. Posi-
type and do not use shims for adjustment. DO NOT tion the gauging plastic in the middle of the
FILE RODS OR ROD CAPS. If clearances are found bearing shell. Bearings are eccentric and
to be excessive, a new bearing will be required. Ser- false readings could occur if placed else-
vice bearings are available in standard size and .001 where.
in. and .002 in. undersize for use with new and used
standard size crankshafts, and in .010 in. and .020 in.
undersize for use with reconditioned crankshafts.
On removing a connecting rod cap, it is possible to
find a .010 in. undersize bearing. These are used in
manufacturing for selective fitting.
Inspection and Replacement
IMPORTANT: Before you remove the connecting a

rod cap, mark the side of the rod and cap with the
cylinder number to assure matched reassembly
of rod and cap.
1. With oil pan and oil pump removed, remove the
connecting rod cap and bearing.
72361
2. Inspect the bearing for evidence of wear and a - Gauging Plastic
damage. Do not reinstall a worn or damaged
bearing.
3. Wipe both upper and lower bearing shells and
b. Install the bearing in the connecting rod and
crankpin clean of oil.
cap.
4. Measure the crankpin for out-of-round or taper
c. Install the bearing cap and evenly torque nuts
with a micrometer. If not within specifications, re-
to 45 lb. ft. (61 N·m).
place or recondition the crankshaft. If within
specifications and a new bearing is to be in-
stalled, measure the maximum diameter of the NOTICE
crankpin to determine new bearing size required. Do not turn the crankshaft with the gauging
plastic installed.
5. If within specifications, measure new or used
bearing clearances with gauging plastic or its
equivalent. If a bearing is being fitted to an
out-of-round crankpin, be sure to fit to the maxi-
mum diameter of the crankpin. If the bearing is
fitted to the minimum diameter, and the crankpin
is out of round .001 in., interference between the
bearing and crankpin will result in rapid bearing
failure.
Index
3A-56 - ENGINES 90-823225--1 1096
d. Remove the bearing cap and using the scale 9. Measure all connecting rod side clearances (see
on the gauging plastic envelope, measure the “Specifications”) between connecting rod caps
gauging plastic width at the widest point as as shown.
shown.
72362
72363
6. If the clearance exceeds specifications, select a

new, correct size bearing and remeasure the
clearance.
Be sure to check what size bearing is being re-
moved in order to determine proper replacement
Connecting Rod/Piston
size bearing. If clearance cannot be brought to Assembly
within specifications, the crankpin will have to be
ground undersize. If the crankpin is already at
maximum undersize, replace crankshaft. Removal
7. Coat the bearing surface with oil, install the rod
1. Remove as outlined:
cap.
a. Oil pan and dipstick tube.
a. All engines except Gen+: Torque nuts to 45
Lb. Ft. (61 N·m). b. Baffle and oil pump.
b. Gen+: Torque nuts to 20 Lb. Ft. (27 N·m) c. Distributor and intake manifold.
8. When all connecting rod bearings have been in- d. Cylinder heads.
stalled, tap each rod lightly (parallel to the crank- 2. Use a ridge reamer to remove any ridge and/or
pin) to make sure they have clearance. deposits from upper end of cylinder bore.
IMPORTANT: Before ridge and/or deposits are re-

moved, turn crankshaft until piston is at bottom
of stroke and place a cloth on top of piston to col-
lect cuttings. After ridge and/or deposits are re-
moved, turn crankshaft until piston is at top of
stroke, then remove cloth and cuttings.
Index
90-823225--1 1096 ENGINES - 3A-57
3. Mark connecting rods and bearing caps (left bank Disassembly
1, 3, 5 and 7; right bank 2, 4, 6 and 8 from front
to rear on same side as piston thrust). Disassemble piston from connecting rod using piston
pin remover as shown. Follow instructions supplied
4. Remove connecting rod cap and install connect- with kit.
ing rod bolt guide (3/8-24) on bolts. Push con-
necting rod and piston assembly out of top of cyl- b
inder block.
NOTE: It will be necessary to turn crankshaft slightly a
to disconnect and remove some connecting rod and
piston assemblies.
d
a
e
72365
a - Piston Pin Remover (J-24086-B)

b - Arched Base
c - Piston
d - Connecting Rod
e - Rod Support
72364
a - Connecting Rod Bolt Guide (3/8-24) J-5239) Cleaning and Inspection
CONNECTING RODS
1. Wash connecting rods in cleaning solvent and
dry with compressed air.
2. Check for twisted and bent rods and inspect for
nicks and cracks. Replace damaged connecting
rods.
Index
3A-58 - ENGINES 90-823225--1 1096
PISTONS 6. Proper clearance of piston ring in its piston ring
groove is very important to provide proper ring
NOTE: Cylinder bore and taper must be within speci-
action and reduce wear. Therefore, when fitting
fications before pistons can be considered for re-use.
new rings, clearances between ring and groove
1. Clean varnish from piston skirts with a cleaning surfaces should be measured. See “Specifica-
solvent. DO NOT WIRE BRUSH ANY PART OF tions.”
PISTON. Clean ring grooves with a groove clean-
er and make sure oil ring holes are clean.
2. Inspect piston for cracked ring lands, skirts and
pin bosses, wavy worn ring lands, scuffed or
damaged skirts, and eroded areas at top of pis-
ton. Replace pistons which are damaged or show
signs of excessive wear.
3. Inspect grooves for nicks and burrs that might
cause rings to hang up.
4. Measure piston skirt and check clearance as out-
lined under “Piston Selection.”
5. Slip outer surface of a new top and second com-
pression ring into respective piston ring groove
and roll ring entirely around the groove to make
sure that ring is free as shown. If binding occurs
at any point, determine cause. If caused by ring 72367
groove, remove by dressing with a fine cut file. If
binding is caused by a distorted ring, recheck
with another ring.
PISTON PINS
1. Piston pin clearance is designed to maintain ade-
quate clearance under all engine operating con-
ditions. Because of this, piston and piston pin are
a matched set and not serviced separately.
2. Inspect piston pin bores and piston pins for wear.
Piston pin bores and piston pins must be free of
varnish and scuffing when measured. Measure
piston pin with a micrometer and piston pin bore
with a dial bore gauge or inside micrometer. If
clearance is in excess of the .001 in. (0.025 mm)
wear limit, replace piston and piston pin assem-
bly.
72366
Index
90-823225--1 1096 ENGINES - 3A-59
Reassembly • Notch on piston must be positioned correctly
for engine that is being repaired.
IMPORTANT: When reassembling pistons and
connecting rods, the following must be kept in
mind.
• Piston and pin are machine fitted to each oth-
er and must remain together as a matched a
set. Do not intermix pistons and pins.
• If original pistons and/or connecting rods are
being used, be sure to assemble pistons and
connecting rods so they can be reinstalled in
same cylinder from which they were re-
moved.
• Connecting rod bearing tangs are always to-
ward outside of cylinder block.
a - Notch 72369
305 CID / 5.0L Engines
72368
a - Rod Bearing Tangs
• To determine if engine is left-hand (standard)

rotation or right-hand (opposite) rotation, in-
spect camshaft drive. If engine has a timing
chain, engine is left-hand rotation. If engine 72370
has timing gears, engine is right-hand rota- 350 CID / 5.7L Engines
tion. All MCM engines are left-hand rotation.
a - Notch - Toward Front in MCM and MIE (LH)
Rotation Engines; Toward Rear in MIE (RH)
Rotation Engines
Index
3A-60 - ENGINES 90-823225--1 1096
1. Assemble piston to connecting rod using piston 3. Measure gap between ends of ring with a feeler
pin remover as shown. Follow instructions gauge as shown.
supplied with kit.
72372
4. If gap between ends of ring is below specifica-

72371 tions, remove ring and try another for fit.
a - Piston Pin Remover (J-24086-B) 5. Fit each compression ring to cylinder in which it
is going to be used.
2. Once assembled, check piston for freedom of 6. Clean and inspect pistons, if not previously done.
movement (back-and-forth and up-and-down) on 7. Install piston rings as follows:
connecting rod. Piston should move freely in all
a. Install oil ring spacer in groove and insert anti-
directions. If it does not, piston pin bore is tight
rotation tang in oil hole.
and piston/pin assembly must be replaced.
b. Hold spacer ends butted and install lower
3. If a new connecting rod has been installed, mark
connecting rod and cap (on side of rod and cap steel oil ring rail with gap properly located.
with slots for connecting rod bearing tangs) with c. Install upper steel oil ring rail with gap proper-
cylinder number in which it will be installed. ly located.
d. Flex the oil ring assembly to make sure ring
PISTON RINGS is free. If binding occurs at any point, the
All compression rings are marked on upper side of cause should be determined and, if caused
ring. When installing compression rings, make sure by ring groove, removed by dressing groove
that marked side is toward top of piston. with a fine cut file. If binding is caused by a
distorted ring, use a new ring.
Oil control rings are a three-piece type, consisting of
two rings and a spacer.
IMPORTANT: Use piston ring expander
1. Select rings comparable in size to cylinder bore (91-24697) for compression ring installation.
and piston size.
e. Install lower compression ring with marked
2. Slip compression ring in cylinder bore, then press side up, using ring expander.
ring down into cylinder bore about 1/4 in. (6 mm)
(below ring travel). Be sure that ring is square f. Install top compression ring with marked side
with cylinder wall. up, using ring expander.
Index
90-823225--1 1096 ENGINES - 3A-61
Installation IMPORTANT: Be sure to install new pistons in
same cylinders for which they were fitted, and
used pistons in same cylinder from which they
IMPORTANT: Cylinder bores must be clean be- were removed. Each connecting rod and bearing
fore piston installation. Clean with a light honing, cap should be marked, beginning at front of en-
as necessary. Then clean with hot water and de- gine (1, 3, 5 and 7 in left bank and 2, 4, 6 and 8 in
tergent wash. After cleaning, swab bores several right bank). Numbers on connecting rod and
times with light engine oil and clean cloth, then bearing cap must be on same side when installed
wipe with a clean dry cloth. in cylinder bore. If a connecting rod is ever trans-
1. Lubricate connecting rod bearings and install in posed from one block or cylinder to another, new
rods and rod caps. bearings should be fitted and connecting rod
should be numbered to correspond with new cyl-
2. Lightly coat pistons, rings and cylinder walls with inder number.
light engine oil.
3. With bearing caps removed, install connecting
rod bolt guide (3/8-24) (J-5239) on connecting
rod bolts.
IMPORTANT: Be sure ring gaps are properly posi-

tioned as shown. a
ENGINE LEFT ENGINE FRONT ENGINE RIGHT
72374
a - Piston Ring Compressor (J-8037)
1-3-5-7 Cylinders 2-4-6-8 Cylinders

5. Remove connecting rod bolt guide.
72373
6. Install bearing caps and torque nuts to 45 lb. ft.
Ring Gap Location (61 N·m).
a - Oil Ring Spacer Gap (Tang in Hole or Slot Within Arc)
7. Check connecting rod side clearance as pre-
b - Oil Ring Rail Gaps
c - 2nd Compression Ring Gap viously described.
d - Top Compression Ring Gap NOTE: If bearing replacement is required, refer to
“Connecting Rod Bearings.”
4. Install each connecting rod and piston assembly
in its respective bore. Install with connecting rod 8. Install as previously outlined:
bearing tangs toward outside of cylinder block. a. Oil pump and baffle.
Use piston ring compressor to compress rings.
b. Dipstick and oil pan.
Guide connecting rod into place on crankshaft
journal with connecting rod bolt guide. Use a c. Cylinder heads.
hammer handle with light blows to install piston d. Intake manifold.
into bore. Hold ring compressor firmly against
cylinder block until all piston rings have entered e. Distributor.
cylinder bore. 9. Fill crankcase with oil. Refer to Section 1 - “Main-
tenance.”
10. Adjust valves as outlined under “Valve Adjust-
ment - Engine Stopped.”
Index
3A-62 - ENGINES 90-823225--1 1096
Crankshaft Cleaning and Inspection
1. Wash crankshaft in solvent and dry with com-
pressed air.
Removal
2. Measure main bearing journals and crankpin di-
1. Remove engine from boat. mensions with a micrometer for out-of-round, ta-
2. Drain crankcase oil. per or undersize (see “Specifications”).
3. Remove as outlined: 3. Check crankshaft for runout (by supporting at

front and rear main bearings journals in V-blocks)
a. Starter. and check at front and rear intermediate journals
b. Flywheel housing. with a dial indicator (see “Specifications”).
c. Drive coupler/plate and flywheel. 4. Replace or recondition crankshaft if not within
specifications.
d. Belts.
e. Water pump.
f. Crankshaft pulley and torsional damper.
Installation
g. Spark plugs. 1. If a new crankshaft is being installed, proceed as
follows:
h. Oil pan and dipstick tube.
a. Remove timing sprocket or gear from old
i. Baffle and oil pump. crankshaft and reinstall on new crankshaft as
j. Timing chain/gear cover. outlined.
4. Turn crankshaft to align timing mark with cam- b. On jackshaft models, if old pilot bushing is to
shaft mark. be reused, bushing can be removed without
damage by filling pilot bushing cavity with
5. Remove camshaft sprocket or gear. grease, then inserting an old transmission in-
6. Remove rear main seal and retainer. put shaft in bore of bushing and hitting it with
a hammer. This will create hydraulic pressure
7. Make sure all bearing caps (main and connecting in pilot bushing cavity which should force
rods) are marked so they can be reinstalled in bushing out.
their original locations.
8. Remove connecting rod bearing caps, then push IMPORTANT: Be sure that all bearings and crank-
piston and rod assemblies toward heads. shaft journals are clean.
9. Remove main bearing caps and carefully lift 2. Install main bearings in engine block as follows.
crankshaft out of cylinder block.
a
10. If new main and/or connecting rod bearings are
b
to be installed, remove main bearing inserts from
cylinder block and bearing caps, and/or connect-
ing rod bearing inserts from connecting rod and
caps. Install new bearings following procedures
outlined.
c
72359
Main Bearing Inserts

a - Lower Bearing Insert (Install in Cap)
b - Upper Bearing Insert (Install in Block)
c - Oil Groove
Index
90-823225--1 1096 ENGINES - 3A-63
3. Carefully lower crankshaft into place. Be careful Removal
not to damage bearing surface.
1. Remove torsional damper, oil pan and crankcase
4. Check clearance of each main bearing, following front cover as outlined.
procedure outlined under “Main Bearings.” If
bearing clearances are satisfactory, apply engine 2. Turn crankshaft until timing marks on crankshaft
oil to journals and bearings. and camshaft sprockets are in alignment as
shown.
5. Install main bearing caps. Torque bolts to 80 lb.
ft. (109 N·m). When tightening rear main bearing NOTE: Flat lifter timing gear is shown. Roller lifter
cap, follow procedure outlined under “Main Bear- gears have similar timing marks.
ings.”
6. Check crankshaft end play as outlined.
7. Install rear main seal retainer and seal. Torque
fasteners to 135 lb. in. (15 N·m).
8. Check clearance for each connecting rod bear-
b
ing, following procedure under “Connecting Rod
Bearings.” If bearing clearances are satisfactory, a
apply engine oil to journals and bearings.
9. Install rod caps and torque nuts to 45 lb. ft.
(61 N·m).
10. Turn crankshaft so mark on timing sprocket or
gear is facing camshaft.
11. Install as outlined:
a. Timing chain and sprocket or gear on cam- 72376
shaft -align marks with crankshaft. Standard (LH) Rotation Shown
b. Timing chain/gear cover. a - Timing Marks Aligned
b - Locating Pin
c. Oil pump and baffle.
d. Dipstick tube and oil pan. 3. Remove camshaft gear or sprocket and timing
e. Spark plugs. chain. (If gear or sprocket does not come off
easily, a light tap on the lower edge of the gear
f. Torsional damper and crankshaft pulley. or sprocket, using a plastic mallet, should dis-
g. Water pump. lodge it.)
h. Belts. 4. If crankshaft sprocket or gear requires replace-
ment, remove as outlined.
i. Flywheel and drive coupler/plate.
j. Flywheel housing.
k. Starter. Cleaning and Inspection
12. Install new oil filter. Fill crankcase with oil. 1. Clean all parts in solvent and dry with com-
pressed air.
2. Inspect timing chain for wear and damage.
Timing Chain and Sprocket 3. Inspect sprockets for wear and damage.
or Timing Gears 4. Inspect timing gears for worn and damaged
teeth.
Left-hand (standard) and right-hand (opposite) rota-
tion engines. 5. Inspect camshaft gear-to-cylinder block contact
surfaces for damage.
Index
3A-64 - ENGINES 90-823225--1 1096
Installation - Timing Gears Crankshaft Sprocket/Gear
(Opposite Rotation Engine)
1. If removed, install crankshaft timing gear as out-
Removal
lined in “Crankshaft Sprocket/Gear.”
2. Position camshaft timing gear so that timing mark 1. Remove torsional damper and crankcase front
aligns with timing mark on crankshaft timing gear, cover as outlined.
then align camshaft dowel with hole in camshaft 2. Remove camshaft timing chain/gear as outlined.
gear and install gear on camshaft.
a. On left-hand rotation engines, remove crank-
shaft sprocket using crankshaft gear and
IMPORTANT: Do not attempt to drive gear on sprocket puller (J-5825-A).
camshaft, as welsh plug at rear of engine can be
dislodged. b. On right-hand rotation engines, remove
crankshaft gear using a universal puller.
3. Install bolts. Torque to 18 lb. ft. (24 N·m).
4. Check timing gear backlash and runout as ex-
plained under “Checking Timing Gear Backlash Installation
and Runout.” 1. Using crankshaft gear and sprocket installer, as
5. Lubricate timing gears with engine oil. shown, install sprocket or gear on crankshaft.
6. Install crankcase front cover, oil pan and torsional
damper as explained. The one-piece gasket for
the oil pan may be re-used if still pliable and not
cracked, torn, etc.
a
Installation - Timing Chain

(Standard Rotation Engine)
1. If crankshaft sprocket was removed, install as
outlined in “Crankshaft Sprocket/Gear.”
2. Install timing chain on camshaft sprocket. Hold
sprocket vertical with chain hanging down. Align
marks on camshaft and crankshaft sprockets.
72377
IMPORTANT: Do not attempt to drive sprocket on
camshaft, as welsh plug at rear of engine can be
dislodged. a - Crankshaft Gear and Sprocket Installer (J-5590)
3. Install sprocket on camshaft. Torque bolts to 18

lb. ft. (24 N·m). 2. Install timing chain or gear as outlined.
4. Lubricate timing chain with engine oil. Install 3. Install crankcase cover and torsional damper as
crankcase front cover and torsional damper as outlined.
outlined.
Checking Timing Chain Deflection

With timing chain and sprockets installed, check tim-
ing chain deflection, as follows:
1. Rotate camshaft (in either direction) to place ten-
sion on one side of the chain.
Index
90-823225--1 1096 ENGINES - 3A-65
2. Establish a reference point on the block (on taut b. Check the backlash between the camshaft
side of chain) and measure from this point to the gear and crankshaft gear while applying in-
chain. ward pressure on camshaft gear.
3. Rotate camshaft in the opposite direction to c. If backlash is not within .004-.006 in. (0.102-
slacken the chain, then force chain out with fin- 0.152 mm) for new gears or 0.004-0.008 in.
gers and again measure the distance between (0.102-0.203 mm) for used gears, check for
reference point and timing chain. improperly machined parts or worn camshaft
or crankshaft bearings. If bearings check out
4. The deflection is the difference between these
good, replace both timing gears.
two measurements. If the deflection exceeds 3/4
in. (19 mm), timing chain should be replaced.
72379
72376 Checking Backlash
a - Reference Point
4. With timing gear installed, check camshaft and

crankshaft timing gear runout, as follows:
Checking Timing Gear Backlash and
a. Mount dial indicator on block so that indicator
Runout stem is perpendicular to camshaft timing gear
1. Remove fuel pump and fuel pump push rod to re- and contacts gear surface just adjacent to
lieve tension on camshaft. teeth.
2. Loosen rocker arm nuts to relieve tension on hy- b. Apply inward pressure on timing gear and
draulic valve lifters. zero indicator, then turn crankshaft as shown.
Check gear runout through one complete rev-
3. With timing gears installed, check cam- olution of camshaft gear.
shaft-to-crankshaft gear backlash, as follows:
c. If not within .004 in. (0.102 mm), check for
a. Mount a dial indicator on engine so that indi- burrs and foreign material between gear and
cator stem contacts one of the teeth on cam- camshaft joining surfaces. If none is found,
shaft gear. Indicator stem should be as per- replace both timing gears.
pendicular to gear tooth surface as possible.
Index
3A-66 - ENGINES 90-823225--1 1096
d. Check crankshaft timing gear runout in same 2. Position indicator with ball socket adaptor tool on
manner. Runout should not exceed .003 in. push rod. Be sure that push rod is in lifter socket.
(0.076 mm). Replace both gears, if runout is
excessive. a
72380
a
a - Ball Socket Adaptor Tool (J-8520-1)
3. Rotate crankshaft torsional damper slowly in di-

rection of rotation until lifter is on heel of cam lobe.
72378 At this point, push rod will be in its lowest position.
Checking Gear Runout 4. Set dial indicator on zero, then rotate balancer
a - Turn Crankshaft in This Direction slowly (or attach an auxiliary starter switch and
“bump” engine over) until push rod is in fully
5. Adjust rocker arm nuts. raised position.
6. Install fuel pump push rod and fuel pump. 5. Compare total lift, recorded from dial indicator,
with “Specifications.”
6. Continue to rotate engine until indicator reads
Camshaft zero. This will be a check on accuracy of original
indicator reading.
7. If camshaft readings for all lobes are within speci-
Measuring Lobe Lift fications, remove dial indicator assembly.
NOTE: Procedure is similar to checking valve timing. 8. Install and adjust valve mechanism as outlined.
If improper valve operation is indicated, measure lift
of each push rod in consecutive order and record
readings. Removal
1. Remove valve lifters as outlined.
IMPORTANT: Engines with Engine Block Code
Letters “CD” have roller lifters and special steel 2. Remove crankcase front cover as outlined.
camshaft with different lobe lift measurements 3. Remove fuel pump and fuel pump push rod.
than engines with flat lifters. Refer to “Engine
Identification” and “Engine Specifications” to 4. Remove camshaft as follows:
verify measurements. a. Remove timing chain and sprocket or timing
1. Remove valve mechanism as outlined. gears as outlined. On the 5.7L engine only,
remove camshaft thrust plate.
Index
90-823225--1 1096 ENGINES - 3A-67
b. Install two 5/16-18 x 5 in. bolts in camshaft Installation
bolt holes and carefully remove camshaft as
shown. 1. Install camshaft as follows:
a. Install two 5/16-18 x 5 in. bolts in camshaft
bolt holes, then lubricate camshaft journals
with engine oil and install camshaft, being
careful not to damage bearings.
b. Lubricate camshaft lobes with General Mo-
tors Cam and Lifter Prelube or equivalent.
c. Install timing chain or gears as outlined.
2. Install fuel pump push rod and fuel pump.
3. Install crankcase front cover and valve lifters as
outlined.
Camshaft Bearings
72381
Removal
Camshaft bearings can be replaced while engine is
disassembled for overhaul or without complete dis-
assembly. To replace bearings without complete dis-
Inspection assembly, remove camshaft and crankshaft, leaving
cylinder heads attached and pistons in place. Before
Measure camshaft bearing journals with a microme-
removing crankshaft, fasten connecting rods against
ter for out-of-round condition. If journals exceed .001
sides of engine so that they will not interfere while re-
in. (0.025 mm) out-of-round, camshaft should be re-
placing camshaft bearings.
placed.
1. With camshaft and crankshaft removed, drive
Also check camshaft for alignment with V-blocks and
camshaft rear plug from cylinder block.
dial indicator which indicates exact amount camshaft
is out of true. If out more than .002 in. (0.051 mm) NOTE: This procedure is based on removal of bear-
(dial indicator reading) camshaft should be replaced. ings from center of engine first, thus requiring a mini-
mum amount of turns to remove all bearings.
On engines with timing gears, inspect camshaft gear
and thrust plate for wear and damage. 2. Using camshaft bearing remover and installer set
(P/N J-6098-01) (with nut and thrust washer in-
stalled to end of threads), position pilot in front
camshaft bearing and install puller screw through
pilot.
3. Install tool with shoulder toward bearing. Be sure
a sufficient amount of threads are engaged.
72382
4. Using two wrenches, hold puller screw while turn-
Checking Camshaft Alignment ing nut. When bearing has been pulled from bore,
remove tool and bearing from puller screw.
Index
3A-68 - ENGINES 90-823225--1 1096
5. Remove remaining bearings (except front and Installation
rear) in same manner. It will be necessary to posi-
tion pilot in rear camshaft bearing to remove rear Front and rear bearings must be installed last as pilot
intermediate bearing. will not fit into bearing bores if bearings are installed.
Lubricate outer surface of new camshaft bearings
with engine oil to ease installation.
a IMPORTANT: All camshaft bearings are not the

same. Be sure to install bearings in proper loca-
tions (Indicated by bearing manufacturer) and to
position bearings as follows (directional refer-
ences are in reference to engine in its normal op-
erating position):
c b
• Front bearing must be positioned so that oil
holes are equal distance from 6 o’clock posi-
tion in the block. Intermediate and center
d 72383 bearings must be positioned so that oil holes
are at the 5 o’clock position (toward left side
a - Index Pilot of block and at a position even with bottom of
b - Puller Screw
c - Driver
cylinder bore). Rear bearing must be posi-
d - Bearing tioned so that oil hole is at the 12 o’clock posi-
tion.
1. Installing intermediate and center bearings:
6. Assemble driver on driver handle and remove a. Install nut and thrust washer all the way onto
front and rear camshaft bearings by driving to- puller screw, then position pilot in front cam-
ward center of cylinder block. shaft bearing bore and insert screw through
pilot.
b. Index center camshaft bearing, then position
appropriate size remover and installer tool in
bearing and thread puller screw into tool. Be
c sure at least 1/2 in. (13 mm) of threads are en-
gaged.
c. Using two wrenches, hold puller screw and
turn nut until bearing has been pulled into po-
sition. Remove the remover and installer tool
and check to ensure that oil hole(s) in bearing
are positioned correctly.
d. Install intermediate bearings in same manner
being sure to index bearings correctly. It will
be necessary to position pilot in rear cam-
b shaft bearing bore to install rear intermediate
a
72384 bearing.
a - Driver 2. Installing front and rear bearings:
b - Driver Handle
c - Bearing a. Install appropriate size remover and installer
tool on drive handle.
b. Index front bearing (as explained in “Impor-
Inspection tant” above), and drive it into position with
tool. Check position of oil hole(s) in bearing to
Clean camshaft bearing bores in cylinder block with ensure bearing is positioned correctly.
solvent and blow out with compressed air. Be sure
c. Install rear bearing in same manner, being
grooves and drilled oil passages are clean.
sure to index bearing correctly.
Index
90-823225--1 1096 ENGINES - 3A-69
3. Install a new camshaft rear plug. 7. Measure cylinder walls for taper, out-of-round or
excessive ridge at top of ring travel. This should
IMPORTANT: Plug must be installed flush to 1/32 be done with a dial indicator or inside micrometer.
in. (0.8 mm) deep and must be parallel with rear Carefully work gauge up and down cylinder to de-
surface of cylinder block. termine taper and turn it to different points around
cylinder wall to determine out-of-round condition.
4. Install crankshaft and camshaft as outlined. If cylinders exceed specifications, boring and/or
honing will be necessary.
a
Cylinder Block

1. Remove all engine components as previously
outlined.
b b
2. Wash cylinder block thoroughly in cleaning sol-
vent and clean all gasket surfaces.
3. Remove oil gallery plugs and clean all oil pas-
sages.
4. Remove expansion plugs.
NOTE: These plugs may be removed with a sharp
punch, or they may be drilled and pried out. a 72385
5. Clean and inspect water passages in cylinder
block.
Cylinder Measurement
6. Inspect cylinder block for cracks in cylinder walls, “A” = At right angle to centerline of engine
water jacket valve lifter bores and main bearing “B” = Parallel to centerline of engine
webs. “Out-of-Round” = Difference between “A” and “B”
“Taper” = Difference between measurement “A”
at top of cylinder bore and “A”
measurement at bottom of cylinder bore
Index
3A-70 - ENGINES 90-823225--1 1096
8. Check cylinder head gasket surfaces for war-
page with a machinist’s straight-edge and a feel-
er gauge, as shown. Take measurements diago-
nally across surfaces (both ways) and straight
down center. If surfaces are warped more than
.003 in. (0.07 mm) in a 6 in. area or .007 in. (0.2
mm) overall, block must be resurfaced by an au-
tomotive machine shop.
a
72386
Measuring Cylinder Bore

b
72388
a - Machinist’s Straight-Edge
b - Feeler Gauge
CYLINDER CONDITIONING
1. Performance of the following operation depends
upon engine condition at time of repair.
2. If cylinder block inspection indicates that block is
suitable for continued use (except for
out-of-round or tapered cylinders), they can be
conditioned by honing or boring.
3. If cylinders have less than .005 in. (0.127 mm) ta-
per or wear, they can be conditioned with a hone
72387 and fitted with high limit standard size piston. A
cylinder bore of more than .005 in. wear or taper
Measuring Cylinder Bore
may not clean up entirely when fitted to a high lim-
it piston. To entirely clean up the bore, it will be
necessary to rebore for an oversize piston. If
more than .005 in. taper or wear, bore and hone
to smallest oversize that will permit complete re-
surfacing of all cylinders.
4. When pistons are being fitted and honing is not
necessary, cylinder bores may be cleaned with a
hot water and detergent wash. After cleaning,
swab cylinder bores several times with light en-
gine oil and a clean cloth, then wipe with a clean
dry cloth.
Index
90-823225--1 1096 ENGINES - 3A-71
CYLINDER BORING PISTON SELECTION
1. Before using any type boring bar, file off top of cyl- 1. Check used piston to cylinder bore clearance as
inder block to remove dirt or burrs. This is very im- follows:
portant to prevent boring bar tilt, with result that
a. Measure cylinder bore diameter with a tele-
rebored cylinder wall is not at right angles to
scope gauge 2-1/2 in. (64 mm) from top of cyl-
crankshaft.
inder bore as follows.
2. Measure piston to be fitted with a micrometer,
measuring at center of piston skirt and at right
angles to piston pin. Bore cylinder to same diam-
eter as piston and hone to give specified clear-
ance.
NOTE: Hone cylinders as outlined under “Cylinder
Honing” and “Piston Selection,” following.
3. Carefully observe instructions furnished by man-
ufacturer of equipment being used.
CYLINDER HONING
1. Follow hone manufacturer’s recommendations
for use of hone and cleaning and lubrication dur-
ing honing. 72386
2. Occasionally, during the honing operation, thor-

oughly clean cylinder bore and check piston for
correct fit in cylinder.
3. When finish-honing a cylinder bore to fit a piston, b. Measure piston diameter at skirt across cen-
move hone up and down at a sufficient speed to ter line of piston pin as shown.
obtain very fine uniform surface finish marks in a
crosshatch pattern of approximately 30 degrees
to cylinder bore. Finish marks should be clean but
not sharp, free from imbedded particles and torn
or folded metal.
4. Permanently mark piston (for cylinder to which it
has been fitted) and proceed to hone cylinders
and fit remaining pistons.
IMPORTANT: Handle pistons with care and do not

attempt to force them through cylinder until cyl-
inder is honed to correct size, as this type piston
can be distorted by careless handling.
5. Thoroughly clean cylinder bores with hot water
and detergent. Scrub well with a stiff bristle brush
and rinse thoroughly with hot water. It is extreme-
ly essential that a good cleaning operation be 72624
performed. If any abrasive material remains in

cylinder bores, it will rapidly wear new rings and
cylinder bores in addition to bearings lubricated c. Subtract piston diameter from cylinder bore
by the contaminated oil. Swab bores several diameter to determine piston-to-bore clear-
times with light engine oil on a clean cloth, then ance.
wipe with a clean dry cloth. Cylinder should not be
cleaned with kerosene or gasoline. Clean re- d. Determine if piston-to-bore clearance is in ac-
mainder of cylinder block to remove excess ma- ceptable range shown in “Specifications.”
terial spread during honing operation.
Index
3A-72 - ENGINES 90-823225--1 1096
2. If used piston is not satisfactory, determine if a Inspection and/or Replacement
new piston can be selected to fit cylinder bore
within acceptable range. Oil by-pass valve and adaptor assembly should be
inspected whenever engine is disassembled for ma-
3. If cylinder bore must be reconditioned, measure jor repair or whenever inadequate oil filtration is sus-
new piston diameter (across centerline of piston pected.
pin), then hone cylinder bore to correct clearance
(preferable range). Refer to “Engine Parts List” when ordering parts for
oil filter by-pass valve, adaptor assembly or remote
4. Mark piston to identify cylinder for which it was oil filter parts.
fitted.
1. Remove oil filter (on engines with block mounted
filter) or cylinder block adaptor (on engines with
remote oil filter) and remove by-pass valve and
Oil Filter By-Pass Valve and adaptor assembly.
Adaptor Assembly 2. Clean by-pass valve and adaptor assembly in
solvent and blow dry with compressed air.
3. Inspect fiber valve for cracks or other damage.
Check that valve fits tightly against its seat. Push
valve down and release it. Valve should return
freely to its seat. If valve operation is question-
able, by-pass valve and adaptor assembly
should be replaced. Bypass valve may be re-
placed separately on remote filter assembly.
Without Remote Oil Filter

72389
72391
Typical By-Pass Valve and Adaptor As-

a sembly
a - Fiber Valve (Be Sure Valve Fits
Tightly Against Its Seal)
72390 4. Wipe out valve chamber in cylinder block to re-

With Remote Oil Filter
move any foreign material.
a - Fiber Valve 5. Install by-pass valve and adaptor assembly or
cylinder block adaptor to engine block. Tighten
bolts to 20 lb. ft. (27 N·m).
6. Lubricate oil filter rubber seal and install
hand-tight only.
Index
90-823225--1 1096 ENGINES - 3A-73
ELECTRICAL SYSTEMS
4
A
72079
STARTING SYSTEM
Index
Table of Contents
Page Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Starting System Components . . . . . . . . . . . . . 4A-15
Replacement Parts Warning . . . . . . . . . . . . . . . 4A-1 Positive Current Flow . . . . . . . . . . . . . . . . . . . . 4A-16
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-16
Battery Cable Recommendations . . . . . . . . 4A-1 PG 200 and PG 250 Starter Motor
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 4A-1 (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . 4A-18
Lubricants/Sealants . . . . . . . . . . . . . . . . . . . . . . 4A-1 Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4A-19
Direct Drive Starter Motor . . . . . . . . . . . . . . . . . 4A-2 Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . 4A-19
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 PG 200 and PG 250 Starter Motor Repair . . 4A-19
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 4A-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-19
Lubricants/Sealants . . . . . . . . . . . . . . . . . . . . . . 4A-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20
Positive Current Flow . . . . . . . . . . . . . . . . . . . . . 4A-2 Cleaning and Inspection . . . . . . . . . . . . . . . 4A-22
Starting System Components . . . . . . . . . . . . . . 4A-3 Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 4A-22
Starter Motor (Exploded View) . . . . . . . . . . . . . 4A-4 Armature Bearing (Commutator End) . . . . 4A-22
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . 4A-5 Gear Bearing . . . . . . . . . . . . . . . . . . . . . . . . 4A-23
Starter Motor Repair . . . . . . . . . . . . . . . . . . . . . . 4A-5 Shaft Assembly Bearing . . . . . . . . . . . . . . . 4A-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5 Drive End Housing Bearing . . . . . . . . . . . . 4A-23
Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . 4A-5 Brushes and Brush Holder . . . . . . . . . . . . . 4A-24
Starter Motor Disassembly . . . . . . . . . . . . . . 4A-7 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4A-25
Cleaning and Inspection . . . . . . . . . . . . . . . . 4A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-27
Armature Tests . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 PG 260 Starter Motor . . . . . . . . . . . . . . . . . . . 4A-28
Field Coil Tests . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 Exploded View . . . . . . . . . . . . . . . . . . . . . . . 4A-28
Loose Electrical Connections . . . . . . . . . . . . 4A-9 Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29
Turning the Commutator . . . . . . . . . . . . . . . . 4A-9 Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . 4A-29
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9 PG 260 Starter Motor Repair . . . . . . . . . . . . . . 4A-29
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4A-30
Permanent Magnet Gear Reduction Cleaning and Inspection . . . . . . . . . . . . . . . 4A-32
(PG200, PG250 and PG260) Starter Motor . 4A-12 Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 4A-33
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Brushes and Brush Holder . . . . . . . . . . . . . 4A-33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4A-35
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-38
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-38
Standard Starter Slave Solenoid . . . . . . . . . . 4A-14
Testing/Replacement . . . . . . . . . . . . . . . . . . 4A-14
NOTICE
For information and procedures on trouble-
shooting, refer to Section 1C.
Index
4A - STARTING
4A-0 SYSTEM
- STARTING SYSTEM 90-823225--1 1096
Identification Replacement Parts Warning
The starter identification number is located as
shown. ! WARNING
Electrical, ignition and fuel system components
on your MerCruiser are designed and manufac-
tured to comply with U.S. Coast Guard Rules and
Regulations to minimize risks of fire and explo-
sion.
Use of replacement electrical, ignition or fuel system
components, which do not comply with these rules
and regulations, could result in a fire or explosion
hazard and should be avoided.
a
72789
Battery
Direct Drive Starter Motor IMPORTANT: Terminals must be soldered to
cable ends to ensure good electrical contact. Use
electrical grade (resin flux) solder only. Do not
use acid flux solder, as it may cause corrosion
and failure.
Battery Cable Recommendations

a
Cable Length Cable Gauge
Up to 3-1/2 Ft. (1.1 m) 4 (25 mm2)
3-1/2 - 6 Ft (1.1-1.8 m) 2 (35 mm2)
6 - 7-1/2 Ft. (1.8-2.3 m) 1 (50 mm2)
7-1/2 - 9-1/2 Ft. (2.3-2.9 m) 0 (50 mm2)
9-1/2 - 12 Ft. (2.9-3.7 m) 00 (70 mm2)
12 - 15 Ft. (3.7-4.6 m) 000 (95 mm2)
15 - 19 Ft. (4.6-5.8 m) 0000 (120 mm2)
72059 Both positive (+) and negative (–) cables
Permanent Magnet Gear Reduction (PG200 and

PG250) Starter Motor
Fastener Location lb. ft. N·m
a Starter Mounting Bolts 30 41
All Other Fasteners Tighten Securely
Lubricants/Sealants
Quicksilver Liquid Neoprene 92-25711-2
Permanent Magnet Gear Reduction (PG260) Quicksilver 2 4 C Marine

92-825407A3
Lubricant With Teflon
Starter Motor
a - Starter Identification Number
Index
90-823225--1 1096 STARTING SYSTEM - 4A-1
Direct Drive Starter Motor
Specifications
No Load Test Brush
Delco Spring Ten-
Engine
Identification
ifi i Min. Max. Min. Max. sion
Rotation Volts
Number Amps Amps RPM RPM Oz. (Grams)
56-105
10455602 LH 10.6 70 120 5400 10800
(1588-2976)
Pinion Clearance .010-.140 (0.25-3.5 mm)
Commutator End Frame Gap .025 Max. (0.6 mm Max.)
Torque Specifications • 20 amp fuse to ignition switch terminal I

(RED-PUR). At this point ignition switch is
Fastener turned to START.
Lb. Ft. N·m
Location • Ignition switch terminal B to terminal S.
Starter Motor • Ignition switch terminal S to neutral start
50 68
To Block switch (YEL-RED). NEUTRAL START SWITCH
All Other MUST BE AT NEUTRAL POSITION.
Tighten Securely
Fasteners
• Neutral start switch to wiring harness plug
terminal 7 (YEL-RED).
• Wiring harness plug to starter solenoid (small
Lubricants/Sealants terminal) (YEL-RED). Also ensure that black
(small terminal) wire is grounded.
• Starter solenoid is now “closed,” completing
Quicksilver Liquid Neoprene 92-25711-2 circuit between large terminal (RED-PUR) and
SAE 10W Oil other large terminal (YEL-RED), causing
Obtain Locally starter motor to crank.
SAE 20W Oil
! CAUTION
Positive Current Flow The starter motor is designed to operate under
great overload and produce a high horsepower
This is a general description of the positive current for its size. It can do this only for a short time,
flow, from the battery and through the system until the since considerable heat accumulates and can
starter motor cranks. cause serious damage. For this reason, the
• Battery to the solenoid switch (on starter) cranking motor must never be used for more than
(RED battery cable). 30 seconds at any one time. Cranking should not
be repeated without a pause of at least 2 minutes
• Solenoid switch to circuit breaker (RED). to permit the heat to escape.
• Circuit breaker to wire junction (RED-PUR).
• Wire junction to wiring harness plug
(RED-PUR) terminal 6.
• Wiring harness plug to 20 amp fuse
(RED-PUR).
Index
4A-2 - STARTING SYSTEM 90-823225--1 1096
Starting System Components
B c
S
I
g e
72930
a - Ignition Switch
b - 20 Amp Fuse
c - Starter Slave Solenoid
d - Circuit Breaker
e - Starter Motor
f - Wire Junction
g - Neutral Safety Switch
Index
Starter Motor (Exploded View)
9
27
1 8
28 2 7
29
3 10
31
4
11
5 13
26 6 25
12
30
24
32 14
19
15
33
21
20
34
22
23
16
17
18
72806
Index
1 - End Housing
2 - End Housing Bushing Periodic Inspection
3 - Thrust Collar Cranking motor and solenoid are completely en-
4 - Retaining Ring - Pinion Stop Collar
5 - Pinion Stop Collar closed in the drive housing to prevent entrance of
6 - Clutch Drive Assembly moisture and dirt. However, periodic inspection is re-
7 - Bearing Plate quired as follows:
8 - Bearing Plate Bushing
9 - Bearing Plate Washer 1. Inspect terminals for corrosion and loose con-
10 - Bearing Plate Screw nections.
11 - Armature
12 - Pole Shoe - Field Coil 2. Inspect wiring for frayed and worn insulation.
13 - Pole Shoe - Field Coil Screw
14 - Field Coil Grommet - Field Frame 3. Check mounting bolts for tightness.
15 - Field Coil Assembly
16 - Leather Washer - Commutator End Frame
17 - Lower Commutator End Frame
18 - Thru Bolt Starter Motor Repair
19 - Insulator Holder - Field Frame Brush
20 - Field Frame Brush - Ground Brush
21 - Field Frame Brush
22 - Brush Lead Screw Removal
23 - Ground And Insulated Holders Support
Package ! WARNING
24 - Field Frame Brush Spring
25 - Dowel Pin - Field Frame Disconnect battery cables at battery before re-
26 - Shift Lever moving starter.
27 - Shift Lever Stud
28 - Shift Lever Stud Washer 1. Disconnect battery cables from battery.
29 - Shift Lever Stud Nut
30 - Shift Lever Plunger 2. Disconnect wires from solenoid terminals.
31 - Plunger To Shift Lever Pin
32 - Plunger Return Spring 3. Remove starter mounting bolts.
33 - Solenoid Switch Screw
4. Pull starter assembly away from flywheel and re-
34 - Solenoid Switch Assembly
move from engine.
Solenoid Switch
REMOVAL
1. Remove starter motor as outlined.
2. Remove screw from field coil connector and sole-
noid attaching screws.
Index
3. Twist solenoid to disengage tab, and remove. IMPORTANT: DO NOT cut starter motor connec-
tor strap terminal wire (to remove terminal) or
b wire will be too short.
b c
f
a h
e
d
i
72631
a - Field Coil Screws J
b - Attaching Screws g
REPLACEMENT OF CONTACTS
72632
1. With solenoid removed from motor, remove nuts a - Solenoid Body
and washers from switch terminal S and starter b - To Hold In Coil
motor connector strap terminal. c - Switch Terminal
d - Motor Connector Strap Terminal
2. Remove solenoid end cover retaining screws e - To Pull In Coil
and washers and remove end cover from sole- f - Contact Ring and Push Rod Assembly
noid body. g - Battery Terminal
h - Contact Finger
3. Remove nut and washer from battery terminal on i - Screw
end cover and remove battery terminal. j - End Cover
4. Remove motor connector strap terminal and sol-

der new terminal in position.
5. Remove and install new battery terminal, washer
and retaining nut to end cover.
6. Place new contact ring and push rod assembly in
solenoid housing.
7. Position end cover over switch and motor termi-
nals and install end cover retaining screws. Also
install washers and nuts on solenoid switch and
starting motor terminals.
Index
INSTALLATION 3. Remove screws, center bearing plate and arma-
ture.
1. Install solenoid onto plunger.
2. Twist solenoid to engage tab.
a
3. Install screws and tighten securely.
b
4. Install field coil connector screw.
c
Starter Motor Disassembly

1. Remove screw from field coil connector.
72634
a - Screws
b - Bearing Plate
c - Armature
4. Slide thrust collar off armature shaft.

a 5. Drive retainer ring toward armature.
6. Remove snap ring, retainer and clutch assembly.
72631
a - Connector Screw Cleaning and Inspection

With starting motor completely disassembled, ex-
2. Remove end frame thru bolts, end frame, washer
cept for removal of field coils, component parts
and field frame.
should be cleaned and inspected. Field coils should
d be removed only where defects are indicated by
tests. Defective parts should be replaced or repaired.
IMPORTANT: DO NOT use grease dissolving sol-
b
vents for cleaning over-running clutch, armature
c
and field coils. Such a solvent would dissolve
grease packed in clutch mechanism and damage
armature and field coil insulation.
1. Test over-running clutch action. Pinion should
turn freely in over-running direction and must not
slip in cranking direction. Check pinion teeth.
Check spring for tension and drive collar for wear.
a Replace if necessary.
72633 2. Check that brush holders are not damaged or
bent and will hold brushes against commutator.
3. Check brushes. Replace if pitted or worn to
a - Thru Bolt
b - End Frame one-half their original length [5/16 in. (8 mm) or
c - Washer less].
d - Field Frame 4. Check fit of armature shaft in bushing of drive
housing. Shaft should fit snugly. Replace bush-
ing, if worn. Apply SAE 20 oil to bushing before
reassembly. Avoid excessive lubrication.
Index
5. Check fit of bushing in commutator end frame. If TEST FOR GROUND
bushing is damaged or worn excessively, replace
1. With continuity meter, place one lead on arma-
end frame assembly. Apply SAE 20 oil to bushing
ture core or shaft and other lead on commutator.
before reassembly. Avoid excessive lubrication.
2. If meter hand moves, armature is grounded and
6. Inspect armature commutator. If rough or
must be replaced.
out-of-round, turn down and undercut. Inspect
points (where armature conductors join commu-
tator bars) for good, firm connection. Burned
commutator bar usually is evidence of poor con- b c
nection.
Armature Tests
d
TEST FOR SHORTS
Check armature for shorts by placing on growler and
holding hack saw blade over armature core while ro-
tating armature. If saw blade vibrates, armature is
c
shorted. After cleaning between commutator bars, a
recheck. If saw blade still vibrates, replace armature.
a
01441
a - Commutator
b - Armature Core
c - Shaft
d - Growler
b
Field Coil Tests
c
TEST FOR OPEN CIRCUIT
1. With continuity meter, place one lead on each
end of field coils (insulated brush and field con-
nector bar).
01440
a - Hacksaw Blade
b - Armature Core
c - Growler
72635
2. If meter does not move, field coils are open and

must be replaced.
Index
TEST FOR GROUND Reassembly
IMPORTANT: Be sure that positive brushes and After all parts are thoroughly tested and inspected
leads do not contact field frame assembly during and worn or damaged parts replaced, reassemble
test, or false reading will result. starter as follows:
1. With continuity meter, place one lead on field 1. Assemble brushes and related parts to field
connector bar and other lead on grounded brush. frame as follows:
a. Assemble brushes to brush holders. Attach
ground wire to grounded brush and field lead
wire to insulated brush.
b. Assemble insulated and grounded brush
holders together with V-spring. Position as a
unit and install support pin. Push holders and
spring to bottom of support and rotate spring
to engage center of V-spring in slot in support.
2. Assemble over-running clutch assembly to arma-
ture shaft as follows:
a. Lubricate drive end of armature shaft with
SAE 10W oil.
b. Slide assist spring and clutch assembly onto
armature shaft with pinion outward.
c. Slide retainer onto shaft with cupped surface
facing end of shaft (away from pinion).
72636
d. Drive snap ring onto shaft and slide down into
2. If meter hand moves, field coils are grounded and groove.
must be replaced.
Loose Electrical Connections

If open soldered connection of armature to commuta-
tor leads is found during inspection, resolder with res-
in flux.
IMPORTANT: Never use acid flux on electrical
connections.
a
Turning the Commutator
b
When inspection shows commutator roughness,
clean as follows:
1. Turn down commutator in a lathe until thoroughly
cleaned.
2. Recheck armature for shorts as outlined. 72073
a - Snap Ring
b - Groove
Index
e. Assemble thrust collar on shaft with shoulder 2. Connect 12 volt battery positive (+) lead to sole-
next to snap ring. noid switch and negative (–) lead to solenoid
frame.
f. Place thrust collar and retainer next to snap
ring and using two pliers squeeze both until 3. Momentarily touch a jumper lead from solenoid
snap ring is forced into retainer. motor terminal M to starter motor frame. This
shifts pinion into cranking position where it will
3. Place 4 or 5 drops of light engine oil in drive hous-
remain until battery is disconnected.
ing bushing. Slide armature and clutch assembly
into place while engaging shift lever with clutch.
4. Position field frame over armature and apply
Quicksilver Liquid Neoprene between frame
against drive housing, observing caution to pre-
vent damage to brushes.
5. Place 4 to 5 drops of light engine oil in bushing in
commutator end frame. Place brake washer and
commutator end frame onto shaft.
6. Install solenoid return spring on plunger.
7. Position solenoid assembly to starter motor end
frame and turn solenoid to engage flange in slot.
8. Install (and tighten securely) screws which hold
solenoid assembly to end frame.
b
9. Secure starter motor connector strap terminal 01447
with screw and washer. a
Clearances a - Jumper Lead

b - Starter Motor Frame
PINION CLEARANCE
Pinion clearance must be checked as follows after
reassembly of motor to insure proper adjustment.
1. Disconnect motor field coil connector from sole-
noid motor terminal and insulate it carefully.
72631
a - Motor Field Coil Connector
Index
4. Push pinion back toward commutator end to COMMUTATOR END FRAME GAP
eliminate slack.
To keep the ignition-proof and safety requirement,
5. Measure distance between pinion and pinion re- the gap between the commutator end frame and field
tainer. coil housing must be checked. See specifications. If
the gap exceeds measurement when checked with
6. If clearance is not within limits of .010-.140 in.
a feeler gauge, the end frame should be checked for
(0.25-3.5 mm), it may indicate excessive wear of
proper seating on the field coil housing. If properly
solenoid linkage shift lever yoke buttons or im-
seated and still found to have excessive gap, the end
proper assembly of shift lever mechanism.
frame must be replaced.
Check for proper assembly, and recheck gap. If
still excessive, replace worn or defective parts,
since no provision is made for adjusting pinion
clearance. Installation
1. Place starter motor and solenoid assembly in po-
a sition and install mounting bolts. Torque bolts to
50 lb. ft. (68 N·m).
b
2. Fasten wires as outlined in wiring diagram.
3. Coat solenoid terminal connections with Quick-
silver Liquid Neoprene.
4. Place rubber boot over positive battery cable
connection.
.
72077
0
a - Pinion
0
b - Retainer
c - Feeler Gauge
b 72637
a - Positive Battery Cable
b - Rubber Boot
Index
Permanent Magnet Gear Reduction
(PG200, PG250 and PG260) Starter Motor
Specifications
PG 200 STARTER MOTOR
Delco No Load Test
I.D. Min. Max. Min. Max.
Number Volts
Amps Amps RPMS RPMS
9000762
10.6 60 90 3000 3000
9000768
Brush Spring Tension 83-104 oz. (2353-2948 g.)
Pinion Clearance .010-.160 in. (0.25-4.00 mm)
Bearing Depth (Gear) .011-.014 in. (0.28-0.38 mm)
Bearing Depth (Drive Housing) .009-.017 in. (0.25-0.45 mm)

Delco No Load Test
ID
I.D. Volts Min. Max. Min. Max.
Number Amps Amps RPMS RPMS
9000789 10.6 60 95 2750 3250

Delco No Load Test
ID
I.D. Volts Min. Max. Min. Max.
Number Amps Amps RPMS RPMS
9000789 10.6 60 95 3000 3000
Index
Maintenance Testing
! WARNING ! CAUTION
DO NOT use jumper cables and a booster battery Test battery in well ventilated area as gases given
to start engine. DO NOT recharge a weak battery off by battery are hazardous.
in the boat. Remove battery and recharge in a
Place battery under heavy load (as during engine
well ventilated area away from fuel vapors,
cranking or with a variable resistor tester) and test
sparks or flames.
cell voltage while under load.
! WARNING Certain conditions must be met before testing:
Batteries contain acid which can cause severe • Battery must be 60 to 100°F (16 to 38°C).
burns. Avoid contact with skin, eyes and cloth- • Electrolyte level must be correct in all cells.
ing. Batteries also produce hydrogen and oxy-
gen gases when being charged. This explosive • Battery must be at least half charged.
gas escapes fill/vent caps and may form an ex- • No obvious defects.
plosive atmosphere around the battery for sever-
al hours after it has been charged; sparks or 1. Check voltage per manufacturer’s specifications.
flames can ignite the gas and cause an explosion 2. If readings are low, recharge and retest.
which may shatter the battery and could cause
blindness or other serious injury. 3. If readings remain low, battery should be re-
placed.
Safety glasses and rubber gloves are recom-
mended when handling batteries or filling elec-
trolyte. Hydrogen gases that escape from the Storage
battery during charging are explosive. When
charging batteries, be sure battery compartment, 1. Remove battery and clean exterior.
or area where batteries are located, is well 2. Check fluid level and fill if low.
vented. Battery electrolyte is a corrosive acid
and should be handled with care. If electrolyte is 3. Cover terminals and bolts with light coat of
spilled or splashed on any part of the body, im- grease.
mediately flush the exposed area with liberal 4. Set battery on wood or in carton; store in cool, dry
amounts of water and obtain medical aid as soon place.
as possible.
5. Check every 20 days for fluid level and slow
charge.
! CAUTION
IMPORTANT: A discharged battery can be dam-
To prevent damage to the electrical system be aged by freezing.
sure to adhere to the following:
• When installing battery, be sure to connect
the positive (+) battery cable to positive (+)
battery terminal first and then the negative (–)
battery cable to negative (–) battery terminal.
• Never disconnect the battery cables while the
engine is running.
• If a charger or booster is to be used, be sure to
connect it in parallel with existing battery
(positive to positive and negative to nega-
tive).
• When applying a booster charge to battery,
disconnect both cables from battery (to pre-
vent damage to voltage regulator).
• Check battery condition periodically.
• Make sure that battery leads are kept clean
and tight.
Index
Standard Starter Slave
Solenoid
Testing/Replacement
1. Using continuity meter, connect test leads as
shown, and connect 12 volt battery with jumper
leads as shown.
72630
2. If no meter movement is present, replace sole-

noid.
Index
Starting System Components
b
g
B
S
I
72929
a - ignition Switch
b - 20 Amp. Fuse
c - Neutral Safety Switch
d - Ground Stud
e - Starter Motor
f - Circuit Breaker
g - Starter Slave Solenoid
h - Wire Junction
Index
Positive Current Flow Description
This is a general description of the positive current The Permanent Magnet Gear Reduction (PG200
flow, from the battery and through the system until the and PG250) starter motors feature small permanent
starter motor cranks. magnets mounted inside the field frame (NOTE: The
actual configuration of these magnets differs be-
• Battery to the solenoid switch (on starter)
tween the PG200, PG250 and PG260; the field
(RED battery cable).
frames with permanent magnets are not inter-
• Solenoid switch to circuit breaker (RED). changeable. Otherwise, the units are similar.) These
• Circuit breaker to wire junction (RED-PUR). magnets take the place of current-carrying field coils
mounted on iron pole pieces. Internal gear reduction,
• Wire junction to wiring harness plug approximately 4 to 1, through planetary gears results
(RED-PUR) terminal 6. in armature speeds in the 7000 RPM range. The ar-
• Wiring harness plug to 20 amp fuse mature and drive shaft are mounted on roller or ball
(RED-PUR). bearings in place of bushings. The solenoid switch,
plunger, return spring, and shift lever are permanent-
• 20 amp fuse to ignition switch terminal I ly mounted in the drive housing.
(RED-PUR). At this point ignition switch is
turned to START.
! CAUTION
• Ignition switch terminal B to terminal S.
The starter motor is designed to operate under
• Ignition switch terminal S to neutral start
great overload and produce a high horsepower
switch (YEL-RED). NEUTRAL START SWITCH
for its size. It can do this only for a short time,
MUST BE AT NEUTRAL POSITION.
since considerable heat accumulates and can
• Neutral start switch to wiring harness plug cause serious damage. For this reason, the
terminal 7 (YEL-RED). cranking motor must never be used for more than
• Wiring harness plug to starter solenoid (small 30 seconds at any one time. Cranking should not
terminal) (YEL-RED). Also ensure that black be repeated without a pause of at least 2 minutes
(small terminal) wire is grounded. to permit the heat to escape.
• Starter solenoid is now “closed,” completing

circuit between large terminal (RED-PUR) and
other large terminal (YEL-RED), causing
starter motor to crank.
Index
THIS PAGE IS INTENTIONALLY BLANK
Index
PG 200 and PG 250 Starter Motor (Exploded View)
19
7
18
3
10
9 6
11
17
12
1
13
14
16 15
72079
Index
1 - Field Frame (with Permanent Magnets)
2 - End Frame Solenoid Switch
3 - Ball Bearing The solenoid switch, along with plunger, return
4 - Brushes With Frame
5 - Brush Spring spring, and shift lever, are completely sealed and
6 - Armature permanently mounted in the drive housing. If sole-
7 - Shield noid is defective, entire drive housing must be re-
8 - Gear placed.
9 - Roller Bearing
10 - Planetary Gear And Shaft Assembly
11 - Drive
12 - Collar
13 - Retaining Ring Periodic Inspection
14 - Thrust Collar
15 - Drive Housing
Cranking motor and solenoid are completely en-
16 - Roller Bearing closed in the drive housing to prevent entrance of
17 - Nut moisture and dirt. However, periodic inspection is re-
18 - Screw quired as follows:
19 - Thru Bolt
* Contains: Starter Solenoid, Plunger, Return Spring and 1. Inspect terminals for corrosion and loose con-
Shift Lever
nections.
2. Inspect wiring for frayed and worn insulation.
3. Check starter mounting bolts for tightness.
PG 200 and PG 250 Starter

Motor Repair
Removal
! WARNING
Disconnect battery cables at battery before re-
moving starter.
2. Disconnect wires from solenoid terminals.
IMPORTANT: Some starter motors may use a

special mounting shim for gaining flywheel
clearance. Do not lose this shim; it will be needed
when remounting starter on engine block.
3. Remove starter mounting bolts.
move from engine.
Index
Disassembly 3. Pull armature out of field frame.
1. Remove brush lead from solenoid and screws NOTE: Permanent magnets inside field frame will be
from end frame. holding armature in place.
a
b
72060 72062
a - Armature
a - Brush Lead
b - Field Frame
b - Screws
4. Pull end frame off bearing.

2. Remove thru bolts and separate field frame with
armature from drive housing.
a b
c
72063
a - End Frame
72061 b - Bearing
a - Field Frame / Armature

b - Drive Housing
c - Thru Bolts
Index
5. Remove shield. 7. Remove thrust collar, retaining ring and collar.
Remove drive.
a c
a 72065
72067
a - Thrust Collar
a - Shield b - Retaining Ring
c - Collar
6. Use a screwdriver, as shown, to disengage shift d - Drive
lever from drive.
8. Remove gear from shaft assembly.
a
a
72064 72066
a - Gear
b - Shaft Assembly
a - Shift Lever
Index
Cleaning and Inspection TEST FOR GROUND
IMPORTANT: Do not use grease dissolving sol- 1. With continuity meter, place one lead on arma-
vents to clean electrical components, planetary ture core or shaft and other lead on commutator.
gears, or drive. Solvent will damage insulation 2. If meter hand moves, armature is grounded and
and wash the lubricant out of the drive and gears. must be replaced.
Use clean rags and compressed air to clean com-
ponents. b c
1. Test over-running clutch action of drive. Pinion

should turn freely in over-running direction and
must not slip in cranking direction. Check pinion
teeth. Check spring for tension and drive collar
for wear. Replace if necessary.
d
2. Check that brush holders are not damaged or
bent and hold brushes against commutator.
Check brushes for wear; refer to “Brushes and
Brush Holder.”
3. Inspect armature commutator. If badly grooved
or out-of-round, turn down and undercut commu- c
a
tator.
4. Inspect all roller bearing surfaces for wear. Check
that bearings roll freely. If any roughness is felt, 01441
replace bearings. a - Commutator

b - Armature Core
5. Inspect planetary gear assembly. Gears must
c - Shaft
mesh easily and roll freely with no binding. d - Growler
Armature Tests
Armature Bearing (Commutator End)
TEST FOR SHORTS
Check armature for shorts by placing on growler and REMOVAL
holding hack saw blade over armature core while ro- Use a universal puller plate, as shown, to remove
tating armature. If saw blade vibrates, armature is bearing.
shorted. After cleaning between commutator bars,
a
b
c
a b
01440
72068
a - Hacksaw Blade
b - Armature Core a - Universal Puller Plate
c - Growler b - Bearing
Index
INSTALLATION Shaft Assembly Bearing
IMPORTANT: Brush holder must be installed on IMPORTANT: Roller bearing is not replaceable. If
armature before installing armature bearing. bearing is defective, replace entire shaft assem-
Using the correct size driver, press on inner bearing bly. Apply Quicksilver 2-4-C Marine Lubricant
race until it contacts shoulder of armature shaft. with Teflon to bearing before starter reassembly.
Gear Bearing
REMOVAL
Using the correct size driver, press bearing out of a
gear.
INSTALLATION
1. Using the correct size driver, press bearing into
gear, from direction shown, to depth (a).
72070
a - Roller Bearing
a Drive End Housing Bearing
REMOVAL
Using the correct size driver, press bearing out of
INSTALLATION
housing.
DIRECTION
INSTALLATION
1. Using the correct size driver, press bearing into
housing, from direction shown, to depth (a).
72625
a
a - See Specifications
2. Lubricate bearing and gear teeth with a small b

amount of Quicksilver 2-4-C Marine Lubricant
with Teflon.
72626
a - See Specifications
b - Installation Direction
2. Lubricate bearing with a small amount of Quick-

silver 2-4-C Marine Lubricant with Teflon.
Index
Brushes and Brush Holder INSTALLATION
1. Push each brush up into its guide to allow spring
INSPECTION to hold it in place, as shown.
Replace brushes and holder when brush leads are c a
touching guide.
Make sure brushes move freely in guides. b
a
72072
a - Brush
b - Guide
c - Brush Spring
72069 2. Place brush holder on armature and push

a - Brush Leads brushes down against commutator, as shown.
b - Guides
c
REMOVAL
a
1. Remove armature bearing as previously de-
scribed.
2. Remove brush holder.
72069
a - Brush Holder
b - Commutator
c - Brush
3. Install armature bearing as previously described.
Index
Reassembly 3. Coat roller bearings and gear with a small
amount of Quicksilver 2-4-C Marine Lubricant
1. Install end frame on brush holder. Align holes of with Teflon.
end frame with holes of brush holder. Tighten
screws securely. a
c
72627
a - Roller Bearing
b - Roller Bearing
b a c - Gear
72063
4. Assemble gear and shaft together, as shown.
a - Holes Of End Frame
b - Holes Of Brush Holder
2. Insert armature into field frame. Align brush hold- a

er lead with notch in field frame.
NOTE: Permanent magnets in field frame will pull
armature in place.
b
a
b
72070
a - Gear Assembly
b - Shaft Assembly
72062
a - Brush Holder Lead 5. Assemble drive on shaft assembly as follows:
b - Notch
a. Lubricate drive end of shaft assembly with
SAE 10W oil.
b. Slide drive assembly onto shaft with pinion
outward.
c. Slide retainer onto shaft with cupped surface
Index
d. Position snap ring on upper end of shaft and 6. Apply a thin coating of Quicksilver 2-4-C Marine
hold in place with block of wood. Strike wood Lubricant with Teflon to roller bearing in drive
block with hammer, thus forcing snap ring housing.
over end of shaft. Slide snap ring down into
7. Insert shaft and drive assembly into drive hous-
groove.
ing. Pins of drive must be snapped into holes of
shift lever. Thrust collar must be in place before
shaft is inserted in housing roller bearing.
a
a
b
c 72628
c
b
72073
a - Snap Ring
b - Groove
c - Retainer
e. Assemble thrust collar on shaft with shoulder

next to snap ring. 72075
a - Pins Of Drive
f. Position retainer and thrust collar next to
b - Holes Of Shift Lever
snap ring. Then, using two pliers, grip retainer c - Thrust Collar
and thrust collar and squeeze until snap ring
is forced into retainer. 8. Install shield. Align brush lead and solenoid ter-
b minal when inserting armature into planetary
gears.
c
b
c
a
72074
a - Retainer 72061
b - Thrust Collar a - Shield
c - Snap Ring b - Brush Lead
c - Solenoid Terminal
Index
9. Install thru bolts and brush lead. Tighten fasten-
ers securely.
IMPORTANT: Do not overtighten thru bolts. Over-

tightening will bend end frame.
72060
a - Thru Bolts
b - Brush Lead
Installation
IMPORTANT: Install special mounting shim (if
equipped) between starter motor and engine
block.
1. Place starter motor in position and install mount-
ing bolts. Torque bolts to 30 lb. ft. (41 N·m).
2. Connect YELLOW/RED wire to terminal S of so-
lenoid. Connect ORANGE wire, RED wire, and
battery cable to large terminal of solenoid. Tight-
en fasteners securely. Coat terminals with Quick-
silver Liquid Neoprene. Install battery cable boot,
if so equipped.
3. Connect battery cables to battery in the following
order. Connect positive (+) cable to positive (+)
battery terminal and tighten cable clamp. Then
connect negative (–) cable to negative (–) termi-
nal and tighten clamp.
Index
PG 260 Starter Motor
Exploded View
20
3
6
8
4
9
5
16
17 10
11
18
12
21
13
14
15
19
74270
Index
1 - Screw (2)
2 - End Cap Solenoid Switch
3 - Brush With Holder The solenoid switch can be removed and replaced if
4 - Armature
5 - Field Frame (With Permanent Magnets) defective.
6 - Washer
7 - Shield
8 - Planetary Gears
9 - Shaft Periodic Inspection
10 - Gear
11 - Drive Cranking motor and solenoid are completely en-
12 - Collar closed in the drive housing to prevent entrance of
13 - Retaining Ring moisture and dirt. However, periodic inspection is re-
14 - Trust Collar
15 - Drive Housing
quired as follows:
16 - Nut 1. Inspect terminals for corrosion and loose con-
17 - Solenoid
18 - Solenoid Drive Arm
nections.
19 - Screw (3) 2. Inspect wiring for frayed and worn insulation.
20 - Thru Bolt (2)
21 - Rubber Grommet 3. Check starter mounting bolts for tightness.
PG 260 Starter Motor Repair
Removal
! WARNING
Disconnect battery cables at battery before re-
moving starter.
2. Disconnect wires from solenoid terminals.
IMPORTANT: Some starter motors may use a

special mounting shim for gaining flywheel
clearance. Do not lose this shim; it will be needed
when remounting starter on engine block.
3. Remove starter mounting bolts.
move from engine.
Index
Disassembly 4. Remove armature and field frame from drive
housing.
1. Remove brush lead from solenoid and screws
from end frame. 5. Pull armature out of field frame.
NOTE: Permanent magnets inside field frame will be

a holding armature in place.
74041
a - Brush Lead b
b - Screws a 74086
2. Remove thru bolts and separate end frame from

field frame and end cap. a - Armature
b - Field Frame
c
6. Remove shield and washer.
a
b
74040
a - End Cap
b - Thru Bolts
c - Drive Housing a
3. Remove brush holder from end cap. b 74038
a - Shield
b - Washer
a
b 74037
a - Brush Holder
b - End Cap
c - Screws (2)
Index
7. Remove the three screws retaining the solenoid. 9. Remove solenoid arm and rubber grommet from
Remove solenoid from drive housing. the drive housing.
a
74105
b
b
74048
a 74036
a - Drive Housing
b - Solenoid
c - Screws (3)
c
8. Remove drive and associated parts from drive
housing.
74018
a - Rubber Grommet
b - Solenoid
c - Drive Housing
74035
a b 10. Remove thrust collar, retaining ring and collar
a - Drive Housing
from planetary shaft.
b - Drive b
a c
74016
a - Thrust Collar
b - Retaining Ring
c - Collar
d - Drive
Index
11. Remove drive and gear from planetary shaft. Cleaning and Inspection
IMPORTANT: Do not use grease dissolving sol-
vents to clean electrical components, planetary
gears, or drive. Solvent will damage insulation
a and wash the lubricant out of the drive and gears.
Use clean rags and compressed air to clean com-
ponents.
1. Test over-running clutch action of drive. Pinion
should turn freely in over-running direction and
must not slip in cranking direction. Check pinion
teeth. Check spring for tension and drive collar
b for wear. Replace if necessary.
2. Check that brush holders are not damaged or
bent and hold brushes against commutator.
Check brushes for wear; refer to “Brushes and
Brush Holder.”
c 3. Inspect armature commutator. If badly grooved
or out-of-round, turn down and undercut commu-
tator.
4. Inspect all roller bearing surfaces for wear. Check
74087
that bearings roll freely. If any roughness is felt,
a - Gear
replace bearings.
b - Shaft Assembly
c - Drive 5. Inspect planetary gear assembly. Gears must
mesh easily and roll freely with no binding.
Index
Armature Tests 2. If meter hand moves, armature is grounded and
must be replaced.
TEST FOR SHORTS
Check armature for shorts by placing on growler and b c
holding hack saw blade over armature core while ro-
tating armature. If saw blade vibrates, armature is
shorted. After cleaning between commutator bars,
a
d
c
a
01441
a - Commutator
b - Armature Core
c - Shaft
d - Growler
01440
Brushes and Brush Holder

a - Hacksaw Blade
b - Armature Core INSPECTION
c - Growler
Replace brushes and holder when brush leads are
TEST FOR GROUND touching guide.
Make sure brushes move freely in guides.
1. With continuity meter, place one lead on arma- a
ture core or shaft and other lead on commutator.
b
72069
a - Brush Leads
b - Guide
Index
INSTALLATION 2. Place brush holder on armature and remove
pieces of wires from brush holder.
1. Push each brush up into its guide, use a 3 inch
piece of coat hanger wire or similar stiff wire to
retain the spring while installing armature, as
shown. b
a
d
c b
72069
a - Brush Holder
b - Brush
a - Brush
b - Guide
c - Brush Spring
d - 3 Inch Piece Of Coat Hanger Or Stiff Wire
Index
Reassembly 2. Install gear and drive over planetary shaft.
1. Install end frame on brush holder. Align holes of

end frame with holes of brush holder. Tighten
screws securely.
b
c
d c
74087
a - Planetary Shaft
b - Gear
c - Drive
3. Assemble drive on shaft assembly as follows:

a - Screw (2) a. Lubricate drive end of shaft assembly with
b - End Cap
c - Brush Holder SAE 10W oil.
d - Armature
b. Place gear over shaft.
c. Slide drive assembly onto shaft with pinion
facing outward.
d. Slide retainer onto shaft with cupped surface
Index
e. Position snap ring on upper end of shaft and 5. Install solenoid arm and rubber grommet in the
hold in place with block of wood. Strike wood drive housing.
block with hammer, thus forcing snap ring
over end of shaft. Slide snap ring down into
groove. a
b
c c
72073
a - Snap Ring
b - Groove
c - Retainer 74135
a - Rubber Grommet
f. Assemble thrust collar on shaft with shoulder b - Solenoid
next to snap ring. c - Drive Housing
g. Position retainer and thrust collar next to

6. Install drive and associated parts in drive hous-
snap ring. Then, using two pliers, grip retainer
ing.
and thrust collar and squeeze until snap ring
is forced into retainer.
b
c
a
a b
74035
a - Drive Housing
b - Drive
72074
a - Retainer
b - Thrust Collar
c - Snap Ring
4. Install the planetary gears on planetary shaft.
Index
7. Place solenoid in drive housing and tighten 9. Install field frame over armature. Align slot in end
screws. cap and field frame for proper positioning of rub-
ber grommet.
c
10. Install field frame and end cap in drive housing

align slots in field frame with recess in drive hous-
a 74036
ing.
a - Drive Housing
b - Solenoid
c - Screw (3)
8. Install shield and washer in drive housing.
a
b
a
b
a - Drive Housing
b - End Cap And Field Frame
74038
a - Shield
11. Install thru bolts and brush lead. Tighten fasten-
b - Washer ers securely.
Index
Clearances 5. Measure distance between pinion and pinion
retainer.
PINION CLEARANCE 6. If clearance is not within limits of .010-.160 in.
Pinion clearance must be checked after reassembly (0.25-4.00 mm), it may indicate excessive wear
of starter motor. of solenoid linkage, shift lever yoke, or improper
assembly of shift lever mechanism. Replace
1. Disconnect brush lead from solenoid motor and worn or defective parts, since no provision is
insulate it carefully. made for adjusting pinion clearance.
a
b
a
74041
a - Brush Lead c
2. Connect 12 volt battery positive (+) lead to bat-

tery terminal and negative (–) lead to frame.
72077
3. Momentarily touch a jumper lead from battery ter-
minal to switch terminal. This shifts pinion into a - Pinion
cranking position where it will remain until battery b - Retainer
c - Feeler Gauge
is disconnected.
Installation
IMPORTANT: Install special mounting shim (if
equipped) between starter motor and engine
block.
1. Place starter motor in position and install mount-
ing bolts. Torque bolts to 30 lb. ft. (41 N·m).
2. Connect YELLOW/RED wire to terminal S of so-
lenoid. Connect ORANGE wire, RED wire, and
battery cable to large terminal of solenoid. Tight-
en fasteners securely. Coat terminals with Quick-
silver Liquid Neoprene. Install battery cable boot,
if so equipped.
3. Connect battery cables to battery in the following
order. Connect positive (+) cable to positive (+)
72629 battery terminal and tighten cable clamp. Then
connect negative (–) cable to negative (–) termi-
4. Push pinion back toward commutator end to
nal and tighten clamp.
eliminate slack.
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
ELECTRICAL SYSTEMS
4
B
72722
THUNDERBOLT IV AND V
IGNITION SYSTEM
Index
4B - IGNITION SYSTEM 90-823224 692
Table of Contents
Page Page
Thunderbolt IV Ignition System . . . . . . . . . . . . . 4B-1 Thunderbolt IV Ignition Timing . . . . . . . . . . . . 4B-13
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Thunderbolt V Ignition System . . . . . . . . . . . . 4B-14
Replacement Parts Warning . . . . . . . . . . . . . . . 4B-1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . 4B-14
Thunderbolt IV (HEI) Electronic General Description . . . . . . . . . . . . . . . . . . . . . 4B-15
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1 Idle Speed Spark Control . . . . . . . . . . . . . . 4B-15
Torque Specifications . . . . . . . . . . . . . . . . . . 4B-1 Acceleration Spark Advance . . . . . . . . . . . 4B-15
Tools/Lubricants/Sealants . . . . . . . . . . . . . . . 4B-1 Mean-Best-Timing (MBT)
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Spark Advance . . . . . . . . . . . . . . . . . . . . . . 4B-15
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Over-Speed Control . . . . . . . . . . . . . . . . . . . 4B-15
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Knock Retard Spark Control . . . . . . . . . . . 4B-15
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Thunderbolt V Spark Control Graph . . . . . . . 4B-16
Distributor Advance Curves . . . . . . . . . . . . . 4B-3 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Ignition Control Module . . . . . . . . . . . . . . . . 4B-17
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Knock Control Module . . . . . . . . . . . . . . . . . 4B-17
Distributor Cap . . . . . . . . . . . . . . . . . . . . . . . . 4B-6 Ignition Control System Timing Lead . . . . 4B-17
Rotor/Sensor Wheel . . . . . . . . . . . . . . . . . . . 4B-7 Ignition System Wiring Diagram . . . . . . . . . . . 4B-18
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Timing and Idle Adjustment Procedures
Thunderbolt IV Ignition Module . . . . . . . . . . 4B-9 For Thunderbolt V Ignition . . . . . . . . . . . . . . . 4B-19
Distributor Repair . . . . . . . . . . . . . . . . . . . . . . . . 4B-9 Setting Base Ignition Timing . . . . . . . . . . . . 4B-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9 Adjusting Idle Mixture . . . . . . . . . . . . . . . . . 4B-19
Thunderbolt IV Exploded View . . . . . . . . . 4B-10 Adjusting Engine Idle Speed . . . . . . . . . . . 4B-19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4B-11 Troubleshooting Thunderbolt V Ignition . . . . . 4B-20
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4B-11 Ignition Control Module / Coil /
Distributor Installation . . . . . . . . . . . . . . . . . . . . 4B-12 Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20
Engine Not Disturbed . . . . . . . . . . . . . . . . . 4B-12 Knock Control Module . . . . . . . . . . . . . . . . . 4B-21
Engine Disturbed . . . . . . . . . . . . . . . . . . . . . 4B-12 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-22
Spark Plug Wires . . . . . . . . . . . . . . . . . . . . . 4B-23
NOTICE
Index
4B - IGNITION
4B-0 SYSTEMIV AND V IGNITION SYSTEM
- THUNDERBOLT 90-823225--1 1096
Thunderbolt IV Ignition Replacement Parts Warning
System ! WARNING
Identification tured to comply with U.S. Coast Guard Rules and
sion.
Use of replacement electrical, ignition or fuel
system components, which do not comply with
these rules and regulations, could result in a fire
or explosion hazard and should be avoided.
Thunderbolt IV (HEI)
Electronic Ignition System
Fastener Location In. Lb. Ft. Lb. N·m
71790
Distributor Clamp 20 27
Spark Plugs (14 mm) 15 20
DISTRIBUTOR WITH IGNITION MODULE Ignition Module
MOUNTED ON EXHAUST ELBOW Retaining Screws 10 1.1
(Stainless Steel)
a
Tools/Lubricants/Sealants
Timing Light 91-99379
Multi-Meter / DVA 91-99750
Torch Lamp 91-63209
Insulating Compound 92-41669--1
Quicksilver Liquid
92-27511-2
Neoprene
Loctite 271
Thermalconductive Obt i Locally
Obtain L ll
Grease
72722
DISTRIBUTOR WITH IGNITION MODULE

MOUNTED ON DISTRIBUTOR BODY
a - Ignition Module
NOTE: Except for ignition module replacement, re-

pair procedures for both distributors are the same.
Index
90-823225--1 1096 THUNDERBOLT IV AND V IGNITION SYSTEM - 4B-1
Specifications Firing Order
Coil Firing Order 1-8-4-3-6-5-7-2
Description Specification
Coil Part Number 392-7803A4
Primary Resistance .60-.80 Ohms
Secondary Resistance 9,400-11,700 Ohms
Spark Plugs
All MIE and MCM
Model
Except Gen+ Engines
Spark Plug .040 In. (1 mm)
AC-MR43T
Spark Plug Type NGK BR6FS 72008
Champion RV15YC4
All MIE and MCM

Model
Gen+ Engines
Spark Plug .045 In. (1.1 mm)
AC-MR43LTS
Spark Plug Type NGK BPR6EFS
Champion RS12YC
Index
4B-2 - THUNDERBOLT IV AND V IGNITION SYSTEM 90-823225--1 1096
Distributor Advance Curves
MCM 5.0L ALPHA/MCM 5.0LX ALPHA/MCM 5.0L BRAVO
IMPORTANT: Distributor advance curve charts do not include the initial engine timing. Basic initial tim-
ing must be added to chart for total advance curve. The spark advance is controlled by the ignition mod-
ule.
Identification Mark: V8-22

Module Advance: 22 Degrees
Initial Timing: 8 Degrees BTDC
Total Advance: 30 Degrees
TOTAL SPARK ADVANCE
MINUS INITIAL TIMING
MAX.
MIN.
ENGINE RPM
72723
Index
MCM 5.7L ALPHA/MIE 5.7L
ing must be added to chart for total advance curve.
IMPORTANT: The spark advance is controlled by the ignition module.
Identification Mark: V8-22A

TOTAL SPARK ADVANCE
MAX.
MIN.
ENGINE RPM
72724
Index
MCM 5.7L BRAVO/MCM 350 MAGNUM ALPHA/MIE 5.7L COMPETITION SKI/MIE 350 MAGNUM
TOURNAMENT SKI
ing must be added to chart for total advance curve.
IMPORTANT: The spark advance is controlled by the ignition module.
Identification Mark: V8-24S

TOTAL SPARK ADVANCE
MAX.
MIN.
ENGINE RPM
72725
Index
Repair IMPORTANT: If high tension leads are removed
from cap refer to “Spark Plug Wires” in this sec-
tion and the following illustrations for installa-
tion.
Precautions
! WARNING
When performing the following procedure, be
sure to observe the following:
• Be sure that engine compartment is well ven-
tilated and that no gasoline vapors are pres-
ent, to avoid the possibility of fire.
• Be sure to keep hands, feet and clothing clear
of moving parts. a
• Do not touch or disconnect any ignition sys-
tem parts while engine is running.
• Do not reverse battery cable connections.
System is negative (–) ground.
• Do not disconnect battery cables while en- 72726
gine is running.
a - Alignment Notch
Distributor Cap
1. Loosen four distributor cap retaining screws.
2. Remove distributor cap.
3. Clean cap with warm soap and water and blow off
with compressed air.
4. Check cap contact for excessive burning or cor-
rosion. Check center contact for deterioration.
5. Check cap for cracks or carbon tracks using mag- a
neto analyzer.
72728
a - Vent
Index
Rotor/Sensor Wheel IMPORTANT: If there is any doubt if sensor wheel
is located properly, lay sensor wheel on top of the
1. Remove distributor rotor/sensor wheel assembly figure above with sensor fingers facing up (to-
from distributor shaft. Rotor and sensor wheel ward you). Line up three screw holes and locat-
are secured to the shaft with Loctite. Use two flat ing pin hole on sensor wheel with the figure. If
blade screwdrivers. The screwdrivers are posi- wheel is indexed properly all the fingers on wheel
tioned opposite each other with the blade tips on will line up with those in the figure.
the underside of the rotor and sensor wheel as-
sembly. Make sure blade tips are toward distribu- 4. If there are pieces of material shaved off the key
tor shaft until they come in contact with shaft. A or if it appears to have been damaged by being
downward push on both screwdriver handles at forced down while misaligned with slot in distribu-
the same time will pry off rotor/sensor wheel as- tor shaft, the rotor must be replaced.
sembly. The use of torch lamp will also aid in the 5. Check rotor for burned or corroded center con-
removal of the rotor/sensor wheel assembly. tact.
6. Check rotor for cracks and carbon tracks using
! WARNING magneto analyzer and instructions supplied with
analyzer.
Wear protective gloves when handling heated ro-
tor/sensor wheel assembly to avoid severe 7. If rotor is damaged, replace rotor by removing
burns. three hex bolts and separating sensor wheel
from rotor. Reinstall sensor wheel to new rotor
making sure locating pin on rotor is installed in lo-
2. With the rotor/sensor wheel assembly removed,
cating hole in sensor wheel. Tighten three hex
inspect the locating key inside the rotor.
bolts securely.
3. The locating key will appear as a clean edged, 1/8
8. Bend carbon brush tang upward slightly until a
in. (3 mm) wide, sloped ramp at the bottom of the
distance of 1/4 in. (6 mm) is obtained between ro-
splined hole.
tor and tang.
72731
c
a - 1/4 in. (6 mm)
9. Put 2 drops of Loctite 271 into the rotor so it lands

72730
on the locating key.
a - Locating Key 10. Put 2 drops of Loctite 271 in keyway on upper
b - Screws
portion of distributor shaft.
c - Senor Wheel
d - Locating Pin 11. Immediately install rotor assembly onto distribu-
tor shaft. Make sure rotor locating key is aligned
with keyway in distributor shaft before pressing
rotor all the way down on the shaft, until it stops,
with the palm of your hand. Let Loctite cure over-
night with distributor in inverted position.
Index
IMPORTANT: The rotor should fit very tight. It 4. Use a magnifying glass and light to inspect the
may be necessary to heat rotor with torch lamp two metal “jumper leads” for cracks. If a crack is
to properly install. It is important not to let any found in either metal “jumper lead,” install a new
Loctite run down distributor shaft. Loctite could sensor.
get into top distributor housing bushing.
12. Reinstall distributor cap on distributor.

13. Install spark plug wires (if removed). Refer to
“Spark Plug Wires” in this section.
Sensor
1. Remove rotor and sensor wheel.
2. Disconnect sensor wires. a
3. Remove two screws that hold sensor into distrib-
utor housing. Remove sensor from housing.
72733
a - Jumper Leads
! CAUTION
Do not use any type of silicone sealer on the in-
side of the distributor. Most silicone sealers give
off an acidic vapor during the curing stage of the
sealer. This acid can cause corrosion on the igni-
tion components.
b 5. Install sensor into housing and install two retain-

ing screws.
a
6. Install sensor wheel, rotor, and distributor cap.
7. Connect WHT/RED and WHT/GRN sensor wires
72732 (ring terminals on engine harness wires, or bullet
connectors from ignition module wires). Tighten
hex nuts securely, if so equipped.
a - Mounting Screws
b - Senor Assembly
Index
Thunderbolt IV Ignition Module Distributor Repair
IGNITION MODULE MOUNTED ON EXHAUST
ELBOW Removal
1. Unplug wiring harness connector from ignition 1. Unplug wiring harness from ignition module on
module. distributor housing, or disconnect wires from igni-
tion module mounted on exhaust elbow. Discon-
2. Remove fasteners and hardware retaining igni-
nect sensor wires.
tion module to exhaust elbow. Remove module.
2. Remove distributor cap. Do not remove high ten-
NOTE: Do not disturb spacers between ignition mod-
sion leads unless necessary.
ule plate and exhaust elbow, unless replacing
spacers. 3. Crank engine over until timing marks line up and
rotor is pointing toward No. 1 cylinder on distribu-
IMPORTANT: BLACK ground (–) wire from engine tor cap.
harness must be placed under ignition module 4. Mark distributor housing in reference to engine
fastener when mounting module. block.
3. Replace ignition module using existing hard- 5. Remove bolt and hold-down clamp and remove
ware. Tighten fasteners securely. Be certain distributor.
BLACK ground (–) wire is in position.
4. Check that terminals of wiring harness connector IMPORTANT: To simplify distributor installation,
are clean and free of corrosion. Plug connector do not turn crankshaft when distributor is re-
into ignition module. moved from engine.
IGNITION MODULE MOUNTED ON

DISTRIBUTOR
1. Unplug wiring harness connector from ignition
module.
2. Remove stainless steel screws retaining ignition
module to distributor body. Remove module.
IMPORTANT: Thermalconductive Grease must

be applied to the back of the ignition module to
conduct heat away from the module and to pre-
vent corrosion.
3. Apply a thin coat of Thermalconductive Grease
evenly across the metal back of the ignition mod-
ule.
4. Install ignition module using the stainless steel
screws. Torque screws to 10 lb. in. (1.1 N·m).
5. Check that terminals of wiring harness connector
are clean and free of corrosion. Plug connector
into ignition module.
Index
Thunderbolt IV Exploded View
2
9 12
10
3
11
13 14
15
5
7
16
17
18
8
19
20
21
22
72058
Index
1 - Distributor Cap Reassembly
2 - Vent
3 - Gasket 1. Lubricate shaft with engine oil. Install E-clip (if
4 - Rotor
5 - Senor Wheel
removed) on shaft in housing.
6 - Screws (5) 2. Install washer on shaft. Install original gear; slide
7 - E-Clip
8 - Shaft
onto shaft and install roll pin.
9 - Screws (2)
10 - Lockwashers (2)
IMPORTANT: Hole may be offset and gear will
11 - Sensor
12 - Upper Bushing only fit in one direction.
13 - Ignition Module , If Equipped (Apply Thermalconductive
Grease) 3. If installing a new gear, the gear will come drilled
14 - Screws (2) on one side. Slide gear onto shaft; align hole in
15 - Distributor Housing gear with hole in shaft. Using these holes as
16 - Lockwasher guides, drill through other side of gear with a
17 - Nut
3/16 in. carbide tripped drill.
18 - Lower Bushing
19 - Gasket
20 - Washer IMPORTANT: If a new gear has only a dimple, you
21 - Gear
22 - Roll Pin
will have to drill through one side of the gear be-
fore you slide gear onto shaft. In most cases it is
recommended to have a machine shop complete
Disassembly the drilling operation for new gear installation.
NOTICE
Refer to exploded view preceding for parts
identification during disassembly and reas-
sembly. a
d
b
1. Remove rotor, sensor wheel, sensor, and ignition
module (if mounted on distributor), as previously
outlined.
2. Remove roll pin, washer and driven gear from
distributor shaft.
3. Check for side play between shaft and distributor
housing bushings. Maximum side play is .002 in. c
(0.05 mm).
4. Remove shaft from housing and check shaft for
being bent with a dial indicator and V-blocks. 72735
Maximum runout is .002 in. (0.5 mm).
a - Drill Press
b - 3/16 in. Carbide Tip Drill
c - V-Block
d - New Gear
4. Install sensor, sensor wheel, rotor, and ignition

module (if mounted on distributor), as previously
outlined.
5. Install distributor as outlined in “Distributor Instal-
lation.”
Index
Distributor Installation b. Remove rocker cover and crank engine until
No. 1 intake valve closes, continuing to crank
slowly until pointer lines up with timing mark
on crankshaft pulley.
Engine Not Disturbed
2. Position distributor to opening in block in normal
1. Install new gasket on distributor housing. installed attitude.
2. Turn rotor approximately 1/8-turn in a counter-
clockwise direction past mark previously IMPORTANT: Make sure oil pump shaft is en-
scratched on distributor housing. gaged in the following. Position (align) oil pump
3. Work distributor down into position in engine shaft end to engage bottom of distributor dive
block with distributor positioned as noted during gear prior to inserting distributor if necessary.
removal.
3. Position rotor to point toward No. 1 cylinder on
IMPORTANT: It may be necessary to move rotor cap (with distributor housing held in installed atti-
slightly to start gear into mesh with camshaft tude), then turn rotor counterclockwise approxi-
gear, but rotor should line up with the mark when mately 1/8-turn more and work distributor down
distributor is down in place. Distributor shaft to engage camshaft and oil pump shaft. It may be
must enter oil pump shaft for complete installa- necessary to rotate rotor slightly until engage-
tion. ment is felt.
4. Replace and tighten distributor hold-down bolt
and clamp. Connect distributor ground (–) leads. ! CAUTION
5. Install cap. Refer to “Spark Plug Wires” and install Avoid severe engine damage. Do not attempt to
wires. force distributor into position using hold-down
clamp and bolt.
6. Plug wiring harness into ignition module on dis-
tributor housing, on distributors so equipped.
Connect wires from ignition module to distributor 4. When distributor housing contacts intake man-
terminals, on all models. ifold, camshaft and oil pump shaft are engaged.
Install hold-down clamp and bolt and snug up
7. Coat any exposed terminals with Quicksilver Liq-
bolt.
uid Neoprene.
5. Connect distributor ground (–) leads, if so
8. Time ignition as outlined under “Ignition Timing.”
equipped.
6. Place distributor cap in position and check that
Engine Disturbed rotor lines up with terminal for No. 1 spark plug.
Install new gasket on distributor housing. Install
1. Locate No. 1 piston in firing position by following cap.
instructions “a” or “b”:
7. Refer to “Spark Plug Wires” and install wires. Re-
a. Remove No. 1 spark plug and, with finger on fer to “Specifications” for firing order.
plug hole, crank engine until compression is
felt in No. 1 cylinder. Continue cranking until 8. Plug wiring harness into ignition module on dis-
pointer lines up with timing mark on crank- tributor housing, on distributors so equipped.
shaft pulley. Connect wires from ignition module to distributor
terminals, on all models.
9. Coat any exposed terminals with Quicksilver Liq-
uid Neoprene.
10. Time ignition as outlined under “Ignition Timing.”
Index
Thunderbolt IV Ignition 5. Adjust timing by loosening distributor clamp and
rotating distributor body as required until timing
Timing mark on damper or pulley lines up with the mark
on tab specified in “Specifications.” Tighten
1. Connect timing light (91-99379 or similar) to No.
clamp and recheck location of timing mark.
1 spark plug. Connect power supply leads on
light to 12 volt battery. Refer to “Specifications” 6. Stop engine and remove timing light.
for cylinder numbering and location.
2. Connect tachometer to engine.
3. Start engine and run at normal idle speed.
4. Aim timing light at timing tab, located on timing
gear cover and crankshaft torsional damper.
IMPORTANT: GM engine timing marks (on tab)

are in 2-degree increments. MCM and MIE LH en-
gines will have “A” (Advance) mark to the left of
“0.” Timing must be set on the “A” side of “0”
(Top Dead Center).
72328
72851
a - Degree Marks
b - Timing Mark
Index
Thunderbolt V Ignition System
Identification
The Thunderbolt V ignition system uses the same distributor as the Thunderbolt IV system. The Ignition Control
Module and Knock Control Module are mounted with the ignition control module.
73999
a - Ignition Control Module

b - Knock Control Module
Index
General Description NOTE: The Audio Warning System is also connected
into the ignition module circuit. If the audio warning
The Thunderbolt V ignition system has several spark system becomes activated by the closing of one of
control features that will be described following: the audio warning system switches, the MBT feature
Idle Speed Spark Control is deactivated.
Acceleration Spark Advance Over-Speed Control

Mean-Best-Timing Spark Advance The ignition module will prevent the engine speed
Over-Speed Control (Rev-Limiter) from exceeding a preset limit by stopping the spark.
This feature has an RPM range that varies from mod-
Knock Retard Spark Control el to model. The over-speed limit for a particular en-
NOTE: The Ski models do not have the Mean Best gine is set slightly higher than the top end of the RPM
Timing feature. range for that model. For example, if the recom-
mended range is 4600-5000 RPM, the over-speed
limit would be set at 5100 RPM. When RPM reaches
Idle Speed Spark Control this limit, spark is turned-off until engine RPM drops
down to a “Reset RPM”, which would be approxi-
The ignition module will control ignition timing to mately 4750 RPM for this example. At this point,
maintain a calibrated idle speed. This is accom- spark comes back on.
plished by making small spark advance adjustments.
This feature is only active within a certain RPM Knock Retard Spark Control
range. This range may be slightly different from one
engine model to another. The approximate range is The knock control feature helps provide protection
400-700 RPM. from harmful detonation. Knock control is handled by
the Knock Control Module. This module receives a
Acceleration Spark Advance signal from a sensor that is mounted on the engine
This feature is active during acceleration only. When block. The knock control module works in conjunc-
accelerating, the ignition module may add more tion with the ignition module to retard the timing if
spark advance to the “Base Spark Timing Curve”. spark knock is present.
The amount of spark advance added, is totally de-
pendant on how fast RPM increases (how fast the
throttle is moved). This feature is also active within a
certain RPM range. This range may be slightly differ-
ent from one engine model to another. The approxi-
mate RPM range for this feature is 1200-4000 RPM.
Within this range, the module can add approximately
10 degrees of spark advance to the base spark timing
curve.
Mean-Best-Timing (MBT)
Spark Advance
During light load cruising, the ignition module
searches for the optimal ignition timing. This is also
accomplished by small changes to the spark ad-
vance. At a given RPM, the module will try to add a
small amount of advance and wait to see if there is
an RPM change. If RPM increases, it will try to in-
crease timing more. The module will continue to ad-
vance timing until it no longer gets an increase in
RPM. Conversely, if it senses an RPM drop, it will
start to retard some of the spark timing. The approxi-
mate RPM range for this feature is 1200-4000 RPM.
Within this range, the ignition module can add
approximately 10-15 degrees of spark advance to
the base spark timing curve.
Index
Thunderbolt V Spark Control Graph
IMPORTANT: The graph below shows the typical advance ranges for a Thunderbolt V ignition control
module. The numbers plotted on the graph are not representative of any particular model. It is only pres-
ented to provide an understanding of how the system functions.
ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
35°
30°
25°
20°
TOTAL SPARK ADVANCE
15°
10° ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÅÅÅÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÅÅÅ
5°
ÅÅÅ
ÅÅÅ
ÅÅÅ
ÅÅÅ
0°
ÅÅÅ
–5°
ÅÅÅ
–10°
ÅÅÅ
–15°
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
ENGINE R.P.M.
ÅÅ
= Base Timing Advance Curve
ÅÅ = Idle Speed Advance Range
= Knock Retard Range
ÇÇ
ÇÇ
ÂÂ
= Acceleration Advance Range
ÂÂ = MBT Advance Range
Index
Circuit Description Knock Control Module
Refer to the circuit wiring diagram on the following The knock control module receives it’s power (+)
page for reference to this circuit description. from the PURPLE wire “4”.
Knock module ground (–) is accomplished thru
Ignition Control Module the BLACK wire “2”.
The ignition module receives its power (+) thru The PURPLE/WHITE wire “3” carries the signal
the PURPLE wire “9”. from the knock control module to the ignition
Ignition module ground (–) is accomplished thru control module.
the BLACK wire “10”. The BLUE wire “1” carries the signal from the
There is also a Case Ground (–) wire “12” that is knock sensor to the knock module.
connected to one of the ignition module attaching
screws.
Ignition Control System Timing Lead
The 12 volt signal from the ignition module to the
distributor is carried thru the WHITE/RED wire The ignition control system has a lead with bullet con-
“8”, to the distributor sensor and back to the nector “11” that is connected into the PURPLE/
ignition module thru the WHITE/GREEN wire “7”. WHITE wire “3”. This lead is used for performing the
The tachometer signal is carried to the following tests and procedures:
instrument panel thru the GRAY wire “11”. Setting “Base Ignition Timing”
The PURPLE/WHITE wire “3” carries the signal Setting “Engine Idle Speed”
from the knock control module to the ignition
Setting “Idle Mixture”
control module.
Testing Knock Control Circuit
There are two BLACK wires “5” that have bullet
connectors. This circuit is reserved for future This lead, when connected to an engine ground (–),
options. On current models, the two BLACK locks the ignition control module into the “Base Tim-
wires must be connected for the system to ing” mode.
function properly.
The TAN/BLU wire “6” carries a signal from the
Audio Warning circuit to the ignition module.
Index
Ignition System Wiring Diagram
BLK = BLACK
BLU = BLUE
TO ENGINE HARNESS TO DISTRIBUTOR
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
16 PUR/WHT
PUR = PURPLE
16 TAN/BLU
16 PUR/WHT
RED = RED
16 BLK
16 PUR
16 BLU
TAN = TAN
16 BLK
16 GRY
16 BLK
16 PUR
WHT = WHITE
YEL = YELLOW
16 PUR/WHT
LIT = LIGHT 5
13
DRK = DARK
16 WHT/GRN
16 WHT/RED
1
2
3 16 BLK
4
5 7 10
6 8
11
3 9
A B C DE
16 BLK
12
KNOCK IGNITION
CONTROL CONTROL
MODULE MODULE
1 - Knock Sensor Wire 8 - Distributor Wire

2 - Ground Wire (–) For Knock Module 9 - Battery (+) Positive Wire To Ignition Module
3 - Knock Module Signal Wire 10- Ground Wire For Ignition Module
4 - Battery (+) Positive Wire To Knock Module 11- Tachometer Wire
5 - Ground (–) For Future Options 12- Ignition Module Case Ground (–)
6 - Audio Warning System Wire 13- Timing Lead (For Setting Timing and Other Tests)
7 - Distributor Wire
Index
Timing and Idle Adjustment 1. Using a jumper wire, connect the ignition system
timing lead “13” (PUR/WHT wire) to a good en-
Procedures For Thunderbolt gine ground (–). This locks the ignition module
into the “Base Timing Mode”.
V Ignition
2. Adjust idle mixture following the procedure in the
appropriate engine service manual.
Setting Base Ignition Timing 3. Remove the jumper wire from the timing terminal.
1. Connect timing light to number 1 spark plug.
Connect timing light power supply leads (if
applicable) to 12 volt source. Adjusting Engine Idle Speed
2. Connect a shop tachometer to engine. This procedure should be done with boat in the water,
drive unit in neutral and engine at normal operating
3. Using a jumper wire, connect the ignition system temperature. Refer to the Operation and Mainte-
timing lead “13” (PUR/WHT wire) to a good en- nance Manual for the correct idle speed.
gine ground (–). This locks the ignition module
into the “Base Timing Mode”. 1. Disconnect the throttle cable from carburetor.
4. Start engine and run at normal idle speed. Allow
engine to reach normal operating temperature. IMPORTANT: In order to properly set idle speed,
the ignition module MUST BE locked in the “Base
5. Aim timing light at timing tab, located on the tim- Timing Mode”. This is necessary because of the
ing gear cover and crankshaft torsional damper. “Idle Speed Control” feature that exists in the
6. Adjust timing using the conventional method. ignition module. See information on the previous
pages about this feature.
IMPORTANT: Be sure to disconnect the jumper 2. Connect a shop tachometer to engine.
wire from the ignition system test terminal before 3. Using a jumper wire, connect the ignition system
attempting to resume normal operations. If the timing lead “13” (PUR/WHT wire) to a good en-
jumper wire is left in place, the ignition module gine ground (–). This locks the ignition module
will operate in the “Base Timing Mode”. This into the “Base Timing Mode”.
means that the additional timing advance fea-
tures would not function. 4. Start engine and allow it to reach normal operat-
ing temperature.
7. Make sure that the distributor has been tight-
ened. Remove the jumper wire from the timing 5. Adjust idle speed to recommended RPM.
terminal. 6. Stop engine. Readjust cable barrel and reinstall
8. Stop engine and remove timing light. the throttle.
IMPORTANT: Be sure to disconnect the jumper

Adjusting Idle Mixture wire from the ignition system test terminal before
attempting to resume normal operations. If the
The procedure for adjusting carburetor idle mixture jumper wire is left in place, the ignition module
can be found in the appropriate engine service manu- will operate in the “Base Timing Mode”. This
al. This procedure also requires that the ignition mod- means that the additional timing advance fea-
ule be locked in the “Base Timing Mode”. tures would not be functioning.
7. Remove the jumper wire from the timing terminal.
IMPORTANT: In order to properly set idle mixture,
Timing Mode”. This is necessary because of the
“Idle Speed Control” feature that exists in the
ignition module. See information on the previous
pages about this feature.
Index
Troubleshooting Thunderbolt V Ignition
Ignition Control Module / Coil / Distributor
Check to ensure that tachometer

GRY lead is not shorted to
ground (–) at the tachometer or
00000
within the harness.
No Spark

and Ignition Coil.
Battery OK?
Distributor Clamping Screw
Tight?
No Spark
Check Engine
Check for 12 Volts at Positive 0 Wiring Harness,
12 Volts Key Switch
Unplug WHT/
RED bullet connector
from Distributor.
0 Check for 12 volts
Volts on lead coming
from module.
12 Volts
Reconnect WHT/RED
bullet connectors.
Remove High-Tension Lead
a Spark Gap Tester from Coil
Tower to Ground. Disconnect Replace Ignition
WHT/GRN Lead from Distribu- Spark Sensor in
tor. Place Ignition Key in RUN at Coil Distributor
Position. Rapidly strike the Ter-
minal of the WHT/GRN Lead
that comes from module,
against Ground (–).
(See “IMPORTANT” below)
No Spark at Coil
Substitute a New Ignition Spark Install New

Coil. Repeat Above Test at Coil Ignition Coil
No Spark at Coil
IMPORTANT: The WHT/GRN lead must be touched against ground (–) 2-3 times per second to simulate
a running engine. Repeat this test several times to ensure that spark is present.
Index
Knock Control Module IMPORTANT: If there is abnormal mechanical en-
gine noise (rattles or knocks), they may give a
The Knock Control Module contains solid state cir- false knock retard signal. If fuel octane is too high
cuitry which monitors the knock sensor’s AC voltage or too low, a false signal can also be sent.
signal and then supplies an 8-10 volt signal, if no
spark knock is present, to the Ignition Control Mod-
ule. If spark knock is present, the Knock module will TESTING KNOCK MODULE AND SENSOR
remove the 8-10 volt signal to the Ignition Control NOTE: A digital volt-ohmmeter (DVOM) and an un-
Module. powered test light (low power test light - 300mA or
less) are needed to conduct the following test.
a b
! WARNING
Avoid fire or explosion. Ensure that engine
compartment is well ventilated and gasoline va-
pors are not present when performing electrical
tests inside the engine compartment. Sparks
generated by electrical tests could ignite gaso-
line vapors causing fire or explosion.
c 1. Start engine and warm it up to normal operating

temperature.
2. Connect the positive (+) lead from the DVOM to
Knock Sensor System
the PURPLE/WHITE timing terminal that comes
a - Positive Lead (12 Volts) from the engine harness (see previous wiring dia-
b - 8-10 Volts To Knock Sensor
gram). Connect the negative (–) lead from the
c - Knock Sensor
DVOM to a good engine ground (–). With the en-
gine running, there should be 8-10 volts on this
It is extremely important that the correct knock mod-
circuit. If voltage is not present, check to ensure
ule and sensor be used for the engine application.
that there is 12 volts to the knock module (PUR-
Using an incorrect knock module or sensor will result
PLE wire Terminal “B”).
in unrecognized spark knock and engine damage.
The Knock module terminal B is powered by 12 volts 3. Advance the throttle to approximately 1500 RPM.
from the ignition switch. If the 12 volt power source 4. Disconnect the harness connector (BLUE wire)
is not present, the knock module cannot send an 8-10 from the knock sensor. Connect the unpowered
volt signal to the ignition control module and a false test light to a positive (+) 12 volt source. To simu-
constant spark retard will result. late an AC voltage, rapidly tap the knock sensor
Terminal “E” of the knock module is the signal line harness terminal with the test light. If knock mod-
from the knock sensor. If this circuit opens or shorts ule and wiring is functioning properly, you should
to ground, the knock module will never remove the see a voltage drop on the DVOM. If a voltage drop
8-10 volt signal from terminal “C” to and no spark re- is not seen, check the BLUE wire from the sensor
tard will occur. The ground circuit for the knock mod- to the knock module for a short or open circuit. If
ule is connected to terminal “D”. If the ground circuit the circuit is functioning properly to this point, the
opens, the knock module will not be able to remove knock sensor may not be functioning. Proceed to
the 8-10 volt signal and spark knock cannot be con- the following step.
trolled. 5. Reconnect the knock sensor harness connector
to the sensor.
IMPORTANT: If knock sensor wire is routed too
6. While still watching the DVOM, lightly and rapidly
close to secondary ignition wires, the Knock
tap on the engine block near the knock sensor
module may see the interference as a knock sig-
with a small hammer. If the knock sensor is func-
nal, resulting in false timing retard.
tioning properly, you should see the voltage de-
crease. If a voltage drop is not seen, the knock
sensor is faulty.
Index
INSTALLATION OF KNOCK SENSOR Spark Plugs
1. Inspect each plug individually for badly worn
IMPORTANT: If installing a new knock sensor, be
electrodes, glazed, broken or blistered porcelain
sure to replace it with an identical part. Knock
and replace where necessary.
sensors are very sensitive and designed for each
specific application. 2. Inspect each spark plug for make and heat range.
All plugs must be the same make and number
and heat range. Refer to “Specifications” for
IMPORTANT: It is very important that the knock
spark plug numbers.
sensor be torqued to the exact specification. In-
correct torquing will result in unsatisfactory per- 3. Adjust spark plug gaps with a round feeler gauge.
formance. DO NOT use sealer on threads. Refer to “Specifications” for proper spark plug
gap.
1. Install knock sensor in engine block. Torque to
12-16 lb. ft. (16.3-21.7 N·m).
f d
a
e 72734
a - Porcelain Insulator
b - Insulator Cracks Often At This Point
73756 c - Shell
d - Proper Gap
a - Knock Sensor e - Side Electrode (Bend To Adjust Gap)
f - Center Electrode (File When Adjusting Gap - DO NOT
2. Connect electrical connector to knock sensor. Bend)
4. Clean spark plug seating area. Do not use gas-

kets on taper seat plugs. Install spark plugs and
torque to specifications. Where used, gasket
must be fully compressed to complete heat trans-
fer and provide a gas- tight seal in cylinder. For
this reason, as well as the necessity of maintain-
ing correct plug gap, correct torque is very impor-
tant during installation.
IMPORTANT: Tapered seat spark plugs are not in-

terchangeable with non-tapered (with gasket)
spark plugs.
Index
Spark Plug Wires
1. Inspect spark plugs for damage.
2. Check spark plugs for continuity using Multi-
Meter / DVA (91-99750) or similar.
3. Replace any wires that are cracked, cut, or have
damaged spark plug boots.
4. Replace any wires that do not show continuity
from end to end.
5. Reinstall wires in proper order. Observe the fol-
lowing:
IMPORTANT: Proper positioning in spark plug

wire supports is important to prevent cross-
firing.
IMPORTANT: Before installing coil wire to coil,

apply approximately 1/2 oz. of insulating com-
pound around top of coil lead tower. Force nipple
into coil and wipe off excess. Make sure boot
does not “hydraulically back off” the distributor
cap terminal.
Index
AT A LATER DATE
Index
ELECTRICAL SYSTEM
4
C
72078
CHARGING SYSTEM
Index
Table of Contents
Page
Mando 55 and 65 Amp Alternator
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
Replacement Parts Warning . . . . . . . . . . . . . . . 4C-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
Tools/Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 4C-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2
System Components . . . . . . . . . . . . . . . . . . . . . 4C-3
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . 4C-3
Drive Belt Tension Adjustment . . . . . . . . . . . . . 4C-4
V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4
Serpentine Belt . . . . . . . . . . . . . . . . . . . . . . . . 4C-4
Troubleshooting Tests (Alternator
on Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-5
Circuitry Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-5
Current Output Test . . . . . . . . . . . . . . . . . . . . 4C-6
Voltage Output Test . . . . . . . . . . . . . . . . . . . . 4C-7
Exploded View . . . . . . . . . . . . . . . . . . . . . . . 4C-10
Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . 4C-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4C-11
Cleaning and Inspection . . . . . . . . . . . . . . . 4C-14
Component Testing . . . . . . . . . . . . . . . . . . . 4C-15
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4C-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-20
Battery Isolators . . . . . . . . . . . . . . . . . . . . . . . . . 4C-21
Dual Battery Charging Systems
Using a Battery Isolator . . . . . . . . . . . . . . . 4C-21
Battery Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-22
Index
4C - CHARGING
4C-0 SYSTEM
- CHARGING SYSTEM 90-823225--1 1096
Mando 55 and 65 Amp Specifications
Alternator Identification Description Specification
Excitation Circuit 1.3 to 2.5 Volts
Current Output
p
A
55 Amp. A
50 Amp. Mi
Min.
c
65 Amp. 60 Amp. Min.
Voltage Output 13.9 to 14.7 Volts
Min. Brush Length 1/4 in. (6 mm)
b Tools/Sealants
Bearing Removal and
91-31229A5
a 72078
Installation Kit
Magneto Analyzer 91-76032
a - Excitation Wire - PURPLE
b - Sensing Wire - RED/PURPLE
Universal Puller Plate 91-37241
c - Mando Part Number (Hidden In This View) Multi-Meter/DVA Tester 91-99750
Quicksilver Liquid
92-27511-2
Neoprene
Replacement Parts Warning Ammeter (0-50 mm) Obtain Locally
! WARNING
on your MerCruiser are designed and manufac- Torque Specifications
Regulations to minimize risks of fire and explo- Fastener Location In. Lb. Ft. Lb. N·m
sion. End Frame Screws 55 5.5
Use of replacement electrical, ignition or fuel Brush Set Screws 18 1.5
these rules and regulations, could result in a fire Regulator Mounting
42 4.2
or explosion hazard and should be avoided. Screws
Regualtor Leads 25 2.5
Ground Terminal Nut 25 2.5
Pulley Nut 42 4.2
Alternator Brace to
20 27
Alternator
Alternator Brace to
30 41
Block
Alternator to Mounting
35 48
Bracket
Alternator Mounting
30 41
Bracket
V-Belt Tension (Note) Depress 1/4 in.
Index
90-823225--1 1096 CHARGING SYSTEM - 4C-1
Description Due to the lack of residual magnetism in the rotor
pole pieces, a small amount of current must be
The alternator has a rotor, which is supported in two supplied to the rotor field to initially start the alternator
end frames by ball bearings, and is driven by a charging. This is accomplished by means of an exci-
pulley at approximately twice engine speed. The rotation circuit in the regulator which is connected to the
tor contains a field winding that is enclosed between ignition switch. Once the alternator begins to produce
two multiple-finger pole pieces. The ends of the field output, field current is supplied solely by the diode
winding are connected to two brushes (mounted in trio, as explained, preceding.
the rear end frame) which make continuous sliding
(or slipping) contact with the slip rings. The current The alternator also is equipped with a fan (mounted
(flowing through the field winding) creates a mag- on the rotor shaft) which induces air flow through the
netic field that causes the adjacent fingers of the alternator to remove the heat created by the rectifiers
pole pieces to become alternate north and south and stator. A capacitor protects the rectifier system
magnetic poles. from high voltages and suppresses radio noise.
A 3-phase stator is mounted directly over the rotor

pole pieces and between two end frames. It consists
of three windings wound 120 degrees electrically Precautions
out-of-phase on the inside of a laminated core. The The following precautions MUST BE observed when
windings are all connected together on one end, working on the alternator system. Failure to observe
while the other ends are connected to a full-wave rec- these precautions may result in serious damage to
tifier bridge. the alternator or alternator system.
The rectifier bridge contains six diodes which are ar- 1. DO NOT attempt to polarize the alternator.
ranged so that current flows from ground, through the
stator and to the output terminal, but not in the oppo- 2. DO NOT short across or ground any of the termi-
site direction. nals on the alternator, except as specifically in-
structed in the “Troubleshooting Tests.”
When current is supplied to the rotor field winding,
and the rotor is turned, the movement of the magnetic 3. NEVER disconnect the alternator output lead or
fields created induces an alternating current into the battery cables when the alternator is being driven
stator windings. The rectifier bridge then changes by the engine.
this alternating current to direct current which ap- 4. NEVER disconnect regulator lead from alternator
pears at the output terminal. A diode trio also is con- regulator terminal when the alternator is being
nected to the stator windings to supply current to the driven by the engine.
regulator and the rotor field during operation.
5. ALWAYS remove negative (–) battery cable from
Voltage output of the alternator is controlled by regu- battery before working on alternator system.
lating the current supplied to the rotor field. This is ac-
complished by a transistorized voltage regulator that 6. When installing battery, BE SURE to connect the
positive (+) battery cable to the positive (+) bat-
senses the voltage at the battery and regulates the
field current to maintain alternator voltage within pre- tery terminal and the negative (–) (grounded) bat-
tery cable to negative (–) battery terminal.
scribed limits for properly charging the battery. Cur-
rent output of the alternator does not require regula- 7. If a charger or booster battery is to be used, BE
tion, as maximum current output is self-limited by the SURE to connect it in parallel with existing battery
design of the alternator. As long as the voltage is reg- (positive to positive; negative to negative).
ulated within the prescribed limits, the alternator can-
not produce excessive current. A cut-out relay in the
voltage regulator also is not required, as the rectifier
diodes (which allow current to flow in one direction
only) prevent the battery from discharging back
through the stator.
Index
4C-2 - CHARGING SYSTEM 90-823225--1 1096
System Components Periodic Maintenance
The alternator system consists of the alternator, bat- The following maintenance check should be per-
tery, the ignition switch and the wiring which connects formed every 50 hours or 60 days (whichever comes
these components. first) in fresh water areas or every 25 hours or 30 days
in salt water areas.
h
! CAUTION
g Remove all battery cables from battery (before
conducting the following check) to prevent acci-
a dentally shorting out electrical system.
1. Inspect entire alternator system for corroded or

loose connectors.
2. Check wiring for frayed or worn insulation.
3. Check alternator drive belt for excessive wear,
cracks, fraying and glazed surfaces. Also, check
b drive belt tension and adjust, if necessary, as ex-
plained under “Drive Belt Tension Adjustment.”
f 4. Check alternator mounting bolts for adequate

tightness.
c 5. Inspect slip ring end frame flame arrestor screen
for debris and clean, if necessary, using com-
pressed air or a cloth. Screen MUST BE clean, or
d alternator may overheat.
e 72933
a - Ignition Switch
b - Alternator
c - Starter Motor
d - Ground Stud
e - Battery
f - Circuit Breaker
g - Harness Plug
h - Battery Meter
Index
Drive Belt Tension Serpentine Belt
Adjustment 1. Loosen 5/8 Inch locking nut on adjustment stud.
Leave wrench on adjustment stud.
2. Use a 5/16 Inch socket and tighten adjusting stud
V-Belt until the correct deflection (1/4 Inch) is obtained.
1. Install drive belt on pulleys and adjust tension as NOTE: Belt deflection should be measured at the
follows: longest distance between two pulleys. This distance
may vary depending on the particular power package
a. Pivot alternator away from engine, as re-
installation.
quired, until correct tension is obtained as
shown. Belt should depress 1/4 in. (6 mm).
a
72669
a - Check Point
a - Check Point - 1/4 Inch Deflection
b - Idler Pulley
b. After obtaining correct tension, securely re-
tighten alternator brace attaching bolts and 3. While holding adjustment stud at the correct belt
alternator mounting bolts. tension, tighten the 5/8 inch locking stud.
2. If a new drive belt has been installed, recheck belt 4. If a new drive belt has been installed, recheck belt
tension after running for five minutes. tension after running for five minutes.
Index
Troubleshooting Tests 2. Wiggle engine wiring harness while observing
voltmeter. Meter should indicate approximate
(Alternator on Engine) battery voltage and should not vary. If no reading
is obtained, or if reading varies, check alternator
Use the following tests in conjunction with the “Trou-
output circuit for loose or dirty connections or
bleshooting” in Section 1. Before proceeding with the
damaged wiring.
tests, however, perform the following checks to elimi-
nate possible problem areas. Also observe “Precau-
tions,” preceding, to prevent damage to alternator
system. d
1. If problem is an undercharged battery, check to
ensure that undercharged condition has not been
caused by excessive accessory current draw or
by accessories which have accidentally been left a
on. Also, check that undercharged condition has
not been caused by running engine at too low a
speed for extended periods of time.
2. Check physical condition and state of charge of
e
battery, as outlined in “Battery - Storage” in Sec-
tion 4A. Battery MUST BE at least 75% (1.230
specific gravity) of fully charged to obtain valid re- c
sults in the following tests. If not, charge battery
before testing system.
b
3. Inspect entire alternator system wiring for de-
fects. Check all connections for tightness and 72784
cleanliness, particularly battery cable clamps
a - Output Wire - ORANGE
and battery terminals. b - Excitation Wire - PURPLE
4. Check alternator drive belt for excessive wear, c - Sensing Wire - RED/PURPLE
d - Voltmeter (0-20 Volts)
cracks, fraying and glazed surfaces and replace
e - Ground
if necessary. Also, check drive belt tension and
adjust if necessary, as outlined under “Drive Belt EXCITATION CIRCUIT
Tension Adjustment.”
1. Connect positive (+) voltmeter lead to tie strap
terminal on alternator and negative (–) lead to a
Circuitry Test ground terminal on alternator (Test 1).
2. Turn ignition switch to ON position and note volt-
Perform the following tests, using a 0-20 volt DC volt-
meter reading. Reading should be 1.3 to 2.5
meter, to check that all of the circuits between the al-
volts.
ternator and the other components within the alterna-
tor system are in good condition. 3. If no reading is obtained, an opening exists in al-
ternator excitation lead or in excitation circuit of
OUTPUT CIRCUIT regulator. Unplug PURPLE lead from regulator.
Connect positive voltmeter lead to PURPLE lead
1. Connect positive (+) voltmeter lead to alternator and negative voltmeter leads to ground (Test 2).
output terminal and negative (–) lead to a ground If voltmeter now indicates approximate battery
terminal on alternator. voltage, voltage regulator is defective and must
be replaced. If no voltage is indicated, check ex-
citation circuit for loose or dirty connections or
damaged wiring.
4. If reading is between .75 and 1.1 volts, rotor field
circuit probably is shorted or grounded. Disas-
semble alternator and test rotor as outlined under
“Alternator Repair,” following.
Index
5. If reading is between 6.0 and 7.0 volts, rotor field 3. Voltmeter should indicate battery voltage. If bat-
circuit probably is open. Remove regulator and tery voltage is not present, check sensing circuit
inspect for worn brushes or dirty slip rings. Re- (red/purple lead) for loose or dirty connection or
place brushes if less than 1/4 in. (6 mm) long. If damaged wiring.
brushes and slip rings are in good condition, dis-
assemble and perform rotor test as outlined un-
der “Component Testing - Rotor” following.
d
TEST 1 TEST 2
d
a
b
c
c
b
72786
a
72785 b - Excitation Wire - PURPLE
c - Sensing Wire - RED/PURPLE
a - Excitation Wire - PURPLE
b - Sensing Wire - RED/PURPLE
e - Ground
c - Tie Bar
e - Ground
Current Output Test
SENSING CIRCUIT Perform this test to check if alternator is capable of
1. Unplug RED/PURPLE lead from voltage regula- producing rated current output, using a 0-50 amp DC
tor. ammeter.
2. Connect positive (+) voltmeter lead to red/purple

! WARNING
lead and negative (–) voltmeter lead to ground
terminal. Be sure that engine compartment is well-venti-
ent (during the test) to prevent the possibility of
an explosion and/or a fire, should a spark occur.
1. Disconnect negative (–) battery cable from bat-

tery.
2. Disconnect orange lead from alternator output
terminal and connect ammeter in series between
lead and output terminal. Connect positive (+)
side of ammeter toward output terminal.
3. Reconnect negative battery cable.
4. Remove coil wire from distributor cap tower and
ground it to block. Turn on all accessories and
crank engine over with starter motor for 15-20
seconds.
Index
5. Turn off accessories and reinstall coil wire. Start 2. Start engine and run at fast idle until engine
engine and adjust engine speed to 1500-2000 reaches normal operating temperature. Adjust
RPM. Quickly observe ammeter. Reading should engine speed to 1500-2000 RPM and observe
be at least 30 amps. voltmeter for highest reading. Reading should be
between 13.9 and 14.7 volts.
6. If reading is low, stop engine and connect a jump-
er wire between alternator output terminal and 3. If reading is high, check for a loose or dirty regula-
regulator terminal. Repeat Steps 4 and 5. tor ground lead connection. If connection is good
(and sensing circuit checked out good in “Circuit-
7. If reading is now within specifications, diodes are
ry Test”), voltage regulator is faulty and must be
faulty. Disassemble alternator and replace
replaced. Be sure to disconnect battery cables
rectifier as explained under “Alternator Repair,”
before attempting to remove regulator.
following, to determine if fault is in regulator or
alternator. a
8. If reading is still low with jumper wire connected, d
perform “Voltage Output Test,” following, to de- e
termine if fault is in regulator or alternator. c
b
a
e 72788

d c b - Excitation Wire - PURPLE
c - Sensing Wire - RED/PURPLE
72787 d - Voltmeter (0-20 Volts)
e - Ground
b - Ammeter (0-50 Amps)
c - Jumper Lead ! WARNING
d - Regulator Lead
e - Ground Be sure that engine compartment is well-venti-
ent (during the next steps) to prevent the possi-
Voltage Output Test bility of an explosion and/or fire, should a spark
occur.
Perform this test to determine if voltage regulator is
operating correctly, using a 0-20 volt DC voltmeter.
! CAUTION
IMPORTANT: Battery MUST BE fully charged DO NOT allow tie jumper wire to contact alterna-
(1.260 or above specific gravity) to obtain proper tor end frame (in next step), as rectifier and diode
voltage reading in this test. If necessary, charge assembly may be damaged.
battery with a battery charger or allow engine to
run a sufficient length of time to fully charge bat-
tery before taking reading.
1. Connect positive (+) voltmeter lead to positive

battery terminal and negative (–) voltmeter lead
to negative terminal.
Index
4. Remove four nuts holding excitation and sensing
wires and Phillips screw. Remove regulator cover
and install wires and nuts for testing. Connect a
jumper wire from the ground stud to the brush ter-
minal on the lower right-hand side of the brush
assembly. Restart engine and gradually increase
engine speed to 1500 RPM while observing volt-
meter. DO NOT allow voltage to exceed 16 volts.
5. If a voltmeter reading of 14.5 volts or above is
now obtained, voltage regulator is faulty and
must be replaced. If voltmeter reading is below
14.5 volts, inspect brushes and slip rings for
wear, dirt or damage. If brushes and slip rings are
good, alternator is faulty internally. Disassemble
alternator and test components, as outlined un-
der “Alternator Repair,” following.
b c
72971
a - Ground
b - Brush / Regulator Assembly
c - Brush Terminal
d - Jumper Wire (Solder Connection Ground)
Index
Index
Exploded View
19
20
22
21
25
24
27 26
3 1
28 6 2 4
29
23 2
3 5
8
10
9
12 2
10 13 2
16 1
15 3 13
17
2
14
18
7
10
11
72276
Index
1 - Screws (3) Disassembly
2 - Nut (9)
3 - Flat Washer (4)
4 - Sensing Wire (RED / PURPLE)
IMPORTANT: The following instructions are for
5 - Excitation Wire (PURPLE)
6 - Cover complete disassembly and overhaul of the alter-
7 - Tie Strap nator. In many cases, however, complete disas-
8 - Rubber Gasket sembly of alternator is not required and, in those
9 - Condenser cases, it is necessary only to perform the opera-
10- Insulator
11- Bolt (4)
tions required to repair or replace the faulty part.
12- End Frame (Rear) 1. Mount alternator in a vise so that rear end frame
13- Cap (2)
14- Brush / Regulator Assembly
is facing you.
15- Rectifier Assembly 2. Disconnect regulator leads from terminals on
16- Flat Washer
17- Screw
rear end frame. Remove four nuts, Phillips head
18- Stator screw and two regulator leads. Then pull regula-
19- Rotor And Slip Ring tor cover away from rear end frame.
20- Retaining Plate
21- Front Bearing
22- End Frame (Front)
23- Screw (3)
24- Fan Spacer
25- Fan
26- Pulley Spacer
27- Pulley
28- Lockwasher
29- Nut
d
c b
Alternator Repair
a
Removal
1. Disconnect negative (–) battery cable from bat-
72963
tery.
2. Disconnect wiring harness from alternator. a - Regulator Leads
b - Nuts (4)
3. Remove alternator brace-to-alternator attaching c - Phillips Head Screw
bolt, washer(s) and spacer (if used). d - Regulator Cover
4. Loosen alternator brace-to-engine attaching bolt
and alternator mounting bolt, then pivot alterna- 3. Remove stud cover insulator, two nuts and tie
tor inward and remove alternator drive belt. strap from brush/regulator assembly.
5. Remove alternator mounting bolt, washers (if

used), spacer and nut, and remove alternator.
Index
4. Remove two brush/regulator attaching screws 7. Separate rear end frame and stator assembly
and remove brush/regulator assembly. from front end frame and rotor assembly using
two thin blade screwdrivers (positioned 180 de-
grees apart from one another) at the locations
shown. Use the two slots shown to initially sepa-
rate units.
b
c
e
c a a
d d
a
72823
72824
a - Screws
b - Brush / Regulator Assembly
a - DO NOT Insert Screwdriver Blades More Than 1/16 In.
c - Stud Cover Insulator
(1.5 mm) Into Slots.
d - Tie Strap
b - Rear End Frame
c - Stator
5. Scribe a mark on rear end frame, stator and front d - Front End Frame
end frame to ensure proper reassembly later. e - Scribe Marks
6. Remove four screws which secure end frames

8. Place rear end frame and stator assembly on the
and stator together.
bench with stator downward. Be sure that bench
is clean and free of metal chips. Remove nuts,
IMPORTANT: DO NOT insert screwdriver blades washers, insulators and condenser from output
more than 1/16 in. (1.5 mm) into openings (in next and ground studs.
step), as stator windings may be damaged.
Index
9. Turn end frame over (stator upward) and remove IMPORTANT: With alternator disassembled to
one Phillips head screw which secures rectifiers this point, stator, rectifier, diodes, and rotor may
to end frame. be tested, as explained under “Component Test-
ing,” following.
IMPORTANT: DO NOT clamp vise on rotor pole

pieces when removing pulley nut (in next step),
as pole pieces may be distorted.
a
12. Remove pulley retaining nut by clamping pulley
in a vise (using an oversize V-belt or protective
jaws to protect pulley) and turning nut counter-
clockwise with a wrench. Remove lockwasher
and slide pulley and fan from shaft. If pulley is dif-
ficult to remove, it may be necessary to use a uni-
versal puller.
72826
a - Rectifier Assembly b
b - Phillips Head Screw
a
10. Separate stator and rectifier assembly from rear
end frame using screwdriver slots.
11. Unsolder the three stator leads from the rectifier
heat sink. Place a needle nose pliers on diode ter-
minal between solder joint and diode body to help
prevent heat damage to diodes. Unsolder joints
as quickly as possible and allow diode terminal to
cool before removing pliers.
72828
b a - Wrench
b - Over-Sized Belt To Protect Pulley
b
72827
a - Heat Sink
b - Stator Leads (3)
Index
13. Remove the three phillips head screws and lock- Cleaning and Inspection
washers which secure the front bearing retaining
plate. 1. Clean all parts with a clean, soft cloth. DO NOT
use solvent, or electrical components may be
damaged.
2. Inspect the following parts for wear and damage:
a a. Brush/regulator assembly - inspect for
cracked casing, damaged brush leads, poor
brush lead solder connections, weak or bro-
ken brush springs or worn brushes. Replace
brush set if brushes are less than 1/4 in. (6
mm) long.
b. Rotor - inspect for stripped threads, scuffed
pole piece fingers or damaged bearing sur-
b faces (because of bearing turning on shaft).
c. Rotor-slip rings - clean slip rings with 400
72829
grain (or finer) polishing cloth while spinning
rotor in a lathe. Blow off dust with com-
a - Phillips Head Screws and Lockwashers
b - Front Bearing Retaining Plate pressed air. Inspect slip rings for grooves,
pits, flat spots or out-of-round [.002 in. (0.051
14. Remove front bearing from front end frame using mm) maximum] and replace rotor, if present.
an arbor press and a suitable size mandrel. (Dis- d. Rotor shaft and front end bearings - in-
card bearing.) spect for damaged seals, lack of lubrication,
discoloration (from overheating) and exces-
sive side or end play. Bearing should turn
freely without binding or evidence of rough
spots.
e. Stator - inspect for damaged insulation or
wires; also inspect insulating enamel for heat
discoloration, as this is usually a sign of a
shorted or grounded winding or a shorted
diode.
f. Front and rear end frames - inspect for
cracks, distortion, stripped threads or wear in
bearing bore (from bearing outer race spin-
ning in bore). End frame(s) MUST BE re-
placed, if bearing has spun. Also, inspect
bearing retainer recess in front end frame for
72830 damage.
Removing Front Bearing from Front End Frame g. Fan - inspect for cracked or bent fins, broken
welds (bi-rotational fan only) or worn mount-
15. If rotor slip rings or rear bearing requires replace- ing hole (from fan spinning on shaft).
ment, entire rotor must be replaced. Parts cannot
be purchased separately. h. Pulley - inspect pulley mounting bore end for
wear. Inspect drive surface of pulley sheaves
for trueness, excessive wear, grooves, pits,
nicks and corrosion. Repair damaged sur-
faces, if possible, with a fine file and a wire
brush or replace pulley, if beyond repair.
Drive surfaces MUST BE perfectly true and
smooth or drive belt wear will be greatly ac-
celerated.
Index
Component Testing d. If reading is low, a short exists in the field cir-
cuit. Inspect slip rings to be sure that they are
ROTOR not bent and touching outer slip ring. Also, be
sure that excess solder is not shorting termi-
1. Test rotor field circuit for opens, shorts or high re- nals to aft slip ring. If cause for short cannot
sistance (Test 1), using an ohmmeter (set on R x1 be found, unsolder field winding leads from
scale), as follows: slip ring terminals and connect ohmmeter di-
TEST 1 TEST 2 rectly to leads. If correct reading is now ob-
tained, or if reading is still low, slip rings and
rotor field windings are shorted, and com-
plete rotor assembly must be replaced.
72831
c
Testing Rotor Field Circuit
a. Connect one ohmmeter lead to each slip ring.

b. Ohmmeter reading should be 4.2 to 5.5 ohms a
with rotor at room temperature 70-80°F 73112
(21-26°C).
c. If reading is high or infinite (no meter move- a - Field Winding Leads
b - Slip Rings
ment), high resistance or an open exists in
c - Rotor Shaft
the field circuit. Check for poor connections d - Pole Pieces
between field winding leads and slip ring ter-
minals. If cause for open or high resistance
2. Test rotor field circuit for grounds (Test 2), using
cannot be found, connect ohmmeter directly
an ohmmeter (set on R x1 scale) as follows:
to slip ring terminals. If correct reading is now
obtained, or if reading is still high or infinite, a. Connect one lead of ohmmeter to either slip
replace complete rotor assembly. ring and the other lead to rotor shaft or pole
pieces.
b. Meter should indicate no continuity (meter
should not move).
c. If continuity does exist, complete rotor as-
sembly must be replaced.
IMPORTANT: If alternator has output at low

speeds, but no output at high speeds, rotor field
winding may be shorting or grounding out, due
to centrifugal force. Replace rotor if all other elec-
trical components test good.
Index
STATOR RECTIFIER AND DIODE ASSEMBLY
NOTE: Failure of any component in tests following
IMPORTANT: Stator leads MUST BE discon- will require replacement of entire rectifier assembly.
nected from rectifier for this test.
1. Test stator for grounds (Test 1), using an ohmme- NEGATIVE (–) RECTIFIER
ter (set on R x1 scale) as follows:
a. Connect one lead of ohmmeter to one of the IMPORTANT: Rectifier MUST BE disconnected
stator leads and the other lead to stator from stator for this test.
frame. Be sure that lead makes good contact
with frame. ! CAUTION
b. Meter should indicate no continuity (meter DO NOT use a test instrument with more than a
should not move). If continuity does exist, sta- 12 volt source (in the following test), as rectifier
tor is grounded and must be replaced. may be damaged.
2. Test for opens in stator (Test 2), using an ohmme- 1. Connect one lead of an ohmmeter (set on R x1
ter (set on R x1 scale) as follows: scale) to negative (–) rectifier heat sink and the
a. Connect ohmmeter between each pair of sta- other lead to one of the rectifier terminals. Note
tor windings (three different ways). the reading.
b. Continuity should be present in all three 2. Reverse leads and again note reading.
cases (meter should move). If it does not, one 3. Meter should indicate a high or infinite resistance
or more of the windings are open and stator (no meter movement) when connected one way
must be replaced. and a low reading when connected the other. If
both readings are high or infinite, rectifier is open.
TEST 1 TEST 2 TEST 2 TEST 2 If both readings are low, rectifier is shorted.
4. Repeat Steps 1 through 3 for two other rectifiers
in heat sink.
5. Replace assembly if any of the rectifiers is
shorted or open.
72833
Testing Stator
3. A short in the stator is difficult to detect without

special equipment, because of the low windings a
72147
resistance. If all other electrical components test
out good, and alternator fails to produce rated
output, stator probably is shorted and should be a - Heat Sink
replaced. Also, examine stator for heat discolor- b - Rectifier Terminal
c - Test These Two Rectifiers In The Same Manner
ation, as this usually is a sure sign of a short.
Index
POSITIVE (+) RECTIFIER AND DIODES 6. Connect one lead of an ohmmeter (set on R x1)
to the common side of the diode and the other
lead to the other side, of one of the three diodes.
! CAUTION
DO NOT use a test instrument with more than a
12 volt source (in the following test), as rectifier
may be damaged.
1. Connect one lead of an ohmmeter (set on R x1

scale) to 1/4 in. stud on positive (+) rectifier heat
sink and the other lead to one of the rectifier ter-
minals. Note the meter reading.
2. Reverse leads and again note reading.
3. Meter should indicate a high or infinite resistance
(no meter movement) when connected one way b
and a low reading when connected the other. If
both readings are high or infinite, rectifier is open. a
If both readings are low, rectifier is shorted.
4. Repeat Steps 1 through 3 for two other rectifiers
in heat sink.
72148
a - Common Side Of Diode Circuit Board
b - Repeat Test For Two Diodes
7. Reverse leads and again note reading.

b
8. Meter should indicate a high or infinite resistance
(no meter movement) when connected one way
and a low reading when connected the other. If
c both readings are high or infinite, diode is open.
If both readings are low, diode is shorted.
9. Repeat Steps 6 through 8 for the other two
diodes.
10. Replace rectifier assembly if any one of the
diodes is shorted or open.
a 72834 CONDENSER
a - Stud 1. Using magneto analyzer and accompanying in-
b - Rectifier Terminal structions, perform the following condenser
c - Repeat Test Between These Terminals And Stud tests:
5. Replace assembly if any one of the rectifiers is a. Condenser Capacity Test (must be .5 mfd).
shorted or open. b. Condenser Short or Leakage Test.
c. Condenser Series Resistance Test.
2. Replace condenser if test results are not within
specifications.
Index
Reassembly 3. Slide front end frame over rotor.
1. Install new front bearing into front end frame

IMPORTANT: DO NOT clamp vise on rotor pole
bearing bore using an arbor press. If necessary,
pieces when tightening pulley nut (in next step),
use a bearing driver that contacts outer race only.
or pole pieces may be distorted.
4. Slide fan spacer onto rotor shaft. Install fan,
pulley, lockwasher and nut on shaft. Clamp pulley
in a vise, using protective jaws or an old oversize
V-belt to protect pulley, and torque nut to specifi-
cations. Tighten vise only enough to allow tight-
ening of nut, as excessive tightening may distort
pulley.
5. Assemble stator to rectifier by soldering the three
leads to the three rectifier terminals.
72835
Installing Front Bearing into Front End Frame
2. Install front bearing retaining plate using three a

Phillips head screws and lockwashers.
72826
a - Stator Lead Connections
NOTE: Be sure to connect leads to their original

positions.
b 6. Install assembled stator and rectifier assembly
into rear end frame, aligning scribe marks on
each (scribed during disassembly), and install
72829 Phillips head screw and washer to retain.
a - Philips Head Screws And Lockwashers
b - Front Bearing Retaining Plate
IMPORTANT: The insulating washers MUST BE
installed as shown or damage to the alternator
will result.
Index
7. Position stator down with rear end frame up and 9. Depress brushes flush with top of brush holder
reinstall insulators, nuts and condenser. and insert a #54, .050 in. drill bit or smaller into
hole in brush holder to hold brushes compressed
b c during reassembly.
b
72561
a - Insulators (3)
b - Nuts (5) - ONE REMOVED
c - Condenser
a
8. Position rear end frame and stator assembly over
front end frame and rotor assembly and align 72836
scribe marks on each (scribed during disassem- a - Drill Bit
bly). Hand-press end frames together, then in-
stall four screws. Tighten screws securely. NOTE: Rubber gasket shown removed for clarity.
10. Install brush/regulator assembly in rear end

frame cavity and secure with two mounting
screws, as shown. Tighten screws securely. Re-
move drill bit to release brushes against slip
rings.
a e
d
a
b 72561
b
a - Rear End Frame
b - Stator
c - Front End Frame
d - Scribe Marks
e - Insert Screws (4) (Two Hidden)
72837
a - Brush / Regulator Assembly

b - Mounting Screws
Index
11. Install tie strap to rectifier stud and stud on brush/ 13. Install insulator caps.
rectifier assembly. Tighten nuts securely.
b
a
a
72823 72078
a - Studs a - Insulator Caps

b - Tie Straps
12. Install cover with one phillips head screw and two Installation
nuts. Install two leads with nuts. 1. Position alternator in mounting bracket and in-
stall mounting bolt, washers (if used), spacer and
nut. Place washers (if used), on each side of
spacer. DO NOT tighten securely at this time.
2. Fasten alternator brace to alternator with bolt,
washers and spacer (if used). DO NOT tighten
bolt at this time.
3. Position alternator drive belt on pulleys and ad-
just tension as explained under “Drive Belt Ten-
sion Adjustment.”
a 4. Reconnect wiring harness to alternator and neg-
b
ative battery cable to battery.
c
72963
d
a - Phillips Head Screw

b - Nuts (4)
c - Leads
c
a 72838
a - Excitation Lead -(PURPLE)

b - Sensing Lead - (RED / PURLPE)
c - Ground Lead - (BLACK)
d - Output Lead - (ORANGE)
Index
Battery Isolators
Dual Battery Charging Systems
Using a Battery Isolator
Battery isolators allow the addition of an auxiliary
(second) battery to the MerCruiser electrical system.
The auxiliary battery is primarily used as a power
source for various accessories installed on the boat.
The battery isolator will allow the alternator to charge
both the cranking and auxiliary batteries at the same
time while preventing accessories, connected to the
auxiliary battery, from drawing power from the crank-
ing battery.
Mercury Marine does not manufacture any battery
isolator systems. Battery isolators must be bought
from an outside manufacturer. Mercury Marine sug-
gests following the manufacturer’s instructions care-
fully.
IMPORTANT: Alternators used on MerCruiser en-

gines ARE NOT equipped with an isolation diode.
! CAUTION
Follow battery isolator manufacturer’s instruc-
tions for wire gauge. Battery isolator installation
must conform to BIA Low Voltage Wiring Stan-
dard No. 125-79.
NOTE: MerCruiser engines equipped with a 3-wire,
belt driven alternator, can use a battery isolator.
Index
Battery Isolator
BLK = BLACK
BLU
BRN
=
=
BLUE
BROWN A 2 B 1
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR = PURPLE 1
RED = RED
TAN = TAN
WHT = WHITE 3
YEL = YELLOW
LIT = LIGHT
DRK = DARK
C 1
73080
4 3
Alternator with Voltmeter Circuit (Typical Wiring Shown)

NOTE: Disconnect ORANGE wire from alternator
”Batt” terminal. Splice sufficient length of proper
gauge wire and connect as shown.
A - Wiring Diagram
1 - Ciruit Breaker
2 - Wiring Harness
3 - Alternator
4 - Starter
5 - Cranking Battery
B - Original Wiring
1 - Alternator
C - Wiring Connections With Isolator
1 - Isolator
2 - Use 8 Gauge Wire Minimum
3 - Auxiliary Battery
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
ELECTRICAL SYSTEM
4
D
72747
INSTRUMENTATION
Index
Table of Contents
Page Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-1 Dual Station Sender identification . . . . . 4D-6
Special Information . . . . . . . . . . . . . . . . . . . . . . . 4D-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-6
Lighting Options . . . . . . . . . . . . . . . . . . . . . . . 4D-1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-6
Commodore and International Series . . 4D-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4D-7
QSI Series . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 Fuel Tank Sender . . . . . . . . . . . . . . . . . . . . . . 4D-7
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 Flange Type . . . . . . . . . . . . . . . . . . . . . . . . 4D-7
Oil, Fuel and Temperature . . . . . . . . . . . . . . 4D-2 Capsule Type . . . . . . . . . . . . . . . . . . . . . . . 4D-8
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-9
Battery Gauge . . . . . . . . . . . . . . . . . . . . . . . . 4D-3 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . 4D-9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-9
Cruiselog Meter . . . . . . . . . . . . . . . . . . . . . . . 4D-4 Lanyard Stop Switches . . . . . . . . . . . . . . . . 4D-10
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-4 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-10
Vacuum Gauge . . . . . . . . . . . . . . . . . . . . . . . . 4D-4 Start/Stop Switch . . . . . . . . . . . . . . . . . . . . . 4D-11
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 4D-4 Audio Warning System . . . . . . . . . . . . . . . . . . . 4D-11
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-4 Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-11
Calibration Chart . . . . . . . . . . . . . . . . . . . . 4D-4 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-11
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-4 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 4D-12
Gauge Replacement . . . . . . . . . . . . . . . . . . . 4D-5 Water Temperature Switch . . . . . . . . . . . . . 4D-12
Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-12
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-13
Dual Station Sender Identification . . . . . 4D-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . 4D-15
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5 Transmission Fluid Temperature Switch . 4D-15
Water Temperature . . . . . . . . . . . . . . . . . . . . 4D-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-15
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . 4D-17
NOTICE
NOTICE
For information and procedures on Fuel In-
jection Engines, refer to Section 5C.
Index
4D - INSTRUMENTATION
4D-0 - INSTRUMENTATION 90-823225--1 1096
Identification Special Information
NOTE: One of three distinct lines (Series) of Quicksil-
ver gauges may be installed (if equipped with Quick- Lighting Options
silver gauges). Aside from different gauge face ap-
pearances and styling, the back of the gauges and COMMODORE AND INTERNATIONAL SERIES
wiring connections are different as shown.
These gauges may be wired so that the illumination
lighting is provided from the ignition switch or a sepa-
rate instrumentation lighting switch.
By removing contact strip “I” from between + terminal
and the screw as shown following, and supplying a
separate +12 V power supply to the screw connec-
tion, illumination lights can be operated independent
of ignition switch.
72746
Back of Commodore and International Series b

Gauge - Typical
a
72966
Ignition Switch Lighting Circuit

a - Positive (+) 12 Volt Power Supply From Ignition Switch
b - Contact Strip “I”
c - Screw Connection
72965
c
Back of QSI Series Gauge - Typical
b
72967
Separate Instrumentation Lighting Circuit Wiring

b - Contact Strip “I”
c - Screw Connection
Index
90-823225--1 1096 INSTRUMENTATION - 4D-1
QSI SERIES Gauges
These gauges are equipped with optional illumina-
tion lighting. Light bulb socket can be removed and Oil, Fuel and Temperature
contacts can be aligned to be used with ignition
IMPORTANT: If testing proves gauge to be defec-
switch lighting circuit +12 V or separate instrumenta-
tive, it must be replaced as there is no repair
tion lighting circuit LT.
available.
IMPORTANT: Light socket must be removed from
gauge and turned counterclockwise (facing back TESTING
of gauge) when adjusting to desired setting. 1. Turn ignition switch to OFF.
Turning socket while still installed in gauge
could result in damage to gauge or socket. 2. Remove wire from terminal S (SEND).
NOTE: For different lighting effects, colored sleeves

are available through the Quicksilver Accessories
and can be assembled to the bulb.
a
72965
72968
Typical
Ignition Switch Lighting Circuit Position a - Terminal S (SEND)
3. Turn ignition switch to RUN. Gauge being tested
must be at position A.
72969
Separate Instrumentation Lighting Circuit Posi-
tion
a - Positive (+) 12 Volt Power Supply From Ignition
b - Positive (+) 12 Volt Power Supply From Separate Instru- Position A
mentation Lighting Circuit
Typical 72747
4. Turn ignition switch to OFF.
Index
5. Connect jumper wire from terminal G (GND) to Battery Gauge
terminal S (SEND).
TESTING
1. Remove cables from battery and fully charge bat-
tery.
2. Connect negative (–) jumper lead from battery to
gauge terminal G (GND).
3. Connect positive (+) jumper lead from battery to
gauge terminal I or +12 V.
72748
Typical
6. Turn ignition switch to RUN.

7. Indicator needle of gauge being tested must read
at position B. If not, replace gauge.
72750
Typical
4. Check gauge reading; if not as shown replace
gauge.
Position B
72749
Typical
72751
Typical
Index
Cruiselog Meter Vacuum Gauge
TESTING
TESTING
1. Disconnect vacuum hose from engine. Connect
1. Connect jumper wire from negative (–) battery service vacuum gauge to engine and record en-
terminal to negative (–) gauge terminal. gine vacuum readings at idle, 1000, 2000 and
2. Connect jumper wire from positive (+) battery ter- 3000 RPM. Reconnect vacuum hose and com-
minal to positive (+) gauge terminal. pare vacuum gauge readings (at specified RPM)
with service gauge readings. Readings should be
within 3 inches of vacuum of each other.
IMPORTANT: Make sure that vacuum hose be-

tween gauge and engine is not leaking and that
all connections are tight.
Speedometer
TESTING
IMPORTANT: When testing speedometer gauge

72752
for accuracy, the air supply used for the test must
be regulated to the specified air pressure. Do not
3. Observe gauge run indicator. If indicator is turn- apply excessive air pressure to speedometer
ing, gauge is operable; if not, replace gauge. gauge.
1. Apply air pressure directly to speedometer gauge
(specified in chart) and note gauge reading. Light
tapping of pressure gauge is required during ac-
curacy check.
2. If gauge readings are not within specifications,
gauge is defective.
CALIBRATION CHART
Air Pressure Guage Speedometer Gauge

PSI MPH (km/Hr)
5.3 20±2 (32±1.6)
a 27.8 45±1 (72±1.6)
72753
a - Indicator Tachometer
TESTING
1. Connect a service tachometer to engine and
compare readings.
2. Replace if not within specifications.
Tachometer Allowance
6000 RPM ± 150 RPM
8000 RPM ± 200 RPM
Index
Gauge Replacement Senders
1. Disconnect battery cables from battery. Oil Pressure
2. Remove wires from back of gauge.
3. Remove hoses (vacuum, speedometer gauge). DUAL STATION SENDER IDENTIFICATION
4. Disconnect light socket. Sender will have 353-AM stamped on hex of sender.
5. Remove holding strap and remove gauge. TESTING

6. Position gauge assembly in appropriate mount-
ing hole. IMPORTANT: Use following test procedure for
checking accuracy of oil pressure sender only. If
7. Install holding strap and nuts. Tighten nuts evenly oil pressure gauge indicates zero oil pressure,
and securely. refer to Section 1C - “Troubleshooting.”
IMPORTANT: Do not distort case or bracket by
over-tightening. 1. Remove wire from sender terminal.
8. Connect ground (BLACK) wire to ground termi- 2. Connect ohmmeter between sender terminal and
nal, if gauge is not mounted in metal panel. sender case. Check ohms reading without en-
9. Connect other wires to gauge as shown in Sec-
gine running (zero pressure), then check reading
tion 4F. with engine running. Compare oil pressure and
ohms readings as shown in following chart:
10. Connect hoses (vacuum, speedometer gauges).
11. Install gauge light socket. d
12. Coat all terminals with Quicksilver Liquid Neo- b
prene. c
13. Reconnect battery cables to battery.
72754
a - Positive Lead
b - Negative Lead
c - Wire Removed
d - Oil Pressure Sender
Oil
Ohms Reading
Pressure Dual
Single
(PSI)
0 227-257 113.5-128.5
20 142-162.5 71-81.25
40 91.7-113.6 45.8-56.8
80 9-49 4.5-24.5
Index
Water Temperature ! WARNING
DUAL STATION SENDER IDENTIFICATION The following test involves the use of intense
heat. Failure to follow appropriate procedures or
Sender will have 362-BC stamped on hex.
warnings can cause burns which can result in se-
vere personal injury. While performing the fol-
REMOVAL lowing test, observe these general precautions:
1. Drain coolant from closed cooling system into a • Wear personal protective clothing such as
suitable container as outlined in Section 6B. rubber gloves, a non-flammable apron, and
2. Remove TAN wire from temperature sender. eye protection - preferably full face shield or
safety glasses.
• The appropriate heat source should only be
electric. Heat source should be operated by a
qualified person. Be sure to follow all instruc-
tions of the manufacturer of the heat source.
The heat source should be checked each time
it is used to be sure it is functioning properly.
• The thermometer used in the test should be a
high-temperature thermometer with a maxi-
b mum reading of at least 300°F (150°C). Under
no circumstances should the operator allow
temperatures to exceed test specifications.
a
• Perform test only in a well ventilated area.
72611 • Use a suitable container, such as metal, to
Typical Water Temperature Sender hold the water. Avoid use of glass containers
a - TAN Wire
unless the operator first confirms for himself/
b - Water Temperature Sender herself that the glass container is an appro-
priate high-temperature vessel.
NOTE: Hoses are shown removed for clarity. • Because the components will reach high tem-
3. Remove temperature sender. peratures DO NOT handle materials or com-
ponents until COMPLETELY cooled.
TESTING
1. Connect an ohmmeter between temperature
sender terminal (+) and hex (case) for ground (–)
as shown.
72768
a - Ohmmeter Leads
b - Water Temperature Sender
Index
2. Follow these instructions: INSTALLATION
a. With ohmmeter connected as outlined and 1. Apply Loctite Pipe Sealant with Teflon to threads
using suitable container, thermometer and of temperature sender.
heat source, suspend sender with tip in water.
2. Install sender in thermostat housing and tighten
b. Heat water and observe thermometer. securely.
c. As temperature rises ohmmeter readings 3. Connect tan wire and coat with Liquid Neoprene.
must be within the ranges specified for each
temperature (see chart below).
d. Turn heat source off. Allow water and compo-
nents to cool.
NOTE: While water cools you may recheck ohmme-
ter readings.
e a
d b 72611
Typical Water Temperature Sender

a - TAN Wire
b - Water Temperature Sender
a 4. Refill closed cooling system with approved cool-

ant as outlined in Section 6B.
c
72769 Fuel Tank Sender
a - Suitable Container
b - Thermometer
FLANGE TYPE
c - Heat Source Testing
d - Water Temperature
e - Ohmmeter Leads 1. Disconnect wire from terminal on sending unit
and ground wire from sending unit mounting
Water Temperature Ohms Reading screw.
140° F (60° C) 121-147 2. Remove sending unit from fuel tank.
194° F (90° C) 47-55 3. Connect ohmmeter between sending unit termi-

nal and sending unit housing.
212° F (100° C) 36-41
3. Replace sender if ohmmeter readings are other

than as shown for each temperature.
Index
4. With float arm in FULL position (arm horizontal), CAPSULE TYPE
ohmmeter should read 30 ohms (+ 5 ohms).
Testing
1. Disconnect wire from terminal on fuel tank
capsule.
2. Remove two screws and remove capsule
assembly.
3. Place a magnet under fuel capsule.
a 4. Connect ohmmeter between fuel capsule termi-
nal and metal portion of capsule housing.
a
b
72755
b
a - Ohmmeter Leads
b - Vertical Float Arm
c
5. With float arm in EMPTY position (arm vertical) 72757
meter should read 240 ohms (+ 5 ohms). Sender a - Ohmmeter Leads
is defective if not within specifications. b - Capsule Assembly
c - Magnet
5. Turn magnet counterclockwise until fuel capsule

indicator reads EMPTY. Ohmmeter should read
a
240 ohms (+ 5 ohms).
72756
72758
a - Ohmmeter Leads
b - Vertical Float Arm
a - Capsule Reading Empty
Index
6. Turn magnet clockwise until fuel capsule indica- 3. With key switch in OFF position, there should be
tor reads FULL. Ohmmeter should read 30 ohms no continuity between switch terminals.
(+ 5 ohms). Fuel capsule is defective if not within
4. With key switch in RUN position, continuity will
specifications.
exist between switch terminals B to I. There
should no continuity between terminal S and any
other terminals.
5. With key switch in START, continuity will exist be-
a tween terminals B to I and B to S.
6. Terminals are to make contact at angles shown
and to stay in contact condition as switch is ro-
tated toward START.
7. If ignition key switch tests bad, unsolder wire con-
nections and remove switch. Test switch again,
as in Steps 2-5, preceding. If switch tests good,
wiring in harness is bad, There should be no con-
tinuity between any harness wires with key
72759
switch removed.
a - Capsule Reading Full f
e
d
Switches c
Ignition Key Switch

a b
TESTING
B
S
! CAUTION I
Disconnect battery cables from battery before

Key View Back View
testing ignition key switch with wires still con-
nected to switch. 72760
a - Key
1. Disconnect battery cables, if testing ignition key
b - Off
switch with wires connected to switch. c - Continuity, B to I Terminals
2. Before testing key switch, check all fuses and/or d - Run
e - Continuity B to S Terminals
circuit breakers in electrical circuit which could
f - Start
prevent operation of starter.
Index
Lanyard Stop Switches
NOTICE
For repair procedures on MPI / EFI Engines,
refer to Section 5C.
TESTING
b
a
74062
b Remote Control Mounted Style Switch - Carbu-

reted Engines
a - Switch Leads
b - Leads (PUR)
a
1. Disconnect switch leads.
74061
2. Test switch as follows.
Remote Control Mounted Style Switch - Electron- a. Connect an ohmmeter to leads.

ic Fuel Injection (EFI) Engines b. There should be continuity with switch lan-
a - Switch Lanyard yard connected and no continuity with switch
b - Leads (BLK/YEL) lanyard disconnected.
1. Disconnect switch leads.

2. Test switch as follows. a
a. Connect an ohmmeter to leads.
b. There should be no continuity with switch lan-
yard connected and continuity with switch b
lanyard disconnected.
72762
Toggle Style Switch

a - Switch Cap
b - Switch
Index
IMPORTANT: The BLK/YEL lead is not used. It Audio Warning System
should be well insulated and taped to harness.
1. Disconnect switch leads. NOTICE
2. Connect an ohmmeter to switch leads.
For repair procedures on Fuel Injection
Engines, refer to Section 5C.
3. Switch should have continuity with toggle in the
RUN position and no continuity with toggle in the
OFF position.
Buzzer
! WARNING
Start/Stop Switch
The following test involves the use of electricity.
TESTING Failure to follow appropriate procedures can
cause burns or shock which can result in severe
! WARNING personal injury or death.
Disconnect battery leads at battery before test- TESTING
ing.
1. Turn key to RUN position (engine off).
1. Disconnect battery leads.
2. Wait 7 to 14 seconds for horn to sound.
2. Check for continuity between the terminals on the
start switch with a continuity meter. 3. If horn does not sound:
a. Connect jumper wires as shown.
b. If horn does not sound, replace it.
4. If horn worked in Step 3:
a. Connect jumper wires as shown.
b. Repeat Step 2.
72763
3. No continuity should exist.

4. Depress switch button and continuity should
exist.
5. Check stop switch in the same manner.
6. If continuity exists when in the OPEN (not de-
pressed) state, replace panel button.
Index
c. If horn sounds, problem is in tan/blue wire Oil Pressure Switch
back to engine or switches on engine.
TESTING
c
1. Remove wire from sender terminal.
e 2. Connect continuity meter between sender termi-
nal and sender hex. (Sender shown removed for
clarity.)
f
b a
– +
g
d
72612
Buzzer For 1994 Model And Older Carbureted En-

gines 72764
a - Jumper Wire To 12 Volt (+) Step 3
b - Jumper Wire To Negative (–) Step 3 3. With engine not running, meter should indicate
c - Jumper Wire To 12 Volt (+) Step 4 full continuity.
d - Jumper Wire To Negative (–) Step 4
e - PURPLE Wire 4. Start engine. With engine running and engine oil
f - RED Wire pressure above 6 PSI (41 kPa), meter should in-
g - TAN/BLUE Wire dicate NO continuity.
Water Temperature Switch
REMOVAL
1. Drain coolant from closed cooling system into a
suitable container as outlined in Section 6B.
2. Remove tan/blue wire from temperature switch.
74046
Buzzer For EFI and 1995 Model And Newer Car-

bureted and EFI Engines (No Timer Circuit) b
a
72613
a - TAN/BLUE Wire
b - Water Temperature Switch
Index
NOTE: Coolant hoses shown removed for clarity. ! WARNING
3. Remove switch. The following test involves the use of intense
heat. Failure to follow appropriate procedures or
TESTING warnings can cause burns which can result in se-
1. Connect an ohmmeter between water tempera- vere personal injury. While performing the fol-
ture switch terminal (+) and hex (case) for ground lowing test, observe these general precautions:
(–) as shown. • Wear personal protective clothing such as
rubber gloves, a non-flammable apron, and
eye protection - preferably full face shield or
safety glasses.
b
qualified person. Be sure to follow all instruc-
a
mum reading of at least 300°F (150°C). Under
no circumstances should the operator allow
temperatures to exceed test specifications.
72765
a - Ohmmeter Leads
b - Water Temperature Switch • Use a suitable container, such as metal, to
hold the sand. Avoid use of glass containers
2. Switch should read no continuity. unless the operator first confirms for himself/
herself that the glass container is an appro-
priate high-temperature vessel.
• Because the components will reach high tem-
peratures DO NOT handle materials or com-
ponents until COMPLETELY cooled.
Index
! WARNING c. As temperature rises, switch will close and
ohmmeter will indicate continuity. Refer to
Use only clean, dry sand such as used for general chart below for specifications.
sandblasting purposes. Use of sand containing
contaminants could result in hazards such as 48952 Switch
fire, short circuiting, hot-spots, or other hazards.
Opens 150-170° F (60-77° C)
Closes 190-200° F (88-93° C)
3. Follow these instructions:
a. With an ohmmeter connected as outlined and 87-86080 Switch
using suitable container, thermometer and
heat source, suspend sender with tip in sand. Opens 175-195° F (60-77° C)
b. Heat sand and observe temperature on ther- Closes 215-225° F (88-93° C)

mometer.
a
b
e b
d
a 72767
Switch Identification
c a - 48952 Switch With Red Mylar Sleeve
b - 87-86080 Switch With Black Mylar Sleeve
72766 4. Turn heat source off. Allow sand to cool. Note

thermometer reading to ensure switch “opens”
a - Suitable Container
b - Thermometer up at specified temperature.
c - Heat Source 5. Replace switch if switch fails to either open or
d - Water Temperature Switch
close within the specified temperatures.
e - Ohmmeter Leads
Index
INSTALLATION REMOVAL
1. Apply Loctite Pipe Sealant with Teflon to threads 1. Disconnect harness wires at switch.
of water temperature switch.
2. Remove switch and sealing washer.
2. Install switch in thermostat housing and tighten
securely. c
3. Connect tan/blue wire and coat connection with

Liquid Neoprene.
b
a
72770
a - Transmission (Typical)
a 72613
b - Transmission Fluid Temperature Switch With Sealing
Washer
c - Harness Wires
a - TAN / BLUE Wire
b - Water Temperature Switch
TESTING
4. Refill closed cooling system with approved cool- 1. Connect one lead of an ohmmeter to one terminal
ant as outlined in Section 6B. of transmission switch. Connect the other lead of
ohmmeter to other terminal.
Transmission Fluid Temperature

Switch
Switch is located on transmission on earlier models
and may be mounted in a fitting on transmission fluid
cooler on later models. Switch is normally open. This
switch is used on all MIE engines, if so equipped. a
87-88031 Switch
b
Opens 180-200° F (82-93° C)
Closes 220-240° F (104-116° C)
72771
a - Ohmmeter Leads
b - Transmission Fluid Temperature Switch
2. Switch should read no continuity.
Index
! WARNING 3. Follow these instructions:
The following test involves the use of intense a. With an ohmmeter connected as outlined and
heat. Failure to follow appropriate procedures or using suitable container, thermometer and
warnings can cause burns which can result in se- heat source, suspend sender with tip in sand.
vere personal injury. While performing the fol- b. Heat sand and observe thermometer.
lowing test, observe these general precautions:
• Wear personal protective clothing such as
rubber gloves, a non-flammable apron, and
eye protection - preferably full face shield or
safety glasses.
e
qualified person. Be sure to follow all instruc- b
mum reading of at least 300°F (150°C). Under a
no circumstances should the operator allow d
temperatures to exceed test specifications. c
• Use a suitable container, such as metal, to
72772
hold the sand. Avoid use of glass containers
unless the operator first confirms for himself/ a - Sutiable Container
b - Thermometer
herself that the glass container is an appro-
c - Heat Source
priate high-temperature vessel. d - Transmisson Fluid Temperature Switch
• Because the components will reach high tem- e - Ohmmeter Leads
peratures DO NOT handle materials or com-
ponents until COMPLETELY cooled. c. As temperature rises, switch will close and
ohmmeter will indicate continuity. Refer to
chart below for specifications.
! WARNING
Use only clean, dry sand such as used for general Switch Condition Temperature
sandblasting purposes. Use of sand containing Opens 180-200° F (82-93° C)
contaminants could result in hazards such as Closes 220-240° F (104-116° C)
fire, short circuiting, hot-spots, or other hazards.
4. Turn heat source off. Allow sand to cool. Note
thermometer reading to ensure switch opens up
at specified temperature.
5. Replace switch if switch fails to either open or
close within the specified temperature.
Index
INSTALLATION
1. Apply Loctite Pipe Sealant with Teflon to threads
of transmission fluid temperature switch.
2. Install switch with sealing washer in transmission
NOTE: Switch is mounted in a fitting on transmission
cooler on some later models.
3. Reconnect harness wires and coat with Liquid
Neoprene.
a
72770
a - Transmission (Typical)
b - Transmission Fluid Temperature Switch With Sealing
Washer
c - Harness Wires
4. Check transmission fluid level.
Index
AT A LATER DATE
Index
ELECTRICAL SYSTEM
4
E
72761
ELECTRICAL KITS
Index
Table of Contents
Page
Wiring Color Code for MerCruiser Products . . 4E-1
Lanyard Stop Switches . . . . . . . . . . . . . . . . . . . . 4E-1
65503A2 Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-1
87-19674A2 or 87-814324A2 Kit . . . . . . . . . 4E-1
Audio Warning System . . . . . . . . . . . . . . . . . . . . 4E-8
86047A14 Kit . . . . . . . . . . . . . . . . . . . . . . . . . 4E-8
NOTICE
For information and procedures on Fuel
Injection Engines, refer to Section 5C.
Index
4E - ELECTRICAL
4E-0 KITS
- ELECTRICAL KITS 90-823225--1 1096
Wiring Color Code for 65503A2 Kit
MerCruiser Products INSTALLATION INFORMATION
BLK = BLACK 1. Route stop switch wire harness to engine so that
BLU = BLUE it will not chafe or flex unnecessarily. Secure har-
BRN = BROWN ness with cable ties provided.
GRY = GRAY
GRN= GREEN 2. Check stop switch operation after installation is
ORN= ORANGE completed.
PNK = PINK 3. Coat all electrical connections with Quicksilver
PUR = PURPLE Liquid Neoprene after checking switch operation.
RED = RED
TAN = TAN 4. Attach stop switch cap to operator’s person with
WHT= WHITE a suitable cord (lanyard). Length of cord should
YEL = YELLOW be no longer than absolutely necessary and
LIT = LIGHT should have a minimum breaking strength of 100
DRK = DARK lbs. (45 kg).
IMPORTANT: To prevent the possibility of dam-

age to ignition components, turn ignition switch
Lanyard Stop Switches to OFF position as soon as possible after safety
stop switch has been activated.
! WARNING 5. To reset stop switch after activation, simply install
Disconnect battery leads at battery before at- stop switch cap with a straight firm push.
tempting to install ignition safety stop switch.
87-19674A2 or 87-814324A2 Kit

! CAUTION
This stop switch is to be used as a safety stop INSTALLATION INFORMATION
switch only. It should not be used as the normal 1. Select a location for lanyard stop switch that will
engine shut-off. allow lanyard to be pulled free without interfer-
ence and will be within wire length limitations.
! WARNING 2. Mark hole locations for flush or surface mounting.
As we cannot possibly know of and advise the Install switch assembly as shown.
boating public of ALL conceivable boat/motor
types and/or poor operating practices, the final IMPORTANT: If using “Surface Mount” configu-
decision of whether to install and use a LAN- ration (as shown following), ensure wires are
YARD STOP SWITCH, rests with the owner/driver. routed to the outside, as shown, to prevent
pinching of wires between the back of switch and
the mounting surface.
! CAUTION
Drilling Tips
Before cutting any holes in dashboard, check
area behind dashboard for obstructions (braces, If dashboard is fiberglass, apply masking tape to
cables, etc.). area that is to be drilled to prevent dashboard from
cracking.
Index
90-823225--1 1096 ELECTRICAL KITS - 4E-1
If dashboard is vinyl covered, use a razor blade to re-
move vinyl from area to be drilled to keep vinyl from
tearing.
a
b
72809
a Surface Mount - Dual Engines

a - Self-Tapping Screw - Drill Pilot Holes Appropriate Drill Bit
Aluminum - 5/32 in. (4 mm)
Wood / Fiberglass 11/64 in. (4.5 mm)
72807
Surface Mount - Single Engine
a - Wires Properly Routed
b - Self-Tapping Screw - Drill Pilot Holes Appropriate Drill Bit
Aluminum - 5/32 in. (4 mm)
Wood / Fiberglass 11/64 in. (4.5 mm)
a a
72810
Flush Mount - Dual Engines
a - 2-1/8 in. (54 mm) Hole - Use Hole Saw
b
IMPORTANT: Be sure to refer to appropriate wir-
ing diagram in the following step.
IMPORTANT: Lanyard stop switch being in-

stalled at second station (flybridge) must use Ex-
tension Harness Kit (84-16866A2) to connect
switch to wiring harness at main (lower) station.
72808
Refer to instructions in extension harness kit.
Flush Mount - Single Engine
a - Secure Mounting Screws With Nuts To Aid Installation 3. Connect lanyard stop switch wires in accordance
b - 2-1/8 in. (54 mm) Hole - Use Hole Saw with appropriate wiring diagram. Route switch
wires to prevent possible chafing or flexing during
boat operation. Secure wires with Sta-Straps.
Index
4E-2 - ELECTRICAL KITS 90-823225--1 1096
4. Secure bullet connectors with retainer and 5. When installation is complete, reconnect battery
Sta-Straps. leads at battery and perform operational test.
b IMPORTANT: On installations where gauge op-

tions will not be used, tape back and isolate any
unused leads.
a
72811
a - Join Connectors
b - Secure With Sta-Strap
Index
LANYARD STOP SWITCH WIRING DIAGRAM - SINGLE ENGINE
b c
d
75328
NOTE: Connect wires together with screw and hex nut. Apply Liquid Neoprene to connection and slide rubber
sleeve over connection.
a - Tachometer
b - Oil Pressure
c - Water Temperature
d - Battery Meter
e - Ignition Switch
f - Lanyard Stop Switch
g - This Lead Not Used On MerCruiser
h - Trim Indicator
Index
LANYARD STOP SWITCH WIRING DIAGRAM - SINGLE FUEL INJECTION ENGINE
d
a
e
f g
b
i
NOTE k
Console Mount J
Remote Control
n
o k k
YEL/BLK
NOTE
q p
m l
m l
NOTE: Lanyard stop switch and neutral start leads must be soldered and covered with shrink tube for a water
proof connection. If alternate method of connection is made (use of electrical butt connector) verify connection
is secure and sealed for waterproof connection.
a - Lanyard Stop Switch (Use With Console Mount Remote Control)
b - Lead Not Used On 454 / 502 Multi-Port Injection
c - Lanyard Stop Switch Multi-Port / Throttle Body Injection Adapter Harness
d - Tachometer
e - Oil Pressure
f - Water Temperature
g - Battery Meter
h - To Engine Harness
i - Ignition Switch
j - Trim Indicator
k - Neutral Start Switch Leads
l - Trim Limit Switch Leads
m- Power Trim Harness Connector
n - Lanyard StopSwitch (Panel Mount Remote Control)
o - Trialer Switch (Console Mounted Remote Control)
p - Lanyard Stop Leads On Panel Mounted Control
q - Lanyard Stop Switch Multi-Port / Throttle Body Injection Adapter Harness (84-805745A2) Purchased Seperately
Index
LANYARD STOP SWITCH WIRING DIAGRAM - DUAL ENGINES
NOTE
NOTE
NOTE
YEL/RED
THESE LEADS NOT

PUR
USED ON MERCRUISER
YEL/RED B
BLK/WHT
BLK/WHT C
PUR PUR D
LANYARD STOP SWITCH 75329
IMPORTANT: On installations where gauge options will not be used, tape back and isolate any unused
leads.
NOTE: Connect wires together with screw and hex nut. Apply Liquid Neoprene to connection and slide rubber
Index
LANYARD STOP SWITCH WIRING DIAGRAM - DUAL ENGINES
NOTE 1
NOTE 1
PUR
YEL/RED
BLK/WHT
A YEL/RED
B
C
D
75330
Index
Audio Warning System c. Coat connections with Quicksilver Liquid
Neoprene.
5. Reconnect water hoses.
! WARNING
Audio Warning Heat Switch on V-8 Engines
Always disconnect battery cables from battery with Closed Cooling
before working around electrical system compo-
nents to prevent injury to yourself and damage to 1. Drain cooling system.
electrical system. 2. Remove TAN/BLUE wire from audio warning
heat switch in rear hole of thermostat housing.
Remove switch.
86047A14 Kit
INSTALLATION INFORMATION
Audio Warning Heat Switch on V-8 Engines
with Standard Cooling
1. Drain cooling system.
2. Disconnect port hoses from thermostat housing. b
3. Remove TAN/BLUE wire from water heat switch

in port side of thermostat housing. Remove
switch. a
NOTE: Hoses shown removed for clarity.
71518
a - Audio Warning Heat Switch
b - TAN / BLUE Wire
3. Install audio warning heat switch as follows:

a
a. Install heat switch into thermostat housing,
using Loctite Pipe Sealant with Teflon (DO
NOT use Teflon tape) to seal threads. Tighten
securely.
b. Attach TAN/BLUE wire to heat switch with nut
and lockwasher. Tighten nut securely.
b
72613 c. Coat connections with Quicksilver Liquid
a - Audio Warning Heat Switch Neoprene.
b - TAN / BLUE Wire
4. Fill closed cooling system with proper water/anti-
4. Install audio warning heat switch as follows: freeze solution. (Refer to “Filling Closed Cooling
Section” in Section 6B.)
a. Install heat switch into aft side of thermostat
housing, using Loctite Pipe Sealant with Te-
flon (DO NOT use Teflon tape) to seal
threads. Tighten securely.
b. Attach TAN/BLUE wire to heat switch with nut
and lockwasher. Tighten nut securely.
Index
Audio Warning Oil Pressure Switch Warning Buzzer
1. Audio warning oil pressure switch (with reducer)
is installed in place of engine block plug at the fol-
lowing location:
72813
72820
a - Engine Block Plug (Typical)
2. Disconnect TAN/BLUE wire (from audio warning

heat switch) at audio warning oil pressure switch.
a - Early Style Warning Buzzer

b - Later Style Warning Buzzer
a ! WARNING
72812 Buzzer is not external ignition-proof; therefore,
DO NOT mount buzzer in engine or fuel tank com-
a - TAN / BLUE Wire Location (Wire Not Shown) partments.
b - Audio Warning Oil Pressure Switch
1. Disconnect battery leads, if not already discon-
3. Remove audio warning oil pressure switch. nected.
4. Install switch as follows: 2. Mount buzzer under dashboard with two screws
(from kit) in location that is not in obvious sight but
a. Install switch using Loctite Pipe Sealant with is easily accessible for installation and mainte-
Teflon (DO NOT use Teflon tape) to seal nance. Location should not restrict buzzer sound
threads. Tighten switch securely. and also should be within limits of 18 in. (460 mm)
b. Coat connections with Quicksilver Liquid PURPLE lead. (Lead will be connected to instru-
Neoprene. ment terminal in dashboard.)
c. Connect TAN/BLUE wire from audio warning

heat switch to audio warning oil pressure
switch with lockwasher and nut. Torque nut to
15 lb. in. (1.7 N·m).
Index
3. Attach PURPLE lead to +12 volt switched termi- 8. Reconnect battery leads.
nal of any adjacent gauge [PURPLE to PURPLE
9. Fill closed cooling system (on engines so
(BIA)]. The attaching terminal should be OFF
equipped) with water/antifreeze solution.
when ignition switch is in the OFF position.
10. Test switch (horn) as explained on decal (Fig-
4. Plug male terminal of TAN/BLUE wire (on buzzer)
ure 1).
to existing TAN/BLUE wire on harness. Be sure
that wire does not chafe or get pinched and does 11. Seal all electrical connections with Quicksilver
not come in contact with bilge water or moving Liquid Neoprene.
parts.
OPERATION
5. Connect TAN/BLUE lead from buzzer to engine
water heat switch with lockwasher and nut. Test the system (per the instructions on the dash-
Torque nut to 15 lb. in. (1.7 N·m). (DO NOT board decal, Figure 2) at least once every five hours
over-tighten). of operation.
6. Place decal (Figure 1) on bottom of glass face of During boat operation, if the horn sounds, look for
water temperature gauge and of oil pressure one or more of the following operation problems:
gauge, if equipped.
PROBLEM REMEDY
ALARM INDICATES LOW Low Engine Oil (Check
Add Oil Per Instructions
OIL OR OVERHEATING Oil Pressure Gauge or
in Owner’s Manual
Dipstick Level)
Figure 1 Cooling Water Pickup is
Blocked Or Clogged Clear The Water Pickup
7. Place decal (Figure 2) in convenient location on (Check Water Tempera- Of Foreign Material
dashboard. ture Gauge)
ENGINE SENSOR HORN WILL SOUND WHEN OIL NOTE: The horn will sound, if, while docking or other-
PRESSURE IS TOO LOW OR TEMP. IS TOO HOT. wise maneuvering slowly, the engine stalls and is not
TO TEST HORN restarted, and the ignition key is left ON (similar to
1.TURN KEY TO ON POSITION (ENGINE OFF) test procedure).
2. WAIT 7 TO 14 SEC. FOR HORN TO SOUND
Figure 2
Index
AT A LATER DATE
Index
ELECTRICAL SYSTEMS
4
F
72938
WIRING DIAGRAMS
Index
Table of Contents
Page
Thunderbolt IV . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-1
Alpha Drive - All Engines With Ignition
Module Mounted On Exhaust Elbow . . . . . 4F-1
MCM V-8 Alpha Thunderbolt V With
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . 4F-7
MCM V-8 Alpha Thunderbolt V Without
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . 4F-8
MCM V-8 Bravo Thunderbolt V With
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 4F-9
MCM V-8 Bravo Thunderbolt V Without
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 4F-10
MIE V-8 (Bluewater) Thunderbolt V Without
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . 4F-11
MIE (Bluewater) V-8 Thunderbolt V With
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 4F-12
MIE (Ski) V-8 Thunderbolt V Without
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 4F-13
EFI System Harness . . . . . . . . . . . . . . . . . . 4F-14
EFI Engine Harness . . . . . . . . . . . . . . . . . . . . . 4F-16
MCM 5.7L EFI Alpha With Vapor
Separator Tank (VST) . . . . . . . . . . . . . . . . 4F-16
MCM 5.7L EFI Alpha With Cool
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 4F-17
MCM 5.7L EFI Bravo WIth Vapor Separator
Tank (VST) . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-18
MCM 5.7L EFI Bravo WIth Cool
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 4F-19
MCM 350 MPI Bravo and Blackhawk
(Including Gen + Engines)
With Vapor Separator Tank (VST) . . . . . . . 4F-20
MCM 350 Gen+ MPI Bravo and
Blackhawk With Cool Fuel System . . . . . 4F-21
MIE 350 Magnum MPI Gen +
Tournament Ski (Black Scorpion) . . . . . . . 4F-22
MIE 350 Magnum EFI Gen + Tournament
Ski / 5.7L Gen+ Inboard
With Cool Fuel System . . . . . . . . . . . . . . . . 4F-23
MCM Quicksilver Instrumentation . . . . . . . 4F-24
Battery Meter Gauge . . . . . . . . . . . . . . . . . . . . 4F-31
Cruiselog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-31
Fuel Gauge and Sender . . . . . . . . . . . . . . . . . . 4F-31
Audio Warning System . . . . . . . . . . . . . . . . . . . 4F-31
Water Temperature Gauge . . . . . . . . . . . . . . . 4F-32
Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 4F-32
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-32
Index
4F-0 - WIRING DIAGRAMS 90-823225--1 1096
Thunderbolt IV
Alpha Drive - All Engines With Ignition Module Mounted On Exhaust Elbow
A. Ignition System C. Audio Warning System

B. Starting and Charging System D. Instrumentation System 50843
Index
90-823225--1 1096 WIRING DIAGRAMS - 4F-1
ALPHA DRIVE - ALL ENGINES WITH IGNITION MODULE MOUNTED ON DISTRIBUTOR
DISTRIBUTOR
BLK
WHT/RED
WHT/GRN
GRY
PUR
72935
B. Starting and Charging System D. Instrumentation System
Index
BRAVO DRIVE - ALL ENGINES WITH IGNITION MODULE MOUNTED ON EXHAUST ELBOW
IGNITION
MODULE
A: Ignition and Choke System C: Audio Warning System

B: Starting and Charging System D: Instrumentation System 50844
Index
BRAVO DRIVE - ALL ENGINES WITH IGNITION MODULE MOUNTED ON DISTRIBUTOR
DISTRIBUTOR
BLK
WHT/RED
WHT/GRN
GRY
PUR

72936
Index
MIE - INBOARD AND SKI ENGINES WITH IGNITION MODULE MOUNTED ON EXHAUST ELBOW
IGNITION
MODULE
A: Ignition and Choke System C: Audio Warning System

B: Starting and Charging System D: Instrumentation System
50773
Index
MIE - ALL INBOARD AND SKI ENGINES WITH IGNITION MODULE MOUNTED ON DISTRIBUTOR
DISTRIBUTOR
BLK
WHT/RED
WHT/GRN
GRY
PUR
72937
Index
MCM V-8 Alpha Thunderbolt V With Knock Sensor
A
1 C
2
3
1 2
3
1 3
2
NOTE
1
5
4
2
3
B
74593
NOTE: TAN/BLU wire is not used at distributor.

A -Ignition System C-Audio Warning System
1 -Distributor 1 -Water Temperature
2 -Ignition Coil 2 -Drive Unit Oil Level (If Equipped)
3 -Shift Cut-Out Switch 3 -Oil Pressure Switch
4 -Knock Sensor D -Instrumentation System
B -Starting System 1 -Oil Pressure Sender
1 -Alternator 2 -Water Temperature Sender
2 -Electric Choke 3 -Trim Sender
3 -Ground Bolt
4 -Starter
5 -Circuit Breaker
6 -Starter Slave Solenoid
Index
MCM V-8 Alpha Thunderbolt V Without Knock Sensor
A C
2
1
3
2
3
D 3
NOTE
2
1
1
5
4
2 3
B
74593

3 -Shift Cut-Out Switch 3 -Oil Pressure Switch
B -Starting System D -Instrumentation System
1 -Alternator 1 -Oil Pressure Sender
2 -Electric Choke 2 -Water Temperature Sender
3 -Ground Bolt 3 -Trim Sender
4 -Starter
5 -Circuit Breaker
Index
MCM V-8 Bravo Thunderbolt V With Knock Sensor
A C
2
1
3
1
2
NOTE 1 D 3
2
1
1
4 5
2 3
B
73996

3 -Knock Sensor 3 -Oil Pressure Switch
4 -Starter
5 -Circuit Breaker
Index
MCM V-8 Bravo Thunderbolt V Without Knock Sensor
A C
2
1
1 3
2
D 3
NOTE 1
2
1
1
5
4
2
3
B
74592

B -Starting System 3 -Oil Pressure Switch
1 -Alternator D -Instrumentation System
2 -Electric Choke 1 -Oil Pressure Sender
3 -Ground Bolt 2 -Water Temperature Sender
4 -Starter 3 -Trim Sender
5 -Circuit Breaker
Index
MIE V-8 (Bluewater) Thunderbolt V Without Knock Sensor
A C
1
1 2
2
D NOTE 2
NOTE 1
1 2
1
5
4 7
2 3
B
74592
NOTE 1: Taped back BROWN/WHITE wire may be used for an accessory. LOAD MUST NOT EXCEED 5 AMPS.
NOTE 2: Taped back TAN/BLUE wire not used.
1 -Distributor 1 -Water Temperature Switch
2 -Ignition Coil 2-Transmission Fluid Temperature Switch
5 -Circuit Breaker
7 -Neutral Safety Switch
Index
MIE (Bluewater) V-8 Thunderbolt V With Knock Sensor
C
A 3
1
1 2
2
D
NOTE 2
NOTE 1
2
1
1
4 5 7
2 3
B
74160
3 -Knock Sensor 3 -Oil Pressure Switch
4 -Starter
5 -Circuit Breaker
Index
MIE (Ski) V-8 Thunderbolt V Without Knock Sensor
A C
1
1
2
2
3
D NOTE 2
NOTE 1
2
1
1 5
4 7
2 3
B
74160
5 -Circuit Breaker
Index
EFI System Harness
MIE
A 2
B
2
1
5
c
7
4
1 b
6
3
C a
2 90 AMP
FUSE
A - Audio Warning System C- Charging and Starting System

1 - Oil Pressure Switch 1- Alternator
2 - Transmission Fluid Temperature 2- Ground Stud
Switch 3- Starter
4- Circuit Breaker
B - Instrumentation System 5- Starter Slave Solenoid
1 - Oil Pressure Sender 6- Neutral Safety Switch
2 - Water Temperature Sender 7- 90 Amp. System Fuse
a - Positive Power Wire To EFI System Harness

b - Harness Connector To EFI System Harness
c - Auxiliary Tachometer Lead
Index
MCM ALPHA, BRAVO AND BLACKHAWK
A 2
OLD STYLE
BOTTLE
1
NEW STYLE
BOTTLE
B 3
1 2
c
1 4
3
b
2
90 AMP
C FUSE
a 71693
A - Audio Warning System C- Charging and Starting System

1 - Oil Pressure Switch 1- Alternator
2 - Drive Unit Oil Level 2- Ground Stud
3- Starter
B- Instrumentation System 4- Circuit Breaker
1- Oil Pressure Sender 5- Starter Slave Solenoid
2- Water Temperature Sender
3- Trim Sender a - Positive Power Wire To EFI System Harness
b - Harness Connector To EFI System Harness
c - Auxiliary Tachometer Lead
Index
EFI Engine Harness
MCM 5.7L EFI Alpha With Vapor Separator Tank (VST)

NOTE 1
3 22
8
4 12
19
9
10
2 6
1
16
11 5
17
20
18 14
13 15
21
NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness.
NOTE 1: As a mid year (96-1/2) model change, the EFI (Throttle Body Injection) models have the lanyard stop
connector removed from the wiring harness. The dual engine capability is relocated by routing the YEL wire to
the Data Link Connector (DLC).
1 - Vapor Separator Tank (VST) 12- Electronic Control Module (ECM)
2 - Throttle Body 13- Fuel Pump Relay
3 - Distributor 14- Ignition/System Relay
4 - Coil 15- Fuel Pump Fuse
5 - Knock Sensor (KS) Module 16- ECM/Ignition Feed/KS Module/Injectors Fuse
6 - Data Link Connector (DLC) 17- ECM/DLC/Battery Fuse
7 - Manifold Absolute Pressure (MAP) Sensor 18- Harness Connector To Starting/Charging Harness
8 - Knock Sensor 19- Harness Connector To Lanyard Stop Switch (Optional)
9 - Idle Air Control (IAC) 20- Harness Connector For Dual Engine Data Link Cable
10- Throttle Position (TP) Sensor 21- Positive (+) Power Wire To Engine Circuit Breaker
11- Engine Coolant Temperature Sensor (ECT) 22- Shift Cutout Switch
Index
MCM 5.7L EFI Alpha With Cool Fuel System
3 22
8
4 12
19
9
10
2 6
16
11 5
17
20
18 14
13 15
21
7371
1
1 - Electric Fuel Pump 12- Electronic Control Module (ECM)
Index
MCM 5.7L EFI Bravo WIth Vapor Separator Tank (VST)
NOTE 1
8
4 12
19
9
10
2 6
1
16
11 5
17
20
14
18
13 15
21
73717
NOTE 1: As a mid year (96-1/2) change, the EFI (Throttle Body Injection) models have the lanyard stop connec-
tor removed from the wiring harness. The dual engine capability is relocated by routing the YEL wire to the Data
Link Connector (DLC).
11- Engine Coolant Temperature Sensor (ECT)
Index
MCM 5.7L EFI Bravo WIth Cool Fuel System
8
4 12
19
9
10
2 6
16
11 5
17
20
14
18
13 15
21
1
73717
Index
MCM 350 MPI Bravo and Blackhawk (Including Gen + Engines)
With Vapor Separator Tank (VST)
NOTE 1
4
2
8
10 9
12 19
GRY
6
17
18 11 5
14 16
20
13 15
21
74182
Note: All BLACK Wires With A Ground Symbol Are Interconnected Within The EFI System Harness.
NOTE 1: As a mid year (96-1/2) model change, the MPI (Multi Port Injection) models have the lanyard stop con-
nector and dual engine data link connector removed from the wiring harness. The dual engine capability is relo-
cated by routing the YEL wire to the Data Link Connector (DLC).
4 - Coil 15- Fuse (15 Amp) Fuel Pump
5 - Electronic Spark Control (KS) Module 16- Fuse (15 Amp) ECM/DLC/Battery
6 - Data Link Connector (DLC) 17- Fuse (10 Amp) ECM/Injector/Ignition/Knock Module
7 - Manifold Absolute Pressure (MAP) Sensor 18- -Harness Connector To Starting/Charging Harness
11- Engine Coolant Temperature (ECT) Sensor
Index
MCM 350 Gen+ MPI Bravo and Blackhawk With Cool Fuel System
4
2
8
10 9
12 19
17
18 11 5
14 16
20
13 15
21
1 74182
1 - Electrical Fuel Pump 12- Electronic Control Module (ECM)
7 - Manifold Absolute Pressure (MAP) Sensor 18- -Harness Connector To Starting/Charging Harness
Index
MIE 350 Magnum MPI Gen + Tournament Ski (Black Scorpion)
NOTE 1
2
6
8 10 17
15
16 9 4
14
12
11 13
18
74893
nector removed from the wiring harness. The dual engine capability is relocated by routing the YEL wire to the
Data Link Connector (DLC).
1 - Fuel Pump 10- Electronic Control Module (ECM)
2 - Distributor 11- Fuel Pump Relay
3 - Coil 12- Ignition/System Relay
4 - Electronic Spark Control (KS) Module 13- Fuse (15 Amp) Fuel Pump
5 - Data Link Connector (DLC) 14- Fuse (15 Amp) ECM/DLC/Battery
6 - Manifold Absolute Pressure (MAP) Sensor 15- Fuse (10 Amp) ECM/Injector/Ignition/Knock Module
7 - Idle Air Control (IAC) 16- Harness Connector To Starting/Charging Harness
8 - Throttle Position (TP) Sensor 17- Harness Connector To Lanyard Stop Switch (Optional)
9 - Engine Coolant Temperature (ECT) Sensor 18- Positive (+) Power Wire To Engine Circuit Breaker
Index
MIE 350 Magnum EFI Gen + Tournament Ski / 5.7L Gen+ Inboard
With Cool Fuel System
NOTE 1
8
4 12
9
10
2 6
16
11 5
17
14
18
13 15
19
1 75001
nector removed from the wiring harness. The dual engine capability is relocated by routing the YEL wire to the
Data Link Connector (DLC).
1 - Fuel Pump 11- Engine Coolant Temperature (ECT) Sensor
2 - Throttle Body 12- Electronic Control Module (ECM)
8 - Knock Sensor 18- -Harness Connector To Starting/Charging Harness
9 - Idle Air Control (IAC) 19- Positive (+) Power Wire To Engine Circuit Breaker
10- Throttle Position (TP) Sensor
Index
MCM Quicksilver Instrumentation
MCM EARLIER STYLE CONTROLS AND AUDIO WARNING BUZZER
B
S
I
72938
NOTE 1: Connect wires together with screw and hex nut. Apply Liquid Neoprene to connection and slide rubber
NOTE 2: Power for a fused accessory panel may be taken from this connection. Load MUST NOT exceed
35-40 amps. Panel ground wire MUST BE connected to instrument terminal that has an 8 gauge black (Ground)
harness wire connected to it.
Index
MCM LATER STYLE CONTROLS AND AUDIO WARNING BUZZER
Refer to gauge manufacturer’s instructions for specific connections.
NOTE 1. Connect Wires Together with Screw and Hex
Nut; Apply Liquid Neoprene to Connection and
Slide Rubber Sleeve over Connection.
NOTE 2. Power for a Fused Accessory Panel May Be
Taken from This Connection. Load Must Not
Exceed 40 Amps. Panel Ground Wire Must Be
Connected to Instrument Terminal That Has an
8-Gauge Black (Ground) Harness Wire Con-
nected to it.
Tachometer
To Engine Harness
Oil Water
Pressure Temperature Battery Meter
IGNITION NOTE 2
SWITCH
NOTE 1
TRIM
NOTE 1 INDICATOR
NOTE 1
74046
Index
MIE QUICKSILVER INSTRUMENTATION
EARLIER STYLE AUDIO WARNING BUZZER
B
S
I
72939
Index
MIE LATER STYLE AUDIO WARNING BUZZER
B
S
I
74274
Index
DUAL STATION WIRINGUSING A NEUTRAL SAFETY SWITCH IN ONLY ONE REMOTE CONTROL
SECONDARY STATION
STOP-START TACHOMETER OIL WATER BATTERY
PANEL PRESSURE TEMPERATURE METER
GND
LT
SW
UNSW
LT GND LT GND LT GND
12V
12V 12V 12V
SEND SEND SEND

SIG
PUR
GRY
LT. BLU
PUR
PUR
PUR
BLK
BLK
BLK
BLK
BLK
TAN
GRY
PUR
YEL/RED
NOTE 3
YEL/RED
NOTE 1
PRIMARY STATION
IGNITION TACHOMETER OIL WATER BATTERY
SWITCH PRESSURE TEMPERATURE METER
RED/PUR
BRN/WHT
GND
LT
20 AMP B SW UNSW
GND GND
FUSE S
I
12V
LT LT
LT
GND
12V 12V 12V
SEND SEND SEND

SIG
RED/PUR
PUR
TAN
PUR
BLK
BLK
LT. BLU
BLK
RED/PUR
YEL/RED
BLK
GRY
PUR
PUR NOTE 2
PUR
YEL/RED
NOTE 3 TO
NOTE 3
ENGINE
NOTE 3
NOTE 1
BRN/WHT
YEL/RED
YEL/RED
72940
NOTE 1: Brown/white wire is taped back at instrument end. If installing on boat that is equipped with MerCruiser
Stern Drive, brown/white wire is connected to trim sender terminal block. If installing on Mercruiser Inboard,
brown/white wire is taped back at engine end, or it may be used for an accessory (limit 5 amps).
NOTE 2: An accessory fuse panel may be connected at this location. The combined current draw of the primary
station and secondary station MUST NOT exceed 35 amps.
Index
DUAL STATION WIRING USING A NEUTRAL SAFETY SWITCH IN BOTH REMOTE CONTROLS
SECONDARY STATION
LT GND
SW
UNSW LT
LT LT GND GND
12V GND
12V 12V 12V
SEND SEND SEND

SIG
PUR
YEL/RED
GRY
LT. BLU
PUR
PUR
PUR
BLK
BLK BLK
BLK
BLK
TAN
GRY
PUR
YEL/RED
NOTE 3
NOTE 3
YEL/RED
NOTE 1
PRIMARY STATION
RED/PUR BRN/WHT
GND
LT
20 AMP S
B SW UNSW
LT GND LT GND LT
GND
FUSE I 12V
12V 12V 12V
SEND SEND SEND

SIG
RED/PUR
BLK
RED/PUR
PUR
PUR
TAN
LT. BLU
BLK
BLK
GRY
PUR
YEL/RED
NOTE 2
BLK
PUR PUR
NOTE 3
TO
ENGINE
YEL/RED
NOTE 1
BRN/WHT YEL/RED
NOTE 3 NOTE 3
YEL/RED
72941
Index
DUAL STATION WIRING USING A NEUTRAL SAFETY SWITCH IN ENGINE WIRING HARNESS
SECONDARY STATION
LT GND
SW
UNSW
LT LT GND LT GND
12V GND
12V 12V 12V
SEND SEND SEND

SIG
PUR
GRY
LT. BLU
PUR
PUR
PUR
BLK
BLK
BLK
BLK
BLK
TAN
GRY
PUR
YEL/RED
NOTE 3
YEL/RED NOTE 1
PRIMARY STATION
RED/PUR BRN/WHT
GND
LT
20 AMP S
B SW UNSW
LT GND LT GND GND
LT
FUSE I 12V
12V 12V 12V
SEND SEND SEND

SIG
ORN
BLK
BLK
PUR
PUR
TAN
LT. BLU
BLK
PUR
RED/PUR
GRY
YEL/RED
ORN
BLK
PUR NOTE 2
PUR
YEL/RED
NOTE 3
TO
NOTE 3 ENGINE
NOTE 1
BRN/WHT YEL/RED
NOTE 3
72942
Index
Battery Meter Gauge Fuel Gauge and Sender
a
72814
a - Lamp Mounting Hole

b - Purple (or White) Jumper Wire from This Terminal to I (or +)
Terminal on Water Temperature or Oil PressureGauge
c - Black Jumper Wire from This Terminal to Ground
Terminal on Water Temperature or Oil Pressure Gauge
72816
Cruiselog Audio Warning System

a ! WARNING
Buzzer is not external ignition-proof; therefore, DO
NOT mount buzzer in engine or fuel tank compart-
ments.
TO 12 VOLT SOURCE
WATER TEMPERATURE
PURPLE HEAT SWITCH
AUDIO
b WARNING
BUZZER
PURPLE
72815
a - Connect to Ignition Switch Activated 12 Volt RED

TAN/BLUE
Positive (+) Source (Purple Wire)
b - Connect to Negative (–) Ground (Black Wire)
TAN/BLUE
TAN/BLUE
OIL PRESSURE SWITCH

72817
Index
Water Temperature Gauge Clock
Connect to a Terminal
on an Adjacent Gauge
or to Another Suitable
Ground
Connect to Instrument
Harness RED/PURPLE
Lead and Slide a Rubber
Sleeve over Connection
b a
Connect to an “I” Terminal of an Adjacent
Gauge or to Any Switched 12 Volt Terminal
72818
c
72819
BIA Color Code Leads to –
(a) Black (a) Ground

(b) Purple (b) Switched 12 Volt Terminal
(c) Tan (c) Sender Lead
Oil Pressure Gauge
b a
c
72819
BIA Color Code Leads to –
(a) Black (a) Ground

(b) Purple (b) Switched 12 Volt Terminal
(c) Light Blue (c) Sender Lead
Index
FUEL SYSTEM
5
A
50830
FUEL DELIVERY SYSTEMS AND

FUEL PUMPS
Index
5A - FUEL DELIVERY SYSTEMS AND FUEL PUMPS 90-823224 692
Table of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Replacement Parts Warning . . . . . . . . . . . . . . . 5A-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 5A-1
Fuel Supply Connections . . . . . . . . . . . . . . . 5A-1
Tools / Lubricants / Sealants . . . . . . . . . . . . . . . 5A-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
Fuel Delivery System . . . . . . . . . . . . . . . . . . . . . 5A-2
Recommendations . . . . . . . . . . . . . . . . . . . . . 5A-2
Fuel System Components . . . . . . . . . . . . . . . . . 5A-3
Carburetor System . . . . . . . . . . . . . . . . . . . . . 5A-3
Throttle Body Injection With Vapor
Separator Tank . . . . . . . . . . . . . . . . . . . . . . . 5A-4
Throttle Body Injection With Cool
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4
Multi-Port Injection With Vapor
Separator Tank (VST) . . . . . . . . . . . . . . . . . 5A-5
Multi-Port Injection With Cool
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5
Earlier Style Starboard Mounted Fuel
System for 350 Magnum MPI Gen +
Tournament Ski (Black Scorpion) . . . . . . . . 5A-6
Water Separating Fuel Filter . . . . . . . . . . . . . . . 5A-7
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8
Sight Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8
Testing Mechanical Fuel Pump . . . . . . . . . . . . . 5A-9
Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . 5A-9
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-9
NOTICE
Index
5A - FUEL
5A-0 DELIVERY
- FUEL SYSTEMS
DELIVERY AND
SYSTEMS FUEL
AND PUMPS
FUEL PUMPS 90-823225--1 1096
Identification Fuel Supply Connections
! WARNING
fuel leak.
TEFLON TAPE.
OVER-TIGHTEN.
72677
Mechanical Fuel Pump tighten fuel line connectors securely.
Replacement Parts Warning

Tools / Lubricants / Sealants
! WARNING
on your MerCruiser are designed and manufac- Fuel Pressure
91-18078
tured to comply with U.S. Coast Guard Rules and Connector (Carburetor)
Regulations to minimize risks of fire and explo- Quicksilver Perfect Seal 92-34227--1
sion.
#592 Loctite Pipe
Use of replacement electrical, ignition or fuel Sealant with Teflon Obtain Locallyy
system components, which do not comply with Fuel Pressure Gauge
Specifications
Torque Specifications Description Specification
Fastener Location Lb. Ft. N·m Mechanical Fuel
3-8 PSI (21-48 kPa)
Fuel Pump To Seawater Pump Pressure
25 34
Pickup Pump Multi-Port Fuel Injection
43 PSI (206 kPa)
Fuel Lines 18 24 With VST
Throttle Body Fuel
Fuel Fittings See Note 30 PSI (296 kPa)
Injection With VST
NOTE: Refer To “Fuel Supply Connections” Warning Throttle Body and Multi-
following this chart. Port Injection With Cool 30 PSI (296 kPa)
Fuel System
Index
90-823225--1 1096 FUEL DELIVERY SYSTEMS AND FUEL PUMPS - 5A-1
Precautions Fuel Delivery System
! WARNING
Recommendations
BEFORE working on fuel system to prevent fire
or explosion. ! WARNING
Boating industry standards (BIA, ABYC, etc.)
! WARNING federal standards and Coast Guard regulations
MUST BE adhered to when installing fuel deliv-
Be careful when changing fuel system compo- ery system.
nents; gasoline is extremely flammable and
highly explosive under certain conditions. Be When designing and installing fuel delivery system,
sure that ignition key is OFF. DO NOT smoke or the following information MUST BE observed:
allow sources of spark or flame in the area while 1. Fuel tank should be mounted below carburetor
changing fuel filters. Wipe up any spilled fuel im- level, if possible. If tank is mounted above
mediately. carburetor level, gravity feed may cause carbure-
tor fuel inlet needle to unseat, and flooding may
result.
! WARNING
2. Fuel pickup should be at least 1 in. (25 mm) from
Make sure that no fuel leaks exist before closing the bottom of the fuel tank to prevent picking up
engine hatch. water or other impurities.
3. Fuel lines used MUST BE Coast Guard approved
! CAUTION (USCG type A) and MUST NOT BE SMALLER
DO NOT operate engine without cooling water THAN 3/8 in. (9.5 mm) I.D. On installations where
being supplied to seawater pickup pump, or long lines or numerous fittings are required, larg-
pump impeller will be damaged and subsequent er size lines should be used.
overheating damage may result. 4. Fuel line should be installed free of stress and
firmly secured to prevent vibration and/or chaf-
ing.
5. Sharp bends in fuel line should be avoided.
6. A flexible fuel line must be used to connect fuel
line to engine to absorb deflection when engine
is running.
Index
5A-2 - FUEL DELIVERY SYSTEMS AND FUEL PUMPS 90-823225--1 1096
Fuel System Components
Carburetor System
f g
b a
c
1
h
d
e
50830
a - Fuel Tank
b - Anti-Siphon Valve
c - Water Separating Fuel Filter
d - Fuel Pump
e - Carburetor
f - Fuel Filter
g - Vent Hose
h - Fuel Line
i - Sight Tube
1 - Boat Fuel System
Index
Throttle Body Injection With Vapor Throttle Body Injection With Cool
Separator Tank Fuel System
a
h
b
c
a i
b
c
d
g
e f
73895 74871
a - Vacuum Line To Flame Arrestor

b - Fuel Pressure Regulator
a - Throttle Body Unit
c - Fuel Cooler
b - Fuel Line To Throttle Body
d - Electric Fuel Pump
c - Return Line From Throttle Body
e - Water Separating Fuel Filter
d - Vapor Separator Tank (VST)
f - Fuel From Tank
e - Inlet Line From VST
g - Direction Of Water Flow
f - Water Separating Fuel Filter
h - Throttle Body Unit
g - Fuel From Tank
i - Fuel Line To Throttle Body
j - Excess Fuel Return To Water Separating Fuel Filter
Index
Multi-Port Injection With Vapor Multi-Port Injection With Cool Fuel
Separator Tank (VST) System
a
k
b l
c
i
d a
b
c
g
e
f e
g
74871
h a - Vacuum Line To Intake Manifold

c - Fuel Cooler
73895 d - Electric Fuel Pump
a - Fuel Injector (8) f - Fuel From Tank
b - Fuel Rail g - Direction Of Water Flow
c - Outlet Fuel Line h - Throttle Body Unit
d - Return Fuel Line i - Fuel Line To Throttle Body
e - Vapor Separator Tank (VST) j - Excess Fuel Return To Water Separating Fuel Filter
f - Fuel Line From Water Separating Fuel Filter k - Fuel Injectors (8)
g - Water Separating Fuel Filter l - Fuel Rail
h - Fuel Line From Tank
Index
Earlier Style Starboard Mounted Fuel System for 350 Magnum MPI Gen +
Tournament Ski (Black Scorpion)
f g
74868
a - Fuel Pressure Regulator

b - Fuel Cooler
c - Electric Fuel Pump
d - In-Line Fuel Filter
f - Starboard Fuel Rail
g - Port Fuel Rail
h - From Fuel Tank
Index
Water Separating Fuel Filter
NOTICE
a
Refer to “Precautions,” in this section,
BEFORE proceeding.
The water separating fuel filter is standard on all en- c

gines. b
The fuel filter consists of the fuel filter base and fil- d
ter element. g
e f
a h
i
J
72678
l
Carburetor and VST Equipped Engines
a - Fuel Filter Mounting Bracket
b - Filter Element
c - Sealing Ring
Cool Fuel System Water Separating Fuel Filter

a - Top Cover
b - Insulator Plate
c - Fuel Outlet To Throttle Body Or Fuel Rail
d - Brass Fitting
e - Fuel Return
f - Brass Fitting
g - Fuel Filter Mounting Bracket
h - Nut
i - Inlet Fuel Fitting
j - Plug
k - Water Separating Fuel Filter
l - Bottom Cover
Index
Replacement
NOTICE a
BEFORE proceeding.

2. Remove fuel filter from base. A filter wrench may
be needed to loosen element.
3. Lubricate sealing ring(s) of new filter with SAE
engine oil.
4. Install new filter, tightening securely by hand.
5. Reconnect battery cables, make sure water is
supplied to cooling system, start engine, and
check for fuel leaks.
b
Sight Tube 74109
Vapor Separator Tank (VST)
Inspection
a - Sight Tube
Fuel pump is equipped with sight tube. Evidence of b - Vapor Separator Tank (VST)
fuel in the sight tube indicates a ruptured diaphragm
and fuel pump must be replaced immediately.
b a
70346
Seawater / Mechanical Fuel Pump
a - Sight Tube
b - Fuel Pump
Index
Testing Mechanical Fuel 1. Disconnect battery cables from battery.
Pump ! CAUTION
NOTICE Plug fuel supply hose after removal to prevent
Refer to “Precautions,” in this section, fuel from leaking into boat.
BEFORE proceeding.
2. Use a wrench to stabilize brass coupling at fuel
filter inlet fitting, loosen fuel line fitting, disconnect
and suitably plug fuel line to prevent fuel in tank
1. Disconnect battery cables from battery. from leaking into bilge.
2. Remove fuel line from carburetor or outlet side of 3. Remove fuel filter.
fuel pump.
4. Using wrench to stabilize brass couplings on fuel
3. Install Fuel Pressure Connector (91-18078) to pump, loosen fuel line fittings and disconnect
carburetor and reinstall fuel line. Tighten connec- from fuel pump.
tor and fuel line securely.
5. Clean gasket from seawater pump.
4. Connect fuel pressure test gauge to connector.
6. Apply Quicksilver Perfect Seal to both sides of
5. Reconnect battery cables, start engine, and run fuel pump gasket and install on fuel pump.
at 1800 RPM.
7. Install fuel pump. Torque bolts to 25 lb. ft.
6. Fuel pressure should be within specifications. If (34 N·m).
not, replace fuel pump.
8. Install fuel inlet and outlet fittings to fuel pump
as outlined next:
Mechanical Fuel Pump ! WARNING

NOTICE Avoid gasoline fire or explosion. Improper instal-
Refer to “Precautions,” in this section, lation of brass fittings or plugs into fuel pump or
BEFORE proceeding. fuel filter base can crack casting and/or cause a
fuel leak.
Replacement TEFLON TAPE.
IMPORTANT: The fuel pump cannot be repaired. • Thread brass fitting or plug into fuel pump or
If pump fails, it must be replaced. fuel filter base until finger tight.
OVER-TIGHTEN.
9. Install sight tube.
10. Install fuel line and fuel filter.
11. Reconnect battery cables.
12. Make sure water is supplied to cooling system
72677
and start engine. Check for fuel leaks.
Index
FUEL SYSTEM
5
B
72681
MERCARB 2 BARREL CARBURETOR
Index
Table of Contents
Page
MerCarb 2 BBL Carburetor . . . . . . . . . . . . . . . . 5B-1
Torque Specifications . . . . . . . . . . . . . . . . . . 5B-1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4
Important Service Information . . . . . . . . . . . . . . 5B-4
Flooding at Idle RPM . . . . . . . . . . . . . . . . . . . 5B-4
Needle/Seat Change . . . . . . . . . . . . . . . . . . . 5B-4
Adjustable Accelerator Pump Lever . . . . . . 5B-5
High Altitude Re-Jetting . . . . . . . . . . . . . . . . 5B-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6
Flame Arrestor with Carburetor Cover . . . . 5B-6
Fuel Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . 5B-7
Choke Inspection . . . . . . . . . . . . . . . . . . . . . . 5B-8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8
Pump Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8
Choke Setting . . . . . . . . . . . . . . . . . . . . . . . . . 5B-9
Choke Unloader . . . . . . . . . . . . . . . . . . . . . . . 5B-9
Preliminary Idle Speed and Mixture . . . . . . 5B-9
Final Idle Speed and Mixture . . . . . . . . . . . 5B-10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12
Cleaning and Inspection . . . . . . . . . . . . . . . 5B-17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5B-18
Index
5B-0 - MERCARB 2 BARREL CARBURETOR 90-823225--1 1096
MerCarb 2 BBL Carburetor
Units of Measurements
In. (mm)
00000
DESCRIPTION LB. FT. N·m
Carburetor To Manifold 20 27
Fuel Line to Carburetor 18 24
Fuel Inlet Filter Nut 18 24
Tools
Universal Carburetor Gauge 91-36392
Boroughs Special Tool and Equipment Inc.
2429 N. Burdick Street
Kalamazoo, MI 49007
(616) 345-5163
Float Gram Scale BT 8128 B
Specifications
In. (mm)
ENGINE
5.0L 5.7L
MODEL
Carburetor
MerCarb 35mm MerCarb 43mm
Type
Carburetor Number 1389-9670 3310-806082 3310-807312
Float Level 9/16 (14) Note 1
Float Drop 1-3/32 (27) Note1
Pump Rod (Location) Middle Hole Of Pump Arm
2 Marks Right
Choke Setting Of Index Mark
(Lean)
Choke Unloader 5/64 [.080] (2)
Idle Mixture Screw 1-1/4 Turns Out
9 Grams
Float Weight
Maximum
Main Jet Size 1.65 mm
Power Valve Size 0.74 mm 0.90 mm
Venturi Cluster
407 463 468
I.D. Number
Accelerator Pump
0.035 (0.889) 0.039 (0.99) 0.039 (0.99)
Discharge Hole Size
Note 1: Measurement taken from gasket
Index
90-823225--1 1096 MERCARB 2 BARREL CARBURETOR - 5B-1
Exploded View
12
11
10
9 44
8
7 45
6
5 46
4 47
3
2 48
1 49
50
51
52
53
54
55
13 56
14 57
15 58
16 59
17 60
18 61
62
19
20
21
22
23
24
25
26
27
28
43
29 42
41
30 40
31 39
38
32 37
33 36
35
34 72686
Index
1 - Rod - Accelerator Pump 32- Washer-Locking
2 - Accelerator Pump Shaft and Lever Assembly 33- Nut
3 - Washer (Outer) 34- Throttle
4 - Washer (Inner) 35- Spring
5 - Screw 36- Screw - Idle Speed Adjustment
6 - Washer 37- Throttle Body
7 - Screw 38- Screw
8 - Spring 39- Washer
9 - Filter 40- Gasket
10- Gasket 41- Check Ball
11- Gasket 42- Spring
12- Nut-Fuel Inlet 43- Retainer
13- Choke Rod 44- Screw
14- Gasket 45- :ever Assembly
15- Clip - Retainer 46- Screw
16- Washer 47- Choke/Housing
17- Pump Shaft and Lever Assembly 48- Gasket
18- Accelerator Pump Assembly 49- Air Horn
19- Screw 50- Inlet Needle and Seal
20- Screw 51- Pin
21- Inlet Needle and Seat (Spring Loaded - Optional) 52- Screw
22- Baffle Plate 53- Gasket
23- Float 54- Screw
24- Float Bowl 55- Screw
25- Cam-Idle 56- Flat Washer
26- Screw 57- Lock Washer
27- Idle Mixture Adjusting Needle 58- Gasket
28- Spring 59- Venturi Cluster
29- Washer 60- Power Valve Assembly
30- Nut 61- Gasket
31- Clip-Pump Rod 62- Gasket
Index
Identification ! WARNING
sion.

33049565 these rules and regulations, could result in a fire
2301 or explosion hazard and should be avoided.
a
b Important Service
Information
72680
Flooding at Idle RPM
Carburetor Part Number Location
a - Part Number
If your engine floods at idle RPM, check the following:
b - Date Code 1. Problem in ignition system causing engine to run
Data Code Explanation: Example 2301 rough.
First Figure is Year: 2. Idle mixture screw adjusted incorrectly.

2 = 1992, 3 = 1993, etc. 3. Bad needle and seat.
Second Figure is Month:
4. Incorrect float level drop.
2 = February, 3 = March, etc.
X = October, Y = November, Z = December
Third and Fourth Figures are Day of Month:
01 = First day, 02 = Second day, etc. Needle/Seat Change
If the preceding steps failed to correct the problem,
change the needle/seat to the other type. MerCarbs
are equipped with either the solid or the spring loaded
needle.
a
b 72290
72779 Needle and Seat Assemblies

a - Spring Loaded Type Needle (Kit - 3302-9029)
b - Solid Type Needle (3302-9407)
Venturi Cluster Identification
a - Identification Number (See Specifications)
Index
Adjustable Accelerator Pump Lever High Altitude Re-Jetting
This new lever with will allow you to change the Engine flooding problems, at idle RPM, are generally
amount of fuel delivered to the engine by the acceler- related to the altitude (above sea level) at which they
ator pump. The hole closest to the lever’s shaft will are operated.
give the same amount of fuel as the single hole lever
If engine is running too rich at higher elevation, order
did. The center hole gives approximately 0.5 cc less
a smaller jet from the chart. A jet stamped “165” is a
fuel and the hole farthest away will give about 1.0 cc
1.65 mm jet.
less fuel.
Jet Size (mm) Quicksilver Part Number
1.30 3302-811849
1.35 3302-811850
a
1.40 3302-811851
b 1.45 3302-9050
c 1.50 3302-811852
1.55 3302-811853
1.60 3302-810923
1.65 3302-9058
1.70 3302-9055
1.75 3302-811854
1.80 3302-811855
1.85 3302-811856
1.90 3302-811857
73131
a - Full Accelerator Pump Stroke

b - 0.5 cc Less Fuel Per Stroke
c - 1.0 cc Less Fuel Per Stroke Description
This MerCarb carburetor is a two bore carburetor and
The technician should be able to correct most “bog- has a separate fuel feed for each venturi. This model
ging” problems with this 3-hole lever, providing the also is equipped with an electric choke. A removable
“bogging” is caused by the carburetor. When install- venturi cluster (secured to float bowl assembly) has
ing the 3-hole lever, remove any metal ball that some- the calibrated main well tubes and pump jets built into
one may have put in the accelerator pump well to limit it. The venturi cluster is serviced as a unit. The ser-
pump travel. Also, make sure that the duration spring viceable main metering jets are bleeds to properly
on the accelerator pump is stock and hasn’t had sev- meter the correct fuel/air mixture to the engine.
eral coils cut off. Make sure the venturi cluster is the
correct one as outlined previously under “Specifica-
tions”.
Index
Precautions Maintenance
Flame Arrestor with Carburetor
! WARNING
Cover
BEFORE working on fuel system to prevent fire NOTICE
or explosion. Refer to “Precautions,” in this section, BEFORE
proceeding.
! WARNING 1. Remove in the following order:

Be careful when cleaning flame arrestor and a. Nut.
crankcase ventilation hose; gasoline is extreme- b. Sealing washer.
ly flammable and highly explosive under certain
conditions. Be sure that ignition key is OFF. DO c. Carburetor cover.
NOT smoke or allow sources of spark or open d. Crankcase ventilation hoses from flame ar-
flame in area when cleaning flame arrestor and restor and rocker arm covers.
crankcase ventilation hose.
e. Flame arrestor.
2. Clean and inspect:
! WARNING a. Clean flame arrestor in solvent and blow dry
Be careful when changing fuel system compo-
nents; gasoline is extremely flammable and b. Clean crankcase ventilation hoses.
highly explosive under certain conditions. Be c. Inspect crankcase ventilation hoses for
sure that ignition key is OFF. DO NOT smoke or cracks or deterioration, and replace if neces-
allow sources of spark or flame in the area while sary.
changing fuel filter. Wipe up any spilled fuel im-
mediately.
! WARNING
Make sure no fuel leaks exist, before closing en-
gine hatch.
! CAUTION
being supplied to water pickup holes in gear
housing, or water pump impeller will be damaged
and subsequent overheating damage to engine
may result.
Index
3. Install in the following order: Fuel Inlet Filter
a. Flame arrestor.
NOTICE
b. Crankcase ventilation hoses to flame arres- Refer to “Precautions,” in this section, BEFORE
tor and rocker arm covers. proceeding.
c. Carburetor cover.
d. Sealing washer. 1. Remove in the following order:
e. Nut (tighten securely). a. Fuel line from fuel inlet filter nut.
c a b. Fuel inlet filter nut and small gasket.

c. Large gasket.
b
d. Filter.
e e. Spring.
f
f. Small gasket - from inside filter nut.
b c d e
e
d
f
d
72086
a - Nut
b - Sealing Washer
c - Carburetor
d - Cable Tie
e - Crankcase Ventilation Hose
f - Flame Arrestor a
72406
a - Fuel Line
b - Fuel Inlet Filter Nut
c - Gasket (Larger)
d - Gasket (Small)
e - FIlter
f - Spring
2. Clean filter nut and spring in solvent and dry with

compressed air.
3. Install in the following order:
a. Spring - place in carburetor body.
b. Filter - open end to inlet filter nut.
c. Small gasket - place inside filter nut.
d. Large gasket - place over filter nut threads.
e. Fuel inlet filter nut - torque nut to 18 lb. ft.
(24 N·m).
f. Fuel line - torque to 18 lb. ft. (24 N·m).
Index
Choke Inspection 2. With throttle valves completely closed, measure
from flame arrestor mounting surface to top of
The choke does not require any periodic mainte- pump rod.
nance; however, if a choke malfunction is suspected,
the following should be done:
1. With engine turned OFF, remove flame arrestor.
2. Open and close choke several times, and check
for binding, loose or disconnected linkages, or
other signs of damage.
3. If choke or linkage binds, sticks, or works slug-
gishly, clean with carburetor choke cleaner. Fol- a
low directions on can.
IMPORTANT: Choke valve and shaft and lever as-
sembly is not serviceable. If valve and/or shaft
and lever assembly is worn or damaged, air horn
assembly must be replaced.
72682
Adjustments a - See Specifications
NOTICE
3. Carefully bend pump rod (where shown) to obtain
Refer to “Precautions,” in this section, specified dimension.
BEFORE proceeding.
Pump Rod
1. Back out idle speed screw until it no longer con-
tacts idle cam.
72683
a - Pump Rod
a b - Bend Here
72284
a - Idle Speed Screw

b - Idle Cam
Index
Choke Setting 4. Bend tang on throttle lever, if necessary, to obtain
specified dimension.
Normal choke setting is such that scribed mark on
cover is in line with long case mark on choke hous-
ing.
a
c b
b
a
72685
a - Tang
72403
b - Throttle Lever
a - Scribed Mark Preliminary Idle Speed and Mixture

b - More Choke
c - Less Choke
If choke adjustment is necessary: IMPORTANT: The following adjustments will pro-
vide a sufficient idle speed and mixture for start-
1. Loosen three choke cover retaining screws and ing engine. Final adjustments must be made with
adjust as shown. engine running.
2. Tighten three choke cover retaining screws se- 1. Back out idle speed screw until it no longer con-
curely. tacts idle cam. Turn idle speed screw in until it just
contacts idle cam, then turn screw in an addition-
Choke Unloader al two turns.
1. Hold throttle valves completely open.
2. Gently press down on choke plate.
3. Using an .080 in. [5/64 in.] (0.2 mm) drill rod, or
appropriate gauge, slide rod between upper
edge of choke plate and air horn assembly. Rod b
should just slide through.
a
b
c a
72284

b - Idle Cam
IMPORTANT: DO NOT turn idle mixture needle

tightly against seat (in the following step), as
damage to seat and/or needle may result.
72684
a - .080 In. (0.2mm) Drill Rod

b - Choke Plate
c - Air Horn
Index
2. Turn idle mixture needle in until lightly seated, 2. If new or rebuilt carburetor has been installed,
then back needle out 1-1/4 turns. turn idle mixture needle in (clockwise) until it
lightly contacts seat, then back out needle 1-1/4
turns. This will provide a sufficient setting to allow
starting engine.
3. Start engine and run at 1500 RPM until engine
reaches normal operating temperature.
! WARNING
DO NOT leave the helm unattended while per-
forming idle speed and mixture adjustments, fol-
lowing. BE CAREFUL NOT TO ACCIDENTALLY
a ACCELERATE ENGINE WHILE PERFORMING
72281 ADJUSTMENTS.
a - Idle Mixture Needle
4. With boat in open water, place remote control in
Final Idle Speed and Mixture forward gear, idle position.
5. Disconnect throttle cable barrel from anchor
IMPORTANT: Boat must be in the water and en-
stud. Be sure not to lose spacer on anchor stud.
gine at normal operating temperature to accu-
rately check and adjust idle speed and mixture. 6. Adjust idle speed adjustment screw to obtain
550-600 RPM, in neutral gear.
Carburetor should be set so that engine idles
smoothly within range given under “Specifications,” 7. With engine running at specified RPM, adjust idle
with boat in the water, engine at normal operating mixture needle as follows:
temperature and drive unit in forward gear. To adjust a. Turn idle mixture needle in (clockwise) until
idle speed and mixture, proceed as follows: the engine speed begins to drop due to lean
IMPORTANT: DO NOT attempt to compensate for mixture.
other engine problems (incorrect ignition timing, b. Turn idle mixture screw out (counterclock-
faulty ignition components, low compression, wise) until the speed begins to drop due to
vacuum leaks, etc.) with carburetor adjustments. rich mixture.
This will only cover the problem, which must be
corrected if engine is to achieve maximum fuel c. Turn screw in to a point between these two
economy and performance. extremes to obtain maximum engine smooth-
ness and RPM.
1. Connect an accurate shop tachometer to engine.
d. Readjust idle speed adjustment screw until
IMPORTANT: DO NOT turn idle mixture needle engine idles at 650-700 RPM in forward gear.
tightly into seat, as damage to needle and/or seat
may result. IMPORTANT: Refer to Section 2 - “Removal and
Installation” for throttle cable installation and ad-
justment.
72281
a
a - Idle Mixture Needle
Index
Repair Installation
1. Thoroughly clean gasket surfaces.
NOTICE
Refer to “Precautions,” in this section, 2. Place new carburetor base gasket on intake
BEFORE proceeding. manifold. Install carburetor and secure with nuts
and washers. Torque to 132 lb. in. (15 N·m).
3. If fuel inlet filter nut was disturbed, remove; clean
all threads with brush and carburetor cleaner or
Removal Quicksilver Leveler.
IMPORTANT: Carburetor malfunctions are, in 4. Connect fuel line to fuel inlet filter nut, and while
many cases, caused by the presence of dirt, wa- stabilizing filter nut with wrench, tighten fuel line
ter or other foreign matter in carburetor. To aid in fitting securely.
diagnosis, carefully remove carburetor from en-
gine without draining fuel from bowl. Contents of 5. Connect fuel pump sight tube to fitting on carbu-
fuel bowl may then be inspected for contamina- retor.
tion as carburetor is disassembled. 6. Connect electric choke wires to choke cover.
1. Remove ventilation hose from flame arrestor, 7. Install throttle cable as explained in Section 2.
then remove flame arrestor.
8. Install flame arrestor and crankcase ventilation
IMPORTANT: Place a clean cloth in bores of car- hose.
buretor to prevent dirt and foreign material from
falling into bores. 9. Reconnect battery cables to battery.
2. Turn fuel supply off at fuel tank. 10. Ensure that water is supplied to cooling system.
Start engine and check for gasoline leaks. If leaks
3. Disconnect throttle cable from carburetor. exist, STOP ENGINE IMMEDIATELY and re-
4. Remove fuel line from fuel inlet nut, using wrench check connections.
to stabilize fuel inlet nut. 11. Adjust idle speed and idle mixture, as outlined
5. Remove fuel pump sight tube from carburetor. under “Adjustments” as previously outlined.
6. Disconnect electric choke.

7. Remove carburetor attaching nuts and washers
and remove carburetor.
IMPORTANT: Place a clean cloth over intake man-
ifold opening to prevent dirt or foreign material
from entering manifold.
8. Remove and discard gaskets.
Index
Disassembly AIR HORN ASSEMBLY
IMPORTANT: Before performing any service on 1. Remove fuel inlet filter nut, washers, spring, and
carburetor, it is essential that carburetor be filter, as outlined previously.
placed in a holding fixture to prevent possible
damage to throttle valves. 2. Remove accelerator pump rod retaining clip.
Pivot rod (as required) until retaining ear on rod
The following is a step-by-step procedure for com- and slot in pump shaft and lever assembly align,
pletely overhauling carburetor removed from engine. allowing rod to be pulled out.
In many cases, however, complete overhaul is not
necessary and, in these cases, only the steps re-
quired to repair the carburetor malfunction should be
performed. Read the instructions carefully to prevent
doing any unnecessary steps.
CHOKE HOUSING ASSEMBLY
1. Remove choke cover. c
b 72283
a - Accelerator Pump Rod

b - Retainer Clip
c - Pump Shaft and Lever Assembly
3. Remove idle cam screw. Also, remove choke rod

a
by pivoting rod (as required) until retaining ear on
rod and slot in choke lever align, allowing rod to
72403 be pulled out.
a - Choke Cover
2. Remove choke lever. Remove choke housing.
a
72401 b
a - Choke Lever 72282
b - Choke Housing
a - Idle Cam Screw
b - Idle Cam
c - Choke Rod
Index
a
c
b 72400
a - Air Horn Assembly
72286 b - Float Bowl Assembly
a - Choke Rod
b - Choke Lever
5. Invert air horn and carefully lay on bench.
c - Slot 6. Remove float hinge pin and lift float assembly
from air horn.
4. Remove air horn attaching screws as shown.
Carefully lift air horn from float bowl assembly.
a
a a
72288
a - Float Hinge Pin

b - Float Assembly
a 72280
a - Air Horn Attaching Screws
Index
7. Check float weight as shown. 9. Remove needle assembly.
a
a
b b
72122
72287
a - Grams Scale
b - Float a - Needle Assembly
b - Needle Seat
8. Remove air horn gasket and baffle.
10. Remove needle seat.
b a 72399 a
a - Baffle b
b - Air Horn Gasket
72289
a - Needle Seat
b - Gasket
c - Screwdriver
Index
FLOAT BOWL ASSEMBLY
1. Remove accelerator pump return spring from

pump well.
a
b 72290
Needle and Seat Assemblies

a
a - Spring Loaded Type Needle (Kit 3302-9029)
b - Solid Type Needle (Kit 3302-9407)
11. Loosen accelerator pump screw. Slide pump

shaft and lever assembly (and washer) out of air
horn, then remove accelerator pump assembly.
a
72402
b
a - Accelerator Pump Spring
2. Remove power valve assembly and gasket.
c
72398
a - Set Screw
b - Lever Assembly
c - Pump Assembly
12. Remove retainer clip and washer from pump

shaft and lever assembly, then remove accelera- b
a
tor pump assembly.
b
72404
c a - Power Valve Assembly

a b - Gasket (Not Shown)
72409
a - Pump Assembly
b - Retainer Clip
c - Lever Assembly
Index
3. Remove main metering jets. 5. Using a needle-nose pliers, remove accelerator
pump check ball spring retainer. Turn float bowl
over to remove spring and check ball.
b b b
72407
72291
a - Spring Retainer
b - Spring and Check Ball (Not Shown)
a - Main Metering Jets

THROTTLE BODY ASSEMBLY
b - Gaskets (Not Shown)
IMPORTANT: Use extreme care when handling

IMPORTANT: Use care when removing venturi
throttle body, so as not to damage throttle valves.
cluster to prevent damaging brass tubes which
protrude from bottom of cluster. DO NOT RE- 1. Place float bowl assembly upside down. Remove
MOVE TUBES. These tubes are permanently three throttle body assembly attaching screws
pressed into the venturi cluster and are not re- and lockwashers, and remove throttle body and
placeable. gasket from float bowl.
4. Remove three venturi cluster screws, and care-

c b
fully lift cluster and venturi gasket straight up.
b
b
72294
a - Screws
b - Lockwashers (Not Shown)
72292
c - Throttle Body
a - Venturi Cluster Brass Tubes d - Gasket (Not Shown)
b - Gasket
Index
2. Remove idle mixture adjusting needle and Cleaning and Inspection
spring.
IMPORTANT: DO NOT use a wire or drill to clean
a jet passages or tubes in carburetor, as this may
enlarge orifices and seriously affect carburetor
b calibration.
! CAUTION
To avoid damage to carburetor DO NOT leave car-
buretor in immersion type carburetor cleaner for
more than two hours.
IMPORTANT: DO NOT clean float bowl gasket

surfaces with a gasket scraper or knife, as seal-
ing bead will be damaged and float bowl replace-
72293 ment will be necessary.
a - Idle Mixture Adjusting Needle
b - Spring
! CAUTION
3. Remove idle speed adjustment screw and The float assembly, float needle, accelerator
spring, if replacement is necessary. pump plunger, and fuel filter MUST NOT BE im-
mersed in carburetor cleaner, as they will swell,
harden, and/or distort.
c
a
b d
72410
a
72395
a - Accelerator Pump Plunger
b - Float Needle
c - Fuel Filter
b - Spring
d - Float Assembly
IMPORTANT: DO NOT remove throttle valves. If

any of the throttle body parts are found to be ! WARNING
worn or damaged, complete throttle body assem- Avoid personal injury by always wearing safety
bly MUST BE replaced. Throttle body assembly goggles when using compressed air.
can be cleaned in carburetor cleaner.
Index
1. Thoroughly clean all metal parts in a commercial placed if choke valve and shaft and lever as-
carburetor cleaner, until all deposits have been sembly are worn or damaged.
removed. Follow cleaner manufacturer’s instruc-
j. Inspect Casting for visible damage. Inspect
tions for proper cleaning and rinsing procedure.
gasket surfaces. Inspect accelerator pump
Dry parts with compressed air.
plunger well for scoring or deposits.
2. Using compressed air, blow out all passages in
carburetor to remove any foreign material.
3. Wipe off all parts that cannot be cleaned in carbu- Reassembly
retor cleaner with a clean, dry cloth.
THROTTLE BODY ASSEMBLY
4. Carefully inspect all carburetor parts for wear and
damage; pay particular attention to the following:
IMPORTANT: DO NOT force idle mixture needle
a. Float Needle and Seat: If float needle or seat against seat as damage to needle and/or seat will
is worn or damaged, replace with new needle result.
and seat assembly.
1. Screw idle mixture needle (and spring) into
IMPORTANT: Float needle and seat are factory throttle body until they lightly seat, then back out
matched and tested and should be replaced as a needle 1-1/4 turns as a preliminary idle mixture
set only. setting. Final adjustment will be made with en-
b. Float Assembly and Hinge Pin: Check float gine running. Refer to “Adjustments.”
density (to see if it is saturated with fuel) by a
comparing weight of float with specifications. b
If weight is high, float assembly must be re-
placed. Check hinge pin and holes for wear.
c. Fuel and Air Passages: Passages must be
perfectly clean for proper carburetor opera-
tion.
d. Accelerator Pump Plunger and Return
Spring: Inspect pump plunger cup, pump
plunger spring (on pump assembly) and re-
turn spring. 72293
e. Power Piston Spring: Check power piston a - Idle Mixing Adjusting Needle
spring for weakness or distortion. b - Spring
f. Idle Mixture Needle: Inspect idle mixture 2. Thread idle speed adjustment screw and spring
needle. If damaged, needle must be re- into throttle lever.
placed.
g. Levers and Linkages: Check levers, links
and rods for wear.
h. Throttle Valve and Shaft: Check throttle
shaft for excessive looseness in throttle body.
Check throttle valve and shaft for binding
through entire operating range, making sure
valve opens and closes completely. Throttle
body assembly must be replaced if throttle
valve and shaft are worn or damaged.
i. Choke Valve and Shaft and Lever Assem-
bly: Check shaft and lever assembly for ex- b
cessive looseness in air horn assembly. a
Check choke valve and shaft and lever as-
sembly for binding through entire operating 72395
range, making sure valve opens and closes a - Idle Speed Screw
completely. Air horn assembly must be re- b - Spring
Index
3. Turn float bowl assembly upside down and place FLOAT BOWL ASSEMBLY
new throttle body gasket on bowl, making sure
gasket is properly positioned on location dowels. IMPORTANT: Place float bowl and throttle assem-
b blies in holding fixture to prevent throttle valves
a from being damaged.
1. Install check ball, spring, and retainer in passage
as shown. Push retainer firmly into slots.
b b
72295
a - Throttle Body Gasket

b - Locating Dowels
4. Install throttle body assembly on float bowl as-

sembly, making sure that screw holes in gasket
72408
line up with screw holes in throttle body. Tighten
screws evenly and securely. a - Check Ball
b - Spring
c b c - Retainer
2. Install new gasket on venturi cluster as shown.

a
b
d
72294
a - Screws
b - Lockwashers (Not Shown) a
c - Throttle Body Assembly
d - Gasket
72296
a - Venturi Cluster (I.D. No. 421)

b - Gasket
Index
3. Install venturi cluster in carburetor as shown. 5. Install main metering jets with gaskets as shown.
Tighten securely.
a
b b
72397
72291
a - Venturi Cluster
a - Main Metering Jets
b - Gasket
b - Gaskets (Not Shown)
4. Install flat washer and new fiber washer on center 6. Install power valve with new gasket. Tighten se-
screw. Lockwashers and flat washers are used curely.
on outer screws. Tighten screws evenly and se-
curely.
a
b b
a
b
72404
72405
a - Center Screw a - Power Valve

b - Outside Screws b - Gasket (Not Shown)
c - Fiber Washer
Index
7. Place accelerator pump spring in pump well. 2. Insert pump shaft and lever assembly (and wash-
er) into air horn; then, align indexed hole in pump
lever with shaft and lever assembly and slide
shaft all the way into lever so that shoulder on
shaft is hitting lever. Tighten setscrew securely.
a
a
72402

c
72398
AIR HORN ASSEMBLY a - Set Screw

b - Lever Assembly
IMPORTANT: Accelerator pump assembly MUST c - Pump Assembly
BE installed correctly. If pump assembly is in-
stalled incorrectly, top of pump assembly will 3. Install needle seat and gasket. Tighten securely.
contact air horn casting.
1. If accelerator pump assembly was removed from
pump lever, secure pump assembly to pump le-
ver with washer and retainer clip, as shown. c
c a
a
b
72289
a - Needle Seat
b - Gasket
72409 c - Screwdriver
IMPORTANT: Float needle and needle seat are

a - Pump Assembly factory matched and tested and should be re-
b - Retainer Clip placed as a set only.
c - Pump Lever
Index
4. Place needle assembly in needle seat. 6. Install float assembly and hinge pin. Pivot float
assembly up and down on hinge pin to ensure it
moves freely.
b
a
72287
a - Needle Assembly a 72297

b - Needle Seat
a - Float Assembly
5. Install baffle and gasket.
b - Float Hinge Pin
FLOAT LEVEL
1. Turn air horn upside down. Pivot float assembly

up and down on hinge pin to ensure it moves
freely.
IMPORTANT: Before checking float level, raise

float and allow it to fall; however, DO NOT force
downward by hand.
2. Measure float level using Universal Carburetor

Gauge (91-36392). Measure from gasket to toe
of float.
b a
72399
a - Baffle
b - Gasket
a
72298
a - Measure From This Point to Gasket
Index
FLOAT DROP
1. Hold air horn right side up to allow float to hang

free.
2. Measure float drop using Universal Carburetor
Gauge (91-36392). Measure from gasket to toe
a
of float.
72687 a
a - Measurement with 2 Piece Solid Inlet Needle - 3/8 in.
(10mm)
Measurement with Spring Loaded Inlet Needle - 9/16 in
(14mm)
3. Bend float arm up or down at point shown to ob-

tain specified dimension.
72689
a - Measurement - 1-3/32 in. (27mm)
3. Bend float assembly tang, as shown, to obtain

specified dimension.
72688 a
a - Bend Float Arm at This Point
4. Visually check float alignment after adjustment.
72690
a - Float Assembly Tang
Index
4. Recheck BOTH float level and float drop. 7. Place end of choke rod in choke lever and collar
assembly.
5. Carefully place air horn on float bowl, making
sure accelerator pump is correctly positioned in
fuel well. Lower air horn straight down to install.
a a
b 72299
72400
a - Air Horn Assembly a - Choke Rod

b - Float Bowl Assembly b - Choke Lever and Collar Assembly
6. Install seven short and one long air horn attach- 8. Place idle cam on choke rod.
ing screws. Tighten screws evenly and securely.
a a
72392
a 72280
a - Idle Cam
a - Air Horn Attaching Screws b - Choke Rod
Index
9. Secure idle cam (with choke rod installed on 11. Insert remaining end of accelerator pump rod into
cam) on float bowl assembly, using screw. Check hole in throttle lever and secure with retainer clip.
that cam is free to move without binding.
b
a
b
a c
72282 72283
a - Screw a - Accelerator Pump Rod

b - Idle Cam b - Throttle Lever
c - Choke Rod c - Retainer Clip
10. Place accelerator pump rod (end with ear) in hole CHOKE HOUSING ASSEMBLY
in pump shaft and lever assembly.
1. Install choke housing on air horn; tighten screws
securely. Install choke lever; tighten screw se-
curely.
a
c
b b
72401
72393
a - Choke Housing
a - Accelerator Pump Rod b - Choke Housing Attaching Screws
b - Pump Shaft and Lever Assembly c - Choke Lever
Index
2. Install choke cover. Make sure hook on end of
choke coil engages with choke lever. Rotate
choke cover until index marks align as shown.
Tighten screws securely.
a
c b
72403
a - Scribed Mark
b - More Choke
c - Less Choke
Index
AT A LATER DATE
Index
FUEL SYSTEMS
5
C
72085
ROCHESTER 4 BARREL CARBURETOR
Index
Table of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
Replacement Parts Warning . . . . . . . . . . . . . . . 5C-1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
Carburetor Specifications . . . . . . . . . . . . . . . . . . 5C-2
Carburetor Adjustment Specifications . . . . . . . 5C-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-3
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-3
Flame Arrestor . . . . . . . . . . . . . . . . . . . . . . . . 5C-3
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Accelerator Pump . . . . . . . . . . . . . . . . . . . . . 5C-5
Air Valve Dashpot . . . . . . . . . . . . . . . . . . . . . . 5C-6
Air Valve Spring Windup . . . . . . . . . . . . . . . . 5C-6
Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Choke Coil Rod . . . . . . . . . . . . . . . . . . . . . . . 5C-7
Vacuum Break . . . . . . . . . . . . . . . . . . . . . . . . 5C-8
Preliminary Idle Speed and Mixture . . . . . . 5C-9
Final Idle Speed and Mixture . . . . . . . . . . . . 5C-9
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Cleaning and Inspection . . . . . . . . . . . . . . . 5C-19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5C-21
Index
5C-0 - ROCHESTER 4 BARREL CARBURETOR 90-823225--1 1096
Identification Tools
91-36392 Universal Carburetor Gauge
91-59339 Tachometer
Kent-Moore Special Tools

Can be ordered from: Kent-Moore Tools, Inc.
29784 Little Mack
Roseville, MI 48066
Phone: (313) 574-2332

J9789-118 Carburetor Stand
J22769 Needle Valve Seat Remover
72085 Wagner Special Tools

Can be ordered from: Wagner Instruments
P.O. Box 1217
Greenwich, CT 06836
Phone: (203) 869-9681
! WARNING Model G.D. 150 Gram Scale (with Round Tip)
Borroughs Special Tools
Regulations to minimize risks of fire and explo- Can be ordered from: Borroughs Tool & Equip. Corp.
sion. 2429 N. Burdick Street
Kalamazoo, MI 48007
Use of replacement electrical, ignition or fuel system Phone: (616) 345-5163
components, which do not comply with these rules
and regulations, could result in a fire or explosion
hazard and should be avoided. BT-8128 B Float Scale
BT-8420 A Float Level Gauge
Fastener Location Lb. In. Ff. Lb. N·m TORX SCREWDRIVERS
Carburetor To Manifold 132 15 Rochester Quadrajet carburetors have a “star”
Fuel Line To shaped socket in the head of the screw. A TORX
Carburetor screwdriver must be used on this type of screw. The
18 24 three sizes used are #9, #20, and #25.
Fuel inlet To
Carburetor
Index
90-823225--1 1096 ROCHESTER 4 BARREL CARBURETOR - 5C-1
Carburetor Specifications
Carb Primary Secondary
Type Mercury No. Primary Metering Metering
Model (Note) (Manufacturer No.) Jet Size Rods Rods
MCM 5.0LX Rochester 1347-9661 .069 In. .042 In. CL
4MV (17080565)
MIE 5.7L Rochester 1347-9415 .069 In. .042 In. CH

Competition Ski 4MV (17085013)
NOTE: Rochester Quadrajets are 4MV type. The “V” or “C” designates choke type, NOT bore size.
Carburetor Adjustment Specifications (Note 1)

UNIT OF MEASUREMENT
In. (mm)
Engine Model MCM 5.0LX MIE 5.7L Competition Ski
Make & Model Rochester 4MV Rochester 4MV
Carburetor Manufacturer 17080565 17085013

Number
Float Level 15/64 (5.9) 15/64 (5.9)
Pump Rod Hole Location Inner Inner
Accelerator Pump (Note 2) 23/64 (9.1) 23/64 (9.1)
Air Valve Dashpot .025 (0.64) .025 (.64)

(Air Valve Rod)
Vacuum Break .080 [5/64] (2.0) .080 [5/64] (2.0)
Air Valve Spring Windup 70-90 GR. 75-85 GR.
Choke Coil Rod(Note 3) Top of Rod Even with Top of Rod Even with
Bottom of Hole Bottom of Hole
Idle Mixture Screw 2-3 Turns 2-3 Turns

Preliminary Setting
Float Weight (Max) 8.3 GR. 8.3 GR.
NOTE 1: All measurements are + 1/64 in. (0.4mm).

NOTE 2: Accelerator pump measurement taken from flame arrestor surface to pump stem with throttle plates
closed.
NOTE 3: Choke valve must be closed, choke rod in bottom of choke lever slot, and choke coil rod pushed down
to end of travel.
Index
Description ! WARNING
The Quadrajet carburetor has two stages in opera- Be careful when changing fuel system compo-
tion. The primary (fuel inlet) side has small bores with nents; gasoline is extremely flammable and
a triple venturi set-up equipped with plain tube highly explosive under certain conditions. Be
nozzles. Its metering principles are similar to most sure that ignition key is OFF. DO NOT smoke or
plain tube carburetors which use the venturi princi- allow sources of spark or flame in the area while
ple. The triple venturi stack-up, plus smaller primary
mediately.
bores, give a more stable and finer fuel control in idle
and economy ranges of operation. Fuel metering in
primary side is accomplished with tapered metering ! WARNING
rods positioned by a manifold vacuum responsive Make sure no fuel leaks exist before closing en-
piston. gine hatch.
Secondary side has two very large bores which have

greatly increased air capacity to meet present and fu- ! CAUTION
ture engine demands. Air valve principle is used in DO NOT operate engine without cooling water
secondary side for metering control and supple- being supplied to water pickup holes in gear
ments fuel flow from primary bores. housing, or water pump impeller will be damaged
and subsequent overheating damage to engine
Using air valve principle, fuel is metered in direct pro- may result.
portion to air passing through secondary bores.
Fuel reservoir is centrally located to avoid problems

of fuel slosh causing engine turn cut-out and delayed
Maintenance
fuel to carburetor bores. Float system uses a single
float pontoon for ease in servicing the unit. Flame Arrestor
NOTICE
Precautions Refer to “Precautions,” in this section, BEFORE
proceeding.
! WARNING
Always disconnect battery cables from battery 1. Remove (in the following order):
BEFORE working on fuel system to prevent fire a. Nut.
or explosion.
b. Sealing washer.
! WARNING
d. Sta-Strap hose retainers and crankcase ven-
Be careful when cleaning flame arrestor and tilation hoses from flame arrestor and rocker
crankcase ventilation hose; gasoline is extreme- arm covers.
conditions. Be sure that ignition key is OFF. DO e. Flame arrestor (lift from carburetor).
NOT smoke or allow sources of spark or open
flame in area when cleaning flame arrestor and
Index
2. Clean and Inspect: Fuel Filter
a. Clean flame arrestor in solvent and blow dry
NOTICE
Refer to “Precautions,” in this section, BEFORE
b. Clean crankcase ventilation hoses. proceeding.
c. Inspect crankcase ventilation hose for cracks
or deterioration; replace if necessary.
1. Remove:
3. Install (in the following order):
• Fuel line from fuel inlet filter nut
a. Flame arrestor (place on carburetor).
• Fuel inlet filter nut
b. Crankcase ventilation hose and Sta-Strap
hose retainers (to flame arrestor and rocker • Large gasket
arm covers).
• Filter
• Spring
d. Sealing washer.
• Small gasket (from inside filter nut)
e. Nut (tighten securely).
a
c
b
e
b
e
a
f
d
d d e 72087
b c
a - Fuel Line
72692 c - Gasket (Large)
d - Gasket (Small)
a - Nut e - Filter
b - Sealing Washer f - Spring
c - Carburetor Cover
d - Sta-Strap
e - Crankcase Ventilation Hose 2. Clean filter nut and spring.
f - Flame Arrestor
3. Install the following:
• Spring (place in carburetor body)
• Filter (open end to inlet filter nut)
• Small gasket (place inside filter nut)
• Large gasket (place over filter nut)
• Fuel inlet filter nut [tighten to 18 lb. ft.
(24 N·m)]
• Fuel line [tighten to 18 lb. ft. (24 N·m)]
Index
Adjustments 3. Close throttle valves completely and measure
from flame arrestor mounting surface to top of
pump plunger stem.
NOTICE
Refer to “Precautions,” in this section, BEFORE
proceeding.
Accelerator Pump
1. Back out idle stop screw until it no longer contacts
throttle lever.
b b
a
c 72089
a - Flame Arrestor Mounting Surface
b - Pump Plunger Stem
c - See Specifications
4. While supporting lever, bend tip of pump lever to

obtain specified dimension in Step 3.
a
72081
a - Idle Stop Screw a

b - Throttle Lever
2. Pump rod must be in inner hole of lever.
b
72090
a - Tip of Pump Lever

b b - Support as Shown
a
72088
a - Pump Rod
b - Inner Hole
Index
Air Valve Dashpot 2. To adjust spring windup, hold tension spring
screw and loosen Allen head screw.
1. Seat vacuum break diaphragm and close air
valve completely. Bend rod to adjust gap to speci- 3. Adjust tension and retighten allen screw secure-
fications. ly.
a 72093
d
b a - Increase
72091 b - Decrease
c - Screw
a - Push in Completely
b - Bend Here to Adjust
c - Specified Gap
d - Fully Closed
Float Level
1. Start engine to fill float bowl, run at idle and insert
Air Valve Spring Windup float gauge into hole next to flame arrestor stud.
1. Rotate gram scale until air valve begins to open;
check scale reading for correct specifications. b
72083
c
a - Gauge Hole
b - Gauge
72092
a - Carburetor Casting
b - Gram Scale
c - Contact Area of Arm on Air Valve
d - Rotate
Index
2. Tap float gauge down lightly to assure free move- Choke Coil Rod
ment.
1. Push choke coil rod down.
72082
a - Gauge
72096
a - Vacuum Break Choke Lever

3. Take gauge reading at top of carburetor casting. b - Choke Coil Rod
2. Choke coil rod top must be even with bottom of

hole in vacuum break choke lever.
a
72084
a
a - Read Here
4. If float requires adjustment, refer to “Reassemb-

ly” later in this section, for adjustment procedure. 72096
a - Top of Rod
b - Bottom of Hole
Index
3. Bend rod to adjust. 2. Rotate vacuum break choke lever counterclock-
wise until tang contacts vacuum break rod.
Choke rod must be at bottom of choke shaft lever
slot.
c
a
72097
72095
a - Tang
a - Bend Here b - Choke Rod
c - Vacuum Break Rod
3. Bend tang as necessary to obtain specified

choke valve gap of 5/64 [.08] in. (2.0 mm).
Vacuum Break b
1. Seat vacuum break control diaphragm by push-

ing in direction shown by arrow.
a a
72097
a - Tang
b - Gap
72097
a - Vacuum Break Control Diaphragm
Index
Preliminary Idle Speed and Mixture Final Idle Speed and Mixture
Initial start setting; make final adjustments with en-
gine running. IMPORTANT: Boat MUST BE in the water and en-
gine at normal operating temperature to accu-
1. Turn idle stop screw out until it does not contact rately check and adjust idle speed and mixture.
throttle lever, then turn in until it just contacts Carburetor should be set so that engine idles
throttle lever. smoothly, with boat in the water, engine at normal op-
erating temperature and drive unit in forward gear. To
b adjust idle speed and mixture, proceed as follows:
IMPORTANT: DO NOT attempt to compensate for

other engine problems (incorrect ignition timing,
faulty ignition components, low compression,
vacuum leaks, etc.) with carburetor adjustments.
This will only cover the problem which must be
corrected if engine is to achieve maximum fuel
economy and performance.
a
1. Connect a shop tachometer to engine.
72081
a - Idle Stop Screw IMPORTANT: DO NOT turn idle mixture needles

b - Throttle Lever
tightly into seat, as damage to needle and/or seat
may result.
2. Turn idle needles until LIGHTLY seated then 2. If a new or rebuilt carburetor has been installed,
back out 2 to 3 turns. turn each idle mixture needle until it LIGHTLY
contacts seat, then back out 2 or 3 turns. This will
provide a sufficient setting to allow starting the
engine.
a
72098
a - Idle Needles
IMPORTANT: Do not turn idle mixture screws

tightly against seat, as damage to seat and/or
needle may result.
Index
! WARNING Repair
DO NOT leave the helm unattended while per-
forming idle speed and mixture adjustments, fol-
lowing. BE CAREFUL NOT TO ACCIDENTALLY NOTICE
ACCELERATE ENGINE WHILE PERFORMING Refer to “Precautions,” in this section, BEFORE
ADJUSTMENTS. proceeding.
4. With boat in open water, place remote control in

forward gear, idle position. IMPORTANT: Carburetor malfunctions are, in
many cases, caused by the presence of dirt, wa-
5. Disconnect throttle cable brass barrel from an- ter or other foreign matter in carburetor. To aid in
chor stud. BE SURE NOT TO LOSE SPACER diagnosis, carefully remove carburetor from en-
ON ANCHOR STUD. gine without draining fuel from bowl. Contents of
6. Adjust idle speed adjustment screw to obtain fuel bowl may then be inspected for contamina-
specified RPM. tion as carburetor is disassembled.
7. With engine running at specified RPM, adjust idle
mixture needles as follows:
Removal
a. Turn idle mixture needle in (clockwise) until
the engine speed begins to drop due to lean 1. Remove flame arrestor.
mixture. 2. Disconnect choke spring rod.
b. Turn idle mixture screw out (counterclock-
wise) until the speed begins to drop due to a
rich mixture.
c. Turn screw in to a point between these two
extremes to obtain maximum engine smooth-
ness and RPM.
d. Repeat procedure with other needle.
b
e. Readjust idle speed adjustment screw, if nec-
essary, to obtain specified RPM. a
IMPORTANT: Refer to Section 2 for throttle cable

installation and adjustment.
72099
a - Choke Link
b - Clip
Index
3. Disconnect sight tube (if equipped). 6. Disconnect throttle cable.
a 72103
72100
a - Throttle Cable
a - Sight Tube
7. Disconnect cable end guide.

IMPORTANT: Place a clean cloth in bores of car-
falling into bores.
4. Turn off fuel supply at the fuel tank.
5. Disconnect fuel line.
a
72102
a - Cable End Guide
a
72101
a - Fuel Line
Index
8. Remove retaining nuts and bolts; remove carbu- Installation
retor and cable bracket.
1. Install new gasket onto manifold.
IMPORTANT: Place a clean cloth over intake man- 2. Install carburetor and throttle bracket and torque
ifold opening to prevent dirt or foreign material to 132 lb. in. (15 N·m).
from entering manifold.
a
a
b
b
72104
c
72104 a - Mounting Bolts
c b - Nuts
a - Mounting Bolts
b - Nuts c - Throttle Bracket
c - Throttle Bracket
3. Connect fuel line and torque to 18 lb. ft. (24 N·m).

9. Remove old gasket from carburetor and man- To prevent over-tightening, hold brass fuel line
ifold. coupling with suitable wrench and tighten fuel
line connector securely.
b
a
72101
a - Fuel Line
b - Fuel Line Coupling
Index
4. Connect fuel sight tube. 6. To install throttle cable refer to Section 2 - “Re-
moval and Installation.”
7. Install flame arrestor and tighten securely.
8. Reconnect battery cables to battery.
9. Start engine and check for gasoline leaks. If leaks
exist, STOP ENGINE IMMEDIATELY and re-
check connections.
10. Adjust idle speed and idle mixture, as previously
outlined under “Adjustments.”
72100
a - Sight Tube
5. Connect choke link and install retaining clip.
b
a
72099
a - Choke Link
b - Clip
Index
2
3 8
7 4
6 5 1
24 9
23
33
15 19
1 - Air Horn Assembly 27 16 10
2 - Screw
3 - Hanger 25 18 29
42
4 - Metering Rod, Secondary
5 - Screw
6 - Screw 26 14 28
7 - Screw 30
8 - Lever 12
9 - Roll Pin 32
10 - Pump
11 - Spring 22
12 - Needle and Seat
13 - Gasket 21 17
14 - Pull Clip
13 31
15 - Gasket 11
16 - Metering Rod, Primary 22
17 - Jet, Primary 34
18 - Float Assembly
19 - Pin, Hinge - Float 36
20 - Lever, Intermediate Choke 35
21 - Rod 20
22 - Clip
23 - Rod
24 - Clip
25 - Screw
26 - Control
27 - Hose
28 - Power Piston
29 - Retainer, Power Piston 37
30 - Retainer, Pump Discharge Ball
38
41 40
31 - Ball, Pump Discharge
32 - Spring, Power Piston 43 39
33 - Insert, Float Bowl
34 - Float Bowl
35 - Screw, Idle Stop
36 - Spring, Idle Stop Screw
37 - Spring, Filter Nut
38 - Filter, Fuel Inlet
39 - Nut, Fuel Inlet
40 - Gasket
41 - Gasket
42 - Rod
43 - Throttle Body 45
44 - Idle Needle
45 - Screw 44
72694
Exploded View - 4MV Quadrajet

(Rochester Carburetor)
Index
Disassembly 2. Remove choke shutter clip and rod.
IMPORTANT: Place carburetor on a holding fix-

ture to prevent throttle valve damage.
a
AIR HORN
1. Remove vacuum pump rod clip and rod.
72107
a - Clip
72105
a - Rod Clip
72108
a - Choke Shutter Rod
72106
a - Rod
Index
3. Drive roll pin back and remove accelerator pump 5. Remove air horn screws and air horn.
lever and rod.
a a
c
72109
72111
a - Roll Pin (Not Shown)
a - Air Horn Screws
b - Pump Lever
c - Rod
a
4. Remove screw, secondary metering rods and
hanger.
a
c
72112
a - Air Horn
72110
a - Screw
b - Metering Rods
c - Hanger
Index
FLOAT BOWL 3. Remove float assembly, needle and retaining
pin.
1. Remove pump plunger, return spring and gasket.
c c
a
b
b
72113
72115
a - Pump Plunger a - Float Assembly
b - Return Spring b - Needle
c - Gasket c - Retaining Pin
4. Remove fuel inlet seat and gasket.

2. Remove insert block, power piston and spring.
72114 b
72116
a - Insert Block
b - Power Piston a - Fuel Inlet Seat
c - Spring b - Gasket
Index
5. Remove primary metering jets, pump discharge 7. Remove vacuum control assembly and hose.
check ball retainer and check ball.
b c
a
a
72117
a - Primary Metering Jets

b - Pump Discharge Retainer
c - Check Ball (Not Shown) 72119
a - Vacuum Control Assembly

b - Hose
6. Remove baffle.
8. Remove fuel inlet filter nut, gaskets, filter and

spring.
a
72118 c
a - Baffle
a
72120
a - Nut
b - Gaskets
c - Filter
d - Spring
Index
9. Separate throttle body from float bowl and re- THROTTLE BODY
move gasket.
1. Remove idle mixture screws and springs.
d
b
a
72121 a
a - Attaching Screws b
72123
b - Throttle Body
c - Gasket a - Screw
d - Float Bowl b - Spring
IMPORTANT: Throttle body should not be disas-

FLOAT WEIGHT sembled any further than shown. Throttle body is
1. Assemble float scale to instructions with scale. serviced as an assembly.
2. Check float weight to specifications.
a
! CAUTION
DO NOT keep carburetor in immersion type car-
buretor cleaner for more than two hours.
! CAUTION
Rubber and plastic parts, pump plungers and di-
aphragm MUST NOT be immersed in carburetor
cleaner. The Delrin air valve cam will withstand
normal carburetor cleaner.
b
! WARNING
72122
Avoid personal injury by always wearing safety
a - Float Scale
b - Float
goggles when using compressed air.
1. Thoroughly clean all metal parts in a commercial

3. Replace float if it exceeds specifications. carburetor cleaner until all deposits have been
removed. Follow cleaner manufacturer’s instruc-
tions for proper cleaning and rinsing procedure.
Dry parts with compressed air.
Index
2. Using compressed air, blow out all passages in b. Maintain seal on hose connection; plunger
carburetor to remove any foreign material. must remain seated. If plunger extends, re-
place unit.
3. Wipe off all parts that cannot be cleaned in
carburetor cleaner with a clean, dry cloth.
4. Carefully inspect all carburetor parts for wear and
damage; pay particular attention to the following:
• Idle mixture needles
• Float needle and seat
• Casting surfaces
• All levers
• Fast idle cam
a
• Power piston
• Accelerator pump seal
5. Check all valves for binding. 72125
6. Check vacuum break unit for leaks as follows: a - Hose Connection

a. Depress plunger and seal hose connection.
IMPORTANT: The idle fuel pickup tubes have a
smaller I.D. at the bottom than the top. Do not
drill.
7. Clean idle fuel pickup tubes with a fine wire of ap-
b proximately .020 in. (0.5 mm) O.D. and blow out
all channels with compressed air.
a
72124
a - Plunger a
b - Hose Connection (Hidden in This View)
72117
a - Idle Fuel Pickup Tubes
Index
Reassembly FLOAT BOWL
THROTTLE BODY IMPORTANT: Place carburetor on a holding fix-

ture to prevent damage to throttle valve.
1. Install baffle plate.
NOTICE
Refer to “Adjustments” for all adjustment pro-
cedures.
IMPORTANT: Seat idle mixture screws lightly or

damage to needles and seats will result.
1. Install idle mixture needles and springs until light-
ly seated, then back out 2 to 3 turns.
a
72118
a - Baffle Plate
2. Install intermediate choke lever and vacuum

break control bracket assembly.
a a. Using choke rod, suspend intermediate

choke lever in float bowl cavity so that flat
72098
sided hole aligns with hole in side of float
a - Idle Mixture Needles and Springs bowl.
2. Install new gasket and assemble throttle body to

float bowl. Tighten securely.
a
b
d
b
72126
a - Choke Rod
a 72121 b - Choke Lever
a - Attaching Screws c - Flat Sided Hole
b - Throttle Body
c - Gasket
d - Float Bowl
Index
b. Insert choke shaft on vacuum break control IMPORTANT: Float needle and seat should be re-
assembly to engage flat sided hole of choke placed as a set only.
lever, and secure with screw. Tighten se-
4. Install float needle seat and gasket.
curely.
a
c
a
b
b 72116
a - Float Needle Seat

72127 b - Gasket
a - Choke Rod
b - Choke Shaft
c - Vacuum Break Control Assembly 5. Install float needle and float assembly.
a. Install pull clip onto needle.
3. Install pump discharge check ball, retainer and
primary main metering jets. Tighten securely.
a
b
a
72128
72129
a - Check Ball (Not Shown)
b - Retainer a - Pull Clip
c - Primary Main Metering Jets b - Needle
Index
b. If a new float or needle and seat are used, 6. If float requires adjustment hold hinge pin firmly,
bend float arm slightly upward at notch for turn carburetor upside down and measure from
easier adjustment. casting surface to toe of float with universal car-
buretor gauge. Check specifications.
7. Bend at float arm notch for adjustment to specifi-
cations.
a 72130
a - Float
b - Float Arm Notch
c. Hook needle pull clip over edge of float arm

closest to pontoon. 72094
c
a
b b
a - Pull Clip 72130
b - Float Arm 72610
d. Install retaining pin into float arm and install a - Hinge Pin
float and needle into bowl. b - Universal Carburetor Gauge (P/N 91-36392)
c - Notch - Bend Here
c
8. Install power piston spring.
b a
a - Float
b - Needle 72115
c - Retaining Pin
IMPORTANT: Top of retaining pin must extend 72131

above casting by .010 in. (0.254 mm) for good pin
retention. a - Power Piston Spring
Index
9. Install primary main metering rods in power pis- 11. Push power piston retainer down until flush with
ton hanger, and connect spring as shown. casting.
a
c
a
72134
72132
a - Power Piston Hanger a - Power Piston Retainer
b - Tension Spring
c - Metering Rods
12. Install filler block.
10. Install power piston assembly, guiding metering

rod tips into main metering jets.
a
72135
a - Filler Block
b
72133
a - Power Piston Assembly

b - Metering Rod Tip in Main Metering Jet
Index
13. Install accelerator pump plunger spring. 2. Install accelerator pump plunger.
72138
72136 a - Plunger
a - Spring
3. Install air horn.

AIR HORN
1. Install new gasket and slide tab under power pis-
ton hanger. a
b
a
72112
72137
a - Air Horn
a - Power Piston Hanger
b - Gasket Tab
Index
4. Install nine attaching screws. Tighten securely in 5. Install secondary metering rods into hanger with
sequence as numbered. upper ends toward each other as shown.
b a
1 2
c b c
b
b
b
3 4
b
8 6 7 9
a
72111 72140
a - Long
b - Short a - Hanger
c - Countersunk b - Metering Rods
6. Install metering rods and hanger and secure with

IMPORTANT: Hanger size may vary from specifi- screw. Tighten securely.
cation chart. Manufacturer varies hanger size to
make up differences in carburetor castings. Al-
ways install the same size hanger as was re-
moved from the carburetor. Difference in hang-
ers is the hole location, which affects secondary
fuel metering. c
b
b
a
a 72139
a - Hole Location Changes Fuel Metering
b - Richer
c - Leaner
72110
a - Screw
b - Metering Rods
c - Hanger
Index
7. Install pump lever rod. 9. Press roll pin into place using a screwdriver.
72080
a - Pump Lever Rod
72141
a - Roll Pin
8. Install rod into lever inner hole and place lever
into casting mount.
10. Install bottom end of choke shutter rod into inter-
mediate choke lever in float bowl.
b
c
a
72109
a - Rod
b - Lever 72108
c - Inner Hole
a - Choke Shutter Rod
d - Casting Mount
Index
11. Install upper end of choke shutter rod into the 13. Install rod into vacuum break arm and install clip.
choke blade lever; install clip onto choke shutter
rod.
a
b
c c
b
72105
a - Rod
a b - Vacuum Break Arm
c - Clip
72107
a - Choke Shutter Rod 14. Install vacuum break hose on carburetor fitting.
b - Clip
c - Choke Blade Lever
12. Install rod into air valve lever.

a
a
b
b
72142
a - Fitting
b - Hose
72106 15. Install vacuum break hose on vacuum dashpot

a - Rod fitting.
b - Air Valve Lever
b 72143
a - Hose
b - Dashpot Fitting
Index
FUEL SYSTEMS
5
D
70389
WEBER 4 BARREL
CARBURETOR
Index
5B - WEBER 4 BARREL CARBURETOR 90-823224 692
Table of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-1
Replacement Parts Warning . . . . . . . . . . . . . . . 5D-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 5D-1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-2
MCM Models . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-2
MIE Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-2
Carburetor Adjustment Specifications . . . . 5D-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-4
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-4
Important Service Information . . . . . . . . . . . . . . 5D-5
Weber Carburetor Adjustable
Accelerator Pump . . . . . . . . . . . . . . . . . . . . . 5D-5
Hard Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-5
Carburetor Metering Rod And Jet
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-7
Flame Arrestor . . . . . . . . . . . . . . . . . . . . . . . . 5D-7
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-9
Accelerator Pump . . . . . . . . . . . . . . . . . . . . . 5D-9
Choke Pull-Off . . . . . . . . . . . . . . . . . . . . . . . 5D-10
Float Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-10
Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-11
Idle Speed and Mixture Adjustments . . . . . . . 5D-12
Thunderbolt IV Equipped Engines . . . . . . 5D-12
Thunderbolt V Equipped Engines . . . . . . . 5D-14
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-16
Exploded View . . . . . . . . . . . . . . . . . . . . . . . 5D-18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5D-19
Cleaning and Inspection . . . . . . . . . . . . . . . 5D-28
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5D-29
NOTICE
Index
5D-0
5D - -WEBER
WEBER44BARREL
BARRELCARBURETOR
CARBURETOR 90-823225--1 1096
Identification Torque Specifications
Fastener Location in. lb. lb. ft. N·m
Carburetor To Manifold 132 15
Fuel Line
18 24
To Carburetor
Tools
Universal Carburetor
a 91-36392
Gauge
70389
Tachometer 91-59339
Universal Carburetor
a - Weber Identification Number Location Stand
Obtain Locally
Torx Screwdriver
(15,20,25)
TORX SCREWDRIVERS
! WARNING Weber carburetors will have a “star” shaped socket
Electrical, ignition and fuel system components in the head of some screws. A TORX screwdriver
on your MerCruiser are designed and manufac- must be used on this type of screw. The sizes used
tured to comply with U.S. Coast Guard Rules and are numbers 15, 20 and 25.
sion.

Index
90-823225--1 1096 WEBER 4 BARREL CARBURETOR - 5D-1
Specifications
MCM Models
Metering
Mercury Number Second- Metering Rod
Carb Primary
Engine Model (Manufacturer ary Jet Rod
Type Jet Size Spring
Number) Size Number
Color
3310-805484 (9661) .104 .101 16-7147 Natural
5.7L
L Al
Alpha
h 3310-806761 (9665) .101 .095 16-7052 Pink
3310-806761 (9665S) .101 .095 16-7052 Pink
Weber
W b 3310-816343A1 (9770) .101 .092 16-6852 Natural
350 Magnum Alpha
WFB 3310-806970
5.7L Bravo .101 .092 16-6850 Natural
(9770SA)
5.7LX, 350 Magnum
With Thunderbolt V 3310-807262 (9781) .098 .092 16-686462 Green
Ignition
MIE Models
Metering
Mercury Number Second- Metering Rod
Carb Primary
Engine Model (Manufacturer ary Jet Rod
Type Jet Size Spring
Number) Size Number
Color
3310-805484 (9661) .104 .101 16-7147 Natural
5 7L
5.7L
3310-806761 (9665S) .101 .095 16-7052 Pink
3310-805484 (9661) .104 .101 16-7147 Natural
5 7L Competition Ski
5.7L
3310-806761 (9665S) .101 .095 16-7052 Pink
W b
Weber
5.7L Competition Ski AFB 3310-806545 (9663) .089 .092 16-656357 Natural
Bodensee
3310-806970 (9770) .101 .092 16-6850 Natural
350 Magnum
Tournament Ski 3310-806970 .101 .092 Natural
16-6850
(9770SA)
350 Magnum
Tournament Ski Weber
3310-807262 (9781) .098 .092 16-686462 Green
With Thunderbolt V WFB
Ignition
Index
5D-2 - WEBER 4 BARREL CARBURETOR 90-823225--1 1096
UNIT OF MEASUREMENT In. (mm)
ALL MEASUREMENTS ARE ± 1/64 In. (0.4 mm).
Carburetor Adjustment Specifications
Float Level 1-9/32 in. (33 mm)

Float Drop 2 in. (51 mm)
Pump Rod Hole Location Third Hole From End
Accelerator Pump 7/16 in. (11 mm) 1
Choke Pull-Off 15/64 in. (6 mm)
Choke Coil Rod Top Of Rod Even With Bottom Of Lever Hole 2
Preliminary Mixture Idle
1-1/4 Turns
Screw Setting
1 Measured from top of carburetor to bottom of S-link

2 Remove choke rod from lever hole. Choke held closed and choke rod pushed down with top edge of rod even
with bottom edge of hole.
Index
Description ! WARNING
Weber WFB carburetor is unique in design, as the Be careful when changing fuel system compo-
main body and flange are cast as a one piece unit. nents: gasoline is extremely flammable and high-
This, along with the bowl cover, make up the two ly explosive under certain conditions. Be sure
piece construction which is made of light, durable that ignition key is OFF. DO NOT smoke or allow
aluminum to dissipate heat. sources of spark or open flame in area while
There are two separate float circuits. Each float cir-
mediately.
cuit supplies fuel to a primary low speed circuit and
a primary and secondary high speed circuit. The
bowls are vented to the inside of the air horn. A con- Fuel Supply Connections
necting vent passage effects a balance of the air
pressure between the two bowls. ! WARNING
The float needle valves are installed at an angle to
provide the best possible seating action on the
needles. This provides better needle response to
float movement, also.
fuel leak.
The high speed circuits use staged step-up rods in
the main metering jets to control the amount of fuel
admitted to the nozzles. The position of the step-up
TEFLON TAPE.
rod is controlled by manifold vacuum applied to the
vacuum piston. • Thread brass fitting or plug into fuel pump or
A primary air bleed located in the venturi cluster pre-
vents a rich condition or bog as the high speed circuit • Tighten fitting or plug an additional 1-3/4 to
is reactivated after deceleration. 2-1/4 turns using a wrench. DO NOT
OVER-TIGHTEN.
Small “L” shaped metal tabs, called “distribution
tab(s),” are attached to some venturi clusters and • Install fuel line. To prevent over-tightening,
protrude into the air stream at the proper location to hold brass fitting with suitable wrench and
aid distribution of fuel on selected applications. tighten fuel line connectors securely.
Precautions ! WARNING
! WARNING gine hatch.
or explosion.
! WARNING housing or water pickup inlet, or water pump im-
Be careful when cleaning flame arrestor and peller will be damaged and subsequent overheat-
crankcase ventilation hose: gasoline is extreme- ing damage to engine may result.
conditions. Be sure that ignition key is OFF. DO
Index
Important Service Hard Starting
Information If a hard starting condition exists, after engine has not
been operated for a period of time, proceed with the
following:
Weber Carburetor Adjustable 1. Before starting engine, remove flame arrestor
Accelerator Pump then operate throttle to see if choke closes.
The accelerator pump lever on Weber Carburetors 2. If choke is stuck open, check choke stove link rod
has three holes in it. The closest hole to the lever’s and choke linkage on both sides of carburetor for
pivot point is the richest, the second hole is leaner cause of sticking. Possible paint or interference
and the hole furthest away is the leanest. All produc- to rod or linkage.
tion carbs have the pump rod installed in the closest 3. If choke plate does not close tight step 2 or 3, then
(richest) hole. If you are having a “rich” bog on accel- choke link rod will have to be bent to make it
eration, move the rod to the second or third hole. shorter so it will close choke plate completely.
Weber put the three holes in the lever so the amount
of fuel delivered by the accelerator pump could be
changed. a
73716
a - Bend Here To Shorten

a
b 4. After installing, ensure that the rod does not rub
against stove cover or carburetor throughout its
c travel.
70472
a - Rich
b - Lean
c - Leaner
Index
Carburetor Metering Rod And Jet METERING JETS
Identification The metering jets in this carburetor are taller than the
jets in a standard carburetor.
METERING ASSEMBLY
Three Step Two Step
The metering rod assemblies are different in the fol-
lowing ways:
b Three Step
a
a b 73728
d
c a - Three Step Metering Rod
b - Two Step Metering Rod
METERING ROD HAS “THREE STEPS” -VS-

TWO
Three Step
e
73732
73726
Two Step
b Two Step a
73724
PISTON SHAPE IS DIFFERENT AND HAS

d c A SECOND SPRING
Three Step
e
73729
73730
a - Piston
b - Metering Rod
c - Spring
d - Jet Two Step
e - Piston Cover
73727
Index
PISTON ASSEMBLY COVER IS HIGHER ELECTRIC CHOKE
The electric choke should be set with marks aligned.
73735
Three Step Two Step
73725
74104
Maintenance
73736 Flame Arrestor

NOTICE
PISTON BORE HAS A STEP ON THREE STEP Refer to “Precautions,” in this section,
MODEL BEFORE proceeding.
1. Remove (in the following order):

a. Nut
b. Sealing washer
c. Carburetor cover
d. Crankcase ventilation hoses from flame ar-
restor and rocker arm covers
e. Flame arrestor
2. Clean and inspect:
a. Clean flame arrestor in solvent and blow dry
b. Clean crankcase ventilation hoses.
73737
c. Inspect crankcase ventilation hoses for
cracks or deterioration, and replace if neces-
sary.
Index
3. Install (in the following order): Fuel Filter
a. Flame arrestor
NOTICE
b. Crankcase ventilation hoses to flame arres- Refer to “Precautions,” in this section,
tor and rocker arm covers BEFORE proceeding.
c. Carburetor cover
d. Sealing washer Carburetor inlet fuel filter is installed in bottom side of
fuel inlet seat (in the carburetor top). Refer to “Disas-
e. Nut (tighten securely) sembly” and “Reassembly” to service.
a
c
b a
d b
d
e
f
e 71372 70447
Flame Arrestor with Carburetor Cover (Typical) a - Fuel Inlet Seat (with Gasket)
a - Nut b - Fuel Inlet Filter
b - Sealing Washer
c - Carburetor Cover
d - Sta-Strap
e - Crankcase Cover
f - Crankcase Ventilation Hose
g - Flame Arrestor
Index
Adjustments 2. Close throttle valves completely.
3. Accelerator pump is set at 7/16 in. (11 mm), which
NOTICE is measured from the carburetor top to the bottom
Refer to “Precautions,” in this section, of the S-link as shown.
BEFORE proceeding.
Accelerator Pump
IMPORTANT: Refer to “Important Service Infor-

mation” in this section, regarding the three ac-
celerator pump linkage holes and placement of
linkage rod.
1. Back out idle speed screw until it no longer con-
tacts throttle lever.
70472
4. Adjustment of accelerator pump is done by bend-

a ing the linkage as necessary to achieve the prop-
er dimension as stated above.
70474

b - Throttle Lever Contact Point
a
70473
a - Bend Here
b
70473
b - Throttle Lever
Index
Choke Pull-Off 2. Bend choke pull-off linkage to achieve setting giv-
en in Step 1.
1. Choke pull-off is checked by holding in on vacu-
um diaphragm and attempting to close choke
plate. The gap between the plate and housing is
to be set at 15/64 in. (6 mm).
a 70471
a - linkage (Bend)
a 70471
d
Float Drop
1. Measure float drop from bottom side of carbure-
tor top to toe of float (lowest part), as shown. It
must be set at 2 in. (51 mm).
70471
a - Vacuum Diaphragm
a 70469
b - Choke Plate
a - Drop Measurement
c - Housing
d - Gap Measurement
2. If float drop is not correct, hold hinge pin firmly
and bend tab shown, as needed.
Index
IMPORTANT: Do not put pressure on fuel needle 2. If float level requires adjustment, hold hinge pin
valve and seat while bending tab, or damage may firmly and bend float arm shown, as needed.
result.
IMPORTANT: Do not put pressure on fuel needle
valve and seat while bending tab, or damage may
result.
a
70470
70468
a - Float
b - Tab (Bend)
a - Float Level Tab (Bend)

Float Level
1. Measure float level from bottom side of carbure-
tor top (with gasket in place) to toe of float as
shown. It must be set at 1-9/32 in. (33 mm).
70468
a - Float Level Measurement

b - Gasket
Index
Idle Speed and Mixture IMPORTANT: Do not turn idle mixture screws
Adjustments needle may result.
Thunderbolt IV Equipped Engines
PRELIMINARY IDLE SPEED AND MIXTURE

Initial start settings are given following. Make final ad-
justment with engine running (refer to “Final Idle
Speed and Mixture”).
1. Turn idle speed screw until it contacts throttle
lever.
a a
71171
a - Idle Mixture Screws (Needles)
70474

b - Throttle Lever Contact Point
2. Turn idle mixture screws (needles) in (clockwise)

until LIGHTLY seated, then back out 1-1/4 turns.
Index
FINAL IDLE SPEED AND MIXTURE 4. With boat in open water, place remote control in
forward gear, idle position.
IMPORTANT: Boat MUST BE in the water and en- 5. Disconnect throttle cable barrel from anchor
gine at normal operating temperature to accu- stud. BE SURE NOT TO LOSE SPACER ON AN-
rately check and adjust idle speed and mixture. CHOR STUD.
Carburetor should be set so that engine idles as 6. Adjust idle speed adjustment screw to obtain
smoothly as possible, with boat in the water, engine specified idle RPM. (Refer to Section 1B -
normal operating temperature and drive unit in for- “Tune-Up Specifications” charts.)
ward gear. To adjust idle speed and mixture, proceed
NOTE: Idle speed must be at specified RPM or less.
as follows:
Or engine will be operating on the off idle circuit. Mix-
ture screw adjustments will be ineffective if this
IMPORTANT: DO NOT attempt to compensate for condition exists.
other engine problems (incorrect ignition timing,
faulty ignition components, low compression,
7. With engine running at or just below specified idle
vacuum leaks, etc.) with carburetor adjustments.
RPM, adjust idle mixture screws as follows:
This will only cover the problem, which must be
corrected if engine is to achieve maximum fuel a. Turn idle mixture needle in (clockwise) until
economy and performance. the engine speed begins to decrease due to
LEAN mixture.
1. Connect a shop tachometer to engine.
b. Turn same idle mixture screw outward (coun-
IMPORTANT: DO NOT turn idle mixture screws terclockwise) until the engine speed begins to
(needles) tightly into seat, as damage to needle decrease due to a RICH mixture.
and/or seat may result. c. Turn screw in to a point between these two
2. If a new or rebuilt carburetor has been installed, extremes to obtain maximum engine smooth-
turn each idle mixture screw until it LIGHTLY con- ness and RPM.
tacts seat (if not already accomplished), then d. Repeat procedure with other mixture screw.
back out 1-1/4 turns. This will provide a sufficient
e. Readjust idle speed adjusting screw, if nec-
setting to allow starting the engine.
essary, to obtain specified idle RPM.
8. Place remote control in neutral. Turn ignition
OFF.
9. Accelerator pump linkage should be rechecked
! WARNING at this time. Refer to Steps 3 and 4, of Adjust-
DO NOT leave helm unattended while performing ments – “Accelerator Pump”, as previously out-
idle speed and mixture adjustments, following. lined and verify pump is set at 7/16 in. (11mm) as
BE CAREFUL NOT TO ACCIDENTALLY specified.
ACCELERATE ENGINE WHILE PERFORMING 10. Refer to SECTION 2. Install and adjust throttle
ADJUSTMENTS. cable following instructions appropriate to your
power package.
Index
Thunderbolt V Equipped Engines IMPORTANT: In order to properly set idle speed,
ADJUSTING IDLE MIXTURE Timing Mode”. This is necessary because of the
“Idle Speed Control” feature that exists in the
The procedure for adjusting carburetor idle mixture ignition module. See information on the previous
can be found in the appropriate engine service manu- pages about this feature.
al. This procedure also requires that the ignition mod-
ule be locked in the “Base Timing Mode”. 2. Connect a shop tachometer to engine.
3. Using a jumper wire, connect the ignition system
IMPORTANT: In order to properly set idle mixture, timing lead “13” (PUR/WHT wire) to a good en-
the ignition module MUST BE locked in the “Base gine ground (–). This locks the ignition module
Timing Mode”. This is necessary because of the into the “Base Timing Mode”.
“Idle Speed Control” feature that exists in the 4. Start engine and allow it to reach normal operat-
ignition module. See information on the previous ing temperature. Place the remote control lever
pages about this feature. in forward gear, idle position.
1. Using a jumper wire, connect the ignition system 5. Adjust idle speed to recommended RPM.
timing lead “13” (PUR/WHT wire) to a good en-
gine ground (–). This locks the ignition module 6. Stop engine. Readjust cable barrel and reinstall
into the “Base Timing Mode”. the throttle.
2. Adjust idle mixture following the procedure in the

IMPORTANT: Be sure to disconnect the jumper
appropriate engine service manual.
wire from the ignition system test terminal before
3. Remove the jumper wire from the timing terminal. attempting to resume normal operations. If the
jumper wire is left in place, the ignition module
ADJUSTING ENGINE IDLE SPEED will operate in the “Base Timing Mode”. This
means that the additional timing advance fea-
This procedure should be done with boat in the water,
tures would not be functioning.
drive unit in neutral and engine at normal operating
temperature. Refer to the Operation and Mainte- 7. Remove the jumper wire from the timing terminal.
nance Manual for the correct idle speed.
1. Disconnect the throttle cable from carburetor.
Index
Repair 4. Disconnect retaining clip and choke linkage rod.
NOTICE
BEFORE proceeding.
Removal b
IMPORTANT: Carburetor malfunctions are, in a

many cases, caused by the presence of dirt, wa-
ter or other foreign matter in carburetor. To aid in
diagnosis, carefully remove carburetor from en- 71096
gine without draining fuel from bowl. Contents of a - Retaining Clip
fuel bowl may, then, be inspected for contamina- b - Linkage Rod
tion as carburetor is disassembled.
5. Remove fuel line and carburetor attaching hard-
1. Turn off fuel supply at fuel tank. ware. Remove carburetor and throttle bracket.
2. Remove carburetor cover. Remove crankcase Discard old gasket from carburetor.
ventilation hoses from flame arrestor, then re-
move flame arrestor.
IMPORTANT: Place a clean cloth in bores of car- a

falling into bores.
3. Disconnect throttle cable attaching hardware

from throttle bracket and throttle lever anchor
studs. Remove throttle cable.
b
b
d 71173
d b
a
c
71097
a - Throttle Cable
b - Bracket c
c - Attaching Hardware
d - Anchor Studs 71172
a - Fuel Line
c - Throttle Bracket
Index
6. Remove adaptor/wedge plate (if so equipped)
from manifold and discard old gasket.
7. Place a clean cloth over intake manifold open-
ings.
IMPORTANT: Covering intake manifold prevents

entry of dirt or foreign material through open-
ings. b
Installation
1. Place appropriate new gasket on intake man-
ifold.
2. If so equipped, install adaptor or wedge plate, de-
pending on model. Place appropriate new gasket a
on top. 71172
3. Install carburetor and throttle bracket with at- a - Throttle Bracket
taching hardware. Torque fasteners to 132 lb. in. b - Attaching Hardware
(15 N·m).
4. Install fuel line. To prevent over-tightening, hold
fuel inlet filter nut with suitable wrench and tight-
en fuel line connector securely.
b
a
a
b
71173
a - Throttle Bracket (Not Visible In This View)

71173
a - Fuel Line
Index
5. Connect choke linkage rod and install retaining
clip.
71096
a - Clip
b - Linkage Rod
6. Refer to Section 2. Install and adjust throttle

cable following instructions appropriate to your
power package.
7. Install flame arrestor and tighten nut securely.
8. Reconnect battery cables to battery by first in-
stalling positive battery cable to positive (+) bat-
tery terminal. Tighten clamp securely. Then, in-
stall negative battery cable to negative (–) battery
terminal. Tighten clamp securely.
9. Turn on fuel supply at fuel tank.
10. Start engine and check for gasoline leaks. If leaks
exist, STOP ENGINE IMMEDIATELY and re-
check connections.
11. Adjust idle speed and idle mixture, as previously
outlined under “Adjustments.”
Index
Exploded View
Weber Carburetor
1
2
3
4
5
6
7
8 35
9 36
10 37
11 38
12 39
13 40
41
14
42
15
16
43
17 44
18 45
19 46
20 47
21 48
22 49
23
50
24
51
25
26
27
28
29
30
31
32
33
34
Index
1-Air Deflector (2) Disassembly
2-Screw (2)
3-Cover, Metering Rod (2) The following is a step-by-step procedure for com-
4-Metering Rod Assembly (2) pletely overhauling carburetor after removal from en-
5-Spring, Metering Rod (2) gine. In many cases, however, complete overhaul is
6-Fuel Inlet Fitting not necessary and, in these cases, only the steps re-
7-Sealing Washer
quired to repair the carburetor malfunction should be
8-Screw
9-Linkage Rod, Choke Pull-Off
performed. Read the instructions carefully to prevent
10- Screw doing unnecessary steps.
11- Air Horn (Carburetor Top)
12- Filter, Fuel Inlet (2) IMPORTANT: Before performing any service on
13- Gasket (2) carburetor, it is essential that carburetor be
14- Seat, Fuel Inlet (2) placed in a holding fixture to prevent possible
15- Needle Valve, Fuel Inlet (2)
damage to throttle valves.
16- Pin (2)
17- Float (2)
18- Secondary Venturi Cluster (2) 1. Remove wire clip to disconnect accelerator pump
19- Baffle Plate, Float Bowl (2) linkage.
20- Screw (4)
21- Primary Venturi Cluster (2)
22- Gasket (2)
23- Jet, Primary Fuel (2)
24- Screw (2)
25- Fuel Pump Injector Housing
26- Gasket
27- Check-Weight (or Check-Spring, if So Equipped) b
28- Check-Ball a
29- Screw
30- Diaphragm, Choke Pull-Off
31- Vacuum Hose
32- Idle Mixture Screw (2)
33- Spring, Idle Mixture Screw (2) 70390
34- Gasket, Carburetor Base
35- Linkage Rod, Choke Plate a - Wire Clip
36- S-Link b - Accelerator Pump Linkage Rod
37- Accelerator Pump Lever
38- Screw
39- Linkage Rod, Accelerator Pump
40- Wire Clip
41- Wire Clip
42- Gasket
43- Screw (4)
44- Gasket (2)
45- Jet, Secondary Fuel (2)
46- Secondary Air Valve and Weight Assembly
47- Plunger Washer
48- Plunger Guide
49- Accelerator Pump
50- Spring, Accelerator Pump
51- Float Bowl/Body (Carburetor Bottom)
Index
2. Remove wire clip to disconnect choke plate link- 4. Remove screws from choke pull-off diaphragm
age. bracket to disengage choke pull-off linkage.
a
NOTE: Depending on amount of service required, it
may not be necessary to remove diaphragm and
bracket.
70391
a
b
b
70394
a - Screws
b - Linkage Rod
70392
IMPORTANT: Metering rods should always be re-
a - Wire Clip
b - Choke Plate Linkage Rod moved before separating top and bottom halves
of carburetor.
NOTE: Do not remove vacuum hose if not servicing
diaphragm.
3. Disconnect vacuum hose from choke pull-off dia-
phragm.
b
a
70393
a - Vacuum Hose
b - Choke Pull-Off Diaphragm
Index
5. Loosen (not necessary to remove, depending on 7. Remove metering rod springs.
amount of service required) metering rod cover
screws. Turn cover, or remove, to expose meter- IMPORTANT: Metering rod springs are color
ing rod. coded and should not be interchanged with other
carburetors.
c
a
b
a
71094
71095
70397
a - Screws
b - Metering Rod Cover(s)
c - Air Deflectors If Equipped) a - Spring(s)
IMPORTANT: Be careful not to mix metering rods 8. Remove nine screws to separate top and bottom
when removing them. halves of carburetor.
6. Carefully lift metering rod assemblies straight
out.
a
a
70398
a - Screw(s)
70396
a - Metering Rod Assembly(s)
Index
9. Carefully lift off carburetor top and disconnect 11. Remove inlet needle from seat.
choke linkage.
IMPORTANT: Be careful not to mix up inlet
needles and seats after removal.
70399 b 70401
10. Slide pin out to remove the float.
IMPORTANT: Be careful not to mix up floats after

removal.
a
a
b
70400
a - Pin(s)
b - Float(s)
70446
a - Inlets Needle(s)
b - Seat(s)
Index
12. Remove seat, gasket, and inlet filter. 14. Remove accelerator pump lever.
IMPORTANT: Be careful not to mix up seats after

removal.
c
b b
a 70449
c
a - Accelerator Pump
b - Accelerator Pump Lever
c - Retaining Screw
15. Remove accelerator pump.
70447
a - Seat
b - Gasket
c - Inlet Filter
a
13. Remove gasket from top of carburetor.
b
c
70448 70450
a - Gasket b - Plunger Guide
c - Plunger Washer (Not Visible In This View)
Index
16. Remove accelerator pump spring from bottom 17. Remove two screws that secure primary venturi
half of carburetor. cluster.
a a
b
b 70451
70453
a - Accelerator Pump Spring a - Screw(s) Two On Each Side

b - Carburetor Bottom b - Primary Venturi Cluster(s)
IMPORTANT: Before removing venturi clusters, it 18. Remove primary venturi cluster by lifting straight
is important to note which clusters are equipped up.
with a “distribution tab.” This distribution tab
arrangement varies from one carburetor to
another.
70454
70452
a - Distribution Tab(s) Location And Total Number May Vary
Index
19. Remove gasket from beneath venturi cluster. 21. Remove secondary venturi cluster by lifting it
straight up.
70455
70457
a - Gasket Primary Venturi Cluster
22. Remove gaskets from beneath secondary ven-
20. Remove two screws that secure secondary venturi clusters.
turi clusters.
a a
70456 70458
a - Screw(s) Two Each Side a - Gasket, Secondary Venturi Cluster

b - Secondary Venturi Cluster(s)
Index
23. Remove secondary air valve and weight assem- 25. Remove pump jet housing.
bly by lifting it straight out.
70461
70459
a - Pump Jet Housing
a - Secondary Air Valve And Weight Assembly
26. Remove gasket from beneath pump jet housing.
24. Remove two screws that secure pump jet hous-
ing.
70462
b a - Gasket, Pump Jet Housing
70460 27. Remove check-ball and check-weight, or

check-ball and check-spring, from hole beneath
a - Screw(s)
b - Pump Jet Housing pump jet housing.
Index
IMPORTANT: If your carburetor had a ball and IMPORTANT: Do not mix up the primary and sec-
weight combination, replace with ball and ondary jets. Make note of the jet sizes and their
weight. If your carburetor used a ball and spring location before removal to be certain that during
combination, replace with ball and spring. reassembly they are installed in the carburetor
side from which they were removed.
NOTE: If jets are difficult to remove, place a screw-

a driver, with the correct width, in the jet slot and lightly
tap the end of the screwdriver with a hammer.
29. Remove primary and secondary jets.
70463
a - Ball Location
b a
a b
70466
c
a a - Primary Fuel Jet
b - Secondary Fuel Jet
IMPORTANT: Before removing mixture screws,

70464 check and note the number of turns from the fully
a - Check Ball seated position. Also, do not mix up the two
b - Check Weight screws.
c - Check Spring
28. Remove float bowl baffle plates, if necessary.
70465
a - Baffle Plate
Index
30. Remove mixture screws. IMPORTANT: DO NOT use a wire or drill to clean
jets, passages, or tubes in carburetor, as this
may enlarge orifices and seriously affect carbu-
a retor calibration.
3. Wipe all parts that cannot be cleaned in immer-
sion cleaner with a clean, dry cloth.
4. Carefully inspect all carburetor parts for damage
or wear; pay particular attention to the following:
b
a. Idle mixture screws - Replace if damaged or
worn.
70467
b. Fuel inlet needle valve and seat - Replace
a - Idle Mixture Screw with new needle and seat if worn or damaged.
b - Spring, Idle Mixture Screw
c. Casting surfaces - Inspect accelerator
pump plunger well for scoring or deposits.
Cleaning and Inspection Replace worn or corroded components.
d. All linkage rods and levers - Replace if
worn or damaged.
! CAUTION
e. Accelerator pump and plunger parts - Re-
Rubber, plastic parts, pump plungers or dia- place pump and parts if worn or damaged.
phragms cannot be immersed in carburetor
cleaner. f. Float assembly and hinge pin - Float weight
of each should be the same. Replace either
if fuel can be heard inside when shaken.
! CAUTION Check hinge pin and holes for wear. Replace
components if worn or defective.
Avoid damage to carburetor. Do not leave carbu-
retor in immersion-type cleaner for more than g. Throttle valves and shafts - Check for bind-
two hours. ing (through entire operating range, making
sure valves open and close completely) or for
IMPORTANT: Do not immerse metering rod looseness in carburetor body.
springs in carburetor cleaner; the color, if not
“natural” metal, may be removed. Clean IMPORTANT: DO NOT remove throttle valves. If
separately as needed. any of the throttle parts or float bowl/carburetor
body shaft bores are found to be worn or dam-
1. Clean metal carburetor parts in a commercial, im-
aged, carburetor replacement is required.
mersion-type cleaner, until all deposits have
been removed. Follow manufacturer’s instruc- h. Choke valve and shaft/lever assembly -
tions of cleaner being used for proper cleaning Check shaft and lever for excessive loose-
and rinsing procedures. ness in air horn. Check choke valve and
shaft/lever assembly for binding through en-
tire operating range. Air horn assembly must
! CAUTION be replaced if choke valve and shaft/lever are
Avoid personal injury. Always wear safety worn.
glasses when using compressed air. 5. Check that choke pull-off diaphragm plunger re-
2. Blow out passages with compressed air. Do not tracts when vacuum is applied to unit, and that it
drill through passages. holds vacuum (plunger remains seated if vacuum
is maintained).
Index
Reassembly 3. Install the float bowl baffle plates, if previously
removed.
1. Install mixture screws (needles) with springs in
place. Turn idle mixture screws in (clockwise) un- a
til LIGHTLY seated, then back out one and quar-
ter (1-1/4) turns if previous settings were not
noted on disassembly.
IMPORTANT: Do not turn idle mixture screws

needle may result.
a
70465
c - Baffle Plate
4. Into bore beneath pump jet housing location, in-

b stall check-ball and then check-weight or, if so
equipped, check-ball and check-spring.
70467 IMPORTANT: If your carburetor had a ball and

weight combination, replace with ball and
a - Idle Mixture Screw weight. If your carburetor used a ball and spring
b - Spring, Idle Mixture Screw combination, replace with ball and spring.
2. Install the primary and secondary jets. Tighten a

only till snug.
IMPORTANT: Be sure that primary and secondary

jets are installed in the appropriate location. Be
sure that the size matches the same size re-
corded during disassembly.
70463
b a
b c d
70466
b
a - Primary Fuel Jet
b - Secondary Fuel Jet
70464
a - Bore
b - Check Ball
c - Check Weight
d - Check Spring
Index
5. Position pump jet housing gasket. 7. Install two screws that secure pump jet housing.
Tighten securely.
b
70462
70460
a - Gasket, Pump Jet Housing
a - Screws
6. Install pump jet housing. b - Pump Jet Housing
8. Install the secondary air valve and weight assem-

bly.
a
70461
a - Pump Jet Housing

70459
a - Secondary Air Valve And Weight Assembly
Index
IMPORTANT: Before installing venturi clusters, it 10. Install the secondary venturi clusters.
is important to note which clusters were
equipped with a “distribution tab.” This distribu- a
tion tab arrangement varies from one carburetor
to another.
70457
a - Secondary Venturi Cluster
11. Secure each cluster with two screws. Tighten se-

curely.
70452
a - Distribution Tab(s) Location And Total Number May Vary a
9. Position the secondary venturi cluster gaskets.
70456
a - Screws (Two On Each Side)

b - Secondary Venturi Cluster(s)
70458
a - Gasket, Secondary Venturi Cluster
Index
12. Position the primary venturi cluster gaskets. 14. Secure each cluster with two screws. Tighten se-
curely.
a a
b
70455
70453
a - Gasket, Primary Venturi Cluster
13. Install the primary venturi clusters. a - Screws (Two Each Side)
b - Primary Venturi Cluster(s)
b 15. Install the accelerator pump spring into bottom

half of carburetor.
a a
70454
a - Gasket, Primary Venturi Cluster (One Not Visible In This

View)
b - Primary Venturi Cluster
b
70451

b - Carburetor Bottom
Index
16. Install accelerator pump in top of carburetor 18. Install gasket on top of carburetor.
housing, after placing washer and guide in posi-
tion.
70448
b a - Gasket
c
19. Install inlet filter in bottom of inlet seat. Install inlet
seat with gasket in place. Tighten securely.
70450
b - Plunger Guide
c - Plunger Washer (Not Visible In This View)
a
17. Connect accelerator pump lever to pump rod us-
ing the S-link. Secure pump lever with pivot b
screw. Tighten securely. Check to ensure lever c
actuates the accelerator pump.
d
70447
a - Seat
b - Gasket
c - Inlet Filter
a
b
70449
a - Accelerator Pump Lever

b - Accelerator Pump
c - S-Link
d - Retainer Screw
Index
IMPORTANT: If using existing needles and seats, 21. Install floats using hinge pins.
be sure to reinstall them as matched sets, as
noted during disassembly.
b
20. Install appropriate inlet needles into inlet seats.
b
a a
a
70400
a - Pin(s)
b - Floats(s)
b
22. Carefully lower top of carburetor onto bottom
part.
70446
b 70401 70399
a - Inlet Needle(s)
b - Seat(s)
IMPORTANT: If using existing floats, be sure to

reinstall them on the same side as removed.
Index
23. Ensure gasket is properly positioned between 25. Carefully install metering rod assemblies in the
the two parts and secure the top to bottom with appropriate holes. Push down lightly on metering
screws (nine total). Tighten securely. rods to ensure that plunger will spring up and
down.
a
70398
a - Screw(s)
24. Install metering rod springs into each metering

rod hole. Be certain to install the appropriate col- 70396
or spring (refer to “Specifications”).
a - Metering Rod Assembly(s)
IMPORTANT: Some carburetors are equipped

with air deflectors that are attached to the screw
a
that holds down the metering rod covers. Be sure
to reinstall the deflectors if your model carbure-
tor requires them.
26. Position metering rod covers (and air deflectors,

if equipped) over metering rods and install
screws. Tighten securely.
c
a
b
70397
71094
a - Spring(s)
IMPORTANT: If using existing metering rods, be

sure that they are reinstalled in the same side
from which removed during disassembly.
71095
a - Screws
b - Metering Cover(s)
c - Air Deflectors (If Equipped)
Index
27. Reconnect choke pull-off linkage to carburetor. 29. Reconnect choke plate linkage. Secure with wire
Reinstall choke pull-off diaphragm. Secure with clip.
two screws and tighten securely.
a
b
70392
70394
b
a - Screw(s)
b - linkage Rod
28. Reconnect vacuum hose to choke pull-off dia-

phragm.
a
70391
a - Choke Plate Linkage Rod

b - Wire Clip
a
70393
a - Vacuum Hose
Index
30. Reconnect accelerator pump linkage rod to hole
in accelerator pump lever where originally con-
nected or refer to “Important Service Information”
in this section for information regarding adjust-
ment. Accelerator pump linkage adjustment
should be checked at this time; refer to Adjust-
ments - “Accelerator Pump” as previously out-
lined. Secure using wire clip.
a
b
70390
a - Accelerator Pump Linkage Rod

b - Wire Clip
31. Refer to “Installation” and install carburetor.
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
FUEL SYSTEMS
5
E
71692
MULTI-PORT AND THROTTLE BODY

FUEL INJECTION
Index
Table of Contents
Page Page
General Information . . . . . . . . . . . . . . . . . . . . . 5E-1 MCM 5.7L EFI Bravo With
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-1 Vapor Separator Tank . . . . . . . . . . . . . . . . 5E-36
Visual/Physical Inspection . . . . . . . . . . . . . . 5E-1 MCM 5.7L EFI Bravo WIth Cool
Basic Knowledge and Tools Required . . . . 5E-1 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 5E-37
Electrostatic Discharge Damage . . . . . . . . . 5E-1 MCM 350 MPI Bravo (Including Gen + Engines)
Diagnostic Information . . . . . . . . . . . . . . . . . 5E-2 With Vapor Separator Tank . . . . . . . . . . . . 5E-38
Wiring Harness Service . . . . . . . . . . . . . . . . 5E-2 MCM 350 MPI Gen+ Bravo With Cool
Wiring Connector Service . . . . . . . . . . . . . . . 5E-2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 5E-39
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-3 MIE 350 Magnum MPI Gen + Tournament
Changes In Terminology . . . . . . . . . . . . . . . . 5E-4 Ski (Black Scorpion) . . . . . . . . . . . . . . . . . . 5E-40
Diagnostic Trouble Codes . . . . . . . . . . . . . . 5E-4 MIE 350 Magnum EFI Gen + Tournament
ECM Self-Diagnostics . . . . . . . . . . . . . . . . . . . . . 5E-5 Ski / 5.7L Gen+ Inboard With Cool
Diagnostic Code Tool With Malfunction Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 5E-41
Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . 5E-5 Multi-Port Injection Wiring Diagram
Intermittent Malfunction Indicator (Chart 1 Of 4) . . . . . . . . . . . . . . . . . . . . . . . . 5E-42
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-5 Multi-Port Injection Wiring Diagram
Reading Codes . . . . . . . . . . . . . . . . . . . . . . . . 5E-5 (Chart 2 Of 4) . . . . . . . . . . . . . . . . . . . . . . . . 5E-43
Scan Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-6 Multi-Port Injection Wiring Diagram
EFI Diagnostic Circuit Check . . . . . . . . . . . . 5E-6 (Chart 3 Of 4) . . . . . . . . . . . . . . . . . . . . . . . . 5E-44
Scan Tool Use with Intermittents . . . . . . . . . 5E-6 Multi-Port Injection Wiring Diagram
Non-Scan Diagnosis of Driveability (Chart 4 Of 4) . . . . . . . . . . . . . . . . . . . . . . . . 5E-45
Concerns (With No Codes Set) . . . . . . . . . 5E-7 Throttle Body Injection Wiring Diagram
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-8 (Chart 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . 5E-46
Service Precautions . . . . . . . . . . . . . . . . . . . . 5E-9 Throttle Body Injection Wiring Diagram
Electronic Control Module (ECM) (Chart 2 Of 4) . . . . . . . . . . . . . . . . . . . . . . . . 5E-47
and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-10 Throttle Body Injection Wiring Diagram
General Description . . . . . . . . . . . . . . . . . . . 5E-10 (Chart 3 Of 4) . . . . . . . . . . . . . . . . . . . . . . . . 5E-48
Computers and Voltage Signals . . . . . . . . 5E-10 Throttle Body Injection Wiring Diagram
Analog Signals . . . . . . . . . . . . . . . . . . . . . . . 5E-10 (Chart 4 Of 4) . . . . . . . . . . . . . . . . . . . . . . . . 5E-49
Digital Signals . . . . . . . . . . . . . . . . . . . . . . . . 5E-11 Diagnostic Circuit Check . . . . . . . . . . . . . . . 5E-51
Engine Control Module (ECM) . . . . . . . . . . 5E-11 Scan Tool Normal Specifications
Speed Density System . . . . . . . . . . . . . . . . 5E-12 (Idle / Warm Engine / Closed
ECM Input and Sensor Descriptions . . . . . 5E-13 Throttle / Neutral) . . . . . . . . . . . . . . . . . . . . 5E-51
Spark Management . . . . . . . . . . . . . . . . . . . . . . 5E-18 No “Malfunction Indicator Lamp”
High Energy Ignition with Ignition (Marine Diagnostic Code
Control (IC) . . . . . . . . . . . . . . . . . . . . . . . . . 5E-18 Tool Installed) . . . . . . . . . . . . . . . . . . . . . . . 5E-54
Modes Of Operation . . . . . . . . . . . . . . . . . . 5E-18 No DLC Data or Will Not Flash Code 12
Distributor Module Mode . . . . . . . . . . . . . . . 5E-18 “Malfunction Indicator Lamp” On Steady
ECM Control Mode . . . . . . . . . . . . . . . . . . . 5E-18 (Marine Diagnostic Code Tool Installed)
Base Ignition Timing . . . . . . . . . . . . . . . . . . 5E-18 Chart A-2 (1 of 2) . . . . . . . . . . . . . . . . . . . . . 5E-56
Results of Incorrect Operation . . . . . . . . . . 5E-20 Engine Cranks but Will Not Run Chart A-3
Fuel Metering System . . . . . . . . . . . . . . . . . . . . 5E-20 (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-58
General Description . . . . . . . . . . . . . . . . . . . 5E-20 Multi-Port Injection Fuel System Diagnosis
Modes of Operation . . . . . . . . . . . . . . . . . . . 5E-20 Chart A-7 (1 of 6) . . . . . . . . . . . . . . . . . . . . . 5E-62
Throttle Body Injection Components . . . . . 5E-22 Throttle Body Injection Fuel System
Multi-Port Injection Components . . . . . . . . 5E-24 Diagnosis Chart A-7 (1 of 6) . . . . . . . . . . . 5E-68
Throttle Body Assembly . . . . . . . . . . . . . . . 5E-25 EFI System/Ignition Relay Check
ECM Connector and Symptom Charts . . . 5E-27 (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-74
ECM Connector and EFI Symptoms Chart Ignition System Check (1 of 2) . . . . . . . . . . 5E-76
(J-1 Circuits) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-28 Ignition System Check (2 of 2) . . . . . . . . . . 5E-78
ECM Connector and EFI Symptoms Chart Idle Air Control (IAC) Functional Test
(J-2 Circuits) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-31 (1 of2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-80
Multi Port Injector Balance Test . . . . . . . . . 5E-32 Lanyard Stop Circuit Check
Fuel Injector Balance Test Set-up (Emergency Stop) Circuit Check
(Multi-Port Injection) . . . . . . . . . . . . . . . . . . 5E-33 (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-82
Wiring Harness Diagrams . . . . . . . . . . . . . . . . 5E-34 Audio Warning Buzzer Circuit Check
MCM 5.7L EFI Alpha With Vapor (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-84
Separator Tank . . . . . . . . . . . . . . . . . . . . . . 5E-34 Discrete Input Circuit Check (Power
MCM 5.7L EFI Alpha With Cool Reduction Mode) (Non-Scan) (1 of 2) . . . 5E-86
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 5E-35
Index
5E-–2 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096
Page Page
Diagnostics-Without Scan Tool . . . . . . . . . . 5E-88 350 CID / 5.7L EFI (4 Barrel Throttle Body)
Code 14: Engine Coolant Temperature (ECT) Induction System . . . . . . . . . . . . . . . . . . . 5E-150
Sensor Circuit (Non-Scan) (1 of 2) . . . . . . 5E-88 Throttle Body . . . . . . . . . . . . . . . . . . . . . . . 5E-152
Code 21: Throttle Position (TP) Sensor Fuel Pressure Relief Procedure . . . . . . . 5E-153
Circuit (Non-Scan) (1 Of 2) . . . . . . . . . . . . 5E-90 Fuel Meter Cover Assembly . . . . . . . . . . . 5E-153
Code 33: Manifold Absolute Pressure (MAP) Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . 5E-154
Sensor Circuit (Non-Scan) (1 Of 2) . . . . . . 5E-92 Throttle Body . . . . . . . . . . . . . . . . . . . . . . . 5E-155
Code 42: Ignition Control (IC) Circuit Throttle Body Adapter Plate . . . . . . . . . . . 5E-156
(Non-Scan) (1 of 2) . . . . . . . . . . . . . . . . . . . 5E-94 Multi-Port Injection System Description . . . . 5E-157
Code 43: Knock Sensor (KS) (Non-Scan) Service Precautions . . . . . . . . . . . . . . . . . . . . 5E-157
(1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-96 Multi-Port Exploded Views . . . . . . . . . . . . . . . 5E-158
Code 51: Calibration Memory Failure Non-Scan Flame Arrestor and Throttle Body
Diagnostics (1 of 2) . . . . . . . . . . . . . . . . . . . 5E-98 (All Multi-Port Injection Engines Equipped
Diagnostics - Using Scan Tool (Scan) . . . 5E-100 Vapor Separator Tank) . . . . . . . . . . . . . . . 5E-158
Code 14 Engine Coolant Temperature 350 MPI Magnum Gen + Tournament Ski
(ECT) Sensor Circuit (Scan) (1 of 2) . . . 5E-100 (Black Scorpion) Induction System . . . . 5E-160
Code 21: Throttle Position (TP) Sensor Fuel Pressure Relief Procedure . . . . . . . 5E-161
Circuit (Scan) (1 of 2) . . . . . . . . . . . . . . . . 5E-102 Multi-Port Components . . . . . . . . . . . . . . . . . . 5E-161
Code 23: Intake Air Temperature (IAT) Flame Arrestor . . . . . . . . . . . . . . . . . . . . . . 5E-161
Sensor Circuit (Scan) (1 of 2) . . . . . . . . . 5E-104 Throttle Body . . . . . . . . . . . . . . . . . . . . . . . 5E-162
Code 33: Manifold Absolute Pressure (MAP) Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-164
Sensor Circuit (Scan) (1 of 2) . . . . . . . . . 5E-106 Pressure Regulator . . . . . . . . . . . . . . . . . . 5E-165
Code 42: Ignition Control (IC) Circuit Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . 5E-166
(Scan) (1 Of 2) . . . . . . . . . . . . . . . . . . . . . . 5E-108 Throttle Body Injection and Multi-Port
Code 43: Knock Sensor (KS) (Scan) Injection Sensor and Module
(1 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-110 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-167
Code 51: Calibration Memory Failure Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 5E-167
(Scan) (1 Of 2) . . . . . . . . . . . . . . . . . . . . . . 5E-112 Electronic Control Module (ECM) . . . . . . 5E-167
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 5E-114 Knock Sensor (KS) Module . . . . . . . . . . . 5E-168
Changes In Terminology . . . . . . . . . . . . . . 5E-114 Engine Coolant Temperature (ECT)
Diagnostic Trouble Codes . . . . . . . . . . . . 5E-114 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-169
Important Preliminary Checks . . . . . . . . . 5E-114 Throttle Body Injection Components-
Troubleshooting Charts . . . . . . . . . . . . . . . 5E-115 Manifold Absolute Pressure (MAP)
Fuel Delivery Systems . . . . . . . . . . . . . . . . . . 5E-136 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-170
Cool Fuel System Exploded View . . . . . . 5E-136 Throttle Position (TP) Sensor . . . . . . . . . . 5E-170
Vapor Separator Tank (VST) Exploded Idle Air Control (IAC) Valve . . . . . . . . . . . 5E-171
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-138 Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 5E-172
Torque Sequence For VST . . . . . . . . . . . . 5E-139 Multi-Port Injection Components-
VST Fuel Pump (Exploded View) . . . . . . 5E-140 Manifold Absolute Pressure
Vapor Separator Tank (VST) . . . . . . . . . . 5E-142 (MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . 5E-174
Float and Needle Assembly . . . . . . . . . . . 5E-143 Throttle Position (TP) Sensor . . . . . . . . . . 5E-175
Diaphragm Assembly . . . . . . . . . . . . . . . . 5E-144 Idle Air Control (IAC) Valve . . . . . . . . . . . 5E-176
Throttle Body Injection Repair Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 5E-177
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-146 Knock Sensor (KS) Module . . . . . . . . . . . 5E-177
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-146 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . 5E-179
Lubricants/Sealants/ Adhesives . . . . . . . . . . 5E-146 Ignition Control (IC) System Components . 5E-179
Torque Specifications . . . . . . . . . . . . . . . . . . . 5E-146 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 5E-179
Throttle Body Injection System Description . . . . . . Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . 5E-180
5E-147 Spark Plug Replacement . . . . . . . . . . . . . 5E-181
Service Precautions . . . . . . . . . . . . . . . . . . . . 5E-147
Throttle Body Exploded Views . . . . . . . . . . . 5E-148
350 CID / 5.7L EFI (2 Barrel Throttle Body)
Induction System . . . . . . . . . . . . . . . . . . . 5E-148
Index
90-823225--1 1096 ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) - 5E-–1
Index
5E-0 - ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) 90-823225--1 1096
General Information Visual/Physical Inspection
A careful visual and physical inspection must be
! CAUTION performed as part of any diagnostic procedure.
This can often lead to fixing a problem without
To reduce the chance of personal injury and/or further steps. Inspect all vacuum hoses for correct
property damage, the following instructions routing, pinches, cuts, or disconnects. Be sure to in-
must be carefully observed: proper service and spect hoses that are difficult to see. Inspect all the
repair are important to the safety of the service wires in the engine compartment for proper connec-
technician and the safe, reliable operation of all tions, burned or chafed spots, pinched wires, or con-
MerCruiser Electronic Fuel Injection (Multi-Port tact with sharp edges or hot exhaust manifolds. This
And Throttle Body) equipped engines. If part re- visual/physical inspection is very important. It must
placement is necessary, the part must be re- be done carefully and thoroughly.
placed with one of the same part number or with
an equivalent part. Do not use a replacement part
of lesser quality. The service procedures recom- Basic Knowledge and Tools Required
mended and described in this service manual are
effective methods of performing service and re- To use this manual most effectively, a general under-
pair. Some of these procedures require the use of standing of basic electrical circuits and circuit testing
tools specially designed for the purpose. Ac- tools is required. You should be familiar with wiring
cordingly, anyone who intends to use a replace- diagrams; the meaning of volts, ohms and amperes;
ment part, service procedure or tool, which is not the basic theories of electricity; and understand what
recommended by the system manufacturer, happens in an open or shorted wire. To perform sys-
must first determine that neither his safety nor tem diagnosis, several special tools and equipment
the safe operation of the engine will be jeopar- are required. Please become acquainted with the
dized by the replacement part, service procedure tools and their use before attempting to diagnose the
or tool selected. It is important to note that this system. Special tools which are required for system
manual contains various “Cautions” and service are listed later in this section (see “Table of
“Notes” that must be carefully observed in order Contents”).
to reduce the risk of personal injury during ser-
vice or repair, or the possibility that improper ser-
vice or repair may damage the engine or render Electrostatic Discharge Damage
it unsafe. It is also important to understand that
these “Cautions” and “Notes” are not exhaus- Electronic components used in control systems are
tive, because it is impossible to warn of all the often designed to carry very low voltage, and are very
possible hazardous consequences that might re- susceptible to damage caused by electrostatic dis-
sult from failure to follow these instructions. charge. It is possible for less than 100 volts of static
electricity to cause damage to some electronic com-
ponents. By comparison, it takes 4,000 volts for a
person to even feel the effect of a static discharge.
Introduction
There are several ways for a person to become stati-
The following manual has been prepared for effective cally charged. The most common methods of charg-
diagnosis of the MerCruiser Electronic Fuel Injection ing are by friction and by induction. An example of
system. charging by friction is a person sliding across a seat,
All information, illustrations and specifications con- in which a charge of as much as 25,000 volts can
tained in this manual are based on the latest product build up. Charging by induction occurs when a per-
information available at the time of publication ap- son with well-insulated shoes stands near a highly
proval. The right is reserved to make changes at any charged object and momentarily touches ground.
time without notice. Charges of the same polarity are drained off, leaving
the person highly charged with the opposite polarity.
An understanding of the material contained herein
Static charges of either type can cause damage;
and in subsequent publications issued when neces-
therefore, it is important to use care when handling
sary, will assist service personnel in properly main-
and testing electronic components.
taining the quality to which MerCruiser engine control
systems are built.
Index
90-823225--1 1096 ELECTRONIC FUEL INJECTION (MULTI-PORT AND THROTTLE BODY) - 5E-1
Diagnostic Information damaged. Always use jumper wires with the corre-
sponding mating terminals between connectors for
The diagnostic charts and functional checks in this circuit checking. NEVER probe through connector
manual are designed to locate a faulty circuit or com- seals, wire insulation, secondary ignition wires,
ponent through logic based on the process of elimi- boots, nipples or covers.
nation. The charts are prepared with the require-
ment that the system functioned correctly at the Microscopic damage or holes will result in eventual
time of assembly and that there are no multiple water intrusion, corrosion and/or component or cir-
failures. cuit failure.
WIRE REPAIR
Wiring Harness Service
1. Locate damaged wire.
Marine engine control circuits contain many special
2. Remove insulation as required.
design features not found in standard land vehicle
wiring. Environmental protection is used extensively
to protect electrical contacts and proper splicing
73048
methods must be used when necessary.
The proper operation of low amperage input/output 3. Splice two wires together using splice clips and
circuits depends upon good continuity between cir- rosin core solder.
cuit connectors. It is important before component re-
placement and/or during normal troubleshooting pro-
cedures that a visual inspection of any questionable 73048
mating connector is performed. Mating surfaces
should be properly formed, clean and likely to make 4. Cover splice with heat shrink sleeve to insulate
proper contact. Some typical causes of connector from other wires.
problems are listed below.
1. Improperly formed contacts and/or connector
housing. 73048
2. Damaged contacts or housing due to improper

engagement.
Wiring Connector Service
3. Corrosion, sealer or other contaminants on the
contact mating surfaces. Most connectors in the engine compartment are pro-
tected against moisture and dirt which could create
4. Incomplete mating of the connector halves dur-
oxidation and deposits on the terminals. This protec-
ing initial assembly or during subsequent trouble-
tion is important because of the very low voltage and
shooting procedures.
current levels found in the electronic system. The
5. Tendency for connectors to come apart due to connectors have a lock which secures the male and
vibration and/or temperature cycling. female terminals together. A secondary lock holds
6. Terminals not fully seated in the connector body. the seal and terminal into the connector.
7. Inadequate terminal crimps to the wire. When diagnosing, open circuits are often difficult to
locate by sight because oxidation or terminal mis-
Wire harnesses should be replaced with proper part alignment are hidden by the connectors. Merely wig-
number harnesses. When signal wires are spliced gling a connector on a sensor or in the wiring harness
into a harness, use the same gauge wire with high may locate the open circuit condition. This should al-
temperature insulation only. ways be considered when an open circuit or failed
With the low current and voltage levels found in the sensor is indicated. Intermittent problems may also
system, it is important that the best possible bond be be caused by oxidized or loose connections.
made at all wire splices by soldering the splices, as Before making a connector repair, be certain of the
shown in the following illustrations. Use care when type of connector. Some connectors look similar but
probing a connector or replacing connector termi- are serviced differently. Replacement connectors
nals. It is possible to short between opposite termi- and terminals are listed in the Parts Catalog.
nals. If this happens, certain components can be
Ensure that the connector seals are not deformed or
crushed when mating the connectors together.
Index
Abbreviations
BARO Barometric Pressure IGN Ignition
BAT Battery Positive Terminal, Battery or INJ Injection
System Voltage
kPa Kilopascal
B+ Battery Positive
KS Knock Sensor System
CKT Circuit
KV Kilovolts
CONN Connector
MAP Manifold Absolute
CYL Cylinder Pressure
DEG Degrees MIL Malfunction Indicator Lamp
DIAG Diagnostic mSec Millisecond
DIST Distributor N/C Normally Closed
DLC Data Link Connector N/O Normally Open
DTC Diagnostic Trouble Code PROM Programmable Read Only Memory
DVOM Digital Volt Ohm Meter RAM Random Access Memory
ECM Engine Control Module REF HI Reference High
ECT Engine Coolant REF LO Reference Low
Temperature
ROM Read Only Memory
EEPROM Electronic Erasable Programmable
Read Only Memory SLV Slave
HEI High Energy Ignition SW Switch
EMI Electromagnetic TACH Tachometer

Interference TERM Terminal
ENG Engine TP Throttle Position
GND Ground V Volts
GPH Gallons Per Hour VAC Vacuum
IAC Idle Air Control WOT Wide Open Throttle
IAT Intake Air Temperature in-hg Inches Of Mercury
IC Ignition Control
Index
Changes In Terminology
Due to industry standardization of terminology for certain electronic engine controls some names and abbrevi-
ations have changed.
From To
(CTS) Coolant Temperature Sensor (ECT) Engine Coolant Temperature
(TPS) Throttle Position Sensor (TP) Throttle Position
(MAT) Manifold Air Temperature (IAT) Intake Air Temperature
(EST) Electronic Spark Timing (IC) Ignition Control
(ESC) Electronic Spark Control (KS) Knock Sensor
(ALDL) Assembly Line Data Link (DLC) Data Link Connector
Diagnostic Trouble Codes
Code Number Code Description

Code 12 Ignition On - Engine Not Running
Code 14 (ECT) Engine Coolant Temperature
Code 21 (TP) Throttle Position Sensor
Code 23 (IAT) Intake Air Temperature
Code 33 (MAP) Manifold Absolute Pressure
Code 42 (IC) Ignition Control
Code 43 (KS) Knock Sensor
Code 51 Calibration Memory Failure
Index
ECM Self-Diagnostics An intermittent code may or may not reset. IF IT IS
AN INTERMITTENT FAILURE, A DIAGNOSTIC
The ECM performs a continual self-diagnosis on cer- CODE CHART IS NOT USED. Consult the “Diagnos-
tain control functions. This diagnostic capability is tic Aids” on the same page as the diagnostic code
complemented by the diagnostic procedures con- chart. “Troubleshooting” also covers the topic of “In-
tained in this manual. The ECM’s language for com- termittents.” A physical inspection of the applicable
municating the source of a malfunction is a system of sub-system most often will resolve the problem.
diagnostic codes. The codes are two digit numbers
that can range from 12 to 51. When a malfunction is
detected by the ECM, a code is set and the Malfunc- Reading Codes
tion Indicator Lamp is illuminated.
The provision for communicating with the ECM is the
Data Link Connector (DLC) connector. It is part of the
Diagnostic Code Tool With EFI engine wiring harness, and is a 10-pin connector,
which is electrically connected to the ECM. It is used
Malfunction Indicator Lamp in the assembly plant to receive information in check-
There are various manufacturers of Diagnostic Code ing that the engine is operating properly before it
Tools. Most Tools are equipped with a Malfunction In- leaves the plant. The code(s) stored in the ECM’s
dicator Lamp (MIL). memory can be read either through a scan tool, (a
diagnostic scanner that plugs into the DLC connec-
• It informs the service technician that a problem tor), or by counting the number of flashes of the Mal-
has occurred and that the vessel is in need of ser- function Indicator Lamp when the diagnostic code
vice as soon as reasonably possible. tool is installed and SERVICE mode is selected.
• It displays Codes stored by the ECM which help
the technician diagnose system problems.
As a bulb and system check, the lamp will come ON
with the key on and the engine not running. When the
engine is started, the light will turn OFF. If the lamp
remains ON, the self-diagnostic system has detected
a problem. If the problem goes away, the light will go
out in most cases after ten seconds, but a code will
remain stored in the ECM. 73053
When the lamp remains ON while the engine is run- DLC Connector
ning, or when a malfunction is suspected due to a
driveability problem, “EFI Diagnostic Circuit Check”
must be performed. These checks will expose mal- Once the diagnostic code tool has been connected,
functions which may not be detected if other diagnos- the ignition switch must be moved to the ON position,
tics are performed prematurely. with the engine not running. At this point, the Mal-
function Indicator Lamp should flash Code 12 three
times consecutively. This would be the following flash
Intermittent Malfunction Indicator sequence: flash, pause, flash-flash, long pause,
Lamp flash, pause, flash-flash, long pause, flash, pause,
flash-flash. Code 12 indicates that the ECM’s diag-
In the case of an intermittent problem, the Malfunc- nostic system is operating. If Code 12 is not indi-
tion Indicator Lamp will light for ten seconds and then cated, a problem is present within the diagnostic sys-
will go out. However, the corresponding code will be tem itself, and should be addressed by consulting the
stored in the memory of the ECM. When unexpected appropriate diagnostic chart in “Diagnostics.”
codes appear during the code reading process, one
can assume that these codes were set by an intermit- Following the output of Code 12, the Malfunction Indi-
tent malfunction and could be helpful in diagnosing cator Lamp will indicate a diagnostic code three times
the system. if a code is present, or it will simply continue to output
Code 12. If more than one diagnostic code has been
stored in the ECM’s memory, the codes will be output
from the lowest to the highest, with each code being
displayed three times.
Index
If a scan tool is used to read the codes, follow the EFI Diagnostic Circuit Check
After the visual/physical inspection, the EFI Diagnos-
SERVICE MODE tic Circuit Check is the starting point for all diagnostic
procedures. Refer to EFI Diagnostic Circuit Check.
When the diagnostic code tool is installed at the Data
Link Connector (DLC) and the selector switch is set The correct procedure to diagnose a problem is to fol-
at SERVICE, the system will enter what is called the low two basic steps.
SERVICE mode. In this mode the ECM will: 1. Are the on-board diagnostics working? This is
1. Display a Code 12 by flashing the Malfunction In- determined by performing the EFI Diagnostic Cir-
dicator Lamp (indicating the system is operating cuit Check. Since this is the starting point for the
correctly). diagnostic procedures, always begin here. If the
on-board diagnostics are not working, the EFI
2. Display any stored codes by flashing the Mal- Diagnostic Circuit Check will lead to a diagnostic
function Indicator Lamp. Each code will be chart in “Diagnostics” to correct the problem. If
flashed three times, then Code 12 will be flashed the on-board diagnostics are working correctly,
again. go to step 2.
3. The IAC valve moves to its fully extended posi- 2. If there is a code stored: If a code is stored, go di-
tion, blocking the idle air passage. This is impor- rectly to the numbered code chart in “Diagnos-
tant to remember, as an attempt to run the vessel tics.” This will determine if the fault is still present.
while in SERVICE mode will most likely result in
an abnormally low idle speed or a stalled engine.
4. Holds ignition advance steady. Scan Tool Use with Intermittents
The scan tool allows manipulation of wiring har-
NORMAL MODE
nesses or components with the engine not running,
Engines can be monitored in the normal mode. Cer- while observing the scan tool readout.
tain parameters can be observed without changing
The scan tool can be plugged in and observed while
the engine operating characteristics.
running the vessel under the condition when the Mal-
function Indicator Lamp turns ON momentarily or
when the engine driveability is momentarily poor. If
Scan Tools the problem seems to be related to certain parame-
The ECM can communicate a variety of information ters that can be checked on the scan tool, they should
through the DLC connector. This data is transmitted be checked while running the vessel. If there does
at a high frequency which requires a scan tool for in- not seem to be any correlation between the problem
terpretation. and any specific circuit, the scan tool can be checked
on each position, watching for a period of time to see
With an understanding of the data which the tool dis- if there is any change in the readings that indicates
plays, and knowledge of the circuits involved, the tool intermittent operation.
can be very useful in obtaining information which
would be more difficult or impossible to obtain with The scan tool is also an easy way to compare the op-
other equipment. erating parameters of a poorly operating engine with
those of a known good one. For example, a sensor
Scan tools do not make the use of diagnostic charts may shift in value but not set a trouble code. Compar-
unnecessary, nor can they indicate exactly where a ing the senor’s readings with those of the typical scan
problem is in a particular circuit. Tree charts incorpo- tool data readings may uncover the problem.
rate diagnosis procedures using a scan tool where
possible or a Diagnostic Code Tool (non-scan) if a The scan tool has the ability to save time in diagnosis
scan tool is unavailable. and prevent the replacement of good parts. The key
to using the scan tool successfully for diagnosis lies
in the technician’s ability to understand the system he
is trying to diagnose as well as an understanding of
the scan tool operation and limitations. The techni-
cian should read the tool manufacturer’s operating
manual to become familiar with the tool’s operation.
Index
CLEARING CODES USING DIAGNOSTIC CODE Non-Scan Diagnosis of Driveability
TOOL (NON-SCAN)
Concerns (With No Codes Set)
1. Install diagnostic code tool.
If a driveability concern still exists after following the
2. Turn key ON. diagnostic circuit check and reviewing “Trouble-
3. Select service mode on code tool. shooting,” an out-of-range sensor may be sus-
pected. Because of the unique design of the EFI sys-
4. To clear codes, move the throttle, while in neutral, tem, fail-safes have been incorporated into the ECM
from 0% to 100% then back to 0%. to replace a sensed value with a default value in the
5. Exit “Service Mode” on code tool. case of a sensor malfunction or sensor wiring con-
cern. By allowing this to occur, limited engine perfor-
6. Start engine and let run for fifteen seconds. mance is restored until the vessel is repaired. A basic
7. Turn key OFF for 5 seconds. understanding of sensor operation is necessary in or-
der to diagnose an out-of-range sensor.
8. Select “Service Mode” on code tool.
If the sensor is within its working or acceptable pa-
9. Turn key ON and read codes. If codes are still
rameters, as shown, the ECM does not detect a prob-
present, check note following and repeat from
lem. If the sensor should happen to fall out of this
Step 1.
“window,” a code will be stored. A known default val-
10. Refer to appropriate Troubleshooting and/or ue will replace the sensed value to restore engine
Diagnostic Charts. performance.
A poorly charged battery or engine cranking problem If the sensor is out of range, but still within the operat-
may result in an ECM “reset” and may not allow ing window of the ECM, the problem will go unde-
stored trouble codes to be cleared from EEPROM tected by the ECM and may result in trouble later.
memory. If this condition exists, BE SURE the battery
A good example of this would be if the coolant sensor
is fully charged.
was reading incorrectly and indicating to the ECM
NOTE: If a low battery condition does exists the au- that coolant temperature was at 20° F, but actual
dio warning buzzer will come on for 2 seconds after coolant temperature was 175° F. This would cause
engine start-up. the ECM to deliver more fuel than was actually need-
ed and result in an overly rich, rough running condi-
CLEARING CODES USING SCAN TOOL (SCAN) tion. This condition would not have caused a code to
set as the ECM interprets this as within its range.
1. Connect scan tool.
To identify a sensor which is out of range, unplug it
2. Start engine.
while running the engine. After approximately two
3. Select clear codes function. minutes, the diagnostic code for that sensor will set,
a code, and replace the sensed value with a default
4. Clear codes.
value. If at that point a noticeable performance in-
5. Turn key OFF. crease is observed, the non-scan code chart for that
6. Turn key ON and read codes. If codes are still particular sensor should be followed to correct the
present, (there is a real fault in system) check fol- problem.
lowing note and repeat Step 1. NOTE: Be sure to clear each code after disconnect-
NOTE: When clearing codes without the use of a ing and reconnecting each sensor. Failure to do so
scan tool, the battery must be fully charged. The abil- may result in a misdiagnosis of the problem.
ity to clear codes is directly dependent on the battery
being fully charged and able to start the engine with
adequate cranking RPM.
Index
Special Tools
Part Number Tool Name Description
Minimum 10 megohm input impedance required on
High Impedance Multi- all voltage ranges. As ammeter, accurately mea-
J-34029-A(Note 1)
meter (DVM) sures low value current flow. As ohmmeter, reads
0-200 ohms, 2/20/200 kΩ, 2/20 mΩ
Vacuum Pump with
Gauge monitors manifold engine vacuum. Hand
J-23738 Gauge - 20 In. Hg
pump used to check fuel pressure regulator
Minimum
Used to check circuit wiring, short to ground, or volt-
J-34142-B (Note 2) Unpowered Test Light
age.
Used to check ignition timing. Must have inductive
91-99379 Timing Light
signal pickup.
91-16850A-1 Fuel Pressure Gauge Used to check fuel system pressure.
Injector Harness Test Visually indicates injector electrical impulses from
J-34730-2A
Light the ECM.
91-823686A2 Quicksilver Scan Tool
Displays problem codes stored in the ECM. It also
84-822560A2 MERCRUISER Cable allows monitoring of various circuits and compo-
nents in the fuel injection system
system.
91-822608--1 MERCRUISER Cartridge
Displays problem codes stored in the ECM. It also
EFI Scan Tool/Injector allows monitoring of various circuits and compo-
94040M Tester nents in the fuel injection system. Allows for test fir-
(Rinda Technologies)
ing injectors.
Diagnostic Code Tool
94008 Flashes light to display problem codes
(Rinda Technologies)
J-35616 Harness Test Adapter Allows multi-meter connections with wiring harness.
91-805918 Fuel Shut Off Tool Used to perform fuel system pressure tests
91-805747A1 Timing Tool Jumper Plug Used to set Ignition timing. Plug connects to DLC
91-806901 Fuel Line Connector Allows connection of Fuel Pressure Gauge
NOTE 1: The High Impedance Multimeter that comes with the existing Outboard EFI Tester (91-11001A1) meets
the requirements listed above.
NOTE 2: Using a test light with 100 mA or less rating may show a faint glow when test actually states no light.
Kent-Moore Tools, Inc. Rinda Technologies
29784 Little Mack 4563 N. Elston Ave.
Roseville, MI 48066 Chicago, IL 60630
Phone: 800-345-2233 Phone: 312-736-6633
Index
Service Precautions (such as the high impedance digital multimeter)
in series with the test light being tested, and pow-
The following requirements must be observed: er the test light ammeter circuit with the vehicle
1. Before removing any ECM system component, battery.
disconnect the negative battery cable.
2. Never start the engine without the battery being
solidly connected.
3. Never separate the battery from the on-board
electrical system while the engine is running.
4. Never separate the battery feed wire from the
charging system while the engine is running.
5. When charging the battery, disconnect it from the
boat’s electrical system.
6. Ensure that all cable harnesses are connected
solidly and that battery connections are thor-
oughly clean.
7. Never connect or disconnect the wiring harness a
at the ECM when the ignition is switched ON.
b
8. Before attempting any electric arc welding, dis-
connect the battery leads and the ECM connec-
tor(s).
9. When steam cleaning engines, do not direct the
steam cleaning nozzle at ECM system compo-
nents. If this happens, corrosion of the terminals a - Test Light
or damage of components can take place. b - Battery
10. Use only the test equipment specified in the diag-
nostic charts, since other test equipment may ei- IMPORTANT: If the ammeter indicates LESS than
ther give incorrect results or damage good com- 3/10 amp. current flow (.3 A or 300 mA), the test light
ponents. is SAFE to use.
If the ammeter indicates MORE than 3/10 amp. cur-
11. All voltage measurements using a voltmeter re- rent flow (.3 A or 300 mA), the test light is NOT SAFE
quire a digital voltmeter with a rating of 10 meg- to use.
ohms input impedance.
NOTE: Using a test light with 100 mA or less rating
12. When a test light is specified, a “low-power” test may show a faint glow when test actually states no
light must be used. DO NOT use a high-wattage light.
test light. While a particular brand of test light is
not suggested, a simple test, as shown below, on 13. When using a DVOM to perform voltage mea-
any test light will ensure it to be safe for system surements, turn the ignition OFF when connect-
circuit testing. Connect an accurate ammeter ing the DVOM to the circuitry to be tested.
Index
Electronic Control Module THREE-WIRE SENSORS (MAP AND TP)
The following figure shows a schematic representa-
(ECM) and Sensors tion of a 3-wire sensor. All 3-wire sensors have a ref-
erence voltage, a ground and a variable “wiper.” The
lead coming off of the wiper will be the signal to the
General Description Engine Control Module (ECM). As this wiper position
The MerCruiser Electronic Fuel Injection system is changes, the signal voltage returned to the computer
equipped with a computer that provides the operator also changes.
with state-of-the-art control of fuel and spark delivery.
Computers use voltage to send and receive informa-
tion.
Computers and Voltage Signals

Voltage is electrical pressure. Voltage does not flow
in circuits. Instead, voltage causes current. Current
does the real work in electrical circuits. It is current,
the flow of electrically charged particles, that ener-
gizes solenoids, closes relays and lights lamps.
3-Wire Sensor
Besides causing currents in circuits, voltage can be
used as a signal. Voltage signals can send informa- TWO-WIRE SENSORS (ECT AND IAT)
tion by changing levels, changing waveform (shape),
or changing the speed at which the signal switches The following figure is the schematic of a 2-wire type
from one level to another. Computers use voltage sensor. This sensor is basically a variable resistor in
signals to communicate with one another. The differ- series with a fixed-known resistor within the comput-
ent sections inside computers also use voltage sig- er. By knowing the values of the input voltage and the
nals to communicate with each other. voltage drop across the known resistor, the value of
the variable resistor can be determined. The variable
There are two kinds of voltage signals, analog and resistors that are commonly used are called thermis-
digital. Both of these are used in computer systems. tors. A thermistor’s resistance varies inversely with
It’s important to understand the difference between temperature.
them and the different ways they are used.
Analog Signals
An analog signal is continuously variable. This
means that the signal can be any voltage within a cer-
tain range. An analog signal usually gives informa-
tion about a condition that changes continuously over
a certain range. For example, in a marine engine,
temperature is usually provided by an analog signal.
There are two general types of sensors that produce
analog signals: the 3-wire and the 2-wire sensor.
2-Wire Sensor
Index
Digital Signals SWITCH TYPES
Digital signals are also variable, but not continuously. Switched inputs (also known as discretes) to the
They can only be represented by distinct voltages computer can cause one bit to change, resulting in in-
within a range. For example, 1 V, 2 V or 3 V would be formation being communicated to the computer.
allowed, but 1.27 V or 2.65 V would not. Digital sig- Switched inputs can come in two types: they are
nals are especially useful when the information can “pull-up” and “pull-down” types. Both types will be
only refer to two conditions - “YES” and “NO,” “ON” discussed.
and “OFF,” or “High” and “Low.” This would be called With a pull-up type switch, the ECM will sense a volt-
a digital binary signal. A digital binary signal is limited age when the switch is CLOSED. With the pull-down
to two voltage levels. One level is a positive voltage, switch, the ECM recognizes the voltage when the
the other is no voltage (zero volts). As you can see switch is OPEN.
in the following figure, a digital binary signal is a
square wave. Discretes can also be used to inform a computer of
FREQUENCY information.
PULSE COUNTERS
For the computer to determine frequency information
HI ON YES from a switched input, the computer must measure
the time between voltage pulses. As a number of
pulses are recorded in a set amount of time, the com-
LO OFF NO
puter can calculate the frequency. The meaning of
the frequency number can have any number of
meanings to the computer.
Digital Binary Signal
An example of a pulse counter type of input is the dis-
tributor reference pulse input. The computer can
The computer uses digital signals in a code that con- count a train of pulses, a given number of pulses per
tains only ones and zeros. The high voltage of the engine revolution, and determine the RPM of the en-
digital signal represents a one (1), and no voltage gine.
represents a zero (0). Each zero and each one is
called a bit of information, or just a “bit.” Eight bits to-
gether are called a “word.” A word, therefore, con- Engine Control Module (ECM)
tains some combination of eight binary code bits:
eight ones, eight zeros, five ones and three zeros, The Engine Control Module (ECM) is the control cen-
and so on. ter of the fuel injection system. It constantly monitors
information from various sensors, and controls the
Binary code is used inside a computer and between
systems that affect engine performance.
a computer and any electronic device that under-
stands the code. By stringing together thousands of The ECM also performs a diagnostic function check
bits, computers can communicate and store an infi- of the system. It can recognize operational problems
nite variety of information. To a computer that under- and store a code or codes which identify the problem
stands binary, 11001011 might mean that it should re- areas to aid the technician in making repairs.
set engine RPM at a lower level. Although the
computer uses 8-bit digital codes internally and when
talking to another computer, each bit can have a
meaning.
72801
Electronic Control Module (ECM)
Index
ECM FUNCTION SPEED
The ECM supplies 5 or 12 volts to power various sen- The engine speed signal comes from the distributor’s
sors or switches. This is done through resistances in High Energy Ignition (HEI) module to the ECM on the
the ECM which are so high in value that a test light distributor reference high circuit. The ECM uses this
will not light when connected to the circuit. In some information to determine the “speed” or RPM factor
cases, even an ordinary shop voltmeter will not give for fuel and ignition management.
an accurate reading because its resistance is too low.
Therefore, the use of a 10 megohm input imped- DENSITY
ance digital voltmeter is required to assure accu-
Two sensors contribute to the density factor, the In-
rate voltage readings.
take Air Temperature (IAT) [Multi-Port models only]
and the Manifold Absolute Pressure (MAP) sensors.
MEMORY
The IAT sensor is a 2-wire sensor that measures the
There are three types of memory storage within the
temperature of the air entering the intake manifold.
ECM: ROM, RAM and EEPROM.
The IAT sensor is a thermistor that changes its resis-
tance depending on the air temperature. When the
ROM temperature is low, the resistance is high, and when
Read Only Memory (ROM) is a permanent memory the temperature is high, the resistance is low.
that is physically soldered to the circuit boards within The Manifold Absolute Pressure (MAP) sensor is a
the ECM. The ROM contains the overall control pro- 3-wire sensor that monitors the changes in intake
grams. Once the ROM is programmed, it cannot be manifold pressure which results from changes in en-
changed. The ROM memory is non-erasable, and gine loads. These pressure changes are supplied to
does not need power to be retained. the ECM in the form of electrical signals.
RAM As intake manifold pressure increases (vacuum de-
creases), the air density in the intake manifold also
Random Access Memory (RAM) is the microproces- increases, and additional fuel is required.
sor “scratch pad.” The processor can write into, or
read from, this memory as needed. This memory is The MAP sensor sends this pressure information to
erasable and needs a constant supply of voltage to the ECM, and the ECM increases the amount of fuel
be retained. injected by increasing the injector pulse width. As
manifold pressure decreases (vacuum increases),
EEPROM the amount of fuel is decreased.
Electronic Erasable Programmable Read Only These three inputs MAP, IAT and RPM are the major
Memory (EEPROM) is the portion of the ECM that determinants of the air/fuel mixture, delivered by the
contains the different engine calibration information fuel injection system.
that is specific to each marine application. The remaining sensors and switches provide electri-
cal inputs to the ECM which are used for modification
of the air/fuel mixture, as well as for other ECM con-
Speed Density System trol functions, such as Idle Air Control (IAC).
The Electronic Fuel Injection system is a speed and
air density system. The system is based on “speed/
density” fuel management.
Three specific data sensors provide the ECM with the
basic information for the fuel management portion of
its operation. That is, three specific signals to the
ECM establish the engine speed and air density fac-
tors.
Index
ECM Input and Sensor Descriptions
The following lists the sensors, switches, and other inputs used by the ECM to control its various systems. Al-
though we will not cover them all in great detail, there will be a brief description of each.
DISCRETE SWITCHES
(AUDIO WARNING)
KNOCK KNOCK
MODULE SENSOR
SYSTEM DIST.
RELAY FOR ECT IAT
REF RPM TP MAP
INPUTS
ECM
OUTPUTS
FUEL IGNITION IAC FUEL

PUMP CONTROL MOTOR INJECTORS
RELAY MODULE
FUEL AUDIO
PUMP WARNING
BUZZER
SERIAL
DATA
Index
ENGINE COOLANT TEMPERATURE (ECT) The ECM supplies a 5 volt signal to the sensor
SENSOR through a resistor in the ECM and measures the volt-
age. The voltage will be high when the intake air is
The Engine Coolant Temperature (ECT) Sensor is a
cold, and low when the intake manifold air is hot.
thermistor (a resistor which changes value based on
temperature) immersed in the engine coolant A failure in the IAT sensor circuit should set a Code
stream. Low coolant temperature produces a high re- 23.
sistance, while high temperature causes low resis-
tance. MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR
The Manifold Absolute Pressure (MAP) sensor is a
b pressure transducer that measures the changes in
the intake manifold pressure. The pressure changes
as a result of engine load and speed change, and the
MAP sensor converts this to a voltage output.
a 73052
c
a - Engine Coolant Temperature (ECT) Sensor
b - Harness Connector
c - Locking Tab
a
The ECM supplies a 5 volt signal to the ECT through
a resistor in the ECM and measures the voltage. The
voltage will be high when the engine is cold, and low
when the engine is hot. By measuring the voltage, the
ECM knows the engine coolant temperature. Engine b
coolant temperature affects most systems the ECM 73046
controls.
A failure in the ECT circuit should set Code 14. Re- a - Manifold Absolute Pressure (MAP) Sensor
member, this code indicates a failure in the coolant b - Electrical Connector
temperature sensor circuit, so proper use of the chart
will lead to either repairing a wiring problem or replac- A closed throttle on engine coast-down would pro-
ing the sensor. duce a relatively low MAP output voltage, while a
wide open throttle would produce a high MAP output
INTAKE AIR TEMPERATURE (IAT) SENSOR voltage. This high output voltage is produced be-
[MULTI-PORT INJECTION MODELS ONLY] cause the pressure inside the manifold is the same
as outside the manifold, so 100% of outside air pres-
The Intake Air Temperature (IAT) sensor is a thermis- sure is measured. When manifold pressure is high,
tor (a resistor which changes value based on temper- vacuum is low. The MAP sensor is also used to mea-
ature) mounted on the underside of the plenum. Low sure barometric pressure under certain conditions,
temperature produces a high resistance, while high which allows the ECM to automatically adjust for dif-
temperature causes a low resistance. ferent altitudes.
c The ECM sends a 5 volt reference signal to the MAP
sensor. As the manifold pressure changes, the elec-
b trical resistance of the MAP sensor also changes. By
monitoring the sensor output voltage, the ECM
knows the manifold pressure. A higher pressure, low
vacuum (high voltage) requires more fuel, while a
a
lower pressure, higher vacuum (low voltage) re-
quires less fuel. The ECM uses the MAP sensor to
73047 control fuel delivery and ignition timing.
a - Intake Air Temperature (IAT) Sensor

A failure in the MAP sensor circuit should set a Code
b - Harness Connector 33.
c - Locking Tab
Index
KNOCK SENSOR It is extremely important that the correct KS sensor
and module be used for the engine application. Using
The knock sensor is mounted on the lower right side
an incorrect KS module will result in unrecognized
of the engine block.
spark knock and engine damage. The KS module ter-
minal B is powered by 12 volts from the ignition
switch thru system relay. If the 12 volt power source
is not present, the KS module cannot send an 8-10
volt signal to the ECM and a false constant spark re-
tard will result. A code 43 will be set.
Terminal E of the KS module is the signal line from the
knock sensor. If this circuit opens or shorts to ground,
the KS module will never remove the 8-10 volt signal
from terminal C to the ECM and no spark retard will
occur. The ground circuit for the KS module is con-
nected to terminal D. If the ground circuit opens, the
KS module will not be able to remove the 8-10 volt
73051 signal to the ECM and spark knock cannot be con-
trolled.
When abnormal engine vibrations (spark knock) are On certain models (1996 And older engines only),
present, the sensor produces a voltage signal which the ECM will do a self test when the following condi-
is sent to the KS Module and then to the ECM. The tions are reached:
ECM uses this signal to aid in calculating ignition tim-
ing. • Engine temperature above 150° F (66° C).
• Engine RPM above 4000 RPM.
KNOCK SENSOR (KS) MODULE
• 5.024 Hg in. (80 kPa) manifold pressure
The KS module contains solid state circuitry which
monitors the knock sensor’s AC voltage signal and THROTTLE POSITION (TP) SENSOR
then supplies an 8-10 volt signal, if no spark knock is
present, to the ECM. If spark knock is present, the KS The Throttle Position (TP) Sensor is a potentiometer
module will remove the 8-10 volt signal to the ECM. connected to the throttle shaft on the throttle body.
The TP has one end connected to 5 volts from the
b ECM and the other to ECM ground. A third wire is
c connected to the ECM to measure the voltage from
the TP. As the throttle valve angle is changed, the
voltage output of the TP also changes. At a closed
throttle position, the voltage output of the TP is low
a
(approximately .5 volt). As the throttle valve opens,
e the output increases so that at wide-open-throttle
(W.O.T.), the output voltage should be near 4.5 volts.
By monitoring the output voltage from the TP, the
ECM can determine fuel delivery based on throttle
valve angle (driver demand). A broken or loose TP
d can cause intermittent bursts of fuel from the injector
and an unstable idle, because the ECM thinks the
Knock Sensor System throttle is moving.
a - Electronic Control Module (ECM)
b - 12 Volts Battery Positive
c - 8-12 Volts
d - Knock Sensor
e - Knock Sensor Module
73049
Index
If the TP circuit is open, the ECM will set a Code 21. Switches which are used with the Fuel Injection sys-
If the TP circuit is shorted, and a trouble Code 21 will tem to detect critical engine operation parameters
be set. A problem in any of the TP circuits will set a are:
Code 21. Once a trouble code is set, the ECM will use
a default value for TP. Switch Normal State
Oil Pressure N/O
DISTRIBUTOR REFERENCE (DIST REF)
I/O Fluid Level on Stern N/O
The distributor reference (engine speed signal) is Drive
supplied to the ECM by way of the “Dist Ref Hi” line Transmission Temperature
from the High Energy Ignition (HEI). This pulse N/O
on MIE Models
counter type input creates the timing signal for the
pulsing of the fuel injectors, as well as the Ignition Engine Coolant Temperature N/O
Control (IC) functions. This signal is used for a num-
IMPORTANT: Models equipped with multiple en-
ber of control and testing functions within the ECM.
gines must use dual engine data link kit and com-
mon ground between engine blocks. Otherwise
DISCRETE SWITCH INPUTS - POWER there will be no serial data communication be-
REDUCTION MODE tween engines and the power reduction mode
(1996 AND OLDER MODELS) will not control both engines.
Several discrete switch inputs are utilized by the sys- • Triple (three) engine applications should connect
tem to identify abnormal conditions that may affect the outboard engines.
engine operation. Pull-down switches are used in
conjunction with the ECM to detect critical conditions • Quad (four) engine applications Should link the
to engine operation. outer two outboard engines with one link and the
two inboard engines with another link.
If a switch changes state from its normal at rest posi-
tion, that is normally open to closed, the ECM senses
a change in voltage and responds by entering power
reduction mode.
This engine protection feature allows the operator full
engine power up to 2800 RPM, but disables half of
the fuel injectors above 2800 RPM until the engine
RPM drops to 1200 RPMS.
This feature allows the operator a comfortable ma-
neuvering speed while removing the possibility of
high RPM engine operation until the problem is cor-
rected.
Index
Index
Spark Management Distributor Module Mode
The following describes IC operation during cranking
High Energy Ignition with Ignition and when the engine starts running. To help under-
stand how IC circuits operate, a relay with a double
Control (IC)
set of contact points is shown in the IC module (refer
The Electronic Fuel Injection is controlled by an En- to the figures “Ignition Control Mode” and “ECM Con-
gine Control Module (ECM). This module is the trol Mode”). Solid state circuitry is used in the module,
nerve/decision center of the system. It uses all the in- but showing the relay makes it easier to visualize how
formation it gathers to manage ignition spark, deliver- the IC module functions.
ing increased fuel economy and maximum engine During cranking, the relay is in the de-energized posi-
performance. tion (see figure “Distributor Module Mode”). This con-
The system uses inputs from sensors to make deci- nects the pickup coil to the base of the transistor via
sions on the amount of spark advance or retard al- the signal converter. When the pickup coil applies a
lowed. positive voltage to the transistor, the transistor turns
ON. When voltage is removed, the transistor turns
The system has been designed to control ignition ad-
OFF. When the transistor turns ON, current flows
vance and retard electronically by the ECM.
through the primary winding of the ignition coil. When
In order for the ECM to properly calculate spark ad- it turns OFF, the primary current stops and a spark is
vance, it must always know at what speed the engine developed at the spark plug. A small amount of ad-
is running. The engine speed signal is accomplished vance is built into the IC module via a timing circuit,
by a circuit within the distributor module which con- in case the engine remains in the ignition module tim-
verts the pickup coil voltage to a square wave refer- ing mode.
ence signal that can be used by the ECM. This
With the relay de-energized, a set of contacts (shown
square wave engine speed reference signal is known
closed) would ground the IC line signal.
as REF HI. The ECM must also have something to
compare the REF HI value against. Therefore, an
additional line is provided between the ECM and the
ECM Control Mode
distributor module that is known as REF LO. These When the engine RPM reaches a predetermined val-
two lines, between the ECM and the distributor, pro- ue (for this example, 300 RPM), the ECM considers
vide a precise indication of engine speed. the engine running and applies five volts on the by-
The two other lines between the ECM and distributor pass line to the IC module. This energizes the relay
which control the Ignition Control (IC) operation are and causes the contacts from the pickup coil as well
known as the bypass and IC circuits. as the grounding contacts for the IC line to open (see
figure “ECM Control Mode”). This connects the IC
line to the base of the transistor, and bypasses the
Modes Of Operation ignition module timing control.
There are two modes of ignition system operation: The IC system is now controlled by the IC signal from
the ECM and the time at which the spark occurs can
DISTRIBUTOR MODULE MODE be determined by a variable time circuit in the ECM.
The ignition system operates independent of the
ECM. The distributor module module in the distribu- Base Ignition Timing
tor maintains a base ignition timing and is able to ad-
In order to check or change base timing on a HEI sys-
vance timing to a total of 27 degrees. This mode is in
tem the ECM has to be entered into the service mode
control when a Code 42 is detected while engine is
by using a scan tool or code tool. The IC module will
running and will have a noticeable affect on engine
go to base timing. The ECM will stabilize timing to al-
operation.
low timing adjustment. The ECM incorporates a
ECM CONTROL MODE spark control override, which allows timing to be low-
ered if spark knock (detonation) is encountered dur-
The ECM control mode controls the ignition timing. ing normal operation. At this time, the timing can be
The ECM calculates the desired ignition timing based adjusted by turning the distributor.
on information it gets from its input sensors.
Index
TRANSISTOR
BASE
MODULE
ADVANCE
IC
Distributor Module Mode
Module
Advance
IC
ECM Control Mode
Index
Results of Incorrect Operation Open or Grounded REF HI Line - This line provides
the ECM with engine speed information. If this line is
Open IC Line from the ECM to the Distributor open or grounded, the ECM will not know that the en-
Module - While the engine is cranking, the ECM ex- gine is cranking or running and will not run.
pects to see the IC signal pulled to virtually zero be-
cause it is grounded in the distributor module. Since Open or Grounded REF LO Line - This wire is
the IC line is open, it cannot be grounded by the mod- grounded in the ignition module and provides a refer-
ule and the IC signal will be able to rise and fall, or do ence ground from the ignition module to the ECM.
what is called toggling. The ECM recognizes the tog- The ECM compares reference ground with reference
gling as an abnormal condition, and will not apply by- high voltage. If this circuit is open, or grounded at any
pass voltage to the distributor module when the en- other location than through the module, it may cause
gine reaches run RPM. poor performance.
Since bypass voltage is not applied to the relay, it re-

mains open and the engine continues to run on the
pickup coil triggering in the ignition module timing Fuel Metering System
mode.
If this condition occurs while the engine is running,
the engine will stop, but it will restart and run in the
General Description
ignition module timing mode with reduced power. The function of the fuel metering system is to deliver
Grounded IC Line - During cranking, the IC voltage the correct amount of fuel to the engine under all op-
is at virtually zero so the ECM does not recognize a erating conditions.
problem. When engine RPM reaches the value for Multi-Port Injection, fuel is delivered to the engine
the run condition, the ECM applies bypass voltage to by individual fuel injectors mounted in the intake
the distributor module. Bypass voltage on the module manifold near each cylinder.
switches the distributor power transistor to the IC Throttle Body Injection, fuel is delivered from two
line. Because the IC line is grounded, it will have no injectors mounted atop the intake manifold.
voltage applied so it cannot operate the power tran-
sistor to enter the IC mode.
Modes of Operation
If the IC line becomes grounded while the engine is
being operated, the engine will stop and will be diffi- The ECM looks at voltages from several sensors to
cult to restart. determine how much fuel to give the engine. The fuel
is delivered under one of several conditions, called
An open or ground in the IC or bypass will cause the
modes. All the modes are controlled by the ECM and
engine to run on the distributor module timing. This
are described below.
will cause reduced performance, poor fuel economy
and erratic idle.
STARTING MODE
Grounded or Open Bypass Line - While the engine
When the ignition switch is turned to the crank posi-
is cranking, the IC line will be grounded and the ECM
tion, the ECM turns ON the fuel pump relay and the
will not notice anything abnormal. When run RPM is
fuel pump builds up pressure. The ECM then checks
reached, the ECM applies bypass voltage to the by-
the Engine Coolant Temperature (ECT) sensor and
pass line but because of the ground or open, it will not
Throttle Position (TP) sensor and determines the
be able to energize the relay. Therefore, the relay will
proper air/fuel ratio for starting. The ECM controls the
stay de-energized and the IC line will remain
amount of fuel delivered in the starting mode by
grounded.
changing how long the injectors are turned ON and
When the ECM sees the IC line not toggling, it will not OFF. This is done by pulsing the injectors for very
enter the IC mode. Since the relay is de-energized, short times.
the engine will continue to run in the ignition module
timing mode.
If this condition occurs while the engine is running,
the engine will simply operate in the ignition module
timing mode.
Index
CLEAR FLOOD MODE POWER REDUCTION MODE
(1996 AND OLDER MODELS)
If the engine floods, it can be cleared by opening the
throttle half way (50%). (Open throttle handle until re- The ECM will go into power reduction mode when the
sistance from secondary throttle [Multi-Port only] is following conditions are met:
felt.) The ECM discontinues fuel injector pulsation as
1. Low oil pressure
long as the throttle is between 50 to 75 % and the en-
gine RPM is below 300. If the throttle position be- 2. Engine overheat
comes more than 75% or less than 50%, the ECM re- 3. Low I/O fluid level (MCM)
turns to the starting mode.
4. High transmission temperature (MIE)
RUN MODE The ECM recognizes change of state in a discrete
When the engine is started and RPM is above 300, switch input that identifies an abnormal condition that
the system operates in the run mode. The ECM will may affect proper drive train operation.
calculate the desired air/fuel ratio based on these As an engine protection feature, power reduction
ECM inputs: RPM, Manifold Absolute Pressure mode allows normal fuel injection up to 2800 RPM.
(MAP) sensor, Intake Air Temperature (IAT) sensor Above 2800 RPM, fuel delivery is limited to half of the
and Engine Coolant Temperature (ECT) sensor. injectors until RPM lowers to 1200 RPM when normal
Higher engine load (from MAP) and colder engine fuel injection resumes.
temperature (from ECT) requires more fuel, or a rich-
er air/fuel ratio. This feature maintains maneuverability of the vessel
while removing the possibility of high RPM operation
until the problem is corrected.
ACCELERATION MODE
The ECM looks at rapid changes in Throttle Position DECELERATION MODE
(TP) and provides extra fuel by increasing the injector
pulse width. The IAC is similar to a carburetor dashpot. It provides
additional air when the throttle is rapidly moved to the
idle position to prevent the engine from dying.
FUEL CUTOFF MODE
No fuel is delivered by the injectors when the ignition
is OFF, to prevent dieseling. Also, fuel pulses are not
delivered if the ECM receives no distributor reference
pulses, which means the engine is not running. The
fuel cutoff mode is also enabled at high engine RPM,
as an overspeed protection for the engine. When cut-
off is in effect due to high RPM, injection pulses will
resume after engine RPM drops slightly.
Index
Throttle Body Injection Components THROTTLE BODY UNIT EXPLODED VIEW
FUEL PUMP ELECTRICAL COMPONENTS
When the ignition switch is turned to the RUN posi-

tion, the ECM will turn ON the fuel pump relay for two
seconds.
d
When the ignition switch is turned to the crank posi-
tion, the ECM turns the fuel pump relay ON causing
e
the fuel pump to start.
If the ECM does not receive ignition reference pulses
(engine cranking or running), it shuts Off the fuel
pump relay, causing the fuel pump to stop. g
THROTTLE BODY UNIT
The throttle body unit consists of three assemblies.

• Fuel meter cover and fuel damper
f
• Fuel meter body and fuel injectors
• Throttle Body
-Two Throttle Valves To Control Air Flow
Into The Engine
-Idle Air Control (IAC) Valve
-Throttle Position (Tp) Sensor
73766
a -Throttle Body
b -Idle Air Control (IAC) Valve
c -
Throttle Position (TP) Sensor
d -
Fuel Meter Cover
e -
Fuel Damper (Cool Fuel) Or Fuel Pressure Regulator
(VST Equipped)
f - Fuel Meter Body
g - Fuel Injector (2)
Index
FUEL INJECTORS FUEL DAMPER (COOL FUEL SYSTEM ONLY)
The injector assembly is a solenoid operated device, The fuel damper acts as an equalization device to re-
controlled by the ECM, that meters pressurized fuel duce the pressure spikes caused by the fuel injec-
to the intake manifold. The ECM energizes the injectors.
tor solenoid, which opens a ball valve, allowing fuel
to flow past the ball valve, and through a recessed
flow director plate.
The director plate has six machined holes that control
the fuel flow, generating a conical spray pattern of
finely atomized fuel at the injector tip. Fuel is directed
at the throttle, causing it to become further atomized
before entering the intake manifold.
a
73766
a
a - Fuel Damper
b IDLE AIR CONTROL (IAC) VALVE

c
The purpose of the IAC valve assembly is to control
engine idle speed, while preventing stalls due to
changes in engine load. The IAC valve, mounted in
d
the throttle body, controls bypass air around the
throttle valves.
73773
a - Fuel Injector
b - Fuel Filter
c - Seal Ring
d - Fuel Meter Body
72800
FUEL PRESSURE REGULATOR
(VST EQUIPPED ONLY)
The pressure regulator is a diaphragm-operated
relief valve with fuel pump pressure on one side, and
regulator spring pressure and intake manifold
vacuum on the other. The regulator’s function is to
maintain a constant pressure differential across the
injectors at all times. The pressure regulator
compensates for engine load by increasing fuel
pressure as engine vacuum drops.
a IAC Valve Air Flow Diagram

73766
a - Fuel Pressure Regulator
Index
By moving a conical valve known as a pintle, IN, to- Multi-Port Injection Components
ward the seat (to decrease air flow), or OUT, away
from the seat (to increase air flow), a controlled FUEL PUMP ELECTRICAL CIRCUIT
amount of air moves around the throttle valve. If RPM
is too low, more air is bypassed around the throttle When the ignition switch is turned to the RUN posi-
valve to increase it. If RPM is too high, less air is by- tion, the ECM will turn ON the fuel pump relay for two
passed around the throttle valve to decrease it. (2) seconds.
The ECM moves the IAC valve in small steps, called When the ignition switch is turned to the crank posi-
counts. These can be measured by scan tool test tion, the ECM turns the fuel pump relay ON causing
equipment, which plugs into the DLC. the fuel pump to start.
During idle, the proper position of the IAC valve is If the ECM does not receive ignition reference pulses
based on engine RPM. If the RPM drops below speci- (engine cranking or running), it shuts OFF the fuel
fication and the throttle valve is closed, the ECM pump relay, causing the fuel pump to stop.
senses a near stall condition and calculates a new
valve position to prevent stalling. FUEL RAIL/INTAKE MANIFOLD ASSEMBLY
• Engine idle speed is a function of total air flow into The fuel rail performs several functions. It positions
the engine based on IAC valve pintle position + the injectors in the intake manifold, distributes fuel
throttle valve stop screws and PCV. evenly to the injectors, and integrates the fuel pres-
sure regulator into the fuel metering system.
• “Controlled” idle speed is programmed into the
ECM, which determines the correct IAC valve
pintle position to maintain the desired idle speed a
for all engine operating conditions and loads.
• The minimum idle air rate is set at the factory with
stop screws. This setting allows enough air flow
by the throttle valves to cause the IAC valve pintle
to be positioned a calibrated number of steps
(counts) from the seat during “controlled” idle op-
eration.
• If the IAC valve is disconnected and reconnected
with the engine running, the idle speed may be
wrong. In this case, the IAC valve can be reset by
doing the following: turn off engine, wait ten se-
conds, and restart engine. b
a - Fuel Rail
b - Fuel Injector
c - Intake Manifold
Index
FUEL INJECTORS PRESSURE REGULATOR ASSEMBLY
The EFI injector assembly is a solenoid-operated de- The pressure regulator is a diaphragm-operated re-
vice, controlled by the ECM, that meters pressurized lief valve with fuel pump pressure on one side, and
fuel to a single engine cylinder. The ECM grounds the regulator spring pressure and intake manifold vacu-
injector solenoid, which opens a pintle valve, allow- um on the other. The regulator’s function is to main-
ing fuel to flow past the pintle valve. The injector tip tain a constant pressure differential across the injec-
has holes that control the fuel flow, generating a coni- tors at all times. The pressure regulator
cal spray pattern of finely atomized fuel at the injector compensates for engine load by increasing fuel pres-
tip. Fuel is directed at the intake valve, causing it to sure as engine vacuum drops.
become further atomized and vaporized before en-
tering the combustion chamber.
An injector that is stuck partly open will cause loss of
pressure after engine shutdown. This can result in
long cranking times. Dieseling can also occur, be-
cause some fuel might be delivered to the engine af-
ter the ignition is turned OFF.
71716
s r
q
Throttle Body Assembly
p The throttle body assembly is attached to the ple-
num, and is used to control air flow into the engine,
o thereby controlling engine output. The throttle valves
within the throttle body are opened by the operator
through the accelerator controls. During engine idle,
n
l the throttle valves are almost closed, and air flow
m control is handled by the Idle Air Control (IAC) valve,
k
J described below.
i The throttle body also provides the location for
g mounting the Throttle Position (TP) sensor for sens-
h ing throttle valve position.
f d
e
a
b c
a 72970
a - Needle Valve
b - Nozzle
c - Cap
d - O-Ring
e - Valve Stopper b
f - Core
g - O-Ring c
h - Spring
72800
i - Housing
j - Solenoid Coil a - Throttle Body
k - Tape b - Idle Air Control (IAC) Valve
l - Bobbin c - Throttle Position Sensor
m- O-Ring
n - Inner Collar
o - Sleeve
p - Terminal
q - Connector
r - Filter
s - O-Ring
Index
IDLE AIR CONTROL (IAC) VALVE • If the IAC valve is disconnected and reconnected
with the engine running, the idle speed may be
The purpose of the IAC valve assembly is to control
wrong. In this case, the IAC valve can be reset by
engine idle speed, while preventing stalls due to
doing the following: Turn off engine, wait ten se-
changes in engine load. The IAC valve, mounted in
conds, and restart engine.
the throttle body, controls bypass air around the
throttle valves.
72800
Idle Air Control (IAC) Valve Assembly
By moving a conical valve known as a pintle, IN, to-

ward the seat (to decrease air flow), or OUT, away
from the seat (to increase air flow), a controlled 72986
amount of air moves around the throttle valve. If RPM
is too low, more air is bypassed around the throttle
valve to increase it. If RPM is too high, less air is by-
passed around the throttle valve to decrease it. IAC Valve Air Flow Diagram
The ECM moves the IAC valve in small steps, called
counts. These can be measured by scan tool test
equipment, which plugs into the DLC connector.
During idle, the proper position of the IAC valve is en-
gine load, and engine RPM. If the RPM drops below
specification and the throttle valve is closed, the ECM
senses a near stall condition and calculates a new
valve position to prevent stalling.
• Engine idle speed is a function of total air flow into
the engine based on IAC valve pintle position.
• “Controlled” idle speed is programmed into the
ECM, which determines the correct IAC valve
pintle position to maintain the desired idle speed
for all engine operating conditions and loads.
• The minimum idle air rate is set at the factory with
stop screws. This setting allows enough air flow
by the throttle valves to cause the IAC valve pintle
to be positioned a calibrated number of steps
(counts) from the seat during “controlled” idle op-
eration.
Index
ECM Connector and Symptom Charts
The following chart will aid in diagnosis of symptoms. These voltages were derived from a known good engine.
The voltages shown were done with the electrical system intact and operational. These are voltage requirements
to operate the different circuits.
! CAUTION
Do not attempt to obtain these voltages by probing wires and connectors. Serious damage could result
in loss of engine operation or wiring damage. Voltages can vary with battery conditions.
J-1
J-1 Front Pin 32 Pin Input Connector
J-2
J-2 Rear 32 Pin Output Connector THESE NOTES APPLY TO FOLLOWING ECM
a - Shaded Area Denotes Pin Connector Location Used On CONNECTOR AND SYMPTOM CHARTS.
Terminal
The “B+” Symbol indicates a system voltage (bat-
NOTE: The Intake Air Temperature (IAT) Sensor tery).
[J1-24], Port Fuel Jumper [J2-7 and J2-22] is not
NOTE 1: Battery voltage for first two seconds, then
used on the Throttle Body Injection system.
0 volts.
IMPORTANT: The following conditions must be
NOTE 2: Varies with temperature.
meet before testing.
NOTE 3: Varies with manifold vacuum.
1. Engine at operating temperature.
NOTE 4: Varies with throttle movement.
2. Ignition on or engine running.
NOTE 5: Less than .5 volt (500 mV).
3. Scan tool not connected.
NOTE 6: Dual or multiple engines must share a com-
mon ground (–) for proper serial data communica-
tions.
Index
ECM Connector and EFI Symptoms Chart (J-1 Circuits)
Circuit Normal Voltage Diag
Pin ((CKT)) nostic
Wire Possible
Pi
Pin Func- N
Num- T bl
Trouble
Color Ignition Engine Symptoms
tion ber Codes
(#) ON Running DTC(s)
Knock Poor Fuel Economy,
J1-1 Sensor 485 BLK 9.5V 9.5V 43 Poor Performance
Signal Detonation
Poor Performance,
ECT 1.95V 1.95V
J1-2 410 YEL 14 Exhaust Odor, Rough Idle
Signal (NOTE 2) (NOTE 2)
RPM Reduction
Not
J1-3 – – – – – –
Used
Not
J1-4 – – – – – –
Used
Master/ Lack Of Data From Other Engine
J1-5 916 YEL B+ B+ None
Slave (Dual Engine Only)
Discrete
J1-6 931 BRN – – None Power Reduction Mode
Switch
Diag-
WHT/
J1-7 nostic 451 B+ B+ None Incorrect Idle, Poor Performance
BLK
Test
Not
J1-8 – – – – – –
Used
Map LT 1.46V Poor Performance, Surge, Poor
J1-9 432 4.9V 33
Signal GRN (NOTE 3) Fuel Economy, Exhaust Odor
TP DK .62V .62V Poor Performance And Accelera-
J1-10 417 21
Signal BLU (NOTE 4) (NOTE 4) tion, Incorrect Idle
Ignition PNK/
J1-11 439 B+ B+ None No Start
Fused BLK
Not
J1-12 – – – – – –
Used
TP and
0 0 High Idle, Rough Idle, Poor Perfor-
J1-13 IAT 813 BLK 21,23
(NOTE 5) (NOTE 5) mance Exhaust Odor
Ground
ECM BLK/ 0 0
J1-14 450 None No Start
Ground WHT (NOTE 5) (NOTE 5)
TP 5V
J1-15 Refer- 416 GRY 5V 5V 21 Lack Of Power, Idle High
ence
J1-16 Battery 440 ORN B+ B+ None No Start
See Page 5E-27 For NOTES
Index
Circuit Normal Voltage Diag-
Pin ((CKT)) nostic
Wire Possible
Pi
Pin Func- N
Num- T bl
Trouble
tion ber Codes
Not
J1-17 – – – – – –
Used
Serial ORN/ No Serial Data
J1-18 461 5V 5V None
Data BLK (NOTE 6)
Not
J1-19 – – – – – –
Used
Not
J1-20 – – – – – –
Used
Lanyard
J1-21 Stop 942 PNK 0 0 NONE No Start
Switch
Not
J1-22 – – – – – –
Used
Not
J1-23 – – – – – –
Used
IAT Poor Fuel Economy, Exhaust
J1-24 472 TAN 5V (NOTE 2) 23
Sensor Odor
Not
J1-25 – – – – – –
Used
Not
J1-26 – – – – – –
Used
Not
J1-27 – – – – – –
Used
Not
J1-28 – – – – – –
Used
MAP 0 0 Lack Of Performance,Exhaust
J1-29 814 BLK 33
Ground (NOTE 5) (NOTE 5) Odor, Stall
ECM BLK/ 0 0
J1-30 450 None No Start
Ground WHT (NOTE 5) (NOTE 5)
MAP 5V
Lack Of Power, Surge, Rough
J1-31 Refer- 416 GRY 5V 5V 33
Idle, Exhaust Odor
ence
J1-32 Battery 440 ORN B+ B+ None No Start
NOTE: The Intake Air Temperature (IAT) Sensor [J1-24] is not used on the Throttle Body Injection system. J1-21
is not used on 1997 and newer models.
See page 5E-27 for NOTES
Index
Pin ((CKT)) nostic
Wire Possible
Pi
Pin Func- N
Num- T bl
Trouble
tion ber Codes
Not
J2-1 – – – – – –
Used
Not
J2-2 – – – – – –
Used
Not
J2-3 – – – – – –
Used
Not
J2-4 – – – – – –
Used
Injector LT
J2-5 468 B+ B+ None Rough Idle, Lack Of Power, Stall
Driver GRN
Ignition
Control BLK/ 0 0
J2-6 463 None Poor Performance
Ref. RED (NOTE 5) (NOTE 5)
Low
Port
J2-7 Fuel 901 WHT – – None –
Jumper
Ignition
Control PUR/
J2-8 430 5V 1.6V None No Restart
Ref. WHT
High
Fuel
Pump DK 0
J2-9 465 GRN/ (NOTE B+ None No Start
Relay
WHT 1&5)
Driver
Not
J2-10 – – – – – –
Used
Coolant
DK Power Reduction Mode or
J2-11 Over 112 0 0 NONE
GRN Improper Audio Warning
temp.
Not
J2-12 – – – – – –
Used
IAC “A” BLU/ Not Not
J2-13 442 None Rough Unstable or Incorrect Idle
Low BLK Usable Usable
IAC “B” GRN/ Not Not
J2-14 443 None Rough Unstable or Incorrect Idle
Low WHT Usable Usable
Injector BLK/ 0 0 Rough Running, Lack Of Power,
J2-15 450 None
Ground WHT (NOTE 5) (NOTE 5) Poor Performance
Not
J2-16 – – – – – –
Used
NOTE: J2-7 is not used on the Throttle Body Injection system.
Index
Pin ((CKT)) nostic
Wire Possible
Pi
Pin Func- N
Num- T bl
Trouble
tion ber Codes
Not
J2-17 – – – – – –
Used
Not
J2-18 – – – – – –
Used
Not
J2-19 – – – – – –
Used
Fuel
BLK/ 0 0 Rough Running, Poor Idle, Lack
J2-20 Injector 450 None
WHT (NOTE 5) (NOTE 5) Of Performance
Ground
Injector DK Rough Idle, Lack Of Power,
J2-21 467 B+ B+ None
Driver BLU Stalling
Port
J2-22 Fuel 901 WHT – – – –
Jumper
Ignition
0 Stall, Will Restart In Bypass
J2-23 Control 423 WHT 1.2V 42
(NOTE 5) Mode, Lack Of Power
Signal
Ignition
TAN/ 0
J2-24 Control 424 4.5V 42 Lack Of Power, Fixed Timing
BLK (NOTE 5)
Bypass
Not
J2-25 – – – – – –
Used
Not
J2-26 – – – – – –
Used
Discrete
J2-27 Switch 31 TAN – – – Audio Warning System Activated
Signal
IAC
BLU/ Not Not
J2-28 “A” 441 None Rough Unstable or Incorrect Idle
WHT Usable Usable
High
IAC
GRN/ Not Not
J2-29 “B” 444 None Rough Unstable or Incorrect Idle
BLK Usable Usable
Low
Not
J2-30 – – – – – –
Used
MIL BRN/ 0 0
J2-31 419 None Lamp Inoperative
Lamp WHT (NOTE 5) (NOTE 5)
Not
J2-32 – – – – – –
Used
NOTE: J2-22 is not used on the Throttle Body Injection system.

See page 5E-27 for NOTES
Index
Multi Port Injector Balance Test At this point, insert clear tubing attached to vent valve
into a suitable container and bleed air from gauge
(Refer to the following figure for test set-up.) and hose to ensure accurate gauge operation. Re-
The injector balance tester is a tool used to turn the peat this step until all air is bled from gauge.
injector ON for a precise amount of time, thus spray-
ing a measured amount of fuel into the manifold. This STEP 2
causes a drop in fuel rail pressure that we can record Turn ignition OFF for ten seconds and then ON again
and compare between each injector. All injectors several times to get fuel pressure to its maximum.
should have the same amount of pressure drop. Any Record this initial pressure reading. Energize tester
injector with a pressure drop that is 1.5 PSI (or more) one time and note pressure drop at its lowest point.
greater or less than the average drop of the other in- (Disregard any slight pressure increase after drop
jectors should be considered faulty and replaced. In- hits low point.) By subtracting this second pressure
jector testers are available for various manufactur- reading from the initial pressure, we have the actual
ers. For 7.4L / 454 and 502 engines: the tester must amount of injector pressure drop.
be capable of selecting an injector pulse width in the
range of 200-400 milliseconds (m sec). The recom- STEP 3
mended starting point for these engines is approxi-
mately 300 m sec. In any case a pulse width that Repeat Step 2 on each injector and compare the
drops the fuel rail pressure to half the normal operat- amount of drop. Usually, good injectors will have
ing pressure, should be used. virtually the same drop. Retest any injector that has
a pressure difference of 1.5 PSI (10 kPa), either more
STEP 1 or less than the average of the other injectors on the
engine. Replace any injector that also fails the retest.
Engine cool down period (ten minutes) is necessary If the pressure drop of all injectors is within 1.5 PSI
to avoid irregular readings due to “hot soak” fuel boil- (10 kPa) of this average, the injectors appear to be
ing. Relieve fuel pressure in the fuel rail as outlined flowing properly. Reconnect them and review “Trou-
in “Fuel Pressure Relief Procedure” in “Repair Proce- bleshooting.”
dures.” Remove plenum as outlined in “Repair Pro-
cedures.” With ignition OFF, connect fuel pressure NOTE: The entire test should not be repeated more
gauge to fuel pressure tap. than once without running the engine to prevent
flooding. (This includes any retest on faulty injectors.)
Disconnect harness connectors at all injectors, and
connect injector tester to one injector. Use adaptor
harness furnished with injector tester to energize in-
jectors. Follow manufacturer’s instructions for use of
adaptor harness. Ignition must be OFF at least ten
seconds to complete ECM shutdown cycle. Fuel
pump should run about two seconds after ignition is
turned ON.
Index
Fuel Injector Balance Test Set-up (Multi-Port Injection)
300ms
EXAMPLE
Cylinder 1 2 3 4 5 6 7 8
1st. 38 PSI 38 PSI 38 PSI 38 PSI 38 PSI 38 PSI 38 PSI 38 PSI
Reading (262 kPa) (262 kPa) (262 kPa) (262 kPa) (262 kPa) (262 kPa) (262 kPa) (262 kPa)
2nd 19 PSI 17 PSI 21 PSI 19 PSI 19 PSI 19 PSI 19 PSI 19 PSI

Reading (131 kPa) (117 kPa) (145 kPa) (131 kPa) (131 kPa) (131 kPa) (131 kPa) (131 kPa)
Amount of 19 PSI 21 PSI 17 PSI 19 PSI 19 PSI 19 PSI 19 PSI 19 PSI

Drop (131 kPa) (145 kPa) (117 kPa) (131 kPa) (131 kPa) (131 kPa) (131 kPa) (131 kPa)
Rich Lean
OK (Too Much (Too Little OK OK OK OK OK
Fuel Drop) Fuel Drop)
Index
Wiring Harness Diagrams
MCM 5.7L EFI Alpha With Vapor Separator Tank
NOTE 1
3 22
8
4 12
19
9
10
2 6
1
16
11 5
17
20
18 14
13 15
21
NOTE 1: As a mid year (96-1/2) model change, the EFI (Throttle Body Injection) models have the lanyard stop
connector removed from the wiring harness. The dual engine capability is relocated by routing the YEL wire to
the Data Link Connector (DLC).

Index
MCM 5.7L EFI Alpha With Cool Fuel System
3 22
8
4 12
19
9
10
2 6
16
11 5
17
20
18 14
13 15
21
7371
1

Index
MCM 5.7L EFI Bravo With Vapor Separator
NOTE 1
8
4 12
19
9
10
2 6
1
16
11 5
17
20
14
18
13 15
21
73717
NOTE 1: As a mid year (96-1/2) change, the EFI (Throttle Body Injection) models have the lanyard stop connec-
tor removed from the wiring harness. The dual engine capability is relocated by routing the YEL wire to the Data
Link Connector (DLC).

Index
MCM 5.7L EFI Bravo WIth Cool Fuel System
8
4 12
19
9
10
2 6
16
11 5
17
20
14
18
13 15
21
73717

Index
MCM 350 MPI Bravo (Including Gen + Engines) With Vapor Separator Tank
NOTE 1
4
2
8
10 9
12 19
GRY
6
17
18 11 5
14 16
20
13 15
21
74182
nector and dual engine data link connector removed from the wiring harness. The dual engine capability is relo-
cated by routing the YEL wire to the Data Link Connector (DLC).

Index
MCM 350 MPI Gen+ Bravo With Cool Fuel System
4
2
8
10 9
12 19
17
18 11 5
14 16
20
13 15
21
1 74182

Index
MIE 350 Magnum MPI Gen + Tournament Ski (Black Scorpion)
2
6
8 10 17
15
16 9 4
14
12
11 13
18
74893
1 - Fuel Pump 10- Electronic Control Module (ECM)

7 - Idle Air Control (IAC) 16- Harness Connector To Starting/Charging Harness
8 - Throttle Position (TP) Sensor 17- Harness Connector To Lanyard Stop Switch (Optional)
9 - Engine Coolant Temperature (ECT) Sensor 18- Positive (+) Power Wire To Engine Circuit Breaker
Index
MIE 350 Magnum EFI Gen + Tournament Ski / 5.7L Gen+ Inboard With Cool Fuel
System
8
4 12
9
10
2 6
16
11 5
17
14
18
13 15
19
1
75001
1 - Fuel Pump 11- Engine Coolant Temperature (ECT) Sensor

2 - Throttle Body 12- Electronic Control Module (ECM)
8 - Knock Sensor 18- Harness Connector To Starting/Charging Harness
9 - Idle Air Control (IAC) 19- Positive (+) Power Wire To Engine Circuit Breaker
10- Throttle Position (TP) Sensor
Index
Multi-Port Injection Wiring Diagram (Chart 1 Of 4)
INJECTORS 2, 3, 5, 8
467 DK BLU
10A
15A INJECTORS 1, 4, 6, 7
DK GRN
15A
87a 30 85 86 87
BLK
441 BLU/WHT
IDLE AIR 442 BLU/BLK
CONTROL
(IAC) VALVE 443 GRN/WHT
444 GRN/BLK
C BLK
DUAL ENGINE DATA LINK
(MULTIPLE ENGINE B 916 YEL J1-5 MASTER/SLAVE
APPLICATION SOME MODELS)
A
SOME MODELS
WILL HAVE THE 461 ORN/BLK
916 YEL
DUAL ENGINE
DATA LINK BLK
DLC
MOVED TO THE
DLC
TO ECM/BAT
FUSE
15A
440 ORN MALFUNCTION INDICATOR LAMP
Index
INTAKE AIR TEMPERATURE

INTAKE AIR
(IAT) SENSOR SIGNAL
TEMPERATURE
(IAT) SENSOR
B
C
(TP)
A
ENGINE COOLANT
TEMPERATURE (ECT) ENGINE COOLANT
SENSOR TEMPERATURE (ECT)
SENSOR SIGNAL
Index
IC MODULE
EST MODULE
B A
ELECTRONIC SPARK TIMING (EST)

IGNITION CONTROL
430 PUR/WHT DIST. REFERENCE “HIGH”
BYPASS
DIST. REFERENCE “LOW”
BRN
FROM KNOCK SENSOR

MODULE (BLACK
SCORPION ONLY)
86
TO KNOCK SEN-
SOR (BLACK BLU E
SCORPION ONLY)
TO BUZZER TAN/BLU D 121 TAN
TO IGN PUR C 3 PNK

TO AUDIO
WARNING BLU/TAN B
SWITCHES
TO TACH GRY A 121 WHT
TO BUZZER
(COOLANT OVERTEMP)
TO BUZZER
(AUDIO WARNING SWITCHES)
J1-6 FROM AUDIO WARNING

931 BRN
SWITCHES
Index
TO IGN COIL TERM B

TO FUEL PUMP RELAY FUSE 15A
TO INJECTORS
SYSTEM/IGNITION RELAY
86 85
87
ECM BAT FUSE/ 10A

DLC 15A
TO DLC CONNECTOR
439 PNK/BLK
KNOCK KNOCK
SENSOR (KS) SENSOR (KS)
MODULE
LANYARD STOP
A SWITCH CIRCUIT
CONNECTOR NOT PRESENT (OPTIONAL)
ON SOME MULTI-PORT MODELS
B BLK
Index
Throttle Body Injection Wiring Diagram (Chart 1 of 4)
INJECTOR
467 DK BLU
10A
15A INJECTOR
DK GRN
15A
87a 30 85 86 87
BLK
441 BLU/WHT
CONTROL
(IAC) VALVE 443 GRN/WHT
444 GRN/BLK
C BLK
DUAL ENGINE DATA LINK
(MULTIPLE ENGINE B 916 YEL J1-5 MASTER/SLAVE
APPLICATION SOME MODELS)
A
SOME MODELS
WILL HAVE THE 461 ORN/BLK
DUAL ENGINE 916 YEL
BLK
DATA LINK DLC
MOVED TO THE
DLC
TO ECM/BAT
FUSE
15A
440 ORN MALFUNCTION INDICATOR LAMP
Index
Throttle Body Injection Wiring Diagram (Chart 2 Of 4)
B
C
(TP)
A
ENGINE COOLANT
TEMPERATURE ENGINE COOLANT
(ECT) SENSOR TEMPERATURE (ECT)
SENSOR SIGNAL
Index
IC MODULE
EST MODULE
B A
ELECTRONIC SPARK TIMING (EST)

IGNITION CONTROL
430 PUR/WHT DIST. REFERENCE “HIGH”
BYPASS
BRN
86
TO KNOCK SEN-
SOR (BLACK
SCORPION ONLY)
TO BUZZER TAN/BLU D 121 TAN
TO IGN PUR C 3 PNK

TO AUDIO
WARNING BLU/TAN B
SWITCHES
TO TACH GRY A 121 WHT
TO BUZZER
(COOLANT OVERTEMP)
TO BUZZER
931 BRN J1-6 FROM AUDIO WARNING

SWITCHES
Index
TO IGN COIL TERM B

TO FUEL PUMP RELAY FUSE 15A
TO INJECTORS
SYSTEM/IGNITION RELAY
86 85
87
ECM BAT FUSE/ 10A

DLC 15A
TO DLC CONNECTOR
439 PNK/BLK
KNOCK KNOCK
SENSOR (KS) SENSOR (KS)
MODULE
LANYARD STOP
A SWITCH CIRCUIT
CONNECTOR NOT PRESENT (OPTIONAL)
ON SOME MULTI-PORT MODELS BLK
B BLK
Index
Index
Diagnostic Circuit Check The scan tool data listed in the table may be used for
comparison. After completing the diagnostic circuit
The Diagnostic Circuit Check is an organized ap- check and finding the on-board diagnostics function-
proach to identifying a problem created by an elec- ing properly and no trouble codes displayed. The
tronic engine control system malfunction. It must be “Typical Data Values” are an average of display val-
the starting point for any driveability complaint diag- ues recorded from normally operating vessels and
nosis because it directs the service technician to the are intended to represent what a normally functioning
next logical step in diagnosing the complaint. system would typically display.
NOTE: A scan tool that displays faulty data should Only the parameters listed below are used in this
not be used, and the problem should be reported to manual for diagnosing. If a scan reads other parame-
the manufacturer. The use of a faulty scan tool can ters, the values are not recommended for use in diag-
result in misdiagnosis and unnecessary parts re- nosing. If all values are within the range illustrated,
placement. refer to “Troubleshooting.”
Scan Tool Normal Specifications
(Idle / Warm Engine / Closed Throttle / Neutral)
Scan Position Units Displayed Typical Data Value
RPM RPM 600-700 RPM
Desired RPM RPM 600 RPM
Coolant Temp. ° F(° C) 150-170° F (66-77° C)
Manifold Air Temp. ° F (° C) Varies with Ambient Temperature
Throttle Position Volts .4 to .8 Volts
Throttle Angle 0-100 % 0-1%
1-3 Volts or (45-55 kPa) (Depends on
MAP Volts or kPa
Vacuum and Baro Pressure)
3-5 Volts (Depends on Altitude and
Baro Volts or kPa
Barometric Pressure)
Bat Volts 12.0-14.5 Volts
Spark Advance Degrees -10 to 30°
Knock Retard Degrees 0°
Idle Air Control IAC Counts (Steps) 0-40 Counts
Minimum IAC Position Counts (Steps) 0-40 Counts
Idle Air Control Follower Counts (Steps) 0 Counts
Injector Pulse Width msec. 2-3 msec.
2.5–3.5 msec. (Depends on Water/Air
Injector On Time Cranking msec.
Temperature)
Fuel Consumption GPH (L/h) 1-2 GPH(3.7-7.5 L/h)
Time From Start 0:00:00-1092:00 Varies
Memory Calibration Check Sum Calibration and Check Sum Varies with Software revision in ECM
Oil Press/IO Level (See Note) OK/LO OK
Engine Overtemp OK/Overheating OK
Power Reduction Mode OFF/ON OFF
Lanyard Stop Mode OFF/ON OFF
NOTE: MCM will read I/O Level and MIE will read Trans.
Index
CLEARING CODES USING DIAGNOSTIC CODE 10. Refer to appropriate Troubleshooting and/or
TOOL (NON-SCAN) Diagnostic Charts.
1. Install diagnostic code tool. NOTE: When clearing codes without the use of a
scan tool, the battery must be fully charged and
2. Turn key ON.
cranking speed must be at least 300 RPM. The ability
3. Select service mode on code tool. to clear codes is directly dependent on the battery be-
4. To clear codes, move the throttle, while in neutral, ing fully charged and able to start the engine with ad-
from 0% to 100% then back to 0%. equate cranking RPM.
5. Exit “Service Mode” on code tool. A poorly charged battery or engine cranking problem
may result in an ECM “reset” and may not allow
6. Start engine and let run for fifteen seconds. stored trouble codes to be cleared from EEPROM
7. Turn key OFF for 5 seconds. memory. If this condition exists, BE SURE the battery
is fully charged. If a low battery condition does exists
8. Select “Service Mode” on code tool. the audio warning buzzer will come on for 2 seconds
9. Turn key ON and read codes. If codes are still after engine start-up.
present, check note following and repeat from
Step 1.
• IGNITION “OFF.” MARINE DIAGNOSTIC CODE TOOL

• INSTALL MARINE DIAGNOSTIC CODE TOOL.
• SWITCH TO NORMAL MODE.
• IGNITION “ON.”
• NOTE “MALFUNCTION INDICATOR LAMP”.
STEADY LAMP NO LAMP FLASHING CODE 12
USE CHART A-1. CHECK FOR GROUNDED

DIAGNOSTIC TEST CKT 451.
YES NO OR FAULTY TOOL.
DID ENGINE START PRIOR USE CHART A-2.

TO DIAGNOSTIC CIRCUIT CHECK
YES
NO
SWITCH CODE TOOL “SERVICE
MODE”ARE ANY CODES OTHER
THAN CODE 12 DISPLAYED? USE CHART A-3.
NO YES
DOES A CUSTOMER COMPLAINT OR

DRIVEABILITY PROBLEM CURRENTLY EXIST? REFER TO APPLICABLE
“NON-SCAN” CODE
CHART. START WITH
YES NO LOWEST CODE FIRST.
REFER TO TROUBLE- FAULT IS NOT

SHOOTING SECTION. PRESENT AT
THIS TIME.
Index
CLEARING CODES USING SCAN TOOL (SCAN) 4. Clear codes.
1. Connect scan tool. 5. Turn key OFF.
2. Start engine. 6. Turn key ON and read codes. If codes are still
present, (there is a real fault in system) check
3. Select clear codes function.
note preceding and repeat Step 1.
LINK SCAN TOOL AND SCAN TOOL

CHECK FOR CODES
DOES SCAN TOOL DISPLAY ECM DATA?
YES NO
DID ENGINE START PRIOR USE CHART A-2.

TO DIAGNOSTIC CIRCUIT CHECK
YES NO
ARE ANY CODES

DISPLAYED? USE CHART A-3.
NO YES
DOES A CUSTOMER COMPLAINT OR

REFER TO APPLICABLE
DRIVEABILITY PROBLEM CURRENTLY EXIST?
“SCAN” CODE CHART.
START WITH LOWEST
CODE FIRST.
YES NO
REFER TO TROUBLE- FAULT IS NOT

SHOOTING SECTION. PRESENT AT
THIS TIME.
Index
No “Malfunction Indicator Lamp” (Marine Diagnostic Code Tool Installed)
Chart A-1 (1 of 2)
DUAL ENGINE DATA LINK B
(DUAL ENGINE APPLICATION C 916 YEL MASTER/SLAVE
J1-5
ONLY) A
461 ORN/BLK
DLC
ECM/DLC
TO ECM FUSE
15AMP 15A
BATTERY
FUSE DIAGNOSTIC TEST
451 WHT/BLK TERMINAL
MALFUNCTION IN-
DICATOR LAMP
ECM, INJECTOR KNOCK

SENSOR MODULE
10 AMP FUSE
MALFUNCTION INDICATOR
LAMP
CIRCUIT DESCRIPTION: DIAGNOSTIC AIDS:

There should always be a steady “Malfunction Indi- Engine runs OK, check:
cator Lamp” when the ignition is ON and engine
• Faulty light bulb.
stopped. Ignition voltage is supplied directly to the
light bulb. The Electronic Control Module (ECM) will • CKT 419 open.
control the light and turn it ON by providing a ground Engine cranks but will not run, check:
path through CKT 419 to the ECM.
• Continuous battery - 50 amp circuit breaker
TEST DESCRIPTION: open.
Number(s) below refer to circled number(s) on the • Open ECM fuse.
diagnostic chart. • Battery circuit to ECM open.
1. This step insures that battery voltage is available • Ignition circuit to ECM open.
to terminal “F” of the DLC connector.
• Poor connection to ECM.
2. This step checks for ground present in DLC con-
nector terminal “E.” This indicates that the ECM • Faulty ECM ground circuit(s).
is capable of completing the ground to the “Mal- Engine will not crank.
function Indicator Lamp”.
• Perform EFI system relay check.
3. This step isolates the cause of incomplete
ground to either a wiring or ECM circuitry.
4. If the engine fails to crank, this may indicate a fail-
ure in the starting system circuit.
Index
No “Malfunction Indicator Lamp”
Chart A-1: (2 of 2)
DOES THE ENGINE START?
YES NO
1 IS THE 10 AND 15 AMP

• IGNITION “ON.” ECM FUSE OK?
• REMOVE MARINE DIAGNOSTIC CODE TOOL.
• USING A TEST LIGHT CONNECTED TO
GROUND, PROBE TERMINAL “F” OF THE
DLC CONNECTOR.
LIGHT SHOULD BE “ON.” IS IT? YES NO
YES NO 4 DOES THE ENGINE CRANK? LOCATE AND CORRECT

SHORT TO GROUND IN
CIRCUIT.
2 • CONNECT TEST LIGHT TO REPAIR OPEN OR
B+BATTERY POSITIVE. SHORTED CKT 440.
• PROBE DLC TERMINAL “E.” YES NO
• LIGHT SHOULD BE “ON.” IS IT?
PERFORM TESTS ON
1 • IGNITION “OFF.”
STARTING SYSTEM CIR-
• DISCONNECT ECM
CUIT. SEE TROUBLE-
CONNECTORS.
SHOOTING IN SECTION
1C.
YES NO • PROBE ECM CONNECTOR
PINS J1-16, J1-32, AND
J1-11 WITH TEST LIGHT
CONNECT TEST LIGHT BETWEEN TO GROUND.
DLC TERMINALS “F” AND “E.” 3 • IGNITION “OFF.” IS THE LIGHT “ON,” ON
LIGHT SHOULD BE “ON.” • DISCONNECT ECM ALL CIRCUITS?
IS IT? “J2” CONNECTOR.
• USING DVM,
MEASURE
RESISTANCE YES NO
YES NO BETWEEN ECM
CONNECTOR
FAULTY ECM GROUNDS PERFORM EFI SYSTEM
FAULTY DIAG- REFER TO TERMINAL “J2-31”
OR ECM. RELAY CHECK. DOES
NOSTIC CODE “DIAGNOSTIC AND DLC
ENGINE START?
TOOL. AIDS” ON CONNECTOR
FACING TERMINAL “E.”
PAGE. • RESISTANCE
SHOULD BE CLOSE YES NO
TO 0 OHMS.
IS IT? REPEAT STEP 1 REPAIR OPEN IN CIRCUIT
OF THIS CHART THAT DID NOT LIGHT
THE TEST LIGHT.
YES NO
FAULTY ECM CHECK FOR SHORT IN

CONNECTIONS OR WIRE 419 BETWEEN J2-31
FAULTY ECM. AND DLC TERMINAL E
Index
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)
DUAL ENGINE DATA LINK C

(DUAL ENGINE APPLICATION B 916 YEL J1-5
ONLY) MASTER/SLAVE
A
461ORN/BLK
DLC
TO ECM 15A
BATTERY
FUSE 451 WHT/BLK
LAMP
LAMP
CIRCUIT DESCRIPTION: TEST DESCRIPTION:

There should always be a steady “Malfunction Indi- Number(s) below refer to circled number(s) on the
cator Lamp” when the ignition is ON and engine diagnostic chart.
stopped. Ignition voltage is supplied to the light bulb.
1. If there is a problem with the ECM that causes a
The Engine Control Module (ECM) will turn the lamp
scan tool to not read serial data, the ECM should
ON by grounding CKT 419 in the ECM.
not flash a Code 12. If Code 12 is flashing, check
With the diagnostic “test” terminal grounded CKT CKT 451 for short to ground. If Code 12 does
419, the lamp should flash a Code 12, followed by flash, make sure that the scan tool is working
any trouble code(s) stored in memory. properly on another engine.
A steady light suggests a short to ground in the lamp 2. If the light goes OFF when the ECM connector is
control CKT 419 or an open in diagnostic CKT 451. disconnected, CKT 419 is not shorted to ground.
3. This step will check for an open diagnostic CKT
451.
4. At this point, the “Malfunction Indicator Lamp”
wiring is OK. If Code 12 does not flash, the ECM
should be replaced.
Index
No DLC Data or Will Not Flash Code 12
Chart A-2: (2 of 2)
• MARINE DIAGNOSTIC CODE TOOL INSTALLED.

• IGNITION “ON,” ENGINE “OFF.”
IS THE “MALFUNCTION INDICATOR LIGHT “ON”?
YES NO
• ENTER SERVICE MODE ON DIAGNOSTIC SEE

CODE TOOL. CHART A-1
DOES “MALFUNCTION INDICATOR LAMP”
FLASH CODE 12?
NO YES
2 • IGNITION “OFF.” 1 • IF PROBLEM WAS NO DLC DATA (USING SCAN TOOL)

• DISCONNECT ECM J-2 CONNECTOR. CHECK SERIAL DATA CKT 461 FOR OPENS OR SHORTS
• IGNITION “ON” AND NOTE “MALFUNCTION INDICATOR TO GROUND. IF OK, IT IS A FAULTY ECM.
LAMP”
LIGHT “OFF” LIGHT “ON”
3 • IGNITION “OFF.” REPAIR SHORT TO

• JUMPER TERMINALS “A” TO “B” AT DLC CONNECTOR. GROUND IN CKT 419.
• CONNECT TEST LIGHT BETWEEN ECM CONNECTOR
TERMINAL “J1-7” AND B+ BATTERY POSITIVE.
LIGHT “ON” LIGHT “OFF”
4 • REPLACE ECM. • CHECK FOR OPEN IN DLC DIAGNOSTIC

• RECHECK FOR CODE 12. TERMINALS “A” AND “B” (CKT 450 AND
CKT 451), REPAIR AS NECESSARY.
Index
Engine Cranks but Will Not Run Chart A-3 (1 of 4)
INJ/ECM/KS
MODULE FUSE
10A
IGNITION CONTROL
DIST. REFERENCE
“HIGH”
BYPASS
DIST. REFERENCE
“LOW”
CIRCUIT DESCRIPTION: 4. All injectors should be within 1.0 ohm of each oth-
er and should not be less than 12 ohms at 70°F
This chart assumes that battery condition and engine
(21°C). If an injector is suspected for a no start
cranking speed are OK, and there is adequate fuel in
condition, unhook the suspected injector and try
the tank.
to start the engine.
TEST DESCRIPTION: 5. Use fuel pressure gauge 91-16850 or J-34730-1.
Wrap a shop towel around the fuel pressure tap
Number(s) below refer to circled number(s) on the
to absorb any small amount of fuel leakage that
diagnostic chart.
may occur when installing the gauge.
1. An ECT sensor that indicates coolant tempera-
ture less than actual temperature can flood the DIAGNOSTIC AIDS:
engine with fuel. An ECT sensor that indicates
• Unless engine enters “Clear Flood” at the first in-
coolant temperature greater than actual can
dication of a flooding condition, it can result in a
starve the engine of fuel. If the TP sensor is at 50
no start.
to 75% of its range, the engine may be in the clear
flood mode, which will cause starting problems. • Check for fouled plugs.
The engine will not start without reference pulses
• Water or foreign material in fuel line, VST, water
and, therefore, the scan tool should read engine
separating fuel filter can cause a no start in cold
RPM (reference) during cranking.
weather.
2. No spark may be caused by one of several com-
• A defective MAP sensor may cause a no start or
ponents related to the high energy ignition/IC
a stall after start. To determine if the sensor is
system. The ignition system will address all prob-
causing the problem, disconnect it. The ECM will
lems related to the causes of a no spark condi-
then use a default value for the sensor, and if the
tion.
condition is corrected and the connections are
3. The test light should blink, indicating the ECM is OK, replace the sensor.
controlling the injectors OK.
• Using injector harness test light (J-34730-2A)
check for blinking light at injector harness on both
banks of the engine. If not OK, check injector
fuses.
If above are all OK, refer to “Troubleshooting.”
Index
Engine Cranks but Will Not Run (Continued)
Chart A-3: (2 of 4)
1
• ENSURE THE ENGINE IS NOT IN SERVICE OR BASE TIMING NOTE 1: IF A SCAN TOOL IS NOT AVAILABLE WHILE
MODE
• CHECK THAT LANYARD STOP SWITCH IS NOT ACTIVATED CHECKING TP AND ECT READINGS, USE THE
CHECK THE FOLLOWING. (NOTE 1) CODE 21 AND 14 NON-SCAN DIAGNOSTIC
• ACTUAL ENGINE TEMPERATURE AND ECT TEMPERATURE
CHARTS TO ENSURE PROPER OPERATION
ON THE SCAN TOOL SHOULD BE CLOSE TO THE SAME, IF
NOT REFER TO CODE 14. OF THOSE COMPONENTS.
• TP SENSOR - IF OVER 2.5 VOLTS AT CLOSED THROTTLE,
USE THE CODE 21 CHART. NOTE 2: A TACHOMETER MAY BE USED IF A SCAN TOOL
IS RPM INDICATED DURING CRANKING? (NOTE 2)
IS NOT AVAILABLE.
PLACE THE LANYARD STOP

SWITCH IN THE RUN POSITION
YES NO
• USING AN INDUCTIVE PICKUP TIMING • USING AN INDUCTIVE PICKUP TIMING LIGHT

LIGHT CONNECTED TO ANY SPARK CONNECTED TO ANY SPARK PLUG WIRE,
PLUG WIRE, CHECK FOR SPARK CHECK FOR SPARK WHILE CRANKING
WHILE CRANKING (CHECK TWO WIRES). (CHECK TWO WIRES).IS SPARK PRESENT?
IS SPARK PRESENT?
3
YES NO
YES NO
• IGNITION “OFF.”
• DISCONNECT ALL 2 BASIC HEI • DISCONNECT DISTRIBUTOR
2 CHECK FOR
INJECTORS. PROBLEM. REFER TO BATTERY
4-WAY CONNECTOR.
• CONNECT TEST LIGHT IGNITION SYSTEM VOLTAGE TO
J-34730-2 OR EQUIVALENT CHECK. • IGNITION “ON.” IGNITION SYSTEM.
TO INJECTOR HARNESS • MOMENTARILY TOUCH IF OK, THERE IS A
CONNECTOR. (TEST ONE HARNESS CONNECTOR BASIC HEI
INJECTOR HARNESS FROM TERMINAL (CKT 430) WITH A PROBLEM. THEN
EACH GROUPING OF TEST LIGHT TO 12 VOLTS. REFER TO IGNI-
INJECTORS.) • SCAN TOOL OR TION SYSTEM
• CHECK FOR BLINKING LIGHT TACHOMETER SHOULD CHECK.
WHILE CRANKING. INDICATE RPM WHEN TEST
IS PERFORMED.
DOES IT?
4 NO BLINKING LIGHT
BLINKING LIGHT
REFER TO LANYARD
STOP CIRCUIT CHECK
• CHECK RESISTANCE ACROSS NO BLINKING LIGHT YES NO
EACH INJECTOR AND COMPARE
VALUES. USE CHART • FAULTY CONNECTION CKT 430 OPEN,
IS RESISTANCE 12 OHMS ± .4? A-3 (4 OF 4) OR IGNITION MODULE. SHORTED TO
GROUND,
5 OR FAULTY ECM.
OK NOT OK
REPLACE INJECTOR(S)
• IGNITION “OFF.” THAT IS OUT OF RANGE.
• INSTALL FUEL PRESSURE GAUGE AND NOTE
PRESSURE WHILE CRANKING ENGINE
SHOULD BE 36 PSI (248 kPa) NOMINAL.
OK NOT OK
• REVIEW THE “DIAGNOSTIC AIDS” ON FACING USE APPROPRIATE CHART A-7

PAGE FOR ADDITIONAL ITEMS TO CHECK. IF ALL MULTI-PORT OR THROTTLE BODY
ARE OK, EFI SYSTEM IS OK.
REFER TO “HARD START” IN THE
TROUBLESHOOTING SECTION.
Index
Chart A-3 (3 of 4)
INJ/ECM
FUSE 10A
INJECTORS
IGNITION CONTROL
DIST. REFERENCE “HIGH”
BYPASS
A B
INJECTORS
A B
THROTTLE BODY
MULTI-PORT
TEST DESCRIPTION: To test for this condition:

Number(s) below refer to circled number(s) on the • Disconnect all injectors.
diagnostic chart.
• Ignition ON.
1. Check for 12 volt supply to injectors. Due to the
• Probe CKT 467 and CKT 468 on the ECM
injectors wired in parallel, there should be a light
side of injector harness with a test light con-
ON on both terminals.
nected to ground. (Test one injector harness
2. Check continuity of CKT 467 and CKT 468. on each side of engine.) There should be no
light. If light is ON, repair short to voltage.
3. All checks made to this point would indicate that
the ECM is at fault. However, there is a possibility • If OK, check the resistance of the injectors.
of CKT 467 or CKT 468 being shorted to a voltage Should be 12 ohms + 4.
source either in the engine harness or in the injec-
• Check injector harness connector. Be sure
tor harness.
terminals are not backed out of connector
and contacting each other.
• If all OK, replace ECM.
Index
Chart A-3: (4 of 4)
FROM
A-3
(2 OF 4)
NO BLINKING LIGHT
AT INJECTOR
NO LIGHT STEADY LIGHT
1 • IGNITION “ON.”
• CHECK INJECTOR DRIVER CIRCUIT WITH TEST
• PROBE INJECTOR HARNESS LIGHT FOR SHORT TO GROUND.
TERMINALS WITH A TEST LIGHT TO
GROUND.
• IF CIRCUIT IS NOT SHORTED, CHECK RESISTANCE
ACROSS EACH INJECTOR IN THE CIRCUIT.
• LIGHT SHOULD BE “ON” AT BOTH
• RESISTANCE SHOULD BE 12 OHMS + .4.
TERMINALS.
OK NOT OK
FAULTY ECM REPAIR SHORT TO GROUND

OR REPLACE ANY INJECTOR
THAT MEASURES UNDER 12
OHMS ± .4 OHMS.
LIGHT “ON” BOTH LIGHT “ON” ONE LIGHT “OFF” BOTH
2 • RECONNECT INJECTOR(S) DUE TO INJECTORS WIRED IN REPAIR OPEN IN INJECTOR

PARALLEL, THERE SHOULD BE A
LIGHT ON BOTH TERMINALS.
FEED CIRCUIT.
• DISCONNECT ECM
• IGNITION “ON.” IF NOT, THE PROBLEM IS AN OPEN
• PROBE TERMINALS “J2-21” AND “J2-5” IN THE HARNESS TO THE TESTED
WITH A TEST LIGHT TO GROUND. INJECTOR.
3 REFER TO FACING PAGE. OPEN CKT 467 OR 468
Index
Multi-Port Injection Fuel System Diagnosis
Chart A-7 (1 of 6)
FUEL INLET
PORT FUEL RAIL PORT FUEL RAIL

SCHRADER
VALVE
CONNECT SCHRADER
FUEL VALVE
PRESSURE FUEL INLET CONNECT
GUAGE FUEL
HERE PRESSURE
GUAGE
HERE
FUEL RETURN
STARBOARD FUEL RAIL STARBOARD FUEL RAIL
EARLIER STYLE (MCM & MIE) FUEL LINE ROUTING LATER STYLE (MCM & MIE) FUEL LINE ROUTING
(BLACK SCORPION FUEL INLET IS
LOCATED ON THE REAR OF STARBOARD FUEL RAIL)
CIRCUIT DESCRIPTION: Ignition ON. This pressure is controlled by spring

pressure within the regulator assembly.
During engine cranking, the Engine Control Module
(ECM) will turn ON the electric fuel pump in the vapor 3. When the engine is idling, high vacuum is applied
separator tank. It will remain ON as long as the en- to the fuel regulator diaphragm. This will offset
gine is cranking or running, and the ECM is receiving the spring and result in a lower fuel pressure. This
reference pulses. If there are no reference pulses, idle vacuum will vary somewhat depending on
the ECM will shut OFF the fuel pump. barometric pressure; however, the fuel pressure
at idle should be less, indicating fuel pressure
The pump will deliver fuel to the fuel rail and injectors,
regulator control.
then to the pressure regulator, where the system
pressure is controlled to about 36 PSI (248 kPa) 4. Pressure that leaks down is caused by one of the
nominal. Excess fuel is then returned to the vapor following:
separator tank.
• Fuel pressure regulator valve leaking.
TEST DESCRIPTION: • Injector(s) sticking open.
Number(s) below refer to circled number(s) on the • Check vent line from VST to see if diaphragm
diagnostic chart. is leaking.
1. If pump does not run check fuel pump relay and 5. If an injector is stuck open, it will send fuel to its
fuse. respective cylinder, which may saturate or foul
spark plug(s). In order to determine which injec-
2. Wrap a shop towel around the fuel pressure con- tor is leaking, the spark plugs must be removed
nector to absorb any small amount of fuel leak- and inspected for fouling or saturation. Once the
age that may occur when installing the gauge. saturated spark plug(s) is found, replace the cor-
responding injector(s) and install new spark
plug(s).
FUEL PRESSURE
Multi-Port Fuel Injection
With Vapor Separator 43 PSI (206 kPa)
Tank
Multi-Port Injection With
30 PSI (296 kPa)
Cool Fuel System
Index
Multi-Port Injection Fuel System Diagnosis (Continued)
Chart A-7: (2 of 6)
FROM
CHART A-3 NOTE: THE IGNITION MAY HAVE TO BE CYCLED
(2 OF 4) “ON” MORE THAN ONCE TO OBTAIN MAXIMUM
PRESSURE. ALSO, IT IS NORMAL FOR THE PRESSURE
1
• INSTALL FUEL PRESSURE GAUGE, 91-16850 . TO DROP SLIGHTLY WHEN THE PUMP STOPS.
• IGNITION “OFF” FOR 10 SECONDS.
• IGNITION “ON.” FUEL PUMP WILL RUN FOR ABOUT 2 SECONDS.
• NOTE FUEL PRESSURE, WITH PUMP RUNNING, SHOULD HOLD
STEADY WHEN PUMP STOPS.
OK NOT OK
2 3
• START AND IDLE ENGINE AT
PRESSURE BUT
NOT HOLDING
PRESSURE BELOW
34 PSI (234 kPa)
PRESSURE ABOVE
38 PSI (262 kPa)
NO
PRESSURE
NORMAL OPERATING
TEMPERATURE.
• PRESSURE SHOULD BE LOWER
•
BY 3-10 PSI (21-69 kPa). • IGNITION “OFF” FOR SEE IGNITION “OFF.”
10 SECONDS. CHART A-7 • APPLY 12 VOLTS TO FUEL
• IGNITION “ON.” 4 OF 6 PUMP CONNECTOR(GRAY
• BLOCK FUEL PRESSURE LINE USING WIRE).
OK NOT OK SPECIAL TOOL (SHUT-OFF VALVE) • LISTEN FOR FUEL PUMP
• PRESSURE SHOULD HOLD. RUNNING.
NO TROUBLE FOUND.
REVIEW THE TROUBLE- NOT HOLDING HOLDS
SHOOTING SECTION.
• IGNITION “OFF” FOR 10 SECONDS. CHECK:
• USING AN EXTERNAL • IGNITION “ON.” • LEAKING PUMP FITTINGS,
VACUUM SOURCE, APPLY 10 • BLOCK FUEL RETURN LINE USING OR HOSE.
INCHES OF VACUUM TO FUEL SPECIAL TOOL (SHUT-OFF VALVE) • FAULTY VST PUMP.
PRESSURE REGULATOR. • RECHECK PRESSURE.
• FUEL PRESSURE SHOULD DROP
3-10 PSI (21-69 kPa).
OK NOT OK HOLDS NOT HOLDING
REPAIR VACUUM REPLACE FAULTY FUEL PRESSURE 4 LOCATE AND CORRECT

SOURCE TO REGULATOR REGULATOR. LEAKING INJECTOR(S).
REGULATOR. ASSEMBLY.
PUMP RUNS PUMP NOT RUNNING
CHECK FOR: CHECK FOR:

• RESTRICTED FUEL LINE. • OPEN WIRE IN CKT 120.
• DISCONNECTED HOSE • OPEN PUMP GROUND
CKT 150.
IF OK IF OK
REPLACE ELECTRIC FUEL PUMP.
Index
Chart A-7 (3 of 6)
FUEL INLET
PORT FUEL RAIL PORT FUEL RAIL

SCHRADER
VALVE
CONNECT SCHRADER
FUEL VALVE
PRESSURE CONNECT
GUAGE FUEL INLET
FUEL
HERE PRESSURE
GUAGE
HERE
FUEL RETURN
STARBOARD FUEL RAIL STARBOARD FUEL RAIL
EARLIER STYLE (MCM & MIE) FUEL LINE ROUTING LATER STYLE (MCM & MIE) FUEL LINE ROUTING
(BLACK SCORPION FUEL INLET IS
LOCATED ON THE REAR OF PORT FUEL RAIL)
Check for contaminated fuel tank, struck anti siphon 2. Restricting the fuel return line (Using Special Tool
valve or vacuum leak anywhere before the mechani- - Shut-Off Valve) allows the fuel pressure to build
cal fuel pump. Also possible slipping seawater/fuel above regulated pressure. With battery voltage
pump drive belt. applied to the fuel pump, pressure should rise to
60 PSI (414 kPa) as the fuel return hose is gradu-
TEST DESCRIPTION: ally pinched.
Number(s) below refer to circled number(s) on the NOTE: Do not allow fuel pressure to exceed 60 PSI
diagnostic chart. (414 kPa); damage to the pressure regulator may re-
sult.
1. Pressure less than 34 PSI (234 kPa) falls into two
areas: 3. This test determines if the high fuel pressure is
due to a restricted fuel return line or a pressure
• Regulated pressure less than 34 PSI (234 kPa).
regulator problem.
The system will be running lean. Also, hard start-
ing when cold and overall poor performance will
be noticed.
• Restricted flow causing pressure drop. Normally,
an engine with a fuel pressure of less than 24 PSI
(165 kPa) at idle will not be driveable. However,
if the pressure drop occurs only while underway,
the engine will surge then stop running as pres-
sure begins to drop rapidly. This is most likely
caused by a restricted fuel line or plugged water
separating fuel filter.
Index
Chart A-7: (4 of 6)
CONTINUED FROM
* NOTE: THE IGNITION MAY HAVE TO BE CYCLED
CHART A-7 “ON” MORE THAN ONCE TO OBTAIN MAXI-
(2 OF 6) MUM PRESSURE.
1 HAS PRESSURE, BUT LESS ABOVE 38 PSI (262 kPa)

THAN 34 PSI (234 kPa)
3 • DISCONNECT FUEL RETURN LINE.
• FOLLOWING MANUFACTURER’S INSTRUCTIONS, ATTACH
FLEX HOSE TO RETURN LINE. INSERT THE OTHER END IN AN
CHECK FOR RESTRICTED APPROVED GASOLINE CONTAINER. NOTE FUEL PRESSURE
FUEL LINES. WITHIN 2 SECONDS AFTER IGNITION IS TURNED “ON.”
OK NOT OK
ABOVE 38 PSI (262 kPa) 34-38 PSI (234-262 kPa)
REPAIR FUEL LINE
AND RECHECK. CHECK FOR RESTRICTED FUEL LOCATE AND CORRECT
RETURN LINE FROM FUEL RESTRICTED FUEL RETURN
2 • IGNITION “OFF.” PRESSURE REGULATOR TO LINE TO VAPOR SEPARATOR
POINT WHERE FUEL LINE WAS
• BLOCK FUEL RETURN LINE FOLLOWING
DISCONNECTED.
TANK.
INSTRUCTIONS.
• CYCLE IGNITION “ON.” PRESSURE
SHOULD RISE ABOVE 38 PSI (262 kPa).
IF LINE OK, REPLACE FUEL
PRESSURE REGULATOR.
ABOVE 38 PSI HAS PRESSURE, BUT LESS

(262 kPa) THAN 34 PSI (234 kPa)
FAULTY
FAULTY PRESSURE
FUEL PUMP
REGULATOR.
Index
Chart A-7 (5 of 6)
TO
SYSTEM 902 RED 339 PNK/BLK ECM
RELAY FUEL PUMP
RELAY FUSE
15A
87a
FUEL 30
PUMP 85 465 DK GRN/WHT J2-9 FUEL PUMP
RELAY RELAY DRIVER
86 450 BLK/WHT
87
120 GRY A M B 150 BLK

FUEL PUMP
TEST DESCRIPTION:
diagnostic chart.
1. This step checks if there is power to the fuel pump
relay.
2. Bypassing the relay circuit should cause the fuel
pump to run. This step should identify if the fault
is in the relay or in the fuel pump circuit.
3. This step checks if there is an open in the ground
circuit.
4. This step checks if the ECM is functioning proper-
ly.
Index
Chart A-7: (6 of 6)
FROM CHART
A-7
(4 OF 6)
• REMOVE FUEL PUMP RELAY.
• WITH TEST LIGHT CONNECTED TO
GROUND, PROBE FUEL PUMP RELAY
CONNECTOR CAVITY “30” TEST LIGHT
SHOULD BE “ON.” IS IT?
YES
NO
• USING FUSED JUMPER, CONNECT • CHECK FUEL PUMP RELAY FUSE.
TERMINALS “30” AND “87” OF FUEL IS IT OK?
PUMP RELAY CONNECTOR TOGETHER.
• FUEL PUMP SHOULD RUN. DOES IT? YES NO
REPAIR OPEN CKT REPAIR SHORT TO

339 OR 902 GROUND IN CKT 339
AND REPLACE FUSE
YES NO
• DISCONNECT FUSED JUMPER. CHECK FOR:
• CONNECT TEST LIGHT TO BATTERY POSITIVE • OPEN WIRE IN CKT 120.
B+ AND PROBE CAVITY “86” OF THE • OPEN PUMP GROUND CKT 150. IF OK,
FUEL PUMP RELAY CONNECTOR. REPLACE FUEL PUMP.
YES NO
4 • CONNECT TEST LIGHT TO GROUND REPAIR OPEN

AND PROBE CAVITY “85” OF THE FUEL GROUND CKT 450
PUMP RELAY CONNECTOR.
• TEST LIGHT SHOULD BE “ON” FOR
2 SECONDS AND THEN GO “OFF.”
DOES IT?
YES NO
• REPLACE FUEL PUMP RELAY AND RETEST.

IF STILL NO PRESSURE, CHECK THE FOLLOWING: CHECK FOR OPEN
• VAPOR LOCK CONDITION. IN CKT 465. IF OK,
• RESTRICTED FUEL LINE. REPLACE ECM.
• DISCONNECTED HOSES.
• PROPER FUEL LEVEL.
IF OK, REPLACE FUEL PUMP.
Index
Throttle Body Injection Fuel System Diagnosis
Chart A-7 (1 of 6)
FUEL LINE TO
ELECTRIC FUEL PUMP
WATER SEPARATING
FUEL FILTER
SHUT-OFF TOOL
IMPORTANT: Check for contaminated fuel tank, NOTE: If pump does not run, check fuel pump relay
stuck anti-siphon valve or fuel system vacuum and fuse.
leak anywhere before the electrical fuel pump
1. Install the fuel pressure adapter in-line at the
and after the fuel pressure regulator.
throttle body.
CIRCUIT DESCRIPTION: 2. Wrap a shop towel around the fuel pressure con-
nector to absorb any small amount of fuel leak-
During engine cranking, the Engine Control Module age that may occur when installing the gauge.
(ECM) will turn ON the electric fuel pump. It will re-
main ON as long as the engine is cranking or running, Ignition ON, pump pressure should be 28-32 PSI
and the ECM is receiving reference pulses. If there (234-207 kPa). This pressure is controlled by
are no reference pulses, the ECM will shut OFF the spring pressure within the regulator assembly.
fuel pump. 3. Pressure that leaks down is caused by one of the
The pump will deliver fuel to the injectors and pres- following:
sure regulator, where the system pressure is con- • Fuel pressure regulator valve leaking.
trolled to about 30 PSI (207 kPa) nominal. Excess
fuel is then returned to the water separating fuel filter. • Injector(s) sticking open.
• Check valve in fuel pump leaking.
TEST DESCRIPTION:
4. An injector that is stuck open will leak or drip fuel
Number(s) below refer to circled number(s) on the into the plenum of intake manifold, which may
diagnostic chart. saturate or foul spark plug(s). In order to deter-
mine which injector is leaking, remove the flame
arrestor and observe both fuel injectors with “key
on” and “engine off”.
Index
Throttle Body Injection Fuel System Diagnosis (Continued)
Chart A-7: (2 of 6)
NOTE: THE IGNITION MAY HAVE TO BE CYCLED
“ON” MORE THAN ONCE TO OBTAIN MAXIMUM
FROM PRESSURE. ALSO, IT IS NORMAL FOR THE PRESSURE
CHART A-3 TO DROP SLIGHTLY WHEN THE PUMP STOPS.
(2 OF 4)
1 • INSTALL FUEL PRESSURE GAUGE, 91-16850 AND FUEL PRESSURE ADAPTER

• IGNITION “OFF” FOR 10 SECONDS.
• IGNITION “ON.” FUEL PUMP WILL RUN FOR ABOUT 2 SECONDS.
• NOTE FUEL PRESSURE, WITH PUMP RUNNING, SHOULD BE
28-32 PSI (193-221 kPa) AND HOLD STEADY WHEN PUMP STOPS.
OK NOT OK
2 3 PRESSURE BUT PRESSURE BELOW PRESSURE ABOVE NO

NO TROUBLE FOUND. NOT HOLDING 28 PSI (193 kPa) 32 PSI (221 kPa) PRESSURE
REVIEW THE TROUBLE-
SHOOTING SECTION.
• REMOVE FLAME
ARRESTOR AND VISUALLY SEE
CHECK FOR LEAKAGE CHART A-7
FROM INJECTORS 4 OF 6 • IGNITION “OFF.”
• APPLY 12 VOLTS TO FUEL
PUMP CONNECTOR (GRAY
WIRE).
NO LEAKAGE
LEAKAGE • LISTEN FOR FUEL PUMP
RUNNING.
REPLACE LEAKING • INSTALL FUEL SHUT-OFF TOOL
4 INJECTOR • IGNITION “OFF” FOR 10 SECONDS.
• BLOCK FUEL RETURN LINE USING
SPECIAL TOOL (SHUT-OFF VALVE)
• PRESSURE SHOULD HOLD
NOT HOLDING HOLDS
FAULTY FUEL PRESSURE CHECK:

REGULATOR. • LEAKING PUMP FITTINGS,
OR HOSE.
• REPLACE FUEL PUMP
PUMP RUNS PUMP NOT RUNNING

CHECK FOR: CHECK FOR:
• RESTRICTED FUEL LINE. • OPEN WIRE IN CKT 120.
• DISCONNECTED HOSE • OPEN PUMP GROUND
CKT 150.
IF OK
IF OK
REPLACE ELECTRIC FUEL PUMP.
Index
Chart A-7 (3 of 6)
RETURN LINE FROM FUEL

PRESSURE REGULATOR
WATER SEPARATING
FUEL FILTER
SHUT-OFF TOOL
IMPORTANT: Check for contaminated fuel tank, 2. Restricting the fuel return line (Shut-Off Valve) al-
stuck anti-siphon valve or fuel system vacuum lows the fuel pressure to build above regulated
leak anywhere before the electrical fuel pump pressure. With battery voltage applied to the fuel
and after the fuel pressure regulator. pump, pressure should rise to 60 PSI (414 kPa)
as the fuel return hose is shut off with special tool.
TEST DESCRIPTION: NOTE: Do not allow fuel pressure to exceed 60 PSI
Number(s) below refer to circled number(s) on the (414 kPa); damage to the pressure regulator may re-
diagnostic chart. sult.
1. Pressure less than 28 PSI (193 kPa) falls into two 3. This test determines if the high fuel pressure is
areas: due to a restricted fuel return line or a pressure
regulator problem.
• Regulated pressure less than 28 PSI (193 kPa).
The system will be running lean. Also, hard start-
ing when cold and overall poor performance will
be noticed.
• Restricted flow causing pressure drop. Normally,
an engine with a fuel pressure of less than 24 PSI
(165 kPa) at idle will not be driveable. However,
if the pressure drop occurs only while underway,
the engine will surge then stop running as pres-
sure begins to drop rapidly. This is most likely
caused by a restricted fuel line or plugged water
separating fuel filter.
Index
Chart A-7: (4 of 6)
CONTINUED FROM
* NOTE: THE IGNITION MAY HAVE TO BE CYCLED
CHART A-7 “ON” MORE THAN ONCE TO OBTAIN MAXI-
(2 OF 6) MUM PRESSURE.
1 HAS PRESSURE, BUT LESS ABOVE 32 PSI (231 kPa)

THAN 28 PSI (193 kPa)
3 • DISCONNECT FUEL RETURN LINE.
• ATTACH FLEX HOSE TO RETURN LINE. INSERT THE OTHER END
IN AN APPROVED GASOLINE CONTAINER. NOTE FUEL PRES
CHECK FOR RESTRICTED SURE WITHIN 2 SECONDS AFTER IGNITION IS TURNED “ON.”
FUEL LINES.
OK NOT OK
ABOVE 32 PSI (231 kPa) 28-32 PSI (193-231 kPa)
REPAIR FUEL LINE
AND RECHECK. CHECK FOR RESTRICTED FUEL LOCATE AND CORRECT
RETURN LINE FROM FUEL RESTRICTION IN WATER SEP-
2 • IGNITION “OFF.” PRESSURE REGULATOR TO ARATING FUEL FILTER
POINT WHERE FUEL LINE WAS
• BLOCK FUEL RETURN LINE FOLLOWING
DISCONNECTED.
INSTRUCTIONS.
• CYCLE IGNITION “ON.” PRESSURE
SHOULD RISE ABOVE 32 PSI (231 kPa).
IF LINE OK, REPLACE FUEL
PRESSURE REGULATOR.
ABOVE 32 PSI HAS PRESSURE, BUT LESS

(231 kPa) THAN 28 PSI (193 kPa)
FAULTY
FAULTY PRESSURE
FUEL PUMP
REGULATOR.
Index
Chart A-7 (5 of 6)
TO
SYSTEM 902 RED 339 PNK/BLK ECM
RELAY FUEL PUMP
RELAY FUSE
15A
87a
FUEL 30
PUMP 85 465 DK GRN/WHT J2-9 FUEL PUMP
RELAY RELAY DRIVER
86 450 BLK/WHT
87
120 GRY A M B 150 BLK

FUEL PUMP
TEST DESCRIPTION:
diagnostic chart.
1. This step checks if there is power to the fuel pump
relay.
2. Bypassing the relay circuit should cause the fuel
pump to run. This step should identify if the fault
is in the relay or in the fuel pump circuit.
3. This step checks if there is an open in the ground
circuit.
4. This step checks if the ECM is functioning proper-
ly.
Index
Chart A-7: (6 of 6)
FROM CHART
A-7 (4 OF 6)
• REMOVE FUEL PUMP RELAY.
• WITH TEST LIGHT CONNECTED TO
GROUND, PROBE FUEL PUMP RELAY
CONNECTOR CAVITY “30” TEST LIGHT
SHOULD BE “ON.” IS IT?
YES NO
• USING FUSED JUMPER, CONNECT • CHECK FUEL PUMP RELAY FUSE.
TERMINALS “30” AND “87” OF FUEL IS IT OK?
PUMP RELAY CONNECTOR TOGETHER.
• FUEL PUMP SHOULD RUN. DOES IT? YES NO
REPAIR OPEN CKT REPAIR SHORT TO

339 OR 902 GROUND IN CKT 339
AND REPLACE FUSE
YES NO
• DISCONNECT FUSED JUMPER. CHECK FOR:
• CONNECT TEST LIGHT TO BATTERY POSITIVE • OPEN WIRE IN CKT 120.
B+ AND PROBE CAVITY “86” OF THE • OPEN PUMP GROUND CKT 150. IF OK,
FUEL PUMP RELAY CONNECTOR. REPLACE FUEL PUMP.
YES NO
4 • CONNECT TEST LIGHT TO GROUND REPAIR OPEN

AND PROBE CAVITY “85” OF THE FUEL GROUND CKT 450
PUMP RELAY CONNECTOR.
• TEST LIGHT SHOULD BE “ON” FOR
2 SECONDS AND THEN GO “OFF.”
DOES IT?
YES NO
• REPLACE FUEL PUMP RELAY AND RETEST.

IF STILL NO PRESSURE, CHECK THE FOLLOWING: CHECK FOR OPEN
• VAPOR LOCK CONDITION. IN CKT 465. IF OK,
• RESTRICTED FUEL LINE. REPLACE ECM.
• DISCONNECTED HOSES.
• PROPER FUEL LEVEL.
IF OK, REPLACE FUEL PUMP.
Index
EFI System/Ignition Relay Check
(1 of 2)
TO IN-LINE BOAT HARNESS
50A
CIRCUIT
BREAKER 86 85
90 AMP
FUSE 30 87
15A
INJ/ECM/KS
MODULE FUSE
10A
CIRCUIT DESCRIPTION: 2. This step ensures that battery and ignition volt-
age are available at the relay. An open or shorted
Battery voltage is constantly supplied to terminal 30
condition in either supply would cause the relay
of the system relay. When the ignition switch is
not to operate.
moved to the run position, battery voltage is supplied
to terminal 86 of the system relay. The pull-in coil is 3. This step ensures that a good ground exists to
then energized, creating a magnetic field which terminal 85 of the system relay. An open ground
closes the contacts of the system relay. Voltage and to this terminal would not allow current to flow
current are then supplied to the ignition coil, injectors, through the pull-in coil.
ECM and fuel pump relay fuse through terminal 87 of
4. At this point, the circuits leading to the relay have
the system relay.
been checked, and a careful visual inspection of
the relay terminals should be preformed prior to
TEST DESCRIPTION: replacement of the system relay.
diagnostic chart.
1. This step identifies if the relay is functioning prop-
erly. If a fault in the relay circuit were present, volt-
age would not be available at terminal B of the
ignition coil.
Index
EFI System / Ignition Relay Check (Continued)
(2 of 2)
• USING A TEST LIGHT CONNECTED TO
GROUND, PROBE IGNITION COIL
CONNECTOR TERMINAL “B.”
• LIGHT SHOULD BE “ON.”
IS IT?
NO YES
REFER TO “IGNITION
• REMOVE SYSTEM RELAY CONNECTOR. SYSTEM CHECK” CHART
• WITH TEST LIGHT STILL CONNECTED TO
GROUND, PROBE RELAY CONNECTOR
CAVITIES “86” AND “30.”
• TEST LIGHT SHOULD LIGHT “ON” BOTH
TERMINAL CAVITIES.
DID IT?
YES NO
3 • CONNECT TEST LIGHT TO BATTERY POSITIVE

(B+) AND PROBE RELAY CONNECTOR CAVITY “85.” REPAIR OPEN OR SHORT
TO GROUND IN CIRCUIT
• TEST LIGHT SHOULD LIGHT. DID IT?
THAT DID NOT LIGHT
YES NO
4 • CHECK RELAY CONNECTOR FOR REPAIR OPEN OR GROUND

POOR CONTACT OR CKT 150 AND RETEST
CORROSION. IF OK, REPLACE
SYSTEM RELAY.
Index
Ignition System Check
(1 of 2)
IGNITION CONTROL
BYPASS
TO TACH
TO DISTRIBUTOR
TEST DESCRIPTION: 4. Checks for a shorted module or grounded circuit

from the ignition coil to the module. The distribu-
tor module should be turned OFF, so normal volt-
diagnostic chart.
age should be about 12 volts.
1. Two spark plug wires are checked, to ensure that
If the module is turned ON, the voltage would be
an open is not present in a spark plug wire.
low, but above 1 volt. This could cause the igni-
If spark occurs with Ignition Control (IC) connection coil to fail from excessive heat.
tor disconnected, magnetic field output is too low
With an open ignition coil primary winding, a
for Ignition Control (IC) operation.
small amount of voltage will leak through the
2. A spark indicates the problem must be the distrib- module from the Battery Positive (B+) to the
utor cap or rotor. “Tach” terminal.
3. Normally, there should be battery voltage at the
“C” and “+” terminals. Low voltage would indicate
an open or a high resistance circuit from the dis-
tributor to the coil or ignition switch. If “C” terminal
voltage was low, but “+” terminal voltage is 10
volts or more, circuit from “C” terminal to ignition
coil or ignition coil primary winding is open.
Index
Ignition System Check(1 of 2)
1 • DISCONNECT TACH BEFORE PROCEEDING WITH THE TEST.
• CHECK SPARK AT PLUG WIRE USING AN INDUCTIVE PICKUP TIMING LIGHT
WHILE CRANKING. A FLASHING LIGHT INDICATES SPARK. (IF NO SPARK ON FIRST
WIRE, CHECK SECOND WIRE.) A FEW SPARKS AND THEN NOTHING
IS CONSIDERED NO SPARK.
NO SPARK SPARK
• DISCONNECT 4 TERMINAL CONNECTOR

1A ON DISTRIBUTOR AND CHECK FOR CHECK FUEL, SPARK PLUGS, ETC.
SPARK. SEE “TROUBLESHOOTING.”
NO SPARK SPARK
2 • CHECK FOR SPARK AT COIL WIRE WITH TIMING REPLACE MAGNETIC

LIGHT WHILE CRANKING. (LEAVE TIMING LIGHT SHAFT ASSEMBLY.
CONNECTED TO COIL WIRE FOR STEPS 3-6).
NO SPARK SPARK
3 DISCONNECT DISTRIBUTOR 2 WIRE TERMINAL INSPECT CAP FOR WATER,

• “C/+” PNK/BRN CONNECTOR. CRACKS, ETC. IF OK,
IGNITION SWITCH “ON,” ENGINE STOPPED. REPLACE ROTOR.
• CHECK VOLTAGE AT “+ BRN” AND “C PNK” TERMI
NALS OF DISTRIBUTOR HARNESS CONNECTION.
BOTH TERMINALS 10 BOTH TERMINALS UNDER 10 VOLTS “C

VOLTS OR MORE UNDER 10 VOLTS PNK”TERMINAL ONLY
4
REPAIR WIRE FROM MOD- CHECK FOR OPEN OR

• RECONNECT DISTRIBUTOR 2
ULE “+” TERMINAL TO “B” GROUND IN CKT. FROM “C”
TERMINAL CONNECTOR.
TERMINAL OF BLACK IGNI- TERMINAL TO IGNITION COIL.
• WITH IGNITION “ON,” CHECK VOLT-
TION COIL CONNECTOR IF CKT IS OK, FAULT IS IGNI-
AGE FROM TACH. TERMINAL TO
OR PRIMARY CKT. TO IGNI- TION COIL OR CONNECTION.
GROUND
TION SWITCH.
OVER 10 VOLTS UNDER 1 VOLT 1 TO 10 VOLTS
REPLACE MODULE AND

• CONNECT TEST LIGHT FROM TACH. REPAIR OPEN TACH.
LEAD OR CONNEC- CHECK FOR SPARK FROM
TERMINAL TO GROUND.
COIL AS IN STEP 6.
• CRANK ENGINE AND OBSERVE TION AND REPEAT
LIGHT. TEST #4.
SPARK NO
SPARK
SYSTEM REPLACE
OK IGNITION
CHART CONTINUED COIL.
ON PAGE 79
a b
Index
Ignition System Check
(2 of 2)
IGNITION CONTROL
BYPASS
TO IN-LINE HARNESS (TACH)
TO DISTRIBUTOR
TEST DESCRIPTION: 2. This should turn OFF the module and cause a
spark. If no spark occurs, the fault is most likely
in the ignition coil because most module prob-
diagnostic chart.
lems would have been found before this point in
1. Applying a voltage (1.5 to 8 volts) to module ter- the procedure.
minal “P” should turn the module ON and the
“Tach” terminal voltage should drop to about 7-9
volts. This test will determine whether the module
or coil is faulty or if the pick-up coil is not generat-
ing the proper signal to turn the module “ON.”
This test can be performed by using a DC battery
with a rating of 1.5 to 8 volts. The use of the test
light is mainly to allow the “P” terminal to be
probed more easily. Some digital multimeter can
also be used to trigger the module by selecting
ohms, usually the diode position. In this position,
the meter may have a voltage across its terminals
which can be used to trigger the module. The volt-
age in the ohms position can be checked by using
a second meter or by checking the manufactur-
er’s specification of the tool being used.
Index
Ignition System Check (2 of 2)
TEST LIGHT
TO DC
POWER
a b SUPPLY
CHART CONTINUED (1.5 to 8 V)
FROM PAGE 75
LIGHT ON LIGHT
STEADY BLINKS
Fig. 1
5 • DISCONNECT DISTRIBUTOR 4 TERMINAL CONNECTOR. REPLACE IGNITION COIL AND

• REMOVE DISTRIBUTOR CAP. RECHECK
• DISCONNECT PICK-UP COIL CONNECTOR FROM MODULE. FOR SPARK WITH TIMING
• CONNECT VOLTMETER FROM TACH. TERMINAL TO GROUND. LIGHT. IF STILL
• IGNITION “ON.” NO SPARK, REINSTALL ORIGI-
• INSULATE A TEST LIGHT PROBE TO 1/4, FROM TIP AND NOTE NAL COIL
VOLTAGE, AS TEST LIGHT IS MOMENTARILY CONNECTED FROM A AND REPLACE DISTRIBUTOR
VOLTAGE SOURCE (1.5 TO 8 V) TO MODULE TERMINAL “P” (CHART MODULE.
1 OF 2 PAGE 78).
VOLTAGE DROPS NO DROP IN VOLTAGE
6 • CHECK FOR SPARK FROM COIL WIRE CHECK MODULE GROUND.

WITH TIMING LIGHT AS TEST LIGHT IS IF OK, REPLACE MODULE.
REMOVED FROM MODULE TERMINAL
NO SPARK SPARK
• REPLACE IGNITION COIL • IS ROTATING POLE

AND REPEAT STEP 5. PIECE STILL MAGNE-
TIZED?
NO SPARK SPARK
YES NO
IGNITION COIL REMOVED IS OK, SYSTEM OK

REINSTALL COIL AND CHECK COIL CHECK PICK-UP COIL OR REPLACE POLE
WIRE FROM DIST. CAP. IF OK, RE- CONNECTIONS (COIL PIECE AND
PLACE DISTRIBUTOR MODULE. RESISTANCE SHOULD BE SHAFT ASSEMBLY.
500-1500 OHMS AND
NOT GROUNDED.)
Index
Idle Air Control (IAC) Functional Test
(1 of 2)
441 BLU/WHT
CONTROL
443 GRN/WHT
(IAC) VALVE
444 GRN/BLK

The ECM controls idle speed to a calculated, “de- Check for vacuum leaks, unconnected or brittle vacu-
sired” RPM based on sensor inputs and actual en- um hoses, cuts, etc. Examine manifold and throttle
gine RPM, determined by the time between succes- body gaskets for proper seal. Check for cracked in-
sive ignition reference pulses from the ignition take manifold/plenum. Check open, shorts, or poor
module. The ECM uses four circuits to move an Idle connections to IAC valve in CKTs 441, 442, 443 and
Air Control (IAC) valve, which allows varying 444.
amounts of air flow into the intake manifold, control-
An open, short, or poor connection in CKTs 441, 442,
ling idle speed.
443, or 444 will result in improper idle control and
IMPORTANT: Improper IAC readings or improper may cause improper idle.
idle speed can result from other faults ie: flood-
An IAC valve which is stopped and cannot respond
ing VST, fouled spark plugs, bad sensors. These
to the ECM, a throttle stop screw which has been
items should be in proper working order to en-
tampered with, or a damaged throttle body or linkage
sure correct diagnosis.
could cause improper idle.
TEST DESCRIPTION:
functional check chart.
1. This step determines if the IAC valve is function-
ing properly.
2. This step determines if the circuitry or the IAC
valve is faulty.
Index
Idle Air Control Functional Test
(2 of 2)
• START ENGINE, ALLOW IDLE TO STABILIZE, AND RECORD ENGINE RPM.

1A • PLACE ENGINE IN BASE TIMING OR SERVICE MODE.. DOES A
NOTICEABLE DROP IN RPM OCCUR OR DOES ENGINE DIE? SEE NOTE.
YES NOTE IN STEP 1A:

A 502/BLACKHAWK MAY NOT
DIE, BUT IDLE WILL DROP
EXIT SERVICE MODE AND DRASTICALLY.
1B RESTART ENGINE. ENGINE SPEED SHOULD
GRADUALLY RETURN WITHIN 75 RPM OF
RECORDED RPM WITHIN 30 SECONDS.
DOES IT?
YES NO
IAC CIRCUIT FUNCTIONING PROPERLY. 2 • IGNITION “OFF” FOR 10 SECONDS.

• UNPLUG IAC CONNECTOR
IF CONNECTED.
• RESTART ENGINE WITH A TEST LIGHT
CONNECTED TO GROUND.
• PROBE EACH ONE OF THE FOUR IAC
TERMINALS, AND THE TEST LIGHT
SHOULD BLINK WHEN TOUCHED TO
ALL TERMINALS. DOES IT?
NO YES
STICKY OR
CHECK IAC CIRCUIT FAULTY
THAT DID NOT BLINK FOR IAC VALVE.
OPEN OR SHORTED
FROM IAC HARNESS TO
J-2 CONNECTOR
CIRCUIT. IF OK,
REPLACE ECM.
Index
Lanyard Stop Circuit Check (Emergency Stop) Circuit Check
(1 of 2)
ECM
IN LINE 2 WAY
CONNECTOR
NORMALLY
OPEN
A 942 PNK J1-21 LANYARD STOP SWITCH CIRCUIT

1996 AND EARLIER MODELS
B BLK
LANYARD STOP SWITCH
NOTE: Some models are no longer equipped with 4. This step identifies which half of the circuitry is
this option in the wiring harness. Connection of the shorted to ground; i.e., ECM side or switch side.
lanyard stop switch (if equipped) is performed at the
5. This step identifies if the circuitry or ECM is the
instrument panel.
cause of the short to ground.
CIRCUIT DESCRIPTION:
DIAGNOSTIC AIDS:
The Lanyard Stop circuit is a safety feature incorpo-
An intermittent problem may be caused by a poor or
rated in boats to stop the engine in the event that the
corroded connection, rubbed through wire connec-
operator is removed from a safe control position dur-
tion, a wire that is broken inside the insulation, or a
ing normal operation. The Lanyard Stop switch is a
corroded wire.
normally open switch that is physically connected to
the operator by a tether. In the event that the operator Any circuitry that is suspected as causing the inter-
is removed from a control position, the tether con- mittent complaint should be thoroughly checked for
nected to the switch will be pulled out, closing the backed-out terminals, improper mating, broken
switch. This information from the Lanyard Stop locks, improperly formed or damaged terminals, poor
switch will then be used by the ECM to cease engine terminal-to-wiring connections, corroded terminals
operation until the position of the switch is restored and/or wiring, or physical damage to the wiring har-
to its normally open position and the ignition key ness.
switch has been cycled.
TEST DESCRIPTION:
1. If a Lanyard Stop was recognized by the ECM,
cycling the ignition will clear the Lanyard Stop
condition in the ECM.
2. This step checks to see if the Lanyard Stop switch
is in the correct position. If the switch is closed, a
Lanyard Stop condition will exist.
3. This step checks for Lanyard Stop switch or Lan-
yard Stop circuitry that is shorted to ground.
Index
Lanyard Stop (Emergency Stop) Circuit Check
(2 of 2)
NOTE: THIS CHART ASSUMES THE ENGINE CRANKS BUT WILL NOT START.
1 • TURN IGNITION “OFF.”

• TURN IGNITION “ON” AND CRANK ENGINE DOES ENGINE START?
NO YES
LANYARD STOP CIRCUIT FUNCTIONING

2 • CHECK LANYARD STOP SWITCH TO MAKE PROPERLY. REFER TO “DIAGNOSTIC AIDS”
SURE SWITCH IS IN ITS NORMAL POSITION.
ON FACING PAGE.
IS IT?
YES NO
NO
POSITION SWITCH CORRECTLY AND
3 • DISCONNECT 2 WAY HARNESS CONNECTOR. REPEAT STEP #1.
• USING A DVOM, MEASURE RESISTANCE
BETWEEN PIN A (CKT 942) AND PIN B (GRD) OF
OF 2 WAY CONNECTOR. RESISTANCE SHOULD
BE LESS THAN 5K OHMS IS IT?
• RESISTANCE SHOULD BE INFINITE ON LANYARD
STOP HARNESS SIDE. IS IT?
NO
NO YES
YES
4 RESISTANCE LOWER ON RESISTANCE LOWER ON BASIC HEI PROBLEM.

ECM SIDE OF CONNECTOR. 4 LANYARD STOP SWITCH REFER TO “IGNITION
SIDE OF CONNECTOR. SYSTEM CHECK.”
5 • DISCONNECT ECM J-1 CHECK FOR FAULTY

CONNECTOR. LANYARD STOP SWITCH.
• MEASURE RESISTANCE IF OK, REPAIR SHORT TO
BETWEEN PIN J1-21 OF GROUND IN CKT 942
ECM CONNECTOR AND AND RETEST.
GROUND. RESISTANCE
SHOULD BE INFINITE.
IS IT?
YES
YES
YES NO
NO
NO
FAULTY ECM. REPLACE ECM REPAIR SHORT TO GROUND

AND RETEST LANYARD STOP IN CKT 942 BETWEEN ECM
CIRCUIT. J1 CONNECTOR AND LAN-
YARD STOP SWITCH.
Index
Audio Warning Buzzer Circuit Check
(1 of 2)
TAN/ D
TO BUZZER 121 TAN
BLU
TO IGN PUR
PPL C 3 PNK TO SYSTEM
TO AUDIO BLU/ RELAY TERM
WARNING B
SWITCHES TAN “87”
TO TACH GRY A
TO BUZZER
(COOLANT OVERTEMP)
121 WHT
TO BUZZER
TO
FROM AUDIO WARNING
IGN 931 BRN J1-6
SWITCHES
COIL
CIRCUIT DESCRIPTION: 4. This step identifies if the fault is a short in the har-
ness or a faulty ECM.
The audio warning buzzer function of the ECM is
used to alert the operator of a critical engine function 5. This step checks for an open in the circuitry from
parameter. Used in conjunction with the discrete in- the harness connector to the ignition fuse.
put circuitry, the ECM will supply ignition current to
6. This step identifies if the open circuit is due to a
activate the buzzer if a change of state is indicated by
faulty ECM or warning buzzer circuitry.
any of the discrete inputs. When a discrete switch
changes state from normally open to closed, the
DIAGNOSTIC AIDS:
ECM interprets that an anomaly is present and will
complete the ground to the affected buzzer circuit, An intermittent problem may be caused by a poor or
energizing the buzzer. corroded connection, rubbed through wire connec-
TEST DESCRIPTION: corroded wire.
Number(s) below refer to circled number(s) on the Any circuitry that is suspected as causing the inter-
functional check chart. mittent complaint should be thoroughly checked for
backed-out terminals, improper mating, broken
1. This step performs a functional check of the
locks, improperly formed or damaged terminals, poor
buzzer circuit.
terminal-to-wiring connections, corroded terminals
2. This step identifies a short to ground in the control and/or wiring, or physical damage to the wiring har-
circuit. ness.
3. This step identifies an open in the control circuit.
Index
Audio Warning Buzzer Circuit Check
(2 of 2)
BUZZER SHOULD SOUND AND THEN
SILENCE WITHIN 2 SECONDS.
DOES IT?
NO YES
NO PROBLEM FOUND. RE-

FER TO DIAGNOSTIC AIDS
ON FACING PAGE.
2 • BUZZER REMAINS “ON” CONSTANTLY 3 • BUZZER NEVER SOUNDS.

WITH IGNITION “ON.”
DISCONNECT HARNESS CONNECTOR TO CHECK CIRCUIT BREAKER IN

BUZZER, BUZZER SHOULD SILENCE. STARTING/CHARGING SYS-
DOES IT? TEM.
YES NO NO YES
4 • RECONNECT REPAIR SHORT TO

5 • DISCONNECT CHECK FOR
HARNESS GROUND IN HARNESS CONNECTOR. SHORT TO
CONNECTOR. AFFECTED CIRCUIT • USING FUSED JUMPER
GROUND IN
• IGNITION “OFF.” BETWEEN BUZZER
CONNECTED TO
AFFECTED CIR-
CUIT. IF CIRCUIT IS
AND CONNECTOR.
• DISCONNECT ECM GROUND, PROBE
NOT SHORTED, RE-
“J2” CONNECTOR. CONNECTOR (BUZZER
PLACE FUSE.
• IGNITION “ON.” SIDE) OF AFFECTED
CIRCUIT. BUZZER
BUZZER SHOULD BE
SHOULD SOUND.
SILENT. IS IT?
DOES IT?
NO YES NO YES
REPAIR SHORT FAULTY ECM. REPLACE BUZZER 6 • IGNITION “OFF.”

TO GROUND REPLACE ECM AND RECHECK. IF • RECONNECT HARNESS
BETWEEN AND RETEST BUZZER STILL DOES CONNECTOR.
HARNESS BUZZER CIR-
CONNECTOR CUIT.
NOT SOUND, REPAIR
• DISCONNECT ECM “J2”
OPEN IN AFFECTED
CONNECTOR.
AND ECM “J2” CIRCUIT.
CONNECTOR. • WITH FUSED JUMPER
STILL CONNECTED TO
GROUND, PROBE ECM
HARNESS ON AFFECTED
CIRCUITS. BUZZER
SHOULD SOUND.
DOES IT?
YES NO
FAULTY ECM. REPAIR

REPLACE ECM OPEN WIRE
AND RETEST. OR FAULTY
CONNECTOR
IN AFFECTED
CIRCUIT.
Index
Discrete Input Circuit Check (Power Reduction Mode) (Non-Scan)
(1 of 2)
TO SYSTEM
RELAY TERM
“87”
TAN/ 121 TAN

TO BUZZER D
BLU
TO IGN PUR
PPL C 3 PNK
TO AUDIO BLU/
WARNING TAN B
SWITCHES
TO TACH GRY
A
TO BUZZER
(COOLANT OVERTEMP)
121 WHT
TO BUZZER
TO (AUDIO WARNING SWITCHES)
IGN
COIL FROM AUDIO WARNING
SWITCHES
931 BRN J1-6

Several discrete switch inputs are utilized by the fuel NOTE: Refer to Section 4C to test transmission tem-
injection system to identify abnormal conditions that perature switch.
may affect engine operation. A pull-up switch is cur-
1. This step checks if wiring from the engine
rently used in conjunction with the ECM to detect criti-
switches to the ECM is not shorted to ground.
cal conditions to engine operation.
2. This step ensures that the discrete switches are
If a switch changes states from its normal at-rest
functioning properly by changing state. (I/O oil
position, that is normally open to closed, the ECM
level, transmission temperature will not change
senses a change in voltage and responds by entering
state.)
power reduction mode. (And activating the audio
warning system.)
DIAGNOSTIC AIDS:
NOTE: Power reduction mode is not used 1997 and
• Check engine oil and I/O fluid levels, transmis-
later models.
sion fluid, overheat.
This engine protection feature allows the driver full
• If above diagnostics are performed and no
engine power up to 2800 RPM, but disables four fuel
change in performance is made, refer to “Trou-
injectors above 2800 RPM until the engine RPM
bleshooting.”
drops to 1200 RPM.
This feature allows the operator a comfortable ma-
neuvering speed while removing the possibility of
tion, or a wire that is broken inside the insulation.
high RPM engine operation until the problem is cor-
rected.
Index
Discrete Input Circuit Check
(2 of 2)
OIL PRESSURE SWITCH
DISCONNECT TAN/BLU WIRE FROM OIL PRESSURE SWITCH. START ENGINE, THERE SHOULD BE
RESISTANCE (NO CONTINUITY) FROM OIL PRESSURE SWITCH AND GROUND (ENGINE BLOCK).
ENGINE OFF, IGNITION ON, CHECK RESISTANCE FROM OIL PRESSURE SWITCH AND GROUND
(ENGINE BLOCK). RESISTANCE SHOULD BE NEAR ZERO (CONTINUITY CIRCUIT).
YES NO
DISCONNECT ECM J1 CONNECTOR FROM ECM. CHECK REPLACE FAULTY

FOR CONTINUITY BETWEEN J1-6 AND TAN/BLU WIRE SWITCH IN CIRCUIT.
FROM OIL PRESSURE SWITCH
YES NO
DISCRETE INPUT CIRCUIT DISCONNECT IN-LINE HARNESS AND CHECK CONTINUITY ON TAN/BLU
FUNCTIONING PROPERLY. WIRE FROM OIL PRESSURE SWITCH TO IN-LINE HARNESS CONNECTOR
YES NO
CHECK CONTINUITY ON TAN/BLU WIRE FROM IN-LINE HARNESS REPAIR SHORT

CONNECTOR TO J1-6 TERMINAL ON ECM CONNECTOR IN CIRCUIT.
YES NO
REPLACE ECM REPAIR SHORT

AND RETEST. IN CIRCUIT.
I/O LEVEL SWITCH (GEAR LUBE MONITOR)
DISCONNECT TAN/BLU WIRE FROM I/O OIL LEVEL SWITCH. START ENGINE, CHECK RESISTANCE
FROM TAN/BLU WIRE AND BLK GROUND WIRE. RESISTANCE SHOULD BE NEAR ZERO.
YES NO
DISCONNECT ECM J1 CONNECTOR FROM ECM. CHECK REPLACE GEAR

FOR CONTINUITY BETWEEN J1-6 AND TAN/BLU WIRE LUBE BOTTLE.
FROM OIL LEVEL SWITCH
YES NO
DISCRETE INPUT CIRCUIT DISCONNECT IN-LINE HARNESS AND CHECK CONTINUITY ON TAN/BLU
FUNCTIONING PROPERLY. WIRE FROM OIL LEVEL SWITCH TO IN-LINE HARNESS CONNECTOR.
YES NO
CHECK CONTINUITY ON TAN/BLU WIRE FROM IN-LINE HARNESS REPAIR SHORT

CONNECTOR TO J1-6 TERMINAL ON ECM CONNECTOR. IN CIRCUIT.
YES NO
REPLACE ECM REPAIR SHORT

AND RETEST. IN CIRCUIT.
REFER TO REPAIR PORTION OF THIS SECTION FOR TESTING OF TRANSMISSION FLUID TEMPERATURE SWITCH.
Index
Diagnostics-Without Scan Tool
Code 14: Engine Coolant Temperature (ECT) Sensor Circuit (Non-Scan)
(1 of 2)
ENGINE
ENGINE
CIRCUIT DESCRIPTION: 3. This step will isolate the problem to CKT 410 (5
volt reference) or to the sensor ground.
The Engine Coolant Temperature (ECT) sensor uses
a thermistor to control the signal voltage to the ECM. 4. This step identifies if CKT 410 is open or shorted
The ECM applies a voltage on CKT 410 to the sensor. to ground.
When the engine coolant is cold, the sensor (thermis-
tor) resistance is high; therefore, the ECM will see DIAGNOSTIC AIDS:
high signal voltage.
As the engine coolant warms, the sensor resistance corroded connection, rubbed through wire connec-
becomes less, and the voltage drops. tion, a wire that is broken inside the insulation, or a
corroded wire.
TEST DESCRIPTION:
Any circuitry that is suspected as causing the inter-
Number(s) below refer to circled number(s) on the mittent complaint should be thoroughly checked for
diagnostic chart. backed-out terminals, improper mating, broken
1. This step checks if there is a problem with the
ECM and wiring or if the problem is the coolant
and/or wiring, or physical damage to the wiring har-
sensor.
ness. After repairs, clear codes following “Clearing
2. Check the harness terminals thoroughly for loose Codes” in “ECM Self-Diagnostics.” Failure to do so
connection. If the resistance or the coolant sen- may result in codes not properly being cleared.
sor is monitored, the resistance should steadily Check harness routing for a potential short to ground
decrease as the engine coolant warms up. The in CKT 410. See “Intermittents” in “Troubleshooting.”
resistance reading would stabilize when the ther-
IMPORTANT: If replacing the ECT, tighten hand
mostat opens.
tight plus 2-1/2 turns maximum.
Index
Code 14: ECT Circuit (Non-Scan)
(2 of 2)
• DISCONNECT ECT SENSOR CONNECTOR.
• CONNECT DVM ACROSS COOLANT SENSOR HARNESS TERMINALS.
IS VOLTAGE ABOVE 4 VOLTS?
NO YES
3 • CONNECT POSITIVE DVM LEAD FROM HARNESS 2 INTERMITTENT CONNECTIONS

TERMINAL “B” CKT 410 (5 VOLT REFERENCE). OR
• CONNECT NEGATIVE DVM LEAD TO A GOOD FAULTY ECT SENSOR. REFER
GROUND ON ENGINE. TO DIAGNOSTIC AID CHART
IS VOLTAGE ABOVE 4 VOLTS? FOR SENSOR VALUES
NO YES
• REMOVE DOVM. OPEN SENSOR GROUND CKT 814

• IGNITION “ON.” OR
FAULTY CONNECTION AT ECM
• CONNECT A TEST LIGHT TO BATTERY OR FAULTY ECM.
POSITIVE (B+).
• TOUCH TEST LIGHT TO SENSOR
HARNESS TERMINAL “B” (CKT 410).
IS TEST LIGHT “ON”?
NO YES
CKT 410 OPEN • DISCONNECT ECMJ-1

OR CONNECTOR.
FAULTY CONNECTION AT ECM IS TEST LIGHT “ON”?
OR
FAULTY ECM.
YES NO
CKT 410 SHORTED TO SENSOR GROUND

CKT 410 SHORTED
OR
TO GROUND.
FAULTY ECM.
DIAGNOSTIC AID
ECT SENSOR
TEMPERATURE TO RESISTANCE VALUES
(APPROXIMATE)
°F °C OHMS
210 100 185
160 70 450
100 38 1,800
70 20 3,400
40 4 7,500
20 -7 13,500
0 -18 25,000
-40 -40 100,700
Index
Code 21: Throttle Position (TP) Sensor Circuit (Non-Scan)
(1 Of 2)
B
B
C C TP
A
A

The Throttle Position (TP) sensor provides a voltage An intermittent problem may be caused by a poor or
signal that changes, relative to the throttle blade. Sig- corroded connection, rubbed through wire connec-
nal voltage should vary from about .7 volts at idle to tion, a wire that is broken inside the insulation, or a
about 4.5 volts at Wide Open Throttle (W.O.T.). corroded wire.
TEST DESCRIPTION: mittent complaint should be thoroughly checked for
Number(s) below refer to circled number(s) on the backed-out terminals, improper mating, broken
diagnostic chart. locks, improperly formed or damaged terminals, poor
1. This step checks for a voltage from terminal “C”
(5 volt reference) to terminal “A” (sensor ground).
2. This step will identify if the problem is in the sup- Codes” in “ECM Self-Diagnostics.” Failure to do so
ply or ground circuit. may result in codes not properly being cleared. If
Code 23 is also set, check CKT 813 for faulty wiring
3. This step determines if the TP sensor signal cir-
or connections. Check terminals at sensor for good
cuit to the ECM is open.
contact.
4. This step completes the test for the ECM and wir-
ing. If the test light is not ON, the TP sensor has
an internal problem.
Index
Code 21: Throttle Position (TP) Sensor Circuit (Non Scan)
• DISCONNECT THROTTLE POSITION SENSOR
ELECTRICAL CONNECTOR.
• CONNECT A DVM FROM HARNESS TERMINAL “A”
(5 VOLT REFERENCE TO HARNESS TERMINAL “B”
SENSOR GROUND).
IS VOLTAGE READING OVER 4 VOLTS?
YES NO
3 • CONNECT DVM FROM HARNESS TERMINAL “A” 2 • CONNECT DVM FROM THROTTLE POSITION
(CKT 416) TO HARNESS TERMINAL “C” (THROTTLE SENSOR HARNESS TERMINAL “A” TO A GOOD
POSITION SENSOR SIGNAL, CKT 417). GROUND ON ENGINE.
IS VOLTAGE READING OVER 4 VOLTS? IS VOLTAGE OVER 4 VOLTS?
YES NO NO YES
4 • IGNITION “OFF.” • CONNECT DVM FAULTY CONNECTION FAULTY CONNECTION

• CONNECT A TEST LIGHT BETWEEN HARNESS AT ECM AT ECM
TERMINAL “C” AND OR OR CKT 813 OPEN
TO B+ BATTERY POSITIVE. CKT 416 OPEN
ENGINE GROUND. OR
• TOUCH TEST LIGHT TO
IS VOLTAGE OVER 4 OR FAULTY ECM.
HARNESS TERMINAL “C” VOLTS? SHORTED TO GROUND
(THROTTLE POSITION OR
SENSOR SIGNAL). FAULTY ECM.
YES NO
CKT 417 SHORTED OPEN CKT 417

TO VOLTAGE. OR
FAULTY CONNECTION
AT ECM
YES NO OR
FAULTY ECM.
• DISCONNECT ECM.
THROTTLE POSITION
• TOUCH TEST LIGHT
SENSOR FAULTY.
CONNECTED TO B+ (BAT
TERY POSITIVE) TO
HARNESS TERMINAL “C”.
YES NO
CKT 417 SHORTED FAULTY ECM.

TO GROUND.
Index
Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Non-Scan)
(1 Of 2)
814 BLK
MAP AND
ECT SENSOR ECT
GROUND

The Manifold Absolute Pressure (MAP) sensor re- An intermittent problem may be caused by a poor or
sponds to changes in manifold pressure (vacuum). corroded connection, rubbed through wire connec-
The ECM receives this information as a signal volt- tion, a wire that is broken inside the insulation, or a
age that will vary from about 1-1.5 volts at closed corroded wire.
throttle idle, to 4-4.8 volts at Wide Open Throttle
(W.O.T.) (low vacuum).
mittent complaint should be thoroughly checked for
If the MAP sensor fails, the ECM will substitute a fixed backed-out terminals, improper mating, broken
MAP value and use the engine RPM to control fuel locks, improperly formed or damaged terminals, poor
delivery. terminal-to-wiring connections, corroded terminals
TEST DESCRIPTION: ness. After repairs, clear codes following “Clearing
Codes” in “ECM Self-Diagnostics.” Failure to do so
Number(s) below refer to circled number(s) on the may result in codes not properly being cleared. If
diagnostic chart. Code 14 is also set, check for open ground CKT 814.
1. This step will determine if there is an adequate MAP SENSOR
vacuum supply to the MAP sensor. If the gauge ALTITUDE VOLTAGE
reading is erratic, refer to “Stalling, Rough, Un- Feet Meters RANGE
stable or Incorrect Idle” in “Troubleshooting.” Below 1,000 Below 305 3.8-5.5 V
2. Low manifold vacuum may result from vacuum 1,000-2,000 305-610 3.6-5.3 V
leaks in the engine induction system. 2,000-3,000 610-914 3.5-5.1 V
3. This step checks for a voltage from terminal “C” 3,000-4,000 914-1219 3.3-5.0 V
(5 volt reference) to terminal “A” (sensor ground).
4,000-5,000 1219-1524 3.2-4.8 V
4. This step will identify if the problem is in the sup- 5,000-6,000 1524-1829 3.0-4.6 V
ply 5 V reference or ground circuit.
6,000-7,000 1829-2133 2.9-4.5 V
5. This step determines if the MAP signal circuit to 7,000-8,000 2133-2438 2.8-4.3 V
the ECM is open.
8,000-9,000 2438-2743 2.6-4.2 V
6. This step completes the test for the ECM and wir- 9,000-10,000 2743-3048 2.5-4.0 V
ing. If the test light is not ON, the MAP sensor has
an internal problem. To confirm an internal MAP LOW ALTITUDE = HIGH PRESSURE = HIGH VOLTAGE
sensor problem, use the MAP output voltage
check chart.
Index
Code 33: MAP Circuit (Non-Scan)
(2 of 2)
• DISCONNECT VACUUM PLUG LOCATED UNDER
PLENUM AT FRONT AND INSTALL A VACUUM
GAUGE IN THE VACUUM PORT.
• START ENGINE AND RAISE RPM TO ABOUT 1000
RPM. VACUUM GAUGE READING SHOULD BE 14in.
Hg (45.5 kPa) OR MORE AND STEADY. IS IT?
YES NO
3 2
REPAIR LOW OR UNSTEADY
VACUUM PROBLEM.
• REMOVE VACUUM GAUGE AND REINSTALL VACUUM
PLUG IN VACUUM PORT.
• DISCONNECT MAP SENSOR ELECTRICAL CONNECTOR.
• CONNECT A DVM FROM HARNESS TERMINAL “C” (CKT
416, 5 VOLT REFERENCE) TO HARNESS TERMINAL “A”
(CKT 814, SENSOR GROUND).
YES NO
5 • CONNECT DVM FROM HARNESS TERMINAL “C” 4 • CONNECT DVM FROM MAP SENSOR HARNESS
(CKT 416) TO HARNESS TERMINAL “B” (MAP TERMINAL “C” TO A GOOD GROUND ON ENGINE.
SENSOR SIGNAL, CKT 432). IS VOLTAGE OVER 4 VOLTS?
YES NO NO YES
6 • IGNITION “OFF.” CONNECT DVM FAULTY CONNECTION AT ECM FAULTY CONNECTION

• CONNECT A TEST LIGHT TO BETWEEN HARNESS OR AT ECM
TERMINAL “B” AND CKT 416 OPEN OR
BATTERY POSITIVE B+. OR
ENGINE GROUND. CKT 814 OPEN
• TOUCH TEST LIGHT TO HARNESS IS VOLTAGE OVER 4 SHORTED TO GROUND OR
TERMINAL “B” (MAP SENSOR VOLTS? OR FAULTY ECM.
SIGNAL). IS TEST LIGHT “ON”? FAULTY ECM.
YES NO YES NO
• DISCONNECT ECM.
MAP CKT 432 OPEN CKT 432
• TOUCH TEST LIGHT
SENSOR SHORTED OR
CONNECTED TO FAULTY. TO VOLTAGE. FAULTY
BATTERY POSITIVE CONNECTION
B+ TO HARNESS AT ECM
TERMINAL “B”. OR
IS TEST LIGHT FAULTY ECM.
“ON”? SEE NOTE
NO
CKT 432 SHORTED FAULTY ECM.

TO GROUND.
NOTE: USING A TEST LIGHT WITH 100 mA OR LESS RATING MAY

SHOW A FAINT GLOW WHEN TEST ACTUALLY STATES NO LIGHT.
Index
Code 42: Ignition Control (IC) Circuit (Non-Scan)
(1 of 2)
IGNITION CONTROL (IC)

MODULE
902 RED BA
3 PNK DIST. REFERENCE “HIGH”

BYPASS
DIST. REFERENCE
121 GRY “LOW”
121 WHT TO IN-LINE HARNESS (TACH)
TO DISTRIBUTOR

When the system is running on the ignition module, Number(s) below refer to circled number(s) on the
that is, no voltage on the bypass line, the ignition diagnostic chart.
module grounds the IC signal. The ECM expects to
1. Code 42 means the ECM has seen an open or
detect no voltage on the IC line during this condition.
short to ground in the IC or bypass circuits. This
If it detects a voltage, it sets Code 42 and will not go
test confirms Code 42 and that the fault causing
into the IC mode.
the code is present.
When the RPM for IC is reached (about 300 RPM),
2. Check for a normal IC ground path through the
and bypass voltage applied, the IC should no longer
ignition module. An IC CKT 423 shorted to
be grounded in the ignition module, so the IC voltage
ground will also read more than 3000 ohms; how-
should be varying.
ever, this will be checked later.
If the bypass line is open or grounded, the ignition
3. As the test light voltage touches CKT 424, the
module will not switch to IC mode so the IC voltage
module should switch, causing the DVM reading
will be low and Code 42 will be set.
to go from over 3000 ohms to under 1000 ohms.
If the IC line is grounded, the ignition module will The important thing is that the module “switched.”
switch to IC but, because the line is grounded, there
4. The module did not switch and this step checks
will be no IC signal. A Code 42 will be set.
for:
• IC CKT 423 shorted to ground.
• Bypass CKT 424 open.
• Faulty ignition module connection or module.
5. Confirms that Coded 42 is a faulty ECM and not
an intermittent in CKT 423 or CKT 424.
Index
Code 42: IC Circuit (Non-Scan) (2 of 2)
DIAGNOSTIC AIDS: backed-out terminals, improper mating, broken
corroded wire.
Any circuitry that is suspected as causing the inter- may result in codes not properly being cleared.
1 • INSTALL MARINE DIAGNOSTIC CODE TOOL.

• CLEAR CODES (REFER TO CLEARING CODES).
• 00000
IDLE ENGINE FOR 1 MINUTE OR UNTIL MALFUNCTION INDICATOR
LAMP COMES “ON.”
• IGNITION “ON,” ENGINE STOPPED.
• ENTER SERVICE MODE ON CODE TOOL AND NOTE CODES.
CODE 42 NO CODE 42
2 • IGNITION “OFF.” CODE 42 INTERMITTENT. IF NO

• DISCONNECT ECM CONNECTORS J1 AND J2 ADDITIONAL CODES WERE STORED,
REFER TO “INTERMITTENTS” IN TROUBLE-
• IGNITION “ON.” SHOOTING SECTION, OR “DIAGNOSTIC AIDS”
• DVOM SELECTOR SWITCH IN THE OHM RANGE ABOVE WHERE APPLICABLE.
• PROBE ECM HARNESS CONNECTOR CKT 423 WITH AN
OHMMETER TO GROUND.
IT SHOULD READ MORE THAN 3KΩ OHMS.
DOES IT?
YES NO
• PROBE ECM HARNESS CONNECTOR CKT 424 WITH OPEN CKT 423. FAULTY CONNECTION
A TEST LIGHT TO 12 VOLTS AND NOTE LIGHT. OR FAULTY IGNITION MODULE.
3 • WITH OHMMETER STILL CONNECTED TO ECM HARNESS • DISCONNECT IGNITION MODULE 4-WAY
CKT 423 AND GROUND, AGAIN PROBE ECM HARNESS CONNECTOR.
CKT 424 WITH THE TEST LIGHT CONNECTED TO 12
VOLTS. AS TEST LIGHT CONTACTS CKT 424,
RESISTANCE SHOULD SWITCH FROM OVER 3KΩ TO
UNDER 1KΩ OHMS.
DOES IT?
CKT 424 SHORTED FAULTY IGNITION
TO GROUND. MODULE.
NO YES
4 • DISCONNECT DIST. 4-WAY CONNECTOR. NOTE OHM 5 • RECONNECT ECM AND IDLE ENGINE FOR
METER THAT IS STILL CONNECTED TO CKT 423 AND ONE MINUTE OR UNTIL MALFUNCTION IN
GROUND. RESISTANCE SHOULD HAVE GONE HIGH (OPEN DICATOR LAMP COMES “ON.”
CIRCUIT). DOES IT?

YES NO
CODE 42 CODE 42 INTERMITTENT.
CKT 424 OPEN. FAULTY CKT 423
CONNECTIONS OR FAULTY SHORTED TO
IGNITION MODULE. GROUND. FAULTY ECM NO TROUBLE FOUND. CHECK
HARNESS AND CONNECTORS FOR AN
INTERMITTENT OPEN OR SHORT TO
GROUND IN CKT 423 AND 424.
Index
Code 43: Knock Sensor (KS) (Non-Scan)
(1 of 2)
FUSE 15A
TO SYSTEM
RELAY
KNOCK SENSOR KNOCK SENSOR

MODULE SIGNAL

The ability to sense engine knock or detonation is ac- If CKT 496 is routed too close to secondary ignition
complished with a module that sends a voltage signal wires, the KS module may see the interference as a
to the ECM. As the knock sensor detects engine knock signal, resulting in false retard.
knock, the voltage from the KS module to the ECM
drops, and this signals the ECM to retard timing. corroded connection, rubbed through wire connec-
diagnostic chart. mittent complaint should be thoroughly checked for
1. This step ensures that the knock sensor circuitry backed-out terminals, improper mating, broken
is within the proper resistance value.
2. Applying 12 volts with a test light to CKT 496 sim- and/or wiring, or physical damage to the wiring har-
ulates a signal from the knock sensor. The knock ness. After repairs, clear codes following “Clearing
sensor is faulty if a response occurs. Codes” in “ECM Self-Diagnostics.” Failure to do so
may result in codes not properly being cleared.
3. This step checks if a voltage signal from the KS
module is present at the ECM.
4. This step determines if ignition voltage is avail-
able to power up the KS module.
5. This step confirms the ability of the KS module to
remove the voltage from the signal line when it
sees spark knock. Since the knock sensor pro-
duces an AC voltage signal, it may be necessary
to repeatedly touch the harness connector with
the test light probe to simulate this type of signal.
6. This step checks the ground circuit from the KS
module. If the test light is dim, check ground (CKT
486) for excessive resistance.
Index
Code 43: Knock Sensor (KS) Circuit (Non-Scan)
(2 of 2)
1 • DISCONNECT 5 WAY KS MODULE CONNECTOR.

• USING DVM, MEASURE RESISTANCE BETWEEN
TERMINAL “E” AND GROUND.
• RESISTANCE SHOULD BE BETWEEN 3.3KΩ AND 4.5KΩ
OHMS.
IS IT?
YES NO
2 • RECONNECT 5 WAY KS MODULE CONNECTOR. CHECK FOR OPEN OR SHORT

• DISCONNECT KNOCK SENSOR HARNESS CONNECTOR. IN CKT 496.
IF OK, REPLACE KNOCK
• CONNECT A TEST LIGHT TO BATTERY POSITIVE BATTERY POSITIVE (B+).
SENSOR.
• START ENGINE.
• HOLD ENGINE SPEED STEADY AT 2500 RPM.
• REPEATEDLY TOUCH TEST LIGHT TO KNOCK SENSOR HARNESS
CONNECTOR TERMINAL (CKT 496).
• DOES A NOTICEABLE RPM DROP OCCUR OR USING TIMING LIGHT DID TIMING DROP?
NO YES
3 • IGNITION “OFF.” INSPECT KNOCK SENSOR TERMINAL

CONTACTS. IF OK, REPLACE KNOCK
• DISCONNECT ECM CONNECTOR J-2
SENSOR.
• CONNECT DVOM FROM ECM HARNESS
CONNECTOR TERMINAL “C” (CKT 485) TO
GROUND.
ARE 8-10 VOLTS PRESENT?
YES NO
5 • ALLOW DVM VOLTAGE TO STABILIZE. 4 • CONNECT A TEST LIGHT TO GROUND.

• TOUCH A TEST LIGHT CONNECTED TO • DISCONNECT KS MODULE HARNESS CONNECTOR.
B+ TO THE KNOCK SENSOR HARNESS • TOUCH THE TEST LIGHT TO KS MODULE HARNESS
CONNECTOR TERMINAL (CKT 496). CONNECTOR TERMINAL “B” (CKT 439).
DOES THE VOLTAGE VALUE CHANGE? IS THE TEST LIGHT “ON”?
NO YES YES NO
6 • DISCONNECT KS MODULE HARNESS FAULTY ECM. CKT 485 OPEN REPAIR OPEN
CONNECTOR. OR OR
• CONNECT A TEST LIGHT TO BATTERY SHORTED TO GROUND GROUNDED
OR CKT 439.
POSITIVE B+.
FAULTY KS MODULE.
• TOUCH THE TEST LIGHT TO KS HARNESS
CONNECTOR TERMINAL “D” (CKT 486).
IS THE TEST LIGHT “ON”?
YES NO
CKT 496 OPEN REPAIR OPEN

OR GROUND CKT
SHORTED TO GROUND 486.
OR
FAULTY KS MODULE.
Index
Code 51: Calibration Memory Failure Non-Scan Diagnostics
(1 of 2)
72801

This test allows the ECM to check for a calibration An intermittent Code 51 may be caused by a bad cell
failure by comparing the calibration value to a known in the EEPROM that is sensitive to temperature
value stored in the EEPROM. changes. If Code 51 failed more than once, but is in-
termittent, replace ECM.
This test is also used as a security measure to pre-
vent improper use of calibrations or changes to these An intermittent problem may be caused by a poor or
calibrations that may alter the designed function of corroded connection, rubbed through wire connec-
the EFI system. tion, a wire that is broken inside the insulation, or a
corroded wire.
TEST DESCRIPTION: Any circuitry that is suspected as causing the inter-
1. This step checks to see if the fault is present dur- terminal-to-wiring connections, corroded terminals
ing diagnosis. If present, the ECM is not function- and/or wiring, or physical damage to the wiring har-
ing correctly and must be replaced. ness. After repairs, clear codes following “Clearing
IMPORTANT: At the time of printing, vessels with may result in codes not properly being cleared.
Fuel Injection were not being field repro-
grammed to correct this failure. Replacement of
the ECM with a factory reprogrammed ECM is
necessary if Code 51 is current and resets when
clearing codes is completed.
Index
Code 51: Calibration Memory Failure (Non-Scan)
(2 of 2)
• USING CLEAR CODE PROCEDURE, CLEAR CODES.
DOES CODE 51 RESET?
YES NO
REPLACE ECM AND VERIFY CODE DOES NOT RESET. FAULT IS NOT PRESENT AT THIS TIME.
REFER TO “DIAGNOSTIC AIDS” ON
FACING PAGE.
Index
Diagnostics - Using Scan Tool (Scan)
Code 14 Engine Coolant Temperature (ECT) Sensor Circuit (Scan)
(1 of 2)
ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
ENGINE COOLANT
TEMPERATURE (ECT)

The Engine Coolant Temperature (ECT) Sensor Check harness routing for a potential short to ground
uses a thermistor to control the signal voltage to the in CKT 410.
ECM. The ECM applies a voltage on CKT 410 to the
Scan tool displays engine temperature in degrees
sensor. When the engine coolant is cold, the sensor
Fahrenheit and Celsius. After engine is started, the
(thermistor) resistance is high, therefore, the ECM
temperature should rise steadily, reach normal oper-
will see high signal voltage. As the engine coolant
ating temperature, and then stabilize when thermo-
warms, the sensor resistance becomes less, and the
stat opens.
voltage drops. At normal engine operating tempera-
ture, 160-180°F (71-82°C), the voltage will measure See “Intermittents” in “Troubleshooting.”
about 1.5 to 2.0 volts. An intermittent problem may be caused by a poor or
TEST DESCRIPTION: tion, a wire that is broken inside the insulation, or a
Number(s) below refer to circled number(s) on the corroded wire.
diagnostic chart. Any circuitry that is suspected as causing the inter-
1. Code 14 will set if:
• Signal voltage indicates a coolant tempera- locks, improperly formed or damaged terminals, poor
ture above 266°F (130°C). terminal-to-wiring connections, corroded terminals
• Signal voltage indicates a coolant tempera- ness. After repairs, clear codes following “Clearing
ture below –22°F (–30°C). Codes” in “ECM Self-Diagnostics.” Failure to do so
2. This test will determine if CKT 410 is shorted to may result in codes not properly being cleared.
ground, which will cause the condition for Code
14.
Index
Code 14: ECT Circuit (Scan)
(2 of 2)
DOES SCAN TOOL DISPLAY A COOLANT
TEMPERATURE VALUE GREATER THAN
266°F (130°C) OR LESS THAN –22°F (–30°C)?
YES NO
CODE 14 IS INTERMITTENT. IF NO
ADDITIONAL CODES WERE STORED,
FACING PAGE.
COOLANT TEMPERATURE COOLANT TEMPERATURE

SCAN DISPLAY GREATER SCAN DISPLAY LESS
THAN 266°F (130°C). THAN –22°F (–30°C).
2 • IGNITION “OFF.” • IGNITION “OFF.”

• DISCONNECT ENGINE COOLANT TEMPERATURE (ECT) • DISCONNECT COOLANT TEMPERATURE
SENSOR. SENSOR.
• IGNITION “ON.” • JUMPER TERMINALS “A” AND “B”
• SCAN TOOL SHOULD DISPLAY COOLANT TOGETHER.
TEMPERATURE BELOW –22°F (–30°C). • IGNITION “ON.”
DOES IT? • SCAN TOOL SHOULD DISPLAY
COOLANT TEMPERATURE ABOVE 266°F
(130°C).
DOES IT?
NO YES NO YES
CKT 410 SHORTED TO GROUND REPLACE ENGINE CKT 410 OPEN REPLACE ENGINE
OR COOLANT OR COOLANT
FAULTY ECM. TEMPERATURE SENSOR GROUND TEMPERATURE
SENSOR. OPEN SENSOR.
OR
FAULTY ECM.
Index
Code 21: Throttle Position (TP) Sensor Circuit (Scan)
(1 of 2)
B
B
C C TP
A
A

The Throttle Position (TP) Sensor provides a voltage The scan tool reads throttle position in voltage and
signal that changes as throttle blades open or close. percentage of throttle blade opening. With ignition
Signal voltage should vary from about .7 volts at idle ON or at idle, TP signal voltage should read between
to about 4.5 volts at Wide Open Throttle (W.O.T.). .3 and .8 volt with the throttle closed, and increase at
a steady rate as throttle is moved toward Wide Open
The TP signal is one of the most important inputs
Throttle (W.O.T.).
used by the Electronic Control Module (ECM) for fuel
control and for most of the ECM controlled outputs. If Code 23 is also set, check CKT 813 for faulty wiring
or connections. Check terminals at sensor for good
TEST DESCRIPTION: contact.
Number(s) below refer to circled number(s) on the An intermittent problem may be caused by a poor or
diagnostic chart. corroded connection, rubbed through wire connec-
1. With throttle closed the TP sensor should read corroded wire.
between .3 and .8 volt. If it does not, check throttle
cable adjustment or for bent linkage. Any circuitry that is suspected as causing the inter-
2. With the TP sensor disconnected, the TP voltage backed-out terminals, improper mating, broken
should go low if the ECM and wiring are OK. locks, improperly formed or damaged terminals, poor
3. Probing CKT 813 with a DVOM to CKT 416 terminal-to-wiring connections, corroded terminals
checks the sensor ground. A faulty sensor
ground will cause a Code 21. Codes” in “ECM Self-Diagnostics.” Failure to do so
Index
Code 21: TP Sensor Circuit (Scan)
(2 of 2)
1 • THROTTLE CLOSED.
DOES SCAN TOOL INDICATE THROTTLE
POSITION SENSOR VOLTAGE GREATER
THAN 4 VOLTS OR LESS THAN .36 VOLT?
YES NO
CODE 21 IS INTERMITTENT, REFER TO

“DIAGNOSTIC AIDS” ON FACING PAGE.
VOLTAGE LESS THAN .36 VOLT. VOLTAGE GREATER THAN 4 VOLTS.
• IGNITION “OFF.” 2 • IGNITION “OFF.”

• DISCONNECT THROTTLE POSITION SENSOR • DISCONNECT THROTTLE POSITION
ELECTRICAL CONNECTOR. JUMPER THROTTLE SENSOR CONNECTOR.
POSITION SENSOR HARNESS TERMINALS “A” AND “C” • IGNITION “ON.”
TOGETHER. DOES SCAN TOOL INDICATE
• IGNITION “ON.” VOLTAGE OVER 4 VOLTS?
• SCAN TOOL SHOULD INDICATE THROTTLE
POSITION SENSOR VOLTAGE GREATER THAN 4 VOLTS.
DOES IT?
NO YES NO YES
• IGNITION “OFF.” REPLACE THROTTLE 3 CONNECT DVOM CKT 417 SHORTED

TO VOLTAGE
• CONNECT DVM BETWEEN POSITION SENSOR. BETWEEN THROTTLE
OR
THROTTLE POSITION SENSOR POSITION HARNESS
CONNECTOR FAULTY ECM
HARNESS TERMINAL “A” AND CONNECTION
GROUND. TERMINALS “C” AND OR
“A.” VOLTAGE
• IGNITION “ON.” SHOULD BE GREATER
FAULTY ECM.
IS VOLTAGE OVER 4 VOLTS? THAN 4 VOLTS.
IS IT?
NO YES
CKT 416 OPEN THROTTLE POSITION YES NO

OR SENSOR SIGNAL (CKT
FAULTY ECM CONNECTION 417) OPEN OR REPLACE THROTTLE OPEN SENSOR GROUND
OR SHORTED TO POSITION SENSOR CKT 813
FAULTY ECM. GROUND OR
OR FAULTY ECM
FAULTY CONNECTION CONNECTION
AT ECM OR
OR FAULTY ECM.
FAULTY ECM.
Index
Code 23: Intake Air Temperature (IAT) Sensor Circuit (Scan)
(1 of 2)
INTAKE
B A IAT SENSOR SIGNAL
REFERENCE

The Intake Air Temperature (IAT) sensor uses a The scan tool reads temperature of the air entering
thermistor to control the signal voltage to the Elec- the engine and should read close to ambient air tem-
tronic Control Module (ECM). The ECM applies a perature when engine is cold, and rises as engine
voltage (about 5 volts) on CKT 472 to the sensor. compartment temperature increases.
When the air is cold, the sensor (thermistor) resis-
The IAT sensor in this engine is located on the star-
tance is high; therefore, the ECM will see a high sig-
board underside of the plenum.
nal voltage. If the air is warm, the sensor resistance
is low; therefore, the ECM will see a low voltage. Carefully check harness and connections for pos-
sible open.
TEST DESCRIPTION: If the engine has been allowed to sit overnight, the in-
Number(s) below refer to circled number(s) on the take air temperature and coolant temperature values
diagnostic chart. should read within a few degrees of each other.
1. A Code 23 will set, due to an open sensor, wire An intermittent problem may be caused by a poor or
or connection. This test will determine if the wir- corroded connection, rubbed through wire connec-
ing and ECM are OK. If the scan tool indicates a tion, a wire that is broken inside the insulation, or a
temperature of over 266°F (130°C), the jumper corroded wire.
harness to the sensor should be checked before Any circuitry that is suspected as causing the inter-
replacing the sensor. mittent complaint should be thoroughly checked for
2. This will determine if the IAT sensor signal (CKT
472) or the IAT sensor ground (CKT 813) is open. terminal-to-wiring connections, corroded terminals
3. This step will determine if the fault is in the IAT and/or wiring, or physical damage to the wiring har-
sensor or the circuit. ness. After repairs, clear codes following “Clearing
Index
Code 23: IAT Circuit (Scan)
(2 of 2)
• DOES SCAN TOOL DISPLAY IAT
TEMPERATURE OF LESS THAN –22°F (–30°C)
OR GREATER THAN 266°F (130°C).
YES NO
CODE 23 IS INTERMITTENT, REFER TO

“DIAGNOSTIC AIDS” ON FACING PAGE.
TEMPERATURE LESS THAN –22°F (–30°C) TEMPERATURE GREATER THAN 266°F (130°C).
1 • IGNITION “OFF.” 3 • IGNITION “OFF.”

• DISCONNECT IAT SENSOR. • DISCONNECT IAT SENSOR.
• JUMPER HARNESS TERMINALS TOGETHER. • IGNITION “ON.”
• IGNITION “ON.” • SCAN TOOL SHOULD DISPLAY
• SCAN TOOL SHOULD DISPLAY TEMPERATURE LESS THAN –22°F (–30°C).
TEMPERATURE GREATER THAN 266°F (130°C). DOES IT?
DOES IT?
NO YES NO YES
2 • IGNITION “OFF.” FAULTY CONNECTION

CKT 472 SHORTED TO FAULTY IAT
GROUND SENSOR.
• JUMPER CKT 472 TO ENGINE OR OR
GROUND. IAT SENSOR. FAULTY ECM.
• SCAN TOOL SHOULD
DISPLAY TEMPERATURE
GREATER THAN 266°F (130°C).
DOES IT?
YES NO
OPEN SENSOR OPEN CKT 472

GROUND CIRCUIT FAULTY CONNECTION
FAULTY CONNECTION OR
OR FAULTY ECM.
FAULTY ECM.
Index
Code 33: Manifold Absolute Pressure (MAP) Sensor Circuit (Scan)
(1 of 2)
814 BLK
ECT MAP AND ECT

GROUND

The Manifold Absolute Pressure (MAP) sensor re- If the idle is rough or unstable, refer to “Troubleshoot-
sponds to changes in manifold pressure (vacuum). ing” for items which can cause an unstable idle.
The ECM receives this information as a signal volt-
With the ignition ON and the engine OFF, the man-
age that will vary from about 1-1.5 volts at closed
ifold pressure is equal to atmospheric pressure and
throttle idle, to 4.0-4.8 volts at Wide Open Throttle
the signal voltage will be high. This information is
(W.O.T.) (low vacuum).
used by the ECM as an indication of vessel altitude
The scan tool displays manifold pressure in kPa of and is referred to as BARO. Comparison of this
pressure and voltage. Low pressure (high vacuum) BARO reading, with a known good vessel with the
reads a low voltage while a high pressure (low vacu- same sensor, is a good way to check accuracy of a
um) reads a high voltage. “suspect” sensor. Reading should be the same, + .4
volt.
If the MAP sensor fails, the ECM will substitute a
fixed MAP value and use engine RPM to control fuel An intermittent problem may be caused by a poor or
delivery. corroded connection, rubbed through wire connec-
diagnostic chart. mittent complaint should be thoroughly checked for
1. Engine misfire or a low unstable idle may set locks, improperly formed or damaged terminals, poor
Code 33. Disconnect MAP sensor and system terminal-to-wiring connections, corroded terminals
will go into backup mode. If the misfire or idle and/or wiring, or physical damage to the wiring har-
condition remains, refer to “Troubleshooting.” ness. After repairs, clear codes following “Clearing
2. If the ECM recognizes the low MAP signal, the may result in codes not properly being cleared.
ECM and wiring are OK.
Index
Code 33: MAP Circuit (Scan)
(2 of 2)
• IF ENGINE IDLE IS ROUGH, UNSTABLE, OR

INCORRECT, CORRECT CONDITION
BEFORE USING CHART, SEE THE
TROUBLESHOOTING SECTION.
• ENGINE IDLING.
DOES SCAN TOOL DISPLAY A MAP
SENSOR VOLTAGE OF LESS THAN 1 VOLT
OR GREATER THAN 4 VOLTS?
YES NO
CODE 33 IS INTERMITTENT, IF NOT

ADDITIONAL CODES WERE STORED,
FACING PAGE.
VOLTAGE LESS THAN 1 VOLT. VOLTAGE GREATER THAN 4 VOLTS.
• IGNITION “OFF.” • IGNITION “OFF.”

1 • DISCONNECT MAP SENSOR ELECTRICAL
2 • DISCONNECT MAP SENSOR ELECTRICAL
CONNECTOR. CONNECTOR.
• JUMPER MAP SENSOR HARNESS TERMINALS • START ENGINE.
“C” AND “B” TOGETHER. • “SCAN” TOOL SHOULD DISPLAY A
• START ENGINE. VOLTAGE OF LESS THAN 1 VOLT.
DOES SCAN TOOL DISPLAY MAP SENSOR DOES IT?
VOLTAGE GREATER THAN 4 VOLTS?
NO YES YES NO
• IGNITION “OFF.” CHECK FOR MAP • IGNITION “OFF.” • IGNITION “OFF.”

SENSOR SIGNAL CKT
• CONNECT DVOM BETWEEN
432 SHORTED TO
• CONNECT DVM • MAP SENSOR
MAP SENSOR HARNESS GROUND. IF OK, BETWEEN MAP SIGNAL CKT 432
TERMINAL “C” AND A. REPLACE MAP SENSOR HARNESS SHORTED TO
• IGNITION “ON.” SENSOR. TERMINAL “A” VOLTAGE
IS VOLTAGE OVER 4 VOLTS? AND “C”. OR
• IGNITION “ON.” FAULTY ECM
• VOLTAGE SHOULD CONNECTIONS
BE GREATER THAN OR
FAULTY ECM.
4 VOLTS.
NO YES IS IT?
CKT 416 OPEN FAULTY MAP SENSOR SIGNAL

ECM CONNECTION CKT 432 OPEN OR
OR SHORTED TO
FAULTY ECM. GROUND YES NO
OR
FAULTY CONNECTION FAULTY MAP SENSOR OPEN SENSOR
AT ECM GROUND CIRCUIT
OR
FAULTY ECM.
Index
Code 42: Ignition Control (IC) Circuit (Scan)
(1 Of 2)
IGNITION CONTROL
(IC)
MODULE
902 RED BA
3 PNK DIST. REFERENCE “HIGH”
BYPASS

121 GRY
121 WHT TO IN-LINE HARNESS (TACH)
TO DISTRIBUTOR

When the system is running on the ignition module, Number(s) below refer to circled number(s) on the
that is, no voltage on the bypass line, the ignition diagnostic chart.
module grounds the IC signal. The ECM expects to
1. Code 42 means the ECM has seen an open or
detect a low voltage on the IC line during this condi-
short to ground in the IC or bypass circuits. This
tion. If it detects a voltage, it sets Code 42 and will not
test confirms Code 42 and that the fault causing
go into the IC mode.
the code is present.
When the RPM for IC is reached (about 300 RPM),
2. Check for a normal IC ground path through the
and bypass voltage applied, the IC should no longer
ignition module. An IC CKT 423 shorted to
be grounded in the ignition module, so the IC voltage
ground will also read more than 3000 ohms; how-
should be varying.
ever, this will be checked later.
If the bypass line is open or grounded, the ignition
3. As the test light voltage touches CKT 424, the
module will not switch to IC mode so the IC voltage
module should switch, causing the DVOM read-
will be low and Code 42 will be set.
ing to go from over 3000 ohms to under 1000
If the IC line is grounded, the ignition module will ohms. The important thing is that the module
switch to IC but, because the line is grounded, there “switched.”
will be no IC signal. A Code 42 will be set.
4. The module did not switch and this step checks
for:
• IC CKT 423 shorted to ground.
• Bypass CKT 424 open.
• Faulty ignition module connection or module.
5. Confirms that Coded 42 is a faulty ECM and not
an intermittent in CKT 423 or CKT 424.
Index
Code 42: IC Circuit (Scan)
(2 of 2)
DIAGNOSTIC AIDS: Any circuitry that is suspected as causing the inter-
Refer to “Intermittents” in “Troubleshooting.”
An intermittent problem may be caused by a poor or locks, improperly formed or damaged terminals, poor
corroded connection, rubbed through wire connec- terminal-to-wiring connections, corroded terminals
tion, a wire that is broken inside the insulation, or a and/or wiring, or physical damage to the wiring har-
corroded wire. ness. After repairs, clear codes following “Clearing
1 • CLEAR CODES.
• IDLE ENGINE FOR 1 MINUTE OR UNTIL CODE 42 SETS.
DOES CODE 42 SET?
YES NO
2 • IGNITION “OFF.” CODE 42 INTERMITTENT. REFER TO

• DISCONNECT ECM CONNECTORS. “DIAGNOSTIC AIDS” ABOVE.
• USE DVM WITH SELECTOR IN OHMS RANGE.
• PROBE ECM HARNESS CONNECTOR CKT 423 WITH
DVM TO GROUND.
IT SHOULD READ MORE THAN 3000 OHMS.
DOES IT?
YES NO
• PROBE ECM HARNESS CONNECTOR CKT 424 WITH OPEN CKT 423. FAULTY CONNECTION
A TEST LIGHT TO BATTERY VOLTAGE. OR FAULTY IGNITION MODULE.
3 • WITH OHMMETER STILL CONNECTED TO ECM HARNESS CKT • DISCONNECT IGNITION MODULE 4-WAY CONNECTOR.
423 AND GROUND, AGAIN PROBE ECM HARNESS CKT 424
WITH THE TEST LIGHT CONNECTED TO BATTERY VOLTAGE.
(AS TEST LIGHT CONTACTS CKT 424, RESISTANCE SHOULD LIGHT “ON” LIGHT “OFF”
SWITCH FROM OVER 3000 TO UNDER 1000 OHMS.)
DOES IT?
CKT 424 SHORTED FAULTY IGNITION
TO GROUND. MODULE.
NO YES
4 • DISCONNECT DIST. 4-WAY CONNECTOR. NOTE 5 • RECONNECT ECM AND IDLE ENGINE FOR
OHMMETER THAT IS STILL CONNECTED TO CKT ONE MINUTE OR UNTIL MALFUNCTION IN
423 AND GROUND. RESISTANCE SHOULD HAVE DICATOR “ON.”
GONE HIGH (OPEN CIRCUIT).
DOES IT?
YES NO YES NO
CKT 424 OPEN. FAULTY CKT 423 FAULTY ECM CODE 42 INTERMITTENT.
CONNECTIONS OR FAULTY SHORTED TO REFER TO “DIAGNOSTIC
IGNITION MODULE. GROUND. AIDS” ON FACING PAGE.
NOTE:CLEAR DIAGNOSTIC TROUBLE CODE (DTC) STOP ENGINE FOR AT LEAST ONE MINUTE AFTER REPAIR IS PER-
FORMED. RESTART ENGINE AND CHECK FOR CODES.
Index
Code 43: Knock Sensor (KS) (Scan)
(1 Of 2)
FUSE 15A
TO SYSTEM
RELAY
KNOCK SIGNAL KNOCK SENSOR

MODULE (KS) SIGNAL

Sensing engine detonation or spark knock is accom- If CKT 496 is routed too close to secondary ignition
plished with a module that sends a voltage signal to wires, the KS module may see the interference as a
the ECM. As the knock sensor detects engine knock, knock signal, resulting in false retard.
the voltage from the KS module to the ECM drops,
and this signals the ECM to retard timing. The ECM corroded connection, rubbed through wire connec-
will retard the timing when knock is detected and tion, a wire that is broken inside the insulation, or a
RPM is above a certain value. corroded wire.

Number(s) below refer to circled number(s) on the backed-out terminals, improper mating, broken
diagnostic chart. locks, improperly formed or damaged terminals, poor
1. This step determines if there is a problem in the and/or wiring, or physical damage to the wiring har-
circuit. When an KS circuit fails, the ECM will ness. After repairs, clear codes following “Clearing
switch to a default value of about 3.2 degrees of Codes” in “ECM Self-Diagnostics.” Failure to do so
timing retard. may result in codes not properly being cleared.
2. This step checks if there is a voltage source to the
knock sensor from the KS module.
3. This step will determine if the knock sensor is
faulty.
Index
Code 43: KS Circuit (Scan)
(2 of 2)
1 • INSTALL SCAN TOOL.
• ENGINE IDLING, COOLANT TEMP. ABOVE 150°F (66°C).
DOES SCAN TOOL INDICATE A FIXED VALUE GREATER
THAN ZERO DEGREES OF KNOCK RETARD?
YES NO
2 • RECONNECT 5 WAY KS MODULE CONNECTOR. CHECK FOR OPEN OR SHORT

• DISCONNECT KNOCK SENSOR HARNESS CONNECTOR. IN CKT 496.
IF OK, REPLACE KNOCK
• CONNECT A TEST LIGHT TO BATTERY POSITIVE (B+).
SENSOR.
• START ENGINE.
• HOLD ENGINE SPEED STEADY AT 2500 RPM.
• RAPIDLY TOUCH TEST LIGHT TO KNOCK SENSOR HARNESS
CONNECTOR TERMINAL (CKT 496).
• DOES A NOTICEABLE RPM DROP OCCUR OR USING TIMING LIGHT,
DID TIMING DROP ?
NO YES
3 • IGNITION “OFF.” INSPECT KNOCK SENSOR TERMINAL

• DISCONNECT ECM CONNECTOR J-2
CONTACTS. IF OK, REPLACE KNOCK
SENSOR.
• CONNECT DVOM FROM ECM HARNESS
CONNECTOR TERMINAL “C” (CKT 485) TO
GROUND.
ARE 8-10 VOLTS PRESENT?
YES NO
5 • ALLOW DVM VOLTAGE TO STABILIZE. 4 • CONNECT A TEST LIGHT TO GROUND.

• RAPIDLY TOUCH A TEST LIGHT CONNECTED TO • DISCONNECT KS MODULE HARNESS CONNECTOR.
BATTERY POSITIVE (B+) TO THE KNOCK
SENSOR HARNESS CONNECTOR TERMINAL (CKT 496). • TOUCH THE TEST LIGHT TO KS MODULE HARNESS
DOES THE VOLTAGE VALUE CHANGE? CONNECTOR TERMINAL “B” (CKT 439).
NO YES YES NO
6 • DISCONNECT KS MODULE HARNESS FAULTY ECM. CKT 485 OPEN REPAIR OPEN
CONNECTOR. OR OR
• CONNECT A TEST LIGHT TO BATTERY SHORTED TO GROUND GROUNDED
OR CKT 439.
POSITIVE (B+).
FAULTY KS MODULE.
• TOUCH THE TEST LIGHT TO KS HARNESS
CONNECTOR TERMINAL “D” (CKT 486).
YES NO
CKT 496 OPEN REPAIR OPEN

OR GROUND CKT
SHORTED TO GROUND 486.
OR
FAULTY KS MODULE.
Index
Code 51: Calibration Memory Failure
(Scan) (1 Of 2)
72801

This test allows the ECM to check for a calibration An intermittent Code 51 may be caused by a bad cell
failure by comparing the calibration value to a known in the EEPROM that is sensitive to temperature
value stored in the EEPROM. changes. If Code 51 failed more than once, but is in-
termittent, replace ECM.
This test is also used as a security measure to pre-
vent improper use of calibrations or changes to these An intermittent problem may be caused by a poor or
calibrations that may alter the designed function of corroded connection, rubbed through wire connec-
EFI. tion, a wire that is broken inside the insulation, or a
corroded wire.
1. This step checks to see if the fault is present dur- terminal-to-wiring connections, corroded terminals
ing diagnosis. If present, the ECM is not function- and/or wiring, or physical damage to the wiring har-
ing correctly and must be replaced. ness. After repairs, clear codes following “Clearing
IMPORTANT: At the time of printing, vessels with may result in codes not properly being cleared.
fuel injection were not being field reprogrammed
to correct this failure. Replacement of the ECM
with a factory reprogrammed ECM is necessary
if Code 51 is current and resets when clearing
codes is completed.
Index
Code 51: Calibration Memory Failure (Scan)
(2 of 2)
• USING SCAN TOOL, CLEAR CODES.
DOES CODE 51 RESET?
YES NO
REPLACE ECM AND VERIFY CODE DOES NOT RESET. FAULT IS NOT PRESENT AT THIS TIME.
FACING PAGE.
Index
Troubleshooting
Changes In Terminology
Due to industry standardization of terminology for certain electronic engine controls some names and abbrevi-
ations have changed.
From To
(CTS) Coolant Temperature Sensor (ECT) Engine Coolant Temperature
(TPS) Throttle Position Sensor (TP) Throttle Position
(MAT) Manifold Air Temperature (IAT) Intake Air Temperature
(EST) Electronic Spark Timing (IC) Ignition Control
(ESC) Electronic Spark Control (KS) Knock Sensor
(ALDL) Assembly Line Data Link (DLC) Data Link Connector
Diagnostic Trouble Codes

Code Number Code Description
Code 14 (ECT) Engine Coolant Temperature
Code 21 (TP) Throttle Position Sensor
Code 23 (IAT) Intake Air Temperature
Code 33 (MAP) Manifold Absolute Pressure
Code 42 (IC) Ignition Control
Code 43 (KS) Knock Sensor
Code 51 Calibration Memory Failure
Important Preliminary Checks

Before using this section, you should verify the cus- 2. Vacuum hoses for splits, kinks and proper con-
tomer complaint, and locate the correct symptom. nections.
Check the items indicated under that symptom.
3. Air leaks at throttle body, plenum and intake man-
Several of the following symptom procedures call for ifold.
a careful visual/physical check.
4. Ignition wires for cracking, hardness and proper
The importance of this step cannot be stressed too routing.
strongly, it can lead to correcting a problem without
5. Wiring for proper connections, pinches, and cuts.
further checks and can save valuable time.
If wiring harness or connector repair is neces-
1. Ensure that engine is in good mechanical condi- sary.
tion.
Index
Troubleshooting Charts
IMPORTANT PRELIMINARY CHECKS

BEFORE USING THIS SECTION
Before using this section you should have performed the “EFI Diagnostic Circuit Check” and de-
termined that:
1. The ECM is operating correctly.
2. There are no diagnostic trouble codes (DTC) stored.
SYMPTOM
Verify the customer complaint, and locate the correct symptom. Check the items indicated under that
symptom.
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a careful visual/physical check. The importance of
this step cannot be stressed too strongly. It can lead to correcting a problem without further
checks and can save valuable time. These checks should include:
1. ECM grounds and sensors for being clean, tight and in their proper locations.
2. Vacuum hoses for splits, kinks, and proper connections. Check thoroughly for any type of leak
or restriction.
3. Air leaks at throttle body mounting area and intake manifold sealing surfaces.
4. Ignition wires for cracking, hardness, proper routing and carbon tracking.
5. Wiring for proper connections, pinches and cuts.
6. Moisture in distributor cap, primary or secondary ignition circuit connections.
7. Salt corrosion on electrical connections and exposed throttle body linkages.
8. Ensure engine is in good mechanical condition.
Index
INTERMITTENTS
Definition: Problem occurs randomly. May or may not store a Diagnostic Trouble Code (DTC).
DO NOT use the diagnostic trouble code charts for intermittent problems, unless instructed to do
so. If a fault is intermittent, incorrect use of diagnostic trouble code charts may result in replacement
of good parts.
Most intermittent problems are caused by faulty electrical connections or wiring. Perform careful
check of suspected circuits for:
1. Poor mating of the connector halves or terminals not fully seated in the connector body (backed
out or loose).
2. Improperly formed or damaged terminals and or connectors. All connector terminals and con-
nectors in problem circuit should be carefully reformed or replaced to insure proper contact ten-
sion.
3. Poor terminal to wire connection (crimping).
An intermittent may be caused by:
1. Electrical system interference caused by a sharp electrical surge. Normally, the problem will oc-
cur when the faulty component is operated.
2. Improper installation of electrical options, such as lights, ship to shore radios, sonar, etc.
3. Improperly routed knock sensor wires. Wires should be routed AWAY from spark plug wires, igni-
tion and charging system components.
4. Secondary ignition shorted to ground.
5. Arching at spark plug wires, spark plugs or open ignition coil ground (coil mounting brackets).
Part of internal circuitry shorted to ground such as in starters, relays and alternators.
If a visual/physical check does not find the cause of the problem, the EFI system can be tested with
a voltmeter or a scan tool connected while observing the suspected circuit. An abnormal reading,
when the problem occurs, indicates the problem may be in that circuit.
Index
HARD START
Definition: Engine cranks OK, but does not start for a long time. Engine does eventually run, or
may start but immediately dies.
PRELIMINARY CHECKS
Make sure proper starting procedure is being used. See Owner’s Manual.
Perform the careful visual/physical checks as described at the start of “Troubleshooting Charts”
section.
CHECK FUEL SYSTEM FOR:
1. Proper operation of fuel pump relay. Relay will operate fuel pump for 2 seconds when ignition is
turned “ON.” Also look for open in CKT 465, fuel pump relay driver.
2. Clogged or dirty water separating fuel filter.
3. Contaminated fuel or winter grade fuel during warm weather.
4. Vapor lock condition or engine flooding. Check fuel pressure.
5. VST fault-stuck float, leaking vapor regulator.
6. Electric fuel pump check valve or fuel pressure regulator and / or fuel damper leaking.
CHECK IGNITION SYSTEM FOR:
1. Proper ignition timing.
2. Ignition wires for cracking, hardness and proper connections at both distributor cap and spark
plugs.
3. Wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Repair or replace
as necessary.
4. Distributor cap inside and out for moisture, dust, cracks, burns, and arcing to coil mounting screws.
5. Worn distributor shaft. Bare and shorted wires. Pick-up coil resistance and connections. Try to turn
distributor shaft by hand. Drive pin may be broken.
Index
HARD START (continued)
CHECK SENSORS AND CONTROLS FOR:
1. Possible open in Engine Coolant Temperature (ECT) sensor and Manifold Absolute Pressure
(MAP) sensor Ground CKT 814. Also may have set a DTC 14 and/or DTC 33.
2. Throttle Position (TP) sensor,ground CKT 813 could have a possible open and set DTC 21.
3. A sticking throttle shaft or binding linkage causes a high Throttle Position (TP) sensor voltage.
Using a scan tool and/or voltmeter, TP sensor voltage should read less than .7 volt with throttle
closed.
4. Proper Idle Air Control (IAC) operation.
CHECK ENGINE FOR:
1. Restricted exhaust.
2. Proper cylinder compression.
3. Proper camshaft timing/valve train problem.
Index
SURGES
Definition: Engine power variation under steady throttle or cruise. Feels like the engine speeds up
and slows down with no change in the throttle control.
PRELIMINARY CHECKS
Perform the visual/physical checks as described at the start of “Troubleshooting Charts” section.
1. Fuel pressure to be within specification while condition exists.
1. Condition of 4-terminal Ignition Control (IC) connector at distributor. Connector wires must not
be routed near spark plug wires.
2. Intermittent ground connection on ignition coil.
3. Proper operation (advancing or retarding) of Ignition Control (IC).
4. Condition of distributor cap, rotor, and spark plug wires.
5. Proper and clean connection on distributor pick-up coil terminal.
6. Spark plugs that may be fuel fouled, cracked, worn, improperly gapped, burned electrodes, or
heavy deposits. Repair or replace as necessary.
1. Intermittent opens in Manifold Absolute Pressure (MAP) or Engine Coolant Temperature (ECT)
sensor grounds CKT 814. If intermittent for a very brief period, will not set DTC.
2. Intermittent short to grounds or opens in Manifold Absolute Pressure (MAP) sensor 5 volt refer-
ence CKT 416 and Manifold Absolute Pressure (MAP) sensor signal CKT 432. If intermittent for
a very brief period, will not set DTC.
Index
SURGES (continued)
ADDITIONAL CHECKS FOR:
1. Proper alternator output voltage.
2. Leaks or kinks in vacuum lines.
3. Power reduction mode activated (if equipped).
4. Clean and tight ECM grounds and in their proper locations.
Index
HESITATION, SAG OR STUMBLE
Definition: Momentary lack of response as the throttle is opened. Can occur at all engine speeds.
May cause engine to stall if severe enough.
PRELIMINARY CHECKS
1. Water contaminated fuel and dirty or restricted fuel filter.
2. Fuel pressure within specification.
3. Proper functioning of fuel injectors.
4. Worn throttle linkage.
1. Ignition Control (IC) system for proper timing and advancing.
2. Faulty spark plug wires, fouled or improperly gapped spark plugs.
3. Power reduction mode activated (if equipped).
4. Knock Sensor (KS) system operational.
Index
HESITATION, SAG OR STUMBLE (continued)
1. Binding or sticking Throttle Position (TP) sensor or salt corrosion. Throttle Position (TP) sensor
voltage should increase as throttle is moved toward Wide Open Throttle (WOT).
2. Throttle Position (TP) sensor-5 volt reference CKT 416 for open, DTC 21 may be set.
3. Throttle Position (TP) sensor circuit for open or grounds, DTC 21 may be set.
4. Manifold Absolute Pressure (MAP) output voltage check.
5. Coolant sensor out of specification (Hi or low).
ADDITIONAL CHECKS:
2. Faulty or incorrect thermostat.
3. Throttle linkage sticking, binding, or worn.
Index
DETONATION/SPARK KNOCK
Definition: A mild to severe ping, usually worse under acceleration or heavy load. The engine
makes sharp metallic knocks that change with throttle opening.
PRELIMINARY CHECKS
1. Contaminated fuel.
2. Poor fuel quality and proper octane rating.
1. Proper ignition timing.
2. Proper operation of Knock Sensor ( KS) system. Ensure wires are routed AWAY from secondary
or primary ignition wires.
3. Ignition system ground.
4. Proper heat range and gapped spark plugs.
5. Incorrect knock sensor or knock sensor module.
1. Engine Coolant temperature (ECT) has shifted value.
2. Binding or sticking Throttle Position (TP) sensor or salt corrosion. Voltage should increase as
throttle is moved toward Wide Open Throttle (WOT).
Index
DETONATION/SPARK KNOCK (continued)
CHECK ENGINE FOR:
1. Low oil level.
2. Excessive oil in the combustion chamber. Valve seals for leaking.
3. Perform a compression test.
4. Combustion chambers for excessive carbon build-up. Remove carbon with top engine cleaner.
5. Proper camshaft timing.
6. Incorrect basic engine parts such as cam, heads, pistons, etc.
Index
LACK OF POWER, SLUGGISH OR SPONGY
Definition: Engine delivers less than expected power. Little or no increase in speed when
throttle control is moved toward Wide Open Throttle (WOT).
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at the start of “Troubleshooting Charts”
section.
Remove flame arrestor and check for dirt, or for being plugged. Replace as necessary.
1. Dirty or plugged water separating fuel filter.
2. Contaminated fuel.
3. Possible open in injector driver CKTs 467 or 468.
4. Improper fuel pressure.
5. Flooded VST (if equipped).
1. Proper initial engine timing.
2. Secondary ignition voltage.
3. Proper operation of Ignition Control (IC)/Knock Sensor (KS), open or short to ground in CKT 423
or 485 will set a DTC 42 or 43.
Index
LACK OF POWER, SLUGGISH OR SPONGY
(continued)
1. Possible open in Engine Coolant Temperature (ECT) and Manifold Absolute Pressure (MAP)
sensors (Ground CKT 814). Also could have and set a DTC 14 and/or 33.
2. Throttle Position (TP) sensor circuit if DTC 21 set for open or grounds.
3. Using a scan tool and/or voltmeter record Throttle Position (TP) sensor voltage. It should read
less than .7 volt with throttle closed or at idle position. A sticky throttle shaft or binding linkage
causes a high voltage.
4. Power reduction mode activated.
5. Diagnostic test CKT 451 for being grounded, (maximum RPMs be will lower).
CHECK ENGINE FOR:
1. Restricted exhaust system.
3. Proper valve timing and worn camshaft.
ADDITIONAL CHECKS:
2. Clean, tight and properly located ECM grounds.
3. Excessive resistance on bottom of boat (dirt, barnacles, etc.).
4. Proper size and pitch propeller for application.
Index
CUTS OUT AND MISSES
Definition: Steady pulsation or jerking that follows engine speed, usually more pronounced
as engine load increases.
PRELIMINARY CHECKS
Perform the important preliminary checks as described at the start of the “Troubleshooting Charts”
section.
1. Cylinder miss
a. Start engine, allow engine to stabilize, record RPM, then disconnect IAC motor. Stop engine,
ground one spark plug wire at a time. Restart engine and record RPM.
b. If there is an RPM drop on all cylinders, go to “Stalling, Rough, or Incorrect Idle” section. With
engine “OFF” reconnect IAC motor.
c. If there is no RPM drop on one or more cylinders, or excessive variation in RPM drop, check
for spark on the suspected cylinder(s).
d. If there is a spark, remove spark plug(s) in these cylinders and check for: Insulation cracks,
insulator cracks,wear, improper gap, burned electrodes, heavy deposits.
e. Spark plug wire resistance (should not exceed 30,000 ohms).
f. Faulty ignition coil.
g. With engine running, spray distributor cap and spark plug wires with a fine mist of water to
check for shorts.
1. Contaminated or restricted water separating fuel filter.
2. Fuel pressure within specification. (Fuel pressure can be checked on fuel rail at the schrader
valve. Mechanical pump can be checked with a carburetor fuel pressure gauge downstream
from the pump prior to VST.
3. Faulty fuel injectors.
Index
CUTS OUT AND MISSES (continued)
1. Open or grounds in CKT 417 Throttle Position (TP) sensor signal.
2. Open or grounds in CKT 416 Throttle Position (TP) sensor 5 volt reference.
CHECK ENGINE MECHANICAL FOR:
2. Bent push rods, worn rocker arms, broken valve springs, worn camshaft lobes. Repair or replace
as necessary.
ADDITIONAL CHECKS:
A misfire can be caused by Electromagnetic Interference (EMI) on the reference circuit. EMI can usu-
ally be detected by monitoring engine RPM with a scan tool or a tachometer. A sudden increase in
RPM with little change in actual engine RPM change, indicates EMI is present. If the problem exists,
check routing of secondary wires, check ground circuit.
Index
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING
Definition: Engine runs unevenly or rough at idle, also the idle may vary in RPM (called hunt-
ing). Either condition may be severe enough to cause stalling. Engine idles at incorrect
speed.
PRELIMINARY CHECKS
section.
1. Open in CKTs 467 or 468.
2. Fuel injector(s) leaking.
1. Correct ignition timing.
2. Possible opens in the following circuits, CKTs 424,430 and 423.
3. Possible short to ground in the following circuits, CKTs 430, 424, and 423.
4. Faulty spark plugs, wires, etc.
Index
ROUGH, UNSTABLE, OR INCORRECT IDLE,
STALLING
(continued)
1. Proper Idle Air Control (IAC) operation.
2. Possible open the in following circuits for CKTs 410, 417, 416, 813 and 814.
3. Possible short to ground in CKT 417, Throttle Position (TP) sensor signal, CKT 416 Throttle
Position (TP) sensor 5 volt reference and CKT 451 diagnostic test circuit.
4. A sticking throttle shaft, binding linkage or salt corrosion will cause a high Throttle Position (TP)
sensor voltage (open throttle indication), the ECM will not control idle. Using a scan tool or volt-
meter record Throttle Position (TP) sensor voltage. It should read approximately .7 volt closed
throttle and approximately 4.5 volts at Wide Open Throttle (WOT).
CHECK ENGINE FOR:
2. Proper camshaft or weak valve springs.
ADDITIONAL CHECKS:
1. Sticking or binding throttle linkage and salt corrosion.
3. Battery cables and ground straps should be clean and secure. Erratic voltage will cause Idle Air
Control (IAC) to change its position, resulting in poor idle quality.
Index
BACKFIRE (INTAKE)
Definition: Fuel ignites in the manifold, making a loud popping noise.
PRELIMINARY CHECKS
section.
1. An abnormal fuel system condition: If necessary perform fuel system diagnosis.
2. Properly functioning fuel injectors.
1. Opens and grounds in CKTs 423, 424 and 430.
2. Proper output voltage of ignition coil.
3. Cross-fire between spark plugs, (distributor cap, spark plug wires and proper routing of plug
wires).
4. Faulty or corroded spark plug wires and boots.
5. Faulty spark plugs.
6. Power reduction mode activated. (1996 Models and Older).
CHECK ENGINE FOR:
1. Sticking or leaking valves.
2. Proper valve timing, broken or worn valve train parts.
Index
BACKFIRE (EXHAUST)
Definition: Fuel ignites in the manifold, making a loud popping noise.
PRELIMINARY CHECKS
Perform the important preliminary checks as described at the start of the “Troubleshooting” section.
1. An abnormal fuel system condition: If necessary perform fuel system diagnosis.
2. Proper functioning of fuel injectors.
1. Opens and grounds in CKTs 423, 424 and 430.
2. Properly functioning (advancing and retarding of timing) Ignition Control (IC).
3. Proper output voltage of ignition coil.
4. Faulty or corroded spark plug wires and boots.
5. Faulty spark plugs.
CHECK ENGINE FOR:
1. Possible sticking or leaking valves.
Index
DIESELING, RUN-ON
Definition: Engine continues to run after key is turned “OFF,” but runs very roughly. If engine
runs smoothly, check ignition switch and adjustment.
PRELIMINARY CHECKS
Perform the important preliminary checks as described at the start of the “Troubleshooting” section.
1. Leaking injectors.
2. Flooded VST
2. Correct heat range spark plugs.
3. Proper operation of system relay.
CHECK COOLING SYSTEM FOR:
1. Faulty or incorrect thermostat.
2. Cooling system restriction causing overheating.
3. Loose belts.
Index
POOR FUEL ECONOMY
Definition: Fuel economy is noticeably lower than expected.
PRELIMINARY CHECKS
Perform the important preliminary checks as described at the start of “Troubleshooting” section.
1. Operator’s driving habits.
2. Dirty or plugged flame arrestor.
3. Fuel leaks.
1. Quality and type of fuel.
2. Flooded VST.
1. Correct base timing.
3. Fuel fouled, cracked, worn, improperly gapped spark plugs, burned electrodes, or heavy depos-
its. Repair or replace as necessary.
4. Knock sensor system operation.
Index
POOR FUEL ECONOMY (continued)
1. If MAP, TP, or Coolant Sensor are erratic there will be poor economy.
CHECK ENGINE FOR:
2. Exhaust system restriction.
3. Excessive resistance on bottom of boat (dirt, barnacles, etc.).
4. Proper size and pitch propeller for application.
Index
Fuel Delivery Systems
Cool Fuel System Exploded View
1
2
3 6
7
8
9 15
16
10
11
17
14
12
18
19 25
13 21
26
20
22
27
23
24
Index
1 -Screws (4)
2 -Nut (2)
3 -Bracket
4 -Cover Base
5 -Reference Line To Plenum Or Flame Arrestor
6 -Fitting
7 -Tubing
8 -Fuel Pressure Regulator
9 -Screw (2)
10 -Washer (2)
11 -Washer
12 -Fuel Return Line Fitting
13 -Rubber Bushing (8)
14 -Filter
15 -Outlet Fuel Line To Fuel Rail Or Throttle Body
16 -O-Ring
17 -Fuel Cooler
18 -O-Ring
19 -Drain Plug
20 -Elbow Fitting
21 -O-Rings (4)
22 -Electric Fuel Pump
23 -O-Ring
24 -Fuel Pump Inlet Fitting
25 -Retainer Bracket
26 -Nut (2)
27 -Cover
Index
Vapor Separator Tank (VST) Exploded View
32
23 38
22 31
39
21 24 30
40
25 29 41
28 33
47 48
34
20 49
46 35
19 45 36
37 a
1
27
18
44
17
16
4
15 5
3
2 6
43
8
26
7 9
10
13 11
42
14
12
72803
Index
1 -Cover Torque Sequence For VST
2 -Seal
3 -Spring 3 2
4 -Diaphragm
5 -O-ring
6 -Diaphragm Cover
7 -Screw
8 -Valve Seat 5 6
9 -Float Valve
10 -Float Valve Pin
11 -Clip
12 -Float
13 -Float Arm Pin 1 4
14 -VST Body
15 -Fuel Screen
16 -Plate a
17 -Rubber Cushion 73895
18 -Electric Fuel Pump
19 -Plate a - Tighten Screws Securely
20 -O-ring
21 -Adapter
22 -O-ring
23 -Collar
24 -O-ring
25 -Adapter
26 -Lockwasher
27 -Screw
28 -O-ring
29 -Insulator
30 -Lockwasher
31 -Nut
32 -Electrical Connector
33 -Screw
34 -Lockwasher
35 -L-Joint
36 -O-ring
37 -O-ring
38 -Nut
39 -Lockwasher
40 -Insulator
41 -O-ring
42 -Screw
43 -Grommet
44 -Lockwasher
45 -Clip
46 -Lockwasher
47 -Screw
48 -Plug
49 -O-ring
a - A VST equipped with elbow fitting on top of VST

will have this configuration diaphragm and
spring.
Index
VST Fuel Pump (Exploded View)
16
1 15
2 14
13
3
l
12
23
4 17
24 18
5 19
20
21
6 25
7
22
8
10
11
72803
1 - Collar 13- Insulators (2)

2 - O-Rings (2) 14- Lockwashers (2)
3 - Adapters (2) 15- Nuts (2)
4 - O-Ring 16- Electrical Connector
5 - Plate 17- Screw
6 - Electric Fuel Pump 18- Spring Washer
7 - Rubber Cushion 19- L-Joint
8 - Plate 20- O-Ring
9 - Fuel Filter 21- O-Ring
10- Seal 22- Cover
11- Chamber Body 23- Screws (6)
12- O-Rings (2) 24- Lockwashers (6)
25- Clip
Index
VAPOR SEPARATOR TANK (VST)
6
2
1
7
3
9 9
10
11 73719
1 - Vapor Separator Tank (VST)

2 - Grommet
3 - Hose (Some Models Connected To Top Fitting)
4 - Fuel Line Return
5 - Plug
6 - O-Ring
7 - Fuel Line VST Supply
8 - Grommet
9 - Bushing
10- Screw
11- Fuel Line Supply
Index
Vapor Separator Tank (VST) INSTALLATION
1. Install VST to intake manifold. Apply Loctite 8831
NOTICE to threads of attaching screw. Torque bolt to 105
Refer to “Service Precautions,” in “Repair lb. in. (12 N·m).
Procedures,” BEFORE proceeding.
2. Connect all lines to cover of vapor separator tank.
Torque fuel line fittings to 23 lb. ft. (31 N·m).
REMOVAL 3. Connect fuel pump electrical connector.
1. Disconnect fuel pump electrical connector. 4. With engine off, cycle ignition switch to on,waiting
2. Label and then disconnect all fuel lines from 2 seconds and then off, four times waiting 10 se-
cover of vapor separator tank. conds after each key off to prime the fuel system
and check for leaks.
NOTE: If VST is dry, remove the vent screw and fill
with fuel.
REMOVAL - VST FUEL PUMP

b
c a d 1. Disconnect fuel pump electrical connector.
2. Label and then disconnect all lines from cover of
vapor separator tank.
3. Remove electrical line from retaining clip.
4. Remove screw from L-joint and pull L-joint from
e cover.
5. Disconnect fuel pump electrical connectors as
follows:
73759
a. Gently pry each side of connector cover up
a - VST
b - Bracket
and over retaining tabs.
c - Screw b. Remove connector retaining nuts and re-
d - Bushing move connectors.
e - Grommet
6. Remove cover screws and remove cover and
3. Remove screw and VST from intake manifold. electrical line retaining clip.
7. Carefully slide fuel pump assembly from cover.
8. Remove O-ring, plate, adaptors and collar from
fuel pump.
9. Remove screen from fuel pump.
10. Remove plate and rubber cushion.
NOTE: When replacing fuel pump, make certain to
replace with a fuel pump of the identical part number.
Index
INSTALLATION Float and Needle Assembly
1. Install rubber cushion and plate, making sure to
align cutout in plate with pump inlet. REMOVAL
2. Install screen on fuel pump. 1. Disconnect fuel pump electrical connector. (Elec-
tric fuel pump removed for visual clarity.)
3. Install adaptors, collar, plate and new O-ring on
fuel pump. Be sure that fuel pump relief valve fits 1
through hole in plate.
4. Slide fuel pump into cover.
5. Apply Loctite Type 8831 to threads of cover
screws. Install cover and electrical line retainer
clip and tighten cover screws securely.
a
6. Connect fuel pump electrical connectors. Snap 4
connector covers in place. Secure electrical line
in retainer clip. 3
7. Install L-joint onto cover. Tighten screw securely. 5
8. Connect all fuel lines to cover of vapor separator
tank. Torque fuel line fittings to 23 lb. ft. (31 N·m).
2
9. Connect fuel pump electrical connector.
10. With engine OFF, cycle ignition switch to ON, wait
2 seconds and then OFF, four times waiting 10
seconds after each key off to prime the fuel sys-
a
tem and check for leaks.
NOTE: If VST is dry, remove the vent screw and fill
with fuel.
6f
7
8
9
11
12
10
72803
a - A VST equipped with elbow fitting on top of VST

will have this configuration diaphragm and
spring.
1 - Electrical Connector
2 - Cover
3 - Lockwashers (6)
4 - Screws (6)
5 - Clip
6 - Valve Seat
7 - Float Valve
8 - Float Valve Pin
9 - Clip
10- Float
11- Float Arm Pin
12- Screw
Index
2. Label and then disconnect all fuel lines from Diaphragm Assembly
cover of vapor separator tank.
3. Remove electrical line from retaining clip (some REMOVAL
models). 1. Disconnect fuel pump electrical connector. (Elec-
4. Remove cover screws and remove cover and tric fuel pump removed for visual clarity.)
electrical line retainer clip.
1
5. Remove float arm pin retaining fastener and re-
move float and needle assembly.
6. Disassemble float and needle assembly; i.e.,
float valve, float valve pin, clip and float.
CLEANING AND INSPECTION 4 a

1. Clean components with carburetor cleaner.
7 3
IMPORTANT: Do not soak float or float valve in
carburetor cleaner. 5
2. Inspect float valve seat for wear. Replace if nec-
essary. 2
3. Inspect float and needle assembly; i.e., float
valve, float valve pin, clip and float. Replace parts
as necessary.
a
INSTALLATION 6
1. Assemble float and needle assembly; i.e., float 8
valve, float valve pin, clip and float. 9
NOTE: Float is not adjustable. 10
2. Install float and needle assembly and secure float 12

arm pin using fastener.
11
3. Apply Loctite 8831 to threads of cover screws.
Install cover and electrical line retainer clip and
tighten cover screws securely.
4. Secure electrical line in retainer clip.
tank. Torque fuel line fittings to 23 lb. ft. (31 N·m). 72803
6. Connect fuel pump electrical connector. a - A VST equipped with elbow fitting on top of VST
7. With engine OFF, cycle ignition switch to ON wait- will have this configuration diaphragm and
ing for 2 seconds, and then OFF, waiting 10 se- spring.
conds after each key off four times to prime the 1 - Electrical Connector
fuel system and check for leaks. 2 - Cover
3 - Lockwashers (6)
NOTE: IF VST is dry. remove vent screw and fill with 4 - Screws (6)
fuel. 5 - Clip
6 - Spring
7 - Diaphragm
8 - O-Ring
9 - Diaphragm Cover
10- O-Ring
11- Screw
12- Lockwasher
Index
2. Label and then disconnect all fuel lines from
cover of vapor separator tank.
3. Remove electrical line from retainer clip.
4. Remove cover screws and remove cover and
electrical line retaining clip.
5. Remove float arm pin retaining fastener and re-
move float and needle assembly.
6. Remove diaphragm cover screws and remove di-
aphragm cover, O-ring, diaphragm and spring.
CLEANING AND INSPECTION

1. Clean and inspect all parts. Check diaphragm for
damage. Replace if necessary.
2. Inspect spring for wear. Replace if necessary.
INSTALLATION
1. Install spring, diaphragm, O-ring and diaphragm
cover using diaphragm cover screws. Tighten
screws.
2. Install float and needle assembly and secure float
arm pin using fastener.
3. Apply Loctite 8831 to threads of cover screws.
Install cover and electrical line retainer clip and
tighten cover screws securely.
3 2
5 6
1 4
73895
Torque Sequence For VST
4. Secure electrical line in retainer clip.

tank. Torque fuel line fittings to 23 lb. ft. (31 N·m).
6. Connect fuel pump electrical connector.
7. With engine OFF, cycle ignition switch to ON,wait
for 2 seconds, then OFF, four times, waiting 10
seconds after each key off to prime the fuel sys-
tem and check for leaks.
Index
Throttle Body Injection Torque Specifications
Repair Procedures Fastener Location Lb. In. Lb. Ft. N•m
Flame Arrestor To
50 6
! WARNING Throttle Body
Electrical, ignition and fuel system components Throttle Body To
on your MerCruiser are designed and manufac- Adapter
30 40
tured to comply with U.S Coast Guard Rules and Adapter To Intake
Regulations to minimize risks of fire and explo- Manifold
sion. Use of replacement electrical, ignition or Intake Manifold To
fuel system components, which do not comply 25 34
Heads
with these rules and regulations, could result in
VST Cover To Body 6 8
a fire or explosion hazard and should be avoided.
Spark Plugs 11 15
VST To Throttle Body 23 31
Special Tools Sensors And Plugs To Hand Tight Plus 2-1/2
Thermostat Housing Turns Maximum
Description Part Number Knock Sensor 14 19
Fuel Pressure Gauge 91-168850A1 TP Sensor 20 2
IAC Valve 13 18
Distributor Hold-Down
30 40
Lubricants/Sealants/ Clamp
Adhesives MAP Sensor 53 6

Loctite 8831 92-823089-1
Loctite 262
Obtain Locally
Loctite 242
Index
Throttle Body Injection ! WARNING
System Description Be sure that the engine compartment is well ven-
tilated and that no gasoline vapors are present to
avoid the possibility of fire.
Service Precautions ! WARNING

! WARNING Make sure no fuel leaks exist before closing en-
gine hatch.
or explosion.
Fuel pressure MUST BE relieved before servicing
! WARNING any component in the fuel system.
Be careful when cleaning flame arrestor and ! CAUTION

crankcase ventilation hoses; gasoline is ex-
tremely flammable and highly explosive under
being supplied to seawater pump or water pump
certain conditions. Be sure that ignition key is
impeller will be damaged and subsequent over-
OFF. DO NOT smoke or allow sources of spark or
heating damage to engine may result.
open flame in area when cleaning flame arrestor
and crankcase ventilation hoses. The following information MUST BE adhered to
when working on the fuel system:
! WARNING
• Always keep a dry chemical fire extinguisher
Be careful when changing fuel system compo- at the work area.
nents; gasoline is extremely flammable and high-
• Always install new O-rings when assembling
ly explosive under certain conditions. Be sure
fuel system parts.
that ignition key is OFF. DO NOT smoke or allow
sources of spark or open flame in the area while • DO NOT replace fuel pipe with fuel hose.
changing fuel filter(s). Wipe up any spilled fuel • Always relieve system fuel pressure prior to
immediately. servicing any component in the fuel system.
• DO NOT attempt any repair to the fuel system
until instructions and illustrations relating to
that repair are thoroughly understood.
• Observe all Notes and Cautions.
Index
Throttle Body Exploded Views
350 CID / 5.7L EFI (2 Barrel Throttle Body) Induction System
9
1
11 10
12
13
2
14
15
16
3 17
5
19
18
6 73766
75067
A 74109 B
Index
1- Throttle Body
2- Screws (3)
3- Gasket
4- Throttle Body Adapter
5- Screws (4)
6- Gasket
7- Intake Manifold
8- Fuel Meter Cover
9- Gasket
10 -O-ring
11 -Fuel Pressure Regulator
12 -Gasket
13 -Fuel Injector
14 -Fuel Meter Body
15 -Gasket
16 -Fuel Inlet And Outlet Connections
17 -Throttle Body
18 -Idle Air Control (IAC)
19 -Throttle Position Sensor (TP)
A - MCM Throttle Linkage
B - MIE Throttle Linkage 5.7L / 350 Magnum Ski Models Only
Index
350 CID / 5.7L EFI (4 Barrel Throttle Body) Induction System
8
1
9
11 10
12
13
2
14
15
3
16
17
4
19
18
73766
73965
A 74109 B
Index
1 - Screw (3)
2 - Throttle Body Unit
3 - Gasket
4 - Manifold Absolute Pressure (MAP) Sensor
5 - Screw (4)
6 - Throttle Body Adapter
7 - Gasket
8 - Fuel Meter Cover
9 - Gasket
10- Fuel Line From VST To Fuel Filter
11- Fuel Pressure Regulator
12- Gasket
13- Fuel Injector
14- Fuel Meter Body
15- Gasket
16- Fuel Inlet And Outlet Connections
17- Throttle Body
18- Idle Air Control (IAC)
19- Throttle Position Sensor (TP)
A - MCM Throttle Linkage

B - MIE Throttle Linkage 5.7L / 350 Magnum Ski Models Only
Index
Throttle Body
1
2
4
3
5
7
6
8
9
10
11
12
13
20
13
14
17
15
18
16
73766
19
1 - Cap Screw 11- Body

2 - Cover Assembly 12- Throttle Body To Fuel Meter Body Gasket
3 - Fuel Pressure Regulator 13- Throttle Body
4 - Cover Assembly Gasket 14- Throttle Position (TP) Sensor
5 - Upper O-Ring 15- Screws (2)
6 - Fuel Meter Outlet Gasket 16- Seal
7 - Fuel Injector (2) 17- O-Ring
8 - Fuel Filter (2) 18- Idle Air Control (IAC) Valve
9 - Lower O-Ring 19- Screws (2)
10- Screw 20- Fuel Inlet
Index
Fuel Pressure Relief Procedure 4. Remove fuel meter cover assembly.
d
NOTICE
Refer to “Service Precautions,” in “Repair
a
1. Disconnect electrical connector from fuel pump.

2. Crank engine for ten seconds (if engine starts al-
low it to run until it dies) to relieve any fuel pres-
sure in the system. b
c
e
Fuel Meter Cover Assembly
NOTICE
73767
a - Fuel Meter Cover

! CAUTION b - Fuel Damper
c - Gaskets (Regulator Passages)
DO NOT remove the four screws securing the d - Screws
pressure regulator to the fuel meter cover. The e - Fuel Meter Outlet Gasket
fuel pressure regulator includes a large spring
under heavy compression which, if accidentally CLEANING AND INSPECTION
released, could cause personal injury. IMPORTANT: DO NOT immerse the fuel meter
cover (with pressure regulator) in cleaner, as
REMOVAL damage to the regulator diaphragm and gasket
1. Remove the flame arrestor from the throttle body. could occur.
2. Disconnect electrical connectors to fuel injectors. 1. Inspect pressure regulator seating area for pit-
(Squeeze plastic tabs and pull straight up.) ting, nicks, burrs or irregularities. Use a magnify-
ing glass if necessary. If any of the above is pres-
3. Remove the fuel meter cover screw assemblies. ent, replace the cover assembly.
Index
INSTALLATION 1. Remove flame arrestor and fuel meter cover as
outlined in this section.
1. Install new pressure regulator seal, fuel meter
outlet passage gasket, and cover gasket. 2. Using a screwdriver carefully pry up on fuel in-
jector to remove it from the fuel meter body (Use
2. Install fuel meter cover assembly.
a screwdriver or rod under the the screwdriver
3. Install attaching screws, precoated with appropri- when prying up. Leave old gasket in place to pre-
ate locking compound to threads. (Short screws vent damage to fuel meter body).
are next to injectors.)
4. Torque screws to 28 lb. in. (3 N⋅m).
5. Connect electrical connectors to fuel injectors.
6. With engine “OFF,” and ignition “ON,” check for
leaks around gasket and fuel line couplings.
d
a
73770

b Inspect fuel injectors for damage; replace if neces-
c
sary.
IMPORTANT: When replacing injectors, be cer-
tain to replace with the identical part and part
number. Other injectors may have the same ap-
pearance, yet have a different part number and be
calibrated for a different flow rate, and if installed,
73767 would cause performance difficulty or damage to
the ECM.
a - Fuel Meter Cover
b - Pressure Regulator Assembly
a
c - Gaskets (Regulator Passages)
d - Screws
Fuel Injectors
73772
NOTICE
a - Part Indentification Number
REMOVAL
NOTE: Use care in removing fuel injectors to prevent
damage to the electrical connector and nozzle.
IMPORTANT: The fuel injector is an electrical
component. DO NOT soak in any liquid cleaner or
solvent, as damage may result.
Index
INSTALLATION Throttle Body
1. Install new lower O-rings on fuel injectors. Lubri-
cate O-rings using a water soap solution. REMOVAL
! CAUTION
Ensure that fuel pressure is relieved before re-
b moving the fuel inlet and return lines.
a IMPORTANT: DO NOT allow the TP sensor, fuel
pressure regulator, fuel injectors and IAC valve
to come into contact with solvent or cleaner.
c These components should be removed prior to
immersion in solvent.
d 1. Remove the flame arrestor from the throttle body.
2. Disconnect throttle cable.
3. Disconnect the electrical connections from the
TP sensor, IAC and fuel injectors. (Squeeze plas-
73766
tic tabs on injectors and pull straight up).
a - Fuel Injector a
b - Upper O-Ring
c - Lower O-Ring
d - Fuel Filter
2. Install upper O-rings in fuel meter body. Lubricate

O-rings with water soap solution.
3. Install fuel injectors into the fuel meter body. Align
the raised lug on the injector base with the notch
in fuel meter cavity.
73750
a
a - Electrical Connections
4. Remove fuel inlet and outlet lines from throttle

body.
5. Remove screws retaining the throttle body to
73771 adapter plate.
NOTE: Place a shop rag over the intake manifold
NOTE: The electrical terminals of the injectors opening to prevent debris from entering intake man-
should be parallel with throttle shaft. ifold.
4. Install gasket and fuel meter cover, torque
screws to 28 in. lb. (3.0 N⋅m) and flame arrestor
as outlined in this section.
5. Connect electrical connections to fuel injectors.
6. With engine “OFF,” and ignition “ON,” check for
leaks around gasket and fuel line couplings.
Index
CLEANING AND INSPECTION Throttle Body Adapter Plate
1. Thoroughly clean metal parts of throttle body in
a cold immersion type cleaner. Dry with com- NOTICE
pressed air. Make certain that all passages are Refer to “Service Precautions,” in “Repair
free of dirt and burrs. Procedures,” BEFORE proceeding.
2. Inspect mating surfaces for damage that could

affect gasket sealing. REMOVAL
3. Inspect throttle body for cracks in casting. IMPORTANT: Place a clean shop towel over the
4. Inspect throttle plates, linkage, return springs, intake manifold opening to prevent foreign mate-
etc., for damage, wear and foreign material. rial from entering the engine.
5. Check intake manifold plenum for loose parts 1. Remove flame arrestor.
and foreign material. 2. Remove throttle body refer to Throttle Body Sec-
tion.
INSTALLATION 3. Remove screws and the throttle body adapter
1. Install fuel injectors and fuel meter body as pre- from the intake manifold.
viously described in this section.
2. Install a new gasket on adapter plate. 1
3. Install throttle body on adapter plate and torque
the screws 30 ft. lb. (40 N⋅m).
4. Connect throttle linkage to throttle body.
2
5. Move throttle from idle to WOT and check that the
throttle movement is not binding.
6. Connect the fuel inlet and return lines. Torque to
23 ft. lb. (31 N⋅m).
7. Connect TP sensor, IAC, and fuel injectors con- 3
nections.
8. Turn key to on position and check for fuel leaks 4
around the inlet and return line connections.
9. Start engine and check for fuel leaks. 5
73965
1 - Screws (3)
2 - Throttle Body Unit
3 - Gasket
4 - Screws (4)
5 - Throttle Body Adapter
6 - Gasket
7 - Intake Manifold
Index
Multi-Port Injection System ! WARNING
Description Make sure no fuel leaks exist, before closing en-
gine hatch.
Service Precautions ! CAUTION

! WARNING
Fuel pressure MUST BE relieved before servicing
Always disconnect battery cables from battery high pressure component in the fuel system.
or explosion.
! CAUTION
! WARNING DO NOT operate engine without cooling water
Be careful when cleaning flame arrestor and being supplied to water pickup holes in gear
crankcase ventilation hose; gasoline is extreme- housing, or water pump impeller will be damaged
ly flammable and highly explosive under certain and subsequent overheating damage to engine
conditions. Be sure that ignition key is OFF. DO may result.
NOT smoke or allow sources of spark or open The following information MUST BE adhered to
flame in area when cleaning flame arrestor and when working on the fuel system:
• Always keep a dry chemical fire extinguisher
! WARNING at the work area.
Be careful when changing fuel system compo- • Always install new O-rings when assembling
nents; gasoline is extremely flammable and high- fuel pipe fittings.
ly explosive under certain conditions. Be sure • DO NOT replace fuel pipe with fuel hose.
sources of spark or open flame in the area while • DO NOT attempt any repair to the fuel system
changing fuel filter(s). Wipe up any spilled fuel until instructions and illustrations relating to
immediately. that repair are thoroughly understood.
! WARNING • Observe all Notes and Cautions.
Be sure that the engine compartment is well ven-

tilated and that no gasoline vapors are present to
avoid the possibility of fire.
Index
Multi-Port Exploded Views
Flame Arrestor and Throttle Body (All Multi-Port Injection Engines Equipped
Vapor Separator Tank)
5
1 2 3 4 6
21
8 22
7
9
11
12 12 10
12
14 13
20
19 22
a 15 23
b
16
17
18
75068
Index
1 - Nut (4)
2 - Flame Arrestor
3 - Stud (4)
4 - Throttle Body
5 - Manifold Absolute Pressure (MAP) Sensor
6 - Plenum
7 - Screw (4)
8 - Fuel Line From Fuel Filter To Starboard Fuel Rail
9 - Fuel Filter
10- Fuel Line From VST To Fuel Filter
11- Fuel Line From Starboard To Port Fuel Rail
12- Fuel Rail (2)
13- Fuel Pressure Regulator
14- Fuel Block
15- Fuel Line From Fuel Block To VST
16- Fuel Injector (8)
17- Intake Manifold
19- Fuel Line - From Front Of Starboard Fuel Rail To Rear Of
Port Fuel Rail
20- Fuel Line - From Rear Of Starboard Fuel Rail To Front Of
Port Fuel Rail
21- Fuel Line From Cool Fuel System
22- Adapter Block
23- Schrader Valve
a - VST Equipped System

b - Cool Fuel System
Index
350 MPI Magnum Gen + Tournament Ski (Black Scorpion) Induction System
2
3
4
5
6
7 18
8 7
7
9
11
10 10
12 20
18 19 13
7
a 14 13 b
15
16
17
75046
Index
1 - Flame Arrestor Fuel Pressure Relief Procedure
2 - Flame Arrestor Clamp
3 - Throttle Body
4 - Throttle Body Gasket NOTICE
5 - Manifold Absolute Pressure (MAP) Sensor Refer to “Service Precautions,” in “Repair
6 - Plenum Procedures,” BEFORE proceeding.
7 - Fuel Rail Fitting (2)
8 - Fuel Line
9 - Screw (2)
10- Fuel Rail (2) 1. Disconnect electrical connector at fuel pump.
11- Fuel Damper
12- Fuel Rail Fitting (2) 2. Crank engine for ten seconds (if engine starts al-
13- Schrader Valve low it run until it dies) to relieve any fuel pressure
14- Fuel Line in the system.
15- Fuel Injector (8)
16- Manifold
18-
19-
Inlet Fuel Fitting From Cool Fuel System
Fuel Line - From Front Of Starboard Fuel Rail To Rear Of Multi-Port Components
Port Fuel Rail
20- Fuel Line - From Rear Of Starboard Fuel Rail To Front Of
Port Fuel Rail
Flame Arrestor
a - Earlier Fuel Hose System
b - Cool Fuel System NOTICE
REMOVAL
Remove four flame arrestor mounting cap nuts and
remove flame arrestor from throttle body.
72790
a - Flame Arrestor
b - Cap Nuts (4)

Clean flame arrestor in solvent and dry with com-
pressed air.
INSTALLATION
1. Install flame arrestor to throttle body.
2. Apply Loctite 242 to threads of studs. Install four
flame arrestor mounting cap nuts. Torque cap
nuts to 50 lb. in. (6 N·m).
Index
Throttle Body 3. Remove four throttle body mounting studs using
a stud driver.
NOTICE
Refer to “Service Precautions,” in “Repair a
REMOVAL
1. Remove four flame arrestor mounting cap nuts
and remove flame arrestor from throttle body.
a b
b 72792
a - Throttle Body
b - Throttle Body Mounting Studs
4. Turn throttle body as shown and disconnect TP, drain

tube and IAC electrical connectors.
b
a
72790
a - Flame Arrestor c
b - Cap Nuts (4)
2. Disconnect throttle linkage.
72793
a a - Throttle Body
b - Throttle Position (TP) Sensor
c - Idle Air Control (IAC) Valve
74183 d - Drain Tube
IMPORTANT: To prevent damage to throttle

valve, it is essential that throttle body be placed
on a holding fixture before performing service.
IMPORTANT: Insert a clean shop towel into the

opening of the plenum to prevent foreign materi-
al from entering the engine.
74174
a - Throttle Linkage Connections
Index
5. Remove TP with O-ring and IAC valve with O-ring INSTALLATION
from throttle body.
NOTE: To prevent difficult removal of fasteners and
damage to fastener heads, do not use a higher
strength thread locking compound than recom-
b mended.
1. Connect TP and IAC electrical connectors, then
install throttle body with new gasket using four
throttle body mounting studs.
b
a
a
d
72794
a - Throttle Position (TP) Sensor

b - Idle Air Control (IAC) valve 72793
a - Throttle Body
CLEANING AND INSPECTION b - Throttle Position (TP) Sensor
c - Idle Air Control (IAC) Valve
d - Sight Tube
IMPORTANT: DO NOT use cleaners containing
methyl ethyl ketone. It is not necessary for clean- 2. Apply Loctite 242 to threads of studs. Using a
ing throttle bore and valve deposits. stud driver, torque studs to 165 lb. in. (18.6 N·m).
IMPORTANT: DO NOT allow the TP and IAC valve a

to come into contact with solvent or cleaner.
IMPORTANT: Use care when removing gasket

material from plenum and throttle body. Failure
to do so could result in damage to the plenum
and throttle body. b
1. Carefully remove all gasket material from plenum 72792
and throttle body. a - Throttle Body
b - Throttle Body Mounting Studs
2. Thoroughly clean all parts of throttle body. Make
certain that all passages are free of dirt and burrs.
affect gasket sealing.
4. Inspect throttle body for cracks in casting.
5. Inspect throttle plates, linkage, return springs,
etc., for damage, wear and foreign material.
6. Check plenum for loose parts and foreign
material.
Index
NOTE: If Boat is equipped with Quicksilver Zero Ef- 4. Install flame arrestor to throttle body. Apply Loc-
fort Controls, the throttle cable mounting stud must tite 242 to threads of studs. Install four flame ar-
be most forward position on throttle lever. restor mounting cap nuts. Torque cap nuts to 50
lb. in. (6 N·m).
a
72790
73855 a - Flame Arrestor
b - Cap Nuts (4)
a - Position For Zero Effort Controls
3. Connect throttle linkage. Secure cable barrel an- Plenum

chor stud with locknut and tighten securely. Se-
cure cable end guide to lever stud. Thread lock- NOTICE
nut on stud until it contacts end guide. Refer to “Service Precautions,” in “Repair
REMOVAL
1. Remove flame arrestor and throttle body as out-
lined previously.
a 2. Disconnect MAP sensor electrical connector.
74183
74174
a - Throttle Linkage Connections
Index
3. Remove eight plenum mounting fasteners and lift CLEANING AND INSPECTION
straight up from intake manifold. Turn plenum
IMPORTANT: Use care when removing gasket
slightly and rest on intake manifold as shown.
material from intake manifold and plenum. Fail-
a
ure to do so could result in damage to the intake
manifold and plenum.
1. Carefully remove all gasket material from intake
b manifold and plenum.
2. Clean plenum in solvent and dry with com-
pressed air.
affect gasket sealing.
4. Inspect plenum for cracks in casting.
INSTALLATION
1. Install gasket on the intake manifold.
2. Rest plenum on intake manifold as shown.
Torque fasteners to 150 lb. in. (17 N·m).
3. Install throttle body and flame arrestor as outlined
74339 previously.
All Multi-Port Engines (Except Black Scorpion)
a - Plenum Pressure Regulator
b - Screws (8)
NOTICE
b REMOVAL
c NOTE: Black Scorpion and later Multi-Port Injection
models have the fuel pressure regulator to the Cool
Fuel system in Section 5A.
1. Relieve fuel pressure per recommendations in
this seciton.
a
2. Remove fuel line from VST to adapter block.
c 3. Remove the fuel line from rear of port side fuel
75046 rail.
Black Scorpion 4. Remove port fuel rail from fuel injectors.
a - Plenum 5. Reomve the adapter block from fuel rail.
b - Screws (6)
c - Nuts (Hidden In This View)
4. Black Scorpion only: Remove the nut from the

starboard bottom side of the plenum.
IMPORTANT: Place a clean shop towel over in-

take manifold openings to prevent foreign mate-
rial from entering the engine.
Index
6. Remove screws and fuel pressure regulator. 1. Install new O-rings on fuel injectors. Lubricate O-
rings using a water soap solution.
a b
c
b
d
75068
a - Fuel Rail a
c - Adapter Fitting
d - Adapter Block
72799
Fuel Injectors
a - Fuel Injector
NOTICE b - O-Ring
Procedures,” BEFORE proceeding. 2. Install fuel injectors as outlined in “Fuel Rail” and
“Intake Manifold.”
3. Install fuel rail, plenum, throttle body and flame
REMOVAL arrestor as outlined in this section.
NOTE: Use care in removing fuel injectors to prevent
damage to the electrical connector and nozzle.
IMPORTANT: The fuel injector is an electrical
solvent, as damage may result.
1. Remove flame arrestor, throttle body, plenum
and fuel rail as outlined in this section.
2. Remove fuel injectors from fuel rail and intake
manifold.

Inspect fuel injectors for damage; replace if neces-
sary.
INSTALLATION
IMPORTANT: When replacing injectors, be cer-
tain to replace with the identical part and part
number. Other injectors may have the same ap-
pearance, yet have a different part number and be
calibrated for a different flow rate, and if installed,
would cause performance difficulty or damage to
the ECM.
Index
Throttle Body Injection and REMOVAL
1. Disconnect J1 and J2 electrical connectors at en-
Multi-Port Injection Sensor gine control module (ECM).
and Module Servicing
Precautions
! WARNING
BEFORE attempting to disconnect and remove
any module or sensor, check to make sure that
the engine ignition system is OFF. Then discon-
nect the negative (–) battery cable from the termi-
nal. DO NOT reconnect the negative (–) battery
cable until the module or sensor removed has a
been re-installed with secure connections.
IMPORTANT: Modules and sensors are electrical
devices easily damaged by contact with liquid
cleaners or solvents. Clean with a dry cloth un-
less specifically directed to do otherwise.
Electronic Control Module (ECM) d

c
IMPORTANT: The ECM is a sensitive electrical de-
vice, subject to electrostatic damage. Therefore, b 72801
take care not to touch connector pins when re-

moving or installing the module.
Typical
NOTICE a - Electrical Bracket
Refer to “Service Precautions,” in “Repair b - ECM
Procedures,” BEFORE proceeding. c - J1- Electrical Connector (Front Connector)
d - J2- Electrical Connector (Rear Connector)
2. Remove ECM from electrical bracket.

1. Clean the exterior of the ECM with a dry cloth be-
ing careful to avoid contact with connector pins.
2. Inspect outer surfaces for any obvious damage
3. Visually inspect electrical pins at both ends of
ECM for straightness and corrosion.
4. Visually inspect J1 and J2 connectors on the wir-
ing harness for corrosion and terminals that may
have backed of the harness.
NOTE: The ECM is a sealed electrical component. If
a Code 51 check has shown it to be defective, re-
place the unit with another ECM having the same part
number and service number as the original.
Index
INSTALLATION Knock Sensor (KS) Module
1. Mount new ECM to electrical bracket.
NOTICE
2. Connect J1 and J2 electrical connectors to the Refer to “Service Precautions,” in “Repair
ECM. Procedures,” BEFORE proceeding.
REMOVAL
1. Remove Knock Sensor from electrical bracket.
d c
b 72801
All Engines Except Black Scorpion

a - Electrical Bracket
b - ECM 72801
c - J1- Electrical Connector (Front Connector)
d - J2- Electrical Connector (Rear Connector)
All Engines Except Black Scorpion
b - Knock Sensor (KS) Sensor
2. Disconnect electrical connector at Knock Sensor

(KS) module.

1. Clean the external surfaces of the KS module
with a dry cloth.
2. Inspect surfaces of KS module for evidence of
damage.
Index
INSTALLATION 1. Disconnect electrical connector at Engine Cool-
ant Temperature (ECT) sensor.
1. Connect electrical connector to the Knock Sen-
sor (KS) module.
2. Mount KS module to electrical bracket.
b b
72799
a - Thermostat Housing
b - Engine Coolant Temperature (ECT) Sensor
a
2. Remove ECT from thermostat housing.

1. Clean with a dry cloth, removing any excess seal-
ant from the base threads.
2. Look for evidence of any physical damage to
base or connector surfaces of the ECT.
INSTALLATION
72801
1. Install ECT in thermostat housing. TIGHTEN
All Engines Except Black Scorpion HAND TIGHT PLUS 2-1/2 TURNS MAXIMUM.
b - Knock Sensor (KS) Sensor
2. Connect electrical connector to ECT.
Engine Coolant Temperature (ECT)

Sensor
NOTICE
REMOVAL
NOTE: Handle the ECT carefully as any damage to
it will affect operation of the system.
Index
Throttle Body Injection Components- Throttle Position (TP) Sensor
Manifold Absolute Pressure (MAP)
NOTICE
Sensor Refer to “Service Precautions,” in “Repair
NOTICE
Procedures,” BEFORE proceeding. REMOVAL
1. Disconnect electrical connector at throttle posi-
REMOVAL tion (TP) sensor.
1. Disconnect electrical connector at manifold ab- 2. Remove TP sensor from throttle body.
solute pressure (MAP) sensor. c a
b
73758
a - Throttle Body
c - Screws

b 73753
1. Clean the surfaces of the TP sensor with a dry
cloth.
a
2. Inspect the TP sensor for signs of wear or dam-
a - Throttle Body Adapter Plate age.
b - Manifold Absolute Pressure (MAP) Sensor
2. Remove MAP sensor from throttle body adapter.

1. Clean off any foreign matter with a dry cloth.
2. Inspect for any obvious signs of physical damage
to the sensor.
INSTALLATION
1. Install MAP sensor to throttle body adapter using
screws. Torque screws to 44-62 lb. in. (5-7 N·m).
2. Connect electrical connector to MAP sensor.
Index
INSTALLATION Idle Air Control (IAC) Valve
IMPORTANT: If the TP sensor is to be replaced
with a new unit, be sure to secure it in place with NOTICE
the new screws which are included in the service Refer to “Service Precautions,” in “Repair
package. Procedures,” BEFORE proceeding.
1. Install TP sensor to throttle body using screws

with washers and Loctite 242 applied to threads. REMOVAL
Torque screws to 20 lb. in. (2 N·m).
1. Remove flame arrestor, throttle cable and throttle
body as outlined in “Throttle Body.”
a 2. Disconnect electrical connector at idle air control

(IAC) valve.
b a
d b
c
73758 73754
a - Throttle Body a - Throttle Body
b - Throttle Position (TP) Sensor b - Idle Air Control (IAC) Valve
c - Screws With Lockwashers
d - Seal
3. Remove IAC from throttle body.
2. Connect electrical connector to TP sensor.
3. Install throttle body, throttle linkage and flame ar-
1. Remove and discard sealing O-ring from IAC
restor as outlined in “Throttle Body.”
valve. Clean sealing surfaces, pintle valve seat,
4. Start engine and check for TP sensor output volt- and air passage with a carburetor cleaner to re-
age. It should be approximately .7 V at idle and move carbon deposits, being careful not to push
4.5 V at W.O.T. or pull on the IAC valve pintle. Force exerted on
the pintle might damage the worm drive. DO NOT
use a cleaner that contains the extremely strong
solvent methyl ethyl ketone.
NOTE: Shiny spots on the pintle, or seat, are normal
and do not indicate misalignment or a bent pintle
shaft.
2. Inspect the entire assembly for any obvious
physical damage.
Index
INSTALLATION 4. Reset IAC valve pintle position after reconnect-
ing negative (–) battery cable.
IMPORTANT: If installing a new IAC valve, be sure
to replace it with the correct IAC valve pintle a. Turn ignition key ON for ten seconds.
shape and diameter are designed for the specific
b. Turn ignition key OFF for ten seconds.
application.
c. Restart engine and check for proper idle op-
1. Install new O-ring on IAC valve.
eration.
a
Knock Sensor
NOTICE
REMOVAL
c 1. Disconnect electrical connector at knock sensor
located just ahead of starter motor.
d
73766
a - Throttle Body
b - Idle Air Control (IAC) Valve
c - O-Ring
d - Screws
2. Install IAC valve in throttle body using screws. a

Torque to 20 lb. in. (2 N·m).
3. Connect electrical connector to IAC valve. 73757
a a - Knock Sensor
2. Remove knock sensor from engine block.
73754
a - Throttle Body
Index
1. Clean knock sensor with a dry cloth, paying spe-
cial attention to threads on base.
2. Inspect surfaces of knock sensor for signs of
wear or physical damage.
INSTALLATION
IMPORTANT: If installing a new knock sensor, be
sure to replace it with an identical part. Knock
specific application.
IMPORTANT: In the following step, it is very im-
portant that the knock sensor be torqued to the
precise specification. Incorrect torquing will re-
sult in unsatisfactory performance. DO NOT use
sealer on threads.
IMPORTANT: Ensure that the knock sensor is
installed in the upper location on the Y-fitting.
12-16 lb. ft. (16.3-21.7 N·m).
73756
a - Knock Sensor
2. Connect electrical connector to knock sensor.
Index
Multi-Port Injection Components- 2. Remove screws from MAP sensor.
Manifold Absolute Pressure (MAP) 3. Remove MAP sensor from plenum.
Sensor
NOTICE
1. Clean off any foreign matter with a dry cloth.
Procedures,” BEFORE proceeding. 2. Inspect for any obvious signs of physical damage
to the sensor.
3. Inspect seal for damage.
REMOVAL
1. Disconnect electrical connector at manifold ab- INSTALLATION
solute pressure (MAP) sensor. 1. Install MAP sensor to plenum using screws.
d Torque screws to 44-62 lb. in. (5-7 N·m).
a 2. Connect electrical connector to MAP sensor.

b
75068
Multi-Port Plenum (Except Black Scorpion)

a - Manifold Absolute Pressure (MAP) Sensor
b - Seal
c - Plenum
d - Screws
c a
b
75046
Black Scorpion
a - Manifold Absolute Pressure (MAP) Sensor
b - Seal
c - Plenum
d - Screws
Index
Throttle Position (TP) Sensor CLEANING AND INSPECTION
1. Clean the surfaces of the TP with a dry cloth.
NOTICE
Refer to “Service Precautions,” in “Repair 2. Inspect the TP for signs of wear or damage.
INSTALLATION
1. Install TP sensor to throttle body using screws
REMOVAL
with washers and Loctite 242 applied to threads.
1. Remove flame arrestor, throttle cable and throttle Torque screws to 20 lb. in. (2 N·m).
body as outlined in “Throttle Body.”
2. Install throttle body, throttle cable and flame ar-
restor as outlined in “Throttle Body.”
a 3. When negative (–) battery cable has been recon-
nected, start engine and check for TP sensor out-
put voltage. It should be approximately .7 V at idle
and 4.5 V at W.O.T.
b c
72800

a - Throttle Body
c - Screws With Lockwashers
d - O-Ring
a
b 75326
Black Scorpion
a - Throttle Position (TP) Sensor
b - Screws
2. Remove TP from throttle body.
Index
Idle Air Control (IAC) Valve CLEANING AND INSPECTION
NOTICE 1. Remove and discard sealing O-ring from IAC

Refer to “Service Precautions,” in “Repair valve. Clean sealing surfaces, pintle valve seat,
Procedures,” BEFORE proceeding. and air passage with a carburetor cleaner to re-
move carbon deposits, being careful not to push
or pull on the IAC valve pintle. Force exerted on
the pintle might damage the worm drive. DO NOT
REMOVAL use a cleaner that contains the extremely strong
1. Remove flame arrestor, throttle cable and throttle solvent methyl ethyl ketone.
body as outlined in “Throttle Body.” NOTE: Shiny spots on the pintle, or seat, are normal
2. Disconnect electrical connector at idle air control and do not indicate misalignment or a bent pintle
(IAC) valve. shaft.
2. Inspect the entire assembly for any obvious
physical damage.
INSTALLATION
a IMPORTANT: If installing a new IAC valve, be sure
to replace it with an identical part. IAC valve
pintle shape and diameter are designed for the
specific application.
1. Install new O-ring on IAC valve.
2. Install IAC valve in throttle body using screws.
d Torque to 20 lb. in. (2 N·m).
3. Install throttle body, throttle linkage and flame ar-
b restor as outlined in “Throttle Body.”
c 72800
4. Reset IAC valve pintle position.
a - Throttle Body a. Turn ignition key ON for ten seconds.
b. Turn ignition key OFF for ten seconds.
c - O-Ring
d - Screws c. Restart engine and check for proper idle op-
b eration.
75326
Black Scorpion
a - Idle Air Control (IAC) Valve
b - Screws (One Hidden In This View)
3. Remove IAC from throttle body.
Index
Knock Sensor Knock Sensor (KS) Module
NOTICE NOTICE
Refer to “Service Precautions,” in “Repair Refer to “Service Precautions,” in “Repair
Procedures,” BEFORE proceeding. Procedures,” BEFORE proceeding.
REMOVAL REMOVAL
1. Disconnect electrical connector at knock sensor 1. Remove KS module from electrical bracket or
located just ahead of starter motor. electrical box (Black Scorpion).
a
72846
a
a - Knock Sensor
2. Remove knock sensor from engine block.

1. Clean knock sensor with a dry cloth, paying spe-
cial attention to threads on base.
2. Inspect surfaces of knock sensor for signs of
wear or physical damage.
72801
INSTALLATION
IMPORTANT: If installing a new knock sensor, be a - Electrical Bracket
sure to replace it with an identical part. Knock b - Knock Sensor Module
specific application. 2. Disconnect electrical connector at Knock Sensor
(KS) module.
IMPORTANT: In the following step, it is very im-
portant that the knock sensor be torqued to the CLEANING AND INSPECTION
precise specification. Incorrect torquing will re-
1. Clean the external surfaces of the KS module
sult in unsatisfactory performance. DO NOT use
with a dry cloth.
sealer on threads.
2. Inspect surfaces of KS module for evidence of
damage.
12-16 lb. ft. (16.3-21.7 N·m).
INSTALLATION
2. Connect electrical connector to knock sensor.
1. Mount KS module to electrical bracket or electri-
cal box (Black Scorpion).
2. Connect electrical connector to the KS module.
Index
ELECTRICAL BOX (EXCEPT BLACK SCORPION)
2
7
6
3 9
4 5 8
11
12
10
13
14
18 16
17
15
19
72801
1 - Bracket
2 - Relay
3 - Relay
4 - Screw
5 - Knock Sensor (KS) Sensor
6 - Screw
7 - Slave Solenoid
8 - Nut
9 - Circuit Breaker
10- Screw
11- Screw
12- MerCathode
13- Data Link Connector (DLC)
14- Circuit Breaker Fuse
17- Screw
18- Nut
19- Engine Control Module (ECM)
Index
Fuel Pump Relay Ignition Control (IC) System
NOTICE Components
Precautions
REMOVAL ! WARNING
1. Detach fuel pump relay from bracket. When performing the following procedures, be
a sure to observe the following precautions to
avoid damage to equipment or personal injury:
DO NOT touch or disconnect any ignition system
parts while the engine is running.
DO NOT reverse battery cable connections. Sys-
tem is negative (–) ground.
DO NOT disconnect battery cables while engine
is running.
When it is necessary to move any of the wiring,
whether to lift wires away from their harnesses or
b move harnesses to reach components, take care
that all wiring is replaced in its original position
and all harnesses are routed correctly. Electrical
problems can result from wiring or harnesses be-
coming loose and moving from their original
positions or from being re-routed.
72801

a - Fuel Pump Relay
b - Bracket
2. Disconnect electrical connector and remove fuel

pump relay.
IMPORTANT: The fuel pump relay is an electrical
solvent; damage may result.
INSTALLATION
1. Insert electrical connector into fuel pump relay.
2. Attach fuel pump relay to bracket.
Index
Ignition Coil RESISTANCE CHECK
Use an ohmmeter or the ohms function of a DVM for
NOTICE the following check.
Procedures,” BEFORE proceeding. 1. Connect meter as shown with meter 1 in the fig-
ure below.
REMOVAL
1. Disconnect wire harness connectors at coil.
b 3
1
72920
2. Setting the meter to its highest ohms scale, check

resistance. The reading should indicate infinite
72921
resistance. If it does not, replace the coil.
a - Wire Harness Connection 3. Connect meter as shown with meter 2 in the fig-
b - High Tension Coil Lead Connection ure above.
4. Setting the meter to its lowest ohms scale, check
2. Remove high tension coil lead. resistance. The reading should be very low or
3. Remove coil bracket fasteners and remove coil zero resistance. If it is not, replace the coil.
bracket with coil. 5. Connect meter as shown with meter 3 in the fig-
ure above.
6. Setting the meter to its highest ohms scale, check
resistance. The reading should not indicate infi-
nite resistance. If it does, replace the coil.
INSTALLATION
1. Install coil bracket with coil to engine bracket us-
ing fasteners.
Index
2. Connect high tension coil lead. Spark Plug Replacement
b
SPARK PLUG WIRING AND BOOT
PRECAUTIONS
1. Twist boots one-half turn before removing.
a 2. When removing boot, DO NOT use pliers or
other sharp tools which might tear the boot.
3. DO NOT force any object between the wire
and the boot or through the silicone jacket of
the wiring.
4. DO NOT pull on the wires to remove the boot.
Pull on the boot or use a tool designed for this
purpose.
72921
5. Special care must be used when installing
a - Wire Harness Connection spark plug boots to ensure that the metal ter-
b - High Tension Coil Lead Connection minal within the boot is fully seated on the
spark plug terminal and that the boot has not
3. Connect wire harness connectors. moved on the wire. If boot-to-wire movement
has occurred, the boot will give a fast visual
IGNITION TIMING SET PROCEDURE impression of being seated. To make sure
that boots have been properly installed, push
The engine must be at NORMAL OPERATING TEM-
sideways on them. If they have been correctly
PERATURE for this adjustment. Two items of test
installed, the boots will fit tightly with only a
equipment are required: an inductive pickup timing
slight looseness. If the terminal has not been
light and either a Scan Tool, Diagnostic Code Tool, or
firmly seated on the spark plug, only the re-
MerCruiser Special Timing Tool (91-805747A1).
sistance of the rubber boot will be felt when
1. Connect timing light to number 1 ignition wire. pushed sideways.
2. Connect the appropriate tool (as listed above) to
the DLC connector of the wiring harness. REMOVAL
3. Manually adjust the engine throttle to 1800 RPM 1. Disconnect spark plug wires from spark plugs.
+ 200. 2. Remove spark plugs.
4. If Not Using MerCruiser Timing Tool: With en-
gine running, set the scan tool or Diagnostic CLEANING AND INSPECTION
Code Tool to service mode. 1. Clean spark plugs and spark plug wires with a dry
5. Shine the timing light at the timing mark indicator cloth.
located on the timing chain cover. 2. Check each spark plug for wear and gap width
NOTE: If adjustment is needed, loosen the distributor per MerCruiser specifications. Replace any
hold-down bolt and rotate the distributor clockwise or which fail to meet the standards.
counterclockwise to adjust the timing. Then repeat 3. Check spark plug wires for damage to insulation,
the timing light check until the specification (8 de- boots and connectors. Replace if necessary.
grees BTDC) is met.
6. Torque distributor hold-down bolt to 30 lb. ft.
(40 N·m).
7. Set Scan Tool or Diagnostic Code Tool to normal
mode. If using the MerCruiser Special Timing
Tool, disconnect it from DLC connector.
8. Manually close throttle to bring engine down to
idle state.
Index
INSTALLATION
1. Install spark plugs. Torque to 11 lb. ft. (15 N·m).
2. Connect spark plug wires to their respective
spark plug.
IMPORTANT: Wire routing must be kept intact
during service and followed exactly when wires
have been disconnected or when wire replace-
ment is necessary. Failure to route wires properly
can lead to radio frequency interference, cross
firing of the plugs, and/or shorting of leads to
ground.
NOTE: When replacing spark plug wires, it is good
practice to replace one wire at a time to reduce the
risk of error.
REMOVAL AND INSTALLATION

1. Disconnect one spark plug wire at spark plug and
distributor.
2. Connect new spark plug wire at spark plug and
distributor.
3. Continue steps 1 and 2 until all spark wires have
been replaced.
3 6
4 5
8 7
1 2
8
7
F
6 R 5
O
N
4 T
3
2
1
Engine Rotation and Firing Order
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
FUEL SYSTEMS
5
F
73662
BOS / SAV EMISSIONS
Index
Table of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Replacement Parts Warning . . . . . . . . . . . . . . . 5F-1
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 5F-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Carburetor Specifications . . . . . . . . . . . . . . . . . . 5F-2
Carburetor Adjustment Specifications . . . . . . . 5F-2
Engine Specifications . . . . . . . . . . . . . . . . . . . . . 5F-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-3
Special Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-3
Carburetor Top Cover . . . . . . . . . . . . . . . . . . 5F-3
Sealed Idle Mixture Screws . . . . . . . . . . . . . 5F-3
Metering Assembly . . . . . . . . . . . . . . . . . . . . 5F-4
Metering Jets . . . . . . . . . . . . . . . . . . . . . . . 5F-4
Piston assembly cover is higher . . . . . . . 5F-5
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-6
Flame Arrestor . . . . . . . . . . . . . . . . . . . . . . . . 5F-6
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-6
Positive Crankcase Ventilation (PCV) . . . . 5F-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-7
Checking Ported Vacuum Switch
and Carburetor Vacuum Circuit for
Correct Operation . . . . . . . . . . . . . . . . . . . 5F-7
Service Procedures . . . . . . . . . . . . . . . . . . . . . . . 5F-8
Checking Positive Crankcase
Ventilation (PCV) Valve . . . . . . . . . . . . . . . 5F-8
Removing Seals From
Idle Mixture Screws . . . . . . . . . . . . . . . . . . 5F-9
Installing New Seals . . . . . . . . . . . . . . . . . . . 5F-9
Carburetor Installation . . . . . . . . . . . . . . . . . . 5F-9
Ported Vacuum Switch Installation . . . . . . 5F-10
Emissions System Connections . . . . . . . . 5F-11
Propane Assisted Idle Set Procedure . . . . 5F-12
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 5F-14
Emissions Testing . . . . . . . . . . . . . . . . . . . . . . . 5F-14
Index
5F-0 - BOS / SAV EMISSIONS 90-823225--1 1096
Identification Torque Specifications
The Bodensee Emissions version of the Weber WFB
Description lb. ft. lb. in. N·m
carburetor has vacuum fittings on the front side.
Carburetor to
NOTE: The third fitting on the 5.7L version is for the 132 15
Manifold
fuel pump sight tube connection.
Fuel Line to
18 24
Carburetor
Special Tools
Mercury Marine Special Tools
Universal Carburetor Gauge 91-36392
Tachometer 91-59339
Other Special Tools

a
b
73701 Universal Carburetor Stand
TORX Screwdrivers
a - Vacuum Fittings (15,20&25) Ob i Locally
Obtain L ll
b - Extra Fitting for Fuel Pump Sight Tube on 5.7L
Propane Bottle
[14 oz. (400 grams)]
(1) J26911
Replacement Parts Warning Propane Enrichment Kit
(2) YA7148
(Various Suppliers)
! WARNING (3) 7148
Ported Vacuum Switch (PVS) (1) No PN
Electrical, ignition and fuel system components Socket Wrench (2) S9842A
on your MerCruiser are designed and manufac- (Various Suppliers) (3) 7267
Regulations to minimize risks of fire and explo- Special Tool Suppliers:
sion. Use of replacement electrical, ignition or (1) Kent-Moore Part Number
fuel system components, which do not comply (2) Snap-On Part Number
with these rules and regulations, could result in (3) OTC Part Number
a fire or explosion hazard and should be avoided. NOTE: Weber carburetors will have a “star” shaped
socket in the head of some screws. A TORX screw-
driver must be used on this type of screw. The sizes
used are numbers 15, 20 and 25.
Index
90-823225--1 1096 BOS / SAV EMISSIONS - 5F-1
Carburetor Specifications
In. (mm)
Meter-
Second-
Primary Metering ing
Carb Mercury Number ary
Engine Model Jet Rod Rod
Type (Manufacturer Number) Jet
Size Number Spring
Size
Color
MCM
3310-806545 (9663) .089 .092 16-656357 Natural
1994 Models and Earlier Weber
MIE and MCM WFB
3310-808012 (9668) .089 .086 16-666459 Green
1995 Models and Earlier
Carburetor Adjustment Specifications

Make And Model Weber WFB
Float Level 1-9/32 (33)
Float Drop 2 In. (51)
Number 3 from end
Pump Rod Hole Location
(Hole closest to lever pivot point)
Accelerator Pump 7/16 (11) (Note 1)
Choke Pull Off 1/8 (3.5)
Choke Coil Rod Top of Rod Even with Bottom of Lever Hole (Note 2)
Note: 1. Measured from top of Carburetor to bottom of “S”-Link

Note: 2. Remove choke rod from lever hole, choke held closed and choke rod is pushed down with top edge of
rod even with bottom edge of hole.
Engine Specifications
Thermostat 160°F (71°C)
Ignition Timing 10° BTDC
Idle Speed in Neutral 775 RPM
Propane Idle Speed
850 RPM
(See Procedure)
Index
Description Special Notes
The Bodensee Emissions system is designed to IMPORTANT: Disassembly and repair of the Bo-
lower exhaust emissions to meet regulations on the densee Emissions carburetor is basically the
“Bodensee”. It consists of the following items: a same as the other Weber WFB carburetors. There
Positive Crankcase Ventilation (PCV) circuit, a are some internal and external differences that
Ported Vacuum Switch (PVS) circuit, a higher are noted following:
temperature thermostat [160°F (71°C)], and a
specially designed Weber WFB carburetor.
Weber WFB carburetor is unique in design, as the Carburetor Top Cover
main body and flange are cast as a one piece unit. The carburetor top cover (air-horn) has vacuum fit-
This, along with the bowl cover, make up the two tings for connection to the “Ported Vacuum Switch”
piece construction which is made of light, durable (PVS). The 5.7L version also has a fitting for the fuel
aluminum to dissipate heat. pump sight tube.
There are two separate float circuits. Each float cir-
cuit supplies fuel to a primary low speed circuit and
a primary and secondary high speed circuit. The
bowls are vented to the inside of the air horn. A con-
necting vent passage effects a balance of the air
pressure between the two bowls.
The float needle valves are installed at an angle to
provide the best possible seating action on the
needles. This provides better needle response to
float movement, also.
The PVS circuit is used in conjunction with the idle
circuit. When the engine is cold, the PVS circuit is
closed. This shuts off a metered air-bleed to the idle
circuit, to maintain a rich idle circuit for warm-up.
a
Once the engine warms up [approximately 128°F
(54°C)], the PVS opens, allowing a metered amount b 73701
of air to be mixed into the idle circuit. This leans the
a - Vacuum Fittings
idle circuit to the proper operating air-fuel ratio. b - Fitting for Fuel Pump Sight Tube (5.7L ONLY)
The high speed circuits use staged step-up rods in
the main metering jets to control the amount of fuel
admitted to the nozzles. The position of the step-up Sealed Idle Mixture Screws
rod is controlled by manifold vacuum applied to the
vacuum piston. The idle mixture screws have seals that prevent tam-
pering with the idle mixture after the mixture has been
A primary air bleed located in the venturi cluster pre- properly adjusted.
vents a rich condition or bog as the high speed circuit
is reactivated after deceleration.
Small “L” shaped metal tabs, called “distribution
tab(s),” are attached to some venturi clusters and
protrude into the air stream at the proper location to
aid distribution of fuel on selected applications.
The PCV circuit ventilates crankcase vapors (un-
burned gases) back into the intake manifold to be
burned again.
a 71798
a - Screw Seals
Index
Metering Assembly METERING JETS
The metering rod assemblies are different in the fol- The metering jets in this carburetor are taller than the
lowing ways: jets in a standard carburetor.
b Emissions Emissions Standard

a
d
c
a b 73728
a - Jet for 3-Step Metering Rod

b - Jet for 2-Step Metering Rod
e
73732 METERING ROD HAS “THREE STEPS” -VS-
TWO
Emissions
b Standard a 73726
Standard
d c
73724
e PISTON SHAPE IS DIFFERENT AND HAS

A SECOND SPRING
73729
a - Piston Emissions
b - Metering Rod
c - Spring
d - Jet
e - Piston Cover
73730
Standard
73727
Index
PISTON ASSEMBLY COVER IS HIGHER Precautions
! WARNING
or explosion.
! WARNING
Be careful when cleaning flame arrestor and
73735 crankcase ventilation hose: gasoline is extreme-
conditions. Be sure that ignition key is OFF. DO
Emissions Standard ! WARNING

Be careful when changing fuel system compo-
73725
nents: gasoline is extremely flammable and high-
ly explosive under certain conditions. Be sure
sources of spark or open flame in area while
mediately.
! WARNING
73736
gine hatch.
PISTON BORE HAS A STEP ON EMISSIONS ! CAUTION
MODEL
housing or water pickup inlet, or water pump im-
peller will be damaged and subsequent overheat-
ing damage to engine may result.
73737
Index
Maintenance Fuel Filter
Maintenance for fuel inlet filters is the same as stan-
dard engine (see the Weber WFB carburetor section
Flame Arrestor of the appropriate MerCruiser Service Manual).
Maintenance for the flame arrestor is the same as
standard engine (See the Weber WFB carburetor
section of the appropriate MerCruiser Service Manu- Positive Crankcase Ventilation (PCV)
al). The only difference in the flame arrestor on an en- The Positive Crankcase Ventilation (PCV) valve
gine with the Bodensee Emissions system is in the should be replaced once a year.
vent hose bracket. This bracket has a fitting on one
side only.
a
b
b
a
71798
71925
a - PCV Valve
b - Hose
71797
a - Stud
b - Vent Hose Bracket
c - Vent Hose to Starboard Valve Cover
d - NO VENT HOSE ON THIS SIDE
Index
Troubleshooting 2. Plug the hose with your finger. You should not feel
vacuum on the hose at this time.
NOTE: Review the “Description” section of this
manual for an understanding of system operation,
before troubleshooting the carburetor. Do not as-
sume that a problem exists inside the carburetor
without first eliminating other engine system compo-
nents as potential problem areas. Be sure to check
the following items:
• Engine operating temperature (Proper Thermo-
stat - See “Engine Specification Chart”).
• Correct ignition timing (See “Engine Specification
Chart”).
• Cylinder compression.
• Ported Vacuum Switch (PVS) functioning 73734
properly.
3. Allow engine to run and warm up to normal oper-
Use the following procedure to check for a faulty ating temperature. Disconnect the hose again
Ported Vacuum Switch (PVS): and check for vacuum. If PVS is functioning prop-
erly, there should be vacuum present at this time.
If vacuum is not present, check to ensure that
Checking Ported Vacuum Switch hoses are properly connected and are not
and Carburetor Vacuum Circuit for cracked or plugged. Then, proceed to check the
Correct Operation carburetor vacuum circuit.
NOTE: The engine must be cold before performing 4. Reconnect rear hose to carburetor.
the first 4 steps. NOTE: The engine must be warm before performing
1. Start engine. Disconnect the hose from the car- the next step.
buretor at the location shown. 5. Start engine and allow it to reach normal operat-
ing temperature.
6. Disconnect the two hoses on the front of carbu-
retor.
73738
73733
Index
IMPORTANT: Ensure that engine is running at Service Procedures
775 RPM or below. This ensures that the carbure-
tor is not running on the “Off-Idle” circuit. Checking Positive Crankcase
7. Connect a tachometer to the engine. Ventilation (PCV) Valve
8. Plug the vacuum ports on the front of the carbure- 1. Start engine and allow it to reach normal operat-
tor. Be sure to only plug one port at a time. When ing temperature.
vacuum port is covered, the engine RPM should
increase. Repeat test on the other port. If vacuum 2. Remove PCV valve from valve cover. Plug the
is not present, a vacuum port may be plugged. opening with your finger. A vacuum should be
Clean vacuum ports and repeat the entire test. felt.
3. Stop the engine.
4. Shake the valve to ensure that the internal com-
ponents are free to move.
73740
73743
73739
9. When test is complete and PVS is determined to

be functioning properly, reconnect all hoses in
vacuum circuit.
Index
Removing Seals From 2. Align the opening in the plug with the tab on the
cup and push down until it snaps in place.
Idle Mixture Screws
! WARNING
Avoid fire or explosion. Using a cutting wheel to
cut the seals will cause sparks, which will ignite
any fuel that is present. Ensure that there is no
fuel present and that carburetor is removed from
engine prior to cutting the seals from the carbu-
retor idle mixture screws.
1. Remove carburetor from the engine.
2. Drain all fuel from the carburetor. a
3. Using a cutting wheel, make a cut on both sides
of the seal casing. Using a suitable device, pry b
the plug from the inside of the seal. Once the plug
73789
is removed, the idle mixture screw can be re-
moved and the seal casing can be removed. a - Opening in Plug
b - Tab on Cup
Carburetor Installation
NOTE: The adapter plate is not used on the 4.3LX Al-
pha model.
1. If adapter plate was removed, place the gasket
that matches the outside edge of the intake man-
ifold surface between the intake manifold and the
plate. Install carburetor adapter plate. Secure
with the allen-head screws. Torque to 132 lb. in.
(15 N⋅m). Apply Loctite 271 to threads and install
studs.
73744 c
Installing New Seals

1. Install new seal cup, spring and idle mixture
screw. b
IMPORTANT: Do not install the seal plug until the
“Propane Assisted Idle Mixture Adjustment” pro-
cedure has been completed.
a
73551
a - Adapter Plate (Not on 4.3LX Alpha Model)

b - Screws
c - Studs
Index
2. Install new carburetor as follows: Ported Vacuum Switch Installation
a. Place new gasket on adapter plate.
! CAUTION
b. Install carburetor and throttle bracket and se-
cure with new attaching hardware. Torque Be careful not to break off fittings when installing
fasteners to 132 lb. in. (15 N⋅m). the ported vacuum switch (PVS) in the following
step.
c. Connect fuel line. To prevent over-tightening,
hold fuel inlet nut with a suitable wrench and NOTE: A special tool is available to install the PVS.
tighten fuel line connector securely. Refer to the “Tool Chart” at the beginning of this
manual.
1. If removed, install ported vacuum switch (PVS)
into reducer bushing. Apply Loctite Pipe Sealant
d
with Teflon to threads before installing. Tighten it
securely and position the fittings toward back of
engine as shown.
c
71173 b
a
71913
a - Reducer Bushing
b - Ported Vacuum Switch (PVS)
a
71172
a - Throttle Bracket
c - Fuel Line
d - Fuel Inlet Nut
Index
Emissions System Connections 3. Connect hoses to ported vacuum switch (PVS)
as shown.
1. Install the positive crankcase ventilation (PCV)
valve in the port valve cover.
2. Connect hose to PCV valve. Connect opposite
b
end of hose to fitting on front of carburetor.
b c
d a
71924
71925
e
a
a - Ported Vacuum Switch

73702
b - Hoses (Switch to Y-Fitting)
c - Hoses (To Front Side of Carburetor)
d - Hose (Y-Fitting to Back Side of Carburetor)
e - Sight Tube from Mechanical Fuel Pump (Clear Hose)
c 73701
a - PCV Valve
b - Hose
c - Carburetor Fitting (Connect Hose Here)
Index
IMPORTANT: The hose that runs from the T-Fit- Propane Assisted Idle Set Procedure
ting to the back side of the carburetor must be
routed beneath the throttle linkage as shown in ! WARNING
the following illustration. Use care to ensure that
the hose does not rub against linkage. Avoid fire or explosion. Observe the following
precautions when performing this procedure.
• Do not operate the engine without the flame
arrestor installed, above the speeds listed in
this procedure.
• Propane is extremely flammable and explo-
sive. Ensure that the following test is per-
formed in a well ventilated area with the en-
gine hatch open.
• Ensure that there is no spark or open flame in
the test area.
• Do not start the flow of propane until the hose
has been placed into the carburetor and the
engine has been started.
• Keep a fire extinguisher available when per-
forming this test.
b a 71916 NOTE: This test must be performed any time the car-
buretor has been disassembled and internal compo-
nents have been disturbed or the idle mixture screws
have been tampered with. The test should also be
performed if other component parts of the emissions
system have been altered, repaired, or replaced.
IMPORTANT: Ensure that the PVS is functioning
properly before performing this procedure.
1. As a starting point, set both idle mixture screws
at 1 turn out from the fully seated position.
2. Start engine and allow it to warm up to normal op-
erating temperature. If engine has been run
above idle speed, allow engine to idle for 3 to 5
minutes to stabilize the engine.
71917
4. Insert special “Y”-Adapter hoses into carburetor
a-T-Fitting as shown. Place the hoses behind the choke
b - Hose T-Fitting to Back of Carburetor) plate to help hold them in place.
73731
Index
5. Connect the hose from the propane bottle valve 8. Release the propane flow valve and allow engine
to the “Y”-Fitting. speed to stabilize. Slowly adjust the mixture
screws by equal amounts, pausing between ad-
6. With engine idling at normal operating tempera-
justments to allow engine speed to stabilize, to
ture, press the propane flow button on the valve.
achieve 775 RPM.
Slowly begin opening the propane metering
valve until maximum engine RPM is reached.
When too much propane is added, engine RPM
will decrease. “Fine tune” the metering valve to
obtain the highest RPM.
b 73673
73722
a - Propane Flow Valve
b - Propane Metering Valve 9. Press the propane flow valve. Engine RPM
should increase to 850 RPM. If it does not, repeat
7. With propane still flowing, adjust the idle speed steps 5 thru 7.
screw (not the mixture screws) to obtain 850
RPM. Again, “fine tune” the propane metering
valve to obtain the highest engine RPM. If there
has been a change in the maximum RPM, read-
just the idle speed screw to 850 RPM.
73662
10. If after performing the above procedure several

times, the correct results can still not be obtained,
check the following:
• PVS not working properly.
• Incorrect float level.
• Vacuum leaks.
Index
11. Once the idle speed and mixture adjustment is Emissions Testing
correct, install the seal plugs over mixture
screws. Ensure the opening in plug snaps into NOTE: This test will be performed by an authorized
the tab in the cup. agency for the area that the boat will be operated.
This agency will be equipped with the appropriate
test equipment and adapters for this engine. The only
item that must be supplied by the boat owner/opera-
tor are the exhaust test probes. These test probes
should be carried aboard the vessel at all times. The
c following steps will explain how these probes are to
be installed.
b 73789
a
b a
71926
71798 a - Exhaust Test Probes (2)

b - Exhaust Elbow Adapter Fittings (2)
a - Screw Seals
b - Tab in Cup 1. Remove plugs from both exhaust elbows.
c - Opening in Plug
12. Reinstall the flame arrestor.

a
Test Equipment
The following equipment is needed to perform an
emissions test on this engine:
• Test Probes (Supplied in Kit).
• Test Probe Collector (Testing Agency).
• Exhaust System Analyzer (Testing Agency).
b
71921
a a - Plugs (Port and Starboard Elbows)
73723
a - Exhaust Probe Collector

b - To Exhaust Analyzer
Index
2. Install exhaust elbow adapter fittings into elbows. NOTE: Be certain to place test probes and adapter
Apply Loctite Pipe Sealant with Teflon to threads fittings in suitable storage aboard the boat for use in
that go into elbow. Tighten securely. the future.
3. Insert exhaust test probes into fittings and tighten
securely.
NOTICE TO OWNER/OPERATOR
Your engine is equipped with special de-
sign features and special tuning to mini-
mize the emission output from the en-
gine. You should follow:
a • Recommended maintenance sched-
ules particularly as to the ignition sys-
tem.
• Proper engine tuning procedures to
ensure these features remain in good
operating order.
• Proper steps to maintain the engine
within specification.
71923 The instructions in the Emissions Kit
provide the necessary information to
properly convert the engine to meet the
b applicable Bodensee Regulations.
There is another item within the regula-
tion that is beyond the control of Mercu-
ry Marine. This item is related to the fuel
filling system on the boat. The require-
ments for the fuel filler neck are as fol-
lows:
• Must be designed so that it is impossi-
ble to use a fuel nozzle with an outside
diameter of more than 23.6 mm.
• The filler neck shall be durable and de-
signed so that modifications are not
71919 possible.
a - Fittings • A durable, legible plate shall be
b - Exhaust Test Probes mounted on the boat near the fuel filler
neck. This plate shall read: “UN-
4. When exhaust emissions test is complete, re- LEADED GASOLINE ONLY”.
move test probes and adapter fittings and rein-
Any questions about the fuel filler neck re-
stall the plugs. Apply Perfect Seal to threads be-
quirement and availability of the required
fore installing. Tighten them securely.
components should be directed to the
boat manufacturer.
Index
COOLING SYSTEM
6
A
22381
SEAWATER COOLING MODELS
Index
Table of Contents
Page
MCM 350 CID / 5.7L . . . . . . . . . . . . . . . . . . . 6A-1
Torque Specifications . . . . . . . . . . . . . . . . 6A-1
Tools/Lubricants/Sealants . . . . . . . . . . . . 6A-1
specifications . . . . . . . . . . . . . . . . . . . . . . . 6A-1
Seawater Inlet Recommendations . . . . . . . . . . 6A-2
Transom Mounted or Thru-Hull
Seawater Pickups and Hose . . . . . . . . . . . . 6A-2
Seacock (Seawater Inlet Valve) . . . . . . . . . . 6A-2
Sea Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Seawater Pickups . . . . . . . . . . . . . . . . . . . . . . . . 6A-3
Thru-Hull Mounted . . . . . . . . . . . . . . . . . . . . . 6A-3
Transom Mounted . . . . . . . . . . . . . . . . . . . . . 6A-3
Sea Strainer (Quicksilver) . . . . . . . . . . . . . . . . . 6A-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Stern Drive Unit Seawater Pickup
Pump Output Test . . . . . . . . . . . . . . . . . . . . . . . 6A-6
Pump Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7
Water Circulating Pump Replacement . . . . . . . 6A-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7
Cleaning and Inspection . . . . . . . . . . . . . . . . 6A-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7
Flushing Seawater Cooling System . . . . . . . . . 6A-8
Engines with Stern Drive Seawater
Pickup Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-8
Check/Clean Seawater Strainer . . . . . . . . . 6A-8
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-11
Draining Seawater Cooling System . . . . . . . . 6A-12
Draining Precautions . . . . . . . . . . . . . . . . . . 6A-12
(MCM) Stern Drive Drain Location . . . . . . 6A-15
MIE (Inboard) Models . . . . . . . . . . . . . . . . . 6A-16
Auxiliary Hot Water Heater Installation . . . . . 6A-18
Water Flow Diagrams . . . . . . . . . . . . . . . . . . . . 6A-20
MCM Alpha . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20
MCM Alpha Gen+ With Cool Fuel
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
MCM Bravo . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-22
MCM Bravo With Cool Fuel System . . . . . 6A-23
MIE Inboard Models . . . . . . . . . . . . . . . . . . 6A-24
MIE Inboard With Cool Fuel System . . . . . 6A-25
Index
6A-0 - SEAWATER COOLING MODELS 90-823225--1 1096
MCM 350 CID / 5.7L
TORQUE SPECIFICATIONS
Alternator Brace to Alternator 192 28
Alternator Brace to Block
Alternator to Mounting Bracket
Alternator/Power Steering Pump
Mounting Bracket
Power Steering Pump Brace to
Block 30 41
Power Steering Pump Bracket
Thermostat Cover
Thermostat Housing
Water Circulating Pump
Water Temperature Sender 20 27
Drain Plugs (See Note)
Hose Clamps
Securely
S l
Petcocks
Pulleys
NOTE: Coat threads with Quicksilver Perfect Seal before installing.
TOOLS/LUBRICANTS/SEALANTS

Quicksilver Flushing Attachment 73971A2
Obtain Locally
Marine Caulking
SPECIFICATIONS
Cooling System Capacity 15 Qts (14.1 L)

Thermostat (Type) Stainless Steel 160° F (71° C)
Thermostat (Type) Brass 143° F (60° C)
Index
90-823225--1 1096 SEAWATER COOLING MODELS - 6A-1
Seawater Inlet Seacock (Seawater Inlet Valve)
Recommendations If a seacock is being used, it must be installed be-
tween water pickup and seawater pickup pump (or
sea strainer), to allow operator to shut off the seawa-
Transom Mounted or Thru-Hull ter in case of a leak or when boat is not in use. This
will allow the operator to flush or drain the engine, or
Seawater Pickups and Hose clean the sea strainer while boat is in the water. Sea-
Water pickup must be large enough to permit suffi- cock used must have an internal cross-sectional area
cient water flow to engine seawater pickup pump for equal to or greater than hose to prevent restricting
adequate engine cooling [30 gal. per min. (114 L per water flow. Install seacock in an area where it will be
min.) minimum]. Pickup also must supply a positive easily accessible and self-supporting to prevent hose
head while underway. fatigue.
a
! CAUTION
Do not install water pickup directly in line with
propeller, as pickup may create turbulence and
allow air to flow into the “propeller slipstream.”
This will cause propeller ventilation and will ad- b
versely affect boat performance.
Water pickup should be located as close to seawater

pickup pump inlet as possible and in an area where
an uninterrupted, solid stream of water will flow past
when boat is underway. Connect water pickup to sea-
water pickup pump inlet with 1-1/4 in. (32 mm) I.D.
wire reinforced hose of adequate wall thickness to c d
prevent it from collapsing from pump suction. Be sure
70355
to secure hose connections with hose clamps.
Seacock (With Thru-Hull Pickup Shown)
a - Hose Connector [1-1/4 In. (32mm) I.D.] to Seawater Pump
Inlet
b - Seacock [1-1/4 In. (32mm)] Brass Ball or Gate Valve
c - Seawater Pickup
d - Direction of Seawater Flow
Sea Strainer
If boat is equipped with a sea strainer, it must be of
sufficient size to ensure that an adequate supply of
water is maintained for engine cooling. Install
seawater strainer in an area where it will be easily
accessible for inspection and cleaning. Strainer
should be installed in water inlet hose after water inlet
valve to allow operator to shut off water when
cleaning strainer.
Index
Seawater Pickups Transom Mounted
(Quicksilver Part Number: 88845A1)
NOTICE
a b
Refer to manufacturer’s instructions for in- c
formation on removal and installation of d
other than Quicksilver Seawater Pickups.
e
f
IMPORTANT: Seal the inside edges of any hole
made through the hull with a suitable sealant to
prevent water absorption and deterioration.
g
Thru-Hull Mounted h
(Quicksilver 68670A2)
i
b J
d
72640
c
Seawater Pickup Installation
a - Hose Nipple
b - Nuts (4)
c - Gasket - Between Pickup and Transom
72639
a d - O-Ring (4)
e - Washer (4)
f - Screw (4)
Quicksilver Thru-Hull Seawater Pickup Shown g - Plastic Plug
a - Seawater Pickup h - Pickup
b - Seawater Inlet Slot (MUST Face Forward - Parallel with i - Screen
Water Flow j - Screw
c - Mounting Screw Holes (If So Designed)
d - Nut 1. Seal the inside edges of the 1-1/2 in. (38 mm)
1. Seal inside edges of 1-3/4 in. (44 mm) hole in hull hole for hose nipple.
using a suitable sealer. 2. Be certain hose nipple and plastic plug are in
2. Apply marine caulking (sealer) to mounting sur- place and threads have been sealed with Loctite
face on seawater pickup where hull contact will Pipe Sealant with Teflon prior to tightening each
occur when installed. securely.
3. Ensure slots in seawater pickup are facing for- 3. Position one flat washer and one rubber O-ring
ward (toward bow of boat) and install seawater on each 5/16 in. x 4 in. (102 mm) long, round head
pickup through hull. The slots must be parallel screw as shown. Coat each screw shaft with sili-
with flow of water. cone sealant or equivalent.
4. Fasten pickup with four appropriate mounting 4. Place new gasket on pickup housing and hold
screws (if so designed). pickup in place on transom. Install four round
head screws (with washers and O-rings in place)
5. Apply marine caulking as needed inside boat. into pickup mounting holes and through drilled
Apply Loctite to threads of nut and install on pick- 21/64 in. (8.5 mm) holes in transom.
up on inside of boat and torque nut to 35 lb. ft.
(42 N·m).
NOTE: If pickup being used does not have mounting
screws on underside where mounted to hull, be cer-
tain, after nut is torqued, that slots are still facing for-
ward.
Index
NOTE: Some installations may have 7/32 in. (5.5 Removal
mm) holes drilled in transom using four 5/16 in. diam-
eter stainless steel lag bolts in place of round head
screws. In any case, flat washers and O-rings are re- ! CAUTION
quired as outlined.
If boat is in water while working on seawater
strainer, close seacock, if so equipped. If boat is
not equipped with a seacock, remove and plug
seawater inlet hose to prevent a siphoning action
a that may occur, allowing seawater to flow from
b the drain holes or removed hoses and enter boat.
IMPORTANT: Be certain engine is off and cooling

system is cold.
1. Follow “a” or “b” instructions:
72641 a. Models Equipped with Seacock:
Water Pickup Installed on Transom (1) Close seacock (seawater inlet valve).
a - Diagonal Mount - Leading Edge of Pickup 1/8 In. (3mm)
from Boat Bottom
(2) Disconnect seawater inlet hose from sea-
b - Vertical Mount - Corner of Leading Edge of Pickup 1/8 In. water strainer.
(3mm) from Boat Bottom
5. Secure water pickup from inside with locknuts

and washers (unless using lag bolts).
6. Tighten fasteners securely.
a
b
72691
Sea Strainer (Quicksilver) a - Seawater Inlet Hose
b - Seawater Strainer
NOTICE
Refer to manufacturer’s instructions for in- b. Models without Seacock:
formation on removal and installation of
(1) Disconnect seawater inlet hose from sea-
other than Quicksilver Sea Strainer.
water strainer inlet and plug seawater in-
let hose.
a
b c d
70062
a - Seawater Inlet Hose

b - Seawater Strainer
c - Seawater Strainer Inlet
d - Plug
Index
2. Remove outlet hose. Drain into a suitable con- 2. Install inlet and outlet hoses. Use two hose
tainer. clamps on each hose connection. Tighten
clamps securely.
c c
a
a
b b
72645
72643
a - Seawater Inlet Hose
a - Seawater Outlet Hose b - Seawater Strainer
b - Seawater Strainer c - Double Hose Clamps
3. Remove mounting bolts. Remove strainer. 3. Check drain plug and lens cover bolts. Tighten
securely. Do not over-tighten cover bolts or cover
may warp and leak water into boat.
Installation
IMPORTANT: Mount seawater strainer in a vibra- b
tion-free location. Never mount it on the engine
or transmission. Hoses must not be kinked or al-
lowed to come in contact with hot or moving en-
gine or transmission parts.
1. Mount seawater strainer (arrow must point to-
ward seawater pump). a
Tighten mounting bolts securely.
b
72644
a - Drain Plug
b - Lens Cover Bolt (2, One Hidden in This View)
c c
72644
a - Seawater Strainer
b - Arrow
c - Mounting Bolt Hole Location (Bolts Not Shown)
Index
Stern Drive Unit Seawater 1. Remove water inlet hose, which runs between
gimbal housing water tube and engine, and re-
Pickup Pump Output Test place with another hose of same diameter, but
approximately 3 ft. (1 m) longer. Hose should be
If an overheating problem exists, use this test to de- wire reinforced or of adequate wall thickness to
termine if a sufficient amount of water is being prevent it from kinking when performing test.
supplied to cool engine. Clamp hose at gimbal housing water tube only.
Do not clamp hose at engine end.
IMPORTANT: The following information should
be observed before proceeding with test:
• BOAT MUST BE IN THE WATER FOR THIS

TEST. This test CANNOT BE performed with a
flush-test device and water hose.
c
• The ability of this test to detect a problem is
greatly dependent upon the accuracy in
which it is performed. An error in setting the
engine RPM, timing the test or measuring the
water output will affect the overall accuracy
of the test and may produce misleading re-
sults. To help ensure accurate results, a shop
tachometer with an error of less than 5%
should be used. The boat tachometer defi-
nitely should not be used as its accuracy is
questionable. A stop watch should be used to a b
time the duration of the test to help ensure 72614
that the accuracy is maintained within one
second. An 8 U.S. qt. (7.6 L) or larger capacity a - Water Tube
b - Hose Clamp
container should be used to measure water c - Water Hose
output.
2. Place an 8 U.S. qt. (7.6 L) or larger container near
• Due to the manner in which this test is per- unclamped end of hose.
formed, it may not be possible to detect a
marginal condition or a high-speed water
pump output problem. ! CAUTION
Do not run engine for more than 15 seconds with
hose disconnected, in next step, as internal dam-
age to engine and exhaust system may result.
3. With assistance of another person, start engine

and adjust speed to exactly 1000 RPM while
holding unclamped end of hose on connection on
engine. Remove hose from connection on engine
and direct water flow into container for exactly 15
seconds. At the end of 15 seconds, direct the wa-
ter flow overboard, return engine to idle and stop
engine. Reconnect hose to engine.
4. Measure quantity of water discharged into con-
tainer and compare with specifications given in
chart following.
Index
5. Repeat test four times to check repeatability of 5. Remove pump pulley attaching bolts, lockwash-
results. ers, clamping ring (if so equipped) and pulley.
6. Disconnect hose(s) from pump.
Alpha Stern Drive Pump Output
for 15 Second Period 7. Remove bolts, which secure pump to cylinder
block, and remove pump and old gaskets (dis-
Minimum Quantity card gaskets).
Drive Unit Gear Ratio U.S. Qts. (L)
1.98:1 3.0 (2.8)

1.84:1 3.3 (3.1)
1. Clean gasket surfaces on water pump and cylin-
1.65:1 3.6 (3.4) der block.
2. Inspect water pump for blockage, cracks, sand
1.50:1 4.0 (3.8)
holes, corrosion or other damage. Inspect pump
1.32:1 4.5 (4.3) impeller for cracks and erosion. Replace com-
plete pump if any damage exists.
3. Check impeller shaft and bearings for excessive
Stern Drive Unit Seawater side play. If play can be felt, replace complete
pump.
Pickup Pump Repairs
4. Inspect pump pulley for bends, cracks, corrosion
or other physical damage. Inspect pulley for rota-
NOTICE tional trueness. Replace pulley if damaged or un-
MCM (Stern Drive) Models equipped with true.
Alpha Drive Units have a seawater pickup
pump mounted in stern drive unit. Refer to
appropriate Stern Drive Service Manual for Installation
further testing and repairs.
1. Coat both sides of new circulating pump gasket
with Quicksilver Perfect Seal, then position gas-
kets and circulating pump on cylinder block. Coat
Water Circulating Pump threads of circulating pump attaching bolts with
Replacement Quicksilver Perfect Seal and install bolts and al-
ternator brace (if applicable). Torque bolts to
Removal specifications.
1. Drain water from cylinder block. Refer to “Drain- 2. Reconnect hoses to pump.
ing Seawater Cooling System” as outlined later in 3. Install pump pulley and clamping ring (if used) on
this section. pump hub and secure with bolts and lockwash-
2. Loosen circulating pump pulley attaching bolts. ers. Tighten bolts securely.
Do not remove bolts at this time. 4. Install drive belts and adjust tension as outlined
3. Loosen power steering pump brace and pump in “Drive Belt Tension Adjustment.”
mounting bolts, then pivot pump inward and re- 5. Start engine and check for leaks.
move drive belts.
4. Loosen alternator brace attaching bolts and alter-
nator mounting bolt, then pivot alternator inward
and remove drive belt.
Index
Flushing Seawater Cooling 2. Connect hose between flushing attachment and
water tap.
System
If engine is operated in salty, polluted or mineral-
laden waters, seawater cooling system should be
flushed periodically (preferably after each use) with
fresh water to reduce corrosion and prevent the
accumulation of deposits in the system. Seawater
cooling system also should be thoroughly flushed
prior to storage.
! WARNING
a
When flushing, be certain the area around pro-
peller is clear, and no one is standing nearby. To
avoid possible injury, remove propeller. b
! CAUTION 72672
Do not run engine above 1500 RPM when flush- a - Quicksilver Flushing Attachment
b - Garden Hose
ing. Suction created by seawater pickup pump
may collapse flushing hose, causing engine to 3. With drive unit in normal operating position, par-
overheat. tially open water tap (about 1/2 maximum) and al-
low cooling system to fill completely. Cooling sys-
IMPORTANT: If cooling system is to be flushed
tem is full when water is discharged through the
with boat in the water, seacock (if so equipped)
propeller. Do not use full tap water pressure.
must be closed, or water inlet hose must be dis-
connected and plugged to prevent water from 4. Place remote control in NEUTRAL, idle speed
flowing into boat. position and start engine. Operate engine at idle
speed, in NEUTRAL, for about 10 minutes, or un-
! CAUTION til discharge water is clear. Watch temperature
gauge on instrument panel to ensure that engine
Watch temperature gauge at dash to ensure the does not overheat.
5. Stop engine. Shut off tap water and remove flush-
ing attachment.
Engines with Stern Drive Seawater
Pickup Pump Check/Clean Seawater Strainer
! CAUTION NOTICE
To prevent engine or stern drive unit damage DO Refer to manufacturer’s instructions for in-
NOT run engine or drive unit without water being formation on checking and cleaning of oth-
supplied to water intake openings on gear hous- er than Quicksilver Seawater Strainer.
ing.
1. Visually inspect seawater strainer through glass
If flushing cooling system with boat in water, raise top.
drive unit to trailer position, install flushing attach-
ment and lower drive unit to full IN/DOWN position. ! WARNING
1. Install Quicksilver Flushing Attachment (or When cleaning seawater strainer, close seacock,
equivalent) over water intake openings in gear if so equipped. If boat is not equipped with a sea-
housing. cock, remove and plug seawater inlet hose to
prevent a siphoning action that may occur, allow-
ing seawater to flow from the drain holes or re-
moved hoses.
Index
! CAUTION NOTE: If equipped with a lifting eye (not shown in
following), note placement of lifting eye so that it may
Do not over-tighten cover screws or cover will be positioned exactly the same upon installation, or
warp and leak. it may interfere with the fit of the flame arrestor
2. With engine off, close seacock, if so equipped, or cover.
remove and plug seawater inlet hose, if no sea- a
cock exists. Remove two screws and washers,
and cover. Remove strainer, and drain plug and b
washer. Clean any debris from strainer housing; c
flush both strainer and housing with clean water.
Check gasket; replace when necessary (if it d
leaks). Reinstall strainer, drain plug and washer. e
Reattach cover with screws and washers. Open
seacock, or unplug and reconnect seawater inlet f
hose. Tighten hose clamps securely. After start-
ing engine, check for leaks and/or air in system,
which would indicate an external leak.
b a
c
d 72589
6 Hose Thermostat Housing

a - Cover
e b - Gasket
c - Spacer
h d - Thermostat
e - O-Ring
f f - Housing
g
a
72673
Quicksilver Seawater Strainer Shown

a - Screws and Washers
b - Cover b
c - Glass
d - O-Ring c
e - Strainer
f - Housing
g - Drain Plug and Sealing Washer
h - Gasket d
Thermostat e
Removal 71758
1. Drain water from cylinder block and exhaust 4 Hose Thermostat Housing
manifolds. a - Housing
b - O-Ring
2. Remove thermostat cover attaching bolts and c - Thermostat (Stainless Steel)
lockwashers, then remove cover and gasket. d - Spacer
e - Gasket
3. Remove thermostat from thermostat housing or
cover.
Index
Testing 4. Check opening and closing temperature of ther-
mostat (using a tester similar to the one shown)
1. Clean thermostat in soap and water to remove as follows:
any deposits or debris.
a. Fill tester to within 1 in. (25mm) of top with tap
2. Inspect thermostat for corrosion or other visible water. Do not use distilled water.
damage.
b. Open thermostat valve and insert nylon
string. Position thermostat on string so that it
will be just below water level when sus-
b pended, then allow valve to close. Suspend
a thermostat in water.
c. Place thermometer in container and position
so that bottom of thermometer is even with
bottom of thermostat. Do not allow thermom-
eter to touch container.
b
72674 71801
a - Brass Thermostat
b - Stainless Steel Thermostat
3. If thermostat is suspected of producing insuffi- c

cient engine temperature, check thermostat for
leakage by holding it up to a lighted background.
Light leakage around the thermostat valve indi-
cates that thermostat is not closing completely
and should be replaced. (A small amount of leak-
age at one or two points around the valve perime- 72675
ter is acceptable.) a - Thermometer
b - Nylon String
c - Thermostat (Typical)
IMPORTANT: When performing procedures

“d”-“f,” water must be agitated thoroughly to ob-
tain accurate results.
d. Plug in tester and observe temperature at
which thermostat opens (thermostat drops off
thread). Thermostat must open at specified
temperature stamped on thermostat.
e. Continue to heat water until a temperature
25°F (14°C) above temperature specified on
thermostat is obtained. Thermostat valve
must be completely open at this temperature.
a f. Unplug tester and allow water to cool to a

temperature 10°F (5°C) below specified tem-
72717 perature on thermostat. Thermostat must be
completely closed at this temperature.
Brass Thermostat Shown (Stainless Similar)
a - Check for Light Leakage Around Perimeter of Valve g. Replace a thermostat that fails to meet all of
the preceding tests.
Index
Installation 8. Reconnect hose(s) to thermostat housing. Tight-
en hose clamps securely.
1. Clean gasket surfaces on thermostat cover and
thermostat housing. 9. Start engine and inspect for leaks.
2. If thermostat housing was disturbed during re- a

moval of thermostat, remove thermostat hous-
ing. Clean gasket surfaces on thermostat hous- b
ing and intake manifold and replace thermostat
c
housing-to-intake manifold gasket.
d
IMPORTANT: If gasket has continuity rivets, do e
not coat with Quicksilver Perfect Seal, or audio
warning temperature switch may not work prop- f
erly.
3. Place O-ring in the thermostat housing. Be cer-
tain it is positioned properly on mounting flange
in housing.
4. Install thermostat in thermostat housing as
shown.
72589
6 Hole Thermostat Housing

a - Cover
b - Gasket
c - Spacer
d - Thermostat
e - O-Ring
f - Housing
a b a
Brass Thermostat Stainless Steel
Thermostat
72674 71801
a - Install Thermostat With This End (Down) Toward b

Thermostat Housing
c
5. Align tang on sleeve with groove in thermostat
housing bore and install sleeve into housing.
d
6. Coat both sides of new thermostat cover-to-ther-
mostat housing gasket with Quicksilver Perfect
Seal and position on housing. e
7. Reinstall thermostat cover (with engine lifting 71758

eye, if so equipped) and torque screws with lock-
washers to 30 lb. ft. (41 N·m). 4 Hole Thermostat Housing
a - Housing
b - O-Ring
c - Thermostat (Stainless Steel)
d - Spacer
e - Gasket
Index
Draining Seawater Cooling NOTE: If possible, place a container under drains
System
NOTICE
NOTICE
Refer to “Draining Precautions,” in this
For cold weather or extended storage infor- section, BEFORE proceeding.
mation and procedures, refer to SECTION 1B.
1. Check that engine is as level as possible to en-
sure complete draining of cooling system.
Draining Precautions 2. Remove drain plugs (port and starboard) from
cylinder block.
! CAUTION
If boat is in the water, seacock (water inlet valve),
to be restarted to prevent water from flowing
be left disconnected and plugged to prevent wa-
ter from flowing back into cooling system and/or
the ignition switch or steering wheel of the boat
with the warning that the seacock must be
opened or the water inlet hose reconnected prior
to starting the engine.
IMPORTANT: Observe the following information a 72993
to ensure complete draining of cooling system. Starboard Side Shown (Port Similar)
• Engine must be as level as possible. a - Drain Plug (Port and Starboard)
• A wire should be repeatedly inserted into all 3. Repeatedly clean out drain holes using a stiff
drain holes to ensure there are no obstruc- piece of wire. Do this until entire system is
tions in passages. drained.
IMPORTANT: To prevent threads in manifolds, el- NOTE: It may be necessary to lift, bend, or lower
bows and cylinder blocks from rusting out dur- hoses to allow water to drain completely when hoses
ing storage, reinstall plugs using Quicksilver are disconnected.
Perfect Seal on threads. Never leave drain plugs 4. Remove hose or drain plug from bottom of port
out during storage. and starboard manifolds.
Index
NOTE: With the engine level, sufficient draining of 5. Remove the engine water circulating pump hose
manifolds will occur when exhaust manifold-to-ther- as shown.
mostat housing hoses are removed.
a
72993
72587
a - Hose, Water Circulating Pump to Thermostat Housing
a - Bottom Hose, Exhaust Manifold to Thermostat Housing
6. Remove the power steering fluid cooler seawater
hose, as shown.
b
a
72588
a - Hose, Seawater Pump to Cooler
b - Drain Plug in Exhaust Manifold Elbow

c - Later Models Are Equipped With This Style Of Drain Plug.
Index
7. Bravo models need to remove both hoses from b. Remove the drain plug from the water tube
seawater pump. (carburetor models) or Cool Fuel system (fuel
injection models).
a 71170
a - Seawater Inlet And Outlet Hoses
8. For 1996 and newer models, the additional

a 75081
following steps must be performed:
a. Remove the drain plug from the Y-fitting from
the port side of the block.
b
a 75018
a - Drain Plug (Cool Fuel System - Fuel Cool System)

a - Drain Plug b - Drain Plug (Water Tube - Carburetor Models)
Index
(MCM) Stern Drive Drain Location b. Bravo Drive Equipped Models: Insert a
small wire (repeatedly) to make sure that
1. Follow instructions “a” or “b”: speedometer pitot tube, trim tab cavity vent
a. Alpha equipped models: Insert a small wire hole, and trim tab cavity drain passage are
(repeatedly) to make sure that vent holes and unobstructed and open.
water drain holes and passages (as shown)
are unobstructed and open.
e
b
c
d a
f
a 71217
c
b - Trim Tab Cavity Vent Hole
71216
c. After cooling system has been drained com-
pletely, install and tighten securely all drain
plugs. Reconnect all hoses and tighten all
hose clamps securely.
2. Remove belt driven seawater pump inlet hose as
shown (if so equipped).
f
c
70134
a -
Speedometer Pitot Tube
b -
Trim Tab Cavity Vent Hole
c -
d -
Gear Housing Water Drain Hole (One Each - Port and
Starboard)
b a
72532
Index
3. Crank engine over SLIGHTLY with starter motor 4. Remove hose or drain plug from bottom of port
to purge any water trapped in seawater pickup and starboard manifolds.
pump. DO NOT ALLOW ENGINE TO START.
NOTE: Some exhaust manifolds have draincock(s)
4. After cooling system has been drained complete- or plug(s) on the end(s). For those that don’t, suffi-
ly, install and tighten securely all petcocks or cient draining of manifolds will occur when exhaust
drain plugs. Reconnect all hoses and tighten all manifold-to-thermostat housing hoses are removed
hose clamps securely. if engine is level.
MIE (Inboard) Models

NOTICE
Refer to “Draining Precautions,” in this
1. Check that engine is as level as possible or front

of engine slightly higher to properly drain cooling
system.
2. Remove petcocks or plugs (port and starboard) a 72586
a - Bottom Hose Exhaust Manifold To Thermostat Housing
a a
72586
a - Petcock (or Plug)
72586
3. Repeatedly clean out drain holes using a stiff

drained.
b
are disconnected.
a - Drain Plug Located In Exhaust Manifold Elbow

b - Later Models Are Equipped With Thumbscrew Drain Plug.
Index
5. Remove the engine water circulating pump hose 7. Remove seawater pump inlet hose as shown.
as shown.
a
72587 b
72532
a - Hose, Water Circulating Pump-to-Thermostat Housing
6. Remove the transmission fluid cooler hose, as b - Seawater Inlet Hose
shown.
8. Crank engine over SLIGHTLY, with starter motor,

to purge any water trapped in seawater pickup
9. After cooling system has been drained complete-
ly, install and tighten securely all petcocks and
drain plugs. Reconnect all hoses and tighten all
hose clamps securely.
72588
a - Hose, Seawater Pickup Pump-to-Cooler
Index
10. Remove the transmission fluid cooler hose as Auxiliary Hot Water Heater
shown.
Installation
IMPORTANT: When connecting a cabin heater or
hot water heater, certain requirements must be
met.
• Supply hose (from engine to heater) and re-
turn hose (from heater to engine) MUST NOT
EXCEED 5/8 in. (15.8 mm) I.D. (inside diame-
ter).
• Engine with a Closed Cooling System: Heater
a MUST BE LOWER than fill cap on the heat ex-
changer. If the heater is higher than the fill cap
72721 on the heat exchanger and some coolant is
lost in the system, an air pocket may form in
the closed cooling system. This, in turn, can
cause the engine to overheat.
• Make heater connections ONLY at locations
described in the following instructions.
• Check complete system for leaks after heater
is connected into cooling system.
• Check for overheating condition (of engine)
after heater is connected.
a
71782
1. Refer to “Changing Coolant - Draining Instruc-
Typical Transmission Fluid Cooler Locations tions”; drain closed cooling system.
c - Hose 2. Inspect for appropriate location of supply hose at
following:
a
NOTE: Hot water heater supply hose can be con-
nected at several different locations. On some mod-
els, there may be other accessories and options that
are utilizing these hot water supply locations. One of
the following should be available for use when install-
a ing a hot water heater system.
IMPORTANT: Do not reposition engine tempera-
ture switch; it must remain where installed by
factory.
75192
Walter V-Drive Transmission

Index
SUPPLY HOSE CONNECTION - ENGINES WITH RETURN HOSE CONNECTION - ENGINES WITH
RAW WATER OR CLOSED COOLING SYSTEM RAW WATER OR CLOSED COOLING SYSTEM
c
b a
72708
72705
Primary Location
a - Plug
Earlier Style Quicksilver Kit Location
b - Reducer Bushing a - T-Fitting
c - Hose Connector
b
a
71758
Raw Water Cooling Models - Alternate Location

a - Location for Hot Water Supply (Install Bayonet
Fitting Here)
72702
Later Style Quicksilver Kit Location

a - Pipe Plug
b - Hose Connector
c - T-Fitting
d - Hose Clamps
Index
Water Flow Diagrams
MCM Alpha
OVERBOARD
ENGINE BLOCK
INTAKE MANIFOLD
AND CYLINDER HEAD WATER INLET
ASSY. (FROM STERN
DRIVE)
EXHAUST ELBOW
THERMOSTAT
COVER
RESTRICTOR
POWER
THERMOSTAT STEERING
HOUSING FLUID
COOLER
EXHAUST
MANIFOLD
ENGINE
CIRCULATING
PUMP
22382
TO EXHAUST
MANIFOLDS
TO EXHAUST
ELBOW
(NOTE)
FROM WATER INLET

(VIA FLUID COOLER)
FROM
22380
ENGINE
THERMOSTAT
LEGEND
NOTE: Thermostat housing TO ENGINE COLD

check-balls will not be present CIRCULATING
PUMP WARM
on later models.
Index
MCM Alpha Gen+ With Cool Fuel System
OVERBOARD
WATER INLET
(FROM STERN
DRIVE)
POWER STEERING
FLUID COOLER
ENGINE BLOCK
INTAKE MANIFOLD EXHAUST ELBOW
AND CYLINDER HEAD
ASSY.
THERMOSTAT
HOUSING
RESTRICTOR
FUEL COOLER
EXHAUST
MANIFOLD
ENGINE
CIRCULATING
PUMP
Index
MCM Bravo
ENGINE OIL
AND POWER
STEERING FLUID
COOLER
72998
TO EXHAUST
MANIFOLDS
TO EXHAUST
ELBOW
(NOTE)
FROM WATER INLET

(VIA FLUID COOLER)
FROM
72532 ENGINE
SEAWATER PUMP
THERMOSTAT
LEGEND
TO ENGINE
COLD 22380
NOTE: Thermostat housing CIRCULATING
PUMP WARM
check-balls will not be present on
later models.
Index
MCM Bravo With Cool Fuel System
WATER INLET
(FROM STERN
OVERBOARD DRIVE)
POWER
STEERING
FLUID
COOLER
ENGINE BLOCK
AND CYLINDER HEAD
ASSY.
THERMOSTAT
HOUSING
RESTRICTOR
FUEL COOLER
EXHAUST
MANIFOLD
ENGINE
CIRCULATING
PUMP
Index
MIE Inboard Models
OVERBOARD
SEAWATER
INLET
ENGINE BLOCK
INTAKE MANIFOLD
AND CYLINDER HEAD ASSY
SEAWATER
PICKUP PUMP
THERMOSTAT
COVER
EXHAUST
ELBOW
RESTRICTOR
THERMOSTAT TRANSMISSION
HOUSING FLUID
COOLER
ENGINE EXHAUST
CIRCULATING MANIFOLD
PUMP
TO EXHAUST
MANIFOLDS
24728
TO EXHAUST
ELBOW
(NOTE)
FROM WATER INLET

(VIA FLUID COOLER)
FROM
ENGINE
THERMOSTAT
LEGEND
TO ENGINE 22380
CIRCULATING COLD
NOTE: Thermostat housing PUMP
check-balls will not be present WARM
on later models.
Index
MIE Inboard With Cool Fuel System
WATER INLET
(FROM STERN
OVERBOARD DRIVE)
TRANSMISSION
FLUID
COOLER
ENGINE BLOCK
AND CYLINDER HEAD
SEAWATER PUMP ASSY.
THERMOSTAT
HOUSING
RESTRICTOR
FUEL COOLER
EXHAUST
MANIFOLD
ENGINE
CIRCULATING
PUMP
75149
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
COOLING SYSTEM
6
B
72987
CLOSED COOLED MODELS
Index
Table of Contents
Page Page
305/350 CID / 5.0L/5.7L . . . . . . . . . . . . . . . . 6B-1 Changing Coolant . . . . . . . . . . . . . . . . . . . . . . . 6B-26
Water Flow Diagrams . . . . . . . . . . . . . . . . . . . . . 6B-2 Closed Cooling Section . . . . . . . . . . . . . . . . 6B-26
Engines With Coolant Flow Thru Exhaust Coolant Recommendations . . . . . . . . . . . . 6B-26
Manifolds (Excluding Gen +) . . . . . . . . . . . . 6B-2 Change Intervals . . . . . . . . . . . . . . . . . . . . . 6B-26
Engines With Raw Water Flow Thru Exhaust Draining Instructions . . . . . . . . . . . . . . . . . . 6B-27
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3 Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . 6B-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Closed Cooling Section . . . . . . . . . . . . . . . . 6B-27
Seawater Pickup Pump (If Equipped) . . . . . . . 6B-4 Seawater Section . . . . . . . . . . . . . . . . . . . . . 6B-27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Flushing Seawater Section of Closed
Stern Drive Unit Seawater Pickup Pump . . 6B-4 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 6B-28
Belt Driven Seawater Pickup Pump . . . . . . 6B-4 Draining Seawater Section of Closed
Closed Cooling Systems With Coolant Flow Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 6B-30
Thru Exhaust Manifolds Draining Precautions . . . . . . . . . . . . . . . . . . 6B-30
(Excluding Engines With Serpentine Belt) . . 6B-17 Filling Closed Cooling Section . . . . . . . . . . . . 6B-32
Maintaining Coolant Level . . . . . . . . . . . . . 6B-17 Closed Cooling System With Raw Water
Pressure Cap Maintenance . . . . . . . . . . . . . . . 6B-17 Flow Thru Exhaust Manifold
Heat Exchanger Repair . . . . . . . . . . . . . . . . . . 6B-18 (Engines With Serpentine Belt Only) . . . . . . 6B-33
Testing Closed Cooling System . . . . . . . . . . . 6B-18 Maintaining Closed Cooling System
Testing Coolant for Alkalinity . . . . . . . . . . . 6B-18 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-33
Pressure Testing System . . . . . . . . . . . . . . 6B-19 Checking Coolant for Alkalinity . . . . . . . . . 6B-34
Testing for Cylinder Head Gasket Leak . . 6B-20 Changing Coolant . . . . . . . . . . . . . . . . . . . . 6B-34
Testing Heat Exchanger . . . . . . . . . . . . . . . 6B-20 Pressure Cap Maintenance . . . . . . . . . . . . 6B-37
Testing Pressure Cap . . . . . . . . . . . . . . . . . 6B-20 Flushing Seawater Section . . . . . . . . . . . . . 6B-38
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Cleaning Seawater Section of Heat
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-21 Exchanger and Fluid Coolers . . . . . . . . . . 6B-39
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-23 Cleaning Closed Cooling Section . . . . . . . 6B-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-24 Cold Weather or Extended Storage . . . . . . . . 6B-41
Seawater Section Draining Instructions . . 6B-41
Serpentine Drive Belt Adjustment . . . . . . . 6B-44
Auxiliary Hot Water Heater Installation . . . . . 6B-45
Index
6B-0 - CLOSED COOLING MODELS 90-823225--1 1096
305/350 CID / 5.0L/ 5.7L
TORQUE SPECIFICATIONS

Heat Exchanger End Caps 36-72 4-8
Seawater Pump Brace
30 (41)
Seawater Pump Bracket to Block
Seawater Pump Cover
Seawater Pump Mounting Nuts to Stamped Steel
Brackets 120 30 14
Thermostat Cover
Thru Hull Pickup Nut
Drain Plugs
Heat Exchanger Mounting Brackets S
Securely
l
Hose Clamps
LUBRICANTS, SEALERS AND ADHESIVES

Quicksilver 2-4-C Marine Lubricant with Teflon 92-825407A3
Quicksilver Liquid Neoprene 92-25711-2
Quicksilver Loctite Type 8831 92-823089-1
Loctite 514 9275505-1
Quicksilver Special Lubricant 101 92-13872A1
Loctite Pipe Sealant with Teflon Obtain Locally
SPECIFICATIONS
Cooling System Capacity With Coolant Flow 20 (19)

Thru Exhaust Manifold
Cooling System Capacity With Raw Water Flow
Thru Exhaust Manifold
Thermostat Stainless Steel 160° F (71 °C)
Thermostat Brass 140° F (67 °C)
Cap Pressure 14 PSI (97 kPa)
Index
90-823225--1 1096 CLOSED COOLING MODELS - 6B-1
Water Flow Diagrams
Engines With Coolant Flow Thru Exhaust Manifolds (Excluding Gen +)
a COOLANT FLOW
b RAW WATER FLOW
c a
a
72989
Typical Thermostat and Thermostat Housing Shown (All Similar)
a - Remove Hoses (Lift, Lower or Bend To Completely Drain)

b - Remove Block Plugs (Repeatedly Clean Out Holes Using A Stiff Wire Until Entire System Is Drained)
c - Remove Drain Plugs From Exhaust Exhaust Manifold Drain Elbows (Repeatedly Clean Out Holes Using A Stiff Wire Until Entire
System Is Drained)
Index
Engines With Raw Water Flow Thru Exhaust Manifolds
a
b
a
c
75005
a COOLANT FLOW
b RAW WATER FLOW
a - Remove Hoses (Lift, Lower or Bend To Completely Drain)

b - Remove Block Plugs (Repeatedly Clean Out Holes Using A Stiff Wire Until Entire System Is Drained)
c - Remove Drain Plugs From Exhaust Exhaust Manifold Drain Elbows (Repeatedly Clean Out Holes Using A Stiff Wire Until Entire
System Is Drained)
Index
Description Seawater Pickup Pump
There are several configurations of this cooling sys- (If Equipped)
tem, but the operation is essentially identical. Basi-
cally, the system is composed of two separate sub-
systems: the seawater system and the closed Maintenance
cooling system. The seawater system is similar in
function to the fan used in an automobile because it Whenever insufficient water flow is suspected, sea-
absorbs heat (from the closed cooling system) as it water pickup pump should be disassembled and in-
passes through the heat exchanger. The closed cool- spected by an authorized MerCruiser Dealer.
ing system is similar in function to the rest of the cool-
ing system in an automobile.
The coolant recovery system keeps the reservoir full.
Normal coolant overflow into recovery bottle is ap- Pump
proximately 1/2 pint (230 mL) during warm-up. The
coolant recovery system draws coolant back into the NOTICE
reservoir from the recovery bottle as the engine Refer to SECTION 6A for information and ser-
cools. As long as there is coolant in the recovery vice procedures on Stern Drive Unit Seawater
bottle, the reservoir should remain completely full. If Pickup Pump.
not, there’s a vacuum leak, usually at the hose leav-
ing the reservoir, or the gasket under the recovery fill-
er cap. The gasket seals against the outer rim of the
filler neck. Belt Driven Seawater Pickup
IMPORTANT: The coolant (antifreeze) flows
Pump
around the outside of the cooling tubes while
seawater flows through the inside of the cooling
tubes in the heat exchanger. e
d a
b 72532
c
a - Seawater PUmp
b - Bracket
c - Pulley
d - Inlet Hose
e - Outlet Hose
Index
OUTPUT TEST 1. Remove water hose, which runs between pump
outlet and engine, and replace with another hose
If an overheating problem exists, use this test to de- of same diameter, but approximately 3 ft. (1 m)
termine if a sufficient amount of water is being longer. Hose should be wire reinforced or of ade-
supplied to cool engine. quate wall thickness to prevent it from kinking
when performing test. Clamp hose at pump outlet
IMPORTANT: The following information should only. Do not clamp hose at engine end.
be observed before proceeding with test:
• BOAT MUST BE IN THE WATER FOR THIS b

TEST. This test CANNOT be performed with a
flush-test device and water hose.
• The ability of this test to detect a problem is
greatly dependent upon the accuracy in
which it is performed. An error in setting the
engine RPM, timing the test or measuring the
water output will affect the overall accuracy
of the test and may produce misleading re- a
72532
sults. To help ensure accurate results, a shop
tachometer with an error of less than 5% a - Seawater Pickup Pump
b - Seawater Outlet Hose
should be used. The boat tachometer defi-
nitely should not be used as its accuracy is
questionable. A stop watch should be used to 2. Place an 8 U.S. qt. (7.6 L) or larger container near
time the duration of the test to help ensure unclamped end of hose.
that the accuracy is maintained within one
second. An 8 U.S. qt. (7.6 L) or larger capacity ! CAUTION
container should be used to measure water Do not run engine for more than 15 seconds with
output. hose disconnected, in next step, as internal dam-
• Due to the manner in which this test is per- age to engine and exhaust system may result.
formed, it may not be possible to detect a
3. With assistance of another person, start engine
marginal condition or a high-speed water
and adjust speed to exactly 1000 RPM while
pump output problem.
holding unclamped end of hose on connection on
engine. Remove hose from connection on engine
and direct water flow into container for exactly 15
seconds. At the end of 15 seconds, direct the wa-
ter flow overboard, return engine to idle and stop
engine. Reconnect hose to engine.
4. Measure quantity of water discharged into con-
tainer and compare with specifications given in
chart following.
5. Repeat test four times to check repeatability of
results.
Belt Driven Pump Output

for 15 Second Period
7.5 U.S. Qts. (7.1 L) Minimum
Index
REMOVAL 3. If pump is to be disassembled, loosen the four
pump pulley attaching screws. Do not remove
! CAUTION screws at this time.
If boat is in the water, be sure to close seacock 4. Remove power steering pump drive belt to allow
before removing inlet hose from pump to prevent removal of seawater pickup pump drive belt.
water from draining into boat. If boat is not fitted 5. Remove pulley attaching screws, then remove
with a seacock, disconnect and plug seawater in- pulley.
let hose after removing.
6. Remove attaching hardware which secures
IMPORTANT: The following procedure describes pump brace to cylinder block.
removal of both pump and mounting bracket
7. Remove pump mounting bracket-to-cylinder
from engine. On some installations, however, it
block attaching hardware and remove pump,
may be possible to remove pump with mounting
mounting bracket and brace as an assembly.
bracket left installed on engine.
8. Remove fasteners securing bracket and brace to
1. Close seacock, if so equipped, or disconnect and
pump and remove both from pump body.
plug seawater inlet hose.
2. Disconnect water inlet and outlet hoses from
pump.
Index
1 1
2 2
3
4 3
5
6 4
7
8 5
9
6
10
7
11
12
8
13
14 9
15
16 10
17
18 11
19 12
20
13
72646
14
Two Piece Pump Assembly
1 - Screw (5)
2 - Washer (5) 74577
3 - Cover
4 - Gasket One Piece Pump Assembly
5 - Wear Plate (Outer) 1 - Screw (5)
6 - Gasket 2 - Washer (5)
7 - Plug 3 - One Piece Body
8 - Impeller 4 - Quad Ring
9 - Body 5 - Impeller
10- Gasket 6 - Wear Plate
11- Wear Plate (Inner) 7 - Oil Seal
12- O-Ring or Quad Ring 8 - Housing
13- Oil Seal 9 - Ball Bearing
14- Housing 10- Shaft
15- Ball Bearing 11- Ball Bearing
16- Shaft 12- Snap Ring
17- Ball Bearing 13- Oil Seal
18- Snap Ring 14- Hub
19- Oil Seal
20- Hub
Index
DISASSEMBLY (TWO PIECE BODY)
1. Remove cover and body attaching screws and

washers.
a c
b
72652
a - Gasket (with Large Opening)
b - Wear Plate (Outer)
c - Gasket (with Two Openings)
72650 3. Slide pump body off shaft. Remove impeller from
pump body and rubber plug from impeller.
a - Cover
2. Remove gasket, outer wear plate and gasket

(discard gaskets).
a 72653
72651 b
72654
a - Rubber Plug
b - Impeller
Index
2. Remove seawater pump body and wear plate
from bearing housing.
c
a 72656 b
a - Quad Ring Seal a 75275
SEAWATER PUMP DISASSEMBLY a - Seawater Pump Body

(ONE PIECE BODY) b - Wear Plate
c - Bearing Housing
1. Remove the five screws from the seawater pump
body.
3. Remove the impeller from seawater pump body.
HOUSING DISASSEMBLY
1. Remove gasket, inner wear plate and quad ring
seal. Discard gasket and quad ring seal.
a
b 75277
a - Screws (5) a
b - Seawater Pump Body 72655
a - Quad Ring Seal
Index
2. Press hub off shaft with Universal Puller Plate 4. Remove snap ring from bearing housing bore
and an arbor press. and press shaft and bearings out pulley end of
housing. Bearings have a slip fit in housing; do
not use excessive force.
a
a
72657
72648
a - Universal Puller Plate (91-37241)
3. Puncture front oil seal with a tool and pry from

bearing housing.
72658
a - Snap Ring
72649
Index
5. If bearings require replacement, remove bear- 6. Inspect pump shaft bearings.
ings from shaft with Universal Puller Plate and an
7. Inspect pump shaft for grooves in surface where
arbor press. Bearings must be replaced, if re-
seals contact shaft. Also inspect surface where
moved.
bearings contact shaft for evidence of inner races
turning on shaft.
8. Inspect pump body.
9. Inspect inner and outer wear plate.
10. Inspect pump impeller for wear on sides and tips
of blades. Also inspect blades for cracks in area
where blades flex. Replace impeller if blades
have taken a set (remain in curved position).
11. Inspect pump pulley.
12. Check drive belt for excessive wear.
REASSEMBLY
Refer to exploded view also.

1. Apply a thin coat of Quicksilver Loctite 8831 to
72659 outside diameter of two new bearing housing
6. If rear seals require replacement, press seals rear seals; then install seals in housing with seal
from bearing housing with an appropriate tool. lips facing impeller end. (Press first seal in until it
bottoms out and second seal in until flush with
housing.)
1. Clean metal parts in solvent and blow dry with b

compressed air.
IMPORTANT: Do not spin bearings at high speed a
when drying with compressed air, as bearings
may be scored.
2. After cleaning, apply a coat of light engine oil to
shaft and bearings to prevent rust.
3. Clean all gasket material and sealer from sealing
surfaces.
72660
4. Inspect bearing housing. Examine surfaces
a - Outer (Water )Seal
(where bearings contact housing) for evidence of b - Face of Housing
bearing outer races turning in housing.
5. Inspect seals in bearing housing. IMPORTANT: It is recommended that Shell Alva-
nia No. 2 Grease be used when packing seal and
bearings in the following steps. If Shell Alvania
No. 2 Grease is not available, it is permissible to
use Quicksilver 2-4-C Marine Lubricant. With Te-
flon However, Quicksilver 2-4-C Marine Lubricant
With Teflon is not recommended for applications
where continuous high speed heavy-duty opera-
tion will be encountered.
2. Pack cavity between seals with Shell Alvania No.
2 Grease or substitute.
Index
3. Using an arbor press and suitable tool, press ball 5. Apply a thin coat of Quicksilver Loctite 8831 to
bearings onto shaft until they seat. Press on inner outside diameter of new bearing housing front oil
race of bearing only. seal and press seal into housing (with seal lip fac-
ing inward) until it bottoms out.
a
a
72663
a - Bearings
4. Pack bearings and cavity between bearings with

Shell Alvania No. 2 Grease or substitute. Slide
bearings and shaft into bearing housing bore and
install snap ring.
72662
a
a - Front Oil Seal
IMPORTANT: Be sure to support impeller end of

pump shaft when installing pulley hub in next
step to prevent placing a load on bearings.
6. Apply Quicksilver Special Lubricant 101 to pump
shaft. Using an arbor press and appropriate tool,
press pulley hub onto pump shaft to dimension
shown.
72661
72664
a - 17/64 In. (6.5mm)
IMPORTANT: Pulley hub must be pressed onto

72658 shaft to exact dimension on pumps with stamped
a - Shaft with Bearings steel mounting bracket as this establishes prop-
b - Snap Ring er drive belt alignment.
Index
7. Clamp bearing housing in a soft jaw vise with REASSEMBLY (TWO PIECE BODY)
flange end up.
8. Coat quad ring seal with Quicksilver 2-4-C Ma- 1. Place inner wear plate on housing and align
rine Lubricant With Teflon and install into groove holes. Coat both sides of a new wear plate gasket
in housing. with a thin film of Quicksilver Perfect Seal and po-
sition on wear plate.
a
a
72656
72665
a - Wear Plate
b - Gasket
2. Install impeller into pump body by turning impel-

ler in direction that it will be turning in operation,
while simultaneously pushing inward. All impeller
blades must face in same direction.
a a
72655
a - Quad Ring Seal
71118
a - Impeller Blade
Index
a
c
71150
72651
a - Impeller
3. Slide impeller and pump body assembly onto
shaft. Position pump body so that holes align with
holes in wear plate, gasket and bearing housing.
5. Install pump cover and secure with five bolts and
Install rubber plug into end of impeller.
washers. Torque bolts to specifications.
4. Coat both sides of new cover gasket and wear
plate gasket with a thin film of Quicksilver Perfect SEAWATER PUMP REASSEMBLY
Seal. Install outer wear plate with new gaskets on (ONE PIECE BODY)
each side, aligning holes in plate and gaskets
with holes in pump body. 1. Lubricate seawater pump impeller with a water
and soap solution. Install impeller into housing by
rotating and pushing it into place. Push it down
until flush with housing.
a 71118
a c
b
72652
71150
a - Impeller
Index
2. Place wear plate over bearing housing shaft. IMPORTANT: Pump must be positioned correctly
or overheating of engine may occur.
3. Place quad ring in groove in seawater pump
body.
a b
a - Quad Ring 72666

b - Seawater Pump
4. Align flats on impeller and bearing housing shaft,

slide seawater pump body on shaft.
5. Install two screws in seawater pump body holes a
as shown. Use these two screws to align pump,
then install the remaining screws.
72667
a a - LH Out - At Top
75277
IMPORTANT: Flat washer must be installed be-
a - Bolt Holes For Alignment tween mounting bracket clamping bosses or
damage to pump may result (if clamping screw is
INSTALLATION over-tightened).
1. Position pump in mounting bracket so that outlet
connection will be directly above inlet connection
when pump is installed.
Index
2. Install pulley on pump and secure with four
screws, lockwashers and clamping ring (some
models). Tighten screws finger-tight only at this
time.
3. Attach pump, mounting bracket and brace as-
sembly to engine. Do not tighten attaching
screws at this time.
4. Torque pump pulley attaching screws.
5. Position drive belt on pulleys and adjust belt ten-
sion as outlined in “Drive Belt Tension Adjust-
ment.”
6. Connect seawater inlet hose to lower fitting on
pump.
7. Connect outlet hose to upper fitting on pump.
8. Tighten hose clamps securely.
9. If applicable, reinstall power steering drive belt.
Adjust tension as outlined in “Drive Belt Tension
Adjustment.”
Index
Closed Cooling Systems If level is low, remove fill cap from coolant recovery
bottle and add required amount of coolant solution.
With Coolant Flow Thru Use a 50/50 mixture of ethylene glycol antifreeze and
pure, soft water for coolant additions. If frequent addi-
Exhaust Manifolds tions of coolant are required, check fresh water sec-
(Excluding Engines With tion for leaks.
IMPORTANT: ALCOHOL OR METHANOL BASE
Serpentine Belt) ANTIFREEZE OR PLAIN WATER ARE NOT REC-
OMMENDED FOR USE IN COOLING SYSTEM AT
Maintaining Coolant Level ANY TIME. In areas where ethylene glycol is not
available, and the possibility of freezing does not
exist, it is permissible to use a solution of rust in-
a hibitor and pure, soft water (mixed to manufac-
turer’s recommendations).
Occasionally, check to ensure that coolant recovery
system is functioning properly by removing pressure
cap from heat exchanger and checking level. Coolant
level should be up to bottom of heat exchanger filler
neck. If low, examine entire fresh water section (es-
pecially coolant recovery system) for leaks and re-
pair, if necessary.
IMPORTANT: When reinstalling pressure cap, be
sure to tighten it until it contacts stops on filler
neck.
72520
Pressure Cap Maintenance
Coolant Recovery Bottle Pressure cap is designed to maintain pressure in
a - Fill Cap fresh water section of closed cooling system once the
engine has attained normal operating temperature.
Before starting engine each day, check to ensure that This raises the boiling point of the coolant, thereby in-
coolant is visible in coolant recovery bottle. creasing the efficiency of the cooling system. To help
ensure proper operation, cap should be cleaned, in-
If coolant is not visible, check fresh water section of spected and pressure tested periodically as follows:
cooling system (including coolant recovery system)
for leaks and repair, as necessary. Refill fresh water
section with recommended coolant solution, as out- ! WARNING
lined under “Changing Coolant,” following.
Allow engine to cool before removing pressure
If coolant is visible, start engine and run until it reach- cap (in next step), as sudden loss of pressure
es normal operating temperature, then recheck cool- could cause hot coolant to boil and discharge vi-
ant level in coolant recovery bottle. Coolant level olently. After engine has cooled, turn cap 1/4 turn
MUST BE between the ADD and FULL marks (on to allow any pressure to escape slowly, then
front of bottle). push down and turn cap all the way off.
! WARNING 1. Remove pressure cap from heat exchanger.
Allow engine to cool before removing pressure 2. Wash cap with clean water to remove any
cap, as sudden loss of pressure could cause hot deposits or debris from sealing surfaces.
coolant to boil and discharge violently. After en- 3. Inspect rubber seal on cap for cuts, cracks or
gine has cooled, turn cap 1/4 turn to allow any other signs of deterioration. If seal is damaged,
pressure to escape slowly, then push down and cap MUST BE replaced.
turn cap all the way off.
4. Inspect coolant recovery gasket for deterioration
and replace if bad.
Index
5. Check condition of locking tabs on cap. Replace Heat Exchanger Repair
cap if tabs are bent or cracked.
IMPORTANT: Braze with BCUP 2 rod or silver sol-
der. Care must be taken not to melt other joints
a during repair.
c
1. Internal leaks can be repaired by brazing shut the
b ends of the leaking tube. This is only a temporary
fix because usually another tube will start leaking
after a short period of time and this also causes
a reduction in cooling capacity. Do not close more
than three tubes.
2. Nipples and drains that have been broken off the
heat exchanger can be reattached by brazing.
72714
a - Rubber Seal (Cap MUST BE Replaced if Damaged)

b - Gasket (Look for Cracks Under Gasket)
Testing Closed Cooling
c - Locking Tabs (1 Hidden)
System
6. Refer to “Testing Pressure Cap” and test pres-
sure cap as outlined. Testing Coolant for Alkalinity
7. Clean sealing surfaces on heat exchanger filler
neck with a cloth. Inspect surfaces for any dam-
age or deposits that may prevent cap from seal- ! WARNING
ing properly. Allow engine to cool before removing pressure
8. Clean coolant recovery passage in heat ex- cap as sudden loss of pressure could cause hot
changer filler neck with a wire and blow out with coolant to boil and discharge violently. After en-
compressed air. gine has cooled, turn cap 1/4 turn to allow any
pressure to escape slowly, then push down and
Coolant in fresh water section should be changed ev-

a
ery two years and should be checked for alkalinity at
least once between change intervals. To check cool-
ant for alkalinity, proceed as follows:
1. Obtain pink litmus paper from a local supplier
b (drug store, pet shop, etc.).
2. Remove pressure cap from heat exchanger and
insert one end of litmus paper into coolant.
3. If pink litmus paper turns blue, coolant is alka-
72715 line and need not be replaced.
a - Inspect for Damage 4. If pink litmus paper remains pink, coolant is
b - Clean Coolant Recovery Passages not alkaline and MUST BE REPLACED, as ex-
9. Reinstall pressure cap, being sure to tighten until plained under “Changing Coolant.”
it contacts stops on filler neck.
Index
Pressure Testing System 7. While maintaining specified pressure on closed
cooling section, visually inspect external portion
of cooling system (hoses, gaskets, drain plugs,
! WARNING petcocks, core plugs, circulating pump seal, etc.)
for leakage. Also listen closely for bubbling or
hissing, as they usually are a sure indication of a
cap. Sudden loss of pressure could cause hot
leak.
coolant to boil and discharge violently. After en-
gine has cooled, turn cap 1/4 turn to allow any 8. Refer to “Testing Heat Exchanger” in this section
pressure to escape slowly, then push down and and test as outlined.
turn cap all the way off. 9. If no leakage could be found in above steps, en-
gine is leaking internally, and it probably is due to
If coolant section of closed cooling system is sus- one or more of the following: (1) loose cylinder
pected of leaking or not holding sufficient pressure, head bolts or damaged gasket, (2) loose intake
and no visible signs of leakage can be found, perform manifold bolts or damaged gasket, (3) loose ex-
the following test: haust elbow or distribution block retaining nuts or
1. Remove pressure cap from heat exchanger or damaged gasket, (4) cracked or porous cylinder
reservoir. head or block, or (5) cracked or porous exhaust
manifold. Proceed as follows until location of in-
2. Clean, inspect and pressure test pressure cap, ternal leak is found.
as outlined under “Testing Pressure Cap,” to
eliminate the possibility that cap is not maintain- a. Start engine. Pressurize system to previously
ing proper pressure in system and is causing specified amount and observe pressure
coolant to boil over. gauge on tester. If needle in gauge vibrates,
compression or combustion is leaking into
3. Clean inside of filler neck to remove any deposits closed cooling section from a leak in the com-
or debris. Examine lower inside sealing surface bustion chamber. Exact cylinders, where
for nicks or other damage. Surface must be per- leakage is taking place, sometimes can be
fectly smooth to achieve a good seal between it found by removing spark plug wires (one at a
and rubber seal on cap. Also check locking cams time) while observing pressure gauge. Vibra-
on sides of filler neck to be sure that they are not tion will decrease or stop when plug wire is re-
bent or damaged. If locking cams are bent or moved from leaking cylinder. Stop engine.
damaged, pressure cap will not hold the proper
pressure. b. Remove spark plugs (one at a time) from cyl-
inders and examine for presence of coolant.
4. Adjust coolant level in fresh water section to 1 in. A spark plug that is perfectly clean or milky
(25 mm) below filler neck. appearing is a sure indication of a leak.
5. Attach an automotive-type cooling system c. Drain oil from engine and examine for pres-
pressure tester to filler neck and pressurize ence of coolant. Oil usually will be milky if
closed cooling section to amount specified in coolant is present. If coolant is present, re-
following chart, based on pressure cap rating for move engine from boat and drop the oil pan.
your engine. With engine in the upright position, pressur-
ize closed cooling section to previously speci-
Amount Of Pressure fied amount and examine internal surfaces of
Pressure Cap Rating Applied To Closed engine to locate leak.
Cooling System
d. If no leakage can be found in above steps, en-
14 PSI (97 kPa) 17 PSI (117 kPa)
tire engine must be disassembled and in-
6. Observe gauge reading for approximately two spected for leakage.
minutes; pressure should not drop during this
time. If pressure drops, proceed with the follow-
ing steps until leakage is found.
Index
Testing for Cylinder Head Gasket Testing Heat Exchanger
Leak FOR INTERNAL LEAK: An internal leak will cause
A leaking head gasket will cause combustion gas to coolant to go into the seawater circuit when pressure
be forced into the cooling system. The mixture of is put on the closed cooling circuit.
coolant and tiny air bubbles is a poor heat conductor 1. Remove a seawater hose from the exchanger.
and will overheat an engine quickly. Compression Do not drain the exchanger.
tests or cooling system pressure check normally will
not detect the leak because the test pressure is far 2. Pressurize the closed cooling circuit to 14-20 PSI
below the combustion pressures which cause the (97-138 kPa) with a radiator tester.
leak. An effective test is as follows: 3. If seawater begins to flow from the nipple there is
IMPORTANT: Run boat in lake for this test. It is a leak.
best to run the engine at or above cruising speed FOR BLOCKAGE:
during this test. Usually a failed head gasket will
IMPORTANT: Seawater flows THROUGH the
not cause the engine to overheat below cruising
tubes in the exchanger. Closed cooling coolant
speed.
flows AROUND the tubes.
1. Install a clear plastic hose between the reservoir
1. Remove end caps and inspect for any blockage
and coolant recovery bottle. Use a 2-3 ft. (61-91
in the seawater circuit (broken impeller blades,
cm) long hose for this test.
weeds, etc.).
2. Route this hose so a “U” is formed.
2. Remove closed cooling circuit hoses and inspect
3. Put enough coolant into hose to fill the center 4 the tubes just inside the nipples. Because the
or 5 inches (10-13 cm) of the “U.” complete exchanger cannot be inspected, the
4. Observe the “U” while the engine is running. heat exchanger should be replaced if blockage is
suspected.
a. During Idle and Warm-Up: Some coolant
and/or air will leave the reservoir.
b. During Cruising Speed (2500-3500 RPM): Testing Pressure Cap
Coolant and/or air leaving the reservoir
Pressure cap is designed to maintain a pressure of
should stop after approximately five minutes
approximately its rated capacity (refer to “Specifica-
running at a given RPM. A leaking head gas-
tions”) in closed cooling section once engine has at-
ket will produce air bubbling through the “U,”
tained operating temperature. Cap should be
going to the coolant recovery bottle. The fre-
cleaned, inspected and pressure-tested at regular
quency and size of the bubbles will depend
tune-up intervals or whenever cap is suspected of
on the size of the leak.
maintaining improper pressure as follows:
c. At Higher Speeds (4000+ RPM): Normal op-
eration is the same as described in “b” above.
A failed head gasket will cause the bubbles to
! WARNING
come faster and may be accompanied by vio- Allow engine to cool before removing pressure
lent, intermittent bursts of coolant. cap. Sudden loss of pressure could cause hot
It is important not to confuse normal warm-up expan- coolant to boil and discharge violently. After en-
sion with a failed head gasket. Normal warm-up pro- gine has cooled, turn cap 1/4 turn to allow any
duces an intermittent flow of coolant which will stop pressure to escape slowly, then push down and
within approximately five minutes at a given RPM. A turn cap all the way off.
head gasket leak will not stop because the one thing
that marks a failed head gasket is the continued pas- 1. Carefully remove pressure cap from reservoir or
sage of air. This may be accompanied by violent, in- heat exchanger.
termittent bursts of coolant leaving the reservoir. If
2. Wash cap with clean water to remove any depos-
coolant continues to flow (not in violent, intermittent
its or debris from sealing surfaces.
bursts) from the reservoir at cruising speed, some-
thing else besides the head gasket is causing the en-
gine to overheat.
Index
3. Inspect gasket (if used) and rubber seal on cap IMPORTANT: Before reinstalling cap in next step,
for tears, cuts, cracks or other signs of deteriora- examine lower inside sealing surface in filler
tion. Replace gasket, if damaged, or entire cap if neck to ensure that it is perfectly smooth and free
rubber seal is damaged. of debris. Also, inspect cam lock flanges on sides
of filler neck to be sure that they are not
bent.
a
c
b
a
72714
a - Rubber Seal (Cap MUST BE Replaced if Damaged)

b - Gasket (Look for Cracks under Gasket)
c - Locking Tabs (1 Hidden) b
72715
4. Check that locking tabs on cap are not bent or a - Inspect for Damage
damaged. b - Cam Lock Flange
5. Using a cooling system pressure tester (similar to 6. Reinstall cap on reservoir or heat exchanger.
one shown), test cap to be sure that it releases at
proper pressure and does not leak. (Refer to in-
structions which accompany tester for correct
test procedure.) Cap must relieve pressure at 14 Thermostat
PSI (97 kPa), and must hold rated pressure for 30
seconds without going below 11 PSI. Replace
cap if it fails to fall within these limits. Removal
1. Follow instructions “a” and “b”:
a. Drain coolant from exhaust manifolds by re-
moving lower hose or drain plugs from each
manifold. Be sure to drain both port and star-
board sides.
NOTE: If coolant flow is restricted or fails to occur, a
wire should be repeatedly inserted into all drain holes
to insure there are no obstructions in passages. Re-
move petcock, if necessary, to insert wire completely
into drain hole.
72716
Index
b. Drain engine block by removing plug or open- 4. Remove thermostat from thermostat housing.
ing petcocks. Be sure to drain both port and
starboard sides.
b
c
a 72993
d
Port Side Shown
a - Drain Plug (Cylinder Block)
b - Hose e
b g
73111
a
Models Without Sleeve
a - Drain Plug (Cylinder Block)
a - Bolts
b - Drain Plug (Exhaust Manifold)
b - Lockwashers
c - Cover
2. Disconnect hoses from thermostat cover. d - Gasket
e - Thermostat (Typical)
3. Remove thermostat cover attaching bolts and f - Housing
lockwashers, then remove cover and gasket. g - Gasket With Continuity Rivets
NOTE: Some engines may be equipped with a Lifting
Eye bracket (not shown following) under thermostat
cover bolts. Observe orientation so that it may be in-
stalled during reassembly exactly as before removal.
Index
Testing
a 1. Clean thermostat in soap and water to remove
any deposits or debris.
2. Inspect thermostat for corrosion or other visible
damage.
3. If thermostat is suspected of producing insuffi-
cient engine temperature, check thermostat for
leakage by holding it up to lighted background.
Light leakage around the thermostat valve indi-
b cates that thermostat is not closing completely
c and should be replaced. (A small amount of leak-
age at one or two points around the valve perime-
ter is acceptable.)
h
a
72717
Brass Thermostat (Stainless Steel Similar)

i a - Check for Light Leakage Around Perimeter of Valve
73110
Models With Sleeve

a - Bolts
b - Lockwashers
c - Cover
d - Gasket
e - Thermostat
f - Cork Gasket (DO NOT Use Perfect Seal)
g - Sleeve (Turned in Lip Toward Thermostat)
h - Housing
i - Plugs (2)
j - Gasket With Continuity Rivets
Index
4. Check opening and closing temperature of ther- Installation
mostat (using a tester similar to the one shown),
as follows:
! CAUTION
a. Fill tester to within 1 in. (25 mm) of top with tap
water. Do not use distilled water. Do not operate engine without cooling water be-
b. Open thermostat valve and insert thread. Po- ing supplied to the seawater pickup pump, or
sition thermostat on nylon string so that it will pump impeller will be damaged.
be just below water level when suspended,
then allow valve to close. Suspend thermo- 1. Remove thermostat housing and gaskets. Dis-
stat in water. card gaskets.
2. Clean gasket surfaces on thermostat cover, ther-
b mostat housing and intake manifold.
3. Position lower gasket (with continuity rivets) on
a intake manifold. Place thermostat housing on
gasket.
IMPORTANT: If gasket has continuity rivets, do
c not coat with Quicksilver Perfect Seal, or audio
warning temperature switch may not work
properly.
4. Install thermostat as shown, into thermostat
housing.
72675
a - Thermometer
b - Nylon String
c - Thermostat
c. Place thermometer in container and position

so that bottom of thermometer is even with
bottom of thermostat. Do not allow thermom-
eter to touch container. a b
IMPORTANT: When performing instructions “d”
and “e,” water must be agitated thoroughly to ob- Brass Thermostat Stainless Steel
tain accurate results. Thermostat
72674 71801
d. Plug in tester and observe temperature at
which thermostat opens (thermostat drops off a - Install Thermostat With This End (Down) Toward
Thermostat Housing
thread). Thermostat must open at 138-145°F
(59-63°C). Thermostat must be completely
open at 170°F (77°C).
e. Unplug tester and allow water to cool to a
temperature 10°F (5°C) below specified tem-
perature on thermostat. Thermostat must be
completely closed at this temperature.
f. Replace a thermostat that fails to meet all of
the preceding tests.
Index
5. Position gasket on thermostat housing and
reinstall thermostat cover. Install lifting eye (not
a
shown following) if so equipped. Torque bolts to
30 lb. ft. (41 N·m).
a
b
c
b
c
d
d
e
e
f
g
f
g h
73111
Models Without Sleeve i

a - Bolts
b - Lockwashers 73110
c - Cover
d - Gasket
e - Thermostat (Typical)
Models With Sleeve
f - Housing a - Bolts
g - Gasket With Continuity Rivets b - Lockwashers
c - Cover
d - Gasket
e - Thermostat
f - Cork Gasket (DO NOT Use Perfect Seal)
g - Sleeve (Turned in Lip Toward Thermostat)
h - Housing
i - Gasket With Continuity Rivets
Index
g Closed Cooling Section
Closed cooling section of closed cooling system
should be kept filled year-round with recommended
coolant solution. Do not drain closed cooling section
for storage, as this will promote rusting of internal
b surfaces. If engine will be exposed to freezing
c temperatures, make sure that closed cooling section
d is filled with an ethylene glycol antifreeze and water
a solution, mixed to manufacturer’s recommended
proportions, to protect engine to lowest temperature
to which it will be exposed. If necessary, change
coolant.
f
Coolant Recommendations
e 74745
! CAUTION
Models With Serpentine Belt
Alcohol or Methanol base antifreeze or plain
a - Thermostat Housing
water are not recommended for use in fresh
b - Thermostat
c - Quad-Ring Seal
water section of closed cooling system at any
d - Screws with Lockwashers time.
e - Thermostat Cover
f - Gasket It is recommended that the coolant section of closed
g - Bleeder Valve
cooling system be filled with 50/50 mixture of ethy-
lene glycol antifreeze and water. In areas where the
6. Connect hoses to thermostat cover. Tighten hose possibility of freezing DOES NOT exist, it is permissi-
clamps securely. ble to use solution of rust inhibitor and water (mixed
to manufacturer’s recommendations).
! CAUTION
Avoid seawater pickup pump impeller damage. Change Intervals
DO NOT operate engine without cooling water Drain and flush coolant from the closed cooling
being supplied to seawater pickup pump. system at least every two years or whenever exhaust
gases have entered the system.
7. With boat in the water and/or cooling water prop-
erly supplied to seawater pickup pump, start en-
gine and inspect for leaks.
Changing Coolant
NOTICE
For information and procedures on draining
the seawater cooling system, refer to SEC-
TION 6A. For cold weather or extended stor-
age, refer to SECTION 1B.
Index
Draining Instructions Cleaning System
! WARNING
Closed Cooling Section
cap. Sudden loss of pressure could cause hot Closed cooling section of the cooling system should
coolant to boil and discharge violently. After en- be cleaned at least once every two years or
gine has cooled, turn cap 1/4 turn to allow any whenever decreased cooling efficiency is experi-
pressure to escape slowly, then push down and enced.
A good grade automotive cooling system cleaning
IMPORTANT: A wire should be inserted into drain solution may be used to remove rust, scale or other
holes to ensure that foreign material is not ob- foreign material. Always follow manufacturer’s in-
structing the drain holes. On later models with structions for the cleaner.
two piece petcock, removal of petcock may be re- If closed cooling section is extremely dirty, a pressure
quired so that wire can be inserted completely flushing device may be used to flush out remaining
into drain hole. deposits. Flushing should be done in direction oppo-
IMPORTANT: Engine must be as level as possible site normal coolant flow to allow water to get behind
to ensure complete draining of cooling system. deposits and force them out. Refer to instructions
which accompany flushing device for proper hookup
IMPORTANT: Closed cooling section must be and flushing procedure.
kept filled year round with recommended cool-
ant. If engine will be exposed to freezing tempera-
tures, make sure closed cooling section is filled NOTICE
with an ethylene glycol antifreeze and water solu- For information and procedures for draining
tion properly mixed to protect engine to lowest and flushing seawater section of cooling sys-
temperature to which it will be exposed. tem, refer to SECTION 6A. For cold weather or
IMPORTANT: Do not use Propylene Glycol Anti- extended storage, refer to SECTION 1B.
freeze in the closed cooling section of the en-
gine.
The following draining instructions apply to all en- Seawater Section
gines equipped with closed cooling. The location of
petcocks that require opening and hoses that require Cooling efficiency of an engine with closed cooling is
removal are represented on the following pages for greatly dependent upon heat transfer through the
the individual engines. tubes within the heat exchanger. During engine oper-
ation, contaminants within the seawater (such as
IMPORTANT: Observe precautions previously salt, silt, lime, etc.) collect on the inside of the tubes,
outlined before proceeding. thus reducing heat transfer and greatly decreasing
1. Remove pressure cap from coolant tank. heat exchanger efficiency. It is, therefore, recom-
mended that the seawater section of the heat ex-
2. Drain coolant from locations as shown for your changer be cleaned at least once every two years or
model and engine. (Refer to the appropriate dia- whenever decreased cooling efficiency is suspected,
gram on the following “Draining Diagrams” as follows:
page.)
IMPORTANT: It may be necessary to remove heat
3. After coolant has drained completely, coat exchanger on some models. If heat exchanger is
threads of drain plugs with Quicksilver Perfect removed, be sure to refill closed cooling section
Seal and install drain plugs and hoses. Tighten with coolant.
clamps and drain plugs securely.
4. Remove coolant recovery bottle from mounting
bracket and pour out coolant.
5. Clean system as outlined in “Cleaning System.”
6. Fill system as outlined in “Filling Closed Cooling
Section.”
Index
1. Remove seawater drain plug from bottom of heat Flushing Seawater Section
exchanger and allow water to drain. After water
has drained completely, coat threads of drain of Closed Cooling System
plug with Quicksilver Perfect Seal and reinstall.
If engine is operated in salty, polluted or mineral-
laden waters, seawater section of closed cooling
system should be flushed periodically (preferably
after each use) with fresh water to reduce corrosion
and prevent the accumulation of deposits in the
e system. Seawater section also should be thoroughly
flushed prior to storage.
a c
! WARNING
When flushing cooling system with boat out of
the water, be certain that area in vicinity of pro-
d peller is clear and that no person is standing
b nearby. As a precautionary measure, it is recom-
mended that propeller be removed.
72718
! CAUTION
a - Bolt
b - End Cap Do not run engine above 1500 RPM when flush-
c - Sealing Washer ing. Suction created by seawater pickup pump
d - Gasket may collapse flushing hose, causing engine to
e - Drain Plug
overheat.
2. Remove bolts which secure end plates to each
end of heat exchanger, then remove end plates, ! CAUTION
seal washers and gaskets. Discard seal washers
and gaskets. Clean gasket material from end If cooling system is to be flushed with boat in the
plates and heat exchanger. water, seacock (if so equipped) must be closed,
or water inlet hose must be disconnected and
3. Clean water passages in heat exchanger by in- plugged to prevent water from flowing into boat.
serting a suitable size wire brush into each pas-
sage. Use compressed air to blow loose particles
out of water passages.
! CAUTION
4. Apply Quicksilver Perfect Seal to both sides of To prevent engine or stern drive unit damage
new end plate gaskets, then reinstall end plates, DO NOT run engine or drive unit without water
using new gaskets and seal washers. (Be sure to being supplied to water intake openings on gear
install seal washers between end plates and gas- housing.
kets.) Torque end plate bolts to specifications.
! CAUTION
! CAUTION Watch temperature gauge at dash to ensure the
Avoid seawater pickup pump impeller damage.
DO NOT operate engine without water being 1. Follow instructions appropriate to your model:
supplied to seawater pickup pump.
NOTE: If flushing cooling system with boat in water,
5. With boat in the water and/or cooling water prop- raise drive unit to trailer position, install flushing at-
erly supplied to seawater pickup pump, start en- tachment and lower drive unit to full IN/DOWN posi-
gine and inspect for leaks. tion.
Index
a. All Models:
(1) Install Quicksilver Flushing Attachment
(or equivalent) over water intake open-
ings in gear housing.
(2) Connect hose between flushing attach-
ment and water tap.
b
a 72532

2. Partially open water tap (approximately 1/2 maxi-

mum capacity) and allow drive unit and cooling
a system to fill completely. Do not use full tap water
pressure.
b NOTE: Drive unit is full when water is discharged out
of drive unit, and/or seawater section of closed
cooled system is full when water is discharged
72672
through propeller.
a - Quicksilver Flushing Attachment 3. Place remote control lever in NEUTRAL position
b - Garden Hose
and start the engine. Operate engine at idle
b. Models Equipped with Belt Driven Seawa- speed in NEUTRAL gear for 10 minutes or until
ter Pickup Pump: In addition to supplying discharge water is clear, then stop engine.
water to the drive (as previously outlined for 4. Shut off tap water. Remove hose and flushing at-
“All Models”), perform the following. tachment from drive unit. On belt driven seawater
pickup pump models, also remove hose and
! CAUTION flushing attachment from pump inlet.
If cooling system is to be flushed with boat in the 5. Follow instructions “a” or “b.”
water, seacock (if so equipped) must be closed,
or water inlet hose must be disconnected and ! CAUTION
plugged to prevent water from flowing into boat.
If boat is in the water, seacock (if so equipped)
must remain closed until engine is to be re-
(1) Close seacock (if so equipped) or discon-
started, to prevent contaminated water from
nect and plug seawater inlet hose.
(2) Loosen hose clamp and remove seawa- fitted with a seacock, water inlet hose must re-
ter inlet hose at location shown. Connect main disconnected and plugged, to prevent wa-
an additional tap water hose to inlet fitting ter from flowing into cooling system and/or boat.
using an appropriate adaptor. As a precautionary measure, attach a tag to the
ignition switch or steering wheel with the warn-
ing that the seacock must be opened or the water
inlet hose reconnected prior to starting the en-
gine.
Index
a. If equipped with seacock: Observing pre- 1. Close seacock (if so equipped) or disconnect and
caution above, open seacock. plug seawater inlet hose.
b. If NOT equipped with seacock: Observing 2. Check that engine is as level as possible to en-
precaution above, remove plug from seawa- sure complete draining of cooling system.
ter inlet hose and reconnect seawater inlet
3. Remove drain plugs (if equipped) from port and
hose. Tighten hose clamps securely.
starboard exhaust elbows.
Draining Seawater Section of

NOTICE
For cold weather or extended storage
information and procedures, refer to
SECTION 1B.
a
Draining Precautions
71330
! CAUTION a - Drain Plug (Port and Starboard)
If boat is in the water, seacock (water inlet valve), 4. Remove drain plug from heat exchanger.
to be restarted to prevent water from flowing
be left disconnected and plugged to prevent wa-
ter from flowing back into cooling system and/or
the ignition switch or steering wheel of the boat
with the warning that the seacock must be
opened or the water inlet hose reconnected prior
to starting the engine. a
IMPORTANT: Observe the following information

to ensure complete draining of cooling system.
• Engine must be as level as possible. 70583
• A wire should be repeatedly inserted into all a - Drain Plug

drain holes to ensure there are no obstruc-
tions in passages.
IMPORTANT: To prevent threads in manifolds, el-

bows and cylinder blocks from rusting out dur-
ing storage, reinstall plugs using Quicksilver
Perfect Seal on threads. Never leave drain plugs
out during storage.
NOTE: If possible, place a container under drains
Index
5. If equipped with 3 in. (76 mm) or 6 in. (152 mm)
risers, remove drain plug as shown from port and
starboard risers (if equipped).
a
b
74752
Rear Mounted Fluid Cooler

73175 a - Hose, From Seawater Pump (Bravo) Or From Transom
Assembly (Alpha)
8. On Engines Equipped with a Belt Driven Sea-

6. Repeatedly clean out drain holes using a stiff water Pickup Pump: Remove seawater inlet
piece of wire. Do this until entire system is hose, as shown.
drained.
are disconnected.
7. Remove the power steering fluid cooler seawater
hose, as shown.
b a
72532
b - Seawater Inlet Host
9. Crank engine over SLIGHTLY with starter motor

to purge any water trapped in seawater pickup
a
72588 ! CAUTION
Port Side Mounted Fluid Cooler If boat is in the water or is to remain in the water,
a - Hose, Seawater Pump to Cover
til engine is to be restarted, to prevent contami-
nated water from flowing back into cooling sys-
tem. If boat is not fitted with a seacock, water inlet
hose must be left disconnected and plugged, to
prevent contaminated water from flowing into
cooling system and/or boat. As a precautionary
measure, attach a tag to the ignition switch or
steering wheel with the warning that the seacock
must be opened or the water inlet hose recon-
nected prior to starting the engine.
Index
10. After seawater section of cooling system has ! CAUTION
been drained completely, coat threads of drain
plugs with Quicksilver Perfect Seal and reinstall. Models with belt drive seawater pickup pump
Tighten drain plugs securely. Reconnect hoses must be in the water when running engine be-
and tighten all hose clamps securely. If NOT cause garden hose will not supply enough water
equipped with seacock: seawater inlet hose to system at higher RPM.
must remain disconnected and plugged until en-
gine is to be restarted. 3. With pressure cap off, start engine and run at fast
idle (1500-1800 RPM). Add coolant solution to
heat exchanger, as required, to maintain coolant
level 1 in. (25 mm) below filler neck.
Filling Closed Cooling
4. After engine has reached normal operating tem-
Section perature (thermostat is fully open), and coolant
level remains constant, fill heat exchanger to bot-
NOTICE tom of filler neck.
See “Specifications” for approximate 5. Observe engine temperature gauge to make
closed cooling system capacity and sure that engine operating temperature is nor-
coolant recommendation. mal. If gauge indicates excessive temperature,
stop engine immediately and examine for cause.
6. Install pressure cap on heat exchanger.
! WARNING
7. Remove cap from coolant recovery reservoir and
Do not remove coolant cap when engine is hot. fill to FULL mark with coolant solution. Reinstall
Coolant may discharge violently. cap.
8. With engine still running, check hose connection,
fittings and gaskets for leaks.
! CAUTION
IMPORTANT: Engine overheating is often due to
Alcohol or Methanol based antifreeze or plain air being trapped in closed cooling section.
water are not recommended for use in fresh wa- Purge air by running engine at 2000 RPM for 10
ter section of cooling system at any time. minutes.
! WARNING
! CAUTION
Front of engine should be higher than rear to cap. Sudden loss of pressure could cause hot
purge trapped air out of the system during initial coolant to boil and discharge violently. After en-
filling. This will minimize the possibility of air be- gine has cooled, turn cap 1/4 turn to allow any
ing trapped in the closed cooling section which pressure to escape slowly, then push down and
can cause engine to overheat. turn cap all the way off.
1. Remove coolant cap on heat exchanger. 9. Recheck coolant level after first open-throttle
2. Fill closed cooling system with coolant mixture boat test and add coolant, if necessary.
through heat exchanger fill neck until coolant 10. Maintain coolant level in coolant recovery reser-
level is 1 in. (.25 mm) below filler neck. voir between ADD and FULL marks with engine
at normal operating temperature.
! CAUTION
Avoid seawater pickup pump impeller damage
and subsequent overheating damage to stern
drive unit. DO NOT operate engine without water
being supplied to seawater pickup pump.
Index
Closed Cooling System With IMPORTANT: ALCOHOL OR METHANOL BASE
ANTIFREEZE OR PLAIN WATER ARE NOT REC-
Raw Water Flow Thru OMMENDED FOR USE IN CLOSED COOLING
SYSTEM AT ANY TIME. In areas where ethylene
Exhaust Manifold glycol is not available, and the possibility of
(Engines With Serpentine freezing does not exist, it is permissible to use a
solution of rust inhibitor and pure, soft water
Belt Only) (mixed to manufacturer’s recommendations).
Maintaining Closed Cooling System ! WARNING

Coolant
Coolant section of Closed Cooling System is
At least weekly, before starting engine, check to en- equipped with a 16 psi (110 kPa) pressure cap (fill
sure that coolant is visible in coolant recovery bottle. cap). Before removing pressure cap, following,
If coolant is not visible, check coolant section of first allow engine to cool down, as sudden loss of
cooling system (including coolant recovery system) pressure could cause hot coolant to boil and dis-
for leaks and repair, as necessary. Refill coolant sec- charge violently. After engine has cooled down,
tion with recommended coolant solution, as outlined turn pressure cap 1/4-turn to allow any pressure
under “Changing Closed Cooling System Coolant,” to escape slowly, then push down and turn cap
following. all-the-way off.
If coolant is visible, start engine and run until it

reaches normal operating temperature, then recheck Occasionally, check to ensure that coolant recovery
coolant level in coolant recovery bottle. Coolant level system is functioning properly by removing pressure
MUST BE between the “ADD” and “FULL” marks (on cap from heat exchanger and checking level. Coolant
front of bottle). If level is low, remove fill cap from level should be up to bottom of heat exchanger filler
coolant recovery bottle and add required amount of neck. If low, inspect entire coolant section (especially
coolant solution. Use a 50/50 mixture of ethylene coolant recovery system) for leaks and repair, as
glycol antifreeze and pure, soft water for coolant necessary.
additions, if frequent additions of coolant are re-
quired, check coolant section for leaks. IMPORTANT: When reinstalling pressure cap, be
a sure to tighten it until its contact stops on filler
neck.
71712
a - Fill Cap
Index
Checking Coolant for Alkalinity
a
! WARNING b

equipped with a 16 psi (110 kPa) pressure cap (fill
cap). Before removing pressure cap (in next
step), first allow engine to cool down, as sudden
loss of pressure could cause hot coolant to boil
and discharge violently. After engine has cooled
down, turn pressure cap 1/4-turn to allow any
a
pressure to escape slowly, then push down and
74073
turn cap all-the-way off.
Carbureted Engines, Starboard Side (Port Side
Coolant in closed cooling section of cooling system Similar)
a - Typical Drain Plug
should be changed every two years and should be
b - Sealing Washer
checked for alkalinity at least once between change
intervals. To check coolant for alkalinity, proceed as
follows: ! CAUTION
1. Obtain pink litmus paper from a local supplier Avoid product damage. Do not disturb the Y-fit-
(drug store, pet shop, etc.). ting when removing the drain plug. There is an
ignition control “Knock Sensor” in the upper
2. Remove pressure cap from heat exchanger and
hole of the fitting. This sensor must not be loos-
insert one end of pink litmus paper into coolant.
ened or removed. It is tightened to a critical spec-
3. If pink litmus paper turns blue, coolant is alkaline ification at the factory.
and need not be replaced.
4. If pink litmus paper remains pink, coolant is not al-
kaline and MUST BE REPLACED, as explained
under “Changing Fresh Water Coolant,” follow-
ing.
Changing Coolant
DRAINING INSTRUCTIONS
1. Remove coolant recovery bottle and pour out a
coolant.
EFI Engines Starboard Side
! WARNING
equipped with a 16 psi (110 kPa) pressure cap (fill
cap). Before removing pressure cap, first allow
engine to cool down, as sudden loss of pressure
could cause hot coolant to boil and discharge
violently. After engine has cooled down, turn
pressure cap 1/4-turn to allow any pressure to
escape slowly, then, push down and turn cap
all-the-way off.
b
2. Remove pressure cap from heat exchanger. 75081
3. Remove drain plugs on each side of cylinder EFI Engines Port Side
block or fitting, as shown. a - Drain Plug - from Y-fitting
b - Drain Plug - from Cylinder Block
Index
4. Disconnect heat exchanger-to-circulating pump FILLING INSTRUCTIONS
hose from pump and allow coolant to drain.
a ! CAUTION
Alcohol or Methanol base antifreeze or plain wa-
ter, are not recommended for use in coolant sec-
tion of Closed Cooling System at any time.
It is recommended that coolant section of Closed

Cooling System be filled with a 50/50 mixture of ethy-
lene glycol antifreeze and pure, soft water. Antifreeze
MUST BE used regardless of whether freezing tem-
peratures are or are not expected to provide ade-
quate corrosion protection. In areas where ethylene
glycol antifreeze is not available and the possibility of
freezing DOES NOT exist, it is permissible to use a
solution of rust inhibitor and pure, soft water (mixed
b to manufacturer’s recommendations).
NOTE: Coolant section capacity is approximately 4
Typical Engine Shown U.S. Gallons (15 L).
a - Heat Exchanger
b - Heat Exchanger-to-Circulating Pump Hose 1. Fill coolant section of Closed Cooling System
with coolant mixture as follows:
5. After coolant has drained completely, reconnect
hose, but, do not tighten hose clamps. a. Open bleeder valve on thermostat housing.
6. With drain plugs still removed, flush closed cool- b. Fill with coolant mixture through heat ex-
ing section with plain water until discharge water changer fill neck until coolant appears at
is clear. bleeder valve opening.
7. Disconnect heat exchanger-to-circulating pump c. Close bleeder valve securely.

hose once again and drain water. d. Continue filling until coolant level is into filler
8. After water has drained completely, apply Perfect neck and begins to flow into coolant recovery
Seal to threads of drain plugs and reinstall. Re- bottle plastic tubing.
connect hose. Be sure to tighten drain plugs and
hose clamps securely. Refill section with coolant,
as explained following.
Index
! CAUTION 6. With engine still running, check hose connec-
tions, fittings and gaskets for leaks. Also observe
DO NOT operate engine without water flowing engine temperature gauge to make sure that
thru seawater pickup pump, as pump impeller engine operating temperature is normal. If gauge
may be damaged and subsequent overheating indicates excessive temperature, stop engine
damage to engine or stern drive unit may result. immediately and examine for cause.
• Front of engine should be higher than rear to
purge trapped air out of the system during ini- ! WARNING
tial filling. This will minimize the possibility of
air being trapped in the closed cooling sec- Allow engine to cool down before removing pres-
tion which can cause engine to overheat. sure cap. Sudden loss of pressure could cause
hot coolant to boil and discharge violently. After
engine has cooled down, turn cap 1/4-turn to al-
low any pressure to escape slowly, then, push
IMPORTANT: This closed cooling system flows
down and turn cap all-the-way off.
coolant at a high rate. Higher idle speeds in-
crease dispersion of trapped air into system
making it more difficult to purge trapped air. Op- 7. Recheck coolant level after first open-throttle
erate at idle during filling and air purging when boat test and add coolant, if necessary.
specified. 8. Maintain coolant level in coolant recovery reser-
voir between “Add” and “Full” marks with engine
2. Start engine and run AT IDLE. Add coolant at normal operating temperature.
solution to heat exchanger, as required, to
maintain coolant level at filler neck. After engine Coolant section of Closed Cooling System should be
has reached normal operating temperature (ther- kept filled year around with recommended coolant
mostat is fully open), and coolant level remains solution. DO NOT drain coolant, fresh water section,
constant, fill heat exchanger until coolant level is for storage, as this will promote rusting of internal sur-
into filler neck and begins to flow into coolant faces. If engine will be exposed to freezing tempera-
recovery bottle plastic tubing. tures, make sure that coolant section is filled with
3. Remove cap from coolant recovery reservoir and ethylene glycol antifreeze and water solution, mixed
fill to “Full” mark with coolant solution. Reinstall to manufacturer’s recommended proportion, to pro-
cap. tect engine to lowest temperature to which it will be
exposed.
4. Lift recovery bottle and plastic tubing above heat
exchanger filler neck. Allow coolant to flow down
through tubing to purge air through filler neck
fitting.
5. Install pressure cap on heat exchanger.
Index
Pressure Cap Maintenance 4. Inspect coolant recovery gasket for deterioration
and replace if bad.
! WARNING 5. Check condition of locking tabs on cap. Replace

cap, if tabs are bent or cracked.
Allow engine to cool down before removing pres- 6. Have pressure cap pressure-tested by your local
sure cap (in next step), as sudden loss of pres- servicing dealer.
sure could cause hot coolant to boil and dis-
charge violently. After engine has cooled down, 7. Clean sealing surfaces on heat exchanger filler
turn cap 1/4-turn to allow any pressure to escape neck with a cloth. Inspect surfaces for any
slowly, then, push down and turn cap all-the-way damage or deposits that may prevent cap from
off. sealing properly.
8. Clean coolant recovery passage in heat ex-
Pressure cap is designed to maintain a pressure of changer filler neck with a wire and blow out with
approximately 16 psi (110 kPa) in coolant section of compressed air.
Closed Cooling System once the engine has attained 9. Reinstall pressure cap, being sure to tighten until
normal operating temperature. This raises the boiling its contacts stops on filler neck.
point of the coolant, thereby increasing the efficiency
of the cooling system. To help ensure proper opera- a
tion, cap should be clean, inspected and pressure
tested (at intervals specified in chart), as follows:
1. Remove pressure cap from heat exchanger.
2. Wash cap with clean water to remove any depos-
its or debris from sealing surfaces.
3. Inspect rubber seal on cap for cuts, cracks or b
other signs of deterioration. If seal is damaged,
cap MUST BE replaced.
c b
70260
a a - Pressure Cap Sealing Surfaces

b - Coolant Recovery Passage
c 70970
a - Rubber Seal
b - Coolant Recovery Gasket
c - Locking Tabs (1 Hidden)
Index
Flushing Seawater Section ! CAUTION
If boat is operated in salty, polluted or mineral-laden DO NOT run engine above 1500 RPM, as suction
waters, seawater section of cooling system should created by seawater pickup pump may collapse
be flushed periodically (preferably after each use) to water supply hole, interrupting water flow and
remove corrosive water and and prevent the accu- causing engine to overheat.
mulation of deposits in the system. Seawater section
also should be thoroughly flushed prior to storage. To
flush seawater section of cooling system, proceed as
follows: ! CAUTION
Watch temperature gauge at dash to ensure that
IMPORTANT: If cooling system is to be flushed engine does not overheat.
with boat in the water, water inlet valve (if so
equipped) MUST BE closed, or water inlet hose 3. Place the remote control lever in neutral position
MUST BE disconnected and plugged, to prevent and start engine. Operate engine at idle speed in
water from flowing into boat and/or cooling sys- neutral gear for 10 minutes or until discharge wa-
tem. ter is clear, then stop engine.
4. Shut off water tap. Remove flushing connector
IMPORTANT: If a valve is to be installed for the
from pump inlet and reconnect water inlet hose.
purpose of draining or flushing seawater sec-
Be sure to tighten hose clamp securely.
tion, valve MUST have an internal cross-section-
al area equal to or greater than water inlet hose
to prevent restricting water flow during normal IMPORTANT: If boat is in the water, DO NOT open
operation. A 1-1/4 in. (32mm) or larger brass ball water inlet valve until engine is to be restarted, to
valve or gate valve is recommended. prevent contaminated water from flowing back
into engine. If boat is not fitted with a valve, leave
water inlet hose disconnected and plugged. As a
1. Disconnect water inlet hose from end of seawater
precautionary measure, attach a tag to the igni-
pickup pump.
tion switch or steering wheel with the warning
2. Using appropriate connector, connect city water that the seacock must be opened or the water in-
tap to pump inlet connection and partially open let hose reconnected prior to starting the engine.
water tap (approximately 1/2 minimum capacity).
DO NOT use full city water pressure.
! WARNING
When flushing cooling system with boat out of
the water, be certain that area in vicinity of pro-
peller is clear and that no person is standing
nearby. As a precautionary measure, it is recom-
mended that propeller be removed.
Index
Cleaning Seawater Section of Heat 3. Follow appropriate instructions “a” or “b”:
Exchanger and Fluid Coolers a. On Engines Without Cool Fuel System:
During operation, contaminants in the seawater may Proceed to Step 4.
collect on tubes within the heat exchanger and fluid b. On Engines With Cool Fuel System: Dis-
coolers reducing their cooling efficiency. This will connect the fore and aft seawater hoses from
cause coolant temperature to gradually rise until an Cool Fuel System cooler.
overheating condition exists. To prevent this from
happening, the seawater section of heat exchanger,
and fluid coolers should be cleaned at least once a
year or whenever a gradual rise in temperature is
observed on water temperature gauge. Clean sea-
water section of heat exchanger and coolers.
b
1. Refer to “Cold Weather or Extended Storage -
Seawater Section Draining Instructions” and
drain seawater section.
d
c
2. Remove end cover, attaching screw, O-ring and
rubber gasket, from port and starboard ends of
heat exchanger.
a 74988
Typical Engine With Cool Fuel System

a - Cool Fuel System
b - Cooler of Cool Fuel System
c - Seawater Hose From Seawater Pump
d - Seawater Hose To Heat Exchanger
d 4. Disconnect hoses from ends of power steering

cooler.
b
a
c
71515
Starboard End Cover Shown (Port Similar)

a - End Cover
b - Screw c a b
c - O-Ring 75020
d - Rubber Gasket a - Power Steering Fluid Cooler
b - Seawater Hose From Seawater Pump
c - Seawater Hose To Heat Exchanger
5. Remove any debris from cavities on ends of heat

exchanger and fluid coolers.
Index
6. Clean tubes (passages) in heat exchanger and 9. Install all hoses previously disconnected . Tight-
coolers by running a suitable wire brush through en hose clamps securely.
each tube.
10. Start engine and check for leaks.
a
Cleaning Closed Cooling Section
Closed Cooling section of cooling system should be
cleaned whenever decreased cooling efficiency (due
to internal deposits) is experienced.
71724 A good grade automotive cooling system cleaning
a - Wire Brush, Sized To Fit Passage solution, that is compatible with copper and cast iron
may be used to remove rust, scale or other foreign
7. Rinse out heat exchanger and fluid cooler tubes material. Manufacturer’s instructions of particular
with tap water from a hose to remove loosened cleaner being used, should be carefully followed to
particles. ensure a safe and effective cleaning operation.
8. Install end covers on heat exchanger as follows: If coolant section is extremely dirty, a pressure
flushing device may be used to flush out remaining
a. Clean gasket mating surfaces on end covers deposits. Flushing should be done in direction
of heat exchanger. opposite normal coolant flow (with thermostat re-
b. Inspect gaskets and O-rings for damage and moved) to allow water to reach behind deposits and
replace if necessary. force them out (refer to “Cooling System Water Flow
Diagram,” following). Follow instructions which ac-
c. Reinstall end covers with components
company flushing device for proper hookup and
shown. Torque end cover screws to 1 to 1-1/2
flushing procedure.
turns past hand tight.
a
c
71515
a - End Cover (Heat Exchanger)

b - Screw
c - O-ring
d - Rubber Gasket
Index
Cold Weather or Extended 1. Remove drain plug from port and starboard ex-
haust manifolds.
Storage
! CAUTION
Seawater section of cooling system MUST BE
COMPLETELY drained for winter storage, or im-
mediately after cold weather use, if the possibil-
ity of freezing temperatures exist or if the boat is
to be stored for an extended period. Failure to
comply may result in trapped water causing
a
freeze and/or corrosion damage to engine.
74073
Seawater Section Draining Starboard Side (Port Side Similar)

Instructions a - Drain Plug
IMPORTANT: Observe the following information 2. Disconnect heat exchanger-to-starboard ex-

to ensure complete draining of cooling system. haust manifold hose at manifold. Lower hose and
allow to drain.
• Engine must be as level as possible.
• A wire should be repeatedly inserted into all
drain holes to ensure there are no obstruc-
tions in passages.
• It may be necessary to lift, lower or bend dis-
connected hoses to allow water to drain com-
pletely.
! CAUTION
If seawater section of the Closed Cooling System b
a
is to be drained with boat in the water, seacock
(water inlet valve), if boat is so equipped, must be
closed or water inlet hose MUST BE discon-
nected from seawater pickup pump and plugged,
to prevent water from flowing into cooling sys-
tem and/or boat.
IMPORTANT: If a seacock (water inlet valve) is to 75212

be installed for draining purpose, valve used Typical Starboard Hose Shown
MUST have an internal cross-sectional area a - Starboard Exhaust Manifold
equal or greater than water inlet hose to prevent b - Starboard Hose
restricting water flow during normal operation. A
1-1/4 in. (32mm) or larger brass ball valve or gate
valve is recommended.
Index
3. Follow instructions “a” or “b”: 4. Repeatedly clean out drain holes using a stiff
a. On Engines With Cool Fuel System: Re-
drained.
move drain plug from Cool Fuel System sea-
water pipe. 5. Remove end cover, attaching screw, O-ring and
rubber gasket, from port and starboard ends of
heat exchanger.
IMPORTANT: Use compressed air to blow any

remaining water from tubes in the heat
exchanger.
a b
74988 d
a - Cool Fuel System Cooler
b - Seawater Pipe Drain Plug
b. On Engines Without Cool Fuel System: b

Remove drain plug from port side seawater a
pipe. c
71515
Typical Engine and Heat Exchanger Shown

a - End Cover
b - Screw
a c - O-ring
d - Rubber Gasket
b 74988
a - Seawater Pipe
b - Seawater Pipe Drain Plug
Index
6. Follow instructions “a” or “b”: (2) Crank engine over slightly, with starter
motor, to purge any water trapped in sea-
a. On Engines WITHOUT Engine Mounted water pickup pump. Do not allow engine
Seawater Pump: Proceed to Step 7. to start.
b. On Engines Equipped WITH Engine 7. After cooling system has drained completely, re-
Mounted Seawater Pump: install drain plugs and connect all seawater
hoses. Tighten each securely.
(1) Disconnect water inlet and outlet hose
from seawater pump. Lower hoses and
allow to drain. Reconnect hoses and ! CAUTION
tighten clamps securely. If boat is in the water, water inlet valve (if so
equipped) MUST be left closed until engine is to
c be restarted, to prevent water from flowing back
into cooling system. If boat is not fitted with a
valve, water inlet hose MUST BE left discon-
nected and plugged. As a precautionary mea-
sure, attach a tag to the ignition switch or steer-
ing wheel with the warning that the valve MUST
BE opened or the hose reconnected prior to start-
ing the engine.
a
b
74942
a - Seawater Pump
b - Seawater Pump Inlet Hose
c - Seawater Outlet Hose
Index
Serpentine Drive Belt Adjustment
1. Loosen 5/8 in. locking nut on adjustment stud.
Leave wrench on adjustment stud.
a 74931
Belt Routing WITH Power Steering and WITHOUT

74908
Engine Mounted Seawater Pump
Typical
a - 5/8 In. Locking Nut
b - Adjustment Stud
2. Install drive belt on pulleys. Route belt for your

type of power package.
3. Belt deflection is to be measured on the belt at the
location that has the longest distance between
two (2) pulleys.
4. Use 5/16 in. socket and tighten adjusting stud
until the correct deflection of 1/4 in. (6 mm) (with
moderate thumb pressure, on the belt at location
74930
indicated by arrow and dashed lines of the belt)
is obtained at location shown. Belt Routing WITHOUT Power Steering and
WITHOUT Engine Mounted Seawater Pump
74933
Belt Routing WITH Power Steering and Equipped
WITH Engine Mounted Seawater Pump
a
74908
Typical
a - 5/8 In. Locking Nut
b - Adjustment Stud
74932 5. Operate the engine for a short period of time. Re-

Belt Routing WITHOUT Power Steering and check belt adjustment.
Equipped WITH Engine Mounted Seawater Pump
Index
Auxiliary Hot Water Heater SUPPLY HOSE CONNECTION
Installation
IMPORTANT: When connecting a cabin heater or c
hot water heater, certain requirements must be
b
met.
• Supply hose (from engine to heater) and re-
turn hose (from heater to engine) MUST NOT
EXCEED 5/8 in. (15.8 mm) I.D. (inside diame- a
ter).
• Engine with a Closed Cooling System: Heater
MUST BE LOWER than fill cap on the heat ex-
changer. If the heater is higher than the fill cap
on the heat exchanger and some coolant is
lost in the system, an air pocket may form in
the closed cooling system. This, in turn, can
cause the engine to overheat. 72708
• Make heater connections ONLY at locations
described in the following instructions. Primary Location
a - Plug
• Check complete system for leaks after heater b - Reducer Bushing
is connected into cooling system. c - Hose Connector
• Check for overheating condition (of engine)
after heater is connected.
1. Refer to “Changing Coolant - Draining Instruc-

tions”; drain closed cooling system.
2. Inspect for appropriate location of supply hose at
following:
NOTE: Hot water heater supply hose can be con-
nected at several different locations. On some mod-
els, there may be other accessories and options that
are utilizing these hot water supply locations. One of a
the following should be available for use when install-
ing a hot water heater system.
IMPORTANT: Do not reposition engine tempera-
75210
ture switch; it must remain where installed by
factory. Alternate Location
a - Location for Hot Water Supply (Install Bayonet
Fitting Here)
Index
RETURN HOSE CONNECTION
72705
Earlier Style Quicksilver Kit Location

a - T-Fitting
b
a
72702
Later Style Quicksilver Kit Location

a - Pipe Plug
b - Hose Connector
c - T-Fitting
d - Hose Clamps
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
EXHAUST SYSTEM
7
72699 A
GENERAL
Index
Table of Contents
Page
Exhaust System Requirements . . . . . . . . . . . . . 7A-1
Determining If Exhaust Elbow Risers
Are Required . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
MCM (Stern Drive) Engines With Thru
Transom Exhaust . . . . . . . . . . . . . . . . . . . . . 7A-1
MIE (Inboard) Engines . . . . . . . . . . . . . . . . . 7A-2
Exhaust Hose Connection . . . . . . . . . . . . . . 7A-2
Exhaust Tube Requirements . . . . . . . . . . . . . . . 7A-3
Index
7A-0 - GENERAL 90-823225--1 1096
Exhaust System MCM (Stern Drive) Engines With Thru
Transom Exhaust
Requirements
When designing and installing exhaust system, the
IMPORTANT: It is the responsibility of the boat following must be observed:
manufacturer or installing dealer to properly lo-
cate the engine and install the exhaust system.
Improper installation may allow water to enter the Minimum Hose Size
exhaust manifolds and combustion chambers Model Single Outlet Dual Outlet
and severely damage the engine. Damage All 4 in. (102 mm) 3 in. (76 mm)
caused by water in the engine will not be covered
by MerCruiser Limited Warranty, unless this
damage is the result of defective part(s). 1. Exhaust flanges must be of proper size to accom-
modate 4 in. (102 mm) I.D. exhaust hoses. They
must also be equipped with internal water shut-
Determining If Exhaust Elbow Risers ters, and use an exhaust flapper over each outlet.
Are Required 2. The exhaust hoses and pipes must not be higher
than exhaust elbows at any point.
On all engines to determine if exhaust elbow risers
are required, take measurements (a) and (b), with 3. The exhaust outlet must be located so that a mini-
boat at rest in the water and maximum load aboard. mum of 1/2 in. (13 mm) drop per foot (305 mm)
Subtract (b) from (a). If (a) minus (b) is less than spe- downward pitch exists in the exhaust hose from
cified in chart, select appropriate size exhaust elbow the engine exhaust elbow to the outlet. (This is an
riser kit and exhaust extension kit that will correctly American Boat & Yacht Council recommenda-
position exhaust elbow. tion.) The drop must be constant so that a low
spot does not exist at any point in the exhaust
hose.
4. Exhaust outlet must be slightly above the water-
line with boat at rest in the water and full load
aboard.
5. Back pressure must not exceed 4 in. (102 mm) of
mercury when measured with a mercury manom-
eter to exhaust elbow outlets.
72700
Exhaust Elbow Measurement
a - From Waterline To Top Of Transom
b - From Highest Point On Exhaust Elbow To Top Of Transom
(a) Minus (b) Must Be

Model
at Least
All 13 In. (330 mm)
Index
90-823225--1 1096 GENERAL - 7A-1
MIE (Inboard) Engines Exhaust Hose Connection
When designing and installing exhaust system, it is 1. Exhaust hoses must be connected to exhaust el-
very important that the following additional points be bows so that they do not restrict the flow of dis-
taken into consideration: charge water from the elbow. If hoses are con-
nected incorrectly, a hot spot in the hose can
1. System layout and construction must prevent
occur, and can eventually burn through.
cooling system discharge water from flowing
back into engine and also must prevent seawater
from entering engine via exhaust at any point.
2. The exhaust hoses and pipes must not be higher
than exhaust elbows at any point. a
3. The exhaust outlet (for routing exhaust to outside

of boat) must be located so that a minimum of 1/2
in. (13 mm) per foot (305 mm) downward pitch
(drop) exists in the exhaust hose or pipe from the
engine exhaust elbow to the outlet, with a mini-
b
mum drop of 4 in. (102 mm) overall. (This is an
American Boat & Yacht Council recommenda-
tion.) The drop must be constant so that a low
spot does not exist at any point in the exhaust
hose or pipe.
4. Exhaust outlet must be slightly above the water-
line with boat at rest in the water and full load
aboard. Exhaust outlet should be equipped with 72538
an internal shutter to prevent seawater from run-
ning back into exhaust system. The use of an ex- a - Correct Connection
haust flapper on each outlet also is recom- b - Incorrect Connection
mended.
2. Exhaust hoses must be secured at each connec-
5. System must not cause excessive back pres-
tion with two hose clamps.
sure. Back pressure MUST NOT exceed 4 in.
(102 mm) of mercury when measured with a mer-
cury manometer at exhaust elbow outlets. Mini-
mum exhaust hose sizes are given in chart.
Minimum Hose Size

Model Single Outlet Dual Outlet
All (Except
5 in. (127 mm) 4 in. (102 mm)
Magnums)
Index
7A-2 - GENERAL 90-823225--1 1096
Exhaust Tube Requirements
IMPORTANT: When installing thru-transom ex-
haust, it is recommended that the exhaust
bellows on the transom assembly be removed.
This is necessary to avoid creating a vacuum at
the exhaust outlet in the propeller at higher boat
speeds. This vacuum could degrade propeller
performance on some boats.
IMPORTANT: When installing thru-propeller ex-

haust:
• With any application, installation of an ex-
haust tube will increase exhaust noise.
• With Bravo One and Bravo Two Drives an ex-
haust tube MAY BE INSTALLED for a slight in-
crease in performance.
• With a Silent Choice Exhaust System the ex-
haust bellows must be removed and an ex-
haust tube MUST BE INSTALLED.
• With most Bravo Three Drive Models an ex-
haust tube MAY BE INSTALLED for a slight in-
crease in performance.
Index
90-823225--1 1096 GENERAL - 7A-3
AT A LATER DATE
Index
7A-4 - GENERAL 90-823225--1 1096
EXHAUST SYSTEM
7
72695
B
MANIFOLDS AND ELBOWS
Index
Table of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 7B-1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 7B-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2
Index
7B - MANIFOLDS
7B-0 AND
- MANIFOLDS ELBOWS
AND ELBOWS 90-823225--1 1096
Torque Specifications 7. Remove exhaust manifold fasteners; remove
manifold assembly and discard gaskets.
Fastener Location Lb. Ft. N·m a
Hose Clamp Securely
Exhaust Elbow
25 34 b
Exhaust Manifold
Sealants
e c
Quicksilver Perfect Seal 92-34227-1 d
Removal
f
! WARNING
72695
Avoid possible injury or damage to equipment Stainless Steel Elbow With Restrictor Gasket
should wires be accidentally shorted. Discon- a - Exhaust Elbow
nect BOTH battery cables from battery before b - Bolts (4)
proceeding. c - Gasket-Seawater Cooled (Aligned As Shown)
d - Exhaust Manifold Assembly
1. Disconnect battery cables from battery. e - Plug
! CAUTION a
To avoid severe engine damage. Exhaust elbows

and manifolds MUST BE drained to prevent water
(or coolant) from entering combustion chambers b
when exhaust elbows are removed.
2. Drain water from manifold and exhaust elbow.
(Refer to SECTION 6A or 6B.)
3. Disconnect exhaust bellows and cooling hoses. e
c
4. Starboard Manifold:
d
a. Disconnect both shift cables (MCM only).
b. Disconnect instrument harness plug from en-
gine harness, if mounted on exhaust elbow.
c. Remove shift plate assembly from exhaust f
elbow (MCM only).
72696
d. Remove bolt holding bracket for Quicksilver
Water Separating Fuel Filter to exhaust man- Stainless Steel Elbow With Separator Gasket
ifold. a - Exhaust Elbow
b - Bolts (4)
5. Port Manifold: c - Manifold Separator Gasket
d - Exhaust Manifold Assembly
a. Remove remote oil filter and bracket. e - Plug
b. Remove ignition module from exhaust elbow
(if so equipped).
6. Remove exhaust elbow.
Index
90-823225--1 1096 MANIFOLDS AND ELBOWS - 7B-1
Cleaning and Inspection 5. Install exhaust elbows and cooling hoses.
1. Clean gasket material from all surfaces and wash 6. On Closed Cooled Models: Refill closed cool-
parts in solvent. ing system to operating level with properly mixed
coolant. Refer to SECTION 6B.
2. Inspect all parts carefully. Machined surfaces
must be clean and free of all marks and deep 7. Reconnect battery cables to battery. Tighten se-
scratches, or water and exhaust leaks may re- curely.
sult. 8. Start engine and check for fuel, exhaust and
3. Check water passages for foreign material. Pas- water leaks.
sages must be clean for efficient cooling.
4. If more thorough inspection is desired, pipe plugs
may be removed from exhaust manifold and ex-
haust elbow. b
IMPORTANT: If plugs are removed, coat threads
a
with Quicksilver Perfect Seal before reinstalling.
5. Check for cracks.
6. To test manifold body for leaks, block-off plates, e c
plugs, or short hoses with plugged ends must be
used. One block-off plate must have a threaded d
hole for attaching compressed air hose. Use new
gaskets when installing block-off plate(s). Apply
40 PSI (276 kPa) of air pressure and submerge
manifold in water. Air bubbles will indicate a leak.
f
Installation 72695
1. Using new gasket, install exhaust manifold to cyl- Stainless Steel Elbow With Restrictor Gasket
inder head. Torque fasteners to 25 lb. ft. (34 N·m). (Cast Iron Elbow Similar)
a - Exhaust Elbow
IMPORTANT: See Section 7C if exhaust risers are
b - Bolts (4)
used. c - Gasket - Seawater Cooled (Aligned As Shown)
2. Using a new gasket, install exhaust elbow to d - Exhaust Manifold
exhaust manifold. Torque fasteners to 25 lb. ft. e - Plug
(34 N·m).
3. Port Manifold:
a. Install remote oil filter and bracket.
b. Install ignition module on exhaust elbow (if so
equipped).
4. Starboard Manifold:
a. Install bolt to secure Quicksilver Water Sepa-
rating Fuel Filter bracket to exhaust manifold.
b. Install shift plate assembly on exhaust elbow
(MCM only).
c. Connect instrument harness plug to engine
harness, if disconnected previously.
d. Connect both shift cables (MCM only).
Index
7B-2 - MANIFOLDS AND ELBOWS 90-823225--1 1096
b
a
e
c
72696
Stainless Steel Elbow With Separator Gasket
(Cast Iron Elbow Similar)
a - Exhaust Elbow
b - Bolts (4)
c - Gasket - Seawater Cooled (Aligned As Shown)
d - Exhaust Manifold
e - Plug
f - Bolts (4)
Index
90-823225--1 1096 MANIFOLDS AND ELBOWS - 7B-3
AT A LATER DATE
Index
7B-4 - MANIFOLDS AND ELBOWS 90-823225--1 1096
EXHAUST SYSTEM
7
70593 C
RISERS
Index
Table of Contents
Page
Exhaust Riser (Kit) Identification . . . . . . . . . . . . 7C-1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-1
Replacement Information . . . . . . . . . . . . . . . . . . 7C-1
Engine Preparation and Parts Removal . . . 7C-1
Engine Preparation and Component
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-2
Exhaust Extension Kit Installation . . . . . . . . 7C-3
Installation Diagrams . . . . . . . . . . . . . . . . . . . . . 7C-3
Cast Iron Elbows . . . . . . . . . . . . . . . . . . . . . . 7C-4
Cast Iron Elbows With Mufflers . . . . . . . . . . 7C-4
Stainless Steel Elbows . . . . . . . . . . . . . . . . . 7C-5
Stainless Steel Elbows With Mufflers . . . . . 7C-5
Index
7C - RISERS
7C-0 - RISERS 90-823225--1 1096
Exhaust Riser (Kit) Replacement Information
Identification
Engine Preparation and Parts
IMPORTANT: All listed MCM and MIE Models can Removal
be adapted to 9 inch (228 mm) exhaust risers by
stacking 3 inch (76 mm) riser kit (93320A7) and
the 6 inch (152 mm) riser kit (9322A4) with stain- ! WARNING
less steel elbows.
Avoid possible injury or damage to equipment
should wires be accidentally shorted. Discon-
nect BOTH battery cables from battery before
Torque Specifications proceeding.
Fastener Location Lb. Ft. N·m 1. Disconnect battery cables from battery.
Exhaust Elbow
27 37 ! CAUTION
Exhaust Riser
Avoid severe engine damage. Exhaust elbows
and manifolds MUST BE drained to prevent water
(or coolant) from entering combustion chambers
Sealants when exhaust elbows are removed.

2. Drain exhaust elbows and exhaust manifolds.
3. Remove any items attached to the elbows on the
engine and carefully lay them aside. Remember
their positioning for reassembly later.
4. Remove fasteners retaining exhaust elbows and
risers to manifolds and retain. Remove exhaust
elbows.
5. Remove and discard old gaskets. Clean gasket
mating surfaces on elbows, manifolds and risers.
Index
90-823225--1 1096 RISERS - 7C-1
Engine Preparation and 6. Assemble harness bracket and plastic backup
plate, if so equipped, using four small screws.
Component Removal
1. Assemble studs to exhaust manifold and position
all gaskets as shown between risers. Refer to “In-
stallation Diagrams” at the end of this section. a
IMPORTANT: Restrictor gaskets or manifold sep- c
arator gaskets must be installed in order shown.
! CAUTION
If engine is equipped with closed cooling, MAN- c
IFOLD SEPARATOR GASKET MUST BE IN-
STALLED ONLY ON EXHAUST MANIFOLD. Fail- d
ure to install separator gaskets on exhaust
e
manifolds, or to install in a location other than
shown, will result in severe engine damage. 70244
2. Install elbow on riser(s) and studs. Attach using Bracket For 6 Inch (152 mm) Riser
nuts and washers. a - Riser Bracket
b - Harness Plate
NOTE: Drain plugs in risers must be positioned fac- c - Back-Up Plate (1) - Screws (4) 7/8 In. (22 mm)
ing flywheel end of engine, unless otherwise noted. d - Screws (6) 3/4 In. (19 mm)
3. Torque all fasteners, in a diagonal pattern, to 27 e - Nuts (6)
lb. ft. (37 N·m).
7. Refill closed cooling system, if so equipped. (Re-
4. Place spacers between riser plate, if so fer to SECTION 6B - “Closed Cooled Models.”)
equipped, and fasten with existing nuts. Tighten
securely. 8. Upon first start-up of engine check for leaks.
5. Reattach and tighten securely all parts previously
removed from elbow to appropriate position on
riser bracket, if so equipped.
IMPORTANT: On elbows with ignition amplifier,
be sure to reconnect amplifier and wiring har-
ness ground wires to one of the attaching screws
and that amplifier spacers are installed between
amplifier and exhaust elbow. Tighten screws se-
curely.
IMPORTANT: On elbows with shift plate (MCM
only) reinstall shift plate and tighten fasteners
securely, then readjust shift cables as outlined in
Index
7C-2 - RISERS 90-823225--1 1096
Exhaust Extension Kit Installation
1. Install appropriate exhaust extension (see “Addi-
tional Kits”) for MCM Models with thru prop ex-
haust, using two hose clamps at each end.
b
50930
Typical Exhaust Extension (See “Additional

Kits” at Front of Section for Kit Part Number)
a - Cut Along Bottom Edge Of Welt For With 3in. (76 mm)
Riser
b - Leave Full Length For Use With 6 In. (152 mm) Riser
2. Tighten hose clamps securely.

3. Upon first start-up of engine check for leaks.
Installation Diagrams
IMPORTANT: Remember what type of gasket
(open, restrictor or separator) is on exhaust man-
ifold after removing the exhaust elbow.
70622
A B
a - Restrictor and Open Gasket

b - Separator Gasket
1. Position gaskets (REFER TO EXPLODED

VIEWS “A” OR “B” ON FOLLOWING PAGES),
install elbows to risers and attach using nuts
and washers from kit. Torque to 23-32 Ft. Lb.
(32-43 N·m).
Index
90-823225--1 1096 RISERS - 7C-3
Cast Iron Elbows Cast Iron Elbows With Mufflers
J J
i i i i
f f a
a
f c
e d
b
c c
d b d
d e
h g h g
h g h g
A B
70621 A B
70622
a - Exhaust Elbow
b - Separator Gasket a - Exhaust Elbow
c - 3 Inch (76 mm) Exhaust Riser b - Muffler Spacer 1-1/4 Inch (32 mm)
d - Open Gasket c - Open Gasket
e - Restrictor Gasket d - Exhaust Riser 3 Inch (76 mm)
f - Nut (8) e - Separator Gasket
g - Stud (8) 9-3/8 Inch (238 mm) f - Restrictor Gasket
h - Stud (8) 10-3/8 Inch (264 mm) Used With Remote Oil Filter g - Nut (8)
i - Washer (8) h - Stud (8) 9-3/8 Inch (238 mm)
j - Exhaust Manifold i - Stud (8) 10-3/8 Inch (264 mm) Used With Remote Oil Filter
j - Washer (8)
k - Exhaust Manifold
Index
7C-4 - RISERS 90-823225--1 1096
Stainless Steel Elbows Stainless Steel Elbows With Mufflers
e e
e f f
e
b
f f
b J i
g
i g
i
h
h
g J
i k
d c d c
d c d c
a
a
A B A B
70593 70602
a - Exhaust Manifold a - Exhaust Manifold

b - Exhaust Elbow b - Exhaust Elbow
c - Stud 6-1/2 Inch (165 mm) c - Stud 9-3/8 Inch (238 mm)
d - Stud 7-1/2 Inch (191 mm) For Use With Remote Oil Filter d - Stud 10-3/8 Inch (264 mm) For USe With Remote Oil Filter
e - Nuts (8) e - Washers (8)
f - Washers (8) f - Nuts (8)
g - Open Gasket g - Muffler Spacer
h - 3 Inch (76 mm) Riser h - 3 Inch (76 mm) Riser
i - Restrictor Gasket i - Open Gasket
j - Separator Gasket j - Restrictor Gasket
k - Separator Gasket
Index
90-823225--1 1096 RISERS - 7C-5
Maintenance Instructions
Maintenance inspection is owner’s responsibility and
must be performed at intervals specified in owner’s
“Operation and Maintenance Manual”.
1. Check to ensure exhaust elbow and manifold fas-
teners are adequately tightened.
2. Check to ensure hose clamps are adequately
tightened.
3. Check area around exhaust elbows, manifolds
and riser gaskets for leakage. Replace gaskets,
if necessary.
4. IF THE POSSIBILITY OF FREEZING EXISTS,
remove drain plug from the exhaust elbow riser
and allow water to drain completely. Install drain
plug with Quicksilver Perfect Seal applied to
threads. In closed cooling MCM 454 / 502 Mag-
num and MIE 8.2L Bluewater Inboard en-
gines, remove water hose to allow water to
drain.
! CAUTION
Water must be completely drained from exhaust
elbow riser during freezing temperatures. Failure
to perform draining procedures can cause se-
vere damage.
Index
7C-6 - RISERS 90-823225--1 1096
AT A LATER DATE
Index
90-823225--1 1096 RISERS - 7C-7
EXHAUST SYSTEM
7
72737 D
COLLECTORS
Index
Table of Contents
Page
Lubricants/Sealants/ Adhesives . . . . . . . . . . . . 7D-1
Shutter Replacement . . . . . . . . . . . . . . . . . . . 7D-1
Component Replacement . . . . . . . . . . . . . . . 7D-2
Thru-Transom Exhaust . . . . . . . . . . . . . . . . . . . . 7D-3
Shutter Replacement . . . . . . . . . . . . . . . . . . . 7D-3
Component Replacement . . . . . . . . . . . . . . . 7D-3
Below Swim Platform Exhaust Pipe Kit . . . . . . 7D-3
Modifying Swim Platform Exhaust Pipe,
If Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-4
Silent Choice Exhaust System . . . . . . . . . . . . . 7D-4
Exhaust Bellows Removal and Exhaust
Tube Installation . . . . . . . . . . . . . . . . . . . . . . 7D-4
Air Tube Routing . . . . . . . . . . . . . . . . . . . . . . 7D-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-6
Exhaust Muffler Kit . . . . . . . . . . . . . . . . . . . . . . . 7D-7
Cleaning and Inspection . . . . . . . . . . . . . . . . 7D-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-8
Maintenance Instructions . . . . . . . . . . . . . . . 7D-8
Index
7D-0 - COLLECTORS 90-823225--1 1096
Torque Specifications Shutter Replacement
IMPORTANT: Engine does not have to be re-
Fastener Location Lb. Ft. N·m moved to change shutters.
Block-Off Plate 1. Loosen clamps and remove exhaust pipe elbow
and exhaust hose.
Exhaust Pipe to Gimbal
Housing 2. Replace water shutter as shown.
Exhaust Pipe to Tee Pipe 3. Reinstall pipe elbow and hose. Tighten clamps
20-25 27-34 securely.
Tee Pipe to Gimbal Housing
Upper Exhaust Pipe to Lower
Exhaust Pipe
Exhaust Elbow
Air Pump Mount a b
c d
Muffler End Plate
Mode Switch S
Securely
l
Hose Clamps
Water Shutter Screw/Nut
Lubricants/Sealants/
Adhesives a
c
Quicksilver 2-4-C Marine
92-825407A3
Lubricant With Teflon
Loctite 35 92-59328-1
Loctite Primer 92-59327-1
Quicksilver Bellows Adhesive 92-86166
Quicksilver Perfect Seal 92-34227-1 72729
Quicksilver Liquid Neoprene 92-25711-2 Earlier Style Shutter

Quicksilver Sound Blanket a - Top Of Pipe
92-25234 b - Shoulder Bushing
Glue
c - Water Shutter
d - Shaft
Index
90-823225--1 1096 COLLECTORS - 7D-1
a c a
b
a
a
a d
b
c e
f
Later Style Shutter
a - Exhaust Flapper 72737
b - Rubber Grommets
a - Clamps
b - Exhaust Pipe Elbow
c - Exhaust Hose
Component Replacement d - Water Shutters
e - Bolts and Lockwashers
To replace any components(s) in exhaust system, f - Exhaust Pipe
the following must be adhered to:
• All mating joint surfaces must be clean.
• O-ring must remain in groove to properly seal
joints to prevent leakage.
• Torque all bolts to 20-25 lb. ft. (27-34 N·m).
• Tighten all clamps securely.
72736
a - Mating Surface
b - O-Ring
Index
7D-2 - COLLECTORS 90-823225--1 1096
Thru-Transom Exhaust Component Replacement
a
d
Shutter Replacement
IMPORTANT: A block off plate must be installed e
when using thru-transom exhaust or below swim
platform kits. g
h
b
c
b f
a 72740
Transom Exhaust Kit

a - Screw And Nut (4)
b - Support Member
22057 c - Water Shutter (Hinge Must Be Vertical)
d - Gasket
a - Block Off Plate
e - Exhaust Flange
b - Bolts (4)
f - Bolts, Washers and Nuts (3)
g - Clamp
1. Remove exhaust hose clamps, then hose. h - Cover (Flapper)
2. Chisel rivets away from both support members.
c Below Swim Platform

d Exhaust Pipe Kit
This exhaust kit may be used on any MerCruiser
Bravo installation having a 4 in. (102 mm) exhaust
elbow.
a
b
c 27761
a - Shutter Hinge
b - Water Shutter - Opens Toward Outside Of Boat
c - Support Member
d - Rivets (4)
a 72742
b
3. Install new shutter as shown in “Component Re-
placement” following. Tighten screws and nut se- a - 8 Per Kit
curely. b - 2 Per Kit
4. Reinstall exhaust hose. Tighten clamps securely.
Index
90-823225--1 1096 COLLECTORS - 7D-3
Modifying Swim Platform Exhaust Silent Choice Exhaust
Pipe, If Required
System
If engine is equipped with thru-prop exhaust, a
thru-transom kit [4 in. (102 mm)], two exhaust bel-
ENGINE
lows, and eight bellows hose clamps, are required.
If engine is equipped with thru-transom exhaust, an
exhaust pipe kit (P/N 44266A6) is required, contain-
ing the exhaust pipe and necessary parts.
IMPORTANT: When installing Silent Choice ex-
haust, it is recommended that the exhaust bel-
a lows on the transom assembly be removed. This
is necessary to avoid creating a vacuum at the
exhaust outlet in the propeller at higher boat
speeds. This vacuum could degrade propeller
TRANSOM performance on some boats.
72743 ! CAUTION
a - Cut Line (See Notes) It is the responsibility of the boat manufacturer or
installing dealer to properly locate the engine
NOTE: If riser kits are installed, or if more vertical and install exhaust system. Improper installation
drop is required, cut “a” must be made, and the upper may allow water to enter the exhaust manifolds
and lower sections of the pipe rejoined with a 4 in. and combustion chambers, and severely dam-
(102 mm) I.D. exhaust hose of the required length. age the engine. Damage caused by water in the
Secure with hose clamps. engine will not be covered by MerCruiser Warran-
NOTE: Prime/paint any raw (cut) aluminum surface. ty, unless this damage is the result of defective
part(s).
IMPORTANT: Each exhaust bellows must be

double clamped at each connection, and the Exhaust Bellows Removal and
hose clamps tightened to 30-40 lb. in. (3-5 N·m).
Exhaust Tube Installation
1. If required, remove and discard clamps and bel-
lows from gimbal housing.
a
22116
Index
7D-4 - COLLECTORS 90-823225--1 1096
2. If required, install exhaust tube on gimbal hous- ! CAUTION
ing as follows:
It is the responsibility of the boat manufacturer or
3. Remove and discard clamps and exhaust bel- installing dealer to properly locate the engine
lows. and install exhaust system. Improper installation
may allow water to enter the exhaust manifolds
! CAUTION and combustion chambers, and severely dam-
Exhaust tube clamp may corrode if grounding age the engine. Damage caused by water in the
clip is not installed. engine will not be covered by MerCruiser Warran-
ty, unless this damage is the result of defective
a. Install grounding clip on tube. part(s).
NOTE: Bellows adhesive is not used when installing
an exhaust tube. a b
b
(1) Position tube so that “SIDE” markings on
tube are facing toward the right and left
sides.
(2) Install clamp.
(3) Tighten clamp. Torque to 35 lb. in.
(4 N·m). b
e
d
72539
22184
a - Silencer Valve Assembly
b - Hose Clamps
c
a b
22184
a - Exhaust Tube
b - Clamp
c - “Side” Marking
d - Exhaust Tube
e - Grounding Clip
Index
90-823225--1 1096 COLLECTORS - 7D-5
Air Tube Routing Maintenance
1. Air Intake Filter (32-17272) must be checked
1. Route air tubing from air pump to silencer valve once each year. If filter is clogged or partially
cylinders. Do not route air tubing close to hot sur- clogged, replace. The filter pad is glued in, and
faces - excessive heat will damage air tubes. may be removed with a needle-nose pliers.
Clean surface in casting, apply a single dot of
Quicksilver Sound Blanket Glue to center of cast-
ing, and install new filter. Be careful not to coat fil-
ter or clog air intake holes with adhesive.
d a e
d J
b c
d
f g
c b e c
72775
Single Engine
a - Air Tube
b - T-Fittings
c - Air Pump Assembly
d - Air Tube To Air Cylinder - On Each Silencer Valve
k h
d d d
a
d i
72534
a - Mode Switch
c b - Keyway - Install In DOWN Position
b
c - BROWN Wire To Terminal 3 - Activates Compressor
72776
d - PURPLE Wire - 12 Volt; Connect To 12 Volt Source In
Dual Engine Control Panel Area
e - GRAY Wire To Terminal 1 - Activates Solenoid
a - Air Tube f - Air Pump
b - T-Fittings g - Solenoid
c - Air Pump Assembly h - Check Valve
d - Air Tube To Air Cylinder - On Each Silencer Valve i - Relief Valve - 30 PSI
j - 2 Ft. (610 mm) Ground Wire - Connect To Terminal 2 Must
Be Grounded To Engine
k - Air Intake Filter
Index
7D-6 - COLLECTORS 90-823225--1 1096
2. Lubricate air cylinder-to-silencer pipe flapper at 1-1/4 INCH MUFFLER RISER
clevis and pin, as needed, with Quicksilver 2-4-C INSTALLATION, ONLY
Marine Lubricant.
IMPORTANT: Restrictor gaskets or separator
gaskets must be installed in order shown.
c
d
g e
f
e h
72778 a
a - Lubricate Clevis and Pin with Quicksilver 2-4-C Marine

Lubricant
Exhaust Muffler Kit A B

This muffler, designed for use on all V-8 engines with
72780
Plus Power exhaust systems (4 in., 7 degrees
downward outlets), requires the installation of 1-1/4 A - Without Separator Gasket
in. (32 mm) exhaust elbow risers, which are included B - With Separator Gasket
in the kit. a -
Exhaust Manifold
b -
Exhaust Elbow
IMPORTANT: If a thru-transom exhaust kit other
c -
Bolt (4 Each Manifold)
than the one from Mercury Marine is used, the ex- d -
Bolt, Remote OIl Filter Bracket (2)
haust kit must be equipped with internal shutters e -
Gasket - Lightly Coat Both Sides With Quicksilver Perfect
and external flappers. Seal
f - Riser 1-1/4 Inch (32 mm) Height
g - Restrictor Gasket
! CAUTION h - Manifold Separator Gasket
It is the responsibility of the boat manufacturer or NOTE: Drain plugs in risers face toward stern.
installing dealer to properly locate the engine
and install exhaust system. Improper installation
may allow water to enter the exhaust manifolds
and combustion chambers, and severely dam-
age the engine. Damage caused by water in the
engine will not be covered by MerCruiser Warran-
ty, unless this damage is the result of defective
part(s).
Index
90-823225--1 1096 COLLECTORS - 7D-7
Cleaning and Inspection IMPORTANT: A MOLDED exhaust tube MUST be
used at exhaust elbow connection to maintain
1. Disassemble muffler as shown. positive separation of exhaust outlet and muffler
inlet.
b
a a
b
d
d
72782
a - Removable End Plate d
b - 4 Screws Secure End Plate 72781
c - O-Ring Seal a - Muffler
d - Element - When Reassembling, Seat Tab In Slot In Cast- b - Molded Exhaust Tube - Muffler To Elbow
ing
c - Exhaust Hose - Muffler To Thru Transom Fitting - Cut To
Length
2. Clean (using pressurized water) and inspect d - Double Clamp Each Connection (Not Shown On Hose C)
parts, including filter element and O-ring seal. If
required, replace O-ring, securing in place with 2. Double clamp each connection; tighten each
Quicksilver Sound Blanket Glue. clamp securely.
3. Reassemble as shown above. Tighten end plate IMPORTANT: After starting engine, check instal-
screws securely. lation for leaks.
Installation
Maintenance Instructions
1. Install muffler, as shown, into exhaust hose and
molded tube. Fabricate muffler to transom using Maintenance inspection is owner’s responsibility and
4-inch I.D. exhaust hose, cut to required length. must be performed at intervals specified in owner’s
Operation and Maintenance Manual.
NOTE: Removable end of muffler ALWAYS goes to- 1. Check exhaust elbow attaching nuts for ade-
ward exhaust elbow. This places direction marks on quate tightness [20-25 lb. ft. (27-34 N·m)].
muffler body casting at the upper rear corner on the 2. Check hose clamps for adequate tightness.
port side.
3. Periodically check tubes/hoses for soft spots,
brittleness, cracks, and general condition. Re-
place as necessary.
72783
Index
7D-8 - COLLECTORS 90-823225--1 1096
4. As needed, depending on use conditions, re- 5. Reinstall muffler end plate with four screws.
move mufflers, then remove four screws secur- Tighten securely.
ing forward end plate, and remove end plate and
6. Reinstall muffler into tubes/hoses. Double clamp.
element and interior of muffler. Clean thoroughly,
Tighten securely.
at least once each year, using pressurized water.
7. Check area around exhaust elbow and riser gas-
b kets for leakage. Replace gaskets, if necessary.
8. If the possibility of freezing exists, remove drain
plug from exhaust elbow riser and allow water to
drain completely. Reinstall drain plug with Quick-
silver Perfect Seal applied to threads.
! CAUTION
a
Water must be completely drained from exhaust
c elbow riser during freezing temperatures, or wa-
ter may freeze and cause severe damage to riser.
72782
a - Removable End Plate

b - 4 Screws Secure End Plate
c - O-Ring Seal
d - Element - When Reassembling, Seat Tab In Slot In Cast-
ing
a. Check condition of O-ring seal; if dried out or

shrunk below mating surface, remove and re-
place. Clean groove thoroughly.
b. Glue new O-ring seal in groove, using Sound
Blanket Glue. Wipe off excess glue immedi-
ately.
Index
90-823225--1 1096 COLLECTORS - 7D-9
AT A LATER DATE
Index
7D-10 - COLLECTORS 90-823225--1 1096
DRIVES
8
VELVET DRIVE IN-LINE
TRANSMISSION A
Index
Table of Contents
Page
Velvet Drive In-Line (71C and 72C)
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1
Transmission Ratios . . . . . . . . . . . . . . . . . . . 8A-1
Torque Specifications . . . . . . . . . . . . . . . . . . 8A-1
Transmission Fluid Capacities . . . . . . . . . . . 8A-2
Transmission Pressure Specifications . . . . 8A-2
Transmission Output Shaft Rolling
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2
Transmission Fluid Specification . . . . . . . . . 8A-2
Important Information . . . . . . . . . . . . . . . . . . . . . 8A-3
Shift Control and Cables . . . . . . . . . . . . . . . . 8A-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
Transmission Shift Lever . . . . . . . . . . . . . . . 8A-4
Shift Cable Adjustment . . . . . . . . . . . . . . . . . . . . 8A-4
Checking Transmission Fluid Level . . . . . . . . . 8A-4
Changing Transmission Fluid . . . . . . . . . . . . . . 8A-5
Draining Transmission . . . . . . . . . . . . . . . . . . 8A-5
Filling Transmission . . . . . . . . . . . . . . . . . . . . 8A-6
Removal and Installation . . . . . . . . . . . . . . . . . . 8A-7
Pump Indexing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-8
Shift Lever Installation . . . . . . . . . . . . . . . . . . . . 8A-9
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-9
Transmission Repair . . . . . . . . . . . . . . . . . . . . . . 8A-9
Index
8A-0 - VELVET DRIVE IN-LINE TRANSMISSION 90-823225--1 1096
Velvet Drive In-Line (71C and 72C) Specifications
The transmission identification plate is located on the top left side of the transmission. Refer to charts following
to determine engine and transmission combinations
a
d
b c
72839
Transmission Identification Plate

a - Model Number
b - Ratio (in Forward Gear)
c - Serial Number
d - Identification Plate Model Color Code
Transmission Ratios
Identification Plate
Ratio in Forward Gear (NOTE 1 & 2)
Color Code
1:1 Red
1:1 Green
1.5:1
2.5:1
2.91:1 Green
NOTE: 1. This ratio is shown on identification plate. Ratio may be rounded off in some cases.
NOTE 2: These transmissions are for LH (standard) rotation engines, and the propeller shaft rotation is LH
(standard) when in forward gear.
DESCRIPTION Lb. Ft. N·m
Drain Plug (Bushing) 25 34
Fluid Hose to Bushing 25 34
Pump Housing to Adapter 17-22 23-29
Rear Mounts to Transmission 45 61
Shift Lever to Valve 8-11 11-15
Transmission to Flywheel Housing 50 68
Neutral Start Switch 8-11 11-14
Index
90-823225--1 1096 VELVET DRIVE IN-LINE TRANSMISSION - 8A-1
Transmission Fluid Capacities
MODEL U.S. QTS. (LITRES)
71C 1-1/2 (1.3) (See Note)
NOTE: Use dipstick to determine fluid exact level.

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

Neutral Gear Forward Gear Reverse Gear
g
Engine RPM PSI (kPa) PSI (kPa) PSI (kPa)
MIn. Max. Min. Max. Min. Max.
250 70 (483) 70 (483)
600 115 (793) 135 (931) 115 (793) 140 (965) 120 (827) 140 (965)
2000 125 (862) 160 (1103) 125 (862) 160 (1103)
3000 135 (931) 180 (1241)
Transmission Output Shaft Rolling Torque

NOTE: Transmission is not installed on engine, no fluid in transmission. Use torque wrench and socket on cou-
pling nut.
MODEL RATIO Lb. In. N·m

71C 1:1 50 Max. 68 Max.
Transmission Fluid Specification

Transmission Type ATF (Dexron III)
71C Direct Drive X
Index
Important Information On MIE engines equipped with in-line transmissions
having 1:1 or 3:1 gear ratios, transmission output
Shift Control and Cables shaft rotation is the same as engine rotation with
transmission in forward gear. Engine rotation is LH
(CCW), so a LH propeller is required.
! CAUTION
1. DO NOT start or crank engine without fluid in
Shift control and shift cable must position trans- transmission.
mission shift lever exactly as stated in this manu-
2. Use only recommended fluid in transmission.
al, or transmission, as a result of improper shift
lever positioning, will not be covered by 3. Except in an emergency, never shift transmission
Borg-Warner Warranty. at engine speeds above 1000 RPM.
IMPORTANT: Velvet Drive Warranty is jeopar- 4. Free wheeling of one propeller (in a twin engine
dized if the shift lever poppet ball or spring is boat), at trolling speeds, will not cause damage
permanently removed, or if shift lever is reposi- to the transmission; however, boat operation
tioned or changed in any manner. above trolling speed should be avoided. Be sure
proper fluid level exists before free wheeling pro-
Remote control used must position transmission shift
peller.
lever over the letter “F” embossed on transmission
case when remote control is placed in forward gear 5. DO NOT paint shift lever poppet ball and spring.
position. Transmission failure will occur if transmis- An accumulation of paint here will prevent proper
sion shift lever is positioned over the letter “R” and the action of the detent.
wrong rotation propeller is used to propel boat for- 6. Always replace oil cooler and hoses after a trans-
ward. mission failure or prior to installing a new or re-
Remote control also must provide a total shift cable built transmission. Metallic particles from a failure
travel (at transmission end) of at least 2-3/4 in. (70 tend to collect in the cooler and hoses and will
mm). This is necessary to position transmission shift gradually flow back into the fluid system and
lever fully in the forward and reverse gear positions. damage transmission.
Insufficient shift cable travel will cause transmission 7. Always use specified oil cooler, hoses and fit-
to slip and eventually fail. tings. Hoses must be at least 13/32 in. (10.5 mm)
I.D. Oil cooler, hoses and fittings must be suffi-
cient size to maintain transmission fluid (in sump)
Engine at 140-190°F (60-88°C).
Engine rotation is indicated on engine specifications
and serial number decal on flame arrestor cover. En-
gine rotation is described when observed from the Propeller
rear of the engine (transmission end) looking forward Propeller rotation is described when observed from
(water pump end). the rear of the boat (stern) looking forward (bow end).
Installed angle of MIE inboard transmission and The term “left-hand” (LH) refers to rotation in the
engine should not exceed a maximum of 18° of the counterclockwise (CCW) direction. The term
water line. “right-hand” (RH) refers to rotation in the clockwise
(CW) direction. A LH propeller will move the boat for-
ward when rotated counterclockwise. A RH propeller
Transmission will move the boat forward when rotated clockwise.
Propeller rotation is not necessarily the same as en-
Transmission gear ratio (in forward gear) is marked gine rotation.
on transmission identification plate, which is located
on the port (left) side of transmission. Transmission
output shaft rotation and propeller rotation required
is indicated on a decal on transmission case. Trans-
mission rotation is described when viewed from the
rear of transmission with transmission in forward
gear selector position.
Index
Transmission Shift Lever IMPORTANT: To accurately check fluid level, en-
gine must be run at 1500 RPM for 2 minutes im-
The lever has three holes as illustrated following. mediately prior to checking level.
71304
72526
a - Dipstick
b - Full Mark
Shift Cable Adjustment c - Dipstick Tube
Refer to Section 2C - “MIE Models - Borg-Warner 1. Start engine and run at 1500 RPM for 2 minutes
Transmissions.” to fill all hydraulic circuits.
Checking Transmission level.
Fluid Level 2. Stop engine and check fluid level. Add transmis-
IMPORTANT: Use only specified transmission sion fluid, if necessary, to bring level up to full
fluid (see “Specifications”). mark on dipstick.
3. Reinstall dipstick. Be sure to tighten T-handle se-
curely. DO NOT over tighten.
4. If transmission fluid level was extremely low,
carefully check transmission, fluid cooler and
hoses for leaks.
Index
Changing Transmission
Fluid
Draining Transmission
1. Clean area around cooler hose shown and pro-
ceed as follows:
a. Disconnect hose from elbow fitting.
a
b. Remove elbow fitting from bushing.
c. Drain oil from transmission, cooler, and cool-
er hoses into a suitable container.
b 72841
Transmission with Reduction Ratios

a - Hose
b - Bushing
2. Remove bushing, spring and strainer tube from

transmission case. Allow transmission to drain
a completely.
3. Clean strainer tube in suitable solvent.
72840 a b c 71307
Transmission With 1:1 Ratio
a - Bushing
a - Hose
b - Spring
b - Elbow Fitting
c - Plastic Strainer Tube
Index
4. Check oil for the following foreign matter: Filling Transmission
• Metal Particles - A few small particles are IMPORTANT: Use only specified transmission
normal. Larger metal chips are an early sign fluid (see “Specifications”).
of transmission failure which may mean
transmission should be disassembled and in- 1. Remove dipstick. Fill transmission with fluid,
spected for internal damage. through dipstick hole, to bring up to full mark.
• Rubber Particles - Indication of cooler hose
wear. Hoses should be inspected for cracks
or fraying. Replace damaged hoses.
! CAUTION a
Avoid severe transmission damage or possible
failure of transmission. Strainer must be properly b
installed as follows.
5. Install plastic strainer tube with the notch DOWN
and OUT toward the side of the case. c
72526
a - Dipstick
b a b - Full Mark
71306
c - Dipstick Tube
a - Plastic Strainer Tube
b - Notch IMPORTANT: To accurately check fluid level, run
engine at 1500 RPM for 2 minutes immediately
6. Install spring. prior to checking level.
7. Coat bushing threads with Quicksilver Perfect 2. Start engine and run at 1500 RPM for 2 minutes
Seal. Install and torque bushing to 25 lb. ft. to fill all hydraulic circuits.
(34 N·m). NOTE: Be sure to push dipstick all the way down into
8. Coat elbow fitting threads with Quicksilver Per- dipstick tube when checking fluid level.
fect Seal and install in bushing. Tighten securely. 3. Stop engine and quickly check fluid level. Add
9. Reconnect hose and tighten securely. transmission fluid, if necessary, to bring level up
to full mark on dipstick.
4. Reinstall dipstick. Be sure to tighten T-handle
securely.
Index
Removal and Installation 20. Connect wires to neutral start safety switch.
NOTICE 21. Connect tan/blue wire to fluid temperature

switch.
The following procedure describes removal
of transmission without removing engine. If 22. Connect fluid cooler hoses to transmission.
engine must be removed, refer to Section 2 23. Connect and adjust shift cable(s) as outlined in
(see “Table of Contents”). Section 2C - “MIE Models - Velvet Drive Trans-
missions.”
1. Drain transmission fluid.
IMPORTANT: Velvet Drive Transmission Warran-
2. Disconnect fluid cooler hoses. ty is jeopardized if the shift lever poppet ball or
3. Disconnect shift cable. spring is permanently removed, if the shift lever
is repositioned or changed in any manner, or if re-
4. Disconnect wires from neutral start safety switch. mote control and shift cable do not position shift
5. Disconnect TAN/BLUE wire from fluid tempera- lever exactly as shown.
ture switch. F–N–R
6. Disconnect propeller shaft coupling. a
7. Remove four rear mount (to engine bed) bolts.
d
8. Support rear part of engine with either a hoist or
by using wooden blocks under flywheel housing.
b F
9. Remove two center transmission-to-flywheel
housing attaching bolts and install two long
studs. R
IMPORTANT: These two long studs will help sup- c
port weight of transmission during removal and
72601
installation. a - Transmission Shift Lever
10. Remove remaining transmission attaching bolts. b - Shift Lever Must Be Over This Letter when Propelling Boat
FORWARD
11. Pull transmission straight back and off engine. c - Shift Lever Must Be Over This Letter when Propelling Boat
in REVERSE
12. Before installing transmission, check transmis- d - Poppet Ball Must Be Centered in Detent Hole for Each
sion pump indexing for correct rotation. Refer to F-N-R Position (Forward Gear Shown)
“Pump Indexing.”
24. Refer to Section 2C - “MIE Models - Velvet Drive
13. Check transmission output shaft rolling torque.
Transmissions” and check engine final alignment
See “Specifications.”
as outlined.
14. Apply Quicksilver Engine Coupler Spline Grease
25. After engine has been properly aligned, connect
to transmission input shaft splines and engine
propeller shaft coupler to transmission output
drive plate splines.
flange. Attach couplers together with bolts, lock-
15. If removed, install rear engine mounting brackets washers and nuts. Torque to 50 lb. ft. (68 N·m).
(to transmission) as outlined in Section 3 (see
26. Refill transmission with specified fluid. Refer to
“Table of Contents”). Torque to 45 lb. ft. (61 N·m).
“Filling Transmission.”
16. Align transmission splines with drive plate
27. Check for leaks and check fluid level after first
splines.
engine start-up.
17. Slide transmission into place and secure with
bolts.
18. Remove two long studs (installed in Step 9) and
install remaining two bolts. Torque all bolts to 50
lb. ft. (68 N·m).
19. Relieve hoist tension and fasten rear engine
mounts to engine bed. Tighten bolts securely.
Index
Pump Indexing 4. Rotate pump until arrow indicating the proper di-
rection of pump rotation is near the top of trans-
Pump must be correctly indexed to correspond with mission.
engine rotation. If pump is not indexed correctly,
pump will not create fluid pressure allowing the trans- 5. Reinstall four pump-to-adaptor attaching bolts
mission to shift. Pump housing has two arrows, each and torque to 204-264 lb. in. (23-29 N·m).
pointing in a different direction. Pump must be posi-
a
tioned so that the arrow (pointing in the direction that
input shaft and pump will be turned by engine) is at
the top of transmission. b
! CAUTION
Position pump housing with cast arrow at top
c
pointing in the same direction as engine rotation.
IMPORTANT: Some transmissions have letters
“RH” and “LH” on pump housing. Letters DO d
NOT indicate shaft rotation.
c
If pump must be indexed, proceed as follows:
1. Remove four pump attaching bolts. e
2. Loosen the pump housing. A soft tip mallet may

be used to tap the fluid passage boss. Do not
strike the bolt bosses.
72842
IMPORTANT: Do not remove the pump from the
shaft unless a seal protector is used to prevent MIE LH (Standard) Rotation Engine
the shaft splines from cutting the pump seal.
a - Top Of Transmission
Care must be taken to ensure that seal, gasket, b - Word “Top” and Cast Arrow
seal and bolt bosses are kept in good condition c - Pump Attaching Bolts
to prevent leaks in those critical areas. d - Input Shaft
e - Pump Assembly
3. Make sure that pump gasket is not sticking to
housing (to prevent gasket from tearing or fold-
ing) when rotating pump.
Index
Shift Lever Installation Pressure Test
IMPORTANT: Velvet Drive Warranty is jeopar- 1. Install pressure gauge.
dized if the shift lever poppet spring and/or ball
is permanently removed, or if the shift lever is
changed in any manner, or repositioned, or if the
linkage between the remote control and the
transmission shift lever does not have sufficient
travel in both directions.
Shift lever and related parts must be assembled as
shown.
1. Lubricate poppet ball, spring, and holes in shift
lever with Quicksilver 2-4-C Marine Lubricant.
a
2. Install poppet spring and ball. Retain ball by
placing shift lever on shaft.
3. Install flat washer, lockwasher and nut on shaft.
72845
4. Torque nut to 96-132 lb. in. (11-15 N·m).
a - Main Line Pressure Tap - Remove Temperature Switch
2. With boat in water, start engine and run until nor-

mal operating temperature is reached.
3. Refer to “Specifications” (see “Table of Con-
tents”) for pressure readings.
e f Transmission Repair
Mercury Marine does not stock or sell replacement
parts for the in-line transmission. Velvet Drive has a
network of distributors throughout the world to ser-
vice their product. These distributors, in turn, have a
c dealer network to service the transmissions. Also,
a b
service manuals (for each transmission) can be ob-
tained from.
IMPORTANT: Refer to “Special Replacement Part
d 72844 Information” before working on transmission.
Typical Shift Lever For the location of your closest distributor or service
literature contact:
a - Nut
b - Lockwasher Velvet Drive Transmissions
c - Flat Washer Division Of Regal Beloit
d - Shift Lever Theodore Rice Boulevard
e - Poppet Ball
Industrial Park
f - Poppet Spring
New Bedford, MA 02745
Phone: (508) 995-2616
5. After installation, move shift lever through for-
ward, neutral and reverse positions. No more
than finger-tip effort should be required. If valve
binds, cause for binding must be found and cor-
rected.
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
DRIVES
8
VELVET DRIVE V-DRIVE AND
WALTER V-DRIVE TRANSMISSION B
Index
Table of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-1
Transmission Ratios . . . . . . . . . . . . . . . . . . . 8B-1
Torque Specifications . . . . . . . . . . . . . . . . . . 8B-1
Transmission Fluid Capacities . . . . . . . . . . . 8B-2
Transmission Pressure Specifications . . . . 8B-2
Transmission Output Shaft Rolling
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2
Transmission Fluid Specification . . . . . . . . . 8B-2
Important Information . . . . . . . . . . . . . . . . . . . . . 8B-3
Shift Control and Cables . . . . . . . . . . . . . . . . 8B-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-3
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-3
Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-3
Transmission Shift Lever . . . . . . . . . . . . . . . 8B-4
Shift Cable Adjustment . . . . . . . . . . . . . . . . . . . . 8B-4
Checking Transmission Fluid Level . . . . . . . . . 8B-4
Changing Transmission Fluid . . . . . . . . . . . . . . 8B-5
Draining Transmission . . . . . . . . . . . . . . . . . . 8B-5
Filling Transmission . . . . . . . . . . . . . . . . . . . . 8B-6
Removal and Installation . . . . . . . . . . . . . . . . . . 8B-7
Pump Indexing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-8
Shift Lever Installation . . . . . . . . . . . . . . . . . . . . 8B-9
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-9
Transmission Repair . . . . . . . . . . . . . . . . . . . . . . 8B-9
V-Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-9
Index
8B-0 - VELVET DRIVE V-DRIVE AND WALTER V-DRIVE TRANSMISSIONS 90-823225--1 1096
Identification
The transmission identification plate is located on the top left side of the transmission. Refer to charts following
to determine engine and transmission combinations.
a
d
b c
72839
Transmission Identification Plate

a - Model Number
b - Ratio (in Forward Gear)
c - Serial Number
d - Identification Plate Model Color Code
Transmission Ratios
Identification Plate
Ratio in Forward Gear (NOTE 1 & 2)
Color Code
1.5:1
1 99:1
1.99:1 R d
Red
2.49:1
NOTE: 1. This ratio is shown on identification plate. Ratio may be rounded off in some cases.
DESCRIPTION Lb. Ft. N·m
Drain Plug (Bushing) 25 34
Fluid Hose to Bushing 25 34
Pump Housing to Adapter 17-22 23-29
Rear Mounts to Transmission 45 61
Shift Lever to Valve 8-11 11-15
Transmission to Flywheel Housing 50 68
Neutral Start Switch 8-11 11-14
Index
90-823225--1 1096 VELVET DRIVE V-DRIVE AND WALTER V-DRIVE TRANSMISSIONS - 8B-1
Transmission Fluid Capacities
MODEL U.S. QTS. (LITRES)
Velvet Drive 71C V-Drive 3 (2-3/4) (See Note)
Walter RV26D V-Drive 1 (.9)
NOTE: Use dipstick to determine fluid exact level.

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

Neutral Gear Forward Gear Reverse Gear
g
Engine RPM PSI (kPa) PSI (kPa) PSI (kPa)
MIn. Max. Min. Max. Min. Max.
250 70 (483) 70 (483)
600 115 (793) 135 (931) 115 (793) 140 (965) 120 (827) 140 (965)
2000 125 (862) 160 (1103) 125 (862) 160 (1103)
3000 135 (931) 180 (1241)
Transmission Output Shaft Rolling Torque

NOTE: Transmission is not installed on engine, no fluid in transmission. Use torque wrench and socket on cou-
pling nut.
MODEL Lb. In. N·m

71C V-Drive (All Ratios) 50 Max. 68 Max.
Transmission Fluid Specification

Velvet Drive 71C V-Drive Mobil 424
SAE 30 Heavy Duty Motor Oil
Walter RV-26D V-Drive Exxon Spartan EP-68 Gear Oil
APG-80 Gear Oil
NOTE: Transmissions (except reduction drive transmissions) supplied with Mobil 424 can be changed to ATF
Dexron III, but transmission must be flushed and refilled at least twice (this includes lines and cooler).
Index
Important Information On MIE engines which are equipped with V-drive
transmissions, transmission output shaft rotation is
Shift Control and Cables the same as engine rotation with transmission in for-
ward gear. Because of reversed engine mounting po-
sition, however, a RH propeller is required, if engine
! CAUTION is LH (CCW) rotation; or a LH rotation propeller is re-
quired, if engine is RH (CW) rotation.
Shift control and shift cable must position trans-
mission shift lever exactly as stated in this manu- 1. DO NOT start or crank engine without fluid in
al, or transmission, as a result of improper shift transmission.
lever positioning, will not be covered by Velvet
2. Use only recommended fluid in transmission.
Drive Warranty.
3. Except in an emergency, never shift transmission
at engine speeds above 1000 RPM.
IMPORTANT: Velvet Drive Warranty is jeopar-
dized if the shift lever poppet ball or spring is 4. Free wheeling of one propeller (in a twin engine
permanently removed, or if shift lever is reposi- boat), at trolling speeds, will not cause damage
tioned or changed in any manner. to the transmission; however, boat operation
above trolling speed should be avoided. Be sure
Remote control used must position transmission shift
proper fluid level exists before free wheeling pro-
lever over the letter “F” embossed on transmission
peller.
case when remote control is placed in forward gear
position. Transmission failure will occur if transmis- 5. DO NOT paint shift lever poppet ball and spring.
sion shift lever is positioned over the letter “R” and the An accumulation of paint here will prevent proper
wrong rotation propeller is used to propel boat for- action of the detent.
ward.
6. Always replace oil cooler and hoses after a trans-
Remote control also must provide a total shift cable mission failure or prior to installing a new or re-
travel (at transmission end) of at least 2-3/4 in. (70 built transmission. Metallic particles from a failure
mm). This is necessary to position transmission shift tend to collect in the cooler and hoses and will
lever fully in the forward and reverse gear positions. gradually flow back into the fluid system and
Insufficient shift cable travel will cause transmission damage transmission.
to slip and eventually fail.
7. Always use specified oil cooler, hoses and fit-
tings. Hoses must be at least 13/32 in. (10.5 mm)
I.D. Oil cooler, hoses and fittings must be suffi-
Engine cient size to maintain transmission fluid (in sump)
Engine rotation is indicated on engine specifications at 140-190°F (60-88°C).
and serial number decal on flame arrestor cover. En-
gine rotation is described when observed from the
rear of the engine (transmission end) looking forward Propeller
(water pump end).
Propeller rotation is described when observed from
Installed angle of MIE inboard transmission and the rear of the boat (stern) looking forward (bow end).
engine should not exceed a maximum of 18° of the The term “left-hand” (LH) refers to rotation in the
water line. counterclockwise (CCW) direction. The term
“right-hand” (RH) refers to rotation in the clockwise
(CW) direction. A LH propeller will move the boat
Transmission forward when rotated counterclockwise. A RH pro-
peller will move the boat forward when rotated clock-
Transmission gear ratio (in forward gear) is marked wise. Propeller rotation is not necessarily the same
on transmission identification plate, which is located as engine rotation.
on the port (left) side of transmission. Transmission
output shaft rotation and propeller rotation required
is indicated on a decal on transmission case.
Transmission rotation is described when viewed
from the rear of transmission with transmission in
forward gear selector position.
Index
Transmission Shift Lever Check transmission fluid before starting engine each
day, as follows:
The lever has three holes as illustrated following.
1. Remove dipstick. Check fluid level as indicated
on dipstick. Fluid level may be somewhat over full
mark, as some of the fluid from transmission fluid
cooler and hoses may have drained back into
transmission. If low, add specified transmission
fluid to bring level up to full mark on dipstick.
71304
Shift Cable Adjustment 72526
Refer to Section 2E - “MIE Models - Velvet Drive a - Dipstick

b - Full Mark
Transmissions.”
c - Dipstick Tube

Checking Transmission gine must be run at 1500 RPM for 2 minutes im-
Fluid Level 2. Start engine and run at 1500 RPM for 2 minutes
to fill all hydraulic circuits.
IMPORTANT: Use only specified transmission
fluid (see “Specifications”).
level.
3. Stop engine and quickly check fluid level. Add
transmission fluid, if necessary, to bring level up
to full mark on dipstick.
4. Reinstall dipstick.
hoses for leaks.
Index
Changing Transmission 3. Coat elbow fitting threads with Quicksilver Per-
fect Seal and install in bushing. Tighten securely.
Fluid 4. Reconnect hose and tighten securely.
Draining Transmission 5. Refill transmission with specified fluid. Refer to
VELVET DRIVE
WALTER V-DRIVE
1. Clean area around cooler hose shown and pro-
ceed as follows: 1. Remove the magnetic drain plug.
a. Disconnect hose from elbow fitting. 2. Disconnect oil hose from strainer fitting on bot-
tom cover.
b. Remove elbow fitting from bushing.
3. Remove oil strainer fitting from bottom cover.
c. Drain oil from transmission, cooler, and cool-
Do not remove elbow fitting from oil strainer
er lines into a suitable container.
fitting.
c b
71305
Typical Velvet Drive MIE Transmission
a - Hose
b - Elbow Fitting
c - Bushing 75192
a
2. Check oil for the following foreign matter: c
• Metal Particles - A few small particles are a - Oil Hose

normal. Larger metal chips are an early sign b - Magnetic Plug
c - Strainer Fitting
of transmission failure which may mean
transmission should be disassembled and in-
spected for internal damage. 4. Clean the outside surface of oil strainer.
• Rubber Particles - Indication of cooler hose 5. Install magnetic plug.

wear. Hoses should be inspected for cracks 6. Install oil strainer and oil hose.
or fraying. Replace damaged hoses.
NOTE: Coat threads of bushing with Quicksilver Per-
fect Seal and install in transmission case if bushing
came loose with elbow fitting. Torque bushing to 25
lb. ft. (34 N·m).
Index
Filling Transmission WALTER V-DRIVE
VELVET DRIVE 1. Remove dipstick from top cover. Fill transmission

with fluid, through dipstick hole, to bring up to full
IMPORTANT: Use only specified automatic trans- mark.
mission fluid (see “Specifications”). a
1. Remove dipstick. Fill transmission with fluid,
through dipstick hole, to bring up to full mark.
75192
c a - Dipstick
IMPORTANT: To accurately check fluid level, run

engine for 2 minutes immediately prior to check-
ing level.
72526
a - Dipstick
b - Full Mark
c - Dipstick Tube
IMPORTANT: To accurately check fluid level, run

engine at 1500 RPM for 2 minutes immediately
prior to checking level.
2. Start engine and run at 1500 RPM for 2 minutes

to fill all hydraulic circuits.
NOTE: Be sure to push dipstick all the way down into

dipstick tube when checking fluid level.
3. Stop engine and quickly check fluid level. Add

automatic transmission fluid, if necessary, to
bring level up to full mark on dipstick.
4. Reinstall dipstick. Be sure to tighten T-handle
securely.
Index
Removal and Installation 19. Relieve hoist tension and fasten rear engine
mounts to engine bed. Tighten bolts securely.
NOTICE 20. Connect wires to neutral start safety switch.
The following procedure describes removal 21. Connect tan/blue wire to fluid temperature
of transmission without removing engine. If switch.
engine must be removed, refer to Section 2
(see “Table of Contents”). 22. Connect fluid cooler hoses to transmission.
23. Connect and adjust shift cable(s) as outlined in
Section 2E - “MIE Models - Velvet Drive Trans-
VELVET DRIVE TRANSMISSION ONLY missions.”
1. Drain transmission fluid. IMPORTANT: Velvet Drive Transmission Warran-

2. Disconnect fluid cooler hoses. ty is jeopardized if the shift lever poppet ball or
spring is permanently removed, if the shift lever
3. Disconnect shift cable.
is repositioned or changed in any manner, or if re-
4. Disconnect wires from neutral start safety switch. mote control and shift cables do not position
shift lever exactly as shown.
5. Disconnect wire from fluid temperature switch.
6. Disconnect propeller shaft coupling. F–N–R
a
7. Remove four rear mount (to engine bed) bolts.
8. Support rear part of engine with either a hoist or d
by using wooden blocks under flywheel housing.
9. Remove two center transmission-to-flywheel
housing attaching bolts and install two long b F
studs.
R
IMPORTANT: These two long studs will help sup- c
port weight of transmission during removal and
72601
installation. a - Transmission Shift Lever
10. Remove remaining transmission attaching bolts. b - Shift Lever Must Be Over This Letter When Propelling Boat
FORWARD
11. Pull transmission straight back and off engine. c - Shift Lever Must Be Over This Letter When Propelling Boat
REVERSE
12. Before installing transmission, check transmis- d - Poppet Ball Must Be Centered In Detent Hole For Each
sion pump indexing for correct rotation. Refer to F-N-R position (Forward Gear Shown)
“Pump Indexing.”
24. Refer to Section 2E - “MIE Models - Velvet Drive
13. Check transmission output shaft rolling torque.
Transmissions” and check engine final alignment
See “Specifications.”
as outlined.
14. Apply Quicksilver Engine Coupler Spline Grease
25. After engine has been properly aligned, connect
to transmission input shaft splines and engine
propeller shaft coupler to transmission output
drive plate splines.
flange. Attach couplers together with bolts, lock-
15. If removed, install rear engine mounting brackets washers and nuts. Torque to 50 lb. ft. (68 N·m).
(to transmission) as outlined in Section 3 (see
26. Refill transmission with specified fluid. Refer to
“Table of Contents”). Torque to 45 lb. ft. (61 N·m).
16. Align transmission splines with drive plate
27. Check for leaks and check fluid level after first en-
splines.
gine start-up.
17. Slide transmission into place and secure with
bolts.
18. Remove two long studs (installed in Step 9) and
install remaining two bolts. Torque all bolts to 50
lb. ft. (68 N·m).
Index
Pump Indexing 5. Reinstall four pump-to-adaptor attaching bolts
and torque to 204-264 lb. in. (23-29 N·m).
Pump must be correctly indexed to correspond with
engine rotation. If pump is not indexed correctly, a
pump will not create oil pressure and transmission
will not shift. Pump housing has two arrows, each b
pointing in a different direction. Pump must be posi-
tioned so that the arrow (pointing in the direction that
input shaft and pump will be turned by engine) is at
the top of transmission.
c
IMPORTANT: Some transmissions have letters
“RH” and “LH” on pump housing. Letters DO
NOT indicate engine rotation.
d
If pump must be re-indexed, proceed as follows: c
1. Remove four pump attaching bolts.
e
2. Loosen the pump housing. A soft tip mallet may
be used to tap the fluid passage boss. Do not
strike the bolt bosses.
IMPORTANT: Do not remove the pump from the 72842

shaft unless a seal protector is used to prevent
the shaft splines from cutting the pump seal. MIE LH (Standard) Rotation Engine
Care must be taken to ensure that seal, gasket, a - Top of Transmission
seal and bolt bosses are kept in good condition b - Top (Or Top RH)
to prevent leaks in those critical areas. c - Pump Attaching Bolts
d - Input Shaft
3. Make sure that pump gasket is not sticking to e - Fluid Passage Boss
housing (to prevent gasket from tearing or fold-
ing) when rotating pump. a
4. Rotate pump until arrow indicating the proper di-

rection of pump rotation is near the top of trans- b
mission.
e
d
c
72843
MIE RH (Opposite) Rotation Engine

a - Top of Transmission
b - Top (Or Top RH)
c - Pump Attaching Bolts
d - Input Shaft
e - Fluid Passage Boss
Index
Shift Lever Installation Pressure Test
1. Install pressure gauge.
IMPORTANT: Velvet Drive Warranty is jeopar-
dized if the shift lever poppet spring and/or ball
is permanently removed, or if the shift lever is
changed in any manner, or repositioned, or if the
linkage between the remote control and the
transmission shift lever does not have sufficient
travel in both directions.
Shift lever and related parts must be assembled as
shown.
1. Lubricate poppet ball, spring, and holes in shift
a
lever with Quicksilver 2-4-C Marine Lubricant.
2. Install poppet spring and ball. Retain ball by plac-
ing shift lever on shaft.
72845
3. Install flat washer, lockwasher and nut on shaft.
4. Torque nut to 96-132 lb. in. (11-15 N·m). a - Main Line Pressure Tap - Models with Audio Warning System,
Remove Temperature Switch; Models without Switch, Remove
3/8 In. Pipe Plug
2. With boat in water, start engine and run until nor-

mal operating temperature is reached.
3. Refer to “Specifications” (see “Table of Con-
tents”) for pressure readings.
e f Transmission Repair
V-Drive
Mercury Marine does not stock or sell replacement
parts for the V-drive transmission. Velvet Drive has a
c network of distributors throughout the world to ser-
a b vice their product. These distributors, in turn, have a
dealer network to service the transmissions. Also,
service manuals (for each transmission) can be ob-
tained from Velvet Drive.
d 72844
Typical Shift Lever IMPORTANT: Refer to “Special Replacement Part

a - Nut Information” before working on transmission.
b - Lockwasher For the location of your closest distributor or service
c - Flat Washer
literature, contact:
d - Shift Lever
e - Poppet Ball Velvet Drive Transmission
f - Poppet Spring Division of Regal Beloit
Theodore Rice Boulevard
5. After installation, move shift lever through for- Industrial Park
ward, neutral and reverse positions. No more New Bedford, MA 02745
than finger-tip effort should be required. If valve Phone: (508) 995-2616
binds, cause for binding must be found and cor-
rected.
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
DRIVES
25280 8
HURTH DOWN ANGLE
TRANSMISSION C
Index
Table of Contents
Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1
Tools/Lubricants/Sealants . . . . . . . . . . . . . . . . . 8C-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2
Transmission Fluid Specification . . . . . . . . . 8C-2
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2
Operating Specifications . . . . . . . . . . . . . . . . 8C-2
Transmission Ratios . . . . . . . . . . . . . . . . . . . 8C-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-3
Shift Cable Installation and Adjustment . . . . . . 8C-3
Checking Transmission Fluid Level . . . . . . . . . 8C-8
Draining Transmission . . . . . . . . . . . . . . . . . . . . 8C-9
Filling Transmission . . . . . . . . . . . . . . . . . . . . . . 8C-9
Transmission Removal . . . . . . . . . . . . . . . . . . . 8C-10
Transmission Installation . . . . . . . . . . . . . . . . . 8C-11
Transmission Repair . . . . . . . . . . . . . . . . . . . . . 8C-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 8C-12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 8C-26
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . 8C-41
Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-46
Index
8C - HURTH
8C-0 DOWN
- HURTH ANGLE
DOWN TRANSMISSION
ANGLE TRANSMISSION 90-823225--1 1096
Identification Tools/Lubricants/Sealants
The transmission identification plate is located on the
top rear of the transmission.
Tapered Roller Bearing
91-813950
Inner Race Puller
91-813951
Outer Bearing Puller
a Pressure Plate
Removal Tool Revers- 91-813952
ing Clutch
91-813953
Inner Race Puller Plate
Mandrel - Input Shaft
91-813955
Seal
Mandrel - Output Shaft
91-813956
Seal
Preload Tool- Input
91-813957
72957 Shaft
a - Transmission Identification Plate Preload Tool -
(Stating: Gear Ratio, Serial Number and Model) 91-816958
Intermediate Shaft
Quicksilver Loctite 8831 92-823089-1
Quicksilver Engine
91-823089-1
Coupler Grease
Thermometer [(3/8 In,
HSW 630A – 1,6 Thread 0-270°F (-18 to
Getr.-Nr. -132°C)]
iA = 1,56 iB = 1,58 Loctite 515 (Split-Line) Obtain
Ob i Locally
L ll
Sealer
71038
Pressure Gauge
Typical Identification Plate (M10x1 Thread)
Fastener Location Lb. Ft. N·m
Transmission Halves Bolts And
36 49
Nuts
Control Block To Housing Bolts 18 25
Output Flange To Output Shaft 63 85
Mounts 50 63
Transmission To Flywheel
50 68
Housing
Index
90-823225--1 1096 HURTH DOWN ANGLE TRANSMISSION - 8C-1
Specifications Operating Specifications
Transmission Fluid Specification 312-377 PSI
Shifting Pressure
(2151-2599 kPa)
Description Part Number Operating Temperature 130-176°F (54-80°C)
ATF Dexron II-D Or Maximum Temperature 220°F (105°C)
Obtain Locally
Dexron lll
Transmission Ratios
Capacity
Transmission Model 630A
Model U.S. Qt (L)
Nominal
Hurth - 630A 1.5 2.0 2.5
3-1/4 (3.0)1 Transmission Ratio
8° Down Angle
Transmission Ratio Shifting
1 Always use dipstick to determine exact quantity of Position “A” 1.56 2.04 2.52
fluid required. (Forward Gear)
Transmission Ratio Shifting
Position “B” 1.58 2.10 2.53
(Reverse Gear)
Index
8C-2 - HURTH DOWN ANGLE TRANSMISSION 90-823225--1 1096
General Shift Cable Installation and
The Hurth transmission is a “full power reversing” Adjustment
transmission, allowing a standard (LH rotation) en-
gine to be used for both rotations. Propeller rotation IMPORTANT: When installing shift cables, be
is determined by shift cable attachment at the remote sure that cables are routed in such a way as to
control. avoid sharp bends and/or contact with moving
parts. DO NOT fasten any items to shift cables.
IMPORTANT: These Hurth transmissions are full
! CAUTION reversing transmissions. Direction of output/
Avoid severe transmission damage. ALL Hurth propeller rotation is determined by hookup of
transmissions require standard left-hand rota- shift cable at remote control.
tion engines. NEVER connect a Hurth transmis-
sion to a right-hand rotation engine. NOTE: Shift cable must be hooked up to remote
control before starting installation and adjustment
IMPORTANT: Transmission propeller rotation is procedures.
determined by the shift cable installation in the For Standard Left-Hand Rotation – shift cable
remote control. hookup at remote control must result in shift cable
• RIGHT-HAND PROPELLER ROTATION - Con- end guide moving in direction (B), when remote con-
trol cable will have to be installed in remote trol handle is placed in forward position.
control so that cable end will move in direction For Right-Hand Rotation – shift cable hookup at re-
(A) when shift handle is placed in the forward mote control must result in shift cable end guide mov-
position. ing in direction (A), when remote control handle is
• LEFT-HAND PROPELLER ROTATION - Control placed in forward position.
cable will have to be installed in remote control so A
that cable end will move in direction (B) when shift
handle is placed in the forward position. B
A 23242
B 1. Be certain anchor stud is installed in the hole

23242
marked for transmission (Model 630A, or 800AM,
respectively).
72709
Shifting
Propeller
Lever in Propeller
Rotation
Position
Opposite to Right Hand
A
Engine Rotation (RH)
Same as Engine Left-Hand
B
Rotation (LH)
Index
! WARNING IMPORTANT: Check that shift lever is positioned
approximately 10 degrees aft of vertical when in
Avoid serious personal injury or property dam- the neutral detent position and that the distance
age caused by improper shifting. Anchor stud for (c) between studs in the following is set at 7-1/8
shift cable must be installed in the correct hole. in. (318 mm). If necessary, loosen clamping bolt
b and position lever so that dimension (c) is as
b shown when in the neutral detent position and
retighten bolt.
a
a
c
c 74090
71020
Shift Cable Bracket - Anchor Stud Position
Shown for 630A Transmission
a - Shift Cable Bracket c
b - Anchor Stud Location
c - Bracket Mounting Bolts
a
72958
d
50228
a - Shift Lever
b - Lever In Neutral Detent, Must Be Approximately 10 De-
grees Of Vertical
c - Dimension Between Studs - 7-1/8 In. (318 mm)
d - Clamping Bolt
Index
2. Place remote control shift lever, and transmission IMPORTANT: Transmission is fully in gear when
shift lever, in neutral position. shift lever comes to a stop, in either direction.
3. Remove nuts and washers from shift cable at-
taching studs. 7. Place remote control shift lever in forward gear
position. Check to ensure transmission is fully in
4. Locate center of remote control and control shift
gear, as follows:
cable play (backlash), as follows:
a. Hold shift lever in position.
a. Check that remote control is in neutral posi-
tion. b. Carefully slide shift cable off of anchor points.
b. Push in on control cable end with enough c. Attempt to move shift lever further.
pressure to remove play, and mark position
(a) on tube. 8. Place remote control shift lever in reverse gear
c. Pull out on control cable end with enough ef- position and again check to ensure transmission
fort to remove play, and mark position (b) on is fully in gear as follows:
tube. a. Hold shift lever in position.
d. Measure distance between marks (a) and (b), b. Carefully slide shift cable off of anchor points.
and mark position (c), halfway between
marks (a) and (b). c. Attempt to move shift lever further.
9. If transmission shift lever will position properly in

b one gear, but not in the other, recheck shift cable
c
adjustment. If transmission shift lever will not po-
sition properly in both gears, move transmission
shift lever stud, from top hole in shift lever to bot-
tom hole, and recheck for proper positioning. If
proper positioning is still not obtained, remote
c a control does not provide sufficient shift cable
travel and must be replaced.
b
72603
5. Center cable-end play, then adjust cable barrel to

align holes in barrel and in cable end guide with
attaching points on transmission.
c
6. Temporarily install shift cable. Do not secure at
this time.
50228
a - Shift Lever Stud (In Bottom Hole, If Required)

b - Lever In Neutral Position, Must Be Approximately 10 De-
grees Aft Of Vertical
c - Shift Lever Top Hole
Index
10. Install nut and washer to cable end guide stud. SINGLE CABLE - FORWARD ENTRY
Tighten until snug, then back off one full turn.
11. Install nut and washer to cable barrel stud.
Tighten until they bottom out. Tighten securely,
but do not over-tighten. e
d
c
72955
50229
a - Cable End Guide
b - Locknut and Washer (Tighten Until Bottoms Out, Then d
Back Off 1/2 Turn) c
c - Spacer
d - Bushings b
e - Cable Barrel
12. Once shift cable adjustment is correct, secure

shift cable(s) with hardware as shown, referring 1
to appropriate configuration following:
NOTE: To change cable approach direction on single

or dual station installations, only the spacer/bushings
have to be switched to the opposite stud (the studs f
are identical). 2
a
b 71210
1 - Cable Barrel Stud
2 - Cable End Guide Stud
a - Cable End Guide

b - Locknut and Washer (Tighten Until Bottoms Out, Then
Back Off 1/2 Turn)
c - Spacer (Fits Over Bushings)
d - Bushing
e - Cable Barrel
f - Spacers (Fits Over Stud)
Index
SINGLE CABLE - REAR ENTRY DUAL CABLE - FORWARD ENTRY
e e
72957
72956
a d
b
b
1 c
1
d
2 c
2 a
b
50229 b 71211
a - Cable End Guide

a - Cable End Guide
b - Locknut and Washer (Tighten Until Bottoms Out, Then
Back Off 1/2 Turn) b - Locknut and Washer (Tighten Until Bottoms Out, Then
Back Off 1/2 Turn)
d - Bushing
d - Bushing
e - Cable Barrel
e - Cable Barrel
f - Spacers (Fits Over Stud)
Index
DUAL CABLE - REAR ENTRY Checking Transmission
Fluid Level
IMPORTANT: Use only specified transmission
fluid (see “Specifications”).
Check transmission fluid before starting engine each
day, as follows:
e
1. Remove dipstick. Check fluid level as indicated
on dipstick. Fluid level may be somewhat over full
mark, as some of the fluid from transmission fluid
cooler and hoses may have drained back into
transmission. If low, add transmission fluid to
bring level up to full mark on dipstick.
72960
27661
a
Typical Hurth Transmission Shown
1
gine must be run at 1500 RPM for two minutes im-
2 d
b 50073 2. Start engine and run at 1500 RPM for two min-
utes to fill all hydraulic circuits.
a - Cable End Guide
b - Locknut and Washer (Tighten Until Bottoms Out, Then level.
Back Off 1/2 Turn)
c - Spacer (Fits Over Bushings) 3. Stop engine and quickly check fluid level. Add
d - Bushing automatic transmission fluid, if necessary, to
e - Cable Barrel bring level up to full mark on dipstick. (Refer to
f - Spacers (Fits Over Stud) “Filling Transmission,” following.)
4. Reinstall dipstick.
hoses for leaks.
Index
Draining Transmission Filling Transmission
IMPORTANT: Use only Automatic Transmission
1. Clean the exterior of transmission before disas- Fluid (ATF) as recommended in “Specifications.”
sembly.
1. Fill transmission to proper level, through oil filter
NOTE: Later model Hurth transmissions have an cavity. (Refer to “Capacity.”)
allen head socket screw on oil filter cover.
2. Install filter as follows:
2. Remove oil filter from housing by turning (coun-
a. Coat O-ring on filter cover with transmission
terclockwise) and pulling at the same time.
fluid.
27666
27662
a - Set Screw (Later Models)

a - Filter Cover
b - O-Ring
3. Push hose of suction pump through suction pipe
and down to the bottom of the housing. Pump
fluid from housing.
71043
Index
! CAUTION Transmission Removal
Transmission fluid filter and cover must be prop-
erly seated to avoid fluid foaming and/or loss of 1. Disconnect wires from neutral safety switch and
fluid, thus resulting in decreased efficiency and/ audio warning temperature switch.
or damage to transmission.
b. Push down until cover is fully seated (top of
cover flush with housing), then turn T-handle
or tighten allen head screw clockwise until
tight.
50686
27666 a - Neutral Safety Switch
b - Audio Warning Temperature Switch
2. Disconnect seawater hoses from transmission

fluid cooler.
a
3. Start engine and run for two minutes to fill system

with fluid.
4. Stop engine and check fluid level. Fluid should be
between min. and max. lines on dipstick.
b
a
72721
a - Seawater Hoses
b - Transmission Fluid Cooler
27661
Index
3. Remove bolts and locknuts and remove trans- 2. Install transmission on flywheel housing and se-
mission. cure with hardware shown. Torque fasteners to
a 50 lb. ft. (68 N·m).
72720
a - Bolts (2), One On Each Side 72720

b - Locknuts (4), Two On Each Side
a - Bolts (2), One On Each Side
b - Locknuts (4), Two On Each Side
Transmission Installation 3. Connect seawater hoses to transmission fluid

cooler and tighten hose clamps securely.
1. Coat splines on input shaft with Quicksilver En-
gine Coupler Spline Grease. a
c
a
a
c 72721
71044
a - Input Shaft a - Seawater Hoses

b - Transmission Fluid Cooler
c - Clamps
Index
4. Connect wires to neutral safety switch and to au- TRANSMISSION FLUID COOLER
dio warning temperature switch. Coat connec-
tions on neutral safety switch with Quicksilver 1. Disconnect transmission fluid hoses from cooler
Liquid Neoprene. and remove clamps that secure cooler to hous-
ing.
b b
50686
72721
a - Neutral Safety Switch
b - Audio Warning Temperature Switch
a - Transmission Fluid Hoses

Transmission Repair b - Clamps
OIL FILTER AND DIPSTICK
Disassembly 1. Remove oil filter from housing by turning T-han-

IMPORTANT: Ensure work area is clean before dle or allen head screw (counterclockwise) and
disassembly is started. Be sure to use lint free pulling at the same time.
cloths when cleaning and/or handling parts.
27666
Index
2. Remove cover and filter element from transmis- 5. Remove dipstick by turning (counterclockwise)
sion. and pulling at the same time.
27662
3. Remove filter element from cover and inspect

O-rings for wear. Replace if necessary.
27661
6. Inspect seal for wear and replace if necessary.
a
50975
a - O-Rings
4. Push hose of suction pump through suction pipe

and down to the bottom of the housing. Pump a
fluid from housing.
27659
a - Seal
71043
Index
BREATHER VALVE OUTPUT FLANGE
1. Remove breather valve. Clean with suitable 1. Remove bolt, washer and O-ring.
cleaner, allow to dry and coat with oil.
a 71049
b
71048
a - Breather Valve
MOUNTS b a
1. Remove mounts from transmission housing. In-

spect mounts for damage and replace if neces-
sary.
71050
a - Bolt
b - Washer
c - O-Ring
72711
a - Transmission Mount
b - Retaining Screws (4 Total On Each Mount - One Hidden In
This View)
Index
2. Reinstall bolt and remove flange using appropri- CONTROL BLOCK
ate puller.
1. Remove hex head bolts.
27661
a - Hex Head Bolts (6)
2. Remove control block and gasket from housing.

b 71051
27666
b
71052
a - Bolt
b - Flange
c - Puller
Index
! CAUTION 2. Remove input side of housing. Be sure to locate
and save locator pins.
Be careful not to allow dirt to enter control block
from front side.
3. Cover openings in control block with a protective a

cloth.
a
71053
27665 a - Locator Pins
a - Openings
3. Remove input shaft assembly.
HOUSING
1. Remove hex head bolts from input side of hous-

ing.
71044
a - Bolts (12)
71054
Index
4. Remove intermediate shaft assembly. 6. Remove output shaft assembly.
71055
5. Remove baffle plate as follows: 71058
a. Bend tabs up away from screws.

b. Remove screws, then remove baffle plate.
BEARING, GEAR AND SEAL INSPECTION
1. Inspect all tapered roller bearings, the piston

rings on the input shaft and all gears for wear. If
damage has been found on the gearing of the in-
a termediate or output shaft, it is ALWAYS neces-
a
sary to replace the complete shaft.
When gears on the input shaft have to be replaced,
the tapered roller bearings and needle bearings
MUST BE replaced as well.
2. Turn gears of input shaft to check correct opera-

tion of the reversing clutch. If it is hard to turn the
71056 gears, the clutch is probably damaged.
a b
a
b
71057
a - Tab
b - Screws
c - Baffle Plate
Index
SEALS b. Remove screws and hold-down plate.
c. Remove suction pipe by pulling downward
1. Remove suction pipe seal as follows: out of seal.
a 71060
a - Screws
b - Hold Down Plate
d. Remove seal from top side.
27666
a - Seal
a. Bend tabs up away from screws.
27660
71059
a - Tabs a - Seal
Index
2. Remove input shaft seal using appropriate man- TAPERED ROLLER BEARING CUPS
drel.
IMPORTANT: Do not remove tapered roller bear-
ing cups unless replacing tapered roller bear-
ings. Bearing and cup must be replaced as a set.
IMPORTANT: Do not mix up shims under cups on
the input housing side. Shims are required for ad-
justing the bearing preload.
1. Pull tapered roller bearing cups from housing us-

a ing special puller as follows:
a. Position appropriate puller guide (large diam-
eter or small diameter) over cup as shown.
27670
a
a - Seal
3. Remove output shaft seals using appropriate

mandrel.
27681
71061
a - Seal
b
72712
a - Small Diameter Puller Guide

b - Large Diameter Puller Guide
Index
b. Pull bearing cup from housing using tool as TAPERED ROLLER BEARINGS
shown.
! CAUTION
Gears should never be removed from intermedi-
ate shaft or output shaft, as this will affect proper
gear alignment.
1. Remove tapered roller bearings from intermedi-

ate shaft and output shaft by using a universal
puller plate and pressing bearings off.
27681
c. Input Housing Side: Remove and retain

shims. DO NOT MIX UP.
71045
27682
71046
Index
REVERSING CLUTCH, GEARS AND TAPERED b. Tighten jaws onto bearing by turning on
ROLLER BEARINGS knurled part of tool. Tighten assembly.
1. Remove tapered roller bearing from splined end

of input shaft using special tool as follows:
a. Place tool over tapered roller bearing. Ensure
jaws of tool will be pulling on bottom edge of
rollers and NOT on the cage.
27671
c. Pull tapered roller bearing from shaft using

tool as shown.
b
27671
a - Jaws
b - Bottom Edge Of Rollers
27672
a - Hold Tool Stationary
b - Turn Top Nut
Index
2. Remove butting ring from splined end of input 4. Remove needle bearings.
shaft by installing special tool as shown and light-
ly tapping upward on tool.
27673
a - Special Tool
b - Butting Ring 27680
3. Remove butting ring and gear assembly.

5. Remove piston rings from shaft.
27675
a - Butting Ring
b - Gear Assembly
27679
Index
6. Remove tapered roller bearing, butting ring and 1. Position snap ring compression tool on clutch as-
gear from piston end of shaft using special tool as sembly so that compression screws are centered
shown. Press all components off at the same over slots in clutch housing.
time. Then remove needle bearings.
2. Remove end disc and snap ring as follows:
a. Tighten all compression screws until a slight
resistance is felt.
b. Tighten compression screws evenly (approx-
imately 1/2 turn at a time).
c. Tap up lightly on bottom edge of compression
tool until snap ring pops up and out of groove
in clutch housing.
27673
a
CLUTCH DISCS
NOTE: Discs on both sides of clutch are removed in

c
the same manner.
IMPORTANT: Reference marks are placed on the
clutch housing and end disc to aid in locating the
snap ring opening.
27674
a - Snap Ring Compression Tool

b - Compression Screws (6)
c - Slots
27675
a - Reference Marks
Index
d. If necessary, remove end disc and snap ring
from tool.
b
a
27675
NOTE: For ease of reassembly, end disc and snap 27676
ring should not be removed from tool unless their a - End Disc
condition is questionable. b - Snap Ring
27676
a - End Disc (Snap Ring Compressed)
Index
IMPORTANT: Thrust discs have a wave pattern. 3. Remove discs.
These discs must be reinstalled in a specific pat-
tern when reassembled. Make note of notches in
thrust disc tabs, and how they are arranged.
50248
27680
a
c b 4. Inspect thrust discs and inner discs for wear. Re-
place if there is any questionable wear.
5. Remove and inspect disc on opposite side of

clutch in same manner.
27679
630A Clutch Arrangement Shown (800AM Simi-

lar)
a - Thrust Discs (5 Per Side) See Note
b - Inner Discs (4 Per Side) See Note
c - Notches
NOTE: 800AM transmissions have additional thrust

discs (6 total per side) and inner discs (5 total per
side).
Index
Reassembly 2. Install discs in clutch housing.
CLUTCH DISCS
IMPORTANT: Thrust discs have a wave pattern.
These discs must be reinstalled in a specific
manner as explained following.
27680
50248
3. Align snap ring opening with reference marks on

1. Arrange thrust discs and inner discs as shown. end disc and clutch housing.
Ensure notches on thrust disc tabs are aligned as
shown.
a
c b
27679
630A Clutch Arrangement Shown (800AM Simi- b
lar)
a - Thrust Discs (5 Per Side) See Note
b - Inner Discs (4 Per Side) See Note
c - Notches
NOTE: 800AM transmissions have additional thrust

discs (6 total per side) and inner discs (5 total per
a
side). b
27678
a - Snap Ring Opening
b - Reference Marks
Index
4. If end disc and snap ring were removed from tool, c. Tighten compression screws evenly to com-
reinstall as follows: pletely compress snap ring into end disc.
a. Loosen all compression screws on tool.
a
27677
a - Compression Screws b
b. Place snap ring into groove in end disc and 27677
compress by hand so that compression dogs
a - End Disc
will hold in on snap ring. b - Compression Screws
d. Carefully lower end disc and special tool onto

clutch housing and align compression dogs
with slots in housing.
b
a
c
b
27677
a - End Disc
b - Snap Ring
27675
c - Compression Dogs
a - Slots
b - Compression Dogs
Index
5. Tap lightly around top of tool until end disc bot- 6. Double check that snap ring has been properly
toms. Loosen compression screws and remove seated by prying up lightly on end disc.
tool.
27679
7. Reinstall discs on opposite side of clutch in same

manner.
27678 NEEDLE BEARINGS
1. Reinstall needle bearings.
27675
27680
Index
GEAR ASSEMBLY TAPERED ROLLER BEARING
1. Reinstall gear assembly. Twist gear assembly ! CAUTION

from side to side to allow splines to engage with
inner discs. Ensure all inner discs are engaged Do not touch bearing once it has been heated. Se-
with splines by observing through slots in clutch vere burns could result. Use special protective
housing. gloves to handle bearing.
1. Heat inner race of tapered roller bearing using a

torch lamp and press bearing onto shaft. When
bearing has cooled (DO NOT cool with water),
carefully tap bearing down to ensure proper
seating against butting ring, using a soft (copper)
punch. Tap on inner race only.
27673
2. Reinstall butting ring.
27674
a - Tapered Roller Bearing

b - Butting Ring
2. Install components on opposite side of clutch as-

sembly in same manner.
! CAUTION
Use care in reinstalling piston rings on input
shaft. Piston rings are brittle and may snap if
spread too far open.
27672
Index
3. Reinstall piston rings on input shaft. Ensure ends OUTPUT SHAFT
of rings are coupled as shown. Then position
rings so that ends are staggered so no two are ! WARNING
aligned. Do not touch bearing once it has been heated. Se-
vere burns could result. Use special protective
gloves to handle bearing.

torch lamp and press bearing onto shaft. When
bearing has cooled (DO NOT cool with water),
drive bearing down against gear using a soft
(copper) punch. Tap on inner race only.
27679
INTERMEDIATE SHAFT
! WARNING
Do not touch bearing once it has been heated. Se- 71046
vere burns could result. Use special protective
gloves to handle bearing. 2. Install tapered roller bearing on opposite end of
shaft in the same manner.
torch lamp and press bearing onto shaft. When NOTE: Tap bearing on splined end of shaft until it is
bearing has cooled (DO NOT cool with water), seated against shoulder on shaft.
carefully tap bearing to ensure proper seating
against gear, using a soft (copper) punch. Tap on
inner race only.
71045
2. Install tapered roller bearing on opposite end of

shaft in the same manner.
Index
PREASSEMBLY OF OUTPUT HALF OF ! WARNING
HOUSING
Use care in handling housing once it has been
IMPORTANT: If tapered roller bearing cups were heated. Severe burns could result. Use special
removed, ensure output shaft seal IS NOT in protective gloves to handle housing.
place, as it will be necessary to heat housing
prior to installing bearing cups.
2. Heat bearing bores of housing using a torch lamp
IMPORTANT: The tapered roller bearing cup on and install bearing cups using a suitable man-
the input shaft (control block end) is properly po- drel.
sitioned by bottoming out on the face of the con-
trol block assembly. It will be necessary to tem-
porarily install control block to install this
tapered roller bearing cup.
b
1. Temporarily install control block on outer hous- a
ing. Tighten bolts securely.
27681
a - Bearing Cups
b - Torch Lamp
3. Allow housing to cool (DO NOT cool with water)

and then tap bearing cup with suitable mandrel to
ensure it is properly seated.
4. Remove control block assembly.
27682
27666
a - Input Shaft Bearing Cup
b - Control Block Face
Index
Output Shaft Seal 2. Reinstall suction pipe. Place one drop of Quick-
silver Loctite 8831 on screw threads. Then se-
1. If bearing were not replaced and no shimming cure suction pipe down with retainer plate. Tight-
is required, push new seal onto special mandrel. en screws securely.
Ensure seal will be positioned with lip of seal fac- 3. Bend tabs down over screws.
ing inward. Drive seal uniformly into bore of hous-
ing to the point that it is countersunk .040 in. (1
mm) with reference to housing surface.
71060
71061 Shafts and Baffle Plate

a - Seal
1. Coat tapered roller bearings with ATF.
Suction Pipe
2. Install output shaft.
1. Reinstall suction pipe seal in bottom of oil filter

bore. Coat seal with ATF (automatic transmission
fluid).
71058
27660
a - Seal
Index
3. Install baffle plate. Apply one drop of Quicksilver 5. Install input shaft. Ensure all gears mesh as
Loctite 8831 to screws. Tighten screws securely shown.
and bend tabs down over screws.
a
b
a
b
71057
a - Tabs
b - Screws
c - Baffle Plate
4. Install intermediate shaft.

71054
71055
71062
Index
PREASSEMBLY OF INPUT HALF OF HOUSING ! WARNING
Use care in handling housing once it has been
1. Install breather valve (do not overtighten). heated. Severe burns could result. Use special
protective gloves to handle housing.
3. Heat each tapered roller bearing cup bore with a

torch lamp. Insert shims (less those removed)
and bearing cups into appropriate bearing bores.
When housing has cooled (DO NOT cool with wa-
ter), tap bearing cups with a suitable mandrel to
ensure that cups are fully seated.
71048
Bearing Preload Adjustment

IMPORTANT: If new tapered roller bearings have
been installed, the preload must be readjusted. If
bearings were not replaced, proceed to the final
reassembly section. 71063
NOTE: The required preload of bearings of the indi-

b
vidual shafts is obtained by using shims beneath the
tapered roller bearing cups in the input half of the
housing.
NOTE: Shims which have been removed during dis-

assembly may be reused.
2. Subtract approximately .008 in. (0.2 mm) of

shims from each bearing cup bore. Remove and
set aside, but do not mix up.
27681
a - Bearing Cups
b - Torch Lamp
Index
4. Install input half of housing onto output half. En- b. Mount dial indicator on input shaft. Turn input
sure locator pins are in place. Install bolts and shaft several times to seat bearing.
lockwashers and torque to 36 lb. ft. (49 N·m).
71064
27685
Input Shaft Preload

c. Zero the dial indicator.
1. Measure bearing clearance as follows:
a. Install special tool as shown. Tighten
hold-down bolts securely.
27863
a - Special Tool
b - Hold Down Bolts 27685
IMPORTANT: The following step should be done

very carefully to obtain the actual bearing clear-
ance. Avoid bumping the input shaft and turn
very slowly on the special tool knob. (Shaft will
only be moving a very small amount.)
Index
d. Slowly turn the special tool knob clockwise to e. Make note of reading. The bearing clearance
push the shaft upward. (Perform the above measured PLUS the preload required is
sequence several times to ensure an accu- equal to the amount of shim thickness to be
rate reading.) ADDED.
27685
Example:
27682 Bearing Clearance Measured .009 in.
+ Bearing Preload Required .004 in.
= Shims to Be Added .013 in.
Index
Intermediate Shaft Preload d. Zero dial indicator.
1. Measure bearing clearance as follows:

a. Remove hex plug from housing.
71065 27685
b. Screw special bolt with nut into intermediate IMPORTANT: The following step should be done
shaft and tighten snugly. Turn nut up until it very carefully, to obtain the actual bearing clear-
touches bolt head. ance. Turn nut very slowly as shaft will only be
c. Mount dial indicator on bolt head. Turn output moving a small amount.
shaft several times to ensure bearing is
seated. e. Hold bolt with one wrench and slowly turn
down nut to pull shaft upward. (Perform the
above sequence several times to ensure ac-
curate reading.)
71066
a
a - Special Bolt with Nut
b
72869
a - Bolt - Hold Stationary

b - Nut - Turn To Move Shaft
Index
f. Make note of the reading. The bearing clear- Output Shaft Preload
ance measured PLUS the preload required is
equal to the amount of shim thickness to be 1. Measure the bearing clearance as follows:
ADDED.
a. Install flange washer and bolt. Tighten snugly.
b. Mount dial indicator on bolt head. Turn output
shaft several times to ensure bearing is
seated.
71069
27686
a - Flange Washer and Bolt
Example: c. Zero dial indicator.

Bearing Clearance Measured .007 in.
g. Remove dial indicator, special bolt and nut,

and reinstall hex plug. Tighten securely.
27685
IMPORTANT: The following step should be done

very carefully to obtain the actual bearing clear-
ance. Pry up gently and evenly to lift shaft. Shaft
will only move a small amount.
Index
d. Pry up on washer to lift output shaft. 2. When thickness of shims to be ADDED has been
determined, the input half of housing must again
be removed. Remove bolts and lockwashers,
then lift off input half of housing.
71068
e. Make note of the reading. The bearing clear-

ance measured PLUS the preload required is
equal to the amount of shim thickness to be
ADDED.
71044
a - Bolts
3. Remove tapered roller bearing cups from hous-

ing using special puller as follows:
a. Position appropriate puller guide (large or
small diameter) over cup as shown.
27686
Example:
Bearing Clearance Measured .010 in.
27681
a - Puller Plate
f. Remove dial indicator. Remove bolt and

flange washer.
Index
b. Pull bearing cup from housing as shown. 5. Heat each tapered roller bearing cup bore with a
torch lamp. Install bearing cups into appropriate
bore and tap into place using a suitable mandrel.
When housing has cooled (DO NOT cool with
water), tap bearing cups to ensure they are fully
seated.
a
27681
4. Add the necessary amount of shims as deter-

mined previously to the appropriate bearing
bores.
27681
27682
! WARNING
Use care in handling housing once it has been 71063
heated. Severe burns could result. Use special a - Torch Lamp
protective gloves to handle housing. b - Bearing Cups
Index
Final Assembly 4. Install bolts and lockwashers and torque to 36 lb.
ft. (49 N·m).
INPUT SHAFT SEAL
1. Push new seal onto special mandrel. Ensure seal

will be positioned with lip of seal facing inward.
Drive seal uniformly into bore of housing to the
point that it is countersunk .040 in. (1 mm) with
reference to housing surface.
71064
5. Double check to ensure that there is no shaft

clearance on all three shafts. Refer back to pre-
vious steps if necessary, and use dial indicator.
6. Remove intermediate shaft hex plug. Apply a

27670
drop of Quicksilver Loctite 8831 to threads and
reinstall in housing. Tighten securely.
2. Coat lips of seals on input and output shafts with

ATF.
3. Apply a thin layer of Loctite 515 Sealer to ma-
chined surfaces on housing halves. Reinstall in-
put half of housing. Ensure locator pins are prop-
erly positioned.
a
b
71065
71053
a - Locator Pins
b - Machined Surface
Index
CONTROL BLOCK FLUID FILTER
1. Ensure piston rings are in place and the key is in 1. Coat new O-rings with ATF.
keyway. Align key on shaft with keyway in control
block.
2. Install new gasket between control block and
housing.
50975
b a - O-Rings
2. Reassemble filter assembly as shown. DO NOT

tighten and compress upper O-ring.
27666
a - Key
b - Piston Rings a
3. Carefully push control block onto input shaft.

4. Coat each hex socket head bolt with a drop of
Quicksilver Loctite 8831. Secure control block to
housing with bolts and lockwashers. Torque to 18
lb. ft. (25 N·m).
72805
a - O-Rings
27661
a - Hex Socket Head Bolts (6)
Index
DIPSTICK 4. Install O-ring into flange and coat with ATF.
5. Install washer and bolt. Torque to 63 lb. ft.
1. Coat sealing ring on dipstick with ATF. (85 N·m).
2. Install dipstick into transmission and tighten by
pressing down and turning clockwise at the same
time.
b a
71050
27661
OUTPUT FLANGE
1. Coat output shaft splines with a thin coat of

Quicksilver Engine Coupler Spline Grease.
2. Coat lip of output shaft seal with ATF.
b a
3. Install output shaft flange. Be careful not to dam-
age output shaft seal.
71049
a - Bolt
b - Washer
c - O-Ring
71052
a - Splines
b - Output Shaft Seal
Index
TRANSMISSION FLUID COOLER 2. Install filter as follows:
a. Bring flat spot on filter into agreement with flat
1. Install transmission fluid cooler on housing. Se- surface inside of housing.
cure with clamps and screws as shown. Torque
to 18 lb. ft. (25 N·m).
2. Connect transmission fluid hoses to cooler as
shown. Tighten securely.
a
b
27662
b a - Filter Cover
b - O-Ring
72721
a - Transmission Fluid Hoses
b - Clamps
a
FILLING WITH TRANSMISSION FLUID
IMPORTANT: Use only ATF (Automatic Transmis-
sion Fluid), such as Dexron II-D or lll.
1. Fill transmission to proper level, through fluid

filter cavity. (Refer to “Transmission Fluid
Capacity”.)
27666
a - Flat Spot
Index
NOTE: Later model Hurth transmissions have an al-
len head socket screw on oil filter cover.
3. Remove oil filter from housing by turning (coun-

terclockwise) and pulling at the same time.
27666
4. Check fluid level. Fluid should be between min.

and max. marks on dipstick.
27661
Index
Functional Test 2. Perform functional tests as shown in chart follow-
ing. Refer to “Operating Specifications” for cor-
rect readings.
1. Connect a pressure gauge and thermometer to
fluid pump at locations shown. Tests to Be Carried Out:
1. Leakages
2. Noise emission
3. Direction of rotation, LH/RH
4. Fluid temperature
5. Shifting pressure
b
a
50686
a - Pressure Gauge (m10x1 Thread - Remove Plug)

b - Thermometer (3/8 In. Thread) - Remove Temperature
Sender
Motor Speed RPM Shift Lever Position Duration Minutes Tests

800-1000 Neutral 5 1 2
600-800 A↔B Position
–– 1 2 3
(Idling Speed) Repeatedly
1500-2500 B Position * 1 2 4
600-800 A↔B Position
–– 1 2 3
(Idling Speed) Repeatedly
Idling
A Position –– 1 2 5**
Maximum Speed
600 -800 From A → B Position –– 1 2
Idling
B Position –– 1 2 5**
Maximum Speed
*Until fluid temperature of 167-176°F (75-80°C) has been reached

**At different speeds
Index
AT A LATER DATE
Index
AT A LATER DATE
Index
DRIVES
8
DRIVE SHAFT / PROPELLER
SHAFT MODELS E
index
Table of Contents
Page
Tools/Lubricants/Sealants . . . . . . . . . . . . . . . . . 8D-1
Flywheel Housing/Output Shaft Housing
Repair (MCM Stern Drive Models) . . . . . . . . . 8D-2
Removal and Installation . . . . . . . . . . . . . . . 8D-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-2
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-2
Drive Shaft Repair
(MCM Stern Drive Models) . . . . . . . . . . . . . . . . 8D-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-4
Replacement Drive Shafts . . . . . . . . . . . . . . 8D-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-5
Bearing Support Repair
(MCM Stern Drive Models) . . . . . . . . . . . . . . . . 8D-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-8
Propeller Shaft
(MIE Inboard Models) . . . . . . . . . . . . . . . . . . . . 8D-9
Checks Made with Boat In Water . . . . . . . . 8D-9
Checks Made with Boat Out of Water and
Shaft Installed . . . . . . . . . . . . . . . . . . . . . . . 8D-10
Checks Made with Propeller Shaft
Removed from Boat . . . . . . . . . . . . . . . . . . 8D-11
Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-12
index
8D-0 - DRIVE SHAFT / PROPELLER SHAFT MODELS 90-823225--1 1096
Torque Specifications Tools/Lubricants/Sealants
Fastener Location Lb. Ft. N·m Description Part Number
Drive Shaft To Bearing Support Quicksilver Alignment
91-805475A1
Flange (MCM Models) Tool
Drive Shaft To Output Shaft Quicksilver Slide
91-34569A1
(MCM Models) 50 68 Hammer Puller
Propeller Shaft Coupling To 2-4-C Marine Lubricant
92-825407A3
Transmission Coupling With Teflon
(MIE Models) U-Joint and Gimbal
92-828052A2
Flywheel Housing To Block Bearing Grease
(MCM Models) Quicksilver Engine
30 41 91-816391A4
Output Shaft Housing To Fly- Coupler Spline Grease
wheel Housing (MCM Models) Quicksilver Loctite 8831 92-823089-1
Engine Coupling 35 48
Loctite 290 Obtain Locally
Coupling Setscrews Securely
(If Equipped) (NOTE)
NOTE: Safety wire set screws.
index
90-823225--1 1096 DRIVE SHAFT / PROPELLER SHAFT MODELS - 8D-1
Flywheel Housing/Output Reassembly
Shaft Housing Repair 1. Install engine coupling. Torque to 35 lb. ft.
(48 N·m).
(MCM Stern Drive Models) 2. Install flywheel housing. Torque to 30 lb. ft.
NOTICE (41 N·m).
The following repair procedure requires re- 3. Using new gasket, install flywheel cover. Tighten
moval of the drive shaft. In most cases, be- screws securely.
cause of engine compartment space limita- IMPORTANT: Groove in outside diameter of ball
tions, the engine also must be removed. bearing must align with grease fitting hole.
4. Install ball bearing into output shaft housing, then
install snap ring.
Removal and Installation 5. Apply Quicksilver 2-4-C Marine Lubricant With
1. Remove drive shaft as outlined following in this Teflon to O-rings (on output shaft), then slide
section. shaft through bearing. Secure shaft with snap
ring.
2. If engine must be removed, refer to appropriate
instructions in Section 2, “Removal and Installa- 6. Apply Quicksilver Engine Coupler Spline Grease
tion.” to splines on output shaft.
7. Install output shaft housing to flywheel housing.
Torque screws to 30 lb. ft. (48 N·m).
Disassembly
8. Secure rear engine mounts to stringer with bolts.
IMPORTANT: This disassembly procedure, be- Tighten securely.
ginning with Step 1, assumes that engine does
9. Remove hoist (or wooden blocks).
not require removal from boat. If, however, en-
gine removal is required, refer to Section 2 for re- 10. Install drive shaft and check alignment. (Refer to
moval and installation instructions. With engine Section 2 for engine and drive shaft alignment if
removed from boat, proceed with disassembly, engine was removed.)
beginning with Step 3.
1. Support rear of engine with overhead hoist or
wooden blocks under the rear of the engine.
2. Remove stringer bolts (rear engine mounts).
3. Remove output shaft housing attaching screws,
then remove housing.
4. Remove snap ring, then pull output shaft out of
housing.
5. Remove snap ring from housing.
6. Using Quicksilver Slide Hammer Puller, remove
bearing from housing.
7. Remove flywheel cover.
8. Remove flywheel housing.
9. Remove engine coupling.
10. Clean and inspect all parts. Replace any dam-
aged parts.
index
11. Using Quicksilver U-Joint and Gimbal Bearing Drive Shaft Repair
Grease, grease ball bearing through grease fit-
ting. (MCM Stern Drive Models)
1 Removal
2 3 10 IMPORTANT: It is not necessary to remove the
4 engine to service the drive shaft.
8
1. Remove top and bottom drive shaft shields
5 around transom end and engine end of drive
shaft.
9 8
14 13 a
15 8
6
12 7
11
8
17 c
16
18
23 e
19
20 d
8 21 22 b
70245
Flywheel Housing/Output Shaft Housing
1 - Output Shaft
2 - O-Rings (Engine End Similar)
3 - Snap Ring - Ball Bearing a - Top Shield
4 - Ball Bearing b - Bottom Shield
5 - Shaft Bearing c - Bolt 3/3-16 x 7/8 In. (22.2 mm); 4 Used
6 - Snap Ring - Output Shaft d - Nut 3/8 16: 4 Used
7 - Rear Engine Mount e - Screws (3 Used Hidden In This View)
8 - Lockwasher
9 - Screw (4)
10- Screw (6)
11- Flywheel Housing
12- Plate
13- Screw (2)
14- Nut (1)
15- Bolt (4)
16- Washer (1)
17- Clamp (1)
18- Stud (1)
19- Gasket
20- Cover - Flywheel
21- Screw (7)
22- Coupling - Engine
23- Bushing
index
2. Suitably mark drive shaft U-joint yokes/flange Repair
connections (engine output and drive unit input)
to assist in exact same positioning during assem- ! CAUTION
bly at engine and transom end.
Be sure U-joint locking rings are seated properly
after replacing U-joints.
1. Replace U-joints, if required.
c 2. Replace flange, if required.
a
b
b
a
b a - Flange
b - U-Joint
70237 c - Drive Shaft
Engine End Shown (Transom End Similar)
a - Suitable Mark On Flange and Drive Shaft Connection
b - Extension Drive Shaft U-Joint Yoke Replacement Drive Shafts
c - Flange
MerCruiser furnishes a 58 in. (1473 mm) or 34-1/2 in.
3. Remove drive shaft fasteners and drive shaft. (876 mm) long drive shaft with extension shaft mod-
els. Some boat manufacturers modify the drive
shafts to a shorter length. Because of this, use the fol-
a lowing procedure to obtain replacement drive shafts.
“X”
a
b e b c
c d d
a - Tube
b - Yoke - Tube
c c - Flange
d - Universal Joint
70237 e - Sound Deadener (Cardboard Tube)
b
Engine End Shown (Transom End Similar) The complete drive shaft can be ordered from
a - Output Shaft Flange Mercury Marine.
b - Drive Shaft
c - Bolt With Nut (4 Total)
index
Drive Shafts Modified to Shorter Lengths ! CAUTION
The complete modified (shortened) drive shaft has to Failure to properly align shaft flanges with
be ordered from the boat manufacturer that installed matching marks made on disassembly may
the MerCruiser Power Package. cause improperly aligned drive unit and exten-
IMPORTANT: Dana Corporation - Spicer Regional sion drive shaft U-joint centerlines resulting in a
Drive Shaft Centers will not shorten replacement severe vibration problem.
drive shafts for dealers or consumers. 2. As shown, attach drive shaft output flange and in-
If a boat manufacturer is currently having extension put shaft flange exactly as marked upon disas-
drive shafts modified, they must be modified by one sembly. Torque fasteners to 50 lb. ft. (68 N·m).
of Dana Corporation - Spicer Regional Drive Shaft
Centers to maintain MerCruiser warranty. The modi-
fied drive shaft must meet the following specifica-
tions. a
• U-joints aligned radially within 0° (± 1/2°).
• U-joints greased, after welding, with Quicksilver
U-Joint and Gimbal Bearing Grease.
• Assembly balanced to within 1.5 oz. in. (0.01 e
N·m) to 4500 RPM.
d
• Tube to have .005 in. (0.127 mm) to .010 in.
(0.254 mm) interference fit with tube yoke.
• Tube must be straight and round within .015 in.
(0.381 mm).
c
Installation b
IMPORTANT: The following instructions are to be 70237
used if ONLY the drive shaft was removed for ser- Engine End Shown (Transom End Similar)
vice. Refer to appropriate sections for installa- a - Output Shaft Flange
tion of other components which require special b - Drive Shaft
c - Screw 7/16-20 x 1-1/2 In. (38 mm) Long (4 Used)
alignment. d - Nut 7/16-20 (4 Used)
1. Grease both drive shaft universal joints with e - Suitable Matching Marks Made upon Disassembly -
Aligned
Quicksilver U-Joint and Gimbal Bearing Grease.
! CAUTION
When attaching shaft in next step, BE SURE that
the pilot on drive shaft flanges are engaged in
input shaft and output shaft flanges. Flanges
MUST BE flush with each other prior to tightening
screws or screws may come loose during
operation.
index
3. Apply Loctite 271 to threads of bottom drive shaft ! CAUTION
shield retaining screws and install bottom shields
on engine and transom end. Then install both top If bearing support is removed, you must remove
shields as shown. Torque all fasteners to 30 lb. ft. the stern drive unit so you can properly align
(41 N·m). drive unit U-joint centerline with extension drive
shaft U-joint centerline. Lack of alignment will
a cause a severe vibration problem.
1. Remove drive shaft as previously outlined.

2. Remove stern drive unit (refer to appropriate
Stern Drive Service Manual).
c
3. Remove bearing support and retain hardware.
a
e b
c
d
b
70245
(Engine End Similar)
a - Top Shield d
b - Bottom Shield
c
c - Bolt 3/8-16 x 7/8 in. (22 mm); 4 Used e 75279
d - Nut 3/8-16; 4 Used
e - Screws (3 Used - Hidden in This View) a - Bolt, Bearing Support (2)
b - Flat Washer (2)
c - Spherical Washer (4)
d - Bearing Support (Tailstock)
Bearing Support Repair e - Nut (2)
(MCM Stern Drive Models)
Removal Disassembly
1. Remove snap ring, then remove input shaft.
engine to service the drive shaft and/or bearing 2. Remove larger snap ring.
support. 3. Using Quicksilver Slide Hammer Puller, remove
ball bearing.
4. Remove oil seal.
5. If required, remove plug from end of input shaft.
6. Clean and inspect all parts.
index
7. Replace any damaged parts. 2. Apply Quicksilver Loctite 8831 to outer diameter
of new oil seal.
a b 3. Press oil seal into bearing support. Lip of seal
c e
J faces away from ball bearing.
c
f 4. Apply Loctite 290 to outer diameter of ball bear-
h ing and inner diameter of bearing support.
g
5. Install bearing (with sealed side toward snap
ring) by using a press. After installation, wipe up
excessive Loctite. Install snap ring.
6. Apply Loctite 290 to outer diameter of input shaft
(bearing area) and inside diameter of bearing
d race.
i 7. Install input shaft, then install snap ring. Wipe up
Magnum excessive Loctite.
75280
IMPORTANT: Do not let Loctite get into ball bear-
ing.
8. Fill bearing area with Quicksilver U-Joint and
Gimbal Bearing Grease through grease fitting.
a b c 9. Apply Quicksilver Engine Coupler Spline Grease
e to splines of input shaft before installing drive
f g unit.
h
a e
b c
f g
h
d
i
Standard 75281
a - Snap Ring - Input Shaft d

b - Snap Ring - Ball Bearing i 75281
c - Ball Bearing
a - Snap Ring - Input Shaft
d - Bearing Support
b - Snap Ring - Ball Bearing
e - Grease Fitting
c - Ball Bearing
f - Oil Seal
d - Bearing Support
g - Grease Fitting
e - Grease Fitting
h - Input Shaft
f - Oil Seal
i - Plug - Input Shaft
g - Grease Fitting
j - Spacer
h - Input Shaft
i - Plug - Input Shaft
Reassembly
1. If removed, install new plug in end of input shaft.
index
Installation 2. Insert solid end of Quicksilver Alignment Tool
through bearing in gimbal housing and into input
1. Install bearing support assembly (tailstock) on shaft splines of bearing support.
transom plate using hardware as shown. Tighten
bolts until snug. DO NOT TORQUE BOLTS AT
THIS TIME.
IMPORTANT: The spherical washers MUST BE
positioned so that the rounded side of the wash- b a
ers are toward the bearing support assembly as
shown.
g
h
a
b
c
d
e
f
75279
a - Bolts 1/2-20 x 4 In. (102 mm) Long 71401

b - Steel Washer (Flat) Typical Stern Drive Unit Shown
c - Spherical Washer (Rounded On One Side) a - Quicksilver Alignment Tool
d - Bearing Support b - Insert This End Of Alignment Tool Through Gimbal Hous-
e - Spherical Washer (Rounded On One Side) ing Assembly
f - Nut 1/2-20
g - Transom Plate
h - Bearing Support (Tailstock)
3. DO NOT remove alignment tool from gimbal
housing.
! CAUTION
Both attaching bolts MUST BE struck firmly in
the following step to properly seat spherical
washers. If procedure is not followed, difficulty
in the installation of the stern drive may be expe-
rienced and subsequent damage to input bear-
ing may result.
index
4. Strike the head of BOTH bearing support attach- Propeller Shaft
ing bolts firmly with a hammer.
(MIE Inboard Models)
NOTICE
The following information can be used as a
guide for determining vibration problems
on boats powered by inboard engines (MIE
models). For installation, alignment and re-
pairs to shafts, struts, shaft logs and rud-
ders, refer to boat manufacturer’s service
manual. If boat is equipped with V-drive, or
a remote mounted V-drive, refer to Section
8B or boat manufacturer’s service manual
for all servicing and troubleshooting. For
MIE engine installation and alignment, re-
71098
fer to Sections 2E and 2F.
5. Torque bolts to 35-54 lb. ft. (47-54 N·m) as

shown. Checks Made with Boat In Water
1. Disconnect propeller shaft coupling from trans-
mission coupling.
2. Check fit of coupling to propeller shaft.
Straight Bore Type:
a. Loosen set screws.
b. Try to move coupling by hand. The bore of the
coupling should be a semi press fit to shaft.
c. Check shaft for wear. If worn, replacement of
shaft may be necessary.
d. If shaft is not worn, try another coupling.
Tapered Bore Type:
71099 a. Check nut on shaft for tightness.
b. If nut was loose, remove coupling and check
6. Refer to appropriate Stern Drive Service Manual for damage to taper on shaft or in coupling.
and install drive unit.
c. Replace worn parts.
7. Refer to appropriate Section 2 - “Removal and In-
stallation - Engine Installation/Alignment,” if en- d. Always make sure key is not sticking out of
gine was removed. coupling.
e. Install coupling on shaft without the key.
f. Mark the shaft (behind the coupling), then re-
move the coupling.
g. Now install the key and coupling. Make sure
coupling still lines up with the mark. This en-
sures that key is not oversize and holding the
tapers apart.
index
3. Check output coupling flange of transmission. Checks Made with Boat Out of Water
and Shaft Installed
Possible causes for vibration may be propeller shaft,
propeller to shaft fit or propeller. All three can be
checked by using the rudder, a strong metal straight
edge and a C-clamp.
1. Check installation of propeller to shaft.
a. Remove propeller.
b. Check for chipped or cracked keyway in pro-
peller on shaft without key.
c. Install propeller on shaft without key.
d. Mark the shaft (behind the propeller), then re-
move propeller.
e. Install the key and propeller. Make sure pro-
peller still lines up with mark. This ensures
that key is not oversize and holding the tapers
apart. Retighten propeller nut.
Checking Coupling Outside Diameter - Rotate f. Be sure key is not sticking out of propeller.
One Complete Turn
2. Check for propeller shaft being bent behind the
strut.
b
a
a - Metal Straight Edge (Held T Rudder With C-Clamp) - Posi-
tion Corner Of Straight Edge At Center Of Shaft. Rotate
Checking Coupling Face - Rotate One Complete Shaft One Complete Turn. If Shaft Wobbles, Replace
Turn Shaft.
b - Rudder
4. If there is movement in Step 3, replace output

coupling.
5. Replace damaged parts and realign engine as
outlined.
6. Torque propeller shaft coupling and transmission
coupling (output flange) to 50 lb. ft. (68 N·m).
Tighten setscrews securely, if so equipped.
Safety wire set screws, if so equipped.
index
3. Check the diameter of all propeller blades. If not Checks Made with Propeller Shaft
the same, repair propeller.
Removed from Boat
1. Check propeller shaft for straightness. Check at
three or four places. If dial indicator deflects over
.004 in. (0.1 mm), replace shaft.
a
b
c
c a
a - V-Blocks
a - Metal Straight Edge (Held T Rudder With C-Clamp) b - Dial Indicator
b - Rudder c - Shaft - Rotate One Complete Turn
c - Rotate Propeller One Complete Turn
2. Check that bore of coupling is 90 degrees from
4. Check that all propeller blades are the same pitch coupling flange. Replace coupling if needle
and that propeller is properly seated on shaft. Re- moves.
pair or replace if necessary.
d
a a
b
b c
a - Metal Straight Edge (Held T Rudder With C-Clamp) a - V-Blocks
b - Rudder b - Dial Indicator
c - Rotate Propeller One Complete Turn. Check At Three Dif- c - Coupling Flange - Rotate One Complete Turn
ferent Points On Blades d - Shaft Against Block To Prevent Fore And Aft Movement
index
Strut
Refer to boat manufacturer’s service manual for
alignment and replacement. Normally, the shaft
should be centered in the cutlass bearing. Shims
(placed between the strut and hull) are used to align
the strut to the shaft.
71091
a - Strut
b - Cutlass Bearing
index
AT A LATER DATE
index
POWER STEERING
72951
PUMP
9
A
Index
Table of Contents
Page
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 9A-1
Tools/Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-1
Power Steering Pump and Components
(Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2
Serpentine Belt Routing . . . . . . . . . . . . . . . . . . . 9A-3
Important Service Information . . . . . . . . . . . . . . 9A-4
Pump Pulley Replacement . . . . . . . . . . . . . . 9A-4
Testing and Repair . . . . . . . . . . . . . . . . . . . . . . . 9A-5
Checking Pump Fluid Level . . . . . . . . . . . . . . . . 9A-5
Filling and Air Bleeding System . . . . . . . . . . . . 9A-5
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-5
V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-5
Serpentine Belt Adjustment . . . . . . . . . . . . . 9A-5
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-6
Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . 9A-7
Hydraulic Hoses and Fluid Cooler . . . . . . . . . . 9A-7
High Pressure Hose (Pump-to-Control
Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-7
Low Pressure Hose (Cooler-to-Pump) . . . . 9A-8
Low Pressure Hose
(Control Valve-to-Cooler) . . . . . . . . . . . . . . 9A-10
Priority Valve Kit (79691A1) Information . . . . 9A-12
Installing Reservoir . . . . . . . . . . . . . . . . . . . 9A-12
Installing Priority Valve . . . . . . . . . . . . . . . . 9A-14
Filling System with Fluid . . . . . . . . . . . . . . . 9A-17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 9A-17
System Flow Diagram . . . . . . . . . . . . . . . . . 9A-18
Index
9A-0 - POWER STEERING PUMP 90-823225--1 1096
Torque Specifications Precautions
! CAUTION
Fastener Location Lb. Ft. Lb. In. N·m
Do not operate engine without cooling water be-
Crankshaft Pulley To ing supplied to water pickup pump or water pump
35 42
Torsional Damper impeller will be damaged and subsequent over-
Torsional Damper To heating damage to engine may result.
60 81
Crankshaft
Pump Mounting ! WARNING
30 41
Bracket To Engine
Recirculation Pump Always disconnect battery cables from battery
240 27 before working on engine to prevent fire or explo-
Pulley
sion.
Early Style
Power
Large 20-25 27-34
Steering ! CAUTION
Hose Fittings
Do not pry on power steering pump or alternator
Early Style when adjusting belt tension. Serious damage
Power may result.
Small 96-108 11-12
Steering
Hose Fittings
Later Style
Power Steering 23 31
Hose Fittings
Tools/Sealants
Pulley Installer 91-93656A1
Pulley Removal Tool
J-25034
(Kent-Moore)
Kent-Moore Special Tools

29784 Little Mack
Roseville, MI 48066
(313) 574-2332
Index
90-823225--1 1096 POWER STEERING - 9A-1
Power Steering Pump and Components
(Exploded View)
6
22 16
21
23
3
4
22
20
23 19
1
18
9 11 17
2
12
10
14
5
7
8
15
13
22
23 14
24
72951
1 - Power Steering Pump Assembly 13- Hose, Pump To Fluid Cooler
2 - Stud 14- Clamp
3 - Cap 15- Hose, Control Valve To Fluid Cooler (Fitting On One End)
4 - Spacer 16- Mounting Bracket, Cast
5 - Brace 17- Bolt
6 - Spacer 18- Spacer (Barrel Shaped)
7 - Lockwasher 19- Lockwasher
8 - Bolt, Pump To Brace 20- Nut (For Item 17)
9 - Pulley 21- Nut (For Item 21)
10- Belt 22- Lockwasher
11- O-Ring, High Pressure Hose Fitting 23- Bolt To Cylinder Block
12- Hose, High Pressure (Fittings on Both Ends) 24- Power Steering Cooler
Index
Serpentine Belt Routing
ALPHA WITH POWER STEERING BRAVO WITH POWER STEERING
ALPHA WITH CLOSED COOLING BRAVO WITHOUT POWER STEERING

WITHOUT POWER STEERING
ALPHA WITH CLOSED COOLING AND BRAVO WITH CLOSED COOLING

POWER STEERING AND POWER STEERING
Index
90-823225--1 1096 POWER STEERING - 9A-3
Important Service INSTALLATION
Install pulley, as follows, using pulley installer tool
Information (91-93656A1), and a long straight edge:
1. Place pulley on pump shaft.
Pump Pulley Replacement 2. Thread stud all the way into pump shaft. Place
bearing over stud. Do not use spacer from kit.
REMOVAL 3. Thread nut onto shaft. Thread tool shaft (and nut)
all the way onto stud (threaded into pump pulley).
IMPORTANT: Kent-Moore Tool J-25034 must be
4. Using a long straight edge (to check drive belt
used to remove the pressed-on pulleys used on
alignment), turn large pusher nut until drive belt
power steering pumps. This tool has an end on it
is parallel to straight edge.
that will not mushroom the end of the pump shaft.
DO NOT use Kent-Moore Tool J-21239 to remove 5. Check pulley installation for correct alignment.
these pulleys. This tool has a tapered end and will d
damage the shaft. c e
b f
1. Install Kent-Moore Tool J-25034 on end of pulley
and shaft as shown.
2. While holding tool with suitable wrench, turn
threaded screw until pulley is removed.
72822
g h
a -
Power Steering Pump Pulley
b -
Stud
72821 c -
Do Not Use Spacer
d -
Bearing
a - Kent-Moore Pulley Removal Tool (J-25034)
e -
Nut
f -
Tool Shaft
g -
Crankshaft Pulley (shown) Or Water Circulating Pump
Pulley
h - Long Straight Edge
i - Drive Belt Parallel
Index
Testing and Repair Serpentine Belt Adjustment
Refer to appropriate MerCruiser Stern Drive 1. Using a 5/8 inch wrench, loosen the nut on the ad-
Service Manual. justment stud.
2. Place the 5/16 inch deep socket on the hex end
of the adjustment stud rotate starboard tensioner
Checking Pump Fluid Level until there is 1/4 inch (6 mm) deflection is
achieved between the pulleys with the greatest
Refer to Section 1B - “Maintenance” (see “Table of distance between them (this location may be dif-
Contents”). ferent with various belt configurations).
3. While holding adjustment stud at the correct belt
Filling and Air Bleeding tension, tighten locking nut.
System
Refer to Section 1B - “Maintenance” (see “Table of
Contents”).
Belt Adjustment b
V-Belt
IMPORTANT: Do not pry on power steering pump a

with pry bar or screwdriver. Serious damage may
result.
74908
1. Install drive belt on pulleys and adjust tension as
follows:
a. Pivot pump away from engine, as required,
until correct tension is obtained, as shown.
b. After obtaining correct tension, securely
tighten pump brace and pump mounting
bolts.
2. If a new drive belt has been installed, recheck belt
tension after running for five minutes.
b
Bravo Model With Power Steering Shown (Other
Configurations Will Be Different)
a - Locking Nut
b - Adjustment Stud
72847
a - Belt Should Depress 1/4 In (6 mm)

b - Screws and Nuts
Index
90-823225--1 1096 POWER STEERING - 9A-5
Pump Assembly 2. Install mounting hardware and fasteners to retain
pump to bracket. (Refer to “Exploded View” for
specific details on your engine.)
IMPORTANT: Be careful to not cross-thread or
over-tighten hose fittings.
1. Be certain a new high pressure hose O-ring is
present, and install threaded fitting in back of
pump assembly. Tighten fitting securely. Connect
low pressure hose on back of pump. Tighten
hose clamp securely.
72849
b
a
c
d 72850
a
a - Pump b
b - Bracket c
c - Threaded Fitting
d - Low Pressure Hose
72848
a - Screw With :Lockwasher
b - Nuts (With Hardware)
c - Spacers
3. Install drive belt and adjust tension. Refer to

“Pump Drive Belt Adjustment” as previously out-
lined.
4. Fill and air bleed system. Refer to Section 1B -
“Maintenance” (see “Table of Contents”).
Index
Mounting Bracket 2. Remove hose where routed and secured (port or
starboard side), across top of engine, near valve
Mounting bracket is removable after pump (refer to cover.
previous instructions) and alternator (refer to Section
4C - “Charging System”) have been removed. See 3. Remove small fitting from control valve at tran-
“Exploded View” and “Torque Specifications.” som. Remove hose.
Hydraulic Hoses and Fluid

Cooler
Refer to Section 6A - “Seawater Cooled Models” or
Section 6B - “Closed Cooled Models” for information
on testing or servicing power steering fluid coolers.
The following is provided to assist in replacement of a
power steering fluid hoses and to assure proper rout-
ing and connection to the cooler. b
Replace high or low pressure hoses following:
50912
a - Control Valve
IMPORTANT: Make hydraulic connections as b - Small Fitting And Hose
INSTALLATION
! CAUTION
High Pressure Hose help avoid kinks in the hoses.
(Pump-to-Control Valve)
REMOVAL over-tighten hose fittings.
NOTE: Catch fluid that drains from pump and hoses 1. Thread small fitting into control valve. Position
in a suitable container. hose properly (as prior to removal).
1. Remove high pressure hose fitting and O-ring Earlier Style Control Valve: Torque small fitting to
seal from rear of pump. 96-108 lb. in. (11-12 N·m).
b a
72026
72848
a - High Pressure Hose a - Small Fitting
b - Fitting (With O-Ring - Not Visible In This View)
Index
90-823225--1 1096 POWER STEERING - 9A-7
Later Style Control Valve: Torque fittings to 23 lb. ft. Low Pressure Hose (Cooler-to-Pump)
(31 N·m).
REMOVAL
NOTE: Catch fluid that drains from hose, cooler
and pump in a suitable container.
1. Loosen hose clamp and remove hose from fluid
cooler.
73786
2. Route hose along valve cover and secure with b

J-clamp(s) provided.
3. Be certain a new high pressure hose O-ring is a 72588
present, and install threaded fitting in back of
pump assembly. Tighten fitting securely. Do not Port Side Mounted Fluid Cooler
cross-thread or over-tighten. a - Fluid Cooler
b - Hose Clamp
c - Hose
72848 a
74752
a - Fitting (With O-Ring - Not Visible In This View)
4. Fill and air bleed system. Refer to Section 1B - a - Fluid Cooler
“Maintenance” (see “Table of Contents”). b - Hose
Index
2. Loosen hose clamp and remove hose from back 2. Using hose clamp, install hose on fluid cooler.
of pump. Tighten clamp securely.
a
72588
a
Port Side Mounted Fluid Cooler
a - Fluid Cooler
b b - Hose Clamp
72848 c - Hose
a - Hose Clamp
b - Hose
INSTALLATION
1. Using hose clamp, install new hose on back of
pump. Tighten clamp securely. b
a 74752

a - Fluid Cooler
b - Hose

a
72848
a - Hose Clamp
b - Hose
Index
90-823225--1 1096 POWER STEERING - 9A-9
Low Pressure Hose 2. Remove hose where routed and secured across
top of engine flywheel housing.
(Control Valve-to-Cooler)
REMOVAL
NOTE: Catch fluid that drains from hose, cooler
and pump in a suitable container.
1. Loosen hose clamp and remove hose from fluid
cooler.
a
72853
Port Side Mounted Fluid Cooler Only

b a - J-Clamps
a 3. Remove large fitting from control valve at tran-

som. Remove hose.
72588
a
a - Fluid Cooler
b - Hose Clamp
c - Hose
b
72026
Earlier Style Control Valve

a - Large Fitting
a 74752
a
a - Fluid Cooler
b - Hose
73786
Later Style Control Valve

a - Rear Fitting
Index
INSTALLATION 3. Using hose clamp, install hose on fluid cooler.
! CAUTION
help avoid stress on the hose fittings and will c
help avoid kinks in the hoses.

1. Thread large fitting into control valve. Position
hose properly (as prior to removal). b
Earlier Style Control Valve: Torque large fitting to
20-25 lb. ft. (27-34 N·m).
a a
72588

a - Fluid Cooler
b - Hose Clamp
c - Hose
72026
a - Large Fitting
Later Style Control Valve: Torque fittings to 23 lb. ft. a

(31 N·m). 74752

a - Fluid Cooler
b - Hose

73786
2. Route hose along flywheel housing and secure

with J-clamp(s) provided.
Index
90-823225--1 1096 POWER STEERING - 9A-11
Priority Valve Kit (79691A1) b. Install reservoir mounting bracket with hard-
ware supplied.
Information
This kit information (in “Installation Instruction” form)
is provided to assist personnel when servicing dual
installations where both engines are equipped with
power steering pumps, coolers, related hardware
and hoses, and one transom assembly is equipped a
with power steering.
Although the system may already be installed, refer
to appropriate sections and follow instructions that
relate to your task when servicing those components.
NOTE: A system flow diagram is located on the
last page of this section.
71402
Installing Reservoir a - Measurement - 6 Inch (152 mm) Minimum
1. Mount reservoir bracket.
2. Position bottle reservoir in mounting bracket and
a. Find a location between both power steering
secure with retainer spring.
pumps that affords both accessibility and
easy visual inspection of fluid level. Location
must be at least 6 in. (152 mm) higher than
a
pump cap to allow fluid from reservoir to flow
freely to pumps (preferably on transom or on
forward engine compartment wall).
e
d
72854
a - Reservoir Bracket
b - Reservoir Spring Retainer Tab
c - Screw and Washer (Not Shown In This View)
d - Reservoir Bottle
e - Retainer Spring
Index
IMPORTANT: A two-way valve is required on the 6. Secure hoses with Sta-Straps to keep them be-
reservoir cap for cold weather operation below low reservoir fluid level line and away from heat
40°F (4°C). and moving parts.
3. If required, install two-way valve in reservoir cap
by removing vent from cover and replacing it with
a two-way check valve. b
b c
a d
e a
72855
72857
a - Reservoir Cap a - Power Steering Pump Cap (Port and Starboard)

b - Vent b - Hose To Reservoir
c - Hose Clamp
b d - Sta-Straps
a
e - Bend Radius (Port and Starboard)
72856
a - Reservoir Cap
b - Two-Way Valve (Installed)
4. Cut two hoses (from bulk hose supplied) of suffi- a

cient length to extend from bottom fittings on res-
ervoir to fill caps on power steering pumps. Allow
extra hose for routing.
b
IMPORTANT: When routing and installing hoses
c
in the following steps, be sure that the bend ra- b 72858
dius in the hose is sufficient to eliminate a load
being placed on power steering pump fill cap. a - Reservoir
b - Hoses From Pumps
c - Hose Clamps
5. Connect hoses, that were just cut, to reservoir
and power steering pump caps (from kit). Secure
with hose clamps. Tighten securely.
Index
90-823225--1 1096 POWER STEERING - 9A-13
Installing Priority Valve NOTE: The 90° elbow locations on priority valve
are marked with a “T” stamped into the valve.
NOTE: Priority valve mounting bracket can be
used in various mounting configurations. 2. Apply liquid pipe joint sealer to threads and install
fittings into priority valve.
c
c a
71404
71403
a - 90 Degree Elbow
b - Large Inverted Flare Fitting
1. Install priority valve mounting bracket. c - Small Inverted Flare Fitting
a. Find a central location that will be accessible
for making and checking hose connections. 3. Mount priority valve on bracket. Torque bolt to
Ensure that location will allow 2 in. (51 mm) 120 lb. in. (14 N·m).
or more, above and below priority valve for b
hose connections and routing (preferably on
a stringer near transom).
b. Mount bracket using lag bolts and washers
supplied.
a
a
d
b
72860
a - Bolt and Washers
b - Washer and Nut (Not Shown In This View)
b c - Bracket
d - Priority Valve
72859
a - Mounting Bracket
b - Lag Bolts and Washers
Index
NOTE: Engines with power steering are 7. Install return hose (large fitting on one end only,
equipped with a hose that is connected to the from kit) to power steering control valve. Route
power steering fluid cooler. A fitting on the other hose to priority valve, cut hose to length, and con-
end of the hose would normally be connected to nect to fitting on priority valve. Secure with hose
the power steering control valve. These hoses clamp. Tighten securely.
are not used and are replaced with bulk hose
supplied with priority valve kit.
4. Remove and discard old (control valve-to-cooler)
hoses which are connected to power steering
cooler (port and starboard).
5. Cut two hoses (from bulk hose supplied) of suffi- a
cient length to extend from power steering cool-
ers to respective fittings on priority valve.
6. Connect one end of each hose to its respective
power steering fluid cooler and other ends to fit-
tings on priority valve. Secure with hose clamps.
Tighten securely.
b
b
72863
c
c
a
72588
a - Power Steering Fluid Cooler
b - Hose b
c - Hose Clamp
b a
72864
a - Priority Valve
b - Hose
c - Hose Clamp
c 72862
b
a - Priority Valve
b - Hose
c - Hose Clamp
Index
90-823225--1 1096 POWER STEERING - 9A-15
8. Install pressure hose (fittings on both ends, from 9. Connect No. 1 (starboard) engine pressure hose
kit) between power steering control valve and (from pump) to inverted flare fitting marked by “1”
large inverted flare fitting on priority valve. (This on priority valve. Connect No. 2 (port) pressure
fitting location is marked with an “S.”) Secure with hose (from pump) to inverted flare fitting marked
hose clamp. Tighten securely. by “2” on priority valve. Secure with hose clamps.
Tighten securely.
b a
b
72865
a - Power Steering Control Valve c

b - Hose Fitting
72867
b
a - Priority Valve
b - No. 1 (Starboard) Pressure Hose
c - No. 2 (Port) Pressure Hose
10. Secure all hoses with Sta-Straps provided.
72866
a - Priority Valve
b - Hose Fitting
Index
Filling System with Fluid Maintenance
1. Fill pump reservoirs with automatic transmission Maintenance inspection is the owner’s responsibility
fluid (ATF) Dexron ll or Dexron lll. and must be performed at the following intervals:
2. Install and tighten pump cap by turning cap clock- Normal Service - Every 50 hrs. of operation or 60
wise approximately 120 degrees. days (whichever comes first)
Severe Service - Every 25 hrs. of operation or 30
days (whichever comes first)
a NOTE: Operation in salt water is considered se-
vere service.
1. Check all connections and hose clamps for ade-
quate tightness. Tighten, if loose.
2. Check all mounting bolts and tighten if necessary.
3. Be sure to check reservoir oil level periodically.
72868
a - Cap
3. Fill reservoir bottle to full mark, then (one at a

time) slightly loosen pump cap to allow fluid to
flow from reservoir to pump until pump just starts
to overflow, then quickly tighten pump cap. Fill
bottle reservoir and repeat this process for the
other pump.
4. Double check both caps to ensure they are both
tight.
Index
90-823225--1 1096 POWER STEERING - 9A-17
System Flow Diagram
3
b 2
c
c
d 5
4
1 d
f
e 5
Pressure Line
Return Line 4
Gravity Feed Line 72995
1 - Reservoir Bottle and Bracket

2 - Priority Valve and Mounting Bracket
3 - Power Steering Control Valve
4 - Power Steering Pump
5 - Power Steering Fluid Cooler
a - Pressure Hose (Fitting On Both Ends - Supplied In Kit)

b - Return Hose (Fitting On One End - Supplied In Kit)
c - Return Hose From Pump (Cut From Bulk Hose Supplied)
d - Pressure Hose From Pump
e - Return Hose From Pump
f - Gravity Feed Hose (Cut From Bulk Hose Supplied)
Index
AT A LATER DATE
Index
90-823225--1 1096 POWER STEERING - 9A-19

Mercruiser Service Manual - 17

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90-823225--1 1096 iii

841-8163 Cylinder Block Assembly includes only standard pistons,

FORE or BOW PORT

a - Standard Left Rotation - All MCM Stern Drive Engines,

overheating and possible piston damage (due to

SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR

SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR

MCM (Stern Drive) Model All Models

TEST FOR ALCOHOL CONTENT IN GASOLINE

a - Fill Cap / Dipstick a - Proper Fluid Level With Engine Cold

4. If level is below bottom of dipstick, but fluid is still

a - Proper Fluid Level With Engine Warm

4. If level is below ADD mark, but fluid is still visible

6. Shut off water tap. Remove garden hose and

IMPORTANT: To accurately check fluid level, en-

Velvet Drive IMPORTANT: Velvet Drive transmission - use 10

MODELS WITH 2 BARREL CARBURETOR

MODELS WITH 4 BARREL CARBURETOR

Bravo One and Two MCM Models - Typical Shift Cable

Velvet Drive MIE Models (Typical) Shift Cable and

MCM Models with Bravo Drives

1. MCM (Stern Drive) Models:

Starboard Shown (Port Similar)

Starboard Side Shown (Port Similar)

a - Drain Plug Located In Exhaust Manifold Elbow

72587 h. Follow instructions “(1)” or “(2)”:

a - Hose, Seawater Pickup Pump-to-Cooler

i. Crank engine over slightly with starter motor

c. Repeatedly clean out drain holes using a stiff

Stainless Steel Thermostat Housing

Starboard Shown (Port Similar) 72587

f. Remove hose from the seawater pump, as

Starboard Shown (Port Similar) b a

DRAINING SEAWATER SECTION OF CLOSED

a. Engine must be as level as possible to ensure

e. Repeatedly clean out drain holes using a stiff

h. Follow instructions “(1)” or “(2)”:

a. Engine must be as level as possible to ensure

Typical Riser Shown (if equipped)

j. After seawater section of cooling system has

i. Crank engine over SLIGHTLY, with starter

1. Check that all cooling system hoses are con-

6. Install fully charged battery. Clean battery cable

Avoid gasoline fire or explosion. Improper in- ! CAUTION

Overheating Scavenger Deposits

IMPORTANT: When working on engine, spark

RPM Too Low

Propeller Damaged; pitch too great; diameter too great.

Dirty or damaged bottom; permanent or power

Thunderbolt IV (HEI) Ignition (No Spark)

Cause Special Information

Moisture on ignition components Distributor cap or spark plug wires arcing

Battery, electrical connections, damaged wiring

Shift interrupter switch (Alpha One Models Only)

Shorted tachometer Disconnect tachometer and try again

Spark plugs Fouled, burned, cracked porcelain

Spark plug wires Faulty insulation, broken wires

Cracked or dirty distributor cap